Service Manual

JCB 8250 Fastrac

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

Publication No.
9803/8040-6

World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377
 Section 1 - General Information

1-0 9803/8040-2 1-0

 Section 1 - General Information

Contents Page No.

Identifying the Machine
Serial Numbers ........................................................................................ 1 - 1
Serial Number Plate ........................................................................... 1 - 1

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1-3
Introduction ......................................................................................... 1-3
Zinc Plated Fasteners (golden finish) ................................................. 1-4
Dacromet Fasteners (mottled silver finish) ......................................... 1-5
Hydraulic Connections ............................................................................. 1-6
'O' Ring Face Seal System ................................................................. 1-6
'Torque Stop' Hose System ................................................................ 1-9

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

1-i 1-i
 Section 1 - General Information

Contents Page No.

1 - ii 1 - ii
 Section 1 - General Information
Identifying the Machine
Serial Numbers

Identifying the Machine

Serial Numbers

Serial Number Plate Unit Identification

Each machine has a serial number plate located at X. The
17 digit Vehicle Identification Number (VIN), and the serial
numbers of the engine and transmission are stamped on
the plate.
The serial number of each major unit is also stamped on
the unit itself as shown below. If a major unit is replaced by
a new one, the serial number on the plate will be wrong.
Either stamp the new number of the unit on the
identification plate, or simply stamp out the old number.
This will prevent the wrong unit number being quoted when
replacement parts are ordered.

Engine M
Gearbox N
Front axle P
Rear axle R

Fig 1.

Typical Vehicle Identification No. (VIN)

Fig 2.
A Manufacturing code
B Machine range
FT = Fastrac
C Engine type
D Transmission type (gearbox & axle
combination) Fig 3.
E Vehicle max. speed
40 = 40 kph
50 = 50 kph
65 = 65 kph
F Serial number

1-1 9803/8040-2 1-1

 Section 1 - General Information
Identifying the Machine
Serial Numbers

N
Fig 4.

Fig 5.

Fig 6.

1-2 9803/8040-2 1-2

 Section 1 - General Information

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

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

The two types of fasteners can be readily identified by

colour and part number suffix as follows:

Fastener Type Colour Part Number

Zinc and Yellow Golden Z (e.g. 1315/3712Z)
finish
Dacromet Mottled D (e.g. 1315/3712D)
silver finish

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.

1-3 9803/8040-2 1-3

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

Zinc Plated Fasteners (golden finish) Metric - All Internal Hexagon

Headed Cap Screws
Use the values on these pages only where no torque
Diameter Torque Settings
setting is specified in the text. Values are for dry threads
and may be within three per cent of the figures stated. For mm Nm kgf m lbf ft
lubricated threads the values should be REDUCED by one M3 2 0.2 1.5
third.
M4 6 0.6 4.5
M5 11 1.1 8
Metric Grade 8.8 Bolts
M6 19 1.9 14
Size Torque Settings
M8 46 4.7 34
Nm kgf m lbf ft
M10 91 9.3 67
Diameter Hexagon (A/F)
(mm) mm M12 159 16.2 117
M16 395 40 292
M5 (5) 8 7 0.7 5 M18 550 56 406
M6 (6) 10 12 1.2 9 M20 770 79 568
M8 (8) 13 28 3.0 21 M24 1332 136 983
M10 (10) 17 56 5.7 42
Verbus Ripp Bolts
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 Fig 7.

Metric Grade 10.9 Bolts Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
Size Torque Settings required settings.
Nm kgf m lbf ft
Diameter Hexagon (A/F)
(mm) mm

M6 (6) 8 16 1.6 12
M8 (8) 13 39 4 29
M10 (10) 17 78 8 57
M12 (12) 19 137 14 101
M16 (16) 24 343 35 253
M20 (20) 30 657 67 485
M24 (24) 36 1157 118 853

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

Dacromet Fasteners (mottled silver Metric Grade 12.9 Bolts

finish) Bolt size Torque Settings

Use the values on these pages only where no torque Dia. Nm kgf m lbf ft
setting is specified in the text. M6 x 1.0 15 1.5 11
M8 x 1.25 40 4.1 29
Note: Dacromet fasteners are lubricated as part of the
plating process. Do not lubricate M10 x 1.5 80 8.2 59
M12 x 1.75 133 13.6 98
Metric Grade 8.8 Bolts 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
M10 x 1.5 47.5 4.8 35 M30 x 3.5 2247 229 1657
M12 x 1.75 80 8.2 59
M14 x 2 133 13.6 98
M16 x 2 200 20.4 148
M18 x 2.5 278 28.4 205
M20 x 2.5 392 40 289
M24 x 3 675 69 498
M30 x 3.5 1348 138 994

Metric Grade 10.9 Bolts

Bolt size Torque Settings
Dia. Nm kgf m lbf ft
M6 x 1.0 13.5 1.4 10
M8 x 1.25 35 3.6 26
M10 x 1.5 62.5 6.4 46
M12 x 1.75 115 11.7 85
M14 x 2 175 17.9 129
M16 x 2 300 30.6 221
M18 x 2.5 395 40 291
M20 x 2.5 559 57 412
M24 x 3 962 98 710
M30 x 3.5 1920 196 1416

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 Section 1 - General Information
Standard Torque Settings
Hydraulic Connections

Hydraulic Connections
T11-003

'O' Ring Face Seal System

Adaptors Screwed into Valve Blocks

Adaptor screwed into valve blocks, seal onto an 'O' ring

which is compressed into a 45° seat machined into the
face of the tapped port.

Table 1. Torque Settings - BSP Adaptors

BSP Adaptor Hexagon (A/F)
Size
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 Tube SAE Port Hexagon (A/F)
Size Thread Size mm Nm kgf m lbf ft
4 7/16 - 20 15.9 20.0 - 28.0 2.0 - 2.8 16.5 - 18.5
6 9/16 - 18 19.1 46.0 - 54.0 4.7 - 5.5 34.0 - 40.0
8 3/4 - 16 22.2 95.0 - 105.0 9.7 - 10.7 69.0 - 77.0
10 7/8 - 14 27.0 130.0 - 140.0 13.2 - 14.3 96.0 - 104.0
12 1 1/16 - 12 31.8 190.0 - 210.0 19.4 - 21.4 141.0 - 155.0
16 1 5/16 - 12 38.1 290.0 - 310.0 29.6 - 31.6 216.0 - 230.0
20 1 5/8 47.6 280.0 - 380.0 28.5 - 38.7 210.0 - 280.0

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

Fig 8.

Hoses 8-B screwed into adaptors 8-A seal onto an `O' ring Note: Dimension 8-D will vary depending upon the torque
8-C which is compressed into a 45° seat machined into the applied.
face of the adaptor port.

Table 3. BSP Hose - Torque Settings

BSP Hose Size Hexagon (A/F)
in. mm Nm kgf m lbf ft
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

1-7 9803/8040-2 1-7

 Section 1 - General Information
Standard Torque Settings
Hydraulic Connections
Adaptors into Component Connections with Bonded Washers

Table 4. BSP Adaptors with Bonded Washers - Torque Settings

BSP Size
in. Nm kgf m lbf ft
1/8 20.0 2.1 15.0
1/4 34.0 3.4 25.0
3/8 75.0 7.6 55.0
1/2 102.0 10.3 75.0
5/8 122.0 12.4 90.0
3/4 183.0 18.7 135.0
1 203.0 20.7 150.0
1 1/4 305.0 31.0 225.0
1 1/2 305.0 31.0 225.0

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 Section 1 - General Information
Standard Torque Settings
Hydraulic Connections

'Torque Stop' Hose System

Fig 9.

`Torque Stop' Hoses 9-B screwed into adaptors 9-A seal Stop' Hoses have an additional shoulder 9-D, which acts
onto an 'O' ring 9-C which is compressed into a 45° seat as a physical stop.
machined in the face of the adaptor port. To prevent the 'O'
ring being damages as a result of over tightening, 'Torque Note: Minimum dimension 9-E fixed by shoulder 9-D.

