JCB JS200, JS210, JS220, JS240, JS260 Tracked Excavator Service Manual - 9803/6400-2
This workshop repair service manual PDF download for the JS200, JS210, JS220, JS240, JS260 JCB Tracked Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. APPLICABLE MODELS :JCB Tracked Excavator JS200 - from S/N: 705001 OnwardsJCB Tracked Excavator JS210 - from S/N: 705648 OnwardsJCB Tracked Excavator JS220 - from S/N: 705001 OnwardsJCB Tracked Excavator JS240 - from S/N: 708501 OnwardsJCB Tracked Excavator JS260 - from S/N: 708501 OnwardsTABLE OF CONTENTS :General InformationCare & SafetyRoutine MaintenanceAttachmentsBody & FrameworkElectricsHydraulicsTransmissionBrakesTrack & Running GearEngineMANUAL SPECIFICATION :File Format : PDFLanguage : EnglishPrintable : YesSearchable : YesBookmarked : YesP/N : 9803/6400 Issue 2Total Pages : 531This JCB Hydraulic Excavator service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.More Info : http://www.sitelux.com-CoverContentsIntroductionSection 1: General Information Bolt and Nut Torque Specifications Service Tools Section C - Electrics Section E - Hydraulics Section F - Transmission Sealing and Retaining Compounds Section 2: Care and Safety Safety Notices General Safety Operating Safety Maintenance Safety Section 3: Routine Maintenance Fluids and Lubricants Lubricants - Health and Safety Service Schedules Greasing Slew Ring Bearing Slew Ring Teeth and Slew Pinion Excavator End Battery Fuses Hydraulics Air Bleeding Procedures Releasing Tank Pressure Air Bleeding from Hydraulic Pump Air Bleeding from Ram Air Bleeding from the Slew Motor Checking the Fluid Level Topping up the Fluid Level Changing the Hydraulic Oil Changing the Return Filter Element Cleaning/Changing the Suction Strainer Changing the Air Breather Element Draining Tank Impurities Changing the Pilot Oil Filter Changing the Breaker In-Line Filter Changing the Drain Line Filter Changing the Nephron Filter Transmission Checking the Track Gearbox Oil Level Changing the Track Gearbox Oil Checking the Slew Gearbox Oil Level Checking the Slew Gearbox Oil Replenishing Slew Gearbox Grease Tracks and Running Gear Cleaning the Tracks Checking/Adjusting the Track Tension Checking the Shoe Plate Checking the Roller and Idler Wheels for Oil Leaks Engine Changing the Air Filter Elements Checking the Oil Level Changing the Oil and Filters Checking the Coolant Level Coolant Mixtures Changing the Coolant Adjusting the Fan Belt Fitting a New Fan Belt Cleaning the Radiator and Oil Cooler Draining Fuel Tank Impurities Draining the Water Separator Changing the Fuel Filter Element Bleeding the Fuel System Component Location Diagram Performance Evaluation JS200/JS240 Checking the FOPS Structure Section B: Body and Framework Torque Specifications Undercarriage Dimensions Main Body Weights Maintenance Specifications JS200, JS200LC Boom and Slew Frame Installation Boom Ram Installation Dipper Ram Installation Dipper Pivot Installation Dipper and Dipper Ram Installation Bucket Ram Installation Dipper and Dipper Link Installlation Bucket and Bucket Link Installation Bucket Link and Bucket Ram Installation Bucket and Dipper Installation Shim Adjustment Table Maintenance Specifications JS240, JS240LC Boom and Slew Frame Installations Boom Ram Installation Dipper Ram Installation Dipper Pivot Installation Dipper and Dipper Ram Installation Bucket Ram Installation Dipper and Dipper Link Installation Bucket and Bucket Link Installation Bucket Link and Bucket Ram Installation Bucket and Dipper Installation Shim Adjustment Table Direct Glazing Air Conditioning Operation Control Safety Procedures Fault Finding Checking Refrigerant Charge Level Leak Testing Tightening Leaking Hoses System Diagnosis Section C: Electrics AMS 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 Revolution Control for Each Mode Control of Engine Speed for Breaker Operation Engine Auto Warm-up Detection of Throttle Motor Assembly Defect (Out-of-step) Engine Reverse Rotation Prevention Pump Control Schematic Flow Chart Boom Lowering Speed Regulation Cushioned Boom Starting Pressure Increasing System 3 Speed Travel and Max. Flow (Q) Cut Soft/Hard Switch Power Supply Cut Delay Swing Brake/Swing Lock Lever Lock Travel Warning Power Transistor Protection Display Monitor Throttle Motor Thottle Motor and Throttle Link Replacement Automatic Adjustment Revolution Sensor Installation Self Test Fault Finding Fault Diagnosis Emergency Engine Stop Refuel Coolant Refill Air Cleaner Clogged Low Engine Oil Pressure Engine Oil Filter Fluid Overheating, water, oil Battery Charging Electrical System, Message Fault Engine Problem Sensor Resistance Valve CAPs II Diagnostic system Section E: Hydraulics Technical Data - JS200/220 and Variants Technical Data - JS240/260 and Variants Torque Specifications Schematics Schematic Hydraulic Circuit JS200 and Variants Schematic Hydraulic Circuit JS240 and Variants Shuttle Block JS200, JS240 Pilot Control Line Hose Connection Diagram, JS200, JS240 Pressure Testing JS200, JS240 Hydraulic Pump JS200, JS240 Schematics, Technical Data Precautions During Use Trouble Shooting Operation Dismantling and Assembly Main Body Wear Limits Regulator JS200, JS240 Specifications Operation Trouble Shooting Dismantling and Assembly Control Valve JS200, JS240 Specification, Technical Data Precautions During Use Operation Trouble Shooting Dismantling and Assembly Relief Valve JS200, JS240 Dismantling and Assembly Port Relief JS200/JS240 Dismantling and Assembly Negative Control Valve Operation Dismantling and Assembly Remote Control Valve Schematics, Technical Data Operation Dismantling and Assembly Trouble Shooting Maintenance Specifications 8-Spool Solenoid Valve JS200, JS240 Schematics, Technical Data Dismantling and Assembly Shuttle Valve Schematic Operation Cushion Valves Schematic Operation Stacked Valve Schematic Operation Hydraulic Rams Specifications Precautions During Use Bucket Ram - Removal and Installation Dipper Ram - Removal and Installation Boom Ram - Removal and Installation Dismantling and Assembly Reconditioning Trouble Shooting Maintenance Specifications Rotary Coupling Schematic, Technical Data Operation Dismantling and Assembly Slew Motor Schematic, Technical Data Operation Maintenance Specifications Motor Assembly/Cylinder Assembly Dismantling and Assembly Relief Valve Dismantling and Assembly Reduction Gear Dismantling and Assembly Fault Finding Section F: Transmission Torque Specifications Track Motor/Gearbox Schematics, Specifications Operation Precautions During Installation Fault Finding Removal and Replacement Track Motor Dismantling and Assembly Maintenance Specifications Track Gearbox Dismantling and Assembly Section J: Track and Running Gear Torque Specification Idler Wheel and Recoil Unit Removal Replacement Idler Wheel Dismantling Assembly Wear Limits Grease Cylinder Removal Replacements Dismantling Assembly Drive Sprocket Removal Replacement Wear Limits Top Roller Removal Replacement Dismantling Assembly Wear Limits Bottom Roller Removal Replacement Dismantling Assembly Wear Limits Section K: Engine Technical Data -