JCB JS200W Wheeled Excavator Repair Service Manual
JCB JS200W Wheeled Excavator Repair Service Manual
- This service manual PDF download for the JS200W Auto Tier III 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 JS200W Tier III Auto - from S/N: 1314600 Onwards
This manual provides information for the following model(s) in the JCB machine range: JCB JS200W Tier III - from S/N: 1314600 to 1314699 JCB JS200W Tier III - from S/N: 1542000 to 1542499
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 K - Engine
MANUAL SPECIFICATION :
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Publication No. : 9803/9540-5 Total Pages : 886
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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9803-9540-5
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 FOPS Data Plate Component Identification Plates Standard 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 Notices 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 Part Numbers and Description
Section 3 - Maintenance Routine Maintenance Service Requirements Introduction Owner/Operator Support Service/Maintenance Agreements Obtaining Replacement Parts Fit for Purpose Tests for Lifting Equipment Health and Safety Lubricants Battery Service Schedules Introduction How to Use the Service Schedules Calender 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 JS130W-160W and Variants JS175W and Variants JS200W and Variants Engine Lubrication Chart Hydraulic Oil Chart Typical Lubrication Chart Coolant Mixtures Fuel Tools Carrying Tools onto the Machine Locations Cleaning the Machine Introduction Exterior Interior Cleaning the Radiator and Oil Cooler Check the Machine for Damage Check the Machine Body and Structure Check the Seat and Seat Belt Checking the FOPS Structure Check the Tyres Daily Checking Greasing Introduction Single Point Greasing Multi Point Greasing Tyres and Wheels Tyre Inflation Checking the Wheel Nut Tightness Electrical System Battery Jump-Starting the Engine Fuses Bolt and Nut Torque Specifications JS130W - 200W and Variants Engine Oil and Filter Engine Air Filter Fan Belt Cooling System 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 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 Level Drive Gearbox Checking the Drive Gearbox Oil Level Changing the Drive Gearbox Oil Axles Front Axle Rear Axle Windscreen Washer Checking the Level Fire Extinguisher (If fitted) 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 JS200W - Monoboom JS200W - Triple Articulated Boom JS200W - Wide Axle Operating Weight Tyre Pressures Turning Radius Dig Depth Chart JS200W 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 Cab Panels Cab Panel Removal Right Hand Cab Panels Left Hand Cab Panels
Section C - Electrics Basic System Operations Circuit Symbols Inputs and Outputs Schematic Diagram JS200W 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 Hardware Sensing Engine Throttle Control Operation Engine Throttle Control for each mode Pressure Switches vs Engine Speed Auto Boost Pressure Operation Engine Oil Level Warning 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 Lever Lock Operation 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 Park Brake Operation 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 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 Heated Seat (Option) Operation Tolerance 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 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 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 ECU1 Fault Diagnosis ECUW 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 Testing Specific Gravity Testing Wiring Harness Repair Introduction Repair Procedure Harness Data Main Harness Connector Location Connector Identification Wheeled Harness Fascia Link Harness - Type 1 Connector Location Connector Identification Fascia Link Harness - Type 2 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 JS200W Basic System Operation Introduction to Hydraulic Schematic Symbols General (Basic and Functional Symbols) Control Valves Example of Schematic Circuit Hydraulic Component Location Hydraulic Schematics Main Hydraulic Schematic JS200W Pilot Line Components Pilot Pressure and Return Line Components Chassis Hydraulics Components Monoboom Hammer/Aux Hydraulics Components TAB Hammer/Aux Hydraulics Components Circuit Descriptions Dipper-in Dipper-out Boom-up Boom-down Boom Speed Regulation - “P” Mode Swing Circuit Auxiliary Mode Hammer Mode ISO-SAE Pattern Drive Circuit Main Control Valve Main Control Valve Hydraulic Pump Hydraulic Pump Operation Introduction Hydraulic Pump Regulation Dismantling and Assembly Driveshaft Seal Dismantling Assembly Regulator Housing Seals Dismantling Assembly Regulator Port Plate Dismantling Assembly Swivel Cradle and Bearings Dismantling Assembly Pump Assembly Dismantling Assembly Inspection 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 (11 Spool) Description Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Inspection Assembly Shuttle Valve Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Inspection Assembly Pilot Valve - Transmission Control Operation Removal and Replacement Removal Replacement Slew Motor Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Inspection Assembly Relief Valves Dismantling Assembly Slew Gearbox Removal and Replacement Removal Replacement Gearbox Disassembly Dismantling Gearbox Inspection Gearbox Reassembly Reassembly Rotary Coupling Operation Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling 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 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 Drive Motor Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Assembly Steering Steering Column Dismantling and Assembly Control Unit General Dismantling Assembly Priority Valve Removal and Replacement Dismantling and Assembly Service Procedure Make the Machine Safe Pressure Testing - General Confirmation of the Oil Temperature Warming-up Procedure Pressure Testing Points MRV Pressure 2 Stage Relief Valve Pressure Servo Relief Pressure Slew Motor Pressure Relief Auxiliary Relief Valves General Valve Section Identification Boom Ram Dipper Ram Bucket Ram Option ARV (Monoboom) Dozer/Stabilisers Brake Service Pressure Steer Stall System Pressure Steer Unit MRV Adjustment 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 Checking the Operation of the Main Hydraulic Spool Test the Pressure Switches Symptoms of Pressure Switch Failures Testing Engine Speed Settings Pressure Switches vs Engine Speed Testing Machine Cycle Times Bucket Ram Speed Dipper Ram Speed Boom Ram Speed Slew Speed Testing Slew Brake Pressure Testing Slew Bearing Checking Slew Bearing Backlash Checking Slew Bearing Vertical Lift Testing for Trapped Air in HBCV Pilot Line Boom HBCV Installation Arm HBCV Installation Ram Creep Tests - All Services Test for Ram Creep
Section F - Transmission Front Axle Unit Identification Identification Removal and Replacement Removal Replacement Dismantling Steering Output Planetary Carrier Brake Hub Knuckle Housing Differential Input Differential Input Pivot Bearing Assembly Input Differential Input Flange Output Knuckle housing Hub Planetary carrier Pivot Bearing Steering Rear Axle Unit Identification Identification Removal and Replacement Removal Replacement Dismantling Output Planetary Carrier Brake Hub Differential Input Differential Assembly Hub Planetary carrier Input Differential Input Flange Output Oil Drain, Oil Filler and Oil Control Plugs Drive Gearbox Description Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling of the Brake Clutch and Planet Carrier Assembly of the Brake Clutch and Planet Carrier Dismantling of the Output Assembly of the Output Dismantling of the Downshift Interlock Assembly of the Downshift Interlock Propshafts Removal and Replacement Removal Replacement
Section K - Engine Technical Data JS200W 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