Jcb 2135 fastrac service repair manual sn：00740000 00741001
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About This Presentation
service repair manual
Slide Content
Service
Manual
Fastrac
2115, 2125, 2135,
2140, 2150
From Serial No 0738000
3155, 3185
From Serial No 0640000
Published by the
TECHNICAL PUBLICATIONS DEPARTMENT
of
JCB SERVICE LTD;
World Parts Centre,
Waterloo Park
Uttoxeter, Staffordshire
ST14 7BS
Publication No. 9803/8020
Issue 17
General Information1
Care & Safety 2
3
Optional EquipmentA
Body & FrameworkB
Electrics C
Controls D
Hydraulics E
Transmission F
Brakes G
Steering H
Suspension S
Engine T
Routine Maintenance
Manual
Fastrac
2115, 2125, 2135,
2140, 2150
From Serial No 0738000
3155, 3185
From Serial No 0640000
Published by the
TECHNICAL PUBLICATIONS DEPARTMENT
of
JCB SERVICE LTD;
World Parts Centre,
Waterloo Park
Uttoxeter, Staffordshire
ST14 7BS
Publication No. 9803/8020
Issue 17
General Information1
Care & Safety 2
3
Optional EquipmentA
Body & FrameworkB
Electrics C
Controls D
Hydraulics E
Transmission F
Brakes G
Steering H
Suspension S
Engine T
Routine Maintenance
9803/8020 Issue 1
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:
“24If the axle is still on the machine, fit the brake calipers (seeBrake 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.
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:
“24If the axle is still on the machine, fit the brake calipers (seeBrake 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.
i
Section 1 General Information
9803/8020
Section 1
i
Issue 4*
Contents Page No.
Machine Identification Plate 1 - 1
Typical Vehicle Identification Number (VIN) 1 - 1
Typical Engine Identification Number 1 - 1
Unit Identification 1 - 1
Torque Settings
Introduction - Zinc Plated Fasteners and Dacromet Fasteners 2 - 1
Zinc Plated Fasteners 2 - 2
Dacromet Fasteners 2 - 3 to 2 - 6
Sealing and Retaining Compounds 3 - 1
Service Tools Numerical List 4 - 1
Service Tools
Body and Framework 5 - 1
Electrics 6 - 1
Hydraulics 7 - 1
Transmission 8 - 1
Brakes 9 - 1
Steering 9 - 1
Suspension 9 - 2
Engine 9 - 2
Moving a Disabled Machine
General 10 - 1
Preparation for Towing 10 - 1
Transporting the Machine 10 - 2
*
Section 1 General Information
9803/8020
Section 1
i
Issue 4*
Contents Page No.
Machine Identification Plate 1 - 1
Typical Vehicle Identification Number (VIN) 1 - 1
Typical Engine Identification Number 1 - 1
Unit Identification 1 - 1
Torque Settings
Introduction - Zinc Plated Fasteners and Dacromet Fasteners 2 - 1
Zinc Plated Fasteners 2 - 2
Dacromet Fasteners 2 - 3 to 2 - 6
Sealing and Retaining Compounds 3 - 1
Service Tools Numerical List 4 - 1
Service Tools
Body and Framework 5 - 1
Electrics 6 - 1
Hydraulics 7 - 1
Transmission 8 - 1
Brakes 9 - 1
Steering 9 - 1
Suspension 9 - 2
Engine 9 - 2
Moving a Disabled Machine
General 10 - 1
Preparation for Towing 10 - 1
Transporting the Machine 10 - 2
*
1 - 1
Machine Identification Plate
Each machine has an identification plate located at X. The
Vehicle Identification Number (VIN), and the serial numbers
of the engine and transmission are stamped on the plate.
Typical Vehicle Identification No. (VIN)
SLP FT 11 3 30 0738010
A B C D E F
A= Manufacturing Code
B= Machine Range
C= Engine Code:
07 = 1006-6T4
10 = 6BTA
13 = New 1000 Series, Rating 1941/2300 (2115)
14 = New 1000 Series, Rating 1929/2300 (2125)
15 = New 1000 Series, Rating 1947/2300 (2135)
16 = New 1000 Series, Rating 1930/2200 (2150)
20 = Fastrac 2140 engine
D= Transmission Speed Code:
3 = 30 km/h
4 = 40 km/h
5 = 55 km/h
6 = 65 km/h
7 = 75 km/h
C = 40 km/h (Fastrac 2140 only
E= Vehicle Max. Speed Code:
30 = 30 km/h
40 = 40 km/h
50 = 50 km/h
80 = 80 km/h
F= Sequential Serial Number
Typical Engine Identification Number
YH 50532 U 123456 X
G H J K L
G= Engine Type:-
YB = Turbocharged 1000 Series, 6 cylinder
YD = Intercooled 1000 Series, 6 cylinder
YH = Turbocharged New 1000 Series, 6 cylinder
YK = Intercooled New 1000 Series, 6 cylinder
H= Build List Number
(see Engine Technical Datafor details)
J= Country of Origin
K= Engine Serial Number
L= Year of Manufacture
Note: Fastrac 2140 and 3185 engines are identified by the
model number and a separate engine serial number.
Unit Identification
The serial number of each major unit is also stamped on the
unit itself as shown below. If a major unit is replaced by a
new one, the serial number on the plate will be wrong. Either
stamp the new number of the unit on the identification plate,
or simply stamp out the old number. This will prevent the
wrong unit number being quoted when replacement parts
are ordered.
Fastrac 2115, 2125, 2135, 2150 and 3155 Engines M
Fastrac 2140 and 3185 Engines T
Transmission (Assembly of all three gearboxes)N
Speed Gearbox P
Front Axle R
Rear Axle S
Section 1 General Information
9803/8020
Section 1
1 - 1
Issue 3*
194601
S
P
X
R
T
M
N
*
*
*
*
Machine Identification Plate
Each machine has an identification plate located at X. The
Vehicle Identification Number (VIN), and the serial numbers
of the engine and transmission are stamped on the plate.
Typical Vehicle Identification No. (VIN)
SLP FT 11 3 30 0738010
A B C D E F
A= Manufacturing Code
B= Machine Range
C= Engine Code:
07 = 1006-6T4
10 = 6BTA
13 = New 1000 Series, Rating 1941/2300 (2115)
14 = New 1000 Series, Rating 1929/2300 (2125)
15 = New 1000 Series, Rating 1947/2300 (2135)
16 = New 1000 Series, Rating 1930/2200 (2150)
20 = Fastrac 2140 engine
D= Transmission Speed Code:
3 = 30 km/h
4 = 40 km/h
5 = 55 km/h
6 = 65 km/h
7 = 75 km/h
C = 40 km/h (Fastrac 2140 only
E= Vehicle Max. Speed Code:
30 = 30 km/h
40 = 40 km/h
50 = 50 km/h
80 = 80 km/h
F= Sequential Serial Number
Typical Engine Identification Number
YH 50532 U 123456 X
G H J K L
G= Engine Type:-
YB = Turbocharged 1000 Series, 6 cylinder
YD = Intercooled 1000 Series, 6 cylinder
YH = Turbocharged New 1000 Series, 6 cylinder
YK = Intercooled New 1000 Series, 6 cylinder
H= Build List Number
(see Engine Technical Datafor details)
J= Country of Origin
K= Engine Serial Number
L= Year of Manufacture
Note: Fastrac 2140 and 3185 engines are identified by the
model number and a separate engine serial number.
Unit Identification
The serial number of each major unit is also stamped on the
unit itself as shown below. If a major unit is replaced by a
new one, the serial number on the plate will be wrong. Either
stamp the new number of the unit on the identification plate,
or simply stamp out the old number. This will prevent the
wrong unit number being quoted when replacement parts
are ordered.
Fastrac 2115, 2125, 2135, 2150 and 3155 Engines M
Fastrac 2140 and 3185 Engines T
Transmission (Assembly of all three gearboxes)N
Speed Gearbox P
Front Axle R
Rear Axle S
Section 1 General Information
9803/8020
Section 1
1 - 1
Issue 3*
194601
S
P
X
R
T
M
N
*
*
*
*
2 - 1
Section 1 General Information
9803/8020
Section 1
2 - 1
Issue 3*
Torque Settings
Introduction - Zinc Plated Fasteners and Dacromet Fasteners
The JCB Fastrac 3000 series from serial number 642494 and the Fastrac 2000 series from serial number 740276 are
assembled using an improved type of corrosion resistant finish on the external fasteners. This type of finish is called Dacromet
and replaces the original Zinc and Yellow plating used on earlier machines.
The two types of fasteners can be readily identified by colour and part number suffix as follows:
Fastener Type Colour Part Number
Zinc and Yellow Golden finish ‘Z’ (e.g. 1315/3712Z)
Dacromet Mottled silver finish ‘D’ (e.g. 1315/3712D)
Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, when servicing the Fastrac it
is important that you are aware of this change of policy and that the information you are using is relevant to the type of
fasteners that you have.
Note:A Dacromet bolt should not be used in conjunction with a Zinc and Yellow plated nut, as this could change the torque
characteristics of the torque settings further. For the same reason, a Dacromet nut should not be used in conjunction with a
Zinc and Yellow plated bolt.
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
Note: Dacromet bolts, due to their high corrosion resistance are used areas where rust could occur. Dacromet bolts are only
used for external applications.
*
Section 1 General Information
9803/8020
Section 1
2 - 1
Issue 3*
Torque Settings
Introduction - Zinc Plated Fasteners and Dacromet Fasteners
The JCB Fastrac 3000 series from serial number 642494 and the Fastrac 2000 series from serial number 740276 are
assembled using an improved type of corrosion resistant finish on the external fasteners. This type of finish is called Dacromet
and replaces the original Zinc and Yellow plating used on earlier machines.
The two types of fasteners can be readily identified by colour and part number suffix as follows:
Fastener Type Colour Part Number
Zinc and Yellow Golden finish ‘Z’ (e.g. 1315/3712Z)
Dacromet Mottled silver finish ‘D’ (e.g. 1315/3712D)
Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, when servicing the Fastrac it
is important that you are aware of this change of policy and that the information you are using is relevant to the type of
fasteners that you have.
Note:A Dacromet bolt should not be used in conjunction with a Zinc and Yellow plated nut, as this could change the torque
characteristics of the torque settings further. For the same reason, a Dacromet nut should not be used in conjunction with a
Zinc and Yellow plated bolt.
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
Note: Dacromet bolts, due to their high corrosion resistance are used areas where rust could occur. Dacromet bolts are only
used for external applications.
*
2 - 2
Section 1 General Information
9803/8020
Section 1
2 - 2
Issue 1*
Torque Settings
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
Bolt size Torque Settings
Dia. (mm) Hexagon Nm kgf m lbf ft
(A/F) mm
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M18 (18) 27 350 36 258
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Metric Grade 10.9 Bolts
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
M16 (16) 24 343 35 253
M20 (20) 30 657 67 485
M24 (24) 36 1157 118 853
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
1
1/2 244 24.9 180 1
1/2 305 31 225
Metric - All Internal Hexagon Headed Cap Screws
Diameter Torque
mm Nm kgf m lbf ft
M3 2 0.2 1.5
M4 6 0.6 4.5
M5 11 1.1 8
M6 19 1.9 14
M8 46 4.7 34
M10 91 9.3 67
M12 159 16.2 117
M16 395 40 292
M18 550 56 406
M20 770 79 568
M24 1332 136 983
Verbus Ripp Bolts
Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.
Note:In most cases Verbus Ripp bolts should not be re-
used. If one is disturbed it should be removed and a new
one fitted in its place. For details of exceptions to this
general rule, see T.I.’s 10/140 (F161/N. Am) and 10/141
(F162 N. Am).
A343780
Section 1 General Information
9803/8020
Section 1
2 - 2
Issue 1*
Torque Settings
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
Bolt size Torque Settings
Dia. (mm) Hexagon Nm kgf m lbf ft
(A/F) mm
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M18 (18) 27 350 36 258
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Metric Grade 10.9 Bolts
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
M16 (16) 24 343 35 253
M20 (20) 30 657 67 485
M24 (24) 36 1157 118 853
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
1
1/2 244 24.9 180 1
1/2 305 31 225
Metric - All Internal Hexagon Headed Cap Screws
Diameter Torque
mm Nm kgf m lbf ft
M3 2 0.2 1.5
M4 6 0.6 4.5
M5 11 1.1 8
M6 19 1.9 14
M8 46 4.7 34
M10 91 9.3 67
M12 159 16.2 117
M16 395 40 292
M18 550 56 406
M20 770 79 568
M24 1332 136 983
Verbus Ripp Bolts
Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.
Note:In most cases Verbus Ripp bolts should not be re-
used. If one is disturbed it should be removed and a new
one fitted in its place. For details of exceptions to this
general rule, see T.I.’s 10/140 (F161/N. Am) and 10/141
(F162 N. Am).
A343780
2 - 3
Section 1 General Information
9803/8020
Section 1
2 - 3
Issue 1*
Torque Settings
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
Bolt size Torque Settings
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
Metric Grade 10.9 Bolts
Bolt size Torque Settings
Dia. Nm kgf m lbf ft
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
Metric Grade 12.9 Bolts
Bolt size Torque Settings
Dia. Nm kgf m lbf ft
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
Section 1 General Information
9803/8020
Section 1
2 - 3
Issue 1*
Torque Settings
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
Bolt size Torque Settings
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
Metric Grade 10.9 Bolts
Bolt size Torque Settings
Dia. Nm kgf m lbf ft
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
Metric Grade 12.9 Bolts
Bolt size Torque Settings
Dia. Nm kgf m lbf ft
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
2 - 4
Section 1 General Information
9803/8020
Section 1
2 - 4
Issue 1*
Torque Settings
Dacromet Fasteners (mottled silver finish) - List of Torque Settings
This list represents those fasteners which have been affected by the change from zinc-plated to Dacromet but are not
mentioned in the service manual. The settings apply to 2000 and 3000 series machines unless otherwise stated.
Location:Gearbox Crossmember
Nm: 200 kgfm: 20 lbf ft: 148
Location:Rockinger Hitch Bolt
Nm: 392 kgfm: 40 lbf ft: 289
A402030
Bolt: Rear Crossmember
Nm:392 kgf m: 40 lbf ft: 289
A402280
Bolt: Left Hand Pannier Step
Nm: 47.5 kgf m: 4.8lbf ft: 35
A402200
Bolt: Right Hand Pannier (rear)
Nm: 80 kgf m: 8.2lbf ft: 59
(2000 series machines only)
A402190
Bolt: Right Hand Pannier (front)
Nm: 47.5 kgf m: 4.8lbf ft: 35
(2000 series machines only)
A402160
Bolt: Front Wrapper (top/bottom)
Nm: 392 kgf m: 40 lbf ft: 289
A402060
Bolt: Rear Lower Crossmember
Nm: 80 kgf m: 8.2lbf ft: 59
(2000 series machines only)
A402050
Bolt: Lower Link Bolt (Hex Head)
Nm: 392 kgf m: 40 lbf ft: 289
A402040
Section 1 General Information
9803/8020
Section 1
2 - 4
Issue 1*
Torque Settings
Dacromet Fasteners (mottled silver finish) - List of Torque Settings
This list represents those fasteners which have been affected by the change from zinc-plated to Dacromet but are not
mentioned in the service manual. The settings apply to 2000 and 3000 series machines unless otherwise stated.
Location:Gearbox Crossmember
Nm: 200 kgfm: 20 lbf ft: 148
Location:Rockinger Hitch Bolt
Nm: 392 kgfm: 40 lbf ft: 289
A402030
Bolt: Rear Crossmember
Nm:392 kgf m: 40 lbf ft: 289
A402280
Bolt: Left Hand Pannier Step
Nm: 47.5 kgf m: 4.8lbf ft: 35
A402200
Bolt: Right Hand Pannier (rear)
Nm: 80 kgf m: 8.2lbf ft: 59
(2000 series machines only)
A402190
Bolt: Right Hand Pannier (front)
Nm: 47.5 kgf m: 4.8lbf ft: 35
(2000 series machines only)
A402160
Bolt: Front Wrapper (top/bottom)
Nm: 392 kgf m: 40 lbf ft: 289
A402060
Bolt: Rear Lower Crossmember
Nm: 80 kgf m: 8.2lbf ft: 59
(2000 series machines only)
A402050
Bolt: Lower Link Bolt (Hex Head)
Nm: 392 kgf m: 40 lbf ft: 289
A402040
2 - 5
Section 1 General Information
9803/8020
Section 1
2 - 5
Issue 2
Torque Settings
Dacromet Fasteners (mottled silver finish) - List of Torque Settings (cont.)
Location:Lower Link Bolt (capscrew)
Nm: 654 kgf m: 67 lbf ft: 482
A402140
Location:Tower Casting to Axle
Nm: 392 kgf m: 40 lbf ft: 289
A402010
Location:Front Lower Crossmember
Nm: 115 kgf m: 12 lbf ft: 85
A401990
Location:Rear Lower Crossmember
Nm: 200 kgf m: 20 lbf ft: 148
(3000 series machines only)
A402260
Location:Fuel Tank Support Strap
Nm: 47.5 kgf m: 4.8lbf ft: 35
(2000 series machines only)
A402090
Location:Front P.T.O. Box
Nm: 200 kgf m: 20 lbf ft: 148
A402230
Location:Front Axle Upper Arm
Mounting Bracket
Nm: 200 kgf m: 20 lbf ft: 148
(3000 series machines only)
A402270
Location:Steershaft Bearing
Nm: 28 kgf m: 2.9lbf ft: 21
(3000 series machines only)
Location:Steershaft Intermediate UJ
Nm: 38 kgf m: 3.9lbf ft: 28
(3000 series machines only)
Section 1 General Information
9803/8020
Section 1
2 - 5
Issue 2
Torque Settings
Dacromet Fasteners (mottled silver finish) - List of Torque Settings (cont.)
Location:Lower Link Bolt (capscrew)
Nm: 654 kgf m: 67 lbf ft: 482
A402140
Location:Tower Casting to Axle
Nm: 392 kgf m: 40 lbf ft: 289
A402010
Location:Front Lower Crossmember
Nm: 115 kgf m: 12 lbf ft: 85
A401990
Location:Rear Lower Crossmember
Nm: 200 kgf m: 20 lbf ft: 148
(3000 series machines only)
A402260
Location:Fuel Tank Support Strap
Nm: 47.5 kgf m: 4.8lbf ft: 35
(2000 series machines only)
A402090
Location:Front P.T.O. Box
Nm: 200 kgf m: 20 lbf ft: 148
A402230
Location:Front Axle Upper Arm
Mounting Bracket
Nm: 200 kgf m: 20 lbf ft: 148
(3000 series machines only)
A402270
Location:Steershaft Bearing
Nm: 28 kgf m: 2.9lbf ft: 21
(3000 series machines only)
Location:Steershaft Intermediate UJ
Nm: 38 kgf m: 3.9lbf ft: 28
(3000 series machines only)
2 - 6
Section 1 General Information
9803/8020
Section 1
2 - 6
Issue 2*
Torque Settings
Dacromet Fasteners (mottled silver finish) - List of Torque Settings (cont.)
Location:Rear Anti-Roll bar
mounting bracket
Nm: 392 kgf m: 40 lbf ft: 289
(3000 series machines only)
A402120
Location:Front Anti-Roll Bar
Fasteners: Pivot Bolt
Nm: 200 kgf m: 20 lbf ft: 148
(3000 series machines only)
A402110
Location:Front Engine Mounting
Nm: 200 kgf m: 20 lbf ft: 148
A402150
Location:Header Tank Clamp Plate
Nm: 30 kgf m: 3 lbf ft: 22
(3000 series machines only)
A402290
Location:Front Anti-Roll Bar
Fasteners: Pivot Bolt
Nm: 278 kgf m: 28 lbf ft: 205
(2000 series machines only)
Location:4.W.S. only rear anti-roll
bar crossmember
Nm: 80 kgf m: 8.2lbf ft: 59
(2000 series machines only)
A402130
A402080
*Location:Front Anti-Roll Bar
Fasteners: Insulators
Nm: 47.5 kgf m: 4.8lbf ft: 35
Section 1 General Information
9803/8020
Section 1
2 - 6
Issue 2*
Torque Settings
Dacromet Fasteners (mottled silver finish) - List of Torque Settings (cont.)
Location:Rear Anti-Roll bar
mounting bracket
Nm: 392 kgf m: 40 lbf ft: 289
(3000 series machines only)
A402120
Location:Front Anti-Roll Bar
Fasteners: Pivot Bolt
Nm: 200 kgf m: 20 lbf ft: 148
(3000 series machines only)
A402110
Location:Front Engine Mounting
Nm: 200 kgf m: 20 lbf ft: 148
A402150
Location:Header Tank Clamp Plate
Nm: 30 kgf m: 3 lbf ft: 22
(3000 series machines only)
A402290
Location:Front Anti-Roll Bar
Fasteners: Pivot Bolt
Nm: 278 kgf m: 28 lbf ft: 205
(2000 series machines only)
Location:4.W.S. only rear anti-roll
bar crossmember
Nm: 80 kgf m: 8.2lbf ft: 59
(2000 series machines only)
A402130
A402080
*Location:Front Anti-Roll Bar
Fasteners: Insulators
Nm: 47.5 kgf m: 4.8lbf ft: 35
3 - 1
Section 1 General Information
9803/8020
Section 1
3 - 1
Issue 2*
*
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 ThreadlockerA 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
Section 1 General Information
9803/8020
Section 1
3 - 1
Issue 2*
*
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 ThreadlockerA 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
*
4 - 1
Service Tools Numerical List
Page No.
1370/0901Z Nut M24 9 - 1
1406/0021 Bonded Washer 7 - 1
1604/0006 Adapter 7 - 1
1604/0008 Adapter 7 - 1
1606/0012 Adapter 7 - 1
1606/0015 Adapter 7 - 1
1612/0006 Adapter 7 - 1
331/64246 Tool Kit for Non-return Valve 7 - 2
331/64265 etaining Bush for Valve spool 7 - 2
4101/0251 JCB Threadlocker and Sealer 3 - 1
4101/0451 JCB Threadlocker 3 - 1
4101/0552 JCB Threadlocker and Sealer
(High Strength) 3 - 1
4101/0651 JCB Retainer (High Strength) 3 - 1
4102/0551 JCB High Strength Threadlocker 3 - 1
4102/0901 JCB Clear Silicone Sealant 3 - 1
4102/1212 JCB Multigasket 3 - 1
4102/1951 JCB Threadseal 3 - 1
4102/2210 Clayton System Seal SC1251 3 - 1
4102/2309 Black Polyurethane Sealant 3 - 1
4103/2109 Ultra Fast Adhesive 3 - 1
4104/0251 JCB Activator (Aerosol) 3 - 1
4104/0253 JCB Activator (Bottle) 3 - 1
4104/1557 JCB Cleaner/Degreaser 3 - 1
4104/1203 Active Wipe 205 (250 g) 3 - 1
4104/1206 Active Wipe 205 (30 ml) 3 - 1
4104/1310 Hand Cleaner 5 - 1
4201/4906 Black Primer 3 - 1
454/30056 Spacer 13.80 mm 8 - 4
477/00437 Gearbox Lifting Adapter 8 - 2
721/00664 Connecting Lead (Psion Workabout) 6 - 1
721/10885 Harness - Diagnostic (J1939) 6 - 2
816/15118 Test Adapter 7 - 1
816/20008 Adapter 7 - 1
816/20013 Adapter 7 - 1
816/55038 Adapter/Test Point 7 - 1
816/55040 Adapter/Test Point 7 - 1
892/00041 Deglazing Tool 9 - 2
892/00078 Connector 7 - 1
892/00137 Micro Bore Hose 7 - 2
892/00174 Measuring Cup 8 - 2
892/00179 Bearing Press 8 - 1
892/00180 Seal Fitting Tool 9 - 1
892/00181 Replacement Plastic Boss 9 - 1
892/00223 Hand Pump 7 - 2
892/00224 Impulse Extractor 8 - 2
892/00225 Adapter for Impulse Extractor 8 - 1
892/00253 Pressure Test Kit 7 - 1
892/00255 Adapter/Test Point 7 - 1
892/00256 Adapter/Test Point 7 - 1
892/00257 Adapter/Test Point 7 - 1
892/00258 Adapter/Test Point 7 - 1
892/00259 Adapter/Test Point 7 - 1
892/00260 Adapter/Test Point 7 - 1
892/00261 Adapter/Test Point 7 - 1
892/00262 Adapter/Test Point 7 - 1 & 7 - 2
892/00263 Adapter/Test Point 7 - 1
892/00264 Adapter/Test Point 7 - 1
892/00265 Adapter/Test Point 7 - 1
892/00268 Flow Monitoring Unit 7 - 1
892/00269 Sensor Head 7 - 1
892/00270 Load Valve 7 - 1
892/00271 Adapter 7 - 1
892/00272 Adapter 7 - 1 892/00273 Sensor Head 7 - 1 892/00274 Adapter 7 - 2 892/00275 Adapter 7 - 1 892/00276 Adapter 7 - 1 892/00277 Adapter 7 - 1 892/00278 Gauge 0 - 40 bar 7 - 2 892/00279 Gauge 0 - 400 bar 7 - 2 892/00281 Avo Meter 6 - 1 892/00282 Shunt 6 - 1 892/00283 Tool Kit Case 6 - 1 892/00284 Digital Tachometer 6 - 1 892/00285 Oil Temperature Probe 6 - 1 892/00286 Surface Temperature Probe 6 - 1 892/00293 Connector Pipe 7 - 1 892/00294 Connector Pipe 7 - 1 892/00298 Fluke Multimeter 6 - 1 892/00311 Brake Test Kit 8 - 4 892/00312 Dummy End Plate 8 - 2 892/00313 Clutch Alignment Tool 8 - 1 892/00314 Accumulator Adapter 9 - 1 892/00315 Engine Support Brackets 8 - 1 892/00318 Hose and Adapter Kit 7 - 2 892/00333 Heavy Duty Socket, 19 mm A/F 8 - 2 892/00334 Gland Seal Fitting Tool 7 - 2 892/00706 Test Probe 7 - 2 892/00800 Splitting Frame 8 - 1 892/00801 Clutch spanner 5 - 3 892/00802 Rotor puller set 5 - 3 892/00803 Rotor installer set 5 - 3 892/00807 Front plate puller 5 - 3 892/00808 Shaft protector 5 - 3 892/00812 Drive Coupling Spanner 8 - 1 892/00817 Heavy Duty Socket, 17 mm A/F 8 - 2 892/00818 Heavy Duty Socket, 22mm A/F 8 - 2 892/00819 Heavy Duty Socket, 15 mm A/F 8 - 2 892/00842 Glass Lifter 5 - 1 892/00843 Folding Stand 5 - 1 892/00844 Long Knife 5 - 2 892/00845 Cartridge Gun 5 - 1 892/00846 Glass Extractor Handles 5 - 2 892/00847 Nylon Spatula 5 - 3 892/00848 Wire Starter 5 - 2 892/00849 Braided Cutting Wire 5 - 2 892/00864 PD 90 Axle Locknut Spanner 8 - 4 892/00871 Frame (Puller Adapter Assembly) 9 - 1 892/00874 Brace (Puller Adapter Assembly) 9 - 1 892/00875 Bar M24 (Puller Adapter Assembly) 9 - 1 892/00876 Block (Puller Adapter Assembly) 9 - 1 892/00882 Socket 6 - 1 892/00883 Spanner (Steer Box Input Shaft Nuts) 9 - 1 892/00884 ‘C’ Spanner (Steer Box Input Shaft
Nuts) 9 - 1
892/00892 Speed Gearbox Locking Tool 8 - 3 892/00916 Spring Compressor 8 - 3 892/00918 Setting Tool Kit 8 - 4 892/00945 Sleeve for M30 Pinion 8 - 4 892/00956 Timing Pin for Fuel Injection Pump 9 - 2 892/01033 Data Link Adapter Kit 6 - 2 892/01045 Peg Socket - Wet Clutch 8 - 5 892/01046 Mandrel - Wet Clutch 8 - 5 892/01047 Jig - Wet Clutch 8 - 5
Section 1 General Information
9803/8020
Section 1
4 - 1
Issue 8*
*
4 - 1
Service Tools Numerical List
Page No.
