Jcb 8250 fastrac service repair manual sn：01138001 011386360

Service Manual JCB 8250 Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/8040-6

World Class Customer Support 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, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377

Section 1 - General Information

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9803/8040-2

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Section 1 - General Information Contents Page No. Identifying the Machine Serial Numbers ........................................................................................ 1 - 1 Serial Number Plate ........................................................................... 1 - 1 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners .....................................

Introduction .........................................................................................

Zinc Plated Fasteners (golden finish) .................................................

Dacromet Fasteners (mottled silver finish) .........................................

Hydraulic Connections .............................................................................

'O' Ring Face Seal System .................................................................

'Torque Stop' Hose System ................................................................

1-3 1-3 1-4 1-5 1-6 1-6 1-9

Service Consumables Sealing and Retaining Compounds ....................................................... 1 - 10

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Section 1 - General Information Contents

1 - ii

Page No.

1 - ii

Section 1 - General Information Identifying the Machine Serial Numbers

Identifying the Machine Serial Numbers Serial Number Plate

Unit Identification

Each machine has a serial number plate located at X. The 17 digit Vehicle Identification Number (VIN), and the serial numbers of the engine and transmission are stamped on the plate.

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 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 are ordered.

Engine

M

Gearbox

N

Front axle

P

Rear axle

R

Fig 1.

Typical Vehicle Identification No. (VIN)

Fig 2.

A

Manufacturing code

B

Machine range FT = Fastrac

C

Engine type

D

Transmission type

E

Vehicle max. speed

(gearbox & axle combination)

Fig 3.

40 = 40 kph 50 = 50 kph 65 = 65 kph F

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Serial number

9803/8040-2

1-1

Section 1 - General Information Identifying the Machine Serial Numbers

N Fig 4.

Fig 5.

Fig 6.

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Section 1 - General Information

Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Introduction Some external fasteners on Fastrac machines are assembled using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow plating used on earlier machines.

The two types of fasteners can be readily identified by colour and part number suffix as follows: Fastener Type

Colour

Part Number

Zinc and Yellow

Golden finish

Z (e.g. 1315/3712Z)

Dacromet

Mottled silver finish

D (e.g. 1315/3712D)

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.

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.

Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox and engine joint seams or internal applications.

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

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Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners

Zinc Plated Fasteners (golden finish)

Metric - All Internal Hexagon Headed Cap Screws

Use the values on these pages only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third.

Diameter

Torque Settings

mm

Nm

kgf m

lbf ft

M3

2

0.2

1.5

M4

6

0.6

4.5

M5

11

1.1

8

M6

19

1.9

14

M8

46

4.7

34

M10

91

9.3

67

M12

159

16.2

117

M16

395

40

292

5

M18

550

56

406

770

79

568

1332 136

Metric Grade 8.8 Bolts Size

Torque Settings Nm

Diameter (mm) M5

(5)

kgf m lbf ft

Hexagon (A/F) mm 8

7

0.7

M6

(6)

10

12

1.2

9

M20

M8

(8)

13

28

3.0

21

M24

M10

(10)

17

56

5.7

42

M12

(12)

19

98

10

72

M16

(16)

24

244

25

180

M18

(18)

27

350

36

258

M20

(20)

30

476

48

352

M24

(24)

36

822

84

607

M30

(30)

46

1633 166

1205

M36

(36)

55

2854 291

2105

Metric Grade 10.9 Bolts Size

Torque Settings Nm

1-4

983

Verbus Ripp Bolts

Fig 7.

Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

kgf m lbf ft

Diameter (mm)

Hexagon (A/F) mm

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

M16

(16)

24

343

35

253

M20

(20)

30

657

67

485

M24

(24)

36

1157 118

853

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Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners

Dacromet Fasteners (mottled silver finish)

Metric Grade 12.9 Bolts

Use the values on these pages only where no torque setting is specified in the text.

Note: Dacromet fasteners are lubricated as part of the plating process. Do not lubricate Metric Grade 8.8 Bolts

Bolt size

Torque Settings

Dia.

Nm

kgf m lbf ft

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

Bolt size

Torque Settings

M16 x 2

350

35.7

258

Dia.

Nm

kgf m lbf ft

M18 x 2.5

463

47

342

M6 x 1.0

9

0.9

7

M20 x 2.5

654

67

482

M8 x 1.25

22.5

2.3

17

M24 x 3

1125 115

830

M30 x 3.5

2247 229

1657

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

Metric Grade 10.9 Bolts Bolt size

Torque Settings

Dia.

Nm

kgf m lbf ft

M6 x 1.0

13.5

1.4

10

M8 x 1.25

35

3.6

26

M10 x 1.5

62.5

6.4

46

M12 x 1.75

115

11.7

85

M14 x 2

175

17.9

129

M16 x 2

300

30.6

221

M18 x 2.5

395

40

291

M20 x 2.5

559

57

412

M24 x 3

962

98

710

M30 x 3.5

1920 196

1-5

1416

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Section 1 - General Information Standard Torque Settings Hydraulic Connections

Hydraulic Connections T11-003

'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.

Table 1. Torque Settings - BSP Adaptors BSP Adaptor Hexagon (A/F) Size

1-6

in.

mm

Nm

kgf m

lbf ft

1/4

19.0

18.0

1.8

13.0

3/8

22.0

31.0

3.2

23.0

1/2

27.0

49.0

5.0

36.0

5/8

30.0

60.0

6.1

44.0

3/4

32.0

81.0

8.2

60.0

1

38.0

129.0

13.1

95.0

1 1/4

50.0

206.0

21.0

152.0

Table 2. Torque Settings - SAE Connections SAE Port Hexagon (A/F)

SAE Tube Size

Thread Size

mm

Nm

kgf m

lbf ft

4

7/16 - 20

15.9

20.0 - 28.0

2.0 - 2.8

16.5 - 18.5

6

9/16 - 18

19.1

46.0 - 54.0

4.7 - 5.5

34.0 - 40.0

8

3/4 - 16

22.2

95.0 - 105.0

9.7 - 10.7

69.0 - 77.0

10

7/8 - 14

27.0

130.0 - 140.0

13.2 - 14.3

96.0 - 104.0

12

1 1/16 - 12

31.8

190.0 - 210.0

19.4 - 21.4

141.0 - 155.0

16

1 5/16 - 12

38.1

290.0 - 310.0

29.6 - 31.6

216.0 - 230.0

20

1 5/8

47.6

280.0 - 380.0

28.5 - 38.7

210.0 - 280.0

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Section 1 - General Information Standard Torque Settings Hydraulic Connections Hoses Screwed into Adaptors

Fig 8.

Hoses 8-B screwed into adaptors 8-A seal onto an `O' ring 8-C which is compressed into a 45° seat machined into the face of the adaptor port.

BSP Hose Size in.

1-7

Note: Dimension 8-D will vary depending upon the torque applied.

Table 3. BSP Hose - Torque Settings Hexagon (A/F) mm

Nm

1/8

14.0

14.0 - 16.00

1.4 - 1.6

10.3 - 11.8

1/4

19.0

24.0 - 27.0

2.4 - 2.7

17.7 - 19.9

3/8

22.0

33.0 - 40.0

3.4 - 4.1

24.3 - 29.5

1/2

27.0

44.0 - 50.0

4.5 - 5.1

32.4 - 36.9

5/8

30.0

58.0 - 65.0

5.9 - 6.6

42.8 - 47.9

3/4

32.0

84.0 - 92.0

8.6 - 9.4

61.9 - 67.8

1

38.0

115.0 - 126.0

11.7 - 12.8

84.8 - 92.9

1 1/4

50.0

189.0 - 200.0

19.3 - 20.4

139.4 - 147.5

1 1/2

55.0

244.0 - 260.0

24.9 - 26.5

180.0 - 191.8

9803/8040-2

kgf m

lbf ft

1-7

Section 1 - General Information Standard Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 4. BSP Adaptors with Bonded Washers - Torque Settings BSP Size

1-8

in.

Nm

kgf m

lbf ft

1/8

20.0

2.1

15.0

1/4

34.0

3.4

25.0

3/8

75.0

7.6

55.0

1/2

102.0

10.3

75.0

5/8

122.0

12.4

90.0

3/4

183.0

18.7

135.0

1

203.0

20.7

150.0

1 1/4

305.0

31.0

225.0

1 1/2

305.0

31.0

225.0

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Section 1 - General Information Standard Torque Settings Hydraulic Connections

'Torque Stop' Hose System

Fig 9. `Torque Stop' Hoses 9-B screwed into adaptors 9-A seal onto an 'O' ring 9-C which is compressed into a 45° seat machined in the face of the adaptor port. To prevent the 'O' ring being damages as a result of over tightening, 'Torque

Stop' Hoses have an additional shoulder 9-D, which acts as a physical stop.

