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jcb JS200 Service Manual

jcb JS200 Service Manual

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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

Issue 2

General Information

Care & Safety

R

Routine Maintenance

Attachments

Body & Framework

Electrics

Hydraulics

Transmission

Brakes

Track & Running Gear

Engine

1

2

3

A

B

C

E

F

G

J

K

Table of Contents

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Table of Contents

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Summary of Contents for jcb JS200

Page 1 708001 JS260 Brakes from machine no. 708501 PUBLISHED BY THE Track & Running Gear TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © WATERLOO PARK, UTTOXETER, STAFFORDSHIRE, ST14 5PA, ENGLAND Tel. ROCESTER (01889) 590312 Engine PRINTED IN ENGLAND Publication No. 9803/6400...
Page 2 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.
Page 3 General Information Section 1 Section 1 Contents Page No. Bolt and Nut Torque Specifications 1 - 1 Service Tools Section C - Electrics 4 - 1 Section E - Hydraulics 5 - 1 Section F - Transmission 6 - 1 Sealing and Retaining Compounds 7 - 1 9803/6400...
Page 4 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 JS200/210/220/240/260 Tightening Point Bolt Diameter Wrench...
Page 5 General Information Section 1 Section 1 4 - 1 4 - 1 Service Tools SECTION C - ELECTRICS Electrical Test Equipment 892/00283 Tool Kit Case 892/00281 AVO Meter 892/00286 Surface Temperature Probe 892/00284 Microtach Digital Tachometer 892/00282 Shunt - open type 892/00285 Hydraulic Oil Temperature Probe 892/00298...
Page 6: Service Tools
General Information Section 1 Section 1 5 - 1 5 - 1 Service Tools (continued) SECTION E - HYDRAULICS Hydraulic Pressure Test Gauges and Connections 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in 892/00347 Connector 892/00254 Hose...
Page 7: Section E - Hydraulics
General Information Section 1 Section 1 5 - 2 5 - 2 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...
Page 8 General Information Section 1 Section 1 5 - 3 5 - 3 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.) SST0033 SST0034...
Page 9 Anchor cross member (supplied loose unwelded) 993/99524 Ram eye end modification 556/43400 Lift ram 545/18000 Lynch pin 811/50232 in Pivot pin 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...
Page 10: Section F - Transmission
General Information Section 1 Section 1 6 - 1 6 - 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...
Page 11 General Information Section 1 Section 1 6 - 2 6 - 2 Service Tools (continued) SECTION F - TRANSMISSION Track Gearbox Jig SST0037 Re-sealing Tool SST0038 Main Bearing Tool SST0039 Main Bearing Tool (All dimensions are in mm.) ø315 ø270 ø304 ø306 SST0037...
Page 12 General Information Section 1 Section 1 6 - 3 6 - 3 Service Tools (continued) SECTION F - TRANSMISSION Track Gearbox Jig SST0040 Ring Nut Tool SST0041 Planet Gear Tool (All dimensions are in mm.) 38.1sq ø9.7 ø9.5 no.4 dowel SST0040 ø233.5 ø248...
Page 13: Sealing And Retaining Compounds
50 ml (High Strength) components. Gasketing for all sizes of flange where the strength of the joint is important. JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/0651 50 ml JCB Threadlocker and Sealer...
Page 14 Care & Safety Section 2 Section 2 Contents Page No. Safety Notices 1 - 1 General Safety 2 - 1 Operating Safety 3 - 1 Maintenance Safety 4 - 1 4 - 2 9803/6400 Issue 1...
Page 15 Care & Safety Section 2 Section 2 1 - 1 1 - 1 In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. ! DANGER Denotes an extreme hazard exists.
Page 16 Note: This section includes a certain amount of operating safety information. But remember that whenever you drive hazardous. When JCB Excavator is correctly operated and the machine or operate its controls, you are in effect a properly maintained, it is a safe machine to work with. But machine operator.
Page 17 It shoul not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor. INT-2-1-14 9803/6400 Issue 1...
Page 18 Care & Safety Section 2 Section 2 4 - 1 4 - 1 Maintenance Safety ! WARNING ! WARNING Soft Ground Fires A machine can sink into soft ground. Never work under a If your machine is equipped with a fire extinguisher, make machine on soft ground.
Page 19 Care & Safety Section 2 Section 2 4 - 2 4 - 2 Maintenance Safety (continued) ! CAUTION ! CAUTION Arc Welding Rams Before carrying out any arc welding on the machine, The efficiency of the rams will be affected if they are not kept completely remove the Control Computer to avoid damage to free of solidified dirt.
Page 20: Table Of Contents
Routine Maintenance Section 3 Section 3 Contents Page No. Fluids and Lubricants 1 - 1 Lubricants - Health and Safety 1 - 2 Service Schedules 2 - 1 Greasing Slew Ring Bearing 3 - 1 Slew Ring Teeth and Slew Pinion 3 - 1 Excavator End 3 - 2...
Page 21 Routine Maintenance Section 3 Section 3 Contents Page No. Engine Changing the Air Filter Elements 8 - 1 Checking the Oil Level 8 - 2 Changing the Oil and Filter(s) 8 - 2 Checking the Coolant Level 8 - 3 Coolant Mixtures 8 - 3 Changing the Coolant...
Page 22: Fluids And Lubricants
310 litres (68.19 UK gal) (81.19 US gal) ENGINE LUBRICATION CHART Use according to ambient temperature (°C) JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F JCB SUPER 10W/30 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F 9803/6400 Issue 3*...
Page 23: Lubricants - Health And Safety
7-3-1-3/1 f. Don't keep oily rags in pockets. Hygiene g. Wash dirty clothing before re-use. JCB lubricants are not a health risk when used properly for h. Throw away oil-soaked shoes. their intended purposes. Waste Disposal However, excessive or prolonged skin contact can remove All waste products should be disposed of in accordance with the natural fats from your skin, causing dryness and irritation.
Page 24: Service Schedules
Routine Maintenance Section 3 Section 3 2 - 1 Service Schedules 2 - 1 Service Intervals for Hydraulic Oil and Filters when using a Breaker, Crusher or Pulveriser When using a breaker, crusher or pulveriser contamination and degradation of the hydraulic oil occurs much more quickly than in normal excavating use.
Page 25 Routine Maintenance Section 3 Section 3 2 - 2 Service Schedules 2 - 2 Initial Precautions for New Machine Usage ! CAUTION If the machine is operated at full load, before its initial run-in procedure is complete it may cause scuffing and seizing which can adversely effect the life of the machine.
Page 26 Routine Maintenance Section 3 Section 3 2 - 3 Service Schedules 2 - 3 Every 10 Operating Hours or Daily Every 100 Operating Hours or 2-Weekly Whichever occurs first Whichever occurs first 1. Clean 1. Do a 50 hour service plus: a.
Page 27 Routine Maintenance Section 3 Section 3 2 - 4 Service schedules (continued) 2 - 4 Every 250 Operating Hours or Monthly Every 1000 Operating Hours or 6-Monthly Whichever occurs first Whichever occurs first 1. Do a 500 hour service plus: 1.
Page 28 Routine Maintenance Section 3 Section 3 2 - 5 Service schedules (continued) 2 - 5 Every 5000 Operating Hours or 2 Years 6 Months Whichever occurs first 1. Do a 1000 hour service plus: 2. Change Hydraulic oil. Hydraulic tank air breather element. Hydraulic suction filter†††.
Page 29: Greasing
Routine Maintenance Section 3 Section 3 3 - 1 Greasing 3 - 1 ! WARNING General Notes You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the For the type of grease to use at each point, see Lubricants starter key and disconnect the battery.
Page 30: Excavator End
Routine Maintenance Section 3 Section 3 3 - 2 Greasing (continued) 3 - 2 ! WARNING Excavator End You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the 16 Grease Points - plus 3 for Triple Articulating Boom (if starter key and disconnect the battery.
Page 31 Routine Maintenance Section 3 Section 3 3 - 3 Greasing (continued) 3 - 3 Excavator End JS240/JS260 JS200/JS220 JS03490 JS03720 JS03750 JS02970 9803/6400 Issue 2*...
Page 32: Battery
Routine Maintenance Section 3 Section 3 4 - 1 Battery 4 - 1 First Aid - Electrolyte Checking the Electrolyte Level Maintenance free batteries used in normal temperate EYES climate applications should not need topping up. FLUSH WITH WATER FOR 15 MINUTES. GET MEDICAL However, in certain conditions (such as prolonged HELP FAST.
Page 33: Hydraulics
Routine Maintenance Section 3 Section 3 5 - 1 Hydraulics 5 - 1 Air Bleeding Procedures Air Bleeding Sequence ! WARNING Air Bleeding Air Bleeding Air Bleeding from slew Check Hydraulic Pressure from pump from ram motor Hydraulic oil or Hydraulic fluid at system pressure can injure you.
Page 34: Air Bleeding From Hydraulic Pump
5 - 2 Air Bleeding from Hydraulic Pump ! WARNING Hydraulic Pressure *JS200/210/220/240/260 Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open.
Page 35: Air Bleeding From The Slew Motor
Hydraulics (continued) 5 - 3 Air Bleeding from the Slew Motor ! WARNING JS200/JS210/JS220 JS240/JS260 DO NOT remove the hydraulic tank filler cap or cover plate when the engine is running. The hydraulic system is under pressure. You or others could be injured. First stop the engine and then release the pressure.
Page 36: Checking The Fluid Level
Routine Maintenance Section 3 Section 3 5 - 4 Hydraulics (continued) 5 - 4 For location of hydraulic oil tank see Component Location Diagram. ! WARNING Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks.
Page 37: Changing The Hydraulic Oil
Routine Maintenance Section 3 Section 3 5 - 5 Hydraulics (continued) 5 - 5 Changing the Hydraulic oil ! WARNING DO NOT remove the hydraulic tank filler cap or cover plate when the engine is running. The hydraulic system is under pressure. You or others could be injured. First stop the engine and then release the pressure.
Page 38: Changing The Return Filter Element
Routine Maintenance Section 3 Section 3 5 - 6 Hydraulics (continued) 5 - 6 Changing the Hydraulic Oil (continued) Bleed the Hydraulic Components See Air Bleeding Procedures Check for leaks a. Start the engine and run it for around 5 minutes without load.
Page 39: Cleaning/Changing The Suction Strainer
Routine Maintenance Section 3 Section 3 5 - 7 Hydraulics (continued) 5 -7 Cleaning/Changing the Suction Strainer Prepare the Machine Position the machine on level ground Stop the engine. Remove the starter key. Locate the suction Strainer See Component Location Diagrams at the end of the section.
Page 40: Changing The Air Breather Element
Routine Maintenance Section 3 Section 3 5 - 8 Hydraulics (continued) 5 - 8 Changing the Air Breather Element Prepare the Machine Position the machine on level ground. Stop the engine. Remove the Starter Key. Release Tank Pressure See Releasing Tank Pressure. Locate the Air Breather Element See Identification of Machine Components.
Page 41: Draining Tank Impurities
Routine Maintenance Section 3 Section 3 5 - 9 Hydraulics (continued) 5 - 9 Draining Tank Impurities ! WARNING Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary.
Page 42: Changing The Breaker In-Line Filter
Routine Maintenance Section 3 Section 3 5 - 10 Hydraulics (continued) 5 - 10 Changing the Breaker In-line Filter Note: This filter should be changed at the intervals stated in Service Schedules or when the visual indicator X has popped up. DO NOT USE THE BREAKER WITH A BLOCKED FILTER.
Page 43: Changing The Nephron Filter
Routine Maintenance Section 3 Section 3 5 - 11 Hydraulics (continued) 5 - 11 Changing the Nephron Filter ! WARNING The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools down (less than 40°C) before beginning maintenance.
Page 44: Transmission
Routine Maintenance Section 3 Section 3 6 - 1 Transmission 6 - 1 Note: There are three alternative configurations of filler, level and drain plugs as shown in figures X, Y and Z. The following text covers all configurations. Checking the Track Gearbox Oil Level Prepare the Machine Position the machine on level ground with the level and drain plugs as illustrated.
Page 45: Checking The Slew Gearbox Oil Level
Transmission (continued) 6 - 2 Checking the Slew Gearbox Oil Level Prepare the Machine *JS200/JS210/JS220 Position the machine on level ground. Stop the engine and remove the starter key. Locate the Slew Gearbox See Component Location Diagrams at the end of this section.
Page 46: Tracks And Running Gear
Routine Maintenance Section 3 Section 3 7- 1 Tracks and Running Gear 7 - 1 Cleaning the Tracks ! WARNING ! WARNING Rotating the tracks off the ground may cause stones and If two people are doing this job make sure that the other debris to be thrown with considerable force.
Page 47: Checking/Adjusting The Track Tension
Routine Maintenance Section 3 Section 3 7 - 2 Tracks and Running Gear (continued) 7 - 2 Checking/Adjusting the Track Tension Prepare the Machine Position the machine on level ground. Run it backwards and forwards several times. Stop after running it forwards.
Page 48: Checking The Shoe Plate
Routine Maintenance Section 3 Section 3 7 - 3 Tracks and Running Gear (continued) 7 - 3 Checking the Shoe Plate Prepare the Machine a. Position the machine on level ground. Run it backwards and forwards several times. Stop after running it forwards.
Page 49 Routine Maintenance Section 3 Section 3 8 - 1 Engine 8 - 1 Changing the Air Filter Elements 1. Prepare the Machine Put the machine on level ground. Lower the bucket to the ground. 2. Stop the Engine Remove the starter key. Note: Renew the inner element every second time you renew the outer element.
Page 50 Routine Maintenance Section 3 Section 3 8 - 2 Engine (continued) 8 - 2 Checking the Oil Level Prepare the Machine Park the machine on level ground. Lower the bucket to the ground. Stop the Engine Open the Engine Compartment Check the Oil Level Remove the dipstick A.
Page 51 Park the Machine on Level Ground To prevent the coolant freezing in cold conditions, antifreeze Stop the engine and let it cool down. Open the engine must be added. JCB Four Seasons Antifreeze and compartment. Summer Coolant will give protection down to the temperatures shown in the table.
Page 52 Routine Maintenance Section 3 Section 3 8 -4 Engine (continued) 8 - 4 Changing the Coolant Do Steps 1 and 2 of 'Checking the Coolant Level' Drain the System Open the radiator drain tap A. Remove the cylinder block drain plug B. Remove the expansion bottle cap (see Checking the coolant Level).
Page 53 Routine Maintenance Section 3 Section 3 8 - 5 Engine (continued) 8 - 5 Adjusting the Fan Belt ! WARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5 Check the Fan Belt Tension There must be 10 mm (0,4 in) slack at D on the belt.
Page 54 Routine Maintenance Section 3 Section 3 8 - 6 Engine (continued) 8 - 6 Cleaning the Radiator and Oil Cooler A clogged radiator and/or oil cooler can lead to engine overheating. Regularly check for a build-up of dirt and debris and, if necessary, use compressed air to clean out the grille.
Page 55 Routine Maintenance Section 3 Section 3 8 - 7 Engine (continued) 8 - 7 Draining Fuel Tank Impurities Stop the engine and remove the key. Loosen the drain tap A on the underside of the fuel tank. Drain the water and deposits until clean diesel oil flows out. Close the drain tap firmly.
Page 56 Routine Maintenance Section 3 Section 3 8 - 8 Engine (continued) 8 - 8 Bleeding the Fuel System Air in the fuel system could cause misfiring or failure to start. Air will enter the system if any part of it is disconnected or emptied.
Page 58 Routine Maintenance Section 3 Section 3 10 - 1 Performance Evaluation JS200/JS240 10 - 1 Introduction It is important before taking measurements that control conditions are maintained. a. Position the machine on a level safe site. b. Adhere strictly to the safety operation.
Page 59 Routine Maintenance Section 3 Section 3 10 - 2 Performance Evaluation JS200/JS240 10 - 2 Speed Measurements a. Bucket Ram speed. The conditions for checking are that the Dipper should be level. Measurement is of the time it takes the bucket to fully open and close from each end of the stroke b.
Page 60 Routine Maintenance Section 3 Section 3 10 - 3 Performance Evaluation JS200/JS240 10 - 3 Other Measurements a. Travel Linearity. MEASUREMENT METHOD The conditions for checking are that the machine should have an approach of 5 metres and a travel distance of 20 metres;...
Page 61 Routine Maintenance Section 3 Section 3 10 - 4 Performance Evaluation JS200/JS240 10 - 4 Other Measurements (continued) c. Lateral Movement in turntable bearing. 2. Install a dial gauge and set the needle to the Zero 1. First set the Dipper in a perpendicular position and position the bucket 200 mm above the ground, stop Point.
Page 62 Routine Maintenance Section 3 Section 3 10 - 5 Performance Evaluation JS200/JS240 10 - 5 Other Measurements (continued) d. Slew Brake 1. The slew brake performance is measured at the minimum slew position. Mark the turntable bearing and lower ring.
Page 63 Routine Maintenance Section 3 Section 3 10 - 6 Performance Evaluation JS200/JS240 10 - 6 Other Measurements (continued) g. Amount of Hydraulic Oil squeezed out by each ram. 1. To check the amount of hydraulic fluid squeezed out by each ram rod, check the oil ring state after moving the rod 100 metres, wipe all the rods and confirm there are no scratches.
Page 64 Routine Maintenance Section 3 Section 3 12-1 12-1 FOPS Structure Checking the FOPS Structure All excavators are designed so that an operator’s Check that all the FOPS mounting bolts are in place and undamaged. Check the FOPS mounting bolts for correct protective structure can be fitted.
Page 65 1 - 1 Undercarriage Dimensions 2 - 1 Main Body Weights 3 - 1 Maintenance Specifications JS200, JS200LC Boom and Slew Frame Installation 4 - 1 Boom Ram Installation 4 - 1 Dipper Ram Installation 4 - 2 Dipper Pivot Installation...
Page 66 Body & Framework Section B Section B 1 - 1 Torque Specifications 1 - 1 Torque Specifications JS200/JS240 Component kgfm lb/ft Remarks Counterweight 1059.1-1235.6/1333.7-1549.5 108-126/136-158 780-910.98/983.28-1142.3 Apply 262 Turntable Bearing (Lower Frame) 521.0-608/784-914 53.1-62/79.9-93.2 383.91-448.26/577.67-673.83 Apply 262 Turntable Bearing (Slew Frame) 521.0-608/784-914...
Page 67 Body & Framework Section B Section B 2 - 1 Undercarriage 2 - 1 Dimensions JS200/JS220 9803/6400 Issue 2*...
Page 68 Body & Framework Section B Section B 2 - 2 Undercarriage 2 - 2 Dimensions JS200LC/JS220LC 9803/6400 Issue 2*...
Page 69 Body & Framework Section B Section B 2 - 3 Undercarriage 2 - 3 Dimensions JS240/JS260 9803/6400 Issue 2*...
Page 70 Body & Framework Section B Section B 2 - 4 Undercarriage 2 - 4 Dimensions JS240LC/JS260LC 9803/6400 Issue 2*...
