Need the factory test values for your excavator? This 884-page JCB JS160 Service Manual PDF (OEM #9803/6570-7) covers the JS160, JS180, and JS190 models. Open to the hydraulics section for fluid routing schematics and system error codes. You get full wiring diagrams for the electrical harness, engine test values, and diagnostic charts for tracking down stubborn track motor faults. Confirm the main hydraulic pump displacement is pushing 63 cm3/rev on your JS180 before locking down the track guard bolts to 290 Nm. Guessing at relief valve pressures will only blow hoses and cost you downtime. Download this bookmarked file, pull up the right numbers on your shop tablet, and get back to turning wrenches.
Complete the set for your JS160 / JS180 / JS190
- Operator Manual: JCB JS115–JS235 Series Excavator Operator Manual
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-47 | Introduction (Identifying Your Machine), Torque Settings (Zinc Plated Fasteners and Dacromet Fasteners, Hydraulic Connections) |
| Care and Safety | 48-67 | Safety Notices, Safety Labels (Important Information, Safety Check List, Introduction, Safety Label Identification, Part Numbers and Description) |
| Routine Maintenance | 68-179 | Service Requirements, Health and Safety, Service Schedules, Fluids Lubricants and Capacities, Tools, Prepare the Machine for Maintenance, Cleaning the Machine, Checking for Damage |
| Body & Framework | 180-223 | Technical Data (Static Dimensions, Shipping Weight, Dig Depth Chart, Air Conditioning), Basic Operation (Automatic Temperature Control System), Fault Finding (Air Conditioning) |
| Electrics | 224-463 | Basic System Operation (Circuit Symbols, Component Identification, Schematic Diagram, A.M.S, Circuit Concepts, Pulse Width Modulation, ECU1/EMS/FACIA Power Supply and Network, ECU 1 Supply to Output Drivers, Engine Throttle Control, Pump Control for Each Mode, Hardware Sensing, Auto Boost Pressure, Engine Oil Level Warning, Engine Pre Heat, Engine Automatic Warm Up, Engine Automatic Idle, Engine One Touch Idle, Engine Start/Stop, Limp Mode System, Lever Lock, Servo Isolator, Wiper, Lower Wiper, Washer, Horn, Travel Alarm, Soft/Hard, Slew Brake, Slew Lock, Slew Brake Solenoid Valve Failure, 3-Speed Travel, Work Lamps, Viscous Fan, Fuel Level Sensor/Warning, Engine Temperature Sensor/Warning, Coolant Level Warning, Air Filter Blocked Warning, Hydraulic Temperature Sensor/Warning, Alternator/No Charge Warning, Quick Hitch, Overload Caution, Beacon, Hammer Only, Scrap Magnet Option, Cab Interior Lamp, Refuelling Pump, Air Conditioning, Heated Seat, Radio and Cigar Lighter, Service Required Warning, Ems Set Menu, Ems Set + Mode Menu) |
| Hydraulics | 464-730 | Technical Data, Basic System Operation (Introduction to Hydraulic Schematic Symbols) |
| Transmission | 731-796 | Technical Data (Track Motor/Reduction Gear), Fault Finding (Transmission), Track Motor (Description, Operation, Removal and Replacement, Start Up and Running in) |
| Track & Running Gear | 797-831 | Idler Wheel and Recoil Unit (Removal, Replacement), Idler Wheel (Dismantling, Assembly), Recoil Unit (Dismantling and Assembly) |
| Engine | 832-884 | Technical Data |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| JS160, JS180, JS190 | ||
| Tightening Torque for Track Guard bolts | 290 Nm (213 lbf ft) | p. 120 |
| Tightening Torque for Turntable Bearing (Slew Frame) bolts | 296/525 Nm (218/387 lbf ft) | p. 120 |
| All Models | ||
| Hydraulic pump does not build pressure (Causes and Remedies) | Causes: Oil leakage inside hydraulic pump (Remedy: Replace hydraulic pump(1)); Air inside the hydraulic pump (Remedy: Refill oil or check hose on suction side); Main relief valve pressure set too low (Remedy: Adjust pressure(1)). Causes: Low hydraulic oil (Remedy: Refill); Clogged suction filter (Remedy: Repair) | p. 175 |
| Piston Rod Outer Diameter Wear Limit (55~80 mm rod) | -0.023 mm | p. 667 |
| Rod Bushing Inner Diameter Wear Limit (55~75 mm rod) | +0.30 mm | p. 667 |
| Pump Exit Hose (Pump - Operation Valve) Replacement Interval | Every 2 years or every 4000 hours, whichever comes first. | p. 86 |
| Boom Ram Line Hose Replacement Interval | Every 2 years or every 4000 hours, whichever comes first. | p. 86 |
| Oil and Filter replacement interval | 500 hours | p. 78 |
| Air Cleaner Outer Element replacement interval | 500 hours | p. 78 |
| JS160/JS180 | ||
| Main Hydraulic Pump Displacement volume, JS160/JS180 | 63 cm3/rev x2 | p. 470 |
| Valve clearance (cold) Inlet | 0.15 mm (0.006 in) | p. 836 |
| JS190 | ||
| Main Hydraulic Pump Displacement volume, JS190 | 80 cm3/rev x2 | p. 470 |
