This workshop repair 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
P/N : 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
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