1370/0901Z Nut M24 9 - 1
1406/0021 Bonded Washer 7 - 1
1604/0006 Adapter 7 - 1
1604/0008 Adapter 7 - 1
1606/0012 Adapter 7 - 1
1606/0015 Adapter 7 - 1
1612/0006 Adapter 7 - 1
331/64246 Tool Kit for Non-return Valve 7 - 2
331/64265 etaining Bush for Valve spool 7 - 2
4101/0251 JCB Threadlocker and Sealer 3 - 1
4101/0451 JCB Threadlocker 3 - 1
4101/0552 JCB Threadlocker and Sealer
(High Strength) 3 - 1
4101/0651 JCB Retainer (High Strength) 3 - 1
4102/0551 JCB High Strength Threadlocker 3 - 1
4102/0901 JCB Clear Silicone Sealant 3 - 1
4102/1212 JCB Multigasket 3 - 1
4102/1951 JCB Threadseal 3 - 1
4102/2210 Clayton System Seal SC1251 3 - 1
4102/2309 Black Polyurethane Sealant 3 - 1
4103/2109 Ultra Fast Adhesive 3 - 1
4104/0251 JCB Activator (Aerosol) 3 - 1
4104/0253 JCB Activator (Bottle) 3 - 1
4104/1557 JCB Cleaner/Degreaser 3 - 1
4104/1203 Active Wipe 205 (250 g) 3 - 1
4104/1206 Active Wipe 205 (30 ml) 3 - 1
4104/1310 Hand Cleaner 5 - 1
4201/4906 Black Primer 3 - 1
454/30056 Spacer 13.80 mm 8 - 4
477/00437 Gearbox Lifting Adapter 8 - 2
721/00664 Connecting Lead (Psion Workabout) 6 - 1
721/10885 Harness - Diagnostic (J1939) 6 - 2
816/15118 Test Adapter 7 - 1
816/20008 Adapter 7 - 1
816/20013 Adapter 7 - 1
816/55038 Adapter/Test Point 7 - 1
816/55040 Adapter/Test Point 7 - 1
892/00041 Deglazing Tool 9 - 2
892/00078 Connector 7 - 1
892/00137 Micro Bore Hose 7 - 2
892/00174 Measuring Cup 8 - 2
892/00179 Bearing Press 8 - 1
892/00180 Seal Fitting Tool 9 - 1
892/00181 Replacement Plastic Boss 9 - 1
892/00223 Hand Pump 7 - 2
892/00224 Impulse Extractor 8 - 2
892/00225 Adapter for Impulse Extractor 8 - 1
892/00253 Pressure Test Kit 7 - 1
892/00255 Adapter/Test Point 7 - 1
892/00256 Adapter/Test Point 7 - 1
892/00257 Adapter/Test Point 7 - 1
892/00258 Adapter/Test Point 7 - 1
892/00259 Adapter/Test Point 7 - 1
892/00260 Adapter/Test Point 7 - 1
892/00261 Adapter/Test Point 7 - 1
892/00262 Adapter/Test Point 7 - 1 & 7 - 2
892/00263 Adapter/Test Point 7 - 1
892/00264 Adapter/Test Point 7 - 1
892/00265 Adapter/Test Point 7 - 1
892/00268 Flow Monitoring Unit 7 - 1
892/00269 Sensor Head 7 - 1
892/00270 Load Valve 7 - 1
892/00271 Adapter 7 - 1
892/00272 Adapter 7 - 1 892/00273 Sensor Head 7 - 1 892/00274 Adapter 7 - 2 892/00275 Adapter 7 - 1 892/00276 Adapter 7 - 1 892/00277 Adapter 7 - 1 892/00278 Gauge 0 - 40 bar 7 - 2 892/00279 Gauge 0 - 400 bar 7 - 2 892/00281 Avo Meter 6 - 1 892/00282 Shunt 6 - 1 892/00283 Tool Kit Case 6 - 1 892/00284 Digital Tachometer 6 - 1 892/00285 Oil Temperature Probe 6 - 1 892/00286 Surface Temperature Probe 6 - 1 892/00293 Connector Pipe 7 - 1 892/00294 Connector Pipe 7 - 1 892/00298 Fluke Multimeter 6 - 1 892/00311 Brake Test Kit 8 - 4 892/00312 Dummy End Plate 8 - 2 892/00313 Clutch Alignment Tool 8 - 1 892/00314 Accumulator Adapter 9 - 1 892/00315 Engine Support Brackets 8 - 1 892/00318 Hose and Adapter Kit 7 - 2 892/00333 Heavy Duty Socket, 19 mm A/F 8 - 2 892/00334 Gland Seal Fitting Tool 7 - 2 892/00706 Test Probe 7 - 2 892/00800 Splitting Frame 8 - 1 892/00801 Clutch spanner 5 - 3 892/00802 Rotor puller set 5 - 3 892/00803 Rotor installer set 5 - 3 892/00807 Front plate puller 5 - 3 892/00808 Shaft protector 5 - 3 892/00812 Drive Coupling Spanner 8 - 1 892/00817 Heavy Duty Socket, 17 mm A/F 8 - 2 892/00818 Heavy Duty Socket, 22mm A/F 8 - 2 892/00819 Heavy Duty Socket, 15 mm A/F 8 - 2 892/00842 Glass Lifter 5 - 1 892/00843 Folding Stand 5 - 1 892/00844 Long Knife 5 - 2 892/00845 Cartridge Gun 5 - 1 892/00846 Glass Extractor Handles 5 - 2 892/00847 Nylon Spatula 5 - 3 892/00848 Wire Starter 5 - 2 892/00849 Braided Cutting Wire 5 - 2 892/00864 PD 90 Axle Locknut Spanner 8 - 4 892/00871 Frame (Puller Adapter Assembly) 9 - 1 892/00874 Brace (Puller Adapter Assembly) 9 - 1 892/00875 Bar M24 (Puller Adapter Assembly) 9 - 1 892/00876 Block (Puller Adapter Assembly) 9 - 1 892/00882 Socket 6 - 1 892/00883 Spanner (Steer Box Input Shaft Nuts) 9 - 1 892/00884 ‘C’ Spanner (Steer Box Input Shaft
Nuts) 9 - 1
892/00892 Speed Gearbox Locking Tool 8 - 3 892/00916 Spring Compressor 8 - 3 892/00918 Setting Tool Kit 8 - 4 892/00945 Sleeve for M30 Pinion 8 - 4 892/00956 Timing Pin for Fuel Injection Pump 9 - 2 892/01033 Data Link Adapter Kit 6 - 2 892/01045 Peg Socket - Wet Clutch 8 - 5 892/01046 Mandrel - Wet Clutch 8 - 5 892/01047 Jig - Wet Clutch 8 - 5
Section 1 General Information
9803/8020
Section 1
4 - 1
Issue 8*
*
*
4 - 2
Service Tools Numerical List (continued)
Page No.
892/01048 Clutch Pack Retainer - Wet Clutch
(2 required) 8 - 4
892/01049 Guide Rod - Wet Clutch
(2 required) 8 - 4
892/01050 Mandrel - Wet Clutch 8 - 5
892/01051 Intermediate Gear Retaining Tool -
Wet Clutch Transmission 8 - 4
892/01052 Locking Plate - Wet Clutch
(2 required) 8 - 4
892/01053 Adapter for impulse extractor
(PTO intermediate shaft,
wet clutch transmission) 8 - 2
892/01092 Wheel Hub Service Kit 8 - 5
926/15500 Rubber Spacer Blocks 5 - 3
992/12300 Mobile Oven 5 - 1
992/12400 Static Oven 5 - 1
992/12600 Static Oven 5 - 1
992/12800 Cut-out Knife 5 - 2
992/12801 'L' Blades 5 - 2
993/45400 Torque Multiplier 8 - 2
993/55700 Direct Glazing Kit 3 - 1
993/59300 Pressure Test Adapter and Clamp 8 - 3
993/70111 Break-back Torque Wrench 8 - 4
993/85700 Battery Tester 6 - 1
997/11000 Drive Head Setting Bracket 8 - 4
997/11100 Adapter for M24 Pinion 8 - 4
The following parts are replacement items for kits and would
normally be included in the relevant kit numbers.
Replacement items for kit no. 892/00253
892/00201 Gauge 0 - 20 bar 7 - 1
892/00202 Gauge 0 - 40 bar 7 - 1
892/00203 Gauge 0 - 400 bar 7 - 1
892/00254 Hose 7 - 1
993/69800 Seal Kit 7 - 1
Replacement parts for kit no. 892/01092
1315/3414Z Bolt M10x60 8 - 5
1315/3731Z Bolt M16x220 8 - 5
1315/3835Z Bolt M20x300 8 - 5
1370/0301Z Nut M10 8 - 5
1370/0401Z Nut M12 8 - 5
1370/0601Z Nut M16 8 - 5
1370/0701Z Nut M20 8 - 5
1420/0009Z Washer M12 8 - 5
1420/0012Z Washer M20 8 - 5
445/12303 Washer 8 - 5
892/00891 Dolly 8 - 5
917/02800 Bearing 8 - 5
998/10606 Bearing Fitting Tube 8 - 5
998/10607 Inner Bearing Plate 8 - 5
998/10608 Bearing Centre Puller 8 - 5
998/10610 Puller Rod 8 - 5
998/10614 Reaction Tube 8 - 5
998/10615 Wheel Bearing Carrier Puller 8 - 5
998/10616 Puller Handle Nut 8 - 5
998/10623 Puller Beam 8 - 5
998/10624 Modified Wheel Stud 8 - 5
Section 1 General Information
9803/8020
Section 1
4 - 2
Issue 6*
*
*
4 - 2
Service Tools Numerical List (continued)
Page No.
892/01048 Clutch Pack Retainer - Wet Clutch
(2 required) 8 - 4
892/01049 Guide Rod - Wet Clutch
(2 required) 8 - 4
892/01050 Mandrel - Wet Clutch 8 - 5
892/01051 Intermediate Gear Retaining Tool -
Wet Clutch Transmission 8 - 4
892/01052 Locking Plate - Wet Clutch
(2 required) 8 - 4
892/01053 Adapter for impulse extractor
(PTO intermediate shaft,
wet clutch transmission) 8 - 2
892/01092 Wheel Hub Service Kit 8 - 5
926/15500 Rubber Spacer Blocks 5 - 3
992/12300 Mobile Oven 5 - 1
992/12400 Static Oven 5 - 1
992/12600 Static Oven 5 - 1
992/12800 Cut-out Knife 5 - 2
992/12801 'L' Blades 5 - 2
993/45400 Torque Multiplier 8 - 2
993/55700 Direct Glazing Kit 3 - 1
993/59300 Pressure Test Adapter and Clamp 8 - 3
993/70111 Break-back Torque Wrench 8 - 4
993/85700 Battery Tester 6 - 1
997/11000 Drive Head Setting Bracket 8 - 4
997/11100 Adapter for M24 Pinion 8 - 4
The following parts are replacement items for kits and would
normally be included in the relevant kit numbers.
Replacement items for kit no. 892/00253
892/00201 Gauge 0 - 20 bar 7 - 1
892/00202 Gauge 0 - 40 bar 7 - 1
892/00203 Gauge 0 - 400 bar 7 - 1
892/00254 Hose 7 - 1
993/69800 Seal Kit 7 - 1
Replacement parts for kit no. 892/01092
1315/3414Z Bolt M10x60 8 - 5
1315/3731Z Bolt M16x220 8 - 5
1315/3835Z Bolt M20x300 8 - 5
1370/0301Z Nut M10 8 - 5
1370/0401Z Nut M12 8 - 5
1370/0601Z Nut M16 8 - 5
1370/0701Z Nut M20 8 - 5
1420/0009Z Washer M12 8 - 5
1420/0012Z Washer M20 8 - 5
445/12303 Washer 8 - 5
892/00891 Dolly 8 - 5
917/02800 Bearing 8 - 5
998/10606 Bearing Fitting Tube 8 - 5
998/10607 Inner Bearing Plate 8 - 5
998/10608 Bearing Centre Puller 8 - 5
998/10610 Puller Rod 8 - 5
998/10614 Reaction Tube 8 - 5
998/10615 Wheel Bearing Carrier Puller 8 - 5
998/10616 Puller Handle Nut 8 - 5
998/10623 Puller Beam 8 - 5
998/10624 Modified Wheel Stud 8 - 5
Section 1 General Information
9803/8020
Section 1
4 - 2
Issue 6*
*
*
5 - 1
Section 1 General Information
9803/8020
Section 1
5 - 1
Issue 1
Service Tools
Section B - Body and Framework
S186240
Hand Cleaner - special blend for the removal of
polyurethane adhesives.
JCB part number - 4104/1310 (454g; 1lb tub)
S186250
12V Mobile Oven- 1 cartridge capacity - required to
pre-heat adhesive prior to use. It is fitted with a male
plug (703/23201) which fits into a female socket
(715/04300).
JCB part number - 992/12300
S186260
240V Static Oven- available with 2 or 6 cartridge
capacity - required to pre-heat adhesive prior to use.
No plug supplied. Note: 110V models available upon
request - contact JCB Technical Service
JCB part number:
992/12400 - 2 cartridge x 240V
992/12600 - 6 cartridge x 240V
S186270
Cartridge Gun - hand operated - essential for the
application of sealants, polyurethane materials etc.
JCB part number - 892/00845
'
S186280
Folding Stand for Holding Glass - essential for
preparing new glass prior to installation.
JCB part number - 892/00843
S186300
Glass Lifter- minimum 2 off - essential for glass
installation, 2 required to handle large panes of glass.
Ensure suction cups are protected from damage
during storage.
JCB part number - 892/00842
Section 1 General Information
9803/8020
Section 1
5 - 1
Issue 1
Service Tools
Section B - Body and Framework
S186240
Hand Cleaner - special blend for the removal of
polyurethane adhesives.
JCB part number - 4104/1310 (454g; 1lb tub)
S186250
12V Mobile Oven- 1 cartridge capacity - required to
pre-heat adhesive prior to use. It is fitted with a male
plug (703/23201) which fits into a female socket
(715/04300).
JCB part number - 992/12300
S186260
240V Static Oven- available with 2 or 6 cartridge
capacity - required to pre-heat adhesive prior to use.
No plug supplied. Note: 110V models available upon
request - contact JCB Technical Service
JCB part number:
992/12400 - 2 cartridge x 240V
992/12600 - 6 cartridge x 240V
S186270
Cartridge Gun - hand operated - essential for the
application of sealants, polyurethane materials etc.
JCB part number - 892/00845
'
S186280
Folding Stand for Holding Glass - essential for
preparing new glass prior to installation.
JCB part number - 892/00843
S186300
Glass Lifter- minimum 2 off - essential for glass
installation, 2 required to handle large panes of glass.
Ensure suction cups are protected from damage
during storage.
JCB part number - 892/00842
Service Tools (continued)
Section B - Body and Framework (continued)
S186310
Wire Starter - used to access braided cutting wire
(below) through original polyurethane seal.
JCB part number - 892/00848
S186320
Glass Extractor (Handles) - used with braided cutting
wire (below) to cut out broken glass.
JCB part number - 892/00846
S186330
Braided Cutting Wire - consumable heavy duty
cut-out wire used with the glass extraction tool
(above).
JCB part number - 892/00849 (approx 25m length)
S186340
Cut-out Knife- used to remove broken glass.
JCB part number - 992/12800
'
S186350
'L' Blades - 25mm (1in.) cut - replacement blades for
cut-out knife (above).
JCB part number - 992/12801 (unit quantity = 5 off)
S186360
Long Knife- used to give extended reach for normally
inaccessible areas.
JCB part number - 892/00844
5 - 2
Section 1 General Information
9803/8020
Section 1
5 - 2
Issue 1
Section B - Body and Framework (continued)
S186310
Wire Starter - used to access braided cutting wire
(below) through original polyurethane seal.
JCB part number - 892/00848
S186320
Glass Extractor (Handles) - used with braided cutting
wire (below) to cut out broken glass.
JCB part number - 892/00846
S186330
Braided Cutting Wire - consumable heavy duty
cut-out wire used with the glass extraction tool
(above).
JCB part number - 892/00849 (approx 25m length)
S186340
Cut-out Knife- used to remove broken glass.
JCB part number - 992/12800
'
S186350
'L' Blades - 25mm (1in.) cut - replacement blades for
cut-out knife (above).
JCB part number - 992/12801 (unit quantity = 5 off)
S186360
Long Knife- used to give extended reach for normally
inaccessible areas.
JCB part number - 892/00844
5 - 2
Section 1 General Information
9803/8020
Section 1
5 - 2
Issue 1
Service Tools (continued)
Section B - Body and Framework (continued)
S186470
Nylon Spatula - general tool used for smoothing
sealants - also used to re-install glass in rubber glazing
because metal tools will chip the glass edge.
JCB part number - 892/00847
892/00801 Clutch spanner
S200940
for air conditioning compressor
892/00802 Rotor puller set
S200950
for air conditioning compressor
892/00803 Rotor installer set
S200960
for air conditioning compressor
S186550
Rubber Spacer Blocks- used to provide the correct
set clearance between glass edge and cab frame.
JCB part number - 926/15500
(unit quantity = 500 off)
892/00807 Front plate puller
S200970
for air conditioning compressor
892/00808 Shaft protector
S200980
for air conditioning compressor
5 - 3
Section 1 General Information
9803/8020
Section 1
5 - 3
Issue 1
Section B - Body and Framework (continued)
S186470
Nylon Spatula - general tool used for smoothing
sealants - also used to re-install glass in rubber glazing
because metal tools will chip the glass edge.
JCB part number - 892/00847
892/00801 Clutch spanner
S200940
for air conditioning compressor
892/00802 Rotor puller set
S200950
for air conditioning compressor
892/00803 Rotor installer set
S200960
for air conditioning compressor
S186550
Rubber Spacer Blocks- used to provide the correct
set clearance between glass edge and cab frame.
JCB part number - 926/15500
(unit quantity = 500 off)
892/00807 Front plate puller
S200970
for air conditioning compressor
892/00808 Shaft protector
S200980
for air conditioning compressor
5 - 3
Section 1 General Information
9803/8020
Section 1
5 - 3
Issue 1
6 - 1
Section 1 General Information
9803/8020
Section 1
6 - 1
Issue 2*
188230
239510
S216770
Electrical Test Equipment
1892/00283 Tool Kit Case
2892/00281 AVO Meter
3892/00286 Surface Temperature Probe
4892/00284 Microtach Digital Tachometer
5892/00282 100 Amp Shunt - open type
6892/00285 Hydraulic Oil Temperature Probe
7892/00298 Fluke 85 Multimeter
Service Tools
Section C - Electrics
993/85700 Battery Tester
892/00882 Socket for Pulley Nut on Magneti Marelli
Alternator.
Psion Workabout 1Mb/RS232 † Docking Holster † Software - Psion Link, Version 1.1 † 721/00664 Connecting Lead 2 x CD ROM ††
† These items to be obtained from your nearest
Psion agent as listed on M.I.’s 569/H, 525 HA and
516E.
†† As detailed on the same M.I.’s as above.
Section 1 General Information
9803/8020
Section 1
6 - 1
Issue 2*
188230
239510
S216770
Electrical Test Equipment
1892/00283 Tool Kit Case
2892/00281 AVO Meter
3892/00286 Surface Temperature Probe
4892/00284 Microtach Digital Tachometer
5892/00282 100 Amp Shunt - open type
6892/00285 Hydraulic Oil Temperature Probe
7892/00298 Fluke 85 Multimeter
Service Tools
Section C - Electrics
993/85700 Battery Tester
892/00882 Socket for Pulley Nut on Magneti Marelli
Alternator.
Psion Workabout 1Mb/RS232 † Docking Holster † Software - Psion Link, Version 1.1 † 721/00664 Connecting Lead 2 x CD ROM ††
† These items to be obtained from your nearest
Psion agent as listed on M.I.’s 569/H, 525 HA and
516E.
†† As detailed on the same M.I.’s as above.
6 - 2
Service Tools
Section C - Electrics
Section 1 General Information
9803/8020
Section 1
6 - 2
Issue 1
A360250
892/01033 Data Link Adapter Kit
Note: Item Aof the Data Link Adapter Kit is unsuitable
for use with the Fastrac and must be replaced by the
‘Harness - Diagnostic (J1939)’ shown below.
8
1514131211109
7654321
D
FAB
C
H
J
E
G
A386040
721/10885 Harness - Diagnostic (J1939)
A A
Service Tools
Section C - Electrics
Section 1 General Information
9803/8020
Section 1
6 - 2
Issue 1
A360250
892/01033 Data Link Adapter Kit
Note: Item Aof the Data Link Adapter Kit is unsuitable
for use with the Fastrac and must be replaced by the
‘Harness - Diagnostic (J1939)’ shown below.
8
1514131211109
7654321
D
FAB
C
H
J
E
G
A386040
721/10885 Harness - Diagnostic (J1939)
A A
7 - 1
Section 1 General Information
9803/8020
Section 1
7 - 1
Issue 1
Pressure Test Adapters
892/00255 1/4 in BSP x Test Point
892/00256 3/8 in BSP x Test Point
892/00257 1/2 in BSP x Test Point
892/00258 5/8 in BSP x Test Point
816/15118 3/4 in BSP x Test Point
892/00259 1 in BSP x Test Point
892/00260 1.1/4 in BSP x Test Point
892/00261 5/8 in UNF x Test Point
Pressure Test 'T' Adapters
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point
816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point
892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point
892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point
Hydraulic Circuit Pressure Test Kit
892/00253 Pressure Test Kit
892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in
2
)
892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in
2
)
892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in
2
)
892/00254 Replacement Hose
:993/69800 Seal Kit for 892/00254 (can also be used with
probe 892/00706)
S188130
S188120
S200140
Service Tools
Section E - Hydraulics
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
892/00271 Adapter 3/4 in F x 5/8 in M BSP
892/00272 Adapter 5/8 in F x 3/4 in M BSP
816/20008 Adapter 3/4 in F x 1/2 in M BSP
892/00275 Adapter 1/2 in F x 3/4 in M BSP
892/00276 Adapter 3/4 in F x 3/8 in M BSP
892/00277 Adapter 3/8 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
1606/0012 Adapter 1 in M x 3/4 in M BSP
816/20013 Adapter 3/4 in F x 1 in M BSP
S188150
Section 1 General Information
9803/8020
Section 1
7 - 1
Issue 1
Pressure Test Adapters
892/00255 1/4 in BSP x Test Point
892/00256 3/8 in BSP x Test Point
892/00257 1/2 in BSP x Test Point
892/00258 5/8 in BSP x Test Point
816/15118 3/4 in BSP x Test Point
892/00259 1 in BSP x Test Point
892/00260 1.1/4 in BSP x Test Point
892/00261 5/8 in UNF x Test Point
Pressure Test 'T' Adapters
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point
816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point
892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point
892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point
Hydraulic Circuit Pressure Test Kit
892/00253 Pressure Test Kit
892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in
2
)
892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in
2
)
892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in
2
)
892/00254 Replacement Hose
:993/69800 Seal Kit for 892/00254 (can also be used with
probe 892/00706)
S188130
S188120
S200140
Service Tools
Section E - Hydraulics
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
892/00271 Adapter 3/4 in F x 5/8 in M BSP
892/00272 Adapter 5/8 in F x 3/4 in M BSP
816/20008 Adapter 3/4 in F x 1/2 in M BSP
892/00275 Adapter 1/2 in F x 3/4 in M BSP
892/00276 Adapter 3/4 in F x 3/8 in M BSP
892/00277 Adapter 3/8 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
1606/0012 Adapter 1 in M x 3/4 in M BSP
816/20013 Adapter 3/4 in F x 1 in M BSP
S188150
Service Tools (continued)
Section E - Hydraulics (continued)
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
female adapter
892/00706 Test Probe
892/00278 Gauge 0-40 bar (0-600 lbf/in
2
)
892/00279 Gauge 0-400 bar (0-6000 lbf/in
2
)
892/00334 Gland Seal Fitting Tool
331/64265 Retaining Bush for Valve Spool
892/00318 Hose And Adapter Kit
To enable flow and pressure test
equipment to be connected to adapters
fitted with 'O' ringface seals.
331/64246 Tool Kit for Non-return Valve
7 - 2
Section 1 General Information
9803/8020
Section 1
7 - 2
Issue 2
S193850
197210
197220
Section E - Hydraulics (continued)
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
female adapter
892/00706 Test Probe
892/00278 Gauge 0-40 bar (0-600 lbf/in
2
)
892/00279 Gauge 0-400 bar (0-6000 lbf/in
2
)
892/00334 Gland Seal Fitting Tool
331/64265 Retaining Bush for Valve Spool
892/00318 Hose And Adapter Kit
To enable flow and pressure test
equipment to be connected to adapters
fitted with 'O' ringface seals.
331/64246 Tool Kit for Non-return Valve
7 - 2
Section 1 General Information
9803/8020
Section 1
7 - 2
Issue 2
S193850
197210
197220
8 - 1
Section 1 General Information
9803/8020
Section 1
8 - 1
Issue 2
892/00315 Engine Support Bracket
892/00812 Drive Coupling Spanner for yoke
couplings
892/00225 Adapter - Impulse Extractor
Small 17mm to 25mm
Medium 25mm to 45mm
Large 45mm to 80mm
Service Tools
Section F - Transmission
892/00800Splitting Frame (complete with ratchet
hoist)
892/00179 Bearing Press
892/00313 Clutch Alignment Tool
197260
188200
197280
107750
197270
197080
Section 1 General Information
9803/8020
Section 1
8 - 1
Issue 2
892/00315 Engine Support Bracket
892/00812 Drive Coupling Spanner for yoke
couplings
892/00225 Adapter - Impulse Extractor
Small 17mm to 25mm
Medium 25mm to 45mm
Large 45mm to 80mm
Service Tools
Section F - Transmission
892/00800Splitting Frame (complete with ratchet
hoist)
892/00179 Bearing Press
892/00313 Clutch Alignment Tool
197260
188200
197280
107750
197270
197080
8 - 2
Service Tools (continued)
Section F - Transmission (continued)
Heavy Duty Sockets
892/00817 17 mm A/F x 3/4in. square drive
892/00818 22 mm A/F x 3/4in. square drive
892/00819 15 mm A/F x 1/2in. square drive
892/00333 19 mm A/F x 3/4in. square drive
892/00224 Impulse Extractor Set
for Hub Bearing Seals
* 892/01053 Adapter for impulse extractor
(PTO intermediate shaft, wet clutch
transmission)
477/00437 Gearbox Lifting Adapter
993/45400 Torque Multiplier
(use in conjunction with a torque wrench to
give a 5 : 1 multiplication)
892/00174 Measuring Cup - Pinion Head Bearing
892/00312 Dummy End Plate for Range Gearbox
Rear Differential Setting Key
Cut from 5 mm plate to dimensions shown. Fabricate
handle to suit.
Section 1 General Information
9803/8020
Section 1
8 - 2
Issue 3*
110
15
40
25 25
S197030
197250
S197070
197200
A197180
S197240
S190770
Service Tools (continued)
Section F - Transmission (continued)
Heavy Duty Sockets
892/00817 17 mm A/F x 3/4in. square drive
892/00818 22 mm A/F x 3/4in. square drive
892/00819 15 mm A/F x 1/2in. square drive
892/00333 19 mm A/F x 3/4in. square drive
892/00224 Impulse Extractor Set
for Hub Bearing Seals
* 892/01053 Adapter for impulse extractor
(PTO intermediate shaft, wet clutch
transmission)
477/00437 Gearbox Lifting Adapter
993/45400 Torque Multiplier
(use in conjunction with a torque wrench to
give a 5 : 1 multiplication)
892/00174 Measuring Cup - Pinion Head Bearing
892/00312 Dummy End Plate for Range Gearbox
Rear Differential Setting Key
Cut from 5 mm plate to dimensions shown. Fabricate
handle to suit.
Section 1 General Information
9803/8020
Section 1
8 - 2
Issue 3*
110
15
40
25 25
S197030
197250
S197070
197200
A197180
S197240
S190770
8 - 3
Section 1 General Information
9803/8020
Section 1
8 - 3
Issue 3
S196750
S226300
S267310
993/59300 2/4 WD Pressure Test Adaptor & Clamp
892/00892 Speed Gearbox Locking Tool
892/00916 Spring Compressor for Splitter and PTO
Clutches
Service Tools (continued)
Section F - Transmission (continued)
Section 1 General Information
9803/8020
Section 1
8 - 3
Issue 3
S196750
S226300
S267310
993/59300 2/4 WD Pressure Test Adaptor & Clamp
892/00892 Speed Gearbox Locking Tool
892/00916 Spring Compressor for Splitter and PTO
Clutches
Service Tools (continued)
Section F - Transmission (continued)
8 - 4
Service Tools (continued)
Section F - Transmission (continued)
Section 1 General Information
9803/8020
Section 1
8 - 4
Issue 6*
Solid Spacer Setting Tools
1892/00918 Setting Tool Kit. Contains the following:
A Sleeve for M24 Pinion
BAdapter for M30 Pinion
CFork (suitable for all axles)
The following setting tools must be purchased
seperately:
892/00945ASleeve for M30 Pinion
997/11100BAdapter for M24 Pinion
2997/11000 Drive Head Setting Bracket
3993/70111 Break-back Torque Wrench
4 - Solid spacer (see parts CD or
michrofiche for part numbers)
A270851
4
3
A
B
2
1
C
S234120
892/00864 PD 90 Axle Locknut Spanner
A361710
A361730
892/01051 Intermediate Gear Retaining Tool - wet
clutch transmission
892/01052 (x2) Locking Plate for locking wet clutch
drum to housing
A361740
892/01049 (x2) Guide Rod - wet clutch
A361720
892/01048 (x2) Clutch Pack Retainer - wet clutch
Service Tools (continued)
Section F - Transmission (continued)
Section 1 General Information
9803/8020
Section 1
8 - 4
Issue 6*
Solid Spacer Setting Tools
1892/00918 Setting Tool Kit. Contains the following:
A Sleeve for M24 Pinion
BAdapter for M30 Pinion
CFork (suitable for all axles)
The following setting tools must be purchased
seperately:
892/00945ASleeve for M30 Pinion
997/11100BAdapter for M24 Pinion
2997/11000 Drive Head Setting Bracket
3993/70111 Break-back Torque Wrench
4 - Solid spacer (see parts CD or
michrofiche for part numbers)
A270851
4
3
A
B
2
1
C
S234120
892/00864 PD 90 Axle Locknut Spanner
A361710
A361730
892/01051 Intermediate Gear Retaining Tool - wet
clutch transmission
892/01052 (x2) Locking Plate for locking wet clutch
drum to housing
A361740
892/01049 (x2) Guide Rod - wet clutch
A361720
892/01048 (x2) Clutch Pack Retainer - wet clutch
8 - 5
Service Tools (continued)
Section F - Transmission (continued)
Section 1 General Information
9803/8020
Section 1
8 - 5
Issue 1
A361750
892/01045 Peg Socket - wet clutch
A361770
892/01046 Mandrel - for bush assembly - wet clutch
A361760
892/01047 Jig, for use when dismantling and
assembling of PTO input gear - wet clutch
A361780
892/01050 Mandrel, for hub seal renewal - wet clutch.