Page 71 Body & Framework Section B Section B 3 - 1 Main Body 3 - 1 Weights JS200, JS200LC, JS220, JS220LC, JS240, JS240LC, JS260, JS260LC 9803/6400 Issue 2*...
Page 72 Body & Framework Section B Section B 3 - 2 Main Body 3 - 2 Weights JS200, JS200LC, JS220, JS220LC Machine fitted with 3 m boom, 600 mm grouser shoes, 0.7 m bucket (JS200/220), 0.8 m bucket (JS200LC/220LC). Weight (kg) Position...
Page 73 Body & Framework Section B Section B 3 - 3 Main Body 3 - 3 Weights JS200, JS200LC, JS220, JS220LC, JS240, JS240LC, JS260, JS260LC Dry Weight (kg) Part Name JS200/220 JS200LC/220LC JS240/260 JS240LC/260LC Travel motor Drive Sprocket Take-up roller Upper roller assembly...
Page 74: Boom Ram Installation
Body & Framework Section B Section B 4 - 1 Maintenance Specifications 4 - 1 Attachments Boom and Slew Frame Installation JS200, JS200LC Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 1. Boom and Slew frame slew frame...
Page 75: Dipper Ram Installation
Body & Framework Section B Section B 4 - 2 Maintenance Specifications 4 - 2 Attachments (continued) Dipper Ram Installation JS200, JS200LC Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 4. Dipper ram Boom installation Dipper ram...
Page 76: Dipper Pivot Installation
Clearance 0.5-1.1 KRV1180 ø90 ø89 Bushing ø90 ø91.5 (Dipper) Bushing ø90 ø91.5 (boom) Boom ø80 Dipper and Dipper Ram Installation JS200, JS200LC Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 6. Dipper and Boom Dipper ram installation...
Page 77: Bucket Ram Installation
Bucket (eye end) Shim for Clearance 0.5-3.0 adjustment KRV1176 ø75 ø74 Bushing ø75 ø76.5 (bucket ram) Dipper and Dipper Link Installation JS200, JS200LC Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 8. Dipper and Dipper Link Dipper...
Page 78: Bucket Link And Bucket Ram Installation
Body & Framework Section B Section B 4 - 5 Maintenance Specifications 4 - 5 Attachments (continued) Bucket and Bucket Link Installation JS200, JS200LC Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 9. Bucket and Bucket bucket link...
Page 79: Bucket And Dipper Installation
Body & Framework Section B Section B 4 - 6 Maintenance Specifications 4 - 6 Attachments (continued) Bucket and Dipper Installation JS200, JS200LC Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 11. Bucket and Bucket dipper installation...
Page 80: Shim Adjustment Table
Body & Framework Section B Section B 4 - 7 Maintenance Specifications 4 - 7 Attachments (continued) Shim Adjustment Table (Unit: mm) Shim Shim Outer Diameter Diameter Thickness KNV0538 BHV1034 KNV0696 KNV0539 KRV1176 KHV0169 KNV0534 KRV1197 KRP1349 KRV1178 KHV0170 KBV0837 KSP0268 KNV0468 9803/6400...
Page 81 Body & Framework Section B Section B 4 - 8 Maintenance Specifications 4 - 8 Attachments (continued) Shim Adjustment Table (continued) (Unit: mm) Shim Outer Diameter Diameter KBV0764 KRV1180 KBV0474 KRV1159 KBV0713 9803/6400 Issue 2*...
Page 82: Boom And Slew Frame Installation
Body & Framework Section B Section B 5 - 1 Maintenance Specifications 5 - 1 Attachments (continued) Boom and Slew Frame Installation JS240, JS240LC Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 1. Boom and Slew frame slew frame installation Boom...
Page 83 Body & Framework Section B Section B 5 - 2 Maintenance Specifications 5 - 2 Attachments (continued) Dipper Ram Installation JS240, JS240LC Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 4. Dipper Ram Boom installation Dipper ram (dump end) Shim for adjustment...
Page 84: Dipper Ram Installation
Body & Framework Section B Section B 5 - 3 Maintenance Specifications 5 - 3 Attachments (continued) Dipper Pivot Installation JS240, JS240LC Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 5. Dipper Pivot Boom 289.5 installation Dipper 285.5 283.5 Shim for...
Page 85 Body & Framework Section B Section B 5 - 4 Maintenance Specifications 5 - 4 Attachments (continued) Bucket Ram Installations JS240, JS240LC Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 7. Bucket ram Dipper installation Bucket (eye end) Shim for Clearance 0.5-3.0...
Page 86: Bucket Link And Bucket Ram Installation
Body & Framework Section B Section B 5 - 5 Maintenance Specifications 5 - 5 Attachments (continued) Bucket and Bucket Link Installation JS240, JS240LC Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 9. Bucket and Bucket bucket link installation Bucket link Shim for...
Page 87: Bucket And Dipper Installation
Body & Framework Section B Section B 5 - 6 Maintenance Specifications 5 - 6 Attachments (continued) Bucket and Dipper Installation JS240, JS240LC Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 11. Bucket and Bucket Dipper installation Dipper Shim for Clearance...
Page 88: Shim Adjustment Table
Body & Framework Section B Section B 5 - 7 Maintenance Specifications 5 - 7 Attachments (continued) Shim Adjustment Table (Unit: mm) Shim Shim Outer Diameter Diameter Thickness KNV0538 BHV1034 KNV0696 KNV0539 KRV1176 KHV0169 KNV0534 KRV1197 KRP1349 KRV1178 KHV0170 KBV0837 KSP0268 KNV0468 9803/6400...
Page 89 Body & Framework Section B Section B 5 - 8 Maintenance Specifications 5 - 8 Attachments (continued) Shim Adjustment Table (continued) (Unit: mm) Shim Outer Diameter Diameter KBV0764 KRV1180 KBV0474 KRV1159 KBV0713 9803/6400 Issue 2*...
Page 90: Direct Glazing
Reference is made to the tools in the text. The majority of these tools can be obtained locally and the remainder from JCB Service (see Service Tools, Section 1). The work must only be carried out in a dry, frost free environment.
Page 91 Body & Framework Section B Section B 6 - 2 6 - 2 Direct Glazing (cont'd) Removing the Broken Glass and Old Sealant (cont'd) Position the machine on level ground and apply the parking brake. Stop the engine. Put protective covers over the cab seat and control pedestals.
Page 92 Body & Framework Section B Section B 6 - 3 6 - 3 Direct Glazing (cont'd) Removing the Broken Glass and Old Sealant (cont'd) b Cut-out Knife F. The cut-out knife can be used as a left handed or right handed tool. For the knife and its replaceable blades, refer to Service Tools, Section (i) Insert the knife blade into the sealant.
Page 93 Body & Framework Section B Section B 6 - 4 6 - 4 Direct Glazing (cont'd) Preparing the New Glass Make sure that the new glass correctly fits the frame aperture K. a Put two spacer blocks L onto the bottom part of the frame aperture.
Page 94 Body & Framework Section B Section B 6 - 5 6 - 5 Direct Glazing (cont'd) Preparing the New Glass (cont'd) Install the Ultra Fast Adhesive cartridge (see Sealing and Retaining Compounds, Section 1 and Note 2 below) into a suitable applicator gun: 10-15 mm a Remove the aluminium disc cover from the base of the cartridge and discard the 'dessicant capsule'.
Page 95 Body & Framework Section B Section B 6 - 6 6 - 6 Direct Glazing (cont'd) Installing the New Glass (cont'd) Make the inside seal smooth: a Wearing surgical gloves, dip your finger in a soapy water solution. b Use your finger to make the inside seal smooth. All exposed edges must be sealed using Black Polyurethane Sealant (see Sealing and Retaining Compounds, Section 1).
Page 96: Air Conditioning (Optional)
Body & Framework Section B Section B 12 - 1 Air Conditioning 12 - 1 Direction of flow through air conditioning system A306820 Compressor Condenser Receiver/Drier Expansion Valve Evaporator Coil Air Filter Air Filter 9803/6400 Issue 1...
Page 97: Operation
Body & Framework Section B Section B 12 - 2 Air Conditioning 12 - 2 Operation The compressor 1 draws in low pressure refrigerant gas from To maintain optimum operator comfort in warm climates or during seasons of high ambient temperature, the air the suction line (evaporator to compressor) and increases conditioning system recirculates, clean, dehumidified air into refrigerant pressure through compression.
Page 98: Control
Body & Framework Section B Section B 12 - 3 Air Conditioning 12 - 3 Operation (cont'd) Safety Procedures The high temperature, high pressure refrigerant is forced by compressor action into the expansion valve 4, which meters The air conditioning system includes a pressurised closed circuit containing a non-CFC, environmentally friendly the amount of refrigerant entering the evaporator.
Page 99 Body & Framework Section B Section B 12 - 4 Air Conditioning 12 - 4 Operation (cont'd) Note: In dusty conditions, it is recommended that air be recirculated within the cab, otherwise the filter may become clogged. Two air vents M are located in the cab rear panel, and two air vents N and P are located on the right hand console.
Page 100: Fault Finding
Body & Framework Section B Section B 12 - 5 Air Conditioning 12 - 5 Fault Finding Procedures that require charging or discharging the system are not given in this manual as they require special equipment that is usually held only by trained refrigeration engineers. Fault indications are given in the table below. The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment.
Page 101 Body & Framework Section B Section B 12 - 6 Air Conditioning 12 - 6 9803/6400 Issue 1...
Page 102 Body & Framework Section B Section B 12 - 7 Air Conditioning 12 - 7 Fault Finding (cont'd) No Air Conditioning CHECK ACTION Are the controls set correctly, i.e. air conditioning YES: Check 2 selected, thermostat switch set to coldest position Reset controls and retest.
Page 103: Checking Refrigerant Charge Level
Body & Framework Section B Section B 12 - 8 Air Conditioning 12 - 8 Checking Refrigerant Charge Level Leak Testing ! WARNING The pressure in the system, i.e. the refrigerant charge level Leak testing in Air Conditioning systems should be can be determined by checking the state of refrigerant at the carried out only in a well ventilated area.
Page 104: System Diagnosis
Body & Framework Section B Section B 12 - 9 Air Conditioning 12 - 9 System Diagnosis Normally Functioning A/C System Normal gauge readings will depend on system components and ambient conditions, make sure that the valves are closed Gauge Readings: and the readings are stable and that the system has a full Low Side Gauge - Normal.
Page 105 Body & Framework Section B Section B 12 - 10 Air Conditioning 12 - 10 System Diagnosis (cont'd) Low R-134a Charge LOW SIDE (RED) HIGH SIDE (BLUE) Gauge Readings: Low Side Gauge - Low. High Side Gauge - Low. Other symptoms: Sight Glass - Bubbles continuously visible.
Page 106 Body & Framework Section B Section B 12 - 11 Air Conditioning 12 - 11 System Diagnosis (cont'd) No Refrigerant Circulation LOW SIDE (RED) HIGH SIDE (BLUE) Gauge Readings: Zero to negative Low Side Gauge - Zero to negative. High Side Gauge - Low. Other symptoms: Receiver-Drier - Frost or moisture on tubes before and after receiver-drier.
Page 107 Body & Framework Section B Section B 12 - 12 Air Conditioning 12 - 12 System Diagnosis (cont'd) Air in System LOW SIDE (RED) HIGH SIDE (BLUE) Gauge Readings: High High Low Side Gauge - High. High Side Gauge - High. Other symptoms: Sight Glass - Bubbles visible during system operation.
Page 108 Electrics Section C Section C Contents Page No. The A.M.S System Technical Data Battery Testing Schematic Diagram Layout Operator’s Cab Right Console Left Console Monitor Control, Function, Operation Engine Control Basic Operation Stepping Motor Throttle Related Function Stop Motor Function Redundancy (back-up) Throttle Control Automatic Engine Adjustment Idling Control...
Page 109: The A.m.s System
1 - 1 1 - 1 The A.M.S. system The JCB A.M.S. system (Advanced Management System) is a whole machine electronic control system which replaces the CAPS II system. The system controls engine speed, pump power, transmission, excavator functions, lights, wiper, auxiliary circuits, warning lamps, etc.
Page 110: Technical Data
Electrics Section C Section C 2 - 1 Technical Data 2 -1 Circuit Protection; Fuse rating and circuit names BACK UP COMPUTER P. KEY SW. COMPUTER C. AIRCON., HEATER SHUT DOWN LAMP LEVER LOCK LAMP (SPARE) LUBRICATOR LAMP (SPARE) WARNING BEACON LAMP (SPARE) OIL PUMP WIPER, WASHER...
Page 111: Battery Testing
Electrics Section C Section C 2 - 2 2 - 2 Batteries Testing - Specific Gravity The specific gravity of the electrolyte gives an idea of the Readings should be as tabulated and should not vary state of charge of the battery. Readings should be taken between cells by more than 0.04.
Page 112: Schematic Diagram
Electrics Section C Section C 2 - 3 Schematic Diagram 2 - 3 Main Components Cigar Lighter Switch - Hydraulic Oil Overheat Loudspeaker Switch - Hydraulic Oil Reserve Tank Level Radio Aerial Lead Switch - Air Filter Blocked Radio (Standard) Control - Hydraulic Pump Radio (AM/FM) (Optional) Pressure Switch - Upper Pilot Pressure...
Page 114: Operator's Cab
Electrics Section C Section C 3 - 1 Layout 3 - 1 Operator’s Cab A296530 Left Excavator Joystick Control Right Console Control Lock Lever Right Excavator Joystick Control Left Console Display Monitor 10 Door Lock Release Lever Right Hand Track Control 11 Optional Circuit Pedal (if fitted) Left Hand Track Control 12 Operators seat...
Page 115: Right Console
Electrics Section C Section C 3 - 2 Layout 3 - 2 Right Console For correct operation and description see 'Operator’s Handbook' RIGHT CONSOLE JS02980 Note: Your machine will be equipped with hand controller type A or B. Idle Switch Right Console Tilt Handle (If fitted)
Page 116 Electrics Section C Section C 3 - 3 Layout 3 - 3 Right Console (continued) Horn Volume Soft/Hard Starter Switch Buzzer Stop Switch Power-up button JS03010 Right Console (side panel) Time Adjust Back-up ADJUST/CLOCK CLOCK 9803/6400 Issue 2*...
Page 117: Left Console
Electrics Section C Section C 3 - 4 Layout 3 - 4 Left Console For correct operation and description see 'Operator’s Manual' LEFT CONSOLE JS02990 Note: Your machine will be equipped with hand controller type A or B. Left Console Swing Brake Switch Tilt Handle SWING BRAKE...
Page 118: Monitor
Electrics Section C Section C 3 - 5 Layout 3 - 5 Monitor For correct operation see 'Operator’s Manual' WORK MODE Message MODE CLOCK WATER TEMP HYD. OIL TEMP FUEL Water Temp Machine Condition Indicators Green White WATER TEMP Lock Indicator Fuel Indicator Green FUEL...
Page 119: Control, Function, Operation
Electrics Section C Section C 3 - 6 Layout 3 - 6 Control, Function, Operation FUNCTION CONTROL OPERATION Slight difference of RPM between each mode Engine speed varies according to mode: Idling RPM is regulated S Mode is100rpm less than H mode Engine revolutions automatic according to the mode L Mode is 200rpm less than H mode...
Page 120 Electrics Section C Section C 3 - 7 Layout 3 - 7 Control, Function, Operation FUNCTION OPERATION CONTROL The supply current to Pump control depends on work such electromagnetic proportional as, H mode, large working load, S Pump control pressure reducing valve which mode, good fuel economy, and L is built into the pump, is mode, for fine operation.
Page 121: Engine Control
Electrics Section C Section C 4 - 1 Engine Control 4 - 1 Basic Operation The engine throttle control is done with the electric throttle motor. A stepping motor is now used as part of the throttle motor. Stepping Motor This rotates in direct synchronization with the amount of pulses received from the pulse oscillator.
Page 122 Electrics Section C Section C 4 - 2 Engine Control 4 - 2 Stepping Motor (continued) Driver Circuit (driver) The driver circuit of a stepping motor consists of a logical section which forms and distributes a pulsed signal from an oscillator and an amplifying section which amplifies and supplies the signal to the motor.
Page 123: Throttle Related Function
Electrics Section C Section C 4 - 3 Engine Control 4 - 3 Throttle related function A signal enters CN2-9 of the controller and ACC of the motor driver from ACC key switch. (24V) The controller and the driver sense that the key switch is ON, when this signal enters. The controller sends a clockwise rotation instruction (CN8-2) to the driver, and the driver sends a pulse clockwise rotation (ABA1B1) to the throttle motor.
Page 124 Electrics Section C Section C 4 - 4 Engine Control 4 - 4 Throttle related function (continued) For the Throttle motor to rotate to the position required by the throttle volume, an instruction from (CN8-4) to rotate counter clockwise is sent from the controller to the motor driver, and when received, sends a counter clockwise pulse from the motor driver the throttle motor.
Page 125 Electrics Section C Section C 4 - 5 Engine Control 4 - 5 Controller rotational instructions After key switch ON When the transistor on the CW side of the controller is turned ON, 5V from a driver circuit drops to ground. At this point the CW line is 0V and CCW line is 5V at the driver side.
Page 126: Stop Motor Function
Electrics Section C Section C 4 - 6 Engine Control 4 - 6 Stop Motor Function With the key switch in the ON position, the power flows through relay and energises the actuating coil of relay 2 A Key Switch ON which supplies current to rotate the stop motor.
Page 127 Electrics Section C Section C 4 - 7 Engine Control 4 - 7 Emergency stop button ON The coil of relay 1 is excited when the emergency stop button is pressed when the key switch is ON (previous section A), and the relay switch turns to the lower position.
Page 128: Redundancy (Back-Up) Throttle Control
Electrics Section C Section C 4 - 8 Engine Control 4 - 8 Redundancy (Back-up) throttle control If the throttle control does not operate due to a controller defect, press the redundancy switch. Throttle control is then taken over by the manual throttle buttons. When pressing a redundancy switch, control power supply to the controller is turned OFF, and the manual throttle circuit is activated.
Page 129: Automatic Engine Adjustment
Electrics Section C Section C 4 - 9 Engine Control 4 - 9 Automatic Engine Adjustment There is a variation in engine RPM depending on each machine. To finely control, in each mode or to eliminate wide variation in idling RPM, store the setting RPM to the controller at an early stage. This is called automatic adjustment. When replacing a new controller or a throttle motor or adjusting and replacing control link between the engine and throttle motor, automatic adjustment must be done.
Page 130: Idling Control
Electrics Section C Section C 4 - 10 Engine Control 4 - 10 Idling Control Time Chart With the key switch ON pressing the one-touch switch causes the switch lamp to come on. A. One-touch idle operation is possible when in one-touch idling mode regardless of whether the pilot pressure switches of IN2, IN3, IN4 are...
Page 131: Revolution Control For Each Mode
Electrics Section C Section C 4 - 11 Engine Control 4 - 11 Revolution Control for Each Mode The machine is in the standard mode when the key switch is ON. This position is 100 rpm less than the FULL rotational position (H mode).
