JCB 3170 FASTRAC Service Repair Manual SN 00643430-00644999 PDF

General Information 1
Care & Safety 2

Routine Maintenance 3
Service Optional Equipment A
Manual Body & Framework B
Electrics C
Fastrac
3170, 3170 Plus
Controls D
3190, 3190 Plus
3200, 3200 Plus
Hydraulics E
3220, 3220 Plus Transmission F
3230, 3230 Plus
Published by the
Brakes G
TECHNICAL PUBLICATIONS DEPARTMENT
H
of
JCB SERVICE LTD;
World Parts Centre,
Steering
Waterloo Park
Uttoxeter, Staffordshire
ST14 7BS
Publication No. 9803/8030

Issue 9
Suspension S
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.
9803/8030 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
Unit Identification 1-1
Torque Settings
Introduction - Zinc Plated Fasteners and Dacromet Fasteners 2-1
Zinc Plated Fasteners 2-2
Dacromet Fasteners 2-3
Sealing and Retaining Compounds 3-1
Service Tools Numerical List 4-1
* Service Tools
Optional Equipment 5-0
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
9803/8030 Issue 2*
1-1 1-1
Serial Number Plate * D = Transmission Type (Gearbox and axle combination)

3170, 3170 Plus All other machines
A = 75 km/h 8 = Standard (40, 50 or 65 km/h)
Each machine has a serial number plate located at X. The 17 B = 65 km/h 9 = High Speed (75 km/h)
digit Vehicle Identification Number (VIN), and the serial D = 50 km/h
numbers of the engine and transmission are stamped on the E = 40 km/h
plate. E = Vehicle Max. Speed
40 = 40 km/h
* Typical Vehicle Identification No. (VIN) 50 = 50 km/h
65 = 65 km/h
75 = 75 km/h
SLP FT 17 A 40 XXXXXXX F = Serial Number
* G = Authenticity Code
* H = year Code (e.g. 6 = 2006)
A B C D E F Unit Identification
Original VIN Configuration The serial number of each major unit is also stamped on the
unit itself as shown below. If a major unit is replaced by a
JCB 23 8 40 X 6 XXXXXXX new one, the serial number on the plate will be wrong. Either
stamp the new number of the unit on the identification plate,
or simply stamp out the old number. This will prevent the
wrong unit number being quoted when replacement parts
A C D E G H F are ordered.
Later VIN Configuration Engine M

Gearbox Assembly (assembly of all three gearboxes) N
A = Manufacturing Code Speed Gearbox P
B = Machine Range Front Axle R
FT = Fastrac Rear Axle S
* C = Engine Type
17 = 3190 or 3190 Plus
18 = 3220 or 3220 Plus
19 = 3170 or 3170 Plus
23 = 3200 or 3200 Plus
24 = 3230 or 3230 Plus
S M
N R
P 417490
9803/8030 Issue 3*
2-1 Torque Settings 2-1
Introduction - Zinc Plated Fasteners and Dacromet Fasteners

Some external fasteners on Fastrac machines are assembled using an improved type of corrosion resistant finish. 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, the torque figures used must
be relevant to the type of fasteners.
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. They are not used in application such as gearbox and engine joint seams or internal
applications.
9803/8030 Issue 1
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
M12 (12) 19 137 14 101 A343780
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.
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
9803/8030 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
9803/8030 Issue 1
Dacromet Fasteners (mottled silver finish) - List of Torque Settings

This list shows Dacromet fasteners that may not be shown in the other sections of the service manual.
Location: Front Wrapper Location: Front Lower Crossmember Location: Front P.T.O. Box
(top/bottom) Nm: 115 kgf m: 12 lbf ft: 85 Nm: 200 kgf m: 20 lbf ft: 148
Nm: 392 kgf m: 40 lbf ft: 289
A402060
A402230
A401990
* Location: Front Axle Upper Arm Location: Front Engine Mounting Location: Header Tank Clamp Plate
Mounting Bracket Nm: 200 kgf m: 20 lbf ft: 148 Nm: 30 kgf m: 3 lbf ft: 22
8.8 grade bolts:
Nm: 200 kgf m: 20 lbf ft: 148
10.9 grade bolts (all bolts with JCB

Threadlocker and Sealer and with
spacer fitted at bolt B):
Nm: 300 kgf m: 30 lbf ft: 220
A402290
A402270 A402150
Location: Steershaft Bearing Location: Steershaft upper UJ

Nm: 28 kgf m: 2.9 lbf ft: 21 Nm: 38 kgf m: 3.9 lbf ft: 28
9803/8030 Issue 2*
Dacromet Fasteners (mottled silver finish) - List of Torque Settings (continued)

Location: Gearbox Crossmember Location: Left Hand Pannier Step Location: Rear Anti-Roll bar mounting
Nm: 200 kgfm: 20 lbf ft: 148 Nm: 47.5 kgf m: 4.8 lbf ft: 35 bracket
Nm: 392 kgf m: 40 lbf ft: 289
A402120
A402200
Location: Tower Casting to Axle Location: Lower Link Capscrew Location: Lower Link Bolt (Hex Head)
Nm: 392 kgf m: 40 lbf ft: 289 Nm: 654 kgf m: 67 lbf ft: 482 Nm: 392 kgf m: 40 lbf ft: 289
A402010
A402040
A402140
Location: Rear Crossmember Location: Rear Lower Crossmember Location: Rockinger Hitch Bolt
Nm: 392 kgf m: 40 lbf ft: 289 Nm: 200 kgf m: 20 lbf ft: 148 Nm: 392 kgfm: 40 lbf ft: 289
A402280
A402260 A402030
9803/8030 Issue 1
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
9803/8030 Issue 2*
4-1 4-1
Service Tools Numerical List 892/00278 Gauge 0 - 40 bar 7-2

