Section 3 Routine Maintenance Section 3

i i

Contents Page No.

Fluids, Lubricants, Capacities and Specifications 1-1

Torque Settings 1-2

Table of Important Torque Settings 1-2

Hydraulic Fittings and Torque Settings 1-3

Fuel System 1-4

Bleeding the System 1-5

Coolant Mixtures 1-6

Service Schedules 2-1

Greasing 3-1

Hydraulic Fluid Level 4-1

Track Gearbox 5-1

Tracks and Running Gear 5-2

9803/9300 Issue 1
Section 3 Routine Maintenance Section 3
1-1 Fluids, Lubricants, Capacities and Specifications 1-1

Note: New engines DO NOT require a running-in period. The engine 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).

ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL

Litres (UK Gal)[US Gal] SPECIFICATION

Fuel Tank 43.0 (11.4) [13.7] Diesel oil ASTM D975-66T Nos. 1D, 2D

Engine (Oil) 4.5 (1.0) [1.2] JCB Extreme Performance 15W/40 CH4/SJ (ACEA E5-B3-A3)
-10 °C to 50 °C (14 °F to 122 °F)

Engine (Coolant)
Canopy 6.5 (1.4) [1.7] JCB Four Seasons Antifreeze ASTM D3306-74
Cab 8.0 (1.5) [1.8] and Summer Coolant (See Coolant Mixtures)

Track Motor
(each)
8027Z 0.7 (0.154) [0.18] JCB SAE 30 CD Engine Oil API CD/SF, MIL-L-46152B
8032Z 0.8 (0.176) [0.21] (NOT Multigrade) MIL-L-2104B

Slew Gearbox
Lubrication Lubricated from hydraulic system

Hydraulic Tank
8027Z 58.0 (12.7) [15.3] JCB Special Hydraulic Fluid
8032Z 58.0 (12.7) [15.3] up to 86° F (30° C)
JCB Hydraulic fluid 46
above 86° F (30° C)

ITEM FLUID/LUBRICANT INTERNATIONAL SPECIFICATION

Swing Ring Bearings JCB MPL Grease Lithium based no 2 consistency

Swing Ring Gear Teeth JCB Slew Pinion Grease
All Other Grease Points JCB MPL Grease Lithium based no 2 consistency

9803/9300 Issue 2
 Section 3 Routine Maintenance Section 3
1-2 Torque Settings 1-2

Only use following when no setting is specified in text of manual.

CAUTION: All bolts used on JCB equipment are high tensile and must not under any circumstances be replaced with bolts of
a lesser tensile specification.

Metric Grade 8.8 Bolts

Bolt Size Hexagon (A/F) Torque settings

(mm) mm Nm kgf m lbf ft

M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105

Table of Important Tightening Torques

Tightening Points Tightening Torque
Nm kgf m lbf ft

Track roller 244 25 180

Idler yoke 98 10 72
Rotary coupling mounting 56 5.7 41
Slew ring 160 12.3 89
* Slew gearbox mounting 395 40 292
* Hydraulic Pump 98 10 72
Hydraulic oil tank 56 5.7 41
Fuel tank 56 5.7 41
Rod end - controls 56 5.7 41
Silencer bolt 28 3.0 21
Exhaust tail pipe 28 5.7 41
Engine shock absorber (to slew frame) 56 5.7 41
Engine shock absorber (to engine) 98 10 72
Engine bracket 118 12 87
Engine bell housing 56 10 72
Counterweight 240 10 72
Slew ring to superstructure 160 16.3 118

Rams: See section E

Valve Block: See section E

Track Motor

Motor to undercarriage bolts 98 10 72

* Drive sprocket to motor bolts 113 11.5 83

Pump Drive Coupling 98 10 72

9803/9300 Issue 2*
Section 3 Routine Maintenance Section 3
1-3 Hydraulic Fittings and Torque Settings 1-3

Adapters screwed to valve blocks etc. seal onto an O-ring which is compressed into a 45º seal machined in the face of the
tapped port.

ADAPTER

SAE SAE Port A/F Tightening Torque

Tube Size Thread Size mm in Nm * lbf ft

4 7/16 - 20 15.9 0.625 20 - 28 15 - 21

6 9/16 - 18 19.1 0.750 46 - 54 34 - 40
8 3/4 - 16 22.2 0.875 95 - 105 70 - 77
10 7/8 - 14 27.0 1.063 130 - 140 96 - 103
12 1.1/16 - 12 31.8 1.250 190 - 210 141 - 155
16 1.5/16 - 12 38.1 1.500 290 - 310 216 - 230
20 1.5/8 - 12 47.6 1.875 280 - 380 210 - 280

FITTING

Tightening Torque
Hose Size Nm * lbf ft Common Spanner Sizes

1/8” BSP 14 10 14 mm
1/4” BSP 27 20 19 mm
3/8” BSP 40 30 22 mm
1/2” BSP 55 40 27 mm
5/8” BSP 65 48 30 mm
3/4” BSP 95 70 32 mm
1” BSP 120 89 38 mm
1-1/4” BSP 189 140
1-1/2” BSP 244 180 .

9803/9300 Issue 2*
Section 3 Routine Maintenance Section 3
1-4 Fuel System 1-4

Types of Fuel Fuel Standards

Use good quality diesel fuel to get the correct power and Consult your fuel supplier, JCB distributor or Perkins dealer
performance from your engine. The recommended fuel about the suitability of any fuel you are unsure of.
specification for Perkins engines is given below.
Low Temperature Fuels
Cetane Number: 45(minimum) Special winter fuels may be available for engine operation at
Viscosity: 2.5/4.5 centistokes at 40 °C(104 °F) temperatures below 0 °C (32 °F). These fuels have a lower
Density: 0.835/0.855 kg/litre viscosity. They also limit wax formation in the fuel at low
(0.872/0.904 lb./pint) temperatures. (Wax forming in the fuel can stop the fuel
Sulphur: 0.5% of mass (maximum) flowing through the filter).
Distillation: 85% at 350 °C (662 °F)
Flow improvers may also be available. These can be added
Cetane Number to the fuel to reduce wax formation.
Indicates ignition performance. Fuel with a low cetane
number can cause cold start problems and affect Petrol
combustion
!WARNING
Viscosity
Do not use petrol in this machine. Do not mix petrol with
Is the resistance to flow. If this is outside limits, the engine
the diesel fuel. In storage tanks the petrol could rise to
performance can be affected.
the top and form flammable vapours.
INT3-1-6
Density
Lower power will reduce engine power. Higher density will
Advice
increase both engine power and exhaust smoke.
If you have to use nonstandard fuels, contact your JCB
distributor for advice on engine adjustments and oil change
Sulphur
periods.
High sulphur content can cause engine wear, (High sulphur
fuel is not normally found in North America, Europe or
Australia). If you have to use high sulphur fuel you must also !WARNING
use a highly alkaline engine lubricating oil: or change the Diesel fuel is flammable; keep naked flames away from
normal oil more frequently. the machine. Do not smoke while refuelling the machine
or working on the engine. Do not refuel with the engine
Distillation running. There could be a fire and injury if you do follow
This indicates the mixture of different hydrocarbons in the these precautions
fuel. A high ratio of lightweight hydrocarbons can affect the INT3-2-2

combustion characteristics.

