Page 1

Service Manual Fastrac 8280 and 8310 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.

9813/0350-1

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 Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400


Section 1 - General Information

Notes:

1-0

9813/0350-1

1-0


Section 1 - General Information Contents Page No. Identification Identifying your Machine ............................................................................ 1-1 Identification Plate .................................................................................1-1 ROPS and FOPS Certification Labels ...................................................1-4 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-5 Introduction ............................................................................................1-5 Zinc Plated Fasteners (golden finish) ....................................................1-6 Dacromet Fasteners (mottled silver finish) ............................................1-7 Hydraulic Connections ............................................................................... 1-8 'O' Ring Face Seal System ....................................................................1-8 'Torque Stop' Hose System ................................................................. 1-11 Special Tools Numerical List .......................................................................................... 1-13 Tool Detail Reference .............................................................................. 1-17 Section B - Body and Framework ........................................................1-17 Section C - Electrics ............................................................................1-20 Section E - Hydraulics .........................................................................1-23 Section F - Transmission .....................................................................1-28 Section G - Brakes ..............................................................................1-29 Section S - Suspension .......................................................................1-30 Service Consumables Sealing and Retaining Compounds ......................................................... 1-31

1-i

1-i


Section 1 - General Information Contents

1-ii

Page No.

1-ii


Section 1 - 1

Identification Identifying your Machine Identification Plate

C100840

Fig 3.

Fig 1. The identification plate A is located under the engine cover as shown. K Fig 1. ( T 1-1) The information on the identification plate will depend on the market for which the machine is built. It will be as shown on one of the following illustrations.

Fig 2.

1-1

9813/0350-1

1-1


Section 1 - 1 Identification Identifying your Machine Typical Product Identification No. (PIN)

Unit Identification

1

2

3

4

5

6

JCB

32

Z

40

E

00123456

1

World Manufacturer Identification (3 Digits)

2

Engine Type (2 Digits)

3

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.

31 = 8.4 litres 191 kW

Engine

M

32 = 8.4 litres 209 kW

Gearbox

N

Front axle

P

Rear axle

R

Transmission Type (1 Digit) Z = 8000 series CVT

4

Vehicle Maximum Speed kph (2 Digits) 40 = 40kph FASTRAC

50 = 50kph 60 = 60kph 65 = 65kph 5

Check Letter (1 Digit) The Check Letter is used to verify the authenticity of the machine's PIN.

6

M

Machine Serial Number (8 Digits) Each machine has a unique serial number.

C100550-B3

Fig 4.

1-2

9813/0350-1

1-2


Section 1 - 1 Identification Identifying your Machine

N Fig 5.

Fig 6.

Fig 7.

1-3

9813/0350-1

1-3


Section 1 - 1 Identification Identifying your Machine

ROPS and FOPS Certification Labels Machines are built to Roll Over Protection Structure (ROPS) and Falling Objects Protection Structure (FOPS) standards and have the following identification label fitted. K Fig 8. ( T 1-4)

332-W8824-1

Fig 8. The FOPS structure provides impact protection for normal agricultural use, as defined in OECD Code10.

!MWARNING Do not use the machine if the falling objects protection level provided by the structure is not sufficient for the application. Falling objects can cause serious injury. 8-2-8-17

1-4

9813/0350-1

1-4


Section 1 - 2

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.

1-5

9813/0350-1

1-5


Section 1 - 2 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

1-6

983

Verbus Ripp Bolts

Fig 1. 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

9813/0350-1

1-6


Section 1 - 2 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

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

1657

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

1-7

1416

9813/0350-1

1-7


Section 1 - 2 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

1-8

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

9813/0350-1

1-8


Section 1 - 2 Standard Torque Settings Hydraulic Connections Hoses Screwed into Adaptors

Fig 2. Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring 2-C which is compressed into a 45° seat machined into the face of the adaptor port.

BSP Hose Size in.

1-9

Note: Dimension 2-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

9813/0350-1

kgf m

lbf ft

1-9


Section 1 - 2 Standard Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 4. BSP Adaptors with Bonded Washers - Torque Settings BSP Size

1-10

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

9813/0350-1

1-10


Section 1 - 2 Standard Torque Settings Hydraulic Connections

'Torque Stop' Hose System

Fig 3. `Torque Stop' Hoses 3-B screwed into adaptors 3-A seal onto an 'O' ring 3-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 3-D, which acts as a physical stop. Note: Minimum dimension 3-E fixed by shoulder 3-D.

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

1-11

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

9813/0350-1

1-11


Section 1 - 2 Standard Torque Settings Hydraulic Connections

Page left intentionally blank

1-12

9813/0350-1

1-12


Section 1 - 3

Special Tools Numerical List The tools listed in the table are special tools required for removal and replacement of Body and Framework parts. These tools are available from JCB Service.

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

1406/0011

Bonded Washer

K Fig 25. ( T 1-24)

1406/0014

Bonded Washer

K Fig 25. ( T 1-24)

1406/0018

Bonded Washer

K Fig 25. ( T 1-24)

1406/0021

Bonded Washer

K Fig 25. ( T 1-24)

1406/0029

Bonded Washer

K Fig 25. ( T 1-24)

1604/0003A Adapter

K Fig 18. ( T 1-23)

1604/0004A Adapter

K Fig 18. ( T 1-23)

1604/0006A Adapter

K Fig 26. ( T 1-25)

1604/2055

Adapter

K Fig 18. ( T 1-23)

1606/0004

Adapter

K Fig 18. ( T 1-23)

1606/0007A Adapter

K Fig 18. ( T 1-23)

1606/0008

Adapter

K Fig 18. ( T 1-23)

1606/0009

Adapter

K Fig 18. ( T 1-23)

1606/0012

Adapter

K Fig 18. ( T 1-23)

1606/0014

Adapter

K Fig 18. ( T 1-23)

1606/0015

Adapter

K Fig 18. ( T 1-23)

1606/0016

Adapter

K Fig 18. ( T 1-23)

1606/0017

Adapter

K Fig 18. ( T 1-23)

1606/2052

Adapter

K Fig 18. ( T 1-23)

1612/2054

Adapter

K Fig 26. ( T 1-25)

816/00017

Adapter

K Fig 21. ( T 1-24)

816/00189A Blanking Cap

K Fig 23. ( T 1-24)

816/00190A Blanking Cap

K Fig 23. ( T 1-24)

816/00439

Adapter

K Fig 18. ( T 1-23)

816/00440

Adapter

K Fig 18. ( T 1-23)

816/15007A Adapter

K Fig 18. ( T 1-23)

816/15008

Adapter

K Fig 18. ( T 1-23)

816/15118

Adapter

K Fig 19. ( T 1-23)

1-13

9813/0350-1

1-13


Section 1 - 3 Special Tools Numerical List Part Number

Description

Tool Detail Reference

816/20008

Adapter

K Fig 26. ( T 1-25)

816/20013

Adapter

K Fig 26. ( T 1-25)

816/50005

Adapter

K Fig 21. ( T 1-24)

816/50043

Adapter

K Fig 21. ( T 1-24)

816/55038

Adapter

K Fig 20. ( T 1-23)

816/55040

Adapter

K Fig 20. ( T 1-23)

816/55045

Adapter

K Fig 20. ( T 1-23)

816/60096

Adapter

K Fig 21. ( T 1-24)

816/90022

Blanking Cap

K Fig 23. ( T 1-24)

816/90045

Blanking Cap

K Fig 23. ( T 1-24)

816/90205

Blanking Cap

K Fig 23. ( T 1-24)

816/90274

Blanking Cap

K Fig 23. ( T 1-24)

826/01099

Rivet Nut

K Fig 5. ( T 1-17)

826/01101

Rivet Nut

K Fig 5. ( T 1-17)

826/01102

Rivet Nut

K Fig 5. ( T 1-17)

826/01103

Rivet Nut

K Fig 5. ( T 1-17)

826/01104

Rivet Nut

K Fig 5. ( T 1-17)

826/01105A Rivet Nut

K Fig 5. ( T 1-17)

892/00047

Adapter

K Fig 21. ( T 1-24)

