JCB 1115, 1115S, 1125 & 1135 Fastrac Tractor Service Manual – 9803/8010-06

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JCB 1115, 1115S, 1125 & 1135 Fastrac Tractor Service Manual – 9803/8010-06
(S/N: 0636001 Onwards) 

This service manual PDF download for the 1115, 1115S, 1125 & 1135 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 1115
JCB Fastrac 1115S
JCB Fastrac 1125
JCB Fastrac 1135
S/N: 0636001 Onwards

TABLE OF CONTENTS :

General Information
Care and Safety
Routine Maintenance
Optional Equipment
Body and Framework
Electrics
Controls
Hydraulics
Transmission
Brakes
Steering
Suspension
Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/8010-06
Total Pages : 562

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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Contents

General Information
Serial Number Plate
Typical Vehicle Identification No. (VIN)
Typical Engine Identification Number
Unit Identification
Torque Settings
Sealing and Retaining Compounds
Service Tools Numerical List
Service Tools
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
Moving a Disabeld Machine
Preparation for Towing
Transporting the Machine

Care and Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety

Routine Maintenance
Lubricants and Capacities
Lubricants – Health and Safety
Service Schedules
Checking for Damage
Opening/Closing the Bonnet
Checking Seat Belt Condition and Security
Greasing
Propshafts and PTO Driveshafts
Steering Swivels
Hydraulic Lift and 3 Point Linkage
Rear PTO Driveshaft Bearings
Rear Suspension Cylinder Pivots
Clutch Operating Mechanism
Rear Anti-roll Bar Ball Joints
Automatic Trailer Coupling
Cab
Checking the ROPS Structure
Checking the Windscreen Washer Fluid Level
Air Conditioning
Cleaning the Filter
Adjusting the Compressor Belt
Checking the Sight Glass
Electrics
Checking the Battery Electrolyte Level
First Aid – Electrolyte
Checking the Beam Alignment
Hydraulics
Checking the Fluid Level
Changing the Filter Element
Changing the Hydraulic Fluid
Cleaning the Suction Strainer
Clutch
Checking the Fluid Level
PTO, Speed and Range Gearboxes
Checking the Oil Level
Changing the Oil and Cleaning the Strainer
Changing the Transmission Oil Filter
Checking the Oil in the Front PTO Transfer Gearbox
Front Axle
Checking the Differential Oil Level
Changing the Differential Oil
Checking the Hub Oil Levels
Changing the Hub Oil
Rear Axle (2WS)
Checking the Oil Level
Changing the Oil
Rear Axle (4WS)
Checking the Differential Oil Level
Changing the Differential Oil
Checking the Hub Oil Levels
Changing the Hub Oil
Front and Rear Axle Steering Swivels (4WS)
Checking the 4WS Right Side Trunnion Seals
Tyres and Wheels
General
Tyre Inflation
Pressures, Speeds and Loads
Checking Wheel Nut Torques
Adjusting the Track Width
Lock Stops
Checking and Adjusting Wheel Alignment
Brakes
Checking and Renewing Foot Brake Pads
Testing the Parking Brake (machines to serial no. 737000)
Testing the Parking Brake (machines from serial no. 737001)
Checking the Foot Brake Fluid Level (machines from serial no. 737001)
Checking and Renewing the Brake Pads(machines from serial no. 737001)
Air System
Draining the Air System Tank
Antifreeze Pump
Engine
Checking Oil Level
Changing the Oil and Filter
Draining/Cleaning the Fuel Sediment Bowl
Draining the Fuel Filters
Changing the Fuel Filter Elements
Cleaning the Fuel Lift Pump
Bleeding the Fuel System
Checking the Coolant Level
Draining the Coolant
Filling the Cooling System
Coolant Mixtures
Cleaning the Radiator
Adjusting the Fan Belts
Cleaning the Pre-Cleaner
Changing the Air Filter Elements

Optional Equipment
Front Lift Ram – Dismantling and Assembly
Front PTO Transfer Box
Dismantling and Assembly
Fitting the Front PTO Output Shaft
Flow Regulator
Flow Testing and Pressure Testing
Removal and Replacement
Dismantling and Assembly

