jcb JS200W Service Manual
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jcb JS200W Service Manual

Wheeled excavators - tier 2 and tier 4i engines
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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
Publication No.
9813/4050-01
World Class
Customer Support
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.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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  • Page 1 Customer Support 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.
  • Page 2 Customer Support 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.
  • Page 3 Section 1 - General Information Notes: 9813/4050-01 Find manuals at https://best-manuals.com...

  • Page 4: Table Of Contents

    Section 1 - General Information Contents Page No. Introduction Identifying Your Machine ................1-1 Safety Introduction ....................1-3 Introduction ....................1-5 Scope ......................1-6 Personnel ....................1-6 Applications ...................1-6 Newest Data ..................1-6 Format ....................... 1-7 Left Side, Right Side .................. 1-8 Hydraulic Schematic Codes ..............
  • Page 5 Section 1 - General Information Contents Contents Page No. 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 1-ii 1-ii Find manuals at https://best-manuals.com...

  • Page 6: Identifying Your Machine

    Section 1 - General Information 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. 9813/4050-01 Find manuals at https://best-manuals.com...
  • Page 7 Section 1 - General Information Introduction Identifying Your Machine Page left intentionally blank 9813/4050-01 Find manuals at https://best-manuals.com...
  • Page 8 Section 1 - General Information Safety Introduction In this manual and on the machine there are safety notices. The safety notices have different signal words as follows: – DANGER – WARNING – CAUTION – Notice For an explanation of the safety notice signal words, refer to Section 2, Introduction, Safety.

  • Page 9: Safety Introduction

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

  • Page 10: Use

    Section 1 - General Information Introduction This topic contains 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 Hydraulic Schematic Codes ( T 1-9)

  • Page 11: Scope

    Section 1 - General Information Scope Scope Personnel This manual 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...

  • Page 12: Format

    Section 1 - General Information Format Format The manual is compiled in sections, the first two are numbered and contain information as follows: General Information - The section includes general information such as torque settings and service tools. Operator Manual - The section contains a copy of the applicable machine Operator Manual.

  • Page 13: Left Side, Right Side

    Section 1 - General Information Left Side, Right Side 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 Fig 1. 9813/4050-01...

  • Page 14: Hydraulic Schematic Codes

    The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure.
  • Page 15 Section 1 - General Information Hydraulic Schematic Codes Page left intentionally blank 1-10 9813/4050-01 1-10...
  • Page 16 Section 1 - General Information Routine Maintenance Maintenance Schedules This publication contains procedures for carrying out the routine maintenance 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.

  • Page 17: Routine Maintenance Maintenance Schedules

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

  • Page 18: General Procedures

    Section 1 - General Information General Procedures Introduction When work is done on the machine it is important that the correct care is taken. This will help to prevent personal injury and reduce the risk of component failure. As part of the procedures in this manual you will need to do some general procedures. Two examples of these general procedures are;...

  • Page 19: Parking The Machine And Making It Safe

    Section 1 - General Information General Procedures Parking the Machine and Making it Safe Parking the Machine and Making it Safe For the correct procedures to park and make the machine safe, refer to Section 2, Maintenance, Maintenance Positions. 1-14 9813/4050-01 1-14...

  • Page 20: Venting The Hydraulic Pressure

    Section 1 - General Information General Procedures Venting the Hydraulic Pressure Venting the Hydraulic Pressure WARNING Hydraulic 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 given in this publication.

  • Page 21: Connecting/Disconnecting Hydraulic Hoses

    Section 1 - General Information General Procedures Connecting/Disconnecting Hydraulic Hoses Connecting/Disconnecting Hydraulic Hoses WARNING Hydraulic 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 given in this publication.

  • Page 22: Battery Disconnection/Connection

    Section 1 - General Information General Procedures Battery Disconnection/Connection Battery Disconnection/Connection For the correct procedures to disconnect/connect the battery, refer to Section 2, Maintenance, Electrical System, Battery. 1-17 9813/4050-01 1-17...

  • Page 23: Removing And Replacing Components

    Make sure that the correct 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 replacing components always tighten the applicable fixings to the correct torque.

  • Page 24: Battery Charging System Precautions

    Section 1 - General Information General Procedures Battery Charging System Precautions Battery Charging System Precautions Obey the procedures below to prevent damage to the alternator and battery. – Ensure that the battery negative terminal is connected to the earthing cable. –...

  • Page 25: Gas Hydraulic Bladder Accumulators

    Section 1 - General Information General Procedures Gas Hydraulic Bladder Accumulators Gas Hydraulic Bladder Accumulators Some hydraulic circuits and valve blocks are fitted with gas WARNING hydraulic bladder type accumulators. Use only nitrogen gas to charge accumulators. The Before removing accumulators make sure hydraulic use of any other gas can cause the accumulators to K Venting pressure...
  • Page 26 Section 1 - General Information General Procedures Gas Hydraulic Bladder Accumulators Connect the accumulator adaptor 1 (from kit 892/ 00239) to the accumulator. Connect the charging unit 6 to the accumulator adaptor. Connect the charging hose to the pressure regulator 3 using the correct adaptor.
  • Page 27 Section 1 - General Information General Procedures Gas Hydraulic Bladder Accumulators Page left intentionally blank 1-22 9813/4050-01 1-22...

  • Page 28: Service Consumables

    Section 1 - General Information 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 are available. K Sealing and Retaining Compounds ( T 1-24) 1-23 1-07-01 Issue 01 1-23...

