jcb 4160 User manual

OPERATOR'S MANUAL
FASTRAC (AGRICULTURAL TRACTOR)
4160, 4190, 4220
EN - 9831/3950
ISSUE 1 - 02/2017
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

OPERATOR'S
MANUAL
FASTRAC (AGRICULTURAL TRACTOR)
4160, 4190, 4220
EN - 9831/3950
ISSUE 1 - 02/2017
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 7-02-02 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Machine Delivery and Installation
Even if you have operated this type of equipment
before, it is very important that your new machines
operations and functions are explained to you by
a JCB Dealer Representative following delivery of
your new machine.
Following the installation you will know how to gain
maximum productivity and performance from your
new product.
Please contact your local JCB dealer if the
Installation Form (included in this manual) has not
yet been completed with you.
Your local JCB Dealer is
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9831/3950-1
Notes:
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Table of Contents
i 9831/3950-1 i
Contents Page No.
Acronyms Glossary ........................................................................................................................................ vii
Introduction
About this Manual
Model and Serial Number ..................................................................................................................... 1
Using the Manual .................................................................................................................................. 1
Left-Hand Side, Right-Hand Side ......................................................................................................... 1
Cross References ................................................................................................................................. 1
Location of Manual ............................................................................................................................... 2
Safety
Safety - Yours and Others .................................................................................................................... 3
Safety Warnings .................................................................................................................................... 3
General Safety ...................................................................................................................................... 4
Clothing and Personal Protective Equipment (PPE) ............................................................................ 4
About the Product
Introduction
General .................................................................................................................................................. 5
Name and Address of the Manufacturer .............................................................................................. 5
Product Compliance .............................................................................................................................. 5
Description
General .................................................................................................................................................. 6
Intended Use ......................................................................................................................................... 6
Danger Zone ......................................................................................................................................... 6
Main Component Locations .................................................................................................................. 7
Product and Component Identification
Machine ................................................................................................................................................. 9
Engine ................................................................................................................................................. 10
Axle ..................................................................................................................................................... 10
Gearbox ............................................................................................................................................... 11
Operator Protective Structure ............................................................................................................. 11
Safety Labels
General ................................................................................................................................................ 13
Safety Label Identification ................................................................................................................... 13
Operator Station
Component Locations ......................................................................................................................... 15
Interior Switches
Ignition Switch ..................................................................................................................................... 17
Multi-Purpose Switch .......................................................................................................................... 17
Cab Interior Light/Step Light ............................................................................................................... 18
Console Switches
General ................................................................................................................................................ 20
Hazard Warning Lights ....................................................................................................................... 21
Operation
Introduction
General ................................................................................................................................................ 23
Operating Safety
General ................................................................................................................................................ 24
Risk Assessment ................................................................................................................................ 26
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Table of Contents
ii 9831/3950-1 ii
Walk-Around Inspection
General ................................................................................................................................................ 28
Entering and Leaving the Operator Station
General ................................................................................................................................................ 30
Emergency Exit ................................................................................................................................... 30
Doors
Operator Door ..................................................................................................................................... 32
Windows
Rear Window ...................................................................................................................................... 33
Battery Isolator
General ................................................................................................................................................ 35
Before Starting the Engine
General ................................................................................................................................................ 36
Operator Seat
General ................................................................................................................................................ 37
Passenger Seat
General ................................................................................................................................................ 40
Seat Belt
Inertia Reel Seat Belt ......................................................................................................................... 41
Mirrors
General ................................................................................................................................................ 43
Starting the Engine
General ................................................................................................................................................ 44
Stopping and Parking
General ................................................................................................................................................ 47
Preparing for Travel
Preparing for Road Travel .................................................................................................................. 49
Drive Controls
Steering Wheel ................................................................................................................................... 50
Steering Column ................................................................................................................................. 50
Instruments
General ................................................................................................................................................ 51
Instrument Panel ................................................................................................................................. 85
Getting the Machine Moving
General ................................................................................................................................................ 92
Slopes
General .............................................................................................................................................. 109
Driving on Slopes ............................................................................................................................. 109
Three Point Linkage
Front Three Point Linkage ................................................................................................................ 110
Rear Three Point Linkage ................................................................................................................ 113
Auxiliary Hydraulics
General .............................................................................................................................................. 120
Auxiliary Electrics
General .............................................................................................................................................. 127
Trailer Hitches
General .............................................................................................................................................. 130
Ladder Hitch ...................................................................................................................................... 132
Pick-up Hitch (PUH) ......................................................................................................................... 138
Swing Drawbar .................................................................................................................................. 141
110mm Ball ....................................................................................................................................... 143
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Table of Contents
iii 9831/3950-1 iii
Trailer Brakes
General .............................................................................................................................................. 145
Power Take-Off (PTO)
Power Take-Off (Front) ..................................................................................................................... 147
Power Take-Off (Rear) ...................................................................................................................... 149
Heating, Ventilating and Air-Conditioning (HVAC)
General .............................................................................................................................................. 155
Air-Conditioning Controls .................................................................................................................. 155
Power Sockets
Auxiliary Power Socket ..................................................................................................................... 158
Moving a Disabled Machine
General .............................................................................................................................................. 159
Jump-Starting the Engine ................................................................................................................. 159
Retrieval ............................................................................................................................................ 160
Recovery Hitch .................................................................................................................................. 161
Transporting the Machine
General .............................................................................................................................................. 164
Operating Environment
Operating in Low Temperatures ....................................................................................................... 165
Operating in High Temperatures ....................................................................................................... 165
Refuelling
General .............................................................................................................................................. 166
Low Fuel Levels ................................................................................................................................ 166
Filling the Tank .................................................................................................................................. 166
Attachments
Implement Mounting Frame
General .............................................................................................................................................. 171
DIN Plate
General .............................................................................................................................................. 175
Front Loader Attachment
General .............................................................................................................................................. 177
Ballast
General .............................................................................................................................................. 178
Global Positioning System (GPS)
General .............................................................................................................................................. 180
Preservation and Storage
Cleaning
General .............................................................................................................................................. 185
Preparation ........................................................................................................................................ 185
Checking For Damage
General .............................................................................................................................................. 187
Storage
General .............................................................................................................................................. 188
Put into Storage ................................................................................................................................ 188
During Storage .................................................................................................................................. 188
Take out of Storage .......................................................................................................................... 189
Security
General .............................................................................................................................................. 190
LiveLink ............................................................................................................................................. 190
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Table of Contents
iv 9831/3950-1 iv
Maintenance
Introduction
General .............................................................................................................................................. 191
Owner/Operator Support ................................................................................................................... 191
Service/Maintenance Agreements .................................................................................................... 191
Obtaining Spare Parts ...................................................................................................................... 192
Maintenance Safety
General .............................................................................................................................................. 193
Fluids and Lubricants ....................................................................................................................... 194
Maintenance Schedules
General .............................................................................................................................................. 198
How to Use the Maintenance Schedules ......................................................................................... 198
Maintenance Intervals ....................................................................................................................... 198
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................. 198
Functional Tests and Final Inspection .............................................................................................. 201
Maintenance Positions
General .............................................................................................................................................. 203
Service Points
General .............................................................................................................................................. 205
Access Apertures
General .............................................................................................................................................. 206
Battery Cover .................................................................................................................................... 206
Engine Compartment Cover ............................................................................................................. 207
Lubrication
General .............................................................................................................................................. 209
Body and Framework
General ............................................................................................................................................. 218
Operator Station
Operator Protective Structure ........................................................................................................... 219
Seat ................................................................................................................................................... 219
Seat Belt ........................................................................................................................................... 220
Heating, Ventilating and Air-Conditioning (HVAC)
Recirculation Filter ............................................................................................................................ 221
Fresh Air Filter .................................................................................................................................. 221
Engine
Oil ...................................................................................................................................................... 223
Drive Belt .......................................................................................................................................... 225
Air Filter
Outer Element .................................................................................................................................. 228
Fuel System
General ............................................................................................................................................. 230
Pre-Filter Element ............................................................................................................................. 230
Cooling System
General ............................................................................................................................................. 232
Coolant .............................................................................................................................................. 232
Cooling Pack .................................................................................................................................... 233
Brakes
General ............................................................................................................................................. 236
Park Brake ........................................................................................................................................ 240
Gearbox
Oil ...................................................................................................................................................... 241
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Table of Contents
v 9831/3950-1 v
Steering System
General ............................................................................................................................................. 242
Wheels
General ............................................................................................................................................. 247
Tyres
General ............................................................................................................................................. 248
Trailer Hitches
General .............................................................................................................................................. 250
Power Take-Off (PTO)
Oil ...................................................................................................................................................... 257
Hydraulic System
General ............................................................................................................................................. 258
Services ............................................................................................................................................ 258
Oil ...................................................................................................................................................... 259
Coupling ............................................................................................................................................ 260
Auxiliary Hydraulic Circuit ................................................................................................................. 261
Electrical System
General ............................................................................................................................................. 263
Battery ............................................................................................................................................... 263
Battery Isolator ................................................................................................................................. 265
Fuses ................................................................................................................................................ 266
Relays ............................................................................................................................................... 267
Window Washer ................................................................................................................................ 267
Technical Data
Static Dimensions
Dimensions ........................................................................................................................................ 269
Weights ............................................................................................................................................. 270
Performance Dimensions
General .............................................................................................................................................. 272
Noise Emissions
General .............................................................................................................................................. 274
Noise Data ........................................................................................................................................ 275
Vibration Emissions
General .............................................................................................................................................. 276
Vibration Data ................................................................................................................................... 277
Fluids, Lubricants and Capacities
General .............................................................................................................................................. 278
Fuel ................................................................................................................................................... 279
Diesel Exhaust Fluid (DEF) .............................................................................................................. 279
Coolant .............................................................................................................................................. 280
Torque Values
General .............................................................................................................................................. 281
Electrical System
General .............................................................................................................................................. 282
Bulbs ................................................................................................................................................. 289
Fuses ................................................................................................................................................. 290
Relays ............................................................................................................................................... 293
Wheels and Tyres
General .............................................................................................................................................. 295
Tyre Sizes and Pressures ................................................................................................................ 296
Adjustable Wheel Rims ..................................................................................................................... 299
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Table of Contents
vi 9831/3950-1 vi
Declaration of Conformity
General .............................................................................................................................................. 301
Data ................................................................................................................................................... 301
Warranty Information
Service Record Sheet ....................................................................................................................... 303
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Table of Contents
vii 9831/3950-1 vii
Acronyms Glossary
2WD Two Wheel Drive
2WS Two Wheel Steer
4WD Four Wheel Drive
4WS Four Wheel Steer
ABS Anti-lock Braking System
ATC Automatic Temperature Control
AWS All Wheel Steer
CAN Controller Area Network
CVT Continuously Variable Transmission
DECU Display Electronic Control Unit
DEF Diesel Exhaust Fluid
ECU Electronic Control Unit
FOPS Falling Object Protective Structure
GPS Global Positioning System
HVAC Heating Ventilation Air Conditioning
ISO International Organization for Standardization
LED Light Emitting Diode
PIN Product Identification Number
PPE Personal Protective Equipment
PTO Power Take-Off
ROPS Roll-Over Protective Structure
RPM Revolutions Per Minute
SCR Selective Catalytic Reduction
VIN Vehicle Identification Number
km/h kilometers per hour
mph miles per hour
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Notes:
viii 9831/3950-1 viii

Introduction
About this Manual
1 9831/3950-1 1
Introduction
About this Manual
Model and Serial Number
This manual provides information for the following model(s) in the JCB machine range:
Model From: To:
4160 2185000
4190 2185000
4220 2185000
Using the Manual
This operator's manual is arranged to give you a good understanding of the machine and its safe operation.
It also contains maintenance and technical data.
Read this manual from the front to the back before you use the machine for the first time, even if you have used
machines of a similar/same type before as the technical specification, systems and controls of the machine
may have changed. Particular attention must be given to all the safety aspects of operating and maintaining
the machine.
If there is anything you are not sure about, ask your JCB dealer or employer. Do not guess, you or others could
be killed or seriously injured.
The general and specific warnings in this section are repeated throughout the manual. Read all the safety
statements regularly, so you do not forget them. Remember that the best operators are the safest operators.
The illustrations in this manual are for guidance only. Where the machines are different, the text and or the
illustration will specify.
The manufacturer's policy is one of continuous improvement. The right to change the specification of the
machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur
between specifications of the machine and the descriptions contained in this manual.
All of the optional equipment included in this manual may not be available in all territories
Left-Hand Side, Right-Hand Side
In this manual, 'left' and 'right' mean your left and right when you are seated correctly in the machine.
Figure 1.
A
B
ALeft BRight
Cross References
In this manual, cross references are made by presenting the subject title in blue (electronic copy only). The
number of the page upon which the subject begins is indicated within the brackets. For example: Refer to:
Cross References (Page 1).

