JCB 2155, 2170 Fastrac Service Manual – 9803/8050-1

(S/N: 742000 Onwards)
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This workshop repair service manual PDF download for the 2155 & 2170 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 2155
JCB Fastrac 2170
S/N: 742000 Onwards

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Maintenance
Section A – Attachments
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 : 9803/8050-1
Total Pages : 910

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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More Info : http://www.sitelux.com

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9803-8050
Fastrac 2155 and 2170

Section 1
General Information
Identifying the Machine
Serial Numbers
Serial Number Plate
Typical Vehicle Identification No. (VIN)
Unit Identification
Special Tools
Numerical List
Tool Detail Reference
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H Steering
Section S – Suspension
Service Consumables
Sealing and Retaining Compounds
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Zinc Plated Fasteners (golden finish)
Verbus Ripp Bolts
Dacromet Fasteners (mottled silver finish)
Hydraulic Connections
‘O’ Ring Face Seal System
Adaptors Screwed into Valve Blocks
Hoses Screwed into Adaptors
Adaptors into Component Connections with Bonded Washers
‘Torque Stop’ Hose System

Section 2
Care and Safety
Safety Check List
Safety Warnings
General Safety
Operating Safety
Maintenance Safety

Section 3
Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Initial Service and Inspection (100 Hours)
Obtaining Replacement Parts
Health and Safety
Lubricants
Introduction
Hygiene
Storage
Waste Disposal
Handling
First Aid – Oil
Spillage
Fires
Battery
First Aid – Electrolyte
Warning Symbols
Service Schedules
How to Use the Service Schedules
Service Schedule Tables
Fluid, Lubricants and Capacities
Coolant Mixtures
Cleaning the Machine
Checking for Damage
Seat Belt
Checking the ROPS Structure
Engine Cover
Opening the Engine Cover
Closing the Engine Cover
Greasing
Propshafts and PTO Drive Shafts
Front axle propshaft
Rear axle propshaft
Rear PTO drive shaft
Front PTO drive shaft (optional)
Rear PTO Drive shaft bearing
Steering Swivels
Rear Anti-roll Bar Ball Joints
Rear Suspension Cylinder Pivots
Front 3-Point Linkage
Cross-shaft
Rams
Hydraulic Lift and 3-Point Linkage
Hydraulic lift cross-shaft
Hydraulic lift rams
Three point linkage lift rods
Stabilizers (standard type)
Rear PTO Drive Shaft Bearing
Automatic Trailer Coupling (if fitted)
Roller Drawbar (If fitted)
Air Conditioning and Heater
Air Conditioning Filters
Cleaning the Heater Filter
Brakes
Checking the Foot Brake Fluid Level
Checking the Trailer Air Tank
Checking the Air Tank Warning Lights
Checking and Renewing Foot Brake Pads
Checking the Park Brake Pads
Electrical
Battery
Checking the Electrolyte Level
Jump-starting the Engine
Checking the Beam Alignment
Fuses
Engine-mounted Fuse
Relay Identification
Engine
Changing the Air Filter Elements
Checking the Oil Level
Changing the Oil and Filter
Checking the Coolant Level
Draining and Refilling the Coolant
Cleaning the Radiator and Coolers
Fan Belt
Fuel System
Types of Fuel
Recommended Fuel Specification
Acceptable Fuel Specification
Sulphur Content
Aviation Kerosene Fuels
Low Temperature Fuels
Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels
Petrol
Advice
Filling the Tank
Draining the Fuel Pre-Filter
Changing the Fuel Pre-Filter Element
Changing the Fuel Filter Element
Bleeding the Fuel System
Hydraulic System
Checking the Fluid Level
Changing the Filter Element
Changing the Hydraulic Fluid and Cleaning the Suction Strainers
Coupling Drains
Transmission
Checking the Gearbox Oil Level
Changing the Gearbox Oil and Suction Strainer
Torque Settings
Changing the Transmission Oil Filter
Front PTO Transfer Gearbox (Optional)
Checking the Oil Level
Front Axle
Checking the Differential Oil Level
Changing the Differential Oil
Checking the Hub Oil Levels
Check each hub separately.
Changing the Hub Oil
Change the oil in each hub separately.
Rear Axle – 2WS
Checking the Oil Level
Changing the Oil
Rear Axle – 4WS (Optional)
Checking the Differential Oil Level
Checking the Hub Oil Levels
Changing the Hub Oil
Changing the Differential Oil
Tyres and Wheels
General
Tyre Inflation
Checking Wheel Nut Torques
Wheel Nut Torque Setting
Adjustable Track Width
Lock Stops
Checking and Adjusting the Wheel Alignment
Check the Alignment
Adjust the Alignment
Rear Wheels (4WS machines)
Fender Adjustment
Windscreen Washer
Checking Fluid Level
Automatic Trailer Coupling (Optional)
Checking for Wear

