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JCB 3185 FASTRAC Service Repair Manual SN 00640001-00641999 PDF
JCB 3185 FASTRAC Service Repair Manual SN 00640001-00641999 PDF
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:
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for
example:
A = Optional Equipment
B = Body & Framework ...etc
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later
issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
Page cross references are generally made by presenting the subject title printed in bold, followed by the title of the section
containing the subject. For example:
“24 If the axle is still on the machine, fit the brake calipers (see Brake Caliper Removal and Replacement, Section G).”
Note: If only the subject title in bold is given, i.e. no section title, the cross reference is to another part of the same section.
Use the contents list at the beginning of each section to find the exact page number.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.
‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.
9803/8020 Issue 1
Section 1 General Information Section 1
i i
Torque Settings
Introduction - Zinc Plated Fasteners and Dacromet Fasteners 2-1
Zinc Plated Fasteners 2-2
Dacromet Fasteners 2 - 3 to 2 - 6
* 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
9803/8020 Issue 4*
Section 1 General Information Section 1
1-1 1-1
T
S M
N R
X
P
194601
9803/8020 Issue 3*
Section 1 General Information Section 1
2-1 Torque Settings 2-1
The two types of fasteners can be readily identified by colour and part number suffix as follows:
Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, when servicing the Fastrac it
is important that you are aware of this change of policy and that the information you are using is relevant to the type of
fasteners that you have.
Note: A Dacromet bolt should not be used in conjunction with a Zinc and Yellow plated nut, as this could change the torque
characteristics of the torque settings further. For the same reason, a Dacromet nut should not be used in conjunction with a
Zinc and Yellow plated bolt.
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
Note: Dacromet bolts, due to their high corrosion resistance are used areas where rust could occur. Dacromet bolts are only
used for external applications.
9803/8020 Issue 3*
Section 1 General Information Section 1
2-2 Torque Settings 2-2
Metric Grade 8.8 Bolts Metric - All Internal Hexagon Headed Cap Screws
M6 (6) 8 16 1.6 12
M8 (8) 13 39 4 29
M10 (10) 17 78 8 57
A343780
M12 (12) 19 137 14 101
M16 (16) 24 343 35 253
M20 (20) 30 657 67 485 Torque settings for these bolts are determined by the
M24 (24) 36 1157 118 853 application. Refer to the relevant procedure for the
required settings.
9803/8020 Issue 1*
Section 1 General Information Section 1
2-3 Torque Settings 2-3
NOTE: DACROMET FASTENERS ARE LUBRICATED AS PART OF THE PLATING PROCESS: DO NOT LUBRICATE.
M6 x 1.0 9 0.9 7
M8 x 1.25 22.5 2.3 17
M10 x 1.5 47.5 4.8 35
M12 x 1.75 80 8.2 59
M14 x 2 133 13.6 98
M16 x 2 200 20.4 148
M18 x 2.5 278 28.4 205
M20 x 2.5 392 40 289
M24 x 3 675 69 498
M30 x 3.5 1348 138 994
M6 x 1.0 15 1.5 11
M8 x 1.25 40 4.1 29
M10 x 1.5 80 8.2 59
M12 x 1.75 133 13.6 98
M14 x 2 225 23 166
M16 x 2 350 35.7 258
M18 x 2.5 463 47 342
M20 x 2.5 654 67 482
M24 x 3 1125 115 830
M30 x 3.5 2247 229 1657
9803/8020 Issue 1*
Section 1 General Information Section 1
2-4 Torque Settings 2-4
Location: Rockinger Hitch Bolt Location: Gearbox Crossmember Bolt: Rear Crossmember
Nm: 392 kgfm: 40 lbf ft: 289 Nm: 200 kgfm: 20 lbf ft: 148 Nm: 392 kgf m: 40 lbf ft: 289
A402280
A402030
Bolt: Left Hand Pannier Step Bolt: Right Hand Pannier (rear) Bolt: Right Hand Pannier (front)
Nm: 47.5 kgf m: 4.8 lbf ft: 35 Nm: 80 kgf m: 8.2 lbf ft: 59 Nm: 47.5 kgf m: 4.8 lbf ft: 35
(2000 series machines only) (2000 series machines only)
Bolt: Front Wrapper (top/bottom) Bolt: Rear Lower Crossmember Bolt: Lower Link Bolt (Hex Head)
Nm: 392 kgf m: 40 lbf ft: 289 Nm: 80 kgf m: 8.2 lbf ft: 59 Nm: 392 kgf m: 40 lbf ft: 289
(2000 series machines only)
A402060
A402050
A402040
9803/8020 Issue 1*
Section 1 General Information Section 1
2-5 Torque Settings 2-5
A402010
A402140 A401990
Location: Rear Lower Crossmember Location: Fuel Tank Support Strap Location: Front P.T.O. Box
Nm: 200 kgf m: 20 lbf ft: 148 Nm: 47.5 kgf m: 4.8 lbf ft: 35 Nm: 200 kgf m: 20 lbf ft: 148
(3000 series machines only) (2000 series machines only)
A402260 A402090
A402230
Location: Front Axle Upper Arm Location: Steershaft Bearing Location: Steershaft Intermediate UJ
Mounting Bracket Nm: 28 kgf m: 2.9 lbf ft: 21 Nm: 38 kgf m: 3.9 lbf ft: 28
Nm: 200 kgf m: 20 lbf ft: 148 (3000 series machines only) (3000 series machines only)
(3000 series machines only)
A402270
9803/8020 Issue 2
Section 1 General Information Section 1
2-6 Torque Settings 2-6
A402080
A402130
A402110
A402290
A402150
9803/8020 Issue 2*
Section 1 General Information Section 1
3-1 3-1
JCB Multigasket A medium strength sealant suitable for all sizes of gasket
flanges, and for hydraulic fittings of 25-65 mm diameter. 4102/1212
JCB High Strength Threadlocker A high strength locking fluid for use with threaded components. 4102/0551
Gasketing for all sizes of flange where the strength of the joint
is important.
JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/0651
JCB Threadlocker & Sealer A medium strength locking fluid for sealing and retaining nuts,
bolts, and screws up to 50 mm diameter, and for hydraulic
fittings up to 25 mm diameter. 4101/0251
JCB Threadlocker & 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
JCB Clear Silicone Sealant To seal butt jointed glass. Also to seal hub planet gear carrier
when no 'O' ring is fitted 4102/0901
Black Polyurethane Sealant To finish exposed edges of laminated glass 4102/2309 310 ml
9803/8020 Issue 2*
Section 1 General Information Section 1
4-1 4-1
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
9803/8020 Issue 6*
Section 1 General Information Section 1
5-1 5-1
Service Tools
Section B - Body and Framework
S186240 S186270
Hand Cleaner - special blend for the removal of Cartridge Gun - hand operated - essential for the
polyurethane adhesives. application of sealants, polyurethane materials etc.
