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JCB JS 200W Diagram Schematic Diagram and Fault Finding

1. JS 200W Electrics Schematic Diagram

>>JS 200W Electrics Schematic Diagram

Main Components (CAPS II)

1 Headlamp (RH dip)
2 Headlamp (LH dip)
3 Number Plate Lamp
4 Pressure Switch
5 Coolant Overheat Switch
6 Engine Oil Pressure Switch
7 Refuelling Pump
8 A/C Compressor
9 Washer
10 Heater Assembly
11 Air Conditioning Assembly
12 Battery
13 Work Lamps
14 Fuse Box
15 Relay
16 Oil Temperature Sensor
17 Oil Overheat Switch
18 Changeover Solenoid Valve
19 Stabiliser Solenoid Valve
20 Column Switch
21 Horn
22 Stabiliser Switch Panel
23 Sub Monitor
24 Wheel Controller
25 Status Monitor
26 Harness
27 Harness
28 Harness
29 Harness
30 Harness
31 Controller Assembly
32 Rear Lamp LH
33 Rear Lamp RH
34 Air Filter Switch
35 A/C Pressure Switch
36 Engine Speed Sensor
37 Sensor – Water Temperature
38 Sensor – Hydraulic Oil Temperature
39 Proportional Solenoid Valve
40 Low Flow (Grab)
41 Transmission Valve
42 Solenoid Valve Assembly
43 Low Flow (W/Cut)
44 Amplifier
45 Low Accumulator Pressure Switch
46 Brake Valve Pressure Switch
47 Fuel Level Sensor
48 Resistor Assembly
49 Travel Pilot Pressure Switch
50 Upper Pressure Switch
51 Swing Solenoid Valve
52 Battery Relay
53 Throttle Motor
54 Panel Switch Assembly LH
55 Panel Switch Assembly RH
56 Key Switch
57 Throttle Driver
59 Monitor

2. JS 200W Hydraulics Schematic Diagram

>> Hydraulics Schematic Diagram

Component Key

1 Sump tank
2 Suction Strainer
3 Breather
4 Main Pump
4/1 Pump Proportional Solenoid
5 Proportional Valve
5/2 Fine Mode Proportional Solenoid
5/16 Boom Priority Solenoid
6 Servo Filter
7 Test Point
8 Transmission Control Valve
8/3 Park Brake Solenoid
8/4 Gear Change Solenoid
9 Clutch Accumulator
10 Servo Accumulator
11 Pressure Switch
12 Park Brake Accumulator
13 9 Station Solenoid Valve
13/5 Servo Isolator Solenoid
13/6 Swing Shut Off Solenoid
13/7 Drive Isolation Solenoid
13/8 Axle Lock Solenoid
13/9 Actuator Isolation Solenoid
13/10 Boom Down Speed Regulation Solenoid
13/11 Creep Speed Regulation Solenoid
13/12 Hammer Speed Regulation Solenoid
13/13 Boost Pressure Solenoid
14 Manifold
15 Stabiliser Control Valve
15/17 Stabiliser Up Solenoid
15/18 Stabiliser LHS Solenoid
15/19 Stabiliser RHS Solenoid
15/20 Stabiliser Down Solenoid
16 Joystick RH
17 Servo Valve Pedal
18 Change Over Valve
18/14 Arm/Dozer Solenoid
18/15 TAB /Hammer – Aux Solenoid
19 Joystick LH
20 Shuttle Valve
21 Pressure Switch
22 Manifold Hose Burst Check Valve
23 Manifold Tank
24 Servo Drain Filter
25 Bypass Filter
26 Relief Valve
27 Steering/Brake Filter
28 Steer Valve Unit
29 Brake Valve
30 Pressure Switch
31 Pressure Switch
32 Brake Accumulator
33 Stop Tap
34 Oil Cooler
35 Return Filter
36 Pressure Switch
37 Main Control Valve
38 Swing Motor
39 Swing Gearbox
40 Swing Brake Valve
40/21 Swing Lock Solenoid
40/22 Swing Brake Solenoid
41 Bucket Ram
42 Arm Ram
43 Arm Hose Burst Check Valve
44 Monoboom Boom Ram
45 TAB Boom Ram
46 Boom Hose Burst Check Valve
47 Pressure Switch
48 TAB Ram
49 TAB Hose Burst Check Valve
50 Change Over Valve
51 Hammer Relief
52 Hammer Filter
53 Coupling
54 Coupling
55 Rotary Coupling
56 Drive Motor
57 Transmission
58 Rear Axle
59 Front Axle
60 Axle Lock Ram
61 Tank Manifold
62 Left Hand Dozer Ram
63 Right Hand Dozer Ram
64 Logic Valve
65 Stabiliser Ram
66 Check Valve
67 Relief Valve
68 Check Valve
69 TAB Section Valve
70 Low Flow Valve
70/23 Low Flow Option Solenoid
70/24 Low Flow Option Solenoid
71 Low Flow Valve
72 Test Point
73 Pressure Switch
74 Drive Motor
75 Manifold Tee
76 Stabiliser Manifold
77 Brake Manifold Tee
78 Relief Valve