892/00279 Gauge 0 - 400 bar 7-2
Page No. 892/00281 Avo Meter 6-1
1370/0901Z Nut M24 9-1 892/00282 Shunt 6-1
1406/0021 Bonded Washer 7-1 892/00283 Tool Kit Case 6-1
1604/0006 Adapter 7-1 892/00284 Digital Tachometer 6-1
1604/0008 Adapter 7-1 892/00285 Oil Temperature Probe 6-1
1606/0012 Adapter 7-1 892/00286 Surface Temperature Probe 6-1
1606/0015 Adapter 7-1 892/00293 Connector Pipe 7-1
1612/0006 Adapter 7-1 892/00294 Connector Pipe 7-1
4101/0251 JCB Threadlocker and Sealer 3-1 892/00298 Fluke Multimeter 6-1
4101/0451 JCB Threadlocker 3-1 892/00311 Brake Test Kit 8-4
4101/0552 JCB Threadlocker and Sealer 892/00312 Dummy End Plate 8-2
(High Strength) 3-1 892/00314 Accumulator Adapter 9-1
4101/0651 JCB Retainer (High Strength) 3-1 892/00318 Hose and Adapter Kit 7-2
4102/0551 JCB High Strength Threadlocker 3-1 892/00333 Heavy Duty Socket, 19 mm A/F 8-2
4102/0901 JCB Clear Silicone Sealant 3-1 892/00334 Gland Seal Fitting Tool 7-2
4102/1212 JCB Multigasket 3-1 892/00706 Test Probe 7-2
4102/1951 JCB Threadseal 3-1 892/00801 Clutch spanner 5-3
4102/2210 Clayton System Seal SC1251 3-1 892/00802 Rotor puller set 5-3
4102/2309 Black Polyurethane Sealant 3-1 892/00803 Rotor installer set 5-3
4103/2109 Ultra Fast Adhesive 3-1 892/00807 Front plate puller 5-3
4104/0251 JCB Activator (Aerosol) 3-1 892/00808 Shaft protector 5-3
4104/0253 JCB Activator (Bottle) 3-1 892/00812 Drive Coupling Spanner 8-1
4104/1557 JCB Cleaner/Degreaser 3-1 892/00817 Heavy Duty Socket, 17 mm A/F 8-2
4104/1203 Active Wipe 205 (250 g) 3-1 892/00818 Heavy Duty Socket, 22mm A/F 8-2
4104/1206 Active Wipe 205 (30 ml) 3-1 892/00819 Heavy Duty Socket, 15 mm A/F 8-2
4104/1310 Hand Cleaner 5-1 892/00842 Glass Lifter 5-1
4201/4906 Black Primer 3-1 892/00843 Folding Stand 5-1
721/00664 Connecting Lead (Wingst) 6-2 892/00844 Long Knife 5-2
721/10885 Harness - ABS Diagnostic (J1939) 6-1 892/00845 Cartridge Gun 5-1
816/15118 Test Adapter 7-1 892/00846 Glass Extractor Handles 5-2
816/20008 Adapter 7-1 892/00847 Nylon Spatula 5-3
816/20013 Adapter 7-1 892/00848 Wire Starter 5-2
816/55038 Adapter/Test Point 7-1 892/00849 Braided Cutting Wire 5-2
816/55040 Adapter/Test Point 7-1 892/00864 PD 90 Axle Locknut Spanner 8-3
892/00041 Deglazing Tool 9-2 892/00871 Frame (Puller Adapter Assembly) 9-1
892/00078 Connector 7-1 892/00874 Brace (Puller Adapter Assembly) 9-1
892/00137 Micro Bore Hose 7-2 892/00875 Bar M24 (Puller Adapter Assembly) 9-1
892/00174 Measuring Cup 8-2 892/00876 Block (Puller Adapter Assembly) 9-1
892/00179 Bearing Press 8-1 892/00892 Speed Gearbox Locking Tool 8-3
892/00223 Hand Pump 7-2 892/00916 Spring Compressor 8-3
892/00224 Impulse Extractor 8-2 892/00918 Setting Tool Kit 8-3
892/00225 Adapter for Impulse Extractor 8-1 892/00945 Sleeve for M30 Pinion 8-3
892/00253 Pressure Test Kit 7-1 892/01033 Data Link Adapter Kit - ABS 6-1
892/00255 Adapter/Test Point 7-1 892/01045 Peg Socket - Wet Clutch 8-5
892/00256 Adapter/Test Point 7-1 892/01046 Mandrel - Wet Clutch 8-4
892/00257 Adapter/Test Point 7-1 892/01047 Jig - Wet Clutch 8-4
892/00258 Adapter/Test Point 7-1 892/01048 Clutch Pack Retainer - Wet Clutch
892/00259 Adapter/Test Point 7-1 (2 required) 8-4
892/00260 Adapter/Test Point 7-1 892/01049 Guide Rod - Wet Clutch
892/00261 Adapter/Test Point 7-1 (2 required) 8-4
892/00262 Adapter/Test Point 7-1&7-2 892/01050 Mandrel - Wet Clutch 8-4
892/00263 Adapter/Test Point 7-1 892/01051 Intermediate Gear Retaining Tool -
892/00264 Adapter/Test Point 7-1 Wet Clutch Transmission 8-4
892/00265 Adapter/Test Point 7-1 892/01052 Locking Plate - Wet Clutch
892/00268 Flow Monitoring Unit 7-1 (2 required) 8-4
892/00269 Sensor Head 7-1 892/01053 Adapter for impulse extractor
892/00270 Load Valve 7-1 (PTO intermediate shaft,
892/00271 Adapter 7-1 wet clutch transmission) 8-2
892/00272 Adapter 7-1 892/01066 Combination Lead 6-2
892/00273 Sensor Head 7-1 * 892/01092 Wheel Hub Service Kit 8-5
892/00274 Adapter 7-2 926/15500 Rubber Spacer Blocks 5-3
892/00275 Adapter 7-1 992/09000 Peg Spanner 5-0
892/00276 Adapter 7-1 992/12300 Mobile Oven 5-1
892/00277 Adapter 7-1 992/12400 Static Oven 5-1
9803/8030 Issue 4*
4-2 4-2
Service Tools Numerical List (continued)

Page No.
992/12600 Static Oven 5-1
992/12800 Cut-out Knife 5-2
992/12801 'L' Blades 5-2
993/45400 Torque Multiplier 8-1
993/55700 Direct Glazing Kit 3-1
993/59300 Pressure Test Adapter and Clamp 8-2
993/69800 Seal Kit 7-1
993/70111 Break-back Torque Wrench 8-3
997/11000 Drive Head Setting Bracket 8-3
997/11100 Adapter for M24 Pinion 8-3
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
* 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
9803/8030 Issue 3*
5-0 5-0
Service Tools
Section A - Optional Equipment
1 992/09000 Peg spanner for piston head of front hitch

ram (including 2 pairs of pegs)
2 992/09003 Replacement pegs for 7.5 mm holes
3 992/09004 Replacement pegs for 10 mm holes
197220
892/00334 Gland Seal Fitting Tool
9803/8030 Issue 1
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 during
JCB part number: storage.
992/12400 - 2 cartridge x 240V
992/12600 - 6 cartridge x 240V JCB part number - 892/00842
9803/8030 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
9803/8030 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
892/01033 Data Link Adapter Kit - ABS

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)
9803/8030 Issue 2*
6-2 6-2

Section C - Electrics (continued)
721/00664 Connecting Lead - Wingst
* 892/01066 Combination Lead

(alternative to 721/00664)
A406950
9803/8030 Issue 2*
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
9803/8030 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
9803/8030 Issue 2
8-1 8-1
Service Tools
Section F - Transmission
188200 107750
892/00179 Bearing Press 892/00812 PTO Drive Coupling Spanner for yoke
couplings
110
25 25
15
40
A197180
892/00225 Adapter - Impulse Extractor
Small 17mm to 25mm * Differential Setting Key
Medium 25mm to 45mm 197080 Cut from 5 mm plate to dimensions shown. Fabricate
Large 45mm to 80mm handle to suit.
993/45400 Torque Multiplier

(use in conjunction with a torque wrench to
give a 5 : 1 multiplication)
S197030
9803/8030 Issue 2*
8-2 8-2
Section F - Transmission (continued)
197250
Heavy Duty Sockets
892/00817 17 mm A/F x 3/4in. square drive S190770
892/00818 22 mm A/F x 3/4in. square drive

892/00174 Measuring Cup - Pinion Head Bearing
892/00224 Impulse Extractor Set

for Hub Bearing Seals
892/01053 Adapter for impulse extractor
(PTO intermediate shaft, wet clutch S197240
transmission) S197070
892/00312 Dummy End Plate for Range Gearbox
993/59300 2/4 WD Pressure Test Adaptor & Clamp
S196750
9803/8030 Issue 2
8-3 8-3
S226300
892/00892 Speed Gearbox Locking Tool
892/00916 Spring Compressor for Splitter and PTO

Clutches
S267310
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
9803/8030 Issue 1
8-4 8-4
A361710
892/01051 Intermediate Gear Retaining Tool - wet 892/01049 (x2) Guide Rod - wet clutch
clutch transmission A361740
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
892/01048 (x2) Clutch

