Month: August 2018

Pages from 9803-6540 – JCB JS330 – Tier II & Tier III Auto Hydraulic Excavator Service Manual

Complete workshop & service manual with electrical wiring diagrams for JCB JS330 – Tier II & Tier III Auto Hydraulic Excavator. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB JS330 – Tier II & Tier III Auto Hydraulic Excavator service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

9803-6540 – JCB JS330 – Tier II & Tier III Auto Hydraulic Excavator Service Manual.pdf

EXCERPT:
Service Manual
JS330 – Tier II and Tier III Auto
Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Routine Maintenance
Section B – Body & Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section J – Track and Running Gear
Section K – E
…
Assembly
Assembly is essentially a reverse of the dismantling procedure in the previous section.
Exchange or repair any parts not in accordance with instructions laid down in the Maintenance Standards.
Ensure that all parts are cleaned in the appropriate solvent and dried with compressed air.
Apply a thin film of hydraulic fluid to all sliding parts, bearings and other contact surfaces before assembly.
Replace all O-rings and seals, where appropriate cover with petroleum jelly before fitting.
1 Cylinder block assembly
Assemble spring seat 17, spring 16 and spring seat 15 to cylinder block 4 and fit snap ring 14.
…

Pages from 9803-9800 – JCB JS290 Tier III Auto Hydraulic Excavator Service Manual

Complete workshop & service manual with electrical wiring diagrams for JCB JS290 Tier III Auto Hydraulic Excavator. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB JS290 Tier III Auto Hydraulic Excavator service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

9803-9800 – JCB JS290 Tier III Auto Hydraulic Excavator Service Manual.pdf

EXCERPT:
Service Manual
JS290 – Tier III Auto
Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Routine Maintenance
Section B – Body & Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section J – Track and Running Gear
Section K – Engine
…
Cushion Control Off
Fig 6. Cushion Control Off
When the cushion switch is illuminated, the cushion solenoid is energised and pilot pressure is fed to port S on the cushion valve. The two inner left and right cushion spools are both pushed into the centre of the outer spool, so that the unrestricted galleries X and the cushion valve spools are open to allow the pilot outputs from the hand controller to pass through the valve unrestricted, to the main control valve. When the dipper hand controller is operated, pilot pressure from the lever to port A, moves the outer spool to the right and pilot pressure is fed to the dipper spool in the control valve, via port C. At the conclusion of the hand controller operation, the returning pilot oil, goes straight back to the lever, with no restriction.
There is no cushioning effect. Hot oil from port R returns to tank via the dipper hand controller, as it does in the warming circuit in the neutral position. K Fig 6. ( T E-117)
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Pages from 9803-9540 – JCB JS200W TIER III Hydraulic Excavator Service Manual

Complete workshop & service manual with electrical wiring diagrams for JCB JS200W Hydraulic Excavator. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB JS200W Hydraulic Excavator service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

FILELIST:
9803-6320 – JCB JS 200W Hydraulic Excavator Service Manual.pdf
9803-9540 – JCB JS200W TIER III Hydraulic Excavator Service Manual.pdf

EXCERPT:
Service Manual
JS200W TIER III
Service Manual – JS200W TIER III
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
…
Horse Power Control Data Logging
Facility
When selected this function will log information on engine speed, pump milliamps and mode over a selectable period up to 15 mins and display the data as a graph.
– Press and hold the “SET” and “MODE” buttons on the EMS simultaneously for 20 seconds, until the “SERVICE OFF” message is displayed.
– Use the scroll arrows until the “HRSEPWR MON” message is displayed.
– Press the “ACK” button. You are now in the datalog function. This is confirmed by the message “MINUTES 1”.
– The time period for logging can now be adjusted from 1 to 15 minutes using the arrow keys.
– Press ‘ACK’ to start recording, the EMS will display “RUNNING” When complete the display will return to normal.
– The results of this test are then viewed through the Service Master, Data logging application using a laptop.
…

Pages from 9813-1250 – JCB JS240, JS260, JS330, JS360 – Tier 4 Hydraulic Excavator Service Manual

Complete workshop & service manual with electrical wiring diagrams for JCB JS200LC, JS240, JS240LC, JS260, JS330, JS300LC, JS360, JS450, JS450LC, JS460 Hydraulic Excavators. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB JS200LC, JS240, JS240LC, JS260, JS330, JS300LC, JS360, JS450, JS450LC, JS460 Hydraulic Excavators service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

FILELIST:
9803-6200 – JCB JS200LC, JS240LC, JS300LC, JS450LC Hydraulic Excavator Service Manual.pdf
9803-6420 – JCB JS330, JS450, JS460 Hydraulic Excavator Service Manual.pdf
9806-2240 – JCB AA-6SD1T Engine (JS460 applicable) Service Manual.pdf
9813-1250 – JCB JS240, JS260, JS330, JS360 – Tier 4 Hydraulic Excavator Service Manual.pdf