Note: Protective plastic cap Ato be removed before use.
A
Service Tools (continued)
Section F - Transmission (continued)
Section 1 General Information
9803/8020
Section 1
8 - 5
Issue 1
A361750
892/01045 Peg Socket - wet clutch
A361770
892/01046 Mandrel - for bush assembly - wet clutch
A361760
892/01047 Jig, for use when dismantling and
assembling of PTO input gear - wet clutch
A361780
892/01050 Mandrel, for hub seal renewal - wet clutch.
Note: Protective plastic cap Ato be removed before use.
A
8 - 6
Section 1
9803/8020
Section 1
8 - 6
Issue 1
General Information
Service Tools (continued)
Section F - Transmission (continued)
Item Description Part No. Qty
A Hub Service Kit 892/01092 1
comprises:
1 Puller Beam 998/10623 1
2 Inner Bearing Plate 998/10607 1
3 Bolt M16x220 1315/3731Z 2
4 Nut M16 1370/0601Z 2
5 Reaction Tube 998/10614 1
6 Modified Wheel Stud 998/10624 2
7 Wheel Bearing Carrier
Puller 998/10615 2
8 Nut M20 1370/0701Z 4
9 Washer M20 1420/0012Z 2
10 Puller Rod 998/10610 2
11 Nut M12 1370/0401Z 2
12 Washer M12 1420/0009Z 2
13 Bearing Centre Puller 998/10608 1
14 Bolt M10x60 1315/3414Z 1
15 Nut M10 1370/0301Z 1
16 Bearing Fitting Tube 998/10606 1
17 Puller Handle Nut 998/10616 1
18 Bolt M20x300 1315/3835Z 2
19 Washer 445/12303 2
20 Bearing 917/02800 1
21 Dolly 892/00891 1
1
A
2
3
4
5
6
7
8,9
10
11,12
8
14
15
21
13
16
17
18
19, 20
Section 1
9803/8020
Section 1
8 - 6
Issue 1
General Information
Service Tools (continued)
Section F - Transmission (continued)
Item Description Part No. Qty
A Hub Service Kit 892/01092 1
comprises:
1 Puller Beam 998/10623 1
2 Inner Bearing Plate 998/10607 1
3 Bolt M16x220 1315/3731Z 2
4 Nut M16 1370/0601Z 2
5 Reaction Tube 998/10614 1
6 Modified Wheel Stud 998/10624 2
7 Wheel Bearing Carrier
Puller 998/10615 2
8 Nut M20 1370/0701Z 4
9 Washer M20 1420/0012Z 2
10 Puller Rod 998/10610 2
11 Nut M12 1370/0401Z 2
12 Washer M12 1420/0009Z 2
13 Bearing Centre Puller 998/10608 1
14 Bolt M10x60 1315/3414Z 1
15 Nut M10 1370/0301Z 1
16 Bearing Fitting Tube 998/10606 1
17 Puller Handle Nut 998/10616 1
18 Bolt M20x300 1315/3835Z 2
19 Washer 445/12303 2
20 Bearing 917/02800 1
21 Dolly 892/00891 1
1
A
2
3
4
5
6
7
8,9
10
11,12
8
14
15
21
13
16
17
18
19, 20
Service Tools (continued)
Section H - Steering
9 - 1
Section 1 General Information
9803/8020
Section 1
9 - 1
Issue 3*
222490
A A
B B
D D
C C
E E
Puller adapter assembly for removal of drop arm from
steering box (3000 Series machines). Comprises:
A892/00871 Frame 1 off
B892/00874 Brace 1 off
C892/00875 Bar M24 2 off
D892/00876 Block 2 off
E1370/0901Z Nut M24 2 off
Use in conjunction with a 20 tonne hydraulic ram as
obtainable from Sykes Pickavant to suit puller bars at 185
mm centres.
220130
GG
F F
Spanners for input shaft nuts on steering box (3000 Series
machines with serial nos. 640001 to 640053 and 640056
to 640058).
F892/00883 Spanner
G892/00884 ‘C’ Spanner
Section G - Brakes
S199470
892/00311 Brake Test Kit
3 x Calibrated Test Gauges - 0-20 bar (0 - 290 lbf/in
2
)
3 x 5 Metre Hoses with Quick Release Adapters 3 x ISO Test Point Adapters
229270
892/00180 Seal Fitting Tool for fitting ‘O’ ring and
back-up ring to Danfoss Orbitrol Unit
892/00181 Replacement Plastic Boss
Section H - Steering
9 - 1
Section 1 General Information
9803/8020
Section 1
9 - 1
Issue 3*
222490
A A
B B
D D
C C
E E
Puller adapter assembly for removal of drop arm from
steering box (3000 Series machines). Comprises:
A892/00871 Frame 1 off
B892/00874 Brace 1 off
C892/00875 Bar M24 2 off
D892/00876 Block 2 off
E1370/0901Z Nut M24 2 off
Use in conjunction with a 20 tonne hydraulic ram as
obtainable from Sykes Pickavant to suit puller bars at 185
mm centres.
220130
GG
F F
Spanners for input shaft nuts on steering box (3000 Series
machines with serial nos. 640001 to 640053 and 640056
to 640058).
F892/00883 Spanner
G892/00884 ‘C’ Spanner
Section G - Brakes
S199470
892/00311 Brake Test Kit
3 x Calibrated Test Gauges - 0-20 bar (0 - 290 lbf/in
2
)
3 x 5 Metre Hoses with Quick Release Adapters 3 x ISO Test Point Adapters
229270
892/00180 Seal Fitting Tool for fitting ‘O’ ring and
back-up ring to Danfoss Orbitrol Unit
892/00181 Replacement Plastic Boss
9 - 2
Section T - Engine
Note: For other engine tools refer to the relevant Engine
Service Manual.
Section 1 General Information
9803/8020
Section 1
9 - 2
Issue 2*
S192390
892/00041 De-glazing Tool for Cylinder Bores (to
assist bedding-in of new piston rings)
A314530
892/00956 Timing pin for fuel injection pumps (Fastrac
2115, 2125, 2135, 2150 only).
Service Tools (continued)
S199480
892/00314 Accumulator and Gas Spring Pressure
Test Adapter
Section S - Suspension
*
Section T - Engine
Note: For other engine tools refer to the relevant Engine
Service Manual.
Section 1 General Information
9803/8020
Section 1
9 - 2
Issue 2*
S192390
892/00041 De-glazing Tool for Cylinder Bores (to
assist bedding-in of new piston rings)
A314530
892/00956 Timing pin for fuel injection pumps (Fastrac
2115, 2125, 2135, 2150 only).
Service Tools (continued)
S199480
892/00314 Accumulator and Gas Spring Pressure
Test Adapter
Section S - Suspension
*
10- 1
General
Do not tow a machine unless there is no alternative.
Remember that more damage might be caused to the
machine by towing it. If at all possible repair the machine
where it stands.
Note:It is not possible to tow-start or push-start the Fastrac
due to the design of the transmission.
Make sure you will be obeying all pertinent laws and
regulations before towing the machine on public roads.
!DANGER
If the engine is not running, there will not be enough air
to apply the service brakes or release the parking brake.
Carefully follow the precautions in this section before
moving the machine or there may be a serious accident.
13-2-2-6/1
!CAUTION
Towing a machine too far or too fast can damage the
transmission. Do not tow the machine further than one
mile. Use a trailer for greater distances. When towing do
not travel faster than 25 km/h (15 mph).
Use a rigid drawbar. If you must use towing chains, then
use two towing vehicles. One towing vehicle should be
coupled to the front of the disabled machine. The other
towing vehicle should be coupled to the rear of the
disabled machine, to provide braking power.
The towing vehicle(s) must have enough pulling and
braking power to move and stop the machine.
2-2-7-3
Preparation for Towing
1 Connect the towing vehicle.
aApply the parking brakes on the towing vehicle and
securely chock the wheels on the Fastrac.
bFit the drawbar between towing vehicle and
Fastrac.
2 Prepare the machine.
aMake sure that the range and speed gearboxes are
both in neutral.
bIf the gearbox has failed, disconnect both
propshafts (see Section F).
cIf an axle has failed, remove the sun gears (see
Section F).
3 Release the Fastrac parking brake.
Note:The Schrader valve Xshown below on the right hand
side of the machine is that for Fastrac 2115, 2125 and 2135
machines. On 2150, 3155 and 3185 machines the valve is on
the left hand side of the machine.
If there is not enough air pressure to release the brake,
start the engine to charge up the air system. If the
engine cannot be run but the brake air system is
serviceable, charge the system to 120 psi (8 bar)
through Schrader valveX. This job must be done by a
qualified mechanic, using the correct equipment.
!DANGER
Ensure that the chocks and towing vehicle will prevent
the Fastrac from moving as it is necessary to work under
the machine to release the parking brake. When the
parking brake has been manually released as described
below, it will be impossible to apply the brake until plate
A has been removed.
13-2-2-11
Alternatively, position plate A(if provided with the
machine) as shown. Keeping nut Btight against clevis
C, turn nut Dagainst the plate so that rod Eis drawn
out of the actuator body and the parking brake is
released.
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.
Section 1 General Information
9803/8020
Section 1
10 - 1
Issue 3*
Moving a Disabled Machine
S261600
S160392
X
C
E
A
D
B
A286550
*
General
Do not tow a machine unless there is no alternative.
Remember that more damage might be caused to the
machine by towing it. If at all possible repair the machine
where it stands.
Note:It is not possible to tow-start or push-start the Fastrac
due to the design of the transmission.
Make sure you will be obeying all pertinent laws and
regulations before towing the machine on public roads.
!DANGER
If the engine is not running, there will not be enough air
to apply the service brakes or release the parking brake.
Carefully follow the precautions in this section before
moving the machine or there may be a serious accident.
13-2-2-6/1
!CAUTION
Towing a machine too far or too fast can damage the
transmission. Do not tow the machine further than one
mile. Use a trailer for greater distances. When towing do
not travel faster than 25 km/h (15 mph).
Use a rigid drawbar. If you must use towing chains, then
use two towing vehicles. One towing vehicle should be
coupled to the front of the disabled machine. The other
towing vehicle should be coupled to the rear of the
disabled machine, to provide braking power.
The towing vehicle(s) must have enough pulling and
braking power to move and stop the machine.
2-2-7-3
Preparation for Towing
1 Connect the towing vehicle.
aApply the parking brakes on the towing vehicle and
securely chock the wheels on the Fastrac.
bFit the drawbar between towing vehicle and
Fastrac.
2 Prepare the machine.
aMake sure that the range and speed gearboxes are
both in neutral.
bIf the gearbox has failed, disconnect both
propshafts (see Section F).
cIf an axle has failed, remove the sun gears (see
Section F).
3 Release the Fastrac parking brake.
Note:The Schrader valve Xshown below on the right hand
side of the machine is that for Fastrac 2115, 2125 and 2135
machines. On 2150, 3155 and 3185 machines the valve is on
the left hand side of the machine.
If there is not enough air pressure to release the brake,
start the engine to charge up the air system. If the
engine cannot be run but the brake air system is
serviceable, charge the system to 120 psi (8 bar)
through Schrader valveX. This job must be done by a
qualified mechanic, using the correct equipment.
!DANGER
Ensure that the chocks and towing vehicle will prevent
the Fastrac from moving as it is necessary to work under
the machine to release the parking brake. When the
parking brake has been manually released as described
below, it will be impossible to apply the brake until plate
A has been removed.
13-2-2-11
Alternatively, position plate A(if provided with the
machine) as shown. Keeping nut Btight against clevis
C, turn nut Dagainst the plate so that rod Eis drawn
out of the actuator body and the parking brake is
released.
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.
Section 1 General Information
9803/8020
Section 1
10 - 1
Issue 3*
Moving a Disabled Machine
S261600
S160392
X
C
E
A
D
B
A286550
*
10 - 2
Transporting the Machine
The safe transit of the load is the responsibility of the
transport contractor and driver. Any machine,
attachments or parts that may move during transit must
be adequately secured.
5-2-5-9
Note: Before transporting the machine make sure you will
be obeying the rules and laws of all the areas that the
machine will be carried through.
Make sure that the transporting vehicle is suitable. See
Static Dimensions(SPECIFICATIONS section in the
machine handbook) for the dimensions of the machine.
!WARNING
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 SPECIFICATIONSsection for the
minimum ground clearance of your machine.
2-2-7-5/1
1Place blocks at the front and rear of the trailer wheels.
2Move the machine on to the trailer as follows:
aMake sure the ramps are correctly in place and
secure.
bCarefully drive the machine onto the trailer.
cSet the drive to neutral and engage the parking
brake.
dSwitch off the engine.
eEnsure that the overall height of the load is within
regulations.
fSecure the cab.
3Anchor the machine to the trailer with chains or suitable
webbing straps. The preferred fixing is to use webbing
straps individually fixing all four wheels to the deck of
the trailer as at A. If chains are used they should be
connected to a suitable part of the drawbar at the rear
of the machine. At the front, use the tie down points.
Avoid chaining any part of the machine where the
chains may damage critical componentry. For example,
chaining around either axle provides the possibility of
damaging the steel brake pipes running along their
length.
4Measure the maximum height of the machine from the
ground. Try to make sure the truck driver knows the
clearance height before he drives away.
Section 1 General Information
9803/8020
Section 1
10 - 2
Issue 1
A288080
AA
Transporting the Machine
The safe transit of the load is the responsibility of the
transport contractor and driver. Any machine,
attachments or parts that may move during transit must
be adequately secured.
5-2-5-9
Note: Before transporting the machine make sure you will
be obeying the rules and laws of all the areas that the
machine will be carried through.
Make sure that the transporting vehicle is suitable. See
Static Dimensions(SPECIFICATIONS section in the
machine handbook) for the dimensions of the machine.
!WARNING
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 SPECIFICATIONSsection for the
minimum ground clearance of your machine.
2-2-7-5/1
1Place blocks at the front and rear of the trailer wheels.
2Move the machine on to the trailer as follows:
aMake sure the ramps are correctly in place and
secure.
bCarefully drive the machine onto the trailer.
cSet the drive to neutral and engage the parking
brake.
dSwitch off the engine.
eEnsure that the overall height of the load is within
regulations.
fSecure the cab.
3Anchor the machine to the trailer with chains or suitable
webbing straps. The preferred fixing is to use webbing
straps individually fixing all four wheels to the deck of
the trailer as at A. If chains are used they should be
connected to a suitable part of the drawbar at the rear
of the machine. At the front, use the tie down points.
Avoid chaining any part of the machine where the
chains may damage critical componentry. For example,
chaining around either axle provides the possibility of
damaging the steel brake pipes running along their
length.
4Measure the maximum height of the machine from the
ground. Try to make sure the truck driver knows the
clearance height before he drives away.
Section 1 General Information
9803/8020
Section 1
10 - 2
Issue 1
A288080
AA
i
Section 2 Care & Safety
9803/8020
Section 2
i
Issue 1
Contents Page No.
Safety Notices 1 - 1
General Safety 2 - 1
Operating Safety 3 - 1
Maintenance Safety 4 - 1
Section 2 Care & Safety
9803/8020
Section 2
i
Issue 1
Contents Page No.
Safety Notices 1 - 1
General Safety 2 - 1
Operating Safety 3 - 1
Maintenance Safety 4 - 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
Section 2 Care & Safety
9803/8020
Section 2
1 - 1
Issue 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
Section 2 Care & Safety
9803/8020
Section 2
1 - 1
Issue 1
2 - 1
Section 2 Care & Safety
9803/8020
Section 2
2 - 1
Issue 1
All construction and agricultural equipment can be
hazardous. When a JCB Fastrac is correctly operated and
properly maintained, it is a safe machine to work with. But
when it is carelessly operated or poorly maintained it can
become a danger to you (the operator) and others.
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
Lifting Equipment
You can be injured if you use faulty lifting equipment. Make
sure that lifting equipment is in good condition. Make sure
that lifting tackle complies with all local regulations and is
suitable for the job. Make sure that lifting equipment is
strong enough for the job.
INT-1-3-7
!!WARNING
Clothing
You can be injured if you do not wear the proper clothing.
Loose clothing can get caught in the machinery. Wear
protective clothing to suit the job. Examples of protective
clothing are: a hard hat, safety shoes, safety glasses, a well
fitting overall, ear-protectors and industrial gloves. Keep
cuffs fastened. Do not wear a necktie or scarf. Keep long
hair restrained.
INT-1-3-6
!!WARNING
Alcohol and Drugs
It is extremely dangerous to operate machinery when under
the influence of alcohol or drugs. Do not consume alcoholic
drinks or take drugs before or whilst operating the machine
or attachments. Be aware of medicines which can cause
drowsiness.
INT-1-3-9
Note: This section includes a certain amount of operating
safety information. But remember that whenever you drive
the machine or operate its controls you are in effect a
machine operator. Therefore you should read and
understand the information given in the Operator Handbook
before driving the machine or operating its controls.
!!WARNING
Care and Alertness
All the time you are working with or on the machine, take
care and stay alert. Always be careful. Always be alert for
hazards.
INT-1-3-5
!!WARNING
Raised Equipment
Raised equipment can fall and injure you. Do not walk or
work under raised equipment unless safely supported.
13-1-1-6
!!WARNING
Machine Modifications
This machine is manufactured in compliance with legislative
and other requirements. It should not be altered in any way
which could affect or invalidate any of these requirements.
For advice consult your JCB Distributor.
Reference should also be made to Optional Attachments
section where appropriate.
INT-1-3-10
Section 2 Care & Safety
9803/8020
Section 2
2 - 1
Issue 1
All construction and agricultural equipment can be
hazardous. When a JCB Fastrac is correctly operated and
properly maintained, it is a safe machine to work with. But
when it is carelessly operated or poorly maintained it can
become a danger to you (the operator) and others.
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
Lifting Equipment
You can be injured if you use faulty lifting equipment. Make
sure that lifting equipment is in good condition. Make sure
that lifting tackle complies with all local regulations and is
suitable for the job. Make sure that lifting equipment is
strong enough for the job.
INT-1-3-7
!!WARNING
Clothing
You can be injured if you do not wear the proper clothing.
Loose clothing can get caught in the machinery. Wear
protective clothing to suit the job. Examples of protective
clothing are: a hard hat, safety shoes, safety glasses, a well
fitting overall, ear-protectors and industrial gloves. Keep
cuffs fastened. Do not wear a necktie or scarf. Keep long
hair restrained.
INT-1-3-6
!!WARNING
Alcohol and Drugs
It is extremely dangerous to operate machinery when under
the influence of alcohol or drugs. Do not consume alcoholic
drinks or take drugs before or whilst operating the machine
or attachments. Be aware of medicines which can cause
drowsiness.
INT-1-3-9
Note: This section includes a certain amount of operating
safety information. But remember that whenever you drive
the machine or operate its controls you are in effect a
machine operator. Therefore you should read and
understand the information given in the Operator Handbook
before driving the machine or operating its controls.
!!WARNING
Care and Alertness
All the time you are working with or on the machine, take
care and stay alert. Always be careful. Always be alert for
hazards.
INT-1-3-5
!!WARNING
Raised Equipment
Raised equipment can fall and injure you. Do not walk or
work under raised equipment unless safely supported.
13-1-1-6
!!WARNING
Machine Modifications
This machine is manufactured in compliance with legislative
and other requirements. It should not be altered in any way
which could affect or invalidate any of these requirements.
For advice consult your JCB Distributor.
Reference should also be made to Optional Attachments
section where appropriate.
INT-1-3-10
3 - 1
Operating Safety
!!
DANGER
Parking
Leaving the machine in gear will not prevent it running away.
Do not leave the driving seat under any circumstances
unless the parking brake is on.
13-2-1-10
!!WARNING
Roll Over Protection Structure (ROPS)
The machine is fitted with a Roll Over Protection Structure
(ROPS). You could be killed or seriously injured if you
operate the machine with a damaged or missing ROPS. If
the ROPS has been in an accident, do not use the machine
until the structure has been renewed. Modifications and
repairs that are not approved by the manufacturer may be
dangerous and will invalidate the ROPS certification.
13-1-1-8/1
!!WARNING
Entering/Leaving
Always face the machine when entering and leaving the cab.
Use the step(s) and handrails. Make sure the step(s),
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.
INT-2-1-7
!!WARNING
Seat
Position the seat so that you can comfortably reach the
machine controls. You could have an accident if you operate
the machine with the seat in the wrong position.
INT-3-3-5
!!WARNING
Seat Belt
Operating the machine without a seat belt can be
dangerous. Before starting the engine, make sure your seat
belt is fastened. Check the tightness and condition of the
seat belt securing bolts regularly (see maintenance
schedules).
INT 2 -1-8/1
!!WARNING
Passengers
Ensure that passengers use the seat provided in the cab.
Passengers must not be carried on the rear deck of the
vehicle under any circumstances.
13-1-1-1/1
!!WARNING
Reversing
Reversing at high speeds can cause accidents. Always drive
at a safe speed to suit working conditions
13-1-1-3
!!WARNING
Visibility
Accidents can be caused by working in poor visibility. Keep
windows clean and use your lights to improve visibility. Do
not operate the machine if you cannot see properly.
INT-2-1-11
!!WARNING
Practice
You or others can be killed or seriously injured if you do
unfamiliar operations without first practising them. Practise
away from the work site on a clear area. Keep other people
away. Do not perform new operations until you are sure you
can do them safely.
INT-2-1-1
!!WARNING
Machine Limits
Operating the machine beyond its design limits can damage
the machine, it can also be dangerous. Do not operate the
machine outside its limits. Do not try to upgrade the
machine performance with unapproved modifications.
INT-2-1-4
!!WARNING
Brakes
Do not coast the machine with the engine stopped as the
main brakes will only operate for a limited number of
applications and hydraulic trailer brakes will not function at
all. Also the steering will become very heavy.
13-1-1-5/2
!!CAUTION
Hydraulic Trailer Brakes
Trailers with single line hydraulic brakes used in the United
Kingdom are subject to a maximum speed of 20 mph (32
kph).
13-2-2-8
!!CAUTION
Trailer Brakes
Trailers with single line air brakes used in the Republic of
Germany are subject to a maximum speed of 25 km/h (15
mph).
13-2-2-13
!!WARNING
Engine
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
Section 2 Care & Safety
9803/8020
Section 2
3 - 1
Issue 1
Operating Safety
!!
DANGER
Parking
Leaving the machine in gear will not prevent it running away.
Do not leave the driving seat under any circumstances
unless the parking brake is on.
13-2-1-10
!!WARNING
Roll Over Protection Structure (ROPS)
The machine is fitted with a Roll Over Protection Structure
(ROPS). You could be killed or seriously injured if you
operate the machine with a damaged or missing ROPS. If
the ROPS has been in an accident, do not use the machine
until the structure has been renewed. Modifications and
repairs that are not approved by the manufacturer may be
dangerous and will invalidate the ROPS certification.
13-1-1-8/1
!!WARNING
Entering/Leaving
Always face the machine when entering and leaving the cab.
Use the step(s) and handrails. Make sure the step(s),
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.
INT-2-1-7
!!WARNING
Seat
Position the seat so that you can comfortably reach the
machine controls. You could have an accident if you operate
the machine with the seat in the wrong position.
INT-3-3-5
!!WARNING
Seat Belt
Operating the machine without a seat belt can be
dangerous. Before starting the engine, make sure your seat
belt is fastened. Check the tightness and condition of the
seat belt securing bolts regularly (see maintenance
schedules).
INT 2 -1-8/1
!!WARNING
Passengers
Ensure that passengers use the seat provided in the cab.
Passengers must not be carried on the rear deck of the
vehicle under any circumstances.
13-1-1-1/1
!!WARNING
Reversing
Reversing at high speeds can cause accidents. Always drive
at a safe speed to suit working conditions
13-1-1-3
!!WARNING
Visibility
Accidents can be caused by working in poor visibility. Keep
windows clean and use your lights to improve visibility. Do
not operate the machine if you cannot see properly.
INT-2-1-11
!!WARNING
Practice
You or others can be killed or seriously injured if you do
unfamiliar operations without first practising them. Practise
away from the work site on a clear area. Keep other people
away. Do not perform new operations until you are sure you
can do them safely.
INT-2-1-1
!!WARNING
Machine Limits
Operating the machine beyond its design limits can damage
the machine, it can also be dangerous. Do not operate the
machine outside its limits. Do not try to upgrade the
machine performance with unapproved modifications.
INT-2-1-4
!!WARNING
Brakes
Do not coast the machine with the engine stopped as the
main brakes will only operate for a limited number of
applications and hydraulic trailer brakes will not function at
all. Also the steering will become very heavy.
13-1-1-5/2
!!CAUTION
Hydraulic Trailer Brakes
Trailers with single line hydraulic brakes used in the United
Kingdom are subject to a maximum speed of 20 mph (32
kph).
13-2-2-8
!!CAUTION
Trailer Brakes
Trailers with single line air brakes used in the Republic of
Germany are subject to a maximum speed of 25 km/h (15
mph).
13-2-2-13
!!WARNING
Engine
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
Section 2 Care & Safety
9803/8020
Section 2
3 - 1
Issue 1
3 - 2
Operating Safety (cont'd)
!!WARNING
Banks and Trenches
Banked material and trenches can collapse. Do not work or
drive too close to banks and trenches where there is danger
of collapse.
INT-2-2-5
!!WARNING
Ramps and Trailers
Water, mud, ice, grease and oil on ramps or trailers can
cause serious accidents. Make sure ramps and trailers are
clean before driving onto them. Use extreme caution when
driving onto ramps and trailers.
INT-2-2-6
!!WARNING
Communications
Bad communications can cause accidents. Keep people
around you informed of what you will be doing. If you will be
working with other people, make sure any hand signals that
may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands.
INT-2-2-3
!!WARNING
Engine/Steering Failure
If the engine or steering fails, stop the machine as quickly as
possible. Do not operate the machine until the fault has been
corrected.
INT-2-1-5
!!DANGER
Sparks
Explosions and fire can be caused by sparks from the
exhaust or the electrical system. Do not use the machine in
closed areas where there is flammable material, vapour or
dust.
INT-2-2-10
!!WARNING
Controls
Keep the machine controls clean and dry. Your hands and
feet could slide off slippery controls. If that happens you will
lose control of the machine.
2-2-3-6
!!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
!!WARNING
Power Take-off Operation
When operating PTO equipment, always observe the
following safety precautions:
Follow the instructions in the implement operator's
handbook.
Rotating equipment is dangerous. Do not wear loose fitting
clothing when working close to rotating shafts.
Always disengage the PTO, stop the engine and wait until
the equipment stops, before:
1 Leaving the cab
2 Attempting to attach or detach an implement to or from
a PTO shaft or
3 Working on or cleaning an implement connected to the
machine via a PTO shaft.
Always ensure that the PTO shaft and driveline are fully
guarded before use.
When using stationary PTO equipment, ensure that the
parking brake is applied.
13-2-1-6
!!WARNING
Power Take-off Jamming
If the PTO becomes jammed, disengage the PTO, stop the
engine and clear the blockage. Wait until the PTO shaft
stops before working on the equipment. If the PTO clutch
slips, immediately disengage the PTO and stop the engine.
13-2-2-2
!!WARNING
Hitching Trailers and Equipment
When the vehicle is approaching a trailer or equipment to be
hitched, make sure that no persons are present between
vehicle and trailer or equipment. When mounting equipment
at the rear of the vehicle, you must ensure that proper
steering control is maintained. The machine must never be
loaded such that less than 20% of the vehicle weight is
carried on the front axle.
13-1-1-13/1
Section 2 Care & Safety
9803/8020
Section 2
3 - 2
Issue 2*
*
Operating Safety (cont'd)
!!WARNING
Banks and Trenches
Banked material and trenches can collapse. Do not work or
drive too close to banks and trenches where there is danger
of collapse.
INT-2-2-5
!!WARNING
Ramps and Trailers
Water, mud, ice, grease and oil on ramps or trailers can
cause serious accidents. Make sure ramps and trailers are
clean before driving onto them. Use extreme caution when
driving onto ramps and trailers.
INT-2-2-6
!!WARNING
Communications
Bad communications can cause accidents. Keep people
around you informed of what you will be doing. If you will be
working with other people, make sure any hand signals that
may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands.
INT-2-2-3
!!WARNING
Engine/Steering Failure
If the engine or steering fails, stop the machine as quickly as
possible. Do not operate the machine until the fault has been
corrected.
INT-2-1-5
!!DANGER
Sparks
Explosions and fire can be caused by sparks from the
exhaust or the electrical system. Do not use the machine in
closed areas where there is flammable material, vapour or
dust.