Pack Retainer - wet
clutch
A361720
9803/8030 Issue 1
8-5 8-5

Item Description Part No. Qty A
A Hub Service Kit 892/01092 1
comprises: 5
1 Puller Beam 998/10623 1

2 Inner Bearing Plate 998/10607 1 1
3 Bolt M16x220 1315/3731Z 2
4 Nut M16 1370/0601Z 2 6
5 Reaction Tube 998/10614 1
6 Modified Wheel Stud 998/10624 2 8,9
7 Wheel Bearing Carrier
Puller 998/10615 2
8 Nut M20 1370/0701Z 4
7
9 Washer M20 1420/0012Z 2 2
10 Puller Rod 998/10610 2
11 Nut M12 1370/0401Z 2
12 Washer M12 1420/0009Z 2
13 Bearing Centre Puller 998/10608 1 10
14 Bolt M10x60 1315/3414Z 1
15 Nut M10 1370/0301Z 1
16 Bearing Fitting Tube 998/10606 1 4 11,12
17 Puller Handle Nut 998/10616 1
18 Bolt M20x300 1315/3835Z 2
19 Washer 445/12303 2
20 Bearing 917/02800 1
3
21 Dolly 892/00891 1
13 16
15
19, 20
14
18
8
21
17
9803/8030 Issue 2
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
D
Puller adapter assembly for removal of drop arm from
steering box (3000 Series machines). Comprises:
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.
9803/8030 Issue 1
9-2 9-2

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

Test Adapter
Section T - Engine
S192390
892/00041 De-glazing Tool for Cylinder Bores (to

assist bedding-in of new piston rings)
Note: For other engine tools refer to the relevant Engine

Service Manual.
9803/8030 Issue 1
10 - 1 Moving a Disabled Machine 10 - 1
General b Fit the drawbar between towing vehicle and

Fastrac.
Do not tow a machine unless there is no alternative.
Remember that more damage might be caused to the 2 Prepare the machine.
machine by towing it. If at all possible repair the machine a Make sure that the range and speed gearboxes are
where it stands. both in neutral.
b If the gearbox has failed, disconnect both
* Note: It is not possible to tow-start or push-start the Fastrac propshafts (see Section F).
due to the design of the transmission. c If an axle has failed, remove the sun gears (see
Section F).
Make sure you will be obeying all pertinent laws and
regulations before towing the machine on public roads. 3 Release the Fastrac parking brake.
If there is not enough air pressure to release the brake,
! DANGER start the engine to charge up the air system. If the
If the engine is not running, there will not be enough air engine cannot be run but the brake air system is
to apply the service brakes or release the parking brake. serviceable, charge the system to 8 bar (120 lbf/in2)
Carefully follow the precautions in this section before through Schrader valve X (machines with ABS) or Y
moving the machine or there may be a serious accident. (machines without ABS). This job must be done by a
13-2-2-6/1 qualified mechanic, using the correct equipment.
! CAUTION ! DANGER
Towing a machine too far or too fast can damage the Ensure that the chocks and towing vehicle will prevent
transmission. Do not tow the machine further than one the Fastrac from moving as it is necessary to work under
mile. Use a trailer for greater distances. When towing do the machine to remove the propshafts or release the
not travel faster than 25 km/h (15 mph). parking brake. When the propshafts have been
disconnected the parking brake cannot prevent the
Use a rigid drawbar. If you must use towing chains, then
machine from moving. When the parking brake has been
use two towing vehicles. One towing vehicle should be
manually released as described below, it will be
coupled to the front of the disabled machine. The other
impossible to apply the brake until plate A has been
towing vehicle should be coupled to the rear of the
removed and the propshafts connected. Anyone working
disabled machine, to provide braking power.
underneath, or near the machine, could be killed or
The towing vehicle(s) must have enough pulling and seriously injured if the machine moved.
13-2-2-11/1
braking power to move and stop the machine.
2-2-7-3
Alternatively, position plate A (if provided with the
machine) as shown. Keeping nut B tight against clevis
Preparation for Towing C, turn nut D against the plate so that rod E is drawn
out of the actuator body and the parking brake is
1 Connect the towing vehicle.
released.
a Apply the parking brakes on the towing vehicle and
securely chock the wheels on the Fastrac.
Note: If the parking brake cannot be released, remove both
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
regulations. Remember that the steering will be much
heavier if the engine is not running.
D E
X
C
B A
S160392
418150
9803/8030 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 B.
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
B 418300
B
9803/8030 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
9803/8030 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
9803/8030 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 * Parts of this machine, for example the braking and fuel
hair restrained. injection systems, are manufactured in compliance with
INT-1-3-6
legislative and other requirements. The machine should not
be altered in any way which could affect or invalidate any of
! WARNING these requirements. Failure to observe this instruction may
Alcohol and Drugs be illegal or invalidate the manufactuer’s warranty. For
It is extremely dangerous to operate machinery when under advice consult your JCB Distributor.
the influence of alcohol or drugs. Do not consume alcoholic
drinks or take drugs before or whilst operating the machine
or attachments. Be aware of medicines which can cause
! CAUTION
drowsiness. Electronic Control Unit
INT-1-3-9 The electronic control unit under the passenger’s seat is
protected by a cover. Do not use the machine with the cover
removed.
0111
9803/8030 Issue 3*
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
9803/8030 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
9803/8030 Issue 1
3-3 3-3
! 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.
13-3-2-5 When driving the machine on the road, use the accelerator
pedal and not the hand throttle or Field Speed Control to
! WARNING control the engine speed. Always set the hand throttle to
Tyre Speed Limitations ‘idle’ and disable the Field Speed Control before road use.
0096
Running tyres outside recommended guidelines may result
in failure of the tyres which at high speeds may endanger
life. BE WARNED. ! WARNING
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
Rear Deck using implements.
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
secured adequately to prevent them rolling about, falling off
! DANGER
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
Weight Distribution trailers or implements that you tow behind the Fastrac. DO
The machine must never be loaded such that less than 20% NOT EXCEED THE MAXIMUM DESIGN SPEED OF
of the vehicle weight is carried on the front axle. TRAILERS OR IMPLEMENTS AS INJURY OR DEATH MAY
13-1-1-11/1 RESULT.
13-2-3-5
! CAUTION
Weight Distribution
! WARNING
The Fastrac has to comply with certain braking regulations Cab Air Filter
which in some countries control weight distribution between The cab air filter is designed to remove dirt from the outside
front and rear axles. Travelling on the road with implements air. When using chemicals (e.g. for crop spraying) follow the
or weights carried on the front when no implement is on the chemical manufacturer’s recommendations for protection
rear may break the law. In this case you should transfer the from dangerous chemicals.
13-2-3-6
front mounted equipment to the rear linkage. It is the
operator's responsibility to know and observe the laws in the
country concerned. ! WARNING
13-2-2-5
Hazardous Atmospheres
! WARNING This machine is designed for use in normal out door
atmospheric conditions. It should not be used in an
Travel Speed
enclosed area without adequate ventilation. Do not use the
Be aware of the load the machine is carrying or towing and
machine in a potentially explosive atmosphere, i.e.
the speed at which you are travelling. Do not corner fast
combustible vapours, gas or dust, without first consulting
when carrying heavy mounted implements or towing trailers.
your JCB Distributor.
Reduce speed when towing non-suspended implements on INT-2-1-14
rough ground.
13-2-2-1
9803/8030 Issue1
3-4 3-4
! WARNING
When driving the machine on the road with an implement or
trailer connected to the hydraulic system, the transport locks
must be engaged to prevent unintentional operation of
electronic linkage or external hydraulics.
0099
! CAUTION
Use caution when operating the engine at full load. Serious
damage could occur if it is allowed to operate at full throttle
for more than 30 seconds whilst running below peak torque
(1500 rev/min). Do not allow the engine to operate in this
condition when running on a dynamometer.
0097
! CAUTION
Do not allow the engine to exceed maximum speed (2520
rev/min). Use caution when travelling down hill in a loaded
condition to prevent accidental engine overspeeding when
selecting lower gears.
0098
! CAUTION
Do not use down shifting of the six speed gearbox to slow
down the tractor. Overspeeding of the gearbox
synchronisers can cause severe damage to the
transmission.
Use the tractor brakes to slow the vehicle and then select a
suitable gear to match the vehicle speed.
Only use trailers with suitable braking systems to prevent