Page 132: Control Of Engine Speed For Breaker Operation
Electrics Section C Section C 4 - 12 Engine Control 4 - 12 Control of Engine Speed for Breaker Operation Note: It is necessary to preset the engine r.p.m. to a speed which delivers the flow rate required for breaker operation (see Setting Function under Self Test Function).
Page 133: Engine Auto Warm-Up
Electrics Section C Section C 4 - 13 Engine Control 4 - 13 Engine Auto Warm-up Time Chart Conditions for automatic warming up Water temperature is less than 50°C. Upper Pilot pressure switch is OFF. (attachment is not operating.) Lower Pilot pressure switch is OFF. (travel is not operating.) One-touch idle is turned OFF.
Page 134: Engine Reverse Rotation Prevention
Electrics Section C Section C 4 - 14 Engine Control 4 - 14 Detection of Throttle Motor Assembly Defect (Out-of-step) Fault When the pulse signal cannot be interrupted by the driver, and deviates from regular rotation. Possible Factors 1. If the adjusting screw of the throttle link is loosened, and the length of the link is changed more than the deflection of the spring.
Page 135: Pump Control
The S,L, and F modes have fixed current values. Current value of each mode Mode Machine Imax Imin Type JS200 495 mA 300 mA 305 ± 20 mA 0 + 10 mA 0 + 10 mA JS240 520 mA 325 mA 330 ±...
Page 136 Electrics Section C Section C 5 - 2 Pump Control 5 - 2 Schematic (continued) S MODE: Pump torque equals 90% of engine target torque T, IS is the constant current value. L MODE: Pump torque equals 70% of engine target torque T, IL is the constant current value. (Same as F mode). If engine RPM is less than 1200 rpm: the current is the same as L MODE irrespective of mode selection.
Page 137: Flow Chart
Electrics Section C Section C 5 - 3 Pump Control 5 - 3 FLOW CHART 9803/6400 Issue 2*...
Page 138: Boom Lowering Speed Regulation
Electrics Section C Section C 5 - 4 Pump Control 5 - 4 Boom Lowering Speed Regulation Circuit Diagram Time Chart Flow Chart Boom Lowering Speed Regulation Regulating the speed of the boom lowering procedure is activated only in L, F mode. When changing to L, F mode, a transistor in the controller turns ON, and switches a solenoid valve.
Page 139: Cushioned Boom Starting
Electrics Section C Section C 5 - 5 Pump Control 5 - 5 Cushioned Boom Starting Circuit Diagram Time Chart * Even though travel limit and boom lowering switches are ON, pulse to solenoid valve does not go ON. When the boom lowering pressure switch turns ON, the solenoid valve switches on for 0.4 sec, and pilot pressure is sent to the negative control signal port of the pump.
Page 140 Electrics Section C Section C 5 - 6 Pump Control 5 - 6 Cushioned Boom Starting (continued) Flow Chart 9803/6400 Issue 1...
Page 141: Pressure Increasing System
Electrics Section C Section C 5 - 7 Pump Control 5 -7 Pressure Increasing System (One-touch digging force UP, Travel power UP) A In only H or S modes, when the one-touch digging force UP switch is turned ON (IN5), the signal enters the controller through the timer in the panel switch and remains for 8 sec, 24V is output from the controller to the now activated solenoid valve.
Page 142 Electrics Section C Section C 5 - 8 Pump Control 5 - 8 Pressure Increasing System (continued) L Mode A Even though the one-touch digging force UP switch is pressed, the voltage is not output to the solenoid valve, and a pressure increase is not obtained.
Page 143 Electrics Section C Section C 5 - 9 Pump Control 5 - 9 Pressure Increasing System (continued) Flow Chart 9803/6400 Issue 1...
Page 144: Speed Travel And Max Flow Cut
Electrics Section C Section C 5 - 10 Pump Control 5 - 10 3-Speed Travel and Max. Flow (Q) Cut Travelling at middle speed (always middle speed as At middle speed travel the key is switched ON). Travel motor swash plate: low side Even though travel and upper pressure switches are ON, Pump: Standard there is no output to solenoid valves A and B.
Page 145 Electrics Section C Section C 5 - 11 Pump Control 5 - 11 3-Speed Travel and Max. Flow Cut (continued) Q cut is done by F mode using the ON signal of upper At middle speed travel pressure S/W for the first time. Travel motor swash plate: low side 1.
Page 146 Electrics Section C Section C 5 - 12 Pump Control 5 - 12 3-Speed Travel and Max. Flow (Q) Cut (continued) Relation of Travel Mode and Motor Swash Plate, Pump Quantity Cut Relation of Travel Mode and Motor Swash Plate, Pump flow (Q) Cut High Speed Middle Speed Low Speed Work mode is independent.
Page 147 Electrics Section C Section C 5 - 13 Pump Control 5 - 13 3-Speed Travel and Max. Flow Cut (continued) Flow Chart 9803/6400 Issue 1...
Page 148: Soft/Hard Switch
Electrics Section C Section C 5 - 14 Pump Control 5 - 14 Cushion (Soft/Hard) Switch Circuit Diagram Time Chart Flow Chart - Cushion (Soft/Hard) Switch Output to the soft/hard solenoid valve is OFF when key switch is ON. This is its SOFT status After the engine is started, the signal received from the panel switch is altered.
Page 149: Power Supply Cut Delay
Electrics Section C Section C 5 - 15 Pump Control 5 - 15 Power Supply Cut Delay Circuit Diagram Time Chart When the signal (IN1) from the key switch is turned OFF, 24V from OUT 3 is output from the controller for 3 seconds. After 3 seconds the output of OUT 3 stops, and power to the coil from the electric battery relay is cut, contacts on the electric battery relay break, and the power supply is cut.
Page 150 Electrics Section C Section C 5 - 16 Pump Control 5 - 16 Power Supply Cut Delay Flow Chart 9803/6400 Issue 1...
Page 151: Swing Brake/Swing Lock
Electrics Section C Section C 5 - 17 Pump Control 5 - 17 Swing Brake/Swing Lock (1) Swing Brake 1) Engine is running and swing lever is in neutral (50% brake). SOL: 2 Swing Swing lock SOL:1 SOL: 3 Monitor lever 100% lock brake...
Page 152 Electrics Section C Section C 5 - 18 Pump Control 5 - 18 Swing Brake/Swing Lock (continued) 2) Engine is running and swing lever operation (brake release) SOL: 2 Swing Swing lock SOL:1 SOL: 3 Monitor lever 100% lock brake Shut off ( P ) 5 sec.
Page 153 Electrics Section C Section C 5 - 19 Pump Control 5 - 19 Swing Brake Swing Lock (continued) (2) Swing Lock (Swing Lock Switch ON, 100% Brake) SOL: 2 Swing Swing lock SOL:1 SOL: 3 Monitor lever 100% lock brake Shut off ( P ) 5 sec.
Page 154 Electrics Section C Section C 5 - 20 Pump Control 5 - 20 Swing brake/Swing lock (continued) Flow Chart 9803/6400 Issue 1...
Page 155: Lever Lock
Electrics Section C Section C 5 - 21 Pump Control 5 - 21 Lever Lock Circuit Diagram Time Chart 9803/6400 Issue 1...
Page 156: Travel Warning
Electrics Section C Section C 5 - 23 Pump Control 5 - 23 Travel Warning Circuit Diagram A travel pilot pressure switch is turned ON by travel lever operation and 24V is output for 10 seconds to the buzzer. 9803/6400 Issue 1...
Page 157 Electrics Section C Section C 5 - 22 Pump Control 5 - 22 Lever Lock (continued) Flow Chart 9803/6400 Issue 1...
Page 158: Power Transistor Protection
Electrics Section C Section C 5 - 24 Pump Control 5 - 24 Power Transistor Protection Controller Position Spare Spare Spare Swing shut off solenoid V Lever lock solenoid V Travel alarm Pressure raising solenoid V Free swing solenoid V Negative control solenoid V Spare Spare...
Page 159: Display Monitor
Electrics Section C Section C 5 - 25 Pump Control 5 - 25 Display Monitor Radiator Water Temperature Circuit Diagram Overheat switch position and the ON signal of the thermostat sensor are OR processed and number 8 is lit. Overheat switch position and the OFF signal of the thermostat sensor are AND processed and number 8 turns off. Number 8 is lit on the condition that numbers 1-7 are lit.
Page 160 Electrics Section C Section C 5 - 26 Pump Control 5 - 26 Display Monitor (continued) Hydraulic Oil Temperature Circuit Diagram Overheat switch position and the ON signal of the thermostat sensor are OR processed and number 8 is lit. Overheat switch position and the OFF signal of the thermostat sensor are AND processed and number 8 turns off.
Page 161 Electrics Section C Section C 5 - 27 Pump Control 5 - 27 Display Monitor (continued) Fuel Remaining Circuit Diagram FUEL REMAINING RESISTANCE (litres) (OHM) MONITOR 284~ 13~10 243~284 21~13 200~243 27~21 158~200 34~27 115~158 44~34 72~115 59~44 39~72 78~59 (1 hour left - 80~78 Refuel)
Page 162 Electrics Section C Section C 5 - 28 Pump Control 5 - 28 Display Monitor (continued) Warning Display (Message Display) START Message Display Key SW ON Key SW ON & Engine Running ! Battery charging Deficient ! Overheat ! Engine oil pressure down ! Electric system abnormality ! Air cleaner clogged ! Refuel...
Page 163: Throttle Motor
Electrics Section C Section C 6 - 1 Throttle Motor 6 -1 Throttle Motor and Throttle Link Replacement Prepare the machine Position the machine on level ground. Stop the engine and remove the starter key. Locate the throttle motor and link See Component Location Diagram in Routine Maintenance.
Page 164 Electrics Section C Section C 6 - 2 Throttle Motor 6 - 2 Throttle Motor Throttle Link Replacement (continued) Installation of the throttle link lever a. Install the lever on the new throttle motor without forcing it. b. Coat the screws D with loctite before fastening. Installation of the throttle link a.
Page 165: Automatic Adjustment
Electrics Section C Section C 6 - 3 Throttle Motor 6 - 3 Automatic Adjustment Always perform the automatic adjustment when the controller and or the throttle motor or linkage is replaced. The controller must be programmed to suit the machine model. There are differences in the controller’s programming for various models and territories.
Page 166 Repeatedly press S Mode switch until the monitor’s Repeatedly press L Mode switch until ‘E’ is displayed on desired language is displayed on the mode screen. the clock (1st digit). All other displays are for non-JCB applications and are therefore not applicable. Mode...
Page 167: Revolution Sensor
Electrics Section C Section C 7 - 1 Revolution Sensor 7 - 1 Revolution Sensor Removal and Installation Prepare the Machine Position the machine on level ground. Stop the engine and remove the starter key. Locate the Flywheel housing a. The flywheel housing is machined to accommodate the sensor.
Page 168: Self Test
Electrics Section C Section C 8 - 1 Self Test 8 - 1 Self Test Function This series of vehicles contain numerous sensors to enable the machine to perform its own self test diagnosis. Below is a list of functions which are monitored by the system.
Page 169 WORK MODE Self-check Change Pattern MODE Select Reset CLOCK When the CHANGE switch is pressed the Country and Model designation is displayed: Message 0200 = JS200 0220 = JS240 CH : MN WORK MODE Self-check Change MODE CLOCK 9803/6400 Issue 2*...
Page 170 Electrics Section C Section C 8 - 3 Self Test 8 - 3 Self Test Function (continued) ENGINE RPM The Self Check items can be displayed by pressing the Message SELECT SWITCH after every singular display in the following order. CH : RPM When the SELECT switch is pressed the Engine RPM is displayed...
Page 171 Electrics Section C Section C 8 - 4 Self Test 8 - 4 Self Test Function (continued) FUEL SENSOR RESISTANCE VALUE Message Pressing SELECT changes the display as shown. CH : FS The fuel sensor resistance is shown in Ohms in the clock display.
Page 172 Electrics Section C Section C 8 - 5 Self Test 8 - 5 Self Test Function (continued) PRESSURE SWITCH INPUT Message Start engine. Pressing SELECT changes the display as shown. CH : PS This monitors pressure switch information in the clock display. WORK MODE 0 =Switch open Self-check...
Page 173 Electrics Section C Section C 8 - 6 Self Test 8 - 6 Self Test Function (continued) Setting Function This section deals with setting separate parameters: Breaker engine speed. Automatic idle time. In addition to the previous sections displays, the following switches are used.
Page 174 Check that the breaker engine RPM setting is correct for the breaker being used as given in the following table: CLOCK Machine Hammermaster Engine Normal flow l/min Message JS200/200LC/ EA: B ( RPM ) 1765 220/220LC JS240/240LC/ 20 Seconds WORK MODE 1700 Self-check 260/260LC...
Page 175 Electrics Section C Section C 8 - 8 Self Test 8 - 8 Self Test Function (continued) Message When the desired AUTOMATIC IDLE TIME is reached, press EA: B ( RPM ) and hold the RESET switch for 20 seconds to enter the setting into the controller.
Page 176: Fault Finding
Electrics Section C Section C 9 - 1 Fault Finding 9 - 1 Fault Diagnosis This section is designed to simplify the Task of Fault Finding. When a message is displayed, the description of the fault is shown and the Problem No. is shown; this in turn then relates to the relevant page showing the Problem No.
Page 177 Electrics Section C Section C 9 - 2 Fault Finding 9 - 2 Fault Diagnosis (continued) This explains how to trouble shoot in the event that the message does not go out even though suitable measures are taken to check and clear the problem. !Mark Message Display Trouble Description...
Page 178 Electrics Section C Section C 9 - 3 Fault Finding 9 - 3 Fault Diagnosis (continued) Judgement Item Value Measure 1. Fuel amount check Refuel 2. Inspection for fuel contaminant Clean, drain 3. Hydraulic oil amount check Refill oil 4. Inspection of hydraulic oil strainer Clean, drain 5.
Page 179: Emergency Engine Stop
Electrics Section C Section C 9 - 4 Fault Finding 9 - 4 Fault Diagnosis (continued) Emergency Engine Stop, Problem No.1 Note: Even if the emergency stop button is pressed the message does not go out. Prior Confirmation Items 1. The "MODE" of the mode display is not flashing. 2.
Page 180: Refuel
Electrics Section C Section C 9 - 5 Fault Finding 9 - 5 Fault Diagnosis (continued) Refuel, Problem No.2 Note: Message does not go out even if refuelled Prior Confirmation Items 1. The "MODE" of the mode display is not flashing. 2.
Page 181: Coolant Refill
Electrics Section C Section C 9 - 6 Fault Finding 9 - 6 Fault Diagnosis (continued) Coolant Refill, Problem No 3 Note: Message does not go out even if coolant is refilled Prior Confirmation Items 1. The "MODE" of the mode display is not flashing. Troubleshoot Cause Remedy...
Page 182 Electrics Section C Section C 9 - 7 Fault Finding 9 - 7 Fault Diagnosis (continued) Air Cleaner clogged, Problem No. 5 Note: Message does not go out even if the filter is washed. Prior Confirmation Items 1. The "MODE" of the mode display is not flashing. Troubleshoot Cause Remedy...
Page 183: Low Engine Oil Pressure
Electrics Section C Section C 9 - 8 Fault Finding 9 - 8 Fault Diagnosis (continued) Low Engine Oil Pressure. Problem No. 6 Note: Message does not go out even if engine oil is satisfactory. Prior Confirmation Items 1. The "MODE" of the mode display is not flashing. Troubleshoot Cause Remedy...
Page 184: Engine Oil Filter
Electrics Section C Section C 9 - 9 Fault Finding 9 - 9 Fault Diagnosis (continued) Engine Oil Filter Blocked, Problem No 7 Note: Message does not go out even if the engine oil filter is replaced and the oil is satisfactory. Prior Confirmation Items 1.
Page 185 Electrics Section C Section C 9 - 10 Fault Finding 9 - 10 Fault Diagnosis (continued) Fluid Overheating, water, oil, Problem No 8 Note: Message does not go out even if the actual temperature is below the following; Hydraulic Oil Temperature 84°C. Engine Coolant Temperature 92°C.
Page 186 Electrics Section C Section C 9 - 11 Fault Finding 9 - 11 Fault Diagnosis (continued) Fluid Overheating, water, oil, Problem No 8 (continued) Note: Message does not go out even if the actual Temperature is below the following:- Hydraulic Oil Temperature 84°C Engine Coolant Temperature 92°C Troubleshoot Cause...
Page 187: Battery Charging
Electrics Section C Section C 9 - 12 Fault Finding 9 - 12 Fault Diagnosis (continued) Battery Charging, Problem No 9 Note: Message does not go out. Prior Confirmation Items 1. The "MODE" of the mode display is not flashing. Troubleshoot Cause Remedy...
Page 188 Electrics Section C Section C 9 - 13 Fault Finding 9 - 13 Fault Diagnosis (continued) Electrical Systems, Message Fault, Problem No 10 Note: Message does not go out. 9803/6400 Issue 2*...
Page 189: Electrical System, Message Fault
Electrics Section C Section C 9 - 14 Fault Finding 9 - 14 Fault Diagnosis (continued) Electrical System, Message Fault, Problem No. 10 (continued) Note: Message does not go out. Troubleshoot Cause Remedy Key switch ON Replace When transistor When electro Electro-magnetic electro output is carried out...
Page 190 Electrics Section C Section C 9 - 15 Fault Finding 9 - 15 Fault Diagnosis (continued) Electrical System, Message Fault, Problem No.10 (continued) Note: Message does not go out. Troubleshoot Cause Remedy Continued from previous page Remove driver connector Breakage or defective CN15 and measure wiring between Repair...
Page 191 Electrics Section C Section C 9 - 16 Fault Finding 9 - 16 Fault Diagnosis (continued) Engine Trouble, Problem No 11 Note: Engine does not start even though the message "electrical system abnormal" is not displayed. Prior Confirmation Items No abnormalities in engine or fuel system. Fuse is not blown.
Page 192 Electrics Section C Section C 9 - 17 Fault Finding 9 - 17 Fault Diagnosis (continued) Engine Trouble, Problem No 11 (continued) Troubleshoot Cause Remedy Key switch ON Engine system Inspect Is fuel cut lever on stop side Abnormality engine system.
Page 193: Engine Problem
Electrics Section C Section C 9 - 18 Fault Finding 9 - 18 Fault Diagnosis (continued) Engine Problem, Problem No 12 Note: Engine revolutions do not change with throttle volume control. Prior Confirmation Items 1. The message "Engine emergency stop" is not displayed. Troubleshoot Cause Remedy...
Page 194: Sensor Resistance Valve
Electrics Section C Section C 9 - 19 Fault Finding 9 - 19 Sensor Resistance Valve Water temperature (Oil temperature) Minimum Maximum 20°C 8.00k 10.20k 30°C 5.35k 6.50k 40°C 3.60k 4.55k 50°C 2.50k 3.10k 60°C 1.70k 2.20k 70°C 1.20k 1.55k 80°C 0.85k 1.15k...
Page 195 Section C Electrics Section C 10 - 1 CAPs II Diagnostic system 10 - 1 Diagnostics for CAPS II Controllers The diagnostic capabilities of the present CAPS II system have been improved to include facilities for storing information on intermittent faults occurring in the electrical system and machine performance data .
Page 196: Caps Ii Diagnostic System
Section C Electrics Section C 10 - 2 CAPs II Diagnostic system 10 - 2 Channel 3 electrical system abnormalities Channel 4 machine performance data Channel 3 will monitor and store information on the Channel 4 will monitor and store information on the following functions: following machine performance: Computer reset (engine stop due to electrical interference)
