JCB Fastrac 2115, 2125, 2135, 2140, 2150, 3155, 3185 Tractor Service Manual 1996–2007 (P/N 9803/8020)

JCB Service Manual P/N 9803/8020, Issue 17 covers Fastrac 2115, 2125, 2135, 2140 and 2150 from Serial No. 0738000, plus 3155 and 3185 from Serial No. 0640000.

PDF Search, Navigation and Wiring Detail

Search and diagram viewing: PDF text search and embedded bookmarks are not available. Small wiring labels are readable when enlarged; several circuit drawings are arranged sideways and benefit from rotating the view.

One printable, English-language PDF contains 1,028 pages, including one cover page, one introduction page and 74 blank pages.

Fastrac Driveline, Hydraulic and Control-System Service

The following selected service areas show the manual’s repair and diagnostic coverage. Further topics include wiring-harness repair and cold-starting equipment.

• Transmission repair: Step-by-step procedures for gearbox removal, wet master-clutch service, PTO and splitter-clutch dismantling, speed-gearbox repair, and range-box assembly.

• Hydraulics and draft control: Pump testing and resealing, control-valve dismantling, main-relief-valve checks, rear lift-ram service, and electronic draft-control fault diagnosis.

• Starting and charging: Circuit fault finding, alternator and starter-motor service, connector-terminal references, wire-number lists, and sectional wiring diagrams.

• Electronic diagnostics: Instrument-cluster programming, transmission error codes, ABS diagnostics, wheel-slip calibration, 4WS sensor calibration, and dry- or wet-clutch calibration procedures.

• Brakes and steering: Caliper overhaul and bleeding, trailer-brake valve testing, steering pressure checks, hydraulic steering-unit service, and wheel alignment.

• Suspension service: Front spring and linkage work, rear ride-height checks, pressure-maintenance-valve service, accumulator and gas-spring testing, and suspension-cylinder dismantling.

• Cab and air conditioning: Cab removal and replacement, direct glazing, refrigerant leak testing, pressure-switch checks, fault finding, and compressor-clutch service.

Written for JCB Distributor Service Engineers receiving or having completed JCB technical training, this manual assumes sound workshop practice and maintenance and repair knowledge.

Maintenance, Lubricants and Fasteners

Separate dry- and wet-clutch schedules cover daily/10-hour checks, 50-hour servicing, the first 100-hour dealer service, and 250-, 500-, 1,000- and 2,000-hour work. The wet-clutch schedule also includes a 5,000-hour/two-year engine valve-clearance check for the 2140.

Service points include PTO and prop shafts, front and rear axles, steering swivels, hydraulic lift and three-point linkage, suspension pivots, brakes, cab filtration, cooling, tires, the ROPS structure and engine service items.

Lubricant and capacity tables distinguish machine configurations. Axle and hub procedures provide fill-level references alongside nominal capacities, while air-conditioning data separates refrigerant charges by machine series.

Zinc-plated and Dacromet fasteners have separate torque data. Dacromet fasteners are lubricated during plating; adding lubricant changes their intended torque behavior.

Engine Coverage and Separate Engine Manuals

Engine data distinguishes the 5.985-liter New 1000 Series in the 2115, 2125, 2135 and 2150 from the 3155’s 5.985-liter 1000 Series engine. The 2150 specification includes turbocharging and intercooling.

The 2140 has the 5.88-liter Cummins QSB, while the 3185 has the 5.88-liter Cummins 6 BTA.

This Fastrac manual covers engine technical data, engine-unit removal and replacement, and the wet-clutch flywheel damper. Detailed internal engine work is referred to separate publications: 9806/2140 for the New 1000 Series, 9806/0100 for the 3155, and 9806/1170 for the 3185.

For the 2140, the references are 9806/2220 for the engine and 9806/2230 for the two-volume fuel-system manual. These separate engine publications are not included in this PDF.

Fuel-system maintenance includes bleeding procedures, with warnings that running an engine while air remains in the system can damage the injection pump.

Clutches, Gearboxes and Axles

The dry transmission uses a 350 mm single dry main clutch. Later machines use a hydraulically actuated, oil-immersed multi-plate master clutch.

