JCB JS200 AUTO TIER3 TRACKED EXCAVATOR Service Repair Manual

14 pages
0 views
of 14

Please download to get full document.

View again

All materials on our website are shared by users. If you have any questions about copyright issues, please report us to resolve them. We are always happy to assist you.
Share
Description
Service Manual JS200-JS260 - Tier III Auto Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section B - Body & Framework…
Transcript
Service Manual JS200-JS260 - Tier III Auto Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track and Running Gear Section K - EnginePublication No.9803/6580-7World Class Customer Support 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400Section 1 - General Information Contents Page No. Introduction About this Manual ...................................................................................... 1-1 Identifying Your Machine ........................................................................... 1-3 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-5 Hydraulic Connections ............................................................................... 1-9 Service Tools Numerical List .......................................................................................... 1-13 Tool Detail Reference .............................................................................. 1-16 Service Consumables Sealing and Retaining Compounds ......................................................... 1-37 Terms and Definitions Colour Coding .......................................................................................... 1-391-i1-iSection 1 - General InformationIntroduction About this Manual Machine Model and Serial Number This manual provides information for the following model(s) in the JCB machine range: JCB JS200-220 from serial number 1610000 to 1612499 and 1459000 to 1461999. JCB JS235 from serial number 1314000 to 1314099The 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!JCB JS240-260 from serial number 1504700 to 1505099.Section NumberingJCB JS240 - JS260 from serial number 1773500 to 1774499The manual is compiled in sections, the first three are numbered and contain information as follows:T11-005Using the Service Manual1General Information - includes torque settings and service tools.2Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.3Maintenance - includes service schedules and recommended lubricants for all the machine.T11-004This 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.The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: AAttachmentsBBody and Framework, etc.Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.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.1-19803/6580-61-1Section 1 - General Information Introduction About this ManualLeft Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine.BA Cross References T1-004 2In 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).1-29803/6580-61-2Section 1 - General Information Introduction Identifying Your MachineIdentifying Your Machine Machine Identification PlateTypical Product Identification Number (PIN)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 base plate of the rear frame.1234JCBJS20CC014212001World Manufacturer Identification (JCB)2Machine Type and Model (J20C= JS200)3Randomly Generated Check Letter.4Machine Serial Number (01421200)T103401Fig 1.732821Fig 2.1-39803/6580-61-3Section 1 - General Information Introduction Identifying Your Machine Typical Engine Identification Number If the engine is replaced by a new one, the data plate serial number will be wrong. Either stamp the new number on the plate or stamp out the old one. This will prevent the wrong number being quoted when you order replacement parts. The engine number is at A.A T016910-1Fig 3. 4HK ab4HK1578550aEngine Typeb Engine Serial Number1-49803/6580-61-4Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet FastenersTorque Settings Zinc Plated Fasteners and Dacromet Fasteners T11-002IntroductionBolts and ScrewsSome external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.Use the following torque setting tables only where no torque setting is specified in the text.The two types of fasteners can be readily identified by colour and part number suffix. K Table 1. Fastener Types ( T 1-5).Torque settings are given for the following conditions:Fastener TypeTable 1. Fastener Types Colour Part No. SuffixNote: Dacromet fasteners are lubricated as part of the plating process, do not lubricate.Condition 1 – Un-lubricated fasteners – Zinc fasteners – Yellow plated fastenersZinc and YellowGolden finish'Z' (e.g. 1315/3712Z)DacrometMottled silver finish 'D' (e.g. 1315/3712D)Condition 2 – Zinc flake (Dacromet) fastenersNote: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener. Note: A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt.– Lubricated zinc and yellow plated fasteners – Where there is a natural lubrication. For example, cast iron componentsVerbus Ripp BoltsNote: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. Note: Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.1-5Fig 1. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.9803/6580-61-5Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Hexagon (A/F) Condition 1Bolt Size in.mmin.Nmkgf mlbf ftNmkgf mlbf ft1/46.37/1611.21.18.310.01.07.45/167.91/222.32.316.420.02.014.73/89.59/1640.04.129.536.03.726.57/1611.15/864.06.547.257.05.842.01/212.73/498.0010.072.388.09.064.99/1614.313/16140.014.3103.2126.012.892.95/815.915/16196.020.0144.6177.018.0130.53/419.01 1/8343.035.0253.0309.031.5227.97/822.21 15/16547.055.8403.4492.050.2362.9125.41 1/2814.083.0600.4732.074.6539.91 1/831.71 7/81181.0120.4871.11063.0108.4784.01 1/438.12 1/41646.0167.81214.01481.0151.01092.3Table 3. Torque Settings - Metric Grade 8.8 Fasteners Hexagon (A/F) Condition 1Bolt Size ISO Metric Thread1-6Condition 2mmmmNmkgf mCondition 2lbf ftNmkgf mlbf ftM5585.80.64.35.20.53.8M66109.91.07.39.00.96.6M881324.02.417.722.02.216.2M10101747.04.834.743.04.431.7M12121983.08.561.274.07.554.6M161624205.020.9151.2184.018.8135.7M202030400.040.8295.0360.036.7265.5M242436690.070.4508.9621.063.3458.0M3030461372.0139.91011.91235.0125.9910.9M3636552399.0244.61769.42159.0220.01592.49803/6580-61-6Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Hexagon (A/F) Condition 1Bolt Size ISO Metric ThreadmmmmNmkgf mCondition 2 lbf ftNmkgf mlbf ftM5588.10.86.07.30.75.4M661013.91.410.212.51.39.2M881334.03.525.030.03.022.1M10101767.06.849.460.06.144.2M121219116.011.885.5104.010.676.7M161624288.029.4212.4259.026.4191.0M202030562.057.3414.5506.051.6373.2M242436971.099.0716.9874.089.1644.6M3030461930.0196.81423.51737.0177.11281.1M3636553374.0344.02488.53036.0309.62239.2Table 5. Metric Grade 12.9 Fasteners Hexagon (A/F) Condition 1Bolt SizeCondition 2ISO Metric ThreadmmmmNmkgf mlbf ftNmkgf mlbf ftM5589.81.07.28.80.96.5M661016.61.712.215.01.511.1M881340.04.129.536.03.726.5M10101780.08.159.072.07.353.1M121219139.014.2102.5125.012.792.2M161624345.035.2254.4311.031.7229.4M202030674.068.7497.1607.061.9447.7M2424361165.0118.8859.21048.0106.9773.0M3030462316.0236.21708.22084.0212.51537.1M3636554049.0412.92986.43644.0371.62687.71-79803/6580-61-7Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric ThreadmmNmkgf mlbf ftM331.20.10.9M443.00.32.0M556.00.64.5M6610.01.07.5M8824.02.518.0M101048.04.935.5M121282.08.460.5Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size1-8ISO Metric ThreadNmkgf mlbf ftM32.00.21.5M46.00.64.5M511.01.18.0M619.01.914.0M846.04.734.0M1091.09.367.0M12159.016.2117.0M16395.040.0292.0M18550.056.0406.0M20770.079.0568.0M241332.0136.0983.09803/6580-61-8Section 1 - General Information Torque Settings Hydraulic ConnectionsHydraulic Connections T11-003'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port. Table 8. Torque Settings - BSP Adaptors BSP Adaptor Hexagon (A/F) Size1-9in.mmNmkgf mlbf ft1/419.018.01.813.03/822.031.03.223.01/227.049.05.036.05/830.060.06.144.03/432.081.08.260.0138.0129.013.195.01 1/450.0206.021.0152.0Table 9. Torque Settings - SAE Connections SAE Port Hexagon (A/F)SAE Tube SizeThread SizemmNmkgf mlbf ft47/16 - 2015.920.0 - 28.02.0 - 2.816.5 - 18.569/16 - 1819.146.0 - 54.04.7 - 5.534.0 - 40.083/4 - 1622.295.0 - 105.09.7 - 10.769.0 - 77.0107/8 - 1427.0130.0 - 140.013.2 - 14.396.0 - 104.0121 1/16 - 1231.8190.0 - 210.019.4 - 21.4141.0 - 155.0161 5/16 - 1238.1290.0 - 310.029.6 - 31.6216.0 - 230.0201 5/847.6280.0 - 380.028.5 - 38.7210.0 - 280.09803/6580-61-9Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITINGNOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.Section 1 - General Information Torque Settings Hydraulic Connections Hoses Screwed into AdaptorsFig 2. Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring 2-C which is compressed into a 45° seat machined into the face of the adaptor port.BSP Hose Size in.1-10Note: Dimension 2-D will vary depending upon the torque applied.Table 10. BSP Hose - Torque Settings Hexagon (A/F) mmNm1/814.014.0 - 16.001.4 - 1.610.3 - 11.81/419.024.0 - 27.02.4 - 2.717.7 - 19.93/822.033.0 - 40.03.4 - 4.124.3 - 29.51/227.044.0 - 50.04.5 - 5.132.4 - 36.95/830.058.0 - 65.05.9 - 6.642.8 - 47.93/432.084.0 - 92.08.6 - 9.461.9 - 67.8138.0115.0 - 126.011.7 - 12.884.8 - 92.91 1/450.0189.0 - 200.019.3 - 20.4139.4 - 147.51 1/255.0244.0 - 260.024.9 - 26.5180.0 - 191.89803/6580-6kgf mlbf ft1-10Section 1 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size1-11in.Nmkgf mlbf ft1/820.02.115.01/434.03.425.03/875.07.655.01/2102.010.375.05/8122.012.490.03/4183.018.7135.01203.020.7150.01 1/4305.031.0225.01 1/2305.031.0225.09803/6580-61-11
Related Search
We Need Your Support
Thank you for visiting our website and your interest in our free products and services. We are nonprofit website to share and download documents. To the running of this website, we need your help to support us.

Thanks to everyone for your continued support.

No, Thanks