JCB JS160W WHEELED EXCAVATOR Service Repair Manual SN：718500 Onwards

Service
Manual
JS130W
JS145W
JS160W
JS175W
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE: ©
UTTOXETER, STAFFORDSHIRE, ST14 7BS,
ENGLAND
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9803/6310
R
General Information
Care & Safety
Routine Maintenance
Attachments
Body & Framework
Electrics
1
2
3
A
B
C
Controls D
EHydraulics
FTransmission
GBrakes
KEngineIssue 5
Open front screen

Contents Page No.
Machine and Axle Identification 1 - 1
Torque Settings 2 - 1
Service Tools
Body and Framework (Section B) 4 - 1
Electrics (Section C) 5 - 1
Hydraulics (Section E) 6 - 1
Transmission (Section F) 7 - 1
Axles (Section F) 8 - 1
Sealing and Retaining Compounds 9 - 1
i
General Information
9803/6310
i
Issue 1
Section 1 Section 1
i

1 - 1
Machine Serial Plates
Each machine has a Data Plate, located to the rear left,
inside the cab as shown at A. The machine serial number is
inscribed at B and the engine number at C.
If the engine is replaced by a new one, the data plate serial
number will be wrong. Either stamp the new number on the
plate or stamp out the old one. This will prevent the wrong
number being quoted when ordering replacement parts.
Axle Serial Plate
The axle serial number is stamped on a plate mounted to the
rear face of the axle, as shown.
1 When replacement parts are required, always ensure
that the correct parts are obtained, e.g. in the case of
gear replacements, always check the part number
stamped on the gear, and the number of teeth.
2 When ordering replacement parts, quote the details on
the serial plate as shown.
Section 1 General Information
9803/6310
Section 1
1 - 1
Issue 1
Machine and Axle Identification
JS06050
JS06060
C
A
B
S156570

2 - 1
9803/6310
Section 1
2 - 1
Issue 2*
Torque Settings
Torque Settings
Note 1: The figures quoted are for non-plated fasteners and are to be used only when there is no torque setting specified in
the relevant procedure in this service manual.
Note 2: The 4T grade settings DO NOT APPLY to fasteners used on the engine. If any 4T specification fasteners are found on
the engine, these must be tightened to the figure quoted in the relevant engine manual.
Bolt
Size Strength Grade of Bolt or Stud
4T 8.8 10.9 12.9
Nm kgf m lbf ft Nm kgf m lbf ft Nm kgf m lbf ft Nm kgf m lbf ft
M3 0.39 0.04 0.28 - - - - - - - - -
M4 0.78 0.08 0.57 - - - - - - - - -
M5 1.67 0.17 1.2 - - - - - - - - -
M6 2.84 0.29 2.1 8.04 0.82 5.9 11.3 1.15 8.3 - - -
M8 7.06 0.72 5.2 19.6 2.00 14.5 27.7 2.82 20.4 48.0 4.9 35
M10 14.0 1.43 10.3 39.1 3.99 28.8 55.0 5.61 40.6 94.0 9.6 69
M12 24.6 2.51 18.1 68.5 6.98 50.5 96.2 9.81 71 166 16.9 122
M16 61.9 6.31 45.7 173 17.6 127.6 242 24.7 178.5 400 40.8 295
M20 122 12.4 90 337 34.4 249 475 48.4 350 - - -
M22 167 17.0 123 464 47.3 342 652 66.5 481 - - -
M24 210 21.4 155 584 59.5 431 821 83.7 606 - - -
M27 311 31.7 229 864 88.1 637 1220 124 900 - - -
M30 420 42.8 310 1170 119 863 1650 168 1217 - - -
M33 576 58.7 425 1600 163 1180 2260 230 1667 - - -
M36 736 75.1 543 2050 209 1512 2880 294 2124 - - -
M39 961 98.0 709 2680 273 1977 3760 383 2773 - - -
M42 1190 121 878 3300 336 2434 4640 473 3422 - - -
M45 1490 152 1099 4140 422 3054 5820 593 4293 - - -
M48 1780 182 1312 4960 506 3659 6970 711 5141 - - -
Note: All bolts are high tensile and must not be replaced by bolts of a lesser tensile specification.*
*

4 - 1
9803/6310
Section 1
4 - 1
Issue 1
Service Tools
Body and Framework (Section B)
S186240
Hand Cleaner - special blend for the removal of
polyurethane adhesives.
4104/1310 (454g; 1lb tub)
S186250
12V Mobile Oven - 1 cartridge capacity - required to
pre-heat adhesive prior to use. It is fitted with a male
plug (703/23201) which fits into a female socket
(715/04300).
992/12300
S186260
240V Static Oven - available with 2 or 6 cartridge
capacity - required to pre-heat adhesive prior to use.
No plug supplied. Note: 110V models available upon
request - contact JCB Technical Service
992/12400 - 2 cartridge x 240V
992/12600 - 6 cartridge x 240V
S186270
Cartridge Gun - hand operated - essential for the
application of sealants, polyurethane materials etc.
892/00845
'
S186280
Folding Stand for Holding Glass - essential for
preparing new glass prior to installation.
892/00843
S186300
Glass Lifter - minimum 2 off - essential for glass
installation, 2 required to handle large panes of glass.
Ensure suction cups are protected from damage
during storage.
892/00842

4 - 2
9803/6310
Section 1
4 - 2
Issue 1
Service Tools (cont’d)
Body and Framework (Section B) (cont’d)
S186310
Wire Starter - used to access braided cutting wire
(below) through original polyurethane seal.
892/00848
S186320
Glass Extractor (Handles) - used with braided cutting
wire (below) to cut out broken glass.
892/00846
S186330
Braided Cutting Wire - consumable heavy duty
cut-out wire used with the glass extraction tool
(above).
892/00849 (approx 25m length)
S186340
Cut-out Knife - used to remove broken glass.
992/12800
'
S186350
'L' Blades - 25mm (1in.) cut - replacement blades for
cut-out knife (above).
992/12801 (unit quantity = 5 off)
S186360
Long Knife - used to give extended reach for normally
inaccessible areas.
892/00844

4 - 3
9803/6310
Section 1
4 - 3
Issue 1
Body and Framework (Section B) (cont’d)
S186470
Nylon Spatula - general tool used for smoothing
sealants - also used to re-install glass in rubber glazing
because metal tools will chip the glass edge.
892/00847
S186550
Rubber Spacer Blocks - used to provide the correct
set clearance between glass edge and cab frame.
926/15500
(unit quantity = 500 off)

5 - 1
9803/6310
Section 1
5 - 1
Issue 2*
Service Tools
SECTION C - ELECTRICS
Electrical Test Equipment
1 892/00283 Tool Kit Case
2 892/00281 AVO Meter
3 892/00286 Surface Temperature Probe
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
892/01033 Data Link Adaptor
Used with AMS Machines Only
A360250

Service Tools (continued)
SECTION E - HYDRAULICS
6 - 1
9803/6310
Section 1
6 - 1
Issue 2*
Pressure Test ‘T’ Adapters
892/00262 1/4 in BSP x 1/4 in F BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point
892/00266 1,1/4 in M BSP x 1,1/4 in F BSP x Test Point
892/00267 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point
Pressure Test Adapters
892/00255 1/4 in BSP x Test Point
892/00259 1 in BSP x Test Point
892/00260 1,1/4 in BSP x Test Point
892/00261 5/8 in UNF x Test Point
Hydraulic Pressure Test Gauges and Connections
1 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2)
3 892/00347 Connector
4 892/00254 Hose
1/2/5

6 - 2
9803/6310
Section 1
6 - 2
Issue 1
Hand Pump Equipment
892/00223 Hand Pump
892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
892/00706 Test Probe
892/00278 Gauge 0 - 40 bar (0 - 600 lb/in2)
892/00279 Gauge 0 - 400 bar (0 - 6000 lb/in2)
892/00280 Gauge 0 - 600 bar (0 - 8500 lb/in2)
816/50005 1/2 in BSP (A) x 1/2 in BSP (B)
816/60096 3/4 in BSP (A) x 3/4 in BSP (B)
816/00018 1 in BSP (A) x 1 in BSP (B)
Female Cone Blanking Plug
892/00055 1/4 in BSP
892/00056 3/8 in BSP
892/00057 1/2 in BSP
892/00058 5/8 in BSP
892/00059 3/4 in BSP
892/00060 1 in BSP
Male Cone Blanking Plug
816/00294 1/4 in BSP
816/00189 3/8 in BSP
816/00190 1/2 in BSP
816/00197 5/8 in BSP
816/00196 3/4 in BSP
816/00193 1 in BSP

6 - 3
9803/6310
Section 1
6 - 3
Issue 2*
Ram Piston Nut Removal/Fitting Rig
993/99525 Rig Assembly (not including spanners and
ram)
993/99522 Anchor Side Plate (supplied loose unwelded)
993/99523 Anchor Cross Member (supplied loose
unwelded)
993/99524 Ram Eye End Modification Plate Assembly
556/43400 Lift Ram
545/18000 Lynch Pin
811/50232 1,1/4” Pivot Pin
Ram Piston Nut Removal/Fitting Spanner
993/99512 Spanner 55 mm A/F
993/99519 Spanner 100 mm A/F
993/99520 Spanner 110 mm A/F
993/99521 Spanner 115 mm A/F
SSP0046 Spanner 80 mm A/F
SSP0047 Spanner 95 mm A/F
JS07050

6 - 4
Hydraulics (Section E) (cont’d)
Slew Motor Unit - JS130W/145W
9803/6310
Section 1
6 - 4
Issue 2*
Seal Fitting Tool (Oil Seal 2) JS07110
30
o
155 (6.10")
2 (0.079")
14 (0.55")
4 (0.16")
ø38.0.2
(1.50"0.008)
+-
+-
ø61.0.2
(2.40"0.008)
+-
+-
ø70(2.76")
Fitting Tool for Inner Ring of Taper Roller Bearing 3
ø42(1.65")
JS07120
100 (3.94")
110 (4.33")
ø32.2.0.1
(ø1.270.004)+-
+-
15
o
ø35.5.0.1
(ø1.400.004)+-
+-
Seal Protector
Heat polyvinyl tube in hot water and form to required shape.
ø38(1.50")
50 (1.97")
80 (3.15")
5 o
JS07130
Fitting Tool for Inner Ring 1
ø40(1.57")
JS07140
ø31.40.1
(1.24"0.004)
+-
+-
50 (1.97")
60 (2.36")
*