9803/9300 Issue 1
Section 3 Routine Maintenance Section 3
1-5 Fuel System 1-5

Bleeding the System

!WARNING 3 The fuel injection pump is self bleeding as the engine is

Air in the fuel system can cause misfiring or failure to cranked.
start. Air will enter the system if any part of it is
disconnected or emptied. !WARNING
When you turn the engine to bleed the fuel lines, do not
!WARNING operate any of the hydraulic control levers.
To bleed the air from the system, the engine must be
turning. When the engine is turning, there are parts 4 Loosen the unions at C, D and E. If you are working
rotating in the engine compartment. Before starting this with an assistant warn him that you are about to turn
job, make sure you have no loose clothing (cuffs, ties the engine.
etc.) which could get caught in rotating parts.
5 Open the throttle a little and turn the starter key to
1 Raise the engine cover. rotate the engine.

2 To bleed air from the filter, slacken bleed screw A. 6 When air-free fuel flows from all three points, tighten the
Operate fuel priming bulb B until air-free fuel flows from unions.
the union.

B D
C

A390960

9803/9300 Issue 1
Section 3 Routine Maintenance Section 3
1-6 Coolant Mixtures 1-6

The protection provided by JCB Universal Antifreeze is

shown below. If any other antifreeze is used, refer to the
manufacturers' instructions and ensure that a corrosion
inhibitor is included.

DO NOT use solutions of more than 60% or less than 50%

or damage to the cooling system will occur.

Solution Maintains circulation Protects

down to against damage
down to

°C °F °C °F

55% - 36 - 33 -41 -42

The strength of the antifreeze solution must be checked at

least once a year, preferably at the beginning of the cold
period.

It is an advantage to leave the antifreeze in all the year round

as it gives continued protection against corrosion. Always
renew the antifreeze every two years.

A 50% antifreeze mixture must be used even if frost

protection is not needed. This gives protection against
corrosion and raises the coolant's boiling point.

Note: In climates where antifreeze is not necessary, a

reputable inhibitor must be used. Renew the mixture every 6
months.

!WARNING
Antifreeze can be harmful. Obey the manufacturers
instructions when handling neat or diluted antifreeze.
7-3-4-4

9803/9300 Issue 1
Section 3 Routine Maintenance Section 3
2-1 Service Schedules 2-1

Every 50 operating hours (or weekly) Every 250 operating hours (or monthly)
whichever occurs first whichever occurs first
Do the daily jobs plus: Do the daily jobs through to 100 hours plus:

Clean Change

1 Drain and clean fuel filter/sedimenter 1 Fuel in-line pre filter

2 Radiator matrix and oil cooler matrix
Grease
Check and adjust where necessary (engine stopped)
2 Slew ring grease nipples
3 Fan belt adjustment

Every 500 operating hours (or 6 months)

Every 100 operating hours (or 2 weeks) whichever occurs first
whichever occurs first
Do the daily jobs through to 250 hours plus:
Do the daily jobs through to 50 hours plus:
Clean
Clean
1 Fuel lift pump
1 Battery terminals 2* Fuel injectors (and test)
3 Engine oil and filter cannister
Check and adjust where necessary (engine stopped)
Change
2 Hose and pipework for security and damage
3 Condition of ram piston rods 4 Fuel filter element
4 All grease seals 5 Hydraulic fluid return filter element
5 Track, plate condition/rubber condition 6 Air cleaner element (in very dusty conditions only)
6 Engine mounting bolts 7 Engine oil and engine oil filter
7 Air cleaner hose security
8 Wiring for damage Check and adjust where necessary
9* Track tension (engine stopped)

Note: Jobs which should only be done by a specialist are 8 Exhaust system security
indicated by *. 9* Tighten cylinder head bolts
10* Adjust valve clearances
11 Engine mounting bolts
First 250 operating hours only 12 Track gearbox oil levels
Check and adjust where ncessary
Do the jobs listed in 250 hours (below) plus: (engine running)

1 Change track gearbox oil 13* Main relief valve pressure

14* Auxiliary relief valve pressure
15* Servo relief valve pressure
16* Cross line relief valve pressure
17* Engine idle speed

Note: Jobs which should only be done by a specialist are

indicated by *.

9803/9300 Issue 1
Section 3 Routine Maintenance Section 3
2-2 Service Schedules 2-2

Every 1000 operating hours (or yearly)

whichever occurs first
Do the daily jobs through to 500 hours plus:

Change

1 Air filter element (outer)

2* Idler wheel and track rollers oil and seal
3 Track gearbox oil

Check

4 Cab mountings (for security)

5 Check security of all bolts retaining major assemblies,
i.e. gearboxes (track and swing) slew ring, engine
mountings, rotary joints etc.
6* Check and clean filter adaptors fitted in pressure
maintenance valve
7 Check and clean air filter dust valve

Grease

8 Slew pinion and slew ring gear teeth

Every 2000 operating hours (or 2 years)

whichever occurs first
Do the daily jobs through to 1000 hours plus:

Change

1 Air filter element (inner)

2 Track gearbox oil
3* Hydraulic fluid and clean suction strainer
4 Engine coolant

Check (engine stopped)

5 Battery electrolyte level (low maintenance)

6* Valve clearance and lubrication
7* Starter motor and alternator brush gear
8* Inspect and renew the pump drive coupling

Note: Jobs which should only be done by a specialist are

indicated by *.

9803/9300 Issue 1
Section 3 Routine Maintenance Section 3
3-1 Greasing - Daily 3-1

! WARNING
You will be working close into the machine for these
jobs. Lower the attachments if possible. Remove the
starter key. This will prevent the engine being started.
8-3-1-3

You must grease the machine regularly to keep it working For the types of grease to use at each point, see the Fluids,
efficiently. Regular greasing will also lengthen the machine's Lubricants, Capacities and Specifications chart at the
working life. start of this section.
Do not mix different types of grease, keep them separate.
Greasing should be done with a grease gun. Normally two
strokes of the gun should be enough. Stop greasing when Note: Some optional attachments may need greasing more
fresh grease appears at the joint. often. See Optional Attachments.

9803/9300 Issue 1
Section 3 Routine Maintenance Section 3
3-2 Greasing 3-2

Every 250 Hours

Slew Ring Bearings
Ensure the slew ring is kept full of grease.

Locate the grease point on the slew ring side.

To ensure distribution of grease, use the following

procedure:

1 Grease in, using 4 strokes of the grease gun. Rotate

180°.

2 Grease in, using 4 strokes of the grease gun. Rotate

180°.

3 Grease in using 4 strokes of the grease gun.

9803/9300 Issue 1
Section 3 Routine Maintenance Section 3
3-3 Greasing 3-3

Greasing - every 1000 hours

Slew Ring Gear Teeth

! WARNING
JCB Slew Pinion Grease Is harmful as It contains
bitumen compounds 2811. Excessive contact may lead
to dermatitis or skin cancer. Always use a barrier cream
or wear gloves; wash contaminated skin thoroughly with
soap and water. In the event of eye contact,
Immediately wash with plenty of water and seek medical
advice.
8-1-1-2

! WARNING
A machine can sink Into soft ground. Never work under
a machine on soft ground.
INT-3-2-1

! WARNING
A machine can roll off jacks and crush you. Do not work
under a machine supported only by jacks.
MD-1-6-1

1 Raise machine and support the undercarriage.

2 Stop the engine and remove the starter key.

3 Remove the bolts A and plate B in the underside of the

undercarriage.

