JCB 926, 930, 940 Rough Terrain Fork Lift Tier 2 Service Manual (9803/5100-16)

JCB 926, 930, 940 Rough Terrain Fork Lift Tier 2 Service Manual (9803/5100-16)

This Tier 2 Service Manual delivers an extensive technical reference for the JCB 926, 930, and 940 rough terrain forklifts, presenting factory-approved servicing procedures, component-level maintenance data, hydraulic and electrical schematics, and advanced diagnostic routines. Engineered to meet the operational demands of high-capacity rough-terrain lifting machines, the manual provides complete coverage of drivetrain, transmission, braking, steering, engine systems, safety protocols, and structural configurations, supporting accurate troubleshooting and reliable long-term machine performance.

Model Covers:

JCB 926 – from Serial Number 602000

JCB 930 – from Serial Number 607700

JCB 940 – Rough Terrain Forklift

Emission Classification: Tier 2

Note: All specifications, pressure settings, and diagnostic procedures correspond exclusively to Tier 2 production models. Always verify machine serial numbers prior to servicing or ordering components.

File Format: PDF

Size: 40.34 MB

No. of pages: 529

Language: English

Delivery Method: Instant Download - Immediate access after purchase.

📑 Included Sections:

Section 1 - General Information

• Machine identification, serial number locations, and rating plates
• Detailed torque settings for structural, hydraulic, and drivetrain fasteners
• Hydraulic connection types, colour codes, and schematic reference tables
• Service tools, diagnostic adapters, and recommended consumables
• Sealing compounds, retaining agents, and contamination control standards

Section 2 - Care and Safety

• Operator and maintenance safety procedures
• Fire prevention, electrical safety, and hazard identification symbols
• Safety decals, label definitions, and operational risk assessments
• Comprehensive safety checklist for technicians and operators

Section 3 - Maintenance

• Full service schedules and interval-based maintenance breakdown
• Routine checks covering hydraulic, drivetrain, and lift systems
• Recommended lubricants, consumables, and fluid specifications
• Greasing points, fluid capacities, and periodic inspection guidelines

Section A - Attachments

• Fork assemblies with dimensional specifications
• Mast structures including channels, rollers, and lift components
• Hydraulic tilt and lift circuits with part grouping and schematic references
• Load guard and protective frame assemblies

Section B - Body and Framework

• Chassis frame construction and load-bearing structure
• Cab assemblies, operator station components, and counterweight groups
• Access panels, covers, and engine bay enclosures
• Mast mounting points and structural reinforcement plates

Section C - Electrics

• Electrical system architecture and wiring harness layout
• Battery, alternator, and starter motor diagnostics
• Lighting circuits, switches, fuses, and relay configuration
• Electrical troubleshooting methods and system voltage testing

Section E - Hydraulics

• Hydraulic pump assemblies, valve blocks, and operational schematics
• Lift and tilt hydraulic ram servicing and seal replacement data
• Hydraulic pressure testing procedures and calibration
• Hydraulic reservoir, filtration, and contamination control guidelines

Section F - Transmission

• Gearbox assemblies and internal component servicing
• Torque converter operation, diagnostics, and fluid management
• Drive shafts, axles, clutch packs, and mechanical linkage servicing
• Transmission testing and adjustment procedures

Section G - Brakes

• Hydraulic brake circuits and master cylinder configurations
• Parking brake systems and mechanical actuation components
• Brake adjustment, maintenance, and system testing

Section H - Steering

• Steering circuit overview with orbitrol steering unit
• Steering ram, linkage mechanisms, and pivot assemblies
• Bleeding procedures, testing methods, and operational diagnostics

Section K - Engine

• Engine identification and mounting details
• Cooling system components including radiator and thermostat
• Fuel delivery system, filters, injectors, and pump components
• Air filtration, exhaust routing, and emission system elements
• Engine-related electrical components and service procedures

This Tier 2 Service Manual is an essential reference for technicians maintaining JCB 926, 930, and 940 rough-terrain forklifts, offering precise diagnostics, structural insights, and system-level guidance required for accurate servicing, repairs, and dependable operational performance.