Jcb 3230 plus fastrac service repair manual

Service
Manual
Fastrac
3170, 3170 Plus
3190, 3190 Plus
3200, 3200 Plus
3220, 3220 Plus
3230, 3230 Plus
Published by the
TECHNICAL PUBLICATIONS DEPARTMENT
of
JCB SERVICE LTD;
World Parts Centre,
Waterloo Park
Uttoxeter, Staffordshire
ST14 7BS
Publication No. 9803/8030
Issue 9
General Information 1
Care & Safety 2
3
Optional Equipment A
Body & Framework B
Electrics C
Controls D
Hydraulics E
Transmission F
Brakes G
Steering H
Suspension S
Engine T
Routine Maintenance

9803/8030 Issue 1
Introduction
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training
by JCB Technical Training Department.
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated
with the maintenance and repair of hydraulic earthmoving equipment.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of
course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe
connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all
else
SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools.
2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for the whole machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for
example:
A = Optional Equipment
B = Body & Framework ...etc
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later
issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
Page cross references are generally made by presenting the subject title printed in bold, followed by the title of the section
containing the subject. For example:
“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.

i
Section 1 General Information
9803/8030
Section 1
i
Issue 2*
Contents Page No.
Machine Identification Plate 1 - 1
Typical Vehicle Identification Number (VIN) 1 - 1
Unit Identification 1 - 1
Torque Settings
Introduction - Zinc Plated Fasteners and Dacromet Fasteners 2 - 1
Zinc Plated Fasteners 2 - 2
Dacromet Fasteners 2 - 3
Sealing and Retaining Compounds 3 - 1
Service Tools Numerical List 4 - 1
Service Tools
Optional Equipment 5 - 0
Body and Framework 5 - 1
Electrics 6 - 1
Hydraulics 7 - 1
Transmission 8 - 1
Brakes 9 - 1
Steering 9 - 1
Suspension 9 - 2
Engine 9 - 2
Moving a Disabled Machine
General 10 - 1
Preparation for Towing 10 - 1
Transporting the Machine 10 - 2
*

1 - 1
9803/8030
Section 1
1 - 1
Issue 3*
417490
S
P
X
R
M
N
Serial Number Plate
Each machine has a serial number plate located at X. The 17
digit Vehicle Identification Number (VIN), and the serial
numbers of the engine and transmission are stamped on the
plate.
Typical Vehicle Identification No. (VIN)
Original VIN Configuration
Later VIN Configuration
A = Manufacturing Code
B = Machine Range
FT = Fastrac
C = Engine Type
17 = 3190 or 3190 Plus
18 = 3220 or 3220 Plus
19 = 3170 or 3170 Plus
23 = 3200 or 3200 Plus
24 = 3230 or 3230 Plus
D = Transmission Type (Gearbox and axle combination)
3170, 3170 Plus All other machines
A = 75 km/h 8 = Standard (40, 50 or 65 km/h)
B = 65 km/h 9 = High Speed (75 km/h)
D = 50 km/h
E = 40 km/h
E = Vehicle Max. Speed
40 = 40 km/h
50 = 50 km/h
65 = 65 km/h
75 = 75 km/h
F = Serial Number
G = Authenticity Code
H = year Code (e.g. 6 = 2006)
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.
Engine M
Gearbox Assembly (assembly of all three gearboxes) N
Speed Gearbox P
Front Axle R
Rear Axle S
*
*
SLP FT 17 A 40 XXXXXXX
A B C D E F
JCB 23 8 40 X 6 XXXXXXX
A C D E G H F
*
*
*

2 - 1
9803/8030
Section 1
2 - 1
Issue 1
Torque Settings
Introduction - Zinc Plated Fasteners and Dacromet Fasteners
Some external fasteners on Fastrac machines are assembled using an improved type of corrosion resistant finish. This type of
finish is called Dacromet and replaces the original Zinc and Yellow plating used on earlier machines.
The two types of fasteners can be readily identified by colour and part number suffix as follows:
Fastener Type Colour Part Number
Zinc and Yellow Golden finish ‘Z’ (e.g. 1315/3712Z)
Dacromet Mottled silver finish ‘D’ (e.g. 1315/3712D)
Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must
be relevant to the type of fasteners.
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. They are not used in application such as gearbox and engine joint seams or internal
applications.

2 - 2
9803/8030
Section 1
2 - 2
Issue 1
Torque Settings
Zinc Plated Fasteners (golden finish)
Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the
figures stated. For lubricated threads the values should be REDUCED by one third.
Metric Grade 8.8 Bolts
Bolt size Torque Settings
Dia. (mm) Hexagon Nm kgf m lbf ft
(A/F) mm
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M18 (18) 27 350 36 258
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Dia. (mm) Hexagon Nm kgf m lbf ft
(A/F) mm
M6 (6) 8 16 1.6 12
M8 (8) 13 39 4 29
M10 (10) 17 78 8 57
M12 (12) 19 137 14 101
M16 (16) 24 343 35 253
M20 (20) 30 657 67 485
M24 (24) 36 1157 118 853
Hydraulic Hose to Adapter Connections Hydraulic Adapter into Component Connections
with bonded washers
Torque Settings Torque Settings
BSP Size Nm kgf m lbf ft BSP Size Nm kgf m lbf ft
(inches) (inches)
1/8 14 1.4 10 1/8 20 2.1 15
1/4 24 2.5 18 1/4 34 3.4 25
3/8 33 3.3 24 3/8 75 7.6 55
1/2 44 4.8 35 1/2 102 10.3 75
5/8 58 6.0 43 5/8 122 12.4 90
3/4 84 8.6 62 3/4 183 18.7 135
1 115 11.8 85 1 203 20.7 150
11/2 244 24.9 180 11/2 305 31 225
Metric - All Internal Hexagon Headed Cap Screws
Diameter Torque
mm Nm kgf m lbf ft
M3 2 0.2 1.5
M4 6 0.6 4.5
M5 11 1.1 8
M6 19 1.9 14
M8 46 4.7 34
M10 91 9.3 67
M12 159 16.2 117
M16 395 40 292
M18 550 56 406
M20 770 79 568
M24 1332 136 983
Verbus Ripp Bolts
Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.
A343780

2 - 3
9803/8030
Section 1
2 - 3
Issue 1
Torque Settings
Dacromet Fasteners (mottled silver finish)
Use only where no torque setting is specified in the text.
NOTE: DACROMET FASTENERS ARE LUBRICATED AS PART OF THE PLATING PROCESS: DO NOT LUBRICATE.
Dia. Nm kgf m lbf ft
M6 x 1.0 9 0.9 7
M8 x 1.25 22.5 2.3 17
M10 x 1.5 47.5 4.8 35
M12 x 1.75 80 8.2 59
M14 x 2 133 13.6 98
M16 x 2 200 20.4 148
M18 x 2.5 278 28.4 205
M20 x 2.5 392 40 289
M24 x 3 675 69 498
M30 x 3.5 1348 138 994
M6 x 1.0 13.5 1.4 10
M8 x 1.25 35 3.6 26
M10 x 1.5 62.5 6.4 46
M12 x 1.75 115 11.7 85
M14 x 2 175 17.9 129
M16 x 2 300 30.6 221
M18 x 2.5 395 40 291
M20 x 2.5 559 57 412
M24 x 3 962 98 710
M30 x 3.5 1920 196 1416
M6 x 1.0 15 1.5 11
M8 x 1.25 40 4.1 29
M10 x 1.5 80 8.2 59
M12 x 1.75 133 13.6 98
M14 x 2 225 23 166
M16 x 2 350 35.7 258
M18 x 2.5 463 47 342
M20 x 2.5 654 67 482
M24 x 3 1125 115 830
M30 x 3.5 2247 229 1657

Location: Front Lower Crossmember
Nm: 115 kgf m: 12 lbf ft: 85
A401990
2 - 4
9803/8030
Section 1
2 - 4
Issue 2*
Torque Settings
Dacromet Fasteners (mottled silver finish) - List of Torque Settings
This list shows Dacromet fasteners that may not be shown in the other sections of the service manual.
Location: Front Wrapper
(top/bottom)
Nm: 392 kgf m: 40 lbf ft: 289
A402060
Location: Front P.T.O. Box
Nm: 200 kgf m: 20 lbf ft: 148
A402230
Location: Front Axle Upper Arm
Mounting Bracket
8.8 grade bolts:
Nm: 200 kgf m: 20 lbf ft: 148
10.9 grade bolts (all bolts with JCB
Threadlocker and Sealer and with
spacer fitted at bolt B):
Nm: 300 kgf m: 30 lbf ft: 220
Location: Steershaft Bearing
Nm: 28 kgf m: 2.9 lbf ft: 21
Location: Steershaft upper UJ
Nm: 38 kgf m: 3.9 lbf ft: 28
Location: Front Engine Mounting
Nm: 200 kgf m: 20 lbf ft: 148
A402150
Location: Header Tank Clamp Plate
Nm: 30 kgf m: 3 lbf ft: 22
A402290
A402270
B
*

Location: Left Hand Pannier Step
Nm: 47.5 kgf m: 4.8 lbf ft: 35
A402200
2 - 5
9803/8030
Section 1
2 - 5
Issue 1
Torque Settings
Dacromet Fasteners (mottled silver finish) - List of Torque Settings (continued)
Location: Lower Link Capscrew
Nm: 654 kgf m: 67 lbf ft: 482
A402140
Location: Tower Casting to Axle
Nm: 392 kgf m: 40 lbf ft: 289
A402010
Location: Rear Lower Crossmember
Nm: 200 kgf m: 20 lbf ft: 148
A402260
Location: Gearbox Crossmember
Nm: 200 kgfm: 20 lbf ft: 148
Location: Rear Anti-Roll bar mounting
bracket
Nm: 392 kgf m: 40 lbf ft: 289
A402120
Location: Rockinger Hitch Bolt
Nm: 392 kgfm: 40 lbf ft: 289
A402030
Location: Rear Crossmember
Nm: 392 kgf m: 40 lbf ft: 289
A402280
Location: Lower Link Bolt (Hex Head)
Nm: 392 kgf m: 40 lbf ft: 289
A402040

