JCB 354, 360 Service Manual

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

9803/9480-1

Publication No.

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel [phone] Fax [phone]

Service Manual

JCB 354/360 TRACTOR

Section 1 - General Information

Section 2 - Care and Safety

Section 3 - Routine Maintenance

Section A - Attachments

Section B - Body and Framework

Section C - Electrics

Section E - Hydraulics

Section F - Transmission

Section G - Brakes

Section H - Hydraulic Steering

Section K - Engine

Section 1 - General Information

1 - 0 1 - 0

9803/9480-1

Notes:

Page No.Contents

Section 1 - General Information

1 - i 1 - i

Introduction

About This Publication ......... ... ... ... ... .......................................... .... ... ... ... . 1 - 1

Identifying Your Machine ........................................... .... ... ... ... ... .... ... ... ... . 1 - 3

Standard Torque Settings

Front Axle Housing and Transmission ..................................................... 1 - 5

Service Consumables

Sealing and Retaining Compounds ......................................................... 1 - 7

Service Tools

Numerical List Section H - Steering ......................................................... 1 - 9

Tool Detail Reference Section H - Steering ........................................... 1 - 10

Page No.Contents

Section 1 - General Information

1 - ii 1 - ii

Section 1 - General Information

1 - 1 1 - 1

9803-9480-1

Introduction

About This Publication

Machine Model and Serial Number

This publication provides information for the following
models in the JCB product range:

– 354 from S/N 1287000 to 1288999
– 360 from S/N 1287000 to 1288999

Using the Service Manual

T11-004

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.

The illustrations in this publication are for guidance only.
Where the machines differ, the text and/or the illustration
will specify.

General warnings in Section 2 are repeated throughout the
manual, as well as specific warnings. Read all safety
statements regularly, so you do not forget them.

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.

Where a torque setting is given as a sing le 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.

The manufacturer's policy is one of continuous
improvement. The right to change the specification of the
machine without notice is reserved. No responsibility will
be accepted for discrepancies which may occur between
specifications of the machine and the descriptions
contained in this publication.

Finally, please remember above all else safety must come
first!

Units of Measurement

T1-001_2

In this publication, the S.I. system of units is used. For
example, liquid capacities are given in litres. The Imperial
units follow in parentheses ( ) eg 28 litres (6 gal).

Section Numbering

T11-005

The manual is compiled in sections, the first three are
numbered and contain information as follows:

The remaining sections are alphabetically coded and deal
with Dismantling, Overhaul etc. of specific components, for
example:

Section contents, technical data, circuit descriptions,
operation descriptions etc. are inserted at the beginning of
each alphabetically coded section.

1 General Information - includes torque settings and

service tools.

2 Care and Safety - includes warnings and cautions

pertinent to aspects of workshop procedures etc.

3 Maintenance - includes service schedules and

recommended lubricants for all the machine.

A Attachments
B Body and Framework, etc.

Section 1 - General Information

Introduction

About This Publication

1 - 2 1 - 2

9803-9480-1

Left Side, Right Side

In this publication, ‘left’ A and ‘right’ B mean your left and
right when you are seated correctly in the machine.

Cross References

T1-004_2

In this publication, page cross references are made by
presenting the subject title printed in bold, italic and
underlined. It is preceeded by the 'go to' symbol. The
number of the page upon which the subject begins, is
indicated within the brackets. For example: K

Cross

References ( T 1-2).

Section 1 - General Information

Introduction

Identifying Your Machine

1 - 3 1 - 3

9803-9480-1

Identifying Your Machine

Machine Identification Plate

Your machine has an identification plate mounted as
shown. Information contained on this plate includes Model,
Type, Engine, V ehicle Identification Number , Manufacturer
and Address.

The machine and engine serial numbers can help identify
exactly the type of equipment you have.

Fig 1.

Section 1 - General Information

Introduction

Identifying Your Machine

1 - 4 1 - 4

9803-9480-1

Typical Vehicle Identification Number (VIN)

A typical Vehicle Identification Number is given below.

