JCB 3230 FASTRAC Service Repair Manual SN：01272000-01272499.pdf
- 1. 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. World Class Customer Support 9803/9970-01 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual 3000 XTRA Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Hitches and Attachments Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine
- 2. Page No. Contents Section 1 - General Information 1-i 1-i Use Introduction ............................................................................................. 1-1-1 Scope ..................................................................................................... 1-1-2 Format .................................................................................................... 1-1-3 Left and Right Sides ............................................................................... 1-1-4 Hydraulic Schematic Codes ................................................................... 1-1-5 Machine Identification Introduction ............................................................................................. 1-2-1 Identifying your Machine ......................................................................... 1-2-2 Torque Settings Introduction ............................................................................................. 1-3-1 Zinc Plated Fasteners and Dacromet Fasteners .................................... 1-3-2 Hydraulic Connections ............................................................................ 1-3-6 `Positional Type' Hydraulic Adaptors .................................................... 1-3-10 Service Tools Numerical List ......................................................................................... 1-4-1 Tool Detail Reference ............................................................................. 1-4-6 Service Consumables Sealing and Retaining Compounds ........................................................ 1-5-1
- 3. Section 1-1 - General Information 1-1-1 1-1-1 9803/9970-01 (1-01-00) Use Introduction This topic contains information about the structure of the manual and how to use the manual. K Scope ( T 1-1-2) K Personnel ( T 1-1-2) K Applications ( T 1-1-2) K Newest Data ( T 1-1-2) K Format ( T 1-1-3) K Left and Right Sides ( T 1-1-4) K Hydraulic Schematic Codes ( T 1-1-5) K Colour Codes ( T 1-1-5)
- 4. Section 1-1 - General Information Use Scope 1-1-2 1-1-2 9803/9970-01 (1-01-00) Scope Personnel This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Finally, please remember above all else SAFETY MUST COME FIRST! Applications This manual contains data relevant to a range of machines. Make sure you reference the data for the correct machine. Newest Data From time to time new machines, systems or devices require the manual to be re-issued. Make sure you have the newest issue. Always check the on-line JCB data system for relevant technical information.
- 5. Section 1-1 - General Information Use Format 1-1-3 1-1-3 9803/9970-01 (1-01-00) Format The manual is compiled in sections, the first three are numbered and contain information as follows: 1 General Information - general information such as torque settings and service tools. 2 Care & Safety - includes warnings, cautions and general procedures related to aspects of workshop procedures contained in the manual. 3 Routine Maintenance - includes service schedules and recommended lubricants for all the machine. The remaining sections are alphabetically coded and deal with dismantling, overhaul etc. of specific components, for example: The sections contain topics. Each topic is a self contained set of data about a machine SYSTEM or Device. Each topic contains data such as specifications, descriptions, fault finding and test procedures. Device topics also contain removal, replacement, dismantle and assemble procedures. Some topics contain procedures and specifications for different variants. This happens because of market requirements, or when the machine specification changes after a period of time. Where applicable, a table in the introduction of each topic contains information to help you identify the correct specifications or procedures. A Attachments B Body and Framework...etc.
- 6. Section 1-1 - General Information Use Left and Right Sides 1-1-4 1-1-4 9803/9970-01 (1-01-00) Left and Right Sides 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.
- 7. Section 1-1 - General Information Use Hydraulic Schematic Codes 1-1-5 1-1-5 9803/9970-01 (1-01-00) Hydraulic Schematic Codes Colour Codes The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. Red Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure. Pink Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red. Orange Pilot: Oil pressure used in controlling a device (Pilot). Blue Neural: Neutral circuit pressure. Green Exhaust: Light Green Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation). Yellow Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).