4 Apply the grease to the pinion using the applicator

(see Fluids, Lubricants and Capacities.)

5 Start the engine and rotate the main frame fully twice.

7 Stop the engine and remove the key.

8 Repeat step 4 as necessary. B

9 Refit the plate B and bolts A.

10 Lower the machine to the ground. A

A395120

9803/9300 Issue 1
Section 3 Routine Maintenance Section 3
4-1 Hydraulic Fluid Level 4-1

!WARNING
Fine jets of hydraulic oil at high pressure can penetrate
the skin. Do not use your fingers to check for leaks. Do
not put your face close to suspected leaks. Hold a piece
of cardboard close to suspected leaks, then inspect the
cardboard for evidence of hydraulic fluid. If hydraulic
fluid penetrates your skin, get medical help immediately.

Checking the fluid level

1 Park the machine on firm level ground and retract all
rams. Stop the engine and remove the starter key.

2 Gain access to the hydraulics bay, by opening the

engine bay cover A, and releasing the hydraulics bay
catch by pulling handle B.

3 Check the hydraulic sight gauge C, located in the

hydraulics bay, for correct level.

Adjusting the fluid level

1 Clean the area around the hydraulic tank filler cap D.
Remove the filler cap.

2 Add fluid until the level in the sight gauge is correct.

Ensure that only the correct grade of fluid is used. See
Lubricants and Capacities.

3 Refit the filler cap and close the hydraulic bay cover.

9803/9300 Issue 1
Section 3 Routine Maintenance Section 3
5-1 Track Gearbox 5-1

Check Level - For interval see Service Schedule Drain & Refill - For interval see Service Schedule

1 Position the machine on firm level ground. Ensure that 1 Position the machine on firm level ground.
the gearbox plugs A and B are positioned as shown.
Stop the engine and remove starter key. 2 Place a suitable container beneath the drain plug B to
collect the oil.
2 Clean the area around the fill/level plug A and remove
the plug, oil should be seen to be level with the hole. !CAUTION
Top up as necessary, for the correct oil see Lubricants
Oil will gush from the hole when the plug is removed. Keep
and Capacities at the end of the section. Clean and refit
to one side when you remove the drain plug.
the plug, make sure it is tight.
3 Remove level filler plug A. Remove the drain plug B.
Allow the oil to drain out. Wipe the drain plug clean.
Make sure that you remove all metal particles. Refit the
drain plug. Make sure it is tight.

4 Fill with new oil through the fill/level plug hole until oil
runs from the hole. For the correct oil to use see
Lubricants and Capacities.

5 Run the machine, operate the track controls and then

make sure there are no leaks.

9803/9300 Issue 1
Section 3 Routine Maintenance Section 3
5-2 Tracks and Running Gear 5-2

! WARNING 3 Remove the screws and the access plate. To tighten

Recoil servicing must only be carried out by JCB the track, pump grease (see Lubricants and
distributors. You could be killed or injured if you tamper Capacities) through nipple B in adjusting screw C until
with it. track tension is correct. Rotate track and re-check
dimension. To slacken the adjustment slacken
Checking the Track Tension adjusting screw C to allow grease to escape, until the
correct tension is achieved. Rotate the track and re-
1 Park the machine on level ground. Run it backwards check dimension. Replace and secure the access plate.
and forwards several times. Position the machine as Lower the track to the ground.
shown with the track to be tensioned raised from the
ground and the undercarriage supported.

2 Check that the tension measured at A is between 70

mm (2.8 in.) and 90 mm (3.6 in.) for a rubber track or
120 mm (4. 8in.) for a steel track.

! CAUTION
Always make sure that the track tension measurement is
not less than specified or severe strain to the track will
result.

A395180

9803/9300 Issue 1
Section A Optional Equipment Section A
i i

Contents Page No.

General Description 1-1

Options 1-1

9803/9300 Issue 1
Section A Optional Equipment Section A
1-1 1-1

General Description
This section lists the options available on the Mini excavators and, where appropriate, details the procedures necessary to
carry out the installation or conversions.

Options
Cab Working Lights
Twin roof-mounted working lights

Double Acting Auxiliary Pipework

Enables forward or reverse operation or various hydraulic attachments.

3CX Hand Controller Pattern

To change the standard ISO hand controller pattern to the 3CX pattern.

Radio Kit
Radio cassette, twin speakers and antenna.

Rubber or Steel Tracks

Refer to Section J, Track and Running Gear for removal and replacement of tracks.

9803/9300 Issue 1
Section B Body & Framework Section B
i i

Contents Page No.

General Description 1-1

Bucket Ram Pivot and Linkage

Removal and Replacement 2-1

Dipper
Removal and Replacement 3-1

Boom
Removal and Replacement 4-1

* Slew Ring
Removal and Replacement 5-1

Kingpost
Removal and Replacement 6-1

Glazing
Direct Glazing 8-1
Removing the Old Glass and Old Sealant 8-1
Preparing the Cab Frame Aperture 8-3
Preparing the New Glass 8-3
Installing the New Glass 8-5

9803/9300 Issue 2*
Section B Body & Framework Section B
1-1 General Description 1-1

The Mini-Excavator body and framework is of fabricated steel construction and comprises the upper structure and front
attachment. The upper structure comprises a fabricated steel base that provides housing and mounting for the machine
controls and services. The machine cab is mounted on the floorplate. The engine is mounted behind the cab. The front
attachment comprises a bucket, dipper and boom assembly attached to the front of the upper structure through a kingpost.
The front attachment is pivoted on the kingpost enabling movement right and left. The bucket dipper and boom are connected
through pivots enabling a full range of bucket, or other attachment operations

9803/9300 Issue 1
Section B Body & Framework Section B
2-1 Bucket Ram Pivot and Linkage 2-1

Removal and Replacement

Removal

1 Remove the bucket.

2 Remove the self-locking nut C and the bolt D.

Support the link H. Drive out the pivot pin E and
remove the link H. Lower the piston rod end of the
bucket ram F clear of the link G.

3 Clean all old grease from the links G and H and pivot
pin E.

Inspection

1 Check that the link bushes and the pivot pin are within
permitted tolerances. Renew pivot pin and/or remove
and replace link bushes as necessary.

Tolerances - Pivot Pin/Pivot Bush

Pin Bush

Reference value 30 mm dia. 30 mm I/D

Allowable limit 29 mm dia. 31 mm I/D

Replacement

! WARNING
DO NOT align pivot pin holes with your fingers.

1 Locate the fork end of the link H into the fork of the
dipper end link G. Locate the rod end of the bucket ram
F into the fork of the link H.

2 Fit the pivot pin E through both links and the ram end.
Secure using bolt D and new self-locking nut C.

3 Grease the linkage through the grease nipple on the

ram end boss, for grease specification and quantity see
Greasing in Routine Maintenance.

