Part of the JCB Repair Manuals.
Publication 9813/6200 earns its keep in the hydraulic chapters. It has pressure checks, a general fault diagnosis chart and hydraulic schematics for the 9, 10 and 11 spool valve blocks on the JCB 48Z-1 and 51R-1. Main relief, port relief and pilot pressures are all printed, so you test against a figure instead of guessing.
The four volumes also cover the Perkins GN 404D-22 engine, fuel and exhaust, cooling, tracks and undercarriage, HVAC, body and framework, and the operator station. The electrical section has wiring schematic sheets 1 to 19, harness diagrams, and Servicemaster diagnostics with ECM fault codes.
What's Inside This JCB 48Z-1, 51R-1 Manual
| System | Pages | Key Topics |
|---|---|---|
| Machine, Safety and General Data | 1-26 | Foreword, Safety, About This Manual, Machine Description, Service Points, General Data |
| Attachments and Options | 27-46 | Quickhitch, Bucket, Rockbreaker, Hydraulic Options |
| Body and Framework | 47-110 | Weights, Access Covers, Excavator Arm, Dozer Blade, Slew Ring, Kingpost, Counterweight, Identification Labels |
| Operator Station | 111-152 | Cab Window, Seat, Seat Belt, Controls, Safety Labels, Floor Plate |
| Heating, Ventilation and Air Conditioning | 153-202 | HVAC Unit, Heater, A/C Compressor, Receiver Drier, Condenser, Filter, Heater Valve, Hoses |
| Engine General Data and Fault Finding | 203-230 | Technical Data, Fault-Finding Tables, Drain and Fill, Crankcase |
| Engine Mechanical | 231-324 | Cylinder Head, Bedplate, Crankshaft, Camshaft, Belt, Oil Filter, Air Filter, Breather, Valves, Connecting Rod, Piston |
| Engine Ancillaries | 325-426 | Manifold, Rocker, Sump, Timing Gear, Flywheel, Oil Pump, Oil Cooler, Alternator, Starter, Glow Plug, Sensors |
| Fuel and Exhaust | 427-528 | Fuel Tank, Level Sender, Fuel Filter, Water Separator, Injection Pump and Injectors, Refuel Pump, Exhaust |
| Cooling System | 529-558 | General Data, Expansion Tank, Coolant Pump, Thermostat, Hoses |
| Tracks and Undercarriage | 559-618 | Track Fault Finding, Steel and Rubber Track, Sprocket, Idler, Rollers, Tensioner, Track Drive Motor |
| Hydraulic System General Data | 619-640 | Technical Data, Pressure Checks, General Fault Diagnosis Chart, Schematic Symbols |
| Hydraulic Schematics | 641-651 | Circuit Introduction, Colour Legend, Hydraulic Schematic Sheets 1-3 for 9, 10 and 11 Spool Valve Blocks |
| Hydraulic Tank, Pump and Cylinders | 652-729 | Tank, Filters, Track and Slew Gearboxes, Hydraulic Pump, Cylinders, Accumulator, Rotary Coupling |
| Hydraulic Valves and Slew Motor | 730-816 | Manifold, Slew Motor, Control Valve Block, MRV and ARV, Flow Control Valve, Hoses |
| Electrical General and Wiring Schematics | 817-881 | How to Read Schematics, Wiring Schematic Sheets 1-19 |
| Electrical Power and Harnesses | 882-945 | Earth Point, Battery, Power Distribution, Harness Repair, Harness Diagrams |
| Electrical Components | 946-1032 | Alarm, Instruments, Switches, Ignition, Horn, Lights, Control Module, Beacon, Washer and Wiper |
| Electrical Diagnostics and Fault Codes | 1033-1112 | Servicemaster, ECM Fault Codes, Sensors, Solenoids, Pressure Switches |
| Fasteners | 1113-1132 | Screws, Bolts, Threaded Inserts |
| Consumables | 1133-1174 | Oil, Grease, Fluids and Antifreeze, Locking Fluids, Solvents, Adhesive, Sealant, Fuel |
| Maintenance Schedules and Special Tools | 1175-1208 | Service Intervals, Ppe, Special Tools, Units of Measurement |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | Perkins 400 series GN 404D-22, Tier 3 | p. 211 |
| Engine power output | 34kW at 2600 RPM | p. 211 |
| Engine swept volume | 2.216L | p. 211 |
| Engine maximum no-load speed | 2800 RPM | p. 211 |
| Valve clearance (cold) | 0.2mm | p. 211 |
| Engine oil sump capacity | 8.9L minimum, 10.6L maximum | p. 344 |
