JCB Fastrac 1115, 1115S, 1125, 1135 Tractor Service Manual, 1990s–2000s (P/N 9803/8010)

JCB service manual P/N 9803/8010 covers Fastrac 1115, 1115S, 1125, and 1135 tractors, including 2WS and 4WS configurations. The engine chapter comprises identification, specifications, and engine-unit removal/replacement; internal engine repair requires separate engine manuals.

Reading the PDF and Wiring Diagrams

Search, navigation, and diagram detail: The PDF has no text-search layer or embedded bookmarks. Small wire numbers and connector labels in the sectional diagrams require zooming.

One printable English-language PDF contains 562 pages, including three opening pages: the original cover, introduction, and color-coding key.

Fastrac Drivetrain, Hydraulic, and Chassis Work

This is a selection of the workshop content, rather than a complete contents list; further topics include headlight alignment and automatic trailer-coupling lubrication.

• Transmission and axles: Main drive and PTO clutch repair, PTO/splitter, six-speed and range gearbox overhaul, JCB Powersplit, propshafts, Maxtrac and NoSPIN differentials, and rear-axle PTO work.

• Hydraulics and draft control: Pump testing and resealing, external hydraulic control-valve service, rear lift ram repair, and Electronic Draft Control functional tests and fault-code diagnosis.

• Selectronic controls: Electro-pneumatic range-change troubleshooting, pneumatic-cylinder repair, microswitch setting, and air regulator/filter service.

• Brakes: Hydraulic and air-brake fault finding, separate bleeding procedures, caliper service, foot- and trailer-brake valve work, parking brakes, and actuator testing.

• Steering and suspension: 2WS/4WS diagnosis, steering ram and Orbitrol service, rear steering-valve tests, suspension pressure and ride-height checks, and gas-spring/accumulator testing.

• Electrical systems: Sectional wiring diagrams, harness connector views and repairs, starting and charging tests, alternator and starter service, and speedometer and 4WS sensor calibration.

• Cab and optional equipment: Direct glazing, air-conditioning diagnosis and compressor-clutch service, front lift ram repair, front PTO transfer-box overhaul, and flow-regulator testing.

Written for JCB distributor service engineers receiving or having completed JCB technical training, this manual assumes sound knowledge of workshop practice and safety procedures.

Build Differences and Engine Coverage

Identification tables distinguish 1000 Series and New 1000 Series engine builds across these models, including early and later 1135 machines. Internal engine work is referred to 9806/0100 for the 1000 Series and 9806/2140 for the New 1000 Series; those engine manuals are not included.

The 737000/737001 break changes hydraulic schematics, brakes, front steering, speedometer connections, and transmission components. Matching these sections to the machine's serial number helps select the appropriate circuit and test procedure before diagnosis begins.

Other distinctions cover R12/R134a air conditioning at 636393/636394, 2WS relay layouts at 736577/736578, throttle cables at 737248/737249, and Selectronic pneumatic cylinders at 737581/737582. The later relay layout also applies to all 4WS machines.

Clutch, Gearbox, and Drive-Head Repair

Step-by-step procedures cover gearbox removal, drivetrain separation, and clutch disassembly and reassembly. Shaft and selector work includes bearing preload, gear end float, synchromesh inspection, and 4WD clutch pressure testing. Axle chapters add pinion-depth setup, crown-wheel contact checks, solid-spacer installation, and differential overhaul.

The range-box chapter distinguishes the standard 4WD clutch on 1115 machines through 737000 from the heavy-duty clutch on all 1135 machines and on 1115S/1125 machines from 737001. June 1996 input- and output-shaft changes separate circlip-retained synchro cones from the earlier bonded-cone repair procedure.

The drive-head instructions warn that excessive rolling torque distorts a collapsible pinion spacer, compromising the bearing setup.

Hydraulic Valves and Electronic Controls

Control-valve coverage reaches spool and detent sections, flow-control and poppet valves, the main relief valve, and draft-control solenoids and pressure compensation. Electronic Draft Control diagnosis links functional checks, position-sensor setting, diagnostic LED interpretation, and error codes to hydraulic or electrical faults.

Pump instructions distinguish resealing and control-valve cleaning from low-output faults requiring pump replacement. Valve-section cautions explain how mixed spool parts or changed shim stacks affect operation and preset pressures; overtightened fasteners can distort parts and impair spool movement.

Brake, Steering, and Suspension Variants

Earlier hydraulic service brakes and the later air-over-hydraulic arrangement have separate fault-finding sections. Repair coverage includes foot- and trailer-brake valves, parking-brake components, air dryer/unloader service, and air/hydraulic actuator bench tests.

Steering pages distinguish single and twin front rams, provide rear steering-valve relief settings, and explain 4WS diagnostic LEDs. They also describe the JCB Headland Management System (HMS). Suspension coverage includes pressure discharge, hydropneumatic circuit diagnosis, and damped versus undamped cylinder repair.

Brake, steering, suspension, and hydraulic work involves stored pressure and heavy assemblies; the procedures assume suitable lifting equipment, test tools, and trained workshop practice.

Maintenance, Cab Repairs, and Workshop References

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

Air-conditioning pages cover leak and electrical diagnosis, pressure-switch testing, and component removal. Refrigerant discharging and charging procedures are excluded and assigned to trained refrigeration personnel with specialist equipment.

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

Factory tools are identified by number: 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. Reference tables supply torque, pressure and flow, lubricant, wear-limit, clearance, preload, end-float, electrical-test, and calibration data.

Examples of PTO, A/C Clutch, and Electrical Test Data

The front PTO transfer-box chapter specifies shaft end float of 0.03–0.08 mm after the retaining nuts are tightened. Compressor-clutch inspection uses an air gap of 0.4–0.8 mm.

The tachometer-feed test specifies 6–8 V at the alternator's small stud relative to its casing, with the engine above idle and the charge lamp extinguished, using an analog multimeter.