jcb JS 200 Series Service Manual Download

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33 - 5

Section E

Hydraulics

9803/6400

Section E

33 - 5

Issue 2*

Control Valve JS200/JS240

Assembly, 4-spool control valve section

Assemble the poppet 23 and spring 22 into the spool 3. After completely degreasing the thread part (and the spool side) of
the plug 19 (Hexagonal 22 A/F), fit the 'O'-ring 21 and backup ring 20 attached, apply adhesive and screw into the spool,
with a torque of 9.8-12 Nm (7.23-8.67 lb/ft).

Assemble the spring seat 16 and spring 17 to the spool end 3 (Hexagonal 22 A/F). Apply adhesive to the thread and screw
into the spool 4, 5, 6, to a torque of 9.8-12 Nm (7.23-8.67 lb/ft).

Assemble the spool assembly into the valve housing 1 at the same position and direction as before.

Assemble the sleeve 40 with the 'O'-ring 41 and backup ring 42 attached and assemble the poppet 39, spring 38, and
spacer assembly 55 and attach the 'O'-ring 37 and backup ring 36 to the plug 35 and assemble into the valve housing.

Assemble the spool 7 into the valve housing and install the spring seat 9 and spring 8.

Tighten the caps 2, 14 with 'O'-rings 10, 18 attached, with socket head bolts 47, 48 (Hexagonal socket 8 A/F) to the valve
housing.

Assemble the spring and piston 51, 56 to the cap 2 and tighten the plug 49 (Hexagonal 38 A/F), with 'O'-ring 50
attached, to a torque of 93-108 Nm (68.68-70.53 lb/ft).

Install the main relief valve 13 (Hexagonal 31.5 A/F) to the valve housing, with a torque of 78-88 Nm (57.84-65.07 lb/ft).

Install the port relief valve 31 (Hexagonal 31.5 A/F) to the valve housing, with a torque of 78-88 Nm (57.84-65.07 lb/ft).

10.

Install the negative control relief valve 24 (Hexagonal 36 A/F) to the valve housing, tightening to a torque of 88-98 Nm
(65.07-72.3 lb/ft).

11.

Screw in the plug 53 (Hexagonal 36 A/F) with the 'O'-ring 54 assembled, with a torque of 83-93 Nm (61.45-68.68.lb/ft).

12.

Assemble the poppet 25, spring 26 to the sleeve 3 and assemble in the valve housing.

13.

Install the check valve assembly 32 (Hexagonal 36 A/F), with a torque of 265-275 Nm (195.21-202.44 lb/ft).

14.

Assemble the poppet 27 and spring 22 into the valve housing and install the 'O'-ring 29 to the plug 30 (Hexagonal 27 A/F)
and fasten with torque of 83-93 Nm (61.45-68.68 lb/ft).

15.

Assemble the poppet 46, spring 45 to the valve housing and install the 'O'-ring 44 to the plug 43 (Hexagonal 27 A/F) and
screw in.
If the plug 12 (Hexagonal 22 A/F) is disassembled, install the 'O'-ring 11 and tighten, to a torque of 49-59 Nm
(36.15-43.38 lb/ft).

16.

If the plug 53 (Hexagonal 36 A/F) is disassembled, install the 'O'-ring 54 and tighten, to a torque of 83-93 Nm
(61.45-68.68 lb/ft).

17.

If the plug 52 (Hexagonal socket 5 A/F) is disassembled, wrap seal tape around the plug periphery (leave one thread open
from the end and wrap to the right 1.5~2 times so that the tape bites into the threads) and tighten, to a torque of 6.85-8.82
(5.06-6.5 lb/ft).

jcb JS 200 Series, Service Manual

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