transmission overload.
0102
9803/8030 Issue 1
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.
! WARNING INT-3-2-10
Turning the Engine
Do not try to turn the engine by pulling the fan or fan belt.
This could cause injury or premature component failure.
0094
9803/8030 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
contaminated with oil thoroughly in warm soapy water. Do
! WARNING
not use petrol, diesel fuel or paraffin to clean your skin. Welding and Modifications
INT-3-2-3 To prevent the possibility of damage to electronic
components, disconnect the battery positive and negative
! WARNING leads before arc-welding on the machine or attached
Hot Coolant implements. Attach the welder earth (ground) cable no more
The cooling system is pressurised when the engine is hot. than 0.6 metres (2 feet) from the part being welded. Do not
Hot coolant can spray out when you remove the radiator connect the welder cable or apply any weld to any part of
cap. Let the system cool before removing the radiator cap. the engine.
To remove the cap; turn it to the first notch and let the
system pressure escape, then remove the cap. Parts of the machine are made from cast iron; welds on cast
INT-3-2-9 iron can weaken the structure and break. Do not weld cast
iron. On no account weld or drill the chassis structure. Non-
! WARNING approved modifications can cause injury and damage.
Contact JCB before modifying the machine.
Wheels 0095
Wheels are heavy. Handle and store with care to ensure that
they cannot fall and cause injury.
13-3-1-7 ! WARNING
Protect your eyes when grinding metal. Wear safety glasses
! WARNING or goggles. Remove or protect any combustible materials
Metal Splinters from the area which could be ignited by sparks.
GEN-1-12
You can be injured by flying metal splinters when driving
metal pins in or out. Use a soft faced hammer or drift to
! WARNING
remove and fit metal pins. Always wear safety glasses.
INT-3-1-3 Radar Speed Sensor (if fitted)
To avoid possible eye damage from microwave signals, do
! WARNING not look directly into the sensor face.
13-1-1-15
Always wear safety glasses when dismantling assemblies
containing components under pressure from springs. This Note: The radar speed sensor is located underneath the
will protect against eye injury from components accidentally machine.
flying out.
GEN 6-2
9803/8030 Issue1
4-3 4-3
Maintenance Safety (cont'd) ! WARNING

Brakes
! WARNING Before working on or around the brake system, always
Fluoroelastomeric Materials observe the following precautions:
Certain seals and gaskets (e.g. crankshaft oil seal) on JCB
machines contain fluoroelastomeric materials such as Viton, 1 Stop the engine and chock all four wheels.
Fluorel and Technoflon. Fluoroelastomeric materials
subjected to high temperatures can produce highly corrosive 2 When the air system is being exhausted, keep hands
hydrofluoric acid. THIS ACID CAN SEVERELY BURN. away from the parking brake actuator pushrod and
caliper, as they may move and trap your fingers.
New fluoroelastomeric components at ambient temperature
require no special safety precautions. 3 Take care if disconnecting an air hose containing
pressure as it may whip as air escapes.
Used fluoroelastomeric components whose temperatures
have not exceeded 300°C require no special safety 4 Never remove or dismantle a component until air
precautions. If evidence of decomposition (e.g. charring) is pressure has been exhausted and you have read and
found, refer to the next paragraph for safety instructions DO understood the recommended procedures.
NOT TOUCH COMPONENT OR SURROUNDING AREA.
5 Wear safety glasses when working with air pressure.
BRAK 8-3/1
Used fluoroelastomeric components subjected to
temperatures greater than 300°C (e.g. engine fire) must be
treated using the following safety procedure. Make sure that
! WARNING
heavy duty gloves and special safety glasses are worn: Brake Pads
Always renew brake pads and locating pins in complete axle
1 Ensure that components have cooled then remove and sets, using genuine JCB parts, otherwise braking will be
place material in plastic bags. unsafe.
13-3-1-10
2 Thoroughly wash contaminated area with 10% calcium

hydroxide or other suitable alkali solution, if necessary
use wire wool to remove burnt remains. ! WARNING
ABS
3 Thoroughly wash contaminated area with detergent and Upon completion of any work done on the brake system of
water. machines fitted with ABS, the ABS test within Servicemaster
must be run satisfactorily before the machine is driven. It is
4 Contain all removed material, gloves etc used in this not sufficient to rely on the ABS self-check which can only
operation in sealed plastic bags and dispose of in check for presence of components, not that they are
accordance with Local Authority Regulations. correctly installed.
0091
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
! WARNING
Cleaning Agents
When using cleaning agents, solvents or other chemicals,
you must adhere to the manufacturer's instructions and
safety precautions.
GEN-1-9
9803/8030 Issue1
Section 3 Routine Maintenance Section 3
i i
Contents Page No.
Engine Oil 1-1

Fluids, Capacities and Lubricants 1-2
Fluids, Capacities and Lubricants (N.America) 1-3
Lubricants - Health and Safety 1-4
Service Schedules 2-1
Cleaning the Machine and Checking for Damage 3-1

Checking Seat Belt Condition and Security 3-1
Opening/Closing the Bonnet 3-2
Greasing
General 4-1
Propshafts and PTO Driveshafts 4-1
Front Axle Steering Swivels 4-2
Front 3 point linkage 4-3
Automatic Trailer Coupling (if fitted) 4-3
Hydraulic Lift & 3 point Linkage 4-4
Rear PTO Driveshaft Bearing 4-4
Rear Suspension Cylinder Pivots 4-4
Steering column Universal Joints 4-5
Rear Anti-roll Bar Ball Joints 4-5
Roller drawbar 4-6
Cab
Checking the ROPS Structure 5-1
Checking the Windscreen Washer Fluid Level 5-2
Air Conditioning
Cleaning the Filter 5-3
Adjusting the Compressor Belt 5-4
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
PTO, Speed and Range Gearboxes

Checking the Oil Level 9-1
Changing the Oil and Cleaning the Strainer 9-2
* Changing the Transmission Oil Filter
3170, 3170 Plus, 3190, 3190 Plus, 3200, 3200 Plus 9-3
3220, 3220 Plus, 3230, 3230 Plus 9-4
Checking the Front PTO Gearbox Oil Level (if fitted) 9-5
9803/8030 Issue 5*
ii ii
Contents Page No.
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
Checking the Oil Level 11 - 1
Changing the Oil 11 - 2
Tyres and Wheels