Section A
Attachments
Technical Data
Hydraulic Units
90 Litre Flow Regulator
Front P.T.O.
Transfer Box
Dismantling and Assembly
When Dismantling
When Assembling
Torque Settings
Fitting the Front PTO Output Shaft
Flow Regulator
Flow Testing and Pressure Testing
Prepare the Machine
Flow Testing
Relief Valve Pressure Testing
Dismantling and Assembly
Dismantling
Assembly
Torque Settings
Cold Starting Aids
Engine Heater
Removal and Replacement
Removal
Replacement
Range Gearbox Heater/Thermostat
Removal and Replacement
Removal
Replacement

Section B
Body and Framework
Cab
Glazing
Direct Glazing
Removing the Broken Glass and Old Sealant
Preparing the Cab Frame Aperture
Preparing the New Glass
Installing the New Glass

Section C
Electrics
General
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
First Aid – Electrolyte
Testing
Specific Gravity Testing
Service Master
Why Use Service Master?
Introduction
Fault Finding
Identify Poor Maintenance
Access Machine Set Up Data
Re-Programming ECUs
Summary
What is Service Master?
Introduction
CANbus Communications System
Service Master Structure
Tool Sets
How to Set Up Service Master
Install Service Master
Start Service Master
Load the DLA Laptop Driver Software
Configure the DLA Type and Communications Port
Check the DLA Firmware File
Connect Service Master to the Machine CANbus
Diagnostic Tools
Connection Method 1
Connection Method 2
Connection Method 3
Connection Method 4
Instrument Cluster
Warnings (Visual only)
Warnings (Audible/Visual)
Instruments
Instrument Cluster Programming
Level `0′ Programming Mode (Normal Operation)
Standard Software Package
Optional Software Package
Level 1 Programming Mode
Level 1 Programming Mode (continued)
Level 1 Programming Mode (continued)
Level 2 Programming Mode
Error Codes
JCB Powershift
Manual Operation
Autoshift (Automatic) Operation
Gear Sequence
Powershift and Master Clutch Calibration
Calibration
Wheel Slip
Slip Control Re-calibration
Slip Control – Normal Operations
ECU Locations
2WS Machines with Mechanical Spool Valves
4WS Machines with Electronic Spool Valves
Spool Valve Calibration
Introduction
To Calibrate Spool Valve Controls
To Access the Spool Valve Controls Calibration Mode
Calibration Mode
To Configure Spool Valve Slices
Introduction
To Access the Configuration Mode
Valve Slices Currently Configured
To Configure `Bosch’ Slices to a 2000 Series Fastrac
Configuration Procedure
To Return 2000 Series Configured Slices to Bosch State
Suspension Calibration
Introduction
ECU 1 Suspension Calibration
To Access the Suspension Calibration Mode
Calibration Mode
Suspension Height Signal Voltages
ECU 4 Suspension Calibration
To Access the Suspension Calibration Mode
Calibration Mode
Suspension Height Signal Voltages
Four Wheel Steering (4WS)
4WS Sensors
Removal
Replacement
When Replacing
4WS Calibration
Introduction
Before Entering Calibration
To Access the 4WS Calibration Mode
Calibration Mode
Harness Data
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wires 000-199
Wires 200-399
Wires 400-599
Wires 600-799
Wires 800-999
Wires In Splices
General Points
Harnesses and Interconnection
Main Chassis Harness
Main Cab Harness
Transmission Harness
4WS and Electronic Spool Valve Harness, Cab
4WS and Electronic Spool Valve Harness, Chassis
2WS Harness, Cab, ECU4 (Mechanical Spool Valve)
4WS Harness, Cab (Mechanical Spool Valve)
4WS Harness, Chassis (Mechanical Spool Valve)
ABS Harness, Chassis 2WS
ABS Harness, Chassis 4WS
ABS Harness, Cab (2WS and 4WS)
Auxiliary Light Harness
Auxiliary Power Output Harness
Drawings
Main Chassis Harness – CAD 332/R6662
Main Cab Harness – CAD 332-R6864
Transmission Harness – CAD 721/12548
4WS and Electronic Spool Valve Harness, Cab – CAD 332/S0278
4WS and Electronic Spool Valve Harness, Chassis – CAD 332/R7263
2WS Harness, Cab, ECU4 (Mechanical Spool Valve)
4WS Harness, Cab (Mechanical Spool Valve) – CAD 332/S0969
4WS Harness, Chassis (Mechanical Spool Valve) – CAD 721/12503
ABS Harness, Chassis 2WS – CAD 332/R7174
ABS Harness, Chassis 4WS – CAD 332/R7175
ABS Harness, Cab (2WS and 4WS) – CAD 332/ R0097
Auxiliary Lights Harness – CAD 332/R1457
Auxiliary Power Harness – CAD 332/R8215
Wiring Harness Repair
Introduction
Repair Procedure
Diagnostic Error Codes
Introduction
Number Error Codes
Non-displayable Fault Codes
Blink Codes
Fault Finding Tables
General Codes (C and D)
4WS Codes (F)
Engine Codes (Q)
Suspension Codes (S)
Transmission Codes (T)
Spool Valve Codes (V, W, X, Y and Z)
ABS
Introduction
ABS Code Tables
Electronic Draft Control
Introduction
Interpreting the Diagnostic LED
Error Codes
ECU Type D+
ECU Type B

