jcb 225 Service Manual
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SERVICE MANUAL
225, 225T, 260, 260T,
280, 300, 300T, 320T, 330
EN - 9813/2300 - ISSUE 2 - 07/2015
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2015 © 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
06 - Body and Framework
09 - Operator Station
12
-
Heating,
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brakes
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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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: 9813/2300-2 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 225, 225T, 260, 260T, 225, 225T, 260, 260T, 280, 300, 300T, 320T, 330 280, 300, 300T, 320T, 330 EN 9813/2300 EN 9813/2300 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4...
  • Page 4 Notes: 9813/2300-2 Find manuals at https://best-manuals.com...
  • Page 5: Table Of Contents

    01 - Machine Contents Page No. 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 01-03-18 Operating Safety ......................01-8 01-03-21 Worksite Safety ......................01-10 01-03-24 Risk Assessment ......................
  • Page 6 Notes: 9813/2300-2 2015-06-22 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 01-03-18 Operating Safety ......................01-8 01-03-21 Worksite Safety ......................
  • Page 8 Notes: 01 - 2 9813/2300-2 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 and on the product, 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

    People can be killed or injured on systems incorporating accumulators, the system if these precautions are not taken. pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may Repairs cause injury.
  • Page 13 01 - Machine 03 - Safety 12 - Maintenance Safety Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton®, FluorelTM Technoflon®. Fluoroelastomeric materials subjected high temperatures produce highly corrosive hydrofluoric acid. This acid can severely burn.
  • Page 14: Operating Safety

    Before doing any job not covered in this manual, find Parking out the correct procedure. Your local JCB distributor will be glad to advise you. An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Fuel Manual to park the machine correctly.
  • Page 15 01 - Machine 03 - Safety 18 - Operating Safety Electrical Power Cables Hands and Feet You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine. the machine or its attachments too close to electrical When using the machine, keep your hands and feet power cables.
  • Page 16: 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 17: 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 18: Maintenance Positions

    01 - Machine 03 - Safety 27 - Maintenance Positions 27 - Maintenance Positions Introduction Introduction ............ 01-12 Make the machine safe before you start a Health and Safety .......... 01-15 maintenance procedure. Refer to (PIL 01-03). You can complete most of the maintenance procedures with the lift arm lowered.
  • Page 19 01 - Machine 03 - Safety 27 - Maintenance Positions Installing the Lift Arm Maintenance Strut 4. Raise the lift arm just far enough to install the strut. Figure 3. Stowage Radial Lift 5. Stop the engine and remove the ignition key. If the keyless ignition option is fitted stop the engine and wait Duration: 15s...
  • Page 20 01 - Machine 03 - Safety 27 - Maintenance Positions 3. Remove the strut. 4. Secure the strut in its stowage position. 5. Lower the lift arm to the ground. Figure 6. Stowage position 01 - 14 9813/2300-2 01 - 14...
  • Page 21 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 22 01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-12 Main Component Locations ................... 01-17 01 - 16 9813/2300-2 01 - 16...
  • Page 23 01 - Machine 09 - Description 12 - Main Component Locations 12 - Main Component Locations Introduction Figure 7. ROPS/FOPS cab Quickhitch Fuel tank Rubber tracks Lift arm/boom Engine top cover Front working lights Wheels/tyres 01 - 17 9813/2300-2 01 - 17...
  • Page 24 Notes: 01 - 18 9813/2300-2 01 - 18...
  • Page 25 03 - Attachments Contents Page No. 03-00 General 03-00-00 General ..........................03-3 03-09 Lift Arm Quickhitch 03-09-00 General ..........................03-7 03-09-03 Mechanical Quickhitch ..................... 03-9 03-09-09 Electronic Quickhitch ...................... 03-11 03-30 Shovel 03-30-00 General ........................... 03-15 9813/2300-2 2015-03-05...
  • Page 26 Notes: 9813/2300-2 2015-03-05...
  • Page 27 03 - Attachments 00 - General 00 - General Contents Page No. 03-00-00 General ..........................03-3 03 - 1 9813/2300-2 03 - 1...
  • Page 28 Notes: 03 - 2 9813/2300-2 03 - 2...
  • Page 29: Attachments

    A wide range of optional attachments are available Health and Safety ........... 03-4 to increase the versatility of your machine. Only JCB approved attachments are recommended for use with your machine. Consult your JCB Distributor for the full list of approved attachments available.
  • Page 30 00 - General 00 - General Health and Safety Attachments Use only the JCB approved attachments that are specified for your machine. Operating with non- specified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yourself or others.
  • Page 31: Lift Arm Quickhitch

    03 - Attachments 09 - Lift Arm Quickhitch 09 - Lift Arm Quickhitch Contents Page No. 03-09-00 General ..........................03-7 03-09-03 Mechanical Quickhitch ..................... 03-9 03-09-09 Electronic Quickhitch ...................... 03-11 03 - 5 9813/2300-2 03 - 5...
  • Page 32 Notes: 03 - 6 9813/2300-2 03 - 6...
  • Page 33: General