6 - 5
Slew Motor Unit - JS160W/JS175W
9803/6310
Section 1
6 - 5
Issue 2*
Puller for Brake Piston
Stud is threaded M10 on both ends for 20 mm (0.8 in) and fitted with two M10 nuts.
JS07100
40
(1.57")
40
(1.57")
2 x ø9 (0.35")
100
(3.94")
200
(9.84")
10(0.39")
180
(7.09")
240
(9.45")
M10
ø11 (0.43")Inner diameter
*

6 - 6
Hydraulic Tank - JS130W/JS145W/JS160W/JS175W
A Dia. 40 mm (1.57 in)
B Dia. 26 mm (1.02 in)
C 40 mm (1.47 in)
D 50 mm (1.97 in)
E Dia. 10 mm (0.39 in)
F 550 mm (21.7 in)
G 9 mm (0.35 in)
H 24 mm (0.94 in)
I Dia. 81 mm (3.91 in )
J Dia. 76 mm (2.99 in )
K 24 mm (0.94 in)
L 95 mm (3.74 in)
M Radius 0.7 mm (0.028 in)
N 120 mm (16.5 in)
O 4.0 mm (0.157 in)
P 3.0 mm (0.118 in)
Q 15°
O-ring G75
9803/6310
Section 1
6 - 6
Issue 2*
+0
-0.1
+0
-0.004
+0
-0.1
+0
-0.004
JS07150
A
B
C D
G
H
F
N
J
I
K
Q O
P
L
M
E
Blank for Suction Strainer
*

6 - 7
Remote Control Valve - JS130W/JS145W/JS160W/JS175W
9803/6310
Section 1
6 - 7
Issue 2*
JS07160
ø30
ø25
ø21
ø28
ø19
42
25
17
19
5013
65
ø26.5
23.5
15
1
2
Joint Removal Tool
Items 1 and 2 are assembled with an interference fit.
*

6 - 8
Hydraulic Pump
9803/6310
Section 1
6 - 8
Issue 1
JS07980
90
1510
7
ø11.5
ø30
ø18.5
ø5
113 0.1
+
-
150
R2
ø34.90.1
+
-
ø56
ø75-.005
ø75+0.15
+0.1
ø90
ø37
ø44
ø50
6
100
M12 x 1.75
ø12
140
20
220
2078
10
M8
M8
M8
1510
7
ø8
ø30
ø18.5
ø5
Guide Rods
Swash Plate Levelling Tool
Front Shaft Protection Tool
Rear Shaft Protection Tool
Oil Seal Insertion Tool
Bearing Insertion Tool

6 - 9
Hydraulic Rams
Reconditioning
9803/6310
Section 1
6 - 9
Issue 1
Bush Removal/Assembly Jig Seal Ring Insertion Jig (Inner)
Bush Removal/Assembly Jig Seal Ring Bedding Jig
Cylinder Head Insertion Jig
Seal Ring Insertion Jig (Outer)
Wiper Ring Installation Jig

Seal Fitting Jig
Transmission (Section F)
Slew Gearbox - JS130W/145W
7 - 1
9803/6310
Section 1
7 - 1
Issue 2*
ø50 (1.97")
14
(0.55")6
(0.236")
15
(0.59")30
(1.18")
JS07170
ø94.5 0.2
(3.72" 0.008)
+
-
+
-
ø120 (4.72")
ø130 (5.43")
3(0.118")
15
o
Seal Protector
Heat polyvinyl tube in hot water and form to the required
shape on the pinion shaft
ø65(2.56")
60 (2.36")
100 (3.94")
5 o
JS07180
Bearing and Oil Seal assembly Jig
Slew Gearbox - JS160W/175W
ø100
(ø3.937")
JS07190
80
(3.15")
+0.3
-0
+0.012"
-0
Seal Fitting Jig
ø149
(ø5.866")
JS07200
2.5(0.098")
ø155
(ø6.094")
*
*

Transmission (Section F) (cont’d)
Slew Gearbox - JS160W/175W (cont’d)
7 - 2
9803/6310
Section 1
7 - 2
Issue 2*
Seal Fitting Jig
ø50
3 1591530
ø99.8
ø124
ø158
JS07210
Seal Fitting Jig (SST0033)
JS07220
30
o
155
2
16
4
ø49.5
80
ø75
Jig for Taper Roller Bearing Inner Ring
ø36
(ø50)
JS07230
100
110
ø30.5.0.1
(ø46.50.1)+-
+-
*

Transmission (Section F) (cont’d)
Drive Gearbox
892/00223 Hand Pump
892/00346 Pressure Gauge (0 - 70 bar)
SSP0027/SSP0028 Striker/Internal Puller
SSP0029/SSP0030/SSP0031 Puller Assembly
SSP0035 Installer
SSP0050 Fitting Tool
SSP0051 Handle
SSP0052 Fitting Tool
SST0011 Measuring Cover
SST0013 Installer Sleeve
SST0018 Hydraulic Connector
SST0019 Pressure Sleeve
SST0020 Clutch Jig
SST0032 Driver
7 - 3
9803/6310
Section 1
7 - 3
Issue 1

992/07609 Adapter - Steer/Drive Axle Pinion Bearing
Cone
992/07606 Measuring Cup - Pinion Bearing
8 - 1
9803/6310
Section 1
8 - 1
Issue 1
Service Tools (cont'd)
Axles (Section F)
992/07604 Replacer - Crownwheel Bearing
and Differential Bearing Cones
992/07614 Adapter Set - Bull Pinion Bearing
Remover/Replacer
892/00182 Bearing Pad Driver
892/00817 17 mm A/F x 3/4 in square drive
992/07601 Spanner for Half Shaft Nuts 992/07603 Replacer - Pinion Head Bearing Cup
992/07607 Spacer - Pinion Bearing Preload

992/04000
Torque Multiplier (use in conjunction with a torque wrench to give a
5:1 multiplication when tightening pinion nuts)
8 - 2
9803/6310
Section 1
8 - 2
Issue 1
Axles (Section F) (cont’d)
892/00174
Measuring Cup - Pinion Head
Bearing
S190770
892/00224
Impulse Extractor Set for Hub Bearing Seals
S197070
892/00812 Drive Coupling Spanner for axle
yoke couplings
S196720
892/00822
Splined Bolt Socket for
driveshafts
S197060
892/00334 Gland Seal Fitting tool
S197030
992/00800 Extractor for removing axle pivot pin

8 - 3
9803/6310
Section 1
8 - 3
Issue 2*
Axles (Section F) (cont’d)
993/59500 Adapter - Impulse Extractor
892/00891 Oil Seal Insertion Tool
A272520
892/00833 Annulus Removal Tool
*

9 - 1
9803/6310
Section 1
9 - 1
Issue 2*
Sealing and Retaining Compounds
JCB Multi-Gasket A medium strength sealant suitable for all sizes of gasket 4102/1212 50 ml
flanges, and for hydraulic fittings of 25-65 mm diameter.
JCB Threadlocker For threads of 50 mm diameter upwards, 4101/0451 50 ml
e.g. suction strainer.
JCB Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml
(High Strength) components. Gasketing for all sizes of flange where
the strength of the joint is important.
JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/0651 50 ml
JCB Threadlocker and Sealer A medium strength locking fluid for sealing and retaining 4101/0250 10 ml
nuts, bolts, and screws up to 50 mm diameter, and 4101/0251 50 ml
for hydraulic fittings up to 25 mm diameter.
JCB Threadlocker and Sealer A high strength locking fluid for sealing and retaining 4101/0550 10 ml
(High Strength) nuts, bolts, and screws up to 50 mm diameter, and for 4101/0552 200 ml
hydraulic fittings up to 25 mm diameter.
JCB Threadseal A medium strength thread sealing compound. 4102/1951 50 ml
JCB Activator A cleaning primer which speeds the curing rate of 4104/0251 Aerosol (1 ltr)
anaerobic products. 4104/0253 Bottle (200 ml)
JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic 4104/1557 Aerosol (400 ml)
adhesives and sealants.
Anti-Seize Paste A compound used for assembly and prevention of 4003/0211
parts seizure.
Direct Glazing Kit For one pane of glass; comprises items marked † below
plus applicator nozzle etc.
† Ultra Fast Adhesive For direct glazing 4103/2109 310 ml
† Active Wipe 205 For direct glazing 4104/1203 250 g
† Black Primer 206J For direct glazing 4201/4906 30 ml
Clear Silicone Sealant To seal butt jointed glass. 4102/0901

Contents Page No.
Safety Notices 1 - 1
General Safety 2 - 1
Operating Safety 3 - 1
Maintenance Safety 4 - 1
i
Care & Safety
9803/6310
i
Issue 1
Section 2 Section 2

1 - 1
Section 2 Care & Safety
9803/6310
Section 2
1 - 1
Issue 2*
In this publication and on the machine, there are safety notices. Each notice starts
with a signal word. The signal word meanings are given below.
!! DANGER
Denotes an extreme hazard exists. If proper precautions are not taken, it is
highly probable that the operator (or others) could be killed or seriously
injured.
INT-1-2-1
!! WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator (or
others) could be killed or seriously injured.
INT-1-2-2
!! CAUTION
Denotes a reminder of safety practices. Failure to follow these safety practices
could result in injury to the operator (or others) and possible damage to the
machine.
INT-1-2-3
*