Page 197 Section C Electrics Section C 10 - 3 CAPs II Diagnostic system 10 - 3 To read stored information on channel 3 Remove redundancy buttons cover. Self-check ADJUST/CLOCK MANUAL THROTTLE BACK UP Change Pattern DOWN Select Reset Switch on the ignition. Cover installation screws x 2 Self-check...
Page 198 Section C Electrics Section C 10 - 4 CAPs II Diagnostic system 10 - 4 To Read stored information on channel 4 Remove redundancy buttons cover. Self-check ADJUST/CLOCK MANUAL THROTTLE BACK UP Change Pattern DOWN Select Reset Switch on the ignition. Cover installation screws x 2 Self-check...
Page 199 Section C Electrics Section C 10 - 5 CAPs II Diagnostic system 10 - 5 To Reset Stored Information Remove redundancy buttons cover. Self-check ADJUST/CLOCK MANUAL THROTTLE BACK UP Change Pattern DOWN Select Reset Switch on the ignition. Cover installation screws x 2 Self-check Change...
Page 200 Section C Electrics Section C 10 - 6 CAPs II Diagnostic system 10 - 6 Calculating max. engine water temperature reached and max. hydraulic oil temperature reached The values given in channel 4 monitor window 8, mode window 9, clock screen value X are digital values and need to be converted to a temperature value using the formula.
Page 201 Section C Electrics Section C 10 - 7 CAPs II Diagnostic system 10 - 7 Kû °C 9803/6400 Issue 1...
Page 202 Section C Electrics Section C 10 - 8 CAPs II Diagnostic system 10 - 8 Channel 3: Service Text SELECT MONITOR MODE CLOCK WINDOW Unit/ SWITCH (*1) WINDOW WINDOW INDICATION ITEM Indication CH; 3 H, S, L or F Hour meter Initial indication hour Computer reset...
Page 203 Section C Electrics Section C 10 - 9 CAPs II Diagnostic system 10 - 9 Channel 3: Service Text (continued) SELECT MONITOR MODE CLOCK WINDOW Unit/ SWITCH (*1) WINDOW WINDOW INDICATION ITEM Indication CH; 3 Wrong electrical contact CN2-10 Battery Level sensor (digital Signal) CN2-3 Lever lock...
Page 204 Section C Electrics Section C 10 - 10 CAPs II Diagnostic system 10 - 10 Channel 4: Performance logging sheet SELECT MONITOR MODE CLOCK WINDOW SWITCH WINDOW WINDOW INDICATION ITEM VALUE CH; 4 H, S, L or F Time H, S, L or F Hour Meter H, S, L or F Machine actual working hours...
Page 205 Maintenance Specifications 43 - 1 Note: Except where indicated otherwise, information for the JS200 applies to all variants of this machine, including the JS220. Similarly, information for the JS240 applies also to all variants of that machine, including the JS260.
Page 206: Precautions During Use
Trouble Shooting 95 - 1 Note: Except where indicated otherwise, information for the JS200 applies to all variants of this machine, including the JS220. Similarly, information for the JS240 applies also to all variants of that machine, including the JS260.
Page 207: Technical Data Js200 And Variants
Hydraulics Section E Section E 1 - 1 Technical Data JS200/220 and Variants 1 - 1 Pump Type Twin variable displacement piston pump Displacement Volume 96.6 (cc/rev) x2 Working Pressure 350 kgf/cm (343 bar, 4977 lb/in Maximum Output 198.7 litre/min (43.7 UK gal)
Page 208 Hydraulics Section E Section E 1 - 2 Technical Data JS200/220 and Variants 1 - 2 Travel Equipment Type Fixed Displacement Piston Motor (automatic 2-speed change) Suction Capacity 157.8/92.9 cc/rev Working Pressure 350 kgf/cm (343 bar, 4977 lb/in Working Flow 199 litre/min (43.7 UK gal)
Page 209: Technical Data Js240 And Variants
Hydraulics Section E Section E 1 - 3 Technical Data JS240/260 and Variants 1 - 3 Pump Type Twin variable displacement piston pump Displacement Volume 96.4 cc/rev x2 Working Pressure 320 kgf/cm (309 bar, 4550lb/in Maximum Output 212.2 litre/min (46.6 UK gal) Fixed Displacement Gear Pump Displacement Volume 10 cc/rev...
Page 210 Hydraulics Section E Section E 1 - 4 Technical Data JS240/260 and Variants 1 - 4 Travel Equipment Motor Fixed displacement piston motor (automatic 2-speed change) Suction Capacity 164.4/98.1 cc/rev Working Pressure 350 kgf/cm (343 bar, 4977 lb/in Working Flow 211 litre/min (46.4 UK UK gal) Reduction Gears Deceleration Ratio...
Page 211 Hydraulics Section E Section E 2 - 1 Torque Specification 2 - 1 All Machines (see Note on Contents Page) Pump Torque Part Name Size Tool Name kgf m lbf ft Hexagonal Socket Head 0.70 B = 4 (Material quality SCM 435) 1.20 3.00 10.00...
Page 212 Rotary coupling motor make-up and by-pass valve; Relief valve Make-up and by-pass cap Relief valve cap Boom Ram JS200 (see Note on Contents Page) This table refers to the JS200 Boom Ram sectional drawing kgf m lbf ft Part No. Remarks Hexagonal socket...
Page 213 Section E 2 - 3 Torque Specification 2 - 3 Bucket Ram JS200 (see Note on Contents Page) This table refers to the JS200 Bucket Ram sectional drawing kgf m lbf ft Part No. Remarks Hexagonal socket M16 x 2...
Page 214: Schematics Hydraulic Circuit Js200 And Variants
Hydraulics Section E Section E 3 - 1 Schematics 3 - 1 Schematic, Hydraulic Circuit JS200 (and Variants) MOTOR; SLEW VALVE; SHUTTLE RAM; DIPPER ACCUMULATOR VALVE; ASSEMBLY VALVE; CHECK MOTOR; TRACTION FILTER; LINE COUPLING; ROTARY PUMP; HYD RAM; BUCKET VALVE; REMOTE CONT RAM;...
Page 215 Section E Hydraulics Section E Schematics 3 - 2 3 - 2 9803/6400 Issue 2*...
Page 216 Hydraulics Section E Section E 3 - 2A Schematics 3 - 2A Schematic, Hydraulic Circuit JS240 (and Variants) MOTOR; SLEW VALVE; SHUTTLE RAM; DIPPER ACCUMULATOR VALVE; ASSEMBLY VALVE; CHECK MOTOR; TRACTION FILTER; LINE COUPLING; ROTARY PUMP; HYD RAM; BUCKET VALVE; REMOTE CONT RAM;...
Page 217 Section E Hydraulics Section E Schematics 3 - 3 3 - 3 9803/6400 Issue 2*...
Page 218: Shuttle Block Js200, Js240
Hydraulics Section E Section E 3 - 5 Schematics 3 - 5 Shuttle Block JS200, JS240 9803/6400 Issue 1...
Page 219: Pilot Control Line Hose Connection Diagram Js200, Js240
Section E Hydraulics Section E Schematics 3 - 6 3 - 6 Pilot Control Line Hose Connection Diagram, JS200, JS240 VALVE SPL KHJ0790U-A HOSE : NYLON HOSE : NYLON SHUTTLE BLOCK SWING MOTOR KNJ1699 KTJ1133 KHJ0834U-A KNJ1968L-A HOSE ASSY COLOUR...
Page 220 Hydraulics Section E Section E 4 - 1 Pressure Testing 4 - 1 Main Relief Valve Pressure Note:- P1 refers to test point on pump. Prepare the machine Put the operator levers into neutral, lower the gate lock lever. Start the engine and place the machine on level ground, lower and open the dipper and set the bucket on the ground.
Page 221 Hydraulics Section E Section E 4 - 2 Pressure Testing 4 - 2 Accumulator Pressure Prepare the engine Put the operators lever into neutral, lower the gate lock lever, Start the engine and place the machine on level ground, lower and open the dipper and set the bucket on the ground. 1.
Page 222 Hydraulics Section E Section E 4 - 3 Pressure Testing 4 - 3 Pilot Relief Pressure Prepare the machine Put the operator levers into neutral, lower the gate lock lever. Start the engine and place the machine on level ground, lower and open the dipper and set the bucket on the ground.
Page 223 Hydraulics Section E Section E 4 - 4 Pressure Testing 4 - 4 Slew Motor Pressure Relief Prepare the machine Put the operators lever into neutral, lower the gate lock lever. Start the engine and place the machine on level ground, lower and open the dipper and set the bucket on the ground.
Page 224 Hydraulics Section E Section E 4 - 5 Pressure Testing 4 - 5 Slew Motor Pressure Relief (continued) 9. Disassemble a. Place the relief valve in a vice and remove the cap A with a 14 mm A/F hexagonal socket, take out the piston B, liner C, poppet E, shim F and spring D.
Page 225 Hydraulics Section E Section E 4 - 6 Pressure Testing 4 - 6 Port Relief Pressure Note: Because port relief pressure is set higher than main relief pressure, it is necessary to temporarily set the main relief pressure higher than port pressure. Temporary setting of main relief pressure Prepare the machine a.
Page 226 Hydraulics Section E Section E 4 - 7 Pressure Testing 4 - 7 Port Relief for Boom Ram Prepare the machine a. Put the operator lever into neutral, lower the gate lock lever. Start the engine and place the machine on level ground, lower and open the arm and set the bucket on the ground.
Page 227 Hydraulics Section E Section E 4 - 8 Pressure Testing 4 - 8 Port Relief for Dipper Ram Prepare the Machine. a. Put the operator lever into neutral, lower the gate lock lever. Start the engine and place the machine on level ground, lower and open the dipper and set the bucket on the ground.
Page 228 Hydraulics Section E Section E 4 - 9 Pressure Testing 4 - 9 Port Relief for Bucket Ram Prepare the Machine a. Put the operator lever into neutral, lower the gate lock lever, start the engine and place the machine on level ground, lower and open the dipper and set the bucket on the ground.
Page 229 Hydraulics Section E Section E 4 - 10 Pressure Testing 4 - 10 Travel Motor Relief Pressure Prepare the Machine a. Put the operator lever into neutral, lower the gate lock lever, start the engine and place the machine on level ground, lower and open the dipper and set the bucket on the ground.
Page 230 Hydraulics Section E Section E 4 - 11 Pressure Testing 4 - 11 Travel Motor Relief Pressure (continued) Adjust the main relief pressure See previous section "Temporary setting of main relief pressure", item 3. Stop the engine and release the hydraulic pressure. (See Releasing Tank Pressure), remove the pressure gauge and adaptor.
Page 231 Hydraulics Section E Section E 4 - 12 Pressure Testing 4 - 12 Hydraulic Pump Proportional Pressure Reduction Valve. Prepare the Machine a. Put the operator lever into neutral, lower the gate lock lever, start the engine and place the machine on level ground.
Page 232: Hydraulic Pump Js200, Js240
Hydraulics Section E Section E 10 - 1 Hydraulic Pump JS200, JS240 10 - 1 9803/6400 Issue 1...
Page 233 Hydraulics Section E Section E 10 - 2 Hydraulic Pump JS200, JS240 10 - 2 9803/6400 Issue 1...
Page 234 Hydraulics Section E Section E 10 - 3 Hydraulic Pump JS200, JS240 10 - 3 9803/6400 Issue 1...
Page 235: Schematics, Technical Data
10 - 4 Hydraulic Pump JS200, JS240 10 - 4 Schematics, Technical Data JS200, JS240 Hydraulic Pump P-Q Line Diagram Magnetic proportional value electric current This diagram shows the values for the new machine. Changes occur depending on the conditions of use.
Page 236: Precautions During Use
Hydraulics Section E Section E 11 - 1 Hydraulic Pump JS200, JS240 11 - 1 Precautions During Use Installation Item Precautions Model 1. Removal of The shaft end spline party is coated with anti-rust coating so remove Both models anti-rust coating it with cleaning agent and apply a lubricant such as molybdenum disulphide and install to the coupling.
Page 237 Hydraulics Section E Section E 12 - 1 Hydraulic Pump JS200, JS240 12 - 1 Pump Trouble Shooting Often the regulator and attendant valves or pump are combined which makes it very difficult to discover the reason for the trouble. Inspect the following categories which will assist in discovering the abnormal point.
Page 238 Hydraulics Section E Section E 12 - 2 Hydraulic Pump JS200, JS240 12 - 2 Pump Trouble Shooting (continued) Abnormal Sound and Vibration Cause Treatment Note 1. Cavitation. 1. Prevent cavitation. 1.1. Boost pressure is low Check to see if hydraulic oil is 1.2.
Page 239 Hydraulics Section E Section E 13 - 1 Hydraulic Pump JS200, JS240 13 - 1 Operation The rotary group consists of the drive shaft F (111), cylinder rod (141), piston shoe (151, 152), press plate (153), spherical bush (156), spacer (158) and cylinder spring (157). The drive shaft is supported on both sides by the bearings (123, 124). The shoe is caulked on the piston and forms the spherical coupler, and because it slides slightly on the shoe plate (211), it has a pocket to balance the oil pressure.
Page 240 Hydraulics Section E Section E 14 - 1 Hydraulic Pump JS200, JS240 14 - 1 Dismantling Refer to the drawing on the previous pages of the pump and Adjusting screws should only be moved when absolutely associated components. necessary. Moving the adjusting screws will alter the power output settings.
Page 241 Hydraulics Section E Section E 14 - 2 Hydraulic Pump JS200, JS240 14 - 2 Dismantling (continued) Pull out the cylinder (141) (keeping it straight in relation to the drive shaft (111)) from the pump casing (271) and also pull out the piston (151), press plate (153), spherical bush (156) and cylinder spring (157) at the same time.
Page 242 Hydraulics Section E Section E 14 - 3 Hydraulic Pump JS200, JS240 14 - 3 Dismantling (continued) Remove the shoe plate (211) and swash plate (212) from the pump casing (271). 10. Lightly tap the drive shaft (111, 113) end with a plastic hammer and remove the drive shaft from the swash plate supporter.
Page 243 Hydraulics Section E Section E 14 - 4 Hydraulic Pump JS200, JS240 14 - 4 Assembly Clean each part in a suitable solvent and dry using All tapped holes and gasket faces should be thoroughly compressed air. degreased by washing as liquid packing and adhesive is used on all gasket surfaces and threads.
Page 244 Hydraulics Section E Section E 14 - 5 Hydraulic Pump JS200, JS240 14 - 5 Assembly (continued) Install the drive shaft (111) which has the bearing (123), bearing spacer (127) and stop ring (824) set on it to the swash plate support (251).
Page 245 Hydraulics Section E Section E 14 - 6 Hydraulic Pump JS200, JS240 14 - 6 Assembly (continued) Aligning the pin, install the valve plate (313) into the valve block (312). Note: Be careful not to mistake the valve plate suction and delivery directions.
Page 246 Hydraulics Section E Section E 14 - 7 Hydraulic Pump JS200, JS240 14 - 7 Main body wear limit If the wear of the parts exceeds the standards below, replace or readjust. However, if they are extremely damaged judging from the external appearance, replace with the appropriate part.
Page 247 Hydraulics Section E Section E 14 - 8 Hydraulic Pump JS200, JS240 14 - 8 Main body wear limit (continued) Cylinder, Valve Plate, Swash Plate (Shoe Plate) Modification Standards Valve Plate (sliding part) Surface roughness requiring modification Swash Plate (shoe plate part)
Page 248: Regulator Js200, Js240
Hydraulics Section E Section E 20 - 1 Regulator JS200. JS240 20 - 1 Specifications Displacement 97.2 (96.5) cc/rev Revolving Speed Range Rated 2070 (2200) rev/min Pressure Rated 320 (320) kgf/cm Max 350 (350) kgf/cm Maximum Flow Rate 201 (211) l/min (Rated revolution load pressure 80 Kgf/cm...
Page 249 Hydraulics Section E Section E 20 - 2 Regulator JS200. JS240 20 - 2 Specifications, (continued) Return spring Tilting pin Servo piston Feedback pin Feedback lever Compensator piston Compensator rod Outer spring Inner spring Pilot piston Pilot spring Sleeve Spool...
Page 250 Hydraulics Section E Section E 20 - 3 Regulator JS200. JS240 20 - 3 Section Part Name Q’ty Adjust screw KR3G-9C12 Hexagonal socket lock screw Locking ring Lock pin Stop ring Hexagon nut O-ring O-ring O-ring O-ring O-ring O-ring O-ring...
Page 251 Hydraulics Section E Section E 20 - 4 Regulator JS200. JS240 20 - 4 Specifications, (continued) Proportional Pressure Reducing Valve Specifications (Reference) 1. Specifications (1) Max. primary pressure 40 kgf/cm (2) Max, back pressure (allowable pressure) 10 kgf/cm (3) Secondary pressure setting range 0-40 kgf/cm (at primary press.=40 kgf/cm...
Page 252 Hydraulics Section E Section E 20 - 5 Regulator JS200. JS240 20 - 5 Specifications, (continued) PROPORTIONAL PRESSURE REDUCING VALVE ALLOWABLE RANGE OF CURRENT-PRESSURE PROFILE • Primary press. 40 kgf/cm (38.6 bar, 568.8 lb/in • Flow in port A 0 l/min •...
Page 253: Operation
Hydraulics Section E Section E 21 - 1 Regulator JS200. JS240 21 - 1 Operation Refer to the sectional drawings at the beginning of this section. The regulator consists of the following control mechanisms: 1. Horsepower control. Automatically reduces the pump swash angle (delivery flow) according to the increase in P pump delivery pressure and P pump delivery pressure and limits the input torque to below a preset value.
Page 254 Hydraulics Section E Section E 22 - 1 Regulator JS200. JS240 22 - 1 Regulator Trouble Shooting Engine Overloads Put a load on each pump to determine if the front or rear pump is malfunctioning. If both pumps are abnormal, check 1 and 2.
Page 255 Hydraulics Section E Section E 23 - 1 Regulator JS200. JS240 23 - 1 Regulator Disassembly Refer to the sectional drawings at the beginning of this section. Before dismantling, blank all inlet and outlet ports and wash the outer surfaces with a suitable solvent to remove all dirt and dust.
Page 256 Hydraulics Section E Section E 23 - 2 Regulator JS200. JS240 23 - 2 Regulator Disassembly (continued) 3. After removing the cover (C) (629) SUB, remove the outer spring (625), inner spring (626), spring base (C) (624) from the compensatory part and pull out the adjusting ring (Q) (645), pilot spring (646), spring base (644) from the pilot part.
Page 257 Hydraulics Section E Section E 23 - 3 Regulator JS200. JS240 23 - 3 Regulator Disassembly (continued) Remove the locking ring (858) and remove the fulcrum plug (614) and adjusting plug (615). Note: For easy removal, use M6 bolt to pull out the fulcrum plug (614) and adjusting plug (615).
Page 258 Hydraulics Section E Section E 23 - 4 Regulator JS200. JS240 23 - 4 Regulator Disassembly (continued) 8. Pull out pin (874) and remove the feedback lever (611). Note: To remove the pin (874) (o4), use a slim steel bar and push out from above taking care not to touch the lever (1) (612).
Page 259 Hydraulics Section E Section E 23 - 5 Regulator JS200. JS240 23 - 5 Regulator Assembly All tapped holes and gasket faces should be thoroughly degreased by washing as liquid packing and adhesive is Clean each part in a suitable solvent and dry using used on all gasket surfaces and threads.
Page 260 Hydraulics Section E Section E 23 - 6 Regulator JS200. JS240 23 - 6 Regulator Assembly (continued) Insert the pin, which is press-fitted into the lever (2) (613), into the pilot piston groove and assemble lever (2). Assemble the fulcrum plug so that the pin, which is press-fitted in the fulcrum plug, is inserted in the lever (2) pin hole.
Page 261 Hydraulics Section E Section E 23 - 7 Regulator JS200. JS240 23 - 7 Regulator Assembly (continued) 10. Assemble the set spring (655) into the spool hole and the compensatory piston (621) and piston case (622) into the compensatory hole. Install the pilot cover (641) and tighten with hexagonal socket head bolts (436) (438).
Page 262: Control Valve Js200/Js240
(Bucket Close) Port Overload Relief Set Pressure: 240 kgf/cm (235 bar, 3407 lb/in (JS220LC Long Reach only) at 20 l/min (4.3 imp gal) Pilot Port Maximum Pressure: (JS200/JS240) P 40 kgf/cm (38.6 bar, 568.8 lb/in †Including all variants. 9803/6400 Issue 2*...
