Jcb 3155 fastrac service repair manual sn：00642001 00643010 by 163048

General Information Care & Safety Routine Maintenance

Service Manual

Optional Equipment Body & Framework Electrics

Fastrac

Controls

2115, 2125, 2135, 2140, 2150

Hydraulics

From Serial No 0738000

Transmission

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

Brakes Steering Suspension Engine

1 2 3 A B C D E F G H S T

Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 1 2 3

= = =

General Information - includes torque settings and service tools. Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. 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 B

= =

Optional Equipment 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

Contents Machine Identification Plate Typical Vehicle Identification Number (VIN) Typical Engine Identification Number Unit Identification

Page No. 1-1 1-1 1-1 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 Electrics Hydraulics Transmission Brakes Steering Suspension Engine

9803/8020

5-1 6-1 7-1 8-1 9-1 9-1 9-2 9-2

Moving a Disabled Machine General Preparation for Towing

10 - 1 10 - 1

Transporting the Machine

10 - 2

Issue 4*

Section 1

General Information

Section 1

1-1

Machine Identification Plate

Typical Engine Identification Number

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.

50532

123456

Typical Vehicle Identification No. (VIN)

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 Data for details) J = Country of Origin K = Engine Serial Number L = Year of Manufacture

SLP

FT 11 3 30 0738010

B C D E

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

* 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 Fastrac 2140 and 3185 Engines Transmission (Assembly of all three gearboxes) Speed Gearbox Front Axle Rear Axle

M T N P R S

T S

X P 194601

9803/8020

Issue 3*

Section 1 2-1 * Introduction

General Information

Section 1

Torque Settings

2-1

- 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 Zinc and Yellow Dacromet

Colour Golden finish Mottled silver finish

Part Number ‘Z’ (e.g. 1315/3712Z) ‘D’ (e.g. 1315/3712D)

Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, when servicing the Fastrac it is important that you are aware of this change of policy and that the information you are using is relevant to the type of fasteners that you have. Note: A Dacromet bolt should not be used in conjunction with a Zinc and Yellow plated nut, as this could change the torque characteristics of the torque settings further. For the same reason, a Dacromet nut should not be used in conjunction with a Zinc and Yellow plated bolt. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. Note: Dacromet bolts, due to their high corrosion resistance are used areas where rust could occur. Dacromet bolts are only used for external applications.

9803/8020

Issue 3*

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Section 1

Torque Settings

2-2

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 - All Internal Hexagon Headed Cap Screws

Metric Grade 8.8 Bolts Bolt size (mm) Hexagon (A/F) mm

Dia.

M5 M6 M8 M10 M12 M16 M18 M20 M24 M30 M36

(5) (6) (8) (10) (12) (16) (18) (20) (24) (30) (36)

8 10 13 17 19 24 27 30 36 46 55

Torque Settings kgf m lbf ft

7 12 28 56 98 244 350 476 822 1633 2854

0.7 1.2 3.0 5.7 10 25 36 48 84 166 291

5 9 21 42 72 180 258 352 607 1205 2105

Bolt size (mm) Hexagon (A/F) mm

M6 M8 M10 M12 M16 M20 M24

(6) (8) (10) (12) (16) (20) (24)

M3 M4 M5 M6 M8 M10 M12 M16 M18 M20 M24

Torque kgf m

2 6 11 19 46 91 159 395 550 770 1332

0.2 0.6 1.1 1.9 4.7 9.3 16.2 40 56 79 136

lbf ft

1.5 4.5 8 14 34 67 117 292 406 568 983

Verbus Ripp Bolts

Metric Grade 10.9 Bolts

Dia.

Diameter mm

8 13 17 19 24 30 36

Torque Settings kgf m lbf ft

16 39 78 137 343 657 1157

1.6 4 8 14 35 67 118

12 29 57 101 253 485 853

A343780

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 reused. 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.â&#x20AC;&#x2122;s 10/140 (F161/N. Am) and 10/141 (F162 N. Am).

Hydraulic Hose to Adapter Connections

BSP Size (inches)

1/8

14 24 33 44 58 84 115 244

1/4 3/8 1/2 5/8 3/4

1 11/2

9803/8020

Hydraulic Adapter into Component Connections with bonded washers

Torque Settings kgf m lbf ft

1.4 2.5 3.3 4.8 6.0 8.6 11.8 24.9

10 18 24 35 43 62 85 180

BSP Size (inches)

1/8

20 34 75 102 122 183 203 305

1/4 3/8 1/2 5/8 3/4

1 11/2

Torque Settings kgf m lbf ft

2.1 3.4 7.6 10.3 12.4 18.7 20.7 31

15 25 55 75 90 135 150 225

Issue 1*

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General Information

Section 1

Torque Settings

2-3

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 Dia.

Torque Settings kgf m lbf ft

M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 2 M16 x 2 M18 x 2.5 M20 x 2.5 M24 x 3 M30 x 3.5

9 22.5 47.5 80 133 200 278 392 675 1348

0.9 2.3 4.8 8.2 13.6 20.4 28.4 40 69 138

7 17 35 59 98 148 205 289 498 994

Metric Grade 10.9 Bolts Bolt size Dia.

Torque Settings kgf m lbf ft

M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 2 M16 x 2 M18 x 2.5 M20 x 2.5 M24 x 3 M30 x 3.5

13.5 35 62.5 115 175 300 395 559 962 1920

1.4 3.6 6.4 11.7 17.9 30.6 40 57 98 196

10 26 46 85 129 221 291 412 710 1416

Metric Grade 12.9 Bolts Bolt size Dia.

M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 2 M16 x 2 M18 x 2.5 M20 x 2.5 M24 x 3 M30 x 3.5

15 40 80 133 225 350 463 654 1125 2247

9803/8020

Torque Settings kgf m lbf ft

1.5 4.1 8.2 13.6 23 35.7 47 67 115 229

11 29 59 98 166 258 342 482 830 1657

Issue 1*

Section 1

General Information

Section 1

Torque Settings

2-4

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: Nm: 392

Rockinger Hitch Bolt kgfm: 40 lbf ft: 289

Location: Nm: 200

Gearbox Crossmember kgfm: 20 lbf ft: 148

Bolt: Nm: 392

Rear Crossmember kgf m: 40 lbf ft: 289

A402280

A402030

Bolt: Nm: 47.5

Left Hand Pannier Step kgf m: 4.8 lbf ft: 35

A402200

Bolt: Nm: 392

Bolt: Right Hand Pannier (front) Nm: 47.5 kgf m: 4.8 lbf ft: 35 (2000 series machines only)

A402160

A402190

Front Wrapper (top/bottom) Bolt: Rear Lower Crossmember Bolt: kgf m: 40 lbf ft: 289 Nm: 80 kgf m: 8.2 lbf ft: 59 Nm: 392 (2000 series machines only)

A402060

9803/8020

Bolt: Right Hand Pannier (rear) Nm: 80 kgf m: 8.2 lbf ft: 59 (2000 series machines only)

A402050

Lower Link Bolt (Hex Head) kgf m: 40 lbf ft: 289

A402040

Issue 1*

Section 1

General Information

Section 1

Torque Settings

2-5

Dacromet Fasteners (mottled silver finish) - List of Torque Settings (cont.) Location: Nm: 654

Lower Link Bolt (capscrew) Location: kgf m: 67 lbf ft: 482 Nm: 392

Tower Casting to Axle kgf m: 40 lbf ft: 289

Location: Nm: 115

Front Lower Crossmember kgf m: 12 lbf ft: 85

A402010

A402140

Location: Rear Lower Crossmember Nm: 200 kgf m: 20 lbf ft: 148 (3000 series machines only)

A402260

Location:

Front Axle Upper Arm Mounting Bracket Nm: 200 kgf m: 20 lbf ft: 148 (3000 series machines only)

A401990

Location: Fuel Tank Support Strap Nm: 47.5 kgf m: 4.8 lbf ft: 35 (2000 series machines only)

A402090

Location: Steershaft Bearing Nm: 28 kgf m: 2.9 lbf ft: 21 (3000 series machines only)

Location: Nm: 200

Front P.T.O. Box kgf m: 20 lbf ft: 148

A402230

Location: Steershaft Intermediate UJ Nm: 38 kgf m: 3.9 lbf ft: 28 (3000 series machines only)

A402270

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Issue 2

Section 1

General Information

Section 1

Torque Settings

2-6

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

Front Anti-Roll Bar Fasteners: Insulators kgf m: 4.8 lbf ft: 35

Nm: 47.5

Location:

Front Anti-Roll Bar Fasteners: Pivot Bolt Nm: 278 kgf m: 28 lbf ft: 205 (2000 series machines only)

A402080

Location:

Rear Anti-Roll bar mounting bracket Nm: 392 kgf m: 40 lbf ft: 289 (3000 series machines only)

Location:

4.W.S. only rear anti-roll bar crossmember Nm: 80 kgf m: 8.2 lbf ft: 59 (2000 series machines only)

A402130

Location:

Front Anti-Roll Bar Fasteners: Pivot Bolt Nm: 200 kgf m: 20 lbf ft: 148 (3000 series machines only)

A402120 A402110

Location: Nm: 200

Front Engine Mounting kgf m: 20 lbf ft: 148

Location: Header Tank Clamp Plate Nm: 30 kgf m: 3 lbf ft: 22 (3000 series machines only)

A402290

A402150

9803/8020

Issue 2*

Section 1

General Information

Section 1

3-1

Sealing and Retaining Compounds * Gasketing - Loctite 509

JCB Multigasket

To seal the joint faces between the PTO/splitter gearbox, the speed gearbox and the range gearbox.

