jcb 225T User manual

SERVICE MANUAL
SKIDSTEER LOADER
225T, 250, 250T, 260, 260T, 270,
270T, 280, 300, 300T, 320T, 325T, 330
EN - 9813/7450 - ISSUE 2 - 12/2017
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, Ventilating and Air-
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

15 - Engine
09 - Bedplate
00 - General
15 - 67 9813/7450-2 15 - 67
00 - General
Introduction .................................................... 15-67
Remove and Install ....................................... 15-68
Introduction
The bedplate acts as the main strength component
of the engine. it maintains the correct alignment and
supports the weight of the internal components.
Figure 145.
1
2
1Bedplate
2Crankcase

15 - Engine
09 - Bedplate
00 - General
15 - 68 9813/7450-2 15 - 68
Remove and Install
Special Tools
Description Part No. Qty.
Template for Sealant
Bedplate to Crankcase
(4 Cyl)
892/12356 1
Torque Wrench
(10-100Nm)
993/70111 1
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Remove the engine, refer to (PIL 15-00).
4. Remove the drive belt, refer to (PIL 15-18).
5. Remove the crankshaft pulley, refer to (PIL
15-12).
6. Remove the oil sump, refer to (PIL 15-45).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96).
8. Remove the rocker cover, refer to (PIL 15-42).
9. Remove the fuel injectors, refer to (PIL 18-18).
10. Remove the rocker assembly including the push
rods, refer to (PIL 15-42).
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however
the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
for example) remove it now, refer to (PIL 15-06).
12. Remove the fuel injection pump, refer to (PIL
18-18).
13. Remove the starter motor, refer to (PIL 15-75).
14. Remove the high duty PTO (Power Take-Off)
device (if installed).
15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
16. Remove the flywheel, refer to (PIL 15-54).
17. Remove the flywheel housing, refer to (PIL
15-54).
18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
20. Remove the high duty PTO idler drive gear (if
installed), refer to (PIL 15-51).
21. Remove the crankshaft drive gear, refer to (PIL
15-51).
22. Remove the camshaft, refer to (PIL 15-15).
23. Remove the rear timing case, refer to (PIL
15-51).
24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
caps, refer to (PIL 15-12).

15 - Engine
09 - Bedplate
00 - General
15 - 69 9813/7450-2 15 - 69
Figure 146.
5
1
18
18
18
18
18
9
11
4
8
12
X
13
18
3
7
6
2
10
P3
1-10 Main bearing bolts (x10) 11 Bedplate peripheral bolts (x16)
12 Bedplate 13 Crankcase
18 Upper bearing shell (x5) P3 O-ring (if installed)
T1 Lifting bolts (obtain locally)

15 - Engine
09 - Bedplate
00 - General
15 - 70 9813/7450-2 15 - 70
Remove
1. Remove the bedplate peripheral bolts.
2. Progressively remove the main bearing bolts in
reverse order starting at bolt 10. The bolts MUST
NOT be re-used. Discard the bolts.
3. Install the four temporary lifting bolts. Carefully
separate the bedplate from the crankcase. Use
suitable lifting equipment (if the bedplate is lifted
manually, two people will be required). DO NOT
use a lever to separate the bedplate.
4. Remove and discard the O-ring.
5. Carefully remove the upper bearing shells from
the bedplate, remove the bedplate.
Figure 147.
18
18
18
18
18
T6
T6
T6
18
12
T6
P3
13
11
A (T5)
V
Y
Y
P2
5
1
9
4
8
3
7
6
2
10
T4
T4
W
P2
B (T5)
Y
Y
P2
X
1-10 Main bearing bolts 11 Bedplate peripheral bolts (x16)
12 Bedplate 13 Crankcase
18 Lower bearing shells (x5) ALeft side template
BRight side template T3 Angle Gauge (obtain locally)

15 - Engine
09 - Bedplate
00 - General
15 - 71 9813/7450-2 15 - 71
T4 Guide pins (x2 obtain locally) T5 Sealant template
T6 Lifting bolts (x4 obtain locally) VSealant template portion for removal
WBearing tab XRear main bearing
YBearing location tab P2 Anaerobic sealant
P3 O-ring