Note: Minimum dimension 9-E fixed by shoulder 9-D.

Table 5. BSP `Torque Stop' Hose - Torque Settings BSP Hose Size Hexagon (A/F)

1-9

in.

mm

Nm

kgf m

lbf ft

1/8

14.0

14.0

1.4

10.0

1/4

19.0

27.0

2.7

20.0

3/8

22.0

40.0

4.1

30.0

1/2

27.0

55.0

5.6

40.0

5/8

30.0

65.0

6.6

48.0

3/4

32.0

95.0

9.7

70.0

1

38.0

120.0

12.2

89.0

1 1/4

50.0

189.0

19.3

140.0

1 1/2

55.0

244.0

24.9

180.0

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Section 1 - General Information Service Consumables Sealing and Retaining Compounds

Service Consumables Sealing and Retaining Compounds T11-001_3

Table 6.

Type

Description

Part No.

Quantity

JCB Multi-Gasket

A medium strength sealant suitable for all sizes of 4102/1212 gasket flanges, and for hydraulic fittings of 25-65 mm diameter.

50 ml

JCB High Strength Threadlocker

A high strength locking fluid for use with threaded 4102/0551 components. Gasketing for all sizes of flange where the strength of the joint is important.

50 ml

JCB Retainer (High Strength)

For all retaining parts which are unlikely to be dismantled.

4101/0651

50 ml

JCB Threadlocker and 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.

4101/0250

10 ml

4101/0251

50 ml

JCB Threadlocker and Sealer (High Strength)

A high strength locking fluid for sealing and retaining 4101/0550 nuts, bolts, and screws up to 50 mm diameter, and 4101/0552 for hydraulic fittings up to 25 mm diameter.

10 ml 200 ml

JCB Threadseal

A medium strength thread sealing compound.

4102/1951

50 ml

JCB Activator

A cleaning primer which speeds the curing rate of anaerobic products.

4104/0251

200 ml (Aerosol)

4104/0253

1 ltr (Bottle)

JCB Cleaner/Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants.

4104/1557

400 ml (Aerosol)

Direct Glazing Kit

For one pane of glass; comprises of:

993/55700

– 1 x Ultra Fast Adhesive (310 ml) – 1 x Active Wipe 205 (30 ml) – 1 x Black Primer 206J (30 ml) – plus applicator nozzle etc.

Ultra Fast Adhesive

For direct glazing.

4103/2109

310 ml

Active Wipe 205

For direct glazing.

4104/1203

250 ml

Black Primer 206J

For direct glazing.

4201/4906

30 ml

Clear Silicone Sealant

To seal butt jointed glass.

4102/0901

Plastic to Metal Bonder

To seal plastic to metal joints.

4103/0956

50 g

Black Polyurethane Sealant

To finish exposed edges of laminated glass.

4102/2309

310 ml

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Section 2 - Care and Safety

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Section 2 - Care and Safety Contents Page No. Safety Check List Introduction .............................................................................................. 2 - 1 Safety First .............................................................................................. 2 - 2 Safety - Yours and Others .................................................................. 2 - 2 General Safety ................................................................................... 2 - 2 Operating Safety ..................................................................................... 2 - 4 Maintenance Safety ................................................................................. 2 - 9

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Section 2 - Care and Safety Contents

2 - ii

Page No.

2 - ii

Section 2 - Care and Safety

Safety Check List Introduction T1-006

!MWARNING Study the Operator Manual before starting the machine. You must understand and follow the instructions in the Operator Manual. You must observe all relevant laws and regulations. If you are unsure about anything, ask your JCB dealer or employer. Do not guess, you or others could be killed or seriously injured.

INT-1-1-1_2

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.

!MDANGER 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

!MWARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured.

INT-1-2-2

!MCAUTION 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

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9803/8040-1

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Section 2 - Care and Safety Safety Check List Safety First

Safety First As well as the warnings in this chapter, specific warnings are given throughout the book. This section is designed to give a safety code for use of the machine generally and for operation and maintenance practices.

Safety - Yours and Others INT-1-3-1_3

All machinary can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others.

In this manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB distributor to explain them.

But safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them.

General Safety

!MWARNING

Operator Manual You and others can be injured if you operate or maintain the machine without first studying the Operator Manual. Read the safety instructions before operating the machine. If you do not understand anything, ask your employer or JCB dealer to explain it. Keep the Operator Manual clean and in good condition. Do not operate the machine without an Operator Manual in the cab, or if there is anything on the machine you do not understand.

INT-1-3-2_2

!MWARNING Care and Alertness All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards.

INT-1-3-5

!MWARNING

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.

If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything.

Remember BE CAREFUL

T1-007

Clothing You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job.

Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, earprotectors and industrial gloves. Keep cuffs fastened.

Do not wear a necktie or scarf. Keep long hair restrained.

INT-1-3-6

BE ALERT

!MWARNING

BE SAFE

Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines which can cause drowsiness.

INT-1-3-9_2

2-2

9803/8040-1

2-2

Section 2 - Care and Safety Safety Check List Safety First

!MWARNING

!MDANGER

Feeling Unwell Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself and those you work with.

Lightning Lightning can kill you. Do not use the machine if there is lightning in your area.

5-1-1-2

8-1-2-4

!MWARNING

!MWARNING Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious injury.

Switch off and do not use your mobile phone when refuelling the machine.

Machine Modifications This machine is manufactured in compliance with legislative and other requirements. It should not be altered in any way which could affect or invalidate any of these requirements. For advice consult your JCB Distributor.

INT-1-3-10_2

INT-3-3-9

!MWARNING Lifting Equipment You can be injured if you use faulty lifting equipment.

Make sure that lifting equipment is in good condition.

Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job.

INT-1-3-7

!MWARNING Raised Equipment Raised equipment can fall and injure you. Do not walk or work under raised equipment unless safely supported.

13-1-1-6

!MWARNING Raised Machine NEVER position yourself or any part of your body under a raised machine which is not properly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed.

INT-3-3-7_1

2-3

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Section 2 - Care and Safety Safety Check List Operating Safety

Operating Safety

!MWARNING

!MWARNING

Machine Condition A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this manual are completed before using the machine.

If the machine is fitted with a Roll Over Protection Structure (ROPS) and a Falling Objects Protection Structure (FOPS). You could be killed or seriously injured if you operate the machine with a damaged or missing ROPS/FOPS. If the ROPS/FOPS has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification.

INT-2-1-2_2

!MWARNING Machine Limits Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications.

INT-2-1-4

!MWARNING Engine/Steering Failure If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected.

INT-2-1-9_4

!MWARNING Work Sites Work sites can be hazardous. Inspect the site before working on it. Look for potholes, weak ground, hidden rocks etc. Check for utilities such as electric cables (overhead and underground), gas and water pipes etc.

Mark the positions of the underground cables and pipes. Make sure that you have enough clearance beneath overhead cables and structures.

INT-2-2-1

!MWARNING

INT-2-1-5

!MWARNING Engine The engine has exposed 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_1

Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing.

If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands.

INT-2-2-3

!MWARNING 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.

!MWARNING Parking An incorrectly parked machine can move without an operator. Follow the instructions in the Operator Manual to park the machine correctly.

INT-2-2-4_2

INT-2-1-10

2-4

9803/8040-1

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Section 2 - Care and Safety Safety Check List Operating Safety

!MWARNING

!MWARNING

Banks and Trenches Banked material and trenches can collapse. Do not work or drive too close to banks and trenches where there is danger of collapse.

Practice You or others can be killed or seriously injured if you do unfamiliar operations without first practising them.

Practise away from the work site on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely.

INT-2-2-5

!MWARNING

INT-2-1-1

Ramps and Trailers Water, mud, ice, grease and oil on ramps or trailers can cause serious accidents. Make sure ramps and trailers are clean before driving onto them. Use extreme caution when driving onto ramps and trailers.

INT-2-2-6

!MWARNING Reversing Reversing at high speeds can cause accidents. Do not reverse in a high gear with full throttle. Always drive at a safe speed to suit working conditions.

INT-2-2-9_1

!MWARNING Safety Barriers Unguarded machines in public places can be dangerous. In public places, or where your visibility is reduced, place barriers around the work area to keep people away.

INT-2-2-8

!MDANGER

!MWARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when fitted). Inspect these areas frequently and clean at the beginning of each work shift or more often if required. Before opening the engine cover, ensure that the top is clear of debris.

