PDF Service Manual JCB JS210 LC Tracked Excavator - 1 MB
Get the complete service and repair information for your JCB JS210 LC tracked excavator.
This manual provides detailed instructions for troubleshooting, disassembly, and repair of all major components including the engine, hydraulics, and electrical systems.
It is the same resource used by professional JCB technicians to keep these powerful machines running at peak performance.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
General Information 1
Care & Safety 2
Routine Maintenance 3
Attachments A
Service
Body & Framework B
Manual
Electrics C
JS 210 LC
110026 On
Hydraulics E
Transmission F
Brakes G
PUBLISHED BY THE
PRODUCT SUPPORT DEPARTMENT Track & Running Gear J
OF JCB SERVICE :
23/7, MATHURA ROAD,
BALLABHGARH, FARIDABAD
TEL. : 0129-4299000
Engine K
Part No. : 9803/6510
--- Page 3 ---
Section 1 General Information Section 1
4-4 Service Tools 4-4
Service Tools
SECTION C - Electrics
Electrical Test Equipment
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
10 Issue 1
--- Page 4 ---
Section 1 General Information Section 1
4 - 14 Service Tools 4 - 14
Service Tools (cont’d)
SECTION F - Transmission
Track Gearbox Jig
STO037Re-sealing Tool
(All dimensions are in mm.)
Stopper for the assembly of Hydraulic A409010
motor on track gearbox
20 Issue 1
--- Page 5 ---
Section 2 Care and Safety Section 2
1-6 1-6
Maintenance Safety (cont’d) WARNING
Arc Welding
CAUTION Before carrying out any arc welding on the machine,
completely remove the Control Computer and The Display
‘0’ rings, Seals and Gaskets
Monitor to avoid damage to the circuits; also disconnect the
Badly fitted, damaged or rotted ‘0’ rings, seals and gaskets
alternator and battery leads.
can cause leakages and possible accidents. Renew
whenever disturbed unless otherwise instructed. Do not use
When welding items to the mainframe make sure that the
Trichloroethane or paint thinners near ‘0’ rings and seals.
earth clamp is positioned on the mainframe and when
INT-3-2-12
welding to the undercarriage make sure that the earth clamp
is positioned on the undercarriage. If you earth one and
WARNING weld the other, you may cause severe damage to the slew
Battery ring.
A battery with frozen electrolyte can explode if it is used or
charged. Do not use a machine with a frozen battery. To help Always connect the earth clamp to any other component
prevent the battery from freezing, keep the battery fully being welded, i.e. boom or dipper, to avoid damage to pivot
charged. pins and bushes.
INT-3-1-7 0008
WARNING WARNING
Battery Gases Repairs
Batteries give off explosive gases. Keep flames and sparks Do not try to do repairs or any other type of maintenance
away from the battery. Do not smoke close to the battery. work you do not understand. Get a Service Manual from
Make sure there is good ventilation in closed areas where your JCB distributor, or get the work done by a specialist
batteries are being used or charged. Do not check the battery engineer.
charge by shorting the terminals with metal; use a hydrometer INT-3-1-1
or voltmeter.
INT-3-1-8 WARNING
Metal Splinters
WARNING You can be injured by flying metal splinters when driving
Battery Terminals metal pins in or out. Use a soft faced hammer or drift to
The machine is negatively earthed. Always connect the remove and fit metal pins. Always wear safety glasses.
negative pole of the battery to earth. INT-3-1-3
When connecting the battery, connect the earth (-) lead last.
When disconnecting the battery, disconnect the earth (-) lead
first.
INT-3-1-9
CAUTION
Never use water or steam to clean inside the cab. The use of
water or steam could damage the on-board computer and
render the machine inoperable. Remove dirt using a brush
or damp cloth.
8-3-4-8
WARNING
Petrol
Do not use petrol in this machine. Do not mix petrol with the
diesel fuel; in storage tanks the petrol will rise to the top and
form flammable vapours.
INT-3-1-6
30 Issue 1
--- Page 6 ---
Section 3 Routine Maintenance Section 3
3-2 Service Schedules 3-2
Regular Maintenance and Lubrication Schedules
A poorly maintained machine is a hazard. Doing the regular Initial Precautions for New Machine Usage :-
maintenance and lubrication jobs listed in these schedules
will help keep the machine in safe running order.
CAUTION
Apart from the daily jobs, the schedules are based on machine If the machine is operated at full load before its initial
running hours. Keep a regular check on the hour meter run-in procedure is complete it may cause scuffing and
reading. Do not use a machine which is due for a regular seizing which can adversely effect the life of the machine.
service. Rectify any defects found during regular maintenance 8-3-1-5
before clearing the machine for use.
