jcb 225 Service Manual

jcb 225 Service Manual

Skidsteer loader
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SERVICE MANUAL
SKIDSTEER LOADER
225, 225T, 260, 260T, 280,
300, 300T, 320T, 325T, 330
EN - 9813/5150 - ISSUE 2 - 09/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2017 © 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.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12
-
Heating,
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
Ventilating
and
Air-

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Table of Contents
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Summary of Contents for jcb 225

  • Page 1 Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
  • Page 2 Notes: 9813/5150-2 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 225, 225T, 260, 260T, 280, 225, 225T, 260, 260T, 280, 300, 300T, 320T, 325T, 330 300, 300T, 320T, 325T, 330 EN 9813/5150 EN 9813/5150 SERVICE MANUAL SERVICE MANUAL Volume 3...
  • Page 4 Notes: 9813/5150-2 Find manuals at https://best-manuals.com...
  • Page 5: Table Of Contents

    01 - Machine Contents Page No. Acronyms Glossary ............................ 01-2 01-03 Safety 01-03-03 Safety - Yours and Others ....................01-3 01-03-06 Safety Warnings ....................... 01-4 01-03-09 General Safety ......................... 01-5 01-03-12 Maintenance Safety ......................01-6 01-03-15 Safety Practice ......................... 01-8 01-03-18 Operating Safety ......................
  • Page 6: Acronyms Glossary

    Acronyms Glossary Parts Identification List 9813/5150-2 2018-07-24 Find manuals at https://best-manuals.com...
  • Page 7 01 - Machine 03 - Safety 03 - Safety Contents Page No. 01-03-03 Safety - Yours and Others ....................01-3 01-03-06 Safety Warnings ....................... 01-4 01-03-09 General Safety ......................... 01-5 01-03-12 Maintenance Safety ......................01-6 01-03-15 Safety Practice ......................... 01-8 01-03-18 Operating Safety ......................
  • Page 8 Notes: 01 - 2 9813/5150-2 01 - 2 Find manuals at https://best-manuals.com...
  • Page 9: Safety

    They inform you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them. Safety is not just a matter of responding to the warnings.
  • Page 10: Safety Warnings

    01 - Machine 03 - Safety 06 - Safety Warnings 06 - Safety Warnings Introduction In this manual there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 11: General Safety

    Keep long hair restrained. Remove altered in any way which could affect or invalidate its rings, watches and personal jewellery. compliance. For advice consult your JCB dealer. Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs.
  • Page 12: Maintenance Safety

    Repairs pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may If your machine does not function correctly in cause serious injury or death.
  • Page 13 Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton®, FluorelTM Technoflon®.
  • Page 14: Safety Practice

    01 - Machine 03 - Safety 15 - Safety Practice 15 - Safety Practice An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a Introduction collection of rules and procedures that coordinates the machines and people that work together in WARNING You or others can be killed or seriously the same area.
  • Page 15: Operating Safety

    Your doing. If you will be working with other people, local JCB distributor will be glad to advise you. make sure any hand signals that may be used are understood by everybody. Worksites can be noisy, do Fuel not rely on spoken commands.
  • Page 16 01 - Machine 03 - Safety 18 - Operating Safety Regulations clearly. Modification of the machine's configuration by the user (e.g. the fitting of large and non- approved attachments) may result in a restriction of Obey all laws, worksite and local regulations which the machine visibility.
  • Page 17 01 - Machine 03 - Safety 18 - Operating Safety has passed. Do not attempt to mount or enter the machine. If the machine is struck by lightning do not use the machine until it has been checked for damage and malfunction by trained personnel. 01 - 11 9813/5150-2 01 - 11...
  • Page 18: Worksite Safety

    01 - Machine 03 - Safety 21 - Worksite Safety 21 - Worksite Safety An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a Introduction collection of rules and procedures that coordinates the machines and people that work together in WARNING You or others can be killed or seriously the same area.
  • Page 19: Risk Assessment

    If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be a specific task, contact your JCB dealer who will be in or to enter the area while operations are in pleased to advise you.
  • Page 20: Maintenance Positions