5-3-1-12_3

Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust.

INT-2-2-10

!MWARNING Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls. If that happens you could lose control of the machine.

2-2-3-6

!MWARNING Hazardous Atmospheres This machine is designed for use in normal out door atmospheric conditions. It should not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor.

INT-2-1-14

!MWARNING Visibility Accidents can be caused by working in poor visibility.

Use your lights to improve visibility. Keep the road lights, windows and mirrors clean.

Do not operate the machine if you cannot see clearly.

5-1-4-7

!MCAUTION Regulations Obey all laws, work site and local regulations which affect you and your machine.

INT-1-3-3

2-5

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Section 2 - Care and Safety Safety Check List Operating Safety

!MWARNING

!MWARNING

Electrical Power Cables You could be electrocuted or badly burned if you get the machine or its attachments too close to electrical power cables.

Controls You or others can be killed or seriously injured if you operate the control levers from outside the cab.

Operate the control levers only when you are correctly seated inside the cab.

You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near electric power lines.

INT-2-1-3

Before you start using the machine, check with your electricity supplier if there are any buried power cables on the site.

Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the correct machine location until you need to use it.

There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier.

2-2-5-4

!MCAUTION If you have an attachment which is not covered in the Operator Manual do not install it, use it or remove it until you have obtained, read and understood the pertinent information. Install attachments only on the machines for which they were designed.

5-5-1-1_2

!MWARNING Use only the JCB approved attachments that are specified for your machine. Operating with nonspecified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yourself or others.

The use of non-approved attachments could invalidate your warranty.

!MWARNING

Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire.

Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use selfcontained breathing apparatus.

INT-3-2-7_2

!MWARNING Should the machine start to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll over, do not try and jump from the cab.

Stay in the cab, with your seat belt fastened.

INT-2-1-12

!MWARNING Passengers Ensure that passengers use the seat provided in the cab. Passengers must not be carried on the rear deck of the vehicle under any circumstances.

13-1-1-1_1

2-4-5-2_1

!MWARNING

!MWARNING Seat Belt Operating the machine without a seat belt can be dangerous. Before starting the engine, make sure your seat belt is fastened. Check the tightness and condition of the seat belt securing bolts regularly (see maintenance schedules).

INT-2-1-8_1

Ensure that any load carried on the rear deck of the machine is firmly secured.

13-1-1-10

!MWARNING The machine must never be loaded such that less than 20% of the vehicle weight is carried on the front axle.

13-1-1-11_1

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Section 2 - Care and Safety Safety Check List Operating Safety

!MWARNING

!MWARNING

Certain tyres fitted as after-market/optional equipment may have maximum permitted speeds below the maximum speed of the vehicle. Brake efficiency is slightly reduced and stopping distance is increased when these tyres are fitted. They will suffer damage if operated at speeds higher than those recommended and may endanger life.

Hitching Trailers and Equipment When the vehicle is approaching a trailer or equipment to be hitched, make sure that no persons are present between vehicle and trailer or equipment. When mounting equipment at the rear of the vehicle, you must ensure that proper steering control is maintained. The machine must never be loaded such that less than 20% of the vehicle weight is carried on the front axle.

13-3-2-5

!MWARNING

13-1-1-13_1

!MCAUTION

You could be killed or injured if a machine tyre bursts.

Do not use the machine with damaged, incorrectly inflated or excessively worn tyres. Recognise the speed limitation of the tyres fitted and do not operate at more than their recommended maximum speed.

Trailers with single line hydraulic brakes used in the United Kingdom are subject to a maximum speed of 20 mph (32 kph).

13-2-1-2

13-2-2-8

!MWARNING

!MCAUTION

Be aware of the load the machine is carrying or towing and the speed at which you are travelling. Do not corner fast when carrying heavy mounted implements or towing trailers. Reduce speed when towing nonsuspended implements on rough ground. (Consult the implement operator's manual for recommended transport speeds).

Trailers with single line air brakes used in the Republic of Germany are subject to a maximum speed of 25 km/ h (15 mph).

13-2-2-1_1

Brakes Do not coast the machine with the engine stopped as the main brakes will only operate for a limited number of applications and trailer brakes may not function at all. Also the steering will become very heavy.

!MDANGER The JCB Fastrac is capable of operating at high speeds. Implements or trailers you tow behind the Fastrac may not be designed for high speed operation.

BE AWARE of the manufacturer's specified maximum speed rating for any trailers or implements that you tow behind the Fastrac. DO NOT EXCEED THE MAXIMUM DESIGN SPEED OF TRAILERS OR IMPLEMENTS AS INJURY OR DEATH MAY RESULT. 13-2-3-5

13-2-2-13

!MWARNING

13-1-1-5_2

!MWARNING When driving the machine on the road, use the accelerator pedal and not the hand throttle to control the engine speed. Always set the hand throttle to 'idle' before using the accelerator pedal.

13-2-1-8_1

!MWARNING When driving the machine on the road with an implement or trailer connected to the machine, the transport locks must be engaged to prevent unintentional operation of electronic linkage, front and rear PTO or external hydraulics.

13-2-4-13

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Section 2 - Care and Safety Safety Check List Operating Safety

!MCAUTION

!MWARNING

Electronic Control Unit The electronic control unit under the passenger's seat is protected by a cover. Do not use the machine with the cover removed.

The cab air filter is designed to remove dirt from the outside air. When using chemicals (e.g. for crop spraying) follow the chemical manufacturer's recommendations for protection from dangerous chemicals.

0103

13-2-3-6

!MWARNING When operating PTO equipment, always observe the following safety precautions: Follow the instructions in the implement Operator Manual.

Rotating equipment is dangerous. Do not wear loose fitting clothing when working close to rotating shafts.

Always disengage the PTO, stop the engine and wait until the equipment stops, before: 1

Leaving the cab

2

Attempting to attach or detach an implement to or from a PTO shaft or

3

Working on or cleaning an implement connected to the machine via a PTO shaft.

Always ensure that the PTO shaft and driveline are fully guarded before use.

When using stationary PTO equipment, ensure that the park brake is applied.

!MWARNING Entering/Leaving Entering or leaving the cab or canopy must only be made where steps and handrails are provided. Always face the machine when entering and leaving. Make sure the step(s), 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.

INT-2-1-7_1

!MDANGER Leaving the machine in gear will not prevent it running away. Do not leave the driving seat under any circumstances unless the park brake is on.

13-2-1-10

!MWARNING The exhaust pipe becomes extremely hot when the engine is running and will remain so for some time after the engine is stopped. If you touch the hot pipe you could be severely burned.

13-2-4-11

13-2-1-6

!MWARNING

!MWARNING If the PTO becomes jammed, disengage the PTO, stop the engine and clear the blockage. Wait until the PTO shaft stops before working on the equipment. If the PTO clutch slips, immediately disengage the PTO and stop the engine.

The cab air filter is designed to remove dirt from the outside air. When using chemicals (e.g. for crop spraying) follow the chemical manufacturer's recommendations for protection from dangerous chemicals.

13-2-3-6

13-2-2-2

!MWARNING When you hear an audible warning, stop the machine as soon as possible. Get the fault put right before using the machine again.

13-2-1-9

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Section 2 - Care and Safety Safety Check List Maintenance Safety

Maintenance Safety

!MWARNING

!MWARNING

Communications Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing. Before starting the engine make sure the others are clear of the danger areas; examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken.

If you try to charge a frozen battery, or jump start and run the engine, the battery could explode. Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge.

INT-3-1-5

!MWARNING Repairs If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result in an accident or affect your health. Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer.

GEN-1-5_2

!MWARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper pin to remove and fit metal pins. Always wear safety glasses.

INT-3-1-3_2

!MWARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.

INT-3-1-4

0125

!MWARNING Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter.

INT-3-1-8

!MDANGER Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses.

INT-3-2-1_3

!MWARNING Battery Terminals The machine is negatively earthed. Always connect the negative pole of the battery to earth.

When connecting the battery, connect the earth (-) lead last.

When disconnecting the battery, disconnect the earth (-) lead first.

INT-3-1-9

!MCAUTION Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged.

INT-3-1-14

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Section 2 - Care and Safety Safety Check List Maintenance Safety

!MWARNING

!MCAUTION

Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.

It is illegal to pollute drains, sewers or the ground.

Clean up all spilt fluids and/or lubricants.

Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites.

INT-3-2-14

INT-3-1-10_2

!MWARNING

!MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you.

Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open.

INT-3-1-11_2

!MWARNING Petrol 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 form flammable vapours.

Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground.

INT-3-2-4

!MWARNING Hot Coolant The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the filler cap. Let the system cool before removing the filler cap. To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap.