4102/3202 4102/3240

A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter.

4102/1212

50ml 315 ml

JCB High Strength Threadlocker A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important.

4102/0551

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

JCB Threadlocker & Sealer (High Strength)

A medium to high strength locking fluid.

4101/0552

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 products.

4104/0251 4104/0253

Aerosol Bottle

JCB Cleaner/Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants. 4104/1557

Aerosol

Direct Glazing Kit

50ml

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 4104/1206

250 g 30 ml

† Black Primer 206J

For direct glazing

4201/4906

30 ml

To seal butt jointed glass. Also to seal hub planet gear carrier when no 'O' ring is fitted

4102/0901

To finish exposed edges of laminated glass

4102/2309

JCB Clear Silicone Sealant Black Polyurethane Sealant

9803/8020

310 ml

Issue 2*

Section 1

General Information

Section 1

4-1

Service Tools Numerical List 1370/0901Z 1406/0021 1604/0006 1604/0008 1606/0012 1606/0015 1612/0006 * 331/64246 * 331/64265 4101/0251 4101/0451 4101/0552 4101/0651 4102/0551 4102/0901 4102/1212 4102/1951 4102/2210 4102/2309 4103/2109 4104/0251 4104/0253 4104/1557 4104/1203 4104/1206 4104/1310 4201/4906 454/30056 477/00437 721/00664 721/10885 816/15118 816/20008 816/20013 816/55038 816/55040 892/00041 892/00078 892/00137 892/00174 892/00179 892/00180 892/00181 892/00223 892/00224 892/00225 892/00253 892/00255 892/00256 892/00257 892/00258 892/00259 892/00260 892/00261 892/00262 892/00263 892/00264 892/00265 892/00268 892/00269 892/00270 892/00271 9803/8020

Page No. Nut M24 9-1 Bonded Washer 7-1 Adapter 7-1 Adapter 7-1 Adapter 7-1 Adapter 7-1 Adapter 7-1 Tool Kit for Non-return Valve 7-2 etaining Bush for Valve spool 7-2 JCB Threadlocker and Sealer 3-1 JCB Threadlocker 3-1 JCB Threadlocker and Sealer (High Strength) 3-1 JCB Retainer (High Strength) 3-1 JCB High Strength Threadlocker 3-1 JCB Clear Silicone Sealant 3-1 JCB Multigasket 3-1 JCB Threadseal 3-1 Clayton System Seal SC1251 3-1 Black Polyurethane Sealant 3-1 Ultra Fast Adhesive 3-1 JCB Activator (Aerosol) 3-1 JCB Activator (Bottle) 3-1 JCB Cleaner/Degreaser 3-1 Active Wipe 205 (250 g) 3-1 Active Wipe 205 (30 ml) 3-1 Hand Cleaner 5-1 Black Primer 3-1 Spacer 13.80 mm 8-4 Gearbox Lifting Adapter 8-2 Connecting Lead (Psion Workabout) 6 - 1 Harness - Diagnostic (J1939) 6-2 Test Adapter 7-1 Adapter 7-1 Adapter 7-1 Adapter/Test Point 7-1 Adapter/Test Point 7-1 Deglazing Tool 9-2 Connector 7-1 Micro Bore Hose 7-2 Measuring Cup 8-2 Bearing Press 8-1 Seal Fitting Tool 9-1 Replacement Plastic Boss 9-1 Hand Pump 7-2 Impulse Extractor 8-2 Adapter for Impulse Extractor 8-1 Pressure Test Kit 7-1 Adapter/Test Point 7-1 Adapter/Test Point 7-1 Adapter/Test Point 7-1 Adapter/Test Point 7-1 Adapter/Test Point 7-1 Adapter/Test Point 7-1 Adapter/Test Point 7-1 Adapter/Test Point 7-1&7-2 Adapter/Test Point 7-1 Adapter/Test Point 7-1 Adapter/Test Point 7-1 Flow Monitoring Unit 7-1 Sensor Head 7-1 Load Valve 7-1 Adapter 7-1

892/00272 892/00273 892/00274 892/00275 892/00276 892/00277 892/00278 892/00279 892/00281 892/00282 892/00283 892/00284 892/00285 892/00286 892/00293 892/00294 892/00298 892/00311 892/00312 892/00313 892/00314 892/00315 892/00318 892/00333 892/00334 892/00706 892/00800 892/00801 892/00802 892/00803 892/00807 892/00808 892/00812 892/00817 892/00818 892/00819 892/00842 892/00843 892/00844 892/00845 892/00846 892/00847 892/00848 892/00849 892/00864 892/00871 892/00874 892/00875 892/00876 892/00882 892/00883 892/00884 892/00892 892/00916 892/00918 892/00945 892/00956 892/01033 892/01045 892/01046 892/01047

Adapter Sensor Head Adapter Adapter Adapter Adapter Gauge 0 - 40 bar Gauge 0 - 400 bar Avo Meter Shunt Tool Kit Case Digital Tachometer Oil Temperature Probe Surface Temperature Probe Connector Pipe Connector Pipe Fluke Multimeter Brake Test Kit Dummy End Plate Clutch Alignment Tool Accumulator Adapter Engine Support Brackets Hose and Adapter Kit Heavy Duty Socket, 19 mm A/F Gland Seal Fitting Tool Test Probe Splitting Frame Clutch spanner Rotor puller set Rotor installer set Front plate puller Shaft protector Drive Coupling Spanner Heavy Duty Socket, 17 mm A/F Heavy Duty Socket, 22mm A/F Heavy Duty Socket, 15 mm A/F Glass Lifter Folding Stand Long Knife Cartridge Gun Glass Extractor Handles Nylon Spatula Wire Starter Braided Cutting Wire PD 90 Axle Locknut Spanner Frame (Puller Adapter Assembly) Brace (Puller Adapter Assembly) Bar M24 (Puller Adapter Assembly) Block (Puller Adapter Assembly) Socket Spanner (Steer Box Input Shaft Nuts) ‘C’ Spanner (Steer Box Input Shaft Nuts) Speed Gearbox Locking Tool Spring Compressor Setting Tool Kit Sleeve for M30 Pinion Timing Pin for Fuel Injection Pump Data Link Adapter Kit Peg Socket - Wet Clutch Mandrel - Wet Clutch Jig - Wet Clutch

7-1 7-1 7-2 7-1 7-1 7-1 7-2 7-2 6-1 6-1 6-1 6-1 6-1 6-1 7-1 7-1 6-1 8-4 8-2 8-1 9-1 8-1 7-2 8-2 7-2 7-2 8-1 5-3 5-3 5-3 5-3 5-3 8-1 8-2 8-2 8-2 5-1 5-1 5-2 5-1 5-2 5-3 5-2 5-2 8-4 9-1 9-1 9-1 9-1 6-1 9-1 9-1 8-3 8-3 8-4 8-4 9-2 6-2 8-5 8-5 8-5

Issue 8*

Section 1

General Information

4-2

Section 1 4-2

Service Tools Numerical List (continued) 892/01048 892/01049 892/01050 892/01051 892/01052 892/01053

* 892/01092 926/15500 992/12300 992/12400 992/12600 992/12800 992/12801 993/45400 993/55700 993/59300 993/70111 993/85700 997/11000 997/11100