General 12 - 1
Tyre Inflation 12 - 1
Pressures, Speeds and Loads See Operator Handbook
Checking and Adjusting Wheel Alignment 12 - 2
Track Width 12 - 3
Checking Wheel Nut Torques 12 - 3
Lock Stops 12 - 3
Fender Adjustment 12 - 4
Brakes
Checking and Renewing Foot Brake Pads 13 - 1
Checking and Renewing the Parking Brake Pads 13 - 2
Checking the Foot Brake Fluid Level 13 - 3
Checking the Trailer Air Tank 13 - 3
Checking the Air Tank Warning Lights 13 - 5
Cleaning the Trailer Brake Control Line Air Filter See Section G
* Engine
Checking the Oil Level 14 - 1
Changing the Oil and Filter 14 - 2
Draining/Renewing Fuel Pre-Filter
(Early Renewable Element Type) 15 - 1
Renewing Fuel Pre-Filter (One-piece Type) 15 - 1
Draining the Fuel Pre-Filter
3200, 3200 Plus, 3230, 3230 Plus 15 - 2
Changing the Fuel Pre-Filter Element
3200, 3200 Plus, 3230, 3230 Plus 15 - 2
Draining the Fuel Filter 15 - 3
Changing the Fuel Filter Element 15 - 4
Bleeding the Fuel System
3170, 3170 Plus 15 - 5
3190, 3190 Plus, 3220, 3220 Plus 15 - 6
3200, 3200 Plus, 3230, 3230 Plus 15 - 8
Checking the Coolant Level 16 - 1
Coolant Mixtures 16 - 1
Draining & Refilling the Coolant 16 - 2
Cleaning the Radiator and Coolers 16 - 3
Fan Belt 16 - 4
Changing the Air Filter Elements 17 - 1
Cleaning the Pre-Cleaner (optional) 17 - 2
9803/8030 Issue 5*
1-1 Engine Oil 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 Engine Oil EP 15W/40

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: 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

- 20 °C to 20 °C (-4 °C to 68 °F).
Engine Oil Specification (N. America)

* Recommended Oil
JCB Engine Oil EP 15W/40

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: 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
- 20 °C to 20 °C (-4 °C to 68 °F).
9803/8030 Issue 2*
1-2 Fluids, Capacities and Lubricants 1-2
ITEM CAPACITY FLUID/LUBRICANT MINIMUM NTERNATIONAL

Litres (UK Gal) SPECIFICATION
Fuel 350 (77) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
* Engine (Oil) - 3200/3230 17.5 (3.9) See Engine Oil (All Machines) at the
Engine (Oil) - All Others 15 (3.3) beginning of this section
Engine (Coolant) 33 (7.3) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
Summer Coolant/water
(See Coolant Mixtures)
PTO, Speed and

Range Boxes 42 (9.3) JCB Super Universal Agricultural Oil API-GL-4, MIL-L-2105
(combined)
* Front Axle
Housing 20 (4.4) JCB Gear Oil HP90 API-GL-5, MIL-L-2105C
Hubs (x2) 2.5 (0.55)
Rear Axle 27 (6.0) JCB Gear Oil HP90 API-GL-5, MIL-L-2105C
* Brake System JCB Brake Fluid Dot 4 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
* Hydraulic System 120 (26.4) JCB Hydraulic Fluid HP46 ISO VG46
- see Note 1 (Above 38 °C, 100 °F)
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 1.56kg (3lb 7oz) HFC R134a CH2 FC F3
- Compressor Lubricant 0.24 (0.05) Polyalkalineglycol PAG SP20
* Front PTO Transfer

Box (optional) 3.0 (0.67) JCB Gear Oil HP90 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.
9803/8030 Issue 2*
1-3 Fluids, Capacities and Lubricants (N. America) 1-3
ITEM CAPACITY FLUID/LUBRICANT MINIMUM INTERNATIONAL

US Gal (Liters) SPECIFICATION
Fuel
92.5 (350) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
* Engine (Oil) - 3200/3230 4.6 (17.5) See Engine Oil (All Machines) at the
Engine (Oil) - All Others 4 (15) beginning of this section
* Engine (Coolant) 8.77 (33.0) JCB Four Seasons Antifreeze & Summer ASTM D3306-74
Coolant/water (See Coolant Mixtures)
PTO, Speed and

Range Boxes 11.2 (42.0) JCB AG Transmission Fluid API-GL-4, MIL-L-2105
(combined)
* Front Axle
Housing 5.3 (20.0) JCB Gear Oil HP90 API-GL-5, MIL-L-2105C
Hubs (x2) 0.66 (2.5)
Rear Axle 7.1 (27.0) JCB Gear Oil HP90 API-GL-5, MIL-L-2105C
* Brake System JCB Brake Fluid Dot 4 SAE J1703 DOT 4

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
* Hydraulic System 31.7 (120) JCB Hydraulic Fluid HP46 ISO VG46
- see Notice 1
Grease Points --- JCB HP Grease Lithium complex NLGI No. 2

consistency including extreme
pressure additives
Air Conditioning System

- Refrigerant 3lb 7oz (1.56kg) HFC R134a CH2 FC F3
- Compressor Lubricant 0.06 (0.24) Polyalkalineglycol PAG SP20
* Front PTO Transfer

Box (optional) 0.8 (3.0) JCB Gear Oil HP90 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 essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
9803/8030 Issue 2*
1-4 Lubricants - Health and Safety 1-4
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.
9803/8030 Issue 1
2-1 Service Schedules 2-1
! WARNING Every 50 Operating Hours or Weekly

Maintenance must be done only by suitably qualified and whichever occurs first
competent persons. Before doing any maintenance
make sure the machine is safe. It should be correctly Do the Daily jobs plus:
parked on firm level ground.
Drain
To prevent anyone starting the engine, remove the 1 Fuel pre-filter.
starter key. Disconnect the battery and chock the
Note: Some machines have a one-piece pre-filter which
wheels when you are working beneath the machine.
cannot be drained.
If you do not take these precautions you could be killed
Clean
or injured.
9-3-1-1
2 Air filter dust valve.
Check (Engine Stopped)

Every 10 Operating Hours or Daily
3 Air conditioning compressor drive belt.
whichever occurs first 4 Front PTO transfer gearbox oil level (optional
equipment).
Clean 5 Brake pad condition.
1 Machine generally. 6 Cab air filter (clean if required).
7 Propshaft security.
Drain
2 Empty hydraulic coupling drain reservoir (if fitted). Grease
3 Fuel filter. 8 Rear PTO drive shaft splines and universal joints.
4 Trailer air tank. 9 Rear PTO drive shaft bearings.
10 Rear axle propshaft.
Check (Engine Stopped) 11 Front axle propshaft.
5 Generally for damage. 12 Front PTO drive shaft (if fitted).
6 Engine oil level and condition. 13 Rear anti-roll bar joints.
7 Check radiator and coolers for blockage and clean if 14 Rear hydraulic lift cross-shaft.
required. 15 Rear hydraulic lift ram pivots.
8 Engine coolant level and condition. 16 Front agricultural 3 point linkage cross shaft (if fitted).
9 Fuel system for leaks and contamination. 17 Front agricultural 3 point linkage lift ram pivots (if fitted).
10 Air cleaner and air inlet hose condition and security. 18 Steering swivels.
11 Fan belt condition. 19 Steering column universal joints.
12 Crankcase Breather Condition. 20 Suspension cylinder pivots.
13 Hydraulic fluid level. 21 3-point linkage lift rods and top link.
14 Hydraulic system for leaks. 22 Automatic trailer coupling (if fitted).
15 Machine generally for oil leaks (axles, engine, 23 Roller drawbar (if fitted).
transmission).
16 Gearbox oil level. Note: It is essential that drive shaft and propshaft joints are
17 Tightness of wheel nuts. lubricated as specified.
18 Windscreen washer level.
19 Tyre pressures and condition.
20 Security of front weights (if fitted). First 100 Hours Dealer Service
21 Seat belt condition and security .
22 Brake fluid levels. Change
1 Engine oil and filter.
Check (Engine Running) 2 Fuel filters.
23 Instrument readings and warning lights. 3 Transmission oil filter.
24 Operation of all electrical equipment. 4 Hydraulic oil filter.
25 Exhaust for excessive smoke. 5 Front axle oil.
26 Operation of clutch and footbrakes. 6 Front hub oil.
27 Operation of steering. 7 Rear axle oil.
28 Operation of transmission.
29 Operation of 3-point linkage Drain
* 30 Operation of front linkage (optional equipment). 8 Fuel pre-filter (early machines only).
31 Parking brake operation. Note: Later machines have a one-piece pre-filter which
32 Throttle and stop controls. cannot be drained.
Check (Engine Stopped)

