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jcb 225 Service Manual

Skid steer large platform
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Service Manual
Skid Steer Large Platform
Service Manual - Skid Steer Large Platform
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Tracks
Section K - Engine
Publication No.
9803/9950-2
World Class
Customer Support
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.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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  • Page 1 Customer Support 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.
  • Page 2 Section 1 - General Information Notes: 9803/9950-2...

  • Page 3: Table Of Contents

    Using the Service Manual ..............1-1 Section Numbering ................1-1 Left Side, Right Side ................1-2 Cab/Canopy ..................1-2 Machine Description .................. 1-3 The JCB Skid Steer Loader ..............1-3 Intended Use ..................1-3 Component Locations ................1-3 Identifying Your Machine ................1-5 Machine Identification Plate ..............1-5 Component Identification ...............1-6...
  • Page 4 Section 1 - General Information Contents Page No. 1-ii 1-ii...

  • Page 5: Introduction

    This manual provides information for the following Section Numbering model(s) in the JCB machine range: T11-005 – 225 225T, 260, 260T, 280, 300, 300T, 320T, 330 from The manual is compiled in sections, the first three are serial number 1745010. numbered and contain information as follows:...

  • Page 6: Left Side, Right Side

    Section 1 - General Information Introduction About this Publication Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. T055600-2 Fig 1. Cab/Canopy T1-003_2 This manual frequently makes references to the cab. For instance, 'do not operate the machine without a manual in the cab'.

  • Page 7: Machine Description

    Section 1 - General Information Introduction Machine Description Machine Description The JCB Skid Steer Loader Component Locations P12-1004 The Skid Steer Loader is a self propelled skid steer ROPS/FOPS Cab machine fitted with either wheels or tracks. The main structural support is designed to carry a front mounted...
  • Page 8 Section 1 - General Information Introduction Machine Description T054330 Fig 2. 9803-9950-2...

  • Page 9: Identifying Your Machine

    The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the JCB = UK Build. serial number on the identification plate will be wrong. Either stamp the new number of the unit on the GEO = USA Build identification plate, or simply stamp out the old number.

  • Page 10: Component Identification

    A typical engine identification number is explained as follows: 320/40001 00001 Engine Type S = 4.4 litre series. JCB Dieselmax (Tier 3) C007820-C2 Fig 4. Engine D = Turbocharged E = Electronic common rail fuel injection F = Turbocharged and after-cooled...

  • Page 11: Rops And Fops

    K FOPS Data overhead demolition or forestry. Plate ( T 1-7). JCB SKID STEER WHEELED LOADERS MAXIMUM UNLADEN MASS: 5276Kg JCB, INC. ROPS FOPS 2000 BAMFORD BLVO.
  • Page 12 Section 1 - General Information Introduction Identifying Your Machine Page left intentionally blank 9803-9950-2...

  • Page 13: Torque Settings

    For the same reason, a Dacromet nut should not be used with a Zinc or 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.
  • Page 14 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 kgf m lbf ft kgf m lbf ft 7/16 11.2 10.0 5/16 22.3...
  • Page 15 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric Thread kgf m lbf ft kgf m lbf ft 13.9 10.2 12.5 34.0 25.0...
  • Page 16 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread kgf m lbf ft 10.0 24.0 18.0 48.0 35.5 82.0 60.5 Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size ISO Metric Thread...

  • Page 17: Hydraulic Connections

    Section 1 - General Information Torque Settings Hydraulic Connections Hydraulic Connections 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.
  • Page 18 Section 1 - General Information Torque Settings Hydraulic Connections Page left intentionally blank 1-14 1-14 9803-9950-2...
  • Page 19 Tool Detail Reference, Section 1. These tools are available from JCB Service. Note: Tools other than those listed will be required. It is Some tools are available as kits or sets, the part numbers expected that such general tools will be available in any for parts within such kits or sets are not listed here.