892/00048

Adapter

K Fig 21. ( T 1-24)

892/00049

Adapter

K Fig 21. ( T 1-24)

892/00055A Blanking Cap

K Fig 22. ( T 1-24)

892/00056A Blanking Cap

K Fig 22. ( T 1-24)

892/00057

Blanking Cap

K Fig 22. ( T 1-24)

892/00058A Blanking Cap

K Fig 22. ( T 1-24)

892/00059A Blanking Cap

K Fig 22. ( T 1-24)

892/00060

Blanking Cap

K Fig 22. ( T 1-24)

892/00051

Adapter

K Fig 21. ( T 1-24)

892/00074

Connector

K Fig 24. ( T 1-24)

892/00075

Connector

K Fig 24. ( T 1-24)

892/00076

Connector

K Fig 24. ( T 1-24)

892/00077

Connector

K Fig 24. ( T 1-24)

892/00078

Connector

K Fig 26. ( T 1-25)

892/00137

Hose

K Fig 31. ( T 1-27)

892/00179

Bearing Press

K Fig 36. ( T 1-28)

892/00201

Replacement Gauge

K Fig 28. ( T 1-26)

892/00202

Replacement Gauge

K Fig 28. ( T 1-26)

1-14

9813/0350-1

1-14


Section 1 - 3 Special Tools Numerical List Part Number

Description

Tool Detail Reference

892/00203

Replacement Gauge

K Fig 28. ( T 1-26)

892/00223

Hand Pump

K Fig 31. ( T 1-27)

892/00224

Impulse Extractor

K Fig 37. ( T 1-29)

892/00225

Adapter for Impulse Extractor

K Fig 38. ( T 1-29)

892/00254

Replacement Hose

K Fig 30. ( T 1-26)

892/00255

Adapter

K Fig 19. ( T 1-23)

892/00256

Adapter

K Fig 19. ( T 1-23)

892/00257

Adapter

K Fig 19. ( T 1-23)

892/00258

Adapter

K Fig 19. ( T 1-23)

892/00259

Adapter

K Fig 19. ( T 1-23)

892/00260

Adapter

K Fig 19. ( T 1-23)

892/00261

Adapter

K Fig 19. ( T 1-23)

892/00262

Adapter

K Fig 31. ( T 1-27)

892/00263

Adapter

K Fig 20. ( T 1-23)

892/00264

Adapter

K Fig 20. ( T 1-23)

892/00265

Adapter

K Fig 20. ( T 1-23)

892/00266

Adapter

K Fig 20. ( T 1-23)

892/00267

Adapter

K Fig 20. ( T 1-23)

892/00268

Flow Monitoring Unit

K Fig 26. ( T 1-25)

892/00269

Sensor Head

K Fig 26. ( T 1-25)

892/00270

Load Valve

K Fig 26. ( T 1-25)

892/00271

Adapter

K Fig 26. ( T 1-25)

892/00272

Adapter

K Fig 26. ( T 1-25)

892/00273

Sensor Head

K Fig 26. ( T 1-25)

892/00274

Adapter

K Fig 26. ( T 1-25)

892/00275

Adapter

K Fig 26. ( T 1-25)

892/00276

Adapter

K Fig 26. ( T 1-25)

892/00277

Adapter

K Fig 26. ( T 1-25)

892/00278

Gauge

K Fig 31. ( T 1-27)

892/00279

Gauge

K Fig 30. ( T 1-26)

892/00280

Gauge

K Fig 30. ( T 1-26)

892/00284

Tachometer

K Fig 15. ( T 1-20)

892/00285

Hydraulic Oil Temperature Probe

K Fig 14. ( T 1-20)

892/00293

Connector Pipe

K Fig 26. ( T 1-25)

892/00298

Fluke Meter

K Fig 13. ( T 1-20)

892/00311

Brake Test Kit

K Fig 39. ( T 1-29)

892/00314

Accumulator Adapter

K Fig 40. ( T 1-30)

1-15

9813/0350-1

1-15


Section 1 - 3 Special Tools Numerical List Part Number

Description

Tool Detail Reference

892/00314

Accumulator and Gas Spring Pressure Test Adapter

K Fig 40. ( T 1-30)

892/00318

Hose and Adapter Kit

K Fig 32. ( T 1-27)

892/00333

Heavy Duty Socket, 19 mm A/F

K Fig 35. ( T 1-28)

892/00347

Connector

K Fig 28. ( T 1-26)

892/00706

Test Probe

K Fig 31. ( T 1-27)

892/00801

Clutch spanner

K Fig 7. ( T 1-19)

892/00802

Rotor puller set

K Fig 9. ( T 1-19)

892/00803

Rotor installer set

K Fig 11. ( T 1-19)

892/00807

Front plate puller

K Fig 8. ( T 1-19)

892/00808

Shaft protector

K Fig 10. ( T 1-19)

892/00817

Heavy Duty Socket, 17 mm A/F

K Fig 35. ( T 1-28)

892/00818

Heavy Duty Socket, 22mm A/F

K Fig 35. ( T 1-28)

892/00819

Heavy Duty Socket, 15 mm A/F

K Fig 35. ( T 1-28)

892/01174

Data Link Adapter Kit

K Fig 16. ( T 1-21)

892/01053

Adapter for impulse extractor (PTO intermediate shaft, wet clutch transmission) K Fig 37. ( T 1-29)

993/45400

Torque Multiplier

K Fig 34. ( T 1-28)

993/68101

Slide Hammer

K Fig 4. ( T 1-17)

993/68102

End Stops

K Fig 4. ( T 1-17)

993/68103

Adapter

K Fig 4. ( T 1-17)

993/68104

Adapter

K Fig 4. ( T 1-17)

993/68105

Adapter

K Fig 4. ( T 1-17)

993/68106

Adapter

K Fig 4. ( T 1-17)

993/68107

Bar

K Fig 4. ( T 1-17)

993/68108

Adapter

K Fig 4. ( T 1-17)

993/68109

Adapter

K Fig 4. ( T 1-17)

993/68110

Adapter

K Fig 4. ( T 1-17)

993/68111

Adapter

K Fig 4. ( T 1-17)

993/69800

Seal Kit

K Fig 28. ( T 1-26)

333/T4418

Urea Sender Tool

K Fig 12. ( T 1-19)

1-16

9813/0350-1

1-16


Section 1 - 3 Special Tools Tool Detail Reference

Tool Detail Reference Section B - Body and Framework Note: Not all service tools are illustrated.

Fig 4. 993/68100 Slide Hammer Kit 1

993/68101

Slide Hammer

7

993/68107

Bar - M20 x M20 X 800 mm

2

993/68102

End Stops

8

993/68108

Adaptor - M20 x 7/8" UNF

3

993/68103

Adaptor - M20 x 5/8" UNF

9

993/68109

Adaptor - M20 x M12

4

993/68104

Adaptor - M20 x 1" UNF

10

993/68110

Adaptor - M20 x 5/8" UNF (Shoulder)

5

993/68105

Adaptor - M20 x M20

11

993/68111

Adaptor - M20 x 1/2" UNF

6

993/68106

Adaptor - M20 x M24 1

826/01099

M6 x 16 mm Rivet Nut

826/01101

M6 x 19 mm Rivet Nut

826/01102

M8 x 18 mm Rivet Nut

826/01103

M8 x 21 mm Rivet Nut

826/01104

M10 x 23 mm Rivet Nut

826/01105A M10 x 26 mm Rivet Nut 2

-

Installation Tool available from: Bollhoff Fastenings Ltd (www.bollhof.com)

Fig 5. Rivet Nut Tool

1-17

9813/0350-1

1-17


Section 1 - 3 Special Tools Tool Detail Reference

1660mm

1800mm

1070mm

C071920-C1

Fig 6. Cab Lifting Frame: Produce locally to dimensions shown. Test to Safe Working Load (SWL) of 1200 kg (2645 lb).

