JCB 8250 Fastrac Tractor Repair Service Manual

(S/N: 1138000 Onwards)
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This service manual PDF download for the 8250 JCB Fastrac Tractor has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

JCB Fastrac 8250
S/N: 1138000 Onwards


TABLE OF CONTENTS :

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


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/8040-6
Total Pages : 691


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

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9803-8040-6
JCB 8250 Fastrac Service Manual


Section 1
Identifying the Machine
Serial Numbers
Serial Number Plate
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Zinc Plated Fasteners (golden finish)
Dacromet Fasteners (mottled silver finish)
Hydraulic Connections
'O' Ring Face Seal System
'Torque Stop' Hose System
Service Consumables
Sealing and Retaining Compounds

Section 2
Safety Check List
Introduction
Safety First
Safety - Yours and Others
General Safety
Operating Safety
Maintenance Safety

Section 3
Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Initial Service and Inspection (100 Hours)
Obtaining Replacement Parts
Health and Safety
Lubricants
Introduction
Hygiene
Storage
Waste Disposal
Handling
New Oil
Used Oil
First Aid - Oil
Eyes
Swallowing
Skin
Spillage
Fires
Battery
First Aid - Electrolyte
GETS INTO YOUR EYES
IS SWALLOWED
GETS ONTO YOUR SKIN
Warning Symbols
Service Schedules
How to Use the Service Schedules
Service Schedule Tables
Fluids, Lubricants and Capacities
Coolant Mixtures
Cleaning the Machine
Checking for Damage
Seats and Seat Belts
Seats
Checking the Seat Belt Condition and Security
Checking the ROPS Structure
Bonnet
Opening the Bonnet
Closing the Bonnet
Greasing
General Information
Propshafts and Rear PTO Drive Shaft
Rear PTO drive shaft
Rear axle propshaft
Front axle propshaft
Front 3-Point Linkage (Optional)
Front Axle Steering Swivels
Steering Column Universal Joints
Rear Suspension Cylinder Pivots
Hydraulic Lift and 3-Point Linkage
Hydraulic lift rams
Three point linkage lift rods
Pick-up Hitch
Cross-Shafts
Automatic Trailer Coupling (if fitted)
Air Conditioning and Heater
Air Conditioning Filters
Cleaning the Standard Air Conditioning Filter
Changing the Heavy Duty Carbon Filter
Cleaning the Heater Filter
Adjusting the Compressor Belt
Brakes
Checking the Foot Brake Fluid Level
Checking the Trailer Air Tank
Checking and Renewing Foot Brake Pads
Checking the Park Brake Pads
Renewing the Park Brake Pads
Electrical System
Battery
Checking the Electrolyte Level
Jump-starting the Engine
Fuses
Engine-mounted Fuses
Relay Identification
Checking the Beam Alignment
Engine
Changing the Air Filter Elements
Checking the Oil Level
Changing the Oil and Filter
Checking the Crankcase Breather Tube
Cooling System
Checking the Coolant Level
Changing the Coolant Filter
Draining and Refilling the Coolant
Cleaning the Radiator and Coolers
Fan Belt
Fuel System
Types of Fuel
Recommended Fuel Specification
Acceptable Fuel Specification
Sulphur Content
Aviation Kerosene Fuels
Low Temperature Fuels
Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels
Petrol
Filling the Tank
Draining the Fuel Filter
Changing the Fuel Filter Elements
Hydraulic System
Checking the Fluid Level
Changing the Filter Element
Changing the Hydraulic Fluid and Cleaning the Suction Strainers
Emptying the Hydraulic Coupling Drain Reservoirs
Transmission
Checking the Transmission Oil Level
Changing the Transmission Oil Filter
Changing the Transmission Oil and Strainer
Checking the Clutch Fluid Level
Axles
Front Axle
Checking the Axle Beam Oil Level
Checking the Hub Oil Levels
Check each hub separately.
Changing the Oil
Rear Axle and PTO
Checking the Oil Level
Changing the Oil
Tyres and Wheels
General
Wheel and Tyre Replacement
Checking Wheel Nut Torques
Wheel Nut Torque Setting
Tyre Inflation
Checking and Adjusting the Front Wheel Alignment
Checking the Alignment
Adjusting the Alignment
Fender Adjustment
To Adjust Front fenders
To adjust rear fenders:
Power Take-off (PTO)
Front PTO
Checking the PTO Oil Level
Changing the PTO Oil and Filter
Rear PTO
Checking the PTO Oil Level
Windscreen Washer
Checking Fluid Level
Automatic Trailer Coupling (Optional)
Checking for Wear

