JCB JS175W Auto Wheeled Excavator Repair Service Manual

(S/N: 1235500 Onwards)
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This service manual PDF download for the JS175W Auto 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 JS175W Auto - from S/N: 1235500 Onwards


TABLE OF CONTENTS :

Section 1 - General Information
Section 2 - Care & Safety
Section 3 - Routine 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
Publication No. : 9803/6550-1
Total Pages : 818


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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9803-6550-1

Section 1 - General Information
Introduction
About this Publication
Schematic Codes
Identifying your Machine
Identification Plates
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
Service Consumables
Sealing and Retaining Compounds

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

Section 3 - Routine Maintenance
Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Obtaining Replacement Parts
Lifting Regulations - Inspections and Tests
Health and Safety
Lubricants
Battery
First Aid - Electrolyte
Service Schedules
Introduction
How to Use the Service Schedules
Pre Start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Service Intervals for Attachments
Periodic Replacement of Safety Related Components
Lubricants and Capacities
JS175W and Variants
Engine Lubrication Chart
Hydraulic Oil Chart
Cleaning the Machine
Exterior
Interior
Checking for Damage
Daily Checking
Bolt and Nut Torque Specifications
JS175W and Variants
Checking the FOPS Structure
Seat Belt
Checking the Seat Belt Condition and Security
Greasing
General Notes
Slew Ring Bearing
Slew Ring Teeth and Slew Pinion
Greasing Points
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Tightness
Electrical System
Battery
Jump-Starting the Engine
Fuses
Engine
Checking the Oil Level
Changing the Oil and Filter
Changing the Outer Air Filter Element
Changing the Inner Air Filter Element
Checking the Fan Belt Tension
Fitting a New Fan Belt
Checking the Coolant Level
Cleaning the Radiator and Oil Cooler
Changing The Coolant
Coolant Mixtures
Fuel System
Types of Fuel
Filling the Tank and Fuel Level Checking
Petrol
Changing the Fuel Filter Element
Cleaning the Lift Pump Strainer
Draining Fuel Tank Impurities
Draining the Water Separator and Engine Fuel Filter
Changing the Water Separator Filter
Bleeding the Fuel System
Hydraulic System
Checking the Fluid Level
Releasing Tank Pressure
Topping-up Fluid Level
Changing the Fluid
Draining Water and Sediment from the Hydraulic Tank
Cleaning/Changing the Suction Strainer
Changing the Return Filter
Changing the Plexus Filter
Changing the Air Breather Element
Changing the Pilot Oil Filter
Changing the Breaker In-line Filter
Changing the Steering Line Filter
Changing the Drain Line Filter
Air Bleeding Procedures
Gearboxes
Checking the Slew Gearbox Oil Level
Changing the Slew Gearbox Oil Level
Checking the Drive Gearbox Oil Level
Changing the Drive Gearbox Oil
Front Axle
Checking the Differential Oil Level
Changing the Differential Oil
Checking the Hub Oil Level
Changing the Hub Oil
Rear Axle
Checking the Differential/Hub Oil Level
Changing the Differential/Hub Oil
Windscreen
Washers
Troubleshooting
Engine and Related Area
Monitor Display - Fault Messages
Operations
Hydraulic pump
Working Attachments
Slew
Hydraulic ram

