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Jcb 403 wheel loading shovel service repair manual sn1070000 to 1070499

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Open front screenService Manual JCB 403 Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body…
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Open front screenService Manual JCB 403 Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section K - EnginePublication No.9803-9490-1World Class Customer Support Copyright Š 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 591400Section 0 - Service ManualNotes:0-09803-9490-10-0Open front screenSection 1General Information Service Manual - JCB 403 Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section K - EnginePublication No.9803-9490-1World Class Customer Support Copyright Š 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 591400Section 1 - 1Notes:1-29803-9490-11-2Section 1 - General Information ContentsContents Page No. About this Manual Introduction ................................................................................................ 1-1 Using the Service Manual .....................................................................1-1 Units of Measurement ...........................................................................1-1 Section Numbering ................................................................................1-1 Cross References ..................................................................................1-1 Using the Machine .................................................................................1-1 Hydraulic Schematic Colour Codes .......................................................1-2 Identifying the Machine Serial Numbers .......................................................................................... 1-3 Machine Model and Serial Number .......................................................1-3 Data Plate ..............................................................................................1-3 Typical Vehicle Identification Number (VIN) ..........................................1-3 Typical Engine Identification Number ....................................................1-3 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-4 Introduction ............................................................................................1-4 Bolts and Screws ...................................................................................1-4 Hydraulic Connections ............................................................................... 1-8 'O' Ring Face Seal System ....................................................................1-8 'Torque Stop' Hose System ................................................................. 1-11 Service Tools Numerical List .......................................................................................... 1-12 Tool Detail Reference .............................................................................. 1-16 Section B - Body and Framework ........................................................1-16 Section C - Electrics ............................................................................1-17 Section E - Hydraulics .........................................................................1-18 Moving a Disabled Machine Towing or Winching ................................................................................. 1-22 Service Consumables Sealing and Retaining Compounds ......................................................... 1-241-i1-iSection 1 - General InformationAbout this Manual Introduction Using the Service ManualSection Numbering T11-004T11-005This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department.The manual is compiled in sections, the first three are numbered and contain information as follows:These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication. Finally, please remember above all else safety must come first!Units of Measurement T1-001 2In this publication, the S.I. system of units is used. For example, liquid capacities are given in litres. The Imperial units follow in parentheses ( ) eg 28 litres (6 gal).1-11General Information - includes torque settings and service tools.2Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.3Maintenance - includes service schedules and recommended lubricants for all the machine.The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: AAttachmentsBBody and Framework, etc.Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.Cross References T1-004 2In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The number of the page upon which the subject begins, is indicated within the brackets. For example: K Cross References ( T 1-1).Using the Machine T1-002 2To use the machine efficiently and safely you must know the machine and have the skill to use it. You must abide by all relevant laws, health and safety regulations that apply to the country you are operating in. This manual instructs you on the machine, its controls and its safe operation; it is not a training manual. If you are a new operator, get yourself trained in the skills of using a machine before trying to work with it. If you don't, you will not do your job well, and you will be a danger to yourself and others.9803-9490-11-1Section 1 - General Information About this Manual IntroductionHydraulic Schematic Colour Codes T11-006The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications.RedFull Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and MRV operating pressure.PinkPressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red.OrangeBlueGreenLight GreenYellow1-2Servo: Oil pressure used in controlling a device (servo).Neural: Neutral circuit pressure.ExhaustCavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).9803-9490-11-2Section 1 - General InformationIdentifying the Machine Serial Numbers Machine Model and Serial NumberTypical Vehicle Identification Number (VIN)This manual provides information for the following machines : 403 from machine serial number 1070000 to 1070499.12345SLP4037E1070000Data Plate1World Manufacturer Identification (SLP = JCB)Your machine has a Data Plate. The serial numbers of the machine, engine and transmission unit are stamped on the plate.2Machine Type (403)3Year of Manufacture (1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004, 5 = 2005, 6 = 2006, 7=2007)4Manufacturers Location (E = England)5Machine Serial Number (1070000)VIN Vehicle Identification NumberEDFITA 522 634 FRONT AXLE SERIAL NUMBER20325164Typical Engine Identification NumberFITA 522 635TRANSMISSION SERIAL NUMBERMACHINE TYPESTERPIN Product Identification Number01009749 ENGINE SERIAL NUMBERWEIGHT (Kg)GI1163000SLP406AL5E11630004600BSI REJCB EARTHMOVERS LIMITED LAKESIDE WORKS, ROCESTER, UTTOXETER, UNITED KINGDOMREAR AXLE SERIAL NUMBER44 / 25002005ENGINE POWER Kw @ RPMYEAR OF CONST.HOMOLOGATION No.Fig 1.If the engine is replaced by a new one, the data plate serial number will be wrong. Either stamp the new number on the plate or stamp out the old one. This will prevent the wrong number being quoted when you order replacement parts. abcdeAB50316J0000012aEngine Type (AB= 4 cylinder turbo)b Engine Parts List cCountry of Manufactured Engine Serial Number e1-39803/9490-1Year of Manufacture1-3Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet FastenersStandard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners T11-002IntroductionBolts and ScrewsSome external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.Use the following torque setting tables only where no torque setting is specified in the text.The two types of fasteners can be readily identified by colour and part number suffix. K Table 1. Fastener Types ( T 1-4).Torque settings are given for the following conditions:Fastener TypeTable 1. Fastener Types Colour Part No. SuffixNote: Dacromet fasteners are lubricated as part of the plating process, do not lubricate.Condition 1 – Un-lubricated fasteners – Zinc fasteners – Yellow plated fastenersZinc and YellowGolden finish'Z' (e.g. 1315/3712Z)DacrometMottled silver finish 'D' (e.g. 1315/3712D)Condition 2 – Zinc flake (Dacromet) fastenersNote: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener. Note: A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt.– Lubricated zinc and yellow plated fasteners – Where there is a natural lubrication. For example, cast iron componentsVerbus Ripp BoltsNote: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. Note: Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.1-4Fig 2. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.9803-9490-11-4Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Hexagon (A/F) Condition 1Bolt Size in.mmin.Nmkgf mlbf ftNmkgf mlbf ft1/46.37/1611.21.18.310.01.07.45/167.91/222.32.316.420.02.014.73/89.59/1640.04.129.536.03.726.57/1611.15/864.06.547.257.05.842.01/212.73/498.0010.072.388.09.064.99/1614.313/16140.014.3103.2126.012.892.95/815.915/16196.020.0144.6177.018.0130.53/419.01 1/8343.035.0253.0309.031.5227.97/822.21 15/16547.055.8403.4492.050.2362.9125.41 1/2814.083.0600.4732.074.6539.91 1/831.71 7/81181.0120.4871.11063.0108.4784.01 1/438.12 1/41646.0167.81214.01481.0151.01092.3Table 3. Torque Settings - Metric Grade 8.8 Fasteners Hexagon (A/F) Condition 1Bolt Size ISO Metric Thread1-5Condition 2mmmmNmkgf mCondition 2lbf ftNmkgf mlbf ftM5585.80.64.35.20.53.8M66109.91.07.39.00.96.6M881324.02.417.722.02.216.2M10101747.04.834.743.04.431.7M12121983.08.561.274.07.554.6M161624205.020.9151.2184.018.8135.7M202030400.040.8295.0360.036.7265.5M242436690.070.4508.9621.063.3458.0M3030461372.0139.91011.91235.0125.9910.9M3636552399.0244.61769.42159.0220.01592.49803-9490-11-5Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Hexagon (A/F) Condition 1Bolt Size ISO Metric ThreadmmmmNmkgf mCondition 2 lbf ftNmkgf mlbf ftM5588.10.86.07.30.75.4M661013.91.410.212.51.39.2M881334.03.525.030.03.022.1M10101767.06.849.460.06.144.2M121219116.011.885.5104.010.676.7M161624288.029.4212.4259.026.4191.0M202030562.057.3414.5506.051.6373.2M242436971.099.0716.9874.089.1644.6M3030461930.0196.81423.51737.0177.11281.1M3636553374.0344.02488.53036.0309.62239.2Table 5. Metric Grade 12.9 Fasteners Hexagon (A/F) Condition 1Bolt SizeCondition 2ISO Metric ThreadmmmmNmkgf mlbf ftNmkgf mlbf ftM5589.81.07.28.80.96.5M661016.61.712.215.01.511.1M881340.04.129.536.03.726.5M10101780.08.159.072.07.353.1M121219139.014.2102.5125.012.792.2M161624345.035.2254.4311.031.7229.4M202030674.068.7497.1607.061.9447.7M2424361165.0118.8859.21048.0106.9773.0M3030462316.0236.21708.22084.0212.51537.1M3636554049.0412.92986.43644.0371.62687.71-69803-9490-11-6Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric ThreadmmNmkgf mlbf ftM331.20.10.9M443.00.32.0M556.00.64.5M6610.01.07.5M8824.02.518.0M101048.04.935.5M121282.08.460.5Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size1-7ISO Metric ThreadNmkgf mlbf ftM32.00.21.5M46.00.64.5M511.01.18.0M619.01.914.0M846.04.734.0M1091.09.367.0M12159.016.2117.0M16395.040.0292.0M18550.056.0406.0M20770.079.0568.0M241332.0136.0983.09803-9490-11-7Section 1 - General Information Standard Torque Settings Hydraulic ConnectionsHydraulic 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. Table 8. Torque Settings - BSP Adaptors BSP Adaptor Hexagon (A/F) Size1-8in.mmNmkgf mlbf ft1/419.018.01.813.03/822.031.03.223.01/227.049.05.036.05/830.060.06.144.03/432.081.08.260.0138.0129.013.195.01 1/450.0206.021.0152.0Table 9. Torque Settings - SAE Connections SAE Port Hexagon (A/F)SAE Tube SizeThread SizemmNmkgf mlbf ft47/16 - 2015.920.0 - 28.02.0 - 2.816.5 - 18.569/16 - 1819.146.0 - 54.04.7 - 5.534.0 - 40.083/4 - 1622.295.0 - 105.09.7 - 10.769.0 - 77.0107/8 - 1427.0130.0 - 140.013.2 - 14.396.0 - 104.0121 1/16 - 1231.8190.0 - 210.019.4 - 21.4141.0 - 155.0161 5/16 - 1238.1290.0 - 310.029.6 - 31.6216.0 - 230.0201 5/847.6280.0 - 380.028.5 - 38.7210.0 - 280.09803-9490-11-8Section 1 - General Information Standard Torque Settings Hydraulic Connections Hoses Screwed into AdaptorsFig 3. Hoses 3-B screwed into adaptors 3-A seal onto an `O' ring 3-C which is compressed into a 45° seat machined into the face of the adaptor port.BSP Hose Size in.1-9Note: Dimension 3-D will vary depending upon the torque applied.Table 10. BSP Hose - Torque Settings Hexagon (A/F) mmNm1/814.014.0 - 16.001.4 - 1.610.3 - 11.81/419.024.0 - 27.02.4 - 2.717.7 - 19.93/822.033.0 - 40.03.4 - 4.124.3 - 29.51/227.044.0 - 50.04.5 - 5.132.4 - 36.95/830.058.0 - 65.05.9 - 6.642.8 - 47.93/432.084.0 - 92.08.6 - 9.461.9 - 67.8138.0115.0 - 126.011.7 - 12.884.8 - 92.91 1/450.0189.0 - 200.019.3 - 20.4139.4 - 147.51 1/255.0244.0 - 260.024.9 - 26.5180.0 - 191.89803-9490-1kgf mlbf ft1-9Section 1 - General Information Standard Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size1-10in.Nmkgf mlbf ft1/820.02.115.01/434.03.425.03/875.07.655.01/2102.010.375.05/8122.012.490.03/4183.018.7135.01203.020.7150.01 1/4305.031.0225.01 1/2305.031.0225.09803-9490-11-10Section 1 - General Information Standard Torque Settings Hydraulic Connections'Torque Stop' Hose SystemFig 4. `Torque Stop' Hoses 4-B screwed into adaptors 4-A seal onto an 'O' ring 4-C which is compressed into a 45° seat machined in the face of the adaptor port. To prevent the 'O' ring being damages as a result of over tightening, 'TorqueStop' Hoses have an additional shoulder 4-D, which acts as a physical stop. Note: Minimum dimension 4-E fixed by shoulder 4-D.Table 12. BSP `Torque Stop' Hose - Torque Settings BSP Hose Size Hexagon (A/F)1-11in.mmNmkgf mlbf ft1/814.014.01.410.01/419.027.02.720.03/822.040.04.130.01/227.055.05.640.05/830.065.06.648.03/432.095.09.770.0138.0120.012.289.01 1/450.0189.019.3140.01 1/255.0244.024.9180.09803-9490-11-11Section 1 - General InformationService Tools Numerical List The tools listed in the table are special tools required for removal and replacement of Body and Framework parts. 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.Part NumberDescriptionTool Detail Reference1406/0011Bonded WasherK Fig 17. ( T 1-19)1406/0014Bonded WasherK Fig 17. ( T 1-19)1406/0018Bonded WasherK Fig 17. ( T 1-19)1406/0021Bonded WasherK Fig 17. ( T 1-19)1406/0029Bonded WasherK Fig 17. ( T 1-19)1604/0003A AdapterK Fig 10. ( T 1-18)1604/0004A AdapterK Fig 10. ( T 1-18)1604/0006A AdapterK Fig 18. ( T 1-20)1604/2055AdapterK Fig 10. ( T 1-18)1606/0004AdapterK Fig 10. ( T 1-18)1606/0007A AdapterK Fig 10. ( T 1-18)1606/0008AdapterK Fig 10. ( T 1-18)1606/0009AdapterK Fig 10. ( T 1-18)1606/0012AdapterK Fig 10. ( T 1-18)1606/0014AdapterK Fig 10. ( T 1-18)1606/0015AdapterK Fig 10. ( T 1-18)1606/0016AdapterK Fig 10. ( T 1-18)1606/0017AdapterK Fig 10. ( T 1-18)1606/2052AdapterK Fig 10. ( T 1-18)1612/2054AdapterK Fig 18. ( T 1-20)816/00017AdapterK Fig 13. ( T 1-19)816/00189A Blanking CapK Fig 15. ( T 1-19)816/00190A Blanking CapK Fig 15. ( T 1-19)816/00439AdapterK Fig 10. ( T 1-18)816/00440AdapterK Fig 10. ( T 1-18)816/15007A AdapterK Fig 10. ( T 1-18)816/15008AdapterK Fig 10. ( T 1-18)816/15118AdapterK Fig 11. ( T 1-18)1-129803-9490-11-12Section 1 - General Information Service Tools Numerical List Part NumberDescriptionTool Detail Reference816/20008AdapterK Fig 18. ( T 1-20)816/20013AdapterK Fig 18. ( T 1-20)816/50005AdapterK Fig 13. ( T 1-19)816/50043AdapterK Fig 13. ( T 1-19)816/55038AdapterK Fig 12. ( T 1-18)816/55040AdapterK Fig 12. ( T 1-18)816/55045AdapterK Fig 12. ( T 1-18)816/60096AdapterK Fig 13. ( T 1-19)816/90022Blanking CapK Fig 15. ( T 1-19)816/90045Blanking CapK Fig 15. ( T 1-19)816/90205Blanking CapK Fig 15. ( T 1-19)816/9
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