    01 - Machine 03 - Safety 27 - Maintenance Positions 27 - Maintenance Positions Introduction For: 225 [T3 GE0], 225 [T4F GE0], 225T [T3 Introduction ............ 01-14 GE0], 225T [T4F GE0], 260 [T3 GE0], 260 Health and Safety .......... 01-19...
  • Page 21 01 - Machine 03 - Safety 27 - Maintenance Positions Lift Arm Lowered Figure 4. Stowage Vertical Lift 1. Park the machine on level, solid ground. Refer to (PIL 01-03). 2. Lower the lift arm. 3. Put the attachment flat on the ground. 4.
  • Page 22 01 - Machine 03 - Safety 27 - Maintenance Positions Figure 5. Figure 6. A Strut B Strap C Stowage position 7. To prevent any chance of the lift arm creeping (For: 225T [T3 GE0], 225T [T4F GE0], 260 down and trapping your fingers, the lift arm [T3 GE0], 260 [T4F GE0], 260T [T3 GE0], should be lowered onto the strut.
  • Page 23 01 - Machine 03 - Safety 27 - Maintenance Positions Figure 7. A Lift arm lowered B Lift arm raised C Lift arm and cab raised Lift Arm Lowered Installing the Lift Arm Maintenance Strut Figure 8. Stowage Radial Lift 1.
  • Page 24 01 - Machine 03 - Safety 27 - Maintenance Positions Figure 9. Stowage Vertical Lift Figure 10. A Lift arm strut B Lift arm strap C Stowage position 7. To prevent any chance of the lift arm creeping 1. Remove the shovel or attachment. down and trapping your fingers, the lift arm should be lowered onto the lift arm strut.
  • Page 25 01 - Machine 03 - Safety 27 - Maintenance Positions Health and Safety WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level ground.
  • Page 26: About This Manual

    01 - Machine 06 - About this Manual 06 - About this Manual Contents Page No. 01-06-03 Model and Serial Number ....................01-21 01-06-06 Using the Manual ......................01-22 01 - 20 9813/5150-2 01 - 20...
  • Page 27: Model And Serial Number

    03 - Model and Serial Number Model From: 2556651 2556850 Introduction 2427801 2428800 2491771 2492270 This manual provides information for the following 2503001 2503500 model(s) in the JCB machine range: 2584341 2584840 Model From: 320T 2427501 2427800 2427501 2427800 2499351 2499500 2499351...
  • Page 28: Using The Manual

