JCB JS200W Wheeled Excavator Service Manual – 9803/9540-5

This workshop repair service manual PDF download for the JS200W Auto Tier III JCB Wheeled Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JCB Wheeled Excavator JS200W Tier III Auto – from S/N: 1314600 Onwards

This manual provides information for the following model(s) in the JCB machine range:
JCB JS200W Tier III – from S/N: 1314600 to 1314699
JCB JS200W Tier III – from S/N: 1542000 to 1542499

TABLE OF CONTENTS :

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 K – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/9540-5
Total Pages : 886

This JCB Hydraulic Excavator service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-9540-5

Section 1 – General Information
Introduction
About this Manual
Machine Model and Serial Number
Using the Service Manual
Section Numbering
Left Side, Right Side
Cross References
Identifying Your Machine
Machine Identification Plate
FOPS Data Plate
Component Identification Plates
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
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

Section 2 – Care and Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Labels
Introduction
Safety Label Identification
Part Numbers and Description

Section 3 – Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Obtaining Replacement Parts
Fit for Purpose Tests for Lifting Equipment
Health and Safety
Lubricants
Battery
Service Schedules
Introduction
How to Use the Service Schedules
Calender 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
JS130W-160W and Variants
JS175W and Variants
JS200W and Variants
Engine Lubrication Chart
Hydraulic Oil Chart
Typical Lubrication Chart
Coolant Mixtures
Fuel
Tools
Carrying Tools onto the Machine
Locations
Cleaning the Machine
Introduction
Exterior
Interior
Cleaning the Radiator and Oil Cooler
Check the Machine for Damage
Check the Machine Body and Structure
Check the Seat and Seat Belt
Checking the FOPS Structure
Check the Tyres
Daily Checking
Greasing
Introduction
Single Point Greasing
Multi Point Greasing
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Tightness
Electrical System
Battery
Jump-Starting the Engine
Fuses
Bolt and Nut Torque Specifications
JS130W – 200W and Variants
Engine
Oil and Filter
Engine Air Filter
Fan Belt
Cooling System
Fuel System
Introduction
Draining Fuel Tank Impurities
Draining the Primary Filter/Sedimenter
Changing the Primary Filter/Sedimenter Element
Changing the Fuel Feed Pump Filter
Draining the Main Filter/Sedimenter
Changing the Main Filter/Sedimenter Element
Bleeding the System
Hydraulic System
Introduction
Releasing Tank Pressure
Oil and Filters
Draining Water and Sediment from the Hydraulic Tank
Air Bleeding Procedures
Slew Gearbox
Checking the Slew Gearbox Oil Level
Changing the Slew Gearbox Oil Level
Drive Gearbox
Checking the Drive Gearbox Oil Level
Changing the Drive Gearbox Oil
Axles
Front Axle
Rear Axle
Windscreen Washer
Checking the Level
Fire Extinguisher (If fitted)
Troubleshooting
Engine and Related Area
Monitor Display – Fault Messages
Operations
Hydraulic pump
Working Attachments
Slew
Hydraulic ram

Section B – Body & Framework
Technical Data
Static Dimensions
JS200W – Monoboom
JS200W – Triple Articulated Boom
JS200W – Wide Axle
Operating Weight
Tyre Pressures
Turning Radius
Dig Depth Chart
JS200W
Air Conditioning (option)
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
Fault Finding
Air Conditioning
Preliminary Checks
Error Codes / Error Diagnosis (Automatic Temperature Control (ATC) System)
Service Procedures
HVAC/Air Conditioning Unit
Removal
Replacement
Air Conditioning Compressor
Removal and Replacement
Cab Structure
Direct Glazing
Checks
Cab Panels
Cab Panel Removal
Right Hand Cab Panels
Left Hand Cab Panels