1-18

9813/0350-1

1-18


Section 1 - 3 Special Tools Tool Detail Reference

Fig 7. Fig 8. 892/00801 Clutch Spanner for air conditioning compressor 892/00807 Font Plate Puller for air conditioning compressor

Fig 10. Fig 9. 892/00802 Rotor Puller Set for air conditioning compressor 892/00808 Shaft Protector for air conditioning compressor

Fig 11. 892/00803 Rotor Installer Set

1-19

Fig 12. 333/ T4418 Urea Sender Tool

9813/0350-1

1-19


Section 1 - 3 Special Tools Tool Detail Reference

Section C - Electrics

Fig 13. 892/00298 Fluke Meter

Fig 14. 892/00285 Hydraulic Temperature Probe

Fig 15. 892/00284 Venture Microtach Digital Tachometer

1-20

9813/0350-1

1-20


Section 1 - 3 Special Tools Tool Detail Reference

1

2 D

C

B

A

J

E F

H

G

3

5 4

6 Fig 16. Data Link Adapter Kit 892/01174 1

Interconnecting cable, DLA to machine ECU diagnostics socket - 721/10472.

2

Interconnecting cable, DLA to machine ECU diagnostics socket - 718/20237.

3

Kit carrying case.

4

Interconnecting cable, DLA to laptop PC USB port - 718/20235.

5

Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable diagnostics software - 718/26500.

6

Interconnecting cable, DLA to laptop PC serial port - 718/20236.

Note: Item 1 of the Data Link Adapter Kit is unsuitable for use with the Fastrac. (See Section C).

1-21

9813/0350-1

1-21


Section 1 - 3 Special Tools Tool Detail Reference 1

Electrical Repair Kit

2A

:7212/0002

2 Way Pin Housing

2B

:7212/0004

2 Way Pin Retainer

2C

:7212/0003

2 Way Socket Retainer

2D

:7212/0001

2 Way Socket Connector

3A

:7213/0002

3 Way Pin Housing

3B

:7213/0004

3 Way Pin Retainer

3C

:7213/0003

3 Way Socket Retainer

3D

:7213/0001

3 Way Socket Connector

4A

:7213/0006

3 Way Pin Housing (DT)

4B

:7213/0008

3 Way Pin Retainer (DT)

4C

:7213/0007

3 Way Socket Retainer (DT)

4D

:7213/0005

3 Way Socket Connector (DT)

5A

:7214/0002

4 Way Pin Housing

5B

:7214/0004

4 Way Pin Retainer

5C

:7214/0003

4 Way Socket Retainer

5D

:7214/0001

4 Way Socket Connector

6A

:7216/0002

6 Way Pin Housing

6B

:7216/0004

6 Way Pin Retainer

6C

:7216/0003

6 Way Socket Retainer

6D

:7216/0001

6 Way Socket Connector

7A

:7218/0002

8 Way Pin Housing

7B

:7218/0004

8 Way Pin Retainer

7C

:7218/0003

8 Way Socket Retainer

7D

:7218/0001

8 Way Socket Connector

8A

:7219/0002

10 Way Pin Housing

8B

:7219/0004

10 Way Pin Retainer

8C

:7219/0003

10 Way Socket Retainer

8D

:7219/0001

10 Way Socket Connector

9A

:7219/0006

14 Way Pin Housing

9B

:7219/0008

14 Way Pin Retainer

9C

:7219/0007

14 Way Socket Retainer

9D

:7219/0005

14 Way Socket Connector

10

:7210/0001

Dummy Plug

11

:7210/0002

Wire Seal (1.4 - 2.2 mm dia.)

12

:7210/0003

Wire Seal (2.2 - 2.9 mm dia.)

1-22

Fig 17.

9813/0350-1

1-22


Section 1 - 3 Special Tools Tool Detail Reference

Section E - Hydraulics Male Adapters - BSP x BSP 1606/2052

3/8 in. x 1/4 in.

1604/0003A 3/8 in. x 3/8 in. 892/00071

3/8 in. x 3/8 in. taper

1606/0004

1/2 in. x 1/4 in.

1606/0007A 1/2 in. x 3/8 in. Fig 18. Male Adaptors

1604/0004A 1/2 in. x 1/2 in. 1606/0017

5/8 in. x 1/2 in.

1606/0008

3/4 in. x 3/8 in.

Male Adapters - BSP x NPT (USA only)

1606/0009

3/4 in. x 1/2 in.

816/00439

3/8 in. x 1/4 in.

1604/2055

3/4 in. x 3/4 in.

816/00440

1/2 in. x 1/4 in.

1606/0012

3/4 in. x 1 in.

816/15007A 3/8 in. x 3/8 in.

1606/0014

3/4 in. x 1.1/4 in.

816/15008

1606/0015

1 in. x 1.1/4 in.

892/00255

1/4 in. BSP x Test Point

892/00256

3/8 in. BSP x Test Point

892/00257

1/2 in. BSP x Test Point

892/00258

5/8 in. BSP x Test Point

816/15118

3/4 in. BSP x Test Point

892/00259

1 in BSP x Test Point

892/00260

1.1/4 in. BSP x Test Point

892/00261

5/8 in. UNF x Test Point

816/55045

1/4 in. M BSP x 1/4 in. F BSP x Test Point

816/55038

3/8 in. M BSP x 3/8 in. F BSP x Test Point

816/55040

1/2 in. M BSP x 1/2 in. F BSP x Test Point

892/00263

5/8 in. M BSP x 5/8 in. F BSP x Test Point

892/00264

3/4 in. M BSP x 3/4 in. F BSP x Test Point

892/00265

1 in. M BSP x 1 in. F BSP x Test Point

892/00266

1.1/4 in. M BSP x 1.1/4 in. F BSP x Test Point

892/00267

1.1/4 in. M BSP x 1.1/2 in. F BSP x Test Point

1/2 in. x 3/8 in.

Fig 19. Pressure Test Adapters

Fig 20. Pressure Test 'T' Adapters

1-23

9813/0350-1

1-23


Section 1 - 3 Special Tools Tool Detail Reference

Fig 21. 'T' Adapters

892/00047

3/8 in. BSP (A) x 1/4 in. BSP (B)

892/00048

1/2 in. BSP (A) x 1/4 in. BSP (B)

892/00049

5/8 in. BSP (A) x 1/4 in. BSP (B)

816/50043

3/4 in. BSP (A) x 1/4 in. BSP (B)

892/00051

1 in. BSP (A) x 1/4 in. BSP (B)

816/50005

1/2 in. BSP (A) x 1/2 in. BSP (B)

816/60096

3/4 in. BSP (A) x 3/4 in. BSP (B)

816/00017

1 in. BSP (A) x 1 in. BSP (B)

892/00055A 1/4 in. BSP 892/00056A 3/8 in. BSP 892/00057

1/2 in. BSP

892/00058A 5/8 in. BSP 892/00059A 3/4 in. BSP Fig 22. Female Blanking Caps

892/00060

1 in. BSP

816/90045

1/4 in. BSP

816/00189A 3/8 in. BSP 816/00190A 1/2 in. BSP

Fig 23. Male Cone Blanking Caps

816/90022

5/8 in. BSP

816/90274

3/4 in. BSP

816/90205

1 in. BSP

892/00074

3/8 in. BSP x 3/8 in. BSP

892/00075

1/2 in. BSP x 1/2 in. BSP

892/00076

5/8 in. BSP x 5/8 in. BSP

892/00077

3/4 in. BSP x 3/4 in. BSP

1406/0011

1/4 in. BSP

1406/0018

1/2 in. BSP

1406/0014

5/8 in. BSP

Fig 24. Female Connectors

Fig 25. Bonded Washers

1-24

1406/0021

3/4 in. BSP

1406/0029

1.1/4 in. BSP

9813/0350-1

1-24


Section 1 - 3 Special Tools Tool Detail Reference Note: No longer available, refer to 998/11046 JCB ServiceMaster Flow Test Kit. K Fig 27. ( T 1-25).

