JCB JS115, JS130, JS130LC, JS145, JS160, JS180 Tracked Excavator Repair Service Manual

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This service manual PDF download for the JS115, JS130, JS130LC, JS145, JS160, JS180 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

JCB JS115 Auto - from S/N 11680031 to 1168999
JCB JS130 Auto - from S/N 1058100 to 1058999 and 1179000 to 1179999
JCB JS130 LC Auto - from S/N 1180001 Onwards
JCB JS145 Auto - from S/N 1289000 to 1289999
JCB JS160 Auto - from S/N 1059000 to 1059999
JCB JS180 Auto - from S/N 1059000 to 1059999
JCB JS190 Auto - from S/N 1224000 to 1224499 and 1238000 to 1238999


TABLE OF CONTENTS :

Section 1 - General Information
Section 2 - Care & Safety
Section 3 - Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track & Running Gear
Section K - Engine


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/6520-3
Total Pages : 772


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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9803-6520-3
Service Manual

Section 1 - General Information
Section 1
Introduction
About this Publication
Schematic Codes
Identifying your Machine
Identifying Your Machine
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
Numerical List Section F - Transmission
Tool Detail Reference Section F - Transmission
Service Consumables
Sealing and Retaining Compounds

Section 2 - Care & Safety
Section 2
Safety Notices
Introduction
Safety Check List
Safety - Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Decals
Safety Decal Recognition

Section 3 - Maintenance
Section 3
Routine Maintenance
Service Requirements
Health and Safety
Service Schedules
Lubricants and Capacities
Cleaning the Machine
Checking for Damage
Daily Checking
Bolt and Nut Torque Specifications
Checking the FOPS Structure
Seat Belt
Greasing
Electrical System
Engine
Fuel System
Hydraulic System
Travel Gearbox
Tracks and Running Gear
Bucket
Windscreen
Troubleshooting

Section B - Body & Framework
Section B
Technical Data
Static Dimensions
Dig Depth Chart
Shipping Weight
Attachments
Air Conditioning (option)
Basic Operation
Air Conditioning
Fault Finding
Air Conditioning
Service Procedures
HVAC/Air Conditioning Unit
Air Conditioning Compressor
Cab Structure
Cab Panels
Cab Panel Removal

Section C - Electrics
Section C
Technical Data
Fuses
Basic System Operation
Controls and Components
Driver Controls and Switches
Operating Levers/Pedals
Circuit Symbols
Component Identification
Schematic Diagram
A.M.S (Advanced Management System)
Circuit Concepts
Pulse Width Modulation (PWM)
ECU1/EMS/FACIA Power Supply and Network
ECU 1 Supply to Output Drivers
Engine Throttle Control
Auto Boost Pressure
Engine Reverse Rotation Prevention
Engine Pre Heat (Glow plugs)
Engine Automatic Warm Up
Engine Automatic Idle
Engine One Touch Idle
Engine Start/Stop
Limp Mode system
Pump Control for Each Mode
Lever Lock
Servo Isolator
Wiper
Lower Wiper (option)
Washer
Horn
Travel Alarm
Soft/Hard (Cushion)
Slew Brake (100%)
Slew lock (100% Slew Brake)
Slew Brake Solenoid Valve Failure.
3-Speed Travel
Work Lamps
Fuel Level Sensor/Warning
Engine Temperature Sensor/Warning
Coolant Level Warning
Air Filter Blocked Warning
Warning Indicator Lamps
Hydraulic Temperature Sensor/Warning
Alternator/ No Charge Warning
Quick hitch (option)
Overload Caution (option)
Beacon
Grab/rotate
Hammer
Scrap Magnet Option
Cab Interior Lamp
Refuelling Pump
Air Conditioning
Heated Seat
24 to 12 Volt Converter, Radio and Cigar Lighter
Service Required Warning
EMS Set Menu.
EMS Set + Mode (5 Sec) Menu
EMS Set+Mode (20 sec) Menu.
Fault Finding
JCB Service Master
Using Service Master
Selecting Service Tool Applications
Service Master 2 Machine Pages
System Menus
HPSetup Overview
Using HPSetup
DLA Port Configuration
Data Link Adaptor
HPDataLogs
FLASH Programming Application
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.
Fault Finding Without using the JCB Service Master Diagnostic Tool
Service Procedure
Testing of ECU Inputs + Outputs
Wiring Harness Repair
Battery
Harness Data
Main Harness
Facia Link Harness
Cab Harness

