JCB 8250 Fastrac Service Manual – 9803/8070-4

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JCB 8250 Fastrac Service Manual – 9803/8070-4 
(S/N: 139000 to 1147999)

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 – Tier III
S/N: 139000 to 1147999

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. : 9803/8070-4
Total Pages : 652

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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9803-8070
JCB 8250 Fastrac

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

Section 2
Care and Safety
Safety First
Important Information
The Operator Manual
Safety Warnings
Safety Check List
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
Engine Cover
Opening the Engine Cover
Closing the Engine Cover
Greasing
General Information
Drive Shafts
Rear PTO drive shaft
Rear axle drive shaft
Front axle drive shaft
Front 3-Point Linkage (Optional)
Front Axle Steering Swivels
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
Cleaning the Fresh Air Filter
Cleaning the Recirculation Air Filter
Adjusting the Compressor Belt
Brakes
Checking the Foot Brake Fluid Level
Checking the Trailer Air Tank
Checking the Air Tank Warning Lights
Checking and Renewing Foot Brake Pads
Testing the Park Brake
Checking the Park Brake Pads
Electrical System
Battery
Battery Disconnection/Connection
Disconnection
Connection
Access Panels
Checking the Electrolyte Level
Jump-starting the Engine
Fuses and Relays
Fuses on the PCB (Machines without Heated Screens)
Left Hand Bank (Looking Backwards)
Centre Bank
Right Hand Bank (Looking Backwards)
Fuses on the PCB (Machines with Heated Screens)
Left Hand Bank (Looking Backwards)
Centre Bank
Right Hand Bank (Looking Backwards)
Fuses in the Fuse and Relay box (MVEC)
Engine-mounted Fuses
Relay Identification
Relays on the PCB
Relays in the Fuse and Relay box (MVEC)
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
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
Adjustable Track Width
Tyre Inflation
Checking and Adjusting the Front Wheel Alignment
Front Fender Adjustment
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
Front Hitch
Position Sensor Calibration
Introduction
Accessing the Calibration Mode
Calibration

Section B
Body and Framework
Technical Data
Air Conditioning
Cab
Removal and Replacement
Removal
Before Lifting
Attach Lifting Equipment
Lifting
Replacement
Glass
Direct Glazing
Removing the Broken Glass and Old Sealant
Preparing the Cab Frame Aperture
Preparing the New Glass
Installing the New Glass
Air Conditioning (HVAC)
Operation
Heater/Air Conditioning Controls
Temperature Control
Auto Mode
To Demist in Hot Weather
To Defrost/Demist in Cold Weather
Fault Codes
Safety Procedures
Leak Testing
Fault Finding
Compressor Clutch
Removal
Replacement

Section C
Electrics
General
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
First Aid – Electrolyte
GETS INTO YOUR EYES
IS SWALLOWED
GETS ONTO YOUR SKIN
Testing
Specific Gravity Testing
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wires 000-199
Wires 200-399
Wires 400-599
Wires 600-799
Wires 800-999
Wires In Splices
General Points
Wiring Harness Repair
Introduction
Repair Procedure
Auxiliary Lighting Relays
Charging System
Fault Finding
Electronics System
Main Components Diagram
Description
Component Key
ECU Locations
Why Use Service Master?
Introduction
Fault Finding
Identify Poor Maintenance
Access Machine Set Up Data
Re-Programming ECUs
Summary
What is Service Master?
Introduction
CANbus Communications System
Service Master Structure
Tool Sets
How to Set Up Service Master
Install Service Master
Start Service Master
Load the DLA Laptop Driver Software
Configure the DLA Type and Communications Port
Check the DLA Firmware File
Connect Service Master to the Machine CANbus
Harness Data
Drawings and Interconnection
Harnesses
Harness Drawings
Schematic Circuits
8250 from Serial No. 1139000
Starter, Alternator, PCB Battery Fuses
PCB Ignition Relays and Fuses
Road Lights
Fastrac Central Controller (ECU 1)
Transmission
Touch Screen (DECU), Instrument Panel (Unideck)
Networks
Heater, Ventilation, Air Conditioning (HVAC), Heated Screens
Radio, Mirrors, Work Lights (MVEC), Auxiliary Sockets, Air Drier
Wash/Wipe, Brakes, Draft Control
Spool Valve, Hitch Controls, Engine
Earths
Instrument Cluster
Description and Programming
Instruments
Warnings (Audible/Visual)
Warnings (Visual only)
EMS Programming – Level 1
Wheel Slip Displays
Touch Screen
Operation
Continuously Variable Transmission (CVT)
Introduction
Start up Display
When Moving Away
Driving Modes
Starting and Driving in Drive Mode
Stopping the Machine in Drive Mode
Power Shift Mode
Stopping the Machine in Power Shift Mode
Manual Mode
Stopping the Machine in Manual Mode
Advanced Operating Modes and Settings
Forward/Reverse Ratio Setting
Joystick Speed of Response Setting
Flexi Mode
Stopping the Machine in Flexi Mode
Speed Hold Modes
Example
To Program Speed Hold
Stopping the Machine in Speed Hold
Revs Hold Mode
Example
To Program Revs Hold Mode
Setting the Lower Limit
Stopping the Machine in Revs Hold Mode
Resume Function
Example
Touch Screen Settings
Programming the Joystick Push Buttons
Introduction
Programming the Joystick Buttons for Front Linkage Control
Programming the Joystick Buttons for Rear Linkage Control
Programming the Joystick Buttons for Front PTO Control
Programming the Joystick Buttons for Rear PTO Control
Programming the Joystick Buttons for 2WD, 4WD and Differential Lock Control
Programming the Joystick Buttons for External Hydraulics Control
Programming the Joystick Buttons for CVT Control Buttons
Automatic Field Settings
Front and Rear PTO Settings
4WD Settings
Differential Lock Settings
Field Area Cut-out Settings
Spool Valve Flow and Time Settings
Work Light Settings
Tyre Size Settings
Touch Screen Display Settings
Wheel Slip
Slip Control Re-calibration
Slip Control – Normal Operations
Headland Management System
To Program an Example Sequence A
To Insert a Function in a Sequence
To Delete a function
To Delete All Functions
To Change a Function
To Link Functions
To Add a Time Delay
To Operate a Headland Management Sequence
Service Information
Calibration of Radar
Information
Error Codes
Accessing Calibration Menu
Calibration
Engine
Hand Throttle
Foot Throttle
Joystick
Joystick Centre Position
Joystick Left/Right Positions
Transmission
Transmission Clutch Pedal
Transmission Range
Transmission Ratio
Transmission Turbo Clutch
PTO
Front PTO
Rear PTO
Steering Angle
Screen Calibration
Suspension Calibration
Introduction
To Access the Suspension Calibration Mode
Calibration Mode
Suspension Height Signal Voltages

Section E
Hydraulics
Technical Data
External Hydraulics
Flow Rates
Pressures
Spool Valve
Other Hydraulic Circuits
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
Electronic Spool Valve Cross Section
Pressure Testing
External Hydraulics
Maximum System Pressure
Serial number 1139001 to 1139114
Serial number 1139115 Onwards
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
Spool Valve Slice Configuration
Introduction
Accessing the Configuration Mode
Valve Slices Currently Configured
Configuring `Bosch’ Slices
Configuration Procedure
To Exit Configuration
Returning Configured Slices to Bosch State
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
General Description
Drive Line Layout
CVT Description
Main Component Identification
Actuator Unit
Hydraulic Circuit
Key
Main Components
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
Low Pressures
High Pressure
Differential Lock and PTO
Differential Lock
PTO Speed Pressures
CVT Valves
Purge Valve
Removal and Replacement
Forward and Reverse High Pressure Relief Valves
Removal and Replacement
CVT Cartridge
Removal and Replacement
Removal
Replacement
Filling the Transmission Oil
Clutch Hydraulics
Master Cylinder
Dismantling and Assembly
Dismantling
Assembly
Filling and Bleeding the System
Front Axle
Removal and Replacement
Removal
Replacement
Hub
Component Key
Dismantling
Inspection
Assembly
Drive Head
Removal and Replacement
Removal
Replacement
Component Key
Dismantling
Inspection
Assembly
Pinion Depth
Crown Wheel and Pinion Adjustment
Rear Axle
Removal and Replacement
Removal
Replacement
Hub
Component Key
Dismantling
Inspection
Assembly
Drive Head
Removal and Replacement
Removal
Replacement
Component Key
Dismantling
Inspection
Assembly
Pinion Depth
Crown Wheel and Pinion Adjustment
Rear PTO Input Shaft
Removal
Replacement
Rear PTO Gearbox
Component Key
Dismantling
Inspection
Assembly

Section G
Brakes
Technical Data
Brake System
Parking Brake
Foot (Service) Brake
Safety
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
Operation
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 Callipers
Removal and Replacement
Removal
Replacement
Torque Settings
Brake System Bleeding
Park Brake Calliper
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
When Dismantling
Inspection
When Assembling
Torque Settings
Actuator Cylinder
Valves
Air Drier/Unloader Valve
Removal and Replacement
Removal
Replacement
Torque Settings
Dismantling and Assembly
Circuit Protection Valve
Removal and Replacement
Removal
Replacement
Torque Settings
Pressure Modulating Valves
Removal and Replacement
Removal
Replacement
Non-Return Air Valve
Dismantling and Assembly
When Dismantling
When Assembling
Trailer Brake Hydraulic Valve
Testing
Dismantling and Assembly
Dismantling
Assembly
Torque Settings
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
Front Suspension
Control Arm
Removal
Replacement
Torque Settings
Panhard Rod
Removal and Replacement
When Removing
When Replacing
Torque Settings
Rear Suspension
Description
Electronic Control
Pressure Testing
Discharging Hydraulic Pressure
Pressure Maintenance Valve
Dismantling and Assembly
Torque Settings
Potentiometer
Removal and Replacement
Removal
Replacement
After Replacement
Suspension Cylinder
Dismantling and Assembly
Dismantling
Assembly
Gland Seal Fitting Procedure
Testing

Section T
Engine
Technical Data
General

 

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