Need the complete factory teardown procedures for your 2004 JCB JS crawler excavator? This 885-page JCB JS200 service manual PDF (OEM #9803/6580-6) breaks down every system for the JS200, JS220, JS235, JS240, and JS260 variants. Inside, you get extensive electrical diagrams, full hydraulic circuit descriptions, and a fault-finding section covering everything from the main control valve to the track gearbox. Open up to complete engine error code charts and detailed step-by-step procedures for rebuilding the remote control valves and travel pedals. Lock down the turntable bearing slew frame bolts to exactly 525 Nm (387 lbf ft) and verify the HYD TMP sensor is not throwing an open-circuit fault before running the equipment. Stop waiting on dealer callbacks while your machine sits idle. Download this bookmarked file directly to your tablet, jump straight to the right section, and get back to work.
Complete the set for your JS200–JS260 Series
Other edition of this manual
What's Inside This Manual
| System | Pages | Key Topics |
|---|
| General Information | 1-44 | Introduction (Identifying Your Machine), Torque Settings (Zinc Plated Fasteners and Dacromet Fasteners, Hydraulic Connections) |
| Care and Safety | 45-64 | Safety Check List, General Safety, Operating Safety, Maintenance Safety, Safety Labels |
| Maintenance | 65-176 | Routine Maintenance, Health and Safety, Service Schedules, Fluids, Lubricants and Capacities, Tools, Prepare the Machine for Maintenance, Cleaning the Machine |
| Body & Framework | 177-226 | Technical Data, Basic Operation, Fault Finding, Service Procedures, Cab Structure, Cab Panels |
| Electrics | 227-455 | Basic System Operation, Fault Finding, Service Procedure, Harness Data |
| Hydraulics | 456-725 | Technical Data, Basic System Operation, Circuit Descriptions, Main Control Valve, Hydraulic Pump/Regulator, Remote Control Valve (Hand Control), Travel Pedal Valve |
| Transmission | 726-793 | Technical Data, Basic System Operation, Removal and Replacement, Start Up and Running in, Fault Finding, Track Motor, Track Gearbox |
| Track and Running Gear | 794-832 | Technical Data, Idler Wheel and Recoil Unit, Idler Wheel, Recoil Unit, Grease Cylinder, Drive Sprocket, Top Roller, Bottom Roller |
| Engine | 833-885 | Technical Data, Engine Error Codes, Fault Finding |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| JS200-260 |
| Turntable Bearing (Slew Frame) Tightening Torque | 525 Nm (387 lbf ft) | p. 118 |
| Lower (Track) Roller Tightening Torque | 290 Nm (213 lbf ft) | p. 118 |
| Engine (Engine Mount) Tightening Torque | 290 Nm (213 lbf ft) | p. 118 |
| Hydraulic Pump Tightening Torque | 68 Nm (50 lbf ft) | p. 118 |
| All Models |
| HYD TMP (Hydraulic Temperature Sensor) | The hydraulic temperature sensor is open-circuit. | p. 385 |
| Engine oil filter replacement | Tighten the filter until the seal bites onto the filter housing, then a minimum of one more full turn. | p. 125 |
| Servo Filter Element replacement | Change | p. 77 |
| Return Filter Element replacement | Change | p. 77 |
| JS115-JS145 |
| Engine Oil Capacity, JS115-JS145 | 15 litres | p. 84 |
| JS200-JS235 |
| Engine Oil Capacity, JS200-JS235 | 23.5 litres | p. 86 |
| Fuel Tank Capacity | 343 litres | p. 86 |
| JS240/260 |
| Hydraulic System Capacity | 241 litres | p. 87 |
