JCB JS115, JS130, JS145 Tracked Excavator Repair Service Manual
JCB JS115, JS130, JS145 Tracked Excavator Repair Service Manual
- This service manual PDF download for the JS115, JS130, JS145 Auto Tier III 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 JS115, JS130, JS145 - Tier III Auto
JCB JS115 - from S/N: 1703500 to 1703599 and 1777500 to 1777999 JCB JS130 - from S/N: 1703500 to 1703599 JCB JS145 - from S/N: 1600011 to 1600999
This manual provides information for the following model(s) in the JCB machine range: JCB Tracked Excavator JS115 - from S/N: 1703500 to 1703599. JCB Tracked Excavator JS115 - from S/N: 1777500 to 1777999. JCB Tracked Excavator JS130 - from S/N: 1535000 to 1535999. JCB Tracked Excavator JS145 - from S/N: 1600011 to 1600999.
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. : 9803/9860-4 Total Pages : 883
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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9803-9860-4
Section 1 - General Information Introduction About this Manual Machine Model and Serial Number Using the Service Manual Section Numbering Left Side, Right Side Cross References Identifying Your Machine Machine Identification Plate Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Introduction Bolts and Screws Hydraulic Connections 'O' Ring Face Seal System 'Torque Stop' Hose System Service Tools Numerical List Tool Detail Reference Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section K - Engine Service Consumables Sealing and Retaining Compounds Terms and Definitions Colour Coding Hydraulic Schematic Colour Codes
Section 2 - Care & Safety Safety Notices Important Information The Operator Manual Safety Warnings Safety Check List Safety - Yours and Others General Safety Operating Safety Maintenance Safety Safety Labels Introduction Safety Label Identification
Section 3 - Maintenance Routine Maintenance Service Requirements Introduction Owner/Operator Support Service/Maintenance Agreements Fit for Purpose Tests for Lifting Equipment Obtaining Replacement Parts Health and Safety Lubricants Battery Service Schedules Introduction How to Use the Service Schedules Calendar Equivalents Pre Start Cold Checks, Service Points and Fluid Levels Functional Test and Final Inspection Service Intervals for Attachments Periodic Replacement of Safety Related Components Fluids, Lubricants and Capacities JS115 - JS145 and Variants JS160 - JS190 and Variants JS200 - JS235 and Variants JS240/260 and Variants JS290 and Variants JS330 and Variants JS360 and Variants Engine Lubrication Chart Hydraulic Oil Chart Typical Lubrication Chart Coolant Mixtures Fuel Tools Carrying Tools onto the Machine Locations Prepare the Machine for Maintenance Introduction How to Make the Machine Safe (Excavator Lowered) Cleaning the Machine Introduction Preparing the Machine for Cleaning Cleaning the Machine Cleaning the Tracks Cleaning the Radiator and Oil Cooler Checking for Damage Check the Machine Body and Structure Check the Seat and Seat Belt Checking the FOPS Structure Daily Checking Greasing Introduction Slew Ring Bearing Slew Ring Teeth and Slew Pinion Greasing Points Electrical System Battery Jump-Starting the Engine Fuses Bolt and Nut Torque Specifications JS115 - JS360 and Variants Engine Oil and Filter Cooling System Fan Belt Engine Air Filter Fuel System Introduction Draining Fuel Tank Impurities Draining the Primary Filter/Sedimenter Changing the Primary Filter/Sedimenter Element Changing the Fuel Feed Pump Filter Draining the Main Filter/Sedimenter Changing the Main Filter/Sedimenter Element Bleeding the System Hydraulic System Introduction Releasing Tank Pressure Releasing the Hydraulic Pressure Oil and Filters Draining Water and Sediment from the Hydraulic Tank Air Bleeding Procedures Slew Gearbox Checking the Slew Gearbox Oil Level Changing the Slew Gearbox Oil Tracks and Running Gear Tracks Running Gear Bucket Checking/Adjusting For Side Play Windscreen Washer Checking the Level Fire Extinguisher (If fitted) Troubleshooting Engine and Related Area Monitor Display - Fault Messages Operations Hydraulic pump Working Attachments Travel Slew Hydraulic ram
