JCB JZ235, JZ255 Tracked Excavator Repair Service Manual

(S/N: 1234500 to 1235499)
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This service manual PDF download for the JZ235, JZ255 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
JZ235, JZ255 - TIER III AUTO (S/N: 1234500 to 1235499)

JCB Tracked Excavator JZ235 - from S/N: 1234500 to 1235499
JCB Tracked Excavator JZ255 - from S/N: 1234500 to 1235499

This manual provides information for the following model(s) in the JCB machine range:
JCB JZ235/255 from serial number 1234500 to 1235499


TABLE OF CONTENTS :

Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine 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. : 9803/6560-3
Total Pages : 816


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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9803-6560-3

Section 1 - General Information
Introduction
About this Manual
Identifying Your Machine
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Hydraulic Connections
Service Tools
Numerical List
Tool Detail Reference
Service Consumables
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding

Section 2 - Care and Safety
Safety Check List
Important Information
Safety Check List
Safety Decals

Section 3 - Routine Maintenance
Routine Maintenance
Service Requirements
Health and Safety
Service Schedules
Lubricants and Capacities
Tools
Cleaning the Machine
Check the Machine for Damage
Daily Checking
Greasing
Electrical System
Bolt and Nut Torque Specifications
Engine
Fuel System
Hydraulic System
Travel Gearbox
Tracks and Running Gear
Bucket
Front Window
Troubleshooting

Section B - Body & Framework
Technical Data
Static Dimensions
Shipping Weight
Dig Depth Chart
Air Conditioning (option)
Basic Operation
Automatic Temperature Control (ATC) System
Fault Finding
Air Conditioning
Service Procedures
HVAC/Air Conditioning Unit
Air Conditioning Compressor
Cab Structure
Cab Panels
Cab Panel Removal

Section C - Electrics
Basic System Operation
Circuit Symbols
Component Identification
Schematic Diagram
A.M.S (Advanced Management System)
Circuit Concepts
Pulse Width Modulation (PWM)
ECU1/EMS/FACIA Power Supply and Network
ECU 1 Supply to Output Drivers
Engine Throttle Control
Pump Control for Each Mode
Hydraulic Fan
Hardware Sensing
Auto Boost Pressure
Engine Oil Level Warning
Engine Pre Heat (Glow plugs)
Engine Automatic Warm Up
Engine Automatic Idle
Engine One Touch Idle
Engine Start/Stop
Limp Mode system
Lever Lock
Servo Isolator
Wiper
Lower Wiper (option)
Washer
Horn
Travel Alarm
Soft/Hard (Cushion)
Slew Brake (100%)
Slew lock (100% Slew Brake)
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 (option)
Overload Caution (option)
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
EMS Set+Mode (20 sec) Menu.
Fault Finding
JCB Servicemaster
Fault Finding Without Using the JCB Servicemaster Diagnostic Tool
Service Procedure
Testing of ECU Inputs + Outputs
Using a Multimeter
Battery
Wiring Harness Repair
Harness Data
Main Harness
Fascia Link Harness - Type 1
Fascia Link Harness - Type 2
Cab Harness - Type A
Engine Harness - Type A
Cab Harness (includes Engine Harness) - Type B
Cab Harness (includes Engine Harness) - Type C

Section E - Hydraulics
Technical Data
General Data
Basic System Operation
Hydraulic Component Location
Introduction to Hydraulic Schematic Symbols
Circuit Descriptions
Hydraulic Schematic
Servo Pilot Line
Servo Pilot Pressure and Return Line
Neutral Circuit
Straight Line Travel
Travel - Middle Speed
Boom Up
Boom Down
Dipper Out
Dipper In
Bucket Opening
Bucket Close
Priority Valves
Slew Circuit
100% Slew Lock
Auxiliary Flow
Merged Flow
Hammer Circuit
Main Control Valve
Description
Port Identification
Hydraulic Pump/Regulator
Hydraulic Pump/Regulator Description
Hydraulic Pump Operation
Hydraulic Pump Removal and Replacement
Hydraulic Pump Dismantling and Assembly
Regulator Dismantling and Assembly
Remote Control Valve (Hand Control)
Operation
Removal and Replacement
Dismantling and Assembly
Travel Pedal Valve
Dismantling and Assembly
Solenoid Valve (8 Station)
Operation
Removal and Replacement
Dismantling and Assembly
Shuttle Valve
Removal and Replacement
Dismantling and Assembly
Cushion Valve
Operation
Removal and Replacement
Dismantling and Assembly
Slew Motor
Motor Operating Principles
Slew Brake Operation
Fault Finding
Removal and Replacement
Slew Motor Configuration
Dismantling and Assembly
Slew Motor Reduction Gear Assembly
Removal and Replacement
Dismantling and Assembly
Rotary Coupling
Operation
Removal and Replacement
Dismantling
Assembly
Hydraulic Rams
Precautions During Use
Removal and Replacement
Dismantling and Assembly
Maintenance Specifications
Service Procedure
Make the Machine Safe
Pressure Testing - General
Pressure Relief Valve Location
Main Relief Valve (MRV) Pressure
Servo Relief Pressure
Auxiliary Relief Valves
Slew Motor Pressure Relief
Travel Motor Relief Pressure
Fault Finding
Hydraulic Contamination
Main Control Valve
Relief Valve
Hydraulic System
Slew Motor
Hydraulic Pump
Hydraulic Rams
Fault Finding Tests
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
Test 007: Testing Engine Speed Settings
Test 008: Testing Machine Cycle Times
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
Test 015: High Gear Selection, Monitor Displays Another Travel Gear
Test 016: Flow testing Hydraulic Pumps
Test 016 - Flow Testing Hydraulic Pumps - Record Sheet
Test 017: Testing Slew Bearing
Ram Creep Tests - All Services

Section F - Transmission
Technical Data
Travel Equipment
Basic System Operation
Description
Operation
Removal and Replacement
Start Up and Running In
Fault Finding
Transmission
Track Motor
Dismantling and Assembly
Track Gearbox
Dismantling and 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
Dismantling and Assembly
Drive Sprocket
Removal and Replacement
Top Roller
Removal
Replacement
Dismantling
Assembly
Bottom Roller
Removal
Replacement
Dismantling
Assembly

Section K - Engine
Technical Data
JZ235-JZ255
Engine Error Codes

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