JCB Excavator JS210 JS220 service manual

Description JCB Excavator JS210 JS220 service manual

JCB Hydraulic Excavator JS210, JS220 pdf service & repair manual + JCB Dieselmax engine service manual

Serial numbers:
JS220 from serial number 2163177 to 2168079
JS210LC from serial number 2163079 to 2163161
JS210LC from serial number 2163079 to 2168079

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
Machine Model and Serial Number
Using the Service Manual
Section Numbering
Left Side, Right Side
Cross References
Machine Description
The JCB Tracked Excavator
Intended Use
Component Location
Identifying Your Machine
Machine Identification Plate
Component Identification Plates
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Bolts and Screws
Hydraulic Connections
'O' Ring Face Seal System
'Torque Stop' Hose System
Service Tools
Numerical List
Tool Detail Reference
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section K - Engine
Service Consumables
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding
Hydraulic Schematic Colour Codes

Care and Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety - Yours and Other
General Safety
Operating Safety
Maintenance Safety

Routine Maintenance
Service Requirements
Owner/Operator Support
Service/Maintenance Agreements
Fit for Purpose Tests for Lifting Equipment
Obtaining Replacement Parts
Health and Safety
Lubricants
Battery
Service Schedules
Introduction
How to Use the Service Schedules
Calendar Equivalents
Pre Start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Service Intervals for Attachments
Periodic Replacement of Safety Related Components
Fluids, Lubricants and Capacities
Engine Lubrication Chart
Hydraulic Oil Chart
Typical Lubrication Chart
Coolant Mixtures
Fuel
Tools
Carrying Tools onto the Machine
Prepare the Machine for Maintenance
How to Make the Machine Safe (Excavator Lowered)
Cleaning the Machine
Preparing the Machine for Cleaning
Cleaning the Machine
Cleaning the Tracks
Cleaning the Radiator and Oil Cooler
Daily Checking
Greasing
Slew Ring Bearing
Slew Ring Teeth and Slew Pinion
Greasing Points
Electrical System
Battery
Checking the Battery Electrolyte Level
Battery Disconnection/Replacement
Terminal Cleaning
Jump-Starting the Engine
Fuses
Bolt and Nut Torque Specifications

Body and Framework
Specifications
Static Dimensions
Dig Depth Chart
Shipping Weight
Air Conditioning (option)
Automatic Temperature Control (ATC) System
Fault Finding
Air Conditioning
Preliminary Checks
Error Codes / Error Diagnosis (Automatic Temperature Control (ATC) System)
Basic Operation
Automatic Temperature Control (ATC) System
Heater/Air Conditioning Controls (ATC)
Air Conditioning System Operation
ATC Control Panel
Safety Procedures
Service Procedures
HVAC/Air Conditioning Unit
Removal
Replacement
Air Conditioning Compressor
Removal and Replacement
Cab Structure
Direct Glazing
Checks
Checking the FOPS Structure
Cab Panels
Cab Panel Removal
Right Hand Cab Panels
Left Hand Cab Panels

Electrics
Basic System Operation
Circuit Symbols
Inputs and Outputs
Schematic Diagram
A.M.S (Advanced Management System)
The AMS System
Circuit Concepts
Inputs
Outputs
Pulse Width Modulation (PWM)
ECU 1 Supply to Output Drivers
Engine Throttle Control
Engine Throttle Control for Each Mode
Pump Control for Each Mode
Hardware Sensing
Auto Boost Pressure
Engine Oil Level Warning
Engine Automatic Warm Up
Engine Automatic Idle
Engine One Touch Idle
Engine Auto Idle and One Touch Idle
Engine Start/Stop
Engine ECM Feed
Engine Cranking
Alternator/No Charge Warning
Limp Mode system
Lever Lock
Servo Isolator
Wiper
Lower Wiper (option)
Washer
Horn
Travel Alarm
Soft/Hard (Cushion)
Slew Brake (100%)
Slew lock (100% Slew Brake)
Slew Brake Solenoid Valve Failure
3-Speed Travel
"E" Economy, "P" Precision & "A" Auto Modes
Relationship between Travel Modes A / E + P, travel motor swash plate position and Pump "Q max cut output"
"L" Lifting Mode
Work Lamps
Viscous Fan
Fuel Level Sensor/Warning
Engine Temperature Sensor/Warning
Coolant Level Warning
Air Filter Blocked Warning
Hydraulic Temperature Sensor/Warning
Quick hitch (option)
Overload Caution (option)
Beacon (Option)
Hammer Only (Option)
Scrap Magnet (Option)
Cab Interior Lamp
Refuelling Pump
Heated Seat (Option)
24 to 12 Volt Converter, Radio and Power Socket
Service Required Warning
Cancellation of the Service indicator
EMS Set Menu
EMS Set + Mode Menu
EMS Set+Mode (20 sec) Menu
Service Off
Solenoid Override
Horse Power Control Data Logging Facility
Throttle Calibration
Fault Finding
JCB Servicemaster
Using Servicemaster
Selecting Service Tool Applications
JS Machine Pages
System Menus
HPSetup Overview
DLA Port Configuration
Data Link Adaptor
HPDataLogs
FLASH Programming Application
Introduction to the Diagnostics Tool
Connecting to the Vehicle
Starting Diagnostic Mode
Circuit Diagrams
Indicator Lights (LEDs)
Stopping Diagnostic Mode 
Language Setting
Electrical Fault Text Messages Displayed on the EMS
Fault Finding Without Using the JCB Servicemaster Diagnostic Tool
Changing Machine Components
Fault Diagnosis (General)
Permanent Battery Supply (Ignition Off)
Ignition On
Ground Tests
Can - Bus Network Tests
Harness Tests
Unit Tests
Fault Diagnosis ECU-1
EMS Failure
Fault Diagnosis - Facia Switch Panel (FSP)
Service Procedure
Testing of ECU Inputs + Outputs
Testing Low Side Input
Testing High Side Input
Testing Low Side Output
Testing High Side Output
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
Testing
Specific Gravity Testing
Wiring Harness Repair
Repair Procedure
Technical Data
Fuses
Fuse Identification
Harness Data
Harness Interconnection
Main Harness
Fascia Link Harness
Cab Harness JS210 (Includes Engine Harness)
Cab Roof Harness (JS220)

Hydraulics
Technical Data
Basic System Operation
Circuit Descriptions
Slew Motor
Shuttle Valve
Rotary Coupling
Remote Control Valve (Hand Control)
Main Control Valve
Hydraulic Rams
Cushion Valve
Hydraulic Pump/Regulator
Travel Pedal Valve
Solenoid Valve (8 Spool)
Slew Motor Reduction Gearbox Assembly
Service Procedure
Fault Finding

Transmission
Track Motor/Gearbox
Dismantling and Assembly
Dismantling
Inspection
Assembly
Track Gearbox
Dismantling and Assembly
Dismantling
Inspection
Assembly
Track Motor
Description
Operation
Middle Speed
Slow Speed Travel (Creep)
High Speed
Brake Valve
Parking Brake
Rotation Direction
Removal and Replacement
Removal
Precautions During Installation
Replacement
Start Up and Running In
Start Up
Running In
Fault Finding
Transmission
Traction Motor
Parking Brake
Relief Valve
Counterbalance Valve
Speed Range Changing

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

Engine
General Information
Care and Safety
Maintenance
Systems Description
Fault Finding
Test Procedures
Fuel System
Cooling System
Lubrication System
Electrical System
Induction and Exhaust System
Base Engine