Section D
Controls
Technical Data
JCB Selectronic
Pneumatic Cylinders
Microswitches
Solenoid Valves
Pressure Regulator
External Hydraulics
Control Valve Linkage
Lever Linkages
Removal and Replacement
Removal
Replacement
2 Spool Layout (Spool I), 4 Spool Layout (Spools I and II)
2 Spool Layout (Spool II), 4 Spool Layout (Spools III and IIII)
Flow Control Linkages
Removal
Replacement
Testing
Setting Flow Control
Power Take-off (PTO)
Speed Selector Cable
Removal and Replacement
Removal
Replacement
Checking
JCB Selectronic
System Description
Selector Switch
Solenoid Valves
Pneumatic Cylinders
Microswitches
Indicators
Visual Indicators
Audible Indicator
Pressure Regulator
Operation
General
Selecting a Forward Range
Selecting Reverse Range
Auto-shuttle
Invalid or Incomplete Range Changes
Electrical/Pneumatic Circuit Description
Neutral (View V)
Low Range Selected (View W)
Reverse Selected (View X)
Medium Range Selected (View Y)
High Range Selected (View Z)
Limp Home Mode
Pneumatic Cylinders
Removal
Replacement
Renewing Microswitches
Setting Up
Setting Range Gearbox Turret Stops
Setting Cylinder Rod Neutral Lengths
Setting Microswitch Positions
Setting Neutral Microswitch Positions
Setting Gear Engaged Microswitch Positions
Pressure Regulator
Removal
Replacement
Throttle Controls
Field Speed Control
Operation
Adjustment