INT-3-2-9_1

!MWARNING

INT-3-1-6

!MWARNING Diesel Fuel Diesel fuel is flammable; keep naked flames away from the fuel system. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions.

INT-3-2-2_1

!MWARNING Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful 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 not use petrol, diesel fuel or paraffin to clean your skin.

INT-3-2-3

2 - 10

Always wear safety glasses when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidentally flying out.

GEN-6-2

!MCAUTION Rams The efficiency of the rams will be affected if they are not 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.

INT-3-2-10

!MCAUTION Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents.

INT-3-2-11

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Section 2 - Care and Safety Safety Check List Maintenance Safety

!MWARNING

!MWARNING

When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions.

Working Under the Machine Make the machine safe before getting beneath it.

Ensure that any fitments on the machine are secure; engage the park brake, remove the starter key, disconnect the battery.

GEN-1-9

!MCAUTION

INT-3-3-8_2

'O' rings, Seals and Gaskets Badly fitted, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents.

Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals.

INT-3-2-12

!MWARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: – Damaged hose ends – Chafed outer covers – Ballooned outer covers – Kinked or crushed hoses

!MWARNING Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton, Fluorel and Technoflon.

Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN. New fluoroelastomeric components at ambient temperature require no special safety precautions.

Used fluoroelastomeric components whose temperatures have not exceeded 300°C (572°F) require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA. Used fluoroelastomeric components subjected to temperatures greater than 300°C (572°F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn:

– Embedded armouring in outer covers – Displaced end fittings.

INT-3-3-2

!MCAUTION Waxoyl contains turpentine substitute which is flammable. Keep flames away when applying Waxoyl.

Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period.

Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.

1

Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.

2

Thoroughly wash contaminated detergent and water.

3

Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.

5-3-1-9

2 - 11

9803/8040-1

area

with

2 - 11

Section 2 - Care and Safety Safety Check List Maintenance Safety DO NOT BURN FLUOROELASTOMERIC MATERIALS.

!MWARNING

If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes.

Get medical attention immediately.

Counterweights Your machine may be fitted with counterweights. They are extremely heavy. Do not attempt to remove them.

INT-3-2-5

INT-3-3-5_2

!MWARNING

!MWARNING Protect your eyes when grinding metal. Wear safety glasses or goggles. Remove or protect any combustible materials from the area which could be ignited by sparks.

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

GEN-1-12

!MWARNING

!MWARNING To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a wire brush to clean components.

HYD-1-3

!MWARNING

INT-3-1-17

Arc Welding To prevent the possibility of damage to electronic components, disconnect the battery and the alternator before arc-welding on the machine or attached implements.

If the machine is equipped with sensitive electrical equipment, i.e. amplifier drivers, electronic control units (E.C.U.s), monitor displays, etc., then disconnect them before welding. Failure to disconnect the sensitive electrical equipment could result in irreparable damage to these components.

Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine.

Always connect the welder earth (ground) cable to the same component that is being welded, i.e. boom or dipper, to avoid damage to pivot pins, bearings and bushes. Attach the welder earth (ground) cable no more than 0.6 metres (2 feet) from the part being welded.

INT-3-1-15_2

Accumulators The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on systems incorporating accumulators, the system pressure must be exhausted by a JCB distributor, as the sudden release of the hydraulic fluid or gas may cause injury.

!MWARNING An exploding tyre can kill. Inflated tyres can explode if over-heated or over-inflated. Follow the instructions given when inflating the tyres. Do not cut or weld the rims. Use a tyre/wheel specialist for all repair work.

2-3-2-7_2

!MWARNING Jacking A machine can roll off jacks and crush you unless the wheels have been chocked. Always chock the wheels at the opposite end of the machine that is to be jacked.

Do not work underneath a machine supported only by jacks. Always support a jacked-up machine on axle stands before working underneath it.

INT-3-2-8

!MWARNING Under no circumstances must the engine be run with the transmission in gear and only one driving wheel jacked clear of the ground, since the wheel on the ground will move the machine.

INT-3-1-16

2 - 12

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Section 2 - Care and Safety Safety Check List Maintenance Safety

!MWARNING

!MWARNING

Wheels and tyres are heavy. Take care when lifting or moving them.

Upon completion of any work on the brake system of machines fitted with ABS, the ABS test within Servicemaster must be run satisfactorily before the machine is driven. It is not sufficient to rely on the ABS self-check which can only check for the presence of components, not that they are correctly installed.

Store with care to ensure that they cannot fall and cause injury.

13-3-1-7_1

0091

!MWARNING

!MWARNING

Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death.

Radar Speed Sensor (if fitted) To avoid possible eye damage from microwave signals do not look directly into the sensor face.

13-3-2-16

13-1-1-15

!MWARNING

!MWARNING

The injector solenoids receive high voltage when the engine is operating. To reduce the possibility of personal injury from electrical shock, do not wear jewellery or damp clothing, and do not touch the injector solenoids or the solenoid wires when the engine is operating.

Always renew brake pads and locating pins in complete axle sets, using genuine JCB parts, otherwise braking will be unsafe.

13-3-1-10

!MWARNING

GEN-1-19

Before working on or around the brake system, always observe the following precautions:

!MWARNING The transmission is in 4 wheel drive until de-selected by hydraulic pressure to 2 wheel drive. If the machine is to be raised and the engine/transmission run, make sure all four wheels are off the ground and supported by axle stands. If only the rear wheels were raised, the machine could still drive through the front axle.

TRANS-8-5

!MCAUTION Never use water or steam to clean inside the cab. The use of water or steam could damage the on-board computer and render the machine inoperable. Remove dirt using a brush or damp cloth.

8-3-4-8

1

Stop the engine and block all four wheels.

2

When the air system is being exhausted, keep hands away from the park brake actuator pushrod and caliper, as they may move and trap your fingers.

3

Take care if disconnecting an air hose containing pressure as it may whip as air escapes.

4

Never remove or dismantle a component until air pressure has been exhausted and you have read and understood the recommended procedures.

5

Never remove or dismantle a component until air pressure has been exhausted and you have read and understood the recommended procedures.

BRAK-8-3_1

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Section 2 - Care and Safety Safety Check List Maintenance Safety

!MWARNING When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned.

13-3-2-15

2 - 14

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Section 3 - Maintenance

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Section 3 - Maintenance Contents Page No. Routine Maintenance Service Requirements ............................................................................. 3 - 1 Introduction ......................................................................................... 3 - 1 Owner/Operator Support .................................................................... 3 - 1 Service/Maintenance Agreements ..................................................... 3 - 1 Initial Service and Inspection (100 Hours) .......................................... 3 - 1 Obtaining Replacement Parts ............................................................. 3 - 2 Health and Safety .................................................................................... 3 - 3 Lubricants ........................................................................................... 3 - 3 Battery ................................................................................................ 3 - 5 First Aid - Electrolyte .......................................................................... 3 - 5 Service Schedules ................................................................................... 3 - 7 How to Use the Service Schedules .................................................... 3 - 7 Service Schedule Tables .................................................................... 3 - 8 Fluids, Lubricants and Capacities .......................................................... 3 - 14 Coolant Mixtures .............................................................................. 3 - 15 Cleaning the Machine ............................................................................ 3 - 16 Checking for Damage ............................................................................ 3 - 17 Seats and Seat Belts ............................................................................. 3 - 18 Seats ................................................................................................ 3 - 18 Checking the Seat Belt Condition and Security ................................ 3 - 18 Checking the ROPS Structure ............................................................... 3 - 19 Bonnet ................................................................................................... 3 - 20 Opening the Bonnet ......................................................................... 3 - 20 Closing the Bonnet ........................................................................... 3 - 20 Greasing ................................................................................................ 3 - 21 General Information .......................................................................... 3 - 21 Propshafts and Rear PTO Drive Shaft .............................................. 3 - 22 Front 3-Point Linkage (Optional) ...................................................... 3 - 23 Front Axle Steering Swivels .............................................................. 3 - 24 Steering Column Universal Joints .................................................... 3 - 25 Rear Suspension Cylinder Pivots ..................................................... 3 - 26 Hydraulic Lift and 3-Point Linkage .................................................... 3 - 27 Pick-up Hitch .................................................................................... 3 - 28 Automatic Trailer Coupling (if fitted) ................................................. 3 - 29 Air Conditioning and Heater .................................................................. 3 - 30 Air Conditioning Filters ..................................................................... 3 - 30 Cleaning the Heater Filter ................................................................ 3 - 32 Adjusting the Compressor Belt ......................................................... 3 - 33 Brakes ................................................................................................... 3 - 34 Checking the Foot Brake Fluid Level ............................................... 3 - 34 Checking the Trailer Air Tank ........................................................... 3 - 35 Checking and Renewing Foot Brake Pads ....................................... 3 - 36 Checking the Park Brake Pads ........................................................ 3 - 38 Renewing the Park Brake Pads ....................................................... 3 - 38 Electrical System ................................................................................... 3 - 40 Battery .............................................................................................. 3 - 40 Jump-starting the Engine ................................................................. 3 - 41 Fuses ................................................................................................ 3 - 43 Relay Identification ........................................................................... 3 - 45 Checking the Beam Alignment ......................................................... 3 - 47

