Service Manual: Fastrac

General Information 1
Care & Safety 2

Routine Maintenance 3
Service Optional Equipment A
Manual Body & Framework B
Electrics C
Fastrac Controls D
2115, 2125, 2135,
2140, 2150
Hydraulics E
From Serial No 0738000
Transmission F
3155, 3185
From Serial No 0640000 Brakes G
Published by the
TECHNICAL PUBLICATIONS DEPARTMENT
of
JCB SERVICE LTD;
World Parts Centre,
Steering H
Waterloo Park
Uttoxeter, Staffordshire
ST14 7BS
Suspension S
Publication No. 9803/8020
Issue 17
Engine T
Introduction
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training
by JCB Technical Training Department.
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated
with the maintenance and repair of hydraulic earthmoving equipment.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of
course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe
connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all
else
SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = 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.
9803/8020 Issue 1
Section 1 General Information Section 1
i i
Contents Page No.
Machine Identification Plate 1-1

Typical Vehicle Identification Number (VIN) 1-1
Typical Engine Identification Number 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 to 2 - 6
Sealing and Retaining Compounds 3-1
Service Tools Numerical List 4-1
* Service Tools
Body and Framework 5-1
Electrics 6-1
Hydraulics 7-1
Transmission 8-1
Brakes 9-1
Steering 9-1
Suspension 9-2
Engine 9-2
Moving a Disabled Machine

General 10 - 1
Preparation for Towing 10 - 1
Transporting the Machine 10 - 2
9803/8020 Issue 4*
1-1 1-1
Machine Identification Plate Typical Engine Identification Number
Each machine has an identification plate located at X. The YH 50532 U 123456 X

Vehicle Identification Number (VIN), and the serial numbers
of the engine and transmission are stamped on the plate.
G H J K L
Typical Vehicle Identification No. (VIN) G = Engine Type:-

YB = Turbocharged 1000 Series, 6 cylinder
SLP FT 11 3 30 0738010 YD = Intercooled 1000 Series, 6 cylinder
YH = Turbocharged New 1000 Series, 6 cylinder
YK = Intercooled New 1000 Series, 6 cylinder
H = Build List Number
A B C D E F
(see Engine Technical Data for details)
J = Country of Origin
A = Manufacturing Code
K = Engine Serial Number
B = Machine Range
L = Year of Manufacture
* C = Engine Code:
07 = 1006-6T4
* Note: Fastrac 2140 and 3185 engines are identified by the
10 = 6BTA
model number and a separate engine serial number.
13 = New 1000 Series, Rating 1941/2300 (2115)
Unit Identification
The serial number of each major unit is also stamped on the
20 = Fastrac 2140 engine
unit itself as shown below. If a major unit is replaced by a
* D = Transmission Speed Code:
new one, the serial number on the plate will be wrong. Either
3 = 30 km/h
stamp the new number of the unit on the identification plate,
4 = 40 km/h
or simply stamp out the old number. This will prevent the
5 = 55 km/h
wrong unit number being quoted when replacement parts
6 = 65 km/h
are ordered.
7 = 75 km/h
C = 40 km/h (Fastrac 2140 only
* Fastrac 2115, 2125, 2135, 2150 and 3155 Engines M
E = Vehicle Max. Speed Code:
Fastrac 2140 and 3185 Engines T
30 = 30 km/h
Transmission (Assembly of all three gearboxes) N
40 = 40 km/h
Speed Gearbox P
50 = 50 km/h
Front Axle R
80 = 80 km/h
Rear Axle S
F = Sequential Serial Number
T
S M
N R
X
P
194601
9803/8020 Issue 3*
2-1 Torque Settings 2-1
* Introduction - Zinc Plated Fasteners and Dacromet Fasteners

The JCB Fastrac 3000 series from serial number 642494 and the Fastrac 2000 series from serial number 740276 are
assembled using an improved type of corrosion resistant finish on the external fasteners. This type of finish is called Dacromet
and replaces the original Zinc and Yellow plating used on earlier machines.
The two types of fasteners can be readily identified by colour and part number suffix as follows:
Fastener Type 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, when servicing the Fastrac it
is important that you are aware of this change of policy and that the information you are using is relevant to the type of
fasteners that you have.
Note: A Dacromet bolt should not be used in conjunction with a Zinc and Yellow plated nut, as this could change the torque
characteristics of the torque settings further. For the same reason, a Dacromet nut should not be used in conjunction with a
Zinc and Yellow plated bolt.
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
Note: Dacromet bolts, due to their high corrosion resistance are used areas where rust could occur. Dacromet bolts are only
used for external applications.
9803/8020 Issue 3*
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 Metric - All Internal Hexagon Headed Cap Screws
Bolt size Torque Settings Diameter Torque

Dia. (mm) Hexagon Nm kgf m lbf ft mm Nm kgf m lbf ft
(A/F) mm
M5 (5) 8 7 0.7 5 M3 2 0.2 1.5

M6 (6) 10 12 1.2 9 M4 6 0.6 4.5
M8 (8) 13 28 3.0 21 M5 11 1.1 8
M10 (10) 17 56 5.7 42 M6 19 1.9 14
M12 (12) 19 98 10 72 M8 46 4.7 34
M16 (16) 24 244 25 180 M10 91 9.3 67
M18 (18) 27 350 36 258 M12 159 16.2 117
M20 (20) 30 476 48 352 M16 395 40 292
M24 (24) 36 822 84 607 M18 550 56 406
M30 (30) 46 1633 166 1205 M20 770 79 568
M36 (36) 55 2854 291 2105 M24 1332 136 983
Metric Grade 10.9 Bolts Verbus Ripp Bolts
Bolt size Torque Settings

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
A343780
M12 (12) 19 137 14 101
M16 (16) 24 343 35 253
M20 (20) 30 657 67 485 Torque settings for these bolts are determined by the
M24 (24) 36 1157 118 853 application. Refer to the relevant procedure for the
required settings.
Note: In most cases Verbus Ripp bolts should not be re-

used. If one is disturbed it should be removed and a new
one fitted in its place. For details of exceptions to this
general rule, see T.I.’s 10/140 (F161/N. Am) and 10/141
(F162 N. Am).
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
9803/8020 Issue 1*
Dacromet Fasteners (mottled silver finish)

Use only where no torque setting is specified in the text.
NOTE: DACROMET FASTENERS ARE LUBRICATED AS PART OF THE PLATING PROCESS: DO NOT LUBRICATE.
Metric Grade 8.8 Bolts

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
9803/8020 Issue 1*
Dacromet Fasteners (mottled silver finish) - List of Torque Settings

This list represents those fasteners which have been affected by the change from zinc-plated to Dacromet but are not
mentioned in the service manual. The settings apply to 2000 and 3000 series machines unless otherwise stated.
Location: Rockinger Hitch Bolt Location: Gearbox Crossmember Bolt: Rear Crossmember
Nm: 392 kgfm: 40 lbf ft: 289 Nm: 200 kgfm: 20 lbf ft: 148 Nm: 392 kgf m: 40 lbf ft: 289
A402280
A402030
Bolt: Left Hand Pannier Step Bolt: Right Hand Pannier (rear) Bolt: Right Hand Pannier (front)
Nm: 47.5 kgf m: 4.8 lbf ft: 35 Nm: 80 kgf m: 8.2 lbf ft: 59 Nm: 47.5 kgf m: 4.8 lbf ft: 35
(2000 series machines only) (2000 series machines only)
A402200 A402190 A402160
Bolt: Front Wrapper (top/bottom) Bolt: Rear Lower Crossmember Bolt: Lower Link Bolt (Hex Head)
Nm: 392 kgf m: 40 lbf ft: 289 Nm: 80 kgf m: 8.2 lbf ft: 59 Nm: 392 kgf m: 40 lbf ft: 289
(2000 series machines only)
A402060
A402050
A402040
9803/8020 Issue 1*
Dacromet Fasteners (mottled silver finish) - List of Torque Settings (cont.)

Location: Lower Link Bolt (capscrew) Location: Tower Casting to Axle Location: Front Lower Crossmember
Nm: 654 kgf m: 67 lbf ft: 482 Nm: 392 kgf m: 40 lbf ft: 289 Nm: 115 kgf m: 12 lbf ft: 85
A402010
A402140 A401990
Location: Rear Lower Crossmember Location: Fuel Tank Support Strap Location: Front P.T.O. Box
Nm: 200 kgf m: 20 lbf ft: 148 Nm: 47.5 kgf m: 4.8 lbf ft: 35 Nm: 200 kgf m: 20 lbf ft: 148
A402260 A402090
A402230
Location: Front Axle Upper Arm Location: Steershaft Bearing Location: Steershaft Intermediate UJ
Mounting Bracket Nm: 28 kgf m: 2.9 lbf ft: 21 Nm: 38 kgf m: 3.9 lbf ft: 28
Nm: 200 kgf m: 20 lbf ft: 148 (3000 series machines only) (3000 series machines only)
A402270
9803/8020 Issue 2
Dacromet Fasteners (mottled silver finish) - List of Torque Settings (cont.)

* Location: Front Anti-Roll Bar Location: Front Anti-Roll Bar Location: 4.W.S. only rear anti-roll
Fasteners: Insulators Fasteners: Pivot Bolt bar crossmember
Nm: 47.5 kgf m: 4.8 lbf ft: 35 Nm: 278 kgf m: 28 lbf ft: 205 Nm: 80 kgf m: 8.2 lbf ft: 59
A402080
A402130
Location: Rear Anti-Roll bar Location: Front Anti-Roll Bar

mounting bracket Fasteners: Pivot Bolt
Nm: 392 kgf m: 40 lbf ft: 289 Nm: 200 kgf m: 20 lbf ft: 148
A402120
A402110
Location: Front Engine Mounting Location: Header Tank Clamp Plate

Nm: 200 kgf m: 20 lbf ft: 148 Nm: 30 kgf m: 3 lbf ft: 22
A402290
A402150
9803/8020 Issue 2*
3-1 3-1
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
9803/8020 Issue 2*
4-1 4-1
Service Tools Numerical List

Page No.
1370/0901Z Nut M24 9-1 892/00272 Adapter 7-1
1406/0021 Bonded Washer 7-1 892/00273 Sensor Head 7-1
1604/0006 Adapter 7-1 892/00274 Adapter 7-2
1604/0008 Adapter 7-1 892/00275 Adapter 7-1
1606/0012 Adapter 7-1 892/00276 Adapter 7-1
1606/0015 Adapter 7-1 892/00277 Adapter 7-1
1612/0006 Adapter 7-1 892/00278 Gauge 0 - 40 bar 7-2
* 331/64246 Tool Kit for Non-return Valve 7-2 892/00279 Gauge 0 - 400 bar 7-2
* 331/64265 etaining Bush for Valve spool 7-2 892/00281 Avo Meter 6-1
4101/0251 JCB Threadlocker and Sealer 3-1 892/00282 Shunt 6-1
4101/0451 JCB Threadlocker 3-1 892/00283 Tool Kit Case 6-1
4101/0552 JCB Threadlocker and Sealer 892/00284 Digital Tachometer 6-1
(High Strength) 3-1 892/00285 Oil Temperature Probe 6-1
4101/0651 JCB Retainer (High Strength) 3-1 892/00286 Surface Temperature Probe 6-1
4102/0551 JCB High Strength Threadlocker 3-1 892/00293 Connector Pipe 7-1
4102/0901 JCB Clear Silicone Sealant 3-1 892/00294 Connector Pipe 7-1
4102/1212 JCB Multigasket 3-1 892/00298 Fluke Multimeter 6-1
4102/1951 JCB Threadseal 3-1 892/00311 Brake Test Kit 8-4
4102/2210 Clayton System Seal SC1251 3-1 892/00312 Dummy End Plate 8-2
4102/2309 Black Polyurethane Sealant 3-1 892/00313 Clutch Alignment Tool 8-1
4103/2109 Ultra Fast Adhesive 3-1 892/00314 Accumulator Adapter 9-1
4104/0251 JCB Activator (Aerosol) 3-1 892/00315 Engine Support Brackets 8-1
4104/0253 JCB Activator (Bottle) 3-1 892/00318 Hose and Adapter Kit 7-2
4104/1557 JCB Cleaner/Degreaser 3-1 892/00333 Heavy Duty Socket, 19 mm A/F 8-2
4104/1203 Active Wipe 205 (250 g) 3-1 892/00334 Gland Seal Fitting Tool 7-2
4104/1206 Active Wipe 205 (30 ml) 3-1 892/00706 Test Probe 7-2
4104/1310 Hand Cleaner 5-1 892/00800 Splitting Frame 8-1
4201/4906 Black Primer 3-1 892/00801 Clutch spanner 5-3
454/30056 Spacer 13.80 mm 8-4 892/00802 Rotor puller set 5-3
477/00437 Gearbox Lifting Adapter 8-2 892/00803 Rotor installer set 5-3
721/00664 Connecting Lead (Psion Workabout) 6 - 1 892/00807 Front plate puller 5-3
721/10885 Harness - Diagnostic (J1939) 6-2 892/00808 Shaft protector 5-3
816/15118 Test Adapter 7-1 892/00812 Drive Coupling Spanner 8-1
816/20008 Adapter 7-1 892/00817 Heavy Duty Socket, 17 mm A/F 8-2
816/20013 Adapter 7-1 892/00818 Heavy Duty Socket, 22mm A/F 8-2
816/55038 Adapter/Test Point 7-1 892/00819 Heavy Duty Socket, 15 mm A/F 8-2
816/55040 Adapter/Test Point 7-1 892/00842 Glass Lifter 5-1
892/00041 Deglazing Tool 9-2 892/00843 Folding Stand 5-1
892/00078 Connector 7-1 892/00844 Long Knife 5-2
892/00137 Micro Bore Hose 7-2 892/00845 Cartridge Gun 5-1
892/00174 Measuring Cup 8-2 892/00846 Glass Extractor Handles 5-2
892/00179 Bearing Press 8-1 892/00847 Nylon Spatula 5-3
892/00180 Seal Fitting Tool 9-1 892/00848 Wire Starter 5-2
892/00181 Replacement Plastic Boss 9-1 892/00849 Braided Cutting Wire 5-2
892/00223 Hand Pump 7-2 892/00864 PD 90 Axle Locknut Spanner 8-4
892/00224 Impulse Extractor 8-2 892/00871 Frame (Puller Adapter Assembly) 9-1
892/00225 Adapter for Impulse Extractor 8-1 892/00874 Brace (Puller Adapter Assembly) 9-1
892/00253 Pressure Test Kit 7-1 892/00875 Bar M24 (Puller Adapter Assembly) 9-1
892/00255 Adapter/Test Point 7-1 892/00876 Block (Puller Adapter Assembly) 9-1
892/00256 Adapter/Test Point 7-1 892/00882 Socket 6-1
892/00257 Adapter/Test Point 7-1 892/00883 Spanner (Steer Box Input Shaft Nuts) 9-1
892/00258 Adapter/Test Point 7-1 892/00884 ‘C’ Spanner (Steer Box Input Shaft
892/00259 Adapter/Test Point 7-1 Nuts) 9-1
892/00260 Adapter/Test Point 7-1 892/00892 Speed Gearbox Locking Tool 8-3
892/00261 Adapter/Test Point 7-1 892/00916 Spring Compressor 8-3
892/00262 Adapter/Test Point 7-1&7-2 892/00918 Setting Tool Kit 8-4
892/00263 Adapter/Test Point 7-1 892/00945 Sleeve for M30 Pinion 8-4
892/00264 Adapter/Test Point 7-1 892/00956 Timing Pin for Fuel Injection Pump 9-2
892/00265 Adapter/Test Point 7-1 892/01033 Data Link Adapter Kit 6-2
892/00268 Flow Monitoring Unit 7-1 892/01045 Peg Socket - Wet Clutch 8-5
892/00269 Sensor Head 7-1 892/01046 Mandrel - Wet Clutch 8-5
892/00270 Load Valve 7-1 892/01047 Jig - Wet Clutch 8-5
892/00271 Adapter 7-1
9803/8020 Issue 8*
4-2 4-2
Service Tools Numerical List (continued)

Page No.
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 8-5
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
* 892/01092 Wheel Hub Service Kit 8-5
926/15500 Rubber Spacer Blocks 5-3
992/12300 Mobile Oven 5-1
992/12400 Static Oven 5-1
992/12600 Static Oven 5-1
992/12800 Cut-out Knife 5-2
992/12801 'L' Blades 5-2
993/45400 Torque Multiplier 8-2
993/55700 Direct Glazing Kit 3-1
993/59300 Pressure Test Adapter and Clamp 8-3
993/70111 Break-back Torque Wrench 8-4
993/85700 Battery Tester 6-1
997/11000 Drive Head Setting Bracket 8-4
997/11100 Adapter for M24 Pinion 8-4
The following parts are replacement items for kits and would
normally be included in the relevant kit numbers.
Replacement items for kit no. 892/00253
892/00201 Gauge 0 - 20 bar 7-1
892/00202 Gauge 0 - 40 bar 7-1
892/00203 Gauge 0 - 400 bar 7-1
892/00254 Hose 7-1
* 993/69800 Seal Kit 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
9803/8020 Issue 6*
5-1 5-1
Service Tools
Section B - Body and Framework
S186240 S186270
Hand Cleaner - special blend for the removal of Cartridge Gun - hand operated - essential for the
polyurethane adhesives. application of sealants, polyurethane materials etc.
JCB part number - 4104/1310 (454g; 1lb tub) JCB part number - 892/00845
'
S186250
12V Mobile Oven - 1 cartridge capacity - required to

pre-heat adhesive prior to use. It is fitted with a male S186280
plug (703/23201) which fits into a female socket Folding Stand for Holding Glass - essential for
(715/04300). preparing new glass prior to installation.
JCB part number - 992/12300 JCB part number - 892/00843
S186260
240V Static Oven - available with 2 or 6 cartridge
S186300
capacity - required to pre-heat adhesive prior to use.
No plug supplied. Note: 110V models available upon Glass Lifter - minimum 2 off - essential for glass
request - contact JCB Technical Service installation, 2 required to handle large panes of glass.
Ensure suction cups are protected from damage
JCB part number: during storage.
992/12400 - 2 cartridge x 240V
992/12600 - 6 cartridge x 240V JCB part number - 892/00842
9803/8020 Issue 1
5-2 5-2
Service Tools (continued)

Section B - Body and Framework (continued)
S186310 S186340
Wire Starter - used to access braided cutting wire Cut-out Knife - used to remove broken glass.
(below) through original polyurethane seal.
JCB part number - 992/12800
'
S186320 S186350
Glass Extractor (Handles) - used with braided cutting 'L' Blades - 25mm (1in.) cut - replacement blades for
wire (below) to cut out broken glass. cut-out knife (above).
JCB part number - 892/00846 JCB part number - 992/12801 (unit quantity = 5 off)
S186330
S186360
Braided Cutting Wire - consumable heavy duty

cut-out wire used with the glass extraction tool Long Knife - used to give extended reach for normally
(above). inaccessible areas.
JCB part number - 892/00849 (approx 25m length) JCB part number - 892/00844
9803/8020 Issue 1
5-3 5-3

Section B - Body and Framework (continued)
S186470 S186550
Nylon Spatula - general tool used for smoothing Rubber Spacer Blocks - used to provide the correct
sealants - also used to re-install glass in rubber glazing set clearance between glass edge and cab frame.
because metal tools will chip the glass edge.
JCB part number - 892/00847 (unit quantity = 500 off)
892/00801 Clutch spanner S200940 892/00807 Front plate puller S200970

for air conditioning compressor for air conditioning compressor
892/00802 Rotor puller set S200950 892/00808 Shaft protector S200980

for air conditioning compressor for air conditioning compressor
892/00803 Rotor installer set S200960

for air conditioning compressor
9803/8020 Issue 1
6-1 6-1
Service Tools
Section C - Electrics
Electrical Test Equipment
1 892/00283 Tool Kit Case
2 892/00281 AVO Meter
3 892/00286 Surface Temperature Probe
4 892/00284 Microtach Digital Tachometer
5 892/00282 100 Amp Shunt - open type
6 892/00285 Hydraulic Oil Temperature Probe
7 892/00298 Fluke 85 Multimeter
188230
239510
993/85700 Battery Tester
Psion Workabout 1Mb/RS232 †

S216770 Docking Holster †
Software - Psion Link, Version 1.1 †
721/00664 Connecting Lead
892/00882 Socket for Pulley Nut on Magneti Marelli
2 x CD ROM ††
Alternator.
† These items to be obtained from your nearest
Psion agent as listed on M.I.’s 569/H, 525 HA and
516E.
†† As detailed on the same M.I.’s as above.
9803/8020 Issue 2*
6-2 6-2
Service Tools
Section C - Electrics
892/01033 Data Link Adapter Kit

A 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.
A360250
D
1 2 3 4 5 6 7 8 E
C
B A F
9 10 11 12 13 14 15 J G
H
A386040
721/10885 Harness - Diagnostic (J1939)
9803/8020 Issue 1
7-1 7-1
Service Tools
Section E - Hydraulics
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)
S188120
Pressure Test Adapters
Pressure Test 'T' Adapters 892/00255 1/4 in BSP x Test Point

892/00256 3/8 in BSP x Test Point S200140
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 892/00257 1/2 in BSP x Test Point
892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point 892/00259 1 in BSP x Test Point
892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point 892/00260 1.1/4 in BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point 892/00261 5/8 in UNF x Test Point
S188130
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
S188150
1606/0012 Adapter 1 in M x 3/4 in M BSP
816/20013 Adapter 3/4 in F x 1 in M BSP
9803/8020 Issue 1
7-2 7- 2

Section E - Hydraulics (continued)
S193850
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 197210
female adapter
892/00706 Test Probe 892/00318 Hose And Adapter Kit
892/00278 Gauge 0-40 bar (0-600 lbf/in2) To enable flow and pressure test
892/00279 Gauge 0-400 bar (0-6000 lbf/in2) equipment to be connected to adapters
fitted with 'O' ringface seals.
197220
892/00334 Gland Seal Fitting Tool 331/64246 Tool Kit for Non-return Valve
331/64265 Retaining Bush for Valve Spool
9803/8020 Issue 2
8-1 8-1
Service Tools
Section F - Transmission
197260 197270
892/00800 Splitting Frame (complete with ratchet 892/00315 Engine Support Bracket
hoist)
188200 107750
892/00179 Bearing Press 892/00812 Drive Coupling Spanner for yoke

couplings
197280 197080
892/00313 Clutch Alignment Tool 892/00225 Adapter - Impulse Extractor

Small 17mm to 25mm
Medium 25mm to 45mm
Large 45mm to 80mm
9803/8020 Issue 2
8-2 8-2
Section F - Transmission (continued)
993/45400 Torque Multiplier

(use in conjunction with a torque wrench to
give a 5 : 1 multiplication)
S197030
197250
Heavy Duty Sockets S190770
892/00817 17 mm A/F x 3/4in. square drive
892/00818 22 mm A/F x 3/4in. square drive 892/00174 Measuring Cup - Pinion Head Bearing
S197070
892/00224 Impulse Extractor Set
for Hub Bearing Seals
* 892/01053 Adapter for impulse extractor S197240
(PTO intermediate shaft, wet clutch
transmission) 892/00312 Dummy End Plate for Range Gearbox
110
25 25
15
40
A197180
197200
Rear Differential Setting Key

Cut from 5 mm plate to dimensions shown. Fabricate
477/00437 Gearbox Lifting Adapter handle to suit.
9803/8020 Issue 3*
8-3 8-3
993/59300 2/4 WD Pressure Test Adaptor & Clamp
S196750
S226300 892/00892 Speed Gearbox Locking Tool
892/00916 Spring Compressor for Splitter and PTO

Clutches
S267310
9803/8020 Issue 3
8-4 8-4
1
A B
C
2
S234120
4
892/00864 PD 90 Axle Locknut Spanner
3 A270851
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 A361730
3 993/70111 Break-back Torque Wrench
4 - Solid spacer (see parts CD or 892/01052 (x2) Locking Plate for locking wet clutch
michrofiche for part numbers) drum to housing
A361710
892/01051 Intermediate Gear Retaining Tool - wet
clutch transmission 892/01049 (x2) Guide Rod - wet clutch
A361740
A361720
892/01048 (x2) Clutch Pack Retainer - wet clutch
9803/8020 Issue 6*
8-5 8-5
A361750
892/01045 Peg Socket - wet clutch 892/01046 Mandrel - for bush assembly - wet clutch
A361770
A361760 A361780
892/01050 Mandrel, for hub seal renewal - wet clutch.
892/01047 Jig, for use when dismantling and
Note: Protective plastic cap A to be removed before use.
assembling of PTO input gear - wet clutch
9803/8020 Issue 1
8-6 8-6

Item Description Part No. Qty

A
5
A Hub Service Kit 892/01092 1
comprises:
1
1 Puller Beam 998/10623 1
2 Inner Bearing Plate 998/10607 1 6
3 Bolt M16x220 1315/3731Z 2
4 Nut M16 1370/0601Z 2 8,9
5 Reaction Tube 998/10614 1
6 Modified Wheel Stud 998/10624 2
7 Wheel Bearing Carrier 7
Puller 998/10615 2 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
10
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 4 11,12
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 3
20 Bearing 917/02800 1
21 Dolly 892/00891 1
13 16
15
19, 20
14
18
8
21
17
9803/8020 Issue 1
9-1 9-1
Section G - Brakes
892/00311 Brake Test Kit
3 x Calibrated Test Gauges - 0-20 bar (0 - 290 lbf/in2)
3 x 5 Metre Hoses with Quick Release Adapters
3 x ISO Test Point Adapters

S199470
Section H - Steering
E
A
B
C 222490
229270
892/00180 Seal Fitting Tool for fitting ‘O’ ring and D

back-up ring to Danfoss Orbitrol Unit Puller adapter assembly for removal of drop arm from
steering box (3000 Series machines). Comprises:
892/00181 Replacement Plastic Boss
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.
220130
Spanners for input shaft nuts on steering box (3000 Series

machines with serial nos. 640001 to 640053 and 640056
to 640058).
F 892/00883 Spanner
G 892/00884 ‘C’ Spanner
9803/8020 Issue 3*
9-2 9-2

Section S - Suspension
S199480
892/00314 Accumulator and Gas Spring Pressure

Test Adapter
Section T - Engine
A314530
S192390
892/00041 De-glazing Tool for Cylinder Bores (to 892/00956 Timing pin for fuel injection pumps (Fastrac
assist bedding-in of new piston rings) 2115, 2125, 2135, 2150 only).
Note: For other engine tools refer to the relevant Engine

Service Manual.
9803/8020 Issue 2*
10- 1 Moving a Disabled Machine 10 - 1
General Preparation for Towing

Do not tow a machine unless there is no alternative. 1 Connect the towing vehicle.
Remember that more damage might be caused to the a Apply the parking brakes on the towing vehicle and
machine by towing it. If at all possible repair the machine securely chock the wheels on the Fastrac.
where it stands. b Fit the drawbar between towing vehicle and
Fastrac.
* Note: It is not possible to tow-start or push-start the Fastrac
2 Prepare the machine.
due to the design of the transmission.
a Make sure that the range and speed gearboxes are
both in neutral.
Make sure you will be obeying all pertinent laws and
b If the gearbox has failed, disconnect both
regulations before towing the machine on public roads.
propshafts (see Section F).
c If an axle has failed, remove the sun gears (see
! DANGER Section F).
If the engine is not running, there will not be enough air
to apply the service brakes or release the parking brake. 3 Release the Fastrac parking brake.
Carefully follow the precautions in this section before Note: The Schrader valve X shown below on the right hand
moving the machine or there may be a serious accident. side of the machine is that for Fastrac 2115, 2125 and 2135
13-2-2-6/1 machines. On 2150, 3155 and 3185 machines the valve is on
the left hand side of the machine.
! CAUTION
Towing a machine too far or too fast can damage the If there is not enough air pressure to release the brake,
transmission. Do not tow the machine further than one start the engine to charge up the air system. If the
mile. Use a trailer for greater distances. When towing do engine cannot be run but the brake air system is
not travel faster than 25 km/h (15 mph). serviceable, charge the system to 120 psi (8 bar)
through Schrader valve X. This job must be done by a
qualified mechanic, using the correct equipment.
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
! DANGER
towing vehicle should be coupled to the rear of the Ensure that the chocks and towing vehicle will prevent
disabled machine, to provide braking power. the Fastrac from moving as it is necessary to work under
the machine to release the parking brake. When the
The towing vehicle(s) must have enough pulling and parking brake has been manually released as described
braking power to move and stop the machine. below, it will be impossible to apply the brake until plate
2-2-7-3 A has been removed.
13-2-2-11
Alternatively, position plate A (if provided with the

machine) as shown. Keeping nut B tight against clevis
C, turn nut D against the plate so that rod E is drawn
out of the actuator body and the parking brake is
released.
Note: If the parking brake cannot be released, remove both

A286550 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
D E regulations.
Remember that the steering will be much heavier if the

C engine is not running.
B A
S160392
S261600
9803/8020 Issue 3*
10 - 2 10 - 2
Transporting the Machine

The safe transit of the load is the responsibility of the 3 Anchor the machine to the trailer with chains or suitable
transport contractor and driver. Any machine, webbing straps. The preferred fixing is to use webbing
attachments or parts that may move during transit must straps individually fixing all four wheels to the deck of
be adequately secured. the trailer as at A. If chains are used they should be
5-2-5-9 connected to a suitable part of the drawbar at the rear
Note: Before transporting the machine make sure you will of the machine. At the front, use the tie down points.
be obeying the rules and laws of all the areas that the Avoid chaining any part of the machine where the
machine will be carried through. chains may damage critical componentry. For example,
chaining around either axle provides the possibility of
Make sure that the transporting vehicle is suitable. See damaging the steel brake pipes running along their
Static Dimensions (SPECIFICATIONS section in the length.
machine handbook) for the dimensions of the machine.
4 Measure the maximum height of the machine from the
ground. Try to make sure the truck driver knows the
! WARNING clearance height before he drives away.
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.
A A
A288080
9803/8020 Issue 1
Section 2 Care & Safety Section 2
i i
Contents Page No.
Safety Notices 1-1
General Safety 2-1
Operating Safety 3-1
Maintenance Safety 4-1
9803/8020 Issue 1
1-1 1-1
In this publication and on the machine, there are safety notices. Each notice starts
with a signal word. The signal word meanings are given below.
! DANGER
Denotes an extreme hazard exists. If proper precautions are not taken, it is
highly probable that the operator (or others) could be killed or seriously
injured.
INT-1-2-1
! WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator (or
others) could be killed or seriously injured.
INT-1-2-2
! CAUTION
Denotes a reminder of safety practices. Failure to follow these safety practices
could result in injury to the operator (or others) and possible damage to the
machine.
INT-1-2-3
9803/8020 Issue 1
2-1 2-1
All construction and agricultural equipment can be Note: This section includes a certain amount of operating
hazardous. When a JCB Fastrac is correctly operated and safety information. But remember that whenever you drive
properly maintained, it is a safe machine to work with. But the machine or operate its controls you are in effect a
when it is carelessly operated or poorly maintained it can machine operator. Therefore you should read and
become a danger to you (the operator) and others. understand the information given in the Operator Handbook
before driving the machine or operating its controls.
Do not work with the machine until you are sure that you can
control it.
Do not start any job until you are sure that you and those
around you will be safe.
If you are unsure of anything, about the machine or the job,

ask someone who knows. Do not assume anything.
Remember
BE CAREFUL
BE ALERT
BE SAFE
GEN-1-6
As well as the warnings in the following pages, specific

warnings are given throughout the book. This section is
designed to give a safety code for use of the machine
generally and for operation and maintenance practices.
General Safety
! WARNING ! WARNING
Lifting Equipment Care and Alertness
You can be injured if you use faulty lifting equipment. Make All the time you are working with or on the machine, take
sure that lifting equipment is in good condition. Make sure care and stay alert. Always be careful. Always be alert for
that lifting tackle complies with all local regulations and is hazards.
suitable for the job. Make sure that lifting equipment is INT-1-3-5
strong enough for the job.

INT-1-3-7 ! WARNING
Raised Equipment
! WARNING Raised equipment can fall and injure you. Do not walk or
Clothing work under raised equipment unless safely supported.
You can be injured if you do not wear the proper clothing. 13-1-1-6
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 ! WARNING
fitting overall, ear-protectors and industrial gloves. Keep Machine Modifications
cuffs fastened. Do not wear a necktie or scarf. Keep long This machine is manufactured in compliance with legislative
hair restrained. and other requirements. It should not be altered in any way
INT-1-3-6
which could affect or invalidate any of these requirements.
For advice consult your JCB Distributor.
! WARNING
Alcohol and Drugs Reference should also be made to Optional Attachments
It is extremely dangerous to operate machinery when under section where appropriate.
the influence of alcohol or drugs. Do not consume alcoholic INT-1-3-10
drinks or take drugs before or whilst operating the machine

or attachments. Be aware of medicines which can cause
drowsiness.
INT-1-3-9
9803/8020 Issue 1
3-1 3-1
Operating Safety
! DANGER ! WARNING
Parking Visibility
Leaving the machine in gear will not prevent it running away. Accidents can be caused by working in poor visibility. Keep
Do not leave the driving seat under any circumstances windows clean and use your lights to improve visibility. Do
unless the parking brake is on. not operate the machine if you cannot see properly.
13-2-1-10 INT-2-1-11
! WARNING ! WARNING
Roll Over Protection Structure (ROPS) Practice
The machine is fitted with a Roll Over Protection Structure You or others can be killed or seriously injured if you do
(ROPS). You could be killed or seriously injured if you unfamiliar operations without first practising them. Practise
operate the machine with a damaged or missing ROPS. If away from the work site on a clear area. Keep other people
the ROPS has been in an accident, do not use the machine away. Do not perform new operations until you are sure you
until the structure has been renewed. Modifications and can do them safely.
INT-2-1-1
repairs that are not approved by the manufacturer may be
dangerous and will invalidate the ROPS certification.
13-1-1-8/1 ! WARNING
Machine Limits
! WARNING Operating the machine beyond its design limits can damage
Entering/Leaving the machine, it can also be dangerous. Do not operate the
Always face the machine when entering and leaving the cab. machine outside its limits. Do not try to upgrade the
Use the step(s) and handrails. Make sure the step(s), machine performance with unapproved modifications.
INT-2-1-4
handrails and your boot soles are clean and dry. Do not
jump from the machine. Do not use the machine controls as
handholds, use the handrails. ! WARNING
INT-2-1-7 Brakes
Do not coast the machine with the engine stopped as the
! WARNING main brakes will only operate for a limited number of
Seat applications and hydraulic trailer brakes will not function at
Position the seat so that you can comfortably reach the all. Also the steering will become very heavy.
13-1-1-5/2
machine controls. You could have an accident if you operate
the machine with the seat in the wrong position.
INT-3-3-5 ! CAUTION
Hydraulic Trailer Brakes
! WARNING Trailers with single line hydraulic brakes used in the United
Seat Belt Kingdom are subject to a maximum speed of 20 mph (32
Operating the machine without a seat belt can be kph).
13-2-2-8
dangerous. Before starting the engine, make sure your seat
belt is fastened. Check the tightness and condition of the
! CAUTION
seat belt securing bolts regularly (see maintenance
schedules). Trailer Brakes
INT 2 -1-8/1 Trailers with single line air brakes used in the Republic of
Germany are subject to a maximum speed of 25 km/h (15
! WARNING mph).
Passengers 13-2-2-13
Ensure that passengers use the seat provided in the cab.

Passengers must not be carried on the rear deck of the ! WARNING
vehicle under any circumstances. Engine
13-1-1-1/1
The engine has rotating parts. Do not open the engine cover
while the engine is running. Do not use the machine with the
! WARNING cover open.
Reversing INT-2-1-6
Reversing at high speeds can cause accidents. Always drive

at a safe speed to suit working conditions
13-1-1-3
9803/8020 Issue 1
3-2 3-2
Operating Safety (cont'd)
! WARNING ! WARNING
Banks and Trenches Power Take-off Operation
Banked material and trenches can collapse. Do not work or When operating PTO equipment, always observe the
drive too close to banks and trenches where there is danger following safety precautions:
of collapse.
INT-2-2-5 Follow the instructions in the implement operator's
handbook.
! WARNING
Rotating equipment is dangerous. Do not wear loose fitting
Ramps and Trailers
clothing when working close to rotating shafts.
Water, mud, ice, grease and oil on ramps or trailers can
cause serious accidents. Make sure ramps and trailers are
Always disengage the PTO, stop the engine and wait until
clean before driving onto them. Use extreme caution when
the equipment stops, before:
driving onto ramps and trailers.
INT-2-2-6
1 Leaving the cab
! WARNING
2 Attempting to attach or detach an implement to or from
Communications
a PTO shaft or
Bad communications can cause accidents. Keep people
around you informed of what you will be doing. If you will be
3 Working on or cleaning an implement connected to the
working with other people, make sure any hand signals that
machine via a PTO shaft.
may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands.
INT-2-2-3
Always ensure that the PTO shaft and driveline are fully
guarded before use.
! WARNING When using stationary PTO equipment, ensure that the

parking brake is applied.
Engine/Steering Failure 13-2-1-6
If the engine or steering fails, stop the machine as quickly as
possible. Do not operate the machine until the fault has been ! WARNING
corrected.
INT-2-1-5
Power Take-off Jamming
If the PTO becomes jammed, disengage the PTO, stop the
engine and clear the blockage. Wait until the PTO shaft
! DANGER stops before working on the equipment. If the PTO clutch
Sparks slips, immediately disengage the PTO and stop the engine.
Explosions and fire can be caused by sparks from the 13-2-2-2
exhaust or the electrical system. Do not use the machine in
closed areas where there is flammable material, vapour or ! WARNING
dust.
INT-2-2-10 Hitching Trailers and Equipment
When the vehicle is approaching a trailer or equipment to be
! WARNING * hitched, make sure that no persons are present between
vehicle and trailer or equipment. When mounting equipment
Controls at the rear of the vehicle, you must ensure that proper
Keep the machine controls clean and dry. Your hands and steering control is maintained. The machine must never be
feet could slide off slippery controls. If that happens you will loaded such that less than 20% of the vehicle weight is
lose control of the machine. carried on the front axle.
2-2-3-6 13-1-1-13/1
! WARNING
Exhaust Gases
Breathing the machine exhaust gases can harm and
possibly kill you. Do not operate the machine in closed
spaces without making sure there is good ventilation. If
possible, fit an exhaust extension. If you begin to feel
drowsy, stop the machine at once. Get out of the cab into
fresh air.
INT-2-1-10
9803/8020 Issue 2*
3-3 3-3
Operating Safety (cont'd)
! WARNING ! WARNING
Tyres - General Stability
You could be killed or injured if a machine tyre bursts. Do In the event of the machine becoming unstable, keep firm
not use the machine with damaged, incorrectly inflated or hold of the steering wheel and do not try to leave the cab.
excessively worn tyres. Recognize the speed limitation of 13-2-2-10
the tyres fitted and do not operate at more than their

recommended maximum speed. ! WARNING
13-2-1-2
Audible Warnings
When you hear an audible warning, stop the machine as
! WARNING soon as possible. Get the fault put right before using the
Certain tyres fitted as after-market equipment may have machine again.
maximum permitted speeds below the maximum speed of 13-2-1-9
the vehicle. Brake efficiency is slightly reduced and stopping
distance is increased when these tyres are fitted. They will ! WARNING
suffer damage if operated at speeds higher than those Controls
recommended and may endanger life. When driving the machine on the road, use the accelerator
13-3-2-5
pedal and not the hand throttle to control the engine speed.
* Always set the hand throttle to ‘idle’ before using the
! WARNING accelerator pedal.
Tyre Speed Limitations 13-2-1-8/1
Running tyres outside recommended guidelines may result
in failure of the tyres which at high speeds may endanger
! WARNING
life. BE WARNED.
13-3-1-6 Safe Working Loads
Overloading the machine can damage it and make it
! WARNING unstable. Study the specifications before loading, towing or
using implements.
Rear Deck 13-1-1-4/1
Passengers must not be carried on the rear deck of the
vehicle. Ensure that loads carried on the rear deck are ! DANGER
secured adequately to prevent them rolling about, falling off
or toppling over. The JCB Fastrac is capable of operating at high speeds.
13-1-1-12/1 Implements or trailers you tow behind the Fastrac may not
be designed for high speed operation. BE AWARE of the
! WARNING manufacturers specified maximum speed rating for any
trailers or implements that you tow behind the Fastrac. DO
Weight Distribution
NOT EXCEED THE MAXIMUM DESIGN SPEED OF
The machine must never be loaded such that less than 20%
TRAILERS OR IMPLEMENTS AS INJURY OR *
of the vehicle weight is carried on the front axle.
13-1-1-11/1
DEATH MAY RESULT.
! CAUTION
13-2-3-5
*
Weight Distribution
The Fastrac has to comply with certain braking regulations
! WARNING
which in some countries control weight distribution between Cab Air Filter
front and rear axles. Travelling on the road with implements The cab air filter is designed to remove dirt from the outside
or weights carried on the front when no implement is on the air. When using chemicals (e.g. for crop spraying) follow the
rear may break the law. In this case you should transfer the chemical manufacturer’s recommendations for protection
front mounted equipment to the rear linkage. It is the from dangerous chemicals.
13-2-3-6
operator's responsibility to know and observe the laws in the
country concerned.
13-2-2-5 ! WARNING
! WARNING Hazardous Atmospheres
This machine is designed for use in normal out door
Travel Speed
atmospheric conditions. It should not be used in an
Be aware of the load the machine is carrying or towing and
enclosed area without adequate ventilation. Do not use the
the speed at which you are travelling. Do not corner fast
machine in a potentially explosive atmosphere, i.e.
when carrying heavy mounted implements or towing trailers.
combustible vapours, gas or dust, without first consulting
Reduce speed when towing non-suspended implements on
your JCB Distributor.
rough ground. INT-2-1-14
13-2-2-1
9803/8020 Issue 2*
4-1 4-1
Maintenance Safety
! WARNING ! WARNING
Working Under the Machine Battery
Make the machine safe before getting beneath it. Do the A battery with frozen electrolyte can explode if it is used or
following: Park on level ground. Engage the parking brake. charged. Do not use a machine with a frozen battery. To
Lower any mounted implements to the ground. Stop the help prevent the battery from freezing, keep the battery fully
engine, remove the starter key, disconnect the battery. charged.
Chock the wheels. INT-3-1-7
13-3-1-1
! WARNING
! WARNING Battery Gases
Soft Ground Batteries give off explosive gases. Keep flames and sparks
A machine can sink into soft ground. Never work under a away from the battery. Do not smoke close to the battery.
machine on soft ground. Make sure there is good ventilation in closed areas where
INT-3-2-4 batteries are being used or charged. Do not check the
battery charge by shorting the terminals with metal; use a
! WARNING hydrometer or voltmeter.
INT-3-1-8
Jacking
A machine can roll off jacks and crush you unless the wheels
have been chocked. Always chock the wheels at the ! WARNING
opposite end of the machine to that which is to be jacked. Battery Terminals
Do not work underneath a machine supported only by jacks. The machine is negatively earthed. Always connect the
Always support a jacked-up machine on axle stands before negative pole of the battery to earth.
working underneath it.
INT-3-2-8 When connecting the battery, connect the earth (-) lead last.
! WARNING When disconnecting the battery, disconnect the earth (-)

Transmission Testing lead first.
INT-3-1-9
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 ! WARNING
wheels are off the ground and supported by axle stands as if Electrical Circuits
only the rear wheels were raised, the machine could still Understand the electrical circuit before connecting or
drive through the front axle. Note that when a NoSpin disconnecting an electrical component. A wrong connection
differential is fitted, both front wheels will be driven even if can cause injury and/or damage.
one is jacked up and the other is on the ground. INT-3-1-4
TRAN 8-1/2
! WARNING
! WARNING Hydraulic Hoses
Diesel Fuel Damaged hoses can cause fatal accidents. Inspect the
Diesel fuel is flammable; keep naked flames away from the hoses regularly for:
machine. Do not smoke while refuelling the machine or Damaged end fittings
working on the engine. Do not refuel with the engine Chafed outer covers
running. There could be a fire and injury if you do not follow Ballooned outer covers
these precautions. Kinked or crushed hoses
INT-3-2-2 Embedded armouring in outer covers
Displaced end fittings.
! WARNING INT-3-3-2
Petrol
! WARNING
Do not use petrol in this machine. Do not mix petrol with the
diesel fuel; in storage tanks the petrol will rise to the top and Rams
form flammable vapours. The efficiency of the rams will be affected if they are not
INT-3-1-6 kept free of solidified dirt. Clean dirt from around the rams
regularly. When leaving or parking the machine, close all
rams if possible to reduce the risk of weather corrosion.
INT-3-2-10
9803/8020 Issue 1
4-2 4-2
Maintenance Safety (cont'd) ! WARNING

Communications
! WARNING Bad communications can cause accidents. If two or more
Hydraulic Pressure people are working on the machine, make sure each is
Hydraulic fluid at system pressure can injure you. Before aware of what the others are doing. Before starting the
disconnecting or connecting hydraulic hoses, stop the engine make sure the others are clear of the danger areas;
engine and operate the controls to release pressure trapped examples of danger areas are: the rotating blades and belt
in the hoses. Make sure the engine cannot be started while on the engine, the attachments and linkages, and anywhere
the hoses are open. beneath or behind the machine. People can be killed or
INT-3-1-11/2 injured if these precautions are not taken.
INT-3-1-5
! WARNING
! WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate the Cleaning
skin. Do not use your fingers to check for hydraulic fluid Cleaning metal parts with incorrect solvents can cause
leaks. Do not put your face close to suspected leaks. Hold a corrosion. Use only recommended cleaning agents and
piece of cardboard close to suspected leaks and then solvents.
INT-3-2-11
inspect the cardboard for signs of hydraulic fluid. If hydraulic
fluid penetrates your skin, get medical help immediately.
INT-3-1-10/1
! WARNING
'O' rings, Seals and Gaskets
! WARNING Badly fitted, damaged or rotted 'O' rings, seals and gaskets
Oil can cause leakages and possible accidents. Renew
Oil is toxic. If you swallow any oil, do not induce vomiting, whenever disturbed unless otherwise instructed. Do not use
seek medical advice. Used engine oil contains harmful Trichloroethane or paint thinners near 'O' rings and seals.
INT-3-2-12
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier
cream or wear gloves to prevent skin contact. Wash skin
! WARNING
contaminated with oil thoroughly in warm soapy water. Do Clutch Fluid
not use petrol, diesel fuel or paraffin to clean your skin. Do not use ordinary hydraulic fluid in the clutch system.
INT-3-2-3 13-3-2-4
! WARNING ! WARNING
Hot Coolant Welding and Modifications
The cooling system is pressurised when the engine is hot. To prevent the possibility of damage to electronic
Hot coolant can spray out when you remove the radiator components, disconnect the battery and withdraw the plug
cap. Let the system cool before removing the radiator cap. from the electronic draft control unit before arc-welding on
To remove the cap; turn it to the first notch and let the the machine or attached implements.
system pressure escape, then remove the cap.
INT-3-2-9 Parts of the machine are made from cast iron; welds on cast
iron can weaken the structure and break. Do not weld cast
! WARNING iron. On no account weld or drill the chassis structure. Non-
Wheels approved modifications can cause injury and damage.
Wheels are heavy. Handle and store with care to ensure that Contact JCB before modifying the machine.
GEN 8-1
they cannot fall and cause injury.
13-3-1-7
! WARNING
! WARNING Protect your eyes when grinding metal. Wear safety glasses
Metal Splinters or goggles. Remove or protect any combustible materials
You can be injured by flying metal splinters when driving from the area which could be ignited by sparks.
metal pins in or out. Use a soft faced hammer or drift to GEN-1-12
remove and fit metal pins. Always wear safety glasses.

INT-3-1-3
! WARNING
Radar Speed Sensor (if fitted)
! WARNING To avoid possible eye damage from microwave signals, do
Always wear safety glasses when dismantling assemblies not look directly into the sensor face.
13-1-1-15
containing components under pressure from springs. This
will protect against eye injury from components accidentally Note: The radar speed sensor is located underneath the
flying out. * machine.
GEN 6-2
9803/8020 Issue 2*
4-3 4-3
Maintenance Safety (cont'd)
! WARNING ! WARNING
Fluoroelastomeric Materials Brake Pads
Certain seals and gaskets (e.g. crankshaft oil seal) on JCB Always renew brake pads and locating pins in complete axle
machines contain fluoroelastomeric materials such as Viton, sets, using genuine JCB parts, otherwise braking will be
Fluorel and Technoflon. Fluoroelastomeric materials unsafe.
subjected to high temperatures can produce highly corrosive 13-3-1-10
hydrofluoric acid. THIS ACID CAN SEVERELY BURN.

! WARNING
New fluoroelastomeric components at ambient temperature
Cleaning Agents
require no special safety precautions.
When using cleaning agents, solvents or other chemicals,
you must adhere to the manufacturer's instructions and
Used fluoroelastomeric components whose temperatures
safety precautions.
have not exceeded 300°C require no special safety GEN-1-9
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. * ! WARNING
ABS
Used fluoroelastomeric components subjected to
Upon completion of any work done on the brake system of
temperatures greater than 300°C (e.g. engine fire) must be
machines fitted with ABS, the ABS test within Servicemaster
treated using the following safety procedure. Make sure that
must be run satisfactorily before the machine is driven. It is
heavy duty gloves and special safety glasses are worn:
not sufficient to rely on the ABS self-check which can only
check for presence of components, not that they are
1 Ensure that components have cooled then remove and
correctly installed.
place material in plastic bags. 0091
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
9803/8020 Issue 2*
Section 3 Routine Maintenance Section 3
i i
Contents Page No.
Engine Oil - (All Machines) 1-1
Lubricants & Capacities (2000 Series Machines) 1-2
Lubricants & Capacities (3155) 1-4
Lubricants & Capacities (3185) 1-6
Lubricants - Health and Safety 1-8
Service Schedules (Dry Clutch Transmission †) 2-1

Service Schedules (Wet Clutch Transmission ††) 2-4
Cleaning the Machine and Checking for Damage 2-8

Checking Seat Belt Condition and Security 2-8
Opening/Closing the Bonnet (2000 Series Machines) 2-9
Opening/Closing the Bonnet (3000 Series Machines) 2-9
Greasing
General 3-1
Propshafts and PTO Driveshafts 3-1
Steering Swivels (2000 Series Machines) 3-2
Front Axle Steering Swivels (3000 Series Machines) 3-3
Hydraulic Lift & 3 point Linkage (2000 Series Machines) 3-4
Rear PTO Driveshaft Bearings (2000 Series Machines) 3-4
Rear Suspension Cylinder Pivots (2000 Series Machines) 3-4
Hydraulic Lift & 3 point Linkage (3000 Series Machines) 3-5
Rear PTO Driveshaft Bearings (3000 Series Machines) 3-5
Rear Suspension Cylinder Pivots (3000 Series Machines) 3-5
Rear Anti-roll Bar Ball Joints (2000 Series Machines) 3-6
Steering Box Input Shaft Seal (3000 Series Machines) 3-7
Rear Anti-roll Bar Ball Joints (3000 Series Machines) 3-7
Automatic Trailer Coupling (if fitted) 3-8
Cab
Checking the ROPS Structure 4-1
Checking the Windscreen Washer Fluid Level 4-2
Air Conditioning
Cleaning the Filter (2000 Series Machines) 5-1
* Adjusting the Compressor Belt (2115, 2125, 2135, 2150) 5-1
Cleaning the Filter (3000 Series Machines) 5-2
* Adjusting the Compressor Belt (2140 and 3000 Series) 5-3
Electrics
Battery Warning Symbols 6-1
First Aid - Electrolyte 6-1
Checking the Battery Electrolyte Level 6-2
Checking the Headlight Beam Alignment 6-3
Fuses See Section C
Hydraulics
Checking the Fluid Level 7-1
Changing the Filter Element 7-1
Changing the Hydraulic Fluid and Cleaning the Suction Strainer 7-2
Emptying the Hydraulic Coupling Drain Reservoir (if fitted) 7-3
* Dry Clutch Hydraulic System †
Checking the Fluid Level 8-1
† 2000 Series to S/N 739999, 3000 Series to S/N 641999

†† 2000 Series from S/N 740000, 3000 Series from S/N 642000
9803/8020 Issue 7*
ii ii
Contents Page No.
PTO, Speed and Range Gearboxes

Checking the Oil Level 9-1
Changing the Oil and Cleaning the Strainer
- (Dry Clutch Transmission) † 9-2
Changing the Oil and Cleaning the Strainer
- (Wet Clutch Transmission) †† 9 - 2A
Changing the Transmission Oil Filter 9-3
Checking the Front PTO Gearbox Oil Level (if fitted) 9-4
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 (2WS)

Checking the Oil Level 11 - 1
Changing the Oil 11 - 2
Rear Axle (4WS)

Checking the Differential Oil Level 11 - 3
Changing the Differential Oil 11 - 3
Checking the Hub Oil Levels 11 - 4
Changing the Hub Oil 11 - 4
Front and Rear Axle Steering Swivels (4WS)

Checking 4WS Right Side Trunnion Seals 11 - 5
Tyres and Wheels

General 12 - 1
Tyre Inflation 12 - 1
Pressures, Speeds and Loads See Operator Handbook
Checking and Adjusting Wheel Alignment 12 - 4
Track Width 12 - 5
Checking Wheel Nut Torques 12 - 5
Lock Stops 12 - 6
Fender Adjustment 12 - 7
* Brakes
Checking and Renewing Foot Brake Pads 13 - 1
Checking and Renewing the Parking Brake Pads 13 - 3
Checking the Foot Brake Fluid Level (2000 Series Machines) 13 - 4
Draining the Air System Tank (2000 Series Machines) 13 - 6
Checking the Foot Brake Fluid Level (3000 Series Machines) 13 - 7
Draining the Air System Tank (3000 Series Machines) 13 - 8
Exhaust Brake (if fitted) (3185 Machines only) 13 - 9
Cleaning the Trailer Brake Control Line Air Filter See Section G

9803/8020 Issue 10*

iii iii
Contents Page No.
Engine
Checking the Oil Level 14 - 1
Changing the Oil and Filter 14 - 2
Draining/Cleaning the Fuel Sediment Bowl 15 - 1
Draining/Renewing Fuel Pre-Filter (when fitted) 15 - 2
Draining the Fuel Filters 15 - 3
Changing the Fuel Filter Elements 15 - 3
* Cleaning the Fuel Lift Pump (2115, 2125, 2135, 2150 and 3155) 15 - 4
* Bleeding the Fuel System (2115, 2125, 2135, 2150 and 3155) 15 - 5
* Bleeding the Fuel System (2140) 15 - 5A
Bleeding the Fuel System (3185) 15 - 6
* Cleaning the Fuel Tank Strainer (Early machines only) 15 - 7
Checking the Coolant Level 16 - 1
* Draining the Coolant (2115, 2125, 2135 and 2150 Machines) 16 - 2
* Filling the Cooling System (2115, 2125, 2135 & 2150 Machines) 16 - 3
Coolant Mixtures 16 - 3
Draining & Refilling the Coolant (3155 Machines) 16 - 4
*Draining & Refilling the Coolant (2140 and 3185 Machines) 16 - 5
Cleaning the Radiator (2000 Series Machines) 16 - 6
Cleaning the Radiator (3000 Series Machines) 16 - 7
Cleaning the Pre-Cleaner (optional) 17 - 1
Adjusting the Fan Belts (Machines Except 3185) 17 - 1
* Adjusting the Fan Belt (2140) 17 - 2
* Adjusting the Fan Belt (3185) 17 - 3
* Changing the Air Filter Elements (Early 2000 Series) 18 - 1
* Changing the Air Filter Elements (Later 2000 Series) 18 - 2
* Changing the Air Filter Elements (3000 Series) 18 - 2
9803/8020 Issue 4*
1-1 * Engine Oil (All Machines) 1-1
New Engines
New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately.
DO NOT use a special running-in oil but use the oil recommended below from new.
Engine Oil Specification

Recommended Oil
JCB Extreme Performance Engine Oil

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

SAE15W/40, API CF4/SG
-10 °C to 50 °C (14 °F to 122 °F)
JCB Super Multigrade 10W/30

† -15 °C to 40 °C (5 °F to 104 °F)
† The temperature range for 2140 and 3185 machines is - 20 °C to 20 °C (-4 °C to 68 °F).
Engine Oil Specification (N. America)

Recommended Oil
JCB Genuine Engine Oil

SAE 15W/40, Grade CH-4/SJ
IMPORTANT NOTICE: IF SAE 15W/40, GRADE CH-4/SJ ENGINE OIL IS NOT AVAILABLE, THEN THE ENGINE OIL MUST BE
CHANGED AT 250 HOURS.
Alternative Oil
If the oil recommended above is not available then the alternatives listed below should be used according to the ambient
temperature.
Notice: (2140 and 3185 machines only). While 15W/40 oil is recommended for most climates, limited use of low viscosity oils
such as 10W/30 is permitted to provide easier starting and sufficient oil flow at ambient temperatures below -5 °C (23 °F).
Continued use of low viscosity oils can decrease engine life.
JCB 15W/40 Engine Oil

-10 °C to 50 °C (14 °F to 122 °F)
JCB Engine Oil 10W/30

SAE10W/30, API CE/SF
† -15 °C to 40 °C (5 °F to 104 °F)
† The temperature range for 2140 and 3185 machines is -4 °C to 68 °F (- 20 °C to 20 °C).
9803/8020 Issue 7*
1-2 Lubricants & Capacities 1-2
(2000 Series Machines)
ITEM CAPACITY FLUID/LUBRICANT MINIMUM INTERNATIONAL
Litres (UK Gal) SPECIFICATION
* Fuel
2115, 2125, 2135, 2140 220 (48) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
2150 350 (77)
* Engine (Oil)
2115, 2125, 2135, 2150 16.5 (3.6) See Engine Oil (All Machines) at the
2140 15 (3.3) beginning of this section
* Engine (Coolant)
2115, 2125, 2135, 2150 34 (7.5) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
2140 33 (7.3) Summer Coolant/water
(See Coolant Mixtures)
PTO, Speed and

Range Boxes 38 (8.4) † JCB Super Universal Agricultural API-GL-4, MIL-L-2105
(combined) 42 (9.3) ††
Front Axle
Housing 7 (1.56) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 1.9 (0.4)
Rear Axle (2WS) 23 (5.0) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C
Rear Axle (4WS)
Hubs (x2) 2.0 (0.4)
Brake System JCB Universal Brake Fluid 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
† Clutch System - JCB Light Hydraulic Fluid - see Note 2 ISO VG15
Hydraulic System JCB High Performance Hydraulic Oil ISO VG46

- see Note 1 82 (18.0) † (Above 38 °C, 100 °F)
120 (26.4) ††
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 0.98 kg (2.16 lb) HFC R134a CH2 FC F3
- Compressor Lubricant 0.24 (0.05) Polyalkalineglycol PAG SP20
Front PTO Transfer

Box (optional) 3.0 (0.67) JCB HD90 Gear Oil 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.
Note 2: It is esssential that the correct specification fluid is used. Contact your JCB Dealer for further information.
† 2000 Series to S/N 739999

†† 2000 Series from S/N 740000
9803/8020 Issue 9*
1-3 Lubricants & Capacities (N. America) 1-3
US Gal (Liters) SPECIFICATION
* Fuel
2115, 2125, 2135, 2140 57.6 (220) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
2150 92.5 (350)
* Engine (Oil)
2115, 2125, 2135, 2150 4.3 (16.5) See Engine Oil (All Machines) at the
2140 4 (15) beginning of this section
* Engine (Coolant) JCB PermanentAntifreeze/water ASTM D3306-74

2115, 2125, 2135, 2150 9.0 (34.0) (See Coolant Mixtures)
2140 8.77 (33)
PTO, Speed and

Range Boxes 10 (38.0) † JCB AG Transmission Fluid API-GL-4, MIL-L-2105
(combined) 11.2 (42.0) ††
Front Axle
Housing 1.8 (7.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Hubs (x2) 0.5 (1.9)
Rear Axle (2WS) 6.1 (23.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C
Rear Axle (4WS)
Hubs (x2) 0.5 (2.0)

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
† Clutch System - JCB Light Hydraulic Fluid - see Notice 2 ISO VG15
Hydraulic System 21.7 (82.0) † JCB High Performance Hydraulic Oil ISO VG46
- see Notice 1 31.7 (120) ††

pressure additives

- Refrigerant 2.16 lb (0.98 kg) HFC R134a CH2 FC F3
Front PTO Transfer

Box (optional) 0.8 (3.0) JCB GL5 80W/90 Gear Oil 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 esssential that the correct specification fluid is used. Contact your JCB Dealer for further information.
† 2000 Series to S/N 739999

9803/8020 Issue 9*
(Fastrac 3155)
Fuel 350 (77) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 16.5 (3.6) See Engine Oil (All Machines) at the
beginning of this section
Engine (Coolant) 34 (7.5) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
Summer Coolant/water
PTO, Speed and

(combined) 42 (9.3) ††
Front Axle
Hubs (x2) 2.5 (0.55)
Rear Axle 21 (4.6) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C

Front 0.75 (0.17)
Do not use ordinary hydraulic fluid in the
brake system.
13-3-2-6
Hydraulic System 82 (18.0) † JCB High Performance Hydraulic Oil ISO VG46
- see Note 1 120 (26.4) †† (Above 38 °C, 100 °F)

(Below 38 °C, 100 °F)

pressure additives

* - Refrigerant 1.41 kg (3.11 lb) HFC R134a CH2 FC F3
Front PTO Transfer

Note 2: It is essential that the correct specification fluid is used. Contact your JCB Distributor for further information.
† 3000 Series to S/N 641999

9803/8020 Issue 7*
(Fastrac 3155)
Fuel
92.5 (350) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 4.3 (16.5) See Engine Oil (All 2000, 3000 Series
Machines) on page 60-00-01/11
Engine (Coolant) 9 (34.0) JCB Permanent Antifreeze/water ASTM D3306-74

PTO, Speed and

Range Boxes 10.1 (38.0) † JCB AG Transmission Fluid API-GL-4, MIL-L-2105
(combined) 11.2 (42.0) ††
Front Axle
Hubs (x2) 0.66 (2.5)
Rear Axle (2WS) 7.1 (27.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C

Front 0.2 (0.75)
Rear 0.2 (0.75)
! CAUTION
brake system.
13-3-2-6
† Clutch System --- JCB Light Hydraulic Fluid - see Notice 2 ISO VG15
- see Notice 1 31.7 (120) ††

pressure additives

* - Refrigerant 3.11 lb (1.41 kg) HFC R134a CH2 FC F3
Front PTO Transfer

tank.
Notice 2: It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
† 3000 Series to S/N 641999

9803/8020 Issue 7*
(Fastrac 3185)
ITEM CAPACITY FLUID/LUBRICANT MINIMUM NTERNATIONAL
Fuel 350 (77) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 15 (3.3) See Engine Oil (All Machines) at the

Engine (Coolant) 33 (7.3) JCB Four Seasons Antifreeze & ASTM D3306, BS6580
Summer Coolant/water
PTO, Speed and

(combined) 42 (9.3) ††
Front Axle
Hubs (x2) 2.5 (0.55)
Rear Axle 27 (6.0) JCB HD90 Gear Oil API-GL-5, MIL-L-2105C

Front 0.75 (0.17)
Do not use ordinary hydraulic fluid in the
brake system.
13-3-2-6
Hydraulic System 82 (18.0) † JCB High Performance Hydraulic Oil ISO VG46
- see Note 1 120 (26.4) †† (Above 38 °C, 100 °F)

(Below 38 °C, 100 °F)

pressure additives

* - Refrigerant 1.41 kg (3.11 lb) HFC R134a CH2 FC F3
Front PTO Transfer

Note 2: It is essential that the correct specification fluid is used. Contact your JCB Distributor for further information.
† 3000 Series to S/N 641999

9803/8020 Issue 7*
(Fastrac 3185)
Fuel
92.5 (350) Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Engine (Oil) 4 (15) See Engine Oil (All Machines) at the

Engine (Coolant) 8.77 (33.0) JCB Permanent Antifreeze/water ASTM D3306-74

PTO, Speed and

Range Boxes 10 (38.0) † JCB AG Transmission Fluid API-GL-4, MIL-L-2105
(combined) 11.2 (42.0) ††
Front Axle
Hubs (x2) 0.66 (2.5)
Rear Axle 7.1 (27.0) JCB GL5 80W/90 Gear Oil API-GL-5, MIL-L-2105C

Front 0.2 (0.75)
Rear 0.2 (0.75)
! CAUTION
brake system.
13-3-2-6
† Clutch System --- JCB Light Hydraulic Fluid - see Notice 2 ISO VG15
- see Notice 1 31.7 (120) ††

pressure additives

* - Refrigerant 3.11 lb (1.41 kg) HFC R134a CH2 FC F3
Front PTO Transfer

tank.
Notice 2: It is essential that the correct specification fluid is used. Contact your JCB Dealer for further information.
† 3000 Series to S/N 641999

9803/8020 Issue 4*
1-8 Lubricants - Health and Safety 1-8
It is most important that you read and understand this FIRST AID - OIL
information and the publications referred to. Make sure all
your colleagues who are concerned with lubricants read it Eyes
too. In the case of eye contact, flush with water for 15 minutes. If
irritation persists, get medical attention.
HYGIENE
Swallowing
JCB lubricants are not a health risk when used properly for If oil is swallowed do not induce vomiting. Get medical
their intended purposes. advice.
However, excessive or prolonged skin contact can remove Skin

the natural fats from your skin, causing dryness and In the case of excessive skin contact, wash with soap and
irritation. water.
Low viscosity oils are more likely to do this, so take special SPILLAGE
care when handling used oils, which might be diluted with
fuel contamination. Absorb spilled oil with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a chemical
Whenever you are handling oil products you should maintain disposal area.
good standards of care and personal and plant hygiene. For
details of these precautions we advise you to read the Fires
relevant publications issued by your local health authority, ! WARNING
plus the following.
Do not use water to put out an oil fire. This will only
spread it because oil floats on water.
STORAGE
Extinguish oil and lubricant fires with carbon dioxide, dry
Always keep lubricants out of the reach of children.
chemical or foam. Fire fighters should use self contained
breathing apparatus.
Never store lubricants in open or unlabelled containers. 7-3-1-3/1
HANDLING
WASTE DISPOSAL
New Oil
All waste products should be disposed of in accordance
There are no special precautions needed for the handling or with all the relevant regulations.
use of new oil, besides the normal care and hygiene
practices. The collection and disposal of used oil should be in
accordance with any local regulations. Never pour used oil
Used Oil into sewers, drains or on the ground.
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.
9803/8020 Issue 1
2-1 Service Schedules - Dry Clutch Transmission 2-1
Every 10 Operating Hours or Daily Every 50 Operating Hours or Weekly

whichever occurs first whichever occurs first
Clean Do the Daily jobs plus:
1 Machine generally.
Drain
Drain 1 Fuel filter.
2 Air system tank. 2 Fuel sediment bowl (all machines except those with
optional fuel flow metering).
Check (Engine Stopped) 3 Fuel pre-filter (machines with optional fuel flow
3 Generally for damage. metering only)
4 Engine coolant level and condition. 4 Empty hydraulic coupling drain reservoir (if fitted)
5 Fuel system for leaks and contamination.
6 Hydraulic fluid level. Check (Engine Stopped)
7 Hydraulic system for leaks. 5 Fan belt tension and condition.
8 Engine and transmission for oil leaks. 6 Air conditioning compressor drive belt.
9 Gearbox oil level. 7 Front PTO transfer gearbox oil level
10 Engine oil level and condition. (optional equipment).
11 Tightness of wheel nuts. 8 Clutch fluid level.
12 Windscreen washer level. 9 Cab air filter (Clean if required).
13 Tyre pressures and condition. 10 Propshaft Security
14 Security of front weights (optional equipment).
15 Seat belt condition and security. Grease
16 Brake fluid levels. 11 Rear PTO drive shaft splines and universal joints.
* 17 Check radiator and coolers for blockage and clean if 12 Rear PTO drive shaft bearings.
required. 13 Front PTO drive shaft (optional equipment).
14 Front axle propshaft.
Check (Engine Running) 15 Rear axle propshaft.
18 Instrument readings and warning lights.
19 Operation of all electrical equipment. Note: It is essential that drive shaft and propshaft joints are
20 Exhaust for excessive smoke. lubricated as specified.
21 Operation of clutch and footbrakes.
22 Parking brake operation.
23 Operation of steering.
24 Operation of transmission.
25 Operation of 3-point linkage.
26 Operation of front linkage (optional equipment).
Note: Some machines have grease nipples fitted to the

external hydraulic control lever pivot points (see External
Hydraulics Control Valve Linkage, Lever Linkages in
section D). Grease at these points if the lever movement
becomes stiff or independent operation becomes difficult.
9803/8020 Issue 6*
First 100 Hours Dealer Service First 100 Hours Dealer Service (continued)
Change Check (engine running) - continued
1 Engine oil and filter. 48 Transmission low pressure circuit pressure maintaining
2 Fuel filters. valve setting.
3 Transmission oil filter. 49 Transmission lubrication pressure.
4 Hydraulic oil filter. 50 Diff. lock pressure relief valve.
51 External hydraulics pressure relief valve.
Clean 52 Instrument readings and warning lights.
5 Fuel lift pump gauze. 53 Operation of all electrical equipment.
6 Fuel sedimenter (drain). 54 Operation of clutch and footbrakes.
Check (Engine Stopped) 56 Operation of transmission.
7 Coolant level/leaks and antifreeze strength. 57 Operation of 3-point linkage.
8 Fuel system for leaks and contamination. 58 Operation of front linkage (optional equipment).
9 Engine pipework routing and security. 59 Rear axle/chassis clearance.
10 Fuel system pipework routing and security. 60 Height corrector valve operation.
11 Fan belt tension and condition. 61 Parking Brake operation.
12 Air conditioning compressor belt tension. 62 Pick-up hitch operation.
13 Clutch fluid level. 63 Spool valve operation.
14 Gearbox oil level. 64 Re-calibrate splitter clutch packs
15 Transmission oil cooler/pipework condition, leakage,
routing and security. Every 250 Operating Hours or 3 Monthly
16 Rear axle oil level. whichever occurs first
17 Rear axle hub oil level (4WS).
18 Front axle oil level. Do the Daily jobs through to 50 hours plus:
19 Front axle hub oil level.
20 Front PTO gearbox oil level. Clean
21 Propellor shaft security. 1 Air filter dust valve.
22 Tyre pressures. 2 Battery terminals.
23 Tightness of wheel nuts.
Check (Engine Stopped)
24 Hydraulic oil level.
3 Front axle oil level.
25 Hydraulic oil cooler/pipework condition, leakage,
4 Front axle hub oil levels.
routing and security.
5 Rear axle oil level.
26 Brake fluid levels.
6 Rear axle hub oil level (4WS) (if fitted).
27 Brake pad security (service and parking).
7 Condition of lift ram piston rods.
28 Brake pipework routing and security.
8 Hose and pipework for chafing and damage.
29 Air system for leaks.
9 Air cleaner and hose condition and security.
30 Panhard rod torque setting.
* 10 Electrical wiring for chafing and routing.
31 Ram piston rods for damage/leaks.
32 Battery charge/terminal condition and tightness. * 11 Brake pad condition and security.
12 Neutral start operation.
33 Wiring for chafing/routing.
34 Headlight alignment. Check (Engine Running)
35 Windscreen washer level. 13 Air conditioning sight glass.
36 Neutral start operation (Including clutch and PTO's). 14 Operating speed of Selectronic range changes.
37 Door locks.
Change
Grease 15† Engine oil and filter.
38 Propellor shafts and universal joints. 16 Fuel Pre-filter (machines with optional fuel flow
39 Steering swivels. metering only).
40 Rear PTO shaft bearings.
41 3 point linkage. Grease
42 Rear lift ram pivots. 17 Steering swivels.
43 Suspension cylinder pivots. 18 Rear anti-roll bar ball joints.
19 Hydraulic lift cross-shaft.
Check (engine running) 20 Hydraulic lift ram pivots.
44 Exhaust smoke. 21 Three-point linkage lift rods and top link.
45 Throttle and stop controls. 22 Suspension cylinder pivots.
46 PTO operation. 23 Automatic Trailer Coupling (when fitted).
47 2/4WD drive and diff. lock selection. 24 Steering box input shaft (3155, 3185 machines)
25 Roller Drawbar (if fitted)
* † Applies only if recommended oil (see Engine Oil) and

Stratopore filter (3185 only) are not available.
9803/8020 Issue 8*
Every 500 Operating Hours or Six Monthly

whichever occurs first
Do the Daily jobs through to 250 hours plus: Check (Engine Stopped)- continued
6 Engine valve clearances and lubrication (3185 first 1000
Clean hour service only).
1 Fuel lift pump gauze (2000 series and 3155).
Check (Engine Running)
Check (Engine Stopped) 7 Transmission lubrication pressure (HPL and LPL).
2 Battery electrolyte level (if battery is not sealed for life). 8 MRV pressure.
3 Battery charge condition. *9 Splitter clutch pack calibration.
4 Exhaust system security.
5 Engine mounting bolts for tightness. Change
6 Steering axle wheel alignment. 10 Outer air filter element.
7 Headlamp alignment. 11 Gearbox oil and clean strainer (see Note (1) below).
8 Panhard rod condition and torque tightness. 12 Front axle oil.
9 Track rod end and steering ram ball joint security. 13 Front hub oil (see Note (2) below).
10 Steering damper condition and security. 14 Rear axle oil (see Note (2) below).
11 4WS Power track rod and ball joints condition and * 14 Rear hub oil (4WS if fitted) (see Note (2) below).
security. 15 Air system dryer dessicant canister.
* 12 Suspension control arms and ‘V’ link condition and
bolt torque. Notes:
* 13 Brake caliper bolt torque.
(1) After a major transmission repair, the new oil should be
Check (Engine Running) run to operating temperature and changed again to
14 Idling speed. remove any contamination which entered during the
15 Max. no load engine speed. repair. Change the oil and filter after a further 100
16 Suspension ride height and corrector valve operation. hours if the oil was heavily contaminated because of, or
17 Suspension pressure maintenance valve pressure. from the failure (e.g. water contamination).
18 Transmission low pressure circuit pressure maintaining
valve setting. (2) After a hub repair, the new oil should be run to
* 19 Differential lock pressure relief valve. operating temperature and changed again to remove
* 20 Pick-up hitch operation. any contamination which entered during the repair.
* 21 Spool valve operation. Change the oil again after a further 100 hours to
* 22 Check for electronic draft control faults and rectify. remove any bedding-in wear.
Change Every 2000 Operating Hours or Every 2

23 † Engine oil and filters.
24 Hydraulic fluid filter element.
Years whichever occurs first
25 Transmission oil filter.
26 Fuel filter (2 elements). Do the Daily jobs through to 1000 hours plus:
*† Applies only if recommended oil (see Engine Oil) and Clean

Stratopore filter (3185 ony) are available. If these are 1 Hydraulic tank suction strainers.
not available this job should be carried out every 250
hours (see Every 250 Operating Hours for suitable Check (Engine Stopped)
alternative oils). 2 Rear suspension gas spring pressure.
3 Rear suspension accumulator pressure.
4 Engine valve clearances and lubrication (3000 Series)
Every 1000 Operating Hours or Yearly 5 Engine vibration damper (3185 only).
6 Compressor, check for leaks.
whichever occurs first 7 Engine belt tensioner bearing (3185 only).
Do the Daily jobs through to 500 hours plus:
Change
8 Inner air filter element.
Clean
9 Coolant.
1 Fuel tank suction strainer.
10 Brake system fluid.
11 Clutch system fluid.
12 Hydraulic fluid (change if sample does not indicate
2 ROPS structure.
otherwise).
3 Quality of coolant.
4 4WS RH side trunnion seals and renew if necessary (if
fitted).
5 Engine valve clearances and lubrication (2000 series
only).
9803/8020 Issue 6*
2-4 Service Schedules - Wet Clutch Transmission 2-4
! WARNING
Maintenance must be done only by suitable qualified and Every 50 Operating Hours or Daily
competent persons. Before doing any maintenance
whichever occurs first
make sure the machine is safe. It should be correctly
parked on firm level ground.
Do the Daily jobs plus:
To prevent anyone starting the engine, remove the
Drain
starter key. Disconnect the battery and chock the
1 Fuel filter.
wheels when you are working beneath the machine.
*2 Fuel pre-filter - when fitted (except 2140).
If you do not take these precautions you could be killed
Clean
or injured. 3 Air filter dust valve.
9-3-1-1
* Every
10 Operating Hours or Daily Check (Engine Stopped)
4 Fan belt tension and condition.
whichever occurs first 5 Air conditioning compressor drive belt.
6 Front PTO transfer gearbox oil level (optional
Clean equipment).
1 Machine generally. 7 Brake pad condition.
8 Cab air filter (clean if required).
Drain 9 Propshaft security.
2 Air system tank.
3 Empty hydraulic coupling drain reservoir (if fitted). Grease
10 Rear PTO drive shaft splines and universal joints.
Check (Engine Stopped) 11 Rear PTO drive shaft bearings.
4 Generally for damage. 12 Front axle propshaft.
5 Engine coolant level and condition. 13 Front PTO drive shaft (optional equipment).
6 Fuel system for leaks and contamination. 14 Rear axle propshaft.
7 Hydraulic fluid level. 15 Rear anti-roll bar joints.
8 Hydraulic system for leaks. 16 Hydraulic lift cross-shafts.
9 Machine generally for oil leaks (axles, engine, 17 Hydraulic lift ram pivots.
transmission). 18 Steering swivels.
10 Gearbox oil level. 19 Suspension cylinder pivots.
11 Engine oil level and condition. 20 3-point linkage lift rods and top link.
12 Tightness of wheel nuts. 21 Automatic trailer coupling (when fitted).
13 Windscreen washer level. 22 Roller drawbar (if fitted).
14 Tyre pressures and condition.
15 Security of front weights (optional equipment). Note: It is essential that drive shaft and propshaft joints are
16 Seat belt condition and security. lubricated as specified.
18 Check radiator and coolers for blockage and clean if
required.
Check (engine running)

19 Instrument readings and warning lights.
20 Operation of all electrical equipment.
21 Exhaust for excessive smoke.
22 Operation of clutch and footbrakes
24 Operation of transmission.
25 Operation of 3-point linkage.
27 Parking brake operation.
28 Throttle and stop controls.
9803/8020 Issue 5*
First 100 Hours Dealer Service 51 Transmission pressure circuit pressure maintaining
valve setting.
Change 52 Transmission lubrication pressure (HPL & LPL).
1 Engine oil and filter. 53 Diff. lock pressure relief valve.
2 Fuel filters. 54 External hydraulics pressure relief valve.
3 Transmission oil filter. 55 Instrument readings and warning lights.
4 Hydraulic oil filter. 56 Operation of all electrical equipment.
5 Front axle oil. 57 Operation of clutch and footbrakes.
6 Front hub oil. 58 Operation of steering.
7 Rear axle oil. 59 Operation of transmission.
8 Rear hub oil (4WS only). 60 Operation of 3-point linkage.
Clean/Drain 62 Rear axle/chassis clearance.
*9 Fuel lift pump gauze (clean - except 2140 and 3185). 63 Height corrector valve operation.
* 10 Fuel pre-filter - when fitted (drain - except 2140). 64 Parking Brake operation.
65 Pick-up hitch operation.
Check (Engine Stopped) 66 Spool valve operation.
11 Coolant level/leaks and antifreeze strength. 67 Re calibrate splitter clutch packs.
12 Fuel system for leaks and contamination.
13 Engine pipework routing and security. Every 250 Operating Hours or 3 Monthly
14 Fuel system pipework routing and security. whichever occurs first
15 Fan belt tension and condition.
16 Air conditioning compressor belt tension. Do the Daily and 50 Hour jobs plus:
17 Gearbox oil level.
18 Transmission oil cooler/pipework condition, leakage, Change
routing and security. 1 †Engine oil and filter.
19 Front PTO gearbox oil level.
20 Propellor shaft security. * † Applies only if recommended oil (see Engine Oil) and
21 Tyre pressures. Stratopore filter (2140 & 3185 only) are not available.
22 Tightness of wheel nuts. See T.I. 10/152.
23 Hydraulic oil level.
24 Hydraulic oil cooler/pipework condition, leakage,
routing and security.
26 Brake pad security (service and parking).
27 Brake pipework routing and security. *
28 Air system for leaks.
29 Panhard rod torque setting.
31 Battery charge/terminal condition and tightness.
32 Wiring for chafing/routing.
33 Headlight alignment.
34 Windscreen washer level.
* 35 Neutral start operation (including clutch and PTO’s).
36 Door locks.
37 Steering axle wheel alignment.
38 Track rod and ball joint security.
* 39 Check for error codes, (EMS and ABS when fitted, plus
engine on 2140), download, rectify and delete.
40 Air cleaner and air inlet hose condition and security.
Grease
41 Propellor shafts and universal joints.
42 Steering swivels.
43 Rear PTO shaft bearings.
44 3 point linkage.
45 Rear lift ram pivots.
46 Suspension cylinder pivots.
Check (engine running)

47 Exhaust smoke.
48 Throttle and stop controls.
49 PTO operation.
50 2/4WD drive and diff. lock selection.
9803/8020 Issue 4*
Every 500 Operating Hours or Six Monthly 47 Rear axle/chassis clearance.

whichever occurs first 48 Spool valve operation.
49 Selection speed of Selectronic range change < 2 kph.
Do the Daily jobs through to 250 hours plus: 50 Check for electronic draft control faults and rectify.
Clean Change
1 Fuel lift pump gauze (all machines except 2140 & 3185). 51 †Engine oil and filters.
52 Hydraulic fluid filter element.
Grease 53 Transmission oil filter.
2 Steering box input shaft (3000 series machines). 54 Fuel filter (2 elements).
55 Front hub oil (see Note (2) below).
Check (Engine Stopped) 56 Rear hub oil (4WS only) (see Note (2) below).
3 Battery electrolyte level (if battery is not sealed for lift). 57 Fuel pre-filter element.
4 Battery charge condition.
5 Exhaust system security. † Applies only if recommended oil (see Engine Oil) and
6 Engine mounting bolts for tightness. Stratopore filter (2140 & 3185 ony) are available. (See
7 Compressor housing for cracks and damage. T.I. 10/152.) If these are not available this job should be
8 Compressor mountings for tightness. carried out every 250 hours (see Every 250 Operating
9 Injection pump mountings for tightness. Hours for suitable alternative oils).
10 Steering axle wheel alignment.
11 Headlamp alignment. Every 1000 Operating Hours or Yearly
12 Panhard rod condition and torque tightness. whichever occurs first
13 Track rod end, steering ram and drag link ball joint
security. Do the Daily jobs through to 250 hours plus:
14 Steering damper condition and security.
15 4WS power track rod and ball joints condition and Clean
security (2000 series machines). 1 Fuel tank suction strainer (early machines only).
16 Suspension control arms and ‘V’ link condition and bolt *2 Trailer brake control line air filter.
torque.
17 Air cleaner and hose condition and security. Check (Engine Stopped)
18 Air system for leaks. 3 ROPS structure.
19 Battery terminals condition and tightness. 4 Quality of coolant.
20 Brake pad security (service and parking). 5 4WS RH side trunnion seals and renew if necessary.
6 Engine valve clearances and lubrication (2115, 2125,
21 Parking brake adjustment
2135 and 2150).
22 Brake pipework security.
7 Engine valve clearances (3185 machines, first 1000
23 Condition of lift ram rods.
hour service only)
24 Coolant level/leaks, quality and anti-freeze strength.
8 Fan belt tensioner (2140 and 3185).
25 Brake caliper bolt torque.
9 Fan hub end play (2140 and 3185).
26 Hoses and pipework for chafing and damage.
27 Neutral start operation.
10 Transmission lubrication pressure (HPL and LPL).
29 Front axle oil level.
11 MRV pressure.
30 Rear axle oil level.
12 Splitter and wet clutch calibration.
31 Transmission and hydraulic oil cooler/pipework
13 ABS system test.
condition, leakage and security.
32 Wiring for chafing and routing.
Change
33 Download EMS Datalog.
14 Outer air filter element.
34 Download ABS error codes and investigate any found.
15 Gearbox oil and clean strainer (see Note (1) below).
35 Download engine error codes, rectify and delete (2140
16 Front axle oil.
only).
17 Rear axle oil.
36 Brake light switch input to ABS ECU using computer
18 Air system dryer dessicant canister.
diagnostic tool.
37 All air warning lamps illuminate after draining down the
Notes:
air tanks.
38 The park brake lamp illuminates after draining down the
(1) After a major transmission repair, the new oil should be
trailer air tank.
run to operating temperature and changed again to
remove any contamination which entered during the
repair. Change the oil and filter after a further 100
39 Idling speed.
hours if the oil was heavily contaminated because of, or
40 Max. no load engine speed.
from the failure (e.g. water contamination).
41 Suspension ride height and corrector valve operation.
42 Suspension pressure maintenance valve pressure.
(2) After a hub repair, the new oil should be run to
43 Transmission pressure circuit pressure maintaining
operating temperature and changed again to remove
valve setting.
any contamination which entered during the repair.
44 Differential lock pressure.
Change the oil again after a further 100 hours to
45 Field speed control.
remove any bedding-in wear.
46 Pick-up hitch operation.
9803/8020 Issue 6*
2-7 Service Schedules- Wet Clutch Transmission 2-7
Every 2000 Operating Hours or every 2

Clean
1 Hydraulic fluid suction strainer.

2 Rear suspension gas spring pressure.
3 Rear suspension accumulator pressure.
*4 Engine valve clearances and lubrication (3185).
5 Engine vibration damper.
*6 Compressor output line, air drier and pressure
regulator: check for carbon deposits and for air leaks.
*7 Radiator hose condition.
8 Transmission accumulator pressure.
Change
9 Inner air filter element.
10 Coolant.
11 Brake system fluid.
12 Hydraulic fluid (change if sample does not indicate
otherwise).
* Every5000 Operating Hours or Every 2


1 Engine valve clearances and adjust if necessary (2140).
9803/8020 Issue 2*
2-8 Cleaning the Machine and Checking for Damage 2-8
Clean the machine using water and/or steam. Pay particular Make sure all pivot pins are correctly in place and secured
attention to the underside. Do not allow mud to build up on by their locking devices.
the engine and transmission. Make sure that the radiator
grille is not clogged up. Ensure that the steps and handrails are undamaged and
secure.
Excessive power washing can cause damage to seals and
bearings. Do not direct high power water jets at oil seals, Check for broken or cracked window glass. Replace
universal joints or electrical components, especially draft damaged items.
control solenoids.
Check all lamp lenses for damage.
On the 4WS machine, take special care to avoid directing
high power water jets at the electrical connections to the Inspect the tyres for damage and penetration by sharp
front and rear axles. objects.
Inspect steelwork for damage. Note damaged paintwork for Check that all safety decals are in place and undamaged, fit
future repair. new decals where necessary.
SEAT BELT
Checking Seat Belt Condition and Security
! WARNING
Replace the seat belt with a new one if it is damaged, if
the fabric is worn, or if the machine has been in an
accident. Fit a new seat belt every three years regardless
of condition.
2-3-1-8
Inspect the seat belt for signs of fraying and stretching.

Check that the stitching is not loose or damaged. Check that
the buckle assembly is undamaged and works correctly.
Check that the belt mounting bolts are undamaged,

correctly installed and tightened.
9803/8020 Issue 1
2-9 Bonnet 2-9
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 and stop the engine. Remove the starter key.
2 Release the required bonnet side by turning the two

turnbuckles A to the vertical position.
A
3 Lift the bonnet side clear of the machine and put it in a
safe place to prevent damage.
Closing the Bonnet

1 Position the bonnet side in the aperture and ensure it
locates at the top. Fasten the bonnet securely by
pushing in each turnbuckle A.
Opening the Bonnet 231810
! WARNING
The engine has rotating parts. Do not open the engine
cover while the engine is running. Do not use the
machine with the cover open.
INT-2-1-6
1 Engage the parking brake, put the transmission in

neutral, turn the front wheels onto full left lock and stop
the engine. Remove the starter key.
2 Release latches by pulling back lever B.
3 Raise the bonnet fully. Do not leave it partly raised as it

could then creep down.
Closing the Bonnet

1 Lower the bonnet by pushing it at the front, centrally B
above the grille, to ensure that it closes squarely. Press
it firmly down to close the latches.
A293970
9803/8020 Issue 1
3-1 Greasing 3-1
General Propshafts and PTO Driveshafts

Read and understand Lubricants - Health and Safety, ! WARNING
before greasing. You must grease the machine regularly to
Make the machine safe before getting beneath it. Do the
keep it working efficiently. Regular greasing will also
following: Park on level ground. Engage the parking
lengthen the machine's working life. Refer to the Service
brake. Lower any mounted implements to the ground.
Schedules for the recommended frequencies.
Stop the engine, remove the starter key, disconnect the
Note: If working in muddy conditions the propshafts and battery. Chock the wheels.
13-3-1-1
PTO driveshafts must be greased daily.
Rear PTO drive shaft
Note: The machine must always be greased after pressure- Grease points 7 to 9.
washing or steam cleaning. Extra care must be taken to
ensure that propshaft universal joints and splines are * Front axle propshaft
greased regularly. Grease points 1 to 3. (Point 2 not fitted to later machines.)
Greasing should be done with a grease gun. Normally, two * Rear axle propshaft
strokes of the gun should be enough. Stop greasing when Grease points 4 to 6. (Point 6 not fitted to later machines.)
fresh grease appears at the joint. Use only JCB HP Grease
Front PTO drive shaft (optional)
or equivalent.
Grease points 10 to 12.
In the following illustrations the grease points are numbered.
Count them off as you grease them. Note: When greasing the universal joints, you must ensure
that grease appears at all four bearing caps. If grease does
Refit the grease point dust caps after greasing. not appear at any cap, move the shaft from side to side and
then re-grease. Wipe away all excess grease.
Rear PTO Drive shaft bearing

0 Grease point 13. Do not exceed 2 to 3 strokes of the grease
gun.
!
2
1 @
8 9
7
65 A286622
9803/8020 Issue 3*
3-2 Greasing 3-2
Steering Swivels
* (2000Series Machines)
! WARNING
battery. Chock the wheels.
13-3-1-1
2WS: Grease points 1 and 2 on each side of the machine.
4WS: Grease points 3 to 6 on the front axle. 1

Grease points 7 to 10 on the rear axle.
Note: After initial greasing, turn the wheels from lock to lock,
then grease again to ensure full penetration.
2 S229870
3 5
4
6
9
7
0 8
250690
9803/8020 Issue 2*
3-3 *Greasing 3-3
Front Axle Steering Swivels

* (3000Series Machines)
! WARNING
13-3-1-1
Note: After initial greasing, turn the wheels from lock to lock,
then grease again to ensure full penetration.
1 3
2 4
A293430
9803/8020 Issue 2*
3-4 Greasing 3-4
*(2000 Series Machines)
* Hydraulic Lift and 3-Point Linkage * Rear PTO Drive Shaft Bearings
Hydraulic Lift Cross-shaft Grease point 9. Do not exceed 2 to 3 strokes of the grease
Grease points 1 and 2. gun.
Hydraulic Lift Rams

Grease points 3 to 6. * Rear Suspension Cylinder Pivots
Three Point Linkage Lift Rods
Grease points 7 and 8. Grease points 10 to 13.
* Stabilisers (Standard Type)

Grease at point 14
Note: Where standard type stabilisers are fitted to both

sides of the machine, there will be a grease point on each
one.
@ 0
£ !
1 2
3 4
9
7 8
5 6
S229981
9803/8020 Issue 2*
3-5 Greasing 3-5
*(3000 Series Machines)
* ! WARNING * Hydraulic Lift and 3-Point Linkage
You will be working close into the machine for these
jobs. Lower the equipment. Remove the starter key and Hydraulic lift cross-shaft
disconnect the battery. This will prevent the engine from Grease points 5 and 6.
being started. Make sure that the parking brake is
Hydraulic lift rams
engaged.
Chock all four wheels before getting under the machine. Three point linkage lift rods
13-3-1-9
Grease at nipples 11 and 12. On later machines grease at
nipples 11, 12, 13 and 14 (lift collars A and B to access
Note: Ladder hitch and trailer coupling omitted for clarity.
nipples 13 and 14). On machines with heavy duty linkage
grease points 15 and 16 also.
* Rear Suspension Cylinder Pivots 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
1 3
2 A B A B A B
4
5 6
I II III
7 8
*
% ^
! @
A B &
9 0
£ $
A286030
9803/8020 Issue 2*
3-6 Greasing 3-6
Rear Anti-roll Bar Ball Joints
! WARNING
13-3-1-1
2WS: Grease points 4 and 5.

4WS: Grease points 6 to 9.
2WS
4 5
262210
4WS
6 8
7 9 A268420
9803/8020 Issue 1
3-7 Greasing 3-7
Steering Box Input Shaft Seal
Grease at point 1 through the hole in the chassis side
member.
Note: Apply only one shot of grease from a manual grease

gun with a rigid connector. Excessive greasing would
damage the internal seals of the steering box.
1
A293980
Rear Anti-roll Bar Ball Joints
! WARNING
13-3-1-1
Grease points 2 and 3.
2 3
262210
9803/8020 Issue 1
3-8 Greasing 3-8
Automatic Trailer Coupling (if fitted)
Note: Whenever the coupling has been pressure-washed it

must always be greased.
Make sure the coupling is in the open position, i.e. the

coupling pin is up and the hand lever A is in its highest
position.
Grease at points 1 and 2.
Operate lever A several times so that the grease is

distributed throughout the bearing.
! CAUTION
Keep your hands out of the funnel or you may be injured
by the coupling pin as it is forced down by its spring.
13-2-2-17
Grease again and operate the hand lever again.
If driving without a trailer attached, close the coupling to

prevent dirt accumulation.
S170201
Roller Drawbar (if fitted)

A B A B A B
I II III
! WARNING
jobs. Lower the equipment. Remove the starter key and
disconnect the battery. This will prevent the engine from
engaged.
Chock all four wheels before getting under the machine.

13-3-1-9
Grease points 3 and 4.

Smear surface 5 with grease.
5
3
4
A309960
9803/8020 Issue 2*
4-1 Cab 4-1
Checking the ROPS Structure
! WARNING
The cab on this machine is designed to give the operator Check the structure for damage.
protection in the event of the machine rolling over
(ROPS). The following points must be strictly observed. Check that the four mounting bolts are installed and
undamaged. Check that torque tightness of nuts A and B is
1 If the machine has been in an accident which has correct (see Table below). Tighten them to the correct
damaged the ROPS structure, the machine must not torque if necessary.
be used until the structure has been renewed. If there
is any doubt about the strength of the ROPS Zinc-Plated Fasteners (colour: golden)
structure, it must be renewed. The operator could be
killed or seriously injured as a result of using a Nm kgf m lbf ft
machine with a damaged or missing ROPS. 375 38 277
2 The ROPS structure must not be modified except as Dacromet Fasteners (colour: mottled silver)
approved by JCB. Unauthorised modifications may
result in weakening of the structure. Nm kgf m lbf ft
365 37 269
3 Always use JCB supplied parts to mount the ROPS
structure on the machine. The use of unapproved
components could reduce the protection given by the
structure.
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
B
A 229990
9803/8020 Issue 3
4-2 Cab 4-2
Checking Windscreen Washer Fluid Level
Fill the windscreen washer bottle X with a suitable liquid. The

liquid should contain a de-icing fluid to prevent freezing. Do X
not use engine coolant antifreeze.
A290350
* 2000 Series Machines
A293830
9803/8020 Issue 2*
5-1 Air Conditioning 5-1
Cleaning the Filter * Adjusting the Compressor Belt
(2115, 2125, 2135, and 2150)
Note: For crop spraying applications, a heavy duty carbon
filter can be used in place of the standard filter. Carbon filters 1 Stop the engine.
must not be cleaned. Keep a log of the hours used and
renew at 250 hour intervals. 2 Remove the left-hand bonnet side panel.
! WARNING
The filter may be filled with dust. Wear goggles and a
! WARNING
face mask when removing the filter. Make sure the engine cannot be started. Disconnect the
2-3-3-6 battery before doing this job.
2-3-3-5
1 Remove nuts A and pull out the filter B.

3 Loosen nuts A, B.
2 Using compressed air at a maximum pressure of 5.5 bar
(80 lbf/in2), blow out the dirt from the clean (gasket) side 4 Position the compressor so that there is 10mm (0.4 in)
to the dirty (grid) side. slack on the longest run of the belt.
3 Check the condition of the filter element and renew if split 5 Retighten nuts A and B.
or worn.
4 Check the condition of the filter gasket. If split or worn ! WARNING

renew the filter. The air conditioning system is a closed loop system and
contains pressurised refrigerant. No part of the system
5 Check and clean the filter sealing face on the cab body. must be disconnected except by a qualified refrigeration
engineer.
4-3-4-1
6 Refit the filter, making sure that the gasket side goes first.
Refit nuts A.
S232630
229880
9803/8020 Issue 3*
Cleaning the Filter
Note: The air conditioning system contains environmentally
safe R-134A refrigerant. Do not use test equipment or
gauges that have contacted R12 refrigerant or the system
will be damaged.
Note: For crop spraying applications, a heavy duty carbon

filter can be used in place of the standard filter. Carbon
filters must not be cleaned. Keep a log of the hours used
and renew at 250 hour intervals.
! WARNING
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6
1 Unclip closing panel A, unscrew and pull out the filter 160800
B.
2 Using compressed air at a maximum pressure of 5.5

bar (80 lbf/in2), blow out the dirt from the clean (gasket)
side to the dirty (grid) side.
3 Check the condition of the filter element and renew if

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

renew the filter.
5 Check and clean the filter sealing face on the cab body.
6 Refit the filter, making sure that the gasket side goes in
first. Refit the closing panel A.
160810
9803/8020 Issue 3
* Adjusting the Compressor Belt

(2140, 3155 and 3185)
1 Stop the engine.
2 Open the bonnet.
! WARNING
Make sure the engine cannot be started. Disconnect the
battery before doing this job.
A B
2-3-3-5
3 Loosen the mountings
* Loosen fasteners A, B, C and D (3155) or E, F and G

(2140 and 3185).
4 Adjust the belt tension C

Position the compressor so that there is 10 mm (0.4 in)
slack on the longest run of the belt.
5 Tighten the Mountings
Retighten fasteners A, B, C and D, or E, F and G. D 272000
! WARNING
The air conditioning system is a closed loop system and
should be disconnected until the system has been
discharged by a refrigeration engineer or a suitably
trained person. You can be severely frostbitten or injured
by escaping refrigerant.
4-3-4-1/2
E F
G
271990
9803/8020 Issue 3*
6-1 Electrics 6-1
Battery Warning Symbols

! CAUTION
The following warning symbols may be found on the battery. 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
Symbol Meaning local environmental waste regulations.
INT-3-1-12
! WARNING
Keep away from children. Batteries give off an explosive gas. Do not smoke when
handling or working on the battery. Keep the battery
away from sparks and flames.
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
Shield eyes. 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

No smoking, no naked flames,
ventilated area. Switch the charging circuit off before
no sparks
connecting or disconnecting the battery. When you have
installed the battery in the machine, wait five minutes
before connecting it up.
First Aid - Electrolyte

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

medical help.
IS SWALLOWED
Battery acid.
Do not induce vomiting. Drink large quantities of water
or milk. Then drink milk of magnesia, beaten egg or
vegetable oil. Get medical help.
GETS ONTO YOUR SKIN
Flush with water, remove affected clothing. Cover burns

Note operating instructions.
with a sterile dressing then get medical help.
5-3-4-3/1
9803/8020 Issue 1
6-2 Electrics 6-2
Checking the Battery Electrolyte Level

* Note: The battery on Fastrac 2115, 2125, 2135 and 2140
machines is located as shown right, on the right of the
machine. On Fastrac 2150 machines the battery is located
on the left hand side.
Maintenance free batteries used in normal temperate climate

applications should not need topping up. However, in
certain conditions (such as prolonged operation at tropical
temperatures or if the alternator overcharges) the electrolyte
level should be checked as described below.
1 Apply the parking brake and stop the engine.

*2 Remove two screws A and swing open the hinged step
unit B (below the right hand cab door). Later machines A
have an upward lifting step unit.
3 Prize out the cell covers. Look at the level in each cell.
B
260030
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
Checking the Electrolyte Level

(Unless Sealed for Life type which needs no checking)
Note: On machines for the UK market only battery 1 is fitted. ! WARNING

On European machines batteries 1 and 2 are fitted. Do not top the battery up with acid. The electrolyte could
boil out and burn you.
2-3-4-6
1 Apply the parking brake and stop the engine. Remove
the battery access panel A. Note: When two batteries are fitted on the machine, they are
connected in parallel. When fitting the cables, ensure that
2 Prize out covers B. Look at the level in each cell. The they are connected as shown on the illustration.
electrolyte should be 6 mm (0.25 in) above the plates.
Top up if necessary with distilled water or de-ionized
water.
A
B
1
A294000
9803/8020 Issue 3*
6-3 Electrics 6-3
Checking the Beam Alignment

1 Park the machine on level ground so that the front
headlights A are 2.00m from a wall.
2 Measure the distance Z from the ground to the centre

of the front headlights A. Subtract 25 mm ± 5 mm from
this distance and mark a horizontal line XX on the wall
at this height. When the auxiliary headlights B are fitted
mark a second horizontal line YY on the wall
approximately 1300 mm above XX.
3 When the headlights are switched on to dipped beam,

the horizontal tops of the light beams should be in line
with the horizontal lines XX and YY on the wall.
4 To adjust the beam, slightly slacken nut C or D,

reposition the light and then tighten the nut.
Note: The illustration shows a 3000 Series machine. The

principle for 2000 Series machines is identical.
B Y
B
Y
1300 mm
A A
X
X
D
Z
2.0 m
C
A293861
9803/8020 Issue 3*
7-1 Hydraulics 7-1
* Note: The hydraulic tank shown below on the right hand Changing the Filter Element
side of the machine is that for the Fastrac 2115, 2125, 2135
and 2140 machines. On the Fastrac 2150, 3155 and 3185 1 Park the machine on level ground. Apply the parking
machines the hydraulic tank is on the left hand side of the brake. Lower the rear linkage to the ground. Stop the
machine. engine. Remove the starter key. Wash off all dirt from
around the tank cap B and element cover plate D.
Checking the Fluid Level
2 Remove the element as follows:
a Remove tank cap B.

! WARNING b Remove nuts C, cover plate D and 'O' ring E.
Fine jets of hydraulic fluid at high pressure can penetrate c Remove the element assembly F and 'O' ring G.
the skin. Do not use your fingers to check for hydraulic d Remove the nut and spring assembly H. Remove the
fluid leaks. Do not put your face close to suspected element J from its spindle.
leaks. Hold a piece of cardboard close to suspected e i Dry clutch machines - discard the complete
leaks and then inspect the cardboard for signs of element J (see view W).
hydraulic fluid. If hydraulic fluid penetrates your skin, get ii Wet clutch machines - remove and discard the
medical help quickly. paper insert Y from metal outer element J (see
INT-3-1-10/1 view X).
f Wet clutch machines only - clean the metal outer
! CAUTION element J.
Using incorrect fluid could damage the system. See g Clean the magnets K.
Fluids, Capacities and Lubricants for the correct fluid.
3 Fit the new element as follows:
The fluid can harm your skin. Wear rubber gloves. Cover
cuts or grazes.
2-3-5-1/2 a Wet clutch machines - fit a new paper insert into
metal outer element J.
1 Park the machine on level ground. Apply the parking b Assemble the new element J (dry clutch machines)
brake. Lower any mounted implements to the ground. or refurbished element J/Y (wet clutch machines) on
Stop the engine. Remove the starter key. to the spindle, using a new seal L. Ensure that the
top lip of the seal locates in the groove inside the
2 Look at the fluid level in the sight gauge A. The level filter head M. Fit and tighten the nut and spring
should be between the two marks on the gauge. If the assembly H.
fluid is cloudy, water or air has entered the system. c Fit the element assembly F using a new 'O' ring G.
Water or air in the system could damage the hydraulic d Refit cover plate D and nuts C using a new 'O' ring
pump. E.
e Tighten nuts C to 7 Nm (5 lbf ft).
3 If necessary, add recommended fluid at tank cap B. f Top up fluid level at tank cap B and refit cap.
C
D
M
K G
L F E
W B
J Y
A
X
H
J
9803/8020 Issue 4*
7-2 Hydraulics 7-2
* Note: The hydraulic tank shown below on the right hand 1 Park the machine on firm, level ground.
side of the machine is that for the Fastrac 2115, 2125, 2135
and 2140 machines. On the Fastrac 2150, 3155 and 3185 2 Place a container that can hold at least 60 litres (13.5
machines the hydraulic tank is on the left hand side of the UK gal; 16.2 US gal) beneath drain plug B. Remove the
machine. plug and allow the oil to drain. Refit the drain plug.
Changing the Hydraulic Fluid and Cleaning ! WARNING

the Suction Strainers Oil will gush from the hole when the drain plug is
removed. Keep to one side when you remove the plug.
! WARNING
2-3-4-2
Fine jets of hydraulic fluid at high pressure can penetrate 3 Remove the strainers as follows:
the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected a Remove tank cap A.
leaks. Hold a piece of cardboard close to suspected b Disconnect pipe C from the filter, remove bolts D
leaks and then inspect the cardboard for signs of and take out filter assembly E.
hydraulic fluid. If hydraulic fluid penetrates your skin, get c Unscrew external hydraulics/draft control hydraulic
medical help quickly. strainer F from its spigot and withdraw from the tank
INT-3-1-10/1 via the filter aperture.
d Repeat step c for the steering, brakes and
! WARNING suspension strainer G.
Make the machine safe before getting beneath it. Do the e Repeat step c for the rear axle steering strainer H
following: Park on level ground. Engage the parking (4WS machines only)
Stop the engine, remove the starter key, disconnect the 4 Clean the strainers with a suitable solvent. Follow the
battery. Chock the wheels. solvent manufacturer's instructions on safety.
13-3-1-1
! CAUTION 5 Refit the strainers, using JCB Activator and JCB
Using incorrect fluid could damage the system. See Threadlocker and Sealer on the threads. Refit the filter.
Fluids, Capacities and Lubricants for the correct fluid. Reconnect pipe C using Clayton System Seal SC1251
The fluid can harm your skin. Wear rubber gloves. Cover to seal the threads.
cuts or grazes.
2-3-5-1/2 6 Fill the tank with the recommended hydraulic fluid.
4WS C E
F A
G
F
H
G
B
9803/8020 Issue 3*
7-3 Hydraulics 7-3
Emptying the Hydraulic Coupling Drain

Reservoir (if fitted)
* Empty reservoir A at least every 50 hours, but more often if
necessary.
A B A B A B
I II III
A297040
9803/8020 Issue 2*
8-1 * Dry Clutch Hydraulic System 8-1
Checking the Fluid Level

1 Stop the engine. Remove the starter key.
2 Open the bonnet.

B
3 Check the fluid level in the reservoir. The fluid level
should be between the two lines moulded into the side of
the reservoir A. If necessary, add fluid as in Step 4. A
4 If fitted, remove and clean the rubber splash guard from
the top of filler cap B. Clean the area around the filler
cap. Remove the cap and carefully pour in the
recommended fluid until it reaches the correct level.
USING THE INCORRECT FLUID CAN DAMAGE THE
SYSTEM. Avoid spillage if possible. Wipe up any
spillage. Do not allow dirt to enter the reservoir. Fit the
cap securely and refit the splash guard, if appropriate.
A293800
9803/8020 Issue 3*
9-1 PTO, Speed and Range Gearboxes 9-1
Checking the Oil Level

1 Park the machine on firm, level ground. Engage the
parking brake. Lower the equipment. Stop the engine.
2 Check that oil is at the top mark on dipstick A. Add the

recommended oil as necessary via filler B. After topping
up, run the engine for 1 minute, then stop the engine and
allow to stand for 2 minutes before re-checking the level.
B
Note: Do not overfill as this would cause oil to be forced
past the oil seals and out of the gearboxes.
229920
194570
9803/8020 Issue 2*
* Changing the Oil and Cleaning the Strainer

(Dry Clutch Transmission)
1 Park the machine on firm, level ground. BD
! WARNING
brake. Lower any mounted implements to the ground. A C
13-3-1-1
332590
2 Place containers beneath drain plugs of the splitter
gearbox A and B, the range box C and the speed box D.
Remove the plugs and allow the oil to drain.
! WARNING
Oil will gush from the hole when the drain plug is
2-3-4-2
*3 Clean the plugs and sealing washers before refitting

them.
Tighten drain plug D. Do not overtighten as the gearbox

casing is alloy and the threads can be stripped easily.
4 Disconnect pipe E. Unscrew strainer F and discard 'O' A

ring G.
Note: Remove the strainer carefully to avoid dislodging any B

332450
contamination on the outside of the strainer.
5 Clean the strainer with a suitable solvent. Follow the

solvent manufacturer's instructions on safety.
6 Refit strainer F, using a new 'O' ring G. Refit pipe E.
Fill the gearboxes with new oil. (Filler is shown on

previous page). After filling, run the engine for 1 minute,
then stop the engine and allow to stand for 2 minutes
before re-checking the level and topping up as required.

* Torque Settings
D
Item Nm kgf m lbf ft 332560
A 101 10.3 74
B 180 18.4 133
C 180 18.4 133
D 32-37 3.3-3.8 24-27
F 80 8.2 59
E
F
G C B 332570
9803/8020 Issue 4*
9 - 2A PTO, Speed and Range Gearboxes 9 - 2A
Changing the Oil and Cleaning the Strainer * Torque Settings

(Wet Clutch Transmission) Item Nm kgf m lbf ft
A 101 10.3 74
1 Park the machine on firm, level ground.
B 180 18.4 133
! WARNING C 180 18.4 133
D 32-37 3.3-3.8 24-27
F 80 8.2 59
13-3-1-1 B
2 Place containers beneath drain plugs of the splitter
gearbox A and B, the range box C and the speed box D.
Remove the plugs and allow the oil to drain.
! WARNING A DC
2-3-4-2
332590
*3 Clean the plugs and sealing washers before refitting
them.
Tighten drain plug D. Do not overtighten as the gearbox

casing is alloy and the threads can be stripped easily.
4 Disconnect pipe E. Unscrew strainer F and discard 'O'

ring G.
Note: Remove the strainer carefully to avoid dislodging any

contamination on the outside of the strainer.
A
5 Clean the strainer with a suitable solvent. Follow the
solvent manufacturer's instructions on safety.
B 332450
6 Refit strainer F, using a new 'O' ring G. Refit pipe E.
Fill the gearboxes with new oil. After filling, run the
engine for 1 minute, then stop the engine and allow to
stand for 2 minutes before re-checking the level and
topping up as required.

D
332560
C
G
F B
E A361900
9803/8020 Issue 2*
Changing the Transmission Oil Filter

Note: If the transmission oil warning light comes on when 2 Position a small container to catch the oil when the
the engine is running and the oil is warm, change the filter bowl is removed.
element before the time shown in the service schedule.
Unscrew element A.
Clean the filter head B. Make sure that seal C is in
! WARNING position, apply a film of oil to the seal and screw the
new element onto the filter head, hand-tight only.
3 Check the oil level and top up if required.
4 Run the engine for a few moments to circulate the oil.
13-3-1-1 Check that the transmission oil warning light has gone
out. Stop the engine and check for leaks around the
filter.
S229070
9803/8020 Issue 1
Checking the Front PTO Gearbox Oil

Level (If Fitted)
1 Park the machine on firm, level ground. Engage the
parking brake. Lower the equipment. Stop the engine.
2 Remove level plug A and check that oil level is up to

the bottom of the hole. Add recommended oil, if
necessary.
232240
9803/8020 Issue 1
10 - 1 Front Axle 10 - 1
Checking the Differential Oil Level Changing the Differential Oil
1 Park the machine on firm, level ground. 1 Park the machine on firm, level ground.
! WARNING ! WARNING
Make the machine safe before getting beneath it. Do the Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking following: Park on level ground. Engage the parking
brake. Lower any mounted implements to the ground. brake. Lower any mounted implements to the ground.
Stop the engine, remove the starter key, disconnect the Stop the engine, remove the starter key, disconnect the
battery. Chock the wheels. battery. Chock the wheels.
13-3-1-1 13-3-1-1
2 Clean the area around the fill/level plug A, then remove 2 Place a container that can hold at least 30 litres (6.6 UK
the plug and its sealing washer. Oil should be level with gal; 27.9 US gal) beneath the drain plug B. Remove the
the bottom of the hole. Add recommended oil, if plug and allow the oil to drain. Clean the plug before
necessary. Clean the plug and sealing washer before refitting.
refitting.
! WARNING
2-3-4-2
3 Fill with the recommended oil at fill/level plug A. Oil

should be level with the bottom of the fill/level hole.
Clean the plug and sealing washer before refitting.

past the oil seals and out of the axle.
A A
B B
S229081 S160642
Fastrac 2115, 2125, 2135 and 2140 Machines * Fastrac 2150 and 3000 Series Machines
9803/8020 Issue 3*
10 - 2 Front Axle 10 - 2
Checking the Hub Oil Levels Changing the Hub Oil

Check each hub separately. Change the oil in each hub separately.
1 Park the machine on firm, level ground with the OIL 1 Park the machine on firm, level ground with the fill/level
LEVEL mark horizontal as shown at A. Engage the plug C at the bottom as shown at B.
parking brake. Stop the engine and remove the starter
key. 2 Place a container that can hold at least 1.5 litres (0.3
UK ga; 0.36 US gal) beneath the drain plug C. Remove
2 Clean the area around the fill/level plug C, then remove the plug and allow the oil to drain.
the plug and its sealing washer. Oil should be level with
the bottom of the hole. Add recommended oil, if
necessary. Clean the plug before refitting.
! WARNING
2-3-4-2
3 Set OIL LEVEL mark to the horizontal as shown at A.

Fill the hub with recommended axle oil, through the
fill/level hole C. Oil should be level with the bottom of
the fill/level hole. Clean and refit fill/level plug C.

A B
OIL
C
LEVEL
LEVEL
OIL
C
A286290
A286290 A286290
9803/8020 Issue 1
11 - 1 Rear Axle (2WS) 11 - 1
! CAUTION A
The axle oil level must be checked with the machine
level, otherwise a false indication of the amount of oil in
the axle will be given.
16-3-5-3
Note: As the same oil is used right through the rear axle, it is
only necessary to check the level at one hub.
1 Park the machine on firm, level ground with the OIL OIL
LEVEL
C
LEVEL mark horizontal as shown at A. Engage the
parking brake. Stop the engine and remove the starter
key.
2 Clean the area around the level plug C, then remove the
plug and its sealing washer. Oil should be level with the
bottom of the hole. If the level is low proceed to step 3.
Otherwise, clean and refit the level plug.
A286290
3 Clean the area around the filler plug E. Remove plug E
and add oil until it runs from the hub. Clean the plugs
before refitting.

160680
9803/8020 Issue 1
11 - 2 Rear Axle (2WS) 11 - 2
Changing the Oil
! WARNING
A
13-3-1-1
LEVEL
1 Position level/drain plug C in both of the hubs at the
OIL
bottom as shown at A.
Note: Depending on the phasing of the hubs, it may not be C

possible to position both hub level/drain plugs at the bottom
at the same time. In this case, do Step 2 at one hub, then
rotate the axle and drain the other hub.
A286290
2 Place containers beneath the two hub level/drain plugs C
and the axle casing drain plug F. Remove the plugs and A286290
allow the oil to drain.
! WARNING
2-3-4-2 B
3 Set OIL LEVEL mark on one of the hubs to the horizontal
as shown at B, leaving out the plug C. Refit plug C on the
other hub.
4 Clean the area around the filler plug E. Remove plug E OIL
and add the specified quantity of oil. Stop filling if oil runs LEVEL
from the hub. Clean and refit plug C.

C
5 Set OIL LEVEL mark on the other hub to the horizontal
as shown at B. Clean the area around plug C, then
remove the plug and its sealing washer. Oil should be
level with the bottom of the hole. If necessary add more
oil at filler plug E. Clean and refit plugs C and E.
Note: Do not overfill as this would cause oil to be forced A286290

* Note: the machine illustrated is typical and does not show a

particular machine. Procedures, however, are identical.
160690
9803/8020 Issue 2*
11 - 3 Rear Axle (4WS) 11 - 3
* Note: Four wheel steer (4WS) is available on Fastrac 2115, Changing the Differential Oil
2125, 2135 and 2140 machines only.
Checking the Differential Oil Level
! WARNING
1 Prepare the Machine Make the machine safe before getting beneath it. Do the
Park the machine on firm, level ground. Engage the brake. Lower any mounted implements to the ground.
parking brake. Stop the engine and remove the starter Stop the engine, remove the starter key, disconnect the
key. battery. Chock the wheels.
13-3-1-1
2 Check/Add Oil
2 Place a container that can hold at least 18 litres (4 UK
gal) beneath the drain plug F. Remove the plug and
a Clean the area around the level plug E, then remove
allow the oil to drain. Clean the plug before refitting.
the plug and its sealing washer. Oil should be level
with the bottom of the hole.
! WARNING
b If the level is low, clean the area around the filler plug Oil will gush from the hole when the drain plug is
G then remove the plug and its sealing washer. Add removed. Keep to one side when you remove the plug.
2-3-4-2
recommended oil as required.
3 Clean the area around the level plug E and filler plug G ,
c Clean the plugs and sealing washers before refitting.
then remove the plugs and sealing washers. Fill with
the recommended oil at filler plug G until oil is level with
the bottom of the hole for level plug E. Clean the plugs
and sealing washers before refitting.

E
S252960
9803/8020 Issue 2*
11 - 4 Rear Axle (4WS) 11 - 4
* Note: Four wheel steer (4WS) is available on Fastrac 2115, Changing the Hub Oil
Change the oil in each hub separately.
Checking the Hub Oil Levels
1 Park the machine on firm, level ground with the fill/level
Check each hub separately. plug C at the bottom as shown at B.
1 Park the machine on firm, level ground with the OIL 2 Place a container that can hold at least 2 litres (0.4 UK
LEVEL mark horizontal as shown at A. Engage the gal) beneath plug C. Remove the plug and allow the oil
parking brake. Stop the engine and remove the starter to drain.
key.
2 Clean the area around the fill/level plug C, then remove

! WARNING
the plug and its sealing washer. Oil should be level with Oil will gush from the hole when the drain plug is
the bottom of the hole. Add recommended oil as removed. Keep to one side when you remove the plug.
2-3-4-2
required. Clean the plug before refitting.
3 Set OIL LEVEL mark to the horizontal as shown at A.

Fill the hub with recommended axle oil, through the
fill/level hole C. Oil should be level with the bottom of
the fill/level hole. Clean and refit fill/level plug C.

A B
OIL
LEVEL
C
LEVEL
OIL
C
A286290
A286290
A286290
9803/8020 Issue 2*
11 - 5 Front and Rear Axle Steering Swivels (4WS) 11 - 5
* Note: Four wheel steer (4WS) is available on Fastrac 2115,

Checking 4WS Right Side Trunnion Seals

1 Park the machine on firm level ground with the front
and rear wheels in the straight ahead position. Apply
the parking brake, switch off the engine and remove the
starter key. 22C
23 22E
22F
2 On the front axle, remove the four bolts 23. Remove
cover plate 22C and hold to one side. Refit two bolts 23 22D
to prevent trunnion 22D separating from hub swivel 14. 14
3 In trunnion 22D check the recess housing
potentiometer 22F which should be dry and clean. Any
sign of water or other contamination indicates a
breakdown of the seal between the trunnion and cover
plate 22C and/or the seal around the potentiometer
wires in the trunnion groove.
4 Remove the two bolts 22E and lift out potentiometer

22F, followed by spindle 22G.
5 The spindle should be clean.

22G
a Check for grease, the presence of which indicates a 22H
damaged O-ring 22H. A249240
b Check for lack of freedom of movement in the bore

of the trunnion.
6 If any of the undesirable symptoms detailed in steps 3

and 5 are present, carry out the trunnion procedures in
Front Axle and Rear (4WS) Axle, Hub and Driveshaft,
Dismantling and Assembly, Section F.
7 Repeat steps 2 to 6 on the rear axle.
8 Calibrate the steering sensors (potentiometers) as

described in Four-wheel Steer (4WS), Sensors,
Calibration in Section C. Finally, check all the steering
modes for correct operation (see Steering System
Description, 4WS Machines - Steer Mode Selection,
Section H).
9803/8020 Issue 2*
12 - 1 Tyres and Wheels 12 - 1
General Tyre Inflation
The versatility of the JCB Fastrac dictates a range of tyre ! WARNING

types which may be operated at differing loads and widely An exploding tyre can kill, inflated tyres can explode if
differing speeds. Agricultural type tyres are designated overheated. Do not cut or weld the rims. Use a
according to both their load carrying ability and their ability tyre/wheel specialist for all repair work.
to operate at certain speeds. 2-3-2-7
Generally, the speed at which a given tyre can operate These instructions are for adding air to a tyre which is
depends upon inflation pressure and the load carried. already inflated. If the tyre has lost all its air pressure, call in
a qualified tyre mechanic. The tyre mechanic should use a
* The tables in the Operator Handbook give the load carrying tyre inflation cage and the correct equipment to do the job.
capacity per tyre at varying pressures and speeds. All tyres
supplied as original equipment may be operated over the full 1 Before adding air to the tyre, make sure it is correctly
speed range of the vehicle provided the pressure is correct fitted on the machine or installed in a tyre inflation cage.
and their loading is no higher than specified.
2 Use only an air supply system which includes a pressure
Note 1: Whatever the loading, it is desirable to inflate rear regulator. Set the regulator no higher than 1.38 bar (20
tyres to 0.3 bar (4.4 lbf/in2) higher than the pressures given lbf/in2) above the recommended tyre pressure.
which are for the front tyres. This results in improved
handling. Use an air hose fitted with a self-locking air chuck and
! WARNING remote shut-off valve.
Running tyres outside recommended guidelines may 3 Make sure that the air hose is correctly connected to the
result in failure of the tyres which at high speeds may tyre valve. Clear other people from the area. Stand
endanger life. BE WARNED. behind the tread of the tyre while adding the air. Inflate
13-3-1-6
the tyre to the recommended pressure. DO NOT OVER-
INFLATE.
! 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
Wheels are heavy. Handle and store with care to ensure
that they cannot fall and cause injury.
13-3-1-7
! WARNING
* When ordering tyres, you must specify not only the tyre
size but also the speed designation. The correct tyres for
the machine are shown in the Pressures, Speeds and
Loads table in the Operator Handbook. On no account
should you use tyres of other designations without first
gaining approval from the machine manufacturer.
13-3-1-8/1
Note 2: It is recommended that tyres larger than 495 mm

section width are not used on machines fitted with a NoSPIN 089571
Differential except for special applications as agreed with
JCB Landpower.
! CAUTION
The high speed capability of the Fastrac dictates that
water ballasting of the tyres is not recommended.
13-3-1-12
9803/8020 Issue 3*
Checking and Adjusting the Wheel

Alignment
! WARNING *4 Refit the track rod end and firmly tighten nut D and
Make the machine safe before getting beneath it. Do the nut/bolt G. Re-check the toe-in. If correct, tighten nut
following: Park on level ground. Engage the parking D to 150 Nm (110 lbf ft, 15 kgf m) and nut/bolt G by
brake. Lower any mounted implements to the ground. means of the nut to 70 - 80 Nm (52 - 59 lbf ft, 7.1 - 8.2
Stop the engine, remove the starter key, disconnect the kgf m).
13-3-1-1 Note: Orientate clamp K as illustrated, i.e. so that nut/bolt G
is horizontal on the underside of the track rod.
Front Wheels (all machines)
5 Align nut D with the split pin hole by tightening to the
1 Ensure that the wheels are pointing straight ahead. next castellation. Fit the split pin C.
Measure the distance A between the leading edge of
the front wheel rims at hub height. Measure the Rear Wheels (Fastrac 2115, 2125 and 2135 4WS
corresponding distance B at the trailing edge. Machines only)
Distance A should be less than distance B by 0 to 5 1 Before stopping the engine, ensure that 2WS is
mm (0 to 0.2 in). If this is incorrect, proceed to Step 2. engaged and the rear wheels are locked in the straight
ahead position.
2 Remove split pin C and nut D. Disconnect the left hand
track rod end E from the steering arm F. The measurements at the leading edge (A1) and trailing
edge (B1) of the rear wheels should be the same i.e.
Note: The use of a ball joint splitter will make this job easier. zero toe-in. Also, to ensure that the wheels track
correctly, the trailing edge of both rear wheels should
! CAUTION be the same distance from the centre line of the
Do not hammer the cast iron lugs on the axle as this will machine. (Measure from the centre of the rear PTO
cause weakness and may lead to steering failure. shaft.)
AXL 8-2
2 To make corrections, loosen locking bolts H and adjust
*3 Position the wheels so that the toe-in measurements
track rod ends as required using a suitable spanner
are mid-way between the limits given in Step 1.
across flats J. When correct tighten bolts H to a torque
of 70 - 80 Nm (52 - 59 lbf ft, 7.1 0 8.2 kgf m).
Slacken locking nut/bolt G and screw the track rod end
E in or out of the track rod as required, ensuring that
the taper of the track rod end E aligns with the taper of
the steering arm F.
F B
K
D
C
G
E
A1
B1
H J A258760
9803/8020 Issue 2*
Track Width * Checking Wheel Nut Torques

Note: When adjusting the track width be aware that the 'V' On a new machine check the wheel nut torques every ten
of the tyre tread pattern must always point forward when at hours until they stay correct. If a wheel has been removed
the top of the wheel . and refitted, check the wheel nut torques every ten hours
until they stay correct. Do not apply oil to the wheel nut
* 2000 Series Machines (Except 2150) threads.
Some wheel/tyre combinations are reversible to provide Wheel nut torque setting Nm kgf m lbf ft
alternative track widths. These normally leave the factory Rear axles with 12 nuts per wheel 600 60.0 440
with a track width of 1830 mm (72 in). To obtain the All other axles 500 51.0 370
alternative track width of 1930 mm (76 in), move the wheels
from one side of the machine to the other and reverse the
wheels on the hubs.
Certain other tyres may be obtained on adjustable rims.

These normally leave the factory set to give a track width of
1830 mm (72 in.).
2000 Series machines may also have original equipment

tyres which provide track widths of 1930 mm (76 in) or 2105
mm (80 in). In these cases, the track width cannot be
altered.
2150 Machines
Some wheel/tyre combinations are reversible to provide

alternative track widths. These normally leave the factory
with a track width of 2015 mm (80 in). To obtain the
alternative track width of 1727 mm (68 in), move the wheels
from one side of the machine to the other and reverse the
wheels on the hubs.
Machines fitted with 16.9 R30 tyres normally leave the

factory with a track width of 1830 mm (72 in). These are
reversible to provide a track width of 1930 mm (76 in).
2150 machines may also have original equipment tyres

which provide track widths of 1930 mm (76 in) or 2105 mm
(80 in) which cannot be altered.
3000 Series Machines
The standard 30 in wheels provide a track width of 2015 mm

(80 in). To obtain an alternative track width of 1930 mm (76
in), move the wheels from one side of the machine to the
other and reverse the wheels on the hubs. Machines can
also be factory fitted with 24 in or 30 in wheels which
provide a track width of 1880 mm (74 in). These are
reversible to provide an alternative track width of 2090 mm
(82 in).
3000 Series machines can also be factory fitted with 26 in

wheels which provide a track width of 2165 mm (85 in).
Note 1: The rear wheels on Fastrac 3185 machines may

provide different track widths than those provided by the
front wheels.
Note 2: In some territories local speed restrictions may

apply in respect of vehicle width.
Note 3: Wider cross-section tyres (i.e. above 540 mm) may

cause problems at the alternative narrow track width setting.
Seek advice before fitment.
9803/8020 Issue 3*
Lock Stops
To prevent the tyres from fouling on the vehicle chassis, lock
stops A must be fitted to the inside of each steering axle
swivel. The correct size of lock stop is fitted at the factory to
suit the tyre and wheel configuration supplied as original
equipment. If a different tyre and wheel configuration is to be
used, refer to the tables below for the size of lockstop
required.
2115, 2125, 2135 and 2140 Machines
Tyre Size Track Lock Stop 160750

mm (in.) mm
Front Rear (4WS)
16.9 R24 1830 (72) 22.5 10
16.9 R28 1830 (72)† 22.5 20 3155 Machines
16.9 R28 2015 (80) 22.5 15
16.9 R28 Adjustable†† 22.5 15 Tyre Size Track Lock Stop
16.9 R30 1830 (72)† 22.5 15 mm (in.) mm
16.9 R30 TRI 1830 (72) 27.5 20
16.9 R30 2015 (80) 22.5 15 16.9 R30 2015 (80) 10
480/70-R28 1830 (72)† 22.5 15 480/70-R30 1830 (72) 25
480/70-R28 2015 (80) 22.5 15 480/70-R30 1880 (74) 12.5
480/70-R28 Adjustable†† 22.5 15 480/70-R30 2015 (80) 10
480/70 R30 1830 (72) 22.5 15 495/70-R24 1880 (74) 15
480/70-R30 1930 (76) 22.5 15 520/65 R30 2015 (80) 15
480/70-R30 2015 (80) 22.5 15 520/70-R30 2015 (80) 15
520/65 R30 1830 (72)† 22.5 540/65-R30 2015 (80) 15‡
520/65 R30 TRI 1880 (74) 25 22.5 540/65-R30 2286 (90) 10
540/65-R28 1830 (72)† 22.5 15 580/70-R26 2165 (85) TBA
540/65-R28 2015 (80) 22.5 15 600/65-R28 1930 (76) 27.5
540/65-R28 Adjustable†† 22.5 15 620/70-R26 2165 (85) 25
* 540/65 R30 1880 (74) 25 22.5
540/65-R30 1930 (76) 22.5 22.5 ‡ With straight control arms, use 22.5mm lockstop on front
540/65-R30 2015 (80) 22.5 22.5 axle.
580/70-R26 1930 (76) 25 15
* 600/65-R28 1930 (76) 22.5 22.5 3185 Machines
* 440/80 R24 1830 (72) 22.5 10
* 440/80 R28 1830 (72) 22.5 20 16.9 R30 2015 (80) 10
* 440/80 R30 1830 (72) 27.5 20 480/70-R30 1880 (74) 12.5
620/70-R26 1930 (76) 40 15 480/70-R30 2015 (80) 10
495/70-R24 1880 (74) 15
† Reversible to 1930mm (76in.). 520/65 R30 2015 (80) 15
†† Adjustable rims are factory set to give 1830 mm (72 in.) 520/70-R30 2015 (80) 15‡
track. 540/65-R30 2015 (80) 15
540/65-R30 2286 (90) 10
2150 Machines 600/65-R28 1930 (76) 27.5
620/70-R26 2165 (85) 25
16.9 R28 1830 (72)† 22.5
16.9 R30 1830 (72)† 22.5 ‡ With straight control arms, use 22.5mm lockstop on front
16.9 R30 2015 (80)†† 22.5 axle.
480/70-R30 1830 (72) 22.5
480/70-R30 1930 (76) 22.5
480/70-R30 2015 (80) 22.5
520/70-R30 2015 (80)†† 30
526/65 R30 1930 (76) 22.5
540/65-R30 1930 (76) 22.5
540/65-R30 2015 (80)†† 22.5
580/70-R26 1930 (76) 25
600/65-R28 1930 (76) 22.5
620/70-R26 1930 (76) 25
† Reversible to 1930mm (76in.).

†† Reversible to 1727mm (68in.).
9803/8020 Issue 9*
Fender Adjustment
Front and Rear Fenders
1 To accommodate various tyre diameters and working

conditions the front fenders can be adjusted vertically.
Proceed as follows:
a Release support arm A clamping screws B.
b Support the fender and then loosen screws C until

support arm A can be moved up and down.
c Adjust the height of the fender, at the same time

aligning the holes in support arm A with screws C.
d Tighten screws C into the holes and clamp firmly.
e Tighten screws B to further clamp support arm A.
2 To maintain the full effectiveness of the fenders when

alternative tyres are fitted or if track width is altered the
fenders can be moved from side-to-side.
Loosen clamping screws D, position the fenders

centrally over the tyre treads and then re-tighten screws
D.
Note: The illustration shows the front fenders. The rear

fenders are mounted on the rear of the chassis but are
adjustable in exactly the same way.
D D
B
C
B
C
A293430
9803/8020 Issue 1
13 - 1 Brakes 13 - 1
B
C
X
A
230000
B
C
A X
209980
9803/8020 Issue 2*
13 - 2 Brakes 13 - 2
* Checking and Renewing Foot Brake Pads

1 Park the machine on firm, level ground. Apply the
parking brake. Lower any mounted implements to the
ground. Jack up the machine and support it on axle
stands. Remove the road wheels.
Note: Disc brakes are fitted to all four wheels. The

illustration shows only the left hand rear brake but the other
brakes are similar.
! WARNING
Oil on the brake disc will reduce brake effectiveness.
Keep oil away from the brake disc. Remove any oil from
the disc with a suitable solvent. Read and understand
the solvent manufacturer's safety instructions. If the
pads are oily, fit new ones.
2-3-2-3/2
2 Check the thickness of all the friction pads A and the

condition of each disc X. If the friction material is 3 mm
(0.12 in) or less on any of the pads, fit a new set. If the
surface of the disc is badly warped or pitted, renew the
disc.
! WARNING
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
Brake pads generate dust which if inhaled, may
endanger health. Wash off the caliper before
commencing work. Clean hands thoroughly after work.
13-3-1-3
3 Tap out pad locating pins B in direction of arrow.

Discard pins and anti-rattle springs C.
4 With a suitable lever, force the worn pads back against

the pistons. Remove the pads. Force both pistons fully
back, taking care not to damage the seals.
5 Ensure that the seals are not leaking and that both
pistons move freely in the caliper.
6 Slide in the new pads and fit new locating pins and
anti-rattle springs.
7 Refit the wheels and tighten wheel nuts to the correct

torque setting (see Tyres and Wheels, Checking
Wheel Nut Torques ).
8 Before driving the machine, start the engine and apply

the brake pedal until the brakes are felt to engage.
Note: Heavy braking should be avoided for the first 50 hours

of operation after fitting new pads.
9803/8020 Issue 2*
13 - 3 Brakes 13 - 3
Checking and Renewing the Parking

Brake Pads
! WARNING 3 Renew the Pads as follows

Brake pads generate dust which if inhaled, may a Slacken locknuts X and remove pin from clevis Y.
endanger health. Wash off the caliper before Apply brake, causing rod Z to draw back into the
commencing work. Clean hands thoroughly after work. actuator. Turn clevis Y through 90°. Remove plastic
13-3-1-3
cap and insert a 1/4 in hexagon allen key at B. Turn
it clockwise to back the pads right away from the
! WARNING disc. Do not turn the key further than necessary to
Before checking the parking brake, park on level ground. allow space for the new pads.
Put chocks each side of all four wheels. Ensure that all
three air tank warning lights are out. Release the parking b Remove split pins C. Fully support the complete
brake, then stop the engine and disconnect the battery brake assembly until guide pins E are replaced at
so that the engine cannot be started. If you do not take step c. From caliper D remove guide pins E.
these precautions the machine could run over you. Withdraw the pads F as they become detached from
13-3-1-4/1 the guide pins, followed by spring plate G (if fitted).
1 Measure the pad thickness c Replace spring plate G (if fitted) and fit new pads F.
Secure with guide pins E and split pins C. Release
If the thickness of the friction material A is 3 mm (0.12 in) or brake, reconnect clevis and tighten locknuts.
less, renew the pads.
d Adjust the brake using the allen key. Support the
weight of the brake with one hand and turn the allen
! WARNING key anti-clockwise until the pads are tight on the
Oil on the brake disc will reduce brake effectiveness. disc. From this position, turn the allen key half a turn
Keep oil away from the brake disc. Remove any oil from clockwise.
the disc with a suitable solvent. Read and understand
the solvent manufacturer's safety instructions. If the 4 Test the Parking Brake
pads are oily, fit new ones.
2-3-2-3/2 Drive the machine for a short distance of 300-400m. If
the brake disc is getting hot, turn the allen key
2 Check the disc condition clockwise slightly, If the brake is rattling slightly, turn
the allen key anti-clockwise slightly. The adjustment
If the surface of the disc is badly warped, pitted or showing should never be less than a 1/4 turn or more than 3/4 of
signs of overheating, it must be renewed. a turn from tight.
! WARNING
The actuator contains a large spring which can exert a
force of up to 1134 kgf (2500 lbf) and cause injury if
suddenly released. When disconnecting or dismantling
the actuator, carefully follow all service instructions.
13-3-1-11
A257970
9803/8020 Issue 1
13 - 4 Brakes 13 - 4
Checking the Foot Brake Fluid Level

X
E G
G
A G
B
F
2115, 2125, 2135, 2140 ABS Machines
A387700
X G
G A
G
B
2150 ABS Machines A387692
9803/8020 Issue 5
13 - 5 Brakes 13 - 5

Note: The non-ABS illustrations show the component 1 Check the Fluid Level in the Reservoirs.
arrangement on the right hand side of Fastrac 2115, 2125,
2135 and 2140 machines. On Fastrac 2150 machines the Early Non-ABS Machines
corresponding components are on the left hand side. The View the fluid levels through the slots in the back plate
component arrangements for ABS versions of the same of the step unit.
machine groupings are shown individually.
ABS Machines and Later Non-ABS Machines
Fully raise hinged step unit F to expose the fluid
! WARNING reservoirs.
If the brake fluid warning light comes on, check the
brake fluid level immediately. * Note: Some machines are fitted with spring loaded catch E.
13-3-1-2/1 Rotate the catch to allow the step to be raised. Non-ABS
machines have two reservoirs. ABS machines have three
! WARNING reservoirs.
Faulty brakes can kill. If you have to top up the brake The fluid level should be between the two lines A and B
reservoir frequently, get the brake system checked by moulded into the side of each reservoir. If necessary,
your JCB distributor. Do not use the machine until the add fluid as in Step 2.
fault has been put right.
2-3-2-5/1 * Note: If the level has fallen below the lower mark, the system
must be checked for leakage and any fault rectified.
! WARNING
Using incorrect brake fluid could damage the system. 2 Add the Specified Brake Fluid
See the Fluids, Capacities and Lubricants chart in this
manual for the correct fluid. The fluid can harm your ! CAUTION
skin. Wear rubber gloves. Cover cuts and grazes. Do not use ordinary hydraulic fluid in the brake system.
2-3-2-6/1 13-3-2-6
Depending on machine specification, either remove two

screws C and swing open the hinged step unit D or fully
raise hinged step unit F.
* Clean the area around the filler caps G. Remove the

caps and carefully pour in the recommended fluid until it
reaches the correct level. Avoid spilling it. Wipe up any
spillage. Do not allow dirt to enter the reservoirs. Fit the
caps securely.
A A
B B G G
D
C S262620
262230
* Early Non-ABS Machines
9803/8020 Issue 4*
13 - 6 Brakes 13 - 6
Draining the Air System Tank

1 Prepare the Machine
Charge the air system by starting the engine. Wait for

the tank warning lights to go out. Stop the engine,
apply the parking brake.
2 Drain Water from the Air Tank
Grip the 'keyring' fitting H at the bottom of tank J and

pull the ring sideways until all water is expelled. The
amount of water released is a guide to the functioning
of dryer X. If purging of water takes much longer than
about 5 seconds, the dryer should be checked.
H
232270
420510
9803/8020 Issue 3
13 - 7 Brakes 13 - 7

G
C C
A A
B B
F
Non-ABS Machines D
E A285850
C
X C C
A
B
G
D
ABS Machines
A387692
9803/8020 Issue 3
13 - 8 Brakes 13 - 8
Checking the Foot Brake Fluid Level Draining the Air System Tanks
(3000 Series Machines) (cont’d) (3000 Series Machines)
! WARNING 1 Prepare the Machine

If the brake fluid warning light comes on, check the
brake fluid level immediately. Charge the air system by starting the engine. Wait for
13-3-1-2/1 the tank warning lights to go out. Stop the engine,
apply the parking brake.
! WARNING
Faulty brakes can kill. If you have to top up the brake 2 Wet System
reservoir frequently, get the brake system checked by
your JCB distributor. Do not use the machine until the Machines not fitted with dryer X have a wet system.
fault has been put right. Drain all three tanks by gripping the ‘keyring’ fitting D at
2-3-2-5/1 the bottom of each tank E, F and G in turn and pull the
ring sideways until all water is expelled.
! WARNING
Using incorrect brake fluid could damage the system. 3 Dry System
manual for the correct fluid. The fluid can harm your skin. Grip ‘keyring’ fitting D at the bottom of tank G and pull
Wear rubber gloves. Cover cuts and grazes. sideways until all water is expelled. The amount of
2-3-2-6/1
water released is a guide to the functioning of dryer X.
*1 Check the Fluid Level in the Reservoirs If purging of water takes much longer than about 5
seconds, the dryer should be checked.
Note: Non-ABS machines have two reservoirs. ABS
machines have three reservoirs.
The fluid level should be between the two lines A and B

moulded into the side of each reservoir. If necessary,
add fluid as in Step 2.
* Note: If the level has fallen below the lower mark, the system
must be checked for leakage and any fault rectified.
2 Add the Specified Brake Fluid
NOTE: DO NOT USE ORDINARY HYDRAULIC FLUID
* Clean the area around the filler caps C. Remove the

caps and carefully pour in the recommended fluid until it
reaches the correct level. Avoid spilling it. Wipe up any
spillage. Do not allow dirt to enter the reservoirs. Fit the
caps securely.
9803/8020 Issue 2*
13 - 9 Brakes 13 - 9
C
D
A B EF
F
C
D
C
D
E B
G B
A
A343730
9803/8020 Issue 1
13 - 10 Brakes 13 - 10
Exhaust Brake (if fitted) (3185 Machines

only)
Servicing is limited to the cleaning and greasing of cylinder Replacement
barrel E and spring/piston assembly F, and the renewal of
main seal G, bolts B, plain washer C and shakeproof washer Replacement is the reverse of Removal.
D.
When Replacing
Before carrying out the servicing procedures, obtain a
genuine service kit containing the necessary new 1 Fit a new main seal G to the base of the piston as
components and high temperature grease. shown in view H.
Removal 2 Liberally coat cylinder barrel E, spring/piston assembly

F and main seal G with the high temperature grease
1 Park the machine on firm level ground and chock the supplied with the service kit.
wheels.
3 Take care not to distort or damage main seal G when
2 Release the brake system air pressure as follows: inserting spring/piston assembly F into cylinder barrel
E.
a Wet Systems - press up and hold the plunger in the
automatic drain valve of the wet tank (refer to the 4 Use new bolts B, plain washers C and shakeproof
brake system descriptions in Section G, Brakes). washers D. Tighten bolts B to a torque of 35 Nm (26 lbf
ft).
b Dry Systems - pump the footbrake pedal until all
residual pressure is released.
H
3 Allow the engine to cool fully before proceeding further.
4 Remove the air pipes from pilot valve A, making a note

of their locations to assist during reassembly.
5 Remove and discard bolts B, plain washers C and

shakeproof washers D.
6 Remove cylinder barrel E complete with spring/piston

assembly F from the main body which remains in the
exhaust system.
7 Remove the spring/piston assembly from the cylinder G

barrel and discard main seal G from the base of the
piston. A343770
! WARNING Testing
Spring/piston assembly F requires the use of special
Start the engine and test the installation for correct
tools, available only to the manufacturer, for safe
operation.
dismantling. To attempt to dismantle the assembly
without these tools could result in serious injury as a
result of the release of the tension in the large outer
spring. Renew the complete assembly if any of the
component parts are damaged.
0030
9803/8020 Issue 1
14 - 1 Engine 14 - 1

ground.
2 Stop the engine and remove the starter key.

A
3 Make sure that the dipstick is fully in before removing it.
Check that the oil level is between the two marks on the
dipstick.
4 If oil is needed, open the bonnet and add only the

recommended oil.
* Dipstick and Filler Identification

A Dipstick 2115, 2125, 2135, 2150
B Dipstick 3000 Series to Serial No. 640777 229900
C Dipstick 3000 Series from Serial No. 640778
D Dipstick 2140
E Filler 2115, 2125, 2135, 2150 and 3155
F Filler 2140
G Filler 3185
G
B
A343350
F
D
420580 S294120
9803/8020 Issue 3*
14 - 2 Engine 14 - 2
Changing the Oil and Filters

1 Drain the oil when the engine is warm as contaminants
held in suspension will then be drained with the oil.
Park the machine on firm ground.
! WARNING
Make the machine safe before getting beneath it. Do the C
13-3-1-1
! CAUTION
removed. Hot oil and engine components can burn you.
Keep to one side when you remove the plug. 229910
13-3-1-15
*2 Place a container that can hold at least 18 litres (4UK

gal) beneath the engine to catch the oil. Remove drain
plug C and its 'O' ring. Make sure the 'O' ring is not
damaged. Let the oil drain out, then clean and refit the
drain plug and its 'O' ring. Tighten to 80 Nm (59 lbf ft, 8
kgf m) on 2140 and 3185. On other machines, tighten
to 34 Nm (25 lb ft, 3.5 kgf m).
3 Open the bonnet. Unscrew the two filters E.
* Note: 2140 and 3185 machines have only one filter.
a Clean the filter head F and check tightness of

adapter G (when fitted).
b Add clean engine lubricating oil to the new filter(s).
Allow enough time for the oil to pass through the
filter element.
c Smear the seal H on the new filter(s) with oil. Screw
in the new filter(s), hand-tight only.
4 Fill the engine to the upper mark on the dipstick with

new oil through the filler B (shown on previous page). 2115, 2125, 2135, 3155 160540
Wipe off any spilt oil. Check for leaks. Make sure the
filler cap is correctly refitted.
* Note: Before starting the engine, remove the ESOS fuse and
rotate the engine on the starter until the oil pressure low light
has gone out. Refit the fuse and start the engine. On the
2140, the electronic control unit will prevent the engine from
starting until the minimum required oil pressure has been
reached. H
5 Run the engine and check for leaks. Stop the engine.
F
When the engine has cooled, recheck the oil level.
2140, 3185 209540
9803/8020 Issue 2*
15 - 1 Engine 15 - 1
Draining/Cleaning the Fuel Sediment Bowl

1 Check the contents of bowl X. If it contains sediment 2150
do Steps 2 to 7. If there is water but no sediment, drain
off the water by opening tap Y.
3 Remove screws V and lift off cover W (2000 Series

Machines).
4 Support the bowl X; unscrew and remove nut Z.

Remove the bowl.
5 Wash the bowl using clean fuel.

V
6 Refit the bowl, make sure seals are seated correctly.
7 Bleed the fuel system. V W

3155, 3185
Z
X
Y A229861
Y A296230
2115, 2125, 2135
V
W
Y
V A290440
9803/8020 Issue 2*
15 - 2 Engine 15 - 2
Draining/Renewing Fuel Pre-Filter Renewing Fuel Pre-Filter

(Early Machines) (2140 Machines)
The fuel pre-filter is fitted to machines equipped with fuel 1 Disconnect hoses C and D.
flow metering. The pre-filter is located in the position
occupied by the fuel sediment bowl on all other machines 2 Unscrew bolt E, remove and discard filter F.
(see Dismantling/Cleaning the Fuel Sediment Bowl).
3 Fit new filter, ensuring that the arrows on the filter point
Draining in the direction of flow of fuel.
Note: If the arrows are not visible, ensure that the end face
Open tap A until water-free fuel flows out. of the filter having three dimples on it faces towards the front
of the machine.
Renewing
4 Refit bolt E. Connect hoses C and D.
1 Unscrew quick-change ring 1 to release filter 2 from
mounting head 3. 5 Bleed the fuel system.
2 Discard filter 2. Check seal 4 for damage and renew if

necessary.
3 Install seal 4 on the shoulder of a new filter 2. Slide

quick-change ring 1 over the filter and locate the ring on
mounting head 3.
4 Tighten the quick change ring through 120° until its

locating rings drop into the corresponding detents in
mounting head 3. An audible click indicates correct
location of quick-change ring 1 with mounting head 3. A
further indication of correct location is when a set of
arrows on the ring is directly below air vent valve B.
5 Bleed the fuel system.
B
3
E C
2
F
D
A 1
311370
A714390
9803/8020 Issue 4
15 - 3 Engine 15 - 3
Draining the Fuel Filters

1 Turn the front wheels onto full left lock. Stop the engine.
Remove the starter key.
2 Open the bonnet.
*3 Machines except 2140 and 3185
Open both taps A until water-free fuel flows out.
2140 and 3185 Machines

A A
Open tap B by approximately 11/2 to 2 turns until clear
fuel, free from water is visible. When closing the tap, do
not over tighten or the threads maybe damaged.
260090
Note: 2140 machines have only one fuel filter.
4 If the filters have been drained completely, bleed the

fuel system (see Bleeding the Fuel System).
B 209570
Changing the Fuel Filter Elements

* Note: When renewing the filter element, always fit a genuine
JCB replacement part. This may differ from the element
being removed which, if it was factory fitted, may have had
its thread treated with a special sealant. To ensure adequate
sealing, some JCB replacement elements have an inner seal
H secured by plastic clip J.
2 Open the bonnet.
*3 On 2140 machines, disconnect the electrical connection

from the water in fuel sensor at the base of the filter.
Unscrew the sensor and fit it to the new filter, using a
new ‘O’ ring.
4 Unscrew the element X.

H
5 Lightly lubricate the seals of the new element with clean
fuel. To assist bleeding, fill with fuel before fitting. J
Tighten the element hand-tight only. Check for leaks.
6 Repeat Steps 4 and 5 for second filter (if fitted). X

8 Run the engine and ensure that there are no fuel leaks.
9803/8020 Issue 3*
15 - 4 Engine 15 - 4
* Cleaningthe Fuel Lift Pump

(2115, 2125, 2135, 2150 and 3155)
1 Stop the engine and remove the key. 5 Refit the gauze into the pump, making sure it is seated
correctly. Fit a new sealing ring C, then fit the cap. Fit
2 Disconnect the battery. a new sealing ring E to the bolt. Fit and tighten the
bolt only enough to seal the joint. DO NOT overtighten
3 Open the bonnet. the bolt as this will distort the seal and cause leaks.
Check for leaks.
! WARNING
Hot oil and engine components can burn you. Make sure
the engine is cool before doing this job.
2-3-3-2
4 Unscrew bolt A. Lift off the cap B, sealing ring C and

gauze D. Wash the gauze with clean fuel and a soft
brush.
S229850
9803/8020 Issue 3*
15 - 5 Engine 15 - 5
* Bleedingthe Fuel System

(2115, 2125, 2135, 2150 and 3155)
Air in the fuel system could cause misfiring or failure to start.
Air will enter the fuel system if any part of the system has
been drained or disconnected.
! CAUTION
Running the engine with air in the system could damage
the fuel injection pump. After maintenance, remove air
from the system as detailed below.
2-3-3-7
1 Open the bonnet.
! WARNING
the engine is cool before doing this job.
2-3-3-2
2 Set the starter key to the IGN position.
3 Operate the fuel lift pump priming lever X slowly, for

approximately two minutes.
Note: If no fuel is moved when the fuel lift pump priming X

lever X is operated, then the pump diaphragm may have
rested in a 'maximum lift' position. To move the diaphragm,
use the starter key to turn the engine, then try the priming
S229890
lever again.
The engine is now ready to start. If the engine runs smoothly

for a short time, and then begins to run roughly or stops,
check again for air in the fuel system. Check all seals and
connections, especially in the low pressure side of the
system.
9803/8020 Issue 3*
15 - 5A Engine 15 - 5A
Bleeding the Fuel System 6 Operate the starter motor. When air free fuel flows from
the connection, tighten the nut to 24 Nm (18 lb ft).
(2140 Machines)
7 Repeat step 6 at each injector in turn until the engine
Air in the fuel system could cause misfiring or failure to start. runs smoothly.
Air will enter the fuel system if the fuel tank has been
emptied or if any part of the system has a leak or has been
disconnected. In addition, bleeding may be required if the
engine has not been started for an extended period.
Note: Small amounts of air will be vented automatically at

the injection pump. Manual bleeding should not be required
after changing the fuel filter if filled with fuel before fitting.
! CAUTION
the fuel injection pump. Remove air from the system as
detailed below.
2-3-3-7/1
1 Open the bonnet.
! WARNING
Hot oil and engine components can burn you. Make sure A
the engine is cool before doing this job. Bleeding a hot
engine could cause fuel to spill on to a hot exhaust
manifold creating a danger of fire.
13-3-1-16
2 Slacken bleed screw A at the filter outlet union.
3 Operate the priming plunger B until air free fuel flows

from the bleed screw. Then tighten the screw.
Note: If no fuel is moved when the fuel lift pump priming

lever B is operated, then the pump diaphragm may have
rested in a 'maximum lift' position. To move the diaphragm,
use the starter key to turn the engine, then try the priming
lever again.
4 Start the engine. If it will not start, bleed the injectors as

B
710360
follows.
! WARNING
To bleed the injectors you must turn the engine. When
the engine is turning, there are parts rotating in the
engine compartment.
Before starting this job make sure that you have no

loose clothing (cuffs, ties etc) which could get caught in
rotating parts.
B
C
When the engine is turning, keep clear of rotating parts.
2-3-3-8
! WARNING
When bleeding the injectors, keep hands and body parts
away from the high pressure fuel lines. Fuel coming from
the high pressure fuel lines is under extreme pressure 209600
and can penetrate the skin.
5 Slacken one of the injector feed pipe nuts C.
9803/8020 Issue 1
15 - 6 Engine 15 - 6
* Bleeding the Fuel System - 3185 Machines

Air in the fuel system could cause misfiring or failure to start.
Air will enter the fuel system if the fuel tank has been
emptied or if any part of the system has a leak or has been
disconnected. In addition, bleeding may be required if the
engine has not been started for an extended period
Note: Small amounts of air will be vented automatically at A

the injection pump. Manual bleeding should not be required
after changing the fuel filters if they are filled with fuel before
fitting.
! CAUTION
the fuel injection pump. Remove air from the system as
detailed below. 209530
2-3-3-7/1
1 Open the bonnet.
! WARNING
the engine is cool before doing this job. Bleeding a hot
engine could cause fuel to spill on to a hot exhaust
manifold creating a danger of fire.
13-3-1-16
2 Open bleed screw A.
3 Operate the priming plunger B until air free fuel flows

from the bleed screw. Then tighten the screw.
! WARNING B
To bleed the injectors you must turn the engine. When
the engine is turning, there are parts rotating in the
engine compartment.
Before starting this job make sure that you have no

loose clothing (cuffs, ties etc) which could get caught in
rotating parts.
When the engine is turning, keep clear of rotating parts.

2-3-3-8
4 Bleed the injectors

a Slacken one of the injector feed pipe nuts C.
b Crank the engine, observing the safety procedures
given in the OPERATION section of the OPERATOR
HANDBOOK. When air free fuel flows from the
connection, tighten the nut. C
c Repeat step b at each injector in turn until the engine
runs smoothly.
209600
9803/8020 Issue 3*
15 - 7 Engine 15 - 7
Cleaning the Fuel Tank Strainer

1 Remove cab floor mat and access plate in cab floor.
Y
2 Disconnect the electrical connector and the fuel hoses. X
Remove retaining bolts A.
3 Lift out the fuel level sender assembly, taking care not to
Z
damage the float B or bend the wire arm C.
4 Clean strainer D using a suitable solvent.
5 Reassemble in the reverse order of dismantling. Ensure A

that the fuel hoses are correctly fitted:
X Feed to sedimenter.
Y Spill off return.
Z Breather.
B
C
D
A303101
9803/8020 Issue 1
16 - 1 Engine 16 - 1
Checking the Coolant Level
! WARNING
The cooling system is pressurised when the coolant is
hot. Hot coolant will burn you. Make sure the engine is
cool before checking the coolant level or draining the
X
system.
2-3-3-3

ground.
2000 series Machines

*
3 Remove filler cap X and visually check that the level of
the coolant is no more than 25-30 mm below the top of
the expansion tank. If required, add pre-mixed
water/antifreeze solution (see Coolant Mixtures). Do
not overfill.
! WARNING
* Antifreeze can be harmful. Obey the manufacturer's
instructions when handling neat or diluted antifreeze.
7-3-4-4
Note: Check the quality of the antifreeze mixture every year

before the cold weather starts. Change it every two years.
4 Refit the filler cap. Make sure it is tight. 2000 Series Machines S229930
5 Run the engine for a while to raise the coolant to

working temperature and pressure. Stop the engine
and check for leaks.
HOT MAX
*
* 3 Open the bonnet.
*
4 Visually check that the level of the coolant is up to the
* lined marked ‘COLD MIN’ but below the line marked
‘HOT MAX’. If the level is low, then continue with COLD MIN
steps 5 to 7.
! WARNING
* Antifreeze can be harmful. Obey the manufacturer's A
7-3-4-4
5 Remove filler cap A,add pre-mixed water/antifreeze

* solution (see Coolant Mixtures) until the level is up to
the line marked ‘COLD MIN’. Do not overfill.
6 Refit the fillercap. Make sure it is tight.

*
7 Refit the engine for a while to raise the coolant to
* working temperature and pressure. Stop the engine
and check for leaks.
Note: Check the quality of the antifreeze mixture every year

* before the cold weather starts. Change it every two years.
9803/8020 Issue 2*
16 - 2 *Engine 2115, 2125, 2135, 2150 16 - 2
Draining the Coolant
! WARNING
3 Remove the drain plugs D and E and let the coolant
drain out. Make sure the drain hole is not blocked.
13-3-1-1
4 Flush the system with clean water. Clean and refit drain
plugs D and E .
! WARNING
cool before checking the coolant level or draining the
system.
2-3-3-3
1 Open the bonnet.
2 Remove the filler cap. Carefully loosen cap X (see

previous page). Let any pressure escape. Remove the
cap.
! CAUTION
Keep your face away from the drain hole when removing
the drain plug.
2-3-3-4
D
S230100
S230090
9803/8020 Issue 3*
16 - 3 Engine 16 - 3
Filling the Cooling System Coolant Mixtures

(2115, 2125, 2135, 2150)
The protection provided by JCB Four Seasons Antifreeze &
1 Fill the system with the correct coolant mixture. Summer Coolant is shown below. If any other anti-freeze is
used, refer to the manufacturer's instructions and ensure
Note: A 50% anti-freeze mixture must be used even if frost that a corrosion inhibitor is included.
protection is not needed. This gives protection against
corrosion and raises the coolant's boiling point. DO NOT use solutions of more than 60% or less than 50%
or damage to the cooling system will occur.
! CAUTION Solution Maintains circulation Protects against
Antifreeze can be harmful. Obey the manufacturer's down to damage down to
instructions when handling neat or diluted antifreeze. deg C deg F deg C deg F
7-3-4-4
55% -36 -33 -41 -42
Remove filler cap X and add pre-mixed water/antifreeze
The strength of the anti-freeze solution must be checked at
solution (see Coolant Mixtures) until the level is 25-30
least once a year, preferably at the beginning of the cold
mm below the top of the expansion tank. Do not
period.
overfill.
It is an advantage to leave the anti-freeze in all the year
2 Check for leaks as follows:
round as it gives continued protection against corrosion.
Always renew the anti-freeze every two years.
Run the engine and raise the coolant to working
temperature and pressure.
A 50% anti-freeze mixture must be used even if frost
Note: Make sure the heater control is in the hot position
corrosion and raises the coolant's boiling point.
before running the engine. This will ensure the coolant
mixture circulates through the entire cooling system.
Note: In climates where antifreeze is not necessary, a
reputable corrosion inhibitor must be used. Renew the
Stop the engine. Check for leaks.
mixture every 6 months.
! WARNING
Antifreeze can be harmful. Obey the manufacturer's
7-3-4-4
S229930
9803/8020 Issue 4*
16 - 4 Engine 16 - 4
Draining and Refilling the Coolant

* (3155Machines)
! WARNING 3 Flush the System with Clean Water. Clean and refit
Make the machine safe before getting beneath it. Do the drain plugs D and E.
brake. Lower any mounted implements to the ground. Note: A 50% anti-freeze mixture must be used even if frost
Stop the engine, remove the starter key, disconnect the protection is not needed. This gives protection against
battery. Chock the wheels corrosion and raises the coolant's boiling point.
13-3-1-1
! WARNING 4 a Remove filler cap A and fill the system with pre-
The cooling system is pressurised when the coolant is mixed water/antifreeze solution (see Coolant and
hot. Hot coolant will burn you. Make sure the engine is Mixtures) until the level is up to the line marked
cool before checking the coolant level or draining the ‘COLD MIN’. Do not overfill.
system.
2-3-3-3 b Refit the filler cap.
1 Open the bonnet. 5 a Run the engine and raise the coolant to working
temperature and pressure.
Carefully loosen cap A (see page 3/16-1). Let any
pressure escape. Remove the cap. Note: Make sure the heater control is in the hot position
before running the engine. This will ensure that the coolant
! CAUTION mixture circulates through the entire cooling system.
the drain plug. b Stop the engine.
2-3-3-4 c Check for leaks.
2 Remove the drain plugs D and E and let the coolant

drain out. Make sure the drain hole is not blocked.
D
A294150
9803/8020 Issue 3*
16 - 5 Engine 16 - 5
Draining and Refilling the Coolant

* (2140and 3185 Machines)
! WARNING
Stop the engine, remove the starter key, disconnect the E
battery. Chock the wheels
13-3-1-1
! WARNING
cool before checking the coolant level or draining the D
system.
2-3-3-3 F
1 Open the bonnet. Carefully loosen the filler cap. Let any
pressure escape. Remove the cap.
! CAUTION
the drain plug.
*2 Remove drain plug D and E (where fitted). Alternatively,

slacken clip F (3185) or G (2140) and disconnect the
hose. Let the coolant drain out.
3 Check for damaged hoses and loose or damaged hose

clips. Check the radiator for damage and build up of
dirt. Clean and repair as required.
*4 Clean and refit drain plugs and/or reconnect hose and G

tighten clips.
5 Prepare a mixture of 19 litres of water and 0.4 kg

sodium carbonate (or a commercially available
alternative).
*6 Open the aftercooler bleed screw H (3185 only) and fill

the system slowly with the mixture to prevent air locks.
Wait 2 to 3 minutes to allow air to be vented, then close
the bleed screw and top up to the level marked 'COLD
MIN'. Do not fit the filler cap at this stage.
7 Run the engine for 5 minutes at the normal running

temperature. Stop the engine and allow to cool. H
8 Drain the cooling system, checking that the coolant is
not dirty. If it is, repeat the flushing process (steps 5 to
8).
9 Refill the system as described at step 6 but using pre-

mixed water/antifreeze solution (see Coolant
Mixtures). Do not overfill. Fit the filler cap.
Note: A 50% anti-freeze mixture must be used even if frost

corrosion and raises the coolant's boiling point.
10 Run the engine and raise the coolant to working

temperature. Stop the engine. Check for leaks
Note: Make sure the heater control is in the hot position

before running the engine. This will ensure that the coolant
mixture circulates through the entire cooling system.
9803/8020 Issue 3*
16 - 6 Engine 2000 Series Machines 16 - 6
Cleaning the Radiator

If the radiator tubes or fins become clogged, the radiator will 4 Brush off all debris from the tubes and fins of the
be less efficient. radiator, coolers and condenser. Make sure all the
loosened material is brushed out of the radiator
1 Stop the engine. enclosure.
! WARNING 5 Reposition the coolers and the condenser. Refit nuts C

and D.
2-3-3-5 6 Refit the grille and secure with fasteners A.
2 Release fasteners A (one each side) and lift out grille B.
3 Remove nuts C and D. Swing the coolers and

condenser E forwards and downwards.
B
C C
D D
S229940
9803/8020 Issue 1
16 - 7 Engine 3000 Series Machines 16 - 7
Cleaning the Radiator

If the radiator tubes or fins become clogged, the radiator will
be less efficient.
1 Stop the Engine. 4 Clean the Radiator
Brush off all debris from the radiator tubes and fins.
! WARNING Make sure all the loosened material is brushed out of
Make sure the engine cannot be started. Disconnect the the radiator enclosure.
2-3-3-5
5 Secure the Coolers
Remove the Grille
Reposition the coolers and the condensor. Refit nuts C
and D.
2 Unscrew fasteners A. Tilt grille B forwards and lift out.
6 Refit the Grille
3 Swing the Coolers Clear
Locate the bottom of the grille by entering the lugs in
Remove nuts C and D. Swing the condensor E and
the holes provided and secure at the top with fasteners
cooler F forwards and downwards.
A.
C F C
D
D
A A
A294310
9803/8020 Issue 1
17 - 1 Engine 17 - 1
* Adjusting
the Fan Belts
(2115, 2125, 2135, 2150 and 3155)
1 Stop the engine.
2 Open the bonnet.
! WARNING
A
2-3-3-5 B
3 Slacken bolts A, B, C and D.
4 Position the alternator so that there is 10 mm (0.4 in) B

slack at point E.
! CAUTION
Any leverage required to position the alternator must be
D
applied at the drive end bracket only, using a wooden
lever. C
8-3-2-1
5 Tighten bolts A, B, C and D. Make sure that bolt A is

the last bolt to be tightened. E
Note: If a new belt is needed, the belts must be renewed in
pairs and tension must be checked again after the first 20
A297020
hours of operation.
Cleaning the Pre-cleaner (optional)

F E
1 Park the machine on level ground. Apply the parking
brake. Lower the rear linkage to the ground. Stop the
engine. Remove the starter key.
Note: Do not run the engine with the dust bowl or the
cover removed. If the dust bowl is more than a third full,
empty it.
2 Unscrew the wing nut E and remove the cover F.
3 Carefully remove the dust bowl G, empty out dust

and make sure that none is spilt into the air intake. G
4 Wipe the bowl clean. Remove oil or grease by
washing in hot water with a little detergent.
5 Refit the dust bowl, replace the cover and secure

with the wing nut. Do not over tighten.
S261190
9803/8020 Issue 4*
17 - 2 Engine 17 - 2
Fan Belt (2140)

1 Stop the engine.
2 Open the bonnet.
! WARNING
2-3-3-5
! WARNING B
A
Do not try to turn the engine by pulling the fan or fan C
belt. This could cause injury or premature component
failure. B
0094
3 Inspect the belt for damage C

209630
Cracks across the belt width A are acceptable.
Cracks across the belt which intersect those in the

direction of the belt length B are not acceptable.
Renew the belt if it has unacceptable cracks or if it is

frayed or has pieces of material missing as at C.
4 Check the Belt Tension
The belt tension is automatically maintained by the

tensioner which must be checked at 1000 hour
intervals.
5 Renew the Belt (if damaged or tension incorrect)
a Slacken the tension of the air conditioning

compressor belt and lift the belt clear of the fan G
pulley (see Adjusting the Compressor Belt).
b Using a 3/8 in square drive inserted into the square F

hole in the belt tensioner as shown at F, lever the
tensioner roller in the direction of the arrow to allow
the belt to be lifted clear. Do not use excessive force
or the tensioner will be damaged.
b Before fitting the new belt, check that the tensioner

710390
roller and the fan pulley rotate smoothly and that
there is no play in the bearings.
c Fit the new belt and allow the tensioner to return to

its normal position.
d Check that bolt G is tightened to 43 Nm (32 lbf ft).
e Refit the compressor belt and adjust the tension.
9803/8000 Issue 3
17 - 3 Engine 17 - 3
Fan Belt (3185)

1 Stop the engine.
2 Open the bonnet.

A
! WARNING C
2-3-3-5
B
! WARNING
Do not try to turn the engine by pulling the fan or fan
C
belt. This could cause injury or premature component
failure.
0094
3 Inspect the belt for damage
Cracks across the belt width A are acceptable.
Cracks across the belt which intersect those in the

direction of the belt length B are not acceptable.
Renew the belt if it has unacceptable cracks or if it is

frayed or has pieces of material missing as at C.
D
4 Check the Belt Tension
The maximum deflection on the longest run of the belt

as at D should be 9.5 to 12.7 mm (0.375 to 0.5 in). If the
deflection is excessive, renew the fan belt.
5 Renew the Belt and Check the Belt Tensioner

E
a Slacken the tension of the air conditioning
compressor belt E and lift the belt clear of the fan
pulley (see Adjusting the Compressor Belt).
b Using a 3/8 in square drive inserted into the square

hole in the belt tensioner as shown at F, lever the
tensioner roller in the direction of the arrow to allow G
the belt to be lifted clear. Do not use excessive force
or the tensioner will be damaged.
b Before fitting the new belt, check that the tensioner F

roller and the fan pulley rotate smoothly and that
there is no side play in the bearings.
c Fit the new belt and allow the tensioner to return to

its normal position.
d Check that bolt G is tightened to 43 Nm (32 lbf ft).
e Refit the compressor belt and adjust the tension.
9803/8020 Issue 1
18 - 1 Engine 18 - 1
* Changing
the Air Filter Elements (2000
Series Machines)
4 Remove the End Cover
2115, 2125, 2135 to Machine 738561
2150 to Machine 738559 Unscrew knob A. Remove the end cover B.
Note: In a dusty working environment, the outer element 5 Remove the Elements
may have to be renewed more frequently than the service
schedule recommendation. A new inner element must be Unscrew the wingnut C. Pull out the outer element D.
fitted at latest, every third time the outer element is Take care not to tap or knock the element as you
changed. As a reminder, mark the inner element with a felt remove it. If necessary, unscrew nut J and pull out
tip pen each time you change only the outer element. DO the inner element K.
NOT attempt to wash or clean elements - they must be
renewed. 6 Clean the Canister
! CAUTION Clean the inside of the canister E, end cover B and
The outer element must be renewed immediately if the dust valve F.
warning light on the instrument panel illuminates.
2-3-3-1
7 Fit the New Elements
1 Turn the front wheels onto full left lock and stop
Carefully insert the new elements into the canister.
the engine. Remove the starter key.
Make sure they seat correctly, by smearing the seals
G and L with grease and checking for a witness mark
2 Open the bonnet
on the canister base. Fit and tighten nuts J and C.
3 If Changing the Inner Element Disconnect the
8 Connect the Induction Hose and Fit the End Cover
Filter Induction Hose
Connect the induction hose. Fit the end cover B onto
To prevent dust getting into the engine, disconnect
the canister. Make sure that the dust valve F is at the
the induction hose H. Cover the hose to prevent rain
bottom. Tighten knob A. Make sure the air filter
and dirt getting into the engine.
blocked switch connector is fitted. Check all hoses
for condition and tightness.
S191901
9803/8020 Issue 3*
18 - 2 Engine 18 - 2
Changing the Elements (3000 Series and

Later 2000 Series Machines)
4 Remove the End Cover
* All 3000 Series Machines
2115, 2125, 2135 and 2140 from Machine 738562 Release the four clips B and remove end cover C.
2150 from Machine 738560
5 Remove the Elements
Note: In a dusty working environment, the outer element
may have to be renewed more frequently than the service Pull out the outer element D. Take care not to tap or
schedule recommendation. A new inner element must be knock the element as you remove it. Pull out the inner
fitted at latest, every third time the outer element is changed. element E.
As a reminder, mark the inner element with a felt tip pen
each time you change only the outer element. DO NOT 6 Clean the Canister
attempt to wash or clean elements - they must be renewed.
Clean the inside of canister F, end cover C and dust
valve G.
! CAUTION
The outer element must be renewed immediately if the 7 Fit the New Elements
warning light on the instrument panel illuminates.
2-3-3-1
Carefully insert the new elements into the canister.
Make sure they seat correctly, by smearing the seals H
1 Turn the front wheels onto full left lock and stop the
and J with grease and checking for a witness mark on
engine. Remove the starter key.
the canister base.
2 Open the bonnet
8 Connect the Induction Hose and Fit the End Cover
3 If Changing the Inner Element Disconnect the Filter
Connect induction hose A. Fit end cover C onto the
Induction Hose
canister. Secure the four clips B. Make sure the air filter
blocked switch connector K is fitted. Check all hoses
To prevent dust getting into the engine, disconnect
for condition and tightness.
induction hose A. Cover the hose to prevent rain and
dirt getting into the engine.
A
K
F
J
B E
H
C
G
A293441
9803/8020 Issue 3*
Section A Optional Equipment Section A
Contents Page No.

Technical Data 1-1
Front Hitch Drop Flow Control Valve

Removal and Replacement 2-1
Dismantling and Assembly 2-1
Front Lift Ram

Front PTO Transfer Box

Fitting the Front PTO Output Shaft 6-2
Rear PTO Drive Shaft See Section F
Flow Regulator
Flow Testing and Pressure Testing 9-1
Removal and Replacement 10 - 1
Dismantling and Assembly
- 55 litre Flow Regulator 10 - 2
- 90 litre Flow Regulator 10 - 3
* Cold Starting Aids

Engine Heater (if fitted) 12 - 1
Range Gearbox Heater/Thermostat (if fitted) 12 - 1
9803/8020 Issue 4*
1-1 Technical Data 1-1
55 litre Flow Regulator
Relief valve pressure Not higher than Main Relief Valve pressure (see Section E,
Hydraulics, Technical Data)
Flow rate 5 to 55 litres (1 to 12 UK gal; 1 to 14.4 US gal)/minute
Relief valve pressure 185 bar (189 kgf/cm2; 2682 lbf/in2)
Flow rate 5 to 90 litres (1 to 20 UK gal; 1 to 24 US gal)/minute
9803/8020 Issue 1
2-1 Front Hitch Drop Flow Control Valve (if fitted) 2-1
B D
C A
H
3000 Series Machines G
F
A343910
9803/8020 Issue 1
2-2 Front Hitch Drop Flow Control Valve (if fitted) 2-2
Removal and Replacement Dismantling and Assembly

Removal The drop flow control valve is a non-serviceable item. In the
event of a malfunction the unit must be renewed as a
1 Park the machine on firm level ground, engage the complete assembly.
parking brake and set the transmission to neutral.
Lower any mounted implements and stop the engine.
2 Operate the hydraulic controls to release any trapped

pressure.
3 2000 Series Machines
a Disconnect hoses A and B from tee-piece C.
b Unscrew tee-piece C from drop flow control valve

D.
c Behind bulkhead E disconnect the feed hose from

the main control valve to valve D.
d Behind the bulkhead, unscrew the mounting nut

from the rear of valve D and lift the valve clear.
4 3000 Series Machines
a Disconnect hose F from control valve G.
b Draw back the sleeve of quick release coupling H

and separate the control valve/male quick release
coupling assembly from the bulkhead mounted
female quick release coupling.
c Separate the control valve from the male quick

release coupling.
Replacement
Replacement is the reverse of Removal.
Adjust control valve D (2000 series) or G (3000 Series) to

provide a drop rate suitable for the operating load.
9803/8020 Issue 1
4-1 Front Lift Ram 4-1
9803/8020 Issue 1
4-2 Front Lift Ram 4-2

Dismantling Gland Seal Fitting Procedure
The numerical sequence shown on the illustration is The size (diameter) and position of pins A is determined by
intended as a guide to dismantling. the diameter and radial width of the gland seal being fitted.
For assembly the sequence should be reversed. The pins are screwed into threaded holes in the tool body.
The spacing of the holes are designed to suit small or large
Take extreme care not to damage the cylinder bore or the diameter gland seals.
grooves in guide piece 9.
To fit a new gland seal:
To dismantle the ram assembly 3, remove circlip 1, force the
guide piece into the cylinder until the spring ring 2 is 1 Open the tool as shown at X and insert the new gland
exposed, then remove the ring and withdraw the ram seal. The seal must be fitted behind the two front pins
assembly from the cylinder. but in front of the rear pin as shown.
Discard the following items on removal: circlip 1, spring ring 2 Close the tool as shown at Y. The seal must form a
2, guide rings 6 and 7, composite seal 8, 'O' ring 10, backing reniform (kidney shape).
ring 11, wiper ring 12 and groove ring 13.
3 Locate the seal in the end cap groove, as shown at Z.
Assembly When the seal is in position, open the tool to release
the seal. Make sure the seal is correctly installed in its
Before assembling, check the components for damage and groove and remove the tool.
wear, especially the cylinder bore and seal grooves. Renew
the complete assembly if necessary.
Use new components for those which were discarded

during dismantling.
X
LIghtly oil all seals and 'O' rings.
Use the procedure opposite for fitting gland seals.
Torque Setting Table A

Item Nm kgf m lbf ft 161750X
4 270 27.5 200
Testing
Using a hydraulic hand pump (see Service Tools Section), Y

check for smooth operation of the ram in each direction.
With the ram extended, pressurise to 280 bar (4060 lbf/in2)

and check for leakage. No leakage is permitted.
161750Y
161750Z
9803/8020 Issue 1
6-1 Front PTO 6-1
165530
9803/8020 Issue 1
6-2 Front PTO 6-2
Transfer Box Fitting the Front PTO Output Shaft

Dismantling and Assembly Two alternative stub shafts (item 2) are available:
The numerical sequence shown on the illustration is 21 splines for 1000 PTO RPM
intended as a guide to dismantling. 6 splines for 540 PTO RPM.
For assembly the sequence should be reversed. Each one may be fitted to either shaft 18 or 21 depending
upon application:
When Dismantling
* Shaft 18 gives anti-clockwise rotation of drive shaft into
Drain oil at plug A. equipment. (This is the commonly accepted standard to ISO
8759/1-1985 (E).) Shaft 21 gives clockwise rotation of drive
It may be easier to slacken nuts 3 and 5 before removing the shaft into equipment (non-standard).
gearbox from the machine. Put the transmission in gear and
apply the PTO brake to prevent the shafts from rotating. Fit the stub shaft according to operator requirement and
tighten the eight securing screws (item 1) to 56 Nm (5.7 kgf
When Assembling m, 42 lbf ft).
Apply JCB High Strength Threadlocker to mating faces of ! WARNING

housings 12 and 37 and to cover plate 32.
When operating PTO equipment, always observe the
following safety precautions:
Pack JCB Special MPL grease into cavity between lips of
seals 8, 10 and 13.
Follow the instructions in the equipment operator's
handbook.
Fit new nuts 3 and 5, tighten to the specified torque setting,
then check the end float of shafts 15, 18 and 21. Add or
Rotating equipment is dangerous. Do not wear loose
remove shims 26, 30 and 36 to give an end float on each
fitting clothing when working close to rotating shafts.
shaft of 0.03 to 0.08 mm (0.001 to 0.003 in).
Always disengage the PTO, stop the engine and wait
When end float is correct, re-torque the nuts 3 and 5 and
until the equipment stops, before:
stake into notch in the shaft.
1 Leaving the cab
Refill with the specified lubricant at plug B (see Lubricants
and Capacities, Section 3).
2 Attempting to attach or detach an implement to or
from a PTO shaft or
Before fitting stub shaft 2, read Fitting the Front PTO
Output Shaft.
3 Working on or cleaning an implement connected to
the machine via a PTO shaft.
Torque Settings
Always ensure that the PTO shaft and driveline are fully
Item Nm kg f lbf ft
guarded before use.
1 56 5.7 42
3 490 50 360
When using stationary PTO equipment, ensure that the
5 490 50 360
parking brake is applied.
11 56 5.7 42 13-2-1-6
31 28 3.0 21
9803/8020 Issue 3*
9-1 Flow Regulator 9-1
D
2000 Series A296290
3000 Series
A290391
* 90 litre Flow Regulator

C
F G K C
F G
E K
J E
H1
M N J
H2
A343870
Y
X
S243592
Z
9803/8020 Issue 3*
9-2 Flow Regulator 9-2
Flow Testing & Pressure Testing

! WARNING Note: The adjustable screw is turned clockwise to
Hydraulic Fluid decrease the flow and anticlockwise to increase the flow.
Fine jets of hydraulic fluid at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic 3 Relief Valve Pressure Testing
fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected a Use flow restrictor valve Z to pressurise the circuit.
leaks and then inspect the cardboard for signs of As the pressure rises watch the flow reading which
hydraulic fluid. If hydraulic fluid penetrates your skin, get should start to fall when pressure relief valve J
medical help immediately. operates.
INT-3-1-10/1
! WARNING b Loosen locknut G. Turn adjusting screw C until the

correct relief valve operating pressure is obtained
Hydraulic Pressure
(see Technical Data). Tighten the locknut.
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
4 Stop the engine, vent residual pressure and remove the
engine and operate the controls to release pressure
pressure gauge, flow meter and flow restrictor valve.
trapped in the hoses. Make sure the engine cannot be
started while the hoses are open.
INT-3-1-11/1
Prepare the Machine
1 Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral.
Lower any mounted implements and stop the engine.
2 Flow Testing
A
Note: The following procedures apply to both 55 litre and 90 T P B L
litre flow regulators unless specified otherwise.
a Connect a suitable pressure gauge X, flow meter Y

and flow restrictor valve Z between the output
coupling A and free flow return coupling B.
K
CAUTION: Before starting the engine: J
i Make sure that the flow restrictor valve Z is fully P3
H1
OPEN (adjusting knob screwed fully out).
D
ii Make sure that relief valve J adjusting screw C is 12V
fully OPEN (screwed fully out).
A243451
b Run the engine at 1500 rev/min. At this point, with
switch D in the ‘OFF’ position, oil flow is directed 55 litre Flow Regulator
towards the External Hydraulics/Draft Control Valve
via line L.
c 90 litre Flow Regulator only - there should be no oil

flow from coupling A. If there is some oil flow,
loosen locknut M and adjust valve N clockwise until
P3 H2
CT2 A
the flow stops. Tighten the locknut.
INLET
REG
CT1
d Enable the flow regulator circuit by pressing switch N
D to the ‘ON’ position to energise solenoid K.
J
e Note the flow meter reading; as dictated by the K
requirements of the implement to be used, valve H1
(55 litre flow regulator) or valve H2 (90 litre flow CT3 CT4
regulator) should be set as detailed in Technical
Data. If adjustment is required, loosen locknut E BYPASS DRAIN
and turn adjusting screw F until the correct flow is
obtained. A343851 L 12V
D
9803/8020 Issue 4*
10 - 1 Flow Regulator 10 - 1
Removal and Replacement
Removal ! WARNING
Hydraulic Fluid
Park the machine on firm level ground, engage the parking
Fine jets of hydraulic fluid at high pressure can penetrate
brake and set the transmission to neutral. Lower any
the skin. Do not use your fingers to check for hydraulic
mounted implements and stop the engine.
fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected
Before disconnecting hoses, operate the controls with the
leaks and then inspect the cardboard for signs of
engine stopped to release any trapped pressure. Label the
hydraulic fluid. If hydraulic fluid penetrates your skin, get
hoses to assist correct refitting.
medical help immediately.
INT-3-1-10/1
Blank the open ports to prevent loss of oil and entry of dirt.
Port Connections
Disconnect the solenoid electrical connection.
A Feed from pump (or from trailer hydraulic brake valve, if
Remove bolts E. fitted).
B Carry-over to external hydraulics control valve.
Replacement C Controlled output to quick release coupling.
D Return to tank.
Reverse the removal procedure.
CAUTION: Before starting the engine make sure that the
relief valve adjusting screw X is fully OPEN (screwed fully
out).
After replacement check the flow and pressure settings (see

Flow and Pressure Testing).
X
A
D
D
A
B
* 55 litre Flow Regulator X A343880
C
E
A
B C
D
9803/8020 Issue 2*
* Dismantlingand Assembly -
55 Litre Flow Regulator Valve
The numerical sequence shown on the illustration is Torque Settings

intended as a guide to dismantling.
Item Nm Kgf m lbf ft
For assembly the sequence should be reversed. 4 30 3.0 22
22 45 4.6 33
When Assembling
Renew all seals and ‘O’ rings. Lubricate with JCB Special relief valve adjusting screw X is fully OPEN (screwed fully
Hydraulic Fluid. out).
S209360
9803/8020 Issue 2*
Dismantling and Assembly -

90 Litre Flow Regulator Valve
The numerical sequence shown on the illustration is Torque Settings

For assembly the sequence should be reversed. 1 30 - 35 3 - 3.5 22 - 26
3 45 - 50 4.6 - 5.1 33 - 37
When Assembling 5 60 - 65 6 - 6.6 44 - 48
7 60 - 65 6 - 6.6 44 - 48
Renew all seals and ‘O’ rings. Lubricate with JCB Special 9 30 - 35 3 - 3.5 22 - 26
Hydraulic Fluid.

