JCB JS210, JS230 Excavator Service Repair Manual Instant Download (From 2453501 To 2453750; From 2453251 To 2453500)

Foreword The Operator's Manual You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand. Treat the Operator's Manual as part of the machine. Keep it clean and in good condition. Replace the Operator's Manual immediately if it is lost, damaged or becomes unreadable. EXCAVATOR JS210, JS230 Contents 01 - Machine 03 - Attachments, Couplings and Load Handling EN - 9813/8000 - ISSUE 1 - 10/2016 06 - Body and Framework 09 - Operator Station 12 Conditioning (HVAC) - Heating, Ventilating and Air- 15 - Engine 18 - Fuel and Exhaust System 21 - Cooling System 27 - Driveline This manual contains original instructions, verified by the manufacturer (or their authorized representative). 30 - Hydraulic System 33 - Electrical System 72 - Fasteners and Fixings Copyright 6-10-27 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. 75 - Consumable Products 78 - After Sales www.jcb.com

01 - Machine Contents Page No. Acronyms Glossary .................................................................................................................................... 01-2 01-03 Safety 01-03-03 Safety - Yours and Others ............................................................................................... 01-3 01-03-06 Safety Warnings ............................................................................................................... 01-4 01-03-09 General Safety ................................................................................................................. 01-5 01-03-12 Maintenance Safety ......................................................................................................... 01-6 01-03-18 Operating Safety .............................................................................................................. 01-8 01-03-21 Worksite Safety .............................................................................................................. 01-10 01-03-24 Risk Assessment ............................................................................................................ 01-11 01-03-27 Maintenance Positions ................................................................................................... 01-12 01-06 About this Manual 01-06-06 Using the Manual ........................................................................................................... 01-15 01-09 Description 01-09-12 Main Component Locations ........................................................................................... 01-19 01-09-15 Service Point Locations ................................................................................................. 01-20 9813/8000-1 2016-10-18

Acronyms Glossary ARV FEAD MRV PIL PPE Auxiliary Relief Valve Front End Accessory Drive Main Relief Valve Parts Identification List Personal Protective Equipment 9813/8000-1 2016-10-18

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01 - Machine 03 - Safety 03 - Safety Contents Page No. 01-03-03 Safety - Yours and Others ............................................................................................... 01-3 01-03-06 Safety Warnings ............................................................................................................... 01-4 01-03-09 General Safety ................................................................................................................. 01-5 01-03-12 Maintenance Safety ......................................................................................................... 01-6 01-03-18 Operating Safety .............................................................................................................. 01-8 01-03-21 Worksite Safety .............................................................................................................. 01-10 01-03-24 Risk Assessment ............................................................................................................ 01-11 01-03-27 Maintenance Positions ................................................................................................... 01-12 01 - 1 9813/8000-1 01 - 1

01 - Machine 03 - Safety 03 - Safety - Yours and Others 03 - Safety - Yours and Others Introduction All machinery can be hazardous. When a machine is correctly operated and maintained, it is a safe machine to work with. When it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. In this manual and on the machine you will find warning messages, read and understand them. They inform you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them. Safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking of what hazards there might be and how to avoid them. Do not work with the machine until you are sure that you can control it. Do not start any work until you are sure that you and those around you will be safe. If you are not sure of anything, about the machine or the work, ask someone who knows. Do not assume anything. Remember: Be careful Be alert Be safe. 01 - 3 9813/8000-1 01 - 3

01 - Machine 03 - Safety 06 - Safety Warnings 06 - Safety Warnings Introduction In this manual and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury. The signal word 'WARNING' indicates a hazardous situation which, if not avoided, could result in death or serious injury. The signal word 'CAUTION' indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The signal word 'Notice' indicates a hazardous situation which, if not avoided, could result in machine damage. The safety alert system (shown) also helps to identify important safety messages in this manual and on the machine. When you see this symbol, be alert, your safety is involved, carefully read the message that follows, and inform other operators. Figure 1. The safety alert system 01 - 4 9813/8000-1 01 - 4

