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

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

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