2 - 1
All construction and agricultural equipment can be
hazardous. When a JCB Excavator is correctly operated and
properly maintained, it is a safe machine to work with. But
when it is carelessly operated or poorly maintained it can
become a danger to you (the operator) and others.
Do not work with the machine until you are sure that you can
control it.
Do not start any job until you are sure that you and those
around you will be safe.
If you are unsure of anything, about the machine or the job,
ask someone who knows. Do not assume anything.
Remember
BE CAREFUL
BE ALERT
BE SAFE
GEN-1-6
As well as the warnings in the following pages, specific
warnings are given throughout the book. This section is
designed to give a safety code for use of the machine
generally and for operation and maintenance practices.
General Safety
!!
WARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment. Make
sure that lifting equipment is in good condition. Make sure
that lifting tackle complies with all local regulations and is
suitable for the job. Make sure that lifting equipment is
strong enough for the job.
INT-1-3-7
!!WARNING
Clothing
You can be injured if you do not wear the proper clothing.
Loose clothing can get caught in the machinery. Wear
protective clothing to suit the job. Examples of protective
clothing are: a hard hat, safety shoes, safety glasses, a well
fitting overall, ear-protectors and industrial gloves. Keep
cuffs fastened. Do not wear a necktie or scarf. Keep long
hair restrained.
INT-1-3-6
!!
WARNING
Alcohol and Drugs
It is extremely dangerous to operate machinery when under
the influence of alcohol or drugs. Do not consume alcoholic
drinks or take drugs before or whilst operating the machine
or attachments. Be aware of medicines which can cause
drowsiness.
INT-1-3-9
Note: This section includes a certain amount of operating
safety information. But remember that whenever you drive
the machine or operate its controls, you are in effect a
machine operator. Therefore you should read and
understand the information given in the Operator Handbook
before driving the machine or operating its controls.
!!
WARNING
Care and Alertness
All the time you are working with or on the machine, take
care and stay alert. Always be careful. Always be alert for
hazards.
INT-1-3-5
!!WARNING
Raised Equipment
Raised equipment can fall and injure you. Do not walk or
work under raised equipment unless safely supported.
13-1-1-6
!! DANGER
Before removing the boom from the machine, ensure that
the counterweight is adequately supported as in certain
ground conditions the machine could tip backwards. Never
travel or transport the machine with the boom removed.
BF 6-3
*9803/6310
Section 2
2 - 1
Issue 2*

3 - 1
Operating Safety
!!WARNING
Engine
The engine has rotating parts. Do not open the engine cover
while the engine is running. Do not use the machine with the
cover open.
INT-2-1-6
!!WARNING
Entering/Leaving
Always face the machine when entering and leaving the cab.
Use the step(s) and handrails. Make sure the step(s),
handrails and your boot soles are clean and dry. Do not
jump from the machine. Do not use the machine controls as
handholds, use the handrails.
INT-2-1-7
!!WARNING
Controls
You or others can be killed or seriously injured if you operate
the control levers from outside the cab. Operate the control
levers only when you are correctly seated inside the cab.
INT-2-1-3
!!WARNING
Visibility
Accidents can be caused by working in poor visibility. Keep
windows clean and use your lights to improve visibility. Do
not operate the machine if you cannot see properly.
INT-2-1-11
!!WARNING
Machine Limits
Operating the machine beyond its design limits can damage
the machine, it can also be dangerous. Do not operate the
machine outside its limits. Do not try to upgrade the
machine performance with unapproved modifications.
INT-2-1-4
!!WARNING
Exhaust Gases
Breathing the machine exhaust gases can harm and
possibly kill you. Do not operate the machine in closed
spaces without making sure there is good ventilation. If
possible, fit an exhaust extension. If you begin to feel
drowsy, stop the machine at once. Get out of the cab into
fresh air.
INT-2-1-10
!!WARNING
Front Axle Lock
DO NOT travel on the road unless the front axle is free to
pivot. Lock the axle only while excavating or lifting.
8-2-9-1/1
!!WARNING
Ramps and Trailers
Water, mud, ice, grease and oil on ramps or trailers can
cause serious accidents. Make sure ramps and trailers are
clean before driving onto them. Use extreme caution when
driving onto ramps and trailers.
INT-2-2-6
!!WARNING
Communications
Bad communications can cause accidents. Keep people
around you informed of what you will be doing. If you will be
working with other people, make sure any hand signals that
may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands.
INT-2-2-3
!! DANGER
Sparks
Explosions and fire can be caused by sparks from the
exhaust or the electrical system. Do not use the machine in
closed areas where there is flammable material, vapour or
dust.
INT-2-2-10
!!WARNING
Controls
Keep the machine controls clean and dry. Your hands and
feet could slide off slippery controls. If that happens, you will
lose control of the machine.
2-2-3-6
!!WARNING
Hazardous Atmospheres
This machine is designed for use in normal outdoor
atmospheric conditions. It should not be used in an
enclosed area without adequate ventilation. Do not use the
machine in a potentially explosive atmosphere, i.e.
combustible vapours, gas or dust, without first consulting
your JCB Distributor.
INT-2-1-14
!!WARNING
Boom Removal
Never remove the boom from the machine as this would
severely upset the machine’s balance so that in certain
ground conditions it could tip backwards.
8-2-8-4/2
*9803/6310
Section 2
3 - 1
Issue 2*

4 - 1
Maintenance Safety
!!WARNING
Soft Ground
A machine can sink into soft ground. Never work under a
machine on soft ground.
INT-3-2-4
!!WARNING
Metal Splinters
You can be injured by flying metal splinters when driving
metal pins in or out. Use a soft faced hammer or drift to
remove and fit metal pins. Always wear safety glasses.
INT-3-1-3
!!WARNING
Communications
Bad communications can cause accidents. If two or more
people are working on the machine, make sure each is
aware of what the others are doing. Before starting the
engine, make sure the others are clear of the danger areas;
examples of danger areas are: the rotating blades and belt
on the engine, the attachments and linkages, and anywhere
beneath or behind the machine. People can be killed or
injured if these precautions are not taken.
INT-3-1-5
!!WARNING
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from the
machine. Do not smoke while refuelling the machine or
working on the engine. Do not refuel with the engine running.
There could be a fire and injury if you do not follow these
precautions.
INT-3-2-2
!!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
!!WARNING
Oil
Oil is toxic. If you swallow any oil, do not induce vomiting,
seek medical advice. Used engine oil contains harmful
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier
cream or wear gloves to prevent skin contact. Wash skin
contaminated with oil thoroughly in warm soapy water. Do
not use petrol, diesel fuel or paraffin to clean your skin.
INT-3-2-3
!!WARNING
Fires
If your machine is equipped with a fire extinguisher, make
sure it is checked regularly. Keep it in the operator's cab
until you need to use it.
Do not use water to put out a machine fire, you could spread
an oil fire or get a shock from an electrical fire. Use
carbondioxide, dry chemical or foam extinguishers. Contact
your nearest fire department as quickly as possible. Fire
fighters should use self-contained breathing apparatus.
INT-3-2-7/1
!!WARNING
Battery
A battery with frozen electrolyte can explode if it is used or
charged. Do not use a machine with a frozen battery. To help
prevent the battery from freezing, keep the battery fully
charged.
INT-3-1-7
!!WARNING
Battery Gases
Batteries give off explosive gases. Keep flames and sparks
away from the battery. Do not smoke close to the battery.
Make sure there is good ventilation in closed areas where
batteries are being used or charged. Do not check the
battery charge by shorting the terminals with metal; use a
hydrometer or voltmeter.
INT-3-1-8
!!WARNING
Battery Terminals
The machine is negatively earthed. Always connect the
negative pole of the battery to earth.
When connecting the battery, connect the earth (-) lead last.
When disconnecting the battery, disconnect the earth (-)
lead first.
INT-3-1-9
!!WARNING
Electrical Circuits
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong connection
can cause injury and/or damage.
INT-3-1-4
!! 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
*9803/6310
Section 2
4 - 1
Issue 2*

4 - 2
Maintenance Safety (cont’d)
!! CAUTION
Arc Welding
Before carrying out any arc welding on the machine,
completely remove the Control Computer to avoid damage
to the circuits; also disconnect the alternator plug and
battery leads.
When welding items to the mainframe make sure that the
earth clamp is positioned on the mainframe and when
welding to the undercarriage make sure that the earth clamp
is positioned on the undercarriage. If you earth one and weld
the other, you may cause severe damage to the slew ring.
Always connect the earth clamp to any other component
being welded, i.e. boom or dipper, to avoid damage to pivot
pins and bushes.
8-1-2-6/1
!!WARNING
Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the
hoses regularly for:
Damaged end fittings
Chafed outer covers
Ballooned outer covers
Kinked or crushed hoses
Embedded armouring in outer covers
Displaced end fittings.
INT-3-3-2
!!WARNING
DO NOT remove the hydraulic tank filler cap or cover plate
when the engine is running. The hydraulic system is under
pressure. You or others could be injured. First stop the
engine and then release the pressure.
8-3-4-4/1
!!WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure trapped
in the hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11/1
!!WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate the
skin. Do not use your fingers to check for hydraulic fluid
leaks. Do not put your face close to suspected leaks. Hold a
piece of cardboard close to suspected leaks and then
inspect the cardboard for signs of hydraulic fluid. If hydraulic
fluid penetrates your skin, get medical help immediately.
INT-3-1-10/1
!! CAUTION
Rams
The efficiency of the rams will be affected if they are not kept
free of solidified dirt. Clean dirt from around the rams
regularly. When leaving or parking the machine, close all
rams if possible to reduce the risk of weather corrosion.
INT-3-2-10
!! CAUTION
Cleaning
Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents and
solvents.
INT-3-2-11
!! CAUTION
'O'-rings, Seals and Gaskets
Badly fitted, damaged or rotted 'O'-rings, seals and gaskets
can cause leakages and possible accidents. Renew
whenever disturbed unless otherwise instructed. Do not use
Trichloroethane or paint thinners near 'O' rings and seals.
INT-3-2-12
!!WARNING
Hot Coolant
The cooling system is pressurised when the engine is hot.
Hot coolant can spray out when you remove the radiator
cap. Let the system cool before removing the radiator cap.
To remove the cap; turn it to the first notch and let the
system pressure escape, then remove the cap.
INT-3-2-9
!!WARNING
Protect your eyes when grinding metal. Wear safety glasses
or goggles. Remove or protect any combustible materials
from the area which could be ignited by sparks.
GEN-1-12
*9803/6310
Section 2
4 - 2
Issue 2*