01 - Machine 03 - Safety 09 - General Safety 09 - General Safety Lifting Equipment You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations. Raised Equipment Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped). Make sure that no-one goes near the machine while you install or remove the mechanical device. Raised Machine Never position yourself or any part of your body under a raised machine which is not correctly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed. Lightning Lightning can kill you. Do not use the machine if there is lightning in your area. Machine Modifications This machine is manufactured in compliance with prevailing legislative requirements. It must not be altered in any way which could affect or invalidate its compliance. For advice consult your JCB dealer. Introduction Training To operate the machine safely you must know the machine and have the skill to use it. You must abide by all relevant laws, health and safety regulations that apply to the country you are operating in. The operator's manual instructs you on the machine, its controls and its safe operation; it is not a training manual. If you are a new operator, get yourself trained in the skills of using a machine before trying to work with it. If you don't, you will not do your job well, and you will be a danger to yourself and others. In some markets and for work on certain jobsites you may be required to have been trained and assessed in accordance with an operator competence scheme. Make sure that you and your machine complies relevant local laws and jobsite requirements - it is your responsibility. Care and Alertness All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards. Clothing You can be injured if you do not wear the correct clothing. Loose clothing can get caught in the machinery. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and personal jewellery. Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines which can cause drowsiness. Feeling Unwell Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself and those you work with. Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious injury. Switch off and do not use your mobile phone when refuelling the machine. 01 - 5 9813/8000-1 01 - 5

27 - Driveline 36 - Track 03 - Steel Track 03 - Steel Track Adjust Notice: Always make sure that the track tension measurement is not less than specified or severe strain to the track will result. WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out. If you over-loosen too much grease could spurt out or the valve cover fly out and cause serious injury. Adjust ............................................................ 27-12 Remove and Install ....................................... 27-13 Store and Recommission .............................. 27-15 Track Tension 1. Stop the machine on solid, level ground 2. Move the machine backwards and forwards several times, then move the machine forwards and stop it on level ground. 3. Stop the engine. 4. Check the track tension. 4.1. Place a long, stiff and straight piece of steel or wood on top of the tracks touching above the front idler and the top roller. Figure 381. A A Track tension - measurement 5. Make sure the track tension is within the specified limits. Refer to: Driveline > Track > General (Page 27-11). 6. If necessary, adjust the track tension. 6.1. To adjust the track tension, inject or release grease from the check valve. 27 - 12 9813/8000-1 27 - 12

27 - Driveline 36 - Track 03 - Steel Track Remove and Install Figure 382. WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out. If you over-loosen too much grease could spurt out or the valve cover fly out and cause serious injury. WARNING Stand clear and to one side of the track while you remove the master pin. When the master pin is removed the track could fall forward and injure you. Remove 1. Make the machine safe. Refer to: Machine > Safety (Page 01-1). 6.2. Inject grease to increase the tension. 6.3. Release grease to decrease the tension. 2. Move the track link until the master pin is over the take-up roller in the position shown, place a wooden block under the track shoe. Refer to Figure 383. 6.4. When you open the check valve, always stand to one side and loosen it a slowly until the grease starts to release. 6.5. Do not loosen the check valve too much, grease can spurt out or the cover of the check valve can come off and cause serious injury. Figure 383. 7. Never attempt to disassemble the check valve or try to remove the grease point from the check valve. 8. If there is a clearance between the idler wheel shaft and the track frame, use pressure to apply the grease. 3. Slacken the check valve to bleed out the grease. 9. If there is no clearance after the application of grease the grease cylinder or recoil assembly may be faulty. Figure 384. 10. Do not tension the tracks too much, this will cause the track rail to wear the drive rollers and sprocket. 11. Always make sure you adjust the track tension to the specified limits. Incorrect tension can cause wear to the drive sprocket and the track rail. 12. Repeat the procedure for the other track. 4. Disconnect the track link by removing the locking pin and knocking out the master pin as follows: 4.1. Remove bolts and lift off the track shoe plates adjacent to the master pin. 27 - 13 9813/8000-1 27 - 13

27 - Driveline 36 - Track 03 - Steel Track Figure 385. 6.2. Using suitable equipment pull the track clear of the machine. Install 1. Position the lower frame on the track. 2. Move the track link. Figure 388. 4.2. Position a suitable hydraulic press so that its ram aligns with the master pin. Figure 386. 3. Clean the seal ring housing in the chain link. Insert the seal rings and clamp into position. Figure 389. 4.3. Insert the spacer bar between the master pin and the hydraulic ram. 4.4. Slowly operate the press hydraulic ram and press out the master pin. 4.5. Remove the seal rings from each side of the chain link. 5. Operate the track drive motor to remove the track. 4. Using a plastic hammer, tap the upper link down to align holes. 6. Lift the lower frame clear of the track. 4.1. As the links overlap, the seal rings will be held in position. Remove the clamps. Figure 387. 5. Insert the pointed guide pin from the inner face and tap through its full length. 6.1. Support the lower frame with wooden blocks. 27 - 14 9813/8000-1 27 - 14

