1993–2004 JCB 714 & 718 Articulated Dump Truck Service & Repair Manual (P/N 9803/7160)

JCB publication 9803/7160, Issue 3, covers service and repair of 1993–2004 JCB 714 and 718 articulated dump trucks, including early and later machine configurations.

• Transmission and axles: WG-160 powershift overhaul, HSG-90 control unit service, clutch pack assembly, and limited-slip differential pinion depth and gear mesh adjustment.

• Hydraulics and steering: Pump removal, servo joystick and control-valve repair, overcenter valve service, lift ram resealing, pressure testing, and emergency steering pump overhaul.

• Brake systems: Accumulator charge-valve service, brake pressure tests, service-brake bleeding, pad replacement, and parking-brake adjustment.

• 718 hydraulic suspension: Cylinder and valve service, self-leveling sensor replacement, ride height setup, suspension geometry checks, and calibration after fitting new potentiometers.

• Electrical diagnosis: Wiring diagrams, harness identification, starter and alternator tests, EMS display functions, and transmission and suspension fault code charts.

• Chassis and maintenance: Center pivot separation, tipper body removal, direct glazing of cab windows, service schedules, axle lubrication, cooling system flushing, and air conditioning fault finding.

This manual is written for JCB distributor service engineers in training or already trained, with a sound knowledge of workshop safety and hydraulic earthmoving equipment.

Hydraulic Variants and 718 Suspension

The body tip servo joystick and matching control valve apply from serial 830154 on the 714 and 832020 on the 718. Earlier lever-operated machines have separate procedures and hydraulic circuit layouts.

Steering coverage includes the orbital steering unit, priority circuit, and ground-driven emergency pump. The 718 suspension chapter distinguishes ride height adjustment with original potentiometers from setup using the EMS Calibration Panel after replacements.

Overtightening the body tip control-valve mounting bolts can distort the housing and jam the spool. The ram-sealing procedure identifies fitting tool 892/00334 and protective sleeves used to prevent rod-seal damage.

WG-160 Transmission and Differential Repair

Transmission procedures cover the torque converter, KV/KR and K1–K4 clutch packs, internal oil tubes, bearings, and inductive transmitters. Exploded clutch assembly views accompany the Oil Circulation Schematic and separate Power Flow diagrams for forward and reverse speeds.

EMS ZFCB ERROR charts connect reported faults with wiring, sensor gap, regulator, and clutch pressure checks. Together with the test-point drawings, they help distinguish electrical control faults from hydraulic or mechanical transmission problems.

Axle instructions include hub reduction repairs, separate pinion depth calculations for each model, and crown wheel contact-pattern checks.

Brake Testing and Electrical Fault Finding

Service brake tests cover accumulator charging, pressure retention, and brake-valve operation. The 718 has paired brake calipers at each end of the front axle, with corresponding inspection and bleeding instructions.

The service brake valve section covers seal renewal and inspection only; it specifies complete-valve replacement when internal parts are damaged or excessively worn.

The electrical section explains wire-number identification and multimeter testing. Starter no-load tests, alternator charging checks, and EMS warning-message descriptions support fault tracing beyond the wiring diagrams.

Engine Maintenance and Cab Systems

Engine coverage includes B-series Tier 1 and Tier 2 data, routine servicing, and charge air cooler removal and replacement. Internal engine overhaul is outside this publication’s scope; it refers to the separate Engine Service Manual 9806/1170, which is not included.

Maintenance references include lubricant charts for each model and component torque settings, plus general tables for UNF Grade S and metric Grade 8.8 fasteners.

Cab procedures cover bonded-glass removal and installation, ROPS/FOPS inspection and mounting-bolt specifications, and air conditioning electrical tests. Refrigerant charging and discharging procedures are excluded from the air conditioning coverage.

Before touching any lines, review the documented safety precautions, including articulation lock installation, tipper body support, and release of stored hydraulic pressure.

A Sample of Cooling and Transmission Setup Data

These cooling capacities and transmitter-clearance figures are a small selection of the service data in the manual.

Cooling-system capacity is 30 liters for the 714 and 33 liters for the 718, with separate fluid tables for the two models.

For the WG-160 transmission, the inductive transmitter requires 0.6–0.8 mm clearance between its sensing face and the spur-gear tooth tips. The fitting section explains the associated shim calculation.

PDF Navigation and Download Contents

Text search and diagram detail: Text search is limited, particularly in the transmission section; six circuit sheets have no searchable text. Twenty numbered bookmarks jump to pages at 20-page intervals. Dense wiring sheets require zooming for small wire codes and connector labels.

Download one printable 383-page PDF in English. Its total comprises 380 section pages and three introductory pages: the original cover, introduction, and hydraulic diagram legend.