JCB part number - 4104/1310 (454g; 1lb tub) JCB part number - 892/00845
'
S186250
plug (703/23201) which fits into a female socket Folding Stand for Holding Glass - essential for
(715/04300). preparing new glass prior to installation.
S186260
240V Static Oven - available with 2 or 6 cartridge
S186300
capacity - required to pre-heat adhesive prior to use.
No plug supplied. Note: 110V models available upon Glass Lifter - minimum 2 off - essential for glass
request - contact JCB Technical Service installation, 2 required to handle large panes of glass.
Ensure suction cups are protected from damage
JCB part number: during storage.
992/12400 - 2 cartridge x 240V
992/12600 - 6 cartridge x 240V JCB part number - 892/00842
9803/8020 Issue 1
Section 1 General Information Section 1
5-2 5-2
S186310 S186340
Wire Starter - used to access braided cutting wire Cut-out Knife - used to remove broken glass.
(below) through original polyurethane seal.
JCB part number - 992/12800
JCB part number - 892/00848
'
S186320 S186350
Glass Extractor (Handles) - used with braided cutting 'L' Blades - 25mm (1in.) cut - replacement blades for
wire (below) to cut out broken glass. cut-out knife (above).
JCB part number - 892/00846 JCB part number - 992/12801 (unit quantity = 5 off)
S186330
S186360
JCB part number - 892/00849 (approx 25m length) JCB part number - 892/00844
9803/8020 Issue 1
Section 1 General Information Section 1
5-3 5-3
S186470 S186550
Nylon Spatula - general tool used for smoothing Rubber Spacer Blocks - used to provide the correct
sealants - also used to re-install glass in rubber glazing set clearance between glass edge and cab frame.
because metal tools will chip the glass edge.
JCB part number - 926/15500
JCB part number - 892/00847 (unit quantity = 500 off)
9803/8020 Issue 1
Section 1 General Information Section 1
6-1 6-1
Service Tools
Section C - Electrics
188230
239510
9803/8020 Issue 2*
Section 1 General Information Section 1
6-2 6-2
Service Tools
Section C - Electrics
A360250
D
1 2 3 4 5 6 7 8 E
C
B A F
9 10 11 12 13 14 15 J G
H
A386040
9803/8020 Issue 1
Section 1 General Information Section 1
7-1 7-1
Service Tools
Section E - Hydraulics
S188120
9803/8020 Issue 1
Section 1 General Information Section 1
7-2 7- 2
S193850
female adapter
892/00706 Test Probe 892/00318 Hose And Adapter Kit
892/00278 Gauge 0-40 bar (0-600 lbf/in2) To enable flow and pressure test
892/00279 Gauge 0-400 bar (0-6000 lbf/in2) equipment to be connected to adapters
fitted with 'O' ringface seals.
197220
892/00334 Gland Seal Fitting Tool 331/64246 Tool Kit for Non-return Valve
9803/8020 Issue 2
Section 1 General Information Section 1
8-1 8-1
Service Tools
Section F - Transmission
197260 197270
892/00800 Splitting Frame (complete with ratchet 892/00315 Engine Support Bracket
hoist)
188200 107750
197280 197080
9803/8020 Issue 2
Section 1 General Information Section 1
8-2 8-2
S197030
197250
Heavy Duty Sockets S190770
892/00817 17 mm A/F x 3/4in. square drive
892/00818 22 mm A/F x 3/4in. square drive 892/00174 Measuring Cup - Pinion Head Bearing
892/00819 15 mm A/F x 1/2in. square drive
892/00333 19 mm A/F x 3/4in. square drive
S197070
892/00224 Impulse Extractor Set
for Hub Bearing Seals
* 892/01053 Adapter for impulse extractor S197240
(PTO intermediate shaft, wet clutch
transmission) 892/00312 Dummy End Plate for Range Gearbox
110
25 25
15
40
A197180
197200
9803/8020 Issue 3*
Section 1 General Information Section 1
8-3 8-3
S196750
9803/8020 Issue 3
Section 1 General Information Section 1
8-4 8-4
1
A B
C
2
S234120
4
892/00864 PD 90 Axle Locknut Spanner
3 A270851
A361710
892/01051 Intermediate Gear Retaining Tool - wet
clutch transmission 892/01049 (x2) Guide Rod - wet clutch
A361740
A361720
9803/8020 Issue 6*
Section 1 General Information Section 1
8-5 8-5
A361750
892/01045 Peg Socket - wet clutch 892/01046 Mandrel - for bush assembly - wet clutch
A361770
A361760 A361780
892/01050 Mandrel, for hub seal renewal - wet clutch.
892/01047 Jig, for use when dismantling and
Note: Protective plastic cap A to be removed before use.
assembling of PTO input gear - wet clutch
9803/8020 Issue 1
Section 1 General Information Section 1
8-6 8-6
13 16
15
19, 20
14
18
8
21
17
9803/8020 Issue 1
Section 1 General Information Section 1
9-1 9-1
Section G - Brakes
Section H - Steering
E
A
B
C 222490
229270
220130
F 892/00883 Spanner
G 892/00884 ‘C’ Spanner
9803/8020 Issue 3*
Section 1 General Information Section 1
9-2 9-2
S199480
Section T - Engine
A314530
S192390
892/00041 De-glazing Tool for Cylinder Bores (to 892/00956 Timing pin for fuel injection pumps (Fastrac
assist bedding-in of new piston rings) 2115, 2125, 2135, 2150 only).
9803/8020 Issue 2*
Section 1 General Information Section 1
10- 1 Moving a Disabled Machine 10 - 1
S160392
S261600
9803/8020 Issue 3*
Section 1 General Information Section 1
10 - 2 10 - 2
A A
A288080
9803/8020 Issue 1
Section 2 Care & Safety Section 2
i i
9803/8020 Issue 1
Section 2 Care & Safety Section 2
1-1 1-1
In this publication and on the machine, there are safety notices. Each notice starts
with a signal word. The signal word meanings are given below.
! DANGER
Denotes an extreme hazard exists. If proper precautions are not taken, it is
highly probable that the operator (or others) could be killed or seriously
injured.
INT-1-2-1
! WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator (or
others) could be killed or seriously injured.