Page No. Clutch Pack Retainer - Wet Clutch (2 required) 8-4 Guide Rod - Wet Clutch (2 required) 8-4 Mandrel - Wet Clutch 8-5 Intermediate Gear Retaining Tool Wet Clutch Transmission 8-4 Locking Plate - Wet Clutch (2 required) 8-4 Adapter for impulse extractor (PTO intermediate shaft, wet clutch transmission) 8-2 Wheel Hub Service Kit 8-5 Rubber Spacer Blocks 5-3 Mobile Oven 5-1 Static Oven 5-1 Static Oven 5-1 Cut-out Knife 5-2 'L' Blades 5-2 Torque Multiplier 8-2 Direct Glazing Kit 3-1 Pressure Test Adapter and Clamp 8-3 Break-back Torque Wrench 8-4 Battery Tester 6-1 Drive Head Setting Bracket 8-4 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 Seal Kit 7-1 * 993/69800 * Replacement parts for kit no. 892/01092 1315/3414Z Bolt M10x60 1315/3731Z Bolt M16x220 1315/3835Z Bolt M20x300 1370/0301Z Nut M10 1370/0401Z Nut M12 1370/0601Z Nut M16 1370/0701Z Nut M20 1420/0009Z Washer M12 1420/0012Z Washer M20 445/12303 Washer 892/00891 Dolly 917/02800 Bearing 998/10606 Bearing Fitting Tube 998/10607 Inner Bearing Plate 998/10608 Bearing Centre Puller 998/10610 Puller Rod 998/10614 Reaction Tube 998/10615 Wheel Bearing Carrier Puller 998/10616 Puller Handle Nut 998/10623 Puller Beam 998/10624 Modified Wheel Stud

9803/8020

8-5 8-5 8-5 8-5 8-5 8-5 8-5 8-5 8-5 8-5 8-5 8-5 8-5 8-5 8-5 8-5 8-5 8-5 8-5 8-5 8-5

Issue 6*

Section 1

General Information

Section 1

5-1

Service Tools Section B - Body and Framework

S186240

S186270

Hand Cleaner - special blend for the removal of polyurethane adhesives.

Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc.

JCB part number - 4104/1310 (454g; 1lb tub)

JCB part number - 892/00845

S186250

12V Mobile Oven - 1 cartridge capacity - required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket (715/04300).

Folding Stand for Holding Glass - essential for preparing new glass prior to installation.

JCB part number - 992/12300

JCB part number - 892/00843

S186280

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

9803/8020

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 Issue 1

Section 1

General Information

Section 1

5-2

Service Tools (continued) Section B - Body and Framework (continued)

S186310

S186340

Wire Starter - used to access braided cutting wire (below) through original polyurethane seal.

Cut-out Knife - used to remove broken glass. JCB part number - 992/12800

JCB part number - 892/00848

S186350

S186320

Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass.

'L' Blades - 25mm (1in.) cut - replacement blades for cut-out knife (above).

JCB part number - 892/00846

JCB part number - 992/12801 (unit quantity = 5 off)

S186330 S186360

Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool (above).

Long Knife - used to give extended reach for normally inaccessible areas.

JCB part number - 892/00849 (approx 25m length)

JCB part number - 892/00844

9803/8020

Issue 1

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Section 1

5-3

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.

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)

JCB part number - 892/00847

892/00801

Clutch spanner for air conditioning compressor

S200940

892/00807

Front plate puller for air conditioning compressor

S200970

892/00802

Rotor puller set for air conditioning compressor

S200950

892/00808

Shaft protector for air conditioning compressor

S200980

892/00803

Rotor installer set for air conditioning compressor

S200960

9803/8020

Issue 1

Section 1

General Information

Section 1

6-1

Service Tools Section C - Electrics

Electrical Test Equipment 1 892/00283 Tool Kit Case 2 892/00281 AVO Meter 3 892/00286 Surface Temperature Probe 4 892/00284 Microtach Digital Tachometer 5 892/00282 100 Amp Shunt - open type 6 892/00285 Hydraulic Oil Temperature Probe 7 892/00298 Fluke 85 Multimeter

188230

239510

993/85700

Battery Tester

S216770

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.

9803/8020

Issue 2*

Section 1

General Information

Section 1

6-2

Service Tools Section C - Electrics 892/01033 Data Link Adapter Kit

Note: Item A of the Data Link Adapter Kit is unsuitable for use with the Fastrac and must be replaced by the â&#x20AC;&#x2DC;Harness - Diagnostic (J1939)â&#x20AC;&#x2122; shown below.

A360250

9 10 11 12 13 14 15

A J H

F G

A386040

721/10885

9803/8020

Harness - Diagnostic (J1939)

Issue 1

Section 1

General Information

Section 1

7-1

Service Tools Section E - Hydraulics

Hydraulic Circuit Pressure Test Kit 892/00253 892/00201 892/00202 892/00203 892/00254 :993/69800

Pressure Test Kit Replacement Gauge 0-20 bar (0-300 lbf/in2) Replacement Gauge 0-40 bar (0-600 lbf/in2) Replacement Gauge 0-400 bar (0-6000 lbf/in2) Replacement Hose Seal Kit for 892/00254 (can also be used with probe 892/00706)

S188120

Pressure Test Adapters Pressure Test 'T' Adapters 892/00262 816/55038 816/55040 892/00263 892/00264 892/00265

1/4 in M BSP x 1/4 in F BSP x Test Point 3/8 in M BSP x 3/8 in F BSP x Test Point 1/2 in M BSP x 1/2 in F BSP x Test Point 5/8 in M BSP x 5/8 in F BSP x Test Point 3/4 in M BSP x 3/4 in F BSP x Test Point 1 in M BSP x 1 in F BSP x Test Point

892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261

1/4 in BSP x Test Point 3/8 in BSP x Test Point 1/2 in BSP x Test Point 5/8 in BSP x Test Point 3/4 in BSP x Test Point 1 in BSP x Test Point 1.1/4 in BSP x Test Point 5/8 in UNF x Test Point

S200140

S188130

Flow Test Equipment 892/00268 892/00269 892/00293 892/00270 1406/0021 1604/0006 1612/0006 892/00271 892/00272 816/20008 892/00275 892/00276 892/00277 892/00273 892/00294 1606/0015 892/00078 1604/0008 1606/0012 816/20013

9803/8020

Flow Monitoring Unit Sensor Head 0 - 100 l/min (0 - 22 UK gal/min) Connector Pipe Load Valve Bonded Washer Adapter 3/4 in M x 3/4 in M BSP Adapter 3/4 in F x 3/4 in M BSP Adapter 3/4 in F x 5/8 in M BSP Adapter 5/8 in F x 3/4 in M BSP Adapter 3/4 in F x 1/2 in M BSP Adapter 1/2 in F x 3/4 in M BSP Adapter 3/4 in F x 3/8 in M BSP Adapter 3/8 in F x 3/4 in M BSP Sensor Head 0 - 380 l/min Connector Pipe Adapter 1.1/4 in M BSP x 1 in M BSP Connector 1 in F x 1 in F BSP Adapter 1 in M x 1 in M BSP Adapter 1 in M x 3/4 in M BSP Adapter 3/4 in F x 1 in M BSP

S188150

Issue 1

Section 1

General Information

Section 1

7-2

7- 2

Service Tools (continued) Section E - Hydraulics (continued)

S193850

Hand Pump Equipment 892/00223 892/00137 892/00274 892/00262 892/00706 892/00278 892/00279

Hand Pump Micro-bore Hose 1/4 in BSP x 5 metres Adapter 1/4 in BSP male x 3/8 BSPT male Test Point on 1/4 in BSP male x 1/4 BSP female adapter Test Probe Gauge 0-40 bar (0-600 lbf/in2) Gauge 0-400 bar (0-6000 lbf/in2)

197210

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

197220

892/00334

Gland Seal Fitting Tool

331/64265

Retaining Bush for Valve Spool

9803/8020

Issue 2

Section 1

General Information

Section 1

8-1

Service Tools Section F - Transmission

197260

892/00800 hoist)

Splitting Frame (complete with ratchet

197270

892/00315

Engine Support Bracket

188200

892/00179

107750

892/00812

Bearing Press

Drive Coupling Spanner for yoke couplings

197280

892/00313

9803/8020

Clutch Alignment Tool

197080

892/00225

Adapter - Impulse Extractor Small 17mm to 25mm Medium 25mm to 45mm Large 45mm to 80mm

Issue 2

Section 1

General Information

Section 1

8-2

Service Tools (continued) Section F - Transmission (continued)

993/45400 Torque Multiplier (use in conjunction with a torque wrench to give a 5 : 1 multiplication)

S197030

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 * 892/01053

197250

S190770

892/00174 Measuring Cup - Pinion Head Bearing

S197070 Impulse Extractor Set for Hub Bearing Seals Adapter for impulse extractor (PTO intermediate shaft, wet clutch transmission)

S197240

892/00312 Dummy End Plate for Range Gearbox

110 25

25 15 40

A197180 197200

477/00437

9803/8020

Gearbox Lifting Adapter

Rear Differential Setting Key Cut from 5 mm plate to dimensions shown. Fabricate handle to suit.

