background image

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, 

electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

World Class

Customer Support

9813/4050-01

Publication No.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Service Manual

JS200W - Wheeled Excavators - Tier 2 

and Tier 4i Engines

Section 1 - General Information

Section 2 - Operator’s Manual

Section B - Body & Framework

Section C - Electrics

Section D - Controls

Section E - Hydraulics

Section F - Transmission

Section K - Engine

Summary of Contents for JS200W

Page 1: ...E World Class Customer Support 9813 4050 01 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889...

Page 2: ...3 4050 01 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section 1 General Informat...

Page 3: ...Section 1 General Information 1 0 1 0 9813 4050 01 Notes Find manuals at https best manuals com...

Page 4: ...ttery Disconnection Connection 1 17 Removing and Replacing Components 1 18 Preparation 1 18 Original Components 1 18 New Components 1 18 Torques and Fixings 1 18 Battery Charging System Precautions 1...

Page 5: ...formation Contents 1 ii 1 ii Page No Contents Tool Detail Reference 1 42 Section B Body and Framework 1 42 Section C Electrics 1 46 Section E Hydraulics 1 47 Section H Steering 1 59 Find manuals at ht...

Page 6: ...1 9813 4050 01 Introduction Identifying Your Machine For information about identifying your machine and its main components refer to Section 2 About the Machine Machine and Component Identification Fi...

Page 7: ...Section 1 General Information Introduction Identifying Your Machine 1 2 1 2 9813 4050 01 Page left intentionally blank Find manuals at https best manuals com...

Page 8: ...nation of the safety notice signal words refer to Section 2 Introduction Safety For general safety notices refer to Section 2 Introduction Safety For maintenance safety notices refer to Section 2 Main...

Page 9: ...Section 1 General Information Safety Introduction 1 4 1 4 9813 4050 01 Page left intentionally blank Find manuals at https best manuals com...

Page 10: ...ns information about the structure of the manual and how to use the manual K Scope T 1 6 K Personnel T 1 6 K Applications T 1 6 K Newest Data T 1 6 K Format T 1 7 K Left Side Right Side T 1 8 K Hydrau...

Page 11: ...rocedures and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment Finally please remember above all else SAFETY MUST COME FIRST Applications This manual co...

Page 12: ...e components and controls Refer also to the safety and daily weekly maintenance information The remaining sections are alphabetically coded and deal with dismantling overhaul etc of specific component...

Page 13: ...General Information Use Left Side Right Side 1 8 1 8 9813 4050 01 Left Side Right Side In this manual left A and right B mean your left and right when you are seated correctly in the machine T017280 1...

Page 14: ...ation of a service Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure Pink Pressure Pressure that is above neutral circuit pressure but lower th...

Page 15: ...Section 1 General Information Use Hydraulic Schematic Codes 1 10 1 10 9813 4050 01 Page left intentionally blank...

Page 16: ...ntenance tasks listed on the maintenance schedules Refer to Section 2 Maintenance Schedules The procedures for the daily and weekly 10 and 50 hour tasks are given in Section 2 Maintenance The procedur...

Page 17: ...Section 1 General Information Routine Maintenance Maintenance Schedules 1 12 1 12 9813 4050 01 Page left intentionally blank...

Page 18: ...parking the machine and making it safe and venting hydraulic pressure These procedures are given here as an alternative to again and again in the manual Where applicable you will see a cross reference...

Page 19: ...neral Procedures Parking the Machine and Making it Safe 1 14 1 14 9813 4050 01 Parking the Machine and Making it Safe For the correct procedures to park and make the machine safe refer to Section 2 Ma...

Page 20: ...ressure Hydraulic fluid at system pressure can injure you Before disconnecting or connecting hydraulic hoses or couplings vent the pressure trapped in the hoses in accordance with the instructions giv...

Page 21: ...c Pressure Hydraulic fluid at system pressure can injure you Before disconnecting or connecting hydraulic hoses or couplings vent the pressure trapped in the hoses in accordance with the instructions...

Page 22: ...n General Procedures Battery Disconnection Connection 1 17 1 17 9813 4050 01 Battery Disconnection Connection For the correct procedures to disconnect connect the battery refer to Section 2 Maintenanc...

Page 23: ...new components are installed Do not substitute components from another machine Components may look the same but may not be interchangeable Refer to the JCB parts systems Torques and Fixings When repl...

Page 24: ...any part of the charging circuit whilst the engine is running Disregarding this instruction will result in damage to the regulator or rectifying diodes Main output cables are live even when the engine...

Page 25: ...trogen gas with a suitable pressure reducing valve 3 Correct gas bottle adaptor depending on territory Charging kit 892 00239 Refer to Section 1 Operating charge pressures accumulators are charged to...

Page 26: ...il the pressure reading reaches 4 bar 72 5 psi ABOVE the operating charge pressure Important DO NOT exceed the maximum working pressure of the accumulator The maximum working pressure is marked on the...

Page 27: ...Section 1 General Information General Procedures Gas Hydraulic Bladder Accumulators 1 22 1 22 9813 4050 01 Page left intentionally blank...

Page 28: ...1 Service Consumables Introduction Consumables such as sealing and retaining compounds are necessary to complete some procedures Before you start work make sure that the consumables show in the tables...

Page 29: ...ealer High Strength A high strength locking fluid for sealing and retaining nuts bolts and screws up to 50 mm diameter and for hydraulic fittings up to 25 mm diameter 4101 0550 10 ml 4101 0552 200 ml...

Page 30: ...lus or minus 3 Torque figures are given for fasteners with different surface treatments Make sure you use the correct torque figures Where torques are given in topics within the other sections always...