Section E
Hydraulics
Technical Data
External Hydraulics
Control Valve – Mechanically Actuated
Spools
Control Valve – Electronically Actuated
Spools
Other Hydraulic Circuits
Basic System Operation
Component Location and Neutral Circuits
Rear Electronic Draft Control
Position Sensor
Draft Sensors
Electronic Control Unit
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Example Circuit Key
Schematic Circuits
Hydraulic Circuit – with Mechanically Actuated Spool Valve
Description (Mechanically Actuated Spool Valve)
Hydraulic Circuit – with Electronically Actuated Spool Valve
Description (Electronically Actuated Spool Valve)
Neutral Circuit with Mechanically Actuated Spool Valve
Operation
Flow Regulator Valve
Electronic Draft Control
Machines with Mechanically Actuated Spool Valve
Stop (Neutral)
Raise (Transport)
Lower (Working Position)
System Descriptions
External Hydraulics/Draft Control
Spool Valves
Mechanically Actuated Spool Valve
Electronically Actuated Spool Valve
Valve Cross Section
Rear Electronic Draft Control
Introduction
Operation
Attaching an Implement – Using Controls in Cab
Transport
Attaching an Implement- using External Controls (on fender)
System Activation
FIeld Operation
At the Headland (or when finishing the operation)
Position Control
Draft Control
Mixed Control
Fault Finding
Mechanically Actuated Spool Valve
Electronically Actuated Spool Valve
Rear Electronic Draft Control
Introduction
Functional Test of Control Valve
Fault Finding Tables
Pressure Testing
Main Relief Valve (MRV) – 2155, 2170
Main Relief Valve (MRV) – 2155 Plus, 2170 Plus
Electronic Control Valve Pilot Pressure
Pumps
Pump – Suspension and Steering
Removal and Replacement
When Removing
When Replacing
Torque Settings
Dismantling and Assembly
When Dismantling
Inspection
When Assembling
Torque Settings
Pump – Transmission and External Hydraulics
Removal and Replacement
When Removing
When Replacing
Torque Settings
Dismantling and Assembly
When Dismantling
Inspection
When Assembling
Torque Settings
Rear Electronic Draft Control
Draft Sensor
Removal and Replacement
When Removing
When Replacing
Position Sensor
Removal
Replacement and Setting
Control Valves
Mechanically Actuated Spool Valve
Removal and Replacement
When Removing
When Replacing
After Replacing
Dismantling and Assembly
Dismantling
Assembly
Spool and Detent Section
Dismantling and Assembly
When Assembling
Removing the Non-Return Valves
Replacing the Non-return Valves
Locking the Spool in Neutral
Repairing the Check Valves
Flow Control Valve Section
Dismantling and Assembly
When Assembling
Input section – Main Relief Valve
Dismantling and Assembly
When Dismantling
When Assembling
Input section – Diverter Valve
Dismantling and Assembly
When Assembling
Draft Control Valve – Solenoid Valves
Dismantling and Assembly
When Dismantling
Draft Control Valve – Pressure Compensator
Dismantling and Assembly
When Assembling
Draft Control Valve – Internal Check Valve
Dismantling and Assembly
When Assembling
Draft Control Valve – Check Valve, Body, Seals and Plugs
Dismantling and Assembly
When Dismantling
When Assembling
Electronically Actuated Spool Valve
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Front Hitch Ram
Dismantling and Assembly
When Dismantling
When Assembling
Torque Settings
Wiper Seal Fitting Procedure
Rear Lift Ram
Dismantling and Assembly
When Dismantling
When Assembling
Wiper Seal Fitting Procedure
Testing