892/00268

Flow Monitoring Unit

892/00269

Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)

892/00273

Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min)

892/00293

Connector Pipe

892/00270

Load Valve

1406/0021

Bonded Washer

1604/0006A Adapter 3/4 in M x 3/4 in M BSP

Fig 26. Flow Test Equipment

1612/2054

Adapter 3/4 in F x 3/4 in M BSP

892/00271

Adapter 3/4 in F x 5/8 in M BSP

892/00272

Adapter 5/8 in F x 3/4 in M BSP

816/20008

Adapter 3/4 in F x 1/2 in M BSP

892/00275

Adapter 1/2 in F x 3/4 in M BSP

892/00276

Adapter 3/4 in F x 3/8 in M BSP

892/00277

Adapter 3/8 in F x 3/4 in M BSP

1606/0015

Adapter 1.1/4 in M BSP x 1 in M BSP

892/00078

Connector 1 in F x 1 in F BSP

1604/0008

Adapter 1 in M x 1 in M BSP

1606/0012

Adapter 1 in M x 3/4 in M BSP

816/20013

Adapter 3/4 in F x 1 in M BSP

998/11047

600 LPM Flow Turbine with Loading Valve

998/11048

1-7/8" UNF x1 - 1/4" BSP Flow Block Adaptors x2

998/11049

Carrying Case for Flow Test Kit

998/11050

Temperature Sensor (125°C Max)

Fig 27. 998/11046 JCB ServiceMaster Flow Test Kit

1-25

9813/0350-1

1-25


Section 1 - 3 Special Tools Tool Detail Reference Note: No longer available, refer to 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit. K Fig 29. ( T 1-26).

1

2

3

892/00201

Replacement Gauge 0-20 bar (0-300 lbf/in2)

892/00202

Replacement Gauge 0-40 bar (0-600 lbf/in2)

892/00203

Replacement Gauge 0-400 bar (0-6000 lbf/in2)

892/00254

Replacement Hose

993/69800

Seal Kit for 892/00254 (can also be used with probe 892/00706)

892/00706

Test Probe

892/00347

Connector - Hose to gauge

998/11052

Hand Held 4-Channel ServiceMaster Unit

998/11053

SensoWin Software Kit and PC Cable

998/11054

Equiment Case SCC-750

998/11055

0-600 Bar Pressure Transduce x2

998/11056

0-100 Bar pressureTransducer x2

998/11057

RPM Tachometer (includes fixed cable, 2 meters)

998/11058

5 Meter Connecting Cable

998/11059

M16 Metric Adaptors for Test Points x4

998/11060

400mm Test Hose 90° HSP to M16 x2

998/11061

400mm Test Hose Straight HSP to M16 x2

892/00280

Pressure Gauge 0-600 bar (0-9000 lbf/in2)

892/00279

Pressure Gauge 0-400 bar (0-6000 lbf/in2)

892/00346

Pressure Gauge 0-70 bar (0-1000 lbf/in2)

892/00347

Connector

892/00254

Hose

Fig 28. 892/ 00253 Hydraulic Circuit Pressure Test Kit

Fig 29. 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit

Fig 30. Hydraulic Circuit Test Gauges and Connections

1-26

9813/0350-1

1-26


Section 1 - 3 Special Tools Tool Detail Reference 892/00223

Hand Pump

892/00137

Micro-bore Hose 1/4 in BSP x 3 metres

892/00274

Adapter 1/4 in M BSP x 3/8 in M BSP Taper

892/00262

1/4 in M BSP x 1/4 in F BSP x Test Point

892/00706

Test Probe

892/00278

Gauge 0 - 40 bar (0 - 600 lbf/in2)

892/00279

Gauge 0 - 400 bar (0 - 6000 lbf/in2)

Fig 31. Hand Pump Equipment

Fig 32. 892/00318 Hose and Adapter Kit To enable flow and pressure test equipment to be connected to adapters fitted with `O' ring face seals.

1-27

9813/0350-1

1-27


Section 1 - 3 Special Tools Tool Detail Reference

Section F - Transmission

Fig 33.

892/00280 Gauge 0-600 bar (0-8500 lbf/in2). Required specifically for CVT high pressure check.

Fig 34. 993/45400 Torque Multiplier (use in conjunction with a torque wrench to give a 5:1 multiplication)

Fig 35.

Fig 36. 892/00817 17 mm A/F x 3/4in. square drive 892/00818 22 mm A/F x 3/4in. square drive 892/00819 15 mm A/F x 1/2in. square drive 892/00333 19 mm A/F x 3/4in. square drive

1-28

892/00179 Bearing Press

9813/0350-1

1-28


Section 1 - 3 Special Tools Tool Detail Reference

Fig 37. Fig 38. 892/00224 Impulse Extractor Set for Hub Bearing Seals 892/00225 Adapter - Impulse Extractor 892/01053 Adapter for Impulse Exrtractor (PTO intermediate Small17mm to 25mm, Medium25mm to 45mm, Large45mm shaft, wet clutch transmission) to 80mm

Retaining tool for differential lock spring and circlip.To be made from M24 threaded rod, nuts and spacers as shown

Section G - Brakes 892/00311

Brake Test Kit 3 x Calibrated Test Gauges - 0-20 bar (0 - 290 lbf/in2) 3 x 5 Metre Hoses with Quick Release Adapters 3 x ISO Test Point Adapters

Fig 39.

1-29

9813/0350-1

1-29


Section 1 - 3 Special Tools Tool Detail Reference

Section S - Suspension 892/00314

Accumulator and Gas Spring Pressure Test Adapter

Fig 40.

1-30

9813/0350-1

1-30


Section 1 - 4 Service Consumables Sealing and Retaining Compounds

Service Consumables Sealing and Retaining Compounds T11-001_4

Table 6. Type

Description

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.

4101/0601

10 ml

4101/0651

50 ml

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

JCB Threadlocker and Sealer

Part No.

Quantity

– 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

1-31

9813/0350-1

1-31


Section 1 - 4 Service Consumables Sealing and Retaining Compounds

Page left intentionally blank

1-32

9813/0350-1

1-32


Section 2 - Care and Safety

Notes:

2-0

9813/0350-1

2-0


Section 2 - Care and Safety Contents Page No. Safety First Safety Check List ....................................................................................... 2-1 Safety - Yours and Others .....................................................................2-1 General Safety ......................................................................................2-1 Operating Safety ...................................................................................2-3 Maintenance Safety ...............................................................................2-9

2-i

2-i


Section 2 - Care and Safety Contents

2-ii

Page No.

2-ii


Section 2 - Care and Safety

Safety First Safety Check List P10-1003_3

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

T1-043

To operate the machine safely you must know the machine and have the skill to use it. You must abide by all relevant laws, health and safety regulations that apply to the country you are operating in. The Operator Manual instructs you on the machine, its controls and its safe operation; it is not a training manual. If you are a new operator, get yourself trained in the skills of using a machine before trying to work with it. If you don't, you will not do your job well, and you will be a danger to yourself and others. INT-1-4-1

!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

2-1

9813/0350-1

2-1


Section 2 - Care and Safety Safety First Safety Check List

!MWARNING

!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.

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-1-3-9_2

INT-3-3-7_1

!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). Make sure that no-one goes near the machine while you install or remove the mechanical device. 13-2-3-7_3

2-2

9813/0350-1

2-2


Section 2 - Care and Safety Safety First Safety Check List

!MWARNING

Operating Safety

!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. 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.

Work Sites Work sites can be hazardous. Inspect the site before working on it. You could be killed or injured if the ground gives way under your machine or if piled material collapses onto it. Check for potholes and hidden debris, logs, ironwork etc. Any of these could cause you to lose control of your machine. 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_2

!MWARNING 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

INT-2-1-5

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

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

!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

!MWARNING Before moving the machine onto the trailer, make sure that the trailer and ramp are free from oil, grease and ice. Remove oil, grease and ice from the machine tyres. Make sure the machine will not foul on the ramp angle. See Static Dimensions in SPECIFICATION section for the minimum ground clearance of your machine. 2-2-7-5_1

2-3

9813/0350-1

2-3


Section 2 - Care and Safety Safety First Safety Check List

!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.

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-2-2-8

!MDANGER

5-3-1-12_3

!MWARNING

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.

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.

INT-2-2-10

2-2-3-6

!MWARNING

!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.

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

INT-2-1-14

!MWARNING

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

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

INT-1-3-3

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.