Coat the threads of screws 9 with JCB Threadlocker and relief valve adjusting screw X is fully OPEN (screwed fully
Sealer out).
1 5
6
2 4
9 18
10 17
16
13
15
11 14
12 A356860
9803/8020 Issue 1
12 - 1 Cold Starting Aids 12 - 1
Engine Heater (if fitted) Range Gearbox Heater/Thermostat (if

fitted)
Removal
1 Switch off the engine and let it cool down.
1 Switch off the engine and let it cool down.
2 Drain the engine coolant (see Engine, Draining the
Coolant, Section 3). 2 Remove plug D and drain the gearbox oil.
3 Loosen clip A securing electrical connector B to engine 3 Disconnect the electrical connectors to the two inserts,
heater element C. Remove the electrical connector. thermostat E and heater F.
4 Pry out the heater from the block using a screwdriver or 4 Unscrew inserts E and F .
similar.
5 If the inserts are not to be replaced immediately, fit
Replacement taper plugs in the vacant threaded holes. Refill the
gearboxes with oil (see below).
1 Thoroughly clean the heater aperture in the block,
including removal of any paint.
Replacement
2 Grease the O-ring on the heater element and feed the
element through the aperture and down into the block. Replacement is the reverse of removal.
3 Using a socket of suitable size, tap the heater element Tighten the two inserts firmly, but do not overtighten.
into the block up to its shoulder. It should be an
interference fit. Fill the gearboxes with oil (see Lubricants and Capacities,
Section 3).
4 Refit the electrical connector.
5 Refill the system with coolant (see Engine, Filling the

Cooling System, Section 3).
F
A
C E
B
D
A370460
A302620
9803/8020 Issue 1
Section B Body and Framework Section B
i i
Contents Page No.
Technical data
Air Conditioning system 1-1
Cab
Direct Glazing 2-1
Prepare for Removal - All Machines 2-7
Removal - 2000 Series Machines 2-8
Removal - 3000 Series Machines 2 - 12
Replacement- All Machines 2 - 16
Air Conditioning/Heater Sysem (2000 Series Machines)

Installation Diagram 3-1
Introduction 3-2
System Operation 3-2
System Protection Devices 3-2
Operator Controls 3-2
Safety Procedures 4-1
Refrigerant Type 4-1
Leak Testing 5-1
Hoses and Pipes 5-1
Fault Finding 5 - 1A
Component Removal and Replacement 6-1
Electrical Circuit - Description 7-1
Electrical Circuit Testing - General 7-1
Pressure Switch Testing 7-1
* Electrical Circuit Diagram - See Section C
Air Conditioning (3000 Series Machines)

Operation 9-1
Control 9-1
Safety Procedures 10 - 1
Hoses and Pipes 11 - 1
Leak Testing 11 - 1
Fault Finding 11 - 1A
Component Removal and Replacement 12 - 1
Pressure Switches
Testing 13 - 1
Heater System (3000 Series Machines) 14 - 1
* Air Conditioning/Heater System (3000 Series Machines)

Wiring Diagram
- Early Machines 15 - 1
- Later Machines 15 - 2
Air Conditioning (2000 and 3000 Series Machines)

Compressor Clutch - Removal and Replacement 16 - 1
9803/8020 Issue 5*
Section B Body & Framework Section B

* 2000 Series 3000 Series
* Refrigerant
Refrigerant Type HFC R134a HFC R134a
Refrigerant Charge Weight 0.9 kg (2 lb) 1.42 kg (3 lb 2oz)
Compressor Lubricant
- Type PAG SP20 PAG SP20
- Quantity 240 c.c. (0.05 UK gal) 240 c.c. (0.05 UK gal)
* Switch Pressures
Low Pressure Switch
- Cut in > 2.35 bar (> 34 lb/in2) > 2.35 bar (> 34 lb/in2)
- Cut out < 0.4 bar (< 6 lb/in2) < 0.4 bar (< 6 lb/in2)
High Pressure Switch

- Cut in < 19.3 bar (< 280 lb/in2) < 19.3 bar (< 280 lb/in2)
- Cut out > 27.6 bar (> 400 lb/in2) > 27.6 bar (> 400 lb/in2)
9803/8020 Issue 2*
2-1 Cab 2-1
Direct Glazing
The following procedures explain how to correctly remove
and install panes of glass that are directly bonded to the cab
frame apertures. When carrying out the procedures, relevant
safety precautions must be taken.
1 Always wear safety glasses during both removal and

replacement.
2 Use protective gloves - heavy duty leather gauntlet type

gloves when cutting out the broken glass; 'non-slip'
type gloves when handling/moving panes of glass;
surgical type gloves when using the polyurethane
adhesives.
3 Wear protective overalls.
4 DO NOT smoke - the activators and primers used in the

procedures are highly flammable.
5 Do not attempt to handle or move panes of glass

unless you are using glass lifters (see Service Tools,
Section 1).
Several special tools are required to successfully complete

the removal and replacement procedures. Reference is
made to the tools in the text. The majority of these tools can
be obtained locally and the remainder from JCB Service (see
Service Tools, Section 1).
The work must only be carried out in a dry, frost free

environment. A protective canopy may be required or the
machine/frame must be moved to a sheltered area. In damp
or wet conditions, hinged doors and window frames can be
removed from the machine and taken to a more suitable
(dry) environment.
Glass should not be replaced at temperatures below 5°C

(41°F).
Removing the Broken Glass and Old Sealant
Note: The front screen glass on the Fastrac is laminated, the

other glass is toughened. If a laminated pane breaks it will
stay in one piece even though the glass is cracked. A
toughened pane will shatter and fall apart. The method of
removal of the glass depends upon which type it is. See
WARNING below.
! WARNING
Always wear safety glasses when removing or installing
screen glass. Never use a power operated knife when
removing the sealant around a toughened glass screen.
The action of the knife could cause particles of glass to
be thrown with sufficient force to cause serious injury,
even when safety glasses are being worn. Use only hand
operated tools when working with toughened glass.
BF 2-3
9803/8020 Issue 1
2-2 Cab 2-2
Direct Glazing (cont'd)

Removing the Broken Glass and Old Sealant (cont'd)
1 Position the machine on level ground and apply the

parking brake. Stop the engine. Put protective covers
over the cab seat and control pedestals.
A
2 a Laminated glass - leave installed until the old sealant

has been cut away, after which it will be possible to
lift the broken screen away from its frame housing in
one piece.
S186380
b Toughened glass - remove as much of the shattered
glass as possible prior to cutting out the old sealant.
3 Cut out the old sealant, leaving approximately 1 to 2

mm on the cab frame. There are several tools and
techniques for doing this: B D
a Pneumatic Knife A provides one of the easiest
methods of removing the sealant around laminated E
glass. The tool, powered by compressed air, should C D
be sourced locally.
Note: This tool must not be used on toughened glass (see

WARNING on previous page).
E
(i) Press the handle to start the knife blade
oscillating.
D
(ii) Insert the knife blade into the sealant.
(ii) Slowly move the knife along the sealant with the
S189870
blade positioned as close to the glass as
possible. Do not allow the knife blade to overheat
or the sealant will melt.
b Braided Cutting Wire and Handles B. This method

uses a 3-core wire, a wire starter tube and two
handles (see Service Tools, Section 1).
(i) Insert the steel tube C into the old sealant on the
inside of the glass. C
(ii) Insert the braided cutting wire D down the centre
of the steel tube. If necessary, from the outside,
cut out local sealant at the point of the tube to
gain access to the wire.
S189880
(iii) Using suitable pliers, pull the cutting wire through
the sealant to the outer side of the glass.
(iv) Secure each end of the braided cutting wire in

the special handles E.
(v) Move the cutting wire backwards and forwards in

a sawing motion and at the same time gently
push or pull the wire to cut through the old
sealant.
9803/8020 Issue 1
2-3 Cab 2-3

Removing the Broken Glass and Old Sealant (cont'd)
c Cut-out Knife F. The cut-out knife can be used as a F

left handed or right handed tool. For the knife and its
replaceable blades, refer to Service Tools, Section
1.
(i) Insert the knife blade into the sealant.
(ii) Make sure that the blade of the knife is against

the glass as shown at G.
(iii) Use the 'pull-handle' to pull the knife along and G

cut out the old sealant.
d Craft Knife H. The blades are replaceable.
(i) Insert the knife blade into the sealant.

S189890
(ii) Pull the knife along and cut out the old sealant.
Note: There are other tools available to cut out the old
sealant. For example, there is a long handle type craft knife
to give extended reach. Refer to Service Tools, Section 1, H
for details of this and any other tools.
4 a Laminated glass - lift out the broken pane using

glass lifters (see Service Tools, Section 1).
b Toughened glass - remove the cut off sealant and all

remaining particles of shattered glass.
S186370
5 If necessary, trim off the remaining old sealant to leave
approximately 1 to 2 mm on the upright face of the cab
frame aperture, as shown at J.
6 Apply a coat of 'Black Primer 206J' to the paintwork if:

J
a Paintwork was damaged or scratched during the
glass/sealant removal procedures.
b The old sealant was inadvertently cut back to the

cab frame during the glass/sealant removal
procedures.
Preparing the Cab Frame Aperture
1 If damp or wet, dry the aperture area using a hot air gun
(sourced locally).
2 Use 'Active Wipe 205' to thoroughly clean and 'prime'

the trimmed sealant. Use a lint free cloth to apply the S189900
'Active Wipe 205', allow 5 minutes flash off (drying)
time.
Note: Do not use any other type of cleaning fluids, otherwise

they may be absorbed into the old sealant and ultimately
prevent the new glass from bonding.
9803/8020 Issue 1
2-4 Cab 2-4

K
Preparing the New Glass
! CAUTION
The laminated front screen must be handled with extra M
care to prevent breakage. Wherever possible, store and
handle it in a vertical attitude. When placing or lifting the
screen in a horizontal attitude it must be supported over
its whole area, not just at the edges.
BF 1-8
1 Make sure that the new glass correctly fits the frame
aperture K.
a Put two spacer blocks L onto the bottom part of the

frame aperture.
L
b Install the new glass on the spacer blocks - ALWAYS
USE GLASS LIFTERS M (see Service Tools, Section S189910
1). Check that there is an equal sized gap all round

the edge of the glass.
Note: The spacer blocks are rectangular in section to give N

two common gap widths. If necessary they can be trimmed
to a smaller size to give an equal sized gap around the glass.
IMPORTANT: The glass edges MUST NOT touch the frame,

otherwise movement of the frame will chip and eventually
break the newly installed glass.
2 After checking for size, remove the new glass and place
it on a purpose made glass stand N (see Service
Tools, Section 1). S186280
Small panes of glass will need locating on a 600 x 700 mm x

15 to 19 mm thick plywood board P (sourced locally to fit
the glass stand N). It is recommended that an access hole is
cut in the board to accommodate the glass lifter, making it
easier and safer to handle small panes of glass. The board
P
should be covered with felt or carpet to give an anti-scratch
surface. Resting the glass on four spacer blocks will ensure
clearance of the cartridge nozzle tip during application of the
polyurethane sealant.
3 Make sure the glass is positioned on the stand the

correct way up (i.e. with the black ceramic ink band
upwards) ready for application of primer etc.
S186291
4 a Use 'Active Wipe 205' to thoroughly clean and
'prime' the black ceramic ink band printed on the
glass (see Note 1). Use a lint free cloth to apply the
'Active Wipe 205', allow 5 minutes flash off (drying)
time. R
Note 1: Do not touch the glass after cleaning with the
'Active Wipe 205'.
b If the glass does not have a black ceramic ink band,

paint a band on the glass using 'Black Primer 206J'.
The band should be approximately 25mm (1in) wide,
and the edge should be a neat straight line as shown
at R.
S189920
9803/8020 Issue 1
2-5 Cab 2-5

S
Preparing the New Glass (cont'd)
5 Install the Ultra Fast Adhesive cartridge (see Sealing

and Retaining Compounds, Section 1 and Note 2
below) into a suitable applicator gun:
10-15mm
a Remove the aluminium disc cover from the base of
the cartridge and discard the 'dessicant capsule'. T
b Make sure that the rolled edge of the cartridge is not 8-10mm A186410
damaged - if necessary, the edges should be
pressed flat, otherwise it will be difficult to remove
the cartridge from the applicator gun.
c Pierce the front 'nozzle' end of the cartridge to its

maximum diameter.
d Fit the pre-cut nozzle shown at S.
e Install the cartridge in the applicator gun.
Note 2: Cold material will be very difficult to extrude. The

cartridges must be pre-heated in a special oven (see
T
Service Tools) for 1 hour to a temperature of 80°C (176°F). S189930
Pre-heating the cartridges makes the adhesive more
workable and also brings the 'curing' time down to 30
minutes.
6 Apply the pre-heated adhesive to the glass (do not start

in a corner). Keep the nozzle guide T against the edge
of the glass and make sure that the adhesive forms a
continuous 'pyramid' shape.
Note 3: Once the pre-heated adhesive has been applied to

the glass, install the glass in the aperture as soon as
possible. After approximately 10 minutes the sealant will
form a 'skin', this will prevent the glass from bonding.
7 After applying the adhesive, leave a small amount of

sealant protruding from the nozzle. This will prevent any
adhesive left in the cartridge from 'curing'.
Installing the New Glass
1 If the internal trim strip is damaged, renew it (cut to X

length as required) before fitting the new glass. Make
sure the two spacer blocks are in position (see step 1 of
Preparing the New Glass).
2 Install the glass in the frame aperture:
a ALWAYS use the special lifting tools when moving

the glass. Use a lifting strap to hold large panes of
glass in position as shown W.
b Sit the bottom edge of the glass on the spacer

blocks as shown X.
c Make sure that the glass is correctly positioned, then

gently press around the edges of the glass and
ensure full adhesive contact is achieved. Do not S189910
press too hard or too much adhesive will squeeze
9803/8020 Issue 1
2-6 Cab 2-6

Installing the New Glass (cont'd)
3 Make the inside seal smooth:
a Wearing surgical gloves, dip your finger in a soapy

water solution.
b Use your finger to make the inside seal smooth.
4 All exposed edges must be sealed using Black

Polyurethane Sealant (see Sealing and Retaining
Compounds, Section 1).
5 Fit the external trim strip by cutting to length and

pressing into position.
6 Clean the glass after installation:
IMPORTANT: Use extreme caution when wiping the inside

of the new glass - pushing too hard on the inside of the
glass will affect the integrity of the bonded seal.
a Small amounts of sealant can be cleaned from the

glass using the 'Active Wipe 205'.
b Large amounts of excess sealant should be left to

'cure' (see Note 4) and then cut off with a sharp
knife.
Note 4: On completion of the glass replacement procedures,

the sealant 'curing' time is 30 minutes. This means that the
machine can be driven and used after 30 minutes, but it
MUST NOT be used during the curing period of 30 minutes.
c Clean the glass using a purpose made glass cleaner.
7 On completion of the glass installation procedures tidy

the work area:
a Remove ALL broken glass from the cab area.
b Remove the protective covers from the cab seat and

control pedestals.
c Renew all 'warning' and 'information' decals so that

the new installation conforms with the original cab
installation.
9803/8020 Issue 1
2-7 *Cab - All Machines 2-7

Prepare for Removal - All Machines
B
Cab removal can only be carried out using suitable lifting
equipment such as an overhead crane. A suitable lifting
beam as shown at B will also be required.
All lifting equipment must have a Safe Working Load of at

least 1000kg (2205lb). PERSONNEL MUST BE SUITABLY
QUALIFIED TO USE LIFTING EQUIPMENT.
! WARNING
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
1 Park the machine on firm level ground. Make sure that

the area is suitable for using the lifting equipment and
that there is an area to position the cab once it is
removed. Stop the engine, apply the parking brake and
chock all four wheels.
2 Exhaust all the air from the foot brake circuit by

depressing the brake pedal several times. Exhaust the
air from the air tanks.
3 Allow the engine to cool and remove the bonnet.
4 Disconnect the battery.
Note: It is possible to disconnect many of the hoses, pipes,

control rods etc. at either the ‘cab end’ or the ‘machine end’.
The procedures detailed suggest removal at the ‘machine
end’ where access is likely to be easier.
Note: Many of the procedures are detailed in other sections

of this manual. Cross references to the relevant sections are
given where applicable.
Note: Before disconnecting any components carfully tag the

A353440
components and take note of routings to enable correct
replacing.
9803/8020 Issue 2*
2-8 *Cab - 2000 Series 2-8
4
2
3
4
6 1
5
A353380
9
!
Y
@ @
£
Z
A353420
9803/8020 Issue 2*
2-9 *Cab - 2000 Series 2-9
Removal and Replacement (cont’d)

Removal - 2000 Series Machines
A - Working to the front left hand side of the cab:
1 Undo the steer valve hydraulic hoses.
2 Uncouple the main electrical harness.
3 Disconnect the clutch hydraulic hose (if fitted).
4 Disconnect the hand and foot throttle control cables at

the engine.
5 Disconnect the heater valve control cable.
6 Disconnect the hydraulic hose from the engine driven

steering hydraulic pump.
B - Working inside the cab:
7 Remove the floor mat and access panels beneath (not

shown).
8 Remove the plastic air duct.
9 Undo the gaiter at the base of the gear selection lever.

Uncouple the electrical connector Z from the gear knob
mounted switches. Undo the bolt Y and remove the
lever.
! WARNING
must be disconnected until the system has been
4-3-4-1/2
10 Discharge the air conditioning system. This procedure

must be carried out by a suitably qualified or trained
engineer. Refer to Body and Framework, Air
Conditioning/Heater System - 2000 Series Machines
for further information.
11 Disconnect the air conditioning hose.
12 Trace the heater hoses from the cab. Using suitable

clamps pinch the hoses to prevent coolant loss.
Disconnect the 2 hoses at the heater unit in the cab.
13 On 4 wheel steer machines disconnect the air pipe

located in the left hand compartment under the
passenger seat.
9803/8020 Issue 2*
2 - 10 *Cab - 2000 Series 2 - 10
C
&
%
& &
&
$
&
A353390
D
( )
⁄ ‹
‹
*
‹
‹
¤ A353400
9803/8020 Issue 2*
2 - 11 *Cab - 2000 Series 2 - 11

Removal - 2000 Series Machines (cont’d)
C - Working to the front right hand side of the cab:
14 Disconnect the front and rear screen wash pipes at the

push on connectors.
15 Disconnect the hydraulic tank breather (not 2150).
16 Make sure that the battery leads are disconnected (not

shown).
17 Disconnect the air pipes and electrical connectors from

the foot brake valve.
Y
D - Working to the rear and under the cab:
18 Make sure that the air conditioning system has been

discharged, see step 10. Disconnect the air
conditioning hose from the accumulator.
Z
19 Disconnect the trailer and parking brake air pipes.
20 Uncouple the electrical connectors.
21 Disconnect the PTO speed selector cable at the cab or

at the gearbox. See Section D, Power Take Off
Speed Selector Cable.
22 Disconnect the control rods and drive shafts from the

hydraulic control valve. See Section D, External
Hydraulics Control Valve Linkage.
23 Uncouple the electrical connectors at the Selectronic

pneumatic cylinders. Remove the clips from the cylinder
fork end pivots and lift the cylinders through the access
hatch into the cab. Tie the assembly out of harm’s way.
24 Working at the rear of the machine disconnect the hitch

release cable (not shown).
E - Lifting the Cab:
25 Fit the lifting equipment, see Removal - All Machines.
26 Undo the 2 front mounting bolts Y and rear bolts Z

located at the bottom corners of the cab. Note that
access to the front bolts Y is from inside the cab. Note
the position of the spacers and washers.
27 Carefully lift the cab watching for any components that

may still require disconnecting.
28 Lift the cab clear of the machine. Lower the cab onto
suitable blocks located under the 4 mounting points.
Make sure that the cab is safely supported and that
components are not trapped or crushed under the cab.
9803/8020 Issue 2*
2 - 12 *Cab - 3000 Series 2 - 12
1
2
1
2
6 3
4
7
5
A353410
B
X X
X
A353520
9803/8020 Issue 2*
2 - 13 *Cab - 3000 Series 2 - 13

Removal - 3000 Series Machines
A - Working to the front left hand side of the cab:
1 Disconnect the hand and foot throttle control cables at

the engine.
2 Locate the tee piece in the foot brake air line and
disconnect the 2 larger pipes.
3 Uncouple the main electrical harness.
4 Disconnect the clutch hydraulic hose (if fitted).
5 Disconnect the bonnet catch control cable, or

alternatively, remove the catch assembly from the
chassis.
6 Undo the steering shaft clamp bolt and disconnect the

shaft.
7 Using a suitable clamp pinch the heater hose to prevent

coolant loss. Disconnect the hose at the heater valve.
B - Working inside the cab:
8 Remove the floor mat and access panels beneath (not

shown).
9 Undo the gaiter at the base of the gear selection lever.

Uncouple the electrical connector Z from the gear knob
mounted switches. Undo the bolt Y and remove the
lever.
10 To gain access to the front right hand cab fixing bolt,

remove the cup holder/tray panel as follows:
Remove the 3 caps X from the retaining screws, then
using a socket with a flexible drive, undo the screws.
Undo the 2 screws at positions W. Lift away the panel.
9803/8020 Issue 2*
2 - 14 *Cab - 3000 Series 2 - 14
!
@
!
£ 13
£
£
£ %
$ ^
$
A353430
D
( )
⁄ ‹
‹
*
¤
¤
‹
‹
¤
A353510
9803/8020 Issue 2*
2 - 15 *Cab - 3000 Series 2 - 15

Removal - 3000 Series Machines (cont’d)
C - Working at the front right hand side of the cab: 24 Working at the rear of the machine disconnect the hitch
release cable (not shown).
11 Make sure that the battery has been disconnected and
then disconnect the electrical cables at the starter
motor. Undo and remove the cable clamp. E - Lifting the Cab:
12 Disconnect the bonnet catch control cable, or 25 Fit the lifting equipment, see Removal - All Machines.
alternatively, remove the catch assembly from the
chassis. 26 Undo the 2 front mounting bolts Y and rear bolts Z
located at the bottom corners of the cab. Note that
13 Disconnect the air pipes and electrical connectors from access to the front bolts Y is from inside the cab. Note
the foot brake valve. the position of the spacers and washers.
14 Remove the ties from the main harness at the front of 27 Carefully lift the cab watching for any components that
the cab. may still require disconnecting.
15 Working near the radiator, using a suitable clamp, pinch 28 Lift the cab clear of the machine. Lower the cab onto
the heater hose to prevent coolant loss. Disconnect the suitable blocks located under the 4 mounting points.
hose. Make sure that the cab is safely supported and that
components are not trapped or crushed under the cab.
16 Remove the intermediate section of the exhaust system.
D - Working to the rear and under the cab:
! WARNING
4-3-4-1/2
17 Discharge the air conditioning system. This procedure

Y
must be carried out by a suitably qualified or trained
engineer. Refer to Body and Framework, Air
Conditioning/Heater System - 3000 Series Machines
for further information.
Z
18 Disconnect the 2 air conditioning hoses.
19 Disconnect the trailer and parking brake air pipes.
20 Uncouple the electrical connectors.
21 Disconnect the PTO speed selector cable at the cab or

at the gearbox. See Section D, Power Take Off
Speed Selector Cable.
22 Disconnect the control rods and drive shafts from the

hydraulic control valve. See Section D, External
Hydraulics Control Valve Linkage.
23 Uncouple the electrical connectors at the Selectronic

pneumatic cylinders. Remove the clips from the cylinder
fork end pivots and lift the cylinders through the access
hatch into the cab. Tie the assembly out of harm’s way.
9803/8020 Issue 2*
2 - 16 *Cab - All Machines 2 - 16
Replacement - All Machines
Replacement is the reversal of the removal for the relevant Charge the air conditioning system. Refer to Body and
machine, but note the following: Framework, Air Conditioning/Heater System - 3000
Series or 2000 Series Machines (as applicable) for further
! WARNING information.
The cab on this machine is designed to give the operator
protection in the event of the machine rolling over ! WARNING
(ROPS). The following points must be strictly observed. Leak testing in Air Conditioning systems should be
carried out only in a well ventilated area.
1 If the machine has been in an accident which has BF 1-2
damaged the ROPS structure, the machine must not
be used until the structure has been renewed. If there Start the engine and test all the machine systems. Stop the
is any doubt about the strength of the ROPS engine and check all hose and pipe connections for leaks.
structure, it must be renewed. The operator could be Rectify as required.
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 cab structure for damage. Check the mounting

bolts for signs of damage.
Make sure that all hoses, pipes and open ports are clean and
free form debris, particuarly hydraulic and air conditioning
hoses. Renew any ‘O’ ring seals at hose connections, make
sure that seals are correctly located.
Pay careful attention to hose, pipe and electrical harness

routings. Make sure that they will not become trapped, retain
using new cable ties as applicable.
Locate the 4 cab fixing bolts through the chassis bushes as

the cab is lowered. Lower the cab fully and torque tighten
the fixing bolts to 375 Nm (275 lbf ft). Remove the lifting
equipment.
After fitting the cab and reconnecting all components, top up

the engine coolant. Top up the hydraulic oil. See Section 3,
Routine Maintenance.
Bleed the clutch system (if applicable). See Section F Main

Drive Clutch Booster, Removal and Replacement,
Bleeding.
9803/8020 Issue 3*
3-1 Air Conditioning/Heater System -2000 Series Machines 3-1
*
*To S/N 738748 RPM
SETUP
SELECT
Y
RPM
EXIT
ABS
2 3 !
SETUP
RPM SELECT
Z
RPM
EXIT
F G 1
ABS
2 3 !
*From S/N 738749

L
B
N
K
M
A285983
9803/8020 Issue 4*
3-2 Air Conditioning/Heater System - 2000 Series Machines 3- 2
Introduction Additionally, the suction accumulator coil:
A combined air conditioning/heater unit incorporates a 3- a extracts moisture from the refrigerant by means of the
speed blower to deliver air into the cab. The heater facility dessicant it contains.
can be used independantly by operating the blower with air b ensures that there is a constant supply of refrigerant gas
conditioning not selected, the air temperature being varied to the compressor.
by manually adjusting the flow of engine coolant through a
heat exchanger in the system evaporator unit. Air The low temperature, low pressure, high heat content, dry
conditioning can only be selected if the blower is also refrigerant gas from the suction accumulator is drawn into
selected. The air temperature can still be varied as the compressor to complete the cycle.
described earlier. Air conditioning provides year round
operator comfort in all climates, cool air being available in System Protection Devices
hot conditions and warm air in cold conditions. An additional
benefit is that the air, being dry, greatly reduces the risk of 1 A thermostat monitors the temperature of the
condensation on cab windows in warm humid conditions evaporator coil and in doing so provides cyclic control
and in cold damp conditions. of the system once it has been activated (see Operator
Controls). If the temperature falls to the point where
System Operation condensate is about to freeze on the evaporator coil
the air conditioning relay feed is broken when the
The air conditioning system is a closed circuit through which thermostat opens and the system shuts down. When
the refrigerant is circulated, its state changing from gas to the coil temperature is raised sufficiently by the air flow
liquid and back to gas again as it is forced through the the thermostat closes and the system starts up again.
system. Failure to shut down the system at just above freezing
point would lead to a build-up of ice on the evaporator
The major components of the system are the compressor A, coil and prevent air flow into and around the cab.
condenser B, orifice tube C, evaporator coil D and suction
accumulator E. 2 The air conditioning system can be damaged by either
excessively low or excessively high refrigerant
The system operates whenever the compressor
pressure. If either situation develops, pressure switch
electromagnetic clutch operates to engage the compressor
contacts break the electrical earth line from the air
drive from the engine fan drive.
conditioning relay solenoid (which must be energised to
The compressor A draws in low pressure refrigerant gas operate the compressor clutch before the system can
from the suction line (evaporator to compressor via suction operate) to shut down the system.
accumulator) and increases refrigerant pressure, and hence
refrigerant temperature, through compression. * a The bronze low pressure switch J is in the suction
line M to the compressor. Low pressure leads to a
High pressure refrigerant is forced from the compressor to lack of refrigerant borne lubricant for the compressor
the condenser B, mounted in front of the engine radiator. which can suffer severe damage as a result. Possible
Ambient air is drawn across the condenser fins by the causes of the low pressure are low refrigerant charge
engine cooling fan. In the condenser the refrigerant changes or low ambient temperature.
state to a high pressure, high temperature liquid, but with a
reduced heat content. * b The green high pressure switch K is in the
compressor output line N. Continued high pressure
The liquid refrigerant is forced through orifice tube C, a fixed is likely to damage hoses and seals. The most likely
restrictor which separates the high and low pressure reason for excessivley high pressure is debris
sections of the refrigerant circuit. The orifice tube acts in causing a blockage in the condenser B or the orifice
conjunction with condenser B and suction accumulator E to tube C.
meter refrigerant flow to evaporator coil D. Immediately after
passing through the orifice tube the refrigerant changes to a
Operator Controls
low pressure, low temperature wet vapour.
Air Conditioning
The refrigerant is drawn through the evaporator coil D by the
suction of the compressor. The temperature of the Assuming that the engine is running and the System
refrigerant is considerably lower than that of the ambient Protection Devices are not causing the system to shut
and recirculated air being drawn across the evaporator coil down, the system is activated by setting the air conditioning
by the blower fan. Moisture in the air condenses on the coil switch F to ON, and the blower switch G to fan speed 1, 2 or
and is discharged, via drain tubes, through the cab floor. 3 as required. Air temperature can be varied using the
temperature control H which is mechanically linked to a
Down stream of the evaporator the suction accumulator E
variable tap in heater lines L.
acts as a reservoir for the supply of refrigerant gas to the
evaporator and compressor. When the orifice tube delivers Heater only
more refrigerant than the evaporator requires, the excess is
stored by the suction accumulator. Conversely, when the Set air conditioning switch F to OFF and blower switch G to
evaporator requires more refrigerant than is being delivered fan speed 1, 2 or 3 as required. Vary the air temperature by
by the orifice tube, the suction accumulator releases some means of temperature control H.
of its stored refrigerant to make up the difference.
9803/8020 Issue 3*
4-1 *Air Conditioning/Heater System - 2000 Series Machines 4-1
Safety Procedures
The air conditioning system uses refrigerant under pressure 7 When handling refrigerant, rubber gloves and goggles
in a closed circuit. Any service procedure which breaks into should be worn. Operators should ensure no refrigerant
the closed circuit and therefore requires discharging of the comes into contact with the skin. Particular care should
system, must only be carried out by a qualified refrigeration be taken when connecting or disconnecting system
engineer or suitably trained person. The following guidelines components (e.g. charging hoses or pressure
should be adhered to by all personnel servicing the air switches). When these components are connected to
conditioning system. the system, a short release of refrigerant occurs. This
results in a high velocity, very cold gas being emitted
! WARNING from the connection point.
must be disconnected until the system has been ! WARNING
discharged by a refrigeration engineer or a suitably Goggles and rubber gloves must be worn when pressure
trained person. You can be severely frostbitten or injured switches are removed or fitted. A small amount of
by escaping refrigerant. refrigerant is released which can be harmful to the skin
4-3-4-1/2
and eyes.
BF 1-10
1 It is critical that the correct refrigerant and related
components are used (see Refrigerant Type) and that Refrigerant Type
charging is done only by a qualified refrigeration
engineer or suitably trained person. As a precaution The refrigerant used in the Fastrac air conditioning system is
against possible accidental leakage, discharging and HFC R134a.
charging of the vehicle refrigerant system must be
conducted in a well ventilated area.
! CAUTION
2 It is illegal to discharge the refrigerant into the Air conditioning systems using R-134a refrigerant are
atmosphere during service operations. Either a re- not compatible with systems using R-12 refrigerant. No
cycling charging station should be used or the attempt should be made to charge a system with a
refrigerant gas should be discharged to a canister. different refrigerant from that originally used. No
component that comes into contact with refrigerant can
! WARNING be interchanged between machines using the two
different refrigerants, otherwise contamination of the
Leak testing in Air Conditioning systems should be system will occur.
carried out only in a well ventilated area. BF 1-6
BF 1-2
3 Containers of refrigerant should be stored in a cool The air conditioning system is fitted with quick connect type
environment away from direct sunlight. charging ports. These connectors are designed to be used
with the charging equipment for the correct refrigerant.
4 DO NOT perform welding operations close to
refrigerant hoses (maintain a distance of at least 0.5m
from hoses).
! WARNING
Do not carry out welding operations close to the air
conditioning refrigerant circuit. A poisonous gas is
produced when refrigerant comes into contact with
naked flames. Do not smoke or allow naked flames close
to the refrigerant circuit.
BF 1-9
5 DO NOT steam clean refrigerant system components.
6 When charging or discharging the refrigerant system,

no smoking or naked flames should be allowed in the
immediate vicinity. The refrigerant itself does not give
off a poisonous gas, but when it comes into contact
with a naked flame a poisonous gas is produced.
9803/8020 Issue 2*
5-1 Air Conditioning/Heater System - 2000 Series Machines 5-1
Hoses and Pipes Leak Testing

! WARNING Note: The refrigerant is heavier than air and will leak
downwards from the defective component. Check in still
conditions but in a well ventilated area.
must be disconnected until the system has been Hose or pipe connections are likely leakage points of any
discharged by a refrigeration engineer or a suitably refrigerant circuit.
by escaping refrigerant. * It is essential that an electronic leak detector is used to
4-3-4-1/2
locate leaks accurately. However, if a leak detector is not
Hoses available an approximate source of leakage can be found by
applying soap solution to suspect areas.
The refrigerant hoses have crimped ferrule end fittings. The
hose connectors have an 'O' ring seal which compresses To check for leaks in the high pressure side of the system i.e.
when the connection is tight, creating an air tight seal. from the compressor output to the orifice tube, run the air
conditioning for a few minutes then switch off the engine and
Hoses are used to connect the inlets and outlets of the test immediately for leakage using an electronic leak
compressor, condenser, orifice tube, evaporator coil and detector.
suction accumulator and at bulkhead connectors above and
below the cab floor. To check for leakage in the low pressure side of the system,
switch off the air conditioning and leave for a few minutes to
If leakage is detected from a hose connector, tighten the allow the high and low side pressures to equalise before
connector and repeat the leakage test. If leakage is still testing.
evident, it will be necessary to discharge the system and
! WARNING
renew the connector 'O' ring seal.
Leak testing in Air Conditioning systems should be
Note: It is essential that 'O' rings of the correct material carried out only in a well ventilated area.
BF 1-2
(HNBR - colour coded green) are used. It is also essential to
use the hoses specified by JCB as R134a refrigerant can
permeate through the material used in the hoses designed
for systems using R12 refrigerant.
Pipes
Particular care must be taken when connecting the

compressor hose end pipes to the compressor ports (items
M and N illustrated on page 3 - 1). Suction pipe M should
be tightened to a torque of 32.5 ±3 Nm (24 ±3 lbf ft, 3.3 ±0.4
kgf m), discharge pipe N to a torque of 23.5 ± 3.4 Nm (17.5 ±
2.5 lbf ft, 2.4 ± 0.35 kgf m). Use of excessive torque could
result in cracks in the compressor casting.
9803/8020 Issue 4*
5 - 1A Air Conditioning/Heater System - 2000 Series Machines 5 - 1A
Fault Finding
The following fault finding checks can be undertaken without
discharging the air conditioning system.
Procedures that require charging or discharging the system

are not given in this manual as they require special
equipment that is usually held only by trained refrigeration
engineers.
The system will not function in very low ambient

temperatures, therefore tests should be carried out in a
warm environment.
It is essential that an electronic leak detector is used to

locate leaks accurately (see Leak testing). However, if a leak
detector is not available an approximate source of leakage
can be found by applying soap solution to suspect areas.
* Note: Sight glass checking procedures and indications have

been deleted as experience has shown that sight glass
indications are not reliable on systems charged with HFC
R134a.
General Fault Indications
The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment. It
is recommended that, to locate faults on the system accurately and quickly, an electronic leak detector and a refrigerant
pressure gauge should be used.
There are several indications that may help to determine the fault area on a system not working efficiently:
a) Poor Performance Low accumulator pressure- Repair or renew accumulator

Evacuate and recharge
Plugged orifice tube Renew orifice tube

Evacuate and recharge
Condenser coil air flow restricted- Remove debris from around coil using
compressed air or low pressure water
System overcharged- Evacuate and recharge
b) Blower does not operate Blower resistor failed- Renew resistor.

on all speeds
c) Compressor clutch Condenser coil blockage - Remove debris from around coil/renew condenser.
continually cuts out Overcharging of refrigerant system- Evacuate and recharge system
9803/8020 Issue 2*
5-2 *Air Conditioning/Heater System 2000 - Series Machines 5-2
Fault Finding (Continued)

1. No Air Conditioning
Note: If the fault is that the system is unable to provide cool air, first make sure that the cable operated water temperature
control valve to the heater coil is fully closed. If not, adjust the cable.
CHECK ACTION
a Are the controls set correctly, i.e. air conditioning YES: Go to b.
ON, fan ON? NO: Reset controls and retest.
b Is the compressor clutch fuse blown? YES: Change fuse and retest.
NO: Go to c.
c Does the compressor clutch operate with 12V YES: Go to d.

connected directly to the clutch? NO: Change clutch assembly.
d Is the blower working? YES: Go to e.

NO: Check the electrical connections to the blower
switch,resistor and blower motor. If connections are
correct,replace blower switch and retest. If blower
motor will still not function, replace blower motor
assembly.
e Bypass the low pressure switch (i.e. disconnect the YES: Replace low pressure switch and retest. If still not
electrical leads and connect them together). Does working check the refrigerant system pressure. If
the clutch work? pressure is very low, the refrigerant charge has
leaked from the system. Call in a qualified
refrigeration engineer or a suitably trained person to
determine the fault and recharge the system.
NO: Go to f.
f Bypass the high pressure switch (i.e. disconnect the YES: Replace high pressure switch and retest.
electrical leads and connect them together). Does NO: Go to g.
the clutch work?
g Bypass the thermostat switch (i.e. disconnect the YES: Replace thermostat switch and retest.
electrical leads and connect them together). Does NO: Check all electrical connections.
the clutch work?
2. Compressor clutch cycles frequently, air conditioning performance is only moderate
a Check the sight glass for bubbles. Are bubbles YES: Refrigerant charge is low. Check for leaks (the air
present? conditioning is cycling on the low pressure cut-out
switch).
NO: Go to b.
b Is the condenser coil contaminated with debris? YES: Clean the condenser and retest.
NO: The refrigeration system has an internal blockage.
Call in a qualified refrigeration engineer or a suitably
trained person to determine the fault.
3. Air conditioning performance poor

a Check the system sight glass for bubbles. YES: Refrigerant charge is low. Check system for leaks
Are bubbles present? (the air conditioning is cycling on the low pressure
cut-out switch).
NO: Go to b.
b Check the operation of the blower. Is the blower YES: Go to c.

operating on all three speeds? NO: If the blower will not operate on any speed, replace
the blower switch and retest. If the blower still does
not function, replace the blower motor assembly.
c Check the temperature of the compressor suction hose YES: The orifice tube is being bypassed. Call in a trained
manually. Is the hose warm to the touch? refrigerant engineer to replace the orifice tube valve
and recharge the system.
NO: There is an internal blockage in the refrigerant circuit.
Call in a qualified refrigeration engineer or a suitably
trained person to locate the fault and carry out
repairs.
9803/8020 Issue 2*
6-1 Air Conditioning/Heater System 2000 - Series Machines 6-1
Component Removal and Replacement

*
9803/8020 Issue 3*
Component Removal and Replacement assembly away from the evaporator unit, feeding the
tube through grommet AA.
The following components can be removed without
discharging and recharging the refrigerant.
Replacement
* AD Resistor - blower motor speed control.
Replacement is the reverse of removal. Make sure the
F Air conditioning switch (see Operator Control capillary tube returns to its original location.
Switches)
Blower Motor
G Blower switch (see Operator Control Switches)
Removal
J Low pressure switch (see Pressure Switch Testing)
1 Remove thermostat switch N and capillary tube P (see
K High pressure switch (see Pressure Switch Testing) * Thermostat Switch).
M Air conditioning relay (see Section C)
2 Disconnect the wiring to resistor AD mounted on the
back of blower motor R.
N Thermostat switch (see Thermostat Switch)
3 Remove screws/washers AB and screws AC and lift
P Capillary tube (see Thermostat Switch)
blower motor R away from the evaporator unit.
R Blower motor (see Blower Motor)
Replacement
S Compressor clutch (see Compressor Clutch)
T Electrical harness
F
U U
Operator Control Switches
1 0 1 0
3 2
The air conditioning switch F and blower switch G are
located at the base of the ‘B’ post to the right of the
operator. U U
G
1 Remove the four screws U and raise the cover to
provide access to the rear of the two switches.
2 Disconnect the electrical wires from the switch

terminals.
3 Unscrew the switch mounting nut and remove the

switch from the panel.
Thermostat Switch
The thermostat switch N/capillary tube P assembly is
mounted on the back of the blower motor R at the rear of the
evaporator unit. Remove the cover from the top of the
evaporator unit to provide access.
Removal
1 Disconnect wires W from the thermostat switch N. A290380
2 Remove the nine screws/washers X and lift clear

sideplate Y, taking care not to damage its seal. Replacement is the reverse of removal.
3 Remove the two screws/washers Z securing thermostat

switch N.
4 Make a note of the location of the capillary tube in the

evaporator coil and then remove the switch N/tube P
9803/8020 Issue 3*
Electrical Circuit - Description Removal and Replacement
The 12V supply is fed from the blower switch via the air ! WARNING
conditioning switch and the thermostat switch to the air Goggles and rubber gloves must be worn when pressure
conditioning relay solenoid. The relay solenoid return line switches are removed or fitted. A small amount of
goes via the low and high pressure switches, which are refrigerant is released which can be harmful to the skin
wired in series, to earth. and eyes.
BF 1-10
The low pressure switch requires a minimum refrigerant
pressure to close its contact. The high pressure switch Removal
requires the pressure to remain below the maximum limit to
keep its contact closed. 1 Disconnect the electrical connections and unscrew the
pressure switch.
Both pressure switch contacts must be closed for the air
conditioning relay solenoid, and hence the compressor
Replacement
clutch, to operate. If the compressor clutch does not operate
when air conditioning is selected, the fault may be either
1 Screw the pressure switch into the pressure switch port
electrical or incorrect system pressure.
and tighten just sufficiently to form a gas-tight seal. Do
not overtighten.
Electrical Circuit Testing - General
2 Run the air conditioning and check the pressure
1 Turn the starter switch to IGN. Do not start engine. Set switches for leaks as described under Leak Testing. If
the air conditioning switch to ON and the blower switch any leaks are found, tighten the pressure switch further
to fan speed 1. until the leaking stops.
*2 Disconnect the wires to both pressure switches and,
using a multimeter, check that there is 12V at both
solenoid terminals of the air conditioning relay M2. If
there is 12V at one solenoid terminal but not the other,
the relay is faulty. If the voltage is low or zero at both
terminals, check the fuse, the blower switch, the air
conditioning switch and the thermostat switch.
3 Disconnect the wire from the compressor clutch and

connect 12V directly to the clutch terminal. If the
compressor clutch does not engage, the fault is at the
compressor clutch. If the compressor clutch engages,
the fault is at one of the pressure switches. Continue
testing at High Pressure Switch (see Pressure Switch
Testing).
Pressure Switch Testing

1 Reconnect the wire to the compressor clutch and

disconnect the wires to the high pressure switch K.
Connect the wires together to bypass the high pressure
switch.
2 If the compressor clutch now engages, the fault must K

be at the high pressure switch.
3 If the clutch does not engage, continue testing at Low

Pressure Switch.
Low Pressure Switch
1 Reconnect the wires to the high pressure switch and

disconnect the wires to the low pressure switch J. J
Connect the wires together to bypass the low pressure
switch.
2 If the compressor clutch now engages, the fault must

be at the low pressure switch. A233371
Note: If both pressure switches operate correctly, check all

electrical connections.
9803/8020 Issue 5*
9-1 Air Conditioning - 3000 Series Machines 9-1
Y JH G
F E D
Z
J H G
A343650 F
C
B A
L
N
M
191571
9803/8020 Issue 5*
9-2 Air Conditioning - 3000 Series Machines 9- 2
Operation
To maintain optimum operator comfort in warm climates or Cool de-humidified air is emitted through air vents into the
during seasons of high ambient temperature, the air cab.
conditioning system delivers cool, dehumidified air into the
cab. Cooling is provided by passing the warm ambient air, The low temperature, low pressure, high heat content
together with recirculated air, over an evaporator coil in the refrigerant gas, is now drawn by suction back to the
air conditioning unit. The air conditioning system is a closed compressor, where the cycle is completed.
circuit through which the refrigerant is circulated, its state
changing from gas to liquid and back to gas again, as it is Control
forced through the system. The major components of the
system are the compressor A, condenser B, receiver drier C, Control of the system is achieved by the cyclic action of the
expansion valve D and evaporator unit E. compressor's electromagnetic clutch. The thermostat switch
senses the evaporator coil temperature by means of a
* Operate the air conditioning using the controls in view Y for capillary tube and cycles the compressor clutch on and off to
machines to serial no. 640777 or in view Z for machines from prevent freezing of condensate on the evaporator coil.
serial no. 640778. Move 3-position mode selector switch F to
the extreme right (the centre position is OFF), turn thermostat The signal from the thermostat switch is sent to the
switch G to give a suitably cool air temperature for the compressor clutch via two pressure switches. These are
ambient conditions and select fan speed 1, 2 or 3 on air designed to disengage the compressor clutch and protect
conditioning blower switch H. the system from damage that would be caused by either
refrigerant loss or excessive pressure.
* Note: Switch J is for the heater blower which will operate
only when switch F is moved to the extreme left (see Heater The low pressure switch K is connected to the suction hose
System, Operation). In this mode, the air conditioning adjacent to the compressor. If the pressure in the suction
blower motor R will also operate, always at its lowest speed, hose falls below the low pressure switch setting, it opens,
regardless of the setting of switch H. interrupting the supply from the thermostat to disengage the
compressor clutch.
Provided that the ambient temperature is high enough, the
air conditioning will switch on. The compressor's The high pressure switch L is connected to the discharge
electromagnetic clutch operates, engaging the compressor hose adjacent to the compressor. If the pressure in the
drive from the engine fan drive. The compressor A draws in discharge hose rises above the high pressure switch setting,
low pressure refrigerant gas from the suction line (evaporator it opens, interrupting the supply from the thermostat to
to compressor) and increases refrigerant pressure through disengage the compressor clutch.
compression. Increasing pressure also increases refrigerant
temperature.
High pressure refrigerant is forced from the compressor to

the condenser B, mounted in front of the engine radiator.
Ambient air is drawn across the condenser fins by the engine
cooling fan. In the condenser, the refrigerant changes state
to a high pressure, high temperature liquid but with a lower
heat content.
The refrigerant then passes through the receiver drier C. The

receiver drier serves as a reservoir for refrigerant and also
contains a desiccant to remove moisture from the system.
The high temperature, high pressure refrigerant is forced by
compressor action into the expansion valve D, which meters
the amount of refrigerant entering the evaporator. In the
expansion valve the refrigerant expands to become a low
pressure, low temperature liquid.
The refrigerant is drawn through the evaporator E by the

suction of the compressor. The temperature of refrigerant is
now considerably below that of the air being drawn across
the evaporator coil by the blower. Heat is transferred from
the ambient and recirculated air to the refrigerant, causing
the low pressure liquid to vapourise and become a low
pressure gas. Moisture in the air condenses on the
evaporator coil and is drained away via condensate drain
tubes through the cab floor.
9803/8020 Issue 2*
10 - 1 Air Conditioning - 3000 Series Machines 10 - 1
Safety Procedures
7 When handling refrigerant, rubber gloves and goggles
The air conditioning system uses refrigerant under pressure should be worn. Operators should ensure no refrigerant
in a closed circuit. Any service procedure which breaks into comes into contact with the skin. Particular care should
the closed circuit and therefore requires discharging of the be taken when connecting or disconnecting system
system, must only be carried out by an air conditioning components (e.g. charging hoses or pressure switches).
engineer. The following guidelines should be adhered to by When these components are connected to the system,
all personnel servicing the air conditioning system. a short release of refrigerant occurs. This results in a
high velocity, very cold gas being emitted from the
connection point.
! WARNING
! WARNING
must be disconnected except by a qualified refrigeration Goggles and rubber gloves must be worn when pressure
engineer. switches are removed or fitted. A small amount of
4-3-4-1
refrigerant is released which can be harmful to the skin
and eyes.
BF 1-10
1 It is critical that the correct refrigerant and related
components are used and that charging is done only by
qualified personnel (see Refrigerant Types). As a
precaution against possible accidental leakage,
Refrigerant Types
discharging and charging of the vehicle refrigerant
system must be conducted in a well ventilated area. The refrigerant used in the Fastrac air conditioning system is
Freon R-12 up to machine no. 636393 and R134a from
2 It is illegal to discharge the refrigerant into the machine no. 636394 onwards.
atmosphere during service operations. Either a re-
cycling charging station should be used or the ! CAUTION
refrigerant gas should be discharged to a canister. Air conditioning systems using R-134a refrigerant are not
compatible with systems using R-12 refrigerant. No
! WARNING attempt should be made to charge a system with a
Leak testing in Air Conditioning systems should be different refrigerant from that originally used. No
carried out only in a well ventilated area. component that comes into contact with refrigerant can
BF 1-2
be interchanged between machines using the two
different refrigerants, otherwise contamination of the
3 Containers of refrigerant should be stored in a cool system will occur.
BF 1-6
environment away from direct sunlight.
4 DO NOT perform welding operations close to refrigerant The air conditioning system is fitted with quick connect type
hoses (maintain a distance of at least 0.5m from hoses). charging ports. These connectors are designed to be used
with the charging equipment for the correct refrigerant.
! WARNING
Do not carry out welding operations close to the air
conditioning refrigerant circuit. A poisonous gas is
produced when refrigerant comes into contact with
naked flames. Do not smoke or allow naked flames close
to the refrigerant circuit.
BF 1-9
5 DO NOT steam clean refrigerant system components.
6 When charging or discharging the refrigerant system, no

smoking or naked flames should be allowed in the
immediate vicinity. The refrigerant itself does not give
off a poisonous gas, but when it comes into contact
with a naked flame a poisonous gas is produced.
9803/8020 Issue 2
11 - 1 Air Conditioning - 3000 Series Machines 11- 1
Hoses and Pipes Leak Testing

! WARNING Note: The refrigerant is heavier than air and will leak
The air conditioning system is a closed loop system and downwards from the defective component. Check in still
contains pressurised refrigerant. No part of the system conditions but in a well ventilated area.
discharged by a refrigeration engineer or a suitably Hose or pipe connections are likely leakage points of any
trained person. You can be severely frostbitten or injured refrigerant circuit.
4-3-4-1/2 * It is essential that an electronic leak detector is used to
locate leaks accurately. However, if a leak detector is not
Hoses
available an approximate source of leakage can be found by
The refrigerant hoses have crimped ferrule end fittings. The applying soap solution to suspect areas.
hose connectors have an 'O' ring seal which compresses
when the connection is tight, creating an air tight seal. To test for leaks in the high pressure side of the system i.e.
from the compressor output to the expansion valve, run the
Hoses are used to connect the inlets and outlets of the air conditioning for a few minutes then switch off the engine
compressor, condenser, orifice tube, evaporator coil and and test for leakage using an electronic leak detector.
suction accumulator and at bulkhead connectors above and
below the cab floor. To test for leakage in the low pressure side of the system,
switch off the air conditioning and leave for a few minutes
If leakage is detected from a hose connector, tighten the before testing.
connector and repeat the leakage test. If leakage is still ! WARNING
evident, it will be necessary to discharge the system and
Leak testing in Air Conditioning systems should be
renew the connector 'O' ring seal.
carried out only in a well ventilated area.
BF 1-2
Note: It is essential that 'O' rings of the correct material
(HNBR - colour coded green) are used. It is also essential to
use the hoses specified by JCB as R134a refrigerant can
permeate through the material used in the hoses designed
for systems using R12 refrigerant.
Pipes
Particular care must be taken when connecting the

compressor hose end pipes to the compressor ports (items
M and N illustrated on page 9 - 1). Suction pipe M should
be tightened to a torque of 32.5 ±3 Nm (24 ±3 lbf ft, 3.3 ±0.4
kgf m), discharge pipe N to a torque of 23.5 ± 3.4 Nm (17.5 ±
2.5 lbf ft, 2.4 ± 0.35 kgf m). Use of excessive torque could
result in cracks in the compressor casting.
9803/8020 Issue 3*
11 - 1A Air Conditioning - 3000 Series Machines 11 - 1A
Fault Finding
The following fault finding checks can be undertaken without
discharging the air conditioning system.
Procedures that require charging or discharging the system

are not given in this manual as they require special
equipment that is usually held only by trained refrigeration
engineers.
The system will not function in very low ambient

temperatures, therefore tests should be carried out in a
warm environment.
It is essential that an electronic leak detector is used to

locate leaks accurately (see Leak testing). However, if a leak
detector is not available an approximate source of leakage
can be found by applying soap solution to suspect areas.
* Note: Sight glass checking procedures and indications have

been deleted as experience has shown that sight glass
indications are not reliable on systems charged with HFC
R134a.
General Fault Indications
The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment. It
is recommended that, to locate faults on the system accurately and quickly, an electronic leak detector and a refrigerant
pressure gauge should be used.
There are several indications that may help to determine the fault area on a system not working efficiently:
a) Poor Performance Condenser coil air flow restricted- Remove debris from around coil using
compressed air or low pressure water.
System overcharged- Evacuate and recharge
b) Blower does not operate Blower resistor failed- Renew resistor.

on all speeds.
c) Compressor clutch Condenser coil blockage - Remove debris from around coil/renew condenser.
continually cuts out Overcharging of refrigerant system- Evacuate and recharge system
9803/8020 Issue 2*
Fault Finding (Continued)

1. No Air Conditioning
CHECK ACTION
1 Are the controls set correctly, i.e. air conditioning YES: Check 2
selected, thermostat switch set to coldest position NO: Reset controls and retest.
and blower switched on?
2 Is the air conditioning (evaporator) blower working? YES: Check 3.

NO: Check 4.
3 Is the compressor running (visual check of pulley/clutch)? YES: Check13.

NO: Check 7.
4 Is one of the two air conditioning fuses blown? YES: Renew fuse and retest.
(See section C for fuse number) NO: Check 5.
5 Does the air conditioning relay operate when starter YES: Check 12.
switch is turned off and then to IGN? (Audible test.) NO: Check 6.
6 Are the relay electrical connections OK? YES: Renew relay and retest.
NO: Remake connections and retest.
7 Is there a 12V supply to the pressure switch harness? YES: Check 8.

(See Pressure Switch Testing) NO: Check 11.
8 Does the compressor clutch engage with both YES: Check 9.

pressure switches bypassed? NO: Renew the compressor clutch and retest.
(See Pressure Switch Testing)
9 Does the compressor clutch engage with YES: Renew high pressure switch and retest.
HP switch bypassed? NO: Check 10.
10 Does the compressor clutch engage with YES: Renew low pressure switch and retest.
LP switch bypassed? NO: Charge check required by refrigeration engineer.
11 Does the clutch engage with thermostat switch YES: Renew thermostat switch and retest.
bypassed? NO: Check all electrical connections.
12 Are blower switch and wiring OK? YES: Renew blower motor.
NO: Renew switch or wiring.
13 Is sight glass indication OK? (See Section 3.) YES: Check 14.
NO: Charge check required by refrigeration engineer.
14 Is condensor air flow blocked? YES: Clean condensor and radiator.

NO: Check 15.
15 Is evaporator air flow blocked? YES: Clean filter and, if necessary the evaporator.
NO: Call in refrigeration engineer.
9803/8020 Issue 1
E
V
R1
R
T
U
D
C
M
J
F H
N
9803/8020 Issue 2*
Component Removal and Replacement

The following components can be renewed without Removal
discharging and recharging the refrigerant:
*1 Remove screws B and ease switch panel C/decal D
A Air Conditioning Relay (See Section C). away from evaporator unit U by about 100 mm (4 in),
taking care not to damage capillary tube T.
*F Mode selector switch.
2 Disconnect the electrical connections from the switch.
G Thermostat switch.
3 Unscrew the switch mounting nut and remove the
H Air Conditioning (evaporator) blower switch. switch from the panel.
J Heater blower switch Replacement
K Low pressure switch. For replacement, reverse the sequence.
L High pressure switch. Ensure that decal D is positioned correctly.
*M Resistor - air conditioning blower motor speed control * Components Inside Evaporator Unit Casing
(machines to S/N 640777).
N Diode. The following components can be serviced after removal of

the cover plate E:
P Electrical harness.
G Thermostat Switch
*R Air conditioning (evaporator) blower motor (machines to *M Resistor (machines to S/N 640777)
S/N 640777). N Diode
P Electrical Harness
* R1 Air conditioning (evaporator) blower motor/resistor *R Blower Motor (machines to S/N 640777)
assembly (machines from S/N 640778). * R1 Blower Motor/Resistor Assembly (machines from S/N
640778)
X Compressor clutch.
To gain access, remove the head lining, the 'B' post cover
Note: Any further dismantling can only be done after and 'P' clips, unbolt the evaporator unit and lower it onto the
discharging the refrigerant. This requires special equipment seat. The hose length is sufficient to allow this.
and must be done only by qualified refrigeration engineers.
Instructions for these jobs are therefore not included in this * Thermostat Switch
manual.
* When removing thermostat switch G, follow the procedure
No component that comes into contact with refrigerant can for removal of the other switches, but remove the capillary
be interchanged between machines using the two different tube T from between the evaporator coil fins so that the
refrigerants, otherwise contamination of the system will capillary tube can be withdrawn with the switch. Note the
occur. position of the tube to ensure correct replacement.
! WARNING When replacing, take care not to damage the capillary tube
and insert the tube in its original position to the full depth of
The air conditioning system is a closed loop system and the evaporator coil fins.
must be disconnected except by a qualified refrigeration * Blower Motor
engineer.
4-3-4-1
1 Remove thermostat switch G (see Thermostat Switch).
Switches 2 Remove the four wires from resistor (machines to serial

no. 640777) or the resistor pack on blower
The following switches can be serviced with the evaporator motor/resistor assembly R1 (machines from serial no.
640778).
* unit U in situ:
Note: Pressure switches are covered under Pressure
Switches, the thermostat switch is covered under 3 Remove the mounting screws/washers for blower motor
Components Inside Evaporator Unit Casing. R or R1 and lift clear.
*
F Mode Selector Switch Note: Blower motor/resistor assembly R1 (machines from
H Air Conditioning Blower Switch S/N 640778) should be removed complete with mounting
J Heater Blower Switch plate V and separated when clear of the casing.
9803/8020 Issue 2*
Pressure Switches Removal and Replacement
The 12V supply is fed from the thermostat to the compressor ! WARNING
clutch via the low and high pressure switches which are Goggles and rubber gloves must be worn when pressure
wired in series. switches are removed or fitted. A small amount of
refrigerant is released which can be harmful to the skin
The low pressure switch requires a minimum refrigerant and eyes.
charge level to close its contact. The high pressure switch BF 1-10
requires the charge level to remain below the maximum limit
to keep its contact closed. Removal
Both pressure switch contacts must be closed for the 1 Disconnect the electrical connections and unscrew the
compressor clutch to operate. If the compressor clutch will pressure switch.
not operate when air conditioning is selected, the fault may
be either electrical or system pressure. Replacement
Testing 1 Screw the pressure switch into the pressure switch port
and tighten just sufficiently to form a gas-tight seal.Do
1 Turn start switch to IGN. Do not start engine. Select air not overtighten.
conditioning on mode switch, fan speed 1 and the
coldest setting on the thermostat switch. 2 Run the air conditioning and check the pressure
switches for leaks as described under Leak Testing. If
2 Disconnect the pressure switch harness from the main any leaks are found, tighten the pressure switch further
vehicle harness and using a multimeter, check that until the leaking stops.
there is 12V at the vehicle harness connector (wire 936).
If the voltage is low or zero, check the fuses, the air
conditioning relay and the thermostat switch.
3 Disconnect the wire from the compressor and connect

the vehicle harness connector (wire 936) directly to the
compressor. If the compressor clutch engages, the fault
is at one of the pressure switches. (Continue testing at
High Pressure Switch.) If the compressor clutch does
not engage, the fault is at the compressor clutch .
4 Reconnect the wire to the compressor and disconnect

the wire to the high pressure switch L. Join the vehicle
harness to the compressor via the low pressure switch
to bypass the high pressure switch.

be at the high pressure switch.
If the clutch does not engage, continue testing at Low

Pressure Switch.
Low Pressure Switch K

6 Reconnect the wire to the high pressure switch and
disconnect the wire to the low pressure switch K. Join
the vehicle harness to the compressor via the high
pressure switch to bypass the low pressure switch.
L
be at the low pressure switch.
Note: If both pressure switches operate correctly, check all

electrical connections.
9803/8020 Issue 2
14 - 1 * Heating System - 3000 Series Machines 14 - 1
AZ
F
AY
J
1 0 1 0
3 2
3 2
F
AW AX
AC
AC
A293821
AH
W Z
AJ
AG
AD
AD AD
AD
AD AD
AE
AD
AD
AF
AD
9803/8020 Issue 2*
14 - 2 Heating System - 3000 Series Machines 14 - 2
Operation
Note: The controls in views AY and AW are fitted to
machines to serial no. 640777. the controls in views AX and
AZ are fitted to machines from serial no. 640778.
Set mode selector switch F to the extreme left (the centre

position is OFF) and use heater blower switch J to select a
suitable heater blower motor speed. Vary the air temperature
by means of temperature control AC.
Heater Unit
Removal
1 Remove the cup tray from above the heater unit by

unscrewing the retaining screws from the top face and
the screws along the top front edge.
2 Remove the nine retaining screws AD from the face of

the heater unit and slide the unit towards the drivers
seat to gain access to the hose connectors at the rear.
3 Clamp off the two hoses from the Fastrac cooling

system and disconnect the hoses from the rear of the
heater unit.
4 Separate the electric connectors at the rear of the heater

unit and slide the unit clear. Remove to a work bench
for Dismantling.
Replacement
Replacement is the reverse of removal.
Remove grille AE by extracting push-pull retainer AF to gain

access to air filter AG.
Remove cover AH to gain access to heater blower motor W,

heater blower motor speed control resistor Z and heat
exchanger AJ.
9803/8020 Issue 1
15 - 1 * Air Conditioning/Heater System - 3000 Series Machines 15 - 1
* Wiring Diagram N Diode Wire Colour Code

P1 Harness Connector
- Early Machines R Air conditioning blower motor B Black
Component Key (machines to S/N 640777) G Green
R1 Air conditioning blower motor/resistor O Orange
A Air Conditioning Relay assembly) (machines from R Red
AA Evaporator/blower unit and control S/N 640778) U Blue
panel (machines to S/N 640777) S Heater Unit Y Yellow
AB Evaporator/blower unit and control W Heater blower motor
panel (machines from S/N 640778) X Compressor
A3/C1 Fuse Z Resistor - heater blower motor speed
B9 Fuse control
CR1 Harness Connector
CR11 Harness Connector Note: On some machines, the sequence of
C5 Harness Connector wiring the pressure switches is reversed.
A
C28 Harness Connector
109
F Mode selector switch C4 C6
G Thermostat switch B9
340 C2
H Air conditioning blower switch C8
J Heater blower switch A3/C1
150
K Low pressure switch
L High pressure switch 875
M Resistor - air conditioning blower 876
motor speed control (machines to 873
A L 876 L A
S/N 640777) B 1 K K 1 B
3 2 2 3
4 5 6
C 6
8
5
7
4
J J 7 8 C
11 10 9 9 10 11
13 12 12 13
D 16 15 14 I I 14 15 16 D
18 17 17 18
19 19
E H H E
F G G F 936
936 875
L A A L
K 1 B B 1 K C5 874
876 875 874
J 4
2
5
3
6
C 6
3
5
2
4 874
873 CR1
7 8 C 8 7 J
9 10 11 11 10 9
12 13 13 12
I 14 15 16 D D 16 15 14 I 873 4 3 2 1
2 1 17 18 18 17
H 19
E E 19
H 8 7 6 5
CR11
730 4 3 G F F G
P1 C28 K 670
2 1
4 3
L
R B O Y
W Y/500
401 301 500 S 4 3 2 1

CR11 8 7 6 5 200
X
B U
G F
Z
601
Y/500
R
4 3 2 1 202 G/201
G
CR11 8 7 6 5 200
H J
300
B U 503
G F
601
501 Y Y
R1 N R/401
G/201 300
202 G O/301
H J
400 300
R
503
502
501 Y Y
N R/401
300 400 M
O/301
502
AA
AB
A198731
9803/8020 Issue 3*
15 - 2 Air Conditioning 3000 Series Machines 15 - 2
Wiring Diagram
- Later Machines
Component Key
A Air Conditioning Relay J Heater blower switch Wire Colour Code

AB Evaporator/blower unit and control K Low pressure switch
panel L High pressure switch B Black
A9 Fuse N Rectifier bridge G Green
C5 Harness Connector R Air conditioning blower motor O Orange
CR1 Harness Connector S Heater Unit P Purple
CR11 Harness Connector W Heater blower motor R Red
CR40 Harness Connector X Compressor U Blue
F Mode selector switch Z Resistor - heater blower motor speed Y Yellow
G Thermostat switch control
H Air conditioning blower switch
CR1
171 (2) C5
1
2 5 1
170 (4) 3 6 11 5 2
4 7 12 18 11 6 3
CES9
8 13 19 18 12 7 4
9 14 20 25 19 13 8
A9 10 15 21 26 32
32
25
26
20
21
14
15
9
10
16 22 27 33
17 23 28 34 39
33 27 22 16
39 34 28 23 17
(2.0)
24 29 35 40
(1.0)
40 35 29 24
950
30 36 41 41 36 30
936
31 37 42 45 45 42 37 31
(1.0)
38 43 46 46 43 38
650H
44 47 47 44
48 48
(1.0)
936 A A A
X
874 (1) A A A
875 (1.4)
876 (2) A A
L K
4 3 2 1 950
(2)
2 1 8 7 6 5 954
CR11 (1.0)
730 (1.4)
4 3
670
CR40
Y/500 4 6
S
2 1
CR 4 3 2 1 A
40 4 3 CR11 200 8
8 7 6 5 2
R B O Y
B U
G F
W
401 301 500
601
R
202 G G/201
Z
H 300 J
400
503
501 U P Y
N
R/401
300
O/301
AB
9803/8020 Issue 1
16 - 1 Air Conditioning 2000 and 3000 Series Machines 16 - 1
Compressor Clutch
Removal
1 Hold front clutch plate stationary using tool A

A
(892/00801) and remove compressor shaft nut.
2 Using puller B (892/00807) remove clutch plate from

rotor pulley.
190830
3 Remove shaft key C then release rotor pulley bearing
and front housing circlips D.
4 Fit shaft/thread protector E over compressor shaft then

draw rotor pulley off shaft using puller F (892/00802).
B
Check clutch spacer shims L remain on shoulder of
shaft.
5 Release field coil wire G from cable clip then remove

D
circlip H and coil J from compressor front housing.
C
Replacement
1 Check rotor pulley bearing for serviceability. Clean and

D
relubricate or replace as necessary.
2 Position field coil J on shaft and locate flange protrusion L

in hole in front housing. Secure coil with circlip H and fit
lead G under cable clip.
3 Support compressor on mounting ears at rear of body.

F
190850
Place rotor pulley squarely on compressor shaft then
press (or carefully tap with soft faced mallet) rotor into
place. Refit internal and external circlips D.
4 Check clutch spacer shims L are in place then

assemble key C and front clutch plate on compressor
shaft. Using rotor installer set 892/00803 and shaft E
protector K (892/00808), tap clutch plate into position H
taking care not to damage shaft thread.
5 Refit compressor shaft nut and torque tighten to 34 - 42

J
Nm (3.4 - 4.2 kgf m; 25 - 30 lbf ft).
6 Using a feeler gauge as shown, check clutch air gap is

between 0.4 and 0.8 mm (0.016 and 0.031 in). If air gap G
is not consistent around circumference, prise front plate
up or down at minimum and maximum as appropriate. If
air gap is outside stated limits, remove front clutch plate
and add or subtract spacer shims L as necessary.
190880
9803/8020 Issue 1
Section C Electrics Section C
i i
Contents Page No.
Technical data
General Data 1-1
Fuses 1-2
Relay Identification 1-3
Test Methods
Use of Multimeter 2-1
Measuring DC Voltage 2-3
Measuring Resistance 2-3
Measuring Continuity 2-3
How to Test a Diode or a Diode Wire 2-4
Wiring Diagrams
Introduction to Sectional Wiring Diagrams 7-1
Main Connectors (2115, 2125, 2135, 2150, 3155, 3185) 8-1
Connector Terminals (2115, 2125, 2135, 2150, 3155, 3185) 8-1
Splice Identification (2115, 2125, 2135, 2150, 3155, 3185) 8-4
Contents (2115, 2125, 2135, 2150, 3155, 3185) 8-5
Sectional Diagrams
Component Key (2115, 2125, 2135, 2150, 3155, 3185) 8-6
Alphabetical Index (2115, 2125, 2135, 2150, 3155, 3185) 8-7
Harness Connectors (2115, 2125, 2135, 2150, 3155, 3185) 9-1
Sectional Diagrams (2115, 2125, 2135, 2150, 3155, 3185) 12 - 1
Wire Numbers (2115, 2125, 2135, 2150, 3155, 3185) 13 - 1
Main Connectors (2140) 15 - 1
Connector Terminals (2140) 15 - 2
Splice Identification (2140) 15 - 6
Sectional Diagrams
Contents (2140) 16 - 1
* Alphabetical Index (2140) 16 - 3
Component Key (2140) 17 - 1
Sectional Diagrams (2140) 17 - 2
Wire Numbers (2140) 18 - 1
Fault Finding (Vehicle Electrics)

Starting Circuit 21 - 1
Charging Circuit Test 22 - 1
Tachometer Feed Test 22 - 2
Wiring Harness Repair 25 - 1
Battery
Safety 26 - 1
Battery Testing 26 - 2
Alternator
General Description 27 - 1
Service Precautions 27 - 1
Dismantling and Assembly 27 - 2
Starter Motor
Dismantling 28 - 1
Service and Renewal 28 - 1
Assembly 28 - 1
9803/8020 Issue 9*
ii ii
Contents Page No.
Instrument Cluster
Warnings (Visual only) 29 - 1
Warnings (Audible/Visual) 29 - 2
Instruments 29 - 2
Programming 29 - 4
Error Codes - Transmission 29 - 13
Error Codes - Anti-skid Braking System (ABS) 29 - 14
JCB Powershift 30 - 1
Wheel Slip Calibration 31 - 1
Powershift Clutch Overlap Time (†Dry Clutch Transmission) 31 - 2
Powershift and Master Clutch Calibration
(††Wet Clutch Transmission) 31 - 4
Psion Workabout 33 - 1
Four Wheel Steer (4WS) (if fitted)

Sensors
Calibration 35 - 2
Electronic Control Unit
Bulb Renewal 35 - 3
* Fault Finding (Electronic Management System)

Diagnostic Error Codes - General 40 - 1
Electronic Service Tools Applications 41 - 0
JCB Service Master 41 - 2
Data Link Adaptor 41 - 6
ABS Diagnostics Tool 42 - 1
Wingst Program 43 - 1
Engine Diagnostic Tool 44 - 1
ABS Electronic Control Unit


9803/8020 Issue 7*
General Data
System Type 12 Volts, negative earth

Battery
Cold crank amps for 1 minute to
1.4 Volts per cell at -18 deg C (0 deg F) 800
Reserve capacity (minutes) for 25 Amp load 200
Alternator 100 Amps
Starter motor Lucas M127/2.8
* Light Bulbs (12V rated unless specified otherwise)

Headlights main/dip 60W/55W (Halogen)
Working lamps 55W (Halogen)
Front side lamps 4W
Tail lamps 10W
Stop lamps 21W
Indicator lamps 21W
Indicator side repeater lamps 5W
Reversing lamps 21W
Number plate lamps 10W
Fog lamps 21W
Interior lamps 10W
Panel/Warning lamps 1.7W
Beacon 55W (Halogen)
14 volts
* 4WS Quadtronic control panel † { 18 volts
* † See Electronic Control Unit, Bulb Renewal for further details.
Note: This machine is fitted with a “CAN-BUS” system which links certain Electronic Control Units (ECUs) on the vehicle. This
stands for “Controlled Area Network” and uses a special cable in the vehicle harness which carries two (2) twisted signal
wires. These carry digital messages and are covered by a metal foil casing called a “screen” to help prevent corruption from
electrical interference. The CAN-BUS is used to send text and fault codes from the transmission controller to the instrument
cluster as well as to share information between each other, such as vehicle set-up.
9803/8020 Issue 2*
Fuses
The electrical circuits are protected by fuses. The main fuse D1 Main beam 15
block A contains 27 fuses. It is located, together with in-line D2 Dipped beam 15
fuses E, F and W, under switch panel B. 2140 machines also D3 Rear fog lights 10
have fuses H1 to H5. To gain access, disconnect the D4 LH sidelights 7.5
battery, remove screws C and carefully lift panel B. D5 RH sidelights 7.5
D6 Auxiliary lights switching (3000 series)
There are also six lighting circuit fuses D1 - D6 behind a Not used (2000 series) 5
panel to the left of the steering column. E1 ABS trailer socket 25
E2 ABS trailer socket 5
If a fuse blows, find out why and rectify the fault before E3 Flow divider 5
fitting a new one. E4 4 wheel steer (2000 series, except 2150) 5
Fuse Circuit Fuse
† F1 Tractor ABS 3
No. Rating
(Amps) † F2 Tractor ABS 10
A1 Clutch start. 5 † F3 Tractor ABS 10
A2 Brake lights. 10 † F4 Tractor ABS 5
A3 Rear wash/wipe, suspension seat, 2WD dump
relay, fuse E3. 15 H1 Eelectronic engine (2140 only) 7.5
A4 Front wash/wipe, horn. 10 H2 Eelectronic engine (2140 only) 7.5
* A5 2140 machines: Electronic engine 7.5 H3 Eelectronic engine (2140 only) 7.5
3185 machines: ESOS, start relay 7.5 H4 Eelectronic engine (2140 only) 10
All other machines: ESOS, Waxstat. 7.5 H5 Eelectronic engine (2140 only) 10
A6 EDC IGN. 5
A7 Transmission controller. 15 W ‘Maxifuse’ - Feed to side and headlight switch 40
A8 2WD, front & rear PTO, differential lock
solenoids, PTO brake relay. 15 * Engine-mounted Fuses 2140 and 3185 machines)
A9 Cab heater (3000 series only), ACU,
compressor clutch, 30 To gain access to the engine-mounted fuses, pull off the
B1 Radio memory, interior light, beacon socket, relevant plastic cover as shown. The manifold heater fuses
AG panel illumination. 7.5 are each retained by two nuts J.
B2 Hazard warning lamps. 15
B3 Front work lights. 30 *F Engine Shut-off System (3185 only) 40 Amps
B4 Rear work lights. 20 G Manifold Heaters (Megafuse) 100 Amps
B5 Headlight flasher. 15 H Manifold Heaters (Megafuse) 100 Amps
B6 Radio/cassette power supply. 7.5
B7 Auxiliary socket. 20 † Refer to appropriate schematic for fuse functions.
B8 Cigar lighter. 10
B9 EDC battery, instrument
cluster battery. 3
C1 13 pin trailer socket reverse lights supply
(2000 Series to S/N 738748, 3000 Series to
S/N 640777) 5
C1 Reverse lights ( 2000 Series from S/N 738749,
3000 Series from S/N 640778) 5
C2 Direction indicators. 7.5
* C3 Thermostart (all except 2140 and 3185), starter heater
relays (3185 only). Spare (2140 only) 30
C4 Instrument cluster, lights switch illumination,
speedometer sender, diagnostic connector,
differential lock cut-out switch, fuse C5,
warning bleeper. 7.5
C5 Radar, fuel flow meter. 3
* C6 Starter motor solenoid (all machines except 2140) 30
Diagnostic connector (2140 only) 10
C7 13 Pin trailer socket ignition supply (2000
Series to S/N 738748, 3000 Series to S/N
640777). 5
C7 Auxiliary socket ignition supply (2000 Series
from S/N 738749, 3000 Series from S/N
640778) 5
C8 13 Pin trailer socket battery supply (2000 Series
to S/N 738748, 3000 Series to S/N 640777). 20
C8 Auxiliary socket battery supply (2000 Series
from S/N 738749, 3000 Series from S/N
640778) 20
C9 Air drier, gearbox neutral start. 10
9803/8020 Issue 7*
1 - 2A Technical Data 1 - 2A
F E
1
H5 H1 2
2 3 4 5 6 7 8
1
A
9
W
B
F
C
1 3 5 0
IG N
C 2 4 6
B G
H
J
D5
D4
D3
D2
2000 Series D1 A302640
D2 D3 D4 D5
D6
D1
3000 Series A302650
9803/8020 Issue 4
Relay Identification (Front of Cab)
*
M
J G
L K H
E C A
F D B
With Auxiliary
Lights
A B
C D
E F E C A
F D B
Without Auxiliary
Lights
A303132
2000 Series 3000 Series
Item Colour Description Installation
A Blue Brake lights Standard - all machines

B Blue ‘A’ post work lights Optional - all machines
*C Green Intermittent front wiper Standard - all machines
*D Blue Fog lights Standard - all machines
E - Single trailer turn Optional - all machines
F - Warning buzzer Standard - all machines
G Green Auxiliary lights Optional - 3000 Series
H Green Auxiliary lights Optional - 3000 Series
J Green Auxiliary lights Optional - 3000 Series
K Green Auxiliary lights Optional - 3000 Series
L Green Auxiliary lights Optional - 3000 Series
M Green Auxiliary lights Optional - 3000 Series
9803/8020 Issue 5*
* Relay Identification (Rear of Cab)

N P R
S T U
W
V
X
A1 B1
C1
D1
E1
F1
4 3 2 1
8 7 6 5
A303122
2000 and 3000 Series
Item Colour Description Installation
N Blue Air conditioning unit

compressor clutch Standard - all machines
P Green 2WD dump Standard - all machines
R Blue Start inhibit 2 Standard - all machines
S Green Diff. lock cut-out Standard - all machines
T Black Intermittent rear wiper Standard - all machines
U Blue Start inhibit 1 Standard - all machines
Machines with Dry Clutch Transmission
V Blue 13 - pin trailer socket

reverse lights relay Optional - all machines
W Green Rear PTO drive cut-out relay Optional - all machines
X Green 4WS diff. lock cut-out relay Optional - 2115, 2125, 2135 only
* Machines with Wet Clutch Transmission (see note)
A1 or B1 Blue Reverse lights relay Standard - all machines

B1 or C1 Green Splitter safety dump Standard - all machines
C1 or A1 Green Rear PTO drive cut-out relay Standard - all machines
D1 or E1 Blue Tractor ABS - Ignition ABS Machines
E1 or F1 Green Tractor ABS - Diagnostic ABS Machines
F1 or D1 Green 4WS diff. lock cut-out relay Optional - 2115, 2125, 2135 only
Note: These relays can be found in one of two configurations. Make sure you know which relay configuration you have on
your machine before making any alterations. Note the position of any relays before removing them.
9803/8020 Issue 7*
2-1 Test Methods 2-1
Use Of Multimeters
These instructions cover the use of the recommended AVO 3 When measuring voltage:
2003 and Fluke 85 multimeters, or in case neither of these is Make sure that the correct range is selected, by setting
* available, a moving pointer (analogue) multimeter. the selector to a value equal to or greater than that you
are about to measure.
1 Make sure that the test leads are plugged into the e.g. If asked to measure 12 Volts, set the selector to
correct sockets. The black test lead should be plugged the 12V range. If there is no 12V range, set the selector
into the black socket (sometimes, this socket is also to the next range higher, 20V for instance.
marked by a " – ", or "E" or marked as "COMMON" or If the meter is set to a range that is too low, it may be
"COM"). The red test lead should be plugged into the damaged. e.g. setting to the 2V range to measure
red socket marked with "+", "V" or " ". 12V.
2 When making measurements, ensure that the test

probes have a good clean contact with bare metal, free
from grease, dirt, and corrosion as these can cause a
false reading.
OFF
V/A A
V/A
A
B
C
B
C
A171890
A typical analogue meter
AVO 2003
9803/8020 Issue 2*
FLUKE 85 Multimeter
S153070
9803/8020 Issue 1
Measuring DC Voltage
Measuring Continuity
On the FLUKE 85
Turn the switch to position B. Make sure there is no power to the part of the circuit you are
checking for continuity.
On the AV0 2003
Move the right slider switch to position A, and the left hand Connect one probe to one end of the component or wire to
slider switch to the appropriate range. be checked and the other probe to the other end. It does
not matter which way round the two probes are placed.
On an analogue meter
Turn the dial to the appropriate DC Volts range. On the FLUKE 85
Turn the switch to position C and check that the beeper
Connect the black probe to the nearest available suitable symbol appears at the left hand side of the display window.
earth point, usually this will be the starter motor earth, the If the F sign is on instead, press the button labelled F in the
battery negative, or the chassis. meter drawing.
Connect the red probe to the wire or contact from which you
are measuring the voltage. If there is continuity in the circuit, the beeper will sound. If
there is no continuity (open circuit), the beeper will not
Measuring Resistance sound.
Make sure there is no power to the part of the circuit you are On the AV0 2003
about to measure. Move the right hand slider switch to position B, and the left
hand slider switch to position C.
Connect one probe at one end of the component or wire to
be checked and the other probe at the other end. It does not If there is continuity (i.e. very low resistance) between two
matter which way round the two probes are placed. points the buzzer will sound.
On the FLUKE 85 On an analogue meter

Turn the switch to position C and check that the sign at Turn the dial to the lowest Ohms ( ) range.
the right hand side of the display window is on. If the F sign
is on instead, press the blue button G to change the reading If there is continuity (i.e. very low resistance) between two
to . points the needle will move across fully (or almost fully) to
the right hand side of the scale.
Touch the meter lead probes together and press the REL ³
key on the meter to eliminate the lead resistance from the
meter reading.
On the AV0 2003

Move the right hand slider switch to position B, and the left
hand slider switch to the appropriate Ohms ( ) range.
On an analogue meter
Move the dial to the appropriate Ohms ( ) range.
9803/8020 Issue 1
How to Test a Diode or a Diode Wire
A diode wire is a diode with male connector fitted on one

end and a female connector fitted on the other end. The
diode is sealed in heatshrink sleeving.
On the FLUKE 85
Turn the switch to position D.
Press the HOLD button and check that the H sign appears
at the top right hand side of the display window.
Connect the black probe to the end of the diode with a band
or to the male connector of the diode wire. Connect the red
probe to the other end of the diode or diode wire. If the
beeper does not sound the diode or diode wire is faulty.
Then connect the red probe to the end of the diode marked
with a band, or to the female connector of the diode wire.
Connect the black probe to the other end of the diode or
diode wire. If the beeper sounds or the meter does not read
O.L., the diode or diode wire is faulty.
Press the HOLD button and check that the H sign

disappears from the right hand side of the display window.
On the AV0 2003

Move the right hand slider to position A, and the left hand
slider switch to position C.
Connect the black probe to the end of the diode marked

with a band, or to the male connector of the diode wire,
connect the red probe to the other end of the diode or diode
wire. If the Avometer does not buzz the diode is faulty.
Connect the red probe to the end of the diode marked with a
band, or to the male connector of the diode wire, connect
the black probe to the other end of the diode or diode wire.
If the Avometer does not read "1" the diode is faulty.
* On an analogue meter:
Select the Ohms 100s range.
Connect the black probe to the end of the diode marked
with a band, or to the male connector of the diode wire,
connect the red probe to the other end of the diode or diode
wire. The meter should read 300-400 , if it reads more than
this the diode is faulty.
Select the Ohms 1000s (1k) range.

Connect the red probe to the end of the diode marked with a
band, or to the male connector of the diode wire, connect
the black probe to the other end of the diode or diode wire.
The meter should read 200-400 K , if it reads less than this
the diode is faulty.
9803/8020 Issue 2*
7-1 Wiring Diagrams 7-1
Introduction to Sectional Wiring Diagrams

As an aid to fault finding and repair of wiring, the sectional
diagrams show every wire and wire number on the machine Connectors
together with all the harness connectors and the pins to *
which each wire is connected. Some connectors are featured on a number of diagrams.
These and other important connectors are identified under
* In order to show this amount of detail the sectional diagrams Main Connectors. Terminal details of large connectors to
are spread over a series of pages, details of which are listed the Instrument Cluster, the two Electronic Control Units
under Wiring Diagrams, Contents. (ECU’s) and the Electronic Draft Control (EDC) Control Panel
are given under Connector Terminals.
The first page shows the main feed from the batteries to the
starter motor, alternator and fuses etc. The second page Bulkhead and other connectors which join two harnesses are
shows the common earth returns to the battery. The shown on the diagrams in two parts (i.e. the plug and the
remaining pages show fused circuits, usually starting from socket) linked by dotted lines. Each part of the connector is
the relevant fuse. denoted by one or more letters (to identify the harness to
which it is fitted) followed by a number, e.g. C5 denotes
* The key for the diagrams is listed under Sectional Diagrams Chassis harness connector 5 and CR1 denotes Cab Roof
Component Key. The fold out page can be opened out and harness connector 1 (view A opposite). Pin letters and
used in conjunction with any of the sectional diagrams. numbers are shown on the connectors to indicate the wire
positions.
The diagram extracts on the page opposite show examples
of the way various items are identified on individual Some other connectors on the diagrams may not be labelled.
diagrams. These can usually be found close to the components which
they are feeding.
The item numbers shown in large bold type correspond to
the numbers in the component key, e.g. Item 131 denotes Splices
Trailer Socket Reverse Light Relay (view A opposite).
Individual harnesses incorporate splices, i.e. points where
Fuses are denoted by alpha-numeric annotations in bold two or more wires are joined within the harness. Splices are
type, e.g. C1 (view A opposite). denoted on the wiring diagrams by rectangles containing
code letters, e.g. CRES3 (view A opposite).
Wire numbers are shown in smaller plain type alongside the
lines representing wires on the diagram. The wire number is In the majority of cases the first or first and second letters
followed by a number in brackets indicating the wire size. indicate the harnesses containing the splice, e.g. C =
e.g. 877 (0.6) (view A opposite). Where lines representing Chassis harness, CR = Cab Roof harness. Subsequent
wires intersect, there is no electrical joint unless a solid black letters or letters and numbers describe the electrical function
circle is shown at the point of intersection (view B opposite). of the splice, e.g. CRES3 = earth splice 3 in the Cab Roof
harness.
Where a cross reference is required from one page to
another, an arrow is shown on the diagram, followed by the Other codes do not include a harness reference, but simply
number of the page where the information is continued or, refer to the electrical function, e.g. ASS = Alternator Supply
for clarity, repeated e.g. Ö12-22 (view B opposite). splice, RS = raise splice.
Relays are shown by the conventional relay symbol (e.g. 131) The splices are not visible without dismantling the harnesses
as well as the relay base (view A opposite). but they are shown on the diagrams to act as cross
reference points between one page and another. The same
The diagrams cover both 2000 Series and 3000 Series splice may therefore appear on more than one page to
machines, except where specified otherwise. Where such a provide continuity when following a circuit.
circuit differs from one series to the other (e.g. view C
opposite) the wires are shown as broken lines with an For a full list of splices refer to Splice Identification.
appropriate identification, i.e. 2000 SERIES and 3000
SERIES. Such an identification indicates that all machines in
the range are wired in this way. If only a single model from
one of the series is wired as shown, a specific identification
is given, e.g. 2150 or 3155 (view D opposite).
9803/8020 Issue 2*
Introduction to Sectional Wiring Diagrams

(cont’d)
Examples of Component Identification
131
C1
A309750
B C
1 1A
W 12-22
2000
SERIES 11
1 1A 3
3000
SERIES
11A
A307150 A307160
D 134
3185
3185
2000 3155
SERIES
137
2150
138
A309760
9803/8020 Issue 1
Main Connectors
Connector Description Mating Connector Description Mating
Connector Connector
A2 Rear bulkhead ABS 2 CR43 Column switch ---
ABS1 ABS trailer socket --- CR49 Powershift ECU 1 (Black) ---
ABS2 Rear bulkhead A2 CR50 Powershift ECU 2 (Red) ---
AHL1 Auxiliary lights connector --- CR51 Front bulkhead C28
AHL2 Auxiliary lights connector --- CR64 4WS option (2000 Series) C4
C1 (14-pin) Trailer socket --- CR65 Instrument cluster 1 (Black) ---
C1 (10-pin) Control module CP3 CR66 Instrument cluster 2 (Red) ---
C2 Control module CP2 CR73 Panel - auxiliary light interconnect ---
C4 4WS interconnect - if fitted CR74 Panel - auxiliary light interconnect ---
(2000 Series) CR64 CR87 Vansco instrument cluster E4
C5 Rear bulkhead CR1 CR89 Diagnostic connector ---
C28 Front bulkhead CR51 E1 EDC ECU ---
CP1 Control module --- E2 Control panel ---
CP2 Control module C2 E4 Vansco instrument cluster CR87
CP3 Control module C1 (10-pin) E15 Bulkhead E16
CR1 Rear bulkhead C5 E16 Bulkhead E15
Connector Terminals
Instrument Cluster Instrument Cluster
CR65 (Black) CR66 (Red)
Terminal Wire Function Terminal Wire Function

1 406 Low air pressure - 2 1 479B High range selected
2 409 Low brake fluid level 2 512 Fuel feed signal
3 408 Low air pressure - 3 3 502 Fuel return signal
4 434 Low transmission oil pressure 4 414A Transmission speed signal
5 - 5 410 Engine water temperature
6 - 6 411 Fuel level
7 899A Differential lock solenoid 7 500A Radar speed signal
8 415 Area cut-out 8 517 RS232 RX
9 482 Low range 9 423 Buzzer out
10 473 Auto 10 898 <20 kph speed trigger
11 476 Snail 11 485 >3 kph speed trigger
12 474 Hare 12 505 Increase wheel slip output
13 420 2WD selected 13 484 High range
14 880B Side lights 14 859G Left turn signal
15 511 Option present 15 483 Medium range
16 402 Low engine oil pressure 16 478B Medium range selected
17 405 Transmission oil filter blocked 17 403A Alternator charge
18 444 540 PTO range selected 18 510 Wheel slip setpoint
19 445 1000 PTO range selected 19 516 RS232 TX
20 440 Trailer ABS warning 20 486 >1 kph speed trigger
21 481 Reverse range 21 508 Decrease wheel slip output
22 857B Rear PTO drive selected 22 416 Differential lock cut-out
23 477B Low range selected 23 514F CANL
24 475 Tortoise 24 515F CANH
25 861G Right turn signal 25 501 Radar presence signal
26 418 Main beam 26 497 Transmission speed sensor presence
27 419 2nd trailer turn signal 27 -
28 417 1st trailer turn signal 28 -
29 496 4WS tracking (2000 Series - if fitted) 29 -
30 407 Low air pressure - 1 30 412A Engine rpm
31 400A Park brake ON 31 513 Program
32 - 32 -
33 404 Air filter blocked 33 300B + 12V Battery
34 480B Reverse range selected 34 160B + 12V ignition
35 848B Front PTO drive selected 35 710C Battery earth
36 509B EDC lower signal 36 626 Chassis earth
9803/8020 Issue 1
Connector Terminals (cont’d)

* Powershift - Electronic Control Unit (ECU) * Powershift - Electronic Control Unit (ECU)
Dry Clutch Transmission Dry Clutch Transmission

1 514 CANL 1 477A Low range selected
2 - 2 478A Medium range selected
3 810B Clutch down 3 479A High range selected
4 400C Handbrake on 4 480A Reverse range selected
5 877 Reverse lamps 5 495 Clutch up
6 - 6 485 >3 kph speed trigger
7 Link 1 Link to terminal 32 7 -
8 900 Snail clutch solenoid 8 126 + 12v output (air valve)
9 435A Transmission oil pressure 9 -
10 901 Tortoise clutch solenoid 10 489 Medium range neutral solenoid
11 660J Battery negative 11 660N Battery negative
12 125B + 12v ignition 12 125C + 12v ignition
13 - 13 -
14 515 CANH 14 437 Low range engaged switch
15 434 Transmission oil pressure warning 15 442 Medium range neutral switch
16 450 Bleeper 16 436 Reverse range engaged switch
17 898B <20 kph speed trigger 17 438 Medium range engaged switch
18 476 Snail indicator 18 443 High range neutral switch
19 475 Tortoise indicator 19 441 Low range neutral switch
20 474 Hare indicator 20 446 Reverse range neutral switch
21 473 Auto indicator 21 439 High range engaged switch
22 - 22 492 Low range engage solenoid
23 660H Battery negative 23 -
24 125A + 12v ignition 24 -
25 Link 2 Link to terminal 26 25 486, 486A > 1 kph speed trigger
26 Link 2 Link to terminal 25 26 481 Reverse range indicator
27 413 Accelerator pedal up 27 484 High range indicator
28 470 Up shift switch 28 483 Medium range indicator
29 471 Down shift switch 29 482 Low range indicator
30 472 Auto mode 30 491 Reverse range engage solenoid
31 412B Engine rpm signal 31 490 High range neutral solenoid
32 Link 1 Link to terminal 7 32 493 Medium range engage solenoid
33 625 Chassis ground 33 488 Low range neutral solenoid
34 447 Transmission oil pressure switch 34 487 Reverse range neutral solenoid
35 435B Transmission oil pressure switch 35 494 High range engage solenoid
36 902 Hare clutch solenoid 36 629 Can bus screen
9803/8020 Issue 2*
8 - 2A Wiring Diagrams 8 - 2A

Powershift - Electronic Control Unit (ECU) Powershift - Electronic Control Unit (ECU)
Wet Clutch Transmission Wet Clutch Transmission

2 - - 2 478A Medium range selected
4 400C Handbrake 4 480A Reverse range selected
5 820 Wet clutch solenoid 5 435 Transmission oil pressure switch
6 822 Wet clutch lubrication solenoid 6 485 3 kph speed trigger
7 823 Transmission brake solenoid 7 526 Transmission temperature sender 2
8 900 Snail clutch solenoid return
9 821A Wet clutch current sense resistor 8 126 Ram solenoid 12V supply
10 901 Tortoise clutch solenoid 9 524A Link to CN2 pin 24
11 660J Battery negative 10 489 Medium range neutral solenoid
12 125B + 12v ignition 11 660N Battery negative
13 - - 12 125C +12 V ignition
14 515 CANH 13 525 Transmission temperature sender 1
15 434 Transmission oil pressure warning return
16 450 Buzzer 14 437 Low range neutral switch
17 898, 898B 20 kph speed trigger 15 442 Medium range neutral switch
18 816 Reversing lamps relay coil 16 436 Reverse range engage switch
19 - - 17 438 Medium range engage switch
20 - - 18 443 High range neutral switch
21 - - 19 441 Low range neutral switch
22 523 Clutch pedal potentiometer return 20 446 Reverse range neutral switch
23 660H Battery negative 21 439 High range engage switch
24 125A + 12v ignition 22 492 Low range engage switch
25 522 Clutch pedal potentiometer wiper 23 - -
26 521 Clutch pedal potentiometer supply 24 524B Transmission oil temperature
27 413 Throttle deceleration switch senders (link to CN2
28 470A Up shift switch pin 9)
29 471A Down shift switch 25 486, 486A 1 kph speed trigger
30 472A Auto mode switch 26 - -
31 412B Engine rpm signal 27 - -
32 - - 28 - -
33 625 EMC ground 29 - -
34 - - 30 491 Reverse range engage solenoid
35 - - 31 490 High range neutral solenoid
36 902 Hare clutch solenoid 32 493 Medium range engage solenoid
33 488 Low range neutral solenoid
34 487 Reverse range neutral solenoid
35 494 High range engage solenoid
36 629 Can bus screen
9803/8020 Issue 1

* Electronic Draft Control - Electronic Control Unit (ECU) * Electronic Draft Control (EDC) (Type D+) - Control Panel
(Type D+) E2
E1
* All 2000 Series machines to S/N 738694
* All 2000 Series machines to S/N 738694 2000 Series machines with radar from S/N 738695
2000 Series machines with radar from S/N 738695 All 3000 Series machines to S/N 640709
All 3000 Series machines to S/N 640709 3000 Series machines with radar from S/N 640710
3000 Series machines with radar from S/N 640710
Terminal Wire Function
Terminal Wire Function 1 -
1 725 Draft sensor earth 2 431 Draft/position mix signal
2 506 Control panel supply 3 -
3 427 Raise limit signal 4 506 Power supply in
4 431 Draft/position mix signal 5 -
5 505 Slip setpoint increase 6 507 Earth
6 424 Position sensor signal 7 429 Setpoint level signal
7 425 Left draft sensor signal 8 -
8 518 Slip setpoint decrease 9 428 Control lever signal
9 930 Remote raise/lower switch-common 10 430 Lower speed signal
10 500B Radar signal 11 504A Control valve lower signal
11 414B Transmission speed signal 12 503A Control valve raise signal
12 - 13 427 Raise limit signal
13 403B Alternator charge signal 14 433 Diagnostic LED (+ve)
14 - 15 508 Diagnostic LED (-ve)
15 - 16 -
16 509 Lower signal out 17 -
17 922 Remote switch raise signal 18 -
18 -
19 504/504A Control valve lower signal
20 507 Control panel earth
21 428 Control lever signal
22 429 Setpoint level signal
23 430 Lower speed signal
24 135 +12v ignition
25 -
26 426 Right draft sensor signal
27 -
28 660GA Battery earth
29 300A +12v battery
30 -
31 433 Diagnostic LED (+ve)
32 -
33 -
34 510 Slip setpoint feedback signal
35 924 Control valve common
36 928 Remote switch lower signal
37 503/503A Control valve raise signal
38 715 Position sensor earth
39 920 Position/draft sensor supply
40 -
41 508 Diagnostic LED (-ve)
42-55 -
9803/8020 Issue 2*

Electronic Draft Control - Electronic Control Unit (ECU) * 4WS - Electronic Control Module
(Type B)
E1 C1 - Inputs
Pin 1 +12V ignition (main)
2000 Series machines not fitted with radar from S/N 738695 Pin 2 Earth (main)
3000 Series machines not fitted with radar from S/N 640710 Pin 3 +12V sidelights
Pin 4 Not used
Pin 5 +12V > 1 kph
1 508/660GA Battery 0v
Pin 6 + 12V < 20 kph
Pin 7 +12V EDC power override
Pin 8 +12V axle locked
4 431 Draft/position mix signal
Pin 9 +12V sprayer override - audible warning
5 403B Alternator charge signal
Pin 10 Not used
7 -
C2 - Outputs
Pin 1
9 433 Diagnostic LED+ Left steering valve solenoid
Pin 2
10 922 Fender raise switch
Pin 3
11 509 Lowered signal (area cut-out) Right steering valve solenoid
Pin 4
12 506/930 Fender switch, control panel common
Pin 5 Axle unlock signal
Pin 6
Pin 7 Front axle sensor (potentiometer)
15 715/725 Position/draft sensor earth
Pin 8
Pin 9
17 425 Left draft sensor signal
Pin 10 Rear axle sensor (potentiometer)
Pin 11
19 424 Position sensor signal
Pin 12 Differential lock cut-out signal
20 928 Fender lower switch
Pin 13
21 - Not used
Pin 14
22 427 Top end position signal
23 -
25 135 +12 v ignition
Electronic Draft Control (EDC) (Type B) - Control Panel

E2
2000 Series machines not fitted with radar from S/N 738695

1 -
2 431 Draft/position mix signal
3 -
4 506 Fender switch, control panel
common
5 -
8 -
11 504A Control valve lower signal
12 503A Control valve raise signal
14 433 Diagnostic LED+
15 508 Battery 0v
16 -
17 -
18 -
9803/8020 Issue 2*
Splice Identification
Splice Description Splice Description
ABSSS ABS supply splice OCSS Option-chassis supply splice
ADBS Auxiliary dipped beam splice OFWLS Outer front working lights splice
ADCOS Area differential lock cut-out splice ORWLS Outer rear working lights splice
ALES Auxiliary lights earth splice PES Panel earth splice
ALSS Auxiliary lights supply splice PFS Permanent feed splice
AMBS Auxiliary main beam splice PHS Panel headlights splice
APWLS ‘A’ post work lights splice PIS Panel ignition splice
ASS Alternator signal splice PLIS Panel left indicator splice
* ASSS Autoshift switch splice PRSFS Power range solenoid feed splice
AWS Alternator ‘W’ splice PRHS Power range high splice
BATS Battery splice PRIS Panel right indicator splice
BLS Brake lights splice PRLS Power range low splice
BMS Brakes malfunction splice PRMS Power range medium splice
CANHS CAN high splice PRRS Power range reverse splice
CANLS CAN low splice PSSS Powershift supply splice
CDS Clutch down splice RHIS Right hand indicator splice
CES Chassis earth splice RHSLS Right hand side lights splice
CRES Cab roof earth splice RLSS Reverse lights switching splice
CRPFS Cab roof permanent feed splice RPBS Rear PTO brake splice
CRSIS Cab roof start inhibit splice RPCOS Rear PTO cut-out splice
C9CS Fuse C9 chassis splice RPDS Rear PTO drive splice
DBS Dipped beam splice RS Raise splice
* DSSS Downshift switch splice RSLS Right side lights splice
EDCES Electronic draft control earth splice RSS Radar signal splice
EDCS Electronic draft control splice RWLSS Rear working lights supply splice
ELSS EDC lower signal splice SA 4WS ignition splice
FDES Flow divider earth splice SD 4WS earth splice
FDSS Flow divider supply splice SES Starter motor earth splice
FLES Front lights earth splice SFS Solenoid feed splice
FLS Fog lights splice SSS Speed signal splice (page 12 - 34)
FPDS Front PTO drive splice SSS Solenoid supply splice (page 12 - 9)
FWLSS Front working lights supply splice SSS Sensor supply splice (page 12 - 10)
* HSS Hare solenoid splice * SSS Snail solenoid splice (page 12 - 13A)
IGNS Ignition splice SWFS Switched feed splice
IFWLS Inner front working light supply splice * TAES Tractor ABS earth splice
IRWLS Inner rear working light supply splice * TAIS Tractor ABS ignition splice
* ISRS Inching solenoid resistor splice TOPS Transmission oil pressure splice
LHIS Left hand indicator splice * TOTS Transmission oil temperature splice
LHSLS Left hand side lights splice * TSS Tortoise solenoid splice
LS Lower splice * USSS Upshift switch splice
LSLS Left side lights splice VSS Valve supply splice
MBS Main beam splice 1KSS 1 kph signal splice
OCES Option-chassis earth splice 2WDDS 2WD dump splice
9803/8020 Issue 2*
* Contents - Fastrac 2115, 2125, 2135, 2150, 3155 and 3185

Page No. Contents
12 - 1 Supply Circuit
12 - 2 Earth Circuit
12 - 3 Fuse A1 - Neutral Start (Clutch)
Fuse C6 - Starter Solenoid
Fuse C9 - Air Drier; Neutral Start (Gearbox)
12 - 4 Fuse A2 - Brake Lights
12 - 5 Fuse A3 - Rear Wash/Wipe
12 - 6 Fuse A4 - Front Wash/Wipe; Horn
12 - 7 Fuse A4 (cont’d)
12 - 8 Fuse A5 - Engine Shut-Off Solenoid (E.S.O.S.) (2000 Series, 3155 Dry Clutch Transmission)
12 - 8A Fuse A5 - Engine Shut-Off Solenoid (E.S.O.S.) (2000 Series, 3155 Wet Clutch Transmission)
12 - 9 Fuse A5 - Engine Shut-Off Solenoid (E.S.O.S.) (3185 only) - E.S.O.S. Maxifuse
12 - 10 Fuse A6 - Electronic Draft Control (EDC) D +, Ignition Cab Side.
Fuse B9 - Electronic Draft Control (EDC) D +, Battery Cab Side
12 - 10A Fuse A6 - Electronic Draft Control (EDC) B, Ignition Cab Side.
Fuse B9 - Electronic Draft Control (EDC) B, Battery Cab Side
12 - 11 Fuse A6 - Electronic Draft Control (EDC) D+ and B, Ignition Chassis Side
Fuse B9 - Electronic Draft Control (EDC) D+ and B, Battery Chassis Side
12 - 12 Fuse A7 - Powershift ECU - 3-Speed Splitter (Dry Clutch Transmission)
12 - 13 Fuse A7 (cont’d) - Powershift ECU - Selectronic (Dry Clutch Transmission)
12 - 13A Fuse A7 - Powershift ECU - Selectronic (Wet Clutch Transmission)
12 - 13B Fuse A7 (cont’d) - Powershift ECU - Selectronic (Wet Clutch Transmission)
12 - 13C Fuse A7 (cont’d) - Wet Clutch Control (Wet Clutch Transmission)
12 - 14 Fuse A7 (cont’d) - Powershift ECU - Selectronic
12 - 15 Fuse A8 - Front/Rear PTO; 2WD and Differential Lock Solenoids; Rear PTO Cut-Out
12 - 16 - Rear PTO Cut-Out Option
12 - 17 Fuse A9 - Air Conditioning Circuit
12 - 18 Fuse B1 - Interior Lights; Radio/Cassette; Beacon Socket
12 - 19 Fuse B2 - Hazard Warning LIghts
Fuse C2 - Direction Indicators
12 - 20 Fuse B3 - Front Work Lights
12 - 21 Fuse B4 - Rear Work Lights
12 - 22 Fuse B5 - Headlight Flash
Fuse W (Maxifuse) - Main Lights
12 - 23 Fuse D1 - Main Beam
Fuse D2 - Dipped Beam
12 - 24 Fuse D3 - Rear Fog Lights
12 - 25 Fuse D4 - Side Lights (Left Side)
12 - 26 Fuse D5 - Side Lights (Right Side)
12 - 27 Auxiliary Lights Switching (2000 Series)
12 - 28 Fuse D6 - Auxiliary Lights Switching (3000 Series)
12 - 29 Fuse B6 - Radio Cassette
12 - 30 Fuse B7 - Auxiliary Jack-Plug Socket
12 - 31 Fuse B8 - Cigar Lighter
12 - 32 Fuse C1 - Trailer Socket Reverse Light (Dry Clutch Transmission)
12 - 32A Fuse C1 - Reverse Lights (Wet Clutch Transmission)
12 - 33 Fuse C3 - Thermostart
12 - 34 Fuse C4 - Lights Switch Illumination; Bleeper; Instrument Cluster; Differential Lock Cut-Out; Diagnostic Supply
Connector; Speedo Sensor; Fuse C5 (Dry Clutch Transmission)
12 - 35 Fuse C4 (Dry Clutch Transmission ) (cont’d)
12 - 35A Fuse C4 - Lights Switch Illumination; Bleeper; Instrument Cluster; Differential Lock Cut-Out; Diagnostic Supply
Connector; Speedo Sensor; Fuse C5 (Wet Clutch Transmission)
12 - 35B Fuse C4 (Wet Clutch Transmission) (cont’d)
12 - 36 Fuse C4 (cont’d) - Canbus; Diagnostic Connector
12 - 37 Fuse C5 - Fuel Flow Sensor; Ground Speed Radar Sensor (Dry Clutch Transmission)
12 - 37A Fuse C5 - Fuel Flow Sensor; Ground Speed Radar Sensor (Wet Clutch Transmission)
12 - 38 Fuse C7 - 13-pin Trailer Socket (Ignition)
Fuse C8 - 13-pin Trailer Socket (Battery)
12 - 39 Fuses E1, E2 - Trailer ABS
Fuses F1, F2, F3, F4 - Tractor ABS
12 - 40 Fuse E3 - Flow Divider
12 - 41 Fuse E4 - Four Wheel Steer (4WS) Circuit
12 - 42 - Trailer Sockets
9803/8020 Issue 4*
Sectional Diagrams Component Key 8-6
9803/8020
1 Battery (all machines) 67 Front PTO Brake Solenoid 145 Fuel Level Sender
1A Second Battery (3000 Series only) 68 Rear PTO Drive Solenoid 146 Transmission Oil Filter Switch
Section C
2 Ignition Switch 69 Front PTO Drive Solenoid 147 Air Filter Switch
3 Starter Motor 70 Park Brake Switch 148 Front Brake Reservoir Level
4 Alternator 71 Rear PTO Cut-Out Connector 149 Rear Brake Reservoir Level
*
5 Trailer ABS Socket 71a Rear PTO Termination Connector 149A Rear Brake Reservoir Level (ABS)
5A Tractor ABS Supply (if fitted) (machines without rear PTO cut-out 150 Transmission Oil Pressure Switch
5B Tractor ABS Return (if fitted) option) 151 Speedometer Pick-up
6 Ignition Relay 71b Rear PTO Interconnecting Connector 152 Engine Oil Pressure Switch
7 Worklights Relay (machines with rear PTO cut-out option) 153 Canbus Cable Screen
8 Heater Unit (3000 Series) 72 Diode Connector (E21) (PTO Cut-Out) 154 RF Ground
9 Auxiliary Connector 73 PTO Cut-Out Push-Button (LH Fender) 155 Diagnostic Connector
9A Auxiliary Power Socket (if fitted) 74 PTO Cut-Out Push Button (RH Fender) 156 4WS Interconnecting Connector
10 Air Conditioning Connector (2000 Series) 75 Air Conditioning Blower Switch (2000 157 Non-4WS Connector
10A Air Conditioning Connector (3000 Series) Series only) 158 Fuel Flow Sensor
11 Auxiliary Lights Earth Connector (2000 76 Air Conditioning Switch (2000 Series 159 Radar Speed Sensor
Series) only) 160 ABS Trailer Socket
11A Auxiliary Lights Supply Connector (3000 77 Heater Unit (3000 Series only) 161 Suspension Seat Connector
Series) 78 Air Conditioning Unit 162 Flow Divider Switch
12 Suspension Seat/Flow Divider Connector 79 Air Conditioning Compressor Switch 163 Flow Divider Valve Connector
13 Horn Connector 80 Air Conditioning Compressor Clutch 164 Rear Axle Ram Lock Switch (closed when
14 Start Inhibit Relay 1 81 Air Conditioning Compressor Pressure locked)
15 Start Inhibit Relay 2 Switch (High) 165 Rear Axle Ram Lock Valve
16 Clutch Start Micro-switch 82 Air Conditioning Compressor Pressure 166 Steer Valve (RH)
17 Diode Connector Switch (Low) 167 Steer Valve (LH)
18 Front PTO Switch 83 Air Conditioning Compressor Clutch 168 Front Potentiometer (4WS)
19 Rear PTO Switch Relay 169 Rear Potentiometer (4WS)
20 Brake Lights Switch 84 Radio/Cassette 170 4WS Differential Lock Cut-Out Relay
21 Brake Lights Relay 85 Interior LIght (RH) 171 Trailer Socket (7-pin)
22 Rear Wiper Motor 86 Interior Light (LH) 172 Trailer Socket (13-pin)
23 Rear Wash/Wipe Switch 87 Door Switch (LH) 173 4WS Jack Socket
24 Connector - Rear Washer Pump (2000 88 Beacon Switch 174 Wheel Slip Enable Switch (machines with
Series) 89 Beacon Socket optional software package only)
24A Connector - Rear Washer Pump (3000 90 Hazard Switch (2000 Series from serial no. 788376;
Series) 91 Single Trailer Turn Relay 3000 Series from serial no. 640305)
25 Rear Intermittent Wipe Relay 92 Second Trailer Turn Relay 175 Inching Solenoid Resistor - 4.7 ohm
26 Rear Wiper Connectors 93 Outer Indicator Lights (RH) 176 Column Switch Button
27 Front Washer Pump Connector (2000 94 Outer Indicator Lights (LH) 177 Clutch Potentiometer
Series) 95A Auxiliary Lights Connector (In) 178 Transmission Oil Temperature Sensor 1
27A Front Washer Pump Connector 95B Auxiliary Lights Connector (Out) 179 Transmission Oil Temperature Sensor 2
(3000 Series) 96 Side Repeater (LH) (3000 Series only) (clutch housing oil sump)
28 Horn 97 Side Repeater (RH) (3000 Series only) 180 Clutch Lubrication Solenoid
29 Washer/Horn Switch 98 Trailer Socket 181 Transmission Brake Solenoid
30 Front Wiper Motor 99 Rear Light Cluster (LH) Connector 182 Clutch Control Solenoid
31 Front Intermittent Wipe Relay 100 Rear Light Cluster (RH) Connector 183 Cab Auxiliary Supply Connector
32 Front Wiper Switch 101 Front Light Cluster (RH) Connector (3000 184 Cab Auxiliary Battery Supply - Terminal
33 Cold Advance Switch (2000 Series only) Series only) Ports
33A Waxstat 102 Front Light Cluster (LH) Connector (3000 185 Cab 3-pin Auxiliary Power Socket
34 E.S.O.S. (2000 Series, 3155) Series only) (battery and ignition supplies)
35 E.S.O.S. Relay (3185 only) 103 Front Worklights Switch 186 Cab Auxiliary Power Convenience Socket
36 E.S.O.S. (3185 only) 104 ‘A’ Post Worklights Relay (Option - N.Am. machines)
37 Timer (3185 only) 105 Front Working Light (RH outer) 187 Ignition Switched Relay (supplied with item
38 Area Cut-out Switch (EDC) 106 Front Working Light (RH inner) 186)
39 Connector - EDC Unit 107 Front Working Light (LH inner) * 188 ABS Diagnostic Interconnect
40 Pin position identification for 39 108 Front Working Light (LH outer) * 189 Tractor Diagnostic Interconnect
41 Raise/Lower Switch (EDC) (In cab) 109 Front Working Light (RH ‘A’ post) * 190 Tractor ABS Diagnostic Relay
42L Draft Pin (EDC) (Left Hand) 110 Front Working Light (LH ‘A’ post) * 191 Diagnostic Switch
42R Draft Pin (EDC) (Right Hand) 111 Rear Worklights Switch * 192 Tractor ABS Ignition Relay
43 Position Sensor (EDC) 112 Rear Working Light (RH outer) * 193 ABS Speed Sensor (Front RH)
44A Raise Push-Button (EDC) (RH Fender) 113 Rear Working Light (RH inner) * 194 ABS Speed Sensor (Front LH)
44B Raise Push-Button (EDC) (LH Fender) 114 Rear Working Light (LH inner) * 195 ABS Speed Sensor (Rear RH)
45A Lower Push-Button (EDC) (RH Fender) 115 Rear Working LIght (LH outer) * 196 ABS Speed Sensor (Rear LH)
45B Lower Push-Button (EDC) (LH Fender) 116 Main Lights Switch * 197 ABS Pressure Modulating Valve (Front)
46 Raise Solenoid (EDC) 117 Rear Fog Lights Switch * 198 ABS Pressure Modulating Valve (Rear LH)
47 Lower Solenoid (EDC) 118 Rear Fog LIghts Relay * 199 ABS Pressure Modulating Valve (Rear RH)
48 Gear Lever Powershift Switches 119 Column Lights Switch (Main/Dip/Flash) * 200 Tractor ABS ECU Connectors
a Down 120 Headlight Connector (LH) (3000 Series)
b Up 120A Sidelight Connector (LH) (2000 Series)
c Auto 121 Headlight Connector (RH) (3000 Series)
48A Duplicate Powershift Switches (if fitted) 121A Sidelights Connector (RH (2000 Series)
Electrics
49 Powershift Solenoids 122 Air Gauge Illumination Lamp

Wiring Diagrams
a Snail 123 Number Plate Lamp (LH)

b Tortoise 124 Number Plate Lamp (RH)
c Hare 125 Auxiliary Lights Switch (3000 Series)
49A Splitter Dump Relay 126 Auxiliary Headlights (RH)
50 Accelerator Pedal Switch 127 Auxiliary Headlights (LH)
51 Column Switch 128A Speaker (LH)
52 Powershift Range Neutral Solenoid 128B Speaker (RH)
Connector 129 Auxiliary Socket
53 Powershift Range Engaged Solenoid 130 Cigar Lighter
Connector 131 Trailer Socket Reverse Light Relay
54 4WS Option Connector 132 Mega Fuses - Thermostart (3185 only)
55 Clutch Warning/Selectronic Bleeper 133 Thermostart Heater Relay 1 (3185 only)
56 Powershift Low/Reverse Air Ram 134 Thermostart Heater Relay 2 (3185 only)
57 Powershift Medium/High Air Ram 135 Thermostart Heater 1 (3185 only)
58 2WD/Differential Lock Switch 136 Thermostart Heater 2 (3185 only)
59 Rear PTO Switch 137 Thermostart 1 (2000 Series, 3155)
60 Front PTO Switch 138 Thermostart 2 (2150 only)
61 Differential Lock Switch 139 Buzzer Relay
62 Differential Lock Cut-Out Relay 140 Clutch ‘Up’ Switch
63 2WD Dump Relay 141 Water Temperature Sender
64 2WD Solenoid 142 Air Pressure Switch - Tank 1
65 Differential Lock Solenoid 143 Air Pressure Switch - Tank 2
66 Rear PTO Brake Solenoid 144 Air Pressure Switch - Tank 3
Section C
Issue 5*
8-6
Sectional Diagrams
8-7
Alphabetical Index
9803/8020
Fuses Page No. Item Page No. Item Page No.
Section C
A1 12-3 Air Conditioning 12-17 Starter Solenoid 12-3

A2 12-4 Air Dryer 12-3 Supply Circuit 12-1
A3 12-5 Alternator 12-1 Thermostart 12-33
A4 12-6 & 12-7 Auxiliary Lights Switching 12-27 & 12-28 Trailer ABS Socket 12-39
A5 12-8 & 12-9 Area Cut-out Switch 12-10 Trailer Socket Reverse Lights 12-32
A6 12-10 & 12-11 Auxiliary Jack Plug Socket 12-30 Trailer Sockets 12-38 &12-42
A7 12-12, 12-13 Battery 12-1 Transmission Oil Pressure Switch 12-35
& 12-14 Beacon Socket 12-18 Two Wheel Drive Solenoid 12-15
A8 12-15 Bleeper 12-34 Wash/Wipe-front 12-6 & 12-7
A9 12-17 Brake Lights 12-4 Wash/Wipe-rear 12-6
B1 12-18 Cigar Lighter 12-31 * Wheelslip Enable Switch 12-37
B2 12-19 Diagnostic Supply Connector 12-36 Work Lights - Front 12-20
B3 12-20 Differential Lock Cut-out 12-15 Work Lights - Rear 12-21
B4 12-21 Direction Indicators 12-19
B5 12-22 Earth Circuit 12-2
B6 12-29 Electronic Draft Control system 12-10 & 12-11
B7 12-30 ESOS 12-8 & 12-9
B8 12-31 Flow Divider 12-40
B9 12-10 & 12-11 Fog Lights - Rear 12-24
C1 12-32 Four Wheel Steer (if fitted) 12-41
Electrics
C2 12-19 Fuel Flow Sensor 12-37

C3 12-33 Ground Speed Radar Sensor 12-37
Wiring Diagrams
C4 12-34, 12-35 Hazard Warning Lights 12-19

& 12-36 Head Lights 12-22 & 12-23
C5 12-37 Horn 12-6
C6 12-3 Instrument Cluster 12-34
C7 12-38 Interior Lights 12-18
C8 12-38 Light Switch Illumination 12-34
C9 12-3 Main Lights 12-22
D1 12-23 Maxifuse (W) 12-22
D2 12-23 Neutral Start (Clutch & Gearbox) 12-3
D3 12-24 Powershift ECU - 3-Speed Splitter12-12
D4 12-25 Powershift ECU - Selectronic 12-13 & 12-14
D5 12-26 PTO - Front 12-15
D6 12-28 PTO - Rear 12-15 & 12-16
E1 12-39 Radio/Cassette 12-29
E2 12-39 Side Lights - LH 12-25
E3 12-40 Side Lights - RH 12-26
E4 12-41 Solenoid - Two Wheel Drive 12-15
W 12-22 Solenoid - Differential Lock 12-15
Speedometer Sensor 12-35
Issue 2*
8-7
Section C
Harness Connectors
9-1
The majority of connectors are either connected 3000 SERIES 2000 SERIES
9803/8020
directly to the components they serve or are located
nearby.
Section C
The illustration on this page shows the location of CR1

CR1
the bulkhead connectors and the illustrations on the E16
following pages show those connectors which
interconnect the separate individual harnesses.
C3
E16
Electrics
Wiring Diagrams
3000 SERIES 2000 SERIES
CR51
CR51
A310320
Issue 1
9-1
Section C
Harness Connectors (cont’d)
9-2
Key
9803/8020
* CR10
1 Chassis harness
CR34
Section C
2 Cab harness
3 ESOS harness
4 Electronic draft control (EDC) harness (cab) CR16
5 EDC harness (chassis) CR14 CR29
6 EDC harness (rear fender)
7 4WS harness (cab) (optional) CR35
8 4WS harness (chassis) (optional)
9 Auxiliary lights harness (optional)
10 Trailer ABS harness (cab) 2
CR21
11 Trailer ABS harness (chassis)
12 Flow diverter harness (optional) CR18 C18
C1
13 Engine block heater harness (optional)
CR64
C19
3 CR65 CR1 CR12

CR66
C5
Electrics
Wiring Diagrams
CR49 CR50
CR51
C28
C64
C63 1
A311291
Issue 2*
9-2
Section C
Harness Connectors (cont’d) 9-3
Key
9803/8020
1 Chassis harness
Section C
2 Cab harness
3 ESOS harness FA
4 Electronic draft control (EDC) harness (cab)
6
E12
5 EDC harness (chassis)
7 4WS harness (cab) (optional)
12 Flow diverter harness (optional) E16
13 Engine block heater harness (optional) E15 E13
6
FA
Electrics
Wiring Diagrams
E19
5
A311300
Issue 1
9-3
Section C
Note: Connector C17 connects to CR9 and connector
9803/8020
C18 connects to 2-Wheel Drive/Differential Lock
Switch 58 (see page 12-15). CR9 and 58 are normally
Section C
connected together in a standard harness

arrangement (see page 12-15). *
Key
C2
1 Chassis harness
2 Cab harness C1
3 ESOS harness
6 EDC harness (rear fender) CF
7 C18
10 Trailer ABS harness (cab) C17 CB
11 Trailer ABS harness (chassis) C4
12 Flow diverter harness (optional) C3 C7
13 Engine block heater harness (optional) CA CD
CE
Electrics
Wiring Diagrams
CC
A311311
Issue 2*
9-4
Section C
Key
9803/8020
1 Chassis harness
A4
Section C
2 Cab harness A3
3 ESOS harness
5 EDC harness (chassis) 9
12 Flow diverter harness (optional) A2
13 Engine block heater harness (optional)
ABS2
AHL3
Electrics
Wiring Diagrams
11
AHL9
AHL12
A311320
Issue 1
9-5
Section C
Harness Connectors (cont’d)
9-6
Key
9803/8020
1 Chassis harness
Section C
2 Cab harness
3 ESOS harness
12 Flow diverter harness (optional)
13 Engine block heater harness (optional) FD3
Electrics
Wiring Diagrams
13
A311330
Issue 1
9-6
Section C
*
12 - 1
9803/8020
Section C
A1 12-3
12-39 5
A2 12-4
A3 12-5
2 A4 12-6
A5 12-8
A6 12-10
2 A7 12-12
6 A8 12-15
A9 12-17
12-26 B1 12-18
B2 12-19
B3 12-20
B4 12-21
7
B5 12-22
B6 12-29
Electrics
B7 12-30
7
Wiring Diagrams
B8 12-31
5A B9 12-10
C1 12-32
12-39 C2 12-19
C3 12-33
21
W 12-22 C4 12-34
12-3 C5 12-37
C6 12-3
C7 12-38
1 1A 3 4 C8 12-38
12-4 C9 12-3
A307153
SUPPLY CIRCUIT: BATTERY TO STARTER MOTOR; ALTERNATOR; FUSES A1 - A9, B1 - B9, C1 - C9, W (Maxifuse);
TRAILER ABS CONNECTOR, TRACTOR ABS CONNECTOR
Issue 4*
12 - 1
Section C
*
12 - 2
8
9803/8020
12-4
Section C
3185
12-9
3
9
12-39A 5B
1 1A
Electrics
13
Wiring Diagrams
9A
12
2000
SERIES 11
10
3000
2000
SERIES
SERIES
11A
A307162
10A
3000
SERIES
EARTH CIRCUIT
Issue 3*
12 - 2
Section C
*
CR4-C
660B
C
C6 181 (0.6)
C8 CRES3
12 - 3
180 4 6 (4.0)
+12V
9803/8020
(4.0)
854 C C 856A
C5
14 (0.6) 6 4 (0.6)
8
2 CR8
Section C
C 180
2 (4.0) 3
5 3 A B B A
856A
18 D C C D
(0.6)
105 2/4
+12V IGN A1 (0.6)
856C CR86 1
CRSIS (0.6)
BRAKE
810A 854
(0.6)
17 (0.6)
1 2
856 2 1
(0.6) 3 4
4 3 3
660C
810 810C A B B A
CDS (0.6)
(0.6) (0.6)
19 D C C D
(0.6)
4 6
856B
12-13A 2/4
CR7
15 1
1 2 2 1
181
(4.0)
8
2 855
(0.6)
CR36 5
182 182
(4.0) (4.0)
CR4-D C41
182
1 2 (4.0)
CES7
bb aa
16 D
aa bb
D8 2 1
1 2 B A
A B cc hh
hh C D E F G cc G F E D C
855 D D 856B
810B
(0.6)
D5 H J K L M N N M L K J H
(0.6) 6 4 (0.6)
gg P R S T U dd U T S R P
Electrics
dd gg 2
V W
181 3 4 W V 4 3
5 D ff ee 4 3 C6
2 (4.0) 1
Wiring Diagrams
640K
(1.4)
ee ff
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 CR51 C28
811
(0.6)
811
36 35 34 33 32 31 30 29 28 27 26 25 TH2
(0.6)
1 2
195 195A
C9CS
(1.4) (1.4)
195B
(0.6)
CR49
1 1
2 5 5 2
3 6 11 11 6 3
4 7 12 18 18 12 7 4 195B
8 13 19 19 13 8 (0.6)
9 14 20 25 25 20 14 9
10 15 21 26 32 32 26 21 15 10
195 16 22 27 33 33 27 22 16
+12V IGN C9 39 34 28 23 17 X W W X
(1.4) 17 23 28 34 39 811 K K
24 29 35 40
40 35 29 24 V V
41 36 30 (0.6) L J L
30 36 41 B J H H B
45 42 37 31 U U
31 37 42 45 46 43 38 M C A A C M
38 43 46 47 44 G G
44 47 48 N F T T F N
D E E D
48 S S
O P O
Q R R Q P
C5
CR1 C72 TH1
A309863
FUSE A1 - NEUTRAL START (CLUTCH); FUSE C6 - STARTER SOLENOID;

FUSE C9 - AIR DRIER, NEUTRAL START (GEARBOX)
Issue 4*
12 - 3
Section C
12 - 4
9803/8020
A2
Section C
bb aa
2 B A 1
cc hh
20 G F E D C
N M L K J H
U T S R P
dd gg
V
4 W 3
ee ff
21
Electrics
12-1
Wiring Diagrams
12-42
A307171
FUSE A2 - BRAKE LIGHTS
Issue 2*
12 - 4
Section C
12 - 5
9803/8020
12-15
Section C
A3
26 26
22
24A
12
12-40
3000
SERIES
2000
SERIES
bb aa
2 B A 1
cc hh
G F E D C
N M L K J H
U T S R P
dd gg
Electrics
V
4 W 3
Wiring Diagrams
ee ff
25
23
24
12-25
A307180
FUSE A3 - REAR WASH/WIPE
Issue 1
12 - 5
Section C
12 - 6
9803/8020
A4 12-7
Section C
12-7
12-7
29
3000
SERIES
27
27A
Electrics
2000
Wiring Diagrams
SERIES
bb aa 28
2 B A 1
cc hh
G F E D C
N M L K J H
U T S R P
dd gg
V
4 W 3
ee ff
A307190
FUSE A4 - FRONT WASH/WIPE; HORN
Issue 1
12 - 6
Section C
12 - 7
9803/8020
Section C
12-6
30 31
Electrics
Wiring Diagrams
bb aa
2 B A 1
cc hh
G F E D C
N M L K J H
U T S R P
dd gg
V
4 W 3
ee ff
32
A307200
FUSE A4 (CONT’D) - FRONT WASH/WIPE
Issue 1
12 - 7
Section C
12 - 8
9803/8020
Section C
A5
34
Electrics
Wiring Diagrams
2000
SERIES
33
A307210
* FUSE A5 - ENGINE SHUT-OFF SOLENOID (ESOS) (2000 SERIES, 3155* - DRY CLUTCH TRANSMISSION)
Issue 2*
12 - 8
Section C
12 - 8A
9803/8020
Section C
A5
(2000) (3155)
Electrics
Wiring Diagrams
34
3155 ONLY
2000 SERIES ONLY

33
33A WAXSTAT A353910
* FUSE A5 - ENGINE SHUT-OFF SOLENOID (ESOS) (2000 SERIES, 3155 - WET CLUTCH TRANSMISSION)
Issue 1
12 - 8A
Section C
12 - 9
9803/8020
Section C
3 ESOS (40A)
A5 3
35
37
Electrics
Wiring Diagrams
36
A309870
FUSE A5 - ENGINE SHUT-OFF SOLENOID (ESOS) (3185 ONLY)

ESOS MAXIFUSE
Issue 1
12 - 9
Section C
12 - 10
9803/8020
Section C
42L 42R
39
12-34
12-37
40
860RB
12-37 (0.6)
38
Electrics
Wiring Diagrams
A6
B9
3000
SERIES
2000
SERIES
41 12-41
12-11 * † All 2000 Series machines to S/N 738694
All 3000 Series machines to S/N 640709
3000 Series machines with radar from S/N 640710 A307222
* † ELECTRONIC DRAFT CONTROL (EDC) TYPE D+

FUSE A6 - IGNITION CAB SIDE
FUSE B9 - BATTERY CAB SIDE
Issue 3*
12 - 10
Section C
9803/8020
12 - 10A
Section C
42L 42R
39
40
Electrics
Wiring Diagrams
A6
B9
3000
SERIES
2000
SERIES
12-41
41
† 2000 Series machines not fitted with radar from S/N
12-11 738695
3000 Series machines not fitted with radar from S/N
640710
A343740
† ELECTRONIC DRAFT CONTROL (EDC) TYPE B

FUSE A6 - IGNITION CAB SIDE
FUSE B9 - BATTERY CAB SIDE
Issue 1
12 - 10A
Section C
44A
12 - 11
9803/8020
Section C
43
45A
44B
Electrics
Wiring Diagrams
45B
46
47
A307250
* ELECTRONIC DRAFT CONTROL (EDC) TYPES D+ AND B

FUSE A6 - IGNITION CHASSIS SIDE
FUSE B9 - BATTERY CHASSIS SIDE
Issue 3*
12 - 11
Section C
*
12 - 12
9803/8020
Section C
A7
UP
154
DOWN
48A
50
AUTO
a
b
48 c
Electrics
Wiring Diagrams
bb aa
2 B A 1
49 b cc
G F E D C
N M L K J
U T S R P
dd V
4 W 3
ee ff
c
A307241
* FUSE A7 - POWERSHIFT ECU - 3 SPEED SPLITTER (DRY CLUTCH TRANSMISSION)
Issue 2*
12 - 12
Section C
12-3
55
12 - 13
9803/8020
12-34
51
Section C
52
Electrics
Wiring Diagrams
53
2000
SERIES
54
A307260
* FUSE A7 (CONT’D) - POWERSHIFT ECU - SELECTRONIC (DRY CLUTCH TRANSMISSION)
Issue 2*
12 - 13
Section C
810D (0.6)
125 (2.0)
* CDS 4 6 660N
810C 660L (1.0)
(0.6) (0.6) 660J
9803/8020
CRES3
12 - 13A
12-3 (1.0)
660H
8 660ZA (1.0) 125C
CRES3 12 11 10 9 8 7 6 5 4 3 2 1
2 (0.6) (1.0)
24 23 22 21 20 19 18 17 16 15 14 13
CR50
660X
Section C
CR97 (1.0) 36 35 34 33 32 31 30 29 28 27 26 25
49A 5
+12V IGN A7 PSSS CR62
UP
(0.6)
660ZB
625
900A (1.0)
901 901A (0.6)
CR95 TSS
(0.6) (0.6) 154
(0.6)
660ZC
470B 900 125B
SSS CR49
A B B A (0.6) (1.0)
(0.6)
D C C D 12 11 10 9 8 7 6 5 4 3 2 1
901B 125A
(0.6) 24 23 22 21 20 19 18 17 16 15 14 13
902 902A (1.0)
HSS 36 35 34 33 32 31 30 29 28 27 26 25
(0.6) (0.6)
471B
48A (0.6) 127 (2.0)
472B 413
DOWN (0.6) 50
CR96 (0.6) 472A CR61
ASSS
472 (0.6) 902B
(0.6) (0.6)
B A A B 471A 1 2
DSSS 2 1
471 (0.6) 1
(0.6) 3
815 (1.0)
470 3
3
(0.6) 470A
USSS
(0.6)
AUTO
720E
PES3
C21 (0.6)
DOWN
a 127 (2.0)
UP 1 901B (0.6)
1 2 2 5
b 2 1
3 6 11 900B (0.6)
aa bb
4 7 12 18
48 3 4 8 13 19 1 A B
2 902B (0.6)
AUTO 4 3
c 9 14 20 25
10 15 21 26 32 hh C D E F G cc
16 22 27 33 H J K L M N
17 23 28 34 39
24 29 35 40 gg P R S T U dd
30 36 41
660ZD
CRES3
31 37 42 45 V W (0.6)
3 4
(1.4)
640B
38 43 46 ff ee 412B
44 47 1 2 3
CES7 412 (0.6)
48
Electrics
AWS CR102 4 5 6 7
(0.6)
8 9 10
Wiring Diagrams
CR51
CR1 12-36
471
(1.4) 514H (0.6)
TH5 1 2 470
(1.4) 631 (1.0)
a 472 12 11 10 9 8 7 6 5 4 3 2 1
(1.4) 515H (0.6)
900 900 24 23 22 21 20 19 18 17 16 15 14 13
(0.6)
(0.6) 125 (2.0)

412A
(0.6) 36 35 34 33 32 31 30 29 28 27 26 25
1 bb aa
5 2 810D (0.6)
W X 11 6 3 2 1
X W B A
K K 18 12 7 4 cc hh
49 TH7 1 2 V J L L V 19 13 8 SNAIL
815A J G F E D C
H B B H 25 20 14 9 TORTOISE LOW
b U M M U 32 26 21 15 10 CR66
(0.6) A C C A N M L K J H MEDIUM
SDS G G 33 27 22 16
T F N N F T 39 34 28 23 17 HARE
815B E D D E 40 35 29 24 U T S R P
S S 41 36 30 dd gg HIGH
(0.6) O O P
R Q P Q R 45 42 37 31 W V
46 43 38 4 3 3 2 1 3 2 1
47 44 C'DOWN
48 C28 ee ff 7 6 5 4 7 6 5 4
TH4 1 2 C5 +12v SPLICE
815C SUPPLY
c C50 W 10 9 8 10 9 8
(0.6) 815 TH1 C72 815 (1.0)
412
(1.0)
(1.4)
901 901 CAN L
(0.6) (0.6)
902 902 CAN H
(0.6) (0.6)
P'SHIFT CAN
SUPPLY MH1 SCRN
A353921
FUSE A7 - POWERSHIFT ECU - SELECTRONIC (WET CLUTCH TRANSMISSION)
Issue 2*
12 - 13A
Section C
12-3
55
9803/8020
12-35A
12 - 13B
51
Section C
52
Electrics
Wiring Diagrams
53
2000
SERIES
54
A353940
FUSE A7 (CONT’D) - POWERSHIFT ECU - SELECTRONIC (WET CLUTCH TRANSMISSION)
Issue 1
12 - 13B
Section C
CR98
*
TH3
CR66 2 1
176 179
CES7
9803/8020
1 2
12 - 13C
2 1
12 11 10 9 8 7 6 5 4 3 2 1
Section C
820
24 23 22 21 20 19 18 17 16 15 14 13
(0.6)
36 35 34 33 32 31 30 29 28 27 26 25 820 (0.6)
X W W X
K V K
821
L J V J L
B H H
(0.6)
B
499 (0.6)
640M (0.6)
M U U
C A C M
G G A
640N (0.6)
C72 N F T T F N
498 (0.6) 821 (0.6) 821 (0.6) D E E D
S S
O P O
Q R R QP
820 (0.6)
CR99
CR1 TH1
175
1 C5
1 2 2 5
2 1 3 6 11
1
5 2
4 7 12 18 11 6 3
8 13 19 18 12 7 4
9 14 20 25 19 13 8
10 15 21 26 32 25 20 14 9
16 22 27 33 32 26 21 15 10
17 23 28 34 39 33 27 22 16
526 (0.6)
821B (0.6) 24 29 35 40 39 34 28 23 17
30 36 41 40 35 29 24
4R7 ISRS 31 37 42 45 41 36 30
821A (0.6) 38 43 46 45 42 37 31
44 47 46 43 38
47 44
524D (0.6)
48
48
660A
CRES3
(0.6) 822 (0.6)
526 (0.6)
524D (0.6)
823 (0.6)
822 (0.6)
640N (0.6)
640M (0.6)
823 (0.6)
823 (0.6)
822 (0.6)
CR49 CLUTCH
PEDAL
525
DOWN (0.6)
524
5K
(0.6)
RT
12 11 10 9 8 7 6 5 4 3 2 1
TOTS2
24 23 22 21 20 19 18 17 16 15 14 13 RP 1K
D.O.R.
Electrics
36 35 34 33 32 31 30 29 28 27 26 25
CLUTCH
PEDAL 3 2 1
UP 524D
Wiring Diagrams
(0.6)
177 CR53 526 (0.6)
1 2 3
523 (0.6)
522 (0.6)
TH8
TH6
521 (0.6) TH9 C71
524C (0.6)
524B (0.6)
182 178 181 180
524 (0.6)
TOTS1
524A (0.6) 1 2
1 2 1 2 1 2
526 (0.6)
525 (0.6)
12 11 10 9 8 7 6 5 4 3 2 1
A353892
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
CR50
FUSE A7 (CONT’D) - WET CLUTCH CONTROL (WET CLUTCH TRANSMISSION)
Issue 3*
12 - 13C
Section C
Note: Items 56 and 57 shown in neutral position.
12 - 14
9803/8020
Section C
56
Electrics
Wiring Diagrams
57
A309580
FUSE A7 (CONT’D) - POWERSHIFT ECU - SELECTRONIC (CONT’D)
Issue 1
12 - 14
Section C
64
12 - 15
9803/8020
65
Section C
66
67
68
70
58
69
59 12-34
Electrics
63
Wiring Diagrams
60
12-34
12-26
12-34
12-3
A8 61
71a
71 A309591
71b * † Wire 400A only fitted on later machines
12-16
FUSE A8 - FRONT/REAR PTO; 2WD AND DIFFERENTIAL LOCK SOLENOIDS; REAR PTO CUT-OUT
Issue 3*
12 - 15
Section C
12 - 16 Wiring Diagrams 12 - 16
A309950
73
74
REAR PTO CUT-OUT OPTION

72
71b
9803/8020 Issue 1
12 - 17
9803/8020
Section C
A9
79 80
2000 3000
SERIES SERIES
75 2000
SERIES
2000
SERIES
2000
SERIES
81 82
3000
3000
3000
SERIES
SERIES
SERIES
Electrics
Wiring Diagrams
78
77
76
3000
2000
SERIES
SERIES
83
A309620
FUSE A9 - AIR CONDITIONING CIRCUIT
Issue 1
12 - 17
Section C
12 - 18
9803/8020
Section C
B1
84 86
85
87
88 2000 SERIES
Electrics
Wiring Diagrams
3000
SERIES
89
A309630
FUSE B1 - INTERIOR LIGHTS; RADIO/CASSETTE; BEACON SOCKET
Issue 1
12 - 18
Section C
3000
SERIES
94
12 - 19
2000
9803/8020
SERIES
95B 95A bb aa
2 B A 1 3000
2000 cc hh
Section C
SERIES G F E D C SERIES
93 N M L K J H
3000
U T S R P
SERIES dd gg
W V
4 3
ee ff
3000
SERIES
3000
SERIES
C2
B2 96
97
3000
SERIES
98
Electrics
90
Wiring Diagrams
3000
SERIES
99
51 101
92
91
3000
100 SERIES
102
A309601
FUSE B2 - HAZARD WARNING LIGHTS

FUSE C2 - DIRECTION INDICATORS
Issue 2*
12 - 19
Section C
12 - 20
109 110
9803/8020
Section C
B3
105 106 107 108
103
3000
SERIES
2000
SERIES
Electrics
Wiring Diagrams
104
2000
SERIES
A309640
FUSE B3 - FRONT WORK LIGHTS
Issue 1
12 - 20
Section C
A309650
115
114
FUSE B4 - REAR WORK LIGHTS

113
112
111
B4
9803/8020 Issue 1
12 - 22
9803/8020
W
B5
Section C
119
12-34
116
D1
12-23
D2
118
117 12-23
Electrics
Wiring Diagrams
D3
12-24
D4
12-25
D5
12-26
D6
3000
SERIES 12-27
A309660
FUSE B5 - HEADLIGHT FLASH

FUSE W (MAXIFUSE) - MAIN LIGHTS
Issue 1
12 - 22
Section C
12 - 23
9803/8020
D1
Section C
D2 2000
SERIES
120
3000
SERIES
3000
SERIES
3000
2000
SERIES
95A
SERIES 2000
2000 SERIES
SERIES
3000
95B
SERIES
3000 121
SERIES
3000
SERIES
2000
SERIES
Electrics
2000
Wiring Diagrams
SERIES
bb aa
2 B A 1
cc hh
G F E D C
N M L K J H
U T S R P
dd gg
V
4 W 3
ee ff
A309670
FUSE D1 - MAIN BEAM

FUSE D2 - DIPPED BEAM
Issue 1
12 - 23
Section C
12 - 24
9803/8020
Section C
D3
98
bb aa 99
2 B A 1
cc hh
Electrics
G F E D C
Wiring Diagrams
N M L K J H
U T S R P
dd gg
W V
4 3
ee ff
100
A309680
FUSE D3 - REAR FOG LIGHTS
Issue 1
12 - 24
Section C
2 B A 1
12 - 25
9803/8020
G F E D C
N M L K J H 121 98
Section C
U T S R P
W V
4 3
3000
SERIES
3000
SERIES
2000
SERIES
100
95A 95B
121A
Electrics
12-29 123
2000 12-41
Wiring Diagrams
D5 ES
SERI
12-15
12-10
124
12-31
12-1 A309690
FUSE D4 - SIDE LIGHTS (LEFT SIDE)
Issue 1
12 - 25
Section C
12 - 26
9803/8020
2 B A 1
Section C
G F E D C
N M L K J H 121 98
U T S R P
W V
4 3
3000
SERIES
3000
SERIES
2000
SERIES
100
95A 95B
121A
Electrics
Wiring Diagrams
12-29 123
D5 2000 12-41
ES
SERI
12-15
12-10
124
12-31
12-1 A309690
FUSE D5 - SIDE LIGHTS (RIGHT SIDE)
Issue 1
12 - 26
Section C
12 - 27
9803/8020
Section C
127
126
125
12-23
12-25 12-23 12-23
Electrics
12-23 12-25
Wiring Diagrams
95A
95B
12-26
12-19 12-19
12-19
12-26
12-19
A309710
AUXILIARY LIGHTS SWITCHING (2000 SERIES)
Issue 1
12 - 27
Section C
12 - 28
9803/8020
Section C
11A
D6
125
126
12-23
12-25 12-23 127
Electrics
Wiring Diagrams
95A
12-23
12-26 12-23 12-25
12-19
12-19
95B
12-19
12-26
12-19
A309700
FUSE D6 - AUXILIARY LIGHTS SWITCHING (3000 SERIES)
Issue 1
12 - 28
Section C
128B
A309720
12-18
FUSE B6 - RADIO/CASSETTE
128A
84
B6
12-26
9803/8020 Issue 1
12 - 30
9803/8020
Section C
B7
330 (3)
+12V BAT
129
Electrics
Wiring Diagrams
CR30
680 (3)
A309730
FUSE B7 - AUXILIARY JACK-PLUG SOCKET
Issue 1
12 - 30
Section C
A309740
FUSE B8 - CIGAR LIGHTER

130
12-26
B8
9803/8020 Issue 1
12 - 32
9803/8020
Section C
131
C1
98
99
Electrics
Wiring Diagrams
100
A309752
* FUSE C1 - TRAILER SOCKET REVERSE LIGHTS* (DRY CLUTCH TRANSMISSION)

*Note: Item 98 plus wires 620A and 878 are fitted only up to machine numbers 640777 (3000 series) and 738748 (2000 Series)
Issue 3*
12 - 32
Section C
A354000
FUSE C1 - REVERSE LIGHTS (WET CLUTCH TRANSMISSION)

100
99
131
C1
9803/8020 Issue 1
A309760
135
136
FUSE C3 - THERMOSTART
133
134
137
138
2000 3155
2150
SERIES
3185
3185
132
3
C3
9803/8020 Issue 1
*
12 - 34
55
9803/8020
Section C
140
12-22
C4 12-36
12-15 C5
12-15
2000
139 SERIES
3000
SERIES
12-41
Electrics
Wiring Diagrams
12-35(C28)
2000
2000 SERIES
SERIES 2000
SERIES
3000
SERIES
2000
SERIES
12-10
12-15
A309771
FUSE C4 - LIGHTS SWITCH ILLUMINATION; BLEEPER; INSTRUMENT CLUSTER; DIFFERENTIAL LOCK CUT-OUT;
DIAGNOSTIC SUPPLY CONNECTOR; SPEEDO SENSOR; FUSE C5* (DRY CLUTCH TRANSMISSION)
Issue 3*
12 - 34
Section C
12 - 35
9803/8020
141 143
Section C
bb aa 142
12-34(CR51)
2 B A 1
cc hh
G F E D C
144
N M L K J H
U T S R P
dd gg
V
4 W 3
ee ff
146
145
148
147
Electrics
Wiring Diagrams
149
150
151
152 A309780
FUSE C4* (DRY CLUTCH TRANSMISSION) (CONT’D)
Issue 2*
12 - 35
Section C
55
9803/8020
12 - 35A
Section C
12-22
C4 12-36
12-15 C5
12-15
2000
139 SERIES
3000
SERIES
12-41
Electrics
Wiring Diagrams
12-35B(C28)
2000
2000 SERIES
SERIES 2000
SERIES
3000
SERIES
2000
SERIES
12-10
12-15
A353980
FUSE C4 - LIGHTS SWITCH ILLUMINATION; BLEEPER; INSTRUMENT CLUSTER; DIFFERENTIAL LOCK CUT-OUT;
DIAGNOSTIC SUPPLY CONNECTOR; SPEEDO SENSOR; FUSE C5 (WET CLUTCH TRANSMISSION)
Issue 1
12 - 35A
Section C
*
C34
C52 1 2
406 650D
9803/8020
(0.6) (0.6)
12 - 35B
141 1 2 650F 143

CES9
(0.6) CES9
Section C
C33
410
(0.6) 407 1 2 650C
(0.6) (0.6)
C8
bb aa 142
2 1
12 - 35A (CR51)
640H 408 2 1
B A C28 C3
(0.6) (0.6) cc hh
G F E D C A B
640C
CES7
144 (0.6)
N M L K J H
CES7 U T S R P
C20
dd gg 405 A B
W V (0.6)
4 3
640A 411 ee ff
2 1
(0.6) (0.6)
C14
C54 146 1 2
409A 640F
145 (0.6) (0.6)
2 1
1 2
148
C9
409B 1 2
409 640G
BMS CES7
(0.6) (0.6) (0.6)
650G
CES9
147 (0.6) 149
404 (0.6)
C49/C50 409C 1 2 640P
C31
(0.6) (0.6)
640L (0.6)
W 412 (1.4) C73
402 1 2 650E
403 (1.4) CES9 149A
IND (0.6) (0.6)
4
2 1
Electrics
C5
Wiring Diagrams
414 (1.4)
710P (1.4)
435 1
(0.6) 5 2
B 11 6 3
A
160E (1.4)
18 12 7 4
19 13 8 152
C55 25 20 14 9
150 32 26 21 15 10
33 27 22 16
39 34 28 23 17
40 35 29 24
41 36 30
45 42 37 31 C72
46 43 38 TH1
47 44 414 (0.6)
48
X W W X
K V K TH10
L J V J L
B H H B
M U U
C A C M
G G A 2 1
N F T T
D E F D N
S E
O S
P O 4 3
Q R R Q P
710P
(0.6) 151
160E
(0.6)
497 (1.4) 497
(0.6)
A353951
FUSE C4 (WET CLUTCH TRANSMISSION) (CONT’D)
Issue 2*
12 - 35B
Section C
631 (1.0)
153
* 1 2 3
4 5 6 7
9 10
12 - 36
8 514H (0.6)
9803/8020
515H (0.6)
Section C
CR102
C2
515C (0.6)
515E (0.6) 515 or (515B) 515 3 2 1

CANHS3
(0.6) (0.6)
515A 7 6 5 4
CANHS2
660Y (0.6) 3000 SERIES 11 10 9 8
CRES3
(0.6)
14 13 12
R1
189 155
513 (0.6)
514A
4 3 2 1 (0.6)
515D (1.0) 1 2 3 4
515D
(0.6)
SCRN 514
153 (0.6) 8 7 6 5 (0.6)
5 6 7 8 514 or (514B)
CANLS2
514D
(0.6)
(0.6) R1
A15
160F CR89
PISC4
(0.6)
515A
(0.6)
515B
(0.6)
514B
(0.6)
514A
(0.6)
12 11 10 9 8 7 6 5 4 3 2 1
514E
R1 CANLS3 24 23 22 21 20 19 18 17 16 15 14 13
(0.6)
514D
(1.0)
36 35 34 33 32 31 30 29 28 27 26 25
514C
660Y (1.0)
(0.6)
SCRN
515G
514G
CR49
(0.6)
(0.6)
CANHS1
CANLS1
(1.0) 1 2 3
160F (1.0)
4 5 6 7
D 560(1.0)
C E 9 10
8
B A F A16 12 11 10 9 8 7 6 5 4 3 2 1
561
515C
514C
J
(0.6)
(0.6)
CANHS1
CANLS1
(1.0) 24 23 22 21 20 19 18 17 16 15 14 13
Electrics
H
1 2
516 (0.6)
517 (0.6)
36 35 34 33 32 31 30 29 28 27 26 25 C4
A14 156
Wiring Diagrams
514F
515F
(0.6)
(0.6)
CR50
188 629
153 (1.0)
1 2 3
A17
12 11 10 9 8 7 6 5 4 3 2 1 4 5 6 7
12 - 39A 2 1 CR66 157
24 23 22 21 20 19 18 17 16 15 14 13 3 1 8 9 10
2
36 35 34 33 32 31 30 29 28 27 26 25
7 6 5 4
560(1.0)
10 9 8
CR83 2000 SERIES 2000 SERIES
626 (1.0) CR64

515
514
(1.0)
(1.0)
154
627 (1.0) R1
153
1 12 A309792
561 (1.0)
6 7
A18
FUSE C4 (CONT’D) - CANBUS; DIAGNOSTIC CONNECTOR
Issue 3
12 - 36
Section C
12 - 37
39
9803/8020
12-34(CR66)
Section C
C5 40
EDCIS
161C
(0.6)
Electrics
Wiring Diagrams
158
161D
660RB (0.6)
12-10 (0.6) 432
(0.6)
+8 1 +3 4 6
174 1 2
-7 2 5
660GJ
159 (0.6)
660GK
(0.6)
A309801
* FUSE C5 - FUEL FLOW SENSOR; GROUND SPEED RADAR SENSOR

WHEELSLIP ENABLE SWITCH (DRY CLUTCH TRANSMISSION)
Issue 4*
12 - 37
Section C
12-35A 39
9803/8020
12 - 37A
Section C
C5 40
Electrics
Wiring Diagrams
12-10
174
A353960
159
* FUSE C5 - FUEL FLOW SENSOR (DRY CLUTCH TRANSMISSION); GROUND SPEED RADAR SENSOR
WHEELSLIP ENABLE SWITCH (WET CLUTCH TRANSMISSION)
Issue 2*
12 - 37A
Section C
12 - 38
C7
9803/8020
Section C
C8
Electrics
98
Wiring Diagrams
C1
A309810
FUSE C7 - 13 PIN TRAILER SOCKET (IGNITION)

FUSE C8 - 13 PIN TRAILER SOCKET (BATTERY)
* (2000 SERIES TO S/N 738748, 3000 SERIES TO S/N 640777)
Issue 2*
12 - 38
Section C
APS2
RED BLACK
9803/8020
12 - 38A
355A 685A
(3.0) (3.0)
Section C
184
191
(1.0) APS3
15/30 31
82
20A 355B 685B
355 355 (3.0) (3.0)
+12V BAT C8 PFSC8
(3.0) CR94 183 (3.0)
5A A A
191 191 185
+12V IGN C7 B B
(1.0) (1.0)
C C
685 685
APS1 PSES
(3.0) (3.0)
APS4
(3.0)
355C
685C 3
(3.0) 2 1
(1.0)
685D
186
Electrics
(3.0)
355D
192
(3.0)
191A
Wiring Diagrams
(1.0) 4 6
191
(1.0)
8
2
187
355D
2
191A (3.0)
(1.0)
685D
4 6
(1.0)
191
192
(1.0) 8
(3.0)
APS5
A370430
FUSE C7 - AUXILIARY SOCKET (IGNITION SUPPLY)

FUSE C8 - AUXILIARY SOCKET (BATTERY SUPPLY)
(2000 SERIES FROM S/N 738749, 3000 SERIES FROM S/N 640778)
Issue 1
12 - 38A
Section C
CR100
+12V +12V
2
IGN BAT
36 24
12 A B 4 5 6
35 23 11 12 - 1 D C
34 22
10
12 - 39
8
9803/8020
33 21 9 883D +12V
32 20 (0.6) BAT
8
31 19
7
5A 192
30 18 6
A9
Section C
17 A12
29 5 A5
16 4 6
28 4 15K 154 665E
15 B A F1 TAES
27 3 (1.0) (0.6) (0.6)
26 14 C D
2 A6
25 13
1 20A (2.0)
265A (2.0) 8 20 (4) F2
2 A7
265B (2.0) 20B (2.0)
CR66 TAIS F3
5 A8
20C
F4
2 (1.0)
151
(2.0)
153 (1.0)
152
(2.0)
4 5 6 883 (1.4)
A13
8
190
4 6 449 465 (1.0) 200 200
12 - 2 A B
(1.0) A19 A20
153A 1 12
(1.0) 191
8 1 12 1 12
A10 2 A B 200
CR101 A11
6 7
A B C C B A
5B 5
6 7 6 7
448 (1.0) A18
448 (1.0)
665A (3) 562 (1.0)
665A (3) 665C (2.0) 563 (1.0)
665B (3)
665B (3) TAES 665D (2.0) 564 (1.0)
565 (1.0)
1808 (1.4)
BAT -VE CR47 A1 440 (1.4)

1806 (1.4)
12 - 1 +12V A4
IGN 015J (1.0) 1 2 150 (1.0)
1807
E2 566 (1.0)
1800 (1.4)
(1.4)
1803 (1.4)
1801 (1.4)
1802 (1.4)
1805 (1.4)
1804 (1.4)
440 A B FUSE 5A 567 (1.0)

B A
(0.6) 568 (1.0)
C D D C 260 (3) 1 A3 2 370B (3)
569
270 (3) E1 370A (1.0)
24 +12V +12V (3)
36 12 FUSE 25A
23
BAT BAT
35 11 5 A21 A J
34 22 B K H
10 M
21 C L G
33 9 193
Electrics
20 D F
32 8 ABS11 ABS10 196 195 E
31 19 ABS8 ABS9
7
18 1 2 1 2
30 6
561(1.0)
560(1.0)
194 1 2 1 2
Wiring Diagrams
17
29 5
16
28 4 (566) BLACK
CR65 15
27 3 (1.0)
26 14 (567)
2 BROWN
BROWN
(1.0)
BLACK
(1.0)
13 (1.0)
BLACK
(1.0)
BROWN
(1.0)
BLACK
(1.0)
BROWN
(1.0)
25 1
(569)
J A
H 1 1 H H K B
M
(563)
(562)
G
(564)
(565)
A A L C
G M G
(568)
M J F D
J E
N B N
1804 (1.4)
B F
F AP1
L K K L 1803
C C E (1.4)
E
D D A17
2 2
1807 (1.4)
1806 (1.4)
1808 (1.4)
1 ABS2 1805
1801
2
(1.4)
A2 2 1 1 (1.4) 1
605 (1.4)
7 3 2 3 2 3
1
615 (6.0)
1802 (1.4)
1800 (1.4)
6 4 2 3
AP2 AP4
5
AP3
12 - 39 197 199
12 - 36 198
370B (3)
370 (6)
ABSSS
370A (3)
440 (1.4)
150 (1.4)
FUSES E1, E2 - TRAILER ABS

* FUSES F1, F2, F3, F4 - TRACTOR ABS
Issue 3*
12 - 39
Section C
12 - 40
9803/8020
FLOW DIVIDER FLOW DIVIDER WARNING
Section C
12 11 10 9 8 7 6 5 4 3 2 1
WARNING LAMP LAMP FEED
24 23 22 21 20 19 18 17 16 15 14 13
205 203
36 35 34 33 32 31 30 29 28 27 26 25
827A 827A
(0.5) A A (0.6)
CR66
CR93 FD6
INST CLUSTER 2 RED
206 FD2
116A (0.6) FD4
115EB 116 FLOW
1 LITTLE 2
(0.6) FUSE DIVIDER
115E (0.6) -7 +8
12-6
115E FDSS VALVE
(1.4) (1.4) 1
IN LINE 163
FUSE E3
CR52 FD5 +3
202
SUSPENSION SEAT 2 2 B A
POWER 2
/ FLOW DIVIDER 12 204 IN
(SEE SHEET 6) 1 1
827
Electrics
750C (0.6) 2 (0.6)

750
Wiring Diagrams
750 750B (0.6)

(1.5) (1.4) FDES
FD3 162
FLOW DIVIDER
SWITCH
115EA (1.4)
2
FD1
1 SUSPENSION
SEAT
161 SHEET 6A
750A (1.4) 481/11375
FUSE E3 - FLOW DIVIDER
Issue 2
12 - 40
Section C
166 167
164
12 - 41
9803/8020
165
Section C
168
169
12-15
170 12-15
58
E4
Electrics
Wiring Diagrams
12-26
173 12-1
156 54
12-34
12-34
153
12-13
153
12-36 12-36
12-36 A309840
12-34
FUSE E4 - FOUR WHEEL STEER (4WS) CIRCUIT
Issue 1
12 - 41
Section C
12 - 42
9803/8020
Section C
171
8
Electrics
7 9
1
6 10
4 2 98
Wiring Diagrams
5 11
3
13 12
172
A309851
Connector C1 (98) Pin Functions

1 LH Direction Indicator (see page 12 - 19) 5 RH Side Light (see page 12 - 26) 9 Battery Feed (see page 12 - 38)
TRAILER SOCKETS 2 Rear Fog Light (see page 12 - 24) 6 Brake Lights (see page 12 - 4) 10 IGN Feed (see page 12 - 38)
3 Earth for pins 1 to 8 7 LH Side Light (see page 12 - 25) 11/12/14 Spare
4 RH Direction Indicator (see page 12 - 19) 8 Rev. Lights (see page 12 - 32) 13 Earth for Pins 9 to 12 (see page 12 - 38)
Issue 2
12 - 42
Section C
Wire Numbers
UNFUSED IGN FEEDS 116 0.6 Flow divider in-line fuse to flow divider 140D 0.6 Solenoid feed splice to rear PTO brake
13 - 1
switch. solenoid.
9803/8020
No. Size Description 116A 0.6 Flow divider switch to flow divider switch 140E 0.6 Solenoid feed splice to rear diff. lock
0 3.0 Ignition switch to fusebox - fuse C6a. illumination. solenoid.
4 4.0 Ignition switch (starter control) to ignition 120 2.0 Fuse A4 to panel IGN splice A4. 140F 0.6 Solenoid feed splice to 2 wheel drive
Section C
switch (Thermostart) 120A 2.0 Panel IGN splice A4 to column switch. solenoid.
5 4.0 Ignition switch to fusebox - fuse C3a. 120B 1.0 Panel IGN splice A4 to front intermittent wipe 141 0.6 Fuse A8 to rear PTO drive cut-out harness
10 6.0 Ignition relay to IGN splice 1 relay. connector or relay.
10A 1.4 IGN splice 1 to fusebox - fuse A2a. 120C 1.0 Panel IGN splice A4 to front wiper motor. 145 1.4 Fuse C2 to hazard switch.
10B 2.0 IGN splice 1 to fusebox - fuse A4a. * 125 2.0 Minder relay or interconnector to powershift 150 1.0 Trailer ABS fuse E2 to ABS trailer socket.
10C 2.0 IGN splice 1 to fusebox - fuse A3a. supply splice. 155 1.4 Fuse C1 to reverse lights relay.
* 10D 1.4 IGN splice 1 to fusebox - fuse C1a (wet 125A 1.0 Powershift supply splice to control * 155A 0.6 Reverse lights relay coil link (wet clutch
clutch machines only) unit (ECU). machines only).
10E 1.4 IGN splice 1 to fusebox - fuse C7a. 125B 1.0 Powershift supply splice to control unit 160 1.0 Fuse C4 to cab roof ignition splice C4.
10F 1.4 IGN splice 1 to fusebox - fuse C2a. (ECU). 160A 1.0 Cab roof ignition splice C4 to panel ignition
10G 4.0 IGN splice 1 to fusebox - fuse A9a. 125C 1.0 Powershift supply splice to control unit splice C4.
10H 1.0 IGN splice 1 to fusebox - fuse B6a (ECU). 160B 0.6 Panel IGN splice C4 to instrument cluster.
14 0.6 Ignition switch to ignition relay coil. 126 0.6 Control unit (ECU) to power range solenoid 160C 0.6 Panel IGN splice C4 to lights switch illum.
15 4.0 Ignition switch to IGN splice 2. feed splice. 160E 0.6 Panel IGN splice C4 to speed sender.
15A 0.6 IGN splice 2 to fusebox - fuse A1a. 126A 0.6 Power range solenoid feed splice to neutral 160F 0.6 Panel IGN splice C4 to diagnostics
15B 1.4 IGN splice 2 to fusebox - fuse C9a. solenoid connector (reverse). connector.
15C 0.6 IGN splice 2 to fusebox - fuse A6a. 126B 0.6 Power range solenoid feed splice to neutral 160G 0.6 Panel IGN splice C4 to diff. lock cut-
15D 2.0 IGN splice 2 to fusebox - fuse A8a. solenoid connector (low). out switch.
15E 1.0 IGN splice 2 to fusebox - fuse C4a. 126C 0.6 Power range solenoid feed splice to neutral 160H 0.6 Panel IGN splice C4 to fusebox - fuse
15F 2.0 IGN splice 2 to fusebox - fuse A7a. solenoid connector (medium). C5a.
15G 1.0 IGN splice 2 to fusebox - fuse A5a. 126D 0.6 Power range solenoid feed splice to neutral 160J 0.6 Panel IGN splice C4 to clutch
15H 1.0 IGN splice 2 to fuse E4 (4WS) solenoid connector (high). warning/selectronic bleeper.
15J 1.0 Ignition splice 2 to fuse E2 126E 0.6 Power range solenoid feed splice to select 161 0.6 Fuse C5 to option chassis supply splice
Electrics
(ABS/trailer brake) solenoid connector (reverse). (dry clutch transmission).

15K 1.0 IGN splice 2 to tractor ABS supply connector 126F 0.6 Power range solenoid feed splice to select 161 Fuse C5 to radar signal splice (wet clutch
solenoid connector (low). transmission).
FUSED IGN FEEDS
126G 0.6 Power range solenoid feed splice to select * 161A 0.6 Option chassis supply splice to radar speed
No. Size Description
solenoid connector (medium). sensor (dry clutch machines only).
105 0.6 Fuse A1 to clutch down switch.
126H 0.6 Power range solenoid feed splice to select * 161B 0.6 Option chassis supply splice to fuel flow
110 1.4 Fuse A2 to brake lights relay.
solenoid connector (high). meter (dry clutch machines only).
111 0.6 Brake lights relay to brake lights switch.
* 127 2.0 Fuse A7 to minder ignition splice or 161C 0.6 EDC IGN splice to EDC bulkhead connector.
115 2.0 Fuse A3 to cab roof IGN splice.
interconnect. 161D 0.6 Wheel slip enable switch to EDC ignition
115A 1.0 Cab roof IGN splice to rear wash/wipe
* 127A 2.0 Minder ignition splice to minder relay. splice.
switch.
* 127B 0.6 Minder ignition splice to minder relay coil. 165 1.0 Fuse B6 to radio/cassette.
115B 1.0 Cab roof IGN splice to rear wiper motor.
* 127C 0.6 Minder ignlition splice to minder ECU. 166 0.6 Trailer brake fuse 4 to handbrake warning
115C 1.0 Cab roof IGN splice to rear intermittent wipe
130 1.0 Fuse A5 to ESOS. light (dry clutch transmission).
relay
130 Fuse A5 to cold advance switch (2000 Series) 170 4.0 Fuse A9 to blower switch (2000 series)
* 115DA - Heated front screen.
130A 1.0 ESOS to cold advance temperature switch. Fuse A9 to ACU (3000 series)
* 115DB - Heated front screen
135 0.6 Fuse A6 to electronic control unit (electronic 171 2.0 Fuse A9 to compressor clutch relay.
115E 1.4 Cab roof IGN splice to suspension seat or
draft control). 175 2.0 Fuse C3 to Thermostart (except 3185)
flow divider supply splice.
140 2.0 Fuse A8 to solenoid feed splice. Fuse C3 to heater relay 1coil (3185 only)
115EA 1.4 Flow divider supply splice to suspension
140A 0.6 Solenoid feed splice to front PTO drive 176 2.0 Fuse C3 to Thermostart 2 (2150)
seat.
solenoid. 2.0 Fuse C3 to heater relay 2 coil (3185 only)
115EB 0.6 Flow divider supply splice to flow divider
140B 0.6 Solenoid feed splice to rear PTO drive 180 3.0 Fuse C6 to start relay 1.
in-line fuse.
solenoid. 181 3.0 Start Relay 1 to start relay 2.
115F 0.6 Cab roof IGN splice to 2WS dump relay coil.
140C 0.6 Solenoid feed splice to front PTO brake 182 3.0 Start relay 2 to starter solenoid.
Issue 7*
13 - 1
Section C
solenoid. 185 1.0 Fuse (4WS) to 4WS IGN splice.

Wire Numbers
13 - 2
FUSED IGN FEEDS (continued) 283 15 Starter motor positive to Megafuse (3185 355B 3.0 PFSC8 to 3 pin power socket.
9803/8020
Elite heater relay 1 only) 355C 3.0 PFSC8 to convenience socket.
No. Size Description 284 15 Starter motor positive to Megafuse (3185 355D 3.0 PFSC8 to convenience socket relay.
Section C
* 185A 0.6 4WS IGN splice to 4WS control panel. Elite heater relay 2 only) 360 6.0 Maxifuse to panel main lights splice.
* 185B 0.6 4WS IGN splice to 4WS ‘ram locked’ switch. * 290 - Heated front screen. 360A 3.0 Panel main lights splice to lights switch
* 185C 0.6 4WS IGN splice to 4WS jack socket. * 291 - Heated front screen. (headlights).
* 190 1.4 Fuse C7 to trailer socket (machines with 13- 360B 0.6 Panel main lights splice to fuse D6 (3000
pin trailer socket only). FUSED FEEDS DIRECT FROM BATTERY series).
* 191 1.0 Fuse C7 to 3 pin power socket or 360C 2.0 Panel main lights splice to lights switch
convenience socket relay coil. No. Size Description (headlights).
* 191A 1.0 Convenience socket relay coil to 3 pin 300 0.6 Fuse B9 to permanent feed splice B9. 360D 1.4 Panel main lights splice to rear fog lights
power socket. 300A 0.6 Permanent feed splice B9 to electronic relay.
* 192 3.0 Convenience socket relay to convenience control unit (EDC). 362 0.6 Fuse D6 to auxiliary lights switch (3000
socket. 300B 0.6 Permanent feed splice B9 to instrument series).
195 1.4 Fuse C9 to C9 chassis splice. cluster. 365 6.0 Tractor ABS ignition relay to tractor ABS
195A 1.4 C9 chassis splice to air drier. 305 3.0 Fuse B1 to cab roof permanent feed splice ignition splice (dry clutch machines).
195B 0.6 C9 chassis splice to 6 speed neutral switch. 305A 0.6 Cab roof permanent feed splice to 370 6.0 ABS supply splice to ABS trailer socket.
radio/cassette. 370A 2.5 Trailer ABS fuse E1 to ABS supply splice.
UNFUSED FEEDS DIRECT FROM BATTERY 305B 0.6 Cab roof permanent feed splice to LH 370B 2.5 Trailer ABS fuse E1 to ABS supply splice.
interior light. 380 6.0 Maxifuse to ESOS relay (3185 only)
No. Size Description 305C 1.0 Cab roof permanent feed splice to beacon 383 15 Megafuse to heater relay 1 (3185 only)
200A 4.0 Battery positive to ignition switch. switch. 384 15 Megafuse to heater relay 2 (3185 only)
200B 4.0 Battery positive to ignition switch. 305E 0.6 Cab roof permanent feed splice to AG panel * 390 - Heated front screen
201 6.0 Battery positive to ignition relay. illumination. * 391 - Heated front screen
202 6.0 Battery positive to worklights relay. 310 2.0 Fuse B2 to hazard switch.
203 4.0 Worklights relay to fusebox - fuse B3a. 315 4.0 Fuse B3 to front work lights supply splice. INSTRUMENTATION SIGNAL WIRES
204 3.0 Worklights relay to fusebox - fuse B4a. 315A 1.4 Front worklights supply splice to front
Electrics
210 4.0 Battery positive to battery splice 1. worklights switch. No. Size Description
210B 2.0 Battery splice 1 to fusebox - fuse B2a. 315B 1.4 Front worklights supply splice to front 400 0.6 Park brake warning switch to 2WD dump
210D 3.0 Battery splice 1 to fusebox - fuse B7a. worklights switch. splice.
210E 1.4 Battery splice 1 to fusebox - fuse B8a. 315C 0.6 Front worklights supply splice to front * 400A 0.6 2WD dump splice to instrument cluster (park
220 6.0 Alternator to starter motor positive. worklights switch illumination. brake indicator) (dry clutch machines only).
230 6.0 Alternator to starter motor positive. 315D 1.4 Front worklights supply splice to front ‘A’ 400B 0.6 2WD dump splice to 2WD dump relay coil.
240 4.0 Battery positive to battery splice 2. post worklights relay. 400C 0.6 2WD dump splice to control unit (ECU).
240A 1.0 Battery splice 2 to fusebox - fuse B1a. 320 3.0 Fuse B4 to rear work lights supply splice. 401 0.6 Control unit (ECU) link (clutch lube override).
240B 1.4 Battery splice 2 to fusebox - fuse B5a. 320A 1.4 Rear worklights supply splice to rear 402 0.6 Instrument cluster to engine oil pressure
* 240C 1.0 Battery splice 2 to fusebox - fuse B6a (not worklights switch. switch.
fitted to machines with ignition feed to 320B 1.4 Rear worklights supply splice to rear 403 0.6 Alternator signal splice to alternator.
radio). worklights switch. 403A 0.6 Instrument cluster to alternator signal splice.
240D 0.6 Battery splice 2 to fusebox - fuse B9a. 320C 0.6 Rear worklights supply splice to rear 403B 0.6 Alternator signal splice to electronic control
240E 2.0 Battery splice 2 to fusebox - fuse C8a. worklights switch illumination. unit (EDC).
250 6.0 Battery positive to Maxifuse (main lights). 325 1.4 Fuse B5 to column switch (headlights flash). 404 0.6 Instrument cluster to air filter vacuum switch.
260 3.0 Battery positive to fuse E1 (ABS trailer 330 3.0 Fuse B7 to auxiliary jack plug socket. 405 0.6 Instrument cluster to transmission oil filter switch.
brakes). 335 1.4 Fuse B8 to cigar lighter. 406 0.6 Instrument cluster to air tank 2 pressure switch.
265A 3.0 Battery positive to tractor ABS ignition relay. * 345 1.0 Fuse B6 to radio/cassette (not fitted to 407 0.6 Instrument cluster to air tank 1 pressure switch.
265B 3.0 Battery positive to tractor ABS ignition relay. machines with ignition feed to radio). 408 0.6 Instrument cluster to air tank 3 pressure switch.
270 3.0 Battery positive to fuse E1 (ABS trailer * 350 2.0 Fuse C8 to trailer socket (machines with 13- 409 0.6 Instrument cluster to brake malfunction splice.
brakes). pin trailer socket only). 409A 0.6 Brake malfunction splice to front brake reservoir.
280 6.0 Starter motor positive to Maxifuse (3185 355 3.0 Fuse C8 to permanent feed slice C8. 409B 0.6 Brake malfunction splice to rear brake
ESOS only) 355A 3.0 PFSC8 to +VE Terminal post. reservoir.
Issue 5*
13 - 2
Section C
Wire Numbers
Note: Where the term ‘CAN’ is used in the wire number list, this is an abbreviation for CAN-BUS (see Technical Data).
13 - 3
INSTRUMENTATION SIGNAL WIRES (continued) 432 0.6 Control panel (EDC) to wheel slip enable 453 0.6 4WS RH steer valve to 4WS control panel.
9803/8020
switch. 454 0.6 4WS LH steer valve to 4WS control panel.
No. Size Description 433 0.6 Control panel (EDC) to electronic control 455 0.6 4WS LH steer valve to 4WS control panel.
Section C
* 410 0.6 Instrument cluster to water temperature unit. 456 0.6 4WS lock valve to 4WS control panel.
sensor. 434 0.6 Control unit (ECU) to instrument cluster 457 0.6 Front potentiometer (4WS) to 4WS control
* 411 0.6 Instrument cluster to fuel level sender. (transmission oil pressure) panel.
* 412 0.6 Alternator to alternator ‘W’ splice. * 435 0.6 Transmission oil pressure switch to 458 0.6 Front potentiometer (4WS) to 4WS control
* 412A 0.6 Alternator ‘W’ splice to instrument cluster. transmission oil pressure splice (dry clutch panel.
* 412B 0.6 Alternator ‘W’ splice to control unit (ECU). machines only). 459 0.6 Front potentiometer (4WS) to 4WS control
* 413 0.6 Control unit (ECU) to accelerator pedal * 435 0.6 Transmission oil pressure switch to panel.
switch. powershift ECU (wet clutch machines only) 460 0.6 Rear potentiometer (4WS) to 4WS control
* 414 0.6 Speed signal pick-up to speed signal * 435A 0.6 Transmission oil pressure splice to control panel.
splice. unit (ECU) (dry clutch machines only). 461 0.6 Rear potentiometer (4WS) to 4WS control
* 414A 0.6 Speed signal splice to instrument cluster. * 435B 0.6 Transmission oil pressure splice to control panel.
* 414B 0.6 Speed signal splice to EDC ECU. unit (ECU) (dry clutch machines only). 462 0.6 Rear potentiometer (4WS) to 4WS control
* 415 0.6 Instrument cluster to area cut-out selection 436 0.6 Low/rev ram connector to control unit panel.
switch. (ECU) (reverse selected ram switch). 463 0.6 4WS diff. lock cut-out relay to 4WS control
* 416 0.6 Area differential lock cut-out splice to 437 0.6 Low/rev ram connector to control unit panel.
instrument cluster. (ECU) (low selected ram switch). 464 0.6 4WS jack socket to 4WS control panel.
* 416A 0.6 Differential lock cut-out relay to area 438 0.6 Med/high ram connector to control unit 470 0.6 USSS to gear knob connector (split up).
differential lock cut-out splice. (ECU) (medium selected ram switch). 470A 0.6 USSS to power shift ECU (split up).
* 416B 0.6 Area cut-out switch to area differential lock 439 0.6 Med/high ram connector to control unit 470B 0.6 USSS to duplicate autoshift button (split
cut-out splice. (ECU) (high selected ram switch). up).
417 0.6 Single trailer turn relay to instrument cluster 440 0.6 Instrument cluster to ABS trailer socket. 471 0.6 DSSS to gear knob connector (split down).
(1st trailer turn). 441 06 Low/rev ram connector to control unit 471A 0.6 DSSS to powershift ECU (split down).
418 0.6 Fuse D1 to instrument cluster (main beam (ECU) (low neutral ram switch). 471B 0.6 DSSS to duplicate autoshift button (split
warning). 442 0.6 Med/high ram connector to control unit down).
Electrics
419 0.6 Second trailer turn relay to instrument (ECU) (medium neutral ram switch). 472 0.6 ASSS to gear knob connector (split auto).
cluster (2nd trailer turn). 443 0.6 Med/high ram connector to control unit 472A 0.6 ASSS to powershift ECU (auto split).
420 0.6 Instrument cluster to 2WD/differential lock (ECU) (high neutral ram switch). 472B 0.6 ASSS to duplicate autoshift button
switch (4WD indicator). 444 0.6 Instrument cluster to 540 PTO range (autoshift).
421 0.6 Second trailer turn relay to single trailer turn switch. * 473 0.6 Powershift ECU to instrument cluster
relay. 445 0.6 Instrument cluster to 1000 PTO range (‘Auto’ indicator) (dry clutch machines only).
422 0.6 Area cut-out selection switch to jack plug switch. * 474 0.6 Powershift ECU to instrument cluster
socket. 446 0.6 Low/rev ram connector to control unit (‘Hare’ indicator) (dry clutch machines only).
423 0.6 Buzzer to instrument cluster. (ECU ) (reverse neutral ram switch). * 475 0.6 Powershift ECU to instrument cluster
424 0.6 Position sensor to electronic draft control * 447 0.6 Transmission oil pressure switch to control (‘Tortoise’ indicator) (dry clutch machines
unit. unit (ECU) (dry clutch machines only). only).
425 0.6 LH draft pin to electronic draft control unit. 448 0.6 Trailer handbrake warning light to oil * 476 0.6 Powershift ECU to instrument cluster
426 0.6 RH draft pin to electronic draft control unit pressure switch (dry clutch transmission). (‘Snail’ indicator) (dry clutch machines
427 0.6 Control panel (EDC) to electronic draft 448 Tractor ABS warning light relay to only).
control unit. instrument cluster (wet clutch 477 0.6 Range change column switch to power
428 0.6 Control panel (EDC) to electronic draft transmission). range low splice.
control unit. 449 0.6 Trailer brake relay to air pressure switch 477A 0.6 Power range low splice to control unit
429 0.6 Control panel (EDC) to electronic control (dry clutch transmission). (ECU).
unit. 450 0.6 Clutch warning/Selectronic bleeper to 477B 0.6 Power range low splice to instrument
430 0.6 Control panel (EDC) to electronic control control unit (ECU). cluster.
unit. 451 0.6 4WS ram locked switch to 4WS control 478 0.6 Range change column switch to power
431 0.6 Control panel (EDC) to electronic control panel. range medium splice.
unit. 452 0.6 4WS RH steer valve to 4WS control panel.
Issue 6*
13 - 3
Section C
Wire Numbers
13 - 4
INSTRUMENTATION SIGNAL WIRES (continued) 491 0.6 Control unit (ECU) to select solenoid 514E 0.6 CAN low splice 3 to CAN low splice 1.
9803/8020
connector (reverse). 514F 0.6 CAN low splice 1 to instrument cluster.
No. Size Description 492 0.6 Control unit (ECU) to select solenoid 514G 0.6 CAN low splice 1 to resistor (instrument
Section C
* 478A 0.6 Power range medium splice to control unit connector (low). cluster end).
(ECU). 493 0.6 Control unit (ECU) to select solenoid * 514H 0.6 CAN low splice 3 to Minder interconnect or
* 478B 0.6 Power range medium splice to instrument connector (medium). Minder ECU
cluster. 494 0.6 Control unit (ECU) to select solenoid 515 0.6 Control unit (ECU) to CAN high splice 2.
* 479 0.6 Range change column switch or column connector (high). 515A 0.6 CAN high splice 2 to resistor (control unit
switch splice (less Hi range) to power * 495 0.6 Powershift ECU to clutch up switch (dry ECU end).
range high splice. clutch machines only). 515B 0.6 CAN high splice 2 to CAN high splice 3.
* 479A 0.6 Power range high splice to control unit 496 0.6 4WS control panel to instrument cluster 515C 0.6 CAN high splice 3 to 4WS control panel
(ECU). (4WS). (4WS).
* 479B 0.6 Power range high splice to instrument 497 0.6 Speed sensor to instrument cluster (+12v 515D 0.6 CAN high splice 3 to diagnostic connector.
cluster. presence). 515E 0.6 CAN high splice 3 to CAN high splice 1.
* 479C 0.6 Column switch splice to column switch * 498 0.6 Column switch button to instrument cluster 515F 0.6 CAN high splice 1 to instrument cluster.
(less HI range). (wet clutch machines only). 515G 0.6 CAN high splice 1 to resistor (instrument
* 479D 0.6 Column switch splice to column switch * 499 0.6 Column switch button to instrument cluster cluster end).
(less HI range). (wet clutch machines only). * 515H 0.6 CAN high splice 3 to Minder interconnect or
* 480 0.6 Range change column switch to power 500 0.6 Radar speed sensor to radar signal splice. Minder ECU.
range reverse splice. 500A 0.6 Radar signal splice to instrument cluster. 516 0.6 Instrument cluster to diagnostics connector
* 480A 0.6 Power range reverse splice to control unit 500B 0.6 Radar signal splice to EDC ECU. (serial TX).
(ECU). 501 0.6 Radar speed sensor to instrument cluster 517 0.6 Instrument cluster to diagnostics connector
* 480B 0.6 Power range reverse splice to instrument (presence signal). (serial RX).
cluster. 502 0.6 Instrument cluster to fuel return meter. 518 0.6 Instrument cluster to EDC ECU (slip -).
* 481 0.6 Powershift ECU to instrument cluster (‘R’ 503 0.6 ECU to raise solenoid (EDC). * 520 - Heated front screen.
display) (dry clutch machines only). 503A 0.6 ECU to control panel (EDC). * 521 0.6 Powershift ECU to clutch pedal
* 482 0.6 Powershift ECU to instrument cluster (‘L’ 504 0.6 ECU to lower solenoid (EDC). potentiometer (wet clutch machines only).
Electrics
display) (dry clutch machines only). 504A 0.6 ECU to control panel (EDC). * 522 0.6 Powershift ECU to clutch pedal
* 483 0.6 Powershift ECU to instrument cluster (‘M’ 505 0.6 Instrument cluster to EDC ECU (slip +). potentiometer (wet clutch machines only).
display) (dry clutch machines only). 506 0.6 Control panel to ECU (EDC). * 523 0.6 Powershift ECU to clutch pedal
* 484 0.6 Powershift ECU to instrument cluster (‘H’ 507 0.6 Control panel to ECU (EDC). potentiometer (wet clutch machines only).
display) (dry clutch machines only). 508 0.6 EDC ECU to EDC control panel. * 524 0.6 Trans oil temp splice 2 to trans oil temp
485 0.6 Control unit (ECU) to instrument cluster (3 509 0.6 EDC ECU to EDC lower signal splice. splice 1 (wet clutch machines only).
kph signal). 509A 0.6 Lower signal splice to 4WS control panel. * 524A 0.6 Trans oil temp splice 1 to Powershift ECU
486 0.6 Control unit (ECU) to instrument cluster (1 509B 0.6 Lower signal splice to instrument cluster. (wet clutch machines only).
kph signal splice) (2000 series) 510 0.6 Instrument cluster to EDC ECU (slip * 524B 0.6 Trans oil temp splice 1 to Powershift ECU
Control unit (ECU) to instrument cluster (1 setpoint). (wet clutch machines only).
kph signal) (3000 series) 511 0.6 Instrument cluster to EDC earth splice * 524C 0.6 Trans oil temp splice 2 to oil temp sensor 1
486A 0.6 1 kph signal splice to instrument cluster (1 (option present). (wet clutch machines only).
kph signal) (2000 series) * 512 0.6 Instrument cluster to fuel flow meter (dry * 524D 0.6 Trans oil temp splice 2 to oil temp sensor 2
486B 0.6 1 kph signal splice to 4WS control panel (1 clutch machines only). (wet clutch machines only).
kph signal) (2000 series) 513 0.6 Instrument cluster to diagnostics connector * 525 0.6 Powershift ECU to oil temp sensor 1 (wet
487 0.6 Control unit (ECU) to neutral solenoid (program). clutch machines only).
connector (reverse). 514 0.6 Control unit (ECU) to CAN low splice 2. * 526 0.6 Powershift ECU to oil temp sensor 2 (wet
488 0.6 Control unit (ECU) to neutral solenoid 514A 0.6 CAN low splice 2 to resistor (control unit clutch machines only).
connector (low). (ECU) end). * 530 1.0 Powershift ECU to splitter dump inhibit
489 0.6 Control unit (ECU) to neutral solenoid 514B 0.6 CAN low splice 2 to CAN low splice 3. switch (clutch fully down checking lamp†).
connector (medium). 514C 0.6 CAN low splice 3 to 4WS control panel * 531 1.0 Powershift ECU to splitter dump inhibit
490 0.6 Control unit (ECU) to neutral solenoid (4WS). splice (calibration link †).
connector (high). 514D 0.6 CAN low splice 3 to diagnostic connector.
Issue 5*
13 - 4
Section C
Wire Numbers
* INSTRUMENTATION SIGNAL WIRES (continued) * 610 4.0 Battery negative to cab roof earth splice 2. 630 1.0 Starter motor negative to chassis earth
13 - 5
* 610A 1.0 Cab roof earth splice 2 to rear RH outer splice 2.
9803/8020
* No. Size Description work light. 630A 0.6 Chassis earth splice 2 to low/rev ram (rev
* 532 1.0 Powershift ECU to splitter dump inhibit * 610B 1.0 Cab roof earth splice 2 to rear RH inner neutral switch).
Section C
switch (clutch fully down †). work light. 630B 0.6 Chassis earth splice 2 to low/rev ram (rev
* 533 1.0 Powershift ECU to splitter dump inhibit * 610C 1.0 Cab roof earth splice 2 to rear LH outer engaged switch).
splice (clutch fully down †). work light. 630C 0.6 Chassis earth splice 2 to low/rev ram (low
* 562 1.0 Tractor ABS ECU x2 pin 5 to front RH speed * 610D 1.0 Cab roof earth splice 2 to rear LH inner neutral switch).
sensor 1 (black) work light. 630D 0.6 Chassis earth splice 2 to low/rev ram (low
* 563 1.0 Tractor ABS ECU x2 pin 6 to front RH speed * 610E 1.0 Cab roof earth splice 2 to rear wiper motor. engaged switch).
sensor 2 (brown). * 610F 1.0 Cab roof earth splice 2 to beacon socket. 630E 0.6 Chassis earth splice 2 to high/med ram (med
* 564 1.0 Tractor ABS ECU x2 pin 7 to front LH speed Cab roof earth splice 2 to RH number plate neutral switch).
* 610G 0.6
sensor 1 (black). light (2000 series). 630F 0.6 Chassis earth splice 2 to high/med ram (med
* 565 1.0 Tractor ABS ECU x2 pin 8 to front LH speed Cab roof earth splice 2 to marker lights engaged switch).
sensor 2 (brown). earth splice (3000 series) (dry clutch 630G 0.6 Chassis earth splice 2 to high/med ram (high
* 566 1.0 Tractor ABS ECU x3 pin 1 to front LH speed transmission) neutral switch).
sensor 1 (black). * 610H 0.6 Cab roof earth splice 2 to LH number plate 630H 0.6 Chassis earth splice 2 to high/med ram (high
* 567 1.0 Tractor ABS ECU x3 pin 2 to front LH speed light. engaged switch).
sensor 2 (brown). 610J 0.6 Marker lights earth splice to RH number * 631 1.0 CAN shield to Minder interconnect.
* 568 1.0 Tractor ABS ECU x3 pin 3 to front RH speed plate light (3000 series) (dry clutch 640 3.0 Starter motor negative to chassis earth
sensor 1 (black). transmission). splice 7.
* 569 1.0 Tractor ABS ECU x 3 pin 4 to front RH 610K 0.6 Marker lights earth splice to LH number 640A 0.6 Chassis earth splice 7 to fuel level sender.
speed sensor 2 (brown). plate light (3000 series) (dry clutch 640B 0.6 Chassis earth splice 7 to gear knob
* 595 0.6 Minder relay coil to Minder ECU. transmission). connector.
610L 0.6 Marker lights earth splice to RH number 640C 0.6 Chassis earth splice 7 to transmission oil
* EARTHS plate light (3000 series). filter switch.
615 6.0 ABS trailer socket to starter motor negative * 640D 06 Chassis earth splice 7 to splitter high
No. Size Description (ABS). solenoid (dry clutch machines only).
Electrics
* 600 6.0 Battery negative to cab roof earth splice 1. 620 4.0 Starter motor negative to chassis earth * 640E 06 Chassis earth splice 7 to splitter medium
* 600A 1.0 Cab roof earth splice 1 to front RH outer splice 1. solenoid (dry clutch machines only).
work light. 620A 2.0 Chassis earth splice 1 to trailer socket. 640F 0.6 Chassis earth splice 7 to front brake
* 600B 1.0 Cab roof earth splice 1 to front RH inner 620B 1.4 Chassis earth splice 1 to LH rear lights reservoir.
work light. cluster. 640G 0.6 Chassis earth splice 7 to rear brake
* 600C 1.0 Cab roof earth splice 1 to front LH inner 620C 1.4 Chassis earth splice 1 to RH rear lights reservoir.
work light. cluster. 640H 0.6 Chassis earth splice 7 to air tank 3 pressure
* 600D 1.0 Cab roof earth splice 1 to front LH outer 620F 2.0 Chassis earth splice 1 to trailer socket switch.
work light. (13-pin). * 640J 0.6 Chassis earth splice 7 to splitter low
* 600E 1.4 Cab roof earth splice 1 to radio/cassette. 625 1.0 Control unit (ECU) to RF ground. solenoid (dry clutch machines only).
* 600F 0.6 Cab roof earth splice 1 to LH interior light. 626 1.0 Instrument cluster to RF ground. 640K 1.4 Chassis earth splice 7 to air drier.
* 600G 0.6 Cab roof earth splice1 to AG panel illum 627 1.0 CAN shield to RF ground (instrument cluster 640L 0.6 Chassis earth splice 7 to transmission oil
light. end). pressure switch.
* 600J 0.6 Cab roof earth splice 1 to LH indicator/side 628 1.0 CAN shield (4WS harness connector pair) to 640M 0.6 Chassis earth splice 7 to wet clutch lube
lamp (2000 series) CAN shield splice. solenoid.
* 600K 0.6 Cab roof earth splice 1 to RH indicator/side 628A 1.0 CAN shield splice to diagnostic connector 640N 0.6 Chassis earth splice 7 to wet clutch brake
lamp (2000 series) pair shield. solenoid.
* 600L 1.0 Cab roof earth splice 1 to front RH ‘A’ post 628B 1.0 CAN shield splice to instrument cluster pair 650 1.4 Starter motor negative to chassis earth
worklight (2000 series) shield. splice 9.
* 600M 1.0 Cab roof earth splice 1 to front LH ‘A’ post 628C 1.0 CAN shield to control unit (ECU) pair shield. 650A 1.0 Chassis earth splice 9 to front wiper motor.
worklight (2000 series) * 628D 1.0 CAN shield splice to minder interconnect 650B 1.0 Chassis earth splice 9 to ESOS.
* 605 1.0 ABS trailer socket to starter motor negative pair shield. 650C 0.6 Chassis earth splice 9 to air tank 1.
(ABS). 629 1.0 CAN shield to control unit (ECU). 650D 0.6 Chassis earth splice 9 to air tank 2.
Issue 6*
13 - 5
Section C
Wire Numbers
EARTHS (continued) * 660L 0.6 Cab roof earth splice 3 to splitter dump 710 3.0 Battery negative to panel earth splice 1.
13 - 6
relay (wet clutch machines only). 710A 0.6 Panel earth splice 1 to single trailer turn
9803/8020
No. Size Description * 660M 1.0 Cab roof earth splice 3 to 4WS earth splice. relay.
* 650E 0.6 Chassis earth splice 9 to engine oil * 660MA 0.6 4WS earth splice to 4WS control panel. 710B 0.6 Panel earth splice 1 to rear wash/wipe
Section C
pressure switch. * 660MB 0.6 4WS earth splice to 4WS lock valve. switch illum.
* 650F 0.6 Chassis earth splice 9 to water temperature * 660MC 0.6 4WS earth splice to diff. lock cut-out relay. 710C 0.6 Panel earth splice 1 to instrument cluster.
sender. * 660N 0.6 Cab roof earth splice 3 to control unit (ECU). 710D 0.6 Panel earth splice 1 to beacon switch illum.
* 650G 0 6 Chassis earth splice 9 to air filter switch. * 660P 0.6 Cab roof earth splice 3 to LH door switch 710E 0.6 Panel earth splice 1 to ‘A’ post worklights
* 650H 0.6 Chassis earth splice 9 to compressor (2000 series) relay coil.
switch. * 660R 0.6 Cab roof earth splice 3 to reverse lights relay 710F 0.6 Panel earth splice 1 to lights switch
* 650J 1.0 Chassis earth splice 9 to front washer pump coil (machines with 13-pin trailer socket illumination.
(2000 series). only). 710G 0.6 Panel earth splice 1 to second trailer turn
* 650K 1.0 Chassis earth splice 9 to rear washer pump * 660T 0.6 Cab roof earth splice 3 to 540 PTO range relay.
(2000 series). selected switch. 710H 1.0 Panel earth splice 3 to rear washer pump
* 660 4.0 Battery negative to cab roof earth splice 3. * 660U 0.6 Cab roof earth splice 3 to 1000 PTO range (3000 series).
* 660A 0.6 Cab roof earth splice 3 to inching solenoid selected switch. 710J 1.0 Panel earth splice 3 to front washer pump
resistor (wet clutch machines only). * 660V 0.6 Cab roof earth splice 3 to diff. lock cut-out (3000 series).
* 660B 0.6 Cab roof earth splice 3 to front PTO switch. switch illum. 710K 0.6 Panel earth splice 1 to front intermittent
* 660C 0.6 Cab roof earth splice 3 to rear PTO switch. * 660W 0.6 Cab roof earth splice 3 to work lights relay wipe relay.
* 660D 0.6 Cab roof earth splice 3 to rear intermittent coil. 710L 0.6 Panel earth splice 1 to front worklights
wipe relay. * 660X 1.0 Cab roof earth splice 3 to splitter dump switch illum.
* 660E 0.6 Cab roof earth splice 3 to handbrake relay (wet clutch machines only). 710M 1.4 Panel earth splice 1 to brake lights relay coil.
warning switch. * 660Y 0.6 Cab roof earth splice 3 to diagnostics 710N 1.0 Panel earth splice 1 to rear worklights
* 660F 0.6 Cab roof earth splice 3 to ignition relay coil. connector. switch illum.
* 660G 0.6 Cab roof earth splice 3 to EDC earth splice * 660Z 1.4 Cab roof earth splice 3 to cigar lighter. 710P 0.6 Panel earth splice 1 to speed sensor.
(EDC). 660ZA 0.6 Cab roof earth splice 3 to duplicate autoshift 710R 1.0 Panel earth splice 1 to rear fog lights relay
* 660GA 0.6 EDC earth splice to ECU (EDC). connector (UP). coil.
Electrics
* 660GB 0.6 EDC earth splice to hitch raise/lower switch 660ZB 0.6 Cab roof earth splice 3 to duplicate autoshift 715 0.6 Electronic control unit to position sensor
(EDC). connector (DOWN). (EDC).
* 660GC 0.6 EDC earth splice to area cut-out selection 660ZC 0.6 Cab roof earth splice 3 to duplicate autoshift 720 3.0 Battery negative to panel earth splice 3.
switch (EDC). connector (AUTO). 720A 0.6 Panel earth splice 3 to warning buzzer.
* 660GD 0.6 EDC earth splice to area cut-out jack socket * 660ZD 0.6 Cabroof earth splice 3 to Minder 720B 0.6 Panel earth splice 3 to LH door switch
(EDC). interconnect or Minder ECU. (3000 series).
* 660GE 0.6 EDC earth splice to option connector (EDC). 665A 3.0 Battery negative to tractor ABS earth splice. 720C 0.6 Panel earth splice 3 to LH side repeater
* 660GF 0.6 EDC earth splice to option chassis earth 665B 3.0 Battery negative to tractor ABS earth splice. (3000 series).
splice (EDC) (dry clutch transmission). 670 4.0 Battery negative to air conditioning unit. 720D 0.6 Panel earth splice 3 to RH side repeater
* 660GF EDC earth splice to radar speed sensor 680 3.0 Battery negative to auxiliary jack plug (3000 series).
(EDC) (wet clutch transmission). socket. 720E 0.6 Panel earth splice 3 to accelerator pedal
* 660GG 0.6 Option chassis earth splice to radar speed 685 3.0 Battery negative to power socket earth switch.
sensor (EDC) (dry clutch machines only). splice. 720F 0.6 Panel earth splice 3 to RH ‘A’ post work
* 660GH 0.6 Option chassis earth splice to fuel flow 685A 3.0 PSES to -VE terminal post. light (3000 series).
meter (EDC (dry clutch machines only). 685B 3.0 PSES to 3 pin power socket. 720G 0.6 Panel earth splice 3 to LH ‘A’ post work light
* 660GJ 0.6 EDC earth splice to wheel slip enable switch 685C 3.0 PSES to conenience socket. (3000 series).
(EDC). 685D 1.0 PSES to convenience socket relay coil. 720H 0.6 Panel earth splice 3 to hazard lights switch
* 660GK 0.6 EDC earth splice to wheel slip enable switch 690 2.0 Starter motor negative to horn. illumination.
(EDC). 700 2.0 Starter motor negative to front lights earth 720J 0.6 Panel earth splice 3 to rear fog lights switch
* 660H 1.0 Cab roof earth splice 3 to control unit (ECU). splice. illumination.
* 660J 1.0 Cab roof earth splice 3 to control unit (ECU). 700A 1.4 Front lights earth splice to LH headlight. 720K 0.6 Panel earth splice 3 to range change column
* 660K 0.6 Cab roof earth splice 3 to 4WD/differential 700B 1.4 Front lights earth splice to RH headlight. switch.
lock switch. 706 0.6 Radio/cassette to RH speaker. 720L 0.6 Panel earth splice 3 to air gauge
707 0.6 Radio/cassette to LH speaker. illumination.
Issue 6*
13 - 6
Section C
Wire Numbers
13 - 7
* EARTHS (continued) * 780A 3.0 Earth splice to timer module (3185 only) 809C 1.4 Fog lights splice to trailer socket.
9803/8020
* 780B 3.0 Earth splice to ESOS (3185 only) 810 0.6 Clutch down switch to clutch down splice.
No. Size Description * 780C 0.6 Earth splice to ESOS relay (3185 only) 810A 0.6 Clutch down splice to diode connector.
Section C
* 720N 0.6 Panel earth splice 3 to clutch up switch (dry * 790 - Heated front screen. 810B 0.6 Clutch down splice to control unit (ECU).
clutch machines only). * 790A - Heated front screen. * 810C 0.6 Clutch down splice to splitter dump relay
* 725 0.6 Electronic control unit to sensor earth * 790B - Heated front screen. (wet clutch machines only).
splice (EDC). * 790C - Heated front screen. * 810D 0.6 Clutch down splice to Minder interconnect
* 725A 0.6 Sensor earth splice to RH electronic draft * 790D - Heated front screen. or Minder ECU.
control pin (EDC). * 790E - Heated front screen. 811 0.6 6 speed neutral switch to diode connector.
* 725B 0.6 Sensor earth splice to LH electronic draft * 790F - Heated front screen. 812 1.0 Rear fog lights switch to rear fog lights
control pin (EDC). relay coil.
* 730 1.4 Battery negative to heater unit (3000 series) SWITCHED SUPPLIES AND LINKS * 815 1.0 Splitter dump relay to splitter dump splice
* 740 0.6 Starter motor negative to trailer brake valve (wet clutch machines only).
solenoid (dry clutch transmission). No. Size Description * 815A 0.6 Splitter dump splice to splitter low solenoid
* 741 0.6 Starter motor negative to air pressure switch * 800 1.4 Front work lights switch to outer front (wet clutch machines only).
(trailer brake) (dry clutch transmission). worklights splice. * 815B 0.6 Splitter dump splice to splitter medium
* 742 0.6 Starter motor negative to oil pressure switch * 800A 1.0 Outer front worklights splice to front RH solenoid (wet clutch machines only).
(trailer brake) (dry clutch transmission). outer worklight. * 815C 0.6 Splitter dump splice to splitter high
* 750 1.4 Battery negative to suspension seat or flow * 800B 1.0 Outer front worklights splice to front LH solenoid (wet clutch machines only).
divider earth splice. outer worklight. 816 0.6 Reverse lights relay to powershift ECU.
* 750A 1.4 Flow divider earth splice to suspension seat. * 800C 0.6 Front worklights switch to ‘A’ post 817 0.6 Auxiliary lights switch to auxiliary lights
* 750B 0.6 Flow divider earth splice to flow divider valve worklights relay coil. supply splice (3000 series).
solenoid. * 801 1.4 Front worklights switch to inner front 817A 0.6 Auxiliary lights supply splice to main beam
* 750C 0.6 Flow divider earth splice to flow divider worklights splice. switching relay (3000 series).
switch illumination. * 801A 1.0 Inner front worklights splice to front RH 817B 0.6 Auxiliary lights supply splice to dip beam
* 760 3.0 Battery negative to auxiliary lights earth inner worklight. switching relay (3000 series).
connector or splice. 1.0 Inner front worklights splice to front LH inner 817C 0.6 Auxiliary lights supply splice to LH sidelight
Electrics
* 801B
* 760A 0.6 Auxiliary lights earth splice to switching relay worklight. switching relay (3000 series).
(m/beam). * 802 0.6 Differential lock cut-out relay to differential 817D 0.6 Auxiliary lights supply splice to RH sidelight
* 760B 1.4 Auxiliary lights earth splice to LH auxiliary lock switch (4WS). switching relay (3000 series).
headlight. * 803 0.6 Differential lock cut-out switch to differential 817E 0.6 Auxiliary lights supply splice to LH indicator
* 760C 0.6 Auxiliary lights earth splice to switching lock cut-out relay coil. switching relay (3000 series).
relay (d/beam). * 804 1.4 ‘A’ post worklights relay to ‘A’ post 817F 0.6 Auxiliary lights supply splice to RH indicator
* 760D 1.4 Auxiliary lights earth splice to RH auxiliary worklights splice. switching relay (3000 series).
headlight. * 804A 1.0 ‘A’ post worklights splice to front RH ‘A’ * 820 0.6 Powershift ECU to wet clutch inching
* 760E 0.6 Auxiliary lights earth splice to switching post worklight. solenoid (wet clutch machines only).
relay (LH s/light). 804B 1.0 ‘A’ post worklights splice to front LH ‘A’ post * 821 0.6 Inching solenoid to inching solenoid
* 760F 0.6 Auxiliary lights earth splice to LH auxiliary worklight. resistor splice (wet clutch machines only).
s/light-d/indicator. 805 1.4 Rear worklights switch to outer rear * 821A 0.6 Inching solenoid resistor splice to
* 760G 0.6 Auxiliary lights earth splice to switching worklights splice. powershift ECU (wet clutch machines only).
relay (RH s/light). 805A 1.0 Outer rear worklights splice to rear RH outer * 821B 0.6 Inching solenoid resistor splice to inching
* 760H 0.6 Auxiliary lights earth splice to RH auxiliary worklight. solenoid resistor (wet clutch machines
s/light indicator. 805B 1.0 Outer rear worklights splice to rear RH inner only).
* 760J 0.6 Auxiliary lights earth splice to switching worklight. * 822 0.6 Powershift ECU to wet clutch lube
relay (LH d/indicator). 806 1.4 Rear fog lights switch to fusebox - fuse D3a. solenoid (wet clutch machines only).
* 760K 0.6 Auxiliary lights earth splice to switching 807 2.0 Lights switch to fusebox - fuse D4a. * 823 0.6 Powershift ECU to wet clutch brake
relay (RH d/indicator). 808 1.0 Fusebox - fuse D4a to fusebox - fuse D5a. solenoid (wet clutch machines only).
* 760L 0.6 Auxiliary lights earth splice to auxiliary lights 809 1.4 Fuse D3 to fog lights splice. 827 0.6 Flow divider switch to flow divider valve
switch illum. 809A 0.6 Fog lights splice to RH rear lights cluster. solenoid.
* 780 6.0 Starter motor negative to earth splice (3185 809B 0.6 Fog lights splice to LH rear lights cluster. 827A 0.6 Flow divider switch to instrument panel.
Issue 7*
13 - 7
Section C
only)
Wire Numbers
* SWITCHED SUPPLIES AND LINKS (continued) 2.0 Column switch to horn. 857E 0.6 Rear PTO drive cut-out splice 2 to RH
13 - 8
* 841
1.0 Column switch to front washer pump. fender cut-out button.
9803/8020
* 842
No. Size Description * 843 0.6 Rear wash/wipe switch to rear intermittent 858 2.0 Hazard switch to second trailer turn relay.
* 828 1.4 Cold advance temperature switch to wipe relay. 859 1.4 Hazard switch to panel left indicator splice.
Section C
Waxstat. * 844 1.0 Rear wash/wipe switch to rear washer 859A 0.6 Panel left indicator splice to LH side
* 829 1.4 Fuse D1 to auxiliary lights connector or pump. repeater (3000 series).
switch (2000 series). * 845 0.6 Rear wash/wipe switch to rear intermittent 859B 1.4 Panel left indicator splice to LH indicator
1.4 Fuse D1 to auxiliary lights connector or wipe relay. splice.
switching relay (3000 series) * 846 1.0 Rear intermittent wipe relay to rear wiper 859C 1.4 Panel left indicator splice to column switch.
* 830 0.6 Column switch to front intermittent wipe motor. 859D 0.6 Panel left indicator splice to auxiliary lights
relay. * 847 1.0 Rear intermittent wipe relay to rear wiper connector or switching relay (3000 series).
* 831 1.0 Column switch to front intermittent wipe motor. 859E 0.6 LH indicator splice to LH rear light cluster.
relay. * 848 0.6 Front PTO drive solenoid to front PTO drive 859F 1.4 LH indicator splice to trailer socket.
* 832 1.0 Front intermittent wipe relay to front wiper splice. 859G 0.6 Panel left indicator splice to instrument
motor. * 848A 0.6 Front PTO dirve splice to front PTO switch. cluster.
* 833 1.0 Column switch to front wiper motor (speed * 848B 0.6 Front PTO drive splice to instrument cluster 860 1.0 Fuse D5 to RH side lights splice.
1). (front PTO indicator). 860A 1.0 Right side lights splice to trailer socket.
* 834 1.0 Column switch to front wiper motor (speed * 849 0.6 Front PTO brake solenoid to front PTO 860B 0.6 RH side lights splice to cab roof side lights
2). switch. splice.
* 835 1.4 Rear work lights switch to inner rear * 850 0.6 Rear PTO drive solenoid to rear PTO drive 860C 0.6 RH side lights splice to auxiliary lights
worklights splice. cut-out connector or relay. connector (2000 series).
* 835A 1.0 Inner rear worklights splice to RH inner rear * 851 0.6 Rear PTO brake solenoid to rear PTO brake 0.6 RH sidelights splice to auxiliary lights
worklight. splice. switching relay (3000 series).
* 835B 1.0 Inner rear worklights splice to LH inner rear * 851A 0.6 Rear PTO brake splice to rear PTO switch. 860D 0.6 Right side lights splice to RH rear light
worklight. * 851B 0.6 Rear PTO brake splice to rear PTO drive cluster.
* 836 1.4 Auxiliary lights connector or switch to front cut-out connector or diode connector. 860E 0.6 Cab roof side light splice to radio/cassette.
lights main beam splice (2000 series) * 852 0.6 Two wheel drive solenoid to 2WD dump 860F 0.6 Cab roof side light splice to RH number
Electrics
1.4 Auxiliary lights connector or switching relay relay. plate light (2000 series).
to front lights main beam splice (3000 * 853 0.6 Differential lock cut-out relay (EDC 0.6 Cab roof sidelights splice to marker lights
series) triggered) to differential lock switch or diff. supply splice (3000 series) (dry clutch
* 836A 1.0 Front lights main beam splice to front LH lock cut-out relay (4WS). transmission).
lights connection. * 854 06 Start relay 1 coil to front PTO switch 860G 0.6 Cab roof side light splice to LH number
* 836B 1.0 Front lights main beam splice to front RH (brake). plate light.
lights connection. * 855 06 Start relay 2 coil to rear PTO switch (brake). 860H 0.6 Marker lights supply splice to RH number
* 837 1.4 Auxiliary lights switch to auxiliary main * 856 0.6 Diode connector (clutch down signal) to plate (3000 series) (dry clutch transmission).
beam splice (2000 series). cab roof start inhibit splice. 860J 0.6 Marker lights supply splice to RH marker
1.4 Auxiliary lights switch or switching relay to * 856A 0.6 Cab roof start inhibit splice to start relay 1 light (3000 series) (dry clutch transmission).
auxiliary main beam splice (3000 series). coil. 860K 0.6 Marker lights supply splice to LH marker
* 837A 1.0 Auxiliary main beam splice to LH auxiliary * 856B 0.6 Cab roof start inhibit splice to start relay 2 light (3000 series) (dry clutch transmission).
headlight. coil. 860L 1.0 RH sidelights splice to right sidelights
* 837B 1.0 Auxiliary main beam splice to RH auxiliary * 856C 0.6 Cab roof start inhibit splice to diode splice.
headlight. connector (neutral switch signal). 860M 0.6 Cab roof side light splice to 4WS control
* 838 3.0 Lights switch to panel headlights splice. * 857 0.6 Rear PTO drive cut-out connector or relay panel connector (2000 series).
* 838A 1.4 Panel headlights splice to column switch. to rear PTO drive splice. 860P 0.6 Cab roof side light splice to differential lock
* 838B 1.4 Panel headlights splice to rear fog lights * 857A 0.6 Rear PTO drive splice to rear PTO switch. cut-out switch illumination.
switch. 857B 0.6 Rear PTO drive splice to instrument cluster 860R 0.6 Cab roof sidelight splice to EDC raise/lower
* 838C 0.6 Panel headlights splice to rear fog lights (rear PTO indicator). switch illumination.
switch illumination. 857C 0.6 Rear PTO drive cut-out relay to rear PTO 860RA 0.6 EDC raise/lower switch illumination to area
* 838D 0.6 Panel headlights splice to worklights cut- drive cut-out splice 2. cut-out switch illumination.
out relay (dry clutch transmission). 857D 0.6 Rear PTO drive cut-out splice 2 to LH 860RB 0.6 Wheel slip enable switch illumination to
* 839 1.4 Column switch to fusebox - fuse D2a. fender cut-out button. area cut-out switch illumination.
Issue 5*
13 - 8
Section C
Wire Numbers
13 - 9
SWITCHED SUPPLIES AND LINKS (continued) 1.4 Air conditioning unit to heater unit 885 0.6 Auxiliary lights switching relay (LH
9803/8020
*
(speed 2) (3000 series). sidelights) to auxiliary lights switch
No. Size Description * 876 2.0 Air conditioning unit to blower switch illumination.
Section C
* 860T 0.6 Cab roof sidelight splice to cigar lighter (speed 3) (2000 series). 886 0.6 Diode connector to rear PTO drive cut-out
illumination. 2.0 Air conditioning unit to heater unit relay.
* 860U 0.6 Cab roof sidelight splice to worklights relay (speed 3) (3000 series). 886A 0.6 Diode connector to rear PTO drive cut-out
coil. * 877 0.6 Reverse lights splice to reverse lights relay relay.
* 861 1.4 Hazard switch to panel right indicator (wet clutch machines only). 887 0.6 Rear PTO drive cut-out relay coil to rear
splice. * 877A 0.6 Reverse lights splice to LH rear lights PTO drive cut-out splice 1.
* 861A 0.6 Panel right indicator splice to RH side cluster. 887A 0.6 Rear PTO drive cut-out splice 1 to LH
repeater (3000 series). * 877B 0.6 Reverse lights splice to RH rear lights fender cut-out button.
* 861B 1.4 Panel right indicator splice to RH indicator cluster. 887B 0.6 Rear PTO drive cut-out splice 1 to RH
splice. * 877C 0.6 Reverse lights switching splice to reverse fender cut-out button.
* 861C 1.4 Panel right indicator splice to column lights splice (mchines with 13-pin trailer 887C 0.6 Rear PTO drive cut-out relay coil to diode
switch. socket only). connector.
* 861D 0.6 Panel right indicator splice to aux. lights * 877D 0.6 Reverse lights switching splice to reverse 894 0.6 Trailer brake relay to trailer brake valve
connector or switching relay (3000 series). lights relay coil (machines with 13-pin trailer solenoid (dry clutch transmission).
* 861E 0.6 RH indicator splice to RH rear light cluster. socket only). 895 0.6 2WD dump relay to 2WD switch.
* 861F 1.4 RH indicator splice to trailer socket. * 878 1.4 Reverse lights relay to trailer socket (13 pin) 898 0.6 Instrument cluster to 20 kph signal splice.
* 861G 0.6 Panel right indicator splice to instrument (machines with 13-pin trailer socket only). 898A 0.6 20 kph signal splice to 4WS control panel
cluster. * 880 1.0 Fuse D4 to LH sidelights splice (20 kph signal).
* 862 2.0 Second trailer turn relay to single trailer turn * 880A 0.6 LH side lights splice to hazard lights switch 898B 0.6 20 kph signal splice to control unit (ECU)
relay. illumination. (20 kph signal).
* 863 2.0 Single trailer turn relay to hazard switch. * 880B 0.6 LH side lights splice to instrument cluster. 899 0.6 Differential lock cut-out relay to rear
* 864 1.4 Second trailer turn relay to column switch. * 880C 0.6 LH side lights splice to beacon switch differential lock solenoid (2000 series).
* 865 2.0 Second trailer turn relay to hazard switch. illumination. 0.6 Differential locks cut-out relay to differential
* 866 0.6 Auxiliary lights connector (out) to RH front 0.6 LH side lights splice to auxiliary lights lock solenoid (3000 series).
Electrics
* 880D
sidelight (2000 series). connector or switch (2000 series) 899A 0.6 Differential lock cut-out relay to instrument
0.6 Auxiliary lights switching relay to RH 0.6 LH sidelights splice to auxiliary lights cluster.
front sidelights (3000 series). connector or switching relay (3000 series). * 900 0.6 Snail solenoid splice to snail solenoid.
* 867 0.6 Auxiliary lights switching relay to RH * 880F 1.0 LH side lights splice to left side lights * 900A 0.6 Powershift controller to snail solenoid
auxiliary sidelights (3000 series). splice. splice.
* 868 0.6 Auxiliary lights connector (out) to LH front * 880G 0.6 LH side lights splice to air gauge * 900B 0.6 Minder interconnect to snail solenoid
indicator (2000 series). illumination. splice.
0.6 Auxiliary lights switching relay to LH front * 880H 1.0 Left side lights splice to trailer socket. * 901 0.6 Tortoise solenoid splice to tortoise
indicator (3000 series). * 880J 0.6 Left side lights splice to LH rear light solenoid.
* 869 0.6 Auxiliary lights switching relay to LH cluster. * 901A 0.6 Powershift controller to tortoise solenoid
auxiliary indicator (3000 series). * 880K 0.6 LH side lights splice to rear wash/wipe splice.
* 870 0.6 Auxiliary lights connector (out) to RH front switch illumination. * 901B 0.6 Minder interconnect to tortoise solenoid
indicator (2000 series). * 881 0.6 Auxiliary lights connector (out) or switch to splice.
0.6 Auxiliary lights switching relay to RH front LH front sidelight (2000 series). * 902 0.6 Hare solenoid splice to hare solenoid.
indicator (3000 series). 0.6 Auxiliary lights connector or switching relay * 902A ? Powershift controller to hare solenoid
* 871 0.6 Auxiliary lights switching relay to RH to LH front sidelight (3000 series). splice.
auxiliary indicator (3000 series). * 882 0.6 Auxiliary switching relay to LH front * 902B ? Minder interconnect to hare solenoid splice.
* 874 1.0 Air conditioning unit to blower switch auxiliary sidelight (3000 series). 904 1.4 Fuse D2 to auxiliary lights connector or
(speed 1) (2000 series). * 883 1.4 Brake lights relay to brake lights splice. switch (2000 series).
1.0 Air conditioning unit to heater unit * 883A 0.6 Brake lights splice to RH rear lights cluster. 1.4 Fuse D2 to auxiliary lights connector or
(speed 1) (3000 series). * 883B 0.6 Brake lights splice to LH rear lights cluster. switching relay (3000 series).
* 875 1.4 Air conditioning unit to blower switch * 883C 1.4 Brake lights splice to trailer socket. 905 1.4 Auxiliary lights connector or switch to front
(speed 2) (2000 series). 884 0.6 Brake lights switch to brake lights relay coil. lights dipped beam splice (2000 series).
Issue 3*
13 - 9
Section C
Wire Numbers
13 - 10
SWITCHED SUPPLIES AND LINKS (continued) 930 0.6 Electronic control unit to in-cab raise/lower
9803/8020
switch (EDC).
No. Size Description 932 0.6 In-cab raise/lower switch to fender
Section C
905 1.4 Auxiliary lights connector or switching relay raise/lower switch (EDC).
to front lights dipped beam splice (3000 932A 0.6 Switch feed splice to LH fender connector
series). (EDC).
905A 1.0 Front lights dipped beam splice to LH lights 932B 0.6 Switch feed splice to RH fender connector
connection. (EDC).
905B 1.0 Front lights dipped beam splice to RH 932C 0.6 Fender switch feed splice to fender raise
lights connection. button (EDC).
906 1.4 Auxiliary lights switch to auxiliary dipped 932D 0.6 Fender switch feed splice to fender lower
beam splice (2000 series). button (EDC).
1.4 Auxiliary lights switching relay to auxiliary 934 1.0 Beacon switch to beacon socket.
dipped beam splice (3000 series). 935 0.6 Powersplit low button to powersplit relay 2
906A 1.0 Auxiliary dipped beam splice to LH auxiliary (low) (dry clutch transmission).
headlight. 936 0.6 Compressor clutch relay coil to compressor
906B 1.0 Auxiliary dipped beam splice to RH pressure switch.
auxiliary headlight. 950 2.0 Compressor clutch relay to compressor
907 1.4 Column switch to fusebox - fuse D1a. clutch.
912 0.6 Radio/cassette to RH speaker. 951 0.6 Blower switch to air conditioning switch
913 0.6 Radio/cassette to LH speaker. (2000 series).
914 0.6 LH interior light to LH door switch. 952 0.6 Air conditioning switch to air conditioning
920 0.6 Electronlc control unit to sensor supply unit (2000 series).
splice (EDC). 954 0.6 Air conditioning unit to compressor clutch
920A 0.6 Sensor supply splice to RH draft pin (EDC). relay coil.
920B 0.6 Sensor supply splice to LH draft pin (EDC). 980 6.0 ESOS relay to timer/solenoid supply splice
920C 0.6 Sensor supply splice to position sensor (3185 only).
Electrics
(EDC). 980A 3.0 Timer/solenoid supply splice to timer

922 0.6 Electronlc control unit to in-cab raise/lower module (3185 only).
switch (EDC). 980B 3.0 Timer/solenoid supply splice to timer ESOS
923 0.6 Fender raise/lower switch to in-cab (3185 only).
raise/lower switch (EDC). 983 3.0 ESOS to timer module (3185 only).
923B 0.6 Raise splice to RH fender connector (EDC). 984 15 Heater relay 1 to heater 1 (3185 only).
923C 0.6 Raise splice to LH fender connector (EDC). 985 15 Heater relay 2 to heater 2 (3185 only).
924 0.6 Electronic control unit to valve supply 990 - Heated front screen.
splice (EDC). 990A - Heated front screen.
924A 0.6 Valve supply splice to raise solenoid (EDC). 990B - Heated front screen.
924B 0.6 Valve supply splice to lower solenoid 990C - Heated front screen.
(EDC).
925 0.6 Fender raise button to fender lower button
(EDC).
926 0.6 Fender raise to button fender lower button
(EDC) (dry clutch machines only).
928 0.6 Electronic control unit to in-cab raise/lower
switch (EDC).
929 0.6 Fender raise/lower switch to in-cab
raise/lower switch (EDC).
929B 0.6 Lower splice to LH fender connector (EDC).
929C 0.6 Lower splice to RH fender connector (EDC).
Issue 1
13 - 10
Section C
15 - 1 Wiring Diagrams - Fastrac 2140 15 - 1
Main Connectors
Connector Description Mating Connector Description Mating
Connector Connector
A2 Rear bulkhead ABS 2 CR50 Powershift ECU 2 (Red) ---
ABS1 ABS trailer socket --- CR51 Front bulkhead C28
ABS2 Rear bulkhead A2 CR64 4WS option C4
AHL1 Auxiliary lights connector --- CR65 R.H. Instrument cluster 1 (Black) ---
AHL2 Auxiliary lights connector --- CR66 L.H. Instrument cluster 2 (Red) ---
C1 (8-pin) Trailer socket --- CR73 Panel - auxiliary light interconnect ---
C1 (10-pin) Control module CP3 CR74 Panel - auxiliary light interconnect ---
C2 Control module CP2 CR87 Instrument cluster E4
C4 Rear diffferential lock solenoid CR64 CR89 Diagnostic connector ---
and 4WS interconnect (if fitted) CR104 Engine Bulkhead C78
C5 Rear bulkhead CR1 E1 EDC ECU ---
C28 Front bulkhead CR51 E2 Control panel ---
C72 Transmission TH1 E4 Instrument cluster CR87
C74 Engine Bulkhead --- E15 Bulkhead E16
C75 Engine ECU --- E16 Bulkhead E15
C78 Engine Bulkhead CR104 TH1 Transmission C72
CP1 Control module (4WS) ---
CP2 Control module (4WS) C2
CP3 Control module (4WS) C1 (10-pin)
CR1 Rear bulkhead C5
CR43 R.H. Column switch ---
CR49 Powershift ECU 1 (Black) ---
9803/8020 Issue 1
Connector Terminals
Instrument Cluster Instrument Cluster
1 406 Low air pressure - 2 1 479B High range selected
2 409 Brake malfunction splice 2 512 Fuel feed signal
3 408 Low air pressure - 3 3 502 Fuel return signal
4 434 Low transmission oil pressure 4 414A Transmission speed signal
5 - 5 -
6 440 ABS trailer socket 6 411 Fuel level
7 899A Differential lock solenoid 7 500A Radar speed signal
8 415 Area cut-out selection switch 8 517 RS232 RX
9 - 9 423 Buzzer out
10 - 10 898 <20 kph speed trigger
12 - 12 505 Increase wheel slip output
13 420 2WD/4WD switch (4WD indicator) 13 -
14 880B L.H. Side lights splice 14 859G Left turn signal
15 511 EDC Earth splice 15 -
16 - 16 478B Medium range selected
17 405 Transmission oil filter blocked 17 403A Alternator charge
18 444 540 PTO range selected 18 510 Wheel slip setpoint
19 445 1000 PTO range selected 19 516 RS232 TX
21 - 21 518 Decrease wheel slip output
22 857B Rear PTO drive selected 22 416 Differential lock cut-out
23 477B Low range selected 23 514F CANL
24 - 24 515F CANH
25 861G Right turn signal 25 501 Radar presence signal
26 418 Main beam 26 497 Transmission speed sensor presence
27 419 2nd trailer turn signal 27 827A Flow divider ON splice
28 417 1st trailer turn signal 28 499 Column switch button
29 496 4WS tracking 29 448 Tractor ABS warning light
30 407 Low air pressure - 1 30 412A Alternator ‘W’ splice
31 - * 31 513 Diagnostics connector (program)
32 - 32 498 Column switch button
33 404 Air filter blocked 33 300B + 12V Battery permanent feed splice
34 480B Reverse range selected B9
35 848B Front PTO drive selected 34 160B + 12V ignition PISC4
36 509B EDC lower signal 35 710C Battery earth PES1
36 626 Chassis earth RF
9803/8020 Issue 2*
Connector Terminals (continued)

Powershift - Electronic Control Unit (ECU) Powershift - Electronic Control Unit (ECU)
Wet Clutch Transmission Wet Clutch Transmission

2 - - 2 478A Medium range selected
4 400C 2WD dump splice 4 480A Reverse range selected
5 820 Wet clutch inching solenoid 5 435 Transmission oil pressure switch
6 822 Wet clutch lubrication solenoid 6 485 3 kph speed trigger
7 823 Transmission brake solenoid 7 526 Transmission temperature sender 2
8 900 Snail clutch solenoid return
9 821A Inching solenoid resistor splice 8 126 Ram solenoid 12V supply
10 901 Tortoise clutch solenoid 9 524A Transmission oil temperature TOTS1
11 655A Battery negative CRES5 10 489 Medium range neutral solenoid
12 125B + 12v ignition PSSS 11 655C Battery negative
13 - - 12 125C +12V ignition PSSS
14 515 CANHS 13 525 Transmission temperature sender 1
15 434 Transmission oil pressure warning return
16 450 Buzzer 14 437 Low selected ram switch
17 898B 20 kph speed trigger 15 442 Medium range neutral switch
18 816 Reversing lamps relay coil 16 436 Reverse range engage switch
19 - - 17 438 Medium range engage switch
20 - - 18 443 High range neutral switch
21 - - 19 441 Low range neutral switch
22 523 Clutch pedal potentiometer return 20 446 Reverse neutral ram switch
23 655B Battery negative CRES5 21 439 High selected ram switch
24 125A + 12v ignition PSSS 22 492 Low range engage switch
25 522 Clutch pedal potentiometer wiper 23 - -
26 521 Clutch pedal potentiometer supply 24 524B Transmission oil temperature senders
27 413 Accelerator pedal switch 25 486 or 486A 1 kph speed trigger
28 470A Up shift switch 26 - -
29 471A Down shift switch 27 - -
30 472A Auto mode switch 28 - -
31 412 Electronic engine ECU 29 - -
32 - - 30 491 Reverse range engage solenoid
33 625 RF ground 31 490 High range neutral solenoid
34 - - 32 493 Medium range engage solenoid
35 - - 33 488 Low range neutral solenoid
36 902 Hare clutch solenoid 34 487 Reverse range neutral solenoid
35 494 High range engage solenoid
36 629 CANBUS screen
9803/8020 Issue 1

Electronic Draft Control - (Type D+) Electronic Draft Control (EDC) (Type D+)
Electronic Control Unit (ECU) E1 (machines with radar) - Control Panel E2 (machines with radar)

1 725 Draft sensor earth 1 -
2 506 Control panel supply 2 430 ECU terminal 23
3 427 Raise limit signal 3 -
4 431 Control panel terminal 10 4 506 Power supply in
5 505 Slip setpoint increase 5 -
6 424 Position sensor signal 6 507 Earth
7 425 Left draft sensor signal 7 429 Setpoint level signal
8 518 Slip setpoint decrease 8 -
9 930 Remote raise/lower switch-common 9 428 Control lever signal
10 500B Radar signal 10 431 ECU terminal 4
11 414B Transmission speed signal 11 504A Control valve lower signal
12 - 12 503A Control valve raise signal
13 403B Alternator charge signal 13 427 Raise limit signal
14 Link ECU terminal 43 14 433 Diagnostic LED (+ve)
15 - 15 508 Diagnostic LED (-ve)
16 509 Lower signal out 16 -
17 922 Remote switch raise signal 17 -
18 - 18 -
23 430 Control panel terminal 2
24 135 +12v ignition fuse A6
25 -
27 -
28 660GA Battery earth
29 300A +12v battery PFSB9
30 -
31 433 Diagnostic LED (+ve)
32 -
33 -
34 510 Slip setpoint feedback signal
36 928 Remote switch lower signal
38 715 Position sensor earth
40 -
41 508 Diagnostic LED (-ve)
42 -
43 Link ECU terminal 14
44-55 -
9803/8020 Issue 1

Electronic Draft Control (Type B) Electronic Draft Control (EDC) (Type B)
- Electronic Control Unit (ECU) E1 - Control Panel E2
(machines not fitted with radar) (machines not fitted with radar)

1 508/660GA Battery 0v 1 -
2 503/503A Control valve raise signal 2 430 ECU terminal 24
3 507 Control panel earth 3 -
4 431 Control panel terminal 10 4 506 Fender switch, control panel
5 403B Alternator charge signal common
6 924 Control valve common 5 -
7 - 6 507 Control panel earth
8 428 Control lever signal 7 429 Setpoint level signal
9 433 Diagnostic LED+ 8 -
10 922 In-cab raise/lower switch 9 428 Control lever signal
11 509 Lowered signal (area cut-out) 10 431 ECU terminal 4
12 506/930 Fender switch, control panel 11 504A Control valve lower signal
common 12 503A Control valve raise signal
13 920 Position/draft sensor supply 13 427 Top end position signal
14 504/504A Control valve lower signal 14 433 Diagnostic LED+
15 715/725 Position/draft sensor earth 15 508 Battery 0v
16 429 Setpoint level signal 16 -
17 425 Left draft sensor signal 17 -
18 426 Right draft sensor signal 18 -
19 424 Position sensor signal
20 928 In-cab raise/lower switch
21 935 Hitch damping resistor
23 -
24 430 Control panel terminal 2
25 135 +12 v ignition
9803/8020 Issue 1
Splice Identification
Splice Description Splice Description
ABSSS ABS supply splice OCSS Option-chassis supply splice
ADBS Auxiliary dipped beam splice OFWLS Outer front working lights splice
ADCOS Area differential lock cut-out splice ORWLS Outer rear working lights splice
ALES Auxiliary lights earth splice PES Panel earth splice
ALSS Auxiliary lights supply splice PFS Permanent feed splice
AMBS Auxiliary main beam splice PFSB9 Permanent feed fuse B9 splice
APWLS ‘A’ post work lights splice PHLS Panel headlights splice
ASS Alternator signal splice PISA4 Panel ignition fuse A4 splice
ASSS Autoshift switch splice PISC4 Panel ignition splice
AWS Alternator ‘W’ splice PLIS Panel left indicator splice
BATS Battery splice PMLS Panel main lights splice
BLS Brake lights splice PRSFS Power range solenoid feed splice
BMS Brakes malfunction splice PRHS Power range high splice
CANHS CAN high splice PRIS Panel right indicator splice
CANLS CAN low splice PRLS Power range low splice
CDS Clutch down splice PRMS Power range medium splice
CES Chassis earth splice PRRS Power range reverse splice
CRBLS Cab roof ‘B’ lights splice PRSFS Power range feed splice
CRES Cab roof earth splice PSSS Powershift supply splice
CRIS Cab roof ignition splice RFWLS Rear fender warning lights splice
CRPFS Cab roof permanent feed splice RGSS Radar ground speed resistor splice
CRSIS Cab roof start inhibit splice RHIS Right hand indicator splice
C9CS Fuse C9 chassis splice RHSLS Right hand side lights splice
DBS Dipped beam splice RLS Reverse lights switching splice
DSSS Downshift switch splice RLSS Raise/lower switch splice
ECUIS ECU ignition splice RPBS Rear PTO brake splice
ECUES ECU earth splice RPCOS Rear PTO cut-out splice
ECUSLS ECU side lights splice RPDS Rear PTO drive splice
ECUFRS ECU flow rate splice RS Raise splice
ECURGS ECU reference ground splice RSLS Right side lights splice
ECURSS ECU reference supply splice RSS Radar signal splice
EDCES Electronic draft control cab earth splice RWLSS Rear working lights supply splice
EDCIS Electronic draft control ignition splice SA 4WS ignition splice
EDCS Electronic draft control splice SD 4WS earth splice
ELSS EDC lower signal splice SES Sensor earth splice
ETDRS Engine torque derate resistor splice SFS Solenoid feed splice
FDES Flow divider earth splice SSS Speed signal splice (page 17 - 23)
FDSS Flow divider supply splice SSS Sensor supply splice (page 17 - 9)
FLES Front lights earth splice SVCES Spool valve control earth splice
FLS Fog lights splice SWFS Switched feed splice
FPDS Front PTO drive splice TAES Tractor ABS earth splice
FWLSS Front working lights supply splice TAIS Tractor ABS ignition splice
HBWLS Headlight bars warning light splice TGSRS True ground speed resistor splice
HSS Hare solenoid splice TOPS Transmission oil pressure splice
IGNS Ignition splice TOTS Transmission oil temperature splice
IFWLS Inner front working light supply splice TSS Tortoise solenoid splice
IRWLS Inner rear working light supply splice USSS Upshift switch splice
ISRS Inching solenoid resistor splice VSS Valve supply splice
LHIS Left hand indicator splice 1KSS 1 kph signal splice
LHSLS Left hand side lights splice 2WDDS 2WD dump splice
LS Lower splice 20KSS 20 kph speed signal
LSLS Left side lights splice
MBS Main beam splice
OCES Option-chassis earth splice
9803/8020 Issue 1
Contents - Fastrac 2140

Note: Some of the diagrams on the following pages contain reference to 3000 series machines. They are not referring to the
3155 or 3185 machines but are referring to the 3170, 3190 and 3220 because the diagrams were originally drawn to cover
those machines before adding the 2140.
Do not use this manual for 3170, 3190 and 3220 information as the circuits are not complete for those machines. For the
complete set of circuit diagrams, see service manual 9803/8030. For circuit diagrams on 3155 or 3185 machines see earlier
pages in this manual as detailed on Contents page C8-5.
* Page No. Circuit

17 - 2 Supply Circuit
17 - 3 Earth Circuit
17 - 4 Fuse A1 - Neutral Start (Clutch) to machine number 740001
Fuse C9 - Air Drier; Neutral Start (Gearbox) to machine number 740001
17 - 4 - 2 Fuse A1 - Neutral Start (Clutch) from machine number 740002
Fuse C9 - Air Drier; Neutral Start (Gearbox) to machine number 740002
17 - 5 Fuse A2 - Brake Lights
17 - 6 Fuse A3 - Rear Wash/Wipe, Suspension Seat
17 - 6A Fuse E3 - Flow Divider
17 - 7 Fuse A4 - Front Wash/Wipe; Horn
17 - 7A Fuse A4 - Front Wiper Circuit
17 - 8 Fuses A5, H1 to H5 - Electronic Engine
17 - 8B Fuses A5, H1 to H5 - Electronic Engine - continued
17 - 8D Fuses A5, H1 to H5 - Electronic Engine - continued
17 - 9 Fuse A6 - Electronic Draft Control (EDC) Type D +, Ignition Cab Side.
Fuse B9 - Electronic Draft Control (EDC) Type D +, Battery Cab Side
17 - 9A Fuse A6 - Electronic Draft Control (EDC) Type B, Ignition Cab Side.
Fuse B9 - Electronic Draft Control (EDC) Type B, Battery Cab Side
17 - 9B Fuse A6 - Electronic Draft Control (EDC) D+ and B, Ignition Chassis Side
Fuse B9 - Electronic Draft Control (EDC) D+ and B, Battery Chassis Side
17 - 10 Fuse A7 - Powershift ECU - 3-Speed Splitter, Splitter Dump Relay
17 - 10A Fuse A7 (continued) - Powershift ECU - Selectronic
17 - 10B Fuse A7 (continued) - Powershift ECU - Selectronic (continued)
17 - 10C Fuse A7 (continued) - Wet Clutch Control
17 - 11 Fuse A8 - Front/Rear PTO; 2WD and Differential Lock Solenoids to machine number 740001
17 - 11 Fuse A8 - Front/Rear PTO; 2WD and Differential Lock Solenoids from machine number 740002
17 - 11A Fuse A8 (continued) - Rear PTO Cut-Out Option
17 - 12 Fuse A9 - Air Conditioning Circuit
17 - 13 Fuse B1 - Interior Lights; Radio/Cassette; Beacon Socket
17 - 14 Fuse B2 - Hazard Warning LIghts
Fuse C2 - Direction Indicators
17 - 15C Fuse B3 - Front Work Lights
17 - 16B Fuse B4 - Rear Work Lights
17 - 17 Fuse B5 - Headlight Flash
Fuse W (Maxifuse) - Main Lights
17 - 17A Fuse D1 - Main Beam
Fuse D2 - Dipped Beam
17 - 17B Fuse D3 - Rear Fog Lights
17 - 17C Fuse D4 - LH Side Lights, Cluster Signal, Rear Wash/wipe & Beacon Switch Illumination, Air Gauge Illumination
17 - 17D Fuse D5 - RH Side Lights, Number Plate Lights, Radio Cassette, Differential Lock, Raise/Lower & Area Cut-out
Switch Illumination, Cigar Lighter Illumination, Work Lights Relay Coil
17 - 17F Fuse D6 - Auxiliary Lights Switching
17 - 18 Fuse B6 - Radio Cassette
17 - 19 Fuse B7 - Auxiliary Jack-Plug Socket
17 - 20 Fuse B8 - Cigar Lighter
17 - 21 Fuse C1 - Reverse Lights
17 - 23 Fuse C4 - Lights Switch Illumination; Bleeper; Instrument Cluster; Differential Lock Cut-Out; Speedometer
Sensor; Fuse C5
17 - 23A Fuse C4 (continued) - Chassis Side
17 - 23B Fuse C5 (continued) - Ground Speed Radar
17 - 24 Fuse C6 - Diagnostic Socket and Connector
17 - 25 Fuses C7 & C8 - Auxiliary Power Sockets
17 - 26 Fuses E1, E2 - Trailer ABS
Fuses F1, F2, F3, F4 - Tractor ABS
9803/8020 Issue 3*
Contents - Fastrac 2140 (Continued)
Page No. Crcuit

* 17 - 30 Four Wheel Steering (4WS) to machine number 740001
* 17 - 30 Four Wheel Steering (4WS) to machine number 740001
17 - 31 Trailer Sockets
17 - 32 Front and Rear Light Clusters
17 - 33 CANBUS - Cab and Chassis
9803/8020 Issue 2*
Sectional Diagrams
16 - 3
Alphabetical Index
9803/8020
Fuses Page No. Item Page No. Item Page No.
Section C
A1 17-4 ABS 17-26 Reverse Lights 17-21

A2 17-5 Air Conditioning 17-12 Side Lights - LH 17-17C
A3 17-6 Air Drier 17-4 Side Lights - RH 17-17D
A4 17-7, 17-7A Alternator 17-2 Solenoid - Two Wheel Drive 17-11
A5 17-8, 17-8B, 17-8D Auxiliary Lights Switching 17-17F Solenoid - Differential Lock 17-11
A6 17-9, 17-9A, 17-9B Area Cut-out Switch 17-9 Speedometer Sensor 17-23
A7 17-10, 17-10A, 17-10B, 17-10C Auxiliary Jack Plug Socket 17-19 Starter Motor 17-2
A8 17-11, 17-11A Battery 17-2 Supply Circuit 17-2
A9 17-12 Beacon Socket 17-13 Trailer ABS Socket 17-26
B1 17-13 Bleeper 17-23 Trailer Sockets 17-31
B2 17-14 Brake Lights 17-5 Transmission Oil Pressure Switch 17-23A
B3 17-15C CANBUS 17-33 Two Wheel Drive Solenoid 17-11
B4 17-16B Cigar Lighter 17-20 Wash/Wipe-front 17-7
B5 17-17 Diagnostic Connector 17-24, 17-26 Wash/Wipe-rear 17-6
B6 17-18 Differential Lock 17-11 Wet Clutch Control 17-10C
B7 17-19 Differential Lock Cut-out 17-23 Wheelslip Enable Switch 17-23B
B8 17-20 Direction Indicators 17-14 Work Lights - Front 17-15C
B9 17-9, 17-9A, 17-9B Earth Circuit 17-3 Work Lights - Rear 17-16B
C1 17-21 Electronic Engine 17-8, 17-8B, 17-8D
C2 17-14 Draft Control system 17-9, 17-9A, 17-9B
Electrics
C3 Blank Four Wheel Steering (4WS) 17-30

C4 17-23, 17-23A Flow Divider 17-6A
C5 17-23, 17-23B Fog Lights - Rear 17-17B
C6 17-24 Ground Speed Radar Sensor 17-23B
C7 17-25 Hazard Warning Lights 17-14
Wiring Diagrams - Fastrac 2140
C8 17-25 Head Lights 17-17, 17-32

C9 17-4 Horn 17-7
D1 17-17A Instrument Cluster 17-23
D2 17-17A Interior Lights 17-13
D3 17-17B Light Switch Illumination 17-23
D4 17-17C Main Lights 17-17
D5 17-17D Maxifuse (W) 17-17
D6 17-17F Neutral Start 17-4
E1 17-26 Powershift ECU - 3-Speed Splitter 17-10
E2 17-26 Powershift ECU - Selectronic 17-10A, 17-10B
E3 17-6A PTO - Front 17-11
E4 17-30 PTO - Rear 17-11, 17-11A
F1 to F4 17-26 Radio/Cassette 17-18
H1 to H5 17-8, 17-8B, 17-8D
W 17-17
Issue 1
16 - 3
Section C
Sectional Diagrams Component Key - Fastrac 2140 17 - 1
9803/8020
1 Battery (all machines) 72 Diode Connector (E21) (PTO Cut-Out) 159 Radar Speed Sensor
1A Second Battery (3000 Series only) 73 PTO Cut-Out Push-Button (LH Fender) 160 ABS Trailer Socket
Section C
2 Ignition Switch 74 PTO Cut-Out Push Button (RH Fender) 161 Suspension Seat Connector
3 Starter Motor 75 Air Conditioning Blower Switch 162 Flow Divider Switch
4 Alternator 76 Air Conditioning Switch 163 Flow Divider Valve Connector
5 Trailer ABS Connector 77 Compressor Switch Earth 164 Rear Axle Ram Lock Switch (closed when
5A Tractor ABS Supply (if fitted) 78 Air Conditioning Unit locked)
5B Tractor ABS Return (if fitted) 79 Air Conditioning Compressor Switch 165 Rear Axle Ram Lock Valve
6 Ignition Relay 80 Air Conditioning Compressor Clutch 166 Steer Valve (RH)
7 Work lights Relay 81 Air Conditioning Compressor Pressure Switch 167 Steer Valve (LH)
8 Heater Unit (3000 Series) (High) 168 Front Potentiometer (4WS)
9 Auxiliary Connector 82 Air Conditioning Compressor Pressure Switch 169 Rear Potentiometer (4WS)
9A Auxiliary Power Socket (if fitted) (Low) 170 4WS Differential Lock Cut-Out Relay
10 Air Conditioning Connector 83 Air Conditioning Compressor Clutch Relay 171 Trailer Socket (U.S.A.)
12 Suspension Seat/Flow Divider Connector 84 Radio/Cassette 172 Trailer Socket (Standard)
*
13 Horn Connector 85 Interior Light (RH) 173 4WS Jack Socket
14 Start Inhibit Relay 1 86 Interior Light (LH) 174 Wheel Slip Enable Switch (machines with
15 Start Inhibit Relay 2 87 Door Switch (LH) radar only)
16 Clutch Start Micro-switch 88 Beacon Switch 175 Inching Solenoid Resistor
17 Diode Connector 89 Beacon Socket 176 Column Switch Button
18 Front PTO Switch 90 Hazard Switch 177 Clutch Potentiometer a Clutch Pedal Down
19 Rear PTO Switch 91 Single Trailer Turn Relay b Clutch Pedal Up
20 Brake Lights Switch 92 Second Trailer Turn Relay 178 Transmission Oil Temperature Sensor 1
21 Brake Lights Relay 93 Outer Indicator Lights (RH) 179 Transmission Oil Temperature Sensor 2
22 Rear Wiper Motor 94 Outer Indicator Lights (LH) 180 Clutch Lubrication Solenoid
23 Rear Wash/Wipe Switch 95A Auxiliary Lights Connector (In) 181 Transmission Brake Solenoid
24 Connector - Rear Washer Pump 95B Auxiliary Lights Connector (Out) 182 Inching Solenoid
25 Rear Intermittent Wipe Relay 96 Side Repeater (LH) (3000 Series only) 183 Cab Auxiliary Supply Connector
26 Rear Wiper Connectors 97 Side Repeater (RH) (3000 Series only) 184 Cab Auxiliary Battery Supply - Terminal
27 Front Washer Pump Connector 98 Trailer Socket Posts
28 Horn 99 Rear Light Cluster (LH) Connector 185 Cab 3-pin Auxiliary Power Socket
29 Washer/Horn Switch 100 Rear Light Cluster (RH) Connector (battery and ignition supplies)
30 Front Wiper Motor 101 Front Light Cluster (RH) Connector (3000 186 Cab Auxiliary Power Convenience Socket
31 Front Intermittent Wipe Relay Series only) (Option)
32 Front Wiper Switch 102 Front Light Cluster (LH) Connector (3000 187 Ignition Switched Relay (supplied with item
33 Cold Advance Switch (2000 Series only) Series only) 186)
33A Waxstat 103 Front Work lights Switch 188 ABS Diagnostic Interconnect
34 PTO Cut-out Relay 104 ‘A’ Post Work lights Relay 189 Tractor Diagnostic Interconnect
35 Jack Socket 105 Front Working Light (RH outer) 190 Tractor ABS Diagnostic Relay
36 EDC Connector 106 Front Working Light (RH inner) 191 Diagnostic Switch
37 EDC Control Panel 107 Front Working Light (LH inner) 192 Tractor ABS Ignition Relay
38 Area Cut-out Switch (EDC) 108 Front Working Light (LH outer) 193 ABS Speed Sensor (Front RH)
39 Connector - EDC Unit 109 Front Working Light (RH ‘A’ post) 194 ABS Speed Sensor (Front LH)
40 Pin position identification for 39 110 Front Working Light (LH ‘A’ post) 195 ABS Speed Sensor (Rear RH)
41 Raise/Lower Switch (EDC) (In cab) 111 Rear Work lights Switch 196 ABS Speed Sensor (Rear LH)
42L Draft Pin (EDC) (Left Hand) 112 Rear Working Light (RH outer) 197 ABS Pressure Modulating Valve (Front)
42R Draft Pin (EDC) (Right Hand) 113 Rear Working Light (RH inner) 198 ABS Pressure Modulating Valve (Rear LH)
43 Position Sensor (EDC) 114 Rear Working Light (LH inner) 199 ABS Pressure Modulating Valve (Rear RH)
44A Raise Push-Button (EDC) (RH Fender) 115 Rear Working LIght (LH outer) 200 Tractor ABS ECU Connectors
44B Raise Push-Button (EDC) (LH Fender) 116 Main Lights Switch 201 Heated Mirror Supply
45A Lower Push-Button (EDC) (RH Fender) 117 Rear Fog Lights Switch 202 Interconnect
*
45B Lower Push-Button (EDC) (LH Fender) 118 Rear Fog Lights Relay 203 Rear Bulkhead Connector
46 Raise Solenoid (EDC) 119 Column Lights Switch (Main/Dip/Flash) 204 Engine Bulkhead Connector
47 Lower Solenoid (EDC) 120 Side/head Light Connector (LH) (3000 Series) 205 ECU 3 Connector
48 Gear Lever Powershift Switches 120A Side/head Light Connector (LH) (2000 Series) 206 Engine Torque De-rate Resistor Connector
a Down 121 Side/head Light Connector (RH) (3000 Series) 207 ISC (Field Speed Control) Validation
b Up 121A Side/head Lights Connector (RH (2000 Series) 208 Hand Throttle
c Auto 122 Air Gauge Illumination Lamp 209 Throttle Pedal Position Sensor
48A Duplicate Powershift Switches (if fitted) 123 Number Plate Lamp (LH) 210 Throttle Pedal Idle Validation Switch
a Up 124 Number Plate Lamp (RH) Connector
b Down 125 Auxiliary Lights Switch 211 Accelerator Switch
c Auto 126 Auxiliary Headlights (RH) 212 Hand Throttle Connectors
49 Powershift Solenoids 127 Auxiliary Headlights (LH) 213 Pedal Throttle Connectors
a Snail 128A Speaker (LH) 214 Powershift ECU 1(Black)
b Tortoise 128B Speaker (RH) 215 Fan Clutch
c Hare 129 Auxiliary Socket 216 Front Bulkhead Connector
49A Splitter Dump Relay 130 Cigar Lighter 217 Engine ECU
50 Accelerator Pedal Switch 131 Reverse Light Relay 218 Water in Fuel Sensor
51 Column Switch 133 Heater Relay 1 219 Bulkhead Connector
52 Powershift Range Neutral Solenoid Selector 134 Heater Relay 2 220 Engine Speed Control Switch
53 Powershift Range Engaged Solenoid 135 Engine Grid Heater 1 221 Intermediate (or Field) Speed Control
Electrics
Connector 136 Engine Grid Heater 2 222 Interconnect (less ECU 1)

54 4WS Option Connector 139 Buzzer Relay 223 Resistor
55 Clutch Warning/Selectronic Bleeper 140 Clutch ‘Up’ Switch 224 EPS 2 Relay
56 Powershift Low/Reverse Air Ram 141 Water Temperature Sender 225 Megafuse
57 Powershift Medium/High Air Ram 142 Air Pressure Switch - Tank 1 226 Upper Front Work Lights Relay (CR121)
58 2WD/Differential Lock Switch 143 Air Pressure Switch - Tank 2 227 Headlight Bar Work Lights Cut-out Relay
59 Front PTO 144 Air Pressure Switch - Tank 3 228 Rear Upper Changeover Work Lights Relay
60 Rear PTO 145 Fuel Level Sender 229 Upper Front Work Lights Relay (WH3)
61 Differential Lock Switch 146 Transmission Oil Filter Switch 230 Headlight Bar Work Lights Relay
62 Differential Lock Cut-Out Relay 147 Air Filter Switch 231 Work Lights Connector - 4 Front Work Lights
63 2WD Dump Relay 148 Front Brake Reservoir Level 232 Work Lights Connector - 6 Front Work Lights
64 2WD Solenoid 149 Rear Brake Reservoir Level 233 Work Lights Connector - 6 Front Work Lights
65 Differential Lock Solenoid 149A Brake Reservoir 3 Level 234 Work Light - RH Rear Fender
66 Rear PTO Brake Solenoid 150 Transmission Oil Pressure Switch 235 Work Light - LH Rear Fender
67 Front PTO Brake Solenoid 151 Speedometer Pick-up 1 236 Rear Fender Work Lights Cut-out Relay
68 Rear PTO Drive Solenoid 151A Speedometer Pick-up 2 237 Work Light - Rear Fender
69 Front PTO Drive Solenoid 152 Engine Oil Pressure Switch 238 CR121E Relay Base
70 Park Brake Switch 153 CANBUS Cable Screen 239 CR121D Relay Base
71 Rear PTO Cut-Out Connector 154 RF Ground 240 Work Lights Harness Interconnect 1
71a Rear PTO Termination Connector (machines 155 Diagnostic Connector 241 Harness Interconnect for 4 Rear Work Lights
without rear PTO cut-out option) 156 4WS Interconnecting Connector 242 ‘A’ Post Work Light Relay
71b Rear PTO Interconnecting Connector 157 Control Module Connector 243 Instrument Cluster 1 (Black)
(machines with rear PTO cut-out option) 158 Fuel Flow Sensor 244 Auxiliary Lights 6-way Relay Base
Section C
Issue 3*
17 - 1
Sectional Diagrams Component Key - Fastrac 2140 (continued) 17 - 1A
9803/8020
245 Auxiliary Lights Single Relay Base 289 540 PTO Range Connector
332 Kick-out Indicator 1
246 Fuse Box (Fuses H1 to H7) 290 Diagnostic Socket
333 Kick-out Indicator 2
Section C
247 Air Gauge Illumination 291 Diagnostic Connector

334 Levers 3 and 4 Connector (Brown/Grey)
248 Powershift ECU 2 (Red) 292 Bulkhead Connector (Pannier)
335 Heating Element
249 ECU 2 Connector B 293 ABS Trailer Socket
336 0V Lower/+12V Raised
250 Instrument Cluster 2 (Red) 294 ABS Trailer Connector (Power in)
337 0V Right/+12V Left
251 Diagnostic Socket 295 Mirror Joystick Controller
338 0V Left/+12V Right
252 CANBUS Through Connector 296 Heated Front Screen Switch
339 0V Raised/+12V Lower
253 CANBUS Terminating Resistor 297 Interconnect Cab Roof
340 Interconnect (with ECU 1)
254 ECU 4 298 Timer Module
341 Throttle Pedal Position and Validation
255 Engine CANBUS Interconnect 299 Momentary Switch - In
Switch Connector
*
256 CANBUS Terminating Resistor Connector 300 Timed Out
342 Roof Liner Harness Connector
257 Spool Valve 5 Solenoid 301 LH Mirror
258 Spool Valve 4 Solenoid 302 RH Mirror
259 Spool Valve 3 Solenoid 303 LH Screen
260 Spool Valve 2 Solenoid 304 RH Screen
261 Spool Valve 1 Solenoid 305 Heated Screen Relay
262 Spool Valve Bulkhead Connector 306 Front Hitch Control
263 Cluster RF Ground 307 Front Hitch Position Sensor
264 Work Light Harness Interconnect WH2 308 Raise/Lower Interconnect
265 Work Light Harness Interconnect CR127 a Raise
266 Starter Solenoid b Lower
267 Air Drier 309 6 Way Resistor Plug
268 Transmission Connectors 310 Transport Switch
269 Neutral Start 311 8 Way Resistor Plug
270 Clutch Down Switch 312 ISO 11786 Resistor Connector
Electrics
271 Flow Divider Warning Light 313 ISO 11786 Socket Connector
272 Flow Divider In-line Fuse 314 Lock-out Pressure Switch
273 Flow Divider Warning Light Feed 315 Pilot Valve
274 Suspension Seat/Flow Divider Power In 316 Levers 1 & 2 Connectors
275 ECU 1 Connector A 317 Connector 1
Wiring Diagrams -Fastrac 2140
276 Flow Divider Interconnect 318 Connector 2

277 ECU 1 Interconnect (with Flow divider 319 Lever 1 Kick-out
Option) 320 Lever 2 Kick-out
278 3-Way Resistor Plug (less Flow Divider) 321 Active
279 Power-in Connector 322 Full Flow
280 With Rear PTO Cut-out 323 Float
281 Without Rear PTO Cut-out 324 Lever 1 Validation
282 Autoshift Connector 325 Lever 2 Validation
283 Work Light - RH Headlight Bar 326 Flow 1 Kick-out
284 Work Light - LH Headlight Bar 327 Flow 2 Kick-out
285 Front Fuse Panel 328 Lever Kick-out Solenoid 1
286 Sensor Disconnect Relay 329 Lever Kick-out Solenoid 2
287 ECU 1 Interconnect 330 Lever Kick-out Control 1
288 1000 PTO Range Connector 331 Lever Kick-out Control 2
Section C
Issue 2*
17 - 1A
10J
(1.0)
B A TRAILER ABS CONNECTOR

17 - 2
SEE SHEET 26 17-26
9803/8020
CR116 440 5 015J
CR65-6
HEATED MIRROR (0.6) (1)
SUPPLY
CR3 SEE SHEET 27 015A
B A A1 SEE SHEET 4 17-4
Section C
(0.6)
IGN. SWITCH 010A
C D A2 SEE SHEET 5 17-5
2 (1.4)
014 (0.6)
010C
015 (6) (2.0) A3 SEE SHEET 6 17-6
7 6 260 (3) CR47 010B
5 270 (3) A4 SEE SHEET 7 17-7
(2)
8 4
9 015G
A5 SEE SHEET 8 17-8
(1.0)
3 2 CR33
10 015C
1 A6 SEE SHEET 9 17-9
201 (6) (0.6)
1 3 4 660F
CRES3 015F
004 014(0.6) 660F (0.6) A7 SEE SHEET 10 17-10
3 4 (2.0)
(1.0) (0.6)
010 (6) 2 015D
A8 SEE SHEET 11 17-11
6 2 (2.0)
201 (6) 1 010G
A9 SEE SHEET 12 17-12
(4)
SEE IGNITION
000 (4)
RELAY 240A
SHEET 010 B1 SEE SHEET 13 17-13
17-17D IGNS1 (1.0)
17D
(0.6)
(6)
660W
210B
860U B2 SEE SHEET 14 17-14
RHSLS (2.0)
(0.6)
203
860N (0.5) B3 SEE SHEET 15 17-15C
3 4 (6)
202 (6) 204
015 B4 SEE SHEET 16 17-16B
1 IGNS2 (3)
860U 660W (6)
3 4 240B
(0.6) (0.6) 2 B5 SEE SHEET 17 17-17
1 (1.4)
2
CR4-C2 203 (4) 7 010H
B6 SEE SHEET 18 17-18
200B (4)
200A (4)
SEE SHEET 4 (1.0)
204 (3) CR54 210D
W/LIGHTS BATS1 (3)
17-4 RELAY 210E
(1.4)
015K(1.0)
240D
B9 SEE SHEET 9 17-9
210 (4) (0.6)
010D
240 (4) C1 SEE SHEET 21 17-21
BATS2 (1.4)
010F
202 C2 SEE SHEET 14 17-14
(1.4)
Electrics
CR100 (8) (3170 ONLY) 005

C3 SEE SHEET 8B
TRACTOR ABS CR46 (1.0)
A B 250 (6)
(SUPPLY) 015E
5A D C SEE SHEET 17 C4 SEE SHEET 23 17-23
SEE (1.0)
SHEET 26 MAXIFUSE 17-17 SEE SHEET 23 C5 17-23B
SEE SHEET 23B
17-26 265A(3) 17-23 240F
C6 SEE SHEET 24 17-24
265B(3) (1.5)
SEE +
SHEET 5 + 3 STARTER 010E
C7 SEE SHEET 25 17-25
MOTOR (1.0)
(3000 ONLY) 1 1A
883D (0.6)
BATTERY 2 C39 C12 240E
CR45 C8 SEE SHEET 25 17-25
CRBLS 3000 + (3)
BATTERY 1 4
SERIES ONLY 015B
- - C9 SEE SHEET 4 17-4
ALTERNATOR (1.4)
H1 7.5A SEE SHEET 8 17-8

4 6 CR103
H2 7.5A SEE SHEET 8
283
(15)
17-8
245 (2140,2190,3220)
883D (0.6)
(2000 ONLY)
H3 7.5A SEE SHEET 8 17-8
(6.0)
8
2 H4 10A SEE SHEET 8 17-8
MEGA HEATER FUSE 1
CR39-D FUSE SEE SHEET 8B
284
(15)
BRAKE LIGHTS H5 10A SEE SHEET 8 17-8
5
RELAY
SEE 17-5 225 (3000 SERIES) 15L H6 15A SEE SHEET 28 17-8
SHEET 5 MEGA HEATER FUSE 2 (4.0)
H7 15A SEE SHEET 29 17-8
FUSE SEE SHEET 8B
005 (3170 ONLY)
SHEET 2
481/11371
SUPPLY CIRCUIT: BATTERY TO STARTER MOTOR; ALTERNATOR; FUSES A1 - A9, B1 - B9, C1 - C9, H1 - H5;
TRAILER ABS CONNECTOR, TRACTOR ABS SUPPLY CONNECTOR
Issue 1
17 - 2
Section C
17 - 3
CR40
8 720
9803/8020
HEATER UNIT 2 1 PES3 (3)
(3000 SERIES) 650
CES9
ONLY 4 3 (2.0)
Section C
710
PES1 (3) 640
CES7
(3)
730 (1.4) 700
FLES
(4)
600 630
CRES1 CES2
(6) (1.4)
610
CRES2
(4) 645 3
CES8
(6) 3 STARTER
660 C40
CRES3 MOTOR
(2.0)
635
CRES4
(2.0)
3 2 1
655 620
CRES5 7 6 5 4 202 CES1
(2.0) (6)
8
CR112
11 10 9
2 ECU1
14 13 12
680 INTERCONNECT
CR30 SEE SHEET 29
AUX. CONN.
9 (3) 636 (3000 ONLY)
1 (2.0)
690 2 1
(2)
CR101 665B(3) 637
638
(2.0)
C (2.0)
TRACTOR ABS 665A(3)
(RETURN)
5B B 13 C48
+ + HORN
448(1.0)
Electrics
A
SEE CR38
SHEET 26
17-26 BAT 1 BAT 2
1
CR94 685
C
(3) - -
AUX POWER 9A B
SOCKETS
A
2
750
1
4 3 2 1 (1.4)
CR11
10 161 CR52
AIR CON 8 7 6 5 CR72
SUSP. SEAT
AUX
2000 760
LIGHTS
2000
A
SERIES
SERIES (3)
11A EARTH
(4)
670
CR85
670 3000
AUX
(4) SERIES 3000 760
B A LIGHTS SHEET 3
SERIES (3) 481/11372
SUPPLY
EARTH CIRCUIT
Issue 1
17 - 3
Section C
CR4-C 660B
START INHIBIT C
181 (0.6)
C8 CRES3
4 6 RELAY. (4.0)
17 - 4
14
854 C C 856A
9803/8020
C5
(0.6) 6 4 (0.6) CR8
8 FRONT PTO
000 2
+12V START
SEE SHEET 2 (4) C 000 59
Section C
2 (4.0) 3
17-2 5 3 A B B A
SWITCH
856A F/PTO 18
FUSE D C C D
(0.6)
105 2/4
+12V IGN A1 CR86
(0.6)
856C 1
DIODE CONNECTOR
CRSIS (0.6)
BRAKE
810A 854
(0.6)
17 (0.6)
1 2
856 2 1
(0.6) 3 4
4 3 3
660C
810 810C A B B A
CDS (0.6)
(0.6) (0.6) SWITCH 19
SEE D C C D
R/PTO
(0.6)
856B
4 6 2/4
SHEET 60
10
1 CR7
1 2 2 1 REAR PTO
181
BRAKE
(4.0)
8
2 855
(0.6)
(0.6)
810B
270
CR36 SEE
CLUTCH DOWN 5
SHEET 15 182 182
SWITCH 10A (4.0) (4.0)
CR4-D
17-10A START INHIBIT RELAY
C41
STARTER
182 SOLENOID
1 2 (4.0)
CES7
1 1
266
H H
D
D8 A A
811
G G M
(0.6)
M J
J
B N N B
16 855 D D 856B F F
CLUTCH START D5 K L L K
(0.6) 6 4 (0.6) C C
MICRO SWITCH E E
D D 2
2 2
Electrics
181 C6 4 3
5 D
2 (4.0) AIR 1
640K
(1.4)
DRiER
195
(1.4)
C78
267
REAR BULKHEAD
CR104
CONNECTORS 2
811
203 TH2
(0.75)
FUSE 1 2
195 NEUTRAL
+12V IGN 195A
C9 (1.5) C9CS START

195B
(1.4)
(0.75)
269
1 1
2 5 5 2
3 6 11 11 6 3
4 7 12 18 18 12 7 4 195B
8 13 19 19 13 8 (0.6)
9 14 20 25 25 20 14 9
10 15 21 26 32 32 26 21 15 10
16 22 27 33 33 27 22 16
39 34 28 23 17 X W W X
17 23 28 34 39 811 K K
24 29 35 40
40 35 29 24 V V
41 36 30 (0.6) L J L
30 36 41 B J H H B
45 42 37 31 U U
31 37 42 45 46 43 38 M C A C M
38 43 46 47 44 G G A
44 47 48 N F T T F N
D E E D
48 S S
O P O
Q R R Q P
203 C5
REAR BULKHEAD
CR1 CONNECTORS C72 268 TH1
TRANSMISSION
SHEET 4
CONNECTORS 481/11373
*FUSE A1 - NEUTRAL START (CLUTCH);

TO MACHINE NUMBER 740001
Issue 2
17 - 4
Section C
CR4-C 660B
C
START INHIBIT 181 (0.6)
C8 CRES3
4 6 RELAY. (4.0)
14 856A
854 C C5 C
6 4
9803/8020
(0.6) (0.6) CR8
8
17 - 4 - 2
2 FRONT PTO
+12V START 000
SEE SHEET 2 (4) C 000 59
2 (4.0) 3
Section C
17-2 5 3 4 1 1 4
FUSE SWITCH
5 AMP 856A F/PTO 3 2 2 3
(0.6) 18
105 2/4
+12V IGN A1 CR86
(0.6)
856C DIODE CONNECTOR 1
CRSIS (0.6)
17 BRAKE
810A 854
(0.6) (0.6)
CR7
1 2
856 2 1 REAR PTO
(0.6) 3 4
4 3 60
3
810 810C 4 1 1 4
(0.6) CDS (0.6) SWITCH 660C
SEE R/PTO (0.6)
856B
(0.6)
4 6 19 3 2 2 3
SHEET 2/4
270 10
1
181
1 2 2 1
(4.0)
8 BRAKE
2 855
810B
(0.6)
(0.6)
CR36 SEE
CLUTCH DOWN 15 5
SHEET 182 182
SWITCH 10A (4.0)
CR4-D (4.0)
17-10A START INHIBIT RELAY
C41
STARTER
182 SOLENOID
1 2 (4.0)
CES7
266
1 H H 1
D
811
D8 A A
G G
(0.6)
M M
J J
B N N B
16 855 D D 856B F F
CLUTCH START D5 K L L K
(0.6) 6 4 (0.6) C E E C
MICRO SWITCH 203
D D 2
2 2
4 3
Electrics
D 181
5 C6 1
2 (4.0) 267
640K
(1.4)
AIR
195
DRiER
(1.4)
REAR BULKHEAD C78

CR104
CONNECTORS 2
811
FUSE
10 AMP TH2
(0.75)
1 2
195 NEUTRAL
+12V IGN C9 195A START
(1.5) C9CS
195B
(1.4)
(0.75)
269
1 1
2 5 5 2
3 6 11 203 11 6 3
4 7 12 18 18 12 7 4 195B
8 13 19 19 13 8 (0.6)
9 14 20 25 25 20 14 9
10 15 21 26 32 32 26 21 15 10
16 22 27 33 33 27 22 16
17 23 28 34 39 39 34 28 23 17 X W W X
40 35 29 24
811 K K
24 29 35 40 L V V J L
41 36 30 (0.6) B J H H B
30 36 41 45 42 37 31
31 37 42 45 M U U M
46 43 38 C A G G A C
38 43 46 47 44
44 47 48 N F T T F N
D E E D
48 S S
O P O
Q R R Q P
C5
REAR BULKHEAD
CR1 CONNECTORS C72 268 TH1
TRANSMISSION SHEET 4
CONNECTORS 481/11373 Issue 2
FUSE A1 - NEUTRAL START (CLUTCH);

FROM MACHINE NUMBER 740002
Issue 1
17 - 4 - 2
Section C
FUSE
10 AMP
883
17 - 5
+12V IGN A2 BLS
(1.4)
9803/8020
1
Section C
1
2 5 5 2
3 6 11 11 6 3
4 7 12 18 18 12 7 4
8 13 19 19 13 8
9 14 20 25 25 20 14 9
10 15 21 26 32 32 26 21 15 10
BRAKE LIGHT 16 22 27 33 33 27 22 16
17 23 28 34 39 39 34 28 23 17
SWITCH 24 29 35 40 40 35 29 24
30 36 41 41 36 30
20 31 37 42 45 45 42 37 31
38 43 46 46 43 38
44 47 47 44
48 48
2 1 216
FRONT
BULKHEAD C28
CR51
CR57 C18
1 2 R.H. LIGHT 620C (1.4)
CLUSTER
110
(1.4)
SEE APPENDIX B 100
883
(1.4)
17-32 3 2 1
883(1.4)
2000 ONLY
883A (0.6)
PES1 CR117
4
884
6 5
(0.6)
HIGH LEVEL
BRAKE LIGHT
(0.6)
710M
4 (3000 SERIES 12-31
111
(0.6)
ONLY)
6 620B (1.4)
(3000 ONLY) 1 2
8
883F 883E
2 CRBLS
(1.4) (0.5) 3 2 1
883B (0.6)
Electrics
21 5 A B 6 5 4
883D (0.6) 883D
CR39-D D C
(2000 ONLY) (0.6) 99 C19
BRAKE LIGHTS
(0.5)
635H
L.H. LIGHT
RELAY 5A CR100
CLUSTER
SEE SHEET 2
17-2 SEE APPENDIX B
17-32
883 (1.4) (2000) CES1

CRES4
620A (2.0)
D 883D (0.6) (2000)
D8
883F (1.4) (3000) C1
4 3 2 1
TRAILER SOCKET 98
SEE APPENDIX A 8 7 6 5
710M D D 884
D5 883C (1.4)
(0.6) 6 4 (0.6)
SHEET 5
481/11374
D 110
5
2 (1.4)
111
(0.6)
FUSE A2 - BRAKE LIGHTS
Issue 1
17 - 5
Section C
115B (1.0)
115F CR4-E4
17 - 6
FUSE (0.6) SEE SHEET 11
9803/8020
15 AMP 17-11
115 (2.0) REAR 610E (1.0)
CRES2
+12V IGN A3 CRIS WIPER
Section C
MOTOR -
22
1 2 2 1
CR26
(1.4)
115E
M REAR WIPER
CR37 3 4 4 3
PUMP PARK 26
REAR WASHER
(3000 SERIES) 2 WIPE
CR52
SUSP +
710H (1.0) 1
2 PES1 SEAT
12
1
750
(1.4) B
844 (1.0)
3 6 9
3000
SERIES
2 5 8
2000
SERIES
1 4 7
844
FRONT
(1.0)
C28 BULKHEAD CR51
1
CR4
5 2 1
11 6 3 2 5
18 12 7 4 3 6 11 843 (0.6)
19 13 8 4 7 12 18
Electrics
25 20 14 9 8 13 19
32 26 21 15 10 9 14 20 25
33 27 22 16 10 15 21 26 32 B1
39 34 28 23 17 16 22 27 33
40 35 29 24 17 23 28 34 39
115A (1.0)
41 36 30 24 29 35 40
845 (0.6) 660D
45 42 37 31 30 36 41
46 43 38 31 37 42 45
B6 CRES3
47 44 38 43 46 (0.6)
48 44 47 B4
48
2 6
25 CR4
844 (1.0) 5
INT. WIPER
RELAY
3
115C (1.0) B8
2
B2 846 (1.0)
1
2 1 710B -7
PES1 880K B5
(0.6) +8 SEE SHEET
LHSLS
(0.6) 17C 847 (1.0)
C58
24 23 17-17C
PUMP CR5
REAR WASHER REAR WASH SHEET 6
481/11375
(2000 SERIES) WIPE SWITCH
650J
CES9
(1.0)
FUSE A3 - REAR WASH/WIPE, SUSPENSION SEAT
Issue 1
17 - 6
Section C
17 - 6A
9803/8020
FLOW DIVIDER FLOW DIVIDER WARNING
Section C
12 11 10 9 8 7 6 5 4 3 2 1
WARNING LAMP LAMP FEED
24 23 22 21 20 19 18 17 16 15 14 13
271 273
36 35 34 33 32 31 30 29 28 27 26 25
827A 827A
(0.5) A A (0.6)
CR66
CR93 FD6
INST CLUSTER 2 RED
250 FD2
116A (0.6) FD4
115EB 116 FLOW
1 LITTLE 2
(0.6) FUSE DIVIDER
115E (0.6) -7 +8
17-6
115E FDSS VALVE
(1.4) (1.4) 1
IN LINE 163
FUSE E3
CR52 FD5 +3
272
SUSPENSION SEAT 2 2 B A
POWER 2
/ FLOW DIVIDER 12 274 IN
(SEE SHEET 6) 1 1
827
Electrics
750C (0.6) 2 (0.6)

750 750 750B (0.6)
(1.5) (1.4) FDES
FD3 162
FLOW DIVIDER
SWITCH
115EA (1.4)
2
FD1
1 SUSPENSION
SEAT
161 SHEET 6A
750A (1.4) 481/11375
FUSE E3 - FLOW DIVIDER
Issue 1
17 - 6A
Section C
120B (1.0)
FUSE SEE SHEET 7A
15 AMP 17-7A
17 - 7
17-7A (32)SEE SHT 7A FOR
120 (2) 120A (2)
9803/8020
+12V IGN A4 PISA4 FRONT WIPER
MOTOR SWITCH
Section C
120C (1.0)
SEE SHEET 7A
17-7A
3 2 1 1 2 3
7 6 5 4 4 5 6 7
11 10 9 8 8 9 10 11
14 13 12 12 13 14 WASH HORN
51
CR43
COLUMN SWITCH
842 (1)
842 (1) 3000 SERIES
C59
PUMP
2 1 FRONT WASHER
710J (1) (2000 SERIES)
2
27
841 (2)
1
Electrics
650K
842 (1)
CES9
CR48 (1.0)
2000 SERIES
PUMP
FRONT WASHER
(3000 SERIES)
841
(2)
1
2 5 1
3 6 11 5 2
4 7 12 18 11 6 3
8 13 19 18 12 7 4 C48
9 14 20 25 19 13 8 2 1
10 15 21 26 32 25 20 14 9 HORN
16 22 27 33 32 26 21 15 10
17 23 28 34 39 33 27 22 16 28
24 29 35 40 39 34 28 23 17
30 36 41 40 35 29 24
31 37 42 45 41 36 30
38 43 46 45 42 37 31 690 (2)
PES1 44 47
216 46 43 38
48 47 44
48
SHEET 7
CR51 C28 481/11376
FRONT B/HEAD
CONNECTOR
* FUSE A4 - FRONT WASH/WIPE, HORN
Issue 1
17 - 7
Section C
(0.6)
CR39-E
710K
17 - 7A
9803/8020
FRONT INT.
830 WIPE RELAY
E7 E4 E1 (0.6)
Section C
830 (0.6)
31
17-7 120B 831 E1
- 120 (2) (1) E8 E5 E2 (1)
PISA4 E4 710K
SEE SHEET E6 PES1
(0.6)
7
E9 E6 E3 832
M (1)
PARK
+
II E8
+ I E2
WIPE 831
120B (1) (1)
E5
832 (1)
120A (2)
C30
FRONT WIPER
MOTOR 832 (1)
30 3 2 1 1 2 3
1 2 3 120C 3 2 1 7 6 5 4 4 5 6 7
(1) 834 (1) 11 10 9 8 8 9 10 11
4 5 6 6 5 4 14 13 12 12 13 14
833 (1)
(1)
120C
Electrics
CR43 51
RIGHT HAND
COLUMN SWITCH
650A
CES9
(1)
833
(1)
(1)
834
1
2 5
3 6 11 1
4 7 12 18 5 2
8 13 19 11 6 3
9 14 20 25 18 12 7 4
10 15 21 26 32 19 13 8
16 22 27 33 FRONT B/HEAD 25 20 14 9
17 23 28 34 39 32 26 21 15 10
24 29 35 40 CONNECTOR 33 27 22 16
30 36 41 39 34 28 23 17 32
31 37 42 45 40 35 29 24
38 43 46 216 41 36 30
44 47 45 42 37 31 WIPER SWITCH SHEET 7A
48
46 43 38
33A 47 44
48 481/11376
C28
* FUSE A4 (CONTINUED) - FRONT WIPER CIRCUIT
Issue 1
17 - 7A
Section C
17 - 8
9803/8020
C32
ESOS
Section C
130 (1.0)
7.5A
130 (1.0)
+12V IGN A5
C74
ENGINE
(3170 ONLY)
BULKHEAD
ELEC' ENG'
645B (2.0) 204
FUSEBOX
CR103
246 CR104 REAR C78 (2140,3190,3220) 130 (1.0)
7.5A
340 (1.5)
BULKHEAD 2
+12V BAT H1 341 (1.5)
203
7.5A
341 (1.5) 1 H H 1 X W
+12V BAT K V
H2 A A
L
B
J
H
M G G M U
J J M C A
7.5A G
B N N B T
342 (1.5) F F N D F
+12V BAT E
H3 K L L K 645D (2.0) S
C C O P
E E Q R
10A D D
2 2
343 (2.0)
+12V BAT H4 340 (1.5)
10A
344 (2.0) 343 (2.0)
+12V BAT H5
Electrics
342 (1.5)
344 (2.0)
645E (2.0)
645A (2.0)
645B (2.0)
645C (2.0)
645D (2.0)
SHEET 8
645E (2.0) 481/11377
645A (2.0)
1A
645C (2.0)
CR125
BATTERY
NEGATIVE 2
FUSES A5, H1 TO H5 - ELECTRONIC ENGINE
Issue 1
17 - 8
Section C
17 - 8B
9803/8020
C75
ENGINE ECU
217
Section C
10 9 8 7 6 5 4 3 2 1
20 11
30 21
40 31
50 41
554 (0.5)
C1
HEATER RELAY 1
3 133
STARTER MOTOR
+VE 553 (0.5) C47 C43
ENGINE
GRID
HEATER 1
100A
200J (10)
283 (15) C3 C15 383 (15)
MEGA FUSE (718/56069)
C45 135
225
284 (15) C4 C16 384 (15)
MEGA FUSE
(0.6)
650L
100A
3A CES9
175A (0.5)
(3170 ONLY)
+12V 175 (1.0)
Electrics
HEAT C3 (0.6)
(3170 ONLY) 650M
175 (1.0) C44
ENGINE
C57 GRID
HEATER 2
1 200J (10)
2 5 1 C46
3 6 11 5 2 (718/56069)
4 7 12 18 11 6 3
8 13 19 18 12 7 4
9 14 20 25 19 13 8
134 136
10 15 21 26 32 25 20 14 9
16 22 27 33 32 26 21 15 10
17 23 28 34 39 33 27 22 16 HEATER RELAY 2
24 29 35 40 39 34 28 23 17
30 36 41 40 35 29 24
31 37 42 45 41 36 30
38 43 46 45 42 37 31
44 47 46 43 38
48 47 44
48 SHEET 8B
REAR 481/11377
BULKHEAD
CR1 C5
FUSES A5, H1 TO H5 - ELECTRONIC ENGINE (CONTINUED)
Issue 1
17 - 8B
Section C
CR114
ENGINE SPEED
CONTROL SWITCH
220 558 (0.5)

SEE 549 (0.5)
SHEET 860K (0.5)
RHSLS 559 (0.5)
17 - 8D
9803/8020
17D
860J (0.5) +8 1 3 4 6
17-17D 1416 (0.5)
558 (0.5) C75

Section C
2 CR1 C5 ENGINE ECU

REAR
559 (0.5)
BULKHEAD
635G (0.5) 217
-7 2 5 1 555 10 9 8 7 6 5 4 3 2 1
2 5
203 1
635 635F (0.5) 3 6 11 5 2 (0.5)
CRES4 4 7 12 18 11 6 3
(2.0) 8 13 19 18 12 7 4
635A (0.5) 9 14 20 25 19 13 8
10 15 21 26 32 25 20 14 9 C76
32 26 21 15 10
20 11
16 22 27 33 WATER
17 23 28 34 39 33 27 22 16 30 21
24 29 35 40 39 34 28 23 17 IN FUEL
635B (0.5) 40 35 29 24 40 31
30 36 41
+8 1 +3 4 6 31 37 42 45 41 36 30 50 41
38 43 46 45 42 37 31 218
44 47 46 43 38
48 47 44
48 B A
552 650N
555 (0.5)
1 2 (1.0) (1.0)
-7 2 5 539 (0.5)
SEE 160K (0.5)
SHEET PISC4 551 (0.5)
23 CR105 650
CES9
INTERMEDIATE (2.0)
550 (0.5)
17-23 SCI
CR49
C28
550 (0.5)
551 (0.5)
549 (0.5)
543 (0.5)
540 (0.5)
539 (0.5)
POWERSHIFT
544 (0.5)
ECU 1 1
214 CR51 2 5 1
3 6 11 5 2
542 (0.5)
541 (0.5)
4 7 12 18 11 6 3
8 13 19 18 12 7 4
9 14 20 25 19 13 8
10 15 21 26 32 25 20 14 9
8 2 16 22 27 33 32 26 21 15 10
12 11 10 9 7 6 5 4 3 1 17 23 28 34 39 33 27 22 16
24 29 35 40 39 34 28 23 17
30 36 41 40 35 29 24
24 23 22 21 20 19 18 17 16 15 14 13 31 37 42 45 41 36 30
38 43 46 45 42 37 31
44 47 46 43 38
36 35 34 33 32 31 30 29 28 27 26 25 48 47 44
FRONT 48
BULKHEAD
216
1416 (0.5)
Electrics
542 (0.5)
541 (0.5)
540 (0.5)
543 (0.5)
544 (0.5)
720
PES3
2 1 B A (3.0)
635 635J (0.5)
CRES4 E D C B A
(2.0) 3 C
K J H G F
207 CR118 208 CR106
CR108 THROTTLE PEDAL
ISC HAND POSITION AND
VALIDATION THROTTLE 341
VALIDATION SWITCH
CONNECTOR 720M (0.5)
HAND THROTTLE CONNECTORS PEDAL THROTTLE CONNECTOR

(SHOWN AT IDLE)
1 2 212 213
A B
3 C A B C D E
F G H J K
PPS
SIG. 1
+5V REF
IVS
LOW
(GRD)
COMMON
BRN
GRD
RED
+5V
WHT
O/P
ZERO V
SHEET 8D
IVS N.C.
IVS N.O.
481/11377
FUSES A5, H1 TO H5 - ELECTRONIC ENGINE (CONTINUED)
Issue 1
17 - 8D
Section C
920 920B (0.6)
(0.6)
511 SSS 920A (0.6)
CR65-15 920C
(0.6) (0.6) 725A (0.6)
725
17 - 9
505 SES
CR66-12 (0.6) 725B (0.6)
(0.6) 505 (0.6) E5 E6
9803/8020
17-23 433 (0.6) LH DRAFT PIN RH DRAFT PIN
CR66-21 518 518 (0.6)
(0.6) 508 (0.6) 42L 42R
SEE 416B 414B 503 (0.6)
SHEET ADCOS (0.6)
Section C
(0.6) E1
510 (0.6) 1 2 3 1 2 3
23 EDC ELECTRONIC
E4
414B LINK (0.5) CONTROL UNIT
SSS (0.6)
39
SPEED SIGNAL
3 2 1 1 2 3
SPLICE 426
4 7 38 55
7 6 5 4 5 6 (0.6)
20 37
510 11 10 9 8 8 9 10 11 503A
CR66-18 1 19
(0.6) (0.6)
14 13 12 12 13 14
415
1
CR65-8 504A
(0.6) (0.6)
20
38
CR87 500B SEE

2
RSS SHEET 17-23B

(0.6)
23B
21
39
425 (0.6)
430 (0.6)
427 (0.6)
36
54
506 (0.6)
18
507 (0.6) 40
37
55
19
504 (0.6) 1
2 12 ENLARGED VIEW OF
924 (0.6)
CAVITY ID'S FOR E1
928 (0.6) 3 14 13 11
SEE 17-23B 860RB 930 (0.6)
SHEET E23-8
(0.6) 4 18 10
23B 922 (0.6) 15 17
509 (0.6) 5 16 9
416B (0.6) 403B (0.6)
6 8
+8 1 +3 4 6 7
424 (0.6)
715 (0.6)
38 300A (0.6)
E10 135 (0.6) E2
AREA CONTROL
660GD (0.6)
660GA
(0.6)
CUT-OUT 1 2 PANEL 37
SWITCH 660GE (0.6)
429 (0.6)
660GC (0.6)
EDCES
-7 2 5 660G (0.6)
415 428 (0.6)
Electrics
923 660GB (0.6)

(0.6)
(0.6)
660GC 660G (0.6) 431 (0.6)
(0.6) CRES3
135
A (0.6)
M B 1 2 3 FUSE
3 2 1 A6
2 35 E9 L U N C +12V IGN
4 5 6 300A
422 JACK K T V P D 6 5 4 (0.6) 300 FUSE
(0.6) 1 SOCKET PFSB9 B9
S R (0.6) +12V BAT
J E 36 CR2
E3 279
H F EDC
G POWER-IN CONNECTOR 300B
E16 CR66-33 (SEE SHT 23) 17-23
CONNECTOR (0.6)
860R
(0.6)
BULKHEAD
300C 3000 12 11 10 9 8 7 6 5 4 3 2 1
929
CONNECTOR
(0.6)
(0.5) CR112-9 (SEE SHT 28) SERIES
860RA (0.6) 219 403B 24 23 22 21 20 19 18 17 16 15 14 13
(0.6) SEE 3000 36 35 34 33 32 31 30 29 28 27 26 25
ASS SHEET 23 SERIES
509 (0.6)
17-23
CR65
A 243
B M 509B INST CLUSTER 1 BLK
C N U L 860R (0.6) SEE (0.6)
+8 1 3 4 6 RHSLS SHEET 17D 2000
D P V T K SERIES
17-17D ELSS
E R S J E11
219 509A CR64-4
E15 F H 2 RAISE/LOWER (0.6)
932
RLSS
G
(0.6)
SWITCH
BULKHEAD
CONNECTOR
(SEE SHEET 9B) -7 2 5 SHEET 9
931
41 481/11378
17-9B (0.6)
FUSE A6 - ELECTRONIC DRAFT CONTROL (EDC) TYPE D +, IGNITION CAB SIDE

FUSE B9 - ELECTRONIC DRAFT CONTROL (EDC) TYPE D +, BATTERY CAB SIDE
Issue 1
17 - 9
Section C
920 920B (0.6)
(0.6)
SSS 920A (0.6)
920C
(0.6) 725A (0.6)
SES
725B (0.6)
17 - 9A
E5 E6
9803/8020
725 (0.6) LH DRAFT PIN RH DRAFT PIN
935 (0.5) 42L 42R
504 (0.6)
Section C
1 2 3 1 2 3
425 (0.6)
426 (0.6)
504A
(0.6)
RS2
25 14
13
13 1
39
25
12
508 (0.6)
24
928 (0.6)
E1 503A (0.6)
560 Ohms EDC ELECTRONIC 433 (0.6)
CONTROL UNIT 430 (0.6)
15
427 (0.6)
2
506 (0.6)
40
14
507 (0.6)
RS1
1
2 12 ENLARGED VIEW OF
924 (0.6)
CAVITY ID'S FOR E1
3 14 13 11
930 (0.6)
4 18 10
922 (0.6) 15 17
509 (0.6) 5 16 9
403B (0.6)
6 8
7
424 (0.6)
715 (0.6)
E2
660GA
(0.6)
503 (0.6)
CONTROL
PANEL 37
429 (0.6)
EDCES
428 (0.6)
Electrics
660G (0.6)
135 (0.6)
923 660GB (0.6) 431 (0.6)
(0.6)
660G (0.6)
E3 CRES3
135
A (0.6) FUSE
M B 1 2 3
3 2 1 A6 +12V IGN
L U N C
4 5 6 300A
K T V P D 6 5 4 (0.6) 300 FUSE
PFSB9 B9
S R (0.6) +12V BAT

J E 279 36 CR2
POWER-IN
H F EDC 300B
E16 G CONNECTOR CR66-33 (SEE SHT 23) 17-23
CONNECTOR (0.6)
860R
(0.6)
BULKHEAD
300C 3000
929
CONNECTOR
(0.6)
(0.5) CR112-9 (SEE SHT 28) SERIES 12 11 10 9 8 7 6 5 4 3 2 1
219 403B 24 23 22 21 20 19 18 17 16 15 14 13
(0.6) SEE 3000 36 35 34 33 32 31 30 29 28 27 26 25
ASS SHEET 23 SERIES
509 (0.6) 17-23

A CR65
B M 243
509B INST CLUSTER 1 BLK
C N U L
+8 1 3 4 6 860R (0.6) SEE (0.6)
RHSLS SHEET 17D 2000
D P V T K
SERIES
R S E11 17-17D ELSS
E J
932
(0.6)
219 2 RAISE/LOWER 509A
F H CR64-4
RLSS
E15 G (0.6)
SWITCH
BULKHEAD
CONNECTOR SHEET 9A
(SEE SHEET 9B) -7 2 5
41 481/11378
931
933 (0.6)
(0.5)
FUSE A6 - ELECTRONIC DRAFT CONTROL (EDC) TYPE B, IGNITION CAB SIDE

FUSE B9 - ELECTRONIC DRAFT CONTROL (EDC) TYPE B, BATTERY CAB SIDE
Issue 1
17 - 9A
Section C
LESS REAR
PTO CUT-OUT 5 44A
932 (0.6)
E19 281 FB
17 - 9B
POSITION
9803/8020
923 RAISE
SENSOR 43 (0.6)
7
2 1 1 2
Section C
926
(0.6)
1 2 3 3 3 5 45A
FC
E12
929 LOWER
RH FENDER FA
(0.6)
7
3 2 1 1 2 3
6 5 4 4 5 6
920C (0.6)
932B (0.6)
932 (0.6)
SWFS
424 (0.6)
715 (0.6)
932A (0.6)
WITH REAR
PTO CUT-OUT
(SEE SHEET 11A) 17-11A
280
923B (0.6)
923 (0.6)
RS 3 2 1 1 2 3
923C (0.6)
6 5 4 4 5 6
929B (0.6)
929 (0.6) E13 5
44B
LS 932
929C (0.6) LH FENDER (0.6) FB
923 RAISE
Electrics
A A (0.6)
M B B M
L C 1 2
U N C N U L 2 1
926
(0.6)
K T V P D D P V T K 3 5
3 45B
J S R E E R S J FC
H F F H 929 LOWER
G G LESS REAR FA
PTO CUT-OUT (0.6)
7
281
E16 E15 219
BULKHEAD
219 BULKHEAD 46 E8
SEE SHEETS 503 (0.6) 1 2 RAISE
9 & 9A SOLENOID
17-9 & 9A 924A (0.6)

924 (0.6) 47
VSS E7
1 2 LOWER
SOLENOID
504 (0.6) 924B (0.6)
SHEET 9B
481/11378
FUSE A6 - ELECTRONIC DRAFT CONTROL (EDC) D+ AND B, IGNITION CHASSIS SIDE

FUSE B9 - ELECTRONIC DRAFT CONTROL (EDC) D+ AND B, BATTERY CHASSIS SIDE
Issue 1
17 - 9B
Section C
481/11379
CDS 4 6 655C
810C 660L (1.0)
(0.6) (0.6) 655A
17 - 10
SEE CRES5
9803/8020
(1.0)
SHEET 4 655B
8 660ZA (1.0) 125C
17-4 CRES3 12 11 10 9 8 7 6 5 4 3 2 1
2 (0.6) (1.0)
24 23 22 21 20 19 18 17 16 15 14 13 CR50
660X FUSE
Section C
CR121-B 49A (1.0) 36 35 34 33 32 31 30 29 28 27 26 25

P/SHIFT ECU 2 RED
5 15 AMP
SPLITTER 248
125
DUMP RELAY +12V IGN A7 PSSS
UP 48A (2.0)
(0.6)
660ZB
CR95
DUPLICATE 900
AUTO-SHIFT 901 (0.6)
(0.6)
(0.6)
660ZC
125B CR49
470B
A B B A (1.0) P/SHIFT ECU 1 BK
(0.6)
D C C D 902 (0.6) 12 11 10 9 8 7 6 5 4 3 2 1 214
125A 24 23 22 21 20 19 18 17 16 15 14 13 CR61
(1.0) ACCELERATOR PEDAL
471B (0.6) 36 35 34 33 32 31 30 29 28 27 26 25
SWITCH
(3000 ONLY)
CR96 472B(0.6)
DUPLICATE 413
DOWN b AUTO-SHIFT 472C(0.5) 472A (0.6)
48A ASSS
(0.6) 50
472
(0.6)
B A A B 471C (0.5) 471A 1 2
815 (1.0)
DSSS 2 1
471 (0.6) (0.6) 1
3
470 (0.6) 3
CR113 470C (0.5) 470A 3
AUTOSHIFT 2 1 USSS
(0.6)
AUTO c CONNECTOR
(3000 PLUS ONLY) 282 4 3 720E
PES3
635E 412 (0.6)
CRES4
(0.5) (0.6)
C21 1
GEAR LEVER 2 5
DOWN 3 6 11
4 7 12 18
8 13 19
9 14 20 25
UP 10 15 21 26 32
1 2 16 22 27 33
2 1
17 23 28 34 39
3 4 24 29 35 40
48 4 3 30 36 41
AUTO 31 37 42 45
38 43 46
Electrics
44 47
48
203 CR1
(1.4)
640B
REAR BULKHEAD
CONNECTOR
49a CES7
471
TH5 (1.4)
SNAIL 1 2 470
SOL'ND (1.4)
472
(1.4)
900 TRANSMISSION 900

(0.75) (0.6)
CONNECTORS
49b 1
268 5 2
TH7 W X X W
11 6 3
K K 18 12 7 4
TORTOISE 1 2 V J L L J V 19 13 8
SOL'ND 815A H B B H 25 20 14 9
(0.75) U M M U 32 26 21 15 10
G A C C A G 33 27 22 16 C5
SDS T T 39 34 28 23 17
203
815B F D N N D F
E E 40 35 29 24 REAR BULKHEAD
S S 41 36 30
(0.75) O O P CONNECTOR
49c R Q P Q R 45 42 37 31
46 43 38
TH4 47 44
48 C50 W
HARE 1 2 815C
SOL'ND ALTERNATOR
(0.75) TH1 C72 815 (1.0)
815
(0.75) 412
(1.4)
901 901
(0.75) (0.6) 4
902 902
(0.75) (0.6)
SHEET 10
481/11379
FUSE A7 - POWERSHIFT ECU - 3 SPEED SPLITTER, SPLITTER DUMP RELAY
Issue 1
17 - 10
Section C
R SEE 810B (0.6)
CDS
N SHEET 4
F
17-4
SEE 160J + S
450 (0.6)
PISC4
9803/8020
CR44 SHEET 23 (0.6)
17 - 10A
COLUMN SWITCH
720K 17-23
PES3
(0.6) 12 11 10 9 8 7 6 5 4 3 2 1
CR42
Section C
3 2 1 51 1 2 3 BLEEPER
55 24 23 22 21 20 19 18 17 16 15 14 13 214 CR49
36 35 34 33 32 31 30 29 28 27 26 25 P/SHIFT ECU 1 BK
6 5 4 4 5 6
L
M
H
485A AND 485B
477
(0.6)
477A (0.6) 3190/3220 ONLY
478A (0.6)
PRLS
478
479A (0.6)
(0.6)
480A (0.6) 3 2 1
485 (0.6) 485B 7 6 5 4
479
(0.6)
3KSS
(0.5)
126 (0.6) 10 9 8
480
(0.6)
PRMS 126A (0.6)
126B (0.6)
126C (0.6)
CR75
4 3 2 1 RANGE NEUTRAL
0.5)
126D 52 202
PRHS (0.6) SOLENOID SELECTOR
CR112
485 OR 485A
8 7 6 5
487 (0.6) ECU1
INTERCONNECT
488 (0.6)
489 (0.6)
PRRS 490 (0.6)
478B
(0.6)
479B
(0.6)
477B
(0.6)
126E (0.6) 12 11 10 9 8 7 6 5 4 3 2 1
PRSFS
24 23 22 21 20 19 18 17 16 15 14 13 248 CR50
36 35 34 33 32 31 30 29 28 27 26 25
P/SHIFT ECU 2 RED
126F (0.6)
Electrics
494
126G (0.6) (0.6)
12 11 10 9 8 7 6 5 4 3 2 1
126H (0.6) 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 8 7 6 5
480B
(0.6)
CR76
492
(0.6)
RANGE ENGAGE 53
491 (0.6)
SOLENOID CONNECTOR
(0.6)
250 CR64
CR66
493 (0.6) 4WS OPTION CONNECTOR
486 OR 486A
INST. CLUSTER 2 RED (2000 SERIES ONLY)

486 (0.6)
1KSS
486B
(0.6)
3 2 1
7 6 5 4
12 11 10 9 8 7 6 5 4 3 2 1 10 9 8
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
SHEET 10A
481/11379
243
CR65
INST. CLUSTER 1 BK
FUSE A7 (CONTINUED) - POWERSHIFT ECU - SELECTRONIC
Issue 1
17 - 10A
Section C
Note: Items 56 and 57 shown in neutral position
9803/8020
17 - 10B
12 11 10 9 8 7 6 5 4 3 2 1
CR50 248 24 23 22 21 20 19 18 17 16 15 14 13
Section C
P/SHIFT ECU 2 RED 36 35 34 33 32 31 30 29 28 27 26 25
437 (0.6)
441 (0.6)
438 (0.6)
443 (0.6)
439 (0.6)
446 (0.6)
441 (0.6)
436 (0.6)
442 (0.6)
437 (0.6)
436 (0.6)
446 (0.6)
1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5
630A (0.6)
630B (0.6)
630C (0.6)
C26 630D (0.6)
1
LOW REVERSE 1 2 5
5 2 3 6 11
11 6 3
18 12 7 4 4 7 12 18
56 19 13 8 8 13 19
25 20 14 9 9 14 20 25
32 26 21 15 10 10 15 21 26 32
33 27 22 16 16 22 27 33
39 34 28 23 17 17 23 28 34 39
40 35 29 24 24 29 35 40
41 36 30 30 36 41
Electrics
45 42 37 31 31 37 42 45
46 43 38 38 43 46
47 44 44 47
C5 48 48
439 (0.6)
443 (0.6) 203
REAR BULKHEAD
438 (0.6) CR1
CONNECTOR
442 (0.6)
1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5
C27
630E (0.6) CES2
630F (0.6)
HIGH MEDIUM 630G (0.6)
57 630H (0.6)
SHEET 10B
481/11379
FUSE A7 (CONTINUED) - POWERSHIFT ECU - SELECTRONIC (CONTINUED)
Issue 1
17 - 10B
Section C
CR98
COLUMN SWITCH
BUTTON TH3 2 1
CR66 INCHING
9803/8020
INST CLUSTER 176 CES7 SOLENOID
17 - 10C
2 RED 250 1 2 182

2 1
Section C
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
†
820
(0.75)
36 35 34 33 32 31 30 29 28 27 26 25 820 (0.6)
X W W X
640N (0.6)
640M (0.6)
K V K
L J V J L
B H
821
H B
(0.75)
499 (0.6) M U U
C A C M
G G A
N F T T F N
498 (0.6) 821 (0.6) 821 (0.6) D E E D
S S
O P O
Q R R QP
820 (0.6)
CR99
INCHING SOLENOID
RESISTOR CONNECTOR 268 268
CR1 TH1
C72
175 1 C5 TRANSM'N TRANSM'N
1 2 2 5 CONNECTOR CONNECTOR
2 1 3 6 11
1
5 2
4 7 12 18 11 6 3
8 13 19 18 12 7 4
9 14 20 25 19 13 8
10 15 21 26 32 25 20 14 9
16 22 27 33 32 26 21 15 10
17 23 28 34 39 33 27 22 16
526 (0.6)
821B (0.6) 24 29 35 40 39 34 28 23 17
30 36 41 40 35 29 24
4R7 ISRS 31 37 42 45 41 36 30
821A (0.6) 38 43 46 45 42 37 31
44 47 46 43 38
203 47 44
524D (0.6)
48
48
REAR B/HEAD
CONNECTOR
655D
CRES5
(1.0) 822 (0.6)
526 (0.75)
823 (0.75)
524D (0.75)
822 (0.75)
640N (0.75)
640M (0.75)
823 (0.6)
823 (0.6)
822 (0.6)
CLUTCH
PEDAL
525
DOWN (0.6)
CR49
5K
524
P/SHIFT ECU 1 BK a
(0.6)
RT
12 11 10 9 8 7 6 5 4 3 2 1
214 177 TOTS2
24 23 22 21 20 19 18 17 16 15 14 13 RP 1K
D.O.R.
36 35 34 33 32 31 30 29 28 27 26 25 b
Electrics
CLUTCH
PEDAL 3 2 1
UP 524D
(0.75)
177 CR53 526
1 2 3 CLUTCH (0.75)
POTENTIOMETER
523 (0.6)
522 (0.6) TH8 TH6

521 (0.6) TH9 CLUTCH BRAKE LUBE

SOLENOID
524C (0.6)
SOLENOID
OIL TEMP 2
524B (0.6) 179 181 180
524 (0.6)
TOTS1
524A (0.6) 1 2
1 2 1 2
2 1
526 (0.6)
178
C71
525 (0.6) OIL TEMP 1 SHEET 10C
12 11 10 9 8 7 6 5 4 3 2 1
481/11379
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
248 CR50
P/SHIFT ECU 2 RED
FUSE A7 (CONTINUED) - WET CLUTCH CONTROL
Issue 1
17 - 10C
Section C
CR65
INST CLUSTER H 1 C13
1 BLK 1 H 852 (0.6) 2WD
243 A
G M 2 1 SOLND
17 - 11
A J 140A (0.6) 64
9803/8020
M G N
J B
F 140E (0.6)
12 11 10 9 8 7 6 5 4 3 2 1 B N L
F K
24 23 22 21 20 19 18 17 16 15 14 13 L E C 140D (0.6)
K
C E D 140
36 35 34 33 32 31 30 29 28 27 26 25 2 SFS 140C (0.6) C4
(2)
Section C
D 2 203 140B (0.6) D/LOCK

REAR BULKHEAD 2 1 SOLND
CONNECTORS C78 140F (0.6) 65
CR104 CR112-2
848 (0.6) SEE SHEET 28
(3000 SERIES)
848B (0.6) 848A (0.6)
FPDS
C36
899 (0.6)
851 (0.6)
R/PTO BRAKE
2 1
851B (0.6) 851A (0.6) SOLND
RPBS 66
851 (0.6)
857B (0.6) 857F (0.5)
857 (0.6) 857A (0.6) 1

RPDS 5 2
11 6 3
18 12 7 4
660E (0.6) 19 13 8 849 (0.6) C38
25 20 14 9
32 26 21 15 10 2 1 F/PTO BRAKE
660B (0.6) 33 27 22 16
39 34 28 23 17 67 SOLND
660V (0.6) 40 35 29 24
41 36 30
45 42 37 31
CRES3 660C (0.6) 46 43 38
47 44
48 CR58
660K (0.6) C35 PARKBRAKE
203 850 (0.6)
R/PTO DRIVE SWITCH
420 (0.6) C5 2 1
SOLND 70
CR9 REAR BULKHEAD 68
2WD/DL CONNECTOR 2 1
660E 400
(0.6) (0.6)
3 D/L
853 (0.6)
A B B A
SWITCH 895 (0.6) C37
58 4WD D C C D
2WD/DL F/PTO DRIVE
2/4 848 (0.6) 2 1 SOLND
1 69
2WD CR7 17-6
REAR PTO CR1 SEE
60 REAR BULKHEAD SHEET 6
140 (2)
857 (0.6)
CONNECTOR
899A (0.6)
3 DRIVE 1 115F 4 6 400B 400C
A B B A 2 5 CRIS 2WDDS CR49-4
203 (0.6) (0.6) (0.6)
Electrics
3 6 11 SEE
SWITCH 19 4 7 12 18
NEUTRAL 8 13 19
SHEET
R/PTO D C C D
2/4 9 14 20 25 8 23
10 15 21 26 32 2
16 22 27 33 852 (0.6) E 17-23
1 17 23 28 34 39 E7 E4 E1
24 29 35 40
BRAKE CR8 30 36 41 5 115F
31 37 42 45 (0.6)
FRONT PTO 38 43 46 63
44 47 CR4-E E E E2
852
48 8 5 (0.6)
3 DRIVE
59 2WD DUMP RELAY
895
A B
B A (0.6)
SWITCH 18 17-23 E9 E6 E3
NEUTRAL D C 849 SEE
F/PTO C D SHEET 23
2/4 (0.6) SEE
17-17DSHEET
-7 +8 17D
416A
1 1 ADCOS
SEE 860P (0.6)
RHSLS
BRAKE SHEET 23 (0.6)
(0.6)
400B
2 +3
START 855 (0.6) 4 6
160G 803 62 A
INHIBIT CIRCUIT PISC4
(0.6) CR4-A A 853 (0.6)
SEE SHEET 4 854 (0.6) (0.6)
61 2
17-23 DIFF LOCK
17-4 CR88 8 C/O RELAY
DIFF LOCK 2 803 A A 416A (0.6)
+12V 2 SWITCH A5
A8 (0.6) 4 6
IGN 141 (0.6) A B
FUSE LESS REAR 850 (0.6) 899 (1.0) 5 899 (1.0)
LINK
D C PTO C/O
CR90 899A (0.6)
71a A8 899A (0.6)
B A
E20
REAR PTO C D
CUT OUT PTO CUT-OUT
A B INTER-CONNECT SHEET 11
D C SEE SHEET 11A 481/11380
71b 17-11A
*FUSE A8 - FRONT/REAR PTO, 2WD, DIFFERENTIAL LOCK SOLENOID

Issue 2*
17 - 11
Section C
243 CR65
INST CLUSTER H 1 C13
1 BLK 1 H 852 (0.6) 2WD
A
G M 2 1 SOLND
A J 140A (0.6)
9803/8020
M G N 64
J B
F 140E (0.6)
12 11 10 9 8 7 6 5 4 3 2 1 B N L
F K
C
17 - 11 - 2
24 23 22 21 20 19 18 17 16 15 14 13 K L E 140D (0.6)
C E D 140
36 35 34 33 32 31 30 29 28 27 26 25 2 SFS 140C (0.6) C4
Section C
D (2)
2 203 D/LOCK
140B (0.6)
REAR BULKHEAD 2 1 SOLND
CONNECTORS C78 140F (0.6)
65
CR104 CR112-2
848 (0.6) SEE SHEET 28
(3000 SERIES)
848B (0.6) 848A (0.6)
FPDS
C36
899 (0.6)
851 (0.6)
R/PTO BRAKE
2 1
851B (0.6) 851A (0.6) SOLND
RPBS 66
851 (0.6)
857B (0.6) 857F (0.5)
857 (0.6) 857A (0.6) 1

RPDS 5 2
11 6 3
18 12 7 4
660E (0.6) 19 13 8 849 (0.6) C38
25 20 14 9
32 26 21 15 10 2 1 F/PTO BRAKE
660B (0.6) 33 27 22 16 SOLND
39 34 28 23 17 67
660V (0.6) 40 35 29 24
41 36 30
45 42 37 31
CRES3 46 43 38
660C (0.6) 47 44
48 CR58
660K (0.6) 203 850 (0.6) C35 PARKBRAKE
C5 R/PTO DRIVE SWITCH
420 (0.6) CR9 2 1
SOLND 70
2WD/DL REAR BULKHEAD 68
CONNECTOR 2 1
660E 400
(0.6) (0.6)
3 D/L
853 (0.6)
4 1 1 4
58
SWITCH 895 (0.6) C37
4WD 2 3
2WD/DL 3 2 F/PTO DRIVE
2/4 848 (0.6) 2 1 SOLND
1
CR7
69
2WD 60
REAR PTO CR1 SEE
REAR BULKHEAD SHEET 6
140 (2)
857 (0.6)
899A (0.6)
3 DRIVE 1
CONNECTOR 4 6
115F 400B 400C
2 5 CRIS 2WDDS CR49-4
1 4
Electrics
19 4 1 3 6 11 203 (0.6) (0.6) (0.6)

SEE
4 7 12 18
SWITCH 8 13 19 SHEET
NEUTRAL 2 3
R/PTO 3 2 9 14 20 25 8 23
2/4 10 15 21 26 32
852 (0.6) 2 17-23
16 22 27 33 E
1 17 23 28 34 39 E7 E4 E1
24 29 35 40
BRAKE CR8 30 36 41 5 115F
FRONT PTO 31 37 42 45 (0.6)
59 38 43 46
44 47 CR4-E 63 E E E2
852
48 8 5 (0.6)
3 DRIVE 2WD DUMP RELAY
895
1 1 4
18 4 849 (0.6)
SWITCH (0.6) E9 E6 E3
NEUTRAL 3 SEE
F/PTO 3 2 2
2/4 SEE SHEET 23
17-17D SHEET 17D
-7 +8
416A
1 1 ADCOS 17-23
SEE 860P (0.6)
RHSLS
400B
(0.6)
BRAKE SHEET 23 2 (0.6)

+3
START 855 4 6
(0.6) 160G 803 A
INHIBIT CIRCUIT PISC4
(0.6) (0.6) A 853 (0.6)
SEE SHEET 4 2
854 (0.6) 61
17-4 17-23 CR88 8
DIFF LOCK 2 803 A A 416A (0.6)
+12V A5
A8 2 SWITCH (0.6) 4 6 481/11380
IGN A B
141 (0.6) LESS REAR 899 (1.0)
FUSE 850 (0.6) 899 (1.0) 5
PTO C/O 62
LINK
D C SHEET 11
15 AMP CR90 899A (0.6)
71a CR4-A A8 899A (0.6)
B A DIFF LOCK
E20
REAR PTO C D C/O RELAY
CUT OUT PTO CUT-OUT
A B INTER-CONNECT
D C SEE SHEET 11A
FOR REAR PTO
17-11A
71b
C/O OPTION
FUSE A8 - FRONT/REAR PTO, 2WD, DIFFERENTIAL LOCK SOLENOID

Issue 1
17 - 11 - 2
Section C
887 (0.6)
FD
PTO CUT-OUT
9803/8020
1 2 3
17 - 11A
887C FA
(0.6) INTERCONNECT 4 5 6 1 2 3
Section C
886A 2 1 1 2
857
(0.6) 72 (0.6)
3 4
4 3
3 2 1
851B (0.6) 3 2 1
E13 73
E21 LH FENDER FENDER
PTO CUT-OUT 6 5 4 BUTTON
DIODE CONNECTOR
E20
PTO CUT-OUT
886
(0.6)
(0.6)
INTER-CONNECT 857D
(0.6)
887A
71b 141 A A 857C

(0.6) 4 6 M B B M RPCOS2
(0.6)
887 L U N C C N U L
857
A B (0.6)
(0.6) K T V P D D P V T K
D C
8 S R R S
2 J E E J
H F F H
(0.6)
857E
G G 887
850 5 219 RPCOS1
(0.6)
(0.6) BULKHEAD
857C
E16 E15 3 2 1
34 (0.6)
E12
Electrics
E22 6 5 4 RH FENDER
887B
(0.6)
PTO CUT-OUT
RELAY BASE
887 (0.6)
2 FD
PTO CUT-OUT
1 2 3
4 5 6 FA
4 5 6
INTERCONNECT 1 2 3
8
857
(0.6)
3 2 1
74 FENDER
BUTTON
SHEET 11A
481/11380
FUSE A8 (CONTINUED) - REAR PTO CUT-OUT OPTION
Issue 1
17 - 11A
Section C
CR1
REAR B/HEAD
17 - 12
C5
9803/8020
CONNECTOR
171 (2) 203
FUSE 1
2 5 1
Section C
+12V IGN 3 6 11 5 2
170 (4) 4 7 12 18 11 6 3
A9 8 13 19 18 12 7 4
9 14 20 25 19 13 8
25 20 14 9
CES9
10 15 21 26 32
16 22 27 33 32 26 21 15 10
17 23 28 34 39
33 27 22 16
39 34 28 23 17
24 29 35 40 40 35 29 24
30 36 41 41 36 30
1 951 (0.6) 31 37 42 45 45 42 37 31
38 43 46 46 43 38
950
(2.0)
936
(1.0)
44 47 47 44
48 48
0
(1.0)
650H
874 (1.0) 2
I
875 (1.4) 3 + 170 (4.0)
II
876 (2.0) 4 C53 C60 C65
III A A A
936
(1.0)
COMPRESSOR COMPRESSOR
CR67 2000 SERIES 3000 SERIES CLUTCH COMPRESSOR SWITCH
SWITCH
79 80 EARTH
BLOWER SWITCH
(2000 SERIES) 2000 SERIES 874 (1)
77
ONLY 75
A A A
2000 SERIES 875 (1.4)
2000 SERIES 876 (2)

1
A A
+
81 82
3 2 COMPRESSOR COMPRESSOR
4 PRESSURE SWITCH PRESSURE SWITCH
(HIGH) (LOW)
3000 SERIES
3000 SERIES
3000 SERIES
Electrics
4 3 2 1 950
10 (2)
2 1 954
8 7 6 5 (1.0)
730 (1.4) CR11
(2)
936
4 3
171
(1.0)
AIR CON UNIT
8 CR40
F
HEATER UNIT
2
SEE SHEET 3 (3000 SERIES)
ONLY
12-3 4 6 954
(1.0) 4 6
83
2000 SERIES
3000 SERIES
8
8 CR4-F
2
COMPRESSOR
951 (0.6) 952 (0.6) CLUTCH RELAY
(4)
(4)
670
670
(2)
950
76 CR41
AIR CON SWITCH
(2000 SERIES) SHEET 12
ONLY SEE SHEET 3 17-3
481/11381
FUSE A9 - AIR CONDITIONING
Issue 1
17 - 12
Section C
305B (0.6) 2000 ONLY
CR20 84
17 - 13
RADIO/CASSETTE 600E (1.4)
9803/8020
FUSE 305A (0.6)
7.5 AMP 2000 ONLY
7 5 3 1 1 (ROSSO)
305 (1.0) 305E (0.6)
Section C
+12V BAT B1 CRPFS 2000 ONLY 8 6 4 2

2 (NERO)
86
3 (BIANCO)
600F
CRES1 (0.6)
CR19
INTERIOR LIGHT
L.H.
1 2 600G (0.6)
305G (1.0)
3000 ONLY
85
305C (1.0)
2
CR15
INTERIOR LIGHT
R.H. 914 (0.6)
+3 CR63
2 L.H. DOOR
2000
SERIES
880C SWITCH
LHSLS 1 87
(0.6) +8 -7 1
914 (0.6) 2 660P (0.6)
88 CRES3
3000 SERIES
CR32
BEACON (2000 SERIES)
SWITCH
Electrics
1 860E
710D (0.6) 5 2 720B
PES1 (0.5) PES3
4 3 (0.6)
165 (1.0) SEE (3000 SERIES)

SHEET
600N (1.5) 18A
2
CR128
ROOF LINER 342
934 HARNESS CONNECTOR
1
(1.0) (3000 ONLY)
89
CR31
BEACON
SOCKET
SHEET 13
610F (1.0) 481/11382
CRES2
FUSE B1 - INTERIOR LIGHTS, RADIO CASSETTE, BEACON SOCKET
Issue 1
17 - 13
Section C
CR56 3000 868 (0.6)
LH OUTER 94 2000 SERIES SERIES FRONT B/HEAD
INDICATOR ONLY AUX LIGHTS IN
1 2 OUT 95A CONNECTOR
LIGHTS 95B CONNECTOR
600J (0.6) 868 (0.6) 216
1 2 3 3 2 1
3
17 - 14
CRES1 1 1
2000 2 5 5 2
9803/8020
3 6 11 11 6 3
SERIES 4 5 6 6 5 4 4 7 12 18 18 12 7 4
8 13 19 19 13 8
ONLY 1 2 870 (0.6) 9 14 20 25 25 20 14 9
CR65 243 10 15 21 26 32 32 26 21 15 10
600K 16 22 27 33 33 27 22 16
INST CLUSTER 1 BK 93 CR55 CR74 CR73 17 23 28 34 39 39 34 28 23 17
(0.6) 3 24 29 35 40 40 35 29 24
Section C
30 36 41 41 36 30
3000
RH OUTER 31 37 42 45 45 42 37 31
3000 870 (0.6)
SERIES
INDICATOR 38 43 46 46 43 38
SERIES 44 47 47 44
LIGHTS 48 48
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 861G 861D (0.6)
(0.6) C28
36 35 34 33 32 31 30 29 28 27 26 25 861B (1.4)
PRIS
861 CR51
861A (1.4) 3000
(1.4)
SERIES
(1.4)
859B
861C (1.4)
419
(0.6) 3000
417 SERIES
FUSE
7.5 AMP (0.6)
145 (1.4)
+12V IGN C2 RH SIDE (3000)
REPEATER ONLY
97 720D
FUSE B
(1.4)
15 AMP A
310 (2.0) CR71
+12V BAT B2 859D (0.6) PES3
LH SIDE (3000)
REPEATER ONLY LHIS
10(-) 859 859B (1.4)
(1.4)
B
96 720C
2 859C (1.4) (1.4)
PLIS A 861F 861B
1 RHIS
CR70 (1.4) (1.4)
858 2 859A 3000 620A
(2.0) 3 (1.4) SERIES (2.0)
859G (0.6)
859 5 17 4 3 2 1 859F
(1.4) 12 11 10 9 8 7 6 5 4 3 2 1 (1.4)
24 23 22 21 20 19 18 17 16 15 14 13 8 7 6 5
+8 36 35 34 33 32 31 30 29 28 27 26 25
864
880A 18 (1.4)
LHSLS
(0.6)
868
C1 98
(0.6)
SEE
SHEET 17C CR68 250 TRAILER
CR66
870
(0.6)
HAZZARD SWITCH SOCKET

17-17C INST CLUSTER 2 RED
3 2 1
Electrics
90
7 6 5 4 859E
710C
720H 11 10 9 8 (0.6)
PES3 (0.6) (1.4)
14 13 12
3 2 1 620B 3 2 1
(1.4)
865 700B 3000
6 5 4
(2.0) (1.4) SERIES 6 5 4
417 51
C19 101
(0.6) LH REAR C64
CR43
CR39-F COLUMN LIGHT CLUSTER RH FRONT
421
SINGLE SWITCH LIGHT CLUSTER
(1.0) 99 FLES
TRAILER 861E (SEE APP B)
TURN (0.6)
RELAY 14 13 12 17-32
F 11 10 9 8
91 3 2 1 620C
2 7 6 5 4
710G (1.4)
3 2 1 6 4 3 2 1
C3 C2 31 (0.6) 5
F F 3000
700A
4 6
862 49a (1.4) SERIES 6 5 4
49 C 100 C18
F8 (2.0) RH REAR
92 LIGHT CLUSTER C63
102
CR69
SECOND TRAILER LH FRONT
863 RIGHT LIGHT CLUSTER
TURN RELAY
(2.0) (SEE APP B)
710A LEFT 17-32
(0.6) CES1
PES1 SHEET
481/113
FUSE B2 - HAZARD WARNING LIGHTS

FUSE C2 - DIRECTION INDICATORS
Issue 1
17 - 14
Section C
9803/8020
17 - 15C
Section C
710E (0.6) CR60 CR59

FR WORK LIGHT FR WORK LIGHT
315C (0.6) R,H, A POST L,H, A POST
PES1
-7 +8 109 110
710L (0.6)
1
2 1 2 1
315A 2 +3
FUSE (1.4) CR14 CR16 CR18 CR21
30 AMP
FR WORK LIGHT FR WORK LIGHT FR WORK LIGHT FR WORK LIGHT
315 315B 5 R,H, INNER L.H. INNER L.H, OUTER
FWLSS 6
R,H, OUTER
B3 (4) (1.4)
2
+12V
SIDE LIGHTS 105 2 1 106 2 1 107 2 1 108 2 1
CR24 103
FRONT
WORKLIGHTS 804B
801A
804A (1.0)
SWITCH (1.0)
(1.0) 600C (1.0)
800 (1.4)
600B
(1.0)
600A
(1.0)
801B
(1.0)
800B (1.0)
800A
CR39-C OFWLS (1.0)
A POST
315D (1.4)
WORKLIGHT
RELAY.
800C
(1.0)
(1.0)
600D
(0.6)
600M
Electrics
242
C4 C6
C8 APWLS CRES1
804 (1.4)
C2
C5 801 (1.4)
IFWLS
600L (1.0)
C
804
C8
(1.4)
710E C C 800C
C5
(0.6) 6 4 (0.6)
SHEET 15C
C 315D 481/11384
3
2 (1.4)
FUSE B3 - FRONT WORK LIGHTS
Issue 1
17 - 15C
Section C
9803/8020
17 - 16B
Section C
320C (0.6)
PES1
-7 +8
710N (0.6) 1
320A 2
FUSE +3
(1.4)
20 AMP CR10 CR34 CR29 CR35
320 320B 5 R WORK LIGHT R WORK LIGHT R WORK LIGHT R WORK LIGHT
B4 (3) RWLSS (1.4) 6 R,H, OUTER R,H, INNER L.H. INNER L.H, OUTER
2
+12V
SIDE LIGHTS 112 113 114
2 1 2 1 2 1
115 2 1
CR28 114
REAR WORKLIGHTS
SWITCH 835A
(1.0) 610D
(1.0)
805 (1.4)
610B
(1.0)
610A
(1.0)
835B
(1.0)
610C (1.0)
805B (1.0)
Electrics
805A
ORWLS (1.0)
CRES2
835 (1.4)
IRWLS SHEET 16B
481/11385
FUSE B4 - REAR WORK LIGHTS
Issue 1
17 - 16B
Section C
COLUMN SWITCH
CR46 MAIN / DIP / FLASH
MAXIFUSE 119
FUSE CR43 FLASH MAINBEAM
17 - 17
360 (6.0)
9803/8020
+12V BAT W +12V BAT
325 COLUMN
B5 (1.4) SWITCH
3 2 1 1 2 3
Section C
119
7 6 5 4 4 5 6 7
PMLS 838D SEE SHEET 15 11 10 9 8 8 9 10 11
(1.5) 17-15 3000 SERIES 12 13 14
14 13 12
ONLY
838A (1.4)
838
(2.0)
360C
-7
PHLS
+8 (2.0)
(2.0)
360A
1
2
+3
(1.5)
710R
6
160C B
2 PISC4 B3 B6 B9
(0.6)
907 (1.4)
839 (1.4)
116 SEE SHEET 23
838B (1.5)
838C (1.5)
CR77 17-23
MAIN 360D B B 806 CR79
B2
LIGHTS (1.4) 5 8 (1.4) FRONT FUSE
SWITCH PANEL
285
-7 +8 FUSE
B1 B4 B7
1 MAIN BEAM 17-17A
2
D1
SEE SHEET 17A
+3
CR78
FUSE
812
REAR FOG
(1.5)
118 17-17A
LIGHTS 117 D2 DIPPED BEAM
CR39-B
Electrics
SWITCH 2 4 6 SEE SHEET 17A

812 REAR FOG LIGHT
(1.5) RELAY
FUSE
8 806 (1.4) REAR FOG LIGHTS
D3 17-17B
360D (1.4) 2 SEE SHEET 17B
5
(1.5)
710R FUSE
807 (2.0) LH SIDE LIGHTS
D4 17-17C
SEE SHEET 17C
720J (1.0)
PES3 FUSE
808 D5 RH SIDE LIGHTS
(1.5) SEE SHEET 17D 17-17D
710F (1.0)
PES1
FUSE
360B (1.5) 3000 SERIES AUX. LIGHTS SWITCHING
D6 SEE SHEET 17F
ONLY 17-17F SHEET 17
481/11386
FUSE B5 - HEADLIGHT FLASH

FUSE W (MAXIFUSE) - MAIN LIGHTS
Issue 1
17 - 17
Section C
FUSE
15 AMP CR65
418 (0.6)
MAIN INST CLUSTER 1 BLK
BEAM D1 829 (1.4)
243
9803/8020
17 - 17A
12 11 10 9 8 7 6 5 4 3 2 1
Section C
FUSE
15 AMP 24 23 22 21 20 19 18 17 16 15 14 13 C63
36 35 34 33 32 31 30 29 28 27 26 25 LH H/LIGHT 120A
DIPPED 904 SEE APPENDIX B
BEAM D2 (1.4) 17-32
CR79
FRONT FUSE
PANEL 1 6 1 4
2 3
3 4
3 2 1 CR73
3000 2000
AUX LIGHTS IN
836A
(1.0)
SERIES SERIES
SEE SHEET 17F 700A
6 5 4
(1.4)
95A 17-17F
FLES
700B
(1.4)
836 (1.4) 1 6
1 2 3
CR74 MBS
AUX LIGHTS OUT 836B 1 4
SEE SHEET 17F (1.0) 3 4
4 5 6 3
2
95B 17-17F
3000
SERIES 2000
Electrics
SERIES
905
836
(1.4)
(1.4)
905B (1.0) 121A C64
905 (1.4) RH H/LIGHT
DBS 905A (1.0)
SEE APPENDIX B
17-32
1 1
2 5 5 2
3 6 11 11 6 3
4 7 12 18 18 12 7 4
8 13 19 19 13 8
9 14 20 25 25 20 14 9
10 15 21 26 32 32 26 21 15 10
16 22 27 33 33 27 22 16
17 23 28 34 39 39 34 28 23 17
24 29 35 40 40 35 29 24
30 36 41 41 36 30
31 37 42 45 45 42 37 31
38 43 46 46 43 38
44 47 47 44
48 48
216
FRONT B/HEAD SHEET 17A
CONNECTOR C28
CR51 481/11386
FUSE D1 - MAIN BEAM

FUSE D2 DIPPED BEAM
Issue 1
17 - 17A
Section C
9803/8020
17 - 17B
Section C
809
(1.4)
620A (2)
1
2 5 CES1
3 6 11
FUSE 4 7 12 18
8 13 19
C1
9 14 20 25
4 3 2 1
D3 10 15 21 26 32 98 TRAILER
16 22 27 33 SOCKET
17 23 28 34 39
17-17 24 29 35 40 8 7 6 5
30 36 41
CR79 31 37 42 45
38 43 46
44 47
FOG LIGHTS 48
SEE SHEET 17 CR51
620B
809C
(1.4)
(1.4)
FRONT B/HEAD
CONNECTOR C19
3 2 1 LH REAR
216 809 809B 99 LIGHT
FLS CLUSTER
(1.4) (0.6) 6 5 4
Electrics
1
5 2
11 6 3
18 12 7 4 620C
19 13 8
25 20 14 9 (1.4)
32 26 21 15 10
33 27 22 16 C18
39 34 28 23 17
40 35 29 24
41 36 30 3 2 1 RH REAR
45 42 37 31
46 43 38 100 LIGHT
47 44 809A CLUSTER
48 C28 (0.6) 6 5 4
SHEET 17B
481/11386
FUSE D3 - REAR FOG LIGHTS
Issue 1
17 - 17B
Section C
9803/8020
17 - 17C
Section C
C63 1 2
1 FRONT B/HEAD L/H H/LIGHT 700A 600J
2 5 1 CRES1 CRES1
3 6 11 CONNECTOR 5 2 3 (0.6)
4 7 12 18 11 6 3 (1.4)
8 13 19 18 12 7 4 120
9 14 20 25 19 13 8 (2OOO SERIES)
10 15 21 26 32 216 25 20 14 9
16 22 27 33 32 26 21 15 10 3000 ONLY
17 23 28 34 39 33 27 22 16 CR56
24 29 35 40 39
40
34
35
28
29
23
24
17
1 6
SERIES 120A
30 36 41 LH OUTER LIGHTS 17-32
31 37 42 45 41 36 30 ONLY
38 43 46 45 42 37 31
44 47 46 43 38 (SIDE LIGHTS)
48 47 44
CR51 C28 48 3 4 2000 SERIES
ONLY
620A (2.0)
881 CES1
(0.6)
3000 SERIES
ONLY
CR73 4 3 2 1 C1
880F TRAILER
881
CR74 LSLS
(0.6)
95A (1.0) SOCKET
880D 95B 8 7 6 5
(0.6) AUX. 98
12 11 10 9 8 7 6 5 4 3 2 1
3 2 1 LIGHTS 1 2 3
24 23 22 21 20 19 18 17 16 15 14 13 OPTION.
880F (1.0)
SEE 880H
36 35 34 33 32 31 30 29 28 27 26 25 6 5 4 4 5 6
SHEET 17F (1.0)
620B (1.4)
243 CR65 C19
INST CLUSTER 1 BLK LH REAR
1 4
3 2 1 LIGHT
2 3 CLUSTER
4
(0.6)
C63 6 5
880B
99
Electrics
L/H H/LIGHT
2000 SERIES 880J (0.6)
17-32
17-14
880A (0.6) SEE SHEET 14

FUSE
880 HAZARD SWITCH 90
D4 LHSLS
(1.0) 17-6
880K (0.6) SEE SHEET 6
SIDE LIGHTS REAR WASH/WIPE SWITCH 23
SEE SHEET 17 247
17-13 CR81
17-17 880C (0.6) SEE SHEET 13 PES3
BEACON SWITCH 88 AIR GAUGE
ILLUM
880G (0.6) 720L (0.6)
1 2
SHEET 17C 481/11386
FUSE D4 - LH SIDELIGHTS, CLUSTER SIGNAL, REAR WASH/WIPE & BEACON SWITCH ILLUMINATION
AIR GAUGE ILLUMINATION
Issue 1
17 - 17C
Section C
REAR B/HEAD FRONT B/HEAD C64
CR1 CONNECTOR CONNECTOR RH H/LIGHT
CR51 700B (1.4)
C5 C28 SEE FLES
9803/8020
APPENDIX B
17 - 17D
1
216 203
2 5 1 1
17-32
1
3 6 11 5 2 2 5 5 2
4 7 12 18 11 6 3 3 6 11 11 6 3 121
Section C
8 13 19 18 12 7 4 4 7 12 18 18 12 7 4
9 14 20 25 19 13 8 8 13 19 19 13 8
1 6
10 15 21 26 32 25 20 14 9 9 14 20 25 25 20 14 9
620A (2.0)
16 22 27 33 32 26 21 15 10 10 15 21 26 32 32 26 21 15 10 CES1
17 23 28 34 39 33 27 22 16 16 22 27 33 33 27 22 16
24 29 35 40
216 39 34 28 23 17 17 23 28 34 39 39 34 28 23 17
30 36 41 40 35 29 24 24 29 35 40 40 35 29 24
3 4
31 37 42 45 41 36 30 30 36 41 41 36 30
38 43 46 45 42 37 31 31 37 42 45 45 42 37 31
44 47 46 43 38 38 43 46 46 43 38 C1
48 47 44 44 47 47 44
48 48 48 866 4 3 2 1 98 TRAILER
(0.6) SOCKET
3000
8 7 6 5 SEE
SERIES
APPENDIX A
860L (1.0) 17-31
860A (1.0)
RSLS
2000 866
860L (0.6)
SERIES
(1.0)
620C
CR55 (1.4)
RH DI
SIDELIGHT CR73 CR74
(0.5)
C18
860V
(2000 ONLY) AUX LIGHTS IN AUX LIGHTS OUT
1 4
100 RH REAR
SEE SHEET 17F SEE SHEET 17F 3 2 1
95A LIGHT
1 2 95B 3 CLUSTER
600K 2
CRES1 6 5 4 SEE
(0.6) 3 2 1 1 2 3
3 121 C64 APPENDIX B
RH H/LIGHT 860D (0.6) 17-32
6 5 4 4 5 6 SEE APPENDIX B
(2000 SERIES ONLY)
860J 17-32
SEE CR105-8 CR27
(0.5)
860C (0.6) LH No PLATE
Electrics
SHEET 8A 860K
CR114-8 ROOF LINER HARNESS LIGHT 123
17-8D (0.5) SEE SHEET 18A (3000 SERIES)
860E (0.6) 610H
B B
RADIO/CASSETTE (0.6)
SEE SHEET 18 (2000 SERIES) 17-18 CRES2
FUSE A A
860M (0.6)
7.5 AMP 4WS OPTION (2000 SERIES)
SEE SHEET 30 17-30
860 860G (0.6)
RHSLS
(1.0)
SIDE LIGHTS 860F (0.6)
CR25
610G
(0.6)
SEE SHEET 17
12-17 860P (0.6) DIFF LOCK SWITCH RH No PLATE
SEE SHEET 11 LIGHT 124
17-11
860R (0.6) EDC
B B
SEE SHEET 9 17-9
860T (0.6) A A
CR116-A 860N CIGAR LIGHTER
SEE SHEET 27 (0.5) SEE SHEET 20 17-20
12-27 860U (0.6) W/LIGHTS RELAY SHEET 17D
3000 SERIES SEE SHEET 2
ONLY
17-2 481/11386
860H (0.5) ECU 1
SEE SHEET 28 12-28
FUSE D5 - RH SIDELIGHTS, NUMBER PLATE LIGHTS, RADIO CASSETTE ILLUMINATION, DIFF. LOCK, RAISE/LOWER &
AREA CUT-OUT SWITCH ILLUMINATION, CIGAR LIGHTER ILLUMINATION,
WORK LIGHTS RELAY COIL
Issue 1
17 - 17D
Section C
9803/8020
17 - 17F
837A (1.0)
837
(1.4) AMBS
CR72 AHL6 837B (1.0)
Section C
AUX LIGHTS AHL4

AUX LIGHTS 1 4 126 AUX
EARTH EARTH FEED
H/LIGHT
2 3 L.H.
760 760 760B (1.4)

A A
(3.0) (3.0)
ALES
CR38 AHL5
1 4 127 AUX
BAT -VE
H/LIGHT
2 3 R.H.
906A
(1.0)
AHL3 ADBS
906B
(0.6)
760L
(1.0)
-7 +8
1
1 760D (1.4)
2
829 (1.4) +3
NOTE:
4 SIDE LIGHT BULB
5 REMOVED AND REPLACED
904 6 WITH A GROMMET
(1.4) 906
2 (1.4)
125 836 (1.4)

SEE SHEETS: 880D (0.6)
Electrics
17 -17A
17-17C 17A AUX. LIGHTS 905 (1.4)
CR73 SEE SHEETS:
17C 17A AHL1 SWITCH
17-17A 17A
881 AHL2 17A CR74 17C 17-17C
3 2 1 1 2 3 (0.6)
95A 3 2 1 1 2 3
6 5 4 4 5 6
17 -17D
6 5 4 4 5 6
17-14 17D
14
14 AUX LIGHTS 861D (0.6) AUX 14
95B
CONNECTOR LIGHTS 17D
PANEL - AUX. 14 17-14
CONNECTOR 17-17D
LIGHTS INTERCONNECT
PANEL - AUX.
859D (0.6) LIGHTS INTERCONNECT
SHEET 17F
860D (0.6) 481/11386
FUSE D6 - AUXILIARY LIGHTS SWITCHING
Issue 1
17 - 17F
Section C
17 - 18
9803/8020
CR22 CR17
LH SPEAKER RH SPEAKER
913 (0.6) 912 (0.6)
Section C
128A 128B
+ 7 5 3 1 +
FUSE
8 6 4 2
+12V IGN - -
165 (1.0)
B6 707 (0.6) 706 (0.6)
CR20
7 5 3 1
RADIO 84
8 6 4 2
CASSETTE
Electrics
860E (0.6) 305A (0.6)

RHSLS CRPFS
SEE SHEET 17D SEE SHEET 13

17-17D 17-13
600E (1.4) SHEET 18

CRES1
481/11387
FUSE B6 - RADIO CASSETTE
Issue 1
17 - 18
Section C
17 - 19
9803/8020
Section C
FUSE
+12V BAT
330 (3)
B7
CR30 1
AUXILIARY 129
SOCKET 2
Electrics
680 (3)
SHEET 19
481/11388
FUSE B7 - AUXILIARY JACK-PLUG SOCKET
Issue 1
17 - 19
Section C
17 - 20
9803/8020
Section C
+12V RHSLS
SEE
SHEET 17D
17-17D
860T
(0.6)
FUSE
+12V BAT 3
335 660Z
B8 (1.4) + - (1.4) CRES3
Electrics
130
CR82
CIGAR SHEET 20
LIGHTER 481/11389
FUSE B8 - CIGAR LIGHTER
Issue 1
17 - 20
Section C
17 - 21
9803/8020
Section C
155A 155
2
(0.6) (0.6)
816 4 6
4 5 6
(0.6)
877
8 1 REAR B/HEAD
(0.6)
(0.6)
155A
8 2 5 1
877 3 6 11
CONNECTOR
2 5 2
(0.6) 4 7 12 18 11 6 3
8 13 19
203 18 12 7 4
9 14 20 25 19 13 8
5 10 15 21 26 32 25 20 14 9
16 22 27 33 32 26 21 15 10
816 (0.6) 131 17 23 28 34 39 33 27 22 16
24 29 35 40 39 34 28 23 17
CR121-A 30 36 41 40 35 29 24
REVERSE LIGHTS 31 37 42 45
41 36 30
45 42 37 31
RELAY 38 43 46 46 43 38
44 47 47 44
48 48
FUSE
155 (0.6)
+12V IGN C1
C5
CR1
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
620B (1.4)
877 (0.6)
36 35 34 33 32 31 30 29 28 27 26 25
Electrics
C19
99 LH LIGHT
3 2 1
214 CLUSTER
CR49 SEE APPENDIX B
POWERSHIFT ECU 1 BLK 6 5 4
17-32
877A (0.6)
RLS
620C (1.4)
C 3 2 1
E
S 6 5 4
1 100
C18 877B (0.6)
RH LIGHT 17-32
CLUSTER
SEE APPENDIX B SHEET 21
481/11390
FUSE C1 - REVERSE LIGHTS
Issue 1
17 - 21
Section C
CR42
BLEEPER 55 CR50
160J (0.6) 450 (0.6) P/SHIFT ECU 2 RED
+ S
435 248
INTERMEDIATE SPEED
160K (0.5) CONTROL 1
17-8D (0.6)
17 - 23
SEE SHEET 8A
9803/8020
CR1 12 11 10 9 8 7 6 5 4 3 2 1
REAR BULKHEAD CR39 24 23 22 21 20 19 18 17 16 15 14 13
FUSE 160C (0.6) LIGHTS SWITCH ILLUM 17-17 1
SEE SHEET 17 CONNECTOR 2 5 SPEED SENSOR
7.5 AMP 3 6 11 36 35 34 33 32 31 30 29 28 27 26 25
FUSE 203 4 7 12 18
DISCONNECT
160 160G (0.6) DIFF LOCK C/0 SWITCH
Section C
PISC4 17-11 3 AMP 8 13 19 RELAY

C4 (1.0) SEE SHEET 11 9 14 20 25
PES3
(3190/3220) 400B (0.6)
160H 10 15 21 26 32 286 SEE
+12V IGN C5 16 22 27 33
(0.6) 17 23 28 34 39 400C (0.6) 400 (0.6) SHEET 11
24 29 35 40
2WDDS
CR12 17-11
30 36 41 720P
31 37 42 45
720A 38 43 46 C4 C6 (0.5)
PES3 44 47
9 8 6 5 4 3 2
(0.6) 48
12 11 10 7 1 CR49
C8 24 23 22 21 20 19 18 17 16 15 14 13 P/SHIFT ECU 1 BK
C2
36 35 34 33 32 31 30 29 28 27 26 25
720R 214 B A ABS CONNECTOR
(0.5) C D
SEE SHEET 26
C5
F
2 412 (0.6) 412 (0.6)(3190/3220) 17-26
AWS CR47
412B (0.6)(3170)
F F 440 (0.6)
4 6 161 (0.6)
F8 414 (0.6) 414B

SSS
406 (0.6) (0.6)
CR39-A 139
BUZZER 423 (0.6) 511 (0.6)
RELAY.
434
409 (0.6)
(0.6)
408 (0.6)
160E (0.6) 405 (0.6)

497 (0.6) 402(0.5) 415
CR64 412C (0.5) 3170 (0.6) 17-9& 23B
CR2 4WS OPTION (3170 ONLY)
EDC CR87
(2000 SERIES) CR65 VANSCO
CONNECTOR 12 11 10 9 8 7 6 5 4 3 2 1
(SEE SHEET 30)
(SEE SHEET 9) 54 INST OPTION
36 3 2 1 1 24 23 22 21 20 19 18 17 16 15 14 13
2 5
CLUSTER SEE
898B (0.6)
17-30 7 6 5 4 3 6 11 36 35 34 33 32 31 30 29 28 27 26 25 1 BLK SHEETS
3 2 1 4 7 12 18
17-9 10 9 8 8 13 19 9 & 23B
9 14 20 25
578
6 5 4
(0.5)
10 15 21 26 32 243
16 22 27 33 407
17 23 28 34 39 (0.6)
24 29 35 40 404 3 2 1
30 36 41 500A
(0.6) RSS2
31 37 42 45 (0.5) 7 6 5 4
496 38 43 46 411
Electrics
44 47 11 10 9 8
(0.6) 48
(0.6) 410 (0.5) 500AA(0.6)
509A 14 13 12
(0.6) CR51 216 3170 414A
509 2000 (0.6)
SERIES ELSS FRONT BULKHEAD
(0.6) 509B 2000
CONNECTOR 160ED
(0.6) SERIES 17-23A (0.5) 512
(SEE SHEET 23A) (0.6)
509 3000
(0.6) SERIES 505
12 11 10 9 8 7 6 5 4 3 2 1
445 (0.6) (0.6)
501
(0.6)
PES1
24 23 22 21 20 19 18 17 16 15 14 13
502
(2000) 444 (0.6) (0.6)
3170
710W(0.5) 36 35 34 33 32 31 30 29 28 27 26 25
412A (0.5)
3 2 1 898 (0.5)
CR112 20KSS
7 6 5 4 898A
ECU 1 (0.5) 510 (0.6)
11 10 9 8 CR92 CR91
INTERCONNECT 1000 PTO
14 13 12 540 PTO 518 (0.6)
(3000 ONLY) RANGE RANGE
(SEE SHEETS 1 1 2
8A & 29) 288 289 CR66 300B (0.6) SEE SHEET 9
3 2 1 2 1 INST CLUSTER PFSB9
3
2 RED
3 3 710C (1.4) 17-9
660U (0.6)
PES1
710P (0.6)
CRES3 403 (0.6)
660T (0.6) 403A
ASS
(0.6) 416B (0.6)
403B (0.6)
416 (0.6)
ADCOS
416A CR4-A6
500AB (0.5) (0.6) SEE SHEET 11
SHEET 23
17-11 481/11392
160B (0.6)
FUSE C4 - LIGHTS SWITCH ILLUMINATION; BLEEPER; INSTRUMENT CLUSTER;

DIFFERENTIAL LOCK CUT-OUT; SPEEDO SENSOR; FUSE C5
Issue 1
17 - 23
Section C
C52
650F 410 (0.5)

(0.5) 2 1 3170 ONLY
C34
141
WATER
143 1 2 650D
9803/8020
TEMP. SENDER 406
17 - 23A
CES9 (1.4) (1.4)

C31 AIR TANK No2
CES9
Section C
650E 402 (0.5)

(0.5) 3170 ONLY C33
2 1
152 407
142 1 2 650C
ENGINE 1
OIL PRESSURE 5 2 (1.4) (1.4)
C8 11 6 3 216 C28
18 12 7 4 AIR TANK No1
19 13 8 CONNECTOR
640H 2 1 408 25 20 14 9 FRONT B/HEAD C3
32 26 21 15 10
(1.4) (1.4) 33 27 22 16 SEE CR51 ON
39 34 28 23 17 SHEET 23 640C
AIR TANK No3 40 35 29 24 A B CES7
(0.6)
144 41 36 30 17-23
45 42 37 31
CES7 C20 46 43 38
FUEL LEVEL 47 44 405
SENDER 48
(0.6)
640A
A B FRONT BRAKE
411
(0.6) (0.6) RESERVOIR LEVEL
2 1 C14
146 148
145
C54 710W (0.5) 1 2
409A 640F
(2000) (0.6) (0.6)
2 1
1 2
TRANS. OIL
FILTER SWITCH C9
409 409B 1 2
640G
BMS CES7
(0.6) (0.6) (0.6)
650G
CES9
149
REAR BRAKE
(0.6)
AIR FILTER 147 578 (0.5) RESERVOIR LEVEL
SWITCH
404 (0.6)
1 2
640L (0.6)
C49/C50 409C 640P
(0.6) (0.6)
412 (1.4) X W
W K V 149A C73
4 L J
B H BRAKE
403 (1.4) U
IND M C A RESERVOIR 3
G C74
N F T ENGINE
D E
ALTERNATOR S BULKHEAD
O P
Q R
C5 204
REAR B/HEAD
TRANS OIL CONNECTOR
PRESS SWITCH
Electrics
150 203
435 1
(0.6) 5 2 710PB (0.75)
11 6 3
B A 18 12 7 4 160ED (0.5) 3190/3220
19 13 8 TRANSMISSION
25 20 14 9 3190/3220 414 (0.75)
32 26 21 15 10
CONNECTORS (3190/3220
C55 33 27 22 16
C72 ONLY)
39 34 28 23 17 268 TH1
40 35 29 24 SPEEDO
710P (0.6)
17-23 41 36 30 SPEEDO
45 42 37 31 PICK-UP 2
46 43 38 X W W X PICK-UP 1 TH11
SEE CR1 ON 47 44 K V K TH10
48 L J V J L
414 (0.6)
SHEET 23 B H H B
M U U M 710PA 151
C A G C SSES
G A (0.75) 2 1 2 1
N F T T
D E F D N
S E
O S
P O 4 3 4 3
Q R R Q P
710P
(0.75)
(0.75)
160EA
160E
SSIS
(0.75)
160EB
(0.75)
(0.75)
160EC
547 (0.5) 160E (0.6) 497 +12V IGN

(0.75)
3190/3220
497 (0.6)
10 9 8 7 6 5 4 3 2 1
547 (0.75) 547A (0.75)
3190/3220 SSRS1
3190/3220
20 11 SSIRS2
30 21 4K7
40 31 4.7K Ohms
50 41 3190/3220 160ED (0.75) SHEET 23A
481/11392
C75 217
ENGINE ECU
FUSE C4 (CONTINUED) - CHASSIS SIDE
Issue 1
17 - 23A
Section C
502
CR66-3
1
(0.6)
20
38
512 39 E1
9803/8020
CR66-2 EDC ELECTRONIC
17 - 23B
(0.6)
CONTROL UNIT
1
SEE CR66-7 500A SEE
RSS2
20
38
Section C
SHEET (0.5) SHEET
2
23 9
21
39
501 E4 17-9
17-23 CR66-25
(0.6)
500A
3 2 1 1 2 3 (0.6) 500B
RSS (0.6)
7 6 5 4 4 5 6 7
36
54
FUSE
18
+12V 161 11 10 9 8 8 9 10 11
C5
37
55
IGN (0.6)
37
55
14 13 12 12 13 14
19
19
CR87
161
40
EDCIS
(0.6) ENLARGED VIEW OF
CAVITY ID'S FOR E1
161C
(0.6)
501
(0.6)
660GF (0.6)
660G (0.6) EDCES
660G (0.6)
CRES3
A
M B
L U N C
1 2 3 3 2 1
K T V P D 36
S R 4 5 6
J E 6 5 4
H F
G
E3 CR2
POWER-IN EDC
502 219 500 CONNECTOR CONNECTOR
Electrics
(0.6) (0.6)
E16
BULKHEAD
CONNECTOR
SEE 660RB (0.6) 432 (0.6)

SHEET E10-8
9 +8 1 +3 4 6
17-9
A E23
B M
161 (2.0) C L WHEEL SLIP
N U 174 1 2
ENABLE
D P V T K SWITCH
E R S J
219 -7 2 5
F H 660GJ (0.6)
G
660GF (2.0) E15
BULKHEAD 660GK (0.6)
CONNECTOR
161D (0.6)
E17 500 (2.0)
1 6
159 SHEET 23B
501 (2.0)
RADAR 3 4 481/11392
SPEED
SENSOR
FUSE C5 (CONTINUED) - GROUND SPEED RADAR
Issue 1
17 - 23B
Section C
561 (1.0)
560 (1.0)
17 - 24
9803/8020
CANBUS
1 2 SEE
FUSE
Section C
10 AMP PAGE 17-33

D
C E 17-33
365A
C6 B A F
CR120 (1.5) J G
J1708 H
CONNECTOR 290
CR119
DIAGNOSTIC
SOCKET
635C
CRES4
(1.5)
660Y CR89
CRES3
(0.6) DIAGNOSTIC
291 A17 CONNECTOR
ABS
291
DIAGNOSTIC 513 (0.6)
CONNECTOR
4 3 2 1
2 1
8 7 6 5
Electrics
365B
(1.5)
561 (1.0)
560 (1.0)
1 12
517 (0.6)
516 (0.6)
6 7
200 A18
TRACTOR ABS
ECU X1 250
12 11 10 9 8 7 6 5 4 3 2 1
SEE SHEET 26 CR66
17-26 24 23 22 21 20 19 18 17 16 15 14 13 INST. CLUSTER
(2 RED)
36 35 34 33 32 31 30 29 28 27 26 25
SHEET 24
481/11393
FUSE C6 - DIAGNOSTIC SOCKET & CONNECTOR
Issue 1
17 - 24
Section C
17 - 25
9803/8020
Section C
APS2
TERMINAL
POSTS
RED BLACK
355A 685A
(3.0) (3.0)
184
191 APS3
(1.0) 3 PIN POWER
CR94 SOCKET
AUX POWER 15/30 31
82
FUSE SOCKETS 355B 685B
355 355 (3.0) (3.0)
+12V BAT C8 PFSC8
(3.0) 183 (3.0)
FUSE A A
+12V IGN
191
B B 191 185
C7 (1.0) (1.0)
C C
685 685 PSES

(3.0) (3.0)
APS1
AUX POWER APS4
SOCKETS CONVENIENCE
INTERCONNECT SOCKET
(3.0)
355C
685C 3
(3.0) 2 1
(1.0)
685D
186
(3.0)
355D
Electrics
192
(3.0)
191A
(1.0) 4 6
191
(1.0)
8
2
187
2 355D
191A (3.0)
(1.0)
685D
4 6
(1.0)
191
(1.0) 192
8
(3.0)
APS5
SHEET 25
CONVENIENCE
SOCKET RELAY 481/11394
FUSES C7 & C8 - AUXILIARY POWER SOCKETS
Issue 1
17 - 25
Section C
+12V +12V
2
CR100 IGN BAT
24 TRACTOR ABS
36 12 (SUPPLY) A B 4 6
5A 5
35 23 11 D C
34 22
10 17-2
21 8
17 - 26
33 9 883D +12V
SEE SHEET 2
9803/8020
32 20 (0.6) BAT
8
31 19 A12
7
30 18 6
192 TRACTOR ABS
17 IGN RELAY
29 5 A9 A5
16
Section C
28 4 TRACTOR ABS 5A 15K 1 2 4 6

B A 154 665E
27 15 3 (POWER IN) (1.0) F1 TAES
(0.6) (0.6)
14 CONNECTOR C D FUSE
26 2 A6
25 13 1 2
1 20A (2.0)
265A (2.0) 8 20 (4) F2
2 A7
265B (2.0) 20B (2.0) 1 2 FUSE
250 TAIS F3
CR66 5 A8
INST CLUSTER 20C 1 2 FUSE
2 RED (1.0) F4
151
(2.0)
153 (1.0) FUSE
152
(2.0)
883 (1.4)
A13
TRACTOR TRACTOR
4 6 449 465 (1.0) ABS ECU X2 ABS ECU X3
CR101 A B
A10 (1.0) A19 A20
TRACTOR ABS 153A DIAGNOSTIC
TRACTOR ABS 1 12 200
(RETURN) (1.0)
190 A11 191 SWITCH
(RETURN) CONNECTOR
8 TRACTOR ABS 200 12 1 12
5B 5B 2 DIAG'C RELAY
A B 200 1
TRACTOR 6 7
A B C C B A ABS ECU X1
5
6 7 6 7
448 (1.0) A18
448 (1.0)
665A (3) 562 (1.0)
665A (3) 665C (2.0) 563 (1.0)
665B (3)
665B (3) TAES 665D (2.0) 564 (1.0)
1808 (1.4)
565 (1.0)
BAT -VE 440 (0.6)
SEE 17-2 1806 (1.4)
SHEET 2 +12V A4
015J (1.0) 1 2 150 (1.0)
(1.4)
IGN 1807
1800 (1.4)
1803 (1.4)
1801 (1.4)
1802 (1.4)
1805 (1.4)
1804 (1.4)
E2 566 (1.0)
440 A B FUSE 567 (1.0)
B A
(0.6) 568 (1.0)
C D D C 260 (2.5) 1 A3 2 370B (2.5)
569
294 270 (2.5) E1 370A (1.0)
24 +12V +12V (2.5)
36 12 FUSE
23
BAT 5 BAT
35 11 A1 A21 A J
CR47 ABS8
34 22 TRAILER ABS REAR RH H
10 TRAILER ABS REAR LH
B K
M
33 21 (POWER IN) SPEED C L G
9 CONNECTOR SPEED
20 CONNECTOR SENSOR D F
32 8 ABS10 SENSOR E
31 19 FRONT RH ABS9
7 BULKHEAD
18 ABS11 SPEED 1 2 1 2
561(1.0)
560(1.0)
30 6 194 1 2 193 1 2 SENSOR

196 195 CONNECTOR
17 FRONT LH (PANNIER)
243 29 5
16 SPEED
28 4 SENSOR (566) BLACK 203 292
CR65 27 15 3 (1.0) REAR B/HEAD
(1.0)
INST CLUSTER 14
(1.0)
CONNECTOR
Electrics
26 2 (567) BROWN
BROWN
(1.0)
(1.0)
(1.0)
BLACK
(1.0)
1 BLACK 13
BLACK
BROWN
(1.0)
BROWN
25 1
(569) BULKHEAD
CONNECTOR
A J
(562) BLACK
(PANNIER)
(564)
(563)
1 1
(565)
H H H K B
M
A A G L C 292
G G
(568)
M M F D
J J E
N B B N
1804 (1.4)
F F AP1
L K K L 1803
C C E (1.4)
E
D D A17
1807 (1.4)
1806 (1.4)
1808 (1.4)
2 2
1801
(1.4)
1 2 ABS2 1805
REAR B/HEAD A2 2 1 1 (1.4) 1

605 (1.4)
7 3 CONNECTOR 2 3 2 3
1
1802 (1.4)
1800 (1.4)
615 (6.0) 203 2 3

6 4
AP2 AP4
5
ABS1 291 FRONT AP3 REAR RH
ABS3 ABS
ABS TRAILER STARTER MODULATOR REAR LH MODULATOR
DIAGNOSTIC
SOCKET MOTOR -VE MODULATOR
293 CONNECTOR 197 199
370B (3) SEE SHEET 24 198
370 (6) SHEET 26
ABSSS 17-24 481/11395
370A (3)
440 (1.4)
150 (1.4)
FUSES E1, E2 - TRAILER ABS

FUSES F1, F2, F3, F4 - TRACTOR ABS
Issue 1
17 - 26
Section C
RAM LOCK
SWITCH CC CD
(CLOSED WHEN)
LOCKED RH STEER LH STEER
VALVE VALVE
185B 1 2 1 2
164 (0.6)
17 - 30
9803/8020
LOCK C7 CB 166
1 1 452 167
VALVE 2 2 (0.6)
453 (0.6) 455 (0.6)
2 1
Section C
165 451
459 (1.0) CE FRONT
(0.6) 168
457 (1.0) POTENTIOMETER
459 (0.6) A A
B B
458 (1.0) C C
456
J A A J
(0.6)
462 (0.6) H B B H 462
462 (0.6) K K
M M (1.0)
461 (0.6) G L C C L G
660MB F D D F
E E
454 (0.6) (0.6)
458
453 (0.6) (0.6) 454 (0.6)
457 (0.6)
458 (0.6) C3 CA CF REAR
454 (0.6) 169 POTENTIOMETER
457 (0.6) 460 (1.0)
A A
453 461 (1.0)
456 (0.6) B B
(0.6)
452 C C
452 (0.6)
1 2 3 3 2 1 (0.6)
455 (0.6) 4 5 6 7 7 6 5 4 455 660K (0.6)
8 9 10 11 11 10 9 8 (0.6)
459 (0.6) 12 13 14 14 13 12 420 (0.6)
460 (0.6)
460 (0.6) 463 (0.6)
CP2 157 853 (0.6) A B B A 2WD/DL
463 (0.6) 451 (0.6)
185B SWITCH CONNECTOR
CONTROL C2 461 (0.6) C D
(0.6) D C SEE SHEET 11
MODULE
13 12 11 10 9 8 7 6 5 4 3 2 1
OUTPUTS
25 24 23 22 21 20 19 18 17 16 15 14 185A (0.6) C16 C17 CR9 17-11
802 (0.6) 58
660MA (0.6) 4 6 660MC
CP1 157
CONTROL 860H (0.6) (0.6) B A A B 2WD/DL
CONTROL
MODULE MODULE SWITCH
403D (0.6) 170 8 C D D C
CONNECTOR INPUTS 2 SEE SHEET 11
1 2 3 3 2 1
4 5 6 7 157 7 6 5 4
C18
8 9 10 10 9 8 5 17-11
888A (0.6) 4WS DIFF
LOCK CUT OUT 660MA 660M (1.0) 895 (0.6)
(0.6) SD
451 (0.6) CP3 C1 C5
185A (0.6) 185
464 (0.6) SA 2 LITTLE 1
FUSE
Electrics
(1.0)
860M (0.6)
898 (0.6) IN LINE E4
496 (0.6)
FUSE E4 (5A)
509A (0.6)
015H (0.6)
464 (0.6)
660M (1.0)
486B (0.6) 860M (0.6)
RHSLS SEE SHEET 17D
C6 17-17D
CR64
2 660M (1.0)
C4 CRES3 SEE SHEET 3
17-3
509A (0.6)
JACK 1 1 2 3 3 2 1 015H (1.0)
IGNS2 SEE SHEET 2 17-2
SOCKET 4 5 6 7 7 6 5 4
185C 156 8 9 10 54 10 9 8 509A (0.6)
173 898A (0.6) ELSS SEE SHEET 23
(0.6) 4WS 17-23
OPTION 898A (0.6)
20KSS SEE SHEET 23 17-23
628
CANSCREEN 486B (0.6)
(0.6) 1KSS SEE SHEET 10A 17-10A
153
SCRN (0.6)
515C CANSCREEN
SEE SHEET 23B CANHS
(0.6)
515C (0.6)
17-23B CANHS3 SEE SHEET 23B 17-23B
514C 514C (0.6)
SEE SHEET 23B CANLS CANLS3 SEE SHEET 23B 17-23B
(0.6)
17-23B 496 (0.6) CR65-29
SEE SHEET 23 17-23 481/11400
SHEET 30
*FUSE E4 - FOUR WHEEL STEERING (4WS)

Issue 2*
17 - 30
Section C
RAM LOCK
SWITCH CC CD
(CLOSED WHEN)
LOCKED RH STEER LH STEER
VALVE VALVE
185B 1 2 1 2
164 (0.6)
9803/8020
LOCK C7 3 CB 3
1 2 2 1 452 166 167
VALVE 4 4 (0.6)
17 - 30 - 2
453 (0.6) 455 (0.6)

2 1
165 451
Section C
459 (1.0) CE FRONT

(0.6)
457 (1.0) 168 POTENTIOMETER
459 (0.6) A A
B B
458 (1.0)
456
C C
(0.6)
J A A J
462 (0.6) H B B H 462
462 (0.6) K K
M M (1.0)
G L C C L G
461 (0.6)
660MB F D D F
E E
454 (0.6) (0.6)
458
453 (0.6) (0.6) 454 (0.6)
457 (0.6)
458 (0.6) C3 CA CF REAR
454 (0.6) POTENTIOMETER
457 (0.6) 460 (1.0) A A
453 461 (1.0)
456 (0.6) B B
(0.6)
452 C C
452 (0.6)
1 2 3 3 2 1
(0.6)
455 (0.6) 4 5 6 7 7 6 5 4 455 660K (0.6)
8 9 10 11 11 10 9 8 (0.6)
459 (0.6) 12 13 14 14 13 12 420
460 (0.6) (0.6)
460 (0.6) 463 (0.6)
CP2 157 853 (0.6) 4 1 1 4 2WD/DL
463 (0.6) 451 (0.6)
185B SWITCH CONNECTOR
CONTROL C2 461 (0.6) 3 2 3 SEE SHEET 11
(0.6) 2
13 12 11 10 9 8 7 6 5 4 3 2 1
MODULE
OUTPUTS
25 24 23 22 21 20 19 18 17 16 15 14 185A (0.6) C16 CR9
C17 17-11
802 (0.6)
660MA (0.6) 4 6
660MC
CP1 157 860H (0.6) CONTROL (0.6) 1 4
58 4 1 2WD/DL
CONTROL MODULE SWITCH
403D (0.6) 8 2 3 3 2
MODULE 1 2 3 INPUTS 3 2 1
170 2 SEE SHEET 11
CONNECTOR 4 5 6 7 7 6 5 4
8 9 10
157 10 9 8 5 17-11
888A (0.6) 4WS DIFF C18
LOCK CUT OUT 660MA 660M (1.0) 895 (0.6)
(0.6) SD
451 (0.6) CP3 C1 C5
185A (0.6) 185 2 LITTLE 1
464 (0.6) SA FUSE
(1.0)
860M (0.6)
Electrics
898 (0.6) IN LINE E4