Page 263 Hydraulics Section E Section E 30 - 2 Control Valve JS200/JS240 30 - 2 9803/6400 Issue 1...
Page 264 Hydraulics Section E Section E 30 - 3 Control Valve JS200/JS240 30 - 3 9803/6400 Issue 1...
Page 265 Hydraulics Section E Section E 30 - 4 Control Valve JS200/JS240 30 - 4 9803/6400 Issue 1...
Page 266 Hydraulics Section E Section E 30 - 5 Control Valve JS200/JS240 30 - 5 9803/6400 Issue 1...
Page 267 Hydraulics Section E Section E 30 - 6 Control Valve JS200/JS240 30 - 6 9803/6400 Issue 1...
Page 268 Hydraulics Section E Section E 30 - 7 Control Valve JS200/JS240 30 - 7 9803/6400 Issue 1...
Page 269 Hydraulics Section E Section E 31 - 1 Control Valve JS200/JS240 31 - 1 Precautions During Use Installation • Be careful that excessive force is not put on the valve by the piping. • Tighten the installation bolts in the same manner.
Page 270 Hydraulics Section E Section E 31 - 2 Control Valve JS200/JS240 31 - 2 The following details refer to the illustrations at the beginning of this Section. Operation The control valve is constructed with the 4-spool and 5-spool sides overlapping and integrated into one.
Page 271 Hydraulics Section E Section E 31 - 3 Control Valve JS200/JS240 31 - 3 Operation (continued) Individual Operation 1. Travel Spool Switch (Refer to Fig. 1,3,4). When the P ) is pressurised and the 5-spool travel spool is selected (Fig. 4), the neutral passage A is closed and...
Page 272 Hydraulics Section E Section E 31 - 4 Control Valve JS200/JS240 31 - 4 Operation (continued) Dipper Spool Selection 1. Dump (Refer to Fig. 9). When the pilot port P is pressurised and the arm I spool is selected, the oil delivered from P...
Page 273 Hydraulics Section E Section E 31 - 5 Control Valve JS200/JS240 31 - 5 Operation (continued) Bucket Spool Selection Dump: Crowd (Refer to Fig. 11). When the pilot port P ) is pressurised and the bucket I spool is selected, the 4-spool neutral passage a is cut off and...
Page 274 Hydraulics Section E Section E 31 - 6 Control Valve JS200/JS240 31 - 6 Operation (continued) Combined Operations 1. Travel Combination Operations (Refer to Fig. 1, 13). When travelling forward or backward (including spin turn) any spool other than the travel spool is selected or when operating the excavator, when the travel spool (left, right travel) spool is selected, the signal passage and tank passage are cut off at that spool signal land and the signal passage pressure rises to the relief set pressure.
Page 275 Hydraulics Section E Section E 31 - 7 Control Valve JS200/JS240 31 - 7 Operation (continued) Load Holding Valve 1. Boom Section (refer to fig. 5, 6, 14) . When the boom is lowered (Fig 6), the spool moves to the right as shown. At the same time, when P is pressurised, the load holding valve piston D pushes the poppet B, connecting Dr port.
Page 276 Hydraulics Section E Section E 31 - 8 Control Valve JS200/JS240 31 - 8 Operation (continued) 9803/6400 Issue 1...
Page 277 Hydraulics Section E Section E 31 - 9 Control Valve JS200/JS240 31 - 9 Operation (continued) 9803/6400 Issue 1...
Page 278 Hydraulics Section E Section E 31 - 10 Control Valve JS200/JS240 31 - 10 Operation (continued) Travel (Fig.4) 9803/6400 Issue 1...
Page 279 Hydraulics Section E Section E 31 - 11 Control Valve JS200/JS240 31 - 11 Operation (continued) 9803/6400 Issue 1...
Page 280 Hydraulics Section E Section E 31 - 12 Control Valve JS200/JS240 31 - 12 Operation (continued) 9803/6400 Issue 1...
Page 281 Hydraulics Section E Section E 31 - 13 Control Valve JS200/JS240 31 - 13 Operation (continued) 9803/6400 Issue 1...
Page 282 Hydraulics Section E Section E 31 - 14 Control Valve JS200/JS240 31 - 14 Operation (continued) 9803/6400 Issue 1...
Page 283 Hydraulics Section E Section E 31 - 15 Control Valve JS200/JS240 31 - 15 Operation (continued) 9803/6400 Issue 1...
Page 284 Hydraulics Section E Section E 31 - 16 Control Valve JS200/JS240 31 - 16 Operation (continued) Poppet Throttle Filter Spring Poppet (fig. 14-4) Spring Cavity JS03700 Piston * Load Holding Valve : Boom (fig. 14) 9803/6400 Issue 2*...
Page 285 Hydraulics Section E Section E 31 - 17 Control Valve JS200/JS240 31 - 17 Operation (continued) JS03710 Poppet Spring Spring Cavity Passage Ram port passage Passage Throttle (fig. 15-4) * Load Holding Valve : Dipper (fig. 15) 9803/6400 Issue 2*...
Page 286 Hydraulics Section E Section E 31 - 18 Control Valve JS200/JS240 31 - 18 Operation (continued) 9803/6400 Issue 1...
Page 287 Hydraulics Section E Section E 32 - 1 Control Valve JS200/JS240 32 - 1 Control Valve Trouble Shooting Control Valve in General Symptoms Possible Causes Countermeasures Spool sticking 1. Oil temperature is abnormally high. Remove the obstruction. 2. Hydraulic oil is dirty Replace the hydraulic oil and clean the circuit at the same time.
Page 288 Hydraulics Section E Section E 32 - 2 Control Valve JS200/JS240 32 - 2 Control Valve Trouble Shooting (continued) Relief Valve Symptoms Possible Causes Countermeasures Pressure does not rise at all 1. The main poppet, sleeve or pilot Check whether foreign matter is in each poppets are sticking open or poppet.
Page 289 Hydraulics Section E Section E 33 - 1 Control Valve JS200/JS240 33 - 1 These procedures refer to the sectional drawings at the beginning of this section. Dismantling Notes: 1. All parts are manufactured with a high degree of precision and require the utmost care when handling. Do not let parts knock against each other and take extra precautions when handling parts to prevent them being dropped.
Page 290 Hydraulics Section E Section E 33 - 2 Control Valve JS200/JS240 33 - 2 Dismantling (continued) 18. Remove the main relief valve 13 (Hexagonal 32 A/F) from the valve housing. 19. Remove the port relief valve 31 (Hexagonal 31.5 A/F) from the valve housing.
Page 291 Hydraulics Section E Section E 33 - 3 Control Valve JS200/JS240 33 - 3 Assembly Note: 1. During assembly, be careful when handling the 'O'-rings as follows. a. Check for defects due to improper handling or from manufacturing. b. Apply grease to the 'O'-ring and to the area where it is fitted.
Page 292 Section E Section E 33 - 4 Control Valve JS200/JS240 33 - 4 Assembly, 5-spool control valve section (continued) 13. Install the main relief valve 13 (Hexagonal 31.5 A/F) to the valve housing, with a torque of 78-88 Nm (57.84-65.07 lb/ft).
Page 293 Section E Section E 33 - 5 Control Valve JS200/JS240 33 - 5 Assembly, 4-spool control valve section Assemble the poppet 23 and spring 22 into the spool 3. After completely degreasing the thread part (and the spool side) of the plug 19 (Hexagonal 22 A/F), fit the 'O'-ring 21 and backup ring 20 attached, apply adhesive and screw into the spool, with a torque of 9.8-12 Nm (7.23-8.67 lb/ft).
Page 294 Hydraulics Section E Section E 34 - 1 Relief Valve JS200/JS240 34 - 1 Dismantling Loosen the cap 1 (Hexagonal 31.5 A/F) and remove from plug 2. Remove the sleeve 3 and take out the main poppet 4 and spring 11.
Page 295 Hydraulics Section E Section E 34 - 2 Port Relief Valve JS200/JS240 34 - 2 Dismantling Remove the plug 2 and disassemble the sleeve 3, main poppet 4, piston 5 and springs 7, 8. Loosen the adjuster nut 10 and take out the pilot poppet 6 and spring 9.
Page 296 Hydraulics Section E Section E 35 - 1 Negative Control Relief Valve JS200/JS240 35 - 1 Operation The negative control relief valve is situated between the neutral passage HP and low pressure passage LP and operates in the following manner.
Page 297 Hydraulics Section E Section E 35 - 2 Negative Control Relief Valve JS200/JS240 35 - 2 Dismantling Remove plug 3 (Hexagonal 36 A/F) and remove spring 4 and poppet 2 from the plug 1 (Hexagonal 36 A/F). Keep the disassembled negative control relief parts in such a way that they can be assembled so as to achieve the same set relief pressure after reassembly.
Page 298: Remote Control Valve Js200/Js240
Hydraulics Section E Section E 40 - 1 Remote Control Valve JS200/JS240 40 - 1 Schematics, Technical Data JS03600 Symbol Part Name Qty Symbol Part Name Qty Symbol Part Name Case Plug 221-2 Spring Port plate 212-1 Push rod 221-3...
Page 299 Hydraulics Section E Section E 40 - 2 Remote Control Valve JS200/JS240 40 - 2 Schematics, Technical Data Working pressure 40 kgf/cm (38.6 bar, 568.9 lb/in Primary pressure Max. 100 kgf/cm (96.7 bar, 1422 lb/in Secondary pressure 0~45 (maximum control pressure) kgf/cm (0-43 bar, 639.2 lb/in...
Page 300: Operation
Hydraulics Section E Section E 40 - 3 Remote Control Valve JS200/JS240 40 - 3 Operation The structure of the pilot valve is shown in the assembly drawings (see previous page). The pressure reduction valve unit is built into the vertical bore in the casing.
Page 301 Hydraulics Section E Section E 41 - 1 Remote Control Valve JS200/JS240 41 - 1 Dismantling Notes: All parts are manufactured with a high degree of precision and require the utmost care when handling. Do not let parts knock against each other and take extra precautions when handling parts to prevent them being dropped.
Page 302 Hydraulics Section E Section E 41 - 2 Remote Control Valve JS200/JS240 41 - 2 Dismantling (continued) 4. Wash the pilot valve (by itself) with kerosene. Note: Blank off the parts with plugs. 5. Using a copper or lead plate for protection, secure the pivot valve in the vice.
Page 303 Hydraulics Section E Section E 41 - 3 Remote Control Valve JS200/JS240 41 - 3 Dismantling (continued) 8. Remove the Plate (151) 9. If the return springs (221) are weak, the sliding resistance of the 'O'-ring causes the plugs (211) to stick in the casing.
Page 304 Hydraulics Section E Section E 41 - 4 Remote Control Valve JS200/JS240 41 - 4 Dismantling (continued) 12. Remove the port plate (111) and 'O'-ring (122) from the casing. 13. Remove the bushing (131) from the casing. 14. To disassemble the pressure reduction assembly, stand...
Page 305 Hydraulics Section E Section E 41 - 5 Remote Control Valve JS200/JS240 41 - 5 Dismantling (continued) 16. Remove the push rod (212) from the plug (211). 17. Remove the 'O'-ring (214) and the seal (213) from the plug (211). Use a small straight-headed screwdriver to remove the seal.
Page 306 Hydraulics Section E Section E 41 - 6 Remote Control Valve JS200/JS240 41 - 6 Assembly Mount the bushing (131) and 'O'-ring (122) on the casing (101). Attach the port plate with hexagonal socket head bolts (125) and seal washer (121) to the casing (101).
Page 307 Hydraulics Section E Section E 41 - 7 Remote Control Valve JS200/JS240 41 - 7 Assembly (continued) Tighten the hexagonal socket head bolts (125) to the specified torque. (300 kgf-cm). Note: Tighten the bolts alternately a little at a time until they are tightened to the specified torque.
Page 308 Hydraulics Section E Section E 10 - 11 Remote Control Valve JS200/JS240 10 - 11 Assembly (continued) 7. Mount the 'O'-rings (214) into the plug (211). 8. Mount the seals (213) into the plug (211). Note: Mount the seals so that the lips are as shown in the illustration.
Page 309 Hydraulics Section E Section E 41 - 9 Remote Control Valve JS200/JS240 41 - 9 Assembly (continued) 10. Mount the plug assembly into the casing. If the return springs are weak, the sliding resistance of the 'O'-rings will hold the plugs in place in the casing.
Page 310 Hydraulics Section E Section E 41 - 10 Remote Control Valve JS200/JS240 41 - 10 Assembly (continued) 14. Mount the adjusting nut (312) and tighten it to the specified torque, using a spanner on the flats of the disk. (Adjusting nut tightening torque 68.6 ± 4.9 Nm (50 ± 3.6 lb/ft).
Page 311: Trouble Shooting
Hydraulics Section E Section E 42 - 1 Remote Control Valve JS200/JS240 42 - 1 Trouble Shooting Symptoms Possible Causes Counter measures 1. Low secondary pressure a. Primary pressure is low. Apply the correct primary pressure. b. Spring (241) is damaged.
Page 312: Maintenance Specifications
Hydraulics Section E Section E 43 - 1 Remote Control Valve JS200/JS240 43 - 1 Maintenance Specifications Maintenance Item Standard Note Leakage Amount Replace if the leakage exceeds 1000cc/min Condition with the handle in the neutral position or Primary pressure 30 kgf/cm 2000cc/min during operation.
Page 313 Hydraulics Section E Section E 50 - 1 Solenoid Valve (8-spool) JS200/JS240 50 - 1 Schematics, Technical Data 24B* 24A* JS03690 Parts Name Housing Housing Plug O-ring Socket head bolt Spring O-ring O-ring O-ring 10A❊ Body 10B❊ Spool O-ring Pipe...
Page 314 Hydraulics Section E Section E 50 - 2 Solenoid Valve (8-spool) JS200/JS240 50 - 2 Schmatics, Technical Data 9803/6400 Issue 1...
Page 315 Hydraulics Section E Section E 50 - 3 Solenoid Valve (8-spool) JS200/JS240 50 - 3 Schematics, Technical Data Rated Pressure 40 kgf/cm (38.69 bar, 568.8 lb/in Rated Flow 5 l/min (1.09 imp gal) Pressure Loss Characteristic <.967 bar (1.0 kgf/cm , 14.22 lb/in...
Page 316 Hydraulics Section E Section E 51 - 1 Solenoid Valve (8-spool) 51 - 1 Refer to illustrations at the end of this section. Dismantling Notes: All parts are manufactured with a high degree of precision and require the utmost care when handling. Do not let parts knock against each other and take extra precautions when handling parts to prevent them being dropped.
Page 317 Hydraulics Section E Section E 51 - 2 Solenoid Valve (8-spool) 51 - 2 Dismantling (continued) Remove the coil assembly (21) from the cap (22). Remove the spacer (20) from the coil assembly. Remove the inner housing (19). Remove slowly so that the parts inside the housing do not fly out.
Page 318 Hydraulics Section E Section E 51 - 3 Solenoid Valve (8-spool) 51 - 3 Dismantling (continued) Remove the rod (26), stopper (17), plunger (16), spring (15), and spring seat (14). If the spring seat is stuck to the inside of the inner housing, use tweezers to remove Pull out the pipe (13) from the inner housing using a nylon brush.
Page 319 Hydraulics Section E Section E 51 - 4 Solenoid Valve (8-spool) 51 - 4 Dismantling (continued) Remove the body (24A) with the special tool (A). Remove the spring (6) using tweezers. 10. Line up the disassembled parts on a clean place in such a way to facilitate reassembly.
Page 320 Hydraulics Section E Section E 51 - 5 Solenoid Valve (8-spool) 51 - 5 Dismantling (continued) 11. Use a socket or torque wrench to remove the plug (31). 12. Use a socket or torque wrench to remove the socket head bolt (5). 9803/6400 Issue 1...
Page 321 Hydraulics Section E Section E 51 - 6 Solenoid Valve (8-spool) 51 - 6 Assembly Install the 'O'-ring (4) on the housing (1). Use the socket head bolt for housing (1) and (2) and tighten to 24.5 + 4.9 Nm (18.08 + 0.5 kgf m). - 0 Nm - 0 kgf m Install the 'O'-ring (7) on the plug (31) and assemble to...
Page 322 Hydraulics Section E Section E 51 - 7 Solenoid Valve (8-spool) 51 - 7 Assembly (continued) Install the 'O'-rings (8, 9, 23) on the body (24A) and use the special tool (B) on the housing and push it in. The inner diameter of the S8 body is 12 mm. (Apply grease to the 'O'-ring).
Page 323 Hydraulics Section E Section E 51 - 8 Solenoid Valve (8-spool) 51 - 8 Assembly (continued) After inserting the spool, push the top of the spool with your finger and slide it. The spool should slide smoothly and if there is any resistance, do not use it. Fit the 'O'-ring to the inner housing (19) and install pipe (13), spring seat (14), spring (15), plunger (16), stopper (17) and rod (26) into the housing.
Page 324 Hydraulics Section E Section E 51 - 9 Solenoid Valve (8-spool) 51 - 9 Assembly (continued) Place the housing horizontally and install the inner housing (19). Take care that parts which are assembled to the inner housing do not drop off. (Apply grease to the 'O'-ring).
Page 325 Hydraulics Section E Section E 51 - 10 Solenoid Valve (8-spool) 51 - 10 Assembly (continued) 12. Apply anaerobic adhesive Loctite 242 to the screw thread and using a torque wrench, tighten it to 29.4 ± 9.3 Nm (21.1 ± 7.23 lb/ft). Solenoids S1, S3~S7 The assembly procedure for the solenoids at housing positions C1 and C3 to C7 is identical to that described in...
Page 326 Hydraulics Section E Section E 51 - 11 Solenoid Valve (8-spool) 51 - 11 *24B *24A JS02620 9803/6400 Issue 2*...
Page 327 Hydraulics Section E Section E 51 - 12 Solenoid Valve (8-spool) 51 - 12 9803/6400 Issue 1...
Page 328 Hydraulics Section E Section E 55 - 1 Shuttle Valve 55 - 1 Schematic 9803/6400 Issue 1...
Page 329: Operation
Hydraulics Section E Section E 55 - 2 Shuttle Valve 55 - 2 Operation When right slew is selected, pressurised oil enters the A1 Control valve port of the shuttle block from the remote control valve. The Control valve pressurised oil moves steel ball (a) to the left side and enters right slew left slew the right slew port of the control valve from the B1 port.
Page 330 Hydraulics Section E Section E 55 - 3 Cushion Valves 55 - 3 Schematic 9803/6400 Issue 1...
Page 331 Hydraulics Section E Section E 55 - 4 Cushion Valves 55 - 4 Dipper Control Valve Boom Control Valve Hydraulic Oil Tank Filter Cushion Valve Solenoid Valve Cushion Switch Dipper Remote Control Boom Remote Control Valve Pilot Gear Pump 9803/6400 Issue 1...
Page 332 Hydraulics Section E Section E 55 - 5 Cushion Valves 55 - 5 Operation In the Soft State When lever is in neutral (Refer to Fig. 1). The hot oil separated from the oil cooler line enters the R port of the cushion valve. It flows through the reverse notch spool interior and through passages e and f.
Page 333 Hydraulics Section E Section E 55 - 6 Cushion Valves 55 - 6 Operation (continued) During Dipper Closed and Stopping a. When the pilot pressure from the remote control valve stops, the reverse notch spool returns to neutral. b. Also, the cushion spool returns to neutral and the pilot oil returning from the control valve passes through the throttle a and b.
Page 334 Stacked (Slew Brake) Valve 60 - 1 Schematic Solenoid Part Valve Part 1. Voltage DC24V 1. Working Pressure 3.9 MPa (40 kgf/cm 2. Consumed Power 2. Working Flow 16 l/min 3. Other Surge Suppressor 3. Decompressor Pressure JS200/240 Pressure kgf/cm 9803/6400 Issue 3*...
Page 335 Hydraulics Section E Section E 60 - 2 Stacked (Slew Brake) Valve 60 - 2 Operation Hydraulic Brake Release The pilot pressure (40 kgf/cm ) enters P port of A section and passes through the outer periphery of the sleeve of the solenoid valve for slew brake and enters passageway a.
Page 336 Hydraulics Section E Section E 60 - 3 Stacked (Slew Brake) Valve 60 - 3 Operation (continued) Hydraulic Slew Brake - 100% Engagement When the solenoid valve for slew lock is put ON (locking the slew lock switch), the spool moves downwards. The pressurised oil from passageway C is stopped by the spool.
