JCB 3200 3230 FASTRAC Service Repair 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 9803/9970-01 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual 3000 XTRA Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Hitches and Attachments Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Section 1 - General Information 1-0 1-0 9803/9970-01 Notes:

Page No. Contents Section 1 - General Information 1-i 1-i Use Introduction ............................................................................................. 1-1-1 Scope ..................................................................................................... 1-1-2 Format .................................................................................................... 1-1-3 Left and Right Sides ............................................................................... 1-1-4 Hydraulic Schematic Codes ................................................................... 1-1-5 Machine Identification Introduction ............................................................................................. 1-2-1 Identifying your Machine ......................................................................... 1-2-2 Torque Settings Introduction ............................................................................................. 1-3-1 Zinc Plated Fasteners and Dacromet Fasteners .................................... 1-3-2 Hydraulic Connections ............................................................................ 1-3-6 `Positional Type' Hydraulic Adaptors .................................................... 1-3-10 Service Tools Numerical List ......................................................................................... 1-4-1 Tool Detail Reference ............................................................................. 1-4-6 Service Consumables Sealing and Retaining Compounds ........................................................ 1-5-1

Page No. Contents Section 1 - General Information 1-ii 1-ii

Section 1-1 - General Information 1-1-1 1-1-1 9803/9970-01 (1-01-00) Use Introduction This topic contains information about the structure of the manual and how to use the manual. K Scope ( T 1-1-2) K Personnel ( T 1-1-2) K Applications ( T 1-1-2) K Newest Data ( T 1-1-2) K Format ( T 1-1-3) K Left and Right Sides ( T 1-1-4) K Hydraulic Schematic Codes ( T 1-1-5) K Colour Codes ( T 1-1-5)

Section 1-1 - General Information Use Scope 1-1-2 1-1-2 9803/9970-01 (1-01-00) Scope Personnel 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. Finally, please remember above all else SAFETY MUST COME FIRST! Applications This manual contains data relevant to a range of machines. Make sure you reference the data for the correct machine. Newest Data From time to time new machines, systems or devices require the manual to be re-issued. Make sure you have the newest issue. Always check the on-line JCB data system for relevant technical information.

Section 1-1 - General Information Use Format 1-1-3 1-1-3 9803/9970-01 (1-01-00) Format The manual is compiled in sections, the first three are numbered and contain information as follows: 1 General Information - general information such as torque settings and service tools. 2 Care & Safety - includes warnings, cautions and general procedures related to aspects of workshop procedures contained in the manual. 3 Routine Maintenance - includes service schedules and recommended lubricants for all the machine. The remaining sections are alphabetically coded and deal with dismantling, overhaul etc. of specific components, for example: The sections contain topics. Each topic is a self contained set of data about a machine SYSTEM or Device. Each topic contains data such as specifications, descriptions, fault finding and test procedures. Device topics also contain removal, replacement, dismantle and assemble procedures. Some topics contain procedures and specifications for different variants. This happens because of market requirements, or when the machine specification changes after a period of time. Where applicable, a table in the introduction of each topic contains information to help you identify the correct specifications or procedures. A Attachments B Body and Framework...etc.

Section 1-1 - General Information Use Left and Right Sides 1-1-4 1-1-4 9803/9970-01 (1-01-00) Left and Right Sides 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.

Section 1-1 - General Information Use Hydraulic Schematic Codes 1-1-5 1-1-5 9803/9970-01 (1-01-00) Hydraulic Schematic Codes Colour Codes The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. Red Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure. Pink Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red. Orange Pilot: Oil pressure used in controlling a device (Pilot). Blue Neural: Neutral circuit pressure. Green Exhaust: Light Green Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation). Yellow Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).

Section 1-1 - General Information Use Hydraulic Schematic Codes 1-1-6 1-1-6 9803/9970-01 (1-01-00)

JCB 3200 3230 FASTRAC Service Repair Manual

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