15 - Engine
09 - Bedplate
00 - General
15 - 72 9813/7450-2 15 - 72
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
Important: Anaerobic sealant will not start to cure
whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are
put together) it will immediately start to harden. Make
sure that all the necessary tools, bolts etc. are readily
available prior to assembling the components. The
parts must be installed and tightened to the correct
torque value within 5 minutes (with a maximum
permissible time of 15 minutes).
Important: BEFORE installing the bedplate: DO NOT
rotate the crankshaft. Make sure that the upper main
bearing shells are flush with the bottom face of the
crankcase.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Make sure that all items are clean and free from
damage and corrosion.
3. Install the two guide pins T4 to the crankcase
bedplate fixing holes as shown.
4. Install the four lifting bolts T6 to the bedplate as
shown.
5. Install a new O-ring at the bedplate.
6. Use a suitable degreasing agent to clean both
sides of the lower bearing shells. Assemble the
lower bearing shells into the bedplate. Lubricate
the lower bearing shells with clean engine oil.
Note: Make sure that the location tab W engages
in the slot as shown.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
7. Note: The sealant template T5 is used on
the crankcase, NOT the bedplate. The sealant
template T5 comprises of two pieces, A and B.
Modify the template A by removing portion V.
Special Tool: Template for Sealant Bedplate to
Crankcase (4 Cyl) (Qty.: 1)
8. Locate the holes in the templates A and B using
four fixing bolts at positions Y. Use the templates
as a guide apply beads of sealant P2 around the
crankcase/bedplate mating face as shown to the
dimension specified.
Length/Dimension/Distance: 1.5mm
9. Remove the four fixing bolts at positions Y.
Remove the templates A and B, make sure
you do not smudge the sealant. Discard the
templates.
10. Add beads of sealant P2 around the four bolt
holes at positions Y, so as to join the sealant
beads as shown at X.
11. Make sure that the location guide pins T4 are in
position in the crankcase. Assemble the bedplate
to the crankcase use the alignment guide pins.
12. Note: The bedplate is heavy. Two people will
be required to lift and rotate the bedplate safely
on to the crankcase. Install new main bearing
bolts 1-10. Tighten the bolts to the correct torque
value in pairs, starting in the centre and working
outwards (in sequence 1-10) to the 1st stage pre-
torque.
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
13. Install the bedplate peripheral bolts. Tighten the
bolts to the correct torque value.
14. After installation and tightening the bedplate
peripheral bolts, further tighten the main bearing
bolts in pairs, starting in the centre and working
outwards (in sequence 1-10) to the 2nd stage
pre-torque.
15. Finally, angle tighten the main bearing bolts in
pairs, starting in the centre and working outwards
(in sequence 1-10) for the final stage torque. Use
the torque and angle method, refer to Fasteners
and Fixings, General, Introduction (PIL 72-00).
Important: If the parts have not been tightened to the
correct torque value within the maximum 15 minute
time period, then the parts must be separated,
thoroughly cleaned and fresh sealant applied.
After Installation
1. Check that the crankshaft can be freely rotated
by hand. Remove the bedplate lifting bolts T6.
2. Carry out the procedures listed, Before removal
in reverse order.
Table 54. Torque Table
Item Torque Value
1-10 (1st Stage) 50N·m
1-10 (2nd Stage) 115N·m

15 - Engine
12 - Crankshaft
00 - General
15 - 76 9813/7450-2 15 - 76
Technical Data
Table 55.
Main bearing journal diameter (x4)
- min 87.98mm
- max 88mm
Main rear bearing journal diameter (x1)
- min 99.98mm
- max 100mm
Connecting rod bearing journal diameter
- min 72.98mm
- max 73mm
Maximum wear and ovality on journals(1)
Crankshaft induction hardness 55 HRc min on surface
Thrust washer width
- min 2.44mm
- max 2.5mm
Crankshaft end float
- min 0.05mm
- max 0.28mm
(1) No visible damage/wear or marks

15 - Engine
12 - Crankshaft
00 - General
15 - 77 9813/7450-2 15 - 77
Component Identification
Figure 148.
B
A
ACrankcase
BCrankshaft

15 - Engine
12 - Crankshaft
00 - General
15 - 78 9813/7450-2 15 - 78
Operation
Lubrication
Oil is fed from the main gallery via five drillings, one
to each of the main bearings. A groove around the
diameter of the upper main bearing shell allows oil
transfer to cross drillings in the crankshaft to feed
each of the big end bearings. Crankshaft gear is
'splash' lubricated. Front and rear crankshaft oil seals
prevent oil leakage from, and dirt ingress to, the
engine.
Figure 149.
1Main gallery 2Drillings (x5)
3Main bearings 4Big end bearings
5Cross drillings 6Crankshaft gear
7Crankshaft oil seal 8Crankshaft oil seal

