- This service manual PDF download for the JS200, JS210, JS220, JS240, JS260 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
JCB JS200 Auto - from S/N 1018001 to 1019999, 1202500 to 1203999, 1701500 to 1702499
JCB JS210 Auto - from S/N 1018001 to 1019999, 1202500 to 1203999, 1701500 to 1702499
JCB JS220 Auto - from S/N 1018001 to 1019999, 1202500 to 1203999, 1701500 to 1702499
JCB JS240 Auto - from S/N 1040000 to 1041999
JCB JS260 Auto - from S/N 1040000 to 1041999
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. : 9803/6510-03 Total Pages : 824
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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8903-6510-03 Service Manual JS200, JS210, JS220, JS240, JS260
Section 1 - General Information General Information Introduction About this Publication Schematic Codes Colour Codes Identifying your Machine Identifying Your Machine Data Plate Typical Product Identification Number (PIN) Typical Engine Identification Number 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 Section B - Body and Framework Tool Detail Reference Section B - Body and Framework Numerical List Section C - Electrics Tool Detail Reference Section C - Electrics Numerical List Section E- Hydraulics Tool Detail Reference Section E- Hydraulics Inserting seal ring and correction jig Jig for pulling out, press-fitting bushing Jig for press-fitting wiper ring Jig for inserting cylinder head Seal Ring and Connector Jig Bush Removal Jig Bush Fitting Jig Wiper Ring Fitting Jig Wiper Ring Fitting Jig Numerical List Section F - Transmission Tool Detail Reference Section F - Transmission Service Consumables Sealing and Retaining Compounds
Section 2 - Care and Safety Care and Safety Safety Check List Safety Notices Safety - Yours and Others General Safety Operating Safety Maintenance Safety Safety Decals Safety Decal Recognition Chart Definitions
Section 3 - Routine Maintenance Routine Maintenance Routine Maintenance Service Requirements Introduction Owner/Operator Support Service/Maintenance Agreements Obtaining Replacement Parts Lifting Regulations - Inspections and Tests Identification of Machine Components Health and Safety Lubricants Battery First Aid - Electrolyte Service Schedules Introduction How to Use the Service Schedules Pre Start Cold Checks, Service Points and Fluid Levels Functional Test and Final Inspection Service Intervals for Attachments Periodic Replacement of Safety Related Components Lubricants and Capacities JS200/210/220/235HD and Variants JS240/260 and Variants Engine Lubrication Chart Hydraulic Oil Chart Cleaning the Machine Exterior Interior Checking for Damage Daily Checking Bolt and Nut Torque Specifications JS200 - JS260 and Variants Checking the FOPS Structure Cab Mounted Frame Mounted Seat Belt Checking the Seat Belt Condition and Security Greasing General Notes Slew Ring Bearing Slew Ring Teeth and Slew Pinion Greasing Points Electrical System Battery Jump-Starting the Engine Fuses Engine Checking the Oil Level Changing the Oil and Filter Changing the Outer Air Filter Element Changing the Inner Air Filter Element Checking the Fan Belt Tension Fitting a New Fan Belt Checking the Coolant Level Cleaning the Radiator and Oil Cooler Changing The Coolant Coolant Mixtures Fuel System Types of Fuel Filling the Tank and Fuel Level Checking Petrol Changing the Fuel Filter Element Cleaning the Lift Pump Strainer Draining Fuel Tank Impurities Draining the Water Separator - early models Cleaning the Water Separator - early models Draining the Water Separator and Engine Fuel Filter - later models Changing the Water Separator Filter - later models Bleeding the Fuel System Hydraulic System Checking the Fluid Level Releasing Tank Pressure Topping-up Fluid Level Changing the Fluid Draining Water and Sediment from the Hydraulic Tank Cleaning/Changing the Suction Strainer Changing the Return Filter Changing the Plexus Filter Changing the Air Breather Element Changing the Pilot Oil Filter Changing the Breaker In-line Filter Changing the Drain Line Filter Checking the Slew Gearbox Oil Level Changing the Slew Gearbox Oil Level Air Bleeding Procedures Travel Gearbox Checking the Track Gearbox Oil Level Changing the Track Gearbox Oil Tracks and Running Gear Cleaning the Tracks Checking/Adjusting the Track Tension Checking Rollers and Idler Wheels for Oil Leaks Track Plate Inspection Bucket Checking/Adjusting for side play Windscreen Washers Troubleshooting Engine and Related Area Monitor Display - Fault Messages Operations Hydraulic pump Working Attachments Travel Slew Hydraulic ram