Section F
Transmission
Technical Data
Clutches and Gearboxes
Master Clutch
Power Take-off Gearbox (PTO)
JCB Powershift
Speed Gearbox
Range Gearbox
Transmission Hydraulics
Pump
Control Valve
Differential Lock Control Valve
Axles
Front Axle
Rear Axle
System Descriptions
Complete Transmission
NoSPIN Differential (Front Axle)
Operation
Schematic Circuits
Gearbox Hydraulic Circuit
Key
Lubrication Restrictors
Powershift
Differential Lock Hydraulic Circuit
Fault Finding
Complete Transmission, Clutches, Gearboxes and Axles
Complete Transmission
Wet Master Clutch
Power Take Off Clutches
4/2 Wheel Drive
Differential Lock
Pressure Testing
Powershift Clutches
Transmission Brake
Wet Master Clutch
Transmission Accumulator
Pressure Maintenance Valve
Lubrication Pressure
Differential Lock Control Valve
Gearbox Assembly
Removal and Replacement
Removal
Stage A – Prepare for Removal
Stage B – Prepare to Lift
Stage C – Lifting the Gearbox
Replacement
Dismantling and Assembly
Dismantling
Assembly
Wet Master Clutch
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Clutch Drum and Hub
Dismantling
Assembly
Clutch Plates and Plate Carrier
Dismantling
Assembly
Clutch Drum Carrier and PTO Input gear
Dismantling
Assembly
Clutch Pedal
Clutch Down Switch and Potentiometer
Clutch Down Switch
Adjusting
Potentiometer (Position Sensor)
Removing
Replacing
PTO and Splitter Gearbox
Removal and Replacement
Dismantling and Assembly
PTO Clutches
Removal
Replacement
Dismantling and Assembly
Six-Speed Gearbox/Rear Housing
Removal
PTO Clutches, Front and Rear
Removal and Replacement
Removal
Replacement
Front PTO Clutch
Dismantling and Assembly
Dismantling
Assembly
Rear PTO Clutch
Dismantling and Assembly
Dismantling
Assembly
Splitter Clutches
Removal
Replacement
Dismantling and Assembly
When Dismantling
When Assembling
Speed Selector Shaft Assembly
Removal
Replacement
Dismantling
Assembly
Output Section
Dismantling and Assembly
Dismantling
Assembly
Idler Gear
Removal and Dismantling
When Assembling
Housing
Replacing
Speed Gearbox
Remote Control
Dismantling and Assembly
When Dismantling
When Assembling
Rear Housings
Removal and Replacement
When Replacing
Front Oil Seal and Housing
Removal and Replacement
Input Shaft, Mainshaft and Layshaft
Removal
Replacement
Layshaft Bearing Preload
Example: (all dimensions in millimetres)
Mainshaft
Dismantling and Assembly
End Float Check
Dismantling
Inspection (before assembly)
Assembly
Assembling the Synchro Hub and Sleeve
Layshaft
Dismantling and Assembly
When Dismantling
When Assembling
Selector Shaft and Forks
Dismantling and Assembly
When Dismantling
When Assembling
Range Gearbox
Removal and Replacement
Removal (with Cab in Place)
Replacement
Dismantling and Assembly
Front Casing
Removal and Replacement
Removal
Replacement
Brake Calliper Bracket
Replacing Bushes
Clutch and Gear Assemblies
Removal and Replacement
Removal
Replacement
4-Wheel Drive Clutch
Dismantling and Assembly
Dismantling
Assembly
Fitting PTFE Piston Ring Seals
Pressure Testing
Input Shaft
Dismantling and Assembly
Dismantling
Assembly
Output Shaft
Dismantling
Assembly
Inspection Prior to Assembly
General
Synchromesh
Assembling the Synchro Hub and Sleeve
Propshafts
Removal and Replacement
Removal
Coupling Type A
Coupling Type B
Coupling Type C
Coupling Type D
Coupling Type E (not illustrated)
Replacement
Dismantling and Assembly
Dismantling
Assembly
Front and Rear Axles
Differential Oil Seal
Removal and Replacement
Front Axle and Rear 4WS Axle
Hub and Drive Shaft
Dismantling
Assembly
Torque Settings
Drive Head
Removal and Replacement
Removal
Replacement
Front Axle
Removal and Replacement
Removal
Replacement
Drive Head
Dismantling
Pinion Depth
Solid Spacer Installation
Assembly
Crown Wheel and Pinion Adjustment
Maxtrac Differential
Dismantling and Assembly
Dismantling
Assembly
NoSPIN Differential
Dismantling and Assembly
Dismantling
Inspection
Assembly
Testing
Rear Axle
Removal and Replacement
Removal
Replacement
Hub and Drive Shaft
Dismantling
Assembly
Drive Head
Removal and Replacement
Removal
Replacement
Pinion Depth
Solid Spacer Installation
Dismantling and Assembly
Dismantling
Assembly
Crown Wheel and Pinion Adjustment
Differential
Dismantling and Assembly
Dismantling
Assembly
Rear PTO Drive Shaft
Dismantling and Assembly
When Dismantling
Assembly
Rear PTO Output Shaft
General
Fitting
Valves
Main Control Valve
Removal
Replacement
Dismantling
Assembly
Differential Lock Control Valve
Dismantling and Assembly
Solenoid
Powershift Control Valves
Removal and Replacement
Removal
Replacement
Accumulator
Wet Clutch Transmission Brake Solenoid Valve
Removal
Replacement
Wet Clutch Lubrication Control Valve
Removal
Replacement
Solenoid Valve
Dismantling and Assembly
When Dismantling
When Assembling
Wet Clutch Control Valve
Removal
Needle Roller Bearings
Checking for Damage or Distortion