Contents Page No.
Lubricants and Capacities 1 - 1
Lubricants - Health and Safety 1 - 3
Service Schedules 2 - 1
Greasing
Slew Ring Teeth and Slew Pinion 3 - 1
Slew Ring Bearing 3 - 1
Greasing (50 hours) 3 - 2
Greasing (General) 3 - 4
Battery 4 - 1
Fuses See Section C
Tyres and Wheels
Tyre Inflation 5 - 1
Checking the Wheel Nut Tightness 5 - 1
Hydraulics
Checking the Fluid Level 7 - 1
Releasing Tank Pressure 7 - 1
Topping-up Fluid Level 7 - 1
Changing the Fluid 7 - 2
Changing the Return Filter Element 7 - 3
Flushing Filters 7 - 3
Cleaning/Changing the Suction Strainer 7 - 4
Changing the Plexus Filter 7 - 5
Changing the Air Breather Element 7 - 7
Draining Tank Impurities 7 - 7
Changing the Servo Oil Filter 7 - 8
Changing the Drain Line Filter Element 7 - 9
Changing the Steering Line Filter Element 7 - 9
Changing the Breaker In-line Filter (if fitted) 7 - 10
Air Bleeding Procedures 7 - 11
Transmission
Checking the Slew Gearbox Oil Level 8 - 1
Changing the Slew Gearbox Oil 8 - 1
Replenishing Slew Gearbox Grease 8 - 2
Checking the Drive Gearbox Oil Level 8 - 3
Changing the Drive Gearbox Oil 8 - 3
Checking the Front Axle Differential Oil Level 8 - 4
Changing the Front Axle Differential Oil 8 - 4
Checking the Front Axle Hub Oil Level 8 - 5
Changing the Front Axle Hub Oil 8 - 5
Checking the Rear Axle Differential/Hub Oil Level 8 - 6
Changing the Rear Axle Differential/Hub Oil 8 - 6
i
Routine Maintenance
9803/6310
i
Issue 4*
Section 3 Section 3
*

ii
Routine Maintenance
9803/6310
ii
Issue 2*
Section 3 Section 3
Contents Page No.
Engine
Changing the Air Filter Outer Element 9 - 1
Changing the Air Filter Inner Element 9 - 2
Checking the Oil Level 9 - 3
Changing the Oil and Filters 9 - 3
Checking the Coolant Level 9 - 4
Coolant Mixtures 9 - 4
Changing the Coolant 9 - 5
Cleaning the Radiator and Oil Cooler 9 - 5
Adjusting the Fan Belt 9 - 6
Fitting a New Fan Belt 9 - 6
Draining Fuel Tank Impurities 9 - 7
Draining the Fuel System Water Separator 9 - 7
Changing the Fuel Filter Element 9 - 8
Cleaning the Fuel Lift Pump Strainer 9 - 8
Bleeding the Fuel System 9 - 9
Component Location Diagrams 10 - 1
Falling Objects Protection Structure (FOPS)
Checking the FOPS structure 12 - 1
*

1 - 1
Section 3 Routine Maintenance
9803/6310
Section 3
1 - 1
Issue 2*
Lubricants and Capacities
Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately;
glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no
circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
International Capacity
Item Fluid/Lubricant Specification
JS130W JS145W/JS160W
ENGINE See separate chart 12.1 litres 12.1 litres
(2.7 UK gal) (2.7 UK gal)
SLEW GEARBOX JCB Gear Oil HD90 API-GL-5: MIL-L-2105C 5 litres 5 litres
(1.09 UK gal) (1.09 UK gal)
JCB HP Grease Lithium based, No. 2 1 litre 1 litre
consistency (0.22 UK gal) (0.22 UK gal)
HYDRAULIC SYSTEM JCB Special Hydraulic Vickers 35VQ25/V104C: 124 litres 124 litres
Fluid HP46 Sundstrand, Denison and (27.3 UK gal) (27.3 UK gal)
FZG Approval Tests
SLEW RING
- BEARINGS JCB HP Grease Lithium based, No. 2 - -
- GEAR TEETH JCB HP Grease consistency 17 kg (37.48 lb) 17 kg (37.48 lb)
PROPSHAFTS JCB HP Grease Lithium based, No. 2
consistency
ALL OTHER GREASE Lithium based, No. 2
POINTS JCB HP Grease consistency
COOLING SYSTEM See Coolant Mixtures ASTM D3306-74 16.4 litres 17.2 litres
(3.6 UK gal) (3.78 UK gal)
FUEL TANK See Fuel System, ASTM D975-66T 240 litres 240 litres
Types of Fuel in
Operator Handbook Nos 1D, 2D (52.8 UK gal) (52.8 UK gal)
FRONT AXLE
- DIFFERENTIAL JCB Special Gear Oil Plus API GL4: M2C-41B/134D, 18 litres 18 litres
JD20C (3.9 UK gal) (3.9 UK gal)
- HUB (x 2) JCB Special Gear Oil Plus MGF M1135/M1141/M1143 1.5 litres 1.5 litres
(0.33 UK gal) (0.33 UK gal)
REAR AXLE
- DIFFERENTIAL JCB Special Gear Oil Plus API GL4: M2C-41B/134D, 17.7 litres 17.7 litres
AND HUBS (x 2) JD20C (3.9 UK gal) (3.9 UK gal)
MGF M1135/M1141/M1143
DRIVE GEARBOX JCB Super 15W/40 API CF4/SG: MIL-L-2104F 3.8 litres 3.8 litres
Multigrade Engine Oil (0.83 Uk gal) (0.83 UK gal)

1 - 2
9803/6310
Section 3
1 - 2
Issue 2*
Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately;
glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under
no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
International Capacity
Item Fluid/Lubricant Specification
JS175W
ENGINE See separate chart 21.5 litres
(4.72 UK gal)
SLEW GEARBOX JCB Gear Oil HD90 API-GL-5: MIL-L-2105C 5 litres
(1.09 UK gal)
HYDRAULIC SYSTEM JCB Special Hydraulic Vickers 35VQ25/V104C: 124 litres
Fluid HP46 Sundstrand, Denison and (27.3 UK gal)
FZG Approval Tests
SLEW RING
- BEARINGS JCB HP Grease Lithium complex (NLGI) inc. -
- GEAR TEETH JCB HP Grease extreme pressure additives 17 kg (37.48 lb)
PROPSHAFTS JCB HP Grease Lithium complex (NLGI) inc.
extreme pressure additives
ALL OTHER GREASE Lithium complex (NLGI) inc.
POINTS JCB HP Grease extreme pressure additives
COOLING SYSTEM See Coolant Mixtures ASTM D3306-74 25.5 litres
(5.6 UK gal)
FUEL TANK See Fuel System, ASTM D975-66T 240 litres
Types of Fuel Nos 1D, 2D (52.8 UK gal)
FRONT AXLE
- DIFFERENTIAL JCB Special Gear API GL4: M2C-41B/134D, 18 litres
Oil Plus JD20C (3.9 Uk gal)
- HUB (x 2) JCB Special Gear MGF M1135/M1141/ 1.5 litres
Oil Plus M1143 (0.33 UK gal)
REAR AXLE
- DIFFERENTIAL JCB Special Gear API GL4: M2C-41B/134D 17.7 litres
AND HUBS (x 2) Oil Plus JD20C, (3.9 UK gal)
MGF M1135/M1141/
M1143
DRIVE GEARBOX JCB Super 15W/40 API CF4/SG: MIL-L-2104F 3.8 litres
Multigrade Engine Oil (0.83 UK gal)

1 - 3
9803/6310
Section 3
1 - 3
Issue 2*
(continued)
Use according to ambient temperature (°C)
Engine Lubrication Chart - All Machines
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL
API CF4/SG MIL L-2104F
JCB SUPER 10W/30 MULTIGRADE ENGINE OIL
API CF4/SG MIL L-2104F
-30 -20 -10 0 10 20 30 40 50

1 - 4
First Aid - Oil
Swallowing.
If oil is swallowed you should not induce vomiting. Get
medical advice.
Skin
In the case of excessive skin contact you should wash with
soap and water.
Eyes
In the case of eye contact, flush with water for 15 minutes. If
irritation persists, get medical attention.
Fires
Extinguish with carbon dioxide, dry chemical or foam.
Firefighters should use self contained breathing apparatus.
Hygiene
JCB lubricants are not a health risk when used properly for
their intended purposes.
However, excessive or prolonged skin contact can remove
the natural fats from your skin, causing dryness and
irritation.
Low viscosity oils are more likely to do this, therefore
particular care is necessary in handling used oils which can
be diluted with fuel contamination.
Whenever you are handling oil products you should maintain
good standards of care and personal and plant hygiene. For
details of these precautions we advise you to read the
relevant publications issued by your local health authority,
and note the following:
Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled containers.
Handling
New Oil
There are no special precautions needed for the handling or
use of new oil, beside normal care and hygiene practices.
Used Oil
Used engine crankcase lubricants contain harmful
contaminants. In laboratory tests it was shown that used
engine oils can cause skin cancer.
Here are precautions to protect your health when handling
used engine oil:
1 Avoid prolonged, excessive or repeated skin contact
with used engine oils.
2 Apply a barrier cream to the skin before handling used
engine oil.
3 Note the following when removing engine oil from skin:
a Wash your skin thoroughly with soap and water.
b Using a nail brush will help.
c Use special hand cleansers to help clean dirty
hands.
d Never use petrol, diesel fuel or gas oil.
e Avoid skin contact with oil soaked clothing.
f Don't keep oily rags in pockets.
g Wash dirty clothing before re-use.
h Throw away oil-soaked shoes.
Waste Disposal
All waste products should be disposed of in accordance
with all the relevant regulations.
The collection and disposal of used engine oil should be in
accordance with any local regulations. Never pour used
engine oil into sewers or drains.
Spillage
Absorb on sand or a locally approved brand of absorbent
granules. Scrape up and remove to a chemical disposal
area.
9803/6310
Section 3
1 - 4
Issue 1*
Lubricants - Health and Safety
It is most important that you read and understand this information and the publications referred to. Make sure that all
of your colleagues who are concerned with lubricants read it too.

