JCB 3185 FASTRAC Service Repair Manual SN 00642001-00643010 PDF

General Information 1
Care & Safety 2

Routine Maintenance 3
Service Optional Equipment A
Manual Body & Framework B
Electrics C
Fastrac Controls D
2115, 2125, 2135,
2140, 2150
Hydraulics E
From Serial No 0738000
Transmission F
3155, 3185
From Serial No 0640000 Brakes G
Published by the
TECHNICAL PUBLICATIONS DEPARTMENT
of
JCB SERVICE LTD;
World Parts Centre,
Steering H
Waterloo Park
Uttoxeter, Staffordshire
ST14 7BS
Suspension S
Publication No. 9803/8020
Issue 17
Engine T
Introduction
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.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of
course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe
connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all
else
SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools.

2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for the whole machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for
example:
A = Optional Equipment
B = Body & Framework ...etc
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later
issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
Page cross references are generally made by presenting the subject title printed in bold, followed by the title of the section
containing the subject. For example:
“24 If the axle is still on the machine, fit the brake calipers (see Brake Caliper Removal and Replacement, Section G).”
Note: If only the subject title in bold is given, i.e. no section title, the cross reference is to another part of the same section.
Use the contents list at the beginning of each section to find the exact page number.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.
‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.
9803/8020 Issue 1
Section 1 General Information Section 1
i i
Contents Page No.
Machine Identification Plate 1-1

Typical Vehicle Identification Number (VIN) 1-1
Typical Engine Identification Number 1-1
Unit Identification 1-1
Torque Settings
Introduction - Zinc Plated Fasteners and Dacromet Fasteners 2-1
Zinc Plated Fasteners 2-2
Dacromet Fasteners 2 - 3 to 2 - 6
Sealing and Retaining Compounds 3-1
Service Tools Numerical List 4-1
* Service Tools
Body and Framework 5-1
Electrics 6-1
Hydraulics 7-1
Transmission 8-1
Brakes 9-1
Steering 9-1
Suspension 9-2
Engine 9-2
Moving a Disabled Machine

General 10 - 1
Preparation for Towing 10 - 1
Transporting the Machine 10 - 2
9803/8020 Issue 4*
1-1 1-1
Machine Identification Plate Typical Engine Identification Number
Each machine has an identification plate located at X. The YH 50532 U 123456 X

Vehicle Identification Number (VIN), and the serial numbers
of the engine and transmission are stamped on the plate.
G H J K L
Typical Vehicle Identification No. (VIN) G = Engine Type:-

YB = Turbocharged 1000 Series, 6 cylinder
SLP FT 11 3 30 0738010 YD = Intercooled 1000 Series, 6 cylinder
YH = Turbocharged New 1000 Series, 6 cylinder
YK = Intercooled New 1000 Series, 6 cylinder
H = Build List Number
A B C D E F
(see Engine Technical Data for details)
J = Country of Origin
A = Manufacturing Code
K = Engine Serial Number
B = Machine Range
L = Year of Manufacture
* C = Engine Code:
07 = 1006-6T4
* Note: Fastrac 2140 and 3185 engines are identified by the
10 = 6BTA
model number and a separate engine serial number.
13 = New 1000 Series, Rating 1941/2300 (2115)
Unit Identification
The serial number of each major unit is also stamped on the
20 = Fastrac 2140 engine
unit itself as shown below. If a major unit is replaced by a
* D = Transmission Speed Code:
new one, the serial number on the plate will be wrong. Either
3 = 30 km/h
stamp the new number of the unit on the identification plate,
4 = 40 km/h
or simply stamp out the old number. This will prevent the
5 = 55 km/h
wrong unit number being quoted when replacement parts
6 = 65 km/h
are ordered.
7 = 75 km/h
C = 40 km/h (Fastrac 2140 only
* Fastrac 2115, 2125, 2135, 2150 and 3155 Engines M
E = Vehicle Max. Speed Code:
Fastrac 2140 and 3185 Engines T
30 = 30 km/h
Transmission (Assembly of all three gearboxes) N
40 = 40 km/h
Speed Gearbox P
50 = 50 km/h
Front Axle R
80 = 80 km/h
Rear Axle S
F = Sequential Serial Number
T
S M
N R
X
P
194601
9803/8020 Issue 3*
2-1 Torque Settings 2-1
* Introduction - Zinc Plated Fasteners and Dacromet Fasteners

The JCB Fastrac 3000 series from serial number 642494 and the Fastrac 2000 series from serial number 740276 are
assembled using an improved type of corrosion resistant finish on the external fasteners. 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 finish ‘Z’ (e.g. 1315/3712Z)
Dacromet Mottled silver finish ‘D’ (e.g. 1315/3712D)
Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, when servicing the Fastrac it
is important that you are aware of this change of policy and that the information you are using is relevant to the type of
fasteners that you have.
Note: 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.
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
Note: Dacromet bolts, due to their high corrosion resistance are used areas where rust could occur. Dacromet bolts are only
used for external applications.
9803/8020 Issue 3*
Zinc Plated Fasteners (golden finish)

Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the
figures stated. For lubricated threads the values should be REDUCED by one third.
Metric Grade 8.8 Bolts Metric - All Internal Hexagon Headed Cap Screws
Bolt size Torque Settings Diameter Torque

Dia. (mm) Hexagon Nm kgf m lbf ft mm Nm kgf m lbf ft
(A/F) mm
M5 (5) 8 7 0.7 5 M3 2 0.2 1.5

M6 (6) 10 12 1.2 9 M4 6 0.6 4.5
M8 (8) 13 28 3.0 21 M5 11 1.1 8
M10 (10) 17 56 5.7 42 M6 19 1.9 14
M12 (12) 19 98 10 72 M8 46 4.7 34
M16 (16) 24 244 25 180 M10 91 9.3 67
M18 (18) 27 350 36 258 M12 159 16.2 117
M20 (20) 30 476 48 352 M16 395 40 292
M24 (24) 36 822 84 607 M18 550 56 406
M30 (30) 46 1633 166 1205 M20 770 79 568
M36 (36) 55 2854 291 2105 M24 1332 136 983
Metric Grade 10.9 Bolts Verbus Ripp Bolts
Bolt size Torque Settings

Dia. (mm) Hexagon Nm kgf m lbf ft
(A/F) mm
M6 (6) 8 16 1.6 12
M8 (8) 13 39 4 29
M10 (10) 17 78 8 57
A343780
M12 (12) 19 137 14 101
M16 (16) 24 343 35 253
M20 (20) 30 657 67 485 Torque settings for these bolts are determined by the
M24 (24) 36 1157 118 853 application. Refer to the relevant procedure for the
required settings.
Note: In most cases Verbus Ripp bolts should not be re-

used. If one is disturbed it should be removed and a new
one fitted in its place. For details of exceptions to this
general rule, see T.I.’s 10/140 (F161/N. Am) and 10/141
(F162 N. Am).
Hydraulic Hose to Adapter Connections Hydraulic Adapter into Component Connections

with bonded washers
Torque Settings Torque Settings

BSP Size Nm kgf m lbf ft BSP Size Nm kgf m lbf ft
(inches) (inches)
1/8 14 1.4 10 1/8 20 2.1 15

1/4 24 2.5 18 1/4 34 3.4 25
3/8 33 3.3 24 3/8 75 7.6 55
1/2 44 4.8 35 1/2 102 10.3 75
5/8 58 6.0 43 5/8 122 12.4 90
3/4 84 8.6 62 3/4 183 18.7 135
1 115 11.8 85 1 203 20.7 150
11/2 244 24.9 180 11/2 305 31 225
9803/8020 Issue 1*
Dacromet Fasteners (mottled silver finish)

Use only where no torque setting is specified in the text.
NOTE: DACROMET FASTENERS ARE LUBRICATED AS PART OF THE PLATING PROCESS: DO NOT LUBRICATE.
Metric Grade 8.8 Bolts

Dia. Nm kgf m lbf ft
M6 x 1.0 9 0.9 7
M8 x 1.25 22.5 2.3 17
M10 x 1.5 47.5 4.8 35
M12 x 1.75 80 8.2 59
M14 x 2 133 13.6 98
M16 x 2 200 20.4 148
M18 x 2.5 278 28.4 205
M20 x 2.5 392 40 289
M24 x 3 675 69 498
M30 x 3.5 1348 138 994

M6 x 1.0 13.5 1.4 10

M8 x 1.25 35 3.6 26
M10 x 1.5 62.5 6.4 46
M12 x 1.75 115 11.7 85
M14 x 2 175 17.9 129
M16 x 2 300 30.6 221
M18 x 2.5 395 40 291
M20 x 2.5 559 57 412
M24 x 3 962 98 710
M30 x 3.5 1920 196 1416

M6 x 1.0 15 1.5 11
M8 x 1.25 40 4.1 29
M10 x 1.5 80 8.2 59
M12 x 1.75 133 13.6 98
M14 x 2 225 23 166
M16 x 2 350 35.7 258
M18 x 2.5 463 47 342
M20 x 2.5 654 67 482
M24 x 3 1125 115 830
M30 x 3.5 2247 229 1657
9803/8020 Issue 1*
Dacromet Fasteners (mottled silver finish) - List of Torque Settings

This list represents those fasteners which have been affected by the change from zinc-plated to Dacromet but are not
mentioned in the service manual. The settings apply to 2000 and 3000 series machines unless otherwise stated.
Location: Rockinger Hitch Bolt Location: Gearbox Crossmember Bolt: Rear Crossmember
Nm: 392 kgfm: 40 lbf ft: 289 Nm: 200 kgfm: 20 lbf ft: 148 Nm: 392 kgf m: 40 lbf ft: 289
A402280
A402030
Bolt: Left Hand Pannier Step Bolt: Right Hand Pannier (rear) Bolt: Right Hand Pannier (front)
Nm: 47.5 kgf m: 4.8 lbf ft: 35 Nm: 80 kgf m: 8.2 lbf ft: 59 Nm: 47.5 kgf m: 4.8 lbf ft: 35
(2000 series machines only) (2000 series machines only)
A402200 A402190 A402160
Bolt: Front Wrapper (top/bottom) Bolt: Rear Lower Crossmember Bolt: Lower Link Bolt (Hex Head)
Nm: 392 kgf m: 40 lbf ft: 289 Nm: 80 kgf m: 8.2 lbf ft: 59 Nm: 392 kgf m: 40 lbf ft: 289
(2000 series machines only)
A402060
A402050
A402040
9803/8020 Issue 1*
Dacromet Fasteners (mottled silver finish) - List of Torque Settings (cont.)

Location: Lower Link Bolt (capscrew) Location: Tower Casting to Axle Location: Front Lower Crossmember
Nm: 654 kgf m: 67 lbf ft: 482 Nm: 392 kgf m: 40 lbf ft: 289 Nm: 115 kgf m: 12 lbf ft: 85
A402010
A402140 A401990
Location: Rear Lower Crossmember Location: Fuel Tank Support Strap Location: Front P.T.O. Box
Nm: 200 kgf m: 20 lbf ft: 148 Nm: 47.5 kgf m: 4.8 lbf ft: 35 Nm: 200 kgf m: 20 lbf ft: 148
A402260 A402090
A402230
Location: Front Axle Upper Arm Location: Steershaft Bearing Location: Steershaft Intermediate UJ
Mounting Bracket Nm: 28 kgf m: 2.9 lbf ft: 21 Nm: 38 kgf m: 3.9 lbf ft: 28
Nm: 200 kgf m: 20 lbf ft: 148 (3000 series machines only) (3000 series machines only)
A402270
9803/8020 Issue 2
Dacromet Fasteners (mottled silver finish) - List of Torque Settings (cont.)

* Location: Front Anti-Roll Bar Location: Front Anti-Roll Bar Location: 4.W.S. only rear anti-roll
Fasteners: Insulators Fasteners: Pivot Bolt bar crossmember
Nm: 47.5 kgf m: 4.8 lbf ft: 35 Nm: 278 kgf m: 28 lbf ft: 205 Nm: 80 kgf m: 8.2 lbf ft: 59
A402080
A402130
Location: Rear Anti-Roll bar Location: Front Anti-Roll Bar

mounting bracket Fasteners: Pivot Bolt
Nm: 392 kgf m: 40 lbf ft: 289 Nm: 200 kgf m: 20 lbf ft: 148
A402120
A402110
Location: Front Engine Mounting Location: Header Tank Clamp Plate

Nm: 200 kgf m: 20 lbf ft: 148 Nm: 30 kgf m: 3 lbf ft: 22
A402290
A402150
9803/8020 Issue 2*
3-1 3-1
Sealing and Retaining Compounds

* Gasketing - Loctite 509 To seal the joint faces between the PTO/splitter gearbox, the 4102/3202 50ml
speed gearbox and the range gearbox. 4102/3240 315 ml
JCB Multigasket A medium strength sealant suitable for all sizes of gasket
flanges, and for hydraulic fittings of 25-65 mm diameter. 4102/1212
JCB High Strength Threadlocker A high strength locking fluid for use with threaded components. 4102/0551
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 dismantled. 4101/0651
JCB Threadlocker & Sealer A medium strength locking fluid for sealing and retaining nuts,
bolts, and screws up to 50 mm diameter, and for hydraulic
fittings up to 25 mm diameter. 4101/0251
JCB Threadlocker For threads of suction strainer. 4101/0451 50ml
JCB Threadlocker & Sealer A medium to high strength locking fluid. 4101/0552
(High Strength)
JCB Threadseal Medium strength thread sealant (for patch bolts that are re-used). 4102/1951 50 ml
Clayton System Seal SC1251 A thread sealant used mainly on air brake system hose adapters. 4102/2210 2ml
JCB Activator A cleaning primer which speeds the curing rate of anaerobic 4104/0251 Aerosol
products. 4104/0253 Bottle
JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic adhesives
and sealants. 4104/1557 Aerosol
Direct Glazing Kit For one pane of glass, comprises items marked † below plus
applicator nozzle etc. 993/55700
† Ultra Fast Adhesive For direct glazing 4103/2109 310 ml
† Active Wipe 205 For direct glazing 4104/1203 250 g

4104/1206 30 ml
† Black Primer 206J For direct glazing 4201/4906 30 ml
JCB Clear Silicone Sealant To seal butt jointed glass. Also to seal hub planet gear carrier
when no 'O' ring is fitted 4102/0901
Black Polyurethane Sealant To finish exposed edges of laminated glass 4102/2309 310 ml
9803/8020 Issue 2*
4-1 4-1
Service Tools Numerical List

