JCB Workmax 800D UTV OEM 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 9813/0450-1 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual Workmax 800D Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section B - Body and Framework Section C - Electrics Section D - Controls Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section S - Suspension

Section 0 - Service Manual 0-0 0-0 9813/0450-1 Notes:

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 9813/0450-1 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 1 General Information Service Manual - Workmax 800D Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section B - Body and Framework Section C - Electrics Section D - Controls Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section S - Suspension

Section 1 - General Information 1-0 1-0 9813/0450-1 Notes:

Page No. Contents Section 1 - General Information 1-i 1-i Introduction About this Manual ...................................................................................... 1-1 Machine Model and Serial Number ....................................................... 1-1 Using this Manual .................................................................................. 1-1 Left Side, Right Side .............................................................................. 1-1 Cab/Canopy .......................................................................................... 1-1 Cross References .................................................................................. 1-1 Machine Description .................................................................................. 1-2 The JCB Workmax 800D ....................................................................... 1-2 Intended Use ......................................................................................... 1-2 Component Location ............................................................................. 1-2 Identifying Your Machine ........................................................................... 1-3 Machine Identification Plate .................................................................. 1-3 Typical Product Identification Number Data Plate ................................. 1-4 Component Identification Plates ............................................................ 1-4 Fastener Torque Chart Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-7 Introduction ............................................................................................ 1-7 Bolts and Screws ................................................................................... 1-7 Service Tools Numerical List .......................................................................................... 1-11 Consumables Sealing and Retaining Compounds ......................................................... 1-13

Page No. Contents Section 1 - General Information 1-ii 1-ii

Section 1 - General Information 1-1 1-1 9813/0450-1 Introduction About this Manual Machine Model and Serial Number This manual provides information for the following model(s) in the JCB machine range: – Workmax 800D SN 1629000 to 1632999. Using this Manual T1-044 This manual is arranged to give you a good understanding of the machine and its safe operation. It also contains maintenance information and specification data. Read this manual from front to back before using the machine for the first time. Particular attention must be given to all the safety aspects of operating and maintaining the machine. If there is anything you are not sure about, ask your JCB distributor or employer. Do not guess, you or others could be killed or seriously injured. General warnings in this chapter are repeated throughout the book, as well as specific warnings. Read all the safety statements regularly, so you do not forget them. Remember that the best operators are the safest operators. The illustrations in this manual are for guidance only. Where the machines differ, the text and or the illustration will specify. This manual contains original instructions, verified by the manufacturer (or their authorised representative). 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. All optional equipment included in this manual may not be available in all territories. Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. Cab/Canopy T1-003_2 This manual frequently makes references to the cab. For instance, 'do not operate the machine without a manual in the cab'. It should be noted that these statements also apply to canopy build machines. Cross References T1-004_2 In 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) .

Section 1 - General Information Introduction Machine Description 1-2 1-2 9813/0450-1 Machine Description The JCB Workmax 800D The JCB Workmax 800D is a utility vehicle fitted with a loadbay. The vehicle has a diesel engine which drives through a Continuously Variable Transmission (CVT). The driven axles have differentials, the rear differential incorporates a differential lock. The brakes are hydraulically operated, with discs and callipers on all four wheels. Intended Use The machine is intended to be used under normal conditions for the applications described in this manual. If the machine is used for other purposes or in dangerous environments, for example in a flammable atmosphere or in areas with dust containing asbestos, special safety regulations must be followed and the machine must be equipped for use in these environments. Component Location Note: The illustration(s) show a typical machine model; your machine may look different from the model shown. 1 Front access panel 2 Roll Over Protection Structure (ROPS) 3 Loadbay 4 Engine (below the loadbay) 5 Gearbox (below the loadbay) 6 Battery (below the loadbay) C100390-B1 Fig 1. C100790-B5 Fig 2.

Section 1 - General Information Introduction Identifying Your Machine 1-3 1-3 9813/0450-1 Identifying Your Machine Machine Identification Plate Your machine has an identification plate mounted as shown. The Product Identification Number (PIN), weight, engine power, year of manufacture and serial number of the machine are shown on the plate. Note: The machine model and build specification is indicated by the PIN. Refer to Typical Product Identification Number (PIN). If the engine is replaced by a new one, the serial number on the identification plate will be wrong. Either get a replacement identification plate from your JCB Dealer or simply remove the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered. The machine and engine serial numbers can help identify exactly the type of equipment you have. Fig 3. Position of Identification Plate Product Identification Number, PIN, ISO 10261 YEAR OF MANUFACTURE 817/18435 JCB COMPACT PRODUCTS LIMITED HAREWOOD ESTATE, LEEK ROAD, CHEADLE, STOKE ON TRENT, UNITED KINGDOM, ST10 2JU. ENGINE POWER kW @ RPM ISO 14396 WEIGHT kg, ISO 6016 TYPE

Section 1 - General Information Introduction Identifying Your Machine 1-4 1-4 9813/0450-1 Typical Product Identification Number Data Plate A - World Manufacturer Identification (3 Digits) B - Machine Model (5 Digits) C - Randomly Generated Check Letter (1 Digit) D - Year of Manufacture (1 Digit) E - Machine Serial Number (7 Digits) Each machine has a unique serial number. Component Identification Plates Typical Engine Identification Plate C100740 Fig 4. The plate is attached to the engine at G. K Fig 5. ( T 1-4) C100750 Fig 5. In addition to the plate at G, the engine model and serial number are stamped on flat pads on the left side of the crankcase Code A B C D E Example JCB B E 1629000 A = 2010 B = 2011 C = 2012 Engine Model 3TNM68A THIS ENGINE COMPLIES WITH USA EPA AND CALIFORNIA REGULATIONS FOR 2009 M.Y. AND STATIONARY/OFF ROAD DIESEL ENGINES 9YDXLO. 78V3N 0.784 3TN M68A EM

JCB Workmax 800D UTV OEM Service & Repair Manual

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