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JCB 3200 PLUS FASTRAC Service Repair Manual PDF
JCB 3200 PLUS FASTRAC Service Repair Manual PDF
H
of
JCB SERVICE LTD;
World Parts Centre,
Steering
Waterloo Park
Uttoxeter, Staffordshire
ST14 7BS
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated
with the maintenance and repair of hydraulic earthmoving equipment.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of
course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe
connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all
else
SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for
example:
A = Optional Equipment
B = Body & Framework ...etc
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later
issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
Page cross references are generally made by presenting the subject title printed in bold, followed by the title of the section
containing the subject. For example:
“24 If the axle is still on the machine, fit the brake calipers (see Brake Caliper Removal and Replacement, Section G).”
Note: If only the subject title in bold is given, i.e. no section title, the cross reference is to another part of the same section.
Use the contents list at the beginning of each section to find the exact page number.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.
‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.
9803/8030 Issue 1
Section 1 General Information Section 1
i i
Torque Settings
Introduction - Zinc Plated Fasteners and Dacromet Fasteners 2-1
Zinc Plated Fasteners 2-2
Dacromet Fasteners 2-3
* Service Tools
Optional Equipment 5-0
Body and Framework 5-1
Electrics 6-1
Hydraulics 7-1
Transmission 8-1
Brakes 9-1
Steering 9-1
Suspension 9-2
Engine 9-2
9803/8030 Issue 2*
Section 1 General Information Section 1
1-1 1-1
A B C D E F Unit Identification
Original VIN Configuration The serial number of each major unit is also stamped on the
unit itself as shown below. If a major unit is replaced by a
JCB 23 8 40 X 6 XXXXXXX new one, the serial number on the plate will be wrong. Either
stamp the new number of the unit on the identification plate,
or simply stamp out the old number. This will prevent the
wrong unit number being quoted when replacement parts
A C D E G H F are ordered.
S M
N R
P 417490
9803/8030 Issue 3*
Section 1 General Information Section 1
2-1 Torque Settings 2-1
The two types of fasteners can be readily identified by colour and part number suffix as follows:
Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must
be relevant to the type of fasteners.
Note: A Dacromet bolt should not be used in conjunction with a Zinc and Yellow plated nut, as this could change the torque
characteristics of the torque settings further. For the same reason, a Dacromet nut should not be used in conjunction with a
Zinc and Yellow plated bolt.
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
Note: Dacromet bolts, due to their high corrosion resistance are used areas where rust could occur. Dacromet bolts are only
used for external applications. They are not used in application such as gearbox and engine joint seams or internal
applications.
9803/8030 Issue 1
Section 1 General Information Section 1
2-2 Torque Settings 2-2
Metric Grade 8.8 Bolts Metric - All Internal Hexagon Headed Cap Screws
M6 (6) 8 16 1.6 12
M8 (8) 13 39 4 29
M10 (10) 17 78 8 57
M12 (12) 19 137 14 101 A343780
9803/8030 Issue 1
Section 1 General Information Section 1
2-3 Torque Settings 2-3
NOTE: DACROMET FASTENERS ARE LUBRICATED AS PART OF THE PLATING PROCESS: DO NOT LUBRICATE.
M6 x 1.0 9 0.9 7
M8 x 1.25 22.5 2.3 17
M10 x 1.5 47.5 4.8 35
M12 x 1.75 80 8.2 59
M14 x 2 133 13.6 98
M16 x 2 200 20.4 148
M18 x 2.5 278 28.4 205
M20 x 2.5 392 40 289
M24 x 3 675 69 498
M30 x 3.5 1348 138 994
M6 x 1.0 15 1.5 11
M8 x 1.25 40 4.1 29
M10 x 1.5 80 8.2 59
M12 x 1.75 133 13.6 98
M14 x 2 225 23 166
M16 x 2 350 35.7 258
M18 x 2.5 463 47 342
M20 x 2.5 654 67 482
M24 x 3 1125 115 830
M30 x 3.5 2247 229 1657
9803/8030 Issue 1
Section 1 General Information Section 1
2-4 Torque Settings 2-4
Location: Front Wrapper Location: Front Lower Crossmember Location: Front P.T.O. Box
(top/bottom) Nm: 115 kgf m: 12 lbf ft: 85 Nm: 200 kgf m: 20 lbf ft: 148
Nm: 392 kgf m: 40 lbf ft: 289
A402060
A402230
A401990
* Location: Front Axle Upper Arm Location: Front Engine Mounting Location: Header Tank Clamp Plate
Mounting Bracket Nm: 200 kgf m: 20 lbf ft: 148 Nm: 30 kgf m: 3 lbf ft: 22
8.8 grade bolts:
Nm: 200 kgf m: 20 lbf ft: 148
A402290
A402270 A402150
9803/8030 Issue 2*
Section 1 General Information Section 1
2-5 Torque Settings 2-5
A402120
A402200
Location: Tower Casting to Axle Location: Lower Link Capscrew Location: Lower Link Bolt (Hex Head)
Nm: 392 kgf m: 40 lbf ft: 289 Nm: 654 kgf m: 67 lbf ft: 482 Nm: 392 kgf m: 40 lbf ft: 289
A402010
A402040
A402140
Location: Rear Crossmember Location: Rear Lower Crossmember Location: Rockinger Hitch Bolt
Nm: 392 kgf m: 40 lbf ft: 289 Nm: 200 kgf m: 20 lbf ft: 148 Nm: 392 kgfm: 40 lbf ft: 289
A402280
A402260 A402030
9803/8030 Issue 1
Section 1 General Information Section 1
3-1 3-1
JCB Multigasket A medium strength sealant suitable for all sizes of gasket
flanges, and for hydraulic fittings of 25-65 mm diameter. 4102/1212
JCB High Strength Threadlocker A high strength locking fluid for use with threaded components. 4102/0551
Gasketing for all sizes of flange where the strength of the joint
is important.
JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/0651
JCB Threadlocker & Sealer A medium strength locking fluid for sealing and retaining nuts,
bolts, and screws up to 50 mm diameter, and for hydraulic
fittings up to 25 mm diameter. 4101/0251
JCB Threadlocker & Sealer A medium to high strength locking fluid. 4101/0552
(High Strength)
JCB Threadseal Medium strength thread sealant (for patch bolts that are re-used). 4102/1951 50 ml
Clayton System Seal SC1251 A thread sealant used mainly on air brake system hose adapters. 4102/2210 2ml
JCB Activator A cleaning primer which speeds the curing rate of anaerobic 4104/0251 Aerosol
products. 4104/0253 Bottle
JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic adhesives
and sealants. 4104/1557 Aerosol
Direct Glazing Kit For one pane of glass, comprises items marked † below plus
applicator nozzle etc. 993/55700
JCB Clear Silicone Sealant To seal butt jointed glass. Also to seal hub planet gear carrier
when no 'O' ring is fitted 4102/0901
Black Polyurethane Sealant To finish exposed edges of laminated glass 4102/2309 310 ml
9803/8030 Issue 2*
Section 1 General Information Section 1
4-1 4-1
The following parts are replacement items for kits and would
normally be included in the relevant kit numbers.
