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Service Manual JCB 354/360 TRACTOR Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine

Publication No.

9803/9480-1

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

Notes:

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Section 1 - General Information Contents Page No. Introduction About This Publication ............................................................................. 1 - 1 Identifying Your Machine ......................................................................... 1 - 3 Standard Torque Settings Front Axle Housing and Transmission ..................................................... 1 - 5 Service Consumables Sealing and Retaining Compounds ......................................................... 1 - 7 Service Tools Numerical List Section H - Steering ......................................................... 1 - 9 Tool Detail Reference Section H - Steering ........................................... 1 - 10

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Section 1 - General Information Contents

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Page No.

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Section 1 - General Information

Introduction About This Publication Machine Model and Serial Number

Finally, please remember above all else safety must come first!

This publication provides information for the following models in the JCB product range:

Units of Measurement T1-001_2

In this publication, the S.I. system of units is used. For example, liquid capacities are given in litres. The Imperial units follow in parentheses ( ) eg 28 litres (6 gal).

– 354 from S/N 1287000 to 1288999 – 360 from S/N 1287000 to 1288999

Using the Service Manual T11-004

This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department.

Section Numbering T11-005

The manual is compiled in sections, the first three are numbered and contain information as follows:

These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment.

1

General Information - includes torque settings and service tools.

2

Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.

The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify.

3

Maintenance - includes service schedules and recommended lubricants for all the machine.

General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt.

The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: A

Attachments

B

Body and Framework, etc.

Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.

Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication.

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Section 1 - General Information Introduction About This Publication

Left Side, Right Side In this publication, ‘left’ A and ‘right’ B mean your left and right when you are seated correctly in the machine.

Cross References T1-004_2

In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The number of the page upon which the subject begins, is indicated within the brackets. For example: K Cross References ( T 1-2).

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Section 1 - General Information Introduction Identifying Your Machine

Identifying Your Machine Machine Identification Plate Your machine has an identification plate mounted as shown. Information contained on this plate includes Model, Type, Engine, Vehicle Identification Number, Manufacturer and Address. The machine and engine serial numbers can help identify exactly the type of equipment you have.

Fig 1.

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Section 1 - General Information Introduction Identifying Your Machine Typical Vehicle Identification Number (VIN)

ROPS Certification Plate

A typical Vehicle Identification Number is given below.

Your machine is built to the ROPS standard and has an identification label fitted to the cab. A typical identification label is shown below.

35NH

X

01

0001

1

2

3

4

1

Machine Model

2

Year of Manufacture

3

Month of Manufacture

4

Machine Serial Number

0098 APPLICATION MODEL 354

Component Identification Plates

Fig 3.

Typical Engine Identification Number The engine identification plate A is attached to the rocker cover. The information stamped on this plate includes the engine model and serial number.

Fig 2.

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Section 1 - General Information

Standard Torque Settings Front Axle Housing and Transmission Introduction The following table gives the torque tightening values for the major parts of the Front Axle Housing (4WD Type) and the Transmission.

Major Part

Table 1. Standard Torque Settings Bolt and Nut Size (Hardness)

Torque Value

Nm

kgf/m

lbf/ft

5/8-11UNC (9T)

156.9 - 176.5

16.0 - 18.0

115.7 - 130.2

Front pivot metal

M14 (9T)

156.9 - 176.5

16.0 - 18.0

115.7 - 130.2

Rear pivot metal

M18 (7T)

196.0 - 235.2

20.0 - 24.0

144.6 - 173.5

Front axle final case

M12 (7T)

88.2 - 107.9

9.0 - 11.0

65.1 - 79.6

Bearing cover

M14 (7T)

132.3 - 137.2

13.5 - 14.0

97.6 - 101.2

Wheel shaft cover

M8 (7T)

53.9 - 68.6

5.5 - 7.0

39.8 - 50.6

Front wheel

M18 (7T)

225.4 - 235.2

23.0 - 24.0

166.3 - 173.5

Bevel gear case

M12 (7T)