496 (0.6)
FUSE E4 (5A)
509A (0.6)
015H (0.6)
464 (0.6)
660M (1.0)
486B (0.6) 860M (0.6)
C6 RHSLS SEE SHEET 17D 17-17D
CR64
2 660M (1.0)
C4 CRES3 SEE SHEET 3
17-3
509A (0.6)
JACK 1 1 2 3 3 2 1 015H (1.0)
IGNS2 SEE SHEET 2
SOCKET 4 5 6 7 7 6 5 4 17-2
185C
156 8 9 10
54 10 9 8 509A (0.6)
173 898A (0.6) ELSS SEE SHEET 23
(0.6) 4WS 17-23
OPTION 898A (0.6)
20KSS SEE SHEET 23 17-23
153 628
CANSCREEN 486B (0.6)
(0.6) 1KSS SEE SHEET 10A 17-10A
17-23B SCRN (0.6)
515C CANSCREEN
SEE SHEET 23B CANHS
(0.6)
515C (0.6)
CANHS3 SEE SHEET 23B
17-23B
514C 514C (0.6)
SEE SHEET 23B CANLS CANLS3 SEE SHEET 23B
(0.6) 17-23B
496 (0.6) CR65-29
17-23B SEE SHEET 23 17-23 481/11400
SHEET 30 Issue 2
*FUSE E4 - FOUR WHEEL STEERING (4WS)

Issue 1
17 - 30 - 2
Section C
TB
7 PIN TRAILER C1
SOCKET 620A TRAILER SOCKET
(USA ONLY) (2.0) CONNECTOR
17 - 31
TA
9803/8020
171 31 98
860A
1 (1.0)
58R 58L
Section C
6 58L 2 1 2 3 4 4 3 2 1
R 7 3L
859F 5 6 7 8 8 7 6 5
5 54 3
(1.4)
4
809C
(1.4)
883C
(1.4)
861F
(1.4)
880H
(1.0)
TB
7 PIN TRAILER C1
SOCKET 859F TRAILER SOCKET
(STANDARD)
Electrics
(1.4) TA CONNECTOR
172 98
L
1
54 54g
809C 1 2 3 4 4 3 2 1
6 58L 2
(1.4)
58R 7 31
620A 5 6 7 8 8 7 6 5
5 R 3
(2.0)
4
817C
(1.0)
861F
(1.4)
860A
(1.0)
883C APPENDIX A
(1.4) 481/11399
Connector C1 Pin Functions
1 LH Direction Indicator (see page 17 - 14) 5 RH Side Light (see page 17 - 17D)
TRAILER SOCKETS 2 Rear Fog Light (see page 17 - 17B) 6 Brake Lights (see page 17 - 5)
3 Earth for pins 1 to 8 7 LH Side Light (see page 17 - 17C)
4 RH Direction Indicator (see page 17 - 14)
Issue 1
17 - 31
Section C
17 - 32
9803/8020
Section C
LL/LR LL/LR
HEADLIGHT HEADLIGHT
CONNECTOR CONNECTOR
(3000 SERIES) (2000 SERIES)
1 6
1 4
4 2 3
3
1 - 1 DIPPED BEAM (SEE SHEET 17A)

120A & 121A
2 DIPPED BEAM (SEE SHEET 17A) 2 MAIN BEAM (SEE SHEET 17A)
3 MAIN BEAM (SEE SHEET 17A) 3 SIDE LIGHT (SEE SHEETS 17C & 17D)
4 SIDE LIGHT (SEE SHEETS 17C & 17D) 4 EARTH
5 INDICATOR (SEE SHEET 14)
6 EARTH
C18/C19
Electrics
3 2 1 1 2 3
6 5 4 4 5 6
1 EARTH 99 & 100

2 INDICATOR (SEE SHEET 14)
3 BRAKE (SEE SHEET 5)

4 TAIL (SEE SHEETS 17C & 17D)
5 REVERSE (SEE SHEET 21) APPENDIX B
6 FOG (SEE SHEET 17B) 481/11399
Head Light Connector (120A & 121A) Pin Rear Light Connector (99 & 100) Pin Functions
Functions 1 Earth
1 - 2 Direction Indicator (see page 17 - 14)
FRONT AND REAR 2 Dipped Beam (see page 17 - 17A) 3 Brake (see page 17 - 5)
3 Main Beam (see page 17 - 17A) 4 Tail (see page 17 - 17C & 17 - 17D)
LIGHT CLUSTERS 5 Reverse (see page 17 - 21)
4 Side Light (see page 17 - 17C & 17 - 17D)
5 Direction Indicator (see page 17 - 14) 6 Fog (see page 17 - 17B)
Issue 2*
17 - 32
Section C
6 Earth
GREEN
(514K 0.5)
C28 C79 CANBUS
TERMINATING TERMINATING
1 RESISTOR RESISTOR
5 2 CONNECTOR
11 6 3
18 12 7 4 120 Ohms
17 - 33
19 13 8 CANLS4 253
9803/8020
25 20 14 9 GRE GREEN 256
32 26 21 15 10
33 27 22 16 EN (514 EN (514M 0.5)
39 34 28 23 17 M 0.5 12 11 10 9 8 7 6 5 4 3 2 1
40 35 29 24
GRE .5)
K0 ) CR50
41 36 30 (514 24 23 22 21 20 19 18 17 16 15 14 13
(51
45 42 37 31 P/SHIFT
EEN
4L
46 43 38
47 44 YELLOW YELLOW A B B A 36 35 34 33 32 31 30 29 28 27 26 25 ECU2 RED
Section C
GR 0.5)
48 (515K 0.5) YEL (515M 0.5)
(515 LOW C C
K 0.5 248
SCRN ) W DRAINWIRE 629 (1.0)
FRONT (0.5) YELLO )
0.5 (0.5)
BULKHEAD
216 CANHS4 (515M
CR51
YEL GREEN GREEN (514 0.6)
(51 LOW
(514L 0.5) C80
INW
5L 0
(0.5
DRA )
ENGINE
IRE
.5)
1
CANBUS
2 5 INTERCONNECT
3 6 11 YELLOW A B
4 7 12 18
8 13 19 (515L 0.5) 12 11 10 9 8 7 6 5 4 3 2 1
9 14 20 25 C 255 CR49
)
AIN
10 15 21 26 32
DR
24 23 22 21 20 19 18 17 16 15 14 13
(0.5 WIRE
16 22 27 33 E P/SHIFT
17 23 28 34 39 DRAINWIRE
24 29 35 40
INWIR 36 35 34 33 32 31 30 29 28 27 26 25 ECU1 BLK
30 36 41
DRA ) (0.5)
31 37 42 45 (0.5
38 43 46
44 47 CANSS4 CR64 214
48 C129 4WS OPTION
TERMINATING 120 Ohms (2000 ONLY)
RESISTOR
CONNECTOR 2140, 3190 & 3220 ONLY 54
(3170 ONLY) 3 2 1
7 6 4
(2. 625
5
GREEN
0)
(514K 0.5)
10 9 8
A B B A
(0.5)
SCRN
YELLOW
(515 0.6)
C C
YELLOW
(515K 0.5)
SCRN (0.5) 154
CANBUS CR62
TERMINATING P/SHIFT
RESISTOR YELLOW (515C 0.5) RF GROUND
GREEN (514C 0.5)
GREEN
(514K 0.5)
SCRN (0.5)
YELLOW (515K 0.5)
CANLS1 CANLS3 GRE CANLS2 GRE
EN GRE
EN EN (514 EN (514 EN
GRE .5) (514 B 0.5 EN 0.5)
K0 E 0.5 GRE .5) ) GRE .5)
(514 ) E0 B0
(514 (514
(51
(51
EEN
EEN
)
4
4J
GR
0.5
GR 0.5)
GR D 0.5
4F
EEN )
(51
YELL
(515 OW
E 0.5 YELLO
YE OW ) (515B W
(515K LLOW YELL 0.5)
E W 0.5) W
0.5) (515 YELLO YELLO
0.5) .5)
(515B (515 0
Electrics
CANHS1 CANHS3 CANHS2

YEL (51 YELLO
W (51 LOW 5J 0 W
AIN
(628
(62
5D .5)
E
YELLO .5)
INW
F0 0.5
)
E
IRE
(515
DRA 0.5)
DR 8B 0.5
)
WIR )
IN
E 0.5
(6 2
DRA
8
(628 WIRE
WIR
E
DR K 0.5
AIN )
.5)
W
)
AIN
80 E
AIN
0.5
DR
DRA
DR
(62 WIR
8B IRE
(628 INWIRE E E
(62
F 0.5
) INWIR INWIR
DRA 0.5) DRA 0.5)
D J
(628 (628
CANSS1 CANSS3 CANSS2

GREEN
YELLOW
(514J 0.5)
(515J 0.5)
(0.5)
DRAINWIRE
CR115
CANBUS
THROUGH A B
CONNECTOR
GREEN CR83 C
(1.0)
627
(3000 ONLY)
(514F 0.5) CLUSTER
RF GROUND
TH
EC
120 Ohms
U1
(0.5)
263
SCRN
LE
W I U1
YELLOW
YELLOW
GREEN
EC SS
(515D 0.5)
626
(514D 0.5)
(1.0)
(515F 0.5)
D
CANBUS
CR119 C E TERMINATING B A B A
12 11 10 9 8 7 6 5 4 3 2 1 ECU4
DIAGNOSTIC B A F RESISTOR
24 23 22 21 20 19 18 17 16 15 14 13 SOCKET J
C C
G (3000 ONLY)
H
36 35 34 33 32 31 30 29 28 27 26 25
251
APPENDIX D
481/11399
CR66
LH CLUSTER 250
2 RED
CANBUS - CAB AND CHASSIS
Issue 1
17 - 33
Section C
Wire Numbers - Fastrac 2140
UNFUSED IGN FEEDS 115C 1.0 Cab roof ignition splice to rear intermittent 140 2.0 Fuse A8 to solenoid feed splice
18 - 1
wipe relay 140A 0.6 Solenoid feed splice to front PTO drive
9803/8020
No. Size Description 115E 1.4 Cab roof ignition splice to suspension seat or solenoid
0 4.0 Ignition switch to start relay 1 flow divider supply splice (less ECU1) 140B 0.6 Solenoid feed splice to rear PTO drive
4 4.0 Ignition switch (starter control) to ignition 115EA 1.4 Flow divider supply splice to suspension seat solenoid
Section C
switch (thermostart) (less ECU1) 140C 0.6 Solenoid feed splice to front PTO brake
5 4.0 Ignition switch to fuse box - fuse C3a 115EB 0.6 Flow divider supply splice to flow divider in- solenoid
10 6.0 Ignition relay to ignition splice 1 line fuse (less ECU1) 140D 0.6 Solenoid feed splice to rear PTO brake
10A 1.4 Ignition splice 1 to fuse box - fuse A2a 115EC 1.5 Work light interlock supply splice to solenoid
10B 2.0 Ignition splice 1 to fuse box - fuse A4a suspension seat (Italian) 140E 0.6 Solenoid feed splice to rear diff lock
10C 2.0 Ignition splice 1 to fuse box - fuse A3a 115ED 1.0 Fuse E5 to work light interlock supply splice solenoid
10D 1.4 Ignition splice 1 to fuse box - fuse C1a (Italian) 140F 0.6 Solenoid feed splice to 2 wheel drive
10E 1.0 Ignition splice 1 to fuse box - fuse C7a 116 0.6 Flow divider in-line fuse to flow divider solenoid
10F 1.4 Ignition splice 1 to fuse box - fuse C2a switch (less ECU1) 141 0.6 Fuse A8 to rear PTO drive cut-out harness
10G 4.0 Ignition splice 1 to fuse box - fuse A9a 116A 0.6 Flow divider switch to flow divider switch connector or relay
10H 1.0 Ignition splice 1 to fuse box - fuse B6a illumination (less ECU1) 145 1.4 Fuse C2 to hazard switch
10J 1.0 Ignition splice 1 to powered mirrors fuse (G3) 120 2.0 Fuse A4 panel ignition splice A4 150 1.0 Trailer ABS in line fuse to ABS trailer socket
14 0.6 Ignition switch to ignition relay coil 120A 2.0 Panel ignition splice A4 to column switch (ABS trailer socket)
15 6.0 Ignition switch to ignition splice 2 120B 1.0 Panel ignition splice A4 to front intermittent 151 2.0 Tractor ABS in line fuse D2 to tractor ABS
15A 0.6 Ignition splice 2 to fuse box - fuse A1a wipe relay ECU
15B 1.4 Ignition splice 2 to fuse box - fuse C9a 120C 1.0 Panel ignition splice A4 to front wiper motor 152 2.0 Tractor ABS in ine fuse f3 to tractor ABS
15C 0.6 Ignition splice 2 to fuse box - fuse A6a 125 2.0 Fuse A7 to Powershift supply splice ECU
15D 2.0 Ignition splice 2 to fuse box - fuse A8a 125A 1.0 Powershift supply splice to powershift ECU 153 1.0 Tractor ABS in ine fuse F4 to tractor ABS
15E 1.0 Ignition splice 2 to fuse box - fuse C4a 125B 1.0 Powershift supply splice to powershift ECU warning light relay
15F 2.0 Ignition splice 2 to fuse box - fuse A7a 125C 1.0 Powershift supply splice to powershift ECU 153A 1.0 Tractor ABS warning light relay link
15G 1.0 Ignition splice 2 to fuse box - fuse A5a 126 0.6 Powershift ECU to power range solenoid 155 0.6 Fuse C1 to reverse lights relay
15J 1.0 Ignition splice 2 to in ine fuse (ABS trailer feed splice 155A 0.6 Reverse lights relay coil link
socket) 126A 0.6 Power range solenoid feed splice to neutral 160 1.0 Fuse C4 to cab roof ignition splice c4
Electrics
15K 1.0 Ignition splice 2 to tractor ABS ignition relay solenoid connector (reverse) 160A 1.0 Cab roof ignition splice C4 to panel ignition
in line fuse F1a 126B 0.6 Power range solenoid feed splice to neutral splice C4
15L 4.0 Ignition splice 2 to electronic engine fuse box solenoid connector (low) 160B 0.6 Panel ignition splice C4 to instrument cluster
(fuses H6 - H7) 126C 0.6 Power range solenoid feed splice to neutral 160C 0.6 Panel ignition splice C4 to lights switch
20 4.0 Tractor ABS ignition relay to tractor ABS solenoid connector (medium) illumination
ignition splice 126D 0.6 Power range solenoid feed splice to neutral 160E 1.4 Panel ignition splice C4 to speed sender
20A 2.0 Tractor ABS ignition splice to tractor ABS solenoid connector (high) 160F 0.6 Panel ignition splice C4 to diagnostics
in ine fuse F2a 126E 0.6 Power range solenoid feed splice to select connector
20B 2.0 Tractor ABS ignition splice to tractor ABS solenoid connector (reverse) 160G 0.6 Panel ignition splice C4 to diff lock cut-out
in line fuse F3a 126F 0.6 Power range solenoid feed splice to select switch
20C 1.0 Tractor ABS ignition splice to tractor ABS in solenoid connector (low) 160H 0.6 Panel ignition splice C4 to fuse box - fuse
line fuse F4a 126G 0.6 Power range solenoid feed splice to select C5a
solenoid connector (medium) 160J 0.6 Panel ignition splice C4 to clutch
FUSED IGN FEEDS 126H 0.6 Power range solenoid feed splice to select warning/Selectronic bleeper
solenoid connector (high) 160K 0.5 Panel ignition splice C4 to field speed
No. Size Description 127 2.0 Fuse A7 to minder ignition splice or control switch illumination
105 0.6 Fuse A1 to clutch down switch interconnect 161 2.0 Fuse C5 to EDC ignition splice
110 1.4 Fuse A2 to brake lights relay 127A 2.0 Minder ignition splice to minder relay 161A 0.6 Option chassis supply splice to radar speed
111 0.6 Brake lights relay to brake lights switch 127B 0.6 Minder ignition splice to minder relay coil sensor
115 2.0 Fuse A3 to cab roof ignition splice 127C 0.6 Minder ignition splice to minder ECU 161B 0.6 Option chassis supply splice to fuel flow
115A 1.0 Cab roof ignition splice to rear wash/wipe 130 1.0 Fuse A5 to electronic engine meter
switch 135 0.6 Fuse A6 to electronic control unit (EDC ) 161C 0.6 EDC ignition splice to EDC bulkhead
115B 1.0 Cab roof ignition splice to rear wiper motor connector
Issue 1
18 - 1
Section C
18 - 2
161D 0.6 EDC ignition splice to wheel slip enable 270 3.0 Battery positive to in ine fuse (ABS trailer 342 1.5 Fuse H3 to electronic engine bulkhead
9803/8020
switch socket) connector
165 1.0 Fuse B6 to radio/cassette 290 6.0 Battery +ve to heated screen & mirrors relay 343 2.0 Fuse H4 to electronic engine bulkhead
Section C
166A 0.5 Fuse E5 to light block (Italian) connector

166B 0.5 Fuse E5 to pressure switch (Italian) 344 2.0 Fuse H5 to electronic engine bulkhead
170 4.0 Fuse A9 to ACU connector
171 2.0 Fuse A9 to compressor clutch relay FUSED FEEDS DIRECT FROM BATTERY 355 3.0 Fuse C8 to permanent feed splice c8
180 4.0 Fuse C6 to start relay 1 355A 3.0 PFSC8 to +ve terminal post
181 4.0 Start relay 1 to start relay 2 No. Size Description 355B 3.0 PFSC8 to 3 pin power socket
182 4.0 Start relay 2 to starter solenoid 300 0.6 Fuse B9 to permanent feed splice B9 355C 3.0 PFSC8 to convenience socket
190 1.4 Fuse C7 to trailer socket (13 pin) 300A 0.6 Permanent feed splice B9 to electronic 355D 3.0 PFSC8 to convenience socket relay
191 1.0 Fuse C7 to 3 pin power socket or control unit (EDC) 360 6.0 Maxifuse to panel main lights splice
convenience socket relay coil 300B 0.6 Permanent feed splice B9 to instrument 360A 2.0 Panel main lights splice to lights switch
191A 1.0 Convenience socket relay coil to 3 pin power cluster (headlights)
socket 305 1.0 Fuse B1 to cab roof permanent feed splice 360B 1.0 Panel main lights splice to fuse box - fuse
192 3.0 Convenience socket relay to convenience 305A 0.6 Cab roof permanent feed splice to D6a
socket radio/cassette 360C 2.0 Panel main lights splice to lights switch
195 1.4 Fuse C9 to C9 chassis splice 305B 0.6 Cab roof permanent feed splice to LH interior (headlights)
195A 1.4 C9 chassis splice to air drier light 360D 1.4 Panel main lights splice to rear fog lights
195B 0.6 C9 chassis splice to 6 speed neutral switch 305C 1.0 Cab roof permanent feed splice to beacon relay
switch 362 0.6 Fuse D6 to auxiliary lights switch
305E 0.6 Cab roof permanent feed splice to 365A 1.5 Fuse C6 to diagnostic socket
UNFUSED FEEDS DIRECT FROM BATTERY agricultural control panel illumination 365B 1.5 Fuse C6 to diagnostic connector
310 2.0 Fuse B2 to hazard switch 370 6.0 ABS trailer socket to ABS supply splice
No. Size Description 315 2.5 Fuse B3 to front work lights supply splice 370A 3.0 ABS supply splice to in ine fuse (ABS trailer
200A 4.0 Battery positive to ignition switch 315A 1.4 Front work lights supply splice to front work socket)
200B 4.0 Battery positive to ignition switch lights switch 370B 3.0 ABS supply splice to in ine fuse (ABS trailer
Electrics
201 6.0 Battery positive to ignition relay 315B 1.4 Front work lights supply splice to front work socket)
202 8.0 Battery positive to work lights relay lights switch
203 6.0 Work lights relay to fuse box - Fuse B3a 315C 1.5 Front work lights supply splice to front work INSTRUMENTATION, SIGNAL WIRES
204 3.0 Work lights relay to fuse box - Fuse B4a lights switch illumination.
210 4.0 Battery positive to battery splice 1 315E 2.5 Fuse B3 to work light connector or front No. Size Description
210B 2.0 Battery splice 1 to fuse box - fuse B2a upper work lights relay 400 0.6 Park brake warning switch to 2WD dump
210D 3.0 Battery splice 1 to fuse box - fuse B7a 315F 1.5 Front work lights supply splice to front splice
210E 1.4 Battery splice 1 to fuse box - fuse B8a headlight bars work lights relay 400B 0.6 2WD dump splice to 2WD dump relay coil
220 6.0 Alternator to starter motor positive 320 2.5 Fuse B4 to rear work lights supply splice 400C 0.6 2WD dump splice to Powershift ECU
230 6.0 Alternator to starter motor positive 320A 1.4 Rear work lights supply splice to rear work 403 1.4 Alternator to alternator signal splice
240 4.0 Battery positive to battery splice 2 lights switch 403A 0.6 Alternator signal splice to instrument cluster
240A 1.0 Battery splice 2 to fuse box - fuse B1a 320B 1.4 Rear work lights supply splice to rear work 403B 0.6 Alternator signal splice to electronic control
240B 1.4 Battery splice 2 to fuse box - fuse B5a lights switch unit (EDC)
240D 0.6 Battery splice 2 to fuse box - fuse B9a 320C 0.6 Rear work lights supply splice to rear work 404 0.6 Instrument cluster to air filter vacuum switch
240E 3.0 Battery splice 2 to fuse fox - fuse C8a lights switch illumination. 405 0.6 Instrument cluster to transmission oil filter
240F 1.5 Battery splice 2 to fuse fox - fuse c6a 320D 1.5 Fuse B4 to rear inner work lights relay switch
245 6.0 Battery positive to electronic engine fuse box 325 1.4 Fuse B5 to column switch (headlights flash) 406 0.6 Instrument cluster to air tank 2 pressure
(fuses H1 - H5) 330 3.0 Fuse B7 to auxiliary jack plug socket switch
250 6.0 Battery positive to maxifuse (main lights) 335 1.4 Fuse B8 to cigar lighter 407 0.6 Instrument cluster to air tank 1 pressure
* 260 3.0 Battery positive to in line fuse (ABS trailer 340 1.5 Fuse H1 to electronic engine bulkhead switch
socket) connector 408 0.6 Instrument cluster to air tank 3 pressure
265A 3.0 Battery positive to tractor ABS ignition relay 341 1.5 Fuse H2 to electronic engine bulkhead switch
265B 3.0 Battery positive to tractor ABS ignition relay connector
Issue 2*
18 - 2
Section C
18 - 3
409 0.6 Instrument cluster to brake malfunction 433 0.6 Electronic control unit to control panel 471B 0.6 Downshift switch splice to duplicate
9803/8020
splice (EDC) autoshift button (shift down)
409A 0.6 Brake malfunction splice to front brake 434 0.6 Powershift ECU to instrument cluster 471C 0.5 Downshift switch splice to autoshift
Section C
reservoir (transmission oil pressure) connector (split down)

409B 0.6 Brake malfunction splice to rear brake 435B 0.6 Transmission oil pressure splice to 472 1.4 Gear knob connector (split auto) to autoshift
reservoir Powershift ECU switch splice
409C 0.6 Brake malfunction splice to brake reservoir 436 0.6 Low/rev ram connector to Powershift ECU 472A 0.6 Autoshift switch splice to Powershift ECU
3 (reverse selected ram switch) (auto split)
411 0.6 Instrument cluster to fuel level sender 437 0.6 Low/rev ram connector to Powershift ECU 472B 0.6 Autoshift switch splice to duplicate autoshift
412 0.5 Electronic engine ECU to Powershift ECU (low selected ram switch) button (autoshift)
413 0.6 Powershift ECU to accelerator pedal switch 438 0.6 Med/high ram connector to Powershift ECU 472C 0.5 Autoshift switch splice to autoshift
414 1.4 Speed signal pick-up to speed signal splice (medium selected ram switch) connector (autoshift)
414A 0.6 Speed signal splice to instrument cluster 439 0.6 Med/high ram connector to Powershift ECU 477 0.6 Range change column switch to power
414B 0.6 Speed signal splice to EDC ECU (high selected ram switch) range low splice
415 0.6 Instrument cluster to area cut-out selection 440 0.6 Instrument cluster to ABS trailer socket 477A 0.6 Power range low splice to Powershift ECU
switch 441 0.6 Low/rev ram connector to Powershift ECU 477B 0.6 Power range low splice to instrument
416 0.6 Area diff lock cut-out splice to instrument (low neutral ram switch) cluster
cluster 442 0.6 Med/high ram connector to Powershift ECU 478 0.6 Range change column switch to power
416A 0.6 Diff lock cut-out relay to area diff lock cut- (medium neutral ram switch) range medium splice
out splice 443 0.6 Med/high ram connector to Powershift ECU 478A 0.6 Power range medium splice to Powershift
416B 0.6 Area cut-out switch to area diff lock cut-out (high neutral ram switch) ECU
splice 444 0.6 Instrument cluster to 540 PTO range switch 478B 0.6 Power range medium splice to instrument
417 0.6 Single trailer turn relay to instrument cluster 445 0.6 Instrument cluster to 1000 PTO range cluster
(1st trailer turn) switch 479 0.6 Range change column switch or column
418 0.6 Fuse D1 to instrument cluster (main beam 446 0.6 Low/rev ram connector to Powershift ECU switch splice (less high range) to power
warning) (reverse neutral ram switch) range high splice
419 0.6 Second trailer turn relay to instrument 448 1.0 Tractor ABS warning light relay to 479A 0.6 Power range high splice to Powershift ECU
Electrics
cluster (2nd trailer turn) instrument cluster 479B 0.6 Power range high splice to instrument
420 0.6 Instrument cluster to 2WD/diff lock switch 449 1.0 Tractor ABS warning light relay to cluster
(4WD indicator) diagnostic button 479C 0.6 Column switch splice to column switch (less
421 1.0 Second trailer turn relay to single trailer turn 450 0.6 Clutch warning/Selectronic bleeper to high range)
relay Powershift ECU 479D 0.6 Column switch splice to column switch (less
422 0.6 Area cut-out selection switch to jack socket 465 1.0 Tractor ABS diagnostic switch to tractor high range)
423 0.6 Buzzer to instrument cluster ABS ECU 480 0.6 Range change column switch to power
424 0.6 Electronic control unit to position sensor 466 0.5 Oil pressure switch to light block (Italian) range reverse splice
(EDC) 467 0.5 Work lights lock-lock relay to work lights 480A 0.6 Power range reverse splice to Powershift
425 0.6 Electronic control unit to LH draft pin (EDC) relay (coil) (Italian) ECU
426 0.6 Electronic control unit to RH draft pin (EDC) 470 1.4 Gear knob connector (split up) to upshift 480B 0.6 Power range reverse splice to instrument
427 0.6 Electronic control unit to control panel switch splice cluster
(EDC) 470A 0.6 Upshift switch splice to Powershift ECU 485 0.6 Powershift ECU to instrument cluster (3 kph
428 0.6 Electronic control unit to control panel (split up) signal)
(EDC) 470B 0.6 Upshift switch splice to duplicate autoshift 486 0.6 Powershift ECU to instrument cluster (1 kph
429 0.6 Electronic control unit to control panel button (split up) signal)
(EDC) 470C 0.5 Upshift switch splice to autoshift connector 487 0.6 Powershift ECU to neutral solenoid
430 0.6 Electronic control unit to control panel (split up) connector (reverse)
(EDC) 471 1.4 Gear knob connector (split down) to 488 0.6 Powershift ECU to neutral solenoid
431 0.6 Electronic control unit to control panel downshift switch splice connector (low)
(EDC) 471A 0.6 Downshift switch splice to Powershift ECU 489 0.6 Powershift ECU to neutral solenoid
432 0.6 Electronic control unit to wheel slip enable (split down) connector (medium)
switch (EDC)
Issue 1
18 - 3
Section C
18 - 4
490 0.6 Powershift ECU to neutral solenoid 515 0.6 Powershift ECU to CAN high splice 2 526 0.6 Powershift ECU to oil temp sensor 2
9803/8020
connector (high) 515B 0.6 CAN high splice 2 to CAN high splice 3 530 1.0 Powershift ECU to splitter dump inhibit
491 0.6 Powershift ECU to select solenoid 515D 0.6 CAN high splice 3 to diagnostic connector switch (clutch fully down checking lamp)
Section C
connector (reverse) 515E 0.6 CAN high splice 3 to CAN high splice 1 531 1.0 Powershift ECU to splitter dump inhibit
492 0.6 Powershift ECU to select solenoid 515F 0.6 CAN high splice 1 to instrument cluster splice (calibration link)
connector (low) 515J 0.5 CAN high splice 2 to terminating resistor or 532 1.0 Powershift ECU to splitter dump inhibit
493 0.6 Powershift ECU to select solenoid CAN high splice 5 (ECU1-cab) switch (clutch fully down)
connector (medium) 515K 0.5 CAN high splice 1 to CAN high splice 4 533 1.0 Powershift ECU to splitter dump inhibit
494 0.6 Powershift ECU to select solenoid (chassis) splice (clutch fully down)
connector (high) 515L 0.5 CAN high splice 4 (chassis) to electronic 534 0.5 ECU1 to theoretical ground speed resistor
497 1.4 Speed sensor to instrument cluster (+12v engine splice
presence) 515M 0.5 CAN high splice 4 (chassis) to terminating 534A 0.5 Theoretical ground speed resistor splice to
498 0.6 Column switch button to instrument cluster resistor resistor connector 1
499 0.6 Column switch button to instrument cluster 515N 0.5 CAN high splice 5 (ECU1-cab) to ECU1 534B 0.5 Theoretical ground speed resistor splice to
500 2.0 Radar speed sensor to radar signal splice 515P 0.5 CAN high splice 5 (ECU1-cab) to CAN high resistor connector 1
500A 0.6 Radar signal splice to radar signal splice 2 splice 6 (ECU1-chassis) 535 0.5 Resistor connector to ISO 11786 connector
500AA 0.5 Radar signal splice 2 to instrument cluster 515R 0.5 CAN high splice 6 (ECU1-chassis) to (theoretical ground speed)
500B 0.6 Radar signal splice to EDC ECU electronic spool valve 1 536 0.5 ECU1 to radar ground speed resistor splice
501 2.0 Radar speed sensor to instrument cluster 515T 0.5 CAN high splice 7 (ECU1-chassis) to 536A 0.5 Radar ground speed resistor splice to
(presence signal) electronic spool valve 2 resistor connector 1
502 0.6 Instrument cluster to fuel return meter 515U 0.5 CAN high splice 8 (ECU1-chassis) to 536B 0.5 Radar ground speed resistor splice to
503 0.6 ECU to raise solenoid (EDC) electronic spool valve 3 resistor connector 1
503A 0.6 ECU to control panel (EDC) 515V 0.5 CAN high splice 9 (ECU1-chassis) to 537 0.5 Resistor connector to ISO 11786 connector
504 0.6 ECU to lower solenoid (EDC) electronic spool valve 4 (radar ground speed)
504A 0.6 ECU to control panel (EDC) 515W 0.5 CAN high splice 10 (ECU1-chassis) to 538 0.5 Resistor connector to front hitch control
505 0.6 Instrument cluster to EDC ECU (slip +) electronic spool valve 5 539 0.5 Electronic engine ECU to intermediate speed
506 0.6 Control panel to ECU (EDC) 515X 0.5 CAN high splice 10 (ECU1-chassis) to control validation switch
Electrics
507 0.6 Control panel to ECU (EDC) terminating resistor 540 0.5 Electronic engine ECU to foot throttle
508 0.6 EDC ECU to EDC control panel 516 0.6 Instrument cluster to diagnostics connector (supply)
509 0.6 EDC ECU to EDC lower signal splice (serial TX) 541 0.5 Electronic engine ECU to foot throttle (signal)
509B 0.6 Lower signal splice to instrument cluster 517 0.6 Instrument cluster to diagnostics connector 542 0.5 Electronic engine ECU to foot throttle (return)
510 0.6 Instrument cluster to EDC ECU (slip (serial RX) 543 0.5 Electronic engine ECU to foot throttle (on
setpoint) 518 0.6 Instrument cluster to EDC ECU (slip -) idle switch)
511 0.6 Instrument cluster to EDC earth splice 521 0.6 Powershift ECU to clutch pedal 544 0.5 Electronic engine ECU to foot throttle (off
(option present) potentiometer idle switch)
513 0.6 Instrument cluster to diagnostics connector 522 0.6 Powershift ECU to clutch pedal 545 0.5 Electronic engine bulkhead connector to fan
(program) potentiometer clutch drive
514 0.6 Powershift ECU to CAN low splice 2 523 0.6 Powershift ECU to clutch pedal 546 0.5 ECU1 to resistor connector 2
514B 0.6 CAN low splice 2 to CAN low splice 3 potentiometer 547 0.5 Electronic engine ECU to gearbox speed
514D 0.6 CAN low splice 3 to diagnostic connector 524 0.6 Transmission oil temp splice 2 to sensor
514E 0.6 CAN low splice 3 to CAN low splice 1 transmission oil temp splice 1 548 0.5 Electronic engine ECU to gearbox speed
514F 0.6 CAN low splice 1 to instrument cluster 524A 0.6 Transmission oil temp splice 1 to Powershift sensor
514J 0.5 CAN low splice 2 to terminating resistor or ECU 549 0.5 Electronic engine ECU to hand throttle
CAN low splice 5 (ECU1-cab) 524B 0.6 Transmission oil temp splice 1 to Powershift (supply)
514K 0.5 CAN low splice 1 to CAN low splice 4 ECU 550 0.5 Electronic engine ECU to hand throttle
(chassis) 524C 0.6 Transmission oil temp splice 2 to oil temp (signal)
514L 0.5 CAN low splice 4 (chassis) to electronic sensor 1 551 0.5 Electronic engine ECU to hand throttle
engine 524D 0.6 Transmission oil temp splice 2 to oil temp (return)
514M 0.5 CAN low splice 4 (chassis) to terminating sensor 2 552 1.0 Electronic engine ECU to water-in-fuel
resistor 525 0.6 Powershift ECU to oil temp sensor 1 sensor
Issue 1
18 - 4
Section C
553 0.5 Electronic engine ECU to grid heater relay 1 600F 0.6 Cab roof earth splice 1 to LH interior light 630D 0.6 Chassis earth splice 2 to low/rev ram (low
18 - 5
554 0.5 Electronic engine ECU to grid heater relay 2 600G 0.6 Cab roof earth splice 1 to agricultural control engaged switch)
9803/8020
555 0.5 Electronic engine ECU to foot throttle panel illumination light 630E 0.6 Chassis earth splice 2 to high/med ram (med
(supply) 605 1.0 ABS trailer socket to starter motor negative neutral switch)
Section C
556 0.5 Electronic engine ECU to engine torque (ABS) 630F 0.6 Chassis earth splice 2 to high/med ram (med
derate resistor splice 610 4.0 Battery negative to cab roof earth splice 2 engaged switch)
556A 0.5 Engine torque derate resistor splice to ECU1 610A 1.0 Cab roof earth splice 2 to rear RH outer work 630G 0.6 Chassis earth splice 2 to high/med ram (high
556B 0.5 Engine torque derate resistor splice to light neutral switch)
resistor connector 610B 1.0 Cab roof earth splice 2 to rear RH inner work 630H 0.6 Chassis earth splice 2 to high/med ram (high
558 0.5 Electronic engine ECU to engine speed light engaged switch)
control switch (increase) * 610C 1.0 Cab roof earth splice 2 to rear LH outer work 632 1.0 ECU1 to RF ground
559 0.5 Electronic engine ECU to engine speed light 635 2.0 Battery negative to cab roof earth splice 4
control switch (decrease) 610D 1.0 Cab roof earth splice 2 to rear LH inner work 635A 0.5 Cab roof earth splice 4 to intermediate
560 1.0 Tractor ABS ECU to tractor ABS diagnostic light speed control 1 switch
socket (J1708) 610E 1.0 Cab roof earth splice 2 to rear wiper motor 635B 0.5 Cab roof earth splice 4 to intermediate speed
561 1.0 Tractor ABS ECU to tractor ABS diagnostic 610F 1.0 Cab roof earth splice 2 to beacon socket control 1 switch
socket (J1708) 610G 0.6 Cab roof earth splice 2 to RH number plate 635C 1.5 Cab roof earth splice 4 to diagnostics socket
562 1.0 Tractor ABS ECU x2 pin 5 to front RH speed light 635D 0.5 Cab roof earth splice 4 to front upper work
sensor 1 (black) 610H 0.6 Cab roof earth splice 2 to LH number plate lights relay coil
563 1.0 Tractor ABS ECU x2 pin 6 to front RH speed light 635E 0.5 Cab roof earth splice 4 to autoshift
sensor 2 (brown) 615 6.0 ABS trailer socket to starter motor negative connector
564 1.0 Tractor ABS ECU x2 pin 7 to front LH speed (ABS) 635F 0.5 Cab roof earth splice 4 to engine speed
sensor 1 (black) 620 4.0 Starter motor negative to chassis earth control switch
565 1.0 Tractor ABS ECU x2 pin 8 to front LH speed splice 1 635G 0.5 Cab roof earth splice 4 to engine speed
sensor 2 (brown) 620A 2.0 Chassis earth splice 1 to trailer socket control switch
566 1.0 Tractor ABS ECU x3 pin 1 to rear LH speed 620B 1.4 Chassis earth splice 1 to LH rear lights 635H 0.5 Cab roof earth splice 4 to high level brake
sensor 1 (black) cluster light
567 1.0 Tractor ABS ECU x3 pin 2 to rear LH speed 620C 1.4 Chassis earth splice 1 to RH rear lights 635J 0.5 Cab roof earth splice 4 to FSC validation
Electrics
sensor 2 (brown) cluster switch

568 1.0 Tractor ABS ECU x3 pin 3 to rear RH speed 620D 1.0 Chassis earth splice 1 to RH rear fender 635K 0.5 Cab roof earth splice 4 to rear inner work
sensor 1 (black) work light lights relay coil
569 1.0 Tractor ABS ECU x3 pin 4 to rear RH speed 620E 1.0 Chassis earth splice 1 to LH rear fender work 635L 0.5 Cab roof earth splice 4 to rear inner work
sensor 2 (brown) light lights cut-out relay coil
625 1.0 Powershift ECU to RF ground 640 3.0 Starter motor negative to chassis earth splice
Note: Instrumentation, signal wires are continued from 626 1.0 Instrument cluster to RF ground 7
wire number 1400 627 1.0 CAN shield to RF ground (instrument cluster 640A 0.6 Chassis earth splice 7 to fuel level sender
end) 640B 1.4 Chassis earth splice 7 to gear knob
628A 1.0 CAN shield splice to diagnostic connector connector
EARTHS pair shield 640C 0.6 Chassis earth splice 7 to transmission oil
628B 1.0 CAN shield splice to instrument cluster pair filter switch
No. Size Description shield 640F 0.6 Chassis earth splice 7 to front brake reservoir
600 6.0 Battery negative to cab roof earth splice 1 628C 1.0 CAN shield to Powershift ECU pair shield 640G 0.6 Chassis earth splice 7 to rear brake reservoir
600A 1.0 Cab roof earth splice 1 to front RH outer 629 1.0 CAN shield to Powershift ECU 640H 0.6 Chassis earth splice 7 to air tank 3 pressure
work light 630 1.0 Starter motor negative to chassis earth switch
600B 1.0 Cab roof earth splice 1 to front RH inner splice 2 640K 1.4 Chassis earth splice 7 to air drier
work light 630A 0.6 Chassis earth splice 2 to low/rev ram (rev 640L 0.6 Chassis earth splice 7 to transmission oil
600C 1.0 Cab roof earth splice 1 to front LH inner neutral switch) pressure switch
work light 630B 0.6 Chassis earth splice 2 to low/rev ram (rev 640M 0.6 Chassis earth splice 7 to wet clutch
600D 1.0 Cab roof earth splice 1 to front LH outer engaged switch) lubrication solenoid
work light 630C 0.6 Chassis earth splice 2 to low/rev ram (low 640N 0.6 Chassis earth splice 7 to wet clutch brake
600E 1.4 Cab roof earth splice 1 to radio / cassette neutral switch) solenoid
Issue 2*
18 - 5
Section C
18 - 6
640P 0.6 Chassis earth splice 7 brake reservoir 3 660GE 0.6 EDC earth splice to option connector (EDC) 700 4.0 Starter motor negative to front lights earth
9803/8020
645 6.0 Starter motor negative to chassis earth splice 8 660GF 2.0 EDC earth splice to radar speed sensor splice
645A 2.0 Battery negative or chassis earth splice 8 to (EDC) 700A 1.4 Front lights earth splice to LH headlight
Section C
electronic engine bulkhead 660GJ 0.6 EDC earth splice to wheel slip enable switch 700B 1.4 Front lights earth splice to RH headlight
645B 2.0 Battery negative or chassis earth splice 8 to (EDC) 700C 1.0 Front lights earth splice to RH headlight bar
electronic engine bulkhead 660GK 0.6 EDC earth splice to wheel slip enable switch work light
645C 2.0 Battery negative or chassis earth splice 8 to (EDC) 700D 1.0 Front lights earth splice to LH headlight bar
electronic engine bulkhead 660H 1.0 Cab roof earth splice 3 to Powershift ECU work light
645D 2.0 Battery negative or chassis earth splice 8 to 660J 1.0 Cab roof earth splice 3 to Powershift ECU 706 0.6 Radio / cassette to RH speaker
electronic engine bulkhead 660K 0.6 Cab roof earth splice 3 to 4WD / diff lock 707 0.6 Radio / cassette to LH speaker
645E 2.0 Battery negative or chassis earth splice 8 to switch 710 3.0 Battery negative to panel earth splice 1
electronic engine bulkhead 660L 0.6 Cab roof earth splice 3 to splitter dump relay 710A 0.6 Panel earth splice 1 to single trailer turn
645F 1.0 Chassis earth splice 8 to water-in-fuel sensor 660T 0.6 Cab roof earth splice 3 to 540 PTO range relay
645G 0.5 Chassis earth splice 8 to fan clutch driver selected switch 710B 0.6 Panel earth splice 1 to rear wash/wipe
650 2.0 Starter motor negative to chassis earth splice 9 660U 0.6 Cab roof earth splice 3 to 1000 PTO range switch illumination.
650A 1.0 Chassis earth splice 9 to front wiper motor selected switch 710C 1.4 Panel earth splice 1 to instrument cluster
650C 0.6 Chassis earth splice 9 to air tank 1 660V 0.6 Cab roof earth splice 3 to diff lock cutout 710D 0.6 Panel earth splice 1 to beacon switch
650D 0.6 Chassis earth splice 9 to air tank 2 switch illumination. illumination.
650G 0.6 Chassis earth splice 9 to air filter switch 660W 0.6 Cab roof earth splice 3 to work lights relay 710E 0.6 Panel earth splice 1 to front upper work
650H 0.6 Chassis earth splice 9 to compressor switch coil lights cut-out relay coil
650L 0.6 Chassis earth splice 9 to induction heater 660X 1.0 Cab roof earth splice 3 to splitter dump 710F 1.0 Panel earth splice 1 to lights switch
relay 1 relay illumination
650M 0.6 Chassis earth splice 9 to induction heater 660Y 0.6 Cab roof earth splice 3 to diagnostics 710G 0.6 Panel earth splice 1 to second trailer turn
relay 2 connector relay
650N 1.0 Chassis earth splice 9 to water-in-fuel sensor 660Z 1.4 Cab roof earth splice 3 to cigar lighter 710H 1.0 Panel earth splice 1 to rear washer pump
650P 0.5 Chassis earth splice 9 to fan clutch driver 660ZA 0.6 Cab roof earth splice 3 to duplicate 710J 1.0 Panel earth splice 1 to front washer pump
655 2.0 Battery negative to cab roof earth splice 5 autoshift connector (up) 710K 0.6 Panel earth splice 1 to front intermittent
Electrics
655A 1.0 Cab roof earth splice 5 to Powershift ECU 660ZB 0.6 Cab roof earth splice 3 to duplicate wipe relay
655B 1.0 Cab roof earth splice 5 to Powershift ECU autoshift connector (down) 710L 0.6 Panel earth splice 1 to front work lights
655C 1.0 Cab roof earth splice 5 to Powershift ECU 660ZC 0.6 Cab roof earth splice 3 to duplicate switch illumination.
655D 1.0 Cab roof earth splice 5 to inching solenoid autoshift connector (auto) 710M 0.6 Panel earth splice 1 to brake lights relay coil
resistor 665A 3.0 Battery negative to tractor ABS earth splice 710N 0.6 Panel earth splice 1 to rear work lights
660 2.0 Battery negative to cab roof earth splice 3 665B 3.0 Battery negative to tractor ABS earth splice switch illumination.
660B 0.6 Cab roof earth splice 3 to front PTO switch 665C 2.0 Tractor ABS earth splice to tractor ABS 710P 1.4 Panel earth splice 1 to speed sensor
660C 0.6 Cab roof earth splice 3 to rear PTO switch ECU 710R 1.0 Panel earth splice 1 to rear fog lights relay
660D 0.6 Cab roof earth splice 3 to rear intermittent 665D 2.0 Tractor ABS earth splice to tractor ABS coil
wipe relay ECU 710T 0.5 Panel earth splice 1 to headlight bar work
660E 0.6 Cab roof earth splice 3 to handbrake warning 665E 0.6 Tractor ABS earth splice to tractor ABS lights cut-out relay coil
switch ignition relay 710U 0.5 Panel earth splice 1 to rear fender work
660F 0.6 Cab roof earth splice 3 to ignition relay coil 670 4.0 Battery negative to air conditioning unit lights cut-out relay coil
660G 0.6 Cab roof earth splice 3 to EDC earth splice 680 3.0 Battery negative to auxiliary jack plug 710V 0.5 Panel earth splice 1 to work lights harness
(EDC) socket or work lights harness earth spice
660GA 0.6 EDC earth splice to ECU (EDC) 685 3.0 Battery negative to power socket earth 710VA 0.5 Work lights harness earth splice to front
660GB 0.6 EDC earth splice to hitch raise/lower switch splice upper work lights relay
(EDC) 685A 3.0 PSES to -ve terminal post 710VB 0.5 Work lights harness earth splice to rear
660GC 0.6 EDC earth splice to area cut-out selection 685B 3.0 PSES to 3 pin power socket upper work lights changeover relay
switch (EDC) 685C 3.0 PSES to convenience socket 710VC 0.5 Work lights harness earth splice to rear
660GD 0.6 EDC earth splice to area cut-out jack socket 685D 1.0 PSES to convenience socket relay coil fender work lights changeover relay
(EDC) 690 2.0 Starter motor negative to horn 710VD 0.5 Work lights harness earth splice to head
light bar work lights cut out relay
Issue 1
18 - 6
Section C
18 - 7
710VE 0.5 Work lights harness earth splice to head 750H 0.5 Work light interlock earth splice to work 801A 1.5 Inner front work lights splice to front RH
9803/8020
light bar work lights relay light interlock relay (Italian) inner work light
715 0.6 Electronic control unit to position sensor 760 3.0 Battery negative to auxiliary lights earth 801B 1.5 Inner front work lights splice to front LH
Section C
(EDC) connector or splice inner work light

720 3.0 Battery negative to panel earth splice 3 760A 0.6 Auxiliary lights earth splice to switching 803 0.6 Differential lock cut-out switch to differential
720A 0.6 Panel earth splice 3 to warning buzzer relay (main beam) lock cut-out relay coil
720B 0.6 Panel earth splice 3 to LH door switch 760B 1.4 Auxiliary lights earth splice to LH auxiliary 804 1.5 Work light harness or head light bar work
720C 1.4 Panel earth splice 3 to LH side repeater headlight light cut out relay to ‘A’ post work lights
720D 1.4 Panel earth splice 3 to RH side repeater 760C 0.6 Auxiliary lights earth splice to switching splice
720E 0.6 Panel earth splice 3 to accelerator pedal relay (dip beam) 804A 1.5 ‘A’ post work lights splice to front RH "A"
switch 760D 1.4 Auxiliary lights earth splice to RH auxiliary post work light
720F 0.6 Panel earth splice 3 to front RH "A" post headlight 804B 1.5 ‘A’ post work lights splice to front LH "A"
work light 760E 0.6 Auxiliary lights earth splice to switching post work light
720G 0.6 Panel earth splice 3 to front LH "A" post relay (LH side light) 804C 1.0 ‘A’ post work lights splice to front upper
work light 760F 0.6 Auxiliary lights earth splice to LH auxiliary work lights cut-out relay
720H 0.6 Panel earth splice 3 to hazard lights switch sidelight-direction indicator 804D 1.5 Front work light switch to work light harness
illumination 760G 0.6 Auxiliary lights earth splice to switching or headlight bar work light cut out relay
720J 1.0 Panel earth splice 3 to rear fog lights switch relay (RH side light) 805 1.5 Work light harness or upper rear work light
illumination 760H 0.6 Auxiliary lights earth splice to RH auxiliary changeover relay to outer rear work lights
720K 0.6 Panel earth splice 3 to range change sidelight-direction indicator splice
column switch 760J 0.6 Auxiliary lights earth splice to switching 805A 1.5 Outer rear work lights splice to rear RH
720L 0.6 Panel earth splice 3 to air gauge illumination relay (LH direction indicator) outer work light
720M 0.5 Panel earth splice 3 to throttle pedal (IVS) 760K 0.6 Auxiliary lights earth splice to switching relay 805B 1.5 Outer rear work lights splice to rear LH
720N 0.6 Panel earth splice 3 to clutch up switch (RH direction indicator) outer w/light
720P 0.5 Panel earth splice 3 to brake signal relay 760L 0.6 Auxiliary lights earth splice to auxiliary lights 805C 0.5 Outer rear work lights splice to rear inner
720R 0.5 Panel earth splice 3 to brake signal relay switch illumination work lights cut-out relay
* 725 0.6 Electronic control unit to sensor earth splice 790 6.0 Battery negative to heated screen earth 805D 1.5 Rear work light switch to work light harness
Electrics
(EDC) splice or rear fender work light cut out relay

725A 0.6 Sensor earth splice to RH draft pin (EDC) 790A 2.5 Heated screen earth splice to LH heated 805E 1.5 Rear fender work light cut out relay to rear
725B 0.6 Sensor earth splice to LH draft pin (EDC) screen upper work lights changeover relay
730 1.4 Battery negative to heater unit 790B 2.5 Heated screen earth splice to RH heated 806 1.4 Rear fog lights relay to fuse box fuse D3a
750 1.4 Battery negative to suspension seat or flow screen 807 2.0 Lights switch to fuse box fuse D4a
divider earth splice 790C 0.5 Heated screen earth splice to timer relay 808 1.0 Fuse box fuse D4a to fuse box fuse D5a
750A 1.4 Flow divider earth splice to suspension seat 790D 0.5 Heated screen earth splice to switching 809 1.4 Fuse D3 to fog lights splice
750B 0.6 Flow divider earth splice to flow divider relay 809A 0.6 Fog lights splice to RH rear lights cluster
valve solenoid 790E 0.5 Heated screen earth splice to switch 809B 0.6 Fog lights splice to LH rear lights cluster
750C 0.6 Flow divider earth splice to flow divider (illumination) 809C 1.4 Fog lights splice to trailer socket
switch illumination. 810 0.6 Clutch down switch to clutch down splice
750D 0.5 Flow divider earth splice to flow divider SWITCHED SUPPLIES AND LINKS 810A 0.6 Clutch down splice to diode connector
switch 810B 0.6 Clutch down splice to Powershift controller
750E 1.5 Work light interlock earth splice to No. Size Description 810C 0.6 Clutch down splice to splitter dump relay
suspension seat (Italian) 800 1.5 Work light harness or upper front work 811 0.6 6 speed neutral switch to diode connector
750F 0.5 Work light interlock earth splice to trailer lights relay to outer front work lights splice 812 1.0 Rear fog lights switch to rear fog lights relay
brake valve earth splice (Italian) 800A 1.5 Outer front work lights splice to front RH coil
* 750FA 0.5 Trailer brake valve earth splice to outer work light 813 1.5 Front work light switch to work light harness
trailer brake valve solenoid (Italian) 800B 1.5 Outer front work lights splice to front LH interconnect or roof work lights relay
750FB 0.5 Trailer brake valve earth splice to trailer outer work light 813A 1.0 Front work lights switch to front upper work
brake valve earth pressure switch (Italian) 801 1.5 Work light harness or upper front work lights cut-out relay coil
750G 0.5 Work light interlock earth splice to work lights relay to inner front work lights splice 813B 1.5 Front work lights switch to headlight bar
lights interlock relay (coil) (Italian) work lights cut-out relay
18 - 7
Section C
Issue 2*
814 1.5 Work lights harness or head light bar work 827B 0.5 Flow divider on splice to flow divider 839 1.4 Column switch to fuse box - fuse D2a
18 - 8
lights relay to head light bar work lights solenoid 840 1.5 Rear work lights switch to work light
9803/8020
splice 827C 0.5 Flow divider on splice to flow divider switch harness or upper rear work light changeover
814A 1.5 Headlight bar work lights splice to RH 828 1.4 Cold advance temperature switch to relay
Section C
headlight bar work light waxstat 840A 0.5 Rear work lights switch to inner rear work
814B 1.5 Headlight bar work lights splice to LH 829 1.4 Fuse D1 to aux lights switching relay lights cut-out relay coil
headlight bar work light 830 0.6 Column switch to front intermittent wipe 841 2.0 Column switch to horn
815 1.0 Splitter dump relay to splitter dump splice relay 842 1.0 Column switch to front washer pump
815A 0.6 Splitter dump splice to splitter low solenoid 831 1.0 Column switch to front intermittent wipe 843 0.6 Rear wash/wipe switch to rear intermittent
815B 0.6 Splitter dump splice to splitter medium relay wipe relay
solenoid 832 1.0 Front intermittent wipe relay to front wiper 844 1.0 Rear wash/wipe switch to rear washer
815C 0.6 Splitter dump splice to splitter high solenoid motor pump
816 0.6 Reverse lights relay to Powershift ECU 833 1.0 Column switch to front wiper motor (speed 845 0.6 Rear wash/wipe switch to rear intermittent
817 0.6 Auxiliary Lights switch to aux. Lights supply 1) wipe relay
splice 834 1.0 Column switch to front wiper motor (speed 846 1.0 Rear intermittent wipe relay to rear wiper
817A 0.6 Auxiliary Lights supply splice to main beam 2) motor
switching relay 835 1.5 Work light harness or upper rear work lights 847 1.0 Rear intermittent wipe relay to rear wiper
817B 0.6 Auxiliary Lights supply splice to dip beam changeover relay to inner rear work lights motor
switching relay splice 848 0.6 Front PTO drive solenoid to front PTO drive
817C 0.6 Auxiliary Lights supply splice to LH side 835A 1.5 Inner rear work lights splice to RH inner rear splice
light switching relay work light 848A 0.6 Front PTO drive splice to front PTO switch
817D 0.6 Auxiliary Lights supply splice to RH side 835B 1.5 Inner rear work lights splice to LH inner rear 848B 0.6 Front PTO drive splice to instrument cluster
light switching relay work light (front PTO indicator)
817E 0.6 Auxiliary Lights supply splice to LH 836A 1.0 Front lights main beam splice to front LH 849 0.6 Front PTO brake solenoid to front PTO
direction indicator switching relay lights connection switch
817F 0.6 Auxiliary Lights supply splice to RH 836B 1.0 Front lights main beam splice to front RH 850 0.6 Rear PTO drive solenoid to rear PTO drive
direction indicator switching relay lights connection cut-out connector or relay
Electrics
820 0.6 Powershift ECU to wet clutch inching 837 1.4 Switching relay to auxiliary main beam 851 0.6 Rear PTO brake solenoid to rear PTO brake
solenoid splice splice
821 0.6 Inching solenoid to inching solenoid resistor 837A 1.0 Aux main beam splice to LH auxiliary 851A 0.6 Rear PTO brake splice to rear PTO switch
splice headlight 851B 0.6 Rear PTO brake splice to rear PTO drive
821A 0.6 Inching solenoid resistor splice to 837B 1.0 Aux main beam splice to RH auxiliary cut-out connection or diode connection
Powershift ECU headlight 852 0.6 2 wheel drive solenoid to 2WD dump relay
821B 0.6 Inching solenoid resistor splice to inching 838 2.0 Lights switch to panel headlights splice 854 0.6 Start relay 1 coil to front PTO switch (brake)
solenoid resistor 838A 1.4 Panel headlights splice to column switch 855 0.6 Start relay 2 coil to rear PTO switch (brake)
822 0.6 Powershift ECU to wet clutch lubrication 838B 1.0 Panel headlights splice to rear fog lights 856 0.6 Diode connector (clutch down signal) to cab
solenoid switch roof start inhibit splice
823 0.6 Powershift ECU to wet clutch brake 838C 1.0 Panel headlights splice to rear fog lights 856A 0.6 Cab roof start inhibit splice to start relay 1
solenoid switch illumination coil
824 1.5 Head light bar work light cut-out relay to 838D 1.0 Panel head light splice to work light harness 856B 0.6 Cab roof start inhibit splice to start relay 2
head light bar work lights relay coil or work light headlight splice coil
825 1.5 Work light harness or rear fender work lights 838DA 0.5 Work light headlight splice to head light bar 856C 0.6 Cab roof start inhibit splice to diode
cut out relay to rear fender work lights work light cut out relay connector (neutral switch signal)
splice 838DB 0.5 Work light headlight splice to rear fender 857 0.6 Rear PTO drive cut-out connector or relay
825A 1.5 Rear fender work lights splice to RH rear work light cut out relay to rear PTO drive splice
fender work light 838DC 0.5 Work light headlight splice to rear upper 857A 0.6 Rear PTO drive splice to rear PTO switch
825B 1.5 Rear fender work lights splice to LH rear work light changeover relay 857B 0.6 Rear PTO drive splice to instrument cluster
fender work light 838E 1.0 Panel headlights splice to rear fender work (rear PTO indicator)
826 0.5 Rear inner work lights cut-out relay to rear lights cut-out relay 857C 0.6 Rear PTO drive cut-out relay to rear PTO
inner work lights relay coil 838F 0.5 Work lights lock-lock relay (coil) to fog light drive cut-out splice 2
827A 0.6 Flow divider on splice to instrument cluster switch (Italian)
Issue 1
18 - 8
Section C
18 - 9
857D 0.6 Rear PTO drive cut-out splice 2 to LH 860T 0.6 Cab roof sidelight splice to cigar lighter 880D 0.6 LH sidelights splice to aux lights
9803/8020
fender cut-out button illumination connection or sw switching relay
857E 0.6 Rear PTO drive cut-out splice 2 to RH 860U 0.6 Cab roof sidelight splice to work lights relay 880F 1.0 LH sidelights splice to left sidelights splice
Section C
fender cut-out button coil 880G 0.6 LH sidelights splice to air gauge illumination
857F 0.5 Rear PTO drive splice to power switching 861 1.4 Hazard switch to panel right indicator splice 880H 1.0 Left sidelights splice to trailer socket
relay 861A 1.4 Panel right indicator splice to RH side 880J 0.6 LH sidelights splice to LH rear light cluster
858 2.0 Hazard switch to second trailer turn relay repeater 880K 0.6 LH sidelights splice to rear wash/wipe
859 1.4 Hazard switch to panel left indicator splice 861B 1.4 Panel right indicator splice to RH indicator switch illumination
859A 1.4 Panel left indicator splice to LH side splice 881 0.6 Switching relay to LH front sidelight
repeater 861C 1.4 Panel right indicator splice to column switch 882 0.6 Aux lights switching relay to LH auxiliary
859B 1.4 Panel left indicator splice to LH indicator 861D 0.6 Panel right indicator splice to aux. Lights side light
splice connector or switching relay 883 1.4 Cab roof brake lights splice to brake lights
859C 1.4 Panel left indicator splice to column switch 861E 0.6 RH indicator splice to RH rear light cluster splice
859D 0.6 Panel left indicator splice to aux. Lights 861F 1.4 RH indicator splice to trailer socket 883A 0.6 Brake lights splice to RH rear lights cluster
connector or switching relay 861G 0.6 Panel right indicator splice to instrument 883B 0.6 Brake lights splice to LH rear lights cluster
859E 0.6 LH indicator splice to LH rear light cluster cluster 883C 1.4 Brake lights splice to trailer socket
859F 1.4 LH indicator splice to trailer socket 862 2.0 Second trailer turn relay to single trailer turn 883D 0.6 Cab roof brake lights splice to tractor ABS
859G 0.6 Panel left indicator splice to instrument relay supply connector
cluster 863 2.0 Single trailer turn relay to hazard switch 883E 0.5 Cab roof brake lights splice to high level
860 1.0 Fuse D5 to RH sidelights splice 864 1.4 Second trailer turn relay to column switch brake light
860A 1.0 Right sidelights splice to trailer socket 865 2.0 Second trailer turn relay to hazard switch 883F 1.4 Brake lights relay to cab roof brake lights
860B 0.6 RH sidelights splice to cab roof sidelights 866 0.6 Auxiliary lights connector (out) or switching splice
splice relay to RH front sidelight 884 0.6 Brake lights switch to brake lights relay coil
860C 0.6 RH sidelights splice to auxiliary lights 867 0.6 Auxiliary lights switching relay to RH 884A 0.5 Brake lights relay to brake signal relay
connector or switching relay auxiliary side light 885 0.6 Auxiliary lights switching relay (LH side
860D 0.6 Right sidelights splice to RH rear light 868 0.6 Auxiliary lights connector (out) or switching lights) to auxiliary lights switch illumination
cluster relay to LH front direction indicator 886 0.6 Diode connector to rear PTO drive cut-out
Electrics
860E 0.6 Cab roof sidelight splice to radio / cassette 869 0.6 Auxiliary lights switching relay to LH relay
860F 0.6 Cab roof sidelight splice to RH number auxiliary direction indicator 886A 0.6 Diode connector to rear PTO drive cut-out
plate light 870 0.6 Auxiliary lights connector (out) or switching relay
860G 0.6 Cab roof sidelight splice to LH number plate relay to RH front direction indicator 887 0.6 Rear PTO drive cut-out relay coil to rear
light 871 0.6 Auxiliary lights switching relay to RH PTO drive cut-out splice 1
860H 0.5 RH sidelights splice to ECU sidelights splice auxiliary direction indicator 887A 0.6 Rear PTO drive cut-out splice 1 to LH
860HA 0.5 ECU sidelights splice to ECU1 874 1.0 Air conditioning unit to heater blower fender cut-out button
860HB 0.5 ECU sidelights splice to flow divider switch (speed 1) 887B 0.6 Rear PTO drive cut-out splice 1 to RH
860J 0.5 RH sidelights splice to intermediate speed 875 1.4 Air conditioning unit to heater blower fender cut-out button
control 1 switch (speed 2) 887C 0.6 Rear PTO drive cut-out relay coil to diode
860K 0.5 RH sidelights splice to engine speed control 876 2.0 Air conditioning unit to heater blower connector
switch (speed 3) 894 0.5 Trailer brake valve solenoid to pressure
860L 1.0 RH sidelights splice to right sidelights splice 877 0.6 Reverse lights relay to reverse lights splice switch (Italian)
860N 0.5 RH sidelights splice to heated 877A 0.6 Reverse lights splice to LH rear lights 895 0.6 2WD dump relay to 2WD switch
screen/mirrors switch cluster 898 0.6 Instrument cluster to 20kph signal splice
860P 0.6 Cab roof sidelight splice to diff lock cut-out 877B 0.6 Reverse lights splice to RH rear lights 898B 0.6 20kph signal splice to Powershift controller
switch illumination cluster (20kph signal)
860R 0.6 Cab roof sidelight splice to EDC raise/lower 880 1.0 Fuse D4 to LH sidelights splice 899 1.0 Differential lock cut-out relay to differential
switch illumination 880A 0.6 LH sidelights splice to hazard lights switch lock solenoid
860RA 0.6 EDC raise/lower switch illumination to area illumination 899A 0.6 Differential lock cut-out relay to instrument
cutout switch illumination 880B 0.6 LH sidelights splice to instrument cluster cluster
860RB 0.6 Area cutout switch illumination. to wheel 880C 0.6 LH sidelights splice to beacon switch
slip enable switch illumination illumination
Issue 1
18 - 9
Section C
18 - 10
900 0.6 Powershift controller to snail solenoid 932A 0.6 Switch feed splice to LH fender connector
9803/8020
901 0.6 Powershift controller to tortoise solenoid (EDC)
902 0.6 Powershift controller to hare solenoid 932B 0.6 Switch feed splice to RH fender connector
Section C
904 1.4 Fuse D2 to switching relay (EDC)

905 1.4 Auxiliary lights relay to front lights dipped 933 0.5 Raise/lower switch splice to hitch damping
beam splice resistor (EDC)
905A 1.0 Front lights dipped beam splice to LH lights 934 1.0 Beacon switch to beacon socket
connection 935 0.5 Electronic control unit to hitch damping
905B 1.0 Front lights dipped beam splice to RH lights resistor (EDC)
connection 936 0.6 Compressor clutch relay coil to compressor
906 1.4 Auxiliary lights switching to auxiliary dipped pressure switch
beam splice 950 2.0 Compressor clutch relay to compressor
906A 1.0 Auxiliary dipped beam splice to LH auxiliary clutch
headlight 954 0.6 Air conditioning unit to compressor clutch
906B 1.0 Auxiliary dipped beam splice to RH auxiliary relay coil
headlight 988 0.5 Timer module to heated screen & mirrors
907 1.4 Column switch to fuse box - fuse D1a relay
912 0.6 Radio/cassette to RH speaker 989A 2.5 Heated screen supply splice to LH heated
913 0.6 Radio/cassette to LH speaker screen fuse (G1)
914 0.6 LH interior light to LH door switch 989B 2.5 Heated screen supply splice to RH heated
920 0.6 Electronic control unit to sensor supply screen fuse (G2)
splice (EDC) 989C 1.5 Heated screen supply splice to heated door
920A 0.6 Sensor supply splice to RH draft pin (EDC) mirrors fuse (G3)
920B 0.6 Sensor supply splice to LH draft pin (EDC) 990 2.5 LH heated screen fuse (G1) to LH heated
920C 0.6 Sensor supply splice to position sensor screen
(EDC) 991 2.5 RH heated screen fuse (G2) to RH heated
922 0.6 Electronic control unit to in-cab raise/lower screen
Electrics
switch (EDC) 1800 1.4 ABS ECU to ABS modulator rear LH - x3 pin
923 0.6 Fender raise/lower switch to in-cab 12 - hold solenoid
raise/lower switch (EDC) 1801 1.4 ABS ECU to ABS modulator rear LH - x3 pin
923B 0.6 Raise splice to RH fender connector (EDC) 11 - earth
923C 0.6 Raise splice to LH fender connector (EDC) 1802 1.4 ABS ECU to ABS modulator rear LH - x3 pin
924 0.6 Electronic control unit to valve supply splice 10 - release solenoid
(EDC) 1803 1.4 ABS ECU to ABS modulator rear RH - x3
924A 0.6 Valve supply splice to raise solenoid (EDC) pin 9 - hold solenoid
924B 0.6 Valve supply splice to lower solenoid (EDC) 1804 1.4 ABS ECU to ABS modulator rear RH - x3
926 0.6 Fender raise button to fender lower button pin 8 - earth solenoid
(EDC) 1805 1.4 ABS ECU to ABS modulator rear RH - x3
928 0.6 Electronic control unit to in-cab raise/lower pin 7 - release solenoid
switch (EDC) 1806 1.4 ABS ECU to ABS modulator front - x2 pin
929 0.6 Fender raise/lower switch to in-cab 10 - release solenoid
raise/lower switch (EDC) 1807 1.4 ABS ECU to ABS modulator front - x2 pin 4
929B 0.6 Lower splice to LH fender connector (EDC) - hold solenoid
929C 0.6 Lower splice to RH fender connector (EDC) 1808 1.4 ABS ECU to ABS modulator front - x2 pin
930 0.6 Electronic control unit to raise/lower switch 11 - earth
splice (EDC)
931 0.5 Raise/lower switch splice to in-cab
raise/lower switch (EDC)
932 0.6 Raise/lower switch splice to switch feed
splice (EDC)
Issue 1
18 - 10
Section C
21 - 1 * Fault Finding (Vehicle Electrics) 21 - 1
Starting Circuit
Circuit Description
With the 6-speed gearbox lever set to neutral and starter

switch A turned to 'IGN', the battery supply is fed via fuse
Ca and the 6-speed gearbox neutral switch C (now closed
as shown on the diagram) to the solenoids of the two inhibit
start relays D and E. To eliminate the need to select neutral
in the 6-speed gearbox, an alternative supply route to the
solenoids of the start inhibit relays is provided via Ba the
clutch depressed switch H (see Note). With the front and
rear power take off (PTO) switches F and G turned to the
braking position, as shown in the diagram, an earth return is
provided for the inhibit start relay solenoids, causing them to
energise.
When the starter switch is turned to the start ('HS') position,

the battery supply is fed via fuse Bb and the relay contacts
of the inhibit start relays D and E to the starter solenoid J,
which energises and connects the battery supply to the
starter motor K.
Note: The clutch operating system is power assisted when

the engine is running. With the engine switched off
considerably greater effort than normal is required to
depress the clutch pedal.
Ca
F G O
IGN
C Ba HS
H
A
Bb
D E
J1 J2
J
+
K1
K -
K2
A297190
9803/8020 Issue 3*
Starting Circuit (continued)

Testing
The following test procedure covers the starter motor, be faulty or a poor connection may exist between the
starter solenoid and battery. battery and the starter solenoid, or between the starter
solenoid and the main terminal K1.
Before carrying out the voltmeter tests, check the condition
of the battery (see Battery - Specific Gravity) and ensure 3 Connect the voltmeter between the solenoid terminal
that all connections are clean and tight. J1 (+) and a good earth. Minimum reading with starter
switch in 'HS' position should be 8.0 Volts.
To prevent the engine from starting during the tests ensure
that the engine shut off solenoid is disconnected. 4 Connect the voltmeter between starter motor earth
connection K2 (+) and battery negative. The voltage
Check the readings in the following sequence using a reading with the starter switch in position 'HS' should
voltmeter (+ or - in the text indicates which voltmeter lead to be practically zero. If the reading is appreciably above
use at the particular test point). Unless otherwise stated, the zero, a high resistance in the earth lead or connections
readings must be taken with the starter switch in the 'HS' is indicated.
position, the 6-speed gearbox gear lever set to nuetral and
the front and rear PTO switches turned to the ' brake' 5 Connect the voltmeter between battery positive (+) and
positions. the starter motor main terminal K1 (-). With the starter
switch 'OFF', the voltmeter should indicate battery
1 Connect the voltmeter across the battery terminals. voltage, but it should fall to practically zero when the
With starter switch in 'HS' position and starter motor switch is turned to position 'HS'. If the reading is
running, the voltage reading should be approximately appreciably above zero, a high resistance is present in
10 volts. A low reading probably indicates a fault in the the insulated lead or in the solenoid. Connect the
starter motor. voltmeter between the battery positive (+) and solenoid
connection D. If the voltmeter now reads zero with the
2 Connect the voltmeter between the starter motor main
switch closed, the fault is in the solenoid.
terminal K1 (+) and the starter motor earth connection
K2 (-). With starter switch in 'HS' position and starter Finally, reconnect the engine shut off solenoid.
motor running, the voltage reading should not be more
than 0.5 volt below the reading in Test 1. If the voltage
reading is significantly more than 0.5 volt below the
reading in Test 1, the starter solenoid contacts may
Ca
F G O
IGN
C Ba HS
H
A
Bb
D E
J1 J2
J
+
K1
K -
K2
A297190
9803/8020 Issue 3*
Charging Circuit Test

* Note: The illustration below shows the battery location on Start the engine and run at maximum speed (see Technical
Fastrac 2115, 2125 and 2135 machines. On Fastrac 2150 Data, Section T). Meter should show the maximum alternator
machines, the battery is on the left hand side of the machine output in Amps (see Technical Data, in this section).
and on 3000 Series machines the battery is in the cab.
Note: The meter reading should be taken as soon as
Before doing the following test, make sure that the battery possible after starting the engine, as the charging current
and alternator connections are in good condition and that will fall rapidly.
the fan belt is correctly adjusted.
A zero reading indicates failure of the alternator and may be
If the battery is in a fully charged condition, switch on the caused by one of the following conditions. These are listed
working lights for 3 minutes before commencing the test. in the order of probability.
Alternatively, operate the starter for a few moments with
fuse A5 removed. a Defective suppression capacitor.
Disconnect the positive lead from battery terminal A. b Dirty sliprings or worn brushes.
Install a 100 Amp open-type shunt between the positive lead c Defective regulator.
and the battery positive terminal A.
d Defective rectifier.
Connect a multimeter positive lead to vehicle side of the
shunt and negative lead to battery side of the shunt. e Open or short-circuited field (rotor) windings.
Connect the leads to the meter and set the meter to the
relevant range as follows: f Open or short-circuited power (stator) windings.
AVO 2002 Red lead to volts (middle) socket on meter. To check for fault a, disconnect the capacitor and repeat the
Black lead to negative on meter. charging test. Renew the capacitor if necessary.
RH slider to DC voltage.
LH slider as illustrated below. To check for faults b and c, remove the regulator and brush
box assembly. Check the condition of the brushes and, if
AVO 2003 Red lead to amps socket (marked A) on meter. necessary, clean the sliprings using extra-fine glasspaper.
Black lead to negative on meter. The regulator may only be checked by substitution.
RH slider to DC voltage.
LH slider to 200 Shunt. Faults d, e, and f may be checked only by removing and
dismantling the alternator for further testing.
FLUKE 85 Red lead to volts socket (marked V ) on meter.
Black lead to COM socket on meter.
Set dial to mV.
A290400
9803/8020 Issue 3*
Tachometer Feed Test
Use the hand throttle to set the engine speed to a value

higher than idling speed, so that the charge lamp is
extinguished. Using a pointer type (analogue) multimeter set
to DC 10 volts range, measure the voltage (‡) at the small
stud on the alternator with respect to the alternator casing.
The voltage reading should be between 6 volts and 8 volts.
(‡)Refer to Test Methods, Measuring DC Voltage for

instructions on measuring voltage.
9803/8020 Issue 2*
25 - 1 Wiring Harness Repair 25 - 1
Harness Repair
Introduction Tools Required
Instances do occur where it is necessary to incorporate 892/00307 Service kit

auxiliary electrical components into existing electrical 892/00349 Crimp tool 1
circuits and, although unlikely with present wiring harnesses, 892/00350 Butane Heater assembly 1
repair or replace specific individual wires within a harness. 892/00351 Splice 0.5-1.5 mm (Red) 50
This will also apply to other machines in addition to those of 892/00352 Splice 1.5-2.5 mm (Blue) 50
JCB manufacture. 892/00353 Splice 3.0-6.0 mm (Yellow) 50
To ensure that either the inclusion of an auxiliary electrical Procedure

component or a repair within a harness is completed to an
acceptable standard it is strongly recommended that the 1 Cut the wire and remove the protective insulation for a
following tools, equipment and procedures are always used. suitable distance dependent upon the size of wire and
Note that JCB harnesses have an International Protection splice to be used. For the splices detailed above, the
rating of 67 (I.P.67). dimension is 7mm.
The sheath covering of the recommended splice is heat 2 Using the correct sized splice, attach the new section
shrunk onto the original wire insulation. This results in a seal of wire required or auxiliary flying lead to the existing
and corresponding joint to IP 67 specifications. harness and secure using the crimp tool X, part number
892/00349.
Note that each of the splices detailed is colour-coded

! CAUTION to make size and range readily visible. They are
secured using the corresponding size and matching
When installing Auxiliary Electrical Components always
colour-coded jaws of the crimp tool to ensure joint
ensure that the additional load rating is suitable for that
security. This tool also incorporates a ratchet closing
particular circuit. It is unacceptable to simply increase
mechanism which will not release until the splice is fully
the fuse rating as this can cause overloading and
closed to the correct compression size.
consequential failure of wiring, along with failure of
integral circuit components, which the fuse is protecting.
ELEC 2 - 1
! WARNING
In addition to the warnings incorporated into the
procedure, extreme care should be taken when handling
the gas heating tool to ensure that the flame does not
damage or set fire to any items in the vicinity of the
repair, i.e. other wires, floor panels, floor mats, sound
proofing, paintwork. etc. This tool should not be used in
any restricted location prohibiting the use of "Naked
Flames' or where risk of explosive gas or similar safety 7
parameters apply. No other heat source should be used
to attempt a sealed joint .
ELEC 2 - 2
!CAUTION X
When the heater is in use, the reflector and the air
coming out are extremely hot. Keep away to avoid
accidental burns. Do not touch the reflector until it has
had time to cool down after switching off. If flame
reappears at the reflector when the heater is in use, the
catalytic element is damaged or used up. Stop work
immediately and replace the heater.
ELEC 2-3
S189530
9803/8020 Issue 1
Harness Repair (cont'd)

Procedure (cont'd)
3 With the Butane Heater assembly 892/00350, seal the A

connection using the following procedure.
a Remove the cap A from the end of the disposable

gas cartridge B. B
S189490/1
b Before assembling the gas cartridge to the reflector

element C, turn the red ring D to the left, (in the
direction of the minus sign marked on the ring).
C
S189490/2
c Position the tube hanging down from inside the

reflector assembly into the hole at the top of the gas
cartridge. Then press the gas cartridge up into the
reflector assembly as far as possible until the two
s
elements are clasped firmly together. A click will be
heard.
S189490/3
d Turn the small ring E so that the air holes at F are

completely closed.
F
E
S189490/4
9803/8020 Issue 1
Harness Repair (cont'd)

Procedure (cont'd)
e Turn the red ring D to the right (in the direction of the
plus sign) in order to turn on the gas.
IMPORTANT: Before turning the heater on, make sure that

the cartridge is not hotter than the reflector element. This
may occur if the cartridge is held in the hand for a long time. D
The temperature difference between the cartridge and the
reflector element may cause long yellow flames to appear on
ignition.
S189490/5
f Hold the heater vertically and, using a match or

cigarette lighter, light the gas as shown.
Note: The fact that the sound of liquid cannot be heard when
the cartridge is shaken does not mean it is empty. No sound F
will be heard even when the cartridge is full.
Hold the heater vertically for 1 to 2 minutes until the

E
catalytic reaction occurs. This is indicated when the
blue flame fades and the ceramic element glows
red. Then turn the small ring E until the air holes at F
are completely open. The tool is ready for use.
S189490/6
The heater can be used in two modes:
g Side wings G down, reflector head completely open.

In this mode the infra-red heat waves are dominant
(recommended for the light coloured plastic splices). G
Side wings G up (see fig at step 3.h), reflector head
opening reduced. In this mode the heating is done
only by the hot gas (use for dark coloured plastic
splices).
S189490/7
h To switch off the heater, turn the red ring D to the

left (in the direction of the minus sign). G
S189490/8
9803/8020 Issue 1
26 - 1 Battery 26 - 1
* Safety * Maintenance
! WARNING To ensure that the battery provides optimum performance

the following steps should be observed:
Batteries give off an explosive gas. Do not smoke when
handling or working on the battery. Keep the battery away
1 Make sure that the electrical connections are clean and
from sparks and flames.
tight. Smear petroleum jelly on connectors to prevent
corrosion.
Battery electrolyte contains sulphuric acid. It can burn you if
it touches your skin or eyes. Wear goggles. Handle the
2 Never allow the electrolyte level to fall below the
battery carefully to prevent spillage. Keep metallic items
(watches, rings, zips etc) away from the battery terminals. recommended level - 6 mm (1/4 in) above the plates.
Such items could short the terminals and burn you.
3 Use only distilled water for topping up.
Set all switches in the cab to OFF before disconnecting and
connecting the battery. When disconnecting the battery, 4 Keep the battery at least three quarters charged,
take off the earth (-) lead first. otherwise the plates may become sulphated (hardened)
- this condition makes recharging the battery very
When reconnecting, fit the positive (+) lead first. difficult.
Re-charge the battery away from the machine, in a well Extra precautions must be taken when bench charging
ventilated area. Switch the charging circuit off before maintenance free batteries, they are more prone to damage
connecting or disconnecting the battery. When you have by overcharging than the standard type of battery:
installed the battery in the machine, wait five minutes before
connecting it up. - NEVER boost-charge a maintenance free battery.
- NEVER charge a maintenance free battery at a

First-Aid Electrolyte voltage in excess of 15.8 Volts.
Do the following if electrolyte: - NEVER continue to charge a maintenance free

battery after it begins to gas.
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
! 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
9803/8020 Issue 2*
26 - 2 Battery 26 - 2
Specific Gravity
The specific gravity (SG) of the electrolyte gives an idea of Readings should be as tabulated and should not vary
the state of charge of the battery. Readings should be taken between cells by more than 0.04. A greater variation
using a hydrometer, when the electrolyte temperature is indicates an internal fault on that particular cell.
15°C (60°F). If the battery has recently been on charge, wait
approximately one hour (or slightly discharge the battery) to If the electrolyte temperature is other than 15°C (60°F) a
dissipate the 'surface charge' before testing. 'correction factor' must be applied to the reading obtained.
Add 0.07 per 10°C (18°F) if the temperature is higher than
15°C (60°F) and subtract the same if the temperature is
lower.
Specific Gravity at 15°C (60°F)
Fully Charged Half Discharged Fully Discharged
Ambient temperature up to 27°C (80°F) 1.270 - 1.290 1.190 - 1.210 1.110 - 1.130
Ambient temperature above 27°C (80°F) 1.240 - 1.260 1.170 - 1.190 1.090 - 1.110
Battery Testing
This test is to determine the electrical condition of the 5 Set the CHECK/LOAD switch A to LOAD and hold down
battery and to give an indication of the remaining useful for 5 - 10 seconds until the meter reading stabilises. The
'life'. reading should be at least 9 volts.
Before testing ensure that the battery is at least 75% Note: Do not hold the switch in the LOAD position for more
charged (SG of 1.23 to 1.25 for ambient temperature up to than 10 seconds.
27°C).
6 If the foregoing tests are unsatisfactory, consult Fault
Ensure that the battery is completely disconnected from the Diagnosis below.
vehicle.
Connect up the battery tester (part no. 993/85700) as

follows:
1 Set the CHECK/LOAD switch A to OFF.
2 Set rocker switch B to the battery voltage (12V).
3 Connect the red flying lead to the battery positive (+)

terminal and the black flying lead to the battery negative
A
(-) terminal.
4 Set the CHECK/LOAD switch A to CHECK to read the

B 239510
Fault Diagnosis
Battery Tester Readings Remedy
1 CHECK: 0 - 12.6 Volts Renew battery.

LOAD: Less than 6 Volts
2 CHECK: 6 - 12.4 Volts Recharge and re-test. If tests still unsatisfactory renew
LOAD: Less than 9 Volts and falls steadily but battery.
remains in yellow zone.
3 CHECK: Less than 10 Volts Indicates battery has been over-discharged and unlikely
LOAD: Less than 3 Volts to recover. Renew battery.
4 CHECK: More than 11 Volts Charge battery which will probably recover.
LOAD: 6 - 10 Volts steady
9803/8020 Issue 1
27 - 1 27 - 1
Alternator
General Description
The alternator is a three phase generator having a rotating

field winding and static power windings.
When the starter switch is turned to position IGN , current

from the battery flows by way of the 'Charge' warning lamp
to the field winding. This creates a magnetic field which
supplements the residual magnetism in the rotor poles. As
the engine is started, the fan belt drives the rotor and
alternating current is generated in the power windings as
they are cut by the rotating magnetic field. Output is
controlled by a solid state regulator which varies the field
current in accordance with electrical demand.
Service Precautions
a Ensure that the battery negative terminal is connected

to the earthing cable.
b Never make or break connections to the battery or

alternator, or any part of the charging circuit whilst the
engine is running. Disregarding this instruction will
result in damage to the regulator or rectifying diodes.
c Main output cables are 'live' even when the engine is

not running. Take care not to earth the ring connectors
if they are removed from the alternator.
160580
d During arc welding on the machine, protect the

alternator by removing the output cables from their
studs.
e If slave starting is necessary, connect the second

battery in parallel without disconnecting the vehicle
battery from the charging circuit. The slave battery may
then be safely removed after a start has been obtained.
Take care to connect batteries positive to positive,
negative to negative. See also note b.
Disconnect cables from rear of alternator, remove bolts A, B

and C and withdraw unit from the machine.
Replace by reversing the removal sequence.
Position the alternator until the belt deflection at E is

approximately 10mm (0.4in) before tightening bolts B and C.
It may be necessary to slacken bolt D to allow full movement
of the alternator. Tighten bolt A last of all.
9803/8020 Issue 1
27 - 2 27 - 2
S215650
9803/8020 Issue 1
27 - 3 27 - 3
Alternator (cont’d)
When Dismantling
Remove suppressor 2 (if fitted) by removing nut 1 and

disconnecting lead E from terminal F.
Unscrew bolts 3 and disconnect lead G from terminal H to

remove the brush box and regulator assembly 4. If the brush
length is less than 5mm (0.2 in.), new length 17mm (0.67 in.),
or if spring pressure is less than 1.3N the brush box and
regulator assembly must be renewed.
Remove nuts and washers 5, bolts 6 and nuts 7. Remove

slip ring end bracket 8.
Carefully remove rectifier 10 and stator 11 as an assembly.

Unsolder the interconnecting wires at X, Y, and Z only if
renewing either of these components.
Remove nut and washer 12 using an 8mm Allen key in the

shaft hexagon hole to prevent rotation. If necessary, use a
press to remove rotor 19 from the drive end bracket 17.
Check the rotor poles and the inner faces of the stator for
signs of rubbing, which indicates worn bearings. The drive
end bearing is part of bracket 17 and cannot be removed
separately. If requiring renewal, needle roller bearing 20
should be pressed out in the direction of the arrow.
When Assembling
Reverse the dismantling procedure, but note the following:
Ensure that spacers 14,16, and 18 are correctly positioned

as shown.
Ensure that the slip rings J are clean and smooth, using
extra fine glasspaper to rectify slight imperfections.
Ensure that insulation bushes 9 and washers 5 are

positioned as shown.
Take care not to damage the brushes when fitting the brush
box and regulator assembly.
Torque Settings
Item Nm kgf m lbf ft

3 2.7 0.28 2.0
5 4.1 0.41 3.0
6 3.4 0.35 2.5
7 5.4 0.55 4.0
12 60.0 6.10 44.2
9803/8020 Issue 1
28 - 1 28 - 1
Starter Motor
Removal and Replacement Assembly
Disconnect cables from the battery. Remove cables from Align crosspin C with the notches in the brake shoes 28
main starter terminal and solenoid terminal. Unscrew three before assembling brush carrier and back plate to motor
securing nuts and remove starter motor. yoke. Ensure that brushes 14A are correctly located in the
insulated brush boxes.
Replace by reversing the removal sequence.
Smear drive shaft splines and operating collar bearing
Dismantling surface with JCB MPL Grease before assembly. Assemble
operating fork 19 with curved face toward the armature.
Note: Dismantle only to item 34 unless the field windings are
to be renewed. Test the windings electrically before Set the movement of drive pinion 24 by connecting a 6V
removing them from the motor yoke 15. battery and switch as shown. Operate switch and check
dimension D. Adjust to 0.13-1.14mm (0.005-0.045in.) by
Using a slotted steel tube, displace ring 23 to permit slackening locknut 17 and rotating eccentric pin 18 as
withdrawal of ring 22. necessary. Re-tighten locknut.
Allow brake shoes 28 to remain in the end plate 11 unless

requiring renewal.
Servicing and Renewal
Renew brushes 14 and 14A if their length is less than 8mm

(0.3in.).
Clean the commutator A. If individual copper bars are

burned or eroded the armature has broken windings and
must be renewed. Otherwise polish with fine grade glass
paper (not emery). Renew armature if commutator diameter
is 38mm (1.5in.) or less.
Check the field windings for open circuits by connecting an

ohm meter (0 to 100 Ohms) between the stud terminal B and
each positive brush 14A in turn. A high or infinity reading
indicates an open circuit. Similarly, connect the meter
02303A
between brushes 14A and the motor yoke 15. Any reading
other than infinity indicates a short circuit between the coils
and the yoke. Renew the coils as necessary, removing
screws 36 with a pole shoe screwdriver C50 (obtainable
from Lucas dealers).
Check bronze bushes 32 and 34 for wear.
9803/8020 Issue 1
28 - 2 28 - 2
2043C
9803/8020 Issue 1
29 - 1 Instrument Cluster 29 - 1
27
29
AM
28
30
ENGINE
31 miles 32
SETUP
A mph RPM SELECT D

0 RPM
B @$ !14 5 C
AUTO
17A
( ) 21 7 * & 17B EXIT
3
540
2 ABS
1000 ABS
1 2 3 ! P
26 22 23 24 25 8
£ % 6 9^ A285902
2115, 2125, 2135, 2150, 3155, 3185
2A 2B
‡
AM
· °
‚
ENGINE
31 miles
32SETUP
A mph RPM SELECT D
0 RPM
B C
AUTO
@$ 17A
!14 5 ()⁄7*3 19AEXIT
& 8
£ % 15A
6 9^ fl¤‹ ›fi 17B
417380
2140
Immediately following ignition switch-on and for a period of 2B (2140)
3 seconds, all lamps and display LCD segments illuminate 3 (2115, 2125, 2135, 2150, 3155, 3185)
and a bleeper operates. This is followed by a brief sounding Right Direction Indicators On - Green flashing light
of the buzzer. If any of the lamps, the LCD segments or Flashes with the right direction indicators
either of the audible alarms do not operate, carry out the
necessary repairs before using the machine. 3 Wait to Start (2140 only)
Indicates that engine cold start system is operating. Do
Warnings (Visual only) not start engine until this light has gone out.
1 Main Beam On - Blue Light
Lights up when the headlight main beams are switched 4 Trailer Direction Indicators On - Green flashing light
on. Switch the main beams off for on-coming vehicles. Flashes with items 2 or 3 when a trailer is fitted.
2 (2115, 2125, 2135, 2150, 3155, 3185) 5 Second Trailer Direction Indicators On - Green
2A (2140) flashing light
Left Direction Indicators On - Green flashing light Flashes with items 2 or 3 and 4 when a second trailer is
Flashes with the left direction indicators. fitted.
9803/8020 Issue 5
Warnings (Visual only)(continued) Warnings (Audible/Visual)

6 Differential Lock Engaged - Red light
Lights up when the differential lock is selected.
! WARNING
When you hear an audible warning relating to one of the
7 Air Filter Blocked following functions, stop the machine as soon as
Operates if the engine air filter element needs renewal. possible. Get the fault put right before using the
8 Parking Brake machine.
Operates when the parking brake is engaged. The light 13-2-1-10
should go out when the parking brake control is pushed
18 No Charge
down and the air pressure is high enough to release the
Operates if the battery charging circuit fails while the
parking brake. Always engage the parking brake before engine is running. The light should go out a few
leaving the machine. If the machine is driven at a speed seconds after the engine is started.
greater than 0.5 kph with handbrake engaged, the
buzzer sounds and the warning lamp flashes. 19 Engine Oil Pressure Low
Operates if the engine oil pressure is low. The light
9 Four Wheel Drive Engaged - green light should go out when the engine is started.
Operates when the four wheel drive is actually engaged
19A Engine Fault (2140 only))
10 Gear Display Indicates an engine fault other than low oil pressure.
Shows JCB Autoshift Ratio and JCB Selectronic Range Engine performance may be affected. Error code will be
selected (see JCB Selectronic System, Section D). displayed on centre display 30.See System Error
Codes
11 Side Lights On
Lights when the side lights are switched on. 20 Transmission Oil Pressure Low
Operates if the transmission oil pressure is low. The
12 Power Take Off Speed 540 rpm light should go out shortly after the engine is started.
After selection of 540 rpm PTO speed, illuminates when
PTO is switched on. 21 Transmission Oil Filter
Operates if the transmission oil filter element needs
13 Power Take Off Speed 1000 rpm renewal.
After selection of 1000 rpm PTO speed, illuminates
Note: If the transmission oil filter warning light comes on
when PTO is switched on.
when the engine is running and the oil is warm, change the
14 Front Power Take Off Selected filter element before the time shown in the service schedule.
Illuminates upon selection of front PTO operation.
22 Front Brake Circuit Air Tank Pressure
15 Rear Power Take Off Selected See item 24.
Illuminates upon selection of rear PTO operation.
23 Rear Brake Circuit Air Tank Pressure
15A Not Used See item 24.
16 Wheel Slip Active 24 Parking/Trailer Brake Circuit Air Tank Pressure

Illuminates when slip control has been selected. Lights 22, 23 and 24 operate if the air pressure is low in
the relevant circuit(s).
17 System Errors
The icon flashes to alert the operator to the existence of Note: When the engine is started the pressure builds up
control system error(s) (see System Error Codes, progressively through the circuits. Lights 22 and 23 should
Number Error Codes). therefore go out before light 24. The foot brakes require
pressure to apply them whilst the parking brake requires
17A Flow Regulator pressure for release. This ensures that the machine cannot
Illuminates when flow regulator is selected. be driven away until all the brake circuits are charged.
17B Tractor Anti-lock Brake System (ABS) 25 Brake Fluid
When the starter switch is turned ON the lamp Operates if the fluid level is low in either of the two
illuminates while the ABS ECU carries out a self-check. brake fluid reservoirs.
If the ABS system is functioning correctly the lamp
extinguishes after a short time. If the lamp remains lit or 26 Trailer Anti-lock Brake System (ABS)
subsequently lights, a system fault is indicated. In this When a trailer fitted with ABS is connected, the warning
condition the effects of braking without ABS will be lamp should light as the starter switch is turned ON and
available. Rectify the fault as soon as possible. then remain lit until road speed exceeds 10 km/h (6
mph)
If the lamp does not light when the starter switch is

turned ON or it remains lit above 10 km/h (6 mph), there
is a fault in the ABS system. Do not use the trailer until
the fault has been put right.
9803/8020 Issue 3
27
AM
29 28
30
ENGINE
31 miles 32SETUP
A mph RPM SELECT D
0 RPM
B @ $ 17A C
AUTO
!14 5 ( ) 21 7 * & 17B EXIT

3
540
2 ABS
1000 ABS
1 2 3 ! P
26 22 23 24 25
£ % 6 9^ 8 A293452
Instruments 29 Road Speed Display

The current road speed is shown on the digital display
27 Clock in the centre of the dial as well as on the LCD bar graph
Time of day in 12 hour format with AM/PM indication is around the outer rim. The speed can be either kph or
permanently displayed except when Level 1 mph, with the selected units shown below the display,
programming is in progress. See Level 1 and this setting can be changed (see Level 1
Programming Mode for setting the correct time and Programming Mode).
appropriate alternative displays. The clock display is
lost if the vehicle battery is disconnected. The tyre icon at the bottom of the dial will be
illuminated when the system has been set up for a non-
28 Engine/PTO Data Display standard (i.e. optional) tyre size. The radar icon
Engine or PTO RPM is shown digitally across the illuminates if the tractor has radar fitted and it is actually
middle of the display. The LCD bar graph around the measuring speed. Above 32 kph, when a gearbox
outer rim always shows engine rpm even when PTO sensor takes over speed measurement, the radar icon
rpm is shown on the digital display. Press RPM/EXIT is extinguished.
button C to toggle between digital ENGINE and PTO
30 Centre Display
readings as identified by the icon above the digital
a Standard Software Package
display. When PTO is selected and the PTO gear
Display normally shows trip distance travelled in
selector is in neutral the display shows ‘-----’.
either miles or kilometres (see Level 0
Programming Mode). For the first 10 seconds after
Note: When the AUTO transmission mode has been
power up the total distance travelled by the
selected the bar graph indicates the engine rpm levels at
machine is displayed. Press RPM/EXIT button C,
which changes of range occur.
start the engine or wait 20 seconds for the normal
display to be resumed. If appropriate, system error
The digital display below the RPM icon is the vehicle
data is also displayed (see System Error Codes,
hourmeter and normally shows the total running time of
Number Error Codes).
the engine. A flashing spanner icon below the digital
display indicates that a service is due. However, for the
b Optional Software Package
first 10 seconds after ‘ignition switch ON’ the display
As well as the features available with the standard
shows how many hours remain until the next service is
software package this package can be set to
due and is accompanied by solid illumination of the
display ‘area worked’, and one of ‘hours of fuel
spanner icon. If the service is overdue, the ‘hours
remaining at present work rate’, ‘current work rate’,
remaining’ display indicates negative and the spanner
‘percentage wheel slip’ or ‘rate of fuel usage’ (see
icon flashes. The normal display returns when the
Level 0 Programming Mode). The display also
engine is started, RPM/EXIT button C is pressed or
indicates, when appropriate, that a machine
after a 10 second delay. The spanner icon will continue
parameter is being set up. See Level 1
to flash after the display reverts to the normal display.
Programming Mode for details and method of
selecting these parameters.
9803/8020 Issue 4
31 Fuel Gauge Optional Software Package

The contents of the fuel tank are displayed on an LCD
bar graph. When the tank is only 10% full the bar graph The optional software package includes the distance
flashes. An audible alarm also sounds for 5 seconds travelled feature from the standard package plus a number
every 10 minutes until the tank is topped up to more of other features.
than 10%.
1 a The LH side of centre display 30 shows either ‘trip
distance travelled’ or ‘area worked’ data. Press
32 Engine Coolant Temperature
button A to toggle between ‘trip distance travelled’
Coolant temperature is displayed on an LCD bar graph.
and ‘area worked’ to select the desired item. To
The top of the graph corresponds to 140 °C while the
select imperial or metric data (i.e. miles or km, acres
bottom corresponds to 40 °C. If the temperature
or Ha) refer to Level ‘1’ Programming Mode, Step
exceeds 105 °C the currently displayed segments of
2.
the bar graph flash and an alarm sounds. The alarm
sounds for 5 seconds every 10 minutes until the b With the ‘area worked’ feature selected, press SET
temperature falls below 105 °C. In this event, stop the UP/SELECT button D to cause the FIELD icon to
engine and investigate the cause of the overheating. flash. While it is still flashing use buttons A and B to
scroll through the list of fields (1 - 25) to select the
one required. The facility enables individual
Programming recordings to be made of the area worked in each
of a number of fields. Select ‘FIELD ALL’ to display
The programming procedures detailed in the following the sum total of the area worked in all the fields.
pages provide the means of selecting and/or setting up the After scrolling has ceased and following a short
functions of the electronic control systems. Note that the delay or after pressing RPM/EXIT button C the
bold annotations in the text refer to the annotations on the FIELD icon stops flashing.
illustrations on pages 29-1 and 29-3.
Note: Unless specified otherwise the following procedures

refer to all versions of the EMS Software.
* The programme levels can be set-up as follows:
Level ‘0’ -via the dashboard only
Level ‘1’ -via the dashboard, Wingst or the Psion (see
Wingst Program or Psion Walkabout).
miles
Level ‘2’ -via the dashboard, Wingst or the Psion
Level ‘3’ (not covered under Instrument Cluster) - via
FIELD
Wingst or the Psion only.
Level ‘0’ Programming Mode (Normal Operation)

acres
Standard Software Package
With the standard software package, centre display 30 A285940
continuously shows the trip distance travelled† . To choose

between miles or kilometres with the relevant units displayed
below the figures, refer to Level ‘1’ Programming Mode,
Step 2.
Press buttons A and B at the same time and hold for 5

seconds to reset the distance values to zero.
Note: The trip distance travelled cannot be displayed greater

than ‘9999’. Beyond this the display shows ‘----’. At this
point the distance value should be reset to zero as detailed
above.
† In the event of electronic transmission controller system or

any other ECU errors, error code information is displayed
alternately with the trip distance information, each being
shown for 2 seconds (see System Error Codes).
9803/8020 Issue 4*
Programming (continued)
(continued)
Optional Software Package (continued) FIELD
During the progress of an area count the cross

hatched icon to the left of the field number flashes
when work is interrupted due to the raising of the Ha
rear hitch or, if the optional area cut-out system is
fitted, due to the implement sending a signal to A285950
indicate cessation of its function.
To reset the stored value of ‘area worked’ for one or

more of the fields listed, select each one in turn as
described earlier and then press buttons A and B
together and hold for 5 seconds. To reset the stored
values for all fields select ‘FIELD ALL’ and then
press the buttons as described for individual fields.
To return to the display showing ‘trip distance

travelled’, press button A with the FIELD icon not
flashing.
2 To change the RH side of centre display 30 press

button B to step between the four available options:
a Hours of fuel remaining at current average work rate

averaged over 10 minutes.
hrs
* Note: Only available if fuel meters are fitted.

A285990
b Work rate, acres or hectares (Ha) per hour. To select

imperial or metric data, refer to step 2 of Level ‘1’
Programming Mode.
Acres/hr
A286000
c Wheel slip - During normal operation the display

shows the actual percentage rate of wheel slip. If
active wheel slip (a pre-determined acceptable
level) is programmed the display indicates by means
of a bar in front of the figure, whether the actual
wheel slip is above, below or equal to the
programmed level (refer to Wheel Slip, Slip Control %
- Normal Operation).
A286010
d Fuel usage - this facility is provided so that where

fuel economy is of paramount importance, the
operator can compare readings obtained with the
machine in alternative speed ranges. The figures are
averages over a 5 second period and indicate
litres/hour.
* Note: Only available if fuel meters are fitted. A286020
Note: From EMS Software Version 5.00 (JCBV0500),

the fuel usage is displayed only when the engine speed
is 1250 rpm or higher.
9803/8020 Issue 4*
29 - 5A Instrument Cluster 29 - 5A
(continued)
Optional Software Package (continued)
3 From EMS Software Version 7.00 onwards
a Adjusting Implement Width
Press and hold the SET UP/SELECT button D for

approximately 3 seconds to bring up on the centre
display 30 the flashing message ‘IMPWIDTH’.
Release button D. The clock display 27 shows the
previously stored implement width in metres. Use
button A or B to select the width of the new
implement. Press the EXIT button to resume the
normal display and store the new value.
A286050
If the EXIT button is not pressed the storing

procedure is carried out automatically 20 seconds
after the last operation of the SET UP/SELECT or
the A or B buttons
Note: With EMS Software prior to Version 7.00 the

‘IMPWIDTH’ setting can only be carried out at level ‘1’
programming.
b Adjusting Warning Lamps Dimming Level
Switch ON the sidelights or headlamps so that the

warning lamps are dimmed. Press and hold SET
UP/SELECT button D for approximately 3 seconds
to bring up the flashing message ‘IMPWIDTH’ on
centre display 30. Release button D. Press button D
again to bring up the flashing ‘DIMMING’ message
on the centre display. Release button D. The
number in clock display 27 shows, as a percentage,
the current dimming level of the warning lamps.
100% indicates zero dimming, i.e. maximum
brightness, 10% indicates the maximum available
A386210
dimming. Press arrow button A or B to set up the
required level. If buttons A, B or D are not pressed
for 20 seconds, or if EXIT button is pressed, the
normal displays 27 and 30 are resumed.
9803/8020 Issue 1
Level ‘1’ Programming Mode
Level ‘1’ programming mode is concerned with the setting-

up of various parameters which may be subject to change
from time-to-time. To access level ‘1’ programming press
SET UP/SELECT button D before and whilst turning the
ignition switch ON. Do not start the engine. This will initiate
the following sequence of events:
1 The centre display 30 shows the message ‘SPEEDO’

and Road Speed Display 29 shows either mph or kph,
depending on the setting previously made. Press
button A or button B to toggle between the two options
and select the desired setting.
mph
A286080
* 2 Press SET UP/SELECT button D to bring up the

message ‘CENTRE’ on centre display 30. Press button
A or B to toggle between MET and IMP units for level
‘0’ programming displays of area/distance (Ha/km or
acres/miles) and work rate (acres or hectares (Ha)/hour)
for the appropriate LH side display at Level ‘0’
Programming.
A290360
3 Press SET UP/SELECT button D to enter the tyre mode

and show the flashing message ‘TYRE-OPT’ on centre
display 30.
a The clock display 27 will show the setting previously

made-OFF if standard tyres were fitted, ON if
optional tyres were fitted. Depending on the current
requirement, press button A or B to toggle between
ON and OFF to select the relevant setting.
A286070
b Press SET UP/SELECT button D to display the

message ‘TYRE-RC’ on centre display 30. At the
same time clock display 27 shows the rolling
circumference in metres of the tyre previously
selected. If OFF was selected at a above, the centre
display message is continuous and the rolling
circumference quoted is the machines standard tyre
size. This is for reference purposes only and cannot
be changed. If ON was selected at a above, the
centre display message flashes, to indicate that the
rolling circumference shown can be changed to the A286040
dimension of a new optional tyre by pressing button
A or button B as necessary (see Tyres & Wheels,
Pressures, Speeds and Loads, Section 3).
9803/8020 Issue 3*
Level ‘1’ Programming Mode (continued)
*4 Press SET UP/SELECT button D to initiate the flashing

message ‘IMPWIDTH’ on centre display 30. The clock
display 27 shows the previously stored implement
width. Press button A or button B to set the new
dimensions.
Note: From EMS Software Version 7.00 onwards the

‘IMPWIDTH’ setting can also be carried out at level ‘0’
programming.
A286050
*5 From EMS Software Version 7.00 onwards
Press SET UP/SELECT button D to initiate the flashing
message ‘SERVICE’ on centre display 30.
The engine running hours display on right hand display

28 shows the total running hours at which the next
service is due. Press button A or B to adjust this
setting.
E.g. If current engine hours is 520 and the next service

is due at 1000 hours (this can only be incremented in
50 hour steps), set up the display at 1000. On next
power-up the service hours counter (shown with the
A386360
spanner icon) will show 480 hours, being the time
remaining until the next service is due.
*6 Press SET UP/SELECT button D to initiate the flashing AM

message ‘CLOCK’ on centre display 30. The clock
display 27 shows the current setting. Step the display
setting forwards or backwards to set-up the correct
time by pressing button A or button B respectively.
Note that the clock is 12 hour format with AM or PM
indication.
A286060
*7 Press SET UP/SELECT button D to initiate the flashing

message ‘RADARCAL’ on centre display 30. The clock
display 27 shows one of the following:
a OFF. The factory set calibration value will be used

by the EMS.
b The current numerical calibration value in

pulses/metre (132.2 in the example shown).
A334000
c CAL. Ready to do a new calibration.
Note: Radar calibration should only be necessary if the radar

unit has been replaced or if the operator has reason to
suspect that the radar is inaccurate. It should be carried out
on level ground in dry conditions. Very wet ground,
particularly pools of standing water, will cause inaccuracies.
Depending on the requirement, press button A or

button B to toggle between the current value stored for
the radar calibration, radar OFF or CAL.
A336670
9803/8020 Issue 4*
8 To re-calibrate the radar, accurately measure a

distance along the ground of 100 metres in a straight
line from the point directly below the centre of a wheel
hub. Mark a line at this point.
Ensure that the clock display 27 is showing ‘CAL’ and

drive the tractor along the course to the point where the
wheel hub is directly above the mark made 100 metres
from the start position. It is advised that someone walks
alongside the tractor to ensure that the final position is
accurate.
A334010
When the 100 metre mark is reached, exit Level ‘1’

Programming Mode to complete the calibration.
* Note: During the 100 metre run, display 27 changes from

displaying ‘CAL’ to a continually increasing number. This
number ceases to increase at the end of the run. The final
value displayed is the value in pulses/metre which is stored
as the calibration value. If this value differs by more than
±10% from the factory set value (132.7 for UK machines,
131.8 for non-UK machines), then the value is deemed
invalid and the calibration value defaults to the setting in use
before calibration started. If this happens, recheck the 100
metre measurement and repeat the calibration. If still
unsatisfactory, the radar unit should be checked using
Wingst or the Psion (see Wingst Program or Psion
Walkabout, this Section.
9 To return to the MPH-KPH mode (step 1) press SET

UP/SELECT button D. To exit level 1 programming
either switch the ignition OFF or start the engine or
press EXIT/RPM button C.

To check the axle speed sensor (which calculates the
machine’s actual speed), press SET UP/SELECT button
D to initiate the flashing message ‘AXLECAL’ on centre
display 30. The clock display 27 shows one of the
following:
a OFF. The factory set calibration value will be used

by the EMS.
A386140
b The current numerical calibration value in
pulses/metre (132.2 in the example shown).
c CAL. Ready to do a new calibration.
Note: Axle sensor calibration should only be necessary if the

operator has reason to suspect that it is inaccurate. It should
be carried out on level ground in dry conditions. Any wheel
slippage will cause inaccuracies.
Depending on the requirement, press button A or button B

to toggle between the current value stored for axle sensor
OFF (a), axle sensor calibration (b) or CAL (c). A386150
9803/8020 Issue 5*
11 From EMS Software Version 7 onwards

To re-calibrate the axle sensor, accurately measure a
distance along the ground of 100 metres in a straight
line from the point directly below the centre of a wheel
hub. Mark a line at this point.
Ensure that the clock display 27 is showing ‘CAL’ and

drive the tractor along the course to the point where the
wheel hub is directly above the mark made 100 metres
from the start position. It is advised that someone walks
alongside the tractor to ensure that the final position is
accurate.
A386160
When the 100 metre mark is reached, exit Level ‘1’

Programming Mode to complete the calibration.
* Note: During the 100 metre run, display 27 changes from

displaying ‘CAL’ to a continually increasing number. This
number ceases to increase at the end of the run. The final
value displayed is the value in pulses/metre which is stored
as the calibration value. If this value differs by more than
±10% from the factory set value, then the value is deemed
invalid and the calibration value defaults to the setting in use
before calibration started. If this happens check that the
machine has correct values for ‘Tyre RC’ and ‘Speed Sensor
Pulses’. Then recheck the 100 metre measurement and
repeat the calibration. If still unsatisfactory, the axle sensor
unit should be checked using Wingst or the Psion (see
Wingst Program or Psion Walkabout, this Section.
Level 2 Programming Mode
Level ‘2’ programming mode is for the use of JCB

Distributor service personnel only. Machines leaving the
factory will already have been calibrated and set-up by
means of this programming mode, but there are certain
instances when it will be necessary to carry out all the
following procedures (if a new Instrument Cluster has been
fitted) or individual procedures as appropriate.
Level ‘2’ programming provides access to the following

variable parameters:
a PTO 1000 gear set-up

b PTO 540 gear set-up
c Maximum vehicle speed
d Standard tyre size
e Pulses per wheel revolution
f Fuel tank capacity
g Service interval counter adjustment
h Language option
9803/8020 Issue 3*
* Level ‘2’ Programming Mode (continued)
* To access level ‘2’ progamming press and hold buttons A

and B whilst and after turning the ignition switch ON. Within
5 seconds press SET UP/SELECT button D and hold down
for 15 seconds until the message on the centre display 30
shows the software number installed in the EMS.
* EMS Software prior to Version 7.00

The software number is displayed briefly followed
continuously by the first level ‘2’ option (‘PTO 1000’).
* EMS Software from Version 7.00 onwards

The software number is displayed continuously. Press SET
UP /SELECT button D to display the first level ’2’ option (‘HZ
RPM’).
* The message displayed represents initiation of the following

sequence of setting procedures. After completion of each of
the procedures press RPM/EXIT button C to exit the
programme and restore the normal display, or press SET
UP/SELECT button D to proceed to the next level ‘2’
programming option. Having reached the last option, press
button D to return to option 1.
*1 From EMS Software Version 7.00 onwards

The message ‘HZ-RPM’ is the alternator calibration
value for the rev. counter. This should be factory set at
370 for all models except 3185 which should be 355.
This value is the frequency of the alternator rpm signal
when the engine is running at 1500 rpm. It may be
measured and calibrated if required.
*2 The message ‘PTO 1000’ on centre display 30 identifies

the procedure for PTO 1000 gear set-up. Clock display
27 shows the engine rpm required to produce a PTO
speed of 1000 rpm when selected (see Standard
Values). Adjust for the required engine rpm by means
of button A (up) or button B (down).
*3 The message ‘PTO 540’ on centre display 30 identifies

the procedure for PTO 540 gear set-up. Repeat step 1
for the appropriate PTO speed.
*4 The message ‘MAXSPEED’ on centre display 30

identifies the procedure for calibrating the bar graph on
Engine/PTO data Display 28 so that the maximum
vehicle speed corresponds with a ‘full’ bar graph. Clock
display 27 shows the currently set vehicle speed (see
Level ‘1’ Programming, Step 1) in the units (mph or
kph) shown on centre display 30. Press button A or B
to set/reset the vehicle speed (see Standard Values)
on clock display 27.
*5 The message ‘TYRE-STD’ on centre display 30

identifies the procedure for setting/resetting the
standard tyre size (rolling circumference) called up in
Level ‘1’ Programming, step 3. Press button A or B to
set the clock 27 display to the correct value for the
machine (see Standard Values). If a tyre size different
from the standard value is used continually, set the
display accordingly.
9803/8020 Issue 2*
6 The message ‘SPDSENSE’ on centre display 30

identifies the procedure for setting the calibration value
(pulses per wheel revolution) of the speed sensor. Press
button A or B to adjust the calibration value shown on
clock display 27 (see Standard Values) in the form
123.4 (i.e. one decimal place).
7 When required the message ‘FUEL TANK’ will be

displayed on the centre display 30. This message
identifies the procedure for setting the capacity of the
fuel tank in litres. Press button A or button B to toggle
between the two available values (220 or 350) shown
on clock display 27 as appropriate for the machine
concerned (see Lubricants and Capacities, Section 3).

The message ‘FUELMETR’
OFF = no fuel meters fitted
ON = fuel meters fitted.

The message ‘SLPSWITCH’.
YES = wheel slip switch fitted to Ag. panel.
NO = no wheel slip switch.

The message ‘FLOW DIV’
OFF = flow divider not fitted (lamp disabled).
ON = flow divider fitted (lamp enabled).
* 11 From EMS Software Version 7.00 onwards

The message ‘FUEL-LEV’
1 = float arm type fuel level sender fitted.
2 = later ‘linear’ stick type fuel sender fitted.
12 This message (the previously selected language from

those listed below) on centre display 30 identifies the
procedure for selecting the required language for the
messages on the instrument cluster. Press button A to
step through the following languages in sequence:
ENGLISH, FRANCAIS, DEUTSCH, ESPAGNOL,
PORTUGUE, CESKY, ITALIANO, NORSK, SVENSKA,
NL, DANSK, SUOMI, AMERICAN. Press button B to
reverse the sequence.
Note: AMERICAN is only available with the software from

Version 7.00 onwards.
9803/8020 Issue 3*
Standard Values
Option Applies to : Setting
‘PTO 1000’ Fastrac 2115, 2125, 2135 2088

* Fastrac 2140 1986
Fastrac 2150 1986
Fastrac 3155, 3185 2196
‘PTO 540’ Fastrac 2115, 2125, 2135, 2150 1894

* Fastrac 2140 1894
Fastrac 3155 2118
Fastrac 3185 2002
‘MAXSPEED’ Fastrac 2115, 2125, 2135, 2150

(50 kph) 55
* Fastrac 2140 (50 kph) 55
Fastrac 3155, 3185 (40 kph) 45
Fastrac 3155, 3185 (65 kph) 75
Fastrac 3155, 3185 (80 kph) 85
‘TYRE-STD’ Tyre size :

495/70 R24 3.913
580/70 R26 4.300
620/70 R26 4,496
420 R28 4.240
480/70 R28 4.240
540/65 R28 4.230
600/65 R28 4.415
16.9 R28 4.305
480/70 R30 4.395
520/70 R30 4.615
540/65 R30 4.432
16.9 R30 4.388
‘SPDSENSE’ Fastrac 2115, 2125, 2135 544

* Fastrac 2140 544
Fastrac 2150, 3155 (40 kph) 684
Fastrac 3155 (65 kph) 574
* ‘HZ-RPM’ Fastrac 2115, 2125, 2135, 2150 370

Fastrac 2140 450
Fastrac 3155 370
Fastrac 3185 355
9803/8020 Issue 2
Error Codes - Transmission

The electronic transmission controller diagnostic system Number Error Codes (All Machines)
communicates problems to the operator via a series of
codes. Transmission Electronic Control Unit (ECU) errors are drawn
to the operators attention by the flashing of the ‘book’ icon
Blink Codes (2000 Series to S/N 739999; 3000 series to 17. This is accompanied by the showing of error codes on
S/N 641999) centre display 30. The error code information alternates with
the basic data (i.e. distance travelled) of centre display 30 in
The blink codes are displayed via the snail, tortoise and hare the form of 2 second displays of each. The error information
Powershift icons on Gear Display 10. The actual blink codes begins with a statement of the number of errors in the
are shown as a slow flashing of one of the icons system e.g. ‘3 ERRS’, followed by up to 20 error codes
(approximately 1 second ON, 1 second OFF) followed by an displayed sequentially, e.g. ‘ERR T022’, in the order in which
obvious pause with the icon OFF. The number of flashes they occurred. If there are more than 20 error codes in the
between pauses is the blink code. Interpret the blink codes system, the opening statement will indicate that number, but
as follows: only the first 20 will be identified.
Icon Flashing Blink Code Fault Indicated * For diagnosis of the Error Codes, together with suggested
remedial action, see Diagnostic Error Codes - General,
Snail 2 Snail solenoid - open this Section.
circuit
Snail 4 Snail solenoid - short

circuit or overloading
Tortoise 2 Tortoise solenoid - open

circuit
Tortoise 4 Tortoise solenoid - short

Hare 2 Hare solenoid - open

circuit
Hare 4 Hare solenoid - short

AM
‡
‚ °
ENGINE
miles
SETUP
A mph RPM SELECT D

0 RPM
B C
AUTO
& EXIT
540
ABS
1000 ABS
1 2 3 ! P
A285902
9803/8020 Issue 2*
Error Codes -
Anti-skid Braking System (ABS)
ABS faults are conveyed to the operator via the Machine
ABS icon 17B in the form of blink codes. These blink codes
are displayed in response to the pressing of the diagnostic
push-button X. Lamp 17B illuminates every time the
diagnostic push-button is pressed. X
The fault codes consist of two numbers. These are displayed
by two blink-code blocks. The blocks can be identified as
follows (times are approximate):
Duration of a blink pulse 0.5 seconds

Pause between blink pulses 0.5 seconds
Pause between first block and
HS
H
second block 1.5 seconds
0 IGN
Pause between second block of one
code and the first block of following
code 4.5 seconds
2 4 6
1 3 5
For diagnosis of the ABS Fault Codes, see ABS Diagnostic
Fault Code Tables following.
To completely erase an existing fault memory, press the

diagnostic push button while the ignition switch is being
turned ON and for a short period thereafter. Leave the
ignition switched ON for a further 5 seconds. A387840
After erasing the fault memory, the storage of further fault

codes in the memory is inhibited. To overcome this inhibition
the ignition must be switched OFF and then ON again
before driving the machine.
AM
ENGINE
miles
SETUP
RPM
mph SELECT
RPM
AUTO
17B EXIT
540
ABS
1000 ABS
1 2 3 ! P
A285902
9803/8020 Issue 1
Error Codes - Anti-skid Braking System (ABS) (continued)

* JCB Fastrac ABS Error Code Explanation and Fault Finding
Error Code Description Possible Solution
2-1 Front Left speed sensor Air gap to large Inspect sensor and push into contact with pole wheel. Drive to
between pole wheel and speed sensor above 10kph, ABS light should go out.
2-2 Front Left speed sensor missing signal at Possibly in conjunction with 17-12 Error Code
drive off. Inspect sensor and push into contact with pole wheel.
Possible Causes Drive to above 10kph, ABS light should go out.
Air gap too large between sensor and pole Check sensor plug and wiring for damage
wheel Check Continuity between sensor harness plug and ECU pins
ECU plug X2 pin 8
ECU plug X2 pin 7
2-3 Front Left pole wheel damaged Check pole wheel condition over full circumference
Check air gap between pole wheel and sensor
Inspect sensor and push into contact with pole wheel.
Drive to above 10kph, ABS light should go out.
2-4 Long Term Front Left speed sensor signal Check pole wheel condition over full circumference
instability Check air gap between pole wheel and sensor
Check signal using service master ABS software
2-5 Loss of Front Left speed sensor signal Check air gap between pole wheel and sensor
Check sensor plug and wiring for damage
Check Continuity between sensor harness plug and ECU pins
ECU plug X2 pin 8
ECU plug X2 pin 7
2-6 Front Left Speed Sensor Fault, Check sensor plug and wiring for damage
Possible Causes Check Continuity between sensor harness plug and ECU pins
Sensor Wiring shorted to ground ECU plug X2 pin 8
Sensor Wiring shorted to battery ECU plug X2 pin 7
Broken Wire
2-7 Front Left speed sensor internal failure Inspect sensor and push into contact with pole wheel.
Replace Sensor if light does not go out
2-8 Sensor Configuration Error Check ABS ECU has correct JCB Part number attached
3-1 Front Right speed sensor Air gap to large Inspect sensor and push into contact with pole wheel. Drive to
between pole wheel and speed sensor above 10kph, ABS light should go out
3-2 Front Right speed sensor missing signal at Possibly in conjunction with 17-12 Error Code
ECU plug X2 pin 6
ECU plug X2 pin 5
3-3 Front Right pole wheel damaged Check pole wheel condition over full circumference
9803/8020 Issue 2*

JCB Fastrac ABS Error Code Explanation and Fault Finding (continued)
3-4 Long Term Front Right speed sensor signal Check pole wheel condition over full circumference
3-5 Loss of Front Right speed sensor signal Check air gap between pole wheel and sensor
ECU plug X2 pin 6
ECU plug X2 pin 5
3-6 Front Right Speed Sensor Fault, Check sensor plug and wiring for damage
Broken Wire
3-7 Front Right speed sensor internal failure Inspect sensor and push into contact with pole wheel.
4-1 Rear Left speed sensor Air gap to large Inspect sensor and push into contact with pole wheel. Drive to
4-2 Rear Left speed sensor missing signal at Possibly in conjunction with 17-12 Error Code
ECU plug X3 pin 1
ECU plug X3 pin 2
4-3 Rear Left pole wheel damaged Check pole wheel condition over full circumference
4-4 Long Term Rear Left speed sensor signal Check pole wheel condition over full circumference
4-5 Loss of Rear Left speed sensor signal Check air gap between pole wheel and sensor
ECU plug X3 pin 1
ECU plug X3 pin 2
9803/8020 Issue 1*

4-6 Rear Left Speed Sensor Fault, Check sensor plug and wiring for damage
Broken Wire
4-7 Rear Left speed sensor internal failure Inspect sensor and push into contact with pole wheel.
5-1 Rear Right speed sensor Air gap to large Inspect sensor and push into contact with pole wheel. Drive to
5-2 Rear Right speed sensor missing signal at Possibly in conjunction with 17-12 Error Code
ECU plug X3 pin 3
ECU plug X3 pin 4
5-3 Rear Right pole wheel damaged Check pole wheel condition over full circumference
5-4 Long Term Rear Right speed sensor signal Check pole wheel condition over full circumference
5-5 Loss of Rear Right speed sensor signal Check air gap between pole wheel and sensor
ECU plug X3 pin 3
ECU plug X3 pin 4
5-6 Rear Right Speed Sensor, Check sensor plug and wiring for damage
Broken Wire
5-7 Rear Right speed sensor internal failure Inspect sensor and push into contact with pole wheel.
9803/8020 Issue 1*

8-1 Front modulator wiring fault Check Modulator Connectors

Possible causes:- Check Pannier bulkhead connector
Modulator release solenoid wiring shorted Check continuity or for damage between the ECU and the
to battery modulator
Modulator release solenoid ground wire ECU Plug X2 Pin 10 to Modulator Pin 2 (Wire No 1806)
broken ECU Plug X2 Pin 11 to Modulator Pin 1 (Wire No 1808)
ECU Plug X2 Pin 4 to Modulator Pin 3 (Wire No 1807)
8-2 Front Modulator Fault Check Modulator Connectors

Possible causes Check Pannier bulkhead connector
Shorted to ground release solenoid wire Check continuity or for damage between the ECU and the
broken release solenoid wire modulator
8-3 Broken wire on front modulator release Check Modulator Connectors

solenoid Check Pannier bulkhead connector
Check continuity or for damage between the ECU and the
modulator
8-4 Broken Wire on Front Modulator pin 1 Check Modulator Connectors

Check Pannier bulkhead connector
modulator
8-8 Modulator Configuration error Check ABS ECU has correct JCB Part number attached
9-5 Front modulator hold solenoid shorted to Check Modulator Connectors

battery Check Pannier bulkhead connector
modulator
9-6 Front modulator hold solenoid fault Check Modulator Connectors

possible causes Check Pannier bulkhead connector
Hold Solenoid wiring shorted to ground Check continuity or for damage between the ECU and the
Hold solenoid wiring broke modulator
9-7 Front Modulator hold solenoid broken wire Check Modulator Connectors
modulator
10-1 Rear Left modulator wiring fault Check Modulator Connectors

Modulator release solenoid wiring shorted to Check continuity or for damage between the ECU and the
battery modulator
9803/8020 Issue 1*

10-2 Rear Left Modulator Fault Check Modulator Connectors

10-3 Broken wire on Rear Left modulator release Check Modulator Connectors
modulator
10-4 Broken Wire on Rear Left Modulator pin 1 Check Modulator Connectors
modulator
10-5 Rear Left modulator hold solenoid shorted Check Modulator Connectors
to battery Check Pannier bulkhead connector
modulator
10-6 Rear Left modulator hold solenoid fault Check Modulator Connectors
10-7 Rear Left Modulator hold solenoid broken Check Modulator Connectors
wire Check Pannier bulkhead connector
modulator
10-10 Modulator ground shorted to battery Check continuity and for damage between ECU Plug X1 Pin 11
and Battery -ve.
Check continuity between modulator ground wires and battery
ECU Plug X3 Pin 11 to Rear Left Modulator Pin 1 (Wire No 1801)
10-11 Modulator ground shorted to ground Check Modulator Connectors

modulator
ECU Plug X3 Pin 11 to Rear Left Modulator Pin 1 (Wire No1801)
9803/8020 Issue 1*

11-1 Rear Right modulator wiring fault Check Modulator Connectors

Modulator release solenoid wiring shorted to Check continuity or for damage between the ECU and the
battery modulator
11-2 Rear Right Modulator Fault Check Modulator Connectors

11-3 Broken wire on Rear Right modulator release Check Modulator Connectors
modulator
11-4 Broken Wire on Rear Right Modulator pin 1 Check Modulator Connectors
modulator
11-5 Rear Right modulator hold solenoid shorted Check Modulator Connectors
to battery Check Pannier bulkhead connector
modulator
11-6 Rear Right modulator hold solenoid fault Check Modulator Connectors
11-7 Rear Right Modulator hold solenoid broken Check Modulator Connectors
wire Check Pannier bulkhead connector
modulator
11-10 Modulator ground shorted to battery Check continuity and for damage between ECU Plug X1 Pin 12
and Battery -ve.
Check continuity between modulator ground wires and battery
ECU Plug X3 Pin 12 to Rear Right Modulator Pin 1 (Wire No
1800)
ECU Plug X2 Pin 4 to Front Modulator Pin 1 (Wire No 1807)
9803/8020 Issue 1*

11-11 Modulator ground shorted to ground Check Modulator Connectors

modulator
ECU Plug X3 Pin 12 to Rear Right Modulator Pin 1 (Wire No
1800)
ECU Plug X2 Pin 4 to Front Modulator Pin 1 (Wire No 1807)
15-1 ECU Defective Replace ECU

to
15-12 ECU Defective Replace ECU
16-1 ECU Plug X1 Pin 1 Voltage too high Check battery voltage (charging and not charging)
16-2 ECU Plug X1 Pin 1 Voltage too low Check battery condition
Check battery voltage (charging and not charging)
16-3 ECU Plug X1 Pin 1 Broken wire Check Fuse F3 (10A)

Check Relay A12
Check continuity between ECU plug X1 pin 1 and fuse F3 (Wire
No 152)
16-4 ECU Plug X1 Pin 12 broken Ground Wire Possibly in conjunction with 16-8
Check Pannier bulkhead connector is correctly connected
Check continuity between ECU Plug X 1Pin12 and battery -ve
(Wire No665C)
16-5 ECU Plug X1 Pin 2 Voltage too high Check battery voltage (charging and not charging)
16-6 ECU Plug X1 Pin 2 Voltage too low Check battery condition
Check battery voltage (charging and not charging)
16-7 ECU Plug X1 Pin 2 Broken wire Check Fuse F2 (10A)

Check Relay A12
Check continuity between ECU plug X1 pin 2 and fuse F2 (Wire
No 151)
16-8 ECU Plug X1 Pin 11 broken Ground Wire Possibly in conjunction with 16-4
Check Pannier bulkhead connector is correctly connected
Check continuity between ECU Plug X1 Pin 11 and battery -ve
16-9 ECU Voltage too high Check battery condition and voltage, Alternator charge etc
16-10 ECU Voltage too low Check 10A fuses F2 and F3

Check supply wiring condition ECU plug X1
Wire No's 665C, 665D, 152, 151, 561, 560, 465.
16-11 Voltage difference between ECU plug X1 Check fuses

pin 1 and pin 2 Check the condition of Plug X1 pin 1 and Plug X2 pin 2
Check supply wiring condition ECU plug X1 (all wires)
Wire No's 665C, 665D, 152, 151, 561, 560, 465.
17-5 Difference in front to rear tyre size too large Fit matching tyres and wheels (JCB approved)
17-6 EEPROM value faulty Check ABS ECU has correct JCB Part number attached
17-7 Stop light switch not pushed during this Check stop light input is functioning Plug X2 pin 1 (Wire No 883)
power on cycle
9803/8020 Issue 1*

17-12 Not Permanent Inspect sensor and push into contact with pole wheel.
Speed sensor failure in previous power on Drive to above 10kph, ABS light should go out.
9803/8020 Issue 1*
* JCB Powershift
Manual Operation Z
Manual operation is controlled by two buttons on the top of
the speed gearbox lever (view Z) or, alternatively,
corresponding buttons on the right hand control panel (view
Y). Change down from ‘High’ to Medium’ or from ‘Medium’
to ‘Low’ using a button B. Change up through the ratios
using a button C. B C
The ratio currently employed is indicated by an illuminated
symbol on the gear display (see Instrument Cluster, D
Warnings (Visual only)).
Snail = Low speed

Tortoise = Medium speed
Hare = High speed
Except for changes down when the engine speed exceeds

2750 rpm, changes may be made at any time without the A293920
use of clutch.
Autoshift (Automatic) Operation
Selection and setting-up of automatic operation is carried Y

out by means of buttons B, C and D. In this mode, the
AUTO icon on the gear display is illuminated and automatic
ratio changes take place according to the engine speed. Of
the four options, within the AUTO mode three (‘PLOUGH’,
‘PTO’ (540 or 1000) and ‘TRAILER’) have their ‘change up’
and ‘change down’ engine speeds factory set. The fourth
option (‘USER’) is intended to be set by the operator.
C
D
B A343300
9803/8020 Issue 6*
(continued)
JCB Powershift (continued)
Autoshift (Automatic) Operation (continued)
To select AUTO mode press and release orange button D.

As AUTO mode is selected the option (PLOUGH, TRAILER,
PTO or USER) currently selected will be displayed on the
centre display.
To exit AUTO mode press button D again or manually select

an Autoshift range using buttons B or C. The centre display
will briefly show the message ‘AUTO OFF’. A286340
To select an alternative AUTO mode option, press and hold

orange button D. The AUTO icon on the gear display
flashes. While still holding button D, after 7 seconds the
message ‘AUTOPROG’ shows briefly on the centre display,
followed after 4 seconds by the four options in sequence.
Release button D when the desired option is displayed.
AUTO mode is now selected.
A286320
To set the change UP/change DOWN engine rpm points,

press orange button D for 3 seconds until AUTOPROG is
displayed. Release the orange button. AUTOPROG will
continue to be displayed with the currently set-up change
rpm marks on the bar graph flashing. ENGINE
To alter the range ‘change UP’ engine speed, run the engine
at the required speed, say 2100 rpm, as shown on the
Engine/PTO Data display. Press button C to memorise the RPM
‘change UP’ speed.
A286380
Repeat the previous paragraph to set up the range ‘change

DOWN’ engine speed, say 1800 rpm. With the engine
running at the required speed, press button B to memorise
the ‘change DOWN’ speed. ENGINE
RPM
A286390
While the button is pressed all three Powershift range icons

(snail, tortoise, hare) illuminate and the message ‘PROG OK’
is shown on the centre display to confirm recognition and
acceptance of the change. When the button is released the
icons are extinguished and the centre display temporarily
shows ‘AUTO OFF’ before returning to normal operation.
A286350
9803/8020 Issue 1
(continued)
JCB Powershift (continued)
Autoshift (Automatic) Operation (continued)
Having been set up, the ‘USER’ option is activated each

time AUTO mode is selected regardless of any previously
set AUTO options. The Engine/PTO Data display shows the
current engine speed (805 rpm in the example right) both
digitally and on the bar graph. The bar graph also indicates ENGINE
the range change points previously set-up. Using the
AUTOPROG settings described earlier as an example, the
Autoshift range changes up at 2100 rpm engine speed when
in the Snail and Tortoise ranges, and changes down at 1800 RPM
rpm engine speed when in the Hare and Tortoise ranges.
A286400
If unsuitable settings have been attempted, e.g. UP and

DOWN points too close together or the wrong way round,
the message ‘AUTOFAIL’ is shown on the centre display and
the AUTO icon flashes slowly. Either programme suitable
UP/DOWN points or use one of the factory preset AUTO
options (i.e. ‘PLOUGH’, ‘PTO’ or ‘TRAILER’).
A286360
Gear Sequence
Consult the gear speed decal to determine which Powershift

ratio and speed box gears to use for any particular
circumstances.
Manual Range Change and Reverse Selection
The letters on the decal indicate:
M - Medium Range R - Reverse

H - High Range L - Low Range
The range box is fully synchronised to make range changing 5

3
easier at low speed, for example on headlands.
1 6
4
Do not attempt to change ranges at speeds greater than 3 R
2
km/h. M
L
Always stop the machine and drop engine speed to idle H
before changing from forward to reverse or vice versa.
A297120
9803/8020 Issue 1
Wheel Slip
Slip Control Re-calibration
The following procedure should be carried out when one set 2 The measured wheel slip is more than 1% lower than
of wheels has been exchanged for a set of a different size, or the ‘wheel slip’ setting. Note that the bottom bar is
if a slip reading not near 0% is observed when the machine illuminated.
is being driven on a tarmac surface. Proceed as follows:
1 Fit an implement to the rear hitch e.g. a plough.
2 Operate the draft control up and down after starting the

engine to ensure that the draft control is unlocked. %
3 Set the draft control main lever to the UP position i.e. in A286250
the transport position.
3 The measured wheel slip is within ± 1% of the ‘wheel
4 Drive the tractor on tarmac at a speed in excess of 15 slip’ setting. Note that the centre bar is illuminated.
kph for a minimum of 12 minutes.
5 The draft control and instrument cluster will by now

have been automatically re-calibrated.
Slip Control - Normal Operations %
Having selected the ‘Wheel Slip’ display (see Level ‘0’ A286010
Programming), press SET-UP/SELECT button D until the
wheel slip icon flashes. Centre display 30 will show either 4 ‘Wheel slip’ is switched OFF, as indicated by the
‘OFF’ or a percentage figure i.e. wheel slip active or absence of a bar in front of the current reading, which
disabled. Press buttons A and B at the same time to toggle continues to be displayed. Warning lamp 16 on the
between active and disabled. Warning lamp 16 illuminates Instrument Cluster is not illuminated.
when ‘wheel slip’ is active.
With warning lamp 16 illuminated, use button A or B to

achieve the required ‘wheel slip’ setting between 5% and
40%. Toggle between active and disabled by pressing
buttons A and B at the same time. When activated, wheel %
slip resumes at the previously set level.

A286260
After a delay of 20 seconds or after pressing RPM/EXIT
button C the normal display will resume. The following
examples show how to interpret the display, assuming an
‘active wheel slip’ setting of 14%.
1 The measured wheel slip is more than 1% higher than

the ‘wheel slip’ setting. Note that the top bar is
illuminated.
A286240
9803/8020 Issue 1
* Powershift Clutch Overlap Time

(Dry Clutch Transmission)
Calibration
All machines will have been calibrated before leaving the

factory. The following calibration procedure will only need to 1 3
be repeated when a replacement ECU has been fitted or

after a transmission rebuild.
A B
Note 1: During the calibration procedure the transmission
control module detects the precise point at which the
clutches start to engage. This engagement is detected by C
virtue of a reduction in engine speed. It is therefore essential
during calibration that no action is taken which might cause
the engine speed to vary. To this end, make sure that the air
conditioning and all electrical equipment is switched off and
do not operate the PTO or any hydraulic controls.
1 Drive the machine on the road for at least 15 minutes

until the transmission oil is hot.
A286330
2 Apply the handbrake and switch off the engine.
! WARNING 10 Use the hand throttle lever to set the engine speed to
During the calibration procedure, the machine should approximately 1500 rpm. The Hare (high range) icon
remain still. However, to avoid the possibility of illuminates when the correct speed is obtained. Do not
accidents due to inadvertent, unexpected movement, disturb the hand throttle lever from this point
make sure that personnel and equipment are kept well onwards unless, due to a change in engine speed,
clear of the machine, especially to the front or rear. the Hare icon is not lit continuously.
ELEC 5-2
11 Depress the clutch pedal. On Selectronic models,
3 Press and hold all three buttons (DOWN change A, UP select high (H) range using the LH column mounted
change B, AUTO C) on the top of the speed box gear switch. On manual range change models, select high
change lever. range using the range change gearstick. The Tortoise
(medium range) icon illuminates in addition to the Hare
4 Switch on the ignition, but do not start the engine. icon.
Release the gear change lever push buttons A, B, C.
12 Select 6th gear on the speedbox.
5 The Fastrac transmission software number is now
shown on the centre display of the instrument cluster. 13 Release the clutch pedal to illuminate the Snail (low
range) icon in addition to the Hare and Tortoise icons.
6 If the calibration mode has been successfully accessed
the Hare, Tortoise, Snail and Auto icons will flash 14 The Snail, Tortoise, Hare and Auto icons should now be
quickly and continuously. illuminated. Press the AUTO button (C) once to
automatically calibrate the Snail clutch. Record the
Note 2: If the calibration mode has not been accessed, overlap time shown on the centre display e.g. ‘SNA
switch off the ignition and repeat from step 3. 0314’ where 0314 denotes the overlap in milliseconds.
7 Start the engine. 15 Wait 5 seconds and then press the AUTO button (C)
once to automatically calibrate the Tortoise clutch.
8 A two minute countdown (in 1 second steps) starts and Record the overlap time (see step 14) e.g. ‘TOR 314.’
is shown on the centre display e.g. TCAL 95.
16 Wait 5 seconds and then press the AUTO button (C)
9 At the conclusion of the countdown, the Hare, Tortoise, once to automatically calibrate the Hare clutch. Record
Snail and Auto icons stop flashing. The countdown the overlap time (see step 14) e.g. ‘HAR 314.’
display is replaced by one indicating the type of range
box fitted as detected by the new ECU i.e. MAN Note 3: Enter the calibration values obtained at steps 14, 15,
RANGE for manual range box or SEL RANGE for and 16 in the tractor’s service history records.
Selectronic range box. If the range box display is wrong
press button A to choose SEL RANGE or button B to
choose MAN RANGE.
9803/8020 Issue 3*
* Powershift Clutch Overlap Time (Dry Clutch

Transmission) (continued)
Note 4: With reference to steps 14, or 15, or 16, if the Snail,
or Tortoise, or Hare icon respectively flashes or the message
‘SNA FAIL’, or ‘TOR FAIL’, or ‘HAR FAIL’ respectively is
shown, this indicates that the overlap time is too long
(> 1 second). Investigate the cause which could be
hydraulic, mechanical or electrical.
17 Select neutral on both the range box and the speed

gearbox and then set the hand throttle lever to idle.
18 Switch OFF the engine. The powersplit calibration is

now complete and the tractor will drive normally when
restarted.
9803/8020 Issue 4*

(Wet Clutch Transmission)
Calibration
1 3
All machines will have been calibrated before leaving the

factory. During normal operation recalibration will not be
required. Recalibration will however, be required after any of A B
the following service procedures:
a Replacement of the transmission ECU.

C
b Transmission rebuild or replacement.
c Clutch pedal potentiometer (position sensor)

adjustment or replacement.
After carrying out any of the above procedures calibrate the

transmission before moving the machine using the
procedure below. When the initial calibration has been A286330
completed successfully the machine should be driven for at 4 The Fastrac transmission software number is now
least 15 miniutes to ensure that the transmission oil is hot. shown on the centre display of the instrument cluster.
The transmission should then be recalibrated using the
procedure below. 5 If the calibration mode has been successfully accessed
the Hare, Tortoise, Snail and Auto icons will flash
The calibration procedure includes the following elements: quickly and continuously.
a Overlap time for the Powershift clutches (Snail, Hare Note 2: If the calibration mode has not been accessed,
and Tortoise). switch off the ignition and repeat from step 3.
b Clutch pedal calibration. This sets the operating range 6 Start the engine.
of the clutch pedal and its potentiometer (position
sensor). 7 A two minute countdown (in 1 second steps) starts and
is shown on the centre display e.g. TCAL 95.
c Master clutch bite point calibration. This sets the bite
point of the clutch by detecting a reduction in engine *8 When the countdown reaches zero the Hare, Tortoise,
speed as the clutch is engaged. Snail and Auto icons will stop flashing. CPED will
appear with a 3 digit number. Depress the clutch pedal
Note 1: During the calibration procedure the transmission fully and then release fully. Values relating to the pedal
control module detects the precise point at which the position will be displayed. Record the maximum and
clutches start to engage. This engagement is detected by minimum values. The values must be within the range
virtue of a reduction in engine speed. It is therefore essential as follows:
during calibration that no action is taken which might cause Minimum value = not less than 30
the engine speed to vary. To this end, make sure that the air Maximum value = not greater than 225
conditioning and all electrical equipment is switched off and
do not operate the PTO or any hydraulic controls. 9 Depress and release the clutch pedal fully twice more
to ensure that the pedal has reached the full range of
1 Apply the handbrake and switch off the engine. travel. Recheck the maximum and minimum values
against the range given in step 8. If the values
! WARNING displayed are outside this range then further
During the calibration procedure, the machine should investigation will be required.
remain still. However, to avoid the possibility of
accidents due to inadvertent, unexpected movement, 10 Press the AUTO button (C). The display will now
make sure that personnel and equipment are kept well indicate the type of range box fitted as detected by the
clear of the machine, especially to the front or rear. new ECU i.e. MAN RANGE for manual range box or
ELEC 5-2 SEL RANGE for Selectronic range box. If the range box
display is wrong press button A to choose SEL RANGE
2 Press and hold all three buttons (DOWN change A, UP or button B to choose MAN RANGE.
change B, AUTO C) on the top of the speed box gear
change lever.
3 Switch on the ignition, but do not start the engine.

Release the gear change lever push buttons A, B, C.
9803/8020 Issue 2*

(Wet Clutch Transmission) (Continued)
* 11 Press the AUTO button (C). The display will now show Note 3: Enter the calibration values obtained at steps 8, 11,
the transmission oil temperatures in °C. The 17, 18, 19 and 20 in the tractor’s service history records.
temperature of the oil in the wet clutch is shown on the
left of the display and the temperature of the oil in the Note 4: With reference to step 17, if the engine speed does
transmission oil filter pipe is shown on the right. Record not decrease by 100 rev/min and WCL FAIL is displayed,
the values. The values should be similar. If they are not investigate the cause. This could be electrical, hydraulic or
as expected (if the vehicle has recently been driven it is mechanical and will be related to the clutch or its control
likely that the wet clutch oil will be hotter than the system.
transmission sump oil) or if ‘OILSENSE’ flashes on the
display then the sensors should be checked before Note 5: With reference to steps 18, or 19, or 20, if the Snail,
calibration continues. ‘OILSENSE” will also flash on the or Tortoise, or Hare icon respectively flashes or the message
display if either sensor value is less than zero. ‘SNA FAIL’, or ‘TOR FAIL’, or ‘HAR FAIL’ respectively is
shown, this indicates that the overlap time is too long
12 Use the hand throttle lever to set the engine speed to (> 1 second). Investigate the cause which could be
approximately 1500 rpm. The Hare (high range) icon hydraulic, mechanical or electrical.
illuminates when the correct speed is obtained. Do not
disturb the hand throttle lever from this point 20 Select neutral on both the range box and the speed
onwards unless, due to a change in engine speed, gearbox and then set the hand throttle lever to idle.
the Hare icon is not lit continuously.
21 Switch OFF the engine. The powershift and master
clutch calibration is now complete and the tractor will
13 Depress the clutch pedal. On Selectronic models, drive normally when restarted.
select high (H) range using the LH column mounted
switch. On manual range change models, select high Note 6: If problems are experienced during pedal calibration
range using the range change gearstick. The Tortoise refer to Clutch Pedal - Wet Clutch Transmission, Clutch
(medium range) icon illuminates in addition to the Hare Down Switch, Adjusting in Section F.
icon.
14 Check that the handbrake is still applied. If it is, the

AUTO icon (as well as the handbrake warning lamp) will
be illuminated.
15 Select 6th gear on the speedbox.
16 Release the clutch pedal to illuminate the Snail (low

range) icon in addition to the Hare and Tortoise icons.
17 The Snail, Tortoise, Hare and Auto icons should now be

illuminated. Press the AUTO button (C), the display will
now show WCL 0200. This is the value of the current
supplied to the master clutch control valve in mA. The
current will be increased automatically until the engine
speed decreases by 100 rev/min. If the engine speed
does not decrease by 100 rev/min the display will show
WCL FAIL. The final electrical current value will be
displayed, record the value.
18 After 5 seconds the Snail, Tortoise, Hare and Auto

icons should illuminate. Press the AUTO button (C)
once to automatically calibrate the Snail clutch. Record
the overlap time shown on the centre display e.g. ‘SNA
0314’, where 0314 denotes the overlap in milliseconds.

once to automatically calibrate the Tortoise clutch.
Record the overlap time (see step 18) e.g. ‘TOR 314.’

once to automatically calibrate the Hare clutch. Record
the overlap time (see step 18) e.g. ‘HAR 314.’
9803/8020 Issue 4*
33 - 1 Psion Workabout 33 - 1
Contents Page No.
Introduction 33 - 2
Dealer Requirements 33 - 2
Installation of Psion and Fastrac Software 33 - 2
Starting-up the Fastrac Software 33 - 3A
Using the Fastrac Software 33 - 4
Main Menu Options

Set-up Menu Options 33 - 5
Set-up from Vehicle Type 33 - 5
Set-up from VIN 33 - 6
Program Specific Items
Level ‘0’ Menu 33 - 7
Special Menu Option 33 - 10
Save Settings 33 - 10
Load Settings 33 - 10A
Update EMS Software 33 - 10A
Logging Main Menu Options 33 - 12

Download Data Log 33 - 13
Download Data Log Menu Options 33 - 14
Comm Menu 33 - 14
View Menu 33 - 14
Filter Menu 33 - 14
Special Menu 33 - 16
Erase Datalog Memory Option 33 - 17
Load File Option 33 - 17
Diagnostics
Transmission 33 - 19
EMS 33 - 21
* Wet Clutch †† 33 - 24
* Special Main Menu Options 33 - 25

EMS Information 33 - 25
Preferences 33 - 26
About 33 - 26
Exit 33 - 26
Error Codes 34 - 1
Factory Default Settings 34 - 2
* †† 2000 Series from S/N 740000, 3000 Series from S/N 642000
9803/8020 Issue 4*
Introduction Installation of Psion and Fastrac Software

The Psion Workabout is the JCB Group standard service 1 Installing PsiWin software (Refer to PsiWin user
tool for Electronic Control Units (ECU’s). For the Fastrac it guide for detailed instructions)
has four distinct functions:
a Windows 3.1 users
1 Setting up the Electronic Monitoring System (EMS - i Insert disc 1 of 3 into your desktop floppy drive
also known as the Digital Dash or Instrument Cluster) (normally identified as Drive A:)
for a particular vehicle ii Open ‘Program Manager’ in Windows.
iii Open ‘Main’ in Program Manager.
2 Updating the EMS with new software iv Open ‘File Manager’ in Main.
v Click on ‘File’ pull down menu and select ‘run’.
3 Downloading fault codes and other datalogging
vi In the command line type ‘A:\SETUP/EXE’.
information from the EMS
Click OK.
4 Diagnostic use vii Then follow the set up procedure as instructed
by the computer.
The Psion is used to obtain information not only from the
EMS but also from other ECU’s connected to a special data b Windows 95 users
link. This link is called the Controlled Area Network (CAN) i Insert disc 1 of 3 into your desktop floppy drive
bus and at present connects the EMS, Transmission ECU (normally identified as Drive A:).
and diagnostic socket together and allows information to be ii Click windows ‘Start’ and select ‘Run’.
shared between them. More ECU’s will be connected to this iii Type ‘A:\SETUP.EXE’ in the open command
in the near future. box then click OK.
iv Then follow the set up procedure as instructed
The Psion is connected to the vehicle electronic system by by the computer.
means of an eight way Sumitomo diagnostic connector
which can be found clipped underneath the fuse and ignition 2 Connecting the PC to the Psion
switch cover. A Fastrac diagnostic lead connects between a Assemble the docking holster.
this and the ‘RS232’ connector at the top of the Psion unit. b Insert the Ps/Win Link between docking holster and
For the Psion to talk to the EMS the vehicle ignition must be PC. Note which serial port connection is sued on
switched on and the engine must not be running. the PC, e.g. COM 1 or COM 2 in most cases.
c Insert Psion into docking holster.
3 Run the Software

Dealer Requirements a Starting Link from the Psion Command Processor
The following hardware and software is required to enable Switch ON the Psion Workabout. The ‘start-up’
the functions above to be carried out: screen below should be displayed. If it is not, press
the ‘Ctrl’ and ‘Del’ keys simultaneously to reset the
1 Psion workabout Psion. This will take approximately 5 seconds.
available from Psion Distributors
2 Docking holster
ref. MI 569/H, 525/HA, 516/A
3 Psion software
4 Psion to Fastrac link (part no. 721/00664, ref MI 608/H,

536/HA, 546/E.
*5 JCB software as supplied on parts CD ROM. The

software is located within directories ‘psion’ and
‘landpower’. 301151
Note: ‘landpower’ will be abbreviated to ‘land~13’ or Start-up Screen

‘landpowe’ on some software.
b Selecting Command Processor
Press MENU key you invoke system interface.
9803/8020 Issue 3*
* Installation of Psion and Fastrac Software

(cont’d)
3 Run the Software (cont’d)

b Selecting Command Processor d Configuring Remote Link Option
Press MENU key to invoke system interface.
318750
301160
i Press right or left arrow key to set link ON.
System Interface Screen ii Use up or down arrow keys to select ‘Baud
rate’ option.
Use up and down arrows to highlight command iii Press right or left hand arrows to select 19200.
processor. iv Use up or down keys to select ‘Port’ option.
v Press right or left hand arrows to select C.
Press ENTER to invoke the command processor. vi The screen should be as shown below.
vii Press ENTER to activate ‘Remote’ link.
c Selecting Remote Link Option
318760
301170
Command Processor Screen Remote link options enabled
Press MENU key to invoke command processor 4 Downloading Psion Programs to the Workabout
options. a Run link program on Workabout from Command
Processor screen (see Step 3).
Select ‘Special’ using left or right arrow keys.
b Run the Psi/Win Psion Manager on the PC (see
Psion Workabout User Guide).
c Select the ‘Copy’ option from the ‘File’ menu.

Note: Make the following checks if PsiWin fails to
establish link
i Click ‘setup’ and check the ‘Link Settings’ on
the ‘communication settings’ screen. Should
read as follows:
In the ‘Port’ window select the appropriate
318740 communication port, (normally com1). In the
‘Baud Rate’ window select 19200.
Command Processor Screen. Special Options. ii Ensure that the Psion Workabout is switched
ON (it automatically switches OFF when left for
Select ‘Remote Link’ using up or down keys. a short time).
iii Ensure that all physical connections are good.
Press ENTER.
9803/8020 Issue 2*
33 - 3A Psion Workabout 33 - 3A
Installation of Psion and Fastrac Software Starting-up the Fastrac Software

(cont’d)
The procedure for starting-up the software will vary
according to the condition of the Psion when it was last
4 Downloading Psion Programs to the Workabout switched off.
(cont’d)
d Specify the ‘From’ drive as follows: The main possibilities are shown below.
Press ‘Browse’.
In the ‘Computer’ window select ‘PC’. 1 The following screen is displayed when the Psion is
In the ‘Drives’ window select ‘D’ or appropriate switched on for the first time, after a battery change or
drive. after a reset. Press the Menu button near the top of the
In the ‘Directories’ window double click on psion Psion
directory then double click on the landpower
directory (abbreviated to ‘land~13’ or ‘landpowe’ on
some software).
In the ‘File Name’ window, type ‘gst.img’.
e Specify the ‘To’ drive as follows:

Press ‘Browse’.
In the ‘Computer’ window select ‘PSION’.
In the ‘Drives’ window select ‘Internal (RAMDRIVE).’
In the ‘File Name’ window type ‘gst.img’.
301151
Click on the ‘OK’ to select this as the drive to which
program files are to be written. The display will change to Psion Menu Screen. Use the
Click on ‘OK’ to copy the file between the PC and Up and Down arrow keys to highlight ‘Command
the Psion. processor’ and press the Enter key.
If asked ‘Confirm File Replace’, click on ‘Yes to All’.
* f Repeat the file copy process for the following files:

jcbv0600.hex
fdl495_1.hex
sys$8087.Idd
gst01.rzc
gst02.rzc
gst03.rzc
gst04.rzc
gst05.rzc 301160
At the following screen, type in gst and press Enter.
301170
9803/8020 Issue 2*
33 - 3B Psion Workabout 33 - 3B
Starting-up the Fastrac Software (cont’d)

2 If the display is as follows, press the Menu key to At the following screen, type in gst and press Enter.
display the ‘Pull-Down’ menu. The Fastrac software is now activated.
301180 301170
Select ‘Special’ by using the Left and Right keys, then 3 If the above procedures do not work, press the Ctrl, U
select ‘Exit’ by using the Up and Down keys. and Del keys together. The screen will go blank for about
10 seconds and then the Psion Menu Screen will appear.
Follow the procedure from that screen as outlined above.
301190
Press Enter to make the selection.
The Psion will ask for confirmation of ‘Exit System

screen’.
301200
Press Y for yes.
9803/8020 Issue 1
* Using the Fastrac Software

* Once the software has been activated, the Title Screen will
be displayed.
301220
Press the Menu key to display the menu options.
301231
The menu options at the top of the screen are selected by

pressing the yellow Left or Right arrow keys. Under each
option title a list of further sub options appear. These can be
selected using yellow Up or Down arrow keys. The choice
selected is shown by a black highlight bar over the option.
To confirm selection press Enter. If an option is selected by
mistake it is possible to return to the main menu using the
‘special’ menu option or by pressing the On/Esc key.
9803/8020 Issue 2*
Main Menu Options
Set-up Menu Options The next screen will ask for rated vehicle speed. Select the
rated speed by pressing the Left or Right arrow keys to
This Menu option allows an EMS to be configured to suit a select a speed from the list.
particular vehicle.
Available Options
1 Set-up from Vehicle Type: This sets up the EMS using

factory defaults derived from the model type, maximum
rated speed, required language, tyre size and the
machine serial number (the last 7 digits of the VIN).
2 Set-up from VIN: This sets up the EMS using factory

defaults derived from the full VIN and required language
301250
and tyre size.
3 Program Specific Items: Allows any individual item to
be set-up. The next screen will ask for the required language. Select
this from the list by pressing the Left or Right arrow keys.
Set-up from Vehicle Type

To select this menu item, highlight it by using the Up and
Down keys.
301260
The next screen will ask for the standard tyre size.
301231 Either
Note: The Psion will automatically detect the version

number of the software in the EMS and compare it with the
version number in the Psion. If the EMS has an earlier
version, the option to update the software will be displayed.
(See Update EMS Software).
The first of the set-up screens will ask for the vehicle type.
Select the vehicle type (e.g. 2135) from the built in list using 301270
the Left and Right arrow keys.
a Select the tyre size from the list using the Left and
Right arrow keys. The ‘New Tyre Size’ display shows
the rolling circumference for the selected tyre.
Or
b If the required tyre size is not in the list, press the Down
arrow key to highlight ‘New Tyre Size’ and enter the
rolling circumference of the tyre in metres to 3 decimal
places. If the wrong digit is pressed in error press the
Del key to erase the last digit.
301240
In both cases press Enter to make the required selection.
9803/8020 Issue 2*
Main Menu Options (cont’d)
Set-up from Vehicle Type (cont’d)
Optional Package - Fuel Flow Meters
If the optional package is present the next screen will ask to The next screen will ask for the serial number (the last seven
see whether the fuel flow meters are fitted. If the fuel flow digits of the VIN). Type in the serial number. Press the Del
meters are not fitted press Escape for no and refer to Enter key if a digit is entered in error.
the Serial Number opposite (fuel calibration values will be
skipped) if they are press Enter for yes to input the fuel
calibration values for the fuel feed signal.
301280

S353870
The next screen will determine the method of
The fuel feed calibration value is stamped on the fuel meter enabling/disabling the wheel slip (i.e. using an external wheel
with ‘F’ beside it. If this value is different from that displayed slip switch or the arrow keys on the EMS).
on the Psion, type the new value in and press Enter,
otherwise press Enter to accept the value displayed.
Pressing Escape will cancel programming and return the
Psion back to its menu screen.
317810
Press Enter if an external wheel slip switch is fitted.

The next screen will determine whether to enable the flow
S353880 divider lamp. If there is no flow divider or no icon on the
warning lamp display on the EMS then the answer to the
The following screen then asks for the fuel return calibration question is ‘No’.
value, which is stamped on the fuel meter with ‘R’ beside it.
If this value is different from that displayed on the Psion type
the new value in and press Enter, otherwise press Enter to
accept the value displayed. Pressing Escape will cancel
programming and return the Psion back to its menu screen.
317820
There will be a short delay while the EMS datalog memory is

being updated. When the Main Menu title screen re-appears,
the factory defaults have been set.
S360500
9803/8020 Issue 1
33 - 5B Psion Workabout 33 - 5B
Main Menu Options (cont’d)
Set-up from Vehicle Type (cont’d)

The Psion will automatically detect the version number of When the update has finished the Psion will ask for the
the software in the EMS and will compare it with the latest ignition to be switched off again. When the EMS is next
EMS software in the Psion. If the Psion has newer software it switched on, it should appear to operate normally although it
will start the update procedure. may have some new features due to its updated software.
On the next screen the Psion will then ask for the ignition to
be switched off.
301470
Press On/Esc to return to the Main Menu.

301440
If, during the updating process there is a problem, the
Switch Off the ignition then press Enter to continue. following screen may appear.
The Psion will now ask for the ignition to be switched on

again.
301480
To try again press Enter for ‘Yes’, the Psion will attempt the
301450 update process again. Pressing On/Esc will revert to the
‘Fastrac Main Menu’ Title Screen.
Switch On the ignition then press Enter to continue.
If the update fails after several attempts, check the Psion
The EMS display may become corrupted for a short while, diagnostic lead. If the lead is not faulty switch off the
this is normal. ignition, remove the fuse supplying the permanent 12V to
the EMS and replace it after a few seconds. If the EMS has
The next Psion screen should be a bar graph showing the ‘locked’ with a corrupt display this may clear it. Attempt the
progress of ‘Transmitting EMS Program’. The update will update process again.
take a few minutes, the EMS centre display should show
‘REPROG’ while the update is taking place.
301460
9803/8020 Issue 1
* Set-up from VIN

This option is similar to the “Set-up from vehicle type” but it
asks for the full seventeen digit VIN instead of model type,
followed by Language and Tyre Size.
Select this option by choosing the ‘Set-up from VIN’ option

from the Main Menu using the Up and Down arrow keys.
301291
The first display will ask for the ‘VIN’ to be entered.
301300
Enter the full seventeen digit VIN.
Note: The first five digits ‘SLPFT’ have already been entered
and only the remaining twelve digits need be entered. Press
the Del key if an incorrect digit is entered and make the
correction. Press Enter.
If the VIN is invalid a message will warn of this when the

Enter key is pressed. Check the actual VIN with digits
entered. Having identified the error, press the Del key
enough times to delete all the digits back to and including
the error. Enter these digits again. Press Enter.
The software will now ask for Language and Tyre Size to be
entered, follow the instructions as given in Set up from
Vehicle Type.
9803/8020 Issue 3*
Program Specific Items

This allows all EMS items to be entered on an individual Most of the Level 1 and 2 items can set-up manually
basis. Highlight ‘Program Specific Items’ using the Up and without use of the Psion, but the process is lengthy and not
Down arrow keys. as flexible (e.g. the Psion can enter tyre sizes, with all
available options, from a built-in database).
*
Note: Level 3 items are Factory Defaults and should only be
changed under special circumstances.
Level 0 Items
Level 0 items are not programmable via the Psion. For
details of setting-up manually via the dashboard, refer to
318710 Instrument Cluster, Programming, Level 0 programming
mode.
Press Enter to select.
A new Title Screen will appear.

Level 1 Items
301320
301330
Press Menu to display the options.
Units for Speed Display mph or kph
Units for Centre Display Ha & km or Acres & miles
Optional Tyre Mode On or Off
Optional Tyre Size Rolling circumference in metres
Implement Width In metres (for area calculations)
Clock 12 hour (am/pm format)
Continue pressing Down arrow key to display this option
Date Psion only DD:MM:YY (used for

datalogging)
301330 Select the item required, using the Up and Down keys and
press Enter to select.
There are 4 levels of set-up in total (0, 1, 2 and 3), only levels
1, 2 and 3 are available to the Psion.
Level 0 Normal Display

(Available to Operator and JCB Dealers).
Level 1 Operator Set-up

(Available to Operator and JCB Dealers)
Level 2 Dealer Set-up

(Available to JCB Dealers only).
Level 3 Factory Set-up

(Available to JCB Dealers only).
9803/8020 Issue 2*
Level 1 Items (cont’d)
Setting the Tyre Size Continue pressing Down arrow key to display these options
There are two methods of setting the tyre size. These are Service Hour Counter Resets service counter after a
under Level 1 for ‘Optional Tyre Size’ and Level 2 for service has been performed.
‘Standard Tyre Size’. It is not necessary to enter the rolling Language Selects language displayed on
circumference when using the Psion, instead the tyre type EMS and transmission functions
(e.g. 520/70R30) can be selected from a list using the Left
and Right arrow keys. The rolling circumference for this To return to the Main Menu either press On/Esc or the
selection is displayed for information. Press Enter to accept Menu key and select the ‘Goto Main Menu’ option from the
these values. If the required tyre size is not in the list, then ‘Special’ menu and press Enter.
rolling circumference can be entered from ‘Set-up from
Vehicle-Type’. Example: Service Hour Counter
Example: Implement Width The service hour counter, counts down from its current value
and warns the operator, via the dashboard, that a service is
When Enter is pressed, the display will change to show the due.
currently set valve of the Implement Width in the EMS.
When this is manually set on the EMS it is only possible to
add or subtract the standard service length (250 hours) to
the current value of the service counter on the EMS. With
the Psion it is not only possible to do this but also to set the
exact value required for the service counter or to
automatically calculate the service counter value by entering
the engine hours when the next service is required.
Note: This option is below ‘Fuel Tank Size’, continue

pressing the Down arrow key to display this option.
301340
The new value suggested for the implement width is 2.0

metres (the factory default). If this is not the required value
type in the required value in metres using one decimal place
if required. (In the above example the current value is
already set to the factory default). Press Enter when the
required value has been entered. The ‘Program Specific
Items’ menu title will appear with a brief ‘DONE’ message if
the item has been successfully set up.
To return to the Main Menu either press On/Esc or the 301380

Menu key and select the ‘Goto Main Menu’ option from the
‘Special’ menu and press Enter. When Enter is pressed a new screen will appear.
Level 2 Items
PTO 1000 Ratio Engine RPM when at 1000 PTO

rpm (used for PTO display)
PTO 540 Ratio Engine RPM when at 540 PTO
rpm (used for PTO display)
Maximum Speed Sets full scale of Bar Graph in
speed display
301390
Standard Tyre Size Rolling circumference in metres
(Used for speed display) Note: To access the ‘View Current Values’ sub-menu press
Ground Speed Gear Ratio the Tab key. Pressing Enter will re-set the ‘Service Counter ‘
Calibration of transmission and ‘Engine hrs @ service’ to the displayed values.
speed sensor in pulses per road
wheel revolution.
Fuel Tank Size 250 or 350 litre. (Used for fuel
remaining display).
9803/8020 Issue 1
Level 2 Items (cont’d)

The figures displayed against ‘Service Counter’ and ‘Engine Example:
hrs @ service’ are the values the software is suggesting that
the ‘Service Counter’ and ‘Engine hrs @ service’ are re-set Current Service is 90 hours overdue.
to. (Based on current values plus the Standard Service
Length of 250 hours). Current value of Service Counter -90.0
Suggested setting of Service Counter
Normally, if the service counter was near to 0 this would be (Current value + Standard Service Length) 160.0
OK and only Enter would need to be pressed to accept the
new values suggested by the screen. The suggested setting would ensure that the next service
will be called at the right time.
However, the suggested values are not always acceptable
and may require changing. There are three methods by If the Service Counter had been re-set to 250 hours, the
which this can be carried out. next required service would also be 90 hours late.
a View Current Values Option c Engine hrs @ service Option
When this item is highlighted on the previous screen When this is highlighted (use Up and Down arrow keys)
(use the Up and Down arrow keys and then press the it is possible to enter the engine hours at which the next
Tab key) it is possible to view the values that are service is required. As this is done the Service Counter
currently stored in the EMS. The following screen will value will be calculated and displayed. To accept these
appear. values press Enter. The screen will revert to the
‘Program Specific Items’ Menu Title Screen with a brief
‘DONE’ message.
301400
This screen shows that the Service counter on the EMS

is currently at 250.0 hours and that this corresponds to
the next service occurring at 263.7 engine hours,
Press On/Esc to revert to the ‘Set the Service Hour

Counter’ screen.
b Service Counter Option
When this option is highlighted (use the Up and Down

arrow keys) it is possible to enter the required value of
the service counter. As this figure is entered the ‘Engine
hours at next service’ will be calculated and displayed.
Press Enter to accept these values. The screen will
revert to the ‘Programme Specific Items’ Menu Title
Screen with a brief ‘DONE’ message.
Note: It would be unwise to always re-set the Service

Counter to 250 hours, especially if the current service is
already well overdue.
9803/8020 Issue 1
Level 3 Items Transmission Type Format for EMS transmission

display.
Note: Level 3 items should only be changed from the Clear datalog memory Erases historic fault codes and
Factory Defaults under special circumstances. datalogging information on EMS
To return to the Main Menu either press On/Esc or the

Menu key and select the ‘Goto Main Menu’ option from the
‘Special’ menu and press Enter.
Special Menu Option
301360
Engine Pulses Alternator calibration value for

engine rpm signal, in Hz per
1500 rpm.
LED Dimming Adjusts % brightness of EMS
warning lamps when sidelights 301370
are on.
Fuel Flow Pulses Fuel meter calibration in pulses
per litre (used for fuel rate Set Factory Defaults
displays on EMS)
Fuel Return Pulses Fuel meter calibration in pulses This allows crude factory defaults to be set.
per litre (used for fuel rate
displays on EMS) See Factory Default Settings.
Radar Calibration Calibration value in Hz/mph for
radar speed sensor. Goto Main Menu
Service Length Standard service interval in
hours (used for service counter) Pressing Enter on this option returns to the Main Menu.
Pressing the On/Esc key at any time will also return to the
Continue pressing Down arrow key to display these options Main Menu.
Hitch Controller Select either EDC or EMS. Save Settings

ECD - external wheel slip switch
is fitted (no need for EMS Once all the level 1, 2 and 3 settings are correct in the EMS
enable/disable wheel slip software save this as a file on the internal memory of the
facility) Psion, in a directory of the machine serial number. Select the
EMS - no external wheel slip ‘Save Settings’ option to initiate the process by pressing the
switch fitted (EMS yellow up and down arrow keys to highlight the option.
enable/disable wheel slip
facility required).
Fuel Meter Damping Select ‘slow’ or ‘quick’
response. Cummins engines required slow
response.
Perkins engine will operate with
either slow or quick response.
Flow Divider Select ‘enable’ if a flow divider
is fitted, thereby activating the
dash lamp.
Note: If the function is ‘enabled’ 317830
when no flow divider is
fitted, the dash lamp will be permanently Press the Enter key. The ‘DONE’ message flashes briefly
lit. once the operation is carried out. The file is stored in ‘cfg’
* Fuel Flow Meters Machines fitted with optional file format, in the directory of the machine serial number,
fuel flow meters can have the under a file name based on the entry date e.g.
meters enabled or disabled using this 08071998.cfg.
option. Note: Version 5.02 EMS
software must be installed for
this option to work.
9803/8020 Issue3*
Load Settings Update EMS Software

To load the machines EMS level 1 and 3 settings file from The EMS is computer controlled and contains ‘Flash’
the Psion, select ‘Load Settings’ by pressing the yellow Up memory chips to store the computer program. This is a form
or Down arrow keys to highlight the option. of memory that can be erased and reprogrammed without
the need to remove it from the EMS.
JCB may release product enhancements or problem fixes

which require an updated program to be loaded into the
EMS. To carry out this process, press the Up or Down arrow
keys to highlight the ‘Update EMS Software’ option.
317840
Press the Enter key. A new screen appears that asks for the
EMS Setting File. The EMS automatically shows the .ctg files
stored in the directory of the serial number.
318720
Press Enter to make the selection. A new screen appears

that asks for the programme file name.
317850
Select the required file by pressing the left or right arrow

keys to scroll through a list of files stored in the Psion. When
the required file name appears press the Enter’ key to
accept.
When the operation is complete the ‘DONE’ message

flashes briefly.
9803/8020 Issue 1
Update EMS Software (cont’d)

Switch On the ignition then press Enter to continue.
Note: The EMS display may become corrupted for a short

while, this is normal.
The next Psion screen should be a bar graph showing the

progress of ‘Transmitting EMS Program’. The update will
take a few minutes, the EMS centre display should show
‘REPROG’ while the update is taking place.
301420
Select the required software file name by pressing the left or

right arrow keys to scroll through a list of files stored in the
Psion. When the required file name appears press Enter to
accept.
This may check that the selected file has not been corrupted
and may take a few minutes. A bar graph displays the
progress of the check. 301460
When the update has finished the Psion will ask for the
ignition to be switched off again. When the EMS is next
switched on, it should appear to operate normally although it
may have some new features due to its updated software.
301430
The Psion will then ask for the ignition to be switched off.
301470
Press On/Esc to return to the Main Menu.
If, during the updating process there is a problem, the

following screen may appear
301440
Switch Off the ignition then press Enter to continue.
The Psion will now ask for the ignition to be switched on

again.
301480
To try again press Enter for ‘Yes’, the Psion will attempt the
update process again. Pressing On/Esc will revert to the
‘Fastrac Main Menu’ Title Screen.
If the update fails after several attempts, check the Psion

diagnostic lead. If the lead is not faulty switch off the
ignition, remove the fuse supplying the permanent 12V to
301450 the EMS and replace it after a few seconds. If the EMS has
‘locked’ with a corrupt display this may clear it. Attempt the
update process again.
9803/8020 Issue 1
Logging Main Menu Options

d Time that the machine has been travelling greater than
20 kph
e Maximum voltage seen by the electrical system
f Maximum engine rpm
g Maximum vehicle speed
h Maximum engine coolant temperature

301490
*I Maximum transmission temperature (wet clutch
Much of the Fastrac electronic system uses a ‘CAN’ bus transmission)
(Controlled Area Network) data link to send fault codes and
other information from any ‘CAN’ connected ECU to the Note: The maximum values are erased when the data log
EMS. This then warns the driver, via the EMS centre display, memory is erased. The counters are never erased
that there is a problem. throughout the machine life. Removing the vehicle battery
will not cause the datalog, counter or maximum values to be
Once a fault code is generated by an ECU the EMS will ‘log’ lost. Only the date and time will need resetting on the EMS
it, along with the following values: after a battery disconnection.
a A unique log entry number All of the above information can be downloaded from the
EMS to the Psion to assist the Service Engineer to trace
b ‘Fault session’ number (a number representing the faults and track use history. It can also be used to establish
occasions that the machine has been switched on with if a particular fault is a real problem or whether the machine
a new fault logged) has been abused in some way, (e.g. running on overheat for
thirty minutes on several occasions). This information may
c Date also assist to support or reject warranty claims.
d Time The data logging menu options may be displayed by

selecting the ‘logging’ option from the ‘Main Menu’ by first
e Fault code pressing the Menu key then pressing the Left and Right
arrow keys to highlight ‘Logging’.
f Engine hours
g Total distance in kilometres
h Whether the fault occurred or disappeared (some fault

codes only log if the fault occurred)
i Engine rpm
j Ground speed shown on speedometer

301490
k Coolant temperature
* l Transmission temperature (wet clutch transmission) The ‘Logging’ menu options are then displayed and the
option required can be highlighted by pressing the Up and
These datalog entries are stored in the EMS memory like Down arrow keys. Pressing Enter will select the option.
‘snapshots’ of the vehicle system when a fault occurs.
As well as these fault codes, the EMS will also store a

number of counters and maximum values that the machine
has seen. These can also be viewed by the Psion and are:
a Time that the clutch beeper has been operating at high

engine rpm
b Time that the clutch beeper has been operating at low

engine rpm
c Time that the PTO has been operated
9803/8020 Issue 2*
Logging Main Menu Options (cont’d)

Options Available When the download is complete the Psion will save the
information as a file for future use. A bar graph will display
a Download Data Log the progress of the save.
This downloads the Fault Code Logs (Data Logs) from

the EMS to the Psion for viewing. The Data Log is also
stored on the Psion as a file that can be viewed at a
later date or transferred to a PC.
b Erase Datalog Memory
This clears all of the Data Logs from the EMS memory,
also re-setting the maximum values to zero. This option
should only be chosen if the EMS Data Logs have been 301510
recently downloaded or are not required. Once erased,
the Data Logs in the EMS cannot be restored. Note: This display may appear twice during the save.
*c Load file When the file save has finished a new screen will appear
asking if the Data Log memory should be erased.
This allows the Psion to view a Data Log file that was
previously downloaded from the EMS. The Psion does
not have to be connected to the vehicle to do this. This
file includes the counter and maximum values which
are saved with the file date.
Download Data Log

Highlight the option by using the Up and Down arrow keys.
* 301520
This shows how much available memory is used as a

percentage value. If this value is quite high (e.g. 50%) select
‘Yes’ by pressing Enter. Otherwise select ‘No’ by pressing
On/Esc.
The datalog will then be displayed in a ‘summary’ screen,

this shows a brief list of all fault codes logged with their
respective log numbers and engine hours.
318730
Pressing Enter will start downloading the Data Log from the
EMS to the Psion. A bar graph will display the progress of
the download.
301530
‘Log 1’ is the first fault code stored by the EMS. The log
numbers increase by one after every fault code log entry is
made. The status column on the right of the screen shows a
cross when a fault code was logged as ‘occurred’, or a tick
301500 when logged as ‘disappeared’ (‘D’ type fault codes only at
present).
9803/8020 Issue 2*
Logging Main Menu Options (cont’d)

To scroll up and down the list press either the Up or Down View menu
arrow keys. *
The Data Log that is marked by the small triangular cursor
on the left of the screen can be viewed in more detail by
pressing the Enter key. The screen then changes to the
‘detailed’ screen showing all of the values in that Log.
301560
The options ‘Detailed’ and ‘Summary’ select the required

level of detail for the information screen. Highlight the
required option using the Up or Down arrow keys and press
Enter to select. This is similar to pressing Enter to switch
301540 between the two information screen types.
* The log entries can still be scrolled up and down by pressing Filter menu
the Up or Down arrow keys. To get back to the summary
screen press Enter. When viewing the summary screen,
page up and down by pressing the ∪ key with the Up/Down
arrow keys.
Download Data Log Menu Options

* Once the Data Log has been downloaded from the EMS
another set of menu options is available to view the data. 301570
These options are available from both the ‘summary’ and

‘detailed’ information screens. This menu option allows the Data Log information screen to
be selective about which Data Logs are displayed. This
To access these options press Menu. option is particularly useful if there are a large number of
* Data Logs and only certain ones need to be viewed.
The items under the ‘Filter’ menu can be highlighted by

pressing the Up and Down arrow keys and selected by
pressing Enter.
Note: Having selected a Filter option it is possible to obtain

a description of a particular fault. Highlight it on the screen
using the Up and Down arrow keys and then press Tab.
This will bring up a screen such as the one below. Press Esc
to return to the original list.
301551
*
Options Available
Comm menu
*
317870
301551
This set of sub menus is a duplicate of the options found in

the ‘Logging’ option of the Main Menu.
9803/8020 Issue 2*
Download Data Log Menu Options (cont’d)

* Filter Menu (cont’d) Example
Options Available
If all occurrences of fault code T016 are required, type in
All T016 and press Enter.
301570
301610
Displays all Data Logs as normal The Data Log information screen will now only display those
Data Logs caused by fault code T016.
Transmission
301580 301620
Displays only transmission Data Logs (‘T’ type fault codes) Displaying a particular range of fault codes is also possible
by using a ‘wildcard’ entry. The wildcard allows any digit to
‘pass-through’ the filter at that point. The symbol for the
wildcard is ‘*’.
Example
To display all ‘T’ codes from T010 to T019, the filter would
be T01*
301590
Display
Displays only EMS Data Logs (‘D’ type fault codes)
Other
301630
When Enter is pressed the Data Log information screen will

display all Data Logs caused by fault codes starting with
T01.
301600
This option allows the user to customise the Data Log Filter.
Pressing Enter will select this option when highlighted and
the software will ask for a filter to be entered.
9803/8020 Issue 2*
Download Data Log Menu Options (cont’d)
* ‘Fault Description’
*
301640
301651
Any number of wildcards can be used in any of the 4 fault
code digits (e.g. entering **** as the filter would cause all
Data Logs to be displayed). * To obtain a further description, press Menu and select Goto
Main Menu. Press the On/Esc key enough times to step
To scroll up or down the list press either the Up or Down back to the Download Data Log Menu options.
arrow keys.
* From the Filter menu bring up the relevant Data Log and
select the required fault. Press Menu and select Special
* Special Menu
followed by ‘Fault Description’.
*
* If a number of fault descriptions are required proceed as per
the ‘short-cut’ described in the ‘Note’ under Download
Data Log Menu Options, Filter Menu.
* This option provides a description of the fault selected in the

Filter option from the Data Log menu. Selecting ‘Fault
Description’ displays a description such as the typical
example below.
301651 *
* This menu provides additional functions which may be

useful in interpreting the Data Log information.
* Highlight the required menu option by pressing the Up and

Down keys and then press Enter to select.
317870
9803/8020 Issue 2*
* Download Data Log Menu Options (cont’d) * Erase Datalog Memory Option
* Create Engineering File Note: Do not select this option unless you are sure that the
Data Log stored in the EMS is no longer required.
Once erased the Data Log in the EMS cannot be
restored.
317880
Selection of this option initiates the generation of an

engineering file which is a more detailed log file intended for 301660
JCB Landpower use.
Press Enter to select this option.
Collection of the data may take a few minutes, with a bar
graph indicating progression of the collection. The Psion will display the amount of Data Log memory being
used in the EMS as a percentage. Confirmation is required
before erasing the Data Log from EMS memory.
317890
Once all the data has been collected the Psion writes the
301520
engineering file. This may also take a few minutes with a bar
graph charting progress.
If the percentage used is high (e.g. 50% or more). Press
Enter to start the erase process or press On/Esc to return
* Goto Main Menu to the Main Menu Title Screen.
Pressing Enter returns the user to Main Menu.
* Load File Option

General Information
When a Data Log is downloaded from the EMS it is

automatically stored in the Psion with the following
parameters:
The Psion creates a new directory (if required) using the 7

317900 digit Serial Number of the machine as the directory name.
This directory will be used to store all Data Logs
Note: To revert to a stage somewhere between the current downloaded from that machine.
position and the Main Menu, step back one stage at a time
using the On/Esc key. Note: If the EMS is not set-up correctly with a VIN number,
the directory ‘_NO_VIN’ will be created.
The Psion then chooses a filename for the Data Log. This
filename is in two parts, the first is an 8 digit name (made
from the date of the download) followed by a 3 character
extension.
9803/8020 Issue 2*
Load File Option (cont’d)

* The extension is in the form ‘.lg*’, where ‘*’ can be any * Use the Up and Down keys to scroll through the list and
character (0 to 9 and A to Z). The first Data Log has ‘0’ in highlight the required directory.
place of *, the second Data Log will have ‘1’ and so on up to
9, after which the letters A to Z will be used. This allows 36 *
Data Logs to be stored from the same machine on the same
day, before the first file will be overwritten.
* Example
Machine Serial Number 0738052

Date 14 Feb 1998
The Psion will create the directory ‘0738052’ (if it does not
301700
already exist).
The first download will have the filename ‘14021998.lg0’ * Press Enter to display the contents of the directory.
A second download (on the same date) will have the *
filename ‘14021998.lg1’
* Selecting a File to Load

*
301710
* As shown in the above example, 3 downloads where made

on 13 Feb 1998. Highlight the required file using the Up and
301671
Down keys and press Enter to select.
*
* Press Enter with this option highlighted to select.
* The EMS Serial Number selection screen will be displayed.

