JCB JS130W, JS145W, JS160W, JS175W Wheeled Excavator Repair Service Manual

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This service manual PDF download for the JS130W, JS145W, JS160W, JS175W JCB Wheeled 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 Wheeled Excavator JS130W - from S/N: 716500 Onwards
JCB Wheeled Excavator JS145W - from S/N: 816000 Onwards
JCB Wheeled Excavator JS160W - from S/N: 718500 Onwards
JCB Wheeled Excavator JS175W - from S/N: 875000 Onwards


TABLE OF CONTENTS :

General Information
Care & Safety
Routine Maintenance
Attachments
Body & Framework
Electrics
Controls
Hydraulics
Transmission
Brakes
Engine


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/6310 Issue 5
Total Pages : 570


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
Machine and Axle Identification
Torque Settings
Service Tools
Body and Framework (Section B)
Electrics (Section C)
Hydraulics (Section E)
Transmission (Section F)
Axles (Section F)
Sealing and Retaining Compounds

Care and Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety

Routine Maintenance
Lubricants and Capacities
Lubricants - Health and Safety
Service Schedules
Greasing
Slew Ring Teeth and Slew Piston
Slew Ring Bearing
Greasing (50 Hours)
Greasing (General)
Battery
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Tightness
Hydraulics
Checking the Fluid Level
Releasing Tank Pressure
Topping-up Fluid Level
Changing the Fluid
Changing the Return Filter Element
Flushing Filters
Cleaning/Changing the Suction Strainer
Changing the Nephron Filter
Changing the Air Breather Element
Draining Tank Impurities
Changing the Servo Oil Filter
Changing the Drain Line Filter Element
Changing the Steering Line Filter Element
Changing the Breaker In-Line Filter (if fitted)
Air Bleeding Procedures
Transmission
Checking the Slew Gearbox Oil Level
Changing the Slew Gearbox Oil
Replenishing Slew Gearbox Grease
Checking the Drive Gearbox Oil Level
Changing the Drive Gearbox Oil
Checking the Front Axle Differential Oil Level
Changing the Front Axle Differential Oil
Checking the Front Axle Hub Oil Level
Changing the Front Axle Hub Oil
Checking the Rear Axle Differential/Hub Oil Level
Changing the Rear Axle Differential/Hub Oil
Engine
Changing the Air Filter Outer Element
Changing the Air Filter Inner Element
Checking the Oil Level
Changing the Oil and Filters
Checking the Coolant Level
Coolant Mixtures
Changing the Coolant
Cleaning the Radiator and Oil Cooler
Adjusting the Fan Belt
Fitting a New Fan Belt
Draining Fuel Tank Impurities
Draining the Fuel System Water Seperator
Changing the Fuel Filter Element
Cleaning the Fuel Lift Pump Strainer
Bleeding the Fuel System
Component Location Diagrams
Falling Objects Protection Structure (FOPS)
Checking the FOPS Structure

Body and Framework
Cab
Direct Glazing
Air Conditioning (Optional)
Operation
Control
Safety Procedures
Fault Finding
Checking Refrigerant Charge Level
Leak Testing
Tightening Leaking Hoses
System Diagnosis

Electrics
Introduction
The AMS System
AMS Schematic Diagram
Battery
Testing - Specific Gravity
Battery Testing
Schematic Diagram
Basic Circuit (JS 130W/160W - Caps II)
Additional Circuit for Wheeled Machines
Layout
Operator's Cab (CAPS II)
Right Console (CAPS II)
Left Console (CAPS II)
Monitor Panel (CAPS II)
Control, Function, Operation (CAPS II)
Engine Control (CAPS II)
Basic Operation
Stepping Motor
Throttle Related Function
Revolution Increase, Engine Stop
Controller Rotational Instructions
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 Prevention
Pump Control (CAPS II)
Schematic
Flow Chart
Boom Lowering Speed Regulation
Cushioned Boom Starting
Pressure Incresing System
Soft/Hard Switch
Power Supply Cut Delay
Swing Brake/Swing Lock
Lever Lock
Power Transistor Protection
Display Monitor
Throttle Motor (CAPS II)
Throttle Motor and Throttle Link replacement
Automatic Adjustment
Initial Setup of the Controller for Machine Identification
Revolution Sensor (CAPS II)
Installation
Self Test (CAPS II)
Fault Finding (CAPS II)
Fault Diagnosis
Emergency Engine Stop
Refuel
Coolant Refill
Air Cleaner Clogged
Low Engine Oil Pressure
Engine Oil Filter
Fluid Overheat, water, oil
Battery Charging
Electrical System, Message Fault
Engine Trouble
Sensor Resistance Valve
Computer Re-programming/Programming

