Service Manual JCB 8250 Fastrac
Contents
1. BSP Adaptor Hexagon A F Size in mm Nm kgf m Ibf ft 1 4 19 0 18 0 1 8 13 0 3 8 22 0 31 0 3 2 23 0 1 2 27 0 49 0 5 0 36 0 5 8 30 0 60 0 6 1 44 0 3 4 32 0 81 0 8 2 60 0 1 38 0 129 0 13 1 95 0 1 1 4 50 0 206 0 21 0 152 0 Table 2 Torque Settings SAE Connections SAE Tube SAE Port Hexagon A F Size Thread Size mm Nm kgf m lbf ft 4 7 16 20 15 9 20 0 28 0 2 0 2 8 16 5 18 5 6 9 16 18 19 1 46 0 54 0 4 7 5 5 34 0 40 0 8 3 4 16 22 2 95 0 105 0 9 7 10 7 69 0 77 0 10 7 8 14 27 0 130 0 140 0 13 2 14 3 96 0 104 0 12 11 16 12 31 8 190 0 210 0 19 4 21 4 141 0 155 0 16 1 5 16 12 38 1 290 0 310 0 29 6 31 6 216 0 230 0 20 1 5 8 47 6 280 0 380 0 28 5 38 7 210 0 280 0 9803 8040 2 Hoses Screwed into Adaptors Hoses 8 B screwed into adaptors 8 A seal onto an O ring 8 C which is compressed into a 45 seat machined into the face of the adaptor port Section 1 General Information Standard Torque Settings Fig 8 Hydraulic Connections Table 3 BSP Hose Torque Settings BSP Hose Size Hexagon A F in mm Nm kgf m Ibf ft 1 8 14 0 14 0 16 00 1 4 1 6 10 3 11 8 1 4 19 0 24 0 27 0 2 4 2 7 17 7 19 9 3 8 22 0 33 0 40 0 3 4 4 1 24 3 29 5 1 2 27 0 44 0 50 0 4 5 5 1 32 4 36 9 5 8 30 0 58 0 65 0 5 9 6 6 42 8 47 9 3 4 32 0 84 0 92 0 8 6 9 4 61 9 67 8 1 38 0 115 02. Service Manual JCB 8250 Fastrac Section 1 General Information Section 2 Care and Safety Section 3 Maintenance Section A Optional Equipment Section B Body and Framework Section C Electrics Section E Hydraulics Section F Transmission Section G Brakes Section H Steering Section S Suspension Section T Engine Publication No 9803 8040 6 oe A ort ere de ihe 9803 8040 2 Section 1 General Information Section 1 General Information Contents Page No Identifying the Machine Serial NUMBES richen ea vasued Ades ccddd sea vansadeasaantndidessontinlenessancldatennades 1 1 Serial Number Plate ccccceeeseeeeeeeeeaeceeeeeeeeeeeeeeeeeseeeeeaeeeeeeeeeees 1 1 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ccecceeeeeseeeeeeeeeee 1 3 Introducti saien inasa naaa n i aa a a a 1 3 Zinc Plated Fasteners golden finish eeeeeeeeeeeeesrreseeerreeeeeeesene 1 4 Dacromet Fasteners mottled silver finish 0 1 5 Hydraulic Connections oeaiei dren nnniia nnan Na ANAA NAAN ERA 1 6 O Ring Face Seal System cccceceescccceeeessecceeeeeeeeceeeeeeneeeeeeeesnnnaaes 1 6 Torque Stop Hose System ceseececcecceeeeeeeeeeeeseseeesnnnaeceeeeeeees 1 9 Service Consumables Sealing and Retaining COMPOUNAS ee cceceeeeeeteeeeeeeeneeeeeeeeeetaeeeeeeeeaas 1 10 Section
3. 126 0 11 7 12 8 84 8 92 9 1 1 4 50 0 189 0 200 0 19 3 20 4 139 4 147 5 1 1 2 55 0 244 0 260 0 24 9 26 5 180 0 191 8 9803 8040 2 Note Dimension 8 D will vary depending upon the torque applied Section 1 General Information Standard Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 4 BSP Adaptors with Bonded Washers Torque Settings BSP Size in Nm kgf m Ibf ft 1 8 20 0 2 1 15 0 1 4 34 0 3 4 25 0 3 8 75 0 7 6 55 0 1 2 102 0 10 3 75 0 5 8 122 0 12 4 90 0 3 4 183 0 18 7 135 0 1 203 0 20 7 150 0 11 4 305 0 31 0 225 0 1 1 2 305 0 31 0 225 0 1 8 9803 8040 2 1 8 Section 1 General Information Standard Torque Settings Hydraulic Connections Torque Stop Hose System 45 B Fig 9 Torque Stop Hoses 9 B screwed into adaptors 9 A seal Stop Hoses have an additional shoulder 9 D which acts onto an O ring 9 C which is compressed into a 45 seat as a physical stop machined in the face of the adaptor port To prevent the O ring being damages as a result of over tightening Torque Note Minimum dimension 9 E fixed by shoulder 9 D Table 5 BSP Torque Stop Hose Torque Settings BSP Hose Size Hexagon A F in mm Nm kgf m Ibf ft 1 8 14 0 14 0 1 4 10 0 1 4 19 0 27 0 2 7 20 0 3 8 22 0 40 0 4 1 30 0 1 2 27 0 55 0 5 6 40 0 5 8 30 0 65 0 6 6 48
4. 0 3 4 32 0 95 0 9 7 70 0 1 38 0 120 0 12 2 89 0 11 4 50 0 189 0 19 3 140 0 1 1 2 55 0 244 0 24 9 180 0 1 9 9803 8040 2 1 9 Sealing and Retaining Compounds Section 1 General Information Service Consumables Sealing and Retaining Compounds Service Consumables 711 001_3 Table 6 Type Description Part No Quantity JCB Multi Gasket 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 JCB Retainer High Strength For all retaining parts which are unlikely to be 4101 0651 50 ml dismantled JCB Threadlocker and Sealer A medium strength locking fluid for sealing and 4101 0250 10 ml retaining nuts bolts and screws up to 50 mm 4101 0251 50 ml diameter and for hydraulic fittings up to 25 mm diameter JCB Threadlocker and Sealer A high strength locking fluid for sealing and retaining 4101 0550 10 ml High Strength nuts bolts and screws up to 50 mm diameter and 4101 0552 200 mi for hydraulic fittings up to 25 mm diameter JCB Threadseal A medium strength thread sealing compound 4102 1951 50 ml JCB Activator A cleaning primer which speeds the curing rate of 4104 0251 200 ml Aer
