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

Issue9

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

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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.

9803/8030

Issue 1

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Section 1	General Information			Section 1
i				i
	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

9803/8030

Issue 2*

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Section 1	General Information	Section 1
1 - 1		1 - 1

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)

SLP FT 17 A 40 XXXXXXX

* 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)

A B C D E F

Original VIN Configuration

JCB 23 8 40 X 6 XXXXXXX

A C D E G H F

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

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

S M

N R

X

P

417490

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Issue 3*

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Section 1	General Information	Section 1
2 - 1	Torque Settings	2 - 1

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.

9803/8030

Issue 1

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Section 1	General Information	Section 1
2 - 2	Torque Settings	2 - 2

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						Metric - All Internal Hexagon Headed Cap Screws
	Bolt size		Torque Settings			Diameter		Torque
Dia.	(mm)	Hexagon	Nm	kgf m	lbf ft	mm	Nm	kgf m	lbf ft
		(A/F) mm
M5	(5)	8	7	0.7	5	M3	2	0.2	1.5
M6	(6)	10	12	1.2	9	M4	6	0.6	4.5
M8	(8)	13	28	3.0	21	M5	11	1.1	8
M10	(10)	17	56	5.7	42	M6	19	1.9	14
M12	(12)	19	98	10	72	M8	46	4.7	34
M16	(16)	24	244	25	180	M10	91	9.3	67
M18	(18)	27	350	36	258	M12	159	16.2	117
M20	(20)	30	476	48	352	M16	395	40	292
M24	(24)	36	822	84	607	M18	550	56	406
M30	(30)	46	1633	166	1205	M20	770	79	568
M36	(36)	55	2854	291	2105	M24	1332	136	983

Metric Grade 10.9 Bolts						Verbus Ripp 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	A343780
M16	(16)	24	343	35	253	Torque settings for these bolts are determined by the
M20	(20)	30	657	67	485
M24	(24)	36	1157	118	853	application. Refer to the relevant procedure for the
						required settings.

	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
11/2		244	24.9	180	11/2		305	31	225
9803/8030										Issue 1

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Section 1	General Information	Section 1
2 - 3	Torque Settings	2 - 3

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

9803/8030

Issue 1

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