INT-2-2-10
!!WARNING
Controls
Keep the machine controls clean and dry. Your hands and
feet could slide off slippery controls. If that happens you will
lose control of the machine.
2-2-3-6
!!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
!!WARNING
Power Take-off Operation
When operating PTO equipment, always observe the
following safety precautions:
Follow the instructions in the implement operator's
handbook.
Rotating equipment is dangerous. Do not wear loose fitting
clothing when working close to rotating shafts.
Always disengage the PTO, stop the engine and wait until
the equipment stops, before:
1 Leaving the cab
2 Attempting to attach or detach an implement to or from
a PTO shaft or
3 Working on or cleaning an implement connected to the
machine via a PTO shaft.
Always ensure that the PTO shaft and driveline are fully
guarded before use.
When using stationary PTO equipment, ensure that the
parking brake is applied.
13-2-1-6
!!WARNING
Power Take-off Jamming
If the PTO becomes jammed, disengage the PTO, stop the
engine and clear the blockage. Wait until the PTO shaft
stops before working on the equipment. If the PTO clutch
slips, immediately disengage the PTO and stop the engine.
13-2-2-2
!!WARNING
Hitching Trailers and Equipment
When the vehicle is approaching a trailer or equipment to be
hitched, make sure that no persons are present between
vehicle and trailer or equipment. When mounting equipment
at the rear of the vehicle, you must ensure that proper
steering control is maintained. The machine must never be
loaded such that less than 20% of the vehicle weight is
carried on the front axle.
13-1-1-13/1
Section 2 Care & Safety
9803/8020
Section 2
3 - 2
Issue 2*
*
3 - 3
Operating Safety (cont'd)
!!WARNING
Tyres - General
You could be killed or injured if a machine tyre bursts. Do
not use the machine with damaged, incorrectly inflated or
excessively worn tyres. Recognize the speed limitation of
the tyres fitted and do not operate at more than their
recommended maximum speed.
13-2-1-2
!!WARNING
Certain tyres fitted as after-market equipment may have
maximum permitted speeds below the maximum speed of
the vehicle. Brake efficiency is slightly reduced and stopping
distance is increased when these tyres are fitted. They will
suffer damage if operated at speeds higher than those
recommended and may endanger life.
13-3-2-5
!!WARNING
Tyre Speed Limitations
Running tyres outside recommended guidelines may result
in failure of the tyres which at high speeds may endanger
life. BE WARNED.
13-3-1-6
!!WARNING
Rear Deck
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
or toppling over.
13-1-1-12/1
!!WARNING
Weight Distribution
The machine must never be loaded such that less than 20%
of the vehicle weight is carried on the front axle.
13-1-1-11/1
!!CAUTION
Weight Distribution
The Fastrac has to comply with certain braking regulations
which in some countries control weight distribution between
front and rear axles. Travelling on the road with implements
or weights carried on the front when no implement is on the
rear may break the law. In this case you should transfer the
front mounted equipment to the rear linkage. It is the
operator's responsibility to know and observe the laws in the
country concerned.
13-2-2-5
!!WARNING
Travel Speed
Be aware of the load the machine is carrying or towing and
the speed at which you are travelling. Do not corner fast
when carrying heavy mounted implements or towing trailers.
Reduce speed when towing non-suspended implements on
rough ground.
13-2-2-1
!!WARNING
Stability
In the event of the machine becoming unstable, keep firm
hold of the steering wheel and do not try to leave the cab.
13-2-2-10
!!WARNING
Audible Warnings
When you hear an audible warning, stop the machine as
soon as possible. Get the fault put right before using the
machine again.
13-2-1-9
!!WARNING
Controls
When driving the machine on the road, use the accelerator
pedal and not the hand throttle to control the engine speed.
Always set the hand throttle to ‘idle’ before using the
accelerator pedal.
13-2-1-8/1
!!WARNING
Safe Working Loads
Overloading the machine can damage it and make it
unstable. Study the specifications before loading, towing or
using implements.
13-1-1-4/1
!!DANGER
The JCB Fastrac is capable of operating at high speeds.
Implements or trailers you tow behind the Fastrac may not
be designed for high speed operation. BE AWARE of the
manufacturers specified maximum speed rating for any
trailers or implements that you tow behind the Fastrac. DO
NOT EXCEED THE MAXIMUM DESIGN SPEED OF
TRAILERS OR IMPLEMENTS AS INJURY OR
DEATH MAY RESULT.
13-2-3-5
!!WARNING
Cab Air Filter
The cab air filter is designed to remove dirt from the outside
air. When using chemicals (e.g. for crop spraying) follow the
chemical manufacturer’s recommendations for protection
from dangerous chemicals.
13-2-3-6
!!WARNING
Hazardous Atmospheres
This machine is designed for use in normal out door
atmospheric conditions. It should not be used in an
enclosed area without adequate ventilation. Do not use the
machine in a potentially explosive atmosphere, i.e.
combustible vapours, gas or dust, without first consulting
your JCB Distributor.
INT-2-1-14
Section 2 Care & Safety
9803/8020
Section 2
3 - 3
Issue 2*
*
*
*
Operating Safety (cont'd)
!!WARNING
Tyres - General
You could be killed or injured if a machine tyre bursts. Do
not use the machine with damaged, incorrectly inflated or
excessively worn tyres. Recognize the speed limitation of
the tyres fitted and do not operate at more than their
recommended maximum speed.
13-2-1-2
!!WARNING
Certain tyres fitted as after-market equipment may have
maximum permitted speeds below the maximum speed of
the vehicle. Brake efficiency is slightly reduced and stopping
distance is increased when these tyres are fitted. They will
suffer damage if operated at speeds higher than those
recommended and may endanger life.
13-3-2-5
!!WARNING
Tyre Speed Limitations
Running tyres outside recommended guidelines may result
in failure of the tyres which at high speeds may endanger
life. BE WARNED.
13-3-1-6
!!WARNING
Rear Deck
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
or toppling over.
13-1-1-12/1
!!WARNING
Weight Distribution
The machine must never be loaded such that less than 20%
of the vehicle weight is carried on the front axle.
13-1-1-11/1
!!CAUTION
Weight Distribution
The Fastrac has to comply with certain braking regulations
which in some countries control weight distribution between
front and rear axles. Travelling on the road with implements
or weights carried on the front when no implement is on the
rear may break the law. In this case you should transfer the
front mounted equipment to the rear linkage. It is the
operator's responsibility to know and observe the laws in the
country concerned.
13-2-2-5
!!WARNING
Travel Speed
Be aware of the load the machine is carrying or towing and
the speed at which you are travelling. Do not corner fast
when carrying heavy mounted implements or towing trailers.
Reduce speed when towing non-suspended implements on
rough ground.
13-2-2-1
!!WARNING
Stability
In the event of the machine becoming unstable, keep firm
hold of the steering wheel and do not try to leave the cab.
13-2-2-10
!!WARNING
Audible Warnings
When you hear an audible warning, stop the machine as
soon as possible. Get the fault put right before using the
machine again.
13-2-1-9
!!WARNING
Controls
When driving the machine on the road, use the accelerator
pedal and not the hand throttle to control the engine speed.
Always set the hand throttle to ‘idle’ before using the
accelerator pedal.
13-2-1-8/1
!!WARNING
Safe Working Loads
Overloading the machine can damage it and make it
unstable. Study the specifications before loading, towing or
using implements.
13-1-1-4/1
!!DANGER
The JCB Fastrac is capable of operating at high speeds.
Implements or trailers you tow behind the Fastrac may not
be designed for high speed operation. BE AWARE of the
manufacturers specified maximum speed rating for any
trailers or implements that you tow behind the Fastrac. DO
NOT EXCEED THE MAXIMUM DESIGN SPEED OF
TRAILERS OR IMPLEMENTS AS INJURY OR
DEATH MAY RESULT.
13-2-3-5
!!WARNING
Cab Air Filter
The cab air filter is designed to remove dirt from the outside
air. When using chemicals (e.g. for crop spraying) follow the
chemical manufacturer’s recommendations for protection
from dangerous chemicals.
13-2-3-6
!!WARNING
Hazardous Atmospheres
This machine is designed for use in normal out door
atmospheric conditions. It should not be used in an
enclosed area without adequate ventilation. Do not use the
machine in a potentially explosive atmosphere, i.e.
combustible vapours, gas or dust, without first consulting
your JCB Distributor.
INT-2-1-14
Section 2 Care & Safety
9803/8020
Section 2
3 - 3
Issue 2*
*
*
*
4 - 1
Maintenance Safety
!!WARNING
Working Under the Machine
Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking brake.
Lower any mounted implements to the ground. Stop the
engine, remove the starter key, disconnect the battery.
Chock the wheels.
13-3-1-1
!!WARNING
Soft Ground
A machine can sink into soft ground. Never work under a
machine on soft ground.
INT-3-2-4
!!WARNING
Jacking
A machine can roll off jacks and crush you unless the wheels
have been chocked. Always chock the wheels at the
opposite end of the machine to that which is to be jacked.
Do not work underneath a machine supported only by jacks.
Always support a jacked-up machine on axle stands before
working underneath it.
INT-3-2-8
!!WARNING
Transmission Testing
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
wheels are off the ground and supported by axle stands as if
only the rear wheels were raised, the machine could still
drive through the front axle. Note that when a NoSpin
differential is fitted, both front wheels will be driven even if
one is jacked up and the other is on the ground.
TRAN 8-1/2
!!WARNING
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from the
machine. Do not smoke while refuelling the machine or
working on the engine. Do not refuel with the engine
running. There could be a fire and injury if you do not follow
these precautions.
INT-3-2-2
!!WARNING
Petrol
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
form flammable vapours.
INT-3-1-6
!!WARNING
Battery
A battery with frozen electrolyte can explode if it is used or
charged. Do not use a machine with a frozen battery. To
help prevent the battery from freezing, keep the battery fully
charged.
INT-3-1-7
!!WARNING
Battery Gases
Batteries give off explosive gases. Keep flames and sparks
away from the battery. Do not smoke close to the battery.
Make sure there is good ventilation in closed areas where
batteries are being used or charged. Do not check the
battery charge by shorting the terminals with metal; use a
hydrometer or voltmeter.
INT-3-1-8
!!WARNING
Battery Terminals
The machine is negatively earthed. Always connect the
negative pole of the battery to earth.
When connecting the battery, connect the earth (-) lead last.
When disconnecting the battery, disconnect the earth (-)
lead first.
INT-3-1-9
!!WARNING
Electrical Circuits
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong connection
can cause injury and/or damage.
INT-3-1-4
!!WARNING
Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the
hoses regularly for:
Damaged end fittings
Chafed outer covers
Ballooned outer covers
Kinked or crushed hoses
Embedded armouring in outer covers
Displaced end fittings.
INT-3-3-2
!!WARNING
Rams
The efficiency of the rams will be affected if they are not
kept free of solidified dirt. Clean dirt from around the rams
regularly. When leaving or parking the machine, close all
rams if possible to reduce the risk of weather corrosion.
INT-3-2-10
Section 2 Care & Safety
9803/8020
Section 2
4 - 1
Issue 1
Maintenance Safety
!!WARNING
Working Under the Machine
Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking brake.
Lower any mounted implements to the ground. Stop the
engine, remove the starter key, disconnect the battery.
Chock the wheels.
13-3-1-1
!!WARNING
Soft Ground
A machine can sink into soft ground. Never work under a
machine on soft ground.
INT-3-2-4
!!WARNING
Jacking
A machine can roll off jacks and crush you unless the wheels
have been chocked. Always chock the wheels at the
opposite end of the machine to that which is to be jacked.
Do not work underneath a machine supported only by jacks.
Always support a jacked-up machine on axle stands before
working underneath it.
INT-3-2-8
!!WARNING
Transmission Testing
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
wheels are off the ground and supported by axle stands as if
only the rear wheels were raised, the machine could still
drive through the front axle. Note that when a NoSpin
differential is fitted, both front wheels will be driven even if
one is jacked up and the other is on the ground.
TRAN 8-1/2
!!WARNING
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from the
machine. Do not smoke while refuelling the machine or
working on the engine. Do not refuel with the engine
running. There could be a fire and injury if you do not follow
these precautions.
INT-3-2-2
!!WARNING
Petrol
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
form flammable vapours.
INT-3-1-6
!!WARNING
Battery
A battery with frozen electrolyte can explode if it is used or
charged. Do not use a machine with a frozen battery. To
help prevent the battery from freezing, keep the battery fully
charged.
INT-3-1-7
!!WARNING
Battery Gases
Batteries give off explosive gases. Keep flames and sparks
away from the battery. Do not smoke close to the battery.
Make sure there is good ventilation in closed areas where
batteries are being used or charged. Do not check the
battery charge by shorting the terminals with metal; use a
hydrometer or voltmeter.
INT-3-1-8
!!WARNING
Battery Terminals
The machine is negatively earthed. Always connect the
negative pole of the battery to earth.
When connecting the battery, connect the earth (-) lead last.
When disconnecting the battery, disconnect the earth (-)
lead first.
INT-3-1-9
!!WARNING
Electrical Circuits
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong connection
can cause injury and/or damage.
INT-3-1-4
!!WARNING
Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the
hoses regularly for:
Damaged end fittings
Chafed outer covers
Ballooned outer covers
Kinked or crushed hoses
Embedded armouring in outer covers
Displaced end fittings.
INT-3-3-2
!!WARNING
Rams
The efficiency of the rams will be affected if they are not
kept free of solidified dirt. Clean dirt from around the rams
regularly. When leaving or parking the machine, close all
rams if possible to reduce the risk of weather corrosion.
INT-3-2-10
Section 2 Care & Safety
9803/8020
Section 2
4 - 1
Issue 1
4 - 2
Maintenance Safety (cont'd)
!!WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure trapped
in the hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11/2
!!WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate the
skin. Do not use your fingers to check for hydraulic fluid
leaks. Do not put your face close to suspected leaks. Hold a
piece of cardboard close to suspected leaks and then
inspect the cardboard for signs of hydraulic fluid. If hydraulic
fluid penetrates your skin, get medical help immediately.
INT-3-1-10/1
!!WARNING
Oil
Oil is toxic. If you swallow any oil, do not induce vomiting,
seek medical advice. Used engine oil contains harmful
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
not use petrol, diesel fuel or paraffin to clean your skin.
INT-3-2-3
!!WARNING
Hot Coolant
The cooling system is pressurised when the engine is hot.
Hot coolant can spray out when you remove the radiator
cap. Let the system cool before removing the radiator cap.
To remove the cap; turn it to the first notch and let the
system pressure escape, then remove the cap.
INT-3-2-9
!!WARNING
Wheels
Wheels are heavy. Handle and store with care to ensure that
they cannot fall and cause injury.
13-3-1-7
!!WARNING
Metal Splinters
You can be injured by flying metal splinters when driving
metal pins in or out. Use a soft faced hammer or drift to
remove and fit metal pins. Always wear safety glasses.
INT-3-1-3
!!WARNING
Always wear safety glasses when dismantling assemblies
containing components under pressure from springs. This
will protect against eye injury from components accidentally
flying out.
GEN 6-2
!!WARNING
Communications
Bad communications can cause accidents. If two or more
people are working on the machine, make sure each is
aware of what the others are doing. Before starting the
engine make sure the others are clear of the danger areas;
examples of danger areas are: the rotating blades and belt
on the engine, the attachments and linkages, and anywhere
beneath or behind the machine. People can be killed or
injured if these precautions are not taken.
INT-3-1-5
!!WARNING
Cleaning
Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents and
solvents.
INT-3-2-11
!!WARNING
'O' rings, Seals and Gaskets
Badly fitted, damaged or rotted 'O' rings, seals and gaskets
can cause leakages and possible accidents. Renew
whenever disturbed unless otherwise instructed. Do not use
Trichloroethane or paint thinners near 'O' rings and seals.
INT-3-2-12
!!WARNING
Clutch Fluid
Do not use ordinary hydraulic fluid in the clutch system.
13-3-2-4
!!WARNING
Welding and Modifications
To prevent the possibility of damage to electronic
components, disconnect the battery and withdraw the plug
from the electronic draft control unit before arc-welding on
the machine or attached implements.
Parts of the machine are made from cast iron; welds on cast
iron can weaken the structure and break. Do not weld cast
iron. On no account weld or drill the chassis structure. Non-
approved modifications can cause injury and damage.
Contact JCB before modifying the machine.
GEN 8-1
!!WARNING
Protect your eyes when grinding metal. Wear safety glasses
or goggles. Remove or protect any combustible materials
from the area which could be ignited by sparks.
GEN-1-12
!!WARNING
Radar Speed Sensor (if fitted)
To avoid possible eye damage from microwave signals, do
not look directly into the sensor face.
13-1-1-15
Note: The radar speed sensor is located underneath the
machine.
Section 2 Care & Safety
9803/8020
Section 2
4 - 2
Issue 2*
*
Maintenance Safety (cont'd)
!!WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure trapped
in the hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11/2
!!WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate the
skin. Do not use your fingers to check for hydraulic fluid
leaks. Do not put your face close to suspected leaks. Hold a
piece of cardboard close to suspected leaks and then
inspect the cardboard for signs of hydraulic fluid. If hydraulic
fluid penetrates your skin, get medical help immediately.
INT-3-1-10/1
!!WARNING
Oil
Oil is toxic. If you swallow any oil, do not induce vomiting,
seek medical advice. Used engine oil contains harmful
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
not use petrol, diesel fuel or paraffin to clean your skin.
INT-3-2-3
!!WARNING
Hot Coolant
The cooling system is pressurised when the engine is hot.
Hot coolant can spray out when you remove the radiator
cap. Let the system cool before removing the radiator cap.
To remove the cap; turn it to the first notch and let the
system pressure escape, then remove the cap.
INT-3-2-9
!!WARNING
Wheels
Wheels are heavy. Handle and store with care to ensure that
they cannot fall and cause injury.
13-3-1-7
!!WARNING
Metal Splinters
You can be injured by flying metal splinters when driving
metal pins in or out. Use a soft faced hammer or drift to
remove and fit metal pins. Always wear safety glasses.
INT-3-1-3
!!WARNING
Always wear safety glasses when dismantling assemblies
containing components under pressure from springs. This
will protect against eye injury from components accidentally
flying out.
GEN 6-2
!!WARNING
Communications
Bad communications can cause accidents. If two or more
people are working on the machine, make sure each is
aware of what the others are doing. Before starting the
engine make sure the others are clear of the danger areas;
examples of danger areas are: the rotating blades and belt
on the engine, the attachments and linkages, and anywhere
beneath or behind the machine. People can be killed or
injured if these precautions are not taken.
INT-3-1-5
!!WARNING
Cleaning
Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents and
solvents.
INT-3-2-11
!!WARNING
'O' rings, Seals and Gaskets
Badly fitted, damaged or rotted 'O' rings, seals and gaskets
can cause leakages and possible accidents. Renew
whenever disturbed unless otherwise instructed. Do not use
Trichloroethane or paint thinners near 'O' rings and seals.
INT-3-2-12
!!WARNING
Clutch Fluid
Do not use ordinary hydraulic fluid in the clutch system.
13-3-2-4
!!WARNING
Welding and Modifications
To prevent the possibility of damage to electronic
components, disconnect the battery and withdraw the plug
from the electronic draft control unit before arc-welding on
the machine or attached implements.
Parts of the machine are made from cast iron; welds on cast
iron can weaken the structure and break. Do not weld cast
iron. On no account weld or drill the chassis structure. Non-
approved modifications can cause injury and damage.
Contact JCB before modifying the machine.
GEN 8-1
!!WARNING
Protect your eyes when grinding metal. Wear safety glasses
or goggles. Remove or protect any combustible materials
from the area which could be ignited by sparks.
GEN-1-12
!!WARNING
Radar Speed Sensor (if fitted)
To avoid possible eye damage from microwave signals, do
not look directly into the sensor face.
13-1-1-15
Note: The radar speed sensor is located underneath the
machine.
Section 2 Care & Safety
9803/8020
Section 2
4 - 2
Issue 2*
*
4 - 3
Maintenance Safety (cont'd)
!!WARNING
Fluoroelastomeric Materials
Certain seals and gaskets (e.g. crankshaft oil seal) on JCB
machines contain fluoroelastomeric materials such as Viton,
Fluorel and Technoflon. Fluoroelastomeric materials
subjected to high temperatures can produce highly corrosive
hydrofluoric acid. THIS ACID CAN SEVERELY BURN.
New fluoroelastomeric components at ambient temperature
require no special safety precautions.
Used fluoroelastomeric components whose temperatures
have not exceeded 300°C require no special safety
precautions. If evidence of decomposition (e.g. charring) is
found, refer to the next paragraph for safety instructions DO
NOT TOUCH COMPONENT OR SURROUNDING AREA.
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
heavy duty gloves and special safety glasses are worn:
1 Ensure that components have cooled then remove and
place material in plastic bags.
2 Thoroughly wash contaminated area with 10% calcium
hydroxide or other suitable alkali solution, if necessary
use wire wool to remove burnt remains.
3 Thoroughly wash contaminated area with detergent and
water.
4 Contain all removed material, gloves etc used in this
operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations.
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
If contamination of skin or eyes occurs, wash the affected
area with a continuous supply of clean water or with calcium
hydroxide solution for 16-60 minutes. Get medical attention
immediately.
INT - 3 - 3 - 5/1
!!WARNING
Brake Pads
Always renew brake pads and locating pins in complete axle
sets, using genuine JCB parts, otherwise braking will be
unsafe.
13-3-1-10
!!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
!!WARNING
ABS
Upon completion of any work done on the brake system of
machines fitted with ABS, the ABS test within Servicemaster
must be run satisfactorily before the machine is driven. It is
not sufficient to rely on the ABS self-check which can only
check for presence of components, not that they are
correctly installed.
0091
Section 2 Care & Safety
9803/8020
Section 2
4 - 3
Issue 2*
*
Maintenance Safety (cont'd)
!!WARNING
Fluoroelastomeric Materials
Certain seals and gaskets (e.g. crankshaft oil seal) on JCB
machines contain fluoroelastomeric materials such as Viton,
Fluorel and Technoflon. Fluoroelastomeric materials
subjected to high temperatures can produce highly corrosive
hydrofluoric acid. THIS ACID CAN SEVERELY BURN.
New fluoroelastomeric components at ambient temperature
require no special safety precautions.
Used fluoroelastomeric components whose temperatures
have not exceeded 300°C require no special safety
precautions. If evidence of decomposition (e.g. charring) is
found, refer to the next paragraph for safety instructions DO
NOT TOUCH COMPONENT OR SURROUNDING AREA.
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
heavy duty gloves and special safety glasses are worn:
1 Ensure that components have cooled then remove and
place material in plastic bags.
2 Thoroughly wash contaminated area with 10% calcium
hydroxide or other suitable alkali solution, if necessary
use wire wool to remove burnt remains.
3 Thoroughly wash contaminated area with detergent and
water.
4 Contain all removed material, gloves etc used in this
operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations.
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
If contamination of skin or eyes occurs, wash the affected
area with a continuous supply of clean water or with calcium
hydroxide solution for 16-60 minutes. Get medical attention
immediately.
INT - 3 - 3 - 5/1
!!WARNING
Brake Pads
Always renew brake pads and locating pins in complete axle
sets, using genuine JCB parts, otherwise braking will be
unsafe.
13-3-1-10
!!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
!!WARNING
ABS
Upon completion of any work done on the brake system of
machines fitted with ABS, the ABS test within Servicemaster
must be run satisfactorily before the machine is driven. It is
not sufficient to rely on the ABS self-check which can only
check for presence of components, not that they are
correctly installed.
0091
Section 2 Care & Safety
9803/8020
Section 2
4 - 3
Issue 2*
*
i
Section 3 Routine Maintenance
9803/8020
Section 3
i
Issue 7*
Contents Page No.
Engine Oil - (All Machines) 1 - 1
Lubricants & Capacities (2000 Series Machines) 1 - 2
Lubricants & Capacities (3155) 1 - 4
Lubricants & Capacities (3185) 1 - 6
Lubricants - Health and Safety 1 - 8
Service Schedules (Dry Clutch Transmission †) 2 - 1
Service Schedules (Wet Clutch Transmission ††) 2 - 4
Cleaning the Machine and Checking for Damage 2 - 8
Checking Seat Belt Condition and Security 2 - 8
Opening/Closing the Bonnet (2000 Series Machines) 2 - 9
Opening/Closing the Bonnet (3000 Series Machines) 2 - 9
Greasing
General 3 - 1
Propshafts and PTO Driveshafts 3 - 1
Steering Swivels (2000 Series Machines) 3 - 2
Front Axle Steering Swivels (3000 Series Machines) 3 - 3
Hydraulic Lift & 3 point Linkage (2000 Series Machines) 3 - 4
Rear PTO Driveshaft Bearings (2000 Series Machines) 3 - 4
Rear Suspension Cylinder Pivots (2000 Series Machines) 3 - 4
Hydraulic Lift & 3 point Linkage (3000 Series Machines) 3 - 5
Rear PTO Driveshaft Bearings (3000 Series Machines) 3 - 5
Rear Suspension Cylinder Pivots (3000 Series Machines) 3 - 5
Rear Anti-roll Bar Ball Joints (2000 Series Machines) 3 - 6
Steering Box Input Shaft Seal (3000 Series Machines) 3 - 7
Rear Anti-roll Bar Ball Joints (3000 Series Machines) 3 - 7
Automatic Trailer Coupling (if fitted) 3 - 8
Cab
Checking the ROPS Structure 4 - 1
Checking the Windscreen Washer Fluid Level 4 - 2
Air Conditioning
Cleaning the Filter (2000 Series Machines) 5 - 1
Adjusting the Compressor Belt (2115, 2125, 2135, 2150) 5 - 1
Cleaning the Filter (3000 Series Machines) 5 - 2
Adjusting the Compressor Belt (2140 and 3000 Series) 5 - 3
Electrics
Battery Warning Symbols 6 - 1
First Aid - Electrolyte 6 - 1
Checking the Battery Electrolyte Level 6 - 2
Checking the Headlight Beam Alignment 6 - 3
Fuses See Section C
Hydraulics
Checking the Fluid Level 7 - 1
Changing the Filter Element 7 - 1
Changing the Hydraulic Fluid and Cleaning the Suction Strainer 7 - 2
Emptying the Hydraulic Coupling Drain Reservoir (if fitted) 7 - 3
Dry Clutch Hydraulic System †
Checking the Fluid Level 8 - 1
† 2000 Series to S/N 739999, 3000 Series to S/N 641999
†† 2000 Series from S/N 740000, 3000 Series from S/N 642000
*
*
*
Section 3 Routine Maintenance
9803/8020
Section 3
i
Issue 7*
Contents Page No.
Engine Oil - (All Machines) 1 - 1
Lubricants & Capacities (2000 Series Machines) 1 - 2
Lubricants & Capacities (3155) 1 - 4
Lubricants & Capacities (3185) 1 - 6
Lubricants - Health and Safety 1 - 8
Service Schedules (Dry Clutch Transmission †) 2 - 1
Service Schedules (Wet Clutch Transmission ††) 2 - 4
Cleaning the Machine and Checking for Damage 2 - 8
Checking Seat Belt Condition and Security 2 - 8
Opening/Closing the Bonnet (2000 Series Machines) 2 - 9
Opening/Closing the Bonnet (3000 Series Machines) 2 - 9
Greasing
General 3 - 1
Propshafts and PTO Driveshafts 3 - 1
Steering Swivels (2000 Series Machines) 3 - 2
Front Axle Steering Swivels (3000 Series Machines) 3 - 3
Hydraulic Lift & 3 point Linkage (2000 Series Machines) 3 - 4
Rear PTO Driveshaft Bearings (2000 Series Machines) 3 - 4
Rear Suspension Cylinder Pivots (2000 Series Machines) 3 - 4
Hydraulic Lift & 3 point Linkage (3000 Series Machines) 3 - 5
Rear PTO Driveshaft Bearings (3000 Series Machines) 3 - 5
Rear Suspension Cylinder Pivots (3000 Series Machines) 3 - 5
Rear Anti-roll Bar Ball Joints (2000 Series Machines) 3 - 6
Steering Box Input Shaft Seal (3000 Series Machines) 3 - 7
Rear Anti-roll Bar Ball Joints (3000 Series Machines) 3 - 7
Automatic Trailer Coupling (if fitted) 3 - 8
Cab
Checking the ROPS Structure 4 - 1
Checking the Windscreen Washer Fluid Level 4 - 2
Air Conditioning
Cleaning the Filter (2000 Series Machines) 5 - 1
Adjusting the Compressor Belt (2115, 2125, 2135, 2150) 5 - 1
Cleaning the Filter (3000 Series Machines) 5 - 2
Adjusting the Compressor Belt (2140 and 3000 Series) 5 - 3
Electrics
Battery Warning Symbols 6 - 1
First Aid - Electrolyte 6 - 1
Checking the Battery Electrolyte Level 6 - 2
Checking the Headlight Beam Alignment 6 - 3
Fuses See Section C
Hydraulics
Checking the Fluid Level 7 - 1
Changing the Filter Element 7 - 1
Changing the Hydraulic Fluid and Cleaning the Suction Strainer 7 - 2
Emptying the Hydraulic Coupling Drain Reservoir (if fitted) 7 - 3
Dry Clutch Hydraulic System †
Checking the Fluid Level 8 - 1
† 2000 Series to S/N 739999, 3000 Series to S/N 641999
†† 2000 Series from S/N 740000, 3000 Series from S/N 642000
*
*
*
ii
Section 3 Routine Maintenance
9803/8020
Section 3
ii
Issue 10*
Contents Page No.