5. 1 General Information Contents Page No 1 ii 1 ii Section 1 General Information Identifying the Machine Serial Numbers Identifying the Machine Serial Numbers Serial Number Plate Each machine has a serial number plate located at X The 17 digit Vehicle Identification Number VIN and the serial numbers of the engine and transmission are stamped on the plate A Manufacturing code B Machine range FT Fastrac C Engine type D Transmission type gearbox amp axle combination E Vehicle max speed 40 40 kph 50 50 kph 65 65 kph F Serial number Unit Identification The serial number of each major unit is also stamped on the unit itself as shown below If a major unit is replaced by a new one the serial number on the plate will be wrong Either stamp the new number of the unit on the identification plate or simply stamp out the old number This will prevent the wrong unit number being quoted when replacement parts are ordered Engine M Gearbox N Front axle P Rear axle R 1 1 9803 8040 2 1 1 Fig 6 C022680 022670 9803 8040 2 Section 1 General Information Identifying the Machine Serial Numbers Section 1 General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Introduction Some external fasteners on Fastrac machines are assembled using an improved type of corrosion resistant f
6. in the text Values are for dry threads Diameter Torque Settings and may be within three per cent of the figures stated For mm Nm kgfm Ibfft lubricated threads the values should be REDUCED by one M3 2 0 2 15 mn M4 6 0 6 4 5 Metric Grade 8 8 Bolts M5 E 11 8 Size Torque Settings M6 19 1 9 14 Nm kgfm Ibfft Me ee ee Diameter Hexagon A F M10 91 9 3 67 mm mm M12 159 16 2 117 M16 395 40 292 M5 5 8 7 07 5 M18 550 56 406 M6 6 10 12 12 9 M20 770 79 568 M8 8 13 28 30 21 M24 1332 136 983 M10 10 17 56 57 42 M12 12 19 98 10 75 Verbus Ripp Bolts M16 16 24 244 25 180 M18 18 27 350 36 258 M20 20 30 476 48 352 M24 24 36 822 84 607 M30 30 46 1633 166 1205 M36 36 55 2854 291 2105 Metric Grade 10 9 Bolts Torque settings for these bolts are determined by the application Refer to the relevant procedure for the Size Torque Settings required settings Nm kgfm Ibf ft Diameter Hexagon A F mm mm M6 6 8 16 1 6 12 M8 8 13 39 4 29 M10 10 17 78 8 57 M12 12 19 137 14 101 M16 16 24 343 35 253 M20 20 30 657 67 485 M24 24 36 1157 118 853 1 4 9803 8040 2 1 4 Section 1 General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Dacromet Fasteners mottled silver Metric Grade 12 9 Bolts f
7. hen 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 find 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 that 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 9803 8040 1 General Safety 11 007 A WARNING 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
8. inish Bolt size Torque Settings Use the values on these pages only where no torque Dia Nm kgfm Ibfft setting is specified in the text M6 x 1 0 15 1 5 11 Note Dacromet fasteners are lubricated as part of the wees ii a ae plating process Do not lubricate M10 x 1 5 80 8 2 59 M12 x 1 75 133 13 6 98 Metric Grade 8 8 Bolts M14x2 225 23 166 Bolt size Torque Settings M16 x 2 350 35 7 258 Dia Nm kgfm Ibf ft M18 x 2 5 463 47 342 M6 x 1 0 9 09 7 M20 x 2 5 654 67 482 M8 x 1 25 22 5 23 17 M24 x 3 1125 115 830 M10 x 1 5 475 48 35 M30 x 3 5 2247 229 1657 M12 x 1 75 80 8 2 59 M14 x2 133 13 6 98 M16 x2 200 204 148 M18 x 2 5 278 284 205 M20 x 2 5 392 40 289 M24 x3 675 69 498 M30 x 3 5 1348 138 994 Metric Grade 10 9 Bolts Bolt size Torque Settings Dia Nm kgfm Ibf ft M6 x 1 0 13 5 1 4 10 M8 x 1 25 35 3 6 26 M10 x 1 5 625 64 46 M12 x 1 75 115 11 7 85 M14 x2 175 17 9 129 M16 x2 300 306 221 M18 x 2 5 395 40 291 M20 x 2 5 559 57 412 M24 x3 962 98 710 M30 x 3 5 1920 196 1416 1 5 9803 8040 2 1 5 Section 1 General Information Standard Torque Settings Hydraulic Connections Hydraulic Connections T11 003 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 Table 1 Torque Settings BSP Adaptors
