JCB 125, 135, 145, 150, 155, 185 Fastrac Tractor Service Manual – 9803/8000-14

This workshop repair service manual PDF download for the 125, 135, 145, 150, 155, 185 JCB Fastrac Tractor has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JCB Fastrac 125
JCB Fastrac 135
JCB Fastrac 145
JCB Fastrac 150
JCB Fastrac 155
JCB Fastrac 185

TABLE OF CONTENTS :

Section 1: General Information
Section 2: Care and Safety
Section 3: Routine Maintenance
Section A: Optional Equipment
Section B: Body and Framework
Section C: Electrics
Section D: Controls
Section E: Hydraulics
Section F: Transmission
Section G: Brakes
Section H: Steering
Section S: Suspension
Section T: Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/8000-14
Total Pages : 677

This JCB Fastrac service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Contents
Replacement Page Index

Section 1: General Information
Location of Serial Numbers
Typical Vehicle Identification Number
Typical Engine Identification Number
Unit Identification
Torque Settings
Hose and Pipe Connections
Service Tools Numerical List
Sealing and Retaining Compounds
Service Tools
Body and Framework
Electrics
Hydraulics
Transmission
Brakes
Steering
Suspension
Engine
Moving a Disabled Machine
Preparation for Towing
Transporting the Machine

Section 2: Care and Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety

Section 3: Routine Maintenance
Lubricants and Capacities
Lubricants – Health and Safety
Service Schedules
Cleaning the Machine and Checking for Damage
Opening the Bonnet
Checking the Seat Belt Condition and Security
Greasing
Propshafts and PTO Drive Shafts
Front Axle
Steering Box Input Shaft Seal
Clutch Operating Mechanism
Hydraulic Lift and 3 Point Linkage
Rear PTO Drive Shaft Bearing
Rear Suspension Cylinder Pivots
Automatic Trailer Coupling
Rear Anti-roll Bar Ball Joints
Cab
Checking the ROPS Structure
Air Conditioning
Cleaning the Filter
Adjusting the Compressor Belt
Checking the Sight Glass
Electrics
Checking the Electrolyte Level
First Aid – Electrolyte
Checking the Beam Alignment
Fuses
Hydraulics
Checking the Fluid Level
Changing the Filter Element
Cleaning teh Hydraulic Fluid
Cleaning the Suction Strainers
Clutch
Checking the Fluid Level
PTO, Speed and Range Gearboxes
Checking the Oil Level
Changing the Oil and Cleaning the Strainer
Changing the Transmission Oil Filter
Checking the Front PTO Gearbox Oil Level (if fitted)
Speed Gearbox
Checking the Oil Level
Changing the Oil
Front Axle
Checking the Differential Oil Level
Changing the Differential Oil
Checking the Hub Oil Levels
Changing the Hub Oil
Rear Axle
Checking the Oil Level
Changing the Oil
Tyres and Wheels
General
Pressures, Speeds and Loads
Ordering Tyres
Tyre Inflation
Checking Wheel Nut Torques
Adjusting the Track Width
Checking and Adjusting the front Wheel Alignment
Brakes
Checking the Foor Brake Oil Level
Draining the Air Ayatem Tanks
Checking and Renewing Foot Brake Pads
Testing the Parking Brake
Checking and Renewing the Parking Brake Pads
Servicing the Exhaust Brake (optional equipment)
Antifreeze Pump (optional equipment)
Engine
Checking the Oil Level
Changing the Oil and Filter(s)
Perkins Engine
Cummins Engine
Draining/Cleaning the Fuel Sediment Bowl
Draining the Fuel Filters
Changing the Fuel Filter Elements
Cleaning the Fuel Lift Pump (All Perkins Engines Except 160TW)
Bleeding the Fuel System
All Perkins Engines Except 160TW
Perkins 160TW Engine (Euro 1)
Cummins Engine
Checking the Ether Cylinder (Cummins Engine)
Cleaning the Fuel Tank Strainer
Checking the Coolant Level
Draining the Coolant (Perkins Engine)
Filling the Cooling System (Perkins Engine)
Coolant Mixtures (all engines)
Draining and Refilling the Coolant (Cummins Engine)
Cleaning the Radiator
Adjusting the Fan Belts (Perkins Engine)
Fan Belt (Cummins Engine)
Changing the Air Filter Element