2 - 1
Every 10 Operating Hours or Daily
Whichever occurs first
1 Clean
a Machine generally.
(When steam cleaning do not direct jet at grease
nipples.)
2 Grease
(If operating in very wet or severe conditions).
a Bucket/dipper pivot points.
3 Check (Engine Stopped)
a Generally for damage.
b For oil and coolant leakage.
c Security of bolts and nuts †.
d For disconnected or shorted wiring, loose terminals.
e Hydraulic fluid level.
f Engine oil level.
g Engine coolant level.
h Windscreen washer fluid level.
j Fuel system for leaks.
k Fuel level.
l Tyre pressures and condition.
m Seat belt condition and security.
n Tightness of wheel nuts (with wheel brace).
p The auxiliary circuit hydraulic oil filter visual indicator
(if using a rockbreaker or crusher).
† Tapping with a hammer will identify any loose nuts and
bolts which should then be tightened to the specified
torque.
4 Check (Engine Running)
a Operation of warning lights and audible alarm.
b Operation of brake lights and reversing lights.
c Operation of other electrical equipment.
d Exhaust for excessive smoke.
e Excavator operation.
f Dozer, stabiliser and attachment operation.
g Transmission operation.
h Footbrake operation.
j Steering operation.
k Parking brake operation.
l Operation of slew brake.
m Operation of hour meter.
Every 50 Operating Hours or Weekly
1 Do the daily jobs plus:
2 Clean
a Drain water and sediment from fuel tank.
b Drain fuel water separator.
3 Grease
a All pivot pins.
9803/6310
Section 3
2 - 1
Issue 2*
Service Schedules
*

2 - 2
Every 100 Operating Hours or 2-Weekly
1 Do a 50 hour service plus:
2 Clean
a Battery terminals.
b Fuel lift pump strainer.
3 Grease
a Slew ring bearing.
b Axle pivot and steering joints ††.
c Propshafts.
4 Change
a Engine oil main filter element ††.
b Engine oil ††.
c Servo oil filter element ††.
d Engine oil filter by-pass element ††.
e Return filter element ††.
f Drain filter element ††.
g Slew gearbox oil ††.
h Front axle hub oil ††.
j Rear axle hub/differential oil ††.
k Drive gearbox oil ††.
l Fuel filter element ††.
a Hose and pipework for chafing or damage.
b Condition of ram piston rods.
c Bucket pivot pin grease seals ††.
d All grease seals.
e Tightness of engine mounting bolts.
f Security of major unit mounting bolts and nuts ††.
If loose, tighten to specified torque.
g Wiring for chafing.
h Fan belt tension.
j Accumulator operation.
k Radiator for damage.
l Oil cooler for damage.
m Exhaust system security.
n Teeth and sidecutters.
a Operation of throttle system.
b Operation of overload warning.
c Operation of stop control.
†† These procedures are only to be carried out after the
first 100 hours use of a new machine. Thereafter they
are to be carried out as detailed in the following periodic
checks.
Every 250 Operating Hours or Monthly
2 Clean
a Drain water and deposits from hydraulic oil tank.
b Air cleaner dust valve.
c Pre-cleaner
3 Grease
a Door and canopy hinges.
b Slew ring bearing.
a Battery electrolyte level.
b Security of major unit mounting bolts and nuts.
If loose, tighten to specified torque.
c Slew gearbox oil level.
d Fan belt adjustment.
e Front axle hub oil and differential oil levels.
f Rear axle hub/differential oil level.
g Drive gearbox oil level.
h Air inlet system security.
9803/6310
Section 3
2 - 2
Issue 2*
Service Schedules
*
*

2 - 3
Every 500 Operating Hours or 3-Monthly
2 Clean
a Radiator, grille and oil cooler fins.
3 Grease
a Slew ring teeth and slew pinion.
b Axle pivot and steering joints.
(JCB HP Grease should be used on all axle grease
points. If an alternative grease is used the service
interval must be reduced to 50 hours or weekly.)
4 Change
a Engine oil.
b Engine oil full flow filter elements.
c Fuel filter element.
d Engine oil filter by-pass element.
e Front axle hub oil.
f Rear axle hub/differential oil.
a Exhaust system security.
b Propshaft +.
c Servo accumulator operation +.
d Brake accumulator operation +.
e Hydraulic oil (check the degradation and cleanliness
by sampling).
f Seat belt condition and security.
g Teeth and sidecutters.
a Operation of throttle system.
b Operation of overload warning.
c Operation of stop control.
Every 1000 Operating Hours or 6-Monthly
2 Clean
a Fuel lift pump strainer.
b Hydraulic fluid suction strainer.
3 Grease
a Replenish slew gearbox grease.
4 Change (Engine Stopped)
a Engine air filter element (outer).
b Hydraulic tank air breather element.
c Slew gearbox oil.
d Return filter element †††.
e Nephron filter †††.
f Servo oil filter element †††.
g Drain filter †††.
h Front axle differential oil.
j Steering line filter element †††.
a Hub brake friction plates for wear.
Renew as necessry +.
Every 2000 Operating Hours or Yearly
2 Clean
a Injectors (and test) +.
a. Valve clearance and lubrication.
b Sample hydraulic oil and replace if necessary.
4 Change
a Hydraulic fluid suction strainer.
b Engine air filter element (inner).
c Drive gearbox oil.
††† If using a breaker or crusher, see Revised Service
Schedules - Rockbreaker or Crusher Usage in
this section.
+ Indicates jobs which should be done by a specialist.
9803/6310
Section 3
2 - 3
Issue 2*
Service Schedules
*
*
*
*
*
*
*
*

2 - 4
Every 4000 Operating Hours or 2 Years
2 Change
a Long life coolant.
b Fuel hose (fuel tank - engine).
c Fuel hose (fuel filter - injection pump).
d Hydraulic pump exit hose (pump - operation valve).
e Boom ram line hose.
f Dipper ram line hose.
g Bucket ram line hose.
Every 5000 Operating Hours or 2 Years
6 Months
1. Do a 1000 hour service plus:
2. Change
a Hydraulic oil †††.
b Hydraulic tank air breather element.
c Hydraulic suction filter †††.
††† If using a breaker or crusher, see Revised Service
Schedules - Rockbreaker or Crusher Usage in
this section.
9803/6310
Section 3
2 - 4
Issue 1
Service Schedules

2 - 5
Revised Service Schedules -
Rockbreaker or Crusher Usage
Note: The following servicing intervals should be adopted
instead of those called for in the main Service Schedules,
when a rockbreaker or crusher is used regularly.
+ It is recommended that oil samples are taken and
analysed immediately prior to each Return Filter Element
change.
9803/6310
Section 3
2 - 5
Issue 2*
Service Schedules
Servicing Intervals (hours)
Servicing Operation
100% usage 40% usage 20% usage 10% usage
Hydraulic Oil - check level 10 10 10 10
- change 600 1500 3000 4000
Return Filter Element - change+ 100 300 600 800
Suction Strainer - clean 100 300 600 800
- change 600 1500 3000 4000
Servo Oil Filter - change 100 300 600 800
Drain Filter - change 100 300 600 800
Nephron Filter - change 100 300 600 800
Breaker In-line Filter - change 100 300 600 800
Hydraulic Oil - sampling 200 300 600 800
Steering Filter 100 300 600 800*

3 - 1
For the type of grease to use at each point, see Lubricants
and Capacities.
Do not mix different types of grease. Keep them separate.
Slew Ring Teeth and Slew Pinion
Ensure slew ring is kept full of grease. Always grease
whenever the machine has been steam-cleaned.
For location of the slew ring gear refer to Component
Location Diagrams at the end of this section.
1 Make the Machine Safe
Stop the engine and remove the starter key.
2 Grease the Slew Ring
a Remove the cover A.
b Apply grease to the slew ring via aperture B.
3 Slew the Machine
Start the engine and slew the machine a few degrees.
Stop the engine, remove the starter key and apply
grease again.
Repeat until the whole ring is greased. Check that
grease exudes around the entire circumference.
4 Refit the Cover
Slew Ring Bearing
Two remote nipples are mounted on plate C. A third nipple is
at D.
! WARNING
You will be working close into the machine for these
jobs. Lower the attachments if possible. Remove starter
key and disconnect the battery. This will prevent the
engine being started.
8-3-1-3
9803/6310
Section 3
3 - 1
Issue 1
Greasing
JS04070
D
C
JS03980
A B

3 - 2
Greasing (50 hours) ! WARNING
jobs. Lower the attachments if possible. Remove the
starter key and disconnect the battery. This will prevent
the engine being started.
8-3-1-3
9803/6310
Section 3
3 - 2
Issue 2*
Greasing
JS05820
JS130W/JS145W/JS160W/JS175W
JS05830
1
2
3
4
9 2
3
2
1
5
6
4
7
8
0 2
1 2 3
4 5 6
7
9
0

3 - 3
Greasing (50 hours) (cont’d)
† Except JS130W/145W monoboom.
! WARNING
jobs. Lower the attachments if possible. Remove starter
key and disconnect the battery. This will prevent the
engine being started.
8-3-1-3
†† JS130W/145W monoboom only.
9803/6310
Section 3
3 - 3
Issue 2*
Greasing
JS06730
JS05810
}
JS160W/JS175W only
JS05800
JS130W/JS145W only
7
8
9
0
7
0
†
††

3 - 4
Greasing (General)
All items shown, except X and Y should be greased every 50
hours. Item X should be greased every 1000 hours, items Y
every 100 hours.
The steering joint X should be smeared with grease.
! WARNING
jobs. Lower the attachments if possible. Remove the
starter key and disconnect the battery. This will prevent
the engine being started.
8-3-1-3
9803/6310
Section 3
3 - 4
Issue 3*
Greasing
JS06000
X
Y
Y
*

4 - 1
First Aid - Electrolyte
EYES
FLUSH WITH WATER FOR 15 MINUTES. GET MEDICAL
HELP FAST.
IF SWALLOWED
DO NOT INDUCE VOMITING. DRINK LARGE QUANTITIES
OF WATER OR MILK. Then drink milk of magnesia, beaten
egg or vegetable oil.
SKIN
FLUSH WITH WATER. REMOVE AFFECTED CLOTHING.
! WARNING
Batteries give off an explosive gas. Do not smoke when
handling or working on the battery. Keep the battery
away from sparks and naked flames.
Battery electrolyte contains sulphuric acid. It can burn
you if it touches your skin or eyes. Wear goggles.
Handle the battery carefully to prevent spillage.
Keep metallic items (watches, rings, zippers etc) away
from the battery terminals. Such items could short the
terminals and burn you.
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
before connecting it up.
5-3-4-3
! CAUTION
Do not disconnect the alternator, the battery, or any part
of the charging circuit with the engine running.
8-3-4-1
Checking the Electrolyte Level
1 Open the Battery Compartment A
Remove the bolts securing the metal plate above the
batteries. Remove the plate.
2 Check the Level
Remove covers B. Look at the level in each cell. The
electrolyte should be 6 mm (0.25 in) above the plates.
Top up if necessary with distilled water or de-ionized
water.
! WARNING
Do not top the battery up with acid. The electrolyte could
boil out and burn you.
2-3-4-6
3 Check the Connections
Make sure that the terminals are tight and clean. Coat
them with petroleum jelly to prevent corrosion.
9803/6310
Section 3
4 - 1
Issue 1
Battery
JS03950
JS04030
A
B

