JCB JS175W Auto Wheeled Excavator Repair Service Manual
JCB JS175W Auto Wheeled Excavator Repair Service Manual
(S/N: 1235500 Onwards) - This service manual PDF download for the JS175W Auto 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 JS175W Auto - from S/N: 1235500 Onwards
TABLE OF CONTENTS :
Section 1 - General Information Section 2 - Care & Safety Section 3 - Routine Maintenance Section B - Body & Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section K - Engine
MANUAL SPECIFICATION :
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Publication No. : 9803/6550-1 Total Pages : 818
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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9803-6550-1
Section 1 - General Information Introduction About this Publication Schematic Codes Identifying your Machine Identification Plates Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Hydraulic Connections Service Tools Numerical List Section B - Body and Framework Tool Detail Reference Section B - Body and Framework Numerical List Section C - Electrics Tool Detail Reference Section C - Electrics Numerical List Section E- Hydraulics Tool Detail Reference Section E- Hydraulics Service Consumables Sealing and Retaining Compounds
Section 2 - Care & Safety Safety Notices Introduction Safety Check List Safety - Yours and Others General Safety Operating Safety Maintenance Safety Safety Decals Safety Decal Recognition Chart Definitions
Section 3 - Routine Maintenance Maintenance Service Requirements Introduction Owner/Operator Support Service/Maintenance Agreements Obtaining Replacement Parts Lifting Regulations - Inspections and Tests Health and Safety Lubricants Battery First Aid - Electrolyte Service Schedules Introduction How to Use the Service Schedules Pre Start Cold Checks, Service Points and Fluid Levels Functional Test and Final Inspection Service Intervals for Attachments Periodic Replacement of Safety Related Components Lubricants and Capacities JS175W and Variants Engine Lubrication Chart Hydraulic Oil Chart Cleaning the Machine Exterior Interior Checking for Damage Daily Checking Bolt and Nut Torque Specifications JS175W and Variants Checking the FOPS Structure Seat Belt Checking the Seat Belt Condition and Security Greasing General Notes Slew Ring Bearing Slew Ring Teeth and Slew Pinion Greasing Points Tyres and Wheels Tyre Inflation Checking the Wheel Nut Tightness Electrical System Battery Jump-Starting the Engine Fuses Engine Checking the Oil Level Changing the Oil and Filter Changing the Outer Air Filter Element Changing the Inner Air Filter Element Checking the Fan Belt Tension Fitting a New Fan Belt Checking the Coolant Level Cleaning the Radiator and Oil Cooler Changing The Coolant Coolant Mixtures Fuel System Types of Fuel Filling the Tank and Fuel Level Checking Petrol Changing the Fuel Filter Element Cleaning the Lift Pump Strainer Draining Fuel Tank Impurities Draining the Water Separator and Engine Fuel Filter Changing the Water Separator Filter Bleeding the Fuel System Hydraulic System Checking the Fluid Level Releasing Tank Pressure Topping-up Fluid Level Changing the Fluid Draining Water and Sediment from the Hydraulic Tank Cleaning/Changing the Suction Strainer Changing the Return Filter Changing the Plexus Filter Changing the Air Breather Element Changing the Pilot Oil Filter Changing the Breaker In-line Filter Changing the Steering Line Filter Changing the Drain Line Filter Air Bleeding Procedures Gearboxes Checking the Slew Gearbox Oil Level Changing the Slew Gearbox Oil Level Checking the Drive Gearbox Oil Level Changing the Drive Gearbox Oil Front Axle Checking the Differential Oil Level Changing the Differential Oil Checking the Hub Oil Level Changing the Hub Oil Rear Axle Checking the Differential/Hub Oil Level Changing the Differential/Hub Oil Windscreen Washers Troubleshooting Engine and Related Area Monitor Display - Fault Messages Operations Hydraulic pump Working Attachments Slew Hydraulic ram