Page 337 Hydraulics Section E Section E 60 - 4 Stacked (Slew Brake) Valve 60 - 4 Operation (continued) Hydraulic Slew Brake - 50% Engagement When the slew lever is placed in neutral and 5 seconds have passed, an electric signal enters the solenoid valve for slew brake from the controller and the spool is selected.
Page 338 Hydraulics Section E Section E 70 - 1 Hydraulic Rams 70 - 1 Specifications JS200/JS200LC JS240/JS240LC Boom Ram Cylinder Inside Diameter: 125mm Cylinder Inside Diameter: 130mm Left & Right Rod Diameter: 85mm Rod Diameter: 90mm Max. Contraction: 1790mm Max. Contraction:...
Page 339 Use genuine JCB parts when replacing parts. If parts other than genuine JCB parts are used, the desired results may not be obtained. Use only genuine JCB parts. Caution during disassembly and reassemble.
Page 340 Hydraulics Section E Section E 72 - 1 Hydraulic Rams 72 - 1 Bucket Ram Removal ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses.
Page 341 Hydraulics Section E Section E 72 - 2 Hydraulic Rams 72 - 2 Bucket Ram (continued) Remove nuts and bolts. Push the pin out using a bar and hammer. Restrain the eye end of the bucket ram rod to the ram cylinder to prevent the ram rod from extending.
Page 342 Hydraulics Section E Section E 72 - 3 Hydraulic Rams 72 - 3 Bucket Ram (continued) Attach a sling and lift the bucket ram. Remove the nuts and bolts. Push out the pin using a bar and hammer. Installation Attach a sling to the bucket ram and lift it into the dipper. Install the pin, bolt and nuts.
Page 343 Hydraulics Section E Section E 72 - 4 Hydraulic Rams 72 - 4 Bucket Ram (continued) Connect the hose to the bucket ram. Hoist the bucket ram to align with the link. Install the pin, bolt and nuts. When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight but must have approximately 3mm of play so that the pin is free from...
Page 344 Hydraulics Section E Section E 73 - 1 Hydraulic Rams 73 - 1 Dipper Ram ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses.
Page 345 Hydraulics Section E Section E 73 - 2 Hydraulic Rams 73 - 2 Dipper Ram (continued) Remove the nuts and bolts. Push out the pin, using a bar and hammer. Restrain the eye end of the Dipper ram rod to the ram cylinder to prevent the rod from extending.
Page 346 Hydraulics Section E Section E 73 - 3 Hydraulic Rams 73 - 3 Dipper Ram (continued) Remove the grease tube, from the Dipper ram. Attach a sling and lift the Dipper ram. 10. Remove the nuts and bolts, push out the pin using a bar and hammer.
Page 347 Hydraulics Section E Section E 73 - 4 Hydraulic Rams 73 - 4 Dipper Ram (continued) Install the pin, bolts and nuts. When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight but must have approximately 3mm of play so that the pin is free from tension.
Page 348 Hydraulics Section E Section E 73 - 5 Hydraulic Rams 73 - 5 Dipper Ram(continued) Install the pin, bolt and nuts. When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight but must have approximately 3mm of play so that the pin is free from tension.
Page 349 Hydraulics Section E Section E 74 - 1 Hydraulic Rams 74 - 1 Boom Ram ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses.
Page 350 Hydraulics Section E Section E 74 - 2 Hydraulic Rams 74 - 2 Boom Ram (continued) a. Remove the nuts, bolt and collar. b. Push out the pin, using a bar and hammer. Lower the Boom ram and place it on a stand. Restrain the eye end of the Boom ram rod to the ram cylinder, to prevent movement of the rod.
Page 351 Hydraulics Section E Section E 74 - 3 Hydraulic Rams 74 - 3 Boom Ram (continued) Remove the boom ram hoses, and install plugs or caps to prevent contamination. Remove the nut and bolt and push out the pin with a hammer and bar.
Page 352 Hydraulics Section E Section E 74 - 4 Hydraulic Rams 74 - 4 Boom Ram (continued) Install the pin and then the bolt and nuts. When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight but must have approximately 3mm of play so that the pin is free from tension.
Page 353 Hydraulics Section E Section E 74 - 5 Hydraulic Rams 74 - 5 Boom Ram (continued) 6. Install the collar and then the bolt and nuts. When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight but must have approximately 3mm of play so that the pin is free from tension.
Page 354 Section E 75 - 1 Hydraulic Rams 75 - 1 Disassembly JS200/JS240 Details of Service Tools used in the dismantling and Assembly procedures are given in Service Tools, Section 1 . Before starting work, clean all surfaces with a suitable solvent and dry with compressed air.
Page 355 Section E Section E 75 - 2 Hydraulic Rams 75 - 2 Disassembly JS200/JS240 (continued) Remove the piston rod. Make sure that the piping ports are opened. Catch the oil coming out from the rod side (cylinder head side) port.
Page 356 Section E Section E 75 - 3 Hydraulic Rams 75 - 3 Disassembly JS200/JS240 (continued) Remove the piston, cushion bearing, cushion seal, cylinder head in that order. (There is no cushion seal for the bucket ram). Remove the piston seal.
Page 357 Section E 75 - 4 Hydraulic Rams 75 - 4 Disassembly JS200/JS240 (continued) 11. Dismantling the retraction side cushion (dipper ram). When there is a cushion bearing installed on the piston rod, after removing the nut A, disassemble as indicated below.
Page 358 Section E 75 - 5 Hydraulic Rams 75 - 5 Assembly JS200/JS240 Clean each part in a suitable solvent and dry using compressed air. Inspect all parts and replace as required. Care must be taken not to let dust or dirt adhere to parts after cleaning and that parts do not become dented, scratched or damaged.
Page 359 75 - 6 Hydraulic Rams 75 - 6 Assembly JS200/JS240 (continued) Note: Be careful to install the seal in the proper direction. Installing it backwards causes extremely high pressure to build up between it and the U-ring and could cause deformation of the cylinder head.
Page 360 75 - 7 Hydraulic Rams 75 - 7 Assembly JS200/JS240 (continued) e. After tightening the piston nut BB, insert the steel ball CC and install the set screw DD, tighten it to the specified torque, then stake the set screw in two places with a punch EE.
Page 361 Section E 75 - 8 Hydraulic Rams 75 - 8 Assembly JS200/JS240 (continued) Assemble the piston rod into the cylinder. a. Secure the cylinder vertically or horizontally, insert the piston into the cylinder. b. If the cylinder is vertical the piston rod will enter under its own weight.
Page 362 Section E Section E 75 - 9 Hydraulic Rams 75 - 9 Assembly JS200/JS240 (continued) 9. Inspection after Assembly No-load Operation Operations are smooth and there are no abnormalities with each part after full stroking more Inspection than five times with no load.
Page 363 Hydraulics Section E Section E 75 - 10 Hydraulic Rams 75 - 10 Ram Piston Head Nut JS00980 9803/6400 Issue 1...
Page 364 ) or from the auxiliary rig with the piston rod supported by block J. circuit of a JCB machine equipped with quick-release couplings. In either case, small bore hoses E (Part No. Secure the eye end of the piston rod to the rig at 892/00137 - 2 off) must be used to connect the rig to the position G, using a suitable pivot pin.
Page 365 Hydraulics Section E Section E 75 - 12 Hydraulic Rams 75 - 12 Ram Piston Head Nut (cont’d) Nut Fitting (cont’d) JS200 Ram Location Piston Nut Piston Nut Torque Gauge Pressure AF (mm) Nm (lbf ft) bar (lb/in Boom 5000 (3700)
Page 366 Hydraulics Section E Section E 76 - 1 Hydraulic Rams 76 - 1 Reconditioning Structure and Characteristics of Special Jigs for Repair of Rams Inserting seal ring and correction jig. a. Jig components Part no Part Name Note WDB 2052 Seal ring inserting and correction jig set Inner Guide Outer Guide...
Page 367 Hydraulics Section E Section E 76 - 2 Hydraulic Rams 76 - 2 Reconditioning (continued) Bushing press-fitting jig a. Jig components Part no Part Name Note WDB 2166 Bushing press-fitting jig set Also to be used for removing bushing Chuck assembly WDB 2166-1 Retainer Also to be used for press-fitting wiper ring...
Page 368 Hydraulic Rams 76 - 3 Reconditioning (continued) Jig Table For inserting and correcting seal ring Note: The mark O in the table below indicates KCH type. Cylinder inner diameter Unit: mm Boom JS200/ Dipper 200LC Bucket Boom JS240/ Dipper 240LC Bucket...
Page 369 76 - 4 Reconditioning (continued) For press-fitting wiper ring (Can be used for pulling out and press-fitting bushing) Note: The mark O in the table below indicates KCH type. Piston rod diameter Unit: mm Boom JS200/ Dipper 200LC Bucket Boom JS240/ Dipper...
Page 370 Hydraulics Section E Section E 76 - 5 Hydraulic Rams 76 - 5 Reconditioning (continued) Jig Usage Note: The special jigs are different, according to the cylinder diameter, so choose the appropriate jig from the table. The lower part of the inner guide jig is very thin, so be careful with handling and storage. Procedures for inserting, correcting the seal ring.
Page 371 Hydraulics Section E Section E 76 - 6 Hydraulic Rams 76 - 6 Reconditioning (continued) Jig Usage (continued) 4. Outer guide jig fitting Put the plate on the outer guide jig and then continue to push the plate by hand until the seal ring touches the outer guide jig.
Page 372 Hydraulics Section E Section E 76 - 7 Hydraulic Rams 76 - 7 Reconditioning (continued) Jig Usage (continued) 7. Correction jig preparation Set the correction jig underneath the press. Apply a thin coat of lubricant to the tapered section of the correction jig and place the jig with the tapered section facing up.
Page 373 Hydraulics Section E Section E 76 - 8 Hydraulic Rams 76 - 8 Reconditioning (continued) Jig Usage (continued) 10. Removal of correction jig After completion of the correction of the seal ring, remove the jig in the following order. 1. Remove the press rod. 2.
Page 374 Hydraulics Section E Section E 77 - 1 Hydraulic Rams 77 - 1 Reconditioning (continued) Bush removal Note: The jigs differ, depending on the piston rod diameter, so please refer to the table and select the appropriate jig. The chuck blade section is a very important part, so handle and store with utmost care. 1.
Page 375 Hydraulics Section E Section E 77 - 2 Hydraulic Rams 77 - 2 Reconditioning (continued) Bush removal (continued) 3. Setting the chuck assembly (jig) Gradually insert the chuck assembly into the cylinder head until its blade end reaches the bushing end. 1.
Page 376 Hydraulics Section E Section E 77 - 3 Hydraulic Rams 77 - 3 Reconditioning (continued) Bush removal (continued) 5. Attaching the retainer Gently place the retainer on the stepped portion of the wedge inside the chuck assembly (jig). 1. Place so that the larger diameter (collar) is facing up as shown in the figure.
Page 377 Hydraulics Section E Section E 77 - 4 Hydraulic Rams 77 - 4 Reconditioning (continued) Bush removal (continued) 7. Block (jig) preparation Prepare a block and align the shaft centre while placing the cylinder head on the block. Choose a block suitable in shape and size from the table below.
Page 378 Hydraulics Section E Section E 77 - 5 Hydraulic Rams 77 - 5 Reconditioning (continued) Bush removal (continued) 9. Removing chuck assembly (jig) with bushing 1. After removing the cylinder head assembly (retainer jig attached and chuck assembly jig attached) from under the press, remove the retainer from the cylinder head and, grasping both sides of the cylinder head, move it to another place.
Page 379 Hydraulics Section E Section E 77 - 6 Hydraulic Rams 77 - 6 Reconditioning (continued) Bush removal (continued) 11. Retightening the adjuster With the chuck assembly (jig) and bushing removed, turn the adjuster with your fingers until there is no gap between the adjuster and the wedge upper surface.
Page 380 Hydraulics Section E Section E 77 - 7 Hydraulic Rams 77 - 7 Reconditioning (continued) Bush Assembly Note: The jigs differ, depending on the piston rod diameter, so please refer to the table and select the appropriate jig. The chuck blade section is a very important part, so handle and store with utmost care. 1.
Page 381 Hydraulics Section E Section E 77 - 8 Hydraulic Rams 77 - 8 Reconditioning (continued) Bush Assembly (continued) 4. Attaching the retainer (jig) Gently place the retainer so that its end is aligned with the wedge stepped section of the chuck assembly jig. Place the retainer so that the larger diameter part is facing up as shown.
Page 382 Hydraulics Section E Section E 77 - 9 Hydraulic Rams 77 - 9 Reconditioning (continued) Bush Assembly (continued) 6. Press-fitting the bushing At the press, push on the bolt head of the adjuster and gradually press-fit the bushing into the specified position in the cylinder head.
Page 383 Hydraulics Section E Section E 77 - 10 Hydraulic Rams 77 - 10 Reconditioning (continued) Wiper Ring Assembly 1. Setting the cylinder head Set the cylinder head on the work bench with the tube connecting surface facing down. Keep the work bench clean so that no dust or other foreign matter can damage the bottom surface of the cylinder head.
Page 384 Hydraulics Section E Section E 77 - 11 Hydraulic Rams 77 - 11 Reconditioning (continued) Wiper Ring Assembly (continued) 4. Preparation for press-fitting Move the cylinder head with the retainer (jig) on it underneath the press. Adjust so that the shaft centre of the press (ram) and retainer are in line.
Page 385 Hydraulics Section E Section E 77 - 12 Hydraulic Rams 77 - 12 Reconditioning (continued) Cylinder Head Assembly 1. Fixing the piston rod Fix the piston rod so that the threaded part is facing you. Handle the piston rod with care so that no damage is done to its outer peripheral surface.
Page 386 Hydraulics Section E Section E 77 - 13 Hydraulic Rams 77 - 13 Reconditioning (continued) Cylinder Head Assembly (continued) 3. Inserting the cylinder head Insert the cylinder head onto the piston rod, wiper ring side first, to the specified position, sliding on the peripheral surface of the guide (jig).
Page 387: Trouble Shooting
Hydraulics Section E Section E 78 - 1 Hydraulic Rams 78 - 1 Trouble Shooting Hydraulic ram trouble and its remedies. It is not easy to find the part causing the trouble. In the chart below, possible problems are listed. Repair is difficult so refer to the estimated cause and treatment listed in the chart.
Page 388: Trouble Shooting
Hydraulics Section E Section E 78 - 2 Hydraulic Rams 78 - 2 Trouble Shooting (continued) Item Symptoms Related Parts Trouble Treatment Packaging rubber elasticity is The packing life or hydraulic oil gone and breaks into pieces. deterioration and high temperature are possible reasons.
Page 389: Trouble Shooting
Hydraulics Section E Section E 78 - 3 Hydraulic Rams 78 - 3 Trouble Shooting (continued) Item Symptoms Related Parts Trouble Treatment Foreign matter biting on inner • Remove foreign matter. and outer diameter. • Replace 'O'-ring if damaged. • Inspect inside tube: if any scratches or O-ring damaged.
Page 390 Hydraulics Section E Section E 78 - 4 Hydraulic Rams 78 - 4 Trouble Shooting (continued) Item Symptoms Related Parts Trouble Treatment Poor Bending is more than the • Replace with new part. operation Piston rod specified limit. The seal and sliding part material may be cylinder tube (Bending distortion: damaged too, so inspect.
Page 391 Hydraulics Section E Section E 78 - 5 Hydraulic Rams 78 - 5 Trouble Shooting (continued) Item Symptoms Related Parts Trouble Treatment Air remaining inside ram • Bleed the air. Operation is unsteady For rams that do not have an air bleeder, operate back and forth several times at low pressure and low speed to bleed the air.
Page 392 Hydraulics Section E Section E 79 - 1 Hydraulic Rams 79 - 1 Maintenance Specifications In order to ensure long life of the hydraulic ram, carry out inspection and maintenance regularly. If an abnormal point is found, repair as soon as possible referring to the troubleshooting chart. Inspection, Inspection, Maintenance Point...
Page 393 Hydraulics Section E Section E 79 - 2 Hydraulic Rams 79 - 2 Maintenance Specifications JS200/JS240 Use Limit Piston Rod Outer Diameter Wear Limit Nominal diameter (mm) Minimum outer diameter (mm) Treatment 55~80 -0.023 Replace or replate 85~120 -0.027 Replace or replate...
Page 394 Hydraulics Section E Section E 80 - 1 Rotary Coupling 80 - 1 Schematic, Technical Data Item Part Name Axle V-ring Rotor O-ring Packing ring Thrust plate Hexagonal socket head bolt O-ring Cover Plug Plug 9803/6400 Issue 1...
Page 395 Hydraulics Section E Section E 80 - 2 Rotary Coupling 80 - 2 Schematic, Technical Data (continued) Item Part Name High strength bolt High strength washer Loctite 262 Lock bar Seal washer Seal cap Rubber packing Seal ring Rotating joint assmebly The unit weighs 35kg.
Page 396 Hydraulics Section E Section E 81 - 1 Rotary Coupling 81 - 1 Operation The rotary coupling consists of the inner axle and outer rotor with packing rings, 'O'-rings, thrust plate and cover. In the axle and rotor, there are pairs of ports and oil passages each pair being sealed from the others by packing rings and 'O'-rings. Both the axle and rotor can rotate and the oil can flow freely through the oil grooves.
Page 397 Section E 82 - 1 Rotary Coupling 82 - 1 Dismantling JS200/JS240 Refer to the sectional illustration on the previous page as a guide to the dismantling and assembly procedures. Details of the service tools used in the dismantling and assembly procedures are given in Section 1, Service Tools.
Page 398 Section E 82 - 2 Rotary Coupling 82 - 2 Dismantling JS200/JS240 (continued) Remove the cover 19 with the bolt 17. Remove the 'O'-ring 18. Do not reuse the 'O'-ring 18. Remove the thrust plate 16 with the bolt 17.
Page 399 Section E 82 - 3 Rotary Coupling 82 - 3 Dismantling JS200/JS240 (continued) 9. Remove the V-ring 12 from the axle 11. Note: Do not reuse the V-ring 12. 10. Remove the 'O'-ring 14, and packing ring from the rotor Note: Do not reuse the packing ring 15.
Page 400 Section E 82 - 4 Rotary Coupling 82 - 4 Assembly JS200/JS240 Inspect the parts for signs of wear, pitting, scratching, discolouration etc. Polish out scratches using a fine grade oil stone. Before assembly, thoroughly clean all parts using a suitable solvent: Do NOT use solvents on 'O'-rings, backup rings and seals.
Page 401 Section E 82 - 5 Rotary Coupling 82 - 5 Assembly JS200/JS240 (continued) After installing the 'O'-ring, packing ring and packing, check with a mirror to see if they are installed correctly. After checking, coat with grease then check once more for any protrusion, twisting, etc.
Page 402 Section E Section E 82 - 6 Rotary Coupling 82 - 6 Assembly JS200/JS240 (continued) Install the 'O'-ring. Install the cover. Align the coupling (9) to the lower frame and tighten the rotating joint installation bolt (1) and. Tighten the lock bar installation bolt (1) and washer (2) to the specified torque, 109-127 Nm (11.1-12.9 Kgf/m,...