Section E - Hydraulics
Section E
Technical Data
General Data
Basic System Operation
Hydraulic Component Location
Introduction to Hydraulic Schematic Symbols
Circuit Descriptions
Hydraulic Schematics
Servo Line
Servo Pressure and Return Line
Main Control Valve
Hydraulic Pump Operation
Hydraulic Pump Regulation
Neutral Circuit
Straight Line Travel
Travel - Middle Speed
Travel motor operation (Middle speed)
Slow speed travel (Creep)
Travel motor operation (High speed)
Boom Up
Boom Down
Dipper Out
Dipper In
Bucket Opening
Bucket Close
Slew Circuit
100% Slew Lock
Auxiliary Flow
Hammer
ISO/SAE Controls
Service Procedure
Pressure Testing - General
Pressure Relief Valve Location
Main Relief Valve (MRV) Pressure
Servo Relief Pressure
Slew Motor Pressure Relief
Auxiliary Relief Valves
Travel Motor Relief Pressure
Hydraulic Pump/Regulator
Hydraulic Pump Removal and Replacement
Hydraulic Pump Dismantling and Assembly
Regulator
Remote Control Valve (Hand Control)
Operation
Removal and Replacement
Dismantling and Assembly
Travel Pedal Valve
Dismantling and Assembly
Solenoid Valve (8 Spool)
Operation
Removal and Replacement
Dismantling and Assembly
Shuttle Valve
Removal and Replacement
Dismantling and Assembly
Cushion Valve
Operation
Removal and Replacement
Dismantling and Assembly
Slew Motor and Gearbox
Removal and Replacement
Slew Motor Configuration
Motor Disassembly
Motor Reassembly
Gearbox Disassembly
Gearbox Inspection
Gearbox Reassembly
Rotary Coupling
Operation
Removal and Replacement
Dismantling
Assembly
Hydraulic Rams
Precautions During Use
Removal and Replacement
Dismantling and Assembly
Ram Piston Head Nut
Reconditioning
Fault Finding
Hydraulic Contamination
Main Control Valve
Relief Valve
Hydraulic System
Slew Motor
Hydraulic Pump
Hydraulic Rams
Fault Finding Tests
Test 001: Testing Negative Control Signal
Test 002: Test Max Flow 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
Test 007: Testing Engine Speed Settings
Test 008: Testing Machine Cycle Times
Test 010: Testing Hose Burst Check Valve - Dipper Ram
Test 011: Testing Swing brake pressure
Test 012: Testing Track Motor Relief Valve Settings
Test 013: Testing Track Motor Drain Line Flow Rate
Test 014: Loss of High Speed Tracking
Test 015: High Gear Selection, Monitor Displays Another Travel Gear
Test 016: Flow testing Hydraulic Pumps
Test 016 - Flow Testing Hydraulic Pumps - Record Sheet
Test 017: Testing Slew Bearing
Ram Creep Tests - All Services

Section F - Transmission
Section F
Technical Data
Travel Equipment
JS115 - JS145
JS160 - JS180
Fault Finding
Introduction
Fault Finding
Track Motor
Removal and Replacement
Removal
Precautions during Installation
Replacement
Start Up and Running In
Start Up
Running In
Dismantling and Assembly
Dismantling
Inspection
Assembly
Track Gearbox
Dismantling and Assembly
Dismantling
Inspection
Assembly

Section J - Track & Running Gear
Section J
Technical Data
Torque Specifications
Idler Wheel and Recoil Unit
Removal
Replacement
Idler Wheel
Dismantling
Assembly
Wear Limits
Recoil Unit
Dismantling
Assembly
Grease Cylinder
Dismantling
Assembly
Drive Sprocket
Removal
Replacement
Wear Limits
Top Roller
Removal
Replacement
Dismantling
Assembly
Bottom Roller
Removal
Replacement
Dismantling
Assembly
Wear Limits

Section K - Engine
Technical Data
JS115 - JS180

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