    06 - Using the Manual Introduction Information in this manual conforms to a standard List). These headings are assigned numerical JCB service manual format. The format uses section identification references. headings taken from a PIL (Parts Identification Table 1. Example...
  • Page 29 01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-12 Main Component Locations ................... 01-25 01-09-15 Service Point Locations ....................01-27 01 - 23 9813/5150-2 01 - 23...
  • Page 30 Notes: 01 - 24 9813/5150-2 01 - 24...
  • Page 31 12 - Main Component Locations 12 - Main Component Locations Introduction (For: 225 [T3 GE0], 225 [T4F GE0], 225T [T3 GE0], 225T [T4F GE0], 260 [T3 GE0], 260 [T4F GE0], 260T [T3 GE0], 260T [T4F GE0], 280 [T3 GE0], 280 [T4F GE0], 300...
  • Page 32 01 - Machine 09 - Description 12 - Main Component Locations Figure 11. 1 ROPS/FOPS cab 2 Fuel tank filler point 3 Lift arm/boom 4 Front working lights 5 Quickhitch 6 Rubber tracks 7 Engine top cover 8 Wheels/tyres 9 Exhaust 01 - 26 9813/5150-2 01 - 26...
  • Page 33 15 - Service Point Locations 15 - Service Point Locations Introduction For: 225 [T3 GE0], 225 [T4F GE0], 225T [T3 GE0], 225T [T4F GE0], 260 [T3 GE0], 260 [T4F GE0], 260T [T3 GE0], 260T [T4F GE0], 280 [T3 GE0], 280 [T4F GE0], 300 [T3 GE0],...
  • Page 34 09 - Description 15 - Service Point Locations (For: 225 [T3 GE0], 225 [T4F GE0], 225T [T3 GE0], 225T [T4F GE0], 260 [T3 GE0], 260 [T4F GE0], 260T [T3 GE0], 260T [T4F GE0], 280 [T3 GE0], 280 [T4F GE0], 300 [T3 GE0],...
  • Page 35 01 - Machine 09 - Description 15 - Service Point Locations Tracked Machines Figure 13. A Coolant expansion bottle B Fuel sedimenter C Air intake D Engine oil filler cap E Engine oil dipstick F Hydraulic oil level indicator, Hydraulic oil filler G Battery isolator H Battery J Radiator...
  • Page 36 01 - Machine 09 - Description 15 - Service Point Locations Service Label The label shows a picture of the machine. On the machine are marked the positions of the service items to check. Surrounding the machine are four The service label is located inside the rear door. It 'tracks'.
  • Page 37 01 - Machine 09 - Description 15 - Service Point Locations Figure 15. 225, 260, 280, 300,330 01 - 31 9813/5150-2 01 - 31...
  • Page 38 01 - Machine 09 - Description 15 - Service Point Locations Figure 16. 225T, 260T, 300T, 320T, 325T 01 - 32 9813/5150-2 01 - 32...
  • Page 39 01 - Machine 09 - Description 15 - Service Point Locations (For: 225T [T3 GE0], 225T [T4F GE0], 260 [T3 GE0], 260 [T4F GE0], 260T [T3 GE0], 260T [T4F GE0], 280 [T3 GE0], 280 [T4F GE0], 300 [T3 GE0], 300 [T4F GE0], 300T [T3 GE0], 300T [T4F GE0], 320T [T3 GE0], 320T [T4F GE0], 325T [T4F GE0], 330 [T3 GE0], 330 [T4F GE0]) Wheeled Machines...
  • Page 40 01 - Machine 09 - Description 15 - Service Point Locations C Air intake D Engine oil filler cap E Engine oil dipstick F Hydraulic oil level indicator, Hydraulic oil filler G Battery isolator H Battery J Radiator K Radiator cap L Window washer fluid bottle M Chain case oil port 01 - 34...
  • Page 41 01 - Machine 09 - Description 15 - Service Point Locations Tracked Machines Figure 18. A Coolant expansion bottle B Fuel sedimenter C Air intake D Engine oil filler cap E Engine oil dipstick F Hydraulic oil level indicator, Hydraulic oil filler G Battery isolator H Battery J Radiator...
  • Page 42 01 - Machine 09 - Description 15 - Service Point Locations N Track Sprocket 01 - 36 9813/5150-2 01 - 36...
  • Page 43 01 - Machine 09 - Description 15 - Service Point Locations Service Label check are marked on the corresponding track depending on their frequency. The service label is located inside the rear door. It The number next to each symbol cross refers to the is a visual representation of the daily, weekly and service schedule in this manual.
  • Page 44 01 - Machine 09 - Description 15 - Service Point Locations Figure 20. Wheeled 01 - 38 9813/5150-2 01 - 38...
  • Page 45 01 - Machine 09 - Description 15 - Service Point Locations R Radial lift machines V Vertical lift machines Figure 21. Tracked 01 - 39 9813/5150-2 01 - 39...
  • Page 46 01 - Machine 09 - Description 15 - Service Point Locations R Radial lift machines V Vertical lift machines 01 - 40 9813/5150-2 01 - 40...
  • Page 47 01 - Machine 33 - Cleaning 33 - Cleaning Contents Page No. 01-33-00 General ........................... 01-43 01 - 41 9813/5150-2 01 - 41...
  • Page 48 Notes: 01 - 42 9813/5150-2 01 - 42...
  • Page 49 01 - Machine 33 - Cleaning 00 - General 00 - General Introduction WARNING When using cleaning agents, solvents Introduction ............ 01-43 or other chemicals, you must adhere to Preparation ............ 01-44 the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when...
  • Page 50 01 - Machine 33 - Cleaning 00 - General Preparation Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine 1. Make the machine safe. Stop the machine and is to be washed using a high pressure system.
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