3 - 1
9803/8030
Section 1
3 - 1
Issue 2*
Sealing and Retaining Compounds
Gasketing - Loctite 509 To seal the joint faces between the PTO/splitter gearbox, the 4102/3202 50ml
speed gearbox and the range gearbox. 4102/3240 315 ml
JCB Multigasket A medium strength sealant suitable for all sizes of gasket
flanges, and for hydraulic fittings of 25-65 mm diameter. 4102/1212
JCB High Strength Threadlocker A high strength locking fluid for use with threaded components. 4102/0551
Gasketing for all sizes of flange where the strength of the joint
is important.
JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/0651
JCB Threadlocker & Sealer A medium strength locking fluid for sealing and retaining nuts,
bolts, and screws up to 50 mm diameter, and for hydraulic
fittings up to 25 mm diameter. 4101/0251
JCB Threadlocker For threads of suction strainer. 4101/0451 50ml
JCB Threadlocker & Sealer A medium to high strength locking fluid. 4101/0552
(High Strength)
JCB Threadseal Medium strength thread sealant (for patch bolts that are re-used). 4102/1951 50 ml
Clayton System Seal SC1251 A thread sealant used mainly on air brake system hose adapters. 4102/2210 2ml
JCB Activator A cleaning primer which speeds the curing rate of anaerobic 4104/0251 Aerosol
products. 4104/0253 Bottle
JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic adhesives
and sealants. 4104/1557 Aerosol
Direct Glazing Kit For one pane of glass, comprises items marked † below plus
applicator nozzle etc. 993/55700
† Ultra Fast Adhesive For direct glazing 4103/2109 310 ml
† Active Wipe 205 For direct glazing 4104/1203 250 g
4104/1206 30 ml
† Black Primer 206J For direct glazing 4201/4906 30 ml
JCB Clear Silicone Sealant To seal butt jointed glass. Also to seal hub planet gear carrier
when no 'O' ring is fitted 4102/0901
Black Polyurethane Sealant To finish exposed edges of laminated glass 4102/2309 310 ml
*

4 - 1
Service Tools Numerical List
Page No.
1370/0901Z Nut M24 9 - 1
1406/0021 Bonded Washer 7 - 1
1604/0006 Adapter 7 - 1
1604/0008 Adapter 7 - 1
1606/0012 Adapter 7 - 1
1606/0015 Adapter 7 - 1
1612/0006 Adapter 7 - 1
4101/0251 JCB Threadlocker and Sealer 3 - 1
4101/0451 JCB Threadlocker 3 - 1
4101/0552 JCB Threadlocker and Sealer
(High Strength) 3 - 1
4101/0651 JCB Retainer (High Strength) 3 - 1
4102/0551 JCB High Strength Threadlocker 3 - 1
4102/0901 JCB Clear Silicone Sealant 3 - 1
4102/1212 JCB Multigasket 3 - 1
4102/1951 JCB Threadseal 3 - 1
4102/2210 Clayton System Seal SC1251 3 - 1
4102/2309 Black Polyurethane Sealant 3 - 1
4103/2109 Ultra Fast Adhesive 3 - 1
4104/0251 JCB Activator (Aerosol) 3 - 1
4104/0253 JCB Activator (Bottle) 3 - 1
4104/1557 JCB Cleaner/Degreaser 3 - 1
4104/1203 Active Wipe 205 (250 g) 3 - 1
4104/1206 Active Wipe 205 (30 ml) 3 - 1
4104/1310 Hand Cleaner 5 - 1
4201/4906 Black Primer 3 - 1
721/00664 Connecting Lead (Wingst) 6 - 2
721/10885 Harness - ABS Diagnostic (J1939) 6 - 1
816/15118 Test Adapter 7 - 1
816/20008 Adapter 7 - 1
816/20013 Adapter 7 - 1
816/55038 Adapter/Test Point 7 - 1
892/00041 Deglazing Tool 9 - 2
892/00078 Connector 7 - 1
892/00137 Micro Bore Hose 7 - 2
892/00174 Measuring Cup 8 - 2
892/00179 Bearing Press 8 - 1
892/00223 Hand Pump 7 - 2
892/00224 Impulse Extractor 8 - 2
892/00225 Adapter for Impulse Extractor 8 - 1
892/00253 Pressure Test Kit 7 - 1
892/00262 Adapter/Test Point 7 - 1 & 7 - 2
892/00268 Flow Monitoring Unit 7 - 1
892/00269 Sensor Head 7 - 1
892/00270 Load Valve 7 - 1
892/00271 Adapter 7 - 1
892/00272 Adapter 7 - 1
892/00273 Sensor Head 7 - 1
892/00274 Adapter 7 - 2
892/00275 Adapter 7 - 1
892/00276 Adapter 7 - 1
892/00277 Adapter 7 - 1
892/00278 Gauge 0 - 40 bar 7 - 2
892/00279 Gauge 0 - 400 bar 7 - 2
892/00281 Avo Meter 6 - 1
892/00282 Shunt 6 - 1
892/00283 Tool Kit Case 6 - 1
892/00284 Digital Tachometer 6 - 1
892/00285 Oil Temperature Probe 6 - 1
892/00286 Surface Temperature Probe 6 - 1
892/00293 Connector Pipe 7 - 1
892/00294 Connector Pipe 7 - 1
892/00298 Fluke Multimeter 6 - 1
892/00311 Brake Test Kit 8 - 4
892/00312 Dummy End Plate 8 - 2
892/00314 Accumulator Adapter 9 - 1
892/00318 Hose and Adapter Kit 7 - 2
892/00333 Heavy Duty Socket, 19 mm A/F 8 - 2
892/00334 Gland Seal Fitting Tool 7 - 2
892/00706 Test Probe 7 - 2
892/00801 Clutch spanner 5 - 3
892/00802 Rotor puller set 5 - 3
892/00803 Rotor installer set 5 - 3
892/00807 Front plate puller 5 - 3
892/00808 Shaft protector 5 - 3
892/00812 Drive Coupling Spanner 8 - 1
892/00818 Heavy Duty Socket, 22mm A/F 8 - 2
892/00842 Glass Lifter 5 - 1
892/00843 Folding Stand 5 - 1
892/00844 Long Knife 5 - 2
892/00845 Cartridge Gun 5 - 1
892/00846 Glass Extractor Handles 5 - 2
892/00847 Nylon Spatula 5 - 3
892/00848 Wire Starter 5 - 2
892/00849 Braided Cutting Wire 5 - 2
892/00864 PD 90 Axle Locknut Spanner 8 - 3
892/00871 Frame (Puller Adapter Assembly) 9 - 1
892/00874 Brace (Puller Adapter Assembly) 9 - 1
892/00875 Bar M24 (Puller Adapter Assembly) 9 - 1
892/00876 Block (Puller Adapter Assembly) 9 - 1
892/00892 Speed Gearbox Locking Tool 8 - 3
892/00916 Spring Compressor 8 - 3
892/00918 Setting Tool Kit 8 - 3
892/00945 Sleeve for M30 Pinion 8 - 3
892/01033 Data Link Adapter Kit - ABS 6 - 1
892/01045 Peg Socket - Wet Clutch 8 - 5
892/01046 Mandrel - Wet Clutch 8 - 4
892/01047 Jig - Wet Clutch 8 - 4
892/01048 Clutch Pack Retainer - Wet Clutch
(2 required) 8 - 4
892/01049 Guide Rod - Wet Clutch
(2 required) 8 - 4
892/01050 Mandrel - Wet Clutch 8 - 4
892/01051 Intermediate Gear Retaining Tool -
Wet Clutch Transmission 8 - 4
892/01052 Locking Plate - Wet Clutch
(2 required) 8 - 4
892/01053 Adapter for impulse extractor
(PTO intermediate shaft,
wet clutch transmission) 8 - 2
892/01066 Combination Lead 6 - 2
892/01092 Wheel Hub Service Kit 8 - 5
926/15500 Rubber Spacer Blocks 5 - 3
992/09000 Peg Spanner 5 - 0
992/12300 Mobile Oven 5 - 1
992/12400 Static Oven 5 - 1
9803/8030
Section 1
4 - 1
Issue 4*
*

4 - 2
992/12600 Static Oven 5 - 1
992/12800 Cut-out Knife 5 - 2
992/12801 'L' Blades 5 - 2
993/45400 Torque Multiplier 8 - 1
993/55700 Direct Glazing Kit 3 - 1
993/59300 Pressure Test Adapter and Clamp 8 - 2
993/69800 Seal Kit 7 - 1
993/70111 Break-back Torque Wrench 8 - 3
997/11000 Drive Head Setting Bracket 8 - 3
997/11100 Adapter for M24 Pinion 8 - 3
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
Replacement parts for kit no. 892/01092
1315/3414Z Bolt M10x60 8 - 5
1315/3731Z Bolt M16x220 8 - 5
1315/3835Z Bolt M20x300 8 - 5
1370/0301Z Nut M10 8 - 5
1370/0401Z Nut M12 8 - 5
1370/0601Z Nut M16 8 - 5
1370/0701Z Nut M20 8 - 5
1420/0009Z Washer M12 8 - 5
1420/0012Z Washer M20 8 - 5
445/12303 Washer 8 - 5
892/00891 Dolly 8 - 5
917/02800 Bearing 8 - 5
998/10606 Bearing Fitting Tube 8 - 5
998/10607 Inner Bearing Plate 8 - 5
998/10608 Bearing Centre Puller 8 - 5
998/10610 Puller Rod 8 - 5
998/10614 Reaction Tube 8 - 5
998/10615 Wheel Bearing Carrier Puller 8 - 5
998/10616 Puller Handle Nut 8 - 5
998/10623 Puller Beam 8 - 5
998/10624 Modified Wheel Stud 8 - 5
9803/8030
Section 1
4 - 2
Issue 3*
Service Tools Numerical List (continued)
Page No.
*

5 - 0
9803/8030
Section 1
5 - 0
Issue 1
Service Tools
Section A - Optional Equipment
1 992/09000 Peg spanner for piston head of front hitch
ram (including 2 pairs of pegs)
2 992/09003 Replacement pegs for 7.5 mm holes
3 992/09004 Replacement pegs for 10 mm holes
197220
892/00334 Gland Seal Fitting Tool

5 - 1
9803/8030
Section 1
5 - 1
Issue 1
Service Tools
Section B - Body and Framework
S186240
Hand Cleaner - special blend for the removal of
polyurethane adhesives.
JCB part number - 4104/1310 (454g; 1lb tub)
S186250
12V Mobile Oven - 1 cartridge capacity - required to
pre-heat adhesive prior to use. It is fitted with a male
plug (703/23201) which fits into a female socket
(715/04300).
JCB part number - 992/12300
S186260
240V Static Oven - available with 2 or 6 cartridge
capacity - required to pre-heat adhesive prior to use.
No plug supplied. Note: 110V models available upon
request - contact JCB Technical Service
JCB part number:
992/12400 - 2 cartridge x 240V
992/12600 - 6 cartridge x 240V
S186270
Cartridge Gun - hand operated - essential for the
application of sealants, polyurethane materials etc.
'
S186280
Folding Stand for Holding Glass - essential for
preparing new glass prior to installation.
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.

Service Tools (continued)
Section B - Body and Framework (continued)
S186310
Wire Starter - used to access braided cutting wire
(below) through original polyurethane seal.
S186320
Glass Extractor (Handles) - used with braided cutting
wire (below) to cut out broken glass.
S186330
Braided Cutting Wire - consumable heavy duty
cut-out wire used with the glass extraction tool
(above).
JCB part number - 892/00849 (approx 25m length)
S186340
Cut-out Knife - used to remove broken glass.
'
S186350
'L' Blades - 25mm (1in.) cut - replacement blades for
cut-out knife (above).
JCB part number - 992/12801 (unit quantity = 5 off)
S186360
Long Knife - used to give extended reach for normally
inaccessible areas.
5 - 2
9803/8020
Section 1
5 - 2
Issue 1

Section B - Body and Framework (continued)
S186470
Nylon Spatula - general tool used for smoothing
sealants - also used to re-install glass in rubber glazing
because metal tools will chip the glass edge.
892/00801 Clutch spanner S200940
for air conditioning compressor
892/00802 Rotor puller set S200950
892/00803 Rotor installer set S200960
S186550
Rubber Spacer Blocks - used to provide the correct
set clearance between glass edge and cab frame.
(unit quantity = 500 off)
892/00807 Front plate puller S200970
892/00808 Shaft protector S200980
5 - 3
9803/8030
Section 1
5 - 3
Issue 1

Service Tools
Section C - Electrics
6 - 1
9803/8030
Section 1
6 - 1
Issue 2*
188230
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
8
1514131211109
7654321
D
FAB
C
H
J
E
G
A386040
721/10885 Harness - Diagnostic (J1939)
A360250
892/01033 Data Link Adapter Kit - ABS
Note: Item A of the Data Link Adapter Kit is unsuitable
for use with the Fastrac and must be replaced by the
‘Harness - Diagnostic (J1939)’ shown below.
AA
*

6 - 2
Section C - Electrics (continued)
9803/8030
Section 1
6 - 2
Issue 2*
721/00664 Connecting Lead - Wingst
A406950
892/01066 Combination Lead
(alternative to 721/00664)
*

7 - 1
9803/8030
Section 1
7 - 1
Issue 1
Pressure Test Adapters
892/00255 1/4 in BSP x Test Point
892/00259 1 in BSP x Test Point
892/00260 1.1/4 in BSP x Test Point
892/00261 5/8 in UNF x Test Point
Pressure Test 'T' Adapters
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point
Hydraulic Circuit Pressure Test Kit
892/00253 Pressure Test Kit
892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in2
)
)
)
892/00254 Replacement Hose
:993/69800 Seal Kit for 892/00254 (can also be used with
probe 892/00706)
S188130
S188120
S200140
Service Tools
Section E - Hydraulics
Flow Test Equipment
892/00268 Flow Monitoring Unit
892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)
892/00293 Connector Pipe
892/00270 Load Valve
1406/0021 Bonded Washer
1604/0006 Adapter 3/4 in M x 3/4 in M BSP
1612/0006 Adapter 3/4 in F x 3/4 in M BSP
892/00273 Sensor Head 0 - 380 l/min
892/00294 Connector Pipe
1606/0015 Adapter 1.1/4 in M BSP x 1 in M BSP
892/00078 Connector 1 in F x 1 in F BSP
1604/0008 Adapter 1 in M x 1 in M BSP
1606/0012 Adapter 1 in M x 3/4 in M BSP
816/20013 Adapter 3/4 in F x 1 in M BSP
S188150

Section E - Hydraulics (continued)
Hand Pump Equipment
892/00223 Hand Pump
892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in BSP male x 3/8 BSPT male
892/00262 Test Point on 1/4 in BSP male x 1/4 BSP
female adapter
892/00706 Test Probe
892/00278 Gauge 0-40 bar (0-600 lbf/in2
)
892/00279 Gauge 0-400 bar (0-6000 lbf/in2
)
892/00334 Gland Seal Fitting Tool
331/64265 Retaining Bush for Valve Spool
892/00318 Hose And Adapter Kit
To enable flow and pressure test
equipment to be connected to adapters
fitted with 'O' ringface seals.
331/64246 Tool Kit for Non-return Valve
7 - 2
9803/8030
Section 1
7 - 2
Issue 2
S193850
197210
197220

8 - 1
9803/8030
Section 1
8 - 1
Issue 2*
892/00812 PTO Drive Coupling Spanner for yoke
couplings
Differential Setting Key
Cut from 5 mm plate to dimensions shown. Fabricate
handle to suit.
993/45400 Torque Multiplier
(use in conjunction with a torque wrench to
give a 5 : 1 multiplication)
Service Tools
Section F - Transmission
892/00179 Bearing Press
892/00225 Adapter - Impulse Extractor
Small 17mm to 25mm
Medium 25mm to 45mm
Large 45mm to 80mm
188200 107750
197080
110
15
40
25 25
A197180
S197030
*

Section F - Transmission (continued)
Heavy Duty Sockets
892/00817 17 mm A/F x 3/4in. square drive
892/00224 Impulse Extractor Set
for Hub Bearing Seals
892/01053 Adapter for impulse extractor
(PTO intermediate shaft, wet clutch
transmission)
892/00174 Measuring Cup - Pinion Head Bearing
892/00312 Dummy End Plate for Range Gearbox
993/59300 2/4 WD Pressure Test Adaptor & Clamp
8 - 2
9803/8030
Section 1
8 - 2
Issue 2
197250
S197070
S197240
S190770
S196750

8 - 3
9803/8030
Section 1
8 - 3
Issue 1
892/00892 Speed Gearbox Locking Tool
892/00916 Spring Compressor for Splitter and PTO
Clutches
S226300
S267310
Solid Spacer Setting Tools
1 892/00918 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
2 997/11000 Drive Head Setting Bracket
3 993/70111 Break-back Torque Wrench
4 - Solid spacer (see parts CD or
michrofiche for part numbers)
A270851
4
3
A B
2
1
C
S234120
892/00864 PD 90 Axle Locknut Spanner
A361730
892/01052 (x2) Locking Plate for locking wet clutch
drum to housing

8 - 4
9803/8030
Section 1
8 - 4
Issue 1
A361710
892/01051 Intermediate Gear Retaining Tool - wet
clutch transmission A361740
892/01049 (x2) Guide Rod - wet clutch
A361720
892/01048 (x2) Clutch
Pack Retainer - wet
clutch
A361750
892/01045 Peg Socket - wet clutch
A361770
892/01046 Mandrel - for bush assembly - wet clutch
A361760
892/01047 Jig, for use when dismantling and
assembling of PTO input gear - wet clutch
A361780
892/01050 Mandrel, for hub seal renewal - wet clutch.
Note: Protective plastic cap A to be removed before use.
A

8 - 5
Section 1
9803/8030
Section 1
8 - 5
Issue 2
General Information
Item Description Part No. Qty
A Hub Service Kit 892/01092 1
comprises:
1 Puller Beam 998/10623 1
2 Inner Bearing Plate 998/10607 1
3 Bolt M16x220 1315/3731Z 2
4 Nut M16 1370/0601Z 2
5 Reaction Tube 998/10614 1
6 Modified Wheel Stud 998/10624 2
7 Wheel Bearing Carrier
Puller 998/10615 2
8 Nut M20 1370/0701Z 4
9 Washer M20 1420/0012Z 2
10 Puller Rod 998/10610 2
11 Nut M12 1370/0401Z 2
12 Washer M12 1420/0009Z 2
13 Bearing Centre Puller 998/10608 1
14 Bolt M10x60 1315/3414Z 1
15 Nut M10 1370/0301Z 1
16 Bearing Fitting Tube 998/10606 1
17 Puller Handle Nut 998/10616 1
18 Bolt M20x300 1315/3835Z 2
19 Washer 445/12303 2
20 Bearing 917/02800 1
21 Dolly 892/00891 1
1
A
2
3
4
5
6
7
8,9
10
11,12
8
14
15
21
13 16
17
18
19, 20

Section H - Steering
9 - 1
9803/8030
Section 1
9 - 1
Issue 1
222490
AA
BB
DD
CC
EE
Puller adapter assembly for removal of drop arm from
steering box (3000 Series machines). Comprises:
A 892/00871 Frame 1 off
B 892/00874 Brace 1 off
C 892/00875 Bar M24 2 off
D 892/00876 Block 2 off
E 1370/0901Z Nut M24 2 off
Use in conjunction with a 20 tonne hydraulic ram as
obtainable from Sykes Pickavant to suit puller bars at 185
mm centres.
Section G - Brakes
S199470
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

9 - 2
Section T - Engine
Note: For other engine tools refer to the relevant Engine
Service Manual.
9803/8030
Section 1
9 - 2
Issue 1
S192390
892/00041 De-glazing Tool for Cylinder Bores (to
assist bedding-in of new piston rings)
S199480
892/00314 Accumulator and Gas Spring Pressure
Test Adapter
Section S - Suspension

10 - 1
General
Do not tow a machine unless there is no alternative.
Remember that more damage might be caused to the
machine by towing it. If at all possible repair the machine
where it stands.
Note: It is not possible to tow-start or push-start the Fastrac
due to the design of the transmission.
Make sure you will be obeying all pertinent laws and
regulations before towing the machine on public roads.
! DANGER
If the engine is not running, there will not be enough air
to apply the service brakes or release the parking brake.
Carefully follow the precautions in this section before
moving the machine or there may be a serious accident.
13-2-2-6/1
! CAUTION
Towing a machine too far or too fast can damage the
transmission. Do not tow the machine further than one
mile. Use a trailer for greater distances. When towing do
not travel faster than 25 km/h (15 mph).
Use a rigid drawbar. If you must use towing chains, then
use two towing vehicles. One towing vehicle should be
coupled to the front of the disabled machine. The other
towing vehicle should be coupled to the rear of the
disabled machine, to provide braking power.
The towing vehicle(s) must have enough pulling and
braking power to move and stop the machine.
2-2-7-3
Preparation for Towing
1 Connect the towing vehicle.
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.
2 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).
3 Release the Fastrac parking brake.
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 8 bar (120 lbf/in2)
through Schrader valve X (machines with ABS) or Y
(machines without ABS). 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 remove the propshafts or release the
parking brake. When the propshafts have been
disconnected the parking brake cannot prevent the
machine from moving. 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 and the propshafts connected. Anyone working
underneath, or near the machine, could be killed or
seriously injured if the machine moved.
13-2-2-11/1
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).
The machine is now ready for towing. If you will be steering
the Fastrac, make sure you understand what the towing
driver will be doing. Obey his instructions and all relevant
regulations. Remember that the steering will be much
heavier if the engine is not running.
9803/8030
Section 1
10 - 1
Issue 3*
Moving a Disabled Machine
S160392
C
E
A
D
B
418150
Y
X
*

10 - 2
Transporting the Machine
The safe transit of the load is the responsibility of the
transport contractor and driver. Any machine,
attachments or parts that may move during transit must
be adequately secured.
5-2-5-9
Note: Before transporting the machine make sure you will
be obeying the rules and laws of all the areas that the
machine will be carried through.
Make sure that the transporting vehicle is suitable. See
Static Dimensions (SPECIFICATIONS section in the
machine handbook) for the dimensions of the machine.
! WARNING
Before moving the machine onto the trailer, make sure
that the trailer and ramp are free from oil, grease and
ice. Remove oil, grease and ice from the machine tyres.
Make sure the machine will not foul on the ramp angle.
See Static Dimensions in SPECIFICATIONS section for the
minimum ground clearance of your machine.
2-2-7-5/1
1 Place blocks at the front and rear of the trailer wheels.
2 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.
3 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 B.
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.
4 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.
9803/8030
Section 1
10 - 2
Issue 1
AA
418300B
B

i
Section 2 Care & Safety
9803/8030
Section 2
i
Issue 1
Contents Page No.
Safety Notices 1 - 1
General Safety 2 - 1
Operating Safety 3 - 1
Maintenance Safety 4 - 1