Section A: Optional Equipment
Front Ram Lift
Dismantling and Assembly
Front PTO Transfer Box
Dismantling and Assembly
Fitting the Front PTO Output Shaft
Rear PTO Driveshaft and Bearing Housing to Machine 636000
Dismantling and Assembly
Fitting the Rear PTO Output Shaft
Rear PTO Driveshaft and Bearing Housing from Machine 636001
Flow Regulator
Flow Testing and Pressure Testing
Removal and Replacement
Dismantling and Assembly

Section B: Body and Framework
Technical Data
Cab
Direct Glazing
Air Conditioning
Operation
Safety Procedures
Leak Testing
Fault Finding
Component Removal and Replacement
Pressure Switches
Testing
Removal and Replacement
Wiring Diagram
Compressor Clutch
Removal and Replacement

Section C: Electrics
Technical Data
General Data
Fuses
UK Machines to serial No. 635329
UK Machines 635330 to 636000 and All Other Machines to 636000
From Machine No. 636001
Relay Identification
To Machine No. 636000
From Machine No. 636001
Test Methods
Use of Multimeters
Measuring Voltage
Measuring Resistance
Measuring Continuity
How to Test a Diode or a Diode Wire
Complete Machine Circuit Diagrams
UK Machines to serial No. 635329
Wire Coding
UK Machines from 635330 to 636000 and All Other Machines to 636000
Sectional Wiring Diagrams
Introduction and Key to Symbols
Sectional Diagrams up to machine No. 636000
Component Key
Contents
Alphabetic Index
Harness Connector Positions
Wire Numbers
Schematic Diagrams from machine no. 6326001 to 637739
Sectional Diagrams from machine no. 636001
Component Key
Contents
Alphabetic Index
Harness Connector Positions
Wire Numbers
Fault Finding
Starting Circuit Test
Charging Circuit Test
Tachometer Feed Test
Wiring Harness Repair Policy
Batteries
Testing – Specific Gravity
High Rate Discharge Test
Alternator
General Description
Service Precautions
Removal and Replacement
Dismantling and Assembly
Lucas
Magneti Marelli (85A or 100A)
Bosch (Fastrac185)
Starter Motor
Removal and Replacement
Dismantling
Service and Renewal
Assembly
Digital Speedometer (optional)
Operation and Calibration

Section D: Controls
Technical Data
Foot Throttle Control Cable
Removal and Replacement
Hand Throttle Control Linkage
Removal and Replacement
External Hydraulics Control Valve Linkage
Removal and Replacement
Power Take-Off Speed Selector Cable
Removal and Replacement
JCB Selectronic System (Air Assisted Range Change)
System Description
Operation
Electrical/Pneumatic Circuit Description
Fault Finding
Pneumatic Cylinders (to machine no. 638649)
Removal and Replacement
Mechanical Adjustments
Switch Adjustments
Dismantling and Assembly
Pneumatic Cylinders (from machine no. 638650)
Removal and Replacement
Renewing Microswitches
Setting Microswitch Positions