A new machine is only dispatched when all inspection
procedures are complete, but operating it under severe
WARNING conditions from new will affect its performance and shorten
Maintenance must be done only by suitably qualified and its service life.
competent persons.
1 Carry out the daily inspection procedure.
Before doing any maintenance make sure the machine
is safe, it should be correctly parked on level ground. 2 Always warm up the machine (see Warming-up under
Using Your Machine).
To prevent anyone starting the engine, remove the starter
key. Disconnect the battery when you are not using 3 Check to see if the machine is running normally.
electrical power. If you do not take these precautions you
could be killed or injured. 4 Avoid running or slewing the machine rapidly. ‘-
8-3-1-1
5 Avoid sudden shocks e.g. suddenly stopping the boom
when lowering.
6 Where applicable, grease the front pins daily.
40 Issue 1
--- Page 7 ---
Section 3 Routine Maintenance Section 3
7-1 Fuel System 7-1
Types of Fuel Filling the Tank and Fuel Level Checking
Use good quality diesel fuel to get the correct power and For location of fuel tank refer to Identification of Machine
performance from your engine. The recommended fuel Components at the end of this section
specification is given below.
WARNING
Cetane Number : 45 (minimum) Diesel fuel is flammable. Keep flames away from the
Viscosity : 2.5/4.5 centistokes at 40°C (104°F) machine. Do not smoke while fuelling the machine or
Density : 0.836/0.866 kg/litre (1.046/1.084 Ib/pint) working on the engine. Do not refuel with the engine
Sulphur : 0.5% of mass (maximum) running. There could be a fire and injury if you do not
follow these precautions.
Distillation : 85% at 350°C (662°F) INT-3-2-2
Cetane Number 1 Prepare the Machine
Indicates ignition performance. Fuel with a low cetane number Park the machine on level ground. Lower the bucket
can cause cold start problems and affect combustion. to the ground.
2. Stop the Engine
Viscosity Remove the starter key.
This is the resistance to flow. If this is outside limits, the engine 3 Filling the tank
performance can be affected. a At the end of every working day, fill the tank with
the correct type of fuel. This will prevent overnight
Density condensation from developing in the fuel tank.
Lower density will reduce engine power. Higher density will b We recommend that you lock the fuel cap to prevent
increase both engine power and exhaust smoke. theft and tampering.
c After filling, check the fuel level by looking at the fuel
Sulphur gauge.
High sulphur content can cause engine wear. (High sulphur
fuel is not normally found in North America, Europe or Petrol
Australia). If you have to use a high sulphur fuel you must
also use a highly alkaline engine lubricating oil; or change WARNING
the normal oil more frequently. Do not use petrol in this machine. Do not mix petrol with,
the diesel fuel, in storage tanks the petrol could rise to
Distillation the top and form flammable vapours.
This indicates the mixture of different hydrocarbons in the INT-3-1-6
fuel. A high ratio of lightweight hydrocarbons can affect the
combustion characteristics.
Low Temperature Fuels
Special winter fuels may be available for engine operation at
temperatures below DoC (32°F). These fuels have a lower
viscosity. They also limit wax formation in the fuel at low
temperatures. (Wax forming in the fuel can stop the fuel flowing
through the filter).
Flow improvers may also be available. These can be added
to the fuel to reduce wax formation.
Advice
Consult your fuel supplier or JCB distributor concerning the
suitability of any fuel you are not sure about. If you have to
use non-standard fuels, contact your JCB distributor for advice
on engine adjustments and oil change periods.
Fatty Acid Methyl Ester Fuels as a replacement for Diesel
Fuels
Fuel resources such as Rape Methyl Ester and Soybean
Methyl Ester, collectively known as Fatty Acid Methyl Esters
are being used as alternatives and extenders for mineral oil.
Fatty Acid Methyl Esters must conform to certain standards
to be of acceptable quality, just as mineral oils do at present.
Consult your JCB distributor for advice about the use of Fatty
Acid Methyl Ester fuels, as improper application may impair
engine performance.
50 Issue 2*
--- Page 8 ---
Section 3 Routine Maintenance Section 3
8-7 Engine 8-7
Changing The Coolant Coolant Mixtures
1 Do Steps 1 and 2 of Checking the Coolant Level. To prevent the coolant freezing in cold conditions, antifreeze
must be added. JCB Four Seasons Antifreeze and
2 Drain the system. Summer Coolant will give protection down to the
Remove the radiator pressure cap. Open the radiator drain temperatures shown in the table.
tap A. Remove the cylinder block drain plug B. Remove the
expansion bottle cap (see Checking the Coolant Level). Antifreeze Solution Starts to freeze at
Let the coolant drain out. 55% -36°C (-33°F)
Never use less than a 50% solution, otherwise there will not
CAUTION be enough corrosion protection.
