JCB 323HST 327HST COMPACT TRACTOR Service Repair Manual Instant Download

1
Service Manual
General Information
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section C - Electrics
Section E - Hydraulics
Section F - Gearboxes
Section G - Brakes
Section H - Steering
Section K - Engine

Publication No. 9803/9470-1
World Class Customer Support
Copyright 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB
Service, World Parts Centre, Beamhurst,
Uttoxeter, Staffordshire, ST14 5PA, England. Tel
44 1889 590312 Fax [phone]
2
Section 1 - General Information
Contents Page No. Introduction About This
Publication ......................................
....................................... 1 -
1 Identifying Your Machine .......................
..................................................
1 - 3 Standard Torque Settings Front Axle
Housing and Transmission .........................
............................ 1 - 5 Service
Tools Numerical List Section H - Steering
..................................................
....... 1 - 7 Tool Detail Reference Section H -
Steering .........................................
.... 1 - 8
1 - i
1 - i
3
Section 1- General Information Introduction Abou
t This Publication
Machine Model and Serial Number
Finally, please remember above all else safety
must come first!
This manual provides information for the
following model(s) in the JCB machine range
Units of Measurement
T1-001_2 In this publication, the S.I. system of
units is used. For example, liquid capacities are
given in litres. The Imperial units follow in
parentheses ( ) eg 28 litres (6 gal).

• 323 HST from serial number 1285000 to 1286999
• 327 HST from serial number 1285000 to 1286999.
• Using the Service Manual
• T11-004
• This publication is designed for the benefit of
  JCB Distributor Service Engineers who are
  receiving, or have received, training by JCB
  Technical Training Department.

Section Numbering
T11-005 The manual is compiled in sections, the
first three are numbered and contain information
as follows
These personnel should have a sound knowledge of
workshop practice, safety procedures, and
general techniques associated with the
maintenance and repair of hydraulic earthmoving
equipment.

1. General Information - includes torque settings
   and service tools.
2. Care and Safety - includes warnings and cautions
   pertinent to aspects of workshop procedures etc.
3. Maintenance - includes service schedules and
   recommended lubricants for all the machine.

The illustrations in this publication are for
guidance only. Where the machines differ, the
text and/or the illustration will specify.
The remaining sections are alphabetically coded
and deal with Dismantling, Overhaul etc. of
specific components, for example
General warnings in Section 2 are repeated
throughout the manual, as well as specific
warnings. Read all safety statements regularly,
so you do not forget them.