*
301720
* The Psion will show the name of the selected file, to

continue loading this file press Enter, otherwise press
301681
On/Esc.
* Use the Left/Right arrow keys to select the relevant serial

number and then press Enter.
* Press the Tab key to display the contents of the Psion’s root
directory.
*
301690
9803/8020 Issue 2*
Load File Option (cont’d) Diagnostics - Transmission
Selecting a File to Load (cont’d) *
While the selected file is loading, a bar graph will display its
progress.
318361
Pressing the Enter key with this option highlighted accesses

the ‘Transmission ECU Diagnostics’ mode, as indicated by
301730
the screen below.
When the file has finished loading the Data Log information
screen will be displayed in ‘summary’ mode.
318380
Press the Menu key to reveal the options (‘Values’, ‘Inputs’,

‘Outputs’ and ‘Special’) as shown below. Select the desired
301530 option using the Left and Right arrow keys.
Press the Menu key to access the Data Log Menu.
Diagnostics
* When this main menu option is highlighted a number of
options are shown in a list below. ‘Wet Clutch’ option only
appears for machines with a wet clutch transmission.
*
318390
The Menu options provide the following menus:
‘Values’ menu
318361
This option provides a status report of the various inputs

and outputs, and values for the EMS or the Transmission
Controller.
Note: These functions can be carried out with the engine 318390
running to allow diagnostics to be carried out.
This menu option allows the input or stored values from the
Transmission Controller to be checked. Information includes:
Rpm which include Actual and User Mode values (User
Mode includes rpm change points of the Autoshift).
Distance travelled
Clutch pack calibration times
9803/8020 Issue 3*
Diagnostics - Transmission (cont’d)

‘Inputs’ menu Pedal Switches
318400 318430
This menu option allows the status of the various inputs to * Shown the status of the ‘Clutch Up’† and ‘Clutch Down’†
the Transmission Controller to be checked (‘on’ or ‘off’). The switches and the Throttle and Handbrake switches.
Psion constantly updates the display to the current status.
* † - Dry clutch transmission only. for diagnostics on the wet
Column Switches clutch pedal see Diagnostics - Wet Clutch.
(Off = switch closed = 0v at ECU input for ‘handbrake’,

‘throttle’ and ‘clutch up’, On = switch open = 12v at ECU
input for ‘clutch down’.)
Speed Triggers
318410
Shown the current status of the Selectronic column switches

for Low, High, Medium and Reverse (switch closed - 0v at
ECU input).
Ram Switches 318440
Shows the status of the three speed triggers 1, 3 and 20 kph

(<means speed less than, > means speed greater than).
Gear Knob Switches
318420
Shows the current status of the Selectronic ram switches.

(Off = switched closed = 0 v at ECU input).
318450
Shows the status of the switches and if they are functioning

correctly.
9803/8020 Issue 2*
Diagnostics - Transmission (cont’d) Diagnostics EMS

‘Outputs’ menu
S318491
318460
Pressing the Enter key with this option highlighted accesses
the ‘EMS ECU Diagnostics’ mode as indicated by the screen
Solenoid Status below.
318470
318500
Shows the status of the three speed solenoids, on (12V) or Press the Menu key to reveal the options (‘Values’, ‘Inputs’,
off (0V), along with a serviceability status (OK or Fault). A ‘Outputs’ and ‘Special’) as shown below. Select the desired
solenoid shown as off (0V) and a fault status of OK may have option using the Left and Right arrow keys.
been switched off by the ECU due to a fault. ‘Rev Lmps’
only appears for machines with dry clutch transmission.
‘Special’ Menu
318510
These Menu options provide the following menus:

318480
‘Values’ Menu
This menu option provides a way back to the Main Menu.
318510
Allows the values on the dash display to be checked e.g.

gauges.
9803/8020 Issue 3*
Diagnostics - EMS (cont’d)

‘Values’ Menu (cont’d) ‘Range Display’
318530 318570
This shown the signal values and what they actually mean * Provides a means of checking the current range status from
e.g. @ 38 °C the input voltage is 2.607 V. the transmission ECU and of verifying the dash. ‘Current
Gear’ only appears for machines with dry clutch
‘Inputs’ Menu transmissions.
* ‘Autoshift Display’ (only appears for machines with dry

clutch transmission).
318540

318580
‘LED Inputs’
Provides a means of checking the Autoshift dash displays

are functioning correctly by monitoring the outputs of the
transmission ECU.
‘Centre Display’
318550
Checks the actual display with the inputs into the dash.
‘EMS Buttons’
318590
This option checks that the EMS inputs correspond with the
dash.
318560
Provides a means of testing the buttons on the dash.
9803/8020 Issue 2*
Diagnostics - EMS (cont’d)

‘Inputs’ Menu (cont’d) ‘Diff Lock Cut-out’
‘Diagnostics’
318630
318600
Shows the status of the diff-lock cut-out at the relay
This option checks for the presence of axle speed contacts.
sensor/radar detected inputs along with the status of the
Programme input line. The ‘Prog Input’ option is only used ‘Speed Triggers’
when updating the Psion software.
‘Outputs’ Menu
318640
Shows the status of the speed trigger outputs.

318610
‘Special’ Menu
‘Faults Status’
318650
This menu option provides a way back to the Main Menu.

318620
Reports if faults occur in any of the speed triggers, diff-lock

cut-outs and relays.
9803/8020 Issue 1
* Diagnostics - Wet Clutch

The options are:
‘Position’
S360370
Pressing the ‘Enter’ key with this option highlighted will enter
S360400
into the ‘Wet Clutch Diagnostics’ mode.
Shows the current position of the clutch pedal in terms of

how the ECU interprets it (bits), how the ECU reads if (Volts)
and as a percentage of the calibration values.
‘Mapping’
S360380
Press the ‘Menu’ key to reveal the options (‘Pedal’, ‘Values’,

‘Misc’ and ‘Special’) shown below.
S360410
The ramp information describes the amount of clutch

engagement relative to clutch pedal position. This effects
the ‘feel’ of the pedal. These numbers are intended for
viewing and cannot be changed. The clutch bite point
indicates the percentage pedal position at which the clutch
will bite.
S360390 ‘Calibration’
The menu options provide the following menus:
‘Pedal’ Menu
S360420
These numbers are obtained during calibration. The pedal

up/down values are the values read by the ECU with the
pedal in the fully up/down position respectively. The
S360390 Calibration temperature is the wet clutch oil temperature
Options under the ‘Pedal’ menu relate to the clutch pedal during calibration and the calibration current is the current
position, mapping of the clutch pedal characteristics and through the master clutch solenoid required to drop the
values obtained during the calibration. engine speed by 100 rev/min during calibration.
9803/8020 Issue 2*
* Diagnostics - Wet Clutch (continued)

‘Values’ Menu ‘Misc’ Menu
S360460
S360430
The ‘Misc’ menu displays miscellaneous information relating
This menu displays options that give the ability to view the to wet clutch vehicles.
current status of the master wet clutch current and auxiliary
clutch status. ‘Auto Reverse’
‘Master Clutch Currents’
S360470
The ‘Auto Reverse’ option displays the status of the Auto

Reverse button and information relating to the Auto Reverse
S360440
characteristics which cannot be changed.
The ‘Required mA’ value is the current the ECU wants to
achieve for a command signal to the master clutch solenoid. Note: ‘Auto Reverse’ is also known as ‘Auto-Shuttle’ .
The ‘Measures mA’ value is the current the ECU measures
for a given command signal. These numbers will differ ‘Transmission Oil’
slightly.
‘Aux. Clutch Solenoids’
S360480
This option displays the current bulk and master clutch oil
temperatures. Bulk refers to the oil in the main transmission
lubrication circuit.
S360450
This option shows whether the Auxiliary clutch solenoids ‘Special’ Menu
(clutch lubrication solenoid and transmission brake solenoid)
are on or off along with the fault and status indicators. If
there is a fault the ECU may have switched the solenoid off
which resets the fault status to OK. (‘Lube Rate’ Low = 12 V,
High = 0 V and ‘Clutch Brake’ Off = 0 V On = 12 V).
Note: ‘Clutch Brake’ is also referred to as ‘Transmission

Brake’ in other parts of this manual.
S360490
This allows a way out back to the main menu.
9803/8020 Issue 2*
Special Main Menu Options

Highlight this option on the Main Menu using the Left and Delete Files
Right arrow keys.
301761 318660
These options give information about the EMS fitted to the Pressing Enter with this option highlighted will ask you to
machine and the software version in the Psion. The required select an EMS serial number.
option can be highlighted by pressing the Up or Down arrow
keys.
EMS Information
301681
Select the required software file name by pressing the Left

301761
or Right arrow keys to scroll through a list of files stored in
the Psion. When the required file name appears press the
Pressing Enter with this option highlighted will cause the Enter key to accept.
Psion to interrogate the EMS and display the following
information: The Psion will then ask whether to ‘delete files older than 30
days’.
a Machine VIN
b JCB part number of EMS fitted
c Hardware revision number on internal EMS electronics
d Software version that is currently loaded in the EMS
e The Manufacturer of the EMS Esc Enter

f The Manufacturers part number for the EMS.
318680
This value can be changed using the numerical key pad. If it

is required to delete all files then use 0 days. Pressing the
Enter key confirms this and deletes the appropriate files.
This also deletes setup (.cfg) and engineering files (.eg)
To return to the Main Menu press the On/Esc key.
301770
To return to the Main Menu press Enter or On/Esc.
9803/8020 Issue 1
Special Main Menu Options (cont’d)

Preferences
318690 301791
Pressing Enter when this option is highlighted will allow the

language to be selected. This displays the software version currently running in the
Psion. In the above example it is version 2.12. It also shows
the most up-to-date EMS software file name that will be
used in the set-up programme for automatic updating.
To return to the Main Menu press Enter or On/Esc.
Exit
318700
Select the required language by pressing the Left or Right

arrow keys to scroll through the list of available languages
stored in the Psion. When the required language appears
press the Enter key to accept.
To start operating the new language, the ‘gst’ program must 301800
be restarted.
Pressing Enter with this option highlighted will exit the
About Fastrac Service program.
301781
Pressing Enter with this option highlighted will display

information about the Psion Fastrac Software.
9803/8020 Issue 1
Error Codes Factory Default Settings

Displayed Error Codes The items below are set to the factory defaults when the ‘Set
factory defaults’ option is chosen from the ‘special’
Most Transmission Electronic Control Unit (ECU) and submenu of the ‘Programme Specific Items’ menu. Also the
instrument panel Electronic Management System (EMS) ‘Set-up from VIN’ and ‘Set-up from Vehicle Type’ options
errors are drawn to the operator’s attention by the flashing set these factory defaults before setting the items peculiar to
of the ‘book’ icon on the instrument panel. This is the machine being set up.
accompanied by the showing of error codes on the centre
display. The errors are also logged in the Data Log to aid Level 1 Settings
fault diagnosis.
Units for speed display mph
Non-Displayed Error Codes
Units for centre display acres & miles
There are certain fault codes that are used for datalogging
Optional tyre mode Off
purposes but are not displayed to the driver. This is because
these codes represent “abuse” information as opposed to Optional tyre size as standard tyre size
an actual failure of the vehicle electrical system. E.g. If the oil
pressure warning lamp is on for more than 10 seconds of Implement width 2.0 metres
engine running a fault code will be generated inside the EMS
for datalogging purposes. The driver does not see this code * Clock current time stored by Psion or
as the condition is indicated by the warning lamp. laptop computer
Both displayed and non-displayed codes may be accessed * Date current date stored by Psion or
via the Psion Workabout, see Download Data Log Menu laptop computer
Options, this Section. Level 2 Settings
PTO 1000 ratio 1986

* For diagnosis of the Error Codes, together with suggested
remedial action, see Diagnostic Error Codes - General, PTO 540 ratio 1894
this Section.
Maximum speed 80 kph
Standard tyre size 4.615
Ground speed gear ratio 430.0
Fuel tank size 350 litre
Service hour counter 250 hours
Language English
Level 3 Settings
Engine Pulses 363 Hz per 1500
LED dimming 50 %
Fuel flow pulses/litre 1000 pulses/litre

Fuel return pulses/litre
Radar calibration 59.30 Hz/mph
Service length 250 hours
Transmission type LMHR display
Clear datalog memory YES
Hitch controller EMS (no external wheel slip

switch)
Fuel meter Slow response
Flow regulator Disabled
9803/8020 Issue 4*
Set-up values from VIN or Vehicle Type 34 - 2
When the ‘Set-up from VIN’ or ‘Set-up from Vehicle Type’ options are used the factory defaults are used as a basis for the set up. After this specific items are set-up
9803/8020
that are peculiar to that machine (e.g. tyres).
Section C
Table of Configuration Values for Psion Setup of Vansco EMS
Machine Rated PTO PTO Speed Max Bar Alternator Comments VIN code trans nominal
Type Speed 1000 540 Sensor Graph Setup † prefix engine max
km/h pulses Speed Hz/1500rpm speed
wheel rev km/h km/h
3185 80 2196 2002 430 85 355 sometimes called 75 km/h SLPFT 10 7 75
3185 65 2196 2002 581 75 355 SLPFT 10 6 65
3185 50 2196 2002 581 55 355 as 65 km/h but 6th gear blocked SLPFT 10 5 50
3185 40 2196 2002 693 45 355 SLPFT 10 4 40
3155 80 2196 2118 431 85 370 sometimes called 75 km/h SLPFT 07 7 75
3155 65 2196 2118 574 75 370 SLPFT 07 6 65
3155 40 2196 2118 684 45 370 SLPFT 07 4 40
2150 50 1986 1894 684 55 370 SLPFT 16 5 50
Electrics
2150 30 1986 1894 684 35 370 as 50km/h but HIGH range blocked SLPFT 16 3 30
*
Psion Workabout
2140 50 1986 1894 544 55 450 SLPFT 20 C 50
*
2140 40 1986 1894 544 45 450 SLPFT 20 C 40
2135 50 2088 1894 544 55 370 SLPFT 15 5 50
2125 50 2088 1894 544 55 370 SLPFT 14 5 50
2115 50 2088 1894 544 55 370 SLPFT 13 5 50
*
For the 2115, 2125, 2135 and 2140 models the fuel tank is set to 250 litres. The language is set depending upon country of use.
† From Psion software V2.15 onwards
Issue 4*
34 - 2
Section C
35 - 1 Four-Wheel Steer (4WS) (if fitted) 35 - 1
Sensors
It will normally only be necessary to remove a steering
*
sensor (potentiometer) if it needs renewing. The installation
is virtually identical on the right side front and rear axle
trunnions. B
Removal
1 Disconnect the electrical connector on the sensor flying

leads from the harness connector attached to cover
plate A.
A
*2 Remove the four trunnion mounting studs B and gently
ease cover plate A (with the flexible and rigid hydraulic
pipes still attached) clear of trunnion C, taking care not
to bend or damage the Bundy pipe.
3 Remove the two retaining screws D and lift out sensor D

E from the recess in trunnion C. Only remove spindle F
if necessary.
E
Replacement
Replacement is the reverse of removal. F

After replacement or removal of a sensor it is necessary to
re-calibrate the sensors (see Calibration on the following
page).
C
When Replacing
1 If appropriate, install sensor spindle F, via the centre

hole of trunnion C, so that its flat end locates in the
machined slot in the axle beam. With the axle in the
straight ahead position the flat on the top ‘D’ section of
the spindle should be at approximately 60° to the
centre-line of the axle beam G (as shown bottom right)
(see Note below).
Note: It is possible to, but important not to, locate the A243551
spindle 180° out of phase. Incorrect spindle installation
renders correct calibration impossible.
2 Locate sensor E on the spindle with its connecting

wires facing upwards and in line with the slot in the
trunnions. The shallow spigot on the bottom face of the
sensor should locate in the recess in the centre of the E
trunnion. Do not overtighten the fixing screws.
60º
3 To make the installation waterproof, apply JCB Clear
Silicone Sealant to the mating surfaces of cover plate D
A and trunnion C, and also liberally to the groove in the
trunnion and the sensor wires which run through it. G
Torque Settings F C
*B See Note below.
D 3.5 0.36 2.6
A243560
* Note: Refer to Front Axle and Rear (4WS) Axle, Hub and
Driveshaft, Assembly in Section F.
9803/8020 Issue 2*
Sensors (cont’d)
Calibration
Note: This procedure must be carried out whenever a

steering sensor (potentiometer) has been disturbed or if the
4WS electronic control module has been replaced by
another unit. (The electronic control module can be removed
2 O/R
and the same one refitted without re-calibration.)
1
1 Ensure that the machine is parked on even, level
ground, free from obstacles that would restrict wheel
movement. Check that the front and rear wheel
alignment is correct (see Tyres and Wheels, Checking
and Adjusting Wheel Alignment in Section 3). 4 4
2 With the engine running, select 2WS and operate the A B

steering so that the rear wheels lock in the straight
ahead position. Then use a suitable method to set the
front wheels straight ahead.
Switch off the engine, leaving the ignition key in.

4 4
3 To calibrate the front axle: C D

a Press and hold buttons A and C while turning the
ignition to ‘ON’. Do not start the engine.
b Continue to hold the buttons until the 2WS LED

above 2WS button 1 flashes (approximately 15
seconds).
c Release buttons A and C and then press 2WS

button 1. After a short time the 2WS LED stops
flashing and lights continuously.
d Turn the ignition ‘OFF’ to complete front axle

calibration.
4 To calibrate the rear axle:
a Press and hold buttons B and D while turning the

ignition to ‘ON’. Do not start the engine. A248960
b Continue to hold the buttons until the 2WS LED

above 2WS button 1 flashes (approximately 15
seconds).
c Release buttons B and D and then press 2WS

button 1. After a short time the 2WS LED stops
flashing and lights continuously.
d Turn the ignition ‘OFF’ to complete rear axle

calibration.
9803/8020 Issue 1
Electronic Control Unit (ECU)
Bulb Renewal
This procedure covers the two bulbs behind the ‘Tick’ and
‘Cross’ icons and the single fibre optics bulb. It is
recommended that all three bulbs be renewed at the same
time, i.e. while the unit has been dismantled. Proceed as
follows:
1 Switch off the ignition.
2 Remove the four screws A securing panel B to housing

C.
3 Remove the panel, complete with the ECU, from the

housing and disconnect at the ECU from its cab
harness connector.
4 Remove the 12 screws securing panel B to the ECU

and carefully separate the two. Note the orientation of
the grey wires connecting the two items and
disconnect at the ECU end.
Note: Do not disconnect the grey leads at the panel end to

avoid the possibility of wrongly reconnecting them later.
A
5 Remove the two screws securing the fibre optic ‘steady
bar’ to the panel. Lift the ‘steady bar’ and fibre optic
assembly away from the p.c.b. to expose the bulb. The
three bulbs should now be accessible.
O/R
6 The bulbs are a push-fit into their holders where they

are secured with a blob of ‘hot melt’ glue to prevent 2
them being vibrated loose. Carefully use a blade to

remove the glue after which it should be possible to pull 4
out the bulbs. 4
Note: It is important that only the bulbs specified below are

used as replacements. Use of any other types could damage
the ECU and/or provide unsatisfactory illumination. B
7 Fit new bulbs of the following types:
‘Tick’ and ‘Cross’ bulbs C A302010

(Bi-pin T 13/4 in, 14V, 1.12W)
‘Fibre optic’ bulb
(Bi-pin T 13/4 in, 18V, 1.12W)
8 When fitting the bulbs, take care to align their pins with
the receptacles in the bulb holders. Secure with a blob
of ‘hot melt’ glue applied with a commercial glue gun.
In the absence of a glue gun, but only as a temporary
solution, wrap masking tape around the barrel of the
bulb so that it grips the holder.
9 Re-assemble the ECU by reversing steps 3 to 5 above.
10 Switch on the ignition and check ECU operation.
9803/8020 Issue 1
40 - 1 Diagnostic Error Codes - General 40 - 1
Diagnostic Error Code Tables

Error codes are able to identify individual faults within the system. It is unlikely that individual error codes will be generated
erroneously by either the EMS or Transmission ECU. In the unlikely event that either of these units should fail, there will be a
major failure.
Before any diagnostic work is carried out, it is recommended that the initial start up sequence is watched closely to ensure that
the both the EMS and the Transmission ECU are functioning correctly.
To check both units, turn the starter key to ‘ON’.
For a period of approximately 3 seconds the display is tested. Ensure that each of the display segments on the EMS
display are functioning. Check that all of the display lamps are also illuminated.
Ensure that the external buzzer sounds following display test; if not check the buzzer.
If any of this does not happen, suspect a fault within the EMS. Reprogramming the EMS may cure this; if this fails, change
the EMS.
Following directly on from this, the centre display will display “HELLO” (dry clutch transmission) or “HI THERE” (wet clutch
transmission) for approximately 2 seconds. This is done to inform the operator that the data link between the
Transmission ECU and the EMS has been established correctly.
If this does not happen, suspect the Transmission ECU is disconnected, or has an internal fault. Check all connections
between the EMS and Transmission ECU, particularly the CAN bus. Turn the ignition off and on again to retest; if the fault
persists, change the Transmission ECU.
The dashboard will then revert back to its normal operation mode.
Non-displayable Fault Codes
There are certain fault codes (D224 - D236 and T230) that are used for datalogging purposes but are not displayed to the
driver. This is because these codes represent “abuse” information as opposed to an actual failure of the vehicle electrical
system. E.g. If the oil pressure warning lamp is on for more than 10 seconds of engine running a fault code will be generated
inside the EMS for datalogging purposes. The driver does not see this code as it is already supported by the warning lamp.
Remember that the codes are historical data and oil levels, etc., may have been corrected since the faults were recorded
In the following tables, the possible causes for each error code are listed in order of probability, and should always be checked
in the order given.
Instrument Cluster Internal Error Codes
Code Description Possible Cause Action and Remedy
D001 EMS ROM memory EMS internal fault. Reprogram EMS using updated
error. software. Change EMS if problem
persists.
D002 EMS EPROM May occur once after updating EMS software Switch off ignition and switch on. This
memory error. or setup values. should clear code.
EMS internal fault. Change EMS.
D003 EMS CAN Bus EMS has detected a problem with the Check CAN Bus link for short or
switched off. CAN Bus link. open circuit.
(continued)
9803/8020 Issue 4
D010 Datalog memory The Datalog memory has reached capacity Download Datalog memory, investigate
full. and can no longer store new error codes. codes and erase Datalog memory.
Note: This code was removed at new If required, update EMS software to latest
software introduction JCBV0400.HEX. version.
Handbook warning icon now illuminates
if datalog becomes full.
D020 Speed sensor Speed sensor supply fuse ruptured. Check speed sensor supply fuse.
“present” line
disconnected. Speed sensor disconnected. Check speed sensor connected.
Poor continuity of speed sensor supply line With the ignition turned on, check for the
and “present” line. presence of +12V at “present” line input
to EMS.
D021 Speed sensor is This error is an ASSUMPTION, as the tractor Check function and operation of the speed
assumed to have appears to have been driven, but the EMS has sensor using a multimeter or the diagnostics
failed. not received any signals from the speed function of the PSION Workabout.
sensor.
May be caused by repeatedly operating Advise operator of cause to prevent further

the Selectronic range change with the recurrences.
tractor stationary and the park brake off.
Damaged wiring. Check continuity of signal line from speed

sensor to the EMS.
Note: If this error occurs, the EMS sets the

speed triggers to illegal settings which make
the tractor usable but safe, causing error
code T060, and disabling Selectronic High
and Medium ranges.
* D022 Propshaft speed over Engine speed limiter has become Check wiring from the gearbox speed sensor
4750 rpm disconnected. to the engine ECU.
D030 Radar sense line Radar supply fuse ruptured. Check radar supply fuse.
disconnected.
Radar disconnected. Check radar connected.
Poor continuity of radar supply line and With the ignition turned on, check for the
“present” line. presence of +12V at “present” line input to
EMS.
This code is deleted from
JCBV0301 onwards, replaced by flashing
radar symbol and non-displayed code
D236.
D031 No Bosch slip point Break in wiring between EMS and Bosch Check integrity of wiring from EMS to the
signal. Hitchtronic ECU. Bosch ECU.
Options connectors have been joined on Disconnect options connectors; refer to wiring
tractor without option package fitted (radar diagrams.
and fuel meters).
Faulty Bosch ECU, or wrong type of Bosch Check Bosch ECU part number is correct
ECU fitted. for options package fitted or change ECU.
9803/8020 Issue 3*
D032 No fuel meter Air in fuel lines means meter is not turning. Check fuel lines and check Datalog to see
return signal. (Can occur briefly in return line when first engine rpm when fault recorded.
starting engine; from JCB V0500 software,
condition must persist for 20 seconds).
D033 No fuel meter
feed signal. Fuel meter is sticking. Check fuel meter function and operation.
Options connectors have been joined on Disconnect options connectors; refer to wiring
tractor without option package fitted (radar diagrams.
and fuel meters).
Damaged wiring. Check integrity of wiring from fuel meter to the

EMS.
D034 Fuel meter signal This code was used in JCBV0301 only. Check connections, referring to wiring
lines appear to have diagrams.
been swapped over. Update EMS software.
* D035 Multiple torque curve Multiple torque curve wiring fault or Check wiring.
selection error. tampering
D040 Both PTO 1000 and Sometimes occurs when changing PTO speed Check Datalog to ensure that engine rpm was
PTO 540 selected. selector if ignition is on, as the two switches zero when code was logged. Advise operator
are close to each other and lever has short of need to switch engine off before changing
travel. PTO speed.
Damaged wiring or short circuit switch. Check integrity of wiring from PTO selector to
the EMS and operation of both switches .
D041 Engine rpm over Tampering with fuel injection pump settings. Check fuel injection pump; refer to engine
2850 rpm. manual.
Engine over sped by, for example, travelling Check for signs of overspeeding; refer to
downhill. engine manual.
EMS calibration figures incorrectly set up. Check calibration figures in EMS setup.
D042 Over voltage Faulty alternator/voltage regulator. Check supply voltage.

detected (>16V)
Jump start attempted from 24V battery. Only use 12V battery for jump start.
D050 Coolant temperature Faulty sensor. Check sensor for operation and function.
sensor open circuit
(after 20 minutes Damaged wiring. Check continuity of wiring from sensor to the
running). EMS.
D051 Coolant temperature Faulty sensor. Check sensor for correct operation and
sensor short circuit. function.
Damaged wiring. Check integrity of wiring from sensor to the

EMS.
D052 Fuel tank level Sometimes occurs when fuel tank filled. Update EMS software.
sensor short circuit. This code deleted from JCBV0200 onwards.
9803/8020 Issue 4*
Notes for Non-displayable Fault Codes:
† Fault must be present for 10 seconds with the engine running before the code is logged.
†† Fault must be present for 1 minute before the code is logged.
‡ Code will be logged if the vehicle has been moving at > 1 kph and the fault present for 5 seconds.
Non-displayable Fault Codes
D224† Engine oil pressure Low engine oil pressure. Check engine oil pressure; refer to engine
low. service manual for causes of low oil
pressure.
Faulty engine oil pressure switch. Check pressure switch for correct operation.
Damaged wiring. Check integrity of wiring from switch to EMS.
D225† Transmission oil Low transmission oil pressure. Check transmission oil pressure; see
pressure low. Transmission, Section F.
Faulty transmission oil pressure switch. Check pressure switch for correct operation.
Damaged wiring between switch and Check integrity of wiring from transmission
Transmission ECU. oil pressure switch to Transmission ECU,
noting that one pressure switch pin
connects to two ECU pins; refer to wiring
diagrams.
Damaged wiring between Transmission Check integrity of warning light wiring from
ECU and EMS. Transmission ECU to EMS; refer to wiring
diagrams.
D226† Transmission oil Blockage in transmission oil filter. Change filter, see Changing the
filter blocked. Transmission Oil Filter, Section 3.
Note: It is important also to investigate the

cause of the filter blockage, see
Fault Finding in Transmission, Section F
for other symptoms or defects which could
be associated with this fault.
Faulty blockage switch. Check pressure switch for correct

operation.
D227† Air filter blocked Blockage in air filter. Change the outer air filter and also the
inner filter if required; see Changing the
Air Filter Elements in Section 3.
Faulty blockage switch. Check pressure switch for correct

operation.
D228† Trailer ABS fault Signal from trailer ABS system. Investigate trailer system.
(continued)
9803/8020 Issue 3
Non-displayable Fault Codes (cont’d)
D229† Alternator “No Slack or worn alternator drive belts. Check alternator drive belt tension and
Charge” warning. condition. See Adjusting the Fan Belt(s),
Section 3.
Internal alternator fault. Check alternator output and operation, see

Charging Circuit Test, this Section.
D230† Brake fluid level low. Low brake fluid level in one or both actuator Check level of fluid on both brake fluid
reservoirs. reservoirs.
Faulty fluid level switch. Check operation of switches by pressing

test buttons on switch body.
D231‡ Air tank 1 pressure Low pressure in air tank. Check for leaks, etc.
low.
Faulty air pressure switch. Check air pressure switch fo correct
D232‡ Air tank 2 pressure operation and function.
low.
Air tank not charging. Check operation of circuit protection valve.
D233‡ Air tank 3 pressure
low. Damaged wiring. Check integrity of wiring from switch to EMS.
D234 Handbrake on when Driving before handbrake is released.

moving.
Faulty air pressure switch. Check air pressure switch for correct
operation and function.
The code will be

logged if the vehicle
has been moving at
> 3 kph for 10
seconds and:
(i) instantly the
handbrake is
applied(up to
JCBV0400)
(ii) the handbrake
has been on for
10 seconds (from
JCBV0500)
D235†† Engine coolant Excessive datalogging by older versions of Check version of software. Update to
over temperature. EMS software. current version.
Blocked radiator. Check radiator and grille for blockage, see

Note: From Cleaning the Radiator, Section 3.
JCBV0400 on,
Fault must be Insufficient coolant in radiator. See Checking the Coolant Level, Section 3.
present for 1 minute
before it is logged. Slack or worn drive belts See Adjusting the Fan Belt(s), Section 3.
Faulty thermostat. Check operation of thermostat.
Faulty temperature switch. Check operation of temperature switch.

Damaged wiring. Check integrity of wiring from temperature
switch to EMS.
(continued)
9803/8020 Issue 4
Non-displayable Fault Codes (cont’d)
D236† Radar not Options connectors have been joined on Disconnect options connectors; refer to
connected. tractor without option package fitted (radar wiring diagrams.
and fuel meters).
(Radar symbol also Break in wiring between radar unit and EMS. Check integrity of wiring from radar unit to
flashes). EMS.
Note: This code

replaces D030
from JCBV0301 on.
D240 EMS CAN Bus has EMS has detected a problem with the CAN Check CAN Bus link for open or short circuit
reset due to an error Bus link.
* Note 1: The Original Equipment Manufacturer or OEM harness refers to the harness around the engine that was supplied by
Cummins and is a part of the main tractor harness.
Note 2: If the EMS cannot communicate with the engine then the EMS changes to mechanical engine mode. Once in
mechanical engine mode the EMS will not detect the transmission control ECU used on electronic engine machines.
Note 3: The transmission control ECU used on machines with mechanical engines use different CAN Bus messages from
machines with electronic engines.
* E000 No comunication Power supply to engine ECU failed. Check fuse and power supply. Check
between the Open circuit in CAN Bus wiring. connections. Check integrity of insulation with
instruement cluster and Short circuit in CAN Bus wiring. multimeter. Check CAN Bus resistors. Use
the engine Faulty resistor in CAN Bus wiring engine diagnostic tool to investigate if
diagram. Engine ECU faulty. communication with the engine ECU is possible;
if not replace engine ECU.
9803/8020 Issue 3
Code Description Possible Cause Effect Cummins

Fault Code
E001 Engine Control Module - ECM internal hardware error. Possible no effect or engine may run 111
Critical internal failure rough or not start.
(111)
E002 Engine Speed/Position No engine speed signal detected at Engine power derate. Possible white 115
Sensor Circuit - lost pin 17 of the engine harness. smoke.
both of two signals from
the magnetic pickup
sensor (115)
E008 Intake Manifold High voltage detected at the boost Engine will derate to no-boost fuelling. 122
Pressure Sensor # 1 pressure sensor signal pin 45 of the
Circuit - shorted high engine harness.
(122)
E009 Intake Manifold Low voltage detected at the boost Engine will derate to no-boost fuelling. 123
Pressure Sensor # 1 pressure sensor signal pin 45 of the
Circuit - shorted low engine harness.
(123)
E010 Accelerator Pedal High voltage detected at accelerator Engine idles when idle validation 131
Position Sensor Circuit - position signal pin 30 of the tractor switch indicates idle and ramps up to
shorted high (131) (OEM) harness. at a default set speed when the idle
validation switch indicates off-idle.
E011 Accelerator Pedal Low voltage detected at accelerator Engine idles when idle validation 132
Position Sensor Circuit - position signal pin 30 of the tractor switch indicates idle and ramps up to
shorted low (132) (OEM) harness. at a default set speed when the idle
validation switch indicates off-idle.
E012 Hand Throttle Position High voltage detected at the remote Engine will not respond to remote 133
Sensor Circuit - shorted throttle position signal circuit. throttle input.
high (133)
E013 Hand Throttle Position Low voltage detected at the remote Engine will not respond to remote 134
Sensor Circuit - shorted throttle position signal circuit. throttle input.
low (134)
E014 Engine Oil Pressure High voltage detected at oil pressure Default value used for oil pressure. No 135
Sensor Circuit - shorted sensor signal pin 33 of the engine engine protection for oil pressure.
high (135) harness.
E015 Engine Oil Pressure Low voltage detected at oil pressure Default value used for oil pressure. No 141
Sensor Circuit - shorted sensor signal pin 33 of the engine engine protection for oil pressure.
low (141) harness.
E016 Engine Oil Pressure Low Oil pressure signal indicates oil Power and/or speed derate and 143
- Warning (143) pressure below the low engine possible engine shutdown if engine
protection limit. protection shutdown feature enabled.
E017 Engine Coolant High voltage detected at the coolant Default value used for engine coolant 144
Temperature Sensor temperature signal pin 23 of the temperature. No engine protection for
Circuit - shorted high engine harness. coolant temperature.
(144)
E018 Engine Coolant Low voltage detected at the coolant Default value used for engine coolant 145
Temperature Sensor temperature signal pin 23 of the temperature. No engine protection for
Circuit - shorted low engine harness. coolant temperature.
(145)
E019 Engine Coolant Coolant temperature signal indicates Power derate and possible engine 146
Temperature High - coolant temperature has exceeded shutdown if engine protection
Warning (146) the minimum engine protection limit. shutdown feature is enabled.
9803/8020 Issue 3

Fault Code
E022 Engine Coolant Coolant engine temperature signal Power and/or speed derate and 151
Temperature High - indicates coolant temperature has possible engine shutdown if engine
Critical (151) exceeded the engine protection protection shutdown feature is
limit. enabled.
E023 Intake Manifold High voltage detected at intake Default value used for intake manifold 153
Temperature Sensor # 1 manifold temperature signal pin 34 temperature. No engine protection for
Circuit - shorted high of the engine harness. intake manifold temperature.
(153)
E024 Intake Manifold Low voltage detected at intake Default value used for intake manifold 154
Temperature Sensor # 1 manifold temperature signal pin 34 temperature. No engine protection for
Circuit - shorted low of the engine harness. intake manifold temperature.
(154)
E025 Intake Manifold Intake manifold air temperature Speed derate and possible engine 155
Temperature # 1 High - signal indicates the intake manifold shutdown if engine protection
Critical (155) air temperature is above the engine shutdown feature is enabled.
protection limit.
E026 Engine Control Module If the error persistently occurs then If the error persistently occurs then 184
Identification Input State replace ECU. replace ECU.
Error (184)
E037 Engine Speed High - Engine speed signal indicates Fuel to the injectors disabled until the 234
Critical (234) engine speed has exceeded the engine speed falls below the
overspeed limit. overspeed limit.
E040 Vehicle Speed Sensor - Either: 241

Appears to be faulty 1 Vehicle Speed Signal to the Check vehicle speed pick up and
(241) engine ECU has been lost. wiring.
or
2 Excessive throttle movement has Move machine forwards or backwards

been detected with no vehicle - switch off ignition to clear fault.
movement.
E041 Vehicle Speed Sensor - Either: 242

Appears to be faulty 1 Vehicle Speed Signal to the Check vehicle speed pick up and
(242) engine ECU has been lost. wiring.
or
2 Excessive throttle movement has Move machine forwards or backwards

been detected with no vehicle - switch off ignition to clear fault.
movement.
E043 Fan Clutch Circuit - Error detected in fan clutch relay Electronic control module (ECM) can 245
shorted low (245) enable circuit at pin 31 of the engine not control the engine cooling fan. Fan
harness. will remain either on or off.
E046 Fuel Temperature High - Fuel temperature signal indicates Power derate. 261
Warning (261) fuel temperature has exceeded the
engine protection limit and/or pump
protection limit.
E048 Fuel Temperature Injection pump internal failure. Low power, engine power derate, or 264
Sensor Circuit - data out engine stops.
of range (264)
9803/8020 Issue 4

Fault Code
E058 Fuel Priming Pump Error detected in lift pump circuit at The engine possibly loses power, dies, 278
Control Circuit - shorted pin 11 of the engine harness. or is difficult to start.
high/low (278)
E062 Engine Speed/Position High voltage detected at main The electronic control module (ECM) 283
Sensor # 1 (Crankshaft) engine speed sensor voltage supply will use the injection pump speed
Supply Voltage Circuit - pin 8 of the engine harness. signal as a backup. Possible white
shorted high (283) smoke, hard start, and power derate.
E063 Engine Speed/Position Low voltage detected at main engine The electronic control module (ECM) 284
Sensor # 1 (Crankshaft) speed sensor voltage supply pin 8 of will use the injection pump speed
Supply Voltage Circuit - the engine harness. signal as a backup. Possible white
shorted low (284) smoke, hard start, and power derate.
E065 SAE J1939 Multiplexing If the error persistently occurs then If the error persistently occurs then 286
Configuration Error (286) replace ECU. replace ECU.
E094 Transmission Output The auxiliary speed or auxiliary Engine will go to idle and lose ability 349
Shaft (Tailshaft) Input pressure indicates the frequency is to control the speed of the auxiliary
Error (349) above a calibrated threshold value. device.
E095 Sensor Supply Voltage Low voltage detected at + 5-VDC Default value for sensors connected to 352
# 1 Circuit - shorted low supply, pin 10 of the engine harness. this + 5-VDC supply. Engine will
(352) derate to no-boost fuelling and loss of
engine protection for oil pressure,
intake manifold pressure, and coolant
temperature.
E096 Fuel Pump Control Injection pump internal failure. Low power, engine power derate, or 361
Module, Fuel Control engine stops.
Valve Circuit - shorted
high (361)
E097 Fuel Pump Control Low current or no current detected Engine will die or run rough. 362
Module, Fuel Control at the injection pump fuel-metering
Valve Circuit - shorted value.
low (362)
E098 Fuel Pump Control No fuel-metering value movement Engine power derate. Engine possibly 363
Module, Fuel Control detected by the injection pump stops.
Valve - mechanically controller.
stuck (363)
E099 Fuel Pump Control No communications or invalid data Engine will run in a backup mode set 364
Module, CAN transfer rate detected on datalink speed when accelerator is off idle or
Communication Error - between ECM and fuel injection engine will not start.
abnormal update rate pump control module at pins 4 and
(364) 13 of the engine harness or no
voltage detected at pin 7 of the fuel
injection pump connector.
E100 Fuel Pump Control Low voltage detected at injection Possible engine dying, running rough, 365
Module, Supply Voltage pump controller supply voltage or no effect.
Circuit - shorted low circuit.
(365)
E101 Fuel Pump Control Fuel injection pump internal failure. Low power, engine power derate, or 366
Module, Supply Voltage engine stops.
Circuit - data incorrect
(366)
9803/8020 Issue 3

Fault Code
Module, Increment engine stops.
Angle Time Sensor Error
(367)
E103 Fuel Pump Control The injection pump can not achieve Engine power derate. 368
Module, Timing Error the timing value being commanded
(368) by the electronic control module
(ECM).
E104 Fuel Pump Control Injection pump controller does not Engine power derate. Possible white 369
Module, Engine detect engine position pulse at pin 7 smoke.
Synchronisation Error of the engine harness.
(369)
E105 Fuel Pump Control Injection pump controller detects The engine will either only idle or will 372
Module, Idle Validation continuous voltage at idle select pin be stuck at a slightly higher set speed.
Error (372) 16 of the engine harness, or pump
controller detects an open circuit to
ground at idle select pin 16 of the
engine harness.
E106 Fuel Pump Control High voltage detected at fuel shut Fuelling to injectors disabled. Engine 373
Module, Fuel Shut off off signal pin 6 of the engine stops.
Error (373) harness.
Module, Self-Test Error engine stops.
(374)
E108 Fuel Pump Control ECM is requesting a fuelling or Possible no effect or engine will not 375
Module, Electronic timing value that the VP44 pump can run at a backup mode set speed when
Calibration Code Error not achieve. accelerator is off-idle.
(375)
Module, Fuelling or engine stops.
Engine Speed Mismatch
(376)
E110 Fuel Pump Control Injection pump controller is not Equipment batteries can be drained 377
Module, Stuck Relay powering down when key switch low during long shutdown periods.
Error (377) power is removed from the
electronic control module (ECM).
E114 Sensor Supply Voltage High voltage detected at + 5-VDC Default value for sensors connected to 386
# 1 Circuit - shorted supply, pin 10 of the engine harness. this + 5-VDC supply. Engine will
high (386) derate to no-boost fuelling and loss of
engine protection for oil pressure,
intake manifold pressure, and coolant
temperature.
E116 Fan Clutch Circuit Error If the error persistently occurs then If the error persistently occurs then 389
(389) replace ECU. replace ECU.
E117 Fuel Shut off Valve Short to ground detected in njection Engine will not start; it dies. 391
Supply Voltage error pump power supply relay enable
(391) circuit at pin 43 of the engine
harness.
E118 Engine Oil Pressure Low Oil pressure signal indicates oil Power and/or speed derate and 415
- Critical (415) pressure below the very low engine possible engine protection shutdown
protection limit. if feature is enabled.
9803/8020 Issue 4

Fault Code
E119 Water in Fuel Indicator Water-in-fuel (WIF) signal indicates Excessive water in the fuel can lead to 418
High - Maintenance water in the fuel filter needs to be severe fuel system damage.
(418) drained.
E120 Engine Coolant Level Voltage detected simultaneously on No engine protection for coolant level. 422
Sensor Circuit - data both the coolant level high and low
incorrect (422) signal pins 27 and 37 of the engine
harness, or no voltage detected on
either pin.
E123 Water in Fuel Sensor Low voltage detected at WIF signal No water in fuel detection capability. 429
Circuit - shorted low pin 40 of the tractor (OEM) harness.
(429)
E124 Accelerator Pedal Idle Idle validation signals on pins 25 and No effect on performance but loss of 431
Validation Circuit - data 26 of the tractor's (OEM) harness idle validation.
incorrect (431) indicate + 5 VDC present at both
pins 25 and 26.
E125 Accelerator Pedal Idle No voltage detected at pin 26 of the Engine will only idle. 432
Validation Circuit - out tractor's (OEM) harness indicates
of calibration (432) the accelerator is at the idle position
when the accelerator position signal
at pin 30 of the tractor (OEM)
harness indicates the accelerator is
not at the idle position, or idle
validation signal at pin 26 of the
tractor (OEM) harness indicates the
accelerator is not at the idle position
when the accelerator position signal
pin 30 of the tractor (OEM) harness
indicates the accelerator is at the
idle position.
E126 Intake Manifold Boost pressure signal indicates Possible overfuelling during 433
Pressure Sensor Circuit boost pressure is high when other acceleration. Increase in black smoke.
- data incorrect (433) engine parameters (i.e. speed and
load) indicate boost pressure should
be low.
E127 Power Lost without Supply voltage fell below (+) 6.2 No effect on performance. Fault code 434
Ignition Off (434) VDC for a fraction of a second, or table, trip information data, and
the electronic control module (ECM) maintenance monitor data can be
was not allowed to power down inaccurate.
correctly (retain battery voltage for
30 seconds after key-off).
E129 Battery Voltage Low - Voltage detected at electronic Engine will die or run rough. 441
Warning (441) control module (ECM) power supply
pins 38, 39 and 40 of the engine
harness indicates ECM supply
voltage fell below (+) 6 VDC.
E130 Battery Voltage High - Voltage detected at electronic No effect on performance. 442
Warning (442) control module (ECM) power supply
pins 38, 39 and 40 of the engine
harness indicates ECM supply
voltage is above the maximum
system voltage level.
E132 OEM Sensor Supply Low voltage detected at remote The remote accelerator, coolant level 444
Voltage Low - Warning accelerator position sensor supply sensor, and water-in-fuel (WIF) sensor
(444). pin 10 of the tractor (OEM) harness. will not function.
9803/8020 Issue 3

Fault Code
E136 Intake Manifold Intake manifold air temperature Power derate. 488
Temperature High - signal indicates the intake manifold
Warning (488). air temperature is approaching the
engine protection limit.
E137 Transmission Output The auxiliary speed or auxiliary Engine will go to idle and lose ability 489
Shaft (Tailshaft) Speed pressure indicates the frequency is to control the speed of the auxiliary
Low - Warning (489). below a calibrated threshold value. device.
E140 Sensor Supply Circuit - High voltage detected at the coolant No engine protection for coolant level. 515
shorted high (515). level + 5-VDC sensor supply voltage
pin 49 of the engine harness.
E141 Sensor Supply Circuit - Low voltage detected at the coolant No engine protection for coolant level. 516
shorted low (516). level + 5-VDC sensor supply voltage
pin 49 of the engine harness.
E142 Fuel Metering Solenoid - If the error persistently occurs then Engine may shut down. 517
bad device (517). replace fuel injection pump.
E148 Accelerator Pedal Idle Check wiring and throttle pedal. Engine may shut down 511
Validation Circuit -
shorted low (511).
E144 Auxiliary output driver A Damaged wiring. Investigate and fix wiring. Output 527
shorted high. This is should change at 5% throttle. Check
connected to the also transmission controller.
transmission ECU to
provide throttle at idle
information.
E155 OEM Commanded Dual The dual-output feature in this Engine will shut down. 599
Output Shutdown (599). customer-specialised calibration has
initiated an engine shutdown based
on operating conditions, engine
sensor values, or tractor (OEM)
inputs to the ECM.
E156 Engine Hot Shutdown The engine was shut down with the No action is taken by the ECM. 611
(611). key switch before proper engine
cool down.
E162 Sensor Supply Voltage Either, high voltage detected at Engine idles when accelerator is not 387 or
Shorted High (387 or accelerator position sensor supply pressed and ramps up to default set 515
515). pin 29 of the tractor's (OEM) speed when off-idle. Or, no engine
harness, or, high voltage detected at protection for coolant level.
the coolant level + 5-VDC sensor
supply voltage pin 49 of the engine
harness.
E163 Sensor Supply Voltage Low voltage detected at accelerator Engine idles when accelerator is not 443 or
Shorted Low (443 or position sensor supply pin 29 of the pressed and ramps up to a default set 516
516). tractor (OEM) harness, or, low speed when off-idle, or, no engine
voltage detected at the coolant level protection for coolant level.
+ 5-VDC sensor supply voltage pin
49 of the engine harness.
E164 Intake Heater Relay Error detected in cold start air relay Intake air heater can not be energised 381 or
Fault - Circuit data 1 enable circuit at pin 41 of the by the electronic control module 282
incorrect (381 or 282) tractor (OEM) harness. If the error (ECM). Possible white smoke and/or
persistently occurs then replace hard starting in cold ambient
ECU. conditions.
9803/8020 Issue 2
40 - 13 Diagnostics Error Codes - General 40 - 13

T000 No CAN alive messages Power supply to transmission ECU Check fuse and power supply. Check
from the transmission failed. Open circuit in CAN Bus connections. Check integrity of insulation with
ECU arriving at the wiring. Short circuit in CAN Bus multimeter. Check CAN Bus resistors; refer to
instrument cluster wiring. Faulty resistor in CAN Bus wiring. Change Transmission ECU.
wiring diagram. Transmission ECU
faulty.
T001 EEPROM not working - Transmission ECU internal fault. If fault persistently occurs change transmission
Transmission ECU.
T002 EEPROM not retaining Transmission ECU internal fault. If fault persistently occurs change transmission
data - Transmission ECU.
T003 EEPROM busy line Transmission ECU internal fault. If fault persistently occurs change transmission
stuck - Transmission ECU.
T004 EEPROM factory set Transmission ECU internal fault. If fault persistently occurs reload the transmission
data not valid - EEPROM using the WINGST tool and if the error
Transmission still occurs replace the transmission ECU.
T005 EEPROM calibration Wet clutch not calibrated or Re-Calibrate the clutch. See Powershift and
data not valid - calibrated incorrectly. Master Clutch Calibration.
Transmission
T010 Snail solenoid open Internal breakdown of solenoid coil. Check solenoid for continuity. Check continuity of
circuit Damaged wiring. wiring from solenoid to both transmission ECU
and earth; refer to wiring diagram.
T011 Snail solenoid short Solenoid coil faulty internally. Check solenoid resistance, which should be 5
circuit Damaged wiring. ohms. Check for short circuit to earth between
solenoid and Transmission ECU.
T012 Snail solenoid over Caused by abnormally high current Check solenoid resistance, which should be 5
temperature drawn from transmission ECU (the ohms. Check for short circuit or low resistance to
driver inside the ECU and is not earth between solenoid and Transmission ECU.
serviceable). Solenoid coil faulty.
Damaged wiring.
T013 Tortoise solenoid open Internal breakdown of solenoid coil. Check solenoid for continuity. Check continuity of
T014 Tortoise solenoid short Internal breakdown of solenoid coil. Check solenoid for continuity. Check for short
circuit Damaged wiring. circuit to earth in wiring between solenoid and
transmission ECU.
T015 Tortoise solenoid over Caused by abnormally high current Check solenoid resistance, which should be 5
driver inside the ECU and is not earth between solenoid and Transmission ECU.
serviceable). Solenoid coil faulty
internally. Damaged wiring.
T016 Hare solenoid open Internal breakdown of solenoid coil. Check solenoid for continuity. Check continuity of
T017 Hare solenoid short Solenoid coil faulty internally. Check solenoid resistance, which should be 5
circuit Damaged wiring. ohms. Check for short circuit to earth in wiring
between solenoid and Transmission ECU.
9803/8020 Issue 2
T018 Hare solenoid over Caused by abnormally high current Check solenoid resistance, which should be 5
driver is inside the Ecu and is not earth in wiring between solenoid and
serviceable). Solenoid coil faulty Transmission ECU.
T019 Clutch lubrication Solenoid coil faulty internally. Check solenoid for continuity. Check for short
solenoid open circuit Damaged wiring. circuit to earth in wiring between solenoid and
transmission ECU.
T020 Clutch lubrication Solenoid coil faulty internally. Check solenoid resistance, which should be 5
solenoid short circuit Solenoid short. Damaged wiring. ohms. Check for short circuit to earth in wiring
T021 Clutch lubrication Caused by abnormally high current Check solenoid resistance, which should be 5
solenoid over drawn from transmission ECU (the ohms. Check for short circuit or low resistance to
temperature driver is inside the ECU and is not earth in wiring between solenoid and
T022 Reversing lamp open For this circuit to be open, both Check reversing light bulbs and relay (if fitted);
circuit reversing bulbs and the trailer refer to wiring diagrams.
reverse light relay (if fitted) must all
have failed open circuit. Damaged
wiring.
T023 Reversing lamp short Trailer reversing light bulb or relay Check reversing light bulbs and relay. Check
circuit short circuit. Damaged wiring. integrity of wiring from Transmission ECU to
reversing lights and trailer reverse lights relay (if
fitted); refer to wiring diagram.
T024 Reversing lamp driver Caused by abnormally high current Check relay for function. Check for short circuit or
over temperature drawn from transmission ECU (the low resistance to earth in wiring from ECU to
driver is inside the ECU and is not reversing lights and trailer reverse lights relay (if
serviceable). Internal failure of the fitted); refer to wiring diagram. Check bulbs and
relay. Damaged wiring. Incorrect replace and replace as necessary.
wattage bulbs fitted.
T025 L ram in solenoid open Internal breakdown of solenoid coil. Check individual solenoid for continuity, as
circuit Wiring fault. guided by the individual fault code. Check supply
and wiring between Transmission ECU and
relevant solenoid(s); refer to wiring diagram.
Note: if either all four neutral solenoids or all four
engage solenoids are showing failures, it is likely
to be a supply fault. If there is only one solenoid
failure, it is likely to be an individual solenoid
return.
T026 R ram in solenoid open Internal breakdown of solenoid coil. Check individual solenoid for continuity, as
return.
9803/8020 Issue 2
T027 M ram in solenoid open Internal breakdown of solenoid coil. Check individual solenoid for continuity, as
return.
T028 H ram in solenoid open Internal breakdown of solenoid coil. Check individual solenoid for continuity, as
return.
T029 L ram out solenoid open Internal breakdown of solenoid coil. Check individual solenoid for continuity, as
return.
T030 R ram out solenoid Internal breakdown of solenoid coil. Check individual solenoid for continuity, as
open circuit Wiring fault. guided by the individual fault code. Check supply
return.
T031 M ram out solenoid Internal breakdown of solenoid coil. Check individual solenoid for continuity, as
return.
T032 H ram out solenoid Internal breakdown of solenoid coil. Check individual solenoid for continuity, as
relevant solenoid(s); refer to wiring diagram. Note:
if either all four neutral solenoids or all four
return.
9803/8020 Issue 2
T033 One of the ram Internal solenoid failure. Check solenoid resistance, which should be 75 to
solenoids is short circuit 80 ohms. Determine which solenoid has failed by
sequencing through all Selectronic gear changes.
T034 Ram supply line short Damaged wiring. Check that the common air valve supply lines
circuit form the Transmission ECU are not shorting to
earth; refer to wiring diagrams.
T035 Ram supply line driver Caused by abnormally high current Check all air solenoid resistance, which should
over temperature drawn from the Transmission ECU each be 75 to 80 ohms. Check for shirt circuit or
(the driver is inside the ECU and is low resistance to earth on common supply from
not serviceable). Internal solenoid Transmission ECU to air solenoids.
failure. Damaged wiring.
T040 R ram engage All these switches appear to be Check air pressure and operation of the switches.
switch/ram open circuit OPEN and should be CLOSED. Check for air cylinder leaks. Check switch
fault These codes can also result from operation using a magnet and multimeter, or by
attempting to use Selectronic with using the diagnostics function of the WINGST.
insufficient air pressure, causing Check supply and return wiring between
insufficient cylinder movement to Transmission ECU and switches; refer to wiring
operate the switches normally , or air diagram.
cylinder leaks which also cause slow
or weak air cylinder movement.
Failed switch (open circuit). Wiring
faulty.
T041 L ram engage All these switches appear to be Check air pressure and operation of the switches.
faulty.
T042 M ram engage All these switches appear to be Check air pressure and operation of the switches.
faulty.
T043 H ram engage All these switches appear to be Check air pressure and operation of the switches.
faulty.
9803/8020 Issue 1
T044 R ram neutral All these switches appear to be Check air pressure and operation of the switches.
faulty.
T045 L ram neutral All these switches appear to be Check air pressure and operation of the switches.
faulty.
T046 M ram neutral All these switches appear to be Check air pressure and operation of the switches.
faulty.
T047 H ram neutral All these switches appear to be Check air pressure and operation of the switches.
faulty.
T050 R ram engage All these switches appear to be Check air pressure and operation of the switches.
switch/ram short circuit OPEN and should be CLOSED. Check for air cylinder leaks. Check switch
faulty.
9803/8020 Issue 1
T051 L ram engage All these switches appear to be Check air pressure and operation of the switches.
faulty.
T052 M ram engage All these switches appear to be Check air pressure and operation of the switches.
faulty.
T053 H ram engage All these switches appear to be Check air pressure and operation of the switches.
faulty.
T054 R ram neutral All these switches appear to be Check air pressure and operation of the switches.
faulty.
T055 L ram neutral All these switches appear to be Check air pressure and operation of the switches.
faulty.
9803/8020 Issue 1
T056 M ram neutral All these switches appear to be Check air pressure and operation of the switches.
faulty.
T057 H ram neutral All these switches appear to be Check air pressure and operation of the switches.
faulty.
T060 Speed triggers <3, <1 & The EMS sets the speed triggers to Check for error codes D020 or D021. Check
>20kph these values if it detects a speed continuity of 20 kph line, referring to wiring
sensor fault. These settings make diagrams.
the tractor systems safe but
useable. Break in 20 kph signal line
form EMS to Transmission ECU.
T061 Speed triggers <3, >1 & Break in 3 kph and/or 20 kph line Check continuity of 3 kph and/or 20 kph lines,
>20kph from EMS to Transmission ECU. referring to wiring diagrams.
T062 Speed triggers >3, <1 & Break in 1 kph line from EMS to Check continuity of 1 kph line, referring to wiring
>20kph Transmission ECU. diagrams.
T063 Speed triggers >3, <1 & Break in 1 kph line from EMS to Check continuity of 1 kph line, referring to wiring
<20kph Transmission ECU. Short to 12V on diagrams. Check for short on 3 kph line, referring
3 kph line from EMS to Transmission to wiring diagrams.
ECU.
T070 Clutch switches One of clutch pedal switches is Check both switches for correct operation and
detected as clutch fully faulty or jammed. function.
up and down
T071 Clutch brake solenoid Solenoid coil faulty internally. Check solenoid for continuity. Check for short
open circuit Damaged wiring. circuit to earth in wiring between solenoid and
transmission ECU.
T072 Clutch brake solenoid Solenoid coil faulty internally. Check solenoid resistance, which should be 5
short circuit Solenoid short. Damaged wiring. ohms. Check for short circuit to earth in wiring
T073 Clutch brake solenoid Caused by abnormally high current Check solenoid resistance, which should be 5
over temperature drawn from transmission ECU (the ohms. Check for short circuit or low resistance to
driver is inside the ECU and is not earth in wiring between solenoid and
T075 Clutch pedal fully down Clutch pedal potentiometer and Check wiring.Check pedal switch. Check pedal
switch open circuit with clutch pedal switch conflict over potentiometer.
pedal up pedal position.
9803/8020 Issue 1
T076 Clutch pedal fully down Clutch pedal potentiometer and Check wiring.Check pedal switch. Check pedal
switch wiring shorted to clutch pedal switch conflict over potentiometer.
ground pedal position.
T077 Transmission oil over Low transmission oil level. Blocked Check and correct oil level. Clean or renew
temperature trip. Note: or damaged oil cooler. Faulty sensor cooler. Renew sensor unit, check potentiometer
The low transmission oil unit. operation. Service clutch.
pressure light will flash
when this fault is
present.
T078 Wet clutch over Low transmission oil level. Check and correct oil level. Check clutch
temperature trip Lubrication oil supply failure. lubrication oil pressures. Check clutch control
Excessive clutch slip. valve operation, potentiometer operation. Service
clutch.
T079 Oil temperature sensor Faulty sensor unit. Damaged wiring. Renew sensor. Check for short circuit or low
fault resistance to earth in wiring between sensor and
Transmission ECU.
T080 Column switch L & R Faulty column switch. Damaged Check switch for correct operation and function,
contacts shorted wiring. using a multimeter or the diagnostics function of
together the WINGST. Check integrity of wiring from
column switch to both the EMS and the
Transmission ECU.
T081 Column switch L & M Faulty column switch. Damaged Check switch for correct operation and function,
Transmission ECU.
T082 Column switch L & H Faulty column switch. Damaged Check switch for correct operation and function,
Transmission ECU.
T083 Column switch H & R Faulty column switch. Damaged Check switch for correct operation and function,
Transmission ECU.
T084 Column switch M & R Faulty column switch. Damaged Check switch for correct operation and function,
Transmission ECU.
T085 Column switch M & H Faulty column switch. Damaged Check switch for correct operation and function,
Transmission ECU.
T100 Wet clutch solenoid Solenoid coil faulty internally. Faulty Check solenoid for continuity. Check resistance
open circuit inching resistor. Damaged wiring. of inching resistor, which should be 4.7 ohms.
Check for open circuit in wiring between solenoid
and Transmission ECU.
9803/8020 Issue 1
T101 Wet clutch solenoid Solenoid coil faulty internally. Faulty Check solenoid resistance, which should be 7 to
short circuit inching resistor. Damaged wiring. 14 ohms. Check resistance of inching resistor
which should be 4.7 ohms. Check for short circuit
to earth in wiring.
T102 Wet clutch solenoid Caused by abnormally high current Check solenoid resistance. Check for short circuit
over temperature drawn from transmission ECU (the or low resistance to earth in wiring between
driver is inside the ECU and is not solenoid and Transmission ECU.
serviceable). Solenoid coil faulty
T103 Not enough valve Solenoid coil faulty internally. Faulty Check solenoid for continuity. Check resistance
current when clutch inching resistor. Damaged wiring. of inching resistor, which should be 4.7 ohms.
pedal is up Low ECU supply voltage. Check for open circuit in wiring between solenoid
and Transmission ECU. Check ECU supply
wiring.
T114 Clutch pedal is fully Clutch pedal not adjusted correctly. Adjust pedal - see Section F. Check switch
down but clutch switch Faulty clutch switch. Damaged operation. Check for an open circuit.
has not operated wiring.
T115 Clutch pedal is fully up Faulty clutch switch. Damaged Check switch operation. Check for short circuit.
but clutch down switch wiring.
has not released
T120 Clutch pot calibrated Faulty potentiometer or installation. Check potentiometer mounting and operation.
position is to high
T121 Clutch pot calibrated See code T120. See code T120.
position is to low
T122 Clutch pot is above See code T120. See code T120.
calibrated limits
T123 Clutch pot is below See code T120. See code T120.
calibrated limits
T124 Clutch pot is above Faulty potentiometer. Faulty wiring. Check potentiometer operation. Check related
electrical limits wires for damage.
T125 Clutch pot is below Faulty potentiometer. Faulty wiring. Check potentiometer operation. Check related
electrical limits wires for damage.
T126 Clutch pedal calibrated Clutch operation not calibrated Calibrate clutch, see powershift and Master
range too small correctly. Clutch Calibration in this section.
T130 Splitter safety dump Relay faulty. Relay wiring faulty. Check relay. Check wiring.
relay does not operate
when clutch fully down
T131 Splitter safety dump Relay faulty. Relay wiring faulty. Check relay. Check wiring.
relay operates even
though clutch is
released
T230 Selectronic limp home Driver used "Limp Home" mode. Find reason for use of this mode and rectify any
mode was operated Damaged wiring. faults. Check integrity of wiring from switch to
EMS.
9803/8020 Issue 1
Non-displayable Datalogging Special Codes (Software Version 7.00 onwards)
Code Description
Z200 Datalog erased by service tool.
Z201 EMS erased some old datalogs to make room for new ones.
Z211 Datalogs were downloaded by service tool.
Z220 Maximum vehicle speed occurred.
Z221 Maximum engine r.p.m. occurred.
Z222 Maximum voltage occurred.
Z223 Maximum engine coolant temperature occurred.
Z224 Maximum transmission temperature occurred.
9803/8020 Issue 1
41 - 0 Electronic Service Tools Applications 41 - 0
Electronic Tool Selection

(2115, 2125, 2135, 2150, 3155, 3185) A
The diagnostics software for the EMS dash board and
the transmission controller can be used by means of the
Psion or laptop.
The following laptop Electronic Service Tools are

available though the Service Master software:
B
1 The Wingst program for use with the Electronic
Monitoring System (EMS) - also known as Digital Dash
or Instrument Cluster). This tool reproduces the PSION
functions.
Note: When using Wingst, connection to the tractor is direct
from the laptop PC (serial port RS232), using lead 2000 Series
721/00664. The Data Link Adaptor is not used.
2 Software for setting up, erasing fault codes and

diagnostics for the ABS. A
diagnostics for the engine.
3000 Series
Fault Code Information and Electronic Tool Selection Table

(2115, 2125, 2135, 2150, 3155, 3185)
Electronic Unit Lamp Indicating Error Code Errors Code Logged Fault Diagnostic Tool
Originating Fault Fault Letter on Displayed on Download or
EMS Display Erase Tool
Tool Connection Tool Connection
EMS Dash Book symbol on EMS D EMS Dash Board Wingst RS232 to Wingst RS232 to
Board or Psion rectangular or Psion rectangular
8 pin A 8 pin A
Transmission Book symbol on EMS T EMS Dash Board Wingst RS232 to Wingst RS232 to
Controller or Psion rectangular or Psion rectangular
8 pin A 8 pin A
Rear Linkage Fault Light on rear None Blink code on rear None None None
linkage control linkage control
panel panel
ABS ABS Fault light on EMS None Blink codes on ABS tool DLA to ABS tool DLA to
ABS fault light round round
when button connector B connector B
pressed
9803/8020 Issue 1
41 - 1 Electronic Service Tools Applications 41 - 1
Electronic Tool Selection (2140 Machine)

A
The following Fastrac Electronic Service Tools are
available though the Service Master software:
1 The Wingst program for use with the Electronic

Monitoring System (EMS) - also known as Digital Dash
or Instrument Cluster). This tool reproduces the PSION
functions.
Note: When using Wingst, connection to the tractor is direct B
from the laptop PC (serial port RS232), using lead
721/00664. The Data Link Adaptor is not used.

diagnostics for the ABS.

diagnostics for the engine.
Fault Code Information and Electronic Tool Selection Table (2140)
Electronic Unit Lamp Indicating Error Code Errors Code Logged Fault Diagnostic Tool
Originating Fault Fault Letter on Displayed on Download or
EMS Display Erase Tool
Tool Connection Tool Connection
EMS Dash Book symbol on EMS D EMS Dash Board Wingst RS232 to Wingst RS232 to
Board rectangular rectangular
8 pin A 8 pin A
Transmission Book symbol on EMS T EMS Dash Board Wingst RS232 to Wingst RS232 to
Controller rectangular rectangular
8 pin A 8 pin A
Engine Engine Fault light on E EMS Dash Board Wingst RS232 to Engine DLA to
EMS rectangular tool round
8 pin A connector B
Engine DLA to
tool round
connector B
Rear Linkage Fault Light on rear None Blink code on rear None None None
linkage control linkage control
panel panel
ABS ABS Fault light on EMS None Blink codes on ABS tool DLA to ABS tool DLA to
ABS fault light round round
when button connector B connector B
pressed
9803/8020 Issue 2
41 - 2 JCB Service Master 41 - 2
Service Master is a gateway application allowing a large

number of Vehicle Support Applications to be linked using
one familiar interface. The interface acts as a graphical tool
for selecting the target vehicle from a database of Vehicle
Families and triggering the particular Service Tool
Application desired. This removes the need for a user to
'remember' every individual service tool available and select
which one is intended for a particular machine.
The Service Master also provides several key features that

will accompany all JCB projects, a Multi Language editing
tool that provides a means of individual text string
translation for all JCB applications and the means to select a
localised language translation for each JCB application.
The contents of this document aim to explain to you, the

User, how to operate this application and to make most of
its functionality.
1. Using Service Master

The Service Master Application consists of a database of
records relating Vehicle Product Ranges and Service Tool
Applications. At most, any one product range has one
application for each of the Service Tool modules. In the
image adjacent, we see two JCB Product Ranges depicted,
currently the selected vehicle range is the 'Heavy Products'
range of excavators. The application buttons (or icons)
visible below the vehicle images are gateways to the
individual Service Tool Applications. The user need only to
decide which type of tool is required for the task at hand,
click the respective icon and the service tool will be opened.
Product Range Selectors Use the two arrow icons to

toggle through the database list
of 'Product Ranges supported
by Service Master.
Application Buttons These buttons access the

underlying service tool
applications available for the
selected Product Range
System Menus Functions are accessed by

clicking the right mouse button
anywhere on the main form.
2. Selecting Service Tool Applications
Service Tool Applications are selected by firstly locating and

selecting from the list of Product Ranges the range which
contains the vehicle that is to be worked on. The Service
Tool Applications which are available to the specific Product
Range selected are made accessible by clicking on one of
the icons that will be displayed on the lower portion of the
main screen.
Only those applications which are supported by the CFE will

have a visible icon. As and when new applications are made
available by software vendors they can be included into the
product range by updating the Product Range database.
9803/8020 Issue 1*
Vehicle Setup Operating Parameter settings, Option/Attachment control,

Alternative Language Support, Model/Serial Number
Identification.
Data Logging Running Data Collection, Operating Data, Statistics, Device

Error Log Recording.
Service History Service/Engine Hour records, Service Dealership Codes.
Module Programming ECU Reprogramming and Software update/Revision capability.
Diagnostics ECU I/O (input and output) testing and diagnostics.
3. System Menus
System menu functions are accessed by pressing the right

mouse button anywhere on the main Service Master form.
Manage Applications Opens the Configure Applications

form which allows the User to add,
delete, update information relating
to the applications supported by
Product Ranges.
Multi Lingual Support Opens a text editing tool used to

control Application Text strings
which can be translated into almost
any WINDOWS supported
language.
DLA Programmer Opens an application for the

reprogramming of the DLA module.
Properties Used to define various options and

settings used by the Service Master
Application.
About Box Shows software version, date,

developers information etc.
4. Managing Applications
The Installable version of Service Master will come with all
known Products and Applications configured and ready to
run. There are however several cases where the user may
need to change these settings.
New Applications from other vendors

Local Prototype Tool Development
Changes to the default Installation destination (hard
drive
9803/8020 Issue 1*
To make changes to the current Product/Applications

relationships
Open Service Master
Right click on the form and select Manage Applications
Range Details the names of the vehicle

product range that is to be
displayed when viewed on the
main selection screen.
Photo Each Range of vehicles requires
a graphic image depicting the
vehicle.
Load Opens a graphic viewing and
selection tool so that the user
can preview images before
attaching it to the current
product range.
Tools A list of Service Tools and
Applications is maintained by
the system, the contents of
which defines which
applications are associated with
which product Range.
Add Sets a path to the application
used for viewing the Service
History.
Delete Deletes the current Service Tool
selected in the Tools List.
Edit Allows the User to modify
attributes of the Service Tool
currently selected.
Use the record selector buttons to navigate through Product
Range records.
Add Application
Adding new applications to the list of Service Tools available
for a vehicle range requires that the Manage Applications
form is opened and the 'Add' button clicked. This will open
the following form.
Name Enter a name for the Service
Tool which will be displayed on
the main Service Master screen.
Path Enter or browse and search for
the file or executable that is to
be opened when the application
is opened.
Parameters Enter and parameters
associated with the application.
Working Directory Enter the working directory used
by the application, e.g. C:/.
Icon Use the browse button to open
the Icon loading form. Any
standard icon file can be loaded
for this application.
Update Saves the new Application
record.
Note: The name and the Path Fields must be set,
parameters and working directory are optional and should
only be used if the Service tool requires them to be set to
specific values, read the Service Tool documentation.
9803/8020 Issue 1*
Edit Application
The Service Tool Application or attributes can be changed
anytime by opening the Manage Applications form, select
the application from the Tools list and clicking the Edit
button.
Name Name of the Service Tool that
will be displayed on the main
Service Master screen.
Path Enter or browse and search for
the file or executable that is to
be opened when the application
is opened.
Parameters Enter and parameters
associated with the application.
Working Directory Enter the working directory used
by the application.
Icon Use the browse button to open
the Icon loading form. Any
standard icon file can be loaded
for this application.
Update Saves the current application
record.
Note: The name and the Path Fields must be set,
parameters and working directory are optional and should
only be used if the Service tool requires them to be set to
specific values, read the Service Tool documentation.
4.1 Record Selectors

Record Selectors allow the user to navigate around the
database record sets.
Go to the first record in the current record set
Go to previous record in record set
Go to next record in record set
Go to Last record in record set
Delete current record from record set
Add new record to record set
5. Properties
Provision in Service Master is made to allow the User to
configure several features of the application. This will
improve the ability to work with the software in a more user
friendly manner.
Multi Language Support Tool
Offers the ability to the user to change the default Text
Editing application.
Country
Using the Drop Down box containing the International Flag
of the target country the user can define which resource file
is used. Only those countries supported by the application
will be listed in the selection list.
9803/8020 Issue 1*
41 - 6 Data Link Adaptor 41 - 6
* The DLA kit part number 892/01033, shown right, is a 5. With the Vehicle power ON, start HPSetup application
universal device for connecting several data and visually observe the CAN activity LED and note the
communications systems to the PC. error message displayed by the PC. If the LED does not
flash off/ON several times after it has been initialised by
* To use the DLA on the Fastrac, cable A must be replaced by
the PC then there is probably a hardware problem with
cable C part number 721/10885 whcih must be connected
the DLA. Replace the DLA. Error messages displayed by
to socket B on the Fastrac.
the DLA driver software often indicates the origin of the
Power for the DLA is taken from the vehicle power supply problem. It may help to power down the vehicle, wait a
so it requires no internal source of power and is self few seconds and then retry establishing connection.
regulating up to +40V.
Once connected to the PC the DLA is auto detected and
initialised by software eliminating any need for the user to
determine port settings, data transfer rates. A
DLA Trouble Shooting

Failure of the software to initialise the DLA will prevent any
read/write operations. This section will help debug the error
and get the DLA working. Follow this list of checks to
perform to help diagnose the problem.
1. Cables, ensure that the correct cables are used between
the PC/DLA/On-Vehicle connector.
2. Inspect cables for possible damage, replace if
necessary.
3. Check that good firm connections have been made
between all devices.
4. Power up the vehicle and make sure the power LED on
the DLA is ON, if the LED is not illuminated there may be
a problem with the power supplied to the unit or the
DLA regulator system is not working. To check the
power to the DLA unplug the DLA from the vehicle, use A360250
a digital multi-meter to check the voltage between pins
6 and 8. There should be a minimum of 12 V DC (or
D
IGNITION Voltage, see vehicle specifications) between 1 2 3 4 5 6 7 8
B
C
A
E
F
J G
these two pins. Suspect the vehicle power supply if 9 10 11 12 13 14 15
H
there is not, else the DLA should be replaced because

of a problem with it's internal circuitry.
C A386040
B
B
9803/8020 Issue 2*
42 - 1 ABS Diagnostics Tool 42 - 1
ABS Diagnostics Software
Introduction
The Landpower Diagnostics Tool is part of the JCB Service

Master program (see page C\41-1). It presently comprises
the following applications:
ABS System Diagnostics
This application consists of 4 modules:
ABS System Test - Performs a functional test of the system,

including wheel speed sensors, relays and air modulators.
Extract Fault Codes - Displays a list of Active Fault Codes

(also known as ‘Error Codes’) retrieved by the ABS ECU.
These indicate current ABS problems which have been
detected by the ECU. Also displayed is a list of ‘Previously
Active Fault Codes’. This is a historical list of faults and the
number of times they have occurred.
Erase Fault Codes - Clears the list of Fault Codes stored in

the ECU.
Modulators and Speed Sensors - Allows the user to view

individual wheel speeds and to switch the ABS Relays and
Modulators on and off from his computer.
9803/8020 Issue 1*
ABS System Test

System Preparation
* 1 Connect the computer to the ABS Diagnostics socket B

using the Data Link Adaptor (Part No. 892/01033) and
connector Harness 721/10885. See Service Tools,
Electrics, in Section 1.
2000 Series
2 With the computer connected to the ABS socket, sure

that the ignition is turned ON before opening ‘JCB
Service Master.’
3000 Series
3 Start ‘JCB Service Master’, then use the selector

arrows in the centre panel to select the ‘Landpower’
screen illustrated by the Fastrac. Click on the ‘First Aid
Box’ symbol. The Landpower Diagnostics Tool window
will appear.
4 Press either the F9 key, the ‘a’ key or click on the ‘ABS
System’ text to display the list of options, as shown.
9803/8020 Issue 2*
ABS System Test
!WARNING
For the following test the machine must be safely
supported on stands so all four wheels are not in contact
with the ground. Never perform this test with the
machine in motion.
This test is software-driven. At various stages during the test

you will be prompted by on-screen instructions to operate
the brake and drive controls
1 Press the F5 key or click in the ‘ABS System Test’

checkbox to open the module.
2 Follow the on-screen instructions until the test is

complete.
Note that the first instruction you receive will be to start the
engine, select 2WD, then select an appropriate gear and
throttle setting to achieve a wheel speed of just above 3.5
kph. Use the speed indicator on the screen, rather than the
machine’s speedometer, when setting the wheel speed.
3 At the end of the test you will be asked if you wish to

view the Fault Log. If you click ‘Yes’ a Notepad file will
open, giving the results of the test you have just
performed.
9803/8020 Issue 1*
ABS System Test - Continued

Extract Fault Codes
1 Click the F7 key or click in the ‘Extract Fault Codes’

checkbox to open the module. The screen will show any
present faults which have been detected by the ECU,
plus (unless they have been erased) a list of ‘Previously
Active Faults’. The ECU can store up to a maximum of
10 active faults.
See Error Codes - Anti-Lock Braking System (ABS).
Erase Fault Codes
1 Click the F6 key or click in the ‘Erase Fault Codes’

checkbox to open the module. When the module opens
you will be asked to confirm that you want do delete the
Codes.
9803/8020 Issue 1*
ABS System Test - Continued
Modulators and Speed Sensors
!WARNING
For the following test the machine must be safely
supported on stands so that the roadwheels are off the
ground. Never perform this test with the machine in
motion.
The purpose of this module is to allow the Service Engineer

to check that the ABS modulators and speed sensors are
operating as they should be. When this module is in use, and
the machine is running in gear with a wheel speed of 3.5 kph,
modulators can be switched so that no air gets to a particular
wheel, depending on which green ‘button’ has been switched
on or off, and allow the other wheel to turn twice as fast
1 Press the F8 key or click in the ‘Modulators and Speed

Sensors’ checkbox to open the module.
The screen shows a graphical representation of the ABS

system. Green ‘buttons’ alongside the system relay and
modulator symbols allow you to switch the actual machine
components ‘off’ and ‘on’ directly from your computer.
Connector pin numbers are also shown.
To switch a component off or on, use the mouse to click on

the appropriate button. (A bright green button means that the
component is ‘on’; a dull green button means that the
component is ‘off’.)
The button adjacent to the brake switch symbol is ‘read only’;

you cannot control the brake switch from the computer.
The speed of each roadwheel is shown adjacent to the

appropriate wheel symbol.
Note that when this module is closed down, the relays and
modulators will be reset to their normal operating conditions.
9803/8020 Issue 1*
43 - 1 Wingst Program 43 - 1
Contents Page
Introduction 43 - 2
Equipment Required 43 - 2
Installation of the Software 43 - 3
Connecting the PC to the Fastrac 43 - 6
Starting the Program 43 - 7

Main Screen Menu 43 - 8
File 43 - 8
Delete Files 43 - 8
Exit Files 43 - 8
Edit 43 - 9
Copy 43 - 9
Preferences 43 - 9
Setup 43 - 9
Setup from Vehicle Type 43 - 10
Setting from VIN 43 - 11
Programme Specific Items 43 - 12
Level 1 43 - 13
Level 2 43 - 13
Level 3 43 - 14
Save Settings 43 - 14
Load Settings 43 - 15
Reload Transmission EEPROM 43 - 15
Update EMS Software 43 - 16
Data Logging 43 - 18
Download Data Log 43 - 18
Filter 43 - 19
Fault Description 43 - 20
Erase Datalog Memory 43 - 20
Load File 43 - 21
Window 43 - 22
Glossary of Data Log Terms 43 - 22
Diagnostics 43 - 23
Transmission 43 - 23
Values 43 - 23
Inputs 43 - 25
Outputs 43 - 27
EMS 43 - 27
Values 43 - 27
Inputs
LED Inputs 43 - 29
Outputs 43 - 33
Wet Clutch 43 - 34
Pedal 43 - 34
Values 43 - 35
Misc 43 - 36
Help 43 - 37
EMS Information 43 - 38
About 43 - 38
9803/8020 Issue 1
1 Introduction
The program 'wingst' is the laptop PC version of the Fastrac Psion Service Tool. It has 4 main functions:
1 Setting up the Electronic Monitoring System (EMS - also known as the Digital Dash or Instrument Cluster) for a particular
vehicle.
2 Updating the EMS with new software.
3 Downloading fault codes and other datalogging information from the EMS.
4 Diagnostic use.
The 'wingst' program is used to obtain information not only from the EMS but also from other ECU's connected to it by the
CANBUS.
1.1 Equipment Required
There are essentially 3 items required:
1 A laptop PC.
2 The latest version of the JCB Service Master Software, which includes the 'wingst' program.
3 A connecting lead from the PC to the Fastrac (see below).
There are 2 compatible connection leads for the Fastrac:
Cable Part No Additional Info
Fastrac connection cable 721/00664 same lead as was used for connecting the
Psion to the Fastrac
Combination lead 892/01066 can also be used
A406950
Note: Software dongle 728/10100 is not required for ‘wingst’ version 4.00 onwards.
9803/8020 Issue 1
1 Introduction (continued)
1.2 Installation of the ‘Wingst’ Software
Insert the CD containing the JCB Service Master Software into the laptop and open the corresponding CD drive. The
following should appear:
Open the folder labelled 'Electronic Diagnostics Tools':
Open the folder labelled 'Service Master Installation':
Double-click on the program labelled 'Setup.exe'. This will take you to the following screen:
9803/8020 Issue 1
1.2 Installation of the Software (continued)
Click on the button labelled 'Extras'. The next screen will appear:
Choose JCB Fastrac Tool and press 'Install'. The program will commence with the installation process.
At the first screen to appear simply press the 'Next' button, after having read all the important information. The following
screen will then show:
9803/8020 Issue 1
1.2 Installation of the Software (continued)
This screen is important as it selects the location of 'wingst' program. The default location is at: C:\wingst as shown above.
It is advisable not to change this, but if you do make a note of the new location! Then press the 'Next' button to continue.
The next screen that appears is simply to add the 'wingst' program to the Start Menu on the PC. So just press the 'Next'
button.
The final screen to arrive is just to confirm the installation so press the 'Finish' button. This automatically takes you to the
following screen:
However do not launch the program yet.
The location of the above folder is: C:\Windows\Start Menu\Programs\Fastrac Service Tool\
Note: If you want to create a shortcut to the Fastrac Service Tool to place on the Desktop of the PC for easy and quick
access to the program, right-click on the icon shown above and select 'Copy'. Then go to the Desktop and right-click again
somewhere on the background selecting 'Paste'. This will leave the desired shortcut on the Desktop.
Then close the folder.
The program can be launched either the Start Menu, or from the shortcut (if one has been placed on the desktop) or from
within the Fastrac section of Service Master.
9803/8020 Issue 1
1.3 Connecting the PC to the Fastrac
The laptop is connected to the vehicle electronic system by means of a rectangular 8 way Sumitomo diagnostic connector A
which can be found clipped underneath the fuse and ignition switch cover. A Fastrac diagnostic lead goes between connector
A and the laptop.
Note: This connection is direct from the laptop serial port (RS232) to the machine, e.g. not using the DLA.
A A
Error Messages!
While trying to operate the program the following messages may appear:
This indicates that the laptop PC is not correctly connected to the Fastrac. It is therefore wise to check the following:
1 The ignition is on.
2 The engine is stopped.
3 The connection from the PC to the tractor is made.
4 The correct COM port is selected (see next section).
For older version of the software (pre version 4.00) the following screens may appear indicating you required a Dongle. It is
advisable to update to the latest version of software that does not require one.
9803/8020 Issue 1
1.3 Connecting the PC to the Fastrac
2.0 Starting the Program

The first screen that will appear when launching the program for the first time is the Preferences screen as shown below:
If the screen does not show, and the first screen that is displayed is the one below, it may be because the COM Port
automatically chosen by the program will be the correct port on the computer or PC. In this case skip ahead to Section 2.1.
The left-hand column is for selecting the required language for the program. To start operating in the new language the
'wingst' program must be restarted.
The right hand column labelled Communications Port is to select the port on your computer through which you want to
communicate with the Fastrac. It will be the serial port that the lead is connected to.
There is a choice of four. If the one you select is already being used for another application then the following message will
appear and you can simply select another:
The box at the bottom labelled Use compatibility mode for flash downloads should be ticked if using Windows 2000, NT or XP
and not ticked for Windows 95 or 98.
9803/8020 Issue 1
2.0 Starting the Program (continued)

2.1 Main Screen Menu
Once you have passed the initial setup screen you will arrive at the main screen menu:
It has 6 different sections: File, Edit, Setup, Data Logging, Diagnostics, and Help.
2.2 File
2.2.1 Delete Files
The left-hand box labelled EMS Serial Number is for selecting a particular machine, which is done by scrolling down the list.
The folder where all the data corresponding to a particular machine is named is the same as the machines serial number.
The right-hand box labelled Delete Files Older Than is to select a time period, at the end of which any EMS file that still
exists will be automatically deleted. This function also deletes setup (.cfg) and engineering files (.eg).
2.2.2 Exit
To exit the JCB Fastrac Service Tool Program.
9803/8020 Issue 1
2.0 Starting the Program (continued)

2.3 Edit
2.3.1 Copy
Part of the standard Windows copy and paste function.
2.3.1 Preferences
This screen is where you are able to select the language and necessary COM Ports (See Starting the Program).
3.0 Setup
This menu allows an EMS to be configured to suit a particular vehicle.
Available Options:
Note: Options 1 and 2 achieve the same results by different routes.
1 Setup from Vehicle Type: This sets up the EMS using factory defaults derived from the model type, maximum rated
speed, required language, tyre size and the machine serial number (the last 7 digits of the VIN or Vehicle Identification
Number).
2 Setup from VIN: This sets up the EMS using factory defaults derived from the full VIN and required language and tyre
size.
3 Programme Specific Items: Allows any individual item to be set-up.
9803/8020 Issue 1
3.0 Setup (continued)

3.1 Setup from Vehicle Type
Note: This option only needs to be used if a new dashboard is fitted to the machine.
Note: On the Vehicle Type selection the letter 'E' represents an Electronic engine.
Vehicle Type to select the corresponding type of Fastrac, e.g. 3220
Rated Vehicle Speed to select the speed of the Fastrac, e.g. 65 kph
Language to select the language the Fastrac dash displays, e.g. English
Tyre Size to select the correct size tyres on the Fastrac (the number on the right corresponds the
rolling radius)
Serial Number enter here the serial number of the Fastrac (seven digits)
Wheel Slip Switch to either enable or disable the wheel slip (select the Disabled option if using an external
wheel slip switch)
Flow Divider to either enable or disable the flow divider (if no flow divider is fitted or no icon or warning
lamp appears on the EMS then disable)
Fuel Flow Meters sets the Fuel Flow and Fuel Return rates (in Pulses/Litre) (Not required on electronic
engine Fastracs)
Fuel Level Sensor select either Stick or Arm depending on the Fastrac
The Fuel Flow Meters are an optional package on the Fastrac and their section will only be highlighted if they are fitted.
9803/8020 Issue 1
3.2 Setup from VIN
Note: This option only needs to be used if a new dashboard is fitted to the machine.
VIN the individual Vehicle Identification Number of the Fastrac (a 12 digit number that is automatically prefixed by the
letters SLPFT for every Fastrac)
Note: If an invalid VIN is entered the following screen will appear. In this case go back and insert the correct VIN.
For further information on the make up of the Fastrac's individual VIN see Section 1, Page No. 1 - 1 in the JCB Fastrac
Service Manual.
The rest of the settings are the same as those of the Setup from Vehicle Type (see previous Section 3.1).
9803/8020 Issue 1
3.3 Programme Specific Items
The sub menu displays the following programming options: Level 1, Level 2, and Level 3. The function of these is covered
below:
Level 0 Normal Display (Available to Operator and JCB Dealers)
Level 1 Operator Set-up (Available to Operator and JCB Dealers)
Level 2 Dealer Set-up (Available to JCB Dealers Only)
Level 3 Factory Set-up (Available to JCB Dealers Only)
Each of the different levels is laid out in a similar form. Down the left-hand side is a description of the settings that can be
changed. In the centre-left column are the current settings that are already on the Fastrac. In the centre-right column you can
change the settings as required.
On the right-hand side are 3 buttons:
Programme to program the new settings onto the Fastrac
Cancel to return to the main menu with NO SETTINGS BEING CHANGED
Defaults to return all the settings back to the values shown in the Current column
9803/8020 Issue 1
3.3 Programme Specific Items (continued)
Note: For correct settings for each option refer to Technical Data.
3.3.1 Level 1
Speed Display to set the speed display to either kph or mph

Centre Display to set the centre display to either work in metric (kilometres & hectares) or imperial (miles
& acres)
Optional Tyre Mode to set the tyre size to Standard or Optional
Optional Tyre Size to select the size of the Optional tyre on the Fastrac (the box on the right displays the
rolling radius of the selected tyre)
Implement Width to set the width of the implement being operated by the Fastrac
Clock displays the time on the Fastrac dash (it can only be changed using the dash buttons)
Date displays the date on the Fastrac dash (it can only be changed using the dash buttons)
3.3.2 Level 2
PTO 1000 Ratio the engine rpm when at 1000 PTO rpm (used for PTO display)
PTO 540 Ratio the engine rpm when at 540 PTO rpm (used for PTO display)
Maximum Speed to set the full scale of Bar Graph in the speed display
Standard Tyre Size to set the tyre size for the speed display
Ground Speed Gear Ratio calibration of transmission speed sensor (pulses / road wheel revolution)
Fuel Tank Size either 250 litres or 350 litres (used for fuel remaining display)
Service Counter to reset counter after a service has been performed
Engine hrs. @ Service sets the standard service interval (usually 250 hours)
Language to set the language displayed on the EMS and transmission functions
Note: The Service Counter counts down from its current value and warns the operator, via the dashboard, that a service is
due.
9803/8020 Issue 1
3.3 Programme Specific Items (continued)
3.3.3 Level 3
Note: Level 3 items should only be changed from the Factory Defaults under special circumstances.
Engine Pulses the alternator calibration value for the engine rpm signal (Hz / 1500rpm)
LED Dimming to adjust the % brightness of the EMS warning lamps when the sidelights are on (100% =
max brightness)
Fuel Flow Pulses/Litre the fuel meter calibration (used for fuel rate displays on the EMS on non-electronic
engines)
Fuel Return Pulses/Litre the fuel meter calibration (used for fuel rate displays on the EMS on non-electronic
engines)
Radar Calibration the calibration value for the radar speed sensor (Hz / mph)
Hitch Controller either EMS or EDC
EDC - an external wheel slip switch is fitted (no need for EMS enable/disable facility)
EMS - no external wheel slip switch is fitted (EMS enable/disable facility required)
Fuel Meter Damping either Slow Response or Quick Response:
Cummins Mechanical Engine = Slow Response
Perkins Engine = (will operate with either)
Flow Divider select Enabled if fitted (this will activate the dash lamp), or Disabled if not fitted (if not
fitted and Enabled is selected the dash lamp will be permanently lit)
Fuel Flow Meters select either Not Fitted or Fitted
Fuel Level Sensor select either Type 2 (Stick) or Type 1 (Arm)
Selectronic Audible Warning select either On or Off
Auto Reverse Audible Warning select either On or Off
Auto Reverse Speed select from: Fast, Standard, Slow, or Ex Slow
3.4 Save Settings
If a new EMS is going to be fitted it is possible to save all the settings in the old EMS by following this function.
The settings will be saved to a file in a directory located in: C:\wingst\. The file is stored in 'cfg' file format (meaning that all
the files are suffixed by '.cfg'), in the directory of the machine serial number, under a file name based on the entry date e.g.
05092002.cfg.
9803/8020 Issue 1
3.5 Load Settings
If a new EMS has been fitted and the settings of the old one were saved, this function will load them into the new unit.
To load the EMS level 1, 2 and 3 settings onto the PC from a file. The settings file can be found in a directory labelled with the
serial number of the Fastrac in: C:\wingst\ in the same format they were saved in (see previous Section):
3.6 Reload Transmission EEPROM
This option allows the transmission controller settings and calibration to be set back to the same as the brand new unit. After
this operation has been completed the controller will require calibration.
The file containing the settings is called Eeprom1.ini
Clicking on ‘Open’ will load the information into the transmission controller.
9803/8020 Issue 1

3.7 Update EMS Software
The EMS is computer controlled and contains 'Flash' memory chips to store the computer program. This is a form of memory
that can be erased and reprogrammed without the need to remove it from the EMS.
JCB may release product enhancements or problem fixes, which require an updated program to be loaded into the EMS.
This software comes in the form of 'Hex Files', which are suffixed with '.hex'. They should be located in the main 'wingst'
directory: C:\wingst\. If an update becomes available then it should simply be placed into the main 'wingst' directory.
Note: During this sequence care should be taken that each part is fully completed before the next step is started.
Select the software required from the files starting ‘Jcbv’ followed by the version number and ending in ‘.hex’.
Turn off the ignition and wait for the EMS to go blank. Then click ‘OK’.
9803/8020 Issue 1

3.7 Update EMS Software (continued)
Turn on the ignition and the EMS display will be random. Then click ‘OK’.
Wait while the transmitting bar graph completes.
When requested turn off the ignition. Then click ‘OK’.
Click on ‘OK’ and when the ignition is next turned on the EMS will operate.
9803/8020 Issue 1
4.0 Data Logging

Much of the Fastrac electronic system uses a CAN (Controlled Area Network) bus link to send fault codes and other
information from any CAN connected ECU to the EMS. This then warns the driver, via the EMS centre display, that there is a
problem. Each fault will then be logged in the memory of the EMS for later recall.
4.1 Download Data Log
To download the Data Log from the Fastrac to the PC for viewing. It can also be stored as a file and viewed at a later date.
When the Download Data Log option is selected the following screen will appear showing the progress of the download:
The screen below will then follow it:
This shows how much available memory is used as a percentage value. If this value is quite high (e.g. 40%) it is advisable to
select Yes to erase the log and free up memory space for future use. Otherwise select No and the data log will be retained on
the EMS.
The data log should now show up in a white window (see snapshot below):
9803/8020 Issue 1
4.0 Data Logging (continued)
4.1 Download Data Log (continued)
Once the Data Log has been downloaded a selection of new options will arrive on the Data Logging menu. A new main menu
named Window will also appear. (See below)
4.2 Filter
The new options that have arrived are Filter and Fault Description. The Filter option then has a sub-menu containing the
following options: All, Transmission, Display, Error and Other.
The filter option is simply to help organise the data log. There are 5 different options:
All displays all the error codes in the log

Transmission shows only the transmission 'T' codes
Display shows only the EMS 'D' codes
Error shows only the engine 'E' codes
Other…
This filter option allows the user to customise their search. A specific error code can be found, for example a T016, or a
particular range of codes can be found using a 'wildcard'. The wildcard allows any digit to 'pass-through' the filter at that
point. The symbol for the wildcard is '*'. For example, to display all 'T' codes from T010 to T019, the filter would be T01*. Any
number of wildcards can be used in any of the 4 fault code digits (entering **** as the filter would cause all the codes to be
displayed).
9803/8020 Issue 1

4.3 Fault Description
This is to find out the cause of a particular fault. Simply highlight a part on the required row of the Data Log:
Then select the Fault Description option from the Data Logging Menu. The following screen should appear stating the
source of the error:
A record of all the data log error codes can be found in the JCB Service Manual.
4.4 Erase Datalog Memory
This clears all the data logs from the EMS memory. It also resets all the maximum values to zero. Once erased, the data logs
in the EMS cannot be restored. (See Download Data Log - Memory Illustration)
9803/8020 Issue 1

4.5 Load File
Note: The laptop PC does not need to be connected to the Fastrac to recall a saved data log.
This option is to load a previously downloaded Data Log. These can be found in the following folder: C:\wingst\ as shown
below:
Opening the folder named 'wingst' will arrive at a second screen showing files labelled with the 7 digit serial numbers of any
Fastrac that has information stored on the PC. Open up the desired one of these and the next screen will appear:
The logs are all automatically placed in a folder corresponding to the 7 digit serial number of the Fastrac. In this case the file is
0642489, located in the 'wingst' folder: C:\wingst\0642489
Note: If the EMS is not set up with the correct VIN number a folder labelled '_NO_VIN' will be created.
Within the file the logs are all indexed by their date. For example 04092002 was taken on the 4th September 2002. The
suffixes at the end of each log describe the type they are:
lg normal log (lists all the errors)

eg engineering log (contains more information about before and after the error occurs)
The numbers at the end simply correspond to the order in which the logs were taken. For example 04092002.lg0 was the first
log to be taken on that day. Then 04092002.lg1 was the second log etc. These end values can be any character 0 to 9 and A
to Z. This allows 36 data logs to be stored from the same machine on the same day, before the first file will be overwritten.
9803/8020 Issue 1

4.6 Window
The window menu simply gives you the options to arrange the data logs in a variety of different ways:
It will also indicate which data log window you have currently selected by placing a tick by it at the bottom of the scroll menu.
Other options that will appear are a Print option in the File menu. Also the Reload Transmission EEPROM setting in the
Setup menu disappears.
4.7 Glossary of Data Log Terms:
Serial Number the serial number of the Fastrac (7 digits)

File Name the file name of the data log
Product ID the product identification number
JCB Part Number (not now supported)
Hardware Revision (not now supported)
Software Revision the software version that is currently loaded in the EMS
JCB Software Part No. the JCB Part number of the software
The EMS automatically stores a number of counters and maximum values that the Fastrac has seen. The maximum values will
be erased when the data log memory is erased. However the counters are never erased throughout the machine life.
Fast Slip Time the time that the clutch beeper has been operating at over 1250 rpm
Slow Slip Time the time that the clutch beeper has been operating at under 1250 rpm
Max Coolant Temp. the maximum recorded temperature within the coolant system during operation (°C)
Max Transmission Temp. the maximum recorded temperature within the transmission system during operation (°C)
Max Ground Speed the maximum ground speed recorded
Max Engine RPM the maximum engine rpm recorded
Max Voltage the maximum voltage recorded
Time Ground Speed >20kph the time spent at a speed greater than 20kph
Time PTO Engaged the time that the PTO has been operated
Once a fault code is generated by an ECU the EMS will take a 'log' of the vehicle's system which includes the following
values:
Session Number the number of the session representing the occasions that the machine has been switched
on with a new fault logged
Log Number the unique log entry number
Event Date the date of the event
Event Time the time of the event
ECU ID the fault code
Error Code the error code
Machine Hours the engine hours
Cumulative Distance the total distance (kilometres)
Error Status the error status (a '0' indicates a fault occurred and a '1' indicates the fault disappeared)
Engine RPM the rpm of the engine
Ground Speed the speed of the Fastrac
Coolant Temp the temperature of the coolant
Transmission Temp the temperature of the transmission (wet clutch)
9803/8020 Issue 1

4.7 Glossary of Data Log Terms: (continued)
Note: Removing the vehicle battery will not cause the datalog, counter or maximum values to be lost.
All of the above information can be downloaded from the EMS to assist the service engineer to trace faults and track use
history. It can also be used to establish if a particular fault is a real problem or whether the machine has been abused in some
way. This information may also assist to support or reject warranty claims.
5.0 Diagnostics
These diagnostics modes are simply for reading information from the Fastrac and no settings can be changed.
When this main menu option is highlighted 3 options are shown. The Wet Clutch option will not appear for older machines
with a dry clutch transmission.
Each of the 3 options provide a status report of the various inputs and outputs, and values for the EMS, the Transmission
Controller or the Wet Clutch if fitted.
When one of the options is accessed, the centre display on the Fastrac's EMS will display 'DIAGMODE'.
Note: These functions can be carried out with the engine running to allow diagnostics to be carried out.
5.1 Transmission
This is the Transmission ECU Diagnostics mode.
To exit and return back to the main screen menu simply click on Done.
5.1.1 Values
This menu option allows the input or stored values from the Transmission Controller to be checked.
9803/8020 Issue 1
5.0 Diagnostics (continued)

5.1 Transmission (continued)
5.1.1 Values (continued)
RPM
The RPM menu includes information on the Actual Engine RPM and User Mode Values. These values are the Upper and
Lower rpm change points of the Autoshift.
Hours/Distance
The Distance travelled and Transmission hours are both displayed.
Calibration
This shows the Clutch pack calibration times for each of the 3 speeds in the Selectronic Range Change: Snail, Tortoise and
Hare.
9803/8020 Issue 1

5.1.2 Inputs
This menu option allows the status of the various inputs to the Transmission Controller to be checked (either On or Off). The
'wingst' program constantly updates the display to the current status.
Column Switch
Shows the current status of the Selectronic Column Switches for Low, High, Medium and Reverse. At the present the column
switch is in neutral (switch closed = 0V at ECU input).
Ram Switches
Displays the current status of the Selectronic Ram Switches. The current screen shows the range box in neutral (Off = switch
closed = 0V at ECU input).
9803/8020 Issue 1

5.1.2 Inputs (continued)
Pedal Switches
The picture above shows the Throttle at idle and the Handbrake on.
Off = switch closed = 0V at ECU input

On = switch open = 12V at ECU input
For dry clutch transmissions it will display Clutch 'Up' / 'Down'.
Speed Triggers
Shows the status of the 3 Speed Triggers 1, 3 and 20 kph. At present the vehicle is at a speed less than 1 kph (< means
speed less than, > means speed greater than).
Gear Knob Switches
Shows the status of the switches and if they are functioning correctly. None of the buttons are presently being pressed.
Note: These switches are duplicated on the right-hand control panel as well as the gear stick.
9803/8020 Issue 1

5.1.3 Outputs
Solenoid Status
Shows the status of the 3 speed solenoids, on (12V) or off (0V), along with serviceability status (OK or Fault). A solenoid
shown as off (0V) and a fault status of OK may have been switched off by the ECU due to a fault.
Another selection labelled 'Rev Lmps' will appear on older machines with the dry clutch transmission.
5.2 EMS
This is the EMS ECU Diagnostics mode.
5.2.1 Values
Allows the values on the dash display to be checked.
9803/8020 Issue 1

5.2 EMS (continued)
Gauges
This screen shows the current values on the gauges on the EMS and their signal values, e.g. at 14°C the input voltage is
2.607V.
Note: Not on an electronic engine as coolant temperature is transmitted over the CAN Bus, and so is not displayed here.
Dials
This displays the Engine RPM, Axle and Radar speeds (in kph) and their corresponding frequencies.
Fuel Meters
Note: For electronic engines there no display for the flow rate of the Feed and Return meters and their frequencies, as it is
transmitted over the CAN Bus.
9803/8020 Issue 1

5.2 EMS (continued)
5.2.2 Inputs
Note: For dry clutch machines an extra option will become available that is labelled 'Autoshift Display'.
5.2.2.1 LED Inputs
The above sub menu provides the option to check the actual display with the inputs into the dash, to ensure that it is
displaying correct information. These inputs are either displayed as On or Off.
LED Inputs - PTO
'On' / 'Off' indicates that the relevant PTO option is engaged/disengaged respectively.
9803/8020 Issue 1

5.2 EMS (continued)
5.2.2.1 LED Inputs
LED Inputs - Lamps
Shows the current status of the Sidelights and the Main Beam.
LED Inputs - Other
Displays the status of the Differential Lock, 4WD and Flow Divider.
LED Inputs - Indicators
Shows the status of the indicators on the Fastrac, First Trailer, and Second Trailer (if they are connected).
9803/8020 Issue 1

5.2 EMS (continued)
5.2.2.1 LED Inputs (continued)
LED Inputs - Air Tanks
Displays the status of the 3 air tanks. The 'Off' indicates the status of the light on the dash for each corresponding tank. They
will change to 'On' when the tank gets low.
LED Inputs - Brakes
This screen has the status of the Brake Fluid, Trailer ABS and Handbrake. If their status changes the light on the dash will be
illuminated and an 'On' will appear.
LED Inputs - Engine
Shows the status of the different Pressures and Filters, as well as the alternator. The Engine Oil Pressure is measured through
the CAN bus on the electronic engines.
Note: If the Transmission Oil Pressure is labelled as 'Bad', as above, it will probably be due to the Engine not having been
started.
9803/8020 Issue 1

5.2 EMS (continued)
EMS Buttons
Provides a means of testing the buttons on the dash. When the corresponding button is selected on the dash an 'On' will
appear indicating that it is functioning correctly.
Range Display
Provides a means of checking the current range status from the transmission ECU and of verifying the dash. When the
corresponding gear is selected an 'On' will appear instead.
Note: For machines with a dry clutch an extra line will appear labelled 'Current Gear'.
Centre Display
This option checks that the EMS inputs correspond with the dash.
9803/8020 Issue 1

5.2 EMS (continued)
Diagnostics
This option checks for the presence of Axle/Radar Speed Sensor detected inputs, along with the status of the Program line
input. The Prog Input option is only used when updating the software.
5.2.3 Outputs
Fault Status
Reports if faults occur in any of the speed triggers, diff-lock cut-outs and relays.
Diff Lock Cutout
Show the status of the Differential Lock Cutout at the relay contacts.
9803/8020 Issue 1

5.2 EMS (continued)
5.2.3 Outputs (continued)
Speed Triggers
Shows the status of the speed trigger outputs (< means speed less than, > means speed greater than).
5.3 Wet Clutch
This is the Wet Clutch Diagnostics mode.
5.3.1 Pedal
The 3 options relate to the clutch pedal position, mapping of the clutch pedal characteristics and values obtained during the
calibration.
Position
9803/8020 Issue 1
5.3 Wet Clutch (continued)
5.3.1 Pedal (continued)
Position (continued)
Shows the current position of the clutch pedal in terms of how the ECU interprets it (a number between 0 and 255), how the
ECU reads if (Volts) and as a percentage of the calibration values (0% = fully depressed, 100% = fully up).
The Clutch Down Switch indicates the whether it is Open, or Closed (this only occurs when the clutch is fully depressed).
Mapping
The ramp information describes the amount of clutch engagement relative to clutch pedal position. This effects the 'feel' of
the pedal. These numbers are intended for viewing and cannot be changed. The Clutch Bite Point indicates the average
percentage pedal position at which the clutch will bite.
Calibration
These numbers are obtained during calibration. The Pedal Up/Down Values are the values read by the ECU with the pedal in
the fully up/down position respectively.
The Calibration Temperature is the wet clutch oil temperature measured during calibration. The Calibration Current is the
current through the master clutch solenoid required to drop the engine speed by 100 rev/min during calibration.
5.3.2 Values
This menu displays options that give the ability to view the current status of the master wet clutch current and auxiliary clutch
status.
9803/8020 Issue 1
Master Clutch Currents
The Required mA value is the current the ECU wants to achieve for a command signal to the master clutch solenoid. The
Measures mA value is the current the ECU measures for a given command signal. These numbers will differ slightly.
Aux Clutch Solenoids
This option shows whether the Auxiliary clutch solenoids, the clutch lubrication solenoid and transmission brake solenoid, are
on or off along with the fault and status indicators.
Lube Rate: Low = 12V High = 0V

Clutch Brake: Off = 0V On = 12V
If there is a fault the ECU may have switched the solenoid off which resets the fault status to OK.
Note: Clutch Brake is also referred to as Transmission Brake in other parts of the manual.
5.3.3 Misc
9803/8020 Issue 1
5.3.3 Misc (continued)
Auto Reverse
The Auto Reverse option displays the status of the Auto Reverse button and information relating to its characteristics. These
cannot be changed.
Switch Status either On or Off (i.e. engaged/not engaged)

Switch Diag to check the switch is working properly
Ramp Time the time delay for the clutch to engage
Back Off Value how much the clutch is disengaged before ramping starts
Note: Auto Reverse is also known as Auto-Shuttle.
Transmission Oil
This option displays the current Bulk and master Clutch oil temperatures. Bulk refers to the oil in the main transmission circuit
close to the filter.
6.0 Help
These options give information about the EMS fitted to the machine and the software being operated.
9803/8020 Issue 1
6.0 Help (continued)
6.1 EMS Information
VIN the Machine VIN (17 characters)

JCB Part Number (not now supported)
Hardware Revision (not now supported)
Software Revision the software version that is currently loaded in the EMS
Product ID the manufacturers part number for the EMS
6.2 About
This displays the information about the Software on the PC: the current version running and the latest EMS software file
name. This will be used in the set-up program for automatic updating.
If the latest EMS file is labelled as 'None', then there is no EMS file loaded onto the transmitting computer.
Note: If the software version in the EMS is lower than the software version in the computer it should be updated (see Update
EMS Software, page 43 - 16). All the latest software is fully compatible with the older machines.
9803/8020 Issue 1
44 - 1 Electronic Service Tools 44 - 1
Engine Diagnostic Tool

This tool has been added to JCB Service Master to help with diagnosing and fixing problems involving the engine.
1 General Information 9 Identification

2 When the program is started 10 Inlet Exhaust Conditions
3 Help 11 Field Speed Control (FSC)
4 Options - Metric or Imperial 12 Throttle Control
5 Engine Oil Pressure 13 Vehicle Electrical Power
6 Engine Speed & Hours 14 Vehicle Speed
7 Engine Temperatures 15 Fault Codes
8 Fuelling Information
1 General Information
The information displayed by this program is taken directly from

the engine ECU. Therefore if an unexpected reading is observed
an independent device should be used to verify the information
seen by this program. This check will identify if the unexpected
reading is as a result of an engine sensor system fault or if the
engine is operating incorrectly.
Connect the computer to the diagnostics socket B using the B

Data Link Adaptor (Part No. 892/01033) and Connector Harness
721/10855. See Service Tools.
With the computer connected to the diagnostics socket (also

used for ABS diagnostics), ensure that the ignition is turned ON
before opening JCB Service Master.
Start JCB Service Master, then use the selector arrows in the
centre panel to select the ‘Fastrac’ screen. Click on the Engine
First Aid symbol. The Engine Diagnostics Tool window will
appear.
9803/8020 Issue 1
Engine Diagnostic Tool (continued)
2 When the program is started.
When the program is running, communication is started by "clicking" on the green circle B.
Once communication has been established then the red and green circles C and D will flicker on and off.
C D
9803/8020 Issue 1
3 Help 4 Options - Metric or Imperial
The "Help" and "About" option can be used to find which Within the "Options" list the operator can chose between
version level of this program is installed on the computer. working in Metric or Imperial units.
New versions of the program are released when required on
the service CD set. For example: To swap between pressures displayed in Bar
or lbf/in2.
The screen below shows the program currently installed on

the computer is version 1.0.0.7
9803/8020 Issue 1

5 Engine Oil Pressure
This option allows the status of the engine oil pressure switch to be monitored. The switch is installed in the engine block and
operates at 0.4 bar (6 lbf/in2).
If the engine oil pressure is less than 0.4 bar (6 lbf/in2) the switch remains open and the engine oil pressure readout will display
zero.
An engine oil pressure of greater than 0.4 bar (6 lbf/in2) causes the switch to close. When the switch is closed it is assumed
the engine oil pressure is healthy and the engine oil pressure readout will display 3.8 bar ( 54.5 lbf/in2).
9803/8020 Issue 1

6 Engine Speed & Hours
This option shows the engine speed and the engine hours. The engine hours displayed figure is the hours logged by engine
ECU and may be different from the machine hours displayed on the EMS dashboard.
9803/8020 Issue 1

7 Engine Temperatures
This screen displays the temperatures from the coolant temperature sensor in the engine block and the air temperature sensor
in the inlet manifold. Also the fuel temperature at the fuel injection pump is displayed.
The coolant temperature is the same as that displayed by the EMS dashboard. From these figures the engine ECU controls
the fan and the estimated percentage fan drive figure is calculated and displayed. This gives an indication of how much
engaged the fan should be.
9803/8020 Issue 1

8 Fuelling Information
This screen shows the quantity of fuel being used by the engine per hour. The status of the "Water in Fuel" sensor is also
displayed.
9 Identification
This screen shows engine identification information. Many of the areas are left blank within the Fastrac engine ECU.
9803/8020 Issue 1

10 Inlet Exhaust Conditions
This screen shows the inlet manifold boost pressure and temperature, according to the engine sensors.
9803/8020 Issue 1
11 Field Speed Control (FSC)
This is also known as Intermediate Speed Control. The screen shows the status of the increment and decrement switches.
The Enable and Validation switches are shown for wiring information, but their status cannot be determined by this program.
9803/8020 Issue 1

12. Throttle Control
This option shows the status of the throttle controls. The foot throttle idle validation switch position is displayed as either on or
off. The position of the hand throttle potentiometer is given as a percentage. The total throttle readout displays the position of
whichever throttle (hand or foot) position is highest.
The percentage engine load is also displayed.
9803/8020 Issue 1

13 Vehicle Electrical Power
This screen shows the supply voltage to the engine ECU and also the status of the "wait to start" lamp.
14 Vehicle Speed
This screen shows the vehicle speed according to the engine ECU. This speed will be similar to that shown on the EMS
dashboard, but it may not be identical as it is measured by a different sensor.
9803/8020 Issue 1
44 - 12 Electronic Service Tools 44 -12

15 Fault Codes
This screen shows the engine fault codes as logged by the engine ECU which may be different from those logged by the EMS
dashboard.
The screen is split into the faults that are currently present and those that have occurred previously. The screen is
automatically updated at regular intervals.
The "Erase" button erases the logged faults from the engine ECU. It does not erase them from the EMS dashboard.
The screen below shows that no faults are currently active and no faults have occurred since the memory was last erased.
9803/8020 Issue 1

The following screen shows the Fault Codes panel with two previously active fault codes logged. A description of the fault, the
number of times it has occurred and its effect or the action taken by the engine ECU are displayed. A description of the failure
mode is shown below. The number in brackets at the end of the fault description is the Troubleshooting Fault Code, as used
in the Troubleshooting and Repair Manual.
Failure Mode Description
0 Data valid but above normal operational range

1 Data valid but below normal operational range
2 Data erratic, intermittent or incorrect
3 Voltage above normal or shorted high
4 Voltage below normal or shorted low
5 Current below normal or open circuit
6 Current above normal or grounded circuit
7 Mechanical system NOT responding properly
8 Abnormal frequency, pulse width or period
9 Abnormal update rate
10 Abnormal rate of change
11 Failure mode NOT identifiable
12 Bad intelligent device or component
13 Out of calibration
14 Special instructions
15 Data valid but above normal operational range (least severe)
16 Data valid but above normal operational range (moderately severe)
17 Data valid but below normal operational range (least severe)
18 Data valid but below normal operational range (moderately severe)
19 Received network data in error
9803/8020 Issue 1
45 - 1 ABS Electronic Control Unit 45 - 1
Removal
1 Remove the passenger seat as follows:

From beneath the cab locate the four nuts/studs
securing the seat. Remove the nuts and lift the seat
clear to provide access to the E.C.U. behind it.

From within the cab, remove the three Pozidriv self
tapping screws along the underside of the front edge of
the seat base pressing. Lift out the foam pad of the
seat. Locate the four M8 bolts/nuts which secure the
seat base pressing to the fore/aft mounting rails. Use a
pair of spanners to remove the four sets (nuts
lowermost) and release the seat. Lift the seat clear to
reveal the E.C.U. attached to its mounting plate (which
has been unclamped as a result of the above
procedure).
2 2000 Machines Only A

Take off the plastic moulding protecting the E.C.U. after A
removing the three M6 socket-head screws which
secure it.
3 Remove the E.C.U. cover as follows:

Move the sliding catches A to one side and ease the
A387780
covers over each end of the unit to reveal the
connector. Remove the three connectors.
4 Remove the E.C.U. as follows:

The E.C.U. is secured to its mounting bracket by three
socket-head screws. (Note that one of the screws is
situated between the two connectors at one end.)
Remove these screws and lift the E.C.U. clear.

Lift the E.C.U., complete with its mounting bracket,
clear of its cab location and remove to workbench
before separating the two components.
Replacement
9803/8020 Issue 1*
Section D Controls Section D
Contents Page No.
Technical Data 1-1
* Throttle Controls
Foot Throttle Control Cable (All machines except 2140)
Hand Throttle Control Cable (All machines except 2140)
Field Speed Control (2140 only)
Operation 2-3
Adjustment 2-3
External Hydraulics Control Valve Linkage

Lever Linkages - Removal and Replacement 3-1
Flow Control Linkages 3-2
Setting Flow Control 3-2
Power Take-off Speed Selector Cable

JCB Selectronic System (Air Assisted Range Change)

System Description 11 - 1
Operation 11 - 3
Limp Home Mode 11 - 8
Pneumatic Cylinders
Renewing Microswitches 13 - 2
Setting-Up
Setting Range Gearbox Turret Stops 13 - 2
Setting Cylinder Rod Neutral Lengths 13 - 2
Setting Microswitch Positions 13 - 3
Pressure Regulator
9803/8020 Issue 5*
JCB Selectronic
* Pneumatic Cylinders
Piston Bore and Stroke (Dry Clutch) 32 mm (1.26 in) x 50 mm (1.97 in)
Piston Bore and Stroke (Wet Clutch) 40 mm (1.57 in) x 50 mm (1.97 in)
Maximum Operating Pressure See Pressure Regulator, Pressure Setting
Microswitches
Reed Switch Type 500 mA
Solenoid Valves
Maximum Operating Pressure 7.0 bar (102 lbf/in2)

Supply Voltage 12V DC ( -15% to +10%)
Pressure Regulator
Type Pressure Reducing Valve
Pressure Setting
* Dry Clutch
2000 Series to S/N 739999, 3000 Series to S/N 641999 6.9 bar (100 lbf/in2)
* Wet Clutch
2000 Series from S/N 740000, 3000 Series from S/N 642000 4.5 bar (65 lbf/in2)
9803/8020 Issue 3*
2-1 Throttle Controls 2-1
*
16
15
21 17
19
18
3
1 4
5
2
23
22
12
11
10
7 13
20
14
23
A290411
9803/8020 Issue 3*
Foot Throttle Control Cable * Hand Throttle Control Cable

Removal Removal
Slacken spring lock nut 1. Loosen reaction bracket lock nuts Set hand throttle lever 14 (2000 Series machines) or 22
2 and 3 and remove the cable from reaction bracket 4. (3000 Series, see inset) to the closed position, i.e. fully
Unhook spring 5 from throttle control lever 6. Unscrew forward.
spring 5 from the cable and retain.
Remove split pin/washer 15 and withdraw retaining pin 16
Remove the steering column shroud. Unlock and remove from clevis 17, releasing it from throttle control lever 6.
foot pedal clevis retaining pin 7. Slacken clevis lock nut 8. Remove reaction bracket locknuts 18 and 19 and remove
Remove clevis 9, locknut 8 and bellows 10 from the cable the cable from reaction bracket 4. Feed the cable end
end and, if being re-used, retain these items. through the bulkhead and then back into the cab below the
hand throttle lever, making a note of the route followed and
Slacken and remove engine/cab bulkhead cab side locknut the positions of any ties to aid refitting. Pull off the hand
11 and push the cable forward through the bulkhead. throttle lever knob 23. Unscrew the screws and nuts
Remove the complete cable. securing the hand throttle lever mechanism 14 (2000 Series)
or 22 (3000 Series) and remove the cable, feeding the lever
Replacement
through the slot in the console.
If fitting a new cable, remove clevis 9, retaining pin 7, clevis
lock nut 8, bellows 10 and rearmost bulkhead lock nut 11 Replacement
from it.
Pass the cable end into the cab through the engine/cab
bulkhead. Refit bulkhead lock nut 11, bellows 10, clevis lock Setting Cable Length
nut 8 and clevis 9 to the cable, ensuring that the clevis is
screwed onto the cable end until the cable end is visible in With the foot pedal 13 released and hand lever 14 (2000
the clevis opening. Tighten bulkhead locknuts 11 and 12. Series) or 22 (3000 Series) fully forward, adjust clevis 17
and/or reaction bracket locknuts 18 and 19 so that clevis
Connect clevis 9 to pedal 13 by means of retaining pin 7. retaining pin 16 locates the front end of clevis slot 21.
Slacken reaction bracket lock nuts 2 and 3 and fit the cable
Push the foot throttle control pedal down fully and check
into reaction bracket 4. Screw spring 5 onto the cable end
that clevis retaining pin 16 slides freely in slot 21. Release
and hook onto throttle control lever 6 ensuring that the lever
the foot pedal.
is held in the closed position by its spring. Tighten lock nut
1.
Move hand throttle lever to maximum, fully back, and check
Adjust the position of the foot pedal, in relation to the other that throttle control lever 6 is against its built-in maximum
pedals, by slackening lock nut 8, unlocking and removing stop. If not, move hand throttle lever to fully closed. Loosen
clevis retaining pin 7 and screwing the clevis in or out, reaction bracket locknut 19 and adjust locknut 18 so as to
ensuring that enough rod thread remains in the clevis. Refit shorten the cable. Recheck the maximum hand throttle
and lock clevis retaining pin 7. Lock clevis with lock nut 8. If position. When satisfactory, tighten reaction bracket locknut
there is insufficient adjustment using this method, slacken 19.
bulkhead lock nuts 11 and 12 and move the cable in or out
as required. Tighten lock nuts 11 and 12 when satisfactory. Move both hand and foot throttle controls over their
complete ranges and check that there is no interference
Take up any cable slack between throttle control lever 6 and between throttle functions.
reaction bracket 4 by disconnecting spring 5 and screwing it
in or out, always ensuring that the throttle control lever is Start the engine and, using the hand throttle, increase
against its built-in minimum stop. Tighten lock nut 1. engine speed to the maximum no-load speed. Check that
engine speed remains constant.
If further adjustment is required, release reaction bracket
lock nuts 2 and 3 and move the cable forward or back to
achieve the necessary adjustment. Tighten lock nuts 2 and
3.
Get someone to press the foot pedal down to its maximum
and check that throttle control lever 6 moves on to its built-
in maximum stop. Adjust spring 5 so that with the throttle
control lever 6 on the maximum stop the spring is slightly
extended.
Check that all lock nuts are tight and that clevis retaining pin
7 is locked. Refit the steering column shroud. Close the
bonnet.
Start the engine and progressively increase engine speed
over the whole range. Check that the acceleration is smooth.
Release the foot pedal and check that the engine speed falls
to idle.
9803/8020 Issue 2*
Field Speed Control (2140 only)
Operation
! WARNING
When driving the machine on the road, use the 1 3
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
D
Once it has been set up, the Field Speed Control (FSC)
allows the operator to instantly select or deselect an
additional preset engine speed. A E
To set up the required preset speed:
1 Start and run the engine until normal operating

temperature has been reached.
710420
2 Move the hand throttle A forward a little from its normal
idle position.
3 Switch on the FSC enable switch B. (The switch lights

up when the FSC is enabled.)
4 Press increment switch C upwards to increase the

preset speed or downwards to reduce the preset
speed.
E
You can now toggle between the setting of the hand throttle
and the preset FSC setting by using switch B.
Note: If the hand throttle is moved back to its normal idle

position, the FSC system will be disabled. To re-enable the
FSC system, move the hand throttle forward, switch off
switch B and switch it back on again. C B
Adjustment
The field speed control (FSC) must be set as follows so that
it is disabled when the hand throttle is set to run the engine
below 1000 rpm.
1 With the engine stopped, remove fixing screws and lift

out control panel E to gain access to the back of the
hand throttle control.
2 Start the engine and set the hand throttle until an engine
speed of 1000 rpm is displayed on the instrument
cluster. Make sure the hand throttle does not move and
then stop the engine. H
3 Slacken screws F and G.
4 Disconnect plug H and using a multimeter, check for

F
J
continuity between pins 1 and 3 of plug H.
G
5 Slide bracket J slowly forwards and backwards to find
the point at which continuity is made or broken. Tighten
screws F and G with the bracket in this position.
6 Start the engine and check the operation of the FSC.

714600
7 Stop the engine and refit panel E.
9803/8020 Issue 1
3-1 External Hydraulics Control Valve Linkage 3-1
S229471
162511
B D
C
13 A B
12
12
A233401
9803/8020 Issue 2*
3-2 External Hydraulics Control Valve Linkage 3-2
Lever Linkages
Removal /Replacement 2 Spool Layout (Spool II), 4 Spool Layout (Spools III and
IIII)
The removal/replacement procedure is identical for all the
external hydraulic control valve linkages. Each lever has two detent positions when moved forward
and one when moved to the rear.
Removal
In turn, lift the locking collar 2 of each lever and lock the
Set cab control lever 1 to the neutral position and lock by collar in the operating position.
pressing locking collar 2 down into the locking hole 3.
Move the control lever forward to each of the detents,
Unlock and remove clevis retaining pins 4 and 5 from the releasing the lever at each position. The lever should remain
ends of the control rod and remove the rod. in that position. Move the lever to the rear detent position
and release. The lever should remain in that position. Return
Replacement the lever to the neutral position and lock using the locking
collar 2.
Set cab control lever 1 to the neutral position and lock by
pressing locking collar 2 down into the locking hole 3. Flow Control Linkages
Loosely assemble the control rod, ensuring that each clevis Removal
is screwed onto the rod so that the rod end is just visible in
the clevis opening. Loosen the grub screws 12 to release the telescopic rod 13
from both the control valve and the cab control. Retract the
Measure the distance between cab control actuating lever 6 rod and lift clear.
and spool eye end 7. Adjust the length of the control rod to
the above measurement, clevis to clevis, by screwing the Replacement
clevis ends in or out. Adjustment should always be achieved
equally between the clevis ends to ensure that enough rod Replacement is the reverse of the removal procedure.
thread remains in each clevis.
When the telescopic rod has been installed, fit a control
Connect clevis 8 to cab actuating lever 6 using clevis knob to the in-cab control and wind it clockwise to the limit
retaining pin 4. Connect clevis 9 to spool eye end 7 using of its travel. Remove the knob and reposition it so that the
clevis retaining pin 5, making sure that the flat of spool eye lowest knob graduation (1) is in the vertical position. Verify
end 7 is vertical when finally set-up. Adjust the clevis in or correct knob positioning by winding it fully anti-clockwise.
out to ensure the correct fit. Tighten clevis lock nuts 10 and The highest knob graduation (10) should be in the vertical
11. position.
*
Note: Some machines have grease nipples 14 fitted on the Testing
control lever pivots. Grease at these points after assembly
or if the levers become stiff or difficult to operate Fit a flow meter to the quick release coupling for the spool
independently. concerned. With the in-cab knob turned to ‘10’ and the
engine running at maximum speed, a flow of 40 litres/min.
Check the operation of the controls as follows:- should be recorded. If the required flow cannot be achieved
refer to Setting Flow Control, below.
2 Spool Layout (Spool I), 4 Spool Layout (Spools I and II)
Setting Flow Control
Each 3-position control lever has one forward detent and
one rear detent. 1 Disconnect the lower end of the telescopic rod 13 to
reveal the slotted end of spindle A.
Lift the locking collar 2 of lever l and lock the collar in the
operating position. 2 Loosen the two grub screws B securing collar C.
Move the control lever to the forward detent and release. 3 With a flow meter set up as in Testing above, adjust
The lever should remain in that position. Move the lever to spindle A with a screwdriver until the meter records a
the rear detent position and release. The lever should remain flow of 40 litres/min.
in that position. Return the lever to the neutral position and
lock the lever using the locking collar 2. 4 Whilst holding it against collar D, rotate collar C anti-
clockwise until it stops and then tighten grub screws B.
Repeat for lever ll (4 Spool layout only).
5 Reconnect the telescopic rod (see Flow Control
Linkages, Replacement).
9803/8020 Issue 2*
4-1 Power Take-off Speed Selector Cable 4-1
11
12 8
9
X 13
10
Y
1
14
15
5 17 16
C
D
E
A293250
9803/8020 Issue 2
4-2 Power Take-off Speed Selector Cable 4-2
Removal /Replacement
Removal Adjust lock nuts 8 and 9 so that selector lever 1 is in the
central position. Reconnect the electrical connectors from
Ensure that the gearbox is in neutral and that power take-off lever position switches X and Y making sure they return to
selector lever 1 is in the central position. the locations from which they were removed.
At the gearbox end of the cable, slacken lock nut 2 and slide Switch the ignition ON but do not start the engine. Turn
it back onto the cable. switch B to drive position D and check the 540 and 1000
PTO symbols on the instrument cluster are not illuminated. If
Remove the two housing retaining bolts 3 and slide housing either is illuminated re-adjust lock nuts 8 and 9 until neither
4 back onto the cable. is lit. Switch the ignition OFF.
Remove clevis pin retainer 5 and clevis retaining pin 6. Push the selector lever assembly into position in the control
box and secure with bolts 7.
Disconnect the electrical connectors from lever position
switches X and Y making a note of their mating connectors. Checking
In the cab, remove four mounting plate securing bolts 7 and Check the operation of the power take-off (PTO) control as
withdraw the whole selector lever assembly and cable. follows:-
Slacken lock nuts 8 and 9. With the engine stopped, move selector lever 1 up to select
the slower PTO speed. Do not force the lever if the gear will
Unlock and remove clevis retaining pin 10 and disconnect not engage. Turn the engine over on the starter, switch off
clevis 11 from actuator lever 12. and attempt to select the required PTO speed.
Slacken clevis lock nut 13. Remove and retain clevis 11 and * With the PTO switch in brake position E, start the engine.
retaining pin 10.
With the engine at tickover to protect the clutch and
Replacement driveline, check that the rear PTO shaft is not rotating.
Slacken lock nuts 8 and 9 and screw them apart. Push the Engage the PTO by turning switch B to the drive position D.
cable into the mounting bracket opening 14.
Check that the rear PTO shaft is rotating and that only the
Screw clevis 11 onto the cable end until the thread just 540 PTO lamp is illuminated.
appears in the clevis opening. Tighten lock nut 13.
Return switch B to the neutral position C and stop the
Connect clevis 11 to actuating lever 12 using retaining pin engine.
10 and lock.
Move selector lever 1 down to select the faster PTO speed
Pass the power take-off housing end of the cable through and repeat the above procedure this time checking that only
the hole in the control box wall and down to the gearbox. the 1000 rpm lamp is illuminated.
At the gearbox, check that the selector control rod 15 Note: A detent should be felt in all three selector lever
protrudes approximately 74 mm from the gearbox positions. Selector lever 1 travel is 32mm in each direction
(measured from the gearbox face to the rod hole centre). If from the centre.
the dimension is incorrect, push or pull the rod to achieve
the dimension.
Slacken lock nut 2 and slide it back onto the cable. Also
slide housing 4 back onto the cable.
Check that collar 16 is screwed onto the threaded cable

outer with approximately one thread showing.
Connect clevis 17 to selector control 15 with retaining pin 6.

Secure using clevis pin retainer 5.
Slide housing 4 back over the clevis to mount onto the

gearbox. Secure the housing with retaining bolts 3. Tighten
lock nut 2.
9803/8020 Issue 2*
11 - 1 JCB Selectronic 11 - 1
D E
A miles
G F
AUTO
A290431
9803/8020 Issue 2*
System Description
‘JCB Selectronic’ is an electro/pneumatic range change Pneumatic Cylinders
system. The system utilises a column selector switch to
operate the range gearbox for the selection of High, Low, Two pairs of cylinders, mounted back to back actuate lever
Medium ranges and Reverse. Operation is by means of arms on the range gearbox turret. The levers operate
solenoid valves which operate pneumatic cylinders. Lever selector forks in the range gearbox and select the required
arms connected to the cylinder piston rods operate range and direction.
selector forks in the range gearbox.
The cylinders are mounted on the transmission cross
The JCB Selectronic system is primarily designed to member. One of each pair of piston rods is attached to the
reduce driver fatigue. Other features include a pre-select cross member.
facility to improve operational performance, and additional
safety features. Cylinder configuration: C - Reverse/Low
D - Medium/High
* The control system inhibits range and direction selection
until the speed falls below 3 km/h and the clutch pedal is Microswitches
operated. This enables the driver to pre-select the next
range/direction required and, when the speed has fallen Two microswitches E are mounted on each cylinder. The
below 3 km/h, operate the clutch pedal to make the switches are reed type switches whose contacts are
range/direction change. closed by the proximity of the cylinder piston head. When
the piston operates, one microswitch contact opens,
If the range fails to engage when selected, either because disabling the other pair of cylinders. The other microswitch
of driver error or gears baulking, the system prevents the contacts close, switching its corresponding indicator lamp.
range engaging unexpectedly when the fault subsequently Operation of this microswitch only occurs when the piston
clears. This is because the driver is required to press the is at full stroke.
clutch pedal again before the change is made. This
ensures that the machine cannot move off unexpectedly Indicators
with the driver out of position in the event of a fault
suddenly clearing and gears engaging. Whenever the Visual Indicators
column-mounted selector switch is put into neutral and The Centre Display F of the dashboard Instrument
speed is below 1 km/h, both splitters and range box will be Cluster shows, from right to left, the splitter clutch
put into neutral. engaged, the Selectronic range currently selected, the
direction of travel and, if applicable, the Selectronic range
The JCB Selectronic system comprises the following pre-selected in readiness for the next range change. For
components: example, item F on the illustration indicates that the
medium (Tortoise icon) splitter clutch is engaged, the
Selector Switch Selectronic ‘high’ forward range is selected and the ‘low’
forward range has been pre-selected.
The selector switch A, is column mounted, selects high,
low, medium, forward, reverse and neutral. The range selected indications are initiated by
microswitches mounted on the range change cylinders. A
Solenoid Valves ‘gear selected’ indication is displayed only when the
appropriate cylinder has fully operated, and not at the time
* The solenoid valves B are energised by relays in sequence of selection.
depending on the range/direction selected. The four
solenoid valves each operate one of four pneumatic Audible Indicator
cylinders. The valves are mounted on a manifold block In strong sunlight the Instrument Cluster may not be clearly
below the passenger seat on 2000 Series machines, and visible. Each time a range is selected, a buzzer is energised
below the battery box on 3000 Series machines. and an audible tone sounds in the cab. The audible tone
does not sound when Neutral is selected.
Solenoid valve 1 operates reverse gear
Solenoid valve 2 operates low range Pressure Regulator
Solenoid valve 3 operates medium range
Solenoid valve 4 operates high range. Air for pneumatic operation is taken from port 24 of the
circuit protection valve and is fed to a pressure regulator G
which maintains the air shift system pressure.
See Technical Data in this section for the pressure setting.
9803/8020 Issue 4*
Operation
* General
The JCB Selectronic range change is controlled by a lever
mounted switch on the left hand side of the steering column.
A360030
* When the JCB Selectronic range change is in neutral (N) the

gear display of the instrument cluster (see Instrument
Cluster, Warnings (Visual only), item 10) indicates as
shown right.
A286420
* Selecting a Forward Range

To select a forward range when at rest, depress the clutch
pedal fully, lift the switch lever towards the steering wheel
and move it forward to position F. The range selected on the
lever switch will be shown on the gear display. A typical
example, Low range in the slow (snail) Powersplit ratio, is
shown right. A buzzer sounds to indicate that the gear has
been selected. Release the clutch pedal and drive off.
A293470
To change range whilst travelling forward, rotate the barrel
of the switch to the desired setting L, M or H. The gear
display will continue to show the range already engaged
plus a flashing icon to show the new pre-selected range e.g.
H as shown right. The range change will not take place until
the clutch has been fully depressed and the machine has
slowed to 3 km/h. The buzzer indicates completion of the
shift and the gear display indicates the range selected (H).
Release the clutch pedal to complete the range change
A293480
A286440
9803/8020 Issue 3*
(continued)
* Operation (continued)
Selecting Reverse Range
To select reverse from forward range, pull the lever
backwards into the N (neutral) position and then, whilst
holding it up towards the steering wheel, move it to position
R. The gear display will continue to show the range already
engaged (H) plus a flashing icon R to show that reverse
range has been selected. The change will not take place
until the clutch has been fully depressed and the machine
has slowed to 3 km/h. The buzzer indicates completion of
the shift and the gear display indicates the range selected A286450
(R). If a forward range different from the previous one is then
required, rotate the switch barrel to the appropriate position
before re-selecting forward.
Auto-shuttle (Wet Clutch Machines only)

Auto-shuttle provides an alternative method, which does not A286460
involve depression of the clutch pedal, of changing from
forward movement to reverse movement, or vice-versa. With
this mode selected the machine cannot be moved from rest
and changes between forward ranges cannot be
implemented.
If, at any time during an Auto-shuttle sequence, the clutch

pedal is fully depressed, Auto-shuttle is disabled and control
of pre-selected range changes reverts to the clutch pedal.
The following full description deals with changing from

forward movement to reverse movement.
Carry out Selecting Reverse Range to the point where the

flashing icon R is displayed.
! WARNING
When the Autoshuttle has been engaged and the tractor
is slowing down to below 3 km/h, there is no
transmission or engine braking.
0048
Once the machine speed falls below 20 kph press button X

on the end of the range change switch to select Auto-
shuttle. This disconnects all the range change clutches so
that no engine braking is available. Using the foot brake if
necessary, reduce the machine speed to 3 km/h to activate
Auto-shuttle. Reverse gear is selected followed by switch
main clutch engagement. As the clutch engages the
machine stops and begins to reverse.
To change from reverse movement to forward movement,

select a forward range using the range change switch (see
Selecting a Forward Range). If too high a forward range is
selected the engine may stall. Select Auto-shuttle and
proceed as above.
9803/8020 Issue 3*
(continued)
* Operation (continued)
Invalid or Incomplete Range Changes
If an invalid gear has been selected by the Selectronic air
cylinders, e.g. if one of the microswitches is faulty or if a
gear change was not made soon enough to engage, the
gear display indicates a double dash (see right).
A286470
If the operator releases the clutch pedal before a range

change has been completed (as indicated by a ‘beep’ from
the buzzer) the transmission adopts a ‘neutral dump state’.
This holds the Powersplit gears in neutral to prevent
transmission damage. If this happens the gear display right
hand indication flashes to show the range box status and
the left hand indicator flashes to show the pre-selected
range (see right).
A286480
To resume normal operation press the clutch pedal fully
down until the buzzer sounds. The pre-select indication
should extinguish and the range selected indication should
show the new range as on the illustration right.
A286460
9803/8020 Issue 2*
(continued)
Operation (Cont’d)
The rotary section of the column selector switch selects Compressed air from compressor P is fed to the pressure
high, low or medium range. Forward is selected by moving regulator A. When range selection has been made, the
the lever forward, reverse is selected by moving the lever appropriate solenoid valve is energised to direct air to the
back. Neutral is selected with the lever centralised. cylinder required. The piston operates, actuating levers and
selecting the required range. Air exhausts back through the
Before range or direction can be changed the speed must solenoid valve and out to atmosphere beneath the cab. the
be below 3 km/h and only then if the clutch pedal is pneumatic circuit components are as follows:
pressed. This arrangement allows a range or direction to be
pre-selected, with the change made only when these A Pressure regulator
conditions are met. F Reverse cylinder
G Low range cylinder
Every time the clutch pedal is pressed, drive is H High solenoid
disconnected from the transmission at the splitter gearbox. J Medium range cylinder
When the range or direction is changed, drive can only be K High range cylinder
re-connected if the range/direction gears are properly L Low solenoid
engaged. If not properly engaged, the splitter gearbox M Medium solenoid
clutch is prevented from engaging and resuming drive. See N Exhaust
Electrical/Pneumatic Circuit Description. P Compressor
R Reverse solenoid
The system is electrically configured so that if either the
LOW or REVERSE cylinders are operated, microswitch
contacts open, preventing the operation of the HIGH or
MEDIUM range cylinders. Similarly, if either the HIGH or
MEDIUM range cylinders are operated, the LOW and
REVERSE cylinders are disabled.
N
A
P
a b a b a b a b
R L M H
A2 B2 C2 D2
J K
M5 M6 M7 M8
A1 B1 C1 D1
F G
M1 M2 M3 M4
9803/8020 Issue 1
Operation (Cont'd)
Neutral (View V)
V
* With 'NEUTRAL' selected, solenoids Ra, La, Ma and Ha are
energised when the clutch pedal is pressed. This feeds air
to port B1 on the reverse cylinder, port D1 on the low
cylinder, port B2 on the medium cylinder and port D2 on the
high cylinder. When neutral gear is selected, the pistons are
as shown.
Low Range Selected (View W)
* When the rotary switch is switched to the 'LOW'

'FORWARD' range position, the Low relay is energised (if
machine speed is less than 3 km/h and the clutch pedal is W
pressed). This in turn de-energises solenoid La and
energises solenoid Lb. Air is fed to port C1 of the LOW
cylinder. The cylinder extends and air from the rod side is
vented to atmosphere via the solenoid valve. When the
cylinder is fully extended, low range is selected. The piston
causes microswitch M4 contacts to close, providing a circuit
for the LOW indicator light which illuminates. Microswitch
M3 contacts break, preventing the medium and high
solenoids from operating.
Reverse Selected (View X)
* When 'REVERSE' is selected on the lever, with the rotary X

switch in any position, the reverse relay is energised
(machine speed less than 3 km/h, clutch pedal pressed).
Solenoid Ra is de-energised, solenoid Rb is energised. Air is
fed to port A1 of the reverse cylinder. The cylinder retracts,
venting air from the head side via the solenoid valve. When
fully retracted, reverse range is selected. Microswitch
contacts M2 close illuminating the REVERSE indicator light.
Microswitch M1 contacts break, preventing the medium and
high solenoids from operating.
Medium Range Selected (View Y)

Y
* When the rotary switch is switched to the 'MED'
'FORWARD' range position, the medium relay is energised
Solenoid Ma is de-energised, solenoid Mb is energised. Air
is fed to port A2 of the medium cylinder. The cylinder
retracts, venting air from the head side via the solenoid
valve. When fully retracted medium range is selected.
Microswitch contacts M6 close, illuminating the MEDIUM
indicator light. Microswitch M5 contacts break, preventing
the low and reverse solenoids from operating.
High Range Selected (View Z) Z

* When the rotary switch is switched to the 'HIGH'
'FORWARD' range position, the high relay is energised
Solenoid Ha is de-energised, solenoid Hb is energised. Air is
fed to port C2 of the high cylinder. The cylinder extends,
venting air from the rod side via the solenoid valve. When
fully extended, high range is selected. Microswitch contacts
M8 close, illuminating the HIGH indicator light. Microswitch
228240
M7 contacts break, preventing the low and reverse
solenoids from operating.
9803/8020 Issue 2*
(continued)
Limp Home Mode
In circumstances where it is not possible to select the
required range due to serious Selectronic ram switch failure,
‘Limp Home Mode’ can be used. Selection of this mode
enables the machine to be moved to a location suitable for
N
repairs to be carried out or for the machine to be loaded
onto a trailer. Either ‘forward low’ or ‘reverse’ gear can be
selected by bypassing the ram switches to power the
solenoids directly.
A
Note: ‘LIMP HOME MODE’ IS ONLY FOR USE IN
EMERGENCY SITUATIONS SO THAT THE TRACTOR CAN
BE MOVED FOR REPAIR. IT IS NOT INTENDED FOR 191981
NORMAL USE.
To select ‘Limp Home Mode’ proceed as follows:
1 With the tractor stationary and the engine running,

select the neutral range N on column switch A.
2 Simultaneously hold down the Powershift ‘upshift’ B

and ‘downshift’ C buttons on the speed box lever and
fully depress the clutch pedal.
C
3 The EMS displays ‘LIMP HOME’.
B
4 Release the ‘upshift’ B and ‘downshift’ C buttons.
5 Select the required gear, F (forward/low) or R (reverse),

using column switch A.
Note: In this mode, when forward gear is selected the range A293920
box always defaults to ‘low’ irrespective of the setting of the
range select switch.
6 Select a suitable gear in the speed gearbox.
7 Release the clutch pedal.
Normal drive is established as selected at step 5.
Note: During the course of moving the machine, every time

the clutch is depressed the ‘Limp Home Mode’ is
automatically de-selected. Therefore the selection procedure
A370580
must be repeated from step 1 before movement can be
continued.
9803/8020 Issue 1
Pneumatic Cylinders 4 Make sure the air pipework and electrical cables are
correctly routed and cannot foul the lever arms when the
pistons are operated.
! WARNING
Make the machine safe before getting beneath it. Do the 5 Re-set the neutral rod lengths (see Setting Cylinder Rod
following: Park on level ground. Engage the parking Neutral Lengths).
13-3-1-1
* ! WARNING
The grease used within the pneumatic cylinders can
create a hazardous gas at high temperatures. Do not
smoke cigarettes, etc. when working with the grease. If
you have been in contact with the pneumatic cylinder
grease, wash your hands thoroughly before smoking.

Removal B 5
1 Make sure that all residual air pressure is vented.
2 Separate the cylinder assembly electrical connector

and note its mating connector.
3 Label all air connections (not visible opposite) for

reassembly. Remove air pipework by pushing the pipe
in, then pushing the collet in and removing the pipe
whilst holding the collet in.
4 Note the orientation of the cylinder. The piston rods at

the fixed end of the cylinder have a non-rotating section
as shown in view A. The piston rods at the lever arm
end have a circular section as shown in view B.
5 From each end of the cylinder remove R-clip 1, pin 2

and anti-vibration washer 3. Remove the cylinder from
the vehicle.
A 1
6 Renew faulty microswitch and/or carry out the
procedures for Setting Microswitch Positions.
4
Replacement
2
Before fitting the cylinder check and adjust microswitch
positions as required (see Setting Microswitch Positions)
and if appropriate, set the range gearbox turret stops (see
Setting Range Gearbox Turret Stops).
1 Position the cylinder between cross-member bracket 4 3

and lever arm 5, making sure the non-rotating piston rod
A301110
is attached to the cross-member bracket. Fit the pins 2,
anti-vibration washers 3 and R-clips 1.
2 Refit the air pipework connectors by pushing them firmly

and squarely into the correct fittings.
3 Re-connect the cylinder assembly electrical connector.
9803/8020 Issue 3*
Pneumatic Cylinders (Continued)

*
Renewing Microswitches
*
Remove the two connector pins of the faulty microswitch
from the 8-pin connector which serves the complete set of
microswitches. Loosen and release the retaining band and
take the microswitch off the cylinder. Install a new
microswitch and insert its connector pins into the 8-pin
connector. Position the microswitch (see Setting
Microswitch Positions) and secure by means of the
retaining band tightened to a torque of 1.7 Nm (15 lbf in).
*
Setting-Up *
6
!WARNING 2
4
jobs. Lower the equipment. Remove the starter key and
disconnect the battery. This will prevent the engine from
engaged.
5
Chock all four wheels before getting under the machine. 3
13-3-1-9
*
Setting Range Gearbox Turret Stops
The turret stops are set correctly on manufacture but in the

* event of turret removal the following procedure must be
followed with the rams disconnected from the levers. 1
1 Manually select each gear in turn (one lever
approximately 50 mm away from the central position
while leaving the other lever in the central position).
2 With the relevant locknut 1 slackened off, adjust the

screw so that lever play is only just removed. Tighten
the locknut. Re-check the play and return the lever to its
central position.
*
3 Repeat steps 1) and 2) with each of the three other
* gears in turn.
A301120
Setting Cylinder Rod Neutral Lengths
*
1 Connect the machine battery, turn the starter switch ON
and select neutral.
2 Selecting neutral should position the piston rods as
follows:
a Rods connected to control levers fully retracted.
* b Rods connected to chassis fully extended.
3 Ensure that the range gearbox levers are set to
* NEUTRAL, i.e. both levers in the central position.
4 Slacken locknuts 2, adjust clevises 3 so that the clevis
pin 4 freely enters the clevis and anti-vibration washer
5. Secure with R-clips 6.
Ensure that each clevis has adequate thread engagement on
the piston rod. If necessary this can be compensated by
adjusting the rod length on the opposite end of the
cylinder.
9803/8020 Issue 2*
Pneumatic Cylinders (Continued) 1 Start the engine to ensure that the air reservoirs are
fully charged. On the speed gearbox select Neutral.
2 Switch off the engine and turn the starter switch to IGN.
Setting Microswitch Positions
On the range gearbox select medium/forward range
and turn the starter switch to O.
!CAUTION 3 With the continuity tester across pins 2 and 6, slacken
DO NOT use a test lamp when checking voltages around microswitch 2 retaining band. Move the microswitch to
the JCB Selectronic circuit. The relatively high current ensure that the switch is located in the centre of its
will destroy the logic and range indicator microswitches. operating band width as follows:
Use an Avometer or digital voltmeter. Slide the microswitch towards the front of the
ELEC 5-1 machine and then rearwards until the tester just shows
continuity. Mark the ram cylinder opposite a reference
point on the microswitch. Continue to move the switch
Setting Neutral Microswitch Positions rearwards until continuity is lost. Move the switch
forwards until the tester just shows continuity once
The neutral microswitches are numbers 1 and 3 again. Mark the ram cylinder opposite the same
(Medium/High) cylinder and 5 and 7 (Reverse/Low cylinder). reference point on the microswitch as previously.
Position the microswitch centrally between the two
To determine the correct microswitch position, connect a marks.
continuity tester across the relevant pins of the connector. Note: Do not exceed a torque of 1.7 Nm (15 lbf in) on the
retaining band.
Switch 1: pins 1 and 5. Switch 5: pins 1 and 5 4 Select neutral range and restart the engine to re-charge
Switch 3: pins 3 and 7. Switch 7: pins 3 and 7 the air reservoirs.
5 Repeat steps 2 to 4 for the remaining microswitches
1 Ensure that the range gearbox is in neutral, i.e. both
levers in the central position. selecting the appropriate range as shown below.
Microswitch 4 - High/forward range
2 With the continuity tester across pins 1 and 5, slacken Microswitch 6 - Reverse range
microswitch 1 retaining band. Move the microswitch to
ensure that the switch is located in the centre of its Microswitch 8 - Low/forward range.
operating band width as follows:
Slide the microswitch towards the rear of the machine

and then forward until the tester just shows continuity.
Mark the ram cylinder opposite a reference point on the
microswitch. Continue to move the switch forwards
until continuity is lost. Move the switch rearwards until
1
the tester just shows continuity once again. Mark the 5
ram cylinder opposite the same reference point on the
microswitch as previously. Position the microswitch
centrally between the two marks. 2
Note: Do not exceed a torque of 1.7 Nm (15 lbf in) on the 6 A
retaining band. 3
3 Repeat steps 1 and 2 for microswitches 3, 5 and 7
7
connecting the continuity tester to the appropriate pins 4
of the connector.
8
Setting Gear Engaged Microswitch Positions
The gear engaged microswitches are numbers, 2 and 4

(Medium/High) cylinder and 6 and 8 (Reverse/Low cylinder).
To determine the correct microswitch position, connect a

continuity tester across the relevant pins of the connector.
Switch 2: pins 2 and 6. Switch 6: pins 2 and 6

Switch 4: pins 4 and 8. Switch 8: pins 4 and 8
9803/8020 Issue 3
* Pressure Regulator
The unit is located in the cab on the left side of the machine,
beneath the passenger seat.
Removal
Disconnect the air hoses A making a note of the ports from

which they were removed.
A
Remove the two cap screws/washers/nuts B and lift the
assembly clear.
Replacement
B B
A
A302540
9803/8020 Issue 3*
Section E Hydraulics Section E
i i
Contents Page No.

Technical Data 1-1
Schematic Circuits
2000 Series Machines 2-1
3000 Series Machines 2-4
Flow Regulator Valves 2-7
External Hydraulics/Draft Control Valve Type 1† -
Neutral Circuit 2-8
External Hydraulics/Draft Control Valve Type 2†† -
Neutral Circuit 2-9
External Hydraulics/Draft Control Valve - Type 1†

Three Position Spool (D Type) 3-1
Four Position Spool 3-3
Pressure Testing
Main Relief Valve (MRV) Type 1† 6-1
Main Relief Valve (MRV) Type 2 †† 6-2
Pumps
Pump Type 1† - Suspension and Front Axle Steering

Pump Type 2†† - Suspension and Front Axle Steering
Pump Type 1† - Transmission, Rear Axle Steering (4WS) (if fitted) and
External Hydraulics
Pump Type 2†† - Transmission, Rear Axle Steering (4WS) (if fitted) and
External Hydraulics
Control Valve Type 1† - External Hydraulics/Draft Control

Control Valve - Spool Sections
Spool and Detent - Dismantling and Assembly 22 - 1
Flow Control Valve - Dismantling and Assembly 22 - 3
Poppet Valve - Dismantling and Assembly 22 - 5
Main Relief Valve - Dismantling and Assembly 23 - 1
Draft Control Valve
Solenoids - Dismantling and Assembly 24 - 1
Pressure Compensator - Dismantling and assembly 24 - 3
Internal Check Valve - Dismantling and Assembly 24 - 5
Check Valve, Body Seals and Plugs
- Dismantling and Assembly 24 - 7

9803/8020 Issue 5*
ii ii
Contents Page No.

* Control Valve Type 2†† - External Hydraulics/Draft Control
Control Valve - Spool Sections
Spool and Detent - Dismantling and Assembly 26 - 1
Removing the Non- return Valves 26 - 3
Replacing the Non- return Valves 26 - 3
Locking the Spool in Neutral 26 - 4
Repairing the Check Valves 26 - 4
Flow Control Valve - Dismantling and Assembly 26 - 7
Input Section
Main Relief Valve - Dismantling and Assembly 27 - 1
Diverter Valve - Dismantling and Assembly 27 - 7
Draft Control Valve
Solenoid Valves - Dismantling and Assembly 28 - 1
Pressure Compensator - Dismantling and Assembly 28 - 3
Internal Check Valve - Dismantling and Assembly 28 - 5
Rear Lift Rams

Electronic Draft Control

Introduction 51 - 1
System Activation Procedure 51 - 2
Operation 51 - 3
System Description 52 - 1
Hydraulic Circuit Operation 52 - 3
Fault Finding
Introduction 54 - 1
Functional Test of Control Valve 54 - 2
Arms Cannot be Raised or Lowered 54 - 3
Fault Diagnosis 55 - 1
Control Valve - Removal and Replacement 58 - 1
Draft Pin - Removal and Replacement 58 - 1
Position Sensor (Linear Type)
Removal and Replacement/Setting 58 - 2
Position Sensor (Rotary Type)
Removal and Replacement/Setting 58 - 3
† † 2000 Series from S/N 740000, 3000 Series from S/N 642000
9803/8020 Issue 5*
External Hydraulics
* Pump Type Front section (P3) of gear type double pump (triple pump
on 4WS machines), driven by PTO gearbox.
* Type 1†
Flow at Maximum System Pressure
Standard pump at 2400 engine rev/min 77 litres/min (17 UK gal/min; 20.3 US gal/min)
Optional pump at 2400 engine rev/min 96 litres/min (21 UK gal/min; 25.4 US gal/min)
* Type 1†
Main Relief Valve Pressure
At 2400 rev/min bar kgf/cm2 lbf/in2
Early machines - non adjustable 210 214 3045
Later machines - adjustable 210 + 0/-5 214 + 0/-5 3045 + 0/-72.5
* Type 1†
Control Valve
Two-spool valve - spool I Variable flow, 3-position, double acting spools with
Three-spool valve - spools I and II hydraulic kick-out. For single/double acting rams or motors.
Four-spool valve - spools I and II
Two-spool valve - spool II Fixed flow, 4-position, double acting spools with hydraulic
Three-spool valve - spool III kick-out and float. For single/double acting rams or motors.
Four-spool valve - spool III Fitted with zero leak check valve.
Four-spool valve - spool IIII Fixed flow, 4-position, double acting spools with
hydraulic kick-out and float. For front 3-point linkage
operation. Fitted with zero leak check valave.
* Type 2 ††
Flow at Maximum System Pressure
At 1500 engine rev/min 60 litres/min (13.2 UK gal/min; 15.9 US gal/min)
* Type 2 ††
Main Relief Valve Pressure
at 1500 rev/min bar kgf/cm2 lbf/in2

210 + 0/-5 214 + 0/-5 3045 + 0/-72.5
* Type 2 ††
Control Valve
Two-spool valve - spool I Variable flow, 4-position, double acting spools with
Three-spool valve - spools I and II hydraulic kick-out and float. For single/double acting rams
or motors.
Four-spool valve - spools I and II Fitted with zero leak check valve.
Two-spool valve - spool II Fixed flow, 4-position, double acting spools with hydraulic
Three-spool valve - spool III kick-out and float. For single/double acting rams or motors.
Four-spool valve - spool III Fitted with zero loak check valve.
Four-spool valve - spool IIII Fixed flow, 4-position, double acting spools with
hydraulic kick-out and float. For front 3-point linkage
operation. Fitted with zero leak check valave.

DO NOT EXCEED STATED PRESSURE
Other Hydraulic Circuits

Note: For technical data of other hydraulic systems, refer to the following sections of the Service Manual:
Transmission: Section F
Steering: Section H
Suspension: Section S
9803/8020 Issue 4*
2-1 *Schematic Circuits 2-1

Description Component Key
The diagram shows the hydraulic circuits of the machine to
clarify the way in which they relate to each other. A External Hydraulics/Draft Control Valve
AA Steering Rams (front axle)
* Note that later machines are fitted with a different External AB Steering Pump Relief Valve
Hydraulics/Draft Control Valve A (Type 2††). Be sure to refer AC Feed to Hydraulic Trailer Brake Connector TH
to the correct circuit diagram, Schematic Circuit - 2000 AD Power Track Rod (rear wheel steering) (optional)
Series Machines (Type 1†) or Schematic Circuit - 2000 AE Flow Regulator Valve (optional)
Series Machines (Type 2††) as applicable. AE1 Flow Regulator Valve Auxiliary Output Circuit
AWS Four-wheel Steer Valve (optional)
The circuits each have their own pump section: A1 Main Relief Valve
B Hydraulic Trailer Brake Valve (optional)
P1 Suspension/Rear Axle Differential Lock CS Steering Circuit Cooler
P2 Steering (front axle) (2WS/4WS) Fm Main Filter
P3 External Hydraulic Services/Draft Control G Front Auxiliary Circuit (Optional)
P4 Transmission H Rear Auxiliary Circuits
P5 Steering (rear axle) (4WS) (if fitted) M Accumulator - Ride Height Adjustment
P1 and P2 are the two sections of the engine-driven pump. N Ride Height Corrector Valves
P3, P4 and P5 (if fitted) are the sections of the gearbox- P1 Pump - Suspension/Rear Axle Differential Lock
driven pump.
P2 Pump - Steering (front axle)
The external hydraulics and draft control circuits are P3 Pump - External Hydraulics/Draft Control
described in detail in this section of the manual. More details P4 Pump - Transmission
on the other circuits are given in the relevant sections of the P5 Pump - Steering (rear axle) (optional)
manual. Q Pilot Feed from Front Brakes Hydraulic Brake Fluid Line
R Front Lift Rams (Optional)
When a machine is fitted with provision for hydraulic trailer RD Drop Flow Control Valve (front lift rams) (optional)
brakes, line 1 from the pump feeds the hydraulic trailer brake RR Rear Lift Rams
valve B and line 1A is not fitted. S Suspension Cylinders
When there is no hydraulic trailer brake valve, line 1A is SP Proportional Solenoid Valve (optional)
fitted to give a direct feed to control valve A which controls SU Steering Unit
feeds to the external services by means of spools l, ll and lll. T Tank
A four spool control valve is illustrated but two and three V Suspension Pressure Maintenance/Differential Lock
spool valves are also available to the same general design. Valve
When the four spool valve is fitted, spool llll feeds the front X Rear Axle Differential Lock
linkage lift rams R. The optional lift ram drop flow control Y Differential Lock Relief Valve
valve RD can be fitted when extra control is required while
lowering front attachments, especially heavy attachments. * Note 2: Certain ports of valve A are identified by the letters a
and b cast into the valve block. These identifications are
When the machine is fitted with the optional Flow Regulator included in the schematic opposite but do not relate to the
Valve AE, line 2A is not required, the oil flow to External letters A and B on the control lever decal or the quick
Hydraulics/Draft Control Valve A coming from port B of valve release coupling decals.
AE. Flow Regulator Valve AE provides the means of
adjusting flow to external implements (see Flow Regulator, * Note 3: Machines with Type 2†† External Hydraulics/Draft
Flow Testing and Pressure Testing in Section A). Control Valves use colour codes on the relevant control and
hydraulic coupling decals. The valve spools correspond with
* Note 1: The optional Flow Regulator Valve AE is shown in the colour code as follows:
outline only. For the internal details see Schematic Circuits
- Flow Regulator Valve. * Valve Spool Colour Code
Control valve A incorporates the main relief valve A1. It also I Green
incorporates a draft control section which feeds the rear lift
II Blue
rams RR.
Exhaust oil returns from control valve A to tank through filter

III Brown
Fm. IIII Orange
The above colour code key only relates to the Type 2††
circuit diagram. Do not relate the key to the Type 1†
circuit.
*† 2000 Series to S/N 739999,
* †† 2000 Series from S/N 740000,
9803/8020 Issue 4*
2-2 *Schematic Circuits - 2000 Series Machines - Type 1 2-2
N
V RR
M
TP1
S1 A
X N T S a
RD
R
Y
T
R1
D T
b
0 a
F 1 2
IIII
SP Fm
G
1A 1.2
AC
b
AD 0 a
P N B F 1 2
III
A BP T TP
P
A 1.2
R
CT1 B Fm
b
CT3 0 a
B CT2 1 2
T II
AWS Y
T
Q 1.2
CS Fm
P1 P2
b
2A 0 a
1 1 2 I
Fm AE1
AB P3 P5 b c d
1.2
T P4
Fm
a A1
AE Fm
R2 P B A B A B A
3 AA
3A I II III
a
SU b
T H
A249312
9803/8020 Issue 4*
2-3 *Schematic Circuits - 2000 Series Machines - Type 2 2-3
N
V M A
RD
TP1
S1
N T A2 A
X S R2 P M
R1
R2
Y
T
D 3A A1
6 4
1.2
R
4A
1 0 2 F
SP a
1A b
AC
3
AD
1.2
F G
P N B T
A BP T TP
1 0 2 F A
P
A a
R B III
CT1 B F
b
2 A
1.2
B II
CT3
H
B CT2
T 1 0 2 F
A
AWS Y a B
9 T
I
b
Q
CS 1
P1 P2 F 1.2
F
2A 1 0 2 F
a
F AE1
b
P3 P5 b c d T
T P4
F 8
a
RR
a
AE
A1
AA
3A
a
A3
SU b 420320
T 7
9803/8020 Issue 4
2 - 3A *Schematic Circuits 2 - 3A

The diagram shows the hydraulic circuits of the machine to
clarify the way in which they relate to each other. A External Hydraulics/Draft Control Valve
* A1 Load-sensing Dump Valve
Note that later machines are fitted with a different External * A2 Main Relief Valve
Hydraulics/Draft Control Valve A (Type 2††). Be sure to refer AA Steering Rams (front axle)
to the correct circuit diagram, Schematic Circuit - 2000 AC Feed to Hydraulic Trailer Brake Connector TH
Series Machines (Type 1†) or Schematic Circuit - 2000 AD Power Track Rod (rear wheel steering) (optional)
Series Machines (Type 2†† ) as applicable. AE Flow Regulator Valve (optional)
AE1 Flow Regulator Valve Auxiliary Output Circuit
The circuits each have their own pump section: AWS Four-wheel Steer Valve (optional)
A1 Main Relief Valve
P1 Suspension/Rear Axle Differential Lock B Hydraulic Trailer Brake Valve (optional)
P2 Steering (front axle) (2WS/4WS) CS Steering Circuit Cooler
P3 External Hydraulic Services/Draft Control F Main Filter
P4 Transmission G Front Auxiliary Circuit (Optional)
P5 Steering (rear axle) (4WS) (if fitted) H Rear Auxiliary Circuits
P1 and P2 are the two sections of the engine-driven pump. M Accumulator - Ride Height Adjustment
P3, P4 and P5 (if fitted) are the sections of the gearbox- N Ride Height Corrector Valves
driven pump. P1 Pump - Suspension/Rear Axle Differential Lock
The external hydraulics and draft control circuits are P2 Pump - Steering (front axle)
described in detail in this section of the manual. More details P3 Pump - External Hydraulics/Draft Control
on the other circuits are given in the relevant sections of the P4 Pump - Transmission
manual. P5 Pump - Steering (rear axle) (optional)
Q Pilot Feed from Front Brakes Hydraulic Brake Fluid Line
* When a machine is fitted with provision for hydraulic trailer R Front Lift Rams (Optional)
brakes, pump P3 feeds the hydraulic trailer brake valve B RD Drop Flow Control Valve (front lift rams) (optional)
directly and line 1A is not fitted. RR Rear Lift Rams
* When there is no hydraulic trailer brake valve, line 1A is S Suspension Cylinders
fitted to give a direct feed to the main control valve A which SP Proportional Solenoid Valve (optional)
is mechanically actuated by manual levers. The control valve SU Steering Unit
shown has spools 1, 2, and 3 for rear external hydraulics T Tank
and an optional spool 4. When the four spool valve is fitted, V Suspension Pressure Maintenance/Differential Lock
spool 4 feeds the front linkage lift rams R. The optional lift Valve
ram drop flow control valve RD can be fitted when extra X Rear Axle Differential Lock
control is required while lowering front attachments, Y Differential Lock Relief Valve
especially heavy attachments.
Note 2: Certain ports of valve A are identified by the letters a
When the machine is fitted with the optional Flow Regulator and b cast into the valve block. These identifications are
Valve AE, line 2A is not required, the oil flow to External included in the schematic opposite but do not relate to the
Hydraulics/Draft Control Valve A coming from port d of valve letters A and B on the control lever decal or the quick
AE. Flow Regulator Valve AE provides the means of release coupling decals.
adjusting flow to external implements (see Flow Regulator,
Flow Testing and Pressure Testing in Section A). Note 3: Machines with Type 2†† External Hydraulics/Draft
Control Valves use colour codes on the relevant control and
Note 1: The optional Flow Regulator Valve AE is shown in hydraulic coupling decals. The valve spools correspond with
outline only. For the internal details see Schematic Circuits the colour code as follows:
- Flow Regulator Valve.
Valve Spool Colour Code
* The external hydraulics control valve also incorporates the 1 Green
main relief valve A2. The neutral circuit continues through 2 Blue
the control valve via to draft control valve A3 which feeds 3 Brown
the rear lift rams RR. 4 Orange
* Exhaust oil returns via lines 6, 7, 8 and 9 to tank where it
passes through filter F. The above colour code key only relates to the Type 2††
circuit diagram. Do not relate the key to the Type 1†
circuit.
† 2000 Series to S/N 739999,
†† 2000 Series from S/N 740000,
9803/8020 Issue 2*
2-4 *Schematic Circuits 2-4

* The diagrams show the four hydraulic circuits of the
machine to clarify the way in which they relate to each other. A External Hydraulics/Draft Control Valve
A1 Main Relief Valve
* Note that later machines are fitted with a different External B Hydraulic Trailer Brake Valve (optional)
Hydraulics/Draft Control Valve A (Type 2††). Be sure to refer B1 Feed to Hydraulic Trailer Brake Connector TH
to the correct circuit diagram, Schematic Circuit - 3000 CS Steering Circuit Cooler
Series Machines (Type 1†) or Schematic Circuit - 3000 D Flow Regulator Valve (optional)
Series Machines (Type 2††) as applicable. D1 Flow Regulator Valve Auxiliary Output Circuit
F Main Filter
The four circuits each have their own pump section: G Front Auxiliary Circuit (optional)
H Rear Auxiliary Circuits
P1 Suspension N Ride Height Corrector Valves
P2 Steering P1 Pump - Suspension Pump
P3 External Hydraulic Services P2 Pump - Steering Pump
P4 Transmission P3 Pump - External Hydraulics Pump
P1 and P2 are the two sections of the engine-driven pump. P4 Pump - Transmission Pump
P3, P4 are the two sections of the gearbox-driven pump. R Front Lift Rams
RD Drop Flow Control Valve (front lift rams ) (optional)
The external and draft control circuits are described in detail RR Rear Lift Rams
in this section of the manual. More details on the other S Suspension Cylinders
circuits are given in the relevant sections of the manual. SB Steering Box
When a machine is fitted with provision for hydraulic trailer

brakes, line 1 from the pump feeds the hydraulic trailer * Note 2: Certain ports of valve A are identified by the letters a
brake valve B and line 1A is not fitted. and b cast into the valve block. These identifications are
When there is no hydraulic trailer brake valve, line 1A is included in the schematic opposite but do not relate to the
fitted to give a direct feed to the main control valve A which letters A and B on the control lever decal or the quick
controls feeds to the external services by means of spools l, release coupling decals.
ll and lll. A four spool control valve is illustrated but two and
three spool valves are also available to the same general * Note 3: Machines with Type 2†† External Hydraulics/Draft
design. When the four spool valve is fitted, spool llll feeds Control Valves use colour codes on the relevant control and
the front linkage lift rams R. The optional lift ram drop flow hydraulic coupling decals. The valve spools correspond with
control valve RD can be fitted when extra control is required the colour code as follows:
while lowering front attachments, especially heavy
attachments. * Valve Spool Colour Code
I Green
When the machine is fitted with the optional Flow Regulator
Valve D, line 2A is not required, the oil flow to External II Blue
Hydraulics Control Valve A coming from port B of valve D.
Flow Regulator Valve D provides the means of adjusting flow III Brown
to external tools (see Flow Regulator, Flow Testing and
Pressure Testing in Section A).
IIII Orange
* Note 1: The optional Flow Regulator Valve D is show in The above colour code key only relates to the Type 2††
outline only. For the internal details see Schematic Circuits circuit diagram. Do not relate the key to the Type 1†
- Flow Regulator Valve. circuit.
The main control valve also incorporates the main relief

valve A1. The neutral circuit continues through the control
valve via line 3 to draft control valve C which feeds the rear
lift rams RR.
Exhaust oil returns via lines 4, 5, 6 and 8 to tank where it

passes through filter F.
* † 3000 Series to S/N 641999
* †† 3000 Series from S/N 642000
9803/8020 Issue 3*
2-5 Schematic Circuits - 3000 Series Machines Type 1 2-5
RR
A
V N
RD
R
X
R1
N S T
b
0 a
F 1 2
IIII
F
G
1.2
0 a
F 1 2
III
1 1.2
P3 P4
b
0 a
1 2
II
1A 6 1.2
B1 b
2 TH 0 a
1 2 I
P1 P2 2A 1.2
D1
F b c d
A1

F

R2 P B A B A B A
SB

B
8 D I II III
T H
CS A243311
9803/8020 Issue 1
2-6 Schematic Circuits - 3000 Series Machines Type 2 2-6
V N
X
RD
N S
A2 A
P M
R1
R2
3A A1
1.2
4 R IIII
4A
1 1 0 2 F
a
6 b
P3 P4
III
1.2
Fm G
T
1 0 2 F A
a
B III
1A b
A
1.2
II B II
H
B1
A
2 TH 1 0 2 F
a B
I
b
P1 P2 2A 1.2
I
Fm
D1
1 0 2 F
a
F b c d
b
A1 T
8 D a RR
B
SB
T
5
a
A3
CS
A403761A
9803/8020 Issue 2
2 - 6A *Schematic Circuits 2 - 6A

The diagrams show the four hydraulic circuits of the
machine to clarify the way in which they relate to each other. A External Hydraulics/Draft Control Valve
* A1 Load-sensing Dump Valve
Note that later machines are fitted with a different External A2 Main Relief Valve
Hydraulics/Draft Control Valve A (Type 2††). Be sure to refer B Hydraulic Trailer Brake Valve (optional)
to the correct circuit diagram, Schematic Circuit - 3000 B1 Feed to Hydraulic Trailer Brake Connector TH
Series Machines (Type 1†) or Schematic Circuit - 3000 CS Steering Circuit Cooler
Series Machines (Type 2†† ) as applicable. D Flow Regulator Valve (optional)
D1 Flow Regulator Valve Auxiliary Output Circuit
The four circuits each have their own pump section: F Main Filter
G Front Auxiliary Circuit (optional)
P1 Suspension H Rear Auxiliary Circuits
P2 Steering N Ride Height Corrector Valves
P3 External Hydraulic Services P1 Pump - Suspension Pump
P4 Transmission P2 Pump - Steering Pump
P1 and P2 are the two sections of the engine-driven pump. P3 Pump - External Hydraulics Pump
P3, P4 are the two sections of the gearbox-driven pump. P4 Pump - Transmission Pump
R Front Lift Rams
The external and draft control circuits are described in detail RD Drop Flow Control Valve (front lift rams ) (optional)
in this section of the manual. More details on the other RR Rear Lift Rams
circuits are given in the relevant sections of the manual. S Suspension Cylinders
SB Steering Box
When a machine is fitted with provision for hydraulic trailer
brakes, line 1 from the pump feeds the hydraulic trailer brake
valve B and line 1A is not fitted. Note 2: Certain ports of valve A are identified by the letters a
When there is no hydraulic trailer brake valve, line 1A is and b cast into the valve block. These identifications are
fitted to give a direct feed to the main control valve A which included in the schematic opposite but do not relate to the
controls feeds to the external services by means of spools l, letters A and B on the control lever decal or the quick
ll and lll. A four spool control valve is illustrated but two and release coupling decals.
three spool valves are also available to the same general
design. When the four spool valve is fitted, spool llll feeds Note 3: Machines with Type 2†† External Hydraulics/Draft
the front linkage lift rams R. The optional lift ram drop flow Control Valves use colour codes on the relevant control and
control valve RD can be fitted when extra control is required hydraulic coupling decals. The valve spools correspond with
while lowering front attachments, especially heavy the colour code as follows:
attachments.
Valve Spool Colour Code
* When the machine is fitted with the optional Flow Regulator I Green
Valve D, line 2A is not required, the oil flow to External
Hydraulics Control Valve A coming from port d of valve D. II Blue
Flow Regulator Valve D provides the means of adjusting flow
to external tools (see Flow Regulator, Flow Testing and III Brown
Pressure Testing in Section A).
IIII Orange
Note 1: The optional Flow Regulator Valve D is shown in
outline only. For the internal details see Schematic Circuits The above colour code key only relates to the Type 2††
- Flow Regulator Valve. circuit diagram. Do not relate the key to the Type 1†
circuit.
The main control valve also incorporates the main relief
valve A1. The neutral circuit continues through the control
valve via line 3 to draft control valve C which feeds the rear
lift rams RR.
Exhaust oil returns via lines 4, 5, 6 and 8 to tank where it

passes through filter F.
† 3000 Series to S/N 641999
9803/8020 Issue 2*
2-7 Schematic Circuits 2-7
Flow Regulator Valves

On the main schematics, the Flow Regulator Valve is shown
in outline only. Two types of valve are available. The internal
details are shown below.
b c d
A343830
55 litre Flow Regulator Valve
CT2
a c
CT1
CT3 CT4
A343841
d b
90 litre Flow Regulator Valve
9803/8020 Issue 2*
External Hydraulics/Draft Control 2-8
Valve Type 1 - Neutral Circuit
RR
9803/8020
*
Description
Section E
1A
Oil for the External Hydraulic/Draft Control Valve A 3 A
is drawn either directly or indirectly from tank T by 2
pump P3 which is the front section of a gearbox-
driven pump.
R
In the absence of either of the options, Trailer Brake
Valve B and Flow Regulator Valve AE, the feed to
valve A is direct from pump P3 via lines 1A and 2A. B
T
When a machine is fitted with either one or both of
the options, the feed to valve A is indirect. Lines 1A 1
0
and/or 2A are not fitted and the feed to valve A is F 1 2 IIII
derived via valve B and/or valve AE. Fm G
T
A four spool control valve with an integral draft
control valve and main relief valve is illustrated. Two 0
F 1 2
III
spool valves are also available to the same general P3
design.
The main control valve incorporates the sub-plate

containing the main relief valve A1 and at the
0
Hydraulics
opposite end, the solenoid operated draft control 1 2

II
valve.
Schematic Circuits
Exhaust oil returns in line 3 to tank via filter Fm.
*
0
1 2 I
Indicates the end of the valve nearest the
centre of the machine. Fm
AE
A1 Fm
2A I II III
H
T A229423
2-8
Issue 2*
Section E
External Hydraulics/Draft Control RD 2-9
Valve Type 2 - Neutral Circuit
9803/8020
*
Description
The inlet section contains the load-sensing dump A2 A
Section E
P M
valve A1 and the main relief valve A2. R1
R2
The valve illustrated has three spools for rear A1
external hydraulics. Two of these spools AA have
remotely operated flow controls F. Spool AB and 4A
front linkage spool A4 do not have this feature. 3A
There is also an integral draft control valve A3.