Front Rear
Nm lbf ft Nm lbf ft
500 369 500 369
! WARNING
If, for whatever reason, a wheel stud is renewed, all the
studs for that wheel must be changed as a set, since the
remaining studs may have been damaged.
2-3-2-8
089571
5 - 1
Tyre Inflation
These instructions are for adding air to a tyre which is
already inflated. If the tyre has lost all its air pressure, call in
a qualified tyre mechanic. The tyre mechanic should use a
tyre inflation cage and the correct equipment to do the job.
! WARNING
An exploding tyre can kill, inflated tyres can explode if
overheated. Do not cut or weld the rims. Use a
tyre/wheel specialist for all repair work.
2-3-2-7
1 Prepare the Wheel
Before you add air to the tyre, make sure it is correctly
fitted on the machine or installed in a tyre inflation cage.
2 Prepare the Equipment
Use only an air supply system which includes a pressure
regulator. Set the regulator no higher than 1.38 bar (20
psi) above the recommended tyre pressure. See table
below for recommended tyres and pressures for your
machine.
Use an air hose fitted with a self-locking air chuck and
remote shut-off valve.
3 Add the Air
Make sure that the air hose is correctly connected to the
tyre valve. Clear other people from the area. Stand
behind the tread of the tyre while adding the air.
Inflate the tyre to the recommended pressure. Do not
over-inflate.
Checking the Wheel Nut Tightness
On new machines, and whenever a wheel has been
removed, check the wheel nut torques every two hours until
they stay correct.
Every day, before starting work, check that the wheel nuts
are tight.
The correct torques are shown in the table opposite.
9803/6310
Section 3
5 - 1
Issue 1
Tyres and Wheels
Pressure - Bar (lbf/in2)
Type Tyre Size
Front Rear
Dual Wheels 10.0 X 20 - 16PR 8.0 (116) 8.0 (116)
Single Wheels 18 R 19.5 SUPER 6.5 (94) 6.5 (94)

Topping-up Fluid Level
1 Prepare the Machine
Position the machine on level ground. Stop the engine.
Remove the starter key.
2 Release Tank Pressure
See Releasing Tank Pressure.
3 Add Fluid
Remove the hydraulic tank filler plug E and add fluid to
the required level as indicated on the sight tube B. See
Lubricants and Capacities for type of fluid to use.
4 Refit Filler Plug E.
7 - 1
For location of hydraulic oil tank refer to Component
Location Diagrams at the end of this section.
! WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates your skin get
medical help immediately.
INT-3-1-10/1
Checking the Fluid Level
Position the machine on level ground with the bucket
and dipper rams fully extended and the boom lowered
to rest the attachment on the ground, as at A.
2 Check the Level
Look at the fluid level in the sight tube B. The level
should be between the two marks on the tube. If the
fluid is cloudy, water or air has entered the system.
Water or air in the system could damage the hydraulic
pump. Contact your JCB distributor if the fluid is cloudy.
Releasing Tank Pressure
! WARNING
DO NOT remove the hydraulic tank filler cap or cover
plate when the engine is running. The hydraulic system
is under pressure. You or others could be injured. First
stop the engine and then release the pressure.
8-3-4-4/1
2 Locate Breather C on Top of the Hydraulic Oil Tank
Remove cap D. Press and hold the projection revealed
until all pressure has been released.
9803/6310
Section 3
7 - 1
Issue 1
Hydraulics
JS04510
A
B
C
D
E

7 - 2
Changing the Fluid
2 Locate Breather Mounting Plate A and Drain Plug C
These are, respectively, on the top and bottom of the
hydraulic oil tank (see Component Location
Diagrams).
4 Empty the Tank
a Remove plate A and O-ring B.
b Use a pump to discharge the hydraulic oil into an
empty container.
c Remove drain plug C and drain the remaining oil
from the tank into a suitable drain pan.
5 Renew the Suction Strainer D and Return Filter E
See Cleaning/Changing the Suction Strainer and
Changing the Return Filter.
6 Tighten drain plug C securely.
7 Refill the tank with the specified oil to the specified level
(see Lubricants and Capacities).
8 To seal the system, install O-ring B and breather
mounting plate A.
Note: If the O-ring is damaged, fit a new one.
9 Bleed air from the hydraulic components (see Air
Bleeding Procedures).
10 Start the engine and run it for about 5 minutes without
load. Slowly operate the rams several times and
then carry out step 1 above.
11 Check the hydraulic oil level (see Checking the Fluid
Level) and top up if necessary (see Topping-up Fluid
Level).
9803/6310
Section 3
7 - 2
Issue 1
Hydraulics
JS06090
E
D
B
C
A

7 - 3
Changing the Return Filter Element
2 Locate the Return Filter
Refer to Component Location Diagrams.
4 Remove the Element
a Remove cover A and O-ring B.
b Remove spring C, valve D and return filter E from
the tank.
5 Fit a New Element
Re-assemble in reverse order using a new filter
element E and a new cover O-ring B.
Flushing Filters
A slave hydraulic flushing element can now be obtained for
the machine. It is a mandatory requirement that the hydraulic
system is flushed when:
1 The hydraulic system has become contaminated with
debris.
2 Major hydraulic components such as pumps, valve
blocks, rams, tanks, motors etc. are changed.
3 An oil sample report indicates that the system needs to
be cleaned.
The slave filter should be fitted in place of the main return
filter during flushing only.
1 Vent hydraulic tank pressure (see Releasing Tank
Pressure) and then remove tank cover A and ‘O’ ring B,
main hydraulic filter E, relief valve D and spring C.
2 Fit flushing filter element, relief valve D and spring C.
3 Refit tank cover A, ensuring that the ‘O’ ring B is
positioned correctly.
4 Start up machine and test for leaks.
5 Run the machine as described below:
The filter should be left in the machine for a minimum of
4 hours, during which time all hydraulic services must
be operated a minimum of 20 times to ensure complete
system cleanliness.
6 After the required flushing time has elapsed, stop the
engine and vent hydraulic pressure (see Releasing Tank
Pressure).
7 Remove flushing filter element and save in a clean
condition until step 10 is completed.
8 Fit new main hydraulic filter and refit tank cover.
9 Take oil sample and send for analysis.
10 If analysis shows that the oil is out of specification the
flushing procedure should be repeated until analysis
confirms that the oil is satisfactory.
Element Required
SSP0061
9803/6310
Section 3
7 - 3
Issue 2*
Hydraulics
JS06090
A B
C
D
E
*

7 - 4
Cleaning/Changing the Suction Strainer
2 Locate the Suction Strainer
3 Release the Tank Pressure
4 Remove the Suction Strainer
a Remove breather mounting plate F and O-ring G.
b Remove suction strainer H from the tank and clean
with a suitable solvent or, if renewing, discard.
5 Fit the Suction Strainer
Fitting is the reverse of removal. When changing the
suction strainer, fit a new O-ring seal G to breather
mounting plate F and secure the fasteners.
6 Check the hydraulic oil level (see Checking the Fluid
Level) and top up if necessary (see Topping-up Fluid
Level).
9803/6310
Section 3
7 - 4
Issue 2*
Hydraulics
JS06090
F
H
G
*

7 - 5
Changing the Plexus Filter (Early machines)
2 Locate Plexus Filter A
4 Remove the Plexus Filter
a Close the two filter case cocks B and C by turning
them to position X.
b Remove bolts D, cover E and remove the O-ring F
and spring G.
c Lift up the Plexus filter element H carefully and
remove. Take care not to drop any sediment.
5 Fit a New Element
a Peel off the 4 foil seals of the new Plexus filter
element H (one on the lower side, two on the sides
and one on the upper side).
Note: If the foil is not removed, the filter will not function.
b Slowly insert Plexus filter element H. Install spring G,
O-ring F, cover E and bolts D. Open the cocks B and
C by turning them to position Y.
6 Prime the Plexus Filter
Start the engine and set at low idling. Loosen plug J and
then re-tighten when hydraulic oil flows out.
7 Stop the engine. Check the hydraulic oil level (see
Checking the Fluid Level) and, if necessary, top-up
(see Topping-up Fluid Level).
9803/6310
Section 3
7 - 5
Issue 4*
Hydraulics
JS04490
A
X
Y
D J E
G
H B C
F
*

7 - 6
9803/6310
Section 3
7 - 6
Issue 4*
Hydraulics
Changing the Plexus Filter
1. Prepare the Machine
2. Locate the Plexus Filter
Refer to the Component Location Diagrams.
3. Release Tank Pressure
(See Releasing Tank Pressure).
4. Remove the Plexus Filter
a. Close the two filter case cocks B and C by turning
them to position X.
b. Remove bolts and washers E,
c Slacken the nuts G and insert the screws F to lift
off the cover D.
d Remove the cover D and remove the O-ring H.
e Lift up the Plexus filter A carefully and remove.
Take care not to drop any sediment.
5. Fit a New Element
a Slowly immerse the new Plexus filter A. Install the
O-ring H, cover D, nuts G and bolts F and bolts E.
b Torque tighten bolts E to 20Nm (14.75 lbf ft)
c Open the cocks B and C by turning them to
position Y.
6. Priming the Plexus Filter
a Start the engine and set at low idling, loosen plug
J, then tighten the plug when hydraulic oil flows
out.
b. Stop the engine, check the hydraulic oil level and
top-up if low. (See Checking the Fluid Level).
E J
D
F
G
H
B
B
C
C
A
A
X
Y
*