3. Hydraulics Fault Finding

Some problems which may occur in the hydraulic system are listed below, either for the system as a whole or for individual components

 

1 a 2 a b c Symptom Hydraulic System The hydraulic system is defective or does not operate at all. Hydraulic Pump Oil is not discharged from the pump. Pump output is low. Hydraulic pressure does not increase. The pump makes an abnormal noise. Possible Cause 1 The pump is defective. 2 Dirt is clogging the inside of the relief valve. 3 The relief valve is defective. 4 A ram is worn. 5 Negative pressure is low. 6 A valve is cracked. 7 A spool is not operating over its full stroke. 8 The oil level in the tank is too low. 9 Circuit filters are clogged. 10 The circuit pipes are restricted. 1 The tank strainer or intake pipe is blocked. 2 The end of the inlet pipe is above the tank oil level. 3 One or more of the pump major components is damaged or the input shaft or coupling are defective. 1 The pressure does not increase because of problems with the hydraulic pump or control valve. 2 Internal leakage within the hydraulic pump with excessive fluid drain from pump drain port. 3 Air is being drawn into the pump from the inlet side. 4 Inlet resistance causing cavitation. 1 Oil level is low and the pump is drawing in air. Action Check pump pressure and renew if defective. Dismantle and clean the relief valve. Strip and check the relief valve. Repair or renew the ram. Check circuit pressure. Renew the valve. Check the movement of the spool or the operational linkage. Replenish the oil. Clean or renew filters. Check the piping. Clean the strainer and clean the intake pipe. Replenish the oil tank. Dismantle and inspect pump. Renew damaged components and reassemble the pump. Renew shaft or coupling. Check hydraulic pump and control valve. Renew as required. Strip and inspect the hydraulic pump, paying particular attention to sliding surfaces. Repair or renew as necessary. Reassemble the pump. Check tank oil level and strainer for clogging. Correct as necessary. If OK, check tightness of pump inlet connection. Check correct oil . Check pump low pressure inlet pipe for collapse. Renew as required. Check and replenish oil level. Run the pump under no load to bleed air from the hydraulic system.
Symptom Possible Cause Action
2 Hydraulic Pump (cont’d) 2 3 4 5 6 Clogging of the tank strainer. Oil temperature is too low or wrong oil specification. Coupling defective. The pump is resonating with external equipment. Internal damage to pump. Clean strainer. If strainer is severely clogged, drain and flush hydraulic system. Check correct oil for ambient temperature, see Lubrication Chart, Section 3. Check shaft run out. Check pump mounting bolts for tightness. Tighten as required. Dismantle and inspect pump, paying particular attention to bearings and sliding surfaces.
d Engine overload (engine speed very low or engine stalled). 1 2 3 Regulator torque set too high. The servo flow within the regulator is blocked or internal components are seized. Pump is seized or worn. Adjust as necessary. Remove the regulator from the pump and check filter for blockage. Clean as necessary. If filter OK, dismantle and inspect regulator. Dismantle and inspect pump, paying particular attention to sliding surfaces. Repair or renew as necessary. Reassemble the pump.
e Oil leakage. 1 2 Internal leakage within the pump causing oil seal damage and oil leakage. Damaged or blocked drain pipe. Dismantle and inspect pump, paying particular attention to oil seals and sliding surfaces. Renew as necessary, ensuring that lips of oil seals are not damaged when installed. Inspect and renew as necessary.
