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 |