  • Page 20: Service Tools Numerical List

    Section 1 - General Information Service Tools Numerical List Part Description See Section Number Hydraulic Hand Pump Equipment - see Tool Detail Reference (Section 1) 992/10100 Spool Clamp 892/00039 Spool Clamp 992/02800 ARV Extractor 892/00346 Gauge 892/00279 Gauge 892/00280 Gauge 892/00347 Connector 892/00254...

  • Page 21: Tool Detail Reference

    Section 1 - General Information Service Tools Tool Detail Reference Tool Detail Reference Section B - Frame and Bodywork Fig 1. 993/68100 Slide Hammer Kit 993/68101 Slide Hammer 993/68107 Bar - M20 x M20 X 800 mm 993/68102 End Stops 993/68108 Adaptor - M20 x 7/8"...
  • Page 22 Section 1 - General Information Service Tools Tool Detail Reference Fig 3. 892/00842 Glass Lifter Minimum 2 off - Essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage. Fig 6.
  • Page 23 K Fig 6. ( T 1-18). Approx 25 m length. Note: 110V models available upon request - contact JCB Technical Service. Fig 10. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.
  • Page 24 Section 1 - General Information Service Tools Tool Detail Reference Fig 15. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub). 1-20 1-20 9803/9550-2...

  • Page 25: Section C - Electrics

    Section 1 - General Information Service Tools Tool Detail Reference Section C - Electrics Fig 16. 892/00298 Fluke Meter Fig 19. 892/01174 Interconnecting cable, DLA to machine ECU diagnostics socket. Fig 17. 892/00285 Hydraulic Temperature Probe Interconnecting cable, DLA to machine ECU diagnostics socket.

  • Page 26: Section E - Hydraulics

    Section 1 - General Information Service Tools Tool Detail Reference Section E - Hydraulics 892/01016 For 25 mm Rod Diameter 892/01017 For 30 mm Rod Diameter 892/01018 For 40 mm Rod Diameter 892/01019 For 50 mm Rod Diameter 892/01020 For 50 mm Rod Diameter (slew ram) 892/01021 For 60 mm Rod Diameter 892/01022...
  • Page 27 Section 1 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11046 JCB 892/00268 Flow Monitoring Unit ServiceMaster Flow Test Kit. K Fig 24. ( T 1-23). 892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min) 892/00273 Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min)
  • Page 28 Section 1 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11051 JCB 892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit. K Fig 26. ( T 1-24). 892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in...
  • Page 29 Section 1 - General Information Service Tools Tool Detail Reference 892/00223 Hand Pump 892/00137 Micro-bore Hose 1/4 in BSP x 3 metres 892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 892/00706 Test Probe 892/00278...

  • Page 30: Section K - Engine

    Section 1 - General Information Service Tools Tool Detail Reference Section K - Engine Fig 30. 892/00041 - De-glazing Tool for Cylinder Bores To assist bedding-in of new piston rings. For details of other engine service tools refer to: – Publication No. 9806/2100 English –...

  • Page 31: Service Aids

    A medium strength sealant suitable for all sizes of 4102/1212 50 ml gasket flanges, and for hydraulic fittings of 25-65 mm diameter. JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml components. Gasketing for all sizes of flange where the strength of the joint is important.
  • Page 32 Section 1 - General Information Service Aids Sealing and Retaining Compounds Page left intentionally blank 1-28 1-28 9803-9950-2...
  • Page 33 Section 2 - Care and safety Notes: 9803/9950-1...
  • Page 34 Section 2 - Care and safety Contents Page No. Safety Notices Important Information ................2-1 The Operator Manual ................2-1 Safety Warnings ..................2-1 Safety Check List ..................2-2 Safety - Yours and Others ..............2-2 General Safety ..................2-2 Operating Safety ...................2-4 Maintenance Safety ................2-8...
  • Page 35 Section 2 - Care and safety Contents Page No. 2-ii 2-ii...

  • Page 36: Safety Notices

    Operator Manual. If you do not other operators. understand anything, ask your employer or JCB dealer to explain it. In this publication and on the machine, there are safety INT-1-4-2 notices.

