JCB JS210 LC Tracked Excavator Service Repair Manual – PDF Download

Service Manual

General Information

1

Care & Safety

2

Routine Maintenance

3

Attachments

A

Body & Framework

B

Electrics

C

Hydraulics

E

Transmission

F

Brakes

G

JS 210 LC 110026 On

PUBLISHED BY THE PRODUCT SUPPORT DEPARTMENT

Track & Running Gear

J

Engine

K

OF JCB SERVICE : 23/7, MATHURA ROAD, BALLABHGARH, FARIDABAD TEL. : 0129-4299000 Part No. : 9803/6510

Section 1

General Information

Section 1

i

i CONTENTS

PAGE NO.

Machine Identification Plate

1-1

Typical Vehicle Identification Number (VIN)

1-1

Typical Engine Identification Number

1-1

Torque Settings

2-1

Service Tools - Body and Frame

4-1

- Electrics

4-3

- Hydraulics

4-6

- Transmission Sealing and Retaining Compounds

1

4 - 14 5-1

Issue 1

Section 1

2

General Information

Section 1

Issue 1

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

Section 1

General Information

Section 1

Introduction This 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.

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 dir t. Finally, please remember above all else SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 1 2 3

= = =

General Information - includes torque settings and service tools.

Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.

Routine Maintenance - includes service schedules and recommended lubricants for all the machine.

The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: A

B

= =

Attachments

Body & Framework ...etc.

The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual.

Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each alphabetically coded section.

All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference.

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.

3

Issue 1

Section 1

General Information

Section 1

Colour Coding The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service publications.

~ Red - Full Pressure Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and M.R.V. operating pressure.

~ Pink

-

Pressure

Pressure that is above neutral circuit pressure but lower than that denoted by red.

~ Orange

-

Servo

Oil pressure used in controlling a device (servo).

~ Blue

-

Neutral

Neutral circuit pressure.

~ -

Green - Exhaust

Light - Cavitation

Green Oil subjected to a partial vacuum due to a drop in pressure (cavitation).

- Yellow - Lock Up Oil trapped within a chamber or line, preventing movement of components (lock up).

A390940

4

Issue 1

Section 1

General Information

Section 1

1-1

1 -1 Typical Vehicle Identification Number (VIN)

Machine Identification Plate Your machine has an identification plate mounted outside the cab at A. The serial numbers of the machine and its major units are stamped on the plate.

The machine serial number is inscibed at B which is the base plate of the rear frame and the engine number is at C.

SLP

JS915

3

E

0 930000

A

B

C

D

E

A

World Manufacturer Identification

B

Machine Model Code

C

Year of Manufacture:

2 3 4 5 6 7 8

= = = = = = =

2002 2003 2004 2005 2006 2007 2008

401730

JCB HEAVY PRODUCTS LTD UTTOXETER, STAFFS ST14 8TL, ENGLAND

VIN

D

Manufacturer Location (E = England)

E

Product Identification Number (PIN)

Typical Engine Identification Number

Vehicle Identification Number

Product Identification Number

6 A

MACHINE WEIGHT kg ENGINE SERIAL No. ENGINE POWER kW RPM CONSTRUCTION YEAR

BGI B

145941 C

A

Engine Type “6 Cylinder”

B

Build code

C

Engine Identification Number

JS06060

5

Issue 1

Section 1

General Information

Section 1

2-1

2-1

Torque Settings Use only where no torque setting is specified in the test. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threade the values should be REDUCED by one third.

UNF Grade ‘S’ Bolts Bolt Size In 1/4 5/18 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 11/4 11/2

(mm) (6.3) (7.9) (9.5) (11.1) (12.7) (14.3) (15.9) (19.0) (22.2) (25.4) (31.7) (38.1)

Hexagon (A/F) In 7/16 1/2 9/16 5/8 3/4 13/16 15/16 11/8 15/16 11/2 17/8 21/4

Nm 14 28 49 78 117 170 238 407 650 970 1940 3390

Torque Settings kgf m 1.4 2.8 5.0 8.0 12.0 17.3 24.3 41.5 66.3 99.0 198.0 345.0

Ibf ft 10 20 36 58 87 125 175 300 480 715 1430 2500

Metric Grade 8.8 Bolts Bolt Size M5 M6 M8 M10 M12 M16 M20 M24 M30 M36

Hexagon (A/F) (mm) (5) (8) (8) (10) (12) (16) (20) (24) (30) (36)

mm 8 10 13 17 19 24 30 36 46 55

Torque Settings Nm 7 12 28 56 98 244 476 822 1633 2854

kgf m 0.7 1.2 3.0 5.7 10 25 48 84 166 291

Ibf ft 5 9 21 42 72 180 352 607 1205 2105

River Nut Bolts/Screws Bolt Size M3 M4 M5 M6 M8 M10 M12

(mm) (3) (4) (5) (6) (8) (10) (12)

Torque Settings (for steel rivet nuts) Nm kgf m 1.2 0.12 3.0 0.3 6.0 0.6 10.0 1.0 24.0 2.5 48.0 4.9 82.0 8.4

Ibf ft 0.9 2.0 4.5 7.5 18.0 35.5 60.5

Note : All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

6

Issue 1

Section 1 4-1

General Information

Section 1

Service Tools

4-1

Service Tools SECTION B - Body and Framework

Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc.