3 a Control Valve A spool is sticking. 1 2 3 4 5 6 7 Oil temperature abnormally high. The hydraulic oil is dirty. The service pipe connection is overtightened. The valve housing was twisted during installation. Pressure too high. A spool is bent. A return spring is broken. Check correct oil, see Lubrication Chart, Section 3. Check oil cooler and grille for blockage. Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system. Check tightening torque. Loosen retaining bolts and tighten to correct torque figures. Check system pressure. Renew the control valve section. Renew as necessary.
Symptom Possible Cause Action
3 Control Valve (cont’d) 8 9 A return spring or cap is out of alignment. Temperature distribution within control valve not uniform. Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts. Warm the entire system up before using service.
b A spool does not move over its full stroke. 1 Dirt is clogging the inside of the valve. Remove the dirt (flush out the valve).
c The dipper/boom falls under load with the spool in neutral. 1 2 3 Oil is leaking past the ram/ boom piston seals. Oil is bypassing dipper/boom spool. Oil is leaking past dipper/boom ARV. Renew piston seals. Renew control valve section. Remove ARV and clean housing seat and relief valve seat. Refit ARV.
d The dipper/boom falls under load when the spool is moved to a position higher than neutral. 1 2 Dirt is clogging the load hold check valve. The load hold check valve seat is scratched or damaged. Dismantle and clean the load hold check valve. Renew the poppet or smooth the poppet and seat with very fine emery cloth.
4 a Main Relief Valve System pressure does not rise at all. 1 The main poppet, check valve poppet or pilot poppet is sticking open, or dirt is caught in the valve seat. Remove MRV and dismantle. Inspect and clean all parts. Assemble MRV, ensuring that all parts slide freely. Refit the MRV.
b Relief pressure is unstable. 1 2 The pilot poppet seat is scratched or the pilot piston is sticking with the main poppet. Parts worn. The lock nut and adjusting screw are loose. Remove MRV and dismantle. Inspect and clean all parts. Renew damaged parts or remove scratches with very fine emery cloth. Assemble MRV, ensuring that all parts slide freely. Refit MRV. Tighten the lock nut and reset MRV pressure.
c Oil leak 1 Worn ‘O’ rings. Remove MRV and renew ‘O’ rings.
5 Slew Motor
a Motor does not turn. 1 Internal damage to the motor. Measure the oil drain volume. If the supply volume approaches drain volume, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary.
2 Internal damage to the motor. Disconnect motor inlet and outlet ports and apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try to rotate shaft with a torque of approximately 4.8 – 9.8 Nm (3.6 – 7.2 lbf ft.). If the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary.
Symptom Possible Cause Action
5 a Slew Motor (cont’d) Motor does not turn. (cont’d) 3 Relief valve in the circuit not correctly set. Fit a pressure gauge and measure load pressure Reset as necessary.
4 The pressure does not rise because the relief valve is incorrectly set. 5 The relief valve plunger sticks. 6 The relief valve plunger choke is blocked. 7 The relief valve plunger seat is defective. 8 The motor is thermally seized. 9 The brake piston is stuck. 10 The brake friction plate is thermally seized. Set the relief valve to the correct setting. Dismantle and inspect the relief valve. Repair or renew as necessary. Dismantle and inspect the relief valve. Clean or renew as necessary. Dismantle and inspect the relief valve, paying particular attention to the valve seat. Renew the seat if abrasions or damage is found. Dismantle and inspect the motor, as detailed on page 35-1. Repair or renew as necessary. Dismantle and check the brake, as detailed on page 35-1. Repair or renew as necessary. Dismantle and check the brake, as detailed on page 35-1. Renew as necessary.
b The direction of rotation is reversed. 1 Motor assembled incorrectly. 2 The inlet and outlet pipe connections are reversed. Dismantle and assemble as detailed on page 35-1. Fit pipes to correct positions.
