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JS220
jcb JS220 Service Manual
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Service
Manual
JS200
from machine no. 705001
JS210
from machine no. 705648
JS220
from machine no. 705001
JS240
from machine no. 708001
JS260
from machine no. 708501
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; ©
WATERLOO PARK, UTTOXETER,
STAFFORDSHIRE, ST14 5PA, ENGLAND
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9803/6400
R
General Information
Car
e & Safety
Routine Maintenance
Attachments
Body & Framework
Electrics
1
2
3
A
B
C
Hydraulics
E
F
T
ransmission
G
Brakes
J
T
rack & Running Gear
K
Engine
Issue 2
2
Table of Contents
General Information Section 1
3
Service Tools
6
Section E - Hydraulics
7
Section F - Transmission
10
Sealing and Retaining Compounds
13
Routine Maintenance Section 3
20
Table of Contents
20
Fluids and Lubricants
22
Lubricants - Health and Safety
23
Service Schedules
24
Greasing
29
Slew Ring Bearing
29
Slew Ring Teeth and Slew Pinion
29
Excavator End
30
Battery
32
Air Bleeding Procedures
33
Hydraulics
33
Releasing Tank Pressure
33
Air Bleeding from Hydraulic Pump
34
Air Bleeding from Ram
34
Air Bleeding from the Slew Motor
35
Checking the Fluid Level
36
Topping up Fluid Level
36
Changing the Hydraulic Oil
37
Changing the Return Filter Element
38
Cleaning/Changing the Suction Strainer
39
Changing the Air Breather Element
40
Changing the Pilot Oil Filter
41
Draining Tank Impurities
41
Changing the Breaker In-Line Filter
42
Changing the Drain Line Filter
42
Changing the Nephron Filter
43
Changing the Track Gearbox Oil
44
Checking Track Gearbox Oil Level
44
Transmission
44
Changing the Slew Gearbox Oil
45
Checking the Slew Gearbox Oil Level
45
Replenishing Slew Gearbox Grease
45
Cleaning the Tracks
46
Tracks and Running Gear
46
Checking/Adjusting the Track Tension
47
Checking the Rollers and Idler Wheels for Oil Leaks
48
Checking the Shoe Plate
48
Body & Framework Section B
65
Boom Ram Installation
74
Dipper Ram Installation
75
Dipper Pivot Installation
76
Bucket Ram Installation
77
Bucket Link and Bucket Ram Installation
78
Bucket and Dipper Installation
79
Shim Adjustment Table
80
Boom and Slew Frame Installation
82
Boom Ram Installation
82
Dipper Ram Installation
84
Bucket Link and Bucket Ram Installation
86
Bucket and Dipper Installation
87
Shim Adjustment Table
88
Direct Glazing
90
Air Conditioning (Optional)
96
Operation
97
Control
98
Safety Procedures
98
Fault Finding
100
Checking Refrigerant Charge Level
103
Leak Testing
103
Tightening Leaking Hoses
103
System Diagnosis
104
Electrics Section C
108
The A.M.S System
109
Technical Data
110
Battery Testing
111
Schematic Diagram
112
Operator's Cab
114
Right Console
115
Left Console
117
Monitor
118
Control, Function, Operation
119
Basic Operation
121
Engine Control
121
Stepping Motor
121
Throttle Related Function
123
Stop Motor Function
126
Redundancy (Back-Up) Throttle Control
128
Automatic Engine Adjustment
129
Idling Control
130
Revolution Control for each Mode
131
Control of Engine Speed for Breaker Operation
132
Engine Auto Warm-Up
133
Engine Reverse Rotation Prevention
134
Pump Control
135
Schematic
135
Flow Chart
137
Boom Lowering Speed Regulation
138
Cushioned Boom Starting
139
Pressure Increasing System
141
Speed Travel and Max Flow Cut
144
Soft/Hard Switch
148
Power Supply Cut Delay
149
Swing Brake/Swing Lock
151
Lever Lock
155
Travel Warning
156
Power Transistor Protection
158
Display Monitor
159
Throttle Motor
163
Throttle Motor and Throttle Link Replacement
163
Automatic Adjustment
165
Installation
167
Revolution Sensor
167
Self Test
168
Fault Diagnosis
176
Fault Finding
176
Emergency Engine Stop
179
Refuel
180
Coolant Refill
181
Low Engine Oil Pressure
183
Engine Oil Filter
184
Battery Charging
187
Electrical System, Message Fault
189
Engine Problem
193
Sensor Resistance Valve
194
Caps II Diagnostic System
196
Hydraulics Section E
205
All Variants of this Machine, Including the JS220. Similarly, Information for the JS240 Applies also to All Variants of that Machine, Including the JS260
206
Note: Except Where Indicated Otherwise, Information for the JS200 Applies to
206
Precautions During Use
206
Technical Data JS200 and Variants
207
Technical Data JS240 and Variants
209
Schematics Hydraulic Circuit JS200 and Variants
214
Shuttle Block JS200, JS240
218
Pilot Control Line Hose Connection Diagram JS200, JS240
219
Hydraulic Pump JS200, JS240
232
Schematics, Technical Data
235
Precautions During Use
236
Regulator JS200, JS240
248
Specifications
248
Operation
253
Control Valve JS200/JS240
262
Specification, Technical Data
262
Remote Control Valve JS200/JS240
298
Schematics, Technical Data
298
Operation
300
Trouble Shooting
311
Maintenance Specifications
312
Operation
329
Trouble Shooting
387
Trouble Shooting
388
Trouble Shooting
389
Torque Specifications
439
Removal
500
Replacement
501
Dismantling
502
Assembly
503
Removal
507
Assembly
508
Removal
508
Replacement
508
Removal
511
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Operator's Manual
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jcb JS220 Specifications
General
Brand
jcb
Model
JS220
Category
Excavators
Language
English
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