EXCERPT:
Service Manual
JS240, JS260, JS330, JS360 – Tier 4
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 – Engine
…
JS460 ENGINE SERVICE MANUAL AA-6SDIT
TABLE OF CONTENTS
Chapter 1 General Information . . . . . 1
Chapter 2 Maintenance. . . . . . . 21
Chapter 3 Engine I (Disassembly) . . 37
Chapter 4 Engine II (Inspection and Repair) . . . . 55
Chapter 5 Engine III (Assembly) . . . . 85
Chapter 6 Lubricating System. . . . . . 117
Chapter 7 Cooling system. . . . 129
Chapter 8 Fuel System. . . . . . . . 139
Chapter 9 Turbocharger . . . . . . 153
Chapter 10 Engine Electrical . . 173
Chapter 11 Troubleshooting. . . 197
Chapter 12 Special Tools. . . . . . . 219
Chapter 13 Repair Standard. . . 223
Note:
Before using this manual to perform maintenance and repairs, be sure to read the section “General Servicing Precautions” included in Chapter 1 (General Information).
…
Assembly
1 Position main housing 301 on a bench with the flange for valve housing 303 uppermost.
2 Take output shaft 101 and fit stop ring 432 and spacer 106 at the splined output end. Shrink fit bearing 443 to the output shaft with annulus A against the spacer.
3 If renewing bearing 444, shrink fit inner race to the output shaft, followed by stop ring 433.
4 Install the output shaft assembly into main housing 301. Tap the outer casing of bearing race 443 using a copper bar until it is fully seated.
Fig 34.
Fig 35.
5 Using a suitable jig, install a new oil seal 491 into front cover 304. Make sure the oil seal is installed the right way round (see Dismantling, step 17).
6 Apply a little grease to the lip of oil seal 491 and new O-ring 471. Cover the spline of output shaft 101 with tape and then install front cover 304 carefully by tapping gently with a plastic hammer at different positions all round the outside edge.
7 Secure front cover 304 with snap ring 437.
8 Position main housing 301 horizontally on the bench.
Smear shoe plate 124 with grease and then install with its large chamfered side against the housing.
…

JCB JS200, JS210, JS220, JS240, JS260

Complete workshop & service manual with electrical wiring diagrams for JCB JS200, JS210, JS220, JS235, JS240, JS260 Hydraulic Excavator. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB JS200, JS210, JS220, JS235, JS240, JS260 Hydraulic Excavator service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

FILELIST:
9803-6400 – JCB JS200, JS210, JS220, JS240, JS260 Hydraulic Excavator Service Manual.pdf
9803-6510 – JCB JS200, JS210, JS220, JS240, JS260 Hydraulic Excavator Service Manual.pdf
9803-6510IND – JCB JS210LC Hydraulic Excavator Service Manual.pdf
9803-6580 – JCB JS200-JS260 (JS200, JS210, JS220, JS235, JS240, JS260) Tier III Auto Hydraulic Excavator Service Manual.pdf
9813-0400 – JCB JS200 Asia Pacific Hydraulic Excavator Service Manual.pdf
…

EXCERPT:
Section E – Hydraulics
Remote Control Valve (Hand Control)
Dismantling and Assembly
Dismantling

Note: All parts are precision made and require the utmost care when being handled.
Note: During dismantling, do not use excessive force to separate components which could cause scratches or burrs on bearing surfaces. Failure to observe this instruction will cause oil leaks leading to poor performance.
Note: Label all parts during dismantling, to ensure correct assembly.
Note: Storing the valve when dismantled could cause rusting of parts. Ensure they are suitably protected by antirust treatment.
Note: For part number identification for the Remote Control Valve assembly, K Fig 126. ( T E-135) and K Table 18. ( T E-136).
1 Push down upper section of gaiter 126-19 and remove roll pin 126-20.
2 Remove control handle from mounting knuckle 126-3.
Note: Take care when removing handle to avoid damage to wiring loom and switches. These should be removed by separating the line connectors in the control handle and below the valve body.
3 Remove gaiter 126-19 from valve housing.
4 Slacken locknut 126-22 and remove mounting knuckle 126-23.
5 Slacken and remove joint nut 126-24 and rocker plate 126-25.
!WARNING
Always wear safety glasses when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidentally flying out.
Note: The return spring 126-15, retaining plate 126-18 and plunger 126-11 will rise when knuckle joint 126-26 is loosened.
6 Using a jig, slacken and unscrew knuckle joint 126-26, releasing retaining plate 126-18.
Note: Ensure retaining plate moves freely to prevent sudden release due to spring pressure beneath.
7 Clean the valve exterior using approved solvent and using soft metal pads for protection, clamp the valve body into a vice.
8 If the return springs 126-15 are weak, the sliding resistance of the seal 126-9 will cause the guides 126-8 to stick in the casing. Using a screw driver, carefully ease out the guides 126-8 and plungers 126-11.
Note: Care must be taken to prevent damage to the guides when removing. Ensure the guides do not fly out due to the force of the return springs.
9 Remove spring seats126-13, split washers 126-12, return springs 126-15, pressure control springs 126-14 and spools 126-17.
Note: Identify each set of parts and their locations for assembly.
10 Loosen the two hex bolts 126-27 on the base of the valve. Remove the base plate and O-ring 126-30 from the valve casing.
11 Slacken and remove body assembly screw 126-6.
Remove and discard `O’-ring 126-7.
12 Separate upper and lower body sections 126-1 and 126-2 and remove dowel pins 126-5.
13 Remove and discard `O’-rings 126-3 and 126-4.
Note: The surface of spool 126-17 and spring 126-13 can be damaged by mis-handling. Take care not to damage the surface of the spool during removal and do not push the spring seat down more than 6mm (0.24 in).
…