JCB JS160W WHEELED EXCAVATOR Service Repair Manual SN：718500 Onwards

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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 Issue 5

General Information

1

Care & Safety

2

Routine Maintenance

3

Attachments

A

Body & Framework

B

Electrics

C

Controls

D

Hydraulics

E

Transmission

F

Brakes

G

Engine

K

Section 1

General Information

Section 1

i

i

Contents

9803/6310

Page No.

Machine and Axle Identification

1-1

Torque Settings

2-1

Service Tools Body and Framework (Section B) Electrics (Section C) Hydraulics (Section E) Transmission (Section F) Axles (Section F)

4-1 5-1 6-1 7-1 8-1

Sealing and Retaining Compounds

9-1

Issue 1

Section 1 1-1

General Information

Section 1

Machine and Axle Identification

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.

A

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.

B

JS06050

C

JS06060

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.

S156570

9803/6310

Issue 1

Section 1

General Information

Section 1

Torque Settings

2-1

2-1

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.

9803/6310

Issue 2*

Section 1

General Information

Section 1

4-1

4-1

Service Tools Body and Framework (Section B)

S186240

S186270

Hand Cleaner - special blend for the removal of polyurethane adhesives.

Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc.

4104/1310 (454g; 1lb tub)

892/00845

'

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).

Folding Stand for Holding Glass - essential for preparing new glass prior to installation.

992/12300

892/00843

S186280

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 9803/6310

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 Issue 1

Section 1

General Information

Section 1

4-2

4-2

Service Tools (cont’d) Body and Framework (Section B) (cont’d)

S186310

S186340

Cut-out Knife - used to remove broken glass.

Wire Starter - used to access braided cutting wire (below) through original polyurethane seal.

992/12800 892/00848

'

S186350 S186320

Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass.

'L' Blades - 25mm (1in.) cut - replacement blades for cut-out knife (above).

992/12801 (unit quantity = 5 off)

892/00846

S186360

S186330

Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool (above).

Long Knife - used to give extended reach for normally inaccessible areas.

892/00844

892/00849 (approx 25m length) 9803/6310

Issue 1

Section 1

General Information

4-3

Section 1 4-3

Service Tools (cont’d) 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

9803/6310

S186550

Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame.

926/15500 (unit quantity = 500 off)

Issue 1

Section 1

General Information

Section 1

5-1

5-1

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

A360250

892/01033

9803/6310

Data Link Adaptor Used with AMS Machines Only

Issue 2*

Section 1

General Information

Section 1

6-1

6-1

Service Tools (continued) SECTION E - HYDRAULICS

Hydraulic Pressure Test Gauges and Connections 1

892/00279

Pressure Gauge 0-400 bar (0-6000 lbf/in2)

2

892/00346

Pressure Gauge 0-70 bar (0-1000 lbf/in2)

3

892/00347

Connector

4

892/00254

Hose

5

892/00280

Pressure Gauge 0-600 bar (0-9000 lbf/in2)

1/2/5

Pressure Test ‘T’ Adapters

Pressure Test Adapters

892/00262 816/55038 816/55040 892/00263 892/00264 892/00265 892/00266 892/00267

892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261

9803/6310

1/4 in BSP x 1/4 in F BSP x Test Point 3/8 in BSP x 3/8 in F BSP x Test Point 1/2 in BSP x 1/2 in F BSP x Test Point 5/8 in BSP x 5/8 in F BSP x Test Point 3/4 in BSP x 3/4 in F BSP x Test Point 1 in M BSP x 1 in F BSP x Test Point 1,1/4 in M BSP x 1,1/4 in F BSP x Test Point 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point

1/4 in BSP x Test Point 3/8 in BSP x Test Point 1/2 in BSP x Test Point 5/8 in BSP x Test Point 3/4 in BSP x Test Point 1 in BSP x Test Point 1,1/4 in BSP x Test Point 5/8 in UNF x Test Point

Issue 2*

Section 1

General Information

Section 1

6-2

6-2

Service Tools (continued) SECTION E - HYDRAULICS

Hand Pump Equipment 892/00223 892/00137 892/00274 892/00262 892/00706 892/00278 892/00279 892/00280

Hand Pump Micro-bore Hose 1/4 in BSP x 5 metres Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1/4 in M BSP x 1/4 in F BSP x Test Point Test Probe Gauge 0 - 40 bar (0 - 600 lb/in2) Gauge 0 - 400 bar (0 - 6000 lb/in2) Gauge 0 - 600 bar (0 - 8500 lb/in2)

816/50005 816/60096 816/00018

1/2 in BSP (A) x 1/2 in BSP (B) 3/4 in BSP (A) x 3/4 in BSP (B) 1 in BSP (A) x 1 in BSP (B)

Female Cone Blanking Plug

Male Cone Blanking Plug

892/00055 892/00056 892/00057 892/00058 892/00059 892/00060

816/00294 816/00189 816/00190 816/00197 816/00196 816/00193

9803/6310

1/4 in BSP 3/8 in BSP 1/2 in BSP 5/8 in BSP 3/4 in BSP 1 in BSP

1/4 in BSP 3/8 in BSP 1/2 in BSP 5/8 in BSP 3/4 in BSP 1 in BSP

Issue 1

Section 1

General Information

Section 1

6-3

6-3

Service Tools (continued) SECTION E - HYDRAULICS

JS07050

Ram Piston Nut Removal/Fitting Spanner

Ram Piston Nut Removal/Fitting Rig 993/99525 993/99522 993/99523 993/99524 556/43400 545/18000 811/50232

9803/6310

Rig Assembly (not including spanners and ram) Anchor Side Plate (supplied loose unwelded) Anchor Cross Member (supplied loose unwelded) Ram Eye End Modification Plate Assembly Lift Ram Lynch Pin 1,1/4� Pivot Pin