JCB part number 892/00845

Hand Cleaner - special blend for the removal of polyurethane adhesives.

JCB pan number - 4104/1310 (454g; 1 Ib tub) S186270

S186240

Folding Stand for Holding Glass essential for preparing new glass prior to installation.

12V Mobile Oven - 1 canridge capacity - required to pre-heat adhesive prior to use. It is fitted with a male

JCB part number 892/00843

plug (703/23201) which fits into a female socket (715/04300).

JCB pan number - 992/12300

S186280

S186250

240V Static Oven - available with 2 or 6 canridge

Glass Lifter - minimum 2 off - essential for glass

capacity - required to pre-heat adhesive prior to use.

No plug supplied. Note: 110V models available upon request - contact JCB Technical Service.

installation, 2 required to handle large panes of glass.

Ensure suction cups are protected from damage during storage.

JCB pan number: 992/12400 - 2 Canridge x 240V 992/12600 - 6 Can ridge x 240V

JCB part number - 892/00842

S186260

7

S186300

Issue 1

Section 1

General Information

4-2

Section 1

Service Tools

4-2

Service Tools (cont’d) SECTION B - Body and Framework (cont’d)

Wire Starter - used to access braided cutting wire(below) through original polyurethane seal.

Cut-Out Knife - used to remove broken glass.

JCB part number - 992/12800 JCB part number - 892/00848 S186340 S186310

‘L’ Blades - 25 mm (1 in) cut - replacementblades for cut-out knife (above).

JCB part number - 992/12801 (unit quantity = 5 off)

Glass Extractor (Handles) - usedwith braided cutting wire (below) to cut out broken glass.

JCB Part number - 892/00846 S186320

S186350

Braided Cutting Wire - Consumble heavy duty

Long Knife - used to give extended reach for normally inaccessible areas.

cut-out wire used with the glass extraction tool (above).

JCB part number - 892/00844

JCB part number - 829/00849 (approx 25m length)

S186330

8

S186360

Issue 1

Section 1

General Information

4-3

Service Tools

Section 1 4-3

Service Tools SECTION B - Body and Framework (cont’d) Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame.

JCB part number - 926/15500 (unit quantity = 500 off)

Nylon Spatula (unit quantity = 500 off) general tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge.

JCB part number - 892/00847 S186470

826/01099 826/01101 826/01103 826/01102 826/01104 826/01105

S186550

M6 x 16mm Rivet Nut M6 x 19mm Rivet Nut M8 x 18mm Rivet Nut M8 x 21 mm Rivet Nut M10 x 23mm Rivet Nut M10 x 26mm Rivet Nut

Installation Tool Available from: Bollhoff Fastenings Ltd. Midacre The Willenhall Estate Rose Hill Willenhall West Midlands, WV13 2JW S261210

9

Issue 1

Section 1 4-4

General Information

Section 1

Service Tools

4-4

Service Tools SECTION C - Electrics

Electrical Test Equipment

10

1 892/00283

Tool Kit Case

2 892/00281

AVO Meter

3 892/00286

Surface Temperature

4 892/00284

Microtach Digital Tachometer

5 892/00282

Shunt - open type

6 892/00285

Hydraulic Oil Temperature Probe

7 892/00298

Fluke 85 Multimeter

993/85700

Battery Tester

Issue 1

Section 1

General Information

4-5 Service Tools

Section 1

Service Tools

4-5

SECTION C - Electrics (cont’d) Electronic Service Tool Kit 892/01033 Kit comprises: 1

Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable diagnostics software.

2

Interconnecting cable, DLA to laptop PC. Several cables are included to enable compatibility with different PC port types.

3

Interconnecting cable, DLA to machine ECU diagnostics socket.

4.

Kit carrying case.