1. Attachments
2. Body and Framework, etc.

Renewal of oil seals, gaskets, etc., and any
component showing obvious signs of wear or damage
is expected as a matter of course. It is expected
that components will be cleaned and lubricated
where appropriate, and that any opened hose or
pipe connections will be blanked to prevent
excessive loss of hydraulic fluid and ingress of
dirt.
Section contents, technical data, circuit
descriptions, operation descriptions etc. are
inserted at the beginning of each alphabetically
coded section.
Where a torque setting is given as a single
figure it may be varied by plus or minus 3.
Torque figures indicated are for dry threads,
hence for lubricated threads may be reduced by
one third. The manufacturer's policy is one
of continuous improvement. The right to change
the specification of the machine without notice
is reserved. No responsibility will be accepted
for discrepancies which may occur between
specifications of the machine and the
descriptions contained in this publication.
1 - 1
4
Section 1 - General Information Introduction About
This Publication
Left Side, Right Side In this publication, left
A and right B mean your left and right when you
are seated correctly in the machine. Cross
References T1-004_2 In this publication, page
cross references are made by presenting the
subject title printed in bold, italic and
underlined. It is preceeded by the 'go to'
symbol. The number of the page upon which the
subject begins, is indicated within the brackets.
For example K Cross References ( 1-2).
1 - 2
5
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Section 1 - General Information Introduction Ident
ifying Your Machine Identifying Your Machine
Machine Identification Plate
Type, Engine, Vehicle Identification Number,
Manufacturer and Address.
Your machine has an identification plate mounted
as shown. Information contained on this plate
includes Model,
The machine and engine serial numbers can help
identify exactly the type of equipment you have.
Fig 1.
7
Section 1 - General Information Introduction
Identifying Your Machine Drawbar Certification
Plate
Typical Vehicle Identification Number (VIN)
A typical Vehicle Identification Number is given
below.
The draw bar on your machine is built to a
standard and has an identification label fitted
to the top of the trailer hitch. A typical
identification label is shown below.
35NH X 01 0001
1 2 3 4
1 Machine Model
2 Year of Manufacture
0043 3000 KG 300 KG
3 Month of Manufacture
4 Machine Serial Number Component Identification
Plates
Fig 3.
Typical Engine Identification Number The engine
identification plate is attached to the rocker
cover. The information stamped on this plate
includes the engine model and serial number. The
engine model identification is also embossed on
the right side of the engine block and the engine
serial number is also stamped on the cylinder
block. ROPS Certification Plate Your machine is
built to the ROPS standard and has an
identification label fitted to the left hand side
of the ROPS frame. A typical identification label
is shown below.
0043 APPLICATION MODEL 323HST/327HST Fig 2.
8
Section 1- General Information Standard Torque
Settings Front Axle Housing and
Transmission Introduction
The following table gives the torque tightening
values for the major parts of the Front Axle
Housing (4WD Type) and the Transmission. Table
1. Standard Torque Settings
Major Part Bolt and Nut Size (Hardness) Torque Value Torque Value Torque Value
Nm kgf/m lbf/ft
Front Axle Housing
Axle bracket to engine M16 (7T) 156.9 - 176.5 16.0 - 18.0 115.7 - 130.2
Front pivot metal M12 (7T) 88.2 - 107.9 9.0 - 11.0 65.1 - 79.6
Rear pivot metal M14 (7T) 127.5 - 147.1 13.0 - 15.0 94.0 - 108.5
Front axle final case M12 (7T) 88.2 - 107.9 9.0 - 11.0 65.1 - 79.6
Bearing cover M18 (7T) 19.6 - 23.5 2.0 - 2.4 14.5 - 17.3
Wheel shaft cover M10 (7T) 53.9 - 68.6 5.5 - 7.0 39.8 - 50.6
Front wheel M16 (7T) 156.9 - 176.5 16.0 - 18.0 115.7 - 130.2
Bevel gear case M8 12.7 - 17.7 1.3 - 1.8 9.4 - 13.1
Diff-metal (support) M8 12.7 - 17.7 1.3 - 1.8 9.4 - 13.1
Ring gear diff-metal (support) M8 12.7 - 17.7 1.3 - 1.8 9.4 - 13.1
Transmission
Front transmission - engine M12 (7T) 88.2 - 107.9 9.0 - 11.0 65.1 - 79.6
Front transmission - spacer M12 (7T) 88.2 - 107.9 9.0 - 11.0 65.1 - 79.6
Space transmission - rear transmission M12 (7T) 88.2 - 107.9 9.0 - 11.0 65.1 - 79.6
Input metal (support) M12 (7T) 88.2 - 107.9 9.0 - 11.0 65.1 - 79.6
Drive pinion metal (support) M10 (7T) 53.9 - 68.6 5.5 - 7.0 39.8 - 50.6
Drive pinion
Diff-case metal (support) M12 53.9 - 68.6 5.5 - 7.0 39.8 - 50.6
Diff-case ring gear M12 (7T) 88.2 - 107.9 9.0 - 11.0 65.1 - 79.6