Replacement items for kit no. 892/00253
892/00201 Gauge 0 - 20 bar 7-1
892/00202 Gauge 0 - 40 bar 7-1
892/00203 Gauge 0 - 400 bar 7-1
892/00254 Hose 7-1
9803/8030 Issue 3*
Section 1 General Information Section 1
5-0 5-0
Service Tools
Section A - Optional Equipment
197220
9803/8030 Issue 1
Section 1 General Information Section 1
5-1 5-1
Service Tools
Section B - Body and Framework
S186240 S186270
Hand Cleaner - special blend for the removal of Cartridge Gun - hand operated - essential for the
polyurethane adhesives. application of sealants, polyurethane materials etc.
JCB part number - 4104/1310 (454g; 1lb tub) JCB part number - 892/00845
'
S186250
plug (703/23201) which fits into a female socket Folding Stand for Holding Glass - essential for
(715/04300). preparing new glass prior to installation.
S186260
240V Static Oven - available with 2 or 6 cartridge
S186300
capacity - required to pre-heat adhesive prior to use.
No plug supplied. Note: 110V models available upon Glass Lifter - minimum 2 off - essential for glass
request - contact JCB Technical Service installation, 2 required to handle large panes of glass.
Ensure suction cups are protected from damage during
JCB part number: storage.
992/12400 - 2 cartridge x 240V
992/12600 - 6 cartridge x 240V JCB part number - 892/00842
9803/8030 Issue 1
Section 1 General Information Section 1
5-2 5-2
S186310 S186340
Wire Starter - used to access braided cutting wire Cut-out Knife - used to remove broken glass.
(below) through original polyurethane seal.
JCB part number - 992/12800
JCB part number - 892/00848
'
S186320 S186350
Glass Extractor (Handles) - used with braided cutting 'L' Blades - 25mm (1in.) cut - replacement blades for
wire (below) to cut out broken glass. cut-out knife (above).
JCB part number - 892/00846 JCB part number - 992/12801 (unit quantity = 5 off)
S186330
S186360
JCB part number - 892/00849 (approx 25m length) JCB part number - 892/00844
9803/8020 Issue 1
Section 1 General Information Section 1
5-3 5-3
S186470 S186550
Nylon Spatula - general tool used for smoothing Rubber Spacer Blocks - used to provide the correct
sealants - also used to re-install glass in rubber glazing set clearance between glass edge and cab frame.
because metal tools will chip the glass edge.
JCB part number - 926/15500
JCB part number - 892/00847 (unit quantity = 500 off)
9803/8030 Issue 1
Section 1 General Information Section 1
6-1 6-1
Service Tools
Section C - Electrics
188230
A360250
D
1 2 3 4 5 6 7 8 E
C
B A F
9 10 11 12 13 14 15 J G
H
A386040
9803/8030 Issue 2*
Section 1 General Information Section 1
6-2 6-2
A406950
9803/8030 Issue 2*
Section 1 General Information Section 1
7-1 7-1
Service Tools
Section E - Hydraulics
S188120
9803/8030 Issue 1
Section 1 General Information Section 1
7-2 7- 2
S193850
female adapter
892/00706 Test Probe 892/00318 Hose And Adapter Kit
892/00278 Gauge 0-40 bar (0-600 lbf/in2) To enable flow and pressure test
892/00279 Gauge 0-400 bar (0-6000 lbf/in2) equipment to be connected to adapters
fitted with 'O' ringface seals.
197220
892/00334 Gland Seal Fitting Tool 331/64246 Tool Kit for Non-return Valve
9803/8030 Issue 2
Section 1 General Information Section 1
8-1 8-1
Service Tools
Section F - Transmission
188200 107750
892/00179 Bearing Press 892/00812 PTO Drive Coupling Spanner for yoke
couplings
110
25 25
15
40
A197180
892/00225 Adapter - Impulse Extractor
Small 17mm to 25mm * Differential Setting Key
Medium 25mm to 45mm 197080 Cut from 5 mm plate to dimensions shown. Fabricate
Large 45mm to 80mm handle to suit.
S197030
9803/8030 Issue 2*
Section 1 General Information Section 1
8-2 8-2
197250
Heavy Duty Sockets
892/00817 17 mm A/F x 3/4in. square drive S190770
S196750
9803/8030 Issue 2
Section 1 General Information Section 1
8-3 8-3
S226300
892/00892 Speed Gearbox Locking Tool
1
A B
C
2
S234120
4
892/00864 PD 90 Axle Locknut Spanner
3 A270851
9803/8030 Issue 1
Section 1 General Information Section 1
8-4 8-4
A361710
892/01051 Intermediate Gear Retaining Tool - wet 892/01049 (x2) Guide Rod - wet clutch
clutch transmission A361740
A361750
892/01045 Peg Socket - wet clutch 892/01046 Mandrel - for bush assembly - wet clutch
A361770
A361760 A361780
892/01050 Mandrel, for hub seal renewal - wet clutch.
892/01047 Jig, for use when dismantling and
Note: Protective plastic cap A to be removed before use.
assembling of PTO input gear - wet clutch
9803/8030 Issue 1
Section 1 General Information Section 1
8-5 8-5
13 16
15
19, 20
14
18
8
21
17
9803/8030 Issue 2
Section 1 General Information Section 1
9-1 9-1
Section G - Brakes
Section H - Steering
E
A
B
C 222490
D
Puller adapter assembly for removal of drop arm from
steering box (3000 Series machines). Comprises:
9803/8030 Issue 1
Section 1 General Information Section 1
9-2 9-2
S199480
Section T - Engine
S192390
9803/8030 Issue 1
Section 1 General Information Section 1
10 - 1 Moving a Disabled Machine 10 - 1
! CAUTION ! DANGER
Towing a machine too far or too fast can damage the Ensure that the chocks and towing vehicle will prevent
transmission. Do not tow the machine further than one the Fastrac from moving as it is necessary to work under
mile. Use a trailer for greater distances. When towing do the machine to remove the propshafts or release the
not travel faster than 25 km/h (15 mph). parking brake. When the propshafts have been
disconnected the parking brake cannot prevent the
Use a rigid drawbar. If you must use towing chains, then
machine from moving. When the parking brake has been
use two towing vehicles. One towing vehicle should be
manually released as described below, it will be
coupled to the front of the disabled machine. The other
impossible to apply the brake until plate A has been
towing vehicle should be coupled to the rear of the
removed and the propshafts connected. Anyone working
disabled machine, to provide braking power.
underneath, or near the machine, could be killed or
The towing vehicle(s) must have enough pulling and seriously injured if the machine moved.