Page No.
1370/0901Z Nut M24 9-1 892/00272 Adapter 7-1
1406/0021 Bonded Washer 7-1 892/00273 Sensor Head 7-1
1604/0006 Adapter 7-1 892/00274 Adapter 7-2
1604/0008 Adapter 7-1 892/00275 Adapter 7-1
1606/0012 Adapter 7-1 892/00276 Adapter 7-1
1606/0015 Adapter 7-1 892/00277 Adapter 7-1
1612/0006 Adapter 7-1 892/00278 Gauge 0 - 40 bar 7-2
* 331/64246 Tool Kit for Non-return Valve 7-2 892/00279 Gauge 0 - 400 bar 7-2
* 331/64265 etaining Bush for Valve spool 7-2 892/00281 Avo Meter 6-1
4101/0251 JCB Threadlocker and Sealer 3-1 892/00282 Shunt 6-1
4101/0451 JCB Threadlocker 3-1 892/00283 Tool Kit Case 6-1
4101/0552 JCB Threadlocker and Sealer 892/00284 Digital Tachometer 6-1
(High Strength) 3-1 892/00285 Oil Temperature Probe 6-1
4101/0651 JCB Retainer (High Strength) 3-1 892/00286 Surface Temperature Probe 6-1
4102/0551 JCB High Strength Threadlocker 3-1 892/00293 Connector Pipe 7-1
4102/0901 JCB Clear Silicone Sealant 3-1 892/00294 Connector Pipe 7-1
4102/1212 JCB Multigasket 3-1 892/00298 Fluke Multimeter 6-1
4102/1951 JCB Threadseal 3-1 892/00311 Brake Test Kit 8-4
4102/2210 Clayton System Seal SC1251 3-1 892/00312 Dummy End Plate 8-2
4102/2309 Black Polyurethane Sealant 3-1 892/00313 Clutch Alignment Tool 8-1
4103/2109 Ultra Fast Adhesive 3-1 892/00314 Accumulator Adapter 9-1
4104/0251 JCB Activator (Aerosol) 3-1 892/00315 Engine Support Brackets 8-1
4104/0253 JCB Activator (Bottle) 3-1 892/00318 Hose and Adapter Kit 7-2
4104/1557 JCB Cleaner/Degreaser 3-1 892/00333 Heavy Duty Socket, 19 mm A/F 8-2
4104/1203 Active Wipe 205 (250 g) 3-1 892/00334 Gland Seal Fitting Tool 7-2
4104/1206 Active Wipe 205 (30 ml) 3-1 892/00706 Test Probe 7-2
4104/1310 Hand Cleaner 5-1 892/00800 Splitting Frame 8-1
4201/4906 Black Primer 3-1 892/00801 Clutch spanner 5-3
454/30056 Spacer 13.80 mm 8-4 892/00802 Rotor puller set 5-3
477/00437 Gearbox Lifting Adapter 8-2 892/00803 Rotor installer set 5-3
721/00664 Connecting Lead (Psion Workabout) 6 - 1 892/00807 Front plate puller 5-3
721/10885 Harness - Diagnostic (J1939) 6-2 892/00808 Shaft protector 5-3
816/15118 Test Adapter 7-1 892/00812 Drive Coupling Spanner 8-1
816/20008 Adapter 7-1 892/00817 Heavy Duty Socket, 17 mm A/F 8-2
816/20013 Adapter 7-1 892/00818 Heavy Duty Socket, 22mm A/F 8-2
816/55038 Adapter/Test Point 7-1 892/00819 Heavy Duty Socket, 15 mm A/F 8-2
816/55040 Adapter/Test Point 7-1 892/00842 Glass Lifter 5-1
892/00041 Deglazing Tool 9-2 892/00843 Folding Stand 5-1
892/00078 Connector 7-1 892/00844 Long Knife 5-2
892/00137 Micro Bore Hose 7-2 892/00845 Cartridge Gun 5-1
892/00174 Measuring Cup 8-2 892/00846 Glass Extractor Handles 5-2
892/00179 Bearing Press 8-1 892/00847 Nylon Spatula 5-3
892/00180 Seal Fitting Tool 9-1 892/00848 Wire Starter 5-2
892/00181 Replacement Plastic Boss 9-1 892/00849 Braided Cutting Wire 5-2
892/00223 Hand Pump 7-2 892/00864 PD 90 Axle Locknut Spanner 8-4
892/00224 Impulse Extractor 8-2 892/00871 Frame (Puller Adapter Assembly) 9-1
892/00225 Adapter for Impulse Extractor 8-1 892/00874 Brace (Puller Adapter Assembly) 9-1
892/00253 Pressure Test Kit 7-1 892/00875 Bar M24 (Puller Adapter Assembly) 9-1
892/00255 Adapter/Test Point 7-1 892/00876 Block (Puller Adapter Assembly) 9-1
892/00256 Adapter/Test Point 7-1 892/00882 Socket 6-1
892/00257 Adapter/Test Point 7-1 892/00883 Spanner (Steer Box Input Shaft Nuts) 9-1
892/00258 Adapter/Test Point 7-1 892/00884 ‘C’ Spanner (Steer Box Input Shaft
892/00259 Adapter/Test Point 7-1 Nuts) 9-1
892/00260 Adapter/Test Point 7-1 892/00892 Speed Gearbox Locking Tool 8-3
892/00261 Adapter/Test Point 7-1 892/00916 Spring Compressor 8-3
892/00262 Adapter/Test Point 7-1&7-2 892/00918 Setting Tool Kit 8-4
892/00263 Adapter/Test Point 7-1 892/00945 Sleeve for M30 Pinion 8-4
892/00264 Adapter/Test Point 7-1 892/00956 Timing Pin for Fuel Injection Pump 9-2
892/00265 Adapter/Test Point 7-1 892/01033 Data Link Adapter Kit 6-2
892/00268 Flow Monitoring Unit 7-1 892/01045 Peg Socket - Wet Clutch 8-5
892/00269 Sensor Head 7-1 892/01046 Mandrel - Wet Clutch 8-5
892/00270 Load Valve 7-1 892/01047 Jig - Wet Clutch 8-5
892/00271 Adapter 7-1
9803/8020 Issue 8*
4-2 4-2
Service Tools Numerical List (continued)

Page No.
892/01048 Clutch Pack Retainer - Wet Clutch
(2 required) 8-4
892/01049 Guide Rod - Wet Clutch
(2 required) 8-4
892/01050 Mandrel - Wet Clutch 8-5
892/01051 Intermediate Gear Retaining Tool -
Wet Clutch Transmission 8-4
892/01052 Locking Plate - Wet Clutch
(2 required) 8-4
892/01053 Adapter for impulse extractor
(PTO intermediate shaft,
wet clutch transmission) 8-2
* 892/01092 Wheel Hub Service Kit 8-5
926/15500 Rubber Spacer Blocks 5-3
992/12300 Mobile Oven 5-1
992/12400 Static Oven 5-1
992/12600 Static Oven 5-1
992/12800 Cut-out Knife 5-2
992/12801 'L' Blades 5-2
993/45400 Torque Multiplier 8-2
993/55700 Direct Glazing Kit 3-1
993/59300 Pressure Test Adapter and Clamp 8-3
993/70111 Break-back Torque Wrench 8-4
993/85700 Battery Tester 6-1
997/11000 Drive Head Setting Bracket 8-4
997/11100 Adapter for M24 Pinion 8-4
The following parts are replacement items for kits and would
normally be included in the relevant kit numbers.
Replacement items for kit no. 892/00253
892/00201 Gauge 0 - 20 bar 7-1
892/00202 Gauge 0 - 40 bar 7-1
892/00203 Gauge 0 - 400 bar 7-1
892/00254 Hose 7-1
* 993/69800 Seal Kit 7-1
* Replacement parts for kit no. 892/01092

1315/3414Z Bolt M10x60 8-5
1315/3731Z Bolt M16x220 8-5
1315/3835Z Bolt M20x300 8-5
1370/0301Z Nut M10 8-5
1370/0401Z Nut M12 8-5
1370/0601Z Nut M16 8-5
1370/0701Z Nut M20 8-5
1420/0009Z Washer M12 8-5
1420/0012Z Washer M20 8-5
445/12303 Washer 8-5
892/00891 Dolly 8-5
917/02800 Bearing 8-5
998/10606 Bearing Fitting Tube 8-5
998/10607 Inner Bearing Plate 8-5
998/10608 Bearing Centre Puller 8-5
998/10610 Puller Rod 8-5
998/10614 Reaction Tube 8-5
998/10615 Wheel Bearing Carrier Puller 8-5
998/10616 Puller Handle Nut 8-5
998/10623 Puller Beam 8-5
998/10624 Modified Wheel Stud 8-5
9803/8020 Issue 6*
5-1 5-1
Service Tools
Section B - Body and Framework
S186240 S186270
Hand Cleaner - special blend for the removal of Cartridge Gun - hand operated - essential for the
polyurethane adhesives. application of sealants, polyurethane materials etc.
JCB part number - 4104/1310 (454g; 1lb tub) JCB part number - 892/00845
'
S186250
12V Mobile Oven - 1 cartridge capacity - required to

pre-heat adhesive prior to use. It is fitted with a male S186280
plug (703/23201) which fits into a female socket Folding Stand for Holding Glass - essential for
(715/04300). preparing new glass prior to installation.
JCB part number - 992/12300 JCB part number - 892/00843
S186260
240V Static Oven - available with 2 or 6 cartridge
S186300
capacity - required to pre-heat adhesive prior to use.
No plug supplied. Note: 110V models available upon Glass Lifter - minimum 2 off - essential for glass
request - contact JCB Technical Service installation, 2 required to handle large panes of glass.
Ensure suction cups are protected from damage
JCB part number: during storage.
992/12400 - 2 cartridge x 240V
992/12600 - 6 cartridge x 240V JCB part number - 892/00842
9803/8020 Issue 1
5-2 5-2
Service Tools (continued)

Section B - Body and Framework (continued)
S186310 S186340
Wire Starter - used to access braided cutting wire Cut-out Knife - used to remove broken glass.
(below) through original polyurethane seal.
JCB part number - 992/12800
'
S186320 S186350
Glass Extractor (Handles) - used with braided cutting 'L' Blades - 25mm (1in.) cut - replacement blades for
wire (below) to cut out broken glass. cut-out knife (above).
JCB part number - 892/00846 JCB part number - 992/12801 (unit quantity = 5 off)
S186330
S186360
Braided Cutting Wire - consumable heavy duty

cut-out wire used with the glass extraction tool Long Knife - used to give extended reach for normally
(above). inaccessible areas.
JCB part number - 892/00849 (approx 25m length) JCB part number - 892/00844
9803/8020 Issue 1
5-3 5-3

Section B - Body and Framework (continued)
S186470 S186550
Nylon Spatula - general tool used for smoothing Rubber Spacer Blocks - used to provide the correct
sealants - also used to re-install glass in rubber glazing set clearance between glass edge and cab frame.
because metal tools will chip the glass edge.
JCB part number - 892/00847 (unit quantity = 500 off)
892/00801 Clutch spanner S200940 892/00807 Front plate puller S200970

for air conditioning compressor for air conditioning compressor
892/00802 Rotor puller set S200950 892/00808 Shaft protector S200980

for air conditioning compressor for air conditioning compressor
892/00803 Rotor installer set S200960

for air conditioning compressor
9803/8020 Issue 1
6-1 6-1
Service Tools
Section C - Electrics
Electrical Test Equipment
1 892/00283 Tool Kit Case
2 892/00281 AVO Meter
3 892/00286 Surface Temperature Probe
4 892/00284 Microtach Digital Tachometer
5 892/00282 100 Amp Shunt - open type
6 892/00285 Hydraulic Oil Temperature Probe
7 892/00298 Fluke 85 Multimeter
188230
239510
993/85700 Battery Tester
Psion Workabout 1Mb/RS232 †

S216770 Docking Holster †
Software - Psion Link, Version 1.1 †
721/00664 Connecting Lead
892/00882 Socket for Pulley Nut on Magneti Marelli
2 x CD ROM ††
Alternator.
† These items to be obtained from your nearest
Psion agent as listed on M.I.’s 569/H, 525 HA and
516E.
†† As detailed on the same M.I.’s as above.
9803/8020 Issue 2*
6-2 6-2
Service Tools
Section C - Electrics
892/01033 Data Link Adapter Kit

A Note: Item A of the Data Link Adapter Kit is unsuitable
for use with the Fastrac and must be replaced by the
‘Harness - Diagnostic (J1939)’ shown below.
A360250
D
1 2 3 4 5 6 7 8 E
C
B A F
9 10 11 12 13 14 15 J G
H
A386040
721/10885 Harness - Diagnostic (J1939)
9803/8020 Issue 1
7-1 7-1
Service Tools
Section E - Hydraulics
Hydraulic Circuit Pressure Test Kit
892/00253 Pressure Test Kit

892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in2)
892/00254 Replacement Hose
:993/69800 Seal Kit for 892/00254 (can also be used with
probe 892/00706)
S188120
Pressure Test Adapters
Pressure Test 'T' Adapters 892/00255 1/4 in BSP x Test Point

892/00256 3/8 in BSP x Test Point S200140
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 892/00257 1/2 in BSP x Test Point
892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point 892/00259 1 in BSP x Test Point
892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point 892/00260 1.1/4 in BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point 892/00261 5/8 in UNF x Test Point
S188130
Flow Test Equipment
892/00268 Flow Monitoring Unit

892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)
892/00293 Connector Pipe
892/00270 Load Valve
1406/0021 Bonded Washer
1604/0006 Adapter 3/4 in M x 3/4 in M BSP
1612/0006 Adapter 3/4 in F x 3/4 in M BSP
892/00273 Sensor Head 0 - 380 l/min
892/00294 Connector Pipe
1606/0015 Adapter 1.1/4 in M BSP x 1 in M BSP
892/00078 Connector 1 in F x 1 in F BSP
1604/0008 Adapter 1 in M x 1 in M BSP
S188150
1606/0012 Adapter 1 in M x 3/4 in M BSP
816/20013 Adapter 3/4 in F x 1 in M BSP
9803/8020 Issue 1
7-2 7- 2

Section E - Hydraulics (continued)
S193850
Hand Pump Equipment
892/00223 Hand Pump

892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in BSP male x 3/8 BSPT male
892/00262 Test Point on 1/4 in BSP male x 1/4 BSP 197210
female adapter
892/00706 Test Probe 892/00318 Hose And Adapter Kit
892/00278 Gauge 0-40 bar (0-600 lbf/in2) To enable flow and pressure test
892/00279 Gauge 0-400 bar (0-6000 lbf/in2) equipment to be connected to adapters
fitted with 'O' ringface seals.
197220
892/00334 Gland Seal Fitting Tool 331/64246 Tool Kit for Non-return Valve
331/64265 Retaining Bush for Valve Spool
9803/8020 Issue 2
8-1 8-1
Service Tools
Section F - Transmission
197260 197270
892/00800 Splitting Frame (complete with ratchet 892/00315 Engine Support Bracket
hoist)
188200 107750
892/00179 Bearing Press 892/00812 Drive Coupling Spanner for yoke

couplings
197280 197080
892/00313 Clutch Alignment Tool 892/00225 Adapter - Impulse Extractor

Small 17mm to 25mm
Medium 25mm to 45mm
Large 45mm to 80mm
9803/8020 Issue 2
8-2 8-2
Section F - Transmission (continued)
993/45400 Torque Multiplier

(use in conjunction with a torque wrench to
give a 5 : 1 multiplication)
S197030
197250
Heavy Duty Sockets S190770
892/00817 17 mm A/F x 3/4in. square drive
892/00818 22 mm A/F x 3/4in. square drive 892/00174 Measuring Cup - Pinion Head Bearing
S197070
892/00224 Impulse Extractor Set
for Hub Bearing Seals
* 892/01053 Adapter for impulse extractor S197240
(PTO intermediate shaft, wet clutch
transmission) 892/00312 Dummy End Plate for Range Gearbox
110
25 25
15
40
A197180
197200
Rear Differential Setting Key