Section B - Body & Framework Technical Data Static Dimensions JS175W - Monoboom JS175W - Triple Articulated Boom Operating Weight Tyre Pressures Dig Depth Chart JS175W Attachments Location Boom and Slew Frame Installation Boom Ram 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 Air Conditioning (option) Basic Operation Air Conditioning Operation Heater/Air Conditioning Controls Air Conditioning System Operation Control Pressures Switch Settings Safety Procedures Fault Finding Air Conditioning Preliminary Checks Electrical Component Location Electrical Fault Finding Service Procedures HVAC/Air Conditioning Unit Removal and Repacement Air Conditioning Compressor Removal and Repacement Cab Structure Direct Glazing Checks Checking the FOPS Structure Cab Panels Cab Panel Removal Right Hand Cab Panels Left hand Cab Panels
Section C - Electrics Technical Data Fuses Fuse Identification Basic System Operations Location of Controls and Components Driver Controls and Switches Drive Controls Right Console Left Console Left Console Switch Panel Multi Purpose Steering Column Switch Monitor Panel Fascia Panel Emergency back-up switch One Touch / Automatic Idle Switch Heater/Air Conditioning Controls Radio (If fitted) Cab Interior Lights Operating Levers and Pedals Excavating Controls Stabilisers (if fitted) Dozer (if fitted) Circuit Symbols Inputs and Outputs Component Identification JS175W Schematic Diagram JS175W A.M.S (Advanced Management System) Operation The AMS System Circuit Concepts Inputs Outputs Pulse Width Modulation (PWM) ECU1/EMS/FACIA Power Supply and Network ECU 1 Supply to Output Drivers ECU W Supply to Output Drivers ECU W / LH Switch Panel Supply and Network Engine Throttle Control Introduction Throttle control system Throttle control circuit Engine Throttle Control for each mode Stop Solenoid Setting Procedure Auto Boost Pressure Operation Engine Reverse Rotation Prevention Operation Engine Pre Heat (Glow plugs) Operation Engine Automatic Warm Up Operation Engine Automatic Idle Operation Engine One Touch Idle Operation Engine Auto Idle and One Touch Idle Engine Start/Stop Operation Limp Mode system Operation Pump Control for Each Mode Operation Pump torque is set by pump control mA signal "A" Auto Mode and “D” Drive Mode "E" Economy mode "L" Lifting mode & "P" Precision mode Lever Lock Operation Drive Isolator Wiper Lower Wiper (option) Operation Washer Horn Operation Travel Alarm - Optional Operation Slew Brake (100%) Operation Slew lock (100% Slew Brake) Operation Travel Mode Operation Cruise Control - Optional 3 Speed Travel Operation Work Lights (Boom and Cab) Operation Head Lights Operation Side Lights Operation Brake Lights Operation Indicators Operation Fog/Reversing Lights Fog Lights Reversing Lights Fog/Reversing Light Schematic Hazard Warning Operation Park Brake Operation Axle Lock Manual Automatic Stabilisers Operation Dozer Operation Viscous Fan Operation Fuel Level Sensor/Warning Operation Engine Temperature Sensor/Warning Operation Coolant Level Warning Operation Air Filter Blocked Warning Operation Warning Indicator Lamps Hydraulic Temperature Sensor/Warning Operation Brake Pressure Warning Operation Engine Oil Pressure/Emergency Steering Warning Operation Alternator/ No Charge Warning Operation Alternator Charging and Battery Relay Quick hitch (option) Operation Overload Caution (option) Operation Beacon Operation Grab/rotate Operation Hammer Operation Scrap Magnet Option Operation Cab Interior Lamp Operation Refuelling Pump Automatic Mode Manual Mode Air Conditioning Heated Seat 24 to 12 Volt Converter, Radio and Cigar Lighter 24 to 12 Volt Converter. Radio Cigar lighter Service Required Warning Operation Cancellation of the Service indicator EMS Set Menu. EMS Set + Mode (5 Sec) Menu EMS Set+Mode (20 sec) Menu. Service off Throttle calibration Solenoid Override Horse Power Control Data Logging Facility Fault Finding JCB Service Master Using Service Master Selecting Service Tool Applications System Menus HPSetup Overview Features Using HPSetup 1 Connecting the Data Link Adaptor (DLA) 2 Starting HPSetup 3 Setting Up A Vehicle Profile 4 Writing Vehicle Profile <F12 5 Reading Vehicle Profile <F11 6 Closing HPSetup 7 Options - Multi Language Support Guidelines for setting up a vehicle using the set up tool Alternative Language Cross Reference Data Link Adaptor DLA Trouble Shooting HPDataLogs Using HPDataLogs FLASH Programming Application "FLASHECU" Training Guide Using FLASHECU Introduction to the Diagnostics Tool Connecting to the vehicle Starting Diagnostic Mode Circuit Diagrams Indicator Lights (LEDs) Stopping Diagnostic Mode Language Setting List of text messages displayed on the EMS. Table 1: Error messages Table 2: Status messages Table 3: Electrical fault error code Fault Finding Without using the JCB Service Master Diagnostic Tool Introduction Changing Machine Components Fault Diagnosis (General) Permanent Battery Supply. (Ignition Off) Ignition On Ground Tests. Can - Bus Network Tests. Harness Tests. Unit Tests. Fault Diagnosis ECU-1 EMS Failure. Fault Diagnosis - Facia Switch panel (F S P) Service Procedure Testing of ECU Inputs + Outputs Testing low side input Testing High side input Testing low side output Testing high side output Wiring Harness Repair Introduction Repair Procedure Battery Maintenance First Aid - Electrolyte Testing Specific Gravity Testing Harness Data Main Harness Main Harness A Main Harness B Main Harmess C Main Harness D Wheeled Harness Wheeled Harness A Wheeled Harness B Wheeled Harness C Cab Harness Cab Harness A Cab Harness B Cab Harness C Fascia Link Harness Facia Link Harness A Facia Link Harness B Worklights Cab Worklight Boom Worklight
Section D - Controls Steering Column Dismantling and Assembly
Section E - Hydraulics Technical Data General Data Hydraulic Pump Slew Gearbox Slew Motor Main Contol Valve Rams Ram Torque Settings Basic System Operation Hydraulic Component Location Introduction to Hydraulic Schematic Symbols General (Basic and Functional Symbols) Control Valves Example of Schematic Circuit Circuit Descriptions Hydraulic Schematic Servo Line Components Servo Pressure and Return Line Components Chassis Hydraulics Components Monoboom Hammer/Aux Hydraulics Components Tab Hammer/Aux Hydraulics Components Main Control Valve Hydraulic Pump Operation Main Pumps (P1 and P2) Hydraulic Pump Regulation Neutral Circuit Drive Creep Speed Middle speed High Speed Boom Up Boom Down Dipper In Dig End Isolate Bucket Close Slew Circuit 100% Slew Lock Auxiliary Flow Hammer ISO/SAE Controls Gear Change Cruise Control (Optional) Stabiliser and Dozer Stabiliser Operation Dozer Operation Park Brake Park Brake On Park Brake Off Brake and Steering Brake Charging Brake Charged Steering Circuit Grab Rotate Axle Lock Rams Service Procedure Pressure Testing General Pressure Testing Points Pressure Settings Pressure Relief Valve Location Main Relief Valve (MRV) Pressure Servo Relief Pressure Slew Motor Pressure Relief Auxiliary Relief Valves Servo Accumulator Brake Service Pressure Steer Stall System Pressure Clutch Pressure Park Brake Pressure Hydraulic Pump/Regulator Hydraulic Pump Removal and Replacement Removal Replacement Pump Hydraulic Circuit Diagram Hydraulic Pump/Regulator Hydraulic Pump Hydraulic Pump Dismantling and Assembly Dismantling Assembly Regulator Regulator Dismantiling and Assembly Remote Control Valve (Hand Control) Operation Function Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Inspection Assembly Fault Finding Travel Pedal Valve Dismantling and Assembly Dismantling Inspection Assembly Solenoid Valve (8 Spool) Operation Slew Brake. (CT1) Isolator. (CT2) Slew Lock. (CT3) Maximum