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:
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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
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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
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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
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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
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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
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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
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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
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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
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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
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Section 1 - 4 Service Consumables Sealing and Retaining Compounds
Page left intentionally blank
1-32
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Section 2 - Care and Safety
Notes:
2-0
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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
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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.
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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.)
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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.
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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
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Section 3 - Maintenance Routine Maintenance Greasing
Greasing General Information Read and understand Lubricants - Health and Safety, before greasing. You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Refer to the Service Schedules for the recommended frequencies. Note: If working in muddy conditions the 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.
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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
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