JCB Excavator JS200 JS210 JS220 JS235 JS240 JS260 Tier 3 Auto service manual

Description JCB Excavator JS200 JS210 JS220 JS235 JS240 JS260 Tier 3 Auto service manual

JCB Hydraulic Excavator JS200-JS260 Tier III Auto pdf service & repair manual + Isuzu engine 4HK1, 6HK1 workshop service manual

JS200/210/220 - Monoboom SC/NC/LC
JS200/210/220 - Triple Articulated Boom SC/NC/LC
JS235 - Monoboom HD
JS235 - Triple Articulated Boom HD
JS240/260 - Monoboom SC/NC/LC
JS240/260 - Triple Articulated Boom SC/NC/LC

Serial numbers:
JS200 - JS220 1459000 - 1461999, 1610000 - 1612499
JS235 1314000 - 1314099
JS240 - JS260 1504700 - 1505099
JS240 - JS260 1773500 - 1774499

Technical documentation, specifications, testing, troubleshooting, maintenance, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
General Information
Introduction
About this Manual
Identifying Your Machine
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Hydraulic Connections
Service Tools
Numerical List
Tool Detail Reference
Service Consumables
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding

Care and Safety
Safety Check List
Important Information
Safety Check List
Safety Labels

Maintenance
Routine Maintenance
Service Requirements
Health and Safety
Service Schedules
Fluids, Lubricants and Capacities
Tools
Prepare the Machine for Maintenance
Cleaning the Machine
Checking for Damage
Daily Checking
Greasing
Electrical System
Bolt and Nut Torque Specifications
Engine
Fuel System
Hydraulic System
Slew Gearbox
Tracks and Running Gear
Bucket
Windscreen Washer
Fire Extinguisher (If fitted)
Troubleshooting

Body & Framework
Technical Data
Static Dimensions
Shipping Weight
Dig Depth Chart
Air Conditioning (option)
Basic Operation
Automatic Temperature Control (ATC) System
Fault Finding
Air Conditioning
Service Procedures
HVAC/Air Conditioning Unit
Air Conditioning Compressor
Cab Structure
Cab Panels
Cab Panel Removal

Electrics
Basic System Operation
Circuit Symbols
Component Identification
Schematic Diagram
A.M.S (Advanced Management System)
Circuit Concepts
Pulse Width Modulation (PWM)
ECU1/EMS/FACIA Power Supply and Network
ECU 1 Supply to Output Drivers
Engine Throttle Control
Pump Control for Each Mode
Hardware Sensing
Auto Boost Pressure
Engine Oil Level Warning
Engine Pre Heat (Glow plugs)
Engine Automatic Warm Up
Engine Automatic Idle
Engine One Touch Idle
Engine Start/Stop
Limp Mode system
Lever Lock
Servo Isolator
Wiper
Lower Wiper (option)
Washer
Horn
Travel Alarm
Soft/Hard (Cushion)
Slew Brake
Slew lock
Slew Brake Solenoid Valve Failure
3-Speed Travel
Work Lamps
Viscous Fan
Fuel Level Sensor/Warning
Engine Temperature Sensor/Warning
Coolant Level Warning
Air Filter Blocked Warning
Hydraulic Temperature Sensor/Warning
Alternator/No Charge Warning
Quick hitch (option)
Overload Caution (option)
Beacon
Hammer Only
Scrap Magnet Option
Cab Interior Lamp
Refuelling Pump
Air Conditioning
Heated Seat
Radio and Cigar Lighter
Service Required Warning
EMS Set Menu
EMS Set + Mode Menu
EMS Set+Mode (20 sec) Menu
Fault Finding
JCB Servicemaster
Fault Finding Without Using the JCB Servicemaster Diagnostic Tool
Service Procedure
Testing of ECU Inputs + Outputs
Using a Multimeter
Battery
Wiring Harness Repair
Harness Data
Harness Interconnection
Main Harness
Fascia Link Harness
Cab Harness - Type A
Engine Harness - Type A
Cab Harness (includes Engine Harness) - Type B
Cab Harness (includes Engine Harness) - Type C