The driveline combines a six-speed synchromesh speed gearbox, a high/medium/low/reverse synchromesh range gearbox, and JCB Powershift splitter clutches. JCB Selectronic coverage adds air-assisted range-change operation, cylinder and microswitch settings, and limp-home operation.

The serial-number distinctions carry through transmission controls, electrical diagnosis, calibration and service schedules, helping technicians select the correct procedures for the tractor.

Axle chapters distinguish SD55 front axles with standard NoSPIN or optional MaxTrac differentials from the SD70 front axle used on the 3155 and 3185. The SD70 uses a soft-engage differential lock with electro-hydraulic control.

Rear-axle coverage separates PD70 applications on 2WS machines other than the 3185, the 3185’s PD90 axle, and SD70 steering axles on 4WS machines. Repair material includes drive heads, hubs, pinion depth, solid spacers, and crown-wheel and pinion adjustment.

Hydraulic Repair and Draft-Control Diagnosis

Type 1 and Type 2 hydraulic sections have separate pump, valve and pressure-test procedures. The External Hydraulics/Draft Control Valve neutral-circuit schematics support the associated control-valve and electronic draft-control diagnosis.

Pump repair coverage has specific limits: resealing and control-valve work are described, but worn gears, bearing blocks or housings can require replacement of the pump or complete pump section.

During Type 1 suspension/steering-pump work, the interference-fit plug has a critical installed position. Bearing blocks and gears remain matched components; abrasive refinishing can destroy their manufacturing dimensions.

Electrical Tests and Electronic Diagnostics

Circuit references include the Supply Circuit and the 2140’s Fuses A5, H1 to H5 – Electronic Engine drawings. Connector terminals, splice identification and wire-number lists support tracing circuits between components.

Some 2140 drawings retain references to 3170, 3190 and 3220 machines. Their circuits are incomplete here; those models require the circuit documentation in service manual 9803/8030.

Diagnostic material covers JCB Service Master, Psion Workabout, the Wingst program and Data Link Adapter use. It includes Powershift clutch-overlap adjustment on dry-clutch machines and Powershift/master-clutch calibration on wet-clutch machines.

Service-tool references include Hydraulic Circuit Pressure Test Kit 892/00253, Brake Test Kit 892/00311, Clutch Alignment Tool 892/00313, Accumulator and Gas Spring Pressure Test Adapter 892/00314, and Data Link Adapter Kit 892/01033. The adapter instructions identify diagnostic harness 721/10885 for Fastrac use.

Brakes, Steering and Suspension

Brake material includes the Brake System (Dry) (Non ABS) layout, ABS-equipped configurations, lining and disc wear limits, and trailer-brake valve bench tests. For ABS machines, the manual requires the Service Master ABS test after brake work; the dashboard self-check does not establish correct installation.

Steering sections distinguish the 2000 Series hydraulic steering unit from the 3000 Series steering box. The Steering System Description – Fastrac 2000 Series material includes 4WS modes and JCB Headland Management System operation where applicable.

Suspension coverage separates coil-spring and microcellular-spring front arrangements from the hydropneumatic rear system. Rear procedures cover the height-corrector valve, pressure-maintenance valve, spring boxes, accumulators, gas springs and suspension cylinders.

Cab Work and Optional Equipment

Cab procedures distinguish 2000 and 3000 Series removal arrangements. Air-conditioning sections cover component replacement and electrical testing as well as system operation.

Optional-equipment sections add front hitch drop-flow control valve repair, front lift-ram overhaul and pressure testing, front PTO transfer-box and output-shaft service, flow-regulator repair, and engine or range-gearbox heating equipment.

Service precautions: High-pressure hydraulic and suspension circuits, compressed-air brakes, rotating driveline components, and heavy tractor assemblies require the manual’s isolation, pressure-release, support and lifting precautions.

Sample Hydraulic Flow and Powershift Pressure Data

At maximum system pressure, Type 1 external hydraulics are specified at 77 L/min with the standard pump or 96 L/min with the optional pump, both at 2,400 engine rpm. Type 2 systems specify 60 L/min at 1,500 rpm.

The Powershift clutch-pressure reference is 13.5 bar (195 psi) at 1,500 rpm for the splitter-clutch circuits, with transmission oil at working temperature.