Issue 3*

Section 1

General Information

Section 1

8-3

Service Tools (continued) Section F - Transmission (continued)

993/59300

2/4 WD Pressure Test Adaptor & Clamp

S196750

S226300

892/00892

Speed Gearbox Locking Tool

892/00916

Spring Compressor for Splitter and PTO Clutches

S267310

9803/8020

Issue 3

Section 1

General Information

Section 1

8-4

Service Tools (continued) Section F - Transmission (continued)

2 S234120

892/00864

PD 90 Axle Locknut Spanner

A270851

Solid Spacer Setting Tools 1

2 3 4

892/00918

Setting Tool Kit. Contains the following: A Sleeve for M24 Pinion B Adapter for M30 Pinion C Fork (suitable for all axles) The following setting tools must be purchased seperately: 892/00945 A Sleeve for M30 Pinion 997/11100 B Adapter for M24 Pinion 997/11000 Drive Head Setting Bracket 993/70111 Break-back Torque Wrench Solid spacer (see parts CD or michrofiche for part numbers)

A361730

892/01052 (x2)

Locking Plate for locking wet clutch drum to housing

892/01049 (x2)

Guide Rod - wet clutch

A361710

892/01051

Intermediate Gear Retaining Tool - wet clutch transmission

A361740

A361720

892/01048 (x2)

9803/8020

Clutch Pack Retainer - wet clutch

Issue 6*

Section 1

General Information

Section 1

8-5

Service Tools (continued) Section F - Transmission (continued)

A361750

892/01045

Peg Socket - wet clutch

892/01046

Mandrel - for bush assembly - wet clutch

A361770

A361760

892/01047

9803/8020

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 A to be removed before use.

Issue 1

General Information

Section 1

8-6

Service Tools (continued) Section F - Transmission (continued) Item A

Description Hub Service Kit

Part No. 892/01092

comprises: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Qty 1

Puller Beam Inner Bearing Plate Bolt M16x220 Nut M16 Reaction Tube Modified Wheel Stud Wheel Bearing Carrier Puller Nut M20 Washer M20 Puller Rod Nut M12 Washer M12 Bearing Centre Puller Bolt M10x60 Nut M10 Bearing Fitting Tube Puller Handle Nut Bolt M20x300 Washer Bearing Dolly

998/10623 998/10607 1315/3731Z 1370/0601Z 998/10614 998/10624

1 1 2 2 1 2

998/10615 1370/0701Z 1420/0012Z 998/10610 1370/0401Z 1420/0009Z 998/10608 1315/3414Z 1370/0301Z 998/10606 998/10616 1315/3835Z 445/12303 917/02800 892/00891

2 4 2 2 2 2 1 1 1 1 1 2 2 1 1

6 8,9 7 2

10 11,12

19, 20 14

18 8 21

9803/8020

Issue 1

Section 1

General Information

Section 1

9-1

Service Tools (continued) Section G - Brakes

892/00311

Brake Test Kit

3 x Calibrated Test Gauges - 0-20 bar (0 - 290 lbf/in2) 3 x 5 Metre Hoses with Quick Release Adapters 3 x ISO Test Point Adapters S199470

Section H - Steering

E B C

229270

892/00180

892/00181

A 222490

Seal Fitting Tool for fitting ‘O’ ring and back-up ring to Danfoss Orbitrol Unit

Puller adapter assembly for removal of drop arm from steering box (3000 Series machines). Comprises:

Replacement Plastic Boss A B C D E

892/00871 892/00874 892/00875 892/00876 1370/0901Z

Frame Brace Bar M24 Block Nut M24

1 off 1 off 2 off 2 off 2 off

Use in conjunction with a 20 tonne hydraulic ram as obtainable from Sykes Pickavant to suit puller bars at 185 mm centres.

G F 220130

Spanners for input shaft nuts on steering box (3000 Series machines with serial nos. 640001 to 640053 and 640056 to 640058). F G

892/00883 892/00884

9803/8020

Spanner ‘C’ Spanner Issue 3*

Section 1

General Information

9-2

Section 1 9-2

Service Tools (continued) Section S - Suspension *

S199480

892/00314

Accumulator and Gas Spring Pressure Test Adapter

Section T - Engine

A314530 S192390

892/00041

De-glazing Tool for Cylinder Bores (to assist bedding-in of new piston rings)

892/00956

Timing pin for fuel injection pumps (Fastrac 2115, 2125, 2135, 2150 only).

Note: For other engine tools refer to the relevant Engine Service Manual.

9803/8020

Issue 2*

Section 1

General Information

Section 1

Moving a Disabled Machine

10- 1

10 - 1

General

Preparation for Towing

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.

Connect the towing vehicle. a Apply the parking brakes on the towing vehicle and securely chock the wheels on the Fastrac. b Fit the drawbar between towing vehicle and Fastrac.

Prepare the machine. a Make sure that the range and speed gearboxes are both in neutral. b If the gearbox has failed, disconnect both propshafts (see Section F). c If an axle has failed, remove the sun gears (see Section F).

* 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

3 Release the Fastrac parking brake. Note: The Schrader valve X shown 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 valve X. 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 B tight against clevis C, turn nut D against the plate so that rod E is drawn out of the actuator body and the parking brake is released. Note: If the parking brake cannot be released, remove both propshafts (see Section F).

A286550

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.

D E C

Remember that the steering will be much heavier if the engine is not running.

S160392 S261600

9803/8020

Issue 3*

Section 1

General Information

Section 1

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.

Anchor 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.

Measure the maximum height of the machine from the ground. Try to make sure the truck driver knows the clearance height before he drives away.

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 SPECIFICATIONS section for the minimum ground clearance of your machine. 2-2-7-5/1

Place blocks at the front and rear of the trailer wheels.

Move the machine on to the trailer as follows: a Make sure the ramps are correctly in place and secure. b Carefully drive the machine onto the trailer. c Set the drive to neutral and engage the parking brake. d Switch off the engine. e Ensure that the overall height of the load is within regulations. f Secure the cab.

A288080

9803/8020

Issue 1

Section 2

Care & Safety

Section 2

Contents

9803/8020

Page No.

Safety Notices

1-1

General Safety

2-1

Operating Safety

3-1

Maintenance Safety

4-1

Issue 1

Section 2

Care & Safety

1-1

Section 2 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

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.

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.

Do not work with the machine until you are sure that you can control it. Do not start any job until you are sure that you and those around you will be safe. If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE GEN-1-6

As well as the warnings in the following pages, specific warnings are given throughout the book. This section is designed to give a safety code for use of the machine generally and for operation and maintenance practices.

General Safety ! WARNING

! WARNING

Lifting Equipment 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.

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

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.

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

INT-1-3-9

9803/8020

Issue 1

Section 2

Care & Safety

Section 2

3-1

Operating Safety ! DANGER

! WARNING

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.

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.

13-2-1-10

INT-2-1-11

! 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.

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

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.

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

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

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

13-1-1-3

9803/8020

Issue 1

Section 2

Care & Safety

Section 2

3-2

Operating Safety (cont'd) ! WARNING

! 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.

Power Take-off Operation When operating PTO equipment, always observe the following safety precautions:

INT-2-2-5

Follow the instructions in the implement operator's handbook.

! 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.

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:

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

Leaving the cab

Attempting to attach or detach an implement to or from a PTO shaft or

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

! 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

Operating Safety (cont'd) ! WARNING

! 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.

Stability In the event of the machine becoming unstable, keep firm hold of the steering wheel and do not try to leave the cab.

13-2-1-2

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.

! 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.

13-2-2-10

! WARNING

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

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.

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

13-2-2-1

9803/8020

Issue 2*

Section 2

Care & Safety

Section 2

4-1

Maintenance Safety ! WARNING

! 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.

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

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.

! 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.

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.

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

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 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

9803/8020

Issue 1

Section 2

Care & Safety

Section 2

4-2

! WARNING

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

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 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.

! WARNING Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents. INT-3-2-11

! WARNING

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.