!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. INT-2-1-1

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

2-4

9813/0350-1

2-4


Section 2 - Care and Safety Safety First Safety Check List

!MCAUTION

!MWARNING

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.

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

5-5-1-1_2

!MWARNING

!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.

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. 0179_2

!MWARNING

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

Do not carry passengers in the passenger seat unless the vehicle is travelling on public roads. Passengers could be crushed when a risk of rollover exists. Do not carry passengers on the rear deck of the vehicle.

2-4-5-2_1

!MDANGER Working Platform Using the machine as a working platform is hazardous; you can fall off and be killed or injured. Never use the machine as a working platform.

13-1-1-32

5-1-5-9

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.

!MWARNING 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. 5-2-6-5

!MWARNING

!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.

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-3-2-7_2

INT-2-1-9_6

INT-2-1-12

2-5

!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.

9813/0350-1

2-5


Section 2 - Care and Safety Safety First Safety Check List

!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.

Starting/Using the Machine Reduce speed when towing or operating around hazards, on rough ground or steep slopes.

INT-2-1-7_1

13-2-3_14

!MWARNING Ensure that any load carried on the rear deck of the machine is firmly secured. 13-1-1-10

!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).

!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

!MWARNING

INT-2-1-8_1

Check daily that tyre pressures are correct for operational weight and speed. Make sure that the combined deck and hitch imposed loads do not exceed the capability of the tyres.

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.

13-2-4-20

13-3-2-5

!MWARNING

!MWARNING

!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.

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.

13-2-4-11

13-2-1-2

!MWARNING Starting/Using the Machine Start only from the operator's seat, with the transmission in neutral. Make sure everyone is clear of the machine before starting or using the machine. 13-2-3_13

!MWARNING Do not start the machine until all shields are in place.

!MWARNING 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). 13-2-2-1_1

13-2-3-12

2-6

9813/0350-1

2-6


Section 2 - Care and Safety Safety First Safety Check List

!MDANGER

!MWARNING

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. Make sure that the braking sytem on the tractor is correct for the trailer to be towed.

Brakes Do not coast the machine with the engine stopped as this will cause a loss of air and hydraulic pressure with the following dangerous effects:.

13-2-3-5_2

!MWARNING 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. 13-1-1-13_1

1

The main brakes will only operate for a limited number of applications.

2

The trailer brakes may not function at all.

3

The park brake may come on although the lever is at the off position.

4

The steering will become very heavy.

13-1-1-5_3

!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

!MWARNING Dragged or towed loads should be hitched only to the drawbar. Hitching loads to any other part of the machine can cause machine instability. We recommend that a safety chain is used between the tractor and the implement, as detailed in this manual. 13-2-3-10

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

!MCAUTION

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

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

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

13-2-2-8

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

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.

13-2-2-13

2-7

9813/0350-1

2-7


Section 2 - Care and Safety Safety First Safety Check List Always ensure that the PTO shaft and driveline are fully guarded before use.

!MWARNING

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

Make sure all drawbar pins are properly fitted otherwise an implement or trailer could become detached and cause injury and damage. 13-1-1-30

Always Ensure that the correct PTO speed is selected to match the implement requirements.

!MCAUTION

13-2-1-6_1

Do not use an external PTO button or a joystick button for an emergency PTO stop.

!MWARNING

13-3-2-32

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

!MWARNING 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

!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 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

!MWARNING Keep Your Hands and Feet Inside the Vehicle When using the machine, keep your hands and feet clear of moving parts. Keep your hands and feet within the operator compartment while the vehicle is in motion. 13-1-1-17

2-8

9813/0350-1

2-8


Section 2 - Care and Safety Safety First 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

!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.

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 and gloves. 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_3

!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 Fuel Fuel is flammable; keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions. INT-3-2-2_3

INT-3-1-3_2

!MWARNING

!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

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

2-9

9813/0350-1

2-9


Section 2 - Care and Safety Safety First Safety Check List

!MCAUTION

!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.

'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-3-2-14

INT-3-2-12

!MWARNING

!MWARNING

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

Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly. Do not use the machine if a hose or hose fitting is damaged.

INT-3-2-4

INT-3-3-2_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

!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.

!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. 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

INT-3-2-11

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

2-10

9813/0350-1

2-10


Section 2 - Care and Safety Safety First 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.

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

New fluoroelastomeric components at ambient temperature require no special safety precautions.

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.

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. INT-3-3-5_3

HYD-1-3_2

!MWARNING

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 Counterweights Your machine may be fitted with counterweights. They are extremely heavy. Do not attempt to remove them. INT-3-2-5

!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.

Compressed air is dangerous. Wear suitable eye protection and gloves. Never point a compressed air jet at yourself or others.

GEN-1-12

0147_1

2-11

9813/0350-1

2-11


Section 2 - Care and Safety Safety First Safety Check List

!MWARNING

!MDANGER

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.

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

INT-3-1-17

!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.

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.

INT-3-1-6

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

!MCAUTION

INT-3-1-9

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

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.

INT-3-1-14

!MWARNING 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 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

2-3-2-7_2

!MWARNING Jacking A machine can roll off jacks and crush you unless the wheels have been blocked. Always block 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

9813/0350-1

2-12


Section 2 - Care and Safety Safety First Safety Check List

!MWARNING

!MWARNING

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

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

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

13-1-1-15

!MWARNING

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.

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.

8-3-4-8

0091

!MWARNING

!MWARNING

You can be killed or injured by moving machinery. Wait for all movement to stop before servicing machinery.

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

13-3-2-3

13-3-1-10

!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.

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

13-3-2-16

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

Wear safety glasses when working with air pressure.

!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. GEN-1-19

!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.

BRAK-8-3_2

TRANS-8-5

2-13

9813/0350-1

2-13


Section 2 - Care and Safety Safety First Safety Check List

!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

9813/0350-1

2-14


Section 3 - Maintenance

Notes:

3-0

9813/0350-1

3-0


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 ............................................................ 3-14 Carrying Tools onto the Machine ............................................................. 3-17 Preparing the Machine for Maintenance .................................................. 3-18 Cleaning the Machine .............................................................................. 3-19 Checking for Damage .............................................................................. 3-23 Seats and Seat Belts ............................................................................... 3-25 Greasing .................................................................................................. 3-26 Access Panels ......................................................................................... 3-34 Air Conditioning and Heater .................................................................... 3-36 Brakes ..................................................................................................... 3-39 Electrical System ..................................................................................... 3-45 Engine ..................................................................................................... 3-50 Fuel System ............................................................................................. 3-61 Hydraulic System ..................................................................................... 3-64 Transmission ........................................................................................... 3-69 Tyres and Wheels .................................................................................... 3-79 Power Take-off (PTO) .............................................................................. 3-86 Windscreen Washer ................................................................................ 3-89 Automatic Trailer Coupling (Optional) ..................................................... 3-90

3-i

3-i


Section 3 - Maintenance Contents

3-ii

Page No.

3-ii


Section 3 - Maintenance

Routine Maintenance Service Requirements Introduction

Owner/Operator Support T3-095

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.

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

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

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

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

1

Giving your name, address and telephone number.

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 Manual for your machine is available from your JCB Distributor. The Service Manual contains information on how to repair, dismantle and assemble your machine correctly.

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.

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.

Obtaining Replacement Parts T3-096

If you use non-genuine JCB parts or consumables, then you can compromise the health and safety of the operator and cause machine failure

9813/0350-1

3-1


Section 3 - Maintenance Routine Maintenance Service Requirements A Parts Book for your machine is available from your JCB Distributor. The 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 (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

9813/0350-1

3-2


Section 3 - Maintenance Routine Maintenance Health and Safety

Health and Safety Lubricants T3-060_2

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.

Hygiene JCB lubricants are not a health risk when used properly for their intended purposes. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.

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.

Handling

!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

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.

Storage

New Oil There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices. Used Oil Used engine crankcase lubricants contain harmful contaminants. Here are precautions to protect your health when handling used engine oil:

Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers.

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:

Waste Disposal

!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. INT-3-2-14

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

3-3

9813/0350-1

a

Wash your skin thoroughly with soap and water.

b Using a nail brush will help. c

Use special hand cleansers to help clean dirty hands.

