JCB 722 Articulated Dump Truck Service Manual – 9803/7170-05

(S/N: 0833000 Onwards)
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This workshop repair service manual PDF download for the 722 JCB Articulated Dump Truck has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JCB Articulated Dump Truck 722 – S/N: 0833000 Onwards

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Routine Maintenance
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H – Hydraulic Steering
Section K – Engine
Section S – Suspension

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/7170-05
Total Pages : 562

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-7170-05

Section 1 – General Information
General Information
Identification
Vehicle Identification
Vehicle Identification Plate
Explanation of the Vehicle Identification Number (VIN)
Unit Identification
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Service Tools
Numerical List Section B – Body and Framework
Section B – Body and Framework
Numerical List Section C – Electrics
Section C – Electrics
Numerical List Section E – Hydraulics
Section E – Hydraulics
Numerical List Section F – Transmission
Section F – Transmission
Numerical List Section K – Transmission
Section K – Engine
Sealing and Retaining Compounds
Sealing and Retaining Compounds
Towing
General
Preparation for Towing
Hydraulic Hoses
Connecting/Disconnecting
Venting Hydraulic Pressure
Connecting the Hoses
Disconnecting the Hoses
Hydraulics
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Procedure
Contamination Standards
Filters

Section 2 – Care and Safety
Care and Safety
Safety Notices
Introduction
Safety Check List
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Decals

Section 3 – Routine Maintenance
Routine Maintenance
Maintenance
Health and Safety
Lubricants
Battery
First Aid – Electrolyte
General Safety
General Precautions
Service Schedules
Introduction
Periodic Replacement of Safety Related Components
Lubricants and Capacities
ROPS/FOPS Structure
Checking for Damage
Damage
Cleaning the Machine
Checking the Seat Belt Security and Condition
Articulation Lock
Installing the Articulation Lock
Stowing the Articulation Lock
Oscillation Lock
General
Fitting the Oscillation Lock
Stowing the Oscillation Lock
Tipper Body Safety Support
Fitting
Stowing
Engine Cover
Opening the Engine cover
Closing the Engine Cover
Greasing
Tipper Body Rams and Body Pivot Points
Centre Pivot and Steering Rams
Propshafts
Centre Bearing Carrier
Hydraulic Suspension Cylinder
Propshaft Centre Bearing
Checking the Oil Level
Draining and Refilling the Oil
Parking Brake
Adjusting the Parking Brake
Checking the Parking Brake Pad Wear
Test the Parking Brake
Electrical System
Battery
Battery Isolator
Engine Oil and Filter
Checking the Oil Level
Changing the Engine Oil and Filter
Engine Air Filter
Changing the Elements
Cab Ventilation Filters
Engine Cooling System
Checking the Coolant Level
Draining and Refilling the Coolant
Coolant Mixtures
Cleaning the Charge Air Cooler
Engine Drive Belt
Check the Engine Drive Belt
Air Conditioning Compressor Drive Belt (to Machine No. 833199 only)
Fuel System
Types of Fuel
Draining the Fuel Filter (from Machine no. 833200)
Changing the Suction Side Fuel Filter Element (from Machine no. 833200)
Changing the Pressure Side Fuel Filter Element (from Machine no. 833200)
Priming the Fuel System (from Machine no. 833200)
Draining the Fuel Filter (to Machine No. 833199)
Changing the Fuel Filter Element (to Machine No. 833199)
Priming the Fuel System (to Machine No. 833199)
Draining the Sedimenter Bowl (to Machine No. 833199)
Cleaning the Sedimenter Bowl (to Machine No. 833199)
Transmission
Checking the Transmission Oil Level
Changing the Transmission Oil and Filter
Front, Intermediate and Rear Axles
Checking the Differential Oil Level
Drain and Refill the Differential Oil
Checking the Hub Oil Level
Draining and Refilling the Hub Oil
Hydraulic System
Checking the Hydraulic Fluid Level
Hydraulic Tank Cap
Changing the Hydraulic Filter Element
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torques
Windscreen Washer
Fill the Windscreen Washer Bottle