'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

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.

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.

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 iron. On no account weld or drill the chassis structure. Nonapproved modifications can cause injury and damage. Contact JCB before modifying the machine.

! WARNING Wheels Wheels are heavy. Handle and store with care to ensure that they cannot fall and cause injury.

GEN 8-1

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.

! 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

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.

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.

GEN 6-2

9803/8020

Issue 2*

Section 2

Care & Safety

Section 2

4-3

Maintenance Safety (cont'd) ! WARNING

! 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.

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

New fluoroelastomeric components at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose temperatures have not exceeded 300Â°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 300Â°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.

Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.

Thoroughly wash contaminated area with detergent and water.

Contain all removed material, gloves etc used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.

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

DO NOT BURN FLUOROELASTOMERIC MATERIALS. If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 16-60 minutes. Get medical attention immediately. INT - 3 - 3 - 5/1

9803/8020

Issue 2*

Section 3

Routine Maintenance

Section 3

Contents

Page No.

Engine Oil - (All Machines) Lubricants & Capacities (2000 Series Machines) Lubricants & Capacities (3155) Lubricants & Capacities (3185) Lubricants - Health and Safety

1-1 1-2 1-4 1-6 1-8

Service Schedules (Dry Clutch Transmission †) Service Schedules (Wet Clutch Transmission ††)

2-1 2-4

Cleaning the Machine and Checking for Damage Checking Seat Belt Condition and Security Opening/Closing the Bonnet (2000 Series Machines) Opening/Closing the Bonnet (3000 Series Machines)

2-8 2-8 2-9 2-9

Greasing General Propshafts and PTO Driveshafts Steering Swivels (2000 Series Machines) Front Axle Steering Swivels (3000 Series Machines) Hydraulic Lift & 3 point Linkage (2000 Series Machines) Rear PTO Driveshaft Bearings (2000 Series Machines) Rear Suspension Cylinder Pivots (2000 Series Machines) Hydraulic Lift & 3 point Linkage (3000 Series Machines) Rear PTO Driveshaft Bearings (3000 Series Machines) Rear Suspension Cylinder Pivots (3000 Series Machines) Rear Anti-roll Bar Ball Joints (2000 Series Machines) Steering Box Input Shaft Seal (3000 Series Machines) Rear Anti-roll Bar Ball Joints (3000 Series Machines) Automatic Trailer Coupling (if fitted)

3-1 3-1 3-2 3-3 3-4 3-4 3-4 3-5 3-5 3-5 3-6 3-7 3-7 3-8

Cab Checking the ROPS Structure Checking the Windscreen Washer Fluid Level

4-1 4-2

Air Conditioning Cleaning the Filter (2000 Series Machines) Adjusting the Compressor Belt (2115, 2125, 2135, 2150) * Cleaning the Filter (3000 Series Machines) * Adjusting the Compressor Belt (2140 and 3000 Series) Electrics Battery Warning Symbols First Aid - Electrolyte Checking the Battery Electrolyte Level Checking the Headlight Beam Alignment Fuses

5-1 5-1 5-2 5-3

6-1 6-1 6-2 6-3 See Section C

Hydraulics Checking the Fluid Level Changing the Filter Element Changing the Hydraulic Fluid and Cleaning the Suction Strainer Emptying the Hydraulic Coupling Drain Reservoir (if fitted)

7-1 7-1 7-2 7-3

* Dry Clutch Hydraulic System †

Checking the Fluid Level

8-1

† 2000 Series to S/N 739999, 3000 Series to S/N 641999 †† 2000 Series from S/N 740000, 3000 Series from S/N 642000

9803/8020

Issue 7*

Section 3

Routine Maintenance

Section 3

Contents

Page No.

PTO, Speed and Range Gearboxes Checking the Oil Level Changing the Oil and Cleaning the Strainer - (Dry Clutch Transmission) † Changing the Oil and Cleaning the Strainer - (Wet Clutch Transmission) †† Changing the Transmission Oil Filter Checking the Front PTO Gearbox Oil Level (if fitted)

9 - 2A 9-3 9-4

Front Axle Checking the Differential Oil Level Changing the Differential Oil Checking the Hub Oil Levels Changing the Hub Oil

10 - 1 10 - 1 10 - 2 10 - 2

Rear Axle (2WS) Checking the Oil Level Changing the Oil

11 - 1 11 - 2

Rear Axle (4WS) Checking the Differential Oil Level Changing the Differential Oil Checking the Hub Oil Levels Changing the Hub Oil

11 - 3 11 - 3 11 - 4 11 - 4

Front and Rear Axle Steering Swivels (4WS) Checking 4WS Right Side Trunnion Seals

11 - 5

Tyres and Wheels General Tyre Inflation Pressures, Speeds and Loads Checking and Adjusting Wheel Alignment Track Width Checking Wheel Nut Torques Lock Stops Fender Adjustment

12 - 1 12 - 1 See Operator Handbook 12 - 4 12 - 5 12 - 5 12 - 6 12 - 7

9-1 9-2

* 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 † 2000 Series to S/N 739999, 3000 Series to S/N 641999 †† 2000 Series from S/N 740000, 3000 Series from S/N 642000

9803/8020

Issue 10*

Section 3

Routine Maintenance

Section 3

iii

Contents

Page No.

Engine Checking the Oil Level 14 - 1 Changing the Oil and Filter 14 - 2 Draining/Cleaning the Fuel Sediment Bowl 15 - 1 Draining/Renewing Fuel Pre-Filter (when fitted) 15 - 2 Draining the Fuel Filters 15 - 3 Changing the Fuel Filter Elements 15 - 3 * Cleaning the Fuel Lift Pump (2115, 2125, 2135, 2150 and 3155) 15 - 4 * Bleeding the Fuel System (2115, 2125, 2135, 2150 and 3155) 15 - 5 15 - 5A * Bleeding the Fuel System (2140) Bleeding the Fuel System (3185) 15 - 6 15 - 7 * Cleaning the Fuel Tank Strainer (Early machines only) Checking the Coolant Level 16 - 1 16 - 2 * Draining the Coolant (2115, 2125, 2135 and 2150 Machines) * Filling the Cooling System (2115, 2125, 2135 & 2150 Machines) 16 - 3 Coolant Mixtures 16 - 3 Draining & Refilling the Coolant (3155 Machines) 16 - 4 16 - 5 *Draining & Refilling the Coolant (2140 and 3185 Machines) 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 17 - 2 * Adjusting the Fan Belt (2140) 17 - 3 * Adjusting the Fan Belt (3185) 18 - 1 * Changing the Air Filter Elements (Early 2000 Series) 18 - 2 * Changing the Air Filter Elements (Later 2000 Series) 18 - 2 * Changing the Air Filter Elements (3000 Series)

9803/8020

Issue 4*

Section 3 1-1

Routine Maintenance * Engine

Oil (All Machines)

Section 3 1-1

New Engines New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately. DO NOT use a special running-in oil but use the oil recommended below from new.

Engine Oil Specification Recommended Oil JCB Extreme Performance Engine Oil SAE 15W/40 API CH-4 or ACEA E3/B3A3 IMPORTANT NOTE: IF SAE 15W/40, API CH-4 OR ACEA E3/B3A3 ENGINE OIL IS NOT AVAILABLE, THEN THE ENGINE OIL MUST BE CHANGED AT 250 HOURS. Alternative Oil If the oil recommended above is not available then the alternatives listed below should be used according to the ambient temperature. Note: (2140 and 3185 machines only). While 15W/40 oil is recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below -5 °C (23 °F). Continued use of low viscosity oils can decrease engine life. JCB Super Multigrade 15W/40 SAE15W/40, API CF4/SG -10 °C to 50 °C (14 °F to 122 °F) JCB Super Multigrade 10W/30 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).

