PDF Service Repair Manual JCB JS115 JS130 JS145 Excavator - 5 MB
This comprehensive service repair manual covers the JCB excavator models JS115, JS130, and JS145, including T23 variants.
It's the ultimate guide for technicians, containing step-by-step instructions for every repair and maintenance procedure imaginable.
With detailed diagrams and specifications, this manual empowers you to perform everything from routine service to complete overhauls.
Trust this factory-approved information to get the job done right.
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--- Page 1 ---
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
SERVICE MANUAL Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
EXCAVATOR
JS115, JS115 [T2/3], Contents
JS130, JS130 [T2/3], JS145
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
27 - Driveline
EN - 9813/7050 - ISSUE 1 - 04/2018
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
75 - Consumable Products
78 - After Sales
Copyright 2017 © 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.
www.jcb.com
--- Page 3 ---
01 - Machine
03 - Safety
24 - Risk Assessment
24 - Risk Assessment Loading/Unloading Area
• Is it level? Any slope of more than 2.5% (1 in
Introduction 40) must be carefully considered.
• Is more than one direction of approach to the
load possible? Approaching across the slope
It is the responsibility of the competent people that must be avoided, if possible.
plan the work and operate the machine to make a • Is the ground solid? Will it support the weight of
judgement about the safe use of the machine, they the machine when loaded?
must take into account the specific application and • How rough is the ground? Are there any
conditions of use at the time. sharp projections which could cause damage,
particularly to the tyres?
It is essential that a risk assessment of the work to be • Are there any obstacles or hazards in the area,
done is completed and that the operator obeys any for example, debris, excavations, manhole
safety precautions that the assessment identifies. covers, power lines?
• Is the space sufficient for safe manoeuvring?
If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be
a specific task, contact your JCB dealer who will be in or to enter the area while operations are in
pleased to advise you. progress?
The following considerations are intended as
suggestions of some of the factors to be taken into The Route to be Travelled
account when a risk assessment is made. Other • How solid is the ground, will it provide sufficient
factors may need to be considered. traction and braking? Soft ground will affect the
stability of the machine and this must be taken
A good risk assessment depends on the training and into account.
experience of the operator. Do not put your life or the • How steep are any slopes, up/down/across?
lives of others at risk. A cross slope is particularly hazardous, is it
possible to detour to avoid them?
Personnel
• Are all persons who will take part in the Weather
operation sufficiently trained, experienced and • How windy is it? High wind will adversely affect
competent? Are they fit and sufficiently rested? the stability of a loaded machine, particularly if
A sick or tired operator is a dangerous operator. the load is bulky.
• Is supervision needed? Is the supervisor • Is it raining or is rain likely? The ground that
sufficiently trained and experienced? was solid and smooth when dry will become
• As well as the machine operator, are any uneven and slippery when wet, and it will not
assistants or lookouts needed? give the same conditions for traction, steering
or braking.
The Machine
• Is it in good working order?
• Have any reported defects been corrected?
• Have the daily checks been carried out?
• Are the tyres still at the correct pressure and
in good condition and is there sufficient fuel to
complete the job (if applicable)?
The Load
• How heavy is it? Is it within the capabilities of
the machine?
• How bulky is it? The greater the surface area,
the more affected it will be by wind speeds.
• Is it an awkward shape? How is the weight
distributed? Uneven loads are more difficult to
handle.
• Is there a possibility of the load shifting while
being moved?
01 - 11 9813/7050-1 01 - 11
--- Page 4 ---
01 - Machine
09 - Description
15 - Service Point Locations
Figure 9. Hydraulic compartment - T4f
B
A
C
A Engine fuel filter B Main fuel filter
C Engine oil filter
01 - 27 9813/7050-1 01 - 27
--- Page 5 ---
03 - Attachments, Couplings and Load Handling
10 - Excavator End Quickhitch
06 - Hydraulic Quickhitch
Figure 17. Electrical Schematic- Quickhitch Unlocked
A Q/H BUTTON PRESSED
ECU: HYDRAULIC
CONTROL ECU (J2)
C154
C095
JOYSTICK RH HANDLE
CAB BASE EARTH
POINT (INT) (EP07)
REVOLVER EARTH
STUD (EP03)
C155
SOLENOID: QUICK HITCH
C085
LIGHT: QUICK HITCH BOOM STATUS
REVOLVER EARTH
STUD (EP03)
ECU: HYDRAULIC
CONTROL ECU (J1)
C153
A Quickhitch joystick control switch pressed C095 Joystick control switch - quickhitch
C153 HECU-connector J1 C154 HECU-connector J2
C155 Solenoid - quickhitch control valve
03 - 11 9813/7050-1 03 - 11
--- Page 6 ---
06 - Body and Framework
15 - Excavator End
03 - Boom
Figure 22.