Table 5. BSP `Torque Stop' Hose - Torque Settings

BSP Hose Size Hexagon (A/F)
in. mm Nm kgf m lbf ft
1/8 14.0 14.0 1.4 10.0
1/4 19.0 27.0 2.7 20.0
3/8 22.0 40.0 4.1 30.0
1/2 27.0 55.0 5.6 40.0
5/8 30.0 65.0 6.6 48.0
3/4 32.0 95.0 9.7 70.0
1 38.0 120.0 12.2 89.0
1 1/4 50.0 189.0 19.3 140.0
1 1/2 55.0 244.0 24.9 180.0

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 Section 1 - General Information
Service Consumables
Sealing and Retaining Compounds

Service Consumables
Sealing and Retaining Compounds
T11-001_3

Table 6.
Type Description Part No. Quantity
JCB Multi-Gasket A medium strength sealant suitable for all sizes of 4102/1212 50 ml
gasket flanges, and for hydraulic fittings of 25-65 mm
diameter.
JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml
components. Gasketing for all sizes of flange where
the strength of the joint is important.
JCB Retainer (High Strength) For all retaining parts which are unlikely to be 4101/0651 50 ml
dismantled.
JCB Threadlocker and Sealer A medium strength locking fluid for sealing and 4101/0250 10 ml
retaining nuts, bolts, and screws up to 50 mm 4101/0251 50 ml
diameter, and for hydraulic fittings up to 25 mm
diameter.
JCB Threadlocker and Sealer A high strength locking fluid for sealing and retaining 4101/0550 10 ml
(High Strength) nuts, bolts, and screws up to 50 mm diameter, and 4101/0552 200 ml
for hydraulic fittings up to 25 mm diameter.
JCB Threadseal A medium strength thread sealing compound. 4102/1951 50 ml
JCB Activator A cleaning primer which speeds the curing rate of 4104/0251 200 ml (Aerosol)
anaerobic products. 4104/0253 1 ltr (Bottle)
JCB Cleaner/Degreaser For degreasing components prior to use of 4104/1557 400 ml (Aerosol)
anaerobic adhesives and sealants.
Direct Glazing Kit For one pane of glass; comprises of: 993/55700

– 1 x Ultra Fast Adhesive (310 ml)

– 1 x Active Wipe 205 (30 ml)
– 1 x Black Primer 206J (30 ml)
– plus applicator nozzle etc.
Ultra Fast Adhesive For direct glazing. 4103/2109 310 ml
Active Wipe 205 For direct glazing. 4104/1203 250 ml
Black Primer 206J For direct glazing. 4201/4906 30 ml
Clear Silicone Sealant To seal butt jointed glass. 4102/0901
Plastic to Metal Bonder To seal plastic to metal joints. 4103/0956 50 g
Black Polyurethane Sealant To finish exposed edges of laminated glass. 4102/2309 310 ml

1 - 10 9803/8040-2 1 - 10
 Section 2 - Care and Safety

2-0 9803/8040-2 2-0

 Section 2 - Care and Safety

Contents Page No.

Safety Check List
Introduction .............................................................................................. 2 - 1
Safety First .............................................................................................. 2 - 2
Safety - Yours and Others .................................................................. 2 - 2
General Safety ................................................................................... 2 - 2
Operating Safety ..................................................................................... 2 - 4
Maintenance Safety ................................................................................. 2 - 9

2-i 2-i
 Section 2 - Care and Safety

Contents Page No.

2 - ii 2 - ii
 Section 2 - Care and Safety

Safety Check List

Introduction
T1-006

!MWARNING
Study the Operator Manual before starting the
machine. You must understand and follow the
instructions in the Operator Manual. You must
observe all relevant laws and regulations. If you are
unsure about anything, ask your JCB dealer or
employer. Do not guess, you or others could be killed
or seriously injured.
INT-1-1-1_2

In this publication and on the machine, there are safety

notices. Each notice starts with a signal word. The signal
word meanings are given below.

!MDANGER
Denotes an extreme hazard exists. If proper
precautions are not taken, it is highly probable that the
operator (or others) could be killed or seriously
injured.
INT-1-2-1

!MWARNING
Denotes a hazard exists. If proper precautions are not
taken, the operator (or others) could be killed or
seriously injured.
INT-1-2-2

!MCAUTION
Denotes a reminder of safety practices. Failure to
follow these safety practices could result in injury to
the operator (or others) and possible damage to the
machine.
INT-1-2-3

2-1 9803/8040-1 2-1


Safety First
As well as the warnings in this chapter, specific warnings
are given throughout the book. This section is designed to
give a safety code for use of the machine generally and for
operation and maintenance practices.
Safety - Yours and Others
INT-1-3-1_3
All machinary can be hazardous. When a machine is
correctly operated and properly maintained, it is a safe
machine to work with. But when it is carelessly operated or
poorly maintained it can become a danger to you (the
operator) and others.
In this manual and on the machine you will find warning
messages. Read and understand them. They tell you of
potential hazards and how to avoid them. If you do not fully
understand the warning messages, ask your employer or
JCB distributor to explain them.
But safety is not just a matter of responding to the
warnings. All the time you are working on or with the
machine you must be thinking what hazards there might be
and how to avoid them.
Do not work with the machine until you are sure that you
can control it.
Do not start any job until you are sure that you and those
around you will be safe.
If you are unsure of anything, about the machine or the job,
ask someone who knows. Do not assume anything.
Remember
BE CAREFUL
BE ALERT
BE SAFE
2-2 9803/8040-1
Section 2 - Care and Safety
Safety Check List
Safety First
General Safety
T1-007
!MWARNING
Operator Manual
You and others can be injured if you operate or
maintain the machine without first studying the
Operator Manual. Read the safety instructions before
operating the machine. If you do not understand
anything, ask your employer or JCB dealer to explain
it. Keep the Operator Manual clean and in good
condition. Do not operate the machine without an
Operator Manual in the cab, or if there is anything on
the machine you do not understand.
INT-1-3-2_2
!MWARNING
Care and Alertness
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always be
alert for hazards.
INT-1-3-5
!MWARNING
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.
INT-1-3-6
!MWARNING
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be aware
of medicines which can cause drowsiness.
INT-1-3-9_2
2-2
 Section 2 - Care and Safety
Safety Check List
Safety First

!MWARNING !MDANGER
Feeling Unwell Lightning
Do not attempt to operate the machine if you are Lightning can kill you. Do not use the machine if there
feeling unwell. By doing so you could be a danger to is lightning in your area.
yourself and those you work with. 5-1-1-2
8-1-2-4

!MWARNING
Mobile Phones
Switch off your mobile phone before entering an area
with a potentially explosive atmosphere. Sparks in
such an area could cause an explosion or fire
resulting in death or serious injury.
Switch off and do not use your mobile phone when
refuelling the machine.
INT-3-3-9
!MWARNING
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

!MWARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
INT-1-3-7

!MWARNING
Raised Equipment
Raised equipment can fall and injure you. Do not walk
or work under raised equipment unless safely
supported.
13-1-1-6

!MWARNING
Raised Machine
NEVER position yourself or any part of your body
under a raised machine which is not properly
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be
killed.
INT-3-3-7_1

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 Section 2 - Care and Safety
Safety Check List
Operating Safety

Operating Safety

!MWARNING !MWARNING
Machine Condition If the machine is fitted with a Roll Over Protection
A defective machine can injure you or others. Do not Structure (ROPS) and a Falling Objects Protection
operate a machine which is defective or has missing Structure (FOPS). You could be killed or seriously
parts. Make sure the maintenance procedures in this injured if you operate the machine with a damaged or
manual are completed before using the machine. missing ROPS/FOPS. If the ROPS/FOPS has been in
INT-2-1-2_2 an accident, do not use the machine until the structure
has been renewed. Modifications and repairs that are
!MWARNING not approved by the manufacturer may be dangerous
and will invalidate the ROPS/FOPS certification.
Machine Limits INT-2-1-9_4
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
!MWARNING
upgrade the machine performance with unapproved Work Sites
modifications. Work sites can be hazardous. Inspect the site before
INT-2-1-4 working on it. Look for potholes, weak ground, hidden
rocks etc. Check for utilities such as electric cables
!MWARNING (overhead and underground), gas and water pipes etc.
Mark the positions of the underground cables and
Engine/Steering Failure pipes. Make sure that you have enough clearance
If the engine or steering fails, stop the machine as beneath overhead cables and structures.
quickly as possible. Do not operate the machine until INT-2-2-1
the fault has been corrected.
INT-2-1-5
!MWARNING
!MWARNING Communications
Bad communications can cause accidents. Keep
Engine people around you informed of what you will be doing.
The engine has exposed rotating parts. Do not open If you will be working with other people, make sure any
the engine cover while the engine is running. Do not hand signals that may be used are understood by
use the machine with the cover open. everybody. Work sites can be noisy, do not rely on
INT-2-1-6_1 spoken commands.
INT-2-2-3

!MWARNING
Exhaust Gases
!MWARNING
Breathing the machine exhaust gases can harm and Parking
possibly kill you. Do not operate the machine in closed An incorrectly parked machine can move without an
spaces without making sure there is good ventilation. operator. Follow the instructions in the Operator
If possible, fit an exhaust extension. If you begin to Manual to park the machine correctly.
feel drowsy, stop the machine at once. Get out of the INT-2-2-4_2
cab into fresh air.
INT-2-1-10

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 Section 2 - Care and Safety
Safety Check List
Operating Safety

!MWARNING !MWARNING
Banks and Trenches Practice
Banked material and trenches can collapse. Do not You or others can be killed or seriously injured if you
work or drive too close to banks and trenches where do unfamiliar operations without first practising them.
there is danger of collapse. Practise away from the work site on a clear area. Keep
INT-2-2-5 other people away. Do not perform new operations
until you are sure you can do them safely.
!MWARNING INT-2-1-1

Ramps and Trailers

Water, mud, ice, grease and oil on ramps or trailers can
!MWARNING
cause serious accidents. Make sure ramps and trailers Reversing
are clean before driving onto them. Use extreme Reversing at high speeds can cause accidents. Do not
caution when driving onto ramps and trailers. reverse in a high gear with full throttle. Always drive at
INT-2-2-6 a safe speed to suit working conditions.
INT-2-2-9_1

!MWARNING
Safety Barriers
!MWARNING
Unguarded machines in public places can be Airborne particles of light combustible material such
dangerous. In public places, or where your visibility is as straw, grass, wood shavings, etc. must not be
reduced, place barriers around the work area to keep allowed to accumulate within the engine compartment
people away. or in the propshaft guards (when fitted). Inspect these
INT-2-2-8 areas frequently and clean at the beginning of each
work shift or more often if required. Before opening
!MDANGER the engine cover, ensure that the top is clear of debris.
5-3-1-12_3
Sparks
Explosions and fire can be caused by sparks from the
exhaust or the electrical system. Do not use the
!MWARNING
machine in closed areas where there is flammable Keep the machine controls clean and dry. Your hands
material, vapour or dust. and feet could slide off slippery controls. If that
INT-2-2-10 happens you could lose control of the machine.
2-2-3-6

!MWARNING
Hazardous Atmospheres
This machine is designed for use in normal out door
atmospheric conditions. It should not be used in an
enclosed area without adequate ventilation. Do not
use the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or dust,
without first consulting your JCB Distributor.
INT-2-1-14
!MWARNING
Visibility
Accidents can be caused by working in poor visibility.
Use your lights to improve visibility. Keep the road
lights, windows and mirrors clean.
Do not operate the machine if you cannot see clearly.
5-1-4-7

!MCAUTION
Regulations
Obey all laws, work site and local regulations which
affect you and your machine.
INT-1-3-3

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 Section 2 - Care and Safety
Safety Check List
Operating Safety

!MWARNING
Electrical Power Cables
You could be electrocuted or badly burned if you get
the machine or its attachments too close to electrical
power cables.
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.
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
!MCAUTION
If you have an attachment which is not covered in the
Operator Manual do not install it, use it or remove it
until you have obtained, read and understood the
pertinent information. Install attachments only on the
machines for which they were designed.
5-5-1-1_2
!MWARNING
Use only the JCB approved attachments that are
specified for your machine. Operating with non-
specified attachments can overload the machine,
causing possible damage and machine instability
which could result in injury to yourself or others.
The use of non-approved attachments could invalidate
your warranty.
2-4-5-2_1
!MWARNING
Controls
You or others can be killed or seriously injured if you
operate the control levers from outside the cab.
Operate the control levers only when you are correctly
seated inside the cab.
INT-2-1-3
!MWARNING
Fires
If your machine is equipped with a fire extinguisher,
make sure it is checked regularly. Keep it in the correct
machine location until you need to use it.
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-3-2-7_2
!MWARNING
Should the machine start to roll over, you can be
crushed if you try to leave the cab. If the machine
starts to roll over, do not try and jump from the cab.
Stay in the cab, with your seat belt fastened.
INT-2-1-12
!MWARNING
Passengers
Ensure that passengers use the seat provided in the
cab. Passengers must not be carried on the rear deck
of the vehicle under any circumstances.
13-1-1-1_1

!MWARNING
!MWARNING Ensure that any load carried on the rear deck of the
Seat Belt machine is firmly secured.
Operating the machine without a seat belt can be 13-1-1-10
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
!MWARNING
maintenance schedules). The machine must never be loaded such that less than
INT-2-1-8_1 20% of the vehicle weight is carried on the front axle.
13-1-1-11_1

2-6 9803/8040-1 2-6


!MWARNING
Certain tyres fitted as after-market/optional equipment
may have maximum permitted speeds below the
maximum speed of the vehicle. Brake efficiency is
slightly reduced and stopping distance is increased
when these tyres are fitted. They will suffer damage if
operated at speeds higher than those recommended
and may endanger life.
13-3-2-5
!MWARNING
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.
13-2-1-2
!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 non-
suspended implements on rough ground. (Consult the
implement operator's manual for recommended
transport speeds).
13-2-2-1_1
!MDANGER
The JCB Fastrac is capable of operating at high
speeds. Implements or trailers you tow behind the
Fastrac may not be designed for high speed operation.
BE AWARE of the manufacturer's specified maximum
speed rating for any trailers or implements that you
tow behind the Fastrac. DO NOT EXCEED THE
MAXIMUM DESIGN SPEED OF TRAILERS OR
IMPLEMENTS AS INJURY OR DEATH MAY RESULT.
13-2-3-5
2-7 9803/8040-1
Section 2 - Care and Safety
Safety Check List
Operating Safety
!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
!MCAUTION
Trailers with single line hydraulic brakes used in the
United Kingdom are subject to a maximum speed of 20
mph (32 kph).
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).
13-2-2-13
!MWARNING
Brakes
Do not coast the machine with the engine stopped as
the main brakes will only operate for a limited number
of applications and trailer brakes may not function at
all. Also the steering will become very heavy.
13-1-1-5_2
!MWARNING
When driving the machine on the road, use the
accelerator pedal and not the hand throttle to control
the engine speed. Always set the hand throttle to 'idle'
before using the accelerator pedal.
13-2-1-8_1
!MWARNING
When driving the machine on the road with an
implement or trailer connected to the machine, the
transport locks must be engaged to prevent
unintentional operation of electronic linkage, front and
rear PTO or external hydraulics.
13-2-4-13
2-7
 Section 2 - Care and Safety
Safety Check List
Operating Safety

!MCAUTION !MWARNING
Electronic Control Unit The cab air filter is designed to remove dirt from the
The electronic control unit under the passenger's seat outside air. When using chemicals (e.g. for crop
is protected by a cover. Do not use the machine with spraying) follow the chemical manufacturer's
the cover removed. recommendations for protection from dangerous
0103 chemicals.
13-2-3-6

!MWARNING
When operating PTO equipment, always observe the
following safety precautions:
Follow the instructions in the implement Operator
Manual.
Rotating equipment is dangerous. Do not wear loose
fitting clothing when working close to rotating shafts.
Always disengage the PTO, stop the engine and wait
until the equipment stops, before:
!MWARNING
Entering/Leaving
Entering or leaving the cab or canopy must only be
made where steps and handrails are provided. Always
face the machine when entering and leaving. Make
sure the step(s), handrails and your boot soles are
clean and dry. Do not jump from the machine. Do not
use the machine controls as handholds, use the
handrails.
INT-2-1-7_1

1 Leaving the cab

2 Attempting to attach or detach an implement to or
from a PTO shaft or
3 Working on or cleaning an implement connected
to the machine via a PTO shaft.
Always ensure that the PTO shaft and driveline are
fully guarded before use.
When using stationary PTO equipment, ensure that
the park brake is applied.
13-2-1-6
!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
The exhaust pipe becomes extremely hot when the
engine is running and will remain so for some time
after the engine is stopped. If you touch the hot pipe
you could be severely burned.
13-2-4-11

!MWARNING
If the PTO becomes jammed, disengage the PTO, stop
the engine and clear the blockage. Wait until the PTO
shaft stops before working on the equipment. If the
PTO clutch slips, immediately disengage the PTO and
stop the engine.
13-2-2-2
!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

!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

2-8 9803/8040-1 2-8

 Section 2 - Care and Safety
Safety Check List
Maintenance Safety

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.
INT-3-1-3_2
!MWARNING
Electrical Circuits
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
INT-3-1-4
!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
!MDANGER
Electrolyte
Battery electrolyte is toxic and corrosive. Do not
breathe the gases given off by the battery. Keep the
electrolyte away from your clothes, skin, mouth and
eyes. Wear safety glasses.
INT-3-2-1_3
!MWARNING
Battery Terminals
The machine is negatively earthed. Always connect
the negative pole of the battery to earth.
When connecting the battery, connect the earth (-) lead
last.
When disconnecting the battery, disconnect the earth
(-) lead first.
INT-3-1-9

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

2-9 9803/8040-1 2-9

 Section 2 - Care and Safety
Safety Check List
Maintenance Safety

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2
!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

!MWARNING
!MWARNING Soft Ground
Hydraulic Pressure A machine can sink into soft ground. Never work
Hydraulic fluid at system pressure can injure you. under a machine on soft ground.
Before connecting or removing any hydraulic hose, INT-3-2-4
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
!MWARNING
hoses. Make sure the engine cannot be started while Hot Coolant
the hoses are open. The cooling system is pressurised when the engine is
INT-3-1-11_2 hot. Hot coolant can spray out when you remove the
filler cap. Let the system cool before removing the
!MWARNING filler cap. To remove the cap; turn it to the first notch
and let the system pressure escape, then remove the
Petrol cap.
Do not use petrol in this machine. Do not mix petrol INT-3-2-9_1
with the diesel fuel; in storage tanks the petrol will rise
to the top and form flammable vapours.
INT-3-1-6
!MWARNING
Always wear safety glasses when dismantling
!MWARNING assemblies containing components under pressure
from springs. This will protect against eye injury from
Diesel Fuel components accidentally flying out.
Diesel fuel is flammable; keep naked flames away from GEN-6-2
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
!MCAUTION
do not follow these precautions. Rams
INT-3-2-2_1 The efficiency of the rams will be affected if they are
not kept free of solidified dirt. Clean dirt from around
!MWARNING the rams regularly. When leaving or parking the
machine, close all rams if possible to reduce the risk
Oil of weather corrosion.
Oil is toxic. If you swallow any oil, do not induce INT-3-2-10
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
!MCAUTION
necessary. Always use barrier cream or wear gloves to Cleaning
prevent skin contact. Wash skin contaminated with oil Cleaning metal parts with incorrect solvents can cause
thoroughly in warm soapy water. Do not use petrol, corrosion. Use only recommended cleaning agents
diesel fuel or paraffin to clean your skin. and solvents.
INT-3-2-3 INT-3-2-11

2 - 10 9803/8040-1 2 - 10
 Section 2 - Care and Safety
Safety Check List
Maintenance Safety

!MWARNING !MWARNING
When using cleaning agents, solvents or other Working Under the Machine
chemicals, you must adhere to the manufacturer's Make the machine safe before getting beneath it.
instructions and safety precautions. Ensure that any fitments on the machine are secure;
GEN-1-9 engage the park brake, remove the starter key,
disconnect the battery.
!MCAUTION INT-3-3-8_2

'O' rings, Seals and Gaskets

Badly fitted, damaged or rotted 'O' rings, seals and
gaskets can cause leakages and possible accidents.
Renew whenever disturbed unless otherwise
instructed. Do not use Triochloroethane or paint
thinners near 'O' rings and seals.
INT-3-2-12
!MWARNING
Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the
hoses regularly for:
– Damaged hose ends
– Chafed outer covers
– Ballooned outer covers
– Kinked or crushed hoses
– Embedded armouring in outer covers
– Displaced end fittings.
INT-3-3-2
!MCAUTION
Waxoyl contains turpentine substitute which is
flammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep
flames away during the drying period.
Do not weld near the affected area during the drying
period. Take the same precautions as for oil to keep
Waxoyl off your skin. Do not breathe the fumes. Apply
in a well-ventilated area.
5-3-1-9
!MWARNING
Certain seals and gaskets (e.g. crankshaft oil seal) on
JCB machines contain fluoroelastomeric materials
such as Viton, Fluorel and Technoflon.
Fluoroelastomeric materials subjected to high
temperatures can produce highly corrosive
hydrofluoric acid. THIS ACID CAN SEVERELY BURN.
New fluoroelastomeric components at ambient
temperature require no special safety precautions.
Used fluoroelastomeric components whose
temperatures have not exceeded 300°C (572°F) require
no special safety precautions. If evidence of
decomposition (e.g. charring) is found, refer to the
next paragraph for safety instructions DO NOT TOUCH
COMPONENT OR SURROUNDING AREA.
Used fluoroelastomeric components subjected to
temperatures greater than 300°C (572°F) (e.g. engine
fire) must be treated using the following safety
procedure. Make sure that heavy duty gloves and
special safety glasses are worn:
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.
3 Contain all removed material, gloves etc. used in
this operation in sealed plastic bags and dispose
of in accordance with Local Authority
Regulations.

2 - 11 9803/8040-1 2 - 11
 Section 2 - Care and Safety
Safety Check List
Maintenance Safety
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
!MWARNING
If contamination of skin or eyes occurs, wash the Counterweights
affected area with a continuous supply of clean water Your machine may be fitted with counterweights. They
or with calcium hydroxide solution for 15-60 minutes. are extremely heavy. Do not attempt to remove them.
Get medical attention immediately. INT-3-2-5
INT-3-3-5_2

!MWARNING
!MWARNING Turning the Engine
Protect your eyes when grinding metal. Wear safety Do not try to turn the engine by pulling the fan or fan
glasses or goggles. Remove or protect any belt. This could cause injury or premature component
combustible materials from the area which could be failure.
ignited by sparks. 0094
GEN-1-12

!MWARNING
!MWARNING Accumulators
To avoid burning, wear protective gloves when The accumulators contain hydraulic fluid and gas at
handling hot components. To protect your eyes, wear high pressure. Prior to any work being carried out on
goggles when using a wire brush to clean systems incorporating accumulators, the system
components. pressure must be exhausted by a JCB distributor, as
HYD-1-3 the sudden release of the hydraulic fluid or gas may
cause injury.
!MWARNING INT-3-1-17

Arc Welding
To prevent the possibility of damage to electronic
components, disconnect the battery and the alternator
before arc-welding on the machine or attached
implements.
If the machine is equipped with sensitive electrical
equipment, i.e. amplifier drivers, electronic control
units (E.C.U.s), monitor displays, etc., then disconnect
them before welding. Failure to disconnect the
sensitive electrical equipment could result in
irreparable damage to these components.
Parts of the machine are made from cast iron; welds
on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable or
apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to the
same component that is being welded, i.e. boom or
dipper, to avoid damage to pivot pins, bearings and
bushes. Attach the welder earth (ground) cable no
more than 0.6 metres (2 feet) from the part being
welded.
INT-3-1-15_2
!MWARNING
An exploding tyre can kill. Inflated tyres can explode if
over-heated or over-inflated. Follow the instructions
given when inflating the tyres. Do not cut or weld the
rims. Use a tyre/wheel specialist for all repair work.
2-3-2-7_2
!MWARNING
Jacking
A machine can roll off jacks and crush you unless the
wheels have been chocked. Always chock the wheels
at the opposite end of the machine that is to be jacked.
Do not work underneath a machine supported only by
jacks. Always support a jacked-up machine on axle
stands before working underneath it.
INT-3-2-8
!MWARNING
Under no circumstances must the engine be run with
the transmission in gear and only one driving wheel
jacked clear of the ground, since the wheel on the
ground will move the machine.
INT-3-1-16

2 - 12 9803/8040-1 2 - 12

!MWARNING
Wheels and tyres are heavy. Take care when lifting or
moving them.
Store with care to ensure that they cannot fall and
cause injury.
13-3-1-7_1
!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.
13-3-2-16
!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.
TRANS-8-5
!MCAUTION
Never use water or steam to clean inside the cab. The
use of water or steam could damage the on-board
computer and render the machine inoperable. Remove
dirt using a brush or damp cloth.
8-3-4-8
2 - 13 9803/8040-1
Section 2 - Care and Safety
Safety Check List
Maintenance Safety
!MWARNING
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.
0091
!MWARNING
Radar Speed Sensor (if fitted)
To avoid possible eye damage from microwave
signals do not look directly into the sensor face.
13-1-1-15
!MWARNING
Always renew brake pads and locating pins in
complete axle sets, using genuine JCB parts,
otherwise braking will be unsafe.
13-3-1-10
!MWARNING
Before working on or around the brake system, always
observe the following precautions:
1 Stop the engine and block all four wheels.
2 When the air system is being exhausted, keep
hands away from the park brake actuator pushrod
and caliper, as they may move and trap your
fingers.
3 Take care if disconnecting an air hose containing
pressure as it may whip as air escapes.
4 Never remove or dismantle a component until air
pressure has been exhausted and you have read
and understood the recommended procedures.
5 Never remove or dismantle a component until air
pressure has been exhausted and you have read
and understood the recommended procedures.
BRAK-8-3_1
2 - 13
 Section 2 - Care and Safety
Safety Check List
Maintenance Safety

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

13-3-2-15

2 - 14 9803/8040-1 2 - 14
 Section 3 - Maintenance

3-0 9803/8040-6 3-0

 Section 3 - Maintenance

Contents Page No.

Routine Maintenance
Service Requirements ............................................................................. 3 - 1
Introduction ......................................................................................... 3 - 1
Owner/Operator Support .................................................................... 3 - 1
Service/Maintenance Agreements ..................................................... 3 - 1
Initial Service and Inspection (100 Hours) .......................................... 3 - 1
Obtaining Replacement Parts ............................................................. 3 - 2
Health and Safety .................................................................................... 3 - 3
Lubricants ........................................................................................... 3 - 3
Battery ................................................................................................ 3 - 5
First Aid - Electrolyte .......................................................................... 3 - 5
Service Schedules ................................................................................... 3 - 7
How to Use the Service Schedules .................................................... 3 - 7
Service Schedule Tables .................................................................... 3 - 8
Fluids, Lubricants and Capacities .......................................................... 3 - 14
Coolant Mixtures .............................................................................. 3 - 15
Cleaning the Machine ............................................................................ 3 - 16
Checking for Damage ............................................................................ 3 - 17
Seats and Seat Belts ............................................................................. 3 - 18
Seats ................................................................................................ 3 - 18
Checking the Seat Belt Condition and Security ................................ 3 - 18
Checking the ROPS Structure ............................................................... 3 - 19
Bonnet ................................................................................................... 3 - 20
Opening the Bonnet ......................................................................... 3 - 20
Closing the Bonnet ........................................................................... 3 - 20
Greasing ................................................................................................ 3 - 21
General Information .......................................................................... 3 - 21
Propshafts and Rear PTO Drive Shaft .............................................. 3 - 22
Front 3-Point Linkage (Optional) ...................................................... 3 - 23
Front Axle Steering Swivels .............................................................. 3 - 24
Steering Column Universal Joints .................................................... 3 - 25
Rear Suspension Cylinder Pivots ..................................................... 3 - 26
Hydraulic Lift and 3-Point Linkage .................................................... 3 - 27
Pick-up Hitch .................................................................................... 3 - 28
Automatic Trailer Coupling (if fitted) ................................................. 3 - 29
Air Conditioning and Heater .................................................................. 3 - 30
Air Conditioning Filters ..................................................................... 3 - 30
Cleaning the Heater Filter ................................................................ 3 - 32
Adjusting the Compressor Belt ......................................................... 3 - 33
Brakes ................................................................................................... 3 - 34
Checking the Foot Brake Fluid Level ............................................... 3 - 34
Checking the Trailer Air Tank ........................................................... 3 - 35
Checking and Renewing Foot Brake Pads ....................................... 3 - 36
Checking the Park Brake Pads ........................................................ 3 - 38
Renewing the Park Brake Pads ....................................................... 3 - 38
Electrical System ................................................................................... 3 - 40
Battery .............................................................................................. 3 - 40
Jump-starting the Engine ................................................................. 3 - 41
Fuses ................................................................................................ 3 - 43
Relay Identification ........................................................................... 3 - 45
Checking the Beam Alignment ......................................................... 3 - 47

3-i 3-i
 Section 3 - Maintenance
Contents

Contents Page No.