721/01885-

Interconnecting cable, DLA to machine ECU diagnostics socket. (part of 892/01033 Kit above) A408030

11

Issue 1

Section 1 4-6

General Information

Section 1

Service Tools

4-6

Service Tools (cont’d) SECTION E - Hydraulics

Hydraulic Pressure Test Gauges and Connections 1 892/00279 Pressure Gauge 0-400 bar (0-6000 Ibf/in2) 2 2 892/00346 Pressure Gauge 0-70 bar (0-1000 Ibf/in2) 3 892/00347 Connector 4 892/00254 Hose

PressureTest’T’Adapters

Pressure Test Adapters

892/00262 816/55038 816/55040 892/00263 892/00264 892/00265 892/00266 892/00267

892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261

12

1/4 in BSP x 1/4 in F BSP x Test Point 3/8 in BSP x 3/8 in F BSP x Test Point 1/2 in BSP x 1/2 in F BSP x Test Point 5/8 in BSP x 5/8 in F BSP x Test Point 3/4 in BSP x 3/4 in F BSP x Test Point 1 in M BSP x 1 in F BSP x Test Point 1,1/4 in M BSP x 1,1/4 in F BSP x Test Point 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point

1/4 in BSP x Test Point 3/8 in BSP x Test Point 1/2 in BSP x Test Point 5/8 in BSP x Test Point 3/4 in BSP x Test Point 1 in BSP x Test Point 1,1/4 in BSP x Test Point 5/8 in UNF x Test Point

Issue 1

Section 1 4 -7

General Information

Section 1

Service Tools

4 -7

Service Tools (cont’d) SECTION E - Hydraulics (con’d)

Hand Pump Equipment 892/00223 892/00137 892/00274 892/00262 892/00706 892/00278 892/00279 892/00280

Hand Pump Micro-bore Hose 1/4 in BSP x 5 metres Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1/4 in M BSP x 1/4 in F BSP x Test Point Test Probe Gauge 0 - 40 bar (0 - 600 Ib/in2) Gauge 0 - 400 bar (0 - 6000 Ib/in2) Gauge 0 - 600 bar (0 - 8500 Ib/in2)

816/50005 1/2 in BSP (A) x 1/2 in BSP (B) 816/60096 3/4 in BSP (A) x 3/4 in BSP (B) 816/00018 1 in BSP (A) x 1 in BSP (B)

Female Cone Blanking Plug

Male Cone Blanking Plug

892/00055 892/00056 892/00057 892/00058 892/00059 892/00060

816/00294 816/00189 816/00190 816/00197 816/00196 816/00193

13

1/4 in BSP 3/8 in BSP 1/2 in BSP 5/8 in BSP 3/4 in BSP 1 in BSP

1/4 in BSP 3/8 in BSP 1/2 in BSP 5/8 in BSP 3/4 in BSP 1 in BSP

Issue 1

Section 1

General Information

4-8

Section 1

Service Tools

4-8

Service Tools (cont’d) SECTION E - Hydraulics (con’d) Socket Box Wrench For

disassembly and assembly of slew motor gearbox.

Nut Adapter

14

For disassembly and assembly of slew motor gearbox.

Issue 1

Section 1

General Information

4-9

Section 1

Service Tools

4-9

Service Tools (cont’d) SECTION E - Hydraulics (con’d)

Seal Ring Tool

for assembly and disassembly of slew motor gearbox seal

Stopper

for assembly of slew motor gearbox.

A40890

15

Issue 1

Section 1 4 - 10

General Information

Section 1

Service Tools

4 - 10

Service Tools (cont’d) SECTION E - Hydraulics (con’d)

1

2

Bearing Rig

for removal of slew m otor bearing.

A408870

16

Issue 1

Section 1

General Information

4 - 11

Section 1

Service Tools

4 - 11

Service Tools (cont’d) SECTION E - Hydraulics (cont’d) Ram Dismantling and Assembly Ram Piston Head Nut Item

Part Number

Description

Quantity

1

993/99525

Rig assembly (not including spanners and ram)

1

2

993/99522

Anchor side plate (supplied loose unwelded)

1

3

993/99523

Anchor cross member (supplied loose unwelded)

1

4

993/99524

Ram eye end modification

1

5

556/43400

Lift ram

1

6

545/18000

Lynch pin

1

7

811/50232

11/4 in Pivot pin

1

Spanner Requirements 993/99518

Bucket ram

90 mm A/F Nut

SSPO047

Boom ram

95 mm A/F Nut

993/99519

Dipper ram

100 mm A/F Nut

993/99519

Bucket ram

100 mm A/F Nut

993/99519

Boom ram

100 mm A/F Nut

993/99521

Dipper ram

115 mm A/F Nut

Note: All spanners have operating centres of 500 mm.

