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JCB 714 & 718 ARTICULATED DUMP TRUCK Service Manual

Introduction:

This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received training by
the JCB Training Department.
These personnel should have a sound knowledge of workshop practice, safety procedures and general techniques associated
with the maintenance and repair of hydraulic earth moving equipment.
Renewal of oil seals, gaskets etc. and any component showing obvious wear or damage is expected as a matter of course. It is
expected that components will be thoroughly cleaned and lubricated where appropriate, and that any opened hose or pipe connections
will be blanked to prevent entry of dirt and excessive loss of hydraulic fluid. Finally, please remember above all else
SAFETY MUST COME FIRST!

Contents

General Information

Contents Page No.

Identification

Vehicle Identification Plate 1 – 1

Explanation of the Vehicle Identification Number 1 – 1

Unit Identification 1 – 1

Torque Settings 2 – 1

Service Tools

– Numerical List 3 – 1

– Section B – Body and Framework 4 – 1

– Section C – Electrics 5 – 1

– Section E – Hydraulics 6 – 1

– Section F – Transmission 7 – 1

– Section K – Engine 8 – 1

Sealing and Retaining Compounds 9 – 1

Towing – General 10 – 1

Connecting/Disconnecting Hydraulic Hoses 11 – 1

Hydraulic Contamination 12 – 1

Care and Safety

Safety Notices 1 – 1

General Safety 2 – 1

Operating Safety 2 – 2

Maintenance Safety 2 – 4

Safety Decals 3 – 1

Routine Maintenance

Contents Page No.

Lubricants – Health and Safety

Hygiene 1 – 1

Storage 1 – 1

Waste Disposal 1 – 1

Handling 1 – 1

First Aid – Oil 1 – 1

Spillage 1 – 1

Fires 1 – 2

General Safety 3 – 1

Service Schedules

10 Hours – Daily Checks 4 – 1

100 Hours – First Service 4 – 1

100 Hours 4 – 2

500 Hours or Six Monthly 4 – 2

1000 Hours or Yearly 4 – 3

2000 Hours or Two Yearly 4 – 3

* Tipper Body Safety Support

General 5 – 1

Fitting the Tipper Body Safety Strut

(Early Machines) 5 – 1

Stowing the Tipper Body Safety Strut

(Early Machines 5 – 2

* Fitting and Stowing the Tipper Body Safety Stay

(Later Machines) 5 – 3

Articulation Lock

Installing the Articulation Lock 6 – 1

Stowing the Articulation Lock 6 – 2

ROPS/FOPS Structure

Checking the ROPS/FOPS Structure 7 – 1

Engine Cover

Opening the Engine Cover 8 – 1

Closing the Engine Cover 8 – 1

Greasing

Tipper Body Rams and Body Pivot Points 9 – 1

Centre Pivot and Steering Rams 9 – 2

Propshafts 9 – 3

Centre Bearing Carrier 9 – 4

* Hydraulic Suspension Cylinder 9 – 4

Propshaft Centre Bearing

Checking the Oil Level 10 – 1

Draining and Refilling the Oil 10 – 1

Issue

Body and Framework

Contents Page No

Cab

– Direct Glazing 2 – 1

– ROPS/FOPS Structure Checking 5 – 1

Centre Pivot

– Separating the Front and Rear Chassis 7 – 1

– Centre Casting – Removal and Replacement 7 – 4

Rivet Nuts

– Fitting Procedure 10 – 1

– Specifications 10 – 1

* Tipper Body

– Tipper Body Removal and Replacement 20 – 1

* Air Conditioning/Heater System – ADT Series Machines

Introduction 30 – 2

System Operation 30 – 2

System Protection Devices 30 – 4

Operator Controls 30 – 4

Safety Procedures 30 – 5

Refrigerant Type 30 – 5

Hoses and Pipes 30 – 6

Leak Testing 30 – 6

Fault Finding 30 – 7

Component Removal and Replacement 30 – 9

Operator Control Switches 30 – 10

Thermostat Switch 30 – 10

Blower Motor 30 – 10

Electrical Circuit Description 30 – 11

Electrical Circuit Testing – General 30 – 12

Pressure Switch Testing 30 – 14

Issue

Electrics

Contents Page No.

Technical Data

Bulbs 1 – 1

Fuses 1 – 2

* Relays – ADT 714 Machine 1 – 4

* Relays – ADT 718 Machine 1 – 4

Test Methods

Using a Multimeter 2 – 1

Measuring DC Voltage 2 – 3

Measuring Resistance 2 – 3

Measuring Continuity 2 – 3

Testing a Diode or a Diode Wire 2 – 4

Measuring Frequency 2 – 4

Batteries

Safety 3 – 1

Warning Symbols 3 – 1

Maintenance 3 – 2

Testing – Specific Gravity 3 – 3

Battery Testing 3 – 3

Alternator

Service Precautions 4 – 1

Charging Test 4 – 1

Removal and Replacement 4 – 2

Dismantling 4 – 3

Assembly 4 – 3

Starter Motor

No Load Test 5 – 1

Removal and Replacement 5 – 2

Dismantling 5 – 3

Cleaning 5 – 3

Assembly 5 – 3

Fault Finding 5 – 4

Circuit Diagrams 6 – 1

* Circuit Diagram – ADT 718 Machine Only 6 – 9

Harness and Wire Number Identification

Explanation of Wire/Harness Numbers 7 – 1

Fault Finding

Introduction to Fault Finding Techniques 8 – 1

* Fuses and Relays

Accessing the Fuse Locations 20 – 1

Accessing the Relay Locations 20 – 3

Issue

Hydraulics

Contents Page No.

Technical Data 1 – 1

General Description 2 – 1

Schematic Circuits

Introduction to Hydraulic Schematic Symbols 3 – 1

Hydraulic Circuit Component Key –

∗ ADT 714 up to Machine Serial No. 830153

∗ ADT 718 up to Machine Serial No. 832019 3 – 7

Hydraulic Circuit 3 – 8

Hydraulic Circuit Component Key –

∗ ADT 714 from Machine Serial No. 830154

∗ ADT 718 from Machine Serial No. 832020 3 – 8B

Hydraulic Suspension Circuit

– ADT 718 Machine Only 3 – 9

Hydraulic Suspension Circuit Component Key

– ADT 718 Machine Only 3 – 9

Hydraulic Pump

Pump Operation 10 – 1

Hydraulic Pump – Removal and Replacement 10 – 3

∗ Servo Joystick

Servo Joystick – Removal and Replacement 50 – 2

Servo Joystick – Dismantling and Assembly 50 – 4

Control Valve

Control Valve – Operation 60 – 2

Control Valve – Removal and Replacement 60 – 4

Control Valve – Dismantling and Assembly 60 – 6

∗ Servo Control Valve – Removal and Replacement 60 – 8

∗ Servo Control Valve – Dismantling and Assembly 60 – 10

∗ Overcentre Valve

Removal and Replacement 65 – 2

Dismantling and Assembly 65 – 2

Body Lift Ram

Lift Rams – Removal and Replacement 70 – 2

Lift Rams – Dismantling and Assembly 70 – 4

JCB Ram Sealing Procedure 70 – 6

Pressure Testing

Main Relief Valve Pressure Testing 80 – 1

Adjusting the Main Relief Valve 80 – 1

Steering Stand-by Pressure Testing 80 – 2

Steer Relief Valve Pressure Testing 80 – 2

Fault Finding 90 – 1

i i

Transmission

Contents Page No

Technical Data 1 – 1

Power Shift Transmission WG160

Description

Main Components 3 – 1

Oil Circulation Schematic 3 – 2

Power Flow – Forward Speeds 3 – 3

Power Flow – Reverse Speeds 3 – 4

Test Points and Connections 3 – 5

Electro-Hydraulic Shift Control 3 – 7

Dismantling 5 – 1

– Separate Hydraulic Control Unit (HSG-90)