13-2-2-11/1
braking power to move and stop the machine.
2-2-7-3
Alternatively, position plate A (if provided with the
machine) as shown. Keeping nut B tight against clevis
Preparation for Towing C, turn nut D against the plate so that rod E is drawn
out of the actuator body and the parking brake is
1 Connect the towing vehicle.
released.
a Apply the parking brakes on the towing vehicle and
securely chock the wheels on the Fastrac.
Note: If the parking brake cannot be released, remove both
propshafts (see Section F).
D E
X
C
B A
S160392
418150
9803/8030 Issue 3*
Section 1 General Information Section 1
10 - 2 10 - 2
A A
B 418300
B
9803/8030 Issue 1
Section 2 Care & Safety Section 2
i i
9803/8030 Issue 1
Section 2 Care & Safety Section 2
1-1 1-1
In this publication and on the machine, there are safety notices. Each notice starts
with a signal word. The signal word meanings are given below.
! DANGER
Denotes an extreme hazard exists. If proper precautions are not taken, it is
highly probable that the operator (or others) could be killed or seriously
injured.
INT-1-2-1
! WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator (or
others) could be killed or seriously injured.
INT-1-2-2
! CAUTION
Denotes a reminder of safety practices. Failure to follow these safety practices
could result in injury to the operator (or others) and possible damage to the
machine.
INT-1-2-3
9803/8030 Issue 1
Section 2 Care & Safety Section 2
2-1 2-1
All construction and agricultural equipment can be Note: This section includes a certain amount of operating
hazardous. When a JCB Fastrac is correctly operated and safety information. But remember that whenever you drive
properly maintained, it is a safe machine to work with. But the machine or operate its controls you are in effect a
when it is carelessly operated or poorly maintained it can machine operator. Therefore you should read and
become a danger to you (the operator) and others. understand the information given in the Operator Handbook
before driving the machine or operating its controls.
Do not work with the machine until you are sure that you can
control it.
Do not start any job until you are sure that you and those
around you will be safe.
Remember
BE CAREFUL
BE ALERT
BE SAFE
GEN-1-6
General Safety
! WARNING ! WARNING
Lifting Equipment Care and Alertness
You can be injured if you use faulty lifting equipment. Make All the time you are working with or on the machine, take
sure that lifting equipment is in good condition. Make sure care and stay alert. Always be careful. Always be alert for
that lifting tackle complies with all local regulations and is hazards.
suitable for the job. Make sure that lifting equipment is INT-1-3-5
9803/8030 Issue 3*
Section 2 Care & Safety Section 2
3-1 3-1
Operating Safety
! DANGER ! WARNING
Parking Visibility
Leaving the machine in gear will not prevent it running away. Accidents can be caused by working in poor visibility. Keep
Do not leave the driving seat under any circumstances windows clean and use your lights to improve visibility. Do
unless the parking brake is on. not operate the machine if you cannot see properly.
13-2-1-10 INT-2-1-11
! WARNING ! WARNING
Roll Over Protection Structure (ROPS) Practice
The machine is fitted with a Roll Over Protection Structure You or others can be killed or seriously injured if you do
(ROPS). You could be killed or seriously injured if you unfamiliar operations without first practising them. Practise
operate the machine with a damaged or missing ROPS. If away from the work site on a clear area. Keep other people
the ROPS has been in an accident, do not use the machine away. Do not perform new operations until you are sure you
until the structure has been renewed. Modifications and can do them safely.
INT-2-1-1
repairs that are not approved by the manufacturer may be
dangerous and will invalidate the ROPS certification.
13-1-1-8/1 ! WARNING
Machine Limits
! WARNING Operating the machine beyond its design limits can damage
Entering/Leaving the machine, it can also be dangerous. Do not operate the
Always face the machine when entering and leaving the cab. machine outside its limits. Do not try to upgrade the
Use the step(s) and handrails. Make sure the step(s), machine performance with unapproved modifications.
INT-2-1-4
handrails and your boot soles are clean and dry. Do not
jump from the machine. Do not use the machine controls as
handholds, use the handrails. ! WARNING
INT-2-1-7 Brakes
Do not coast the machine with the engine stopped as the
! WARNING main brakes will only operate for a limited number of
Seat applications and hydraulic trailer brakes will not function at
Position the seat so that you can comfortably reach the all. Also the steering will become very heavy.
13-1-1-5/2
machine controls. You could have an accident if you operate
the machine with the seat in the wrong position.
INT-3-3-5 ! CAUTION
Hydraulic Trailer Brakes
! WARNING Trailers with single line hydraulic brakes used in the United
Seat Belt Kingdom are subject to a maximum speed of 20 mph (32
Operating the machine without a seat belt can be kph).
13-2-2-8
dangerous. Before starting the engine, make sure your seat
belt is fastened. Check the tightness and condition of the
! CAUTION
seat belt securing bolts regularly (see maintenance
schedules). Trailer Brakes
INT 2 -1-8/1 Trailers with single line air brakes used in the Republic of
Germany are subject to a maximum speed of 25 km/h (15
! WARNING mph).
Passengers 13-2-2-13
9803/8030 Issue 1
Section 2 Care & Safety Section 2
3-2 3-2
! WARNING ! WARNING
Banks and Trenches Power Take-off Operation
Banked material and trenches can collapse. Do not work or When operating PTO equipment, always observe the
drive too close to banks and trenches where there is danger following safety precautions:
of collapse.
INT-2-2-5 Follow the instructions in the implement operator's
handbook.
! WARNING
Rotating equipment is dangerous. Do not wear loose fitting
Ramps and Trailers
clothing when working close to rotating shafts.
Water, mud, ice, grease and oil on ramps or trailers can
cause serious accidents. Make sure ramps and trailers are
Always disengage the PTO, stop the engine and wait until
clean before driving onto them. Use extreme caution when
the equipment stops, before:
driving onto ramps and trailers.
INT-2-2-6
1 Leaving the cab
! WARNING
2 Attempting to attach or detach an implement to or from
Communications
a PTO shaft or
Bad communications can cause accidents. Keep people
around you informed of what you will be doing. If you will be
3 Working on or cleaning an implement connected to the
working with other people, make sure any hand signals that
machine via a PTO shaft.
may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands.
INT-2-2-3
Always ensure that the PTO shaft and driveline are fully
guarded before use.
! WARNING
Exhaust Gases
Breathing the machine exhaust gases can harm and
possibly kill you. Do not operate the machine in closed
spaces without making sure there is good ventilation. If
possible, fit an exhaust extension. If you begin to feel
drowsy, stop the machine at once. Get out of the cab into
fresh air.