27 - Driveline 36 - Track 03 - Steel Track Store and Recommission Figure 390. During storage, or non continuous work periods in wet environmental conditions, the track link joints can seize. Figure 392. 6. Position a suitable hydraulic press so that its ram aligns with the guide pin. When the machine is used, wear occurs between the pin and bush in the track link. This results in the gap between the pin and bushes increasing. 7. Insert the master pin into its locating hole. 8. Slowly operate the hydraulic press ram to press the master pin into position. Figure 393. Figure 391. B C F E 9. Install the track shoe plates. Refer to: Driveline > Track > Shoe Plate (Page 27-17). B Traction C Gap increase E Pitch elongation F Wear 10. Adjust the track tension. Refer to: Driveline > Track > Steel Track (Page 27-12). The metal particles worn from the pin and bush can accumulate in the bush leading to seizure of the link joint. To help prevent seizure make sure to complete the following steps. 1. Operate the machine (making sure that the machine travels on its tracks) at least once per week to keep the link joints flexible. 2. Do the undercarriage basic maintenance before you stop the machine (washing and mud cleaning). 27 - 15 9813/8000-1 27 - 15

27 - Driveline 36 - Track 03 - Steel Track 3. Avoid allowing the machine to stand for long periods in a wet environment (such as in wet soil or water). 4. Do a regular check of the track tension to avoid excessive joint wear (excessive track tension affects joint internal wear). Refer to: Driveline > Track > Steel Track (Page 27-12). 27 - 16 9813/8000-1 27 - 16

27 - Driveline 36 - Track 04 - Shoe Plate 04 - Shoe Plate Check (Condition) Check (Condition) .......................................... 27-17 Remove and Install ....................................... 27-18 If a track shoe plate is used when it is loose, it may fail. Immediately tighten the track plate bolts whenever they are found to be loose. To check the track shoe plate bolts proceed as follows: 1. Torque tighten the bolts in the sequence shown and check that the nuts and shoe are closely installed to the link joining surface. Figure 394. 2. Start the engine and move the machine forwards or backward to get access to the next set of track bolts. Stop the engine. 3. Do the step 1 again. 4. Repeat the above procedures until all the track bolts have been checked. Table 175. Track Shoe Plate Bolts - Checking Torques Machines JS200 Series Checking Torque N m 756-801 27 - 17 9813/8000-1 27 - 17

27 - Driveline 36 - Track 04 - Shoe Plate Remove and Install Remove 1. Start the engine and move the machine forwards or backward to get access to the applicable set of track shoe plate bolts. Stop the engine. 2. Remove the bolts followed by the track shoe plate. Install 1. Check that the track shoe plate and its fixing nuts are closely installed to the link joining surface. 2. Torque tighten the bolts to the specified torque in the sequence shown. Refer to Table 176. Figure 395. Table 176. Track Shoe Plate Bolts - Tightening Torques Machines JS200 Series Torque N m 840-890 27 - 18 9813/8000-1 27 - 18

27 - Driveline 36 - Track 12 - Gearbox Sprocket 12 - Gearbox Sprocket Figure 398. Remove and Install Consumables Description JCB Threadseal Part No. 4102/1951 Size 0.05L WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out. If you over-loosen too much grease could spurt out or the valve cover fly out and cause serious injury. WARNING Stand clear and to one side of the track while you remove the master pin. When the master pin is removed the track could fall forward and injure you. 4. Support the drive sprocket, remove the bolts and lever it away from the gearbox unit. Figure 399. Remove 1. Slacken the check valve to bleed out grease. Figure 396. Install 2. Disconnect the track link. 1. Support the sprocket and position it on the gearbox. Figure 397. 1.1. Install the bolts and washers, using sealant on the bolt threads. Consumable: JCB Threadseal 1.2. Tighten the bolts in a diagonal sequence to the specified torque. Refer to Table 177. 3. Lift the side of the undercarriage high enough to permit drive sprocket removal. Support with wooden blocks. 27 - 19 9813/8000-1 27 - 19

27 - Driveline 36 - Track 12 - Gearbox Sprocket Figure 400. A A Bolt 2. Remove the wooden blocks. Connect the track link. 3. Apply grease through the check valve to adjust the track tension. Refer to: Driveline > Track > Steel Track (Page 27-12). Figure 401. Table 177. Torque Settings Item A - Bolt size M14 M16 M20 M20 (1) JS100 series machines (2) JS300 series machines Torque N m 165 290 415 506 (1) (2) 27 - 20 9813/8000-1 27 - 20