88.2 - 107.9

9.0 - 11.0

65.1 - 79.6

Diff-metal (support)

M10 (7T)

73.5 - 87.2

7.5 - 8.9

9.4 - 13.1

Front Axle Housing Axle bracket to engine

Transmission Front transmission - engine

M12 (7T)

88.2 - 107.9

9.0 - 11.0

65.1 - 79.6

Front transmission - spacer

M12 (7T)

88.2 - 107.9

9.0 - 11.0

65.1 - 79.6

Space transmission - rear transmission

M12 (7T)

88.2 - 107.9

9.0 - 11.0

65.1 - 79.6

Input metal (support)

M12 (7T)

88.2 - 107.9

9.0 - 11.0

65.1 - 79.6

Drive pinion metal (support)

M10 (7T)

53.9 - 68.6

5.5 - 7.0

39.8 - 50.6

M12

53.9 - 68.6

5.5 - 7.0

39.8 - 50.6

M12 (7T)

88.2 - 107.9

9.0 - 11.0

65.1 - 79.6

Drive pinion Diff-case metal (support) Diff-case ring gear

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Section 1 - General Information Standard Torque Settings Front Axle Housing and Transmission

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Section 1 - General Information

Service Consumables Sealing and Retaining Compounds Table 2. Type

Description

Part No.

Quantity

JCB Multi-Gasket

A medium strength sealant suitable for all sizes of 4102/1212 50 ml gasket flanges, and for hydraulic fittings of 25-65 mm diameter.

JCB High Strength Thread locker

A high strength locking fluid for use with threaded 4102/0551 50 ml components. Gasketing for all sizes of flange where the strength of the joint is important.

JCB Retainer (High Strength)

For all retaining parts which are unlikely to be dismantled.

4101/0651 50 ml

JCB Thread locker 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 Thread locker and Sealer (High Strength)

A high strength locking fluid for sealing and retaining 4101/0550 10 ml nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. 4101/0552 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

1-7

For degreasing components prior to use of anaerobic 4104/1557 400 ml (Aerosol) adhesives and sealants.

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Section 1 - General Information Service Consumables Sealing and Retaining Compounds

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Section 1 - General Information

Service Tools Numerical List Section H - Steering The tools listed in the table are special tools required for removal and replacement of the steering valve parts.

Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.

Part Number

Description

Tool Detail Reference

SJ150L9001-01

Holding Tool

K Fig 4. ( T 1-10)

SJ150L4011-01

Assembly Tool for Shaft Seal 17.5 dia.

K Fig 5. ( T 1-10)

SJ150L4012-01

Assembly Tool for Shaft Seal 19.2 dia.

K Fig 6. ( T 1-10)

SJ150L0396-01

Assembly Tool for Dust Seal Ring

K Fig 7. ( T 1-10)

SJ150-9000-25

Pliers for Piston in Relief Valve

K Fig 8. ( T 1-10)

SJ151G9000-1

Fork for fitting Cardan Shaft

K Fig 9. ( T 1-10)

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Section 1 - General Information Service Tools Tool Detail Reference Section H - Steering

Tool Detail Reference Section H - Steering

Fig 9.

Fig 4.

Fig 5.

Fig 6.

Fig 7.

Fig 8.

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Section 2 - Care and Safety

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Section 2 - Care and Safety Contents Page No. Safety Notices Important Information .............................................................................. 2 - 1 Safety Check List ..................................................................................... 2 - 2

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Section 2 - Care and Safety

Safety Notices Important Information T1-015

The Operator Manual

Safety Warnings

!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

This safety alert system identifies important safety messages in this manual. When you see this symbol, be alert, your safety is involved, carefuly read the message that follows, and inform other operators. 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.

Do not operate the machine without an Operator Manual. Treat the Operator Manual as part of the machine. Keep it clean and in good condition. Replace the Operator Manual immediately if it is lost, damaged or becomes unreadable.