Cut from 5 mm plate to dimensions shown. Fabricate
477/00437 Gearbox Lifting Adapter handle to suit.
9803/8020 Issue 3*
8-3 8-3
993/59300 2/4 WD Pressure Test Adaptor & Clamp
S196750
S226300 892/00892 Speed Gearbox Locking Tool
892/00916 Spring Compressor for Splitter and PTO

Clutches
S267310
9803/8020 Issue 3
8-4 8-4
1
A B
C
2
S234120
4
892/00864 PD 90 Axle Locknut Spanner
3 A270851
Solid Spacer Setting Tools
1 892/00918 Setting Tool Kit. Contains the following:

A Sleeve for M24 Pinion
B Adapter for M30 Pinion
C Fork (suitable for all axles)
The following setting tools must be purchased
seperately:
892/00945 A Sleeve for M30 Pinion
997/11100 B Adapter for M24 Pinion
2 997/11000 Drive Head Setting Bracket A361730
3 993/70111 Break-back Torque Wrench
4 - Solid spacer (see parts CD or 892/01052 (x2) Locking Plate for locking wet clutch
michrofiche for part numbers) drum to housing
A361710
892/01051 Intermediate Gear Retaining Tool - wet
clutch transmission 892/01049 (x2) Guide Rod - wet clutch
A361740
A361720
892/01048 (x2) Clutch Pack Retainer - wet clutch
9803/8020 Issue 6*
8-5 8-5
A361750
892/01045 Peg Socket - wet clutch 892/01046 Mandrel - for bush assembly - wet clutch
A361770
A361760 A361780
892/01050 Mandrel, for hub seal renewal - wet clutch.
892/01047 Jig, for use when dismantling and
Note: Protective plastic cap A to be removed before use.
assembling of PTO input gear - wet clutch
9803/8020 Issue 1
8-6 8-6

Item Description Part No. Qty

A
5
A Hub Service Kit 892/01092 1
comprises:
1
1 Puller Beam 998/10623 1
2 Inner Bearing Plate 998/10607 1 6
3 Bolt M16x220 1315/3731Z 2
4 Nut M16 1370/0601Z 2 8,9
5 Reaction Tube 998/10614 1
6 Modified Wheel Stud 998/10624 2
7 Wheel Bearing Carrier 7
Puller 998/10615 2 2
8 Nut M20 1370/0701Z 4
9 Washer M20 1420/0012Z 2
10 Puller Rod 998/10610 2
11 Nut M12 1370/0401Z 2
10
12 Washer M12 1420/0009Z 2
13 Bearing Centre Puller 998/10608 1
14 Bolt M10x60 1315/3414Z 1
15 Nut M10 1370/0301Z 1 4 11,12
16 Bearing Fitting Tube 998/10606 1
17 Puller Handle Nut 998/10616 1
18 Bolt M20x300 1315/3835Z 2
19 Washer 445/12303 2 3
20 Bearing 917/02800 1
21 Dolly 892/00891 1
13 16
15
19, 20
14
18
8
21
17
9803/8020 Issue 1
9-1 9-1
Section G - Brakes
892/00311 Brake Test Kit
3 x Calibrated Test Gauges - 0-20 bar (0 - 290 lbf/in2)
3 x 5 Metre Hoses with Quick Release Adapters
3 x ISO Test Point Adapters

S199470
Section H - Steering
E
A
B
C 222490
229270
892/00180 Seal Fitting Tool for fitting ‘O’ ring and D

back-up ring to Danfoss Orbitrol Unit Puller adapter assembly for removal of drop arm from
steering box (3000 Series machines). Comprises:
892/00181 Replacement Plastic Boss
A 892/00871 Frame 1 off
B 892/00874 Brace 1 off
C 892/00875 Bar M24 2 off
D 892/00876 Block 2 off
E 1370/0901Z Nut M24 2 off
Use in conjunction with a 20 tonne hydraulic ram as

obtainable from Sykes Pickavant to suit puller bars at 185
mm centres.
220130
Spanners for input shaft nuts on steering box (3000 Series

machines with serial nos. 640001 to 640053 and 640056
to 640058).
F 892/00883 Spanner
G 892/00884 ‘C’ Spanner
9803/8020 Issue 3*
9-2 9-2

Section S - Suspension
S199480
892/00314 Accumulator and Gas Spring Pressure

Test Adapter
Section T - Engine
A314530
S192390
892/00041 De-glazing Tool for Cylinder Bores (to 892/00956 Timing pin for fuel injection pumps (Fastrac
assist bedding-in of new piston rings) 2115, 2125, 2135, 2150 only).
Note: For other engine tools refer to the relevant Engine

Service Manual.
9803/8020 Issue 2*
10- 1 Moving a Disabled Machine 10 - 1
General Preparation for Towing

Do not tow a machine unless there is no alternative. 1 Connect the towing vehicle.
Remember that more damage might be caused to the a Apply the parking brakes on the towing vehicle and
machine by towing it. If at all possible repair the machine securely chock the wheels on the Fastrac.
where it stands. b Fit the drawbar between towing vehicle and
Fastrac.
* Note: It is not possible to tow-start or push-start the Fastrac
2 Prepare the machine.
due to the design of the transmission.
a Make sure that the range and speed gearboxes are
both in neutral.
Make sure you will be obeying all pertinent laws and
b If the gearbox has failed, disconnect both
regulations before towing the machine on public roads.
propshafts (see Section F).
c If an axle has failed, remove the sun gears (see
! DANGER Section F).
If the engine is not running, there will not be enough air
to apply the service brakes or release the parking brake. 3 Release the Fastrac parking brake.
Carefully follow the precautions in this section before Note: The Schrader valve X shown below on the right hand
moving the machine or there may be a serious accident. side of the machine is that for Fastrac 2115, 2125 and 2135
13-2-2-6/1 machines. On 2150, 3155 and 3185 machines the valve is on
the left hand side of the machine.
! CAUTION
Towing a machine too far or too fast can damage the If there is not enough air pressure to release the brake,
transmission. Do not tow the machine further than one start the engine to charge up the air system. If the
mile. Use a trailer for greater distances. When towing do engine cannot be run but the brake air system is
not travel faster than 25 km/h (15 mph). serviceable, charge the system to 120 psi (8 bar)
through Schrader valve X. This job must be done by a
qualified mechanic, using the correct equipment.
Use a rigid drawbar. If you must use towing chains, then
use two towing vehicles. One towing vehicle should be
coupled to the front of the disabled machine. The other
! DANGER
towing vehicle should be coupled to the rear of the Ensure that the chocks and towing vehicle will prevent
disabled machine, to provide braking power. the Fastrac from moving as it is necessary to work under
the machine to release the parking brake. When the
The towing vehicle(s) must have enough pulling and parking brake has been manually released as described
braking power to move and stop the machine. below, it will be impossible to apply the brake until plate
2-2-7-3 A has been removed.
13-2-2-11
Alternatively, position plate A (if provided with the

machine) as shown. Keeping nut B tight against clevis
C, turn nut D against the plate so that rod E is drawn
out of the actuator body and the parking brake is
released.
Note: If the parking brake cannot be released, remove both

A286550 propshafts (see Section F).
The machine is now ready for towing. If you will be steering

the Fastrac, make sure you understand what the towing
driver will be doing. Obey his instructions and all relevant
D E regulations.
Remember that the steering will be much heavier if the

C engine is not running.
B A
S160392
S261600
9803/8020 Issue 3*
10 - 2 10 - 2
Transporting the Machine

The safe transit of the load is the responsibility of the 3 Anchor the machine to the trailer with chains or suitable
transport contractor and driver. Any machine, webbing straps. The preferred fixing is to use webbing
attachments or parts that may move during transit must straps individually fixing all four wheels to the deck of
be adequately secured. the trailer as at A. If chains are used they should be
5-2-5-9 connected to a suitable part of the drawbar at the rear
Note: Before transporting the machine make sure you will of the machine. At the front, use the tie down points.
be obeying the rules and laws of all the areas that the Avoid chaining any part of the machine where the
machine will be carried through. chains may damage critical componentry. For example,
chaining around either axle provides the possibility of
Make sure that the transporting vehicle is suitable. See damaging the steel brake pipes running along their
Static Dimensions (SPECIFICATIONS section in the length.
machine handbook) for the dimensions of the machine.
4 Measure the maximum height of the machine from the
ground. Try to make sure the truck driver knows the
! WARNING clearance height before he drives away.
Before moving the machine onto the trailer, make sure
that the trailer and ramp are free from oil, grease and
ice. Remove oil, grease and ice from the machine tyres.
Make sure the machine will not foul on the ramp angle.
See Static Dimensions in SPECIFICATIONS section for the
minimum ground clearance of your machine.
2-2-7-5/1
1 Place blocks at the front and rear of the trailer wheels.
2 Move the machine on to the trailer as follows:

a Make sure the ramps are correctly in place and
secure.
b Carefully drive the machine onto the trailer.
c Set the drive to neutral and engage the parking
brake.
d Switch off the engine.
e Ensure that the overall height of the load is within
regulations.
f Secure the cab.
A A
A288080
9803/8020 Issue 1
Section 2 Care & Safety Section 2
i i
Contents Page No.
Safety Notices 1-1
General Safety 2-1
Operating Safety 3-1
Maintenance Safety 4-1
9803/8020 Issue 1
1-1 1-1
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.
! 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
! 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
! 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
9803/8020 Issue 1
2-1 2-1
All construction and agricultural equipment can be Note: This section includes a certain amount of operating
hazardous. When a JCB Fastrac is correctly operated and safety information. But remember that whenever you drive
properly maintained, it is a safe machine to work with. But the machine or operate its controls you are in effect a
when it is carelessly operated or poorly maintained it can machine operator. Therefore you should read and
become a danger to you (the operator) and others. understand the information given in the Operator Handbook
before driving the machine or operating its controls.
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
GEN-1-6
As well as the warnings in the following pages, 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.
General Safety
! WARNING ! WARNING
Lifting Equipment Care and Alertness
You can be injured if you use faulty lifting equipment. Make All the time you are working with or on the machine, take
sure that lifting equipment is in good condition. Make sure care and stay alert. Always be careful. Always be alert for
that lifting tackle complies with all local regulations and is hazards.
suitable for the job. Make sure that lifting equipment is INT-1-3-5
strong enough for the job.

INT-1-3-7 ! WARNING
Raised Equipment
! WARNING Raised equipment can fall and injure you. Do not walk or
Clothing work under raised equipment unless safely supported.
You can be injured if you do not wear the proper clothing. 13-1-1-6
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 ! WARNING
fitting overall, ear-protectors and industrial gloves. Keep Machine Modifications
cuffs fastened. Do not wear a necktie or scarf. Keep long This machine is manufactured in compliance with legislative
hair restrained. and other requirements. It should not be altered in any way
INT-1-3-6
which could affect or invalidate any of these requirements.
For advice consult your JCB Distributor.
! WARNING
Alcohol and Drugs Reference should also be made to Optional Attachments
It is extremely dangerous to operate machinery when under section where appropriate.
the influence of alcohol or drugs. Do not consume alcoholic INT-1-3-10
drinks or take drugs before or whilst operating the machine

or attachments. Be aware of medicines which can cause
drowsiness.
INT-1-3-9
9803/8020 Issue 1
3-1 3-1
Operating Safety
! DANGER ! WARNING
Parking Visibility
Leaving the machine in gear will not prevent it running away. Accidents can be caused by working in poor visibility. Keep
Do not leave the driving seat under any circumstances windows clean and use your lights to improve visibility. Do
unless the parking brake is on. not operate the machine if you cannot see properly.
13-2-1-10 INT-2-1-11
! WARNING ! WARNING
Roll Over Protection Structure (ROPS) Practice
The machine is fitted with a Roll Over Protection Structure You or others can be killed or seriously injured if you do
(ROPS). You could be killed or seriously injured if you unfamiliar operations without first practising them. Practise
operate the machine with a damaged or missing ROPS. If away from the work site on a clear area. Keep other people
the ROPS has been in an accident, do not use the machine away. Do not perform new operations until you are sure you
until the structure has been renewed. Modifications and can do them safely.
INT-2-1-1
repairs that are not approved by the manufacturer may be
dangerous and will invalidate the ROPS certification.
13-1-1-8/1 ! WARNING
Machine Limits
! WARNING Operating the machine beyond its design limits can damage
Entering/Leaving the machine, it can also be dangerous. Do not operate the
Always face the machine when entering and leaving the cab. machine outside its limits. Do not try to upgrade the
Use the step(s) and handrails. Make sure the step(s), machine performance with unapproved modifications.
INT-2-1-4
handrails and your boot soles are clean and dry. Do not
jump from the machine. Do not use the machine controls as
handholds, use the handrails. ! WARNING
INT-2-1-7 Brakes
Do not coast the machine with the engine stopped as the
! WARNING main brakes will only operate for a limited number of
Seat applications and hydraulic trailer brakes will not function at
Position the seat so that you can comfortably reach the all. Also the steering will become very heavy.
13-1-1-5/2
machine controls. You could have an accident if you operate
the machine with the seat in the wrong position.
INT-3-3-5 ! CAUTION
Hydraulic Trailer Brakes
! WARNING Trailers with single line hydraulic brakes used in the United
Seat Belt Kingdom are subject to a maximum speed of 20 mph (32
Operating the machine without a seat belt can be kph).
13-2-2-8
dangerous. Before starting the engine, make sure your seat
belt is fastened. Check the tightness and condition of the
! CAUTION
seat belt securing bolts regularly (see maintenance
schedules). Trailer Brakes
INT 2 -1-8/1 Trailers with single line air brakes used in the Republic of
Germany are subject to a maximum speed of 25 km/h (15
! WARNING mph).
Passengers 13-2-2-13
Ensure that passengers use the seat provided in the cab.