and Duct Plate From Gearbox 5 – 2

– Hydraulic Pump 5 – 4

– Converter Back Pressure Valve 5 – 4

– Remove Output Shaft, Input Shaft

and Clutches 5 – 6

– Clutches KV and KR 5 – 10

– Clutches K1, K2 and K3 5 – 12

– Clutch K4 5 – 14

– Drive Shaft 5 – 16

Assembly 6 – 1

– Install Oil Tubes 6 – 1

– Install Studs, Plugs and Sealing Covers 6 – 2

– Clutches KV and KR 6 – 4

– Clutches K1, K2 and K3 6 – 8

– Clutch K4 6 – 14

– Drive Shafts 6 – 18

– Pre-assembly and Installation –

Output Shaft 6 – 20

– Install Pre-assembled Drive Shaft

and Clutches 6 – 21

– Install Pump Shaft 6 – 24

– Install Oil Seal Covers 6 – 24

– Install Output Flanges 6 – 24

– Installation – Converter Back

Pressure Valve 6 – 26

– Installation – Oil Feed

Housing/Transmission Pump 6 – 26

– Installation – Torque Converter 6 – 28

– Installation – Duct Plate and

Hydraulic Control Unit 6 – 30

– Installation – Plugs and Oil Level Tube 6 – 30

– Installation – Speed Sensor and

Inductive Transmitters 6 – 31

i i

Brakes

Contents Page No.

Technical Data 1 – 1

∗ Parking Brake

Description 2 – 2

Parking Brake – Removal and Replacement 2 – 4

Adjusting the Parking Brake 2 – 6

Checking the Parking Brake Pad Wear 2 – 6

Replacing the Parking Brake Pads 2 – 8

Bleeding the Parking Brake 2 – 8

Parking Brake – Dismantling and Assembly 2 – 10

Service Brakes Circuits, Valves and Pedals

Service Brake Circuit Description 3 – 2

Service Brake Valve – Removal and Replacement 3 – 3

Brake Valve Setting 3 – 3

Service Brake Valve – Dismantling and Assembly 3 – 4

Service Brake System Testing 3 – 6

Accumulator Charge Valve – Removal and Replacement 3 – 7

Accumulator Charge Valve – Dismantling and Assembly 3 – 9

Service Brakes – Checking the Brake Pad Wear 3 – 10

Service Brakes – Renewing the Brake Pads 3 – 12

Bleeding the Service Brakes 3 – 13

Service Brakes – Removal and Replacement 3 – 15

i i

Issue

Hydraulic Steering

Contents Page No.

Technical Data 1 – 1

General Description 1 – 1

Descriptions

– Steering Valve – Operation 2 – 2

– Emergency Steering Operation 2 – 4

Hydraulic Steering Unit

– Hydraulic Steering Unit – Removal and Replacement 3 – 2

– Hydraulic Steering Unit – Dismantling 3 – 4

– Hydraulic Steering Unit – Inspecting 3 – 4

– Hydraulic Steering Unit – Assembly 3 – 4

Emergency Steering Pump

– Removal and Replacement 4 – 2

– Dismantling and Assembly 4 – 4

Steering Rams

– Removal and Replacement 5 – 2

– Dismantling and Assembly 5 – 4

* Emergency Steering Valve

– Removal and Rerplacement 10 – 1

– Dismantling and Assembly 10 – 3

i i

Engine

Contents Page No.

Technical Data

∗ ADT 714 Machine (Tier 1 Engine) 1 – 1

∗ ADT 718 Machine (Tier 1 Engine) 1 – 1

∗ ADT 714 and 718 (Tier 2 Engines) 1 – 1

∗ Description

Description of Tier 2 Engines 10 – 1

∗ Charge Air Cooler

Removal and Replacement 20 – 1

Hydraulic Suspension

Contents Page No.

Technical Data 1 – 1

Description

Description 5 – 1

Hose and Pipework Layout 5 – 3

Deactivating the Hydraulic Suspension

Deactivating and Activating 10 – 1

Hydraulic Suspension Cylinders

Removal and Replacement 20 – 1

Dismantling and Assembly 20 – 3

Remove and Replace the Bearings 20 – 4

Control Arms and Panhard Rod

Removal and Replacement 30 – 1

Bump Stops

Checking 40 – 1

Removal and Replacement 40 – 1

Main Suspension Valve

Removal and Replacement 50 – 1

∗ Dismantling and Assembly 50 – 4

Suspension Control Valve and Accumulators

Removal and Replacement 60 – 1

∗ Dismantling and Assembly 60 – 3

Self-levelling Sensor Switch

Removal and Replacement 70 – 1

∗ Suspension Setting-up

Setting-up the Suspension Ride Height 80 – 2

Checking the Suspension Geometry 80 – 4

Fault Finding

∗ Error Codes 90 – 1

 
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