9. inish This type of finish is called Dacromet and replaces the original Zinc and Yellow plating used on earlier machines The two types of fasteners can be readily identified by colour and part number suffix as follows Fastener Type Colour Part Number Zinc and Yellow Golden Z e g 1315 3712Z finish Dacromet Mottled D e g 1315 3712D silver finish As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners the torque figures used must be relevant to the type of fasteners A Dacromet bolt should not be used in conjunction with a Zinc and Yellow plated nut as this could change the torque characteristics of the torque settings further For the same reason a Dacromet nut should not be used in conjunction with a Zinc and Yellow plated bolt Dacromet bolts due to their high corrosion resistance are used in areas where rust could occur Dacromet bolts are only used for external applications They are not used in applications such as gearbox and engine joint seams or internal applications Note All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification 1 3 9803 8040 2 Section 1 General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Zinc Plated Fasteners golden finish Metric All Internal Hexagon Headed Cap Screws Use the values on these pages only where no torque setting is specified
10. ne INT 3 3 9 A WARNING 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 A WARNING Raised Equipment Raised equipment can fall and injure you Do not walk or work under raised equipment unless safely supported 13 1 1 6 A WARNING 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 9803 8040 1 Lightning Lightning can kill you Do not use the machine if there is lightning in your area 5 1 1 2 A WARNING 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
11. osol anaerobic products 4104 0253 1 Itr Bottle JCB Cleaner Degreaser For degreasing components prior to use of 4104 1557 400 ml Aerosol anaerobic adhesives and sealants Direct Glazing Kit For one pane of glass comprises of 993 55700 1x Ultra Fast Adhesive 310 ml 1x Active Wipe 205 30 ml 1 x Black Primer 206J 30 ml plus applicator nozzle etc Ultra Fast Adhesive For direct glazing 4103 2109 310 ml Active Wipe 205 For direct glazing 4104 1203 250 ml Black Primer 206J For direct glazing 4201 4906 30 ml Clear Silicone Sealant To seal butt jointed glass 4102 0901 Plastic to Metal Bonder To seal plastic to metal joints 4103 0956 50g Black Polyurethane Sealant To finish exposed edges of laminated glass 4102 2309 310 ml 9803 8040 2 9803 8040 2 Section 2 Care and Safety Section 2 Care and Safety Contents Page No Safety Check List IATOGUGUON penia a ied heed dele eee eal 2 1 Dalety FINS 2d cccvsecieds cceelehed preteens aged svadd hedieied gaeativhte phe aep add tagueeiaphedeetoat 2 2 Safety Yours and Others 00 00 ccccccceesencccceeeeeeaceeeeeeeneneceeeseeeeeeeeeseanes 2 2 General Se oae a Gesadevesesspeceez E deesshessedeecuniee dees eeee 2 2 Operating Sately venias a EA E 2 4 Maintenance Safety 222 ccceccieeeeeceteteeseceetetepedeeeneteneeeceneeepeaedeneteeeeecesteeees 2 9 Contents Section 2 Care and Safety Page No Section 2 Care and Safety Safety Check Li
12. st Introduction T1 006 A WARNING 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 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 A DANGER 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 A WARNING Denotes a hazard exists If proper precautions are not taken the operator or others could be killed or seriously injured INT 1 2 2 A CAUTION 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 2 1 9803 8040 1 2 1 Section 2 Care and Safety Safety Check List Safety First Safety First As well as the warnings in this chapter specific warnings are given throughout the book This section is designed to give a safety code for use of the machine generally and for operation and maintenance practices Safety Yours and Others INT 1 3 1_3 All machinary can be hazardous W
13. understand INT 1 3 2_2 A WARNING 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 A WARNING 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 ear protectors and industrial gloves Keep cuffs fastened Do not wear a necktie or scarf Keep long hair restrained INT 1 3 6 A WARNING 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 A WARNING Section 2 Care and Safety Safety Check List Safety First A DANGER 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 A WARNING 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 machi
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