Section B - Body & Framework
Technical Data
Static Dimensions
JS175W - Monoboom
JS175W - Triple Articulated Boom
Operating Weight
Tyre Pressures
Dig Depth Chart
JS175W
Attachments
Location
Boom and Slew Frame Installation
Boom Ram and Slew Frame Installation
Boom Ram Installation
Dipper Ram Installation
Dipper Pivot Installation
Dipper and Dipper Ram Installation
Bucket Ram Installation
Dipper and Dipper Link Installation
Bucket and Bucket Link Installation
Bucket Link and Bucket Ram Installation
Bucket and Dipper Installation
Air Conditioning (option)
Basic Operation
Air Conditioning
Operation
Heater/Air Conditioning Controls
Air Conditioning System Operation
Control
Pressures Switch Settings
Safety Procedures
Fault Finding
Air Conditioning
Preliminary Checks
Electrical Component Location
Electrical Fault Finding
Service Procedures
HVAC/Air Conditioning Unit
Removal and Repacement
Air Conditioning Compressor
Removal and Repacement
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
Technical Data
Fuses
Fuse Identification
Basic System Operations
Location of Controls and Components
Driver Controls and Switches
Drive Controls
Right Console
Left Console
Left Console Switch Panel
Multi Purpose Steering Column Switch
Monitor Panel
Fascia Panel
Emergency back-up switch
One Touch / Automatic Idle Switch
Heater/Air Conditioning Controls
Radio (If fitted)
Cab Interior Lights
Operating Levers and Pedals
Excavating Controls
Stabilisers (if fitted)
Dozer (if fitted)
Circuit Symbols
Inputs and Outputs
Component Identification
JS175W
Schematic Diagram
JS175W
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
ECU W Supply to Output Drivers
ECU W / LH Switch Panel Supply and Network
Engine Throttle Control
Introduction
Throttle control system
Throttle control circuit
Engine Throttle Control for each mode
Stop Solenoid Setting Procedure
Auto Boost Pressure
Operation
Engine Reverse Rotation Prevention
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
Pump Control for Each Mode
Operation
Pump torque is set by pump control mA signal
"A" Auto Mode and “D” Drive Mode
"E" Economy mode
"L" Lifting mode & "P" Precision mode
Lever Lock
Operation
Drive Isolator
Wiper
Lower Wiper (option)
Operation
Washer
Horn
Operation
Travel Alarm - Optional
Operation
Slew Brake (100%)
Operation
Slew lock (100% Slew Brake)
Operation
Travel Mode
Operation
Cruise Control - Optional
3 Speed Travel
Operation
Work Lights (Boom and Cab)
Operation
Head Lights
Operation
Side Lights
Operation
Brake Lights
Operation
Indicators
Operation
Fog/Reversing Lights
Fog Lights
Reversing Lights
Fog/Reversing Light Schematic
Hazard Warning
Operation
Park Brake
Operation
Axle Lock
Manual
Automatic
Stabilisers
Operation
Dozer
Operation
Viscous Fan
Operation
Fuel Level Sensor/Warning
Operation
Engine Temperature Sensor/Warning
Operation
Coolant Level Warning
Operation
Air Filter Blocked Warning
Operation
Warning Indicator Lamps
Hydraulic Temperature Sensor/Warning
Operation
Brake Pressure Warning
Operation
Engine Oil Pressure/Emergency Steering Warning
Operation
Alternator/ No Charge Warning
Operation
Alternator Charging and Battery Relay
Quick hitch (option)
Operation
Overload Caution (option)
Operation
Beacon
Operation
Grab/rotate
Operation
Hammer
Operation
Scrap Magnet Option
Operation
Cab Interior Lamp
Operation
Refuelling Pump
Automatic Mode
Manual Mode
Air Conditioning
Heated Seat
24 to 12 Volt Converter, Radio and Cigar Lighter
24 to 12 Volt Converter.
Radio
Cigar lighter
Service Required Warning
Operation
Cancellation of the Service indicator
EMS Set Menu.
EMS Set + Mode (5 Sec) Menu
EMS Set+Mode (20 sec) Menu.
Service off
Throttle calibration
Solenoid Override
Horse Power Control Data Logging Facility
Fault Finding
JCB Service Master
Using Service Master
Selecting Service Tool Applications
System Menus
HPSetup Overview
Features
Using HPSetup
1 Connecting the Data Link Adaptor (DLA)
2 Starting HPSetup
3 Setting Up A Vehicle Profile
4 Writing Vehicle Profile <F12
5 Reading Vehicle Profile <F11
6 Closing HPSetup
7 Options - Multi Language Support
Guidelines for setting up a vehicle using the set up tool
Alternative Language Cross Reference
Data Link Adaptor
DLA Trouble Shooting
HPDataLogs
Using HPDataLogs
FLASH Programming Application
"FLASHECU" Training Guide
Using FLASHECU
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.
Table 1: Error messages
Table 2: Status messages
Table 3: Electrical fault error code
Fault Finding Without using the JCB Service Master 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 (F S P)
Service Procedure
Testing of ECU Inputs + Outputs
Testing low side input
Testing High side input
Testing low side output
Testing high side output
Wiring Harness Repair
Introduction
Repair Procedure
Battery
Maintenance
First Aid - Electrolyte
Testing
Specific Gravity Testing
Harness Data
Main Harness
Main Harness A
Main Harness B
Main Harmess C
Main Harness D
Wheeled Harness
Wheeled Harness A
Wheeled Harness B
Wheeled Harness C
Cab Harness
Cab Harness A
Cab Harness B
Cab Harness C
Fascia Link Harness
Facia Link Harness A
Facia Link Harness B
Worklights
Cab Worklight
Boom Worklight