Section A
Optional Equipment
Front Power Take-off (PTO)
PTO Drive Shaft and Flexible Couplings
Removal and Replacement
When Removing
When Replacing
Torque Settings
PTO Gearbox
Dismantling
Assembly
Torque Settings
PTO Clutch Dismantling and Assembly

Section B
Body and Framework
Technical Data
Air Conditioning
Special Tools
Service Tools Selection List
Cab
Direct Glazing
Removing the Broken Glass and Old Sealant
Preparing the Cab Frame Aperture
Preparing the New Glass
Installing the New Glass
Air Conditioning
Operation
Control
Safety Procedures
Refrigerant Types
Hoses and Pipes
Hoses
Pipes
Leak Testing
Fault Finding
Component Removal and Replacement
Components Renewable without Discharging the Refrigerant
Switches
Removal
Replacement
Components Inside Evaporator Unit Casing
Thermostat Switch
Blower Motor
Pressure Switch
Testing
Removal and Replacement
Removal
Replacement
Compressor Clutch
Removal
Replacement
Heating System
Operation
Heater Unit
Removal
Replacement
Dismantling and Assembly

Section C
General
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
First Aid - Electrolyte
Testing
Specific Gravity Testing
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wiring Harness Repair
Introduction
Repair Procedure
Electronics System
Main Components Diagram
Harness Data
Drawings and Interconnection
Harnesses
Instrument Cluster
Description and Programming
Instruments
Warnings (Audible/Visual)
Warnings (Visual only)
EMS Programming Mode Levels 0 and 1
Wheel Slip
Touch Screen Calibration
Accessing Calibration Menu
Calibration
Hand Throttle
Foot Throttle
Joystick Centre Position
Joystick Left/Right Positions
Transmission Clutch Pedal
Transmission Range
Transmission Ratio
Transmission Turbo Clutch
Front PTO
Rear PTO
Steering Angle
Spool Valve Controls Calibration
Introduction
Accessing the Spool Valve Calibration Mode
Calibration Mode
Spool Valve Slice Configuration
Introduction
Accessing the Configuration Mode
Valve Slices Currently Configured
Configuring ‘Bosch’ Slices to an 8000 Series Fastrac
Diagnostic Error Codes
Introduction
Non-displayable Fault Codes
Diagnostic Error Codes - ABS
Introduction
ABS Code Tables
Codes Prefixed C to Z

Section E
Hydraulics
Technical Data
External Hydraulics
Control Valve - Electronically Actuated
Spools
Other Hydraulic Circuits
Special Tools
Service Tools Selection List
Schematic Circuits
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Example Circuit Key
Complete Machine Circuit without Power Beyond Service
Component Key
Complete Machine Circuit with Power Beyond Service
Component Key
System Descriptions
External Hydraulics
Electronically Actuated Spool Valve
Typical Electronically Actuated Spool
General Description
Electronic Actuation
Spool AA in Neutral
Spool AA Selected
Pressure Testing
External Hydraulics
Maximum System Pressure
Pilot Stand-by Pressure
Pumps
Removal and Replacement
Removal
Gear Pump A (Suspension and Steering)
Replacement
Gear Pump A (Suspension and Steering)
Torque Settings
Piston Pump B (External Hydraulics)
Torque Settings
Piston Pump (External Hydraulics)
Control Valve
Removal and Replacement
Dismantling and Assembly
Sealing the Driveshaft
Pump Dismantling and Assembly
Dismantling
Inspection
Assembly
Gear Pump (Suspension and Steering)
Dismantling and Assembly
When Dismantling
Inspection
When Assembling
Torque Settings
Control Valves
Electronically Actuated Spool Valve
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Valve Slices (Green, Blue, Brown, Grey and Front Hitch)
Dismantling and Assembly
When Assembling
Locking the Spool in Neutral
Repairing the Check Valves
Removing the Electronic Actuator
Removing the Non-Return Valves
Replacing the Non-return Valves
Replacing the Actuator
Pilot Control Valve Slice
Dismantling and Assembly
Rear Hitch Slice
Dismantling and Assembly
When Dismantling
When Assembling
Rams
Rear Lift Ram
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Wiper Seal Fitting Procedure
Torque Settings
Testing