Section B - Body & Framework 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 JS220/260 - Long Reach (LR) 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 Attachments Location Boom and Slew Frame Installation Boom Ram and Slew Frame Installation Boom Ram Installation Dipper Ram Installation Dipper Pivot Installation Dipper and Dipper Ram Installation Bucket Ram Installation Dipper and Dipper Link Installation Bucket and Bucket Link Installation Bucket Link and Bucket Ram Installation Bucket and Dipper Installation Air Conditioning (option) Basic Operation Air Conditioning Operation Heater/Air Conditioning Controls Air Conditioning System Operation Control Pressures Switch Settings Safety Procedures Fault Finding Air Conditioning Preliminary Checks Electrical Component Location Electrical Fault Finding Service Procedures HVAC/Air Conditioning Unit Removal and Repacement Air Conditioning Compressor Removal and Repacement 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 Electrics Technical Data Fuses Fuse Box A Basic System Operation Controls and Components Driver Controls and Switches Right Console Left Console Monitor Panel Fascia Panel Emergency back-up switch Heater/Air Conditioning Controls Cab Interior Lights Radio (If Fitted) Operating Levers/Pedals Travel Levers Travel Speed Change Button Operation Levers Optional Circuit Pedal (if fitted) ISO Operating Method Circuit Symbols Inputs and Outputs Component Identification JS200/JS210/JS220/JS240/JS260 Schematic Diagram Component Identification JS200/JS210/JS220/JS240/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 Throttle control system Throttle control circuit Engine Throttle Control for each mode Stop Solenoid Setting Procedure Auto Boost Pressure Operation Engine Reverse Rotation Prevention 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 Pump Control for Each Mode Operation Pump torque is set by pump control mA signal “A” Auto Mode “E” Economy mode “L” Lifting mode & “P” Precision mode Lever Lock Operation Servo Isolator Operation Lever Lock and Servo Isolator Wiper Operation Lower Wiper (option) Operation Washer Operation Horn Operation Travel Alarm Operation Soft/Hard (Cushion) Operation Boom Down Delay (If fitted) Operation Slew/Boom Priority (High Dump) Operation Slew lock (100% Slew Brake) 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 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 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 Air Conditioning Heated Seat 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 (5 Sec) Menu EMS Set+Mode (20 sec) Menu. Service off Throttle calibration Solenoid Override Horse Power Control Data Logging Facility Fault Finding JCB Service Master Using Service Master Selecting Service Tool Applications Service Master 2 Machine Pages JS Pages System Menus HPSetup Overview Features Using HPSetup 1 Connecting the Data Link Adaptor (DLA) 2 Starting HPSetup 3 Setting Up A Vehicle Profile 4 Writing Vehicle Profile <F12 5 Reading Vehicle Profile <F11 6 Closing HPSetup 7 Options - Multi Language Support Guidelines for setting up a vehicle using the set up tool Alternative Language Cross Reference DLA Port Configuration Data Link Adaptor DLA Trouble Shooting HPDataLogs Using HPDataLogs FLASH Programming Application "FLASHECU" Training Guide Using FLASHECU Introduction to the Diagnostics Tool Connecting to the vehicle Starting Diagnostic Mode Circuit Diagrams Indicator Lights (LEDs) Stopping Diagnostic Mode Language Setting List of text messages displayed on the EMS. Table 1: Error messages Table 2: Status messages Table 3: AMS System fault error code - For software version 7 and below Throttle Errors Table 3: Electrical fault error code- Sftware version 8 and above. 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 ECU-1 EMS Failure. Fault Diagnosis - Facia Switch panel (F S P) Service Procedure Using a Multimeter Measuring DC Voltage Measuring Resistance Measuring Continuity Measuring Frequency Testing a Diode or a Diode Wire Testing of ECU Inputs + Outputs Testing low side input Testing High side input Testing low side output Testing high side output Wiring Harness Repair Introduction Repair Procedure Battery Maintenance First Aid - Electrolyte Testing Specific Gravity Testing Harness Data Main Harness Connector Location Key to Connectors Key To Wire Colours Main Harness A Main Harness B Main Harmess C Main Harness D Main Harness Data Splice - Example: CTAP A31 Splice - Example: S/Joint 13 Facia Link Harness Connector Location Facia Link Harness A Facia Link Harness B Facia Link Harness Data Splice - Example: CTAP A31 Splice - Example: S/Joint 13 Cab Harness Connector Location Cab Harness A Cab Harness B Cab Harness C Cab Harness D Cab Harness E Cab Harness F Cab Harness Data Splice - Example: CTAP A31 Splice - Example: S/Joint 13