Keep your face away from the drain hole when removing
the drain plug. Never use more than 60% solution, otherwise the cooling
2-3-3-4 system may be damaged.
3 Flush the system Leave the antifreeze in all the year round as it gives. protection
If necessary. Use clean water. against corrosion.
4 Refit the drain plug Check the strength of antifreeze solution at least once a
Clean and refit the cylinder block drain plug, making sure year, preferably at the start of the cold period. Always renew
it is tight. Close the radiator drain tap. the antifreeze every two years.
5 Fill the system A 50% antifreeze mixture should be used even if frost
Using the necessary mix of clean, soft water and antifreeze protection is not needed. This gives protection against
(see Coolant Mixtures) fill via the expansion bottle cap corrosion and raises the coolant’s boiling point.
until the level in the bottle is between the FULL and LOW
marks.
6 Refit the Radiator Pressure Cap
Make sure it is tight.
7 Refit the Expansion Bottle Cap
Make sure it is tight.
8 Check for Leaks
Run the engine for a while to raise the coolant to working
temperature and pressure. Stop the engine. Check for
leaks. Re-check the level in the expansion bottle and top
up if necessary.
60 Issue 1
--- Page 9 ---
Section 3 Routine Maintenance Section 3
10 - 1 Battery 10 - 1
WARNING Checking the Electrolyte Level
Batteries give off an explosive gas. Do not smoke when Maintenance free batteries used in normal temperate climate
handling or working on the battery. Keep the battery away applications should not need topping up. However, in certain
from sparks and naked flames. conditions (such as prolonged operation at tropical
Battery electrolyte contains sulphuric acid. It can burn temperatures or if the alternator overcharges) the electrolyte
you if it touches your skin or eyes. Wear goggles. Handle level should be checked as described below.
the battery carefully to prevent spillage. Keep metallic
items (watches, rings, zips etc) away from battery 1 Open the Battery Compartment A
terminals. Such items could short the terminals and burn Remove the bolts securing the metal plate above the
you. batteries. Remove the plate.
Set all switches in the cab to OFF before disconnecting
the battery. When disconnecting the battery, take off the
earth (-) lead first.
When reconnecting, fit the positive (+) lead first.
Re-charge the battery away from the machine, in a well-
ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you have
installed the battery in the machine, wait five minutes JSO3353
before connecting it up.
First Aid - Electrolyte 2 Check the Level
Do the following if electrolyte: Remove the covers and check the electrolyte level in each
cell. The electrolyte should be 15 mm (0.6 in) above the
GETS INTO YOUR EYES plates.
Immediately flush with water for 15 minutes always get Top-up if necessary with distilled water or de-ionised
medical help. water.
IF SWALLOWED
Do not induce vomiting. Drink large quantities of water or WARNING
milk. Then drink milk of magnesia, beaten egg or vegetable Do not top the battery up with acid. The electrolyte
oil. Get medica! help. Icould boil out and burn you.
2-3-4-6
GETS INTO YOUR SKIN 3 Check the Connections
Flush with water, remove affected clothing. Cover burns with Make sure that the terminals are tight and clean. Coat
a sterile dressing then get medical help. them with petroleum jelly to prevent corrosion.
5-3-4-3/1
CAUTION
Do not disconnect the alternator, the battery, or any part
of the charging circuit with the engine running.
8-3-4-1
A361680
70 Issue 1
--- Page 10 ---
Section 3 Routine Maintenance Section 3
16 - 1 Trouble Shooting 16 - 1
To extend the service life and improve the operation of the machine, daily inspection and lubrication are necessary as well as
immediately isolating any problem found and dealing with it. If the machine is operated with the problem uncorrected, it may
lead to larger trouble and possibly to a big accident.
If trouble occurs, search for the cause in the items below and make adjustments, repairs, etc. as necessary.
Engine and Related Area
Problem Cause Remedy
Defective starter switch (Starter does not run) Connect, repair connection.
Defective rotation of starter (Starter rotates slowly) Discharged battery, starter problems,
contaminated or loose wiring connection.
Improper viscosity of engine oil Inspect and replace as necessary.
Excessive cooling of engine (Cold weather) Preheat with air heater.
Warm up the coolant (add hot water).
Engine does not start Possible seizure in engine *Repair.
Incomplete air bleeding of fuel system Completely bleed air.
No fuel in fuel tank Refill.
Fuel quality unsuitable Inspect and replace as necessary.
