jcb JS220, Service Manual

Page 1: ...rst 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 Do not opera...

Page 2: ...9813 7350 1 Notes Find manuals at https best manuals com...

Page 3: ...JS210 JS220 JS235 EN 9813 7350 SERVICE MANUAL Volume 2 JS200 JS210 JS220 JS235 EN 9813 7350 SERVICE MANUAL Volume 3 JS200 JS210 JS220 JS235 EN 9813 7350 SERVICE MANUAL Volume 4 JS200 JS210 JS220 JS23...

Page 4: ...Notes 9813 7350 1 Find manuals at https best manuals com...

Page 5: ...al 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 Manua...

Page 6: ...50 1 2016 04 22 Acronyms Glossary ARV Auxiliary Relief Valve DEF Diesel Exhaust Fluid FEAD Front End Accessory Drive MRV Main Relief Valve PIL Parts Identification List Find manuals at https best manu...

Page 7: ...y 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 Assessme...

Page 8: ...Notes 01 2 9813 7350 1 01 2 Find manuals at https best manuals com...

Page 9: ...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...

Page 10: ...ion 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 N...

Page 11: ...are 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...

Page 12: ...er Hydraulic Pressure Hydraulic fluid at system pressure can injure you Before connecting or removing any hydraulic hose residual hydraulic pressure trapped in the service hose line must be vented Mak...

Page 13: ...dence of decomposition e g charring is found refer to the next paragraph for safety instructions Do not touch component or surrounding area Used fluoroelastomeric components subjected to temperatures...

Page 14: ...r bystanders if they are inhaled Do not operate the machine in closed spaces without making sure there is good ventilation If possible install an exhaust extractor If you begin to feel drowsy stop the...

Page 15: ...s configuration by the user e g the fitting of large and non approved attachments may result in a restriction of the machine visibility Hands and Feet Keep your hands and feet inside the machine When...

Page 16: ...leak is suspected contact the local gas company immediately and warn all personnel on the site Ban smoking make sure that all naked lights are extinguished and switch off any engines which may be runn...

Page 17: ...nd is there sufficient fuel to complete the job if applicable The Load How heavy is it Is it within the capabilities of the machine How bulky is it The greater the surface area the more affected it wi...

Page 18: ...with the upper structure parallel to the undercarriage 2 If applicable lower the dozer blade 3 Lower the excavator so the dipper is flat on the ground Figure 2 A A Excavator lowered with the dipper f...

Page 19: ...01 Machine 06 About this Manual 01 13 9813 7350 1 01 13 06 About this Manual Contents Page No 01 06 06 Using the Manual 01 15...

Page 20: ...Notes 01 14 9813 7350 1 01 14...

Page 21: ...machine variant the applicable information sets are included within the same PIL reference Headings are included to identify which information is for which variant Make sure you use the correct infor...

Page 22: ...s do not operate as expected 30 00 15 Parallel Open Centre System FF 1 09 27 09 Controls Excavator Arm 30 50 00 Excavator Control Valve Block 30 50 06 ARV Auxiliary Relief Valve FF 1 30 15 00 Cylinder...

Page 23: ...01 Machine 09 Description 01 17 9813 7350 1 01 17 09 Description Contents Page No 01 09 12 Main Component Locations 01 19 01 09 15 Service Point Locations 01 20...

Page 24: ...Notes 01 18 9813 7350 1 01 18...

Page 25: ...9813 7350 1 01 19 12 Main Component Locations Introduction Main Assemblies Figure 3 M A Bucket attachment B Tipping link C Bucket ram D Dipper E Tipping lever F Dipper ram G Boom H Boom ram J Operator...

Page 26: ...Figure 4 Upper structure A D B C E F H G A Cover suction strainer B Breather hydraulic tank C Cover main filter D In line filter cushion valve E Oil filler port slew motor gearbox if applicable F Oil...

Page 27: ...cription 15 Service Point Locations 01 21 9813 7350 1 01 21 Figure 5 Hydraulic compartment A C B D A Servo filter element T2 T4i B In line drain filter element C Servo filter element T4f D Plexus filt...

Page 28: ...B E H C D F G A Exhaust system B Engine oil level dip stick C Crankcase ventilation filter D Fan belt and FEAD Front End Accessory Drive belt E Engine oil filler port F Coolant expansion bottle G Indu...