!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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Section 2 - Care and Safety Safety Notices Safety Check List

Safety Check List Safety - Yours and Others

General Safety INT-1-3-1_3

All machinery 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.

!MWARNING

T1-007_3

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

Do not work with the machine until you are sure that you can control it.

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.

Do not start any job until you are sure that you and those around you will be safe.

INT-1-3-5

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

!MWARNING 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. Remove rings, watches and personal jewellery. INT-1-3-6_2

!MWARNING 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

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Section 2 - Care and Safety Safety Notices Safety Check List

!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.

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

Switch off and do not use your mobile phone when refuelling the machine. 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 Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped). 13-2-3-7_2

!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

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

Operating Safety

!MWARNING Drive Safely Drive the machine smoothly. Avoid repeated start/stop or spin turn manoeuvres. Avoid unnecessary zig-zag driving. 8-1-2-2

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 and get into fresh air. INT-2-1-10_2

!MWARNING

!MWARNING

Machine Safety Stop work at once if a fault develops. Abnormal sounds and smells can be signs of trouble. Inspect and repair before resuming work.

The engine has exposed rotating parts. Switch OFF the engine before working in the engine compartment. Do not use the machine with the engine cover open.

8-1-2-3

5-2-6-5

!MWARNING

!MWARNING

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.

Controls You or others can be killed or seriously injured if you operate the control levers from outside the machine. Operate the control levers only when you are correctly seated in the machine. 0179

INT-2-1-1

!MWARNING

!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.

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.

INT-2-1-4

5-3-1-12_3

!MWARNING

!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.

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. 8-1-2-4

INT-2-1-7_1

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

!MCAUTION

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.

Passengers Passengers in or on the machine can cause accidents. Do not carry passengers. INT-2-2-2_1

!MWARNING

INT-2-1-2_2

!MWARNING Fibre Optic Cables If you cut through a fibre optic cable, Do not look into the end of it, your eyes could be permanently damaged.

Safe Working Loads Overloading the machine can damage it and make it unstable. Study the specifications in the Operator Manual before using the machine. 7-1-1-8_2

!MWARNING

8-2-9-20

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

Hillsides Operating the machine on hillsides can be dangerous if proper precautions are not taken. Ground conditions can be changed by rain, snow, ice etc. Check the site carefully. When applicable, keep all attachments low to the ground.

INT-2-2-4_2

8-1-1-1

!MWARNING

!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.

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

INT-2-2-8

!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. INT-2-2-5

INT-1-3-10_2

!MDANGER 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

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.

!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

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Section 2 - Care and Safety Safety Notices Safety Check List A wide range of optional attachments is available to increase the versatility of your machine. Only JCB approved attachments are recommended for use with your machine. Consult your JCB Distributor for the full list of approved attachments available. JCB attachments are designed and manufactured specifically to suit the machine's hydraulic system, mounting arrangements and safe load requirements. Attachments which are not designed for use with this machine may cause damage and create safety hazards for which JCB cannot be held responsible. In addition the machine's warranty, "CE" and any other legislative compliance may be affected by the use of non JCB approved attachments. 2-4-1-13_2

!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.

!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

!MWARNING 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. INT-3-1-10_2

!MWARNING 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.

INT-3-1-3_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. INT-3-1-6

!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

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

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

!MCAUTION

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.

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

INT-3-1-11_2

!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.

'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

INT-3-2-9_1

When operating PTO equipment, always observe the following safety precautions:

!MCAUTION Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents. INT-3-2-11

!MWARNING

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:

Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for:

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.

– Damaged hose ends – Chafed outer covers – Ballooned outer covers – Kinked or crushed hoses

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

– Embedded armouring in outer covers – Displaced end fittings. INT-3-3-2

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

!MWARNING

13-2-1-6

Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground. INT-3-2-4

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Section 2 - Care and Safety Safety Notices Safety Check List

!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. 13-2-2-2

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

Maintenance Safety

!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. INT-3-1-5

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. 0125

!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.

