jcb JS200 Service Manual page 293

Section E
33 - 5
Assembly, 4-spool control valve section
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1. 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).
2. Assemble the spring seat 16 and spring 17 to the spool end 3 (Hexagonal 22 A/F). Apply adhesive to the thread and screw
into the spool 4, 5, 6, to a torque of 9.8-12 Nm (7.23-8.67 lb/ft).
3. Assemble the spool assembly into the valve housing 1 at the same position and direction as before.
4. Assemble the sleeve 40 with the 'O'-ring 41 and backup ring 42 attached and assemble the poppet 39, spring 38, and
spacer assembly 55 and attach the 'O'-ring 37 and backup ring 36 to the plug 35 and assemble into the valve housing.
5. Assemble the spool 7 into the valve housing and install the spring seat 9 and spring 8.
6. Tighten the caps 2, 14 with 'O'-rings 10, 18 attached, with socket head bolts 47, 48 (Hexagonal socket 8 A/F) to the valve
housing.
7. Assemble the spring and piston 51, 56 to the cap 2 and tighten the plug 49 (Hexagonal 38 A/F), with 'O'-ring 50
attached, to a torque of 93-108 Nm (68.68-70.53 lb/ft).
8. 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).
9. Install the port relief valve 31 (Hexagonal 31.5 A/F) to the valve housing, with a torque of 78-88 Nm (57.84-65.07 lb/ft).
10. Install the negative control relief valve 24 (Hexagonal 36 A/F) to the valve housing, tightening to a torque of 88-98 Nm
(65.07-72.3 lb/ft).
11. Screw in the plug 53 (Hexagonal 36 A/F) with the 'O'-ring 54 assembled, with a torque of 83-93 Nm (61.45-68.68.lb/ft).
12. Assemble the poppet 25, spring 26 to the sleeve 3 and assemble in the valve housing.
13. Install the check valve assembly 32 (Hexagonal 36 A/F), with a torque of 265-275 Nm (195.21-202.44 lb/ft).
14. Assemble the poppet 27 and spring 22 into the valve housing and install the 'O'-ring 29 to the plug 30 (Hexagonal 27 A/F)
and fasten with torque of 83-93 Nm (61.45-68.68 lb/ft).
15. Assemble the poppet 46, spring 45 to the valve housing and install the 'O'-ring 44 to the plug 43 (Hexagonal 27 A/F) and
screw in.
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If the plug 12 (Hexagonal 22 A/F) is disassembled, install the 'O'-ring 11 and tighten, to a torque of 49-59 Nm
(36.15-43.38 lb/ft).
16. If the plug 53 (Hexagonal 36 A/F) is disassembled, install the 'O'-ring 54 and tighten, to a torque of 83-93 Nm
(61.45-68.68 lb/ft).
17. If the plug 52 (Hexagonal socket 5 A/F) is disassembled, wrap seal tape around the plug periphery (leave one thread open
from the end and wrap to the right 1.5~2 times so that the tape bites into the threads) and tighten, to a torque of 6.85-8.82
(5.06-6.5 lb/ft).
18. Check for any disassembled parts not reassembled and tightened.
The above tightening torque values are for threads lubricated with hydraulic oil).
9803/6400
Hydraulics
Control Valve JS200/JS240
Section E
33 - 5
Issue 2*