Section E - Hydraulics Technical Data General Data Main Hydraulic Pump Servo Pump Proportional Pressure Reducing Valve Slew Motor Main Contol Valve JS200/210/220 Main Contol Valve JS240/260 Spool Stroke versus Pilot Pressure Boom Ram Dipper Ram Bucket Ram Basic System Operation Hydraulic Component Location Introduction to Hydraulic Schematic Symbols General (Basic & Functional Symbols) Control Valves Example of Schematic Circuit Circuit Descriptions Hydraulic Schematic JS200/210/220 Upto Serial No 1202887 JS200/210/220 From Serial No 1202888 JS240/260 Upto Serial No 1040099 JS240/260 From Serial No 1040100 Servo Line JS200/210/220 JS240/260 Components Servo Pressure and Return Line JS200/210/220 JS240/260 Components Main Control Valve Hydraulic Pump Operation Main Pump 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 Remote Control Valve (Services) Function Cushion Valve Solenoid Valve (8 Spool) Operation Solenoid Valve (8 Spool) Slew Brake. (CT1) Isolator. (CT2) Slew Lock. (CT3) Maximum flow cut. (CT4) 2 Stage travel. (CT5). Slew shut off (CT6) 2 Stage relief. (CT7) Cushion control. (CT8) Shuttle Valve Rotary Coupling Service Procedure 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 Slew Motor Pressure Relief Auxiliary Relief Valves General Boom Ram Travel Motor Relief Pressure Hydraulic Pump Hydraulic Pump Removal and Replacement Removal Replacement Hydraulic Pump Hydraulic Pump Dismantling and Assembly Dismantling Inspection Assembly Regulator Regulator Dismantiling and 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 Spool) JS200-220 upto Serial No 1202887, JS240/260 upto Serial No 1040099 Removal Replacement Dismantling Inspection Assembly JS200/210/220 From Serial No 1202888 JS240/260 From Serial No 1040100 Removal Replacement Dismantling Inspection Assembly Shuttle Valve Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Inspection Assembly Cushion Valve Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Inspection Assembly Slew Brake Valve Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Inspection Assembly Slew Motor Removal and Replacement Removal Replacement Torque Settings Dismantling and Assembly Dismantling Inspection Assembly Relief Valves Dismantling Assembly Slew Motor Reduction Gear Assembly Dismantling and Assembly Dismantling Inspection Assembly Rotary Coupling 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 Dismantling and Assembly (Early Serial Numbers) 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 piston rod with cushion ring on the piston rod side Assembly of piston rod with cushion ring on the piston rod & cylinder bottom side Assembly of piston rod in cylinder tube Reconditioning (Early Serial Numbers) Structure and Characteristics of Special Jigs for Repair of Rams Jig Table Jig Usage Dismantling and Assembly (Later Serial Numbers) 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 Ram Piston Head Nut Removal and Fitting Maintenance Specifications Use Limit 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 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: Testing Pressure Switches Symptoms of Pressure Switch Failures Test 007: Testing Engine Speed Settings Test 008: Testing Machine Cycle Times a Bucket Ram speed. b Dipper Ram speed c Boom Ram speed d Slew Speed e Travel Speed f Travel Linearity. Test 010: Testing Hose Burst Check Valve - Dipper Ram Test 010: Testing Hose Burst Check Valve - Boom Ram Test 011: Testing Swing brake pressure Test 012: Testing Track Motor Relief Valve Settings Testing Track Motor ARV 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 Transmission Technical Data Travel Equipment JS200, JS210, JS220 JS240, JS260 Basic System Operation Travel Motor Operation Middle Speed Slow Speed Travel (Creep) High Speed Fault Finding Introduction Fault Finding Track Motor Removal and Replacement Removal Precautions during Installation Replacement Motor Bleeding Track Gearbox Dismantling and Assembly Dismantling Inspection Assembly Track Motor Dismantling and Assembly Dismantling Inspection Assembly Torque Setting
Section J - Track and Running Gear Track and Running Gear Technical Data Torque Specifications Idler Wheel and Recoil Unit Removal Replacement Idler Wheel Dismantling Assembly Wear Limits Grease Cylinder Removal and Replacement Removal Replacement Dismantling Assembly Drive Sprocket Removal Replacement Wear Limits Top Roller Removal Replacement Dismantling Assembly Wear Limits Bottom Roller Removal Replacement Dismantling Assembly Wear Limits
Section K - Engine Engine Technical Data JS200, JS210, JS220 JS240, JS260