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

3-3


Section 3 - Maintenance Routine Maintenance Health and Safety 3

Avoid skin contact with oil soaked clothing.

4

Don't keep oily rags in pockets.

5

Wash dirty clothing before re-use.

6

Throw away oil-soaked shoes.

DEF Fluid

!MWARNING Diesel Exhaust Fluid (DEF) If large quantities of DEF have been swallowed a doctor should be called immediately. Do not induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to an unconscious person.

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

Avoid prolonged or repeated skin contact. After contact with skin wash thoroughly with plenty of soap and water. If irritation develops seek medical advice. Avoid contact with eyes, skin and clothing. Wear chemical resistant gloves, overalls and safety goggles complying with an approved standard. If in contact with eyes, rinse immediately with plenty of clean water. If irritation occurs seek medical attention. Always wash hands and arms thoroughly after handling before eating, drinking, smoking or using the lavatory. DEF is corrosive to some metals such as copper and its alloys. Use only recommended storage and dispensing systems. DEF solution is very polluting to to surface water and groundwater. DEF may not be removed by oil separators so it is important to isolate drainage from the dispensing area to prevent pollution in the event of a spill. Store below 30 deg C in a segregated, approved and labelled area. Keep container closed.

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

13-2-1-15

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

3-4

9813/0350-1

3-4


Section 3 - Maintenance Routine Maintenance Health and Safety

!MCAUTION

Battery

!MWARNING

T3-061

Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. 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. Set all switches to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first.

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 an approved battery tester. INT-3-1-8_2

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. When reconnecting, fit the positive (+) lead first. 5-3-4-12

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

!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

3-5

9813/0350-1

3-5


Section 3 - Maintenance Routine Maintenance Health and Safety Warning Symbols

First Aid - Electrolyte

The following warning symbols may be found on the battery.

Do the following if electrolyte: Gets into your eyes

Symbol

Meaning

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

Keep away from children.

Is swallowed A289230-1

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

Shield eyes.

Gets onto your skin

A289260-1

No smoking, no naked flames, no sparks. Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help. A289280

Explosive Gas.

A289250

Battery acid.

A289240

Note operating instructions.

A289270

3-6

9813/0350-1

3-6


Section 3 - Maintenance Routine Maintenance Service Schedules

Service Schedules Introduction

How to Use the Service Schedules

!MWARNING

T3-036_3

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_3

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. Important: Services should be carried out at either the hourly interval or calendar interval, whichever occurs first. Refer to Calendar Equivalents.

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 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. 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. When there is no hourmeter fitted, use the calendar equivalents to determine the service intervals. Refer to Calendar Equivalents. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately.

795390-1

Calendar Equivalents Every 10 Hours = Daily

T3-088

Every 50 Hours = Weekly Every 500 Hours = Six Months Every 1000 Hours = Yearly Every 2000 Hours = 2 Years Every 5000 Hours = 5 Years

3-7

9813/0350-1

3-7


Section 3 - Maintenance Routine Maintenance Service Schedules

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

- Check

Oil and Filter

Air Cleaner Outer Element

…

- Change

(3)

Air Cleaner Inner Element

- Change

Air Cleaner Hose and Clamp Security Air Compressor Mountings

Air Compressor Discharge Lines

- Check

…

…

- Check

(5) (5)

- Check

Fuel Tank (4) (5)

- Drain water

Fuel Filter

- Drain water

…

…

…

Fuel Filter

Coolant Level

- Check

Coolant Antifreeze and Coolant Additive Concentration(5)

- Check

Coolant

- Change

DEF Filter

- Change

Fan Belt Condition

…

…

- Check (5)

Valve Clearances (5) (6)

- Check

… …

… …

… …

… … … …

…

…

…

…

…

… …

… … …

… … … … …

…

…

…

…

- Check and Adjust

Air Conditioning Compressor Belt Tension and Condition

- Check

Engine Mounting Bolts for Tightness(5)

- Check

Radiator and Coolers

- Clean

Charge Air Cooler Hose and Clamp Security

- Check

Charge Air Cooler

- Check

Turbocharger(5)

- Check

Engine

… …

…

… …

… …

… …

… … … … …

…

- Change

(4)

Fan Belt Tensioner

…

- Change

(2) (4)

… …

- Steam Clean

… …

TRANSMISSION, AXLES AND STEERING Transmission Oil Level Transmission Oil(7)

3-8

- Check

…

- Change

9813/0350-1

…

…

… …

…

3-8


Section 3 - Maintenance Routine Maintenance Service Schedules Operation 10 Hr 50 Hr Transmission Strainer(5)

- Change

Transmission Filter

- Change

Clutch Fluid Level Axle Oil Level (incl. Hubs)

- Check (8)

Axle Oil (incl. Hubs)(9) Tyre Pressures/Condition Oil Cooler and Pipework Front PTO Gearbox Oil Level Front PTO Gearbox Oil Front PTO Gearbox Oil Filter

…

…

100 Hr(1)

… …

- Check - Change - Check

…

…

- Check and Clean

500 Hr

… …

1000 Hr

2000 Hr

4000 5000 Hr Hr

… … …

… … …

… … …

… … …

… … …

… … …

… … …

… … …

… …

… … …

… …

… …

… …

… …

… …

… …

…

- Check - Change - Clean - Security/ Grease

…

…

…

…

…

…

…

Steer Axle Pivots

- Grease

Steering Column Universal Joints

- Grease

… …

… … …

… … … …

… … … …

… … … …

… … … …

… … … …

…

…

…

Drive Shafts

Steering Axle Wheel Alignment

- Check

Pitman Arm, Drag Link, Track Rod End, Steering Ram and Damper Condition and Torque Tightness(5) (10)

- 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

Hydraulic Oil Cooler and Pipework

- Clean

Hydraulic Coupling Drain Reservoir

- Empty

…

…

…

… …

… …

… …

… …

… …

… …

…

…

…

…

…

…

…

… …

… …

… …

… …

… …

…

… …

… …

…

…

- Check and Clean

Hydraulic Oil Strainer

3-9

…

…

…

9813/0350-1

…

…

…

3-9


Section 3 - Maintenance Routine Maintenance Service Schedules Operation 10 Hr 50 Hr Security of Front Weight

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

4000 5000 Hr Hr

- Check

…

…

…

…

…

…

…

…

- Drain

…

…

…

…

… … …

… … …

…

…

…

…

… … … …

… … … …

… …

…

BRAKES Air System Tank Air System Drier Canister(5)

- Change

Trailer Brake Control Line Air Filter(5)

- 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(5)

- Check

Pipework Security

- Check

… …

ELECTRICS Wiring for Chaffing/Routing

- Check

Battery Terminals for Condition and Tightness

- Check

Battery Charge Condition

- Check

Headlamp Alignment

- Check

…

BODY AND FRAMEWORK Chassis Fabrication

- Visually Inspect for Damage

Engine Cover Hinges

- Lubricate

Seat Belt Condition and Security

- Check

Air Conditioning Condenser

- Clean

ROPS Structure

- Check

Cab Air Intake Filter (standard type only)(11)

- Clean

Door Locks

- Check

Windscreen Washer Fluid Level

- Check

Condition of Paintwork

- Check

(5)

Machine Generally Automatic Trailer Coupling (if fitted)

3-10

- Check and Clean

… …

… …

… …

… …

…

…

…

… … …

…

…

- Grease

9813/0350-1

3-10


Section 3 - Maintenance Routine Maintenance Service Schedules Operation 10 Hr 50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

4000 5000 Hr Hr

… …

… …

… …

… …

… …

…

…

…

…

…

SUSPENSION

Rear Anti-roll Bar Condition and Torque Tightness(5) (10)

- Check

… …

Panhard Rod Condition and Torque Tightness(5) (10)

- Check

…

Control Arms Condition and Torque Tightness(5)

- Check

…

…

…

…

…

`V' Link Condition and Torque Tightness(5)

- Check

…

…

… … …

… … …

…

Cylinder Pivots

- Grease

Accumulator Pressure

- Check

Gas Spring Pressure(5)

- Check

(5)

…

(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) Do this job at start of winter. (5) Jobs which should only be done by a specialist. (6) Check valve clearances after 1st 500 hours, then every 1000 hours. (7) 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). (8) Check for leaks every 50 hours, check level if leaking. (9) 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. (10) Recheck the torque tightness after a short road test. (11) Heavy duty carbon type filters must be changed at 250 hour intervals.