993/99512 993/99513 993/99514 993/99515 993/99516 993/99517 993/99518 993/99519 993/99520 993/99521 SSP0046 SSP0047

Spanner 55 mm A/F Spanner 60 mm A/F Spanner 65 mm A/F Spanner 70 mm A/F Spanner 75 mm A/F Spanner 85 mm A/F Spanner 90 mm A/F Spanner 100 mm A/F Spanner 110 mm A/F Spanner 115 mm A/F Spanner 80 mm A/F Spanner 95 mm A/F

Issue 2*

Section 1

General Information

Section 1

6-4

6-4

Service Tools (cont’d) Hydraulics (Section E) (cont’d)

30

ø70 (2.76")

ø38.+- 0.2 (1.50"+-0.008)

ø61.+- 0.2 (2.40"+-0.008)

Slew Motor Unit - JS130W/145W

o

2 (0.079") 14 (0.55")

155 (6.10")

4 (0.16") Seal Fitting Tool (Oil Seal 2)

JS07110

ø32.2.+- 0.1 (ø1.27+-0.004)

o

ø35.5.+- 0.1 (ø1.40+-0.004)

ø42 (1.65")

15

100 (3.94") 110 (4.33") Fitting Tool for Inner Ring of Taper Roller Bearing 3

50 (1.97") 80 (3.15")

ø31.4+-0.1 (1.24"+-0.004)

5o

ø40 (1.57")

JS07120

ø38 (1.50")

*

50 (1.97") 60 (2.36")

JS07130

Seal Protector Heat polyvinyl tube in hot water and form to required shape.

9803/6310

JS07140

Fitting Tool for Inner Ring 1

Issue 2*

Section 1

General Information

Section 1

6-5

6-5

Service Tools (cont’d) Hydraulics (Section E) (cont’d) Slew Motor Unit - JS160W/JS175W

40 (1.57")

2 x ø9 (0.35")

40 (1.57")

200 (9.84")

100 (3.94") Inner diameter ø11 (0.43")

10 (0.39")

*

M10 180 (7.09") 240 (9.45") JS07100

Puller for Brake Piston Stud is threaded M10 on both ends for 20 mm (0.8 in) and fitted with two M10 nuts.

9803/6310

Issue 2*

Section 1

General Information

Section 1

6-6

6-6

Service Tools (cont’d) Hydraulics (Section E) (cont’d)

*

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 -0.1 (3.91 in

+0 -0.004 )

J

Dia. 76 mm +0 (2.99 in

+0 ) -0.004

K

24 mm (0.94 in)

L

95 mm (3.74 in)

M

Radius 0.7 mm (0.028 in)

A

N

120 mm (16.5 in)

B

O

4.0 mm (0.157 in)

P

3.0 mm (0.118 in)

Q

15°

O-ring

G75

+0

-0.1

C

D

E

F

N G M

Q

O

H

L P J I K

JS07150

Blank for Suction Strainer

9803/6310

Issue 2*

Section 1

General Information

Section 1

6-7

6-7

Service Tools (cont’d) Hydraulics (Section E) (cont’d) Remote Control Valve - JS130W/JS145W/JS160W/JS175W

13

ø26.5 23.5

1

50

65

ø19 ø28

2

19

17

25

42

*

ø21 ø25 ø30

JS07160

Joint Removal Tool

15

Items 1 and 2 are assembled with an interference fit.

9803/6310

Issue 2*

Section 1

General Information

Section 1

6-8

6-8

Service Tools (cont’d) Hydraulics (Section E) (cont’d) Hydraulic Pump

140 ø12

20

M12 x 1.75

Guide Rods 220 10

15

ø30

20

10

M8 7 8

ø18.5

ø5

ø11.5

7

M8

Rear Shaft Protection Tool

M8

10

15 7

+ 3 0.1 150

11

Oil Seal Insertion Tool

ø5

ø8

R2

ø30

ø90

ø56

90

ø18.5

+ ø34.9 0.1 -

ø75 -.005 ø75 + 0.15 +0.1

Swash Plate Levelling Tool

ø44

ø50

ø37

Front Shaft Protection Tool

6 100

JS07980

Bearing Insertion Tool

9803/6310

Issue 1

Section 1

General Information

6-9

Section 1 6-9

Service Tools (cont’d) Hydraulics (Section E) (cont’d) Hydraulic Rams Reconditioning

Bush Removal/Assembly Jig

Seal Ring Insertion Jig (Inner)

Bush Removal/Assembly Jig

Seal Ring Bedding Jig

Cylinder Head Insertion Jig

Wiper Ring Installation Jig

Seal Ring Insertion Jig (Outer)

9803/6310

Issue 1

Section 1

General Information

Section 1

7-1

7-1

Service Tools (cont’d) Transmission (Section F)

*

Slew Gearbox - JS130W/145W

15 o ø94.5 +- 0.2 (3.72" +- 0.008) ø120 (4.72")

ø65 (2.56")

5o

60 (2.36")

3 (0.118")

14 15 (0.55") 6 (0.59") 30 (0.236") (1.18")

ø50 (1.97")

100 (3.94")

JS07180

ø130 (5.43") JS07170

Heat polyvinyl tube in hot water and form to the required shape on the pinion shaft

Seal Fitting Jig

Slew Gearbox - JS160W/175W

ø100 (ø3.937")

2.5 (0.098")

ø155 (ø6.094")

80 +0.3 -0 (3.15"+0.012" ) -0

*

Seal Protector

ø149 (ø5.866") JS07200

JS07190

Bearing and Oil Seal assembly Jig

9803/6310

Seal Fitting Jig

Issue 2*

Section 1

General Information

Section 1

7-2

7-2

Service Tools (cont’d) Transmission (Section F) (cont’d) Slew Gearbox - JS160W/175W (cont’d)

