jcb JS 200 Series Manuale utente
Service
Manual
JS200
from machine no. 705001
JS210
from machine no. 705648
JS220
from machine no. 705001
JS240
from machine no. 708001
JS260
from machine no. 708501
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; ©
WATERLOO PARK, UTTOXETER,
STAFFORDSHIRE, ST14 5PA, ENGLAND
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9803/6400
R
General Information
Care & Safety
Routine Maintenance
Attachments
Body & Framework
Electrics
1
2
3
A
B
C
Hydraulics E
F
Transmission
G
Brakes
J
Track & Running Gear
K
Engine
Issue 2
9803/6400 Issue 1
Introduction
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.
2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for the whole machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:
A = Optional Equipment
B = 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.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
Page cross references are generally made by presenting the subject title printed in bold, followed by the title of the section
containing the subject. For example:
“24 If the axle is still on the machine, fit the brake calipers (see Brake Caliper Removal and Replacement, Section G).”
Note: If only the subject title in bold is given, i.e. no section title, the cross reference is to another part of the same section.
Use the contents list at the beginning of each section to find the exact page number.
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.
1 - 1
Section 1 General Information
9803/6400
Section 1
1 - 1
Issue 3*
*
Bolt and Nut Torque Specifications
Tighten the bolts and nuts according to the table. Before and after daily work, check the bolts and nuts for looseness and for
those missing. Tighten if loose and replace if missing.
Tighten the bolts and nuts after the first 50 hours of the running-in stage and every 250 hours thereafter.
Tightening Torque Table
Note: Use Loctite 262 (adhesive) on those marked † and tighten to the torque listed in the above table.
The tightening torque for the bolts and nuts not listed above are as follows:
JS200/210/220/240/260
No Tightening Point Bolt Diameter Wrench Tighten Torque
Nm kgf m lbf ft
1† Travel Motor M16 24mm
270~310 27.2~31.8 200~230
2† Drive Sprocket M16 24mm
270~310 27.2~31.8 200~230
3† Idler Wheel M16 24mm
270~310 27.2~31.8 200~230
4† Upper (Carrier) Roller M20 30mm
520~608 53.2~62.2 385~450
5† Lower (Track) Roller M18 27mm
370~430 37.8~44.1 275~315
6† Track Guard M18 27mm
380~440 38.7~45.2 280~325
7Shoe Bolt M16 24mm
380~450 38.7~46.0 275~330
8Counter weight M27/M30 41/46mm
1058~1235/1335~1545
1
08~126/136~158 780~910/985~1140
9† Turntable Bearing
(Undercarriage)
M20/M24 30/36mm
475~550/780~910 48.4~55.3/80~93 350~400/575~670
10† Turntable Bearing (Slew Frame) M20/M24 30/36mm
475~550/780~910 48.4~55.3/80~93 350~400/575~670
11† Slew Equipment M20/M24 30/36mm
525~605/785~910 53.1~62/80~93 390~440/580~670
12† Engine (Engine Mount) M16 24mm
265~310 27.0~32 195~230
13† Engine Bracket M10 17mm
65~75 6.6~7.6 47~55
14 Radiator M16 24mm
150~175 15~18 108~130
15† Hydraulic Pump M10 17mm
65~75 6.6~7.6 47~55
16† Hydraulic Oil Tank M16 24mm
235~285 23.7~29.5 175~210
17† Fuel Tank M16 24mm
255~285 25.7~29.5 185~210
18† Control Valve M16 24mm
270~310 27.6~31.8 200~230
19† Rotary Coupling M12 19mm
110~125 11.1~13 80~94
20 Cab M16 24mm
127~135 13~14 94~101
21 Battery M10 17mm
20~30 2.1~2.9 15~21
Bolt Diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench mm 10 13 17 19 22 24 27 30
Hex. bolt Tightening Nm 6.9 15.7 32.3 58.8 98.0 137.2 196.0 274.4
Torque kgf m 0.7 1.6 3.2 5.9 9.8 13.7 19.6 27.4
lb ft 5 12 24 43 72 101 145 202
Wrench mm 5 6 8 10 12 14 14 17
Hex. socket head Tightening Nm 8.8 21.6 42.1 78.4 117.6 176.4 245.0 343.0
bolt Torque kgf m 0.8 2.2 4.2 7.8 11.8 17.6 24.5 34.3
lb ft 6.5 16 31 58 87 130 181 253
4 - 1
Section 1 General Information
9803/6400