Body and Framework
Technical Data
Air Conditioning System
Cab – Direct Glazing
Air Conditioning/Heater System
Installation Diagram
Introduction
System Operation
System Projection Devices
Operator Controls
Safety Procedures
Refrigerant Type
Leak Testing
Tightening Leaking Hoses
Fault Finding
Component Removal and Replacement
Electrical Circuit – Description
Pressure Switch Testing
Electrical Circuit Diagram
Compressor Clutch – Removal and Replacement

Electrics
Technical Data
General Data
Fuses
Relay Identification
Test Methods
Use of Multimeters
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
How to Test a Diode or a Diode Wire
Wiring Diagrams
Introduction to Sectional Wiring Diagrams
Sectional Wiring Diagrams
Component Key
Contents
Alphabetical Index
Harness Connections
Sectional Diagrams
Wire Numbers
Fault Finding
Starting Circuit
Charging Circuit Test
Tachometer Feed Test
Wiring Harness Repair
Battery
Testing Specific Gravity
Battery Testing
Alternator
General Description
Service Precautions
Removal and Replacement
Dismantling and Assembly
Starter Motor
Removal and Replacment
Dismantling
Service and Renewal
Assembly
Digital Speedometer
Functions
Operation
New Unit Calibration
Four Wheel Steer (4WS) (if fitted)
Sensors
Removal and Replacement
Calibration

Controls
Technical Data
Throttle Controls
Foot Throttle Control Cable – Removal and Replacement
Hand Throttle Control Cable – Removal and Replacement
External Hydraulics Control Valve Linkage
Lever Linkages – Removal and Replacement
Flow Control Linkages
Setting Flow Control
Power Take-off Speed Selector Cable
Removal and Replacement
JCB Selectronic System (Air Assisted Range Change)
System Description
Operation
Electrical/Pneumatic Circuit
Description
Operation
Fault Finding
Pneuamtic Cylinders
Removal and Replacement
Setting Range Gearbox Turret Stops
Setting Cylinder Rod Neutral Lengths
Setting Logic Switch Microswitch Positions
Setting Indicator Light Microswitch Position
Dismantling and Assembly
Air Regluator/Filter
Removal and Replacement
Dismantling and Assembly

Hydraulics
Technical Data
Schematic Circuit
External Hydraulics/Draft Control
Neutral Circuit
Single and Double Acting Spools
Hydraulic Kick-out Spools
Pressure Testing – Main Relief Valve (MRV)
Pump – Suspension and Steering
Removal and Replacement
Dismantling and Assembly
Pump – External Hydraulics and Transmission
Removal and Replacement
Dismantling and Assembly
Control Valve – Suspension Pressure Maintenance/Service Brakes/Differential Lock
Replacing the Pump P1 Line Filter
Control Valve – External Hydraulics/Draft Control
Removal and Replacement
Dismantling and Assembly
Control Valve – Spool Sections
Spool and Detent – Dismantling and Assembly
Flow Control Valve – Dismantling and Assembly
Poppet Valve – Dismantling and Assembly
Main Relief Valve – Dismantling and Assembly
Draft Control Valve
Solenoids and Spools – Dismantling and Assembly
Pressure Compensator – Dismantling and Assembly
Internal Check Valve – Dismantling and Assembly
Check Valve, Body Seal and Plugs – Dismantling and Assembly
Rear Lift Rams
Removal and Replacement
Dismantling and Assembly
Electronic Draft Control
Introduction
System Activation Procedure
Operation
System Description
Hydraulic Circuit Operation
Fault Finding
Introduction
Functional Test of Control Valve
Arms Cannot be raised or Lowered
Arms Cannot be Lowered
Arms Cannot be Raised
Fault Diagnosis
Error Codes
Control Valve – Removal and Replacement
Draft Pin – Removal and Replacement
Position Sensor – Removal and Replacment
Position Sensor Setting