3

ø30.5.+- 0.1 (ø46.5 +-0.1)

15

9

15

ø36 (ø50)

30

ø50

100

ø99.8

110

ø124 ø158

JS07230 JS07210

Jig for Taper Roller Bearing Inner Ring

Seal Fitting Jig

o

80

ø49.5

30 ø75

*

2 16

155 4 JS07220

Seal Fitting Jig (SST0033)

9803/6310

Issue 2*

Section 1

General Information

7-3

Section 1 7-3

Service Tools (cont’d) Transmission (Section F) (cont’d) Drive Gearbox 892/00223 892/00346 SSP0027/SSP0028 SSP0029/SSP0030/SSP0031 SSP0035 SSP0050 SSP0051 SSP0052 SST0011 SST0013 SST0018 SST0019 SST0020 SST0032

9803/6310

Hand Pump Pressure Gauge (0 - 70 bar) Striker/Internal Puller Puller Assembly Installer Fitting Tool Handle Fitting Tool Measuring Cover Installer Sleeve Hydraulic Connector Pressure Sleeve Clutch Jig Driver

Issue 1

Section 1

General Information

Section 1

8-1

8-1

Service Tools (cont'd) Axles (Section F)

992/07604

992/07609

Replacer - Crownwheel Bearing and Differential Bearing Cones

Spacer - Pinion Bearing Preload

992/07614

Adapter Set - Bull Pinion Bearing Remover/Replacer

9803/6310

Measuring Cup - Pinion Bearing

Adapter - Steer/Drive Axle Pinion Bearing Cone

992/07607

992/07601

992/07606

Spanner for Half Shaft Nuts

892/00817 892/00818 892/00819 892/00333

892/00182

992/07603

17 mm A/F x 3/4 in square drive 22 mm A/F x 3/4 in square drive 15 mm A/F x 1/2 in square drive 19 mm A/F x 3/4 in square drive

Bearing Pad Driver

Replacer - Pinion Head Bearing Cup

Issue 1

Section 1

General Information

Section 1

8-2

8-2

Service Tools (cont'd) Axles (Section F) (cont’d)

992/04000 Torque Multiplier (use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts)

S197030

892/00822 Splined Bolt Socket for driveshafts 892/00174 Measuring Cup - Pinion Head Bearing

S190770

S197060

S197070

892/00224 Impulse Extractor Set for Hub Bearing Seals

892/00812

892/00334

Gland Seal Fitting tool

992/00800

Extractor for removing axle pivot pin

Drive Coupling Spanner for axle yoke couplings

S196720

9803/6310

Issue 1

Section 1

General Information

Section 1

8-3

8-3

Service Tools (cont'd) Axles (Section F) (cont’d)

892/00833

993/59500

Annulus Removal Tool

Adapter - Impulse Extractor

*

A272520

892/00891

9803/6310

Oil Seal Insertion Tool

Issue 2*

Section 1

General Information

Section 1

9-1

9-1

Sealing and Retaining Compounds JCB Multi-Gasket

A medium strength sealant suitable for all sizes of gasket 4102/1212 flanges, and for hydraulic fittings of 25-65 mm diameter.

50 ml

JCB Threadlocker

For threads of 50 mm diameter upwards, e.g. suction strainer.

4101/0451

50 ml

JCB Threadlocker (High Strength)

A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important.

4102/0551

50 ml

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 nuts, bolts, and screws up to 50 mm diameter, and 4101/0251 for hydraulic fittings up to 25 mm diameter.

10 ml 50 ml

JCB Threadlocker and Sealer (High Strength)

A high strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter.

4101/0550 4101/0552

10 ml 200 ml

JCB Threadseal

A medium strength thread sealing compound.

4102/1951

50 ml

JCB Activator

A cleaning primer which speeds the curing rate of anaerobic products.

4104/0251 4104/0253

Aerosol (1 ltr) Bottle (200 ml)

JCB Cleaner/Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants.

4104/1557

Aerosol (400 ml)

Anti-Seize Paste

A compound used for assembly and prevention of parts seizure.

4003/0211

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

To seal butt jointed glass.

4102/0901

Clear Silicone Sealant

9803/6310

Issue 2*

Section 2

Care & Safety

Section 2

i

i

Contents

9803/6310

Page No.

Safety Notices

1-1

General Safety

2-1

Operating Safety

3-1

Maintenance Safety

4-1

Issue 1

Section 2

Care & Safety

1-1

Section 2 1-1

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

9803/6310

Issue 2*

Section 2

Care & Safety

Section 2

2-1

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.

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.

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

!

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.

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

INT-1-3-7

!WARNING !WARNING

Raised Equipment Raised equipment can fall and injure you. Do not walk or work under raised equipment unless safely supported.

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.

13-1-1-6

INT-1-3-6

BF 6-3

! 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.

!

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

*9803/6310

Issue 2*

Section 2

Care & Safety

Section 2

3-1

3-1

Operating Safety !WARNING

!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.

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-2-1-6

INT-2-2-6

!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 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

!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

! 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

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

*9803/6310

Issue 2*

Section 2

Care & Safety

Section 2

4-1

4-1

Maintenance Safety !WARNING

!WARNING

Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground.

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.

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.

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

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 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

Issue 2*

Section 2

Care & Safety

Section 2

4-2

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.

! 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

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.

! CAUTION Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents.

INT-3-2-11

8-1-2-6/1

! CAUTION !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

'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.

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.

INT-3-2-9

8-3-4-4/1

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.