INT-1-2-2
! CAUTION
Denotes a reminder of safety practices. Failure to follow these safety practices
could result in injury to the operator (or others) and possible damage to the
machine.
INT-1-2-3
9803/8020 Issue 1
Section 2 Care & Safety Section 2
2-1 2-1
All construction and agricultural equipment can be Note: This section includes a certain amount of operating
hazardous. When a JCB Fastrac is correctly operated and safety information. But remember that whenever you drive
properly maintained, it is a safe machine to work with. But the machine or operate its controls you are in effect a
when it is carelessly operated or poorly maintained it can machine operator. Therefore you should read and
become a danger to you (the operator) and others. understand the information given in the Operator Handbook
before driving the machine or operating its controls.
Do not work with the machine until you are sure that you can
control it.
Do not start any job until you are sure that you and those
around you will be safe.
Remember
BE CAREFUL
BE ALERT
BE SAFE
GEN-1-6
General Safety
! WARNING ! WARNING
Lifting Equipment Care and Alertness
You can be injured if you use faulty lifting equipment. Make All the time you are working with or on the machine, take
sure that lifting equipment is in good condition. Make sure care and stay alert. Always be careful. Always be alert for
that lifting tackle complies with all local regulations and is hazards.
suitable for the job. Make sure that lifting equipment is INT-1-3-5
9803/8020 Issue 1
Section 2 Care & Safety Section 2
3-1 3-1
Operating Safety
! DANGER ! WARNING
Parking Visibility
Leaving the machine in gear will not prevent it running away. Accidents can be caused by working in poor visibility. Keep
Do not leave the driving seat under any circumstances windows clean and use your lights to improve visibility. Do
unless the parking brake is on. not operate the machine if you cannot see properly.
13-2-1-10 INT-2-1-11
! WARNING ! WARNING
Roll Over Protection Structure (ROPS) Practice
The machine is fitted with a Roll Over Protection Structure You or others can be killed or seriously injured if you do
(ROPS). You could be killed or seriously injured if you unfamiliar operations without first practising them. Practise
operate the machine with a damaged or missing ROPS. If away from the work site on a clear area. Keep other people
the ROPS has been in an accident, do not use the machine away. Do not perform new operations until you are sure you
until the structure has been renewed. Modifications and can do them safely.
INT-2-1-1
repairs that are not approved by the manufacturer may be
dangerous and will invalidate the ROPS certification.
13-1-1-8/1 ! WARNING
Machine Limits
! WARNING Operating the machine beyond its design limits can damage
Entering/Leaving the machine, it can also be dangerous. Do not operate the
Always face the machine when entering and leaving the cab. machine outside its limits. Do not try to upgrade the
Use the step(s) and handrails. Make sure the step(s), machine performance with unapproved modifications.
INT-2-1-4
handrails and your boot soles are clean and dry. Do not
jump from the machine. Do not use the machine controls as
handholds, use the handrails. ! WARNING
INT-2-1-7 Brakes
Do not coast the machine with the engine stopped as the
! WARNING main brakes will only operate for a limited number of
Seat applications and hydraulic trailer brakes will not function at
Position the seat so that you can comfortably reach the all. Also the steering will become very heavy.
13-1-1-5/2
machine controls. You could have an accident if you operate
the machine with the seat in the wrong position.
INT-3-3-5 ! CAUTION
Hydraulic Trailer Brakes
! WARNING Trailers with single line hydraulic brakes used in the United
Seat Belt Kingdom are subject to a maximum speed of 20 mph (32
Operating the machine without a seat belt can be kph).
13-2-2-8
dangerous. Before starting the engine, make sure your seat
belt is fastened. Check the tightness and condition of the
! CAUTION
seat belt securing bolts regularly (see maintenance
schedules). Trailer Brakes
INT 2 -1-8/1 Trailers with single line air brakes used in the Republic of
Germany are subject to a maximum speed of 25 km/h (15
! WARNING mph).
Passengers 13-2-2-13
9803/8020 Issue 1
Section 2 Care & Safety Section 2
3-2 3-2
! WARNING ! WARNING
Banks and Trenches Power Take-off Operation
Banked material and trenches can collapse. Do not work or When operating PTO equipment, always observe the
drive too close to banks and trenches where there is danger following safety precautions:
of collapse.
INT-2-2-5 Follow the instructions in the implement operator's
handbook.
! WARNING
Rotating equipment is dangerous. Do not wear loose fitting
Ramps and Trailers
clothing when working close to rotating shafts.
Water, mud, ice, grease and oil on ramps or trailers can
cause serious accidents. Make sure ramps and trailers are
Always disengage the PTO, stop the engine and wait until
clean before driving onto them. Use extreme caution when
the equipment stops, before:
driving onto ramps and trailers.
INT-2-2-6
1 Leaving the cab
! WARNING
2 Attempting to attach or detach an implement to or from
Communications
a PTO shaft or
Bad communications can cause accidents. Keep people
around you informed of what you will be doing. If you will be
3 Working on or cleaning an implement connected to the
working with other people, make sure any hand signals that
machine via a PTO shaft.
may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands.
INT-2-2-3
Always ensure that the PTO shaft and driveline are fully
guarded before use.
! WARNING
Exhaust Gases
Breathing the machine exhaust gases can harm and
possibly kill you. Do not operate the machine in closed
spaces without making sure there is good ventilation. If
possible, fit an exhaust extension. If you begin to feel
drowsy, stop the machine at once. Get out of the cab into
fresh air.
INT-2-1-10
9803/8020 Issue 2*
Section 2 Care & Safety Section 2
3-3 3-3
! WARNING ! WARNING
Tyres - General Stability
You could be killed or injured if a machine tyre bursts. Do In the event of the machine becoming unstable, keep firm
not use the machine with damaged, incorrectly inflated or hold of the steering wheel and do not try to leave the cab.
excessively worn tyres. Recognize the speed limitation of 13-2-2-10
9803/8020 Issue 2*
Section 2 Care & Safety Section 2
4-1 4-1
Maintenance Safety
! WARNING ! WARNING
Working Under the Machine Battery
Make the machine safe before getting beneath it. Do the A battery with frozen electrolyte can explode if it is used or
following: Park on level ground. Engage the parking brake. charged. Do not use a machine with a frozen battery. To
Lower any mounted implements to the ground. Stop the help prevent the battery from freezing, keep the battery fully
engine, remove the starter key, disconnect the battery. charged.