9
Section 1- General Information Service
Consumables Sealing and Retaining Compounds
Table 2.
Type Description Part No. Quantity
JCB Multi-Gasket A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter. 4102/1212 50 ml
JCB High Strength Thread locker A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important. 4102/0551 50 ml
JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/0651 50 ml
JCB Thread locker and Sealer A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. 4101/0250 10 ml
JCB Thread locker and Sealer A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. 4101/0251 50 ml
JCB Thread locker and Sealer (High Strength) A high 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. 4101/0550 10 ml
JCB Thread locker and Sealer (High Strength) A high 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. 4101/0552 200 ml
JCB Threadseal A medium strength thread sealing compound. 4102/1951 50 ml
JCB Activator A cleaning primer which speeds the curing rate of anaerobic products. 4104/0251 200 ml (Aerosol)
JCB Activator A cleaning primer which speeds the curing rate of anaerobic products. 4104/0253 1 ltr (Bottle)
JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic adhesives and sealants. 4104/1557 400 ml (Aerosol)
1 - 7
1 - 7
10
Section 1 - General Information Service
Tools Numerical List Section H - Steering
The tools listed in the table are special tools
required for removal and replacement of the
steering valve parts.
Note Tools other than those listed will be
required. It is expected that such general tools
will be available in any well equipped workshop
or be available locally from any good tool
supplier.
Part Number Description Tool Detail Reference
SJ150L9001-01 Holding Tool K Fig 4. ( 1-10)
SJ150L4011-01 Assembly Tool for Shaft Seal 17.5 dia. K Fig 5. ( 1-10)
SJ150L4012-01 Assembly Tool for Shaft Seal 19.2 dia. K Fig 6. ( 1-10)
SJ150L0396-01 Assembly Tool for Dust Seal Ring K Fig 7. ( 1-10)
SJ150-9000-25 Pliers for Piston in Relief Valve K Fig 8. ( 1-10)
SJ151G9000-1 Fork for fitting Cardan Shaft K Fig 9. ( 1-10)
1 - 9
11
Section 1 - General Information Service
Tools Tool Detail Reference Section H -
Steering Tool Detail Reference Section H -
Steering
Fig 9.
Fig 4.
Fig 5.
Fig 6.
Fig 7.
Fig 8.
1 - 10
12
Section 2 - Care and Safety
Contents Page No. Safety Notices Introduction
..................................................
............................................ 2 -
1 Safety Check List ..............................
..................................................
..... 2 - 2
2 - i
2 - i
13
Section 2 - Care and Safety Safety
Notices Important Information Safety
Notices Important Information T1-015
The Operator Manual
Safety Warnings
WARNING Study the Operator Manual before
starting the machine. You must understand
and follow the
This safety alert system identifies important
safety messages in this manual. When you see
this symbol, be alert, your safety is involved,
carefuly read the message that follows, and
inform other operators.
instructions in the Operator Manual. You
must observe all relevant laws and regulations.
If you are unsure about anything, ask your JCB
dealer or employer. Do not guess, you or others
could be killed or seriously injured.
In this publication and on the machine, there are
safety notices. Each notice starts with a signal
word. The signal word meanings are given below.
INT-1-1-1_2
Do not operate the machine without an Operator
Manual.
DANGER
Treat the Operator Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator Manual immediately if it is lost,
damaged or becomes unreadable.
Denotes an extreme hazard exists. If proper
precautions are not taken, it is highly probable
that the operator (or others) could be killed or
seriously injured.
INT-1-2-1
WARNING Denotes a hazard exists. If proper
precautions are not taken, the operator (or
others) could be killed or seriously
injured. INT-1-2-2 CAUTION Denotes a reminder of
safety practices. Failure to follow these safety
practices could result in injury to the operator
(or others) and possible damage to the
machine. INT-1-2-3
2-1
14
Section 2 - Care and Safety Safety Notices Safety
Check List Safety Check List
Safety - Yours and Others
General Safety
INT-1-3-1_3 All machinery can be hazardous. When
a machine is correctly operated and properly
maintained, it is a safe machine to work with.
But when it is carelessly operated or poorly
maintained it can become a danger to you (the
operator) and others.
T1-007_3
WARNING
Operator Manual You and others can be injured
if you operate or maintain the machine without
first studying the Operator Manual. Read the