| Engine oil pressure at low idle | 0.49bar (7.1psi) | p. 220 |
| Engine oil grade | Minimum API CJ4 | p. 1142 |
| Thermostat fully open | 95°C (202.9°F) | p. 534 |
| Main relief valve (MRV) | 240bar (3,478.2psi) | p. 627 |
| Port reliefs, boom, dipper, bucket, dozer and swing | 270bar (3,913.0psi) | p. 627 |
| Hydraulic tank | 55L | p. 627 |
| Auxiliary high flow at 2000 RPM | 90L/min | p. 627 |
| Hydraulic pump maximum pressure | 285bar (4,130.4psi) | p. 680 |
| Pilot pressure | 32bar (463.8psi) | p. 635 |
| Travel speed, high | 5km/h (3.1mph) | p. 564 |
| Operating weight and ground pressure, 48Z-1, 400mm steel track | 4,946kg, 0.29bar (4.2psi) | p. 570 |
| Operating weight and ground pressure, 51R-1, 400mm steel track | 5,266kg, 0.31bar (4.5psi) | p. 570 |
| Track sag, 400mm rubber track | 15mm to 25mm | p. 571 |
| Alternator output voltage | 13.5-14.5V | p. 383 |
| Track gearbox oil | 0.33L | p. 671 |
JCB 48Z-1, 51R-1 Common Problems This Manual Covers
Engine does not start
Work through the engine fault-finding table in order. Clean sulphated or corroded battery terminals, then recharge or replace a low battery. Refuel if the level is low. Replace a clogged fuel filter or air filter, and replace any open fuse.
Manual Section: Engine - Fault finding, Table 23 p. 214Engine overheats
The fault-finding table lists the causes. Top up low coolant and clean a clogged radiator. If the sump level is high, replace the engine oil. Replace a damaged injector, a defective thermostatic valve, or a defective or worn coolant pump. The cooling system section covers the thermostat and pump.
Manual Section: Engine - Fault finding, Table 32 p. 216Track motor slips down on a slope
Use the track fault-finding table. If motor efficiency is poor, replace the traction motor. If there is too much leakage inside the brake valve, replace the brake valve or rear flange. Replace a broken parking brake spring or a worn parking brake friction plate.
Manual Section: Tracks and undercarriage - Track fault finding, Table 115 p. 565Engine oil pressure low critical fault
The engine ECM fault code table lists low engine oil pressure as a critical fault. The display turns red, the buzzer sounds, and an icon and fault code appear. The book gives engine oil pressure at low idle as 0.49bar (7.1psi).
Manual Section: Electrical diagnostics - ECM fault codes, Table 211 p. 1071Frequently Asked Questions
Which engine does the JCB 48Z-1 and 51R-1 use?
Both models use the same engine, a Perkins 400 series GN 404D-22, Tier 3. It makes 34kW at 2600 RPM from a 2.216L swept volume, and maximum no-load speed is 2800 RPM. Cold valve clearance is 0.2mm. p. 211
What are the engine oil and hydraulic tank capacities on the 48Z-1 and 51R-1?
The engine oil sump holds 8.9L minimum and 10.6L maximum. Oil must be at least API CJ4 grade. The whole hydraulic system holds 100L, and the hydraulic tank holds 55L. The book does not print fuel tank or coolant capacity, so do not expect those figures. p. 344
What are the service intervals on the JCB 48Z-1 and 51R-1?
The maintenance schedule has checks at 10 hours (daily), 50 hours (weekly), 500 hours (six months), 1000 hours (yearly) and 2000 hours (two years). The antifreeze gets renewed every two years. p. 1180
What are the hydraulic relief and pilot pressures on the 48Z-1 and 51R-1?
The main relief valve is set at 240bar (3,478.2psi). Port reliefs for boom, dipper, bucket, dozer and swing are 270bar (3,913.0psi). The auxiliary port relief is 190bar (2,753.6psi), and pilot pressure is 32bar (463.8psi). p. 627
How tight should the tracks be on the 48Z-1 and 51R-1?
Track sag on 400mm and 550mm steel tracks is 50mm to 60mm. Geo-Grip tracks run at 40mm to 50mm, and 400mm rubber tracks at 15mm to 25mm. Tension is set with a grease cylinder. p. 571
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