Chock the wheels. INT-3-1-7
13-3-1-1
! WARNING
! WARNING Battery Gases
Soft Ground Batteries give off explosive gases. Keep flames and sparks
A machine can sink into soft ground. Never work under a away from the battery. Do not smoke close to the battery.
machine on soft ground. Make sure there is good ventilation in closed areas where
INT-3-2-4 batteries are being used or charged. Do not check the
battery charge by shorting the terminals with metal; use a
! WARNING hydrometer or voltmeter.
INT-3-1-8
Jacking
A machine can roll off jacks and crush you unless the wheels
have been chocked. Always chock the wheels at the ! WARNING
opposite end of the machine to that which is to be jacked. Battery Terminals
Do not work underneath a machine supported only by jacks. The machine is negatively earthed. Always connect the
Always support a jacked-up machine on axle stands before negative pole of the battery to earth.
working underneath it.
INT-3-2-8 When connecting the battery, connect the earth (-) lead last.
Petrol
! WARNING
Do not use petrol in this machine. Do not mix petrol with the
diesel fuel; in storage tanks the petrol will rise to the top and Rams
form flammable vapours. The efficiency of the rams will be affected if they are not
INT-3-1-6 kept free of solidified dirt. Clean dirt from around the rams
regularly. When leaving or parking the machine, close all
rams if possible to reduce the risk of weather corrosion.
INT-3-2-10
9803/8020 Issue 1
Section 2 Care & Safety Section 2
4-2 4-2
! WARNING
! WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate the Cleaning
skin. Do not use your fingers to check for hydraulic fluid Cleaning metal parts with incorrect solvents can cause
leaks. Do not put your face close to suspected leaks. Hold a corrosion. Use only recommended cleaning agents and
piece of cardboard close to suspected leaks and then solvents.
INT-3-2-11
inspect the cardboard for signs of hydraulic fluid. If hydraulic
fluid penetrates your skin, get medical help immediately.
INT-3-1-10/1
! WARNING
'O' rings, Seals and Gaskets
! WARNING Badly fitted, damaged or rotted 'O' rings, seals and gaskets
Oil can cause leakages and possible accidents. Renew
Oil is toxic. If you swallow any oil, do not induce vomiting, whenever disturbed unless otherwise instructed. Do not use
seek medical advice. Used engine oil contains harmful Trichloroethane or paint thinners near 'O' rings and seals.
INT-3-2-12
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier
cream or wear gloves to prevent skin contact. Wash skin
! WARNING
contaminated with oil thoroughly in warm soapy water. Do Clutch Fluid
not use petrol, diesel fuel or paraffin to clean your skin. Do not use ordinary hydraulic fluid in the clutch system.
INT-3-2-3 13-3-2-4
! WARNING ! WARNING
Hot Coolant Welding and Modifications
The cooling system is pressurised when the engine is hot. To prevent the possibility of damage to electronic
Hot coolant can spray out when you remove the radiator components, disconnect the battery and withdraw the plug
cap. Let the system cool before removing the radiator cap. from the electronic draft control unit before arc-welding on
To remove the cap; turn it to the first notch and let the the machine or attached implements.
system pressure escape, then remove the cap.
INT-3-2-9 Parts of the machine are made from cast iron; welds on cast
iron can weaken the structure and break. Do not weld cast
! WARNING iron. On no account weld or drill the chassis structure. Non-
Wheels approved modifications can cause injury and damage.
Wheels are heavy. Handle and store with care to ensure that Contact JCB before modifying the machine.
GEN 8-1
they cannot fall and cause injury.
13-3-1-7
! WARNING
! WARNING Protect your eyes when grinding metal. Wear safety glasses
Metal Splinters or goggles. Remove or protect any combustible materials
You can be injured by flying metal splinters when driving from the area which could be ignited by sparks.
metal pins in or out. Use a soft faced hammer or drift to GEN-1-12
9803/8020 Issue 2*
Section 2 Care & Safety Section 2
4-3 4-3
! WARNING ! WARNING
Fluoroelastomeric Materials Brake Pads
Certain seals and gaskets (e.g. crankshaft oil seal) on JCB Always renew brake pads and locating pins in complete axle
machines contain fluoroelastomeric materials such as Viton, sets, using genuine JCB parts, otherwise braking will be
Fluorel and Technoflon. Fluoroelastomeric materials unsafe.
subjected to high temperatures can produce highly corrosive 13-3-1-10
9803/8020 Issue 2*
Section 3 Routine Maintenance Section 3
i i
Contents Page No.
Engine Oil - (All Machines) 1-1
Lubricants & Capacities (2000 Series Machines) 1-2
Lubricants & Capacities (3155) 1-4
Lubricants & Capacities (3185) 1-6
Lubricants - Health and Safety 1-8
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
9803/8020 Issue 7*
Section 3 Routine Maintenance Section 3
ii ii
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
* 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
Engine
Checking the Oil Level 14 - 1
Changing the Oil and Filter 14 - 2
Draining/Cleaning the Fuel Sediment Bowl 15 - 1
Draining/Renewing Fuel Pre-Filter (when fitted) 15 - 2
Draining the Fuel Filters 15 - 3
Changing the Fuel Filter Elements 15 - 3
* Cleaning the Fuel Lift Pump (2115, 2125, 2135, 2150 and 3155) 15 - 4
* Bleeding the Fuel System (2115, 2125, 2135, 2150 and 3155) 15 - 5
* Bleeding the Fuel System (2140) 15 - 5A
Bleeding the Fuel System (3185) 15 - 6
* Cleaning the Fuel Tank Strainer (Early machines only) 15 - 7
Checking the Coolant Level 16 - 1
* Draining the Coolant (2115, 2125, 2135 and 2150 Machines) 16 - 2
* Filling the Cooling System (2115, 2125, 2135 & 2150 Machines) 16 - 3
Coolant Mixtures 16 - 3
Draining & Refilling the Coolant (3155 Machines) 16 - 4
*Draining & Refilling the Coolant (2140 and 3185 Machines) 16 - 5
Cleaning the Radiator (2000 Series Machines) 16 - 6
Cleaning the Radiator (3000 Series Machines) 16 - 7
Cleaning the Pre-Cleaner (optional) 17 - 1
Adjusting the Fan Belts (Machines Except 3185) 17 - 1
* Adjusting the Fan Belt (2140) 17 - 2
* Adjusting the Fan Belt (3185) 17 - 3
* Changing the Air Filter Elements (Early 2000 Series) 18 - 1
* Changing the Air Filter Elements (Later 2000 Series) 18 - 2
* Changing the Air Filter Elements (3000 Series) 18 - 2
9803/8020 Issue 4*
Section 3 Routine Maintenance Section 3
1-1 * Engine Oil (All Machines) 1-1
New Engines
New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately.
