Part of the JCB Repair Manuals.
Diagnosing and rebuilding the JCB JS200W wheeled excavator, standard and Tier III builds alike, is what this 557-page JCB JS200W service manual PDF (publication 9803/9540-6) was written for. Hydraulic schematics, colour-coded to the factory key, trace oil from the pump through the main control valve and remote control valve, and the hydraulics and electrics chapters together fill roughly two fifths of the book. Wiring diagrams sit with harness data and A.M.S fault finding for your electrical work, while the transmission chapter covers both axles, the drive gearbox and propshafts, and the engine chapter carries its own error codes. Fill the hydraulic system to 200 L, and seat the pilot filter bowl at 24.4 to 34.3 Nm. An intermittent fault in an unmarked harness can idle a crew all day. Bookmarked and text-searchable, this copy is yours to keep for as long as the JS200W stays on your fleet.
What's Inside This JCB JS200W, JS200W TIER III Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 6-11 | Identifying Your Machine (Machine Identification Plate, FOPS Data Plate, Component Identification Plates) |
| Standard Torque Settings | 12-19 | Zinc Plated Fasteners and Dacromet Fasteners (Introduction, Bolts and Screws), Hydraulic Connections (O Ring Face Seal System, Torque Stop Hose System) |
| Service Tools | 20-43 | Numerical List, Tool Detail Reference (Body and Framework, Electrics, Hydraulics, Engine) |
| Service Consumables | 44-45 | Sealing and Retaining Compounds |
| Terms and Definitions | 46 | Colour Coding, Hydraulic Schematic Colour Codes |
| Care and Safety | 47-66 | Safety Notices, Operator Manual, Safety Warnings, Safety Check List, Safety Labels |
| Maintenance | 67-166 | Routine Maintenance, Service Schedules, Fluids and Lubricants, Engine Maintenance, Fuel System, Hydraulic System, Troubleshooting |
| Body and Framework | 167-206 | Static Dimensions, Operating Weight, Air Conditioning, Cab Structure, Cab Panels |
| Electrics | 207-306 | Basic System Operations, A.M.S, Circuit Concepts, Fault Finding, Harness Data |
| Hydraulics | 307-406 | Hydraulic Schematics, Circuit Descriptions, Main Control Valve, Hydraulic Pump, Remote Control Valve |
| Transmission | 407-506 | Front Axle, Rear Axle, Drive Gearbox, Propshafts |
| Engine | 507-557 | Engine Mounts, Engine Error Codes, Fault Finding, Engine Components, Schematics |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| EGR cooler plug torque | 25 Nm | p. 121 |
| Pilot filter bowl torque (Item A) | 24.4 to 34.3 Nm, 2.5 to 3.5 kgf m, 18.07 to 25.5 lbf ft | p. 151 |
| Engine Oil Capacity (JS200W) | 24.5L | p. 88 |
| Cooling System Capacity (JS200W) | 33.3L | p. 88 |
| Hydraulic System Capacity (JS200W) | 200L | p. 88 |
| Slew Gearbox Oil Capacity (JS200W) | 5L | p. 88 |
| Main Relief Valve Pressure | 372 bar | p. 314 |
| Transmission Relief Setting | 420 bar | p. 315 |
| Engine Power (JS200W) | 128 KW | p. 511 |
JCB JS200W, JS200W TIER III Common Problems This Manual Covers
JCB JS200W wheeled excavator common rail diesel engine does not start or stops during operation
Check the fuel system first, then read stored codes against the Engine Error Codes tables. Test common rail pressure, injectors, glow plugs and the engine sensors using the Engine Component Fault Finding procedure for your engine, 4HK/6HK or 4JJ. Work through the Engine Troubleshooting chart before condemning a sensor or injector.
Manual Section: Engine TroubleshootingEngine oil level topped up correctly but low oil pressure still shows during operation
Check the engine oil level and grade against the Fluids and Lubricants data before anything else. Then work through the low oil pressure branch of the Engine Troubleshooting chart. Test the engine switches and sensors using Engine Component Fault Finding, and read any stored engine trouble codes before replacing parts.
Manual Section: Engine TroubleshootingMain relief valve or hydraulic pump fault with all hydraulic rams slow and weak under load
Check the hydraulic oil for contamination first, then fit a gauge and test main relief pressure following page 314. Compare the reading against 372 bar. If relief pressure holds but the rams stay slow, test the hydraulic pump and main control valve using the Hydraulic Fault Finding checks before stripping any ram.
Manual Section: Hydraulic Fault Finding p. 314Slew motor or main control valve fault with slew slow or not operating
Check the hydraulic oil for contamination before suspecting the motor. Confirm main relief pressure so you are not chasing a supply problem, then test the main control valve and slew motor using the Hydraulic Fault Finding checks. Inspect the slew gearbox oil level before ordering parts.
Manual Section: Hydraulic Fault FindingHydraulic oil contamination found with debris collecting in the pilot filter bowl
Drain a sample and check the hydraulic oil condition, then work through the contamination checks in Hydraulic Fault Finding. Remove the pilot filter bowl, clean it, replace the filter, and torque the bowl following page 151 to 24.4 to 34.3 Nm. Find the contamination source before refilling the system.
Manual Section: Hydraulic Fault Finding p. 151Cab air conditioning not working with an air conditioning error code displayed
Check the preliminary items in Air Conditioning Fault Finding first. Read the displayed code and look it up in the error code table on page 188, then follow the matching error diagnosis steps. Run the system afterward to confirm the code does not return.
Manual Section: Air Conditioning Fault Finding p. 188Frequently Asked Questions
How do you calibrate the throttle potentiometer on a JCB JS200W?
During calibration, the ECU notes the maximum and minimum positions of the throttle position sensor. The maximum point becomes the A mode maximum. When the working mode is selected, the ECU scales the full deflection of the throttle dial (0-5V) to adjust the engine speed between the idle position and the maximum speed for the particular mode selected. p. 96
What is the recommended torque setting for the engine mounting bolts (M16) on a JS200W?
The recommended torque setting for the engine mounting bolts (M16) on a JS200W is 289 Nm (213 lbf ft). p. 116
What is the engine oil capacity for a JCB JS200W?
The engine oil capacity for a JS200W is 24.5 litres (5.4 UK gal) (6.5 US gal). p. 88
What is the valve clearance for the engine on a JS200W?
The valve clearance for both the inlet and exhaust valves on the JS200W engine is 0.40 mm (0.016 in) when cold. p. 511
How often should the hydraulic oil be sampled when using a breaker, crusher, or pulverizer?
When using a breaker, crusher, or pulverizer, the hydraulic oil sampling interval depends on the frequency of use. For greater than 75% use, it should be sampled every 200 hours. For 10-25% use, it should be sampled every 600 hours. p. 84
Do I get instant access to this JCB JS200W Service Manual?
Delivery is instant: a 557-page searchable PDF is yours the second checkout clears. Laptop, tablet, or phone, all fine.
Can I print a copy of this JCB JS200W Service Manual for the shop?
Yes. Print a chapter or just the pages for the job at hand, for use in your own shop. Any home or office printer works.
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