PTO, Speed and Range Gearboxes
Checking the Oil Level 9 - 1
Changing the Oil and Cleaning the Strainer
- (Dry Clutch Transmission) † 9 - 2
Changing the Oil and Cleaning the Strainer
- (Wet Clutch Transmission) †† 9 - 2A
Changing the Transmission Oil Filter 9 - 3
Checking the Front PTO Gearbox Oil Level (if fitted) 9 - 4
Front Axle
Checking the Differential Oil Level 10 - 1
Changing the Differential Oil 10 - 1
Checking the Hub Oil Levels 10 - 2
Changing the Hub Oil 10 - 2
Rear Axle (2WS)
Checking the Oil Level 11 - 1
Changing the Oil 11 - 2
Rear Axle (4WS)
Checking the Differential Oil Level 11 - 3
Changing the Differential Oil 11 - 3
Checking the Hub Oil Levels 11 - 4
Changing the Hub Oil 11 - 4
Front and Rear Axle Steering Swivels (4WS)
Checking 4WS Right Side Trunnion Seals 11 - 5
Tyres and Wheels
General 12 - 1
Tyre Inflation 12 - 1
Pressures, Speeds and Loads See Operator Handbook
Checking and Adjusting Wheel Alignment 12 - 4
Track Width 12 - 5
Checking Wheel Nut Torques 12 - 5
Lock Stops 12 - 6
Fender Adjustment 12 - 7
Brakes
Checking and Renewing Foot Brake Pads 13 - 1
Checking and Renewing the Parking Brake Pads 13 - 3
Checking the Foot Brake Fluid Level (2000 Series Machines) 13 - 4
Draining the Air System Tank (2000 Series Machines) 13 - 6
Checking the Foot Brake Fluid Level (3000 Series Machines) 13 - 7
Draining the Air System Tank (3000 Series Machines) 13 - 8
Exhaust Brake (if fitted) (3185 Machines only) 13 - 9
Cleaning the Trailer Brake Control Line Air Filter See Section G
† 2000 Series to S/N 739999, 3000 Series to S/N 641999
†† 2000 Series from S/N 740000, 3000 Series from S/N 642000
*
Section 3 Routine Maintenance
9803/8020
Section 3
ii
Issue 10*
Contents Page No.
PTO, Speed and Range Gearboxes
Checking the Oil Level 9 - 1
Changing the Oil and Cleaning the Strainer
- (Dry Clutch Transmission) † 9 - 2
Changing the Oil and Cleaning the Strainer
- (Wet Clutch Transmission) †† 9 - 2A
Changing the Transmission Oil Filter 9 - 3
Checking the Front PTO Gearbox Oil Level (if fitted) 9 - 4
Front Axle
Checking the Differential Oil Level 10 - 1
Changing the Differential Oil 10 - 1
Checking the Hub Oil Levels 10 - 2
Changing the Hub Oil 10 - 2
Rear Axle (2WS)
Checking the Oil Level 11 - 1
Changing the Oil 11 - 2
Rear Axle (4WS)
Checking the Differential Oil Level 11 - 3
Changing the Differential Oil 11 - 3
Checking the Hub Oil Levels 11 - 4
Changing the Hub Oil 11 - 4
Front and Rear Axle Steering Swivels (4WS)
Checking 4WS Right Side Trunnion Seals 11 - 5
Tyres and Wheels
General 12 - 1
Tyre Inflation 12 - 1
Pressures, Speeds and Loads See Operator Handbook
Checking and Adjusting Wheel Alignment 12 - 4
Track Width 12 - 5
Checking Wheel Nut Torques 12 - 5
Lock Stops 12 - 6
Fender Adjustment 12 - 7
Brakes
Checking and Renewing Foot Brake Pads 13 - 1
Checking and Renewing the Parking Brake Pads 13 - 3
Checking the Foot Brake Fluid Level (2000 Series Machines) 13 - 4
Draining the Air System Tank (2000 Series Machines) 13 - 6
Checking the Foot Brake Fluid Level (3000 Series Machines) 13 - 7
Draining the Air System Tank (3000 Series Machines) 13 - 8
Exhaust Brake (if fitted) (3185 Machines only) 13 - 9
Cleaning the Trailer Brake Control Line Air Filter See Section G
† 2000 Series to S/N 739999, 3000 Series to S/N 641999
†† 2000 Series from S/N 740000, 3000 Series from S/N 642000
*
iii
Section 3 Routine Maintenance
9803/8020
Section 3
iii
Issue 4*
Contents Page No.
Engine
Checking the Oil Level 14 - 1
Changing the Oil and Filter 14 - 2
Draining/Cleaning the Fuel Sediment Bowl 15 - 1
Draining/Renewing Fuel Pre-Filter (when fitted) 15 - 2
Draining the Fuel Filters 15 - 3
Changing the Fuel Filter Elements 15 - 3
Cleaning the Fuel Lift Pump (2115, 2125, 2135, 2150 and 3155) 15 - 4
Bleeding the Fuel System (2115, 2125, 2135, 2150 and 3155) 15 - 5
Bleeding the Fuel System (2140) 15 - 5A
Bleeding the Fuel System (3185) 15 - 6
Cleaning the Fuel Tank Strainer (Early machines only) 15 - 7
Checking the Coolant Level 16 - 1
Draining the Coolant (2115, 2125, 2135 and 2150 Machines) 16 - 2
Filling the Cooling System (2115, 2125, 2135 & 2150 Machines) 16 - 3
Coolant Mixtures 16 - 3
Draining & Refilling the Coolant (3155 Machines) 16 - 4
Draining & Refilling the Coolant (2140 and 3185 Machines) 16 - 5
Cleaning the Radiator (2000 Series Machines) 16 - 6
Cleaning the Radiator (3000 Series Machines) 16 - 7
Cleaning the Pre-Cleaner (optional) 17 - 1
Adjusting the Fan Belts (Machines Except 3185) 17 - 1
Adjusting the Fan Belt (2140) 17 - 2
Adjusting the Fan Belt (3185) 17 - 3
Changing the Air Filter Elements (Early 2000 Series) 18 - 1
Changing the Air Filter Elements (Later 2000 Series) 18 - 2
Changing the Air Filter Elements (3000 Series) 18 - 2
*
*
*
*
*
*
*
*
*
*
*
*
Section 3 Routine Maintenance
9803/8020
Section 3
iii
Issue 4*
Contents Page No.
Engine
Checking the Oil Level 14 - 1
Changing the Oil and Filter 14 - 2
Draining/Cleaning the Fuel Sediment Bowl 15 - 1
Draining/Renewing Fuel Pre-Filter (when fitted) 15 - 2
Draining the Fuel Filters 15 - 3
Changing the Fuel Filter Elements 15 - 3
Cleaning the Fuel Lift Pump (2115, 2125, 2135, 2150 and 3155) 15 - 4
Bleeding the Fuel System (2115, 2125, 2135, 2150 and 3155) 15 - 5
Bleeding the Fuel System (2140) 15 - 5A
Bleeding the Fuel System (3185) 15 - 6
Cleaning the Fuel Tank Strainer (Early machines only) 15 - 7
Checking the Coolant Level 16 - 1
Draining the Coolant (2115, 2125, 2135 and 2150 Machines) 16 - 2
Filling the Cooling System (2115, 2125, 2135 & 2150 Machines) 16 - 3
Coolant Mixtures 16 - 3
Draining & Refilling the Coolant (3155 Machines) 16 - 4
Draining & Refilling the Coolant (2140 and 3185 Machines) 16 - 5
Cleaning the Radiator (2000 Series Machines) 16 - 6
Cleaning the Radiator (3000 Series Machines) 16 - 7
Cleaning the Pre-Cleaner (optional) 17 - 1
Adjusting the Fan Belts (Machines Except 3185) 17 - 1
Adjusting the Fan Belt (2140) 17 - 2
Adjusting the Fan Belt (3185) 17 - 3
Changing the Air Filter Elements (Early 2000 Series) 18 - 1
Changing the Air Filter Elements (Later 2000 Series) 18 - 2
Changing the Air Filter Elements (3000 Series) 18 - 2
*
*
*
*
*
*
*
*
*
*
*
*
1 - 1
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 1
Issue 7*
New Engines
New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately.
DO NOT use a special running-in oil but use the oil recommended below from new.
Engine Oil Specification
Recommended Oil
JCB Extreme Performance Engine Oil
SAE 15W/40 API CH-4 or ACEA E3/B3A3
IMPORTANT NOTE: IF SAE 15W/40, API CH-4 OR ACEA E3/B3A3 ENGINE OIL IS NOT AVAILABLE, THEN THE ENGINE OIL
MUST BE CHANGED AT 250 HOURS.
Alternative Oil
If the oil recommended above is not available then the alternatives listed below should be used according to the ambient
temperature.
Note:(2140 and 3185 machines only). While 15W/40 oil is recommended for most climates, limited use of low viscosity oils
such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below -5 °C (23 °F).
Continued use of low viscosity oils can decrease engine life.
JCB Super Multigrade 15W/40
SAE15W/40, API CF4/SG
-10 °C to 50 °C (14 °F to 122 °F)
JCB Super Multigrade 10W/30
SAE10W/30, API CF4/SG
† -15 °C to 40 °C (5 °F to 104 °F)
† The temperature range for 2140 and 3185 machines is - 20 °C to 20 °C (-4 °C to 68 °F).
Engine Oil Specification (N. America)
Recommended Oil
JCB Genuine Engine Oil
SAE 15W/40, Grade CH-4/SJ
IMPORTANT NOTICE: IF SAE 15W/40, GRADE CH-4/SJ ENGINE OIL IS NOT AVAILABLE, THEN THE ENGINE OIL MUST BE
CHANGED AT 250 HOURS.
Alternative Oil
If the oil recommended above is not available then the alternatives listed below should be used according to the ambient
temperature.
Notice:(2140 and 3185 machines only). While 15W/40 oil is recommended for most climates, limited use of low viscosity oils
such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below -5 °C (23 °F).
Continued use of low viscosity oils can decrease engine life.
JCB 15W/40 Engine Oil
SAE15W/40, API CF4/SG
-10 °C to 50 °C (14 °F to 122 °F)
JCB Engine Oil 10W/30
SAE10W/30, API CE/SF
† -15 °C to 40 °C (5 °F to 104 °F)
† The temperature range for 2140 and 3185 machines is -4 °C to 68 °F (- 20 °C to 20 °C).
* Engine Oil (All Machines)
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 1
Issue 7*
New Engines
New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately.
DO NOT use a special running-in oil but use the oil recommended below from new.
Engine Oil Specification
Recommended Oil
JCB Extreme Performance Engine Oil
SAE 15W/40 API CH-4 or ACEA E3/B3A3
IMPORTANT NOTE: IF SAE 15W/40, API CH-4 OR ACEA E3/B3A3 ENGINE OIL IS NOT AVAILABLE, THEN THE ENGINE OIL
MUST BE CHANGED AT 250 HOURS.
Alternative Oil
If the oil recommended above is not available then the alternatives listed below should be used according to the ambient
temperature.
Note:(2140 and 3185 machines only). While 15W/40 oil is recommended for most climates, limited use of low viscosity oils
such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below -5 °C (23 °F).
Continued use of low viscosity oils can decrease engine life.
JCB Super Multigrade 15W/40
SAE15W/40, API CF4/SG
-10 °C to 50 °C (14 °F to 122 °F)
JCB Super Multigrade 10W/30
SAE10W/30, API CF4/SG
† -15 °C to 40 °C (5 °F to 104 °F)
† The temperature range for 2140 and 3185 machines is - 20 °C to 20 °C (-4 °C to 68 °F).
Engine Oil Specification (N. America)
Recommended Oil
JCB Genuine Engine Oil
SAE 15W/40, Grade CH-4/SJ
IMPORTANT NOTICE: IF SAE 15W/40, GRADE CH-4/SJ ENGINE OIL IS NOT AVAILABLE, THEN THE ENGINE OIL MUST BE
CHANGED AT 250 HOURS.
Alternative Oil
If the oil recommended above is not available then the alternatives listed below should be used according to the ambient
temperature.
Notice:(2140 and 3185 machines only). While 15W/40 oil is recommended for most climates, limited use of low viscosity oils
such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below -5 °C (23 °F).
Continued use of low viscosity oils can decrease engine life.
JCB 15W/40 Engine Oil
SAE15W/40, API CF4/SG
-10 °C to 50 °C (14 °F to 122 °F)
JCB Engine Oil 10W/30
SAE10W/30, API CE/SF
† -15 °C to 40 °C (5 °F to 104 °F)
† The temperature range for 2140 and 3185 machines is -4 °C to 68 °F (- 20 °C to 20 °C).
* Engine Oil (All Machines)
1 - 2
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 2
Issue 9*
Lubricants & Capacities
(2000 Series Machines)
ITEM CAPACITY FLUID/LUBRICANT MINIMUM INTERNATIONAL
Litres (UK Gal) SPECIFICATION
Fuel
2115, 2125, 2135, 2140 220 (48) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
2150 350 (77)
Engine (Oil)
2115, 2125, 2135, 2150 16.5 (3.6) See Engine Oil (All Machines)at the
2140 15 (3.3) beginning of this section
Engine (Coolant)
2115, 2125, 2135, 2150 34 (7.5) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
2140 33 (7.3) Summer Coolant/water
(SeeCoolant Mixtures)
PTO, Speed and
Range Boxes 38 (8.4) † JCB Super Universal Agricultural API-GL-4, MIL-L-2105
(combined) 42 (9.3) ††
Front Axle
Housing 7 (1.56) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 1.9 (0.4)
Rear Axle (2WS) 23 (5.0) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Rear Axle (4WS)
Housing 17 (3.7) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 2.0 (0.4)
Brake System JCB Universal Brake Fluid SAE J1703 DOT 4
Front 0.75 (0.17)
Rear 0.75 (0.17)
! !CAUTION
Do not use ordinary hydraulic fluid
in the brake system.
13-3-2-6
† Clutch System - JCB Light Hydraulic Fluid - see Note 2 ISO VG15
Hydraulic System JCB High Performance Hydraulic Oil ISO VG46
- seeNote 1 82 (18.0) † (Above 38 °C, 100 °F)
120 (26.4) ††
JCB Hydraulic Fluid HP32 ISO VG32
(Below 38 °C, 100 °F)
Grease Points --- JCB HP Grease Lithium complex NLGI No. 2
consistency including extreme
pressure additives
Air Conditioning System
- Refrigerant 0.98 kg (2.16 lb)HFC R134a CH
2
FC F
3
- Compressor Lubricant0.24 (0.05) Polyalkalineglycol PAG SP20
Front PTO Transfer
Box (optional) 3.0 (0.67) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.
Note 2: It is esssential that the correct specification fluid is used. Contact your JCB Dealer for further information.
†2000 Series to S/N 739999
††2000 Series from S/N 740000
*
*
*
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 2
Issue 9*
Lubricants & Capacities
(2000 Series Machines)
ITEM CAPACITY FLUID/LUBRICANT MINIMUM INTERNATIONAL
Litres (UK Gal) SPECIFICATION
Fuel
2115, 2125, 2135, 2140 220 (48) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
2150 350 (77)
Engine (Oil)
2115, 2125, 2135, 2150 16.5 (3.6) See Engine Oil (All Machines)at the
2140 15 (3.3) beginning of this section
Engine (Coolant)
2115, 2125, 2135, 2150 34 (7.5) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
2140 33 (7.3) Summer Coolant/water
(SeeCoolant Mixtures)
PTO, Speed and
Range Boxes 38 (8.4) † JCB Super Universal Agricultural API-GL-4, MIL-L-2105
(combined) 42 (9.3) ††
Front Axle
Housing 7 (1.56) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 1.9 (0.4)
Rear Axle (2WS) 23 (5.0) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Rear Axle (4WS)
Housing 17 (3.7) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 2.0 (0.4)
Brake System JCB Universal Brake Fluid SAE J1703 DOT 4
Front 0.75 (0.17)
Rear 0.75 (0.17)
! !CAUTION
Do not use ordinary hydraulic fluid
in the brake system.
13-3-2-6
† Clutch System - JCB Light Hydraulic Fluid - see Note 2 ISO VG15
Hydraulic System JCB High Performance Hydraulic Oil ISO VG46
- seeNote 1 82 (18.0) † (Above 38 °C, 100 °F)
120 (26.4) ††
JCB Hydraulic Fluid HP32 ISO VG32
(Below 38 °C, 100 °F)
Grease Points --- JCB HP Grease Lithium complex NLGI No. 2
consistency including extreme
pressure additives
Air Conditioning System
- Refrigerant 0.98 kg (2.16 lb)HFC R134a CH
2
FC F
3
- Compressor Lubricant0.24 (0.05) Polyalkalineglycol PAG SP20
Front PTO Transfer
Box (optional) 3.0 (0.67) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.
Note 2: It is esssential that the correct specification fluid is used. Contact your JCB Dealer for further information.
†2000 Series to S/N 739999
††2000 Series from S/N 740000
*
*
*
1 - 3
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 3
Issue 9*
Lubricants & Capacities (N. America)
(2000 Series Machines)
ITEM CAPACITY FLUID/LUBRICANT MINIMUM INTERNATIONAL
US Gal (Liters) SPECIFICATION
Fuel
2115, 2125, 2135, 2140 57.6 (220) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
2150 92.5 (350)
Engine (Oil)
2115, 2125, 2135, 2150 4.3 (16.5) See Engine Oil (All Machines)at the
2140 4 (15) beginning of this section
Engine (Coolant) JCB PermanentAntifreeze/water ASTM D3306-74
2115, 2125, 2135, 2150 9.0 (34.0) (See Coolant Mixtures)
2140 8.77 (33)
PTO, Speed and
Range Boxes 10 (38.0) † JCB AG Transmission Fluid API-GL-4, MIL-L-2105
(combined) 11.2 (42.0) ††
Front Axle
Housing 1.8 (7.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 0.5 (1.9)
Rear Axle (2WS) 6.1 (23.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Rear Axle (4WS)
Housing 4.5 (17.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 0.5 (2.0)
Brake System JCB Universal Brake Fluid 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
† Clutch System - JCB Light Hydraulic Fluid - see Notice 2 ISO VG15
Hydraulic System 21.7 (82.0) † JCB High Performance Hydraulic Oil ISO VG46
- seeNotice 1 31.7 (120) ††
Grease Points --- JCB HP Grease Lithium complex NLGI No. 2
consistency including extreme
pressure additives
Air Conditioning System
- Refrigerant 2.16 lb (0.98 kg)HFC R134a CH
2
FC F
3
- Compressor Lubricant0.06 (0.24) Polyalkalineglycol PAG SP20
Front PTO Transfer
Box (optional) 0.8 (3.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic
tank.
Notice 2: It is esssential that the correct specification fluid is used. Contact your JCB Dealer for further information.
†2000 Series to S/N 739999
††2000 Series from S/N 740000
*
*
*
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 3
Issue 9*
Lubricants & Capacities (N. America)
(2000 Series Machines)
ITEM CAPACITY FLUID/LUBRICANT MINIMUM INTERNATIONAL
US Gal (Liters) SPECIFICATION
Fuel
2115, 2125, 2135, 2140 57.6 (220) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
2150 92.5 (350)
Engine (Oil)
2115, 2125, 2135, 2150 4.3 (16.5) See Engine Oil (All Machines)at the
2140 4 (15) beginning of this section
Engine (Coolant) JCB PermanentAntifreeze/water ASTM D3306-74
2115, 2125, 2135, 2150 9.0 (34.0) (See Coolant Mixtures)
2140 8.77 (33)
PTO, Speed and
Range Boxes 10 (38.0) † JCB AG Transmission Fluid API-GL-4, MIL-L-2105
(combined) 11.2 (42.0) ††
Front Axle
Housing 1.8 (7.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 0.5 (1.9)
Rear Axle (2WS) 6.1 (23.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Rear Axle (4WS)
Housing 4.5 (17.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 0.5 (2.0)
Brake System JCB Universal Brake Fluid 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
† Clutch System - JCB Light Hydraulic Fluid - see Notice 2 ISO VG15
Hydraulic System 21.7 (82.0) † JCB High Performance Hydraulic Oil ISO VG46
- seeNotice 1 31.7 (120) ††
Grease Points --- JCB HP Grease Lithium complex NLGI No. 2
consistency including extreme
pressure additives
Air Conditioning System
- Refrigerant 2.16 lb (0.98 kg)HFC R134a CH
2
FC F
3
- Compressor Lubricant0.06 (0.24) Polyalkalineglycol PAG SP20
Front PTO Transfer
Box (optional) 0.8 (3.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic
tank.
Notice 2: It is esssential that the correct specification fluid is used. Contact your JCB Dealer for further information.
†2000 Series to S/N 739999
††2000 Series from S/N 740000
*
*
*
ITEM CAPACITY FLUID/LUBRICANT MINIMUM INTERNATIONAL
Litres (UK Gal) SPECIFICATION
Fuel 350 (77) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 16.5 (3.6) See Engine Oil (All Machines)at the
beginning of this section
Engine (Coolant) 34 (7.5) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
Summer Coolant/water
(SeeCoolant Mixtures)
PTO, Speed and
Range Boxes 38 (8.4)† JCB Super Universal Agricultural API-GL-4, MIL-L-2105
(combined) 42 (9.3)††
Front Axle
Housing 20 (4.4) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 2.5 (0.55)
Rear Axle 21 (4.6) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Brake System JCB Universal Brake Fluid SAE J1703 DOT 4
Front 0.75 (0.17)
Rear 0.75 (0.17)
! !CAUTION
Do not use ordinary hydraulic fluid in the
brake system.
13-3-2-6
† Clutch System - JCB Light Hydraulic Fluid - see Note 2 ISO VG15
Hydraulic System 82 (18.0) † JCB High Performance Hydraulic Oil ISO VG46
- seeNote 1 120 (26.4) †† (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 1.41 kg (3.11 lb)HFC R134a CH
2
FC F
3
- Compressor Lubricant0.24 (0.05) Polyalkalineglycol PAG SP20
Front PTO Transfer
Box (optional) 3.0 (0.67) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.
Note 2:It is essential that the correct specification fluid is used. Contact your JCB Distributor for further information.
†3000 Series to S/N 641999
††3000 Series from S/N 642000
1 - 4
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 4
Issue 7*
Lubricants & Capacities
(Fastrac 3155)
*
Litres (UK Gal) SPECIFICATION
Fuel 350 (77) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 16.5 (3.6) See Engine Oil (All Machines)at the
beginning of this section
Engine (Coolant) 34 (7.5) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
Summer Coolant/water
(SeeCoolant Mixtures)
PTO, Speed and
Range Boxes 38 (8.4)† JCB Super Universal Agricultural API-GL-4, MIL-L-2105
(combined) 42 (9.3)††
Front Axle
Housing 20 (4.4) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 2.5 (0.55)
Rear Axle 21 (4.6) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Brake System JCB Universal Brake Fluid SAE J1703 DOT 4
Front 0.75 (0.17)
Rear 0.75 (0.17)
! !CAUTION
Do not use ordinary hydraulic fluid in the
brake system.
13-3-2-6
† Clutch System - JCB Light Hydraulic Fluid - see Note 2 ISO VG15
Hydraulic System 82 (18.0) † JCB High Performance Hydraulic Oil ISO VG46
- seeNote 1 120 (26.4) †† (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 1.41 kg (3.11 lb)HFC R134a CH
2
FC F
3
- Compressor Lubricant0.24 (0.05) Polyalkalineglycol PAG SP20
Front PTO Transfer
Box (optional) 3.0 (0.67) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.
Note 2:It is essential that the correct specification fluid is used. Contact your JCB Distributor for further information.
†3000 Series to S/N 641999
††3000 Series from S/N 642000
1 - 4
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 4
Issue 7*
Lubricants & Capacities
(Fastrac 3155)
*
1 - 5
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 5
Issue 7*
Lubricants & Capacities (N. America)
(Fastrac 3155)
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) 4.3 (16.5) See Engine Oil (All 2000, 3000 Series
Machines)on page 60-00-01/11
Engine (Coolant) 9 (34.0) JCB Permanent Antifreeze/water ASTM D3306-74
(SeeCoolant Mixtures)
PTO, Speed and
Range Boxes 10.1 (38.0) † JCB AG Transmission Fluid API-GL-4, MIL-L-2105
(combined) 11.2 (42.0)††
Front Axle
Housing 5.3 (20.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 0.66 (2.5)
Rear Axle (2WS) 7.1 (27.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Brake System JCB Universal Brake Fluid 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
† Clutch System --- JCB Light Hydraulic Fluid - see Notice 2 ISO VG15
Hydraulic System 21.7 (82.0) † JCB High Performance Hydraulic Oil ISO VG46
- see Notice 1 31.7 (120) ††
Grease Points --- JCB HP Grease Lithium complex NLGI No. 2
consistency including extreme
pressure additives
Air Conditioning System
- Refrigerant 3.11 lb (1.41 kg)HFC R134a CH
2
FC F
3
- Compressor Lubricant0.06 (0.24) Polyalkalineglycol PAG SP20
Front PTO Transfer
Box (optional) 0.8 (3.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic
tank.
Notice 2:It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
†3000 Series to S/N 641999
††3000 Series from S/N 642000
*
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 5
Issue 7*
Lubricants & Capacities (N. America)
(Fastrac 3155)
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) 4.3 (16.5) See Engine Oil (All 2000, 3000 Series
Machines)on page 60-00-01/11
Engine (Coolant) 9 (34.0) JCB Permanent Antifreeze/water ASTM D3306-74
(SeeCoolant Mixtures)
PTO, Speed and
Range Boxes 10.1 (38.0) † JCB AG Transmission Fluid API-GL-4, MIL-L-2105
(combined) 11.2 (42.0)††
Front Axle
Housing 5.3 (20.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 0.66 (2.5)
Rear Axle (2WS) 7.1 (27.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Brake System JCB Universal Brake Fluid 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
† Clutch System --- JCB Light Hydraulic Fluid - see Notice 2 ISO VG15
Hydraulic System 21.7 (82.0) † JCB High Performance Hydraulic Oil ISO VG46
- see Notice 1 31.7 (120) ††
Grease Points --- JCB HP Grease Lithium complex NLGI No. 2
consistency including extreme
pressure additives
Air Conditioning System
- Refrigerant 3.11 lb (1.41 kg)HFC R134a CH
2
FC F
3
- Compressor Lubricant0.06 (0.24) Polyalkalineglycol PAG SP20
Front PTO Transfer
Box (optional) 0.8 (3.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic
tank.
Notice 2:It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
†3000 Series to S/N 641999
††3000 Series from S/N 642000
*
1 - 6
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 6
Issue 7*
Lubricants & Capacities
(Fastrac 3185)
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) 15 (3.3) See Engine Oil (All Machines)at the
beginning of this section
Engine (Coolant) 33 (7.3) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
Summer Coolant/water
(SeeCoolant Mixtures)
PTO, Speed and
Range Boxes 38 (8.4) † JCB Super Universal Agricultural API-GL-4, MIL-L-2105
(combined) 42 (9.3) ††
Front Axle
Housing 20 (4.4) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 2.5 (0.55)
Rear Axle 27 (6.0) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Brake System JCB Universal Brake Fluid SAE J1703 DOT 4
Front 0.75 (0.17)
Rear 0.75 (0.17)
! !CAUTION
Do not use ordinary hydraulic fluid in the
brake system.
13-3-2-6
† Clutch System - JCB Light Hydraulic Fluid - see Note 2 ISO VG15
Hydraulic System 82 (18.0) † JCB High Performance Hydraulic Oil ISO VG46
- see Note 1 120 (26.4) †† (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 1.41 kg (3.11 lb)HFC R134a CH
2
FC F
3
- Compressor Lubricant0.24 (0.05) Polyalkalineglycol PAG SP20
Front PTO Transfer
Box (optional) 3.0 (0.67) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.
Note 2:It is essential that the correct specification fluid is used. Contact your JCB Distributor for further information.
†3000 Series to S/N 641999
††3000 Series from S/N 642000
*
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 6
Issue 7*
Lubricants & Capacities
(Fastrac 3185)
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) 15 (3.3) See Engine Oil (All Machines)at the
beginning of this section
Engine (Coolant) 33 (7.3) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
Summer Coolant/water
(SeeCoolant Mixtures)
PTO, Speed and
Range Boxes 38 (8.4) † JCB Super Universal Agricultural API-GL-4, MIL-L-2105
(combined) 42 (9.3) ††
Front Axle
Housing 20 (4.4) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 2.5 (0.55)
Rear Axle 27 (6.0) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Brake System JCB Universal Brake Fluid SAE J1703 DOT 4
Front 0.75 (0.17)
Rear 0.75 (0.17)
! !CAUTION
Do not use ordinary hydraulic fluid in the
brake system.