1.2
Valves with fewer spools are also available to the R IIII A4
2A
same general design. AE S
1 0 2 F
a
Operation
5A b
Oil for the external hydraulics/draft control valve A is
drawn from tank T by pump P3 which is the front 1A AB
1.2
section of a gearbox-driven pump. III Fm G
2 T
S
If neither of the options (trailer brake valve B and 1 0 2 F A
flow regulator valve AE) is fitted, the feed to valve A a
B III
is direct from pump P3 via lines 1A and 2A. b
B AA A
When a machine is fitted with either one or both of 1 1.2
II B II
3
Hydraulics
the options, the feed to valve A is indirect. Lines 1A H

and/or 2A are not fitted and the feed to valve A is S A
Schematic Circuits
P3 1 0 2 F
derived via valve B and/or valve AE. a B
F I
b
Oil enters the valve A at port P. If no spools are
operated the dump valve A1 diverts oil back to tank 1.2
AA
I
via line 3A and exhaust port R1. When one or more Fm Fm
spools are operated, valve A1 closes and oil is S
1 0 2 F
diverted into gallery 4A in order to provide the a
pressure feed to the spools. b
Oil from within the control valve enters gallery 5A,

providing a pilot feed to the main relief valve A2 and T
S
load sensing signals from all the spools via shuttle
valves S to dump valve A1.
a RR
T
A3
Exhaust oil returns via line 3A, exhaust port R1 and
back to tank in line 3 via filter Fm.
Indicates the end of the valve nearest

A403751A
the centre of the machine. A3
A3
Issue 3*
2-9
Section E
3-1
;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;
9803/8020
;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;
Section E
B
;;;;; E
;;;;;;;;;;;; A
C ;;;;;
;;;;;
V ;;;;; ;;;;;;;;;;;;
;;;;;;;;
;;;;; ;;;; ;;;;;;;;
;;;;;;;;;;;;; ;;;;;;;;
;;;;;;;;;;;;; ;;;;;;;;
;;;
;;;;; ;;;; ;;;;;;;;
;;;;;;
;;;
;;;;;;;;;
; ;;
;;;;;; ;;;;;;;;;
; ;;
;;;;;;;;
;;;;;
;;;
;;;;;; ;;;; ;;
;;;;;;;;;
;;;;; ;;;; R ;;;;;;;;;
*External
;;;;; ;;;;;;;; ;;;;;;;;;

;;;;
;;;
;;;;; ;;;;;;;;
;;;;; ;;;;;;;;
;;;;;;;;;
;;;;;;;;;
;;;;;;;; ;; ;;;;;;;;;
;;;;;;;;;;;
;;;;;;;; ;; ;;;;;;;;;
;;;;;;;;;
;;;
;;;;;;;;;;;
;;;;
;;;;;;;;;;;
;;
;; ;;;;;;;;;
;;;;;;;;;
;;
;; B E ;;;;;;;;;
A
;;;;;;;;;
V ;;;;;;
;;;;;;;;;
;;;; ;;
;;;;;; ;;;;;;
Hydraulics
P S ;;;;;;
;;;;;;;;;; ;;;;;;
;;;;;;
C ;;;;;;
;;;;;;;;;;;;; ;;;;;;
;;;;;;; ;;;;;;
;; ;;;;;;
;;;;
;;;;;;
;; ;;;; ;;;;;;;;
;; ;;
;;
;;;;;;
;;
;; ;;;;
;;;;;;
;; ;;;; ;;
;;;;;;
;;;; ;;;;;;
Hydraulics/Draft Control - Type 1
;;
;;
;; ;;;;
;; ;;;;
;; ;;
;;;; ;;
;;;;;;
;;
;;;;;;
;;;; ;;
;;
;;;; ;;;;;;;; R
;;;; ;;;;;;;;
;
;;
;;;; ;;;;;;;;
;;;;;;;;
;;;;;;;;;;;
;;;;;;;;
;;;;;;;;;;;
;;;;
;;
;;;;;;;;;;;
N A275500
P S
;;
Issue 2*
3-1
Section E
Three Position Spool (D Type) 3-2
9803/8020
Features Single-Acting Operation (view Y)
Section E
Selectable single/double acting When the spool is connected to a single acting ram, port A is
Flow control connected to the ram and the other port B is effectively
Parallel gallery blanked by the disconnected quick release coupling.
Hydraulic kick-out
Load hold check valves When the poppet valve V is screwed out, service port B is
connected to exhaust whatever the position of the spool. To
Description extend the ram, the spool is pushed in and pressure is
supplied in the usual way. This operation is therefore not
The machine may be fitted with a 2, 3 or 4 spool illustrated.
control valve. The illustration shows a 4 spool valve
with integrated draft control valve and sub-plate To retract the ram, the spool is pulled forward as illustrated.
*External
incorporating the main pressure relief valve. The weight of the equipment acts on the ram and pushes the
hydraulic oil back through port A and into the exhaust gallery.
Each spool is numbered I, II, III or IIII. Spool
numbers I, II and III control the feed to pairs of Pump flow through neutral gallery N is blocked by the
quick release hose couplings which have selected spool and is diverted into parallel gallery P and
corresponding numbers and are colour coded to service port B.
identify the spool with the relevant pair of couplings.
If the poppet valve V is closed, the pump pressure would
build up and actuate the main relief valve but in fact the
Hydraulics
The illustration shows sectional views of spools I

and II in their double acting mode (view X) and poppet is open allowing the build up of pressure to be bled off
into exhaust gallery E.
single acting mode (view Y).
The spools are of conventional design, except for
The control operated from the cab rotates spindle R in the
the provision of the adjustable poppet valve V which
flow control valve causing spool S to increase or decrease
is controlled by the knurled knob C.
the hydraulic flow to the service ports A and B.
Double-Acting Operation (view X)
When the poppet valve V is screwed fully home by

means of the knurled knob C, the spool operates in
the conventional double-acting mode.
When the spool is pulled outwards, oil from the flow

control valve P is directed by the spool into service
port B.Oil returning from the double-acting ram is
directed from service port A into the exhaust gallery
E.
Issue 2*
3-2
Section E
3-3
9803/8020
Section E
K B
;;;;;; ;;;;;
A K
;;;;;;;;;
;;;;;; ;;;;;;
;;;;;
;;;;;;;;;
;;;;;;
GL H J ;;;;;;
;;;;;;;;; ;;;; ;;;;;;;;
;;;;;;;;; ;;;; ;;;;;;;;
;;;;;;;;;
;; ;;;;;;
;;
;;;; ;;;;;; S
;;;
;;;;;;;;;
;;
;;;;;;;;;;;;
; ;;
;;;
;; ;;;
;;;; ;;;;;;
;;;
;;;;;;;;;
;; ;;;
;;;;
;;;;;;;;;;;;;;; ;;;;;;
;;
;;;;;;;;;
;;;;;;;
;;
;;;;;;;;;;;; ;;;;;;
;
;;;;;;;;;;;;
;;;
;;;;;;; ;;
;;; ;
;;;;;;;;;
;;;;;
; ;;; ;;
;;
;;;;;;
*External
;;;;;;;
;;; ;;;;;;
;;; ;;;;;;
M D C F
P E
K ;;;;;;
B A K
Hydraulics
;;;;;;
;;;;;;; ;;;;
;;;;;;; ;;;;;
;;;;
GL H J ;;;;;;; ;;;;;
;;;;;;; ;;;; ;;;;;
;;;;;
;;;;;;; ;;;; ;;;;;
;;;;;;;
;;;;;;; ;;;; ;;;;; S
;;;;;;;
;;;
;;;;;;;;;;;
;;;;;;;;;;;;
;;;;;;;
;;;;;;;
;;
;;;;;;;;;;;
; ;;;; ; ;;;;;
;;;;;;;
;;
;;;;;;;;;;;
; ;;;; ; ;;;;;
;;;;;;;
;;; ;;
;;; ;; ;;
;;;;
;;;;;;;
;;; ;;;;;
;;; ;;;;;
M D C F
P E
A275510
Issue 2*
3-3
Section E
Four Position Spool
3-4
Features Spool Held in Detent (View X) Spool Kicking Out (View Y)
9803/8020
Hydraulic kick-out When the 'spool in' detent is selected, balls L are When the ram reaches the end of its stroke, the
Section E
Float facility pushed radially into groove G by piston C which is service pressure rises sufficiently to overcome the
Service line leak-free check valves held in the position shown by spring D. force of spring F and open thrust pin P.
Description Service pressure is fed through the hollow centre of The thrust pin contacts the end of piston C causing
the spool E. The pressure is felt on the end of thrust it to move back so that the narrower section of the
The machine may be fitted with a 2 or 4 spool pin P but the pressure is not sufficient to overcome piston is in line with the groove G.
control valve. The illustration shows the 4 spool the force of spring F which is holding the thrust pin
valve with integrated draft control. The hydraulic closed. The balls L are then released from the groove
kick-out feature is fitted to all spools. allowing the large spring M to 'kick-out' the spool
Oil pressure and flow opens leak-free check valve to neutral.
Each spool is numbered l, ll, lll or llll. Spool K to feed the attachment via port A. At the same
numbers l, ll and lll control the feed to pairs of time leak-free check valve K in the return line (port In neutral, both check valves K are held closed,
*External
quick-release hose couplings which have B) is mechanically opened by the spool to provide either under spring pressure alone or by a
corresponding numbers and are colour-coded to free flow of return oil. For double acting functions combination of spring pressure and the pressure of
identify the spool with the relevant pair of the principle is applied to flow in the opposite oil trapped in the attachment feed line. This locks
couplings. direction. the attachment in its adopted position to prevent
further movement.
The illustration shows sectioned views of spools lll
and llll which are identical in design.
These spools S can be held in three alternative

Hydraulics
detent positions by means of spring-loaded balls L

which locate in the following grooves:
G Kick-out Detent (spool in)

H Kick-out Detent (spool out)
J Float Detent
The kick-out detents will hold the spool in the open

position, providing a full flow feed to each service

until the ram reaches the end of its stroke and
pressure builds up sufficiently to automatically kick-
out the spool back to neutral.
The float detent allows both service ports to be

connected to exhaust so that the equipment fitted
to the service can follow ground contours.
Issue 2*
3-4
Section E
6-1 Pressure Testing 6-1
Main Relief Valve (M.R.V.) Type 1

X
* Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to the
pressure test connector on the control valve inlet pipe (if
fitted) or to a quick-release coupling labelled B fed by a
spool which does not have flow control.
Run engine, operate the appropriate spool to full travel and

check the gauge reading against the MRV pressure given in
Technical Data. E
Note: Do not select 'float' or hydraulic kick-out detents or an
incorrect reading may be obtained.
Early Machines (View X)

If the pressure is incorrect, replace the MRV E.
Note: The MRV is preset and not adjustable.

Y
Recheck the gauge reading after replacing the MRV.
Later Machines (View Y)

If the pressure is incorrect, adjust the MRV by removing
protective cap A, loosening locknut C and turning adjusting
screw D. Turn clockwise to increase the pressure setting
and anti-clockwise to reduce the setting.
DO NOT EXCEED STATED PRESSURE. A

After adjustment, tighten the locknut and recheck the gauge
reading.
D C A318990
Repeat if necessary until the correct setting is achieved.
B B B B
I II III IIII
A290500
9803/8020 Issue 5*
Main Relief Valve (M.R.V.) Type 2

* Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to the
pressure test connector on the control valve inlet pipe or to a
quick-release coupling labelled B fed by a spool which does
not have flow control.
Run engine, operate the appropriate spool to full travel and

check the gauge reading against the MRV pressure given in
Technical Data.
Note: Do not select 'float' or hydraulic kick-out detents or an

incorrect reading may be obtained.
If the pressure is incorrect, adjust the MRV by removing

protective cap A, loosening locknut B and turning adjusting
screw C. Turn clockwise to increase the pressure setting
and anti-clockwise to reduce the setting.
DO NOT EXCEED STATED PRESSURE.
After adjustment, tighten the locknut and recheck the gauge

reading.
Repeat if necessary until the correct setting is achieved.
Torque Settings
Items Nm kgf m lbf ft A

B 2.1 - 2.8 0.21 - 0.28 1.5 - 2.0
C
B
A360190
9803/8000 Issue 3*
11 - 1 Pumps 11 - 1
* Pump Type 1 - Suspension and Front Axle

Steering (continued)
* Type 1 - fitted to machines as follows: When Removing

2000 Series to S/N 739999
3000 Series to S/N 641999 Blank hydraulic connections 1 2, 3 and 5 to prevent
excessive oil loss and entry of dirt.
Note: Before removing and dismantling the pump, check
flow and pressure. If either of these is low, the only When Replacing
recommended pump repair is removal of the flow and Ensure that compressor drive tangs are undamaged.
pressure control valves for cleaning or renewal. If this does
not cure the fault, the pump must be renewed. Renewal of Renew 'O' rings 6 and 11.
components such as gears, bearings and housings will not
effect a permanent cure. If the pump output is satisfactory Fit adapters 9 and 10.
but there is external leakage, the pump may be removed and
dismantled for re-sealing only. Before fitting the port adapters, make sure that the gear
teeth are well oiled.
Torque Settings
The numerical sequence shown on the illustration is
intended Item Nm kgf m lbf ft
as a guide to dismantling. 7 91 9.3 67
For assembly the sequence should be reversed.
The pump is positioned in the engine compartment as

shown at A.
9803/8020 Issue 2*
11 - 2 Pumps 11 - 2
195971
9803/8020 Issue 1
11 - 3 Pumps 11 - 3
* Pump Type 1 - Suspension and Front Axle

Note: Before removing and dismantling the pump, check Pack between lips of shaft seal with grease. Protect the
flow and pressure. If either of these is low, the only shaft seal lips from damage by wrapping tape around the
recommended pump repair is removal of the flow and shaft splines whilst they are passing through the seal.
pressure control valves for cleaning or renewal. If this does
not cure the fault, the pump must be renewed. Renewal of Renew all inter-section seals and 'O' rings, holding them in
components such as gears, bearings and housings will not position with grease. Ensure that the ends of seals 23 and
effect a permanent cure. If the pump output is satisfactory 28 and back-up rings 22 and 27 do not overhang the
but there is external leakage, the pump may be removed and bearing blocks to become trapped in the housings.
dismantled for re-sealing only.
Fit bearing blocks with grooves X positioned towards the
Dismantling and Assembly inlet side and notch B positioned towards the outlet side of
the pump.
intended Ensure that adapter A is in position on the shaft when fitting
as a guide to dismantling. the pump to the engine.
For assembly the sequence should be reversed. Torque Settings
When Dismantling Item Nm kgf m lbf ft

10 54-61 5.5-6.2 40-45
Retain shim(s) 3 for re-use (see When Assembling)
DO NOT remove plug C as it is an interference fit,

assembled to a critical dimension.
Mark housings and covers to ensure correct re-assembly.
Remove sharp edges and burrs from shafts to avoid seal

damage.
Keep bearing blocks 19, 21, 30, 32 and gears 20 and 31

together in sets to ensure refitting of the bearing blocks in
their original positions.
Inspection
It is normal for the gears to have cut a slight track in the

body bore on the inlet side. The gear track wear cannot be
measured accurately but will be related to bearing wear.
Examine the bores of the bearing blocks 19, 21, 30 and 32
which are coated during manufacture with PTFE. If the grey
PTFE is worn through so that the bronze base is visible, the
complete pump must be renewed.
Renew pump if faces of bearing blocks are scored or if side

faces of gears are chipped or damaged. DO NOT use any
abrasives on the bearing blocks or gears as this would
destroy critical manufacturing dimensions.
When Assembling
Ensure that shims 3 (which affect the relief valve setting) are
refitted without any change to the total thickness.
Note: The relief valve pressure MUST NOT under any
circumstances be set any higher than the figure specified in
Technical Data. Check the pressure setting after refitting
the pump.
Wash all components, paying special attention to the

passages in the valve housing. Apply hydraulic oil
immediately afterwards to prevent moisture from collecting.
9803/8020 Issue 1
13 - 1 Pumps 13 - 1
Pump Type 2 - Suspension and Front Axle

Steering
Type 2 - fitted to machines as follows: When Removing

2000 Series from S/N 740000
Blank off all open ports and hoses to prevent excessive oil
loss and entry of dirt.
The pump is positioned in the engine compartment as Unless the pump or rear cover are to be renewed it is not
shown at X and is driven by the engine via the air normally necessary to remove adaptors A and B.
compressor. The pump is a tandem type with a front section
(P1) - suspension and rear section (P2) - steering. The rear When Replacing
cover incorporates a flow control valve and a pressure relief
valve (3000 Series machines only). Before removing and
Ensure that the pump drive shaft splines C and the internal
dismantling the pump, check the flow and pressure for each
section of the pump (see Section H, Steering and Section S, drive shaft splines of compressor D are undamaged.
Suspension - Technical Data). If the values are low the
following procedures are the only recommended repairs: Renew ‘O’ rings 5B, 6B and 10.
a Renew the complete pump. Before fitting adapters 5 and 6, make sure the pump gear
b Renew the pump section (P1 or P2) as required. teeth are well oiled.
c Renew the rear cover with flow control valve.
d Renew the pressure relief valve. Test steering pump pressure setting (3000 series machines
only) see Section H.
Renewal of components such as gears, bearings and
housings will not effect a permanent cure. If the pump Torque Settings
output is satisfactory but there is external leakage, the pump
may be dismantled for re-sealing only. Item Nm kgf m lbf ft
5A 25 - 30 2.5 - 3.0 18.4 - 22
Removal and Replacement 6A 10 - 13 1.0 - 1.3 7.4 - 9.5
8 91 9.3 67
The numerical sequence shown on the illustration is A 50 - 60 5.1 - 6.1 37 - 44
intended as a guide to dismantling. B 50 - 60 5.1 - 6.1 37 - 44
9803/8020 Issue 1
13 - 2 Pumps 13 - 2
28
30
29
24
25
23
33 24
26 19 16
27 18
17
32 18
21 14
31 20
13
22
9 8
12
7 1
10
11
36 2
15
34
36A 35
35A
5 3
35B
4
A358740
9803/8020 Issue 1
13 - 3 Pumps 13 - 3
Pump Type 2 - Suspension and Front Axle

Before removing and dismantling the pump, check the flow The bores and side faces of the bearing blocks and gears
and pressure for each section of the pump (see Section H, are coated with Teflon during manufacture. If the coating is
Steering and Section S, Suspension - Technical Data). If worn away, or if the bearing surfaces are scored or
the values are low the following procedures are the only damaged the pump must be renewed. If the faces of the
recommended repairs: gear teeth are damaged the pump must also be renewed.
a Renew the complete pump.
b Renew the pump section (P1 or P2) as required. Inspect the flow control valve spool 35A for signs of wear or
c Renew the rear cover with flow control valve. damage. Inspect the spool bore in cover 2. If the valve is not
*d Renew pressure relief valve (if fitted). functioning correctly due to wear or damage then the end
cover 2 complete with the valve 35 must be renewed.
housings will not effect a permanent cure. If the pump DO NOT use any abrasives on the bearing blocks or gears
output is satisfactory but there is external leakage, the pump as this would destroy critical manufacturing dimensions.
may be dismantled for re-sealing only.
It is only worth reassembling (with new seals) if the body,
Dismantling and Assembly bearings, bushes and gears are in perfect condition.
* Note: The pump configuration differs slightly in the areas of

When Assembling
the front and rear covers 2 and 23, depending on the
machine model. The orientation of seals 4/5, 10/11 and
26/27 together with the housings in which they are located Renew shaft seal 33 and pack between lips of the seal with
will also vary according to the direction of pump rotation. grease. Protect the shaft seal lips from damage using a
Otherwise the dismantling and assembly procedures are tapered sleeve, or, alternatively, by wrapping tape around
identical for all pump variants. the shaft splines whilst they are passing through the seal.
The numerical sequence shown on the illustration is * Note the correct orientation of bearing blocks, housings and
intended seals.
as a guide to dismantling.
Note the location of dowels 8 (2 off), 18 (2 off) and 24 (2 off).
For assembly the sequence should be reversed. Renew ‘O’ ring 31.
When Dismantling Renew all inter-section seals and 'O' rings, holding them in
position with grease. Ensure that the ends of seals 4, 10, 20
Mark housings and covers to ensure correct re-assembly. and 26 and back-up rings 5, 11, 21 and 27 do not overhang
the bearing blocks to become trapped in the housings.
damage. Renew ‘O’ rings 36A and 35B.
Remove all the seals. Torque Settings
Keep bearing blocks 12, 14, 28, 29 and gears 13 and 30 Item Nm kgf m lbf ft
together in sets to ensure refitting of the bearing blocks in 1 55-63 5.5-6.3 40-46
their original positions.
Inspection
Clean all the components using a proprietary washing agent

(do not use trichloroethylene or similar as this will damage
the seals.) Dry the components immediately afterwards with
compressed air. Be sure to blow out the ports and cross
drillings in the end cover 2. Make sure that the relief valve 34
(if fitted) and flow control components 35 are free from dirt.
Inspect the components for damage or signs of wear.

body bore on the inlet (large port) side. A groove upto
0.3mm (0.01 in) deep across the full width of the gear teeth
is permissible. If the wear is greater than 0.3mm (0.01 in),
renew the pump.
9803/8020 Issue 2*
15 - 1 Pumps 15 - 1
2WS Machines
226912
9803/8020 Issue 1
15 - 2 Pumps 15 - 2
* Pump Type 1 - Transmission, Rear Axle

Steering (4WS) (if fitted) and External
Hydraulics
When Removing
* Type 1 - fitted to machines as follows: Drain oil from PTO gearbox (see Section 3).
2000 Series to S/N 739999
3000 Series to S/N 641999 Remove cab floor mat and floor plate.
Removal and Replacement Remove pipe clamp 1, to allow pipe to be moved clear.
Note 1: The illustration opposite shows the arrangement on Blank hydraulic connections 2 to 5 (2WS), 2 to 7 (4WS) to
2WS machines. 4WS machines differ in the area prevent excessive oil loss and entry of dirt.
encompassed by box A. The corresponding area on 4WS
machines is shown below in box B. To gain access to the two cap screws 9, first remove the
pipe secured by the four cap screws 8.
Note 2: Before removing and dismantling the pump, check
each section for flow and pressure. If either of these When Replacing
parameters is low (see Technical Data in appropriate
section) and cannot be corrected at the relief valve, the Before fitting the port adapters, make sure that the gear
appropriate pump section must be renewed completely. teeth are well oiled.
housings will not effect a permanent cure. If the pump Refill gearboxes with recommended oil (see Section 3).
should be removed and dismantled for re-sealing only. Torque Settings
The numerical sequences shown on the illustrations are Item Nm kgf m lbf ft
intended as a guide to removal. 8 98 10 72
9 98 10 72
For replacement the sequences should be reversed. 10 98 10 72
10
2
3
6
9
5
8
4 A248970
A248970
9803/8020 Issue 2*
16 - 1 Pumps 16 - 1
20,37,47 10,26
42
31
9,25,41
31A
43
Y
W
44
31A
47
X
45
39 48 Z
40 42
38
46 41
30
35
34
33
28 32
26
25
27 24 31
36
20 37
19
14
18 10 21
9 22
29 24
17
23
12
13
8
11 16 17
2 7 15
8 4
5
1
6
3
6,22
40
5,21,39
A248940
9803/8020 Issue 1
16 - 2 Pumps 16 - 2
* PumpType 1 - Transmission, Rear Axle

Hydraulics (continued)
Note 1: The illustration opposite shows the arrangement for When Assembling
4WS machines. On 2WS machines the centre section
comprising items 15 to 30 is not fitted. Bolts 1 are shorter to Wash all components, then apply hydraulic oil immediately
compensate. afterwards to prevent moisture from collecting.
Note 2: Before removing and dismantling the pump, check Pack between lips of shaft seals 20, 37 and 47 with grease
each section for flow and pressure. If either of these and fit the two seals back to back as shown.
section) and cannot be corrected at the relief valve, the Renew all inter-section seals and 'O' rings, holding them in
appropriate pump section must be renewed completely. position with grease.
housings will not effect a permanent cure. If the pump Seals 31A should only be fitted to the bolts 31 fitted at
output is satisfactory but there is external leakage, the pump positions W and Z of mounting flange 48.
should be removed and dismantled for re-sealing only.
Make sure that all bearing blocks and gears are re-
Dismantling and Assembly assembled in exactly the same positions as those from
which they were dismantled.
intended Torque Settings
For assembly the sequence should be reversed. 1 34-41 3.5-4.2 25-30
31 61-68 6.2-6.8 45-50
When Dismantling

damage.
Keep bearing blocks and gears together in sets to ensure

refitting of the bearing blocks in their original positions and
orientation, i.e. set 11, 12, 13, set 27, 28, 29 and set 43, 44,
45.
Inspection

Examine the bores of the bearing blocks 11, 13, 27, 29, 43
and 45 which are coated during manufacture with PTFE. If
the grey PTFE is worn through so that the bronze base is
visible, the complete pump section must be renewed.

9803/8020 Issue 2*
17 - 1 Pumps 17 - 1
*
A
A353861
9803/8020 Issue 2*
17 - 2 Pumps 17 - 2
Pump Type 2 - Transmission, Rear Axle

Hydraulics
Type 2 - fitted to machines as follows:

Note 1: The illustration opposite shows the arrangement on

2WS machines. 4WS machines feature an additional pump
section as shown at A. With the exception of the extra feed
and suction pipes the removal and replacement procedure
for both types is identical.
Note 2: Before removing and dismantling the pump, check

each section for flow and pressure. If either of these
section) and cannot be corrected at the relief valve, the
appropriate pump section must be renewed completely.
housings will not effect a permanent cure. If the pump
should be removed and dismantled for re-sealing only.
When Removing
Drain oil from PTO gearbox (see Section 3).
Remove cab floor mat and floor plate.
Undo the clamps and brackets retaining feed pipes 1, 2 and

3 as applicable. Undo the screws 4 and lift the feed pipes
clear of the pump. Retrieve the ‘O’ ring seals and cap the
open ports and pipes.
Undo the clips 5 on the suction hoses (4WS machines have

three suction hoses). Pull the hoses off the pump adaptor
manifolds 6. Cap the open hoses and ports.
Undo the two retaining screws 7 and remove the pump.
Undo the cap screws 8 and remove the adaptor manifolds 6.

Retrieve the ‘O’ rings and cap the open ports.
When Replacing
Renew all the ‘O’ ring seals at the suction and feed ports.
Fit the adaptor manifolds 6 before refitting the pump.
Before fitting the feed pipes, make sure that the gear teeth
are well oiled.
Refill gearboxes with recommended oil (see Section 3).
Torque Settings

4 25-30 2.5-3 18.5-22
7 98 10 72
8 25-30 2.5-3 18.5-22
9803/8020 Issue 1
18 - 1 Pumps 18 - 1
53
61 62
60
59
58
57
45
44
67
65 55 54
64 56 51
66
50
63
46
47
48 19
49 21
52
24
28 20
22
29
36 31
37
35 23
25
26
27
43
41 29
39 29
30 8
35 35
10
33 34 14
42 32
40 38 15
7
8
8
9
14
14 1
12 2
13
18 17 11
16
3
5 4
6
A362540
9803/8020 Issue 1
18 - 2 Pumps 18 - 2
Pump Type 2 - Transmission, Rear Axle

Hydraulics (continued)
Note 1: The illustration opposite shows the arrangement for When Assembling
4WS machines. On 2WS machines the centre section
comprising items 16 to 35 is not fitted. Bolts 1 are shorter to Wash all components, then apply hydraulic oil immediately
compensate. afterwards to prevent moisture from collecting.
Note 2: Before removing and dismantling the pump, check * Pack between lips of shaft seals 20, 22, 39, 40, 65 and 66
each section for flow and pressure. If either of these with grease and fit each pair of seals back to back as
parameters is low (see Technical Data in appropriate shown.
section) and cannot be corrected at the relief valve, the
appropriate pump section must be renewed completely. Renew all inter-section seals and 'O' rings, holding them in
Renewal of components such as gears, bearings and position with grease.
housings will not effect a permanent cure. If the pump
output is satisfactory but there is external leakage, the pump Make sure that all bearing blocks and gears are re-
should be removed and dismantled for re-sealing only. assembled in exactly the same positions as those from
which they were dismantled.
Torque Settings
intended as a guide to dismantling. Item Nm kgf m lbf ft
1 55-63 5.6-6.4 40-46
For assembly the sequence should be reversed. 36 25-30 2.5-3.1 18-22
44 85-100 8.7-10.2 63-74
When Dismantling

damage.
Keep bearing blocks and gears together in sets to ensure

refitting of the bearing blocks in their original positions and
orientation, i.e. set 8, 9, 10, 14, set 29, 30, 31, 35 and set 53,
54, 55, 56.
Inspection

Examine the bores of the bearing blocks 8, 14, 29, 35, 53
and 56 which are coated during manufacture with PTFE. If
the grey PTFE is worn through so that the bronze base is
visible, the complete pump section must be renewed.

9803/8020 Issue 2*
21 - 1 *Control Valve Type 1 - External Hydraulics/Draft Control 21 - 1
Note: The control valve incorporates a solenoid operated

draft control spool and either 2 or 4 mechanically operated
spools for external hydraulic services. The illustration shows
the 4-spool version.

The numerical sequence shown on the illustration is When Replacing
intended as a guide to removal.
Refer to Section D for adjustment of control rods 6 and flow
For replacement the sequence should be reversed. control linkages 7.
When Removing After Replacing
Before disconnecting hoses, operate the controls with the Check MRV setting.
engine stopped to release any trapped pressure. Label the
Note: For clarity all the hoses are not illustrated.
Blank the open ports to prevent loss of oil and entry of dirt.
1
4
7
3
2
6
5
11
10
A293230
9803/8020 Issue 2*
9803/8020 Issue 3*

Remove hexagon nut 1 from tie rod 2 and the two hexagon
nuts 1A from tie rods 2A. Separate and remove valve
assembly sections 3, end plate 4, draft valve 5 and main
relief valve 6.
When Assembling
Renew all ‘O’ rings and seals.
Lubricate items 7 and 8 with JCB Special Hydraulic Fluid

before assembly.
Inset X shows a typical inter-spool sub-plate. All sub-plates

should face in the same direction.
Note:
If valve assembly sections are dismantled for cleaning only,

always renew seals and ‘O’ rings.
Do not disturb any adjustments within the valve system.
Do not dismantle the draft control valve except for re-

sealing.
When shims are removed, always replace the same total

thickness as those removed.
If spool movement is impaired, this may be due to distortion

caused by overtightening of screws and bolts. Care must be
taken in maintaining the correct torque settings given below:
Torque Settings
Items Nm kgf m lbf ft
1 15 1.5 11
1A 30 3 22
9803/8020 Issue 3*
A272570
9803/8020 Issue 2*
Spool and Detent Section

Note: Spool dismantling and assembly sequences are

identical for all basic valve assemblies (I, II, III and IIII).
Component parts must not be interchanged between
spools.
Item 14 is fitted to spools I and II on a 3-spool and 4-spool

valve (spool I on a 2-spool valve), item 14A is fitted to
spools III and IIII on a 4-spool valve (spool II on a 2-spool
valve, spool III on a 3-spool valve).
Check valves items 41 - 47 fitted only to valve blocks III and

IIII on a 4-spool valve (block II on a 2-spool valve, block III
on a 3-spool valve).

When Assembling
Renew all ‘O’ rings and seals where permissible. Remaining

components 4 - 36 should not be disturbed except to renew
seals and ‘O’ rings as given below.
Lubricate items 17, 18, 23, 25 and 26 with JCB ‘Special’

Hydraulic Fluid before assembly.
Note:

always renew all seals and ‘O’ rings.

Spool 27 must be inserted with the flat end projection in a

vertical position, as shown.

Torque Settings

1 5.5 0.5 4
4 25 3.5 18
21 5.5 0.5 4
28 25 3.5 18
35 2.75 0.3 2
9803/8020 Issue 2*
A272550
18
20
17
19
21
14
16
A
7
15 10
5 13
3 11 6
4
1 9
2
12
1 A258780
9803/8020 Issue 2*
Flow Control Valve Section


When Dismantling
The assemblies comprising items 5, 9, 10, 11, 12, items 13,

14, 15, 16 and items 17, 19, 20, 21 need not be dismantled
unless components are suspect.
When Assembling
1 Renew ‘O’ rings 6, 12, 18. Lubricate with JCB ‘Special’

Note: If valve assembly sections are dismantled for cleaning

only, always renew all seals and ‘O’ rings.
2 If necessary, make up the assemblies detailed in When

Dismantling before starting.
3 When installing assembly 13, 14, 15, 16 make sure that

slots A in item 13 locate with pin 21.
4 When installing assembly 5, 9, 10, 11, 12 locate pin 9

with the slot in item 16.
5 Do not disturb any adjustments within the valve system.
6 When shims are removed, always replace the same

total thickness as those removed.
7 If spool movement is impaired, this may be due to

distortion caused by overtightening of screws and
bolts. Care must be taken in maintaining the correct
torque settings given below:
Note: Refer to Setting Flow Control, Section D for setting

up procedure.
Torque Settings

1 1.15 0.12 0.85
3 1.15 0.12 0.85
5 137 14 100
17 137 14 100
9803/8020 Issue 2*
A272550
9803/8020 Issue 2*
Poppet Valve Section


When Assembling
Renew all ‘O’ rings and seals.
Lubricate items 5 and 9 with JCB ‘Special’ Hydraulic Fluid

before assembly.
Note:



caused by overtightening of screws and bolts.
9803/8020 Issue 2*
A314560
Early Machines - non adjustable
Later Machines - adjustable
9803/8020 Issue 3*
Main Relief Valve (M.R.V.)

When Dismantling
Later Machines
Assembly 2 should initially be removed intact. Only
dismantle if any of the component parts are to be renewed.
When Assembling
Renew all 'O' rings and seals.
Lubricate items 3, 8, 9 and 11 (early machines) or 3, 8, 9 and

12 (later machines) with JCB 'Special' Hydraulic Fluid before
assembling.
Note:
When the valve is dismantled for cleaning only, always

renew all seals and ‘O’ rings.

Do not disturb any adjustments within the valve system. If

spool movement is impaired, this may be due to distortion
taken in maintaining the correct torque settings given below.
Later Machines
When assembly is complete and the control valve fully
installed check and, if necessary, adjust the setting of the
MRV (see Pressure Testing, Main Relief Valve (MRV)).
Torque Settings

2 - 0 -0 -0
67 + 22 6.8 + 2.2 49 +16
6 -0 -0 -0
46 + 15 4.7 + 1.5 34 + 11
9803/8020 Issue 3*
A272580
3
4
2
7
5
1
8
6
A290750
9803/8020 Issue 2*
Draft Control Valve

Solenoid Valves
Note: Solenoids 2 can be renewed without the need for

recalibration. Simply follow the dismantling sequence.

Note: Disturbance of pressure tube 8 will result in loss of

factory calibration.
When Dismantling
The assembly comprising items 1, 3, 4, 5 should be

removed intact to release solenoid 2. Check protective cap
3, ‘O’ ring 4 and sealing ring 5 for damage and renew if
necessary.
Having removed solenoid 2, if there is evidence of hydraulic

oil leakage onto pressure tube 8, remove items 6, 7, 8 and 9.
Renew ‘O’ ring 9. Otherwise do not disturb.
9803/8020 Issue 3*
A272580
9803/8020 Issue 2*
Draft Control Valve (cont’d)
Pressure Compensator

When Assembling
Lubricate items 2 and 4 with JCB 'Special' Hydraulic Fluid

before assembling.
Note:
If valve sections are dismantled for cleaning only, always



Torque Settings

1 61 6 45
9803/8020 Issue 2*
A272580
9803/8020 Issue 2*
Internal Check Valve

When Assembling

before assembling.
Note:



Torque Settings

1 75 8 55
6 19 2 14
9803/8020 Issue 2*
A272580
1
2
4 5 3
6
A258940
9803/8020 Issue 2*

When Assembling

before assembling.
Note:



Torque Settings

4 15 1.5 11
6 5.9 0.6 4.5
9803/8020 Issue 2*
25 - 1 Control Valve Type 2 - External Hydraulics/Draft Control 25 - 1

Note: The control valve incorporates a solenoid operated Disconnect the control rods B and drive shafts C at the
draft control spool and either 2, 3 or 4 mechanically spools as applicable.
operated spools for external hydraulic services. The
illustration shows the 4-spool version. Remove the fixing nuts D.
When Removing When Replacing
Before disconnecting hoses, lower the front and rear Do not rotate the spools when fitting the control rods B.
linkages and operate the controls with the engine stopped to
release any trapped pressure. Refer to Section D for adjustment of control rods B and
flow control linkages C.
Clean off all dirt and debris from the valve assembly.
Torque Settings
Label the hoses to assist correct refitting.
Note: For clarity the hoses are not illustrated. D 23 2.3 17
Blank the open ports to prevent loss of oil and entry of dirt. After Replacing
Uncouple the two electrical connectors at the draft control Check MRV pressure setting.
valve section A.
B
C
D
A360182
9803/8020 Issue 2
Dismantling and Assembly Measure the diameters of all ports Y.
* Important: Do not clean the valve block using a high If port Y ‘O’ ring groove is 22.3 mm outside diameter, fit 18
pressure washer. Free all surfaces from contaminants, dirt, mm inside diameter ‘O’ ring without back-up ring.
paint residues and rust but do not use cleaning agents that:
- affect plastics or change their properties If port Y ‘O’ ring groove is 24.3 mm outside diameter, fit 18
- corrode metals or react to them mm inside diameter ‘O’ ring with back-up ring supplied.
- leave residues.
If the seal kit for each slice contains two ‘O’ rings of 20 mm
Remove the nuts E, F and G and then remove the end cover inside diameter, fit one at port P and one at port R both
H followed by the valve slices V as applicable. without a back-up ring.
* Note positions of any spacing washers on the tie rods so If ‘O’ ring supplied for port P is 18 mm inside diameter, fit
that they can be refitted in their original positions. back-up ring supplied.
Take care not to lose the shuttle valves S that are positioned Note: Port R should always have a 20 mm inside diameter
loosely between valve slices. ‘O’ ring but no back-up ring.
* Remove any adhesive shims from between the slices. Lubricate the seals with JCB Special Hydraulic Fluid before
assembly.
* Check that the sealing surfaces for O-rings on the flange
surface and on the undercut of the flange surface are not When shims are removed, always replace the same total
damaged. In case of damage, the respective valve slice must thickness as those removed.
be replaced by a new one.
Ensure that shuttle valves S are positioned between the
When Assembling spool slices as illustrated.
Renew all ‘O’ rings and seals. Before fitting the seals * Important: Do not tilt the shuttle valves.
between the valve slices, ensure selection of correct ‘O’
rings and back-up rings from the seal kits as follows. * Make sure that there is a clearance of approximately 0.5 mm
9803/8020 Issue 3*
between the face of the valve slice and the top face of the
shuttle valve at X.
Oil the tie rods and ensure that any spacing washers on the
tie rods are refitted in their original positions. If any adhesive
shims have been applied previously, one spacer must be
threaded onto each of tie rods. If the slice face has
corrugations which have been smoothed with a dressing
stone, one spacer must be threaded onto each of tie rods.
Tighten the tie rod nuts to the correct torque in the

sequence E, F, G.
Ensure fasteners are tightened to the correct torque as

overtightening could cause valve block distortion and impair
spool movement.
Torque Settings

E, F, G 30 - 33 3 - 3.3 22 - 24
9803/8020 Issue 1
9803/8020 Issue 3
Spool and Detent Section

Note 1: Spool dismantling and assembly sequences are

identical for all basic valve assemblies (I, II, III and IIII).
Component parts must not be interchanged between
spools.
* Note 2: The non-return valve design is changed on later

production valve slices. Items 31 to 37 are replaced by
items 31a to 37a.
Important: Do not try to service the check valves items 39

to 54 or the non return valve items 31 to 37 without following
the procedures in this manual (see Removing the Non-
return Valve and Repairing the Check Valves). Using any
other procedures will cause damage to the valve slice.

When Assembling
Renew all ‘O’ rings and seals where permissible. Remaining

components 4 - 30 should not be disturbed except to renew
seals and ‘O’ rings as given below.
Lubricate items 16 and 17 with JCB ‘Special’ Hydraulic Fluid

before assembly.


Spool 21 must be inserted with the flat end projection in a

vertical position, as shown.

Torque Settings

1 5.5+1.8 0.56+0.18 4+1.3
4 19+6.3 1.9+0.7 14+4.9
22 19+6.3 1.9+0.7 14+4.9
29 3+0.92 0.3+0.09 2.2+0.68
38 1.4+0.5 0.14+0.05 1+0.37
47 67+22 6.8+2.24 49+16
9803/8020 Issue 3*
Removing the Non-return Valves Replacing the Non-return Valves

1 Service tool kit 331/64246 must be used. Press the 1 Insert the valve cone and compression spring into the
edge of the protective cap gently with the wire hook bore. Thread the plug into the compression spring and
provided in the tool kit until the cap twists slightly. Pull push it into the bore.
the protective cap out of the bore with the hook.
2 Push the snap ring and mandrel into the bore until it the
mandrel meets resistance and touches the valve
2 Open the collet of the mandrel provided in the tool kit housing.The snap ring will slide into the groove.
about 3 mm and grease lightly. Insert the mandrel into Remove the mandrel.
the bore and push in until the mandrel is flush with the
plug.
3 Check the security of the snap ring as follows:
Insert the testing tool. Retract the retaining sleeve and

3 Continue to push in hard until the tool touches the valve hook the testing hook on to the pin on the plug.
housing and the circlip is forced out of its groove.
Tighten the mandrel with the rotary handle and the
circlip is drawn into the retaining bush.
Push the retaining sleeve until it stops against the plug.

Check the seating of the snap ring by puling with the
testing tool. If the plug can be pulled out of the housing,
repeat the assembly procedure.
4 Pull the tool out of the valve bore. Open the mandrel 4 Remove the testing tool and insert the plastic sealing
with the rotary handle and remove the circlip and plug. cap
5 Using the wire hook, remove the compression spring

from the bore.
6 Pull the valve cone out of the valve housing using the
magnetic gripper. Clean the bore and ensure no dirt is
introduced
9803/8020 Issue 2
Locking the Spool in Neutral Repairing the Check Valves

1 Service tool 331/64265 must be used. This tool Important: To avoid the possibility of parts dropping into the
consists of retaining bush B and a selection of screws. valve slice and causing serious damage, it is essential to
Fit the retaining bush B over spool S and fit screw C lock the spool in neutral before starting to remove the check
through the spool eye end Tighten screw C as tightly as valves (see Locking the Spool in Neutral).
possible by hand.
Each slice contains a check valve in port A and a check

valve in port B. The check valve in port A is retained by a
plug. The check valve in port B is retained by a circlip 39
* Note: The retaining bush is not symmetrical. Make sure that and retaining plate 40 (see illustration on page E26-1).
it is fitted the correct way round so that the holes in the
retaining bush align with the hole in the spool eye end and 1 Port B only:
holes D in the spool body (see illustration on page E26 - 1).
Use a screwdriver to bend both clips on the circlip
*2 Fit M6 screws E into holes D in the spool body (see upwards about 20 degrees. Turn the circlip clockwise
illustration on page E26 - 1). Tighten the screws to no 90 degrees.
more than 2 Nm (17 lbf in2).
Grasp the retaining plate with flat-nose pliers and press

down and out of the groove.Twist the retaining plate
with circlip counter clockwise 90 degrees to turn it into
the recess. Tilt the retaining plate in the recess in port
B.
Guide the retaining plate out of port B. Remove the

circlip. Continue at step 2.
9803/8020 Issue 3
2 Ports A and B. 9 Select the new thrust pin from the repair kit according
to the calculations.
Take the large compression spring out of the housing.
Use a magnetic gripper to remove the valve cone from 10 Lightly grease the new ball, compression springs,
the bore together with the small compression spring, washer, valve cone and thrust pin.
the disk and the ball; discard.
11 Insert the thrust pin into the bore with the narrow
Note: Check valves in ports A and B must be measured section facing upwards.
independently of the other.
12 Insert the ball in the valve cone.
3 Measure depth dimension Z from the top edge of the
housing to the thrust pin. Take out the thrust pin with 13 Insert the small compression spring in the valve cone
tweezers. Measure thrust pin length DL. bore.
14 Lightly grease the valve cone and insert in the

corresponding valve bore.
4 Insert new valve cone with new ball.

15 Port B only:
5 Measure depth dimension Y from top edge of housing
to the ball. Place the circlip in the valve bore so that the circlip lies
in the cavity, properly flush with the check valve
6 Remove the valve cone together with the ball. seating.
Align the circlip so that the open side of the ring faces
in the axial direction of the valve spool.
16 Ports A and B:
Using tweezers, place the washer in the greased valve

cone bore on top of the small compression spring.
With tweezers, position the greased large compression

spring on top of the washer.
7 Clean the bore and remove any pieces that have
broken off. Ensure that no dirt is introduced.
8 Calculate length of new thrust pin as shown in the table

below (all dimensions in millimetres).
+ Depth dimension Z =
+ Thrust pin length DL =
– Depth dimension Y =
– Gap width X (0.2. to 0.3 mm) = – 0.2–0.1
– Ball Ø mm = – 4.0 17 Port B:
Length of new thrust pin =
Use needle-nose pliers or tweezers to insert the
retaining plate at an angle in the valve bore in the
direction of the moulded pocket assemblies, so that the
pin on the retaining plate engages with the spring
9803/8020 Issue 1
Note: The moulded pocket assemblies lie in the same 23 Seal the bore with the threaded plug and tighten to
direction as the axis of the valve spool. 67+22 Nm (49 + 16 lbf ft). Remove the retaining bush
from the spool.
18 Gently press the retaining plate down and clockwise
through 90 degrees to seat it in the securing recess.
The circlip turns with it.
19 Use tweezers to turn the circlip counter clockwise until

the securing clip is located over the retaining plate.
Note: The retaining plate must not be allowed to become

dislodged from its seating.
20 Check that the large compression spring and the

washer are correctly seated in the valve cone.
21 Use a screwdriver to press the circlip down so that the

end of the retaining clip touches the circlip. The circlip
holds the retaining plate in place and must therefore
not be allowed to turn any further.
22 Port A:
Check that the large compression spring and the

washer are correctly seated.
Inspect the O-ring on the threaded plug for damage

and proper seating.
Sealing surfaces must be clean and undamaged.
Thread the spring guide pin on the threaded plug into

the compression spring.
9803/8020 Issue 1
9803/8020 Issue 1
Flow Control Valve Section


When Assembling
1 Renew ‘O’ rings 4, 6, 11. Lubricate with JCB ‘Special’


2 Do not disturb any adjustments within the valve system.
3 When shims are removed, always replace the same

total thickness as those removed.
4 If spool movement is impaired, this may be due to

distortion caused by overtightening of screws and
bolts. Care must be taken in maintaining the correct
torque settings given below:
Note: Refer to Setting Flow Control, Section D for setting

up procedure.
Torque Settings

1 1.15+0.38 0.14+0.05 1+0.37
10 67+22 6.8+2.24 49+16
9803/8020 Issue 1
9803/8020 Issue 1
Input Section
Main Relief Valve (M.R.V.)

When Dismantling
The assembly comprising items 2, 3, 4, 5, should initially be

removed intact. Only dismantle if any of the component
parts are to be renewed.
When Assembling
Note: When the valve is dismantled for cleaning only, always

Do not disturb any adjustments within the valve system. If

spool movement is impaired, this may be due to distortion
taken in maintaining the correct torque settings given below.
When assembly is complete and the control valve fully

installed check and, if necessary, adjust the setting of the
MRV (see Pressure Testing, Main Relief Valve (MRV)).
Torque Settings

2 13.5+4.5 1.38+0.46 10+3.3
9803/8020 Issue 1
S362391
9803/8020 Issue 2
27 -4 Control Valve Type 2 - External Hydraulics/Draft Control 27 - 4
Input Section
Diverter Valve

For assembly the sequence should be reversed
When Assembling
Renew all “O rings” and seals.
Note: When the valve is dismantled for cleaning only, always

renew all seals and “O rings”.
Torque Settings

1 13.5+4.5 1.38+0.46 10+3.3
10 67+22 6.8+2.24 49+16
9803/8020 Issue 1
9803/8020 Issue1
Draft Control Valve

Solenoid Valves
Note: Solenoids 2 can be renewed without the need for

recalibration. Simply follow the dismantling sequence.

Note: Disturbance of pressure tube 7 will result in loss of

factory calibration.
When Dismantling
The assembly comprising items 1, 3, 4 should be removed

intact to release solenoid 2. Check protective cap 3, and ‘O’
ring 4 for damage and renew if necessary.
Having removed solenoid 2, if there is evidence of hydraulic

oil leakage onto pressure tube 7, remove items 5, 6, 7 and 8.
Renew ‘O’ ring 8. Otherwise do not disturb.
Torque Settings

5 2.6+0.5 0.26+0.05 1.9+0.37
9803/8020 Issue 1
9803/8020 Issue 1*
Pressure Compensator

When Assembling

before assembling.
Note: If valve sections are dismantled for cleaning only,



Torque Settings

1 46+15 4.7+1.5 34+11
3 46+15 4.7+1.5 34+11
9803/8020 Issue 1
28 - 5 Control Valve Type 2 - External Hydraulics/Draft Control 28- 5
9803/8020 Issue 1
Internal Check Valve

When Assembling

before assembling.



Torque Settings

1 64+10 6.6+1 48+7.37
6 15+4 1.5+0.5 11+2.9
9803/8020 Issue 1
9803/8020 Issue 1

* When Dismantling
* Do not disturb any adjustments within the valve system

especially items 5 and 7.
When Assembling
* Lubricate with JCB 'Special' Hydraulic Fluid before

assembling.



Torque Settings

1, 9 1.4+0.5 0.14+0.05 1+0.37
5 11+3.7 1.1+0.38 8+2.7
7 5.9 0.6 4.35
9803/8020 Issue 2*
32 - 1 Rear Lift Ram 32 - 1
164400
9803/8020 Issue 1

Note: The procedure given is for the left hand ram only. The
procedure for the right hand ram is similar but to avoid
damage, the position control sensor must be removed first
(see Position Sensor Removal and Replacement).
Removal
1 Ensure that lift rams are fully closed as pressure cannot

be vented by operating controls with engine stopped.
2 Remove left hand rear wheel.
3 Slacken the five bolts A.
Note: This may not always be necessary as it is only

required to release any loading on pin F.
4 Lower the pick-up hitch to the ground.
5 Remove pin B and lower the left hand lower link and lift
rod to the ground.
6 Disconnect and blank the hydraulic connection C.
7 Remove circlip D, washer E and drive out the bottom

pin F as far as necessary to release the ram.
8 Support the ram, remove circlip G, washer H and drive

out top pin J.
Replacement
9803/8020 Issue 1
9803/8020 Issue 1

Dismantling Gland Seal Fitting Procedure
The numerical sequence shown on the illustration is The size (diameter) and position of pins C is determined by
intended as a guide to dismantling. the diameter and radial width of the gland seal being fitted.
For assembly the sequence should be reversed. The pins are screwed into threaded holes in the tool body.
The spacing of the holes is designed to suit small or large
Take extreme care not to damage the cylinder bore or the diameter gland seals.
groove in the piston 8.
To fit a new gland seal:
To dismantle the ram assembly, remove plug 5 from the
dismantling port. Insert a blunted screwdriver into the 1 Open the tool as shown at X and insert the new gland
dismantling port and prise spring ring 7 out of groove A on seal. The seal must be fitted behind the two front pins
piston 8, towards the open end of the cylinder and into deep but in front of the rear pin as shown.
groove B. Then withdraw the piston from the cylinder.
2 Close the tool as shown at Y. The seal must form a
Discard the following items on removal: Spring ring 7, rod reniform (kidney shape).
seal 9, wiper ring 10 and bearing rings 11 and 12.
3 Locate the seal in the groove. When the seal is in
Assembly position, open the tool to release the seal. Make sure
the seal is correctly installed in its groove and remove
Before assembling, check the components for damage and the tool.
wear, especially the cylinder bore. Renew the complete
assembly if necessary.
Use new components for those which were discarded

during dismantling. X
Lightly oil the seals.
Use the procedure opposite for fitting gland seals.
Ensure that spring ring 7 is located in groove B. Before

replacing plug 5, insert a blunted screwdriver into the
dismantling port and prise spring ring 7 towards the closed C
end of the cylinder and into groove A on piston 8.
Testing
Using a hydraulic hand pump (see Service Tools Section), Y

check for smooth operation of the ram.

9803/8020 Issue 2*
51 - 1 Electronic Draft Control 51 - 1
Introduction
Note: As an aid to understanding the operating principles G Diagnostic LED - Red Light flashes to identify system
and fault diagnosis, the first four pages of this section are faults (see Interpreting the Diagnostic LED under
instructions reproduced from the operator handbook. Fault Diagnosis).
The machine is equipped with an electronic control system H Position control/draft control selector - Raise pointer to
giving precise fingertip control of the rear three point linkage top position for full position control. Lower pointer to
from the control panel positioned by the driver's seat. bottom position for full draft control. Sensitivity to draft
signals is controlled automatically.
Alternatively, simple raise/lower action of the linkage is
controlled by pairs of buttons provided on the control panel J Linkage lifting indicator - Red light illuminates when
and externally on one of the rear fenders. linkage is being raised.
A Main control lever K Linkage lowering indicator - Green light illuminates

1 Raise when linkage is being lowered.
2 Stop
3 Lower L
4 Fast lower (spring return to 3) Lift (L)/lower (M) switch
M
B Transport lock - slides in to lock main control lever in
raised position. Note: The lift/lower switch will work whenever the engine is
running but before it can be used, the main control lever A
C Rate of drop control - increases rate of drop from must be put into either the neutral or lower position. Each
minimum (position '0' on scale) to maximum as knob is time the switch is used, the control panel is switched off and
turned clockwise. must be re-activated (see System Activation Procedure).
D Setpoint (implement height/depth) control knob -

Bottom limit of linkage travel is lowest when knob is at
position '1' on the scale. Bottom limit position rises (or
implement depth decreases) as knob is turned
clockwise.
E Maximum lift height control - Maximum lift height

decreases as pointer is turned anti-clockwise.
L
M
G
JD
A H
1
C
2
3
B K E
4
A285800
9803/8020 Issue 2*
System Activation Procedure
As a safety feature the electronic draft control system is put

in stand-by mode when either the starter switch is turned
OFF, a major or moderate fault is detected (see Fault
Diagnosis) or one of the raise or lower buttons is used.
When the starter switch is first turned ON the diagnostic

LED (see Fault Diagnosis) lights briefly and then, after a
short time, lights continuously. This indicates that the control
system is locked-up.
! WARNING
Before carrying out the System Activation Procedure,
ensure that the positions of the panel controls are such
that no dangerous movements of the linkage can occur
once the panel is re-activated.
13-2-4-5
To activate the system, the main control lever A must be

moved to lift position (1) and then to lower position (3).
Note: When the system is first activated the rate of

movement of the control linkages is limited. Subsequent
movement commands can be carried out at maximum
speed.
L
M
G
JD
A H
1
C
2
3
B K E
4
A285800
9803/8020 Issue 2*
Operation
Attaching an Implement 4 When the implement is at the desired height, push in

- Using Controls in Cab the red transport lock B, which will then prevent the
main control lever from being moved to the lower
1 Start the engine. position.
2 Move selector H to the top setting (Position Control).

Attaching an Implement
3 Carry out the System Activation Procedure. - using External Controls (on fender)
4 Adjust the linkage height using the height/depth control 1 Start the engine.
knob D. Indicators J and K will show whether the
linkage is lifting or lowering. 2 Move main control lever A to either neutral position (2)
or lower position (3).
5 To lift the linkage, turn the height/depth control knob D
clockwise. The red indicator J will illuminate.
! WARNING
6 Engage the lower link hooks on the linkage balls and Keep clear of the linkage when using external controls.
13-2-1-3
secure using latches Z. Finally, attach the top link and
adjust as necessary.
3 Press button X to raise the linkage or button Y to lower
it. The movement of the linkage will stop as soon as the
button is released.
Transport
Note: The rate of drop of the linkage when the external
1 Move selector H to the top setting (Position Control).
control button is used is 70% of the maximum speed.
2 Move main control lever A to lift position (1).
4 Engage the lower link hooks on the linkage balls and
secure using latches Z. Finally, attach the top link and
3 Adjust the maximum lift height to suit the implement
adjust as necessary.
being transported, using maximum lift height control E.
Start from the minimum setting (slide fully anti-
5 Once the external controls have been used, remember
clockwise) and move clockwise to increase the lift
to re-activate the control panel (see System Activation
height.
Procedure).
S159361
9803/8020 Issue 1
Operation (continued)
Field Work At the Headland
(or when finishing the operation)
1 Adjust the working depth using control D.
1 Move main control lever A to lift position (1). The
2 Use knob C to obtain a satisfactory rate of drop for the implement will rise to the height set by maximum lift
implement. Start from a slow rate of drop (knob fully height control E.
anti-clockwise) and increase the rate of drop by turning
the knob clockwise. 2 To enter work again, move the main control lever A to
lower position (3). The implement will drop at the speed
3 Use control H to select position control or draft control selected by control C to the working depth previously
to suit the implement and the ground conditions. set.
As a guide, use either: Note: If lever A is pushed against the spring to position 4
the implement will drop at an increased speed. Therefore
Position control - where you need to maintain the when using a heavy plough, position 3 should be used to
implement at a constant height above the ground. lower the plough to the ground and position 4 should be
used to rapidly achieve working depth.
or
Draft control - for soil engaging implements which are

required to maintain a constant depth of work.
The system allows variable selection between position

control and draft control. An intermediate setting
should be used to achieve satisfactory implement
control.
G
JD
1
A
2 C H
B
3 K E
4
A286270
9803/8020 Issue 1
Operation (continued)
Position Control
With control H moved to its highest position, implement is

held to the depth selected by control D.
Draft Control
With control H moved to its lowest position, the implement is

raised as resistance (soil density) increases and lowered as
resistance decreases, thus maintaining the preselected
draw-bar pull
Mixed Control
The intermediate settings of control H allow the effects of

position control and draft control to be varied as the ground
conditions require.
For example, if soil density is very inconsistent, full draft

control may give too great a variation in the operating depth.
228190
9803/8020 Issue 1
332490
A P
B
C
F E G
D
T H
A243440
System Description
The electronic control unit A receives the preselected set-

point values from the control panel B and the actual values
* from the position sensor C or P (see below) and the two
draft sensors D.
These values are processed by the electronic control unit

and then transmitted as electrical signals to the raise and
lower solenoids of the draft control section of Draft
Control/External Hydraulics Valve E.
Hydraulic oil is fed from pump F to the control valve which

then directs oil to or from the lift cylinders G in order to raise
or lower the 3 point linkage arms H.
* Position Sensor (Linear Type)
The linear position sensor C consists of a differential coil and

an iron core which moves inside the coil without actually
touching it. The core is therefore wear-free. Depending upon
the position of the cam J, the iron core moves inside the
coil, thereby varying the inductive reactance in the coil and
therefore the output voltage. This voltage is transmitted to
the electronic control unit.
M
On later machines, the position sensor is a rotary type P. D

This operates on exactly the same principle as the linear
type, except that the moving part is fixed to, and rotates
with, the linkage arm boss. Consequently, depending upon
the angular position of the linkage arm, the iron core moves N
inside the coil, varying the inductive reactance in the coil and
therefore the output voltage to the electronic control unit. L H
K
S198410
9803/8020 Issue 2*
System Description (continued)
Electronic Control Unit
The electronic control unit (ECU) is located behind a trim

panel inside the rear of the cab. The setpoint and actual
values are processed in the ECU, compared and transmitted
as electrical signals to the solenoids of the control valve until
the setpoint value and actual value coincide.
The ECU is designed to regulate position, draft and mixture

control. In addition, an interlock prevents the linkage arms
from moving unintentionally when the engine is started. The
interlock is disengaged only when the control lever is moved
from neutral position to raise.
In the event of a major or moderate fault in the system (see

Fault Diagnosis), the ECU switches off so that the linkage
cannot be moved.
! WARNING
To prevent the possibility of damage to electronic
components, disconnect the battery and withdraw the
plug from the electronic draft control unit before arc-
welding on the machine or attached implements.
Parts of the machine are made from cast iron; welds on

cast iron can weaken the structure and break. Do not S186191
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.
GEN 8-1
9803/8020 Issue 1
Hydraulic Circuit Operation

Unit A houses the draft control spools B and C as well as the
external hydraulic spools I,II , II I , IIII . Draft control is inhibited RR
if either of spools II I or IIII are not in neutral (as shown) or the
float (F) position.
Note: The unit A shown here incorporates the maximum

number of external hydraulic spools. An alternative version
T A
contains only two external hydraulic spools, one each of the
types I and III.
a
Neutral
J
Pump flow is dead ended by lift spool B (as shown) when C B
solenoid D is not energised. Pressure rises until 2-way
pressure compensator H operates, to dump the flow to tank E D
via port R2.
R1
Lift T
Solenoid D energises when ‘lift’ is initiated. Spool B moves G H
against spring pressure and pump flow is routed through b
load check valve J to lift rams RR. When neutral is re- 0 a
selected, solenoid D de-energises and spool B closes the F 1 2
IIII
path to check valve J, which closes, to trap oil in the rams
and hold the load.
1.2
If the rams RR reach the end of their travel with a ‘lift’ button
b
still pressed, the pressure build-up operates the main relief
valve K, to dump the excess to tank via port R1. 0 a
F 1 2
III
If the rams are held aloft with neutral selected, external
shock loads will cause an increase of pressure in the rams,
1.2
leading to operation of shock load valve G, to dump the
excess to tank via port R1.
Lower
b
Solenoid E energises when ‘lower’ is initiated. Spool C 0 a
moves against spring pressure, to allow the oil from the rams 1 2
II
to flow back to tank via port R1.
1.2
b
0 a
1 2 I
1.2
R2
A228342
P
9803/8020 Issue 1
Fault finding
Introduction
The Electronic Draft Control System is self-monitoring for

faults. These are identified by error codes indicated by a
diagnostic LED. Refer to Interpreting the Diagnostic LED
under Fault Diagnosis.
Experience has shown that faults are unlikely to lie within the
electronic components.
Understand how the system works before attempting

rectification (see Introduction, System Activation
Procedure and Operation to ensure that all controls are set
to allow full linkage movement).
Note: If you are unable to diagnose a fault by following the

fault finding procedure or by visual examination, contact
JCB Landpower Service for further assistance.
9803/8020 Issue 1
Fault Finding (continued)
Functional Test of Control Valve 1 Start engine.
If the rear lift arms do not function correctly carry out the 2 When button A on the control valve is pressed, the lift
following tests. arms should lower to their lowest position.
Note: In order to test the control valve, draft links must be 3 When button B on the control valve is pressed, the lift
loaded to approximately 800 kg (1700 lb). arms should rise to their highest position.
! WARNING 4 If the functions at steps 2 and 3 operate correctly, the

fault is electrical. If the arms do not raise or lower
The procedure below must be carried out with the
smoothly at steps 2 and 3, the fault is hydraulic.
engine running. Apply the parking brake, chock the
wheels and ensure that no-one enters the cab.
SUS 1-1
5 Use the Fault Finding table on the next page to identify
the fault.
A293220
9803/8020 Issue 1
Fault Finding (continued)
Arms Cannot be Raised or Lowered
Run engine at tickover
CHECK ACTION
1 Do hydraulics move when control valve solenoids are YES: Check 2.

pressed manually? NO: Check 3.
2 Are the relevant fuses intact? YES: Check Diagnostic LED indication.
NO: Renew fuses.
3 Are pump P3 flow and MRV settings correct? YES: Renew defective control valve.
NO: Check and adjust MRV/overhaul pump.
Arms Cannot be Lowered
Run engine at tickover, adjust setpoint control to fully

lowered.
CHECK ACTION
1 Is rate of drop control on minimum rate setting? YES: Move to mid position.
NO: Check 2.
2 Do arms move when control valve solenoids are YES: Check Diagnostic LED indication.
pressed manually? NO: Renew defective control valve.
Arms Cannot be Raised
Run engine at tickover, set height limitation control to

maximum height.
CHECK ACTION
1 Do arms move when control valve solenoids are YES: Check Diagnostic LED indication.
pressed manually? NO: Renew defective control valve.
9803/8020 Issue 1
Fault Diagnosis
The faults indicated by the flashing diagnostic LED (see 3 Minor Faults
Interpreting the Diagnostic LED) are classified in three
categories, see Error Codes, and the control unit reacts Draft control is maintained, but the diagnostic LED
accordingly. operates. Wherever draft control is activated, the LED
will operate until the fault has been rectified.
1 Major Fault
Interpreting the Diagnostic LED
As a result of such a fault the draft control is inhibited
and locked up. The control unit shuts down to protect All fault codes consist of two digits. The LED flashes the
its output stages. Until the fault is cleared, control will same number of times as the digit, e.g. six flashes for the
remain inhibited and the diagnostic LED will flash every number 6. It is therefore necessary to count the flashes
time an attempt is made to activate draft control. Once following a long pause and then count the flashes following a
the fault has been cleared, draft control can be short pause in order to decipher the digits, e.g. error code
resumed by switching the ignition from OFF to ON and 36, shows as: long pause - three flashes - short pause - six
then carrying out the System Activation Procedure. flashes. The LED keeps on repeating the two digit code.
2 Moderate Fault Note: Some of the error codes utilise the same two digits,
e.g. 13 and 31. To avoid confusion, remember that the first
Moderate faults cause the same reaction as for major digit follows a long pause, the second digit follows a short
faults except that the control unit does not pause.
automatically shut down. Once the fault has been
cleared, draft control can be resumed, with the ignition Refer to Error Codes for fault details.
already ON, by carrying out the System Activation
Procedure.
Error Codes (E.C.U. Type D+)
Major Faults
Error Fault Control Unit Possible Cause

Code pin no.
11 No output (raise circuit) 37 i Raise solenoid output stage faulty.

ii Open circuit solenoid lead to pin 35.
iii No voltage at pin 29 - check fuse C9.
12 No output (lower circuit) 19 i Lower solenoid output stage faulty.

13 Short circuit (raise/lower circuit). 35 Short circuit between pins 35 and 19 or pins
35 and 37.
Excessive current at pin 35. Possible solenoid short circuit.
14 Open circuit (raise/lower circuit). 35 i Open circuit in lead(s) from pins 19, 37, 35 to
No current at pin 35 when solenoids.
solenoid actuated. ii Possible solenoid fault (open circuit).
15 Rear button(s) not working. 9 i Open circuit from pin 9 to button feeds.
ii Faulty button(s).
16 Control unit supplies faulty. 2 Stabilised supply faulty.

20 Poor earth connection
17 Battery non-switched voltage. 29 Check battery.
18 Control lever A inoperative 21 Check continuity between control

unit and control panel.
9803/8020 Issue 1
* Fault Diagnosis (continued)
Error Codes (E.C.U. Type D+) (continued)

Moderate Faults

Code pin no.
22 Position sensor signal faulty. 6 i Sensor open circuit or not connected.

ii Possible short circuit or short to earth.
iii Position sensor needs adjusting.
23 Set command control D 22 Potentiometer open circuit or not connected.

potentiometer signal faulty.
24 Upper limit control E 3 Potentiometer open circuit or not connected.

Minor Faults

Code pin no.
31
32
Right force-sensing pin signal faulty.
Left force-sensing pin signal faulty.

26
7 } i
ii
iii
Sensor open circuit or not connected.
Possible short circuit or short to earth.
Possible overload of force sensing pin.
33 Battery switched voltage below 11.5V. 24 Check battery.
34 Lowering control C potentiometer 23 Potentiometer open circuit or not connected.

signal faulty.
36 Mix control H potentiometer signal faulty. 4 Potentiometer open circuit or not connected.
37 Hitch fails to lift with active current 37 If engine running:

at pin 37. i No oil pressure.
ii Valve seized.
41 Radar signal absent, transmission 10 i Sensor open circuit or not connected.

signal present with Differential Lock ii Possible short circuit or short to earth.
selected.
42 Transmission signal absent, radar 11 i Sensor open circuit or not connected.

signal present with Differential Lock ii Possible short circuit or short to earth.
selected.
9803/8020 Issue 2*
Fault Diagnosis (continued)
Error Codes (E.C.U. Type B)

Major Faults

Code pin no.
11 No output (raise circuit) 2 i Raise solenoid output stage faulty.

12 No output (lower circuit) 14 i Lower solenoid output stage faulty.

13 Short circuit (raise/lower circuit) 6 Short circuit between pins 6 and 2 or pins 6
and 14.
Excessive current at pin 6. Possible solenoid short circuit.
14 Rear up button not working 10 i Open circuit from pin 10 to button feed.
ii Faulty button.
15 Rear down button not working. 20 i Open circuit from pin 20 to button feed.
ii Faulty button.
16 Control unit supply faulty 12 Supply faulty.

Poor earth connection.
18 Control lever A inoperative 8 Check continuity between control unit and

control panel.
Moderate Faults

Code pin no.
22 Position sensor signal faulty. 19 i Sensor open circuit or not connected.

ii Possible short circuit or short to earth.
iii Position sensor needs adjusting.
23 Set command control D 16 Potentiometer open circuit or not connected.

24 Upper limit control E 22 Potentiometer open circuit or not connected.

Minor Faults

Code pin no.
31 Right force-sensing pin signal faulty. 18 i Sensor open circuit or not connected.
32 Left force-sensing pin signal faulty 17

} ii
iii
Possible short circuit or short to earth.
Possible overload of force sensing pin.
34 Lowering control C potentiometer 24 Potentiometer open circuit or not connected.

signal faulty.
36 Mix control H potentiometer signal faulty. 4 Potentiometer open circuit or not connected.
9803/8020 Issue 1
Control Valve
Refer to Control Valve - External Hydraulics and Draft

Control
Draft Pin
Removal and Replacement When Replacing
Note: The machine is fitted with two draft pins. Only the left Before fully tightening bolt 6 and fitting cover 4, screw in bolt
hand one is illustrated but procedures are the same for both. 3 hand-tight to make sure that the bottom hole in the keep
plate is in line with threaded bolt hole. Then tighten bolt 6 to
The numerical sequence on the illustration is intended as a the specified torque setting, remove bolt 3 and refit to
guide to removal. secure cover 4.
For replacement, the sequence should be reversed. When connecting the wiring, allow sufficient un-clipped
harness length to accommodate total suspension
When Removing movement.
Ensure that lift arms are fully lowered. Stop engine and Torque Settings
disconnect battery.
* Zinc-Plated (colour: golden)
Ensure that arm A is supported by leaving lift rod B
connected. Item Nm kgf m lbf ft
1 56 5.7 42
Disconnect sensor cable 5 at harness plug inside cab. 3 56 5.7 42
6 56 5.7 42
Remove keep plate 7 and withdraw pin 8.
Dacromet (colour: mottled silver)

1 47.5 4.8 35
3 47.5 4.8 35
6 47.5 4.8 35
162360
9803/8020 Issue 2*
Position Sensor (Linear Type)

Removal
1 Ensure that lift arms are fully lowered. *5 Start the engine and set lever A to raise position 1 until
rams stop extending. Select neutral position 2.
2 Stop engine.
6 Press button X and measure the distance that the rams
3 Disconnect the battery. extend before limit of movement is reached.
4 Disconnect sensor cable at harness plug. 7 Fully lower the arms.
5 Unscrew nut N and remove sensor S. 8 If ram extension at step 6 is less than 10 mm (0.4 in),
adjust sensor downwards.
Replacement and Setting
If ram extension at step 6 exceeds 10 mm (0.4 in),
1 Reverse the removal procedure steps 3 to 5. adjust sensor upwards.
2 Ensure that lift arms are fully lowered.
Note: The position sensor is extremely sensitive. Each
3 Set the sensor S at its highest position so that plunger complete rotation of the locking nuts M and N represents
P is pushed fully in. Then lower the position of the approximately 75 mm of movement on the lift ram. Therefore
sensor by one full turn of lock nuts M and N. to adjust the ram by 10 mm, the locking nuts M and N need
only be rotated by HALF A FLAT (1/12th of a turn).
4 Adjust the draft controls as follows:
9 Repeat steps 5 and 6 and re-adjust as required.
C Set to maximum on scale
D Set to minimum on scale Note: If the machine has no automatic pick-up hitch fitted,
E Set pointer fully anticlockwise the sensor may be set to allow the arms to raise to the top
H Set to maximum on scale limit by operation of lever A. In this case, ensure that no
distortion of linkage occurs by setting the sensor cut-off
! WARNING position to coincide with the mechanical stops.
SUS 1-1
D
1
H
C
2 E
A
162372
9803/8020 Issue 4*

Removal 4 Adjust the draft controls as follows:
1 Ensure that lift arms are fully lowered. C Set to maximum on scale
D Set to minimum on scale
2 Stop engine. E Set pointer fully anticlockwise
H Set to maximum on scale
! WARNING
4 Remove screws 1, nuts 2 and washers 3 and remove
cover 4.
5 Disconnect sensor cable at sensor.
SUS 1-1
6 Remove screws 5 and washers 6. Remove sensor 7

*5 Start the engine and set lever A to raise position 1 until
and mounting bracket 8.
rams stop extending. Select neutral position 2.
Note: The mounting bracket will remain attached to the
6 Press button X and measure the distance that the rams
sensor cable. If it is intended to remove the cable also,
extend before limit of movement is reached.
disconnect from the harness plug and remove cable clamp
9, then disconnect cable from the main harness.
7 Fully lower the arms.
Replacement and Setting
8 Adjust the rotary sensor and repeat steps 5 and 6 until
the measurement at step 6 is 10 mm (0.4 in). Rotating
1 Reverse the removal procedure steps 3 to 6, making
the position sensor anti-clockwise will increase the
sure that the peg on the sensor engages with the slot in
height whilst rotating the position sensor clockwise will
bush 10. Ensure that the cable has adequate free
lower it.
movement to accommodate full travel of the linkage.
Leave screws 5 loose at this stage.
9 Tighten screws 5.
2 Rotate the sensor fully clockwise.
10 Raise and lower the arms through full travel and check
that there is no chafing or fouling.
3 Ensure that lift arms are fully lowered.
11 Fit cover 4, using screws 1, nuts 2 and washers 3.
G
D
1 1
3 2
C H
3 E
4 A4
2 8
7
0
6
9
5
332250
162373
9803/8020 Issue 2*
Section F Transmission Section F
i i
Contents Page No.

Technical Data 1-1
Towing Procedure See Section 1
* General Description - †Dry Clutch Transmission 4-1
* General Description - ††Wet Clutch Transmission 4-3
Fault Finding
Complete Transmission 5-1
* Wet Master Clutch 5-2
Power Take Off Clutches 6-1
4/2 Wheel Drive 7-1
Differential Lock 8-1
Transmission Hydraulic Circuit

* Gearbox - †Dry Clutch Transmission 13 - 1
* Gearbox - ††Wet Clutch Transmission 13 - 3
* Powershift 13 - 5
Differential Lock 13 - 6
* Pressure Testing
* Powershift Clutches 14 - 1
Note: For Powershift Dismantling & Assembly, see PTO/Splitter Gearbox
* Transmission Brake (if applicable) 14 - 1
* Wet Master Clutch (if applicable) 14 - 2
Pump See Section E
Filter See Section 3
Valves
* Control Valve - †Dry Clutch Transmission 15 - 1
Removal, Replacement, 15 - 2
Dismantling, Assembly 15 - 2
Testing
Pressure Maintenance Valve 15 - 2
Lubrication Pressure 15 - 2
* Control Valve - ††Wet Clutch Transmission 15 - 3
Removal, Replacement, 15 - 4
Dismantling, Assembly 15 - 4
Testing
Pressure Maintenance Valve 15 - 5
Lubrication Pressure 15 - 5
* Differential Lock Control Valve 16 - 1
* Powershift Solenoid Valve 16 - 2
* Transmission Brake Solenoid Valve (if applicable) 16 - 3A
* Wet Clutch Lubrication Control Valve (if applicable) 16 - 4
* Solenoid Valve 16 - 5
* Wet Clutch Control Valve (if applicable) 16 - 6
* Main Drive Clutch - †Dry Clutch Transmission

Removal, Inspection and Replacement 17 - 1
* † 2000 Series to S/N 739999, 3000 Series to S/N 641999

9803/8020 Issue 6*
ii ii
Contents Page No.

Main Drive Clutch Master Cylinder - †Dry Clutch Transmission
Clutch Pedal Adjustment 18 - 2
Main Drive Clutch Booster - †Dry Clutch Transmission

General Description 19 - 1
Booster Operation 19 - 2
Bleeding 19 - 4
- Clutch Booster 19 - 5
- Clutch Slave Cylinder 19 - 5
Shim Calculation 19 - 6
Main Drive Clutch Check Valve (if fitted) 19 - 7
Clutch Pedal - ††Wet Clutch Transmission

Clutch Down Switch
Potentiometer (Position Sensor) 19 - 8
* Flywheel Damper - ††Wet Clutch Transmission see Section T
Gearbox Assembly
Removal and Replacement -
†Dry Clutch Transmission 20 - 1
Removal and Replacement -
††Wet Clutch Transmission 20 - 4
Wet Master Clutch

Housing Removal and Replacement 21 - 3
PTO Clutches
* Front PTO Clutch (All Models)
* Rear PTO Clutch (3000 Series)
* Rear PTO Clutch (2000 Series) -
PTO/Splitter Gearbox
Six-Speed Gearbox/Rear Housing
- Removal and Replacement 23 - 2
Splitter Clutches
- Removal and Replacement -
†Dry Clutch Transmission 23 - 2
- Removal and Replacement -
††Wet Clutch Transmission 23 - 3
PTO Gearbox
Speed Selector Shaft Assembly

9803/8010 Issue 7*
iii iii
Contents Page
* PTO/Splitter Gearbox
Splitter Clutches
* Output Section - †Dry Clutch Transmission
* Output Section - ††Wet Clutch Transmission
* Input Section - †Dry Clutch Transmission
* Idler Gear - ††Wet Clutch Transmission
- Removing and Dismantling 26 - 11
* Housing - ††Wet Clutch Transmission 26 - 12
Speed Gearbox
Removal and Replacement See page 20 - 1,
or 20 - 4 as applicable
Remote Control
Rear Oil Seals
Front Oil Seal and Housing
Input Shaft, Mainshaft and Layshaft
Layshaft Bearing Preload 27 - 7
Mainshaft
End Float Check 27 - 9
Layshaft
Selector Shaft and Forks
Range Box
Front Casing
Removing and Replacing 31 - 2
Replacing Brake Caliper Wear Bushes 31 - 4
Turret Assembly
Dismantling and Assembly 31 - 4A
Clutch and Gear Assemblies
Heavy Duty 4-Wheel Drive Clutch
PTFE Piston Ring Seals
Fitting Procedure 31 - 9
Pressure Testing - 4-Wheel Drive Clutch 31 - 10
Input Shaft
Output Shaft
Syncromesh Assembly 31 - 13

9803/8020 Issue 5*
iv iv
Contents Page No.

Needle Roller Bearings
- Checking for Damage or Distortion 32 - 1
Propshafts
Front and Rear Axles

Differential Oil Seal
Hub and Driveshaft (Steering axles)
Front Axle
Drive Head
Dismantling 52 - 7A
Assembly 52 - 9
Maxtrac Differential (SD55 Axle - Optional)
NoSPIN Differential (SD55 Axle - Standard)
Description 52 - 11
Testing 52 - 15
Soft Engage Differential Lock - 3155 and 3185
(SD70 Axle)
* Front and Rear Axles

Pinion Depth 53 - 1
Solid Spacer Installation 54 - 1
Crown Wheel and Pinion Adjustment 54 - 2
Rear Axle
2115, 2125, 2135, 2140 55 - 1
2150, 3155 and 3185 55 - 3
Hub and Driveshaft - 2000 Series and 3155
(2WS, PD70 Axle)
Soft Engage Differential Lock - All Machines
(PD70/SD70 /PD90 Axles)
Drive Head
Drive Head - Dismantling 56 - 7
Drive Head - Assembly 56 - 11
Differential Case
Hub and Driveshaft - 3185 (PD90 Axle)
Rear PTO Driveshaft
Rear PTO Output Shaft 57 - 3
9803/8020 Issue 4*
Main Clutch (Dry Clutch Transmission †)
Type Cover Plate: Diaphragm sprung with live drive for P.T.O. Box.
Driven Plate: Spring centre, non-asbestos single dry plate.
Nominal Diameter 350 mm (14 in)
Master Clutch (Wet Clutch Transmission ††)
Type Multiplate oil-immersed hydraulically actuated (pressure on to engage).

Clutch drum/drum carrier transmit a live drive for P.T.O. box.
Actuating hydraulic pressure measured at the control valve test point

(TPE) at 1500 rev/min:
Minimum - Clutch disengaged (pedal fully down) -

0.7 - 1.4 bar (10 - 20 lbf/in2).
Maximum - Clutch engaged (pedal fully up) -

12 - 13 bar† (175 - 190 lbf/in 2).
Power Take Off Gearbox
Type Live drive from engine; constant mesh with sliding sleeve - non
synchromesh.
* Output 2115, 2125, 2135 2140 2150 3155 3185

Engine speed at 540 PTO rev/min 1894 rev/min 1894 rev/min 1894 rev/min 2118 rev/min 2002 rev/min
Engine speed at 1000 PTO rev/min 2088 rev/min 1986 rev/min 1986 rev/min 2196 rev/min 2196 rev/min
Power Take Off Clutches Electro-hydraulic engagement. Multi-plate oil-immersed clutches with
yoke output connections.
JCB Powershift
Type Low, medium and High Splitter Clutches in PTO/Splitter Box
Clutch Pressure at 1500 rev/min 13.5 bar (195 lbf/in2)
* Clutch Pack End Float 3.0 - 3.5 mm (when fitting new or used plates)
Transmission brake (wet clutch machine only) Operating Pressure at 1500 rev/min - 13.5 bar (195 lbf/in2)
Speed Gearbox
Type 6 speed (all forward) synchromesh
Range Gearbox
Type High, medium, low and reverse ranges, all synchromesh.

Flange outputs to front and rear axles.
4 Wheel Drive Clutch Spring-engaged, multi-plate, oil-immersed clutch.

Electro-hydraulic dis-engagement to select 2WD.

9803/8020 Issue 4*
* Pump (Dry Clutch Transmission †)
Type Rear section (P4) of gear type double pump (triple pump on
4WS machines), driven by PTO gearbox.
Flow Rate at 13.5 bar (195 lbf/in2) 28.5 litres/min (6.3 UK gal/min; 7.6 US gal/min) at 2400 rev/min
* Pump (Wet Clutch Transmission ††)
Type Rear section (P4) of gear type double pump (triple pump on
4WS machines), driven by PTO gearbox.
Flow Rate at 13.5 bar (195 lbf/in2) 28.5 litres/min (6.3 UK gal/min; 7.6 US gal/min) at 1500 rev/min.
* Control Valve (Dry Clutch Transmission †)
Type Remote, chassis-mounted control valve. Incorporates pressure

maintenance valve, check valve and solenoid valves.
Pressure Maintenance Valve Setting 13.5 bar (195 lbf/in2)
Check Valve Cracking Pressure 1.5 bar (22 lbf/in2)
Solenoid Valves 12V dc, 3 position, 4-way
Lubrication Pressure at 1500 rev/min. 1 - 2 bar (14.5 - 29 lbf/in2)
* Control Valve (Wet Clutch Transmission††)
Type Remote, chassis-mounted control valve. Incorporates pressure

maintenance valve, check valve and solenoid valves.
Pressure Maintenance Valve Setting (CT1) 13.5 bar (195 lbf/in2)
Check Valve Cracking Pressure
CT2 2 bar (29 lbf/in2)

CT3 5 bar (72.5 lbf/in2)
CT4 2 bar (29 lbf/in2)
Solenoid Valves 12V dc, 3 position, 4-way
Low Pressure Lubrication (LPL) at 1500 rev/min. 1 - 2 bar (14.5 - 29 lbf/in2)

9803/8020 Issue 3*
* Differential Lock Control Valve
Type Solenoid and pressure maintenance valve for 'soft-engage'

diff. lock mounted in suspension valve block
Pressure Maintenance Valve Setting 38 bar (550 lbf/in2) at 2400 rev/min.
Front Axle
Model SD55 (2000 Series)

SD70 (3000 Series)
Type Crown wheel and pinion primary reduction with epicyclic hub
reduction
Mounting 3 leading link control arms and Panhard rod
Weight (approximate) SD55 - 510 kg (1124 lb)

SD70 - TBA
Differential SD55 - NoSPIN (standard)

Maxtrac (optional)
SD70 - Soft engaged differential lock with electro - hydraulic control
Rear Axle
Model PD70 (all 2WS machines except 3185)

PD90 (3185 machines only)
SD70 (4WS machines)
Type Crown wheel and pinion primary reduction with epicyclic hub
reduction
Mounting 2 trailing link control arms and 'V' link
Weight (approximate) PD70 - 590 kg (1300 lb)

PD90 - 555 kg (1224 lb)
SD70 - TBA
Brakes Single caliper solid disc on each hub
Differential Soft-engaged differential lock with electro-hydraulic control
Note: For technical data on wheels and tyres, see Routine Maintenance, Section 3.
9803/8020 Issue 1
4-1 General Description - Dry Clutch Transmission 4-1
* N
P N
P
C D
L J
A B E
M
F
G
H
P N P
B
C D
A B3
E
B1
H
B2
G
F
A290312
9803/8020 Issue 4*
4-2 * General Description - Dry Clutch Transmission 4-2
The top part of the illustration shows the complete Note: Removing all or part of the transmission is easier with
transmission system as described below. the cab removed. However, it is possible to remove all or
part of the transmission with the cab in place.
The bottom part of the illustration shows the power flow
through the gear box . The gearbox assemblies can be removed in three ways: -
The main clutch A is driven by the engine and provides a live a The range gearbox only.
drive for the power take off (PTO) box B by means of a
hollow shaft which is splined to the clutch cover. The PTO b The complete assembly consisting of the power take
gearbox incorporates the front power take off clutch C and off box, the speed gearbox and the range gearbox.
rear power take off clutch D.
c The front or rear PTO clutches (C, D) can be removed
The main clutch has a dry (non-asbestos) driven plate. independently.
The PTO box incorporates JCB Powersplit, consisting of There are no other options.
three hydraulic clutches B1, B2 and B3. The main clutch
driven plate is splined onto the input shaft of low clutch B1. Illustration Key
This shaft runs inside the hollow shaft which drives the PTO
gearbox and the speed gearbox input shaft is driven by the A Main clutch
splitter clutch. B PTO box
B1 Splitter clutch, low
If low clutch B1 is engaged, direct drive is provided through B2 Splitter clutch, high
to the speed box. Alternatively, if high clutch B2 is engaged, B3 Splitter clutch, medium
the drive to the speed box is at an overdrive ratio of 1.44:1 C Front PTO clutch
or if medium clutch B3 is engaged, the drive to the speed D Rear PTO clutch
box is at an overdrive ratio of 1.20:1. The splitter clutches E Speed gearbox
are controlled by a pair of buttons on top of the speed box F Range gearbox
lever. G 2WD/4WD Clutch
H Rear drive shaft
All 6 gears from the speed gearbox E have synchromesh J Rear drive axle
and are obtainable in all forward ranges and reverse. The K Rear axle drive head
gears are selected manually from the cab. L Front drive axle
M Front axle drive head
High, medium and low ranges are available from the range N Brake caliper
gearbox F, together with reverse. The Selectronic system P Brake discs
provides air assisted selection of the range change using a
steering column-mounted selector.
The 4WD/2WD clutch G is normally held in 4WD by spring

pressure and is electro-hydraulically selected to 2WD by a
rotary switch in the cab. All forward and reverse gears are
available in both 4WD and 2WD.
Final drive to the rear road wheels is through a short output

shaft H to the rear drive axle J. This axle consists of a single
piece casting which houses the drive head K and the half
shafts. The wheel hubs are connected to the half shafts by
sun and planet gearing inside the hubs. The drive head
contains a differential and a hydraulically operated
differential lock. In 4WD the front axle L is also driven, via
the front drive head M.
Two half shafts carried in the front axle are connected to the
wheel hubs through universal joints and sun and planet
gearing located in the hubs. The wheel hubs are carried on
axle swivel arms to facilitate steering.
Braking on both axles is by calipers N on solid discs P

mounted at the hubs.
9803/8020 Issue 3*
4-3 General Description - Wet Clutch Transmission 4-3
P N
P
C D
L J
A B E F
M
G
H
P N P
B
C D
B3
A
E
B1
H
B2
G
F
A353360
9803/8020 Issue 1
4-4 General Description - Wet Clutch Transmission 4-4
The top part of the illustration shows the complete Braking on both axles is by calipers N on solid discs P
transmission system as described below. mounted at the hubs.
The bottom part of the illustration shows the power flow Two half shafts carried in the front axle are connected to the
through the gearbox with JCB Powersplit. wheel hubs through universal joints and sun and planet
gearing located in the hubs. The wheel hubs are carried on
Drive from the engine is transmitted to master clutch A via axle swivel arms to facilitate steering.
flywheel mounted vibration damper (see Section K).
Note: In order to remove the complete transmission the cab
The master clutch A is a wet multiplate type. The outer must first be removed, see Section B, Body and
clutch drum is driven by the engine and provides a constant Framework . However, it is possible to remove part of the
‘live’ drive to the power take off (PTO) box B. The PTO transmission with the cab in place.
gearbox incorporates the front power take off clutch C and
rear power take off clutch D. The PTO box B also The gearbox assemblies can be removed in three ways: -
incorporates the JCB Powersplit.
a The range gearbox only (cab in place).
The master clutch A is engaged hydraulically via an
electronically controlled valve. Drive is then transmitted to b The complete assembly consisting of the master clutch,
the JCB Powersplit via a shaft which runs through the hollow PTO/Splitter box, the speed gearbox and the range
PTO input shaft. The Powersplit consists of three hydraulic gearbox (cab removed).
clutches B1, B2 and B3. Drive is transmitted via one of the
clutches to the speed box E. c The front or rear PTO clutches (C, D) can be removed
independently (cab in place).
If low clutch B1 is engaged, direct drive is provided through
to the speed box. Alternatively, if high clutch B2 is engaged, There are no other options.
the drive to the speed box is at an overdrive ratio of 1.44:1 or
if medium clutch B3 is engaged, the drive to the speed box Illustration Key
is at an overdrive ratio of 1.20:1. The splitter clutches are
controlled by a pair of buttons on top of the speed box lever. A Master clutch
B PTO/Splitter box
The medium clutch B3 incorporates a hydraulically actuated B1 Splitter clutch, low
transmission brake. The brake operates automatically via an B2 Splitter clutch, high
electronically controlled valve. When master clutch A is B3 Splitter clutch, medium
disengaged the viscosity of the transmission oil causes some C Front PTO clutch
drive to be transmitted from the engine to the Powersplit. D Rear PTO clutch
The brake holds the clutch input stationary when the master E Speed gearbox
clutch is disengaged and the machine is not in motion. This F Range gearbox
ensures smooth gear selection. G 2WD/4WD Clutch
H Rear drive shaft
All 6 gears from the speed gearbox E have synchromesh and J Rear drive axle
are obtainable in all forward ranges and reverse. The gears K Rear axle drive head
are selected manually from the cab. L Front drive axle
M Front axle drive head
High, medium and low ranges are available from the range N Brake caliper
gearbox F, together with reverse. The Selectronic system P Brake discs
provides air assisted selection of the range change using a
steering column-mounted selector. An ‘auto reverse’ can be
selected from the cab. This enables quick selection of
reverse by automatic electronic control of the master clutch
and selectronic system.
The 4WD/2WD clutch G is normally held in 4WD by spring

pressure and is electro-hydraulically selected to 2WD by a
rotary switch in the cab. All forward and reverse gears are
available in both 4WD and 2WD.
Final drive to the rear road wheels is through a short output

shaft H to the rear drive axle J. This axle consists of a single
piece casting which houses the drive head K and the half
shafts. The wheel hubs are connected to the half shafts by
sun and planet gearing inside the hubs. The drive head
contains a differential and a hydraulically operated
differential lock. In 4WD the front axle L is also driven, via the
front drive head M.
Braking on both axles is by calipers N on solid discs P
mounted at the hubs.
9803/8020 Issue 1
5-1 Fault Finding 5-1
Complete Transmission
If the problem is noise rather than loss of drive start at check
7.
CHECK ACTION
1 Is drive being transmitted to the road wheels? YES: Check 7.

NO: Check 2.
2 Is the clutch actuation system functioning? YES: Check 3.

NO: * Check clutch actuation. See Note 2 below.
3 Is the clutch slipping? YES: * Examine and repair clutch. See Note 2 below.
NO: Check 4.
4 Are range and speed gearboxes both in gear? YES: Check 5.

NO: Engage gear/check gearchange linkages.
5 Is 6-speed gearbox heard to drive with the range YES: Check 6.

gearbox in neutral? NO: Remove and examine 6-speed gearbox.
6 Does rear axle driveshaft rotate with both gearboxes in YES: Check rear axle.
gear? NO: Check range gearbox.
7 Is fault noise rather than loss of drive? YES: Check 8.

NO: Check 10.
8 Is transmission noisy with speed gearbox in gear and YES: Examine speed gearbox for worn/damaged
range gearbox in neutral? components.
NO: Check 9.
9 Isolate noise source to range box or rear axle or front Examine relevant transmission element for
axle by disconnecting relevant drive shafts. worn/damaged components.
10 Is transmission oil level low? YES: Fill to correct level.
* Note 1: When carrying out fault finding on the transmission

always check for any error codes that may have been
generated by the electronic management system. See Fault
Finding (Electronic Management System) Section C.
* Note 2: For machines fitted with a wet master clutch

transmission see Fault Finding - Wet Master Clutch.
9803/8020 Issue 2*
Wet Master Clutch

Symptom A
Clutch fails to engage. Clutch slips. Clutch engages erratically.
CHECK ACTION
1 Is the transmission oil level low? YES: Fill to correct level.

NO: Check 2.
2 Is the pressure maintenance valve set correctly? YES: Check 3.

NO: Set the valve to the correct pressure.
3 Is the clutch pedal potentiometer faulty? YES: Renew the potentiometer.

NO: Check 4.
4 Is the clutch hydraulic pressure low? YES: Recheck 2, check related external pipework for
leaks.
Check 5.
NO: Check 5.
5 Is the clutch control valve operating correctly? YES: Check 6.

NO: Renew the valve.
*6 Is pedal calibration correct? YES: Check 7.

NO: Re-calibrate pedal - see Powershift and Master
Clutch Calibration, Section C.
*7 Are the clutch piston seals leaking? YES: Renew piston seals, see the Note below.
NO: Check 8.
Note: The following checks can only be carried out after the complete gearbox assembly has been removed from the machine.
Make sure that all other checks have been carried out correctly before contemplating removal of the gearbox.
*8 Is the clutch piston check valve faulty? YES: Renew the check valve.
*9 Are the clutch friction plates worn? YES: Renew the plates.
* 10 Are steps visible in the drive tangs on the clutch drum? YES: Renovate or renew the drum as required.
Symptom B
Clutch fails to disengage correctly when machine is in motion (clutch drag).
CHECK ACTION
1 Is the transmission oil level too high? YES: Adjust oil level, check for oil contamination.
NO: Check 2.
2 Is the clutch external return line pipework damaged? YES: Renew pipes as required.
NO: Check 3.
3 Is the clutch pedal potentiometer faulty? YES: Renew the potentiometer.

NO: Check 4.
4 Is the clutch control valve operating correctly? YES: Check 5.

*5 Is pedal calibration correct? YES: Check 6.

NO: Re-calibrate pedal - see Powershift and Master
Clutch Calibration, Section C.
*6 Is the clutch piston check valve faulty? YES: Renew the check valve.
*7 Are steps visible in the drive tangs on the clutch drum? YES: Renovate or renew the drum as required.
*8 Are the clutch return springs worn or broken? YES: Renew the springs.
NO: Always renew the springs even if they appear
serviceable.
9803/8020 Issue 2*
Wet Master Clutch (continued)

Symptom C
Clutch fails to disengage correctly when selecting a gear with the machine stationary (clutch drag).
CHECK ACTION
1 Carry out checks 1 to 4 for symptom B then carry out check 2 below.
2 Is the transmission brake hydraulic pressure low? YES: Check 3.

NO: Check 5.
3 Is the transmission oil level low? YES: Fill to correct level.

NO: Check 4.
4 Is the pressure maintenance valve set correctly? YES: Check 5.

NO: Set the valve to the correct pressure.
5 Is the brake solenoid valve operating correctly? YES: Check 5.

6 Are the brake piston seals leaking? YES: Renew piston seals, see the Note below.
NO: Check 7.
7 Are the brake friction plates worn? YES: Renew the plates.
NO: Check 8.
8 Carry out checks 5 to 7 for symptom B.
9803/8020 Issue 1
Power Take Off Clutches

If the problem is a partial or complete lack of drive to PTO
drive lines start at check 1.
If the problem is that the PTO shaft continues to rotate when

selector switch is in the 'brake' position, start at check 12.
CHECK ACTION
1 Are both front and rear PTO drive lines fitted? YES: Check 2.
NO: Check 3.
2 Has drive been lost to both shafts? YES: Check 3.

NO: Check 4.
3 Is the PTO speed selector lever engaged and YES: Rectify fault in PTO gearbox.
cable/selector mechanism intact? NO: Rectify cable/selector mechanism and engage gear.
Note: Checks from 4 onwards refer to either front or rear

PTO operating mechanism.
4 Is PTO drive line intact? YES: Check 5.

NO: Repair as necessary.
5 Is there a leak in the extended pipework to the PTO YES: Rectify leak.
drive clutch? NO: Check 6.
6 Is the transmission hydraulic circuit pressure correct? YES: Check 7.

NO: Adjust pressure.
7 Is the transmission hydraulic circuit pressure filter YES: Replace filter element.
blocked? NO: Check 8.
8 Is current reaching the PTO drive solenoid? YES: Check 9.

NO: Check 10.
9 Is the PTO drive solenoid defective? YES: Replace the defective solenoid.
NO: Check 10.
10 Is the PTO selector switch passing current in the PTO YES: Check 11.
'drive' position? NO: Replace PTO selector switch.
11 Is the PTO drive solenoid spool sticking? YES: Free off or renew valve.
NO: Remove and dismantle PTO clutch pack and
inspect condition.
12 Does the PTO shaft continue to rotate when the PTO YES: Check 13.
selector switch is in the 'brake' position? NO: Check 14.
13 Is there a leak in the external pipework to the PTO YES: Rectify leak.
brake? NO: Check 14.

16 Is current reaching the PTO brake solenoid? YES: Check 17.

NO: Check 18.
9803/8020 Issue 1
Power Take Off Clutches (continued)

CHECK ACTION
17 Is the PTO brake solenoid defective? YES: Replace solenoid.

NO: Check 18.
18 Is the PTO selector switch passing current in the PTO YES: Check 19.
'brake' position? NO: Replace PTO selector switch.
19 Is the PTO brake solenoid spool sticking? YES: Free off or renew valve.
NO: Dismantle and examine PTO brake assembly.
9803/8020 Issue 1
4/2 Wheel Drive

No four-wheel drive but all gears functioning in two-wheel
drive.
CHECK ACTION
1 Is the front axle drive train intact? YES: Check 2.

NO: Repair as required.
2 Is 2WD dump switch permanently closed with parking YES: Replace 2WD dump switch.
brake on? NO: Check 3.
3 Is the 2/4WD solenoid spool sticking? YES: Dismantle/renew valve.

NO: Check 4.
4 Put the starter switch in "IGN" position. Select 4WD. Is YES: Renew 2/4WD switch.
there a voltage reading at the 4WD relay? NO: Check 5.
5 Put the starter switch in"'IGN" position. Select 4WD. Is YES: Renew 2/4WD drive relay.
there a voltage reading at the 2/4WD solenoid socket? NO: Dismantle 4WD clutch and inspect condition.
Two-wheel drive cannot be engaged (or four-wheel drive will

not disengage).
CHECK ACTION
1 Is there a leak in the external pipework to the 2/4WD YES: Rectify leak.
clutch? NO: Check 2.

4 Is current reaching the 2/4WD solenoid when the starter YES: Check 5.
switch is in "IGN" position and 2WD is selected'? NO: Check 6.
5 Is the 2WD dump switch permanently open, even with YES: Renew 2/4WD dump switch.
the park brake disengaged? NO: Dismantle 4WD clutch and check condition,
particularly the piston seals.
6 Is the 2/4WD solenoid defective? YES: Replace the defective solenoid.

NO: Check 7.
7 Is the 2/4WD selector switch passing current in the YES: Check 8.

2WD position? NO: Renew 2/4WD selector switch.
8 Is the 2/4WD solenoid spool sticking? YES: Free off or renew valve.
9803/8020 Issue 1
Differential Lock
Differential lock will not engage.
CHECK ACTION
1 Is there a leak in the external pipework to the differential YES: Rectify leak.
lock? NO: Check 2.

4 Is current reaching the differential lock solenoid? YES: Check 5.

NO: Check 6.
5 Is the differential lock solenoid defective? YES: Replace the defective solenoid.
NO: Check 7.
6 Is the 4WD/differential lock selector switch passing YES: Check 7.

current in the 4WD and diff. lock position? NO: Replace 4WD drive/differential lock selector switch.
7 Is the differential lock solenoid spool sticking? YES: Free off or renew valve.
NO: Dismantle differential lock mechanism and check
condition of drive plates and piston seals.
Differential lock will not disengage.
CHECK ACTION
1 Put the starter switch in "IGN" position. Is current YES: Renew 4WD/differential lock selector switch.
reaching the differential lock solenoid when only 4WD is NO: Check 2.
selected?
2 Is the differential lock solenoid spool sticking? YES: Free off or renew valve.
NO: Dismantle differential lock mechanism and check
condition of release spring and piston for sticking.
9803/8020 Issue 1
*
Gearbox Hydraulic Circuit
Dry Clutch Transmission
13 - 1
9803/8020
Section F
F1
PB
CT B
A
P L
TS
P4
CH
B3
3
A3
CM RB
CL C D
W B2 2
A2
F
Transmission
LH LMLL
B1 1
L E A1
TPL P T
TPM X2
AC
X1
X
TPH
S A293504
Issue 7*
13 - 1
Section F
*
Dry Clutch Transmission
13 - 2
9803/8020
Pump P4 feeds the PTO clutches, the 4WD clutch, Each end of the solenoid valve block has a port Key
the splitter solenoid valve, the main drive clutch marked P. The one on the end of the block nearest
Section F
booster and the lubrication circuit. The circuit is the right side of the machine is for the feed from the A-F Restrictors
self-contained, using transmission oil. pump via filter F1. Port P on the opposite end of the CH Splitter clutch - high
block feeds the splitter solenoid valve S (port L of CL Splitter clutch - low
Note: Pump P4 is the rear section of a pump which which provides lubrication feeds to the PTO CM Splitter clutch - medium
is driven by the PTO gearbox. The front section(s) clutches and the gearbox bearings) and the main CT Transmission oil cooler
of the pump supply the external hydraulic services drive clutch booster X which is actuated from the F1 Transmission oil filter
*
and 4WS (if fitted), and use hydraulic oil. The clutch pedal via port X1 to operate the clutch LH, LM Restrictors (2, 5 mm)
sections of the pump are separated by oil seals. mechanism via port X2. PB PTO gearbox
P1 Pump - differential lock/suspension circuits
Transmission oil is drawn from the range gearbox Additional pipework provides air balance and P4 Pump - transmission circuit
RB by pump P4 and delivered first to the cooler lubrication links between the PTO, speed and range RB Range gearbox
CT. gearboxes which all use the same oil. S Splitter solenoid valve
TS Solenoid valve block-transmission
Oil from the cooler flows via filter F1 to the solenoid Note: Special adapters with restrictor orifices are W 4WD clutch
valve block TS which contains a pressure fitted to certain lubrication inlets on the gearboxes X Main drive clutch booster
maintenance valve and three solenoids 1, 2 and 3. and it is essential that the correct size restrictors are
fitted as follows.
Solenoid 2 is only fitted to machines having the
optional front PTO. Port A2 of this solenoid A Front PTO clutch housing (both with and
pressurises the front PTO clutch pack in the main without a front PTO fitted) - 1/2 inch BSP
PTO gearbox PB. Port B2 pressurises the front male x 3/8 inch BSP female with 2.5 mm
PTO brake. Solenoid 3 supplies the rear PTO clutch restrictor.
Transmission
in the same way.

B Rear PTO clutch housing - 1/2 inch BSP
Port A1 of solenoid 1 pressurises the 4WD clutch male x 3/8 inch BSP female with 2.5 mm
restrictor.
W in the range gearbox. Port B1 is not used.
C and D Speed gearbox - 3/8 inch BSP male x 1/4

inch BSP male with 2 mm restrictor.
E Range gearbox front bearing - 1/2 inch

BSP male x 1/4 inch BSP male with 1.5 mm
positional restrictor (see Range Gearbox
Removal and Replacement for fitting
instructions).
F Range gearbox rear bearing - 7/16 inch

UNF x 1/4 inch BSP male with 1 mm
restrictor.
Issue 5*
13 - 2
Section F
*
Wet Clutch Transmission
13 - 3
S1
9803/8020
F1
Section F
PB
CT
L
LPL
K
HPL
S
P2
VWC AC
TS
PS
G
H
J
P4
TPG
CH B3
3
TPE
CT2
A3
RB T
CT4
TB CM
M N
S2 CL W B2 2
R A2
CT3
D E F
CB
TP
CT1
T
VL L
1
Transmission
P A1
VTB
P1
DRAIN
VCL
C P
VCM AC
VCH
SB
B A TPH TPM TPB TPL
Issue 2*
13 - 3
Section F
A358461
Gearbox Hydraulic Circuit -
The solenoid control valve block TS also Key
Wet Clutch Transmission
13 - 4
incorporates feeds for lubrication circuits from ports
9803/8020
HPL and LPL. High pressure lubrication (HPL) and A-T Restrictors
Pump P4 feeds the PTO clutches, the 4WD clutch, low pressure lubrication (LPL) feeds are connected CH Splitter clutch - high
the splitter solenoid valve and the lubrication
Section F
to wet clutch lubrication valve VL. When the clutch CL Splitter clutch - low
circuit. The circuit is self-contained, using is ‘slipped’ by the operator the valve supplies high CM Splitter clutch - medium
transmission oil. pressure lubrication to the clutch plates. Note that CT Transmission oil cooler
the valve is mounted on the wet clutch housing F1 Transmission oil filter
Note: Pump P4 is the rear section of a pump which
integral valve block CB. Sensors S1 and S2 warn of PB PTO gearbox
is driven by the PTO gearbox. The front section(s)
overheating transmission oil. S2 is fitted to the P4 Pump - transmission circuit
of the pump supply the external hydraulic services
clutch housing oil sump. S1 is fitted in the pipe next PS Pressure Switch
and 4WS (if fitted), and use hydraulic oil. The
to the transmission oil filter. RB Range gearbox
sections of the pump are separated by oil seals.
S1 Transmission oil temperature sensor 1
Low pressure lubrication oil from port LPL is S2 Transmission oil temperature sensor 2
Note that the Wet master clutch, PTO/Splitter,
supplied to clutches and bearings throughout the SB Splitter solenoid valve block (integral with
speed and range gearboxes all use the same oil.
transmission. Many of these lubrication connections PTO/Splitter gearbox housing)
incorporate restrictors inside special adaptors. It is TB Transmission brake
Transmission oil is drawn from the range gearbox
essential that the correct restrictors are fitted as TS Solenoid valve block-transmission
RB by pump P4 and delivered first to the cooler
follows: VCH Splitter clutch control valve - high
CT.
VCM Splitter clutch control valve - medium
Lubrication Restrictors VCL Splitter clutch control valve - low
Oil from the cooler flows via filter F1 to the solenoid
VL Wet clutch lubrication control valve
valve block TS which contains a pressure
Wet Clutch VTB Transmission brake control valve
maintenance valve and three solenoids 1, 2 and 3.
*
A High flow lubrication 4.0 mm dia VWC Wet clutch control valve
A pressure switch PS is fitted to activate a low oil
B Low flow lubrication 3.0 mm dia W 4WD clutch
pressure warning in the cab.
PTO/Splitter Gearbox Pressure Test Points
Transmission
Solenoid 2 is only fitted to machines having the

C 13.8 bar engagement feed 3.0 mm dia TP Clutch engagement feed
optional front PTO. Port A2 of this solenoid
D 2 bar lube - Splitter clutch H 3.5 mm dia TPB Transmission Brake
pressurises the front PTO clutch pack in the main
E 2 bar lube - Splitter clutch M 3.5 mm dia TPE Master clutch
PTO gearbox PB. Port B2 pressurises the front
* * * *
F 2 bar lube - Splitter clutch L No restrictor TPL Low splitter Clutch
PTO brake. Solenoid 3 supplies the rear PTO clutch
G Input/Idler gear mesh 1.0 mm dia TPM Medium splitter clutch
in the same way.
H Idler shaft 1.0 mm dia TPH High splitter Clutch
J Intermediate shaft 1.0 mm dia TPG Low pressure lubrication
Port A1 of solenoid 1 pressurises the 4WD clutch
*
K Front PTO pod 2.5 mm dia
W in the range gearbox.
L Rear PTO pod 2.5 mm dia
Port P2 on the solenoid valve block is for the feed
Speed Gearbox
from the pump via filter F1. Port P1 on the opposite
M Front restrictor 1.5 mm dia
end of the block feeds the splitter and transmission
N Rear restrictor 1.5 mm dia
brake solenoid control valves VCL, VCM, VCH and
VTB. Note that the valves are mounted on a valve
Range Box
block SB that is an integral part of the PTO/Splitter
P Input shaft front feed (angled) 1.5 mm dia
* *
gearbox housing.
R Input shaft rear feed (in plate) No restrictor
S Output shaft front feed 1.0 mm dia
A feed is also provided for the wet clutch control
T Output shaft rear feed 1.0 mm dia
valve VWC.
Issue 2*
13 - 4
Section F
13 - 5 Transmission Hydraulic Circuit 13 - 5
Powershift
The Powershift circuit is fed from the main transmission For fault finding purposes, pressure test points are provided
solenoid valve TS as shown on the applicable transmission for each of the splitter clutches, TPL (low), TPM (medium),
hydraulic circuit, on the preceding pages. TPH (high).
The Powershift hydraulic schematic is shown below. The Machines with wet master clutch transmissions incorporate
component parts are mounted on the outside of the a hydraulically operated transmission brake (TB). Signals to
PTO/Splitter gearbox . the transmission ECU lead to energization of the valve
solenoid. The brake solenoid control valve is mounted on the
Whenever the engine is running, oil from transmission outside of the PTO/Splitter gearbox. A pressure test point
solenoid valve TS is fed into the PTO/Splitter gearbox at port TPB is provided.
P in order to pressurise either the low (CL), the medium (CM)
or the high (CH) splitter clutch as required. Pressure is
maintained and smoothed by an accumulator at port AC.
Lubrication oil for the splitter clutches is routed via port L.
The ports marked T feed exhaust oil back into sump of the
gearbox assembly.
Manual selection of the splitter clutch required is initiated

from the buttons on top of the speed gearbox selector lever.
Signals to the transmission ECU lead to energisation of the
appropriate solenoid valve which routes pressurised oil to
the clutch pack causing it to engage.
Automatic splitter clutch selection can be set-up and

initiated from the same buttons. In this mode of operation
the transmission ECU selects splitter clutches according to
pre-determined criteria.
TB T CH CM CL LH LM LL T TT
TPB
VTB
L
TPL
TPM VCL
TPH
P
VCM AC
VCH
A293511
9803/8020 Issue 1
13 - 6 Transmission Hydraulic Circuit 13 - 6
Differential Lock Hydraulic Circuit
Pump P1 feeds the differential lock via valve SV which

incorporates a solenoid to control the engagement of the
differential locks DLR and DLF (as applicable).
Note: Pump P1 is the front section of the engine driven

pump.
Note: Valve SV also feeds the suspension circuit (Section S).
Key
DLR Differential lock, rear axle

DLF Differential lock, front axle (3000 Series only)
SV Suspension charge valve
W Solenoid valve spool
Y Pressure maintence valve
DLR
P1
D
Y SV
DLF
S
A358510
9803/8020 Issue 1
14 - 1 Pressure Testing 14 - 1
Powershift Clutches
! WARNING
SUS 1-1
* Note: Dry clutch machines are not fitted with solenoid valve
A.
1 Ensure that the transmission oil is at working

temperature. Connect a 0-20 bar (0-300 lbf/in2) gauge
to test point TPL.
2 Put speed gearbox in neutral, select any range and

confirm engagement.
3 Run engine at 1500 rev/min. Remove foot from clutch

pedal and, using the buttons on the speed change
lever, select the low (snail) Powershift clutch.
AC
4 Note gauge reading which will indicate pressure in low
clutch circuit (see Technical Data).
5 Repeat steps 1 to 4 with gauge connected to test point

TPM and the medium (tortoise) Powershift clutch
selected.
L
Note: Some machines may not feature the 90° adapter P
shown at TPH.
TPH
6 Repeat steps 1 to 4 with gauge connected to test point VCH
TPH and the high (hare) Powershift clutch selected.
7 If all clutch pressures are equal but incorrect, check the

setting of the transmission pressure maintenance valve.
If one clutch pressure is low, suspect leakage at the
solenoid or clutch pack. TPL VCL
Note: The pressure maintenance valve must not be set
above the specified figure under any circumstances. A
Transmission Brake (Wet Clutch Machines) TPM
1 Make sure that the transmission pressure maintenance

valve is set correctly.
2 Ensure that the transmission oil is at working VCM

temperature. Connect a 0-20 bar (0-300 lbf/in2) gauge
to test point TPB.
3 Put the speed gearbox into neutral, select any range

using the Selectronic control and confirm engagement. TPB
Run the engine at 1500 rev/min and fully depress the A353370
clutch pedal.
4 Note the gauge reading which will indicate the pressure

in the transmission brake cylinder (see Technical
Data). If the reading is zero, suspect a faulty
transmission brake control valve, possibly the solenoid.
If the pressure is low, suspect leakage at the brake
piston seals.
* Note: The wiring loom connector for the transmission brake

solenoid valve is coloured red and has wires 823 and 640N.
9803/8020 Issue 4*
Wet Master Clutch (if applicable)
! WARNING
SUS 1-1
1 Make sure that the transmission pressure maintenance

valve is set correctly.

temperature. Connect a 0 - 20 bar (0 - 300 lbf/in2)
pressure gauge to test point TPE.
3 Put the speed gearbox into neutral, select any range

using the Selectronic control. Confirm engagement.
4 Run the engine at 1500 rev/min and fully depress the

clutch pedal. Release the pedal slowly and note the
gauge reading. The control valve VWC is proportional
and as the clutch is engaged the pressure should rise TPE
proportionally (see typical graph below). If the pressure VWC
readings are erratic, suspect a faulty clutch
potentiometer (see Clutch Pedal (Wet Clutch
Transmission)) or control valve (VWC). If the pressure is
less than the value given in Technical Data when the
clutch is fully engaged (clutch pedal fully released),
suspect a faulty control valve (VWC) or leaking clutch
piston seals. A leaking clutch piston non return valve is
also a possibility.
The electrical circuit for the control valve VWC
incorporates an inching resistor X.
If the pressure reading does not alter when the clutch
pedal is released the resistor may be faulty. The resistor
is located next to the relays in the cab. A358521
See Section C, Sectional Diagrams Component Key
for specifications of the resistor.
C D
B A370250
Key
A Clutch pressure
X
B Clutch pedal position
C Down
D Up
A360060
E Pressure maintenance valve setting A360060
* 9803/8020 Issue 6*
Testing Transmission Accumulator

1 Remove accumulator AC from the machine and screw it
into pipe B (part no. 830/10683 or 481/00605). Blank off
the pipe at point C. + H G
Note: The pipe B to carry the accumulator can be the actual
pipe removed from the machine or a suitable spare .
2 Connect a hand pump and 0 - 20 bar (0 - 300 lbf/in2)

pressure gauge to the vacant end of pipe B. D
F
3 Loosen the pipe blanking plug and gently operate the
hand pump to bleed all air from the pipe B. Tighten the
blanking cap.
0
0 +
4 Operate the hand pump and watch the reading on the
pressure gauge: E
A370480
a If the accumulator is in good condition the pressure
should rise steadily to the charge pressure F (see
Technical Data) and then rise more slowly as curve
G. Stop pumping when the pressure reaches 8 bar
(120 lbf/in2).
C
b If the pressure continues to rise steadily to well past
the charge pressure (as curve H) the diaphragm is
ruptured and the unit must be renewed.
! CAUTION AC
Do not let the pressure exceed 20 bar (300 lbf/in2) to
avoid damage to the pressure gauge.
0049
Key
D Pressure
E Pump actuation
A370490
9803/8020 Issue 1
15 - 1 Valves 15 - 1
9803/8020 Issue 1
15 - 2 Valves 15 - 2
* Control Valve - Dry Clutch Transmission

Removal Dismantling
Note: The control valve should not be removed unless Note: If a front PTO is not fitted then a blanking plate will be
absolutely necessary. It is so designed that its component fitted in place of the solenoid valve and hydraulic
valve cartridges can be removed individually without connections will be plugged at A2 and B2.
disturbing the main valve.
1 Remove the check valve cartridge 3, then remove and
1 Stop the engine. discard 'O' rings 4, 5, and back-up ring 6. DO NOT
DISMANTLE THE CARTRIDGE. If the valve is faulty
2 Label, disconnect and blank off all hydraulic pipes. then it must be renewed as a unit.
3 Label and separate the electrical connections K. 2 Remove the pressure maintenance valve cartridge 7,
then remove and discard 'O' rings 8, 9, 10 and back-up
4 Remove bolts 1 and take off the valve 2. ring 11. DO NOT DISMANTLE THE CARTRIDGE.
Immerse the cartridge in clean hydraulic fluid and
Replacement operate the plunger by means of a plastic rod inserted
through the nose of the valve. If the valve is faulty then
1 Replace the valve body on the chassis with bolts 1 and it must be renewed as a unit.
torque tighten to 56 Nm (42 lbf ft, 5.7 kgf m).
3 Remove the solenoid valves. Each valve is held on the
2 Reconnect all pipes as detailed below. main valve block by four screws 14.
Note: The port markings are stamped into the body of the 4 Blow all galleries clear with air pressure.
valve. The letter P is used at two ports but the illustration is
marked P and T on the pipework as the ports are not visible 5 Check all machined surfaces for damage i.e. gouging
on the left hand side of the valve. marks, chips etc.
Port Marking Destination of pipework Assembly

A1 2/4WD clutch
A2 Front PTO clutch 1 Wash the valve block through with hydraulic fluid,
A3 Rear PTO clutch check that all galleries are clear.
B1 Blank
B2 Front PTO Brake 2 Fit new 'O' rings 4, 5, 8, 9, 10 and back-up rings 6, 11
B3 Rear PTO brake to the valve cartridges 3, 7.
L Lubrication line to gearboxes
P (LH) Pressure inlet (from filter) 3 Screw the valve cartridges into the valve 2. Torque the
P (RH) Splitter check valve cartridge 3 to 60 Nm (44 lbf ft, 6.1 kgf m).
T Dump Torque pressure maintenance valve cartridge 7 to 60
Nm (44 lbf ft, 6.1 kgf m).
3 Reconnect the solenoid valve electrical leads.
4 Fit the solenoid valves, using new seals (see Solenoid
4 Start up the engine and allow pressure to build up. Valve Dismantling and Assembly).
Check the system for leaks. Carry out tests detailed
below.
Testing - Pressure Maintenance Valve Testing - Lubrication Pressure
1 Ensure that the transmission oil is at working 1 Ensure that the transmission oil is at working
temperature. Connect a 0-20 bar (0-300 lbf/in2) temperature. Connect a suitable pressure gauge to test
pressure gauge to test point G. Run the engine at 1500 point X.
rev/min. Note: The gauge must be capable of indicating
pressures of 1-2 bar (15-30 lbf/in2) and should be
2 Adjust the pressure maintenance valve to the setting sourced locally. An engine oil pressure gauge may be
given in Technical Data which must not be exceeded suitable.
under any circumstances. To adjust the setting, slacken
nut 12, and turn adjuster 13 clockwise to increase the 2 Run the engine at 1500 rev/min. The gauge reading
setting and counter clockwise to decrease the setting. should indicate the lubrication pressure given in
Tighten the locknut when adjustment is complete. Technical Data. If the pressure is low, suspect that
check valve 3 is sticking open.
3 To check for correct operation, operate 4WD and the
front and/or rear PTO. The gauge should drop very
slightly towards zero then almost immediately return to
its original reading.
9803/8020 Issue 2*
15 - 3 Valves 15 - 3
A3 A2 A1
T
P1 B3 B2
D DRAIN
CT4
CT1 K CT1
14
TP P2
CT3
HPL
PS
2 LPL
CT2
B A
11
4
8
10
6
9
5
A358500
9803/8020 Issue 2*
15 - 4 Valves 15 - 4
* Control Valve - Wet Clutch Transmission

Removal Dismantling
Note: The control valve should not be removed unless Note: If a front PTO is not fitted then a blanking plate will be
absolutely necessary. It is so designed that its component fitted in place of the solenoid valve and hydraulic
valve cartridges can be removed individually without connections will be plugged at A2 and B2.
disturbing the main valve.
1 Remove the check valve cartridges CT2, CT3, and CT4
1 Stop the engine. (shown at A) then remove and discard 'O' rings 4, 5,
and back-up ring 6. DO NOT DISMANTLE THE
2 Label, disconnect and blank off all hydraulic pipes. CARTRIDGES. If the valve is faulty then it must be
renewed as a unit.
3 Label and separate the electrical connections K.
2 Remove the pressure maintenance valve cartridge CT1
4 Remove bolts 1 and take off the valve 2. (shown at B), then remove and discard 'O' rings 8, 9, 10
and back-up ring 11. DO NOT DISMANTLE THE
Replacement CARTRIDGE. Immerse the cartridge in clean hydraulic
fluid and operate the plunger by means of a plastic rod
1 Replace the valve body on the chassis with bolts 1 and inserted through the nose of the valve. If the valve is
torque tighten to the correct torque. faulty then it must be renewed as a unit.
2 Reconnect all pipes as detailed below. 3 Remove the solenoid valves. Each valve is held on the
main valve block by four screws 14.
Note: The port markings are stamped into the body of the
valve. 4 Blow all galleries clear with air pressure.
Port Marking Destination of pipework 5 Check all machined surfaces for damage i.e. gouging
A1 2/4WD clutch marks, chips etc.
A2 Front PTO clutch
A3 Rear PTO clutch Assembly
B2 Front PTO Brake
B3 Rear PTO brake 1 Wash the valve block through with hydraulic fluid,
DRAIN Range gearbox lubrication point R check that all galleries are clear.
HPL Lubrication line to wet master clutch
LPL Lubrication line to gearboxes 2 Fit new 'O' rings 4, 5, 8, 9, 10 and back-up rings 6, 11
P1 Splitter valve block and master clutch to the valve cartridges CT1, CT2, CT3 and CT4.
control valve
P2 Pressure inlet (from filter) 3 Screw the valve cartridges into the valve 2. Tighten the
T Dump to gearbox sump check valve cartridges to the correct torque (see
below).
3 Reconnect the solenoid valve electrical leads.
4 Fit the solenoid valves, using new seals (see Solenoid
4 Start up the engine and allow pressure to build up. Valve Dismantling and Assembly).
Check the system for leaks. Carry out tests detailed on
the following pages. Torque Settings

1 56 5.7 42
CT1 100 10.2 73.7
CT2 60 6.1 44
CT3 60 6.1 44
CT4 60 6.1 44
9803/8020 Issue 4*
15 - 5 Valves 15 - 5
Control Valve - Wet Clutch Transmission

(continued)
Testing - Pressure Maintenance Valve

temperature. Connect a 0-20 bar (0-300 lbf/in2)
pressure gauge to test point TP. Run the engine at
1500 rev/min.
2 Adjust the pressure maintenance valve CT1 to the

setting given in Technical Data which must not be
exceeded under any circumstances. To adjust the
setting, slacken nut 12, and turn adjuster 13 clockwise
to increase the setting and counter clockwise to
decrease the setting. Tighten the locknut when
adjustment is complete.
TPG
3 To check for correct operation, operate 4WD and the
front and/or rear PTO. The gauge should drop very
slightly towards zero then almost immediately return to
its original reading.
Testing - Lubrication Pressure
1 Obtain a pressure gauge capable of indicating

pressures of 1 - 5 bar (15 - 75 lbf/in2). Ensure that the
transmission oil is at working temperature.
2 Connect the pressure gauge to test point TPG.
Pressure test the Low Pressure Lubrication (LPL) as follows:
3 Run the engine at 1500 rev/min. Leave the clutch pedal

fully up (clutch released) for at least 2 minutes before
taking pressure reading from the gauge. DO NOT touch
the clutch pedal when taking a pressure reading.
4 The gauge reading should indicate the lubrication

pressure given in Technical Data. If the pressure is
low, suspect that check valve CT4 is sticking open.
Also the high pressure lubrication feed (HPL) to the wet
master clutch may be permanently engaged (controlled
by valve VL).
TP
Pressure test the High Pressure Lubrication (HPL) as follows:
5 Hold the clutch pedal half way down.

CT1 A360050
6 The LPL pressure should now be approximately half
that measured previously during the LPL test.
7 If the LPL pressure drops too low, check that the @

control restrictor A (see Gearbox Hydraulic Circuit - £
Wet Clutch Transmission) is fitted and the operation
of check valves CT2 and CT3.
8 If the LPL pressure does not drop, check the operation

of the wet master clutch lubrication control valve VL
(see Gearbox Hydraulic Circuit - Wet Clutch
Transmission).
9803/8020 Issue 1
16 - 1 Valves 16 - 1
* Differential Lock Control Valve

*
C
B
Note: The valve block also incorporates feeds to the brake
circuit and the suspension pressure maintenance valve. For
further information, see Sections G and S.
D
! WARNING
The rear of the chassis is supported by suspension
E
components which are charged with pressurised F
hydraulic fluid when the engine is running. When the
engine is stopped, pressure is trapped in components
downstream of the check valve.
Before disconnecting pipework or removing hydraulic

components, the chassis must be lowered to discharge
the pressure. See Section S Contents for correct
procedure.
SUS 1-2/1
Note: Provided that the above WARNING is observed in

respect of the suspension components (see Section S), the
valve can be dismantled in situ.
If the pressure maintenance valve A leaks oil or cannot be

adjusted to give the correct pressure setting (see Pressure
Testing), it can be removed for cleaning and/or renewal of
seals.
Unscrew the cartridge from the body.
Immerse the cartridge in clean hydraulic fluid and operate

the plunger by means of a plastic rod inserted through the
nose of the cartridge.
A 195990
Renew the seals and refit the cartridge.
*
* Check the pressure setting (see Pressure Testing below).
Solenoid
The solenoid coil B can be removed and replaced after

unscrewing nut C.
If the complete solenoid is removed, renew the seals on re-

assembly. The three seal grooves D, E and F each have a
seal with a back-up ring on each side.
Pressure Testing
Connect a 0-40 bar (0-600 lbf/in2) gauge to the front test

point (TP1) as shown.
Run the engine at tickover and select differential lock.
Gradually increase the engine speed to prevent the

possibility of damage to the gauge if the valve was set too
high. The gauge reading at maximum engine speed will
indicate the setting of the pressure maintenance valve (see
Technical Data).
If required, adjust at X. X
9803/8020 Issue 3*
16 - 2 Valves 16 - 2
Dry Clutch Transmission Wet Clutch Transmission
E D
B C
A C
C
B
C
C C A
A361910
9803/8020 Issue 1
16 - 3 Valves 16 - 3
Powershift Control Valves

Note: Solenoid valves can be removed individually. Although
the following procedure describes one particular valve, the
same can be applied to all three.
Removal
1 Drain the transmission oil from the PTO gearbox. If the oil
is not being changed, take precautions to prevent
contamination.
2 If necessary, disconnect the front propshaft at the range

box end to improve access to the valve.
3 Un-clip electrical plug from the solenoid.
4 Unscrew the four capscrews A. Remove the solenoid

valve from the transmission casing. Discard the ‘O’ rings
B.
Replacement
Note: Before refitting the valve, ensure that the five plugs C
and grub screw D are in place and secure in the
transmission casing orifices. Note that the plug and screw
positions are only applicable to machines with dry clutch
transmissions. For detailed information on plugs for wet
clutch transmissions see PTO/Splitter Gearbox, Housing -
Wet Clutch Transmission.
1 Refit solenoid valve to the transmission casing and

secure with capscrews A. Do not over tighten.
2 Re-connect electrical plug to the solenoid valve.
3 Refill the transmission (PTO, speed and range

gearboxes) to the correct level (see Lubricants and
Capacities, Section 3).
4 If previously disconnected, re-install the front propshaft.

Tighten the flange bolts to a torque of 78 Nm (57 lbf ft).
5 Run the machine and check for oil leaks. Re-check the
transmission oil level.
Accumulator
When renewing or refitting the accumulator E, coat the

threads with JCB Threadlocker and Sealer before installing.
9803/8020 Issue 1
16 - 3A Control Valves 16 - 3A
* Wet Clutch Transmission Brake Solenoid

Valve
Removal
1 Clean off any dirt or debris from around the valve. Drain
the transmission oil from the PTO gearbox.

3 Uncouple electrical connector from the solenoid.
* Note: The wiring loom connector for the transmission brake

solenoid valve is coloured red and has wires 823 and 640N.
4 Undo nut 1 and then remove the solenoid coil 2.
5 Using an extended socket undo the valve stem 3 and

withdraw it from the transmission housing.
6 Discard ‘O’ rings 4, 5 and 6.
Replacement
1 Clean the valve stem and renew ‘O’ rings 4, 5 and 6.
2 Coat the ‘O’ rings with transmission oil and carefully

insert the stem into the gearbox housing. Be sure not to
damage the ‘O’ rings.
3 Tighten the stem 3 to the correct torque.

6
4 Fit the solenoid coil 2 and tighten to the correct torque.
5 Re-connect electrical plug to the solenoid valve. 5

4
3 Refill the transmission (PTO, speed and range
gearboxes) to the correct level (see Lubricants and
3
2
Torque Settings
A358490
Item Nm kgf m lbf ft 1
1 7 0.7 5
*3 22 2.2 16.2
9803/8020 Issue 2*
16 - 4 Control Valves 16 - 4
* Wet Clutch Lubrication Control Valve
Removal

2 Un-clip electrical plug from solenoid.
3 Unscrew the four capscrews F. Remove the solenoid

valve from the transmission casing. Discard the ‘O’ rings
G.
Replacement
1 Refit solenoid valve to the clutch casing and secure with

capscrews F. Do not over tighten.
2 Re-connect electrical plug to the solenoid valve.

A358540
9803/8020 Issue 2*
16 - 5 Valves 16 - 5
Solenoid Valve

For clarity, only one solenoid has been numbered in the

dismantling sequence.
When Dismantling
Unscrew the knurled nut 2 and remove O-ring 3, withdraw

the solenoid 4 and O-ring 5.
Hold the solenoid valve body 6 in a vice. Using the spanner

flats A, remove spindle 7 and O-ring 8.
Pull out actuating pin 9, spring 10, spring retainer 11 and

spool 12.
Dismantle the opposite solenoid in the same sequence as

described above.
Inspect the spool and spool bore for signs of wear, nicks
scratches etc.
When Assembling
Renew all O-rings.
Lightly lubricate all parts with clean gearbox oil before

assembling.
Check that the flying leads are secure and that the
connectors are intact.
161590
9803/8020 Issue 1
16 - 6 Valves 16 - 6
* Wet Clutch Control Valve

Removal Replacement
The control valve is situated on the right hand side of the Replacement is the reversal of removal, but note the
clutch housing. Clean off any dirt or debris from around the following:
valve and housing 1.
Renew ‘O’ rings 6, 7 and 8. Coat the ‘O’ rings with
1 Uncouple the electrical connector at position 2. transmission oil and carefully insert the stem 5 into the
housing 1. Be sure not to damage the ‘O’ rings. Tighten the
2 Undo the nut 3 and then remove the coil 4. stem 5 and nut 3 to the correct torque.
3 Using an extended socket, undo the valve stem 5.

Torque Settings
4 Carefully withdraw the stem 5 from the housing 1.
Discard the ‘O’ rings 6, 7 and 8. Item Nm kgf m lbf ft
3 5.4 - 8.1 0.6 - 0.8 4-6
5 16.3 - 20.3 1.7 - 2.0 12 - 15
Cleaning and Inspection
Clean the valve stem with a proprietary cleaning fluid. Make Accumulator
sure that the filter screens at A and B are clean. If the
screens have collected dirt or debris, further investigations When renewing or refitting the accumulator X, coat the
must be carried out to determine the source. threads with JCB Threadlocker and Sealer before installing.
A358481
9803/8020 Issue 2*
17 - 1 * Main Drive Clutch - Dry Clutch Transmission 17 - 1
8 9
333970
9803/8020 Issue 5*
17 - 2 Main Drive Clutch - Dry Clutch Transmission 17 - 2
Removal, Inspection and Replacement

Access to the main drive clutch is obtained by separating 3 Engine Flywheel (Machines except 3185)
the engine/power take off (PTO) gearbox interface. See
Gearbox Removal (Section F) or Engine Removal (Section If the friction face of the engine flywheel is scored or
T). worn by more than 0.5 mm (0.020 in), all cracking and
scoring should be removed by machining off no more
* Note: The EMS data logging system stores information than 1.5 mm (0.060 in) from face A. The same amount
about clutch slip times and provides additional evidence of must be machined from face B and from the inner ends
clutch usage history. The counters cannot be reset and of the dowels C.
therefore should be noted for future reference when a clutch
is being replaced Note: After machining, dimension X must not be less than
38.04 mm (1.498 in)
Removal
Note: It is not possible to do worthwhile machining on a
1 Mark the engine flywheel 7 and clutch cover assembly 3185 machine flywheel.
3 to ensure their correct alignment when reassembling.
If the flywheel cannot be made serviceable, fit a new
2 Progressively loosen the eight bolts 1 and, while one as detailed in the engine service manual.
supporting the clutch cover assembly, remove the bolts
and their washers 2. Check spigot bearing 8 for wear. If necessary fit a new
bearing as follows:
3 Lift away the clutch cover assembly, taking care to
catch the clutch driven plate 4 as it drops out. Also take a Extract the spigot bearing 8 from the engine flywheel
care not to lose dowels 5 and 6 which should remain 7. Check that plug 9 is correctly positioned in the
located in their holes in the engine flywheel. If the end of the crankshaft as shown.
dowels do come out of the flywheel, or partially so,
relocate them before proceeding. b Press the new spigot bearing 8 as far as it will go
into the flywheel 7.
Inspection
Note: Use only JCB parts when renewing the spigot bearing.
1 Driven Plate.
Replacement
Note: If either the driven plate or the cover assembly are
faulty, it is advisable for both to be replaced at the same 1 The driven plate splines should be lubricated sparingly
time, together with the clutch release bearing/cylinder with JCB HP Grease. Position the plate centrally
assembly (see PTO/Splitter Gearbox, Input Section - against the engine flywheel with the protruding splined
Dismantling and Assembly, item 10). boss facing the flywheel as shown on the sectioned
view. While holding the driven plate in place, position
Renew the driven plate if any of the following are the clutch cover assembly 3 over the top to align the
present: locating marks on the cover and the flywheel.
a Excessive wear or cracking of the friction linings. Note: The cover assembly must locate with dowels 5 and 6.
Note that the dowel holes in the cover assembly are of
b Oil contamination of the friction linings caused by different sizes and will only fit properly when located with the
either a leaking crankshaft rear oil seal or a leaking correct dowel. If you have difficulty locating the assembly on
PTO gearbox input shaft oil seal. Renew the faulty oil the dowels, turn it through 180° to achieve correct
seal(s). alignment.
c Rim distortion, cracks, broken springs or loose 2 Refit the eight bolts 1 and washers 2. Hand tighten
rivets. Excessive wear of the splined hole. evenly all round.
Renew the PTO gearbox input shaft if its splines are 3 Use a clutch alignment tool (JCB Part No. 892/00313)
damaged. to align the clutch driven plate with the clutch cover
assembly and spigot bearing 8 in the engine crankshaft.
2 Clutch Cover Assembly
4 Tighten the eight bolts 1 evenly all round, progressively
a Check the clutch cover assembly for deep grooves increasing the torque to 78 Nm (58 lbf ft, 8 kgf m) for all
or heavy scoring to the machined friction surface. machines except 3185 or 48 Nm (36 lbf ft, 5 kgf m) for
Renew the assembly if necessary. 3185 machines.
b If there are any cracks or splits in the assembly, or if 5 Remove the clutch alignment tool.
the diaphragm spring fingers are stepped due to
wear from the clutch release bearing, renew the
assembly.
9803/8020 Issue 5*
18 - 1 * Main Drive Clutch Master Cylinder - Dry Clutch Transmission 18 - 1

Removal
Empty the hydraulic fluid from the clutch operating system,

either by disconnecting the hydraulic feed pipe to the main
drive clutch booster (fitted on the left side of the splitter B
gearbox housing) and allowing it to drain, or by connecting a
bleed tube to the booster bleed nipple, releasing it and
pumping the clutch foot pedal. When draining is complete,
remove the bleed tube and tighten the bleed nipple.
D
C A
Working inside the cab, disconnect master cylinder push rod
A from the clutch pedal by removing clevis pin B.
From inside the engine compartment, disconnect pressure

pipe C from the port on the master cylinder. Disconnect
plastic tube D from the master cylinder. Remove the two
bolts E securing the master cylinder to the bulkhead and
take it out.
E
Replacement
Position the cylinder through the engine compartment

bulkhead and loosely connect pressure pipe C to the port on
the master cylinder. Refit plastic tube D.
With bolts E secure the cylinder to the bulkhead, taking care

not to apply excessive force. Tighten the pressure pipe
union.
Fill the clutch hydraulic system with new fluid (see Section
3).
Do not connect the master cylinder to the foot pedal at this
A293631
stage. Carry out the Clutch Pedal Adjustment.
9803/8020 Issue 4*
18 - 2 Main Drive Clutch Master Cylinder - Dry Clutch Transmission 18 - 2
Clutch Pedal Adjustment

* Note: DO NOT adjust the clutch pedal in an effort to * Z1
make the brake and clutch pedals the same height.
*1 Remove the clutch pedal return spring to allow easier Y1

adjustment.
*2 Screw in bolt X1 and screw out bolt Y1 so that the

master cylinder rod can be set accurately.
*3 Lower the pedal to the bulkhead and adjust the rod of X1

the master cylinder so that the pedal hits the bulkhead
just before the master cylinder reaches the end of its R1
stroke.
*4 Adjust bolt Y1 so that when the pedal rises it is stopped

just before pulling on the end of the master cylinder,
ensuring some free play.
*5 Lower the pedal by 5 mm and adjust the clutch up

switch at Z1 so that it is just touching the clutch pedal.
Allow the pedal to rise fully and make sure it is not
fouling the switch body.
A319150A
*6 Check that the system is bled correctly. Check for

correct operation of the clutch pedal with the engine
running.
*7 Use bolt X1 to set the clutch down switch R1, which

controls the engagement of the splitters, so that the
splitters engage and disengage before the main clutch.
*8 Before checking clutch operation, confirm that the

pedal strikes the cab bulkhead before reaching the end
of switch R1 travel. If this does not happen, re-adjust
bolt X1 as necessary.
*9 With this setting correct, refit the clutch pedal spring,

start the engine and check the operation of the clutch.
9803/8020 Issue 4*
18 - 3 * Main Drive Clutch Master Cylinder - Dry Clutch Transmission 18 - 3

Reverse the sequence for assembly.
When Dismantling
Pull back dust cover 1 and remove circlip 2 with washer 3

and pushrod 4. Remove seal 5.
Remove the piston assembly comprising items 6 to 14 from

cylinder 15 either by shaking the cylinder or by using
compressed air.
Examine the working surfaces of piston and cylinder. If these

are not in perfect condition the piston assembly and cylinder
must be renewed.
If the piston/cylinder is to be re-used continue dismantling

by lifting the leaf of thimble 6 to release it from piston 13.
Compress spring 11 and disengage valve stem 7 from

thimble 6. Remove and discard seals 9 and 12.
When Assembling
Clean and lubricate all components, including new seals.

USE ONLY JCB LIGHT HYDRAULIC FLUID (which meets
ISO VG15) OR SERIOUS DAMAGE WILL BE CAUSED.
Take care not to damage the machined faces of piston 13

when assembling new seal 12, which must be located as
shown at A, and seal 14.
Position seal 9 on stem 7 as illustrated at B.
Thread washer 8, collar 10 and spring 11 onto the stem and

locate the stem in the keyhole in thimble 6. Fit the thimble
over the tapered section of piston 13 and secure by pressing
the leaf of the thimble behind the piston shoulder, as shown
at A.
Insert the piston assembly (items 6 to 14) into the cylinder

and fit pushrod 4, washer 3, circlip 2 and dust cover 1.
9803/8020 Issue 2*
19 - 1 Main Drive Clutch Booster - Dry Clutch Transmission 19 - 1
General Description
The main drive clutch booster is provided to minimise driver
effort in overcoming the powerful clutch release spring. To
do this, the unit utilises the 13.5 bar (195 lbf/in 2 )
transmission hydraulic circuit pressure in response to
activation of the clutch pedal.
The clutch reservoir A feeds clutch master cylinder B as well

as clutch mechanism C via clutch slave cylinder D. The
slave cylinder is integral with clutch booster E. Transmission
hydraulic circuit pressure F is applied to the clutch booster
via port E1 with a return path G to the transmission sump via
port E2.
* When the clutch pedal is depressed, the output pressure

from master cylinder B is applied to port E3 of clutch
booster E. The clutch booster utilises transmission hydraulic
circuit pressure F to assist operation of the clutch slave
cylinder D, thereby activating clutch operating mechanism C
via check valve H. Refer to Booster Operation for a detailed
description.
Key
A Reservoir
B Clutch Master Cylinder
C Clutch Release Bearing/Cylinder Assembly
D Clutch Slave Cylinder
E Booster
* F Transmission Hydraulic Circuit Pressure LIne
* G Transmission Hydraulic Circuit Return Path
* H Check Valve
G
H F
E2 E1
C E3
D E
A302761
9803/8020 Issue 4*
19 - 2 * Main Drive Clutch Booster - Dry Clutch Transmission 19 - 2
Booster Operation
;;;
;;;
1 Y
U ;;;;;;;;;
E2 E1
X
;;;;;;;;;
;; ;;;;;;;;; ;;;;;
;;
;;
;; ;;;;;;;;; ;;;;;
;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;
;;;;;;;;;
;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;
;;;;;;;;;
;;;;;;;;;;;;;;;;;;;
;;;;;;;;
;;
;;;;;;;;;;;;;; ;;;;;;;; ;;;;;
;;;;;;;;;;;;;;;;;;;
E3
;;;;;;;;;;;; ;;;;;;;;
;;;
W S
D V T Y
;;;;;;;;
E2 E1 X
U
2
;;;;;;;;
;;;
;;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;
;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;
;;;;;;;;
;;;
;;;;;;;;;;;;;;;;; ;;;;;;;;;
;;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;; E3
;; ;;;;;;;; ;;;;;;;;;
;;;;;;;; ;;;;;;;;;
;;;;;;;;
;;
S
W
D
;;;;
;;
;;
;;;;;;
E2 E1
3 ;;;;;;
;;;;;;;;;;;;;; ;;;;;;
;;;;
;;
;
;;;
;;;;;;;;;;;
;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;
;;;;;;;;;;;;;;
;;;;;;;;;;;;;; ;;;;;;
;; ;;;;;; ;;;;;;;;;;;
;;;;;;
;;
;;
;;;;;;;;;;; E3
;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;
;;;;;; ;;;;;;;;;;;
;;;
;;;
T Y
E2 E1 X
4 ;;;;;;;;;
;;;;;;;;;
;;;
;; ;;;;;;;;; ;;;;;
;; ;;;;;;;;; ;;;;;
;;
;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;
;;;;;;;;; ;;;;;
;;
;;;;;;;;;;;;;;
;;;;;;;;;;;;;; ;;;;;;;;;
;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;
;;;;;;;; E3
;;;;;;;;;;;;;;;;;;;
;;;;;;;;
;;;;;;;;
S
A301990
9803/8020 Issue 2*
Booster Operation (continued)

Key to Illustration
;;; Low pressure

;;;
{
;;
Clutch Fluid ;;;
;;;; High pressure
;;;;
;;;;
;;
{ ;;;;
Low pressure
Transmission oil
High pressure
A306840
1 Booster at Rest
With the clutch pedal released the pressure at port E3

is zero. Plunger X and piston Y adopt the positions
shown under the force of the clutch mechanism and
springs U, V and W. Port S in piston Y is closed by
plunger X to prevent boost pressure getting behind
piston Y which remains in the position shown. This
results in low clutch fluid pressure in clutch slave
cylinder D and the clutch is engaged.
2 Booster Applied
Depression of the clutch pedal applies clutch fluid

pressure at port E3 to move plunger X to the left.
Initially, with port T open between the front and rear of
piston Y, the low pressure transmission oil is pushed
out from the rear of the piston. This allows the plunger
to move to the left to close port T. Plunger X
overcomes the force of spring W to open port S.
Pressurised transmission oil flows behind piston Y,
pushing it to the left against the force of springs U and
V. This in turn moves the piston of clutch slave cylinder
D to pressurise the clutch circuit and disengage the
clutch. As long as the clutch pedal is being
progressively depressed the clutch slave cylinder
continues to move, increasing the separation of the
clutch plates within their physical limits.
3 Booster Balanced
Once the clutch pedal ceases to be further depressed

and is held constant, the total pressure of the
transmission oil boost circuit and the now stationary
clutch master cylinder circuit is insufficient to cause the
clutch slave cylinder piston to move further, but
sufficient to make it retain its attained position.
4 Booster Return to Rest
As the clutch pedal is released, a drop in pressure

occurs to the right of plunger X. The plunger moves to
the right, causing a drop of pressure behind piston Y
which also moves to the right. When the clutch pedal is
fully released the movement of piston Y to the right
causes port T to open, releasing the transmission oil
pressure behind piston Y. Plunger X moves fully to the
right to close port S and cut off the booster supply.
9803/8020 Issue 2*

Removal
! WARNING
Make the machine safe before working underneath it.
Park the machine on level ground. Apply the parking
brake, put the transmission in neutral and stop the
C B
engine. Chock both sides of all four wheels.
D A
Disconnect the battery, to prevent the engine being
started while you are beneath the machine.
GEN - 1 - 2
1 Remove grease and dirt from the outside of the

assembly, paying particular attention to the hydraulic and
other connections.
J K L
2 Disconnect transmission circuit hoses A and B, feed pipe
C from the hydraulic reservoir and clutch circuit hydraulic
G
pipes D and E.
E F
3 Remove screws F and lift the assembly clear of its
mounting bracket.
F
4 If slave cylinder J is to be dismantled for servicing,
remove the two cap screws K and lift the cylinder clear A293531
of booster L. Retain the shims from between the two for
possible re-use. *
Replacement
If slave cylinder J has been separated from booster L but M

not dismantled, refit the original shims between the two. If
the slave cylinder or booster has been renewed fit new
shims as described under Clutch Slave Cylinder, Shim
Calculation.
Tighten cap screws K to a torque of 22 - 28 Nm (16 - 21 lbf

ft).
Tighten screws F to a torque of 98 Nm (72 lbf ft).
When installation is complete, fill the clutch hydraulic fluid

reservoir with new fluid (see Section 3) and bleed the A358820
system (see Bleeding).
Bleeding
1 Top up the clutch fluid reservoir (see section 3) and,

during bleeding, ensure that the level does not fall below
the low level. Do not start the engine.
* Note: Later 2000 Series machines feature a remote booster
bleed point M. Remove the inspection cover from the cab
floor to gain access. The bleed point is located on the left
hand side of the machine.
*2 Connect a transparent plastic tube to booster bleed H
nipple G or M (as applicable) and slacken the screw.
Operate the clutch pedal fully. Pump the pedal rapidly
through its full stroke until air-free fluid spurts from the
bleed valve. Tighten the bleed screw and refit the
dustcap.
3 Repeat step 2 by connecting the plastic tube to bleed

screw H on the left side of the bell housing.
A293790
4 The hydraulic system is now ready for normal operation.
9803/8020 Issue 4*
Clutch Booster
The clutch booster is not serviceable and should be

renewed in the event of malfunction.
Clutch Slave Cylinder

Separate the clutch slave cylinder from the booster as
described under Removal and Replacement.
The numerical sequence shown on the illustration opposite

is intended as a guide to dismantling.
Assembly is the reverse of Dismantling.
When Dismantling
Remove the piston assembly comprising items 4 to 12 from

cylinder 13 either by shaking the cylinder or by using
compressed air.
Examine the working surfaces of the piston and cylinder. If

these are not in perfect condition the piston assembly and
cylinder must be renewed.
If the piston/cylinder is to be re-used continue dismantling

by lifting the leaf of thimble 4 to release it from piston 11.
Compress spring 9 and disengage valve stem 5 from thimble

4. Remove and discard seals 7 and 10.
When Assembling
Clean and lubricate all components, including new seals.

USE ONLY JCB LIGHT HYDRAULIC FLUID (which meets
ISO VG15) OR SERIOUS DAMAGE WILL BE CAUSED.
Take care not to damage the machines faces of piston 11

when assembling new seal 10, which must be located as
shown at A, and seal 3.
Position seal 7 on stem 5 as illustrated at B.
Thread washer 6, collar 8 and spring 9 onto the stem and

locate the stem in the keyhole in thimble 4. Fit the thimble
over the tapered section of piston 11 and secure by pressing
the leaf of the thimble behind the piston shoulder, as shown
at A.
Insert the piston assembly into the cylinder and fit seal 3,
washer 2 and circlip 1.
9803/8020 Issue 2*
19 - 6 Main Drive Clutch Booster - Dry Clutch Transmission 19 - 6
Clutch Slave Cylinder (cont’d)

Shim Calculation
When renewing a slave cylinder or booster assembly it is

important to achieve the correct clearance S. It may be
necessary to fit shims V between booster W and slave S
cylinder X to achieve this. Three shims are supplied with
service replacement slave cylinders and boosters.
V W
To determine the number of shims required proceed as
follows:
1 Measure the dimensions A and B (mm) on slave

cylinder X.
2 Measure dimension C (mm) on booster W.
3 Calculate S = B + C - A.
4 Use the table below to determine the number of shims

required, based on the value of S.
5 Discard any unused shims.

A314550
X
S (mm) No. of shims required
+0.5 t +1.1 0 C
A
0 t +0.5 1
-0.5 t 0 2
-1 t -0.5 3
B
* Alternative Method
If difficulty is experienced with the above method of shim
calculation, the following alternative procedure should be X
carried out. W
a Lightly bring together booster W and slave cylinder X
with no shims V fitted. A314540
Note: Do not apply any pressure.
b Attempt to rock the two units with respect to each

other.
c If any rocking occurs add individual shims until no

further movement is felt.
d Add one further shim to achieve the correct clearance

S.
9803/8020 Issue 4*

Removal
1 Disconnect pipes A and B from main drive clutch check

valve C.
2 Remove the two nuts D/washers E and slide the check

valve off bolts F.
3 Remove bolts F from the mounting bracket, taking care

not to lose spacers G.
Replacement
When Replacing
Make sure that spacers G are fitted on bolts F between the
check valve and its mounting bracket.
Tighten bolts F/nuts D to a torque of 12 Nm (9 lbf ft).
Secure pipes A and B firmly, but do not overtighten.
When the installation is complete, fill the clutch hydraulic

fluid reservoir with new fluid (see Section 3) and bleed the
system (see Main Drive Clutch Booster, Bleeding). Check
for correct operation of the clutch.
F
C
G
A E
D
B
A343760
9803/8020 Issue 2*
19 - 8 Clutch Pedal - Wet Clutch Transmisssion 19 - 8
S
L
Y
X
N P
N P
L
RR N
RR
N M
L T
T
V V
A358730
9803/8020 Issue 3
19 - 9 Clutch Pedal - Wet Clutch Transmisssion 19 - 9
Clutch Down Switch Potentiometer (Position Sensor)

* Note: The clutch pedal configuration for 2000 Series * Note: The clutch pedal configuration for 2000 Series
machines is shown at X. The configuration for 3000 Series machines is shown at X. The configuration for 3000 Series
machines is shown at Y. 3000 series machines from serial machines is shown at Y. 3000 series machines from serial
number 642359 have a revised potentiometer actuating pin number 642359 have a revised potentiometer actuating pin
as shown at Z. as shown at Z.
Adjusting
Note: The potentiometer P cannot be adjusted in relation to
1 Fully depress the clutch pedal. The switch W should be the clutch pedal. If a faulty potentiometer is suspected it
heard to operate (click) when the pedal pad V is between must be renewed.
6 and 10% from the bottom of its travel.
2 If the switch does not operate correctly, calibrate as Removing

follows:
1 Uncouple the electrical connnector T. On 2000 Series
a Press and hold the ‘auto reverse’ pushbutton on the machines undo and remove the actuating pin S.
left hand column stalk.
2 Undo the 2 fixing screws R. Pull the potentiometer away
b Turn the ignition ON but do not start the engine. from the location pins N and then clear of the pedal
assembly.
c When all the buzzers have stopped, release the
‘auto reverse’ pushbutton.
Replacing
d Press and release the ‘auto reverse’ pushbutton.
Replacing is the reverse of removal but note the following:
e The oil temperatures of the two gearboxes are
displayed on the centre of the dashboard. Apply JCB Threadlocker and Sealer to actuating pin S (2000
Series machines only).
E.g. +012+030
* Make sure that the actuating lever L is properly engaged
f Press and release the ‘auto reverse’ pushbutton. with pin S, M or Z as applicable.
g The percentage pedal position and the current
Calibrate the clutch pedal, see Powershift and Master
being fed to the clutch control valve are displayed
Clutch Calibration (Wet Clutch Transmission), Section C.
on the centre of the dashboard.
E.g. 100 595 to indicate 100% (pedal fully raised)

and 595 mA
or 000 208 to indicate 0% (pedal fully down)

and 208 mA
h Press and release the ‘auto reverse’ pushbutton.
j The percentage pedal position and the status of the

clutch down switch are displayed on the centre of
the dashboard.
E.g. 100 OFF to indicate 100% (pedal fully raised),

‘clutch down’ switch not operated.
or 000 ON to indicate 0% (pedal fully down),

‘clutch down’ switch operated.
k The buzzer sounds when the splitter SAFETY Dump

relay is activated by operation of the ‘clutch down’
switch.
If the buzzer does not sound when the clutch is
depressed there is a machine FAULT.
l Adjust the bolt U so that the ‘clutch down’ switch is

heard to operate (‘click’) at a reading of 6% to 10%
at step (g) of the calibration procedure. Re-adjust
and repeat the procedure as necessary until correct.
m Switch OFF the ignition.
9803/8020 Issue 2*
20 - 1 Gearbox Assembly 20 - 1
9803/8020 Issue 1
Removal and Replacement - Dry Clutch

Transmission
5 Disconnect all drive shafts, i.e. front PTO (if fitted) rear
! WARNING PTO, 4WD and main drive shaft.
*6 Remove the fuel system accumulator on 3185 models
Make sure that lifting equipment is in good condition. fitted with fuel meters.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that 7 Remove the parking brake caliper and brake disc.
lifting equipment is strong enough for the job.
INT-1-3-7 8 Remove all connections to the chassis.
! WARNING
Maintenance must be done by suitably qualified 9 Remove the speedo connection from the range box.
personnel.
A-3-1-1 10 Ensure all gear linkages are disconnected.
! WARNING
A raised and badly supported machine can fall on you. * 11 Remove fuel line accumulator to prevent damage when
Position the machine on a firm, level surface before lowering engine (3185 machines with fuel metering
raising one end. Ensure the other end is securely only).
chocked. Do not rely solely on the machine hydraulics or
jacks to support the machine when working under it. * 12 Install two engine support brackets (892/00315), one
each side of the flywheel housing as shown at J.
started while you are beneath the machine. * 13 Lower the trolley jack until the support brackets rest on
GEN-1-1 the chassis. Keep the pressure on the trolley jack.
Note: Drain the oil from the three gearboxes into suitable * 14 Position the splitting frame (Part No. 892/00800)
containers. DO NOT TIP DIRTY OIL INTO DRAINS. through the hatch until it fits on the chassis longitudinal
members as shown on the opposite page.
Always support the machine on suitable axle stands before
working underneath.
! CAUTION
Take care when lifting/handling this equipment. It
weighs 600 kg (1325 lb). A
TRAN 8 - 2
B
Removal With Cab in Place
Note: If cab has been removed, start at step 2 and use a

C 225740
suitable overhead hoist in place of step 13. Remember the
complete power train weighs 600 kg (1320 lb).
1 Remove the cab floor mat, taking care when lifting it

over gear levers. A large hatch will be revealed in the
cab floor, this hatch is split transversely and is removed
in two sections.
2 Position a trolley jack to take the weight of the power

train.
H
J
3 Remove the gearbox cross member A by removing the
two end bolts B and nuts/bolts C.
4 Disconnect all hydraulic connections to: -
Main clutch servo

Main drive clutch
PTO clutches and clutch brakes
4WD clutch and hydraulic pumps
Blank all pipes to prevent excessive loss of fluid and

entry of dirt. 225750
9803/8020 Issue 3*
* Removal and Replacement - Dry Clutch

Transmission (continued)
14 Fit a lifting adapter (477/00437, see Service Tools, Tighten the bolts to settings for 8.8 grade given in Section 1.
Section 1) to the gearbox, with its offset lifting point
towards the front of the machine, using bolts C. Attach
the hoist to the adapter and just take the weight of the
gearbox (approx. 600 kg (1320 lb)).
15 To allow space for the gearbox assembly to be drawn

backwards, chassis cross-member D must be
removed:
a Remove nuts/bolts E to release suspension control A

rod F.
B
b Remove the six nuts/bolts G at each end of the
cross-member and lift clear, allowing control rod F to
lower to the floor. C 225740
16 Remove bolts H from around the PTO box bell

housing.
17 Slide the gearbox assembly back approximately 100

mm (4 in) until the transmission clears the clutch.
18 Lower the gearbox assembly to the ground, by lowering

the hoist and trolley jack simultaneously (i.e. keep the
weight on the trolley jack.
Note: For work on the main clutch or the crankshaft rear oil
seal, the gearbox assembly may be left in this position.
G
G
19 To provide clearance under the machine to enable
complete removal of the gearboxes, either hoist up the G E
rear of the machine if a suitable crane is present, or
alternatively remove the fuel tank and drag the
assembly out sideways.
G E
G F
Note 1: If working out in the open, take care to protect the
gearbox from the elements once removed from the machine. G
Note 2: Before attempting to pressure clean the gearbox, D
the clutch release bearing/cylinder assembly (see
PTO/Splitter Gearbox, Input Section - Dismantling and A225770
Assembly, item 10) MUST be removed to avoid the risk of
water contamination.
Replacement
Replacement is the reverse of the removal procedure.
Take care when locating the gearbox assembly onto the

engine not to force the components together. Align the H
clutch splines by putting the transmission in gear and J
turning the engine slowly through the access plate in the
bottom of the bell housing.
If difficulty is experienced in aligning the PTO input shaft

splines with the clutch cover, remove the air balance pipe
front connection from the PTO gearbox and insert a suitable
lever to rotate the transmission pump shaft. This will in turn,
rotate the PTO input shaft.
Fill the gearboxes with the correct oil (see Section 3).
225750
9803/8020 Issue 3*
HPL
LPL
B
9
9
C
5
5
£ @
@
F $
!
%
7
E D
* ^
A
& 4
5
5
A358601
A358600
9803/8020 Issue 2*
Removal and Replacement - Wet Clutch

Transmission
Note: Gearboxes with a wet master clutch must be removed 1 Remove the cab, see Section B.
from above the machine, requiring the cab to be removed.
2 Clean off all dirt and debris from around the gearbox
Note: The complete gearbox assembly (which includes the casings. Drain the oil from the gearboxes.
wet clutch) must be manoeuvred with great care during 3 Drain the hydraulic fluid tank.
removal and replacement. Use of an overhead crane is
recommended to ensure precise control when 4 Remove the parking brake caliper, see Section G.
lifting/lowering. The drive shaft from the engine can be
damaged beyond repair if it is strained when removing or 5 Disconnect all driveshafts, i.e. front PTO (if fitted) rear
replacing the gearbox. PTO, 4WD and main drive shaft.
6 Ensure that the PTO speed selector cable is

! WARNING disconnected from the PTO gearbox (not shown, see
Maintenance must be done by suitably qualified Section D).
personnel.
A-3-1-1
7 Uncouple the speedo electrical connector from the
! WARNING range box.
A raised and badly supported machine can fall on you. 8 Uncouple the electrical connectors at the solenoid
Position the machine on a firm, level surface before control valves shown at A, B and C and temperature
raising one end. Ensure the other end is securely sensor located in the clutch housing oil sump (shown at
chocked. Do not rely solely on the machine hydraulics or F) .
jacks to support the machine when working under it.
*9 2000 Series
Disconnect the battery, to prevent the engine being Remove the clutch lubrication hoses 9 (view B).
started while you are beneath the machine. 3000 Series
GEN-1-1
Remove the clutch lubrication hoses (not shown) and
feed pipes shown at B.
Note: Drain the oil from the three gearboxes into suitable
containers. DO NOT TIP DIRTY OIL INTO DRAINS. 10 Disconnect the hydraulic suction pipes at the gearbox
driven pump shown at D.
Always support the machine on suitable axle stands before
working underneath. 11 Remove the hydraulic suction pipe.
12 Disconnect the feed pipes from the gearbox driven

hydraulic pump.
Removal
13 Remove the hydraulic pump suction pipe (engine driven
The removal sequence is divided into 3 main stages: pump).
Stage A - Prepare for Removal
Stage B - Prepare to Lift 14 Remove the gear selector linkage from the speed
Stage C - Lifting the Gearbox gearbox.
15 Disconnect the rear PTO hydraulic hoses. Disconnect

the front PTO hydraulic hoses if fitted (not shown).
Stage A - Prepare for Removal
16 Remove the oil level dipstick and tube.
Note: Remember that the gearbox will be lifted out of the
17 Disconnect the output shaft lubrication hose from the
machine from above. With this in mind it is important to
rear of the range box.
ensure that all hoses and pipes etc. are removed or tied
back to allow clearance. When disconnecting/removing 18 Disconnect the output bearing lubrication hose.
components ensure that they are tagged to enable correct
replacement. EVERY PRECAUTION MUST BE TAKEN TO 19 Identify the gearbox lubrication distribution pipe E.
PREVENT DEBRIS OR DIRT ENTERING THE GEARBOX. Disconnect and remove interconnecting hoses from the
Bank off all open ports, hoses and pipes, including those of gearbox as required.
components removed from the machine.
9803/8020 Issue 2*
G
V
B
X Z C
D
Y 225740
F
E
A353540
W
L
N
R P
K
R
P T
U R
M R M
P R P
A358620
A370450
M
9803/8020 Issue 3
Removal and Replacement - Wet Clutch

Transmission (continued) Stage C - Lifting the Gearbox
Removal - continued 1 Using the crane, carefully manoeuvre the gearbox back
from the engine, disengaging the drive shaft G as
Stage B - Prepare to Lift shown at H. Make sure that no strain is put on the shaft
G.
Note: As previously mentioned, the use of an overhead
crane is recommended when lifting the gearbox. In addition, 2 Once clear of the drive shaft G, use the pulley block Z
suitable slings and a pulley block must also be available. and crane to position the gearbox as shown at J. With
the gearbox tilted sufficiently to allow clearance, use
All lifting equipment must have a Safe Working Load of at the crane to lift the assembly clear of the machine.
least 1000kg (2205lb). PERSONNEL MUST BE SUITABLY
QUALIFIED TO USE LIFTING EQUIPMENT. Note: If working out in the open, take care to protect the
gearbox from the elements once removed from the machine.
! WARNING
Replacement
Make sure that lifting equipment is in good condition. Replacement is the reversal of removal but note the
Make sure that lifting tackle complies with all local following:
lifting equipment is strong enough for the job. Pack the female splined cavity of the gearbox input shaft K
INT-1-3-7 with 6 ml of grease.
1 Rig the slings and pulley block Z as shown at V. Make Use extreme care when locating the gearbox onto the
sure that the slings are tight around the gearbox casing drive shaft. Keep the gearbox square and in line with the
and that components will not be crushed under the engine at all times. Do not to force the components
slings. together. Align the input drive shaft splines by putting
the transmission in gear and turning the engine slowly
2 Use the crane to gently take the weight of the gearbox. through the access plate in the bottom of the flywheel
Remove the cross member B by removing 2 off bolts C housing.
and 2 off bolts D.
When replacing the gearbox/flywheel housing bolts note that
3 Place a suitable support bar E between the engine the gearbox housing has bolt holes (shown at W) for
sump and flywheel housing. Rest the bar on the different machine types as follows:
suspension arms F at either side of the machine as
shown. L 9 off bolts 2150, 3155, 3185
M 3 off studs 2150, 3155, 3185
4 Gently lower the gearbox until the rear of the engine is
supported on the bar E. N 8 off bolts 2115, 2125
P 4 off studs 2115, 2125
5 Undo the gearbox/flywheel housing bolts (shown at W).
Start at the bottom, leaving the uppermost bolts until *N 7 off bolts 2140
last. When undoing the last bolt make sure that the *R 5 off studs 2140
gearbox remains square to the engine. If necessary
adjust the crane to keep the gearbox and engine in Note: On early machines positions T and U were occupied
line. If the gearbox moves out of line the drive shaft by a bolt L and a bolt N respectively.
G on the engine vibration damper assembly will be
damaged. If difficulty is experienced in aligning the PTO input shaft
* Ensure that the range gearbox restrictor/adapters are

correctly fitted (see Range Gearbox Removal and
Replacement (with cab in place).
Fill the gearboxes with the correct oil (see Section 3).
9803/8020 Issue 3*
JE
9803/8020 Issue 2*
Note: Before splitting the drive train make sure that ALL 4 With the PTO box standing on its bell housing, check
parts are properly supported by proofed lifting devices. that the inner faces of the splitter clutches have a
complete set of roller bearings. Carefully lower the
Dismantling - Machines with Wet Master Clutch speed box onto the PTO box until the flanges butt
together. Ensure that the clutch shafts enter their rear
Note: Depending on service requirements, transmissions bearings correctly.
with a wet master clutch can be dismantled as follows:
5 Fit the bolts E after treating with JCB Threadlocker and
1 For service of the wet master clutch only, the Sealer and torque tighten.
transmission should be split at the splitter speed box
joint J by removing bolts E. Since the clutch section
must be disassembled in a vertical plane, remove the Torque Settings
rear housing D from the speed box H and temporarily
refit to the PTO/splitter housing. Make sure that there is Item Nm kgf m lbf ft
no ingress of dirt or debris. C 56 5.7 42
E 56 5.7 42
2 For service of the splitter clutches and transmission F 98 10 72
brake the wet master clutch can be left attached to the
PTO/Splitter gearbox. See step 1 of Dismantling - All Note: Do not overtorque, especially bolts F, because the
Machines. speed box has a cast alloy housing and its threads could be
stripped.
Note: For complete dismantling of the PTO/Splitter gearbox
the wet clutch must first be dismantled and its housing
removed. See Wet Master Clutch, Dismantling and
Assembly.
Dismantling - All Machines

H
1 Separate splitter rear housing D from the PTO/splitter
gearbox by removing bolts E. The splitter rear housing
can be left attached to the speed box unless the housing
or the speed box require attention.
2 Carefully draw the PTO box away from the speed box
until the drive shaft of the speed box is clear. The PTO G G
box can now be removed for maintenance and/or
examination.
3 Remove the ring of bolts C connecting the speed box to

the range box.
4 Draw the speed box away from the range box taking
care with the output gear on the speed box. The speed
box and range box can now be removed for
maintenance and/or examination.
Assembly
*1 Apply Loctite 509 to the rear flange of the speed box.

Carefully fit the speed box to the range box, ensuring
correct meshing of the output gear.
2 Fit bolts C after treating with JCB Threadlocker and

Sealer and torque tighten.
*3 Apply Loctite 509 to the front flange of the speed box.

If housing D has been removed, apply JCB
Threadlocker and Sealer to the two bolts F that are
fitted into holes G.
9803/8020 Issue 3*
21 - 1 * Wet Master Clutch 21 - 1
5
W X
17
1 A 6
E
B 2
7
C
A
3 B
4
E
C C
1
J 16
K
D
B
A353071
A353060
D A356880
Y Z
Y 10 F 13
8 12
9 F 15
6
6
H 14
11
H G
16
A353080 A353090
9803/8020 Issue 4*
21 - 2 Wet Master Clutch 21 - 2
Removal and Replacement Make sure that the clutch components are carefully
inspected for any signs of wear or damage, even if the only
To facilitate removal of the wet clutch assembly it will be reason for removal was to service other components in the
necessary to remove the entire gearbox. The clutch and gearbox. See Wet Clutch - Dismantling and Assembly. If
PTO/Splitter casings must also be separated from the speed any of the friction or counter plates are damaged or if any of
box/range box assemblies (see Gearbox Assembly - the friction plates are excessively worn (thickness less than
Removal and Replacement). 3.5 mm or oil grooves less than 0.1 mm deep) renew the
complete set of plates.
Removal
The clutch is removed mainly as a series of sub-assemblies Note: New friction plates should be soaked in transmission
in stages as follows: oil before fitting.
Stage1 (shown at W) Inspect the thrust washer 11 for signs of wear. If the
thickness or outside diameter measures less than the
1 Position the clutch, PTO/Splitter assembly on suitable dimensions in the table below, renew the thrust washer.
blocks as shown. Before fitting a new thrust washer soak it in transmission oil
for at least 1 hour.
2 Undo the 18 bolts 1, insert 3 M10 jacking bolts A. Screw
in the bolts evenly until the cover 2 is clear of its spigot. Item Thickness mm Outside Diameter mm
Insert 2 M10 threaded lifting eyes B. Carefully lift off the 11 3.9 110.0
cover 2, keeping it square to the housing. Be sure to
retrieve and discard the 4 ‘O’ ring seals 3 (shown at C). Replacement is the reverse of the removal procedure, but
Remove the jacking bolts. note the following:
3 Remove and discard the cover ‘O’ ring seal 4. Prise out Do not apply any thread locking compound to any of the
and discard the oil seal 5, be sure not to damage the bolts or screws.
seal housing in cover 2.
Make sure that the oil feed cross drillings are clear. Check
Stage 2 (shown at X) the torque tightness of plugs 17 to prevent oil gallery
leakage.
4 Fit 2 special locking plates D to prevent the clutch
assembly K rotating. Use cover bolts I and the special It will not be possible to locate the clutch drum 7 over the
screws J supplied with the locking plates to lock the clutch plates and carrier assembly 8 inside the housing. First
clutch assembly to the housing 16. Undo the 12 clutch sub-assemble the components on the bench, using special
drum bolts 6. Remove the locking plate D. Fit 2 M8 retainers to hold the assembly together during replacement -
threaded lifting eyes E to the clutch drum 7. Attach see Wet Clutch - Dismantling and Assembly.
suitable lifting equipment and carefully withdraw the
drum, hub and pressure plate assembly. Before replacing the drum, plates, carrier and hub assembly
fit 2 guide pins to the M10 threaded holes H in the drum
Stage 3 (shown at Y) carrier 14.
5 Fit 2 special pack retainers F to the clutch plate carrier 8. Important Note: Be sure to remove any assembly aids
Lift out the carrier together with the clutch plates 9 and after use (pack retainers or eyes etc.).
thrust washer 10. Remove the second thrust washer 11.
Fit new oil seal 5 using a special mandrel L (see Service
Stage 4 (shown at Z) Tools below).
6 Undo the 5 button head cap screws 12 and remove oil Important Note: If the clutch plates 9 have been renewed
baffle plate 13. check to make sure that the clutch is disengaged before
fitting the cover 2. See Note 1 of Clutch Plates and Plate
7 Rotate the drum carrier 14 to align the 5 holes with the Carrier - Assembly, for the recommended procedure.
countersunk cap screws 15 beneath. Undo the screws
15. Fit 3 M10 jacking bolts G and jack the drum carrier Lightly oil and fit new ‘O’ rings 3 and 4.
out of the housing. Fit 2 drum bolts 6 as an aid for lifting
the drum carrier clear of the housing. The drum carrier * Torque Settings
will be removed complete with the PTO input gear and Item Nm kgf m lbf ft
bearing. 1 56 5.6 41
6 52 5.3 38
8 There is no need to remove the clutch housing 16 unless 12 12 1.2 8.8
it is damaged, or unless the PTO/Splitter gearbox is to 15 38 3.8 28
be dismantled. To remove the housing see Wet Clutch - 17 (black) 22 2.2 16.2
Housing Removal. 17 (gold) 12 1.2 8.8
Replacement Service Tools

Item Part No.
Before replacing: F 892/01048 (x2)
D 892/01052 (x2)
L 892/01050
9803/8020 Issue 5*
21 - 3 Wet Master Clutch (continued) 21 - 3
Housing Removal and Replacement

There is no need to remove the clutch housing 16 unless it is Replacement
damaged, or unless the PTO/Splitter gearbox is to be
dismantled. * If the clutch housing is to be renewed, ensure that cross
drilling blanking plug 19 is fitted to the new housing (see
Removal Torque Settings below). Make sure that the oil feed cross
drillings are clear.
1 Undo the 12 Verbus Ripp bolts 17, discard the bolts.
Using a soft faced hammer separate the housing 16 from Carefully clean off all traces of sealing compound from the
the PTO/splitter gearbox. Lift off the housing 16. clutch and PTO/Splitter housing mating faces. Make sure
that the oil feed cross drillings are clear. Lightly oil and fit
2 Remove and discard the sealing ‘O’ ring 18. new ‘O’ ring 18. Apply even beads of JCB Multigasket to the
PTO/Splitter housing as shown at H (around the outer
diameter and around each threaded bolt hole).
The Verbus Ripp bolts used in this assembly must not be

reused. Fit new Verbus Ripp bolts 17.
Torque Settings

17 75 7.6 55
* 19 15 1.5 11
17
16
19
18
H
A353100
9803/8020 Issue 2*
11
10
E
10
1 8
12
11
8 7
D
9
6
N
A353121
3 N D
4
2 M
M
17
17
F 19
F 18
14
11
16 A353110
15
13
20
9803/8020 Issue 2*

A
After removal from its housing the clutch will be in 3 main
sub-assemblies:
Clutch drum, hub and pressure plate sub-assembly shown

at A.
Clutch plates and plate carrier sub-assembly shown at B.
Clutch drum carrier and PTO input gear sub-assembly
shown at C.
Clutch Drum and Hub - Dismantling
1 Undo and remove lubrication nozzles 1.
2 Undo bolts 2, remove the release springs 3 and spring

pillars 4. Discard the springs.
* 3 Lift off the oil baffle plate 5 from the locating dowels M.
B
* 4 Remove the pressure plate 6, taking care not to lose
dowels M and N.
5 Remove the piston 7 from the drum 8. Use 2 M6 bolts at

positions D and suitable levers to aid removal. Remove
and discard the outer seal 9 from the piston 7.
6 With the assembly positioned as shown at E undo and

remove the 8 socket head capscrews 10. Use a suitable
bar to prevent the drum rotating. Using a soft faced
hammer tap out the hub 11 from the drum 8. Remove
and discard ‘O’ ring 12 from the drum 8.
7 Remove circlip 13. Using a suitable drift, tap out the C

blanking disc 14 together with inner bearing 15. Remove
and discard ‘O’ ring 16.
8 Remove and discard the iron sealing rings 17. The rings
will almost certainly break during removal.
9 Remove and discard the inner piston seal 18 from the

hub 11.
10 Do not remove the outer bearing 19 unless it is to be

renewed. Removing the bearing can damage it. If it is
A353170
removed it must be discarded. To remove the bearing
screw in 2 jacking bolts at positions F.
11 In the unlikely event that the bronze bush 20 requires

renewal, remove using a suitable puller and slide
hammer.
9803/8020 Issue 2*
21-6 Wet Master Clutch 21 - 6
10
K
11
7 1 8
12
Y
X Y X
11
9 L
N
6
0.5mm
3 N
4
2 M
G
M
A353271
17
17
19
18
14
11
16
15
13
A353280
20
9803/8020 Issue 2*
Dismantling and Assembly (continued)

Clutch Drum and Hub - Assembly
Assembly is basically the reverse of the dismantling If the drum 8 and hub 11 have been separated the bearing
procedure, but note the following: 19 and screws 10 must be renewed. Before fitting ensure
that the springs 3 have been fitted (see previous paragraph).
Check that all oil feed slots and drillings are clear. Check the Fit the bearing using a suitable press, exerting force on the
condition of the pressure plate 6. Renew the plate if it is inner race only. Note that the piston rings 17 cannot be fitted
excessively scored. before bearing 19.
If a new pressure plate is required new dowels M and N Apply one drop of JCB Threadlocker and Sealer, one or two
must be fitted to the plate before assembly. The large dowel threads from the end, on lubrication nozzles 1.
N should be tapped into the blind holes on one face of the
plate. The smaller dowels M should be tapped into the Fit new piston rings 17. Use extreme care when fitting, the
through holes on the opposite face so that they reach rings are easily broken. Note the interlocking ends (shown at
through the plate but do not protrude. H).
Inspect the faces L of the drive tangs on the drum 8. If there

are small burrs carefully remove them using a file.
Inspect the pressure relief ball valve in piston 7 (shown at P).

Torque Settings
The ball should be free to move against its spring. Test the
valve for leak tightness. Place a drop of paraffin in the orifice Item Nm kgf m lbf ft
X, there should be no leakage to the other side of the ball. If 1 15 1.5 11
there is leakage the piston/valve assembly must be 2 28 2.8 20.6
renewed. 10 85 8.7 63
If bronze bush 20 is to be renewed ensure that the oil

grooves align with the oil feed drillings in the hub 11 (shown
at G). Use a suitable mandrel R (see Service Tools), to
press in the bush until it is 0.5 mm below the end face of the
hub as shown.
Lightly grease and fit new ‘O’ ring 12 to drum 8.
Align the oil feed holes in the hub with the oil feed slots in
P
the drum (shown at J). Keep the hub square to the drum to
avoid damage to ‘O’ ring 12. Fit the screws 10 and X
progressively tighten to the specified torque.
Lightly oil and fit new piston seals 9 and 18.
Align the threaded holes X in piston 7 with the guide hole Y

in the hub 11 as shown at K. Locate the piston 7 inside its
groove. Locate the larger dowel pins on pressure plate 6 into
the drilled holes in piston 7.
Using a suitable press, push on the pressure plate to press

in the piston. Remove the pressure plate and ensure there is
no evidence of damaged seals in the form of small slices of
seal material. If damage is suspected, remove the piston, fit
new seals and reassemble. Remember to align the pressure
A358610
plate correctly.
Replace the oil baffle plate 5 on the locating dowels M.

Service Tools
Fit new springs 3. Remove any debris that may have been
Item Part No.
pushed from the bolt holes in the hub 11.
*R 892/01046
9803/8020 Issue 4*
1
10
2
1
A
3 Y W
X
2 Y
B
X
A353230
9803/8020 Issue 1

Clutch Plates and Plate Carrier - Dismantling
1 Remove the friction plates 1 and counter plates 2 from *6 The drum, hub, plates and plate carrier can now be
the plate carrier 3. Note that the plates can only be replaced inside the clutch housing as a complete
removed from one end of the carrier 3. There are 6 assembly, (see Wet Clutch - Replacement). Remove
friction plates and 5 counter plates. If thrust washer 10 retainers W and fit plugs to the holes in the clutch drum.
had not been removed during Removal, remove it now.
Note 1: If the clutch plates have been renewed the plate
Clutch Plates and Plate Carrier - Assembly stack height will have changed. If the stack height is too
great the clutch will be permanently engaged. Carry out the
* Before assembling inspect the friction plates and counter following check:
plates for any signs of damage or wear (friction plates
should not be less than 3.5 mm thick or have oil grooves a Assemble the clutch components inside the housing as
less than 0.1 mm deep). If either is apparent it would be shown below (for the correct procedure see Wet Clutch
prudent to renew the plates. The plates should only be - Replacement). Do not fit the cover 11.
replaced as a complete set.
b Make sure that the bolts 12 are tightened and the splitter
Check the thrust washer 10 for wear. If the thickness or input shaft 14 is engaged in the clutch plate carrier.
outside diameter measures less than the dimensions in the
table below, renew the thrust washer. c Turn the clutch drum/hub assembly 13 and, at the same
time hold the splitter shaft stationary. Some drag is
Item Thickness mm Outside Diameter mm normal.
10 2.9 90.0
Before fitting new friction plates 1 and new thrust washer 10 11

soak them in transmission oil for at least 1 hour.
Start assembly with a friction plate 1 followed by a counter

plate 2 and so on. Note the correct orientation of oil slots in
the friction plates relative to the plate carrier 3 (shown at A).
The counter plates should be positioned relative to the 2
threaded holes X (as shown at B). 13
12
As mentioned in Wet Clutch - Replacement, it will not be
possible to replace the clutch drum and hub assembly Z
inside the clutch housing unless it is first fitted to the plates
and plate carrier assembly.
Proceed as follows:
1 Fit the thrust washer 10 to the plate carrier 3. 14
2 Fit 2 suitable guide rods Y to the threaded holes in the

plate carrier 3.
3 Using suitable lifting equipment, carefully lower the drum

and hub sub-assembly Z over the plates. Ensure that the
guide rods locate through the corresponding holes in the
drum.
4 Make sure that the drive tangs on the counter plates

engage with the cut-outs in the drum. It may be A361660
necessary to rotate the drum and plates slightly to obtain
alignment. Service Tools
5 With the drum and hub fully lowered, remove the guide Item Part No.
rods and fit 2 special pack retainers W to temporarily W 892/01048 (x2)
hold the assembly together. DO NOT USE BOLTS OR Y 892/01049 (x2)
SCREWS, they may be left in place inadvertently. This
would render the clutch inoperable. The special retainers
W prevent further assembly until they are removed.
9803/8020 Issue 2*
2
X
3 D
4
3
6 2
5
1
4 A353150
4
A
1
2
B
C
E
A353160
9803/8020 Issue 1

Clutch Drum Carrier and PTO Input Gear - Dismantling
1 Undo the stake nut 1 as follows:
a Using a vice and suitable jig E, position the

assembly as shown at C.
b To avoid damage to the input gear threaded shaft,

carefully cut-away the staked portion of the collar
on the nut 1 (shown at A) using a hacksaw. Be sure
not to damage the shaft. The staked portion can
now be easily bent clear of the shaft (shown at B).
c Using the special peg socket F (see Service Tools),

loosen the nut 1. The nut will be very tight, take care
not to damage the gear shaft.
d Support the input gear 2 and undo the stake nut 1.

Remove the gear and bearing retainer plate 3 from
the drum carrier plate 4. Discard the nut.
2 Using a suitable press, push off the bearing 5 and then

remove the loose bearing rib 6.
Clutch Drum Carrier and PTO Input Gear - Assembly
Assembly is basically the reverse of the dismantling

procedure, but note the following:
Be sure to fit bearing 5 the correct way round, as shown at

D. Note the position of loose bearing rib 6.
Note the orientation of retainer plate 3. The counter sunk

side of the fixing screw holes X face the drum carrier plate 4.
Use a new stake nut 1. Lightly oil the threads and tighten the
nut to the specified torque using a torque multiplying wrench
and peg socket. Stake the nut into the two positions on the
shaft.
Torque Settings

*1 1000 102 738
Service Tools
Item Part No.