27 - Driveline 36 - Track 18 - Idler Wheel 18 - Idler Wheel Remove and Install WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out. If you over-loosen too much grease could spurt out or the valve cover fly out and cause serious injury. WARNING Stand clear and to one side of the track while you remove the master pin. When the master pin is removed the track could fall forward and injure you. Remove and Install ....................................... 27-21 Disassemble and Assemble .......................... 27-23 Remove 1. Slacken the check valve to bleed out grease. Figure 402. 2. Disconnect the track link. Move the idler wheel and recoil assembly to the end of the undercarriage using a bar. Figure 403. 3. Fasten a sling around the idler wheel and recoil assembly and remove it from the undercarriage. 27 - 21 9813/8000-1 27 - 21

27 - Driveline 36 - Track 18 - Idler Wheel Figure 404. Figure 407. 3. Position the idler wheel in the undercarriage using a bar. 4. Remove the bolts and remove the idler wheel from the recoil unit. Figure 408. Figure 405. 4. Connect the track link. Apply grease through the check valve to adjust the track tension. Refer to: Driveline > Track > Steel Track (Page 27-12). Install 1. Before fitting the idler wheel, check the oil level at position A. If required, top up with the specified oil. Assemble the idler wheel to the recoil unit and fit the mounting bolts. Figure 409. Figure 406. 2. Fasten a sling around the idler wheel and recoil assembly and enter it into the undercarriage. 27 - 22 9813/8000-1 27 - 22

27 - Driveline 36 - Track 18 - Idler Wheel Disassemble and Assemble Figure 412. C D G Disassemble 1. Clean the idler wheel with a suitable solvent. Remove the plug from the hub and drain the oil. Figure 410. F C Hub D Shaft F O-ring B A 4. Remove the wire clip or roll pin (later machines) and separate the hub from shaft. Remove the O- ring from the shaft. A Plug B Hub Figure 413. C 2. On one side of the unit only, remove the wire clip or roll pin (later machines) and separate the hub from the shaft. E Figure 411. F D C Hub D Shaft E Wire clip F O-ring 5. Remove the floating seal from each hub using a pry bar. C E G D 5.1. Remove the floating seal from each side of the idler wheel using a pry bar. C Hub D Shaft E Wire clip G Idler wheel 3. Remove the O-ring from the shaft. Pull out the shaft from the idler wheel. 27 - 23 9813/8000-1 27 - 23

27 - Driveline 36 - Track 18 - Idler Wheel Figure 414. 2. Check components for wear. Polish out scratches and roughness using an oil stone. Apply a coat of engine oil to all parts. C G 3. Carefully drive new bushes into the idler wheel, using a suitable dolly. Figure 416. G K J K J C C Hub G Idler wheel J Floating seals G Idler wheel K Bushes 6. If badly worn or damaged, remove the bushes from the idler wheel using a press or puller. 4. Apply a coating of grease and install a new floating seal into each side of the idler wheel and hub. 6.1. Protect parts from moisture and dust if left dismantled for some time. Figure 415. 4.1. Ensure that the floating seals are fitted correctly. G K K G Idler wheel K Bushes Assemble 1. Clean all parts thoroughly in a suitable solvent. Dry the shaft and bore of the idler wheel using compressed air in a place free of dust and moisture. 27 - 24 9813/8000-1 27 - 24

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27 - Driveline 36 - Track 18 - Idler Wheel Figure 417. Figure 419. C G C D G J J C F G C C Hub D Shaft F O-ring G Idler wheel J J 7. Apply grease to a new O-ring and install it on the shaft. 7.1. Clean the metallic face of the floating seal and coat it with engine oil. C Hub G Idler wheel J Floating seals 7.2. Install the hub onto the shaft. Fit new wire clip or roll pin (later machines). 5. Grease a new O-ring and install at one end of the shaft. Install the shaft into the hub. Fit a new wire clip or roll pin (later machines). 7.3. Wrap sealing tape around the plug with one thread remaining uncovered. Insert this plug but leave the other one out until after testing. Figure 418. C E F D C Hub D Shaft E Wire clip F O-ring 6. Coat the shaft with grease. Clean the metallic face of the floating seal and coat it with engine oil. Insert the shaft into the idler wheel. 27 - 25 9813/8000-1 27 - 25

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