INT-2-1-10
9803/8030 Issue 1
Section 2 Care & Safety Section 2
3-3 3-3
! WARNING ! WARNING
Tyres - General Stability
You could be killed or injured if a machine tyre bursts. Do In the event of the machine becoming unstable, keep firm
not use the machine with damaged, incorrectly inflated or hold of the steering wheel and do not try to leave the cab.
excessively worn tyres. Recognize the speed limitation of 13-2-2-10
! CAUTION
Weight Distribution
! WARNING
The Fastrac has to comply with certain braking regulations Cab Air Filter
which in some countries control weight distribution between The cab air filter is designed to remove dirt from the outside
front and rear axles. Travelling on the road with implements air. When using chemicals (e.g. for crop spraying) follow the
or weights carried on the front when no implement is on the chemical manufacturer’s recommendations for protection
rear may break the law. In this case you should transfer the from dangerous chemicals.
13-2-3-6
front mounted equipment to the rear linkage. It is the
operator's responsibility to know and observe the laws in the
country concerned. ! WARNING
13-2-2-5
Hazardous Atmospheres
! WARNING This machine is designed for use in normal out door
atmospheric conditions. It should not be used in an
Travel Speed
enclosed area without adequate ventilation. Do not use the
Be aware of the load the machine is carrying or towing and
machine in a potentially explosive atmosphere, i.e.
the speed at which you are travelling. Do not corner fast
combustible vapours, gas or dust, without first consulting
when carrying heavy mounted implements or towing trailers.
your JCB Distributor.
Reduce speed when towing non-suspended implements on INT-2-1-14
rough ground.
13-2-2-1
9803/8030 Issue1
Section 2 Care & Safety Section 2
3-4 3-4
! WARNING
When driving the machine on the road with an implement or
trailer connected to the hydraulic system, the transport locks
must be engaged to prevent unintentional operation of
electronic linkage or external hydraulics.
0099
! CAUTION
Use caution when operating the engine at full load. Serious
damage could occur if it is allowed to operate at full throttle
for more than 30 seconds whilst running below peak torque
(1500 rev/min). Do not allow the engine to operate in this
condition when running on a dynamometer.
0097
! CAUTION
Do not allow the engine to exceed maximum speed (2520
rev/min). Use caution when travelling down hill in a loaded
condition to prevent accidental engine overspeeding when
selecting lower gears.
0098
! CAUTION
Do not use down shifting of the six speed gearbox to slow
down the tractor. Overspeeding of the gearbox
synchronisers can cause severe damage to the
transmission.
Use the tractor brakes to slow the vehicle and then select a
suitable gear to match the vehicle speed.
9803/8030 Issue 1
Section 2 Care & Safety Section 2
4-1 4-1
Maintenance Safety
! WARNING ! WARNING
Working Under the Machine Battery
Make the machine safe before getting beneath it. Do the A battery with frozen electrolyte can explode if it is used or
following: Park on level ground. Engage the parking brake. charged. Do not use a machine with a frozen battery. To
Lower any mounted implements to the ground. Stop the help prevent the battery from freezing, keep the battery fully
engine, remove the starter key, disconnect the battery. charged.
Chock the wheels. INT-3-1-7
13-3-1-1
! WARNING
! WARNING Battery Gases
Soft Ground Batteries give off explosive gases. Keep flames and sparks
A machine can sink into soft ground. Never work under a away from the battery. Do not smoke close to the battery.
machine on soft ground. Make sure there is good ventilation in closed areas where
INT-3-2-4 batteries are being used or charged. Do not check the
battery charge by shorting the terminals with metal; use a
! WARNING hydrometer or voltmeter.
INT-3-1-8
Jacking
A machine can roll off jacks and crush you unless the wheels
have been chocked. Always chock the wheels at the ! WARNING
opposite end of the machine to that which is to be jacked. Battery Terminals
Do not work underneath a machine supported only by jacks. The machine is negatively earthed. Always connect the
Always support a jacked-up machine on axle stands before negative pole of the battery to earth.
working underneath it.
INT-3-2-8 When connecting the battery, connect the earth (-) lead last.
Petrol
! WARNING
Do not use petrol in this machine. Do not mix petrol with the
diesel fuel; in storage tanks the petrol will rise to the top and Rams
form flammable vapours. The efficiency of the rams will be affected if they are not
INT-3-1-6 kept free of solidified dirt. Clean dirt from around the rams
regularly. When leaving or parking the machine, close all
rams if possible to reduce the risk of weather corrosion.
! WARNING INT-3-2-10
Turning the Engine
Do not try to turn the engine by pulling the fan or fan belt.
This could cause injury or premature component failure.
0094
9803/8030 Issue 1
Section 2 Care & Safety Section 2
4-2 4-2
! WARNING
! WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate the Cleaning
skin. Do not use your fingers to check for hydraulic fluid Cleaning metal parts with incorrect solvents can cause
leaks. Do not put your face close to suspected leaks. Hold a corrosion. Use only recommended cleaning agents and
piece of cardboard close to suspected leaks and then solvents.
INT-3-2-11
inspect the cardboard for signs of hydraulic fluid. If hydraulic
fluid penetrates your skin, get medical help immediately.
INT-3-1-10/1
! WARNING
'O' rings, Seals and Gaskets
! WARNING Badly fitted, damaged or rotted 'O' rings, seals and gaskets
Oil can cause leakages and possible accidents. Renew
Oil is toxic. If you swallow any oil, do not induce vomiting, whenever disturbed unless otherwise instructed. Do not use
seek medical advice. Used engine oil contains harmful Trichloroethane or paint thinners near 'O' rings and seals.
INT-3-2-12
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier
cream or wear gloves to prevent skin contact. Wash skin
contaminated with oil thoroughly in warm soapy water. Do
! WARNING
not use petrol, diesel fuel or paraffin to clean your skin. Welding and Modifications
INT-3-2-3 To prevent the possibility of damage to electronic
components, disconnect the battery positive and negative
! WARNING leads before arc-welding on the machine or attached
Hot Coolant implements. Attach the welder earth (ground) cable no more
The cooling system is pressurised when the engine is hot. than 0.6 metres (2 feet) from the part being welded. Do not
Hot coolant can spray out when you remove the radiator connect the welder cable or apply any weld to any part of
cap. Let the system cool before removing the radiator cap. the engine.
To remove the cap; turn it to the first notch and let the
system pressure escape, then remove the cap. Parts of the machine are made from cast iron; welds on cast
INT-3-2-9 iron can weaken the structure and break. Do not weld cast
iron. On no account weld or drill the chassis structure. Non-
! WARNING approved modifications can cause injury and damage.
Contact JCB before modifying the machine.