Introduction
About this Manual
2 9831/3950-1 2
Location of Manual
The manual is located in the case behind the seat. The manual should always be returned to its case after use.
Figure 2.
A
AManual location

Introduction
Safety
3 9831/3950-1 3
Safety
Safety - Yours and Others
All machinery can be hazardous. When a machine is correctly operated and maintained, it is a safe machine
to work with. When it is carelessly operated or poorly maintained it can become a danger to you (the operator)
and others.
In this manual and on the machine you will find warning messages, read and understand them. They inform
you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your
employer or JCB dealer to explain them.
Safety is not just a matter of responding to the warnings. All the time you are working on or with the machine
you must be thinking of what hazards there might be and how to avoid them.
Do not work with the machine until you are sure that you can control it.
Do not start any work until you are sure that you and those around you will be safe.
If you are not sure of anything, about the machine or the work, ask someone who knows. Do not assume
anything.
Remember:
• Be careful
• Be alert
• Be safe.
Safety Warnings
In this manual and on the machine, there are safety notices. Each notice starts with a signal word. The signal
word meanings are given below.
The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
The signal word 'WARNING' indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
The signal word 'CAUTION' indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
The signal word 'Notice' indicates a hazardous situation which, if not avoided, could result in machine damage.
The safety alert system (shown) also helps to identify important safety messages in this manual and on the
machine. When you see this symbol, be alert, your safety is involved, carefully read the message that follows,
and inform other operators.
Figure 3. The safety alert system

Introduction
Safety
4 9831/3950-1 4
General Safety
Training
To operate the machine safely you must know the machine and have the skill to use it. You must abide by
all relevant laws, health and safety regulations that apply to the country you are operating in. The operator's
manual instructs you on the machine, its controls and its safe operation; it is not a training manual. If you are a
new operator, get yourself trained in the skills of using a machine before trying to work with it. If you don't, you
will not do your job well, and you will be a danger to yourself and others. In some markets and for work on certain
jobsites you may be required to have been trained and assessed in accordance with an operator competence
scheme. Make sure that you and your machine comply with relevant local laws and jobsite requirements - it
is your responsibility.
Care and Alertness
All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be
alert for hazards.
Clothing
You can be injured if you do not wear the correct clothing. Loose clothing can get caught in the machinery.
Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and
personal jewellery.
Alcohol and Drugs
It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume
alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines
which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself
and those you work with.
Mobile Phones
Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such
an area could cause an explosion or fire resulting in death or serious injury.
Switch off and do not use your mobile phone when refuelling the machine.
Raised Equipment
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which
is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control
is operated (even with the engine stopped).
Make sure that no-one goes near the machine while you install or remove the mechanical device.
Raised Machine
Never position yourself or any part of your body under a raised machine which is not correctly supported. If the
machine moves unexpectedly you could become trapped and suffer serious injury or be killed.
Lightning
Lightning can kill you. Do not use the machine if there is lightning in your area.
Machine Modifications
This machine is manufactured in compliance with prevailing legislative requirements. It must not be altered in
any way which could affect or invalidate its compliance. For advice consult your JCB dealer.
Clothing and Personal Protective Equipment (PPE)
Do not wear loose clothing or jewellery that can get caught on controls or moving parts. Wear protective clothing
and personal safety equipment issued or called for by the job conditions, local regulations or as specified by
your employer.

About the Product
Introduction
5 9831/3950-1 5
About the Product
Introduction
General
Before you start using the machine, you must know how the machine operates. Use this part of the manual
to identify each control lever, switch, gauge, button and pedal. Do not guess, if there is anything you do not
understand, ask your JCB dealer.
Name and Address of the Manufacturer
JCB Landpower Limited, Lakeside Works, Rocester, Staffordshire, United Kingdom, ST14 5JP.
Product Compliance
Your JCB product was designed to comply with the laws and regulations applicable at the time of its manufacture
for the market in which it was first sold. In many markets, laws and regulations exist that require the owner to
maintain the product at a level of compliance relevant to the product when first produced. Even in the absence
of defined requirements for the product owner, JCB recommend that the product compliance be maintained
to ensure safety of the operator and exposed persons and to ensure the correct environmental performance.
Your product must not be altered in any way which could affect or invalidate any of these requirements. For
advice consult your JCB dealer.
For its compliance as a new product, your JCB and some of its components may bear approval numbers
and marking's, and may have been supplied with a Declaration/Certificate of Conformity. These marking's and
documents are relevant only for the country/region in which the product was first sold to the extent that the
laws and regulations required them.
Re-sales and import/export of products across territories with different laws and regulations can cause new
requirements to become relevant for which the product was not originally designed or specified. In some cases,
pre owned products irrespective of their age are considered new for the purposes of compliance and may be
required to meet the latest requirements which could present an insurmountable barrier to their sale/use.
Despite the presence of any compliance related marking's on the product and components, you should not
assume that compliance in a new market will be possible. In many cases it is the person responsible for import
of a pre owned product into a market that becomes responsible for compliance and who is also considered
the manufacturer.
JCB may be unable to support any product compliance related enquiry for a product which has been moved out
of the legislative country/region where it was first sold, and in particular where a product specification change
or additional certification would have been required in order for the product to be in compliance.