Section C – Electrics
Basic System Operations
Circuit Symbols
Inputs and Outputs
Schematic Diagram
JS200W
A.M.S (Advanced Management System)
Operation
The AMS System
Circuit Concepts
Inputs
Outputs
Pulse Width Modulation (PWM)
ECU1/EMS/FACIA Power Supply and Network
ECU 1 Supply to Output Drivers
ECU W Supply to Output Drivers
ECU W / LH Switch Panel Supply and Network
Hardware Sensing
Engine Throttle Control
Operation
Engine Throttle Control for each mode
Pressure Switches vs Engine Speed
Auto Boost Pressure
Operation
Engine Oil Level Warning
Engine Pre Heat (Glow plugs)
Operation
Engine Automatic Warm Up
Operation
Engine Automatic Idle
Operation
Engine One Touch Idle
Operation
Engine Auto Idle and One Touch Idle
Engine Start/Stop
Operation
Limp Mode system
Operation
Pump Control for Each Mode
Operation
Lever Lock
Operation
Wiper
Lower Wiper (option)
Operation
Washer
Horn
Operation
Travel Alarm – Optional
Operation
Slew Brake (100%)
Operation
Slew lock (100% Slew Brake)
Operation
Travel Mode
Operation
Cruise Control – Optional
Park Brake
Operation
3 Speed Travel
Operation
Work Lights (Boom and Cab)
Operation
Head Lights
Operation
Side Lights
Operation
Brake Lights
Operation
Indicators
Operation
Fog/Reversing Lights
Fog Lights
Reversing Lights
Fog/Reversing Light Schematic
Hazard Warning
Operation
Axle Lock
Manual
Automatic
Stabilisers
Operation
Dozer
Operation
Viscous Fan
Operation
Fuel Level Sensor/Warning
Operation
Engine Temperature Sensor/Warning
Operation
Coolant Level Warning
Operation
Air Filter Blocked Warning
Operation
Warning Indicator Lamps
Hydraulic Temperature Sensor/Warning
Operation
Brake Pressure Warning
Operation
Engine Oil Pressure/Emergency Steering Warning
Operation
Alternator/ No Charge Warning
Operation
Alternator Charging and Battery Relay
Quick Hitch (option)
Operation
Overload Caution (option)
Operation
Beacon
Operation
Grab/rotate
Operation
Hammer
Operation
Scrap Magnet Option
Operation
Cab Interior Lamp
Operation
Refuelling Pump
Automatic Mode
Manual Mode
Heated Seat (Option)
Operation
Tolerance
24 to 12 Volt Converter, Radio and Cigar Lighter
24 to 12 Volt Converter.
Radio
Cigar lighter
Service Required Warning
Operation
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
Introduction
Using Servicemaster
Selecting Service Tool Applications
JS Machine Pages
System Menus
Using ECM Setup
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 Service Master Diagnostic Tool
Introduction
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 ECU1
Fault Diagnosis ECUW
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
Introduction
Repair Procedure
Harness Data
Main Harness
Connector Location
Connector Identification
Wheeled Harness
Fascia Link Harness – Type 1
Connector Location
Connector Identification
Fascia Link Harness – Type 2
Connector Location
Connector Identification
Cab Harness – Type A
Connector Location
Connector Identification
Engine Harness – Type A
Connector Identification
Cab Harness (includes Engine Harness) – Type B
Connector Identification
Cab Harness (includes Engine Harness) – Type C
Connector Identification

