jcb 135 HD, Service Manual

 01 - Machine

 06 - About this Manual

 06 - Using the Manual

01 - 22

9813/4450-2

01 - 22

06 - Using the Manual
Introduction

Information  in  this  manual  conforms  to  a  standard

JCB service manual format. The format uses section

headings  taken  from  a  PIL  (Parts  Identification

List).  These  headings  are  assigned  numerical

identification references.

Table 1.

Example

Section

Main Assembly / Head-

ing

Component / Sub-head-

ing

PIL reference

33

03

03

Heading

Electrical System

Battery

Isolator Switch

Information  within  each  PIL  reference  is  included

under  a  set  of  standard  headings  such  as

Introduction, Health and Safety, Technical Data and

Operation  for  example.  Where  additional  relevant

information is contained within another PIL reference

a cross reference is provided.

The  main  systems  information  is  contained  in  the

manual as follows.

Table 2.

System

PIL Reference

Heading

Hydraulic System

30-00-50

Schematic Circuit

Electrical System

33-03-03

Battery - Isolator Switch

33-09-00

Power Distribution (including fuses

and relays)

33-00-50

Schematic Circuit

Electronic Diagnostic

33-57

Electronic Diagnostic (including

Servicemaster)

Machine Variants

Where information is different depending on machine

variant, the applicable information sets are included

within  the  same  PIL  reference.  Headings  are

included  to  identify  which  information  is  for  which

variant. Make sure you use the correct information.

Diagnostics

Information  in  this  manual  can  help  you  diagnose

machine faults.

Before attempting to diagnose possible faults check

the following.

•

Ensure  that  the  operator  understands  the

machine controls, functions and use. Refer to

the applicable Operator Manual.

•

Check  that  the  maintenance  record  complies

with the applicable schedule for the operating

environment. Refer to PIL 78-24.

•

Check  that  the  fluids  in  use  comply  with  the

standards specified. Refer to PIL 75-00.

•

Ensure  that  the  machine  electronic  set-up  is

applicable.  Use  the  applicable  Servicemaster

vehicle set-up tool. Refer to PIL 33-57-03.

•

Use the applicable Servicemaster diagnostics

tools. Refer to PIL 33-57-03.

Torque Tightening

When you replace components, always tighten the

applicable fixings to the correct torque value. Use the

torque tightening values contained in the individual

procedures (Remove and Install, Disassemble and

Assemble  etc.).  If  no  torque  values  are  specified,

use  the  standard  torque  tightening  values.  Refer

to  Fasteners  and  Fixings,  Screws,  Bolts,  Nuts,

Technical Data (PIL 72-00). For the torque setting to

be effective, do the following before you install the

fixings.

•

Make  sure  that  all  the  applicable  component

assemblies are correct.

•

Make sure that the applicable fixings are to the

correct  specification.  If  necessary  discard  the

original fixings and replace them with new ones.

The relevant procedures indicate when this is

necessary.

•

Make  sure  that  the  applicable  fixings  and

threaded  holes  are  free  from  contamination.

This  includes  dirt,  debris,  old  sealants  and

compounds, fluids and lubricants.