13-3-2-6
† Clutch System - JCB Light Hydraulic Fluid - see Note 2 ISO VG15
Hydraulic System 82 (18.0) † JCB High Performance Hydraulic Oil ISO VG46
- see Note 1 120 (26.4) †† (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 1.41 kg (3.11 lb)HFC R134a CH
2
FC F
3
- Compressor Lubricant0.24 (0.05) Polyalkalineglycol PAG SP20
Front PTO Transfer
Box (optional) 3.0 (0.67) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.
Note 2:It is essential that the correct specification fluid is used. Contact your JCB Distributor for further information.
†3000 Series to S/N 641999
††3000 Series from S/N 642000
*
1 - 7
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 7
Issue 4*
Lubricants & Capacities (N. America)
(Fastrac 3185)
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) 4 (15) See Engine Oil (All Machines)at the
beginning of this section
Engine (Coolant) 8.77 (33.0) JCB Permanent Antifreeze/water ASTM D3306-74
(SeeCoolant Mixtures)
PTO, Speed and
Range Boxes 10 (38.0) † JCB AG Transmission Fluid API-GL-4, MIL-L-2105
(combined) 11.2 (42.0)††
Front Axle
Housing 5.3 (20.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 0.66 (2.5)
Rear Axle 7.1 (27.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Brake System JCB Universal Brake Fluid 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
† Clutch System --- JCB Light Hydraulic Fluid - seeNotice 2 ISO VG15
Hydraulic System 21.7 (82.0) † JCB High Performance Hydraulic Oil ISO VG46
- seeNotice 1 31.7 (120) ††
Grease Points --- JCB HP Grease Lithium complex NLGI No. 2
consistency including extreme
pressure additives
Air Conditioning System
- Refrigerant 3.11 lb (1.41 kg)HFC R134a CH
2
FC F
3
- Compressor Lubricant0.06 (0.24) Polyalkalineglycol PAG SP20
Front PTO Transfer
Box (optional) 0.8 (3.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic
tank.
Notice 2:It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
†3000 Series to S/N 641999
††3000 Series from S/N 642000
*
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 7
Issue 4*
Lubricants & Capacities (N. America)
(Fastrac 3185)
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) 4 (15) See Engine Oil (All Machines)at the
beginning of this section
Engine (Coolant) 8.77 (33.0) JCB Permanent Antifreeze/water ASTM D3306-74
(SeeCoolant Mixtures)
PTO, Speed and
Range Boxes 10 (38.0) † JCB AG Transmission Fluid API-GL-4, MIL-L-2105
(combined) 11.2 (42.0)††
Front Axle
Housing 5.3 (20.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 0.66 (2.5)
Rear Axle 7.1 (27.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Brake System JCB Universal Brake Fluid 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
† Clutch System --- JCB Light Hydraulic Fluid - seeNotice 2 ISO VG15
Hydraulic System 21.7 (82.0) † JCB High Performance Hydraulic Oil ISO VG46
- seeNotice 1 31.7 (120) ††
Grease Points --- JCB HP Grease Lithium complex NLGI No. 2
consistency including extreme
pressure additives
Air Conditioning System
- Refrigerant 3.11 lb (1.41 kg)HFC R134a CH
2
FC F
3
- Compressor Lubricant0.06 (0.24) Polyalkalineglycol PAG SP20
Front PTO Transfer
Box (optional) 0.8 (3.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic
tank.
Notice 2:It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
†3000 Series to S/N 641999
††3000 Series from S/N 642000
*
1 - 8
It is most important that you read and understand this
information and the publications referred to. Make sure all
your colleagues who are concerned with lubricants read it
too.
HYGIENE
JCB lubricants are not a health risk when used properly for
their intended purposes.
However, excessive or prolonged skin contact can remove
the natural fats from your skin, causing dryness and
irritation.
Low viscosity oils are more likely to do this, so take special
care when handling used oils, which might be diluted with
fuel contamination.
Whenever you are handling oil products you should maintain
good standards of care and personal and plant hygiene. For
details of these precautions we advise you to read the
relevant publications issued by your local health authority,
plus the following.
STORAGE
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled containers.
HANDLING
New Oil
There are no special precautions needed for the handling or
use of new oil, besides the normal care and hygiene
practices.
Used Oil
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:
1Avoid prolonged, excessive or repeated skin contact
with used engine oils.
2Apply a barrier cream to the skin before handling used
engine oil.
3Note the following when removing oil from skin:
aWash your skin thoroughly with soap and water.
bUsing a nail brush will help.
cUse special hand cleansers to help clean dirty
hands.
dNever use petrol, diesel fuel, or paraffin for washing.
eAvoid skin contact with oil soaked clothing.
fDon't keep oily rags in pockets.
gWash dirty clothing before re-use.
hThrow away oil-soaked shoes.
FIRST AID - OIL
Eyes
In the case of eye contact, flush with water for 15 minutes. If
irritation persists, get medical attention.
Swallowing
If oil is swallowed do not induce vomiting. Get medical
advice.
Skin
In the case of excessive skin contact, wash with soap and
water.
SPILLAGE
Absorb spilled oil with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a chemical
disposal area.
Fires
!!WARNING
Do not use water to put out an oil fire. This will only
spread it because oil floats on water.
Extinguish oil and lubricant fires with carbon dioxide, dry
chemical or foam. Fire fighters should use self contained
breathing apparatus.
7-3-1-3/1
WASTE DISPOSAL
All waste products should be disposed of in accordance
with all the relevant regulations.
The collection and disposal of used oil should be in
accordance with any local regulations. Never pour used oil
into sewers, drains or on the ground.
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 8
Issue 1
Lubricants - Health and Safety
It is most important that you read and understand this
information and the publications referred to. Make sure all
your colleagues who are concerned with lubricants read it
too.
HYGIENE
JCB lubricants are not a health risk when used properly for
their intended purposes.
However, excessive or prolonged skin contact can remove
the natural fats from your skin, causing dryness and
irritation.
Low viscosity oils are more likely to do this, so take special
care when handling used oils, which might be diluted with
fuel contamination.
Whenever you are handling oil products you should maintain
good standards of care and personal and plant hygiene. For
details of these precautions we advise you to read the
relevant publications issued by your local health authority,
plus the following.
STORAGE
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled containers.
HANDLING
New Oil
There are no special precautions needed for the handling or
use of new oil, besides the normal care and hygiene
practices.
Used Oil
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:
1Avoid prolonged, excessive or repeated skin contact
with used engine oils.
2Apply a barrier cream to the skin before handling used
engine oil.
3Note the following when removing oil from skin:
aWash your skin thoroughly with soap and water.
bUsing a nail brush will help.
cUse special hand cleansers to help clean dirty
hands.
dNever use petrol, diesel fuel, or paraffin for washing.
eAvoid skin contact with oil soaked clothing.
fDon't keep oily rags in pockets.
gWash dirty clothing before re-use.
hThrow away oil-soaked shoes.
FIRST AID - OIL
Eyes
In the case of eye contact, flush with water for 15 minutes. If
irritation persists, get medical attention.
Swallowing
If oil is swallowed do not induce vomiting. Get medical
advice.
Skin
In the case of excessive skin contact, wash with soap and
water.
SPILLAGE
Absorb spilled oil with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a chemical
disposal area.
Fires
!!WARNING
Do not use water to put out an oil fire. This will only
spread it because oil floats on water.
Extinguish oil and lubricant fires with carbon dioxide, dry
chemical or foam. Fire fighters should use self contained
breathing apparatus.
7-3-1-3/1
WASTE DISPOSAL
All waste products should be disposed of in accordance
with all the relevant regulations.
The collection and disposal of used oil should be in
accordance with any local regulations. Never pour used oil
into sewers, drains or on the ground.
Section 3 Routine Maintenance
9803/8020
Section 3
1 - 8
Issue 1
Lubricants - Health and Safety
2 - 1
Every 10 Operating Hours or Daily
whichever occurs first
Clean
1 Machine generally.
Drain
2 Air system tank.
Check (Engine Stopped)
3 Generally for damage.
4 Engine coolant level and condition.
5 Fuel system for leaks and contamination.
6 Hydraulic fluid level.
7 Hydraulic system for leaks.
8 Engine and transmission for oil leaks.
9 Gearbox oil level.
10 Engine oil level and condition.
11 Tightness of wheel nuts.
12 Windscreen washer level.
13 Tyre pressures and condition.
14 Security of front weights (optional equipment).
15 Seat belt condition and security.
16 Brake fluid levels.
17 Check radiator and coolers for blockage and clean if
required.
Check (Engine Running)
18 Instrument readings and warning lights.
19 Operation of all electrical equipment.
20 Exhaust for excessive smoke.
21 Operation of clutch and footbrakes.
22 Parking brake operation.
23 Operation of steering.
24 Operation of transmission.
25 Operation of 3-point linkage.
26 Operation of front linkage (optional equipment).
Note:Some machines have grease nipples fitted to the
external hydraulic control lever pivot points (see External
Hydraulics Control Valve Linkage, Lever Linkages in
section D). Grease at these points if the lever movement
becomes stiff or independent operation becomes difficult.
Every 50 Operating Hours or Weekly whichever occurs first
Do the Daily jobs plus:
Drain
1 Fuel filter.
2 Fuel sediment bowl (all machines except those with
optional fuel flow metering).
3 Fuel pre-filter (machines with optional fuel flow
metering only)
4 Empty hydraulic coupling drain reservoir (if fitted)
Check (Engine Stopped)
5 Fan belt tension and condition.
6 Air conditioning compressor drive belt.
7 Front PTO transfer gearbox oil level
(optional equipment).
8 Clutch fluid level.
9 Cab air filter (Clean if required).
10 Propshaft Security
Grease
11 Rear PTO drive shaft splines and universal joints.
12 Rear PTO drive shaft bearings.
13 Front PTO drive shaft (optional equipment).
14 Front axle propshaft.
15 Rear axle propshaft.
Note: It is essential that drive shaft and propshaft joints are
lubricated as specified.
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 1
Issue 6*
Service Schedules - Dry Clutch Transmission
*
Every 10 Operating Hours or Daily
whichever occurs first
Clean
1 Machine generally.
Drain
2 Air system tank.
Check (Engine Stopped)
3 Generally for damage.
4 Engine coolant level and condition.
5 Fuel system for leaks and contamination.
6 Hydraulic fluid level.
7 Hydraulic system for leaks.
8 Engine and transmission for oil leaks.
9 Gearbox oil level.
10 Engine oil level and condition.
11 Tightness of wheel nuts.
12 Windscreen washer level.
13 Tyre pressures and condition.
14 Security of front weights (optional equipment).
15 Seat belt condition and security.
16 Brake fluid levels.
17 Check radiator and coolers for blockage and clean if
required.
Check (Engine Running)
18 Instrument readings and warning lights.
19 Operation of all electrical equipment.
20 Exhaust for excessive smoke.
21 Operation of clutch and footbrakes.
22 Parking brake operation.
23 Operation of steering.
24 Operation of transmission.
25 Operation of 3-point linkage.
26 Operation of front linkage (optional equipment).
Note:Some machines have grease nipples fitted to the
external hydraulic control lever pivot points (see External
Hydraulics Control Valve Linkage, Lever Linkages in
section D). Grease at these points if the lever movement
becomes stiff or independent operation becomes difficult.
Every 50 Operating Hours or Weekly whichever occurs first
Do the Daily jobs plus:
Drain
1 Fuel filter.
2 Fuel sediment bowl (all machines except those with
optional fuel flow metering).
3 Fuel pre-filter (machines with optional fuel flow
metering only)
4 Empty hydraulic coupling drain reservoir (if fitted)
Check (Engine Stopped)
5 Fan belt tension and condition.
6 Air conditioning compressor drive belt.
7 Front PTO transfer gearbox oil level
(optional equipment).
8 Clutch fluid level.
9 Cab air filter (Clean if required).
10 Propshaft Security
Grease
11 Rear PTO drive shaft splines and universal joints.
12 Rear PTO drive shaft bearings.
13 Front PTO drive shaft (optional equipment).
14 Front axle propshaft.
15 Rear axle propshaft.
Note: It is essential that drive shaft and propshaft joints are
lubricated as specified.
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 1
Issue 6*
Service Schedules - Dry Clutch Transmission
*
2 - 2
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 2
Issue 8*
Service Schedules - Dry Clutch Transmission
First 100 Hours Dealer Service
Change
1 Engine oil and filter.
2 Fuel filters.
3 Transmission oil filter.
4 Hydraulic oil filter.
Clean
5 Fuel lift pump gauze.
6 Fuel sedimenter (drain).
Check (Engine Stopped)
7 Coolant level/leaks and antifreeze strength.
8 Fuel system for leaks and contamination.
9 Engine pipework routing and security.
10 Fuel system pipework routing and security.
11 Fan belt tension and condition.
12 Air conditioning compressor belt tension.
13 Clutch fluid level.
14 Gearbox oil level.
15 Transmission oil cooler/pipework condition, leakage,
routing and security.
16 Rear axle oil level.
17 Rear axle hub oil level (4WS).
18 Front axle oil level.
19 Front axle hub oil level.
20 Front PTO gearbox oil level.
21 Propellor shaft security.
22 Tyre pressures.
23 Tightness of wheel nuts.
24 Hydraulic oil level.
25 Hydraulic oil cooler/pipework condition, leakage,
routing and security.
26 Brake fluid levels.
27 Brake pad security (service and parking).
28 Brake pipework routing and security.
29 Air system for leaks.
30 Panhard rod torque setting.
31 Ram piston rods for damage/leaks.
32 Battery charge/terminal condition and tightness.
33 Wiring for chafing/routing.
34 Headlight alignment.
35 Windscreen washer level.
36 Neutral start operation (Including clutch and PTO's).
37 Door locks.
Grease
38 Propellor shafts and universal joints.
39 Steering swivels.
40 Rear PTO shaft bearings.
41 3 point linkage.
42 Rear lift ram pivots.
43 Suspension cylinder pivots.
Check (engine running)
44 Exhaust smoke.
45 Throttle and stop controls.
46 PTO operation.
47 2/4WD drive and diff. lock selection.
First 100 Hours Dealer Service (continued)
Check (engine running) - continued 48 Transmission low pressure circuit pressure maintaining
valve setting.
49 Transmission lubrication pressure.
50 Diff. lock pressure relief valve.
51 External hydraulics pressure relief valve.
52 Instrument readings and warning lights.
53 Operation of all electrical equipment.
54 Operation of clutch and footbrakes.
55 Operation of steering.
56 Operation of transmission.
57 Operation of 3-point linkage.
58 Operation of front linkage (optional equipment).
59 Rear axle/chassis clearance.
60 Height corrector valve operation.
61 Parking Brake operation.
62 Pick-up hitch operation.
63 Spool valve operation.
64 Re-calibrate splitter clutch packs
Every 250 Operating Hours or 3 Monthly
whichever occurs first
Do the Daily jobs through to 50 hours plus:
Clean
1 Air filter dust valve.
2 Battery terminals.
Check (Engine Stopped)
3 Front axle oil level.
4 Front axle hub oil levels.
5 Rear axle oil level.
6 Rear axle hub oil level (4WS) (if fitted).
7 Condition of lift ram piston rods.
8 Hose and pipework for chafing and damage.
9 Air cleaner and hose condition and security.
10 Electrical wiring for chafing and routing.
11 Brake pad condition and security.
12 Neutral start operation.
Check (Engine Running)
13 Air conditioning sight glass.
14 Operating speed of Selectronic range changes.
Change
15† Engine oil and filter.
16 Fuel Pre-filter (machines with optional fuel flow
metering only).
Grease
17 Steering swivels.
18 Rear anti-roll bar ball joints.
19 Hydraulic lift cross-shaft.
20 Hydraulic lift ram pivots.
21 Three-point linkage lift rods and top link.
22 Suspension cylinder pivots.
23 Automatic Trailer Coupling (when fitted).
24 Steering box input shaft (3155, 3185 machines)
25 Roller Drawbar (if fitted)
† Applies only if recommended oil (see Engine Oil) and
Stratopore filter (3185 only) are not available.
*
*
*
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 2
Issue 8*
Service Schedules - Dry Clutch Transmission
First 100 Hours Dealer Service
Change
1 Engine oil and filter.
2 Fuel filters.
3 Transmission oil filter.
4 Hydraulic oil filter.
Clean
5 Fuel lift pump gauze.
6 Fuel sedimenter (drain).
Check (Engine Stopped)
7 Coolant level/leaks and antifreeze strength.
8 Fuel system for leaks and contamination.
9 Engine pipework routing and security.
10 Fuel system pipework routing and security.
11 Fan belt tension and condition.
12 Air conditioning compressor belt tension.
13 Clutch fluid level.
14 Gearbox oil level.
15 Transmission oil cooler/pipework condition, leakage,
routing and security.
16 Rear axle oil level.
17 Rear axle hub oil level (4WS).
18 Front axle oil level.
19 Front axle hub oil level.
20 Front PTO gearbox oil level.
21 Propellor shaft security.
22 Tyre pressures.
23 Tightness of wheel nuts.
24 Hydraulic oil level.
25 Hydraulic oil cooler/pipework condition, leakage,
routing and security.
26 Brake fluid levels.
27 Brake pad security (service and parking).
28 Brake pipework routing and security.
29 Air system for leaks.
30 Panhard rod torque setting.
31 Ram piston rods for damage/leaks.
32 Battery charge/terminal condition and tightness.
33 Wiring for chafing/routing.
34 Headlight alignment.
35 Windscreen washer level.
36 Neutral start operation (Including clutch and PTO's).
37 Door locks.
Grease
38 Propellor shafts and universal joints.
39 Steering swivels.
40 Rear PTO shaft bearings.
41 3 point linkage.
42 Rear lift ram pivots.
43 Suspension cylinder pivots.
Check (engine running)
44 Exhaust smoke.
45 Throttle and stop controls.
46 PTO operation.
47 2/4WD drive and diff. lock selection.
First 100 Hours Dealer Service (continued)
Check (engine running) - continued 48 Transmission low pressure circuit pressure maintaining
valve setting.
49 Transmission lubrication pressure.
50 Diff. lock pressure relief valve.
51 External hydraulics pressure relief valve.
52 Instrument readings and warning lights.
53 Operation of all electrical equipment.
54 Operation of clutch and footbrakes.
55 Operation of steering.
56 Operation of transmission.
57 Operation of 3-point linkage.
58 Operation of front linkage (optional equipment).
59 Rear axle/chassis clearance.
60 Height corrector valve operation.
61 Parking Brake operation.
62 Pick-up hitch operation.
63 Spool valve operation.
64 Re-calibrate splitter clutch packs
Every 250 Operating Hours or 3 Monthly
whichever occurs first
Do the Daily jobs through to 50 hours plus:
Clean
1 Air filter dust valve.
2 Battery terminals.
Check (Engine Stopped)
3 Front axle oil level.
4 Front axle hub oil levels.
5 Rear axle oil level.
6 Rear axle hub oil level (4WS) (if fitted).
7 Condition of lift ram piston rods.
8 Hose and pipework for chafing and damage.
9 Air cleaner and hose condition and security.
10 Electrical wiring for chafing and routing.
11 Brake pad condition and security.
12 Neutral start operation.
Check (Engine Running)
13 Air conditioning sight glass.
14 Operating speed of Selectronic range changes.
Change
15† Engine oil and filter.
16 Fuel Pre-filter (machines with optional fuel flow
metering only).
Grease
17 Steering swivels.
18 Rear anti-roll bar ball joints.
19 Hydraulic lift cross-shaft.
20 Hydraulic lift ram pivots.
21 Three-point linkage lift rods and top link.
22 Suspension cylinder pivots.
23 Automatic Trailer Coupling (when fitted).
24 Steering box input shaft (3155, 3185 machines)
25 Roller Drawbar (if fitted)
† Applies only if recommended oil (see Engine Oil) and
Stratopore filter (3185 only) are not available.
*
*
*
2 - 3
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 3
Issue 6*
Service Schedules - Dry Clutch Transmission
Every 500 Operating Hours or Six Monthly
whichever occurs first
Do the Daily jobs through to 250 hours plus:
Clean
1 Fuel lift pump gauze (2000 series and 3155).
Check (Engine Stopped)
2 Battery electrolyte level (if battery is not sealed for life).
3 Battery charge condition.
4 Exhaust system security.
5 Engine mounting bolts for tightness.
6 Steering axle wheel alignment.
7 Headlamp alignment.
8 Panhard rod condition and torque tightness.
9 Track rod end and steering ram ball joint security.
10 Steering damper condition and security.
11 4WS Power track rod and ball joints condition and
security.
12 Suspension control arms and ‘V’ link condition and
bolt torque.
13 Brake caliper bolt torque.
Check (Engine Running)
14 Idling speed.
15 Max. no load engine speed.
16 Suspension ride height and corrector valve operation.
17 Suspension pressure maintenance valve pressure.
18 Transmission low pressure circuit pressure maintaining
valve setting.
19 Differential lock pressure relief valve.
20 Pick-up hitch operation.
21 Spool valve operation.
22 Check for electronic draft control faults and rectify.
Change
23 † Engine oil and filters.
24 Hydraulic fluid filter element.
25 Transmission oil filter.
26 Fuel filter (2 elements).
† Applies only if recommended oil (see Engine Oil) and
Stratopore filter (3185 ony) are available. If these are
not available this job should be carried out every 250
hours (see Every 250 Operating Hoursfor suitable
alternative oils).
Every 1000 Operating Hours or Yearly
whichever occurs first
Do the Daily jobs through to 500 hours plus:
Clean
1 Fuel tank suction strainer.
Check (Engine Stopped)
2 ROPS structure.
3 Quality of coolant.
4 4WS RH side trunnion seals and renew if necessary (if
fitted).
5 Engine valve clearances and lubrication (2000 series
only).
Check (Engine Stopped)- continued 6 Engine valve clearances and lubrication (3185 first 1000
hour service only).
Check (Engine Running)
7 Transmission lubrication pressure (HPL and LPL).
8 MRV pressure.
9 Splitter clutch pack calibration.
Change
10 Outer air filter element.
11 Gearbox oil and clean strainer (see Note (1) below).
12 Front axle oil.
13 Front hub oil (see Note (2) below).
14 Rear axle oil (see Note (2) below).
14 Rear hub oil (4WS if fitted) (see Note (2) below).
15 Air system dryer dessicant canister.
Notes:
(1) After a major transmission repair, the new oil should be
run to operating temperature and changed again to
remove any contamination which entered during the
repair. Change the oil and filter after a further 100
hours if the oil was heavily contaminated because of, or
from the failure (e.g. water contamination).
(2) After a hub repair, the new oil should be run to
operating temperature and changed again to remove
any contamination which entered during the repair.
Change the oil again after a further 100 hours to
remove any bedding-in wear.
Every 2000 Operating Hours or Every 2
Years whichever occurs first
Do the Daily jobs through to 1000 hours plus:
Clean
1 Hydraulic tank suction strainers.
Check (Engine Stopped)
2 Rear suspension gas spring pressure.
3 Rear suspension accumulator pressure.
4 Engine valve clearances and lubrication (3000 Series)
5 Engine vibration damper (3185 only).
6 Compressor, check for leaks.
7 Engine belt tensioner bearing (3185 only).
Change
8 Inner air filter element.
9 Coolant.
10 Brake system fluid.
11 Clutch system fluid.
12 Hydraulic fluid (change if sample does not indicate
otherwise).
*
*
*
*
*
*
*
*
*
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 3
Issue 6*
Service Schedules - Dry Clutch Transmission
Every 500 Operating Hours or Six Monthly
whichever occurs first
Do the Daily jobs through to 250 hours plus:
Clean
1 Fuel lift pump gauze (2000 series and 3155).
Check (Engine Stopped)
2 Battery electrolyte level (if battery is not sealed for life).
3 Battery charge condition.
4 Exhaust system security.
5 Engine mounting bolts for tightness.
6 Steering axle wheel alignment.
7 Headlamp alignment.
8 Panhard rod condition and torque tightness.
9 Track rod end and steering ram ball joint security.
10 Steering damper condition and security.
11 4WS Power track rod and ball joints condition and
security.
12 Suspension control arms and ‘V’ link condition and
bolt torque.
13 Brake caliper bolt torque.
Check (Engine Running)
14 Idling speed.
15 Max. no load engine speed.
16 Suspension ride height and corrector valve operation.
17 Suspension pressure maintenance valve pressure.
18 Transmission low pressure circuit pressure maintaining
valve setting.
19 Differential lock pressure relief valve.
20 Pick-up hitch operation.
21 Spool valve operation.
22 Check for electronic draft control faults and rectify.
Change
23 † Engine oil and filters.
24 Hydraulic fluid filter element.
25 Transmission oil filter.
26 Fuel filter (2 elements).
† Applies only if recommended oil (see Engine Oil) and
Stratopore filter (3185 ony) are available. If these are
not available this job should be carried out every 250
hours (see Every 250 Operating Hoursfor suitable
alternative oils).
Every 1000 Operating Hours or Yearly
whichever occurs first
Do the Daily jobs through to 500 hours plus:
Clean
1 Fuel tank suction strainer.
Check (Engine Stopped)
2 ROPS structure.
3 Quality of coolant.
4 4WS RH side trunnion seals and renew if necessary (if
fitted).
5 Engine valve clearances and lubrication (2000 series
only).
Check (Engine Stopped)- continued 6 Engine valve clearances and lubrication (3185 first 1000
hour service only).
Check (Engine Running)
7 Transmission lubrication pressure (HPL and LPL).
8 MRV pressure.
9 Splitter clutch pack calibration.
Change
10 Outer air filter element.
11 Gearbox oil and clean strainer (see Note (1) below).
12 Front axle oil.
13 Front hub oil (see Note (2) below).
14 Rear axle oil (see Note (2) below).
14 Rear hub oil (4WS if fitted) (see Note (2) below).
15 Air system dryer dessicant canister.
Notes:
(1) After a major transmission repair, the new oil should be
run to operating temperature and changed again to
remove any contamination which entered during the
repair. Change the oil and filter after a further 100
hours if the oil was heavily contaminated because of, or
from the failure (e.g. water contamination).
(2) After a hub repair, the new oil should be run to
operating temperature and changed again to remove
any contamination which entered during the repair.
Change the oil again after a further 100 hours to
remove any bedding-in wear.
Every 2000 Operating Hours or Every 2
Years whichever occurs first
Do the Daily jobs through to 1000 hours plus:
Clean
1 Hydraulic tank suction strainers.
Check (Engine Stopped)
2 Rear suspension gas spring pressure.
3 Rear suspension accumulator pressure.
4 Engine valve clearances and lubrication (3000 Series)
5 Engine vibration damper (3185 only).
6 Compressor, check for leaks.
7 Engine belt tensioner bearing (3185 only).
Change
8 Inner air filter element.
9 Coolant.
10 Brake system fluid.
11 Clutch system fluid.
12 Hydraulic fluid (change if sample does not indicate
otherwise).
*
*
*
*
*
*
*
*
*
2 - 4
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 4
Issue 5*
Service Schedules - Wet Clutch Transmission
!WARNING
Maintenance must be done only by suitable qualified and
competent persons. Before doing any maintenance
make sure the machine is safe. It should be correctly
parked on firm level ground.
To prevent anyone starting the engine, remove the
starter key. Disconnect the battery and chock the
wheels when you are working beneath the machine.
If you do not take these precautions you could be killed
or injured.
9-3-1-1
Every 10 Operating Hours or Daily
whichever occurs first
Clean
1 Machine generally.
Drain
2 Air system tank.
3 Empty hydraulic coupling drain reservoir (if fitted).
Check (Engine Stopped)
4 Generally for damage.
5 Engine coolant level and condition.
6 Fuel system for leaks and contamination.
7 Hydraulic fluid level.
8 Hydraulic system for leaks.
9 Machine generally for oil leaks (axles, engine,
transmission).
10 Gearbox oil level.
11 Engine oil level and condition.
12 Tightness of wheel nuts.
13 Windscreen washer level.
14 Tyre pressures and condition.
15 Security of front weights (optional equipment).
16 Seat belt condition and security.
17 Brake fluid levels.
18 Check radiator and coolers for blockage and clean if
required.
Check (engine running)
19 Instrument readings and warning lights.
20 Operation of all electrical equipment.
21 Exhaust for excessive smoke.
22 Operation of clutch and footbrakes
23 Operation of steering.
24 Operation of transmission.
25 Operation of 3-point linkage.
26 Operation of front linkage (optional equipment).
27 Parking brake operation.
28 Throttle and stop controls.
Every 50 Operating Hours or Daily whichever occurs first
Do the Daily jobs plus:
Drain
1 Fuel filter.
2 Fuel pre-filter - when fitted (except 2140).
Clean
3 Air filter dust valve.
Check (Engine Stopped)
4 Fan belt tension and condition.
5 Air conditioning compressor drive belt.
6 Front PTO transfer gearbox oil level (optional
equipment).
7 Brake pad condition.
8 Cab air filter (clean if required).
9 Propshaft security.
Grease
10 Rear PTO drive shaft splines and universal joints.
11 Rear PTO drive shaft bearings.
12 Front axle propshaft.
13 Front PTO drive shaft (optional equipment).
14 Rear axle propshaft.
15 Rear anti-roll bar joints.
16 Hydraulic lift cross-shafts.
17 Hydraulic lift ram pivots.
18 Steering swivels.
19 Suspension cylinder pivots.
20 3-point linkage lift rods and top link.
21 Automatic trailer coupling (when fitted).
22 Roller drawbar (if fitted).
Note: It is essential that drive shaft and propshaft joints are
lubricated as specified.