7 - 7
Changing the Air Breather Element
3 Locate the Air Breather X
See Component Location Diagram.
4 Replace the Air Breather Element
a Remove cover F, hexagonal nut A, seal washer B
and cover C.
Note: The cover C can only fit in one of two positions
because of the slot G in the cover which locates over a
similar shaped protrusion on the mounting stud.
b Remove old filter element D together with sponge
packing E.
c Install a new filter element D followed by new
sponge packing E.
5 Refit Filter Cover C
Rotate the cover so that it fits over the stud. Then, in
order, install seal washer B, hexagonal nut A and cover
F.
Draining Tank Impurities
3 Remove Filler Plug Y
4 Draining the Water and Sediment
Loosen drain plug Z on the bottom of the tank and drain
the sediment and water accumulated. The task is
complete when clean hydraulic fluid flows out. Tighten
drain plug Z.
5 Top up the Hydraulic Oil Tank.
See Topping-up Fluid Level. Refit filler plug Y.
9803/6310
Section 3
7 - 7
Issue 3*
Hydraulics
JS03660
F
B
A
G
C
E
D X
JS06090
Y
Z
X
*

7 - 8
Changing the Servo Oil Filter
Position the machine on level ground. Stop the engine
by pressing the Emergency Engine Stop Switch (see
Left Console in OPERATION section of Operator
Handbook). Operate all the hydraulic servo controls to
release system pressure. Press the Emergency Engine
Stop Switch again to deselect the function. Turn the
starter key to OFF and then remove it.
See Releasing Tank Pressure. Remove the filler plug.
3 Locate the Servo Oil Filter
Refer to Component Location Diagrams at the end of
this section.
4 Dismantle the Filter
a Using a wrench on the case, unscrew filter case A
from filter head B. Take care not to spill the oil it
contains.
b Remove and discard element C and 'O' ring D.
5 Clean the Filter Base and Case
Discard any fluid in the filter case. Clean out the case
and the underside of the head.
6 Fit New Filter Components
a Coat the new 'O' ring D with hydraulic fluid and
locate in filter head B.
b Coat the seal area of the new element C and install
it in the filter case.
c Screw filter case A to filter head B and tighten with
the wrench.
7 Check the Hydraulic Oil Level
Check (see Checking the Fluid Level) and, if necessary,
top-up the hydraulic oil tank (see Topping-up Fluid
Level). Refit the filler plug.
9803/6310
Section 3
7 - 8
Issue 3*
Hydraulics
B
D
C
A
*
*

7 - 9
Changing the Drain Line Filter Element
See Releasing Tank Pressure. Remove the filler plug
3 Locate the Drain Line Filter Element
this section.
4 Remove the Filter
Unscrew filter A from the filter head B.
5 Clean the Filter Head
6 Fit a New Filter
Coat the sealing ring on the new filter with hydraulic oil
and screw hand-tight into the filter head.
Changing the Steering Line Filter Element
See Releasing Tank Pressure. Remove the filler plug
3 Locate the Steering Line Filter Element
this section.
4 Remove the Filter
Unscrew filter C from the filter head D.
5 Clean the Filter Head
6 Fit a New Filter
Coat the sealing ring on the new filter with hydraulic oil
and screw hand-tight into the filter head.
9803/6310
Section 3
7 - 9
Issue 3*
Hydraulics
JS02830
A
B
JS08740
C
D
*
*
*

7 - 10
Changing the Breaker In-line Filter (if
fitted)
Note: This filter should be changed at the intervals stated in
Service Schedules or when the visual indicator X has
popped up. DO NOT USE THE ROCKBREAKER OR
CRUSHER WITH A BLOCKED FILTER.
3 Locate the Filter
Refer to Component Location Diagram.
4 Remove the Oil Filter
Unscrew and remove filter A from head B.
5 Fit the New Filter
Coat the seal of the new filter with clean hydraulic fluid.
Screw the new filter into head B and tighten.
6 Check (see Checking the Fluid Level) and top up the
hydraulic oil tank (see Topping-up Fluid Level).
9803/6310
Section 3
7 - 10
Issue 3*
Hydraulics
JS06700
A
X
B
*

7 - 11
Air Bleeding Procedures
After replacing the hydraulic oil or repairing or replacing
hydraulic components or removing hydraulic pipes, bleed air
from the hydraulic circuit.
Bleeding Air from the Hydraulic Pump
If the air is not completely bled, the life of the pump will be
reduced or serious trouble can occur.
2 Locate the Hydraulic Pump
Refer to Component Location Diagram at the end of
this section.
3 Temporarily loosen air bleeding plug A.
4 If oil comes out, re-tighten the plug. If oil does not come
out, remove the air bleeding plug A and prime the pump
by pouring hydraulic oil into the pump case through the
air bleeding port.
5 Temporarily tighten air bleeding plug A. Start the engine
and idle at low speed. Slightly loosen air bleeding plug A
and continue to run the engine until oil exudes from the
air bleeding port.
6 Tighten the air bleeding plug firmly.
7 Stop the engine and allow any bubbles in the system to
make their way through the hydraulic tank.
9803/6310
Section 3
7 - 11
Issue 3*
Hydraulics
JS06710
A
*

7 - 12
Air Bleeding Procedures (cont’d)
Bleeding Air from the Rams
If air is not bled from the rams when replaced or repaired,
the piston and/or seals may be damaged.
Idle the engine at low speed and extend and retract
each ram 4 or 5 times, stopping the ram 100 mm before
the end of each stroke.
2 Bleeding
Operate each ram 3 or 4 times over the full stroke in
both directions to completely bleed the air.
Bleeding Air from the Slew Motor
If air is not completely bled from the slew motor the motor
bearing or other parts may be damaged.
Position the machine on level ground. Stop the Engine.
2 Locate the Slew Motor
Refer to the Component Location Diagrams at the end
of this section.
3 Bleeding the Slew Motor
a Start the engine and idle at low speed.
b Loosen air bleeding plug A and check that oil seeps
out.
Note: Do not operate any other equipment .
c If no oil seeps out, stop the engine and remove air
bleeding plug A. Fill the motor case with hydraulic
oil.
d Temporarily tighten air bleeding plug A.
e Idle the engine at low speed again. Slightly loosen
air bleeding plug A and continue to run until oil runs
out of the port.
4 Sealing the System
a Tighten air bleeding plug A firmly.
b Idle the engine at low speed and slowly slew the
machine left to right evenly, two or more times.
5 Stop the engine and allow any bubbles in the system to
make their way through the hydraulic tank.
9803/6310
Section 3
7 - 12
Issue 1*
Hydraulics
A
JS160W
JS 175W
A
JS130W
JS 145W
*
*

8 - 1
Checking the Slew Gearbox Oil Level
and remove the starter key.
2 Locate the Slew Gearbox
this section.
3 Check the Level
a Remove the dipstick A, wipe it clean and re-fit.
b Remove the dipstick again and check that the oil
level is within the range B.
c If necessary, top up through filler port C. Refer to
Lubricants and Capacities for oil type.
4 Re-fit the Dipstick.
Changing the Slew Gearbox Oil
2 Drain the Oil
a Remove the drain plug D. Allow the oil to drain out.
b Wipe the drain plug clean. Remove any metallic
particles.
c Refit the drain plug. Make sure it is tight.
3 Fill with New Oil
Refer to Lubricants and Capacities for oil type and
volume.
Fill with new oil through filler port C until it reaches the
full mark on the dipstick when settled. Refit the dipstick.
4 Check for Leaks
Run the machine, operate the slew controls and make
sure there are no leaks.
9803/6310
Section 3
8 - 1
Issue 2*
Transmission
JS130W/JS145W
A
B
C
A
JS160W/JS175W
C
B
A
A
D
D

8 - 2
Replenishing Slew Gearbox Grease
2 Remove Air Bleed Plug A
! CAUTION
Failure to remove the bleed plug before adding grease
could damage the inner seal.
8-3-4-7
3 Fill Up with Grease
Refer to Lubricants and Capacities for grease type.
Pump in grease through nipple B until the grease starts
to ooze from bleed plug A. Refit and tighten the bleed
plug.
9803/6310
Section 3
8 - 2
Issue 1
Transmission
BA

8 - 3
Checking the Drive Gearbox Oil Level
! WARNING
Make the machine safe before getting beneath it. Lower
the attachments to the ground; engage the parking
brake; remove the starter key, disconnect the battery.
2-3-2-2
Park the machine on level ground. Engage the parking
brake. Lower the attachments to the ground. Stop the
engine and remove the starter key.
2 Check/Add Oil
Clean the area around the fill/level plug A, then remove
the plug and its sealing washer. Oil should be level with
the bottom of the hole.
Add recommended oil if necessary (see Lubricants and
Capacities).
Clean and refit the plug and sealing washer. Torque
tighten to 60 Nm (44 lbf ft).
Changing the Drive Gearbox Oil
! WARNING
2-3-2-2
Note: This job should be done with the oil at operating
temperature.
2 Drain the Oil
a Place a container of suitable size beneath plug B to
catch the oil.
b Remove the drain plug B and its washer. Allow oil to
drain out. Wipe it clean. Metallic particles should be
carefully removed.
c Fit the drain plug and its washer. Tighten to 60 Nm
(44 lbf ft).
3 Fill with New Oil
Fill with recommended oil through fill/level hole A (see
Lubricants and Capacities). Clean and refit the plug
and its washer. Torque tighten to 60 Nm (44 lbf ft).
9803/6310
Section 3
8 - 3
Issue 2*
Transmission
A314100
AA
BB
*

8 - 4
Checking the Front Axle Differential Oil
Level
! WARNING
2-3-2-2
! CAUTION
The axle oil level must be checked with the machine
level, otherwise a false indication of the amount of oil in
the axle will be given.
16-3-5-3
2 Check/Add Oil
Clean the area around the fill/level plug A, then remove
the plug and its sealing washer. Oil should be level with
the bottom of the hole.
Note: If the oil gives off a foul smell it is a sign that the oil
has degraded and should be changed.
Capacities).
Clean and refit the plug and sealing washer. Tighten
firmly.
Changing the Front Axle Differential Oil
! WARNING
2-3-2-2
temperature.
2 Drain the Oil
a Place a container of suitable size beneath plug B to
catch the oil.
b Remove the drain plug B and its washer. Allow oil to
drain out. Wipe it clean. Metallic particles should be
carefully removed.
c Fit the drain plug and its washer. Tighten firmly.
3 Fill with New Oil
Fill with recommended oil through fill/level hole A (see
Lubricants and Capacities). Clean and refit the plug
and its washer. Tighten firmly.
9803/6310
Section 3
8 - 4
Issue 1
Transmission
JS04130B
A

8 - 5
Checking the Front Axle Hub Oil Level
Check each hub separately
Park the machine on level ground with the OIL LEVEL
mark vertical and plug C at the top, as shown in fig. 2.
Engage the parking brake.
! WARNING
If the hub is hot to the touch there may be a
considerable build-up of pressure inside the hub. This
pressure could tend to force the fill/level plug rapidly out
of its hole as it is being unscrewed. If possible wait until
the hub has cooled before doing this job.
8-3-5-3
! CAUTION
Always follow the procedure below to fully vent hub
internal pressure before removing the oil filler/drain plug.
Otherwise, if the plug is below the oil level when it is
removed, oil could spurt out and possibly cause
personal injury.
8-3-5-2
2 Release Hub Pressure
Slowly unscrew fill/level plug C to allow any internal
pressure to escape. When all pressure is released, re-
tighten plug C.
3 Move the machine slowly until plug C is positioned as
shown in fig. 1. Stop the engine and remove the starter
key.
4 Check/Add Oil
Clean the area around the fill/level plug C. Remove the
plug. Oil should be level with the bottom of the hole.
Capacities).
Clean and refit the plug and sealing washer.
Changing the Front Axle Hub Oil
Change the oil in each hub separately.
Park the machine on level ground with the OIL LEVEL
mark vertical and plug C at the top, as shown in fig. 2.
Engage the parking brake.
! WARNING
If the hub is hot to the touch there may be a
considerable build-up of pressure inside the hub. This
pressure could tend to force the fill/level plug rapidly out
of its hole as it is being unscrewed. If possible wait until
the hub has cooled before doing this job.
8-3-5-3
! CAUTION
Always follow the procedure below to fully vent hub
internal pressure before removing the oil filler/drain plug.
Otherwise, if the plug is below the oil level when it is
removed, oil could spurt out and possibly cause
personal injury.
8-3-5-2
2 Release Hub Pressure
Slowly unscrew fill/level plug C to allow any internal
pressure to escape. When all pressure is released, re-
tighten plug C.
3 Position the Machine
Move the machine slowly until plug C is at its lowest
position, as shown in fig. 3. Stop the engine and remove
the starter key.
4 Drain the Oil
a Place a container of suitable size beneath plug C to
catch the oil.
b Remove fill/level plug C and allow the oil to drain
out.
5 Fill with New Oil
a Start the engine.
! CAUTION
There will be no oil in the hub when the machine is
moved. Move the machine only far enough to position
the OIL LEVEL mark horizontal as shown.
8-3-5-1
b Move the machine slowly to bring the 'OIL LEVEL'
mark on the hub in the horizontal position, as shown
in fig. 1.
c Fill with recommended oil through fill/level hole C
(see Lubricants and Capacities).
Clean and refit the plug and sealing washer.
9803/6310
Section 3
8 - 5
Issue 1
Transmission
JS06450
CC
CC
CC
1 2
3

8 - 6
Note: The oil galleries of the axle differential housing and the
wheel hubs are interconnected.
Checking the Rear Axle Differential/Hub
Oil Level
! WARNING
2-3-2-2
! CAUTION
The axle oil level must be checked with the machine
level, otherwise a false indication of the amount of oil in
the axle will be given.
16-3-5-3
2 Check/Add Oil
Clean the area around the differential fill/level plug A,
then remove the plug and its sealing washer. Oil should
be level with the bottom of the hole.
Capacities).
Clean and refit the plug and sealing washer. Tighten
firmly.
Changing the Rear Axle Differential/Hub
Oil
! WARNING
2-3-2-2
temperature.
2 Drain the Oil
a Differential Housing
i Place a container of suitable size beneath plug
B to catch the oil.
ii Remove the drain plug B and its washer. Allow
oil to drain out. Wipe it clean. (Metallic particles
should be carefully removed.)
iii Fit the drain plug and its washer. Tighten firmly.
b Hubs
Drain each of the hubs as described under
Changing the Front Axle Hub Oil steps 1 to 4.
Refit the drain plugs and sealing washers.
3 Fill with New Oil
Fill with recommended oil through differential fill/level
hole A (see Lubricants and Capacities). Clean and refit
the plug and its washer. Tighten firmly.
9803/6310
Section 3
8 - 6
Issue 1
Transmission
JS04140
A
B

9 - 1
9803/6310
Section 3
9 - 1
Issue 2*
Engine
A336941
AA
FF
CC
EE
BB
DD
Changing the Air Filter Outer Element
! CAUTION
The outer element must be renewed immediately if the
warning light on the instrument panel illuminates.
2-3-3-1
Note: Do not attempt to wash or clean the elements - they
must only be renewed.
Note: Do not run the engine with the dust valve F removed.
Note: Change the outer element more frequently if
operating in dusty conditions. A new inner element must be
fitted at least every third time the outer element is changed.
As a reminder, mark the inner element with a felt tipped pen
each time the outer element is changed.
1 Stop the engine.
2 Press clips A and lift off cover B. Remove outer element
C. Take care not to tap or knock the element.
3 Clean the inside of cover B and canister D.
4 Insert a new element into the canister, check seal E is
fully seated. Fit cover B with dust valve F at the bottom.
Push the cover firmly into position and make sure it is
secured by clips A.
5 Make sure that the wire is connected to the Air Filter
Blocked switch.
6 Check all hoses for condition and tightness.

9 - 2
9803/6310
Section 3
9 - 2
Issue 2*
Engine
A336941
AA
CC
GG
EE
BB
DD
FF
JJ
HH
Changing the Air Filter Inner Element
Note: Do not attempt to wash or clean the elements - they
must only be renewed.
Note: Do not run the engine with the dust valve F removed.
Note: A new inner element must be fitted at least every
third time the outer element is changed. As a reminder,
mark the inner element with a felt tipped pen each time the
outer element is changed.
1 Stop the engine.
2 Press clips A and lift off cover B. Remove outer
element C.
3 Lift up pulls J and remove inner element G.
4 Clean the inside of cover B and canister D.
5 Carefully insert the new inner element G into the
canister. Make sure it seats correctly. Check seal H is
fully seated.
6 Insert a new outer element C into the canister, check
seal E is fully seated. Fit cover B with dust valve F at
the bottom. Push the cover firmly into position and
make sure it is secured by clips A.
7 Make sure that the wire is connected to the Air Filter
Blocked switch.
8 Check all hoses for condition and tightness.

9 - 3
Checking the Oil Level
Park the machine on level ground. Lower the bucket to
the ground.
2 Stop the Engine
3 Open the Engine Compartment
4 Check the Oil Level
Remove dipstick A. Oil should be between H and L
marks except on Tier 2 engines. Add oil if necessary,
through filler B. Use only the recommended oil, see
Lubricants and Capacities. Make sure that the dipstick
and filler cap are secure.
Changing the Oil and Filters
1 Do steps 1 to 3 of Checking the Oil Level
2 Drain the Oil
Place an oil collecting container of suitable size beneath
the engine sump drain point.
a All machines except for German market and Tier
2 engines
Remove the drain plug at C and allow the oil to
drain completely. Clean the drain plug and its
aperture in the sump, refit and tighten firmly. Do not
overtighten or the threads could be stripped.
b Tier 2 engines only
Remove the belly plate and place an oil collecting
container of suitable size beneath the engine
sump drain point.
Note: The machine is fitted with a self sealing drain plug D.
Remove the self sealing drain plug outer threaded
cover and fit the self sealing drain kit threaded union
(with attached pipe) E, stored in the tool box. Drain
sump oil into a suitable container.
Remove the self seal drain kit, clean and refit the
outer cover. (Do not over tighten the cover).
c German machines only
Obtain from the tool box the drain tube. Remove the
sump drain valve dust cover from location C. In its
place, after locating the drain tube inside the oil
collecting container, firmly attach the drain tube to
the adapter. The oil will automatically drain once the
tube is connected. When the oil has drained
completely, remove the tube and clean the drain
valve and the valve dust cover. Refit the dust cover.
3 Change the Filters
a Unscrew the filter canisters F. Remember that the
filters will be full of oil.
b Clean the filter heads.
c Smear the seal on each new filter with oil.
d Tighten the filter until the seal bites onto the filter
housing.
e Tighten the filter a minimum of one more full turn.
9803/6310
Section 3
9 - 3
Issue 2*
Engine
4 Fill the System
Fill the engine with new oil through the filler B. See
Lubricants and Capacities for type and amount.
Wipe off any spilt oil. Check for leaks. Make sure the
filler cap is correctly refitted.
5 Check for Leaks
Start the engine and allow the engine to go through the
AUTO WARM-UP procedure (see Starting the
Engine).
When the AUTO WARM-UP is complete, stop the
engine and check for leaks.
448030
A
B
F
F
448040
AA
BB
FF
DD EE
Tier 2 engine only
C
*

9 - 4
Checking the Coolant Level
1 Park the Machine on Level Ground
Stop the engine and let it cool down. Open the engine
compartment.
! WARNING
The cooling system is pressurised when the coolant is
hot. Hot coolant will burn you. Make sure that the engine
is cool before checking the coolant level or draining the
system.
2-3-3-3
2 Release System Pressure
For location of engine cooling radiator, refer to
Component Location Diagrams at the end of this
section.
Carefully slacken cap A. Let any pressure escape.
Remove the cap.
3 Check the Level
The level should be between the FULL and LOW marks
on the expansion bottle B. Top up the bottle with pre-
mixed water/antifreeze if necessary. See Coolant
Mixtures.
4 Refit the Pressure Cap A
Make sure it is tight.
Note: Check the quality of the antifreeze mixture every year
- before the cold weather starts. Change it every two years.
Coolant Mixtures
To prevent the coolant freezing in cold conditions, antifreeze
must be added. JCB Universal Antifreeze will give protection
down to the temperatures shown in the table.
Antifreeze Solution Starts to freeze at
55% -36 °C (-33 °F)
Never use less than a 50% solution otherwise there will not
be enough corrosion protection.
Never use more than 60% solution otherwise the cooling
system may be damaged.
Leave the antifreeze in all the year round as it gives
protection against corrosion.
Check the strength of antifreeze solution at least once a
year, preferably at the start of the cold period. Always renew
the antifreeze every two years.
A 50% antifreeze mixture should be used even if frost
protection is not needed. This gives protection against
corrosion and raises the coolant's boiling point.
9803/6310
Section 3
9 - 4
Issue 1
Engine
JS04410
JS03930
A
B

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