Section B - Body & Framework Technical Data Static Dimensions JS115 - Monoboom JS130LC - Monoboom JS130/JS145 - Monoboom JS130/JS145 - Triple Articulated Boom Shipping Weight Dig Depth Chart JS115 - Monoboom JS130LC - Monoboom JS130/JS145 - Monoboom JS130/JS145 - Triple Articulated Boom Air Conditioning (option) Automatic Temperature Control (ATC) System Basic Operation Automatic Temperature Control (ATC) System Heater/Air Conditioning Controls (ATC) Air Conditioning System Operation ATC Control Panel Safety Procedures Fault Finding Air Conditioning Preliminary Checks Error Codes / Error Diagnosis (Automatic Temperature Control (ATC) System) Service Procedures HVAC/Air Conditioning Unit Removal Replacement Air Conditioning Compressor Removal Replacement 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 Basic System Operation Circuit Symbols Inputs and Outputs Component Identification JS115/130/145 Schematic Diagram 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 Engine Throttle Control Operation Engine Throttle Control for Each Mode Pump Control for Each Mode Operation Hardware Sensing Operation Auto Boost Pressure Operation Engine Oil Level Warning 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 Lever Lock Operation Servo Isolator Operation Wiper Operation Lower Wiper (option) Operation Washer Operation Horn Operation Travel Alarm Operation Soft/Hard (Cushion) Operation Slew Brake (100%) Operation Slew lock (100% Slew Brake) Operation Slew Brake Solenoid Valve Failure Operation 3-Speed Travel Operation "E" Economy, "P" Precision & "A" Auto Modes Relationship between Travel Modes A / E + P, travel motor swash plate position and Pump "Q max cut output" "L" Lifting Mode Work Lamps Operation Viscous Fan Operation Fuel Level Sensor/Warning Operation Engine Temperature Sensor/Warning Operation Coolant Level Warning Operation Air Filter Blocked Warning Operation Hydraulic Temperature Sensor/Warning Operation Alternator/No Charge Warning Operation Quick hitch (option) Operation Overload Caution (option) Operation Beacon Operation Hammer Only Operation Scrap Magnet Option Operation Cab Interior Lamp Operation Refuelling Pump Operation Air Conditioning Heated Seat Operation Radio and Cigar Lighter Operation Service Required Warning Operation Cancellation of the Service indicator EMS Set Menu EMS Set + Mode Menu EMS Set+Mode (20 sec) Menu. Service Off Solenoid Override Horse Power Control Data Logging Facility Throttle Calibration Fault Finding JCB Servicemaster Introduction Using Servicemaster Selecting Service Tool Applications JS Machine Pages System Menus Using ECM Setup HPSetup Overview 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 Electrical Fault Text Messages Displayed on the EMS. Fault Finding Without Using the JCB Servicemaster 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 (FSP) Service Procedure Testing of ECU Inputs + Outputs Testing Low Side Input Testing High Side Input Testing Low Side Output Testing High Side Output Using a Multimeter Measuring DC Voltage Measuring Resistance Measuring Continuity Measuring Frequency Testing a Diode or a Diode Wire Battery Maintenance Testing Specific Gravity Testing Wiring Harness Repair Introduction Repair Procedure Harness Data Harness Interconnection Main Harness Fascia Link Harness - Type 1 Connector Location Connector Identification Fascia Link Harness - Type 2 Connector Location Connector Identification Fascia Link Harness - Type 3 Connector Location Connector Identification Cab Harness - Type A Connector Location Connector Identification Engine Harness - Type A Connector Identification Cab Harness (includes Engine Harness) - Type B Connector Identification Cab Harness (includes Engine Harness) - Type C Connector Identification Cab Harness (includes Engine Harness) - Type D (Live Link 1) Connector Identification Cab Harness (includes Engine Harness) - Type E (Live Link 2) Connector Identification Live Link 1 Harness Live Link 2 Harness
Section E - Hydraulics Technical Data General Data Main Hydraulic Pump Servo Pump Proportional Pressure Reducing Valve Slew Motor Main Control Valve Spool Stroke versus Pilot Pressure Boom Ram Dipper Ram Bucket Ram 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 Schematics JS115 JS130/145 Servo Line Components Servo Pressure and Return Line Components Hydraulic Pump Regulation Neutral Circuit Straight Line Travel Travel - Middle Speed Boom Up Boom Down Dipper Out Dipper In Bucket Opening Bucket Close Slew Circuit Slew over Dipper Priority (A) 100% Slew Lock Auxiliary Flow Hammer ISO/SAE Controls Main Control Valve Description Hydraulic Pump/Regulator Hydraulic Pump Operation Main Pumps (P1 and P2) Pump Hydraulic Circuit Diagram Hydraulic Pump/Regulator Exploded View Hydraulic Pump/Regulator Plan View Hydraulic Pump Removal and Replacement Removal Replacement Hydraulic Pump Dismantling and Assembly Dismantling Assembly Regulator Dismantling