jcb JS210 Service Manual
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SERVICE MANUAL
EXCAVATOR
JS210, JS230
EN - 9813/8000 - ISSUE 1 - 10/2016
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 6-10-27 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12
-
Heating,
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
Ventilating
and
Air-

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Summary of Contents for jcb JS210

  • Page 1 Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
  • Page 2 Notes: 9813/8000-1 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 JS210, JS230 JS210, JS230 EN 9813/8000 EN 9813/8000 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4 JS210, JS230 JS210, JS230 EN 9813/8000 EN 9813/8000 9813/8000-1 Find manuals at https://best-manuals.com...
  • Page 4 Notes: 9813/8000-1 Find manuals at https://best-manuals.com...
  • Page 5: Table Of Contents

    01 - Machine Contents Page No. Acronyms Glossary ............................ 01-2 01-03 Safety 01-03-03 Safety - Yours and Others ....................01-3 01-03-06 Safety Warnings ....................... 01-4 01-03-09 General Safety ......................... 01-5 01-03-12 Maintenance Safety ......................01-6 01-03-18 Operating Safety ......................01-8 01-03-21 Worksite Safety ......................
  • Page 6: Acronyms Glossary

    Acronyms Glossary Auxiliary Relief Valve FEAD Front End Accessory Drive Main Relief Valve Parts Identification List Personal Protective Equipment 9813/8000-1 2016-10-18 Find manuals at https://best-manuals.com...
  • Page 7: Safety

    01 - Machine 03 - Safety 03 - Safety Contents Page No. 01-03-03 Safety - Yours and Others ....................01-3 01-03-06 Safety Warnings ....................... 01-4 01-03-09 General Safety ......................... 01-5 01-03-12 Maintenance Safety ......................01-6 01-03-18 Operating Safety ......................01-8 01-03-21 Worksite Safety ......................
  • Page 8 Notes: 01 - 2 9813/8000-1 01 - 2 Find manuals at https://best-manuals.com...
  • Page 9: Safety - Yours And Others

    They inform you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them. Safety is not just a matter of responding to the warnings.
  • Page 10: Safety Warnings

    01 - Machine 03 - Safety 06 - Safety Warnings 06 - Safety Warnings Introduction In this manual and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 11: General Safety

    Keep long hair restrained. Remove altered in any way which could affect or invalidate its rings, watches and personal jewellery. compliance. For advice consult your JCB dealer. Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs.
  • Page 12: Maintenance Safety

    Repairs pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may If your machine does not function correctly in cause injury.
  • Page 13 Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton®, FluorelTM Technoflon®.
  • Page 14: Operating Safety

    Before doing any job not covered in this manual, find Parking out the correct procedure. Your local JCB distributor will be glad to advise you. An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Fuel Manual to park the machine correctly.
  • Page 15 01 - Machine 03 - Safety 18 - Operating Safety Electrical Power Cables Hands and Feet You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine. the machine or its attachments too close to electrical When using the machine, keep your hands and feet power cables.
  • Page 16: Worksite Safety

    01 - Machine 03 - Safety 21 - Worksite Safety 21 - Worksite Safety An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a Introduction collection of rules and procedures that coordinates the machines and people that work together in WARNING You or others can be killed or seriously the same area.
  • Page 17: Risk Assessment

    If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be a specific task, contact your JCB dealer who will be in or to enter the area while operations are in pleased to advise you.
  • Page 18: Maintenance Positions

    01 - Machine 03 - Safety 27 - Maintenance Positions 27 - Maintenance Positions Introduction Maintenance Position (Excavator Arm Lowered) 1. Park the machine on solid, level ground, with the upper structure parallel to the undercarriage. 2. If applicable, lower the dozer blade. 3.
  • Page 19: About This Manual

    01 - Machine 06 - About this Manual 06 - About this Manual Contents Page No. 01-06-06 Using the Manual ......................01-15 01 - 13 9813/8000-1 01 - 13...
  • Page 20 Notes: 01 - 14 9813/8000-1 01 - 14...
  • Page 21: Using The Manual