E 892/01047
F 892/01045
9803/8020 Issue 2*
22 - 1 PTO Clutches 22 - 1
9803/8020 Issue 1

* The illustration opposite shows the clutches on a 2000
Series machine. The following procedure applies to all
machines.
Note: The following procedures apply to both clutches,

except where indicated.
Removal
! WARNING
A raised and badly supported machine can fall on you.
Position the machine on a firm, level surface before
raising one end. Ensure the other end is securely

GEN - 1 - 1
1 Disconnect and blank off the PTO clutch hydraulic

connections.
2 Disconnect the PTO drive shaft at the yoke (see

Propshafts).
3 Remove the six M10 setscrews 1 and withdraw the rear

clutch assembly 2. Remove ‘O’ ring 3 and discard.
4 Undo five M10 setscrews 4 and remove bearing retainer

5. Remove clutch drive shaft 6 along with its bearing and
bearing carrier 7.
5 Remove six M10 setscrews 8 and withdraw the front PTO

clutch assembly 9. Remove ‘O’ ring 10 and discard.
6 Undo the five M10 setscrews 4A, and remove bearing

retainer 5A. Remove clutch drive shaft 6A along with its
bearing and bearing carrier 7A.
7 Cover the hole in the main PTO casing to prevent ingress

of dirt or foreign material.
Replacement
Replacement is the reverse of the removal procedure, but

note the following:
Check all mating surfaces are clean. Use JCB Multigasket on

all joint faces that have no gasket. Use JCB Threadlocker
and Sealer on all bolts, except those with plastic patches.
These must be replaced.
Lightly oil new 'O' ring 3 and 3A before assembly.
When fitting a clutch assembly to the main housing, gently

rotate the drive flange in both directions to engage the
friction plate teeth with the clutch drive shaft. Do not use
force. When mating surfaces are butted together all clutch
plates will be engaged. Do not use the bolts 1 and 8 to pull
the mating surfaces together. Torque tighten the bolts to 56
Nm (41.3 lbf ft).
9803/8020 Issue 2*
23 - 1 PTO/Splitter Gearbox 23 - 1
22
*
24
23
20
21
19
17
13
18
16
6 4 5
14 3
15
11
12 A275431
9803/8020 Issue 2*
The PTO/splitter gearbox is part of the overall power train. Splitter Clutches - Dry Clutch
This dismantling and assembly procedure assumes that the
transmission assembly, i.e. PTO/splitter gearbox, six-speed Transmission
gearbox and range gearbox, has been removed from the
machine chassis. The sequence for dismantling the Removal
transmission is as follows:
1 Withdraw layshaft assembly (medium ratio clutch) 14
1 Rear PTO clutch housing (to provide access to all from housing 13. Prise outer race of roller bearing 16
splitter gearbox rear housing flange bolts). out of the housing.
2 Six-speed gearbox/rear housing assembly (to provide Note: The outer race of roller bearing 15 is located in rear
access to PTO/splitter gearbox). casing 12.
To effect complete dismantling and assembly of the 2 Withdraw layshaft assembly (high ratio clutch) 17 from
PTO/splitter gearbox, the full sequence given in this section housing 13. Prise outer race of roller bearing 19 out of
must be followed. the housing.
PTO Clutches Note: The outer race of roller bearing 18 is located in rear
casing 12.
Note: Removal and replacement is best carried out with the
bell housing resting on the bench. 3 Withdraw input shaft assembly (low ratio clutch) 20
from housing 13. Prise outer race of roller bearing 22
out of the housing.
Removal
Note: The outer race of roller bearing 21 is located in rear
Carry out steps 3 to 6 of PTO Clutches, Removal.
casing 12.
Replacement 4 Remove roller bearing inner races from the clutch
shafts and keep inner and outer races in matched pairs.
Refer to PTO Clutches, Replacement.
Replacement
Note: The rear PTO clutch must not be fitted until after the
six-speed gearbox/rear housing assembly has been fitted, in Note: During assembly all seals should be packed between
order to provide access to all rear housing flange bolts. their outer lips with JCB HP Grease. Lightly smear all shafts,
splines, gears and bearing shells.
1 Gently tap outer race of roller bearing 22 into the
Refer to PTO Clutches, Dismantling and Assembly.
housing. Press inner races of bearings 21 and 22 onto
the shaft of the low ratio clutch assembly 20. Fit the
sealing rings 23.
Six-Speed Gearbox/Rear Housing
2 Insert the input shaft of low ratio clutch assembly 20
Removal into the housing and through the hollow input gear.
Take care not to damage the input gear oil seal.
* Support the six-speed gearbox and undo bolts 11 securing
the rear housing 12 to the main housing 13. Separate the 3 Gently tap the outer race of bearing 21 into position in
PTO/splitter gearbox from the six-speed gearbox/rear the rear casing 12, in preparation for the refitting of the
housing assembly. The rear housing remains bolted to the six-speed gearbox/rear housing assembly.
six-speed gearbox.
4 Fit high ratio clutch assembly 17 and bearings 18 and
Note: The outer races of splitter clutch bearings 15, 18 and 19 by repeating steps 1 to 3.
21 will remain located in the rear housing 12. See separate
section on Gearbox Assembly for details of refitting the six 5 Fit medium ratio clutch assembly 14 and bearings 15
speed gearbox. and 16 by repeating steps 1 to 3.
Note: The output gear of clutch 20 is a loose fit and is held

in position by the outer race of bearing 21 and the splined
shaft of the six speed gearbox after it has been refitted.
Torque Settings

11 56 5.7 41
Refer to Splitter Clutches, Dismantling and Assembly.
9803/8020 Issue 5*
15 3
1 4
17
14
X
16 Y
12
11
13
6
W
Z
7
W 9
8
10
3
4
A353131
9803/8020 Issue 2*
Splitter Clutches - Wet Clutch

Transmission
Removal Replacement
1 Withdraw the layshaft assembly (medium ratio clutch) 1 * Note: During assembly all seals should be packed between
from the housing 2 together with the transmission brake their outer lips with JCB HP Grease. Lightly smear all shafts,
friction plate 3 and counter plate 4. Prise outer race of splines, gears and bearing shells with transmission oil.
roller bearing 5 out of the housing 2.
1 Lightly oil and fit new piston seals 9 and 10 to the
Note: The outer race of roller bearing 6 is located in the rear piston 8. With the 2 threaded holes W uppermost,
casing 7. press the piston into its bore in housing 2. Keep the
piston square to the bore. Check for any signs of seal
2 Remove the piston 8 from the housing 2. Insert 2 damage in the form of thin pieces of cut seal. If damage
suitable screws in the threaded holes (M3) W of the is suspected remove the piston and renew the seals.
piston, then, using 2 pairs of pliers, grip the screws and
pull out the piston. 2 Gently tap outer race of roller bearing 15 into the
3 Remove and discard the piston seals 9 and 10. the shaft of the low ratio clutch assembly 14. Fit the
sealing rings 17.
4 Withdraw layshaft assembly (high ratio clutch) 11 from 3 Insert the input shaft of low ratio clutch assembly 14
housing 2. Prise outer race of roller bearing 12 out of into the housing and through the hollow PTO input
the housing. gear. If the master clutch is in situ, engage the splines
on the input shaft with the clutch plate carrier.
Note: The outer race of roller bearing 13 is located in rear
casing 7. Note: The output gear of clutch 14 is a loose fit and is held
in position by the outer race of bearing 16 and the splined
5 Withdraw input shaft assembly (low ratio clutch) 14 shaft of the six speed gearbox after it has been refitted.
from housing 2. Prise outer race of roller bearing 15 out
of the housing. 4 Gently tap the outer race of bearings 16, 6 and 13 into
position in the rear casing 7, in preparation for the
Note: The outer race of roller bearing 16 is located in rear refitting of the six-speed gearbox/rear housing
casing 7. assembly.
6 Do not remove the inner races of bearings from the 5 Gently tap outer race of roller bearing 5 into the
clutch shafts unless they are to be renewed. The housing. Press inner races of bearings 5 and 6 onto the
bearings will damaged during removal. Take care not to shaft of the medium ratio clutch assembly 1.
damage the clutch shafts when removing the bearings.
6 Inspect the transmission brake friction plates 3 and
counter plate 4 for signs of wear. In any event it would
be prudent to renew the plates. The plates must only be
renewed as a complete set.
7 Locate the plates on the clutch 1, starting with a friction

plate 3 followed by counter plate 4. Locate the the
counter plate on the 3 drive pins X. Fit the remaining
friction plate. Align the cut outs Y on the 2 friction
plates.
8 Whilst holding the brake plates onto the clutch 1, insert

the input shaft into the housing 2. Locate the friction
plates on the 3 reaction pins Z, if necessary rotate the
clutch to align the plates.
9 Look through the oil drain hole in casing 2 and confirm

visually that the friction and counter plates are correctly
engaged with their respective pins.
10 Gently tap outer race of roller bearing 12 into the

the shaft of the high ratio clutch assembly 11. Insert the
input shaft into the housing 2.
Refer to Splitter Clutches, Dismantling and Assembly.
9803/8020 Issue 2*
160061
164990
9803/8020 Issue 1
Front PTO Clutch - All Models

Rear PTO Clutch - 3000 Series Assembly
Dismantling and Assembly Assembly is basically the reverse of the dismantling

procedure, but note the following:
Dismantling
Use new 'O' rings, seals and bearings. 'O' rings should be
Note: Drive shaft assembly A will have been separated from
lightly oiled before assembly.
the clutch assembly during removal.
! WARNING If piston liner 28 is not a good fit on piston 27, fit a new one.
Always wear safety glasses when dismantling
assemblies containing components under pressure from Check for wear on the internal splines of casing 31 which
springs. This will protect against eye injury from mate with the teeth of retaining plates 19 and 22. If wear is
components accidentally flying out. evident, dress the worn splines with a file and position the
GEN 6-2 teeth of the retaining plates away from the worn areas.
Ensure that the teeth do not mask the lubrication holes in
1 Support the clutch assembly in a suitable jig or vice. the casing.
2 Use tool 892/00812 to prevent the yoke 4 from rotating
and remove stake nut 2 and washer 3. Discard the Install Belleville spring 23 with its convex side towards
stake nut. piston 27. Install spring 11 so that its convex side is towards
spring 12.
3 Remove the yoke 4.
Use only complete matched sets of friction plates 20 and
4 Remove and discard oil seal 5.
counter plates 21. Install alternating plates, starting and
5 Remove the circlip 6 from the housing 1 then drive the finishing with a friction plate (see Step 11 in Dismantling).
clutch out of the housing using a soft-faced hammer.
Ensure that the toothed diameters of the plates are aligned
6 Remove bearing 7 using a suitable puller. before installing the clutch pack into the casing 31.
7 Remove plug 8 and bonded washer 9. Remove circlip
10. Carefully remove springs 11 and 12. After fitting circlip 18, measure the endfloat of pressure plate
19 using a dial test indicator. This should be 3.5-4.8 mm
8 Withdraw the PTO brake piston 13 and brake pad 14. (0.138-0.189 in). If necessary, adjust the endfloat by fitting
Remove and discard 'O' ring 15. shim plate X.
9 Remove plug 16 and washer 17.
Lubricate the lips of the new seal 5 with JCB HP Grease. Fit
10 Carefully remove circlip 18 and retaining plate 19 the new seal into the housing, taking care not to distort it.
(collect and retain shim plates X if fitted). Ensure that the seal is square and pushed fully home.
* 11 Remove the clutch friction/counter plates. There are
Before fitting the yoke 4, check that the bearing end of the
twelve friction plates 20 and eleven counter plates 21
for the front clutch pack and twelve friction plates 20 yoke is not fretted and renew the yoke if required. Clean any
and eleven counter plates 21 for the rear clutch pack. oil from the splines of the yoke and the shaft. Run an even 2
These must be kept together in sets. DO NOT mix the mm diameter bead of JCB Threadlocker and Sealer around
plates with those from other clutches. the outer end of the shaft spline.
12 Remove retaining plate 22 and Belleville spring 23. Use a new stake nut 2. Stake the nut axially only, using a
square ended staking tool.
13 Position the clutch assembly in a press to compress
piston spring 26, using a suitable tool as shown at Y,
then remove circlip 24. Ease the press to allow the On completion, use an airline to check that pistons 13 and
spring to expand, then remove spring retainer 25 and 27 operate smoothly.
the spring.
Torque Settings
14 Knock the clutch shaft on a piece of aluminium (or
wood) to remove piston 27. Check that the piston liner Item Nm kgf m lbf ft
28 is a good fit on the piston. 2 400 40.8 295
15 Remove and discard 'O' ring 29 from the piston and 'O' 8 305 31 225
ring 30 from the shaft of item 31. 16 102 10.4 75.2
16 Remove and discard the three piston rings 32.

17 Dismantle the shaft assembly A by removing bearing
33, circlip 34 and bearing 35.
9803/8020 Issue 3*
15
14
A 34 31 28
18
17
33 16
25
32
23
20
19
26
24 27
18 22
11
13
12
9 10
21
30 8
17 2
4
5
21
6
3
29
7
A234841
9803/8020 Issue 1
* Rear PTO Clutch - 2000 Series

Dismantling Assembly
Note: Drive shaft assembly A will have been separated from Assembly is basically the reverse of the dismantling
the clutch assembly during removal. procedure, but note the following:
Use new ‘O’ rings, seals and bearings. ‘O’ rings should be
! WARNING lightly oiled before assembly.
Always wear safety glasses when dismantling
assemblies containing components under pressure from If piston liner 27 is not a good fit on piston 26, fit a new one.
springs. This will protect against eye injury from
components accidentally flying out. Check for wear on the internal splines of casing 21 which
GEN 6-2 mate with the teeth of pressure plates 16 and 19. If wear is
evident, dress the worn splines with a file and position the
1 Support PTO housing 1 in a suitable jig or vice. teeth of the pressure plates away from the worn areas.
Ensure that the teeth do not mask the lubrication holes in
2 Use tool 892/00812 to prevent yoke 4 from rotating and the casing.
remove stake nut 2 and washer 3. Discard the stake
nut. Install Belleville spring 20 with its convex side towards
piston 26.
3 Remove yoke 4.
Use only complete matched sets of friction plates 17 and
4 Remove and discard oil seal 5. counter plates 18. Install alternating plates, starting and
finishing with a friction plate (see Step 10 in Dismantling).
5 Remove circlip 6 from housing 1 then drive the clutch
out of the housing using a soft-faced hammer against Ensure that the toothed diameters of the plates are aligned
the end of the shaft of clutch housing 21. before installing the clutch pack into casing 21.
6 Remove bearing 7 using a suitable puller. After fitting circlip 14, measure the endfloat of pressure plate
16 using a dial test indicator. This should be 3.5 - 4.8 mm
7 Remove friction plate 8, dowels 9, brake piston 10 and (0.138 - 0.189 in). If necessary, correct the endfloat by fitting
needle bearing 11 from inside housing 1. If necessary the necessary thickness of shim plate(s) 15.
gently tap the open end of the housing 1 against a
piece of wood to dislodge piston 10. Lubricate the lips of new seal 5 with JCB HP Grease. Fit the
new seal into the housing, taking care not to distort it.
8 Remove and discard brake seals 12 and 13 from piston Ensure that the seal is square and pushed fully home.
10.
Before fitting yoke 4, check that the bearing end of the yoke
9 Carefully remove circlip 14, shim plate(s) 15 (if fitted) is not fretted and renew the yoke if required. Clean any oil
and pressure plate 16 (retain the shim plates). from the splines of the yoke and the shaft. Run an even 2 mm
diameter bead of JCB Threadlocker and Sealer around the
* 10 Remove the clutch friction/counter plates. There are outer end of the shaft spline.
twelve friction plates 17 and eleven counter plates 18.
These must be kept together in sets. DO NOT mix the Use a new stake nut 2. Stake the nut axially only, using a
plates with those from other clutches. square ended staking tool.
11 Remove pressure plate 19 and Belleville spring 20. On completion, use an airline to check that pistons 10 and
26 operate smoothly.
12 Position the clutch housing 21 in a press to compress
piston spring 24, then remove circlip 22. Ease the press Torque Setting
to allow the spring to expand, then remove spring
retainer 23 and the spring. Item Nm kgf m lbf ft
2 350 35.7 258
13 Knock the shaft of housing 21 on a piece of wood to
remove piston 26. Check that the piston liner 27 is a
good fit on the piston.
14 Remove and discard ‘O’ ring 28 from the piston and ‘O’
ring 29 from the shaft of item 21.
15 Remove and discard the three shaft sealing rings 30.
16 Dismantle the shaft assembly A by removing bearing

31, circlip 32 and bearing 33 from drive shaft 34.
9803/8020 Issue 3*
25 - 1 PTO Gearbox 25 - 1
A290330
9803/8020 Issue 1
25 - 2 PTO Gearbox 25 - 2
Speed Selector Shaft Assembly

Removal
1 Remove the six retaining bolts 1 and lift the housing 2

clear of the PTO gearbox housing.
2 Remove and discard gasket 3.
Replacement
1 Position the housing 2 on the underside of the PTO

gearbox, using a new gasket 3.
2 Locate both slots in selector fork 10 with the rib around

the circumference of the sliding sleeve in the PTO
gearbox (see Output Section, Dismantling and
Assembly).
3 Secure the assembly housing 2 to the PTO gearbox

with bolts 1. Tighten to a torque of 56 Nm (41.3 lbf ft,
5.7 kgf m).
Dismantling
1 Remove detent plug 4 then take out detent spring 5

and detent ball 6.
2 Release the locking screw 7.
3 Remove and discard seal 8 then withdraw selector

shaft 9 from the housing to release selector fork 10
complete with selector fork bushing inserts 11. Remove
the bushing inserts by opening out the tabs.
Assembly
Note: During assembly all seals should be packed between

their outer lips with JCB HP Grease. Use the same grease to
lightly smear all shafts, splines, gears and bearing shells.
Assembly is the reverse of the dismantling procedure, but

noting the following points.
Fit new bushing inserts 11 to selector fork 10. Bend the tabs
to secure.
Insert the selector shaft 9 with its machined flat face towards
the detent plug, spring and ball assembly (4, 5, 6).
When fitting locking screw 7, locate it with the hole in

selector shaft 9. Smear the thread with JCB Threadlocker
and Sealer and tighten to a torque of 35 Nm (25.8 lbf ft, 3.6
kgf m).
When fitting seal 8 ensure that lips of seal face inwards.
Apply JCB Threadlocker and Sealer to threads of screw 4.
9803/8020 Issue 1
18
17 21A
16
13
8
15
14
21
7
5
19
20
12
10
6 4
2
3
11
32
22
9 23
24
1 25
33 29
34
35
26
27
28
30
W 38
31
36 37
39
41
40
A275451
9803/8020 Issue 2*
Splitter Clutches
Note: The low ratio clutch comprises items 1 to 18. The high After fitting circlips 3 and 26, measure the end float of
ratio clutch comprises items 19 to 41. The medium ratio pressure plates 5 and 28 as follows:
clutch comprises items 19, 20, 21A, 22 - 41. Note: It is particularly important that this procedure is
The numerical sequence shown on the illustration is followed when re-building the 3-speed splitter gearbox
assembly because of special wave type friction plates.
a Confirm the clutch pack is fully built and circlip 3 or 26
For assembly the sequence should be reversed. is correctly located.
Dismantling
b Using an airline nozzle inserted into the clutch
!WARNING engagement pressure port, carefully apply air pressure
Always wear safety glasses when dismantling (6 bar maximum) behind the piston to clamp up the
assemblies containing components under pressure from clutch pack. This will push and locate circlip 3 or 26 to
springs. This will protect against eye injury from the top of its groove in preparation for measuring end
components accidentally flying out. float.
GEN 6-2
c Remove the airline. Push the clutch pack towards the
When Dismantling piston, using thumb pressure, to ensure the plates are
fully seated. Release the thumb pressure.
If a shim 4 and/or 27 is fitted, retain for assembly purposes.
d Place dial indicator clock base on the outside of the
DO NOT mix the clutch plates from one clutch with those clutch drum. Place the indicator finger onto pressure
from other clutches. plate 5 or 28 and record the dial test indicator reading.
Use a suitable press-operated tool as shown at W (or tool e Lift pressure plate 5 or 28 by hand so that it is against
part no. 892/00916 if a press is not available) to compress circlip 3 or 26 and record the dial test indicator reading.
spring 11 or 34 and thus permit removal of circlip 9 or 32.
Then gently release the press. f Calculate the difference between the two readings to
determine the clutch pack end clearance.
If available, use compressed air to blow out the piston 14 or
g Repeat procedures c to f three times with the indicator
36. Alternatively, turn the assembly over and knock the
finger at different radial positions and work out the
clutch shaft on a wooden block. Check that the piston liner average end clearance.
is a good fit on the piston.
*h The average end clearance should be 3.0 - 3.5 mm if
When Assembling using either new or worn clutch plates. If necessary
Use new ‘O’ rings, seals and bearings, (see Needle Roller adjust by fitting an alternative pressure plate (5 or 28)
and/or shim (4 or 27).
* Bearings, Checking For Damage or Distortion ). ‘O’ rings
should be lightly oiled before assembly. Pack between the j Repeat the full procedure for each clutch pack.
lips of seals with JCB HP Grease.
Note 1: If the shim plate fitted has no external teeth, discard
Check for wear on the internal splines of clutch housings 17 and fit a new externally toothed shim.
and 40 which mate with the teeth of the retaining plates 5
and 28. If wear is evident, dress the worn splines with a file Note 2: Do not fit the sealing rings 18 and 41 until the
and position the teeth of the retaining plates away from the bearing inner races have been pressed onto the clutch shaft,
worn areas. Ensure that the teeth do not mask the see Removal and Replacement.
lubrication holes in the casing.
Install Belleville springs 8 and 31 with their convex sides

towards the pistons 14 and 36.
Use only complete matched sets of six friction plates 6 and

29 and six counter plates 7 and 30. Install alternating plates,
starting with a counter plate and finishing with a friction
plate.
Make sure that the toothed diameters of the plates are

aligned before installing the clutch pack into the casing.
Fit pressure plates 5 and 28 of 4 mm, 6 mm or 6.5 mm as

appropriate.
9803/8020 Issue 6*
9803/8020 Issue 1
Output Section - Dry Clutch Transmission

The numerical sequence shown on the illustration is 4 Continue tapping the shaft through the intermediate
intended as a guide to dismantling. gear assembly and thrust washers. During this
procedure, take care not to damage the 'O' ring as it
For assembly the sequence should be reversed. passes the circlip groove in the housing.
Dismantling 5 Fit circlip 17.
1 Remove both PTO clutches (see PTO Clutches, 6 Fit new needle roller bearings 13, 14 and 8, 9 to the
Removal and Replacement). high speed gear 12 and the low speed gear 7.
2 Remove the speed selector shaft assembly (see Speed 7 Lightly oil taper roller bearing 16 and locate it inside the
Selector Shaft Assembly, Removal). housing, with the taper towards the housing.
Note: Items A ('O' ring) B (bearing retainer) and C
8 Assemble high speed gear 12, sliding sleeve 10 and
(setscrews) are removed as part of the PTO clutch
low speed gear, onto output gear shaft 11. The
assembly.
shoulders of the speed gears should be facing each
3 Remove bearing housing 1 and gasket (not shown). other.
Circlip 2 which is located inside the bearing housing,
need not be removed unless damaged. Note: The output gear shaft is not symmetrical about the
toothed gear. The thrust spacer 15 locates end of the shaft
4 Remove shim 3 (if fitted) and spacer 4. which has the longer shoulder.
5 Gently tap out the output gear shaft 11, taking care not 9 Fit the thrust spacer 15 against the high speed gear 12
to damage the internal spline or the outer surfaces. and thrust washer 6 against the low speed gear 7.
Note: The gear shaft 11 may take with it the following items 10 Fit the assembled items, into the taper roller bearing 16,
when removed: taper roller bearings 5 and 16, thrust washer previously fitted in the housing. Make sure the speed
6, low speed gear 7, needle roller bearings 8 and 9, sliding gears mesh correctly with the intermediate gears 20.
sleeve 10, high speed gear 12, needle roller bearings 13 and
14 and thrust spacer 15. Take steps to prevent any of these 11 Insert shim 3 (if previously fitted) and spacer 4 into the
items from dropping out and contacting dust and grit. bearing housing 1 up against the circlip 2. Follow this
with taper roller bearing 5, lightly oiled, with the taper
6 Remove circlip 17.
towards the bearing housing.
7 Remove intermediate gear shaft 18 using a suitable bolt
in the threaded hole and a slide hammer. Take care 12 Locate the bearing housing gasket (not shown) onto the
when removing the shaft to catch thrust washers 19, 23, bearing housing 1. Locate the assembly over the end of
and the intermediate gear assembly, comprising the output gear shaft 11.
intermediate gear 20 and needle roller bearings 21, 22. (If
these items do not come out with the shaft, remove them 13 Temporarily fit the bearing housing 1 using three bolts
separately.) from the selector cover plate. Tighten to 56Nm (41.3 lbf
ft).
8 Remove 'O' ring 24 and discard.
Note: When the PTO splitter gearbox is fully assembled, the
Assembly bearing housing 1 is held in position by the same setscrews
C which secure the rear PTO clutch housing.
* Note: During assembly all seals should be packed between
their outer lips with JCB HP Grease. Use transmission oil to
lightly smear all shafts, splines, gears and bearing shells.
Use new 'O' rings and needle roller bearing assemblies,
(see Needle Roller Bearings, Checking For Damage or
Distortion ).
1 Fit new needle roller bearings 21 and 22 into the

intermediate gear 20. Position thrust washers 19 and 23
and hold in place using a light coating of grease.
2 Fit a new 'O' ring 24 on to the intermediate gear shaft

18 and grease lightly.
3 Gently tap the intermediate gear shaft 18 into the

housing aperture. Simultaneously, support the
intermediate gear assembly inside the housing.
9803/8020 Issue 4*
* Output Section - Dismantling and

Assembly - Dry Clutch Transmission
(continued)
Assembly (cont’d)
14 Temporarily fit the front PTO clutch bearing retainer

assembly in a similar manner.
Note: Do not fit the front or rear PTO clutch drive shafts at
this stage (see PTO Clutch, Removal).
15 The following procedure for checking the end float of

the output gear shaft 11, is most easily done with the
bell housing resting on the bench.
a) Use a dial gauge graduated in 0.01 mm steps.

Insert the gauge probe through the bearing retainer
(see step 14) onto the inner race of taper roller
bearing 5. Insert a bar through the selector
assembly aperture and lever the gear shaft down
towards the bench. Do not use excessive force.
Zero the dial gauge whilst exerting a downward
force and moving the bar back and forth to rotate
the shaft.
b) Now lever the gear shaft upwards, using a similar

force. Take an average reading of the dial gauge,
whilst moving the bar back and forth to rotate the
shaft.
16 Calculate the shim thickness required to achieve an

end float of 0.03 mm to 0.08 mm. Select shims from
JCB Shim Kit, Part No. 921/50800.
17 Remove the rear bearing housing 1. Insert selected

shims 3 between circlip 2 and spacer 4. Check the end
float again and repeat this process until the desired end
float is achieved.
18 Refit the speed selector shaft assembly (see Speed

Selector Shaft Assembly).
Note: Items A, B and C are fitted as part of the PTO clutch

assembly (see PTO Clutch, Replacement)
9803/8020 Issue 2*
G
X
9803/8020 Issue 3*
Output Section - Dismantling and Assembly Assembly

Machines with Wet Master Clutch Note: During assembly all seals should be packed between
their outer lips with JCB HP Grease. Use the same grease to
The numerical sequence shown on the illustration is lightly smear all shafts, splines, gears and bearing shells.
intended as a guide to dismantling. Use new 'O' rings .
For assembly the sequence should be reversed. 1 Fit new double roller bearings 23 and 25 together with
spacer 24 into the intermediate gear 22. Make sure that
Dismantling the roller bearings are fitted the correct way round, with
the radiused ends of the shells adjacent to each other,
1 Remove both PTO clutches (see PTO Clutches, as shown at D. Insert special retaining tool H, tighten
Removal and Replacement). the cap screw to clamp it in position as shown at J.
2 Remove the speed selector shaft assembly (see Speed 2 Fit a new 'O' ring 21 in the housing and grease lightly.
Selector Shaft Assembly, Removal).
3 Lower the intermediate gear assembly K into the
Note: Items A ('O' ring) B (bearing retainer) and C housing aperture and align with the shaft bore in the
(setscrews) are removed as part of the PTO clutch housing at Y.
assembly.
4 Slacken the cap screw and remove the tool H, pulling it
3 Remove bearing housing 1 and gasket (not shown). out through the housing. Hold the gear assembly in
Circlip 2 which is located inside the bearing housing, position and gently tap the intermediate gear shaft 20
need not be removed unless damaged. through the intermediate gear assembly. Be sure to fit
the shaft the correct way round.
4 Remove the spacer 3 and shim 4 (if fitted).
5 Push the shaft until it exposes the ‘O’ ring groove in the
5 Lift out the output shaft assembly 11, comprising: housing at Y. Fit new ‘O’ ring 19 and then circlip 18.
The gear shaft 11, taper roller bearings 5 and 16, thrust Push shaft 20 back against circlip 18 and then fit circlip
washer 6, low speed gear 7, needle roller bearings 8 17. Make sure that the intermediate gears rotate freely,
and 9, sliding sleeve 10, high speed gear 12, needle there should be some end float. Using an open ended
roller bearings 13 and 14 and thrust spacer 15. spanner position the flats X on the shaft 20 relative to
the housing as shown at E.
6 Remove circlip 18.
6 Fit new needle roller bearings 13, 14 and 8, 9 to the
7 Fit a slide hammer (892/00224) to the intermediate gear high speed gear 12 and the low speed gear 7.
shaft 20, use adaptor G in the lubrication port F. Use
the slide hammer to withdraw the shaft 20 from the end 7 Lightly oil the cup of taper roller bearing 16 and locate it
with flats X. Take care to support the intermediate gear inside the housing, with the taper towards the housing.
assembly 22 inside the housing.
8 Assemble high speed gear 12, sliding sleeve 10 and
8 Insert special retaining tool H into the intermediate gear low speed gear, onto output gear shaft 11. The
assembly. Tighten the cap screw to clamp the tool in shoulders of the speed gears should be facing each
position as shown at J. Remove the gear assembly K. other.
9 Slacken the cap screw and remove the tool H. Take Note: The output gear shaft is not symmetrical about the
care when removing the double roller bearings 23 and toothed gear. The thrust spacer 15 locates the end of the
25, the rollers will be lost if not retained in a suitable shaft which has the longer shoulder.
sleeve.
9 Fit the thrust spacer 15 against the high speed gear 12
10 Remove spacer 24. and thrust washer 6 against the low speed gear 7.
11 Remove circlip 17. 10 Press the bearing cones 5 and 16 onto the output gear
shaft 11.
12 Remove and discard ‘O’ rings 19 and 21.
11 Fit the assembled items, into the cup of taper roller
13 Carefully inspect all components for signs of wear or bearing 16, previously fitted in the housing. Make sure
damage. If in doubt renew components as applicable. the speed gears mesh correctly with the intermediate
gears 22.
Service Tools
12 Insert shim 4 (if previously fitted) and spacer 3 into the
Item Part No. bearing housing 1 up against the circlip 2.
H 892/01051
G 892/01053
9803/8020 Issue 3*
Output Section - Dismantling and

Assembly - Machines with Wet Master
Clutch (Cont'd)
Assembly (cont’d)
13 Locate the bearing housing gasket (not shown) onto the

bearing housing 1. Locate the assembly over the end of
the output gear shaft 11. Make sure that the flats on
shaft 20 align with the flat X on the housing 1 as shown
E.
14 Temporarily fit the bearing housing 1 using three bolts

from the selector cover plate. Tighten to 56Nm (41.3 lbf
ft).
Note: When the PTO splitter gearbox is fully assembled, the

bearing housing 1 is held in position by the same setscrews
C which secure the rear PTO clutch housing.
Note: Do not fit the front or rear PTO clutch drive shafts at
this stage (see PTO Clutch, Removal).
15 The following procedure for checking the end float of

the output gear shaft 11, is most easily done with the
bell housing resting on the bench.
a) Use a dial gauge graduated in 0.01 mm steps.

Insert the gauge probe through the bearing retainer
(see step 14) onto the inner race of taper roller
bearing 5. Insert a bar through the selector
assembly aperture and lever the gear shaft down
towards the bench. Do not use excessive force.
Zero the dial gauge whilst exerting a downward
force and moving the bar back and forth to rotate
the shaft.
b) Now lever the gear shaft upwards, using a similar

force. Take an average reading of the dial gauge,
whilst moving the bar back and forth to rotate the
shaft.
16 Calculate the shim thickness required to achieve an

end float of 0.03 mm to 0.08 mm. Select shims from
JCB Shim Kit, Part No. 921/50800.
17 Remove the rear bearing housing 1. Insert selected

shims 4 between spacer 3 and bearing 5. Check the
end float again and repeat this process until the desired
end float is achieved.
18 Refit the speed selector shaft assembly (see Speed

Selector Shaft Assembly).
Note: Items A, B and C are fitted as part of the PTO clutch

assembly (see PTO Clutch, Replacement)
9803/8020 Issue 1
1 5
2 6
3 7
4 8
25
26
10
18 9
15
17
16
14
13
25
11 12
26
22
24
20
19
23
21
A290370
9803/8020 Issue 1
Input Section - Dismantling and Assembly

- Dry Clutch Transmission
Dismantling

When Assembling
Before a new input shaft is fitted, the shaft and clutch cover
splines must be mated together to check for adverse
tolerances which would cause the shaft to be a tight fit in the
clutch cover.
The parts should fit together freely by hand. If this is not so,
check the splines on both parts for damage and renew as
required.
When fitting the shaft into the gearbox, wrap the splines to
avoid damage to the oil seal.
Item 12 must be fitted with the drain hole at the bottom.
Note: All seals should be packed between their outer lips

with JCB HP Grease. Use the same grease to lightly smear
all shafts, splines, gears and bearing shells. Lightly grease all
'O' rings before assembly.
Torque Settings

1 50 5.1 37
5 50 5.1 37
9 28 2.9 21
11 56 5.7 41
25 75 7.6 55
9803/8020 Issue 1
5 4
4 6
A
2 5
7
1
6
A353251
D X
D
D
D
D
D C
D
D
C B
B
D
B
C
D
A358760
9803/8020 Issue 2*
Idler Gear - Wet Clutch Transmission

Removing and Dismantling

intended as a guide to removal and subsequent dismantling
of the idler gear assembly.
For assembly and replacement the seqence should be

reversed.
When Assembling
* Make sure that the oil ways in shaft 2 are clear. If shaft 2 is
to be renewed make sure that the blanking screw 7 is fitted
to the new shaft.
* Note: New screws 7 are pre treated with a sealant ‘patch’.

When refitting an existing screw apply JCB Threadlocker
and Sealer.
* When fitting the ‘L’ shaped circlips 4 be sure to fit them the
correct way round as shown at A.
Housing - Wet Clutch Transmission

Replacing
Inspect the housing X before commencing assembly of the

various PTO/Splitter components. Ensure that all the plugs
are fitted to the oil way cross drillings. This is particuarly
important if the housing has been renewed or the plugs were
removed for cleaning the oil ways. Plugs are fitted as
follows:
Type Size
B 6mm (Rivet type plug)
C M8
D 1/8 BSP
Note: New plugs are pre treated with a sealant ‘patch’.

When refitting an existing plug apply JCB Threadlocker and
Sealer.
9803/8020 Issue 2*
27 - 1 Speed Gearbox 27 - 1
*
1B
7 8
20
21
27 29
28
1A
A317790
9803/8020 Issue 3*
Remote Control
Note: Where local legislation demands, the speed gearbox

may be limited to 5 speeds by the addition of a stop in the
remote control housing to prevent engagement of 6th
speed. The arrangement shown at inset A, comprising items
27, 28 and 29, blanks out 6th speed on 2000 Series
machines to serial no. 738360 and 3000 Series machines to
serial no. 640051. The plate 1A shown at inset B blanks out
6th speed on 2000 Series machines from serial no. 738361
and 3000 Series machines from serial no. 640052.
The numerical sequence shown on the illustration, and inset

if relevant, is intended as a guide to dismantling.
Dismantling
Ensure that neutral is selected then unscrew bolts 1 to

remove the remote control assembly from the gearbox.
* Note: Later gearboxes are fitted with Verbus Ripp bolts 1B

in place of normal bolts 1.
Remove plug 20 to gain access to pin 21. When removing

the pin, support the shaft 22 and lever 23 to avoid causing
damage to the bushes.
If these are worn, remove bushes 24 and 25 using an

impulse extractor (892/00224).
Assembling
Refit shaft 22 in the direction of the arrow to prevent the

shaft splines from damaging the oil seal 26.
Apply JCB High Strength Threadlocker to the flange face of

the remote control housing. Ensure that lever 23 locates in
the selector block inside the main gearbox casing.
* Be sure to tighten standard type bolts 1 (when fitted) to the

correct torque. Over tightening may strip threads or break
the bolts.
* Note: Verbus Ripp Bolts (when fitted)

In this application the Verbus Ripp bolts 1B can be reused.
Before fitting remove any alloy that may be clogged in the
serrations on the head. Make sure that the bolt thread is in
good condition, if in doubt, renew the bolt. Apply JCB
Threadlocker and Sealer and tighten to the correct torque.
Note: These bolts are special and should not be used on
other applications.
Torque Settings

1 35-39 3.5-4.0 26-29
* 1B 70-75 7.2-7.6 52-55
3 20-27 2.1-2.8 15-20
7 15-22 1.5-2.2 11-16
10 20-24 2.1-2.4 15-18
9803/8020 Issue 3*
3A
S225823
W
X
V Y
226290
9803/8020 Issue 4*
27 - 3A Speed Gearbox 27 - 3A
* Rear Oil Seal and Housing

Removal and Replacement Using the Gearbox Locking Tool
The numerical sequence shown on the illustration is 1 Slacken the two bolts V.
2 Fit tool W to the speed gearbox flage and tighten nuts
For replacement the sequence should be reversed. X to the specified torque.
When removing or fitting stake nut 1, use gearbox locking
tool (892/00892) as described opposite. 3 Rotate the output gear to allow locking plate Y to be
fully engaged in the gear teeth. Tighten the bolts V to
Note 1: The seal can be renewed with the gearbox either the specified torque.
removed or fitted.
4 Remove or replace the nut Z, torque tightening as
Note 2: The illustration is intended as a guide only; some specified and then remove the tool.
differences exist between various builds of gearbox. Refer
to TI 10/127 (F146//N.Am) for further information.
Note 3: Later gearboxes are fitted with Verbus Ripp bolts 3A

in place of normal bolts 3.
When Removing
Remove the range gearbox from the rear of the speed

gearbox.
Check that sleeve 6 is not scored or worn.
When Replacing
Be sure to tighten standard type bolts 3 (when fitted) to the

correct torque. Over tightening may strip threads or break
the bolts.
Note: Verbus Ripp Bolts (when fitted)

In this application the Verbus Ripp bolts 3A can be reused.
Before fitting remove any alloy that may be clogged in the
serrations on the head. Make sure that the bolt thread is in
good condition, if in doubt, renew the bolt. Apply JCB
Note: These bolts are special and should not be used on
other applications.
Ensure that seal 5 faces in the right direction as shown at A.
Apply grease to the lips of the seals.
Always fit a new stake nut 1. After torque tightening, support

the nut by means of a large hammer (positioned as shown B)
and stake axially, ensuring the metal is folded and only split
axially. If any radial splitting occurs, discard and fit a new
nut.
Note: Failure to support the nut while staking could cause

damage to the shaft parallel roller output bearing.
Torque Settings

* 1 (Z) 700 71 515
3 35-39 3.5-4.0 26-29
3A 70-75 7.2-7.6 52-55
V 56 5.6 41
X 56 5.6 41
9803/8020 Issue 3*
*
2A
*
1A
*
17A
*
11A
9803/8020 Issue 2*
Front Oil Seal and Housing

First remove the gearbox from the machine. Position the gearbox vertically as shown, supported on
wooden blocks (or a suitable stand) so that the rear end of
Note: If the gearbox is then positioned with the input shaft the output shaft is clear of the floor.
pointing upwards as shown, it is not essential to drain the
oil. Note: Do not use pry-bars or chisels to separate housings or
they may be damaged beyond repair.
* Note: Later gearboxes are fitted with Verbus Ripp bolts 1A,
and 2A in place of normal bolts 1 and 2. * Note: Later gearboxes are fitted with Verbus Ripp bolts 1A,
2A, 11A and 17A in place of normal bolts 1, 2, 11 and 17.
Unscrew bolts 1 and 2 and remove housing 3. Prise out the
old seal 6. Unscrew bolts 1 and 2 and remove cover 3. Retain spacer 4
and shims 5.
Carefully fit a new seal ensuring that the seal lip faces
towards the rear of the gearbox. Remove circlip 7, spacer 8 and bearing flange 9. Remove
casing fasteners 10 and 11, noting that some of the bolts are
Apply grease to the lip of seal 6 and refit housing 3. fitted into threaded holes in the rear casing 14.
* Apply JCB Threadlocker and Sealer to the threads of bolts 1 Before lifting the front casing 13, rotate the selector block
90° to the left as shown at 12. This will release the detent
and 2 (or 1A and 2A as applicable) and tighten to the torque
plunger 21 from engagement in the selector block and allow
setting given below. Ensure that bolts are not overtightened
the front casing to be lifted clear without fouling.
as the threads in the alloy gearbox casing are easily
stripped.
Note: Even with the detent plunger removed it is still
necessary to turn the selector block to prevent it from
* Be sure to tighten standard type bolts 1 and 2 (when fitted)
fouling the casing. Therefore it is not necessary to remove
to the correct torque. Over tightening may strip threads or
the detent plunger unless it requires attention.
break the bolts.
Lift off input shaft 22, complete with synchro flange 23 and
* Note: Verbus Ripp Bolts (when fitted) bearing inner race 28.
In this application the Verbus Ripp bolts 1A and 2A can be
reused. Before fitting remove any alloy that may be clogged
Note: If it is necessary to renew either the input shaft or the
in the serrations on the head. Make sure that the bolt thread
synchro flange, follow instructions for removing and
is in good condition, if in doubt, renew the bolt. Apply JCB
replacing synchro flanges given under Mainshaft Dismantling
and Assembly.
* Note: These bolts are special and should not be used on Remove needle bearing 24 and synchro ring 25.
other applications.
If the input shaft bearing is to be renewed, press the shaft
Torque Settings out of the inner race 28 and remove circlip 15 to release the
outer race and rollers 16.
1 69-78 7.0-7.9 51-58 To allow the layshaft 26 to be removed, lift the mainshaft
* 1A 85-95 8.7-9.7 63-70 and selector assembly 27 by 10 to 20 mm (0.4 to 0.8 in) and
2 35-39 3.5-4.0 26-29 support it using a wooden block under the rear of the shaft.
* 2A 55-60 5.7-6.0 41-44
Remove the mainshaft and selector assembly 27 as a unit.
Separate the selectors from the synchro sleeves. Remove
Input Shaft, Mainshaft and Layshaft the bearings from the rear housing.
Replacement
Removal
Reverse the removal procedure with the following additions:
Note: It is necessary to remove the front half of the gearbox
casing 13 before the input shaft assembly can be removed. Check cover plate A for oil leakage. If necessary, remove the
This is because the 6th speed synchro flange is bonded to cover plate and clean the gearbox case. Check the cover
the input shaft and is too large to pass through the bearing plate for damage and refurbish/renew if appropriate. Fit a
bore in the front casing. new gasket coated with JCB Clear Silicone Sealant. Tighten
bolts B to the specified torque setting.
Remove gearbox from machine, drain the oil and remove the
remote control (see Speed Gearbox, Remote Control).
Remove the output gear (see Speed Gearbox, Rear Oil

Seals, items 1 and 2 on exploded view).
9803/8020 Issue 2*
Input Shaft, Mainshaft and Layshaft

(continued)
Replacement (continued)
Check the condition of the spigot bearing 24 before fitting Torque Settings
the input shaft assembly. Before fitting the bearing inner
race 28, heat it to 85°C (180°F). This should avoid the need Item Nm kgf m lbf ft
to drift it into place. The bearing should be fitted as far as 1 69 - 78 7.0 - 7.9 51 - 58
the shoulder on the shaft. Fit the rest of the bearing then * 1A 85 - 95 8.7 - 9.7 63 - 70
select a suitable spacer 8 to fit with minimum clearance 2 35 - 39 3.6 - 4.0 25 - 29
between snap ring 7 and bearing flange 9. Check the * 2A 55 - 60 5.7 - 6.0 41 - 44
clearance at several places around the circumference. 11 51 - 58 5.3 - 5.9 38 - 43
* 11A 75 - 85 7.6 - 8.7 55 - 63
Before fitting the front casing 13, apply JCB Multigasket to 17 20 - 24 2.1 - 2.4 15 - 18
the flange face and ensure that the selector block is * 17A 35 - 40 3.6 - 4.1 26 - 30
positioned as for removal. B 35 - 39 3.6 - 4.0 25 - 29
When fitting snap ring 15, ensure that the gap in the snap
ring is over the oil hole in the gearbox casing.
The layshaft preload adjustment is controlled by a standard

thickness spacer 4 and selective thickness shims 5. Fit the
thickest available shim on top of the bearing, followed by
spacer 4.
* Fit cover 3 without sealant and fit bolts 1 (or 1A as

applicable) without spring washers. Carefully and evenly
tighten the bolts while rotating the input shaft 22 backwards
and forwards to seat the bearings. Continue tightening the
bolts until some resistance can be felt on the input shaft.
Check bearing preload as detailed in Layshaft Bearing
Preload.
* When the preload is correct, apply JCB Multigasket to

flange face of cover, apply JCB Threadlocker and Sealer to
the threads of bolts 1 and 2 (or 1A and 2A as applicable)
and tighten to the torque settings given below. Ensure that
bolts are not overtightened as the threads in the alloy
gearbox casing are easily stripped.
* Be sure to tighten standard type bolts 1, 2, 11 and 17 (when

fitted) to the correct torque. Over tightening may strip
threads or break the bolts.

In this application the Verbus Ripp bolts 1A, 2A, 11A and
17A can be reused. Before fitting remove any alloy that may
be clogged in the serrations on the head. Make sure that the
bolt thread is in good condition, if in doubt, renew the bolt.
Apply JCB Threadlocker and Sealer and tighten to the
correct torque.
* Note: These bolts are special and should not be used on

other applications.
Refit the output gear (see Rear Oil Seals, Removal and
Replacement).
9803/8020 Issue 2*
Layshaft Bearing Preload

The required preload depends on whether the bearings are * When the preload is correct, apply JCB Multigasket to
new or used: flange face of cover, apply JCB Threadlocker and Sealer to
the threads of bolts 1 (or 1A as applicable) and tighten to the
Preload with new bearings 0.075 to 0.125 mm torque setting given below. Tighten bolts 2 (or 2A as
Preload with used bearings zero to 0.05 mm applicable) firmly. Ensure that bolts are not overtightened as
the threads in the alloy gearbox casing are easily stripped.
Note: The preload is controlled on production by a standard
thickness spacer 4 and varying thicknesses of shim 5. Shims Item Nm kgf m lbf ft
must be inserted between the spacer and the bearing. 1 69 - 78 7.0 - 7.9 51 - 58
* 1A 85 - 95 8.7 - 9.7 63 - 70
Position the gearbox as detailed for removal and 2 35 - 39 3.6 - 4.0 25 - 29
replacement of the mainshaft and layshaft. * 2A 55 - 60 5.7 - 6.0 41 - 44
* Note: Later gearboxes are fitted with Verbus Ripp bolts 1A,
and 2A in place of normal bolts 1 and 2.

In this application the Verbus Ripp bolts 1A and 2A can be
reused. Before fitting remove any alloy that may be clogged
in the serrations on the head. Make sure that the bolt thread
is in good condition, if in doubt, renew the bolt. Apply JCB
With bolts 2 removed, back off bolts 1 to zero torque then

re-tighten just enough to nip cover 3.
Using feeler gauges, measure the clearance between the

cover 3 and the casing 13 at several places.
If the clearance is within the correct preload range above,

use the existing spacer or spacer and shims.
*
If the clearance is less than the minimum allowed preload, fit 1A *
the next available thicker spacer or shim and recheck the
clearance. 2A
If the clearance is greater than the maximum allowed

preload, subtract the clearance from the existing spacer
thickness. Then add a suitable preload figure from within the
tolerances given above to obtain the required spacer from
the thicknesses available.
Example: (All dimensions in millimetres)
In the following example the bearings are new and the

required preload is therefore 0.075 to 0.125 mm (the ideal
mean figure of 0.1 mm has been used in the calculation).
Existing spacer/shim thickness 3.8

Clearance (subtract) - 0.6
=3.2
Preload (add) 0.1
Required spacer/shim thickness 3.3
9803/8020 Issue 2*
*
A
161651
9803/8020 Issue 2*
Mainshaft Inspection (before assembly)
* Note 1: When removing the mainshaft from the gearbox, Check the fit of each synchro flange to its synchro ring (for
items 1 to 5 are removed separately and item 50 and item 51 example items 4 and 5). Place the ring 5 onto its mating
(if fitted) will remain in the gearbox housing. These parts are flange 4 and while holding the two firmly together, measure
shown here for reference only. the clearance between the two using feeler gauges at
several points around the circumference as shown. The
* Note 2: Gearboxes produced from late 1997 include a clearance should be 0.5 to 1.9 mm, otherwise renew both
redesigned rear housing, incorporating a bearing retaining parts.
flange (as detailed on TI 10/097 (F97/N.Am)). Prior to this
change, spacer 17 was of a smaller diameter and was fitted Renew components if any of the following defects are
together with an oil seal and the bearing 50 was retained by present:
circlip 51. Examine the spacer and replace it if any signs of
wear are visible, but note that the new larger diameter and Housings worn as a result of spinning outer bearing races.
hardened spacer 17 must not be fitted to the earlier rear Damaged bearings.
casing which does not have the integral retaining flange. Pitting or excessive wear on gears, hub end faces or bearing
Refer to TI 10/127 (F146//N.Am) for further information. bores.
Wear, pitting or overheating damage on bearing sleeves.
End Float Check Excessive wear or chipping on dog teeth or splines of
synchro hubs, sleeves or shafts.
Note: It is essential to check the end float of the gears Wear, chipping or overheating damage on teeth or cones of
before dismantling. synchro rings.
Worn or scored thrust washers.
Position the mainshaft and gears assembly vertically on a
suitable flat surface. Position a dial test indicator against Assembling
each gear in turn, raise the gear and check the end float
against the figures shown below. Before fitting the following parts they must be heated for at
least 30 minutes in an oven or on a hotplate set to 85°C
Gear End Floats (mm) (180°F).
Bearing sleeves 19 and 35
Gear (Item) 5th (14) 4th (36) 3rd (47) 2nd (33) 1st (21) Synchro hubs 11, 30 and 44.
Low limit 0.31 0.35 0.35 0.35 0.40
High limit 0.53 0.48 0.48 0.48 0.57 When fitting sleeves 6, 25 and 40, renew springs, plungers
and rollers.
If the end float is outside the limits, check gears, mainshaft,
synchro hubs and bearing sleeves for wear and renew as Ensure that the hubs are fully home then select the thickest
necessary. See Inspection. circlip 10, 16 and 29 which will fit into the groove with
minimum free play.
As each circlip is fitted, check that gear end float is within
The numerical sequence shown on the illustration is limits already given.
Ensure that synchro rings and flanges are correctly paired.
Note: The latest design of synchro hub/synchro flanges (4/6,
Note: A puller and/or a press will be needed to remove and
13 or 40/38, 46 or 25/32, 23) can be used as replacements
fit synchro hubs and gears. Take care not to damage the
on all speed gearboxes. However, due to a change of cone
teeth of the synchro rings.
angle, these parts must always be replaced as a set to avoid
Dismantling the possibility of mixing the new and old designs.
Take care to keep all parts together in their correct relative * Flanges should be secured to the gears as follows (see inset
positions so that parts to be re-used can be correctly re- A opposite):
assembled and wear between mating parts can be
measured. This is especially important for the synchro 1 Ensure that both parts are clean and free from oil or
flanges 4, 13, 38, 46, 32 and 23 and synchro rings 5, 12, 39, grease.
45, 31 and 24. 2 Apply a thin bead of JCB Retainer (High Strength) to
the spline teeth of the gear.
Use soft jaws when holding the shaft assembly in a vice. 3 Press the synchro flange onto the gear, ensuring it is
fully home.
Catch rollers, plungers and springs when removing sleeves 4 Carefully wipe off any excess Loctite, apply a weight of
from synchro hubs 11, 30 and 44. approximately 4.5 kg (10lb) and allow to cure for
approximately 2 hours. If the flange is not square on the
Synchro flanges are bonded to the mating gears. Heat the gear, separate the parts, clean and re-assemble.
gear and flange to de-activate the retaining compound and
separate the parts using a suitable press or puller.
9803/8020 Issue 3*
Layshaft
Dismantling and Assembly Note: Do not remove any more metal than necessary
otherwise the interference fit between the gears and shaft
The numerical sequence shown on the illustration is may not be sufficient.
Ensure that the gear bosses face in the correct direction as
For assembly the sequence should be reversed. shown.
Note: A hydraulic press is needed to remove and fit gears 4 Note: To ensure correct interference fit, gears 4 and 5 must
and 5. be heated to 150°C (302 °F) before being quickly press-
fitted. After starting to press the shaft through the gears, do
When Dismantling not stop until the gears are completely home on the shaft. If
two gears are being fitted, they should be pressed onto the
Use a bearing puller to remove items 2 and 3. shaft separately as quickly as possible. The assembled shaft
and gears must remain under the press with pressure
Note: Items 7 and 8 will remain in the housing when applied until the temperature has normalised (approximately
removing the shaft but are shown here for reference. 10 minutes).
When Assembling Heat inner bearings 2 and 3 to 85 °C (180 °F) before fitting.
Carefully remove all burrs and scores from shaft 6 using a When bearings are fully seated, select the thickest circlip 1
fine oil stone. which will fit into the groove with minimum free play.
9803/8020 Issue 1
Selector Shaft and Forks


For assembly, the sequence should be reversed.
When Dismantling
Note the positions of forks 2, 3 and 4 relative to keys 1 and

7.
(The rear slots A are not used.)
Hold the assembly by the selector block 6 and withdraw key

1 from the rear. Remove forks 2, 3 and 4.
Remove bolt 5 and separate the selector block 6 from the

shaft 8.
When Assembling
If re-using bolt 5 apply JCB Retainer (High Strength). (New

bolts are supplied ready coated with a patch of retaining
compound.)

*5 35-39 3.6 - 4.0 25-29
9803/8020 Issue 2*
30 - 1 Range Box 30 - 1

Removal (with cab in place)
1 Remove the cab floor mat. Take care when lifting the
mat over the gear levers. Remove the floor hatch.
2 Jack up the vehicle and place suitable axle stands in

position under the rear axle which are capable of taking
full weight of the machine.
3 Disconnect and remove the main drive shaft and front

4WD drive shaft (see Propshafts).
4 Drain the oil from the range box using a suitable S194430
container to collect. Note that the range box and PTO
box and speed box are interconnected. These
gearboxes will also drain.
5 Remove the speedometer pickup (see items 17 - 19

under Range box, Removing and Replacing Front
Casing).
6 Remove the pressure supply pipe to 4WD clutches and

the return-to-tank pipe from the hydraulic circuit. Seal
the pipes to limit loss of fluid.
7 Remove the parking brake caliper (see Section G).
8 Remove the rear detachable chassis cross-member

(see Gearbox Assembly, Removal & Replacement.)
9 Remove the brake disc (see Range Box/Front Casing,

Removing and Replacing) and disconnect the gear
linkage to the gear lever.
10 Support the range box on a trolley jack.
11 Remove the range box securing bolts (items C under

Gearbox Assembly, Dismantling and Assembly).
12 The range box can now be moved back to clear the

helical gear on the speed box, (i.e. speed box output
gear). Care should be taken not to damage this gear
and it should be covered for protection while working.
13 Lower the range box to the ground and drag clear of

the machine on the trolley jack if necessary.
Replacement
Replacement is the reversal of the removal procedure.

Tighten the bolts to settings for 8.8 grade given in Section 1.
* No gaskets are used. Seal the flange between the speed
box and range box with Loctite 509. Fill the gearboxes with the correct oil (see Lubricants and
Ensure that the correct restrictor/adapter A is fitted to the
lubrication pipe as shown. The locating tab B MUST point
towards the rear of the machine.
Ensure that rear cover plate D is fitted with the word TOP
facing outward and at the highest point. The correct
restrictor/adapter must be fitted at E .
9803/8020 Issue 2*
31 - 1 Range Box 31 - 1

For clarity, complete dismantling and assembly of the range
box has been split into five stages, each with its relevant
illustration. These stages are:
1 Removing/replacing the front casing.
2 Removing/replacing the clutch and gear assemblies.
3 Dismantling/assembling the 4WD clutch.
4 Dismantling/assembling the input shaft.
5 Dismantling/assembling the output shaft.
To completely dismantle the range box, stages 1 - 5 should

be followed in sequence.
For assembly reverse the sequence.
9803/8020 Issue 1
31 - 2 Range Box 31 - 2
9803/8020 Issue 2*
31 - 3 Range Box 31 - 3
Front Casing - Removing and Replacing 3 Fit new plastic patch screws 33 and torque tighten to
56 Nm (41.3 lbf ft, 5.7 kgf m).
Removing
4 Fit bearing retainer 31 and secure with screw 30.
* Note: On later machines, graded spacers without shims are
fitted instead of the standard size spacers 6, 12 and 28 with *5 Measure and note the total thickness then refit the
shim packs 7, 13 and 29. The graded spacers can also be original spacer 28 and shim(s) 29, if fitted (see Note at
used to replace shims and spacers on earlier machines. top of column 1). Measure the end float on the 4WD
shaft which should be between -0.02 mm and +0.03.
1 Remove nut 1 and washer 2 from the output shaft. Change shims or spacers to give a result in this range.
Discard stake nut 1. Fit circlip 27.
2 Remove brake disc 3 and oil seal 4. Discard oil seal 4. * Example:
3 Remove circlip 5, spacer 6 and shim pack 7 (if fitted). End float measured 0.155 mm
Make a note the size of the shim pack and/or spacer
Add total thickness of original spacer
(see Note above).
and shim (if fitted) 4.150 mm
4 If caliper mounting bracket 9 is damaged, or it is Result 4.305 mm
necessary to replace the caliper wear bushes (if fitted, Subtract ideal end float 0.005 mm
see Range Box, Replacing Brake Caliper Wear Thickness of new spacer 4.300 mm
Bushes), remove by unscrewing five Verbus Ripp bolts (or spacer plus shim)
8.
6 Lubricate the lips of the new seal 26 with JCB HP
5 Remove input shaft end plate 11 by removing four bolts Grease. Fit the new seal into the housing, taking care
10. Note the position of the pipe mounting bracket not to distort it. Ensure that the seal is square and
retained by one of the bolts 10. pushed fully home.
*6 Remove spacer 12 and shim pack 13 (if fitted). Make a 7 Before fitting the yoke 25, check that the bearing end of
note the size of the shim pack and/or spacer (see Note the yoke is not fretted and renew the yoke if required.
above). Clean any oil from the splines of the yoke and the
shaft. Run an even 2 mm diameter bead of JCB
*7 Remove cover 15 by removing screws 14. Discard the
end 'O' ring. Threadlocker and Sealer around the outer end of the
shaft spline.
8 Remove the turret assembly (see Range Box, Turret
Assembly). 8 Tighten new stake nut 23 to 350 Nm (258 lbf ft, 35.7 kgf
m) whilst rotating the shaft to bed-in the bearings.
9 Remove the reverse switch 16. Stake the nut axially using a square ended staking tool.
10 Remove screw 17, speedometer transducer 18, ‘O’ ring *9 Fit original spacer 6 and shim(s) 7, if fitted (see Note at
19 and transducer holder 19A. top of column 1). Lock with circlip 5. Temporarily fit
brake disc 3, washer 2 and nut 1. Tighten the nut to
11 Remove screws 20 and elbow 21. Remove and discard 350 Nm (258 lbf ft, 35.7 kgf m) whilst rotating the disc
'O' ring 22. to bed-in the bearings. Do not stake the nut.
* 12 Turn the gear box on end so that it is sitting on its rear * 10 Measure the output shaft end float by levering through
casing 35. Chock in a vertical position or fit in a suitable the turret hole. Select spacer 6 and shim(s) 7 to give an
fixture. allowable tolerance of 0.03 mm to 0.08 mm in the same
way as for the 4WD shaft.
13 Hold 4WD output yoke 25 with tool part no. 892/00812.
Remove nut/washer 23. Discard the nut. 11 Remove the brake disc, pack the oil seal 4 with JCB HP
Grease and fit it into housing 35. Ensure that the seal is
14 Remove yoke 25, then remove and discard oil seal 26.
square and pushed fully home.
* 15 Remove circlip 27, spacer 28 and shim pack 29 (if
12 If previously removed, refit caliper mounting bracket 9
fitted). Make a note the size of the shim pack and/or
with new Verbus Ripp bolts 8. Torque tighten to 180
spacer (see Note above).
Nm (133 lbf ft, 18.4 kgf m).
16 Remove screw 30 and bearing retainer 31. * 13 Remove the end plate 11 (fitted during clutch and gear
assembly - see Range Box, Clutch and Gear
17 Remove the dipstick tube 32 together with its gland
Assemblies, Replacing) and spacer 12 from the input
and nut.
shaft.
18 Remove and discard plastic patch screws 33 and lift off
the front casing 34. * 14 Fit original shim(s) 13, (if fitted) and spacer 12 (see Note
at top of column 1, then fit the dummy end plate (see
Service Tools), using a new gasket.
Replacing
* 15 By levering the input gears through the turret hole,
1 Apply JCB High Strength Threadlocker to the mating measure the end float by means of a dial gauge
flange face of gear box rear casing 35. through the dummy end plate. Select spacer and
shim(s) to give an allowable tolerance of 0.03 mm to
2 Fit the gear box front case 34. 0.08 mm in the same way as for the 4WD shaft.
9803/8020 Issue 5*
31 - 4 Range Box 31 - 4
Front Casing - Removing and Replacing

(continued)
* 16 Fit plate 11, with the word TOP visible and uppermost 21 Fit the elbow 21 with a new 'O' ring 22 and set screws
using the same new gasket as in step 14. Fit the pipe 20. Torque tighten to 28 Nm (20 lbf ft, 2.8 kgf m).
mounting bracket and tighten bolts 10 to 56 Nm (41.3
lbf ft, 5.7 kgf m). 22 Fit the dipstick tube 32, with its gland and nut.
17 After fitting bolts X into brake disc 3, fit the disc, 23 Fit a new ‘O’ ring 19 into speedometer transducer
washer 2 and nut 1. Torque tighten to 400 Nm (295 lbf holder 19A. Coat the holder 19A with JCB Threadlocker
ft, 40.8 kgf m). Stake the nut axially using a square and Sealer and push into casing 33. Insert
ended staking tool. speedometer sender 18 into holder 19A and secure
18 Install the turret assembly (see Range Gearbox, Turret with bolt 17.
Assembly).
24 Fit the lubrication restrictor/adapter (see item A under
19 Fit the reverse switch 16. Fit the 4WD cover 15 using a Range Box, Removal and Replacement).
new 'O' ring. Torque tighten screws 14 to 56 Nm (41.3
lbf ft, 5.7 kgf m).
20 Fit drain plug 36, together with its bonded washer.
Torque tighten to 102 Nm (75.2 lbf ft, 10.4 kgf m).
Replacing Brake Caliper Wear Bushes

A parking brake bracket with replaceable wear bushes has
been introduced. The new bracket, complete with bushes, B
can be fitted to older machines but the new wear bushes
cannot be fitted into an old bracket.
99/12-1
1 Remove the parking brake caliper and disc as detailed
in the service manual. Then remove the bracket.
2 Remove and replace bushes B using a suitable nut, and

bolt with appropriate spacers.
3 Use a brake pad locating pin to make sure that bushes

are aligned correctly. File the bush or adjust the bracket
as required.
4 Fit the new bracket assembly A to the range box cover

and torque tighten to 180 Nm (133 lbf ft, 18.4 kgf m).
Refit disc and caliper.
A 99/12-2
5 Adjust parking brake and test.
99/12-3
9803/8020 Issue 5*
31 - 4A Range Box 31 - 4A
Turret Assembly
Dismantling and Assembly Assembly
Dismantling Note: Lightly oil all parts before assembly.
1 After removing the turret assembly from the range box, 1 Fit gear shift lever 8 to the housing 9 and secure with
by unscrewing bolts X, discard the gasket 1. pin 7 (do not fully tighten).
2 Remove clips 2, 3 and gaiter 4. Examine the gaiter for 2 Fit retainer 6 to the spring 5, fit over the gear shift lever
splits, particularly at the folds. Renew if necessary. 8.
3 Wind out the spring 5 from the housing. Remove the 3 Wind spring 5 into the housing 9 (compressing the
spring retainer 6. spring at the same time), until the last turn is held by
the two tabs A in the base of the housing. Ensure that
4 Remove pin 7 and withdraw gear shift lever 8. the retainer is seated correctly on the lever 8.
4 Tighten pin 7 fully and check for free movement of the

gear shift lever.
5 Fit gaiter 4 and secure with clips 2, 3.
When replacing the turret assembly on the range box, use a

new gasket 1 and tighten screws X to 56 Nm (43 lbf ft, 5.7
kgf m).
160270
9803/8020 Issue 1
31 - 5 Range Box 31 - 5
9803/8020 Issue 3*
31 - 6 Range Box 31 - 6
Clutch and Gear Assemblies

Removing and Replacing
Removing
1 Lift out the 4WD clutch pack 1.
2 Remove the two ball and spring detent assemblies 2, 3,

4.
3 Slacken off the three locking screws 5, then lift out

selector shafts 6, 7. Retrieve the two selector forks 8, 9
and selector block 10.
4 Remove baulk roller 11, using a hooked piece of wire

as shown in diagram A to catch the roller while pushing
it from its recess with a thin screwdriver or bent piece
of wire. (Plug 12 can be removed to give improved
access to the roller if necessary.)
5 Hold the output shaft assembly 14 away from the input

shaft assembly 13.
6 Remove the input shaft assembly 13.
7 Remove the output shaft assembly 14.
* 8 Reverse idler gear removal. Later machines (typically

those with a wet master clutch) feature a revised idler
gear shaft configuration as shown at A. The early shaft
configuration is shown at B.
Procedure for configuration A:

Remove the circlip 20 followed by cap 21. Undo the
capscrew 22. Withdraw the idler gear shaft 23. Remove
the gear 17.
Procedure for configuration B:

Undo the capscrew 15 and withdraw the idler gear
shaft 16. Remove the gear 17.
9 Remove bearings 18 and spacer 19 from the idler gear

17.
* 10 Remove the input and output shaft bearing cups from

the housing. There is no need to remove the dowels 25
unless the housing is to be renewed.
9803/8020 Issue 2*
31 - 6A Range Box 31 - 6A
9803/8020 Issue 1
31 - 6B Range Box 31 - 6B
Replacing
Note: Lightly oil all bearings before fitting. make sure that all 10 Install the second ball 4, spring 3 and plug 2. Torque
oil ways are clear. tighten plug 2 to 24 Nm (18 lbf ft, 2.5 kgf m).
1 Fit bearings 18 into each side of the reverse idler gear 11 Install the 4WD clutch pack 1.
17, with centre spacer 19 between them. Select spacer
19 as follows: first select a trial spacer (from spacer kit 12 Install dowels 25.
921/51100) which will give an end float on the gear of
0-0.03 mm (0-0.001 in); then select and fit the next
spacer down in size so that a small pre-load is applied C
to the bearings. Before fitting into the gearbox, lightly
clamp the assembly in a vice and check that the gear
will rotate freely. Locate the gear assembly in the
housing.
*2 Reverse idle gear shaft configuration A:

Push shaft 23 through the housing and gear assembly.
Make sure that the dowel pin X locates in the
corresponding hole in the housing, rotate the shaft until
the pin locates. Push the shaft fully into the housing.
Apply JCB Threadseal to screw 22. Torque tighten to
75 Nm (55 lb ft, 7.6 kgf m) to lock the shaft into
position. Fit cap 21 and circlip 20.
* Reverse idle gear shaft configuration B:

Push shaft 16 through the housing and gear assembly
Apply JCB Threadseal to cap screw 15. Pull the shaft
into position using the screw. Torque tighten to 75 Nm
(55 lbf ft, 7.6 kgf m).
3 See Range Box, Front Casing - Removing and
Replacing illustration for item numbers for this step. Fit
the input shaft end plate (11) to the casing and circlip
(5) to output shaft aperture. Fit spacer (12) behind the
end plate (11), and spacer (7) behind circlip (5).
4 Fit new shaft bearing cups for the input and output
shafts into their housings in the case. Install the output
shaft assembly 14.
5 While tilting the output shaft assembly to one side,
lower the input shaft 13 into position.
*6 Install selector shaft 7, complete with its selector fork 9.
Lock the fork in position with screw 5, after treating
with JCB Threadlocker and Sealer, tightened to 35 Nm
(26 lbf ft, 3.6 kgfm).
7 Install the corresponding detent ball 4 and spring 3,
lock up with plug 2 and torque tighten to 24 Nm (18 lbf
ft, 2.5 kgf m).
8 Install baulk roller 11 using a hooked piece of wire to
position and a thin screwdriver (see diagram C). A
smear of grease will hold the roller in position. (If plug
12 was removed, treat it with JCB Threadlocker and
Sealer then refit it.)
9 Install selector shaft 6, together with selector block 10
and selector fork 8. Lock the block and fork in position
with screws 5, after treating with JCB Threadlocker and
Sealer.
9803/8020 Issue 2*
31 - 7 Range Box 31 - 7
S187923
9803/8020 Issue 2*
31 - 8 Range Box 31 - 8
Heavy Duty 4-Wheel Drive Clutch

Dismantling 3 Fit the actuating sleeve 14/anti-rotation pin 14A.
Note: Before dismantling check the pressure required to 4 Install the clutch drum 13 into the actuating sleeve,
release the clutch (see 4-Wheel Drive Clutch, Pressure taking care to engage the anti-rotation pins. Fit the drum
Testing). Make a note of the reading. thrust washer 12 and circlip 11.
Note: Because the clutch friction plates 10 are lined with a
! WARNING paper type material they must be soaked in gearbox oil for
Always wear safety glasses when dismantling as long as possible before assembly.
assemblies containing components under pressure from
springs. This will protect against eye injury from 5 Build up the clutch pack starting with a counter plate 9.
components accidentally flying out. Counter plates 9 and friction plates 10 are fitted
GEN 6-2 alternately. There are twelve friction plates and twelve
counter plates plus an additional counter plate and/or a
1 Place the clutch pack in a vice with the gear uppermost. shim next to pressure plate 8.
2 Remove bearing 1, thrust washer 2 and piston ring 3. 6 Install the pressure plate 8. If a shim and/or additional
plate was previously fitted next to pressure plate 8, this
3 Pull off the output gear 4 together with the two needle
must be fitted when re-assembling.
bearings 5.
7 Use the gear to align the clutch plate splines.
4 Compress the disc springs 7 using a suitable press.
Remove circlip 6. 8 Place the first two disc springs 7 with their concave
sides facing pressure plate 8. (There are four identical
! CAUTION disc springs; install them as shown at A.)
The spring force is in excess of 22240 N (5000 lbf, 2270 9 Place the other two disc springs, with their convex sides
kgf). Proceed carefully. facing pressure plate 8 as shown at A.
TRAN 8-3/1
10 Using a suitable press and tool, compress the disc
5 Remove the springs 7. springs and fit the circlip 6.
6 Remove the pressure plate 8 and the clutch plates,
comprising counter plates 9 and friction plates 10. ! CAUTION
The spring force is in excess of 22240 N (5000 lbf, 2270
Note: Store the counter plates and friction plates as a set.
kgf). Proceed carefully.
They should NOT be mixed with the plates of other clutches TRAN 8-3/1
If a shim plate is fitted between the end counter plate and
pressure plate 8 or instead of the end counter plate, this 11 Ensure that the piston is fully back and check that sleeve
must be retained for use when re-assembling. 14 has some end-float. If required, fit an additional shim
plate or counter plate next to pressure plate 8. Check
7 Remove the circlip 11 and the thrust washer 12. that the clutch plate splines are still aligned (see Step 7).
8 Lift off the clutch drum 13 . Note: Before assembling further, check that the clutch
releases at the correct pressure (see 4-Wheel Drive Clutch,
9 Remove the actuating sleeve 14 , complete with anti-
Pressure Testing).
rotation pins 14A.
* 12 Lightly oil and fit needle roller bearings 5 to the 4WD
10 Remove the piston 15 with liner 16.
output gear 4 (see Needle Bearings, Checking for
11 Remove and discard 'O' rings 17 and 18 from the piston Damage or Distortion). Fit the 4WD output gear.
15. Note: Always fit the needle roller bearings with the
Note: Do not remove the piston housing 19 from the shaft manufacturer's marks outermost. Never apply force to the
20 unless it is damaged. It is a press fit onto the shaft. unmarked faces of these bearings.
13 Fit the bearing thrust washer 2.
12 Remove bearing 21.
14 Oil and fit bearing 1.
13 Check all clutch parts for abnormal or excessive wear
and renew where necessary. 15 Carefully fit a new shaft piston ring 3 (see separate page
on PTFE Piston Ring Seals).
Assembling 16 Oil and fit bearing 21.
1 Fit new 'O' rings 17 and 18 to the piston 15. Note: If the shaft bearings have been renewed, ensure that
their bearing cups in the range box front and rear casings
2 If the piston housing 19 has been removed, grease the are also renewed.
shaft 20. Support the piston housing as near to the
centre as possible and press the shaft squarely into the
housing. Locate the piston 15 into the housing 19. Fit the
liner 16.
9803/8020 Issue 2*
31 - 9 Range Box 31 - 9
PTFE Piston Ring Seals
Fitting Procedure
1 Wind the PTFE seal around your finger as shown, so that

the seal forms a 'coil'.
157250
2 Smear the seal with grease and then fit the seal to the
shaft.
Make sure that the seal sits below or flush with the outer
diameter of the shaft. If necessary, use finger pressure as
shown to make the seal flush with the shaft.
CAUTION: If the seal is not set below or flush with the outer
diameter of the shaft, then the seal will be cut when the shaft
is fitted to its mating component.
157260
9803/8020 Issue 1
31 - 10 Range Box 31 - 10
Pressure Testing - 4-Wheel Drive Clutch

1 Assemble the clutch (see 4-Wheel Drive Clutch -
Dismantling and Assembly).
2 Insert the pressure test adaptor A into the oil gallery in

the end of the clutch shaft and secure with special
B
clamp B which engages in the shaft seal ring groove.
3 Connect a hand pump incorporating a 0 - 20 bar (0 - A

300 lbf/in2) pressure gauge.
4 Using the hand pump, pressurise the clutch assembly

until gear C can be turned by hand, also note the
pressure gauge reading
CAUTION: Do not exceed 13.8 bar (200 lbf/in2) when

testing the 2/4 wheel drive clutch. It may damage the
clutch. All necessary safety procedures should be
observed when testing components under pressure.
*5 Before pressure testing this clutch, when the piston is

fully back, the actuating sleeve D must have some end-
float. After the first application and release of hydraulic
pressure it must be possible for the sleeve to be rotated
using firm hand pressure, within the limits imposed by
anti-rotation pins.
After rebuilding the clutch with new disc springs and

plates, the pressure required initially to allow the gear
to turn by hand will be 11.8 - 13.1 bar (170 - 190
lbf/in2). After several applications of pressure or after a
period of service, it is acceptable for the gauge reading
to be lower but it must not exceed the figure quoted
above. S185720
*6 If the gauge reading is above the maximum pressure

given above, or excessively low, re-check the clutch for
assembly defects and correct shim thickness. Re-test
after checking for (and rectifying) assembly defects.
Note: The pressures quoted above are the clutch release

pressures when the clutch is out of the machine. If the
2/4WD clutch is installed in the machine and a pressure
gauge attached to the clutch circuit, the pressure shown on
the gauge will be the same as the transmission system
pressure (this is higher than the 'release' pressure). D
C
S185730
9803/8020 Issue 2*
31 - 11 Range Box 31 - 11
Input Shaft
Dismantling
1 Place the assembly in a vice and remove bearing 1. Note 2: The latest design of synchro hub 9/synchro flanges
15, 16 can be used as replacements on all range box input
Note: If bearings 1 and 4 are an interference fit, remove as shafts. However, due to a change in the synchro cone angle,
follows. Take off the rollers and cage and carefully apply a these parts must always be renewed as a set to avoid the
ring of weld to the bearing inner race whilst shielding the possibility of mixing the old and new designs.
shaft from weld spatter. After cooling, the race will be easy
to drive off. Alternatively, the bearing race can be split off 1 Place the shaft 13 in a vice, with splined end facing
using a chisel. upwards.
2 Place the assembly on a press with bearing 4 facing
2 Fit two needle roller bearings 11 together with spacer 12.
upwards.
Secure synchro cone 15 to gear 10 with circlip 17. Fit the
Note: The assembly must be supported by gear 10 so that assembly to shaft 13.
the shaft protrudes downwards through the base-plate of
the press. 3 Fit synchro hub assembly 9.
3 Remove bolt 2 and bearing retaining plate 3 followed by 4 Press sleeve 14 onto the shaft.
bearing 4.
5 Fit two needle roller bearings 7 together with spacer 8.
4 Press the shaft out of the gears and bearings.
6 Secure synchro 16 to gear 6 with circlip 18, if
5 To separate synchro cones 15 and 16 from gears 10 and appropriate.
6, remove circlips 17 and 18.
Note: If bearings 1 and 4 are an interference fit, expand
6 Inspect the synchromesh components for wear or before fitting by heating in oil, or with a heat gun, to 100-
damage (see Inspection Prior to Assembly). 110°C. Do not exceed this temperature or the bearings will
Assembly be damaged.
Note 1: See Range Box, Synchromesh Assembly (on a *7 Fit the input gear 5 and taper roller bearing 4. Secure
separate page) for assembly instructions concerning items bearing 4 to the shaft using retaining plate 3 and bolt 2,
9, 15 and 16. Always renew the main bearings 1 and 4. (the threads coated with JCB Threadlocker and Sealer)
Ensure that their bearing cups in the range box front and tightened to a torque of 85 Nm (63 lbf ft, 8.7 kgf m).
rear casings are also renewed. Always renew the needle 8 Reverse the shaft in the vice and fit bearing 1.
roller bearings 7 and 11. Lightly oil all bearings before fitting.
See also Needle Roller Bearings, Checking for Damage
or Distortion.
9803/8020 Issue 5*
31 - 12 Range Box 31 - 12
Output Shaft
Dismantling
1 Place the assembly in a vice and remove bearing 1. Note 2: The latest design of synchro hub s/synchro flanges
13, 14 can be used as replacements on all range box output
Note: If bearings 1 and 2 are an interference fit, remove as shafts. However, due to change of cone angle, these parts
follows. Take off the rollers and cage and carefully apply a must always be renewed as a set to avoid the possibility of
ring of weld to the bearing inner race whilst shielding the mixing the old and new designs.
shaft from weld spatter. After cooling, the race will be easy
to drive off. Alternatively, the bearing race can be split off 1 Place the output shaft 10 in a vice with the threaded end
using a chisel. facing upwards.
2 Place the assembly on a press with bearing 2 facing 2 Fit two needle roller bearings 8 together with spacer 9.
upwards. Secure synchro cone 13 to gear 7 with circlip 15. Fit the
Note: The assembly must be supported by gear 7 so that the assembly to shaft 10.
shaft protrudes downwards through the base-plate of the 3 Fit synchro hub assembly 6.
press.
4 Press sleeve 11 onto the shaft.
3 Press the shaft out of the gears and bearings.
5 Fit two needle roller bearings 4 above the synchro
4 To separate synchro cones 13 and 14 from gears 7 and assembly. (Note that unlike those fitted in Step 2 there is
3, remove circlips 15 and 16. no spacer between these bearings).
5 Inspect the synchromesh components for wear or 6 Secure synchro cone 14 to gear 3 with circlip 16, if
damage (see Inspection Prior to Assembly). appropriate. Fit the assembly to shaft 10.
Assembly Note: If bearings 1 and 2 are an interference fit, expand
before fitting by heating in oil, or with a heat gun, to 100-110
Note 1: See Range Box, Synchromesh Assembly (on a
°C. Do not exceed this temperature or the bearings will be
separate page) for assembly instructions concerning items 6,
damaged.
13 and 14. Always renew the main bearings 1 and 2. Ensure
that their bearing cups in the range box front and rear 7 Fit thrust washer 5 on top of gear 3. Press taper roller
casings are also renewed. Always renew the needle roller bearing 2 onto the shaft after packing bearing 2 with JCB
* bearings 4 and 8. Lightly oil all bearings before fitting. See HP Grease.
also Needle Roller Bearings, Checking for Damage or
Distortion. 8 Reverse the shaft 10 in the vice and press on taper roller
bearing 1.
S201381
9803/8020 Issue 3*
31 - 13 Range Box 31 - 13
Synchromesh Assembly
Inspection Prior to Assembly
Check the fit of each synchro flange to its synchro hub (for
example items 16 (or 15) and 9 respectively on the input
shaft). Place the flange 16 onto its mating hub 9 and while
holding the two firmly together, measure the clearance
between the two using feeler gauges at several points
around the circumference as shown. Repeat for synchro
flange 15. The clearance should be 0.5 to 1.9 mm. If the
clearance in either check is outside the limits quoted renew
all three parts.
Note: The latest design of synchro hub/synchro flanges can

be used as replacements in all range boxes. However, due
to a change of cone angle, these parts must always be 161651
renewed as a set to avoid the possibility of mixing the old
and new designs.
Renew components if any of the following defects are

present:
Housings worn as a result of spinning outer bearing

races.
Damaged bearings.
Pitting or excessive wear on gears, hub and faces or

bearing bores.
Wear, pitting or overheating damage on bearing

sleeves.
Excessive wear or chipping on dog teeth or splines of

synchro hubs, sleeves or shafts.
Wear, chipping or overheating damage on teeth or

cones of synchro rings.
Worn or scored thrust washers.
Assembling the Synchro Hub and Sleeve
1 Insert the three springs D and plungers E into the holes

in the synchro hub F.
2 Support the sleeve G so that the internal groove H is

just above the hub. Position the three rollers J as
shown in the inset, resting on the heads of the
plungers. Press firmly down on the sleeve, compressing
the springs and centralising the sleeve in the neutral
position.
3 Fit a synchro ring K on each side of the hub and sleeve

assembly.
S201370
9803/8020 Issue 2*
32 - 1 Needle Roller Bearings 32 - 1
Checking For Damage or Distortion

When installing new needle roller bearings, or inspecting
needle roller bearings during a repair, it is recommended
that the following checks should be made in addition to
checking the needles for damage, pitting, etc.
Check that the needle bearing assembly A will slide freely

through the bore of the gear B.
If the bearing will not slide freely through the bore, this
indicates that the bearing cage is distorted.
Always fit a new bearing if in doubt.

B
Do not attempt to straighten a distorted bearing cage on A
either a new or used bearing. Fit a new bearing. This will
prevent possible bearing cage failures.
99/32-1
9803/8020 Issue 1
35 - 1 Propshafts 35 - 1

There are three types of propshaft coupling, two of which, Replacement
flange coupled types A/B/C and type D are illustrated
opposite. The third, type E, is described below. Also Lay each propshaft on a flat surface to check that both ends
illustrated opposite are propshaft layouts showing the type are exactly on the same plane, as shown at X. The yokes
of coupling at each location for different machines. must not be at right-angles (as at Y) or at an intermediate
angle (as at Z). If necessary, separate the two halves of the
Removal shaft and re-align.
! WARNING Replacement is basically the reverse of the removal
Make the machine safe before getting beneath it. Do the procedure but ensure match-marks are aligned (see Step 1
following: Park on level ground. Engage the parking in Removal).
Stop the engine, remove the starter key, disconnect the Note: Verbus Ripp bolts 9, illustrated below, must never be
battery. Chock the wheels. re-used. When the propshaft has been disconnected, fit new
13-3-1-1
bolts when re-connecting.
Note: Before separating any of the drive shaft couplings
(flange plates, universal joints, splined shafts), mark both
halves to ensure correct positioning on reassembly.
Coupling Type A
1 Remove nuts 1 from studs 2.

A343780
2 Retract flange 3 by telescoping the shaft and then
lower clear of its mating flange.
On Type D couplings, lightly grease the insides of straps 14
Coupling Type B before assembly and use new bolts 12 and washers 13.
3 Remove nuts 5/bolts 6 and separate driveshaft flange 7 Tighten the nuts according to the table below.
from the gearbox front flange (or axle flange) 8 as
appropriate. Torque Settings

Coupling Type C
4 Remove and discard Verbus Ripp bolts 9. Separate 1 75 - 85 7.65 - 8.7 55.3 - 62.7
drive shaft 10 from axle flange 11. 5 75 - 85 7.65 - 8.7 55.3 - 62.7
9 75 - 85 7.65 - 8.7 55.3 - 62.7
5 Remove the rear driveshaft by lowering to the ground. 12 75 - 85 7.65 - 8.7 55.3 - 62.7
Remove the front driveshaft by withdrawing it from the
driveshaft protective bracket. * Dacromet (colour: mottled silver)
Coupling Type D Item Nm kgf m lbf ft

1 120 12.24 88.5
6 Remove bolts 12, washers 13 and straps 14. 5 62.5 6.38 46.1
9 62.5 6.38 46.1
7 Lower the end of the shaft clear of yoke 15. Dacromet (colour: mottled silver) 3155 and 3185 only
Coupling Type E (not illustrated) Item Nm kgf m lbf ft
5 80 8.16 59
8 This has a yoke end with sliding splines. After 9 62.5 6.38 46.1
disconnecting the other end of the shaft, slide the
splined yoke off the mating shaft. On Type E, grease the splines before fitting.
Note: The rear PTO propshaft must be fitted with the sliding
joint at the axle end to prevent the possibility of fouling when
the limit of suspension travel is reached.
Thoroughly purge all universal joints with grease. If any

bearing fails to purge, move the shaft from side to side and
then purge. This allows greater clearance on the thrust end
of the bearing that is not purging. Wipe away any excess
grease.
9803/8020 Issue 4*
X
D D
E D
B B Y
B A
A290601
* Fastrac 2115, 2125

Z
*
D D
E D A306260
*
B
C C
B A
7
A290601
* Fastrac 2135, 2150, 3155, 3185
5
*
A 8
4
3
2 6 A343820
*
D
1
A302390
*
C
10
11
9 A343810
9803/8020 Issue 3*
C B B B
A A A A
A290610
B
B
9803/8020 Issue 2*
Dismantling
Note: The complete procedure below is for couplings type A 9 Start inserting one of the bearings 4 by hand into one of
and C. For type B couplings, follow steps 1 to 3 only. the bores in flange yoke 3. Put the flange yoke in the
vice. Tighten the vice until the inner end of bearing 4 is
1 Remove the two bearing retainer circlips 1 from flush with the inner edge of the bore in the flange yoke.
driveshaft yoke 6. Put driveshaft yoke 6 in a vice with a
socket on each side of the bearings 2. One socket must 10 Remove flange yoke 3 from the vice. Fit cross 5 into the
have an OD which will fit into the bore of the driveshaft flange yoke.
yoke. The other socket must have an ID larger than the
bore of the driveshaft yoke so that bearing 2 can enter 11 Start inserting the other bearing 4 into the flange yoke
the socket. Tighten the vice to push out bearing 2 as far by hand, until it locates onto the end of the cross.
as possible. Stop tightening when the shoulder of cross
5 is in contact with driveshaft yoke 6. 12 Put the flange yoke in the vice with a socket of the
correct size against bearing 4 (see view below). Tighten
2 Remove the driveshaft from the vice and use pliers to the vice until the outer end of the bearing is just past
remove the bearing completely. the circlip groove in the bore of the yoke. Remove the
yoke from the vice.
3 Manoeuvre driveshaft yoke 6 from the cross.
13 Repeat Step 12 for the other bearing.
4 Remove the two circlips 1 from flange yoke 3. Place
flange yoke 3 in the vice using the correct sockets as in 14 Fit circlips 1.
Step 1 above. Tighten the vice to push out bearing 4 as
far as possible. Stop tightening when the shoulder of
cross 5 is in contact with flange yoke 3.
5 Remove flange yoke 3 from the vice. Use pliers to

remove the bearing completely.
6 Remove the cross 5 from flange yoke 3.
Assembly
Note: The complete procedure below is for couplings type A

and C. For type B couplings, follow steps 1 to 7 only.
1 Remove bearings 4 from two opposite ends of the new

cross 5. Ensure that the needle roller cages do not fall
from the bearings.
2 Start inserting one of the bearings 2 by hand into one of

the bores in driveshaft yoke 6. Put the driveshaft yoke
in the vice. Tighten the vice until the inner end of the
bearing is flush with the inner edge of the bore in the
driveshaft yoke.
3 Remove driveshaft yoke 6 from the vice. Fit the

driveshaft yoke onto cross 5.
4 Start inserting the other bearing 2 by hand into

driveshaft yoke 6 and onto the end of the cross.
5 Put the driveshaft yoke into the vice with a socket of

the correct size against bearing 2 (see view right).
Tighten the vice until the outer end of the bearing is just
inside the circlip groove in the bore on the driveshaft
yoke. Remove the yoke from the vice.
6 Repeat Step 5 for the other bearing.
7 Fit circlips 1.
8 Remove the two bearings 4 from cross 5. Ensure that

the needle bearings do not fall from the bearings.
9803/8020 Issue 1
51 - 1 Front Axle 51 - 1
C
F
K B
G
E
B H
D
L
M J D
A
A290731
9803/8020 Issue 2*
51 - 2 Front Axle 51 - 2

Note: The illustration shows the arrangement on Fastrac 8 Remove the shock absorbers E.
2115, 2125 and 2135 machines. Fastrac 2150 machines are
basically the same but with some detail variations. Fastrac 9 Disconnect the 4WD shaft at F.
3000 Series machines are similar but without the twin
steering rams which are replaced by a steering box, drop 10 Remove Panhard rod G at the axle end, using a suitable
arm and drag link (see Steering System Description ball joint splitter. Tie up the rod clear of the axle.
(Fastrac 3000 Series) Section H).
! CAUTION
Removal
Do not hammer the cast iron lugs on the axle as this will
! WARNING cause weakness and may lead to steering failure.
Make the machine safe before getting beneath it. Do the AXL 8-2

brake. Lower the equipment to the ground. Stop the 11 Completely remove anti-roll bar L assembly by
engine, remove the starter key, disconnect the battery. disconnecting at the two axle mounting points and the
Chock the wheels. two chassis mounting points.
13-3-1-1/1
12 Lower the jack A until springs H are fully extended.

! CAUTION
Take care when lifting/handling this equipment. Use only 13 Lever the springs so that they are not jammed on axle
proofed and serviceable lifting equipment strong enough spigots J.
for the jobs.
SUS 1-5
! CAUTION
1 Remove the four nuts M on each side of the machine Keep your hands clear of the springs until they have
and remove the two fender assemblies. been released and are no longer under load or you may
trap your fingers.
SUS 1-4
2 Loosen the front roadwheel retaining nuts.
14 With the axle still supported by the jack, disconnect the
3 Position a jack A under the axle and jack the machine three control arms K from the axle (see Front
just far enough to install axle stands B (see Step 4). Suspension, Control Arm A in Section S). Tie up the
control arms to prevent them hanging on the ground.
4 Position axle stands B (which should be capable of The axle is now free and can be pulled forwards with
taking the full weight of the machine) on either side of trolley jacks.
the chassis. Lower the jack until the body rests on the
axle stands, but make sure it still supports the weight of Replacement
the axle.
Note: An alternative is to hoist the whole of the front of the Ensure that the chassis is correctly supported as in
machine (if suitable equipment is available) and then insert Removal Step 4.
axle stands. Position a jack beneath the axle and raise it to
take the axle weight. When refitting the fender assemblies tighten nuts M to a
torque of 158 Nm (116 lbf ft, 16 kgf m).
5 Remove the road wheels and drain oil from hubs and
axle. On completion, fill the axle with the correct oil (see Section
3).
* 5a ABS Machines only
Disconnect the axle mounted speed sensor flying leads, See the relevant Removal and Replacement pages for
one at each hub, from their chassis mounted mating correct fitting procedures and torque settings of the
connectors. Tie the cable sheathing to the axle for following:
protection during the following procedure.
Shock absorbers E, Panhard rod G and control arms K
6 Fastrac 2000 Series (Section S); 4WD Propshaft (Section F).
a Remove brake pipes C and seal to prevent entry of Bleed the brakes (see Section G).
dirt.
b Disconnect the hydraulic hoses to steer rams D, On 4WS machines, if the steering sensors have been
making a note of their positions for re-assembly. disturbed or renewed, they must be calibrated (see Four-
c On 4WS machines only, disconnect the electrical wheel Steer (4WS), Sensors, Calibration in Section C).
lead to the top of the right side steering trunnion.
7 Fastrac 3000 series

Disconnect the steering drag link from the steering lug
on the right side hub.
9803/8020 Issue 5*
52 - 1 Front and Rear axles 52 - 1
Differential Oil Seal

This job can be done with the axle either removed or in situ
on the machine.
! WARNING
A raised and badly supported machine can fall on you.
Position the machine on a firm, level surface before

GEN 1-1
1 Remove the road wheels and uncouple the axle

driveshaft. Measure the axle rolling torque and record the
A302510
reading. Mark the relative positions of the pinion shaft
and nut with a scriber.
2 Drain the oil from the rear axle casing or front axle
*
differential casing as applicable (see Routine
Maintenance, Section 3). Using Service Tool 892/00812,
remove the coupling flange together with its stake nut.
3 Remove the seal and fit a new one. Take care not to
damage the housing when removing the old oil seal.
Lubricate the lips of the new seal with JCB HP Grease.
Fit the new seal into the housing, taking care not to
distort it. Ensure that the seal is square and pushed fully
home.
4 Install the old stake nut temporarily. Then, using a torque

wrench determine the torque required to align the scribed
lines (see step 1). Remove and discard the old stake nut.
*
5 Before fitting the flange, check that its bearing end is not
fretted and renew if required. Clean any oil from the
A302520
splines of the flange and the shaft. Run an even 2 mm
diameter bead of JCB Threadlocker and Sealer around
the outer end of the shaft spline.
*
6 Fit the coupling flange with a new stake nut.
a Using Service Tool 892/00812, tighten nut to 250Nm

(184 lbf ft, 25.5 kgf m).
b Measure the rolling torque. The reading should be 0.5
to 1 Nm (0.37 to 0.74 lbf ft, 0.05 to 0.1 kgf m) more
than that recorded in Step 1 (see Note).
c If necessary, progressively torque tighten nut to
achieve correct rolling torque.
Note: If the rolling torque figure (new pinion seal fitted)

exceeds the reading recorded in Step 1 by more than 1 Nm
(0.74 lbf ft, 0.1 kgf m), then the spacer mounted on the axle
pinion MUST be renewed.
d Stake the nut using a square ended staking tool.
7 Fill the axle or differential casing with the specified oil,

(see Routine Maintenance, Section 3).
9803/8020 Issue 2*
52 - 2 Front and Rear (4WS) Axle 52 - 2
23C
15
13 22B
22A 23A
16
22C
7
4
6 22F
5
6 22E
2 22D
22G
9 12
35 23
10 11
8
22
25
24 22H
26
3
40
41
23B
17 14
27
21 18
20
1 28
39
19
38
37
36
35 31 32
33 30
34 29
A303001
9803/8020 Issue 3
52 - 2A Front and Rear (4WS) Axle 52 - 2A
Hub and Driveshaft Note: If the hub swivel 14 and annulus carrier 13 are to be
re-used, the carrier must be assembled in the same angular
Dismantling position as that from which it was removed; match-mark the
hub swivel and carrier before removing the carrier. Fretting
1 Ensure that oil has been drained from the hubs and between the hub swivel 14 and the annulus carrier 13 mating
axle. Remove screws 1. faces might be evident; this condition is normal, do not
attempt to repair.
2 Use a ball joint splitter to separate the steering
connections from the lugs on the hub. Disconnect 10 Remove circlip 15 to separate the annulus ring 16 from
flexible brake pipe 22A and electrical connector 22B the annulus carrier 13.
(where fitted).
11 Remove the brake calipers (see Section G). On ABS
! CAUTION machines remove the ABS sensors (see Section G).
Note: Wheel Hub Service Kit 892/01092 (see Service Tools)
cause weakness and may lead to steering failure.
AXL 8-2
is required throughout steps 12 to 16.
3 Lever off the planet gear carrier 2 at the points provided. 12 Assemble the puller B, screwing the legs A onto two
Discard the 'O' ring 3 (if fitted). Lay the planet gear diametrically opposite wheel studs and placing reaction
carrier on a level, clean surface and examine the planet tube C over the driveshaft. On axles with five wheel
gears 4. Check planet gears for excessive side studs per hub, the modified wheel studs supplied in the
movement on the bearings. Compare with a new item if service kit must be fitted into the bolt holes for
in doubt as to the correct amount of side movement. If mounting planet carrier 2. Use two suitable 10 mm
any wear is found, the planet bearings and gears must bolts (longer than item 1) to secure the modified wheel
be renewed. studs and mount the puller legs A onto the studs.
Note: Some axles have three planet gears item 4 as shown Note: Reaction tube C, MUST be used, otherwise damage
opposite, others have four as shown below. to the driveshaft and drive shaft bearings will occur.
&
3
8
2
Y
4 4
C
A301130 A
4 Remove the planet gears 4 only if necessary. They can
D
only be renewed as an assembly comprising the pinion B
4, the bearing 5 and two circlips 6. To remove a planet
A439380
gear 4 first remove the external circlip 7 then pull off the
planet gear 4.
5 To remove driveshaft thrust pad 8, screw an M6 bolt 13 Screw in D slowly until the bearing carrier 17 together
into the hole provided. with the outer bearing cone 19 and its outer race are
released from the axle. If the bearing carrier starts to
6 Remove circlip 9 and slide sun gear 10 off the turn use a suitable bar Y to prevent further rotation.
driveshaft.
Note: If D becomes too hard to turn, tap the back of the hub
7 To remove the spacer 11 revolve the spacer with a with a plastic hammer to help release the bearing.
suitable drift until the holes in the spacer align with the
space between bolts 12. Using two dowels and two heel Note: If necessary, the brake disc 18 and bearing carrier 17
bars pull out the spacer 11. can be separated by removing bolts 27. If disc 18 is scored,
skimming is permissible but it must not reduce the thickness
8 Remove the M14 Verbus Ripp bolts 12 using heavy duty to less than the dimension given in Section G Technical
tools. These bolts will be very tight and will be less Data.
difficult to slacken if first tightened slightly.
9 See Note following. Using three bolts 12 as jacking

screws, remove the annulus carrier 13.
9803/8020 Issue 1
23C
15
13 22B
22A 23A
16
22C
7
4
6 22F
5
6 22E
2 22D
22G
9 12
35 23
10 11
8
22
25
24 22H
26
3
40
41
23B
17 14
27
21 18
20
1 28
39
19
38
37
36
35 31 32
33 30
34 29
A303001
9803/8020 Issue 5
Hub and Driveshaft - continued Note: The studs 23 or 23A and bolts 23C are alternatives
depending on the type of axle (see parts CD).
Dismantling - continued
18b Front and Rear Axles (right hubs on 4WS machines) -
14 Remove and discard the combination seal 21 by cutting Remove studs 23/23A and bolts 23C (if fitted) and
the outer seal with a sharp chisel and carefully knocking cover plate 22C. Mark the position of top trunnion 22D
the inner seal fully on to the stub axle, taking CARE not with respect to hub swivel 14. Remove the assembly
to damage the seal seat on the stub axle. comprising trunnion 22D, screws 22E and
potentiometer 22F (see Note below), followed by
spindle 22G. Check that the spindle is free of corrosion
and rotates freely in the trunnion. If necessary clean
with fine emery paper. Remove and discard O-ring 22H.
Retain shim pack 24 (if fitted). Remove the bottom
trunnion as described at step 18a. Withdraw hub swivel
14. Remove all traces of sealant from the potentiometer
wires and the corresponding groove in the trunnion.
Note: Do not disturb potentiometer 22F except during

routine maintenance (see Routine Maintenance, Front and
Rear Axle Steering Swivels, Checking 4WS Right Side
Trunnion Seals, Section 3), or if it needs renewing (see Four
Wheel Steer, Sensors in Section C).
) ⁄ 19 Pull off the trunnion bearings 25 and seals 26.
20 Withdraw the driveshaft assembly 28.
C
E
)
F X
D
B A439390
261200
15 Assemble the puller B, with the inner bearing plate E

clamped around the inner bearing 20, attach the puller Check the wear sleeve adjacent to the shoulder at the
rods F and reaction tube C over the driveshaft. outer end of inner drive shaft 39 for seal contact surface
wear or pitting. If wear of pitting exists renew the wear
Note: Reaction tube C, MUST be used, otherwise damage sleeve as follows:
to the driveshaft and drive shaft bearings will occur.
a Place the sleeve X horizontally on an anvil or other
16 Slowly screw in D until the bearing 20 is released. suitable hard surface as shown below. Protect your
eyes by wearing safety glasses or goggles and then
17 Remove the outer races of bearings 19 and 20 from the hammer the sleeve while rotating the shaft.
bearing carrier 17, using a hammer and drift. Continue until the sleeve becomes oval and slides
off the shaft.
18a Front Axle (both hubs on 2WS machines, left hub only
on 4WS machines) - Mark the position of the top b To fit a new sleeve it is necessary to pre-heat it to
trunnion 22 with respect to the hub swivel 14. Remove 100 - 110 °C (212 - 230 °F). To avoid personal injury
studs 23/23A and bolts 23C (if fitted) from trunnion 22 from burning, wear gloves and protective overalls.
and remove the trunnion. Retain the shim pack 24 (if After pre-heating use a suitable tube to press or tap
fitted). Repeat for the bottom trunnion by removing the wear sleeve X onto the shaft, internal chamfered
capscrews 23B. Withdraw hub swivel 14. end first, until it locates fully against the shaft outer
shoulder.
9803/8020 Issue 1
23C
15
13 22B
22A 23A
16
22C
7
4
6 22F
5
6 22E
2 22D
22G
9 12
35 23
10 11
8
22
25
24 22H
26
3
40
41
23B
17 14
27
21 18
20
1 28
39
19
38
37
36
35 31 32
33 30
34 29
A303001
9803/8020 Issue 7
Hub and Driveshaft - continued Note: Axles assembled from new without any shims 24 may
not need shimming on re-assembly . If a new shim 24 has to
Dismantling - continued be fitted, fit a nominal 0.25 mm and leave the top trunnion
bolts finger tight.
21 Prise out the driveshaft oil seal 29 from its housing in the
axle and discard. 8 Attach a spring balance to the track rod swivel as
shown and measure the turning load on the hub swivel.
22 Remove circlip 30. Tighten the top trunnion bolts just enough to eliminate
end float without introducing bearing pre-load. i.e. no
23 Remove the bearing 31 using Service Tools 892/00224 increase in spring balance reading.
and 892/00225.
9 Measure the gap at the top trunnion and subtract 1 mm
24 Remove the oil seal 33 from the hub swivel 14. to give bearing pre-load. Add the result to nominal shim
at top trunnion to give a provisional total shim thickness
25 Remove the needle bearing 34 from the hub swivel 14. which must be verified as follows.
Note: If necessary, the driveshafts can be separated. Use 10 Refit top trunnion 22. Fit two diagonally opposite studs
the item numbers as a guide to dismantling and follow the or bolts and torque tighten (see Torque Settings).
procedure given under Propshaft Dismantling and Check the spring balance reading again (as at step 8).
Assembly. The reading should be 45 N (10 lbf) more than that
recorded at Step 8. If the reading is incorrect, adjust
Assembly the shim thickness as required. When correct, proceed
as follows:
Note: If the driveshafts have been separated, assemble
them in the reverse order of dismantling. Apply JCB Threadlocker and Sealer to all four studs 23.
Fit the studs and torque tighten (see Torque Settings).
1 Tap in the driveshaft inner bearing 31 and secure with
circlip 30. 11 Fit the brake disc 18 to the bearing carrier 17, ensuring
that both surfaces are clean and lightly oiled before
2 Pack JCB HP Grease between the lips of the new oil assembly. Torque tighten bolts 27 (see Torque
seal 29 and fit into the axle flush with the end of the Settings).
housing.
3 Fit the driveshaft 28, taking care to locate the inner end
into the splines of the differential gears.
4 Fit a new needle bearing 34 into swivel 14 (see Needle

Bearing, Checking for Damage or Distortion), pack a
new oil seal 33 with JCB HP Grease and fit to swivel 14
(refer to T.I. GEN 083 for installation details).
5 Press a new trunnion inner oil seal 26 into position

followed by the bearing 25. Lightly oil bearings and seal
before fitting.
160251
6 Locate the hub swivel 14 in position over the driveshaft
28 and fit the bottom trunnion 22. Apply JCB
Threadlocker and Sealer to the capscrews 23B and
torque tighten (see Torque Settings).
Note: If a new swivel 14 is fitted to 4WS rear axle, clearance

at Y must be a minimum of 3mm to 5mm. If necessary, the
profile should be modified as shown to give this clearance.
7 On 4WS machines (right side), lightly grease a new O-

ring 22H and install in the groove at the bottom of the
top trunnion. Refit original shim 24 (if fitted) to the top
trunnion. Install trunnion 22 (2WS and left side on 4WS)
or 22D (right side on 4WS). On 4WS machines, take
Y
care not to dislodge the O-ring during installation. Align
the match marks, and fit studs 23A or bolts 23C finger
tight. Install sensor spindle 22G (see Four Wheel Steer,
Sensors, Replacement in Section C).
9803/8020 Issue 1
23C
15
13 22B
22A 23A
16
22C
7
4
6 22F
5
6 22E
2 22D
22G
9 12
35 23
10 11
8
22
25
24 22H
26
3
40
41
23B
17 14
27
21 18
20
1 28
39
19
38
37
36
35 31 32
33 30
34 29
A303001
9803/8020 Issue 6
Hub and Driveshaft - continued

Assembly - continued
12 Before fitting bearings and oil seal 21, ensure that all & ⁄
paint and dirt are removed from the nose of the carrier
and the housing bore.
13 Install outer bearing race from bearing 19 into bearing

carrier 17.
14 Lightly oil the inner wheel bearing cone 20 and its inner
race, then fit them into the bearing carrier 17.
15 Use service tool 892/00891(see Note below) to drive

the seal 21 squarely into the wheel bearing carrier 17
until the oil seal is level with the wheel bearing carrier
face as shown. DO NOT LUBRICATE THE SEAL
BEFORE FITTING.
Note: Service tool 892/00891 has been produced in two

different versions. The latest version supplied with the Wheel
Hub Service Kit 892/01092 has each side stamped A or B to
identify which side should face the seal. All current Fastrac
machines must have the seal driven in with side B towards
the seal. The original service tool 892/00891 was supplied
with a separate spacer and did not have its sides stamped A
or B. The spacer must be used to prevent the seal from
being driven in too far.

is required throughout steps 16 to 23. Do not allow the H
wheel bearing carrier to become unsupported, otherwise the
oil seal will be damaged.
16 Attach the bearing centre puller H to the centre of the

stub axle using the existing ‘Verbus Ripp’ bolts.
Note: When fitting the annulus carrier, new ‘Verbus Ripp’

bolts must be used.
A439410
17 Lightly oil the inner wheel bearing 20. Position the
bearing carrier (complete with inner bearing) onto the
stub axle over the centre puller H.
18 Slide the bearing fitting tube K over the centre bearing

puller H (the wide opening towards the bearing). Make
sure that the bearing and carrier are square to the shaft.
L
19 Attach the puller handle J to the bearing centre puller
H, making sure that the thrust bearing is fitted between
two thrust washers at L. Using the puller handle, screw
in the bearing fitting tube K until the inner bearing 20 is
pressed correctly into position.
K
20 Remove the puller handle J and bearing fitting tube K.
21 Install the outer bearing 19 into the bearing carrier 17. J

22 Assemble the puller handle J and bearing fitting tube K
onto the centre puller H making sure that the thrust
bearing is fitted between two thrust washers at L.
23 Using the puller handle J, screw in the bearing fitting

tube K until the outer bearing 19 is pressed correctly
into position so as to remove most of the free play.
9803/8020 Issue 1
23C
15
13 22B
22A 23A
16
22C
7
4
6 22F
5
6 22E
2 22D
22G
9 12
35 23
10 11
8
22
25
24 22H
26
3
40
41
23B
17 14
27
21 18
20
1 28
39
19
38
37
36
35 31 32
33 30
34 29
A303001
9803/8020 Issue 8
Hub and Driveshaft - continued Renew bearings if necessary. Remove the planet gear
carrier after checking rolling force.
Assembly - continued
Note: A high rolling force reading may indicate that the
Note: Do not overtighten or the bearing will be damaged. combination seal was damaged during fitting.
24 Remove puller handle J, bearing fitting tube K and 30 Press the driveshaft thrust pad 8 (chamfered side
bearing centre puller H. uppermost) into the recess in the planet carrier 2.
25 Assemble the annulus ring 16 to the annulus carrier 13 31 Fit new planet gears 4 in place of any that were
and secure with circlip 15. removed. (See Dismantling, Step 4.) Secure with
circlips 7. Check the planet gear end floats, which
26 Fit the annulus assembly to the hub swivel in the same should be between 0.4 mm to 0.75 mm (0.016 in to
angular position as it was prior to removal (see Step 9 0.030 in).
in Dismantling) and, using three of the original bolts
12, draw the annulus carrier 13 and hub swivel 14 fully Note: If planet gears 4 or sungear 10 are worn, renew the
together. Remove and discard the three bolts and then complete set.
fit a complete set of new M14 Verbus Ripp bolts 12. Do
not fully tighten the bolts but allow the bearing carrier to 32 Slide on the spacer 11, use a hollow tube of suitable
'rock' slightly to enable measurement of the seal drag - bore and tap spacer fully home. Slide sun gear 10 onto
see step 26. the driveshaft 37. Secure with circlip 9.
27 Check the seal drag rolling force as follows: 33 Fit a new 'O' ring 3.
Temporarily refit the planet gear carrier 2. DO NOT FIT 34 Fit the planet carrier 2 onto the bearing carrier 17,
THE SUN GEAR 10 OR THE CALIPER. Rotate the hub ensuring that the two tapped holes are in line with
several turns to bed-in the seal. those on the bearing carrier. Apply JCB Threadlocker
and Sealer to screws 1 and torque tighten (see Torque
Using a spring balance and cord wrapped around the Settings).
planet carrier flange as shown, pull the spring balance
so that the hub rotates; record the rolling force reading. Note: Never hit the hub in the centre with a hammer.
(Ignore the extra force needed to start the rotation.) Hammering will dislodge the thrust pad 8.
Remove the planet gear carrier after checking rolling 34a On ABS machines replace the ABS sensors (see
force. Section G).
28 Torque tighten bolts 12 evenly (see Torque Settings). 35 Fit the brake calipers (see Section G).
36 Refill the hub with oil (see Section 3).
37 If any of the steering linkage parts have been renewed

or disturbed, check and, if necessary, adjust wheel
alignment (see Tyres and Wheels, Checking and
Adjusting Wheel Alignment, Section 3).
Torque Settings
Zinc-Plated (colour: golden)

1 56 5.7 42
12 320 32.6 236
23 98 10 72
23A 158 16 116
29 Check the rolling force of the bearings as follows. 23B 158 16 116
27 166 16.9 123
Refit the planet gear carrier 2. DO NOT FIT THE SUN
GEAR 10 OR THE CALIPER. Dacromet (colour: mottled silver)
Using a spring balance and cord wrapped around the Item Nm kgf m lbf ft
planet carrier flange as shown, pull the spring balance * 23A 135 13.5 100
so that the hub rotates; record the rolling force reading.
(Ignore the extra force needed to start the rotation.).
Subtract seal drag rolling force (see step 27) from this
reading. The result should be 10 to 120 N (2 to 27 lbf).
9803/8020 Issue 5*
Drive Head connectors. Tie the cable sheathing to the axle for
protection during the following procedure.
3 Remove split pins 1 and nuts 2. Use a suitable ball joint
This job can be done with the axle either removed or in situ splitter and lower track rod 3 clear.
on the machine.
4 Disconnect hydraulic pipes at brake calipers B and
! WARNING differential lock D (if fitted). Remove both sets of top
Make the machine safe before getting beneath it. Do the and bottom trunnions 4, 5 (see Front and Rear Axle,
following: Park on level ground. Engage the parking Hub and Driveshaft, Dismantling.
brake. Lower the equipment to the ground. Stop the
engine, remove the starter key, disconnect the battery. 5 Pull the complete hub and swivel assemblies 6 out of
Chock the wheels. the axle, complete with drive shafts.
13-3-1-1/1
6 Disconnect the propshaft.
Removal
7 Support the drive head 8 on a trolley jack. Remove
Note: Before removing the drive head from a rear axle, bolts 7 and pull out the drive head 8. Remove and
disconnect the rear PTO prop shaft and then remove the discard gasket 9 (if fitted).
PTO drive shaft (see Rear PTO Drive Shaft, Dismantling
and Assembly). 8 Remove and discard axle oil seals 10.
If the axle is in situ do steps 1 to 2a; if the axle is removed Replacement

begin at step 3.
1 Jack up the machine and support it on axle stands. Use a new gasket 9, which should be greased before
assembly. Alternatively, apply JCB Multigasket to the mating
2 Remove the road wheels and drain the oil from axle.
faces. Apply JCB Threadlocker and Sealer to bolts 7 and
Disconnect the drag link or steeering rams from the steer
torque tighten to 166 Nm (122 lbf ft, 17 kgf m).
hubs, using a suitable ball joint splitter.
Pack JCB HP Grease between the lips of new seals 10
! CAUTION before assembly. Ensure that the seals are fitted squarely
Do not hammer the cast iron lugs on the axle as this will and take care not to damage them when inserting the
cause weakness and may lead to steering failure. driveshafts. Grease the exposed parts of the trunnion pivots
AXL 8-2
to prevent rusting.
2a ABS Machines only Set front wheel alignment (see Section 3). Torque tighten the
Disconnect the axle mounted speed sensor flying leads, track rod nuts 2 to 150 Nm (110 lbf ft, 15 kgf m) then tighten
one at each hub, from their chassis mounted mating to next castellation and insert pin 1.
Note: Track rod 3 may be fitted with a steering damper pin.

This pin has no function so that the track rod can be fitted
either way round on Fastrac 2115, 2125, 2135 and 2140
machines. On Fastrac 2150, 3155 and 3185 machines the
damper pin should be uppermost and closest to the RH end
of the axle.
Bleed the braking system.
10
9
7 8 D
2
1
3 5
6
9803/8020 Issue 2
52 - 7A Front Axle 52 - 7A
9803/8020 Issue 1
52 - 8 Front Axle 52 - 8
Drive Head
Dismantling
Note: Drain all oil from the axle.
! CAUTION
Take care when lifting/handling this component. It
weighs 63 kg (139 lb).
TRAN 8-2
1 Remove the drive head from the axle (see Drive Head
Removal and Replacement).
2 Secure the drive head in a vice or suitable jig for

dismantling and examination.
3 Drive out roll pins 3, remove castellated nuts 4 and

extract the bearing caps 5.
4 Pull off the bearings 6 from both sides of the differential

case 10.
5 Remove the differential assembly 7 from its housing 2.
6 Remove the M10 Verbus Ripp bolts 8 using a heavy duty

socket. Remove the crownwheel 9.
Note: See Front Axle, Differential for dismantling and

assembly of the differential.
7 Use Service Tool 892/00812 to prevent the yoke 12 from

rotating. Remove and discard the pinion stake nut 11.
Remove yoke 12.
8 Drive out the pinion 13 complete with spacer 14 and

pinion head bearing 15. Remove the spacer and the
pinion head bearing from the pinion
9 Remove the oil seal 16, bearing 17 and bearing cap 18

from the housing 2.
10 Remove the pinion head bearing cap 19 and shims 20

from the housing 2.
9803/8020 Issue 2*
52 - 9 Front Axle 52 - 9
Drive Head - continued
Assembly
Lightly oil all bearings and seals before assembly.
1 Select shims 20 required for pinion depth setting and fit

behind the bearing cup 19 in drive head housing 2. See
Pinion Depth for calculating shim thickness.
13
2 Press new bearing cone 15 onto pinion 13. 19
3 Fit new pinion tail bearing 17 and cap 18 into the housing 20
2. Lubricate the lips of the new seal 16 with JCB HP
Grease. Fit the new seal into the housing, taking care not
to distort it. Ensure that the seal is square and pushed
fully home. Lightly oil the bearings and locate the pinion
13 into the housing.
11
Fit spacer 14 (see Solid Spacer Installation).
4 Fit the crownwheel 9 using new Verbus Ripp bolts 8,

tighten to 94 Nm (69 lbf ft, 9.6 kgf m). 16
12 17 18 14 15
Note: Do NOT fit the bearings 6 at this stage. A296401
5 Locate the differential assembly 7 into the housing.
6 Drive the bearing cones 6 onto the spigots, lightly oil the
bearings and then fit bearing caps 5 and castellated nuts
4.
Note: Do NOT fit the roll pins 3 at this stage.
*7 Adjust the castellated nut 4 on the crownwheel side until

the backlash is 0.17 to 0.28 mm (0.006 - 0.011 in). Check
crownwheel/pinion backlash in four places.
8 Adjust the other castellated nut 4 until there is no end

float and no pre-load. Always rotate bearings in each
direction to bed in. Tighten nut 4 by a further four
castellations, ensuring that correct backlash is
maintained. Check that the rolling torque on nut 11 is not
over 2 Nm (1.48 lbf ft, 0.2 kgf m) more than that recorded
at Step 11 of Solid Spacer Installation.
9 Using engineers' marker on three or four pinion teeth,

check that correct meshing is achieved (see Crown
Wheel and Pinion Adjustment).
9803/8020 Issue 4*
52 - 10 Front Axle 52 - 10
* Maxtrac Differential (SD55 Axle - Optional)

Dismantling and Assembling Assembling
Dismantling All parts should be lightly lubricated.
Remove the crownwheel and differential assembly from the Note: The bevel gears are a matched set, as are the two
casing (see Drive Head, Dismantling). differential housing halves. These must be renewed as sets if
any of their components are damaged or excessively worn.
Remove bolts 10A and pull the differential case halves 10B Do not use unmatched components.
and 10C apart (always match mark case halves before
dismantling). Assemble the trunnion pins 10F, bevel gears 10D and 10E
and their thrust washers 10G and 10H into differential half
Remove the axle bevel gears 10D, the differential bevel case 10B. (See Note at top of this page.)
gears 10E, trunnion pins 10F and thrust washers 10G from
the case halves. Remove the thrust washers 10H from both Position the differential half case 10C onto half case 10B,
case halves. aligning the match mark letters.
Note: It is recommended that the original bolts 10A (grade

8.8) be replaced with new grade 12.9 bolts if possible.
Treat bolts 10A with JCB Threadlocker and Sealer, fit to case
and torque tighten as per table below.
Check the gears for free rotation.
Refit crownwheel and differential assembly to casing.
Torque Settings (Bolts 10A)
Nm lbf ft kgf m
Grade 8.8 28 21 3
Grade 12.9 46 34 4.7
9803/8020 Issue 2*
52 - 11 Front Axle 52 - 11
159990
9803/8020 Issue 1
52 - 12 Front Axle 52 - 12
* NoSPIN Differential (SD55 Axle - Standard)

Description
The main functions of the NoSPIN differential are:- The progressive stages of disengagement are shown
diagrammatically at Z.
1 To allow variation in driving wheel rotational speed
which must occur when the vehicle is either turning or At position 1, the spider teeth B are driving the clutch D,
travelling over an uneven surface. while the inner clutch teeth G are fully engaged with cam ring
H. The cam is offset by distance K.
2 To prevent loss of traction which would otherwise occur
when one driving wheel spins out. At position 2, the clutch D is accelerating and the inner teeth
G are caused to ride up the cam, thus forcing the clutch out
These functions are achieved by allowing, when necessary, of engagement.
either driving wheel to rotate faster than the crownwheel and
by also ensuring that when power is applied, neither wheel At position 3, the inner teeth have reached the peak of the
can rotate more slowly than the crownwheel. cams and the clutch is now fully disengaged.
The NoSPIN assembly is mounted in a two-piece differential In the reverse condition the spider teeth take up the backlash
case which is bolted to the crownwheel. Drive is transmitted in the unit so that the cams are now displaced to the opposite
from the crownwheel, via the differential case, to the spider side of the spider teeth as shown at 1a.
A. This is provided, on each side, with clutch teeth B which
engage with corresponding teeth on clutch assemblies C and Acceleration of one road wheel in reverse causes clutch
D. The clutches are splined to side gears, which in turn are disengagement, as at 2a and 3a, in the same manner as in
splined to conventional axle shafts, thus conveying the drive forward travel.
to the road wheels.
When a clutch is rotating faster than the spider, continual
When the machine is travelling straight ahead over an even tooth re-engagement would cause excessive noise. This is
surface as at X, both wheels are driven by positive prevented by the provision of a hold-out ring between each
engagement of the teeth on the spider A and on both clutch and the spider to ensure that the clutch remains
clutches C and D. If one wheel loses traction, the clutches disengaged until the speeds again coincide.
remain engaged, ensuring that drive is still transmitted by the
other wheel until traction is regained.
When the machine negotiates a turn as at Y, the outer wheel

E, due to the larger turning radius of its path, is forced to
travel further and rotate faster than the inner wheel. This is
permitted by the disengagement of clutch D from the spider
as shown. A similar action occurs when one wheel is forced
to rotate faster in order to negotiate irregularities in the
ground surface.
The internal operation of the NoSPIN differential is shown on

the lower illustration.
Spider A, rotating in the direction of arrow Aa, is driving

clutch C by means of teeth B. (Positive tooth engagement
being assured by the mating undercuts on the driving faces
of the teeth.) Clutch D, rotating at a greater speed, is shown
disengaged.
In addition to the driven teeth, each clutch is provided with a

row of inner teeth G. Those on clutch C are in engagement
with centre cam H which is therefore rotating and locked in
relation to this clutch.
Due to the tooth backlash J, the engaged clutch C and

centre cam H are trailing behind the spider A, with the effect
that the cams are offset in relation to the spider teeth by
distance K. When a clutch starts to rotate faster than the
spider, the inner teeth of the clutch ride up the cams, thus
forcing the clutch out against spring pressure until the driving
teeth are disengaged as shown on clutch D.
9803/8020 Issue 2*
52 - 13 Front Axle 52 - 13
160000
9803/8020 Issue 1
52 - 14 Front Axle 52 - 14
* NoSPIN Differential (SD55 Axle - Standard)

(continued)
Use the numerical sequence as a guide to dismantling.
For assembly, reverse the sequence.
Remove the crownwheel and differential assembly from the All parts should be lightly lubricated.
casing (see Drive Head, Dismantling).
Ensure that spring retainers 5 and 12 face in the directions
Fit a suitable bolt and nut A fitted with flat washers larger shown.
than 38 mm (1.49 in) but smaller than the case shaft bore to
give clearance. This will retain the NoSPIN components Ensure that extended tooth E locates in the gap of each hold-
against spring pressure. out ring as at F.
Note: The differential case halves 2 and 3 should be marked Ensure that clutch teeth mesh correctly and that there is no
to assist reassembly in their original relative positions. binding or overlapping of spring coils.
Remove bolts 1 and lift off case half 2. Fit a suitable bolt and nut A, together with necessary flat
washers (see Dismantling) to the No SPIN components.
The NoSPIN differential may now be lifted clear.
Fit NoSPIN differential to case halves 2 and 3. Align
Remove the retaining bolt, nut and washers. differential case halves 2 and 3, using the index marks (see
Note in left hand column).
! CAUTION
Springs 6 and 10 exert a force in excess of 353 N (36 kgf, Treat bolts 1 with JCB Threadlocker and Sealer, fit to case
80 lbf). When removing retaining nut, ensure that the and torque tighten to 46 Nm (34 lbf ft, 47 kgf m).
NoSPIN assembly is securely held.
AXL 8-1 Refit crownwheel and differential assembly to casing.
Spider assembly 8 and clutch assemblies 7 and 9 should not
be individually dismantled, as component parts are not
serviceable.
Inspecting
Examine all components for fractures, chipping, burrs,

scoring and excessive wear, paying special attention to
clutch teeth and cams, trunnion holes B, hold-out rings C, all
splines and thrust or bearing surfaces.
Minor chips and burrs may be dressed using an abrasive

stone but if components show wear or scoring, the complete
assembly should be renewed.
Hold-out rings C should be free to rotate on their clutches

with only a little resistance.
Centre cam ring D should be free to rotate within limits

imposed by the extended tooth E.
Springs 6 and 10 should require a load of 230 N (52 lbf, 23.5

kgf) to compress them to a height of 15.5 mm (0.61 in).
9803/8020 Issue 2*
52 - 15 Front Axle 52 - 15
A B
C D
A234551
9803/8020 Issue 1
52 - 16 Front Axle 52 - 16
* NoSPIN Differential (SD55 Axle - Standard) * Soft Engage Differential Lock (SD70 Axle)
(continued)
Testing
Refer to Rear Axle, Soft Engage Differential Lock,
The following test will show whether or not the NoSPIN Differential Case, Dismantling and Assembly for full
differential is operating correctly. procedure.
1 Engage the parking brake, place the transmission in
gear.
2 Raise the front axle until both tyres are completely clear
of the ground. Position adequate supports.
3 With the help of an assistant, rotate both wheels as far

as possible in a forward direction as at A. Both wheels
will normally be stopped after absorbing the backlash in
the NoSPIN assembly and between the crownwheel and
pinion.
4 With the left hand wheel firmly held forward against the
stop, rotate the right hand wheel rearward for one of two
revolutions as at B. (A regular clicking sound may be
heard).
5 Rotate both wheels rearward as far as possible as

shown at C, until stopped when backlash is absorbed as
described in Step 3.
6 With the left hand wheel held firmly rearward against the
stop, rotate the right hand wheel forward for one or two
revolutions as at D. (A regular clicking sound may be
heard).
7 Repeat Steps 3, 4, 5 and 6 but this time hold the right

hand wheel and rotate the left hand wheel.
Note: It is important that the wheel is held firmly against the

stop, otherwise the other wheel will not be free to rotate.
If the NoSPIN is operating correctly, the wheel being rotated

should be free until the direction of its rotation is reversed or
until the pressure on the opposite wheel is relaxed. If the
rotated wheel is not free under the conditions described
check for possible brake drag.
If either wheel is not stopped as described in Step 3, check

that the axle shaft and hub gears are intact before
condemning the NoSPIN assembly.
Note: When one wheel is being rotated a light clicking noise

may be heard as the clutch teeth pass over the cams,
followed by a louder click as the clutch engages when the
rotation is stopped and slightly reversed. If an abnormally
loud clicking is repeatedly heard, it may be that a hold-out
ring is faulty or has been incorrectly assembled into the
spider.
Service Precautions
1 When checking the axle operation or checking brakes

etc., ensure that both wheels are raised clear of the
ground.
2 It is important that the axle is fitted with matching tyres

at equal pressures. If in doubt, check that the distances
9803/8020 Issue 2*
53 - 1 Front and Rear Axles 53 - 1
Pinion Depth
Large Pinion Bearing Small Pinion Bearing
Note: The crown wheel and pinion are a matched pair and Note: The crown wheel and pinion are a matched pair and
must be renewed as a pair if either component is damaged must be renewed as a pair if either component is damaged or
or excessively worn. Do not use unmatched components. excessively worn. Do not use unmatched components.
Measure depth W of bearing A direct. The bearing depth Place the new pinion head inner bearing 15 and bearing cap
should be between 36.51 and 36.71 mm. If measurement is 19 on a flat surface and position bearing cup 892/00174 over
not possible, use the mean dimentsion of 36.61 mm. the bearing. Measure the gap T (e.g. 0.20 mm) and add this
to the cup depth stamped on the tool (e.g. 30.01 mm) to
From the face of the pinion obtain the etched deviation figure
obtain bearing depth.
(e.g. +2) which is in units of 0.01 mm. If positive add this to
bearing depth; if negative, subtract from bearing depth.
From the face of the pinion obtain the etched deviation figure
Obtain the deviation figure (e.g. -1) stamped on the bolt (e.g. +2) which is in units of 0.01 mm. If positive add this to
flange of housing B. If negative, add to the bearing depth; if bearing depth; if negative, subtract from bearing depth.
positive, subtract from the bearing depth.
Obtain the deviation figure (e.g.-1) stamped on the bolt flange
Subtract the total of the above figures from the standard of housing 2. If negative, add to the bearing depth; if positive,
value of 37.27 mm. The result will be the thickness of shims subtract from the bearing depth.
C required behind the pinion head bearing cap.
Subtract the total of the above figures from the standard
value of 31.19 mm. The result will be the thickness of shims
20 required behind the pinion head bearing cap.
Example (all dimensions in millimetres)
Cup depth 30.01

B Gap T +0.20
Bearing depth 30.21
A Pinion deviation (+2) +0.02
Housing deviation(-1) +0.01
A Total 30.24
C
X Standard value 31.19
Less total above 30.24
Shim thickness 0.95
97/11-0 Use shim pack size to the nearest 0.05 mm.
W
T
97/11-2
Example (all dimensions in millimetres) S184400
Bearing depth W 36.61

Pinion deviation (+2) +0.02
Housing deviation (-1) +0.01
Total 36.64
Standard value 37.27

Less total above 36.64
Shim thickness 0.63
Use shim pack size to the nearest 0.05 mm
9803/8020 Issue 2*
54 - 1 Front and Rear Axles 54 - 1
Solid Spacer Installation 10 Remove adapter B and sleeve A. Fit new oil seal,
grease between seal lips before fitting. Before fitting the
Note: Solid spacer setting tools are required for this job (see flange, check that the bearing end of the flange is not
Section 1). fretted and renew the flange if required. Clean any oil
from the splines of the flange and the shaft. Run an
1 Install pinion and bearings into the drive head casing. even 2 mm diameter bead of JCB Threadlocker and
Install largest e.g. 13.6 mm solid spacer X (refer to Sealer around the outer end of the shaft spline. Fit the
illustration in Front and Rear Axles, Pinion Depth (see flange using a new stake nut.
Parts Catalogue for part number) and fit pinion tail
bearing (lightly oiled). Do not fit the oil seal at this stage.
2 Fit special tool sleeve A and special pinion shaft

adapter B and tighten to 50 Nm. If sleeve A is not
available, use the drive flange instead.
3 Fit special bracket C to the drive-head housing using

two M12 x 30 nuts and bolts. Fit special tool support
pillar Y so that the fork end engages in adapter B.
Ensure that fork Y is centrally located on adapter B. If
necessary, re-align bracket C to suit.
4 Fit dial test indicator (DTI) Z. Ensure that the DTI is

mounted on the drive head and not on bracket C.
5 Set torque wrench E to 35 Nm and measure the end

float while rotating the shaft.
* 6 To select the right size spacer X, subtract the end float

obtained at step 5 from the solid spacer size
(e.g 13.6 mm). Also subtract 0.06 mm to allow for
theoretical bearing tolerance and pre load. The result is
the size of spacer to be fitted. If there is no spacer of
this size, fit the next closest size spacer. 11 Progressively torque tighten retaining nut to 300 Nm.
Provided the correct size spacer has been selected the
Example rolling torque should be between 2.3 and 3.4 Nm
including seal drag.
Temporary spacer size 13.60
Subtract end-float 0.52 Note: The nut tightening torque can be increased to a
Total 13.08 maximum of 390 Nm provided that the rolling torque does
Subtract tolerance & preload 0.06 not exceed the maximum of 3.4 Nm.
Result 13.02
12 Finally stake the nut into the slot.
(No spacer available this size, use next closest size
spacer i.e 13.00)
7 Remove sleeve A and fit correct size spacer. Take care

to avoid damaging the outer bearing.
8 Fit sleeve A. Initially tighten adapter B to no more than

50 Nm to protect against bearing damage while spacer
selection is verified. Check there is no end float and
pinion is free to turn smoothly by hand. Then check that
rolling torque is less than 2.0 Nm. If the rolling torque
exceeds 2.0 Nm, check that the shaft has been
assembled correctly.
9 If rolling torque measured at 8 is too high, fit the next

larger size spacer. If rolling torque is too low, fit the
next smallest size spacer. If a correct spacer is not
available from the range, check that drive head is
assembled correctly.
9803/8020 Issue 3*
54 - 2 Rear Axle 54 - 2
Drive Head
Crown Wheel and Pinion Adjustment
Meshing of the gears should be checked by marking three of

the pinion teeth with engineers' marking compound and
rotating the pinion.
The marking will then be transferred to the crown wheel

teeth.
Correct tooth marking.
Pinion too deeply in mesh.
Decrease the thickness of shim 33 between the pinion inner

bearing cup and the axle casing. Move the crown wheel
towards the pinion to correct the backlash.
Pinion too far out of mesh.
Increase the thickness of shim 33 between the pinion inner

bearing cup and the axle casing. Move the crown wheel
away from the pinion to correct the backlash.
9803/8020 Issue 1
55 - 1 Rear Axle 55 - 1
E
C
K E
F
S
B
D
N
L
T
T
D1
A227021
9803/8020 Issue 1
55 - 2 Rear Axle 55 - 2

Fastrac 2115, 2125 and 2135 Machines
Removal 9 Lower the rear suspension so that the chassis sits on
! WARNING its bump stops K, (see Discharging Hydraulic
Pressure, Section S).
10 Wait for the suspension to rise and repeat step 9 to fully
brake. Lower the equipment to the ground. Stop the
discharge the oil pressure in the hydraulic circuit.
engine, remove the starter key, disconnect the battery.
Disconnect both spring boxes L from the control arms
Chock the wheels.
13-3-1-1/1 T.
! WARNING
11 Disconnect the lower pin of the two suspension
Raised equipment can fall and injure you. Do not walk or
cylinders N.
work under raised equipment unless safely supported.
13-1-1-6
! CAUTION 12 Jack up the axle and chassis, place axle stands under
the chassis members. Fully support or sling the axle.
Take care when lifting/handling this equipment. Use only
proofed and serviceable lifting equipment strong enough 13 Remove the clamps/bushes securing the anti-roll bar to
for the jobs. the axle (2WS Machines) or detach the anti-roll bar from
SUS 1-5
the chassis (4WS Machines) (see Rear Suspension,
1 Position trolley jacks under the axle and raise the Anti-roll bar, Section S).
wheels off the ground.
14 Disconnect the 'V' link arm S at the top of the axle.
2 Remove the road wheels and drain oil from the
hubs/axle. 15 Disconnect the two control arms T at the axle end.
* 2a ABS Machines only 16 If using an overhead gantry, lower the axle slightly and
Disconnect the axle mounted speed sensor flying move it out to the rear. If using a jack then lower the
leads, one at each hub, from their chassis mounted axle and drag to the rear.
mating connectors. Tie the cable sheathing to the axle
for protection during the following procedure. Replacement
3 Disconnect brake pipes A, hydraulic hoses to pick-up Replacement is a reversal of the removal procedure.
hitch lift cylinders B plus the hydraulic connections to
the differential lock C. Ensure that all pipes and Before fitting bolts G, ensure that there is no debris between
connections are sealed to prevent loss of fluid and the axle and the linkage brackets that might prevent the axle
ingress of dirt. and brackets from seating correctly.
4 On 4WS machines only (not shown on the illustration), Treat all bolt threads with JCB Threadlocker and Sealer.
disconnect the three hydraulic hoses, the air hose and Tighten bolts G to 700 Nm (516 lbf ft, 71.4 kgf m).
the electrical connection to the forward facing power
track rod. Also disconnect the electrical lead to the top See the relevant Removal and Replacement pages for
of the right hand swivelling trunnion. correct fitting procedures and torque settings of the
following:
5 Disconnect and remove the draft pins and the position
sensor, (see Electronic Draft Control - Draft Pin and Spring boxes L
Position Sensor, Section E). Remove pick-up hitch lift Cylinders N
rods E and remove pins D1 to disconnect the 3 point Anti-roll bar Section S
linkage stabilisers D. Remove the lift rod bottom pins B. V' link S
Control arms T
6 Slacken the linkage bracket bolts G (5 at each outboard
end of the axle). Drive out the pick-up hitch front pivot Propshaft - Section F
pin H and then lower the pick-up hitch down to the
ground. Ensure that clamps P are tightened onto control arms T.
7 Remove the circlips J from top and bottom of the lift Ensure the axle is filled with the correct oil (see Section 3).
cylinders B attachment points and remove the lift
cylinder bottom pins. Slide the cylinders B off the top Set the ride height (see Section S).
pins.
Bleed the brakes (see Section G).
8 Remove driveshafts (i.e. main drive and PTO).
On 4WS machines, if the steering sensors have been
disturbed or renewed, they must be calibrated (see Four-
wheel Steer (4WS), Sensors, Calibration in Section C).
9803/8020 Issue 3*
55 - 3 Rear Axle 55 - 3
160101
9803/8020 Issue 1
55 - 4 Rear Axle 55 - 4

Fastrac 2150, 3155 and 3185 Machines
Removal
9 Wait for the suspension to rise and repeat step 8 to fully
discharge the oil pressure in the hydraulic circuit.
! WARNING Disconnect both spring boxes L from the control arms
Make the machine safe before getting beneath it. Do the T.
brake. Lower any mounted implements to the ground. 10 Disconnect the lower pin of the two suspension
Stop the engine, remove the starter key, disconnect the cylinders N.
13-3-1-1
11 Jack up the axle and chassis, place axle stands under
the tube cross member. Fully support or sling the axle.
! WARNING
Raised equipment can fall and injure you. Do not walk or 12 Remove the clamps/bushes P securing anti-roll bar R
work under raised equipment unless safely supported. to the axle (see Rear Suspension, Anti-roll bar 2WS,
13-1-1-6
Section S).
! CAUTION 13 Disconnect the 'V' link arm S at the top of the axle.
proofed and serviceable lifting equipment strong enough 14 Disconnect the two control arms T at the axle end.
for the jobs.
SUS 1-5 15 If rebound straps are fitted as shown at V, disconnect
the top end of the straps from the chassis by removing
bolts W.
1 Position trolley jacks under the axle and raise the
wheels off the ground. 16 If using an overhead gantry, lower the axle slightly and
move it out to the rear. If using a jack then lower the
2 Remove the road wheels and drain oil from the axle and drag to the rear.
hubs/axle.
Replacement
* 2a ABS Machines only
Disconnect the axle mounted speed sensor flying Replacement is a reversal of the removal procedure.
leads, one at each hub, from their chassis mounted
mating connectors. Tie the cable sheathing to the axle Before fitting bolts G, ensure that there is no debris between
for protection during the following procedure. the axle and the linkage brackets that might prevent the axle
and brackets from seating correctly.
3 Disconnect brake pipes A, hydraulic hoses to pick-up
hitch lift cylinders B plus the hydraulic connection to Treat all bolt threads with JCB Threadlocker and Sealer.
the differential lock C. Ensure that all pipes and Tighten bolts G to 700 Nm (516 lbf ft, 71.4 kgf m).
connections are sealed to prevent loss of fluid and
ingress of dirt. See the relevant Removal and Replacement pages for
correct fitting procedures and torque settings of the
4 Disconnect and remove the draft pins and the position following:
sensor, (see Section B). Remove pick-up hitch lift rods
E and remove pins D1 to disconnect the 3 point linkage Spring boxes L
stabilisers D. Remove the lift rod bottom pins B. Cylinders N
Anti-roll bar R Section S
5 Slacken the linkage bracket bolts G (5 at each outboard V' link S
end of the axle). Drive out the pick-up hitch front pivot Control arms T
pin H and then lower the pick-up hitch down to the
ground. Propshaft - Section F
6 Remove the circlips J from top and bottom of the lift Ensure that bushes X are fitted onto bolts W.
cylinders B attachment points and remove the lift
cylinder bottom pins. Slide the cylinders B off the top Ensure the axle is filled with the correct oil (see Section 3).
pins.
Set the ride height (see Section S).
7 Remove driveshafts (i.e. main drive and PTO).
Bleed the brakes (see Section G).
8 Lower the rear suspension so that the chassis sits on
its bump stops K, (see Discharging Hydraulic
Pressure, Section S).
9803/8020 Issue 3*
56 - 1 Rear Axle 56 - 1
13 14
15
16
7
4
6
5
6
2
11 12
19
9
10 10A 18
8
20
17
27 29
22
28
21
26
25
23
24
A297161
9803/8020 Issue 3
56 - 1A Rear Axle 56 - 1A
Hub and Driveshaft (PD70 Axle) 8 Remove the M14 Verbus Ripp bolts 12 using heavy duty
tools. These bolts will be very tight and will be less
2000 Series and 3155 Machines) difficult to slacken if first tightened slightly.
Dismantling 9 See Note below. Jack the annulus assembly 13 from the
stub 29 using three M12 bolts.
1 Drain oil at plug A. Remove bolts 1.
Note: If the stub and the annulus carrier are to be re-used,
2 Lever off the planet gear carrier 2 at the levering points the carrier must be assembled in the same angular position
provided. Remove and discard the 'O' ring 3. as that from which it was removed; before removing the
carrier assembly 13 make a small indentation on the face of
3 Lay the planet gear carrier on a level, clean surface and the carrier 15 in the 12 o'clock position. Fretting between the
examine the four planet gears 4. Check planet gears for stub and annulus carrier 13 mating faces might be evident.
excessive side movement on the bearings. Compare with This condition is normal, do not attempt to repair.
a new item if in doubt as to the correct amount of side
movement. If any wear is found, the planet bearings and 10 Remove circlip 14 to separate the annulus ring 16 from
gears must be renewed. Only remove the planet gears if the annulus carrier 15.
they are found to be defective.
11 Unscrew pipe 17, nuts 18 and bolts 19, then lift off disc
If wear is found in the bearings, it is essential that the brake caliper 20 from disc 23. On ABS machines remove
same inspection/repair also be carried out on the the ABS sensors (see Section G).
opposite hub.
Note: A planet gear can only be renewed as an assembly. is required throughout steps 12 to 16.
This comprises the gear 4, the bearing 5 and two circlips 6.
4 Remove the external circlip 7 and lift the gear 4/bearing

5/circlips 6 assembly clear. Remove circlips 6 to remove
bearing 5 from gear 4. If the planet gears 4 are worn
and/or pitted they must be renewed along with bearings
Y
5 and sungear 10.
3
C
8
2
A
4 4 D
B
A439380
12 Assemble the puller B, screwing the legs A onto two

diametrically opposite wheel studs and placing reaction
tube C over the driveshaft. On axles with five wheel
studs per hub, the modified wheel studs supplied in the
A301130
service kit must be fitted into the bolt holes for
mounting planet carrier 2. Use two suitable 10 mm
5 Remove the driveshaft thrust pad 8, which is drilled and bolts (longer than item 1) to secure the modified wheel
tapped M6 for removal purposes. studs and mount the puller legs A onto the studs.
6 Pull the driveshaft 9, together with the sungear 10, from Note: Reaction tube C, MUST be used, otherwise damage
the axle housing. to the driveshaft and drive shaft bearings will occur.
7 Remove circlip 11, sungear 10 and spacer 10A for 13 Screw in D slowly until the bearing carrier 22 together
examination of splines. with the outer bearing cone 24 and its outer race are
released from the axle. If the bearing carrier starts to
Note: To remove spacer 10A revolve the spacer with a turn use a suitable bar Y to prevent further rotation.
suitable drift until its holes align with the space between
bolts 12. Use two dowels and two heel bars to pull out the Note: If D becomes too hard to turn, tap the back of the hub
spacer. with a plastic hammer to help release the bearing.
9803/8020 Issue 1
56 - 2 Rear Axle 56 - 2
13 14
15
16
7
4
6
5
6
2
11 12
19
9
10 10A 18
8
20
17
27 29
22
28
21
26
25
23
24
A297161
9803/8020 Issue 4
Hub and Driveshaft (continued) Assembly
14 Remove and discard the combination seal 26 by cutting 1 Apply JCB Multigasket to the mating faces and fit stub
the outer seal with a sharp chisel and carefully knocking 29 to axle casing. Tighten bolts 28 to 400 Nm ( 295 lbf ft,
the inner seal fully on to the stub axle, taking CARE not 40.8 kgf m).
to damage the seal seat on the stub axle.
2 Fit the brake disc 23 to the bearing carrier 22, ensuring
that both surfaces are clean and lightly oiled before
assembly. Torque bolts 21 to 166 Nm (122.5 lbf ft, 16.9
kgf m).
fl
3 Before fitting bearings and combination seal 26, ensure
that all paint and dirt are removed from the nose of the
carrier and the housing bore.
4 Fit the inner and outer bearing cups into the carrier 22.
Lightly oil the inner wheel bearing cone 25 and fit it into
the carrier 22.
4 Use service tool 892/00891(see Note below) to drive the

fi seal 26 squarely into the wheel bearing carrier 22 until
the oil seal is level with the wheel bearing carrier face as
shown. DO NOT LUBRICATE THE SEAL BEFORE
FITTING.
Note: Service tool 892/00891 has been produced in two

different versions. The latest version supplied with the Wheel
Hub Service Kit 892/01092 has each side stamped A or B to
identify which side should face the seal. All current Fastrac
machines must have the seal driven in with side B towards
the seal. The original service tool 892/00891 was supplied
G with a separate spacer and did not have its sides stamped A
E or B. The spacer must be used to prevent the seal from
being driven in too far.
fi
F
D
¤ fl
B A439390
15 Assemble the puller B, with the Inner Bearing Plate

Plate E clamped around the inner bearing 25, attach
the Puller Rods F and Reaction Tube G over the
driveshaft.
Note: Reaction Tube G, MUST be used, otherwise damage

to the driveshaft and drive shaft bearings will occur.
16 Slowly screw in D until the bearing 25 is released.
17 Examine the disc 23 for damage. If it needs to be

separated from the bearing carrier 22, remove bolts 21.
Note: If disc 23 is scored, skimming is permissible but it

must not reduce the thickness to less than the dimension
given in Section G Technical Data.
18 If the wheel bearings are to be renewed, remove the

bearing cups from the carrier 22.
19 Unscrew nuts 27/ bolts 28 and remove stub 29.
9803/8020 Issue 1
56 - 3 Rear Axle 56 - 3
13 14
15
16
7
4
6
5
6
2
11 12
19
9
10 10A 18
8
20
17
27 29
22
28
21
26
25
23
24
A297161
9803/8020 Issue 3
Hub and Driveshaft (continued)

Assembly (continued)

is required throughout steps 5 to 12. Do not allow the wheel
bearing carrier to become unsupported, otherwise the oil
seal will be damaged.
5 Attach the bearing centre puller H to the centre of the

H
stub axle using the existing ‘Verbus Ripp’ bolts.
Note: When fitting the annulus carrier, new ‘Verbus Ripp’
bolts must be used.
6 Lightly oil the inner wheel bearing 25. Position the

bearing carrier (complete with inner bearing) onto the
stub axle over the centre puller H.
7 Slide the bearing fitting tube K over the centre bearing A439410
puller H (the wide opening towards the bearing). Make

sure that the bearing and carrier are square to the shaft.
8 Attach the puller handle J to the bearing centre puller

H, making sure that the thrust bearing is fitted between
two thrust washers at L. Using the puller handle, screw
in the bearing fitting tube K until the inner bearing 25 is L
pressed correctly into position.
9 Remove the puller handle J and bearing fitting tube K.
10 Install the outer bearing 24 into the bearing carrier 22.

› K
11 Assemble the puller handle J and bearing fitting tube K
onto the centre puller H, making sure that the thrust
bearing is fitted between two thrust washers at L.
J
12 Using the puller handle J, screw in the bearing fitting
tube K until the outer bearing 24 is pressed correctly
into position so as to remove most of the free play.
Note: Do not overtighten or the bearing will be damaged
13 Remove puller handle J, bearing fitting tube K and

bearing centre puller H.
14 Assemble the annulus ring 16 to the annulus carrier 15.

Secure with circlip 14.
15 Fit the annulus assembly 13 to the stub 29, in the same

angular position as it was prior to removal (see step 9 in
Dismantling) and, using three of the original bolts 12,
draw the annulus carrier 15 and stub 29 fully together.
Remove and discard the three bolts and then fit a
complete set of new M14 Verbus Ripp bolts 12. Do not
fully tighten the bolts but allow the bearing carrier to
'rock' slightly to enable measurement of the seal drag -
see step 15.
165260
16 Check the seal drag rolling force as follows:
Temporarily refit the planet gear carrier 2. DO NOT FIT

THE SUN GEAR 10 OR THE CALIPER. Rotate the hub
several turns to bed-in the seal.
9803/8030 Issue 1
56 - 4 Rear Axle 56 - 4
13 14
15
16
7
4
6
5
6
2
11 12
19
9
10 10A 18
8
20
17
27 29
22
28
21
26
25
23
24
A297161
9803/8020 Issue 4
Hub and Driveshaft (continued) 24 Push the hub assembly towards the axle, manoeuvring
it as necessary to engage the driveshaft with the spline
Assembly (continued) in the differential unit. Ensure that the planet gear
carrier 2 butts fully against the wheel bearing carrier 22.
Using a spring balance and cord wrapped around the Both mating surfaces must be clean and sealed with
planet carrier flange as shown, pull the spring balance JCB Multigasket.
(Ignore the extra force needed to start the rotation.) 25 After applying JCB Threadlocker and Sealer to the
threads, fit and tighten bolts 1 to a torque of 56 Nm (42
Remove the planet gear carrier. lbf ft, 5.7 kgf m).
17 Torque tighten bolts 12 evenly to 320 Nm (236 lbf ft,

32.6 kgf m).
18 Check the rolling force of the bearings as follows.
Refit the planet gear carrier 2. DO NOT FIT THE SUN

GEAR 10 OR THE CALIPER.
Using a spring balance and cord wrapped around the

planet carrier flange as shown, pull the spring balance
(Ignore the extra force needed to start the rotation.).
Subtract seal drag rolling force (see step 15) from this
reading. The result should be 10 to 120 N (2 to 27 lbf). 165260
Renew bearings if necessary. Remove the planet gear

carrier after checking rolling force.
26 On ABS machines replace the ABS sensors (see
Note: A high rolling force reading may indicate that the oil Section G).
seal was damaged during fitting.
27 Fit the brake caliper 20 (see Section G).
19 Press the driveshaft thrust pad 8 (chamfered side
uppermost) into the recess in the planet gear carrier 2. 28 Refill the hub with oil (see Section 3).
20 Fit planet gears 4 and spacer with circlip 7. Check the

planet gear end floats, which should be between 0.4
mm to 0.75 mm (0.016 in to 0.030 in).
Note: If planet gears 4 or sungear 10 are worn, renew the

complete set.
21 Slide spacer 10A onto driveshaft 9 and use a hollow

tube of suitable bore to tap fully home. Fit sungear 10,
counterbore towards the inside of the hub, and secure
with circlip 11.
22 Insert the driveshaft 9 part way into the axle until about
100 mm (4 in) is left between the sunwheel 10 and the
annulus carrier 15. Oil and fit a new 'O' ring 3 to the
face of the bearing carrier 22.
Note: Driveshaft 9 has a cutaway spline at one end. Ensure

that this end is inserted into the axle.
23 Engage the planet gears 4 in the carrier 2 with the sun

gear 10 on the driveshaft 9. Ensure that the two tapped
holes in the carrier 2 align with the two similar holes in
the bearing carrier 22, to take bolts 1.
Note: Never hammer the hub in the centre. Hammering

dislodges the thrust pad 8.
9803/8020 Issue 1
56 - 5 Rear Axle 56 - 5
9803/8020 Issue 1
56 - 6 Rear Axle 56 - 6
* Soft Engage Differential Lock

- Drive Head (PD70/SD70/PD90 Axle)
Removal and Replacement Replacement
Note: This job can be done with the axle in situ if required. Replacement is the reversal of the removal procedure.
Removal Treat all mating surfaces with JCB Multigasket.
1 If the axle is in situ, support the chassis as described * Fit the two bolts 3 (PD70/SD70) and tighten to a torque of 56
under Rear Axle, Removal (step 12 for 2115, 2125 and Nm (41 lbf ft, 5.7 kgf m).
2135 machines, step 11 for 2150, 3155 and 3185
machines), taking the full weight of the rear of the * Treat bolts 5 with JCB Threadlocker and Sealer. Tighten to a
vehicle on the axle stands, plus overhead craneage if torque of 166 Nm (122 lbf ft, 17 kgf m).
available.
Before connecting the propshafts, refer to Propshaft
2 Remove the road wheels and drain oil from hubs/axle. Removal and Replacement.
3 Disconnect hydraulic connection 1 at the differential

lock. Seal the hydraulic connection to prevent loss of
fluid.
4 Disconnect the main propshaft at flange 2.
Note: Before removing the drive head, disconnect the rear

PTO prop shaft and then remove the PTO driveshaft (see
Rear PTO Drive Shaft, Dismantling and Assembly).
* 5 Remove the two bolts 3 (PD70/SD70). Lever off the

planet gear carrier 4 at one end of the axle, at levering
points provided. Remove and discard the ‘O’ ring (see
Hub and Driveshaft, Dismantling and Assembly).
Repeat for the other end of the axle.
6 Pull the driveshafts out of the axle.
7 Support the drive head 6 with a trolley jack.
! CAUTION
proofed and serviceable lifting equipment strong enough
for the jobs.
SUS 1-5
8 Remove bolts 5 and pull out the drive head 6 from the
axle.
9 Remove two dowels 7 from the axle 8, if loose.
9803/8020 Issue 3*
56 - 7 Rear Axle 56 - 7
9803/8020 Issue 2*
56 - 8 Rear Axle 56 - 8
Soft Engage Differential Lock - Drive Head

(PD70/SD70/PD90 Axle) (continued)
Dismantling
! CAUTION
Take care when lifting/handling this equipment. It weighs
63 kg (139 lb).
TRAN 8-2
1 Remove the drive head from the axle (see Drive Head 15 Remove the taper roller bearing 30 and tap out the
Removal and Replacement) and secure it in a vice or bearing cup 31.
suitable jig for dismantling and examination.
16 Tap out the bearing cup 32 from the opposite bearing
2 Remove circlip 3 from the differential lock housing. housing and remove the drive pinion shim 33.
3 Apply compressed air to the oil feed port (hydraulic 17 Remove the spacer 34 and bearing 35 from the pinion
connector 38) to force out the piston back plate 4 from shaft.
the differential lock housing. Remove and discard 'O'
rings 5 and 6. 18 Remove the bleed valve and dust cap 36 and 37. Keep
the dust cap with the bleed valve.
4 Remove piston 7. Remove 'O' ring 8 and discard.
19 Remove the hydraulic connector 38. Remove and
*5 Remove compression spring 9, thrust sleeve 10, axial discard the 'O' ring 39.
roller bearing 11 and end plate 12.
Note: During a differential lock repair or piston replacement,
6 Remove the roll pins 13 and 14 from the castellated inspect the housing for scores, marks or damage which
nuts. Remove castellated nuts 15 and 16 using a locally could cause a leak. If necessary, polish the housing with oil-
manufactured service tool (see drawing in Section 1). lubricated 800 grade or fine abrasive paper to remove any
marks. Alternatively, renew the housing.
7 Lay the drive head on a flat surface positioned with the
split bearing carrier uppermost. The weight of the
assembly 20 should be sufficient to push the bearing
outer cup 17 off its seat. If not, tap the cup out gently,
using the weight of the differential assembly. If the cup
cannot be removed using this method, remove as
detailed in step 8.
8 Rotate the drivehead through 90° to lie in the position

shown in the illustration. Undo bolts 18 and remove the
split bearing carrier 2A and bearing outer cup 19. Insert
a three leg bearing puller into the differential lock
housing and remove bearing outer cup 17.
9 Rotate drivehead back through 90° to the vertical

position and remove the differential assembly 20.
10 Remove bolts 21 and separate differential assembly

from the crown wheel 22. Do not remove bearings 24
and 25 from differential case assembly 23 unless they
are to be renewed.
11 Remove the pinion nut 26. Use Service Tool 892/00812

to prevent the drive flange 27 from rotating whilst
removing the nut. Discard the nut.
12 Remove the drive flange 27.
13 Drive the pinion shaft 28 out of the drive head carrier.
14 Prise the shaft seal 29 out of the bore.
9803/8020 Issue 4*
56 - 9 Rear Axle 56 - 9
195900
9803/8020 Issue 1
56 - 10 Rear Axle 56 - 10
* Soft Engage Differential Lock

- Differential Case (PD70/SD70/PD90 Axle)
The numerical sequence is intended as a guide to 6 Using a hand pump test the differential lock for correct
dismantling. operation and leaks. Do not exceed a pressure of 35
bar (500 lbf/in2).
7 When satisfactory, apply JCB Threadlocker and Sealer
Dismantling to the threads of bolts 1 and fit. Tighten to 56 Nm, (41.3
lbf ft). Check free rotation of the gears in the horizontal
1 Secure the assembly in a vice or suitable jig for position (see Assembly, step 5).
dismantling and examination.
2 Remove the bolts 1 and separate the differential lock

case 2 from the rest of the assembly.
3 Remove actuating sleeve 3.
4 Remove 11 counter plates 4 and 10 friction plates 5

from the differential pinion gear 8.
5 Separate the differential case halves 6 and 14.
6 Remove the pinion gear 8, bevel gears 10, trunnion pins

9, and thrust washers 11 from the case halves. Remove
the thrust washers 7 and 13 from both case halves.
Assembling
Note: The bevel gears are a matched set, as are the two
differential case halves also the crown wheel and pinion.
These must be renewed as sets if any of their components
are damaged or excessively worn. Do not use unmatched
components.
Note: The differential case halves are stamped for matching

purposes. The stamp on the crown wheel case half can only
be seen when the crown wheel is removed.
1 Assemble the trunnion pins 9, bevel gears 8, 10, 12, and

their thrust washers 7, 11 and 13 into the differential
case half 14.
2 Position the differential case half 6 aligning the match

mark letters.
3 Fit 11 counter plates 4 and 10 friction plates 5, starting

and finishing with a counter plate. Make sure the
counter plate tabs are aligned.
4 Position the actuating sleeve 3 on top of the last

counter plate. Position the differential lock case 2 over
the counter and friction plates and align the bolt holes
with those of the differential case half 6.
5 Check free rotation of the gears in the horizontal

position (If held vertically the friction and counter plates
would prevent rotation).
9803/8020 Issue 2*
56 - 11 Rear Axle 56 - 11
9803/8020 Issue 2*
56 - 12 Rear Axle 56 - 12
Soft Engage Differential Lock

Drive Head - (PD70/SD70/PD90 Axle)
Assembly
Lightly oil all bearings and seals before assembly. 16 Grease the differential lock housing bore and fit sub-
assembly over differential lock actuator. Make sure that
1 Select shims 33 required for pinion depth setting and fit the piston is inserted squarely into the bore.
behind the bearing cup 32 in drive head housing 2. See
Pinion Depth for calculating shim thickness. 17 Fit new 'O' rings 5 and 6 to piston back plate 4. Fit back
2 Fit pinion bearing 35 onto pinion 28. Fit pinion into plate 4 over piston 7.
housing 2.
18 Gently tap the differential lock assembly with a soft
3 Fit spacer 34 (see Solid Spacer Installation). faced hammer to seat all components.
4 Fit crown wheel 22 using new Verbus Ripp bolts 21. 19 Ensure that the groove A in the piston 7 lines up with
Torque tighten bolts to 166 Nm (122 lbf ft). the castellated nut 15. Fit antirotation pin 13 so that it is
flush with the housing and 3 - 5 mm (0.12 - 0.2 in) clear
5 Fit bearings 24 and 25 to differential case spigots (if of the base of groove A.
previously removed) while turning them continuously.
6 Locate differential case assembly 20 into the housing 2. 20 Compress the assembly sufficiently to fit circlip 3.
Locate the differential lock end first by rotating the
assembly about the differential lock housing.
7 Position split bearing carrier 2A. Apply JCB

Threadlocker and Sealer to the threads of bolts 18. Fit
bolts but do not fully tighten. Fit bearing cup 19 and
when correctly seated, torque tighten bolts 18 to 244 28
Nm (180 lbf ft). 32
8 Rotate drive head through 90° so that the differential 33

lock housing is uppermost. Tap bearing cup 17 into
position over bearing 24.
9 Fit both castellated nuts 15 and 16 using a locally

manufactured service tool (see drawing in Section 1).
Tighten both nuts equally to seat all components, then
26
slacken back. Retighten nuts to give an increase in
pinion rolling torque of between 1.5 to 2 Nm (1.1 to 1.5
lbf ft) above that recorded in step 11 of Solid Spacer
Installation. 29
27 30 31 34
10 Using a clock gauge with a magnetic base, check the 35
A296411
crownwheel backlash. This should be 0.17 mm to 0.28
mm (0.006 to 0.011 in). To achieve this figure, back off
one of the castellated nuts and tighten the other one by
a similar amount. It is recommended that this figure is
checked in four diametrically opposed places.
11 Apply engineers’ marker to 3 or 4 teeth then check the

crownwheel and pinion for correct meshing. (See
Crownwheel and Pinion Adjustment. If this is
incorrect, adjust shim 33 accordingly.
* 12 Fit roll pin 14.
13 Fit bleed valve and cap 36 and 37. Fit a new 'O' ring 40
and fit hydraulic connector 38.
14 Secure the drive head with the differential lock housing

uppermost.
15 Fit new 'O' ring 8 to piston 7. Sub-assemble piston 7,

end plate 12, axial roller bearing 11, thrust sleeve 10
and compression spring 9.
9803/8020 Issue 6*
56 - 13 Rear Axle 56 - 13
9803/8020 Issue 2*
56 - 14 Rear Axle 56 - 14
Hub and Driveshaft (PD90 Axle)

1 Drain the oil from the axle and hub. Remove screws 1. Note: Stub Z is secured on early machines by bolts Y which
Use M10 screws (3 off) to jack off cover plate 2. screw into tapped holes on the axle (as shown opposite). On
Remove and discard 'O' ring 3. later machines bolts Y pass through clearance holes on the
axle and are secured by nuts at the rear (not shown
2 Pull out the driveshaft thrust pad 4. opposite).
3 Remove screws 5. *1 Secure stub Z with bolts Y (or bolts/nuts Y as

appropriate), tightened to 650 Nm (480 lbf ft). Lightly oil
4 Suitably support planet gear carrier 6; using M10 the inner wheel bearing. Fit the inner and outer bearing
screws (3 off), separate the carrier from bearing housing cups 19 and 20 and the inner bearing cone 21 into the
7. bearing housing 7.
5 Remove circlip 8, sun gear 9 and thrust washer 10. 2 a Before fitting combination seal 23, ensure that all
paint and dirt are removed from the nose of the
6 Remove and discard 'O' ring 11. carrier and the housing bore. Do not separate the
components of the seal or use excessive force when
7 Remove circlip 12 and annulus ring 13. fitting. DO NOT LUBRICATE THE SEAL.
8 Suitably support bearing housing 7, remove circlip 14 b Without dismantling or lubricating the new seal, drive
and locking plates 15. Remove nut 16 using special tool it into the bearing carrier until the locating lip is flush
892/00864. as shown at B. Use a suitable flat plate to ensure
that the seal is driven in squarely.
9 Remove bearing housing 7 and annulus carrier 17
together. Separate carrier and hub.
9a Remove the brake caliper (see Section G).

B
9b If required, unscrew bolts 30 to remove brake disc W.
Remove bearing cone 18 using a suitable puller. On
ABS machines remove the ABS sensor (see Section G).
10 Remove bearing cups 19 and 20.
11 Remove inner bearing cone 21 and seal 23.
12 Check bearing spacer 22 for damage and security. If

necessary, it can be removed using a suitable puller. To
fit a new spacer, proper heating equipment is required.
13 Check seal shield X for damage, security and

cleanliness.
A370470
14 Mark planet gear pins 24 and planet gear carrier 6 to
make sure pins are returned to the same position when
assembling. 3 Suitably support bearing housing 7. Fit the bearing
housing onto the stub Z.
15 Support planet gear carrier (pin head downwards) on
suitable blocks. Drive out pins 24 one at a time. 4 Lightly oil the outer wheel bearing cone 18. Fit onto
annulus carrier 17.
Note: Retain pin 24, thrust washer 25, needle rollers 26 and
spacer 27. Make sure that components from each position 5 Fit the annulus ring 13 onto the annulus carrier 17.
are not mixed. Make sure that all the rollers are accounted Secure with circlip 12.
for.
16 Remove planet gears 28 and thrust washers 29.
Note: All three pins must be removed before the planet

gears can be removed.
9803/8020 Issue 4*
56 - 15 Rear Axle 56 - 15
Hub and Driveshaft (PD 90 Axle) (continued)

Assembly
6 Fit annulus assembly (items 18, 17, 13 and 12) onto

stub Z. Secure with nut 16.
Note: Rotate bearing carrier backwards and forwards while

carrying out torque tightening sequence.
7 Gradually tighten nut to the lower limit of tightening

torque 700 to 1000 Nm (516 to 738 lbf ft). Fit locking
plates 15. If locking plates will not fit, further tighten
nut.
DO NOT EXCEED UPPER TORQUE LIMIT
8 Fit lock plates 15 and secure with circlip 14.
9 Fit new O ring 11.
10 Position the three planet gears 28 and inner thrust

washers 29 into the planet gear carrier 6.
11 Position thrust washer 25 onto pin 24. Smear the lower

half (head end) of pin with grease and position first row
of twenty-five needle rollers 26. Fit spacer 27, smear
upper portion of pin with grease and position second
row of twenty-five needle rollers.
12 Align planet gear 28 and thrust washer 29. Fit pin as

assembled in step 11. Take great care not to dislodge
any of the needle rollers.
13 Repeat steps 11 and 12 for other two pins.
Note: Make sure that the machined profile on the pin heads
is aligned with the side gear carrier machining.
14 Secure brake disc W with bolts 30 tightened to 166 Nm

(122 lbf ft). Suitably support planet gear carrier 6 and
refit to bearing carrier 7, secure with screws 5. Tighten
to 66 to 74 Nm (49 to 55 lbf ft).
14a On ABS machines replace the ABS sensor (see Section

G).
15 Insert drive shaft, Fit thrust washer 10 onto the

shoulder of sun gear 9. Secure with circlip 8.
16 Force fit driveshaft thrust pad 4 into cover plate 2.

Lubricate 'O' ring 3 with clean oil. Fit 'O' ring to cover
plate.
17 Fit cover plate into side gear carrier.
* 18 Apply JCB Threadlocker and Sealer to screws 1. Fit

screws and tighten to 33 to 37 Nm (24 to 27 lbf ft).
9803/8020 Issue 3*
57 - 1 Rear Axle 57 - 1
9803/8020 Issue 1
57 - 2 Rear Axle 57 - 2
Rear PTO Drive Shaft

7 Pack JCB HP Grease between the lips of a new rear oil
The numerical sequence is intended as a guide to seal 6 and fit into the casing, with the seal lips facing
dismantling. inwards. Make sure the oil seal is fitted squarely and is
fully seated.
8 Check that the final rolling torque with the rear oil seal
When Dismantling fitted is approximately 5 Nm (3.7 lbf ft) greater than that
measured in step 5.
Undo bolts 4 and remove PTO guard 5.
9 Before fitting the PTO output shaft 3, washer 2 and
Disconnect prop shaft from drive flange 8 to gain access to circlip 1, see Rear PTO Output Shaft.
stake nut 7. Remove and discard the stake nut and then
remove drive flange 8. 10 The rear PTO propshaft must be fitted with the sliding
joint at the axle end to prevent the possibility of fouling
Drive out shaft 10 towards the rear of the machine. Make when the limit of suspension travel is reached.
sure the shaft is withdrawn horizontally, otherwise the
collapsible spacer 13 may fall into the axle casing. Note: When assembly is complete, grease both drive shaft
bearings 11 and 14, following the instructions given in
Catch inner bearing race 11 as it falls off the shaft. Inner Routine Maintenance, Section 3. It is important that these
bearing race 14 will remain on the shaft and must be driven greasing instructions are followed correctly.
off if bearings are to be renewed.
Assembling
Note: Soak oil seal 6 in mineral oil for approximately 10

minutes before fitting.
1 Use a suitable length of tube to drive new inner bearing

race 14 onto drive shaft 10 until it butts up to shoulder
C.
Pre pack bearings with JCB HP Grease.
2 Fit bearing cup 12 into the drive head and bearing cup
15 into the axle casing. Fit collapsible spacer 13 to the
drive shaft 10 and insert into the axle. Make sure the
drive shaft is inserted horizontally otherwise the
collapsible spacer may fall off into the axle casing. Fit
bearing 11. Pack JCB HP Grease between the lips of a
new oil seal 9 and fit into the casing, with the seal lips
facing inwards. Make sure the oil seal is fitted squarely
and is fully seated. Do not fit seal 6 at this stage.
3 Apply an even 2mm bead of JCB Threadlocker and

Sealer around the outer end of the drive shaft spline at
the drive flange end. Fit drive flange 8 and a new stake
nut 7.
4 Tighten stake nut 7 until the drive shaft end float is

almost zero. Rotate the drive flange in both directions
to bed in the bearings. Check that the seal drag is
between 0.50 - 1 Nm (0.37 - 0.75 lbf ft).
5 Continue tightening stake nut 7 to collapse the spacer

13 to give a rolling torque of 1 to 1.5 Nm (0.7 to 1.1 lbf
ft) more than the previous reading given in step 4.
Note: If the specified rolling torque is exceeded, the

collapsible spacer 13 will be distorted. This spacer must be
renewed and a start made again at step 2.
6 When pre-load has been set, stake nut 7.
9803/8020 Issue 1
57 - 3 Rear Axle 57 - 3
Rear PTO Output Shaft

General
All models have a two speed capability for PTO drive. Two
rear PTO output shafts are available, as detailed below, to
suit differing implement shaft sizes, speeds and power
requirements.
The standard 35 mm (13/8 in) output shaft A has 6 splines at

one end (for 540 PTO RPM operation) and 21 splines at the
other end (for 1000 PTO RPM operation).
The optional 45 mm (13/4 in) shaft B is available in either 6 or

20 spline versions.
As a general rule, only use the 6 spline (540 PTO RPM) end
of shaft A for equipment having a power requirement of less
than 49 kW (65 hp). Equipment needing a higher power
output should be run at 1000 PTO RPM, using the 21 (A) or
20 (B) splined drive.
Fitting
Refer to the illustration on page 57 - 1 for the numerical

annotations.
Tilt the PTO guard 5 upwards to gain access.
To reverse standard shaft A, remove the circlip 1, washer 2

and withdraw the shaft. Insert the shaft facing the opposite
way and refit the washer and circlip. Ensure that the washer
is fitted with the chamfer towards the shaft housing.
When optional shaft B is required, fit the shaft either way

round and secure with circlip 1. Do not fit the washer 2. 2
227080
9803/8020 Issue 1
Section G Brakes Section G
i i
Contents Page No.

Technical Data 1-1
* Safety 1-1
Descriptions
Brake System - General 2-2
Brake System (Dry) (Non ABS) 2-1
Brake System (Dry) (ABS) 2 - 3A
Brake System (Wet) 2-4
Tractor ABS System (if fitted) 2-6
Routine Maintenance See Section 3
Fault Finding 3-1
Footbrake Calipers
- Caliper Configuration 5-1
- Removal and Replacement 5-1
- Brake System Bleeding 5-2
- Dismantling and Assembly 6-1
Compressor
- Removal and Replacement Refer to Engine Service Manual
Circuit Protection Valve

Footbrake Air Valve

Threshold Valve
Trailer Brake Air Valve

- Testing (in-situ) 53 - 1
- Bench Testing 54 - 2
Non-Return Air Valve

Trailer Brake Air Line Filter

Trailer Brake Hydraulic Valve

- Testing 56 - 1
Trailer Brake Inverse Relay Valve

Trailer Brake Couplings (Palm Couplings)

9803/8020 Issue 7*
ii ii
Contents Page No.

Parking Brake
Caliper
Actuator Cylinder 69 - 2
Parking Brake Air Control Valve

Air Dryer/Unloader Valve

- Dismantling and Assembly
(2000 Series to Serial No. 738755) 75 - 2
(3000 Series to Serial No. 640787) 75 - 2
- Dismantling and Assembly
(2000 Series from Serial No. 738756) 75 - 3
(3000 Series from Serial No. 640788) 75 - 3
Air/Hydraulic Actuator
- Bench Testing 76 - 3
* Failure Conscious Pressure Reducing Valve (Non ABS Machines only)

* ABS Sensors (ABS Machines only)

* Pressure Modulating Valves (ABS Machines only)

9803/8020 Issue 5*
Brake System
Operating Pressure (air) 8 bar (120 lbf/in2)
Parking Brake
Minimum Permissible Lining Thickness 3 mm (0.12 in)
Disc Thickness
- New 9.5 mm (0.374 in)
- Minimum after Skimming 8.9 mm (0.350 in)
Foot (Service) Brake
Minimum Lining Thickness (at renewal) 3 mm (0.125 in)
Front Disc Thickness

- New 22 mm (0.866 in)
- Minimum after Skimming 19.8-20.2 mm (0.780-0.795 in)
Rear Disc Thickness

- New 16 mm (0.630 in)
- Minimum after Skimming 14.3-14.7 mm (0.563-0.579 in)
* Safety
All Machines
! WARNING ! WARNING
Before working on or around the brake system, always Upon completion of any work done on the brake system
observe the following precautions: of machines fitted with ABS, the ABS test within
Servicemaster must be run satisfactorily before the
1 Stop the engine and chock all four wheels. machine is driven. It is not sufficient to rely on the ABS
self-check which can only check for the presence of
2 When the air system is being exhausted, keep components, not that they are correctly installed.
hands away from the parking brake actuator 0091
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
9803/8020 Issue 2*
Brake System (Dry) (non ABS)
N
2-1
9803/8020
XX
K1 K2 YY
TB1 TB2 M ZZ
Section G
L
E
TP3
C F P
TC
TP1
TP2
TP4 D G1 G3 H3
H1
G2 V
J W SL
A H2 U
B TP5
Q
R TH
Y T
H4 TS
R Y
N
X B
L P
M
Brakes
Descriptions
A249263
*
Component Key L Front brake calipers Y In-line check valve (hydraulic brake fluid
M Rear brake calipers line)
A Engine air filter N Pressure reducing valve (failure YY Hydraulic brake fluid lines
B Compressor conscious) ZZ Main hydraulic fluid lines
C Air dryer/unloader/exhaust silencer P Trailer brake air control valve
D Purge tank (early machines only) Q Feed to tractor services (Selectronic, Trailer Connectors
E Schrader valve air seat (if fitted), 4WS axle lock SL Single line air trailer brake (if fitted)
F Circuit protection valve solenoid air valve (if fitted)) TC Twin line air trailer brake, control
G1 Front brake circuit reservoir R Parking brake control valve TH Hydraulic trailer brake (if fitted)
G2 Rear brake circuit reservoir T Parking brake actuator TS Twin line air trailer brake, supply
G3 Trailer/parking brake circuit reservoir TB Threshold Valves (if fitted)
H1-H3 Low pressure warning light switches TP1 - TP5 Air pressure test points
U Tractor services reservoir (see Q)
H4 Parking brake ON warning light/2WD V Non-return valve
dump switch W Inverse relay valve (single line air trailer
J Foot brake valve brakes) (if fitted)
K1 Front brake air/hydraulic actuator X Hydraulic trailer brake valve (if fitted)
K2 Rear brake air/hydraulic actuator XX Air lines
Issue 6*
2-1
Section G
Brake System - General 2-2
The machine has an air over hydraulic brake system In the event of a loss of pressure, such as a pipe The ‘failure conscious’ aspect of valve N is a safety
9803/8020
with independent air and hydraulic circuits for front failure in one or more of the four circuits, the circuit feature in the event of failure of the front brake
and rear brakes. protection valve F ensures that the remaining circuit. When a failure occurs the pilot feed pressure
circuits still receive sufficient air to operate normally. from the front circuit to valve N fails. This causes
Section G
On 2000 Series machines to S/N 738755 and 3000 The four independent circuits are front brakes, rear the pressure limiting function of valve N to be
Series machines to S/N 640787 (referred to as ‘early brakes, trailer/parking brake and tractor services. overridden and allows full pedal braking pressure to
machines’ in this description), two systems, ‘dry’ or reach the rear calipers.
‘wet’, were fitted to suit territorial requirements or Front Brake Circuit
user preference. Trailer/Parking Brake Circuit
Air from the circuit protection valve is fed into the
All 2000 Series machines from S/N 738756 and front brake circuit reservoir G1 which is fitted with a Air from the circuit protection valve F is fed into the
3000 Series machines from S/N 640788 (referred to pressure test point TP1. Air from the reservoir trailer/parking brake circuit reservoir G3 which is
as ‘later machines’ in this description) are fitted with passes a low pressure warning light switch H1 fitted with a manual drain valve and a pressure test
a ‘dry’ system. Additionally, later 2000 Series before entering the dual foot brake valve J. When point TP3. Air from the reservoir passes a low
machines and 3000 Series machines are available the foot brake is operated, air is allowed through the pressure warning light switch H3 before feeding the
with ABS as factory fitted original equipment. valve. trailer brake air valve P. Before it enters the trailer
brake air valve the line branches to feed the parking
Brake System (Dry) (non ABS) The flow divides, some flowing to the trailer brake brake circuit via non-return valve V.
air control valve P to apply the trailer brakes. The
*
Trailer brake air valve P provides a permanent
Filtered air is drawn via engine air filter A into the rest of the air flows into the front brake air/hydraulic supply to the trailer brake coupling TS. It receives
engine mounted compressor B. actuator K1. Air pressure entering the actuator is control signals from the front and rear brakes when
converted into hydraulic pressure. A pilot hydraulic they are operated and responds by feeding the
Air from the compressor is directed to the air line is teed to the pressure reducing valve N. Full control line to the trailer brake coupling TC. On
dryer/unloader valve C which senses the air hydraulic pressure is fed to the front brake calipers some machines, threshold valves TB are fitted to
pressure stored in the braking system. When the L where it applies the brakes. ensure that the trailer pressure reaches a pre-set
braking system pressure is less than the pressure level before air is allowed to flow into the
Brakes
from the compressor, air is directed to purge tank D Rear Brake Circuit air/hydraulic actuators K1 and K2 to operate the
Descriptions
and the circuit reservoirs (early machines ) or to the service brakes of the tractor. When a machine is
circuit reservoirs only (later machines). When the Operation of the rear brake circuit is similar to the fitted with single line trailer air braking, inverse relay
braking system reaches its operating pressure a front, utilising reservoir G2, rear brake air/hydraulic valve W controls the feed via line SL.
purge valve in valve C opens to allow the dryer actuator K2 and rear brake calipers M.
internal pressure to expel accumulated condensate
and solid matter. This decompression of the dryer Additionally, the circuit incorporates a failure
allows dry air from purge tank D (early machines) or conscious pressure reducing valve N. The main
direct from the air system (later machines) to function of the valve is to minimise the risk of the
exhaust via the dryer desiccant, taking with it the rear wheels locking under heavy braking,
accumulated desiccant moisture, preventing it from particularly important when the machine is heavily
becoming saturated. loaded at the front end.
A Schrader valve E (tyre type valve) is fitted so that As braking pressure increases up to 43 bar valve, N
the system can be charged from an external source, has no effect and allows the pressure to the rear
for instance in the event of engine failure. The air brake calipers to increase at the same rate as the
flows, on early machines, past the Schrader valve pressure to the front brake calipers. As the pressure
into purge tank D (dry system) and then to the increases beyond 43 bar, valve N limits the rate of
circuit protection valve F or, on later machines, increase of the rear braking pressure so that the
direct to circuit protection valve F. ratio of front braking pressure increase : rear
braking pressure increase is 2.9 : 1.
Issue 6*
2-2
Section G
Brake System (Dry) (non-ABS) (continued) 2-3
N
9803/8020
XX
K1 K2 YY
Section G
TB1 TB2 M ZZ
L
E
TP3
C F P
TC
TP1
TP2
TP4 D G1 G3 H3
H1
G2 V
J W SL
A H2 U
B TP5
Q
R TH
T
H4 TS
R Y
N
X B
L P
M
Brakes
Descriptions
A249263
*
Parking Brake Circuit Tractor Services Circuit Hydraulic Trailer Brakes (if fitted)
From non-return valve V, the air is fed to the parking Air from the circuit protection valve is fed via line Q A hydraulic trailer brake facility can be provided. A
brake control valve R. When this valve is put into to the tractor services i.e. Selectronic, air seat (if hydraulic trailer brake valve X is fed via port P at
the off position it supplies air pressure to parking fitted), 4WS axle lock solenoid air valve (if fitted). pump pressure which is output via port N to the
brake actuator T to release the caliper parking Back up pressure is provided by reservoir U. external hydraulics valve as well as used internally.
brake. It also supplies a signal pressure to the trailer A tank return is provided via port R. The hydraulic
brake air valve which then cuts off the tractor brake output (port B) to connector TH is activated
control pressure. by pilot pressure into port Y from the front axle
When the control valve R is set to the on position, it service brake circuit. The pressure of hydraulic
exhausts all air downstream of non-return valve V brake output at port B is proportional to the service
with the following effects: brake pressure.
(1) The parking brake actuator applies the parking
brake by the force of its integral spring. (2) The
signal pressure is exhausted from the trailer brake
air valve which then supplies control pressure to
apply the trailer brakes. (3) Switch H4 closes to
operate the park brake light and to break continuity
at the 2WD dump relay.
Issue 5*
2-3
Section G
Brake System (Dry) (ABS) 2 - 3A
9803/8020
XX
K1 K2 K3
YY
N2 BB
Section G
TB1 TB2 TB3 MR ZZ

N1
L N3 CC DD
E
TP3
C F P
BB TC
CC TP1
TP2
TP4 G1 G3 H3
H1
G2 V
J W SL
A H2 U
B TP5
Q
CC R TH
Y T
BB AA TS
H4
R Y CC
N
X B
L P BB
ML
Brakes
Descriptions
A386021
Component Key ML Rear left brake caliper X Hydraulic trailer brake valve (if fitted)
MR Rear right brake caliper XX Air lines
*
A Engine air filter N1 Pressure modulating valve (front Y In-line check valve (hydraulic brake fluid
B Compressor brakes) (ABS) line)
C Air dryer/unloader/exhaust silencer N2 Pressure modulating valve (rear right YY Hydraulic brake fluid lines
E Schrader valve brake) (ABS) ZZ Main hydraulic fluid lines
F Circuit protection valve N3 Pressure modulating valve (rear left
G1 Front brake circuit reservoir brake) (ABS) ABS Electronic Components
G2 Rear brake circuit reservoir P Trailer brake air control valve AA Electronic Control Unit (ECU)
G3 Trailer/parking brake circuit reservoir Q Feed to tractor services (Selectronic, BB Wheel hub mounted sensing rings
H1-H3 Low pressure warning light switches air seat (if fitted), 4WS axle lock CC Axle mounted wheel speed sensors
H4 Parking brake ON warning light/2WD solenoid air valve (if fitted)) DD Signal lines to and from ECU
dump switch R Parking brake control valve
J Foot brake valve T Parking brake actuator Trailer Connectors
K1 Front brake air/hydraulic actuator TP1 - TP8 Air pressure test points SL Single line air trailer brake (if fitted)
K2 Rear right brake air/hydraulic actuator V Non-return valve TC Twin line air trailer brake, control
K3 Rear left brake air/hydraulic actuator W Inverse relay valve (single line air trailer TH Hydraulic trailer brake (if fitted)
L Front brake calipers brakes) (if fitted) TS Twin line air trailer brake, supply
Issue 2*
2 - 3A
Section G
Brake System (Dry) (ABS) 2 - 3B
Filtered air is drawn via engine air filter A into the Rear Brake Circuit Parking Brake Circuit
9803/8020
engine mounted compressor B.
Air from circuit protector valve F is fed into rear From non-return valve V, the air is fed to the parking
Air from the compressor is directed to the air brakes reservoir G2 which is fitted with a pressure brake control valve R. When this valve is put into
Section G
dryer/unloader valve C which senses the air test point TP2. Air from the reservoir passes low the off position it supplies air pressure to parking
pressure stored in the braking system. When the pressure warning light switch H2 before entering brake actuator T to release the caliper parking
braking system pressure is less than the pressure dual foot brake valve J. The air which passes brake. It also supplies a signal pressure to the trailer
from the compressor, air is directed to the circuit through the valve when the foot brake is operated brake air valve which then cuts off the tractor
reservoirs. When the braking system reaches its flows to the rear brake air/hydraulic actuators K2 control pressure.
operating pressure a purge valve in valve C opens and K3, via ABS pressure modulating valves N2† When the control valve R is set to the on position, it
to allow the dryer internal pressure to expel and N3† respectively, to actuate rear brake calipers exhausts all air downstream of non-return valve V
accumulated condensate and solid matter. This MR and ML. with the following effects:
decompression of the dryer allows dry air direct (1) The parking brake actuator applies the parking
from the air system to exhaust via the dryer † Refer to Tractor ABS System, General brake by the force of its integral spring. (2) The
dessicant, taking with it the accumulated dessicant Description and Operation. signal pressure is exhausted from the trailer brake
moisture, preventing it from becoming saturated. air valve which then supplies control pressure to
Trailer/Parking Brake Circuit apply the trailer brakes. (3) Switch H4 closes to
A Schrader valve E (tyre type valve) is fitted so that operate the park brake light and to break continuity
the system can be charged from an external source, Air from the circuit protection valve F is fed into the
at the 2WD dump relay.
for instance in the event of engine failure. The air trailer/parking brake circuit reservoir G3 which is
flows past the Schrader valve direct to circuit fitted with a manual drain valve and a pressure test
Tractor Services Circuit
protection valve F. point TP3. Air from the reservoir passes a low
pressure warning light switch H3 before feeding the
Air from the circuit protection valve is fed via line Q
In the event of a loss of pressure, such as a pipe trailer brake air valve P. Before it enters the trailer
to the tractor services i.e. Selectronic, air seat (if
failure in one or more of the four circuits, the circuit brake air valve the line branches to feed the parking
fitted), 4WS axle lock solenoid air valve (if fitted).
protection valve F ensures that the remaining brake circuit via non-return valve V.
Brakes
circuits still receive sufficient air to operate normally. Trailer brake air valve P provides a permanent Hydraulic Trailer Brakes (if fitted)
Descriptions
The four independent circuits are front brakes, rear supply to the trailer brake coupling TS. It receives
brakes, trailer/parking brake and tractor services. control signals from the front and rear brakes when A hydraulic trailer brake facility can be provided. A
they are operated and responds by feeding the hydraulic trailer brake valve X is fed via port P at
Front Brake Circuit control line to the trailer brake coupling TC. When a pump pressure which is output via port N to the
machine is fitted with single line trailer air braking, external hydraulics valve as well as used internally.
Air from the circuit protection valve is fed into the inverse relay valve W controls the feed via line SL. A tank return is provided via port R. The hydraulic
front brake circuit reservoir G1 which is fitted with a brake output (port B) to connector TH is activated
pressure test point TP1. Air from the reservoir by pilot pressure into port Y from the front axle
passes low pressure warning light switch H1 before service brake circuit. The pressure of hydraulic
entering the dual foot brake valve J. When the foot brake output at port B is proportional to the service
brake is operated, air is allowed through the valve. brake pressure.
The flow divides, some flowing to the trailer brake
air control valve P to apply the trailer brakes. The
rest of the air flows via ABS pressure modulating
valve N1† into the front brake air/hydraulic actuator
K1. Air pressure entering the actuator is converted
into hydraulic pressure and fed to the front brake
calipers L where it applies the brakes.
Issue 2*
2 - 3B
Section G
*
N
9803/8020
XX
Section G
K1 K2 YY
TB1 TB2 M ZZ
L
E
TP3
D F P
TC
DA
TP1
TP4 G1 G2 G3 H3
H1 C
V
J TP2 W SL
B A TP5 H2
Q
R TH
Y T
H4 TS
R Y
N
X B
L P
M
Brakes
Descriptions
A353471
*
Component Key L Front brake calipers Y In-line check valve (hydraulic brake fluid
M Rear brake calipers line)
A Engine air filter N Pressure reducing valve (failure YY Hydraulic brake fluid lines
B Compressor conscious) ZZ Main hydraulic fluid lines
C Unloader valve P Trailer brake air control valve
D Wet tank Q Feed to tractor services (Selectronic, Trailer Connectors
DA Auto drain valve air seat (if fitted), 4WS axle lock SL Single line air trailer brake (if fitted)
E Schrader valve solenoid air valve (if fitted)) TC Twin line air trailer brake, control
F Circuit protection valve R Parking brake control valve TH Hydraulic trailer brake (if fitted)
G1 Front brake circuit reservoir T Parking brake actuator TS Twin line air trailer brake, supply
G2 Rear brake circuit reservoir TB Threshold Valves (if fitted)
G3 Trailer/parking brake circuit reservoir TP1 - TP5 Air pressure test points
H1-H3 Low pressure warning light switches V Non-return valve
H4 Parking brake ON warning light/2WD W Inverse relay valve (single line air trailer
dump switch brakes) (if fitted)
J Foot brake valve X Hydraulic trailer brake valve (if fitted)
K1 Front brake air/hydraulic actuator XX Air lines
K2 Rear brake air/hydraulic actuator
Issue 3*
2-4
Section G
Filtered air is drawn via engine air filter A into the Parking Brake Circuit
9803/8020
engine mounted compressor B. Additionally, the circuit incorporates a failure
conscious pressure reducing valve N. The main From non-return valve V, the air is fed to the parking
brake control valve R. When this valve is put into
Section G
Air from the compressor is directed to the unloader function of the valve is to minimise the risk of the
valve C which senses the air pressure stored in the rear wheels locking under heavy braking, the off position it supplies air pressure to parking
braking system. If sufficient air pressure is stored, it particularly important when the machine is heavily brake actuator T to release the caliper parking
directs the flow from the compressor to atmosphere loaded at the front end. brake. It also supplies a signal pressure to the trailer
via a silencer. If the pressure in the braking system brake air valve which then cuts off the tractor
is low the unloader valve directs the flow into wet As braking pressure increases up to 43 bar valve, N control pressure.
tank D. The wet tank acts as a reservoir for the has no effect and allows the pressure to the rear When the control valve R is set to the on position, it
system and also as a water trap allowing any brake calipers to increase at the same rate as the exhausts all air downstream of non-return valve V
moisture in the air to condense and be expelled to pressure to the front brake calipers. As the pressure with the following effects:
atmosphere by auto drain valve DA. increases beyond 43 bar, valve N limits the rate of (1) The parking brake actuator applies the parking
increase of the rear braking pressure so that the brake by the force of its integral spring. (2) The
A Schrader valve E (tyre type valve) is fitted so that ratio of front braking pressure increase : rear signal pressure is exhausted from the trailer brake
the system can be charged from an external source, braking pressure increase is 2.9 : 1. air valve which then supplies control pressure to
for instance in the event of engine failure. The air apply the trailer brakes. (3) Switch H4 closes to
flows, on early machines, past the Schrader valve The ‘failure conscious’ aspect of valve N is a safety operate the park brake light and to break continuity
into wet tank D and then to the circuit protection feature in the event of failure of the front brake at the 2WD dump relay.
valve F circuit. When a failure occurs the pilot feed pressure
from the front circuit to valve N fails. This causes Tractor Services Circuit
In the event of a loss of pressure, such as a pipe the pressure limiting function of valve N to be
failure in one or more of the four circuits, the circuit overridden and allows full pedal braking pressure to Air from the circuit protection valve is fed via line Q
protection valve F ensures that the remaining reach the rear calipers. to the tractor services i.e. Selectronic, air seat (if
circuits still receive sufficient air to operate normally. fitted), 4WS axle lock solenoid air valve (if fitted).
The four independent circuits are front brakes, rear Trailer/Parking Brake Circuit
Brakes
brakes, trailer/parking brake and tractor services. Hydraulic Trailer Brakes (if fitted)
Descriptions
Air from the circuit protection valve F is fed into the

Front Brake Circuit trailer/parking brake circuit reservoir G3 which is
A hydraulic trailer brake facility can be provided. A
fitted with a manual drain valve and a pressure test
hydraulic trailer brake valve X is fed via port P at
Air from the circuit protection valve is fed into the point TP3. Air from the reservoir passes a low
pump pressure which is output via port N to the
front brake circuit reservoir G1 which is fitted with a pressure warning light switch H3 before feeding the
external hydraulics valve as well as used internally.
pressure test point TP1. Air from the reservoir trailer brake air valve P. Before it enters the trailer
A tank return is provided via port R. The hydraulic
passes a low pressure warning light switch H1 brake air valve the line branches to feed the parking
brake output (port B) to connector TH is activated
before entering the dual foot brake valve J. When brake circuit via non-return valve V.
by pilot pressure into port Y from the front axle
the foot brake is operated, air is allowed through the Trailer brake air valve P provides a permanent service brake circuit. The pressure of hydraulic
valve. supply to the trailer brake coupling TS. It receives brake output at port B is proportional to the service
control signals from the front and rear brakes when brake pressure.
The flow divides, some flowing to the trailer brake they are operated and responds by feeding the
air control valve P to apply the trailer brakes. The control line to the trailer brake coupling TC. On
rest of the air flows into the front brake air/hydraulic some machines, threshold valves TB are fitted to
actuator K1. Air pressure entering the actuator is ensure that the trailer pressure reaches a pre-set
converted into hydraulic pressure and fed to the level before air is allowed to flow into the
front brake calipers L where it applies the brakes. air/hydraulic actuators K1 and K2 to operate the
service brakes of the tractor. When a machine is
Rear Brake Circuit fitted with single line trailer air braking, inverse relay
valve W controls the feed via line SL.
Operation of the rear brake circuit is similar to the
front, utilising reservoir G2, rear brake air/hydraulic
Issue 3*
2-5
Section G
actuator K2 and rear brake calipers M.

