JCB_JS200_JS210_JS220_JS260_Tracked_Excavator_SM_8903-6510.pdf

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Service Manual
JS200, JS210, JS220, JS240, JS260
JS200
S/N: 1018001 - 1019999
S/N: 1202500 - 1203999
S/N: 1701500 - 1702499
JS210
S/N: 1018001 - 1019999
S/N: 1202500 - 1203999
S/N: 1701500 - 1702499
JS220
S/N: 1018001 - 1019999
S/N: 1202500 - 1203999
S/N: 1701500 - 1702499
JS260
S/N: 1040000 - 1041999
Publication No.
9803/6510-03
World Class
Customer Support
Section 1 - General information
Contents
Page No.
Introduction
About this Publication .............................................................................. 1 - 1
Schematic Codes .................................................................................... 1 - 2
Colour Codes ..................................................................................... 1 - 2
Identifying your Machine
Identifying Your Machine .........................................................................
Data Plate ...........................................................................................
Typical Product Identification Number (PIN) ......................................
Typical Engine Identification Number .................................................
1-3
1-3
1-3
1-4
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1 - 5
Introduction ......................................................................................... 1 - 5
Bolts and Screws ................................................................................ 1 - 5
Hydraulic Connections ............................................................................. 1 - 9
'O' Ring Face Seal System ................................................................. 1 - 9
'Torque Stop' Hose System .............................................................. 1 - 12
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 ....................................
1 - 13
1 - 14
1 - 17
1 - 18
1 - 20
1 - 22
1 - 29
1 - 30
1 - 30
1 - 30
1 - 30
1 - 30
1 - 31
1 - 31
1 - 31
1 - 32
1 - 33
Service Consumables
Sealing and Retaining Compounds ....................................................... 1 - 36
1-i
1-i
Section 1 - General information
Contents
Page No.
1 - ii
1 - ii
Section 1 - General Information
Introduction
About this Publication
This publication is designed for the benefit of JCB
Distributor Service Engineers who are receiving, or have
received, training by JCB Technical Training Department.
These personnel should have a sound knowledge of
workshop practice, safety procedures, and general
techniques associated with the maintenance and repair of
hydraulic earthmoving equipment.
Renewal of oil seals, gaskets, etc., and any component
showing obvious signs of wear or damage is expected as
a matter of course. It is expected that components will be
cleaned and lubricated where appropriate, and that any
opened hose or pipe connections will be blanked to
prevent excessive loss of hydraulic fluid and ingress of dirt.
Finally, please remember above all else SAFETY MUST
COME FIRST!
The manual is compiled in sections, the first three are
numbered and contain information as follows:
1
General Information - includes torque settings and
service tools.
Care & Safety - includes warnings and cautions
pertinent to aspects of workshop procedures etc.
Routine Maintenance - includes service schedules
and recommended lubricants for all the machine.
All sections are listed on the front cover; tabbed divider
cards align directly with individual sections on the front
cover for rapid reference.
Where a torque setting is given as a single figure it may be
varied by plus or minus 3%. Torque figures indicated are
for dry threads, hence for lubricated threads may be
reduced by one third.
'Left Hand' and 'Right Hand' are as viewed from the rear of
the machine facing forwards.
This Service Manual covers the following machines:
JS200, JS210, JS220, JS260
2
3
The remaining sections are alphabetically coded and deal
with Dismantling, Overhaul etc. of specific components, for
example:
A
B
Attachments
Body & Framework...etc.
The page numbering in each alphabetically coded section
is not continuous. This allows for the insertion of new items
in later issues of the manual.
Section contents, technical data, circuit descriptions,
operation descriptions etc. are inserted at the beginning of
each alphabetically coded section.
1-1
9803/6510-3
1-1
Section 1 - General Information
Introduction
Schematic Codes
Schematic Codes
Colour Codes
The following colour coding, used on illustrations to denote
various conditions of oil pressure and flow, is standardised
throughout JCB Service Publications.
Red
Full Pressure:
Pressure generated from operation of a service. Depending on application this
may be anything between neutral circuit pressure and MRV operating pressure.
Pink
Pressure:
Pressure that is above neutral circuit pressure but lower than that denoted by Red.
Orange
Servo:
Oil pressure used in controlling a device (servo).
Blue
Neural:
Neutral circuit pressure.
Green
Exhaust:
Light Green
Cavitation:
Oil subjected to a partial vacuum due to a drop in pressure (cavitation).
Yellow
Lock Up:
Oil trapped within a chamber or line, preventing movement of components (lock up).
1-2
9803/6510-3
1-2

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