Section G
Brakes
Technical Data
Brake System
Parking Brake
Foot (Service) Brake
Safety
All Machines
Circuit Descriptions
Brake System (non ABS)
Front Brake Circuit
Rear Brake Circuit
Trailer/Parking Brake Circuit
Parking Brake Circuit
Tractor Services Circuit
Hydraulic Trailer Brakes (if fitted)
Brake System (ABS)
Front Brake Circuit
Rear Brake Circuit
Trailer/Parking Brake Circuit
Parking Brake Circuit
Tractor Services Circuit
Hydraulic Trailer Brakes (if fitted)
Tractor ABS System (if fitted)
Tractor ABS System (if fitted)
General Description
Operation
Fault Finding
Introduction
Fault Tables
Low Pressure Warning Lights On
Service Brakes Poor
Poor Front Brakes, Good Rear Brakes (Non-ABS Machines)
Poor Front Brakes, Good Rear Brakes (ABS Machines)
Poor Rear Brakes, Good Front Brakes (Non-ABS Machines)
Poor Rear Brakes, Good Front Brakes (ABS Machines)
Trailer Brakes Poor
Park Brake Not Holding
Park Brake Not Releasing
Footbrake Callipers
Removal and Replacement
Removal
Replacement
Torque Settings
Zinc-plated (colour: golden)
Dacromet (colour: mottled silver)
Brake System Bleeding
Dismantling and Assembly
Dismantling
Assembly
Capscrew Torque Settings
Parking Brake Calliper
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
When Dismantling
Inspection
When Assembling
Torque Settings
Actuator Cylinder
Valves
Air Dryer/Unloader Valve
Removal and Replacement
Removal
Replacement
Torque Settings
Dismantling and Assembly
Circuit Protection Valve
Removal and Replacement
Removal
Replacement
Pressure Modulating Valve
Removal and Replacement
Removal
Replacement
Foot Brake Air Valve
Removal and Replacement
Removal
Replacement
Torque Settings
Hose Destinations
Test Point Identification
Dismantling and Assembly
Dismantling
Cleaning and Inspection
Assembly
Torque Settings
Non-Return Air Valve
Dismantling and Assembly
When Dismantling
When Assembling
Failure Conscious PRV (Non-ABS Machines only)
Removal and Replacement
Removal
Servicing
Replacement
Torque Settings
Trailer Brake Air Valve
Removal and Replacement
Removal
Replacement
Torque Settings
Testing (in situ)
Dismantling and Assembly
Dismantling
Cleaning and Inspection
Assembly
Torque Settings
Bench Testing
Leakage Testa
Operational Tests
Port Identification
Trailer Brake Hydraulic Valve
Testing
Removal and Replacement
When Removing
When Replacing
Torque Settings
Dismantling and Assembly
Dismantling
Assembly
Torque Settings
Air/Hydraulic Actuator
Removal and Replacement
Removal
Replacement
Torque Settings
Testing (in Situ)
Dismantling and Assembly
When Dismantling
Inspection
Torque Settings
Bench Testing
Trailer Brake Air Line Filter
Dismantling and Assembly
When Dismantling
When Assembling
Trailer Brake Palm Couplings
Dismantling and Assembly
When Dismantling
When Assembling
ABS Sensors (ABS Machines only)
Removal and Replacement
Removal
Replacement