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

When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9

!MDANGER

INT-3-1-4

!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.

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 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

!MWARNING

INT-3-1-3_2

!MCAUTION Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. INT-3-1-14

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. INT-3-1-10_2

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Section 2 - Care and Safety Safety Notices Safety Check List

!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.

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

INT-3-1-11_2

!MWARNING

INT-3-2-4

!MWARNING 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

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. 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

!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

!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

!MCAUTION 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.

!MWARNING When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions. GEN-1-9

INT-3-2-14

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Section 2 - Care and Safety Safety Notices Safety Check List

!MCAUTION

!MWARNING

'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.

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. GEN-1-12

!MWARNING

INT-3-2-12

!MWARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for:

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

– Damaged hose ends – Chafed outer covers – Kinked or crushed hoses

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

– Embedded armouring in outer covers

INT-3-2-5

– Ballooned outer covers

– Displaced end fittings.

!MWARNING

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.

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

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. 5-3-1-9

!MWARNING 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. INT-3-3-8_2

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

!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.

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.

New fluoroelastomeric components at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose temperatures have not exceeded 300째C (572째F) 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 300째C (572째F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: 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.

area

with

3

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

DO NOT BURN FLUOROELASTOMERIC MATERIALS. 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. INT-3-3-5_2

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

!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

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Section 2 - Care and Safety Safety Notices Safety Check List

!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

!MWARNING Wheels and tyres are heavy. Take care when lifting or moving them. Store with care to ensure that they cannot fall and cause injury. 13-3-1-7_1

!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

!MWARNING Asbestos Asbestos dust can damage your lungs. Some engine gaskets contain asbestos. Do not dismantle the engine or exhaust system; get these jobs done by a qualified person who has a copy of the engine service manual. 5-1-6-1

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Section 2 - Care and Safety Safety Notices Safety Check List

Safety Decals

!MWARNING Decals Decals on the machine warn you of particular hazards. You can be injured if you do not obey the decal safety instructions. Each decal is attached close to a part of the machine where there is a possible hazard. Make sure replacement parts include warning decals where necessary. Keep all decals clean and readable. Replace lost or damaged decals. Each decal has a part number printed on it, use this number to order a new decal from your JCB distributor. INT-3-3-3_1

!MWARNING If you need eye-glasses for reading, make sure you wear them when reading the safety decals. Decals are strategically placed around the machine to remind you of possible hazards. Do not over-stretch or place yourself in dangerous positions to read the decals. INT-3-3-4_1

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Section 3 - Maintenance

Notes:

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Section 3 - Maintenance Contents Page No. Routine Maintenance Service Requirements ............................................................................. 3 - 1 Health and Safety .................................................................................... 3 - 3 Service Schedules ................................................................................... 3 - 7 Fluids, Lubricants and Capacities .......................................................... 3 - 11 Safety Checks ....................................................................................... 3 - 13 Cleaning the Machine ............................................................................ 3 - 14 Check for Damage ................................................................................. 3 - 15 Seat Belt ................................................................................................ 3 - 16 ROPS Structure ..................................................................................... 3 - 17 Greasing ................................................................................................ 3 - 18 Access Panels ....................................................................................... 3 - 19 Brakes ................................................................................................... 3 - 20 Clutch .................................................................................................... 3 - 21 Accelerator ............................................................................................ 3 - 22 Electrical System ................................................................................... 3 - 23 Engine Air Filter ..................................................................................... 3 - 26 Engine ................................................................................................... 3 - 28 Fuel System ........................................................................................... 3 - 33 Hydraulic/Transmission System ............................................................ 3 - 38 Tyres and Wheels .................................................................................. 3 - 40 Axles ...................................................................................................... 3 - 41 Air Conditioning ..................................................................................... 3 - 42 Windscreen Washers ............................................................................ 3 - 43

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Section 3 - Maintenance

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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.