Section F
Technical Data
Continuously Variable Transmission (CVT)
Pressure Settings
Axles
Front Axle
Rear Axle
Service Tools
Service Tools Section List
General Description
Drive Line Layout
CVT Description
Main Component Identification
Actuator Unit
Hydraulic Circuit
Key
Valve Block 1
Valve Block 2
High Pressure Relief Valve, Forward/Reverse
Purge Valve
CVT Operation
Operation in Different Modes
Engine at idle, Machine stopped
99% Hydrostatic - 1% Mechanical
50% Hydrostatic - 50% Mechanical
0% Hydrostatic - 100% Mechanical, Machine Speed 67 km/h, Engine 1500 rev/min
100% Hydrostatic Power Transmission, Medium Speed, Annulus rotates faster than engine
Pressure Testing
CVT Pressures
Low Pressures
High Pressure
Diferential Lock and PTO Speed Selection
CVT Valves
Purge Valve
Removal and Replacement
Forward and Reverse High Pressure Relief Valves
Removal and Replacement
Clutch Hydraulics
Master Cylinder
Dismantling and Assembly
Filling and Bleeding the System
CVT Cartridge
Removal and Replacement
Removal
Replacement
Filling the Transmission Oil
Front Axle
Removal and Replacement
Removal
Replacement
Hub
Component Key
Dismantling
Inspection
Assembly
Drive Head
Removal and Replacement
Component Key
Dismantling
Inspection
Assembly
Rear Axle
Removal and Replacement
Removal
Replacement
Hub
Component Key
Dismantling
Inspection
Assembly
Drive Head
Removal and Replacement
Component Key
Dismantling
Inspection
Assembly
Rear PTO Input Shaft
Rear PTO Gearbox
Component Key
Dismantling
Inspection
Assembly

Section G
Technical Data
Brake System
Parking Brake
Foot (Service) Brake
Safety
Special Tools
Service Tools Selection List
Circuit Descriptions
Brake System
Front Brake Circuit
Rear Brake Circuit
Trailer/Parking Brake Circuit
Parking Brake Circuit
Hydraulic Trailer Brakes (if fitted)
Tractor ABS System
General Description
Fault Finding
Introduction
Fault Tables
Low Pressure Warning Lights On
Service Brakes Poor
Poor Front Brakes, Good Rear Brakes
Poor Rear Brakes, Good Front Brakes
Trailer Brakes Poor
Park Brake Not Holding
Park Brake Not Releasing
Footbrake Calipers
Removal and Replacement
Removal
Replacement
Brake System Bleeding
Park Brake Caliper
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
When Dismantling
Inspection
When Assembling
Valves
Air Drier/Unloader Valve
Removal and Replacement
Dismantling and Assembly
Circuit Protection Valve
Removal and Replacement
Pressure Modulating Valves
Removal and Replacement
Non-Return Air Valve
Dismantling and Assembly
Trailer Brake Hydraulic Valve
Testing
Removal and Replacement
Dismantling and Assembly
Trailer Brake Palm Couplings
Dismantling and Assembly
When Dismantling
When Assembling

Section H
Steering
Technical Data
Pressures and Flow Rates
Description
Steer Box
Pressure Testing
Steering Relief Valve
Steer Box
Removal and Replacement
When Removing
When Replacing
Torque Settings
Steering Limiters
Setting
Removal and Replacement

Section S
Suspension
Technical Data
Rear Suspension
Pressures
Flow Rates
Front Suspension
Description
Shock Absorber
Removal and Replacement
When Replacing
Torque Settings
Control Arm
Removal
Replacement
Torque Settings
Panhard Rod
Removal and Replacement
When Removing
When Replacing
Torque Settings
Coil Spring and Microcellular Spring
Removal
Replacement
Torque Settings
Rear Suspension
Description
Pressure Testing
Pressure Maintenance Valve
Gas Spring and Accumulator
Ride Height
Checking the Ride Height
Adjustment
Discharging Hydraulic Pressure
Pressure Maintenance Valve
Dismantling and Assembly
Torque Settings
Suspension Cylinder and Gas Spring
Gas Spring Removal and Replacement
Torque Settings
After Replacement
Suspension Cylinder Removal and Replacement
When Removing
When Replacing
Torque Settings
After Replacement
Dismantling and Assembly
Dismantling
Assembly
Gland Seal Fitting Procedure
Testing
Anti-roll Bar
Removal and Replacement
Removal
Replacement
When Replacing
Torque Settings
‘V’ Link
Removal and Replacement
When Removing
When Replacing
Torque Settings

Section T
Technical Data
General

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