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3-i

Section 3 - Maintenance Contents Contents Page No. Engine ................................................................................................... 3 - 48 Changing the Air Filter Elements ...................................................... 3 - 48 Checking the Oil Level ..................................................................... 3 - 50 Changing the Oil and Filter ............................................................... 3 - 51 Checking the Crankcase Breather Tube .......................................... 3 - 53 Cooling System ..................................................................................... 3 - 54 Checking the Coolant Level ............................................................. 3 - 54 Changing the Coolant Filter .............................................................. 3 - 55 Draining and Refilling the Coolant .................................................... 3 - 56 Cleaning the Radiator and Coolers .................................................. 3 - 58 Fan Belt ............................................................................................ 3 - 59 Fuel System ........................................................................................... 3 - 61 Types of Fuel .................................................................................... 3 - 61 Filling the Tank ................................................................................. 3 - 62 Draining the Fuel Filter ..................................................................... 3 - 63 Changing the Fuel Filter Elements ................................................... 3 - 64 Hydraulic System ................................................................................... 3 - 65 Checking the Fluid Level .................................................................. 3 - 65 Changing the Filter Element ............................................................. 3 - 66 Changing the Hydraulic Fluid and Cleaning the Suction Strainers ... 3 - 68 Emptying the Hydraulic Coupling Drain Reservoirs ......................... 3 - 70 Transmission ......................................................................................... 3 - 71 Checking the Transmission Oil Level ............................................... 3 - 71 Changing the Transmission Oil Filter ............................................... 3 - 72 Changing the Transmission Oil and Strainer .................................... 3 - 73 Checking the Clutch Fluid Level ....................................................... 3 - 74 Axles ...................................................................................................... 3 - 75 Front Axle ......................................................................................... 3 - 75 Rear Axle and PTO .......................................................................... 3 - 78 Tyres and Wheels .................................................................................. 3 - 81 General ............................................................................................. 3 - 81 Wheel and Tyre Replacement .......................................................... 3 - 81 Checking Wheel Nut Torques ........................................................... 3 - 81 Tyre Inflation ..................................................................................... 3 - 82 Checking and Adjusting the Front Wheel Alignment ........................ 3 - 83 Fender Adjustment ........................................................................... 3 - 84 Power Take-off (PTO) ............................................................................ 3 - 85 Front PTO ......................................................................................... 3 - 85 Rear PTO ......................................................................................... 3 - 86 Windscreen Washer .............................................................................. 3 - 87 Checking Fluid Level ........................................................................ 3 - 87 Automatic Trailer Coupling (Optional) ................................................... 3 - 88 Checking for Wear ............................................................................ 3 - 88

3 - ii

3 - ii

Section 3 - Maintenance

Routine Maintenance Service Requirements Introduction T3-002

Your machine has been designed and built to give maximum performance, economy and ease of use under a wide variety of operating conditions. Prior to delivery, your machine was inspected both at the Factory and by your Distributor to ensure that it reaches you in optimum condition. To maintain this condition and ensure trouble free operation it is important that the routine services, as specified in this Manual, are carried out by an approved JCB Distributor at the recommended intervals.

Distributor's Service Department who are there to help you!

You will have been given the names of the relevant service contacts at your Distributor when the machine was installed.

To get the most from your Distributor please help them to satisfy you by: 1

Giving your name, address and telephone number.

This section of the Manual gives full details of the service requirements necessary to maintain your JCB machine at peak efficiency.

2

Quoting your machine model and serial number.

3

Date of purchase and hours of work.

It can be seen from the Service Schedules on the following pages that many essential service checks should only be carried out by a JCB trained specialist. Only JCB Distributor Service Engineers have been trained by JCB to carry out such specialist tasks, and only JCB Distributor Service Engineers are equipped with the necessary special tools and test equipment to perform such tasks, thoroughly, safely, accurately and efficiently.

4

Nature of the problem.

JCB regularly updates its Distributors advising them of any product developments, changes in specifications and procedures. Therefore only a JCB Distributor is fully able to maintain and service your machine.

Service/Maintenance Agreements

A Service Record Sheet or Book is provided which will enable you to plan your service requirements and keep a service history record. It should be dated, signed and stamped by your Distributor each time your machine is serviced.

Remember, if your machine has been correctly maintained, not only will it give you improved reliability but its resale value will be greatly enhanced.

Owner/Operator Support JCB together with your Distributor wants you to be completely satisfied with your new JCB machine. If you do encounter a problem however, you should contact your

3-1

Remember, only your JCB Distributor has access to the vast resources available at JCB to help support you. In addition, your Distributor is able to offer a variety of programmes covering Warranty, Fixed Price Servicing, Safety Inspections, including weight tests, covering both legal and insurance requirements.

To help plan and spread the costs of maintaining your machine, we strongly recommend you take advantage of the many Service and Maintenance Agreements your Distributor can offer. These can be tailor made to meet your operating conditions, work schedule etc.

Please consult your JCB Distributor for details.

Initial Service and Inspection (100 Hours) T3-005

To further protect your machine's performance it is essential your JCB Distributor carries out an initial service and inspection when the machine is one month old or when it has completed 100 hours of operation (whichever occurs first). You should notify your Distributor in advance to allow the necessary arrangements to be made.

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Section 3 - Maintenance Routine Maintenance Service Requirements

Obtaining Replacement Parts T3-004_2

We recommend you fit only JCB Genuine Parts. A Parts Book will help you identify parts and order them from your JCB distributor.

Your dealer will need to know the exact model, build and serial number of your machine. See Identifying Your Machine in INTRODUCTION section.

The data plate also shows the serial numbers of the engine, transmission and axle(s), where applicable. But remember if any of these units have been changed, the serial number on the data plate may be wrong. Check on the unit itself.

3-2

9803-8040-6

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Section 3 - Maintenance Routine Maintenance Health and Safety

Health and Safety T3-001_3

Lubricants

The collection and disposal of used oil should be in accordance with any local regulations. Never pour used engine oil into sewers, drains or on the ground.

Introduction It is most important that you read and understand this information and the publications referred to. Make sure all your colleagues who are concerned with lubricants read it too.

Handling New Oil

Hygiene

There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices.

JCB lubricants are not a health risk when used properly for their intended purposes.

Used Oil

However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.

Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination.

Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following.

Used engine crankcase lubricants contain harmful contaminants.

Here are precautions to protect your health when handling used engine oil: 1

Avoid prolonged, excessive or repeated skin contact with used oil.

2

Apply a barrier cream to the skin before handling used oil. Note the following when removing engine oil from skin: a

Storage

Wash your skin thoroughly with soap and water.

b Using a nail brush will help.

Always keep lubricants out of the reach of children.

c

Never store lubricants in open or unlabelled containers.

Use special hand cleansers to help clean dirty hands.

d Never use petrol, diesel fuel, or paraffin for washing.

Waste Disposal

!MCAUTION

3

Avoid skin contact with oil soaked clothing.

It is illegal to pollute drains, sewers or the ground.

Clean up all spilt fluids and/or lubricants.

4

Don't keep oily rags in pockets.

5

Wash dirty clothing before re-use.

6

Throw away oil-soaked shoes.

Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites.

INT-3-2-14

All waste products should be disposed of in accordance with all the relevant regulations.

3-3

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3-3

Section 3 - Maintenance Routine Maintenance Health and Safety First Aid - Oil Eyes In the case of eye contact, flush with water for 15 minutes.

If irritation persists, get medical attention.

Swallowing If oil is swallowed do not induce vomiting. Get medical advice.

Skin In the case of excessive skin contact, wash with soap and water.

Spillage Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.

Fires

!MWARNING Do not use water to put out an oil fire. This will only spread it because oil floats on water.

Extinguish oil and lubricant fires with carbon dioxide, dry chemical or foam. Fire fighters should use self contained breathing apparatus.

7-3-1-3_1

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Section 3 - Maintenance Routine Maintenance Health and Safety

Battery

Warning Symbols

!MWARNING

The following warning symbols may be found on the battery.

Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames.

Symbol

Meaning Keep away from children.

Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles.

Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you.

Shield eyes.

Set all switches in the cab to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first.

No smoking, no naked flames, no sparks.

Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up.

Explosive Gas.

When reconnecting, fit the positive (+) lead first.

First Aid - Electrolyte

Battery acid.

Do the following if electrolyte:

GETS INTO YOUR EYES Note operating instructions.

Immediately flush with water for 15 minutes, always get medical help.

IS SWALLOWED Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help.

!MCAUTION Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged.

GETS ONTO YOUR SKIN Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.

INT-3-1-14

5-3-4-3_1

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Section 3 - Maintenance Routine Maintenance Health and Safety

!MWARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.

INT-3-1-4

!MDANGER Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses.

INT-3-2-1_3

!MCAUTION Damaged or spent batteries and any residue from fires or spillage should be put in a closed acid proof receptacle and must be disposed of in accordance with local environmental waste regulations.

INT-3-1-12

!MWARNING Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter.

INT-3-1-8

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Section 3 - Maintenance Routine Maintenance Service Schedules

Service Schedules A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition.

!MWARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe. It should be correctly parked on firm level ground.

To prevent anyone starting the engine, remove the starter key. Disconnect the battery and block the wheels when you are working beneath the machine.

If you do not take these precautions you could be killed or injured.

9-3-1-1

Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings to correctly gauge service intervals, see Instruments in Operation Section. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately.

If the machine is operating in ambient temperatures below -18째C [0째F] or above 38째C [100째F], change engine oil and filter, air and fuel filters at shorter intervals. Shorter maintenance intervals are also required if the machine is operated in a dusty environment or if frequent stops are made.

Calendar equivalents: 10 Hours = Daily 50 Hours = Weekly 250 Hours = Three Months 500 Hours = Six Months 1000 Hours = Yearly 2000 Hours = 2 Years 4000 Hours = 4 Years

How to Use the Service Schedules T3-012_2

In the example shown, A shows all service requirements to be carried out every 10 hours and B shows the requirements to be carried out every 500 hours.

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Section 3 - Maintenance Routine Maintenance Service Schedules

Service Schedule Tables Pre-start Cold Checks, Service Points and Fluid Levels

Operation 10 Hr 50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

4000 5000 Hr Hr

ENGINE Oil level Oil and Filter

- Check

Air Cleaner Outer Element

- Change

(3)

Air Cleaner Inner Element

- Change

Air Cleaner Hose and Clamp Security

- Check

Air Compressor Mountings

- Check

(4)

Air Compressor Discharge Lines

(4)

- Check

Fuel Filter

- Drain

Fuel Filter

- Change

Coolant Level

- Check

Coolant Antifreeze and Coolant Additive Concentration(4)

- Check

Coolant

- Change

Coolant Filter

- Change

Fan Belt Condition

- Check

Fan Hub (4)

- Check

Fan Belt Tensioner (4)

- Check

Vibration Damper (4)

- Check

Valve Clearances (4)

- Check and Adjust

Crankcase Breather Tube

- Check

Air Conditioning Compressor Belt Tension and Condition

- Check

Engine Mounting Bolts for Tightness(4)

- Check

Fuel Injection Pump Mounting Bolts for Tightness(4)

- Check

Radiator and Coolers

- Clean

Charge Air Cooler Hose and Clamp Security

- Check

Charge Air Cooler

- Check

Turbocharger(4)

- Check

3-8

- Change

(2)

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Section 3 - Maintenance Routine Maintenance Service Schedules Pre-start Cold Checks, Service Points and Fluid Levels Engine

Operation 10 Hr 50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

4000 5000 Hr Hr

- Steam Clean

TRANSMISSION, AXLES AND STEERING Transmission Oil Level

- Check

- Change

Transmission Oil(5) Transmission Strainer

- Change

(4)

Transmission Filter

- Change

Clutch Fluid Level

- Check

Axle Oil Level (incl. Hubs)

(6)

Axle Oil (incl. Hubs)

(7)

Tyre Pressures/Condition Oil Cooler and Pipework Front PTO Gearbox Oil Level

- Check - Change - Check

- Check and Clean

- Check

- Security/ Grease

Steer Axle Pivots

- Grease

Steering Column Universal Joints

- Grease

Front PTO Gearbox Oil Front PTO Gearbox Oil Filter Propellor Shafts

- Change - Clean

Steering Axle Wheel Alignment

- Check

Drag Link, Track Rod End, Steering Ram and Damper Condition and Security(4)

- Check

Wheel Nut Security

- Check

- Check

HYDRAULICS Oil Level Oil(4)

- Sample/ Change

Oil Filter

- Change

Hydraulic System

- Check for Leaks

Hydraulic Lift and 3 Point Linkage, Front and Rear

- Grease

Rear 3 Point Linkage Cross-shaft Oil level

- Check

Ram Piston Rods Condition

- Check

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Section 3 - Maintenance Routine Maintenance Service Schedules Pre-start Cold Checks, Service Points and Fluid Levels Hydraulic Oil Cooler and Pipework

Operation 10 Hr 50 Hr

100 Hr(1)

- Check and Clean

Hydraulic Oil Strainer

- Clean

Hydraulic Coupling Drain Reservoir

- Empty

Security of Front Weight

500 Hr

1000 Hr

2000 Hr

- Check

- Drain

4000 5000 Hr Hr

BRAKES Air System Tank Air System Drier Canister

(4)

- Change

Trailer Brake Control Line Air Filter(4)

- Clean

Brake System Fluid Level

- Check

Brake System Fluid Park Brake

- Change - Check and Adjust

Park Brake Pad Condition and Security

- Check

Service Brake Pad Condition and Security

- Check

Calliper Bolt Torque(4)

- Check

Pipework Security

- Check

ELECTRICS Battery Electrolyte Level (if applicable)

- Check

Wiring for Chaffing/Routing

- Check

Battery Terminals for Condition and Tightness

- Check

Battery Charge Condition(4)

- Check

Headlamp Alignment

- Check

BODY AND FRAMEWORK Bonnet Hinges

- Lubricate

Seat Belt Condition and Security

- Check

Air Conditioning Condensor

- Clean

ROPS Structure(4)

- Check

Cab Air Intake Filter (standard type only)(8)

- Clean

Door Locks

- Check

Windscreen Washer Fluid Level

- Check

Condition of Paintwork

- Check

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3 - 10

Section 3 - Maintenance Routine Maintenance Service Schedules Pre-start Cold Checks, Service Points and Fluid Levels Machine Generally Automatic Trailer Coupling (if fitted)

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

- Grease

- Grease

Operation 10 Hr 50 Hr - Check and Clean

4000 5000 Hr Hr

SUSPENSION Cylinder Pivots Panhard Rod Condition and Torque Tightness(4)

- Check

Control Arms Condition and Torque Tightness(4)

- Check

`V' Link Condition and Torque Tightness(4)

- Check

- Check

Accumulator Pressure(4)

Gas Spring Pressure(4)

- Check

(1) First 100 Hours Service only, to be completed by your JCB Distributor.

(2) Applies only if recommended oil is available. If this is not available, this job should be carried out every 250 hours. See Fluids, Lubricants and Capacities for suitable alternative oil.

(3) If operating in dusty working environments, change more frequently.

(4) Jobs which should only be done by a specialist.

(5) After a major transmission repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil and filter after a further 100 hours if the oil was heavily contaminated because of, or from the failure (e.g. water contamination).

(6) Check for leaks every 50 hours, check level if leaking.

(7) After a hub repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil again after a further 100 hours to remove any bedding-in wear. This is particularly important if new brake plates have been fitted.

(8) Heavy duty carbon type filters must be changed at 250 hour intervals.

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Section 3 - Maintenance Routine Maintenance Service Schedules Functional Test and and Final Inspection

Operation

10 Hr

50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

ENGINE Idle Speed(2)

- Check

Maximum No Load Speed(2)

- Check

Exhaust System Security(2)

- Check

Cooling System for Leaks

- Check

Fuel System for Leaks and Contamination

- Check

Lubrication System for Leaks

- Check

Stop Control

- Check

TRANSMISSION, AXLES AND STEERING 2WD/4WD/Differential Lock Selection

- Check

Oil Leakage

- Check

Transmission Lubrication Pressure

(2)

4WD/PTO Supply Pressure

(2)

Differential Lock Pressure Relief Valve

(2)

- Check

- Check

- Check

Neutral Start Operation

- Check

PTO Selection and Operation

- Check

Selection of Transmission Modes and Ranges

- Check

Steering Operation

- Check

Steering Pressure Relief Valve

(2)

- Check

HYDRAULICS Maximum System Pressure(2)

- Check and Adjust

Operation All Services

- Check

System for Oil Leakage

- Check

Oil Cooler and Pipework for Damage or Leakage

- Check

BRAKES Foot Brake - Operation

- Check

Park Brake - Operation

- Check

Air System Warning Lights

- Check

ABS(2)

- System Test

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Section 3 - Maintenance Routine Maintenance Service Schedules Functional Test and and Final Inspection

Operation

10 Hr

50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

ELECTRICS Starter Motor Alternator - Output

- Check (2)

All Electrical Equipment Operation, (e.g. warning lights, beacon, alarms, horn, wipers etc.)