9803/8020

Issue 7*

Section 3

Routine Maintenance

1-2

Section 3 1-2

Lubricants & Capacities (2000 Series Machines)

ITEM

CAPACITY FLUID/LUBRICANT Litres (UK Gal)

* Fuel 2115, 2125, 2135, 2140 220 (48) 2150 350 (77) * Engine (Oil) 2115, 2125, 2135, 2150 16.5 (3.6) 2140 15 (3.3) * Engine (Coolant) 2115, 2125, 2135, 2150 34 (7.5) 2140 33 (7.3)

Diesel Oil (See Types of Fuel)

MINIMUM INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D

See Engine Oil (All Machines) at the beginning of this section

JCB Four Seasons Antifreeze & Summer Coolant/water (See Coolant Mixtures)

ASTM D3306, BS6580

PTO, Speed and Range Boxes (combined)

38 (8.4) † 42 (9.3) ††

JCB Super Universal Agricultural

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

7 (1.56) 1.9 (0.4)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Rear Axle (2WS) Rear Axle (4WS) Housing Hubs (x2)

23 (5.0)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

17 (3.7) 2.0 (0.4)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Brake System Front Rear

JCB Universal Brake Fluid

SAE J1703 DOT 4

0.75 (0.17) 0.75 (0.17)

! CAUTION

Do not use ordinary hydraulic fluid in the brake system. 13-3-2-6

† Clutch System Hydraulic System - see Note 1

Grease Points

82 (18.0) † 120 (26.4) ††

---

JCB Light Hydraulic Fluid - see Note 2

ISO VG15

JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F)

ISO VG46

JCB Hydraulic Fluid HP32 (Below 38 °C, 100 °F)

ISO VG32

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 - Compressor Lubricant 0.24 (0.05) Polyalkalineglycol

CH2 FC F3 PAG SP20

Front PTO Transfer Box (optional)

API-GL-5, MIL-L-2105C

3.0 (0.67)

JCB HD90 Gear Oil

Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank. Note 2: It is esssential that the correct specification fluid is used. Contact your JCB Dealer for further information. † ††

2000 Series to S/N 739999 2000 Series from S/N 740000

9803/8020

Issue 9*

Section 3

Routine Maintenance

1-3

Section 3 1-3

Lubricants & Capacities (N. America) (2000 Series Machines)

ITEM

CAPACITY FLUID/LUBRICANT US Gal (Liters)

* Fuel 2115, 2125, 2135, 2140 57.6 (220) 2150 92.5 (350) * Engine (Oil) 2115, 2125, 2135, 2150 4.3 (16.5) 2140 4 (15) * Engine (Coolant) 2115, 2125, 2135, 2150 9.0 (34.0) 2140 8.77 (33)

Diesel Oil (See Types of Fuel)

MINIMUM INTERNATIONAL SPECIFICATION ASTM D975-66T Nos. 1D, 2D

See Engine Oil (All Machines) at the beginning of this section JCB PermanentAntifreeze/water

ASTM D3306-74 (See Coolant Mixtures)

PTO, Speed and Range Boxes (combined)

10 (38.0) † 11.2 (42.0) ††

JCB AG Transmission Fluid

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

1.8 (7.0) 0.5 (1.9)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

6.1 (23.0)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

4.5 (17.0) 0.5 (2.0)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

JCB Universal Brake Fluid

SAE J1703 DOT 4

Rear Axle (2WS) Rear Axle (4WS) Housing Hubs (x2) Brake System Front Rear

0.2 (0.75) 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 - see Notice 1

21.7 (82.0) † 31.7 (120) ††

JCB High Performance Hydraulic Oil

ISO VG46

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 - Compressor Lubricant 0.06 (0.24) Polyalkalineglycol

CH2 FC F3 PAG SP20

Front PTO Transfer Box (optional)

API-GL-5, MIL-L-2105C

0.8 (3.0)

JCB GL5 80W/90 Gear Oil

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

9803/8020

Issue 9*

Section 3

Routine Maintenance

1-4

Section 3 1-4

Lubricants & Capacities (Fastrac 3155)

ITEM

CAPACITY FLUID/LUBRICANT Litres (UK Gal)

MINIMUM INTERNATIONAL 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 & Summer Coolant/water (See Coolant Mixtures)

ASTM D3306, BS6580

PTO, Speed and Range Boxes (combined)

38 (8.4) † 42 (9.3) ††

JCB Super Universal Agricultural

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

20 (4.4) 2.5 (0.55)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Rear Axle

21 (4.6)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Brake System Front Rear

JCB Universal Brake Fluid

SAE J1703 DOT 4

0.75 (0.17) 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 - see Note 1

82 (18.0) † 120 (26.4) ††

JCB High Performance Hydraulic Oil

ISO VG46 (Above 38 °C, 100 °F)

JCB Hydraulic Fluid HP32 (Below 38 °C, 100 °F)

ISO VG32

JCB HP Grease

Lithium complex NLGI No. 2 consistency including extreme pressure additives

Grease Points

---

Air Conditioning System - Refrigerant 1.41 kg (3.11 lb) HFC R134a - Compressor Lubricant 0.24 (0.05) Polyalkalineglycol

CH2 FC F3 PAG SP20

Front PTO Transfer Box (optional)

API-GL-5, MIL-L-2105C

3.0 (0.67)

JCB HD90 Gear Oil

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

9803/8020

Issue 7*

Section 3

Routine Maintenance

1-5

Section 3 1-5

Lubricants & Capacities (N. America) (Fastrac 3155)

ITEM

CAPACITY FLUID/LUBRICANT US Gal (Liters)

MINIMUM INTERNATIONAL SPECIFICATION

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 (See Coolant Mixtures)

ASTM D3306-74

PTO, Speed and Range Boxes (combined)

10.1 (38.0) † 11.2 (42.0) ††

JCB AG Transmission Fluid

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

5.3 (20.0) 0.66 (2.5)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Rear Axle (2WS)

7.1 (27.0)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Brake System Front Rear

JCB Universal Brake Fluid

SAE J1703 DOT 4

0.2 (0.75) 0.2 (0.75)

Fuel

! 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 - see Notice 1

21.7 (82.0) † 31.7 (120) ††

JCB High Performance Hydraulic Oil

ISO VG46

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 - Compressor Lubricant 0.06 (0.24) Polyalkalineglycol

CH2 FC F3 PAG SP20

Front PTO Transfer Box (optional)

API-GL-5, MIL-L-2105C

0.8 (3.0)

JCB GL5 80W/90 Gear Oil

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

9803/8020

Issue 7*

Section 3

Routine Maintenance

1-6

Section 3 1-6

Lubricants & Capacities (Fastrac 3185)

ITEM

CAPACITY FLUID/LUBRICANT Litres (UK Gal)

MINIMUM NTERNATIONAL 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 & Summer Coolant/water (See Coolant Mixtures)

ASTM D3306, BS6580

PTO, Speed and Range Boxes (combined)

38 (8.4) † 42 (9.3) ††

JCB Super Universal Agricultural

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

20 (4.4) 2.5 (0.55)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Rear Axle

27 (6.0)

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

Brake System Front Rear

JCB Universal Brake Fluid

SAE J1703 DOT 4

0.75 (0.17) 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 - see Note 1

82 (18.0) † 120 (26.4) ††

JCB High Performance Hydraulic Oil

ISO VG46 (Above 38 °C, 100 °F)

JCB Hydraulic Fluid HP32 (Below 38 °C, 100 °F)

ISO VG32

JCB HP Grease

Lithium complex NLGI No. 2 consistency including extreme pressure additives

Grease Points

---

Air Conditioning System - Refrigerant 1.41 kg (3.11 lb) HFC R134a - Compressor Lubricant 0.24 (0.05) Polyalkalineglycol

CH2 FC F3 PAG SP20

Front PTO Transfer Box (optional)

API-GL-5, MIL-L-2105C

3.0 (0.67)

JCB HD90 Gear Oil

† ††

3000 Series to S/N 641999 3000 Series from S/N 642000

9803/8020

Issue 7*

Section 3

Routine Maintenance

1-7

Section 3 1-7

Lubricants & Capacities (N. America) (Fastrac 3185)

ITEM

CAPACITY FLUID/LUBRICANT US Gal (Liters)

MINIMUM INTERNATIONAL SPECIFICATION

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 (See Coolant Mixtures)

ASTM D3306-74

PTO, Speed and Range Boxes (combined)

10 (38.0) † 11.2 (42.0) ††

JCB AG Transmission Fluid

API-GL-4, MIL-L-2105

Front Axle Housing Hubs (x2)

5.3 (20.0) 0.66 (2.5)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Rear Axle

7.1 (27.0)

JCB GL5 80W/90 Gear Oil

API-GL-5, MIL-L-2105C

Brake System Front Rear

JCB Universal Brake Fluid

SAE J1703 DOT 4

0.2 (0.75) 0.2 (0.75)

Fuel

! 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 - see Notice 1

21.7 (82.0) † 31.7 (120) ††

JCB High Performance Hydraulic Oil

ISO VG46

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 - Compressor Lubricant 0.06 (0.24) Polyalkalineglycol

CH2 FC F3 PAG SP20

Front PTO Transfer Box (optional)

API-GL-5, MIL-L-2105C

0.8 (3.0)

JCB GL5 80W/90 Gear Oil

† ††

3000 Series to S/N 641999 3000 Series from S/N 642000

9803/8020

Issue 4*

Section 3

Routine Maintenance

Section 3

Lubricants - Health and Safety

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.