!WARNING

!WARNING

GEN-1-12

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

*9803/6310

Issue 2*

Section 3

Routine Maintenance

Section 3

i

i

Contents Lubricants and Capacities Lubricants - Health and Safety

1-1 1-3

Service Schedules

2-1

Greasing Slew Ring Teeth and Slew Pinion Slew Ring Bearing Greasing (50 hours) Greasing (General)

3-1 3-1 3-2 3-4

Battery

4-1

Fuses Tyres and Wheels Tyre Inflation Checking the Wheel Nut Tightness Hydraulics Checking the Fluid Level Releasing Tank Pressure Topping-up Fluid Level Changing the Fluid Changing the Return Filter Element Flushing Filters Cleaning/Changing the Suction Strainer Changing the Plexus Filter * Changing the Air Breather Element Draining Tank Impurities Changing the Servo Oil Filter Changing the Drain Line Filter Element Changing the Steering Line Filter Element Changing the Breaker In-line Filter (if fitted) Air Bleeding Procedures Transmission Checking the Slew Gearbox Oil Level Changing the Slew Gearbox Oil Replenishing Slew Gearbox Grease Checking the Drive Gearbox Oil Level Changing the Drive Gearbox Oil Checking the Front Axle Differential Oil Level Changing the Front Axle Differential Oil Checking the Front Axle Hub Oil Level Changing the Front Axle Hub Oil Checking the Rear Axle Differential/Hub Oil Level Changing the Rear Axle Differential/Hub Oil

9803/6310

Page No.

See Section C

5-1 5-1

7-1 7-1 7-1 7-2 7-3 7-3 7-4 7-5 7-7 7-7 7-8 7-9 7-9 7 - 10 7 - 11

8-1 8-1 8-2 8-3 8-3 8-4 8-4 8-5 8-5 8-6 8-6

Issue 4*

Section 3

Routine Maintenance

Section 3

ii

ii

Contents Engine Changing the Air Filter Outer Element Changing the Air Filter Inner Element Checking the Oil Level Changing the Oil and Filters Checking the Coolant Level Coolant Mixtures Changing the Coolant Cleaning the Radiator and Oil Cooler Adjusting the Fan Belt Fitting a New Fan Belt Draining Fuel Tank Impurities Draining the Fuel System Water Separator Changing the Fuel Filter Element Cleaning the Fuel Lift Pump Strainer Bleeding the Fuel System

*

9803/6310

Page No. 9-1 9-2 9-3 9-3 9-4 9-4 9-5 9-5 9-6 9-6 9-7 9-7 9-8 9-8 9-9

Component Location Diagrams

10 - 1

Falling Objects Protection Structure (FOPS) Checking the FOPS structure

12 - 1

Issue 2*

Section 3

Routine Maintenance

Section 3

1-1

Lubricants and Capacities

1-1

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).

Item

Fluid/Lubricant

International Specification

Capacity JS130W

JS145W/JS160W

12.1 litres (2.7 UK gal)

12.1 litres (2.7 UK gal)

5 litres (1.09 UK gal) 1 litre (0.22 UK gal)

5 litres (1.09 UK gal) 1 litre (0.22 UK gal)

ENGINE

See separate chart

SLEW GEARBOX

JCB Gear Oil HD90

API-GL-5: MIL-L-2105C

JCB HP Grease

Lithium based, No. 2 consistency

JCB Special Hydraulic Fluid HP46

Vickers 35VQ25/V104C: Sundstrand, Denison and FZG Approval Tests

124 litres (27.3 UK gal)

124 litres (27.3 UK gal)

SLEW RING - BEARINGS - GEAR TEETH

JCB HP Grease JCB HP Grease

Lithium based, No. 2 consistency

17 kg (37.48 lb)

17 kg (37.48 lb)

PROPSHAFTS

JCB HP Grease

Lithium based, No. 2 consistency

ALL OTHER GREASE POINTS

JCB HP Grease

Lithium based, No. 2 consistency

COOLING SYSTEM

See Coolant Mixtures

ASTM D3306-74

16.4 litres (3.6 UK gal)

17.2 litres (3.78 UK gal)

FUEL TANK

See Fuel System, Types of Fuel in Operator Handbook

ASTM D975-66T

240 litres

240 litres

Nos 1D, 2D

(52.8 UK gal)

(52.8 UK gal)

JCB Special Gear Oil Plus

API GL4: M2C-41B/134D, JD20C MGF M1135/M1141/M1143

18 litres (3.9 UK gal) 1.5 litres (0.33 UK gal)

18 litres (3.9 UK gal) 1.5 litres (0.33 UK gal)

JCB Special Gear Oil Plus

API GL4: M2C-41B/134D, JD20C MGF M1135/M1141/M1143

17.7 litres (3.9 UK gal)

17.7 litres (3.9 UK gal)

JCB Super 15W/40 Multigrade Engine Oil

API CF4/SG: MIL-L-2104F

3.8 litres (0.83 Uk gal)

3.8 litres (0.83 UK gal)

HYDRAULIC SYSTEM

FRONT AXLE - DIFFERENTIAL - HUB (x 2)

REAR AXLE - DIFFERENTIAL AND HUBS (x 2)

DRIVE GEARBOX

9803/6310

JCB Special Gear Oil Plus

Issue 2*

Section 3

Routine Maintenance

Section 3

1-2

Lubricants and Capacities

1-2

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).