Section D - Controls
Steering Column
Dismantling and Assembly

Section E - Hydraulics
Technical Data
General Data
Hydraulic Pump
Slew Gearbox
Slew Motor
Main Contol Valve
Rams
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 Schematic
Servo Line
Components
Servo Pressure and Return Line
Components
Chassis Hydraulics
Components
Monoboom Hammer/Aux Hydraulics
Components
Tab Hammer/Aux Hydraulics
Components
Main Control Valve
Hydraulic Pump Operation
Main Pumps (P1 and P2)
Hydraulic Pump Regulation
Neutral Circuit
Drive
Creep Speed
Middle speed
High Speed
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
Stabiliser Operation
Dozer Operation
Park Brake
Park Brake On
Park Brake Off
Brake and Steering
Brake Charging
Brake Charged
Steering Circuit
Grab Rotate
Axle Lock Rams
Service Procedure
Pressure Testing
General
Pressure Testing Points
Pressure Settings
Pressure Relief Valve Location
Main Relief Valve (MRV) Pressure
Servo Relief Pressure
Slew Motor Pressure Relief
Auxiliary Relief Valves
Servo Accumulator
Brake Service Pressure
Steer Stall System Pressure
Clutch Pressure
Park Brake Pressure
Hydraulic Pump/Regulator
Hydraulic Pump Removal and Replacement
Removal
Replacement
Pump Hydraulic Circuit Diagram
Hydraulic Pump/Regulator
Hydraulic Pump
Hydraulic Pump Dismantling and Assembly
Dismantling
Assembly
Regulator
Regulator Dismantiling and 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).
Slew shut off (CT6)
2 Stage relief. (CT7)
Boom Speed Regulator. (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
Solenoid Valve (3 Spool)
Operation
Drive Isloator (CT1)
Axle Lock (CT2)
Dig End Isolator (CT3)
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Cushion Valve
Operation
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Slew Motor and Gearbox
Removal and Replacement
Removal
Replacement
Torque Settings
Slew Motor Configuration
Slew Motor Reduction Gear
Reduction Gear Structure and Working Principles
Motor Disassembly
Dismantling
Motor Re assembly
Re assembly
Gearbox Disassembly
Dismantling
Gearbox Inspection
Gearbox Re assembly
Re assembly
Rotary Coupling
Operation
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Drive Motor
Operation
Ports on Motor Body
Ports A and B
Description
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Steering
Control Unit
General
Dismantling
Assembly
Priority Valve
Removal and Replacement
Dismantling and 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
Typical Boom, Dipper, Bucket and TAB Ram
Dozer Rams
Ram Piston Head Nut
Removal and Fitting
Reconditioning
Procedures for inserting and bedding the seal ring.
Bushing Removal
Bushing Assembly
Wiper Ring Assembly
Cylinder Head Assembly
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
Fault Finding Tests
Slow or Underpowered:
Harsh Operation When Selecting:
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/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
Symptoms of Pressure Switch Failures
Test 007: Testing Engine Speed Settings
Test 008: Testing Machine Cycle Times
a Bucket Ram speed.
b Dipper Ram speed
c Boom Ram speed
d Slew Speed
Test 010: Testing Hose Burst Check Valves
Dipper Ram
Boom Ram
TAB Ram
Test 011: Testing Swing brake pressure
Test 016: Flow testing Hydraulic Pumps
To Confirm Minimum Flow Setting
To Confirm Maximum Flow Setting
To Confirm Horse Power Control
Record Sheet
Test 017: Testing Slew Bearing
Checking Slew Bearing Backlash
Checking Slew Bearing Vertical Lift
Test 018: Testing Pump Milliamps
Test 019: Testing Latch Brake Pressure
Testing pressure
Adjusting pressure
Test 020: Testing for Trapped Air in HBCV Pilot Line
Boom HBCV Installation
Arm HBCV Installation
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
Test for Ram Creep

Section F - Transmission
Front Axle
Technical Data
Unit Identification
Identification
Designation
Removal and Replacement
Removal
Replacement
Dismantle and Assembly
Rear Axle
Technical Data
Unit Identification
Identification
Designation
Removal and Replacement
Removal
Replacement
Dismantle and Assembly
Drive Gearbox
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Propshafts
Removal and Replacement
Removal
Replacement
Power Track Rod
Removal and Replacement
Removal
Replacement

Section K - Engine
Technical Data
JS175W

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