JCB JS130, JS160 Tracked Excavator Repair Service Manual

JS130 (from S/N: 758000 Onwards) - JS160 (from S/N: 702000 Onwards)
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This service manual PDF download for the JS130, JS160 JCB Tracked Excavator 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 Tracked Excavator JS130 - from S/N: 758000 Onwards
JCB Tracked Excavator JS160 - from S/N: 702000 Onwards


TABLE OF CONTENTS :

General Information
Care & Safety
Routine Maintenance
Attachments
Body & Framework
Electrics
Hydraulics
Transmission
Brakes
Track & Running Gear
Engine


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/6410 Issue 1
Total Pages : 533


This JCB Hydraulic Excavator 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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Cover
Contents

General Information
Bolt and Nut Torque Specifications
Torque Settings
Service Tools
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Sealing and Retaining Compounds

Care and Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety

Routine Maintenance
Fluids and Lubricants
Lubricants - Health and Safety
Service Schedules
Service Intervals for Hydraulic Oil and Filters when using a Breaker or Crusher
Initial Precautions for New Machine Usage
Operating Hours Schedule
Greasing
Slew Ring Bearing
Slew Ring Teeth and Slew Pinion
Excavator End
Battery
Hydraulics
Air Bleeding Procedures
Releasing Tank Pressure
Air Bleeding from Hydraulic Pump
Air Bleeding from Ram
Air Bleeding from the Slew Motor
Checking the Fluid Level
Topping up Fluid Level
Changing the Hydraulic Oil
Changing the Return Filter Element
Flushing Filters
Cleaning/Changing the Suction Strainer
Changing the Air Breather Element
Draining Tank Impurities
Changing the Pilot Oil Filter
Changing the Breaker in-line Filter
Changing the Drain Line Filter
Changing the Nephron Filter
Transmission
Checking the Track Gearbox Oil Level
Changing the Track Gearbox Oil
Checking the Slew Gearbox Oil Level
Changing the Slew Gearbox Oil
Replenishing Slew Gearbox Grease
Tracks and Running Gear
Cleaning the Tracks
Checking/Adjusting the Track Tension
Checking the Shoe Plate
Checking the Rollers and Idler Wheels for Oil Leeks
Engine
Changing the Air Filter Elements
Checking the Oil Level
Changing the Oil and Filters
Checking the Coolant Level
Coolant Mixtures
Changing the Coolant
Adjusting the Fan Belt
Fitting a New Fan Belt
Cleaning the Radiator and Oil Cooler
Draining Fuel Tank Impurities
Draining the Water Seperator
Changing the Fuel Filter Element
Bleeding the Fuel System
Component Location Diagrams
Performance Evaluation
Falling Objects Protection Structure (FOPS)
Checking the Fops Structure

Body and Framework
Cab
Direct Glazing
Undercarriage - JS130
Dimensions
Undercarriage - JS160
Dimensions
Weights - JS130, JS160
Main Body
Maintenance Specifications - JS130
Boom and Slew Frame Installation
Boom Ram Installation
Dipper Ram Installation
Dipper Pivot Installation
Dipper and Dipper Ram installation
Bucket Ram Installation
Dipper and Dipper Link Installation
Bucket and Bucket Link Installation
Bucket Link and Bucket Ram Installation
Bucket and Dipper Installation
Shim adjustment table
Maintenance Specifications - JS160
Boom and Slew Frame Instalation
Boom Ram Installation
Dipper Ram Installation
Dipper Pivot Installation
Dipper and Dipper Ram Installation
Bucket Ram Installation
Dipper and Dipper Link Installation
Bucket and Bucket Link Installation
Bucket Link and Bucket Ram Installation
Bucket and Dipper Installation
Shim adjustment table
Air Conditioning (Optional)
Operation
Control
Safety Procedures
Fault Finding
Checking Refrigeran Charge Level
Leak Testing
Tightening Leaking Hoses