Controls
Steering Column
Dismantling and Assembly

Hydraulics
Technical Data
Schematic Diagram
Component Key
Schematic Circuit Diagram (JS130W/JS145W/JS160W)
JS160W/JS175W Boom Circuit (TAB Option)
JS130W/JS145W/JS160W Revised Circuit
Schematic Circuit Diagram JS175W
JS175W Revised Circuit
Fault Finding
Pressure Testing
Pressure Measuring points
Pressure Relief Valves
Main Relief Valve
Servo Accumulator
Pilot Relief Valve
Auxiliary Relief Valves
Stabilisers/Blade Auxiliary Relief Pressure
Slew Motor Relief Valve
Brake Service Pressure
Steer Stall System Pressure
Clutch Pressure
Park Brake Pressure
Circuit Descriptions
Pump Circuits
Drive Circuit (CAPS II)
Drive Circuit (AMS only)
Park Brake/Gearchange Circuit
Steering and Brake Circuits
Grab Rotate Circuit
Stabiliser Circuit
Dozer Blade Circuit
Axle Lock Rams
Axle Lock Circuit
Hammer Circuit
Hydraulic Pump/Regulator - JS130W/JS145W/JS160W
Introuction/Specifications
Hydraulic Pump Circuit Diagram
Operation
Dismantling and Assembly
Checks After Installation
Hydraulic Pump/Regulator - JS175W
Introduction/Specifications
Hydraulic Pump Circuit Diagram
Operation
Proportional Reducing Valve
Valves
Control Valve
Introduction/Technical Data
Precautions Before Use
Spool Location
Hydraulic Circuit Diagram
Removal and Replacement
Dismantling and Assembly
Shuttle Valve
Introduction
Service Valves
General Information/Technical Data
Gear Change Valve
Axle Lock Valve
Remote Control Valve (Services)
Cushion Valve - Early Machines
Cushion Valve - Later Machines
Slew Brake Valve (CAPS II)
Slew Brake Valve - All later wheeled machines
Steering Control Unit
Dismantling and Assembly
Steering Priority Valve
Removal and Replacement
Dismantling and Assembly
Rotary Coupling
Removal and Replacement
Dismantling and Assembly
Drive Motor - JS130W/JS160W
Removal and Replacement
Dismantling and Assembly
Drive Motor - JS145W/JS175W
Operation
Slew Motor
Hydraulic Motor Components - JS130W/Js145W
Hydraulic Circuit - JS130W/JS145W/JS160W/JS175W
Operation
Specification - JS130W/JS145W
Dismantling - JS130W/JS145W
Maintenance Specifications - JS130W/JS145W
Assembly - JS130W/JS145W
Relief Valves - JS130W/JS145W
Dismantling
Assembly
Fault Finding - JS130W/JS145W
Specifications - JS160W/JS175W
Hydraulic Motor Components - JS160W/JS175W
Dismantling - JS160W/JS175W
Maintenance Specifications - JS160W/JS175W
Assembly - JS160W/JS175W
Relief Valve - JS160W/JS175W
Hydraulic Rams
Specifications
Bucket Ram
Removal
Replacement
Dipper Ram
Removal
Replacement
Boom Rams (General)
Removal
Replacement
Boom Ram (TAB)
Removal
Replacement
Boom, Dipper, Bucket and TAB Rams
Dismantling and Assembly
Torque Settings
Stabilizer/Dozer Rams
Dismantling and Assembly
Axle Lock Rams
Dismantling and Assembly
Power Track Rod
Dismantling and Assembly
Ram Piston Head Nut
Removal and Fitting
Reconditioning
Fault Finding
Maintenance Specifications
Hydraulic Rams - from various serial numbers
Dismantling the Piston Rod from Cylinder Tube
Dismantling the Piston Rod
Removing the Piston Seals
Removing the Cylinder Head Seals
Assembling the Piston Seals
Assembling the Cylinder Head Seals
Assembly of Piston Rod with Cushion Ring on the Piston Rod Side
Assembly of Piston Rod with the Cushion Ring on the Piston Rod & Cylinder Bottom Side
Assembly of Piston Rod in Cylinder Tube

Transmission
Drive Gearbox
Technical Data
Removal and Replacement
Dismantling and Assembly
Slew Gearbox
Dismantling and Assembly
Fault Finding
Front Axle (SD 70PT)
Technical Data
Removal and Replacement
Propshafts - Removal and Replacement
Power Track Rod - Removal and Replacement
Axle Hub and Driveshaft
Dismantling
Assembly
Drive Head
Dismantling
Assembly
Maxtrac differential
Renewing the Pinion Oil Seal
Service Brakes - Bleeding Procedure
Rear Axle (PD70)
Technical Data
Removal and Replacement
Propshafts - Removal and Replacement
Axle Hub and Driveshafts
Dismantling
Assembly
Drive Head
Renewing the Pinion Oil Seal
Service Brakes - Bleeding Procedure
Front Axle (SD 80PT)
Technical Data
Axle Hub and Driveshaft
Dismantling
Assembly
Rear Axle (PD 80)
Technical Data
Axle Hub and Driveshaft
Dismantling
Assembly

Brakes

Engine
Technical Data

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