Section E – Hydraulics
Technical Data
JS200W
Basic System Operation
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Hydraulic Component Location
Hydraulic Schematics
Main Hydraulic Schematic
JS200W
Pilot Line
Components
Pilot Pressure and Return Line
Components
Chassis Hydraulics
Components
Monoboom Hammer/Aux Hydraulics
Components
TAB Hammer/Aux Hydraulics
Components
Circuit Descriptions
Dipper-in
Dipper-out
Boom-up
Boom-down
Boom Speed Regulation – “P” Mode
Swing Circuit
Auxiliary Mode
Hammer Mode
ISO-SAE Pattern
Drive Circuit
Main Control Valve
Main Control Valve
Hydraulic Pump
Hydraulic Pump Operation
Introduction
Hydraulic Pump Regulation
Dismantling and Assembly
Driveshaft Seal
Dismantling
Assembly
Regulator Housing Seals
Dismantling
Assembly
Regulator Port Plate
Dismantling
Assembly
Swivel Cradle and Bearings
Dismantling
Assembly
Pump Assembly
Dismantling
Assembly
Inspection
Coupling
Assembly
Remote Control Valve (Hand Control)
Operation
Function
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Fault Finding
Travel Pedal Valve
Dismantling and Assembly
Dismantling
Inspection
Assembly
Solenoid Valve (11 Spool)
Description
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Shuttle Valve
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Pilot Valve – Transmission Control
Operation
Removal and Replacement
Removal
Replacement
Slew Motor
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Relief Valves
Dismantling
Assembly
Slew Gearbox
Removal and Replacement
Removal
Replacement
Gearbox Disassembly
Dismantling
Gearbox Inspection
Gearbox Reassembly
Reassembly
Rotary Coupling
Operation
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Hydraulic Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Typical Bucket Ram
Typical Boom Ram
Typical Dipper Ram
Typical Triple Articulated Boom (TAB) Ram
Dismantling and Assembly
Dismantling the Piston Rod from the Cylinder Tube
Dismantling the Piston Rod
Removing the Piston Seals
Removing the Cylinder Head Seals
Assembly of Piston Seals
Assembling the Cylinder Head Seals
Assembly of the Piston Rod
Assembly of Piston Rod in Cylinder Tube
Maintenance Specifications
Use Limit
Drive Motor
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Steering
Steering Column
Dismantling and Assembly
Control Unit
General
Dismantling
Assembly
Priority Valve
Removal and Replacement
Dismantling and Assembly
Service Procedure
Make the Machine Safe
Pressure Testing – General
Confirmation of the Oil Temperature
Warming-up Procedure
Pressure Testing Points
MRV Pressure
2 Stage Relief Valve Pressure
Servo Relief Pressure
Slew Motor Pressure Relief
Auxiliary Relief Valves
General
Valve Section Identification
Boom Ram
Dipper Ram
Bucket Ram
Option ARV (Monoboom)
Dozer/Stabilisers
Brake Service Pressure
Steer Stall System Pressure
Steer Unit MRV Adjustment
Fault Finding
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Main Control Valve
Relief Valve
Hydraulic System
Slew Motor
Hydraulic Pump
Hydraulic Rams
Hydraulic Ram Faults and Remedies
Checking the Operation of the Main Hydraulic Spool
Test the Pressure Switches
Symptoms of Pressure Switch Failures
Testing Engine Speed Settings
Pressure Switches vs Engine Speed
Testing Machine Cycle Times
Bucket Ram Speed
Dipper Ram Speed
Boom Ram Speed
Slew Speed
Testing Slew Brake Pressure
Testing Slew Bearing
Checking Slew Bearing Backlash
Checking Slew Bearing Vertical Lift
Testing for Trapped Air in HBCV Pilot Line
Boom HBCV Installation
Arm HBCV Installation
Ram Creep Tests – All Services
Test for Ram Creep

Section F – Transmission
Front Axle
Unit Identification
Identification
Removal and Replacement
Removal
Replacement
Dismantling
Steering
Output
Planetary Carrier
Brake Hub
Knuckle Housing
Differential Input
Differential
Input
Pivot Bearing
Assembly
Input
Differential
Input Flange
Output
Knuckle housing
Hub
Planetary carrier
Pivot Bearing
Steering
Rear Axle
Unit Identification
Identification
Removal and Replacement
Removal
Replacement
Dismantling
Output
Planetary Carrier
Brake Hub
Differential Input
Differential
Assembly
Hub
Planetary carrier
Input
Differential
Input Flange
Output
Oil Drain, Oil Filler and Oil Control Plugs
Drive Gearbox
Description
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling of the Brake Clutch and Planet Carrier
Assembly of the Brake Clutch and Planet Carrier
Dismantling of the Output
Assembly of the Output
Dismantling of the Downshift Interlock
Assembly of the Downshift Interlock
Propshafts
Removal and Replacement
Removal
Replacement

Section K – Engine
Technical Data
JS200W
Engine Mounts
Engine Error Codes
Fault Finding
Engine Components
4HK/6HK
4JJ
Engine Coolant Temp Sensor
Overheat Switch
Common Rail Pressure Sensor
Engine Oil Pressure Sensor
Crankshaft Position (CKP) Sensor – 4HK/ 6HK
Crankshaft Position Sensor – 4JJ
Camshaft Position (CMP) Sensor – 4HK/ 6HK
Camshaft Position (CMP) Sensor – 4JJ
Exhaust Gas Re-circulation (EGR) Valve
Suction Control Valve
Fuel Temperature (FT) Sensor
Boost Temperature Sensor
Boost Pressure Sensor
Injector
Glow Plug
Engine Oil Level Sensor
Air Intake Temperature Sensor
Barometric Pressure Switch
Schematics

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