    06 - Using the Manual Introduction Information in this manual conforms to a standard List). These headings are assigned numerical JCB service manual format. The format uses section identification references. headings taken from a PIL (Parts Identification Table 1. Example...
  • Page 22 Torque Tightening such as special tools and PPE (Personal Protective Equipment). Where special tools are available from JCB the applicable part numbers are given in the Use the torque tightening values contained in procedures. For data on all available special tools...
  • Page 23 01 - Machine 06 - About this Manual 06 - Using the Manual refer to (PIL 78-00). Use the correct PPE to comply with local and employer regulations. 01 - 17 9813/8000-1 01 - 17...
  • Page 24: Description

    01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-12 Main Component Locations ................... 01-19 01-09-15 Service Point Locations ....................01-20 01 - 18 9813/8000-1 01 - 18...
  • Page 25: Main Component Locations

    01 - Machine 09 - Description 12 - Main Component Locations 12 - Main Component Locations Introduction Main Assemblies Figure 3. A Bucket (attachment) B Tipping link C Bucket ram D Dipper E Tipping lever F Dipper ram G Boom H Boom ram J Operator station K Counterweight...
  • Page 26: Service Point Locations

    01 - Machine 09 - Description 15 - Service Point Locations 15 - Service Point Locations Introduction Service Points - Hydraulics Figure 4. Upper structure A Cover - suction strainer B Breather - hydraulic tank C Cover - main filter D In-line filter - cushion valve E Oil filler port - slew motor gearbox (if applicable) F Oil drain plug - slew motor gearbox (access...
  • Page 27 01 - Machine 09 - Description 15 - Service Point Locations Figure 5. Hydraulic compartment A Servo filter element B In line drain filter element 01 - 21 9813/8000-1 01 - 21...
  • Page 28 01 - Machine 09 - Description 15 - Service Point Locations Service Points - Engine Figure 6. Upper structure A Exhaust system B Engine oil level dip stick C Crankcase ventilation filter D Fan belt and FEAD (Front End Accessory Drive) belt E Engine oil filler port F Coolant expansion bottle...
  • Page 29 01 - Machine 09 - Description 15 - Service Point Locations Figure 7. Battery / cooling compartment A Induction air filter (outer) B Induction air filter (inner) C Air filter dust valve D Cooling pack E Engine coolant drain plug (access from below the machine) 01 - 23 9813/8000-1...
  • Page 30 01 - Machine 09 - Description 15 - Service Point Locations Figure 8. Hydraulic compartment A Main fuel filter B Engine fuel filter C Primary fuel filters (two filters) D Engine oil filter E Fuel lubricity filter 01 - 24 9813/8000-1 01 - 24...
  • Page 31 03 - Attachments, Couplings and Load Handling Contents Page No. Acronyms Glossary ............................ 03-2 03-00 Attachments 03-00-00 General ..........................03-3 03-10 Excavator Arm Quickhitch 03-10-06 Hydraulic Quickhitch ......................03-7 9813/8000-1 2016-10-06...
  • Page 32: Acronyms Glossary

    Acronyms Glossary Controller Area Network DECU Display Electronic Control Unit HECU Hydraulics Electronic Control Unit Light Emitting Diode 9813/8000-1 2016-10-06...
  • Page 33 03 - Attachments, Couplings and Load Handling 00 - Attachments 00 - Attachments Contents Page No. 03-00-00 General ..........................03-3 03 - 1 9813/8000-1 03 - 1...
  • Page 34 Notes: 03 - 2 9813/8000-1 03 - 2...
  • Page 35: Attachments

    03-3 A wide range of optional attachments are available Health and Safety ........... 03-4 to increase the versatility of your machine. Only JCB approved attachments are recommended for use Check (Condition) ..........03-4 with your machine. Consult your JCB Distributor for the full list of approved attachments available.
  • Page 36 Check (Condition) Attachments Purpose Tests Lifting Use only the JCB approved attachments that are Equipment specified for your machine. Operating with non- specified attachments can overload the machine, All lifting equipment (for example forks, lifting hooks causing possible damage and machine instability and shackles) requires inspection and testing by a which could result in injury to yourself or others.
  • Page 37: Excavator Arm Quickhitch