Section H
Steering
Technical Data
Pressure Settings
Descriptions
Schematic Circuits
Two-Wheel Steer Machines
Four-Wheel Steer Machines
Front Axle Steering
Operation 1 – Neutral
Operation 2 – Left Turn
Operation 3 – RIght Turn
Operation 4 – Left Turn, Unassisted
Operation 5 – Pressure Relief Valve
Explanation
Four-Wheel Steering
Steer Mode Selection
Introduction
Steer Mode Selection
Two-Wheel Steer Mode (2WS)
Crab Steer Mode (A)
Typical Applications
Proportional Steer Mode (B)
Typical Applications
True Tracking Mode (C)
Typical Applications
Delay Mode (D)
Typical Applications
Headland Management System (HMS)
3-point linkage Override
External Override
Differential Lock
Fault Finding
Introduction
Front Axle
Heavy Steering
Steering Wander or Free Play
Rear Axle (4WS)
Introduction
Panel Self-Test
Fuses
Diagnosis
Pressure Testing
Steering System Operating Pressure
Steering Unit relief Valve
Steering Column
Dismantling and Assembly
Dismantling
Assembly
Hydraulic Steer Unit
Removal and Replacement
Removal
Replacement
Torque Settings
Dismantling and Assembly
Dismantling
Assembly
Rams
Front Axle Steer Ram
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Torque Settings
Rear Axle Steer Ram
4WS Rear Axle
Steering Valve
Removal and Replacement
Setting the Relief Valve
4WS Dump Valve
4WS Main Relief Valve
Dismantling and Assembly
Power Track Rod
Removal and Replacement
Removal
Replacement
Ball Joint Removal and Replacement
When Removing
When Replacing
Dismantling and Assembly
When Dismantling
When Assembling

Section S
Suspension
Technical Data
Rear Suspension
Pump
Pressures
Front Suspension
Description
Shock Absorber (D)
Removal and Replacement
When Replacing
Torque Settings
Control Arm (A)
Removal and Replacement
Removal
Replacement
Centre Control Arm
Torque Settings
Dacromet (colour: mottled silver)
Panhard Rod and Anti-roll Bar
Panhard Rod (B)
Removal and Replacement
When Removing
When Replacing
Torque Settings
Anti-roll Bar (E)
Removal and Replacement
When Removing
When Replacing
Torque Settings
Dacromet (colour: mottled silver)
Coil Spring and Microcellular Spring
Removal
Replacement
Torque Settings
Rear Suspension
Description
Electronic Control
Pressure Testing
Discharging Hydraulic Pressure
Machines with ECU 1
Machines with ECU 4
Pressure Maintenance Valve
Dismantling and Assembly
Torque Settings
Potentiometer
Removal and Replacement
Removal
Replacement
After Replacement
Potentiometer Operating Link
Removal and Replacement
Removal
Replacement
After Replacement
Accumulator and Gas Spring
Removal and Replacement
Torque Settings
Testing
Suspension Cylinder
Removal and Replacement
When Removing
When Replacing
Torque Settings
Suspension Cylinder
Dismantling and Assembly
Dismantling
Assembly
Gland Seal Fitting Procedure
Testing
Anti-roll Bar
Removal and Replacement
Removal
Replacement
When Replacing
Torque Settings
Dacromet (colour: mottled silver)
Control Arm (J)
Removal and Replacement
When Removing
Torque Settings
Dacromet (colour: mottled silver)
After Replacement
`V’ Link
Removal and Replacement
When Removing
When Replacing
Torque Settings
Dacromet (colour: mottled silver)

Section T
Engine
Technical Data
General
Flywheel Damper
Removal and Replacement
Removal
Replacement

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