Wheels 0095
Wheels are heavy. Handle and store with care to ensure that
they cannot fall and cause injury.
13-3-1-7 ! WARNING
Protect your eyes when grinding metal. Wear safety glasses
! WARNING or goggles. Remove or protect any combustible materials
Metal Splinters from the area which could be ignited by sparks.
GEN-1-12
You can be injured by flying metal splinters when driving
metal pins in or out. Use a soft faced hammer or drift to
! WARNING
remove and fit metal pins. Always wear safety glasses.
INT-3-1-3 Radar Speed Sensor (if fitted)
To avoid possible eye damage from microwave signals, do
! WARNING not look directly into the sensor face.
13-1-1-15
Always wear safety glasses when dismantling assemblies
containing components under pressure from springs. This Note: The radar speed sensor is located underneath the
will protect against eye injury from components accidentally machine.
flying out.
GEN 6-2
9803/8030 Issue1
Section 2 Care & Safety Section 2
4-3 4-3
! WARNING
Cleaning Agents
When using cleaning agents, solvents or other chemicals,
you must adhere to the manufacturer's instructions and
safety precautions.
GEN-1-9
9803/8030 Issue1
Section 3 Routine Maintenance Section 3
i i
Contents Page No.
Greasing
General 4-1
Propshafts and PTO Driveshafts 4-1
Front Axle Steering Swivels 4-2
Front 3 point linkage 4-3
Automatic Trailer Coupling (if fitted) 4-3
Hydraulic Lift & 3 point Linkage 4-4
Rear PTO Driveshaft Bearing 4-4
Rear Suspension Cylinder Pivots 4-4
Steering column Universal Joints 4-5
Rear Anti-roll Bar Ball Joints 4-5
Roller drawbar 4-6
Cab
Checking the ROPS Structure 5-1
Checking the Windscreen Washer Fluid Level 5-2
Air Conditioning
Cleaning the Filter 5-3
Adjusting the Compressor Belt 5-4
Electrics
Battery Warning Symbols 6-1
First Aid - Electrolyte 6-1
Checking the Battery Electrolyte Level 6-2
Checking the Headlight Beam Alignment 6-3
Fuses See Section C
Hydraulics
Checking the Fluid Level 7-1
Changing the Filter Element 7-1
Changing the Hydraulic Fluid and Cleaning the Suction Strainer 7-2
Emptying the Hydraulic Coupling Drain Reservoir (if fitted) 7-3
9803/8030 Issue 5*
Section 3 Routine Maintenance Section 3
ii ii
Front Axle
Checking the Differential Oil Level 10 - 1
Changing the Differential Oil 10 - 1
Checking the Hub Oil Levels 10 - 2
Changing the Hub Oil 10 - 2
Rear Axle
Checking the Oil Level 11 - 1
Changing the Oil 11 - 2
Brakes
Checking and Renewing Foot Brake Pads 13 - 1
Checking and Renewing the Parking Brake Pads 13 - 2
Checking the Foot Brake Fluid Level 13 - 3
Checking the Trailer Air Tank 13 - 3
Checking the Air Tank Warning Lights 13 - 5
Cleaning the Trailer Brake Control Line Air Filter See Section G
* Engine
Checking the Oil Level 14 - 1
Changing the Oil and Filter 14 - 2
Draining/Renewing Fuel Pre-Filter
(Early Renewable Element Type) 15 - 1
Renewing Fuel Pre-Filter (One-piece Type) 15 - 1
Draining the Fuel Pre-Filter
3200, 3200 Plus, 3230, 3230 Plus 15 - 2
Changing the Fuel Pre-Filter Element
3200, 3200 Plus, 3230, 3230 Plus 15 - 2
Draining the Fuel Filter 15 - 3
Changing the Fuel Filter Element 15 - 4
Bleeding the Fuel System
3170, 3170 Plus 15 - 5
3190, 3190 Plus, 3220, 3220 Plus 15 - 6
3200, 3200 Plus, 3230, 3230 Plus 15 - 8
Checking the Coolant Level 16 - 1
Coolant Mixtures 16 - 1
Draining & Refilling the Coolant 16 - 2
Cleaning the Radiator and Coolers 16 - 3
Fan Belt 16 - 4
Changing the Air Filter Elements 17 - 1
Cleaning the Pre-Cleaner (optional) 17 - 2
9803/8030 Issue 5*
Section 3 Routine Maintenance Section 3
1-1 Engine Oil 1-1
New Engines
New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately.
DO NOT use a special running-in oil but use the oil recommended below from new.
IMPORTANT NOTE: IF SAE 15W/40, API CH-4 OR ACEA E3/B3A3 ENGINE OIL IS NOT AVAILABLE, THEN THE ENGINE OIL
MUST BE CHANGED AT 250 HOURS.
Alternative Oil
If the oil recommended above is not available then the alternatives listed below should be used according to the ambient
temperature.
Note: While 15W/40 oil is recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to
provide easier starting and sufficient oil flow at ambient temperatures below -5 °C (23 °F). Continued use of low viscosity oils
can decrease engine life.
IMPORTANT NOTICE: IF SAE 15W/40, GRADE CH-4/SJ ENGINE OIL IS NOT AVAILABLE, THEN THE ENGINE OIL MUST BE
CHANGED AT 250 HOURS.
Alternative Oil
If the oil recommended above is not available then the alternatives listed below should be used according to the ambient
temperature.
Notice: While 15W/40 oil is recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to
provide easier starting and sufficient oil flow at ambient temperatures below -5 °C (23 °F). Continued use of low viscosity oils
can decrease engine life.
9803/8030 Issue 2*
Section 3 Routine Maintenance Section 3
1-2 Fluids, Capacities and Lubricants 1-2
Fuel 350 (77) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
* Engine (Oil) - 3200/3230 17.5 (3.9) See Engine Oil (All Machines) at the
Engine (Oil) - All Others 15 (3.3) beginning of this section
Engine (Coolant) 33 (7.3) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
Summer Coolant/water
(See Coolant Mixtures)
* Front Axle
Housing 20 (4.4) JCB Gear Oil HP90 API-GL-5, MIL-L-2105C
Hubs (x2) 2.5 (0.55)
* Hydraulic System 120 (26.4) JCB Hydraulic Fluid HP46 ISO VG46
- see Note 1 (Above 38 °C, 100 °F)
Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.
9803/8030 Issue 2*
Section 3 Routine Maintenance Section 3
1-3 Fluids, Capacities and Lubricants (N. America) 1-3
Fuel
92.5 (350) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
* Engine (Oil) - 3200/3230 4.6 (17.5) See Engine Oil (All Machines) at the
Engine (Oil) - All Others 4 (15) beginning of this section
* Engine (Coolant) 8.77 (33.0) JCB Four Seasons Antifreeze & Summer ASTM D3306-74
Coolant/water (See Coolant Mixtures)
Rear Axle 7.1 (27.0) JCB Gear Oil HP90 API-GL-5, MIL-L-2105C
* Hydraulic System 31.7 (120) JCB Hydraulic Fluid HP46 ISO VG46
- see Notice 1
Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic
tank.