2
1
3
4
1
8 5
7 A
6
4 9
8
1 Shims 2 Dust seals
3 Bush 4 Boom
5 Locknuts 6 Boom pivot pin
7 Bolt 8 Revolving chassis
9 Boom rams pivot pin A Bolt clearance dimension
06 - 13 9813/7050-1 06 - 13
--- Page 7 ---
06 - Body and Framework
24 - Slew Ring
00 - General
00 - General
Introduction
The slew ring bearing is a rotational rolling-element
bearing that supports the heavy but slow-turning
upper structure. They often use three race elements,
such as an inner ring and two outer ring halves that
clamp together axially. Slew ring bearings are made
with gear teeth integral with the inner or outer race,
used to drive the platform relative to the base.
06 - 29 9813/7050-1 06 - 29
--- Page 8 ---
06 - Body and Framework
66 - Tools
66 - Tools
Contents Page No.
06-66-00 General ........................................................................................................................... 06-47
06-66-03 Toolbox ........................................................................................................................... 06-48
06 - 45 9813/7050-1 06 - 45
--- Page 9 ---
09 - Operator Station
09 - Window
09 - Window
Contents Page No.
09-09-00 General ............................................................................................................................. 09-9
09 - 7 9813/7050-1 09 - 7
--- Page 10 ---
09 - Operator Station
27 - Controls
27 - Controls
Contents Page No.
09-27-01 Controls Isolation ........................................................................................................... 09-25
09-27-09 Excavator End ................................................................................................................ 09-31
09-27-27 Auxiliary Circuit .............................................................................................................. 09-33
09-27-30 Track ............................................................................................................................... 09-34
09 - 23 9813/7050-1 09 - 23
--- Page 11 ---
09 - Operator Station
30 - Trim Panel
30 - A-Post Trim
30 - A-Post Trim
Remove and Install
2. Remove the stowage plate
Components, such as electrical switches, locate in
some of the cab trim panels. During removal and 3. Remove the instruments.
installation be sure to disconnect and reconnect the
applicable harness connectors. 4. Remove two screws and associated nylon
washers.
Remove 5. Remove two bolts and associated nylon
washers.
1. Make the machine safe.
Refer to: PIL 01-03. 6. Lift off the A-post trim panel.
Figure 79.
B
C
A
D
C
B
A A-post trim panel B Bolts
C Screws D Stowage plate
6.1. Do not force the trim panels away from the
cab frame, be sure to remove all the fixings.
09 - 39 9813/7050-1 09 - 39
--- Page 12 ---
12 - Heating, Ventilating and Air-Conditioning (HVAC)
00 - Heating, Ventilating and Air-Conditioning (HVAC)
00 - General
Operation Cool de-humidified air is emitted through air vents
into the cab.
Air Conditioning Operation The low temperature, low pressure, high heat
content refrigerant gas, is now drawn by suction back
To maintain optimum operator comfort in warm to the compressor, where the cycle is completed.
climates or during seasons of high ambient
temperature, the air conditioning system re- ATC Control Panel (User Interface)
circulates, clean, dehumidified air into the cab.