9803/9300 Issue 1
Section B Body & Framework Section B
3-1 Dipper 3-1

Removal and Replacement

Removal

1 Remove the bucket. B

C
2 If necessary remove the bucket ram.

E D
3 Remove the locknut A and bolt B. Drive out the dipper
ram pivot pin C. Separate the dipper ram eye end D
from the dipper pivot E. Position a block of timber on A
which to rest the dipper ram eye end.

4 Attach suitable lifting equipment through the dipper ram

pivot pin location and support the dipper J.

5 Remove the locknut F and the bolt G. Drive out the

pivot pin H.

6 Using suitable lifting equipment, remove the dipper G

from the machine.
H
Inspection

1 Check that the dipper pivot bushes and the pivot pin
are within permitted tolerances. Renew pivot pin and/or
remove and replace dipper pivot bushes as necessary. F
J
Tolerances

Pivot pin Pivot bush

Reference value 30 mm dia. 30 mm I/D
Allowable limit 29 mm dia. 31 mm I/D

Overall Length Weight

8027Z 1100 mm 51 kg
8032Z 1250 mm 58 kg

Replacement
A395430
1 Using suitable lifting equipment, locate the dipper J
onto the boom.

2 Fit the pivot pin H and secure with bolt G and a new
locknut F.

3 Locate the dipper ram end D into the dipper pivot E. Fit
the pivot pin C and secure with the bolt B and new
locknut A.

4 Fit the bucket ram.

5 Fit the bucket.

9803/9300 Issue 1
Section B Body & Framework Section B
4-1 Boom 4-1

Removal and Replacement

Removal Replacement

1 Remove the bucket, bucket link and dipper. Note: The boom weighs 92 kg.

2 Remove the dipper and boom rams. 1 Using suitable lifting equipment, locate the boom A
onto the kingpost.
3 Disconnect the hydraulic hoses at the base of the
boom. Blank off the open ends of hoses and pipes. 2 Fit the pivot pin D and secure with the bolt C and a
new locknut B.
4 Disconnect the boom working light harness.
3 Fit the dipper and boom rams.
Note: The boom weighs 92 kg.
4 Fit the dipper, bucket link and bucket.
5 Attach suitable lifting equipment to the boom A and
take up the slack. 5 Remove the blanks and connect the hydraulic hoses at
the base of the dipper.
6 Remove the locknut B. Remove the bolt C and drive out
the pivot pin D. Remove the boom from the kingpost 6 Restore the hydraulic supply and set up the hydraulic
circuit.
Inspection
7 Connect the boom working lights.
1 Check that the boom pivot bushes and the pivot pin are
within permitted tolerances. Renew pivot pin and/or
boom pivot bushes as necessary.

Tolerances

Pivot Pin Pivot Bush

Reference value 30 mm dia. 30 mm I/D
Allowable limit 29 mm dia. 31 mm I/D

2 Examine the boom structure for wear, damage or

corrosion. Renew as necessary.

D C

A395520

9803/9300 Issue 1
 Section B Body & Framework Section B
5-1 * Slew Ring 5-1

* Removal and Replacement

* Removal

*1 Depending upon lifting equipmenet that is available and 12 Disconnect the instrument panel electrical cables.
the consequential requirement to maintain balance,
remove the excavator assembly if required. 13 Remove the slew motor.

2 Disconnect the interior light and windscreen wiper 13 Remove the hydraulic hoses from the rotary coupling.
motor in the cab/canopy structure. Disconnect the
earth lead and remove the cab. 14 Attach lifting equipment to the upper structure frame.
Remove the bolts A securing the upper structure frame
3 Remove the cab/canopy floor. to the slew ring. Lift the upper structure frame clear of
the machine. Take care not to foul the rotary coupling.
4 Disconnect all electrical cables and hydraulic pipes to (There is a small ‘cut-out’ in the upperstructure to allow
the hand controllers. for the reaction pin on the coupling. Take care that
there is no fouling during removal.)
5 Remove the seat/seat base with dozer lever.
15 Remove the rotary coupling, if necessary.
6 Remove the rear bulkhead. Drain and remove the fuel
tank. 16 Remove the bolts B securing the slew ring C to the
machine undercarriage.
*7 Remove the engine.
17 Remove the slew ring from the machine.
8 Drain the hydraulic system. Remove the hydraulic
pipework. * Replacement

*9 Remove the hydraulic tank. * Replacement is the reverse of the removal procedure. When
installing the slew ring, ensure that the ‘soft spot’ (marked
* 10 Remove the valve block. ‘S’) is towards the right-hand side of the machine.

* 11 Remove the side bulkhead. When installing the upperstructure, be aware of the cut-out
referred to in step 14 above.

* Torque Settings
Item Nm kgf m lbf ft
A 160 16.3 118
B 160 16.3 118

9803/9300 Issue 2*
Section B Body & Framework Section B
6-1 Kingpost 6-1

9803/9300 Issue 1
Section B Body & Framework Section B
6-2 Kingpost 6-2

Removal and Replacement

Removal Replacement

1 Remove the boom, ensure the boom working light is Before mounting the kingpost onto the machine, check the
disconnected. condition of bushes L and M. Renew if necessary.

2 Remove both outer hose clamps A. 1 Clean paint and loose scale from the pin abutment
areas on both the upper and lower kingpost pivot pins
3 Remove the the central hose clamp plate B. and from the kingpost abutment areas.

4 Remove the swing ram keep plate C and drive out the 2 Using suitable lifting equipment, locate the kingpost
rod side pivot pin D. onto the mainframe, threading the hoses through the
centre of the kingpost.
! WARNING
Note: Ensure that thrust washers L and M are returned to
The kingpost weighs 42 kg (93 lb). Take care when lifting
their correct positions.
or handling it.
3 Fit both the lower and upper pivot pins,ensuring that
5 Support the weight of the kingpost with suitable lifting
the slots in the pins are aligned correctly for mounting
equipment.
plates E and G. Bolt mounting plates E and G into
position.
6 Remove mounting plate E, then drive out the upper
pivot pin F in a downward movement, avoiding contact
4 Fit the swing ram pivot pin and secure with the keep
with the hydraulic hoses.
plate C.
7 Remove the mounting plate G.
5 Arrange the boom hoses in the central kingpost clamp
and fit plate B.
8 Drive out lower pivot pin H in an upward movement,
avoiding contact with the hydraulic hoses.
6 Fit both the outer hose clamps.
9 Carefully lift the kingpost away from the machine.
Remove and retain thrust washers J and K. 7 Fit the boom and working light.

9803/9300 Issue 1
 Section B Body & Framework Section B
8-1 Glazing 8-1

* !WARNING Removing the Broken Glass and Old Sealant

These instructions assume that the engineer has a
sound knowledge of safety procedures and has A toughened pane will shatter and fall apart.
been trained in the maintenance and repair of JCB
equipment. If you are unsure or do not understand !WARNING
the information contained then ask your supervisor Always wear safety glasses when removing or
or contact JCB Service for advice. installing screen glass. Never use a power
operated knife when removing the sealant around
Remember SAFETY MUST COME FIRST. a toughened glass screen. The action of the knife
could cause particles of glass to be thrown with
Direct Glazing sufficient force to cause serious injury, even when
safety glasses are being worn. Use only hand
The following procedures explain correctly how to operated tools when working with toughened
remove and install panes of glass that are directly glass.
bonded to the cab frame apertures. When carrying out BF 2-311
the procedures, relevant safety precautions must be
taken: 1 Position the machine on level ground, vent the
hydraulics. Stop the engine. Put protective covers
over the cab seat and control pedestals.
!WARNING
1 Always wear safety glasses during both 2 Remove as much of the shattered glass as
removal and replacement of glass. possible prior to cutting out the old sealant.