Transmission
Technical Data
General Description
Fault Finding
Complete Transmission
Power Take Off Clutches
4/2 Wheel Drive
Differential Lock
Hydraulic Circuit
Powersplit
Solenoid Circuit
Pressure Testing
Valves
Control Valve
Removal and Replacement
Dismantling and Assembly
Testing
Pressure Maintenance Valve
Lubrication Pressure
Differential Lock Control Valve
Powersplit Control Valve
Solenoid Valve
Main Drive Clutch – Removal, Inspection and Replacement
Main Drive Clutch Master Cylinder
Removal and Replacement
Dismantling and Assembly
Main Drive Clutch Servo
Removal and Replacement
Bleeding and Testing
Dismantling and Assembly
Gearbox Assembly
Removal and Replacement
Dismantling and Assembly
PTO Clutches
Removal and Replacement
Front PTO Clutch – Dismantling and Assembly
Rear PTO Clutch – Dismantling and Assembly
PTO/Splitter Gearbox
Six-Speed Gearbox/Rear Housing – Removal and Replacement
Splitter Clutches
Removal and Replacement
Dismantling and Assembly
PTO Gearbox
Speed Selector Shaft Assembly
Removal and Replacement
Dismantling and Assembly
PTO/Splitter Gearbox
Splitter Clutches – Dismantling and Assembly
Output Section – Dismantling and Assembly
Input Section – Dismantling and Assembly
Speed Gearbox
Remote Control – Dismantling and Assembly
Rear Oil Seals – Removal and Replacement
Front Oil Seals and Housing – Removal and Replacement
Input, Mainshaft and Layshaft – Removal and Replacement
Layshaft Bearing Preload
Mainshaft
End Float Check
Dismantling and Assembly
Layshaft – Dismantling and Assembly
Selector Shaft and Forks – Dismantling and Assembly
Range Gearbox
Removal and Replacement
Dismantling and Assembly
Front Casing – Removing and Replacing
Turret Assembly – Dismantling and Assembly
Clutch and Gear Assemblies – Removal and Replacement
Standard 4-Wheel Drive Clutch (all 1135 machines, 1115S machines, 1125 machines from serial no. 737001)
Dismantling and Assembly
Heavy Duty 4-Wheel Drive Clutch (all 1135 machines, 1115S machines, 1125 machines from serial no. 737001)
PTFE Ring Seals – Fitting Procedure
Pressure Testing – 4-Wheel Drive Clutch
Input Shaft – Dismantling and Assembly
Output Shaft – Dismantling and Assembly
Syncromesh Assembly
Needle Roller Bearings – Checking for Damage or Distortion
Propshafts
Removal and Replacement
Dismantling and Assembly
Front and Rear Axles
Differential Oil Seal – Removal and Replacement
Front Axle and Rear (4WS) Axle
Hub and Driveshaft – Dismantling and Assembly
Front Axle
Removal and Replacement
Drive Head
Removal and Replacement
Dismantling and Assembly
Maxtrac Differential – Removal and Replacement
NoSPIN Differential
Description
Dismantling and Assembly
Testing
Front and Rear Axles
Pinion Depth
Crown Wheel and Pinion Adjustment
Solid Spacer Installation
Rear Axle
Removal and Replacement
Hub and Driveshaft – Dismantling and Assembly
Drive Head
Removal and Replacement
Dismantling
Assembly
Differential Case Assembly
Rear Axle PTO
Dismantling and Assembly
Rear PTO Output Shaft