Cooling is provided by passing the recirculated air, The ATC (Automatic Temperature Control) system
over an evaporator coil in the air conditioning unit. includes an electronic control system that protects
the system components if a problem occurs. The
The air conditioning system is a closed circuit control panel (user interface) lets the operator control
through which the refrigerant is circulated, its state the cab temperature, blower fan speed and air flow
changing from gas to liquid and back to gas again, direction. The system status is shown on the LCD
as it is forced through the system. (Liquid Crystal Display). The control panel (user
Interface) is connected to the ATC electronic control
The major components of the system are the unit. The ATCunit monitors the inputs and controls
compressor, condenser, receiver drier, expansion the outputs in the system as selected by the operator
valve and evaporator matrix. and as the temperature conditions change. If a
system problem occurs, the LCD shows an error
Air conditioning system power is generated from code.
the engine, via an electromagnetic clutch to the
compressor. Figure 84. Control Panel (User Interface)
The compressor, draws in low pressure refrigerant
gas from the suction line (evaporator to
compressor) and increases refrigerant pressure
through compression. This process also increases
the refrigerant temperature.
High pressure refrigerant is forced from the
compressor to the condenser, which is mounted
on the radiator on the side of the engine. Ambient ATC System Inputs
air is drawn across the condenser by the engine-
driven cooling fan. In the condenser, the refrigerant High Pressure Switch
changes state to a high pressure, high temperature
liquid but with a lower heat content. The high pressure switch is on the receiver drier. The
switch is an input used to monitor the fluid pressure
The refrigerant passes through the receiver drier, in the high pressure side of the system. The switch
which contains a desiccant to remove moisture from tells the control panel when the high pressure is
the system. The receiver drier serves as a reservoir abnormal.
for refrigerant and also includes a filter to remove
foreign particles from the system. Low Pressure Switch
The high temperature, high pressure refrigerant is The low pressure switch is in the HVAC (Heating
forced by compressor action into the expansion Ventilation Air Conditioning) unit. The switch is used
valve, which meters the amount of refrigerant to monitor the low pressure gas on the low pressure
entering the evaporator. In the expansion valve the side of the system. The switch tells the control panel
refrigerant instantaneously expands to become a low when the low pressure is abnormal.
pressure, low temperature liquid.
Evaporator Temperature Sensor
The refrigerant is drawn through the evaporator
matrix, by the suction of the compressor. The The evaporator temperature sensor is in between
temperature of refrigerant is now considerably below the evaporator cores in the HVAC unit in the cab.
that of the air being drawn across the evaporator The sensor tells the control panel the evaporator
matrix by the blowers. Heat is transferred from temperature. This temperature is for control of the
the ambient and re-circulated air to the refrigerant, compressor clutch and output to stop the evaporator
causing the low pressure liquid to vaporise and cores freezing.
become a low pressure gas. Moisture in the air
condenses on the evaporator matrix and is drained
away via condensate.
12 - 7 9813/7050-1 12 - 7
--- Page 13 ---
12 - Heating, Ventilating and Air-Conditioning (HVAC)
03 - HVAC Unit
00 - General
Remove and Install
4.1. Depending on the machine variant, other
Remove components may be installed on the HVAC
unit casing. Move components clear as
Before removing the HVAC (Heating Ventilation Air necessary.
Conditioning) unit, the air conditioning system must
be discharged. 5. Disconnect the HVAC electrical harness
connector.
1. Make the machine safe. 6. Disconnect the air ducts at the HVAC unit.
Refer to: PIL 01-03.
7. Label the heater hoses (if applicable) and
2. Working in the cab, remove the operator seat disconnect them at the HVAC unit.
from its runners.
8. Label the air conditioning hoses (if applicable)
3. Remove the rear trim panel and get access to the and disconnect them at the HVAC unit.
HVAC unit.
9. Remove four mounting screws from both sides of
Refer to: PIL 09-30-39. the HVAC unit and lift the unit from the machine.
4. Remove the fixings and lift the bracket together
with harness connectors clear of the HVAC unit.
12 - 23 9813/7050-1 12 - 23
--- Page 14 ---
15 - Engine
00 - Engine
00 - General
Internal As viewed on the right hand side. Refer to Figure 93.
The following identifies the main internal components
of a typical engine assembly. Some variants may
differ in detail.
Figure 93.