1 - 1
In this publication and on the machine, there are safety notices. Each notice starts
with a signal word. The signal word meanings are given below.
!! DANGER
Denotes an extreme hazard exists. If proper precautions are not taken, it is
highly probable that the operator (or others) could be killed or seriously
injured.
INT-1-2-1
!! WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator (or
others) could be killed or seriously injured.
INT-1-2-2
!! CAUTION
Denotes a reminder of safety practices. Failure to follow these safety practices
could result in injury to the operator (or others) and possible damage to the
machine.
INT-1-2-3
9803/8030
Section 2
1 - 1
Issue 1

2 - 1
9803/8030
Section 2
2 - 1
Issue 3*
All construction and agricultural equipment can be
hazardous. When a JCB Fastrac is correctly operated and
properly maintained, it is a safe machine to work with. But
when it is carelessly operated or poorly maintained it can
become a danger to you (the operator) and others.
Do not work with the machine until you are sure that you can
control it.
Do not start any job until you are sure that you and those
around you will be safe.
If you are unsure of anything, about the machine or the job,
ask someone who knows. Do not assume anything.
Remember
BE CAREFUL
BE ALERT
BE SAFE
GEN-1-6
As well as the warnings in the following pages, specific
warnings are given throughout the book. This section is
designed to give a safety code for use of the machine
generally and for operation and maintenance practices.
General Safety
!! WARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment. Make
sure that lifting equipment is in good condition. Make sure
that lifting tackle complies with all local regulations and is
suitable for the job. Make sure that lifting equipment is
strong enough for the job.
INT-1-3-7
!! WARNING
Clothing
You can be injured if you do not wear the proper clothing.
Loose clothing can get caught in the machinery. Wear
protective clothing to suit the job. Examples of protective
clothing are: a hard hat, safety shoes, safety glasses, a well
fitting overall, ear-protectors and industrial gloves. Keep
cuffs fastened. Do not wear a necktie or scarf. Keep long
hair restrained.
INT-1-3-6
!! WARNING
Alcohol and Drugs
It is extremely dangerous to operate machinery when under
the influence of alcohol or drugs. Do not consume alcoholic
drinks or take drugs before or whilst operating the machine
or attachments. Be aware of medicines which can cause
drowsiness.
INT-1-3-9
Note: This section includes a certain amount of operating
safety information. But remember that whenever you drive
the machine or operate its controls you are in effect a
machine operator. Therefore you should read and
understand the information given in the Operator Handbook
before driving the machine or operating its controls.
!! WARNING
Care and Alertness
All the time you are working with or on the machine, take
care and stay alert. Always be careful. Always be alert for
hazards.
INT-1-3-5
!! WARNING
Raised Equipment
Raised equipment can fall and injure you. Do not walk or
work under raised equipment unless safely supported.
13-1-1-6
!! WARNING
Machine Modifications
Parts of this machine, for example the braking and fuel
injection systems, are manufactured in compliance with
legislative and other requirements. The machine should not
be altered in any way which could affect or invalidate any of
these requirements. Failure to observe this instruction may
be illegal or invalidate the manufactuer’s warranty. For
advice consult your JCB Distributor.
!! CAUTION
Electronic Control Unit
The electronic control unit under the passenger’s seat is
protected by a cover. Do not use the machine with the cover
removed.
0111
*

3 - 1
Operating Safety
!! DANGER
Parking
Leaving the machine in gear will not prevent it running away.
Do not leave the driving seat under any circumstances
unless the parking brake is on.
13-2-1-10
!! WARNING
Roll Over Protection Structure (ROPS)
The machine is fitted with a Roll Over Protection Structure
(ROPS). You could be killed or seriously injured if you
operate the machine with a damaged or missing ROPS. If
the ROPS has been in an accident, do not use the machine
until the structure has been renewed. Modifications and
repairs that are not approved by the manufacturer may be
dangerous and will invalidate the ROPS certification.
13-1-1-8/1
!! WARNING
Entering/Leaving
Always face the machine when entering and leaving the cab.
Use the step(s) and handrails. Make sure the step(s),
handrails and your boot soles are clean and dry. Do not
jump from the machine. Do not use the machine controls as
handholds, use the handrails.
INT-2-1-7
!! WARNING
Seat
Position the seat so that you can comfortably reach the
machine controls. You could have an accident if you operate
the machine with the seat in the wrong position.
INT-3-3-5
!! WARNING
Seat Belt
Operating the machine without a seat belt can be
dangerous. Before starting the engine, make sure your seat
belt is fastened. Check the tightness and condition of the
seat belt securing bolts regularly (see maintenance
schedules).
INT 2 -1-8/1
!! WARNING
Passengers
Ensure that passengers use the seat provided in the cab.
Passengers must not be carried on the rear deck of the
vehicle under any circumstances.
13-1-1-1/1
!! WARNING
Reversing
Reversing at high speeds can cause accidents. Always drive
at a safe speed to suit working conditions
13-1-1-3
!! WARNING
Visibility
Accidents can be caused by working in poor visibility. Keep
windows clean and use your lights to improve visibility. Do
not operate the machine if you cannot see properly.
INT-2-1-11
!! WARNING
Practice
You or others can be killed or seriously injured if you do
unfamiliar operations without first practising them. Practise
away from the work site on a clear area. Keep other people
away. Do not perform new operations until you are sure you
can do them safely.
INT-2-1-1
!! WARNING
Machine Limits
Operating the machine beyond its design limits can damage
the machine, it can also be dangerous. Do not operate the
machine outside its limits. Do not try to upgrade the
machine performance with unapproved modifications.
INT-2-1-4
!! WARNING
Brakes
Do not coast the machine with the engine stopped as the
main brakes will only operate for a limited number of
applications and hydraulic trailer brakes will not function at
all. Also the steering will become very heavy.
13-1-1-5/2
!! CAUTION
Hydraulic Trailer Brakes
Trailers with single line hydraulic brakes used in the United
Kingdom are subject to a maximum speed of 20 mph (32
kph).
13-2-2-8
!! CAUTION
Trailer Brakes
Trailers with single line air brakes used in the Republic of
Germany are subject to a maximum speed of 25 km/h (15
mph).
13-2-2-13
!! WARNING
Engine
The engine has rotating parts. Do not open the engine cover
while the engine is running. Do not use the machine with the
cover open.
INT-2-1-6
9803/8030
Section 2
3 - 1
Issue 1

3 - 2
Operating Safety (cont'd)
!! WARNING
Banks and Trenches
Banked material and trenches can collapse. Do not work or
drive too close to banks and trenches where there is danger
of collapse.
INT-2-2-5
!! WARNING
Ramps and Trailers
Water, mud, ice, grease and oil on ramps or trailers can
cause serious accidents. Make sure ramps and trailers are
clean before driving onto them. Use extreme caution when
driving onto ramps and trailers.
INT-2-2-6
!! WARNING
Communications
Bad communications can cause accidents. Keep people
around you informed of what you will be doing. If you will be
working with other people, make sure any hand signals that
may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands.
INT-2-2-3
!! WARNING
Engine/Steering Failure
If the engine or steering fails, stop the machine as quickly as
possible. Do not operate the machine until the fault has been
corrected.
INT-2-1-5
!! DANGER
Sparks
Explosions and fire can be caused by sparks from the
exhaust or the electrical system. Do not use the machine in
closed areas where there is flammable material, vapour or
dust.
INT-2-2-10
!! WARNING
Controls
Keep the machine controls clean and dry. Your hands and
feet could slide off slippery controls. If that happens you will
lose control of the machine.
2-2-3-6
!! WARNING
Exhaust Gases
Breathing the machine exhaust gases can harm and
possibly kill you. Do not operate the machine in closed
spaces without making sure there is good ventilation. If
possible, fit an exhaust extension. If you begin to feel
drowsy, stop the machine at once. Get out of the cab into
fresh air.
INT-2-1-10
!! WARNING
Power Take-off Operation
When operating PTO equipment, always observe the
following safety precautions:
Follow the instructions in the implement operator's
handbook.
Rotating equipment is dangerous. Do not wear loose fitting
clothing when working close to rotating shafts.
Always disengage the PTO, stop the engine and wait until
the equipment stops, before:
1 Leaving the cab
2 Attempting to attach or detach an implement to or from
a PTO shaft or
3 Working on or cleaning an implement connected to the
machine via a PTO shaft.
Always ensure that the PTO shaft and driveline are fully
guarded before use.
When using stationary PTO equipment, ensure that the
parking brake is applied.
13-2-1-6
!! WARNING
Power Take-off Jamming
If the PTO becomes jammed, disengage the PTO, stop the
engine and clear the blockage. Wait until the PTO shaft
stops before working on the equipment. If the PTO clutch
slips, immediately disengage the PTO and stop the engine.
13-2-2-2
!! WARNING
Hitching Trailers and Equipment
When the vehicle is approaching a trailer or equipment to be
hitched, make sure that no persons are present between
vehicle and trailer or equipment. When mounting equipment
at the rear of the vehicle, you must ensure that proper
steering control is maintained. The machine must never be
loaded such that less than 20% of the vehicle weight is
carried on the front axle.
13-1-1-13/1
9803/8030
Section 2
3 - 2
Issue 1