Electrics
Torque Specifications
Technical Data
Battery Testing
Schematic Diagram
Layout
Operator's Cab
Right Console
Left Console
Monitor
Control, Function. Operation
Engine Control
Basic Operation
Stepping Motor
Throttle Related Function
Stop Motor Function
Redundancy (Back-up) Throttle Control
Automatic Engine Adjustment
Idling Control
Revolution Control for Each Mode
Control of Engine Speed for Breaker Operation
Engine Auto Warm-up
Detection of Throttle Motor Assembly Defect
Engine Reverse Rotation Protection
Pump Control
Schematic
Flow Chart
Boom Lowering Speed Regulation
Cushioned Boom Starting
Pressure Increasing System
3 Speed Travel and Max Flow Cut
Soft/Hard Switch
Power Supply Cut Delay
Swing Brake/Swing Lock
Lever Lock
Travel Warning
Power Transistor Protection
Display Monitor
Throttle Motor
Throttle Motor and Throttle Link Replacement
Automatic Adjustment
Initial Setup of the Controller for Machine Identification
Revolution Sensor
Installation
Self Test
Fault Finding
Fault Diagnosis
Emergency Engine Stop
Refuel
Coolant Refill
Air Cleaner
Low Engine Oil Pressure
Engine Oil Filter
Fluid Overheat, Water, Oil
Battery Charging
Electrical System, Message Fault
Engine Problem
Sensor Resistance Valve

Hydraulics
Technical Data JS130
Technical Data JS160
Schematics
Schematic Hydraulic Circuit JS130
Schematic Hydraulic Circuit JS160
Shuttle Block
Pilot Control Line Hose Connection Diagram
Pressure Testing
Pressure Measuring points
Pressure Relief Valves
Pressure Testing - General
Main Relief Valve
Servo Accumulator
Pilot Relief Valve
Slew Motor Relief Valve
Auxiliary Relief Valve
Travel Motor Relief Pressure
Hydraulic Pump Regulator
Introduction/Specifications
Schematics
Operation
Fault Finding
Dismantling and Assembly
Hydraulic Pump/Regulator JS130, JS160
Control Valve
Introduction, Technical Data
Precautions During Use
Spool Location
Schematic hydraulic circuit
Neutral Circuit
Operation
Removal and Replacement
Dismantling and Assembly (Sub-assembly Location)
Remote Control Valve (Services)
Introduction, Specification
Technical Data, Schematics
Operation
Dismantling and Assembly
Fault Finding
Maintenance Specification
Remote Control Valve (Travel)
Introduction, Specification
Technical Data
Dismantling and Assembly
Shuttle Valve
Introduction
General Information
Operation
Cushion Valves
Schematic, Technical Data
Operation
Slew Brake Valve
Introduction, Technical Data
Operation
Hydraulic Rams
Specification and Torque Settings
Precautions During Use
Bucket Ram Removal and Installation
Dipper Ram Removal and Installation
Boom Ram Removal and Installation
Dismantling and Assembly
Reconditioning
Fault Finding
Rotary Coupling
Technical Data
Operation
Removal
Replacement
Dismantling
Assembly
Slew Motor
Hydraulic Motor Components
Reduction Gear Components
Hydraulic Circuit
Operation
Specifications
Maintenance Specifications
Motor Assembly/Cylinder Assembly - Dismantling and Assembly
Relief Valve - Dismantling and Assembly
Reduction Gear - Dismantling and Assembly
Fault Finding

Transmission
Traction Motor/Reduction Gear
Specifications
Operation
Preparation for Use
Fault Finding
Removal and Replacement
Motor Bleeding
Testing
Cross Sectional View - JS130
Exploded View (Motor) - JS130
Exploded View (Reduction Gear) - JS130
Component List - JS130
Cross Sectional List - JS160
Exploded View (Motor) - JS160
Exploded View (Gear) - JS160
Component List - JS160
Traction Motor
Dismantling
Inspection
Assembly
Reduction Gear - JS130
Dismantling
Inspection
Assembly
Adjustments
Reduction Gear - JS160
Dismantling
Inspection
Assembly
Adjustments

Track and Running Gear
Torque Specifications
Idler Wheel and Recoil Unit
Removal
Replacement
Idler Wheel
Dismantling
Assembly
Wear Limits
Recoil Unit
Dismantling
Assembly
Grease Cylinder
Dismantling and Assembly
Drive Sprocket
Removal
Replacement
Wear Limits
Top Roller
Removal
Replacement
Dismantling
Assembly
Bottom Roller
Removal
Replacement
Dismantling
Assembly
Wear Limits

Engine
Technical Data

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