2 1
3
5
4 6a
6b
15
6c
6d
16
6
7
13
12
14
10
11
9
8
1 Rocker assembly 2 Valve bridge piece (x8)
3 Valve spring (x8) 4 Inlet valve (x8)
5 Exhaust valve (x8) 6 Piston assembly (x4)
6a Piston ring - top compression (x4) 6b Piston ring - 2nd compression (x4)
6c Piston ring - oil control (x4) 6d Gudgeon pin (x4)
7 Connecting rod assembly (x4) 8 Crankshaft
9 Main bearing - crankshaft (x5) 10 Big end bearing - crankshaft/connecting rod
(x4)
11 Front crankshaft oil seal 12 Front end drive belt pulley
13 Flywheel 14 Starter motor pinion
15 - 5 9813/7050-1 15 - 5
--- Page 15 ---
15 - Engine
00 - Engine
00 - General
Cause Remedy
Fuel filter(s) blocked, fuel supply restricted. Check/replace the fuel filter(s). Check fuel lines for
restriction.
Fuel is aerated. Check the fuel system for loose connections and
possible air ingress points. Rectify and bleed the fuel
system.
Fuel lift pump not operating correctly (fuel supply Check that the lift pump is operating and delivering
inadequate). fuel to the injection pump. Check fuses.
Air intake or exhaust system blocked. Visually check the air intake and exhaust system for
blockage or obstruction - remove as required. Check
the air filter elements for signs of blocking - replace
as required.
One or more fuel injectors worn or malfunctioning. Check the electrical connections at the injectors.
Exhaust leak at the manifold or turbocharger. Check/repair leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
Extra injector sealing washer installed under injector. Remove extra injector sealing washer.
Inlet and exhaust valve clearances set incorrectly. Set the valve clearances to the recommended
clearances.
Worn or malfunctioning high pressure fuel pump. Do all the necessary fault finding checks before
removal of the high pressure fuel pump
Engine compression low in one or more cylinders. Check the engine compression.
Electrical sensor fault. Check the electrical connections at the sensors.
Excessive exhaust back pressure Inspect Catalyst. Check Exhaust pressure readings
using Servicemaster.
Table 47. Engine - Will Not Reach Maximum RPM
Cause Remedy
Tachometer faulty. Verify engine speed with hand tachometer. Repair as
required.
Engine overloaded. Verify high idle speed without load. Investigate
operation to be sure correct gear is being used.
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly.
defective.
Fuel is aerated. Check the fuel system for loose connections and
possible air ingress points. Rectify and bleed the fuel
system.
Fuel lift pump not operating correctly (fuel supply Check that the lift pump is operating and delivering
inadequate). fuel to the injection pump. Check fuses.
Fuel is contaminated or incorrect grade diesel fuel Stop the engine. Replace the fuel filters. Operate
used. the engine with a temporary supply of the correct
grade of clean fuel. Monitor the engine performance.
Dirty fuel will cause damage to the high pressure fuel
pump and injectors.
Fuel filter(s) blocked, fuel supply restricted. Check/replace the fuel filter(s). Check fuel lines for
restriction.
Turbocharger wastegate actuator diaphragm Repair or replace turbocharger.
ruptured.
One or more fuel injectors worn or malfunctioning. Check the electrical connections at the injectors.
Worn or malfunctioning high pressure fuel pump. Do all the necessary fault finding checks before
removal of the high pressure fuel pump.
15 - 21 9813/7050-1 15 - 21
--- Page 16 ---
15 - Engine
03 - Crankcase
00 - General
00 - General Introduction
Introduction .................................................... 15-37 The crankcase is the housing for the crankshaft.
Technical Data ............................................... 15-38 The enclosure forms the largest cavity in the engine
and is located below the cylinders. It is integral with
the cylinder bank and forms an engine block. It has
an opening in the bottom to which an oil sump is
attached with a gasket and bolted joint.
The crankcase protects the crankshaft and
connecting rods from foreign objects it also keeps
the engine oil contained and allows the oil to be
pressurised and also provide the rigid structure with
which to join the engine to the transmission.
Figure 105.
B
A
A Crankcase
B Crankshaft
15 - 37 9813/7050-1 15 - 37
--- Page 17 ---
15 - Engine
09 - Bedplate
00 - General
T4 Guide pins (x2 obtain locally) T5 Sealant template
T6 Lifting bolts (x4 obtain locally) V Sealant template portion for removal
W Bearing tab X Rear main bearing
Y Bearing location tab P2 Anaerobic sealant
P3 O-ring
15 - 53 9813/7050-1 15 - 53
--- Page 18 ---
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
Figure 123.