3 - 3
!! WARNING
Tyres - General
You could be killed or injured if a machine tyre bursts. Do
not use the machine with damaged, incorrectly inflated or
excessively worn tyres. Recognize the speed limitation of
the tyres fitted and do not operate at more than their
recommended maximum speed.
13-2-1-2
!! WARNING
Certain tyres fitted as after-market equipment may have
maximum permitted speeds below the maximum speed of
the vehicle. Brake efficiency is slightly reduced and stopping
distance is increased when these tyres are fitted. They will
suffer damage if operated at speeds higher than those
recommended and may endanger life.
13-3-2-5
!! WARNING
Tyre Speed Limitations
Running tyres outside recommended guidelines may result
in failure of the tyres which at high speeds may endanger
life. BE WARNED.
13-3-1-6
!! WARNING
Rear Deck
Passengers must not be carried on the rear deck of the
vehicle. Ensure that loads carried on the rear deck are
secured adequately to prevent them rolling about, falling off
or toppling over.
13-1-1-12/1
!! WARNING
Weight Distribution
The machine must never be loaded such that less than 20%
of the vehicle weight is carried on the front axle.
13-1-1-11/1
!! CAUTION
Weight Distribution
The Fastrac has to comply with certain braking regulations
which in some countries control weight distribution between
front and rear axles. Travelling on the road with implements
or weights carried on the front when no implement is on the
rear may break the law. In this case you should transfer the
front mounted equipment to the rear linkage. It is the
operator's responsibility to know and observe the laws in the
country concerned.
13-2-2-5
!! WARNING
Travel Speed
Be aware of the load the machine is carrying or towing and
the speed at which you are travelling. Do not corner fast
when carrying heavy mounted implements or towing trailers.
Reduce speed when towing non-suspended implements on
rough ground.
13-2-2-1
!! WARNING
Stability
In the event of the machine becoming unstable, keep firm
hold of the steering wheel and do not try to leave the cab.
13-2-2-10
!! WARNING
Audible Warnings
When you hear an audible warning, stop the machine as
soon as possible. Get the fault put right before using the
machine again.
13-2-1-9
!! WARNING
Controls
When driving the machine on the road, use the accelerator
pedal and not the hand throttle or Field Speed Control to
control the engine speed. Always set the hand throttle to
‘idle’ and disable the Field Speed Control before road use.
0096
!! WARNING
Safe Working Loads
Overloading the machine can damage it and make it
unstable. Study the specifications before loading, towing or
using implements.
13-1-1-4/1
!! DANGER
The JCB Fastrac is capable of operating at high speeds.
Implements or trailers you tow behind the Fastrac may not
be designed for high speed operation. BE AWARE of the
manufacturers specified maximum speed rating for any
trailers or implements that you tow behind the Fastrac. DO
NOT EXCEED THE MAXIMUM DESIGN SPEED OF
TRAILERS OR IMPLEMENTS AS INJURY OR DEATH MAY
RESULT.
13-2-3-5
!! WARNING
Cab Air Filter
The cab air filter is designed to remove dirt from the outside
air. When using chemicals (e.g. for crop spraying) follow the
chemical manufacturer’s recommendations for protection
from dangerous chemicals.
13-2-3-6
!! WARNING
Hazardous Atmospheres
This machine is designed for use in normal out door
atmospheric conditions. It should not be used in an
enclosed area without adequate ventilation. Do not use the
machine in a potentially explosive atmosphere, i.e.
combustible vapours, gas or dust, without first consulting
your JCB Distributor.
INT-2-1-14
9803/8030
Section 2
3 - 3
Issue1

3 - 4
!! WARNING
When driving the machine on the road with an implement or
trailer connected to the hydraulic system, the transport locks
must be engaged to prevent unintentional operation of
electronic linkage or external hydraulics.
0099
!! CAUTION
Use caution when operating the engine at full load. Serious
damage could occur if it is allowed to operate at full throttle
for more than 30 seconds whilst running below peak torque
(1500 rev/min). Do not allow the engine to operate in this
condition when running on a dynamometer.
0097
!! CAUTION
Do not allow the engine to exceed maximum speed (2520
rev/min). Use caution when travelling down hill in a loaded
condition to prevent accidental engine overspeeding when
selecting lower gears.
0098
!! CAUTION
Do not use down shifting of the six speed gearbox to slow
down the tractor. Overspeeding of the gearbox
synchronisers can cause severe damage to the
transmission.
Use the tractor brakes to slow the vehicle and then select a
suitable gear to match the vehicle speed.
Only use trailers with suitable braking systems to prevent
transmission overload.
0102
9803/8030
Section 2
3 - 4
Issue 1

4 - 1
Maintenance Safety
!! WARNING
Working Under the Machine
Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking brake.
Lower any mounted implements to the ground. Stop the
engine, remove the starter key, disconnect the battery.
Chock the wheels.
13-3-1-1
!! WARNING
Soft Ground
A machine can sink into soft ground. Never work under a
machine on soft ground.
INT-3-2-4
!! WARNING
Jacking
A machine can roll off jacks and crush you unless the wheels
have been chocked. Always chock the wheels at the
opposite end of the machine to that which is to be jacked.
Do not work underneath a machine supported only by jacks.
Always support a jacked-up machine on axle stands before
working underneath it.
INT-3-2-8
!! WARNING
Transmission Testing
The transmission is in 4 wheel drive until de-selected by
hydraulic pressure to 2 wheel drive. If the machine is to be
raised and the engine/transmission run, make sure all four
wheels are off the ground and supported by axle stands as if
only the rear wheels were raised, the machine could still
drive through the front axle. Note that when a NoSpin
differential is fitted, both front wheels will be driven even if
one is jacked up and the other is on the ground.
TRAN 8-1/2
!! WARNING
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from the
machine. Do not smoke while refuelling the machine or
working on the engine. Do not refuel with the engine
running. There could be a fire and injury if you do not follow
these precautions.
INT-3-2-2
!! WARNING
Petrol
Do not use petrol in this machine. Do not mix petrol with the
diesel fuel; in storage tanks the petrol will rise to the top and
form flammable vapours.
INT-3-1-6
!! WARNING
Turning the Engine
Do not try to turn the engine by pulling the fan or fan belt.
This could cause injury or premature component failure.
0094
!! WARNING
Battery
A battery with frozen electrolyte can explode if it is used or
charged. Do not use a machine with a frozen battery. To
help prevent the battery from freezing, keep the battery fully
charged.
INT-3-1-7
!! WARNING
Battery Gases
Batteries give off explosive gases. Keep flames and sparks
away from the battery. Do not smoke close to the battery.
Make sure there is good ventilation in closed areas where
batteries are being used or charged. Do not check the
battery charge by shorting the terminals with metal; use a
hydrometer or voltmeter.
INT-3-1-8
!! WARNING
Battery Terminals
The machine is negatively earthed. Always connect the
negative pole of the battery to earth.
When connecting the battery, connect the earth (-) lead last.
When disconnecting the battery, disconnect the earth (-)
lead first.
INT-3-1-9
!! WARNING
Electrical Circuits
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong connection
can cause injury and/or damage.
INT-3-1-4
!! WARNING
Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the
hoses regularly for:
Damaged end fittings
Chafed outer covers
Ballooned outer covers
Kinked or crushed hoses
Embedded armouring in outer covers
Displaced end fittings.
INT-3-3-2
!! WARNING
Rams
The efficiency of the rams will be affected if they are not
kept free of solidified dirt. Clean dirt from around the rams
regularly. When leaving or parking the machine, close all
rams if possible to reduce the risk of weather corrosion.
INT-3-2-10
9803/8030
Section 2
4 - 1
Issue 1

4 - 2
Maintenance Safety (cont'd)
!! WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure trapped
in the hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11/2
!! WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate the
skin. Do not use your fingers to check for hydraulic fluid
leaks. Do not put your face close to suspected leaks. Hold a
piece of cardboard close to suspected leaks and then
inspect the cardboard for signs of hydraulic fluid. If hydraulic
fluid penetrates your skin, get medical help immediately.
INT-3-1-10/1
!! WARNING
Oil
Oil is toxic. If you swallow any oil, do not induce vomiting,
seek medical advice. Used engine oil contains harmful
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier
cream or wear gloves to prevent skin contact. Wash skin
contaminated with oil thoroughly in warm soapy water. Do
not use petrol, diesel fuel or paraffin to clean your skin.
INT-3-2-3
!! WARNING
Hot Coolant
The cooling system is pressurised when the engine is hot.
Hot coolant can spray out when you remove the radiator
cap. Let the system cool before removing the radiator cap.
To remove the cap; turn it to the first notch and let the
system pressure escape, then remove the cap.
INT-3-2-9
!! WARNING
Wheels
Wheels are heavy. Handle and store with care to ensure that
they cannot fall and cause injury.
13-3-1-7
!! WARNING
Metal Splinters
You can be injured by flying metal splinters when driving
metal pins in or out. Use a soft faced hammer or drift to
remove and fit metal pins. Always wear safety glasses.
INT-3-1-3
!! WARNING
Always wear safety glasses when dismantling assemblies
containing components under pressure from springs. This
will protect against eye injury from components accidentally
flying out.
GEN 6-2
!! WARNING
Communications
Bad communications can cause accidents. If two or more
people are working on the machine, make sure each is
aware of what the others are doing. Before starting the
engine make sure the others are clear of the danger areas;
examples of danger areas are: the rotating blades and belt
on the engine, the attachments and linkages, and anywhere
beneath or behind the machine. People can be killed or
injured if these precautions are not taken.
INT-3-1-5
!! WARNING
Cleaning
Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents and
solvents.
INT-3-2-11
!! WARNING
'O' rings, Seals and Gaskets
Badly fitted, damaged or rotted 'O' rings, seals and gaskets
can cause leakages and possible accidents. Renew
whenever disturbed unless otherwise instructed. Do not use
Trichloroethane or paint thinners near 'O' rings and seals.
INT-3-2-12
!! WARNING
Welding and Modifications
To prevent the possibility of damage to electronic
components, disconnect the battery positive and negative
leads before arc-welding on the machine or attached
implements. Attach the welder earth (ground) cable no more
than 0.6 metres (2 feet) from the part being welded. Do not
connect the welder cable or apply any weld to any part of
the engine.
Parts of the machine are made from cast iron; welds on cast
iron can weaken the structure and break. Do not weld cast
iron. On no account weld or drill the chassis structure. Non-
approved modifications can cause injury and damage.
Contact JCB before modifying the machine.
0095
!! WARNING
Protect your eyes when grinding metal. Wear safety glasses
or goggles. Remove or protect any combustible materials
from the area which could be ignited by sparks.
GEN-1-12
!! WARNING
Radar Speed Sensor (if fitted)
To avoid possible eye damage from microwave signals, do
not look directly into the sensor face.
13-1-1-15
Note: The radar speed sensor is located underneath the
machine.
9803/8030
Section 2
4 - 2
Issue1

