This workshop repair service manual PDF download for the JS130W, JS145W, JS160W, JS175W Auto Tier III 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, JS145W, JS160W, JS175W - Tier III Auto
JCB Wheeled Excavator JS130W - from S/N: 1060300 Onwards
JCB Wheeled Excavator JS145W - from S/N: 1314300 Onwards
JCB Wheeled Excavator JS160W - from S/N: 1421600 Onwards
JCB Wheeled Excavator JS175W - from S/N: 1505100 Onwards
This manual provides information for the following model(s) in the JCB machine range:
JCB JS130W from S/N: 01060300 to 01060999.
JCB JS145W from S/N: 01314300 to 01314599.
JCB JS145W from S/N: 01458000 to 01458999.
JCB JS145W from S/N: 01613000 to 1613999.
JCB JS160W from S/N: 01421600 to 01421799.
JCB JS160W from S/N: 01451000 to 01451999.
JCB JS175W from S/N: 01505100 to 01505284.
JCB JS175W from S/N: 01505286 to 01505499.
TABLE OF CONTENTS :
Section 1 - General Information
Section 2 - Care & Safety
Section 3 - 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
P/N : 9803/6590-3
Total Pages : 967
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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9803-6590-3
Section 1 - General Information
Introduction
About this Manual
Identifing Your Machine
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Hydraulic Connections
Service Tools
Numerical List
Tool Detail Reference
Service Consumables
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding
Section 2 - Care & Safety
Safety Notices
Important Information
Safety Check List
Safety Labels
Section 3 - Maintenance
Routine Maintenance
Service Requirements
Health and Safety
Service Schedules
Fluids, Lubricants and Capacities
Tools
Prepare the Machine for Maintenance
Cleaning the Machine
Check the Machine for Damage
Daily Checking
Greasing
Tyres and Wheels
Electrical System
Bolt and Nut Torque Specifications
Engine
Fuel System
Hydraulic System
Slew Gearbox
Drive Gearbox
Axles
Windscreen Washer
Fire Extinguisher (If fitted)
Troubleshooting
Section B - Body & Framework
Technical Data
Static Dimensions
Operating Weight
Tyre Pressures
Dig Depth Chart
Attachments
Air Conditioning (option)
Basic Operation
Automatic Temperature Control (ATC) System
Fault Finding
Air Conditioning
Service Procedures
HVAC/Air Conditioning Unit
Air Conditioning Compressor
Cab Structure
Cab Panels
Cab Panel Removal
Section C - Electrics
Basic System Operations
Circuit Symbols
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
ECU W Supply to Output Drivers
ECU W / LH Switch Panel Supply and Network
Hardware Sensing
Engine Throttle Control
Auto Boost Pressure
Engine Oil Level Warning
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
Wiper
Lower Wiper (option)
Washer
Horn
Travel Alarm - Optional
Slew Brake (100%)
Slew lock (100% Slew Brake)
Travel Mode
Cruise Control - Optional
Park Brake
3 Speed Travel
Work Lights (Boom and Cab)
Head Lights
Side Lights
Brake Lights
Indicators
Fog/Reversing Lights
Hazard Warning
Axle Lock
Stabilisers
Dozer
Viscous Fan
Fuel Level Sensor/Warning
Engine Temperature Sensor/Warning
Coolant Level Warning
Air Filter Blocked Warning
Warning Indicator Lamps
Hydraulic Temperature Sensor/Warning
Brake Pressure Warning
Engine Oil Pressure/Emergency Steering 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 + Mode Menu
EMS Set+Mode (20 sec) Menu.
Fault Finding
JCB Servicemaster
Fault Finding Without Using the JCB Service Master Diagnostic Tool
Service Procedure
Testing of ECU Inputs + Outputs
Using a Multimeter
Battery
Wiring Harness Repair
Harness Data
Main Harness - JS145W Type 1 With 8 Station
Main Harness - JS130W/JS145W Type 2 - With 8 Station
Main Harness - JS130W/JS145W Type 3 With Multi-Station
Main Harness - JS160W
Main Harness - JS175W
Wheeled Harness - Type 1 - With 8 Station
Wheeled Harness - Type 2 - With Multi-Station
Fascia Link Harness - Type 1
Fascia Link Harness - Type 2
Cab Harness - Type A
Engine Harness - Type A
Cab Harness (includes Engine Harness) - Type B
Cab Harness (includes Engine Harness) - Type C
Section D - Controls
Steering Column
Dismantling and Assembly
Section E - Hydraulics
Technical Data
General Data
Basic System Operation
Hydraulic Component Location
Introduction to Hydraulic Schematic Symbols
Circuit Descriptions
Hydraulic Schematic
Servo Line (With 8 Station)
Servo Line (With Multi-Station)
Servo Pressure and Return Line (With 8 Station)
Servo Pressure and Return Line (With Multi-Station)
Transmission Pilot Line (With 8 Station)
Transmission Pilot Line (With Multi-Station)
Chassis Hydraulics
Monoboom Hammer/Aux Hydraulics
Tab Hammer/Aux Hydraulics
Hydraulic Pump Operation
Hydraulic Pump Regulation
Neutral Circuit
Drive
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
Park Brake
Brake and Steering
Grab Rotate
Axle Lock Rams
Main Control Valve
Description
Port Identification
Hydraulic Pump/Regulator
Hydraulic Pump Removal and Replacement
Hydraulic Pump Dismantling and Assembly
Regulator
Coupling
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
Solenoid Valve (3 Spool)
Operation
Removal and Replacement
Dismantling and Assembly
Multi-function Valve (if fitted)
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 Re assembly
Gearbox Disassembly
Gearbox Inspection
Gearbox Re assembly
Rotary Coupling
Operation
Removal and Replacement
Dismantling and Assembly
Drive Motor
Operation
Description
Removal and Replacement
Dismantling and Assembly
Steering
Control Unit
Priority Valve
Hydraulic Rams
Precautions During Use
Removal and Replacement
Dismantling and Assembly
Ram Piston Head Nut
Reconditioning
Service Procedure
Make the Machine Safe
Pressure Testing - General
Pressure Relief Valve Location
Main Relief Valve (MRV) Pressure
Servo Relief Pressure
Slew Motor Pressure Relief
Auxiliary Relief Valves
Dozer/Stabilisers
Brake Service Pressure
Steer Stall System Pressure
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/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
Test 007: Testing Engine Speed Settings
Test 008: Testing Machine Cycle Times
Test 011: Testing Swing brake pressure
Test 016: Flow testing Hydraulic Pumps
Test 017: Testing Slew Bearing
Test 018: Testing Pump Milliamps
Test 019: Testing Latch Brake Pressure
Test 020: Testing for Trapped Air in HBCV Pilot Line
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
Section F - Transmission
Front Axle
Technical Data
Unit Identification
Removal and Replacement
Dismantle and Assembly
Rear Axle
Technical Data
Unit Identification
Removal and Replacement
Dismantle and Assembly
Drive Gearbox
Description
Removal and Replacement
Dismantle and Assembly
Propshafts
Removal and Replacement
Power Track Rod
Removal and Replacement
Section K - Engine
Technical Data
JS Wheeled Tier III
Engine Error Codes
Fault Finding
Engine Components
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