JCB JS200, JS210, JS220, JS235, JS240, JS260 Tracked Excavator Service Manual – 9803/6580-6

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JCB JS200, JS210, JS220, JS235, JS240, JS260 Tracked Excavator Service Manual – 9803/6580-6

This service manual PDF download for the JS200, JS210, JS220, JS235, JS240, JS260 Auto Tier III JCB Tracked 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 Tracked Excavator
JS200-JS260 – Tier III Auto

JCB JS200 – from S/N: 1610000 to 1612499 and 1459000 to 1461999
JCB JS210 – from S/N: 1610000 to 1612499 and 1459000 to 1461999
JCB JS220 – from S/N: 1610000 to 1612499 and 1459000 to 1461999
JCB JS235 – from S/N: 1314000 to 1314099
JCB JS240 – from S/N: 1504700 to 1505099 and 1773500 to 1774499
JCB JS260 – from S/N: 1504700 to 1505099 and 1773500 to 1774499

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Maintenance
Section B – Body & Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section J – Track and Running Gear
Section K – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/6580-6
Total Pages : 879

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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9803-6580-6

Section 1 – General Information
Introduction
About this Manual
Machine Model and Serial Number
Using the Service Manual
Section Numbering
Left Side, Right Side
Cross References
Identifying Your Machine
Machine Identification Plate
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
‘O’ Ring Face Seal System
‘Torque Stop’ Hose System
Service Tools
Numerical List
Tool Detail Reference
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section K – Engine
Service Consumables
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding
Hydraulic Schematic Colour Codes

Section 2 – Care and Safety
Safety Check List
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Labels
Introduction
Safety Label Identification

Section 3 – Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Fit for Purpose Tests for Lifting Equipment
Obtaining Replacement Parts
Health and Safety
Lubricants
Battery
Service Schedules
Introduction
How to Use the Service Schedules
Calendar Equivalents
Pre Start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Service Intervals for Attachments
Periodic Replacement of Safety Related Components
Fluids, Lubricants and Capacities
JS115 – JS145 and Variants
JS160 – JS190 and Variants
JS200 – JS235 and Variants
JS240/260 and Variants
JS290 and Variants
JS330 and Variants
JS360 and Variants
Engine Lubrication Chart
Hydraulic Oil Chart
Typical Lubrication Chart
Coolant Mixtures
Fuel
Tools
Carrying Tools onto the Machine
Locations
Prepare the Machine for Maintenance
Introduction
How to Make the Machine Safe (Excavator Lowered)
Cleaning the Machine
Introduction
Preparing the Machine for Cleaning
Cleaning the Machine
Cleaning the Tracks
Cleaning the Radiator and Oil Cooler
Checking for Damage
Check the Machine Body and Structure
Check the Seat and Seat Belt
Checking the FOPS Structure
Daily Checking
Greasing
Introduction
Slew Ring Bearing
Slew Ring Teeth and Slew Pinion
Greasing Points
Electrical System
Battery
Jump-Starting the Engine
Fuses
Bolt and Nut Torque Specifications
JS115 – JS360 and Variants
Engine
Oil and Filter
Cooling System
Fan Belt
Engine Air Filter
Fuel System
Introduction
Draining Fuel Tank Impurities
Draining the Primary Filter/Sedimenter
Changing the Primary Filter/Sedimenter Element
Changing the Fuel Feed Pump Filter
Draining the Main Filter/Sedimenter
Changing the Main Filter/Sedimenter Element
Bleeding the System
Hydraulic System
Introduction
Releasing Tank Pressure
Releasing the Hydraulic Pressure
Oil and Filters
Draining Water and Sediment from the Hydraulic Tank
Air Bleeding Procedures
Slew Gearbox
Checking the Slew Gearbox Oil Level
Changing the Slew Gearbox Oil
Tracks and Running Gear
Tracks
Running Gear
Bucket
Checking/Adjusting For Side Play
Windscreen Washer
Checking the Level
Fire Extinguisher (If fitted)
Troubleshooting
Engine and Related Area
Monitor Display – Fault Messages
Operations
Hydraulic pump
Working Attachments
Travel
Slew
Hydraulic ram