Section B – Body and Framework
Body and Framework
Service Procedures
Rivet Nuts
Fitting Procedure
Cab
Glazing
Direct Glazing
ROPS/FOPS Structure
Centre Pivot
Separating the Front and Rear Chassis
Removal
Replacement
Centre Casting – Removal and Replacement
Removal
Replacement
Tipper Body
Removal and Replacement
Removal
Replacement

Section C – Electrics
Electrics
Technical Data
Data
Bulbs
Fuses
Relays
Accessing the Fuse Locations
Primary Fuses
Main Fuse Box – ‘CAB REAR’
Lighting Fuse Box – ‘CAB FRONT’
Remove and replace the Pre-heat Fuse
Accessing the Relay Locations
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
First Aid – Electrolyte
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starter Motor
Starting Circuit Test
Fault Finding
Introduction to Fault Finding Techniques
Harness Routing
Circuit Diagrams
722 (to Machine No. 833199)
Main Components
Fuses
Main Components
Fuses
Main Components
Lamps
Fuses
Main Components
Fuses
Main Components
Fuses
Suspension Controller Components
722 (from Machine No. 833200)
Main Components
Fuses
Main Components
Fuses
Main Components
Lamps
Fuses
Main Components
Fuses
Main Components
Fuses
Suspension Controller Components
Wiring Harnesses
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
2 Way Deutsch to Sumi-Socket
2 Way Deutsch to Hirschmann
Alternator Link Lead
Battery Isolator Lead
Battery Negative Lead
Battery Positive Lead
Battery Positive to Mega Fuse & Relay Harness
Fuse Link Harness
Grid Heater & starter Motor Harness
Inter Chassis Harness
Mega Fuse Harness
Rear Body Harness
Rear Chassis Harness
Starter Earth Lead
Suspension Harness
Alternator (to Machine no. 833199)
Removal and Replacement
Removal
Replacement
Starter Motor
Removal and Replacement
Removal
Replacement
Display Panel
Display
Ignition On
Pre-Start Mode
Setting Up
Start Inhibit
Warning
Visual Warning and Message
Automatic Engine Shut Down
Segmented Displays
Indications (Engine Off)
Indications (Engine Running)
Warning Light Test (Daily)
Body Tipping Lever
Body Tipping Lever
Description
Removal and Replacement
Dismantling and Assembly
Error Codes
Engine Error Codes
Transmission Error Codes
Introduction
Definition of Operating Modes
Transmission Fault Codes
Body and Suspension Error Codes

Section E – Hydraulics
Hydraulics
Technical Data
Main System Components
Primary Pump
Ground-drive Pump
Suspension Pump
Main Control Manifold Block
Hydraulic Rams
Accumulator Pre-charge Pressures
Filter (Return Line)
Basic System Operation
Hydraulic Pumps
Main Control Manifold Block (to Machine No. 833199)
Tipping Control Valve (to Machine No. 833199)
Circuit Descriptions (to Machine No. 833199)
Variable Displacement Pump
Manifold Block and Control Valve
Tipping Function
Main Control Manifold Block (from Machine no. 833200)
Circuit Descriptions (from Machine No. 833200)
Variable Displacement Pump
Manifold Block and Control Valve
Tipping Function
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Schematic Circuit
Basic Machine (to Machine No. 833199)
Basic Machine (from Machine No. 833200)
Fault Finding
Hydraulic System
Body Lift (Tipping) Function
Parking Brake Function
Brake Charging System
Steering System
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Pressure Testing
Testing the Main Relief Valve (MRV)
Main Relief Valve Adjustment
Testing the Steer Relief Valve
Hydraulic Pump
Removal and Replacement
Main Control Manifold Block
Removal and Replacement
Dismantle and Assemble
Main Manifold Block Components
Removing the Tipping Control Valve
Tipping Control Valve
Dismantle and Assemble
Differential Locks
Removal and Replacement
Hydraulic Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Lift Rams
Dismantle and Assemble
Lift Rams
JCB Ram Sealing Procedure

Section F – Transmission
Transmission
Technical Data
Data
Axles
Tyres
Transmission
Stall Testing
Axles
Description
Removal and Replacement
Intermediate and Rear Axle Removal and Replacement
Front Axle Removal and Replacement
Hub and Driveshaft
Dismantling and Assembly
Front and Rear Axle – Limited Slip Differential Unit
Dismantling
Dismantling the Dive Pinion Bearing
Assembly
Crown Wheel and Pinion Adjustment
Intermediate Axle Interaxle Differential with Differential Lock and Cross Axle Limited Slip Differential
Dismantling
Assembly
Intermediate Axle without Inter Axle Differential Lock but with Limited Slip Differential
Dismantling
Assembly
Powershift Transmission
WG 210
Main Components
Oil Circulation Schematic
Power Flow – Forward Speeds
Power Flow – Reverse Speeds
Test Points and connections
Electro-Hydraulic Shift Control
Dismantling
Assembly
Hydraulic Control Unit
Propshafts
Removal and Replacement
Removal
Replacement

Section G – Brakes
Brakes
Technical Data
Brakes
Fault Finding
Brake System
Parking Brake Function
Brake Charging System
Service Procedures
Service Brakes
Service Brake System Testing
Checking the Brake Pad Wear
Renewing the Brake Pads
Bleeding
Park Brake
Adjusting the Park Brake
Checking the Parking Brake Pad Wear
Replacing the Parking Brake Pads
Service Brakes
Description and Operation
Description
Operation
Service Brake Valve – Removal, Replacement and Setting
Removal
Replacement
Setting
Dismantling and Assembly
Removal and Replacement
Removal
Replacement
Parking Brake
Description and Operation
Description
Operation
Removal and Replacement
Removal
Replacement
Dismantling and Assembly

Section H – Hydraulic Steering
Hydraulic Steering
Technical Data
Hydraulic Steering Data
Basic System Operation
Hydraulic Steering System
Description
Operation
Steer System Schematics
Emergency Steering
Description
Operation
Emergency Steer System Schematics
Steering Unit
Removal and Replacement
Removal
Removal
Hydraulic Steering Control Unit
Tool Dimensions
Steering Control Unit
General
Preparation for Repair
General
Mounting the SCU for Repair
Disassembly and Assembly
Disassembly
Assembly
Emergency Steering Pump
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Steering Rams
Removal and Replacement
Removal
Replacement
Dismantling and Assembly

Section K – Engine
Engine
Technical Data
General Engine Data
Charge Air Cooler
Description
Removal and Replacement
Removal
Replacement

Section S – Suspension
Suspension
Technical Data
Suspension Data
Description
Front Suspension
Hose and Pipework Layout (to Machine No. 833199)
Circuit Diagram (to Machine No. 833199)
Hose and Pipework Layout (from Machine No. 833200)
Circuit Diagram (from Machine No. 833200)
Rear Suspension
Front Suspension
Deactivating and Activating the “Hydac” System
Deactivating
Activating
Setting-Up the “Hydac” Electro-Hydraulic Suspension System
Manual Raise and Lower
Purging the System
Automatic Mode
Deactivating and Activating the “Vansco” System
Deactivating
Activating
Calibrating the “Vansco” System
Calibration
Hydraulic Suspension Cylinders
Removal and Replacement
Dismantling and Assembly
Hydraulic Suspension Cylinder Bearings
Control Arms
Removal and Replacement
Panhard Rods
Removal and Replacement
Bump Stops
Checking, Removal and Replacement
Suspension Accumulators
Removal and Replacement
Dismantling and Assembly
Rear Suspension
Rear Suspension Rubber Blocks
Removal and Replacement
Rear and Intermediate Panhard Rods
Removal and Replacement
Rear and Intermediate Suspension A-Frames
Removal and Replacement
Rocking Beam
Removal and Replacement
Rocking Beam Bushes
Removal and Replacement
Error Codes
General

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