Looking for the factory JCB 135 service manual pdf? This 677-page JCB FASTRAC Service Manual (OEM #9803/8000) was written for one machine family: the FASTRAC 125, 135, 145, 150, 155, and 185. Electrical schematics map full wiring harness routing, relay identification, and JCB Selectronic system diagnostics, with connector pinout diagrams for every circuit. Hydraulic circuit diagrams cover the external hydraulics, the suspension and steering pump, and electronic draft control. Exploded views and fault-finding procedures reach every major assembly. Rear axle wheel nuts in the 12-nut configuration torque to 600 Nm; standard axle nuts go to 500 Nm. Search by keyword on any device, pull the exact spec, and get back to work.
What's Inside This JCB FASTRAC 125 & variants Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | - | Serial Number Plate, Torque Settings, Service Tools List, Sealing Compounds, Moving Disabled Machine, Transporting Machine |
| Care & Safety | - | Safety Notices, General Safety, Operating Safety, Maintenance Safety, Lifting Equipment, Alcohol and Drugs |
| Routine Maintenance | - | Lubricants & Capacities, Service Schedules, Greasing Procedures, ROPS Structure Check, Air Conditioning Filter, Headlight Beam Alignment |
| Optional Equipment | - | Front Lift Ram, Front PTO Transfer Box, Rear PTO Drive Shaft, Flow Regulator, Dismantling and Assembly |
| Body & Framework | - | Technical Data, Direct Glazing Procedures, Air Conditioning Operation, Leak Testing, Compressor Clutch Removal |
| Electrics | - | Technical Data, Fuses, Relay Identification, Multimeter Use, Wiring Harness Repair, Digital Speedometer |
| Controls | - | Foot Throttle Control Cable, Hand Throttle Control Linkage, External Hydraulics Control Valve Linkage, Jcb Selectronic System, Pneumatic Cylinders, Microswitch Positions |
| Hydraulics | - | External Hydraulics Circuit, Main Relief Valve, Pump - Suspension and Steering, Control Valve, Electronic Draft Control, Position Sensor |
| Transmission | - | Complete Transmission, PTO Clutches, Speed Gearbox, Front Axle, Rear Axle, NoSPIN Differential |
| Brakes | - | Technical Data, Brake System, Footbrake Calipers, Parking Brake, Trailer Brake Air Valve, Air/Hydraulic Actuator |
| Steering | - | Technical Data, Fault Finding, Pump Pressure Testing, Steering Box Limit Valve Setting, Steering Shaft, Universal Joints |
| Suspension | - | Technical Data, Front Suspension, Rear Suspension, Gas Spring and Accumulator, Suspension Cylinder, Anti-Roll Bar |
| Engine | - | Technical Data, Removal and Replacement, Crankshaft Damper, Fuel Spill Pipe, Exhaust Convolute Tube |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Wheel nut torque setting (Rear axles with 12 nuts per wheel) | 600 Nm (60.0 kgf m, 440 Ibf ft) | p. 64 |
| Wheel nut torque setting (All other axles) | 500 Nm (51.0 kgf m, 370 Ibf ft) | p. 64 |
| Bell housing bolts torque setting | 56 Nm (5.7 kgf m, 41.3 Ibf ft) | p. 674 |
| Damper fasteners (either capscrews) torque setting | 35 Nm (3.6 kgf m, 26 Ibf ft) | p. 674 |
| Hydraulic filter element cover nuts C torque setting | 7 Nm (5 Ibf ft) | p. 51 |
| Hydraulic filter element replacement | new 'O' ring E and new 'O' ring G | p. 51 |
| Perkins Engine fuel filter installation torque | hand-tight only | p. 75 |
| Perkins Engine fuel filter replacement | new filter(s) | p. 75 |
| Air filter element replacement | new elements | p. 92 |
| Air filter element nuts J and C torque setting | Fit and tighten | p. 92 |
| Battery system voltage | 12 Volts | p. 124 |
| Number of batteries | Two batteries | p. 124 |
JCB FASTRAC 125 & variants Common Problems This Manual Covers
JCB Fastrac hydraulic lift loses force, implements respond slowly, or PTO shaft won't spin p. 51
Check the hydraulic fluid level against the capacities table on page 32; total system volume is 75 L. If low, inspect hose connections and filter seals for weeping. Replace the hydraulic filter element with new O-rings, torquing cover nuts to 7 Nm (page 51). For PTO drive loss, work the fault-finding procedure to isolate a stuck spool or defective solenoid.