    03 - Attachments 09 - Lift Arm Quickhitch 00 - General 00 - General Introduction Introduction ............03-7 Quickhitches are used on machines to allow the rapid Health and Safety ........... 03-8 change of buckets, shovels and other attachments on the machine. Quickhitches do not normally have a specific function themselves in that they do not carry out handling or digging operations, but when installed on a machine...
  • Page 34 03 - Attachments 09 - Lift Arm Quickhitch 00 - General Health and Safety WARNING Do not lean out of the cab to operate the Quickhitch levers. If the controls are moved accidentally you could be killed or injured. 03 - 8 9813/2300-2 03 - 8...
  • Page 35: Mechanical Quickhitch

    03 - Attachments 09 - Lift Arm Quickhitch 03 - Mechanical Quickhitch 03 - Mechanical Quickhitch Disconnect and Connect Connect 6.1. If the keyless ignition option is fitted stop the engine and wait. 1. Align the machine square to the shovel/ Duration: 15s attachment.
  • Page 36 03 - Attachments 09 - Lift Arm Quickhitch 03 - Mechanical Quickhitch Disconnect Unresolved link (id=1380) 6. Pull levers (one each side of quickhitch plate) 1. Stop and park the machine on level ground. fully out, as at position, to retract the quickhitch 2.
  • Page 37 03 - Attachments 09 - Lift Arm Quickhitch 09 - Electronic Quickhitch 09 - Electronic Quickhitch Introduction Introduction ............ 03-11 The electronic powered quickhitch can be used for Disconnect and Connect ....... 03-12 faster attachment changeover, it has the following advantages: •...
  • Page 38 03 - Attachments 09 - Lift Arm Quickhitch 09 - Electronic Quickhitch Disconnect and Connect Figure 11. Disconnect 1. Rest the attachment on the ground. 2. Press and hold the unlock switch located in the left hand panel. 3. Verify visually that the actuator is fully extended. Refer to Figure 10.
  • Page 39 03 - Attachments 09 - Lift Arm Quickhitch 09 - Electronic Quickhitch 3. Drive the machine slowly forward. Stop when the quickhitch plate just touches the shovel/ attachment. 4. Visually verify that the quickhitch actuator is fully extended prior to engaging the hitch plate into the attachment.
  • Page 40 03 - Attachments 30 - Shovel 30 - Shovel Contents Page No. 03-30-00 General ........................... 03-15 03 - 14 9813/2300-2 03 - 14...
  • Page 41 03 - Attachments 30 - Shovel 00 - General 00 - General Introduction Introduction ............ 03-15 A shovel can be installed on many different types of Health and Safety .......... 03-16 earthmoving machines. The shovel can be directly mounted on to a lift arm assembly or mounted to the Remove and Install ........
  • Page 42 03 - Attachments 30 - Shovel 00 - General Health and Safety CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device. 03 - 16 9813/2300-2 03 - 16...
  • Page 43 03 - Attachments 30 - Shovel 00 - General Remove and Install Lifting Equipment 3. Remove the bolt (x2), washer (x2) from the pivot pin that attaches the shovel and lift arm. You can be injured if you use incorrect or faulty lifting equipment.
  • Page 44 03 - Attachments 30 - Shovel 00 - General Install 1. The installation procedure is the opposite of the removal procedure. 2. Install spacer shims as necessary. 03 - 18 9813/2300-2 03 - 18...
  • Page 45 06 - Body and Framework Contents Page No. Acronyms Glossary ............................ 06-2 06-06 Access Cover 06-06-00 General ..........................06-3 06-06-14 Rear Cover ........................06-4 06-12 Lift Arm 06-12-00 General ..........................06-7 06-12-33 Stop Pad ........................06-12 06-27 Transportation Lock 06-27-00 General ...........................
  • Page 46 Acronyms Glossary FOPS Falling Object Protective Structure Product Identification Number ROPS Roll-Over Protective Structure 9813/2300-2 2014-12-08...
  • Page 47 06 - Body and Framework 06 - Access Cover 06 - Access Cover Contents Page No. 06-06-00 General ..........................06-3 06-06-14 Rear Cover ........................06-4 06 - 1 9813/2300-2 06 - 1...
  • Page 48 Notes: 06 - 2 9813/2300-2 06 - 2...
  • Page 49 06 - Body and Framework 06 - Access Cover 00 - General 00 - General Introduction Access panels provide easy access to the machine major components test and service points and other parts which require routine testing, servicing, adjusting,replacement or repair. Before you operate the machine, make sure that all of the access panels are in their operation position and secure.
  • Page 50 06 - Body and Framework 06 - Access Cover 14 - Rear Cover 14 - Rear Cover Remove and Install Consumables 3. Swing the rear cover open to the left and insert the lynch pin to keep the cover open. Description Part No.
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