safety instructions before operating the machine.
If you do not understand anything, ask your
employer or JCB dealer to explain it. Keep the
Operator Manual clean and in good condition. Do
not operate the machine without an Operator
Manual in the cab, or if there is anything on the
machine you do not understand.
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.
INT-1-3-2_2
WARNING
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 work with the machine until you are sure
that you can control it.
Do not start any job until you are sure that you
and those around you will be safe.
INT-1-3-5
WARNING
If you are unsure of anything, about the machine
or the job, ask someone who knows. Do not assume
anything.
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, ear- protectors and
industrial gloves. Keep cuffs fastened. Do not
wear a necktie or scarf. Keep long hair
restrained. Remove rings, watches and personal
jewellery.
Remember
BE CAREFUL BE ALERT BE SAFE
INT-1-3-6_2
WARNING Alcohol and Drugs It is extremely
dangerous to operate machinery when under the
influence of alcohol or drugs. Do not consume
alcoholic drinks or take drugs before or while
operating the machine or attachments. Be aware of
medicines which can cause drowsiness. INT-1-3-9_2
2-2
15
Section 2 - Care and Safety Safety Notices Safety
Check List
WARNING
DANGER
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
WARNING
WARNING
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.
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.
INT-1-3-10_2 Switch off and do not use your
mobile phone when refuelling the
machine. INT-3-3-9 WARNING 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 WARNING Raised Equipment Never
walk or work under raised equipment unless it is
supported by a mechanical device. Equipment which
is supported only by a hydraulic device can drop
and injure you if the hydraulic system fails or
if the control is operated (even with the engine
stopped). 13-2-3-7_2 WARNING Raised
Machine NEVER position yourself or any part of
your body under a raised machine which is
not properly supported. If the machine moves
unexpectedly you could become trapped and suffer
serious injury or be killed. INT-3-3-7_1
2-3
16
Section 2 - Care and Safety Safety Notices Safety
Check List
Operating Safety
WARNING
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.
DANGER
Drive Safely Drive the machine smoothly, spin
turn manoeuvres, zig-zag driving or turning too
fast can cause the vehicle to overturn.
8-1-2-2_1
INT-2-1-10_2
WARNING
WARNING
Machine Safety Stop work at once if a fault
develops. Abnormal sounds and smells can be signs
of trouble. Inspect and repair before resuming
work.
The engine has exposed rotating parts. Switch OFF
the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
5-2-6-5
8-1-2-3
WARNING
WARNING
Controls You or others can be killed or seriously
injured if you operate the control levers from
outside the machine. Operate the control levers
only when you are correctly seated in the machine.
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.
0179
INT-2-1-1
WARNING
WARNING
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.
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.
5-3-1-12_3
INT-2-1-4
WARNING
WARNING
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.
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.
8-1-2-4
INT-2-1-7_1
2-4
17
Section 2 - Care and Safety Safety Notices Safety
Check List
WARNING
CAUTION
Machine Condition A defective machine can injure
you or others. Do not operate a machine which is
defective or has missing parts. Make sure the
maintenance procedures in this manual are
completed before using the machine.
Passengers Passengers in or on the machine can
cause accidents. Do not carry passengers.
INT-2-2-2_1
WARNING
INT-2-1-2_2
Safe Working Loads Overloading the machine can
damage it and make it unstable. Study the
specifications in the Operator Manual before
using the machine.
WARNING
Fibre Optic Cables If you cut through a fibre
optic cable, Do not look into the end of it, your
eyes could be permanently damaged.
7-1-1-8_2
WARNING
8-2-9-20
Hillsides Operating the machine on hillsides can
be dangerous if proper precautions are not
taken. Ground conditions can be changed by
rain, snow, ice etc. Check the site carefully.
When applicable, keep all attachments low to the
ground.
WARNING
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
8-1-1-1
WARNING
WARNING
Safety Barriers Unguarded machines in public
places can be dangerous. In public places, or
where your visibility is
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.
reduced, place barriers around the work area to
