Technical Bulletin: DATE: April 2012 NUMBER: 12/060 Issue: 1

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TECHNICAL BULLETIN
DATE: April 2012 ISSUE: 1 NUMBER: 12/060
SUBJECT: Cold Climate Start up Procedure
MACHINES AFFECTED: 225,225T,260,260T,280,300,300T,320T,330 Machines
TERRITORIES AFFECTED: All Territories
SERIAL NUMBER RANGE AFFECTED: From 1745019 To 1745482
SERVICE CODE: E3201 REPAIR TIME: 3.5 Hours
TO BE CARRIED OUT: Immediately
SAFETY NOTICE: Instructions in Service Bulletins assume that the engineer has a sound knowledge of safety procedures and has been trained in the
maintenance and repair of JCB products. If you are unsure or do not understand information contained in this or other bulletins, ask your supervisor or contact
JCB Service for advice. REMEMBER SAFETY MUST COME FIRST.
Introduction and 2 of the transmission pump.
Reports have been received of poor drive response in 5 Remove the fittings and pressure sensors installed in
cold climate, JCB has updated the warm-up procedure the ports 1 and 2. K Fig 1. ( T 1).
describe in the operators manual and has design a Cold
Climate Flushing valve, when used together this will
improve the cold climate controllability on initial start-up.
The flushing valve will vent the cold servo drive oil to tank
and replenish the oil with the warm oil from the hydraulic
tank. Follow the procedure to complete the modifications
on all the machines before serial number 1745482.
Warranty Instruction
Table 1. FSI Number SE31

Service Code: E3201
Description: Valve Servo control, Joystick Left side
Repair Time: 3.5 Hours
Failed Part: 332/X3871
Procedure
1 Make the machine safe.
2 Prepare the machine for maintenance with the loader

arm raised and cab tilted. Please refer to the
operators manual for the correct procedure.
3 Operate the controls several times to release the P029890
stored hydraulic pressure. Fig 1.
4 Remove the servo drive lines (X4) from the ports 1 6 Install the T-fitting adaptor L into the ports 1 of the
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, World Class
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. Customer Support
This communication and the information within is intended for the recipient only, for information purposes, is confidential and may not be communicated to any third party.
Whilst the information is believed to be correct, no guarantee is given by JCB as to it’s accuracy and it’s use may not be attributed to JCB.
This bulletin is issued for information only and does not constitute an instruction to carry out warranty repairs on JCB products.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 594700 Fax +44 1889 591400
12/060 2/9
transmission pump.
7 Tighten the T-fitting adapter L to a torque of 20Nms.
8 Install the brass adaptor E into the T-fitting adaptor L.
9 Tighten the brass adapter E to a torque of 12Nms.
10 Lubricate the ends of tube harness H with the

hydraulic oil.
11 Insert the tube harness H into the brass adapter E.

K Fig 2. ( T 2).
P029890-2
Fig 3.
24 Remove the front R-plug from the top of the

transmission pump.
25 Install the brass adaptor J and torque to 20 Nms.

K Fig 4. ( T 2).
P029890-1
Fig 2.
12 Install the brass fitting (removed earlier) back into the

adaptor L.
13 Tighten the brass fitting to a torque of 12 Nms.
14 Lubricate and install the servo drive lines into the

fitting.
P029890-3
15 Install T-adaptor L into the rear port 2 of the Fig 4.
transmission pump and torque to 20 Nms.
26 Mount the flushing valve B to the bracket C using the
16 Install the brass adaptor E into T-adaptor L and bolts F.
torque to 12 Nms.
27 Tighten the bolts F to a torque of 10Nms.
17 Install the T-adaptor M into the front port 2 of the K Fig 5. ( T 2).
transmission and torque to 20 Nms.
18 Install the brass adaptor P into the T-adaptor M and

torque to 12 Nms.
19 Lubricate the ends of tube harness L with hydraulic

oil.
20 Insert the tubes into the brass adaptor E and P.

K Fig 3. ( T 2).
21 Install the brass fittings (removed earlier) back into

the adaptor L and M and torque to 12 Nms.
22 Lubricate the servo drive tubes removed earlier.
23 Insert the servo drive tubes into the brass fittings.

