JCB Tracked Excavator JS200 Factory Service & Work Shop Manual

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. World Class Customer Support 9813/1000-3 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual JS Auto Range - Tracked Excavators - JCB Engine Service Manual - JS Auto Range - Tracked Excavators - JCB Engine Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Section 0 - ServiceManual 0-0 0-0 9813/1000-3 Notes:

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. World Class Customer Support 9813/1000-3 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Section 1 General Information Service Manual - JS Auto Range - Tracked Excavators - JCB Engine Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Section 1 - General Information 1-0 1-0 9813/1000-3 Notes:

Page No. Contents Section 1 - General Information 1-i 1-i Introduction About this Manual ...................................................................................... 1-1 Identifying Your Machine ........................................................................... 1-3 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-7 Hydraulic Connections ............................................................................. 1-11 Service Tools Numerical List .......................................................................................... 1-15 Tool Detail Reference .............................................................................. 1-18 Service Consumables Sealing and Retaining Compounds ......................................................... 1-39 Terms and Definitions Colour Coding .......................................................................................... 1-41

Page No. Contents Section 1 - General Information 1-ii 1-ii

Section 1 - General Information 1-1 1-1 9813/1000 Introduction About this Manual Machine Model and Serial Number This manual provides information for the following model(s) in the JCB machine range: – JCB JS115 from serial no. 01786452 to 01786462. – JCB JS130 from serial no. 01786463 to 01786863. – JCB JS145 from serial no. 01786864 to 01788884. – JCB JS160/JS180 from serial no. 01776500 to 01777499. – JCB JS200/JS210/JS220 from serial no. 01782453 to 01786451. Using the Service Manual T11-004 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. The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication. Finally, please remember above all else safety must come first! Section Numbering T11-005 The manual is compiled in sections, the first three are numbered and contain information as follows: The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. 1 General Information - includes torque settings and service tools. 2 Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. 3 Maintenance - includes service schedules and recommended lubricants for all the machine. A Attachments B Body and Framework, etc.

Section 1 - General Information Introduction About this Manual 1-2 1-2 9813/1000 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. C017280 Fig 1. Cross References T1-004_2 In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The number of the page upon which the subject begins, is indicated within the brackets. For example: K Cross References ( T 1-2) . A B

Section 1 - General Information Introduction Identifying Your Machine 1-3 1-3 9813/1000 Identifying Your Machine Machine Identification Plate Your machine has a data plate, located on the outside the cab as shown at A. The machine serial number is inscribed at B which is the baseplate of the rear frame. Fig 2. Fig 3. Typical Product Identification Number (PIN) 1 World Manufacturer Code (JCB) 2 Machine Type and Model (e.g JS16D = JS160 Tracked) 3 Randomly Generated Check Letter 4 Machine Serial Number (01776500) 1 2 3 4 JCB JS16D C 01776500

Section 1 - General Information Introduction Identifying Your Machine 1-4 1-4 9813/1000 Component Identification Plates Typical Engine Identification Number Engine data labels A are located on the cylinder block at position C and rocker cover D (if fitted). K Fig 4. ( T 1-4) . The data label contains important engine information and includes the engine identification number E. A typical engine identification number is explained as follows: 1 Engine Type SF = 4.4 litre mechanical fuel injection Tier 3 SE = 4.4 litre electronic common rail fuel injection Tier 3 DE = 4.8 litre electronic common rail fuel injection Tier 2 2 Engine part number 3 Country of manufacture U = United Kingdom 4 Engine Serial Number 5 Year of Manufacture The last three parts of the engine identification number are stamped on the cylinder block at position B. C007820-C2 Fig 4. Engine SD 320/40001 U 00001 04 1 2 3 4 5 U 00001 04 B C D B E

JCB Tracked Excavator JS200 Factory Service & Work Shop Manual

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