Passengers must not be carried on the rear deck of the ! WARNING
vehicle under any circumstances. Engine
13-1-1-1/1
The engine has rotating parts. Do not open the engine cover
while the engine is running. Do not use the machine with the
! WARNING cover open.
Reversing INT-2-1-6
Reversing at high speeds can cause accidents. Always drive

at a safe speed to suit working conditions
13-1-1-3
9803/8020 Issue 1
3-2 3-2
Operating Safety (cont'd)
! WARNING ! WARNING
Banks and Trenches Power Take-off Operation
Banked material and trenches can collapse. Do not work or When operating PTO equipment, always observe the
drive too close to banks and trenches where there is danger following safety precautions:
of collapse.
INT-2-2-5 Follow the instructions in the implement operator's
handbook.
! WARNING
Rotating equipment is dangerous. Do not wear loose fitting
Ramps and Trailers
clothing when working close to rotating shafts.
Water, mud, ice, grease and oil on ramps or trailers can
cause serious accidents. Make sure ramps and trailers are
Always disengage the PTO, stop the engine and wait until
clean before driving onto them. Use extreme caution when
the equipment stops, before:
driving onto ramps and trailers.
INT-2-2-6
1 Leaving the cab
! WARNING
2 Attempting to attach or detach an implement to or from
Communications
a PTO shaft or
Bad communications can cause accidents. Keep people
around you informed of what you will be doing. If you will be
3 Working on or cleaning an implement connected to the
working with other people, make sure any hand signals that
machine via a PTO shaft.
may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands.
INT-2-2-3
Always ensure that the PTO shaft and driveline are fully
guarded before use.
! WARNING When using stationary PTO equipment, ensure that the

parking brake is applied.
Engine/Steering Failure 13-2-1-6
If the engine or steering fails, stop the machine as quickly as
possible. Do not operate the machine until the fault has been ! WARNING
corrected.
INT-2-1-5
Power Take-off Jamming
If the PTO becomes jammed, disengage the PTO, stop the
engine and clear the blockage. Wait until the PTO shaft
! DANGER stops before working on the equipment. If the PTO clutch
Sparks slips, immediately disengage the PTO and stop the engine.
Explosions and fire can be caused by sparks from the 13-2-2-2
exhaust or the electrical system. Do not use the machine in
closed areas where there is flammable material, vapour or ! WARNING
dust.
INT-2-2-10 Hitching Trailers and Equipment
When the vehicle is approaching a trailer or equipment to be
! WARNING * hitched, make sure that no persons are present between
vehicle and trailer or equipment. When mounting equipment
Controls at the rear of the vehicle, you must ensure that proper
Keep the machine controls clean and dry. Your hands and steering control is maintained. The machine must never be
feet could slide off slippery controls. If that happens you will loaded such that less than 20% of the vehicle weight is
lose control of the machine. carried on the front axle.
2-2-3-6 13-1-1-13/1
! WARNING
Exhaust Gases
Breathing the machine exhaust gases can harm and
possibly kill you. Do not operate the machine in closed
spaces without making sure there is good ventilation. If
possible, fit an exhaust extension. If you begin to feel
drowsy, stop the machine at once. Get out of the cab into
fresh air.
INT-2-1-10
9803/8020 Issue 2*
3-3 3-3
Operating Safety (cont'd)
! WARNING ! WARNING
Tyres - General Stability
You could be killed or injured if a machine tyre bursts. Do In the event of the machine becoming unstable, keep firm
not use the machine with damaged, incorrectly inflated or hold of the steering wheel and do not try to leave the cab.
excessively worn tyres. Recognize the speed limitation of 13-2-2-10
the tyres fitted and do not operate at more than their

recommended maximum speed. ! WARNING
13-2-1-2
Audible Warnings
When you hear an audible warning, stop the machine as
! WARNING soon as possible. Get the fault put right before using the
Certain tyres fitted as after-market equipment may have machine again.
maximum permitted speeds below the maximum speed of 13-2-1-9
the vehicle. Brake efficiency is slightly reduced and stopping
distance is increased when these tyres are fitted. They will ! WARNING
suffer damage if operated at speeds higher than those Controls
recommended and may endanger life. When driving the machine on the road, use the accelerator
13-3-2-5
pedal and not the hand throttle to control the engine speed.
* Always set the hand throttle to ‘idle’ before using the
! WARNING accelerator pedal.
Tyre Speed Limitations 13-2-1-8/1
Running tyres outside recommended guidelines may result
in failure of the tyres which at high speeds may endanger
! WARNING
life. BE WARNED.
13-3-1-6 Safe Working Loads
Overloading the machine can damage it and make it
! WARNING unstable. Study the specifications before loading, towing or
using implements.
Rear Deck 13-1-1-4/1
Passengers must not be carried on the rear deck of the
vehicle. Ensure that loads carried on the rear deck are ! DANGER
secured adequately to prevent them rolling about, falling off
or toppling over. The JCB Fastrac is capable of operating at high speeds.
13-1-1-12/1 Implements or trailers you tow behind the Fastrac may not
be designed for high speed operation. BE AWARE of the
! WARNING manufacturers specified maximum speed rating for any
trailers or implements that you tow behind the Fastrac. DO
Weight Distribution
NOT EXCEED THE MAXIMUM DESIGN SPEED OF
The machine must never be loaded such that less than 20%
TRAILERS OR IMPLEMENTS AS INJURY OR *
of the vehicle weight is carried on the front axle.
13-1-1-11/1
DEATH MAY RESULT.
! CAUTION
13-2-3-5
*
Weight Distribution
The Fastrac has to comply with certain braking regulations
! WARNING
which in some countries control weight distribution between Cab Air Filter
front and rear axles. Travelling on the road with implements The cab air filter is designed to remove dirt from the outside
or weights carried on the front when no implement is on the air. When using chemicals (e.g. for crop spraying) follow the
rear may break the law. In this case you should transfer the chemical manufacturer’s recommendations for protection
front mounted equipment to the rear linkage. It is the from dangerous chemicals.
13-2-3-6
operator's responsibility to know and observe the laws in the
country concerned.
13-2-2-5 ! WARNING
! WARNING Hazardous Atmospheres
This machine is designed for use in normal out door
Travel Speed
atmospheric conditions. It should not be used in an
Be aware of the load the machine is carrying or towing and
enclosed area without adequate ventilation. Do not use the
the speed at which you are travelling. Do not corner fast
machine in a potentially explosive atmosphere, i.e.
when carrying heavy mounted implements or towing trailers.
combustible vapours, gas or dust, without first consulting
Reduce speed when towing non-suspended implements on
your JCB Distributor.
rough ground. INT-2-1-14
13-2-2-1
9803/8020 Issue 2*
4-1 4-1
Maintenance Safety
! WARNING ! WARNING
Working Under the Machine Battery
Make the machine safe before getting beneath it. Do the A battery with frozen electrolyte can explode if it is used or
following: Park on level ground. Engage the parking brake. charged. Do not use a machine with a frozen battery. To
Lower any mounted implements to the ground. Stop the help prevent the battery from freezing, keep the battery fully
engine, remove the starter key, disconnect the battery. charged.
Chock the wheels. INT-3-1-7
13-3-1-1
! WARNING
! WARNING Battery Gases
Soft Ground Batteries give off explosive gases. Keep flames and sparks
A machine can sink into soft ground. Never work under a away from the battery. Do not smoke close to the battery.
machine on soft ground. Make sure there is good ventilation in closed areas where
INT-3-2-4 batteries are being used or charged. Do not check the
battery charge by shorting the terminals with metal; use a
! WARNING hydrometer or voltmeter.
INT-3-1-8
Jacking
A machine can roll off jacks and crush you unless the wheels
have been chocked. Always chock the wheels at the ! WARNING
opposite end of the machine to that which is to be jacked. Battery Terminals
Do not work underneath a machine supported only by jacks. The machine is negatively earthed. Always connect the
Always support a jacked-up machine on axle stands before negative pole of the battery to earth.
working underneath it.
INT-3-2-8 When connecting the battery, connect the earth (-) lead last.
! WARNING When disconnecting the battery, disconnect the earth (-)

Transmission Testing lead first.
INT-3-1-9
The transmission is in 4 wheel drive until de-selected by
hydraulic pressure to 2 wheel drive. If the machine is to be
raised and the engine/transmission run, make sure all four ! WARNING
wheels are off the ground and supported by axle stands as if Electrical Circuits
only the rear wheels were raised, the machine could still Understand the electrical circuit before connecting or
drive through the front axle. Note that when a NoSpin disconnecting an electrical component. A wrong connection
differential is fitted, both front wheels will be driven even if can cause injury and/or damage.
one is jacked up and the other is on the ground. INT-3-1-4
TRAN 8-1/2
! WARNING
! WARNING Hydraulic Hoses
Diesel Fuel Damaged hoses can cause fatal accidents. Inspect the
Diesel fuel is flammable; keep naked flames away from the hoses regularly for:
machine. Do not smoke while refuelling the machine or Damaged end fittings
working on the engine. Do not refuel with the engine Chafed outer covers
running. There could be a fire and injury if you do not follow Ballooned outer covers
these precautions. Kinked or crushed hoses
INT-3-2-2 Embedded armouring in outer covers
Displaced end fittings.
! WARNING INT-3-3-2
Petrol
! WARNING
Do not use petrol in this machine. Do not mix petrol with the
diesel fuel; in storage tanks the petrol will rise to the top and Rams
form flammable vapours. The efficiency of the rams will be affected if they are not
INT-3-1-6 kept free of solidified dirt. Clean dirt from around the rams
regularly. When leaving or parking the machine, close all
rams if possible to reduce the risk of weather corrosion.
INT-3-2-10
9803/8020 Issue 1
4-2 4-2
Maintenance Safety (cont'd) ! WARNING

Communications
! WARNING Bad communications can cause accidents. If two or more
Hydraulic Pressure people are working on the machine, make sure each is
Hydraulic fluid at system pressure can injure you. Before aware of what the others are doing. Before starting the
disconnecting or connecting hydraulic hoses, stop the engine make sure the others are clear of the danger areas;
engine and operate the controls to release pressure trapped examples of danger areas are: the rotating blades and belt
in the hoses. Make sure the engine cannot be started while on the engine, the attachments and linkages, and anywhere
the hoses are open. beneath or behind the machine. People can be killed or
INT-3-1-11/2 injured if these precautions are not taken.
INT-3-1-5
! WARNING
! WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate the Cleaning
skin. Do not use your fingers to check for hydraulic fluid Cleaning metal parts with incorrect solvents can cause
leaks. Do not put your face close to suspected leaks. Hold a corrosion. Use only recommended cleaning agents and
piece of cardboard close to suspected leaks and then solvents.
INT-3-2-11
inspect the cardboard for signs of hydraulic fluid. If hydraulic
fluid penetrates your skin, get medical help immediately.
INT-3-1-10/1
! WARNING
'O' rings, Seals and Gaskets
! WARNING Badly fitted, damaged or rotted 'O' rings, seals and gaskets
Oil can cause leakages and possible accidents. Renew
Oil is toxic. If you swallow any oil, do not induce vomiting, whenever disturbed unless otherwise instructed. Do not use
seek medical advice. Used engine oil contains harmful Trichloroethane or paint thinners near 'O' rings and seals.
INT-3-2-12
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier
cream or wear gloves to prevent skin contact. Wash skin
! WARNING
contaminated with oil thoroughly in warm soapy water. Do Clutch Fluid
not use petrol, diesel fuel or paraffin to clean your skin. Do not use ordinary hydraulic fluid in the clutch system.
INT-3-2-3 13-3-2-4
! WARNING ! WARNING
Hot Coolant Welding and Modifications
The cooling system is pressurised when the engine is hot. To prevent the possibility of damage to electronic
Hot coolant can spray out when you remove the radiator components, disconnect the battery and withdraw the plug
cap. Let the system cool before removing the radiator cap. from the electronic draft control unit before arc-welding on
To remove the cap; turn it to the first notch and let the the machine or attached implements.
system pressure escape, then remove the cap.
INT-3-2-9 Parts of the machine are made from cast iron; welds on cast
iron can weaken the structure and break. Do not weld cast
! WARNING iron. On no account weld or drill the chassis structure. Non-
Wheels approved modifications can cause injury and damage.
Wheels are heavy. Handle and store with care to ensure that Contact JCB before modifying the machine.
GEN 8-1
they cannot fall and cause injury.
13-3-1-7
! WARNING
! WARNING Protect your eyes when grinding metal. Wear safety glasses
Metal Splinters or goggles. Remove or protect any combustible materials
You can be injured by flying metal splinters when driving from the area which could be ignited by sparks.
metal pins in or out. Use a soft faced hammer or drift to GEN-1-12
remove and fit metal pins. Always wear safety glasses.

INT-3-1-3
! WARNING
Radar Speed Sensor (if fitted)
! WARNING To avoid possible eye damage from microwave signals, do
Always wear safety glasses when dismantling assemblies not look directly into the sensor face.
13-1-1-15
containing components under pressure from springs. This
will protect against eye injury from components accidentally Note: The radar speed sensor is located underneath the
flying out. * machine.
GEN 6-2
9803/8020 Issue 2*
4-3 4-3
Maintenance Safety (cont'd)
! WARNING ! WARNING
Fluoroelastomeric Materials Brake Pads
Certain seals and gaskets (e.g. crankshaft oil seal) on JCB Always renew brake pads and locating pins in complete axle
machines contain fluoroelastomeric materials such as Viton, sets, using genuine JCB parts, otherwise braking will be
Fluorel and Technoflon. Fluoroelastomeric materials unsafe.
subjected to high temperatures can produce highly corrosive 13-3-1-10
hydrofluoric acid. THIS ACID CAN SEVERELY BURN.

! WARNING
New fluoroelastomeric components at ambient temperature
Cleaning Agents
require no special safety precautions.
When using cleaning agents, solvents or other chemicals,
you must adhere to the manufacturer's instructions and
Used fluoroelastomeric components whose temperatures
safety precautions.
have not exceeded 300°C require no special safety GEN-1-9
precautions. If evidence of decomposition (e.g. charring) is
found, refer to the next paragraph for safety instructions DO
NOT TOUCH COMPONENT OR SURROUNDING AREA. * ! WARNING
ABS
Used fluoroelastomeric components subjected to
Upon completion of any work done on the brake system of
temperatures greater than 300°C (e.g. engine fire) must be
machines fitted with ABS, the ABS test within Servicemaster
treated using the following safety procedure. Make sure that
must be run satisfactorily before the machine is driven. It is
heavy duty gloves and special safety glasses are worn:
not sufficient to rely on the ABS self-check which can only
check for presence of components, not that they are
1 Ensure that components have cooled then remove and
correctly installed.
place material in plastic bags. 0091
2 Thoroughly wash contaminated area with 10% calcium

hydroxide or other suitable alkali solution, if necessary
use wire wool to remove burnt remains.
3 Thoroughly wash contaminated area with detergent and

water.
4 Contain all removed material, gloves etc used in this

operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations.
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
If contamination of skin or eyes occurs, wash the affected

area with a continuous supply of clean water or with calcium
hydroxide solution for 16-60 minutes. Get medical attention
immediately.
INT - 3 - 3 - 5/1
9803/8020 Issue 2*
Section 3 Routine Maintenance Section 3
i i
Contents Page No.
Engine Oil - (All Machines) 1-1
Lubricants & Capacities (2000 Series Machines) 1-2
Lubricants & Capacities (3155) 1-4
Lubricants & Capacities (3185) 1-6
Lubricants - Health and Safety 1-8
Service Schedules (Dry Clutch Transmission †) 2-1

Service Schedules (Wet Clutch Transmission ††) 2-4
Cleaning the Machine and Checking for Damage 2-8

Checking Seat Belt Condition and Security 2-8
Opening/Closing the Bonnet (2000 Series Machines) 2-9
Opening/Closing the Bonnet (3000 Series Machines) 2-9
Greasing
General 3-1
Propshafts and PTO Driveshafts 3-1
Steering Swivels (2000 Series Machines) 3-2
Front Axle Steering Swivels (3000 Series Machines) 3-3
Hydraulic Lift & 3 point Linkage (2000 Series Machines) 3-4
Rear PTO Driveshaft Bearings (2000 Series Machines) 3-4
Rear Suspension Cylinder Pivots (2000 Series Machines) 3-4
Hydraulic Lift & 3 point Linkage (3000 Series Machines) 3-5
Rear PTO Driveshaft Bearings (3000 Series Machines) 3-5
Rear Suspension Cylinder Pivots (3000 Series Machines) 3-5
Rear Anti-roll Bar Ball Joints (2000 Series Machines) 3-6
Steering Box Input Shaft Seal (3000 Series Machines) 3-7
Rear Anti-roll Bar Ball Joints (3000 Series Machines) 3-7
Automatic Trailer Coupling (if fitted) 3-8
Cab
Checking the ROPS Structure 4-1
Checking the Windscreen Washer Fluid Level 4-2
Air Conditioning
Cleaning the Filter (2000 Series Machines) 5-1
* Adjusting the Compressor Belt (2115, 2125, 2135, 2150) 5-1
Cleaning the Filter (3000 Series Machines) 5-2
* Adjusting the Compressor Belt (2140 and 3000 Series) 5-3
Electrics
Battery Warning Symbols 6-1
First Aid - Electrolyte 6-1
Checking the Battery Electrolyte Level 6-2
Checking the Headlight Beam Alignment 6-3
Fuses See Section C
Hydraulics
Checking the Fluid Level 7-1
Changing the Filter Element 7-1
Changing the Hydraulic Fluid and Cleaning the Suction Strainer 7-2
Emptying the Hydraulic Coupling Drain Reservoir (if fitted) 7-3
* Dry Clutch Hydraulic System †
Checking the Fluid Level 8-1
† 2000 Series to S/N 739999, 3000 Series to S/N 641999

†† 2000 Series from S/N 740000, 3000 Series from S/N 642000
9803/8020 Issue 7*
ii ii
Contents Page No.
PTO, Speed and Range Gearboxes

Checking the Oil Level 9-1
Changing the Oil and Cleaning the Strainer
- (Dry Clutch Transmission) † 9-2
Changing the Oil and Cleaning the Strainer
- (Wet Clutch Transmission) †† 9 - 2A
Changing the Transmission Oil Filter 9-3
Checking the Front PTO Gearbox Oil Level (if fitted) 9-4
Front Axle
Checking the Differential Oil Level 10 - 1
Changing the Differential Oil 10 - 1
Checking the Hub Oil Levels 10 - 2
Changing the Hub Oil 10 - 2
Rear Axle (2WS)

Checking the Oil Level 11 - 1
Changing the Oil 11 - 2
Rear Axle (4WS)

Checking the Differential Oil Level 11 - 3
Changing the Differential Oil 11 - 3
Checking the Hub Oil Levels 11 - 4
Changing the Hub Oil 11 - 4
Front and Rear Axle Steering Swivels (4WS)

Checking 4WS Right Side Trunnion Seals 11 - 5
Tyres and Wheels

General 12 - 1
Tyre Inflation 12 - 1
Pressures, Speeds and Loads See Operator Handbook
Checking and Adjusting Wheel Alignment 12 - 4
Track Width 12 - 5
Checking Wheel Nut Torques 12 - 5
Lock Stops 12 - 6
Fender Adjustment 12 - 7
* Brakes
Checking and Renewing Foot Brake Pads 13 - 1
Checking and Renewing the Parking Brake Pads 13 - 3
Checking the Foot Brake Fluid Level (2000 Series Machines) 13 - 4
Draining the Air System Tank (2000 Series Machines) 13 - 6
Checking the Foot Brake Fluid Level (3000 Series Machines) 13 - 7
Draining the Air System Tank (3000 Series Machines) 13 - 8
Exhaust Brake (if fitted) (3185 Machines only) 13 - 9
Cleaning the Trailer Brake Control Line Air Filter See Section G
† 2000 Series to S/N 739999, 3000 Series to S/N 641999

†† 2000 Series from S/N 740000, 3000 Series from S/N 642000
9803/8020 Issue 10*

iii iii
Contents Page No.
Engine
Checking the Oil Level 14 - 1
Changing the Oil and Filter 14 - 2
Draining/Cleaning the Fuel Sediment Bowl 15 - 1
Draining/Renewing Fuel Pre-Filter (when fitted) 15 - 2
Draining the Fuel Filters 15 - 3
Changing the Fuel Filter Elements 15 - 3
* Cleaning the Fuel Lift Pump (2115, 2125, 2135, 2150 and 3155) 15 - 4
* Bleeding the Fuel System (2115, 2125, 2135, 2150 and 3155) 15 - 5
* Bleeding the Fuel System (2140) 15 - 5A
Bleeding the Fuel System (3185) 15 - 6
* Cleaning the Fuel Tank Strainer (Early machines only) 15 - 7
Checking the Coolant Level 16 - 1
* Draining the Coolant (2115, 2125, 2135 and 2150 Machines) 16 - 2
* Filling the Cooling System (2115, 2125, 2135 & 2150 Machines) 16 - 3
Coolant Mixtures 16 - 3
Draining & Refilling the Coolant (3155 Machines) 16 - 4
*Draining & Refilling the Coolant (2140 and 3185 Machines) 16 - 5
Cleaning the Radiator (2000 Series Machines) 16 - 6
Cleaning the Radiator (3000 Series Machines) 16 - 7
Cleaning the Pre-Cleaner (optional) 17 - 1
Adjusting the Fan Belts (Machines Except 3185) 17 - 1
* Adjusting the Fan Belt (2140) 17 - 2
* Adjusting the Fan Belt (3185) 17 - 3
* Changing the Air Filter Elements (Early 2000 Series) 18 - 1
* Changing the Air Filter Elements (Later 2000 Series) 18 - 2
* Changing the Air Filter Elements (3000 Series) 18 - 2
9803/8020 Issue 4*
1-1 * Engine Oil (All Machines) 1-1
New Engines
New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately.
DO NOT use a special running-in oil but use the oil recommended below from new.
Engine Oil Specification

Recommended Oil
JCB Extreme Performance Engine Oil

SAE 15W/40 API CH-4 or ACEA E3/B3A3
IMPORTANT NOTE: IF SAE 15W/40, API CH-4 OR ACEA E3/B3A3 ENGINE OIL IS NOT AVAILABLE, THEN THE ENGINE OIL
MUST BE CHANGED AT 250 HOURS.
Alternative Oil
If the oil recommended above is not available then the alternatives listed below should be used according to the ambient
temperature.
Note: (2140 and 3185 machines only). While 15W/40 oil is recommended for most climates, limited use of low viscosity oils
such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below -5 °C (23 °F).
Continued use of low viscosity oils can decrease engine life.
JCB Super Multigrade 15W/40

SAE15W/40, API CF4/SG
-10 °C to 50 °C (14 °F to 122 °F)
JCB Super Multigrade 10W/30

† -15 °C to 40 °C (5 °F to 104 °F)
† The temperature range for 2140 and 3185 machines is - 20 °C to 20 °C (-4 °C to 68 °F).
Engine Oil Specification (N. America)

Recommended Oil
JCB Genuine Engine Oil

SAE 15W/40, Grade CH-4/SJ
IMPORTANT NOTICE: IF SAE 15W/40, GRADE CH-4/SJ ENGINE OIL IS NOT AVAILABLE, THEN THE ENGINE OIL MUST BE
CHANGED AT 250 HOURS.
Alternative Oil
If the oil recommended above is not available then the alternatives listed below should be used according to the ambient
temperature.
Notice: (2140 and 3185 machines only). While 15W/40 oil is recommended for most climates, limited use of low viscosity oils
such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below -5 °C (23 °F).
Continued use of low viscosity oils can decrease engine life.
JCB 15W/40 Engine Oil

-10 °C to 50 °C (14 °F to 122 °F)
JCB Engine Oil 10W/30

SAE10W/30, API CE/SF
† -15 °C to 40 °C (5 °F to 104 °F)
† The temperature range for 2140 and 3185 machines is -4 °C to 68 °F (- 20 °C to 20 °C).
9803/8020 Issue 7*
1-2 Lubricants & Capacities 1-2
(2000 Series Machines)
ITEM CAPACITY FLUID/LUBRICANT MINIMUM INTERNATIONAL
Litres (UK Gal) SPECIFICATION
* Fuel
2115, 2125, 2135, 2140 220 (48) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
2150 350 (77)
* Engine (Oil)
2115, 2125, 2135, 2150 16.5 (3.6) See Engine Oil (All Machines) at the
2140 15 (3.3) beginning of this section
* Engine (Coolant)
2115, 2125, 2135, 2150 34 (7.5) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
2140 33 (7.3) Summer Coolant/water
(See Coolant Mixtures)
PTO, Speed and

Range Boxes 38 (8.4) † JCB Super Universal Agricultural API-GL-4, MIL-L-2105
(combined) 42 (9.3) ††
Front Axle
Housing 7 (1.56) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 1.9 (0.4)
Rear Axle (2WS) 23 (5.0) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Rear Axle (4WS)
Hubs (x2) 2.0 (0.4)
Brake System JCB Universal Brake Fluid SAE J1703 DOT 4

Front 0.75 (0.17)
Rear 0.75 (0.17) ! CAUTION
Do not use ordinary hydraulic fluid
in the brake system.
13-3-2-6
† Clutch System - JCB Light Hydraulic Fluid - see Note 2 ISO VG15
Hydraulic System JCB High Performance Hydraulic Oil ISO VG46

- see Note 1 82 (18.0) † (Above 38 °C, 100 °F)
120 (26.4) ††
JCB Hydraulic Fluid HP32 ISO VG32
(Below 38 °C, 100 °F)
Grease Points --- JCB HP Grease Lithium complex NLGI No. 2

consistency including extreme
pressure additives
Air Conditioning System

- Refrigerant 0.98 kg (2.16 lb) HFC R134a CH2 FC F3
- Compressor Lubricant 0.24 (0.05) Polyalkalineglycol PAG SP20
Front PTO Transfer

Box (optional) 3.0 (0.67) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.
Note 2: It is esssential that the correct specification fluid is used. Contact your JCB Dealer for further information.
† 2000 Series to S/N 739999

†† 2000 Series from S/N 740000
9803/8020 Issue 9*
1-3 Lubricants & Capacities (N. America) 1-3
US Gal (Liters) SPECIFICATION
* Fuel
2115, 2125, 2135, 2140 57.6 (220) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
2150 92.5 (350)
* Engine (Oil)
2115, 2125, 2135, 2150 4.3 (16.5) See Engine Oil (All Machines) at the
2140 4 (15) beginning of this section
* Engine (Coolant) JCB PermanentAntifreeze/water ASTM D3306-74

2115, 2125, 2135, 2150 9.0 (34.0) (See Coolant Mixtures)
2140 8.77 (33)
PTO, Speed and

Range Boxes 10 (38.0) † JCB AG Transmission Fluid API-GL-4, MIL-L-2105
(combined) 11.2 (42.0) ††
Front Axle
Housing 1.8 (7.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 0.5 (1.9)
Rear Axle (2WS) 6.1 (23.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Rear Axle (4WS)
Hubs (x2) 0.5 (2.0)

Front 0.2 (0.75)
Rear 0.2 (0.75)
! CAUTION
Do not use ordinary hydraulic oil in the
brake system.
13-3-2-6
† Clutch System - JCB Light Hydraulic Fluid - see Notice 2 ISO VG15
Hydraulic System 21.7 (82.0) † JCB High Performance Hydraulic Oil ISO VG46
- see Notice 1 31.7 (120) ††

pressure additives

- Refrigerant 2.16 lb (0.98 kg) HFC R134a CH2 FC F3
Front PTO Transfer

Box (optional) 0.8 (3.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic
tank.
Notice 2: It is esssential that the correct specification fluid is used. Contact your JCB Dealer for further information.
† 2000 Series to S/N 739999

9803/8020 Issue 9*
(Fastrac 3155)
Fuel 350 (77) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 16.5 (3.6) See Engine Oil (All Machines) at the
beginning of this section
Engine (Coolant) 34 (7.5) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
Summer Coolant/water
PTO, Speed and

(combined) 42 (9.3) ††
Front Axle
Hubs (x2) 2.5 (0.55)
Rear Axle 21 (4.6) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C

Front 0.75 (0.17)
Do not use ordinary hydraulic fluid in the
brake system.
13-3-2-6
Hydraulic System 82 (18.0) † JCB High Performance Hydraulic Oil ISO VG46
- see Note 1 120 (26.4) †† (Above 38 °C, 100 °F)

(Below 38 °C, 100 °F)

pressure additives

* - Refrigerant 1.41 kg (3.11 lb) HFC R134a CH2 FC F3
Front PTO Transfer

Note 2: It is essential that the correct specification fluid is used. Contact your JCB Distributor for further information.
† 3000 Series to S/N 641999

9803/8020 Issue 7*
(Fastrac 3155)
Fuel
92.5 (350) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 4.3 (16.5) See Engine Oil (All 2000, 3000 Series
Machines) on page 60-00-01/11
Engine (Coolant) 9 (34.0) JCB Permanent Antifreeze/water ASTM D3306-74

PTO, Speed and

Range Boxes 10.1 (38.0) † JCB AG Transmission Fluid API-GL-4, MIL-L-2105
(combined) 11.2 (42.0) ††
Front Axle
Hubs (x2) 0.66 (2.5)
Rear Axle (2WS) 7.1 (27.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C

Front 0.2 (0.75)
Rear 0.2 (0.75)
! CAUTION
brake system.
13-3-2-6
† Clutch System --- JCB Light Hydraulic Fluid - see Notice 2 ISO VG15
- see Notice 1 31.7 (120) ††

pressure additives

* - Refrigerant 3.11 lb (1.41 kg) HFC R134a CH2 FC F3
Front PTO Transfer

tank.
Notice 2: It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
† 3000 Series to S/N 641999

9803/8020 Issue 7*
(Fastrac 3185)
ITEM CAPACITY FLUID/LUBRICANT MINIMUM NTERNATIONAL
Fuel 350 (77) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 15 (3.3) See Engine Oil (All Machines) at the

Engine (Coolant) 33 (7.3) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
Summer Coolant/water
PTO, Speed and

(combined) 42 (9.3) ††
Front Axle
Hubs (x2) 2.5 (0.55)
Rear Axle 27 (6.0) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C

Front 0.75 (0.17)
Do not use ordinary hydraulic fluid in the
brake system.
13-3-2-6
Hydraulic System 82 (18.0) † JCB High Performance Hydraulic Oil ISO VG46
- see Note 1 120 (26.4) †† (Above 38 °C, 100 °F)

(Below 38 °C, 100 °F)

pressure additives

* - Refrigerant 1.41 kg (3.11 lb) HFC R134a CH2 FC F3
Front PTO Transfer

Note 2: It is essential that the correct specification fluid is used. Contact your JCB Distributor for further information.
† 3000 Series to S/N 641999

9803/8020 Issue 7*
(Fastrac 3185)
Fuel
92.5 (350) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 4 (15) See Engine Oil (All Machines) at the

Engine (Coolant) 8.77 (33.0) JCB Permanent Antifreeze/water ASTM D3306-74

PTO, Speed and

Range Boxes 10 (38.0) † JCB AG Transmission Fluid API-GL-4, MIL-L-2105
(combined) 11.2 (42.0) ††
Front Axle
Hubs (x2) 0.66 (2.5)
Rear Axle 7.1 (27.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C

Front 0.2 (0.75)
Rear 0.2 (0.75)
! CAUTION
brake system.
13-3-2-6
† Clutch System --- JCB Light Hydraulic Fluid - see Notice 2 ISO VG15
- see Notice 1 31.7 (120) ††

pressure additives

* - Refrigerant 3.11 lb (1.41 kg) HFC R134a CH2 FC F3
Front PTO Transfer

tank.
Notice 2: It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
† 3000 Series to S/N 641999

9803/8020 Issue 4*
1-8 Lubricants - Health and Safety 1-8
It is most important that you read and understand this FIRST AID - OIL
information and the publications referred to. Make sure all
your colleagues who are concerned with lubricants read it Eyes
too. In the case of eye contact, flush with water for 15 minutes. If
irritation persists, get medical attention.
HYGIENE
Swallowing
JCB lubricants are not a health risk when used properly for If oil is swallowed do not induce vomiting. Get medical
their intended purposes. advice.
However, excessive or prolonged skin contact can remove Skin

the natural fats from your skin, causing dryness and In the case of excessive skin contact, wash with soap and
irritation. water.
Low viscosity oils are more likely to do this, so take special SPILLAGE
care when handling used oils, which might be diluted with
fuel contamination. Absorb spilled oil with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a chemical
Whenever you are handling oil products you should maintain disposal area.
good standards of care and personal and plant hygiene. For
details of these precautions we advise you to read the Fires
relevant publications issued by your local health authority, ! WARNING
plus the following.
Do not use water to put out an oil fire. This will only
spread it because oil floats on water.
STORAGE
Extinguish oil and lubricant fires with carbon dioxide, dry
Always keep lubricants out of the reach of children.
chemical or foam. Fire fighters should use self contained
breathing apparatus.
Never store lubricants in open or unlabelled containers. 7-3-1-3/1
HANDLING
WASTE DISPOSAL
New Oil
All waste products should be disposed of in accordance
There are no special precautions needed for the handling or with all the relevant regulations.
use of new oil, besides the normal care and hygiene
practices. The collection and disposal of used oil should be in
accordance with any local regulations. Never pour used oil
Used Oil into sewers, drains or on the ground.
Used engine lubricants contain harmful contaminants. In

laboratory tests it was shown that used engine oils can
cause skin cancer.
Here are precautions to protect your health when handling

used engine oil:
1 Avoid prolonged, excessive or repeated skin contact

with used engine oils.
2 Apply a barrier cream to the skin before handling used

engine oil.
3 Note the following when removing oil from skin:
a Wash your skin thoroughly with soap and water.

b Using a nail brush will help.
c Use special hand cleansers to help clean dirty
hands.
d Never use petrol, diesel fuel, or paraffin for washing.
e Avoid skin contact with oil soaked clothing.
f Don't keep oily rags in pockets.
g Wash dirty clothing before re-use.
h Throw away oil-soaked shoes.
9803/8020 Issue 1
2-1 Service Schedules - Dry Clutch Transmission 2-1
Every 10 Operating Hours or Daily Every 50 Operating Hours or Weekly

whichever occurs first whichever occurs first
Clean Do the Daily jobs plus:
1 Machine generally.
Drain
Drain 1 Fuel filter.
2 Air system tank. 2 Fuel sediment bowl (all machines except those with
optional fuel flow metering).
Check (Engine Stopped) 3 Fuel pre-filter (machines with optional fuel flow
3 Generally for damage. metering only)
4 Engine coolant level and condition. 4 Empty hydraulic coupling drain reservoir (if fitted)
5 Fuel system for leaks and contamination.
6 Hydraulic fluid level. Check (Engine Stopped)
7 Hydraulic system for leaks. 5 Fan belt tension and condition.
8 Engine and transmission for oil leaks. 6 Air conditioning compressor drive belt.
9 Gearbox oil level. 7 Front PTO transfer gearbox oil level
10 Engine oil level and condition. (optional equipment).
11 Tightness of wheel nuts. 8 Clutch fluid level.
12 Windscreen washer level. 9 Cab air filter (Clean if required).
13 Tyre pressures and condition. 10 Propshaft Security
14 Security of front weights (optional equipment).
15 Seat belt condition and security. Grease
16 Brake fluid levels. 11 Rear PTO drive shaft splines and universal joints.
* 17 Check radiator and coolers for blockage and clean if 12 Rear PTO drive shaft bearings.
required. 13 Front PTO drive shaft (optional equipment).
14 Front axle propshaft.
Check (Engine Running) 15 Rear axle propshaft.
18 Instrument readings and warning lights.
19 Operation of all electrical equipment. Note: It is essential that drive shaft and propshaft joints are
20 Exhaust for excessive smoke. lubricated as specified.
21 Operation of clutch and footbrakes.
22 Parking brake operation.
23 Operation of steering.
24 Operation of transmission.
25 Operation of 3-point linkage.
26 Operation of front linkage (optional equipment).
Note: Some machines have grease nipples fitted to the

external hydraulic control lever pivot points (see External
Hydraulics Control Valve Linkage, Lever Linkages in
section D). Grease at these points if the lever movement
becomes stiff or independent operation becomes difficult.
9803/8020 Issue 6*
First 100 Hours Dealer Service First 100 Hours Dealer Service (continued)
Change Check (engine running) - continued
1 Engine oil and filter. 48 Transmission low pressure circuit pressure maintaining
2 Fuel filters. valve setting.
3 Transmission oil filter. 49 Transmission lubrication pressure.
4 Hydraulic oil filter. 50 Diff. lock pressure relief valve.
51 External hydraulics pressure relief valve.
Clean 52 Instrument readings and warning lights.
5 Fuel lift pump gauze. 53 Operation of all electrical equipment.
6 Fuel sedimenter (drain). 54 Operation of clutch and footbrakes.
Check (Engine Stopped) 56 Operation of transmission.
7 Coolant level/leaks and antifreeze strength. 57 Operation of 3-point linkage.
8 Fuel system for leaks and contamination. 58 Operation of front linkage (optional equipment).
9 Engine pipework routing and security. 59 Rear axle/chassis clearance.
10 Fuel system pipework routing and security. 60 Height corrector valve operation.
11 Fan belt tension and condition. 61 Parking Brake operation.
12 Air conditioning compressor belt tension. 62 Pick-up hitch operation.
13 Clutch fluid level. 63 Spool valve operation.
14 Gearbox oil level. 64 Re-calibrate splitter clutch packs
15 Transmission oil cooler/pipework condition, leakage,
routing and security. Every 250 Operating Hours or 3 Monthly
16 Rear axle oil level. whichever occurs first
17 Rear axle hub oil level (4WS).
18 Front axle oil level. Do the Daily jobs through to 50 hours plus:
19 Front axle hub oil level.
20 Front PTO gearbox oil level. Clean
21 Propellor shaft security. 1 Air filter dust valve.
22 Tyre pressures. 2 Battery terminals.
23 Tightness of wheel nuts.
Check (Engine Stopped)
24 Hydraulic oil level.
3 Front axle oil level.
25 Hydraulic oil cooler/pipework condition, leakage,
4 Front axle hub oil levels.
routing and security.
5 Rear axle oil level.
26 Brake fluid levels.
6 Rear axle hub oil level (4WS) (if fitted).
27 Brake pad security (service and parking).
7 Condition of lift ram piston rods.
28 Brake pipework routing and security.
8 Hose and pipework for chafing and damage.
29 Air system for leaks.
9 Air cleaner and hose condition and security.
30 Panhard rod torque setting.
* 10 Electrical wiring for chafing and routing.
31 Ram piston rods for damage/leaks.
32 Battery charge/terminal condition and tightness. * 11 Brake pad condition and security.
12 Neutral start operation.
33 Wiring for chafing/routing.
34 Headlight alignment. Check (Engine Running)
35 Windscreen washer level. 13 Air conditioning sight glass.
36 Neutral start operation (Including clutch and PTO's). 14 Operating speed of Selectronic range changes.
37 Door locks.
Change
Grease 15† Engine oil and filter.
38 Propellor shafts and universal joints. 16 Fuel Pre-filter (machines with optional fuel flow
39 Steering swivels. metering only).
40 Rear PTO shaft bearings.
41 3 point linkage. Grease
42 Rear lift ram pivots. 17 Steering swivels.
43 Suspension cylinder pivots. 18 Rear anti-roll bar ball joints.
19 Hydraulic lift cross-shaft.
Check (engine running) 20 Hydraulic lift ram pivots.
44 Exhaust smoke. 21 Three-point linkage lift rods and top link.
45 Throttle and stop controls. 22 Suspension cylinder pivots.
46 PTO operation. 23 Automatic Trailer Coupling (when fitted).
47 2/4WD drive and diff. lock selection. 24 Steering box input shaft (3155, 3185 machines)
25 Roller Drawbar (if fitted)
* † Applies only if recommended oil (see Engine Oil) and

Stratopore filter (3185 only) are not available.
9803/8020 Issue 8*
Every 500 Operating Hours or Six Monthly

whichever occurs first
Do the Daily jobs through to 250 hours plus: Check (Engine Stopped)- continued
6 Engine valve clearances and lubrication (3185 first 1000
Clean hour service only).
1 Fuel lift pump gauze (2000 series and 3155).
Check (Engine Running)
Check (Engine Stopped) 7 Transmission lubrication pressure (HPL and LPL).
2 Battery electrolyte level (if battery is not sealed for life). 8 MRV pressure.
3 Battery charge condition. *9 Splitter clutch pack calibration.
4 Exhaust system security.
5 Engine mounting bolts for tightness. Change
6 Steering axle wheel alignment. 10 Outer air filter element.
7 Headlamp alignment. 11 Gearbox oil and clean strainer (see Note (1) below).
8 Panhard rod condition and torque tightness. 12 Front axle oil.
9 Track rod end and steering ram ball joint security. 13 Front hub oil (see Note (2) below).
10 Steering damper condition and security. 14 Rear axle oil (see Note (2) below).
11 4WS Power track rod and ball joints condition and * 14 Rear hub oil (4WS if fitted) (see Note (2) below).
security. 15 Air system dryer dessicant canister.
* 12 Suspension control arms and ‘V’ link condition and
bolt torque. Notes:
* 13 Brake caliper bolt torque.
(1) After a major transmission repair, the new oil should be
Check (Engine Running) run to operating temperature and changed again to
14 Idling speed. remove any contamination which entered during the
15 Max. no load engine speed. repair. Change the oil and filter after a further 100
16 Suspension ride height and corrector valve operation. hours if the oil was heavily contaminated because of, or
17 Suspension pressure maintenance valve pressure. from the failure (e.g. water contamination).
18 Transmission low pressure circuit pressure maintaining
valve setting. (2) After a hub repair, the new oil should be run to
* 19 Differential lock pressure relief valve. operating temperature and changed again to remove
* 20 Pick-up hitch operation. any contamination which entered during the repair.
* 21 Spool valve operation. Change the oil again after a further 100 hours to
* 22 Check for electronic draft control faults and rectify. remove any bedding-in wear.
Change Every 2000 Operating Hours or Every 2

23 † Engine oil and filters.
24 Hydraulic fluid filter element.
Years whichever occurs first
25 Transmission oil filter.
26 Fuel filter (2 elements). Do the Daily jobs through to 1000 hours plus:
*† Applies only if recommended oil (see Engine Oil) and Clean

Stratopore filter (3185 ony) are available. If these are 1 Hydraulic tank suction strainers.
not available this job should be carried out every 250
hours (see Every 250 Operating Hours for suitable Check (Engine Stopped)
alternative oils). 2 Rear suspension gas spring pressure.
3 Rear suspension accumulator pressure.
4 Engine valve clearances and lubrication (3000 Series)
Every 1000 Operating Hours or Yearly 5 Engine vibration damper (3185 only).
6 Compressor, check for leaks.
whichever occurs first 7 Engine belt tensioner bearing (3185 only).
Do the Daily jobs through to 500 hours plus:
Change
8 Inner air filter element.
Clean
9 Coolant.
1 Fuel tank suction strainer.
10 Brake system fluid.
11 Clutch system fluid.
12 Hydraulic fluid (change if sample does not indicate
2 ROPS structure.
otherwise).
3 Quality of coolant.
4 4WS RH side trunnion seals and renew if necessary (if
fitted).
5 Engine valve clearances and lubrication (2000 series
only).
9803/8020 Issue 6*
2-4 Service Schedules - Wet Clutch Transmission 2-4
! WARNING
Maintenance must be done only by suitable qualified and Every 50 Operating Hours or Daily
competent persons. Before doing any maintenance
whichever occurs first
make sure the machine is safe. It should be correctly
parked on firm level ground.
Do the Daily jobs plus:
To prevent anyone starting the engine, remove the
Drain
starter key. Disconnect the battery and chock the
1 Fuel filter.
wheels when you are working beneath the machine.
*2 Fuel pre-filter - when fitted (except 2140).
If you do not take these precautions you could be killed
Clean
or injured. 3 Air filter dust valve.
9-3-1-1
* Every
10 Operating Hours or Daily Check (Engine Stopped)
4 Fan belt tension and condition.
whichever occurs first 5 Air conditioning compressor drive belt.
6 Front PTO transfer gearbox oil level (optional
Clean equipment).
1 Machine generally. 7 Brake pad condition.
8 Cab air filter (clean if required).
Drain 9 Propshaft security.
2 Air system tank.
3 Empty hydraulic coupling drain reservoir (if fitted). Grease
10 Rear PTO drive shaft splines and universal joints.
Check (Engine Stopped) 11 Rear PTO drive shaft bearings.
4 Generally for damage. 12 Front axle propshaft.
5 Engine coolant level and condition. 13 Front PTO drive shaft (optional equipment).
6 Fuel system for leaks and contamination. 14 Rear axle propshaft.
7 Hydraulic fluid level. 15 Rear anti-roll bar joints.
8 Hydraulic system for leaks. 16 Hydraulic lift cross-shafts.
9 Machine generally for oil leaks (axles, engine, 17 Hydraulic lift ram pivots.
transmission). 18 Steering swivels.
10 Gearbox oil level. 19 Suspension cylinder pivots.
11 Engine oil level and condition. 20 3-point linkage lift rods and top link.
12 Tightness of wheel nuts. 21 Automatic trailer coupling (when fitted).
13 Windscreen washer level. 22 Roller drawbar (if fitted).
14 Tyre pressures and condition.
15 Security of front weights (optional equipment). Note: It is essential that drive shaft and propshaft joints are
16 Seat belt condition and security. lubricated as specified.
18 Check radiator and coolers for blockage and clean if
required.
Check (engine running)