DO NOT use a special running-in oil but use the oil recommended below from new.
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.
† The temperature range for 2140 and 3185 machines is - 20 °C to 20 °C (-4 °C to 68 °F).
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.
9803/8020 Issue 7*
Section 3 Routine Maintenance Section 3
1-2 Lubricants & Capacities 1-2
(2000 Series Machines)
ITEM CAPACITY FLUID/LUBRICANT MINIMUM INTERNATIONAL
Litres (UK Gal) SPECIFICATION
* Fuel
2115, 2125, 2135, 2140 220 (48) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
2150 350 (77)
* Engine (Oil)
2115, 2125, 2135, 2150 16.5 (3.6) See Engine Oil (All Machines) at the
2140 15 (3.3) beginning of this section
* Engine (Coolant)
2115, 2125, 2135, 2150 34 (7.5) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
2140 33 (7.3) Summer Coolant/water
(See Coolant Mixtures)
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)
† Clutch System - JCB Light Hydraulic Fluid - see Note 2 ISO VG15
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.
9803/8020 Issue 9*
Section 3 Routine Maintenance Section 3
1-3 Lubricants & Capacities (N. America) 1-3
(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
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)
† 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) ††
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.
9803/8020 Issue 9*
Section 3 Routine Maintenance Section 3
1-4 Lubricants & Capacities 1-4
(Fastrac 3155)
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
(See Coolant Mixtures)
Front Axle
Housing 20 (4.4) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 2.5 (0.55)
† 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)
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.
9803/8020 Issue 7*
Section 3 Routine Maintenance Section 3
1-5 Lubricants & Capacities (N. America) 1-5
(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
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
† 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) ††
Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic
tank.
Notice 2: It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
9803/8020 Issue 7*
Section 3 Routine Maintenance Section 3
1-6 Lubricants & Capacities 1-6
(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 (Coolant) 33 (7.3) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
Summer Coolant/water
(See Coolant Mixtures)
Front Axle
Housing 20 (4.4) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 2.5 (0.55)
† 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)
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.
9803/8020 Issue 7*
Section 3 Routine Maintenance Section 3
1-7 Lubricants & Capacities (N. America) 1-7
(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
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
† 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) ††
Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic
tank.
Notice 2: It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
9803/8020 Issue 4*
Section 3 Routine Maintenance Section 3
1-8 Lubricants - Health and Safety 1-8
It is most important that you read and understand this FIRST AID - OIL
information and the publications referred to. Make sure all
your colleagues who are concerned with lubricants read it Eyes
too. In the case of eye contact, flush with water for 15 minutes. If
irritation persists, get medical attention.
HYGIENE
Swallowing
JCB lubricants are not a health risk when used properly for If oil is swallowed do not induce vomiting. Get medical
their intended purposes. advice.
Low viscosity oils are more likely to do this, so take special SPILLAGE
care when handling used oils, which might be diluted with
fuel contamination. Absorb spilled oil with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a chemical
Whenever you are handling oil products you should maintain disposal area.
good standards of care and personal and plant hygiene. For
details of these precautions we advise you to read the Fires
relevant publications issued by your local health authority, ! WARNING
plus the following.
Do not use water to put out an oil fire. This will only
spread it because oil floats on water.
STORAGE
Extinguish oil and lubricant fires with carbon dioxide, dry
Always keep lubricants out of the reach of children.
chemical or foam. Fire fighters should use self contained
breathing apparatus.
Never store lubricants in open or unlabelled containers. 7-3-1-3/1
HANDLING
WASTE DISPOSAL
New Oil
All waste products should be disposed of in accordance
There are no special precautions needed for the handling or with all the relevant regulations.
use of new oil, besides the normal care and hygiene
practices. The collection and disposal of used oil should be in
accordance with any local regulations. Never pour used oil
Used Oil into sewers, drains or on the ground.
9803/8020 Issue 6*
Section 3 Routine Maintenance Section 3
2-2 Service Schedules - Dry Clutch Transmission 2-2
First 100 Hours Dealer Service First 100 Hours Dealer Service (continued)
Change Check (engine running) - continued
1 Engine oil and filter. 48 Transmission low pressure circuit pressure maintaining
2 Fuel filters. valve setting.
3 Transmission oil filter. 49 Transmission lubrication pressure.
4 Hydraulic oil filter. 50 Diff. lock pressure relief valve.
51 External hydraulics pressure relief valve.
Clean 52 Instrument readings and warning lights.
5 Fuel lift pump gauze. 53 Operation of all electrical equipment.
6 Fuel sedimenter (drain). 54 Operation of clutch and footbrakes.
55 Operation of steering.
Check (Engine Stopped) 56 Operation of transmission.
7 Coolant level/leaks and antifreeze strength. 57 Operation of 3-point linkage.
8 Fuel system for leaks and contamination. 58 Operation of front linkage (optional equipment).
9 Engine pipework routing and security. 59 Rear axle/chassis clearance.
10 Fuel system pipework routing and security. 60 Height corrector valve operation.
11 Fan belt tension and condition. 61 Parking Brake operation.
12 Air conditioning compressor belt tension. 62 Pick-up hitch operation.
13 Clutch fluid level. 63 Spool valve operation.
14 Gearbox oil level. 64 Re-calibrate splitter clutch packs
15 Transmission oil cooler/pipework condition, leakage,
routing and security. Every 250 Operating Hours or 3 Monthly
16 Rear axle oil level. whichever occurs first
17 Rear axle hub oil level (4WS).
18 Front axle oil level. Do the Daily jobs through to 50 hours plus:
19 Front axle hub oil level.
20 Front PTO gearbox oil level. Clean
21 Propellor shaft security. 1 Air filter dust valve.
22 Tyre pressures. 2 Battery terminals.
23 Tightness of wheel nuts.
Check (Engine Stopped)
24 Hydraulic oil level.
3 Front axle oil level.
25 Hydraulic oil cooler/pipework condition, leakage,
4 Front axle hub oil levels.
routing and security.
5 Rear axle oil level.
26 Brake fluid levels.
6 Rear axle hub oil level (4WS) (if fitted).
27 Brake pad security (service and parking).
7 Condition of lift ram piston rods.
28 Brake pipework routing and security.
8 Hose and pipework for chafing and damage.
29 Air system for leaks.
9 Air cleaner and hose condition and security.
30 Panhard rod torque setting.
* 10 Electrical wiring for chafing and routing.