Brakes
Technical Data
Descriptions
Service Brakes (machines to serial no. 737000)
Trailer Brakes (machines to serial no. 737000)
Brake System (machines to serial no. 737001)
Fault Finding
Machines to Serial no. 737000
Machines from Serial no. 737001
Foot Brake Calipers
Removal and Replacement
Dismantling and Assembly
Brake System Bleeding
Automatic Drain Valve (machines to serial no. 737000)
Removal and Replacement
Dismantling and Assembly
Circuit Protection Valve (machines to serial no. 737001)
Removal and Replacement
Foot Brake Valve (machines to serial no. 737000)
Removal and Replacement
Adjusting the Brake Pedal
Dismantling and Assembly
Foot Brake Valve (machines from serial no. 737001)
Removal and Replacement
Dismantling and Assembly
Trailer Brake Air Valve (machines to serial no. 737000)
Removal and Replacement
Dismantling and Assembly
Trailer Brake Air Valve (machines from serial no 737001)
Removal and Replacement
Testing (in situ)
Dismantling and Assembly
Bench Testing
Non-Return Air Valve (machines from serial no. 737001)
Dismantling and Assembly
Trailer Brake Hydraulic Valve
Testing
Removal and Replacement
Dismantling and Assembly
Trailer Brake Inverse Relay Valve – Removal and Replacement
Parking Brake (machines to serial no. 737000)
Hand Brake Adjustment
Caliper
Removal and Replacement
Dismantling and Assembly
Parking Brake (machines from serial no. 737001)
Caliper
Removal and Replacement
Dismantling and Assembly
Actuator Cylinder
Parking Brake Lever (machines to serial no. 737000)
Removal and Replacement
Dismantling and Assembly
Parking Brake Lever Mechanism (machines to serial no. 737000)
Removal and Replacement
Dismantling and Assembly (early machines)
Dismantling and Assembly (later machines)
Parking Brake Air Control Valve (machines from serial no. 737001)
Removal and Replacement
Air Dryer/Unloader Valve (machines from serial no. 737001)
Removal and Replacement
Dismantling and Assembly
Air/Hydraulic Actuator (machines from serial no. 737001)
Removal and Replacement
Dismantling and Assembly
Bench Testing
Failure Conscious Pressure Reducing Valve (machines from serial no. 737001)
Removal and Replacement

Steering
Technical Data
Steering System Description
General
4WS Machines – System Features
4WS Machines – Steer Mode Selection
Machines to Serial No. 737000
JCB Headland MAnagement System (HMS)
Front Axle Steering Operation 1 – Neutral
Front Axle Steering Operation 2 – Left Turn
Front Axle Steering Operation 3 – Right Turn
Front Axle Steering Operation 4 – Left Turn, Unassisted
Front Axle Steering Operation 5 – Shock Valve
Front Axle Pressure Equalising Relief Valve
Machines From Serial no. 737001
Front Axle Steering Operation 1 – Neutral
Front Axle Steering Operation 2 – LEft Turn
Front Axle Steering Operation 3 – Right Turn
Front Axle Steering Operation 4 – Left Turn, Unassisted
Front Axle Steering Operation 5 – Pressure Relief Valve
Fault Finding (Front Axle)
Fault Finding (Rear Axle) (4WS)
Introduction
Diagnosis
Diagnostic LED’s
Pump Pressure Testing (machines to serial no. 737000)
Steering System Operating Pressure Testing (machines from serial no. 737001)
Single Front Axle Steering Ram (machines to serial no. 737000)
Removal and Replacement
Twin Front Axle Steering Rams (machines from serial no. 737001)
Removal and Replacement
Front Axle Steering Rams (all machines)
Dismantling and Assembly
Hydraulic Steering Unit
Removal and Replacement
Dismantling and Assembly
Relief Valves
Pressure Equalising Relief Valve – Front Axle Steering (machines to serial no. 737000)
Steering Column
Dismantling/Removal
Assembly/Replacement
Rear Axle (4WS) Steering Valve
Removal and Replacement
Setting the Relief Valves
Dismantling and Assembly
Rear Axle (4WS) Power Track Rod
Removal and Replacement
Dismantling and Assembly

Suspension
Technical Data
Front Suspension
Description
Shock Absorber – Removal and Replacement
Control Arm – Removal and Replacement
Panhard Rod – Removal and Replacement
Anti-Roll Bar – Removal and Replacement
Coil Spring – Removal and Replacement
Rear Suspension
Description and Hydraulic Circuit Diagram
Pressure Testing
Ride Height
Discharging Hydraulic Pressure
Pressure Maintenance Valve – Dismantling and Assembly
Spring Box – Removal and Replacement
Accumulator/Height Corrector Valve/Gas Spring/Suspension Cylinder – Removal and Replacement
Gas Spring and Accumulator – Testing
Suspension Cylinder – Dismantling and Assembly
Anti-Roll Bar – Removal and Replacement
Control Arm – Removal and Replacement
‘V’ Link – Removal and Replacement

Engine
Technical Data
General
Fuel System
Engine Unit – Removal and Replacement

 

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JCB 1115, 1115S, 1125 & 1135 Fastrac Tractor Service Manual – 9803/8010-06.pdf

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