Section B – Body & Framework
Technical Data
Static Dimensions
JS200/210/220 – Monoboom
JS200/210/220 – Triple Articulated Boom
JS235 – Monoboom
JS235 – Triple Articulated Boom
JS240/260 – Monoboom
JS240/260 – Triple Articulated Boom
Shipping Weight
Dig Depth Chart
JS200/210/220 – Monoboom
JS200/210/220 – Triple Articulated Boom
JS220/260LR – Long Reach
JS235HD – Monoboom
JS235HD – Triple Articulated Boom
JS240/260 – Monoboom
JS240/260 – Triple Articulated Boom
Air Conditioning (option)
Automatic Temperature Control (ATC) System
Basic Operation
Automatic Temperature Control (ATC) System
Heater/Air Conditioning Controls (ATC)
Air Conditioning System Operation
ATC Control Panel
Safety Procedures
Fault Finding
Air Conditioning
Preliminary Checks
Error Codes / Error Diagnosis (Automatic Temperature Control (ATC) System)
Service Procedures
HVAC/Air Conditioning Unit
Removal
Replacement
Air Conditioning Compressor
Removal and Replacement
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
Basic System Operation
Circuit Symbols
Inputs and Outputs
Component Identification
JS200 – JS260
Schematic Diagram
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
Engine Throttle Control
Operation
Engine Throttle Control for Each Mode
Pump Control for Each Mode
Operation
Hardware Sensing
Operation
Auto Boost Pressure
Operation
Engine Oil Level Warning
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
Lever Lock
Operation
Servo Isolator
Operation
Wiper
Operation
Lower Wiper (option)
Operation
Washer
Operation
Horn
Operation
Travel Alarm
Operation
Soft/Hard (Cushion)
Operation
Slew Brake (100%)
Operation
Slew lock (100% Slew Brake)
Operation
Slew Brake Solenoid Valve Failure
Operation
3-Speed Travel
Operation
“E” Economy, “P” Precision & “A” Auto Modes
Relationship between Travel Modes A / E + P, travel motor swash plate position and Pump “Q max cut output”
“L” Lifting Mode
Work Lamps
Operation
Viscous Fan
Operation
Fuel Level Sensor/Warning
Operation
Engine Temperature Sensor/Warning
Operation
Coolant Level Warning
Operation
Air Filter Blocked Warning
Operation
Hydraulic Temperature Sensor/Warning
Operation
Alternator/No Charge Warning
Operation
Quick hitch (option)
Operation
Overload Caution (option)
Operation
Beacon
Operation
Hammer Only
Operation
Scrap Magnet Option
Operation
Cab Interior Lamp
Operation
Refuelling Pump
Operation
Air Conditioning
Heated Seat
Operation
Radio and Cigar Lighter
Operation
Service Required Warning
Operation
Cancellation of the Service indicator
EMS Set Menu
EMS Set + Mode Menu
EMS Set+Mode (20 sec) Menu.
Service Off
Solenoid Override
Horse Power Control Data Logging Facility
Throttle Calibration
Fault Finding
JCB Servicemaster
Introduction
Using Servicemaster
Selecting Service Tool Applications
JS Machine Pages
System Menus
Using ECM Setup
HPSetup Overview
DLA Port Configuration
Data Link Adaptor
HPDataLogs
FLASH Programming Application
Introduction to the Diagnostics Tool
Connecting to the Vehicle
Starting Diagnostic Mode
Circuit Diagrams
Indicator Lights (LEDs)
Stopping Diagnostic Mode
Language Setting
Electrical Fault Text Messages Displayed on the EMS.
Fault Finding Without Using the JCB Servicemaster 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 (FSP)
Service Procedure
Testing of ECU Inputs + Outputs
Testing Low Side Input
Testing High Side Input
Testing Low Side Output
Testing High Side Output
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
First Aid – Electrolyte
Testing
Specific Gravity Testing
Wiring Harness Repair
Introduction
Repair Procedure
Harness Data
Harness Interconnection
Main Harness
Connector Identification
Connector Identification
Fascia Link Harness – Type 1
Connector Location
Connector Identification
Fascia Link Harness – Type 2
Connector Location
Connector Identification
Fascia Link Harness – Type 3
Connector Location
Connector Identification
Cab Harness – Type A
Connector Location
Connector Identification
Engine Harness – Type A
Connector Identification
Cab Harness (includes Engine Harness) – Type B
Connector Identification
Cab Harness (includes Engine Harness) – Type C
Connector Identification