Manual Section: HydraulicsEngine cranks slowly, won't fire at all, or dies immediately after starting p. 265
Test both 12-volt batteries, measuring electrolyte specific gravity with a hydrometer. A fully charged cell at ambient up to 27°C should read 1.270-1.290 (page 265). If the batteries pass, inspect the starter relay and harness connectors for corrosion or pushed-out terminals. Trace fuel delivery next: on Perkins-engined machines, fit a new fuel filter hand-tight only (page 75).
Manual Section: ElectricsTransmission won't engage, shifts harshly, or machine loses drive in forward and reverse
Verify transmission oil level and check for contamination; dirty or low oil causes clutch-pack slip and range loss. Run the complete fault-finding procedure, which covers low oil level, clutch slip, and noisy operation. If clutch drag persists after confirming fluid condition, the main drive clutch torque spec is 78 Nm (page 451), applying to all models except the 185.
Manual Section: Complete Transmission Fault FindingWarning lights stay on, instrument cluster reads incorrectly, or electronic controls stop responding
Inspect all harness connectors and ground points for corrosion before condemning any module. Check system voltage at the battery terminals: the tractor runs two 12-volt batteries (page 124). Pull the fuse panel and test each fuse. For EDC-related fault lights, run the sensor diagnostic tests on page 265 and compare output values against spec, then trace any open circuits on the harness diagram.
Manual Section: ElectricsBrakes feel spongy or won't hold on a slope, parking brake releases but machine drifts p. 574
Confirm brake system air pressure reads 8 bar (page 574). Low pressure points to a compressor fault or an air leak in the trailer valve circuit. Measure parking brake lining thickness: minimum serviceable is 3 mm, and front discs should be at least 22 mm (page 574). Bleed and retest after replacing any component.
Manual Section: BrakesFrequently Asked Questions
How do I reset the transmission fault code on a JCB Fastrac?
There's no dedicated reset procedure for transmission fault codes. The manual instead walks through fault-finding steps for the complete transmission: when a fault shows up, examine and repair the faulty component. For Electronic Draft Control errors, eliminate the fault, then repeat the test step to confirm it's resolved.
What do JCB Fastrac error codes mean?
Electronic Draft Control codes are two digits, shown by the flashing diagnostic LED: the first digit follows a long pause, the second follows a short pause. Once an error appears, eliminate the fault and repeat the test step to confirm the fix. For example, E003 flags 'Lower' solenoid resistance too low, which points to a short-circuit in the solenoid or wiring harness.
How do I clear the hydraulic fault code on a JCB Fastrac?
Clearing a hydraulic fault code on the Electronic Draft Control system comes down to fixing the underlying fault. Once it's gone, recheck the result by repeating the test procedure with the Diagnostic Test Box: if an error message is displayed, press the 'GO/TEST' switch to 'GO' to repeat the test step.
What are the torque specs for JCB Fastrac wheel nuts?
Rear axles with 12 nuts per wheel torque to 600 Nm (60.0 kgf m, 440 lbf ft); all other axles take 500 Nm (51.0 kgf m, 370 lbf ft). On a new machine, or after any refit, recheck wheel nut torques every ten hours until they stay put.
Is this Service Manual a digital download?
Immediate download of the complete 677-page searchable Service Manual. Open it on any device: laptop at your desk or phone out in the field.
Can I print this manual?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need on any home or office printer.
Are there hydraulic schematics in this JCB FASTRAC 125 & variants manual?
Yes. Complete hydraulic schematics with flow diagrams, valve configurations, and pressure specifications are included.
Document Quality
This document is a scanned PDF with an OCR layer, allowing you to search and copy text throughout. The text quality is generally crisp and easy to read, though some smaller fonts may appear slightly less defined. Diagrams and illustrations are clear raster images, with labels that are mostly legible, but they will pixelate upon high zoom. Pages are largely clean, with only minor scan artifacts like faint lines or slight skewing, and there are several blank or filler pages present.
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