JCB 403 Wheel Loader Service & Repair Manual

Copyright © 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. World Class Customer Support 9803-9490-1 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Section 3 Maintenance 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 - Engine

Section 1 - 1 1-2 1-2 9803-9490-1 Notes:

Page No. Contents Section 3 - Routine Maintenance 3-i 3-i Routine Maintenance Service Requirements ............................................................................... 3-1 Introduction ............................................................................................ 3-1 Owner/Operator Support ....................................................................... 3-1 Service/Maintenance Agreements ........................................................ 3-1 Initial Service and Inspection (100 Hours) ............................................. 3-1 Lifting Regulations - Inspections and Tests ........................................... 3-2 Obtaining Replacement Parts ................................................................ 3-2 Service Schedules ..................................................................................... 3-3 Introduction ............................................................................................ 3-3 How to Use the Service Schedules ....................................................... 3-3 Pre-start Cold Checks, Service Points and Fluid Levels ....................... 3-4 Lubricants and Capacities ......................................................................... 3-6 Cleaning the Machine ................................................................................ 3-7 Checking for Damage ................................................................................ 3-8 Seat Belt .................................................................................................... 3-9 Checking the Seat Belt Condition and Security ..................................... 3-9 Checking the ROPS Structure ................................................................. 3-10 Greasing .................................................................................................. 3-11 Access Panels ......................................................................................... 3-13 Engine Cover ....................................................................................... 3-13 Electrical System ..................................................................................... 3-14 Battery ................................................................................................. 3-14 Jump Starting the Engine .................................................................... 3-15 Fuses and Relays ................................................................................ 3-16 Engine ..................................................................................................... 3-17 Checking the Oil Level ........................................................................ 3-17 Changing the Oil and Filter .................................................................. 3-18 Fan Belt ............................................................................................... 3-19 Fuel System ............................................................................................. 3-20 Types of Fuel ....................................................................................... 3-20 Changing the Fuel Filter ...................................................................... 3-22 Bleeding the Fuel System ................................................................... 3-23 Hydraulic System ..................................................................................... 3-24 Checking the Fluid Level ..................................................................... 3-24 Changing the Filter Element ................................................................ 3-25 Refilling the Hydraulic System ............................................................. 3-26 Tyres and Wheels .................................................................................... 3-27 Tyre Inflation ........................................................................................ 3-27 Checking the Wheel Nut Torques ........................................................ 3-27

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Section 3 - Maintenance 3-1 3-1 9803-9490-1 Routine Maintenance Service Requirements Introduction T3-002 Your machine has been designed and built to give maximum performance, economy and ease of use under a wide variety of operating conditions. Prior to delivery, your machine was inspected both at the Factory and by your Distributor to ensure that it reaches you in optimum condition. To maintain this condition and ensure trouble free operation it is important that the routine services, as specified in this Manual, are carried out by an approved JCB Distributor at the recommended intervals. This section of the Manual gives full details of the service requirements necessary to maintain your JCB machine at peak efficiency. It can be seen from the Service Schedules on the following pages that many essential service checks should only be carried out by a JCB trained specialist. Only JCB Distributor Service Engineers have been trained by JCB to carry out such specialist tasks, and only JCB Distributor Service Engineers are equipped with the necessary special tools and test equipment to perform such tasks, thoroughly, safely, accurately and efficiently. JCB regularly updates its Distributors advising them of any product developments, changes in specifications and procedures. Therefore only a JCB Distributor is fully able to maintain and service your machine. A Service Record Sheet or Book is provided which will enable you to plan your service requirements and keep a service history record. It should be dated, signed and stamped by your Distributor each time your machine is serviced. Remember, if your machine has been correctly maintained, not only will it give you improved reliability but its resale value will be greatly enhanced. Owner/Operator Support JCB together with your Distributor wants you to be completely satisfied with your new JCB machine. If you do encounter a problem however, you should contact your Distributor's Service Department who are there to help you! You will have been given the names of the relevant service contacts at your Distributor when the machine was installed. To get the most from your Distributor please help them to satisfy you by: 1 Giving your name, address and telephone number. 2 Quoting your machine model and serial number. 3 Date of purchase and hours of work. 4 Nature of the problem. Remember, only your JCB Distributor has access to the vast resources available at JCB to help support you. In addition, your Distributor is able to offer a variety of programmes covering Warranty, Fixed Price Servicing, Safety Inspections, including weight tests, covering both legal and insurance requirements. Service/Maintenance Agreements To help plan and spread the costs of maintaining your machine, we strongly recommend you take advantage of the many Service and Maintenance Agreements your Distributor can offer. These can be tailor made to meet your operating conditions, work schedule etc. Please consult your JCB Distributor for details. Initial Service and Inspection (100 Hours) T3-005 To further protect your machine's performance it is essential your JCB Distributor carries out an initial service and inspection when the machine is one month old or when it has completed 100 hours of operation (whichever occurs first). You should notify your Distributor in advance to allow the necessary arrangements to be made.

