jcb JS Series Service Manual
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jcb JS Series Service Manual

Tracked excavators
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Service Manual
JS Auto Range - Tracked Excavators
JS85
Section 1 - General Information
Section 2 - Operator’s Manual
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track & Running Gear
Section K - Engine
Publication No.
9813/3750-01
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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  • Page 1 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
  • Page 2 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
  • Page 3 Section 1 - General Information Notes: 9813/3750-01...

  • Page 4: Table Of Contents

    Section 1 - i Contents Page No. Introduction Identifying Your Machine ................1-1 Safety Introduction ....................1-3 Introduction ....................1-5 Scope ......................1-6 Personnel ....................1-6 Applications ...................1-6 Newest Data ..................1-6 Format ....................... 1-7 Left Side, Right Side .................. 1-8 Hydraulic Schematic Codes ..............1-9 Colour Codes ..................1-9 Routine Maintenance Maintenance Schedules ................
  • Page 5 Section 1 - i Contents Contents Page No. Tool Detail Reference ................1-36 Body and Framework ................1-36 Electrics ....................1-40 Hydraulics ....................1-41 Special Tool for removal of the Brake Piston ........... 1-46 Hydraulics ....................1-47 Hydraulic Rams Dismantling and Assembly ........1-47 Boom Cylinder parts break down ............1-48 Arm Cylinder parts break down ............1-50 Bucket Cylinder parts break down ............1-52...

  • Page 6: Identifying Your Machine

    Section 1 - General Information Introduction Identifying Your Machine For information about identifying your machine and its main components, refer to Section 2, About the Machine, Machine and Component Identification. 9813/3750-01...
  • Page 7 Section 1 - General Information Introduction Identifying Your Machine Page left intentionally blank 9813/3750-01...

  • Page 8: Safety Introduction

    Section 1 - General Information Safety Introduction In this manual and on the machine there are safety notices. The safety notices have different signal words as follows: – DANGER – WARNING – CAUTION – Notice For an explanation of the safety notice signal words, refer to Section 2, Introduction, Safety.
  • Page 9 Section 1 - General Information Safety Introduction Page left intentionally blank 9813/3750-01...

  • Page 10: Use Introduction

    Section 1 - General Information Introduction This topic contains information about the structure of the manual and how to use the manual. Scope ( 1-6) Personnel ( 1-6) Applications ( 1-6) Newest Data ( 1-6) Format ( 1-7) Left Side, Right Side ( 1-8) Hydraulic Schematic Codes ( 1-9)

  • Page 11: Scope

    Section 1 - General Information Scope Scope Personnel This manual is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of...

  • Page 12: Format

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

  • Page 13: Left Side, Right Side

    Section 1 - General Information Left Side, Right Side Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. T017280 Fig 1. 9813/3750-01...

  • Page 14: Hydraulic Schematic Codes

    The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. f: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure.
  • Page 15 Section 1 - General Information Hydraulic Schematic Codes Page left intentionally blank 1-10 1-10 9813/3750-01...

  • Page 16: Routine Maintenance Maintenance Schedules

    Section 1 - General Information Routine Maintenance Maintenance Schedules This publication contains procedures for carrying out the routine maintenance tasks listed on the maintenance schedules. Refer to Section 2, Maintenance Schedules. The procedures for the daily and weekly (10 and 50 hour) tasks are given in Section 2, Maintenance.
  • Page 17 Section 1 - General Information Routine Maintenance Maintenance Schedules Page left intentionally blank 1-12 1-12 9813/3750-01...

  • Page 18: General Procedures

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

  • Page 19: Parking The Machine And Making It Safe

    Section 1 - General Information General Procedures Parking the Machine and Making it Safe Parking the Machine and Making it Safe For the correct procedures to park and make the machine safe, refer to Section 2, Maintenance, Maintenance Positions. 1-14 1-14 9813/3750-01...

  • Page 20: Venting The Hydraulic Pressure

    Section 1 - General Information General Procedures Venting the Hydraulic Pressure Venting the Hydraulic Pressure WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.

  • Page 21: Connecting/Disconnecting Hydraulic Hoses

    Section 1 - General Information General Procedures Connecting/Disconnecting Hydraulic Hoses Connecting/Disconnecting Hydraulic Hoses WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.

  • Page 22: Battery Disconnection/Connection

    Section 1 - General Information General Procedures Battery Disconnection/Connection Battery Disconnection/Connection For the correct procedures to disconnect/connect the battery, refer to Section 2, Maintenance, Electrical System, Battery. 1-17 1-17 9813/3750-01...

  • Page 23: Removing And Replacing Components

    Make sure that the correct new components are installed. Do not substitute components from another machine. Components may look the same but may not be interchangeable. Refer to the JCB parts systems. Torques and Fixings When replacing components always tighten the applicable fixings to the correct torque.
  • Page 24 Section 1 - General Information General Procedures Battery Charging System Precautions Battery Charging System Precautions Obey the procedures below to prevent damage to the alternator and battery. – Ensure that the battery negative terminal is connected to the earthing cable. –...
  • Page 25 Section 1 - General Information General Procedures Gas Hydraulic Bladder Accumulators Gas Hydraulic Bladder Accumulators Some hydraulic circuits and valve blocks are fitted with gas WARNING hydraulic bladder type accumulators. Use only nitrogen gas to charge accumulators. The Before removing accumulators make sure hydraulic use of any other gas can cause the accumulators to pressure vented.

This manual is also suitable for:

Js85

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