9 Coolant level/leaks and antifreeze strength.
10 Fuel system for leaks and contamination.
11 Intercooler hose clamp security.
12 Air cleaner and air inlet hose condition and security.
13 Fuel system pipework routing and security.
continued over page
9803/8030 Issue 5*
First 100 Hours Dealer Service (continued) Every 250 Operating Hours or 3 Monthly
whichever occurs first
Check (Engine Stopped) - continued
Do the Daily and 50 hour jobs plus:
* 14 Fan belt tension and condition.
* 15 Air conditioning compressor belt tension. Change
* 16 Gearbox oil level. † Engine oil and filter.
17 Transmission oil cooler/pipework condition, leakage,
routing and security. † Applies only if recommended oil (see Engine Oil) or
18 Front PTO gearbox oil level. Stratopore filter are not available. As an alternative to
19 Propellor shaft security. the recommended oil the following (or similar) should
20 Tyre pressures. be used:
21 Tightness of wheel nuts.
22 Hydraulic oil level. a -10oC to +50oC (14oF to 122oF) JCB Super Multigrade
23 Hydraulic oil cooler/pipework condition, leakage, 15W/40 (SAE 15W/40, API CF4/SG)
routing and security.
24 Brake fluid levels. b -15oC to +40oC (5oF to 104oF) JCB Super Mulitgrade
25 Brake pad security (service and parking). 10W/30 (SAE 10W/30, API CF4/SG).
26 Brake pipework routing and security.
27 Air system for leaks.
28 Panhard rod torque setting. Every 500 Operating Hours or Six Months
29 Rams/piston rods for damage/leaks. whichever occurs first
30 Battery charge/terminal condition and tightness.
31 Wiring for chafing/routing. Do the Daily jobs through to 250 hours plus:
32 Headlight alignment.
33 Windscreen washer level. Check (Engine Stopped)
34 Neutral start operation (Including clutch and PTO's). 1 Battery terminals condition and tightness.
35 Door locks. 2 Battery electrolyte level (if battery is not sealed for life).
36 Check for error codes, (EMS, engine and ABS when 3 Battery charge condition.
fitted), download, rectify and delete. 4 Exhaust system security.
37 Steering axle wheel alignment. 5 Engine mounting bolts for tightness.
38 Track rod and ball joint security. 6 Compressor housing for cracks and damage.
7 Compressor mountings for tightness.
Grease 8 Injection pump mountings for tightness.
39 Propellor shaft splines and universal joints. 9 Steering axle wheel alignment.
40 Steering swivels. 10 Headlamp alignment.
41 Rear PTO shaft bearings. 11 Panhard rod condition and torque tightness.
42 3 point linkage. 12 Track rod end and drag link ball joint security.
43 Rear lift ram pivots. 13 Steering damper condition and security.
44 Suspension cylinder pivots. 14 Suspension control arms and ‘V’ link condition and
bolt torque.
Check (engine running) 15 Air system for leaks.
45 Exhaust smoke. 16 Brake air tank warning lights.
46 Throttle and stop controls. 17 Brake caliper bolt torque.
47 PTO operation. 18 Brake pad security (service and parking).
48 2/4WD drive and diff. lock selection. 19 Parking brake adjustment.
49 Transmission low pressure circuit pressure maintaining 20 Brake pipework security.
valve setting. 21 Condition of lift ram rods.
50 Transmission lubrication pressure. 22 Coolant level/leaks, quality and antifreeze strength.
51 Diff. lock pressure relief valve. 23 Intercooler hose clamp security.
52 External hydraulics pressure relief valve. 24 Hoses and pipework for chafing and damage.
53 Instrument readings and warning lights. 25 Neutral start operation.
54 Operation of all electrical equipment. 26 Ram piston rods for damage/leaks.
55 Operation of clutch and footbrakes. 27 Front axle oil level.
56 Operation of steering. 28 Rear axle oil level.
57 Operation of transmission. 29 Transmission and hydraulic oil cooler/pipework
58 Operation of 3-point linkage. condition leakage and security.
59 Operation of front linkage (optional equipment). 30 Wiring for chafing/routing.
60 Rear axle/chassis clearance. 31 Download EMS Datalog.*
61 Height corrector valve operation. 32 Download ABS error codes, rectify and delete.
62 Parking Brake operation. 33 Brake light switch input to ABS ECU using computer
63 Pick-up hitch operation. diagnostic tool.
64 Spool valve operation. 34 Download engine error codes, rectify and delete.
65 Re-calibrate splitter clutch packs
9803/8030 Issue 3*
Every 500 Operating Hours or Six Months Every 2000 Operating Hours or 2 Years
whichever occurs first (continued) whichever occurs first
Check (Engine Running) Do the Daily jobs through to 1000 hours plus:
35 Idling speed.
36 Max. no load engine speed. Clean
37 Suspension ride height and corrector valve operation. 1 Hydraulic tank suction strainers.
38 Suspension pressure maintenance valve pressure.
39 Transmission low pressure circuit pressure maintaining Check (Engine Stopped)
valve setting. 2 Rear suspension gas spring pressure.
40 Differential lock pressure relief valve. 3 Rear suspension accumulator pressure.
41 Pick-up hitch operation. 4 Engine vibration damper.
42 Rear axle/chassis clearance. 5 Compressor output line, air drier and pressure
43 Spool valve operation. regulator: check for carbon deposits and for air leaks.
44 Field speed control. 6 Radiator hose condition.
45 Selection speed of Selectronic range change 7 Transmission accumulator pressure.
< 2 kph.
46 Check for electronic draft control faults and rectify. Change
8 Inner air filter element.
Change 9 Coolant.
47 †Engine oil and filter. 10 Brake system fluid.
48 Fuel pre-filter. 11 Hydraulic fluid. (Unless sample indicates otherwise.)
49 Hydraulic fluid filter element.
50 Transmission oil filter.
51 Fuel filter. Every 5000 Operating Hours or 4 Years
52 Front hub oil.
whichever occurs first
Clean
53 Air conditioning intake filter Do the Daily jobs through to 1000 hours plus:
† Applies only if recommended oil (see Engine Oil) and Check (Engine Stopped)
Statopore filter are available. If these are not available 1 Engine valve clearances and adjust if necessary.
this job should be carried out every 250 hours,
reference T.I. 10/152 (see Every 250 Operating Hours Notes:
for suitable alternative oil).
(1) After a major transmission repair, the new oil should be
run to operating temperature and changed again to
Every 1000 Operating Hours or Yearly remove any contamination which entered during the
repair. Change the oil and filter after a further 100
whichever occurs first hours if the oil was heavily contaminated because of, or
from the failure (e.g. water contamination).
Do the Daily jobs through to 500 hours plus:
(2) After a hub repair, the new oil should be run to
Check (Engine Stopped) operating temperature and changed again to remove
1 ROPS structure. any contamination which entered during the repair.
2 Quality of coolant. Change the oil again after a further 100 hours to
3 Fan belt tensioner. remove any bedding-in wear.
4 Fan hub end play.
Check (Engine Running)