c Motor speed low. 1 The oil flow rate is insufficient. 2 The oil temperature is high and leakage abnormally high. 3 The motor sliding surfaces are worn or damaged. Check the hydraulic pump delivery rate and the circuit up to the motor. Check the oil cooler and grille for damage and blockage. Dismantle and inspect the motor, as detailed on page 35-1. Repair or renew as necessary.
d The superstructure over swings when neutral is selected. 1 High drainage rate within the motor. Check the motor drain flow. If the flow exceeds 500 cc/min., dismantle and inspect the motor, as detailed on page 35-1 paying particular attention to the sliding surfaces. Repair or renew as necessary.
Symptom Possible Cause Action
5 d Slew Motor (cont’d) The superstructure over swings when neutral is selected. (cont’d) 2 3 The A.R.V. is incorrectly set. The relief valve plunger seat is defective. Set the relief valve to the correct setting. Dismantle and inspect the relief valve, paying particular attention to the valve seat. Renew the seat if damage is found.
e Large slip. 1 2 Wear or damage to the motor sliding surfaces or high pressure seal. Oil hot and large leakage in the motor. Measure the oil drain volume. If the volume exceeds 5 litres/min, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary. Reduce oil temperature.
f Insufficient torque. 1 2 Wear or burning of the motor sliding surfaces. ARV in the circuit not correctly set. Disconnect motor inlet and outlet ports and apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try to rotate shaft with a torque of approximately 4.8 – 9.8 Nm (3.6 – 7.2 lbf ft). If the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1 Repair or renew as necessary. Fit a pressure gauge and measure load pressure, Reset as necessary.
g Abnormal noise. 1 2 3 Internal damage to the motor. Large amounts of air in the oil. Loosening of bolts or connections. Check for metallic particles in the motor drain oil or drain filter. If particles found, dismantle and inspect as detailed on page 35-1. Repair or renew as necessary. Check the oil in the tank and motor casing. Bleed the system. Check pipe connections, mounting bolts for tightness. Retighten to specified torque.
h Abnormal heating. 1 Burning of the motor sliding or turning parts. Check for metallic particles in the motor drain oil or drain filter. Also apply servo pressure of 19.6 bar (284 lb. in2) to the brake release port. Try to rotate the shaft with a torque of approximately 4.8 9.8 Nm (3.6 – 7.2 lbf ft). If particles found or the shaft does not rotate smoothly, dismantle and inspect as detailed on page 35-1 Repair or renew as necessary.
Symptom Possible Cause Action
5 Slew Motor (cont’d)
j Leaks from the oil seal. 1 2 3 Damage or wear to oil seal lip. Damage or wear to shaft seal. Abnormal pressure in the casing. Renew the oil seal, as detailed on page 35-1. Repair the problem or renew the motor assembly. Set the pressure in the casing to below 2.9 bar (43 lb in2) and check drain volume. If drain volume large, dismantle and inspect as detailed on page 35-1. Renew the oil seal and, if possible, repair or renew other damaged parts.
k Oil leaks from mating surface. 1 2 3 An ‘O’ ring is damaged. The seal face is damaged. Bolts are loose. Renew ‘O’ ring. Repair seal face or renew. Check bolts and tighten to the specified torque.
6 a Remote Control Valves Low secondary pressure 1 2 3 4 Servo pressure is low. Spring 14 is damaged. The clearance between the spools and casing is too large. The handle unit is loose. Check servo pressure as detailed on page 26-2 and adjust as necessary. Renew spring. Renew spool and casing assembly. Renew the handle unit.
b Unstable secondary pressure. 1 2 Sliding parts are sticking. Air is trapped in the pipes. Dismantle and inspect as detailed on page 26-2. Repair or renew as necessary. Operate the valve several times to remove the air.
c High secondary pressure. 1 Sliding parts are sticking. Dismantle and inspect as detailed on page 26-2. Repair or renew as necessary.