4 - 3
Maintenance Safety (cont'd)
!! WARNING
Fluoroelastomeric Materials
Certain seals and gaskets (e.g. crankshaft oil seal) on JCB
machines contain fluoroelastomeric materials such as Viton,
Fluorel and Technoflon. Fluoroelastomeric materials
subjected to high temperatures can produce highly corrosive
hydrofluoric acid. THIS ACID CAN SEVERELY BURN.
New fluoroelastomeric components at ambient temperature
require no special safety precautions.
Used fluoroelastomeric components whose temperatures
have not exceeded 300°C require no special safety
precautions. If evidence of decomposition (e.g. charring) is
found, refer to the next paragraph for safety instructions DO
NOT TOUCH COMPONENT OR SURROUNDING AREA.
Used fluoroelastomeric components subjected to
temperatures greater than 300°C (e.g. engine fire) must be
treated using the following safety procedure. Make sure that
heavy duty gloves and special safety glasses are worn:
1 Ensure that components have cooled then remove and
place material in plastic bags.
2 Thoroughly wash contaminated area with 10% calcium
hydroxide or other suitable alkali solution, if necessary
use wire wool to remove burnt remains.
3 Thoroughly wash contaminated area with detergent and
water.
4 Contain all removed material, gloves etc used in this
operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations.
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
If contamination of skin or eyes occurs, wash the affected
area with a continuous supply of clean water or with calcium
hydroxide solution for 16-60 minutes. Get medical attention
immediately.
INT - 3 - 3 - 5/1
!! WARNING
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
Brakes
Before working on or around the brake system, always
observe the following precautions:
1 Stop the engine and chock all four wheels.
2 When the air system is being exhausted, keep hands
away from the parking brake actuator pushrod and
caliper, as they may move and trap your fingers.
3 Take care if disconnecting an air hose containing
pressure as it may whip as air escapes.
4 Never remove or dismantle a component until air
pressure has been exhausted and you have read and
understood the recommended procedures.
5 Wear safety glasses when working with air pressure.
BRAK 8-3/1
!! WARNING
Brake Pads
Always renew brake pads and locating pins in complete axle
sets, using genuine JCB parts, otherwise braking will be
unsafe.
13-3-1-10
!! WARNING
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
9803/8030
Section 2
4 - 3
Issue1

i
Section 3 Routine Maintenance
9803/8030
Section 3
i
Issue 5*
Contents Page No.
Engine Oil 1 - 1
Fluids, Capacities and Lubricants 1 - 2
Fluids, Capacities and Lubricants (N.America) 1 - 3
Lubricants - Health and Safety 1 - 4
Service Schedules 2 - 1
Cleaning the Machine and Checking for Damage 3 - 1
Checking Seat Belt Condition and Security 3 - 1
Opening/Closing the Bonnet 3 - 2
Greasing
General 4 - 1
Propshafts and PTO Driveshafts 4 - 1
Front Axle Steering Swivels 4 - 2
Front 3 point linkage 4 - 3
Automatic Trailer Coupling (if fitted) 4 - 3
Hydraulic Lift & 3 point Linkage 4 - 4
Rear PTO Driveshaft Bearing 4 - 4
Rear Suspension Cylinder Pivots 4 - 4
Steering column Universal Joints 4 - 5
Rear Anti-roll Bar Ball Joints 4 - 5
Roller drawbar 4 - 6
Cab
Checking the ROPS Structure 5 - 1
Checking the Windscreen Washer Fluid Level 5 - 2
Air Conditioning
Cleaning the Filter 5 - 3
Adjusting the Compressor Belt 5 - 4
Electrics
Battery Warning Symbols 6 - 1
First Aid - Electrolyte 6 - 1
Checking the Battery Electrolyte Level 6 - 2
Checking the Headlight Beam Alignment 6 - 3
Fuses See Section C
Hydraulics
Checking the Fluid Level 7 - 1
Changing the Filter Element 7 - 1
Changing the Hydraulic Fluid and Cleaning the Suction Strainer 7 - 2
Emptying the Hydraulic Coupling Drain Reservoir (if fitted) 7 - 3
PTO, Speed and Range Gearboxes
Checking the Oil Level 9 - 1
Changing the Oil and Cleaning the Strainer 9 - 2
Changing the Transmission Oil Filter
3170, 3170 Plus, 3190, 3190 Plus, 3200, 3200 Plus 9 - 3
3220, 3220 Plus, 3230, 3230 Plus 9 - 4
Checking the Front PTO Gearbox Oil Level (if fitted) 9 - 5
*

ii
9803/8030
Section 3
ii
Issue 5*
Contents Page No.
Front Axle
Checking the Differential Oil Level 10 - 1
Changing the Differential Oil 10 - 1
Checking the Hub Oil Levels 10 - 2
Changing the Hub Oil 10 - 2
Rear Axle
Changing the Oil 11 - 2
Tyres and Wheels
General 12 - 1
Tyre Inflation 12 - 1
Pressures, Speeds and Loads See Operator Handbook
Checking and Adjusting Wheel Alignment 12 - 2
Track Width 12 - 3
Checking Wheel Nut Torques 12 - 3
Lock Stops 12 - 3
Fender Adjustment 12 - 4
Brakes
Checking and Renewing Foot Brake Pads 13 - 1
Checking and Renewing the Parking Brake Pads 13 - 2
Checking the Foot Brake Fluid Level 13 - 3
Checking the Trailer Air Tank 13 - 3
Checking the Air Tank Warning Lights 13 - 5
Cleaning the Trailer Brake Control Line Air Filter See Section G
Engine
Changing the Oil and Filter 14 - 2
Draining/Renewing Fuel Pre-Filter
(Early Renewable Element Type) 15 - 1
Renewing Fuel Pre-Filter (One-piece Type) 15 - 1
Draining the Fuel Pre-Filter
3200, 3200 Plus, 3230, 3230 Plus 15 - 2
Changing the Fuel Pre-Filter Element
3200, 3200 Plus, 3230, 3230 Plus 15 - 2
Draining the Fuel Filter 15 - 3
Changing the Fuel Filter Element 15 - 4
Bleeding the Fuel System
3170, 3170 Plus 15 - 5
3190, 3190 Plus, 3220, 3220 Plus 15 - 6
3200, 3200 Plus, 3230, 3230 Plus 15 - 8
Checking the Coolant Level 16 - 1
Coolant Mixtures 16 - 1
Draining & Refilling the Coolant 16 - 2
Cleaning the Radiator and Coolers 16 - 3
Fan Belt 16 - 4
Changing the Air Filter Elements 17 - 1
Cleaning the Pre-Cleaner (optional) 17 - 2
*

1 - 1
9803/8030
Section 3
1 - 1
Issue 2*
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 Engine Oil EP 15W/40
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: 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
- 20 °C to 20 °C (-4 °C to 68 °F).
Engine Oil Specification (N. America)
Recommended Oil
JCB Engine Oil EP 15W/40
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: 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
-10 °C to 50 °C (14 °F to 122 °F)
JCB Engine Oil 10W/30
SAE10W/30, API CE/SF
- 20 °C to 20 °C (-4 °C to 68 °F).
Engine Oil
*
*

1 - 2
9803/8030
Section 3
1 - 2
Issue 2*
Fluids, Capacities and Lubricants
ITEM CAPACITY FLUID/LUBRICANT MINIMUM NTERNATIONAL
Litres (UK Gal) SPECIFICATION
Fuel 350 (77) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) - 3200/3230 17.5 (3.9) See Engine Oil (All Machines) at the
Engine (Oil) - All Others 15 (3.3) beginning of this section
Engine (Coolant) 33 (7.3) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
Summer Coolant/water
(See Coolant Mixtures)
PTO, Speed and
Range Boxes 42 (9.3) JCB Super Universal Agricultural Oil API-GL-4, MIL-L-2105
(combined)
Front Axle
Housing 20 (4.4) JCB Gear Oil HP90 API-GL-5, MIL-L-2105C
Hubs (x2) 2.5 (0.55)
Rear Axle 27 (6.0) JCB Gear Oil HP90 API-GL-5, MIL-L-2105C
Brake System JCB Brake Fluid Dot 4 SAE J1703 DOT 4
Front 0.75 (0.17)
Rear 0.75 (0.17) !! CAUTION
Do not use ordinary hydraulic fluid in the
brake system.
13-3-2-6
Hydraulic System 120 (26.4) JCB Hydraulic Fluid HP46 ISO VG46
- see Note 1 (Above 38 °C, 100 °F)
JCB Hydraulic Fluid HP32 ISO VG32
(Below 38 °C, 100 °F)
Grease Points --- JCB HP Grease Lithium complex NLGI No. 2
consistency including extreme
pressure additives
Air Conditioning System
- Refrigerant 1.56kg (3lb 7oz) HFC R134a CH2 FC F3
- Compressor Lubricant 0.24 (0.05) Polyalkalineglycol PAG SP20
Front PTO Transfer
Box (optional) 3.0 (0.67) JCB Gear Oil HP90 API-GL-5, MIL-L-2105C
Note 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank.
*
*
*
*
*

1 - 3
9803/8030
Section 3
1 - 3Fluids, Capacities and Lubricants (N. America)
ITEM CAPACITY FLUID/LUBRICANT MINIMUM INTERNATIONAL
US Gal (Liters) SPECIFICATION
Fuel
92.5 (350) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) - 3200/3230 4.6 (17.5) See Engine Oil (All Machines) at the
Engine (Oil) - All Others 4 (15) beginning of this section
Engine (Coolant) 8.77 (33.0) JCB Four Seasons Antifreeze & Summer ASTM D3306-74
Coolant/water (See Coolant Mixtures)
PTO, Speed and
Range Boxes 11.2 (42.0) JCB AG Transmission Fluid API-GL-4, MIL-L-2105
(combined)
Front Axle
Housing 5.3 (20.0) JCB Gear Oil HP90 API-GL-5, MIL-L-2105C
Hubs (x2) 0.66 (2.5)
Rear Axle 7.1 (27.0) JCB Gear Oil HP90 API-GL-5, MIL-L-2105C
Brake System JCB Brake Fluid Dot 4 SAE J1703 DOT 4
Front 0.2 (0.75)
Rear 0.2 (0.75)
!! CAUTION
Do not use ordinary hydraulic oil in the
brake system.
13-3-2-6
Hydraulic System 31.7 (120) JCB Hydraulic Fluid HP46 ISO VG46
- see Notice 1
Grease Points --- JCB HP Grease Lithium complex NLGI No. 2
consistency including extreme
pressure additives
Air Conditioning System
- Refrigerant 3lb 7oz (1.56kg) HFC R134a CH2 FC F3
- Compressor Lubricant 0.06 (0.24) Polyalkalineglycol PAG SP20
Front PTO Transfer
Box (optional) 0.8 (3.0) JCB Gear Oil HP90 API-GL-5, MIL-L-2105C
Notice 1: The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic
tank.
Notice 2: It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
*
Issue 2*
*
*
*
*
*

1 - 4
It is most important that you read and understand this
information and the publications referred to. Make sure all
your colleagues who are concerned with lubricants read it
too.
HYGIENE
JCB lubricants are not a health risk when used properly for
their intended purposes.
However, excessive or prolonged skin contact can remove
the natural fats from your skin, causing dryness and
irritation.
Low viscosity oils are more likely to do this, so take special
care when handling used oils, which might be diluted with
fuel contamination.
Whenever you are handling oil products you should maintain
good standards of care and personal and plant hygiene. For
details of these precautions we advise you to read the
relevant publications issued by your local health authority,
plus the following.
STORAGE
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled containers.
HANDLING
New Oil
There are no special precautions needed for the handling or
use of new oil, besides the normal care and hygiene
practices.
Used Oil
Used engine lubricants contain harmful contaminants. In
laboratory tests it was shown that used engine oils can
cause skin cancer.
Here are precautions to protect your health when handling
used engine oil:
1 Avoid prolonged, excessive or repeated skin contact
with used engine oils.
2 Apply a barrier cream to the skin before handling used
engine oil.
3 Note the following when removing oil from skin:
a Wash your skin thoroughly with soap and water.
b Using a nail brush will help.
c Use special hand cleansers to help clean dirty
hands.
d Never use petrol, diesel fuel, or paraffin for washing.
e Avoid skin contact with oil soaked clothing.
f Don't keep oily rags in pockets.
g Wash dirty clothing before re-use.
h Throw away oil-soaked shoes.
FIRST AID - OIL
Eyes
In the case of eye contact, flush with water for 15 minutes. If
irritation persists, get medical attention.
Swallowing
If oil is swallowed do not induce vomiting. Get medical
advice.
Skin
In the case of excessive skin contact, wash with soap and
water.
SPILLAGE
Absorb spilled oil with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a chemical
disposal area.
Fires
!! WARNING
Do not use water to put out an oil fire. This will only
spread it because oil floats on water.
Extinguish oil and lubricant fires with carbon dioxide, dry
chemical or foam. Fire fighters should use self contained
breathing apparatus.
7-3-1-3/1
WASTE DISPOSAL
All waste products should be disposed of in accordance
with all the relevant regulations.
The collection and disposal of used oil should be in
accordance with any local regulations. Never pour used oil
into sewers, drains or on the ground.
9803/8030
Section 3
1 - 4
Issue 1
Lubricants - Health and Safety