Notice 2: It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
9803/8030 Issue 2*
Section 3 Routine Maintenance Section 3
1-4 Lubricants - Health and Safety 1-4
It is most important that you read and understand this FIRST AID - OIL
information and the publications referred to. Make sure all
your colleagues who are concerned with lubricants read it Eyes
too. In the case of eye contact, flush with water for 15 minutes. If
irritation persists, get medical attention.
HYGIENE
Swallowing
JCB lubricants are not a health risk when used properly for If oil is swallowed do not induce vomiting. Get medical
their intended purposes. advice.
Low viscosity oils are more likely to do this, so take special SPILLAGE
care when handling used oils, which might be diluted with
fuel contamination. Absorb spilled oil with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a chemical
Whenever you are handling oil products you should maintain disposal area.
good standards of care and personal and plant hygiene. For
details of these precautions we advise you to read the Fires
relevant publications issued by your local health authority, ! WARNING
plus the following.
Do not use water to put out an oil fire. This will only
spread it because oil floats on water.
STORAGE
Extinguish oil and lubricant fires with carbon dioxide, dry
Always keep lubricants out of the reach of children.
chemical or foam. Fire fighters should use self contained
breathing apparatus.
Never store lubricants in open or unlabelled containers. 7-3-1-3/1
HANDLING
WASTE DISPOSAL
New Oil
All waste products should be disposed of in accordance
There are no special precautions needed for the handling or with all the relevant regulations.
use of new oil, besides the normal care and hygiene
practices. The collection and disposal of used oil should be in
accordance with any local regulations. Never pour used oil
Used Oil into sewers, drains or on the ground.
First 100 Hours Dealer Service (continued) Every 250 Operating Hours or 3 Monthly
whichever occurs first
Check (Engine Stopped) - continued
Do the Daily and 50 hour jobs plus:
* 14 Fan belt tension and condition.
* 15 Air conditioning compressor belt tension. Change
* 16 Gearbox oil level. † Engine oil and filter.
17 Transmission oil cooler/pipework condition, leakage,
routing and security. † Applies only if recommended oil (see Engine Oil) or
18 Front PTO gearbox oil level. Stratopore filter are not available. As an alternative to
19 Propellor shaft security. the recommended oil the following (or similar) should
20 Tyre pressures. be used:
21 Tightness of wheel nuts.
22 Hydraulic oil level. a -10oC to +50oC (14oF to 122oF) JCB Super Multigrade
23 Hydraulic oil cooler/pipework condition, leakage, 15W/40 (SAE 15W/40, API CF4/SG)
routing and security.
24 Brake fluid levels. b -15oC to +40oC (5oF to 104oF) JCB Super Mulitgrade
25 Brake pad security (service and parking). 10W/30 (SAE 10W/30, API CF4/SG).
26 Brake pipework routing and security.
27 Air system for leaks.
28 Panhard rod torque setting. Every 500 Operating Hours or Six Months
29 Rams/piston rods for damage/leaks. whichever occurs first
30 Battery charge/terminal condition and tightness.
31 Wiring for chafing/routing. Do the Daily jobs through to 250 hours plus:
32 Headlight alignment.
33 Windscreen washer level. Check (Engine Stopped)
34 Neutral start operation (Including clutch and PTO's). 1 Battery terminals condition and tightness.
35 Door locks. 2 Battery electrolyte level (if battery is not sealed for life).
36 Check for error codes, (EMS, engine and ABS when 3 Battery charge condition.
fitted), download, rectify and delete. 4 Exhaust system security.
37 Steering axle wheel alignment. 5 Engine mounting bolts for tightness.
38 Track rod and ball joint security. 6 Compressor housing for cracks and damage.
7 Compressor mountings for tightness.
Grease 8 Injection pump mountings for tightness.
39 Propellor shaft splines and universal joints. 9 Steering axle wheel alignment.
40 Steering swivels. 10 Headlamp alignment.
41 Rear PTO shaft bearings. 11 Panhard rod condition and torque tightness.
42 3 point linkage. 12 Track rod end and drag link ball joint security.
43 Rear lift ram pivots. 13 Steering damper condition and security.
44 Suspension cylinder pivots. 14 Suspension control arms and ‘V’ link condition and
bolt torque.
Check (engine running) 15 Air system for leaks.
45 Exhaust smoke. 16 Brake air tank warning lights.
46 Throttle and stop controls. 17 Brake caliper bolt torque.
47 PTO operation. 18 Brake pad security (service and parking).
48 2/4WD drive and diff. lock selection. 19 Parking brake adjustment.
49 Transmission low pressure circuit pressure maintaining 20 Brake pipework security.
valve setting. 21 Condition of lift ram rods.
50 Transmission lubrication pressure. 22 Coolant level/leaks, quality and antifreeze strength.
51 Diff. lock pressure relief valve. 23 Intercooler hose clamp security.
52 External hydraulics pressure relief valve. 24 Hoses and pipework for chafing and damage.
53 Instrument readings and warning lights. 25 Neutral start operation.
54 Operation of all electrical equipment. 26 Ram piston rods for damage/leaks.
55 Operation of clutch and footbrakes. 27 Front axle oil level.
56 Operation of steering. 28 Rear axle oil level.
57 Operation of transmission. 29 Transmission and hydraulic oil cooler/pipework
58 Operation of 3-point linkage. condition leakage and security.
59 Operation of front linkage (optional equipment). 30 Wiring for chafing/routing.
60 Rear axle/chassis clearance. 31 Download EMS Datalog.*
61 Height corrector valve operation. 32 Download ABS error codes, rectify and delete.
62 Parking Brake operation. 33 Brake light switch input to ABS ECU using computer
63 Pick-up hitch operation. diagnostic tool.
64 Spool valve operation. 34 Download engine error codes, rectify and delete.
65 Re-calibrate splitter clutch packs
9803/8030 Issue 3*
Section 3 Routine Maintenance Section 3
2-3 Service Schedules 2-3
Every 500 Operating Hours or Six Months Every 2000 Operating Hours or 2 Years
whichever occurs first (continued) whichever occurs first
Check (Engine Running) Do the Daily jobs through to 1000 hours plus:
35 Idling speed.
36 Max. no load engine speed. Clean
37 Suspension ride height and corrector valve operation. 1 Hydraulic tank suction strainers.
38 Suspension pressure maintenance valve pressure.
39 Transmission low pressure circuit pressure maintaining Check (Engine Stopped)
valve setting. 2 Rear suspension gas spring pressure.