Section E: Hydraulics
Technical Data
Schematic Circuit
Machines to Serial No. 637733
Machines from Serial No. 637734
Descriptions (to serial no. 637733)
External Hydraulics Neutral Circuit
Single and Double Acting Spool
Hydraulic Kick-out Spool
Descriptions (from serial no. 637734)
External Hydraulics Neutral Circuit
Three Position Spool (D-Type)
Four Position Spool
Pressure Testing – M.R.V.
Pump – Suspension and Steering
Removal and Replacement
to machine no. 635661
from machine no. 635662
Dismantling and Assembly
to machine no. 635661
from machine no. 635662
Fastrac 185
Pump – External Hydraulics and Transmission
Removal and Replacement
Dismantling and Assembly
Control Valve (to serial no. 637733)
Removal and Replacement
Dismantling and Assembly
Basic Spools
Hydraulic Kick-out and Float Spools
Main Relief Valve
Control Valve – External Hydraulics/Draft Control (from serial no. 637734)
Removal and Replacement
Dismantling and Assembly
Control Valve – Spool Sections
Spool and Detent – Dismantling and Assembly
Flow Control Valve – Dismantling and Assembly
Poppet Valve – Dismantling and Assembly
M.R.V. – Dismantling and Assembly
Draft Control Valve
Solenoids and Spools – Dismantling and Assembly
Pressure Compensator – Dismantling and Assembly
Internal Check Valve – Dismantling and Assembly
Check Valve, Body Seals and Plugs – Dismantling and Assembly
Rams – Rear Lift
Removal and Replacment
Dismantling and Assembly
Electronic Draft Control (to serial no. 637733)
Introduction
Operation
System Description
Hydraulic Circuit Operation
Fault Finding
Introduction
Initial Checks
Functional Test of Control Valve
Diagnostic Text Box – Introduction
Connecting the Test Box
Control and Display Elements
Explanation of Test Steps
Using the Diagnostic Test Box
Explanation of Error Codes
Draft Pin – Removal and Replacement
Position Sensor – Removal and Replacement
Position Sensor Setting
Control Valve – Removal and Replacement
Control Valve Solenoids
Removal and Replacement
Flow Requirements
Lowering Test Procedure
Lifting Test Procedure
Adjustment
Electronic Draft Control (from serial no. 637734)
Introduction
System Activation Procedure
Operation
System Description
Hydraulic Circuit Operation
Fault Finding
Introduction
Functional Test of Control Valve
Procedures
Fault Diagnosis
Error Codes
Control Valve – Removal and Replacement
Draft Pin – Removal and Replacement
Position Sensor – Removal and Replacement
Position Sensor Setting

Section F: Transmission
Technical Data
General Description
Fault Finding
Complete Transmission
Power Take Off Clutches
4/2 Wheel Drive
Differential Lock
NoSPIN Differential (Front Axle)
Hydraulic Circuit
to machine no. 636000
from machine no. 636001
Powersplit Circuit
Solenoid Circuit Description
Pressure Testing
Valves
Main Control Valve and Pressure Maintenance Valve
to machine no. 636000
from machine no. 636001
Differential Lock Control Valve
Powersplit Control Valve
Main Drive Clutch – Removal, Inspection and Replacement
Main Drive Clutch Master Cylinder
Removal and Replacement
Dismantling and Assembly
Main Drive Clutch Servo
Removal and Replacement
Bleeding and Testing
Dismantling and Assembly
Gearbox Assembly
Removal and Replacement
Dismantling and Assembly
Power Take Off (PTO) Clutches
Removal and Replacement to machine no. 636000
Removal and Replacement from machine no. 636001
Dismantling and Assembly (all machines)
Power Take Off (PTO) Gearbox to machine no. 636000
Input Section Dismantling and Replacement
Output Section Dismantling and Assembly
Speed Selector Shaft Removal and Replacement
Speed Selector Shaft Dismantling and Assembly
PTO/Splitter Gearbox from machine no. 636001
Splitter Clutch
Removal and Replacement
Dismantling and Assembly
Output Section Dismantling and Assembly
Input Section Dismantling and Assembly
Speed Selector Shaft Removal and Replacement
Speed Selector Shaft Dismantling and Assembly
Speed Gearbox
Remote Control Dismantling and Assembly
Front Oil Seal Removal and Replacement
Input Shaft Removal and Replacement
Gearbox Spec. no. Y04041
Gearbox Spec. no. Y04141, Y04198, Y05100
Rear Oil Seal Removal and Replacement
Mainshaft and Layshaft Removal and Replacement
Gearbox Spec. no. Y04041
Gearbox Spec. no. Y04141, Y04198, Y05100
Layshaft Bearing Preload Setting
Mainshaft Dismantling and Assembly
Layshaft Dismantling and Assembly
Selectors Dismantling and Assembly
Gearbox Spec. no. Y04041
Gearbox Spec. no. Y04141, Y04198, Y05100
Range Gearbox
Typical Syncromesh Description
Removal and Replacement
Dismantling and Assembly
Removing and Replacing the Front Casing
Turret Assembly Dismantling and Assembly
Clutch and Gear Assemblies – Removal and Replacement
4 Wheel Drive Clutch Pressure Testing
PTFE Piston Ring Seals Fitting Procedure
4 Wheel Drive Clutch Pressure Testing
Input Shaft Dismantling and Assembly
to machine no. 636000
from machine no. 636001
Output Shaft Dismantling and Assembly
to machine no. 636000
from machine no. 636001
Syncromesh Assembly from machine no. 636001
Needle Roller Bearings – Checking for Damage or Distortion
Propshafts
Removal and Replacement
Dismantling and Assembly
Front Axle
Removal and Replacement
Differential Oil Seal – Removal and Replacement
Hub and Driveshaft – Dismantling and Assembly
Drive Head
Removal and Replacement
Dismantling and Assembly
NoSPIN Differential
Description
Removal and Replacement
Dismantling and Assembly
Testing
Maxtrac Differential – Dismantling and Assembly
Front and Rear Axles
Pinion Depth
Crown Wheel and Pinion Adjustment
Solid Spacer Installation
Rear Axle
Removal and Replacement
Differential Oil Seal – Removal and Replacement
Hubs and Driveshafts
PD70 Axle (all machines except Fastrac 185) – Dismantling and Assembly
Drive Head
Removal and Replacement
Dismantling and Assembly
to machine no. 636000
from machine no. 636001
Pinion Depth
Crown Wheel and Pinion Adjustment
Rear PTO Drive Shaft from machine no. 636001 – Dismantling and Assembly
Hubs and Driveshafts
PD90 Axle (Fastrac 185) – Dismantling and Assembly