19 Instrument readings and warning lights.
20 Operation of all electrical equipment.
21 Exhaust for excessive smoke.
22 Operation of clutch and footbrakes
24 Operation of transmission.
25 Operation of 3-point linkage.
27 Parking brake operation.
28 Throttle and stop controls.
9803/8020 Issue 5*
First 100 Hours Dealer Service 51 Transmission pressure circuit pressure maintaining
valve setting.
Change 52 Transmission lubrication pressure (HPL & LPL).
1 Engine oil and filter. 53 Diff. lock pressure relief valve.
2 Fuel filters. 54 External hydraulics pressure relief valve.
3 Transmission oil filter. 55 Instrument readings and warning lights.
4 Hydraulic oil filter. 56 Operation of all electrical equipment.
5 Front axle oil. 57 Operation of clutch and footbrakes.
6 Front hub oil. 58 Operation of steering.
7 Rear axle oil. 59 Operation of transmission.
8 Rear hub oil (4WS only). 60 Operation of 3-point linkage.
Clean/Drain 62 Rear axle/chassis clearance.
*9 Fuel lift pump gauze (clean - except 2140 and 3185). 63 Height corrector valve operation.
* 10 Fuel pre-filter - when fitted (drain - except 2140). 64 Parking Brake operation.
65 Pick-up hitch operation.
Check (Engine Stopped) 66 Spool valve operation.
11 Coolant level/leaks and antifreeze strength. 67 Re calibrate splitter clutch packs.
12 Fuel system for leaks and contamination.
13 Engine pipework routing and security. Every 250 Operating Hours or 3 Monthly
14 Fuel system pipework routing and security. whichever occurs first
15 Fan belt tension and condition.
16 Air conditioning compressor belt tension. Do the Daily and 50 Hour jobs plus:
17 Gearbox oil level.
18 Transmission oil cooler/pipework condition, leakage, Change
routing and security. 1 †Engine oil and filter.
19 Front PTO gearbox oil level.
20 Propellor shaft security. * † Applies only if recommended oil (see Engine Oil) and
21 Tyre pressures. Stratopore filter (2140 & 3185 only) are not available.
22 Tightness of wheel nuts. See T.I. 10/152.
23 Hydraulic oil level.
24 Hydraulic oil cooler/pipework condition, leakage,
routing and security.
26 Brake pad security (service and parking).
27 Brake pipework routing and security. *
28 Air system for leaks.
29 Panhard rod torque setting.
31 Battery charge/terminal condition and tightness.
32 Wiring for chafing/routing.
33 Headlight alignment.
34 Windscreen washer level.
* 35 Neutral start operation (including clutch and PTO’s).
36 Door locks.
37 Steering axle wheel alignment.
38 Track rod and ball joint security.
* 39 Check for error codes, (EMS and ABS when fitted, plus
engine on 2140), download, rectify and delete.
40 Air cleaner and air inlet hose condition and security.
Grease
41 Propellor shafts and universal joints.
42 Steering swivels.
43 Rear PTO shaft bearings.
44 3 point linkage.
45 Rear lift ram pivots.
46 Suspension cylinder pivots.
Check (engine running)

47 Exhaust smoke.
48 Throttle and stop controls.
49 PTO operation.
50 2/4WD drive and diff. lock selection.
9803/8020 Issue 4*
Every 500 Operating Hours or Six Monthly 47 Rear axle/chassis clearance.

whichever occurs first 48 Spool valve operation.
49 Selection speed of Selectronic range change < 2 kph.
Do the Daily jobs through to 250 hours plus: 50 Check for electronic draft control faults and rectify.
Clean Change
1 Fuel lift pump gauze (all machines except 2140 & 3185). 51 †Engine oil and filters.
52 Hydraulic fluid filter element.
Grease 53 Transmission oil filter.
2 Steering box input shaft (3000 series machines). 54 Fuel filter (2 elements).
55 Front hub oil (see Note (2) below).
Check (Engine Stopped) 56 Rear hub oil (4WS only) (see Note (2) below).
3 Battery electrolyte level (if battery is not sealed for lift). 57 Fuel pre-filter element.
4 Battery charge condition.
5 Exhaust system security. † Applies only if recommended oil (see Engine Oil) and
6 Engine mounting bolts for tightness. Stratopore filter (2140 & 3185 ony) are available. (See
7 Compressor housing for cracks and damage. T.I. 10/152.) If these are not available this job should be
8 Compressor mountings for tightness. carried out every 250 hours (see Every 250 Operating
9 Injection pump mountings for tightness. Hours for suitable alternative oils).
10 Steering axle wheel alignment.
11 Headlamp alignment. Every 1000 Operating Hours or Yearly
12 Panhard rod condition and torque tightness. whichever occurs first
13 Track rod end, steering ram and drag link ball joint
security. Do the Daily jobs through to 250 hours plus:
14 Steering damper condition and security.
15 4WS power track rod and ball joints condition and Clean
security (2000 series machines). 1 Fuel tank suction strainer (early machines only).
16 Suspension control arms and ‘V’ link condition and bolt *2 Trailer brake control line air filter.
torque.
17 Air cleaner and hose condition and security. Check (Engine Stopped)
18 Air system for leaks. 3 ROPS structure.
19 Battery terminals condition and tightness. 4 Quality of coolant.
20 Brake pad security (service and parking). 5 4WS RH side trunnion seals and renew if necessary.
6 Engine valve clearances and lubrication (2115, 2125,
21 Parking brake adjustment
2135 and 2150).
22 Brake pipework security.
7 Engine valve clearances (3185 machines, first 1000
23 Condition of lift ram rods.
hour service only)
24 Coolant level/leaks, quality and anti-freeze strength.
8 Fan belt tensioner (2140 and 3185).
25 Brake caliper bolt torque.
9 Fan hub end play (2140 and 3185).
26 Hoses and pipework for chafing and damage.
27 Neutral start operation.
10 Transmission lubrication pressure (HPL and LPL).
29 Front axle oil level.
11 MRV pressure.
30 Rear axle oil level.
12 Splitter and wet clutch calibration.
31 Transmission and hydraulic oil cooler/pipework
13 ABS system test.
condition, leakage and security.
32 Wiring for chafing and routing.
Change
33 Download EMS Datalog.
14 Outer air filter element.
34 Download ABS error codes and investigate any found.
15 Gearbox oil and clean strainer (see Note (1) below).
35 Download engine error codes, rectify and delete (2140
16 Front axle oil.
only).
17 Rear axle oil.
36 Brake light switch input to ABS ECU using computer
18 Air system dryer dessicant canister.
diagnostic tool.
37 All air warning lamps illuminate after draining down the
Notes:
air tanks.
38 The park brake lamp illuminates after draining down the
(1) After a major transmission repair, the new oil should be
trailer air tank.
run to operating temperature and changed again to
remove any contamination which entered during the
repair. Change the oil and filter after a further 100
39 Idling speed.
hours if the oil was heavily contaminated because of, or
40 Max. no load engine speed.
from the failure (e.g. water contamination).
41 Suspension ride height and corrector valve operation.
42 Suspension pressure maintenance valve pressure.
(2) After a hub repair, the new oil should be run to
43 Transmission pressure circuit pressure maintaining
operating temperature and changed again to remove
valve setting.
any contamination which entered during the repair.
44 Differential lock pressure.
Change the oil again after a further 100 hours to
45 Field speed control.
remove any bedding-in wear.
46 Pick-up hitch operation.
9803/8020 Issue 6*
2-7 Service Schedules- Wet Clutch Transmission 2-7
Every 2000 Operating Hours or every 2

Clean
1 Hydraulic fluid suction strainer.

2 Rear suspension gas spring pressure.
3 Rear suspension accumulator pressure.
*4 Engine valve clearances and lubrication (3185).
5 Engine vibration damper.
*6 Compressor output line, air drier and pressure
regulator: check for carbon deposits and for air leaks.
*7 Radiator hose condition.
8 Transmission accumulator pressure.
Change
9 Inner air filter element.
10 Coolant.
11 Brake system fluid.
12 Hydraulic fluid (change if sample does not indicate
otherwise).
* Every5000 Operating Hours or Every 2


1 Engine valve clearances and adjust if necessary (2140).
9803/8020 Issue 2*
2-8 Cleaning the Machine and Checking for Damage 2-8
Clean the machine using water and/or steam. Pay particular Make sure all pivot pins are correctly in place and secured
attention to the underside. Do not allow mud to build up on by their locking devices.
the engine and transmission. Make sure that the radiator
grille is not clogged up. Ensure that the steps and handrails are undamaged and
secure.
Excessive power washing can cause damage to seals and
bearings. Do not direct high power water jets at oil seals, Check for broken or cracked window glass. Replace
universal joints or electrical components, especially draft damaged items.
control solenoids.
Check all lamp lenses for damage.
On the 4WS machine, take special care to avoid directing
high power water jets at the electrical connections to the Inspect the tyres for damage and penetration by sharp
front and rear axles. objects.
Inspect steelwork for damage. Note damaged paintwork for Check that all safety decals are in place and undamaged, fit
future repair. new decals where necessary.
SEAT BELT
Checking Seat Belt Condition and Security
! WARNING
Replace the seat belt with a new one if it is damaged, if
the fabric is worn, or if the machine has been in an
accident. Fit a new seat belt every three years regardless
of condition.
2-3-1-8
Inspect the seat belt for signs of fraying and stretching.

Check that the stitching is not loose or damaged. Check that
the buckle assembly is undamaged and works correctly.
Check that the belt mounting bolts are undamaged,

correctly installed and tightened.
9803/8020 Issue 1
2-9 Bonnet 2-9
Opening the Bonnet

! WARNING
The engine has rotating parts. Do not open the engine
cover while the engine is running. Do not use the
machine with the cover open.
INT-2-1-6
1 Engage the parking brake, put the transmission in

neutral and stop the engine. Remove the starter key.
2 Release the required bonnet side by turning the two

turnbuckles A to the vertical position.
A
3 Lift the bonnet side clear of the machine and put it in a
safe place to prevent damage.
Closing the Bonnet

1 Position the bonnet side in the aperture and ensure it
locates at the top. Fasten the bonnet securely by
pushing in each turnbuckle A.
Opening the Bonnet 231810
! WARNING
The engine has rotating parts. Do not open the engine
cover while the engine is running. Do not use the
machine with the cover open.
INT-2-1-6
1 Engage the parking brake, put the transmission in

neutral, turn the front wheels onto full left lock and stop
the engine. Remove the starter key.
2 Release latches by pulling back lever B.
3 Raise the bonnet fully. Do not leave it partly raised as it

could then creep down.
Closing the Bonnet

1 Lower the bonnet by pushing it at the front, centrally B
above the grille, to ensure that it closes squarely. Press
it firmly down to close the latches.
A293970
9803/8020 Issue 1
3-1 Greasing 3-1
General Propshafts and PTO Driveshafts

Read and understand Lubricants - Health and Safety, ! WARNING
before greasing. You must grease the machine regularly to
Make the machine safe before getting beneath it. Do the
keep it working efficiently. Regular greasing will also
following: Park on level ground. Engage the parking
lengthen the machine's working life. Refer to the Service
brake. Lower any mounted implements to the ground.
Schedules for the recommended frequencies.
Stop the engine, remove the starter key, disconnect the
Note: If working in muddy conditions the propshafts and battery. Chock the wheels.
13-3-1-1
PTO driveshafts must be greased daily.
Rear PTO drive shaft
Note: The machine must always be greased after pressure- Grease points 7 to 9.
washing or steam cleaning. Extra care must be taken to
ensure that propshaft universal joints and splines are * Front axle propshaft
greased regularly. Grease points 1 to 3. (Point 2 not fitted to later machines.)
Greasing should be done with a grease gun. Normally, two * Rear axle propshaft
strokes of the gun should be enough. Stop greasing when Grease points 4 to 6. (Point 6 not fitted to later machines.)
fresh grease appears at the joint. Use only JCB HP Grease
Front PTO drive shaft (optional)
or equivalent.
Grease points 10 to 12.
In the following illustrations the grease points are numbered.
Count them off as you grease them. Note: When greasing the universal joints, you must ensure
that grease appears at all four bearing caps. If grease does
Refit the grease point dust caps after greasing. not appear at any cap, move the shaft from side to side and
then re-grease. Wipe away all excess grease.
Rear PTO Drive shaft bearing

0 Grease point 13. Do not exceed 2 to 3 strokes of the grease
gun.
!
2
1 @
8 9
7
65 A286622
9803/8020 Issue 3*
3-2 Greasing 3-2
Steering Swivels
* (2000Series Machines)
! WARNING
battery. Chock the wheels.
13-3-1-1
2WS: Grease points 1 and 2 on each side of the machine.
4WS: Grease points 3 to 6 on the front axle. 1

Grease points 7 to 10 on the rear axle.
Note: After initial greasing, turn the wheels from lock to lock,
then grease again to ensure full penetration.
2 S229870
3 5
4
6
9
7
0 8
250690
9803/8020 Issue 2*
3-3 *Greasing 3-3
Front Axle Steering Swivels

* (3000Series Machines)
! WARNING
13-3-1-1
Note: After initial greasing, turn the wheels from lock to lock,
then grease again to ensure full penetration.
1 3
2 4
A293430
9803/8020 Issue 2*
3-4 Greasing 3-4
*(2000 Series Machines)
* Hydraulic Lift and 3-Point Linkage * Rear PTO Drive Shaft Bearings
Hydraulic Lift Cross-shaft Grease point 9. Do not exceed 2 to 3 strokes of the grease
Grease points 1 and 2. gun.
Hydraulic Lift Rams

Grease points 3 to 6. * Rear Suspension Cylinder Pivots
Three Point Linkage Lift Rods
Grease points 7 and 8. Grease points 10 to 13.
* Stabilisers (Standard Type)

Grease at point 14
Note: Where standard type stabilisers are fitted to both

sides of the machine, there will be a grease point on each
one.
@ 0
£ !
1 2
3 4
9
7 8
5 6
S229981
9803/8020 Issue 2*
3-5 Greasing 3-5
*(3000 Series Machines)
* ! WARNING * Hydraulic Lift and 3-Point Linkage
You will be working close into the machine for these
jobs. Lower the equipment. Remove the starter key and Hydraulic lift cross-shaft
disconnect the battery. This will prevent the engine from Grease points 5 and 6.
being started. Make sure that the parking brake is
Hydraulic lift rams
engaged.
Chock all four wheels before getting under the machine. Three point linkage lift rods
13-3-1-9
Grease at nipples 11 and 12. On later machines grease at
nipples 11, 12, 13 and 14 (lift collars A and B to access
Note: Ladder hitch and trailer coupling omitted for clarity.
nipples 13 and 14). On machines with heavy duty linkage
grease points 15 and 16 also.
* Rear Suspension Cylinder Pivots Stabilizers (standard type)

Grease at point 17.
Note: Where standard type stabilizers are fitted to both
sides of the machine, there will be a grease point on each
one.
*
Rear PTO Drive Shaft Bearing
Grease point 18. Do not exceed 2 to 3 strokes of the grease
1 3
2 A B A B A B
4
5 6
I II III
7 8
*
% ^
! @
A B &
9 0
£ $
A286030
9803/8020 Issue 2*
3-6 Greasing 3-6
Rear Anti-roll Bar Ball Joints
! WARNING
13-3-1-1
2WS: Grease points 4 and 5.

4WS: Grease points 6 to 9.
2WS
4 5
262210
4WS
6 8
7 9 A268420
9803/8020 Issue 1
3-7 Greasing 3-7
Steering Box Input Shaft Seal
Grease at point 1 through the hole in the chassis side
member.
Note: Apply only one shot of grease from a manual grease

gun with a rigid connector. Excessive greasing would
damage the internal seals of the steering box.
1
A293980
Rear Anti-roll Bar Ball Joints
! WARNING
13-3-1-1
Grease points 2 and 3.
2 3
262210
9803/8020 Issue 1
3-8 Greasing 3-8
Automatic Trailer Coupling (if fitted)
Note: Whenever the coupling has been pressure-washed it

must always be greased.
Make sure the coupling is in the open position, i.e. the

coupling pin is up and the hand lever A is in its highest
position.
Grease at points 1 and 2.
Operate lever A several times so that the grease is

distributed throughout the bearing.
! CAUTION
Keep your hands out of the funnel or you may be injured
by the coupling pin as it is forced down by its spring.
13-2-2-17
Grease again and operate the hand lever again.
If driving without a trailer attached, close the coupling to

prevent dirt accumulation.
S170201
Roller Drawbar (if fitted)

A B A B A B
I II III
! WARNING
You will be working close into the machine for these
jobs. Lower the equipment. Remove the starter key and
disconnect the battery. This will prevent the engine from
being started. Make sure that the parking brake is
engaged.
Chock all four wheels before getting under the machine.