1 Machine Model
2 Year of Manufacture
3 Month of Manufacture
4 Machine Serial Number

Component Identification Plates

Typical Engine Identification Number

The engine identification plate A is attached to the rocker
cover. The information stamped on this plate includes the
engine model and serial number.

Fig 2.

ROPS Certification Plate

Your machine is built to the ROPS standard and has an
identification label fitted to the cab. A typical identification
label is shown below.

Fig 3.

35NH X 01 0001

1234

CATION MODEL

354

APPLI

0098

Section 1 - General Information

1 - 5 1 - 5

9803-9480-1

Standard Torque Settings

Front Axle Housing and Transmission

Introduction

The following table gives the torque tightening values for
the major parts of the Front Axle Housing (4WD Type) and
the Transmission.

Table 1. Standard Torque Settings

Major Part Bolt and Nut Size

(Hardness)

Torque Value

Nm kgf/m lbf/ft

Front Axle Housing

Axle bracket to engine 5/8-11UNC (9T) 156.9 - 176.5 16.0 - 18.0 115.7 - 130.2
Front pivot metal M14 (9T) 156.9 - 176.5 16.0 - 18.0 115.7 - 130.2
Rear pivot metal M18 (7T) 196.0 - 235.2 20.0 - 24.0 144.6 - 173.5
Front axle final case M12 (7T) 88.2 - 107.9 9.0 - 11.0 65.1 - 79.6
Bearing cover M14 (7T) 132.3 - 137.2 13.5 - 14.0 97.6 - 101.2
Wheel shaft cover M8 (7T) 53.9 - 68.6 5.5 - 7.0 39.8 - 50.6
Front wheel M18 (7T) 225.4 - 235.2 23.0 - 24.0 166.3 - 173.5
Bevel gear case M12 (7T) 88.2 - 107.9 9.0 - 11.0 65.1 - 79.6
Diff-metal (support) M10 (7T) 73.5 - 87.2 7.5 - 8.9 9.4 - 13.1

Transmission

Front transmission - engine M12 (7T) 88.2 - 107.9 9.0 - 11.0 65.1 - 79.6
Front transmission - spacer M12 (7T) 88.2 - 107.9 9.0 - 11.0 65.1 - 79.6
Space transmission - rear transmission M12 (7T) 88.2 - 107.9 9.0 - 11.0 65.1 - 79.6
Input metal (support) M12 (7T) 88.2 - 107.9 9.0 - 11.0 65.1 - 79.6
Drive pinion metal (support) M10 (7T) 53.9 - 68.6 5.5 - 7.0 39.8 - 50.6
Drive pinion
Diff-case metal (support) M12 53.9 - 68.6 5.5 - 7.0 39.8 - 50.6
Diff-case ring gear M12 (7T) 88.2 - 107.9 9.0 - 11.0 65.1 - 79.6

Section 1 - General Information

Standard Torque Settings

Front Axle Housing and Transmission

1 - 6 1 - 6

9803-9480-1

Page left intentionally blank

Section 1 - General Information

1 - 7 1 - 7

9803-9480-1

Service Consumables

Sealing and Retaining Compounds

Table 2.

Type Description Part No. Quantity

JCB Multi-Gasket A medium strength sealant suitable for all sizes of

gasket flanges, and for hydraulic fittings of 25-65 mm
diameter.

4102/1212 50 ml

JCB High Strength
Thread locker

A high strength locking fluid for use with threaded
components. Gasketing for all sizes of flange where
the strength of the joint is important.

4102/0551 50 ml

JCB Retainer (High
Strength)

For all retaining parts which are unlikely to be
dismantled.

4101/0651 50 ml

JCB Thread locker and
Sealer

A medium strength locking fluid for sealing and
retaining nuts, bolts, and screws up to 50 mm
diameter, and for hydraulic fittings up to 25 mm
diameter.

4101/0250 10 ml

4101/0251 50 ml

JCB Thread locker and
Sealer (High Strength)

A high strength locking fluid for sealing and retaining
nuts, bolts, and screws up to 50 mm diameter, and
for hydraulic fittings up to 25 mm diameter.