1-8

FIRST AID - OIL Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention.

HYGIENE JCB lubricants are not a health risk when used properly for their intended purposes.

Swallowing If oil is swallowed do not induce vomiting. Get medical advice.

However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.

Skin In the case of excessive skin contact, wash with soap and water.

Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination.

SPILLAGE

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.

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

HANDLING WASTE DISPOSAL 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

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.

Used engine lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer. Here are precautions to protect your health when handling used engine oil: 1

Avoid prolonged, excessive or repeated skin contact with used engine oils.

Apply a barrier cream to the skin before handling used engine oil.

Note the following when removing oil from skin: a b c d e f g h

Wash your skin thoroughly with soap and water. Using a nail brush will help. Use special hand cleansers to help clean dirty hands. Never use petrol, diesel fuel, or paraffin for washing. Avoid skin contact with oil soaked clothing. Don't keep oily rags in pockets. Wash dirty clothing before re-use. Throw away oil-soaked shoes.

9803/8020

Issue 1

Section 3 2-1

Routine Maintenance

Section 3

Service Schedules - Dry Clutch Transmission

Every 10 Operating Hours or Daily whichever occurs first

Every 50 Operating Hours or Weekly whichever occurs first

Clean 1 Machine generally.

Do the Daily jobs plus:

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).

2-1

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.

Note: Some machines have grease nipples fitted to the external hydraulic control lever pivot points (see External Hydraulics Control Valve Linkage, Lever Linkages in section D). Grease at these points if the lever movement becomes stiff or independent operation becomes difficult.

9803/8020

Issue 6*

Section 3 2-2

Routine Maintenance

Section 3

Service Schedules - Dry Clutch Transmission

2-2

First 100 Hours Dealer Service

First 100 Hours Dealer Service (continued)

Change 1 Engine oil and filter. 2 Fuel filters. 3 Transmission oil filter. 4 Hydraulic oil filter.

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

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.

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 15â&#x20AC; 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) * â&#x20AC; Applies only if recommended oil (see Engine Oil) and Stratopore filter (3185 only) are not available.

9803/8020

Issue 8*

Section 3 2-3

Routine Maintenance

Section 3

Service Schedules - Dry Clutch Transmission

2-3

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 Hours for 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). 9803/8020

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).

Issue 6*

Section 3

Routine Maintenance

Section 3

Service Schedules - Wet Clutch Transmission

2-4

! 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.

Every 50 Operating Hours or Daily whichever occurs first Do the Daily jobs plus: Drain 1 Fuel filter. Fuel pre-filter - when fitted (except 2140). *2 Clean 3 Air filter dust valve.

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 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.

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.

9803/8020

Issue 5*

Section 3 2-5

Routine Maintenance 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).

52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67

Clean/Drain Fuel lift pump gauze (clean - except 2140 and 3185). *9 * 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.

Section 3 2-5

Transmission pressure circuit pressure maintaining valve setting. Transmission lubrication pressure (HPL & LPL). Diff. lock pressure relief valve. External hydraulics pressure relief valve. Instrument readings and warning lights. Operation of all electrical equipment. Operation of clutch and footbrakes. Operation of steering. Operation of transmission. Operation of 3-point linkage. Operation of front linkage (optional equipment). Rear axle/chassis clearance. Height corrector valve operation. Parking Brake operation. Pick-up hitch operation. Spool valve operation. 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.

Grease 41 Propellor shafts and universal joints. 42 Steering swivels. 43 Rear PTO shaft bearings. 44 3 point linkage. 45 Rear lift ram pivots. 46 Suspension cylinder pivots. Check (engine running) 47 Exhaust smoke. 48 Throttle and stop controls. 49 PTO operation. 50 2/4WD drive and diff. lock selection.

9803/8020

Issue 4*

Section 3 2-6

Routine Maintenance 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. 9803/8020

Section 3

47 48 49 50

2-6

Rear axle/chassis clearance. Spool valve operation. Selection speed of Selectronic range change < 2 kph. 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 Hours for 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). Trailer brake control line air filter. *2 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)

(2)

Section 3 2-7

Routine Maintenance Service Schedules- Wet Clutch Transmission

Section 3 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. Engine valve clearances and lubrication (3185). *4 5 Engine vibration damper. Compressor output line, air drier and pressure *6 regulator: check for carbon deposits and for air leaks. Radiator hose condition. *7 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).

9803/8020

Issue 2*

Section 3 2-8

Routine Maintenance 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.

Section 3 2-8

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.

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 the tyres for damage and penetration by sharp objects.

Inspect steelwork for damage. Note damaged paintwork for future repair.

Check that all safety decals are in place and undamaged, fit new decals where necessary.

SEAT BELT Checking Seat Belt Condition and Security ! WARNING Replace the seat belt with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. Fit a new seat belt every three years regardless of condition. 2-3-1-8

Inspect the seat belt for signs of fraying and stretching. Check that the stitching is not loose or damaged. Check that the buckle assembly is undamaged and works correctly. Check that the belt mounting bolts are undamaged, correctly installed and tightened.

9803/8020

Issue 1

Section 3

Routine Maintenance

Section 3

Bonnet

2-9

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

Engage the parking brake, put the transmission in neutral and stop the engine. Remove the starter key.

Release the required bonnet side by turning the two turnbuckles A to the vertical position.

Lift the bonnet side clear of the machine and put it in a safe place to prevent damage.

Closing the Bonnet (2000 Series Machines) 1

Position the bonnet side in the aperture and ensure it locates at the top. Fasten the bonnet securely by pushing in each turnbuckle A.

Opening the Bonnet (3000 Series Machines)

231810

! WARNING The engine has rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open. INT-2-1-6

Engage the parking brake, put the transmission in neutral, turn the front wheels onto full left lock and stop the engine. Remove the starter key.

Release latches by pulling back lever B.

Raise the bonnet fully. Do not leave it partly raised as it could then creep down.

Closing the Bonnet (3000 Series Machines) 1

Lower 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.

B A293970

9803/8020

Issue 1

Section 3

Routine Maintenance

Section 3

Greasing

3-1

General

3-1

Propshafts and PTO Driveshafts

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 pressurewashing 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.

! 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 points 1 to 3. (Point 2 not fitted to later machines.) * Rear axle propshaft Grease points 4 to 6. (Point 6 not fitted to later machines.) Front PTO drive shaft (optional) Grease points 10 to 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.

2 1

ÂŁ 8 9 65 9803/8020

7 A286622

Issue 3*

Section 3

Routine Maintenance

Section 3

Greasing

3-2

Steering Swivels Series Machines)

* (2000

2WS: Grease points 1 and 2 on each side of the machine.

4WS: Grease points 3 to 6 on the front axle. Grease points 7 to 10 on the rear axle. Note: After initial greasing, turn the wheels from lock to lock, then grease again to ensure full penetration.

S229870

6 9

8 250690

9803/8020

Issue 2*

Section 3

Routine Maintenance

Section 3

*Greasing

3-3

Front Axle Steering Swivels Series Machines)

* (3000

Grease points 1 to 4. Note: After initial greasing, turn the wheels from lock to lock, then grease again to ensure full penetration.

4 A293430

9803/8020

Issue 2*

Section 3

Routine Maintenance

Section 3

Greasing *(2000 Series Machines) * Hydraulic Lift and 3-Point Linkage * Rear PTO Drive Shaft Bearings 3-4

Hydraulic Lift Cross-shaft Grease points 1 and 2.

Grease point 9. Do not exceed 2 to 3 strokes of the grease gun.

Hydraulic Lift Rams Grease points 3 to 6.

* Rear

Three Point Linkage Lift Rods Grease points 7 and 8.

* Stabilisers

3-4

Suspension Cylinder Pivots

Grease points 10 to 13.

(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.

ÂŁ

! 1

4 9

8 5

6 $ S229981

9803/8020

Issue 2*

Section 3

Routine Maintenance

Greasing *(3000 Series Machines) * Hydraulic Lift and 3-Point Linkage

3-5

! 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.

3-5

Hydraulic lift cross-shaft Grease points 5 and 6. Hydraulic lift rams Grease points 7 to 10.

Chock all four wheels before getting under the machine.