*
*
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 4
Issue 5*
Service Schedules - Wet Clutch Transmission
!WARNING
Maintenance must be done only by suitable qualified and
competent persons. Before doing any maintenance
make sure the machine is safe. It should be correctly
parked on firm level ground.
To prevent anyone starting the engine, remove the
starter key. Disconnect the battery and chock the
wheels when you are working beneath the machine.
If you do not take these precautions you could be killed
or injured.
9-3-1-1
Every 10 Operating Hours or Daily
whichever occurs first
Clean
1 Machine generally.
Drain
2 Air system tank.
3 Empty hydraulic coupling drain reservoir (if fitted).
Check (Engine Stopped)
4 Generally for damage.
5 Engine coolant level and condition.
6 Fuel system for leaks and contamination.
7 Hydraulic fluid level.
8 Hydraulic system for leaks.
9 Machine generally for oil leaks (axles, engine,
transmission).
10 Gearbox oil level.
11 Engine oil level and condition.
12 Tightness of wheel nuts.
13 Windscreen washer level.
14 Tyre pressures and condition.
15 Security of front weights (optional equipment).
16 Seat belt condition and security.
17 Brake fluid levels.
18 Check radiator and coolers for blockage and clean if
required.
Check (engine running)
19 Instrument readings and warning lights.
20 Operation of all electrical equipment.
21 Exhaust for excessive smoke.
22 Operation of clutch and footbrakes
23 Operation of steering.
24 Operation of transmission.
25 Operation of 3-point linkage.
26 Operation of front linkage (optional equipment).
27 Parking brake operation.
28 Throttle and stop controls.
Every 50 Operating Hours or Daily whichever occurs first
Do the Daily jobs plus:
Drain
1 Fuel filter.
2 Fuel pre-filter - when fitted (except 2140).
Clean
3 Air filter dust valve.
Check (Engine Stopped)
4 Fan belt tension and condition.
5 Air conditioning compressor drive belt.
6 Front PTO transfer gearbox oil level (optional
equipment).
7 Brake pad condition.
8 Cab air filter (clean if required).
9 Propshaft security.
Grease
10 Rear PTO drive shaft splines and universal joints.
11 Rear PTO drive shaft bearings.
12 Front axle propshaft.
13 Front PTO drive shaft (optional equipment).
14 Rear axle propshaft.
15 Rear anti-roll bar joints.
16 Hydraulic lift cross-shafts.
17 Hydraulic lift ram pivots.
18 Steering swivels.
19 Suspension cylinder pivots.
20 3-point linkage lift rods and top link.
21 Automatic trailer coupling (when fitted).
22 Roller drawbar (if fitted).
Note: It is essential that drive shaft and propshaft joints are
lubricated as specified.
*
*
2 - 5
First 100 Hours Dealer Service
Change
1 Engine oil and filter.
2 Fuel filters.
3 Transmission oil filter.
4 Hydraulic oil filter.
5 Front axle oil.
6 Front hub oil.
7 Rear axle oil.
8 Rear hub oil (4WS only).
Clean/Drain
9 Fuel lift pump gauze (clean - except 2140 and 3185).
10 Fuel pre-filter - when fitted (drain - except 2140).
Check (Engine Stopped)
11 Coolant level/leaks and antifreeze strength.
12 Fuel system for leaks and contamination.
13 Engine pipework routing and security.
14 Fuel system pipework routing and security.
15 Fan belt tension and condition.
16 Air conditioning compressor belt tension.
17 Gearbox oil level.
18 Transmission oil cooler/pipework condition, leakage,
routing and security.
19 Front PTO gearbox oil level.
20 Propellor shaft security.
21 Tyre pressures.
22 Tightness of wheel nuts.
23 Hydraulic oil level.
24 Hydraulic oil cooler/pipework condition, leakage,
routing and security.
25 Brake fluid levels.
26 Brake pad security (service and parking).
27 Brake pipework routing and security.
28 Air system for leaks.
29 Panhard rod torque setting.
30 Ram piston rods for damage/leaks.
31 Battery charge/terminal condition and tightness.
32 Wiring for chafing/routing.
33 Headlight alignment.
34 Windscreen washer level.
35 Neutral start operation (including clutch and PTO’s).
36 Door locks.
37 Steering axle wheel alignment.
38 Track rod and ball joint security.
39 Check for error codes, (EMS and ABS when fitted, plus
engine on 2140), download, rectify and delete.
40 Air cleaner and air inlet hose condition and security.
Grease
41 Propellor shafts and universal joints.
42 Steering swivels.
43 Rear PTO shaft bearings.
44 3 point linkage.
45 Rear lift ram pivots.
46 Suspension cylinder pivots.
Check (engine running)
47 Exhaust smoke.
48 Throttle and stop controls.
49 PTO operation.
50 2/4WD drive and diff. lock selection.
51 Transmission pressure circuit pressure maintaining
valve setting.
52 Transmission lubrication pressure (HPL & LPL).
53 Diff. lock pressure relief valve.
54 External hydraulics pressure relief valve.
55 Instrument readings and warning lights.
56 Operation of all electrical equipment.
57 Operation of clutch and footbrakes.
58 Operation of steering.
59 Operation of transmission.
60 Operation of 3-point linkage.
61 Operation of front linkage (optional equipment).
62 Rear axle/chassis clearance.
63 Height corrector valve operation.
64 Parking Brake operation.
65 Pick-up hitch operation.
66 Spool valve operation.
67 Re calibrate splitter clutch packs.
Every 250 Operating Hours or 3 Monthly
whichever occurs first
Do the Daily and 50 Hour jobs plus:
Change
1 †Engine oil and filter.
† Applies only if recommended oil (see Engine Oil) and
Stratopore filter (2140 & 3185 only) are not available.
See T.I. 10/152.
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 5
Issue 4*
Service Schedules - Wet Clutch Transmission
*
*
*
*
*
*
First 100 Hours Dealer Service
Change
1 Engine oil and filter.
2 Fuel filters.
3 Transmission oil filter.
4 Hydraulic oil filter.
5 Front axle oil.
6 Front hub oil.
7 Rear axle oil.
8 Rear hub oil (4WS only).
Clean/Drain
9 Fuel lift pump gauze (clean - except 2140 and 3185).
10 Fuel pre-filter - when fitted (drain - except 2140).
Check (Engine Stopped)
11 Coolant level/leaks and antifreeze strength.
12 Fuel system for leaks and contamination.
13 Engine pipework routing and security.
14 Fuel system pipework routing and security.
15 Fan belt tension and condition.
16 Air conditioning compressor belt tension.
17 Gearbox oil level.
18 Transmission oil cooler/pipework condition, leakage,
routing and security.
19 Front PTO gearbox oil level.
20 Propellor shaft security.
21 Tyre pressures.
22 Tightness of wheel nuts.
23 Hydraulic oil level.
24 Hydraulic oil cooler/pipework condition, leakage,
routing and security.
25 Brake fluid levels.
26 Brake pad security (service and parking).
27 Brake pipework routing and security.
28 Air system for leaks.
29 Panhard rod torque setting.
30 Ram piston rods for damage/leaks.
31 Battery charge/terminal condition and tightness.
32 Wiring for chafing/routing.
33 Headlight alignment.
34 Windscreen washer level.
35 Neutral start operation (including clutch and PTO’s).
36 Door locks.
37 Steering axle wheel alignment.
38 Track rod and ball joint security.
39 Check for error codes, (EMS and ABS when fitted, plus
engine on 2140), download, rectify and delete.
40 Air cleaner and air inlet hose condition and security.
Grease
41 Propellor shafts and universal joints.
42 Steering swivels.
43 Rear PTO shaft bearings.
44 3 point linkage.
45 Rear lift ram pivots.
46 Suspension cylinder pivots.
Check (engine running)
47 Exhaust smoke.
48 Throttle and stop controls.
49 PTO operation.
50 2/4WD drive and diff. lock selection.
51 Transmission pressure circuit pressure maintaining
valve setting.
52 Transmission lubrication pressure (HPL & LPL).
53 Diff. lock pressure relief valve.
54 External hydraulics pressure relief valve.
55 Instrument readings and warning lights.
56 Operation of all electrical equipment.
57 Operation of clutch and footbrakes.
58 Operation of steering.
59 Operation of transmission.
60 Operation of 3-point linkage.
61 Operation of front linkage (optional equipment).
62 Rear axle/chassis clearance.
63 Height corrector valve operation.
64 Parking Brake operation.
65 Pick-up hitch operation.
66 Spool valve operation.
67 Re calibrate splitter clutch packs.
Every 250 Operating Hours or 3 Monthly
whichever occurs first
Do the Daily and 50 Hour jobs plus:
Change
1 †Engine oil and filter.
† Applies only if recommended oil (see Engine Oil) and
Stratopore filter (2140 & 3185 only) are not available.
See T.I. 10/152.
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 5
Issue 4*
Service Schedules - Wet Clutch Transmission
*
*
*
*
*
*
2 - 6
Every 500 Operating Hours or Six Monthly
whichever occurs first
Do the Daily jobs through to 250 hours plus:
Clean
1 Fuel lift pump gauze (all machines except 2140 & 3185).
Grease
2 Steering box input shaft (3000 series machines).
Check (Engine Stopped)
3 Battery electrolyte level (if battery is not sealed for lift).
4 Battery charge condition.
5 Exhaust system security.
6 Engine mounting bolts for tightness.
7 Compressor housing for cracks and damage.
8 Compressor mountings for tightness.
9 Injection pump mountings for tightness.
10 Steering axle wheel alignment.
11 Headlamp alignment.
12 Panhard rod condition and torque tightness.
13 Track rod end, steering ram and drag link ball joint
security.
14 Steering damper condition and security.
15 4WS power track rod and ball joints condition and
security (2000 series machines).
16 Suspension control arms and ‘V’ link condition and bolt
torque.
17 Air cleaner and hose condition and security.
18 Air system for leaks.
19 Battery terminals condition and tightness.
20 Brake pad security (service and parking).
21 Parking brake adjustment
22 Brake pipework security.
23 Condition of lift ram rods.
24 Coolant level/leaks, quality and anti-freeze strength.
25 Brake caliper bolt torque.
26 Hoses and pipework for chafing and damage.
27 Neutral start operation.
28 Ram piston rods for damage/leaks.
29 Front axle oil level.
30 Rear axle oil level.
31 Transmission and hydraulic oil cooler/pipework
condition, leakage and security.
32 Wiring for chafing and routing.
33 Download EMS Datalog.
34 Download ABS error codes and investigate any found.
35 Download engine error codes, rectify and delete (2140
only).
36 Brake light switch input to ABS ECU using computer
diagnostic tool.
37 All air warning lamps illuminate after draining down the
air tanks.
38 The park brake lamp illuminates after draining down the
trailer air tank.
Check (Engine Running)
39 Idling speed.
40 Max. no load engine speed.
41 Suspension ride height and corrector valve operation.
42 Suspension pressure maintenance valve pressure.
43 Transmission pressure circuit pressure maintaining
valve setting.
44 Differential lock pressure.
45 Field speed control.
46 Pick-up hitch operation.
47 Rear axle/chassis clearance. 48 Spool valve operation. 49 Selection speed of Selectronic range change < 2 kph. 50 Check for electronic draft control faults and rectify.
Change
51 †Engine oil and filters.
52 Hydraulic fluid filter element.
53 Transmission oil filter.
54 Fuel filter (2 elements).
55 Front hub oil (see Note (2) below).
56 Rear hub oil (4WS only) (see Note (2) below).
57 Fuel pre-filter element.
† Applies only if recommended oil (see Engine Oil) and
Stratopore filter (2140 & 3185 ony) are available. (See
T.I. 10/152.) If these are not available this job should be
carried out every 250 hours (see Every 250 Operating
Hoursfor suitable alternative oils).
Every 1000 Operating Hours or Yearly
whichever occurs first
Do the Daily jobs through to 250 hours plus:
Clean
1 Fuel tank suction strainer (early machines only).
2 Trailer brake control line air filter.
Check (Engine Stopped)
3 ROPS structure.
4 Quality of coolant.
5 4WS RH side trunnion seals and renew if necessary.
6 Engine valve clearances and lubrication (2115, 2125,
2135 and 2150).
7 Engine valve clearances (3185 machines, first 1000
hour service only)
8 Fan belt tensioner (2140 and 3185).
9 Fan hub end play (2140 and 3185).
Check (Engine Running)
10 Transmission lubrication pressure (HPL and LPL).
11 MRV pressure.
12 Splitter and wet clutch calibration.
13 ABS system test.
Change
14 Outer air filter element.
15 Gearbox oil and clean strainer (see Note (1) below).
16 Front axle oil.
17 Rear axle oil.
18 Air system dryer dessicant canister.
Notes:
(1) After a major transmission repair, the new oil should be
run to operating temperature and changed again to
remove any contamination which entered during the
repair. Change the oil and filter after a further 100
hours if the oil was heavily contaminated because of, or
from the failure (e.g. water contamination).
(2) After a hub repair, the new oil should be run to
operating temperature and changed again to remove
any contamination which entered during the repair.
Change the oil again after a further 100 hours to
remove any bedding-in wear.
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 6
Issue 6*
Service Schedules - Wet Clutch Transmission
*
Every 500 Operating Hours or Six Monthly
whichever occurs first
Do the Daily jobs through to 250 hours plus:
Clean
1 Fuel lift pump gauze (all machines except 2140 & 3185).
Grease
2 Steering box input shaft (3000 series machines).
Check (Engine Stopped)
3 Battery electrolyte level (if battery is not sealed for lift).
4 Battery charge condition.
5 Exhaust system security.
6 Engine mounting bolts for tightness.
7 Compressor housing for cracks and damage.
8 Compressor mountings for tightness.
9 Injection pump mountings for tightness.
10 Steering axle wheel alignment.
11 Headlamp alignment.
12 Panhard rod condition and torque tightness.
13 Track rod end, steering ram and drag link ball joint
security.
14 Steering damper condition and security.
15 4WS power track rod and ball joints condition and
security (2000 series machines).
16 Suspension control arms and ‘V’ link condition and bolt
torque.
17 Air cleaner and hose condition and security.
18 Air system for leaks.
19 Battery terminals condition and tightness.
20 Brake pad security (service and parking).
21 Parking brake adjustment
22 Brake pipework security.
23 Condition of lift ram rods.
24 Coolant level/leaks, quality and anti-freeze strength.
25 Brake caliper bolt torque.
26 Hoses and pipework for chafing and damage.
27 Neutral start operation.
28 Ram piston rods for damage/leaks.
29 Front axle oil level.
30 Rear axle oil level.
31 Transmission and hydraulic oil cooler/pipework
condition, leakage and security.
32 Wiring for chafing and routing.
33 Download EMS Datalog.
34 Download ABS error codes and investigate any found.
35 Download engine error codes, rectify and delete (2140
only).
36 Brake light switch input to ABS ECU using computer
diagnostic tool.
37 All air warning lamps illuminate after draining down the
air tanks.
38 The park brake lamp illuminates after draining down the
trailer air tank.
Check (Engine Running)
39 Idling speed.
40 Max. no load engine speed.
41 Suspension ride height and corrector valve operation.
42 Suspension pressure maintenance valve pressure.
43 Transmission pressure circuit pressure maintaining
valve setting.
44 Differential lock pressure.
45 Field speed control.
46 Pick-up hitch operation.
47 Rear axle/chassis clearance. 48 Spool valve operation. 49 Selection speed of Selectronic range change < 2 kph. 50 Check for electronic draft control faults and rectify.
Change
51 †Engine oil and filters.
52 Hydraulic fluid filter element.
53 Transmission oil filter.
54 Fuel filter (2 elements).
55 Front hub oil (see Note (2) below).
56 Rear hub oil (4WS only) (see Note (2) below).
57 Fuel pre-filter element.
† Applies only if recommended oil (see Engine Oil) and
Stratopore filter (2140 & 3185 ony) are available. (See
T.I. 10/152.) If these are not available this job should be
carried out every 250 hours (see Every 250 Operating
Hoursfor suitable alternative oils).
Every 1000 Operating Hours or Yearly
whichever occurs first
Do the Daily jobs through to 250 hours plus:
Clean
1 Fuel tank suction strainer (early machines only).
2 Trailer brake control line air filter.
Check (Engine Stopped)
3 ROPS structure.
4 Quality of coolant.
5 4WS RH side trunnion seals and renew if necessary.
6 Engine valve clearances and lubrication (2115, 2125,
2135 and 2150).
7 Engine valve clearances (3185 machines, first 1000
hour service only)
8 Fan belt tensioner (2140 and 3185).
9 Fan hub end play (2140 and 3185).
Check (Engine Running)
10 Transmission lubrication pressure (HPL and LPL).
11 MRV pressure.
12 Splitter and wet clutch calibration.
13 ABS system test.
Change
14 Outer air filter element.
15 Gearbox oil and clean strainer (see Note (1) below).
16 Front axle oil.
17 Rear axle oil.
18 Air system dryer dessicant canister.
Notes:
(1) After a major transmission repair, the new oil should be
run to operating temperature and changed again to
remove any contamination which entered during the
repair. Change the oil and filter after a further 100
hours if the oil was heavily contaminated because of, or
from the failure (e.g. water contamination).
(2) After a hub repair, the new oil should be run to
operating temperature and changed again to remove
any contamination which entered during the repair.
Change the oil again after a further 100 hours to
remove any bedding-in wear.
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 6
Issue 6*
Service Schedules - Wet Clutch Transmission
*
2 - 7
Every 2000 Operating Hours or every 2
Years whichever occurs first
Do the Daily jobs through to 1000 hours plus:
Clean
1 Hydraulic fluid suction strainer.
Check (Engine Stopped)
2 Rear suspension gas spring pressure.
3 Rear suspension accumulator pressure.
4 Engine valve clearances and lubrication (3185).
5 Engine vibration damper.
6 Compressor output line, air drier and pressure
regulator: check for carbon deposits and for air leaks.
7 Radiator hose condition.
8 Transmission accumulator pressure.
Change
9 Inner air filter element.
10 Coolant.
11 Brake system fluid.
12 Hydraulic fluid (change if sample does not indicate
otherwise).
Every 5000 Operating Hours or Every 2
Years whichever occurs first
Do the Daily jobs through to 1000 hours plus:
Check (Engine Stopped)
1 Engine valve clearances and adjust if necessary (2140).
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 7
Issue 2*
Service Schedules- Wet Clutch Transmission
*
*
*
*
Every 2000 Operating Hours or every 2
Years whichever occurs first
Do the Daily jobs through to 1000 hours plus:
Clean
1 Hydraulic fluid suction strainer.
Check (Engine Stopped)
2 Rear suspension gas spring pressure.
3 Rear suspension accumulator pressure.
4 Engine valve clearances and lubrication (3185).
5 Engine vibration damper.
6 Compressor output line, air drier and pressure
regulator: check for carbon deposits and for air leaks.
7 Radiator hose condition.
8 Transmission accumulator pressure.
Change
9 Inner air filter element.
10 Coolant.
11 Brake system fluid.
12 Hydraulic fluid (change if sample does not indicate
otherwise).
Every 5000 Operating Hours or Every 2
Years whichever occurs first
Do the Daily jobs through to 1000 hours plus:
Check (Engine Stopped)
1 Engine valve clearances and adjust if necessary (2140).
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 7
Issue 2*
Service Schedules- Wet Clutch Transmission
*
*
*
*
2 - 8
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 8
Issue 1
Cleaning the Machine and Checking for Damage
Clean the machine using water and/or steam. Pay particular
attention to the underside. Do not allow mud to build up on
the engine and transmission. Make sure that the radiator
grille is not clogged up.
Excessive power washing can cause damage to seals and
bearings. Do not direct high power water jets at oil seals,
universal joints or electrical components, especially draft
control solenoids.
On the 4WS machine, take special care to avoid directing
high power water jets at the electrical connections to the
front and rear axles.
Inspect steelwork for damage. Note damaged paintwork for
future repair.
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.
Make sure all pivot pins are correctly in place and secured by their locking devices.
Ensure that the steps and handrails are undamaged and
secure.
Check for broken or cracked window glass. Replace
damaged items.
Check all lamp lenses for damage.
Inspect the tyres for damage and penetration by sharp
objects.
Check that all safety decals are in place and undamaged, fit
new decals where necessary.
SEAT BELT
Section 3 Routine Maintenance
9803/8020
Section 3
2 - 8
Issue 1
Cleaning the Machine and Checking for Damage
Clean the machine using water and/or steam. Pay particular
attention to the underside. Do not allow mud to build up on
the engine and transmission. Make sure that the radiator
grille is not clogged up.
Excessive power washing can cause damage to seals and
bearings. Do not direct high power water jets at oil seals,
universal joints or electrical components, especially draft
control solenoids.
On the 4WS machine, take special care to avoid directing
high power water jets at the electrical connections to the
front and rear axles.
Inspect steelwork for damage. Note damaged paintwork for
future repair.
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.
Make sure all pivot pins are correctly in place and secured by their locking devices.
Ensure that the steps and handrails are undamaged and
secure.
Check for broken or cracked window glass. Replace
damaged items.
Check all lamp lenses for damage.
Inspect the tyres for damage and penetration by sharp
objects.
Check that all safety decals are in place and undamaged, fit
new decals where necessary.
SEAT BELT
2 - 9
Routine Maintenance
9803/8020
2 - 9
Issue 1
Bonnet
Section 3 Section 3
Opening the Bonnet
(2000 Series Machines)
!!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
1Engage the parking brake, put the transmission in
neutral and stop the engine. Remove the starter key.
2Release the required bonnet side by turning the two
turnbucklesA to the vertical position.
3Lift the bonnet side clear of the machine and put it in a
safe place to prevent damage.
Closing the Bonnet
(2000 Series Machines)
1Position the bonnet side in the aperture and ensure it
locates at the top. Fasten the bonnet securely by
pushing in each turnbuckle A.
Opening the Bonnet
(3000 Series Machines)
!!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
1Engage the parking brake, put the transmission in
neutral, turn the front wheels onto full left lock and stop
the engine. Remove the starter key.
2Release latches by pulling back leverB.
3Raise the bonnet fully. Do not leave it partly raised as it
could then creep down.
Closing the Bonnet
(3000 Series Machines)
1Lower the bonnet by pushing it at the front, centrally
above the grille, to ensure that it closes squarely. Press
it firmly down to close the latches.
231810
AA
A293970
B
Routine Maintenance
9803/8020
2 - 9
Issue 1
Bonnet
Section 3 Section 3
Opening the Bonnet
(2000 Series Machines)
!!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
1Engage the parking brake, put the transmission in
neutral and stop the engine. Remove the starter key.
2Release the required bonnet side by turning the two
turnbucklesA to the vertical position.
3Lift the bonnet side clear of the machine and put it in a
safe place to prevent damage.
Closing the Bonnet
(2000 Series Machines)
1Position the bonnet side in the aperture and ensure it
locates at the top. Fasten the bonnet securely by
pushing in each turnbuckle A.
Opening the Bonnet
(3000 Series Machines)
!!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
1Engage the parking brake, put the transmission in
neutral, turn the front wheels onto full left lock and stop
the engine. Remove the starter key.
2Release latches by pulling back leverB.
3Raise the bonnet fully. Do not leave it partly raised as it
could then creep down.
Closing the Bonnet
(3000 Series Machines)
1Lower the bonnet by pushing it at the front, centrally
above the grille, to ensure that it closes squarely. Press
it firmly down to close the latches.
231810
AA
A293970
B
A286622
3 - 1
Routine Maintenance
9803/8020
3 - 1
Issue 3*
Greasing
Section 3 Section 3
General
Read and understand Lubricants - Health and Safety,
before greasing. You must grease the machine regularly to
keep it working efficiently. Regular greasing will also
lengthen the machine's working life. Refer to the Service
Schedules for the recommended frequencies.
Note:If working in muddy conditions the propshafts and
PTO driveshafts must be greased daily.
Note: The machine must always be greased after pressure-
washing or steam cleaning. Extra care must be taken to
ensure that propshaft universal joints and splines are
greased regularly.
Greasing should be done with a grease gun. Normally, two
strokes of the gun should be enough. Stop greasing when
fresh grease appears at the joint. Use only JCB HP Grease
or equivalent.
In the following illustrations the grease points are numbered.
Count them off as you grease them.
Refit the grease point dust caps after greasing.
Propshafts and PTO Driveshafts
!!WARNING
Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking
brake. Lower any mounted implements to the ground.
Stop the engine, remove the starter key, disconnect the
battery. Chock the wheels.
13-3-1-1
Rear PTO drive shaft
Grease points 7 to 9.
Front axle propshaft
Grease points1 to3. (Point2 not fitted to later machines.)
Rear axle propshaft
Grease points4 to6. (Point6 not fitted to later machines.)
Front PTO drive shaft (optional)
Grease points 10to 12.
Note: When greasing the universal joints, you must ensure
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
Grease point 13. Do not exceed 2 to 3 strokes of the grease
gun.
0
!
@
3
7
9
5
6
8
£
4
2
1
*
*
3 - 1
Routine Maintenance
9803/8020
3 - 1
Issue 3*
Greasing
Section 3 Section 3
General
Read and understand Lubricants - Health and Safety,
before greasing. You must grease the machine regularly to
keep it working efficiently. Regular greasing will also
lengthen the machine's working life. Refer to the Service
Schedules for the recommended frequencies.
Note:If working in muddy conditions the propshafts and
PTO driveshafts must be greased daily.
Note: The machine must always be greased after pressure-
washing or steam cleaning. Extra care must be taken to
ensure that propshaft universal joints and splines are
greased regularly.
Greasing should be done with a grease gun. Normally, two
strokes of the gun should be enough. Stop greasing when
fresh grease appears at the joint. Use only JCB HP Grease
or equivalent.
In the following illustrations the grease points are numbered.
Count them off as you grease them.
Refit the grease point dust caps after greasing.
Propshafts and PTO Driveshafts
!!WARNING
Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking
brake. Lower any mounted implements to the ground.
Stop the engine, remove the starter key, disconnect the
battery. Chock the wheels.
13-3-1-1
Rear PTO drive shaft
Grease points 7 to 9.
Front axle propshaft
Grease points1 to3. (Point2 not fitted to later machines.)
Rear axle propshaft
Grease points4 to6. (Point6 not fitted to later machines.)
Front PTO drive shaft (optional)
Grease points 10to 12.
Note: When greasing the universal joints, you must ensure
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
Grease point 13. Do not exceed 2 to 3 strokes of the grease
gun.
0
!
@
3
7
9
5
6
8
£
4
2
1
*
*
3 - 2
Steering Swivels
(2000 Series Machines)
!!WARNING
Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking
brake. Lower any mounted implements to the ground.
Stop the engine, remove the starter key, disconnect the
battery. Chock the wheels.
13-3-1-1
2WS:Grease points 1and 2on each side of the machine.
4WS:Grease points 3to 6on the front axle.
Grease points 7to 10on the rear axle.
Note: After initial greasing, turn the wheels from lock to lock,
then grease again to ensure full penetration.
Section 3 Routine Maintenance
9803/8020
Section 3
3 - 2
Issue 2*
Greasing
1
2
S229870
3
4
5
6
9
0
7
8
250690
*
Steering Swivels
(2000 Series Machines)
!!WARNING
Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking
brake. Lower any mounted implements to the ground.
Stop the engine, remove the starter key, disconnect the
battery. Chock the wheels.
13-3-1-1
2WS:Grease points 1and 2on each side of the machine.
4WS:Grease points 3to 6on the front axle.
Grease points 7to 10on the rear axle.
Note: After initial greasing, turn the wheels from lock to lock,
then grease again to ensure full penetration.
Section 3 Routine Maintenance
9803/8020
Section 3
3 - 2
Issue 2*
Greasing
1
2
S229870
3
4
5
6
9
0
7
8
250690
*
3 - 3
Front Axle Steering Swivels
(3000 Series Machines)
!!WARNING
Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking
brake. Lower any mounted implements to the ground.
Stop the engine, remove the starter key, disconnect the
battery. Chock the wheels.
13-3-1-1
Grease points 1to 4.
Note: After initial greasing, turn the wheels from lock to lock,
then grease again to ensure full penetration.
Section 3 Routine Maintenance
9803/8020
Section 3
3 - 3
Issue 2*
*Greasing
A293430
1
2
3
4
*
Front Axle Steering Swivels
(3000 Series Machines)
!!WARNING
Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking
brake. Lower any mounted implements to the ground.
Stop the engine, remove the starter key, disconnect the
battery. Chock the wheels.
13-3-1-1
Grease points 1to 4.
Note: After initial greasing, turn the wheels from lock to lock,
then grease again to ensure full penetration.
Section 3 Routine Maintenance
9803/8020
Section 3
3 - 3
Issue 2*
*Greasing
A293430
1
2
3
4
*
3 - 4
Hydraulic Lift and 3-Point Linkage
Hydraulic Lift Cross-shaft
Grease points1 and 2.
Hydraulic Lift Rams
Grease points3 to6.
Three Point Linkage Lift Rods
Grease points 7 and 8.
Stabilisers (Standard Type)
Grease at point 14
Note:Where standard type stabilisers are fitted to both
sides of the machine, there will be a grease point on each
one.
Rear PTO Drive Shaft Bearings
Grease point 9. Do not exceed 2 to 3 strokes of the grease
gun.
Rear Suspension Cylinder Pivots
Grease points10 to 13.
