JCB JS200W Wheeled Excavator Repair Service Manual
JCB JS200W Wheeled Excavator Repair Service Manual
- This service manual PDF download for the JS200W 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 - from S/N: 809000 Onwards
TABLE OF CONTENTS :
General Information Care & Safety Routine Maintenance Attachments Body & Framework Electrics Controls Hydraulics Transmission Brakes Engine
MANUAL SPECIFICATION :
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Publication No. : 9803/6320 Issue 2 Total Pages : 452
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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Cover Contents Introduction
Section 1: General Information Machine and Axle Identification Torque Settings Service Tools Body and Framework Electrics Hydraulics Transmission Sealing and retaining Compounds
Section 2: Care and Safety Safety Notices General Safety Operating Safety Maintenance Safety
Section 3: Routine Maintenance Lubricants and Capacities Lubricants - Health and Safety Service Scheldules Greasing Slew Ring Teeth and Slew Pinion Slew Ring Bearing Greasing (50 hours) Greasing (General) Battery Fuses (Section C) Tyres and Wheels Tyre Inflation Checking the Wheel Nut Tightness Hydraulics Checking the Fluid Level Releasing Tank Pressure/Topping Up Fluid Level Changing the Fluid Changing the Return Filter Element Flushing Filters Cleaning/Changing the Suction Strainer Changing the Nephron Filter Changing the Air Breather Element Draining Tank Impurities Changing the Servo Oil Filter Changing the Drain Line Filter Element Changing the Steering Line Filter Element Changing the Breaker In-Line Filter (if fitted) Air Bleeding Procedures Transmission Checking the Slew Gearbox Oil Level Changing the Slew Gearbox Oil Replenishing the Slew Gearbox Grease Checking the Drive Gearbox Oil Level Checking the Drive Gearbox Oil Checking the Front Axle Differential Oil Level Checking the Front Axle Differential Oil Checking the Front Axle Hub Oil Level Changing the Front Axle Hub Oil Checking the Rear Axle Differential/Hub Oil Level Changing the Rear Axle Differential/Hub Oil Engine Changing the Air Filter Outer Element Changing the Air Filter Inner Element Checking the Oil Level Changing the Oil and Filters Checking the Coolant Level Coolant Mixtures Changing the Coolant Cleaning the Radiator and Oil Cooler Adjusting the Fan Belts Fitting New Fan Belts Draining Fuel Tank Impurities Draining the Water Separator Cleaning the Water Separator Cleaning the Lift Pump Gauze Draining the Filters Changing the Filter Elements Prime the System Component Location Diagrams Checking the FOPS Structure
Section B: Body and Framework Direct Glazing
Section C: Electrics The AMS system Technical Data Battery Testing - Specific Gravity Battery Testing Schematic Diagrams Layout Operator's Cab Right Console Left Console Monitor Panel Control, Function, Operation Engine Control Basic Operation Stepping Motor Throttle Related Function Revolution Increase, Engine Stop Controller Rotational Instructions Redundancy (Back-up) Throttle Control Automatic Engine Adjustment Idling Control Revolution Control for Each Mode Engine Auto Warm-up Engine Shutdown Defection of Throttle Motor Assembly Defect (Out-of-step) Pump Control Schematic Flow Chart Boom Lowering Speed Regulation Boom over swing priority Pressure Increasing System Power Supply Cut Delay Swing Brake/Swing Lock Lever Lock Power Transistor Protection Display Monitor Throttle Motor and Throttle Link Replacement Throttle Motor Throttle Motor and Throttle Link Automatic Adjustment Initial Set-up of the Controller for Machine Identification Revolution Sensor Removal and Installation Self Test Fault Finding Fault Diagnosis Emergency Engine Stop Refuel Coolant Refill Air Cleaner Clogged Low Engine Oil Pressure Fluid Overheating, water, oil Battery Charging Electrical System, Message Fault Engine Trouble Sensor Resistance Valve Computer Reprogramming/Programming Circuit Description (Electro-Hydraulic) CAPS II Diagnostic System Diagnostics for CAPS II Controllers
Section D: Controls Steering Column Dismantling and Assembly
Section E: Hydraulics Technical Data Schematic Diagram Component Key Schematic Circuit Diagram Fault Finding Circuit Descriptions Systems Operation Main Hydraulic System Steering and Braking System Pilot Hydraulic System Electronic Control System Pump Circuits Drive Circuit Park Brake/Gearchange Circuit Steering and Brake Circuits Grab Rotate Circuit Stabiliser Circuit Dozer Blade Circuit Axle Lock Circuit Hammer Circuit Valves Control Valve Technical Data Precautions During Use Spool Location Hydraulic Circuit Diagram Removal and Replacement Main Control Valve Neutral Position LUDV Compensator Valve High Pressure Position Low Pressure Position LS Pressure Cut-off Valve Port Relief and Anti-cavitation Valve Anti-cavitation Valve Spool Dampening Shuttle Valve Swing Module Swing Priority Torque Control Valve Nine Station Solenoid Valve Remote Control Valves Introduction Operation Dismantling and Assembly Fault Finding Maintenance Specification Hydraulic Pump/Regulator Introduction Pump Hydraulic Circuit Diagram Pump Compartment Hydraulic Pump Components Pump Control/Horsepower Control Dismantling and Assembly Steering Control Unit Dismatling and Assembly Steering Priority Valve Removal and Replacement Dismantling and Assembly Rotary Coupling Removal and Replacement Dismantling and Assembly Drive Motor Dismantling and Assembly Slew Motor Hydraulic Motor Components Hydraulic Circuit Operation Specification Dismantling Maintenance Specifications Assembly Relief Valves Dismantling Assembly Fault Finding Hydraulic Rams Bucket Ram Removal Replacement Dipper Ram Removal Replacement Boom Rams - General Removal Replacement Triple Articulated Boom (TAB) Ram - General Removal Replacement Specifications Precautions During Use - JS200W Disassembly Assembly Stabiliser/Dozer Rams Dismantling and Assembly Axle Lock Rams Dismantling and Assembly Power Track Rods Removal and Replacement Ram Piston Head Nut Removal and Fitting Reconditioning Fault Finding
Section F: Transmission Routine Maintenance Drive Gearbox Technical Data Removal Replacement Dismantling and Assembly Drive Motor Dismantling and Assembly Slew Gearbox Dismantling and Assembly Fault Finding Front Axle Technical Data Removal and Replacement Propshafts Removal and Replacement Power Track Rod Removal and Replacement Hydraulic Steering Assembly Dismantling and Assembly Steering Axle with Multi DIsk Brakes Dismantling Assembly Differential Carrier Dismantling Assembly Rear Axle Technical Data Removal and Replacement Propshafts Removal and Replacement Axle Hub and Driveshaft Dismantling Assembly
Section G: Brakes Service Brakes Dismantling and Assembly Bleeding Procedure Parking Brake Dismantling and Assembly Slew Brakes Dismantling and Assembly
Section K: Engine Routine Maintenance Technical Data