Item

Fluid/Lubricant

International Specification

Capacity JS175W

ENGINE

See separate chart

SLEW GEARBOX

JCB Gear Oil HD90

API-GL-5: MIL-L-2105C

5 litres (1.09 UK gal)

HYDRAULIC SYSTEM

JCB Special Hydraulic Fluid HP46

Vickers 35VQ25/V104C: Sundstrand, Denison and FZG Approval Tests

124 litres (27.3 UK gal)

SLEW RING - BEARINGS - GEAR TEETH

JCB HP Grease JCB HP Grease

Lithium complex (NLGI) inc. extreme pressure additives

17 kg (37.48 lb)

PROPSHAFTS

JCB HP Grease

Lithium complex (NLGI) inc. extreme pressure additives

ALL OTHER GREASE POINTS

JCB HP Grease

Lithium complex (NLGI) inc. extreme pressure additives

COOLING SYSTEM

See Coolant Mixtures

ASTM D3306-74

25.5 litres (5.6 UK gal)

FUEL TANK

See Fuel System, Types of Fuel

ASTM D975-66T Nos 1D, 2D

240 litres (52.8 UK gal)

JCB Special Gear Oil Plus JCB Special Gear Oil Plus

API GL4: M2C-41B/134D, JD20C MGF M1135/M1141/ M1143

18 litres (3.9 Uk gal) 1.5 litres (0.33 UK gal)

JCB Special Gear Oil Plus

API GL4: M2C-41B/134D JD20C, MGF M1135/M1141/ M1143

17.7 litres (3.9 UK gal)

JCB Super 15W/40 Multigrade Engine Oil

API CF4/SG: MIL-L-2104F

3.8 litres (0.83 UK gal)

FRONT AXLE - DIFFERENTIAL - HUB (x 2)

REAR AXLE - DIFFERENTIAL AND HUBS (x 2)

DRIVE GEARBOX

9803/6310

21.5 litres (4.72 UK gal)

Issue 2*

Section 3

Routine Maintenance

Section 3

1-3

Lubricants and Capacities (continued)

1-3

Engine Lubrication Chart - All Machines Use according to ambient temperature (°C) -30

-20

-10

0

10

20

30

40

50

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

9803/6310

Issue 2*

Section 3 1-4

Routine Maintenance Lubricants - Health and Safety

Section 3 1-4

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.

First Aid - Oil

Handling

Swallowing.

If oil is swallowed you should not induce vomiting. Get medical advice.

New Oil There are no special precautions needed for the handling or use of new oil, beside normal care and hygiene practices.

Skin In the case of excessive skin contact you should wash with soap and water.

Used Oil Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer.

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.

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:

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:

a b c d e f g h

Wash your skin thoroughly with soap and water.

Using a nail brush will help.

Use special hand cleansers to help clean dirty hands.

Never use petrol, diesel fuel or gas oil.

Avoid skin contact with oil soaked clothing.

Don't keep oily rags in pockets.

Wash dirty clothing before re-use.

Throw away oil-soaked shoes.

Waste Disposal All waste products should be disposed of in accordance with all the relevant regulations.

Storage Always keep lubricants out of the reach of children.

Never store lubricants in open or unlabelled containers.

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

Issue 1*

Section 3

Routine Maintenance

Section 3

Service Schedules

2-1

2-1

Every 10 Operating Hours or Daily Whichever occurs first 1

Clean

h

Footbrake operation.

a

j

Steering operation.

k

Parking brake operation.

l

Operation of slew brake.

*

2

Machine generally.

(When steam cleaning do not direct jet at grease nipples.)

Grease (If operating in very wet or severe conditions).

m Operation of hour meter. a 3

Bucket/dipper pivot points.

Check (Engine Stopped)

Every 50 Operating Hours or Weekly

a

Generally for damage.

Whichever occurs first

b

For oil and coolant leakage.

1

Do the daily jobs plus:

c

Security of bolts and nuts †.

2

Clean

d

For disconnected or shorted wiring, loose terminals.

a

Drain water and sediment from fuel tank.

e

Hydraulic fluid level.

b

Drain fuel water separator.

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.

3

Grease a

All pivot pins.

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).

â€

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.

9803/6310

Issue 2*

Section 3

Routine Maintenance

Section 3

Service Schedules

2-2

2-2

Every 100 Operating Hours or 2-Weekly Whichever occurs first 1

Do a 50 hour service plus:

2

Clean

a

Operation of throttle system.

a

Battery terminals.

b

Operation of overload warning.

b

Fuel lift pump strainer.

c

Operation of stop control.

3

Grease

6

Check (Engine Running)

a

Slew ring bearing.

*

b

Axle pivot and steering joints ††.

†† 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.

*

c

Propshafts.

Every 250 Operating Hours or Monthly

4

5

Change

Whichever occurs first

a

Engine oil main filter element ††.

1

Do a 100 hour service plus:

b

Engine oil ††.

2

Clean

c

Servo oil filter element ††.

a

Drain water and deposits from hydraulic oil tank.

d

Engine oil filter by-pass element ††.

b

Air cleaner dust valve.

e

Return filter element ††.

c

Pre-cleaner

f

Drain filter element ††.

g

Slew gearbox oil ††.

a

Door and canopy hinges.

h

Front axle hub oil ††.

b

Slew ring bearing.

j

Rear axle hub/differential oil ††.

k

Drive gearbox oil ††.

a

Battery electrolyte level.

l

Fuel filter element ††.

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.

3

4

Grease

Check (Engine Stopped)

Check (Engine Stopped) 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.

9803/6310

Issue 2*

Section 3

Routine Maintenance

Section 3

Service Schedules

2-3

2-3

Every 500 Operating Hours or 3-Monthly

Every 1000 Operating Hours or 6-Monthly

Whichever occurs first

Whichever occurs first

1

Do a 250 hour service plus:

1

Do a 500 hour service plus:

2

Clean

2

Clean

a 3

Radiator, grille and oil cooler fins.

a

Fuel lift pump strainer.

b

Hydraulic fluid suction strainer.

Grease 3 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.)

Grease a

*

4

5

4

Change

Replenish slew gearbox grease.

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 †††.

a

Engine oil.

b

Engine oil full flow filter elements.

c

Fuel filter element.

d

Engine oil filter by-pass element.

g

Drain filter †††.

e

Front axle hub oil.

h

Front axle differential oil.

f

Rear axle hub/differential oil.

j

Steering line filter element †††.