P029890-4
Fig 5.
12/060 3/9
28 Remove the hydraulic pump mounting bolts 3. 37 Insert the tubes H and J into the brass adaptors E.
29 Clean the threads on the bolt and the transmission 38 Install the brass fitting D into the flushing valve port T
pump. and torque to 20Nms.
30 Apply Loctite to the pump mounting bolts 3. 39 Install the drain line tube G into brass fitting D on the
K Fig 6. ( T 3). flushing valve B and brass fitting J on transmission
pump. K Fig 8. ( T 3).
40 Snug the mounting nut by hand then turn the nut for
one complete revolution for the final torque setting.
Note: Clean all the hydraulic connection of any residual

oil.
P029890-5
Fig 6.
31 Install the flushing valve assembly B and torque to

116Nms.
32 Install the brass adaptors fittings E (X4) into the

flushing valve B and torque to 12 Nms. P029890-7
Fig 8.
33 If equipped install the pressure switches into the
flushing valve B. 41 Use the link harness N and connect the flushing
valve dump solenoid to the main harness at
Note: Reverse alarm pressure switches part number 701/ connector PF wire numbers 824 and 633.
80352 are installed in the ports labelled RAL and brake K Fig 9. ( T 3).
light pressure part number 701/80351 are installed in the
ports BRL.
34 Torque all the switches to 20Nms.
35 If the machine is not equipped with reverse alarm or

brake lights then install the blanking plug Q and
torque to 20Nms. K Fig 7. ( T 3).
P029890-8
Fig 9.
42 Open the Service Master and make a note of the

machine options through the machine Setup tool.
Note: Make sure that Service Master has version 10.3.1

or higher.
P029890-6
Fig 7. 43 Use the Service Master Flash loader tool to update
the machine ECU software to version 2.04 and Right
36 Lubricate the ends of tube harness’s H and J with hand switch panel software to version 1.00.
hydraulic oil.
12/060 4/9
44 Once the software has been updated reopen the b Press and hold the park brake switch for five
Setup tool and write all the machine options, then seconds and release.
close.
c The hydraulic oil temperature light 4 will flash
45 Disconnect the laptop from the machine. indicating that the system has entered into the
flushing circuit. K Fig 10. ( T 4).
46 Lower the cab and secure the cab mounting bolts.
d Operate the drive controller in full forward and full
47 Test the flushing valve by entering into the manual reverse for 30 seconds in each direction.
override mode listed in the operation section of this
bulletin. Note: Hydraulic oil temperature light 4 will flash when
entered into manual mode and also will blink on start up if
48 Once the manual override is completed and the temperatures are below 00 C.
flushing is operating correctly then raise the cab and
check for the leaks.
49 If no leaks is present then lower and secure the cab

as per the operator’s manual.
Flushing Operation
1 The ECU monitors the ambient air temperature

through the built in temperature sensor.
Note: Same temperature sensor is used for grid heater

operation.
2 If the temperature is below 0oC the hydraulic oil

temperature indictor light in the right hand panel will
flash indicating the flushing valve system A can be
activated.
3 The system has two separate operating modes

dependent on temperature.
P029890-9
Temperature Range Count down timer
Fig 10.
0o C to -12o C 120 Seconds
-12o C to – 20o 180 Seconds Parts List

Note: Items B to Q are listed for reference only.
4 Flushing valve system A can be used more than
once when the operator feels the drive response is Table 2.
not satisfactory and the ambient temperature is
Item Part No Description Qty
below 0oC.
A 333/E0050 Flushing valve kit 1
5 Push the park brake switch two times with a three B 332/X5432 Flushing valve 1
second pause each time to bypass the flushing valve C 332/X5922 WA flushing Valve Mount 1
system.
D 332/X2754 Adaptor (Olive ring) 1
6 With the introduction of the system the machine will E 332/X1586 Adaptor (Push Lock Valve) 7
have three possible new error codes:
F 1316/3214Z Bolt 2
a C132 SC to + at flushing valve. G 332/X5456 Flushing Drain Tube 1
H 332/X5921 WA Tube Harness X3 Harness 1
b C232 SC to – at flushing valve.
J 332/X5920 WA Tube Harness X4 Harness 1
c C332 OC at flushing valve. K 332/X2753 Adaptor Return Olive Pump 1
L 332/X2004 Adaptor run ‘T’ pump 3
7 There is also a manual override procedure following
certain repairs such as transmission replacement to M 332/X4286 Adaptor ‘T’ X4 port front 1
bleed the servo drive lines. N 332/X5911 Harness 1
P 332/X1573 Adaptor elbow 90 X4 Port front 1
a Place the left hand control pod in the lower
position and the lap bar in the upper position Q 1745/0002 Blanking Plug 4
when the machine is running.
12/060 5/9
Machine List Dealer A/c. Serial No.