Lifting Regulations - Inspections and Tests T3-003

Only your JCB Distributor can fully meet the requirements of the inspection and test parameters to suit UK Health and Safety Executive (H.S.E.) legal requirements along with providing Annual Inspections to meet your Insurance Company Policy conditions. Only your JCB Distributor has the ability to meet the definition described covering a "Competent Person" to

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Section 3 - Maintenance Routine Maintenance Service Requirements carry out these necessary tests and inspections. This ensures that only JCB Factory trained, experienced and up-to-date Engineers supported with all of the available data and material provided only to a JCB Distributor will ensure a thorough and reliable standard.

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.

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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.

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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 Introduction

Description

A poorly maintained machine is a hazard. Doing the regular maintenance and lubrication jobs listed in these schedules will help keep the machine in safe running order.

!MWARNING

Symbol

Fault found and corrected (Detail on report)

Â…

Follow up required (Detail on report)

8

Note: Original copy to customer, Photocopy to distributor.

How to Use the Service Schedules

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 level ground.

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.

To prevent anyone starting the engine, remove the starter key. Disconnect the battery when you are not using electrical power. If you do not take these precautions you could be killed or injured. 8-3-1-1

A Service History Record Book is supplied with every machine to enable you to plan your service requirements and keep a service history record. This record book should be dated, signed and stamped by your Distributor at machine installation and each time your machine is serviced. 2-3-1-9

Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hour meter reading. Do not use a machine which is due for a regular service. Rectify any defects found during regular maintenance before clearing the machine for use. Calendar equivalents: Every 10 Hours

Daily

Every 50 Hours

Weekly

Every 100 Hours

Monthly

Every 600 Hours

Six Monthly

All jobs should be marked and logged K Table 1. ( T 3-7) Table 1. Description No fault found job complete

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Symbol

9

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Section 3 - Maintenance Routine Maintenance Service Schedules

Pre Start Cold Checks, Service Points and Fluid Levels Operation Daily

50

100 150 200 250 300 350 400 450 500 550 600

… …

…

… … … …

…

…

… …

… …

… …

… … … … … …

ENGINE Engine oil level

- Check

Engine oil

- Change

Engine oil filter(1)

- Change

(1)

Engine coolant level Engine coolant (2)

- Check

- Check

Radiator, fins and screen

- Clean

Radiator hose clamp

- Check

Fuel tank level

- Check

Fuel filter

- Check

Fuel filter

- Clean

Fuel filter

- Change

Air cleaner dust ejector

- Clean

Air cleaner elements

- Clean

Air cleaner elements

- Change

Fan belt

… …

- Change

Radiator

Safety start system

…

- Check - Check and Adjust

… …

… … …

… … … … … … …

…

… …

…

… …

…

… … … …

… … …

…

… … … … … … …

… … …

… …

… …

…

…

… … … … … … … … … … … … … … … … … … … …

…

… … … … … …

…

… …

… …

… … … …

… … … … … …

… …

… …

… … … … … …

… … …

… … … …

… … … … … …

… …

… …

… … … … … …

… …

…

… …

TRANSMISSION

Wheel bolt torque

- Check and Adjust

…

… …

Tyre pressure and condition

- Check and Adjust

…

…

…

Brake adjustment and balance - Check and Adjust

…

…

… …

… … … … …

Grease fittings/nipples

Accelerator pedal

- Lubricate

- Adjust - Check and Adjust

…

…

… …

… …

Steering wheel free play

- Check

Steering wheel joint

- Check

… …

… …

… … … …

Steering wheel joint

- Adjust

… … … … … … …

Clutch pedal free play

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… …

…

… … …

… … …

…

…

… … …

… …

… …

… … … … … …

… … …

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Section 3 - Maintenance Routine Maintenance Service Schedules Operation Daily Steering Toe-in

- Check

Operation of levers

- Check

Transmission oil

- Check

… …

- Change

Transmission oil(3)

- Clean

Strainer(4) Front axle oil

- Change

Front axle oil

- Check

Front wheel hub grease(5)