40 Differential lock pressure relief valve. 3 Rear suspension accumulator pressure.
41 Pick-up hitch operation. 4 Engine vibration damper.
42 Rear axle/chassis clearance. 5 Compressor output line, air drier and pressure
43 Spool valve operation. regulator: check for carbon deposits and for air leaks.
44 Field speed control. 6 Radiator hose condition.
45 Selection speed of Selectronic range change 7 Transmission accumulator pressure.
< 2 kph.
46 Check for electronic draft control faults and rectify. Change
8 Inner air filter element.
Change 9 Coolant.
47 †Engine oil and filter. 10 Brake system fluid.
48 Fuel pre-filter. 11 Hydraulic fluid. (Unless sample indicates otherwise.)
49 Hydraulic fluid filter element.
50 Transmission oil filter.
51 Fuel filter. Every 5000 Operating Hours or 4 Years
52 Front hub oil.
whichever occurs first
Clean
53 Air conditioning intake filter Do the Daily jobs through to 1000 hours plus:
† Applies only if recommended oil (see Engine Oil) and Check (Engine Stopped)
Statopore filter are available. If these are not available 1 Engine valve clearances and adjust if necessary.
this job should be carried out every 250 hours,
reference T.I. 10/152 (see Every 250 Operating Hours Notes:
for suitable alternative oil).
(1) After a major transmission repair, the new oil should be
run to operating temperature and changed again to
Every 1000 Operating Hours or Yearly remove any contamination which entered during the
repair. Change the oil and filter after a further 100
whichever occurs first hours if the oil was heavily contaminated because of, or
from the failure (e.g. water contamination).
Do the Daily jobs through to 500 hours plus:
(2) After a hub repair, the new oil should be run to
Check (Engine Stopped) operating temperature and changed again to remove
1 ROPS structure. any contamination which entered during the repair.
2 Quality of coolant. Change the oil again after a further 100 hours to
3 Fan belt tensioner. remove any bedding-in wear.
4 Fan hub end play.
Change
10 Outer air filter element.
11 Gearbox oil and clean strainer.
12 Front axle oil.
13 Rear axle oil.
14 Air system drier dessicant canister.
Clean
15 Trailer brake control line air filter.
9803/8030 Issue 5*
Section 3 Routine Maintenance Section 3
3-1 Cleaning the Machine and Checking for Damage 3-1
Clean the machine using water and/or steam. Pay particular Make sure all pivot pins are correctly in place and secured
attention to the underside. Do not allow mud to build up on by their locking devices.
the engine and transmission. Make sure that the radiator
grille is not clogged up. Ensure that the steps and handrails are undamaged and
secure.
* Excessive power washing can cause damage to seals and
bearings. Do not direct high power water jets at oil seals, Check for broken or cracked window glass. Replace
universal joints, fuel system or electrical components, damaged items.
especially draft control solenoids.
Check all lamp lenses for damage.
* On ABS machines, take special care to avoid directing high
power water jets at the electrical connections to the front Inspect the tyres for damage and penetration by sharp
and rear axles. objects.
Inspect steelwork for damage. Note damaged paintwork for Check that all safety decals are in place and undamaged, fit
future repair. new decals where necessary.
! WARNING
Replace the seat belt with a new one if it is damaged, if
the fabric is worn, or if the machine has been in an
accident. Fit a new seat belt every three years regardless
of condition.
2-3-1-8
9803/8030 Issue 2*
Section 3 Routine Maintenance Section 3
3-2 Bonnet 3-2
! WARNING
The engine has rotating parts. Do not open the engine
cover while the engine is running. Do not use the
machine with the cover open.
INT-2-1-6
9803/8030 Issue 3*
Section 3 Routine Maintenance Section 3
4-1 Greasing 4-1
Note: The machine must always be greased after pressure- * Front axle propshaft
washing or steam cleaning. Extra care must be taken to Grease points 1 to 2.
ensure that propshaft universal joints and splines are
greased regularly. Rear axle propshaft
Grease points 3 to 4.
Greasing should be done with a grease gun. Normally, two
strokes of the gun should be enough. Stop greasing when Rear PTO drive shaft
fresh grease appears at the joint. Use only JCB HP Grease Grease points 5 to 7.
or equivalent.
Front PTO drive shaft (optional)
In the following illustrations the grease points are numbered. Grease points 8 to 10.
Count them off as you grease them.
Note: When greasing the universal joints, you must ensure
Refit the grease point dust caps after greasing. that grease appears at all four bearing caps. If grease does
not appear at any cap, move the shaft from side to side and
then re-grease. Wipe away all excess grease.
1 0
6 7
5
4 A286623
9803/8030 Issue 2*
Section 3 Routine Maintenance Section 3
4-2 Greasing 4-2
! WARNING
Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking
brake. Lower any mounted implements to the ground.
Stop the engine, remove the starter key, disconnect the
battery. Chock the wheels.
13-3-1-1
Grease points 1 to 4.
Note: After initial greasing, turn the wheels from lock to lock,
then grease again to ensure full penetration.
1 3
2 4
9803/8030 Issue 1
Section 3 Routine Maintenance Section 3
4-3 Greasing 4-3
Read the first page on Greasing for general information Note: Whenever the coupling has been pressure-washed it
about greasing. must always be greased.
Grease at points 1 to 3. Grease again and operate the hand lever again.
2 S170201
9803/8030 Issue 1
Section 3 Routine Maintenance Section 3
4-4 Greasing 4-4
Read the first page on Greasing for general information Hydraulic Lift and 3-Point Linkage
about greasing.
Hydraulic lift cross-shaft
! WARNING Grease points 5 and 6.
You will be working close into the machine for these
Hydraulic lift rams
jobs. Lower the equipment. Remove the starter key and
Grease points 7 to 10.
disconnect the battery. This will prevent the engine from
being started. Make sure that the parking brake is Three point linkage lift rods
engaged. Grease at nipples 11, 12, 13 and 14 (lift collars A and B to
access nipples 13 and 14). On machines with heavy duty
Chock all four wheels before getting under the machine. linkage grease points 15 and 16 also.
13-3-1-9
1 3
2 4
5 6
A B A B A B A B
7 8
*
% ^
! @
A B
9 0 &
£ $
418170
9803/8030 Issue 1
Section 3 Routine Maintenance Section 3
4-5 Greasing 4-5
! WARNING
You will be working close into the machine for these
jobs. Lower the equipment. Remove the starter key and 1
disconnect the battery. This will prevent the engine from
being started. Make sure that the parking brake is
engaged.
! WARNING
Make the machine safe before getting beneath it. Do the 2
following: Park on level ground. Engage the parking
brake. Lower any mounted implements to the ground.