5 Transmission lubrication pressure (HPL and LPL).
6 MRV Pressure.
7 Splitter and wet clutch pack calibration.
8 ABS System test.
*9 Steering relief valve pressure.
Change
10 Outer air filter element.
11 Gearbox oil and clean strainer.
12 Front axle oil.
13 Rear axle oil.
14 Air system drier dessicant canister.
Clean
15 Trailer brake control line air filter.
9803/8030 Issue 5*
3-1 Cleaning the Machine and Checking for Damage 3-1
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, fuel system or electrical components, damaged items.
especially draft control solenoids.
Check all lamp lenses for damage.
* On ABS machines, take special care to avoid directing high
power water jets at the electrical connections to the front Inspect the tyres for damage and penetration by sharp
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.
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.
9803/8030 Issue 2*
3-2 Bonnet 3-2
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, stop the engine. Remove the starter key.
2 Release the latch by pulling up lever A.
*3 The bonnet will rise automatically to the limit imposed

by the restraint cable if secured on the hook B or
fastener C (alternative fittings). This position will allow
access for routine maintenance. If more access is
required, release the restraint cable from the hook or
fasteners and allow the bonnet to rise fully open.
C
Closing the Bonnet
A B
1 Pull the bonnet down by means of the cable and ensure
the cable is secured by the fasteners. To close the 716881
latch, press the bonnet firmly down by means of lever
A.
9803/8030 Issue 3*
4-1 Greasing 4-1
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.
Note: The machine must always be greased after pressure- * Front axle propshaft
washing or steam cleaning. Extra care must be taken to Grease points 1 to 2.
ensure that propshaft universal joints and splines are
greased regularly. Rear axle propshaft
Grease points 3 to 4.
Greasing should be done with a grease gun. Normally, two
strokes of the gun should be enough. Stop greasing when Rear PTO drive shaft
fresh grease appears at the joint. Use only JCB HP Grease Grease points 5 to 7.
or equivalent.
Front PTO drive shaft (optional)
In the following illustrations the grease points are numbered. Grease points 8 to 10.
Count them off as you grease them.
Note: When greasing the universal joints, you must ensure
Refit the grease point dust caps after greasing. that grease appears at all four bearing caps. If grease does
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

8 Grease point 11. Do not exceed 2 to 3 strokes of the grease
gun.
1 0
6 7
5
4 A286623
9803/8030 Issue 2*
4-2 Greasing 4-2
Read the first page on Greasing for general information

about greasing.
Front Axle Steering Swivels
! WARNING
Make the machine safe before getting beneath it. Do the
battery. Chock the wheels.
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
9803/8030 Issue 1
4-3 Greasing 4-3
Read the first page on Greasing for general information Note: Whenever the coupling has been pressure-washed it
about greasing. must always be greased.
Agricultural Front 3-Point Linkage Automatic Trailer Coupling (if fitted)

(Optional)
Make sure the coupling is in the open position, i.e. the
Read the first page on Greasing for general information coupling pin is up and the hand lever A is in its highest
about greasing. position.
Grease at points 1 and 2.

! WARNING
You will be working close into the machine for these Operate lever A several times so that the grease is
jobs. Lower the equipment. Remove the starter key and distributed throughout the bearing.
disconnect the battery. This will prevent the engine from
being started. Make sure that the parking brake is
! CAUTION
engaged.
Keep your hands out of the funnel or you may be injured
Chock all four wheels before getting under the machine. by the coupling pin as it is forced down by its spring.
13-2-2-17
13-3-1-9
Grease at points 1 to 3. Grease again and operate the hand lever again.
If driving without a trailer attached, close the coupling to

prevent dirt accumulation.
2 S170201
9803/8030 Issue 1
4-4 Greasing 4-4
Read the first page on Greasing for general information Hydraulic Lift and 3-Point Linkage
about greasing.
Hydraulic lift cross-shaft
! WARNING Grease points 5 and 6.
You will be working close into the machine for these
Hydraulic lift rams
jobs. Lower the equipment. Remove the starter key and
being started. Make sure that the parking brake is Three point linkage lift rods
engaged. Grease at nipples 11, 12, 13 and 14 (lift collars A and B to
access nipples 13 and 14). On machines with heavy duty
Chock all four wheels before getting under the machine. linkage grease points 15 and 16 also.
13-3-1-9
Stabilizers (standard type)

Note: Ladder hitch and trailer coupling omitted for clarity. Grease at point 17.
Note: Where standard type stabilizers are fitted to both

Rear Suspension Cylinder Pivots 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
gun.
1 3
2 4
5 6
A B A B A B A B
7 8
*
% ^
! @
A B
9 0 &
£ $
418170
9803/8030 Issue 1
4-5 Greasing 4-5
* Steering Column Universal Joints

Read the first page on Greasing for general information
about greasing.
! WARNING
You will be working close into the machine for these
jobs. Lower the equipment. Remove the starter key and 1
engaged.
Block all four wheels before getting under the machine.

13-3-1-9
Note: It may be necessary to turn the steering wheel to put

the grease nipples in an accessible position.
Grease at point 1 from underneath the machine.

A409831
Grease at points 2 and 3 from under the bonnet.
Rear Anti-roll Bar Ball Joints
! WARNING
Make the machine safe before getting beneath it. Do the 2
battery. Chock the wheels.
13-3-1-1
Grease points 4 and 5.
4 5
262210
9803/8030 Issue 2*
4-6 Greasing 4-6
Roller Drawbar (if fitted)
! WARNING
You will be working close into the machine for these A B A B A B A B
jobs. Lower the equipment. Remove the starter key and

engaged.
Chock all four wheels before getting under the machine.

13-3-1-9
Grease points 1 and 2.

Smear surface 3 with grease.
1
2
9803/8030 Issue 1
5-1 Cab 5-1
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
A B
420410
9803/8030 Issue 2
5-2 Cab 5-2
Checking the 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 not use engine coolant antifreeze.
X
A293830
9803/8030 Issue 1
5-3 Air Conditioning 5-3
Cleaning the Standard 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 or very dusty

conditions, 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 change 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
D
E
1 Unscrew the two quarter-turn fasteners A and remove
closing panel B. Remove the two screws C and pull out
the filter D. Check condition of filter and renew if split or
A C
worn.
B 420960
2 If the filter is undamaged, pull foam pre-cleaner E

(fitted to later filters) out of the filter casing, wash it in
low suds detergent and blow dry with compressed air
at a maximum pressure of 5.5 bar (80 lbf/in2). Use the
same compressed air to blow dirt out of filter D in the
opposite direction to the arrows marked on the filter.
3 Check and clean the filter sealing face on the cab body.
4 Refit the pre-cleaner and fit the filter into the cab
aperture using two screws C. Refit the closing panel B.
Changing the Heavy Duty Carbon Filter