* 5

Check (Engine Stopped) a

Exhaust system security.

*

b

Propshaft +.

*

c

Servo accumulator operation +.

*

d

Brake accumulator operation +.

e

Hydraulic oil (check the degradation and cleanliness by sampling).

Check (Engine Stopped) a

*

Hub brake friction plates for wear.

Renew as necessry +.

Every 2000 Operating Hours or Yearly Whichever occurs first

6

f

Seat belt condition and security.

g

Teeth and sidecutters.

1

Do a 1000 hour service plus:

2

Clean a

* 3

Check (Engine Running) a

Operation of throttle system.

b

Operation of overload warning.

c

Operation of stop control.

4

†††

*+

9803/6310

Injectors (and test) +.

Check (Engine Stopped) a.

Valve clearance and lubrication.

b

Sample hydraulic oil and replace if necessary.

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.

Issue 2*

Section 3

Routine Maintenance Service Schedules

2-4

Section 3 2-4

Every 4000 Operating Hours or 2 Years Whichever occurs first 1

Do a 2000 hour service plus:

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 Whichever occurs first 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

Issue 1

Section 3

Routine Maintenance

Section 3

Service Schedules

2-5

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.

Servicing Intervals (hours) Servicing Operation 100% usage

40% usage

20% usage

10% usage

10 600

10 1500

10 3000

10 4000

Return Filter Element - change+

100

300

600

800

Suction Strainer

- clean - change

100 600

300 1500

600 3000

800 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

100

300

600

800

Hydraulic Oil

*

Steering Filter +

- check level - change

It is recommended that oil samples are taken and analysed immediately prior to each Return Filter Element change.

9803/6310

Issue 2*

Section 3

Routine Maintenance

Section 3

Greasing

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.

3-1

! 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

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

3

Grease the Slew Ring a

Remove the cover A.

b

Apply grease to the slew ring via aperture B.

A

B JS03980

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.

D C JS04070

9803/6310

Issue 1

Section 3

Routine Maintenance

Section 3

Greasing

3-2

3-2

! WARNING

Greasing (50 hours)

You will be working close into the machine for these 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

JS130W/JS145W/JS160W/JS175W

0

8 9

9 7

0

2

2

7

3

1

6

2

2 3

5 1 4

4

JS05820

JS130W/JS145W/JS160W/JS175W

1

4

2

3

5

6

JS05830

9803/6310

Issue 2*

Section 3

Routine Maintenance

Section 3

Greasing

3-3

3-3

! WARNING

Greasing (50 hours) (cont’d) JS130W/JS145W/JS160W/JS175W

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

8

JS130W/JS145W only

7

0

9

††

JS05800

†† JS130W/145W monoboom only.

0

†

JS160W/JS175W only

7

} JS06730

† Except JS130W/145W monoboom.

JS05810

9803/6310

Issue 2*

Section 3

Routine Maintenance

Section 3

Greasing

3-4

! WARNING

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.

3-4

You will be working close into the machine for these 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

The steering joint X should be smeared with grease.

JS130W/JS145W/JS160W/JS175W *

X

Y

Y

JS06000

9803/6310

Issue 3*

Section 3

Routine Maintenance

Section 3

Battery

4-1

4-1

First Aid - Electrolyte

Checking the Electrolyte Level

EYES

1

Open the Battery Compartment A

FLUSH WITH WATER FOR 15 MINUTES. GET MEDICAL HELP FAST.

A

IF SWALLOWED DO NOT INDUCE VOMITING. DRINK LARGE QUANTITIES OF WATER OR MILK. Then drink milk of magnesia, beaten egg or vegetable oil.

JS03950

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.

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.

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.

! WARNING

Keep metallic items (watches, rings, zippers etc) away from the battery terminals. Such items could short the terminals and burn you.

Do not top the battery up with acid. The electrolyte could boil out 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.

3

2-3-4-6

Check the Connections Make sure that the terminals are tight and clean. Coat them with petroleum jelly to prevent corrosion.

When reconnecting, fit the positive (+) lead first.

Re-charge the battery away from the machine, in a wellventilated 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

B

! CAUTION Do not disconnect the alternator, the battery, or any part of the charging circuit with the engine running.

8-3-4-1

JS04030

9803/6310

Issue 1

Section 3

Routine Maintenance

Section 3

Tyres and Wheels

5-1

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.

089571

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.

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)

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.

Front

Every day, before starting work, check that the wheel nuts are tight.

Rear

Nm

lbf ft

Nm

lbf ft

500

369

500

369

The correct torques are shown in the table opposite.

! 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

9803/6310

Issue 1

Section 3

Routine Maintenance

Section 3

Hydraulics

7-1

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.

E D C

B

INT-3-1-10/1

Checking the Fluid Level 1

Prepare the Machine 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.

A JS04510

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.

Topping-up Fluid Level 1

8-3-4-4/1

1

Position the machine on level ground. Stop the engine.

Remove the starter key.

Prepare the Machine Position the machine on level ground. Stop the engine.

Remove the starter key.

2

Locate Breather C on Top of the Hydraulic Oil Tank

3

Release Tank Pressure

2

Release Tank Pressure See Releasing Tank Pressure.

3

Remove cap D. Press and hold the projection revealed until all pressure has been released.

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

9803/6310

Prepare the Machine

Refit Filler Plug E.

Issue 1

Section 3

Routine Maintenance

Section 3

Hydraulics

7-2

7-2

Changing the Fluid 1

Prepare the Machine

A

B

Position the machine on level ground. Stop the engine.

Remove the starter key.

2

Locate Breather Mounting Plate A and Drain Plug C

E

These are, respectively, on the top and bottom of the hydraulic oil tank (see Component Location Diagrams).