  • Page 29: Sealing And Retaining Compounds

    A medium strength sealant suitable for all sizes of 4102/1212 50 ml gasket flanges, and for hydraulic fittings of 25-65 mm diameter. JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml components. Gasketing for all sizes of flange where the strength of the joint is important.

  • Page 30: Torque Settings

    Section 1 - General Information Torque Settings Introduction This topic contains information about torques. Torque values are given for types and sizes of bolts and hydraulic connectors and adaptors. Where a torque is given as a single figure it may be varied by plus or minus 3%. Torque figures are given for fasteners with different surface treatments.

  • Page 31: Zinc Plated Fasteners And Dacromet Fasteners

    For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
  • Page 32 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 kgf m lbf ft kgf m lbf ft 7/16 11.2 10.0 5/16 22.3...
  • Page 33 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric Thread kgf m lbf ft kgf m lbf ft 13.9 10.2 12.5 34.0 25.0...
  • Page 34 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread kgf m lbf ft 10.0 24.0 18.0 48.0 35.5 82.0 60.5 Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size ISO Metric Thread...

  • Page 35: Hydraulic Connections

    Section 1 - General Information Torque Settings Hydraulic Connections Hydraulic Connections 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.
  • Page 36 Section 1 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 2. Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring Note: Dimension 2-D will vary depending upon the torque 2-C which is compressed into a 45° seat machined into the applied.
  • Page 37 Section 1 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size kgf m lbf ft 20.0 15.0 34.0 25.0 75.0 55.0 102.0 10.3 75.0 122.0 12.4...
  • Page 38 Section 1 - General Information Torque Settings Hydraulic Connections Procedure – The swivel-nut is hand-tight 4. – The swivel-nut is tightened to the correct torque Torque all of the O-Ring face seal fittings. Always make setting 5. sure that the correct torque is used to tighten the specific K Table 12.
  • Page 39 Section 1 - General Information Torque Settings Hydraulic Connections Table 12. Assembly Torques for UNF Threads on the ORFS Fittings Product Thread size Series Assembly torque Series Port dash size ISO 11296 Non-adjustable end Adjustable end Inch Port connections males stud 7/16-20 and swivel fittings 1/2-20...
  • Page 40 Section 1 - General Information Torque Settings Hydraulic Connections General If there is a leak from the hydraulic system: – Before the hose is disconnected to examine the O- ring, examine the hose swivel-nut for the broken-line white marker. If there is no visible white marker, K Fig 5.

  • Page 41: Torque Stop' Hose System

    Section 1 - General Information Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 6. `Torque Stop' Hoses 6-B screwed into adaptors 6-A seal Stop' Hoses have an additional shoulder 6-D, which acts onto an 'O' ring 6-C which is compressed into a 45° seat as a physical stop.

  • Page 42: Positional Type' Hydraulic Adaptors

    Note: The dimensions and shore hardness of the `O' ring is critical. Should it become necessary to replace the `O' ring, ensure that only JCB Genuine Parts are used. Screw the adaptor into the port of the hydraulic component as far as possible, so that ALL the threads engage and the `O' ring is correctly seated against the sealing face.
  • Page 43 Section 1 - General Information Torque Settings `Positional Type' Hydraulic Adaptors Page left intentionally blank 1-38 1-05-01 Issue 02 1-38...

  • Page 44: Service Tools

    Tool Detail Reference, Section 1. These tools are available from JCB Service. Note: Tools other than those listed will be required. It is Some tools are available as kits or sets, the part numbers expected that such general tools will be available in any for parts within such kits or sets are not listed here.
  • Page 45 Section 1 - General Information Service Tools Numerical List Part Description See Section Number 892/00275 Adapter 892/00276 Adapter 892/00277 Adapter 892/00279 Gauge 892/00280 Gauge 892/00281 AVO Meter 892/00284 Digital Tachometer 892/00285 Hyd. Oil Temperature Probe 892/00298 Fluke Meter 892/00334 Ram Seal Fitting Tool 892/00346 Gauge 892/00347...
  • Page 46 Section 1 - General Information Service Tools Numerical List Part Description See Section Number 992/09600 Hexagon Spanner 85mm A/F 992/09700 Hexagon Spanner 95mm A/F 992/09900 Hexagon Spanner 115mm A/F 992/10000 Hexagon Spanner 125mm A/F 992/10100 Spool Clamp 992/12300 12V Mobile Oven 992/12400 24V Static Oven (2 Cartridge) 992/12800...
  • Page 47 Section 1 - General Information Service Tools Tool Detail Reference Tool Detail Reference Section B - Body and Framework Note: Not all service tools are illustrated. Fig 9. 993/68100 Slide Hammer Kit 993/68101 Slide Hammer 993/68107 Bar - M20 x M20 X 800 mm 993/68102 End Stops 993/68108...
  • Page 48 Section 1 - General Information Service Tools Tool Detail Reference Fig 15. 892/00847 Nylon Spatula General tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will Fig 12. 892/00843 Folding Stand chip the glass edge. Essential for preparing new glass prior to installation.
  • Page 49 K Fig 14. ( T supplied. extraction tool. 1-43). Approx 25 m length. Note: 110V models available upon request - contact JCB Technical Service. Fig 18. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.
  • Page 50 Section 1 - General Information Service Tools Tool Detail Reference Fig 23. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub). 1-45 9813/4050-01 1-45...
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