- 8. Section 1-2 - General Information 1-2-1 1-2-1 9803/9970-01 (1-02-00) Machine Identification Introduction This topic contains information about a machine identification. On the machine and on the machine devices there are identification data plates. K Machine Identification Plate ( T 1-2-2) K Typical Product Identification Number (PIN) ( T 1-2-3) K Component Identification Plates ( T 1-2-4) K ROPS and FOPS Certification Labels ( T 1-2-5)
- 9. Section 1-2 - General Information Machine Identification Identifying your Machine 1-2-2 1-2-2 9803/9970-01 (1-02-00) Identifying your Machine Machine Identification Plate Your machine has an identification plate mounted as shown. The serial numbers of the machine and its major units are stamped on the plate. Note: The machine model and build specification is indicated by the PIN. Refer to Typical Product Identification Number (PIN). The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification 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. The machine and engine serial numbers can help identify exactly the type of equipment you have. C096760 Fig 1. The information on the identification plate will depend on the market for which the machine is built. It will be as shown on one of the following illustrations. C073810 Fig 2. C073980 Fig 3. JCB LANDPOWER LIMITED LAKESIDE WORKS, ROCESTER, UTTOXETER, UNITED KINGDOM, ST14 5JP TRACTOR TYPE ENGINE POWER (Kw) @ rpm YEAR OF MANUFACTURE WEIGHT (Kg) ISO 6016 EEC NUMBER IDENTIFICATION NUMBER TOTAL PERMISSIBLE MASS * PERMISSIBLE FRONT AXLE LOAD * PERMISSIBLE REAR AXLE LOAD * UNBRAKED TOWABLE MASS INDEPENDENTLY BRAKED TOWABLE MASS INERTIA BRAKED TOWABLE MASS POWER BRAKED TOWABLE MASS F AXLE G BOX RANGE ENGINE R AXLE PTO BOX *TYRE DEPENDANT (Kg) (Kg) (Kg) (Kg) (Kg) (Kg) (Kg) 332/W8667 JCB LANDPOWER LIMITED LAKESIDE WORKS, ROCESTER, UTTOXETER, UNITED KINGDOM, ST14 5JP MADE IN THE UK TRACTOR TYPE ENGINE POWER (Kw) @ rpm YEAR OF MANUFACTURE WEIGHT (Kg) ISO 6016 EEC NUMBER IDENTIFICATION NUMBER TOTAL PERMISSIBLE MASS * PERMISSIBLE FRONT AXLE LOAD * PERMISSIBLE REAR AXLE LOAD * UNBRAKED TOWABLE MASS INDEPENDENTLY BRAKED TOWABLE MASS INERTIA BRAKED TOWABLE MASS POWER BRAKED TOWABLE MASS F AXLE G BOX RANGE ENGINE R AXLE PTO BOX *TYRE DEPENDANT (Kg) (Kg) (Kg) (Kg) (Kg) (Kg) (Kg) 332/W8724
- 10. Section 1-2 - General Information Machine Identification Identifying your Machine 1-2-3 1-2-3 9803/9970-01 (1-02-00) Typical Product Identification Number (PIN) T040900-C1 Fig 4. 1 World Manufacturer Identification (3 Digits) 2 Engine Type (2 Digits) 3 Transmission Type (1 Digit) 4 Vehicle Maximum Speed kph (2 Digits) 5 Check Letter (1 Digit) The Check Letter is used to verify the authenticity of the machine's PIN. 6 Machine Serial Number (8 Digits) Each machine has a unique serial number. 27 = QSB 6.7 230Hp (3230) 28 = QSB 6.7 200Hp (3200) J = XTRA Drive Transmission 40 = 40kph 50 = 50kph 60 = 60kph 75 = 75kph
- 11. Section 1-2 - General Information Machine Identification Identifying your Machine 1-2-4 1-2-4 9803/9970-01 (1-02-00) Component Identification Plates C090820 Fig 5. Front axle A Gearbox assembly B Rear axle C Engine D C B D A
- 12. Section 1-2 - General Information Machine Identification Identifying your Machine 1-2-5 1-2-5 9803/9970-01 (1-02-00) ROPS and FOPS Certification Labels The ROPS and FOPS certification label is mounted as shown. C096760-C1 Fig 6. Machines built to Roll Over Protection Structure (ROPS) and Falling Objects Protection Structure (FOPS) standards have the following identification label fitted inside the cab.K Fig 7. ( T 1-2-5) 332_V8803 Fig 7. The FOPS structure provides impact protection for normal agricultural use, as defined in OECD Code10. !MWARNING Do not use the machine if the falling objects protection level provided by the structure is not sufficient for the application. Falling objects can cause serious injury. 8-2-8-17 Machines with a roof hatch fitted have ROPS protection only and have the following label. K Fig 8. ( T 1-2-5) 332_V8826 Fig 8. If the machine is used in any application where there is a risk of falling objects then a falling-objects protective structure (FOPS) must be installed. For further information contact your JCB Dealer. FASTRAC OECDAPPROVALNUMBER CABWAPARTNo. YEAROFMANUFACTURE MAXUNLADENMASS FOPS: COMPLIESTO OECDCODE10 XXXX CABWASERIALNUMBER ROPS: COMPLIESTO 79/622/EEC 4/0549 XXXXXXXXXXXXXXX XXX/XXXXX 8000KG 3000SERIES J.C.B.CABSYSTEMS LAKESIDEWORKS ROCESTER UTTOXETER,STAFFS ST145JP ENGLAND XXX/XXXXX ROPS: COMPLIESTO 79/622/EEC YEAROFMANUFACTURE CABWAPARTNo. 8000KG FASTRAC CABWASERIALNUMBER J.C.B.CABSYSTEMS LAKESIDEWORKS ROCESTER UTTOXETER,STAFFS ST145JP ENGLAND 4/0549 3000SERIES OECDAPPROVALNUMBER MAXUNLADENMASS XXXX