JCB INC. EAST 451 1745032
Table 3.
Dealer A/c. Serial No.
AL GHODWA FOR TRADING 1570 1745431
AGENCIES CO. LTD JCB INC. EAST 451 1745035
CONSTRUCTION MACHINERY LTD 1611 1745305 JCB INC. EAST 451 1745036
DERCO PERU SA 6100 1745291 JCB INC. EAST 451 1745041

DERCO S.A 3618 1745184 JCB INC. EAST 451 1745049

ECI JCB - KTA 1292 1745242 JCB INC. EAST 451 1745058
EMYR EVANS 2359 1745298 JCB INC. EAST 451 1745063
EMYR EVANS 2359 1745397 JCB INC. EAST 451 1745067
G & J PECK LTD (ELY) 1076 1745239 JCB INC. EAST 451 1745069
J C BAMFORD N. V. 3060 1745295 JCB INC. EAST 451 1745070
J C BAMFORD EXCAVATORS LTD 101 1745026 JCB INC. EAST 451 1745073
ESTATES A/C JCB INC. EAST 451 1745074
J C BAMFORD EXCAVATORS LTD 101 1745068 JCB INC. EAST 451 1745075
ESTATES A/C
JCB - BELGIUM N. V. 3074 1745119
JCB - BELGIUM N. V. 3074 1745183
JCB - BELGIUM N. V. 3074 1745387
12/060 6/9
Dealer A/c. Serial No. Dealer A/c. Serial No.

JCB INC. EAST 451 1745090 JCB INC. EAST 451 1745148
12/060 7/9

12/060 8/9

12/060 9/9

JCB INC. EAST 451 1745455 JVM EQUIPMENT INT'L LTD - 1696 1745303
JCB INC. EAST 451 1745456 MOSCOW
MOSCOW
JVM EQUIPMENT INT'L LTD - 1696 1745388
MOSCOW
MOSCOW
JCB INC. EAST 451 1745472 RIATRADE JOINT-STOCK 7203 1745116
COMPANY
RIATRADE JOINT-STOCK 7203 1745123
COMPANY
SALEH & ABDULAZIZ ABAHSAIN & 1320 1745182
JCB INC. EAST 451 1745479 CO LTD
JCB INC. EAST 451 1745480 SALEH & ABDULAZIZ ABAHSAIN & 1320 1745186
JCB INC. EAST 451 1745481 CO LTD
JCB MAQUINARIA S.A. 3062 1745114 SALEH & ABDULAZIZ ABAHSAIN & 1320 1745191
CO LTD
JCB MAQUINARIA S.A. 3062 1745178
SCOT JCB LTD - GLASGOW 141 1745296
JCB S.P.A. 3065 1745059
SCOT JCB LTD - GLASGOW 141 1745304
JCB S.P.A. 3065 1745060
SIMPSON MOTORS LIMITED 1317 1745389
JCB S.P.A. 3065 1745061
JCB S.P.A. 3065 1745062
JCB S.P.A. 3065 1745428
STROYKOMPLEKT 1653 1745135
JCB S.P.A. 3065 1745430
TERRA BULGARIA (BULGARIA 3095 1745188
JCB S.P.A. 3065 1745435 WARRANTY A/C)
JCB S.P.A. 3065 1745437 TERRA BULGARIA (BULGARIA 3095 1745429
JCB S.P.A. 3065 1745440 WARRANTY A/C)
JCB S.P.A. 3065 1745441 TERRA HUNGARIA KFT 3089 1745207
JCB S.P.A. 3065 1745443 (WARRANTY A/C)
JCB S.P.A. 3065 1745444 TERRA HUNGARIA KFT 3089 1745399

