2006 JCB JS200, JS210, JS220, JS240 & JS260 Tracked Excavator Service & Repair Manual (P/N 9803/6400)

JCB service manual P/N 9803/6400, with Issue 2 on the cover and revised pages within individual sections, covers 1998–2005 JS200, JS210, JS220, JS240, and JS260 tracked excavators, including LC variants. Machine-number starting points are listed above; individual sections distinguish configurations where different data applies.

• Electrical diagnosis: Controller self-tests, CAPS II fault logging, sensor resistance tables, throttle motor replacement, automatic adjustment, and electrical fault-finding charts.

• Hydraulic pump and valves: Pressure testing, pump and regulator overhaul, control valve servicing, and troubleshooting for pilot, relief, and solenoid-operated circuits.

• Hydraulic ram repair: Boom, dipper, and bucket ram removal, seal replacement, reconditioning, piston head nut tooling, and post-assembly inspection.

• Travel and slew systems: Track motor and planetary gearbox dismantling, assembly, bleeding, and fault diagnosis, plus rotary coupling and slew motor repair.

• Track and running gear: Idler, recoil unit, grease cylinder, sprocket, and roller servicing, with component-specific wear limits and torque specifications.

• Cab and air conditioning: Direct glazing procedures, refrigerant circuit descriptions, leak testing, charge-level checks, and air-conditioning diagnostic charts.

• Routine maintenance: Service schedules, lubricant specifications, filter replacement, fuel-system bleeding, cooling-system care, track tension checks, and performance evaluation.

Written for JCB distributor service engineers receiving or having completed JCB technical training, this manual assumes sound workshop practice and experience maintaining and repairing hydraulic earthmoving equipment.

Electrical Diagnosis and Controller Adjustment

The electrical section connects monitor messages with fault-finding flow charts, connector checks, and sensor specifications. CAPS II coverage explains intermittent electrical fault storage and machine-performance logging, allowing technicians to investigate faults that may disappear when the machine is restarted.

Throttle motor and linkage replacement includes automatic adjustment and controller setup for machine identification. The out-of-step diagnosis explains the relationship between throttle position, limit-switch signals, and the “0000” clock display. A corroded throttle-link spring chamber that cannot compress can damage the throttle motor.

A.M.S. coverage: An introductory page identifies the Advanced Management System and the applicable machine numbers for separate supplement P/N 9803/6450. Detailed A.M.S. supplement coverage should not be confused with the CAPS II procedures included here.

Hydraulic Testing and Component Repair

Pump, regulator, main control valve, remote control valve, rotary coupling, and slew motor sections combine operating descriptions with dismantling, assembly, and inspection information. Pressure-testing coverage distinguishes main relief, pilot relief, accumulator, individual ram circuits, and travel motor relief.

Variant-specific data: Hydraulic section notes explain when JS200 information also applies to JS220 variants and when JS240 information applies to JS260 variants. Separate JS220LC Long Reach relief specifications prevent standard-machine settings from being applied indiscriminately to that configuration.

Ram repair extends beyond removal and installation to seal arrangements, bushing work, reconditioning jigs, and inspection after assembly. The piston head nut procedure identifies rig assembly 993/99525 and model-specific spanners. The slew gearbox instructions also flag inner-seal damage caused by pressure buildup during incorrect greasing.

Travel Drive, Undercarriage, and Diagnostic Visuals

The transmission section covers the axial-piston travel motor, counterbalance and cross-over relief valves, automatic two-speed mechanism, parking brake, and planetary reduction gearbox. Gearbox assembly notes distinguish replacement of a complete damaged reduction stage from replacement of an individual planet gear.

Running-gear coverage includes idler and roller dismantling, floating seals, grease-cylinder servicing, recoil-unit handling, and wear assessment.

Illustrated references include the electrical Schematic Diagram, JS200 and JS240 Schematic Hydraulic Circuits, Pilot Control Line Hose Connection Diagram, Hydraulic Pump P-Q Line Diagram, and electrical Fault Diagnosis flow charts.

Engine Maintenance, Cab Work, and Scope

Routine engine work covers oil and filter changes, air-cleaner servicing, coolant replacement, fan-belt adjustment, radiator and oil-cooler cleaning, and fuel-system bleeding. The Isuzu engine data distinguishes the A-6BG1TQB-04 and A-6BG1TQB-05 builds.

Internal engine repair: Section K provides technical data and refers further engine service detail to separate publication 9806/2120; that engine service manual is not included.

Cab work includes removal and replacement of directly bonded glass. Optional air-conditioning coverage adds circuit operation, system diagnosis, and leak-testing information.

Follow the manual’s pressure-release, lifting, and load-support precautions before servicing hydraulic components or working around raised equipment.

Selected Factory Specifications

The general torque table distinguishes counterweight bolts by size: M27 entries are 1058–1235 Nm, while M30 entries are 1335–1545 Nm. Engine technical data specifies 0.4 mm cold clearance for both inlet and exhaust valves on the listed engine builds.

PDF Search, Diagram Detail, and Page Count

Text search and diagram access: Most text sections are searchable, but the large electrical wiring schematic has no searchable text layer. Two embedded bookmarks divide the file into broad parts rather than individual chapters. Small wiring labels require zooming.

One printable English PDF contains 531 pages, including the original manual cover and section contents pages. This is a single service manual, not a collection of the separately referenced publications.