JCB 1115, 1115S, 1125, 1135 Tractor Service Manual (P/N 9803/8010)

• Covers JCB Fastrac 1115, 1115S, 1125, and 1135 models, with separate information for 2WS and 4WS machines, early and later builds, and the major serial break at 737000/737001.
• Documents major transmission and axle repair work: main drive and PTO clutches, the PTO/splitter, six-speed, and range gearboxes, JCB Powersplit, 4WD clutch packs, propshafts, axles, drive heads, Maxtrac and NoSPIN differentials, and rear-axle PTO components.
• Details hydraulic and control-system diagnosis for external hydraulics, draft control, suspension/steering pumps, spool and relief-valve sections, rear lift rams, Electronic Draft Control fault codes, and the JCB Selectronic electro-pneumatic range-change system.
• Provides serial-specific brake, steering, and suspension procedures, including hydraulic and air-brake fault finding, bleeding and valve testing, 2WS/4WS steering diagnosis, steering-ram and Orbitrol service, rear-steering valve work, suspension pressure tests, ride-height checks, and gas-spring/accumulator testing.
• Includes electrical, cab, and optional-equipment repair coverage: sectional wiring diagrams, harness connector views, starting and charging tests, harness repair, alternator and starter service, speedometer and 4WS sensor calibration, air-conditioning diagnosis, direct glazing, front lift ram service, front PTO transfer-box overhaul, and flow-regulator testing.
• JCB Publication No. 9803/8010 in a 562-page PDF. The engine section supplies identification data and engine-unit removal/replacement; internal engine repair is assigned to separate JCB engine manuals.

Coverage and Build Differences

Coverage follows the specific configurations used in these Fastrac models. Identification tables distinguish the 1000 Series and New 1000 Series engine builds used by the 1115, 1115S, 1125, and early/later 1135. The air-conditioning pages separate R12 machines through 636393 from R134a machines from 636394. Relay layouts change at 736577/736578, throttle-control cables at 737248/737249, and Selectronic pneumatic cylinders at 737581/737582. The larger 737000/737001 break affects hydraulic schematics, brakes, steering, speedometer connections, and transmission components.

The range-box chapter separates the standard 4WD clutch used on 1115 machines through serial 737000 from the heavy-duty clutch fitted to all 1135 machines and to 1115S and 1125 machines from serial 737001. It also identifies the June 1996 input- and output-shaft redesign, including later circlip-retained synchro cones and the earlier bonded-cone repair procedure.

Factory Repair Procedures

Routine maintenance runs from daily checks through long-interval service, with lubricant and capacity tables, driveline greasing, hydraulic and transmission fluid service, axle oils, brake inspections, fuel and cooling-system work, air-cleaner service, wheel alignment, and ROPS checks.

Transmission coverage goes well beyond adjustments. It includes gearbox removal, drivetrain separation, clutch inspection, PTO and splitter-clutch overhaul, shaft and selector disassembly, bearing preload and gear end-float checks, 4WD clutch pressure testing, synchromesh inspection, pinion-depth setup, crown-wheel contact checking, solid-spacer installation, and axle/differential overhaul. Hydraulic chapters add pump rebuilding, control-valve overhaul, relief testing, rear-lift-ram repair, Electronic Draft Control functional tests, position-sensor setting, diagnostic LED interpretation, and error-code fault isolation.

Brake chapters separate the earlier hydraulic service-brake arrangement from the later air-over-hydraulic system. They cover calipers, foot- and trailer-brake valves, parking-brake components, air dryer/unloader service, actuator bench testing, circuit bleeding, and fault finding. Steering and suspension sections provide front-axle and 4WS troubleshooting, pressure testing, steering-unit overhaul, rear steering-valve relief setting, hydropneumatic suspension diagnosis, ride-height checks, pressure discharge, and suspension-cylinder repair.

Two repair traps are called out clearly. The axle drive-head procedures treat a collapsible pinion spacer as a one-setting component; once preload is exceeded, the spacer must be replaced or bearing preload and gear mesh can be wrong. The hydraulic control-valve pages require spool parts and shim stacks to remain with their original sections, since mixing them can change valve operation and factory-set pressures.

Diagrams, Tools, and Scope

Named visual references include the JCB Selectronic electrical/pneumatic circuit, early/late hydraulic schematics, Electronic Draft Control circuit and fault-code charts, the transmission hydraulic and Powersplit solenoid circuits, the rear-suspension hydraulic circuit, and 2WS/4WS sectional wiring diagrams. Exploded views support gearbox, clutch, valve, ram, and axle repair.

The service-tool section identifies factory equipment by number, including the 892/00800 splitting frame, 477/00437 gearbox lifting adapter, 892/00918 solid-spacer setting kit, 892/00253 hydraulic pressure-test kit, and 892/00311 brake test kit. Related tables provide component torque specifications, pressure and flow test data, fluid capacities and approved lubricants, wear limits, clearances, preload and end-float figures, electrical test values, and calibration data.

The engine chapter does not contain a full internal overhaul. It refers 1000 Series engine work to JCB Publication 9806/0100 and New 1000 Series work to 9806/2140. Brake, steering, suspension, and hydraulic repair can involve stored air or hydraulic pressure and heavy supported assemblies; the procedures assume suitable lifting equipment, test tools, and trained workshop practice.