3-11

9813/0350-1

3-11


Section 3 - Maintenance Routine Maintenance Service Schedules

Functional Test and Final Inspection Operation

10 Hr

50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

… … … …

… … … …

… … … …

… … … …

… … … … …

… …

…

… … … … …

… … … … …

… … … … … … …

…

…

…

… …

… … … … …

… … … … … … … … …

ENGINE Exhaust System Security(2)

- Check

Cooling System for Leaks

- Check

Fuel System for Leaks and Contamination

- Check

Lubrication System for Leaks

- Check

… … …

… … …

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

- Check

Oil Leakage

- Check

Transmission Lubrication Pressure

(2)

…

…

- Check

4WD/PTO Supply Pressure (2)

- Check

Differential Lock Pressure Relief Valve(2)

- 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

GPS Steering Main Relief Valve Pressure(2) (3)

- Check

GPS Steering Pilot Relief Valve Pressure(2) (3)

- 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

… …

- System Test

… … …

… … …

… … …

- Check

…

…

…

…

ABS(2) ELECTRICS Starter Motor

3-12

9813/0350-1

3-12


Section 3 - Maintenance Routine Maintenance Service Schedules Operation Alternator - Output(2)

- Check

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

- Check

10 Hr

…

50 Hr

…

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

… …

… …

… …

… …

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

- Download and Rectify

…

…

…

…

Tractor Datalog(2)

- Download and Rectify

…

…

…

…

- Check

…

…

…

Circuit Pressure(2)

- Check

Rear Axle to Chassis Clearance(2)

- Check

… … …

… … …

… … …

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

Ride Height Operation

(2)

- Check

… …

(1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) Jobs which should only be done by a specialist. (3) GPS Ready machines only.

3-13

9813/0350-1

3-13


Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities ITEM

CAPACITY

Table 1. FLUID/LUBRICANT

JCB PART NUMBER

CONTAINER SIZE(1)

Litres UK Gal Fuel Tank

604

132

Diesel Oil

K Fuel ( T 3-16)

DEF Tank

70

15

DEF

K Diesel Exhaust Fluid (DEF) ( T 3-16)

Engine (Oil)

24

5.3

JCB Optimum Performance 4001/2901, 4001/2905, 4 x 5 litres, 20 litres, 200 litres Engine Oil (-20 to +40 deg C)(2) 4001/2903 API CJ-4, SAE15W/40(3)

Engine (Coolant)

31

6.9

JCB Antifreeze HP/Coolant + Water

4006/1120

20 litres

Transmission

75

16.5

JCB Optimum Performance Transmission Fluid

4004/6305

20 litres

Rear 3 Point Linkage Cross-shaft

0.2

0.04

JCB Optimum Performance Transmission Fluid

4004/6305

20 litres

Clutch

0.5

0.1

JCB Optimum Performance Clutch Fluid

4002/1904

1 litres

Front Axle

JCB HD90 Gear Oil API-GL-5, MIL-L-2105C

- Axle Beam

16

3.5

- Hubs (each)

4

0.9

Rear Axle

JCB HD90 Gear Oil API-GL-5, MIL-L-2105C

- Axle Beam

56

12.3

- Hubs (each)

7

1.5

Brake System - Front

0.75

- Rear (2 reservoirs) 0.75 Hydraulic System

(4)

190

JCB Brake Fluid Dot 4 (capacity 4002/0404 given is for each reservoir)

1 litre

JCB Hydraulic Oil HP46

4002/0805

20 litres

4002/1025

20 litres

JCB HP Grease

4003/2017

400g

JCB HP Universal ATF

4000/2301

5 litres

0.2 0.20 42

(Above 38ºC,100ºF) JCB Hydraulic Oil HP32 (Below 38ºC,100ºF) Grease Points Front PTO Gearbox (optional)

7

1.5

(1) For information about the different container sizes that are available (and their part numbers), contact your JCB Dealer. (2) While 15W/40 oil is recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to provide easier starting and sufficient oil flow at temperatures below -5ºC (23ºF). Continued use of low viscosity oils can decrease engine life and will require different service intervals. (3) It is essential that 15W/40 oil meeting API CJ -4 or ACEA E7/E9 specifications is used. For temperatures of -25ºC to +30ºC refer to your JCB dealer. (4) The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank

3-14

9813/0350-1

3-14


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).

3-15

9813/0350-1

3-15


Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities

Fuel

Low Temperature Fuels

!MCAUTION Consult your fuel supplier or JCB distributor about the suitability of any fuel you are unsure of. GEN-9-2

Special winter fuels may be available for engine operation at temperatures below 0°C (32°F). These fuels have a lower viscosity. They also limit wax formation in the fuel at low temperatures. (Wax forming in the fuel can stop the fuel flowing through the filter.)

See Refuelling the Machine in the Operation section.

Diesel Exhaust Fluid (DEF)

Fuel Specification

See Refuelling the Machine in the Operation section.

Note: You must use ultra low sulphur fuel to the following specifications or the machine warranty will not be valid.

To meet Stage 3B / Tier 4 interim emission standards, this machine has exhaust gas treatment using Selective Catalytic Reduction technology (SCR). In SCR technology a liquid called Diesel Exhaust Fluid (DEF) is injected into the exhaust gases.

EN590: 2009 or ASTM D975-09b 1-D or 2-D.

DEF is specified in standards DIN 70070 and ISO 22241. Most commonly known trademarks of DEF are AdBlue, Air1 and Greenox.

These specifications meet the following requirements: Requirement

Test Method

Density + 15 deg C

0.82 - 0.84 kg/dm3 EN ISO 3675: 1998, EN ISO 12185

Viscosity +40 deg C

2.0 - 4.5 mm2/s

EN ISO 3104

Sulphur Content

Max 15 mg/kg

EN ISO 14596: 1998

Cetane number

Min 51

EN ISO 5165: 1998

Water content

Max 200 mg/kg

pr EN ISO12937: 1996

Lubricity/ HFRR

Max 460 µm

ISO 12156-1

The DEF consumption depends on the duty cycle of the engine. The DEF tank and pipes are heated so that system works in low temperatures. If DEF freezes, it is automatically defrosted when the engine is started. The congealing point of DEF with 32.5 % urea concentration is -11 °C. Note: If defrosting of the DEF is not successful, a fault code will be displayed and the engine will run at reduced power.

Note: Fuels according to EN 590:2009 may contain up to 7% FAME (fatty acid methyl ester) type biodiesel according to EN 141214:2008. Fuels according to ASTM D975-09b may contain up to 5% FAAE (fatty acid alkyl ester) type biodiesel according to ASTM D6751-08. Greater proportions of biodiesel are not allowed. Fuels with higher sulphur content are not allowed. Supplementary admixtures or additives are not allowed. Note: Aviation kerosene fuels are not approved and their use may cause damage to components. Warranty will not be allowed on any component where damage is found to have been caused by the use of aviation kerosene.

3-16

Note: Make sure that genuine DEF is used (DIN 70070 or ISO 22241 certified). Do not dilute DEF or mix it with other substances, it may damage the catalyst.

Note: Supplementary admixtures or additives are not allowed. Do not dilute DEF or mix it with other substances as it may damage the catalyst. If the system detects a problem, it will cause the engine to run at reduced power. Note: Be careful when handling DEF. It is aggressive to some materials and corrosive to some metals. DEF becomes crystalline when in contact with air. In case of a spillage rinse with plenty of water and dry with a clean cloth. Note: The storage of DEF should be done under 30°C, avoiding direct sunlight. Refer to manufacturers instructions.

9813/0350-1

3-16


Section 3 - Maintenance Routine Maintenance Carrying Tools onto the Machine

Carrying Tools onto the Machine When you carry tools onto the machine you must maintain three points of contact with the machine at all times. Lift tools onto the machine in intervals if necessary. Place the tools down before you adjust your grips on the machine. Do not try to adjust your grips on the machine while holding tools.