keep people away.
13-2-4-11
INT-2-2-8
WARNING
WARNING
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.
Banks and Trenches Banked material and trenches
can collapse. Do not work or drive too close to
banks and trenches where there is danger of
collapse.
INT-2-2-5
INT-1-3-10_2
DANGER
CAUTION
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.
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.
INT-2-2-10
5-5-1-1_2
2-5
18
Section 2 - Care and Safety Safety Notices Safety
Check List
A wide range of optional attachments is available
to increase the versatility of your machine. Only
JCB approved attachments are recommended for use
with your machine. Consult your JCB Distributor
for the full list of approved attachments
available.
WARNING
Diesel Fuel Diesel fuel is flammable keep
naked flames away from the fuel system. Do not
smoke while refuelling or working on the fuel
system. Do not refuel with the engine running.
There could be a fire and injury if you do not
follow these precautions.
JCB attachments are designed and manufactured
specifically to suit the machine's hydraulic
system, mounting arrangements and safe load
requirements. Attachments which are not designed
for use with this machine may cause damage and
create safety hazards for which JCB cannot be
held responsible. In addition the machine's
warranty, "CE" and any other legislative
compliance may be affected by the use of non JCB
approved attachments.
INT-3-2-2_1
WARNING
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.
2-4-1-13_2
WARNING
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.
INT-3-2-3
WARNING
Fluid Under Pressure Fine jets of fluid at high
pressure can penetrate the skin. Keep face and
hands well clear of fluid under pressure and wear
protective glasses. Hold a piece of cardboard
close to suspected leaks and then inspect the
cardboard for signs of fluid. If fluid penetrates
your skin, get medical help immediately.
GEN-1-5_2
WARNING
Metal Splinters You can be injured by flying
metal splinters when driving metal pins in or
out. Use a soft faced hammer or copper pin to
remove and fit metal pins. Always wear safety
glasses.
INT-3-1-10_2
WARNING
Fires If your machine is equipped with a fire
extinguisher, make sure it is checked regularly.
Keep it in the correct machine location until you
need to use it.
INT-3-1-3_2
WARNING
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.
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 self- contained breathing
apparatus.
INT-3-1-6
WARNING
INT-3-2-7_2 Electrical Circuits Understand the
electrical circuit before connecting
or disconnecting an electrical component. A wrong
connection can cause injury and/or
damage. INT-3-1-4
2-6
19
Section 2 - Care and Safety Safety Notices Safety
Check List
WARNING
CAUTION
Hydraulic Pressure Hydraulic fluid at system
pressure can injure you. Before connecting or
removing any hydraulic hose, residual hydraulic
pressure trapped in the service hose line must be
vented. Make sure the hose service line has been
vented before connecting or removing hoses. Make
sure the engine cannot be started while the hoses
are open.
Rams The efficiency of the rams will be affected
if they are not kept free of solidified dirt.
Clean dirt from around the rams regularly. When
leaving or parking the machine, close all rams if
possible to reduce the risk of weather corrosion.
INT-3-2-10
CAUTION
INT-3-1-11_2
'O' rings, Seals and Gaskets Badly fitted,
damaged or rotted 'O' rings, seals and gaskets
can cause leakages and possible accidents. Renew
whenever disturbed unless otherwise
instructed. Do not use Triochloroethane or paint
thinners near 'O' rings and seals.
WARNING
Hot Coolant The cooling system is pressurised
when the engine is hot. Hot coolant can spray out
when you remove the filler cap. Let the system
cool before removing the filler cap. To remove
the cap turn it to the first notch and let the
system pressure escape, then remove the cap.
INT-3-2-12
WARNING
INT-3-2-9_1
When operating PTO equipment, always observe the
following safety precautions
CAUTION
Cleaning Cleaning metal parts with incorrect
solvents can cause corrosion. Use only
recommended cleaning agents and solvents.
Follow the instructions in the implement Operator
Manual.
Rotating equipment is dangerous. Do not wear
loose fitting clothing when working close to
rotating shafts.
INT-3-2-11
Always disengage the PTO, stop the engine and
wait until the equipment stops,
before 1 Leaving the cab
WARNING
Hydraulic Hoses Damaged hoses can cause fatal
accidents. Inspect the hoses regularly for
2 Attempting to attach or detach an implement to
or from a PTO shaft or