2 - 1
!! WARNING
Maintenance must be done only by suitably qualified and
competent persons. Before doing any maintenance
make sure the machine is safe. It should be correctly
parked on firm level ground.
To prevent anyone starting the engine, remove the
starter key. Disconnect the battery and chock the
wheels when you are working beneath the machine.
If you do not take these precautions you could be killed
or injured.
9-3-1-1
Every 10 Operating Hours or Daily
whichever occurs first
Clean
1 Machine generally.
Drain
2 Empty hydraulic coupling drain reservoir (if fitted).
3 Fuel filter.
4 Trailer air tank.
Check (Engine Stopped)
5 Generally for damage.
6 Engine oil level and condition.
7 Check radiator and coolers for blockage and clean if
required.
8 Engine coolant level and condition.
9 Fuel system for leaks and contamination.
10 Air cleaner and air inlet hose condition and security.
11 Fan belt condition.
12 Crankcase Breather Condition.
13 Hydraulic fluid level.
14 Hydraulic system for leaks.
15 Machine generally for oil leaks (axles, engine,
transmission).
16 Gearbox oil level.
17 Tightness of wheel nuts.
18 Windscreen washer level.
19 Tyre pressures and condition.
20 Security of front weights (if fitted).
21 Seat belt condition and security .
22 Brake fluid levels.
Check (Engine Running)
23 Instrument readings and warning lights.
24 Operation of all electrical equipment.
25 Exhaust for excessive smoke.
26 Operation of clutch and footbrakes.
27 Operation of steering.
28 Operation of transmission.
29 Operation of 3-point linkage
30 Operation of front linkage (optional equipment).
31 Parking brake operation.
32 Throttle and stop controls.
Every 50 Operating Hours or Weekly
Do the Daily jobs plus:
Drain
1 Fuel pre-filter.
Note: Some machines have a one-piece pre-filter which
cannot be drained.
Clean
2 Air filter dust valve.
3 Air conditioning compressor drive belt.
4 Front PTO transfer gearbox oil level (optional
equipment).
5 Brake pad condition.
6 Cab air filter (clean if required).
7 Propshaft security.
Grease
8 Rear PTO drive shaft splines and universal joints.
9 Rear PTO drive shaft bearings.
10 Rear axle propshaft.
11 Front axle propshaft.
12 Front PTO drive shaft (if fitted).
13 Rear anti-roll bar joints.
14 Rear hydraulic lift cross-shaft.
15 Rear hydraulic lift ram pivots.
16 Front agricultural 3 point linkage cross shaft (if fitted).
17 Front agricultural 3 point linkage lift ram pivots (if fitted).
18 Steering swivels.
19 Steering column universal joints.
20 Suspension cylinder pivots.
21 3-point linkage lift rods and top link.
22 Automatic trailer coupling (if fitted).
23 Roller drawbar (if fitted).
Note: It is essential that drive shaft and propshaft joints are
lubricated as specified.
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.
Drain
8 Fuel pre-filter (early machines only).
Note: Later machines have a one-piece pre-filter which
cannot be drained.
9 Coolant level/leaks and antifreeze strength.
10 Fuel system for leaks and contamination.
11 Intercooler hose clamp security.
12 Air cleaner and air inlet hose condition and security.
13 Fuel system pipework routing and security.
continued over page
9803/8030
Section 3
2 - 1
Issue 5*
Service Schedules
*

2 - 2
First 100 Hours Dealer Service (continued)
Check (Engine Stopped) - continued
14 Fan belt tension and condition.
15 Air conditioning compressor belt tension.
16 Gearbox oil level.
17 Transmission oil cooler/pipework condition, leakage,
routing and security.
18 Front PTO gearbox oil level.
19 Propellor shaft security.
20 Tyre pressures.
21 Tightness of wheel nuts.
22 Hydraulic oil level.
23 Hydraulic oil cooler/pipework condition, leakage,
routing and security.
24 Brake fluid levels.
25 Brake pad security (service and parking).
26 Brake pipework routing and security.
27 Air system for leaks.
28 Panhard rod torque setting.
29 Rams/piston rods for damage/leaks.
30 Battery charge/terminal condition and tightness.
31 Wiring for chafing/routing.
32 Headlight alignment.
33 Windscreen washer level.
34 Neutral start operation (Including clutch and PTO's).
35 Door locks.
36 Check for error codes, (EMS, engine and ABS when
fitted), download, rectify and delete.
37 Steering axle wheel alignment.
38 Track rod and ball joint security.
Grease
39 Propellor shaft splines and universal joints.
40 Steering swivels.
41 Rear PTO shaft bearings.
42 3 point linkage.
43 Rear lift ram pivots.
44 Suspension cylinder pivots.
Check (engine running)
45 Exhaust smoke.
46 Throttle and stop controls.
47 PTO operation.
48 2/4WD drive and diff. lock selection.
49 Transmission low pressure circuit pressure maintaining
valve setting.
50 Transmission lubrication pressure.
51 Diff. lock pressure relief valve.
52 External hydraulics pressure relief valve.
53 Instrument readings and warning lights.
54 Operation of all electrical equipment.
55 Operation of clutch and footbrakes.
56 Operation of steering.
57 Operation of transmission.
58 Operation of 3-point linkage.
59 Operation of front linkage (optional equipment).
60 Rear axle/chassis clearance.
61 Height corrector valve operation.
62 Parking Brake operation.
63 Pick-up hitch operation.
64 Spool valve operation.
65 Re-calibrate splitter clutch packs
Every 250 Operating Hours or 3 Monthly
Do the Daily and 50 hour jobs plus:
Change
† Engine oil and filter.
† Applies only if recommended oil (see Engine Oil) or
Stratopore filter are not available. As an alternative to
the recommended oil the following (or similar) should
be used:
a -10oC to +50oC (14oF to 122oF) JCB Super Multigrade
15W/40 (SAE 15W/40, API CF4/SG)
b -15oC to +40oC (5oF to 104oF) JCB Super Mulitgrade
10W/30 (SAE 10W/30, API CF4/SG).
Every 500 Operating Hours or Six Months
Do the Daily jobs through to 250 hours plus:
1 Battery terminals condition and tightness.
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 Compressor housing for cracks and damage.
7 Compressor mountings for tightness.
8 Injection pump mountings for tightness.
9 Steering axle wheel alignment.
10 Headlamp alignment.
11 Panhard rod condition and torque tightness.
12 Track rod end and drag link ball joint security.
13 Steering damper condition and security.
14 Suspension control arms and ‘V’ link condition and
bolt torque.
15 Air system for leaks.
16 Brake air tank warning lights.
17 Brake caliper bolt torque.
18 Brake pad security (service and parking).
19 Parking brake adjustment.
20 Brake pipework security.
21 Condition of lift ram rods.
22 Coolant level/leaks, quality and antifreeze strength.
23 Intercooler hose clamp security.
24 Hoses and pipework for chafing and damage.
25 Neutral start operation.
26 Ram piston rods for damage/leaks.
27 Front axle oil level.
28 Rear axle oil level.
29 Transmission and hydraulic oil cooler/pipework
condition leakage and security.
30 Wiring for chafing/routing.
31 Download EMS Datalog.*
32 Download ABS error codes, rectify and delete.
33 Brake light switch input to ABS ECU using computer
diagnostic tool.
34 Download engine error codes, rectify and delete.
9803/8030
Section 3
2 - 2
Issue 3*
Service Schedules
*
*
*

2 - 3
Every 500 Operating Hours or Six Months
whichever occurs first (continued)
35 Idling speed.
36 Max. no load engine speed.
37 Suspension ride height and corrector valve operation.
38 Suspension pressure maintenance valve pressure.
39 Transmission low pressure circuit pressure maintaining
valve setting.
40 Differential lock pressure relief valve.
41 Pick-up hitch operation.
42 Rear axle/chassis clearance.
43 Spool valve operation.
44 Field speed control.
45 Selection speed of Selectronic range change
< 2 kph.
46 Check for electronic draft control faults and rectify.
Change
47 †Engine oil and filter.
48 Fuel pre-filter.
49 Hydraulic fluid filter element.
50 Transmission oil filter.
51 Fuel filter.
52 Front hub oil.
Clean
53 Air conditioning intake filter
† Applies only if recommended oil (see Engine Oil) and
Statopore filter are available. If these are not available
this job should be carried out every 250 hours,
reference T.I. 10/152 (see Every 250 Operating Hours
for suitable alternative oil).
Every 1000 Operating Hours or Yearly
1 ROPS structure.
2 Quality of coolant.
3 Fan belt tensioner.
4 Fan hub end play.
5 Transmission lubrication pressure (HPL and LPL).
6 MRV Pressure.
7 Splitter and wet clutch pack calibration.
8 ABS System test.
9 Steering relief valve pressure.
Change
10 Outer air filter element.
11 Gearbox oil and clean strainer.
12 Front axle oil.
13 Rear axle oil.
14 Air system drier dessicant canister.
Clean
15 Trailer brake control line air filter.
Every 2000 Operating Hours or 2 Years
Clean
1 Hydraulic tank suction strainers.
2 Rear suspension gas spring pressure.
3 Rear suspension accumulator pressure.
4 Engine vibration damper.
5 Compressor output line, air drier and pressure
regulator: check for carbon deposits and for air leaks.
6 Radiator hose condition.
7 Transmission accumulator pressure.
Change
8 Inner air filter element.
9 Coolant.
10 Brake system fluid.
11 Hydraulic fluid. (Unless sample indicates otherwise.)
Every 5000 Operating Hours or 4 Years
1 Engine valve clearances and adjust if necessary.
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.
9803/8030
Section 3
2 - 3
Issue 5*
Service Schedules
*