- Check - Check

Error Codes for all systems, Engine, ABS, Electronic Draft Control, Transmission(2)

- Download and Rectify

EMS Datalog(2)

- Download and Rectify

- Check

Circuit Pressure(2)

- Check

Rear Axle to Chassis Clearance(2)

- Check

Ride Height and Corrector Valve Operation(2)

- Check

Brake Light Switch Input to ABS ECU using computer diagnostic tool(2) SUSPENSION

(1) First 100 Hours Service only, to be completed by your JCB Distributor.

(2) Jobs which should only be done by a specialist.

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Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities Note: New engines DO NOT require a running-in period.

The engine/machine should be used in a normal work cycle immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Whilst 15W/40 oil is

ITEM

CAPACITY

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 temperatures below -5ºC (23ºF). Continued use of low viscosity oils can decrease engine life and will require different service intervals.

K Service Schedules ( T 3-7)

Table 1.

FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION

Litres UK Gal Fuel Tank

577

127

Diesel Oil

ASTM D975-66T Nos. 1D, 2D

Engine (Oil)

24

5.3

JCB Engine Oil EP 15W/40 (-20 to +40 deg C)

API CH-4 or ACEA E3/ B3A3, SAE15W/40(1)

Engine (Coolant)

33

7.7

JCB High Performance Antifreeze & Inhibitor/ Water K Coolant Mixtures ( T 3-15)

ASTM D6210

Transmission

75

16.5

JCB V-Tronic Transmission Fluid

ZF TE-ML06, B and C

Rear 3 Point Linkage Cross-shaft

0.2

0.04

JCB V-Tronic Transmission Fluid

ZF TE-ML06, B and C

Clutch

0.5

0.1

JCB V-Tronic Clutch Fluid

Pentosin CHF 11S

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

- Axle Beam

16

3.5

- Hubs (each)

4

0.9 JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

JCB Brake Fluid Dot 4

SAE J1703 DOT 4

JCB Hydraulic Fluid HP46

ISO VG46

Front Axle

Rear Axle - Axle Beam

56

12.3

- Hubs (each)

7

1.5

Brake System - Front - Rear Hydraulic System(2)

0.75

0.2

0.75

0.20

180

40

(Above 38ºC,100ºF) JCB Hydraulic Fluid HP32

ISO VG32

(Below 38ºC,100ºF) Grease Points

Front PTO Gearbox (optional)

7

1.5

JCB HP Grease

Lithium complex NLGI No.2 consistency including extreme pressure additives

JCB HP Universal ATF

ZF TE-MIL 09,11,12,14

(1) If API CH-4 or ACEA E3/B3A3 engine oil AT SAE 15W/40 is not available, the engine oil must be changed at 250 hours, using the following alternative oils: For -20ºC to +40ºC: JCB Engine Oil HP15W/40 or for -25ºC to +30 ºC: JCB Engine Oil HP10W/30.

(2) The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank

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Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities

Coolant Mixtures T3-009_3

Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period.

Replace the coolant mixture according to the intervals shown in the machine's Service Schedule.

!MWARNING Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze.

7-3-4-4_1

You must dilute full strength antifreeze with clean water before use. Use clean water of no more than a moderate hardness (pH value 8.5). If this cannot be obtained, use de-ionized water. For further information advice on water hardness, contact your local water authority.

The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion.

The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below.

50% Concentration (Standard) Protects against damage down to -40 °C (-39 °F) 60% Concentration (Extreme Conditions Only) Protects against damage down to -56 °C (-68 °F) Important: Do not exceed a 60% concentration, as the freezing protection provided reduces beyond this point.

If you use any other brand of antifreeze: – Ensure that the antifreeze complies with International Specification ASTM D6210.

– Always read and understand the manufacturer's instructions.

– Ensure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used.

– Ensure that the antifreeze is ethylene glycol based and does not use Organic Acid Technology (OAT).

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Section 3 - Maintenance Routine Maintenance Cleaning the Machine

Cleaning the Machine

!MWARNING When using a steam cleaner, wear safety glasses or a face shield as well as protective clothing. Steam can cause serious personal injury.

13-3-2-10

Clean the machine using water and/or steam. Pay particular attention to the underside. Do not allow mud to build up on the engine and transmission. Make sure that the radiator grille is not clogged up.

Excessive power washing can cause damage to seals, bearings and electrical connections. Do not direct high power water jets at oil seals, universal joints or electrical components and wiring.

Take special care to avoid directing high power water jets at the electrical connections to the front and rear axle ABS sensors.

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Section 3 - Maintenance Routine Maintenance Checking for Damage

Checking for Damage 1

Inspect steelwork for damage. Note damaged paintwork and repair.

2

Make sure all pivot pins are correctly in place and secured by their locking devices.

3

Ensure that the steps and handrails are undamaged and secure.

4

Check for broken or cracked window glass. Replace damaged items.

5

Check all lamp lenses for damage.

6

Inspect the tyres for damage and penetration by sharp objects.

7

Check that all safety decals are in place and undamaged. Fit new decals where necessary.

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Section 3 - Maintenance Routine Maintenance Seats and Seat Belts

Seats and Seat Belts Seats

If required, the cushion and backrest can be removed for cleaning by removing screws B.

Make sure that the seat mounting bolts are tight.

!MWARNING

Keep the seat slide runners lightly greased.

Check driver's seat for correct operation, ensuring that it can be moved and locked into all positions and can be raised and lowered. If any parts are faulty, repairs should be done by a JCB dealer.

Keep the upholstery clean, using a commercially available upholstery or plastic cleaner. Test first for compatibility on a small concealed area of the seat.

During cleaning, the upholstery should not be soaked through.

Take care with the backrest frame. It may jerk forward and cause injury.

13-3-2-9

Checking the Seat Belt Condition and Security

!MWARNING

T3-008

When a seat belt is fitted to your machine replace it 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.

2-3-1-7_1

B

Inspect the seat belt for signs of fraying and stretching.

Check that the stitching is not loose or damaged. Check that the buckle assembly is undamaged and works correctly.

Check that the belt mounting bolts are undamaged, correctly fitted and tightened.

B

Fig 1.

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3 - 18

Section 3 - Maintenance Routine Maintenance Checking the ROPS Structure

Checking the ROPS Structure

!MWARNING You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protection Structure (ROPS)/Falling Objects Protection Structure (FOPS) has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification.

INT-2-1-9_6

Check the structure for damage.

Check that the four mounting bolts are installed and undamaged. Check that torque tightness of nuts A and B is 365 Nm (270 lbf ft). Tighten them to the correct torque if necessary.

Fig 2.

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3 - 19

Section 3 - Maintenance Routine Maintenance Bonnet

Bonnet Opening the Bonnet

3

!MWARNING Engine The engine has exposed rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open.

Closing the Bonnet 1

To fit the side panels, locate the front edge of the panel and then push the rear edge of the panel firmly into position.

2

Pull the bonnet down by means of the cable, push the bonnet down, make sure it is locked in place.

INT-2-1-6_1

1

Engage the park brake, put the transmission in neutral, stop the engine. Remove the starter key.

To remove the side panels, pull at the rear edge of the panel and lift out the panel from its location at the front.

Fig 3.

2

Release the latch by pulling up handle A. The bonnet will automatically open and be supported on gas struts.

Note: If you need the bonnet open further than the limit of the gas struts, disconnect the gas struts, raise the bonnet and fit a suitable size bolt through the hinge lever mechanism to prevent the bonnet inadvertently closing.

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Section 3 - Maintenance Routine Maintenance Greasing

Greasing General Information Read and understand Lubricants - Health and Safety, before greasing. You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Refer to the Service Schedules for the recommended frequencies.

Note: If working in muddy conditions the propshafts and PTO driveshafts must be greased daily.

Note: The machine must always be greased after pressure-washing or steam cleaning. Extra care must be taken to ensure that propshaft universal joints and splines are greased regularly Greasing should be done with a grease gun. Normally, two strokes of the gun should be enough. Stop greasing when fresh grease appears at the joint. Use only JCB HP Grease.

In the following illustrations the grease points are numbered. Count them off as you grease them.

Refit the grease point dust caps after greasing.

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Section 3 - Maintenance Routine Maintenance Greasing

Propshafts and Rear PTO Drive Shaft

Front axle propshaft

!MWARNING

Grease points 5 to 6

Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and remove the starter key. Make sure the park brake is engaged. Disconnect the battery to prevent the engine being started. Block all four wheels before getting under the machine.

3-3-1-1

Note: When greasing the universal joints, you must ensure 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

2

Fig 5.

4

3 Fig 4.

Fig 6.

Rear PTO drive shaft Grease points 1 to 2

Rear axle propshaft Grease points 3 to 4

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Section 3 - Maintenance Routine Maintenance Greasing

Front 3-Point Linkage (Optional)

!MWARNING You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started. Make sure the park brake is engaged.

Block all four wheels before getting under the machine.

2-3-2-1

.K General Information ( T 3-21) Grease at points 1 to 6.

Fig 7.

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Section 3 - Maintenance Routine Maintenance Greasing

Front Axle Steering Swivels

.K General Information ( T 3-21) Grease points 1 to 4.

!MWARNING Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and remove the starter key. Make sure the park brake is engaged. Disconnect the battery to prevent the engine being started. Block all four wheels before getting under the machine.

3-3-1-1

Note: After initial greasing, turn the wheels from lock to lock, then grease again to ensure full penetration.

!MWARNING When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned.

13-3-2-15

Fig 8.

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Section 3 - Maintenance Routine Maintenance Greasing

Steering Column Universal Joints

.K General Information ( T 3-21) Note: It may be necessary to turn the steering wheel to put the grease nipples in an accessible position.

!MWARNING You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started. Make sure the park brake is engaged.

Block all four wheels before getting under the machine.

2-3-2-1

!MWARNING When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned.

13-3-2-15

Grease at point 1 from underneath the machine.

Grease at points 2 to 4 from under the bonnet.

9

Fig 9.

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Section 3 - Maintenance Routine Maintenance Greasing

Rear Suspension Cylinder Pivots

.K General Information ( T 3-21) Grease points 1 to 4.

!MWARNING You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started. Make sure the park brake is engaged.

Block all four wheels before getting under the machine.

2-3-2-1

4

1

2

3 +

-

+

-

+

-

+

-

Fig 10.

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Section 3 - Maintenance Routine Maintenance Greasing

Hydraulic Lift and 3-Point Linkage

.K General Information ( T 3-21)

!MWARNING

Hydraulic lift rams

You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started. Make sure the park brake is engaged.

Grease points 1 to 4.

Three point linkage lift rods Grease at nipples 5 to 10 (lift collars A and B to access nipples 9 and 10).

Block all four wheels before getting under the machine.

2-3-2-1

+

-

+

-

+

-

+

-

1

3

5 6 9 A

7 8 10 B 2

4

Fig 11.

3 - 27

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Section 3 - Maintenance Routine Maintenance Greasing

Pick-up Hitch

.K General Information ( T 3-21)

Cross-Shafts

!MWARNING You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started. Make sure the park brake is engaged.

Grease points 1 to 4.

Block all four wheels before getting under the machine.

2-3-2-1

Fig 12.

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Section 3 - Maintenance Routine Maintenance Greasing

Automatic Trailer Coupling (if fitted) .K General Information ( T 3-21) Note: Whenever the coupling has been pressure-washed it must always be greased.

Make sure the coupling is in the open position, i.e. the coupling pin is up and the hand lever A is in its highest position.

Grease at points 1 and 2.

Operate lever A several times so that the grease is distributed throughout the bearing.

!MCAUTION Keep your hands out of the funnel or you may be injured by the coupling pin as it is forced down by its spring.

13-2-2-17

Grease again and operate the hand lever again.

If driving without a trailer attached, close the coupling to prevent dirt accumulation.

Fig 13.

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Section 3 - Maintenance Routine Maintenance Air Conditioning and Heater

Air Conditioning and Heater Air Conditioning Filters

2

If the filter is undamaged, pull foam pre-cleaner E out of the filter casing, wash it in low suds detergent and blow dry with compressed air at a maximum pressure of 5.5 bar (80 lbf/in2). Use the same compressed air to blow dirt out of filter D in the opposite direction to the arrows marked on the filter.

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.

Cleaning the Standard Air Conditioning Filter

Fig 14.

Note: The air conditioning system contains environmentally safe R-134A refrigerant. Do not use test equipment or gauges that have contacted R12 refrigerant or the system will be damaged.

Note: For crop spraying applications or very dusty conditions, a heavy duty carbon filter can be used in place of the standard filter. Carbon filters must not be cleaned.

Keep a log of the hours used and change at 250 hour intervals.

!MCAUTION The filter may be filled with dust. Wear goggles and a face mask when removing the filter.

2-3-3-6

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 worn.

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Section 3 - Maintenance Routine Maintenance Air Conditioning and Heater Changing the Heavy Duty Carbon Filter Note: Carbon filters must not be cleaned. Keep a log of the hours used and change at 250 hour intervals.

!MCAUTION The filter may be filled with dust. Wear goggles and a face mask when removing the filter.

2-3-3-6

Fig 16.

2

The new filter is supplied with a separate foam seal K that has a self-adhesive face covered by protective film. Clean the contact face of the new filter L, peel off the protective film from the foam seal and press the foam seal, self-adhesive face downwards, into position on the filter.

3

Check and clean the seal contact face on the cab body.

4

Fit the filter into the cab aperture using two screws H. Refit the closing panel G.

Fig 15.

1

Unscrew the two quarter-turn fasteners F and remove closing panel G. Remove the two screws H and pull out the filter J.

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Section 3 - Maintenance Routine Maintenance Air Conditioning and Heater

Cleaning the Heater Filter

!MCAUTION The filter may be filled with dust. Wear goggles and a face mask when removing the filter.

2-3-3-6

1

Pull out the fastener A and remove grille panel B.

2

Lift out filter C and check for splits or tears. Renew filter if damaged.

3

If the filter is undamaged, use compressed air at a maximum pressure of 5.5 bar (80 lbf/in2) to blow dirt out of the filter in the opposite direction to the air flow when the filter is installed.

4

Refit the filter into the cab aperture.

5

Refit the grille panel, making sure that the tongue D engages in slot E.

Fig 17.

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Section 3 - Maintenance Routine Maintenance Air Conditioning and Heater

Adjusting the Compressor Belt

!MWARNING Make sure the engine cannot be started. Disconnect the battery before doing this job.

2-3-3-5

!MWARNING 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

1

Stop the engine.

2

Open the bonnet.

3

Loosen fasteners A and B.

A

B

Fig 18.

4

Position the compressor so that there is 10 mm (0.4 in) slack on the longest run of the belt.

5

Retighten fasteners A and B.

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Section 3 - Maintenance Routine Maintenance Brakes

Brakes Checking the Foot Brake Fluid Level

!MWARNING If the brake fluid warning light comes on, check the brake fluid level immediately.

13-3-1-2_1

!MWARNING Faulty brakes can kill. If you have to top up the brake reservoir frequently, get the brake system checked by your JCB Dealer. Do not use the machine until the fault has been put right.

2-3-2-5_1

!MCAUTION Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid.

The fluid can harm your skin. Wear rubber gloves.

Cover cuts or grazes.

2-3-5-1_2

1

Unlock and turn handle A, lift the access door B and engage the support stay.

2

Check the fluid level in the three reservoirs C, D and E. The fluid level should be between the two lines F and G moulded into the side of each reservoir. If necessary, add fluid as follows.

Note: If the level has fallen below the lower mark G, the system must be checked by your JCB distributor.

3

Add the specified brake fluid.

Clean the area around the filler cap J. Remove the cap and carefully pour in the recommended fluid until it reaches the correct level. Avoid spilling it. Wipe up any spillage. Do not allow dirt to enter the reservoir.

Fit the cap securely.

Fig 19.

Note: Do not use ordinary hydraulic fluid.

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Section 3 - Maintenance Routine Maintenance Brakes

Checking the Trailer Air Tank 1

Charge the air system by starting the engine. Wait for the tank warning lights to go out. Stop the engine, apply the park brake.

2

Grip `keyring' fitting K at the bottom of tank L and pull sideways until all water is expelled. The amount of water released is a guide to the functioning of the air dryer. If purging of water takes much longer than about 5 seconds, or if oil is present, the system must be checked by your JCB distributor.

Fig 20.

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