Fuel filter clogged Clean or replace.
Low compression *Repair
Defective fuel injection pump *Repair.
No fuel in fuel tank Refill.
Engine stops during Fuel filter clogged Clean and replace.
operation Air is mixed in the fuel system Retighten fuel pipe connections and bleed
system.
Low oil Refill.
Defective oil pressure switch Replace.
Low oil Oil filter clogged Replace element.
pressure Low oil viscosity Replace with oil of viscosity matching
temperature.
Improper operation of oil pump *Replace parts.
Oil leakage at connections Tighten connections.
Excessive oil consumption Disassemble and repair, replace parts.
Excessively low oil viscosity Replace with correct oil.
Exhaust gas from Excessive cooling by radiator Adjust.
engine is white or blue Improper fuel injection timing *Adjust or replace if necessary.
Low compression *Disassemble and repair, replace parts.
Improper fuel Replace with correct fuel.
Exhaust gas from Improper valve clearance Adjust.
engine is black or Defective fuel injection pump/injectors *Adjust or replace if necessary.
dark grey Low compression *Disassemble and repair, replace parts.
Insufficient air intake (air cleaner clogged) Clean or replace the element.
Defective fuel injection pump *Adjust or replace if necessary.
Improper spray from fuel injection nozzle *Adjust or replace if necessary.
Excessive fuel Improper fuel injection timing *Adjust or replace if necessary.
consumption Improper fuel Replace with correct fuel.
Low compression Disassemble and repair, replace parts.
Insufficient air intake Clean or replace element.
Excessive oil Drain oil to proper level.
Low oil viscosity Replace with oil of viscosity matching
Excessive engine oil temperature.
consumption Oil leakage Retighten and replace parts if necessary.
Worn cylinder piston rings *Disassemble and repair, replace parts.
Abnormal noise.(Fuel Bad fuel Replace.
or mechanical) Damage inside muffler Replace.
*Refer to Engine Service Manual Publication No. 9803/2210
80 Issue 1
--- Page 11 ---
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 Hexagon (A/F) Torque Settings
In (mm) In Nm kgf m Ibf ft
1/4 (6.3) 7/16 14 1.4 10
5/18 (7.9) 1/2 28 2.8 20
3/8 (9.5) 9/16 49 5.0 36
7/16 (11.1) 5/8 78 8.0 58
1/2 (12.7) 3/4 117 12.0 87
9/16 (14.3) 13/16 170 17.3 125
5/8 (15.9) 15/16 238 24.3 175
3/4 (19.0) 11/8 407 41.5 300
7/8 (22.2) 15/16 650 66.3 480
1 (25.4) 11/2 970 99.0 715
11/4 (31.7) 17/8 1940 198.0 1430
11/2 (38.1) 21/4 3390 345.0 2500
Metric Grade 8.8 Bolts
Bolt Size Hexagon (A/F) Torque Settings
(mm) mm Nm kgf m Ibf ft
M5 (5) 8 7 0.7 5
M6 (8) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
River Nut Bolts/Screws
Bolt Size Torque Settings (for steel rivet nuts)
(mm) Nm kgf m Ibf ft
M3 (3) 1.2 0.12 0.9
M4 (4) 3.0 0.3 2.0
M5 (5) 6.0 0.6 4.5
M6 (6) 10.0 1.0 7.5
M8 (8) 24.0 2.5 18.0
M10 (10) 48.0 4.9 35.5
M12 (12) 82.0 8.4 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
--- Page 12 ---
Section 1 General Information Section 1
4 - 10 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
--- Page 13 ---
Section B Body & Framework Section B
1-3 Service Tools 1-3
Service Tools
Rubber Spacer Blocks - used to provide the correct
set clearance between glass edge
and cab frame.
Nylon Spatula - JCB part number - 926/15500
(unit quantity = 500 off) (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 S186550
826/01099 M6 x 16mm Rivet Nut
826/01101 M6 x 19mm Rivet Nut
826/01103 M8 x 18mm Rivet Nut
826/01102 M8 x 21 mm Rivet Nut
826/01104 M10 x 23mm Rivet Nut
826/01105 M10 x 26mm Rivet Nut
Installation Tool Available from:
Bollhoff Fastenings Ltd.
Midacre
The Willenhall Estate
Rose Hill
Willenhall
West Midlands, WV13 2JW
S261210
89 Issue 1
--- Page 14 ---
Section B Body & Framework Section B
2-9 Technical Data 2-9
Weights
B
C
A
G D
H
E
F
I
S409590
99 Issue 2*
--- Page 15 ---
Section B Body & Framework Section B
3-1 Basic Operation 3-1
Air Conditioning
*