JCB JS200, JS210, JS220, JS240, JS260 Tracked Excavator Service Repair Manual

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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 JS200 - from S/N: 705001 Onwards
JCB Tracked Excavator JS210 - from S/N: 705648 Onwards
JCB Tracked Excavator JS220 - from S/N: 705001 Onwards
JCB Tracked Excavator JS240 - from S/N: 708501 Onwards
JCB Tracked Excavator JS260 - from S/N: 708501 Onwards


TABLE OF CONTENTS :

General Information
Care & Safety
Routine Maintenance
Attachments
Body & Framework
Electrics
Hydraulics
Transmission
Brakes
Track & Running Gear
Engine


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/6400 Issue 2
Total Pages : 531


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
Bolt and Nut Torque Specifications
Service Tools
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Sealing and Retaining Compounds

Section 2: Care and Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety

Section 3: Routine Maintenance
Fluids and Lubricants
Lubricants - Health and Safety
Service Schedules
Greasing
Slew Ring Bearing
Slew Ring Teeth and Slew Pinion
Excavator End
Battery
Fuses
Hydraulics
Air Bleeding Procedures
Releasing Tank Pressure
Air Bleeding from Hydraulic Pump
Air Bleeding from Ram
Air Bleeding from the Slew Motor
Checking the Fluid Level
Topping up the Fluid Level
Changing the Hydraulic Oil
Changing the Return Filter Element
Cleaning/Changing the Suction Strainer
Changing the Air Breather Element
Draining Tank Impurities
Changing the Pilot Oil Filter
Changing the Breaker In-Line Filter
Changing the Drain Line Filter
Changing the Nephron Filter
Transmission
Checking the Track Gearbox Oil Level
Changing the Track Gearbox Oil
Checking the Slew Gearbox Oil Level
Checking the Slew Gearbox Oil
Replenishing Slew Gearbox Grease
Tracks and Running Gear
Cleaning the Tracks
Checking/Adjusting the Track Tension
Checking the Shoe Plate
Checking the Roller and Idler Wheels for Oil Leaks
Engine
Changing the Air Filter Elements
Checking the Oil Level
Changing the Oil and Filters
Checking the Coolant Level
Coolant Mixtures
Changing the Coolant
Adjusting the Fan Belt
Fitting a New Fan Belt
Cleaning the Radiator and Oil Cooler
Draining Fuel Tank Impurities
Draining the Water Separator
Changing the Fuel Filter Element
Bleeding the Fuel System
Component Location Diagram
Performance Evaluation JS200/JS240
Checking the FOPS Structure

Section B: Body and Framework
Torque Specifications
Undercarriage
Dimensions
Main Body
Weights
Maintenance Specifications JS200, JS200LC
Boom 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 Installlation
Bucket and Bucket Link Installation
Bucket Link and Bucket Ram Installation
Bucket and Dipper Installation
Shim Adjustment Table
Maintenance Specifications JS240, JS240LC
Boom and Slew Frame Installations
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
Shim Adjustment Table
Direct Glazing
Air Conditioning
Operation
Control
Safety Procedures
Fault Finding
Checking Refrigerant Charge Level
Leak Testing
Tightening Leaking Hoses
System Diagnosis

Section C: Electrics
AMS System
Technical Data
Battery Testing
Schematic Diagram
Layout
Operator's Cab
Right Console
Left Console
Monitor
Control, Function, Operation
Engine Control
Basic Operation
Stepping Motor
Throttle Related Function
Stop Motor Function
Redundancy (Back-up) Throttle Control
Automatic Engine Adjustment
Idling Control
Revolution Control for Each Mode
Control of Engine Speed for Breaker Operation
Engine Auto Warm-up
Detection of Throttle Motor Assembly Defect (Out-of-step)
Engine Reverse Rotation Prevention
Pump Control
Schematic
Flow Chart
Boom Lowering Speed Regulation
Cushioned Boom Starting
Pressure Increasing System
3 Speed Travel and Max. Flow (Q) Cut
Soft/Hard Switch
Power Supply Cut Delay
Swing Brake/Swing Lock
Lever Lock
Travel Warning
Power Transistor Protection
Display Monitor
Throttle Motor
Thottle Motor and Throttle Link Replacement
Automatic Adjustment
Revolution Sensor
Installation
Self Test
Fault Finding
Fault Diagnosis
Emergency Engine Stop
Refuel
Coolant Refill
Air Cleaner Clogged
Low Engine Oil Pressure
Engine Oil Filter
Fluid Overheating, water, oil
Battery Charging
Electrical System, Message Fault
Engine Problem
Sensor Resistance Valve
CAPs II Diagnostic system

Section E: Hydraulics
Technical Data - JS200/220 and Variants
Technical Data - JS240/260 and Variants
Torque Specifications
Schematics
Schematic Hydraulic Circuit JS200 and Variants
Schematic Hydraulic Circuit JS240 and Variants
Shuttle Block JS200, JS240
Pilot Control Line Hose Connection Diagram, JS200, JS240
Pressure Testing JS200, JS240
Hydraulic Pump JS200, JS240
Schematics, Technical Data
Precautions During Use
Trouble Shooting
Operation
Dismantling and Assembly
Main Body Wear Limits
Regulator JS200, JS240
Specifications
Operation
Trouble Shooting
Dismantling and Assembly
Control Valve JS200, JS240
Specification, Technical Data
Precautions During Use
Operation
Trouble Shooting
Dismantling and Assembly
Relief Valve JS200, JS240
Dismantling and Assembly
Port Relief JS200/JS240
Dismantling and Assembly
Negative Control Valve
Operation
Dismantling and Assembly
Remote Control Valve
Schematics, Technical Data
Operation
Dismantling and Assembly
Trouble Shooting
Maintenance Specifications
8-Spool Solenoid Valve JS200, JS240
Schematics, Technical Data
Dismantling and Assembly
Shuttle Valve
Schematic
Operation
Cushion Valves
Schematic
Operation
Stacked Valve
Schematic
Operation
Hydraulic Rams
Specifications
Precautions During Use
Bucket Ram - Removal and Installation
Dipper Ram - Removal and Installation
Boom Ram - Removal and Installation
Dismantling and Assembly
Reconditioning
Trouble Shooting
Maintenance Specifications
Rotary Coupling
Schematic, Technical Data
Operation
Dismantling and Assembly
Slew Motor
Schematic, Technical Data
Operation
Maintenance Specifications
Motor Assembly/Cylinder Assembly
Dismantling and Assembly
Relief Valve
Dismantling and Assembly
Reduction Gear
Dismantling and Assembly
Fault Finding

Section F: Transmission
Torque Specifications
Track Motor/Gearbox
Schematics, Specifications
Operation
Precautions During Installation
Fault Finding
Removal and Replacement
Track Motor
Dismantling and Assembly
Maintenance Specifications
Track Gearbox
Dismantling and Assembly

Section J: Track and Running Gear
Torque Specification
Idler Wheel and Recoil Unit
Removal
Replacement
Idler Wheel
Dismantling
Assembly
Wear Limits
Grease Cylinder
Removal
Replacements
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
Technical Data

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