Section 1
4 - 1
Issue 2*
Service Tools
SECTION C - ELECTRICS
Electrical Test Equipment
1892/00283 Tool Kit Case
2892/00281 AVO Meter
3892/00286 Surface Temperature Probe
4892/00284 Microtach Digital Tachometer
5892/00282 Shunt - open type
6892/00285 Hydraulic Oil Temperature Probe
7892/00298 Fluke 85 Multimeter
993/85700 Battery Tester
*
Service Tools (continued)
SECTION E - HYDRAULICS
5 - 1
Section 1 General Information
9803/6400
Section 1
5 - 1
Issue 1
Pressure Test ‘T’ Adapters
892/00262 1/4 in BSP x 1/4 in F BSP x Test Point
816/55038 3/8 in BSP x 3/8 in F BSP x Test Point
816/55040 1/2 in BSP x 1/2 in F BSP x Test Point
892/00263 5/8 in BSP x 5/8 in F BSP x Test Point
892/00264 3/4 in BSP x 3/4 in F BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point
892/00266 1,1/4 in M BSP x 1,1/4 in F BSP x Test Point
892/00267 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point
Pressure Test Adapters
892/00255 1/4 in BSP x Test Point
892/00256 3/8 in BSP x Test Point
892/00257 1/2 in BSP x Test Point
892/00258 5/8 in BSP x Test Point
816/15118 3/4 in BSP x Test Point
892/00259 1 in BSP x Test Point
892/00260 1,1/4 in BSP x Test Point
892/00261 5/8 in UNF x Test Point
Hydraulic Pressure Test Gauges and Connections
1892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2)
2892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2)
3892/00347 Connector
4892/00254 Hose
1/2
34
5 - 2
Section 1 General Information
9803/6400
Section 1
5 - 2
Issue 1
Service Tools (continued)
SECTION E - HYDRAULICS
Hand Pump Equipment
892/00223 Hand Pump
892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
892/00706 Test Probe
892/00278 Gauge 0 - 40 bar (0 - 600 lb/in2)
892/00279 Gauge 0 - 400 bar (0 - 6000 lb/in2)
892/00280 Gauge 0 - 600 bar (0 - 8500 lb/in2)
816/50005 1/2 in BSP (A) x 1/2 in BSP (B)
816/60096 3/4 in BSP (A) x 3/4 in BSP (B)
816/00018 1 in BSP (A) x 1 in BSP (B)
Female Cone Blanking Plug
892/00055 1/4 in BSP
892/00056 3/8 in BSP
892/00057 1/2 in BSP
892/00058 5/8 in BSP
892/00059 3/4 in BSP
892/00060 1 in BSP
Male Cone Blanking Plug
816/00294 1/4 in BSP
816/00189 3/8 in BSP
816/00190 1/2 in BSP
816/00197 5/8 in BSP
816/00196 3/4 in BSP
816/00193 1 in BSP
5 - 3
Section 1 General Information
9803/6400
Section 1
5 - 3
Issue 1
Service Tools (continued)
SECTION E - HYDRAULICS
Slew Motor Jig
SST0033 Oil Seal Jig
SST0034 Taper Bearing Ring Jig
SST0035 Inner Ring Jig
SST0036 Seal Press Fit Jig
(All dimensions are in mm.)
4
2
ø31
ø40
50
60
ø50
ø99.8
ø124
ø158
3
3015915
15°
SST0033
SST0034
SST0035
SST0036
5 - 4
Section 1 General Information
9803/6400
Section 1
5 - 4
Issue 1
Service Tools (continued)
SECTION E - HYDRAULICS
Ram Dismantling and Assembly
Ram Piston Head Nut (Rig Assembly - Section E, page 75 - 10)
Item Part Number Description Quantity
1 993/99525 Rig assembly (not including spanners and ram) 1
2 993/99522 Anchor side plate (supplied loose unwelded) 1
3 993/99523 Anchor cross member (supplied loose unwelded) 1
4 993/99524 Ram eye end modification 1
5 556/43400 Lift ram 1
6 545/18000 Lynch pin 1
7 811/50232 11/4in Pivot pin 1
Spanner Requirements
JS200/JS200LC/JS220/JS220LC
993/99518 Bucket ram 90 mm A/F Nut
SSP0047 Boom ram 95 mm A/F Nut
993/99519 Dipper ram 100 mm A/F Nut
JS240/JS240LC/JS260/JS260LC
993/99519 Bucket ram 100 mm A/F Nut
993/99519 Boom ram 100 mm A/F Nut
993/99521 Dipper ram 115 mm A/F Nut
Note: All spanners have operating centres of 500 mm.
6 - 1
Section 1 General Information
9803/6400
Section 1
6 - 1
Issue 1
Service Tools (continued)
SECTION F - TRANSMISSION
Track Motor Jig
SST0028 Inner Rail Press Jig
SST0029 Snap Ring Jig
SST0030 Oil Seal Jig
SST0031 Case Fixing Jig
SST0032 Bearing Jig
(All dimensions are in mm.)
ø49.5
100
ø40.5
70
ø59.5
10
ø40
SST0028 SST0029
SST0030 SST0031
SST0032
ø115
ø65
185
140
ø61.5
ø45
180
ø54
ø50.5
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