Page 403 Hydraulics Section E Section E 83 - 1 Slew Motor 83 - 1 Hydraulic Motor Components Drain port Pilot port Pilot hole Flow paths Piston bore Flow paths By pass valve Inlet port Outlet port Anti-cavitation check valve Mechanical brake Cross-line relief valve A side cavity B side cavity...
Page 404 Hydraulics Section E Section E 83 - 2 Slew Motor 83 - 2 Reduction Gear Components A chamber B chamber JS00970 Torque path Note: Item numbers are referred to on the following pages. 9803/6400 Issue 2*...
Page 405 Hydraulics Section E Section E 83 - 3 Slew Motor 83 - 3 Hydraulic Circuit Hydraulic motor (151 cm /rev) Bypass/Anti-pendulum valve Anti-cavitation check valve Relief valve (285 kgf/cm @ 155 l/min) Mechanical brake Tank line Drain line JS02680 9803/6400 Issue 2*...
Page 406 Hydraulics Section E Section E 90 - 1 Slew Motor 90 - 1 Operation Slew Motor Configuration Slew Unit Planetary 2-stage Reduction Gear Swash Plate Type Axial Piston Hydraulic Motor Mechanical Brake Relief Valve By-pass Valve Make-up Valve The above diagram indicates the relationships between the main components of the slew motor, whose working principles are described on the following pages.
Page 407 Hydraulics Section E Section E 90 - 2 Slew Motor 90 - 2 Operation (continued) Hydraulic Motor Working Principles Make-Up Valve Working Principles (illustration reference page 83 - 1) Under partial hydraulic cross-line relief braking (relief valve not functioning). Oil supplied from the pump via the control valves enters port A (or port B) on cover 17 and is discharged from port B (or When slowing down the slew structure with the hand port A).
Page 408 Hydraulics Section E Section E 90 - 3 Slew Motor 90 - 3 Operation (continued) Relief Valve Working Principles Reduction Gear Structure and Working Principles (illustration reference page 83 - 2) On starting Power transmitted by the hydraulic motor output shaft is Due to the superstructure’s inertia there is a build-up of transmitted to second sun gear 77 via first sun gear 66, pressure in the motor when it begins to slew.
Page 409 Hydraulics Section E Section E 91 - 1 Slew Motor 91 - 1 Maintenance Specifications Item Inspection and Maintenance Standards The crescent-shaped ports in the balance plate, which are in sliding contact with the end face of the cylinder assembly shaft, act to switch between high and low oil pressure.
Page 410 Hydraulics Section E Section E 92 - 1 Slew Motor 92 - 1 Motor Assembly/Cylinder Assembly Dismantling Refer to the sectional drawing on page E/83-1 as a guide to Remove the level gauge with a pipe wrench. dismantling and assembling. Before attempting to dismantle the slew motor assembly, the inlet and outlet ports should be blanked and the outer surfaces washed down with a suitable solvent to remove all...
Page 411 Hydraulics Section E Section E 92 - 2 Slew Motor 92 - 2 Motor Assembly/Cylinder Assembly Dismantling (cont’d) Remove the caps 37 with 14 mm A/F hexagonal sockets Remove the caps 30 with a 14 mm A/F hexagonal key and remove relief valves 34 from the motor. and take out the springs 31 and check valves 29.
Page 412 Hydraulics Section E Section E 92 - 3 Slew Motor 92 - 3 Motor Assembly/Cylinder Assembly Dismantling (cont’d) Place the motor with the main shaft downwards and lift Remove snap ring 23 and remove the inner ring of off cover 17. needle bearing 22.
Page 413 Hydraulics Section E Section E 92 - 4 Slew Motor 92 - 4 Motor Assembly/Cylinder Assembly Dismantling (cont’d) Remove the bushings 20 with Teflon rings 19 and the Remove the springs 14 from brake piston 12. plate springs 18. Note: Keep the springs in the order in which they are to be reinserted.
Page 414 Hydraulics Section E Section E 92 - 5 Slew Motor 92 - 5 Motor Assembly/Cylinder Assembly Dismantling (cont’d) Attach a puller to the inner ring of taper roller bearing 3 Remove swash plate 6, piston assemblies 8 and at two places and on the end of cylinder 24 spline, then retainer plate 7 together from cylinder 24.
Page 415 Hydraulics Section E Section E 92 - 6 Slew Motor 92 - 6 Motor Assembly/Cylinder Assembly Dismantling (cont’d) Hold the end of cylinder 24 by hand and pull out the Remove the outer ring of taper roller bearing 3 from the cylinder assembly from housing 25.
Page 416 Hydraulics Section E Section E 92 - 7 Slew Motor 92 - 7 ! CAUTION Motor Assembly/Cylinder Assembly Assembly Cleaning Cleaning metal parts with incorrect solvents can cause Refer to the sectional drawing on page 83 - 1 as a guide to corrosion.
Page 417 Hydraulics Section E Section E 92 - 8 Slew Motor 92 - 8 Motor Assembly/Cylinder Assembly Assembly (cont’d) Apply grease to the curved part of cylinder 24 (contact Position the piston assemblies 8 into the holes of face with spring 5) and mount spring 5. retainer plate 7.
Page 418 Motor Assembly/Cylinder Assembly Assembly (cont’d) Mount collar 53 and inner ring of taper roller bearing 1 Apply a thin coat of JCB Retainer where the inner ring is on motor output shaft 24. mounted on motor output shaft 24. Using a jig, (see Special Tools, Section 1) mount inner Apply grease to the lip of seal 2 and use a press and jig ring 1 on output shaft 24.
Page 419 Hydraulics Section E Section E 92 - 10 Slew Motor 92 - 10 Motor Assembly/Cylinder Assembly Assembly (cont’d) Mount the outer ring of the taper roller bearing into 11 Hold the end of cylinder 24 by hand and carefully insert housing 25.
Page 420 Hydraulics Section E Section E 92 - 11 Slew Motor 92 - 11 Motor Assembly/Cylinder Assembly Assembly (cont’d) Apply hydraulic oil to the sliding surface around piston Insert the brake unit springs 14 back into brake piston 12 and slide it into housing 25. Note: It is difficult to insert piston 12 into the housing due to Note: Insert the springs 14 the same order as they were O'-rings 11 and 13.
Page 421 Press needle bearing 22 inner ring into cover 17 and attach snap ring 23. Apply grease to the 'O'-ring and install 'O'-ring 13 to To prevent oil leakage from the cover bolt holes apply cover 17. JCB Multi-gasket to the surface. 9803/6400 Issue 2*...
Page 422 Hydraulics Section E Section E 92 - 13 Slew Motor 92 - 13 Motor Assembly/Cylinder Assembly Assembly (cont’d) Lift cover 17 and balance plate 21 by hand and mount Tighten the cap screws 27 (with a 12 mm A/F hexagonal them carefully on housing 25.
Page 423 Hydraulics Section E Section E 92 - 14 Slew Motor 92 - 14 Motor Assembly/Cylinder Assembly Assembly (cont’d) Final checks after assembling. Degrease the mating faces of the gear unit ring gear 64 and motor housing 25 and apply Multi-gasket to the ring gear.
Page 424 Hydraulics Section E Section E 92 - 15 Slew Motor 92 - 15 Motor Assembly/Cylinder Assembly Assembly (cont’d) Insert plug 26 with an 8 mm Allen key and tighten to torque of 39.32 Nm (29 lbf ft). Apply grease (type and capacity is given in Fluids and Lubricants).
Page 425 Hydraulics Section E Section E 93 - 1 Slew Motor 93 - 1 Relief Valves Dismantling Refer to the sectional drawing on page E/83-1 as a guide to dismantling and assembling. Take steps during dismantling to ensure that all the parts are returned to their original positions.
Page 426 Hydraulics Section E Section E 93 - 2 Slew Motor 93 - 2 Relief Valves Assembly Press fit seat 44 into sleeve 39 which has an 'O'-ring 41. Mount poppet 43, spring 42, shim 40, piston 38, liner 51 onto sleeve 39. Screw cap 37 (with a 14 mm A/F hexagonal socket) with 'O'-ring 36 and back-up 35 mounted, on to sleeve 39 and tighten to a torque of 157 Nm (116 lbf ft).
Page 427 Hydraulics Section E Section E 94 - 1 Slew Motor 94 - 1 Reduction Gear Dismantling Refer to the sectional drawing on page E/83-2 as a guide to dismantling and assembling. Removal of the sun gear, 1st stage holder assembly. Remove the spur gear and 2nd stage holder assembly Remove sun gear 66 and 1st stage holder assembly 65.
Page 428 INT-3-1-3 Ring gear removal Removal of pinion gear assembly. Remove ring gear 64 from gear case 58. JCB High Remove snap ring 55 with a screwdriver using the notch Strength Gasketing is applied on the assembly to in the case for leverage.
Page 429 Hydraulics Section E Section E 94 - 3 Slew Motor 94 - 3 Reduction Gear Dismantling (cont’d) Support the flange part of gear case 58 on 300 mm Remove the roller bearing 62 from gear case 58. (11.8 in) blocks and press shaft end with a hydraulic press to push out shaft 53, collar 54, plate 56, self- aligning roller bearing 57, snap ring 60 and collar 59 from the assembly.
Page 430 Hydraulics Section E Section E 94 - 4 Slew Motor 94 - 4 Reduction Gear Dismantling (cont’d) Carry out the following procedure only when bearing 57 is damaged or badly worn, and dismantling is necessary. Support the self aligning roller bearing 57, then press the motor end of shaft 53 to remove bearing 57, plate 56 and collar 54 from the shaft 53.
Page 431 Hydraulics Section E Section E 94 - 5 Slew Motor 94 - 5 Reduction Gear Assembly Refer to the sectional drawing on page E/83-2 as a guide to dismantling and assembling. Apply clean hydraulic fluid to all sliding contact faces during assembly.
Page 432 Degrease the periphery of oil seal 61 and its mounting Use the seal protector to prevent the splines of pinion face in gear case 58 and apply JCB High Strength shaft 53 from scratching the lip of the oil seal.
Page 433 Degrease the contact surfaces of gear case 58 and ring gear 64. Mount the collars 63 on the gear case and apply JCB Multi-gasket. Also apply a thin coat on the gear case. Holder assembly mounting b Drive in spring pins 75.
Page 434 Hydraulics Section E Section E 94 - 8 Slew Motor 94 - 8 Reduction Gear Assembly (cont’d) Holder assembly 65 mounting b Drive in the spring pin. a Insert planetary gear 69 and the thrust plate into Note: Drive in the pins with the splits facing towards holder 65 and insert shaft assembly 67.
Page 435 Hydraulics Section E Section E 94 - 9 Slew Motor 94 - 9 Reduction Gear Assembly (cont’d) Sun gear 1st stage holder assembly mounting b Carefully insert sun gear 66 and mesh the teeth of planetary gear 69. a Carefully lower the holder assembly so that it meshes correctly with the internal teeth of ring gear 64.
Page 436 Hydraulics Section E Section E 95 - 1 Slew Motor 95 - 1 Fault Finding Table 1. Symptom Cause External Inspection Countermeasure Repair Internal damage to the Measure the oil drain High possibility of Refer to Table 2. motor. volume. damage to the sliding surfaces if the supply volume is approximately...
Page 437 Hydraulics Section E Section E 95 - 2 Slew Motor 95 - 2 Fault Finding (cont’d) Symptom Cause External Inspection Countermeasure Repair Wear or seizure of the Open motor inlet and High possibility of Inspect the parts and motor sliding surfaces. outlet ports and apply 20 internal damage to the bearing according to...
Page 438 Transmission Section F Section F Contents Page No. 1 - 1 Torque Specifications Track Motor/Gearbox Schematics, Specifications 2 - 1 Operation 3 - 1 Precautions during Installation 4 - 1 Fault Finding 5 - 1 Removal and Replacement 6 - 1 Track Motor Dismantling and Assembly 7 - 1...
Page 439: Torque Specifications
Transmission Section F Section F 1 - 1 Torque Specifications 1 - 1 Torque Specifications JS200/JS240 Component kgfm lb/ft Remarks Traction motor 266.6 - 311.6 27.2 - 31.8 196 - 229.9 Apply 262 Locating Bolts Traction Motor This table refers to the Traction Motor sectional drawing...
Page 440 Transmission Section F Section F 1 - 2 Torque Specifications 1 - 2 Gearbox This table refers to the Gearbox sectional drawing Item Component kgfm lb/ft Remarks Ring Nut M320 x 2 Socket head bolt M10 x 25 Plug M22 x 1.5 Socket head screws M12 x 90 9803/6400...
Page 441 Transmission Section F Section F 2 - 1 Motor/Gearbox 2 - 1 Schematics, specifications JS200 JS240 157.8 164.4 Motor /rev 92.9 98.2 Displacement 7004 7297 Reduction gear, etc. value /rev 4123 4359 Cracking pressure MPa (kgf/cm 31.1 {317} at 1.2 l/min...
Page 442 Transmission Section F Section F 2 - 2 Motor/Gearbox 2 - 2 Schematics, specifications 9803/6400 Issue 1...
Page 443 Transmission Section F Section F 3 - 1 Motor/Gearbox 3 - 1 Operation Traction Motor Assembly The traction motor assembly consists of a counter balance valve, cross-over relief valve, 2-speed switch mechanism, swash plate-type axial piston motor with parking brake function and the gearbox. The piston motor converts the liquid energy of the pressurised oil sent from the hydraulic pump to mechanical energy and transmits high speed low torque power to the reduction gear.
Page 444 Transmission Section F Section F 3 - 2 Motor/Gearbox 3 - 2 When reading the operations section, refer to the schematics, specifications section in conjunction with the accompanying section illustrations. Operation Swash Plate Type Axial Piston Motor Valve Plate Fig.1 Swash Plate Type Axial Piston Motor Nine pistons S/A are integrated in the Cylinder block B.
Page 445 Transmission Section F Section F 3 - 3 Motor/Gearbox 3 - 3 Operation (continued) Counterbalance Valve Fig.2 Counterbalance Valve The counterbalance valve serves to prevent the sudden stoppage of the axial piston motor and control its overrun. When in neutral, the control valve's pressure is generated at ports P1 or P2 so ports M1 and M2 are blocked by the flange and check valve so the motor does not rotate.
Page 446 Transmission Section F Section F 3 - 4 Motor/Gearbox 3 - 4 Operation (continued) Counterbalance Valve (continued) Counterbalance Operation Fig. 3 Counterbalance Valve (Counterbalance) When hydraulic oil delivered from the hydraulic pump is guided to P1 port of the counterbalance valve through the control valve, the hydraulic oil goes through the check valve and flows into the piston motor from M1 port and tries to rotate the motor.
Page 447 Transmission Section F Section F 3 - 5 Motor/Gearbox 3 - 5 Operation (continued) Counterbalance Valve (continued) Brake Function Fig. 4 Counterbalance Valve (Brake) When the control valve is returned to neutral, the pressurised oil from the pump is blocked, and pressure at P1 and P2 become equal, and the plunger tries to return to neutral position by the spring.
Page 448 Transmission Section F Section F 3 - 6 Motor/Gearbox 3 - 6 Operation (continued) Shuttle Function The counterbalance valve has a shuttle function. When the plunger moves from the position in Fig. 5-1 to that of Fig. 5-2, the parking brake release port P3 is opened to guide the pressurised oil to the brake releasing cylinder cavity. This releases the parking brake.
Page 449 Transmission Section F Section F 3 - 7 Motor/Gearbox 3 - 7 Operation (continued) Relief Valve (continued) The relief valve works in the following two stages. First Stage: Refer to Fig. 6-1 When the relief valve starts operating, the shockless piston moves to keep the spring cavity at low pressure. The pressure receiving area of the poppet equals the area of the poppet seat (S1) and so it is considerably larger than the pressure receiving area (S1-S2) when the relief is normally set.
Page 450 Transmission Section F Section F 3 - 8 Motor/Gearbox 3 - 8 Operation (continued) 2-Speed Switch Mechanism 2-Speed Switch Mechanism Assembly The swash plate has three surfaces, A, B and C as illustrated in Fig. 7, being assembled in a slantable state in the motor case with two steel balls.
Page 451 Transmission Section F Section F 3 - 9 Motor/Gearbox 3 - 9 Operation (continued) Automatic 2-speed Refer to Fig. 8-1 With pilot pressure Ps = 0, the 2-speed valve is maintained in the position as illustrated and the motor speed is first, or low. Refer to Fig.
Page 452 Transmission Section F Section F 3 - 10 Motor/Gearbox 3 - 10 9803/6400 Issue 1...
Page 453 Transmission Section F Section F 3 - 11 Motor/Gearbox 3 - 11 9803/6400 Issue 1...
Page 454 Transmission Section F Section F 3 - 12 Motor/Gearbox 3 - 12 9803/6400 Issue 1...
Page 455 Transmission Section F Section F 4 - 1 Motor/Gearbox 4 - 1 Precautions during Installation Before installation, check the overall condition of the axial piston motor, are any parts loose, are P1, P2 drain ports and pilot ports completely sealed so that contaminants cannot enter the axial piston. Rotation Direction The relationship between the flow direction of the hydraulic oil and the rotation direction is as shown below.
Page 456 Transmission Section F Section F 4 - 2 Motor/Gearbox 4 - 2 Precautions during Installation (continued) Install the new or repaired and inspected traction motor on the machine and perform the inspection and starting preparations described below. a. Fully fill the piston motor case with clean hydraulic oil. Also bleed air from each part of the piping. Fill gearbox casing to level A.
Page 457 Transmission Section F Section F 5 - 1 Motor/Gearbox 5 - 1 Fault Finding Piston Motor Fault Possible cause Countermeasure or remedy 1. Motor does not 1. Device other than the piston motor or Check whether or not the specified reduction gear may have malfunctioned.
Page 458 Transmission Section F Section F 5 - 2 Motor/Gearbox 5 - 2 Fault Finding (continued) Fault Possible cause Countermeasure or remedy 4. Oil Leaks (continued) 2. Motor case excessively pressurised Repair the motor and resulting in oil leakage. replace oil seal. When inserting new Oil seal pressure resistance oil seal, be careful not to damage the lip.
Page 459 Transmission Section F Section F 5 - 3 Motor/Gearbox 5 - 3 Fault Finding (continued) Relief Valve Fault Possible cause Countermeasure or remedy 1. Motor does not 1. Relief valve closing incorrectly. Completely remove foreign matter, repair run or rotation 1) Foreign matter is clogging damaged part and reassemble after speed is slow.
Page 460 Transmission Section F Section F 5 - 4 Motor/Gearbox 5 - 4 Fault Finding (continued) Double Counterbalance Valve Fault Possible cause Countermeasure or remedy 1. Motor does not 1. Plunger is not switched Inspect the piping for damage. run or rotation 1) Pressurised oil from the pilot speed is slow.
Page 461 Transmission Sectyion F Section F 5 - 5 Motor/Gearbox 5 - 5 Fault Finding (continued) 2-Speed Control Function Fault Possible cause Countermeasure or remedy 1. Travel is not linear 1. Plunger is not switched 1) Foreign matter is caught between Completely remove foreign matter, repair plunger and body.
Page 462 Transmission Section F Section F 6 - 1 Motor/Gearbox 6 - 1 Removal Move the track link until the master pin is over the take-up roller in the position shown, place a wooden block under the track shoe as shown. 2.
Page 463 Transmission Section F Section F 6 - 2 Motor/Gearbox 6 - 2 Removal (continued) Operate the traction motor to remove the track. Lift the side of the undercarriage high enough to permit drive sprocket removal. Support with wooden blocks. Stop the engine and operate the control lever to relieve pressure in the hydraulic system.