About the Product
Description
6 9831/3950-1 6
Description
General
A self-propelled wheeled machine, the main function of which lies in its tractive power and the ability to pull,
push, carry and actuate interchangeable equipment. It is able to tow trailers or machinery and can be adapted
to carry a load.
The JCB Fastrac is designed for safe circulation on public roads. It is equipped with suspension and disc brakes
on each wheel.
For convenience, a second seat is installed for the occasional passenger or for an experienced operator to
give a novice driver instruction.
It is equipped with suspension, disc brakes on each wheel and an emergency steering system in the event
of a malfunction while driving.
Intended Use
The machine is intended to be used for agricultural applications or similar tasks. Use in any other way is
considered as contrary to the intended use.
If the machine is used for other purposes or in dangerous environments, for example in a flammable atmosphere
or in areas with dust containing asbestos, special safety regulations must be followed and the machine must
be equipped for use in these environments.
The product is designed for use with interchangeable equipment or attachments intended for use with this type
of vehicle and the attachment points provided.
Make sure you follow the instructions outlined in the operator’s manual of the mounted or trailed machinery
or trailer.
Do not operate the combination tractor - machine or tractor - trailer unless all instructions have been followed.
To meet T4F emission standards, this machine has exhaust gas treatment using SCR (Selective Catalytic
Reduction) technology. In SCR technology a liquid called DEF (Diesel Exhaust Fluid) is injected into the exhaust
gases.
Danger Zone
The danger zone is the area around the machine and attachments where the moving parts can reach. During
operation of the machine, keep all persons out of the danger zone. Persons in the danger zone could be injured.

About the Product
Description
7 9831/3950-1 7
Main Component Locations
Figure 4.
D
C
B
A
FE
AFuel filler BDEF (Diesel Exhaust Fluid)
CHydraulic filler DFront work lights
EFront 3-point linkage FFront PTO (Power Take-Off)
Figure 5.
A
B
C
ARight hand pannier BHeadlights

About the Product
Description
8 9831/3950-1 8
CFront recovery point
Figure 6.
D
FE
AB
C
ARear work lights B12V beacon electrical sockets
CRear deck implement attachment point
(dependant on machine specification)
DRear 3-point linkage
ERear PTO FTrailer towing hitch (dependant on machine
specification)

About the Product
Product and Component Identification
9 9831/3950-1 9
Product and Component Identification
Machine
The machine identification plate is located inside the cab on the seat base. Refer to Figure 7.
The identification plate is a tamper-proof decal. Do not attempt to modify it in any way.
The identification plate lists the machine's unique VIN (Vehicle Identification Number), serial numbers of main
driveline components and the permissible vehicle loads.
Figure 7.
e11* XXXX/XX* XXXXe11* XXXX/XX* XXXX
TIb
A
G
F
B
C
D
E
13000kg
A-1 : 6500kg
A-2 : 7500kg
JCB43X60EH2185000
Table 1.
A Identification plate (location)
B ECC number
C VIN number
D Total permissible mass
E Axle permissible load. A-1 = Front axle, A-2 = Rear axle
F Braking system. B-1 = Un- braked towable mass, B-2 = Independent braked tow-
able mass, B-3 = Semi or continuous braked mass, B-4 = Power braked towable
mass
G Trailer type. T-1 = Drawbar, T-2 = Rigid drawbar, T-3 = Centre-axle
Table 2.
Tractor type P148XXXX. Varies depending on territory and speed.
EC number Conformity certification number
Typical Product Identification Number
This includes the machine's unique serial number and original build specification. This identification number
is also stamped into the chassis.
Table 3. Typical PIN
JCB 43 X 60 E H 2185000
Table 4. Explanation of the PIN
Digit Description
1 to 3 World Manufacturer Identification. For example, JCB = UK Build.
4 to 5 Engine Type: 41= 6.6L118kW, 42= 6.6L141kW, 43= 6.6L163kW
6 Transmission Type: X= 4190/4220 CVT. SD55/SD88 axles, Y= 4160 CVT. SD55/SD70 axles
7 to 8 Vehicle Maximum Speed (according to territory)
9 Check Letter. A randomly generated letter to verify authenticity of the PIN (Product Identifica-
tion Number)