2 Use protective gloves - heavy duty leather 3 Cut out the old sealant, leaving approximately 1 to
gauntlet type gloves when cutting out the 2 mm on the cab frame. There are several tools
broken glass; ‘non-slip’ type gloves when and techniques for doing this:
handling/moving panes of glass; surgical type
gloves when using the polyurethane adhesives. a Pneumatic Knife (see fig 1) provides one of the
easiest methods of removing the sealant
3 Wear protective overalls. around laminated glass. The tool, powered by
compressed air, should be sourced locally.
4 DO NOT smoke - the activators and primers
used in the procedures are highly flammable.

5 Do not attempt to handle or move panes of

glass unless you are using glass lifters.
A
Several special tools are required to complete the
removal and replacement procedures successfully.
Reference is made to the tools in the text. The majority
of these tools can be obtained locally and the
remainder from JCB Service.
Fig 1
The work must only be carried out in a dry, frost free
environment. A protective canopy may be required or
the machine/frame must be moved to a sheltered
area. In damp or wet conditions, hinged doors and Note: This tool must not be used on toughened glass
window frames can be removed from the machine and (see WARNING).
taken to a more suitable (dry) environment.
(i) Press the handle to start the knife blade
Glass should not be replaced at temperatures below oscillating.
50O C (41O F).
(ii) Insert the knife blade into the sealant.

(ii) Slowly move the knife along the sealant with

the blade positioned as close to the glass as
possible. Do not allow the knife blade to
overheat or the sealant will melt.

9803/9300 Issue 2*
Section B Body & Framework Section B
8-2 Glazing 8-2

b Braided Cutting Wire and Handles B. This c Cut-out Knife F. The cut-out knife can be used
method uses a 3-core wire, a wire starter tube as a left handed or right handed tool,
and two handles (see fig. 2). (see fig. 4).

Fig. 4
Fig. 2

(i) Insert the steel tube C into the old sealant on (i) Insert the knife blade into the sealant.
the inside of the glass, (see fig. 3)
(ii) Make sure that the blade of the knife is against
the glass as shown at G (see fig. 4).

(iii) Use the ’pull-handle’ to pull the knife along and

cut out the old sealant.

d Craft Knife H. The blades are replaceable,

(see fig. 5).

Fig. 3

(ii) Insert the braided cutting wire D down the centre

of the steel tube. If necessary, from the outside,
cut out local sealant at the point of the tube to
gainaccess to the wire.

(iii) Using suitable pliers, pull the cutting wire

through the sealant to the outer side of the glass.

(iv) Secure each end of the braided cutting wire in Fig. 5

the special handles E.
(i) Insert the knife blade into the sealant.
(v) Move the cutting wire backwards and forwards
in a sawing motion and at the same time gently (ii) Pull the knife along and cut out the old sealant.
push or pull the wire to cut through the old
sealant. Note: There are other tools available to cut out the old
sealant. For example, there is a long handle type craft
knife to give extended reach.

9803/9300 Issue 1
Section B Body & Framework Section B
8-3 Glazing 8-3

4 Remove the cut off sealant and all remaining b Install the new glass on the spacer blocks
particles of shattered glass. - ALWAYS USE GLASS LIFTERS M. Check that
there is an equal sized gap all round the edge
5 If necessary, trim off the remaining old sealant to of the glass.
leave approximately 1 to 2 mm on the upright face
of the cab frame aperture, as shown at J. Note: The spacer blocks are rectangular in section to
give two common gap widths. If necessary they can be
trimmed to a smaller size to give an equal sized gap
around the glass.

CAUTION

The glass edges MUST NOT touch the frame,

otherwise movement of the frame will chip
and eventually break the newly installed glass.

Fig. 6

6 Apply a coat of ‘Black Primer 206J’ to the paintwork

if:

a Paintwork was damaged or scratched during

the glass/sealant removal procedures.

b The old sealant was inadvertently cut back to

the cab frame during the glass/sealant removal
procedures.

Preparing the Cab Frame Aperture

1 If damp or wet, dry the aperture area using a hot air

gun (sourced locally).
Fig. 7
2 Use ’Active Wipe 205’ to thoroughly clean and
‘prime’ the trimmed sealant. Use a lint free cloth to 2 After checking for size, remove the new glass and
apply the ‘Active Wipe 205’, allow 5 minutes flash place it on a purpose made glass stand N.
off (drying) time.

Note: Do not use any other type of cleaning fluids, oth-

erwise they may be absorbed into the old sealant and
ultimately prevent the new glass from bonding.

Preparing the New Glass

1 Make sure that the new glass correctly fits the frame
aperture K.

a Put two spacer blocks L onto the bottom part

of the frame aperture.

Fig. 8

9803/9300 Issue 1
Section B Body & Framework Section B
8-4 Glazing 8-4

Small panes of glass will need locating on a thick Install the Ultra Fast Adhesive cartridge into a
plywood board P. It is recommended that an access suitable applicator gun:
hole is cut in the board to accommodate the glass lifter,
making it easier and safer to handle small panes of glass. a Remove the aluminium disc cover from the base
The board should be covered with felt or carpet to give of the cartridge and discard the ‘desiccant
an anti-scratch surface. Resting the glass on four spacer capsule’.
blocks will ensure clearance of the cartridge nozzle tip
during application of the polyurethane sealant. b Make sure that the rolled edge of the cartridge
is ot damaged - if necessary, the edges should
be pressed flat, otherwise it will be difficult to
remove the cartridge from the applicator gun.

c Pierce the front ‘nozzle’ end of the cartridge to

its maximum diameter.

d Fit the pre-cut nozzle shown at S.

· Install the cartridge in the applicator gun.

Fig. 8

3 Make sure the glass is positioned on the stand the

correct way up (i.e. with the black ceramic ink band
upwards) ready for application of primer etc.

4 a Use ’ActiveWipe205’ to thoroughly clean and

’prime’ the black ceramic ink band printed on
the glass (see Note 1). Use a lint free cloth to
apply the ’Active Wipe 205', allow 5 minutes Fig. 11
flash off (drying) time.
Note 2: Cold material will be very difficult to extrude.
Note 1: Do not touch the glass after cleaning with the The cartridges must be pre-heated in a special oven for
‘Active Wipe 205’. 1 hour to a temperature of 80OC (176OF). Preheating
the cartridges makes the adhesive more workable and
b If the glass does not have a black ceramic ink also brings the ’curing’ time down to 30 minutes.
band, paint a band on the glass using ‘Black
Primer 206J’. The band should be approximately
25mm (l in) wide, and the edge should be a
neat straight line as shown at R.

Fig. 12

6 Apply the pre-heated adhesive to the glass (do not

Fig. 10 start in a corner). Keep the nozzle guide T against
the edge of the glass and make sure that the
adhesive forms a continuous ’pyramid’ shape.