13-3-1-9
Grease points 3 and 4.

Smear surface 5 with grease.
5
3
4
A309960
9803/8020 Issue 2*
4-1 Cab 4-1
Checking the ROPS Structure
! WARNING
The cab on this machine is designed to give the operator Check the structure for damage.
protection in the event of the machine rolling over
(ROPS). The following points must be strictly observed. Check that the four mounting bolts are installed and
undamaged. Check that torque tightness of nuts A and B is
1 If the machine has been in an accident which has correct (see Table below). Tighten them to the correct
damaged the ROPS structure, the machine must not torque if necessary.
be used until the structure has been renewed. If there
is any doubt about the strength of the ROPS Zinc-Plated Fasteners (colour: golden)
structure, it must be renewed. The operator could be
killed or seriously injured as a result of using a Nm kgf m lbf ft
machine with a damaged or missing ROPS. 375 38 277
2 The ROPS structure must not be modified except as Dacromet Fasteners (colour: mottled silver)
approved by JCB. Unauthorised modifications may
result in weakening of the structure. Nm kgf m lbf ft
365 37 269
3 Always use JCB supplied parts to mount the ROPS
structure on the machine. The use of unapproved
components could reduce the protection given by the
structure.
4 Make sure the ROPS structure mounting bolts are

not damaged and are tightened to the correct torque.
Always renew the bolts and nuts when the structure
is renewed following an accident. It is essential that
the correct tensile strength of bolt and nut is always
used.
BF 8-1/1
B
A 229990
9803/8020 Issue 3
4-2 Cab 4-2
Checking Windscreen Washer Fluid Level
Fill the windscreen washer bottle X with a suitable liquid. The

liquid should contain a de-icing fluid to prevent freezing. Do X
not use engine coolant antifreeze.
A290350
* 2000 Series Machines
A293830
* 3000 Series Machines
9803/8020 Issue 2*
5-1 Air Conditioning 5-1
Cleaning the Filter * Adjusting the Compressor Belt
(2115, 2125, 2135, and 2150)
Note: For crop spraying applications, a heavy duty carbon
filter can be used in place of the standard filter. Carbon filters 1 Stop the engine.
must not be cleaned. Keep a log of the hours used and
renew at 250 hour intervals. 2 Remove the left-hand bonnet side panel.
! WARNING
The filter may be filled with dust. Wear goggles and a
! WARNING
face mask when removing the filter. Make sure the engine cannot be started. Disconnect the
2-3-3-6 battery before doing this job.
2-3-3-5
1 Remove nuts A and pull out the filter B.

3 Loosen nuts A, B.
2 Using compressed air at a maximum pressure of 5.5 bar
(80 lbf/in2), blow out the dirt from the clean (gasket) side 4 Position the compressor so that there is 10mm (0.4 in)
to the dirty (grid) side. slack on the longest run of the belt.
3 Check the condition of the filter element and renew if split 5 Retighten nuts A and B.
or worn.
4 Check the condition of the filter gasket. If split or worn ! WARNING

renew the filter. The air conditioning system is a closed loop system and
contains pressurised refrigerant. No part of the system
5 Check and clean the filter sealing face on the cab body. must be disconnected except by a qualified refrigeration
engineer.
4-3-4-1
6 Refit the filter, making sure that the gasket side goes first.
Refit nuts A.
S232630
229880
9803/8020 Issue 3*
Cleaning the Filter
Note: The air conditioning system contains environmentally
safe R-134A refrigerant. Do not use test equipment or
gauges that have contacted R12 refrigerant or the system
will be damaged.
Note: For crop spraying applications, a heavy duty carbon

filter can be used in place of the standard filter. Carbon
filters must not be cleaned. Keep a log of the hours used
and renew at 250 hour intervals.
! WARNING
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6
1 Unclip closing panel A, unscrew and pull out the filter 160800
B.
2 Using compressed air at a maximum pressure of 5.5

bar (80 lbf/in2), blow out the dirt from the clean (gasket)
side to the dirty (grid) side.
3 Check the condition of the filter element and renew if

split or worn.
4 Check the condition of the filter gasket. If split or worn

renew the filter.
5 Check and clean the filter sealing face on the cab body.
6 Refit the filter, making sure that the gasket side goes in
first. Refit the closing panel A.
160810
9803/8020 Issue 3
* Adjusting the Compressor Belt

(2140, 3155 and 3185)
1 Stop the engine.
2 Open the bonnet.
! WARNING
Make sure the engine cannot be started. Disconnect the
battery before doing this job.
A B
2-3-3-5
3 Loosen the mountings
* Loosen fasteners A, B, C and D (3155) or E, F and G

(2140 and 3185).
4 Adjust the belt tension C

Position the compressor so that there is 10 mm (0.4 in)
slack on the longest run of the belt.
5 Tighten the Mountings
Retighten fasteners A, B, C and D, or E, F and G. D 272000
! WARNING
The air conditioning system is a closed loop system and
contains pressurised refrigerant. No part of the system
should be disconnected until the system has been
discharged by a refrigeration engineer or a suitably
trained person. You can be severely frostbitten or injured
by escaping refrigerant.
4-3-4-1/2
E F
G
271990
9803/8020 Issue 3*
6-1 Electrics 6-1
Battery Warning Symbols

! CAUTION
The following warning symbols may be found on the battery. Damaged or spent batteries and any residue from fires
or spillage should be put in a closed acid proof
receptacle and must be disposed of in accordance with
Symbol Meaning local environmental waste regulations.
INT-3-1-12
! WARNING
Keep away from children. Batteries give off an explosive gas. Do not smoke when
handling or working on the battery. Keep the battery
away from sparks and flames.
Battery electrolyte contains sulphuric acid. It can burn

you if it touches your skin or eyes. Wear goggles. Handle
the battery carefully to prevent spillage. Keep metallic
items (watches, rings, zips etc) away from the battery
terminals. Such items could short the terminals and burn
Shield eyes. you.
Set all switches in the cab to OFF before disconnecting

and connecting the battery. When disconnecting the
battery, take off the earth (-) lead first.
When reconnecting, fit the positive (+) lead first.
Re-charge the battery away from the machine, in a well

No smoking, no naked flames,
ventilated area. Switch the charging circuit off before
no sparks
connecting or disconnecting the battery. When you have
installed the battery in the machine, wait five minutes
before connecting it up.
First Aid - Electrolyte

Explosive Gas.
Do the following if electrolyte:
GETS INTO YOUR EYES
Immediately flush with water for 15 minutes, always get

medical help.
IS SWALLOWED
Battery acid.
Do not induce vomiting. Drink large quantities of water
or milk. Then drink milk of magnesia, beaten egg or
vegetable oil. Get medical help.
GETS ONTO YOUR SKIN
Flush with water, remove affected clothing. Cover burns

Note operating instructions.
with a sterile dressing then get medical help.
5-3-4-3/1
9803/8020 Issue 1
6-2 Electrics 6-2
Checking the Battery Electrolyte Level

* Note: The battery on Fastrac 2115, 2125, 2135 and 2140
machines is located as shown right, on the right of the
machine. On Fastrac 2150 machines the battery is located
on the left hand side.
Maintenance free batteries used in normal temperate climate

applications should not need topping up. However, in
certain conditions (such as prolonged operation at tropical
temperatures or if the alternator overcharges) the electrolyte
level should be checked as described below.
1 Apply the parking brake and stop the engine.

*2 Remove two screws A and swing open the hinged step
unit B (below the right hand cab door). Later machines A
have an upward lifting step unit.
3 Prize out the cell covers. Look at the level in each cell.
B
260030
The electrolyte should be 6 mm (0.25 in) above the
plates. Top up if necessary with distilled water or de-
ionized water.
! WARNING
Do not top the battery up with acid. The electrolyte could
boil out and burn you.
2-3-4-6
Checking the Electrolyte Level

(Unless Sealed for Life type which needs no checking)
Note: On machines for the UK market only battery 1 is fitted. ! WARNING

On European machines batteries 1 and 2 are fitted. Do not top the battery up with acid. The electrolyte could
boil out and burn you.
2-3-4-6
1 Apply the parking brake and stop the engine. Remove
the battery access panel A. Note: When two batteries are fitted on the machine, they are
connected in parallel. When fitting the cables, ensure that
2 Prize out covers B. Look at the level in each cell. The they are connected as shown on the illustration.
electrolyte should be 6 mm (0.25 in) above the plates.
Top up if necessary with distilled water or de-ionized
water.
A
B
1
A294000
9803/8020 Issue 3*
6-3 Electrics 6-3
Checking the Beam Alignment

1 Park the machine on level ground so that the front
headlights A are 2.00m from a wall.
2 Measure the distance Z from the ground to the centre

of the front headlights A. Subtract 25 mm ± 5 mm from
this distance and mark a horizontal line XX on the wall
at this height. When the auxiliary headlights B are fitted
mark a second horizontal line YY on the wall
approximately 1300 mm above XX.
3 When the headlights are switched on to dipped beam,

the horizontal tops of the light beams should be in line
with the horizontal lines XX and YY on the wall.
4 To adjust the beam, slightly slacken nut C or D,

reposition the light and then tighten the nut.
Note: The illustration shows a 3000 Series machine. The

principle for 2000 Series machines is identical.
B Y
B
Y
1300 mm
A A
X
X
D
Z
2.0 m
C
A293861
9803/8020 Issue 3*
7-1 Hydraulics 7-1
* Note: The hydraulic tank shown below on the right hand Changing the Filter Element
side of the machine is that for the Fastrac 2115, 2125, 2135
and 2140 machines. On the Fastrac 2150, 3155 and 3185 1 Park the machine on level ground. Apply the parking
machines the hydraulic tank is on the left hand side of the brake. Lower the rear linkage to the ground. Stop the
machine. engine. Remove the starter key. Wash off all dirt from
around the tank cap B and element cover plate D.
Checking the Fluid Level
2 Remove the element as follows:
a Remove tank cap B.

! WARNING b Remove nuts C, cover plate D and 'O' ring E.
Fine jets of hydraulic fluid at high pressure can penetrate c Remove the element assembly F and 'O' ring G.
the skin. Do not use your fingers to check for hydraulic d Remove the nut and spring assembly H. Remove the
fluid leaks. Do not put your face close to suspected element J from its spindle.
leaks. Hold a piece of cardboard close to suspected e i Dry clutch machines - discard the complete
leaks and then inspect the cardboard for signs of element J (see view W).
hydraulic fluid. If hydraulic fluid penetrates your skin, get ii Wet clutch machines - remove and discard the
medical help quickly. paper insert Y from metal outer element J (see
INT-3-1-10/1 view X).
f Wet clutch machines only - clean the metal outer
! CAUTION element J.
Using incorrect fluid could damage the system. See g Clean the magnets K.
Fluids, Capacities and Lubricants for the correct fluid.
3 Fit the new element as follows:
The fluid can harm your skin. Wear rubber gloves. Cover
cuts or grazes.
2-3-5-1/2 a Wet clutch machines - fit a new paper insert into
metal outer element J.
1 Park the machine on level ground. Apply the parking b Assemble the new element J (dry clutch machines)
brake. Lower any mounted implements to the ground. or refurbished element J/Y (wet clutch machines) on
Stop the engine. Remove the starter key. to the spindle, using a new seal L. Ensure that the
top lip of the seal locates in the groove inside the
2 Look at the fluid level in the sight gauge A. The level filter head M. Fit and tighten the nut and spring
should be between the two marks on the gauge. If the assembly H.
fluid is cloudy, water or air has entered the system. c Fit the element assembly F using a new 'O' ring G.
Water or air in the system could damage the hydraulic d Refit cover plate D and nuts C using a new 'O' ring
pump. E.
e Tighten nuts C to 7 Nm (5 lbf ft).
3 If necessary, add recommended fluid at tank cap B. f Top up fluid level at tank cap B and refit cap.
C
D
M
K G
L F E
W B
J Y
A
X
H
J
9803/8020 Issue 4*
Thank you very much
for your reading.
Please Click Here
Then Get More
Information.

JCB 3185 FASTRAC Service Repair Manual SN 00642001-00643010 PDF

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General Information 1

Care & Safety 2

1 = General Information - includes torque settings and service tools.

Contents Page No.

Machine Identification Plate 1-1

Sealing and Retaining Compounds 3-1

Service Tools Numerical List 4-1

Moving a Disabled Machine

Transporting the Machine 10 - 2

Machine Identification Plate Typical Engine Identification Number

Each machine has an identification plate located at X. The YH 50532 U 123456 X

Typical Vehicle Identification No. (VIN) G = Engine Type:-

* Introduction - Zinc Plated Fasteners and Dacromet Fasteners

Fastener Type Colour Part Number

Zinc Plated Fasteners (golden finish)

Bolt size Torque Settings Diameter Torque

M5 (5) 8 7 0.7 5 M3 2 0.2 1.5

Metric Grade 10.9 Bolts Verbus Ripp Bolts

Bolt size Torque Settings

Note: In most cases Verbus Ripp bolts should not be re-

Hydraulic Hose to Adapter Connections Hydraulic Adapter into Component Connections

Torque Settings Torque Settings

1/8 14 1.4 10 1/8 20 2.1 15

Dacromet Fasteners (mottled silver finish)

Metric Grade 8.8 Bolts

Bolt size Torque Settings

Metric Grade 10.9 Bolts

Bolt size Torque Settings

M6 x 1.0 13.5 1.4 10

Metric Grade 12.9 Bolts

Bolt size Torque Settings

Dacromet Fasteners (mottled silver finish) - List of Torque Settings

A402200 A402190 A402160

Dacromet Fasteners (mottled silver finish) - List of Torque Settings (cont.)

Dacromet Fasteners (mottled silver finish) - List of Torque Settings (cont.)

Location: Rear Anti-Roll bar Location: Front Anti-Roll Bar

Location: Front Engine Mounting Location: Header Tank Clamp Plate

Sealing and Retaining Compounds

JCB Threadlocker For threads of suction strainer. 4101/0451 50ml

† Ultra Fast Adhesive For direct glazing 4103/2109 310 ml

† Active Wipe 205 For direct glazing 4104/1203 250 g

† Black Primer 206J For direct glazing 4201/4906 30 ml

Service Tools Numerical List

Service Tools Numerical List (continued)

* Replacement parts for kit no. 892/01092

12V Mobile Oven - 1 cartridge capacity - required to

JCB part number - 992/12300 JCB part number - 892/00843

Service Tools (continued)

Braided Cutting Wire - consumable heavy duty

Service Tools (continued)

892/00801 Clutch spanner S200940 892/00807 Front plate puller S200970

892/00802 Rotor puller set S200950 892/00808 Shaft protector S200980

892/00803 Rotor installer set S200960

Electrical Test Equipment

1 892/00283 Tool Kit Case

2 892/00281 AVO Meter

3 892/00286 Surface Temperature Probe

4 892/00284 Microtach Digital Tachometer

5 892/00282 100 Amp Shunt - open type

6 892/00285 Hydraulic Oil Temperature Probe

7 892/00298 Fluke 85 Multimeter

993/85700 Battery Tester

Psion Workabout 1Mb/RS232 †