3

Release Tank Pressure See Releasing Tank Pressure.

4

5

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.

D C

JS06090

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

Issue 1

Section 3

Routine Maintenance

Section 3

Hydraulics

7-3

7-3

Changing the Return Filter Element 1

Prepare the Machine

A B

Position the machine on level ground. Stop the engine.

C D

Remove the starter key.

2

Locate the Return Filter Refer to Component Location Diagrams.

3

Release Tank Pressure

E

See Releasing Tank Pressure.

4

5

Remove the Element a

Remove cover A and O-ring B.

b

Remove spring C, valve D and return filter E from the tank.

JS06090

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:

6

After the required flushing time has elapsed, stop the engine and vent hydraulic pressure (see Releasing Tank Pressure).

1

The hydraulic system has become contaminated with debris.

7

Remove flushing filter element and save in a clean condition until step 10 is completed.

2

Major hydraulic components such as pumps, valve blocks, rams, tanks, motors etc. are changed.

8

Fit new main hydraulic filter and refit tank cover.

9

Take oil sample and send for analysis.

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.

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

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:

SSP0061

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.

9803/6310

Issue 2*

Section 3

Routine Maintenance Hydraulics

7-4 *

Section 3 7-4

Cleaning/Changing the Suction Strainer 1

Prepare the Machine Position the machine on level ground. Stop the engine.

Remove the starter key.

2

F

G

Locate the Suction Strainer Refer to Component Location Diagrams.

3

Release the Tank Pressure See Releasing Tank Pressure.

4

5

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.

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

H JS06090

Check the hydraulic oil level (see Checking the Fluid Level) and top up if necessary (see Topping-up Fluid Level).

9803/6310

Issue 2*

Section 3

Routine Maintenance Hydraulics

7-5 *

Section 3 7-5

Changing the Plexus Filter (Early machines) 1

Prepare the Machine Position the machine on level ground. Stop the engine.

Remove the starter key.

2

Locate Plexus Filter A Refer to 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 D, cover E and remove the O-ring F and spring G. c

5

Lift up the Plexus filter element H carefully and remove. Take care not to drop any sediment.

A

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).

D

J

F G H

E

Y

X BC

JS04490

9803/6310

Issue 4*

Section 3

Routine Maintenance

Section 3

Hydraulics

7-6

* Changing the Plexus Filter 1. Prepare the Machine Position the machine on level ground. Stop the engine.

Remove the starter key.

2. Locate the Plexus Filter Refer to the Component Location Diagrams.

3. Release Tank Pressure (See Releasing Tank Pressure).

7-6 J

E

D A

F G H 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 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.

X B C

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.

Y

C

B

Stop the engine, check the hydraulic oil level and top-up if low. (See Checking the Fluid Level).

9803/6310

Issue 4*

Section 3 *

Routine Maintenance

Section 3

Hydraulics

7-7

7-7

Changing the Air Breather Element 1

Prepare the Machine Position the machine on level ground. Stop the engine.

Remove the starter key.

2

Release Tank Pressure

F A B G C

See Releasing Tank Pressure.

3

Locate the Air Breather X

E D

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.

5

X

b

Remove old filter element D together with sponge packing E.

c

Install a new filter element D followed by new sponge packing E.

JS03660

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 1

Prepare the Machine

X

Y

Position the machine on level ground. Stop the engine.

Remove the starter key.

2

Release Tank Pressure See Releasing Tank Pressure.

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.

Z

JS06090

See Topping-up Fluid Level. Refit filler plug Y.

9803/6310

Issue 3*

Section 3 *

Routine Maintenance Hydraulics

7-8

Changing the Servo Oil Filter 1

*

B D

Release Tank Pressure See Releasing Tank Pressure. Remove the filler plug.

3

7-8

Prepare the Machine 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.

2

Section 3

C

Locate the Servo Oil Filter Refer to Component Location Diagrams at the end of this section.

4

5

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.

A

Clean the Filter Base and Case Discard any fluid in the filter case. Clean out the case and the underside of the head.

6

7

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.

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

Issue 3*

Section 3 *

Routine Maintenance

7-9

Section 3

Hydraulics

7-9

Changing the Drain Line Filter Element 1

Prepare the Machine Position the machine on level ground. Stop the engine.

Remove the starter key.

2

B

Release Tank Pressure See Releasing Tank Pressure. Remove the filler plug (see Topping-up Fluid Level).

3

A

Locate the Drain Line Filter Element Refer to Component Location Diagrams at the end of this section.

4

JS02830

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.

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.

*

Changing the Steering Line Filter Element * 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. Remove the filler plug (see Topping-up Fluid Level).

3

Locate the Steering Line Filter Element

C

D

Refer to Component Location Diagrams at the end of this section.

4

Remove the Filter Unscrew filter C from the filter head D.

5

Clean the Filter Head

6

Fit a New Filter

JS08740

Coat the sealing ring on the new filter with hydraulic oil and screw hand-tight into the filter head.

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

Issue 3*

Section 3 *

7 - 10

Routine Maintenance

Section 3

Hydraulics

7 - 10

Changing the Breaker In-line Filter (if fitted)

X

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. 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

B A

Locate the Filter JS06700

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

Issue 3*

Section 3 *

7 - 11

Routine Maintenance

Section 3

Hydraulics

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.

1

Prepare the Machine Position the machine on level ground. Stop the engine.

Remove the starter key.

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.

A

JS06710

9803/6310

Issue 3*

Section 3 *

Routine Maintenance

Section 3

Hydraulics

7 - 12

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.

1

Prepare the Machine 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.

1

Prepare the Machine 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.

*

A JS160W JS 175W

A JS130W JS 145W

Note: Do not operate any other equipment .

4

5

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.