Page 464 Transmission Section F Section F 6 - 3 Motor/Gearbox 6 - 3 Removal (continued) 8. Support the motor so that the cables are in tension, then remove the motor installation bolts. Replacement Before fitting, clean the gearbox and bleed air out as follows: Turn the gearbox so that the hydraulic oil ports are facing upwards.
Page 465 Transmission Section F Section F 6 - 4 Motor/Gearbox 6 - 4 Replacement (continued) a. Install the covers over the motor. b. Check the amount of oil in the gearbox. c. Bleed air from the motor (see Motor Bleeding). d. If the traction motor has been dismantled and serviced, carry out the functional tests detailed under Testing later in this section.
Page 466 Transmission Section F Section F 6 - 5 Motor/Gearbox 6 - 5 Replacement (continued) Apply grease through the check valve to adjust the track tension (see Tracks and Running Gear, Checking/Adjusting the Track Tension, Section 3). Motor Bleeding Bleeding must be done whenever a track motor is being fitted.
Page 467 Transmission Section F Section F 7 - 1 Motor 7 - 1 Dismantling Note: The numbers in the following section refer to the illustrations on pages F/7-15 and F/7-16. Before starting the dismantling, drain the oil, clean all the surfaces with a suitable solvent and dry with compressed air. Discard all 'O'-rings and seals which are disturbed during dismantling.
Page 468 Transmission Section F Section F 7 - 2 Motor 7 - 2 Dismantling (continued) 3. Counterbalance valve disassemble Loosen (2-6-5) socket head bolt and remove the (2-6) cap. Note: Since the cap is loaded by a spring, loosen the socket head bolt halfway and while pressing the cap by hand, remove the socket head bolt.
Page 469 Transmission Section F Section F 7 - 3 Motor 7 - 3 Dismantling (continued) 7. Base plate disassembly a. Loosen (20) socket head bolt. Note: Since the base plate is forced upwards by springs, loosen the bolts evenly. Remove the (20) socket head bolts and using a screwdriver, etc.
Page 470 Transmission Section F Section F 7 - 4 Motor 7 - 4 Dismantling (continued) 10. Brake piston disassembly a. Through the (1) case (35) orifice, apply compressed air to remove the (25) brake piston from the (1) case and also remove the (26) disk and (27) friction plate.
Page 471 Transmission Section F Section F 7 - 5 Motor 7 - 5 Dismantling (continued) 12. Remove the (6) piston, (7) retainer plate, (8) retainer holder and (19) pin from the (4) cylinder block. 13. Remove the (14) snap ring using a jig or press and remove the (15) spring seat, (16) spring and (17) spring seat.
Page 472 Transmission Section F Section F 7 - 6 Motor 7 - 6 Dismantling (continued) 14. Remove the (3) shaft from the (1) case and remove the (9) swash plate, (11) piston, (40) spring and (10) steel ball from the (1) case. 15.
Page 473 Transmission Section F Section F 7 - 7 Motor 7 - 7 Assembly Assembly is essentially a reverse of the dismantling procedure in the previous section. Exchange or repair any parts not in accordance with instructions laid down in the Maintenance Standards. Ensure that all parts are cleaned in the appropriate solvent and dried with compressed air.
Page 474 Transmission Section F Section F 7 - 8 Motor 7 - 8 Assembly (continued) Assemble the (6) piston into the (7) retainer plate and insert into the (4) cylinder block. Note: Assemble them so that the small diameter of the inner taper of the retainer plate comes into contact with the flange of the piston shoe.
Page 475 Transmission Section F Section F 7 - 9 Motor 7 - 9 Assembly (continued) Assemble the (21) oil seal to the (1) case. Assemble the (12) ball bearings into the (1) case. 9803/6400 Issue 1...
Page 476 Transmission Section F Section F 7 - 10 Motor 7 - 10 Assembly (continued) 7. Assemble the (10) steel balls, (40) spring and (11) piston into the (1) case. Install the (3) shaft into the (1) case. Note: Be careful not to damage the oil seal lip. 9803/6400 Issue 1...
Page 477 Transmission Section F Section F 7 - 11 Motor 7 - 11 Assembly (continued) 9. Assemble the (9) swash plate to the (1) case. 10. Place the (1) case on the work bench horizontally and insert the (4) cylinder block into the (1) case. Next, assemble the (26) disk and (27) friction plate in order.
Page 478 Transmission Section F Section F 7 - 12 Motor 7 - 12 Assembly (continued) 11. Assemble (30) (31) ‘O’-rings which have been greased into (25) brake piston. Assemble the (25) brake piston into the (1) case. Align so that the two pinholes of the (25) brake piston and the two pinholes of the (1) are aligned in a straight line.
Page 479 Transmission Section F Section F 7 - 13 Motor 7 - 13 Assembly (continued) 15. Fix the (1) case in a vice and assemble the (2-1) base plate to the (1) case and tighten with (20) socket head bolts. Note: Coat the sliding surfaces of (4) cylinder block and (5) valve plate with hydraulic oil.
Page 480 Transmission Section F Section F 7 - 14 Motor 7 - 14 Assembly (continued) 19. Assemble the (2-3) spring and (2-5) spring seat in order. 20. Assemble the (2-6-1) cap to the (2-1) base plate and fasten with (2-6-5) socket head bolts. Note: Because it is pushed upwards by the spring, press down by hand and tighten the socket head bolts to the specified tightening torque.
Page 481 Transmission Section F Section F 7 - 15 Motor 7 - 15 9803/6400 Issue 2*...
Page 482 Transmission Section F Section F 7 - 16 Motor 7 - 16 9803/6400 Issue 1...
Page 483 Transmission Section F Section F 8 - 1 Motor 8 - 1 Maintenance Specifications If the seals are disassembled, replace them even though no damage is observed. Part Name Appearance Standard Value Allowable Value Replaceable Part 1. Deeply scarred or rough Cylinder block kit Piston surface is observed on...
Page 484 Transmission Section F Section F 8 - 2 Motor 8 - 2 Maintenance Specifications (continued) Part Name Appearance Standard Value Allowable Value Replaceable Part 1. Sliding area of the (21) Cylinder block kit Shaft oil seal is deeply scarred or rough surface is observed.
Page 485 Screw Breather Plug Washer Cover O-ring Sun Gear 1st. Reduction Assembly 2nd. Reduction Assembly Circlip Planetary Set Spacer Gearbox Housing Longlife Gasket Centering Hub O-ring Coupling Circlip Hydraulic Motor Screw...
Page 486 Transmission Section F Section F 9 - 2 Gearbox 9 - 2 Dismantling Note: The numbers in the following section refer to the illustration at the start of this Section. Before starting dismantling drain the oil. (See Routine Maintenance.) Clean all surfaces with a suitable solvent and dry with compressed air.
Page 487 Transmission Section F Section F 9 - 3 Gearbox 9 - 3 Dismantling (continued) 4. Using pliers remove the (20) circlip, from the (19) coupling. 5. Turn the gearbox around, unscrew and remove the (2) two plugs, from the end of the (4) cover. 6.
Page 488 Transmission Section F Section F 9 - 4 Gearbox 9 - 4 Dismantling (continued) 8. Remove the (5) ‘O’-ring, from its groove in the (4) end cover. 9. Remove the (7) first stage sun gear. 10. Remove the (8) first reduction assembly. 11.
Page 489 Transmission Section F Section F 9 - 5 Gearbox 9 - 5 Dismantling (continued) 12. Remove the (10) circlip, from the planet assembly of the third reduction assembly. 13. Use a puller and remove the (11) five planet gears off the third reduction assembly.
Page 490 Transmission Section F Section F 9 - 6 Gearbox 9 - 6 Dismantling (continued) 16. Remove the (16) centering ring, from the (17) flanged hub. Note: This operation must be carried out only when the hub is to be replaced. 17.
Page 491 Transmission Section F Section F 9 - 7 Gearbox 9 - 7 Assembly Assembly is a reversal of the Dismantling procedure. Note: 1. Exchange or repair all parts that are found to be damaged. In the case of a damaged planet gear, do not replace the single gear but the whole reduction stage.
Page 492 Transmission Section F Section F 9 - 8 Gearbox 9 - 8 Assembly (continued) 1. Fit a (15) half seal, on the tool. 2. Fit the (15) half seal, inside the (14) gearbox housing. 3. Assemble, by using the same tool, the (15) half seal, on the (17) flanged hub.
Page 493 Transmission Section F Section F 9 - 9 Gearbox 9 - 9 Assembly (continued) 5. Fit the lower ball bearing sets in the housing, holding the inner raceway in position with the spacer tools S1 and S2. 6. Place the bearing spacer into position and drop the upper ball bearing sets into position.
Page 494 Transmission Section F Section F 9 - 10 Gearbox 9 - 10 Assembly (continued) 9. Using the special tool screw a new (13) ring nut. 10. Deform the (13) ring nut, at a position next to a space on the (17) flanged hub. 11.
Page 495 Transmission Section F Section F 9 - 11 Gearbox 9 - 11 Assembly (continued) 13. Using circlip pliers, place the (10) circlip, into its groove. 14. Insert the (9) second reduction assembly. 15. Insert the (8) first reduction assembly. 16. Position the (5) O-ring, into its groove in the (4) end cover.
Page 496 Transmission Section F Section F 9 - 12 Gearbox 9 - 12 Assembly (continued) 17. Fit the (4) end cover, on the (14) gearbox housing. 18. Fix the (4) end cover, with the (1) socket screws. 19. Tighten the two plugs, Item 2. 20.
Page 497 Transmission Section F Section F 9 - 13 Gearbox 9 - 13 Assembly (continued) 21. Insert the (19) coupling. 22. Fit the (18) O-ring into the groove on the (21) hydraulic motor. 23. After mounting the (17) hub into the (14) bearing assembly, check the axial dimension of the gearbox determined by the input side shoulder of the (17) hub, with the (20) circlip, inside the (19) coupling.
Page 498 Track and Running Gear Section J Section J Contents Page No. Torque Specifications 1 - 1 Idler Wheel and Recoil Unit Removal 2 - 1 Replacement 2 - 2 Idler Wheel Dismantling 3 - 1 Assembly 3 - 2 Wear Limits 4 - 1 Grease Cylinder Removal...
Page 499 Track and Running Gear Section J Section J 1 - 1 Torque Specifications 1 - 1 Torque Specifications JS200/JS240 Component kgfm lb/ft Remarks Drive sprocket fastening bolts 267-312 27.2-31.8 196.65-229.91 Apply 262 Idler wheel installation bolts 267-312 27.2-31.8 196.65-229.91 Apply 262...
Page 500: Removal
Track and Running Gear Section J Section J 2 - 1 Idler Wheel and Recoil Unit 2 - 1 Removal Slacken the check valve to bleed out grease. ! WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out.
Page 501: Replacement
Track and Running Gear Section J Section J 2 - 2 Idler Wheel and Recoil Unit (continued) 2 - 2 Replacement Before fitting the idler wheel, check the oil level at A. If required, top up with the specified oil (see section 3). Assemble the idler wheel to the recoil unit and fit the mounting bolts.
Page 502: Dismantling
Track and Running Gear Section J Section J 3 - 1 Idler Wheel 3 - 1 Dismantling Clean the idler wheel with a suitable solvent. Remove the plug A from hub B and drain the oil. On one side of the unit only, remove the wire clip E or roll pin F and separate the hub C from shaft D.
Page 503: Assembly
Track and Running Gear Section J Section J 3 - 2 Idler Wheel (continued) 3 - 2 Dismantling (continued) Remove floating seal J from each hub C using a pry bar. Remove floating seal J from each side of idler wheel G using a pry bar.
Page 504 Track and Running Gear Section J Section J 3 - 3 Idler Wheel (continued) 3 - 3 Assembly (continued) Apply a coating of grease and install a new floating seal J into each side of the idler wheel G. Apply a coating of grease and install a new floating seal J into hub C.
Page 505 Track and Running Gear Section J Section J 3 - 4 Idler Wheel (continued) 3 - 4 Assembly (continued) Apply grease to a new 'O'-ring I and install it on the shaft Clean the metallic face of the seal, coat the metallic face with engine oil and install the hub C onto the shaft D.
Page 506 4 - 1 Idler Wheel (continued) 4 - 1 Wear Limits Item Dimension Machine Standard Size Service Limit Action Wheel Diameter JS200 19.4 19.29 Build up or renew JS240 JS200 Build up or renew JS240 Wheel Width JS200 3.14 Build up or renew...
Page 507: Removal
Track and Running Gear Section J Section J 5 - 1 Grease Cylinder 5 - 1 Removal Slacken the check valve to bleed out grease. ! WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out.
Page 508: Replacement
Track and Running Gear Section J Section J 5 - 2 Grease Cylinder (continued) 5 - 2 Removal (continued) ! WARNING RECOIL UNITS ARE DANGEROUS. They must not be dismantled without using suitable tools to compress the spring safely. The spring pressure can cause serious injury if suddenly released.
Page 509 Track and Running Gear Section J Section J 6 - 1 Grease Cylinder (continued) 6 - 1 Dismantling Clean the grease cylinder A with an appropriate detergent. Remove bolt B and washer C, remove the bracket D. Remove the check valve E, together with the grease nipple F from the cylinder A.
Page 510 Track and Running Gear Section J Section J 6 - 2 Grease Cylinder (continued) 6 - 2 Assembly Install a new greased 'O'-ring J, to the grease cylinder A. Install a new back-up ring I. Install the dust seal H using a suitable jig and hammer to the grease cylinder A.
Page 511: Removal
Track and Running Gear Section J Section J 7 - 1 Drive Sprocket 7 - 1 Removal Slacken the check valve to bleed out grease. ! WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out.
Page 512 Support the sprocket and position it on the gearbox. Install the bolts and washers, using Loctite 262 on the bolt threads. Tighten the bolts in a diagonal sequence. Torque Settings Machine lbf ft JS200 267.312 196-230 JS240 267.312 196-230 Remove the wooden blocks. Connect the track link.
Page 513 Track and Running Gear Section J Section J 8 - 1 Drive Sprocket 8 - 1 Wear Limits Item Dimension Machine Standard Size Service Limit Action Width JS200 2.59 2.59 Renew JS240 Diameter JS200 582.5 22.93 576.5 22.69 Renew JS240 Diameter JS200 25.9...
Page 514 Track and Running Gear Section J Section J 9 - 1 Top Roller 9 - 1 Removal Note: The following procedure is applicable to all top rollers but as there are visual differences, the illustrations show only a typical unit. Slacken the check valve to bleed out grease.
Page 515 Track and Running Gear Section J Section J 9 - 2 Top Roller (continued) 9 - 2 Replacement Before fitting the roller, add the specified oil (see Section 3). Install plug using an appropriate pipe thread sealant. With the track supported as shown under Removal, install the roller.
Page 516 Track and Running Gear Section J Section J 10 - 1 Top Roller (continued) 10 - 1 Item Part Name Roller Shaft Bushing Floating seal Bracket Thrust plate Hexagonal bolt O-ring Cover Snap ring Plug Bushing 9803/6400 Issue 1...
Page 517 Track and Running Gear Section J Section J 10 - 2 Top Roller (continued) 10 - 2 Dismantling (Two and Four bolt pedestal). Clean the upper roller A with an appropriate detergent. Remove the plug B from the cover and drain the oil. Remove the retaining ring C, and remove cover D.
Page 518 Track and Running Gear Section J Section J 10 - 3 Top Roller (continued) 10 - 3 Dismantling (continued) Remove the floating seal I from the upper roller A. If badly worn or damaged, remove the bushes J and K, from the roller A.
Page 519 Track and Running Gear Section J Section J 10 - 4 Top Roller (continued) 10 - 4 Assembly (continued) Using a jig M, and hammer, insert the bushing N, and P into the roller A. Install the new floating seal I into the roller A coat oil onto the floating seal surface.
Page 520 Track and Running Gear Section J Section J 10 - 5 Top Roller (continued) 10 - 5 Assembly (continued) Apply grease to the inside face of the thrust plate Q and install it on the shaft using bolt R and washer S. Apply grease to a new 'O'-ring T and install it onto cover D.
Page 521 Section J Section J 11 - 1 Top Roller (continued) 11 - 1 Wear Limits Item Dimension Machine Standard Size Service Limit Action Carrier Roller JS200 4.72 4.40 Renew JS240 JS240 Renew JS240 JS200 3.34 3.11 Renew JS240 Inner Flange width JS200 1.81...
Page 522 Track and Running Gear Section J Section J 12 - 1 Bottom Roller 12 - 1 Removal Note: The following procedure is applicable to all bottom rollers, but as there are visual differences, the illustrations show only a typical unit. Slacken the check valve to bleed out grease.
Page 523 Track and Running Gear Section J Section J 12 - 2 Bottom Roller (continued) 12 - 2 Replacement Before fitting the roller, add the specified oil (see Section 3). Install plug A using an appropriate pipe thread sealant. With the undercarriage lifted and supported as shown under Removal, position the roller on the track link as shown.
Page 524 Track and Running Gear Section J Section J 13 - 1 Bottom Roller (continued) 13 - 1 Item Part Name Roller assembly(outer flange) Roller (outer flange) Roller assembly (inner flange) Roller (inner flange) Shaft Collar Bushing Floating seal O-ring Wire clip Plug Collar 9803/6400...
Page 525 Track and Running Gear Section J Section J 13 - 2 Bottom Roller (continued) 13 - 2 Dismantling Note: The following procedure is applicable to all bottom rollers, but as there are visual differences, the illustrations show only a typical unit. Clean the roller with a suitable solvent.
Page 526 Track and Running Gear Section J Section J 13 - 3 Bottom Roller (continued) 13 - 3 Dismantling (continued) Remove seals F from roller J or H using a pry bar. If badly worn or damaged, remove the bushes from roller J or H, using a press or puller.
Page 527 Track and Running Gear Section J Section J 13 - 4 Bottom Roller (continued) 13 - 4 Assembly (continued) Coat shaft C with grease. Insert the shaft into roller J or H. Apply grease to new 'O'-rings G and install them on shaft C.
Page 528 Track and Running Gear Section J Section J 13 - 5 Bottom Roller (continued) 13 - 5 Assembly (continued) Hammer in locking wires B. Add the specified oil (see Section 3). Install plug A using an appropriate pipe thread sealant. 9803/6400 Issue 1...
Page 529 Section J Section J 14 - 1 Bottom Roller (continued) 14 - 1 Wear Limits Item Dimension Machine Standard Size Service Limit Action Roller Diameter JS200 Renew JS240 5.98 Renew JS200 Renew JS240 Inner Flange width JS200 3.38 3.14 Renew...
Page 530 Engine Section K Section K Contents Page No. Routine Maintenance See Section 3 Technical Data 1 - 1 9803/6400 Issue 1*...
Page 531 Engine Section K Section K 1 - 1 1 - 1 Technical Data Type Isuzu A4BG1T, 6 cylinder in-line, turbocharged, direct injection diesel. Model - JS200 A-6BG1TQB-04 - JS210 A-6BG1TQB-04 - JS220 A-6BG1TQB-04 - JS240 A-6BG1TQB-05 - JS260 A-6BG1TQB-05 Bore 105mm (4.13 in)

This manual is also suitable for:

Js210 Js220 Js240 Js260

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