Service
Manual
Fastrac
3170, 3170 Plus
3190, 3190 Plus
3200, 3200 Plus
3220, 3220 Plus
3230, 3230 Plus
Published by the
TECHNICAL PUBLICATIONS DEPARTMENT
of
JCB SERVICE LTD;
World Parts Centre,
Waterloo Park
Uttoxeter, Staffordshire
ST14 7BS
Publication No. 9803/8030
Issue 9
General Information
1
Care & Safety
2
3
Optional Equipment
A
Body & Framework
B
Electrics
C
Controls
D
Hydraulics
E
Transmission
F
Brakes
G
Steering
H
Suspension
S
Engine
T
Routine Maintenance
9803/8030 Issue 1
Introduction
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.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of
course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe
connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all
else
SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools.
2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for the whole machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for
example:
A = Optional Equipment
B = Body & Framework ...etc
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later
issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
Page cross references are generally made by presenting the subject title printed in bold, followed by the title of the section
containing the subject. For example:
“24 If the axle is still on the machine, fit the brake calipers (see Brake Caliper Removal and Replacement, Section G).”
Note: If only the subject title in bold is given, i.e. no section title, the cross reference is to another part of the same section.
Use the contents list at the beginning of each section to find the exact page number.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.
‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.
i
Section 1 General Information
9803/8030
Section 1
i
Issue 2*
Contents Page No.
Machine Identification Plate 1 - 1
Typical Vehicle Identification Number (VIN) 1 - 1
Unit Identification 1 - 1
Torque Settings
Introduction - Zinc Plated Fasteners and Dacromet Fasteners 2 - 1
Zinc Plated Fasteners 2 - 2
Dacromet Fasteners 2 - 3
Sealing and Retaining Compounds 3 - 1
Service Tools Numerical List 4 - 1
Service Tools
Optional Equipment 5 - 0
Body and Framework 5 - 1
Electrics 6 - 1
Hydraulics 7 - 1
Transmission 8 - 1
Brakes 9 - 1
Steering 9 - 1
Suspension 9 - 2
Engine 9 - 2
Moving a Disabled Machine
General 10 - 1
Preparation for Towing 10 - 1
Transporting the Machine 10 - 2
*
1 - 1
Section 1 General Information
9803/8030
Section 1
1 - 1
Issue 3*
417490
S
P
X
R
M
N
Serial Number Plate
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.
Typical Vehicle Identification No. (VIN)
Original VIN Configuration
Later VIN Configuration
A = Manufacturing Code
B = Machine Range
FT = Fastrac
C = Engine Type
17 = 3190 or 3190 Plus
18 = 3220 or 3220 Plus
19 = 3170 or 3170 Plus
23 = 3200 or 3200 Plus
24 = 3230 or 3230 Plus
D = Transmission Type (Gearbox and axle combination)
3170, 3170 Plus All other machines
A = 75 km/h 8 = Standard (40, 50 or 65 km/h)
B = 65 km/h 9 = High Speed (75 km/h)
D = 50 km/h
E = 40 km/h
E = Vehicle Max. Speed
40 = 40 km/h
50 = 50 km/h
65 = 65 km/h
75 = 75 km/h
F = Serial Number
G = Authenticity Code
H = year Code (e.g. 6 = 2006)
Unit Identification
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 Assembly (assembly of all three gearboxes) N
Speed Gearbox P
Front Axle R
Rear Axle S
*
*
SLP FT 17 A 40 XXXXXXX
A B C D E F
JCB 23 8 40 X 6 XXXXXXX
A C D E G H F
*
*
*
2 - 1
Section 1 General Information
9803/8030
Section 1
2 - 1
Issue 1
Torque Settings
Introduction - Zinc Plated Fasteners and Dacromet Fasteners
Some external fasteners on Fastrac machines are assembled using an improved type of corrosion resistant finish. This type of
finish is called Dacromet and replaces the original Zinc and Yellow plating used on earlier machines.