15 - Engine
12 - Crankshaft
00 - General
15 - 79 9813/7450-2 15 - 79
Check (Condition)
1. Check the main bearing surfaces for damage and
excessive wear.
Figure 150.
A
AMain bearing shells
2. Measure the crankshaft diameters to confirm
they are within service limits, refer to Technical
Data (PIL 15-12).
Figure 151.
B
BCrankshaft
3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oil-ways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling J-jets are clear. If
the J-jets cannot be cleared remove the fixing
screws. Remove theJ-jets and discard them.
5. Install new J-jets.
Figure 152.
D
C
CJ-jets
DFixing screws

15 - Engine
12 - Crankshaft
00 - General
15 - 80 9813/7450-2 15 - 80
Remove and Install
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Remove the engine, refer to (PIL 15-00).
4. Remove the drive belt, refer to (PIL 15-18).
5. Remove the crankshaft pulley, refer to (PIL
15-12).
6. Remove the oil sump, refer to (PIL 15-45).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96).
8. Remove the rocker cover, refer to (PIL 15-42).
9. Remove the fuel injectors, refer to (PIL 18-18).
10. Remove the rocker assembly including the push
rods, refer to (PIL 15-42).
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however
the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
for example) remove it now, refer to (PIL 15-06).
12. Remove the fuel injection pump, refer to (PIL
18-18).
13. Remove the starter motor, refer to (PIL 15-75).
14. Remove the high duty PTO device (if installed).
15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
16. Remove the flywheel, refer to (PIL 15-54).
17. Remove the flywheel housing, refer to (PIL
15-54).
18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
20. Remove the high duty PTO idler drive gear (if
installed), refer to (PIL 15-51).
21. Remove the crankshaft drive gear, refer to (PIL
15-51).
22. Remove the camshaft, refer to (PIL 15-15).
23. Remove the rear timing case, refer to (PIL
15-51).
24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
caps, refer to (PIL 15-12).
25. Remove the bedplate, refer to (PIL 15-09).
Remove
1. Remove the thrust washers between the
crankshaft and crankcase rear main bearing.

15 - Engine
12 - Crankshaft
00 - General
15 - 81 9813/7450-2 15 - 81
Figure 153.
C
B
A
A
AThrust Washers BCrankshaft
CRear main bearing
2. Put labels on the thrust washers to make sure
that they are installed in the correct positions
during assembly.
3. Use suitable lifting equipment to carefully lift the
crankshaft from the crankcase (if the crankshaft
is lifted manually, two people will be required).
4. Carefully lift out the bearing shells.
Figure 154.
D
DMain bearing shells
5. It is recommended that the bearing shells are
replaced. If however they are to be used again,
put label on the shells to make sure that they
are installed in their original positions during
assembly.
6. Inspect the crankshaft and main bearings etc.
for damage and excessive wear. Refer to Check
Condition (PIL 15-12).
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
Important: Cleanliness is of the utmost importance.
Blocked oil-ways or oil jets will cause engine failure.
Before you install the crankshaft make sure that ALL
oil-ways and jets are clear and free from debris.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Make sure that all items are clean and free from
damage and corrosion.
3. If removed or a new crankcase is being installed
then install cooling J jets as follows:

15 - Engine
12 - Crankshaft
00 - General
15 - 82 9813/7450-2 15 - 82
Figure 155.
F
E
EJ jets (x4)
FFixing screws
3.1. Insert the cooling jets into the crankcase.
3.2. Note: There are different types of cooling
jets installed depending on the engine
application. The jets are colour coded.
3.3. Be sure to install the correct jets. Refer to
the relevant parts catalogue for the correct
cooling jet identification.
3.4. Tighten the retaining screws to the correct
torque value.
4. Install the upper bearing shells as follows:
Figure 156.
D
G
DMain bearing shells
GBearing location tab
4.1. Use a suitable degreasing agent to make
sure that the surface of the upper bearing
shells are clean.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
4.2. Assemble the bearing shells into the
crankcase bearing saddles. Make sure that
the location tab engages into the slot as
shown.
4.3. Important: Make sure that the oil-way holes
in the bearing saddles align with the holes
in the bearing shell. If the holes are even
partially misaligned the piston cooling oil jet
will be restricted, causing the engine to fail.
4.4. Lubricate the upper bearing shells with
clean engine oil.
5. Use suitable lifting equipment (if the crankshaft
is lifted manually, two people will be required), to
carefully lower the crankshaft into the crankcase.
DO NOT rotate the crankshaft, the bearing shells
can become dislodged, refer to step 4.
6. Install the thrust washers as follows:

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