• Damaged hose ends
• Chafed outer covers
• Ballooned outer covers
• Kinked or crushed hoses
• Embedded armouring in outer covers
• Displaced end fittings.

3 Working on or cleaning an implement connected
to the machine via a PTO shaft.
Always ensure that the PTO shaft and driveline
are fully guarded before use.
INT-3-3-2
When using stationary PTO equipment, ensure that
the park brake is applied.
WARNING
13-2-1-6
Soft Ground A machine can sink into soft ground.
Never work under a machine on soft
ground. INT-3-2-4
2-7
20
Section 2 - Care and Safety Safety Notices Safety
Check List
WARNING 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
2-8
21
Section 2 - Care and Safety Safety Notices Safety
Check List
Maintenance Safety
WARNING
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.
WARNING
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.
0125
WARNING
Battery Terminals The machine is negatively
earthed. Always connect the negative pole of the
battery to earth.
INT-3-1-5
When connecting the battery, connect the earth
(-) lead last.
WARNING
When disconnecting the battery, disconnect the
earth (-) lead first.
Electrical Circuits Understand the electrical
circuit before connecting or disconnecting an
electrical component. A wrong connection can
cause injury and/or damage.
INT-3-1-9
DANGER
INT-3-1-4
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.
WARNING
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.
INT-3-2-1_3
WARNING
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.
GEN-1-5_2
WARNING
Metal Splinters You can be injured by flying
metal splinters when driving metal pins in or
out. Use a soft faced hammer or copper pin to
remove and fit metal pins. Always wear safety
glasses.
INT-3-1-8
WARNING
INT-3-1-3_2
Fluid Under Pressure Fine jets of fluid at high
pressure can penetrate the skin. Keep face and
hands well clear of fluid under pressure and wear
protective glasses. Hold a piece of cardboard
close to suspected leaks and then inspect the
cardboard for signs of fluid. If fluid penetrates
your skin, get medical help immediately.
CAUTION
Do not disconnect the battery while the engine is
running, otherwise the electrical circuits may be
damaged.
INT-3-1-14
INT-3-1-10_2
2-9
22
Section 2 - Care and Safety Safety Notices Safety
Check List
WARNING
WARNING
Hydraulic Pressure Hydraulic fluid at system
pressure can injure you. Before connecting or
removing any hydraulic hose, residual hydraulic
pressure trapped in the service hose line must be
vented. Make sure the hose service line has been
vented before connecting or removing hoses. Make
sure the engine cannot be started while the hoses
are open.
Soft Ground A machine can sink into soft ground.
Never work under a machine on soft ground.
INT-3-2-4
WARNING
Always wear safety glasses when dismantling
assemblies containing components under pressure
from springs. This will protect against eye
injury from components accidentally flying out.
INT-3-1-11_2
WARNING
GEN-6-2
Petrol Do not use petrol in this machine. Do not
mix petrol with the diesel fuel in storage tanks
the petrol will rise to the top and form
flammable vapours.
WARNING
Hot Coolant The cooling system is pressurised
when the engine is hot. Hot coolant can spray out
when you remove the filler cap. Let the system
cool before removing the filler cap. To remove
the cap turn it to the first notch and let the
system pressure escape, then remove the cap.
INT-3-1-6
WARNING
Diesel Fuel Diesel fuel is flammable keep naked
flames away from the fuel system. Do not smoke
while refuelling or working on the fuel system.
Do not refuel with the engine running. There
could be a fire and injury if you do not follow
these precautions.
INT-3-2-9_1
CAUTION
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-3-2-2_1
WARNING
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-3-2-10
CAUTION
Cleaning Cleaning metal parts with incorrect
solvents can cause corrosion. Use only
recommended cleaning agents and solvents.
INT-3-2-3
INT-3-2-11
CAUTION
WARNING
It is illegal to pollute drains, sewers or the
ground. Clean up all spilt fluids and/or
lubricants.
When using cleaning agents, solvents or other
chemicals, you must adhere to the manufacturer's
instructions and safety precautions.
Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
accordance with local regulations. Use authorised
waste disposal sites.
GEN-1-9
INT-3-2-14
2-10
23
Section 2 - Care and Safety Safety Notices Safety
Check List
CAUTION
WARNING
'O' rings, Seals and Gaskets Badly fitted,
damaged or rotted 'O' rings, seals and gaskets
can cause leakages and possible accidents. Renew
whenever disturbed unless otherwise
instructed. Do not use Triochloroethane or paint
thinners near 'O' rings and seals.
Protect your eyes when grinding metal. Wear
safety glasses or goggles. Remove or protect
any combustible materials from the area which
could be ignited by sparks.
GEN-1-12
WARNING
INT-3-2-12
To avoid burning, wear protective gloves when
handling hot components. To protect your eyes,
wear goggles when using a brush to clean
components.
WARNING
Hydraulic Hoses Damaged hoses can cause fatal
accidents. Inspect the hoses regularly for
HYD-1-3_2
WARNING