Three point linkage lift rods Grease at nipples 11 and 12. On later machines grease at nipples 11, 12, 13 and 14 (lift collars A and B to access nipples 13 and 14). On machines with heavy duty linkage grease points 15 and 16 also.

13-3-1-9

Note: Ladder hitch and trailer coupling omitted for clarity.

Section 3

Rear Suspension Cylinder Pivots

Stabilizers (standard type) Grease at point 17.

Grease points 1 to 4.

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

5 I

6 II

III

8 *

! A ÂŁ

@ 9

A286030

9803/8020

Issue 2*

Section 3

Routine Maintenance

Section 3

Greasing (2000 Series Machines)

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 points 4 and 5. 4WS: Grease points 6 to 9.

2WS

262210

4WS

9803/8020

A268420

Issue 1

Section 3

Routine Maintenance

Section 3

Greasing (3000 Series Machines)

3-7

Steering Box Input Shaft Seal Grease at point 1 through the hole in the chassis side member. Note: Apply only one shot of grease from a manual grease gun with a rigid connector. Excessive greasing would damage the internal seals of the steering box.

A293980

Grease points 2 and 3.

262210

9803/8020

Issue 1

Section 3

Routine Maintenance

Section 3

Greasing

3-8

Automatic Trailer Coupling (if fitted) Note: Whenever the coupling has been pressure-washed it must always be greased. Make sure the coupling is in the open position, i.e. the coupling pin is up and the hand lever A is in its highest position. Grease at points 1 and 2. Operate lever A several times so that the grease is distributed throughout the bearing.

! CAUTION Keep your hands out of the funnel or you may be injured by the coupling pin as it is forced down by its spring. 13-2-2-17

Grease again and operate the hand lever again. If driving without a trailer attached, close the coupling to prevent dirt accumulation.

S170201

Roller Drawbar (if fitted) A

III

! WARNING You will be working close into the machine for these jobs. Lower the equipment. Remove the starter key and disconnect the battery. This will prevent the engine from being started. Make sure that the parking brake is engaged. Chock all four wheels before getting under the machine. 13-3-1-9

Grease points 3 and 4. Smear surface 5 with grease.

5 3

4 A309960

9803/8020

Issue 2*

Section 3

Routine Maintenance

Section 3

Cab

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. The ROPS structure must not be modified except as approved by JCB. Unauthorised modifications may result in weakening of the structure.

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.

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.

Check the structure for damage. Check that the four mounting bolts are installed and undamaged. Check that torque tightness of nuts A and B is correct (see Table below). Tighten them to the correct torque if necessary. Zinc-Plated Fasteners (colour: golden) Nm 375

kgf m 38

lbf ft 277

Dacromet Fasteners (colour: mottled silver) Nm 365

kgf m 37

lbf ft 269

BF 8-1/1

9803/8020

B 229990

Issue 3

Section 3

Routine Maintenance

4-2

Section 3

Cab

4-2

Checking Windscreen Washer Fluid Level Fill the windscreen washer bottle X with a suitable liquid. The liquid should contain a de-icing fluid to prevent freezing. Do not use engine coolant antifreeze.

A290350

* 2000 Series Machines

A293830

* 3000 Series Machines

9803/8020

Issue 2*

Section 3

Routine Maintenance

Section 3

Air Conditioning (2000 Series Machines) * Adjusting the Compressor Belt (2115, 2125, 2135, and 2150)

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.

Stop the engine.

Remove the left-hand bonnet side panel.

! WARNING The filter may be filled with dust. Wear goggles and a face mask when removing the filter. 2-3-3-6

5-1

! WARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5

Remove nuts A and pull out the filter B.

Using compressed air at a maximum pressure of 5.5 bar (80 lbf/in2), blow out the dirt from the clean (gasket) side to the dirty (grid) side.

Check the condition of the filter element and renew if split or worn.

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

Check and clean the filter sealing face on the cab body.

Refit the filter, making sure that the gasket side goes first. Refit nuts A.

Loosen nuts A, B.

Position the compressor so that there is 10mm (0.4 in) slack on the longest run of the belt.

Retighten nuts A and 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

S232630

229880

9803/8020

Issue 3*

Section 3

Routine Maintenance

Section 3

Air Conditioning (3000 Series Machines)

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

Unclip closing panel A, unscrew and pull out the filter B.

Using compressed air at a maximum pressure of 5.5 bar (80 lbf/in2), blow out the dirt from the clean (gasket) side to the dirty (grid) side.

Check the condition of the filter element and renew if split or worn.

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

Check and clean the filter sealing face on the cab body.

Refit the filter, making sure that the gasket side goes in first. Refit the closing panel A.

160800

160810

9803/8020

Issue 3

Section 3

Routine Maintenance

Section 3

Air Conditioning

5-3

* Adjusting

the Compressor Belt (2140, 3155 and 3185) 1

Stop the engine.

Open the bonnet.

! WARNING Make sure the engine cannot be started. Disconnect the battery before doing this job.

2-3-3-5

Loosen the mountings Loosen fasteners A, B, C and D (3155) or E, F and G (2140 and 3185).

Adjust the belt tension Position the compressor so that there is 10 mm (0.4 in) slack on the longest run of the belt.

Tighten the Mountings Retighten fasteners A, B, C and D, or E, F and G.

272000

! WARNING The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person. You can be severely frostbitten or injured by escaping refrigerant. 4-3-4-1/2

G 271990

9803/8020

Issue 3*

Section 3

Routine Maintenance

Section 3

Electrics

6-1

Battery Warning Symbols The following warning symbols may be found on the battery.

Symbol

Meaning

! 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

Keep away from children.

Shield eyes.

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.

No smoking, no naked flames, no sparks

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 Explosive Gas.

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

Battery acid.

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

Note operating instructions.

Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help. 5-3-4-3/1

9803/8020

Issue 1

Section 3

Routine Maintenance

Section 3

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. 1

Apply the parking brake and stop the engine.

Remove two screws A and swing open the hinged step unit B (below the right hand cab door). Later machines have an upward lifting step unit.

Prize 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 deionized water.

A B 260030

! 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 1 is fitted. On European machines batteries 1 and 2 are fitted.

! WARNING

Do not top the battery up with acid. The electrolyte could boil out and burn you. 2-3-4-6

Apply the parking brake and stop the engine. Remove the battery access panel A. Prize out covers B. Look at the level in each cell. The electrolyte should be 6 mm (0.25 in) above the plates. Top up if necessary with distilled water or de-ionized water.

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

9803/8020

Issue 3*

Section 3

Routine Maintenance

Section 3

Electrics

6-3

Checking the Beam Alignment 1

Park the machine on level ground so that the front headlights A are 2.00m from a wall.

Measure the distance Z from the ground to the centre of the front headlights A. Subtract 25 mm Âą 5 mm from this distance and mark a horizontal line XX on the wall at this height. When the auxiliary headlights B are fitted mark a second horizontal line YY on the wall approximately 1300 mm above XX.

When the headlights are switched on to dipped beam, the horizontal tops of the light beams should be in line with the horizontal lines XX and YY on the wall.

To adjust the beam, slightly slacken nut C or D, reposition the light and then tighten the nut.

Note: The illustration shows a 3000 Series machine. The principle for 2000 Series machines is identical.

Y 1300 mm

A X

X D

2.0 m

C A293861

9803/8020

Issue 3*

Section 3

Routine Maintenance Hydraulics

7-1

* 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

Park 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 B and element cover plate D.

Remove the element as follows: a b c d

Remove tank cap B. Remove nuts C, cover plate D and 'O' ring E. Remove the element assembly F and 'O' ring G. Remove the nut and spring assembly H. Remove the element J from its spindle. e i Dry clutch machines - discard the complete element J (see view W). ii Wet clutch machines - remove and discard the paper insert Y from metal outer element J (see view X). f Wet clutch machines only - clean the metal outer element J. g Clean the magnets K.

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

Park the machine on level ground. Apply the parking brake. Lower any mounted implements to the ground. Stop the engine. Remove the starter key.

Look 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.

If necessary, add recommended fluid at tank cap B.

Fit the new element as follows: a Wet clutch machines - fit a new paper insert into metal outer element J. b Assemble 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. c Fit the element assembly F using a new 'O' ring G. d Refit cover plate D and nuts C using a new 'O' ring E. e Tighten nuts C to 7 Nm (5 lbf ft). f Top up fluid level at tank cap B and refit cap.

9803/8020

Y X

M L

7-1

Changing the Filter Element

! WARNING

Section 3

Issue 4*

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