Stop the engine, remove the starter key, disconnect the
battery. Chock the wheels.
13-3-1-1
4 5
262210
9803/8030 Issue 2*
Section 3 Routine Maintenance Section 3
4-6 Greasing 4-6
! WARNING
You will be working close into the machine for these A B A B A B A B
1
2
9803/8030 Issue 1
Section 3 Routine Maintenance Section 3
5-1 Cab 5-1
! WARNING
The cab on this machine is designed to give the operator Check the structure for damage.
protection in the event of the machine rolling over
(ROPS). The following points must be strictly observed. Check that the four mounting bolts are installed and
undamaged. Check that torque tightness of nuts A and B is
1 If the machine has been in an accident which has correct (see Table below). Tighten them to the correct
damaged the ROPS structure, the machine must not torque if necessary.
be used until the structure has been renewed. If there
is any doubt about the strength of the ROPS Zinc-Plated Fasteners (colour: golden)
structure, it must be renewed. The operator could be
killed or seriously injured as a result of using a Nm kgf m lbf ft
machine with a damaged or missing ROPS. 375 38 277
2 The ROPS structure must not be modified except as Dacromet Fasteners (colour: mottled silver)
approved by JCB. Unauthorised modifications may
result in weakening of the structure. Nm kgf m lbf ft
365 37 269
3 Always use JCB supplied parts to mount the ROPS
structure on the machine. The use of unapproved
components could reduce the protection given by the
structure.
A B
420410
9803/8030 Issue 2
Section 3 Routine Maintenance Section 3
5-2 Cab 5-2
A293830
9803/8030 Issue 1
Section 3 Routine Maintenance Section 3
5-3 Air Conditioning 5-3
! WARNING
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6
D
E
1 Unscrew the two quarter-turn fasteners A and remove
closing panel B. Remove the two screws C and pull out
the filter D. Check condition of filter and renew if split or
A C
worn.
B 420960
3 Check and clean the filter sealing face on the cab body.
4 Refit the pre-cleaner and fit the filter into the cab
aperture using two screws C. Refit the closing panel B.
! WARNING J
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6
F G H 417800
3 Check and clean the seal contact face on the cab body.
K
W
FLO
AIR
4 Fit the filter into the cab aperture using two screws H.
Refit the closing panel G. 746220
9803/8030 Issue 3
Section 3 Routine Maintenance Section 3
5-4 Air Conditioning 5-4
! WARNING
Make sure the engine cannot be started. Disconnect the
battery before doing this job.
2-3-3-5
! WARNING
The air conditioning system is a closed loop system and
contains pressurised refrigerant. No part of the system
should be disconnected until the system has been
discharged by a refrigeration engineer or a suitably
trained person. You can be severely frostbitten or injured
by escaping refrigerant.
4-3-4-1/2
A B
417580
9803/8030 Issue 3*
Section 3 Routine Maintenance Section 3
6-1 Electrics 6-1
IS SWALLOWED
9803/8030 Issue 1
Section 3 Routine Maintenance Section 3
6-2 Electrics 6-2
! WARNING
Do not top the battery up with acid. The electrolyte could
boil out and burn you.
2-3-4-6
Note: When two batteries are fitted on the machine, they are
connected in parallel. When fitting the cables, ensure that
they are connected as shown on the illustration.
9803/8030 Issue 1
Section 3 Routine Maintenance Section 3
6-3 Electrics 6-3
B Y
B
Y
1300 m
A
A
X
X
D
Z
2.00 m
C
418260
9803/8030 Issue 1
Section 3 Routine Maintenance Section 3
7-1 Hydraulics 7-1
1 Park the machine on level ground. Apply the parking a Fit a new paper insert Y into metal outer element J.
brake. Lower any mounted implements to the ground. b Assemble the refurbished element J on to the
Stop the engine. Remove the starter key. spindle, using a new seal L. Ensure that the top lip of
the seal locates in the groove inside the filter head
2 Look at the fluid level in the sight gauge A. The level M. Fit and tighten the nut and spring assembly H.
should be between the two marks on the gauge. If the c Fit the element assembly F using a new 'O' ring G.
fluid is cloudy, water or air has entered the system. d Refit cover plate D and nuts C using a new 'O' ring
Water or air in the system could damage the hydraulic E.
pump. e Tighten nuts C to 7 Nm (5 lbf ft).
f Top up fluid level at tank cap B and refit cap.
3 If necessary, add recommended fluid at tank cap B.
M
B
K G
L C
D
F
J Y A
F E
H J
417440
9803/8030 Issue 1
Section 3 Routine Maintenance Section 3
7-2 Hydraulics 7-2
Changing the Hydraulic Fluid and Cleaning 1 Park the machine on firm, level ground.
the Suction Strainers 2 Place a container that can hold at least 120 litres (26.4
UK gal; 31.7 US gal) beneath drain plug B. Remove the
! WARNING plug and allow the oil to drain. Refit the drain plug.
Fine jets of hydraulic fluid at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic ! WARNING
fluid leaks. Do not put your face close to suspected Oil will gush from the hole when the drain plug is
leaks. Hold a piece of cardboard close to suspected removed. Keep to one side when you remove the plug.
leaks and then inspect the cardboard for signs of 2-3-4-2
hydraulic fluid. If hydraulic fluid penetrates your skin, get
medical help quickly. 3 Remove the strainers as follows:
INT-3-1-10/1
a Remove tank cap A.
! WARNING b Disconnect pipe C from the filter, remove bolts D
Make the machine safe before getting beneath it. Do the and take out filter assembly E.
following: Park on level ground. Engage the parking c Unscrew external hydraulics/draft control hydraulic
brake. Lower any mounted implements to the ground. strainer F from its spigot and withdraw from the tank
Stop the engine, remove the starter key, disconnect the via the filter aperture.
battery. Chock the wheels. d Repeat step c for the steering and suspension
13-3-1-1 strainer G.
! CAUTION
Using incorrect fluid could damage the system. See 4 Clean the strainers with a suitable solvent. Follow the
Fluids, Capacities and Lubricants for the correct fluid. solvent manufacturer's instructions on safety.
The fluid can harm your skin. Wear rubber gloves. Cover
cuts or grazes. 5 Refit the strainers, using JCB Activator and JCB
2-3-5-1/2 Threadlocker and Sealer on the threads. Refit the filter.
Reconnect pipe C using Clayton System Seal SC1251
to seal the threads.
D A
C
E
G
B
418370
9803/8030 Issue 1
Section 3 Routine Maintenance Section 3
7-3 Hydraulics 7-3
A B A B A B A B
418050
9803/8030 Issue 1
Section 3 Routine Maintenance Section 3
9-1 PTO, Speed and Range Gearboxes 9-1
194570
9803/8030 Issue 1
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