(WARRANTY A/C)
JCB S.P.A. 3065 1745446
TERRA MET SPOL S R O (CZECH 3085 1745189
JCB S.P.A. 3065 1745447 WARR. A/C)
JCB S.P.A. 3065 1745448 TERRASTROJ SPOL SRO 3086 1745308
JCB S.P.A. 3065 1745449 (SLOVAKIA WARR. A/C)
JCB SA WARRANTY ACCOUNT 3068 1745436 TRIAL AVTO 1693 1745125
JCB SALES LTD 104 1745117 TRIAL AVTO 1693 1745133
JCB SALES LTD 104 1745386 TRIAL AVTO 1693 1745190
JCB VERTRIEB & SERVICE GMBH 1891 1745403 TRIAL AVTO 1693 1745193
JVM EQUIPMENT INT'L LTD - 1696 1745136 UNITRACK S.A 7126 1745129
MOSCOW WATLING JCB LTD - LEICESTER 145 1745241
JVM EQUIPMENT INT'L LTD - 1696 1745302 WATLING JCB LTD - LEICESTER 145 1745438
MOSCOW

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MACHINES AFFECTED: 225,225T,260,260T,280,300,300T,320T,330 Machines

TERRITORIES AFFECTED: All Territories

SERIAL NUMBER RANGE AFFECTED: From 1745019 To 1745482

SERVICE CODE: E3201 REPAIR TIME: 3.5 Hours

TO BE CARRIED OUT: Immediately

Introduction and 2 of the transmission pump.

Table 1. FSI Number SE31

2 Prepare the machine for maintenance with the loader

3 Operate the controls several times to release the P029890

stored hydraulic pressure. Fig 1.

7 Tighten the T-fitting adapter L to a torque of 20Nms.

8 Install the brass adaptor E into the T-fitting adaptor L.

9 Tighten the brass adapter E to a torque of 12Nms.

10 Lubricate the ends of tube harness H with the

11 Insert the tube harness H into the brass adapter E.

24 Remove the front R-plug from the top of the

25 Install the brass adaptor J and torque to 20 Nms.

12 Install the brass fitting (removed earlier) back into the

13 Tighten the brass fitting to a torque of 12 Nms.

14 Lubricate and install the servo drive lines into the

18 Install the brass adaptor P into the T-adaptor M and

19 Lubricate the ends of tube harness L with hydraulic

20 Insert the tubes into the brass adaptor E and P.

21 Install the brass fittings (removed earlier) back into

22 Lubricate the servo drive tubes removed earlier.

23 Insert the servo drive tubes into the brass fittings.

Note: Clean all the hydraulic connection of any residual

31 Install the flushing valve assembly B and torque to

32 Install the brass adaptors fittings E (X4) into the

34 Torque all the switches to 20Nms.

35 If the machine is not equipped with reverse alarm or

42 Open the Service Master and make a note of the

Note: Make sure that Service Master has version 10.3.1

49 If no leaks is present then lower and secure the cab

1 The ECU monitors the ambient air temperature

Note: Same temperature sensor is used for grid heater

2 If the temperature is below 0oC the hydraulic oil

3 The system has two separate operating modes

-12o C to – 20o 180 Seconds Parts List

Machine List Dealer A/c. Serial No.

DERCO PERU SA 6100 1745291 JCB INC. EAST 451 1745041

DERCO PERU SA 6100 1745293 JCB INC. EAST 451 1745042

DERCO PERU SA 6100 1745297 JCB INC. EAST 451 1745043

DERCO PERU SA 6100 1745395 JCB INC. EAST 451 1745044

DERCO PERU SA 6100 1745404 JCB INC. EAST 451 1745045

DERCO PERU SA 6100 1745405 JCB INC. EAST 451 1745046

DERCO PERU SA 6100 1745427 JCB INC. EAST 451 1745048

DERCO S.A 3618 1745184 JCB INC. EAST 451 1745049

DERCO S.A 3618 1745185 JCB INC. EAST 451 1745050

DERCO S.A 3618 1745192 JCB INC. EAST 451 1745051

DERCO S.A 3618 1745299 JCB INC. EAST 451 1745052

DERCO S.A 3618 1745300 JCB INC. EAST 451 1745053

Dealer A/c. Serial No. Dealer A/c. Serial No.

Dealer A/c. Serial No. Dealer A/c. Serial No.

Dealer A/c. Serial No. Dealer A/c. Serial No.

Dealer A/c. Serial No. Dealer A/c. Serial No.

JCB S.P.A. 3065 1745444 TERRA HUNGARIA KFT 3089 1745399

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