Section G: Brakes
Technical Data
Circuit Description
UK Machines
All Other Countries
Fault Finding
Safety Precautions
Footbrake Calipers
Removal and Replacement
Dismantling and Assembly
Brake System Bleeding
Compressor – Removal and Replacement
Unloader Valve – Removal and Replacement
Automatic Drain Valve
Removal and Replacement
Dismantling and Assembly
Circuit Protection Valve – Removal and Replacement
Foot Brake Control Valve
Removal and Replacement
Dismantling and Assembly
Threshold Valve – Removal and Replacement
Air/Hydraulic Actuator
Removal and Replacement
Dismantling and Assembly
Parking Brake Control Valve
Removal and Replacement
UK Machines
All Other Countries
Dismantling and Adjusting – UK Machines
Testing and Adjusting – UK Machines
Trailer Brake Air Valve
Removal and Replacement
Dismantling and Assembly
Non-Return Valve – Dismantling and Assembly
Trailer Brake Hydraulic Valve
Testing
Removal and Replacement
Trailer Brake Inverse Relay Valve – Removal and Replacement
Parking Brake Caliper
Removal and Replacement
Dismantling and Assembly
Parking Brake Actuator Cylinder

Section H: Steering
Technical Data
Description
Hydraulic Circuit Diagram
Fault Finding
Pump Pressure Testing
Steering Box (to machine no. 636371)
Limit Valve Setting
Removal and Replacement
Dismantling and Assembly
Steering Box (from machine no. 636372)
Limit Valve Setting
Removal and Replacement
Dismantling and Assembly

Section S: Suspension
Technical Data
Front Suspension
Description
Shock Absorber – Removal and Replacement
Control Arm – Removal and Replacement
Anti-roll Bar – Removal and Replacement
Panhard Rod – Removal and Replacement
Coil Spring and Microcellular Spring – Removal and Replacement
Rear Suspension
Description and Hydraulic Circuit Diagram
to machine no. 636000
from machine no. 636001
Pressure Testing
Ride Height Setting
Discharging Hydraulic Pressure
Pressure Maintenance Valve
Dismantling and Assembly
Removal and Replacement
Spring Box – Removal and Replacement
Height Corrector Valve
Removal and Replacement
to machine no. 636000
from machine no. 636001
Gas Spring
Removal and Replacement
to machine no. 636000
from machine no. 636001
Testing
Cylinder
Removal and Replacement
to machine no. 636000
from machine no. 636001
Dismantling and Assembly
to machine no. 636000
from machine no. 636001
Accumulator
Removal and Replacement
to machine no. 636000
from machine no. 636001
Testing
Anti-roll Bar
Removal and Replacement
to machine no. 636000
from machine no. 636001
Control Arm
Removal and Replacement
to machine no. 636000
from machine no. 636001
‘V’ Link
Removal and Replacement
Ball Joint – Dismantling and Assembly

Section T: Engine
Technical Data
Machines Except Fastrac 185
Fastrac 185
Engine Unit (except fastrac 185)
Removal and Replacement
to machine no. 636000
from machine no. 636001

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