Hydraulics
Technical Data
General Data
Basic System Operation
Introduction to Hydraulic Schematic Symbols
Circuit Descriptions
Hydraulic Schematic
Servo/Pilot Line
Servo/Pilot Pressure and Return Line
Hydraulic Pump Regulation
Neutral Circuit
Straight Line Travel
Travel - Middle Speed
Boom Up
Boom Down
Dipper Out
Dipper In
Bucket Opening
Bucket Close
Priority Valves
Slew Circuit
Slew Brake Valve
Auxiliary Flow
Merged Flow
Hammer Circuit
Main Control Valve
Description
Hydraulic Pump/Regulator
Hydraulic Pump Operation
Hydraulic Pump Removal and Replacement
Hydraulic Pump Dismantling and Assembly
Regulator Dismantling and Assembly
Coupling
Remote Control Valve (Hand Control)
Operation
Removal and Replacement
Dismantling and Assembly
Travel Pedal Valve
Dismantling and Assembly
Solenoid Valve (8 Station)
Operation
Removal and Replacement
Dismantling and Assembly
Shuttle Valve
Removal and Replacement
Dismantling and Assembly
Cushion Valve
Operation
Removal and Replacement
Dismantling and Assembly
Slew Motor
Motor Operating Principles
Slew Brake Operation
Fault Finding
Removal and Replacement
Slew Motor Configuration
Dismantling and Assembly
Slew Gearbox
Removal and Replacement
Dismantling and Assembly
Rotary Coupling
Operation
Removal and Replacement
Dismantling
Assembly
Hydraulic Rams
Precautions During Use
Removal and Replacement
Dismantling and Assembly
Maintenance Specifications
Service Procedure
Make the Machine Safe
Pressure Testing - General
Pressure Relief Valve Location
Main Relief Valve (MRV) Pressure
Servo Relief Pressure
Auxiliary Relief Valves
Slew Motor Pressure Relief
Travel Motor Relief Pressure
Fault Finding
Hydraulic Contamination
Main Control Valve
Relief Valve
Hydraulic System
Slew Motor
Hydraulic Pump
Hydraulic Rams
Fault Finding Tests
Test 001: Testing Negative Control Signal
Test 002: Test Max Flow Signal
Test 003: Testing Main Pump Pressure
Test 004: Testing Horsepower Control
Test 005: Checking the Operation of the Main Hydraulic Spool
Test 006: Test the Pressure Switches
Test 007: Testing Engine Speed Settings
Test 008: Testing Machine Cycle Times
Test 011: Testing Swing Brake Pressure
Test 012: Testing Track Motor Relief Valve Settings
Test 013: Testing Track Motor Drain Line Flow Rate
Test 014: Loss of High Speed Tracking
Test 015: High Gear Selection, Monitor Displays Another Travel Gear
Test 016: Flow testing Hydraulic Pumps
Test 016 - Flow Testing Hydraulic Pumps - Record Sheet
Test 017: Testing Slew Bearing
Ram Creep Tests - All Services

Transmission
Technical Data
Travel Equipment
Basic System Operation
Description
Operation
Removal and Replacement
Start Up and Running In
Fault Finding
Transmission
Track Motor
Dismantling and Assembly
Track Gearbox
Dismantling and Assembly

Track and Running Gear
Technical Data
Torque Specifications
Idler Wheel and Recoil Unit
Removal
Replacement
Idler Wheel
Dismantling
Assembly
Recoil Unit
Dismantling
Assembly
Grease Cylinder
Removal and Replacement
Dismantling and Assembly
Drive Sprocket
Removal and Replacement
Top Roller
Removal
Replacement
Dismantling
Assembly
Wear Limits
Bottom Roller
Removal
Replacement
Dismantling
Assembly
Wear Limits

Engine
Technical Data
Engine Mounts
Engine Error Codes
Fault Finding
Engine Components