- 13. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
- 14. Section 1-3 - General Information 1-3-1 1-3-1 9803/9970-01 (1-05-00) Torque Settings Introduction This topic contains information about torques. Torque values are given for types and sizes of bolts and hydraulic connectors and adapters. Where a torque is given as a single figure it may be varied by plus or minus 3%. Torque figures are given for fasteners with different surface treatments. Make sure you use the correct torque figures. Where torques are given in topics within the other sections always use these values. K Zinc Plated Fasteners and Dacromet Fasteners ( T 1-3-2) K Introduction ( T 1-3-2) K Bolts and Screws ( T 1-3-2) K Hydraulic Connections ( T 1-3-6) K 'O' Ring Face Seal System ( T 1-3-6) K 'Torque Stop' Hose System ( T 1-3-9) K `Positional Type' Hydraulic Adaptors ( T 1-3-10) K Fitting Procedure ( T 1-3-10)
- 15. Section 1-3 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners 1-3-2 1-3-2 9803/9970-01 (1-05-00) Zinc Plated Fasteners and Dacromet Fasteners T11-002 Introduction Some external fasteners on JCB machines are manufactured 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. K Table 1. Fastener Types ( T 1-3-2). Table 1. Fastener Types Note: 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 fastener. Note: A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. Note: 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 or engine joint seams or internal applications. Bolts and Screws Use the following torque setting tables only where no torque setting is specified in the text. Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate. Torque settings are given for the following conditions: Condition 1 – Un-lubricated fasteners – Zinc fasteners – Yellow plated fasteners Condition 2 – Zinc flake (Dacromet) fasteners – Lubricated zinc and yellow plated fasteners – Where there is a natural lubrication. For example, cast iron components Verbus Ripp Bolts Fig 1. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings. Fastener Type Colour Part No. Suffix Zinc and Yellow Golden finish 'Z' (e.g. 1315/3712Z) Dacromet Mottled silver finish 'D' (e.g. 1315/3712D)
- 16. Section 1-3 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners 1-3-3 1-3-3 9803/9970-01 (1-05-00) Table 2. Torque Settings - UNF Grade 'S' Fasteners Table 3. Torque Settings - Metric Grade 8.8 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 in. mm in. Nm kgf m lbf ft Nm kgf m lbf ft 1/4 6.3 7/16 11.2 1.1 8.3 10.0 1.0 7.4 5/16 7.9 1/2 22.3 2.3 16.4 20.0 2.0 14.7 3/8 9.5 9/16 40.0 4.1 29.5 36.0 3.7 26.5 7/16 11.1 5/8 64.0 6.5 47.2 57.0 5.8 42.0 1/2 12.7 3/4 98.00 10.0 72.3 88.0 9.0 64.9 9/16 14.3 13/16 140.0 14.3 103.2 126.0 12.8 92.9 5/8 15.9 15/16 196.0 20.0 144.6 177.0 18.0 130.5 3/4 19.0 1 1/8 343.0 35.0 253.0 309.0 31.5 227.9 7/8 22.2 1 15/16 547.0 55.8 403.4 492.0 50.2 362.9 1 25.4 1 1/2 814.0 83.0 600.4 732.0 74.6 539.9 1 1/8 31.7 1 7/8 1181.0 120.4 871.1 1063.0 108.4 784.0 1 1/4 38.1 2 1/4 1646.0 167.8 1214.0 1481.0 151.0 1092.3 Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft M5 5 8 5.8 0.6 4.3 5.2 0.5 3.8 M6 6 10 9.9 1.0 7.3 9.0 0.9 6.6 M8 8 13 24.0 2.4 17.7 22.0 2.2 16.2 M10 10 17 47.0 4.8 34.7 43.0 4.4 31.7 M12 12 19 83.0 8.5 61.2 74.0 7.5 54.6 M16 16 24 205.0 20.9 151.2 184.0 18.8 135.7 M20 20 30 400.0 40.8 295.0 360.0 36.7 265.5 M24 24 36 690.0 70.4 508.9 621.0 63.3 458.0 M30 30 46 1372.0 139.9 1011.9 1235.0 125.9 910.9 M36 36 55 2399.0 244.6 1769.4 2159.0 220.0 1592.4