3-17

9813/0350-1

3-17


Section 3 - Maintenance Routine Maintenance Preparing the Machine for Maintenance

Preparing the Machine for Maintenance Making the Machine Safe Make the machine safe as follows before you start a maintenance procedure.

!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 level ground. 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

!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

!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

3-18

9813/0350-1

3-18


Section 3 - Maintenance Routine Maintenance Cleaning the Machine

Cleaning the Machine

!MCAUTION

Introduction T3-062_2

Clean the machine using water and or steam. Do not allow mud, debris etc. to build upon the machine. Before carrying out any service procedures that require components to be removed: 1

2

Cleaning must be carried out either in the area of components to be removed or, in the case of major work, or work on the fuel system, the whole engine and surrounding machine must be cleaned. When cleaning is complete move the machine away from the wash area, or alternatively, clean away the material washed from the machine.

Important: When removing components be aware of any dirt or debris that may be exposed. Cover any open ports and clean away the deposits before proceeding.

The engine or certain components could be damaged by high pressure washing systems; special precautions must be taken if the engine is to be washed using a high pressure system. Ensure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. ENG-3-3

Important: Do not aim the water jet directly at bearings, oil seals or electrical and electronic components such as the engine electronic control unit (ECU), alternator or fuel injectors. Use a low pressure water jet and brush to soak off caked mud or dirt. Use a pressure washer to remove soft dirt and oil.

Detergents Avoid using full strength detergent - always dilute detergents as per the manufacturer's recommendations, otherwise damage to the paint finish may occur.

Note: The machine must always be greased after pressure washing or steam cleaning.

Preparing the Machine for Cleaning

!MWARNING

Always adhere to local regulations regarding the disposal of debris created from machine cleaning.

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

Pressure Washing and Steam Cleaning

2-3-3-5

!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_2

3-19

Important: Stop the engine and allow it to cool for at least one hour. Do not attempt to clean any part of the engine while it is running. Make sure that all electrical connectors are correctly coupled. If connectors are open fit the correct caps or seal with water proof tape.

9813/0350-1

3-19


Section 3 - Maintenance Routine Maintenance Cleaning the Machine

Cleaning the Machine

C101800

Fig 1.

!MWARNING

!MWARNING

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

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.

HYD-1-3_2

5-3-1-12_3

3-20

9813/0350-1

3-20


Section 3 - Maintenance Routine Maintenance Cleaning the Machine

!MCAUTION

2

Engine Do not allow mud to build up on the engine and transmission. Pay particular attention to the exhaust area, remove all combustible material.

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.

Pay particular attention to the underside. Do not allow mud to build up on the engine and transmission.

The engine or certain components could be damaged by high pressure washing systems, special precautions must be taken if the engine is to be washed using a high pressure system.

If the tubes or fins become clogged, the radiator and coolers will be less efficient.

Important: Do not place the jet nozzle closer than 600mm (24 in) to any part of the engine.

8-3-4-8

1

Do not attempt to clean any part of the engine while it is running. Stop the engine and allow it to cool for at least one hour.

The radiator and coolers. a

Stop the engine.

!MWARNING

a

b Do not wash any part of the:

Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5

b Open the engine cover. c

Release latches K Fig 1. ( T 3-20)

A

(one

each

Disconnect the battery.

i

Fuel injection pump.

ii

Cold start device.

iii Electrical shut off solenoid (ESOS).

side).

iv Electrical connections. d Lift and pull forward the cooling pack sections B and C. e

Brush off all debris from tubes and fins on both sides of all parts of the cooling pack and the radiator D.

f

Make sure all the loosened material is brushed out of the cooling area.

c

3

i

If any damage is found, contact your JCB dealer.

j

Close the cooling pack and fasten both latches A.

k

Close the engine cover.

3-21

Transmission On ABS machines, take special care to avoid directing high power water jets at the electrical connections to the front and rear axle ABS sensors.

g Check for cracks, holes or other damage. h Check the charge air piping for leaks, holes, cracks or loose connections. Tighten the hose clamps if required.

Ensure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by high pressure cleaning system.

4

9813/0350-1

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

3-21


Section 3 - Maintenance Routine Maintenance Cleaning the Machine

!MWARNING Take care with the backrest frame. It may jerk forward and cause injury. 13-3-2-9_2

During cleaning, the upholstery should not be soaked through. If required, the cushion and backrest can be removed for cleaning by removing screws B. Keep the seat slide runners lightly greased.

B

B T027040-B2

Fig 2.

3-22

9813/0350-1

3-22


Section 3 - Maintenance Routine Maintenance Checking for Damage

Checking for Damage Check the Machine Body and Structure T3-063_5

Make sure that all guards and protective devices are in place, attached by their locking devices and free from damage. Inspect all steelwork for damage. Pay particular attention to the following:

Install the valve caps firmly to prevent dirt from entering the valve. Inspect for leaks when you check the tyre pressures. Inspect the tyre valve for leaks, when you check the tyre pressures.

Check the Seat and Seat Belt

!MWARNING

– Inspect all lifting point welds. – Inspect all pivot point welds. – Inspect the condition of all pivot pins. – Check pivot pins are correctly in place and secured by their locking devices. Check steps and handrails are undamaged and secure. Check for broken, cracked or crazed window glass and mirrors. Replace damaged items. Check all lamp lenses for damage.

T3-008_2

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

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 all attachment teeth are undamaged and secure.

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

Check all safety and instructional labels are in place and undamaged. Fit new labels where necessary.

Check seats are undamaged and secure. Check seat adjustments for correct operation.

Note damaged paintwork for future repair.

Check the Hydraulic Hoses and Fittings

Check the Tyres

!MWARNING

!MWARNING

T3-065_2

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.

T3-072

Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly. Do not use the machine if a hose or hose fitting is damaged. INT-3-3-2_4

Inspect the hoses regularly for:

13-2-1-2

– Damaged hose ends Always drive with consideration for the condition of the tyres. Incorrect tyre pressures will affect the stability of the machine. Check the tyres daily for the correct tyre pressure and signs of damage. For example: – Signs of distortion (bulges) – Cuts or wear

– Chafed outer covers – Ballooned outer covers – Kinked or crushed hoses – Embedded armouring in outer covers – Displaced end fittings

– Embedded objects (nails, etc.)

3-23

9813/0350-1

3-23


Section 3 - Maintenance Routine Maintenance Checking for Damage Do not use the machine if a hose or hose fitting is damaged. Replace damaged hoses before you use the machine again. Replacement hoses must be of the same size and standard.

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.

A

B C070490

Fig 3.

3-24

9813/0350-1

3-24


Section 3 - Maintenance Routine Maintenance Seats and Seat Belts

Seats and Seat Belts Seats

Check the Seat and Seat Belt

!MWARNING

Make sure that the seat mounting bolts are tight. 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.

T3-008_2

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

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

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.

During cleaning, the upholstery should not be soaked through.

Check that the belt mounting bolts are undamaged, correctly fitted and tightened. Check seats are undamaged and secure. Check seat adjustments for correct operation.

B

B T027040-B2

Fig 4. If required, the cushion and backrest can be removed for cleaning by removing screws B.

!MWARNING Take care with the backrest frame. It may jerk forward and cause injury. 13-3-2-9_2

3-25

9813/0350-1

3-25


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 drive shafts 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 drive shaft 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.

3-26

9813/0350-1

3-26


Section 3 - Maintenance Routine Maintenance Greasing

Drive Shafts

Front axle drive shaft

Make the machine safe. K Preparing the Machine for Maintenance ( T 3-18)

Grease points 5 to 6

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 6.

4

3 Fig 5.

Rear PTO drive shaft Grease points 1 to 2

Rear axle drive shaft

Fig 7.

Grease points 3 to 4

3-27

9813/0350-1

3-27


Thank you very much for your reading. Please Click Here Then Get More Information.

Jcb 8310 fastrac service repair manual sn 01139400 01139999  
Jcb 8310 fastrac service repair manual sn 01139400 01139999  
Advertisement