4. Hydraulics Slew Motor  Fault Finding

 

Symptom Cause External Inspection Countermeasure Repair
Motor does not run Internal damage to the motor. Measure the oil drain volume. High possibility of damage to the sliding surfaces if the supply volume is approximately equal to the drain volume. Dismantle and inspect. Refer to Table 2.
Internal damage to the motor. Open the motor inlet and outlet ports and apply 20 kgf/cm2 (284 lbf/in2) pilot pressure to the brake release port. Try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft). High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect. Renew damaged parts or renew the motor assembly.
Relief valve in circuit not set correctly. Measure pressure. Reset to the prescribed setting.
Excessive slip Wear or damage to the motor sliding surfaces or to the high-pressure seal. Measure the oil drain volume. Leakage is too high if the oil drain volume exceeds 5 l/min (1.1 gal/min). Dismantle and inspect. Refer to table 2.
Oil hot and excessive leakage in the motor. Measure the oil temperature. Reduce the oil temperature. Refer to table 2.
Abnormal heating Seizure of motor sliding parts or circuit. Check for any metallic matter deposited in motor drain oil or drain filter. Apply a 30 kgf/cm2 (427 lbf/in2) pilot pressure to the brake release port and try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft). If metallic matter is discovered or the supply shaft does not rotate smoothly when torque is applied, there is a high possibility of internal damage to the motor. Dismantle and inspect. Repair or renew the damaged parts. Renew the motor assembly.
Leakage from oil seals Damage or wear to oil seal lip. Renew the oil seals.
Damage or wear of the shaft seal. Repair the problem or renew the motor assembly.
Abnormal pressure in the casing. Check the pressure in the casing and measure the drain volume. Set the pressure in the casing below 3 kg/cm2. (43 lbf/in2) Dismantle and inspect if drain volume is excessive. Renew the oil seal. Repair or renew the damaged parts. Renew the motor assembly.
Symptom Cause External Inspection Countermeasure Repair
Wear or seizure of the Open motor inlet and High possibility of Inspect the parts and
motor sliding surfaces. outlet ports and apply 20 kgf/cm2 (284 lbf/in2) pilot internal damage to the motor if the supply shaft bearing according to Table 2 a-e and renew
pressure to the brake does not rotate smoothly any defective parts.
release port.Try to rotate when this torque is
Insufficient torque the shaft with a torque of applied. Dismantle and
approx. 39.32 Nm inspect.
(29 lbf ft).
Relief valve in the circuit Measure relief pressure. Reset to the prescribed
is not set correctly. setting.
Internal damage to the motor. Check if any metallic matter is deposited in the motor drain oil or drain filter. High possibility of internal damage to the motor if metallic matter is discovered. Repair or renew damaged parts. Renew the motor assembly.
Dismantle and inspect.
Large amount of air Check the oil in the tank Thoroughly bleed the air.
Abnormal noise mixed in the oil. and motor casing.
Loosening of bolts or pipes Check if the piping connections, attachment mounting bolts, motor attachment bolts or other Tighten to the specified torque.
bolts are loose.
age fromsurfaces O-ring is damaged Renew O-rings.
Seal face is damaged. Repair seal face or
Oil leakmating renew.
Bolts are loose. Check the bolt tightness. Tighten the bolts to the correct torque.
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