Section 3 - Maintenance Routine Maintenance Service Requirements 3-2 3-2 9803-9490-1 Lifting Regulations - Inspections and Tests T3-003 Only your JCB Distributor can fully meet the requirements of the inspection and test parameters to suit UK Health and Safety Executive (H.S.E.) legal requirements along with providing Annual Inspections to meet your Insurance Company Policy conditions. Only your JCB Distributor has the ability to meet the definition described covering a "Competent Person" to carry out these necessary tests and inspections. This ensures that only JCB Factory trained, experienced and up-to-date Engineers supported with all of the available data and material provided only to a JCB Distributor will ensure a thorough and reliable standard. Obtaining Replacement Parts T3-004_2 We recommend you fit only JCB Genuine Parts. A Parts Book will help you identify parts and order them from your JCB distributor. Your dealer will need to know the exact model, build and serial number of your machine. See Identifying Your Machine in INTRODUCTION section. The data plate also shows the serial numbers of the engine, transmission and axle(s), where applicable. But remember if any of these units have been changed, the serial number on the data plate may be wrong. Check on the unit itself.

Section 3 - Maintenance Routine Maintenance Service Schedules 3-3 3-3 9803-9490-1 Service Schedules Introduction A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition. ! WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe. It should be correctly parked on firm level ground. To prevent anyone starting the engine, remove the starter key. Disconnect the battery and block the wheels when you are working beneath the machine. If you do not take these precautions you could be killed or injured. 9-3-1-1 Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately. Note: Services should be carried out at either the hourly interval or calendar interval, whichever occurs first. How to Use the Service Schedules T3-012_3 In the example shown, A shows all service requirements to be carried out every 10 hours and B shows the requirements to be carried out every 500 hours. Important: Services should be carried out at either the hourly interval or calendar interval, whichever occurs first. Refer to Calendar Equivalents. 795390-1 Calendar equivalents: Every 10 Hours = Daily Every 50 Hours = Weekly Every 100 Hours = Monthly Every 500 Hours = Six Months Every 1000 Hours = 1 Year Every 2000 Hours = 2 Years Every 5000 Hours = 5 Years

Section 3 - Maintenance Routine Maintenance Service Schedules 3-4 3-4 9803-9490-1 Pre-start Cold Checks, Service Points and Fluid Levels Operation 10 50 500 1000 2000 ENGINE Oil Level - Check Oil and Filter (1) - Change Air Cleaner Dust Valve (2) - Clean Air Cleaner Outer Element (3) - Change Air Cleaner Inner Element - Change Fuel System for Leaks and Contamination - Check Fuel Filter - Change Fuel Sedimenter - Drain and Clean Fan Belt Tension/Condition - Check Fan Belt - Change Valve Clearances - Check and Adjust Radiator Hoses Condition - Check Radiator - Clean Coolant Level - Check Coolant - Change External Oil Leaks - Check TRANSMISSION, AXLES AND STEERING Wheel Motor Security Tyre Pressures/Condition - Check Wheel Nut Security - Check HYDRAULICS Oil Level - Check Oil - Change Oil Filter - Change Suction Strainer (Tank) (4) - Change Hoses, Rams and Pipework for Damage and Leaks - Check BRAKES Brake System Fluid Level - Check Brake System Fluid - Change ELECTRICS

Section 3 - Maintenance Routine Maintenance Service Schedules 3-5 3-5 9803-9490-1 Important: Under dusty conditions, carry out the engine cooling system cleaning procedure more frequently. Important: The engine timing belt MUST be replaced at 5000 Hours (5 Yearly). Battery Electrolyte Level (if applicable) - Check Battery Charge and Condition - Check Wiring for Chafing/Routing - Check Battery Terminals for Condition and Tightness - Check BODYWORK AND CAB Wing Mirrors Condition and Security - Check All Pivot Pins - Grease Seat Belt Condition and Security - Check ADDITIONAL SERVICE ITEMS Engine Cooling System - Clean (1) In arduous conditions, change the oil and filter after every 250 hours or three months (whichever comes first). (2) Clean more often when working in dusty environments. (3) Change outer element more frequently in dusty operating environments. (4) Strainer located inside hydraulic tank. Operation 10 50 500 1000 2000

Section 3 - Maintenance Routine Maintenance Lubricants and Capacities 3-6 3-6 9803-9490-1 Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Table 1. ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL SPECIFICATION Litres UK Gal Fuel Tank 42 9.2 Diesel Oil ASTM D975-66T Nos. 1D, 2D Engine (Oil) 10.0 2.2 JCB Extreme Performance Engine Oil 15W/40 ACEA A3/B3/E3/ E5 API CH-4/SJ Coolant 6.5 1.4 JCB High Performance Antifreeze and Inhibitor ASTM D6210 Hydraulic System 40 8.8 JCB Super Multigrade Engine Oil 10W/30 ACEA E2 API CF- 4/SG Grease Points --- --- JCB HP Grease Lithium complex NLGI No.2 consistency including extreme pressure additives or JCB MPL EP Grease (1) (1) JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing must be carried out more frequently. Lithium based NLGI No.2 consistency including extreme pressure additives

JCB 403 Wheel Loader Service & Repair Manual

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