31 Ram piston rods for damage/leaks.
32 Battery charge/terminal condition and tightness. * 11 Brake pad condition and security.
12 Neutral start operation.
33 Wiring for chafing/routing.
34 Headlight alignment. Check (Engine Running)
35 Windscreen washer level. 13 Air conditioning sight glass.
36 Neutral start operation (Including clutch and PTO's). 14 Operating speed of Selectronic range changes.
37 Door locks.
Change
Grease 15† Engine oil and filter.
38 Propellor shafts and universal joints. 16 Fuel Pre-filter (machines with optional fuel flow
39 Steering swivels. metering only).
40 Rear PTO shaft bearings.
41 3 point linkage. Grease
42 Rear lift ram pivots. 17 Steering swivels.
43 Suspension cylinder pivots. 18 Rear anti-roll bar ball joints.
19 Hydraulic lift cross-shaft.
Check (engine running) 20 Hydraulic lift ram pivots.
44 Exhaust smoke. 21 Three-point linkage lift rods and top link.
45 Throttle and stop controls. 22 Suspension cylinder pivots.
46 PTO operation. 23 Automatic Trailer Coupling (when fitted).
47 2/4WD drive and diff. lock selection. 24 Steering box input shaft (3155, 3185 machines)
25 Roller Drawbar (if fitted)
9803/8020 Issue 8*
Section 3 Routine Maintenance Section 3
2-3 Service Schedules - Dry Clutch Transmission 2-3
9803/8020 Issue 6*
Section 3 Routine Maintenance Section 3
2-4 Service Schedules - Wet Clutch Transmission 2-4
! WARNING
Maintenance must be done only by suitable qualified and Every 50 Operating Hours or Daily
competent persons. Before doing any maintenance
whichever occurs first
make sure the machine is safe. It should be correctly
parked on firm level ground.
Do the Daily jobs plus:
To prevent anyone starting the engine, remove the
Drain
starter key. Disconnect the battery and chock the
1 Fuel filter.
wheels when you are working beneath the machine.
*2 Fuel pre-filter - when fitted (except 2140).
If you do not take these precautions you could be killed
Clean
or injured. 3 Air filter dust valve.
9-3-1-1
* Every
10 Operating Hours or Daily Check (Engine Stopped)
4 Fan belt tension and condition.
whichever occurs first 5 Air conditioning compressor drive belt.
6 Front PTO transfer gearbox oil level (optional
Clean equipment).
1 Machine generally. 7 Brake pad condition.
8 Cab air filter (clean if required).
Drain 9 Propshaft security.
2 Air system tank.
3 Empty hydraulic coupling drain reservoir (if fitted). Grease
10 Rear PTO drive shaft splines and universal joints.
Check (Engine Stopped) 11 Rear PTO drive shaft bearings.
4 Generally for damage. 12 Front axle propshaft.
5 Engine coolant level and condition. 13 Front PTO drive shaft (optional equipment).
6 Fuel system for leaks and contamination. 14 Rear axle propshaft.
7 Hydraulic fluid level. 15 Rear anti-roll bar joints.
8 Hydraulic system for leaks. 16 Hydraulic lift cross-shafts.
9 Machine generally for oil leaks (axles, engine, 17 Hydraulic lift ram pivots.
transmission). 18 Steering swivels.
10 Gearbox oil level. 19 Suspension cylinder pivots.
11 Engine oil level and condition. 20 3-point linkage lift rods and top link.
12 Tightness of wheel nuts. 21 Automatic trailer coupling (when fitted).
13 Windscreen washer level. 22 Roller drawbar (if fitted).
14 Tyre pressures and condition.
15 Security of front weights (optional equipment). Note: It is essential that drive shaft and propshaft joints are
16 Seat belt condition and security. lubricated as specified.
17 Brake fluid levels.
18 Check radiator and coolers for blockage and clean if
required.
9803/8020 Issue 5*
Section 3 Routine Maintenance Section 3
2-5 Service Schedules - Wet Clutch Transmission 2-5
First 100 Hours Dealer Service 51 Transmission pressure circuit pressure maintaining
valve setting.
Change 52 Transmission lubrication pressure (HPL & LPL).
1 Engine oil and filter. 53 Diff. lock pressure relief valve.
2 Fuel filters. 54 External hydraulics pressure relief valve.
3 Transmission oil filter. 55 Instrument readings and warning lights.
4 Hydraulic oil filter. 56 Operation of all electrical equipment.
5 Front axle oil. 57 Operation of clutch and footbrakes.
6 Front hub oil. 58 Operation of steering.
7 Rear axle oil. 59 Operation of transmission.
8 Rear hub oil (4WS only). 60 Operation of 3-point linkage.
61 Operation of front linkage (optional equipment).
Clean/Drain 62 Rear axle/chassis clearance.
*9 Fuel lift pump gauze (clean - except 2140 and 3185). 63 Height corrector valve operation.
* 10 Fuel pre-filter - when fitted (drain - except 2140). 64 Parking Brake operation.
65 Pick-up hitch operation.
Check (Engine Stopped) 66 Spool valve operation.
11 Coolant level/leaks and antifreeze strength. 67 Re calibrate splitter clutch packs.
12 Fuel system for leaks and contamination.
13 Engine pipework routing and security. Every 250 Operating Hours or 3 Monthly
14 Fuel system pipework routing and security. whichever occurs first
15 Fan belt tension and condition.
16 Air conditioning compressor belt tension. Do the Daily and 50 Hour jobs plus:
17 Gearbox oil level.
18 Transmission oil cooler/pipework condition, leakage, Change
routing and security. 1 †Engine oil and filter.
19 Front PTO gearbox oil level.
20 Propellor shaft security. * † Applies only if recommended oil (see Engine Oil) and
21 Tyre pressures. Stratopore filter (2140 & 3185 only) are not available.
22 Tightness of wheel nuts. See T.I. 10/152.
23 Hydraulic oil level.
24 Hydraulic oil cooler/pipework condition, leakage,
routing and security.
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.
9803/8020 Issue 4*
Section 3 Routine Maintenance Section 3
2-6 Service Schedules - Wet Clutch Transmission 2-6
Clean Change
1 Fuel lift pump gauze (all machines except 2140 & 3185). 51 †Engine oil and filters.
52 Hydraulic fluid filter element.
Grease 53 Transmission oil filter.
2 Steering box input shaft (3000 series machines). 54 Fuel filter (2 elements).
55 Front hub oil (see Note (2) below).
Check (Engine Stopped) 56 Rear hub oil (4WS only) (see Note (2) below).