• Damaged hose ends
• Chafed outer covers
• Ballooned outer covers
• Kinked or crushed hoses
• Embedded armouring in outer covers
• Displaced end fittings.

Counterweights Your machine may be fitted with
counterweights. They are extremely heavy. Do not
attempt to remove them.
INT-3-2-5
WARNING
INT-3-3-2
Turning the Engine Do not try to turn the engine
by pulling the fan or fan belt. This could cause
injury or premature component failure.
CAUTION Waxoyl contains turpentine substitute
which is flammable. Keep flames away when
applying Waxoyl.
0094
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 WARNING 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
2-11
24
Section 2 - Care and Safety Safety Notices Safety
Check List
WARNING
WARNING
Certain seals and gaskets (e.g. crankshaft oil
seal) on JCB machines contain fluoroelastomeric
materials such as Viton, Fluorel and
Technoflon.
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.
Fluoroelastomeric materials subjected to high
temperatures can produce highly corrosive
hydrofluoric acid. THIS ACID CAN SEVERELY BURN.
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.
New fluoroelastomeric components at ambient
temperature require no special safety
precautions. Used fluoroelastomeric components wh
ose temperatures have not exceeded 300C (572F)
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.
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.
Used fluoroelastomeric components subjected to
temperatures greater than 300C (572F) (e.g.
engine fire) must be treated using the following
safety procedure. Make sure that heavy duty
gloves and special safety glasses are worn
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.

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 area with
   detergent and water.

INT-3-1-15_2
WARNING
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.
3 Contain all removed material, gloves etc. used
in this operation in sealed plastic bags and
dispose of in accordance with Local
Authority Regulations.
INT-3-1-17 DO NOT BURN FLUOROELASTOMERIC
MATERIALS.
INT-3-3-5_3
WARNING
An exploding tyre can kill. Inflated tyres can
explode if over-heated or over-inflated. Follow
the instructions given when inflating the tyres.
Do not cut or weld the rims. Use a tyre/wheel
specialist for all repair work. 2-3-2-7_2
2-12
25
Section 2 - Care and Safety Safety Notices Safety
Check List
WARNING
WARNING
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.
Asbestos Asbestos dust can damage your lungs.
Some engine gaskets contain asbestos. Do not
dismantle the engine or exhaust system get these
jobs done by a qualified person who has a copy of
the engine service manual.
5-1-6-1
INT-3-2-8
WARNING 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 WARNING Wheels and tyres are
heavy. Take care when lifting or moving
them. Store with care to ensure that they cannot
fall and cause injury. 13-3-1-7_1 CAUTION Never
use water or steam to clean inside the cab. The
use of water or steam could damage the on-board
computer and render the machine inoperable.
Remove dirt using a brush or damp
cloth. 8-3-4-8 WARNING Boom Safety Strut A
raised boom can drop suddenly and cause serious
injury. Before working under a raised boom, fit
the boom safety strut. See Boom Safety
Strut, MAINTENANCE section. 5-1-5-7
2-13
26
Section 2 - Care and Safety Safety Notices Safety
Check List
Safety Decals WARNING Decals Decals on the
machine warn you of particular hazards. You can
be injured if you do not obey the decal safety
instructions. Each decal is attached close to a
part of the machine where there is a possible
hazard. Make sure replacement parts include
warning decals where necessary. Keep all decals
clean and readable. Replace lost or damaged
decals. Each decal has a part number printed on
it, use this number to order a new decal from
your JCB distributor. INT-3-3-3_1 WARNING If you
need eye-glasses for reading, make sure you wear
them when reading the safety decals. Decals are
strategically placed around the machine to remind
you of possible hazards. Do not over-stretch or
place yourself in dangerous positions to read the
decals. INT-3-3-4_1
2-14
27
Section 3 - Maintenance
Contents Page No. Routine Maintenance Service
Requirements .....................................
........................................ 3 -
1 Health and Safety ..............................
..................................................
.... 3 - 3 Service Schedules .....................
..................................................
............ 3 - 7 Fluids, Lubricants and
Capacities .......................................
................... 3 - 11 Safety Checks
..................................................
..................................... 3 -
13 Cleaning the Machine ..........................
..................................................
3 - 14 Check for Damage .........................
..................................................
...... 3 - 15 Seat Belt ..........................
..................................................
.................... 3 - 16 ROPS Structure
..................................................
................................... 3 -
17 Greasing ......................................
..................................................
........ 3 - 18 Access Panels ....................
..................................................
................. 3 - 20 Brakes
..................................................
.................................................
3 - 22 Electrical System .........................
..................................................
........ 3 - 23 Engine Air Filter
..................................................
................................... 3 - 25 Engine
..................................................
.................................................
3 - 27 Fuel System ...............................
..................................................
.......... 3 - 33 Hydraulic/Transmission System
..................................................
.......... 3 - 38 Tyres and Wheels
..................................................
................................ 3 - 42 Axles
..................................................
..................................................
.. 3 - 43
3 - i
3 - i
28
Section 3 - Maintenance Routine
Maintenance Service Requirements Routine
Maintenance Service Requirements
Introduction
Distributor's Service Department who are there to
help you!
T3-002 Your machine has been designed and built
to give maximum performance, economy and ease of
use under a wide variety of operating conditions.
Prior to delivery, your machine was inspected
both at the Factory and by your Distributor to
ensure that it reaches you in optimum condition.
To maintain this condition and ensure trouble
free operation it is important that the routine
services, as specified in this Manual, are
carried out by an approved JCB Distributor at the
recommended intervals.
You will have been given the names of the
relevant service contacts at your Distributor
when the machine was installed.

• To get the most from your Distributor please help
  them to satisfy you by
• Giving your name, address and telephone number.
• Quoting your machine model and serial number.
• Date of purchase and hours of work.
• Nature of the problem.
• 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.

This section of the Manual gives full details of
the service requirements necessary to maintain
your JCB machine at peak efficiency.
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.
Service/Maintenance Agreements
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.
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.
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.
Please consult your JCB Distributor for details.
Lifting Regulations - Inspections and Tests
Remember, if your machine has been
correctly maintained, not only will it give you
improved reliability but its resale value will be
greatly enhanced.
T3-003 Only your JCB Distributor can fully meet
the requirements of the inspection and test
parameters to suit UK Health and Safety Executive
(H.S.E.) legal requirements along with providing
Annual Inspections to meet your Insurance Company
Policy conditions.
Owner/Operator Support
JCB together with your Distributor wants you to
be completely satisfied with your new JCB
machine. If you do encounter a problem however,
you should contact your
Only your JCB Distributor has the ability to meet
the definition described covering a "Competent
Person" to
3-1
29
Section 3 - Maintenance Routine
Maintenance Service Requirements
carry out these necessary tests and inspections.
This ensures that only JCB Factory trained,
experienced and up-to-date Engineers supported
with all of the available data and material
provided only to a JCB Distributor will ensure a
thorough and reliable standard. Obtaining
Replacement Parts T3-004_2 We recommend you fit
only JCB Genuine Parts. A Parts Book will help
you identify parts and order them from your JCB
distributor. Your dealer will need to know the
exact model, build and serial number of your
machine. See Identifying Your Machine in
INTRODUCTION section. The data plate also shows
the serial numbers of the engine, transmission
and axle(s), where applicable. But remember if
any of these units have been changed, the serial
number on the data plate may be wrong. Check on
the unit itself.
3-2
30
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Section 3 - Maintenance Routine
Maintenance Health and Safety Health and
Safety T3-001_3
Lubricants
The collection and disposal of used oil should be
in accordance with any local regulations. Never
pour used engine oil into sewers, drains or on
the ground.
Introduction
Handling
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.
New Oil
There are no special precautions needed for the
handling or use of new oil, beside the normal
care and hygiene practices.
Hygiene
JCB lubricants are not a health risk when used
properly for their intended purposes.
Used Oil
Used engine crankcase lubricants contain
harmful contaminants.
However, excessive or prolonged skin contact can
remove the natural fats from your skin, causing
dryness and irritation.
Here are precautions to protect your health when
handling used engine oil
Low viscosity oils are more likely to do this, so
take special care when handling used oils, which
might be diluted with fuel contamination.
1 Avoid prolonged, excessive or repeated skin
contact with used oil.
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.

• 2 Apply a barrier cream to the skin before
  handling used oil. Note the following when
  removing engine oil from skin
• Wash your skin thoroughly with soap and water.
• Using a nail brush will help.

Storage
Always keep lubricants out of the reach of
children.
c Use special hand cleansers to help clean dirty
hands.
Never store lubricants in open or unlabelled
containers.
d Never use petrol, diesel fuel, or paraffin for
washing.
Waste Disposal
CAUTION
3 Avoid skin contact with oil soaked clothing.
It is illegal to pollute drains, sewers or the
ground. Clean up all spilt fluids and/or
lubricants.
4 Don't keep oily rags in pockets.
5 Wash dirty clothing before re-use.
Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
accordance with local regulations. Use authorised
waste disposal sites.
6 Throw away oil-soaked shoes.
INT-3-2-14 All waste products should be disposed
of in accordance with all the relevant
regulations.
3-3
3-3
9803/9470
32
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