JCB 1115, 1115S, 1125, 1135 Fastrac Tractor Repair Service Manual
JCB 1115, 1115S, 1125, 1135 Fastrac Tractor Repair Service Manual
(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.
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