- Check

Clutch chamber oil level

- Check

50

… … … … …

100 150 200 250 300 350 400 450 500 550 600

… … … …

…

… … … … … … …

…

… … … …

… …

…

… … … … … …

… … …

…

…

…

… … …

…

…

HYDRAULICS Hydraulic oil level Hydraulic oil and filter

- Check (4)

Security of mounting bolts and nuts

…

- Change - Check

…

… … …

… … …

… … … …

… … … …

…

…

ELECTRICS Battery electrolyte level

- Check

Wiring for Chaffing/Routing

- Check

Battery Terminals for Condition and Tightness

- Check

(1) (2) (3) (4) (5)

… …

… …

… … … …

… … … … … …

… …

… …

… … … … … … …

… …

Change at initial 50 hour service then every 500 hours. Recommended to be replaced every 200 hours or yearly. Change at initial 50 hour service then every 300 hours. Clean at initial 50 hour service then every 300 hours Grease every 900 hours

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Section 3 - Maintenance Routine Maintenance Service Schedules

Functional Test and Final Inspection Note: Original copy to customer, Photocopy to distributor. Operation Daily

50

100

150

200

250

300

ENGINE - Check

…

…

…

…

Operation All Services

- Check

…

Hoses and Pipework - Damage/Leaks

- Check

… …

… …

… …

…

…

…

…

Fuel System - Leaks and Contamination HYDRAULICS

ELECTRICS All Electrical Equipment Operation

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- Check

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Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities Item

Capacity Litres

Table 2. Fluid / Lubricant

International Specification

Fuel Tanks

72 litre

Diesel Oil

K Types of Fuel ( T 3-33)

Engine (Oil)

7 litre

JCB 10W/30 or SAE 30

API CD/CE

above 25°C (above 77°F) 10W30 Multigrade SAE 20 0°C to 25°C (32°F to 77°F) 10W-30 or SAE 10 below 0°C (32°F) Hydraulic (Oil)

43 litre

RPM Tractor Hydraulic Fluid or Textron TDH Premium (Caltex) TDH Oil or TDH Oil Special (Texaco) Chevron 1000 THF

Engine Coolant Front Axle and final drive case (B) (Oil) All Other Grease

8 litre

JCB Universal Antifreeze/water K Coolant Mixtures ( T 3-11)

ASTM D3306-74

JCB MPL Grease

Lithium based no 2 consistency

16.3 litres

Initial Hydraulic Oil and Filter Change.................50 hours

!MWARNING

Hydraulic Oil and Filter Change, Thereafter......350 hours

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

Initial Engine Oil and Filter Change....................50 hours

7-3-4-4_1

Engine Oil and Filter Change, Thereafter.........100 hours Note: Change intervals stated above are for normal usage. Due to adverse operating conditions that may be experienced (extremely dusty or muddy), change intervals may need to be more frequent.

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.

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)

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Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities 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 Safety Checks

Safety Checks Safety Checks A safety starter switch is installed on the tractor which prevents the engine from starting unless the clutch pedal is fully depressed. Check the safety starter switch daily. Do not by-pass or carry out any maintenance on this switch, only authorised dealers are recommended to carry out work on the safety starter switch. It is recommended that the safety starter switch is replaced every 2000 hours or 4 years, whichever is sooner.

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Section 3 - Maintenance Routine Maintenance Cleaning the Machine

Cleaning the Machine Clean the machine using water and/or steam. If steam is used, the machine must be completely greased afterwards. K Greasing ( T 3-18).

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Section 3 - Maintenance Routine Maintenance Check for Damage

Check for Damage 1

Inspect steelwork for damage. Note any damage for future repair.

2

Inspect the tyres for damage and penetration by sharp objects.

3

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

4

Ensure that the step and handrails are undamaged and secure.

5

Check all lamp lenses for damage.

6

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

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Jcb 354 compact tractor service repair manual sn:1287000 to 1288999  
Jcb 354 compact tractor service repair manual sn:1287000 to 1288999  
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