JCB 3170, 3170 Plus, 3190, 3190 Plus, 3200 Service Manual

...

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

Care & Safety

2 3

Optional Equipment

Body & Framework

Electrics

Controls

Hydraulics

Transmission

Brakes

Steering

Suspension

Engine

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.

Section 1 General Information

9803/8030

Section 1

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

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)

/8 14 1.4 10

/8 20 2.1 15

4 24 2.5 18

4 34 3.4 25

/8 33 3.3 24

/8 75 7.6 55

/2 44 4.8 35

/2 102 10.3 75

/8 58 6.0 43

/8 122 12.4 90

/4 84 8.6 62

/4 183 18.7 135

1 115 11.8 85 1 203 20.7 150

/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

+ 14 hidden pages