2-6 Descriptions 2-6
Tractor ABS System (if fitted)

1 4
E E
A A
F F
C C
B B
D D
G
G A386090 A386120
2 5
E
E
A
A
F
F C
C B
B
D
D
G
G A386100
A386130
Zero pressure
E Braking/trapped pressure
A
C
B Decaying pressure
A386170
G A386110
9803/8020 Issue 1
2-7 Descriptions 2-7
Tractor ABS System (if fitted)

General Description
The Fastrac ABS system incorporates sensor rings attached The control signals from the ECU are applied to solenoid
to each of the four wheel hubs with a speed sensor mounted valves in the PMV’s. The solenoid valves and two check
on the axle adjacent to each. valves control the building-up, maintaining or releasing of
brake pressure to the relevant brake cylinders according to
The interaction of the speed sensors and sensor rings the requirements of the braking situation.
generates signals which are sent to the ABS Electronic
Control Unit (ECU). The ECU interprets the signals and
sends out appropriate control signals to pressure
modulating valves (PMV), one controlling the pair of front
brakes and one controlling each of the two rear brakes
individually.
Operation
Refer to the diagrams opposite.
Braking Situation Pressure Modulating Valve (PMV) Reaction
Normal roading. Foot brake E released. Check valves A and B closed.

Solenoid C de-energised (open).
1 Solenoid D de-energised (closed).
No air pressure from foot brake E.
No air pressure at air/hydraulic brake actuator F.
Foot brake E applied. Against spring pressure, check valve A opens under air
pressure from the foot brake.
Check valve B remains closed due to equal air pressure on
2 both sides.
Solenoids C and D remain de-energised.
Air pressure flows to actuator F to apply the brakes.
Foot brake E applied. ECU signal energises solenoid C which closes.

ABS ECU senses imminent wheel Braking pressure is routed to both sides of check valve A
lock-up and sends signal to PMV. which closes, due to spring pressure, to isolate the foot
brake.
3 Pressure in the actuator chamber is trapped and remains
constant.
Check valve B still remains closed.
Solenoid D still remains de-energised.
Foot brake E applied. Solenoid C remains energised (closed).

ECU still senses imminent wheel lock-up. It The foot brake remains isolated by check valve A.
also senses the need to reduce braking Solenoid D energises (opens).
pressure and sends a further signal to the Solenoid D exhaust port opens to remove the pressure
4 PMV. behind check valve B.
Against spring pressure, check valve B is forced open by the
trapped actuator pressure which decays to atmosphere via
exhaust port G.
Foot brake E applied. Solenoid C de-energises (opens) and solenoid D

ECU senses that wheel lock-up is no de-energises (closes).
longer imminent and stops sending signals Braking pressure overcomes the decaying pressure behind
to the PMV. both check valve A which opens and check valve B which
5 closes.
Foot brake pressure flows directly to actuator F to re-apply
the brake.
The pressure behind check valves A and B continues to
decay via port G until fully exhausted.
9803/8020 Issue 1
Introduction Safety Precautions

! WARNING
The brake system air pressure should be 8 bar (120 lbf/in2). Before working on or around the brake system, always
For diagnostic purposes the air brake system is fitted with observe the following precautions:
test points, on the circuit reservoirs (TP1, TP2), (TP3), on the
foot brake air valve (TP4, TP5) and, on ABS machines, on 1 Stop the engine and chock all four wheels.
the pressure modulating valves (TP6, TP7, TP8). Diagnosis
of system faults requires the use of suitable gauges (three 2 When the air system is being exhausted, keep
are usually sufficient). A service kit of gauges, hoses and hands away from the parking brake actuator
fittings is available as JCB Service Tool 892/00311. pushrod and caliper, as they may move and trap
your fingers.
General air leaks are usually audible with the engine
stopped. For smaller air leaks on valves, soak the valve in 3 Take care if disconnecting an air hose containing
soap solution and watch for the formation of bubbles. pressure as it may whip as air escapes.
As an aid to fault finding the air system pipes are colour 4 Never remove or dismantle a component until air
coded as follows: pressure has been exhausted and you have read
and understood the recommended procedures.
Red - front brake circuit.
5 Wear safety glasses when working with air
pressure.
Yellow - rear brake circuits. BRAK 8-3/1
Green - auxiliary circuit.
Blue - parking brake circuit.
Black - trailer brake system circuit.
Refer to the illustrations during fault finding.
9803/8020 Issue 4*
3 - 1A Fault Finding 3 - 1A
N1 - N3
C
K3 K2
K1
E
V
P F
G3
A387770
G2
G1
* 2115, 2125, 2135, 2140 ABS Machines
K3
C
K2
K1
N3 N2 N1
P
G3
A387692
2150, 3155, 3185 ABS Machines G1 G2 V
9803/8020 Issue 3
3 - 1B Fault Finding 3 - 1B
* Note: The illustration below shows the component layout on

the right side of non-ABS Fastrac 2115, 2125, 2135 and
2140 machines. On non-ABS Fastrac 2150 and 3000 series
machines the components are on the left side and are a
mirror image of the layout below. The component layouts for
ABS machines are shown opposite.
Component Key
C Air Dryer/Unloader Valve TP1 Test Point, Front Circuit (not shown) (on rear of G1)
D Purge Tank (early non-ABS machines only) TP2 Test Point, Rear Circuit (not shown) (on rear of G2)
E Schrader Valve TP3 Test Point, Trailer and Parking Brake Circuit (not
F Circuit Protection Valve shown) (on rear of G3)
G1 Front Circuit Reservoir TP4 Test Point, Front Circuit (for position see Foot Brake
G2 Rear Circuit Reservoir Air Valve, Removal and Replacement)
G3 Trailer/Parking Brake Reservoir TP5 Test Point, Rear Circuit (for position see Foot Brake
K1 Front Brake Air/Hydraulic Actuator (both hubs) Air Valve, Removal and Replacement)
K2 Rear Brake Air/Hydraulic Actuator (both hubs)(non- TP6 Test Point, Front Circuit (ABS only) (not shown) (see
ABS machines) Description, Brake System (Dry) (ABS))
Rear Brake Air/Hydraulic Actuator (right hub) (ABS TP7 Test Point, Right Rear Circuit (ABS only) (not
machines) shown) (see Description, Brake System (Dry)
K3 Rear Brake Air/Hydraulic Actuator (left hub) (ABS (ABS))
machines) TP8 Test Point, Left Rear Circuit (ABS only) (not
N Pressure Reducing Valve (Failure Conscious) shown) (see Description, Brake System (Dry)
(non-ABS machines only) (ABS))
N1- N3 Pressure Modulator Valves (ABS Machines only).
P Trailer Brake Air Control Valve
U Tractor Services Reservoir (early non-ABS machines
only)
V Non-return Valve
K2
C
K1
P E
U V
D
G3
G2
A258160
G1
Non-ABS Machines only
9803/8020 Issue 2*
Low Pressure Warning Lights On

CHECK ACTION
1 Are all three warning lights on? YES: Check 2.

NO: Check 4.
2 Is there a leak between the compressor and the circuit YES: Rectify leak.
protection valve? NO: Check 3.
3 Is air continually pumping from air dryer/unloader valve YES: Renew defective air dryer/unloader valve.
exhaust? NO: Strip and examine compressor.
4 If only one light is on, pressure test relevant tank. Is YES: Renew defective low pressure switch.
pressure OK? NO: Check 5.
5 Drain air from complete system. Recharge. Does fault YES: Renew circuit protection valve.
still exist? NO: System now OK.
Service Brakes Poor

CHECK ACTION
1 Do disc pads have a minimum of 3 mm (0.12 in) friction YES: Check 2.

material? NO: Renew pads (in complete axle sets).
2 Do both brake fluid reservoirs have adequate fluid? YES: Check 3.

NO: Top up and check for leaks.
3 Have brakes been bled? YES: Check 4.

NO: Bleed brakes.
*4 Fit a gauge first to TP4 and then to TP5. Each time YES: Check 5
press the brake pedal. Does the gauge indicate that air NO: Check that air system pressure is reaching the circuit
system pressure is reaching the footbrake valve. protection valve. If not check for a leak in the circuit
from the compressor. If pressure is reaching the
circuit protection valve check the valve for faults.
*5 Are air/hydraulic actuators functioning? YES: Non-ABS machines - check 6.

ABS machines - bleed brakes.
NO: Strip and inspect actuator(s).
*6 Is there evidence of oil leakage at the failure conscious YES: Fit a new valve.
pressure relief valve? (non-ABS machines only). NO: Bleed brakes.
.
* Poor Front Brakes, Good Rear Brakes
(Non - ABS Machines)
CHECK ACTION
1 Fit a gauge to TP1. Charge system. Does TP1 reach YES: Check 2.
system pressure? NO: Check for leaks or faulty circuit protection valve.
YES: Check 3.
2 Operate footbrake. Does the front air/hydraulic actuator NO: Check footbrake valve.
function?
3 Is there evidence of oil leakage at the failure conscious YES: Fit a new valve.
pressure relief valve? NO: Check 4.
4 Has the front hydraulic circuit been bled? YES: Check operation of the caliper and serviceability of
the brake friction pads.
NO: Bleed front hydraulic circuit.
9803/8020 Issue 2*
* Poor Front Brakes, Good Rear Brakes

(ABS Machines)
CHECK ACTION
2 Operate footbrake. Does the front air/hydraulic actuator YES: Check 4.

function? NO: Check 3.
3 Operate footbrake. Does TP4 or TP6 reach system YES: Check pressure modulator valve.
pressure? NO: Check footbrake valve.
4 Has the front hydraulic circuit been bled? YES: Check operation of the caliper and serviceability of
NO: Bleed front hydraulic circuit.
* Poor Rear Brakes, Good Front Brakes

(Non-ABS Machines)
CHECK ACTION
2 Operate footbrake. Does the rear air/hydraulic actuator YES: Check 3.

function? NO: Check footbrake valve.
3 Is there evidence of oil leakage at the failure conscious YES: Fit a new valve.
pressure relief valve? NO: Check 4.
4 Has the rear hydraulic circuit been bled? YES: Check operation of the calipers and serviceability of
NO: Bleed rear hydraulic circuit.
* Poor Rear Brakes, Good Front Brakes

(ABS Machines)
CHECK ACTION
2 Operate footbrake. Does the rear air/hydraulic actuator YES: Check 4.

function? NO: Check 3.
3 Operate footbrake. Does TP5, TP7 or TP8 reach YES: Check both pressure modulator valves.
system pressure? NO: Check footbrake valve..
YES: Check operation of the calipers and serviceability of

4 Has the rear hydraulic circuit been bled? the brake friction pads.
NO: Bleed rear hydraulic circuit.
9803/8020 Issue 2*
Trailer Brakes Poor

CHECK ACTION
1 Fit gauge to TP3. Charge system. Is tank up to system YES: Check 3.

pressure? NO: Check 2.
2 Drain air from complete system. Recharge. Is tank up to YES: System now OK.
system pressure? NO: Renew circuit protection valve.
3 Fit gauges to trailer tappings TS and TC. Is TS at YES: Check 4.

system pressure? NO: Defective trailer brake valve.
4 Operate footbrake. Is TC at system pressure? YES: Fault on trailer brakes.

NO: Defective trailer brake valve.
Park Brake Not Holding

CHECK ACTION
1 Do disc pads have a minimum of 3 mm (0.12 in) friction YES: Check 2.

material? NO: Renew pads.
2 Are pads adjusted correctly? YES: Check 3.

NO: Adjust.
3 Is caliper clamping on disc? YES: Suspect fault in rear axle.

NO: Suspect fault in spring brake actuator.
Park Brake Not Releasing

CHECK ACTION
1 Fit gauge to TP1 and TP3. Charge system. Is pressure YES: Check 3.
OK? NO: Check 2.
2 Is there a leak between the trailer brake valve and the YES: Rectify leak.
park brake actuator? NO: Defective park brake valve.
3 Are pads adjusted correctly? YES: Suspect fault in spring brake actuator.
NO: Adjust.
9803/8020 Issue 1
5-1 Footbrake Calipers 5-1
Caliper Configuration
* Note: Illustrations show typical caliper mounting positions. Replacement
Removal and Replacement * Reverse the removal procedure, ensuring that correct
spacers E and F are fitted and that JCB Threadlocker and
Note: The procedures described here apply to all machines Sealer is applied to the bolts.
unless specified otherwise.
Bleed the brakes as described under Brake System
Removal Bleeding for the appropriate machine.
1 Park the machine on firm, level ground, apply the parking Torque Settings
brake and remove the starter key.
! WARNING
A raised and badly supported machine can fall on you. C 475 48.4 350
Position the machine on a firm, level surface before D 250 25.5 184
chocked. Do not rely solely on the machine hydraulics or Dacromet (colour: mottled silver)
Disconnect the battery, to prevent the engine being C 392 40 289
GEN-001
* D (8.8 grade) 200 20 148
D (10.9 grade) 300 30 220
2 Chock the front wheels. Jack up the appropriate wheel,
support the machine on an axle stand and remove the IMPORTANT - ABS MACHINES: Refer to Safety at the
wheel. front of this section before proceeding further.
3 Disconnect the brake pipe A (front) or B (rear) and catch

the fluid in a suitable container.
4 If the pistons are free, force the pads back until they
clear the disc. If necessary remove the pads to provide
clearance (see Section 3). Remove bolts C (front) or D
(rear) and remove the caliper.
C
E
F
B D
C A F
E S165390
D
9803/8020 Issue 4*
Brake System Bleeding

Note: The hydraulic systems for the front and rear brakes 6 When bleeding the rear system of a vehicle fitted with a
are completely separate and must be bled separately as trailer brake hydraulic valve, bleed air from the bleed
detailed below. screw on the valve after having bled the rear calipers.
(See Trailer Brake Hydraulic Valve - Removal and
* Note: If two calipers are fitted per wheel, they should be Replacement for position of bleed screw.)
bled as a wheel pair via the uppermost caliper in each case.
7 Top up the brake fluid reservoirs.
! WARNING
Before proceeding with the bleeding procedure it is
important to ensure that the parking brake is engaged
and that one pair of wheels is blocked on both sides.
BRAK 1-2
1 With the engine running, check that all three low air
pressure warning lights are extinguished, indicating there
is enough air pressure. Stop the engine.
2 Fill the relevant fluid reservoir with the specified fluid (see
Section 3). Ensure that throughout the bleeding process
the level is not allowed to fall below the lower mark on
the reservoir.
! WARNING
Using incorrect brake fluid could damage the system.
manual for the correct fluid. The fluid can harm your
skin. Wear rubber gloves. Cover cuts and grazes.
2-3-2-6/1
3 Attach a tube to the bleed screw to be bled (X - front, Y -

rear), ensuring that the free end is immersed in fluid in a
suitable container.
4 Open the bleed screw and apply full pedal strokes until
all air is expelled. Close the bleed screw with the pedal
fully depressed.
5 Repeat the procedure for the other brake on the opposite

side of the machine.
S165390
9803/8020 Issue 3*
D
B
C
D
E
C
B
214310
9803/8020 Issue 1
Note: Before dismantling, the caliper must be removed from

the machine (see Foot Brake Calipers, Removal and
Replacement) and thoroughly cleaned. Take great care to
prevent entry of dirt and grit.
! WARNING
endanger health. Wash off the caliper assemblies before
13-3-1-3
Remove the pads and retaining pins (see Checking and

Renewing the Foot Brake Pads, Section 3).
Split the caliper by removing capscrews A.
Use compressed air applied through the hydraulic fluid ports

to force out the pistons B.
Remove and discard dust seals C, anti-extrusion rings D

and 'O' rings E and F.
Wash the piston bores with clean brake fluid and blow dry.
Ensure that the pistons and their bores are free from scoring
and corrosion. If in doubt, renew the pistons or the complete
caliper assembly as required.
Ensure that the mating faces of the caliper halves are

perfectly clean.
Fit new 'O' rings and anti-extrusion rings, lubricated with

clean brake fluid.
Fit new dust seals and reassemble the caliper halves

ensuring that 'O' rings F remain in position.
Fit new capscrews A, tightened evenly to the torque settings

below.
Capscrew Torque Settings

Front 235-255 24-26 173-188
Rear 157-176 16-18 116-130
9803/8020 Issue 1
21 - 1 Circuit Protection Valve 21 - 1
B
A
F
G3
G2
G1
A387720
* 2115, 2125, 2135, 2140 ABS Machines
A
B
B
F
G3
G2
G1 A387731
* 2150, 3155, 3185 ABS Machines
9803/8020 Issue 5*
21 - 2 Circuit Protection Valve 21 - 2
Note 1: The pressure settings of the circuit protection valve 2 Disconnect the hoses from the ports by first pushing in
are factory-set. Adjustment and repairs are not permitted in the hose, then pushing in the sleeve in the elbow or
service. If the fault finding procedure indicates a fault in this adapter, and then pulling out the hose. Remove elbow
valve, a new unit must be fitted. A. Blank the open ports to prevent entry of dirt and
label the hoses to assist correct refitting.
* Note 2: The illustration below shows the component layout
on the right side of non-ABS Fastrac 2115, 2125, 2135 and 3 Remove the two mounting screws B and lift the valve F
2140 machines. On non-ABS Fastrac 2150, 3155 and 3185 clear.
mirror image of the layout below. Replacement
! WARNING Reverse the Removal procedure.

Before working on the brake system make sure the
When fitting elbows, clean the threads and apply Clayton
machine is on level ground and chock all four wheels.
BRAK 1-4 System Seal SC1251.
Torque Settings
Removal
1 Release the system air pressure as follows:
a Grip the “keyring” fitting at the bottom of reservoir B 20 2.0 14.7
G3 and pull sideways until all air is released.
b Repeatedly press the foot brake pedal until the
stored pressure in reservoirs G1 and G2 is IMPORTANT - ABS MACHINES: Refer to Safety at the
exhausted. front of this section before proceeding further.
c Repeatedly work the column selector switch (see
System Description, JCB Selectronic) for the JCB
Selectronic system to exhaust the air pressure in
reservoir U (non-ABS machines only).
F
B
G3
U
G2
G1
A257980
Non-ABS Machines
9803/8020 Issue 3*
27 - 1 Foot Brake Air Valve 27 - 1

! WARNING Replacement
Before working on the brake system make sure the Reverse the removal procedure.
BRAK 1-4
When fitting elbows and tee-pieces, clean the threads and
! CAUTION apply Clayton System Seal SC1251.
If this item is to be dismantled (even partially) on the
Adjust brake pedal return stop W to give a clearance at X
machine, ensure that all pressure has been removed
between the pedal and the control valve plunger of 0.05 to
from the system.
BRAK 8-1
0.25 mm.
Removal Torque Settings
1 Before disconnecting hoses, exhaust all air from the Zinc-Plated (colour: golden)
foot brake circuits by depressing the brake pedal
several times. Item Nm kgf m lbf ft
E 28 3.0 21
2 Disconnect hoses A, B, C and D by first pushing in the
F 28 3.0 21
hose, pushing in the sleeve, then pulling out the hose.
Blank the open ports to prevent entry of dirt and label
* Dacromet (colour: mottled silver)
the hoses to assist correct refitting.
3 Disconnect and label the wiring from low pressure Item Nm kgf m lft ft
switches H1 and H2. E 22.5 2.3 16.6
F 22.5 2.3 16.6
4 Remove bolts E and F.
Hose Destinations
Note: Bolts E are accessible from inside the cab.
A Air/Hydraulic Actuator K1 (Front Brakes)
B Air/Hydraulic Actuator K2 (Rear Brakes)
C Front Brake Air Reservoir G1
D Rear Brake Air Reservoir G2
Test Point Identification

H2 H1 TP4 Test Point, Front Circuit
C TP5 Test Point, Rear Circuit
D
IMPORTANT - ABS MACHINES: Refer to Safety at the
front of this section before proceeding further.
TP4
TP5
B A W X
249330 S190091
9803/8020 Issue 3*
9803/8020 Issue 2*

A Service Kit should be obtained before starting this job.

Note that items 3 and 26 are available only as complete
assemblies.
When Dismantling
Mark the relative positions of the body components to

ensure correct alignment on assembly.
Use a screwdriver (or similar) inserted through one of the

upper valve ports into a slot in valve stem 7 to retain the
valve stem while unscrewing nut 4.
Cleaning and Inspection
Using a proprietary cleaning fluid, clean all components

which are to be re-used. Inspect for wear and damage. If the
pistons, bores or valve seats show signs of appreciable wear
or damage a replacement valve should be obtained.
When Assembling
Use the new components from the Spares Kit during

assembly.
* Ensure that the ears of circlip 25 are installed at 180° to the

ears of the circlip at the lower end of assembly 26.
Lightly grease valve stem 7 and all 'O' rings with the silicone
grease supplied with the Spares Kit. DO NOT LUBRICATE
RUBBER SPRING 17.
After locating rubber spring 17 and spring seat 16 onto the

stem of upper piston 10, secure with nut 15. Screw the nut
down until its top surface is 0.254 mm (0.01 in) above the
top face of piston 10.
Ensure that the tabs on retaining plate 9 locate securely onto

the body 27.
Use the procedure described in When Dismantling to retain

valve stem 7 while screwing down nut 4.
Torque Settings

18 6.8 - 9.5 0.7 - 1.0 5-7
9803/8020 Issue 2*
30 - 1 Threshold Valve 30 - 1
Removal and Replacement (if fitted)
Note: When fitted, the two threshold valves are positioned in

the relevant pannier, left on 2115, 2125, 2135 machines,
right on 2150 and 3000 Series machines. The following
procedure is applicable to either valve.
! WARNING
BRAK 1-4
! CAUTION
If this system is to be dismantled (even partially) on the
from the system.
BRAK 8-1
Removal
1 Exhaust all air from the brake circuits by draining

reservoirs G1 and G2 (see Section 3).
2 Disconnect hoses A and B by first pushing in the hose,

pushing in the sleeve, then pulling out the hose. Blank
the open ports to prevent entry of dirt and label the
3 Remove bolts D.
Replacement
Reverse the Removal procedure.
When fitting elbows, clean the threads and apply Clayton

System Seal SC1251.
Hose Destination
A Inlet from foot brake valve.

B Delivery to air/hydraulic actuator.
* IMPORTANT - ABS MACHINES: Refer to Safety at the

9803/8020 Issue 3*
30 - 2 Threshold Valve 30 - 2
Dismantling and Assembly 1

A K
Early type threshold valves are shown at A. Later valves are
shown at B.
The valves are similar in construction and the numerical 2

sequences shown on the illustrations are intended as a
guide to dismantling.
For assembly the sequence should be reversed. 3

P
Note 1: A Service Kit should be obtained before starting 4 13
this job. Ensure that the kit obtained is correct for the valve
fitted. Items shown grouped as K are the only parts 5
available and are obtainable only as a complete kit.
Note 2: The illustrations show valves as supplied. Remove 6

blanking plugs P as required before fitting.
7
When Dismantling

8
ensure correct alignment on assembly. P
When Assembling
12
10 11
Use the new components from the Service Kit during
assembly.
333990
B K
2
3
1 4 5
7
11
10
9 P
332510
9803/8020 Issue 1
53 - 1 Trailer Brake Air Valve 53 - 1
A V
P
G3
G2
G1
A386060
* 2115, 2125, 2135, 2140 ABS Machines
V
P
G3
G2 A386051
G1
2150, 3155, 3185 ABS Machines
9803/8020 Issue 4*
Removal and Replacement Replacement

* Note: The illustration below shows the component layout on
the right side of non-ABS Fastrac 2115, 2125, 2135 and When fitting elbows and adapters, clean the threads and
2140 machines. On non-ABS Fastrac 2150 and 3000 Series apply Clayton System Seal SC1251.
Port Connections
mirror image of the layout below.
1.1 Reservoir G3, non-return valve V
Park the machine on level ground, switch off the engine and 1.2 Trailer supply line
remove the starter key. 2.2 Trailer control line
! WARNING 4.1 Footbrake valve and air/hydraulic actuator - Front
Before working on the brake system make sure the Circuit
machine is on level ground and chock all four wheels. 4.2 Footbrake valve and air/hydraulic actuator - Rear
BRAK 1-4 Circuit
! CAUTION 4.3 Parking Brake Valve
If this item is to be dismantled (even partially) on the Torque Settings
from the system. Item Nm kgf m lbf ft
BRAK 8-1 A 28 2.8 20.6
Removal IMPORTANT - ABS MACHINES: Refer to Safety at the

1 Release the system air pressure as follows:
a Grip the ‘key ring’ fitting at the bottom of reservoir
Testing (in Situ)
G3 and pull sideways until all air is released. With the valve installed on the vehicle, connect 0-20 bar
b Repeatedly press the foot brake pedal until the (0-300 lbf/in2) pressure gauges into the front service line (at
stored pressure in reservoirs G1 and G2 is port 4.1), the trailer control line (at port 2.2) and the trailer
exhausted. supply line (port 1.2).
c Repeatedly work the column selectronic switch (see
Note: This test should be carried out with the brakes held on
System Description, JCB Selectronic) for the JCB
at a system pressure between 2 and 6 bar (29 - 87 lbf/in2)
Selectronic System to exhaust the air pressure in
reservoir U (non-ABS machines only). Charge the system and apply the service brakes tobetween
2 and 6 bar (29 - 87 lbf/in2). With the brakes held on, check
2 Non-ABS Machines only that the gauge reading at port 2.2 is greater than the reading
Remove the Circuit Protection Valve F (see Circuit at port 4.1 by 0.1 bar (1.5 lbf/in2) on single caliper brakes. On
Protection Valve, Removal and Replacement). twin caliper brakes this difference should be 1.4 bar (20.3
lbf/in2). Release the brakes.
3 Disconnect each Trailer Brake Air Valve hose by
pushing in the hose, then pushing in the sleeve in the Disconnect the delivery line from port 2.2, to simulate a
elbow or adapter and pulling out the hose. Blank the brake failure. Fully apply the brakes and check that trailer
open ports to prevent entry of dirt and label the hoses supply line pressure (at port 1.2) falls to 1.5 bar (22 lbf/in2)
to assist correct refitting. within two seconds. Check also that the trailer brakes are
automatically applied before the pressure drops below 2 bar
4 Remove nuts A to release valve P from its mounting (30 lbf/in2).
bracket and lift clear. Remove non-return valve V and
the elbows and connectors from the ports.
F
A
P
G3 U
G2 A257980
Non-ABS Machines G1
9803/8020 Issue 3*
161980
9803/8030 Issue 1
Dismantling and Assembly Bench Testing

The numerical sequence shown on the illustration is Leakage Tests
For the following tests, apply a soap and water solution to
For assembly the sequence should be reversed. the valve joints and to all ports not connected to the air
supply.
Note: The valve incorporates a trailer 'predominance' (or
'lead') feature which allows the trailer brake pressure to be 1 Connect a small air reservoir and a 0 - 15 bar (0 - 220
set higher than the service brake pressure (ensuring stable lbf/in2) pressure gauge to port C and a supply pressure
braking when a trailer is connected to the machine). This is of 8 bar (116 lbf/in2) at port A.
set at the factory by means of screw X which must not be
disturbed in service. Apply air at a pressure of 8 bar (116 lbf/in2) to each of
the signal ports D, E and F in turn. In each case,
The predominance setting can be checked (but not leakage must not exceed a 25 mm (1 in) bubble in 10
adjusted) as part of the test procedure - see Testing (in seconds.
Situ).
2 Apply air at a pressure of 8 bar (116 lbf/in2) to ports A
! CAUTION and F. Leakage must not exceed a 25 mm (1 in) bubble
in 5 seconds.
Screw X must not be disturbed or unsafe trailer braking
will result.
BRAK 8-6 Operational Tests
When Dismantling With air at 8 bar (116 lbf/in2) connected to ports A and F,
apply a series of signal pressures to ports D and E in turn.
Mark the relative positions of the body components to The signal pressures should vary from 1 - 8 bar (14.5 - 116
ensure correct alignment on assembly. lbf/in2) in 1 bar steps. Check that the valve responds
immediately to the variations in pressure and that no leakage
Link pipe 5 and nut 41 are secured with JCB Threadlocker occurs when the valve is stabilized between variations.
and Sealer. Items 9 to 15 and Items 45 to 55 can be
removed as complete assemblies then dismantled With air at 8 bar (116 lbf/in2) connected to port A and a 0 -
separately. 15 bar (0 - 220 lbf/in2) pressure gauge connected to port C,
apply varying signal pressures (in the range 0 - 4 bar (0 - 60
Cleaning and Inspection lbf/in2) to port F. Check that the valve responds immediately
to variations in signal pressure. (A decrease in signal
Using a proprietary cleaning fluid, clean all components pressure should cause an increase in pressure at port C,
which are to be re-used. Inspect for wear and damage. If the while an increasing signal pressure should produce a
valve seat 47 or the pistons or bores show signs of wear or decreasing pressure at port C.)
damage, a replacement valve should be fitted.
Port Identification
When Assembling (The numbers shown in brackets are cast on the body of the
valve.)
Use the new components from the Spares Kit during
assembly. A (1.1) Main supply
B (1.2) Trailer supply
Secure link pipe 5 and nut 41 with JCB Threadlocker and C (2.2) Trailer control
Sealer. (Ensure that both ends of the link pipe are treated D (4.1) Front service brake line
with sealant.) E (4.2) Rear service brake line
F (4.3) Parking brake line
Torque Settings

1 11 - 14 1.1 - 1.4 8.5 - 10.5
17 11 - 14 1.1 - 1.4 8.5 - 10.5
34 11 - 14 1.1 - 1.4 8.5 - 10.5

9803/8030 Issue 2*
55 - 1 Non-Return Air Valve 55 - 1

Early type - see X X

When Dismantling A
Remove seal 5 from piston 4.
When Assembling
Grease broad edges of new seal 5 with silizium grease

(supplied in the seal kit) and stretch the seal onto the piston.
Note direction of arrow A when refitting components into

6
body.
5
4 3
2
1
163750
Later type - see Y

6
When Dismantling Y 5
A Service Kit should be obtained before starting this job. 4
Ensure that the kit obtained is correct for the valve fitted. 3
Items shown grouped as K are the only parts available and
are obtainable only as a complete kit. 2
When Assembling 1
Use the components from the Service Kit during assembly.

332550
9803/8020 Issue 3*
55 - 2 * Trailer Brake Control Line Air Filter 55 - 2

When Dismantling
Take care when removing item 1 that the rest of the

components do not spring out.
When Assembling
Check O-ring 3 and filter 6 for damage or wear and if

necessary fit new components.
* If re-using, clean filter 6 by washing in clean fuel. Blow dry

with compressed air.

1
A387680
9803/8020 Issue 4*
56 - 1 Trailer Brake Hydraulic Valve 56 - 1
Testing
1 Connect a 0-400 bar (0-6000 lbf/in2) gauge into the trailer
hydraulic brake coupling.
2 Start the engine. Wait for the low air pressure lamps to
go out. Press the foot brake pedal and check the gauge
reading which should be 140 bar (2000 lbf/in2).
3 An incorrect pressure reading can be caused by dirt in

the pilot valve. To rectify, stop the engine, disconnect
hose 5 and remove screws B and pilot valve housing C.
Wash the valve in clean hydraulic fluid, re-assemble,
bleed and re-test.
4 A fault in the trailer brake valve can cause the external

hydraulics to operate slowly. The valve can appear
excessively hot or may make the hydraulic system
cavitate. Check by disconnecting hoses 2 and 4 and
connecting these hoses together to bypass the valve.
Re-test the external hydraulics and if there is a marked
improvement, the trailer brake hydraulic valve should be
renewed.

Park the machine on firm, level ground, apply the parking
brake and remove the starter key.
The numerical sequence on the illustration is intended as a

guide to removal.
For replacement, the sequence should be reversed.
When Removing 3
Label and blank all hydraulic connections to assist correct
replacement and to prevent entry of dirt and excessive oil
loss.
When Replacing 1
2
Renew the 'O' ring seals in the hose connections (see
Section 1 for torque settings).
4
Bleed the rear hydraulic brake circuit of the Fastrac at the
calipers and at screw A (see Brake System Bleeding).
6
Port Connections
1 Tank (via external hydraulics control valve) (port R) 7

2 High pressure carryover to external hydraulics control
valve (port N)
3 Trailer coupling (port B)
4 Feed from pump (port P)
5 Pilot feed from rear hydraulic brake system (port Y)
A
Torque Settings
B

6/7 20.5 - 25.5 2.1 - 2.6 15 - 19 C 5 A290640

6/7 22.5 2.3 16.6

9803/8020 Issue 2*
56 - 2 Trailer Brake Hydraulic Valve 56 - 2

Before dismantling, the trailer brake hydraulic valve must be
removed from the machine (see Trailer Brake Hydraulic
Valve, Removal and Replacement).
Dismantling
The numerical sequence on the illustration is a guide to

dismantling.
Assembly
Assembly is the reverse of dismantling.
Torque Settings
Item Torque
Nm kgf m lbf ft
1 10 - 13 1 - 1.3 7 - 10
3 2.5 - 3.5 0.25 - 0.35 1.8 - 2.6
17 56 - 75 5.7 - 7.7 41 - 55
17
18
16
15
1
5
9 8
14 11
4 3
2
10
7
6
13 12
A290660
9803/8020 Issue 1
58 - 1 Trailer Brake Inverse Relay Valve 58 - 1
! WARNING
BRAK 1-4
! CAUTION
from the system.
BRAK 8-1
Removal
1 Drain air from the brake system.

E
2 Disconnect hoses A, B and C by pushing in the sleeve
in the elbow and pulling out the hose. Blank the open B
ports to prevent entry of dirt and label the hoses to
assist correct refitting.
3 Remove bolts E.
Replacement
D
A
C
When fitting elbow, clean the threads and apply Clayton
System Seal SC1251. 229300
Hose Destinations
A Dual Line Trailer Brakes - Supply (red)

B Dual Line Trailer Brakes - Control (yellow)
C Single Line Trailer Brakes

9803/8020 Issue 3*
58 - 2 Trailer Brake Inverse Relay Valve 58 - 2

1 A
Early type inverse relay valves are shown at A. Later valves
are shown at B.
2
The numerical sequence shown on the illustration is 23
intended as a guide to dismantling. K
4
5 22
Note: A Service Kit should be obtained before starting this 6 21
job. Ensure that the kit obtained is correct for the valve
fitted. Items shown grouped as K are the only parts
7
20
available and are obtainable only as a complete kit. 8
9
When Dismantling 19
10
ensure correct alignment on assembly. 11 18
12
When Assembling
13 17
16
assembly.
14
15
24 333980
1 K
B
3
4
5
6
7
2 23
8
22
9 21
10 20
11 18 19
12
13
17 15
14 16
332510
9803/8020 Issue 1
60 - 1 Trailer Brake Couplings (Palm Couplings) 60 - 1

Palm couplings coded black are shown at A. Palm couplings
coded red and yellow are shown at B. A K

5
Note: A Service Kit should be obtained before starting this 1
job. Ensure that the kit obtained is correct for the coupling
fitted. Items shown grouped as K are the only parts available
and are obtainable only as a complete kit. 12
3
11
When Dismantling 10
9
Mark the relative positions of the body components to 8
ensure correct alignment on assembly. 2 7
6
When Assembling
4
assembly.
332520

B
6
5
4
3
2
1
332530
9803/8020 Issue 2*
68 - 1 Parking Brake 68 - 1
Caliper Removal and Replacement

Removal
! WARNING
Before checking the parking brake, park on level ground. Slacken locknuts X and remove pin from clevis Y. Apply
Put chocks each side of all four wheels. Ensure that all brake, causing rod Z to draw back into the actuator G. Turn
three air tank warning lights are out. Release the parking clevis Y through 90°.
brake, then stop the engine and disconnect the battery
so that the engine cannot be started. If you do not take Disconnect the air feed by first pushing in the hose, pushing
these precautions the machine could run over you. in the sleeve, then pulling out the hose F. Blank the open
13-3-1-4/1 ports to prevent entry of dirt.
! WARNING Remove plastic cap and insert a 1/4 in hexagon allen key at
K and turn it clockwise to back the pads right away from the
disc. Do not turn the screw further than necessary to free the
pads.
13-3-1-3
Supporting the caliper, remove split pins H and support pins
J in direction of arrow. Withdraw the pads L as they become
! WARNING detached from the guide pins, followed by spring plate M.
force of up to 1134 kgf (2500 lbf) and cause injury if Lower the complete brake assembly clear of the brake disc
suddenly released. When working on or near the and remove.
actuator, carefully follow all service instructions.
13-3-1-11/1 Note: If the surface of the disc is badly warped, pitted or
showing signs of overheating, it must be renewed.
When Replacing
Reverse the removal sequence.
Adjust the brake using the allen key. Support the weight of
the brake with one hand and turn the allen key anti-
clockwise until the pads are tight on the disc. From this
position, turn the allen key half a turn clockwise.

Drive the machine for a short distance of 300-400m. If the

brake disc is getting hot, turn the allen key clockwise
slightly. The final adjustment should never be more than 3/4
of a turn from tight.
162442
9803/8020 Issue 2*
9803/8020 Issue 1
Caliper Dismantling and Assembly

The numerical sequence shown on the illustration is When Assembling
Position anti-rotation key 21 so that dimension E is
For assembly the sequence should be reversed. approximately 50 mm (2 in), then ensure that its flats are in
line with the keyway of stator C by screwing out as required.
Note: Items 1 to 5 should be removed when the caliper is
removed from the machine but are shown here for reference Lubricate the following with a molybdenum disulphide
(see Caliper Removal and Replacement). grease:
Entire bore of casting 22.
! WARNING Keyway and all surfaces of shaft, spring and stator assembly
18.
Ball pockets of rotor 16 and stator C.
force of up to 1134 kgf (2500 lbf) and cause injury if
Shank of rotor.
suddenly released. When working on or near the
Thrust bearing 14 and washers 13 and 15.
actuator, carefully follow all service instructions.
13-3-1-11/1
After fitting bracket 12, turn rotor 16 fully anti-clockwise and
! WARNING fit lever 9 in the position shown at F.
Renew pads if lining thickness is 3 mm (0.12 in) or less.
13-3-1-3
Connect actuator 7 when fitting the caliper to the machine
(see Caliper Removal and Replacement).
When Dismantling
Torque Settings
Apply compressed air pressure of 4 to 7 bar (60 to
100lbf/in 2) to inlet A to extend the pushrod until there is Item Nm kgf m lbf ft
clearance for removal of clevis pin 5. Once the pin is 6 150-200 15-21 110-150
removed, release the compressed air slowly. 11 102-108 10-11 75-80
Take care when removing bolts 11. The internal components

are loaded by spring 19 and balls 17 can be lost easily. Actuator Cylinder
Do not dismantle shaft, spring and stator assembly 18 as The actuator cylinder 7 is a non-serviceable item and no
spring B will easily be distorted and components of this attempt should be made to interfere with it. If the cylinder
assembly are not supplied separately. is faulty it MUST be renewed.
Inspection
Ensure that all parts are free from excessive wear, damage
or corrosion. Light scores or stains should be removed.
Renew corroded or deeply scored parts.
Ensure rotor 16 and stator C are free from cracks.
9803/8020 Issue 1
74 - 1 Parking Brake Air Control Valve 74 - 1

6 Remove screws J, the knobs from external hydraulic
! WARNING levers K and bolts L. Remove panel M by carefully
Before working on the brake system make sure the easing it over levers K and parking brake air control
machine is on level ground and chock all four wheels. valve N.
BRAK 1-4
7 Disconnect the hoses from valve N by first pushing in

! CAUTION the hose, pushing in the sleeve, then pulling out the
If this item is to be dismantled (even partially) on the hoses. Blank the open ports to prevent entry of dirt and
machine, ensure that all pressure has been removed label the hoses to assist correct refitting.
from the system.
BRAK 8-1 8 Release and disconnect the clear exhaust hose by
cutting through the plastic retaining tie.
Removal
Replacement
1 Exhaust all air from the parking brake circuit. Grip the
‘key-ring’ fitting at the bottom of reservoir G3, pull Reverse the removal procedure.
sideways until all air is released and then operate the
brake control lever several times. Ensure that the brake When fitting adapters, clean the threads and apply Clayton
is on before disconnecting hoses. System Seal SC1251.
2 Disconnect the battery earth lead. Secure the clear hose with a new plastic tie.
3 Remove screws A. Lift cover B clear and, via the Torque Settings
aperture created, separate the electrical connectors to
controls C. Dacromet (colour: mottled silver)
4 Unscrew the mounting ring of starter switch D and Item Nm kgf m lbf ft
remove screws E. Lift and remove panel F, easing *L 9 0.9 6.6
switch D through its mounting hole.
5 Remove screws G and take off cover H. IMPORTANT - ABS MACHINES: Refer to Safety at the front
of this section before proceeding further.
M F H G
D
K E
C
K
N
E
L
J A
J
B A290470
9803/8020 Issue 2*
75 - 1 Air Dryer/Unloader Valve 75 - 1
* Note: The illustration right shows the component layout on

the right side of Fastrac 2115, 2125, 2135 and 2140
machines. On Fastrac 2150 and 3000 Series machines the
components are on the left side and are a mirror image of
the layout below.
A
Park the machine on level ground, switch off the engine and
remove the starter key.
! WARNING
BRAK 1-4
! CAUTION B
from the system.
BRAK 8-1
A258140
Removal
1 Refer to page 3 - 1 to identify the components involved

in this operation. Release the system air pressure as
follows:
a Grip the ‘key ring’ fitting at the bottom of reservoir
G3 and pull sideways until all air is released.
b Repeatedly press the foot brake pedal until the
stored pressure in reservoirs G1 and G2 is
exhausted.
c Repeatedly press the clutch pedal until the stored
pressure in reservoir U is exhausted.
2 Disconnect hoses by pushing in the hose, then pushing

in the sleeve in the elbow or adapter and pulling out the
hose. Blank the open ports to prevent entry of dirt and
label the hoses to assist correct refitting.
3 Remove the electrical connector from the air

dryer/unloader unit A.
4 Support the unit and remove the three mounting bolts

B. Lift the unit clear.
Replacement
When fitting elbows and adapters, clean the threads and

apply Clayton System Seal SC1251.
Torque Settings
B 17 1.7 12.5

9803/8020 Issue 4*
75 - 2 *Air Dryer/Unloader Valve 75 - 2
(2000 Series to S/N 738755; 3000 Series to S/N 640787)
Dismantling and Assembly Torque Settings
The numerical sequence on the illustration is intended as a Item Nm kgf m lbf ft

guide to dismantling.
1 25 - 35 2.5 - 3.5 18.4 - 25.8
Assembly is the reverse of dismantling. 30 30 - 45 3.0 - 4.6 22.0 - 33.0
43 16 - 22 1.6 - 2.2 11.8 - 16.2
Note 1: As part of the 1000 hour service schedule (see
Section 3) dismantle and assemble the unit only as far as
dessicant canister 5 for the purpose of changing the
canister. 38
36
Note 2: Canister 5 must be installed the right way round. 34
Refer to inset X below.
37 32
39 30
35
33
31
47
1
3 49
45
46
48
40 42
44 29
41 43 28
27
40
4 26
25
2 { 24
23
4 5 22
21 { 20
6 19
5
18
7
17
6
X 8
16
15
14
13
9
10 12
11
A257962
9803/8020 Issue 3*
75 - 3 Air Dryer/Unloader Valve 75 - 3
(2000 Series from S/N 738756; 3000 Series from S/N 640788)
Dismantlng and Assembly
The numerical sequences on the illustration are intended as
a guide to dismantling.
Assembly is the reverse of dismantling.
Note 1: To replace the dessicant canister (see 1000 Hour

Service Schedule, Section 3) unscrew item A1. Secure the
replacement canister hand tight.
Note 2: Items E1 to E9 - all are held in place by circlip E1.

After releasing the circlip, take care to prevent the rest of the
components flying apart.
Note 3: Items F1 to F22 - F1 is a push fit into the base of the

air dryer body.
9803/8020 Issue 1
76 - 1 Air/Hydraulic Actuator 76 - 1
A
A
A
A A
A386060
*
2115, 2125, 2135, 2140 ABS Machines
A386051
2150, 3155, 3185 ABS Machines
9803/8020 Issue 3*

* Note: The illustration below shows the component layout on Replacement
the right side of non-ABS Fastrac 2115, 2125, 2135 and
2140 machines. On non-ABS Fastrac 2150 and 3000 series Reverse the removal procedure but connect the hydraulic
machines the components are on the left side and are a pipe before tightening bolts A.
mirror image of the layout below.
When fitting pneumatic elbows or adapters, clean the
! WARNING threads and apply Clayton System Seal SC1251.
Make the machine safe before getting beneath it. Do the After replacement, bleed the front and/or rear hydraulic
following: Park on level ground. Engage the parking brake system as appropriate.
Stop the engine, remove the starter key, disconnect the Torque Settings
13-3-1-1 Item Nm kgf m lbf ft
A 17 1.7 12.5
Removal
1 Disconnect wiring from the relevant master cylinder front of this section before proceeding further.
hydraulic reservoir level sensor.
Testing (in Situ)
2 Before disconnecting hoses, exhaust all air from the
foot brake circuits by pressing the foot brake pedal Remove the bleed screw from one of the brake calipers of
several times. the front or rear brakes as applicable to the actuator being
tested. Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge
3 Disconnect the air hose from the rear of the diaphragm
to the bleed screw port.
by pushing in the hose, then pushing in the sleeve in
the elbow or adapter and pulling out the hose. Blank Run the engine until the air pressure warning lights are off.
the open port to prevent entry of dirt. If more than one
actuator is to be removed, label the hoses to assist Stop the engine. Apply the foot brakes. Check that the
correct refitting. hydraulic pressure is at least 110 bar (1600 lbf/in2) and that
there are no air or fluid leaks.
4 Disconnect the hydraulic pipe from the master cylinder.
5 Remove two bolts A and withdraw the actuator.
A249330
Non-ABS Machines
9803/8020 Issue 4*
Dismantling and Assembly Bench Testing

The numerical sequence shown on the illustration is Before refitting a repaired actuator, do the following test.
Connect a compressed air supply and a 0-20 bar (0-300
For assembly the sequence should be reversed. lbf/in2) pressure gauge to the air inlet port.
When Dismantling Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to the
hydraulic pipe connection. Add the specified hydraulic fluid
Take care not to drop items 6, 7, 8 when separating items 4 to the reservoir (see Section 3).
and 5 which will be forced apart under the pressure of
spring 8.
! WARNING
Inspection Using incorrect brake fluid could damage the system.
Dismantle the hydraulic master cylinder assembly 13 for manual for the correct fluid. The fluid can harm your
inspection only. Component parts are not supplied skin. Wear rubber gloves. Cover cuts and grazes.
2-3-2-6/1
separately. Fit a new assembly if the original is showing
signs of corrosion or wear.
Raise the air pressure to 6 bar (90 lbf/in2).
Check all other parts for excessive wear, damage or
Check that the hydraulic pressure is at least 110 bar (1600
corrosion. Renew any that are corroded or scored.
lbf/in2) and that there are no air or fluid leaks.
Torque Settings

1/2 11 - 15 1.1 - 1.5 8 - 11
12 34 - 42 3.4 - 4.3 25 - 31
9 15
10
1
3 7
6
12
11 16
4
14
13
2 8
12
3
A258130
9803/8020 Issue 1
77 - 1 Failure Conscious Pressure Reducing Valve 77 - 1
* (Non-ABS Machines only)
! WARNING
13-3-1-1
Removal
1 Exhaust all air from the foot brake circuits by pressing

the foot brake pedal several times.
A
2 Disconnect the hydraulic pipes from the valve. Plug the
pipes and valve ports to prevent the loss of hydraulic oil
and the ingress of dirt.
3 Remove the single mounting bolt/nut A and lift the valve

clear.
Servicing A258150
The valve is sealed and cannot be dismantled or repaired. If

there is evidence of oil leakage and/or malfunction the valve
must be renewed.
Replacement
When fitting elbows or adaptors, clean the threads and apply

Clayton System Seal SC1251.
After replacement bleed the front and rear brake circuits.
Torque Settings

A 28 2.8 20.6
9803/8020 Issue 2*
78 - 1 ABS Sensors (ABS Machines only) 78 - 1

It is necessary to remove the brake caliper on front axles
before the following can be carried out.
The illustration right shows the arrangement on a non-

steering axle. The arrangement on a steering axle is very
similar.
Removal
1 Remove sensor A by pulling it manually from spring

B
bush B. The sensor is a tight fit and, should it be
necessary to pry it out, care should be taken not to A
cause damage.
C
2 Pry out spring bush B from the axle. If damage is
inflicted in the process the bush should be renewed.
Replacement
A386030
1 Insert spring bush B as far as possible so that tabs C
abut the axle.
*2 Apply one or two drops maximum of JB Threadlocker

and Sealer to the sensor at A. Press sensor fully home
into the spring bush.
* Note: Failure to install the sensor correctly could adversely

affect the operation of the ABS system. Application of an
excessive amount of Threadlocker and Sealer will make
future removal of the sensor very difficult.
Note: Make sure that the sensor cable does not touch the
brake disc.
IMPORTANT - ABS MACHINES: Refer to Safety at the front

of this section before proceeding further.
9803/8020 Issue 3*
79 - 1 Pressure Modulating Valves 79 - 1
(ABS Machines only)

This procedure can only be carried out with the pannier 3 Remove the screws/nuts A and lift valve B clear.
removed from the machine.
Note: The M8 mounting screws/nuts A are clearly visible
Removal below for only one of the valves B in each case. The
mounting screws/nuts for the remaining valves can be easily
1 Exhaust all air from the foot brake circuits by pressing located and accessed.
the foot brake pedal several times.
Replacement
2 Disconnect the air hoses from the valve by pushing in
the hose, then pushing in the sleeve in the elbow or Replacement is the reverse of Removal.
adapter and pulling out the hose. If more than one valve
is to be removed, label the hoses to assist correct IMPORTANT - ABS MACHINES: Refer to Safety at the front
refitting. of this section before proceeding further.
B
B
A
A B
* 2115, 2125, 2135, 2140 ABS Machines A386070
A
B B B
2150, 3155, 3185 ABS Machines

A402300
9803/8020 Issue 3*
Section H Steering Section H
i i
Contents Page No.

Technical Data 1-1
* Steering System Description (Fastrac 2000 Series)

General 2-1
4WS Machines (Fastrac 2115, 2125, 2135 and 2140 Machines)
System Features 2-3
Steer Mode Selection 2-4
JCB Headland Management System (HMS) 2-5
Front Axle Steering
Operation 1 - Neutral 2-6
Operation 2 - Left Turn 2-7
Operation 3 - Right Turn 2-8
Operation 4 - Left Turn, Unassisted 2-9
Operation 5 - Pressure Relief Valve 2 - 10
Fault Finding (Front Axle)

- All Machines (Fastrac 2000 Series) 3-1
* Fault Finding (Rear Axle, 4WS)

- Fastrac 2115, 2125 2135 and 2140 Machines only
Introduction 4-1
Diagnosis 4-1
Diagnostic LED’s 5-1
Pressure Testing (Fastrac 2000 Series) 7-1
Wheel Alignment See Section 3
Pump See Section E
Front Axle Steering Rams (Fastrac 2000 Series)

- Removal and Replacement 8-2
- Dismantling and Assembly 8-1
Hydraulic Steering Unit (Fastrac 2000 Series)

Relief Valves
Pump Relief Valve See Pump, Suspension and
Front Axle Steering (Section E)
Steering Column (Fastrac 2000 Series)

- Dismantling/Removal 15 - 1
- Assembly/Replacement 15 - 1
* Rear Axle (4WS) Steering Valve

- Fastrac 2115, 2125 2135 and 2140 Machines
- Setting the Relief Valves 16 - 1
* Rear Axle (4WS) Power Track Rod

- Fastrac 2115, 2125 2135 and 2140 Machines
- Ball Joints, Removal and Replacement 17 - 3
- Power Track Rod, Dismantling and Assembly 17 - 4
9803/8020 Issue 3*
ii ii
Contents Page No.
Steering System Description (Fastrac 3000 Series) 30 - 1
Fault Finding (Fastrac 3000 Series) 31 - 1
Pressure Testing (Fatrac 3000 Series) 32 - 1
Wheel Alignment See Section 3
Pump See Section E
Steering Box (Fastrac 3000 Series)

Limit Valve Setting 34 - 1
* Lock Stops 34 - 1
Fitting the Input Shaft Nut and Star Nut 38 - 3
Steering Shaft (Fastrac 3000 Series

Checking 42 - 1
9803/8020 Issue 2*
2WS (Front Axle) Circuit (Fastrac 2000 and 3000 Series)

Pump (Type 1†)
Type Rear section (P2) of gear type double pump,

driven by engine.
Controlled Flow at 2400 rev/min and system pressure 18.2 litres/min (4 UK gal/min; 4.8 US gal/min)
Pump Relief Valve Pressure (at 1500 r.p.m. engine speed)
Fastrac 2000 Series 200 bar (2900 lb/in2)

* IMPORTANT: The steering relief valve pressure must not be set above the specified figure under any circumstances.
Pump (Type 2††)
Type Rear section (P2) of gear type double pump,

driven by engine.
Controlled Flow at 1500 rev/min and system pressure
Fastrac 2000 Series 27 litres/min (6 UK gal/min; 7.2 US gal/min)+15%-10%
Fastrac 3000 Series 18 litres/min (4 UK gal/min; 4.8 US gal/min)+15%-10%
Pump Relief Valve Pressure (at 1500 r.p.m. engine speed)
Fastrac 2000 Series No pump relief valve, see Steering Unit Relief Valve
Pressure
* IMPORTANT: The steering relief valve pressure must not be set above the specified figure under any circumstances.
Steering Unit Relief Valve Pressure (Fastrac 2000 Series) 180 bar (2610 lb/in2)

4WS (Rear Axle ) Circuit (Fastrac 2115, 2125, 2135, 2140 only)
* Pump
Type Centre section (P5) of gear type triple pump, driven by

PTO gearbox
Flow rate @ 100 bar (1450 lbf/in2) and *1500 rev/min 28.5 litres/min (6.3 UK gal/min; 7.5 US gal/min)
4WS Main Relief Valve Pressure

At 1500 r.p.m. engine speed 100 bar (1450 lbf/in2)
4WS Dump Valve Pressure

At 1500 r.p.m. engine speed 10 bar (145 lbf/in2)
Air Pressure Regulator 7 bar (100 lbf/in2)
9803/8020 Issue 5*
2-1 *Steering System Description 2-1
(Fastrac 2000 Series)
General
Two-wheel Steer Machines
The machine has a hydraulic 2-wheel steering system

powered by an engine driven pump. Oil from the pump P2 is
delivered to a hydraulic steering unit SU at the base of the
steering column. Turning the steering wheel operates the
steering unit which directs oil to steer rams AA and AC on
the front axle. Steer ram AA connects directly to the right
front wheel and steer ram AC connects directly to the left
front wheel. A track rod connects the right and left swivel
hubs together.
With the steering wheel in the neutral position, the ‘open

centre’ hydraulic steering unit routes the pump output
straight back to tank via the oil cooler CS mounted in front of
the engine radiator.
When the steering wheel is turned left or right, the steering

unit directs oil to the rod or head side of the steer rams
respectively, as appropriate.
When steering reaches the end of its travel in either

direction, the pressure build-up is used to operate relief
valve AB in the pump in order to dump the oil to tank via oil
cooler CS.
AB
CS
P1 P2
Fm
AC
T
P a
AA
3A
T
SU b
TP
A290650
9803/8020 Issue 2*
2-2 Steering System Description 2-2
General (cont’d)
* Four-wheel Steer Machines
(Fastrac 2115, 2125, 2135 and 2140 Machines only)
Four-wheel steer (4WS) machines have hydraulically A separate oil pump, P5, provides oil flow for the rear axle
independent circuits for the front and rear axles. The circuit power track rod AD via control valve AWS and proportional
for the front axle is identical to that for the two wheel steer solenoid operated spool SP. Flow is determined by the
(2WS) machines (see previous page). The rear axle circuit is amount of movement of the spool in the relevant direction,
shown below. this being determined by proportional solenoids which
The required steering mode, 2WS or 4WS, is selected by respond to signals from an electronic control box.
pressing the appropriate button(s) on the control panel. The control box compares signals from potentiometers
When 2WS is selected the solenoid of air valve AE is de- mounted on the right side front and rear hub pivots.
energised (as shown). The compressed air supply from According to the 4WS mode selected (see page 2 - 4) the
source Q (see Descriptions, Trailer Brakes in Section G) is rear axle is required to respond to the steering of the front
cut off from power track rod AD to ‘enable’ the mechanical axle. To achieve this the control box sends the necessary
mechanism which locks the rear wheels in the straight ahead signals to the relevant proportional solenoid, thereby
position. When 4WS is selected the solenoid is energised to metering oil to the power track rod.
direct compressed air to the power track rod to ‘disable’ the
locking mechanism and allow the rear wheels to steer. Under
certain circumstances, e.g. speed above 20 kph, 4WS is
automatically overridden (i.e. the machine reverts to 2WS) for Fm
safety or other reasons. The locking mechanism has a vent
line which is routed back to the hydraulic tank to prevent
ingress of moisture and allow the mechanism to be
lubricated by an oil mist from the tank.
T
SP
P5
A BP T TP
P
A
CT1
CT3
B CT2
AWS
AD T
AE
A243471
Q
9803/8020 Issue 3*
* 4WS Machines - System Features
(2115, 2125, 2135 and 2140 Machines)
X Y
Start Up
For safety reasons, no rear wheel movement will occur

under any circumstances until the machine reaches a speed 2 O/R
of approximately 1 kph.
1 2
Immediately after starting the engine, two possible
conditions will apply:
1 Rear Axle Straight Ahead and Locked

4 4
The unlock switch 3 must be pressed at the same time
as one of the switches A to D when any one of these is A B
used to select a four wheel or crab steer mode. There
will be no rear wheel movement below 1 kph.
Note: Once a 4WS mode has been selected, you can then 3
change between modes B, C and D by pressing just the one
relevant switch.
4 4
2 Rear Axle Not Locked Straight Ahead C D

On start-up, 2WS will be selected automatically but no
rear wheel movement will occur until you do one of the
following:
a You drive above 1 kph, when the rear wheels will

automatically centralised and lock.
b You select 2WS, as previously stated.
Forced 2WS
For safety or other reasons the system is forced from 4WS

to 2WS under the following circumstances:
Z
a When road speed exceeds 20 kph. The next time the
rear axle passes the straight ahead position the axle
locks.
b Failure of the front or rear axle position sensors. This is A248960

indicated by indicator X flashing and switch 1 (2WS)
LED lit continuously. The rear wheels will stop steering
and must be brought to the straight ahead position by
manually operating the solenoid. 4WS selection is
inhibited.
c Under the influence of HMS (see JCB Headland

Management System).
System Protection
Under conditions where the rear wheels cannot achieve the

desired steering angles, for example when 4WS is selected
on a stationary machine which is heavily laden and fitted
with large section tyres, it is necessary to avoid generating
excessive hydraulic oil temperatures. This is achieved by an
automatic control which after 5 minutes will return the
machine to the same mode as at start-up, but no rear wheel
movement will occur until 1 kph is exceeded.
9803/8020 Issue 4*
* 4WS Machines - Steer Mode Selection
(2115, 2125, 2135 and 2140 Machines)
When the ignition is first switched on, all the indicator lamps
should light and the buzzer should sound for half a second
as a test. Replace any faulty lamps and rectify an inoperative
buzzer.
During operation, if the red cross X lights up or if the buzzer
sounds continually, a steering system fault is indicated. Only
if the green tick Y is lit, as an indication that the system is
functioning correctly, should the machine be used.
Selection of a function is indicated by illumination of the
LED(s) relating to the switches pressed. Refer to the
illustration on page 2-1B for positions of control panel
operating switches .
Note: The steering angles quoted in the following S250500 S250510
descriptions are approximate and vary according to tyre and 2WS Crab
wheel size.
Two-wheel Steer (2WS)

Select by pressing switch 1. The front wheels will steer
normally and the rear wheels will be locked in the straight-
ahead position. If 2WS is selected when the machine is
already in 4WS the rear wheels automatically move to and
lock in the straight ahead position. Refer to 4WS Machines
- System Features for details of when the system is
automatically forced into 2WS.
Crab Steer Mode

Select by pressing switches 3 and A together. Both front
and rear wheels turn in the same direction to a maximum of
18° for true crabbing. The front wheels can be turned further
to a maximum of 40° while the rear wheels stay at 18°.
Proportional Mode
Select by pressing switches 3 and B together. The front and S250520 S250530
rear wheels turn in opposite directions, the front (maximum
40°) at twice the rate of the rear (maximum 18°). Proportional True Tracking
True Tracking Mode

Select by pressing switches 3 and C together. The front and
rear wheels turn in opposite directions at the same rate to a
maximum of 18°. At this point the buzzer sounds. Beyond
this point the front wheels will continue to turn to a
maximum of 40° while the rear wheels remain at 18°.
Delay Mode
Select by pressing switches 3 and D together. The front and
rear wheels turn in opposite directions. For the first 15° of
front wheel turn the rear wheels remain straight ahead. Over
the next 18° of turn the front and rear wheels turn at the
same rate. Beyond this point the front wheels will turn to a
maximum of 40° while the rear wheels remain at 18°.
Changing AWS Modes

Having selected one of the 4WS modes by means of
switches 3 and B, C or D it is necessary to press only the S250540
appropriate other switch (B, C or D) to change from one of
Delay
these AWS modes to another.
For safety reasons it is not possible to select crab steer by
pressing only switch A. To make such a change, first press
switch 1 (2WS) and then press switches 3 and A together.
9803/8020 Issue 3*
* 4WSMachines - JCB Headland
Management System (HMS)
(2115, 2125, 2135 and 2140 Machines)
The Headland Management System provides automatic Differential Lock
control of 4WS, differential lock and area meter at the To provide automatic control of the diff. lock when using
headland by simple operation of the 3-point linkage or 4WS and 3-point linkage:
sprayer control. This will give instant selection of tighter
1 Turn switch K to position 3.
turning at the headland combined with increased traction
when in work. HMS is available in modes B, C and D but not 2 Select the required 4WS mode B, C or D (see Steer
in crab steer mode. Mode Selection).
Note: If the machine is fitted with an area meter cut-out If selecting delay mode D, it is not necessary to press
system, this is controlled as described in the operator switch O. The diff. lock will be engaged until the rear
handbook under the heading Area Cut-out System. wheels start to steer (this occurs when the front wheels
are at approximately half lock).
3-Point Linkage Override If selecting mode B or C, you must also press override
To provide automatic control of 4WS when using 3-point switch O.
linkage: When the 3-point linkage control lever is in ‘Raise’ or
‘Neutral’ position, the machine will be in the 4WS mode
1 Select the required 4WS mode B, C or D (see Steer that you have selected but the diff. lock will be
Mode Selection). disengaged.
2 Press override switch O. When the 3-point linkage control lever is put into the
‘Lower’ position, the machine will revert to 2WS and the
3 When the 3-point linkage control lever is in ‘Raise’ or diff. lock will engage.
‘Neutral’ position, the machine will be in the 4WS mode
that you have selected. Note: If either mode B or C is selected without pressing the
override switch O, the diff. lock will always be disengaged
4 When the 3-point linkage control lever is put into the until 2WS is selected again.
‘Lower’ position, the machine will revert to 2WS.
3 If the machine is fitted with a sprayer control circuit (see
Sprayer Override Sprayer Override), the diff. lock will cut in when 2WS is
engaged and out when 4WS is engaged as controlled
To provide automatic control of 4WS when using a sprayer by the sprayer switch.
or other implement which has an implement-mounted switch
controlled by the feed mechanism.
Note: The implement-mounted switch must be arranged to

close when spraying begins and open when spraying stops.
The sprayer jack plug must be inserted into socket Z.
1 Select the required 4WS mode B, C or D (see Steer

2 O/R
Mode Selection).
O
2 Press override switch O.
3 When the sprayer control is switched off, the machine

will be in the 4WS mode that you have selected. 4 4
4 When the sprayer control is switched on, the machine B

will revert to 2WS.
4 4
C D
Z
S160321 A248960
9803/8020 Issue 3*
Front Axle Steering
Operation 1 - Neutral
Steering pump P2 output is connected to port P on the
steering unit and enters the unit via non-return valve 3D.
Whenever the steering wheel is stationary inner spool A and
P 3D a
sleeve B are returned to the neutral position by centring
springs K. This action ensures that no further oil flows to or
from the steering ram once the required steering has been 3F
carried out. This can occur at any point of the steering wheel 3E
travel e.g. straight ahead or with the steering wheel
stationary during a turn.
3C
The steering unit is of ‘open centre’, ‘reaction’ design so that 3A 3J
in the neutral position: T
1 The ‘open centre’ design allows oil from the pump to
SU b
pass straight through and back to tank.
2 The ‘reaction’ design allows oil to flow unimpeded from

A271020
one side of the steering rams to the other as the front
wheels follow the ground contours (e.g. the furrows
encountered in field work) during straight ahead driving.
K
;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;
;;;;;;;;; ;;;
;;;;;;;;;;;;;;;
;;;;;;;;; ;;;
;;;;;;;;;;;;;;;
;;;;;;;;; ;;;;;
;;;;;;;;;;;;;;;
;;;;;
;;;;;;;;;;;;;;;
;;;;;;;;; ;;;; A
;;;;;;;;;;;;;;;
;
B
;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;
; ;
;;;;;;;;;;;;;;;
; ;;
;;;
;;;;;;;;;;;;;;;
;;
;;;;;;;;;;;;;;;
;;
;;;;;;;;;;;;;;;
;;; ;;;;;;;;;;;
;;;;;;;;;;;;;;;
;;; ;;;;;;;;;
;;;;;;; ;;;;;;;;;;;;;;;;
a ;;;;;;;;;;;
;;
;;;;;;;;;;;;;;;
;;;;;;;;;
;;;;;;;;;;;;;;;;
;;;;;;;;;;;
;;;;;
3C ;;; ;;
;;;;;;;
;;; ;;;;;;;;;;;;;;;;
;;;;;;;;; ;;;;;;;;;;;
;;;;; 4B
;;;; ;; ;;;;;;;
;;; ;;;;;;;;;;;;;;;;
;;;;;;;;; ;;;;;;;;;;;
;;;;;
;;;;;;;;;;
T ;;;;;;; ;;
;;;;;;;;;
;;;;;;;
;;; ;;;;;;;;;;;;;;;;
;;;;;;;;;;;
;;;;;
;;;;;;;;;
;;;;;;;;;;;;;;;;
;;;;
b ;;;;;;;;;;;
;;;;;
;;;;
;; ;;;;;;;;;
;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;
;;;;;
;; ;;;;;;;;;
;;;;;;;;;;;;;;;;
;;;;;;;;;;;
;;;;;
3E
; ;;;;;;;;;
;;;;;;;;;;;;;;;;
;;;;;;;;;;;
;;;;;
;;;;;;;;;;;;
; ; ;;;;;;;;;;;;;;;;
;;;;;;;;;;;
P ;;;;;;;;;;;;
;;;;;;; ;;;;;;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;;;
;;; ;;;;;;;;;;;;;;;; 4A
;;;;;;;;;;;;
;; ;;;;;;;;;;;;;;;;
;;;;;;;;;;;;
;;;;;;;;;;;;B 3J 3F
3D ;;;;;;;;;;;;
;;;;;;;;;;;;
;;;;;;;;;;;;
;;;;;;;;;;;;
;;;;;;;;;;;;
;;;;;;;;;;;;
D ;;;;;;;;;;;;
;;;;;;;;;;;;
;;;;;;;;;;;;
;;;;;;;;;;;;
A249271
9803/8020 Issue 2*
Front Axle Steering
Operation 2 - Left Turn
The illustration shows the oil flow through the steering unit in
a left turn condition. Turning the steering wheel rotates the
inner spool A a few degrees relative to sleeve B to direct
pressurised oil through six of the twelve holes in the bottom
of the sleeve. A metering unit is linked by a cross pin to
spool A and sleeve B.
The oil from sleeve B is diverted by spool A into stator D

when the rotor lobes pump oil to the rod side of steering ram 3D a
4A and the head side of steering ram 4B, effecting a left P
turn.
3E 3F
3C
3A 3J
T
SU b
A271030
;;;;;;;;
;;;;;;;;; ;;;;;;;;
;;;
;;;;;;;;; ;;;;;;;;
;;;
;;;;;;;;; ;;;;;;;;
;;;
;;;;;;;;
;;;;;;;;; ;;;;;;;;
;;;;;;;;
;; ;;
;;;;;;;;;;;; A
B ;;;;;;;;
;; ;;;;;;;;
;;;;;;;;;;;;
;;;;;;;;;;;;;;
;; ;;;;;;;;
;;;;;;;;;;;;
;;;;;;;;;;;;;;
;; ;; ;;;;;;;;;;;;
;;
;;
;;;;;;;;
;;
;;;;;;
;;;;;
;;;;;;;
;;;;;;;; ;;
;;;;;;
;;;;;
;;;;;;;
; ;;;
;;;;;;
;;;;;;;;;;;;;;
;;;;;;;
;;;
;;;;;;;;
;;;;;
;;;;;
;;;;
;;;;;;;;
;;;;;;;;;;; ;;;;;;;;;;;;;;
;;;;; ;;; ;;;;; ;;;;;;;;;;;;;;;;;;;;;;
a
;;;;;;;;;;;;;;
;;; ;;;;;;;;;;;;;;;;;;;;;;
;;;;;;; ;;;;;
;;;;;;;;;;;;;;
3C
;;;; ;; ;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;
;;; ;;;;;
;;;;;;;;;;;;;;
4B
;;;;;;;;;; ;;;;;;;
;
;;;;;;;
;;; ;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;
;;;;;;;
;;; ;;;;;;;
; ;;;;;;;;;;;;;;;
b ;;;;;
T ;;;;;;;
;;
;;;;;;;
;;; ;;;;;;;
;;;;; ;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;
;;;;;;;
;;
;;;;;;;
;;; ; ; ; ;;
;;;;; ;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;
;;;;;;; ;;;;;
3E
;;;;;;;
;;;
;;;;;;;
;;; ;
;;;
;; ; ;;;;;; ;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;
;;
;;;;;;;;;
;; ;;;;;;;;
;;;;;;;;;;;
; ;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;
P ;;
;;;;;;;
;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;
;;;;;;;;;;;;;; 4A
;;;;;;; ;;;;;;;;
;;;
;;;;;;;;;;;;
;;;; ;;;;;;;;;;;;;;;
;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;
3D ;;;;;;;;
;;;;;;;;; 3F
;;;;;;;;
B 3J
;;;;;;;;;
;;;;;;;;
;;;;;;;;;
;;;;;;;;
;;;;;;;;;
;;;;;;;;;
;;;;;;;;
;;;;;;;;;
;;;;;;;;
;;;;;;;;;
;;;;;;;;
;;
;;;;;;;;;
D ;;;;;;;;
;;
;;;;;;;;
;;
;;;;;;;;
A249281
9803/8020 Issue 2*
Front Axle Steering
Operation 3 - Right Turn
The illustration shows the oil flow through the steering unit in
a right turn condition. The operation is identical to that for a
left turn (see previous page) except that pressurised oil is
pumped to the head side of steering ram 4A and the rod
side of steering ram 4B, effecting a right turn.
P 3D a
3E 3F
3C
3A 3J
T
SU b
A271040
;;;;;;;;;;;;
;;;;;;;;; ;;;;;;;;;;;;
;;;
;;;;;;;;; ;;;;;;;;;;;;
;;;
;;;;;;;;; ;;;;;;;;;;;;
;;;;;;;;;;;;
;;;;
;;;;;;;;; ;;;;;;;;;;;;
;; ;;;;;;;;;;;; A
B ;;;;;;;;;;;;
;;
;;;;;;;;;;;;;;;;;;
;; ;
;;;;;;;;;;;;;;;;;;
;; ; ;; ;
;;;;;;;;;;;;
; ;;
;;
;;;;;;
;;;;;
;;;;;;;
;;;;;;;;;;;;
;;;;;;;;;
;;;;;
;;;;;;
;;;;;;; ;
;;;;;;
;;;;;;;;;;;;;;;;;;
;;;;;
;;;;;;;
;;;;;
;;;;
;;
;;;;;;;;;;;
;;;;;;;;;;; ;;;;;;;;;;;
;;;;; ;;
;
a
;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;; ;;;;;;;;;;;
;;; ;;;;;;;;;
;;;
;;;;;;;;;; ;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;
;;;;;;;
3C
;;;; ;;;;;;;;;
;;;
;;;;;;;;;; ;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;
;;;;;;;
4B
; ;;;;;;;;;;;
;
;;;;;;;;;; ;;;;;;;
;;;
;;;;;;;;;;
; ;;;;;
;;;; ;;;;;;;;;;;;;;;;;;;;;
;;;;;;;
;;;;;;;;;;;;;;;
;;;;;;;
;;;;;
T ;;;;;;;
;;;; ;;;;;
;;;;;;;;;;
b
;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;
;;;;;;;
;;;;;;;
;;;;;
;;;; ; ;
;;;;;;; ;;;; ;;;;;
;;;;;;;;;; ;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;
;;;;;;;
3E
;;;;;;
;;;;;;;; ; ; ;;;;;;;;;;;
;;;; ;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;
;;;;;;;
;;
;;;;;;;
;;;
P ;;;;;;;;;;;; ;;;;;;;;
;;;;; ;;;;
;
;
;;;;;;
;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;
;;;;;;;
;;;;; ; ;;;
;;;;;; ;;;;;;;;;;;;;;;;;;;;;
4A
;;;;;;;
;;;;;;;;;;
;; ; ;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;
;;;;;;; ;;;;;;
3D ;;;;;;;
;;;;;;
B 3J 3F
;;;;;;;
;;;;;;
;;;;;;;
;;;;;;
;;;;;;;
;;;;;;;
;;;;;;
;;;;;;;
;;;;;;
;;;;;;;
;;;;;;
;;;;;;;
;;;;;;
D ;;;;;;
;;;;;;
;;;;;;
A249291
9803/8020 Issue 2*
Front Axle Steering
Operation 4 - Left Turn, Unassisted
The illustration shows the circuit operation with the engine
stopped and no pressurised oil supply.
Turning the steering wheel rotates inner spool A until the

cross pin of the metering unit engages with and rotates
outer sleeve B. This has the effect of metering oil to stator D
and pumping it out to the rod side of steering ram 4A and
the head side of steering ram 4B, but at manual pressure 3D a
only. P
Since there is no pumped oil supply, oil from one side of the 3E 3F
steering ram circuit, supplemented by exhaust oil if
necessary, is used to feed the other side of the steering ram
circuit via non-return valve 3E. 3C
3A 3J
T
SU b
A271030
;;;;;;;;
;;;;;;;;; ;;;;;;;;
;;;
;;;;;;;;; ;;;;;;;;
;;;
;;;;;;;;; ;;;;;;;;
;;;
;;;;;;;;; ;;;;;;;;;;;;;;;;
;; ;; ;;;;;;;;
;;;;;;;;;;;; A
B ;;;;;;;;
;; ;;;;;;;;
;;;;;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;
;; ;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;
;;;;;; ;;
;;;;;;;;;;;;;;;;
;;;;;;
;;;;;;;;
; ;;
;;;;;;;;;;;;;;;;
;;;;;;
;;;;;;;;
;;;;;;;
; ;;
;;;;;
; ;;;;;;;;;;;;;;
;;;;;;
;;;;;;;
; ;;
;;;;; ;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;
a
;;;;;;;;;;;;;;
;;;;;;
;;; ;; ;;;;;;;
;;;;;;;
;;; ;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;
3C
;;;; ;; ;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;
;;; ;;;;;
;;;;;;;;;;;;;;
4B
T;;;;;;; ;;;
;;;;;;;;; ;
;;;;;;;
;;;;;;;
;;; ;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;
;
;;;;;;; ;;;;;;;;;;;;;;;
b ;;;;;
;;;;;;; ;;
;;;;;;;;;
;;;; ;;;;;;;
;;;;; ;;;;;;;;;;;;;;;
;;;;;;; ;;;;;
;;;;;;;;;;;;;;;;;;;
;;;
;;;;;;;;;
;;;; ; ; ;;
;;;;; ;;;;;;;;;;;;;;;
;;;;;;; ;;;;;
;;;;;;;;;;;;;;;;;;;
3E
;
;;;
;;;;;;;;;
;;;; ;; ; ;;;;;; ;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;
P ;; ;;
;;;;;;;;;
;;;; ;; ;;;;;;;;
; ;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;
;;
;;;;;;;;;
;;;; ;;; ;;;;;;;;
;;;;;; ;;;;;;;;;;;;;;;
;;;;;;;;;;;;;; 4A
;;;;;;;;;
;;;; ;;;;;;;;;;;;;
;;; ;;;;;;;;;;;;;;;
;;;;;;;;;
;;;; ;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;
;;;;;
3D ;;;;;;;;
;;;;;;;;;;; B 3J 3F
;;;;;;;;
;;;;;;;;;;;
;;;;;;;;
;;;;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;;;;
;;;;;;;;
;;;;;;;;;;;
;;;;;;;;
;;;;;;;;;;;
;;
D ;;;;;;;;
;;;;;;;;;;;
;;
;;;;;;;;
;;
;;;;;;;;
A268500
9803/8020 Issue 2*
2 - 10 *Steering System Description 2 - 10
Front Axle Steering
Operation 5 - Pressure Relief Valve
In normal operation oil flow from the steering pump entering b Non-return valve 3J is held on its seat by the
the steering unit at port P opens spring loaded non-return generated pressure and non-return valve 3D closes
valve 3D. The steering unit implements the required turning to prevent the shock wave being fed back to the
manoeuvre (left turn shown below). When the steering rams steering pump. Some of the excess pressure opens
reach the end of their travel, pressure relief valve 3C opens non-return valve 3F allowing oil to flow to the
to direct oil from the pump back to tank. opposite side of the steering rams to prevent
cavitation occurring.
To prevent damage to the steering unit and the steering
pump in the event of a pressure shock wave being † The need to prevent a shock wave causing damage to
generated in the system by an outside force †, the steering the steering unit and the steering pump applies only
unit safety devices operate as follows: when a steering manoeuvre is being carried out, i.e. the
steering circuit is not in neutral. In neutral, oil is free to
a Pressure valve 3C opens to vent the generated
flow from one side of the steering rams to the other
pressure to exhaust.
(see Operation 1 - Neutral), thereby achieving the
same protection.
3D a
P
;;;
3E 3F
;;;
3C
3A 3J
;;;;;;;;; ;;;
;;;;;;
;;;;;;;;; ;;; T
b
;;;;;;;;;;;;;;;;;;;;;;
;;;; SU
;;;;;;;;;;;;;;;;;;;;;; A
;;;;;;;;;
B ;;;;;;;;;;;;;
;;;;;;; ;;;;;;;;;;;;;
A271030
;;;;;
;;;;;;; ;;;;;;;;;;;;;
;;
;;
;;;;;;;;;;;;;
;;
;;;;;;; ;;;;;;;;;;;;;
;;;;;;;;;;
;;;;;;;;;;;;;;;;;;
;;;
; ;;;;
;;;;;;;;;
; ;;;;;;;;;;;
;;;;;;;;;;;;;
;;;
;;;
;;;;
;;;
; ;;;;;;; a ;;;;;;;;;;;
;;;;;
;;;;;
;;
;;;;;;;;;;;;;
;;; ;;;;;;;;;
;;; ;;;;;;;;;;;
3C
;;;; ;; ;;;;;;;
;;; ;;;;;;;;;;; 4B
; ;;;;;;;;;;;
;;;
;;;;;;
;;
;;;;;;; ;;;
;;;;;;;
;;; ;;;;;;;
;;;; ;;;;;;;;;
;;;; b ;;;;;;;;;;;
;;;;;;;
;;;
T ;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;
;;;; ; ; ;;;;;;;;; ;;;;;;;;;;;
;;;;;;;
;;; ;
;;; ; ;;;;
; ;;;;;;;;;;;
;;;;;
3E
;;
;;;;;;;
P ;; ;;; ;;;;;;;;;;;
;
;; ;;
; ;;;;;;;;;;;
;;;;;;;;;;;;;;
;;;;;;; ;;;;;;;; ;;;;;;;;;;; 4A
;;;;;;;
;;;;;;;;;;;;;;
;;; ;;
;;;;;;;;;;;;;;
;;;;;;; ;
3D ;;;;;;;;;;; B 3J 3F
;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;;
D ;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;;
A249251
9803/8020 Issue 2*
3-1 *Fault Finding (Front Axle) - All Machines 3-1
Introduction
Before assuming that the steering control unit or the pump is

the cause of a steering problem, ensure that all other
steering system faults have been rectified.
Follow the fault finding procedure on the next page but first
carry out the following checks:
1 Question the driver and drive the machine to establish

the exact nature of the fault.
2 Check that the hydraulic oil level is correct and that

there are no signs of oil leakage from the circuit.
3 Check that the steering linkages are correctly tightened.
9803/8020 Issue 2*
3-2 *Fault Finding (Front Axle) - All Machines 3-2
Heavy Steering
CHECK ACTION
1 Is the front axle overloaded? YES: Reduce load.
NO: Check 2.
2 Are the correct tyres fitted and correctly inflated? YES: Check 3.
NO: Replace / inflate tyres.
*3 Is the 4WD clutch releasing correctly? YES: Check 4

NO: See Section F, Fault Finding
*4 Is the front differential operating correctly? YES: Check 5

5 Are the steering swivels and linkages free? YES: Check 6.

NO: Lubricate and free off.
6 Is the oil cooler free of air blockage? YES: Check 7.

NO: Clean out debris.
7 Is the pump relief valve pressure too low? YES: Check for dirt at relief valve.
NO: Check 8.
8 Is the pump flow rate too low? YES: Check for flow control valve sticking and check 11.
NO: Check 9.
9 Is the steering column turning freely? YES: Check 10.

NO: Free off / check universal joint phasing.
10 Is front wheel alignment correct? YES: Check 11.

NO: Adjust.
11 Are suspension and steering geometry correct? YES: Check 12.

NO: Renew parts as required.
12 Is oil temperature high? YES: Check cooler and pipework for free flow.
NO: Suspect fault in steering control unit.
Steering Wander or Free Play

If the fault is wander, start at check 1.
If the fault is free play, start at check 4.
CHECK ACTION
1 Is the rear axle overloaded? YES: Reduce load.

NO: Check 2.
3 Is the front wheel alignment correct? YES: Check 4.

NO: Adjust.
4 Are the column or steering linkages worn or loose? YES: Tighten or renew.
NO: Check 5.
5 Is the pump flow correct? YES: Check 6.

NO: Check condition of flow control.
6 Is air trapped in the hydraulic oil? YES: Bleed out air.

NO: Suspect fault in steering control unit.
9803/8020 Issue 3*
4-1 Fault Finding (Rear Axle, 4WS) 4-1
*Fastrac 2115, 2125, 2135 and 2140 Machines only
Introduction
Panel Self-Test
When the ignition is first switched on, all the indicator lamps
should light and the buzzer should sound for half a second
as a test. Replace any faulty lamps and rectify an inoperative
buzzer.
During operation, if the red cross X lights up or if the buzzer
sounds continually, a steering system fault is indicated. Only
if the green tick Y is lit, as an indication that the system is
functioning correctly, should the machine be used.
Fuses
The circuits associated with the 4WS system are covered by

the following fuses. (For locations see Section C.)
4WS Main Supply

Alternator Supply
Axle Lock Switch Supply Fuse X (5 Amp)
Axle lock air solenoid valve
Sprayer or implement override
1 kph and 20 kph signal from
instrument cluster Fuse C4 (15 Amp)
Draft control override Fuse A6 (5 Amp)
If the fault continues, use the table below to trace and rectify
the cause.
Diagnosis
FAULT ACTION
1 2WS selected but rear wheels remain off-centre 1 This is likely to be an electrical fault.
when the machine is driven above 1 kph.
To get the machine going the rear wheels can be
centralised and locked manually as follows:
1.1 Make sure that there is no air pressure to the axle lock.
Air pressure should normally be released when the
2WS button is pressed but if air pressure fails to
release, disconnect the electrical supply from the air
solenoid valve.
1.2 Disconnect the electrical supply from the each of the

two 4WS hydraulic valve solenoids.
1.3 Start the engine and set to low idle.
! WARNING
Keep clear of the rear wheels when the engine is running
as you could be injured by unexpected wheel movement.
HYD ST 5-5
1.4 Operate the 4WS hydraulic valve by pushing a suitable

piece of rod or a small screwdriver into either access
hole in the solenoid valves until the rear wheels steer to
the centre and the lock is heard to click into place. (Trial
and error will determine which solenoid is the correct
one.)
1.5 Once the rear wheels are locked, the machine can be
driven safely on the road and used to perform normal
duties in 2WS until the 4WS system can be repaired.
9803/8020 Issue 2*
FAULT ACTION
2 Red X lights up and buzzer sounds 2 This indicates a fault in either a front or rear 4WS
sensor (potentiometer), or in the sensor wiring
Note: A buzzer may be heard (without the red cross harness. 4WS will not work when the red X is
showing) if a foot is resting on the clutch pedal. This is a showing.
warning of operator malpractice and should not be confused
with a machine fault indication. If the fault is intermittent, the warning can be cleared by
turning the ignition switch off and on. The system will
then operate normally until the fault re-occurs.
To trace the fault:
2.1 Disconnect the front axle sensor from the wiring

harness swivel connector. Substitute a known sensor
and manually turn to approximately half way. Switch on
the ignition (no need to start the engine). If the green
tick is now showing, the original front axle sensor is at
fault and should be renewed.
Note: When a sensor has been changed the system must be

re-calibrated (see Sensors, Section C).
2.2 Repeat step 2.1 for the rear axle sensor.
2.3 If both sensors are functional and the fault remains,

there is a fault in the wiring harness. Remove the
Electronic Control Unit (ECU) from the ‘B’ post and
disconnect the machine wiring harness. Trace the fault
by simple continuity tests from this point down to the
swivel connectors at the sensors.
2.4 If both sensors and wiring harness are OK then the fault
must be in the ECU. This cannot be serviced and must
be renewed as a complete unit.
Note: A fault in the ECU is extremely unlikely and the unit

should not be renewed unless it is absolutely certain that it
is at fault.
9803/8020 Issue 2*
FAULT ACTION
3 4WS Fails to engage, rear axle remains locked in 3 Check the Diagnostic LED’s
2WS
3.1 Remove the 4WS control panel to reveal the diagnostic
LED’s (see Diagnostic LED’s).
3.2 When the ignition switch is turned on, LED’s 2 and 3

should be on, indicating the rear axle is locked and the
machine is stationary.
3.3 When the engine is started, LED’s 2, 3 and 5 should be

on (LED 5 indicates engine running.)
3.4 When an attempt to select 4WS is made, LED 6 should

come on (air solenoid valve signal) and LED’s 7 and 8
should cycle off in turn. Check each of the 4WS modes
and crab steer in turn.
If each of the LED’s operates in the sequence shown above,

then check for the following faults:
a) Rear axle power track rod lock failed to release.
b) Rear axle power track rod switch has failed.
c) 4WS electronics out of calibration.
d) The rear axle sensor mechanical linkage has developed
backlash.
a Rear axle power track rod lock failed to release.

a1 Check that air pressure is present at the power track
rod feed.
a2 In 2WS there should be no pressure.
a3 As 4WS is selected, pressure should be present to
unlock the axle. If no pressure is detected, check the air
solenoid valve (inside cab) is operating correctly.
b) Rear axle power track rod switch has failed.

b1 If the power track rod lock has released but the switch
has failed to signal the ECU, the rear wheels will be
seen to ‘dither’ ( slowly oscillate from side to side) while
the 4WS selection is being made.
b2 The switch may be out of adjustment and can be
checked by removing the copper washer fitted behind
the switch.
b3 If the switch still fails to operate, a replacement is
required. Be sure to replace the copper washer if a new
switch is fitted.
b4 If the unit still fails to operate, check the wiring harness
continuity.
c) 4WS electronics out of calibration.

c1 As 4WS selection is attempted, observe LED’s 7 and 8.
The LED’s should cycle on and off in turn. If there is a
bias towards one of the LED’s or if one of the LED’s
remains lit continually, then the 4WS electronic panel is
out of calibration (see Calibration procedure in
Sensors, Section C). Calibration is normally needed
only after sensors or control unit have been dismantled.
If frequent calibration is needed, the rear axle sensor
has probably developed backlash.
d) The rear axle sensor mechanical linkage has

developed backlash.
Remove sensor (potentiometer) top cover. Check the
sensor linkage for backlash by fitting an open ended
spanner over the spindle where it protrudes above the
sensor. Apply moderate pressure in each direction.
There should be no detectable backlash.
9803/8020 Issue 3*
*- Fastrac 2115, 2125, 2135 and 2140 Machines
2 O/R
4 4
4 4
X
O/R
Fm 4
T 4
SP
P5
A BP T TP
P
A
CT1
5 4 3 1 6 7
CT3
B CT2
AWS
1.75
AD T
AE
A243471
Q
2 8 A249140
9803/8020 Issue 2*
Diagnostic LED’s
Eight diagnostic LED’s can be found by removing the front panel of the Electronic Control Unit as shown on the facing
page
LED Number LED Name Indication when ON
1 Draft Control or Sprayer Override a) On when linkage override button 2 (illustration X) is pressed
and linkage is down.
OR
b) On when linkage override button (2) is pressed and sprayer or
implement remote switch is closed.
Note: Active 2WS is operative when LED is on.
2 Rear axle lock signal On when rear axle is locked in 2WS.
3 20 kph Override On at forward speeds under 20 kph. Goes off at speeds over 20 kph.
4 1 kph Override On at forward speeds over 1 kph. Goes off at speeds less than 1 kph.
5 Not used
6 Rear axle unlock - Air

solenoid valve signal On when air solenoid valve (AE) is energised to unlock the rear axle.
7 Hydraulic solenoid valve signal On when the proportional valve (SP) is energised to turn the rear
wheels to the left.
Note: In 4WS steer mode (not crab) the machine will turn to the right.
8 Hydraulic solenoid valve signal On when the proportional valve (SP) is energised to turn the rear
wheels to the right.
Note: In 4WS steer mode (not crab) the machine will turn to the left.
9803/8020 Issue 3*
Steering System Operating Pressure
Testing
Before starting either of the tests, park the machine on firm, * Pump Pressure Relief Valve (Early Machines only)
level ground and apply the parking brake. Switch off the
engine. 1 At the steering unit, disconnect the flexible hose from
the pump. Using suitable adapters, connect a 0-400 bar
Note: The following procedures should be carried out with (0-6000 lb/in2) pressure gauge B and a flow regulator C
the oil at working temperature. between the flexible hose and the hydraulic steering
unit D.
Steering Unit Relief Valve
1 Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to

test point A. Start the engine and run at idle r.p.m. until
normal working temperature is reached. Turn the P2 B C D
A268370
steering wheel to full left lock and hold. Slowly increase
engine speed to 1500 r.p.m. while checking the gauge 2 Start the engine and run at 1500 rpm. Use the flow
reading against the steering unit nominal relief valve regulator to gradually reduce the flow rate until the
pressure given in Technical Data. Switch off the pump pressure relief valve operates. As this point check
engine if the pressure exceeds 180 bar (2610 lb/in2) the gauge reading against the pump relief valve
before engine reaches 1500 r.p.m. pressure given in Technical Data.
Note: High pressure may be observed momentarily as the 3 If the gauge reading is not correct, the pump relief valve
steer valve has only a small aperture to bleed excess should be removed for cleaning (see Section E). The
pressure. pressure setting is controlled by shims (see Pump,
Suspension and Steering) but the pressure MUST
2 If the pressure is incorrect, remove the relief valve and NOT under any circumstances be set higher than the
clean (refer to Hydraulic Steering Unit, Dismantling setting given in Technical Data.
and Assembly).
3 If cleaning fails to rectify the fault, change the relief

valve.
A268360
9803/8020 Issue 3*
8-1 *Front Axle Steering Rams 8-1
9803/8020 Issue 2*
8-2 *Front Axle Steering Rams 8-2
Removal and Replacement Dismantling and Assembly
Removal Dismantling
1 Disconnect the hydraulic hoses, noting their locations 1 Remove snap ring 1.
to aid replacement.
2 Push guide 9 into cylinder 13 until snap ring 2 is visible.
2 Remove the split pins and nuts securing the tapered Remove the snap ring with a blunt screwdriver.
pins.
3 Pull the piston rod assembly (items 3 to 12) out of
3 Using a joint separator, split the tapered pin from its cylinder 13.
mounting point at each end.
4 Remove end nut 4 and slide off the the piston assembly
4 Lift the ram clear. (items 5 to 8) and the guide assembly (items 9 to 12).
Replacement 5 Remove and discard all seals and O-rings from both
assemblies.
Assembly
Tighten the retaining nuts to a torque of 135 Nm (13.8 kgf m,
100 lbf ft). Assembly is the reverse of dismantling.
Fit new seals and O-rings after lubricating with clean

hydraulic oil.
Torque Settings
4 114 ± 11 11.6 ± 1.1 84 ± 8
9803/8020 Issue 2*
11 - 1 *Hydraulic Steering Unit 11 - 1
Removal
Switch off the engine and remove the starter key.
Disconnect the hydraulic hoses to the hydraulic steering unit

A, labelling them to aid reconnection. Plug the ports and
hoses to prevent the ingress of dirt and excessive loss of oil.
Get an assistant to support the steering unit at the rear of

the engine bay and then remove the four mounting screws B
from inside the cab. Withdraw the steering unit into the
engine bay, in the process disconnecting the internally
splined shaft of the steering unit from the splinted output of
the steering column flexible coupling. Note the orientation of
the steering unit. A
Replacement
Note: The steering unit is spring loaded to the neutral

position (i.e. straight ahead). Make sure the steering wheel is
in the straight ahead position when re-connecting the
splines.
Torque Settings
B 45 4.6 33
A228380
9803/8020 Issue 2*
9803/8020 Issue 2*
Use the numerical sequence on page H12 - 1 as a guide to dismantling.
* Note: Pressure relief valve 29 may be removed after removing plug 27 but without removing any other components.
During manufacture, a small mark W will have been made on sleeve 12 and spool 15, close to one of the slots for the centring
springs 13. Before removing the centring springs, check that this mark is visible; if not, make a new mark to ensure correct
assembly.
Assembly
1 Fit spool 15 into sleeve 12, aligning slots for centring

springs 13 and checking that the small marks W (see
facing page) are aligned. Ensure that three slots in spool
partially uncover three holes in sleeve, as at A.
226380
2 Fit two flat centring springs 13 with four curved springs

between them, as shown at B.
Fit seal 24 into steer unit body and insert sleeve X of

tool 892/00180. Fit back up ring 20 and seal 21 onto
plastic boss Y, and position boss on tool spindle Z, as
shown.
Lower steering unit body and tool sleeve over tool

spindle until plastic boss Y is flush with end of bore.
Assemble sleeves 12 and 15 with cross pin 14 and
centring springs 13. Fit bearing components 16 to 19 X
with chamfered face of 17 facing away from bearing 18.
226390
9803/8020 Issue 3*
3 Remove body from tool leaving plastic boss in position,
and lower body over assembled spool.
Y
Apply downward pressure on body until plastic boss Y
is forced out of bore, leaving seals correctly located.
Y
4 Turn unit over and place on a suitable hollow support so

that body does not rest on protruding sleeve, thus
preventing displacement of the new seals (support
example is a pump drive adapter). Place ball 23 into
check valve hole and fit bush 22. Fit new 'O' ring 10.
Fit distributor plate 9 ensuring that holes align. Locate

shaft 11 onto cross-pin 14, noting position of slot. When
rotor 7 is fitted, slot must align with hollows of rotor as
shown at C.
9803/8020 Issue 2*
5 To support the shaft and ensure positive engagement
with the splines of rotor 7, use a suitable piece of rigid
flat material, 0.25mm (0.010 in.) thick (for example a
piece of scrap microfiche).
Locate rotor onto shaft, ensuring alignment as at C (see

previous page). Fit spacing bush 6 into rotor.
Fit 'O' rings 4 and 8 each side of body 5, then position

body over rotor.
Fit at least one bolt 2 before removing support material.
Fit remaining bolts, ensuring that special bolt 1 is

correctly located. Tighten all bolts to 29Nm (22 lbf ft).
226420
6 After renewing seals 28 and 30 tighten plug 27 to a

torque of 50 Nm (37 lbf ft). Check the pressure setting
of steering unit relief valve 29 after the steering unit has
been re-installed on the machine (see Steering System
Operating Pressure Testing).
9803/8020 Issue 2*
15 - 1 Steering Column 15 - 1
9803/8020 Issue 3*
15 - 2 Steering Column 15 - 2
Dismantling/Removal
* The numerical sequence on the illustration opposite is *

intended as a guide to dismantling/removal. 5
Assembly/Replacement
Assembly/replacement is the reverse of

dismantling/removal.
*
When Assembling/Replacing
Having assembled the steering column to provide the C

nominal 91 mm dimension shown (see right), it is important
to make sure that steer drive disc A does not foul the four
bolts D which secure hydraulic steering unit B to the cab
C
bulkhead. This situation can arise if the external spline of A
is pushed too far into the spline of B. If this happens, with
the lower clamp firmly secured by items 9, 10, 11, 12 and
the upper clamp securing bolt 5 loosened, release U-bolts
C. Adjust the position of item 16 so that the splines at E are
fully but not over engaged. Partially tighten the U-bolts. Turn 9, 10, 11, 12 16
the steering wheel and confirm that no fouling occurs.
Finally, fully tighten U-bolts C and upper clamp securing bolt
5.
D A
Torque Settings
D
.0
91
2
5
70
28
7.1
2.8
52
21
E
6 28 2.8 21
* 9/11 28 2.8 21
13/15 28 2.8 21
C TBA TBA TBA B
A302630
9803/8020 Issue 3*
16 - 1 Rear Axle (4WS) Steering Valve 16 - 1
- Fastrac 2115, 2125, 2135 and 2140 Machines
1 Park the machine on firm level ground in 2WS mode
with the rear wheels in the straight ahead position.
Apply the parking brake, switch off the engine and
remove the starter key.
2 Disconnect the hydraulic hoses and electrical
connectors to the 4WS steering valve making a note of
their locations to assist in replacement. Plug the hoses
and ports to prevent loss of oil and ingress of dirt.
3 Remove cap screws/nuts A and lift the valve clear.
4 Replacement is the reverse of removal. Tighten cap
screws/nuts A to a torque of 40 Nm (29.5 lbf ft).
Setting the Relief Valve

4WS Dump Valve A
1 With the machine travelling above a speed of 1 kph,
select 2WS and make sure that the rear wheels lock in
the straight ahead position. Park the machine on firm
level ground and apply the parking brake.
*2 With hydraulic oil at operating temperature and the TP
engine switched off, slowly remove plug X.
Note: Following the removal of plug X there will be an initial
show of oil after which there should be no further flow.
*3 Install a 20 bar (300 lbf/in2) pressure gauge at test point
TP.
*4 Run the engine at 1500 rev/min and set the 4WS dump CT1
valve CT1 to the pressure given in Technical Data. X
5 Switch off the engine and disconnect the pressure
gauge. Refit plug X.
4WS Main Relief Valve Y CT2

1 With the engine switched off, install a 400 bar (6000
lbf/in2) pressure gauge at test point TP. Disconnect the
wiring to the 4WS solenoid valves.
2 Run the engine at 1500 rev/min and ensure that the
machine is still in 2WS with the rear wheels locked in
the straight ahead position.
! WARNING A248950
Keep clear of the rear wheels when the engine is running

as you could be injured by unexpected wheel movement.
HYD ST 5-5
3 Operate the 4WS hydraulic valve by pushing a suitable SP

piece of rod or a small screwdriver into either access
hole in the solenoid valves. This will cause a pressure
build up in the power track rod until the pressure gauge
indicates the setting of the 4WS main relief CT2. Set
the valve to the pressure given in Technical Data.
*4 After setting the pressure, continue to run the engine A BP T TP
and check that the pressure remains stable. If the P

A
correct setting cannot be achieved or if the pressure
CT1
does not remain stable remove orifice Y, using a 3 mm
allen key. Clean out the orifice and refit. Re-adjust as
necessary.
CT3
5 Switch off the engine and disconnect the pressure B CT2
gauge. Reconnect the wiring to the 4WS solenoid
valves. AWS
A243600
9803/8020 Issue 4*
16 - 2 Rear Axle (4WS) Steering Valve 16 - 2
Relief cartridges CT1 and CT2 and shuttle valve CT3 can be
removed with the steering valve in position on the machine. A
Fit new seals A, B and C respectively before replacing.
Proportional solenoid valve SP can also be removed with the

valve in position on the machine. Fit new seals before
replacing.
CT1
Torque settings
Item Nm lbf ft kgf m
CT1 60 44 6.1
CT2 45 33 4.6
CT3 60 44 6.1
D 10 7.3 1.0
CT3
CT2
E C
E
B
SP
D
A249020
9803/8020 Issue 2*
17 - 1 Rear Axle (4WS) Power Track Rod 17 - 1
- Fastrac 2115, 2125, 2135 and 2140 Machines
Removal
The 4WS power track rod can be removed with the axle in Remove the four bolts G and spacers H to release the power
situ on the machine. track rod from the axle and lift clear.
Replacement
Park the machine on firm level ground in the 2WS steer
mode. Apply the parking brake, switch off the engine and Replacement is the reverse of removal.
remove the starter key. Chock the front wheels. Jack up the
rear axle and support on axle stands. Remove the rear * Apply Loctite 2701 to the threads of bolts G.
wheels.
Note: After replacement has been completed check the rear
Disconnect hoses A and B, air line C, electrical connector D wheel alignment (see Checking and Adjusting the Wheel
and drain line E from the power track rod. Alignment, Section 3).
Remove nuts F and use a ball joint splitter to separate the Torque Settings
track rod ends from the steering lugs.
! CAUTION
F 185 135 18.7
cause weakness and may lead to steering failure.
G 244 180 24.9
AXL 8-2

Note: The power track rod is too heavy and unwieldy for one
person to lift out safely. Enlist the help of a second person to
carry out the next step.
* H (8.8 grade) 200 20 148
H (10.9 grade) 300 30 220
F H
C
D B A243500
E
9803/8020 Issue 5*
Ball Joints - Removal and Replacement
When Removing
The piston rod operates at full length, any damage to the

surface will cause fluid leaks. DO NOT attempt to grip the
rod diameter with pipe grips etc.
1 Using two suitable open ended spanners at A and B,

turn them against each other until one ball joint
unscrews.
2 Unscrew the ball joint until an open ended spanner can

be fitted on the rod C. Screw the ball joint against the
spanner to secure the spanner and to prevent damage
to the rod.
3 By turning against each other the spanners at C and B

will undo the other ball joint.
When Replacing
Coat the first few threads of the ball joint with JCB
Threadlocker and Sealer and then tighten firmly.
B
A
B
C
A296390
9803/8020 Issue 3*
12
11
7
6
5 10
13
9
8 42
4
C
D
E
40
39
32
33
34
35
38
37
36
17
31
28
29 19
30
27
26
14
25
24
23
15 D
41
1
2 3
22
16
20 18
21
A243461
9803/8020 Issue 3*
Power Track Rod -
Before dismantling the power track rod, it is necessary to When Assembling
remove the left hand ball joint/track rod end (at end C of
tube 42) as described above. First, make up the assemblies comprising items 10 to 13
and items 19 to 41.
The numerical sequence on the illustration is intended as a
guide to dismantling. Tighten collar 16 so that the grub screw 15 aligns with the
hole in 19.
To facilitate insertion of the assembly comprising items 10 to
Read the appropriate notes before starting the sequence. 13 apply compressed air to port E. Insert the eight balls 14
via the inside of item 19, using grease to retain them in the
Note: Inset D shows items 1, 2 and 3 which are located at holes. After installing the assembly, install item 6 complete
port D on tube 42. with seals 7 to 9 and push far enough in to make the groove
for snap ring 5 accessible. Locate snap ring 5 in its groove
When Dismantling and then push item 10 from the right end until it forces item
1 To allow access to snap ring 5, push item 6 towards the 6 hard up against snap ring 5. Remove the compressed air
centre of tube 42. Remove snap ring 5. Initially remove supply from port E and then push item 10 to the right until
items 6 to 13† as an assembly. The assembly the power track rod locks.
comprising items 5 to 8 can then be slid off the end of
item 10. Dismantle further after removal.
† To facilitate removal of the assembly comprising

items 6 to 13 apply compressed air to port E to release
the eight locking balls 14. Gently tap the right end of
item 10 to drive the assembly out of tube 42. Take care
not to lose balls 14 which will probably drop out when
the assembly is removed.
2 After first removing seal 17, and taking care not to

damage the lip, use a press to push item 19
approximately 10 mm into cylinder 42. To remove snap
ring 18, use a flat ended screwdriver to lift and hold the
end of the snap ring out of its retaining groove. Insert a
thick feeler gauge behind the snap ring to prevent it
expanding back into the groove. Using the screwdriver,
prise the snap ring fully out of its groove and then
remove it. Slowly release the pressure and remove from
the press. Remove the locking system assembly
comprising items 19 to 41 by tapping against the left
end of item 19 with a flat ended bar.
3 When dismantling the locking system assembly, initially

remove items 26 to 30 and items 32 to 38 as
assemblies. Dismantle further after removal.
Note: Take care when removing snap rings 31 and 39 to

avoid damaging the outer surface of item 19.
9803/8020 Issue 2*
30 - 1 Steering System Description 30 - 1
The front axle is steered by a recirculating ball power
assisted steering box SB. Drop arm A and drag link D
transmit the steering effort to the right hand steering swivel
R. This is linked to the left hand steering swivel by track rod
S.
P2 is the rear section of the engine-driven hydraulic pump

which draws fluid from tank T to supply steering box SB. An
adjustable pressure and flow control valve B is built into the
rear cover of the pump.
The steering box incorporates pressure limit valves E and F.

The valves operate just before the steering rack reaches full
lock to vent the power assist pressure to the exhaust side of
the rack.
Fluid exhausted from the steering box joins with the pump S206400
by-pass flow and returns to tank via cooler CS which is
positioned across the front of the radiator.
9803/8020 Issue 1
31 - 1 Fault Finding 31 - 1
Introduction
Before assuming that the steering box or the pump is the

cause of a steering problem, ensure that all other steering
system faults have been rectified.
Follow the fault finding procedure on the next page but first
carry out the following checks:
1 Question the driver and drive the machine to establish

the exact nature of the fault.
2 Check that the hydraulic oil is clean and to the correct

and that there are no signs of oil leakage from the
circuit.
3 Check that the steering box mountings and all steering

and suspension linkages are correctly tightened.
9803/8020 Issue 1
31 - 2 Fault Finding 31 - 2
Heavy Steering
CHECK ACTION
1 Is the front axle overloaded? YES: Reduce load.
NO: Check 2.
*3 Is the 4WD clutch releasing correctly? YES: Check 4

*4 Is the front differential operating correctly? YES: Check 5

5 Are the steering swivels and linkages free? YES: Check 6.

NO: Lubricate and free off.
6 Is the oil cooler free of air blockage? YES: Check 7.

NO: Clean out debris.
7 Is the pump relief valve pressure too low? YES: Check for dirt at relief valve.
NO: Check 8.
8 Is the pump flow rate too low? YES: Check for flow control valve sticking and check 11.
NO: Check 9.
9 Is the steering column turning freely? YES: Check 10.

(See Steering Shaft, Checking) NO: Free off / check universal joint phasing.
10 Is front wheel alignment correct? YES: Check 11.

NO: Adjust.
11 Are suspension and steering geometry correct? YES: Check 12.

NO: Renew parts as required.
12 Is steering box leaking oil? YES: Renew seals.

NO: Check 13.
13 Is oil temperature high? YES: Check cooler and pipework for free flow.
NO: Suspect fault in steering box.
Steering Wander or Free Play

If the fault is wander, start at check 1. If the fault is free play, start at check 4.
CHECK ACTION
1 Is the rear axle overloaded? YES: Reduce load.
NO: Check 2.
3 Is the front wheel alignment correct? YES: Check 4.

NO: Adjust.
4 Are the column or steering linkages worn or loose? YES: Tighten or renew.
NO: Check 5.
5 Is the pump flow correct? YES: Check 6.

NO: Check condition of flow control.
6 Is air trapped in the hydraulic oil? YES: Bleed out air (see Steering Box Replacement.)
NO: Suspect fault in steering box.
9803/8020 Issue 3*
Steering Pump Pressure Testing
1 Park the machine on firm, level ground and apply the
parking brake. Jack up the front of the machine until
the wheels are clear of the ground and support it using
axle stands placed under the axle. Ensure that the
wheels can turn fully from lock to lock without fouling
the axle stands.
! WARNING
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 that 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
2 Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to

test point Y.
3 Fit a 30 mm lock stop (part number 476/40702) at the

left-hand side.
4 Run engine at 1500 rev/min, turn the steering wheel to

full left lock and hold while checking the gauge reading
against the pressure given in Technical Data. Y
* 5 If the gauge reading is not correct, the fault is likely to
be in the pump relief valve which should be removed
for cleaning (see Section E).
* 6 If after cleaning the pressure is still not correct it can be

adjusted, but the pressure MUST NOT under any
circumstances be set higher than the setting given in
Technica Data. Proceed as follows:
*
Machines with Type 1 Pumps X
The pressure setting is controlled by shims inside the
pump (see Pumps - Suspension and Front Axle
Steering in Section E)
Machines with Type 2 Pumps

The pressure setting is controlled by an adustable relief 1
valve cartridge located in the pump end cover (shown
at X).
a Make sure that the engine cannot be started.

Remove the retaining cover 1. Pull out the valve
cartridge 2.
b Grip the cartridge and turn the adjusting screw 3
no more than 1/4 turn, clockwise to increase the
pressure setting and anticlockwise to decrease.
c Replace the cartridge and refit the retaining cap 1.
tighten the cap to the correct torque. DO NOT 3
start the engine unless the cartridge 2 and 2
retaining cap 1 are correctly fitted.
d Start the engine and check the pressure setting. If
further adjustment is required stop the engine and
repeat the above from step ‘a’.
* Torque Settings
Item Nm kgf m lbf ft A1122

1 30-35 3.0-3.5 22-26
9803/8020 Issue 2*
34 - 1 Steering Box 34 - 1
Limit Valve Setting
In the event of altering wheel width and lock stop sizes,
fitting a new steering box or if the adjusting screws have
been disturbed, the limit valves must be set as follows.
Location of the limit valve adjusting screws E and F is shown
on the facing page.
1 Do steps 1 and 2 of Steering Pump Pressure Testing.
2 Check that the correct lock stop D (varies in length

according to track width and tyre specification) plus a
2 mm flat washer is fitted at each side of the machine.
Lock stops to suit the tyres/track width of new
* machines are factory fitted. See Tyres and Wheels,
Lock Stops in Section 3 for details for other tyres/track
widths.
3 Run the engine until the temperature of the oil in the D

hydraulic tank is at least 20 °C and then set the speed
to 1500 rpm.
4 Turn the steering to full left lock. Set the pressure to 38-
40 bar (550-580 lbf/in2) by adjusting the front limit valve
screw E. Use a long thin screwdriver through the hole in
the front cross-member as shown by the arrow X. Turn
clockwise to decrease the pressure and anti-clockwise
to increase.
5 Release the steering wheel and turn it back and forth

(fully onto left lock 5 times and onto right lock at least
once) then re-check the pressure. Adjust if necessary.
Repeat this process until the pressure remains constant
(four or five times is normal to achieve this). If the
pressure will not remain constant, ensure that the lock
stops, steering box, axle and suspension mounting
points are all secure.
! WARNING
Due to the proximity of engine revolving parts and the
possibility of getting trapped between the wheel and the
chassis, rear limit valve screw adjustments should not
be attempted until the engine has been switched off and
stopped. Remove the starter key.
HYD ST 5-4
6 Turn the steering to full right lock and repeat steps 4

and 5, reading right lock instead of left lock and vice-
versa. Adjust rear limit valve screw F using a flexible
shaft screwdriver.
7 Once the pressure settings have been completed,

remove the lock stops D and the 2 mm flat washers.
Re-install only the lock stops.
9803/8020 Issue 4*
Limit Valve Setting (cont’d)
222430
9803/8020 Issue 1
0 0
0
8
9
7
3 A
2
1
5
9803/8020 Issue 1
Note: Before assuming that the steering box is the cause of When Replacing
a steering problem, ensure that all other steering system
faults have been rectified (see Fault Finding). It is absolutely critical that the steering box mounting bolts
are tightened to the torque setting specified below. Failure
Remove the radiator to gain access to the top of the steering to do this may result in erratic steering.
box.
* Before fitting pinch bolt 9, ensure that the steering shaft
The numerical sequence shown on the illustration is universal joints are correctly aligned (see Steering Shaft,
intended as a guide to removal. Checking) and that the steering shaft is not exerting any
end load on the input shaft of the steering box.
For replacement the sequence should be reversed.
After fitting pipework and before fitting drop arm, purge air
! WARNING from the hydraulic system by turning the steering wheel from
lock to lock 3 times and then back to straight ahead (with
engine running at idle).
* When fitting drop arm, align marks X and Y on shaft and
drop arm.
13-3-1-1
Tighten drag link nut 4 to specified torque setting and then
! WARNING on to next split pin hole before fitting split pin.
Do not weld, hammer or apply heat to the drop arm or its
Grease the shaft seal (see Section 3).
shaft. These actions will cause weakness and may result
in steering failure.
HYD ST 5-1
Note: Apply only one shot of grease from a manual grease
gun. Excessive greasing would damage the internal seals of
the steering box.
When Removing
After fitting the steering box, ensure that lock limit valves are
! WARNING correctly set (see Steering Box Limit Valve Setting).
The drop arm will be VERY tight on the splines. Take Torque Settings
great care when pulling off the arm as it is likely to be
released suddenly with considerable force. Zinc-Plated (colour: golden)
HYD ST 5-2
Note the positions of index marks X and Y on shaft and drop Item Nm kgf m lbf ft
arm. 1 16-18 1.7-2.0 12-15
2 915 93 675
Use a suitable ball joint splitter when removing drag link 5. 4 135 13.7 100
*9 75 7.7 55
Do not disturb the length adjustment of drag link 5 which is
preset to 930 mm (36.6 in) between centres of ball pins. Dacromet (colour: mottled silver)
Use puller adapters A with a 20 tonne general purpose Item Nm kgf m lbf ft
hydraulic ram B to remove the drop arm 6. (See Service 10 500 51 370
Tools, Section 1 for details of the tools.)
Before disconnecting pipes, label them to assist correct

refitting. Blank the open ports to prevent loss of oil and entry
of dirt.
9803/8020 Issue 3*
S222451
9803/8020 Issue 2*
The numerical sequence shown on the illustration is When renewing seals 25, ensure that the piston grooves are
intended as a guide to dismantling. free of nicks and burrs. Install energising rings 26 into the
grooves first with the seals 25 over the top as shown at W.
For assembly the sequence should be reversed. Before inserting the input shaft into the bearing cap,
compress the seals into their grooves using a piece of thin
* Note: From machine number 640059 the input seals 43 and sheet steel rolled into a tubular form. Do not rotate the input
44 may be replaced by unscrewing bolts 40 and removing shaft when fitting it into the bearing cap as this is likely to
cover plate 42 (see inset). damage the seals.
Fit the shaft nut, star nut and check bearing preload as
When Dismantling detailed on the next page.
Remove screws 10 and 11 to prevent them being damaged. When fitting new seals to the piston, position back-up 'O'
They must be re-set after fitting the steering box (see ring 23 in the groove and position new seal ring 22 over the
Steering Box Limit Valve Setting). 'O' ring. Due to the nature of the seal material, it will stretch
as it is fitted but will contract over a period of time to allow
When cover 2 has been removed ensure that there are entry into the bore of the housing.
timing marks on adjacent teeth of the sector shaft 5 and
piston rack. If shortage of time does not allow sufficient contraction of
the seal, use a suitable piston ring clamp to compress the
With the steering box positioned so that ball retainer cap 17 seal.
is pointing upwards, carefully withdraw bearing cap and
shaft assembly X and the piston 20 from the main housing Enter the piston 20 into the housing bore with the ball cavity
as one unit. If this is not done carefully, balls 19 may fall out. Y uppermost and just exposed at the end of the bore.
When the piston is out of the housing, remove cap 17 and Enter the input shaft into the piston so that the bearing cap
split race 18, rotate the input shaft 31 to release the balls (24 37 is within 75 mm (3 in) of the end of the piston 20. Slowly
off) and separate the piston from the bearing cap assembly. turn the bearing cap assembly inwards whilst inserting balls
This will allow seal 21 to be removed. at Y until balls start to appear at Z. Insert split race 18 and
press home. Insert final balls and fit cap 17.
Do not remove plugs C and D from the piston.
! CAUTION
Renewal of rotary valve seals 25 and their energising rings
Do not attempt to back the input shaft out of the piston
26 is not necessary unless they are cut or damaged.
during this process. This would cause the steel balls to
bind on the shaft and may cause damage.
To renew input shaft seals 35 and 36 the bearing cap and HYD ST 5-3
shaft assembly (items 27 to 37) must be dismantled.
When sliding the piston through the housing bore, take care
Note: Special spanners will be required to tighten star nut to avoid damaging seals as they pass the edges of the
27 and shaft nut 28 to their correct torque settings. housing bore for sector shaft 5. Position the timing mark on
the piston rack on the centre-line of the sector shaft bore.
To allow star nut 27 to be removed it may be necessary to
split it with a chisel. Take appropriate safety precautions Install the sector shaft so that the timing mark on the sector
when using the chisel. shaft gear tooth aligns with the timing mark on the piston
rack. Tap the end of the sector shaft with a soft hammer to
Note: The gear is secured to the sector shaft 5 by means of ensure full tooth engagement.
dowel 39 and roll pin 38. These should not normally be
removed as the gear and shaft would be renewed as an
assembly. Torque Settings

When Assembling 1 249-263 25.4-26.8 184-19
12 72-85 7.3-8.6 53-63
Remove any burrs from the piston using a fine hand stone. 16 249-263 25.4-26.8 184-19
Apply a light coat of grease to the seals, thrust bearings and

thrust washers.
When fitting shaft seal 36 ensure that the lip faces towards
the inside of the steering box and that the seal bottoms in
the bearing cap bore. Fit the salt seal 35 until it is flush with
the face of the bearing cap.
9803/8020 Issue 2*
Fitting the Input Shaft Nut and Star Nut
1 Ensure that the input shaft, thrust bearings and thrust

washers are correctly installed in the positons shown A
on the assembly illustration. Using spanner A, part no.
892/00883, tighten the shaft nut 28 to 2.8-4.7 Nm (2-3
lbf ft).
222460
2 Fit a new star nut 27. While preventing the shaft nut
from turning using spanner A, tighten the star nut to 14-
16 Nm (10-12 lbf ft) using spanner B (part no.
892/00884). Continue tightening the star nut until two of A
the tangs align with the two plain holes in the bearing
cap. ‡
Note: Do not use the threaded hole in the bearing cap.
This is for the lock limit screw.
Turn the bearing cap over in the vice. Rotate the

splined end of the shaft using a torque meter and a B
suitable socket. The reading should be less than 2.8
Nm (2 lbf ft). If this figure is exceeded, re-check the
torque on the shaft nut.
222470
3 Bend two tangs of the star nut into the two plain holes
in the bearing cap as at C.
Stake the star nut into the shaft nut at the two notches D
D.
222480
9803/8020 Issue 1
42 - 1 Steering Shaft 42 - 1
Checking 3 Re-tighten the U-bolt J evenly, followed by bulkhead
bolts H. With the U-bolt tight, if the bulkhead bolts H
Universal Joints and Phasing are then forced to one side of their holes, the shaft will
be stressed causing binding.
Check for stiff (seized) or worn universal joints (UJ) on the
steering shafts. Inspect all universal joints along the entire 4 To correct this, slot the holes in the cab bulkhead to
length of the shafts. Make sure that the shafts are not compensate for the misalignment. It is important that
rubbing against any other components, (for example hoses the tightening sequence at 3 is followed.
or pipework).
* Note: It is important that high pressure water jets are not

pointed at universal joints during cleaning. The universal D
joints on later shafts have grease nipples which should be
greased if steering becomes stiff or if a new shaft is fitted.
Replace shafts as necessary.
Check that the phasing of the steer shaft is correct. Ensure

that the column shaft UJ (D) is phased with the intermediate E
shaft UJ (E) as shown.
Note: Phasing between the intermediate shaft B and lower

F
shaft C is fixed by a machined groove on the end of the
lower shaft. In the same way phasing is fixed between the F X
column X and bulkhead shaft Y.
A Y
Intermediate Shaft and Bearing
Inspect the bearing A on the lower steering shaft. Check that

F
B
the bearing has not seized. If the bearing appears tight,
apply a light lubricating oil to make the steering smoother.
C
Check that the bearing A has not seized to the shaft. Note
that there should be a small clearance fit between the shaft
and bearing; ensure that grub screws are never fitted/used
to secure the bearing inner race to the shaft. The area of the
shaft on which the bearing is located should always be
lubricated with grease to prevent corrosion.
If you are still unsure of the condition of the bearing, carry

out either of the following.
J
1 Undo the three bolts F securing the self-aligning
housing until the bearing is free.
2 Remove the intermediate shaft B from the end of the

lower shaft C. Using a piece of wire or cable ties,
support the intermediate shaft at roughly its normal
operating position and angle.
If the steering input is smoother then, there is a flaw in the

self aligning bearing. Replace as necessary.
H G
Bulkhead Shaft
If the above are correct, the cab bulkhead shaft G should be

checked for misalignment. Carry out the following:-
1 Remove the dash board shroud.

H
2 Slacken U-bolt J and the four bolts H fixing the shaft to
the cab bulkhead.
A271060
9803/8020 Issue 2*
Section S Suspension Section S
i i
Contents Page No.

Technical Data 1-1
Front Suspension
Description 2-1
Shock Absorber
Control Arm (2000 Series)
Control Arm (3000 Series)
Panhard Rod
Anti-roll Bar
* Coil Spring (Fastrac 2115, 2125, 2135, 2140 Machines)
Coil Spring and Microcellular Spring
(Fastrac 2150 and 3000 Series Machines)
Rear Suspension
Description and Hydraulic Circuit Diagram 11 - 1
Pressure Testing 21 - 1
Ride Height 22 - 1
Discharging Hydraulic Pressure 22 - 2
Pump See Section E
Pressure Maintenance Valve
Spring Box
Accumulator/Height Corrector Valve/Gas Spring/
Suspension Cylinder
Gas Spring and Accumulator
Testing 34 - 1
Suspension Cylinder
Anti-roll Bar
Control Arm
* 'V' Link (Fastrac 2115, 2125, 2135, 2140 Machines)
‘V’ Link (Fastrac 2150 and 3000 Series Machines)
Ball Joint - Dismantling and Assembly 42 - 5
9803/8020 Issue 5*
Pump
Type Front section (P1) of gear type double pump, driven by

engine.
Maximum Flow 9.2 litres/min (2.0 UK gal/min; 2.4 US gal/min)
Pressures
bar kgf/cm2 lbf/in2
Pressure Maintaining Valve

Cut-out pressure 200 204 2900
Cut-in pressure 180 184 2610
Accumulator Charge Pressure 75 76.5 1087
* Gas Spring Charge Pressure

Fastrac 2115, 2125, 2135 (1 x) 26 27 377
(1 x) 35 36 508
Fastrac 2150 and 3000 Series (2 x) 35 36 508
9803/8020 Issue 3*
2-1 Front Suspension 2-1
Description
* Note: The main illustration shows the arrangement on * Fastrac 2115, 2125, 2135, 2140 Machines
Fastrac 2115, 2125, 2135 and 2140 machines. Inset Z shows
the spring/shock absorber arrangement on Fastrac 2150 and Suspension stiffness is provided by coil springs C.
3000 machines. Suspension movement is controlled by two telescopic shock
absorbers D. Anti-roll bar E controls vehicle roll when
All Machines cornering.
The front axle is located by a four link system consisting of 2150 and 3000 Series Machines
three control arms A and Panhard rod B.
The suspension principle is the same as that described
above, except that primary suspension stiffness is provided
by coil springs C, supplemented by microcellular
polyurethane springs (view Z) which offer progressively
increasing suspension stiffness over bumps.
D
A
A
C
A B
C
E
Z
D
C
A290711
9803/8020 Issue 3*
* Shock Absorber (D)

! WARNING When Replacing
When fitting the mounting pin D12 into the axle, apply JCB
Threadlocker and Sealer to the threads.
Stop the engine, remove the starter key, disconnect the Torque Settings
13-3-1-1
Removal and Replacement D1 180 18.4 133
D3 180 18.4 133
The numerical sequence shown on the illustration (items D1 D12 300 31 220
to D12) is intended as a guide to removing.
For Replacement the sequence should be reversed.
Note: This job can be done with the machine standing on its
wheels.
D5
D9
D8
D3
D5
D11 D10
D4
D12
D7 D1
D6
D2
A306740
9803/8020 Issue 3*
Y U
V
W
A2
T
A3
W
A2 A
A1 X
A1
A2
A
A1
A1
A V
A4
A1
A4
A1
A290553
9803/8020 Issue 4
Control Arm (A) (2000 Series)

! WARNING
Make the machine safe before getting beneath it. Do the Control Arm Bosses - 2150 Machines (View Y)
Stop the engine, remove the starter key, disconnect the 1 Check the torque of the four bolts U, securing each
battery. Chock the wheels. front control arm boss T is 98 Nm (72 lbf ft). If any bolt
13-3-1-1
is loose, broken or missing, separate the boss from the
chassis while still connected to the control arm.
Note: View V opposite shows the front end of all three
control arms. View W shows the rear end of all three control 2 Clean the mating surfaces of the chassis and the
arms on Fastrac 2115, 2125, 2135 and 2140 machines. View control arm boss down to bare metal using a medium
X shows the rear end of the centre control arm on Fastrac grade emery cloth to produce the final surface finish.
2150 machines. View Y shows the rear end of the two outer
control arms on Fastrac 2150 machines. 3 Refit the boss to the chassis using bolts U, spacers V
and nuts W (refer to T.I. 10/056) tightened to a torque of
Removal 98 Nm (72 lbf ft).
Just support the weight of the chassis by means of axle Torque Settings - 2000 Series (2150)
stands beneath the lower control arm chassis mount cross
member. Zinc-Plated (colour: golden)

Note: If more than one arm is to be removed it is also
A1 (V) Centre arm - front 350 36 258
necessary to support the axle on stands, so as to maintain
A1 (V) Side arms - front 244 25 180
its location relative to the chassis.
A1/A2 (X) Centre arm - rear 350 36 258
A1 (Y) Side arms - rear 350 36 258
Support the control arm A and remove the two mounting
bolts A1 (V) at the front end and the two bolts A1 (W), bolts
A1/nuts A2 (X) or the nut A3 (Y) as appropriate at the rear
end. Lift the control arm clear.
Replacement
A1 (Y) Side arms - rear 250 26 184
* Ensure that correct spacers A4 are fitted.
* Apply JCB Threadlocker and Sealer to bolt threads and

tighten all bolts and nuts to the specified torque when the
machine is standing on its wheels.
Torque Settings - 2000 Series (2115, 2125, 2135, 2140)

A1 (W) Centre arm - rear 350 36 258
A1 (W) Side arms - rear 350 36 258

A1 (V) Side arms - front (8.8 grade) 200 20 148
A1 (V) Side arms - front (10.9 grade) 300 30 220
A1 (W) Centre arm - rear 350 36 258
A1 (W) Side arms - rear 350 36 258
9803/8020 Issue 6*
*
Y
U
V
W
A2
T
A3
A2 A X
A1
A2
A1
V
A5
W A
A4
A5
A6
A5
A5
A306750
9803/8020 Issue 3*
Control Arm (A) (3000 Series)

! WARNING Torque Settings - 3000 Series (3155, 3185)
A4 (W) Centre arm - front 1400 143 1033
13-3-1-1 A6 (V) Side arms - front 240 25 177
Note: View V opposite shows the front end of the two outer A3 (Y) Side arms - rear 250 26 184
control arms. View W shows the front end of the centre
control arm. View X shows the rear end of the centre control
arm. View Y shows the rear end of the two outer control
arms.
When Removing A4 (W) Centre arm - front 1400 143 1033
Just support the weight of the chassis by means of axle A1/A2 (X) Centre arm - rear 559 57 412
stands beneath the lower control arm chassis mount cross A3 (Y) Side arms - rear 250 26 184
member.
Control Arm Bosses (View Y)
Note: If more than one arm is to be removed it is also
necessary to support the axle on stands, so as to maintain
its location relative to the chassis. 1 Check the torque of the four bolts U, securing each
front control arm boss T is 98 Nm (72 lbf ft). If any bolt
When Replacing is loose, broken or missing, separate the boss from the
chassis while still connected to the control arm.
Tighten all bolts and nuts to the specified torque with the
machine standing on its wheels. 2 Clean the mating surfaces of the chassis and the
control arm boss down to bare metal using a medium
Outer Control Arms grade emery cloth to produce the final surface finish.
3 Refit the boss to the chassis using bolts U, spacers V

Removal
and nuts W (refer to T.I. 10/056) tightened to a torque of
98 Nm (72 lbf ft).
Support the control arm and remove nut A6 (V) at the front
end and nut A3 (Y) at the rear end. Separate the tapers and
lift the control arm clear.
Replacement
Centre Control Arm
Removal
Support the control arm. At the front end, loosen nut A4 (W)
and then remove socket head screws A5 (W). At the rear
end remove bolts A1/nuts A2 (X). Lift the control arm clear.
Separate the control arm from mounting block E by

removing nut A4 and using a 20 tonnes press to force the
tapered stud out of the mounting block.
Replacement
Install the control arm taper in mounting block E and loosely

fit nut A4. After the mounting block socket head screws A5
have been torque tightened to the axle, use a torque
multiplier (993/45400) to tighten nut A4 to the specified
minimum torque. Further tighten to the next castle nut slot
and install split pin. Finally tighten bolts A1/nuts A2 (X) as
specified.
9803/8020 Issue 3*
B6 B4
B5
B3
B2 B1
E4
E3 E6
E7
E1
E7
X
E5 E8
E2
Y A290720
9803/8020 Issue 1
Panhard Rod (B) Anti-roll Bar (E)

Note: The view opposite shows the arrangement on 2000 Note: The view opposite shows the arrangement on 2000
series machines. The principle on 3000 series machines is series machines. The principle on 3000 series machines is
the same. the same.
Removal and Replacement Removal and Replacement
The numerical sequence shown on the illustration (items B1 The numerical sequence shown on the illustration (items E1
to B6) is intended as a guide to dismantling. to E8) is intended as a guide to dismantling.
For assembly the sequence should be reversed. For assembly the sequence should be reversed.
Note: This job can be done with the machine standing on its Note: This job can be done with the machine standing on its
wheels. wheels.
! WARNING ! WARNING
Make the machine safe before getting beneath it. Do the Make the machine safe before getting beneath it. Do the
following: Park on level ground. Engage the parking following: Park on level ground. Engage the parking
brake. Lower any mounted implements to the ground. brake. Lower any mounted implements to the ground.
Stop the engine, remove the starter key, disconnect the Stop the engine, remove the starter key, disconnect the
battery. Chock the wheels. battery. Chock the wheels.
13-3-1-1 13-3-1-1
When Removing
When Removing
Separate the taper ball pins from their brackets using a ball
joint splitter. Remove nuts E1 and bolts E2 from both ends of the anti-roll
bar and then remove the two nuts E3/bolts E4 from each of
! CAUTION the central mounting brackets. Remove the bar forwards out
Do not hammer the cast iron lugs on the axle as this will of the central mounting brackets, complete with plastic
cause weakness and may lead to steering failure. insulators E6, bushes E7 and sleeves E8.
AXL 8-2
When Replacing
When Replacing
Renew sleeves E8 if they are not a good fit between the axle
Before fitting, check dimension X (see below). If necessary, lugs.
adjust by slackening nut Y and screwing ball joint B5 in or
out as required. Retighten nut Y to the specified torque. Do not overtighten nuts E1 and bolts E2.
2115 to 2150 3155 & 3185 Torque Settings

Dimension X 427 to 447 mm 660 to 690 mm
16.8 to 17.5 in 26.5 to 26.7 in Zinc-Plated (colour: golden)
Tighten nuts B2 and B4 to the specified torque and then Item Nm kgf m lbf ft
tighten further until the next slot in the castellation is in line E1/E2 350 36 258 (2000 series)
with the split pin hole. Fit the split pins. E1/E2 244 25 180 (3000 series)
* E3/E4 56 5.7 42 (all machines)
After fitting the Panhard rod, recheck adjustment by
measuring the distance between the top of each front wheel Dacromet (colour: mottled silver)
rim and the chassis side member when the wheels are in the
straight ahead position. The two measurements should be Item Nm kgf m lbf ft
within 5 mm (0.4 in) of each other. If required, re-adjust the * E1/E2 278 28 205 (2000 series)
length of the rod. * E1/E2 200 20 148 (3000 series)
* E3/E4 47.5 4.8 35 (all machines)
100 hours after fitting the Panhard rod, check the torque
tightness of nuts B2 and B4.
Torque Settings

B2/B4 135 13.8 100 (2000 series)
B2/B4 244 25 180 (3000 series)
Y 70-80 7.1-8.2 52-59
9803/8020 Issue 5*
G1 G1
G3
Z C
G2 C
G3
G2
Y
F3
F3
F4
F2
F4
F1
C
F2
F1
A290741
9803/8020 Issue 2*
Coil Spring (View Y) Coil Spring and Microcellular Spring (View Z)

*(Fastrac 2115, 2125, 2135 and 2140) (Fastrac 2150 and 3000 Series Machines)
Removal Removal
Raise both sides of the machine equally by one of the The coil spring C and the microcellular spring G2 must be
following methods: removed together.
! CAUTION Raise both sides of the machine equally by one of the

following methods:
proofed and serviceable lifting equipment, strong
enough for the job. ! CAUTION
SUS 1-5 Take care when lifting/handling this equipment. Use only
proofed and serviceable lifting equipment, strong
a) Use an overhead hoist to raise front of chassis enough for the job.
(minimum lift capacity for basic machine is 3.5 tonnes SUS 1-5
or 5 tonnes with optional equipment). Lift until front
wheels are about to clear the ground. a) Use an overhead hoist to raise front of chassis
(minimum lift capacity for basic machine is 3.5 tonnes
b) Insert a piece of timber 50 x 50 mm (2 x 2 in) between or 5 tonnes with optional equipment). Lift until front
the axle and each bump stop X to prevent the springs wheels are about to clear the ground.
from compressing and to achieve maximum lift on the
jack. Use a jack under the axle to raise the machine and b) Insert a piece of timber 50 x 50 mm ( 2 x 2 in) between
insert stands under the chassis. Lower the jack so that the axle and each bump stop as at X to prevent the
the load is off the springs. springs from compressing and to achieve maximum lift
on the jack. Use a jack under the axle to raise the
Remove nuts F1, washers F2 and bolts F3 which hold the machine and insert stands under the chassis. Lower the
springs to the chassis. jack so that the load is off the springs.
Pry out the coil spring C and spacers F4 from the top and lift Remove bolt G1 which holds the springs to the chassis.
the spring clear of the locating boss on the axle. Allow the microcellular spring G2 and spacer G3 to rest on
top of the axle.
! CAUTION
Pry out coil spring C from the top and lift it clear of the
Keep your hands clear of the springs until they have
locating boss on the axle along with microcellular spring G2
been released and are no longer under load or you may
and spacer G3.
trap your fingers.
SUS 1-4
! CAUTION
Replacement Keep your hands clear of the springs until they have
been released and are no longer under load or you may
Reverse the dismantling sequence. trap your fingers.
SUS 1-4
Torque Settings
Unscrew the microcellular spring from the spacer.
Replacement
F3 400 41 295 Reverse the dismantling sequence.
Dacromet (colour: mottled silver) Note: Tighten the microcellular spring onto the spacer using
hand pressure only.
F3 392 40 289 Torque Settings

G1 392 40 289
9803/8020 Issue 6*
11 - 1 Rear Suspension 11 - 1
L
B V
G
A
H C K S
H
J
V S
X
W
Y B
T
D P
P1 P2 S
Fm
G
T A293384
9803/8020 Issue 6*
Description
The variable rate hydropneumatic rear suspension minimises In operation, as increasing loads cause the chassis to lower
fore and aft vehicle pitch whilst maintaining 'low rate' in relation to the rear axle, the height corrector valves C are
characteristics for ride quality and tractive performance. displaced by the spring boxes H. The valve ports then open
to allow oil flow into the system, pressurising the gas springs
Axle location is by control rods J and 'V' link L. An anti-roll and restoring the pre-set ride height by means of cylinders
bar is also fitted. S. At this point the valves close, trapping oil within the
system. The extra pressure in the gas springs increases
Primary suspension comprises two nitrogen-charged gas suspension stiffness, thereby maintaining vehicle pitching
springs G and one hydraulic cylinder S on each side of the control.
machine. These work in conjunction with height corrector
valves C and spring boxes H to maintain vehicle ride height. As the load is taken off the chassis, it is lifted by the
pressure retained in the system. This action once again
Note: On 4WS machines the control rods J are not straight, displaces the height corrector valves, but in the opposite
as shown opposite, but curved to avoid the steering track direction, opening an escape path to tank for the hydraulic
rod ends. Additionally the forward gas springs are relocated oil.
to a position above the rear end of ‘V’ link L so that they do
not foul the steerable rear wheels (see inset Y on the The reducing pressure allows the chassis to settle until the
illustration on page 32 - 1). corrector valves close, retaining the new volume of oil in the
system and again restoring the ride height to the pre-set
Movement of the axle varies the pressure in the cylinders level.
which in turn works against the pressure in the gas springs
to give a variable rate suspension. Spring/cylinder The height control valves are not affected by normal
assemblies operate independently on either side of the suspension movements which are too rapid for the 6 to 12
vehicle to eliminate any tendency to ride height difference second in-built response delay.
caused by uneven load distribution.
The engine-driven pump has two sections. The rear section

P2 feeds the steering system whilst the front section P1
feeds the suspension system via valve block V. This contains
pressure maintenance valve B which works in conjunction
with accumulator A. From here the feed is split between the
two height corrector valves C which are connected by spring
boxes H to the control arms J. The height corrector valves
open or close in response to axle vertical travel in order to
regulate the flow to and from the suspension cylinders.
Note: Valve block V also contains spool W and pressure

maintenance valve Y which control differential lock X.
9803/8020 Issue 1
Pressure Testing
! WARNING
SUS 1-1
Connect a 0-400 bar (0 - 6000 lbf/in2) gauge to test point A.

B
With engine running, push on one of the spring boxes and
check the gauge reading which should be between the cut-
in and cut-out pressures given in Technical Data.
If the reading is incorrect, adjust the valve at B.

A
Note: If this is the first time the valve has been adjusted, the
adjusting screw will be covered by a plastic cap which
should be removed and discarded.
9803/8020 Issue 1
Ride Height
! WARNING
SUS 1-1
Y
Checking the Ride Height
X
The chassis side members should both be the same height
above the rear axle. With engine running, check that:
a Standard suspension (all machines). Dimension X

X
between the bottom of each bump stop and the axle
casing is 50 mm (2 in ).
*b Heavy duty suspension (2000 series machines only).

Dimension Y between the bottom of each rubber spring
and the axle casing is 5 mm (0.2 in).
Adjustment
1 Disconnect one end of the rear anti-roll bar. Refer to

Rear Suspension, Anti-Roll Bar (KA) (2WS)/(KB)
(4WS) for details as follows:
a View KA - remove nut KA1/bolt KA2.

A258332
b View KB - remove split pin KB1/nut KB2 and
separate the taper of item KB12 from anti-roll bar
KB5.
c View K - remove nut K1/bolt K2.
2 Disconnect each spring box bottom ball joint H5 from

the control arm J and check that the spring boxes will
telescope freely in each direction. If necessary, free off
using penetrating oil.
3 Reconnect the spring boxes and adjust the length by

slackening nut H4 and turning the spring box body H6
until dimension X (or Y) is correct. (Lengthening the
spring box will raise the chassis and vice-versa). Set
the left side, then the right side and re-check and re-
adjust as required until both clearances X (or Y) are
correct. Note that this must be done with the engine
running and pay special attention to the WARNING at
the top of this page.
9803/8020 Issue 5*
Discharging Hydraulic Pressure

components which are charged with pressurised hydraulic
fluid when the engine is running. When the engine is
stopped, pressure is trapped in components downstream of
the check valve.

components, the chassis must be lowered to discharge the
pressure as follows:
! WARNING
13-3-1-1
1 Stop the engine. Pull downwards on the spring box

rods H to allow fluid to be discharged from the
cylinders and the chassis to be lowered down onto the
axle.
! CAUTION
Keep clear of the chassis members as they are lowering
otherwise you could be trapped between them and the
axle casing.
SUS 1-6
2 Release the rods and wait a few moments for pressure

in the accumulators to raise the chassis.
3 Repeat steps 1 and 2 until the chassis remains firmly

down on the axle.
4 Slowly slacken the pipes on either side of the height

corrector valve C to release any residual pressure.
9803/8020 Issue 1
Pressure Maintenance Valve

! WARNING A
components which are charged with pressurised
engine is stopped, pressure is trapped in components
downstream of the check valve.

components, the chassis must be lowered to discharge
the pressure. See Discharging Hydraulic Pressure (Section
S) for correct procedure.
SUS 1-2/2
Note: Provided that the above WARNING is observed, the

valve can be dismantled in situ.
If the cartridge A leaks oil or cannot be adjusted to give the

correct pressure setting, it can be removed for cleaning
and/or renewal of seals. Unscrew the cartridge from the
C
body.
D
Immerse the cartridge in clean hydraulic fluid and operate
the plunger by means of a plastic rod inserted through the
V
nose of the valve. B
Remove cap B to clean and check the non-return valve.
196000
Check the condition of spring C/ball D and also the seat for
the ball inside the housing V. If this is damaged, the
complete housing must be renewed.
Renew the seals and refit the valves.
Check the pressure setting (see Pressure Testing).
Torque Settings

A 75 7.6 55
B 60 6.1 44
9803/8020 Issue 1
Spring Box(H)
Removal and Replacement When Removing
Remove nut H1 on axle control arm bracket and nut H2

! WARNING under height corrector valve.
following: Park on level ground. Engage the parking When Replacing
Stop the engine, remove the starter key, disconnect the Before fitting, check the length between ball joint centres X
battery. Chock the wheels. which should be 308 mm (12.13 in). If incorrect, adjust by
13-3-1-1
slackening nut H4 and turning the spring box body H6.
After Replacing
wheels but wooden blocks should be placed between
chassis and rear axle to prevent the possibility of the ride
Check the suspension ride height (see Ride Height).
height dropping while the spring box is removed.
Torque Settings
H1 12 1.2 9
H2 12 1.2 9
A258321
9803/8020 Issue 3*
Y
G
S1
A228263
9803/8020 Issue 3*
Accumulator (A)
Height Corrector Valve (C)
Gas Spring (G)
Suspension Cylinder (S)
When Removing Gas Spring or Accumulator
Note: These jobs can be done with the machine standing on
its wheels but heed the WARNINGS below. Gas springs G are located as shown in view X on 2WS
machines and as shown in view Y on 4WS machines.
! WARNING
Simply unscrew the unit from its mounting (complete with
square section seal ring). Renew the seal when refitting the
unit.
Note: Gas spring and accumulator are similar in appearance
13-3-1-1
but can be positively identified by the nominal pressure (bar)
stamped on the face of the threaded mounting boss:
26 or 35 indicates gas spring (see Technical Data).
! WARNING 75 indicates accumulator.
components which are charged with pressurised When Removing Height Corrector Valves
engine is stopped, pressure is trapped in components Disconnect the pipes C1, C2, C3 and plastic tube C4 from
downstream of the check valve. the valve.
Before disconnecting pipework or removing hydraulic Disconnect the spring box from the valve by removing nut
components, the chassis must be lowered to discharge C5.
the pressure. See Discharging Hydraulic Pressure (Section
S) for correct procedure. Remove bolts C6 holding valve to chassis.
SUS 1-2/2
When Replacing Height Corrector Valves

Apply JCB Threadlocker and Sealer to the threads of the
For replacement the sequence should be reversed. adapters for hoses C1 to C3.
When Removing Cylinder

After Replacing Any of These Components
Disconnect hose at S1. Remove nut S2. Remove circlips S3
and S4 together with pin S5. Check the suspension ride height (see Ride Height).
When Replacing Cylinder
Torque Settings
Lugs Z at the lower end of the cylinder (see below) should
face the rear of the machine. Item Nm kgf m lbf ft
A 23-30 2.4-3.0 17-22
G 23-30 2.4-3.0 17-22
C5 12 1.2 9
C6 28 3 21
S2 50 5 37
S6 800 81 592
Note: The torque setting given for pin S6 is for use when
fitting the pin into the axle.
Z
Z
9803/8020 Issue 1
Gas Spring and Accumulator

Testing
Note: Gas spring and accumulator are similar in appearance

but can be positively identified by the nominal pressure (bar)
stamped on the face of the threaded mounting boss:
26 or 35 indicates gas spring (see Technical Data).
75 indicates accumulator.
Remove the gas spring G or accumulator A from the

machine and screw it into adapter block X, part number
892/00314.
Connect a hand pump and a 0 to 400 bar (0 to 6000 lbf/in2)

pressure gauge.
Operate the hand pump and watch the reading on the

gauge.
If the gas spring or accumulator is in good condition, the

pressure should rise steadily to the charge pressure (see
Technical Data) and then rise much more slowly for a
period before climbing again.
If the pressure continues to rise steadily to well past the

charge pressure, the diaphragm is ruptured and the unit
must be renewed.
! CAUTION
Do not exceed 245 bar (3500 lbf/in2) or the body may
rupture.
SUS 1-3
162220
9803/8020 Issue 1
13
14
1
16
17 15
5B
A 18
15 9
7 8
6
B
18
9
15
7 8
6
C
W 35mm
5C
10
11
12
A234821
9803/8020 Issue 1
Suspension Cylinder
Dismantling and Assembly Gland Seal Fitting Procedure
Note: Machines can be fitted with either damped or The size (diameter) and position of pins D is determined by
undamped suspension cylinders. The external parts shown the diameter and radial width of the gland seal being fitted.
at A are the same for both types but the part number
stamped on the cylinder will identify which type is fitted (see The pins are screwed into threaded holes in the tool body.
Parts Microfiche). The internal parts are shown at B The spacing of the holes is designed to suit small or large
(undamped) and at C (damped). diameter gland seals.
The numerical sequence shown on the illustration is intended To fit new gland seals 6 to 8:
1 Open the tool as shown at X and insert the new gland
For assembly the sequence should be reversed. seal. The seal must be fitted behind the two front pins
but in front of the rear pin as shown.
Take extreme care not to damage the cylinder bore.
2 Close the tool as shown at Y. The seal must form a
Dismantling kidney shape.
Remove grease nipple 1 and prise off the dust cover 2 in the 3 Locate area E of the seal in the appropriate groove of
direction of the arrow. the gland bearing, as shown at Z. When the seal is in
position, open the tool to release the seal. Remove the
Heat the threaded area of gland bearing 3 to a minimum of tool and expand the seal so that it is correctly installed
300° to release the locking sealant and unscrew the gland in its groove.
bearing from the cylinder 4 .
Withdraw the piston rod 18 complete with the internal parts X

shown at either B or C.
On undamped cylinders, remove circlip 5B to allow gland

bearing 3 to slide off the piston rod.
On damped cylinders, heat the threaded area of seal carrier

5C to a minimum of 300° to release the locking sealant and
unscrew the seal carrier using a suitable peg spanner to fit
D
S161750X
holes W. The holes are 5 mm dia. positioned at a pitch circle
diameter of 35 mm. Removal of the seal carrier will allow
gland bearing 3 to slide off the piston rod.
Remove and discard the sealing components 6 to 9 and also Y

10 to 12 where applicable.
Assembly
Before assembling, check the components for damage and

wear, especially the cylinder bore. Renew the complete
E
S161750Y
assembly if necessary.
Lightly oil all seals. Use the procedure right for fitting gland
seals 6 to 8.
Apply JCB Retainer (High Strength) to the threads of gland Z

bearing 3 (undamped and damped) and seal carrier
`(undamped only). Tighten both to a torque of 200 Nm (148
lbf ft).
Testing
Using a hydraulic hand pump (see Service Tools, Section 1),

check for smooth operation of the ram.
S161750Z

9803/8020 Issue 1
KA KB
KB1
KB15
K15
K16
A293351
9803/8020 Issue 4
Anti-roll Bar (KA) (2WS)/(KB) (4WS)

Removal and Replacement Dacromet (colour: mottled silver)
Note: This job can be done with the machine standing on its Item Nm kgf m lbf ft
wheels. * K1/K2 278 28 205
! WARNING K3 80 8.2 59
Make the machine safe before getting beneath it. Do the K8/K9 22.5 2.3 16.6
following: Park on level ground. Engage the parking K12 100 10 72
brake. Lower any mounted implements to the ground. K15/K16 392 40 289
Stop the engine, remove the starter key, disconnect the KA1/KA2 278 28 205
battery. Chock the wheels. KA3 80 8.2 59
13-3-1-1 KA9/KA10 22.5 2.3 16.6
* KB3/KB4 48 4.8 35
Removal
KB9/KB10 22.5 2.3 16.6
KB13 100 10 72
Note 1: View K refers to Fastrac 2150 machines and 3000
KB15 200 20 148
series.
* Note 2: View KA refers to 2WS (Fastrac 2115, 2125, 2135

and 2140 machines).
* Note 3: View KB refers to 4WS machines (Fastrac 2115,

2125, 2135 and 2140 machines).
The numerical sequences K1 to K16 (view K), KA1 to KA14

(view KA) or KB1 to KB15 (view KB) shown on the
illustrations are intended as a guide to removal. The
illustrations depict only the left end of the anti-roll bar, but
the appropriate steps should be repeated immediately
afterwards on the right end of the bar.
Replacement
When Replacing
Assemble all the component parts of the assembly before

tightening up the nuts and bolts which actually support the
anti-roll bar.
Note: Install clamps K10 (or KA11 or KB11) with the

chamfered sides of the anti-roll bar cut-out facing outwards.
Finally, before tightening nuts K8/bolts K9 (or KA9/KA10 or

KB9/KB10), slide clamps K10 (or KA11 or KB11) outwards
towards clamps K5 (or KA5 or KB6) to leave a 5 mm gap
between the two.
Torque Settings

* K1/K2 350 36 258
K3 100 10 72
K8/K9 28 3 21
K15/K16 476 48 352
KA1/KA2 350 36 258
KA3 100 10 72
KA9/KA10 28 3.0 21
KB2 100 10 72
* KB3/KB4 56 5.7 42
KB9/KB10 28 3.0 21
9803/8020 Issue 5*
J5
J3
J4
J2
J5
J4
J J2
J1
J1
J8
J7 J
J6
J6
A293372
9803/8020 Issue 3*
Control Arm (J)

Note: The illustration shows the control arms as fitted to
2WS machines. The control arms for 4WS machines are
curved to avoid fouling of the power track-rod. The removal
and replacement procedures are identical for both types.
wheels but the rear wheels must be chocked to maintain
axle location.
! WARNING
13-3-1-1
Remove the anti-roll bar first.
The numerical sequence J1 to J8 shown on the illustration is

When Removing
Unscrew nuts J1 and disconnect spring box from control

arm. Remove nuts J2/bolts J3/spacers J4 and nuts J6/bolts
J7 holding the control arm to the axle and chassis
respectively.
Torque Settings
Zinc-Plated (colour golden)

J1 12 1.2 9
* J2/J3 244 25 180 (2115, 2125, 2135, 2140)
J2/J3 350 36 258 (2150, 3155, 3185)
* J6/J7 244 25 180 (2115, 2125, 2135, 2140)
J6/J7 350 36 258 (2150, 3155, 3185)

* J2/J3 200 20 148 (2115, 2125, 2135, 2140)
J2/J3 278 28 205 (2150, 3155, 3185)
* J6/J7 200 20 148 (2115, 2125, 2135, 2140)
J6/J7 278 28 205 (2150, 3155, 3185)
9803/8020 Issue 4*
1
2
A227122
9803/8020 Issue 2*
* 'V'Link
(2115, 2125, 2135 and 2140 Machines)
wheels but the rear axle must be supported by means of an
overhead hoist to prevent it from rotating out of position.
! WARNING
13-3-1-1
Note: This ‘V’ link is not serviceable. In the event of wear

being detected install a new part.
Removal
Support axle and 'V' link L.
Remove bolts 1 and block nuts 2 from front end of 'V' link.
Remove nuts 3 holding rear of 'V' link to axle studs and lift
the 'V' link clear.
Replacement
Replacement is the reversal of removal.
Torque Settings

1 244 25 180
3 475 48 352

1 200 20 148
3 475 48 352
9803/8020 Issue 4*
1
2
L
5 X
6
Y
8
A360201
9803/8020 Issue 3
'V' Link (Fastrac 2150 and 3000 Series Machines)

Note: This job can be done with the machine standing on its *
wheels but the rear axle must be supported by means of an
overhead hoist to prevent it from rotating out of position. Torque Settings

! WARNING
Make the machine safe before getting beneath it. Do the Item Nm kgf m lbf ft
following: Park on level ground. Engage the parking 1 390 39 290
Stop the engine, remove the starter key, disconnect the Dacromet (colour: mottled silver)
13-3-1-1
1 395 40 291
The numerical sequence shown on the illustration is intended
3 475 48 350
as a guide to removal.
6 See Text
When Removing
Support axle and 'V' link L.
Remove bolts 1 and block nuts 2 from front end of 'V' link.
* Note: The rear of ‘V’ link L will be secured to the axle in one
of two ways - see views X and Y. If you need to replace any
of the existing fasteners (items 3 to 8) with new items, please
ensure that you use identical replacements. Do not mix items
from the two different fastening methods.
Note that the spotface on casting Y is larger than on casting

X.
View X
Remove capscrews 3, spacers 4 and nuts 5 holding rear of
'V' link to axle and lift the 'V' link clear.
View Y
Remove bolts 6, spacers 7, and flange nuts 8, holding the
rear of the ‘V’ link to the axle and lift the ‘V’ link clear.
When Replacing
* Always replace damaged fasteners by the specified JCB

supplied parts which will be to the correct grade.
View X
Ensure that capscrews 3 are grade 12.9, 100 mm long, with
spacer 4 fitted between nuts 5 and the tower casting as
shown.
View Y
Ensure that bolts 6, spacers 7, and flange nuts 8 are
assembled as shown. Lightly grease the threads of bolts 6
before assembly. Torque bolts 6 to 100 Nm (10.2 kgf m)
(74.0 lbf ft) then tighten by a further 180o.
9803/8020 Issue 5*
* 'V' Link (Fastrac 2150 and 3000 Series Machines)

(continued) X 1
Ball Joint - Dismantling and Assembly

2
The ‘V’ link ball joint should not be dismantled unless wear is
detected. Items 1 to 9, 11 and 12 plus a tube of special 3
grease constitute a repair kit which should be obtained
before commencing work.
4
Note: Item 9 which is identical to item 5 will not be required
and can be discarded if the lower end of the bore in item 10
5
is chamfered.
The numerical sequence shown on illustration X is intended 6


8
When Dismantling
9
Cover 1 is spot welded to ‘V’ link 10. Remove by grinding off
or otherwise breaking the weld.
10
To separate the taper which connects items 8 and 13 use an
M16 x 1.5 bolt of suitable length screwed down through the
threaded hole in 8 to jack the two apart (see illustration Y).
7
When Assembling
When assembling items 1 to 8 (9 if appropriate) and 10 to 12, 11

pack the joint with the special grease supplied.
12
To secure item 1 in position, spot weld at three points, or
alternatively peen at six points.
Torque Setting
Item Nm Kgf m lbf ft 13

6 135 13.7 99
Y A243370
A243380
9803/8020 Issue 2*
Section T Engine Section T
Contents Page No.
* Technical Data (2000 Series Machines excluding 2140)

General 1-1
Fuel System 1-2
* Technical Data (3000 Series and 2140 Machines)

General 1-3
Fuel System
Fastrac 3155 1-3
* Engine Unit (Typical)

Flywheel Damper - ††Wet Clutch Transmission

* Engine Heater
Removal and Replacement See Section A
* Fault Finding (2140 Electronic Management System) See Section C
††2000 Series from S/N 740000, 3000 Series from s/N 642000
9803/8020 Issue 5*
General 1-1
Fastrac 2115 Fastrac 2125 Fastrac 2135 Fastrac 2150
9803/8020
New 1000 Series, New 1000 Series, New 1000 Series, New 1000 Series
Section T
* Model
Turbocharged, 6 cylinder, Turbocharged, 6 cylinder, Turbocharged, 6 cylinder, Turbocharged/intercooled,
water cooled water cooled water cooled 6 cylinder, water cooled
Rating 1941/2300 1929/2300 1947/2300 1930/2200
Bore 100 mm (3.937 in) 100 mm (3.937 in) 100 mm (3.937 in) 100 mm (3.937 in)
Stroke 127 mm (5 in) 127 mm (5 in) 127 mm (5 in) 127 mm (5 in)
Swept Volume 5985 cm3 (365.2 in3) 5985 cm3 (365.2 in3) 5985 cm3 (365.2 in3) 5985 cm3 (365.2 in3)
Compression Ratio 17.25 : 1 17.25 : 1 17.25 : 1 17.25 : 1

* Technical
Compression Pressure
- Permitted range 20-34 bar (290-500 lbf/in2) 20-34 bar (290-500 lbf/in2) 20-34 bar (290-500 lbf/in2) 20-34 bar (290-500 lbf/in2)
- Maximum variation
between cylinders 3.5 bar (50 lbf/in2) 3.5 bar (50 lbf/in2) 3.5 bar (50 lbf/in2) 3.5 bar (50 lbf/in2)
Firing Order 1, 5, 3, 6, 2, 4 1, 5, 3, 6, 2, 4 1, 5, 3, 6, 2, 4 1, 5, 3, 6, 2, 4
Engine
Valve Clearance (hot or cold)

- Inlet 0.20 mm (0.008 in) 0.20 mm (0.008 in) 0.20 mm (0.008 in) 0.20 mm (0.008 in)
- Exhaust 0.45 mm (0.018 in) 0.45 mm (0.018 in) 0.45 mm (0.018 in) 0.45 mm (0.018 in)
Oil Pressure (hot) at

maximum speed 4 bar (58 lbf/in2) 4 bar (58 lbf/in2) 4 bar (58 lbf/in2) 4 bar (58 lbf/in2)
Idling Speed 750 rev/min 750 rev/min 750 rev/min 750 rev/min
Data (2000 Series excluding 2140)
* Boost Pressure at
rated speed 1.46 bar (21.2 lbf/in2) 1.69 bar (24.5 lbf/in2) 1.15 bar (16.7 lbf/in2) 1.35 bar (19.6 lbf/in2)
Injector Type KF KF KP KH
Working Pressure 283 bar (4304 lbf/in2) 283 bar (4304 lbf/in2) 284 bar (4319 lbf/in2) 283 bar (4304 lbf/in2)
Note: Injectors supplied from new are set at 7 to 10 bar (106 to 152 lbf/in2) higher than working pressure.
Issue 4*
1-1
Section T
1-2 * Technical Data (2000 Series excluding 2140) 1-2
Fuel System
Engine Engine No. Prefix Pump Type Setting Code Max Governed speed Max No Load
Speed
Rating
1941/2300 YH50595 CAV 2644 D106/EH/-/2460 2300 rev/min 2460 ± 50 rev/min

1929/2300 YH50596 CAV 2644 D102/BH/-/2460 2300 rev/min 2460 ± 50 rev/min
1947/2300 YH50597 CAV 2644 D109/FH/-/2460 2300 rev/min 2460 ± 50 rev/min
1930/2200 YK50600 CAV 2200 rev/min 2530 ± 50 rev/min
For further details, see engine service manual, publication No. 9806/2140 (New 1000 Series).
Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately;
glazing of the cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no
circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
9803/8020 Issue 4*
1-3 Technical Data (3000 Series & 2140) 1-3
General
Fastrac 3155 Fastrac 2140 and 3185
Model 1000 Series, Turbocharged, Cummins QSB (2140)

6-cylinder, water cooled Cummins 6 BTA (3185)
Turbocharged, 6-cylinder, water cooled
Rating 1702/2400 -
Bore 100 mm (3.937 in) 102 mm (4.02 in)
Stroke 127 mm (5 in) 120 mm (4.72 in)
Swept Volume 5985 cm3 (365.2 in3) 5880 cm3 (359 in3)
Compression Pressure
- permitted range 20 - 34 bar (290 - 500 lbf/in2) -
- maximum variation
between cylinders 3.5 bar (50 lbf/in2) -
Compression Ratio 16.0 : 1 2140: 18.0 : 1

3185: 16.5 : 1
Firing Order 1, 5, 3, 6, 2, 4 1, 5, 3, 6, 2, 4
Valve Clearance (Engine hot or cold) (Engine cold)

Inlet 0.20 mm (0.008 in) 0.25 mm (0.010 in)
Exhaust 0.45 mm (0.018 in) 0.51 mm (0.020 in)
Oil Pressure at idle 2140: 1.03 bar (15 lbf/in2)

(minimum allowable) - 3185: 0.7 bar (10 lbf/in2)
Oil Pressure at maximum speed 2.8 bar (40 lbf/in2) 2140: 1.03 bar (15 lbf/in2)
(minimum allowable) 3185: 3.1 bar (45 lbf/in2)
Idling Speed 750 rev/min 700-800 rev/min
Maximum No Load Speed 2550-2650 rev/min 2360-2460 rev/min
Boost Pressure at rated speed 1.37 bar (19.9 lbf/in2) -
Injector Type JL -
Working Pressure 253 bar (3847 lbf/in2) -
Note: Injectors supplied from new are set at 7 to 10 bar (106 to 152 lbf/in2) higher than working pressure.
For further information, see the following service manuals:
Fastrac 3155 publication number 9806/0100

Fastrac 3185 publication number 9806/1170
Fastrac 2140 - engine publication number 9806/2220

- fuel system (2 volumes) publication number 9806/2230
Fuel System Fastrac 3155

Engine Type Engine No. Prefix Pump Type Setting Code Max. Governed Speed Max. No Load Speed
1006 - 6T4 YB 50694 CAV RK90L/1100/3/2520 2400 rev/min 2470/2520 rev/min
1006 - 6T4 YB50695 CAV RK90L/1100/3/2520 2400 rev/min 2470/2520 rev/min
9803/8020 Issue 5*
2-1 Engine Unit 2-1
D
A
A234831
9803/8020 Issue 1
2-2 Engine Unit 2-2
! WARNING
8 Disconnect fuel feed pipe at lift pump. Disconnect fuel
return to tank pipe at filter.
Make sure that lifting equipment is in good condition. 9 Disconnect hoses from the header tank. Disconnect
Make sure that lifting tackle complies with all local heater hoses at RH side of the engine.
lifting equipment is strong enough for the job. 10 Remove A/C compressor, move to one side and
INT-1-3-7
support safely.
! WARNING
Make the machine safe before getting beneath it. Do the 11 Remove the two screws C and lift plate D away on both
following: Park on level ground. Engage the parking sides of the engine.
12 Release the bonnet mounting frame by removing
Stop the engine, remove the key, disconnect the battery.
screws E and F on both sides of the engine. Lift the
Chock the wheels.
frame clear.
13-3-1-1
! CAUTION 13 Remove the cooler and lay in a safe position. Remove

Take care when lifting/handling this equipment. The radiator mounting bolts and lift off radiator.
engine weighs 425kg (937 lb).
ENG 8-1 14 Disconnect pipe connections and clamps to
! WARNING suspension/steering hydraulic pump.
Hot oil and components can burn you. Make sure the 15 Disconnect the air compressor pipes .
engine is cool before doing this job.
2-3-3-2
16 Disconnect throttle cable.
Note: After disconnecting pipes, blank off immediately to 17 Remove cooling fan to prevent accidental damage.
limit fluid loss and prevent dirt ingress.
Note: The 17/8 inch retaining nut has a left hand thread.
2 Remove the bonnet side panels (see Bonnet, Opening ! CAUTION

the Bonnet in Section 3). Do not use a hammer when working on the crankshaft
damper. The casing must not be damaged otherwise the
3 Remove the exhaust pipe projecting vertically from the damper will stop working and cause crankshaft
top of the bonnet. breakage.
ENG 8-2
4 Remove the bonnet top panel as follows:
18 Remove speed gearbox levers. (Remove protective
a Remove the locking nuts A, front and rear. Avoid boots, disconnect plug from bottom of speed change
moving nut B which has been set to adjust the lever, slacken clamp pinch bolts and lift out levers).
bonnet height at the front so as not to foul the
engine or engine components. 19 Remove floor mat and floor panels.
b Lift off the panel. 20 Slacken gearbox cross-member bolts but do not
remove them.
Note: Due to the confined space, it may be easier to remove
the front right hand nut A by reaching through from the left 21 Attach lifting chains to front and rear lifting eyes on
side of the engine. engine. Attach lifting chain to lifting device. Take up any
slack. DO NOT TAKE ANY WEIGHT.
5 Disconnect the bottom radiator hose connection to the
radiator, make sure a suitable container is positioned to Note: Chain legs should be as short as possible and
contain the coolant. Allow the coolant to drain. arranged so that engine is supported front end higher than
rear.
6 Remove pipes from air cleaner.
22 Remove bell housing bolts, leave four bolts secure at
7 Disconnect the following electrical connections: engine this time (One at either side at the top and one either
stop, oil pressure switch, water temperature sender, side at the bottom).
starter motor, alternator, air filter switch, air
conditioning (A/C) pressure switches, A/C compressor 23 Place a trolley jack below front end of transmission for
and induction manifold heater. support.
Note: Some parts of the wiring loom may be tie-wrapped to

the frame. Make sure they are free where necessary.
9803/8020 Issue 1
2-3 Engine Unit 2-3
24 Remove nuts and bolts securing engine mounts to

chassis. Slowly lift the engine, keep the trolley jack in
position supporting the transmission.
Note: As the engine is lifted, the rear of the transmission

lowers. Check that clearance remains between transmission
and rear cross member.
Note: Check that lifting chains have equal tension.
25 Remove the remaining four bell housing bolts, continue

lifting the engine, also moving it towards the front of the
machine. The engine should move forward enough to
clear the transmission splined shaft.
26 When the engine is clear of the machine, lower it to a

safe place.
27 Block the transmission and remove the trolley jack.
Replacement
Note: Take care to locate the fuel spill pipe, as the engine is
lowered into position.
Take care when locating the engine onto the transmission,

not to force the components together. If necessary, align the
clutch splines by putting the transmission in gear and
turning the engine through the access plate in the bottom of
the bell housing.
If difficulty is experienced in aligning the PTO input shaft

Make sure all pipes and connections are secure.
When refitting the bonnet top panel, make sure that it does
not foul the engine or engine components. If necessary use
nuts B at the front end to adjust the panel height and
achieve the necessary clearance. Lock the panel in position
by firmly tightening nuts A.
Replenish the engine coolant and hydraulic fluid levels as

necessary.
Start the engine and check for any leaks.
Torque Settings
Bell housing bolts 56 5.7 41.3
9803/8020 Issue 1
2-4 Flywheel Damper - Wet Clutch Transmission 2-4
Note: The flywheel damper is a sealed unit. If the damper is

faulty it must be renewed. The drive shaft X is an integral
part of the damper. If the shaft is damaged then the
complete damper/shaft assembly must be renewed.
Removal
1 Support the damper assembly 1. Progressively undo

the 6 fixing bolts 2. If necessary engage a bar in the
starter teeth on the flywheel Y to prevent the engine
rotating, do not put the shaft X under any strain.
2 Retrieve the hardened spacer washers 3 and lift the

damper assembly from the engine flywheel Y. Store the
damper on its rear face. Do not let the damper rest on
the drive shaft X. Make sure that the drive shaft is not
damaged during storage, it is not designed to
withstand any side loads.
Replacing
Replacing is the reverse of removal but note the following:
Clean the damper assembly. Make sure that the mating

faces of the damper and engine flywheel are perfectly clean
and dry.
Progressively tighten the bolts 2 to the correct torque.

Tighten opposite bolts in order to minimise the risk of
distorting the damper. Do not overtighten the bolts.
Torque Settings

2 72 7.3 53
3
X
2
A353530
9803/8020 Issue 1

Service Manual: Fastrac

Uploaded by

Copyright:

Available Formats

Service Manual: Fastrac

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Manual: Fastrac

Uploaded by

Copyright:

Available Formats

General Information 1

Care & Safety 2

1 = General Information - includes torque settings and service tools.

Contents Page No.

Machine Identification Plate 1-1

Sealing and Retaining Compounds 3-1

Service Tools Numerical List 4-1

Moving a Disabled Machine

Transporting the Machine 10 - 2

Machine Identification Plate Typical Engine Identification Number

Each machine has an identification plate located at X. The YH 50532 U 123456 X

Typical Vehicle Identification No. (VIN) G = Engine Type:-

* Introduction - Zinc Plated Fasteners and Dacromet Fasteners

Fastener Type Colour Part Number

Zinc Plated Fasteners (golden finish)

Bolt size Torque Settings Diameter Torque

M5 (5) 8 7 0.7 5 M3 2 0.2 1.5

Metric Grade 10.9 Bolts Verbus Ripp Bolts

Bolt size Torque Settings

Note: In most cases Verbus Ripp bolts should not be re-

Hydraulic Hose to Adapter Connections Hydraulic Adapter into Component Connections

Torque Settings Torque Settings

1/8 14 1.4 10 1/8 20 2.1 15

Dacromet Fasteners (mottled silver finish)

Metric Grade 8.8 Bolts

Bolt size Torque Settings

Metric Grade 10.9 Bolts

Bolt size Torque Settings

M6 x 1.0 13.5 1.4 10

Metric Grade 12.9 Bolts

Bolt size Torque Settings

Dacromet Fasteners (mottled silver finish) - List of Torque Settings

A402200 A402190 A402160

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

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

Location: Rear Anti-Roll bar Location: Front Anti-Roll Bar

Location: Front Engine Mounting Location: Header Tank Clamp Plate

Sealing and Retaining Compounds

JCB Threadlocker For threads of suction strainer. 4101/0451 50ml

† Ultra Fast Adhesive For direct glazing 4103/2109 310 ml

† Active Wipe 205 For direct glazing 4104/1203 250 g

† Black Primer 206J For direct glazing 4201/4906 30 ml

Service Tools Numerical List

Service Tools Numerical List (continued)

* Replacement parts for kit no. 892/01092

12V Mobile Oven - 1 cartridge capacity - required to

JCB part number - 992/12300 JCB part number - 892/00843

Service Tools (continued)

Braided Cutting Wire - consumable heavy duty

Service Tools (continued)

892/00801 Clutch spanner S200940 892/00807 Front plate puller S200970

892/00802 Rotor puller set S200950 892/00808 Shaft protector S200980

892/00803 Rotor installer set S200960

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