17

Issue 1

Section 1

General Information

4 - 12

Service Tools

Section 1 4 - 12

Service Tools (cont’d) SECTION E - Hydraulics (cont’d) Ram Dismantling and Assembly (cont’d) Jig for inserting and correcting seal ring WDB 2052 WDB 2054 WDB 2164 WDB 2056

Bucket Boom 125mm Boom 130mm Arm 150mm

120mm Cylinder inner diameter Cylinder inner diameter Cylinder inner diameter Cylinder inner diameter

Jig for pulling out, press-fitting bushing WDB 2166 WDB 2167 WDB 2170 WDB 2168 WDB 2168 WDB 2171

Bucket 80mm Boom 85mm Arm 100mm Bucket 90mm Boom 90mm Arm 105mm

Piston Rod diameter Piston Rod diameter Piston Rod diameter Piston Rod diameter Piston Rod diameter Piston Rod diameter

Jig for press-fitting wiper ring WDB 2166-1 WDB 2167-1 WDB 2170-1 WDB 2168-1 WDB 2168-1 WDB 2171-1

Bucket 80mm Boom 85mm Arm 100mm Bucket 90mm Boom 90mm Arm 105mm

Piston Rod diameter Piston Rod diameter Piston Rod diameter Piston Rod diameter Piston Rod diameter Piston Rod diameter

Jig for inserting cylinder head WDB 2174 WDB 2175 WDB 2178 WDB 2176 WDB 2176 WDB 2179

18

Bucket 80mm Boom 85mm Arm 100mm Bucket 90mm Boom 90mm Arm 105mm

Cylinder rod inner diameter Cylinder rod inner diameter Cylinder rod inner diameter Cylinder rod inner diameter Cylinder rod inner diameter Cylinder rod inner diameter

Issue 1

Section 1

General Information

4 - 13

Service Tools

Section 1 4 - 13

Service Tools (cont’d) SECTION E - Hydraulics (cont’d) Ram Dismantling and Assembly (cont’d) Seal Ring and Connector Jig WDB 2052 Seal Ring insert and connection jig set Note: The above Part no. is applicable to a tube diameter of 120mm.

Bush Removal Jig WDB 2166

Bush removal jig

WDB 2166-1

Retainer

Note: The above Part no. is applicable to a rod diameter of 80mm.

Bush Fitting Jig WDB 2166

Bush press fitting jig

WDB 2166-1

Retainer

Note: The above Part no. is applicable to a rod diameter of 80mm.

Wiper Ring fitting Jig WDB 2166-1

Wiper Ring fitting

Note: The above Part no. is applicable to a rod diameter of 80mm.

Wiper Ring fitting Jig WDB 2174 Cylinder Head insertion guide jig Note: The above Part no. is applicable to a rod diameter of 80mm.

19

Issue 1

Section 1

General Information

4 - 14

Section 1

Service Tools

4 - 14

Service Tools (cont’d) SECTION F - Transmission Track Gearbox Jig STO037Re-sealing Tool (All dimensions are in mm.)

Stopper

20

for the assembly of Hydraulic motor on track gearbox

A409010

Issue 1

Section 1

General Information

4 - 15

Service Tools

Section 1 4 - 15

Service Tools (cont’d) SECTION F - Transmission (cont’d) Track Gearbox Jig SSTOO40 Ring Nut Tool SSTOO41 Planet Gear Tool (All dimensions are in mm.)

SST0040

SST0041

21

Issue 1

Section 1

General Information

5-1

Section 1

Service Tools

5-1

Sealing and Retaining Compounds JCB Multi-Gasket

JCB High Strength Threadlocker

JCB Retainer (High Strength)

A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65mm diameter.

4102/1212

50ml

A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important.

4102/0551

50ml

For all retaining parts which are unlikely to be dismantled.

4101/0651

50ml

JCB Threadlocker and Sealer

A high strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50mm diameter, and for hydraulic fittings up to 25mm diameter.

4101/0250 4101/0251

10ml 50ml

Threadseal

A medium strength thread sealing compound.

4102/1951

50ml

Threadlocker

A locking fluid for use on threads larger than 50mm dia.

4101/0451

50ml

4104/0251 4104/0253

(1Itr) Bottle

400ml

Activator

A cleaning primer which speeds the curing rate of anaerobic products.

(200ml)

Cleaner / Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants.

4104/1557

For one pane of glass, comprises items marked t below plus applicator nozzle etc.

993/55700

† Ultra Fast Adhesive

For direct glazing

4103/2109

310 ml

† Active Wipe 205

For direct glazing

† Black Primer 206J

For direct glazing

4104/1206 4104/1203 4201/4906

30 ml 250 g 30 ml

Clear Silicone Sealant

To seal butt jointed glass

4102/0933

Black Polyurethane Sealant

To finish exposed edges of laminated glass

4102/2309

310 ml

JCB Cleaner & Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants.

4104/1538

Aerosol

Direct Glazing Kit

22

Issue 1

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL