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

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support 9803/6520-3 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual JS115 - JS180 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

Section 0 - Service Manual 0 - 0 0 - 0 9803/6520-3 Page left intentionally blank

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support 9803/6520-3 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Section 1 General Information 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

Section 0 - Service Manual 0 - 0 0 - 0 9803/6520-3 Page left intentionally blank

Page No. Contents Section 1 - General Information 1 - i 1 - i Introduction About this Publication .............................................................................. 1 - 1 Schematic Codes .................................................................................... 1 - 2 Identifying your Machine Identifying Your Machine ......................................................................... 1 - 3 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1 - 5 Hydraulic Connections ............................................................................. 1 - 9 Service Tools Numerical List Section B - Body and Framework .................................. 1 - 13 Tool Detail Reference Section B - Body and Framework ...................... 1 - 14 Numerical List Section C - Electrics ...................................................... 1 - 17 Tool Detail Reference Section C - Electrics ........................................... 1 - 18 Numerical List Section E- Hydraulics .................................................... 1 - 20 Tool Detail Reference Section E- Hydraulics ......................................... 1 - 22 Numerical List Section F - Transmission ............................................... 1 - 30 Tool Detail Reference Section F - Transmission .................................... 1 - 31 Service Consumables Sealing and Retaining Compounds ....................................................... 1 - 33

Page No. Contents Section 1 - General Information 1 - ii 1 - ii

Section 1 - General Information 1 - 1 1 - 1 9803/6520-03 Introduction About this Publication This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 1 General Information - includes torque settings and service tools. 2 Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. 3 Routine Maintenance - includes service schedules and recommended lubricants for all the machine. The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual. Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards. A Attachments B Body & Framework...etc. This Service Manual covers the following machines: JS115 JS130 JS130LC JS145 JS160 JS180

Section 1 - General Information Introduction Schematic Codes 1 - 2 1 - 2 9803/6520-03 Schematic Codes Colour Codes The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. Red Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and MRV operating pressure. Pink Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red. Orange Servo: Oil pressure used in controlling a device (servo). Blue Neural: Neutral circuit pressure. Green Exhaust: Light Green Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation). Yellow Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).

Section 1 - General Information 1 - 3 1 - 3 9803/6520-03 Identifying your Machine Identifying Your Machine Data Plate Your machine has a Data Plate, located on the outside the cab as shown at A. The machine serial number is inscribed at B which is the baseplate of the rear frame and the engine number is at C. Fig 1. Fig 2. Typical Product Identification Number (PIN) 1 World Manufacturer Identification (JCB) 2 Machine Type and Model ( JS13C = JS130 Tracked) 3 Randomly generated check letter. 4 Year of Manufacture (1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004, 5 = 2005, 6 = 2006) 5 Machine Serial Number (1018354) 1 2 3 4 5 JCB JS13C C 6 1018354

Section 1 - General Information Identifying your Machine Identifying Your Machine 1 - 4 1 - 4 9803/6520-03 Typical Engine Identification Number If the engine is replaced by a new one, the data plate serial number will be wrong. Either stamp the new number on the plate or stamp out the old one. This will prevent the wrong number being quoted when you order replacement parts. Fig 3. a Engine Type (AB= 4 cylinder turbo) b Engine Parts List c Country of Manufacture d Engine Serial Number e Year of Manufacture a b c d e AB 50316 J 000001 2

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

You're Reading a Preview

Recently Viewed