    03 - Attachments, Couplings and Load Handling 10 - Excavator Arm Quickhitch 10 - Excavator Arm Quickhitch Contents Page No. 03-10-06 Hydraulic Quickhitch ......................03-7 03 - 5 9813/8000-1 03 - 5...
  • Page 38 Notes: 03 - 6 9813/8000-1 03 - 6...
  • Page 39: Hydraulic Quickhitch

    03 - Attachments, Couplings and Load Handling 10 - Excavator Arm Quickhitch 06 - Hydraulic Quickhitch 06 - Hydraulic Quickhitch Introduction Introduction ............03-7 The hydraulic quickhitch is installed in place of a Component Identification ......... 03-8 normal attachment at the dipper and tipping link. A hydraulically operated latch mechanism enables Operation ............
  • Page 40 03 - Attachments, Couplings and Load Handling 10 - Excavator Arm Quickhitch 06 - Hydraulic Quickhitch Component Identification Figure 11. Figure 10. A Solenoid valve (located in the hydraulic compartment above the hydraulic pump) Figure 12. Harness con- nectors (C158, C157, C156) Figure 13.
  • Page 41 03 - Attachments, Couplings and Load Handling 10 - Excavator Arm Quickhitch 06 - Hydraulic Quickhitch Operation released before the procedure is complete the unlock procedure must be repeated from the start. The quickhitch latch electrical control system allows operation of the quickhitch hydraulic latch when the boom and dipper are in the correct position.
  • Page 42 03 - Attachments, Couplings and Load Handling 10 - Excavator Arm Quickhitch 06 - Hydraulic Quickhitch Diagram Figure 15. Electrical Schematic- Quickhitch Locked - Unlock Initiate Q/H SWITCH PRESSED C121 SWITCH: QUICK HITCH CAB BASE EARTH POINT (INT) (EP07) ECU: HYDRAULIC CONTROL ECU (J2) C154 BUCKET CROWD SELECTED...
  • Page 43 03 - Attachments, Couplings and Load Handling 10 - Excavator Arm Quickhitch 06 - Hydraulic Quickhitch Figure 16. Electrical Schematic- Quickhitch Unlocked Q/H BUTTON PRESSED ECU: HYDRAULIC CONTROL ECU (J2) C154 C095 JOYSTICK RH HANDLE CAB BASE EARTH POINT (INT) (EP07) REVOLVER EARTH STUD (EP03) C155...
  • Page 44 Notes: 03 - 12 9813/8000-1 03 - 12...
  • Page 45 06 - Body and Framework Contents Page No. Acronyms Glossary ............................ 06-2 06-06 Moveable Panel and Cover 06-06-00 General ..........................06-3 06-06-03 Battery ..........................06-4 06-06-06 Engine Compartment ....................... 06-6 06-06-07 Cooling Compartment ...................... 06-7 06-06-09 Hydraulic Compartment ....................06-9 06-15 Excavator Arm 06-15-00 General ...........................
  • Page 46 Acronyms Glossary DECU Display Electronic Control Unit Dial Test Indicator FOGS Falling Object Guard System HECU Hydraulics Electronic Control Unit Light Emitting Diode Printed Circuit Board Product Identification Number ROPS Roll-Over Protective Structure TOPS Tip-Over Protective Structure 9813/8000-1 2016-10-20...
  • Page 47 06 - Body and Framework 06 - Moveable Panel and Cover 06 - Moveable Panel and Cover Contents Page No. 06-06-00 General ..........................06-3 06-06-03 Battery ..........................06-4 06-06-06 Engine Compartment ....................... 06-6 06-06-07 Cooling Compartment ...................... 06-7 06-06-09 Hydraulic Compartment ....................
  • Page 48 Notes: 06 - 2 9813/8000-1 06 - 2...
  • Page 49 06 - Body and Framework 06 - Moveable Panel and Cover 00 - General 00 - General Introduction When moved to their maintenance position, the access panels give you access to parts or areas of the machine that are not required during machine operation.
  • Page 50 06 - Body and Framework 06 - Moveable Panel and Cover 03 - Battery 03 - Battery Open and Close Open 3. Pull the handle to release the latch. 4. Open the cover until it latches in position. 1. Make the machine safe. 2.
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