The two types of fasteners can be readily identified by colour and part number suffix as follows:
Fastener Type Colour Part Number
Zinc and Yellow Golden finish ‘Z’ (e.g. 1315/3712Z)
Dacromet Mottled silver finish ‘D’ (e.g. 1315/3712D)
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 fasteners.
Note: 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.
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 areas where rust could occur. Dacromet bolts are only
used for external applications. They are not used in application such as gearbox and engine joint seams or internal
applications.
2 - 2
Section 1 General Information
9803/8030
Section 1
2 - 2
Issue 1
Torque Settings
Zinc Plated Fasteners (golden finish)
Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the
figures stated. For lubricated threads the values should be REDUCED by one third.
Metric Grade 8.8 Bolts
Bolt size Torque Settings
Dia. (mm) Hexagon Nm kgf m lbf ft
(A/F) mm
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M18 (18) 27 350 36 258
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Metric Grade 10.9 Bolts
Bolt size Torque Settings
Dia. (mm) Hexagon Nm kgf m lbf ft
(A/F) mm
M6 (6) 8 16 1.6 12
M8 (8) 13 39 4 29
M10 (10) 17 78 8 57
M12 (12) 19 137 14 101
M16 (16) 24 343 35 253
M20 (20) 30 657 67 485
M24 (24) 36 1157 118 853
Hydraulic Hose to Adapter Connections Hydraulic Adapter into Component Connections
with bonded washers
Torque Settings Torque Settings
BSP Size Nm kgf m lbf ft BSP Size Nm kgf m lbf ft
(inches) (inches)
1
/8 14 1.4 10
1
/8 20 2.1 15
1
/
4 24 2.5 18
1
/
4 34 3.4 25
3
/8 33 3.3 24
3
/8 75 7.6 55
1
/2 44 4.8 35
1
/2 102 10.3 75
5
/8 58 6.0 43
5
/8 122 12.4 90
3
/4 84 8.6 62
3
/4 183 18.7 135
1 115 11.8 85 1 203 20.7 150
1
1
/2 244 24.9 180 11/2 305 31 225
Metric - All Internal Hexagon Headed Cap Screws
Diameter Torque
mm Nm kgf m lbf ft
M3 2 0.2 1.5
M4 6 0.6 4.5
M5 11 1.1 8
M6 19 1.9 14
M8 46 4.7 34
M10 91 9.3 67
M12 159 16.2 117
M16 395 40 292
M18 550 56 406
M20 770 79 568
M24 1332 136 983
Verbus Ripp Bolts
Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.
A343780
2 - 3
Section 1 General Information
9803/8030
Section 1
2 - 3
Issue 1
Torque Settings
Dacromet Fasteners (mottled silver finish)
Use only where no torque setting is specified in the text.
NOTE: DACROMET FASTENERS ARE LUBRICATED AS PART OF THE PLATING PROCESS: DO NOT LUBRICATE.
Metric Grade 8.8 Bolts
Bolt size Torque Settings
Dia. Nm kgf m lbf ft
M6 x 1.0 9 0.9 7
M8 x 1.25 22.5 2.3 17
M10 x 1.5 47.5 4.8 35
M12 x 1.75 80 8.2 59
M14 x 2 133 13.6 98
M16 x 2 200 20.4 148
M18 x 2.5 278 28.4 205
M20 x 2.5 392 40 289
M24 x 3 675 69 498
M30 x 3.5 1348 138 994
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
Metric Grade 12.9 Bolts
Bolt size Torque Settings
Dia. Nm kgf m lbf ft
M6 x 1.0 15 1.5 11
M8 x 1.25 40 4.1 29
M10 x 1.5 80 8.2 59
M12 x 1.75 133 13.6 98
M14 x 2 225 23 166
M16 x 2 350 35.7 258
M18 x 2.5 463 47 342
M20 x 2.5 654 67 482
M24 x 3 1125 115 830
M30 x 3.5 2247 229 1657
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