Note: Carbon filters must not be cleaned. Keep a log of the
hours used and change at 250 hour intervals.
! WARNING J
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6
F G H 417800
1 Unscrew the two quarter-turn fasteners F and remove

closing panel G. Remove the two screws H and pull out
the filter J.
2 The new filter is supplied with a separate foam seal

that has a self-adhesive face K covered by protective
film. Clean the contact face of the new filter L, peel off
L
the protective film from the foam seal and press the
seal into position on the filter.
3 Check and clean the seal contact face on the cab body.
K
W
FLO
AIR
4 Fit the filter into the cab aperture using two screws H.
Refit the closing panel G. 746220
9803/8030 Issue 3
5-4 Air Conditioning 5-4
Adjusting the Compressor Belt

* (3170/3170 Plus, 3190/3190 Plus &
3220/3220 Plus)
* Note: On other models of Fastrac covered by this manual,
there is no separate belt for the air conditioning compressor.
It is driven by the fan belt.
1 Stop the engine.
2 Open the bonnet.
! WARNING
Make sure the engine cannot be started. Disconnect the
battery before doing this job.
2-3-3-5
3 Loosen the mountings
Loosen fasteners A, B and C.
4 Adjust the belt tension
Position the compressor so that there is 10mm (0.4 in)

slack on the longest run of the belt.
5 Tighten the mountings
Retighten fasteners A, B and C.
! 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
A B
417580
9803/8030 Issue 3*
6-1 Electrics 6-1
Battery Warning Symbols ! CAUTION

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

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

Do the following if electrolyte:
Explosive Gas.
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

with a sterile dressing then get medical help.
Note operating instructions. 5-3-4-3/1
9803/8030 Issue 1
6-2 Electrics 6-2
Checking the Battery Electrolyte Level

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. Remove

the battery access panel A.
2 Prize out covers B. Look at the level in each cell. 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
Note: When two batteries are fitted on the machine, they are
connected in parallel. When fitting the cables, ensure that
they are connected as shown on the illustration.
9803/8030 Issue 1
6-3 Electrics 6-3
Checking the Headlight 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 to 30 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 X - X and Y - Y on the wall.
4 To adjust the beam, slightly slacken nut C or D,

reposition the light and then tighten the nut.
B Y
B
Y
1300 m
A
A
X
X
D
Z
2.00 m
C
418260
9803/8030 Issue 1
7-1 Hydraulics 7-1
Checking the Fluid Level Changing the Filter Element

1 Park the machine on level ground. Apply the parking
! WARNING brake. Lower the rear linkage to the ground. Stop the
engine. Remove the starter key. Wash off all dirt from
Fine jets of hydraulic fluid at high pressure can penetrate around the tank cap B and element cover plate D.
the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected 2 Remove the element as follows:
leaks. Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of a Remove tank cap B.
hydraulic fluid. If hydraulic fluid penetrates your skin, get b Remove nuts C, cover plate D and 'O' ring E.
medical help quickly. c Remove the element assembly F and 'O' ring G.
INT-3-1-10/1 d Remove the nut and spring assembly H. Remove the
element J from its spindle.
! CAUTION e Remove and discard the paper insert Y from metal
Using incorrect fluid could damage the system. See outer element J.
Fluids, Capacities and Lubricants for the correct fluid. f Clean the metal outer element J.
The fluid can harm your skin. Wear rubber gloves. Cover g Clean the magnets K.
cuts or grazes.
2-3-5-1/2 3 Fit the new element as follows:
1 Park the machine on level ground. Apply the parking a Fit a new paper insert Y into metal outer element J.
brake. Lower any mounted implements to the ground. b Assemble the refurbished element J on to the
Stop the engine. Remove the starter key. spindle, using a new seal L. Ensure that the top lip of
the seal locates in the groove inside the filter head
2 Look at the fluid level in the sight gauge A. The level M. Fit and tighten the nut and spring assembly H.
should be between the two marks on the gauge. If the c Fit the element assembly F using a new 'O' ring G.
fluid is cloudy, water or air has entered the system. d Refit cover plate D and nuts C using a new 'O' ring
Water or air in the system could damage the hydraulic E.
pump. e Tighten nuts C to 7 Nm (5 lbf ft).
f Top up fluid level at tank cap B and refit cap.
3 If necessary, add recommended fluid at tank cap B.
M
B
K G
L C
D
F
J Y A
F E
H J
417440
9803/8030 Issue 1
7-2 Hydraulics 7-2
Changing the Hydraulic Fluid and Cleaning 1 Park the machine on firm, level ground.
the Suction Strainers 2 Place a container that can hold at least 120 litres (26.4
UK gal; 31.7 US gal) beneath drain plug B. Remove the
! WARNING plug and allow the oil to drain. Refit the drain plug.
Fine jets of hydraulic fluid at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic ! WARNING
fluid leaks. Do not put your face close to suspected Oil will gush from the hole when the drain plug is
leaks. Hold a piece of cardboard close to suspected removed. Keep to one side when you remove the plug.
leaks and then inspect the cardboard for signs of 2-3-4-2
hydraulic fluid. If hydraulic fluid penetrates your skin, get
medical help quickly. 3 Remove the strainers as follows:
INT-3-1-10/1
a Remove tank cap A.
! WARNING b Disconnect pipe C from the filter, remove bolts D
Make the machine safe before getting beneath it. Do the and take out filter assembly E.
following: Park on level ground. Engage the parking c Unscrew external hydraulics/draft control hydraulic
brake. Lower any mounted implements to the ground. strainer F from its spigot and withdraw from the tank
Stop the engine, remove the starter key, disconnect the via the filter aperture.
battery. Chock the wheels. d Repeat step c for the steering and suspension
13-3-1-1 strainer G.
! CAUTION
Using incorrect fluid could damage the system. See 4 Clean the strainers with a suitable solvent. Follow the
Fluids, Capacities and Lubricants for the correct fluid. solvent manufacturer's instructions on safety.
The fluid can harm your skin. Wear rubber gloves. Cover
cuts or grazes. 5 Refit the strainers, using JCB Activator and JCB
2-3-5-1/2 Threadlocker and Sealer on the threads. Refit the filter.
Reconnect pipe C using Clayton System Seal SC1251
to seal the threads.
6 Fill the tank with the recommended hydraulic fluid.
D A
C
E
G
B
418370
9803/8030 Issue 1
7-3 Hydraulics 7-3
Emptying the Hydraulic Coupling Drain

Reservoir (if fitted)
Empty reservoir A at least every 50 hours, but more often if
necessary.
A B A B A B A B
418050
9803/8030 Issue 1
9-1 PTO, Speed and Range Gearboxes 9-1
Checking the Oil Level

1 Park the machine on firm, level ground. Engage the
parking brake. Lower the equipment. Stop the engine.
2 Check that oil is at the top mark on dipstick A. Add the

recommended oil as necessary via filler B. After topping
up, run the engine for 1 minute, then stop the engine and
allow to stand for 2 minutes before re-checking the level. B
Note: Do not overfill as this would cause oil to be forced
past the oil seals and out of the gearboxes.
194570
9803/8030 Issue 1
Thank you very much
for your reading.
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General Information 1

Care & Safety 2

Publication No. 9803/8030

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

Serial Number Plate * D = Transmission Type (Gearbox and axle combination)

Later VIN Configuration Engine M

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

M16 (16) 24 343 35 253

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

10.9 grade bolts (all bolts with JCB

Location: Steershaft Bearing Location: Steershaft upper UJ

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

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 892/00278 Gauge 0 - 40 bar 7-2

Service Tools Numerical List (continued)

* Replacement parts for kit no. 892/01092

1 992/09000 Peg spanner for piston head of front hitch

892/00334 Gland Seal Fitting Tool

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

892/01033 Data Link Adapter Kit - ABS

* 721/10885 Harness - Diagnostic (J1939)