flow cut. (CT4) 2 Stage travel. (CT5). Slew shut off (CT6) 2 Stage relief. (CT7) Boom Speed Regulator. (CT8) Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Inspection Assembly Shuttle Valve Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Inspection Assembly Solenoid Valve (3 Spool) Operation Drive Isloator (CT1) Axle Lock (CT2) Dig End Isolator (CT3) Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Inspection Assembly Cushion Valve Operation Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Inspection Assembly Slew Motor and Gearbox Removal and Replacement Removal Replacement Torque Settings Slew Motor Configuration Slew Motor Reduction Gear Reduction Gear Structure and Working Principles Motor Disassembly Dismantling Motor Re assembly Re assembly Gearbox Disassembly Dismantling Gearbox Inspection Gearbox Re assembly Re assembly Rotary Coupling Operation Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Assembly Drive Motor Operation Ports on Motor Body Ports A and B Description Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Assembly Steering Control Unit General Dismantling Assembly Priority Valve Removal and Replacement Dismantling and Assembly Hydraulic Rams Precautions During Use Installation Caution During Use Maintenance, Inspection Points Removal and Replacement Typical Bucket Ram Typical Boom Ram Typical Dipper Ram Typical Triple Articulated Boom (TAB) Ram Dismantling and Assembly Typical Boom, Dipper, Bucket and TAB Ram Dozer Rams Ram Piston Head Nut Removal and Fitting Reconditioning Procedures for inserting and bedding the seal ring. Bushing Removal Bushing Assembly Wiper Ring Assembly Cylinder Head Assembly Fault Finding Hydraulic Contamination Hydraulic Fluid Quality Effects of Contamination Cleaning Operation Contaminant Standards Filters Main Control Valve Relief Valve Hydraulic System Slew Motor Hydraulic Pump Hydraulic Rams Fault Finding Tests Slow or Underpowered: Harsh Operation When Selecting: Loss of Creep Speed Loss of High Speed Machine Selects High Speed Travel Slew Bearing Faults Test 001: Testing Negative Control Signal Test 002: Test Max Flow Signal/Drive Control Signal Test 003: Testing Main Pump Pressure Test 004: Testing Horsepower Control Test 005: Checking the Operation of the Main Hydraulic Spool Test 006: Testing Pressure Switches Symptoms of Pressure Switch Failures Test 007: Testing Engine Speed Settings Test 008: Testing Machine Cycle Times a Bucket Ram speed. b Dipper Ram speed c Boom Ram speed d Slew Speed Test 010: Testing Hose Burst Check Valves Dipper Ram Boom Ram TAB Ram Test 011: Testing Swing brake pressure Test 016: Flow testing Hydraulic Pumps To Confirm Minimum Flow Setting To Confirm Maximum Flow Setting To Confirm Horse Power Control Record Sheet Test 017: Testing Slew Bearing Checking Slew Bearing Backlash Checking Slew Bearing Vertical Lift Test 018: Testing Pump Milliamps Test 019: Testing Latch Brake Pressure Testing pressure Adjusting pressure Test 020: Testing for Trapped Air in HBCV Pilot Line Boom HBCV Installation Arm HBCV Installation Test 021: Testing the Operation of the Arm 2 Boost Spool Test 022: Testing Drive Motor Threshold Pressure Test 023: Checking Drive Motor Displacement Test 024: Testing Propshaft RPM Test 025: Testing Clutch Pack Pressure/Park Brake Pressure Test 026: Testing Condition of On Road Clutch Ram Creep Tests - All Services Test for Ram Creep
Section F - Transmission Front Axle Technical Data Unit Identification Identification Designation Removal and Replacement Removal Replacement Dismantle and Assembly Rear Axle Technical Data Unit Identification Identification Designation Removal and Replacement Removal Replacement Dismantle and Assembly Drive Gearbox Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Assembly Propshafts Removal and Replacement Removal Replacement Power Track Rod Removal and Replacement Removal Replacement