and Assembly Dismantling Assembly Coupling 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) Boom Priority (CT6) 2 Stage relief (CT7) Cushion control (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 Cushion Valve Operation Cushioned Mode - Hand Controller In Neutral Cushioned Mode - Hand Controller at Dipper In Cushioned Mode - Hand Controller Moved from Dipper In to Neutral Cushion Control Off Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Inspection Assembly Slew Motor Motor Operating Principles Slew Brake Operation Fault Finding Motor Does Not Rotate Motor Rotates in the Reverse Direction Motor Speed is Low Motor Brake Working Poorly Motor is Driven by Exterior Torque Oil Leakage Removal and Replacement Removal Replacement Slew Motor Configuration Dismantling and Assembly Dismantling Assembly Slew Motor Reduction Gearbox Assembly Reduction Gear Structure and Working Principles Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Inspection Assembly Rotary Coupling Operation Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling 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 Dismantling the Piston Rod from the Cylinder Tube Dismantling the Piston Rod Removing the Piston Seals Removing the Cylinder Head Seals Assembly of Piston Seals Assembling the Cylinder Head Seals Assembly of the Piston Rod Assembly of Piston Rod in Cylinder Tube Maintenance Specifications Use Limit Service Procedure Make the Machine Safe Pressure Testing - General Confirmation of the Oil Temperature Warming-up Procedure Pressure Testing Points Pressure Relief Valve Location Main Relief Valve (MRV) Pressure Servo Relief Pressure Auxiliary Relief Valves General Boom Ram Dipper Ram Bucket Ram Option ARV (Monoboom) Slew Motor Pressure Relief Travel Motor Relief Pressure 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 Hydraulic Ram Faults and Remedies Fault Finding Tests Slow or Underpowered: Harsh Operation When Selecting: Tracking Off Line Poor Tractive Effort 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 Test 003: Testing Main Pump Pressure Test 004: Testing Horsepower Control Test 005: Checking the Operation of the Main Hydraulic Spool Test 006: Test the Pressure Switches Symptoms of Pressure Switch Failures Test 007: Testing Engine Speed Settings Pressure Switches vs Engine Speed Test 008: Testing Machine Cycle Times Bucket Ram Speed Dipper Ram Speed Boom Ram Speed Slew Speed Travel Speed Travel Linearity 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 Additional information Test 015: High Gear Selection, Monitor Displays Another Travel Gear Test 016: Flow testing Hydraulic Pumps To Confirm Minimum Flow Setting To Confirm Maximum Flow Setting To Confirm Horse Power Control Test 016 - Flow Testing Hydraulic Pumps - Record Sheet Test 017: Testing Slew Bearing Checking Slew Bearing Backlash Checking Slew Bearing Vertical Lift Ram Creep Tests - All Services Test for Ram Creep
Section F - Transmission Technical Data Travel Equipment JS115 JS130 JS145 Fault Finding Transmission Traction Motor Parking Brake Relief Valve Counterbalance Valve Speed Range Changing Track Motor Description Operation Middle Speed Slow Speed Travel (Creep) High Speed Removal and Replacement Removal Precautions During Installation Replacement Start Up and Running In Start Up Running In Track Motor Dismantling and Assembly Dismantling Inspection Assembly Track Gearbox Dismantling and Assembly Dismantling Inspection Assembly
Section J - Track & Running Gear Technical Data Torque Specifications Idler Wheel and Recoil Unit Removal Replacement Idler Wheel Dismantling Assembly Recoil Unit Dismantling and Assembly Dismantling Assembly Grease Cylinder Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Assembly Drive Sprocket Removal and Replacement Removal Replacement Top Roller Removal Replacement Dismantling Assembly Bottom Roller Removal Replacement Dismantling Assembly
Section K - Engine Technical Data JS115/130/145 Engine Mounts Engine Error Codes Fault Finding Engine Components 4HK/6HK 4JJ Engine Coolant Temp Sensor Overheat Switch Common Rail Pressure Sensor Engine Oil Pressure Sensor Crankshaft Position (CKP) Sensor - 4HK/ 6HK Crankshaft Position Sensor - 4JJ Camshaft Position (CMP) Sensor - 4HK/ 6HK Camshaft Position (CMP) Sensor - 4JJ Exhaust Gas Re-circulation (EGR) Valve Suction Control Valve Fuel Temperature (FT) Sensor Boost Temperature Sensor Boost Pressure Sensor Injector Glow Plug Engine Oil Level Sensor Air Intake Temperature Sensor Barometric Pressure Switch Schematics