3 - 1
9803/8030
Section 3
3 - 1
Issue 2*
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, fuel system or electrical components,
especially draft control solenoids.
On ABS machines, take special care to avoid directing high
power water jets at the electrical connections to the front
and rear axles.
Inspect steelwork for damage. Note damaged paintwork for
future repair.
!! WARNING
Replace the seat belt with a new one if it is damaged, if
the fabric is worn, or if the machine has been in an
accident. Fit a new seat belt every three years regardless
of condition.
2-3-1-8
Inspect the seat belt for signs of fraying and stretching.
Check that the stitching is not loose or damaged. Check that
the buckle assembly is undamaged and works correctly.
Check that the belt mounting bolts are undamaged,
correctly installed and tightened.
Make sure all pivot pins are correctly in place and secured
by their locking devices.
Ensure that the steps and handrails are undamaged and
secure.
Check for broken or cracked window glass. Replace
damaged items.
Check all lamp lenses for damage.
Inspect the tyres for damage and penetration by sharp
objects.
Check that all safety decals are in place and undamaged, fit
new decals where necessary.
Checking Seat Belt Condition and Security
*
*

3 - 2
Routine Maintenance
9803/8030
3 - 2
Issue 3*
Bonnet
Section 3 Section 3
Opening the Bonnet
!! 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
1 Engage the parking brake, put the transmission in
neutral, stop the engine. Remove the starter key.
2 Release the latch by pulling up lever A.
3 The bonnet will rise automatically to the limit imposed
by the restraint cable if secured on the hook B or
fastener C (alternative fittings). This position will allow
access for routine maintenance. If more access is
required, release the restraint cable from the hook or
fasteners and allow the bonnet to rise fully open.
Closing the Bonnet
1 Pull the bonnet down by means of the cable and ensure
the cable is secured by the fasteners. To close the
latch, press the bonnet firmly down by means of lever
A.
716881
B
C
A
*

A286623
4 - 1
Routine Maintenance
9803/8030
4 - 1
Issue 2*
Greasing
Section 3 Section 3
General
Read and understand Lubricants - Health and Safety,
before greasing. You must grease the machine regularly to
keep it working efficiently. Regular greasing will also
lengthen the machine's working life. Refer to the Service
Schedules for the recommended frequencies.
Note: If working in muddy conditions the propshafts and
PTO driveshafts must be greased daily.
Note: The machine must always be greased after pressure-
washing or steam cleaning. Extra care must be taken to
ensure that propshaft universal joints and splines are
greased regularly.
Greasing should be done with a grease gun. Normally, two
strokes of the gun should be enough. Stop greasing when
fresh grease appears at the joint. Use only JCB HP Grease
or equivalent.
In the following illustrations the grease points are numbered.
Count them off as you grease them.
Refit the grease point dust caps after greasing.
Propshafts and PTO Driveshafts
!! WARNING
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
Front axle propshaft
Grease points 1 to 2.
Rear axle propshaft
Rear PTO drive shaft
Front PTO drive shaft (optional)
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 11. Do not exceed 2 to 3 strokes of the grease
gun.
8
9
0
2
5
7
4
6
!
3
1
*

4 - 2
Read the first page on Greasing for general information
about greasing.
Front Axle Steering Swivels
!! WARNING
13-3-1-1
Note: After initial greasing, turn the wheels from lock to lock,
then grease again to ensure full penetration.
9803/8030
Section 3
4 - 2
Issue 1
Greasing
1
2
3
4

4 - 3
about greasing.
Agricultural Front 3-Point Linkage
(Optional)
about greasing.
!! 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 at points 1 to 3.
Note: Whenever the coupling has been pressure-washed it
must always be greased.
Automatic Trailer Coupling (if fitted)
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.
9803/8030
Section 3
4 - 3
Issue 1
Greasing
1
2
33
S170201

4 - 4
about greasing.
!! WARNING
engaged.
13-3-1-9
Note: Ladder hitch and trailer coupling omitted for clarity.
Rear Suspension Cylinder Pivots
Hydraulic Lift and 3-Point Linkage
Hydraulic lift cross-shaft
Grease points 5 and 6.
Hydraulic lift rams
Three point linkage lift rods
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.
Stabilizers (standard type)
Grease at point 17.
Note: Where standard type stabilizers are fitted to both
sides of the machine, there will be a grease point on each
one.
Rear PTO Drive Shaft Bearing
Grease point 18. Do not exceed 2 to 3 strokes of the grease
gun.
9803/8030
Section 3
4 - 4
Issue 1
Greasing
BABAA B A B
1 3
!
%
2
9
£
7 8
65
0
$
^
4
@
&
A B
*
418170

4 - 5
Steering Column Universal Joints
about greasing.
!! WARNING
engaged.
Block all four wheels before getting under the machine.
13-3-1-9
Note: It may be necessary to turn the steering wheel to put
the grease nipples in an accessible position.
Grease at point 1 from underneath the machine.
Grease at points 2 and 3 from under the bonnet.
Rear Anti-roll Bar Ball Joints
!! WARNING
13-3-1-1
9803/8030
Section 3
4 - 5
Issue 2*
Greasing
262210
4
2
5
3
A409831
1
*

4 - 6
Roller Drawbar (if fitted)
!! WARNING
engaged.
13-3-1-9
Smear surface 3 with grease.
9803/8030
Section 3
4 - 6
Issue 1
Greasing
BABAA B A B
3
1
2

5 - 1
Checking the ROPS Structure
!! WARNING
The cab on this machine is designed to give the operator
protection in the event of the machine rolling over
(ROPS). The following points must be strictly observed.
1 If the machine has been in an accident which has
damaged the ROPS structure, the machine must not
be used until the structure has been renewed. If there
is any doubt about the strength of the ROPS
structure, it must be renewed. The operator could be
killed or seriously injured as a result of using a
machine with a damaged or missing ROPS.
2 The ROPS structure must not be modified except as
approved by JCB. Unauthorised modifications may
result in weakening of the structure.
3 Always use JCB supplied parts to mount the ROPS
structure on the machine. The use of unapproved
components could reduce the protection given by the
structure.
4 Make sure the ROPS structure mounting bolts are
not damaged and are tightened to the correct torque.
Always renew the bolts and nuts when the structure
is renewed following an accident. It is essential that
the correct tensile strength of bolt and nut is always
used.
BF 8-1/1
Check the structure for damage.
Check that the four mounting bolts are installed and
undamaged. Check that torque tightness of nuts A and B is
correct (see Table below). Tighten them to the correct
torque if necessary.
Zinc-Plated Fasteners (colour: golden)
Nm kgf m lbf ft
375 38 277
Dacromet Fasteners (colour: mottled silver)
Nm kgf m lbf ft
365 37 269
Routine Maintenance
9803/8030
5 - 1
Issue 2
Cab
Section 3 Section 3
420410
A B

5 - 2
9803/8030
Section 3
5 - 2
Issue 1
Cab
Checking the 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.
A293830
X

5 - 3
Cleaning the Standard 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 or very dusty
conditions, 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 change 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
1 Unscrew the two quarter-turn fasteners A and remove
closing panel B. Remove the two screws C and pull out
the filter D. Check condition of filter and renew if split or
worn.
2 If the filter is undamaged, pull foam pre-cleaner E
(fitted to later filters) out of the filter casing, wash it in
low suds detergent and blow dry with compressed air
at a maximum pressure of 5.5 bar (80 lbf/in2
). Use the
same compressed air to blow dirt out of filter D in the
opposite direction to the arrows marked on the filter.
3 Check and clean the filter sealing face on the cab body.
4 Refit the pre-cleaner and fit the filter into the cab
aperture using two screws C. Refit the closing panel B.
Changing the Heavy Duty Carbon Filter
Note: Carbon filters must not be cleaned. Keep a log of the
hours used and change 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
1 Unscrew the two quarter-turn fasteners F and remove
closing panel G. Remove the two screws H and pull out
the filter J.
2 The new filter is supplied with a separate foam seal
that has a self-adhesive face K covered by protective
film. Clean the contact face of the new filter L, peel off
the protective film from the foam seal and press the
seal into position on the filter.
3 Check and clean the seal contact face on the cab body.
4 Fit the filter into the cab aperture using two screws H.
Refit the closing panel G.
9803/8030
Section 3
5 - 3
Issue 3
Air Conditioning
420960
417800
A B
C
D
E
AIR FLOW
746220
F G
K
H
J
L

5 - 4
Adjusting the Compressor Belt
(3170/3170 Plus, 3190/3190 Plus &
3220/3220 Plus)
Note: On other models of Fastrac covered by this manual,
there is no separate belt for the air conditioning compressor.
It is driven by the fan belt.
1 Stop the engine.
2 Open the bonnet.
!! WARNING
Make sure the engine cannot be started. Disconnect the
battery before doing this job.
2-3-3-5
3 Loosen the mountings
Loosen fasteners A, B and C.
4 Adjust the belt tension
Position the compressor so that there is 10mm (0.4 in)
slack on the longest run of the belt.
5 Tighten the mountings
Retighten fasteners A, B and C.
!! 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
9803/8030
Section 3
5 - 4
Issue 3*
Air Conditioning
417580
CC
AA BB
*
*

Battery Warning Symbols
The following warning symbols may be found on the battery.
Symbol Meaning
Keep away from children.
Shield eyes.
No smoking, no naked flames,
no sparks
Explosive Gas.
Battery acid.
Note operating instructions.
6 - 1
!! CAUTION
Damaged or spent batteries and any residue from fires
or spillage should be put in a closed acid proof
receptacle and must be disposed of in accordance with
local environmental waste regulations.
INT-3-1-12
!! WARNING
Batteries give off an explosive gas. Do not smoke when
handling or working on the battery. Keep the battery
away from sparks and flames.
Battery electrolyte contains sulphuric acid. It can burn
you if it touches your skin or eyes. Wear goggles. Handle
the battery carefully to prevent spillage. Keep metallic
items (watches, rings, zips etc) away from the battery
terminals. Such items could short the terminals and burn
you.
Set all switches in the cab to OFF before disconnecting
and connecting the battery. When disconnecting the
battery, take off the earth (-) lead first.
When reconnecting, fit the positive (+) lead first.
Re-charge the battery away from the machine, in a well
ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you have
installed the battery in the machine, wait five minutes
before connecting it up.
First Aid - Electrolyte
Do the following if electrolyte:
GETS INTO YOUR EYES
Immediately flush with water for 15 minutes, always get
medical help.
IS SWALLOWED
Do not induce vomiting. Drink large quantities of water
or milk. Then drink milk of magnesia, beaten egg or
vegetable oil. Get medical help.
GETS ONTO YOUR SKIN
Flush with water, remove affected clothing. Cover burns
with a sterile dressing then get medical help.
5-3-4-3/1
9803/8030
Section 3
6 - 1
Issue 1
Electrics

6 - 2
Checking the Battery Electrolyte Level
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
the battery access panel A.
2 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.
!! WARNING
Do not top the battery up with acid. The electrolyte could
boil out and burn you.
2-3-4-6
Note: When two batteries are fitted on the machine, they are
connected in parallel. When fitting the cables, ensure that
they are connected as shown on the illustration.
9803/8030
Section 3
6 - 2
Issue 1
Electrics
A

Jcb 3230 plus fastrac service repair manual

Jcb 3230 plus fastrac service repair manual

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