9803/9300 Issue 1
Section B Body & Framework Section B
8-5 Glazing 8-5

Note 3: Once the pre-heated adhesive has been ap- 3 Make the inside seal smooth:
plied to the glass, install the glass in the aperture as
soon as possible. After approximately 10 minutes the a Wearing surgical gloves, dip your finger in a
sealant will form a ’skin’, this will prevent the glass from soapy water solution.
bonding.
b Use your finger to make the inside seal smooth.
7 After applying the adhesive, leave a small amount
of sealant protruding from the nozzle. This will 4 All exposed edges must be sealed using Black
prevent any adhesive left in the cartridge from Polyurethane Sealant.
‘curing’.
· Clean the glass after installation:
Installing the New Glass
CAUTION
1 Make sure the two spacer blocks are in position
(see step 1 of Preparing the New Glass).
Use extreme caution when wiping the inside of the
2 Install the glass in the frame aperture: new glass - pushing too hard on the inside of the
glass will affect the integrity of the bonded seal.
a ALWAYS use the special lifting tools when
moving the glass. a Small amounts of sealant can be cleaned from
the glass using the ’Active Wipe 205'.
b Sit the bottom edge of the glass on the spacer
blocks as shown X. b Large amounts of excess sealant should be left
to ‘cure’ (see Note 4) and then cut off with a
sharp knife.

Note 4: On completion of the glass replacement

procedures, the sealant ‘curing’ time is 30 minutes. This
means that the machine can be driven and used after
30 minutes, but it MUST NOT be used during the curing
period of 30 minutes.

c Clean the glass using a purpose made glass

cleaner.

6 On completion of the glass installation procedures

tidy the work area:

a Remove ALL broken glass from the cab area,

b Remove the protective covers from the cab seat

and control pedestals.
Fig. 13
c Renew all ‘warning’ and ‘information’ decals so
c Make sure that the glass is correctly positioned, that the new installation conforms with the
then gently press around the edges of the glass original cab installation.
and ensure full adhesive contact is achieved.
Do not press too hard or too much adhesive
will squeeze out.

9803/9300 Issue 1
Section C Electrics Section C
i i

Contents Page No.

Technical Data 1-1

Battery 2-1

Fan Belt 3-1

Alternator 4-1

Starter Motor 5-1

Beacon 8-1

Circuit Diagram 10 - 1

Wiring Harnesses
- Main Harness 11 - 1
- Cab Harness 11 - 2
- Canopy Harness 11 - 3
- Boom Light Harness 11 - 4

* Harness Connections 12 - 1

9803/9300 Issue 2*
Section C Electrics Section C
1-1 Technical Data 1-1

System Type 12 Volt negative earth

Battery Type 058

Voltage 12 V
Capacity 75 Ampere/hour (Wet charged)
60 Ampere/hour (Dry charged)
Specific Gravity (fully charged) Between 1.285 and 1.310 at 15 °C (60 °F)

Starter Motor 2.0 kW

Alternator (Type A127/55A)

Nominal Output 12 Volts, 55 Amp
Polarity Negative earth

Fuses

The electrical circuits are protected by fuses. If a fuse blows, 1

find out why before fitting a new one.
2
The secondary fuses are located in the toolbox under the
3
seat. The primary fuse is located in the battery
compartment, below the cab door. 4
5
Rating
6
Primary Fuse 80 A 7
Secondary Fuse Circuit Rating
A390640
1 Instruments, Engine stop solenoid,
Two-speed circuit, Servo solenoid. 7.5 A
2 Wash/Wipe circuit 15 A
3 Slew/Swing circuit, SAE control, Heater Blower 15 A
4 Boom light 7.5 A
5 Work lights 15 A
6 Interior light, Horn, Radio,
Accessory Power Socket 15 A
7 Beacon 10 A

! CAUTION
Always replace fuses with ones of the correct Ampere
rating to avoid damage to the electrical system.

Bulbs
Rating 378020

Cab lights 10 W
Work lights 55 W
Beacon 55 W

9803/9300 Issue 1
Section C Electrics Section C
2-1 Battery 2-1

Negative Earth Electrical System High Rate Discharge Test

1 Always connect the negative terminal of the battery to This test is to determine the electrical condition of the
EARTH. battery and to give an indication of the remaining useful ‘life’
2 When connecting the battery, connect the earth lead
LAST. Before testing, ensure that the battery is at least 75%
3 When disconnecting the battery, disconnect the earth charged.
lead FIRST.
1 Disconnect both terminals of the battery.
Inspection
2 Adjust the discharge tester to 3 x Amp/hour rating of
Check the level of the electrolyte (low maintenance). Make the battery.
sure that the terminals are tight and clean. Coat them with
petroleum jelly to prevent corrosion. 3 Connect the tester to the battery terminals, observing
the polarity.
Testing the Specific Gravity
4 Note the voltmeter reading. The battery should be
The specific gravity of the electrolyte gives an indication of capable of maintaining at least 9 Volts for 10 seconds.
the state of charge of the battery. Readings should be taken A rapidly falling voltage indicates a fault in one or more
using a hydrometer, when the electrolyte temperature is of the battery cells.
15 °C (60 °F). If the battery has recently been charged, wait
approximately one hour, to dissipate the ‘surface charge’ Note: Do not leave the discharge tester connected to the
before testing. battery for longer than is necessary to complete the test.

Readings should not vary between cells by more than 0.04.

A greater variation indicates an internal fault on that
particular cell.

If the electrolyte temperature is other than 15 °C (60 °F) a

'correction factor’ must be applied to the reading obtained.
Add 0.0007 per 1 °C higher than 15 °C, and subtract the
same if the temperature is lower.

9803/9300 Issue 1
Section C Electrics Section C
3-1 Fan Belt 3-1

Removing, Inspection and Fitting

Removing Fitting

1 Park the machine on firm, level ground and remove the 1 Install the fan belt so that it passes around the fan,
starter key. crankshaft, water pump and alternator pulleys.

2 Remove the seat. 2 Use a wooden lever and move the alternator away from
the engine block. Apply pressure at the drive end
3 Remove the bulkhead access plate. bracket only.

! WARNING 3 Adjust the position of the alternator, so that when the

Make sure that the engine cannot be started. belt is depressed at the mid-point C between the
Disconnect the battery. Disconnect the earth lead first. crankshaft and alternator pulleys, the deflection is 5 mm
ENG 6-3 (0.2 in). Use a finger force of approximately 10 N (1 kgf,
0.51 lbf) for this check.
4 Loosen the alternator mounting bolts A and the
adjusting bolt B. 4 Tighten the mounting bolts A and the adjusting bolt B.

5 Move the alternator towards the engine block. 5 Reconnect the battery. Connect the earth lead last.

6 Remove the fan belt from the alternator pulley, water

pump pulley and the crankshaft pulley.

7 Remove the fan belt over the fan.

Inspection

1 Examine the fan belt and pulleys for damage. Renew as

necessary.

D
C

9803/9300 Issue 1
Section C Electrics Section C
4-1 Alternator 4-1

Removing and Fitting

Removing Fitting

1 Raise the engine cover. 1 Put the alternator in position and align with the fan belt.

2 Remove the interior access panel. 2 Fit the mounting nut A and bolt B and the adjusting
bolts C.
3 Disconnect the battery. Disconnect the earth lead
first. 3 Adjust the fan belt tension (see Fan Belt), and tighten
the mounting nut A and bolt B, and the adjusting bolt
4 Disconnect the electrical connections. C.

5 Support the alternator and remove the mounting nut A 4 Connect the electrical connections.
and bolt B.
5 Reconnect the battery. Connect the earth load last.
6 Remove the adjusting bolt C.
6 Refit the interior access panel.
7 Remove the alternator.
7 Close the engine cover.

9803/9300 Issue 1
Section C Electrics Section C
5-1 Starter Motor 5-1

Removing and Fitting

Removing

1 Remove the seat.

2 Remove the bulkhead access plate.

3 Disconnect the battery. Disconnect the earth lead

first.

4 Disconnect the starter electrical connections.

5 Support the starter motor A, loosen and remove the

securing bolts B.

6 Disengage the pinion from the flywheel gear teeth and

remove the starter motor.

Fitting

1 Put the starter motor in position and align the pinion in

the flywheel gear teeth.

2 Fit and tighten the securing bolts B.

3 Connect the electrical connections.

4 Connect the battery terminals. Connect the earth

terminal last.

5 Refit the bulkhead access plate.

6 Refit the seat.

9803/9300 Issue 1
Section C Electrics Section C
8-1 Beacon 8-1

Mounting
The rotating beacon relies on the force of a magnet to hold it
in position on the machine. A cable and plug from the
beacon fits into a socket located on a panel in the cab of the
machine. The panel is wired to provide a beacon operating
switch and warning light.

The intended beacon mounting position must be flat, clean

and dry. When mounted, particularly ensure beacon
positioning conforms to the following:
- Is in accordance with National and local legal
requirements.
- The light is visible from any point at a reasonable
distance from the machine.
- Beacon base parallel to the ground and on the
machine longitudinal centre line.
- If radio equipment is fitted to the machine, there
should be a minimum distance of 500 mm (20 in)
between the beacon and the radio antenna.

! CAUTION
The beacon must be removed before the machine is
towed or loaded onto a trailer for towing. The beacon
must not be fitted if the machine is moved at speeds
exceeding 80 kph (50 mph).

Bulb Change

1 Remove the lens latch locking screw A.

2 Push down the lens latch B. Turn lens C anti-clockwise

to release and remove it.

3 Taking care not to touch the bulb glass, release the bulb
retaining clip D and lift bulb E and attached clip from the
connector F. Disconnect bulb E.

4 Remove the unserviceable bulb from clip D.

5 Fit a new bulb and assemble the beacon in reverse

order of dismantling. Do not tighten the lens latch
locking screw A to more than 0.65 Nm (5.75 lbf in.).

Note: Ensure the drive motor is fitted with the red pulley for
correct operation on 12 V systems.

9803/9300 Issue 1
 Section C Electrics Section C
10 - 1 Circuit Diagram 10 - 1

Main Components
1 Battery
2 Battery Lead
3 Starter Motor
4 Starter Solenoid
5 Glowplug (Common Rail)
6 Alternator
7 E.S.O.S.
8 Water Temperature Switch
9 Engine Oil Press Switch
10 Air Filter Switch
11 Instrument Panel
12 Fuel Sender
13 Instrument Panel
14 2 Speed Solenoid
15 Servo Solenoid
16 Wiper Motor
17 Washer Pump
18 ISO/SAE Controls Solenoid A
19 ISO/SAE Controls Solenoid B
20 Blower Motor
21 Resistor (Blower Motor)
* 22 Latching Relay
23 Swing Solenoid 1
24 Swing Solenoid 2
25 Boom Light
26 Work Lights
27 Horn
28 Accessory Socket
29 Interior Light
30 Radio
31 LH Speaker
32 RH Speaker
33 Beacon
34 Beacon Switch
35 Horn Button
36 Worklights Switch
37 Slew/Swing Button
38 Heater Blower Switch
39 ISO/SAE Switch
40 Wash/Wipe Switch
41 LH Arm Microswitch
42 2 Speed Switch (Latching)
43 Ignition Switch
* 44 Primary Fuse

9803/9300 Issue 2*
 10 - 2

9803/9300
200G MB
BATTERY

2
BATTERY LEAD BATTERY LEAD

PRIMARY
Section C

80A
44
FUSE
MA

PRE

OFF
IGN
START

310D
HEAT
3
310A 1 5 001 M STARTER MOTOR

30
6 001A
2

15/54
3 003A

17
4
MC
STARTER SOLENOID
7 004

50a
8
MH

19
9 003F 003E
5

GLOWPLUG COMMON RAIL

KEY SWITCH

43
MX 310S
B
NH
6

ALTERNATOR
407
MD
7.5A MG
106E 106AS 600
E.S.O.S.
7

FUSE 1
MS BUZZER 12/12
106 8/8

HIGH COOLANT
TEMP 12/3 406 ME 600CK
8

WATER TEMP SWITCH

LOW ENGINE
OIL PRESS 12/2 403 MJ 600HH
9

ENGINE OIL PRESS SWITCH

BLOCKED AIR MK
FILTER 12/4 402 600CF
AIR FILTER SWITCH
10

TRANS
OIL TEMP 12/8
NOT
USED
TRANS
OIL PRESS 12/5
NOT
USED
EXCITATION
RESISTOR
ALTERNATOR
CHARGE 8/5

HOURMETER 8/4 600T

4 4 3 3 INSTRUMENT PANEL
11

408
ML
S 12/6 600CE
FUEL SENDER

+
12

-
12/1
FUEL GAUGE
Electrics

BACKLIGHTING NOT
USED
CONTACT
SHUTDOWN

12/7
Circuit Diagram

958C 8/7 SWING IND

889B 8/6 2 SPEED IND

003F 8/1 GLOW PLUG IND

998C 8/3 SAE 8/2 600NF

INSTRUMENT PANEL
*13

INSTRUMENT CONSOLE MY/MZ

13

MR NK
106BB 889 889A 600KY
14

2 SPEED SWITCH (LATCHING) 2 SPEED SOLENOID

PE NR
106BC 980 600JR
15

LH ARM MICROSWITCH
SERVO SOLENOID
MP

42 41
CAB CONN 3 WIPER CONN 3
15A 103 103H 103H YELLOW

FUSE 2 MP
CAB CONN 2 WIPER CONN 2
MS 833 833 GREEN

LINK +10
1
MP
1 CAB CONN 4 WIPER CONN 4 WIPER CONN 1
2 832 832 RED BLACK 600T
103G 3 M
4
5
WIPER MOTOR
16

106P +8 -7 600ED
2
106BC 701/60082 600DW
PC PK
40

WASH/WIPE SWITCH 839 600BG

M WASHER PUMP
17

NZ3 WASHER PUMP

NZ4
-7 600LA 600KS
1
15A NZ1
102K 102N 2
3 998 998A 601GF
FUSE 3 NZ2 ISO/SAE CONTROLS SOL A
106Y +8
MS 2
701/60000 998B 601GE
39