Page 29: ...int Locations 01 23 9813 7350 1 01 23 Figure 7 Battery cooling compartment A C D E B A Induction air filter outer B Induction air filter inner C Air filter dust valve D Cooling pack E Engine coolant d...

Page 30: ...e 09 Description 15 Service Point Locations 01 24 9813 7350 1 01 24 Figure 8 Hydraulic compartment T2 T4i A B C D A Main fuel filter B Engine fuel filter C Primary fuel filters two filters D Engine oi...

Page 31: ...01 Machine 09 Description 15 Service Point Locations 01 25 9813 7350 1 01 25 Figure 9 Hydraulic compartment T4f B A C A Engine fuel filter B Main fuel filter C Engine oil filter...

Page 32: ...Notes 01 26 9813 7350 1 01 26...

Page 33: ...9813 7350 1 2016 03 22 03 Attachments and Options Contents Page No Acronyms Glossary 03 2 03 00 General 03 00 00 General 03 3 03 10 Excavator Arm Quickhitch 03 10 06 Hydraulic Quickhitch 03 7...

Page 34: ...9813 7350 1 2016 03 22 Acronyms Glossary CAN Controller Area Network DECU Display Electronic Control Unit HECU Hydraulics Electronic Control Unit LED Light Emitting Diode...

Page 35: ...03 Attachments and Options 00 General 03 1 9813 7350 1 03 1 00 General Contents Page No 03 00 00 General 03 3...

Page 36: ...Notes 03 2 9813 7350 1 03 2...

Page 37: ...ents on which it is safe to operate or the safe distance from power lines Practice using attachments off the job before working with them for the first time JCB attachments are designed and manufactur...

Page 38: ...oad on firm level ground Always be alert for possible hazards Take special care when turning or reversing DANGER Before lowering the attachments to the ground make sure that the machine and the area a...

Page 39: ...03 Attachments and Options 10 Excavator Arm Quickhitch 03 5 9813 7350 1 03 5 10 Excavator Arm Quickhitch Contents Page No 03 10 06 Hydraulic Quickhitch 03 7...

Page 40: ...Notes 03 6 9813 7350 1 03 6...

Page 41: ...attachment at the dipper and tipping link A hydraulically operated latch mechanism enables quickhitch compatible attachments to be installed and removed without the need to leave the cab The electro h...

Page 42: ...er position sensor housing B Boom position sensor housing C LED Light Emitting Diode indicator D Position sensing switch located inside housings A and B E Solenoid valve located in the hydraulic compa...

Page 43: ...ncel the request When the HECU receives the input from the switch it will inform the DECU Display Electronic Control Unit via the CAN Controller Area Network bus of a quickhitch unlock request The DEC...

Page 44: ...EP07 ECU HYDRAULIC CONTROL ECU J2 SENSOR ALIGNMENT ARM C154 C158 SENSOR ALIGNMENT BOOM C157 SENSOR PRESSURE QUICK HITCH C156 BUCKET CROWD SELECTED REVOLVER EARTH STUD EP03 REVOLVER EARTH STUD EP03 A Q...

Page 45: ...ECU HYDRAULIC CONTROL ECU J1 C153 JOYSTICK RH HANDLE C095 SOLENOID QUICK HITCH C155 LIGHT QUICK HITCH BOOM STATUS C085 Q H BUTTON PRESSED CAB BASE EARTH POINT INT EP07 REVOLVER EARTH STUD EP03 REVOLV...

Page 46: ...Notes 03 12 9813 7350 1 03 12...

Page 47: ...15 00 General 06 13 06 15 03 Boom 06 15 06 15 06 Dipper 06 19 06 15 15 Tipping Linkage 06 23 06 15 30 Dipper Stroke Limiter 06 27 06 24 Slew Ring 06 24 03 Bearing 06 37 06 24 06 Gear 06 41 06 30 Pivot...

Page 48: ...TI Dial Test Indicator FOGS Falling Object Guard System HECU Hydraulics Electronic Control Unit LED Light Emitting Diode LH Left Hand PCB Printed Circuit Board PIN Product Identification Number RH Rig...

Page 49: ...k 06 Access Cover 06 1 9813 7350 1 06 1 06 Access Cover Contents Page No 06 06 00 General 06 3 06 06 03 Battery 06 4 06 06 06 Engine Compartment 06 6 06 06 07 Cooling Compartment 06 7 06 06 09 Hydraul...

Page 50: ...Notes 06 2 9813 7350 1 06 2...

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