Engine ................................................................................................... 3 - 48
Changing the Air Filter Elements ...................................................... 3 - 48
Checking the Oil Level ..................................................................... 3 - 50
Changing the Oil and Filter ............................................................... 3 - 51
Checking the Crankcase Breather Tube .......................................... 3 - 53
Cooling System ..................................................................................... 3 - 54
Checking the Coolant Level ............................................................. 3 - 54
Changing the Coolant Filter .............................................................. 3 - 55
Draining and Refilling the Coolant .................................................... 3 - 56
Cleaning the Radiator and Coolers .................................................. 3 - 58
Fan Belt ............................................................................................ 3 - 59
Fuel System ........................................................................................... 3 - 61
Types of Fuel .................................................................................... 3 - 61
Filling the Tank ................................................................................. 3 - 62
Draining the Fuel Filter ..................................................................... 3 - 63
Changing the Fuel Filter Elements ................................................... 3 - 64
Hydraulic System ................................................................................... 3 - 65
Checking the Fluid Level .................................................................. 3 - 65
Changing the Filter Element ............................................................. 3 - 66
Changing the Hydraulic Fluid and Cleaning the Suction Strainers ... 3 - 68
Emptying the Hydraulic Coupling Drain Reservoirs ......................... 3 - 70
Transmission ......................................................................................... 3 - 71
Checking the Transmission Oil Level ............................................... 3 - 71
Changing the Transmission Oil Filter ............................................... 3 - 72
Changing the Transmission Oil and Strainer .................................... 3 - 73
Checking the Clutch Fluid Level ....................................................... 3 - 74
Axles ...................................................................................................... 3 - 75
Front Axle ......................................................................................... 3 - 75
Rear Axle and PTO .......................................................................... 3 - 78
Tyres and Wheels .................................................................................. 3 - 81
General ............................................................................................. 3 - 81
Wheel and Tyre Replacement .......................................................... 3 - 81
Checking Wheel Nut Torques ........................................................... 3 - 81
Tyre Inflation ..................................................................................... 3 - 82
Checking and Adjusting the Front Wheel Alignment ........................ 3 - 83
Fender Adjustment ........................................................................... 3 - 84
Power Take-off (PTO) ............................................................................ 3 - 85
Front PTO ......................................................................................... 3 - 85
Rear PTO ......................................................................................... 3 - 86
Windscreen Washer .............................................................................. 3 - 87
Checking Fluid Level ........................................................................ 3 - 87
Automatic Trailer Coupling (Optional) ................................................... 3 - 88
Checking for Wear ............................................................................ 3 - 88

3 - ii 3 - ii

Routine Maintenance
Service Requirements
Introduction
T3-002
Your machine has been designed and built to give
maximum performance, economy and ease of use under a
wide variety of operating conditions. Prior to delivery, your
machine was inspected both at the Factory and by your
Distributor to ensure that it reaches you in optimum
condition. To maintain this condition and ensure trouble
free operation it is important that the routine services, as
specified in this Manual, are carried out by an approved
JCB Distributor at the recommended intervals.
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.
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.
A Service Record Sheet or Book is provided which will
enable you to plan your service requirements and keep a
service history record. It should be dated, signed and
stamped by your Distributor each time your machine is
serviced.
Remember, if your machine has been correctly
maintained, not only will it give you improved reliability but
its resale value will be greatly enhanced.
Owner/Operator Support
JCB together with your Distributor wants you to be
completely satisfied with your new JCB machine. If you do
encounter a problem however, you should contact your
3-1 9803-8040-6
Section 3 - Maintenance
Distributor's Service Department who are there to help
you!
You will have been given the names of the relevant service
contacts at your Distributor when the machine was
installed.
To get the most from your Distributor please help them to
satisfy you by:
1 Giving your name, address and telephone number.
2 Quoting your machine model and serial number.
3 Date of purchase and hours of work.
4 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.
Service/Maintenance Agreements
To help plan and spread the costs of maintaining your
machine, we strongly recommend you take advantage of
the many Service and Maintenance Agreements your
Distributor can offer. These can be tailor made to meet
your operating conditions, work schedule etc.
Please consult your JCB Distributor for details.
Initial Service and Inspection (100
Hours)
T3-005
To further protect your machine's performance it is
essential your JCB Distributor carries out an initial service
and inspection when the machine is one month old or
when it has completed 100 hours of operation (whichever
occurs first). You should notify your Distributor in advance
to allow the necessary arrangements to be made.
3-1
 Section 3 - Maintenance
Routine Maintenance
Service Requirements

Obtaining Replacement Parts

T3-004_2

We recommend you fit only JCB Genuine Parts. A Parts

Book will help you identify parts and order them from your
JCB distributor.

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

The data plate also shows the serial numbers of the

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

3-2 9803-8040-6 3-2

 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
Introduction engine oil into sewers, drains or on the ground.

It is most important that you read and understand this Handling

information and the publications referred to. Make sure all
your colleagues who are concerned with lubricants read it New Oil
too.
There are no special precautions needed for the handling
Hygiene or use of new oil, beside the normal care and hygiene
practices.
JCB lubricants are not a health risk when used properly for
their intended purposes. Used Oil

However, excessive or prolonged skin contact can remove
the natural fats from your skin, causing dryness and
irritation.
Low viscosity oils are more likely to do this, so take special
care when handling used oils, which might be diluted with
fuel contamination.
Whenever you are handling oil products you should
maintain good standards of care and personal and plant
hygiene. For details of these precautions we advise you to
read the relevant publications issued by your local health
authority, plus the following.
Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled containers.
Waste Disposal
Used engine crankcase lubricants contain harmful
contaminants.
Here are precautions to protect your health when handling
used engine oil:
1 Avoid prolonged, excessive or repeated skin contact
with used oil.
2 Apply a barrier cream to the skin before handling
used oil. Note the following when removing engine oil
from skin:
a 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.

!MCAUTION 3 Avoid skin contact with oil soaked clothing.

It is illegal to pollute drains, sewers or the ground. 4 Don't keep oily rags in pockets.
Clean up all spilt fluids and/or lubricants.
5 Wash dirty clothing before re-use.
Used fluids and/or lubricants, filters and contaminated
materials must be disposed of in accordance with 6 Throw away oil-soaked shoes.
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 9803-8040-6 3-3

 Section 3 - Maintenance
Routine Maintenance
Health and Safety
First Aid - Oil

Eyes

In the case of eye contact, flush with water for 15 minutes.

If irritation persists, get medical attention.

Swallowing

If oil is swallowed do not induce vomiting. Get medical

advice.

Skin

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

water.

Spillage

Absorb on sand or a locally approved brand of absorbent

granules. Scrape up and remove to a chemical disposal
area.

Fires

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

Extinguish oil and lubricant fires with carbon dioxide,

dry chemical or foam. Fire fighters should use self
contained breathing apparatus.
7-3-1-3_1

3-4 9803-8040-6 3-4

 Section 3 - Maintenance
Routine Maintenance
Health and Safety

Battery Warning Symbols

!MWARNING The following warning symbols may be found on the

battery.
Batteries give off an explosive gas. Do not smoke
when handling or working on the battery. Keep the Symbol Meaning
battery away from sparks and flames.
Keep away from children.
Battery electrolyte contains sulphuric acid. It can burn
you if it touches your skin or eyes. Wear goggles.
Handle the battery carefully to prevent spillage. Keep
metallic items (watches, rings, zips etc) away from the
battery terminals. Such items could short the Shield eyes.
terminals and burn you.

Set all switches in the cab to OFF before

disconnecting and connecting the battery. When
disconnecting the battery, take off the earth (-) lead
first. No smoking, no naked flames, no sparks.

Re-charge the battery away from the machine, in a well

ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you
have installed the battery in the machine, wait five
Explosive Gas.
minutes before connecting it up.

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

First Aid - Electrolyte

Battery acid.
Do the following if electrolyte:

GETS INTO YOUR EYES

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

IS SWALLOWED

Do not induce vomiting. Drink large quantities of water or

milk. Then drink milk of magnesia, beaten egg or vegetable
oil. Get medical help.
!MCAUTION
Do not disconnect the battery while the engine is
GETS ONTO YOUR SKIN running, otherwise the electrical circuits may be
damaged.
Flush with water, remove affected clothing. Cover burns INT-3-1-14
with a sterile dressing then get medical help.

5-3-4-3_1

3-5 9803-8040-6 3-5

 Section 3 - Maintenance
Routine Maintenance
Health and Safety

!MWARNING
Electrical Circuits
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
INT-3-1-4

!MDANGER
Electrolyte
Battery electrolyte is toxic and corrosive. Do not
breathe the gases given off by the battery. Keep the
electrolyte away from your clothes, skin, mouth and
eyes. Wear safety glasses.
INT-3-2-1_3

!MCAUTION
Damaged or spent batteries and any residue from fires
or spillage should be put in a closed acid proof
receptacle and must be disposed of in accordance
with local environmental waste regulations.
INT-3-1-12

!MWARNING
Battery Gases
Batteries give off explosive gases. Keep flames and
sparks away from the battery. Do not smoke close to
the battery. Make sure there is good ventilation in
closed areas where batteries are being used or
charged. Do not check the battery charge by shorting
the terminals with metal; use a hydrometer or
voltmeter.
INT-3-1-8

3-6 9803-8040-6 3-6

 Section 3 - Maintenance
Routine Maintenance
Service Schedules

Service Schedules

A badly maintained machine is a danger to the operator

and the people working around him. Make sure that the
regular maintenance and lubrication jobs listed in the
service schedules are done to keep the machine in a safe
and efficient working condition.

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

To prevent anyone starting the engine, remove the

starter key. Disconnect the battery and block the
wheels when you are working beneath the machine.

If you do not take these precautions you could be

killed or injured.
9-3-1-1

Apart from the daily jobs, the schedules are based on

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

If the machine is operating in ambient temperatures below

-18°C [0°F] or above 38°C [100°F], change engine oil and
filter, air and fuel filters at shorter intervals. Shorter
maintenance intervals are also required if the machine is
operated in a dusty environment or if frequent stops are
made.

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

How to Use the Service Schedules

T3-012_2

In the example shown, A shows all service requirements to

be carried out every 10 hours and B shows the
requirements to be carried out every 500 hours.

3-7 9803-8040-6 3-7

 Section 3 - Maintenance
Routine Maintenance
Service Schedules

Service Schedule Tables

Pre-start Cold Checks, Service Points Operation 10 Hr 50 Hr 100 500 1000 2000 4000 5000
and Fluid Levels Hr(1) Hr Hr Hr Hr Hr
ENGINE
Oil level - Check … …
Oil and Filter (2) - Change … … … … … …
Air Cleaner Outer Element (3) - Change … … … …
Air Cleaner Inner Element - Change … …
Air Cleaner Hose and Clamp Security - Check … … … … … … … …
Air Compressor Mountings (4) - Check … … … … …
Air Compressor Discharge Lines (4) - Check … …
Fuel Filter - Drain … … …
Fuel Filter - Change … … … … …
Coolant Level - Check … … … … …
Coolant Antifreeze and Coolant Additive - Check … … … … … …
Concentration(4)
Coolant - Change … …
Coolant Filter - Change … … … … …
Fan Belt Condition - Check … … … … … … … …
Fan Hub (4) - Check … … … …
Fan Belt Tensioner (4) - Check … … … …
Vibration Damper (4) - Check … …
Valve Clearances (4) - Check and …
Adjust
Crankcase Breather Tube - Check … … … … … … … …
Air Conditioning Compressor Belt Tension - Check … … … … … … …
and Condition
Engine Mounting Bolts for Tightness(4) - Check … …
Fuel Injection Pump Mounting Bolts for - Check … … … … …
Tightness(4)
Radiator and Coolers - Clean … … … … … … … …
Charge Air Cooler Hose and Clamp Security - Check … … … … … … … …
Charge Air Cooler - Check … … … … …
Turbocharger(4) - Check … … … …

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 Section 3 - Maintenance
Routine Maintenance
Service Schedules

Pre-start Cold Checks, Service Points Operation 10 Hr 50 Hr 100 500 1000 2000 4000 5000
and Fluid Levels Hr(1) Hr Hr Hr Hr Hr
Engine - Steam Clean … …
TRANSMISSION, AXLES AND STEERING
Transmission Oil Level - Check … … … …
Transmission Oil(5) - Change … … … …
Transmission Strainer (4) - Change … … … …
Transmission Filter - Change … … … … …
Clutch Fluid Level - Check
Axle Oil Level (incl. Hubs) (6) - Check …
Axle Oil (incl. Hubs) (7) - Change … … … … …
Tyre Pressures/Condition - Check … … … … … … … …
Oil Cooler and Pipework - Check and … … … … … …
Clean
Front PTO Gearbox Oil Level - Check …
Front PTO Gearbox Oil - Change … … … … … …
Front PTO Gearbox Oil Filter - Clean … … … … … …
Propellor Shafts - Security/ … … … … … … …
Grease
Steer Axle Pivots - Grease … … … … … … …
Steering Column Universal Joints - Grease … … … … … … …
Steering Axle Wheel Alignment - Check … … … … …
Drag Link, Track Rod End, Steering Ram - Check … … … … …
and Damper Condition and Security(4)
Wheel Nut Security - Check … … … … … … … …
HYDRAULICS
Oil Level - Check … … … … … …
Oil(4) - Sample/ … …
Change
Oil Filter - Change … … … … … …
Hydraulic System - Check for … … … … … … … …
Leaks
Hydraulic Lift and 3 Point Linkage, Front and - Grease … … … … … … …
Rear
Rear 3 Point Linkage Cross-shaft Oil level - Check …
Ram Piston Rods Condition - Check … … … … …

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 Section 3 - Maintenance
Routine Maintenance
Service Schedules

Pre-start Cold Checks, Service Points Operation 10 Hr 50 Hr 100 500 1000 2000 4000 5000
and Fluid Levels Hr(1) Hr Hr Hr Hr Hr
Hydraulic Oil Cooler and Pipework - Check and … … … … …
Clean
Hydraulic Oil Strainer - Clean … …
Hydraulic Coupling Drain Reservoir - Empty … … … … … … … …
Security of Front Weight - Check … … … … … … … …
BRAKES
Air System Tank - Drain … … … … … … … …
Air System Drier Canister (4) - Change … … … …
Trailer Brake Control Line Air Filter(4) - Clean … … … …
Brake System Fluid Level - Check … … … … … …
Brake System Fluid - Change … …
Park Brake - Check and … … … … … …
Adjust
Park Brake Pad Condition and Security - Check … … … … … … …
Service Brake Pad Condition and Security - Check … … … … … … …
Calliper Bolt Torque(4) - Check … … … … …
Pipework Security - Check … … … … …
ELECTRICS
Battery Electrolyte Level (if applicable) - Check … … … … …
Wiring for Chaffing/Routing - Check … … … … … … …
Battery Terminals for Condition and - Check … … … … … …
Tightness
Battery Charge Condition(4) - Check … … … … … …
Headlamp Alignment - Check … … … … … …
BODY AND FRAMEWORK
Bonnet Hinges - Lubricate … … … … …
Seat Belt Condition and Security - Check … … … … … … … …
Air Conditioning Condensor - Clean … … … … … … … …
ROPS Structure(4) - Check … … … … …
Cab Air Intake Filter (standard type only)(8) - Clean … … … … …
Door Locks - Check …
Windscreen Washer Fluid Level - Check … … … … … … … …
Condition of Paintwork - Check … … … … … …

3 - 10 9803-8040-6 3 - 10
 Section 3 - Maintenance
Routine Maintenance
Service Schedules

Pre-start Cold Checks, Service Points Operation 10 Hr 50 Hr 100 500 1000 2000 4000 5000
and Fluid Levels Hr(1) Hr Hr Hr Hr Hr
Machine Generally - Check and … … … … … … … …
Clean
Automatic Trailer Coupling (if fitted) - Grease … … … … … … …
SUSPENSION
Cylinder Pivots - Grease … … … … … … …
Panhard Rod Condition and Torque - Check … … … … … …
Tightness(4)
Control Arms Condition and Torque - Check … … … … …
Tightness(4)
`V' Link Condition and Torque Tightness(4) - Check … … … … …
Accumulator Pressure(4) - Check … …
Gas Spring Pressure(4) - Check … …

(1) First 100 Hours Service only, to be completed by your JCB Distributor.
(2) Applies only if recommended oil is available. If this is not available, this job should be carried out every 250 hours. See
Fluids, Lubricants and Capacities for suitable alternative oil.
(3) If operating in dusty working environments, change more frequently.
(4) Jobs which should only be done by a specialist.
(5) After a major transmission repair, the new oil should be run to operating temperature and changed again to remove any
contamination which entered during the repair. Change the oil and filter after a further 100 hours if the oil was heavily
contaminated because of, or from the failure (e.g. water contamination).
(6) Check for leaks every 50 hours, check level if leaking.
(7) After a hub repair, the new oil should be run to operating temperature and changed again to remove any contamination
which entered during the repair. Change the oil again after a further 100 hours to remove any bedding-in wear. This is
particularly important if new brake plates have been fitted.
(8) Heavy duty carbon type filters must be changed at 250 hour intervals.

3 - 11 9803-8040-6 3 - 11
 Section 3 - Maintenance
Routine Maintenance
Service Schedules

Functional Test and and Final Inspection Operation 10 Hr 50 Hr 100 500 Hr 1000 2000
Hr(1) Hr Hr
ENGINE
Idle Speed(2) - Check … … …
Maximum No Load Speed(2) - Check … … …
Exhaust System Security(2) - Check … … … …
Cooling System for Leaks - Check … … … … … …
Fuel System for Leaks and Contamination - Check … … … … … …
Lubrication System for Leaks - Check … … … … … …
Stop Control - Check … … … … … …
TRANSMISSION, AXLES AND STEERING
2WD/4WD/Differential Lock Selection - Check … … … …
Oil Leakage - Check … … … … … …
Transmission Lubrication Pressure (2) - 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 - Check … … … … … …
Ranges
Steering Operation - Check … … … … … …
Steering Pressure Relief Valve (2) - Check … … …
HYDRAULICS
Maximum System Pressure(2) - Check and Adjust … … …
Operation All Services - Check … … … … … …
System for Oil Leakage - Check … … … … … …
Oil Cooler and Pipework for Damage or - Check … … … …
Leakage
BRAKES
Foot Brake - Operation - Check … … … … … …
Park Brake - Operation - Check … … … … … …
Air System Warning Lights - Check … … … …
ABS(2) - System Test … … …

3 - 12 9803-8040-6 3 - 12
 Section 3 - Maintenance
Routine Maintenance
Service Schedules

Functional Test and and Final Inspection Operation 10 Hr 50 Hr 100 500 Hr 1000 2000
Hr(1) Hr Hr
ELECTRICS
Starter Motor - Check … … … …
Alternator - Output (2) - Check … … … …
All Electrical Equipment Operation, (e.g. - Check … … … … … …
warning lights, beacon, alarms, horn, wipers
etc.)
Error Codes for all systems, Engine, ABS, - Download and … … … …
Electronic Draft Control, Transmission(2) Rectify
EMS Datalog(2) - Download and … … … …
Rectify
Brake Light Switch Input to ABS ECU using - Check … … …
computer diagnostic tool(2)
SUSPENSION
Circuit Pressure(2) - Check … … …
Rear Axle to Chassis Clearance(2) - Check … … … …
Ride Height and Corrector Valve - Check … … … …
Operation(2)

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

3 - 13 9803-8040-6 3 - 13
 Section 3 - Maintenance
Routine Maintenance
Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities

Note: New engines DO NOT require a running-in period.
The engine/machine should be used in a normal work
cycle immediately, glazing of the piston cylinder bores,
resulting in excessive oil consumption, could occur if the
engine is gently run-in. Under no circumstances should the
engine be allowed to idle for extended periods; (e.g.
warming up without load). Whilst 15W/40 oil is
recommended for most climates, limited use of low
viscosity oils such as 10W/30 is permitted to provide easier
starting and sufficient oil flow at temperatures below -5ºC
(23ºF). Continued use of low viscosity oils can decrease
engine life and will require different service intervals.
K Service Schedules ( T 3-7)

Table 1.
ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL
SPECIFICATION
Litres UK Gal
Fuel Tank 577 127 Diesel Oil ASTM D975-66T Nos. 1D,
2D
Engine (Oil) 24 5.3 JCB Engine Oil EP 15W/40 (-20 to +40 deg C) API CH-4 or ACEA E3/
B3A3, SAE15W/40(1)
Engine (Coolant) 33 7.7 JCB High Performance Antifreeze & Inhibitor/ ASTM D6210
Water K Coolant Mixtures ( T 3-15)
Transmission 75 16.5 JCB V-Tronic Transmission Fluid ZF TE-ML06, B and C
Rear 3 Point Linkage 0.2 0.04 JCB V-Tronic Transmission Fluid ZF TE-ML06, B and C
Cross-shaft
Clutch 0.5 0.1 JCB V-Tronic Clutch Fluid Pentosin CHF 11S
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 JCB Brake Fluid Dot 4 SAE J1703 DOT 4
- Front 0.75 0.2
- Rear 0.75 0.20
Hydraulic System(2) 180 40 JCB Hydraulic Fluid HP46 ISO VG46
(Above 38ºC,100ºF)
JCB Hydraulic Fluid HP32 ISO VG32
(Below 38ºC,100ºF)
Grease Points JCB HP Grease Lithium complex NLGI No.2
consistency including
extreme pressure additives
Front PTO Gearbox 7 1.5 JCB HP Universal ATF ZF TE-MIL 09,11,12,14
(optional)

(1) If API CH-4 or ACEA E3/B3A3 engine oil AT SAE 15W/40 is not available, the engine oil must be changed at 250 hours,
using the following alternative oils: For -20ºC to +40ºC: JCB Engine Oil HP15W/40 or for -25ºC to +30 ºC: JCB Engine
Oil HP10W/30.
(2) The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank

3 - 14 9803-8040-6 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 9803-8040-6 3 - 15
 Section 3 - Maintenance
Routine Maintenance
Cleaning the Machine

Cleaning the Machine

!MWARNING
When using a steam cleaner, wear safety glasses or a
face shield as well as protective clothing. Steam can
cause serious personal injury.
13-3-2-10

Clean the machine using water and/or steam. Pay

particular attention to the underside. Do not allow mud to
build up on the engine and transmission. Make sure that
the radiator grille is not clogged up.

Excessive power washing can cause damage to seals,

bearings and electrical connections. Do not direct high
power water jets at oil seals, universal joints or electrical
components and wiring.

Take special care to avoid directing high power water jets

at the electrical connections to the front and rear axle ABS
sensors.

3 - 16 9803-8040-6 3 - 16
 Section 3 - Maintenance
Routine Maintenance
Checking for Damage

Checking for Damage

1 Inspect steelwork for damage. Note damaged

paintwork and repair.

2 Make sure all pivot pins are correctly in place and

secured by their locking devices.

3 Ensure that the steps and handrails are undamaged

and secure.

4 Check for broken or cracked window glass. Replace

damaged items.

5 Check all lamp lenses for damage.

6 Inspect the tyres for damage and penetration by

sharp objects.

7 Check that all safety decals are in place and

undamaged. Fit new decals where necessary.

3 - 17 9803-8040-6 3 - 17
 Section 3 - Maintenance
Routine Maintenance
Seats and Seat Belts

Seats and Seat Belts

Seats If required, the cushion and backrest can be removed for

cleaning by removing screws B.
Make sure that the seat mounting bolts are tight.

Keep the seat slide runners lightly greased.

!MWARNING
Check driver's seat for correct operation, ensuring that it Take care with the backrest frame. It may jerk forward
can be moved and locked into all positions and can be and cause injury.
raised and lowered. If any parts are faulty, repairs should 13-3-2-9
be done by a JCB dealer.
Checking the Seat Belt Condition and
Keep the upholstery clean, using a commercially available
upholstery or plastic cleaner. Test first for compatibility on
Security
T3-008
a small concealed area of the seat.
!MWARNING
During cleaning, the upholstery should not be soaked
through. 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.

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

Check that the belt mounting bolts are undamaged,

correctly fitted and tightened.

Fig 1.

3 - 18 9803-8040-6 3 - 18
 Section 3 - Maintenance
Routine Maintenance
Checking the ROPS Structure

Checking the ROPS Structure

!MWARNING
You could be killed or seriously injured if you operate
a machine with a damaged or missing ROPS/FOPS. If
the Roll Over Protection Structure (ROPS)/Falling
Objects Protection Structure (FOPS) has been in an
accident, do not use the machine until the structure
has been renewed. Modifications and repairs that are
not approved by the manufacturer may be dangerous
and will invalidate the ROPS/FOPS certification.
INT-2-1-9_6

Check the structure for damage.

Check that the four mounting bolts are installed and

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

Fig 2.

3 - 19 9803-8040-6 3 - 19
 Section 3 - Maintenance
Routine Maintenance
Bonnet

Bonnet

Opening the Bonnet 3 To remove the side panels, pull at the rear edge of the
panel and lift out the panel from its location at the
front.
!MWARNING
Engine Closing the Bonnet
The engine has exposed rotating parts. Do not open
the engine cover while the engine is running. Do not 1 To fit the side panels, locate the front edge of the
use the machine with the cover open. panel and then push the rear edge of the panel firmly
INT-2-1-6_1 into position.

1 Engage the park brake, put the transmission in 2 Pull the bonnet down by means of the cable, push the
neutral, stop the engine. Remove the starter key. bonnet down, make sure it is locked in place.

Fig 3.

2 Release the latch by pulling up handle A.

The bonnet will automatically open and be supported

on gas struts.

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

3 - 20 9803-8040-6 3 - 20
 Section 3 - Maintenance
Routine Maintenance
Greasing

Greasing

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

Note: If working in muddy conditions the propshafts and

PTO driveshafts must be greased daily.

Note: The machine must always be greased after

pressure-washing or steam cleaning. Extra care must be
taken to ensure that propshaft universal joints and splines
are greased regularly

Greasing should be done with a grease gun. Normally, two

strokes of the gun should be enough. Stop greasing when
fresh grease appears at the joint. Use only JCB HP
Grease.

In the following illustrations the grease points are

numbered. Count them off as you grease them.

Refit the grease point dust caps after greasing.

3 - 21 9803-8040-6 3 - 21
 Section 3 - Maintenance
Routine Maintenance
Greasing

Propshafts and Rear PTO Drive Shaft Front axle propshaft

!MWARNING Grease points 5 to 6

Make the machine safe before getting beneath it. Park

the machine on level ground and lower the
attachments. Stop the engine and remove the starter
key. Make sure the park brake is engaged. Disconnect
the battery to prevent the engine being started. Block
all four wheels before getting under the machine.
3-3-1-1

Note: When greasing the universal joints, you must ensure

that grease appears at all four bearing caps. If grease does
not appear at any cap, move the shaft from side to side and
then re-grease. Wipe away all excess grease.

1 2
Fig 5.

3 4
Fig 4. Fig 6.

Rear PTO drive shaft

Grease points 1 to 2

Rear axle propshaft

Grease points 3 to 4

3 - 22 9803-8040-6 3 - 22
 Section 3 - Maintenance
Routine Maintenance
Greasing

Front 3-Point Linkage (Optional)

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

Block all four wheels before getting under the

machine.
2-3-2-1

.K General Information ( T 3-21)

Grease at points 1 to 6.

Fig 7.

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 Section 3 - Maintenance
Routine Maintenance
Greasing

Front Axle Steering Swivels .K General Information ( T 3-21)

!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
Grease points 1 to 4.
Note: After initial greasing, turn the wheels from lock to
lock, then grease again to ensure full penetration.
!MWARNING
When gaining access for maintenance work, make
sure no-one is in a position to be trapped by the
wheels as the steering wheel is turned.
13-3-2-15

Fig 8.

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 Section 3 - Maintenance
Routine Maintenance
Greasing

Steering Column Universal Joints .K General Information ( T 3-21)

Note: It may be necessary to turn the steering wheel to put

!MWARNING the grease nipples in an accessible position.
You will be working close into the machine for these
jobs. Lower the attachments if possible. Remove the
starter key and disconnect the battery. This will
!MWARNING
prevent the engine being started. Make sure the park When gaining access for maintenance work, make
brake is engaged. sure no-one is in a position to be trapped by the
wheels as the steering wheel is turned.
Block all four wheels before getting under the 13-3-2-15
machine.
Grease at point 1 from underneath the machine.
2-3-2-1

Grease at points 2 to 4 from under the bonnet.

Fig 9.

3 - 25 9803-8040-6 3 - 25
 Section 3 - Maintenance
Routine Maintenance
Greasing

Rear Suspension Cylinder Pivots .K General Information ( T 3-21)

Grease points 1 to 4.
!MWARNING
You will be working close into the machine for these
jobs. Lower the attachments if possible. Remove the
starter key and disconnect the battery. This will
prevent the engine being started. Make sure the park
brake is engaged.

Block all four wheels before getting under the

machine.
2-3-2-1

1 4

2 3
+ -

+ -

+ -

+ -

Fig 10.

3 - 26 9803-8040-6 3 - 26
 Section 3 - Maintenance
Routine Maintenance
Greasing

Hydraulic Lift and 3-Point Linkage .K General Information ( T 3-21)

Hydraulic lift rams

!MWARNING
You will be working close into the machine for these Grease points 1 to 4.
jobs. Lower the attachments if possible. Remove the
starter key and disconnect the battery. This will Three point linkage lift rods
prevent the engine being started. Make sure the park
brake is engaged. Grease at nipples 5 to 10 (lift collars A and B to access
nipples 9 and 10).
Block all four wheels before getting under the
machine.
2-3-2-1

+ -

+ -

+ -

+ -

1 3

5 7
6 8
9 10
A B

2 4

Fig 11.

3 - 27 9803-8040-6 3 - 27
 Section 3 - Maintenance
Routine Maintenance
Greasing

Pick-up Hitch .K General Information ( T 3-21)

Cross-Shafts
!MWARNING
You will be working close into the machine for these Grease points 1 to 4.
jobs. Lower the attachments if possible. Remove the
starter key and disconnect the battery. This will
prevent the engine being started. Make sure the park
brake is engaged.

Block all four wheels before getting under the

machine.
2-3-2-1

Fig 12.

3 - 28 9803-8040-6 3 - 28
 Section 3 - Maintenance
Routine Maintenance
Greasing

Automatic Trailer Coupling (if fitted)

.K General Information ( T 3-21)

Note: Whenever the coupling has been pressure-washed

it must always be greased.

Make sure the coupling is in the open position, i.e. the

coupling pin is up and the hand lever A is in its highest
position.

Grease at points 1 and 2.

Operate lever A several times so that the grease is

distributed throughout the bearing.

!MCAUTION
Keep your hands out of the funnel or you may be
injured by the coupling pin as it is forced down by its
spring.
13-2-2-17

Grease again and operate the hand lever again.

If driving without a trailer attached, close the coupling to

prevent dirt accumulation.
Fig 13.

3 - 29 9803-8040-6 3 - 29
 Section 3 - Maintenance
Routine Maintenance
Air Conditioning and Heater

Air Conditioning and Heater

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

3 Check and clean the filter sealing face on the cab

body.

4 Refit the pre-cleaner and fit the filter into the cab
aperture using two screws C. Refit the closing panel
B.

Fig 14.

Note: The air conditioning system contains

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

Note: For crop spraying applications or very dusty

conditions, a heavy duty carbon filter can be used in place
of the standard filter. Carbon filters must not be cleaned.
Keep a log of the hours used and change at 250 hour
intervals.

!MCAUTION
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6

1 Unscrew the two quarter-turn fasteners A and

remove closing panel B. Remove the two screws C
and pull out the filter D. Check condition of filter and
renew if split or worn.

3 - 30 9803-8040-6 3 - 30
 Section 3 - Maintenance
Routine Maintenance
Air Conditioning and Heater
Changing the Heavy Duty Carbon Filter

Note: Carbon filters must not be cleaned. Keep a log of the

hours used and change at 250 hour intervals.

!MCAUTION
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6

Fig 16.

2 The new filter is supplied with a separate foam seal K

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

3 Check and clean the seal contact face on the cab

body.

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

Fig 15.

1 Unscrew the two quarter-turn fasteners F and remove

closing panel G. Remove the two screws H and pull
out the filter J.

3 - 31 9803-8040-6 3 - 31
 Section 3 - Maintenance
Routine Maintenance
Air Conditioning and Heater

Cleaning the Heater Filter

!MCAUTION
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6

1 Pull out the fastener A and remove grille panel B.

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

filter if damaged.

3 If the filter is undamaged, use compressed air at a

maximum pressure of 5.5 bar (80 lbf/in2) to blow dirt
out of the filter in the opposite direction to the air flow
when the filter is installed.

4 Refit the filter into the cab aperture.

5 Refit the grille panel, making sure that the tongue D

engages in slot E.

Fig 17.

3 - 32 9803-8040-6 3 - 32
 Section 3 - Maintenance
Routine Maintenance
Air Conditioning and Heater

Adjusting the Compressor Belt

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

!MWARNING
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the
system should be disconnected until the system has
been discharged by a refrigeration engineer or a
suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
4-3-4-1_2

1 Stop the engine.

2 Open the bonnet.

3 Loosen fasteners A and B.

Fig 18.

4 Position the compressor so that there is 10 mm (0.4

in) slack on the longest run of the belt.

5 Retighten fasteners A and B.

3 - 33 9803-8040-6 3 - 33
 Section 3 - Maintenance
Routine Maintenance
Brakes

Brakes

Checking the Foot Brake Fluid Level

!MWARNING
If the brake fluid warning light comes on, check the
brake fluid level immediately.
13-3-1-2_1

!MWARNING
Faulty brakes can kill. If you have to top up the brake
reservoir frequently, get the brake system checked by
your JCB Dealer. Do not use the machine until the fault
has been put right.
2-3-2-5_1

!MCAUTION
Using incorrect fluid could damage the system. See
Fluids, Capacities and Lubricants for the correct fluid.
The fluid can harm your skin. Wear rubber gloves.
Cover cuts or grazes.
2-3-5-1_2

1 Unlock and turn handle A, lift the access door B and

engage the support stay.

2 Check the fluid level in the three reservoirs C, D and

E.

The fluid level should be between the two lines F and

G moulded into the side of each reservoir. If
necessary, add fluid as follows.

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

3 Add the specified brake fluid.

Clean the area around the filler cap J. Remove the Fig 19.
cap and carefully pour in the recommended fluid until
it reaches the correct level. Avoid spilling it. Wipe up
any spillage. Do not allow dirt to enter the reservoir.
Fit the cap securely.

Note: Do not use ordinary hydraulic fluid.

3 - 34 9803-8040-6 3 - 34
 Section 3 - Maintenance
Routine Maintenance
Brakes

Checking the Trailer Air Tank

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

2 Grip `keyring' fitting K at the bottom of tank L and pull

sideways until all water is expelled. The amount of
water released is a guide to the functioning of the air
dryer. If purging of water takes much longer than
about 5 seconds, or if oil is present, the system must
be checked by your JCB distributor.

Fig 20.

3 - 35 9803-8040-6 3 - 35
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