  • Page 37: Safety Check List

    JCB distributor to explain them. with it. If you don't, you will not do your job well, and you will be a danger to yourself and others.
  • Page 38 Sparks in altered in any way which could affect or invalidate any such an area could cause an explosion or fire of these requirements. For advice consult your JCB resulting in death or serious injury. Distributor.

  • Page 39: Operating Safety

    Section 2 - Care and safety Safety Notices Safety Check List Operating Safety WARNING Work Sites WARNING Work sites can be hazardous. Inspect the site before working on it. You could be killed or injured if the Machine Condition ground gives way under your machine or if piled A defective machine can injure you or others.
  • Page 40 Do not lights, windows and mirrors clean. machine potentially explosive atmosphere, i.e. combustible vapours, gas or dust, Do not operate the machine if you cannot see clearly. without first consulting your JCB Distributor. 5-1-4-7 INT-2-1-14 WARNING CAUTION Electrical Power Cables Regulations...
  • Page 41 5-5-1-1_2 CAUTION WARNING Fork Spacing Use only the JCB approved attachments that are Loads can fall off incorrectly spaced forks. Always specified for your machine. Operating with non- space the forks correctly for the load. Make sure the specified attachments can overload the machine, forks are completely under the load before lifting.
  • Page 42 Section 2 - Care and safety Safety Notices Safety Check List WARNING WARNING Boom/Machine Travel Hillsides Operating the boom while you travel can cause Operating the machine on hillsides can be dangerous accidents. You will not have total control of the if proper precautions are not taken.

  • Page 43: Maintenance Safety

    Section 2 - Care and safety Safety Notices Safety Check List Maintenance Safety WARNING Entering/Leaving WARNING Entering or leaving the cab or canopy must only be made where steps and handrails are provided. Always Communications face the machine when entering and leaving. Make Bad communications can cause accidents.
  • Page 44 Section 2 - Care and safety Safety Notices Safety Check List WARNING CAUTION Fluid Under Pressure It is illegal to pollute drains, sewers or the ground. Fine jets of fluid at high pressure can penetrate the Clean up all spilt fluids and/or lubricants. skin.
  • Page 45 CAUTION WARNING 'O' rings, Seals and Gaskets Certain seals and gaskets (e.g. crankshaft oil seal) on Badly fitted, damaged or rotted 'O' rings, seals and JCB machines contain fluoroelastomeric materials gaskets can cause leakages and possible accidents. such Viton, Fluorel Technoflon.
  • Page 46 Prior to any work being carried out on systems incorporating accumulators, the system HYD-1-3_2 pressure must be exhausted by a JCB distributor, as the sudden release of the hydraulic fluid or gas may WARNING cause injury.
  • Page 47 Section 2 - Care and safety Safety Notices Safety Check List DANGER WARNING Electrolyte Wheels and tyres are heavy. Take care when lifting or Battery electrolyte is toxic and corrosive. Do not moving them. breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and Store with care to ensure that they cannot fall and eyes.
  • Page 48 Section 3 - Maintenance Notes: 9803/9950-2...
  • Page 49 Section 3 - Maintenance Contents Page No. Routine Maintenance Service Requirements ................3-1 Introduction ....................3-1 Owner/Operator Support ...............3-1 Service/Maintenance Agreements ............3-1 Fit for Purpose Tests for Lifting Equipment ..........3-2 Obtaining Replacement Parts ..............3-2 Health and Safety ..................3-3 Lubricants ....................3-3 Battery ....................3-5 Service Schedules ..................
  • Page 50 Section 3 - Maintenance Contents Contents Page No. Electrical System ..................3-43 Battery ....................3-43 Jump Starting the Engine ..............3-45 Fuses and Relays ................3-46 Battery Isolator (Option) ..............3-50 Engine ..................... 3-51 Oil and Filters ..................3-51 Cooling system ..................3-54 Alternator Belt ..................3-56 Engine Air Filter ...................3-59 Engine Exhaust ...................3-61 Fuel System .....................
  • Page 51 Thank you very much for your reading. Please Click Here Then More Information.

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