4101/0550 10 ml

4101/0552 200 ml
JCB Threadseal A medium strength thread sealing compound. 410 2/1951 50 ml
JCB Activator A cleaning primer which speeds the curing rate of

anaerobic products.

4104/0251 200 ml (Aerosol)

4104/0253 1 ltr (Bottle)
JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic

adhesives and sealants.

4104/1557 400 ml (Aerosol)

Section 1 - General Information

Service Consumables

Sealing and Retaining Compounds

1 - 8 1 - 8

9803-9480-1

Page left intentionally blank

Section 1 - General Information

1 - 9 1 - 9

9803/9480-1

Service Tools

Numerical List Section H - Steering

The tools listed in the table are special tools required for
removal and replacement of the steering valve parts.

Note: Tools other than those listed will be required. It is
expected that such general tools will be available in any
well equipped workshop or be available locally from any
good tool supplier.

Part Number Description Tool Detail

Reference

SJ150L9001-01 Holding Tool K

Fig 4. ( T 1-10)

SJ150L4011-01 Assembly Tool for Shaft Seal 17.5 dia. K Fig 5. ( T 1-10)
SJ150L4012-01 Assembly Tool for Shaft Seal 19.2 dia. K Fig 6. ( T 1-10)
SJ150L0396-01 Assembly Tool for Dust Seal Ring K Fig 7. ( T 1-10)
SJ150-9000-25 Pliers for Piston in Relief Valve K Fig 8. ( T 1-10)
SJ151G9000-1 Fork for fitting Cardan Shaft K Fig 9. ( T 1-10)

Section 1 - General Information

Service Tools

Tool Detail Reference Section H - Steering

1 - 10 1 - 10

9803/9480-1

Tool Detail Reference Section H - Steering

Fig 4.

Fig 5.

Fig 6.

Fig 7.

Fig 8.

Fig 9.

Section 2 - Care and Safety

2 - 0 2 - 0

9803/9480-1

Notes:

Page No.Contents

Section 2 - Care and Safety

2 - i 2 - i

Safety Notices

Important Information .................................................................... ... ... ... . 2 - 1

Safety Check List .......................................... .... ... ... ... .............................. 2 - 2

Page No.Contents

Section 2 - Care and Safety

2 - ii 2 - ii

Section 2 - Care and Safety

2 - 1 2 - 1

9803-9480-1

Safety Notices

Important Information

T1-015

The Operator Manual

!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

Do not operate the machine without an Operator Manual.
Treat the Operator Manual as part of the machine. Keep it

clean and in good condition. Replace the Operator Manual
immediately if it is lost, damaged or becomes unreadable.

Safety Warnings

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

This safety alert system identifies
important safety messages in this
manual. When you see this symbol, be
alert, your safety is involved, carefuly
read the message that follows, and inform
other operators.

Section 2 - Care and Safety

Safety Notices

Safety Check List

2 - 2 2 - 2

9803-9480-1

Safety Check List

Safety - Yours and Others

INT-1-3-1_3

All machinery 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 fin d 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 th at 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

General Safety

T1-007_3

!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, ear­protectors and industrial gloves. Keep cuffs fastened.
Do not wear a necktie or scarf. Keep long hair
restrained. Remove rings, watches and personal
jewellery.

INT-1-3-6_2

!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

Section 2 - Care and Safety

Safety Notices

Safety Check List

2 - 3 2 - 3

9803-9480-1

!MWARNING

Feeling Unwell
Do not attempt to operate the machine if you are
feeling unwell. By doing so you could be a danger to
yourself and those you work with.

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

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
Never walk or work under raised equipment unless it
is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails or if
the control is operated (even with the engine stopped).

13-2-3-7_2

!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

!MDANGER

Lightning
Lightning can kill you. Do not use the machine if there
is lightning in your area.

5-1-1-2

!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



BUYNOW

ThenInstantDownload

theCompleteManual

Thankyouverymuch!