Section 3 Routine Maintenance
9803/8020
Section 3
3 - 4
Issue 2*
Greasing
*(2000 Series Machines)
S229981
00@ @
!£
1 2
3
$
4
9
65
7 8
*
*
*
*
Hydraulic Lift and 3-Point Linkage
Hydraulic Lift Cross-shaft
Grease points1 and 2.
Hydraulic Lift Rams
Grease points3 to6.
Three Point Linkage Lift Rods
Grease points 7 and 8.
Stabilisers (Standard Type)
Grease at point 14
Note:Where standard type stabilisers are fitted to both
sides of the machine, there will be a grease point on each
one.
Rear PTO Drive Shaft Bearings
Grease point 9. Do not exceed 2 to 3 strokes of the grease
gun.
Rear Suspension Cylinder Pivots
Grease points10 to 13.
Section 3 Routine Maintenance
9803/8020
Section 3
3 - 4
Issue 2*
Greasing
*(2000 Series Machines)
S229981
00@ @
!£
1 2
3
$
4
9
65
7 8
*
*
*
*
3 - 5
Section 3 Routine Maintenance
9803/8020
Section 3
3 - 5
Issue 2*
Greasing
*(3000 Series Machines)
!!WARNING
You will be working close into the machine for these
jobs. Lower the equipment. Remove the starter key and
disconnect the battery. This will prevent the engine from
being started. Make sure that the parking brake is
engaged.
Chock all four wheels before getting under the machine.
13-3-1-9
Note: Ladder hitch and trailer coupling omitted for clarity.
Rear Suspension Cylinder Pivots
Grease points 1to4.
Hydraulic Lift and 3-Point Linkage
Hydraulic lift cross-shaft
Grease points 5and 6.
Hydraulic lift rams
Grease points 7to10.
Three point linkage lift rods
Grease at nipples11and 12. On later machines grease at
nipples11, 12,13and14(lift collars AandBto access
nipples 13and 14). On machines with heavy duty linkage
grease points15and 16 also.
Stabilizers (standard type)
Grease at point 17.
Note: Where standard type stabilizers are fitted to both
sides of the machine, there will be a grease point on each
one.
Rear PTO Drive Shaft Bearing
Grease point 18. Do not exceed 2 to 3 strokes of the grease
*
*
*
*
*
AB
II
AB
III
AB
I
A286030
1 3
!
%
2
9
£
7 8
65
0
$
^
4
@
&
A B
*
Section 3 Routine Maintenance
9803/8020
Section 3
3 - 5
Issue 2*
Greasing
*(3000 Series Machines)
!!WARNING
You will be working close into the machine for these
jobs. Lower the equipment. Remove the starter key and
disconnect the battery. This will prevent the engine from
being started. Make sure that the parking brake is
engaged.
Chock all four wheels before getting under the machine.
13-3-1-9
Note: Ladder hitch and trailer coupling omitted for clarity.
Rear Suspension Cylinder Pivots
Grease points 1to4.
Hydraulic Lift and 3-Point Linkage
Hydraulic lift cross-shaft
Grease points 5and 6.
Hydraulic lift rams
Grease points 7to10.
Three point linkage lift rods
Grease at nipples11and 12. On later machines grease at
nipples11, 12,13and14(lift collars AandBto access
nipples 13and 14). On machines with heavy duty linkage
grease points15and 16 also.
Stabilizers (standard type)
Grease at point 17.
Note: Where standard type stabilizers are fitted to both
sides of the machine, there will be a grease point on each
one.
Rear PTO Drive Shaft Bearing
Grease point 18. Do not exceed 2 to 3 strokes of the grease
*
*
*
*
*
AB
II
AB
III
AB
I
A286030
1 3
!
%
2
9
£
7 8
65
0
$
^
4
@
&
A B
*
3 - 6
Rear Anti-roll Bar Ball Joints
!!WARNING
Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking
brake. Lower any mounted implements to the ground.
Stop the engine, remove the starter key, disconnect the
battery. Chock the wheels.
13-3-1-1
2WS:Grease points4 and5.
4WS:Grease points6 to 9.
Section 3 Routine Maintenance
9803/8020
Section 3
3 - 6
Issue 1
Greasing
(2000 Series Machines)
44 5 5
262210
A268420
66
9 97 7
8 8
2WS
4WS
Rear Anti-roll Bar Ball Joints
!!WARNING
Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking
brake. Lower any mounted implements to the ground.
Stop the engine, remove the starter key, disconnect the
battery. Chock the wheels.
13-3-1-1
2WS:Grease points4 and5.
4WS:Grease points6 to 9.
Section 3 Routine Maintenance
9803/8020
Section 3
3 - 6
Issue 1
Greasing
(2000 Series Machines)
44 5 5
262210
A268420
66
9 97 7
8 8
2WS
4WS
3 - 7
Steering Box Input Shaft Seal
Grease at point 1through the hole in the chassis side
member.
Note: Apply only one shot of grease from a manual grease
gun with a rigid connector. Excessive greasing would
damage the internal seals of the steering box.
Rear Anti-roll Bar Ball Joints
!!WARNING
Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking
brake. Lower any mounted implements to the ground.
Stop the engine, remove the starter key, disconnect the
battery. Chock the wheels.
13-3-1-1
Grease points2 and3.
Section 3 Routine Maintenance
9803/8020
Section 3
3 - 7
Issue 1
Greasing
(3000 Series Machines)
A293980
262210
22
3 3
1
Steering Box Input Shaft Seal
Grease at point 1through the hole in the chassis side
member.
Note: Apply only one shot of grease from a manual grease
gun with a rigid connector. Excessive greasing would
damage the internal seals of the steering box.
Rear Anti-roll Bar Ball Joints
!!WARNING
Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking
brake. Lower any mounted implements to the ground.
Stop the engine, remove the starter key, disconnect the
battery. Chock the wheels.
13-3-1-1
Grease points2 and3.
Section 3 Routine Maintenance
9803/8020
Section 3
3 - 7
Issue 1
Greasing
(3000 Series Machines)
A293980
262210
22
3 3
1
3 - 8
Section 3 Routine Maintenance
9803/8020
Section 3
3 - 8
Issue 2*
Greasing
Automatic Trailer Coupling (if fitted)
Note: Whenever the coupling has been pressure-washed it
must always be greased.
Make sure the coupling is in the open position, i.e. the
coupling pin is up and the hand lever Ais in its highest
position.
Grease at points 1and 2.
Operate lever Aseveral times so that the grease is
distributed throughout the bearing.
!!CAUTION
Keep your hands out of the funnel or you may be injured
by the coupling pin as it is forced down by its spring.
13-2-2-17
Grease again and operate the hand lever again.
If driving without a trailer attached, close the coupling to
prevent dirt accumulation.
Roller Drawbar (if fitted)
!!WARNING
You will be working close into the machine for these
jobs. Lower the equipment. Remove the starter key and
disconnect the battery. This will prevent the engine from
being started. Make sure that the parking brake is
engaged.
Chock all four wheels before getting under the machine.
13-3-1-9
Grease points 3and 4.
Smear surface 5with grease.
S170201
AB
II
AB
III
AB
I
A309960
5
3
4
Section 3 Routine Maintenance
9803/8020
Section 3
3 - 8
Issue 2*
Greasing
Automatic Trailer Coupling (if fitted)
Note: Whenever the coupling has been pressure-washed it
must always be greased.
Make sure the coupling is in the open position, i.e. the
coupling pin is up and the hand lever Ais in its highest
position.
Grease at points 1and 2.
Operate lever Aseveral times so that the grease is
distributed throughout the bearing.
!!CAUTION
Keep your hands out of the funnel or you may be injured
by the coupling pin as it is forced down by its spring.
13-2-2-17
Grease again and operate the hand lever again.
If driving without a trailer attached, close the coupling to
prevent dirt accumulation.
Roller Drawbar (if fitted)
!!WARNING
You will be working close into the machine for these
jobs. Lower the equipment. Remove the starter key and
disconnect the battery. This will prevent the engine from
being started. Make sure that the parking brake is
engaged.
Chock all four wheels before getting under the machine.
13-3-1-9
Grease points 3and 4.
Smear surface 5with grease.
S170201
AB
II
AB
III
AB
I
A309960
5
3
4
4 - 1
Checking the ROPS Structure
!!WARNING
The cab on this machine is designed to give the operator
protection in the event of the machine rolling over
(ROPS). The following points must be strictly observed.
1 If the machine has been in an accident which has
damaged the ROPS structure, the machine must not
be used until the structure has been renewed. If there
is any doubt about the strength of the ROPS
structure, it must be renewed. The operator could be
killed or seriously injured as a result of using a
machine with a damaged or missing ROPS.
2 The ROPS structure must not be modified except as
approved by JCB. Unauthorised modifications may
result in weakening of the structure.
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
Check the structure for damage.
Check that the four mounting bolts are installed and
undamaged. Check that torque tightness of nuts Aand Bis
correct (seeTablebelow). Tighten them to the correct
torque if necessary.
Zinc-Plated Fasteners (colour: golden)
Nm kgf m lbf ft
375 38 277
Dacromet Fasteners (colour: mottled silver)
Nm kgf m lbf ft
365 37 269
Routine Maintenance
9803/8020
4 - 1
Issue 3
Cab
Section 3 Section 3
229990A
B
Checking the ROPS Structure
!!WARNING
The cab on this machine is designed to give the operator
protection in the event of the machine rolling over
(ROPS). The following points must be strictly observed.
1 If the machine has been in an accident which has
damaged the ROPS structure, the machine must not
be used until the structure has been renewed. If there
is any doubt about the strength of the ROPS
structure, it must be renewed. The operator could be
killed or seriously injured as a result of using a
machine with a damaged or missing ROPS.
2 The ROPS structure must not be modified except as
approved by JCB. Unauthorised modifications may
result in weakening of the structure.
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
Check the structure for damage.
Check that the four mounting bolts are installed and
undamaged. Check that torque tightness of nuts Aand Bis
correct (seeTablebelow). Tighten them to the correct
torque if necessary.
Zinc-Plated Fasteners (colour: golden)
Nm kgf m lbf ft
375 38 277
Dacromet Fasteners (colour: mottled silver)
Nm kgf m lbf ft
365 37 269
Routine Maintenance
9803/8020
4 - 1
Issue 3
Cab
Section 3 Section 3
229990A
B
4 - 2
Section 3 Routine Maintenance
9803/8020
Section 3
4 - 2
Issue 2*
Cab
Checking Windscreen Washer Fluid Level
Fill the windscreen washer bottle Xwith a suitable liquid. The
liquid should contain a de-icing fluid to prevent freezing. Do
not use engine coolant antifreeze.
A290350
X
2000 Series Machines*
3000 Series Machines*
*
A293830
X
Section 3 Routine Maintenance
9803/8020
Section 3
4 - 2
Issue 2*
Cab
Checking Windscreen Washer Fluid Level
Fill the windscreen washer bottle Xwith a suitable liquid. The
liquid should contain a de-icing fluid to prevent freezing. Do
not use engine coolant antifreeze.
A290350
X
2000 Series Machines*
3000 Series Machines*
*
A293830
X
5 - 1
Cleaning the Filter
Note: For crop spraying applications, a heavy duty carbon
filter can be used in place of the standard filter. Carbon filters
must not be cleaned. Keep a log of the hours used and
renew at 250 hour intervals.
!!WARNING
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6
1Remove nuts Aand pull out the filter B.
2Using compressed air at a maximum pressure of 5.5 bar
(80 lbf/in
2
), blow out the dirt from the clean (gasket) side
to the dirty (grid) side.
3Check the condition of the filter element and renew if split
or worn.
4Check the condition of the filter gasket. If split or worn
renew the filter.
5Check and clean the filter sealing face on the cab body.
6Refit the filter, making sure that the gasket side goes first.
Refit nuts A.
Section 3 Routine Maintenance
9803/8020
Section 3
5 - 1
Issue 3*
Air Conditioning
(2000 Series Machines)
229880
B
A
Adjusting the Compressor Belt
(2115, 2125, 2135, and 2150)
1Stop the engine.
2Remove the left-hand bonnet side panel.
! !WARNING
Make sure the engine cannot be started. Disconnect the
battery before doing this job.
2-3-3-5
3Loosen nuts A, B.
4Position the compressor so that there is 10mm (0.4 in)
slack on the longest run of the belt.
5Retighten nuts Aand B.
! !WARNING
The air conditioning system is a closed loop system and
contains pressurised refrigerant. No part of the system
must be disconnected except by a qualified refrigeration
engineer.
4-3-4-1
B
S232630
*
Cleaning the Filter
Note: For crop spraying applications, a heavy duty carbon
filter can be used in place of the standard filter. Carbon filters
must not be cleaned. Keep a log of the hours used and
renew at 250 hour intervals.
!!WARNING
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6
1Remove nuts Aand pull out the filter B.
2Using compressed air at a maximum pressure of 5.5 bar
(80 lbf/in
2
), blow out the dirt from the clean (gasket) side
to the dirty (grid) side.
3Check the condition of the filter element and renew if split
or worn.
4Check the condition of the filter gasket. If split or worn
renew the filter.
5Check and clean the filter sealing face on the cab body.
6Refit the filter, making sure that the gasket side goes first.
Refit nuts A.
Section 3 Routine Maintenance
9803/8020
Section 3
5 - 1
Issue 3*
Air Conditioning
(2000 Series Machines)
229880
B
A
Adjusting the Compressor Belt
(2115, 2125, 2135, and 2150)
1Stop the engine.
2Remove the left-hand bonnet side panel.
! !WARNING
Make sure the engine cannot be started. Disconnect the
battery before doing this job.
2-3-3-5
3Loosen nuts A, B.
4Position the compressor so that there is 10mm (0.4 in)
slack on the longest run of the belt.
5Retighten nuts Aand B.
! !WARNING
The air conditioning system is a closed loop system and
contains pressurised refrigerant. No part of the system
must be disconnected except by a qualified refrigeration
engineer.
4-3-4-1
B
S232630
*
5 - 2
Cleaning the Filter
Note: The air conditioning system contains environmentally
safe R-134A refrigerant. Do not use test equipment or
gauges that have contacted R12 refrigerant or the system
will be damaged.
Note: For crop spraying applications, a heavy duty carbon
filter can be used in place of the standard filter. Carbon
filters must not be cleaned. Keep a log of the hours used
and renew at 250 hour intervals.
!!WARNING
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6
1Unclip closing panel A, unscrew and pull out the filter
B.
2Using compressed air at a maximum pressure of 5.5
bar (80 lbf/in
2
), blow out the dirt from the clean (gasket)
side to the dirty (grid) side.
3Check the condition of the filter element and renew if
split or worn.
4Check the condition of the filter gasket. If split or worn
renew the filter.
5Check and clean the filter sealing face on the cab body.
6Refit the filter, making sure that the gasket side goes in
first. Refit the closing panel A.
Section 3 Routine Maintenance
9803/8020
Section 3
5 - 2
Issue 3
Air Conditioning
(3000 Series Machines)
160800
160810
Cleaning the Filter
Note: The air conditioning system contains environmentally
safe R-134A refrigerant. Do not use test equipment or
gauges that have contacted R12 refrigerant or the system
will be damaged.
Note: For crop spraying applications, a heavy duty carbon
filter can be used in place of the standard filter. Carbon
filters must not be cleaned. Keep a log of the hours used
and renew at 250 hour intervals.
!!WARNING
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6
1Unclip closing panel A, unscrew and pull out the filter
B.
2Using compressed air at a maximum pressure of 5.5
bar (80 lbf/in
2
), blow out the dirt from the clean (gasket)
side to the dirty (grid) side.
3Check the condition of the filter element and renew if
split or worn.
4Check the condition of the filter gasket. If split or worn
renew the filter.
5Check and clean the filter sealing face on the cab body.
6Refit the filter, making sure that the gasket side goes in
first. Refit the closing panel A.
Section 3 Routine Maintenance
9803/8020
Section 3
5 - 2
Issue 3
Air Conditioning
(3000 Series Machines)
160800
160810
5 - 3
Adjusting the Compressor Belt
(2140, 3155 and 3185)
1 Stop the engine.
2 Open the bonnet.
!!WARNING
Make sure the engine cannot be started. Disconnect the
battery before doing this job.
2-3-3-5
3 Loosen the mountings
Loosen fasteners A, B, Cand D (3155) or E, Fand G
(2140 and 3185).
4 Adjust the belt tension
Position the compressor so that there is 10 mm (0.4 in)
slack on the longest run of the belt.
5 Tighten the Mountings
Retighten fasteners A, B, Cand D, or E, Fand G.
! !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
Section 3 Routine Maintenance
9803/8020
Section 3
5 - 3
Issue 3*
Air Conditioning
GG
E E F F
272000
271990
A A B B
D D
C C
*
*
Adjusting the Compressor Belt
(2140, 3155 and 3185)
1 Stop the engine.
2 Open the bonnet.
!!WARNING
Make sure the engine cannot be started. Disconnect the
battery before doing this job.
2-3-3-5
3 Loosen the mountings
Loosen fasteners A, B, Cand D (3155) or E, Fand G
(2140 and 3185).
4 Adjust the belt tension
Position the compressor so that there is 10 mm (0.4 in)
slack on the longest run of the belt.
5 Tighten the Mountings
Retighten fasteners A, B, Cand D, or E, Fand G.
! !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
Section 3 Routine Maintenance
9803/8020
Section 3
5 - 3
Issue 3*
Air Conditioning
GG
E E F F
272000
271990
A A B B
D D
C C
*
*
Battery Warning Symbols
The following warning symbols may be found on the battery.
Symbol Meaning
Keep away from children.
Shield eyes.
No smoking, no naked flames,
no sparks
Explosive Gas.
Battery acid.
Note operating instructions.
6 - 1
!!CAUTION
Damaged or spent batteries and any residue from fires
or spillage should be put in a closed acid proof
receptacle and must be disposed of in accordance with
local environmental waste regulations.
INT-3-1-12
!!WARNING
Batteries give off an explosive gas. Do not smoke when
handling or working on the battery. Keep the battery
away from sparks and flames.
Battery electrolyte contains sulphuric acid. It can burn
you if it touches your skin or eyes. Wear goggles. Handle
the battery carefully to prevent spillage. Keep metallic
items (watches, rings, zips etc) away from the battery
terminals. Such items could short the terminals and burn
you.
Set all switches in the cab to OFF before disconnecting
and connecting the battery. When disconnecting the
battery, take off the earth (-) lead first.
When reconnecting, fit the positive (+) lead first.
Re-charge the battery away from the machine, in a well
ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you have
installed the battery in the machine, wait five minutes
before connecting it up.
First Aid - Electrolyte
Do the following if electrolyte:
GETS INTO YOUR EYES
Immediately flush with water for 15 minutes, always get
medical help.
IS SWALLOWED
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.
5-3-4-3/1
Section 3 Routine Maintenance
9803/8020
Section 3
6 - 1
Issue 1
Electrics
The following warning symbols may be found on the battery.
Symbol Meaning
Keep away from children.
Shield eyes.
No smoking, no naked flames,
no sparks
Explosive Gas.
Battery acid.
Note operating instructions.
6 - 1
!!CAUTION
Damaged or spent batteries and any residue from fires
or spillage should be put in a closed acid proof
receptacle and must be disposed of in accordance with
local environmental waste regulations.
INT-3-1-12
!!WARNING
Batteries give off an explosive gas. Do not smoke when
handling or working on the battery. Keep the battery
away from sparks and flames.
Battery electrolyte contains sulphuric acid. It can burn
you if it touches your skin or eyes. Wear goggles. Handle
the battery carefully to prevent spillage. Keep metallic
items (watches, rings, zips etc) away from the battery
terminals. Such items could short the terminals and burn
you.
Set all switches in the cab to OFF before disconnecting
and connecting the battery. When disconnecting the
battery, take off the earth (-) lead first.
When reconnecting, fit the positive (+) lead first.
Re-charge the battery away from the machine, in a well
ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you have
installed the battery in the machine, wait five minutes
before connecting it up.
First Aid - Electrolyte
Do the following if electrolyte:
GETS INTO YOUR EYES
Immediately flush with water for 15 minutes, always get
medical help.
IS SWALLOWED
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.
5-3-4-3/1
Section 3 Routine Maintenance
9803/8020
Section 3
6 - 1
Issue 1
Electrics
6 - 2
Checking the Battery Electrolyte Level
(2000 Series Machines)
Note: The battery on Fastrac 2115, 2125, 2135 and 2140
machines is located as shown right, on the right of the
machine. On Fastrac 2150 machines the battery is located
on the left hand side.
Maintenance free batteries used in normal temperate climate
applications should not need topping up. However, in
certain conditions (such as prolonged operation at tropical
temperatures or if the alternator overcharges) the electrolyte
level should be checked as described below.
1Apply the parking brake and stop the engine.
2Remove two screwsA and swing open the hinged step
unit B (below the right hand cab door). Later machines
have an upward lifting step unit.
3Prize out the cell covers. 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
Checking the Electrolyte Level
(3000 Series Machines)
(Unless Sealed for Life type which needs no checking)
Note: On machines for the UK market only battery 1is fitted.
On European machines batteries 1and 2are fitted.
1Apply the parking brake and stop the engine. Remove
the battery access panel A.
2Prize 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.
Section 3 Routine Maintenance
9803/8020
Section 3
6 - 2
Issue 3*
Electrics
260030
B
A
*
*
!!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.
A294000
2
1
A
B
Checking the Battery Electrolyte Level
(2000 Series Machines)
Note: The battery on Fastrac 2115, 2125, 2135 and 2140
machines is located as shown right, on the right of the
machine. On Fastrac 2150 machines the battery is located
on the left hand side.
Maintenance free batteries used in normal temperate climate
applications should not need topping up. However, in
certain conditions (such as prolonged operation at tropical
temperatures or if the alternator overcharges) the electrolyte
level should be checked as described below.
1Apply the parking brake and stop the engine.
2Remove two screwsA and swing open the hinged step
unit B (below the right hand cab door). Later machines
have an upward lifting step unit.
3Prize out the cell covers. 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
Checking the Electrolyte Level
(3000 Series Machines)
(Unless Sealed for Life type which needs no checking)
Note: On machines for the UK market only battery 1is fitted.
On European machines batteries 1and 2are fitted.
1Apply the parking brake and stop the engine. Remove
the battery access panel A.
2Prize 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.
Section 3 Routine Maintenance
9803/8020
Section 3
6 - 2
Issue 3*
Electrics
260030
B
A
*
*
!!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.
A294000
2
1
A
B
6 - 3
Checking the Beam Alignment
1Park the machine on level ground so that the front
headlights Aare 2.00m from a wall.
2Measure the distance Zfrom the ground to the centre
of the front headlights A. Subtract 25 mm ± 5 mm from
this distance and mark a horizontal line XXon the wall
at this height. When the auxiliary headlights Bare fitted
mark a second horizontal line YYon the wall
approximately 1300 mm above XX.
3When the headlights are switched on to dipped beam,
the horizontal tops of the light beams should be in line
with the horizontal lines XXand YY on the wall.
4To adjust the beam, slightly slacken nut Cor D,
reposition the light and then tighten the nut.
Note:The illustration shows a 3000 Series machine. The
principle for 2000 Series machines is identical.
Section 3 Routine Maintenance
9803/8020
Section 3
6 - 3
Issue 3*
Electrics
A293861
B
B
Y
C
D
Z
X
X
Y
1300 mm
2.0 m
*
A A
Checking the Beam Alignment
1Park the machine on level ground so that the front
headlights Aare 2.00m from a wall.
2Measure the distance Zfrom the ground to the centre
of the front headlights A. Subtract 25 mm ± 5 mm from
this distance and mark a horizontal line XXon the wall
at this height. When the auxiliary headlights Bare fitted
mark a second horizontal line YYon the wall
approximately 1300 mm above XX.
3When the headlights are switched on to dipped beam,
the horizontal tops of the light beams should be in line
with the horizontal lines XXand YY on the wall.
4To adjust the beam, slightly slacken nut Cor D,
reposition the light and then tighten the nut.
Note:The illustration shows a 3000 Series machine. The
principle for 2000 Series machines is identical.
Section 3 Routine Maintenance
9803/8020
Section 3
6 - 3
Issue 3*
Electrics
A293861
B
B
Y
C
D
Z
X
X
Y
1300 mm
2.0 m
*
A A
7 - 1
Changing the Filter Element
1Park the machine on level ground. Apply the parking
brake. Lower the rear linkage to the ground. Stop the
engine. Remove the starter key. Wash off all dirt from
around the tank cap Band element cover plate D.
2Remove the element as follows:
aRemove tank cap B.
bRemove nuts C, cover plate Dand 'O' ring E.
cRemove the element assembly Fand 'O' ring G.
dRemove the nut and spring assemblyH. Remove the
element Jfrom its spindle.
ei Dry clutch machines- discard the complete
element J (see view W).
iiWet clutch machines - remove and discard the
paper insert Yfrom metal outer elementJ(see
view X).
fWet clutch machines only- clean the metal outer
elementJ.
gClean the magnetsK.
3Fit the new element as follows:
aWet clutch machines- fit a new paper insert into
metal outer element J.
bAssemble the new element J(dry clutch machines)
or refurbished element J/Y (wet clutch machines) on
to the spindle, using a new seal L. Ensure that the
top lip of the seal locates in the groove inside the
filter head M. Fit and tighten the nut and spring
assembly H.
cFit the element assemblyFusing a new 'O' ring G.
dRefit cover plate D and nuts C using a new 'O' ring
E.
eTighten nuts C to 7 Nm (5 lbf ft).
fTop up fluid level at tank cap B and refit cap.
Section 3 Routine Maintenance
9803/8020
Section 3
7 - 1
Issue 4*
Hydraulics
B
A
M
Y
G
J
J
H
D
K
E
C
F
L
Note: The hydraulic tank shown below on the right hand
side of the machine is that for the Fastrac 2115, 2125, 2135
and 2140 machines. On the Fastrac 2150, 3155 and 3185
machines the hydraulic tank is on the left hand side of the
machine.
Checking the Fluid Level
!!WARNING
Fine jets of hydraulic fluid at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates your skin, get
medical help quickly.
INT-3-1-10/1
!!CAUTION
Using incorrect fluid could damage the system. See
Fluids, Capacities and Lubricants for the correct fluid.
The fluid can harm your skin. Wear rubber gloves. Cover
cuts or grazes.
2-3-5-1/2
1Park the machine on level ground. Apply the parking
brake. Lower any mounted implements to the ground.
Stop the engine. Remove the starter key.
2Look at the fluid level in the sight gauge A. The level
should be between the two marks on the gauge. If the
fluid is cloudy, water or air has entered the system.
Water or air in the system could damage the hydraulic
pump.
3If necessary, add recommended fluid at tank capB.
*
W W
X X
Changing the Filter Element
1Park the machine on level ground. Apply the parking
brake. Lower the rear linkage to the ground. Stop the
engine. Remove the starter key. Wash off all dirt from
around the tank cap Band element cover plate D.
2Remove the element as follows:
aRemove tank cap B.
bRemove nuts C, cover plate Dand 'O' ring E.
cRemove the element assembly Fand 'O' ring G.
dRemove the nut and spring assemblyH. Remove the
element Jfrom its spindle.
ei Dry clutch machines- discard the complete
element J (see view W).
iiWet clutch machines - remove and discard the
paper insert Yfrom metal outer elementJ(see
view X).
fWet clutch machines only- clean the metal outer
elementJ.
gClean the magnetsK.
3Fit the new element as follows:
aWet clutch machines- fit a new paper insert into
metal outer element J.
bAssemble the new element J(dry clutch machines)
or refurbished element J/Y (wet clutch machines) on
to the spindle, using a new seal L. Ensure that the
top lip of the seal locates in the groove inside the
filter head M. Fit and tighten the nut and spring
assembly H.
cFit the element assemblyFusing a new 'O' ring G.
dRefit cover plate D and nuts C using a new 'O' ring
E.
eTighten nuts C to 7 Nm (5 lbf ft).
fTop up fluid level at tank cap B and refit cap.
Section 3 Routine Maintenance
9803/8020
Section 3
7 - 1
Issue 4*
Hydraulics
B
A
M
Y
G
J
J
H
D
K
E
C
F
L
Note: The hydraulic tank shown below on the right hand
side of the machine is that for the Fastrac 2115, 2125, 2135
and 2140 machines. On the Fastrac 2150, 3155 and 3185
machines the hydraulic tank is on the left hand side of the
machine.
Checking the Fluid Level
!!WARNING
Fine jets of hydraulic fluid at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates your skin, get
medical help quickly.
INT-3-1-10/1
!!CAUTION
Using incorrect fluid could damage the system. See
Fluids, Capacities and Lubricants for the correct fluid.
The fluid can harm your skin. Wear rubber gloves. Cover
cuts or grazes.
2-3-5-1/2
1Park the machine on level ground. Apply the parking
brake. Lower any mounted implements to the ground.
Stop the engine. Remove the starter key.
2Look at the fluid level in the sight gauge A. The level
should be between the two marks on the gauge. If the
fluid is cloudy, water or air has entered the system.
Water or air in the system could damage the hydraulic
pump.
3If necessary, add recommended fluid at tank capB.
*
W W
X X
Thank you very much
for your reading.
Please Click Here
Then Get More
Information.
for your reading.
Please Click Here
Then Get More
Information.
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