Section E – Hydraulics
Technical Data
General Data
Main Hydraulic Pump
Servo Pump
Proportional Pressure Reducing Valve
Slew Motor JS200-JS235
Slew Gearbox JS200-JS235
Slew Motor JS240/260
Main Control Valve
Spool Stroke vs Pilot Pressure
Boom Ram
Dipper Ram
Bucket Ram
Basic System Operation
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Circuit Descriptions
Hydraulic Schematic
JS200-JS235
JS240/260
HRC Schematic
Servo/Pilot Line
Components
Servo/Pilot Pressure and Return Line
Components
Hydraulic Pump Regulation
Hydraulic Pump Regulation
Neutral Circuit
Straight Line Travel
Travel – Middle Speed
Boom Up
Boom Down
Dipper Out
Dipper In
Bucket Opening
Bucket Close
Priority Valves
Boom over Slew Priority (A)
Slew over Dipper Priority (B)
Boom Priority over Bucket (C)
Slew Circuit
Slew Motor Configuration
Slew Motor Reduction Gear
Reduction Gear Structure and working principles
Slew Circuit
Slew Brake Valve
A – Slew Brake at 50%
B – Slew Brake Fully Off
C – Slew Brake at 100%
Auxiliary Flow
Merged Flow
Hammer Circuit
Main Control Valve
Description
Hydraulic Pump/Regulator
Hydraulic Pump Operation
Main Pumps (P1 and P2)
Pump Hydraulic Circuit Diagram
Hydraulic Pump/Regulator Exploded View
Hydraulic Pump/Regulator Plan View
Hydraulic Pump Removal and Replacement
Removal
Replacement
Hydraulic Pump Dismantling and Assembly
Dismantling
Assembly
Regulator Dismantling and Assembly
Dismantling
Assembly
Coupling
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 Station)
Operation
Slew Brake (CT1)
Isolator (CT2)
Slew Lock (CT3)
Maximum flow cut (CT4)
2 Stage travel (CT5)
Boom Priority (CT6)
2 Stage relief (CT7)
Cushion control (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
Cushion Valve
Operation
Cushioned Mode – Hand Controller In Neutral
Cushioned Mode – Hand Controller at Dipper In
Cushioned Mode – Hand Controller Moved from Dipper In to Neutral
Cushion Control Off
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Slew Motor
Motor Operating Principles
Slew Brake Operation
Fault Finding
Motor Does Not Rotate
Motor Rotates in the Reverse Direction
Motor Speed is Low
Motor Brake Working Poorly
Motor is Driven by Exterior Torque
Oil Leakage
Removal and Replacement
Removal
Replacement
Slew Motor Configuration
Dismantling and Assembly
Dismantling
Inspection
Assembly
Relief Valves
Slew Gearbox
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Rotary Coupling
Operation
Removal and Replacement
Removal
Replacement
Dismantling
Assembly
Hydraulic Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Typical Bucket Ram
Typical Dipper Ram
Typical Boom Ram
Typical Triple Articulated Boom (TAB) Ram
Dismantling and Assembly
Dismantling the Piston Rod from the Cylinder Tube
Dismantling the Piston Rod
Removing the Piston Seals
Removing the Cylinder Head Seals
Assembly of Piston Seals
Assembling the Cylinder Head Seals
Assembly of the Piston Rod
Assembly of Piston Rod in Cylinder Tube
Maintenance Specifications
Use Limit
Service Procedure
Make the Machine Safe
Pressure Testing – General
Confirmation of the Oil Temperature
Warming-up Procedure
Pressure Testing Points
Pressure Relief Valve Location
Main Relief Valve (MRV) Pressure
Servo Relief Pressure
Auxiliary Relief Valves
General
Boom Ram
Dipper Ram
Bucket Ram
Option ARV (Monoboom)
Slew Motor Pressure Relief
Travel Motor Relief Pressure
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
Hydraulic Ram Faults and Remedies
Fault Finding Tests
Slow or Underpowered:
Harsh Operation When Selecting:
Tracking Off Line
Poor Tractive Effort
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
Test 003: Testing Main Pump Pressure
Test 004: Testing Horsepower Control
Test 005: Checking the Operation of the Main Hydraulic Spool
Test 006: Test the Pressure Switches
Symptoms of Pressure Switch Failures
Test 007: Testing Engine Speed Settings
Pressure Switches vs Engine Speed
Test 008: Testing Machine Cycle Times
Bucket Ram Speed
Dipper Ram Speed
Boom Ram Speed
Slew Speed
Travel Speed
Travel Linearity
Test 011: Testing Swing Brake Pressure
Test 012: Testing Track Motor Relief Valve Settings
Test 013: Testing Track Motor Drain Line Flow Rate
Test 014: Loss of High Speed Tracking
Additional information
Test 015: High Gear Selection, Monitor Displays Another Travel Gear
Test 016: Flow testing Hydraulic Pumps
To Confirm Minimum Flow Setting
To Confirm Maximum Flow Setting
To Confirm Horse Power Control
Test 016 – Flow Testing Hydraulic Pumps – Record Sheet
Test 017: Testing Slew Bearing
Checking Slew Bearing Backlash
Checking Slew Bearing Vertical Lift
Ram Creep Tests – All Services
Test for Ram Creep