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.

Stop the engine and allow any bubbles in the system to make their way through the hydraulic tank.

9803/6310

Issue 1*

Section 3

Routine Maintenance Transmission

8-1

Checking the Slew Gearbox Oil Level 1

Section 3 8-1

JS130W/JS145W

Prepare the Machine Position the machine on level ground. Stop the engine and remove the starter key.

2

Locate the Slew Gearbox Refer to Component Location Diagrams at the end of this section.

3

4

C

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.

B D

Re-fit the Dipstick.

Changing the Slew Gearbox Oil 1

A

A

JS160W/JS175W

Prepare the Machine Position the machine on level ground. Stop the engine and remove the starter key.

2

3

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.

C

A

A

B

Fill with New Oil Refer to Lubricants and Capacities for oil type and volume.

D

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

Issue 2*

Section 3

Routine Maintenance

Section 3

Transmission

8-2

8-2

Replenishing Slew Gearbox Grease 1

Prepare the Machine Position the machine on level ground. Stop the engine and remove the starter key.

2

Remove Air Bleed Plug A

! CAUTION Failure to remove the bleed plug before adding grease could damage the inner seal.

A

B

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

Issue 1

Section 3

Routine Maintenance

Section 3

Transmission

8-3

Checking the Drive Gearbox Oil Level

8-3

Changing the Drive Gearbox Oil

! WARNING

! 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.

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

2-3-2-2

1

Note: This job should be done with the oil at operating temperature.

Prepare the Machine 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

1

Prepare the Machine Park the machine on level ground. Engage the parking brake. Lower the attachments to the ground. Stop the engine and remove the starter key.

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.

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).

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).

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).

*

A B

9803/6310

A314100

Issue 2*

Section 3

Routine Maintenance Transmission

8-4

Checking the Front Axle Differential 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

! CAUTION

Changing the Front Axle Differential Oil ! 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

1

Prepare the Machine 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.

Note: If the oil gives off a foul smell it is a sign that the oil has degraded and should be changed.

Add recommended oil if necessary (see Lubricants and Capacities).

Prepare the Machine Park the machine on level ground. Engage the parking brake. Lower the attachments to the ground. Stop the engine and remove the starter key.

16-3-5-3

2

8-4

Note: This job should be done with the oil at operating temperature.

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.

1

Section 3

3

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.

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.

Clean and refit the plug and sealing washer. Tighten firmly.

A

B

9803/6310

JS04130

Issue 1

Section 3

Routine Maintenance

Section 3

Transmission

8-5

8-5

Checking the Front Axle Hub Oil Level

Changing the Front Axle Hub Oil

Check each hub separately

Change the oil in each hub separately.

1

1

Prepare the Machine 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.

Prepare the Machine 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

! 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.

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

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

! 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

2

Slowly unscrew fill/level plug C to allow any internal pressure to escape. When all pressure is released, retighten plug C. 3

4

Move the machine slowly until plug C is positioned as shown in fig. 1. Stop the engine and remove the starter key.

Slowly unscrew fill/level plug C to allow any internal pressure to escape. When all pressure is released, retighten 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.

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.

Release Hub Pressure

4

Drain the Oil

Note: If the oil gives off a foul smell it is a sign that the oil has degraded and should be changed.

a

Place a container of suitable size beneath plug C to catch the oil.

Add recommended oil if necessary (see Lubricants and Capacities).

b

Remove fill/level plug C and allow the oil to drain out.

5

Clean and refit the plug and sealing washer.

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.

1

2

8-3-5-1

C

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).

C

Clean and refit the plug and sealing washer.

3

C 9803/6310

JS06450

Issue 1

Section 3

Routine Maintenance

Section 3

Transmission

8-6

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

Changing the Rear Axle Differential/Hub Oil

! WARNING

! 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.

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

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.

Note: This job should be done with the oil at operating temperature.

1

Prepare the Machine

16-3-5-3

1

Park the machine on level ground. Engage the parking brake. Lower the attachments to the ground. Stop the engine and remove the starter key.

Prepare the Machine 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

Drain the Oil a

2

Differential Housing

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.

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.

Note: If the oil gives off a foul smell it is a sign that the oil has degraded and should be changed.

Add recommended oil if necessary (see Lubricants and Capacities).

b

Clean and refit the plug and sealing washer. Tighten firmly.

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.

A

B

9803/6310

JS04140

Issue 1

Section 3

Routine Maintenance

Section 3

Engine

9-1

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.

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.

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.

9-1

D E

C B

A F

9803/6310

A336941

Issue 2*

Section 3

Routine Maintenance

Section 3

Engine

9-2

Changing the Air Filter Inner Element

4

Note: Do not attempt to wash or clean the elements - they must only be renewed.

9-2

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.

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.

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.

1

Stop the engine.

7

Make sure that the wire is connected to the Air Filter Blocked switch.

2

Press clips A and lift off cover B. Remove outer element C.

8

Check all hoses for condition and tightness.

3

Lift up pulls J and remove inner element G.

Note: Do not run the engine with the dust valve F removed.

D E G H C J B

A F

9803/6310

A336941

Issue 2*

Section 3

Routine Maintenance

Section 3

Engine

9-3

Checking the Oil Level 1

Prepare the Machine 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.

4

9-3 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.

A

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

B

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.

F F

Remove the self seal drain kit, clean and refit the outer cover. (Do not over tighten the cover). c

German machines only

448030

B

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

C

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.

F

A 448040

Tier 2 engine only

9803/6310

D

E

Issue 2*

Section 3

Routine Maintenance

Section 3

Engine

9-4

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.

A

! 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

JS04410

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 premixed water/antifreeze if necessary. See Coolant Mixtures.

4

Refit the Pressure Cap A

B

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.

JS03930

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

Issue 1

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