ISO/SAE CONTROLS SOL B

18 19

ISO/SAE SWITCH
NE1
102L BROWN 1 2 ORANGE
OFF
LOW
MED

3 RED
HIGH
21

4 YELLOW
NE2
BLACK 600BH
RESISTOR M BLOWER MOTOR
20

HEATER BLOWER
SWITCH
38

BUTTON
LATCH
SLEW/SWING NS
RELAY
BUTTON
(LHS JOYSTICK) NT
3 2 5 4 6
22

1 2
37
102R

NL
1802 958 958A 600GE
102S

SWING SOLENOID 1
NM
958B 600GF
SWING SOLENOID 2
23 24

600MC

-7 600DW
1 1
7.5A 600DY
162 2
916
MM 600AV
3

MS FUSE 4 BOOM LIGHT

25

4 MP
15A F/L
116 5 CAB CONN 5
6 855C 855C 855B 600AS
MS FUSE 5 106L +8
WORKLIGHTS
26

2
106P 701/60002
PB F/R
855A 600AR
WORKLIGHTS
SWITCH
36

NB
310B

15A 304A 304B 870 MN 600EY

HORN
27

FUSE 6 HORN BUTTON

(RHS JOYSTICK)
35

MS 304F 600CC
PF 600ED ACCESSORY SOCKET
28

ACCESSORY SOCKET (5A MAX)

MP
CAB CONN 1
304E 304E 304A 600P

INTERIOR LIGHT
29
30

304 600ML
RADIO
602 601

860 859
RH SPEAKER LH SPEAKER
32
31

-7 600DY
1

10A 303 2
3 894 600AP
FUSE 7 M
106N +8
ND
MS 2
106L 701/60000 BEACON
PA
33
600A

BEACON SWITCH
34

MF
Section C

Issue 2*
10 - 2
Section C Electrics Section C
11 - 1 Harnesses 11 - 1

Main Harness

2 S2 S7 S6 S3 S4 S5 S1
BEACON ND
1

M10
MD
MF
ALTERNATOR
EARTH
LATCHING
ALTERNATOR RELAY
B+ WASHER
PUMP NT
ID
NH
LABEL M6 PK

B+

S8
1 2 MK A1 B1 C1
2 1

2 B2
A3 C3
NL
1
O

2 1

NM
1 6
MC
CAB PLUG MP 2
3
5

4
ME 2 1
STARTER
WATER TEMP SOLENOID 10 9
SWITCH 20 19 1 6 3 6 2 3
18 17 2 5
2 5 1 4
3 4
16 15 1 4
14 13 8 7 NZ
NS
12 11
BLOWER PA ISO/SAE
MOTOR
NE 2 1 FUSEBOX MS 10 9
SLEW/SW
BUTTONS CONNECTOR
BEACON
8 7
2 1 6 5
PLUG PG ML PLUG PH
4 3 10 9
2 1 3 6
FUEL
2 5
SENDER
4 1 4
10

2 8 7
1
3
9
MX 5
8 PB
WORKLIGHTS
IGNITION 6
7
SWITCH

EED
10 9

2 SP
3 6
2 1 5
2
2 2 1
1
MY 7 8 9 10 11 12 1 4
1 2 3 4 5 6 MR PE 8 7 NR
O
O ARM
INSTRUMENT PANEL 2 SPEED O SERVO
MICROSWITCH PC
SWITCH SOLENOID
WASH/WIPE
MZ 5 6 7 8
2 D
1 2 3 4 EE
1 SP
PF 2
BOOM 2 1

2 1
MM LIGHT ACCESSORY
2 1
SOCKET NK
2 SPEED
NB SOLENOID

HORN 2 1
BUTTON

M4 MN
OIL GLOW
PRESSURE MJ 2 1
MH PLUG HORN
SWITCH
2

80A
M6
1
BATTERY MB

MA
PRIMARY
FUSE

2 1

MG ZTS MAIN HARNESS

ESOS

721/10664

9803/9300 Issue 1
 11 - 2

9803/9300
WASHER TUBE
WASHER TUBE
Section C

WIPER
MOTOR
CF
Cab Harness

6 1 CE
1 4 5 2
2 3 MAIN
4 3 CONNECTOR

2
CG RIGHT
SPEAKER
M8
1

2 CA
LEFT EARTH
CH SPEAKER TERMINAL

FRONT LEFT
WORK LIGHT
CC

2 1 7 5 3 1 7 5 3 1
8 6 4 2 8 6 4 2

CJ CK
RADIO RADIO
POWER SPEAKERS
Harnesses
Electrics

INTERIOR
CB LIGHT

CE CF
CAB CONN 3 WIPER CONN 3
103H YELLOW

CE CF WIPER MOTOR
CAB CONN 2 WIPER CONN 2
833 GREEN

CE CF WIPER CF
CAB CONN 4 WIPER CONN 4 CONN 1
832 RED BLACK 600T
M
CE LEFT WORKLIGHT
CAB CONN 5
855C 855B CC 600AS

RIGHT WORKLIGHT
855A CD 600AR

CE
CAB CONN 1
304E 304A 600P

CB
INTERIOR LIGHT

CJ
304 7 8 600ML 600E
RADIO
4 3 5 6 CK
2 1 602 601

860 859
CD RIGHT SPEAKER LEFT SPEAKER
CG CH
FRONT RIGHT
WORK LIGHT
ELECTRICAL SCHEMATIC

Issue 1
11 - 2
Section C
 11 - 3

9803/9300
Section C

6 1 CE
FRONT RIGHT 5 2
WORK LIGHT CD 2 1 MAIN
4 3 CONNECTOR

M8
Canopy Harness

CA
EARTH
TERMINAL

2 1
FRONT LEFT
CC WORK LIGHT
Harnesses
Electrics

CE
CAB CONN 5 LEFT WORKLIGHT
855C 855B CC 600AS

RIGHT WORKLIGHT
855A CD 600AR

ELECTRICAL SCHEMATIC

Issue 1
11 - 3
Section C
Section C Electrics Section C
11 - 4 Circuit Diagrams 11 - 4

Boom Light Harness

2
BB

1
1
BA

9803/9300 Issue 1
Section C Electrics Section C
12 - 1 Harness Connections 12 - 1

32
31

fl
fl

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9803/9300 Issue 1
Section C Electrics Section C
12 - 2 Harness Connections 12 - 2

Item Component Harness

Connector Code

1 Battery MB
2 Fuse Box MS
3 Starter Motor MC
5 Glowplug (Common Rail) MH
6 Alternator MD & NH
7 E.S.O.S. MG
8 Water Temperature Switch ME
9 Engine Oil Press Switch MJ
10 Air Filter Switch MK
11 Instrument Panel MY & MZ
12 Fuel Sender ML
14 2 Speed Solenoid NK
15 Servo Solenoid NR
17 Washer Pump PK
22 Latching Relay NT
23 Swing Solenoid 1 NL
24 Swing Solenoid 2 NM
25 Boom Light MM
26 Work Lights CC & CD
27 Horn MN
30 Radio CJ & CK
31 LH Speaker CH
32 RH Speaker CG
33 Beacon ND
43 Ignition Switch MX
44 Primary Fuse MA

9803/9300 Issue 1