Section F – Transmission
Technical Data
Travel Equipment
JS200 – JS235
JS240, JS260
Basic System Operation
Description
Operation
Middle Speed
Slow Speed Travel (Creep)
High Speed
Brake Valve
Parking Brake
Rotation Direction
Removal and Replacement
Removal
Precautions During Installation
Replacement
Start Up and Running In
Start Up
Running In
Fault Finding
Transmission
Traction Motor
Parking Brake
Relief Valve
Counterbalance Valve
Speed Range Changing
Track Motor
Dismantling and Assembly
Dismantling
Inspection
Assembly
Track Gearbox
Dismantling and Assembly
Dismantling
Inspection
Assembly

Section J – Track and Running Gear
Technical Data
Torque Specifications
Idler Wheel and Recoil Unit
Removal
Replacement
Idler Wheel
Dismantling
Assembly
Recoil Unit
Dismantling
Assembly
Grease Cylinder
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Drive Sprocket
Removal and Replacement
Removal
Replacement
Top Roller
Removal
Replacement
Dismantling
Assembly
Wear Limits
Bottom Roller
Removal
Replacement
Dismantling
Assembly
Wear Limits

Section K – Engine
Technical Data
JS200-260
Engine Mounts
Engine Error Codes
Fault Finding
Engine Components
4HK/6HK
4JJ
Engine Coolant Temp Sensor
Overheat Switch
Common Rail Pressure Sensor
Engine Oil Pressure Sensor
Crankshaft Position (CKP) Sensor – 4HK/ 6HK
Crankshaft Position Sensor – 4JJ
Camshaft Position (CMP) Sensor – 4HK/ 6HK
Camshaft Position (CMP) Sensor – 4JJ
Exhaust Gas Re-circulation (EGR) Valve
Suction Control Valve
Fuel Temperature (FT) Sensor
Boost Temperature Sensor
Boost Pressure Sensor
Injector
Glow Plug
Engine Oil Level Sensor
Air Intake Temperature Sensor
Barometric Pressure Switch
Schematics

 

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JCB JS200, JS210, JS220, JS235, JS240, JS260 Tracked Excavator Service Manual – 9803/6580-6.pdf

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