3 Battery electrolyte level (if battery is not sealed for lift). 57 Fuel pre-filter element.
4 Battery charge condition.
5 Exhaust system security. † Applies only if recommended oil (see Engine Oil) and
6 Engine mounting bolts for tightness. Stratopore filter (2140 & 3185 ony) are available. (See
7 Compressor housing for cracks and damage. T.I. 10/152.) If these are not available this job should be
8 Compressor mountings for tightness. carried out every 250 hours (see Every 250 Operating
9 Injection pump mountings for tightness. Hours for suitable alternative oils).
10 Steering axle wheel alignment.
11 Headlamp alignment. Every 1000 Operating Hours or Yearly
12 Panhard rod condition and torque tightness. whichever occurs first
13 Track rod end, steering ram and drag link ball joint
security. Do the Daily jobs through to 250 hours plus:
14 Steering damper condition and security.
15 4WS power track rod and ball joints condition and Clean
security (2000 series machines). 1 Fuel tank suction strainer (early machines only).
16 Suspension control arms and ‘V’ link condition and bolt *2 Trailer brake control line air filter.
torque.
17 Air cleaner and hose condition and security. Check (Engine Stopped)
18 Air system for leaks. 3 ROPS structure.
19 Battery terminals condition and tightness. 4 Quality of coolant.
20 Brake pad security (service and parking). 5 4WS RH side trunnion seals and renew if necessary.
6 Engine valve clearances and lubrication (2115, 2125,
21 Parking brake adjustment
2135 and 2150).
22 Brake pipework security.
7 Engine valve clearances (3185 machines, first 1000
23 Condition of lift ram rods.
hour service only)
24 Coolant level/leaks, quality and anti-freeze strength.
8 Fan belt tensioner (2140 and 3185).
25 Brake caliper bolt torque.
9 Fan hub end play (2140 and 3185).
26 Hoses and pipework for chafing and damage.
27 Neutral start operation.
Check (Engine Running)
28 Ram piston rods for damage/leaks.
10 Transmission lubrication pressure (HPL and LPL).
29 Front axle oil level.
11 MRV pressure.
30 Rear axle oil level.
12 Splitter and wet clutch calibration.
31 Transmission and hydraulic oil cooler/pipework
13 ABS system test.
condition, leakage and security.
32 Wiring for chafing and routing.
Change
33 Download EMS Datalog.
14 Outer air filter element.
34 Download ABS error codes and investigate any found.
15 Gearbox oil and clean strainer (see Note (1) below).
35 Download engine error codes, rectify and delete (2140
16 Front axle oil.
only).
17 Rear axle oil.
36 Brake light switch input to ABS ECU using computer
18 Air system dryer dessicant canister.
diagnostic tool.
37 All air warning lamps illuminate after draining down the
Notes:
air tanks.
38 The park brake lamp illuminates after draining down the
(1) After a major transmission repair, the new oil should be
trailer air tank.
run to operating temperature and changed again to
remove any contamination which entered during the
Check (Engine Running)
repair. Change the oil and filter after a further 100
39 Idling speed.
hours if the oil was heavily contaminated because of, or
40 Max. no load engine speed.
from the failure (e.g. water contamination).
41 Suspension ride height and corrector valve operation.
42 Suspension pressure maintenance valve pressure.
(2) After a hub repair, the new oil should be run to
43 Transmission pressure circuit pressure maintaining
operating temperature and changed again to remove
valve setting.
any contamination which entered during the repair.
44 Differential lock pressure.
Change the oil again after a further 100 hours to
45 Field speed control.
remove any bedding-in wear.
46 Pick-up hitch operation.
9803/8020 Issue 6*
Section 3 Routine Maintenance Section 3
2-7 Service Schedules- Wet Clutch Transmission 2-7
Clean
1 Hydraulic fluid suction strainer.
Change
9 Inner air filter element.
10 Coolant.
11 Brake system fluid.
12 Hydraulic fluid (change if sample does not indicate
otherwise).
9803/8020 Issue 2*
Section 3 Routine Maintenance Section 3
2-8 Cleaning the Machine and Checking for Damage 2-8
Clean the machine using water and/or steam. Pay particular Make sure all pivot pins are correctly in place and secured
attention to the underside. Do not allow mud to build up on by their locking devices.
the engine and transmission. Make sure that the radiator
grille is not clogged up. Ensure that the steps and handrails are undamaged and
secure.
Excessive power washing can cause damage to seals and
bearings. Do not direct high power water jets at oil seals, Check for broken or cracked window glass. Replace
universal joints or electrical components, especially draft damaged items.
control solenoids.
Check all lamp lenses for damage.
On the 4WS machine, take special care to avoid directing
high power water jets at the electrical connections to the Inspect the tyres for damage and penetration by sharp
front and rear axles. objects.
Inspect steelwork for damage. Note damaged paintwork for Check that all safety decals are in place and undamaged, fit
future repair. new decals where necessary.
SEAT BELT
! 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
9803/8020 Issue 1
Section 3 Routine Maintenance Section 3
2-9 Bonnet 2-9
! 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
! 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
A293970
9803/8020 Issue 1
Section 3 Routine Maintenance Section 3
3-1 Greasing 3-1
Greasing should be done with a grease gun. Normally, two * Rear axle propshaft
strokes of the gun should be enough. Stop greasing when Grease points 4 to 6. (Point 6 not fitted to later machines.)
fresh grease appears at the joint. Use only JCB HP Grease
Front PTO drive shaft (optional)
or equivalent.
Grease points 10 to 12.
In the following illustrations the grease points are numbered.
Count them off as you grease them. Note: When greasing the universal joints, you must ensure
that grease appears at all four bearing caps. If grease does
Refit the grease point dust caps after greasing. not appear at any cap, move the shaft from side to side and
then re-grease. Wipe away all excess grease.
!
2
1 @
8 9
7
65 A286622
9803/8020 Issue 3*
Section 3 Routine Maintenance Section 3
3-2 Greasing 3-2
Steering Swivels
* (2000Series 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
Note: After initial greasing, turn the wheels from lock to lock,
then grease again to ensure full penetration.
2 S229870
3 5
4
6
9
7
0 8
250690
9803/8020 Issue 2*
Section 3 Routine Maintenance Section 3
3-3 *Greasing 3-3
! 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 1 to 4.
Note: After initial greasing, turn the wheels from lock to lock,
then grease again to ensure full penetration.
1 3
2 4
A293430
9803/8020 Issue 2*
Section 3 Routine Maintenance Section 3
3-4 Greasing 3-4
*(2000 Series Machines)
* Hydraulic Lift and 3-Point Linkage * Rear PTO Drive Shaft Bearings
Hydraulic Lift Cross-shaft Grease point 9. Do not exceed 2 to 3 strokes of the grease
Grease points 1 and 2. gun.
@ 0
£ !
1 2
3 4
9
7 8
5 6
S229981
9803/8020 Issue 2*
Section 3 Routine Maintenance Section 3
3-5 Greasing 3-5
*(3000 Series Machines)
* ! WARNING * Hydraulic Lift and 3-Point Linkage
You will be working close into the machine for these
jobs. Lower the equipment. Remove the starter key and Hydraulic lift cross-shaft
disconnect the battery. This will prevent the engine from Grease points 5 and 6.
being started. Make sure that the parking brake is
Hydraulic lift rams
engaged.
Grease points 7 to 10.
Chock all four wheels before getting under the machine. Three point linkage lift rods
13-3-1-9
Grease at nipples 11 and 12. On later machines grease at
nipples 11, 12, 13 and 14 (lift collars A and B to access
Note: Ladder hitch and trailer coupling omitted for clarity.
nipples 13 and 14). On machines with heavy duty linkage
grease points 15 and 16 also.
1 3
2 A B A B A B
4
5 6
I II III
7 8
*
% ^
! @
A B &
9 0
£ $
A286030
9803/8020 Issue 2*
Section 3 Routine Maintenance Section 3
3-6 Greasing 3-6
(2000 Series Machines)
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
4 5
262210
4WS
6 8
7 9 A268420
9803/8020 Issue 1
Section 3 Routine Maintenance Section 3
3-7 Greasing 3-7
(3000 Series Machines)
Steering Box Input Shaft Seal
Grease at point 1 through the hole in the chassis side
member.
A293980
! 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
2 3
262210
9803/8020 Issue 1
Section 3 Routine Maintenance Section 3
3-8 Greasing 3-8
! 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
S170201
! 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.
3
4
A309960
9803/8020 Issue 2*
Section 3 Routine Maintenance Section 3
4-1 Cab 4-1
! WARNING
The cab on this machine is designed to give the operator Check the structure for damage.
protection in the event of the machine rolling over
(ROPS). The following points must be strictly observed. Check that the four mounting bolts are installed and
undamaged. Check that torque tightness of nuts A and B is
1 If the machine has been in an accident which has correct (see Table below). Tighten them to the correct
damaged the ROPS structure, the machine must not torque if necessary.
be used until the structure has been renewed. If there
is any doubt about the strength of the ROPS Zinc-Plated Fasteners (colour: golden)
structure, it must be renewed. The operator could be
killed or seriously injured as a result of using a Nm kgf m lbf ft
machine with a damaged or missing ROPS. 375 38 277
2 The ROPS structure must not be modified except as Dacromet Fasteners (colour: mottled silver)
approved by JCB. Unauthorised modifications may
result in weakening of the structure. Nm kgf m lbf ft
365 37 269
3 Always use JCB supplied parts to mount the ROPS
structure on the machine. The use of unapproved
components could reduce the protection given by the
structure.
B
A 229990
9803/8020 Issue 3
Section 3 Routine Maintenance Section 3
4-2 Cab 4-2
A290350
A293830
9803/8020 Issue 2*
Section 3 Routine Maintenance Section 3
5-1 Air Conditioning 5-1
(2000 Series Machines)
Cleaning the Filter * Adjusting the Compressor Belt
(2115, 2125, 2135, and 2150)
Note: For crop spraying applications, a heavy duty carbon
filter can be used in place of the standard filter. Carbon filters 1 Stop the engine.
must not be cleaned. Keep a log of the hours used and
renew at 250 hour intervals. 2 Remove the left-hand bonnet side panel.
! WARNING
The filter may be filled with dust. Wear goggles and a
! WARNING
face mask when removing the filter. Make sure the engine cannot be started. Disconnect the
2-3-3-6 battery before doing this job.
2-3-3-5
3 Check the condition of the filter element and renew if split 5 Retighten nuts A and B.
or worn.
S232630
229880
9803/8020 Issue 3*
Section 3 Routine Maintenance Section 3
5-2 Air Conditioning 5-2
(3000 Series Machines)
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.
! WARNING
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6
1 Unclip closing panel A, unscrew and pull out the filter 160800
B.
5 Check and clean the filter sealing face on the cab body.
6 Refit the filter, making sure that the gasket side goes in
first. Refit the closing panel A.
160810
9803/8020 Issue 3
Section 3 Routine Maintenance Section 3
5-3 Air Conditioning 5-3
! WARNING
Make sure the engine cannot be started. Disconnect the
battery before doing this job.
A B
2-3-3-5
! WARNING
The air conditioning system is a closed loop system and
contains pressurised refrigerant. No part of the system
should be disconnected until the system has been
discharged by a refrigeration engineer or a suitably
trained person. You can be severely frostbitten or injured
by escaping refrigerant.
4-3-4-1/2
E F
G
271990
9803/8020 Issue 3*
Section 3 Routine Maintenance Section 3
6-1 Electrics 6-1
! WARNING
Keep away from children. Batteries give off an explosive gas. Do not smoke when
handling or working on the battery. Keep the battery
away from sparks and flames.
IS SWALLOWED
Battery acid.
Do not induce vomiting. Drink large quantities of water
or milk. Then drink milk of magnesia, beaten egg or
vegetable oil. Get medical help.
9803/8020 Issue 1
Section 3 Routine Maintenance Section 3
6-2 Electrics 6-2
! WARNING
Do not top the battery up with acid. The electrolyte could
boil out and burn you.
2-3-4-6
A
B
1
A294000
9803/8020 Issue 3*
Section 3 Routine Maintenance Section 3
6-3 Electrics 6-3
B Y
B
Y
1300 mm
A A
X
X
D
Z
2.0 m
C
A293861
9803/8020 Issue 3*
Section 3 Routine Maintenance Section 3
7-1 Hydraulics 7-1
* Note: The hydraulic tank shown below on the right hand Changing the Filter Element
side of the machine is that for the Fastrac 2115, 2125, 2135
and 2140 machines. On the Fastrac 2150, 3155 and 3185 1 Park the machine on level ground. Apply the parking
machines the hydraulic tank is on the left hand side of the brake. Lower the rear linkage to the ground. Stop the
machine. engine. Remove the starter key. Wash off all dirt from
around the tank cap B and element cover plate D.
Checking the Fluid Level
2 Remove the element as follows:
C
D
M
K G
L F E
W B
J Y
A
X
H
J
9803/8020 Issue 4*
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