Page 31: ...plated bolt Note All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification Note Dacromet bolts due to their high corrosion resistance are use...

Page 32: ...6 177 0 18 0 130 5 3 4 19 0 1 1 8 343 0 35 0 253 0 309 0 31 5 227 9 7 8 22 2 1 15 16 547 0 55 8 403 4 492 0 50 2 362 9 1 25 4 1 1 2 814 0 83 0 600 4 732 0 74 6 539 9 1 1 8 31 7 1 7 8 1181 0 120 4 871...

Page 33: ...1 0 M20 20 30 562 0 57 3 414 5 506 0 51 6 373 2 M24 24 36 971 0 99 0 716 9 874 0 89 1 644 6 M30 30 46 1930 0 196 8 1423 5 1737 0 177 1 1281 1 M36 36 55 3374 0 344 0 2488 5 3036 0 309 6 2239 2 Bolt Siz...

Page 34: ...c Bolt Size Nm kgf m lbf ft ISO Metric Thread mm M3 3 1 2 0 1 0 9 M4 4 3 0 0 3 2 0 M5 5 6 0 0 6 4 5 M6 6 10 0 1 0 7 5 M8 8 24 0 2 5 18 0 M10 10 48 0 4 9 35 5 M12 12 82 0 8 4 60 5 Bolt Size Nm kgf m lb...

Page 35: ...ze Hexagon A F Nm kgf m lbf ft in mm 1 4 19 0 18 0 1 8 13 0 3 8 22 0 31 0 3 2 23 0 1 2 27 0 49 0 5 0 36 0 5 8 30 0 60 0 6 1 44 0 3 4 32 0 81 0 8 2 60 0 1 38 0 129 0 13 1 95 0 1 1 4 50 0 206 0 21 0 152...

Page 36: ...2 D will vary depending upon the torque applied Table 10 BSP Hose Torque Settings BSP Hose Size Hexagon A F Nm kgf m lbf ft in mm 1 8 14 0 14 0 16 00 1 4 1 6 10 3 11 8 1 4 19 0 24 0 27 0 2 4 2 7 17 7...

Page 37: ...Component Connections with Bonded Washers Table 11 BSP Adaptors with Bonded Washers Torque Settings BSP Size Nm kgf m lbf ft in 1 8 20 0 2 1 15 0 1 4 34 0 3 4 25 0 3 8 75 0 7 6 55 0 1 2 102 0 10 3 75...

Page 38: ...e the double spanner method of tightening K Fig 3 T 1 33 Torque spanner 1 Open ended combination spanner 2 T044470 Fig 3 Key Points A rubber trapezoid O Ring seal 3 is pre installed in the Captive O R...

Page 39: ...20 UNF 40 40 6 9 16 18 UNF 46 46 8 3 4 16 UNF 80 80 10 7 8 14 UNF 135 135 12 1 1 16 12 UNF 185 185 16 1 5 16 12 UNF 270 270 20 1 5 8 12 UNF 340 340 24 1 7 8 12 UNF 415 415 Dash size of tube or hose en...

Page 40: ...ys check the torque of the hose before its disassembled If the hose or the adaptor is loose you must specify which component is the cause of the leak For example if the hose is tight and the adaptor t...

Page 41: ...ring being damages as a result of over tightening Torque Stop Hoses have an additional shoulder 6 D which acts as a physical stop Note Minimum dimension 6 E fixed by shoulder 6 D Table 13 BSP Torque S...

Page 42: ...the adaptor Note that the washer should not move freely if the washer is slack do not use the adaptor 3 Check the O ring 7 A is fitted and that it is free from damage or nicks Before fitting the adapt...

Page 43: ...Section 1 General Information Torque Settings Positional Type Hydraulic Adaptors 1 38 1 38 1 05 01 Issue 02 Page left intentionally blank...

Page 44: ...rence Section 1 for content E Hydraulic Flow Test Equipment see Tool Detail Reference Section 1 for content E Hydraulic Hand Pump Equipment see Tool Detail Reference Section 1 for content E Male Adapt...

Page 45: ...Rod Diameter E 892 01017 Ram Protection Sleeve for 30 mm Rod Diameter E 892 01018 Ram Protection Sleeve for 40 mm Rod Diameter E 892 01019 Ram Protection Sleeve for 50 mm Rod Diameter E 892 01020 Ram...

Page 46: ...er 95mm A F E 992 09900 Hexagon Spanner 115mm A F E 992 10000 Hexagon Spanner 125mm A F E 992 10100 Spool Clamp E 992 12300 12V Mobile Oven B 992 12400 24V Static Oven 2 Cartridge B 992 12800 Cut Out...

Page 47: ...20 x 1 UNF 10 993 68110 Adaptor M20 x 5 8 UNF Shoulder 5 993 68105 Adaptor M20 x M20 11 993 68111 Adaptor M20 x 1 2 UNF 6 993 68106 Adaptor M20 x M24 Fig 10 Rivet Nut Tool 1 826 01099 M6 x 16 mm Rivet...

Page 48: ...lication of sealants polyurethane materials etc Fig 14 892 00846 Glass Extractor Handles Used with braided cutting wire to cut out broken glass K Fig 17 T 1 44 Fig 15 892 00847 Nylon Spatula General t...

Page 49: ...ame Unit quantity 500 off Fig 19 992 12300 Mobile Oven 12V 1 cartridge capacity Required to pre heat adhesive prior to use It is fitted with a male plug 703 23201 which fits into a female socket 715 0...

Page 50: ...Section 1 General Information Service Tools Tool Detail Reference 1 45 1 45 9813 4050 01 Fig 23 4104 1310 Hand Cleaner Special blend for the removal of polyurethane adhesives 454g 1 lb tub...

Page 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

Reviews: