4.section 3 - Routine Maintenance

Section 3
Routine Maintenance
Service Manual - JS Auto Range - Tracked Excavators - JCB Engine
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track & Running Gear
Section K - Engine
Publication No.
9813/1000-3
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section 3 - Maintenance
Notes:
3-0 9813/1000-3 3-0

Contents Page No.

Routine Maintenance
Service Requirements ..............................................................................3 - 1
Health and Safety .....................................................................................3 - 3
Service Schedules ....................................................................................3 - 7
Fluids, Lubricants and Capacities ...........................................................3 - 16
Tools .......................................................................................................3 - 24
Prepare the Machine for Maintenance ...................................................3 - 25
Cleaning the Machine .............................................................................3 - 26
Checking for Damage .............................................................................3 - 28
Daily Checking ........................................................................................3 - 30
Greasing .................................................................................................3 - 32
Electrical System ....................................................................................3 - 35
Bolt and Nut Torque Specifications .........................................................3 - 43
Engine ....................................................................................................3 - 49
Fuel System ............................................................................................3 - 59
Hydraulic System ....................................................................................3 - 66
Slew Gearbox .........................................................................................3 - 77
Tracks and Running Gear ......................................................................3 - 78
Bucket ....................................................................................................3 - 81
Windscreen Washer ...............................................................................3 - 82
Fire Extinguisher (If fitted) ......................................................................3 - 83
Troubleshooting ......................................................................................3 - 84
3-i 3-i
Contents Page No.
3 - ii 3 - ii
Routine Maintenance
Service Requirements
Introduction Owner/Operator Support

T3-095
Your machine has been designed and built to give JCB together with your Distributor wants you to be
maximum performance, economy and ease of use under a completely satisfied with your new JCB machine. If you do
wide variety of operating conditions. Prior to delivery, your encounter a problem however, you should contact your
machine was inspected both at the Factory and by your Distributor's Service Department who are there to help
Distributor to ensure that it reaches you in optimum you!
condition. To maintain this condition and ensure trouble
free operation it is important that the routine services, as You will have been given the names of the relevant service
specified in this Manual, are carried out by an approved contacts at your Distributor when the machine was
JCB Distributor at the recommended intervals. installed.
This section of the Manual gives full details of the service To get the most from your Distributor please help them to
requirements necessary to maintain your JCB machine at satisfy you by:
peak efficiency.
1 Giving your name, address and telephone number.
A Service Manual for your machine is available from your
JCB Distributor. The Service Manual contains information 2 Quoting your machine model and serial number.
on how to repair, dismantle and assemble your machine
correctly. 3 Date of purchase and hours of work.
It can be seen from the Service Schedules on the following 4 Nature of the problem.
pages that many essential service checks should only be
carried out by a JCB trained specialist. Only JCB Remember, only your JCB Distributor has access to the
Distributor Service Engineers have been trained by JCB to vast resources available at JCB to help support you. In
carry out such specialist tasks, and only JCB Distributor addition, your Distributor is able to offer a variety of
Service Engineers are equipped with the necessary programmes covering Warranty, Fixed Price Servicing,
special tools and test equipment to perform such tasks, Safety Inspections, including weight tests, covering both
thoroughly, safely, accurately and efficiently. legal and insurance requirements.
JCB regularly updates its Distributors advising them of any Service/Maintenance Agreements
product developments, changes in specifications and
procedures. Therefore only a JCB Distributor is fully able To help plan and spread the costs of maintaining your
to maintain and service your machine. machine, we strongly recommend you take advantage of
the many Service and Maintenance Agreements your
A Service Record Sheet or Book is provided which will Distributor can offer. These can be tailor made to meet
enable you to plan your service requirements and keep a your operating conditions, work schedule etc.
service history record. It should be dated, signed and
stamped by your Distributor each time your machine is Please consult your JCB Distributor for details.
serviced.
Remember, if your machine has been correctly

maintained, not only will it give you improved reliability but
its resale value will be greatly enhanced.
3-1 9813/1000 3-1

Routine Maintenance
Service Requirements
Fit for Purpose Tests for Lifting

Equipment
T3-097
All lifting equipment (for example forks, lifting hooks and

shackles) need regular inspection and testing by a
competent person to ensure they are fit for purpose.
This may be needed every six months or at least annually

in some countries to meet and comply with legislation and
for insurance purposes.
Check with your local JCB distributor for further advice.
Obtaining Replacement Parts

T3-096
If you use non-genuine JCB parts or consumables, then

you can compromise the health and safety of the operator
and cause machine failure
A Parts Book for your machine is available from your JCB

Distributor. The Parts Book will help you identify parts and
order them from your JCB distributor.
Your dealer will need to know the exact model, build and
serial number of your machine. See Identifying Your
Machine (Introduction section).
The data plate also shows the serial numbers of the

engine, transmission and axle(s), where applicable. But
remember if any of these units have been changed, the
serial number on the data plate may be wrong. Check on
the unit itself.
3-2 9813/1000 3-2

Routine Maintenance
Health and Safety
Health and Safety
Lubricants The collection and disposal of used oil should be in

T3-060_2
accordance with any local regulations. Never pour used
Introduction engine oil into sewers, drains or on the ground.
It is most important that you read and understand this Handling

information and the publications referred to. Make sure all
your colleagues who are concerned with lubricants read it
too.
!MWARNING
Oil
Hygiene Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
JCB lubricants are not a health risk when used properly for contains harmful contaminants which can cause skin
their intended purposes. cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves to
However, excessive or prolonged skin contact can remove prevent skin contact. Wash skin contaminated with oil
the natural fats from your skin, causing dryness and thoroughly in warm soapy water. Do not use petrol,
irritation. diesel fuel or paraffin to clean your skin.
INT-3-2-3
Low viscosity oils are more likely to do this, so take special
care when handling used oils, which might be diluted with New Oil
fuel contamination.
There are no special precautions needed for the handling
Whenever you are handling oil products you should or use of new oil, beside the normal care and hygiene
maintain good standards of care and personal and plant practices.
hygiene. For details of these precautions we advise you to
read the relevant publications issued by your local health Used Oil
authority, plus the following.
Used engine crankcase lubricants contain harmful
Storage contaminants.
Always keep lubricants out of the reach of children. Here are precautions to protect your health when handling
used engine oil:
Never store lubricants in open or unlabelled containers.
1 Avoid prolonged, excessive or repeated skin contact
with used oil.
Waste Disposal
2 Apply a barrier cream to the skin before handling
!MCAUTION used oil. Note the following when removing engine oil
from skin:
It is illegal to pollute drains, sewers or the ground.
Clean up all spilt fluids and/or lubricants.
a Wash your skin thoroughly with soap and water.
Used fluids and/or lubricants, filters and contaminated
b Using a nail brush will help.
materials must be disposed of in accordance with
local regulations. Use authorised waste disposal sites.
c Use special hand cleansers to help clean dirty
INT-3-2-14 hands.
All waste products should be disposed of in accordance
d Never use petrol, diesel fuel, or paraffin for
with all the relevant regulations.
washing.
3-3 9813/1000 3-3

Routine Maintenance
Health and Safety
3 Avoid skin contact with oil soaked clothing.
4 Don't keep oily rags in pockets.
5 Wash dirty clothing before re-use.
6 Throw away oil-soaked shoes.
First Aid - Oil
Eyes
In the case of eye contact, flush with water for 15 minutes.

If irritation persists, get medical attention.
Swallowing
If oil is swallowed do not induce vomiting. Get medical

advice.
Skin
In the case of excessive skin contact, wash with soap and

water.
Spillage
Absorb on sand or a locally approved brand of absorbent

granules. Scrape up and remove to a chemical disposal
area.
Fires
!MWARNING
Do not use water to put out an oil fire. This will only
spread it because oil floats on water.
Extinguish oil and lubricant fires with carbon dioxide,

dry chemical or foam. Fire fighters should use self
contained breathing apparatus.
7-3-1-3_1
3-4 9813/1000 3-4

Routine Maintenance
Health and Safety
Battery
T3-061
!MCAUTION
Damaged or spent batteries and any residue from fires
!MWARNING or spillage should be put in a closed acid proof
Batteries give off an explosive gas. Do not smoke receptacle and must be disposed of in accordance
when handling or working on the battery. Keep the with local environmental waste regulations.
battery away from sparks and flames. INT-3-1-12
Battery electrolyte contains sulphuric acid. It can burn

you if it touches your skin or eyes. Wear goggles.
!MWARNING
Handle the battery carefully to prevent spillage. Keep Battery Gases
metallic items (watches, rings, zips etc) away from the Batteries give off explosive gases. Keep flames and
battery terminals. Such items could short the sparks away from the battery. Do not smoke close to
terminals and burn you. the battery. Make sure there is good ventilation in
closed areas where batteries are being used or
Set all switches to OFF before disconnecting and charged. Do not check the battery charge by shorting
connecting the battery. When disconnecting the the terminals with metal; use an approved battery
battery, take off the earth (-) lead first. tester.
INT-3-1-8_2
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.
When reconnecting, fit the positive (+) lead first.

5-3-4-12
!MCAUTION
Do not disconnect the battery while the engine is
running, otherwise the electrical circuits may be
damaged.
INT-3-1-14
!MWARNING
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
!MDANGER
Electrolyte
Battery electrolyte is toxic and corrosive. Do not
breathe the gases given off by the battery. Keep the
electrolyte away from your clothes, skin, mouth and
eyes. Wear safety glasses.
INT-3-2-1_3
3-5 9813/1000 3-5

Routine Maintenance
Health and Safety
Warning Symbols First Aid - Electrolyte
The following warning symbols may be found on the Do the following if electrolyte:
battery.
Gets into your eyes
Symbol Meaning
Immediately flush with water for 15 minutes, always get
Keep away from children. medical help.
Is swallowed
A289230-1
Do not induce vomiting. Drink large quantities of water or
Shield eyes.
milk. Then drink milk of magnesia, beaten egg or vegetable
oil. Get medical help.
A289260-1 Gets onto your skin

No smoking, no naked flames, no sparks.
Flush with water, remove affected clothing. Cover burns
with a sterile dressing then get medical help.
A289280
Explosive Gas.
A289250
Battery acid.
A289240
Note operating instructions.
A289270
3-6 9813/1000 3-6

Routine Maintenance
Hydraulic System
Changing the Breaker In-line Filter Changing the Drain Line Filter
Note: This filter should be changed at the intervals stated 1 Prepare the machine. K Prepare the Machine for
in Service Schedules or when the visual indicator X has Maintenance ( T 3-25).
popped up. Do not use the breaker with a blocked filter.
2 Release tank pressure. K Releasing Tank
1 Prepare the machine. K Prepare the Machine for Pressure ( T 3-67).
Maintenance ( T 3-25).
3 Get access to the drain line filter. Refer to
2 Release tank pressure. K Releasing Tank Introduction Section, Component Location.
Pressure ( T 3-67).
4 Unscrew and remove filter A from head B.
3 Get access to the breaker in-line filter. Refer to
Introduction Section, Component Location. 5 Fit the new filter. Coat the seal of the new filter with
clean hydraulic oil. Screw the new filter into head B
4 Unscrew and remove filter A from head B. and tighten. Check and top up the hydraulic oil level.
5 Fit the new filter. Coat the seal of the new filter with
and tighten. Check and top up the hydraulic oil level.
Fig 52.
Fig 51.
3-74 9813/1000 3-74

Routine Maintenance
Service Schedules
Pre Start Cold Checks, Service Points and Fluid Levels
Operation 10 50 250 500 1000 2000 3000 4000 5000 8000

ENGINE
Oil level - Check
Oil and Filter (1)(2) - Sample/
Change
Pre Cleaner (if fitted) - Clean
Air Cleaner Outer Element (3) - Change
Air Cleaner Inner Element - Change
Air Cleaner Dust Valve - Check and
Clean
Crankcase Ventilation Filter (if fitted, - Check and
JS200-220 only) Clean
Fuel Level - Check
Fuel Tank - Water and Sediment - Drain
Coolant Quality/Level - Check
Coolant - Change
Primary Fuel Filter/Sedimenter - Drain and
Clean
Primary Fuel Filter/Sedimenter-filter - Change
Main Fuel Filter/Sedimenter - Drain and
Clean
Main Fuel Filter/Sedimenter-filter - Change
Engine Filter/Sedimenter - Drain and
Clean
Engine Filter/Sedimenter-filter - Change
Fuel Filler Cap - Check and
Clean
Fuel Filler Cap (Dusty conditions) - Check and
Clean
FEAD Belt Tension/Condition - Check
FEAD Belt - Change
Fan Belt Tension/Condition - Check
Fan Belt - Change
Valve Clearances(4) - Check and
Adjust
Engine Mounting Bolts for Tightness - Check
3-8 9813/1000 3-8

Routine Maintenance
Service Schedules
Operation 10 50 250 500 1000 2000 3000 4000 5000 8000

Exhaust System Security - Check
Air Inlet System Security - Check
Radiator - Clean and
Check
All Hoses - Condition - Check
Coolant or Oil Leaks - Check
Radiator Cap - Seal - Clean and
Check
Oil Filter and Dipstick O-rings - Change
Injectors(4) - Change
Injector(s) Leak-Off Rail(4) - Change
High Pressure Fuel Lines(4) - Change
TRANSMISSION
Security of Mounting Bolts and Nuts - Check
Track Gearbox Oil Level - Check
Slew Gearbox Oil Level - Check
Track and Slew Gearbox Oil (5) - Sample/
Change
Track and Slew Gearbox Oil(6) - Sample/
Change
HYDRAULICS
Oil Level - Check
Oil (biodegradable and non- - Sample
biodegradable)
Oil (biodegradable) Change
Oil (Non-biodegradable) Change
Servo Filter Element (5)(7) - Change
Plexus Filter Element(7) - Change
Return Filter Element(5)(7) - Change
Drain Filter Element(5)(7) - Change
Suction Strainer(5) - Clean
Suction Strainer - Change
Cushion Valve Filter - Clean
Cushion Valve Filter - Change
3-9 9813/1000 3-9

Routine Maintenance
Service Schedules
Operation 10 50 250 500 1000 2000 3000 4000 5000 8000

Rams - Chrome Condition - Check
Oil Cooler - Clean
Tank - Water and Sediment - Drain
Hydraulic Tank Air Breather - Change
Auxiliary Circuit Filter Indicator (if - Check
using a rockbreaker)

Pump Line Exit Hose - Change
Boom Ram Hoses - Change
Dipper Line Ram Hoses - Change
Bucket Line Ram Hoses - Change
ELECTRICS
Battery Sight Glass Inspection - - Check
Maintenance Free Batteries
Wiring for Chaffing/Routing - Check
Battery Terminals for Condition and - Check
Tightness

UNDERCARRIAGE
Track Rollers - Check
Idler Wheels - Check
Track Plate Condition and Bolt Torque - Check
Track Tension - Check
Track Wear - Check
BODYWORK AND CAB
All Pins and Bushes (except Boom - Grease
Base and Boom Dipper)

Condition of all Pins and Bushes - Check
Boom/Bucket/Dipper Pivot Pins (if - Check and
used in very wet or severe conditions, Grease
except Boom Base and Boom Dipper)
Boom Base and Boom Dipper Pivot - Grease
Pins
Bucket Pivot Pins Grease Seals - Check
Slew Ring Bearing - Grease
Slew Ring Teeth - Grease
Door/Window Hinges - Lubricate
3-10 9813/1000 3-10

Routine Maintenance
Service Schedules
Operation 10 50 250 500 1000 2000 3000 4000 5000 8000

Cab Heater/Air Con Filter - Clean/
Change
Front Window Washer Fluid Level - Check
Condition of Paintwork - Check
Machine Generally - Check and
Clean
ATTACHMENTS
Engine Speed in Breaker Mode- - Check
Compatible with fitted Breaker.

Quick Hitch - Grease
OPTIONAL EQUIPMENT
As Required - Check
MISC
Visual inspection for broken or loose - Check
fasteners.
Major component torques(8) - Check
Visual inspection of structure for - Check
damage including welds around lifting
points and excavator end main pivots.
(1) If operating under arduous conditions, do an engine oil flush (use the normal recommended engine oil). every 250
hours. Change the engine oil and filter every 250 hours.
(2) Service times may alter depending on fuel used, refer to Fluids, Lubricants and Capacities, Fuel.
(3) If operating in dusty conditions adverse working environments, do these jobs more frequently.
(4) These jobs must be done by a qualified engineer.
(5) These procedures are only to be carried out after the first 500 hours use of a new machine. Thereafter they are to be
carried out as detailed in the following periodic checks.
(6) Sample/change every 500 hours if tracking hours is greater than 20% machine hours.
(7) If using a breaker, crusher or pulverises, refer to Service Schedules, Service Intervals for Attachments.
(8) Tighten the bolts and nuts after the first 50 hours of the running-in stage and every 250 hours thereafter.
3-11 9813/1000 3-11

Routine Maintenance
Service Schedules
Functional Test and Final Inspection
Operation 10 50 250 500 1000 2000 4000

ENGINE
Maximum No-Load Speed - Check
Exhaust Smoke (excessive) - Check
Throttle calibration(1) - Check
Coolant System - Leaks - Check
Stop Control - Operation - Check
Fuel System - Leaks and Contamination - Check
TRANSMISSION
Slew Brake Operation - Check
HYDRAULICS
Operation All Services - Check
Accumulator (engine stopped) - Check
Hoses and Pipework - Damage/Leaks - Check
ELECTRICS
Starter Motor - Connections - Check/Clean
Alternator - Output - Check
All Electrical Equipment Operation, (e.g.
warning lights, beacon, alarms, horn, wipers - Check
etc.)
UNDERCARRIAGE
Track operation - Check
BODYWORK AND CAB
Doors and Canopy - Fitment/Leaks - Check
Locks - Check
SEAT
Seat and Seat Belts - Condition and Security - Check
Seat Adjustments - Correct Operation - Check and Grease
Seat Adjustments - Correctly Setup for - Check
Operator
ATTACHMENTS
Teeth and Side Cutters - Check
Attachment Circuit Pressure - Check
Operation - Check
3-12 9813/1000 3-12

Routine Maintenance
Service Schedules
Operation 10 50 250 500 1000 2000 4000

OPTIONAL EQUIPMENT
Overload Warning - Check
Refuel Pump (if fitted) - Check
LIFTING EQUIPMENT
Fit for Purpose Test(2) - Complete
(1) These jobs must be done by a qualified engineer.

(2) This may be required every six months or at least annually in some countries to meet and comply with legislation and
for insurance purposes
3-13 9813/1000 3-13

Routine Maintenance
Service Schedules
Service Intervals for Attachments Servicing of the hydraulic oil and filters must be done more
frequently according to the percentage of total operating
When using a breaker, crusher or pulveriser, hours involving use of the breaker, crusher or pulverizer.
contamination and degradation of the hydraulic oil occurs When a breaker, crusher or pulverizer is fitted, ensure that
much more quickly than in normal excavating use. If the the oil and filters are changed at the intervals shown in the
machine is used with increasingly degrading oil it can table below.
cause problems in the control valve, premature wear of the
hydraulic pump and damage to the hydraulic system as a The hydraulic oil must be sampled and checked for
whole. contamination and degradation at the intervals shown.
Consult your JCB Distributor who will have the facilities to
do this work and ensure that the hydraulic system is
properly maintained.
Table 1. Service Intervals for Hydraulic Oil and Filters according to Frequency of Breaker, Crusher or Pulverizer
Use
Item Use Frequency
Greater than 75% 50 - 75% 25 - 50% 10 - 25% Less than 10%
10 100 600 10 200 1000 10 300h 1500h 10 600h 3000h 10 800h 4000h
hrs hrs hrs hrs hrs hrs hrs rs rs hrs rs rs hrs rs rs
Hydraulic Oil { z { z { z { z { z
Return Filter(1) z z z z z
Suction Filter (1)
z z z z z
Drain Filter(1) z z z z z
Servo Filter(1) z z z z z
Plexus Filter(1) z z z z z
Breaker In-Line z z z z z
Filter(1)
Hydraulic Oil
Every 200 hrs Every 200 hrs Every 300 hrs Every 600 hrs Every 800 hrs
Sampling
(1) The filters must be changed whenever the period of breaker/crusher/pulverizer use exceeds 100hrs, regardless of the
total number of hours the machine has worked
{ Check oil level and top up as required
z Change
Clean
3-14 9813/1000 3-14

Routine Maintenance
Service Schedules
Periodic Replacement of Safety Related operation the service life of specific parts, so routinely
replace them as important parts every 2 years.
Components
Routinely replace important parts concerned with safety. It
is difficult to determine by visual inspection or from
Table 2. Fuel System

Important Parts Replacement Interval
Fuel Hose (Fuel Tank - Engine)
Every 2 years or every 4000 hours, whichever comes first.
Fuel Hose (Fuel Filter - Injection Pump)
Table 3. Hydraulic System

Important Parts Replacement Interval
Pump Exit Hose (Pump - Operation Valve)
Boom Ram Line Hose
Every 2 years or every 4000 hours, whichever comes first.
Dipper Ram Line Hose
Bucket Ram Line Hose
If any abnormality is found with any of these parts before described K Table 4. ( T 3-15). Retighten, replace, etc,
the replacement time, repair or replace as you would do when any abnormality is found.
normally.
Note: Replace O-rings, gaskets at the same time as
When replacing the hoses, if the hose clamps are found to hoses. Contact your JCB distributor for replacement of
be deformed or cracked, replace the clamps at the same safety parts. Carry out inspection of the hydraulic hoses
time as the hoses. and fuel hoses at the routine inspection described
K Table 4. ( T 3-15).
Regarding hydraulic hoses not included in the routine
replacement of safety parts, carry out the inspection
Table 4.
Inspection Classification Inspection Item
Start-up Inspection Fuel, Hydraulic hose connections, Oil Leakage from caulked parts.
Special Independent Inspection (Monthly Fuel, Hydraulic hose connections, Oil Leakage from caulked parts. Fuel,
Inspection) Hydraulic hose damage (cracks, wear, picking)
Special Independent Inspection (Yearly Fuel, Hydraulic hose connections, Oil Leakage from caulked parts. Fuel,
Inspection) Hydraulic hose interference, squeezing, aging, twisting, damage (cracks,
wear, picking)
3-15 9813/1000 3-15

Routine Maintenance
Fluids, Lubricants and Capacities
JCB recommend that you use the JCB lubricants shown as they have been verified by JCB for use on JCB machines.
However, you could use other lubricants that are equivalent to the JCB standards and quality or offer the same machine
component protection.
JS115/JS130/JS145 and Variants

Table 5.
Item Capacity Fluid/Lubricant JCB Part No. Container
Size(1)
ENGINE 20.4 litres (4.5 UK JCB Engine Oil EP 15W40 - 4001/1805 20 Litres
gal) (5.4 US gal) 10°C to +50°C (14°F to 122°F)
JCB Cold Climate Engine Oil 4001/2705 20 Litres
EP 5W40 -20°C to +50°C (-4°F
to 122°F)
COOLING SYSTEM 19.7 litres (4.3 UK JCB HP Coolant K Coolant 4006/1120 20 Litres
gal) (5.2 US gal) Mixtures ( T 3-20)
TRACK GEARBOX 2 x 3.5 litres (2 x 0.77 JCB HP90 Gear Oil 4000/0301 5 Litres
UK gal) (2 x 0.9 US
gal)
SLEW GEARBOX 2.2 litres (0.5 UK gal) 4000/0305 20 Litres
(0.6 US gal)
TRACK ROLLERS AND
IDLER WHEEL
RECOIL SPRING JCB Special HP Grease 4003/2017 400g
CYLINDER
HYDRAULIC SYSTEM 124 litres (27.3 UK JCB Hydraulic Fluid HP32 - 4002/1024 200 Litres
gal) (32.8 US gal) 20°C to +15°C (-4°F to 59°F)
JCB Hydraulic Fluid HP46 - 4002/0803
10°C to +30°C (14°F to 86°F)
JCB Hydraulic Fluid HP68 0°C 4002/0701
to +40°C (32°F to 104°F)
SLEW RING 60 g (0.13 lb) JCB Special HP Grease 4003/2017 400g
- BEARING
- GEAR TEETH 11 kg (24.25 lb) 4003/2006 12.5kg
ALL OTHER GREASE --
POINTS
FUEL TANK 253 litres (55.6 UK K Fuel ( T 3-21) - -
gal) (66.7 US gal)
(1) For information about the different container sizes that are available (and their part numbers), contact your JCB
Dealer.
3-16 9813/1000 3-16

Routine Maintenance
JS160/JS180 and Variants

Table 6.
Size(1)
gal) (4.9 US gal) 10°C to +50°C (14°F to 122°F)
EP 5W40 -20°C to +50°C (-4°F
to 122°F)
COOLING SYSTEM 19.7 litres (4.3 UK JCB HP Coolant K Coolant 4006/1120 20 Litres
gal) (5.2 US gal) Mixtures ( T 3-20)
TRACK GEARBOX 2 x 4.4 litres (2 x 1 UK JCB HP90 Gear Oil 4000/0301 5 Litres
gal) (2 x 1.2 US gal)
SLEW GEARBOX 6 litres (1.3 UK gal) 4000/0305 20 Litres
(1.6 US gal)
TRACK ROLLERS AND
IDLER WHEEL
RECOIL SPRING CYLINDER JCB Special HP Grease 4003/2017 400g
HYDRAULIC SYSTEM 142 litres (31.2 UK JCB Hydraulic Fluid HP32 - 4002/1024 200 Litres
gal) (37.5 US gal) 20°C to +15°C (-4°F to 59°F)
10°C to +30°C (14°F to 86°F)
JCB Hydraulic Fluid HP68 0°C 4002/0701
to +40°C (32°F to 104°F)
- BEARING
ALL OTHER GREASE --
POINTS
FUEL TANK 253 litres (55.6 UK K Fuel System ( T 3-59) - -
gal) (66.7 US gal)
(1) For information about the different container sizes that are available (and their part numbers), contact your JCB Dealer.
3-17 9813/1000 3-17

Routine Maintenance
JS200/JS210/JS220 and Variants

Table 7.
Size(1)
gal) (5.4 US gal) 10°C to +50°C (14°F to
122°F)
EP 5W40 -20°C to +50°C (-
4°F to 122°F)
COOLING SYSTEM 28 litres (6.2 UK gal) JCB HP Coolant K Coolant 4006/1120 20 Litres
(7.4 US gal) Mixtures ( T 3-20)
TRACK GEARBOX 2 x 4.7 litres (2 x 1 JCB HD90 Gear Oil 4000/0301 5 Litres
UK gal) (2 x 1.2 US
gal)
SLEW GEARBOX 5 litres (1.1 UK gal) 4000/0305 20 Litres
(1.3 US gal)
TRACK ROLLERS AND IDLER
WHEEL
RECOIL SPRING CYLINDER JCB Special HP Grease 4003/2017 400g
HYDRAULIC SYSTEM 200 litres (44 UK gal) JCB Hydraulic Fluid HP32 - 4002/1024 200 Litres
(52.8 US gal) 20°C to +15°C (-4°F to 59°F)
10°C to +30°C (14°F to 86°F)
JCB Hydraulic Fluid HP68 4002/0701
0°C to +40°C (32°F to 104°F)
- BEARING
ALL OTHER GREASE POINTS --
FUEL TANK 343 litres (75.5 UK K Fuel System ( T 3-59) - -
gal) (90.6 US gal)
(1) For information about the different container sizes that are available (and their part numbers), contact your JCB
Dealer.
3-18 9813/1000 3-18

Routine Maintenance
Typical Lubrication Chart Table 9. Icon Definitions
Excavator grease
Engine oil change
Engine oil filter change
Engine coolant change
Fig 1.
Table 8. Location Identifier Engine air filter clean

A Travel gearbox
B Engine oil filter
C Plexus filter
D Engine oil pan Engine air filter change
E Engine cooling system

F Servo oil filter
G Fuel filter Transmission oil change
H Swing ring bearing
J Air cleaner, outer
K Air cleaner, inner
L Drain line filter Transmission oil level
M Fuel separator
N Hydraulic return filter
P Hydraulic tank air breather
Fuel (diesel)
Q Suction strainer
R Hydraulic tank
S Swing ring gear teeth
T Fuel tank Fuel filter change
U Slew gearbox
V Boom/arm grease points
W Boom/arm grease points
Hydraulic oil change
3-19 9813/1000 3-19

Routine Maintenance
Coolant Mixtures
Hydraulic tank breather filter change T3-009_3
Check the strength of the coolant mixture at least once a

year, preferably at the start of the cold period.
Replace the coolant mixture according to the intervals

Hydraulic oil filter change shown in the machine's Service Schedule.
!MWARNING
Antifreeze can be harmful. Obey the manufacturer's
Hydraulic oil filter clean instructions when handling full strength or diluted
antifreeze.
7-3-4-4_1
You must dilute full strength antifreeze with clean water

Hydraulic oil level
before use. Use clean water of no more than a moderate
hardness (pH value 8.5). If this cannot be obtained, use
de-ionized water. For further information advice on water
hardness, contact your local water authority.
Engine oil level
The correct concentration of antifreeze protects the engine
against frost damage in winter and provides year round
protection against corrosion.
Fuel tank level The protection provided by JCB High Performance

Antifreeze and Inhibitor is shown below.
50% Concentration (Standard)

Drain off water/sediment Protects against damage down to -40 °C (-39 °F)
60% Concentration (Extreme Conditions Only)

When using hammer/crusher/ Protects against damage down to -56 °C (-68 °F)
pulveriser
Important: Do not exceed a 60% concentration, as the
freezing protection provided reduces beyond this point.
When using bio-degradeable oil If you use any other brand of antifreeze:
– Ensure that the antifreeze complies with International

Specification ASTM D6210.
When using in wet or severe – Always read and understand the manufacturer's
conditions instructions.
– Ensure that a corrosion inhibitor is included. Serious
damage to the cooling system can occur if corrosion
inhibitors are not used.
– Ensure that the antifreeze is ethylene glycol based
and does not use Organic Acid Technology (OAT).
3-20 9813/1000 3-20

Routine Maintenance
Fuel !MCAUTION
Acceptable and Unacceptable Fuels Consult your fuel supplier or JCB distributor about the
T3-031
suitability of any fuel you are unsure of.
Important: No warranty liability whatsoever will be GEN-9-2
accepted for failure of fuel injection equipment where the
failure is attributed to the quality and grade of the fuel used.
Table 10.
Fuel Specification Applicable Engines Service Requirements
EN590 Diesel fuel types - Auto/C0/C1/C2/ All Dieselmax engines. Obey the usual routine
C3/C4 maintenance schedules and
BS2869 Class A2 procedures.
ASTM D975-91 Class 2, US DF1, US DF2,

US DFA
JIS K2204 (1992) Grades 1, 2, 3 and Special
Grade 3
ASTM D975-91 Class 1DA All Dieselmax engines. Obey the usual routine
MIL T38219 XF63 maintenance schedules and
Important: Engines operated with procedures. Fuel additives are
NATO F63 these fuels may have a reduced recommended for use with low
French EN590 (RME5) with 5% maximum service life. sulphur fuels.
K Additives ( T 3-22).
AVTURFSII, NATO F34, JP8, MIL T83133, All Dieselmax engines. Obey the usual routine
DERD 2463, DEF STAN 91-87 maintenance schedules and
AVCAT FSII, NATO F44, JP5, MIL T5624, Important: Engines operated with procedures. Fuel additives must be
DERD 2452, AVTOR these fuels may have a reduced used. K Additives ( T 3-22).
service life.
NATO F35, JET A1, DEF STAN 91-91,
DERD 2494, JP7
AVCAT, NATO F43 (obsolete), JP5 without
additives
JET A (ASTM D1655)
ASTM D3699 Kerosene
B20 Biodiesel - RME content blended with Dieselmax engines manufactured You must obey special routine
mineral derived diesel (20% maximum) - from 2007 on only(1). maintenance schedules and
ASTM D6751, DIN 51606, ISO 14214 procedures. K Warranty ( T 3-22).
AVTAG (obsolete) These fuels are not acceptable with or
AVTAG FSII (obsolete), NATO F40, JP4, without additives. Engines must not
DERD 2454 be operated with these fuels.
JET B (ASTM D1655)

BS MA100
JIS K2203 No.2
Unmodified vegetable oils
(1) The year of manufacture is part of the engine serial number. Refer to Typical Engine Identification Number.
3-21 9813/1000 3-21

Routine Maintenance
Additives and factory filled with CH4 oil) - this is not approved
with other manufacturers.
The additives listed below are advertised as being suitable – Use heater kits in low ambient temperature territories.
for bringing the lubricity levels of kerosene/low sulphur
– The biodiesel must meet the following standards:
fuels up to those of diesel fuels. They must be used as
ASTM D6751, DIN 51606, ISO 14214
specified by your fuel supplier who will understand the
concentration level necessary.
Note: If necessary use a test kit to confirm the fuel
specification. Testing kits are available (not from JCB
– Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%),
currently), use the internet as a source for the kits.
specifically for Indian Superior Kerosene (SKO) but
may be applicable to other fuels.
Note: If performance related issues are to be reported to
– Lubrizol 539N. Dosage (on Swedish low sulphur fuel) JCB Service, and the engine has been run on biodiesel,
250 ppm. then the fuel system must be filled with standard diesel (at
– Paradyne 7505 (from Infineum). Dosage 500 ppm least 2 x tank fills) to EN590 specification and relevant stall
(0.05%). speeds recorded prior to making the report.
Note: These products are given as examples only. The Warranty

information is derived from the manufacturers data. The
products are not recommended or endorsed by JCB. JCB have shown a commitment to support the
environment by approving the use of biodiesel blended
Service Requirements for use of B20 Biodiesel fuels.
– The engine oil must be a grade CH4 as minimum Using a B20 blend of biodiesel requires caution and
specification. additional servicing of the engine is required. K Service
– Do not leave unused B20 biodiesel in the fuel tank for Requirements for use of B20 Biodiesel ( T 3-22).
extended periods (top up each day).
Failure to follow the additional recommended service
– Make sure that 1 in 5 fuel tank fills use standard diesel
requirements may lead to a warranty claim being declined.
to EN590 specification, this will help to prevent
'gumming'.
Failures resulting by the incorrect use of biodiesels or
– Make sure regular oil sampling is completed (look for other fuel additives are not defects of the JCB Dieselmax
excessive unburnt fuel content, water or wear engine workmanship and therefore will not be supported
particles. by JCB Warranty.
– Change the engine oil and filter more frequently (as a
minimum half the recommended intervals), or as
indicated by oil sampling.
– Change the fuel filters more frequently (as a minimum
half the recommended intervals), or if there are
engine performance related issues.
– Make sure the fuel is stored correctly, care must be
taken to make sure no water enters the machine fuel
tank (or the storage tank). Water will encourage mico-
bacterial growth.
– Make sure that the fuel pre-filter is drained daily (not
every week as currently advised).
– Only JCB engines built after Jan. 2007 are applicable
(i.e. engines with 07 on the end of their serial number
3-22 9813/1000 3-22

Routine Maintenance
Sulphur Content Effects of Fuel Contaminates
T3-032 T3-033
High sulphur content can cause engine wear. (High The effect of dirt, water and other contaminants in diesel
sulphur fuel is not normally found in North America, can be disastrous for injection equipment:
Europe or Australia.) If you have to use high sulphur fuel
you must change the engine oil more frequently. – Dirt - A severely damaging contaminant. Finely
K Table 11. Sulphur Content ( T 3-23). machined and mated surfaces such as delivery
valves and distributor rotors are susceptible to the
Low sulphur fuels must have the appropriate fuel lubricity abrasive nature of dirt particles - increased wear will
additives, these lubricity improvers must not create almost inevitably lead to greater leakage, uneven
residual deposits that block the fuel system, e.g. injectors, running and poor fuel delivery.
filters etc. Contact your fuel Supplier. – Water - Water can enter fuel through poor storage or
careless handling, and will almost inevitably
!MCAUTION condense in fuel tanks. The smallest amounts of
water can result in effects that are just as disastrous
A combination of water and sulphur will have a to the fuel injection pump as dirt, causing rapid wear,
corrosive chemical effect on fuel injection equipment. corrosion and in severe cases, even seizure. It is
It is essential that water is eradicated from the fuel vitally important that water is prevented from reaching
system when high sulphur fuels are used. the fuel injection equipment. The filter/water trap must
ENG-3-2 be drained regularly.
– Wax - Wax is precipitated from diesel when the
Table 11. Sulphur Content
ambient temperature falls below that of the fuel's
Percentage of sulphur in Oil Change Interval cloud point, causing a restriction in fuel flow resulting
the fuel (%) in rough engine running. Special winter fuels may be
Less than 0.5 Normal available for engine operation at temperatures below
0.5 to 1.0 0.75 of normal 0°C (32°F). These fuels have a lower viscosity and
limit wax formation.
More than 1.0 0.50 of normal
3-23 9813/1000 3-23

Routine Maintenance
Tools
Tools
Carrying Tools onto the Machine

When you carry tools onto the machine you must maintain
three points of contact with the machine at all times. Lift
tools onto the machine in intervals if necessary. Place the
tools down before you adjust your grips on the machine.
Do not try to adjust your grips on the machine while holding
tools.
Locations
The machine is equipped with a a grease gun (option) and
remote oil-drain tube attachment.
The grease gun is stowed into position with clips A,

K Fig 2. ( T 3-24).
A
The drain tube is stowed into position by its screw thread
B, K Fig 3. ( T 3-24).
Keep the tools in their stowage positions until they are

needed. The location of the tools will vary dependant on
the machine variant: Fig 2.
All Machines
The grease gun and drain tube(s) are stowed in the

B
toolbox. The toolbox can be locked with the key.
Fig 3.
3-24 9813/1000 3-24

Routine Maintenance
Prepare the Machine for Maintenance
Prepare the Machine for Maintenance
Introduction How to Make the Machine Safe

(Excavator Lowered)
!MWARNING Important: Unless a maintenance procedure instructs you
Maintenance must be done only by suitably qualified differently, you must lower the Excavator.
and competent persons.
1 Park the machine on level, solid ground.
Before doing any maintenance make sure the machine
is safe, it should be correctly parked on level ground. If necessary, refer to Stopping and Parking the
Machine in the Operator Manual.
To prevent anyone starting the engine, remove the
starter key. Disconnect the battery when you are not 2 Lower the excavator so the attachment is flat on the
using electrical power. If you do not take these ground as at A.
precautions you could be killed or injured.
8-3-1-1
Make the machine safe before you start a maintenance

procedure.
Unless a maintenance procedure instructs you differently,

you must lower the Excavator. Refer to How to Make the
Machine Safe (Excavator Lowered).
808071-2
Fig 4.
3 Stop the engine and remove the starter key.
4 Release tank pressure. Refer to Releasing Tank

Pressure.
5 Release the hydraulic pressure. Refer to Releasing

the Hydraulic Pressure.
6 Disconnect the battery to prevent accidental

operation of the engine.
3-25 9813/1000 3-25

Routine Maintenance
Cleaning the Machine
Introduction
T3-062_2
!MCAUTION
Clean the machine using water and or steam. Do not allow The engine or certain components could be damaged
mud, debris etc. to build upon the machine. by high pressure washing systems; special
precautions must be taken if the engine is to be
Before carrying out any service procedures that require washed using a high pressure system.
components to be removed:
Ensure that the alternator, starter motor and any other
1 Cleaning must be carried out either in the area of electrical components are shielded and not directly
components to be removed or, in the case of major cleaned by the high pressure cleaning system.
work, or work on the fuel system, the whole engine ENG-3-3
and surrounding machine must be cleaned.
Important: Do not aim the water jet directly at bearings, oil
2 When cleaning is complete move the machine away seals or electrical and electronic components such as the
from the wash area, or alternatively, clean away the engine electronic control unit (ECU), alternator or fuel
material washed from the machine. injectors.
Important: When removing components be aware of any Use a low pressure water jet and brush to soak off caked
dirt or debris that may be exposed. Cover any open ports mud or dirt.
and clean away the deposits before proceeding.
Use a pressure washer to remove soft dirt and oil.
Detergents
Note: The machine must always be greased after
Avoid using full strength detergent - always dilute pressure washing or steam cleaning.
detergents as per the manufacturer's recommendations,
otherwise damage to the paint finish may occur. Preparing the Machine for Cleaning
P11-3004
Always adhere to local regulations regarding the disposal 1 Make the machine safe with the excavator lowered.
of debris created from machine cleaning. Refer to Prepare the Machine for Maintenance.
Pressure Washing and Steam Cleaning Important: Stop the engine and allow it to cool for at least
one hour. Do not attempt to clean any part of the engine
!MWARNING while it is running.
When using a steam cleaner, wear safety glasses or a 2 Make sure that all electrical connectors are correctly
face shield as well as protective clothing. Steam can coupled. If connectors are open fit the correct caps or
cause serious personal injury. seal with water proof tape.
13-3-2-10_2
3-26 9813/1000 3-26

Routine Maintenance
Cleaning the Machine 1 Prepare the Machine. K Prepare the Machine for
Exterior
Park the machine on level ground. Open the bucket
Clean the exterior of the machine using water and/or and swing the boom until it is at 90° to the track.
steam. Lower the bucket to the ground.
If steam is used the machine must be completely greased 2 Raise the Track.
afterwards. K Greasing ( T 3-32)
Operate the boom and dipper controls so that the
Pay particular attention to the cab windows. Make sure that track on the side nearest the bucket is lifted up clear
the radiator grille is not blocked. of the ground.
Do not allow mud to build up on the tracks and running 3 Rotate the Track.
gear. K Tracks and Running Gear ( T 3-78)
When it is safe to do so and you are sure that
everyone is clear of the machine, operate the controls
Interior
to rotate the track which is off the ground. Rotate it
first one way and then the other to shake off the mud.
!MCAUTION If necessary, the person outside may use water to get
the mud off.
Never use water or steam to clean inside the cab. The
use of water or steam could damage the on-board
4 Inspect the Track.
computer and render the machine inoperable. Remove
dirt using a brush or damp cloth.
When you have finished, inspect the track rollers,
8-3-4-8
sprockets and idler wheels for damage and oil leaks.
Cleaning the Tracks 5 Lower the Track.
!MWARNING Operate the boom and dipper controls to lower the

track to the ground.
If two people are doing this job make sure that the
person operating the controls is a competent operator. 6 Repeat for the Opposite Track.
If the wrong control lever is moved, or if the controls
are moved violently, the other person could be killed Swing the boom round to the other side and repeat
or injured. steps 2 to 5 inclusive for the other track.
If you will be working with another person, make sure Cleaning the Radiator and Oil Cooler
that you both understand what is to be done. Learn
and use the recognised signalling procedures. Do not A clogged radiator and/or oil cooler can lead to engine
rely on shouting - he will not hear you. overheating. Regularly check for a build-up of dirt and
debris and if necessary, use compressed air to clean-out
To clean the tracks, you must turn them. When the the grille. At the same time check all hoses for damage or
tracks are turning, keep clear of rotating parts. Before perishing, and replace if necessary.
starting this job, make sure that you have no loose
clothing (cuffs, ties etc.) which could get caught in
moving parts. Keep people not involved with this job
well away!
MD-3-3-2
3-27 9813/1000 3-27

Routine Maintenance
Checking for Damage
Checking for Damage
Check the Machine Body and Structure Checking the FOPS Structure
T3-063_5
Make sure that all guards and protective devices are in All excavators are designed so that an operator's
place, attached by their locking devices and free from protective structure can be fitted. In certain applications
damage. such as demolition, machines must be fitted with the
optional Falling Objects Protection Structure (FOPS). It is
Inspect all steelwork for damage. Pay particular attention the operator's responsibility to identify the risk of an
to the following: application.
– Inspect all lifting point welds.

– Inspect all pivot point welds.
!MWARNING
You could be killed or seriously injured if you operate
– Inspect the condition of all pivot pins.
a machine with a damaged or missing ROPS/FOPS. If
– Check pivot pins are correctly in place and secured by the Roll Over Protection Structure (ROPS)/Falling
their locking devices. Objects Protection Structure (FOPS) has been in an
accident, do not use the machine until the structure
Check steps and handrails are undamaged and secure. has been renewed. Modifications and repairs that are
not approved by the manufacturer may be dangerous
Check for broken, cracked or crazed window glass and and will invalidate the ROPS/FOPS certification.
mirrors. Replace damaged items. INT-2-1-9_6
Check all lamp lenses for damage. Check that all the FOPS mounting bolts are in place and
undamaged. Check the FOPS mounting bolts for correct
Check all attachment teeth are undamaged and secure. torque tightness.
Check all safety and instructional labels are in place and Cab Mounted
undamaged. Fit new labels where necessary.
Note damaged paintwork for future repair.
Check the Seat and Seat Belt

T3-008_2
!MWARNING
When a seat belt is fitted to your machine replace it
with a new one if it is damaged, if the fabric is worn, or
if the machine has been in an accident. Fit a new seat
belt every three years.
2-3-1-7_1
Inspect the seat belt for signs of fraying and stretching.

Check that the stitching is not loose or damaged. Check
that the buckle assembly is undamaged and works
correctly.
Check that the belt mounting bolts are undamaged,

correctly fitted and tightened.
Fig 5.
Check seats are undamaged and secure. Check seat
adjustments for correct operation.
3-28 9813/1000 3-28

Routine Maintenance
Checking for Damage
1 Torque tightness is 78.4 Nm (58 lbf ft)
Frame Mounted
Fig 6.
1 Torque tightness is 78 Nm (57.5 lbf ft)
2 Torque tightness is 343 Nm (253 lbf ft)
4 Torque tightness is 78 Nm (57.5 lbf ft)
3-29 9813/1000 3-29

Routine Maintenance
Daily Checking
Daily Checking
It is vital to check certain machine functions and

components daily to ensure that the machine can be
!MWARNING
operated safely and efficiently. Do not remove the hydraulic tank filler cap or cover
plate when the engine is running. The hydraulic
1 Prepare the machine. K Prepare the Machine for system is under pressure. You or others could be
Maintenance ( T 3-25). injured. First stop the engine and then release the
pressure.
2 Visual check. Check the machine for the following: 8-3-4-4
a Oil, fuel and coolant leakage. 5 Hydraulic oil level check and refilling. K Checking
the Fluid Level ( T 3-68), K Topping-up Fluid
b Broken or loose fasteners. Level ( T 3-68).
c Wire breakage, short circuit of cables and terminal 6 Check the mounting bolts of the fuel and hydraulic oil
anchorage. tanks for looseness and for fuel and hydraulic oil
leakage.
d Oil cleanliness.
7 Check the mounting bolts of the electrical parts and
e Dust accumulation. battery terminals for looseness and wire breakage.
f Structures for damage. 8 Crawler.
!MWARNING a Check the shoes for looseness, wear and

breakage. Refer to Introduction Section,
The cooling system is pressurised when the coolant is Component Location.
hot. When you remove the cap, hot coolant can spray
out and burn you. Make sure that the engine is cool b Check the track motor, upper/lower rollers and
before you work on the cooling system. idler wheel for oil leakage and wear. Refer to
9-3-3-1_2 Introduction Section, Component Location.
g Coolant level check and refilling. K Checking the c Check each mounting bolt for looseness and/or
Coolant Level ( T 3-51). missing bolts.
3 Checking after initial start-up 9 Boom/Dipper
a Engine oil level is checked automatically. Check Check the high pressure hoses/joints and the
monitor display at start up for possible warning. hydraulic rams for oil leakage.
b Operation of horn and gauges. 10 Accumulator - Check charge
c Ease of engine starting, abnormal noise and a Extend dipper and raise boom.
exhaust gas colour.
b Apply engine shutdown.
d Oil, fuel and coolant leakage.
c Operate boom down function.
4 Fuel level check and refilling. refer to Operation
Section, Refuelling the Machine. d Ensure boom lowers to the ground under its own
weight.
11 Bucket and Linkage.
3-30 9813/1000 3-30

Routine Maintenance
Daily Checking
a Check the bucket teeth and side cutter for
looseness, wear and breakage.
b Check the lubrication of the linkage L and

surrounding parts. Check to see if the bucket side
play is within allowable range. K Checking/
Adjusting For Side Play ( T 3-81).
Fig 7.
3-31 9813/1000 3-31

Routine Maintenance
Greasing
Greasing
Introduction Slew Ring Teeth and Slew Pinion

T3-028_2
You must grease the machine regularly to keep it working Ensure slew ring is kept full of grease. Always grease
efficiently. Regular greasing will also lengthen the whenever the machine has been steam-cleaned.
machine's working life. Refer to the Service Schedule for
the correct intervals. Get access to the slew ring gear. Refer to Introduction
Section, Component Location.
Note: The machine must always be greased after
pressure washing or steam cleaning. 1 Make the machine safe. Stop the engine and remove
the starter key.
Greasing should be done with a grease gun. Normally, two
strokes of the gun should be sufficient. Stop greasing when 2 Grease the Slew Ring.
fresh grease appears at the joint. Use only the
recommended type of grease. Do not mix different types of a Remove the inspection port cover A (on the lower
grease, keep them separate. centre section).
In the following illustrations, the grease points are b Remove the grease discharge port cover B (on
numbered. Count off the grease points as you grease each the lower inner side).
one. Refit the dust caps after greasing.
c Remove contaminated grease.
Note: Where applicable, refer to the manufacturers
manual for instructions on the maintenance of optional d Replace the discharge port cover.
attachments.
e Apply grease to the slew ring via aperture C.
!MCAUTION
Waxoyl contains turpentine substitute which is
flammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep
flames away during the drying period.
Do not weld near the affected area during the drying

period. Take the same precautions as for oil to keep
Waxoyl off your skin. Do not breathe the fumes. Apply
in a well-ventilated area.
5-3-1-9
Slew Ring Bearing

There are two grease nipples on the front of the machine
and one on the front of the ring.
Check that the grease extrudes from under the seal

around the entire circumference.
Note: It is not possible to add too much grease.
3-32 9813/1000 3-32

Routine Maintenance
Greasing
Greasing Points
!MWARNING
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
Table 12.
Greasing Points No. Hours
A Boom Base 3 1000
B Boom ram, eye end pin 2 50
C Dipper ram, dump end pin 1 50
D Boom ram, dump end pin 2 50
E Bucket ram to Bucket linkage 3 50
F Bucket linkage to Bucket pin 1 50
G Dipper to Bucket Linkage pin 1 50
H Dipper to Bucket pin 1 50
J Bucket ram, dump end pin 1 50
K Dipper ram, eye end pin 1 50
L Boom to Dipper, connecting pin 1 1000
Fig 8. M TAB positioning ram, dump end pin 1 50
N TAB positioning ram, eye end pin 1 50
3 Slew the Machine.
JS115-JS180
Start the engine and slew the machine a few O TAB upper/lower boom pivot pin 1 1000
degrees.Stop the engine, remove the starter key and JS200-JS220
apply grease again. O TAB upper/lower boom pivot pin 1 50
Repeat until the whole ring is greased. Check that R Slew Ring Teeth 1 500
grease exudes around the entire circumference. S Slew Ring Bearing 3 250
4 Refit the inspection port cover.
D
Fig 9.
3-33 9813/1000 3-33

Routine Maintenance
Greasing
D
A D L
S
Fig 12.
Fig 10.
Fig 13.
B
C
B
Fig 11.
3-34 9813/1000 3-34

Routine Maintenance
Electrical System
Electrical System
Battery
Note: Before commencing work on the batteries you must
read the following procedure in Health and Safety;
K Battery ( T 3-5).
Note: If a battery requires replacement then both batteries

must be replaced.
Battery Isolator
T3-101
To disconnect the batteries from the machine electrics a

battery isolator has been fitted.
Important: DO NOT use the battery isolator when the

engine is running, this may result in damage to the
machine electrics.
!MCAUTION
Before carrying out arc welding on the machine,
disconnect the battery and alternator to protect the
circuits and components. The battery must still be
disconnected even if a battery isolator is fitted.
INT-3-1-13
At the end of a working cycle or if the machine is being left

Fig 14.
unattended or if carrying out maintenance, the battery
must be isolated. Before attempting to start the engine or
4 Disconnect the batteries from the machine electrics.
use the machine electrics the battery isolator key must be
fitted and switched on.
a Turn the battery isolator key A in a counter-
clockwise direction B and remove.
Note: If the batteries are isolated, the radio may loose its
preset memories.
b Keep the key in a safe place and available for
when the machine is next required.
1 Make the machine safe. Refer to Prepare the
Machine for Maintenance.
To connect the batteries insert the key A and turn in a
clockwise direction C.
2 Locate the battery isolator in the battery bay.
3 To allow the engine ECU to shutdown correctly, you

must wait 30 seconds (X) before you isolate the
battery. The 30 second period starts when you switch
OFF the machine ignition.
3-35 9813/1000 3-35

Routine Maintenance
Electrical System
Battery Disconnection/Connection 5 Replacement is a direct reversal of the removal
procedure.
1 Prepare the machine. K Prepare the Machine for
Maintenance ( T 3-25). When replacing the batteries do not mix old and new
batteries together, they must be replaced as a pair,
2 Gain access to the batteries. Refer to Introduction otherwise the service life of the new battery will be
Section, Component Location. shortened.
3 Disconnect the battery terminals. Disconnect the

ground terminal first. For connection, connect the
ground terminal last.
Note: It may be necessary to remove the battery retaining

plates A and battery covers B first.
4 If removing the batteries, remove the nuts securing

the battery retaining plates A, remove the battery
covers B (if fitted) and then remove the batteries.
Fig 15. Typical Battery Installation
3-36 9813/1000 3-36

Routine Maintenance
Electrical System
Terminal Cleaning Battery Inspection - Maintenance Free Batteries
1 Prepare the machine. K Prepare the Machine for This type of battery must be inspected using the visual
Maintenance ( T 3-25). indicator/sight glass A on a weekly basis.
2 Gain access to the battery and disconnect the

terminals. K Battery Disconnection/
Connection ( T 3-36). A
3 If the terminal is dirty, clean the post. Make sure the
terminals are tight.
Fig 17.

2 Gain access to the batteries. Remove the battery

Fig 16. cover plate (if fitted).
4 If the terminal post is corroded and generates white 3 Remove the nuts securing the battery retaining plates
powder wash the terminal with hot water. If A, and remove the battery covers B (if fitted).
considerable corrosion is detected, clean with a K Fig 15. ( T 3-36).
wire brush or abrasive paper.
4 Check the visual indicator/sight glass A.
5 After cleaning, apply a thin coat of petroleum jelly to
the terminal. Green = Battery OK.
Black = Battery requires charging.
6 Re-connect the terminals. K Battery
Disconnection/Connection ( T 3-36). White = Battery requires replacement.
3-37 9813/1000 3-37

Routine Maintenance
Electrical System
Jump-Starting the Engine a Open the side panel to gain access to the
batteries.
!MWARNING b Connect the positive booster cable to the positive

In temperatures below freezing, the battery electrolyte (+) terminal on the front battery of the machine A.
may freeze if the battery is discharged or poorly
charged. Do not use a battery if its electrolyte is c Connect the other end of this cable to the positive
frozen. To prevent the battery electrolyte from (+) terminal of the booster supply B.
freezing, keep the battery at full charge.
d Connect the negative (-) booster cable to a clean
If you try to charge a frozen battery or jump-start and metal part of the machine C away from and below
run the engine, the battery could explode. the battery.
Batteries produce a flammable gas, which is Note: The connection on the machine must be free from
explosive; do not smoke when checking the paint and dirt. Do not use a pivot pin for an ground.
electrolyte levels.
e Connect the other end of this cable to the negative
When jump-starting from another vehicle, make sure (-) terminal on the booster supply.
that the two vehicles do not touch each other. This
prevents any chance of sparks near the battery. 3 Do the Pre-Start Checks.
Switch off all circuits which are not controlled by the 4 Start the Engine.
starter switch.
Run the machine on Redundancy mode for ten
Do not connect the booster (slave) supply directly minutes before switching to computer mode.
across the starter motor.
5 Disconnect the Booster Cables.
Use only sound jump leads with securely attached
connectors. Connect one jump lead at a time. a Disconnect the negative (-) booster cable from the
machine frame ground. Then disconnect it from
The machine has a negative earth electrical system. the booster supply.
Check which battery terminal is positive (+) before
making any connections. Keep metal watch straps and b Disconnect the positive (+) booster cable from the
jewellery away from the jump lead connectors and the positive (+) terminal on the battery. Then
battery terminals - an accidental short could cause disconnect it from the booster supply.
serious burns and damage equipment. Make sure you
know the voltage of the machine. The booster (slave)
supply must not be higher than that of the machine.
Using a higher voltage supply will damage your
machine's electrical system. If you do not know the
voltage of your booster (slave) supply, then contact
your JCB dealer for advice. Do not attempt to jump-
start the engine until you are sure of the voltage of the
booster (slave) supply.
8-2-7-4
1 Set all Switches in the Cab to OFF.
2 Connect the Booster Cables as follows:
Note: These machines have 2 batteries which are Fig 18.

connected in series to give 24 volts. Use a booster supply
of 24 volts.
3-38 9813/1000 3-38

Routine Maintenance
Electrical System
Fuses and Relays - Cab
!MCAUTION
Fuses
Always replace fuses with ones of correct ampere F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
rating to avoid electrical system damage.
8-3-3-5 R3 R1 R2
The electrical circuits are protected by fuses. The fuse box

is located in the rear stowage area. Open the fuse box
cover A to gain access to fuses. R5 R4
F11 F12 F13 F14 F15 F16 F17 F18 F19 F20
Fig 21.
If a fuse blows, find out why before fitting a new one.
For fuse identification, a label is attached to the rear of

cover A.
Fuse Identification
Fig 19. Machines Built Up To December 2011
Table 13.
Fuse Circuit(s) Protected Rating
F1 Controller Outputs 1-6 15A
Radio (Memory). Cab Interior Lamp
F2 10A
Switch
F3 Key Switch 10A
F4 ECU, EMS Battery Supply 10A
F5 Diagnostic 10A
A F6 Spare, Output Battery Supply 10A
F7 Refuelling Pump 15A
F8 ECU Outputs 17-22 10A
F9 ECU, EMS, Facia Ignition Supply 5A
F10 Fuel Lift Pump 10A
F11 Spare, Output Ignition Supply 15A
Fig 20. Machines Built After December 2011
F12 ECU output 7-12 15A
F13 Ignition Supply Relay R5 10A
F14 ECU Output 13-16 15A
F15 Auxiliary 10A
F16 ECU Output 23-28 10A
3-39 9813/1000 3-39

Routine Maintenance
Electrical System

F17 Heater, ATC 20A
F18 Heated Seat, Wiper 20A
Work Lamps, Optional Hydraulics, Radio
F19 20A
(ignition), Lighter.
F20 Spare, Output Ignition Supply 20A
Relay Identification
Table 14.
Relay Circuit(s)
R1 Not used
R2 Engine Stop
R3 Not used
R4 Beacon
R5 Refuel Pump
3-40 9813/1000 3-40

Routine Maintenance
Electrical System
Fuses and Relays - Battery Bay
!MCAUTION
Fuses
Always replace fuses with ones of correct ampere
rating to avoid electrical system damage.
8-3-3-5
The electrical circuits are protected by fuses. The fuse box

is located in the battery bay. Open the fuse box A to gain
access to fuses (JS160-JS220 only).
If a fuse blows, find out why before fitting a new one.

A
A
Fig 23. JS200/JS210/JS220
RL7 F11
F11 RL7
F10
F10 F9
F9
Fig 24. JS200/JS210/JS220

Fig 22. JS160/JS180
24V
RL2
RL1
F8 F2 F3 F4 F5 F6 F7 F1
24V
RL6 RL5 RL4 RL3
12V 12V 12V 12V
Fig 25. Fuse Box ‘A’
3-41 9813/1000 3-41

Routine Maintenance
Electrical System
Fuse Identification
Table 15.
F1 Ignition Switch 5A
F2 ECU 1 10A
F3 ECU 1 10A
F4 ECU 1 10A
F5 ECU 1 10A
F6 Fuel Lift Pump 10A
F7 Water in Fuel Sensor 5A
F8 Grid Heater 5A
F9 Ignition 70A
F10 Battery 30A
F11 Battery - Engine ECM 30A
Relay Identification
Table 16.
Fuse Circuit(s)
RL1 Voltage Dropper 24V
RL2 Ignition Sense 24V
RL3 Voltage Dropper 24V, 12V coil
RL4 Power Hold
RL5 Fuel Lift Pump
RL6 Grid Heater
RL7 Starter Relay
3-42 9813/1000 3-42

Routine Maintenance
Bolt and Nut Torque Specifications
JS115-JS220 and Variants Tighten the bolts and nuts after the first 50 hours of the
running-in stage and every 250 hours thereafter.
Tighten the bolts and nuts according to the tables below.
Before and after daily work, check the bolts and nuts for For tightening torques for the bolts and nuts not listed
looseness and for those missing. Tighten if loose and K Table 21. ( T 3-48).
renew if missing.
Table 17. JS115 and variants

No. Tightening Point Bolt Wrench Tightening Torque Checking Torque
Diameter mm
Nm lbf ft Nm lbf ft
1 (1) Travel Motor M16 24 290 213 265 195
2 (1) Drive Sprocket M16 24 290 213 265 195
3 (1) Idler Wheel M16 24 290 213 265 195
4 (1) Upper (Carrier) Roller M16/M20 24/30 290/550 213/405 265/515 195/380
5(1) Lower (Track) Roller M16 24 290 213 265 195
6(1) Track Guard M16 24 290 213 265 195
7 Shoe Bolt M16 24 382-440 282-325 344-396 254-292
8 Counter weight M27 41 925 682 840 620
9 (1) Turntable Bearing M16/M20 24/30 296/525 218/387 275/470 203/347
(Undercarriage)
10(1) Turntable Bearing (Slew M16/M20 24/30 296/525 218/387 275/470 203/347
Frame)
11(1) Slew Equipment M16/M20 24/30 290/550 213/405 265/515 195/370
12(1) Engine (Engine Mount) M16 24 290 213 265 195
13(1) Engine Bracket M10/M12 17/19 68/118 50/87 62/107 45/79
14 Radiator M12 19 104 77 94 69
15 (1) Hydraulic Pump M10 17 60 44 54 40
16 (1) Hydraulic Oil Tank M16 24 250 184 225 162
17(1) Fuel Tank M16 24 250 184 225 162
18(1) Control Valve M16 24 290 213 265 195
19 Battery M6 10 7 5 6 4
20 (1) Rotary Coupling M12 19 116 85 105 80
21 Cab M16 24 132 97 125 92
(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed.
3-43 9813/1000 3-43

Routine Maintenance
Table 18. JS130-145 and variants
Diameter mm
Nm lbf ft Nm lbf ft
1 (1) Travel Motor M16 24 290 213 265 195
2(1) Drive Sprocket M16 24 290 213 265 195
3(1) Idler Wheel M16 24 290 213 265 195
5 (1) Lower (Track) Roller M16 24 290 213 265 195
6 (1) Track Guard M16 24 290 213 265 195
7 Shoe Bolt (JS130) M16 24 382-440 282-325 344-396 254-292
7 Shoe Bolt (JS145) M16 24 363-421 268-311 327-379 241-280
7 Shoe Bolt (JS145HD) M20 27 643-757 474-558 579-681 427-502
8 Counter weight M27 41 925 682 840 620
(Undercarriage)
Frame)
12(1) Engine (Engine Mount) M16 24 290 213 265 195
13(1) Engine Bracket M10/M12 17/19 68/118 50/87 62/107 45/79
14 Radiator M12 19 104 77 94 69
15 (1) Hydraulic Pump M10 17 60 44 54 40
17(1) Fuel Tank M16 24 250 184 225 162
18(1) Control Valve M16 24 290 213 265 195
19 Battery M6 10 7 5 6 4
20 (1) Rotary Coupling M12 19 116 85 105 80
21 Cab M16 24 132 97 125 92
3-44 9813/1000 3-44

Routine Maintenance
Table 19. JS160/JS180 and variants
Diameter mm
Nm lbf ft Nm lbf ft
1 (1) Travel Motor M16 24 215 159 194 143
2(1) Drive Sprocket M20 27 415 306 374 276
3(1) Idler Wheel M16 24 290 213 265 195
6 (1) Track Guard M16 24 290 213 265 195
7 Shoe Bolt M20 27 643-757 474-558 579-681 427-502
8 Counter weight M30 46 1147 845 1050 780
(Undercarriage)
Frame)
12 (1) Engine (Engine Mount) M20/M16 27/24 529/271 390/199 476/244 351/180
13 (1) Engine Bracket M12 19 125 92 113 83
14 Radiator M12 19 104 77 94 69
15(1) Hydraulic Pump M10 17 68 50 62 45
17 (1) Fuel Tank M16 24 250 184 225 162
18 (1) Control Valve M16 24 290 213 265 195
19 Battery M6 10 7 5 6 4
20(1) Rotary Coupling M12 19 116 85 105 80
21 Cab M16 24 132 97 125 92
3-45 9813/1000 3-45

Routine Maintenance
Table 20. JS200/JS210/JS220 and variants
Diameter mm
Nm lbf ft Nm lbf ft
1 (1) Travel Motor M16 24 290 213 265 195
2(1) Drive Sprocket M16 24 290 213 265 195
3(1) Idler Wheel M16 24 290 213 265 195
6 (1) Track Guard M16 24 290 213 265 195
7 Shoe Bolt M20 30 840-890 620-656 756-801 558-591
8 Counter weight M30 46 1147 845 1050 780
9 (1) Turntable Bearing M20 30 525 387 470 347
(Undercarriage)
10(1) Turntable Bearing (Slew M20 30 525 387 470 347
Frame)
12 (1) Engine (Engine Mount) M20/M16 27/24 529/271 390/199 476/244 351/180
13 (1) Engine Bracket M12 19 125 92 113 83
14 Radiator M12 19 55 41 50 37
15(1) Hydraulic Pump M10 17 60 44 54 40
17 (1) Fuel Tank M16 24 250 184 225 162
18 (1) Control Valve M16 24 290 213 265 195
19 Battery M6 10 7 5 6 4
20(1) Rotary Coupling M12 19 116 85 105 80
21 Cab M16 24 132 97 125 92
3-46 9813/1000 3-46

Routine Maintenance
2 4 10
1 9 3
7
13 6 5
12
13
12
11
8
15
14 16
19
18
17
Fig 26.
3-47 9813/1000 3-47

Routine Maintenance
Table 21.
Bolt Diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench mm 10 13 17 19 22 24 27 30
Nm 12.5 30 60 104 167 259 506 874
Hex bolt Tightening
kgf m 1.3 3.1 6.1 10.6 17 26.4 51.6 89
Torque
lbf ft 9.2 22.1 44.3 76.7 123.2 191 373.2 645
Wrench mm 5 6 8 10 12 14 16 17
Hex. socket Nm 15 36 72 125 200 311 - 607
head bolt Tightening
kgf m 1.5 3.7 7.3 12.7 20.4 31.7 - 61.9
Torque
lbf ft 11.1 26.6 53.1 92.2 147.5 229.4 - 447.7
3-48 9813/1000 3-48

Routine Maintenance
Engine
Engine
Oil and Filter Changing the Oil and Filter
Checking the Oil Level !MCAUTION

1 Open the Engine Compartment. Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job.
2 Check the Oil Level. 2-3-3-2
a Locate the dipstick A and remove. Oil should be 1 Prepare the machine. K Prepare the Machine for
between the two marks. Add oil if necessary Maintenance ( T 3-25).
through filler B. Use only the recommended oil
K Fluids, Lubricants and Capacities ( T 3-16). 2 Let the engine stand until it is warm. Do not check the
Re-check the oil level about 10-15 minutes after oil straight after the engine has stopped, the oil level
refilling. indicated will actually be lower than it is.
b Make sure that the dipstick and filler cap are 3 Drain the Oil
secure.
a Remove the belly plate
A b Place an oil collecting container of suitable size

beneath the engine sump drain point.
Fig 27.
Fig 28.
c Remove the self sealing drain plug outer cover C.
d Fit the self sealing drain kit threaded union (with

attached pipe) D. Drain sump oil into a suitable
container.
3-49 9813/1000 3-49

Routine Maintenance
Engine
e Remove the self seal drain kit, clean and refit the 6 Check for Leaks
outer cover. (Do not over tighten the cover).
a Before starting the engine, turn the engine over
4 Change the Filter: with the Engine Shutdown Button ON until the oil
pressure warning light goes out.
a Get access to the filter. Refer to Introduction
Section, Component Location. b Allow the engine to stand before checking the oil
level. K Checking the Oil Level ( T 3-49).
b Drain the oil from the filter hoses using the bleed
screw A.
Fig 29.
c Remove the filter.
d Clean the filter head.
e Smear the seal on the new filter E with oil.
f Fill the filter with engine oil before fitting, make

sure the bleed screw is tight.
g Tighten the filter until the seal bites onto the filter
housing.
h Tighten the filter a minimum of one more full turn.
5 Fill the System.
a Fill the engine with new oil through filler B.

K Fig 27. ( T 3-49), K Fluids, Lubricants and
Capacities ( T 3-16).
b Wipe off any spilt oil.
c Check for leaks.
d Make sure the filler cap is correctly refitted.
3-50 9813/1000 3-50

Routine Maintenance
Engine
Cooling System 6 Check the radiator is full of coolant.
Checking the Coolant Level If the level is low:
1 Park the machine on solid, level ground. a Top up the radiator with coolant.
2 Turn the engine OFF and remove the ignition key. b Fit the radiator cap.
3 Let the engine cool down. Note: Manipulate the top radiator hose D to make sure
there are no air locks in the system. K Fig 30. ( T 3-51).
!MWARNING 7 Check the level in the expansion bottle E.

K Fig 30. ( T 3-51).
The cooling system is pressurised when the coolant is
The level must be at top of bracket X.
out and burn you. Make sure that the engine is cool
before you work on the cooling system.
If the level is low:
9-3-3-1_2
a Top-up the expansion bottle E with coolant.
8 Start the engine.
A 9 Switch the cab heater onto hot and full blower speed.
10 Turn the slew lock ON.
E X 11 Stall the `dipper in' service until the coolant

temperature reaches approximately 90°C.
D
Coolant temperature can be checked as follows:
a Simultaneously press the SET and MODE buttons

on the EMS.
b Press the UP or DOWN arrow until `WATER

TEMP' is displayed on the EMS.
c Press the ACK button on the EMS.
The coolant temperature is displayed in °C.
12 Switch the engine OFF.
Fig 30. 13 Remove the ignition key.
4 Carefully release the radiator cap A to release system 14 Let the engine cool down.
pressure.
5 Remove the radiator cap A.
3-51 9813/1000 3-51

Routine Maintenance
Engine
!MWARNING Changing The Coolant
The cooling system is pressurised when the coolant is 1 Park the machine on solid, level ground.
out and burn you. Make sure that the engine is cool 2 Turn the engine OFF and remove the ignition key.
9-3-3-1_2 3 Let the engine cool down.
15 Re-check the levels in the radiator and expansion

bottle. Top up if necessary.
!MWARNING
9-3-3-1_2
4 Drain the system.
B X
D
C
Fig 31.
3-52 9813/1000 3-52

Routine Maintenance
Engine
a Carefully release the radiator cap A to release 17 Check for leaks.
system pressure.
b Remove the radiator cap.

!MWARNING
c Remove the expansion bottle cap B. hot. When you remove the cap, hot coolant can spray
d Remove the radiator drain plug C, before you work on the cooling system.
K Fig 31. ( T 3-52). 9-3-3-1_2
e Let the coolant drain out. 18 Re-check the level in the radiator and expansion
bottle. Top up if necessary.
5 Flush the system if necessary. Use clean water.
The coolant level must be to the top of the expansion
6 Fit the radiator drain plug C. bottle and radiator.
7 Fill the system with pre-mixed water/antifreeze at a Note: Manipulate the top radiator hose to help bleed any
rate of no more than 10 litres per minute (to prevent remaining air in the system.
air pockets). K Coolant Mixtures ( T 3-20).
Note: Manipulate the top radiator hose D to help the

coolant to come through.
8 Fill the expansion bottle until the level in the bottle is

at top of bracket X.
9 Refit the radiator cap and the expansion bottle cap.

Make sure they are tight.
10 Start the engine.
11 Switch the cab heater onto hot and full blower speed.
12 Turn the slew lock ON.
13 Stall the `dipper in' service until the coolant

temperature reaches approximately 90°C.
a Simultaneously press the SET and MODE buttons

on the EMS.
b Press the UP or DOWN arrow until `WATER

TEMP' is displayed on the EMS.
c Press the ACK button on the EMS.
The coolant temperature is displayed in °C.
14 Switch the engine OFF.
15 Remove the ignition key.
16 Let the engine cool down.
3-53 9813/1000 3-53

Routine Maintenance
Engine
Engine Air Filter Changing the Elements
Cleaning the Air Filter Dust Valve

T3-034
!MCAUTION
Important: Do not run the engine with the dust valve K The outer element must be renewed immediately if the
removed. K Fig 32. ( T 3-54). warning light on the instrument panel illuminates.
2-3-3-1
1 Check the dust valve K is not blocked.
2 Inspect the rubber flaps for cuts and nicks and check
!MCAUTION
that the rubber is not perished. Renew if necessary. Do not run the engine when the outer element has
been removed.
16-3-3-1
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 K

removed. K Fig 33. ( T 3-55).
Note: In a dusty environment, the outer element may have

to be changed more frequently than the service schedule
recommendation. A new inner element must be fitted at
least every other time the outer element is changed. As a
reminder, mark the inner element with a felt tipped pen
332260-1 each time the outer element is changed.
Fig 32.
1 Release clips A and lift off cover B. Remove outer
element C. If the inner element is to be changed, pull
handle D and remove inner element E.
Note: Take care not to tap or knock the element.
2 Clean the inside of cover B and canister G.
3 Carefully insert the new inner element E into the

canister. Make sure it seats correctly. check seal H is
fully seated.
4 Insert a new outer element into the canister, check

seal J is fully seated. Fit cover B with dust valve K 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 L.
6 Remove and check hoses M for damage. Clean hose

bores and then replace.
3-54 9813/1000 3-54

Routine Maintenance
Engine
760090-3
Fig 33.
3-55 9813/1000 3-55

Routine Maintenance
Engine
Fan Belt Fitting a New Fan Belt
Checking the Fan Belt Tension !MWARNING

The fan belt is self tensioning. Providing the tensioner is Make sure the engine cannot be started. Disconnect
adjusted to it's maximum position the belt tension will be the battery before doing this job.
correct. K Fitting a New Fan Belt ( T 3-56). 2-3-3-5
B
Fig 34.
1 Remove the old belt. Slacken bolts A and turn bolt B

counter-clockwise so that the fan belt can be
removed.
2 Fit a new fan belt. Make sure the `V' profile locates in
the pulleys correctly.
3 Tighten bolts A to 5-10Nm.
4 Turn bolt B clockwise to its maximum travel.
5 Tighten bolts A and B to 47Nm.
3-56 9813/1000 3-56

Routine Maintenance
Engine
Front End Accessory Drive Belt Inspecting the Drive Belt
Introduction At the recommended service interval, visually inspect the

belt for damage.
The front end accessory drive belt (FEAD) drives the
alternator, water pump and the air conditioning 1 Get access to the drive belt. Refer to Front End
compressor (if fitted). Accessory Drive Belt, Introduction.
The belt is automatically kept in tension so will not need to 2 Inspect the belt for cracks A, fraying B or missing
be adjusted. pieces C.
Fit a new belt as required. Refer to Changing the

!MWARNING Drive Belt.
Make sure the engine cannot be started. Disconnect
the battery before doing this job.
2-3-3-5
!MWARNING
Turning the Engine
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
0094
To get access to the drive belt for maintenance:
1 Remove the under cover.
Fig 35.
3-57 9813/1000 3-57

Routine Maintenance
Engine
Changing the Drive Belt Crankcase Ventilation (if fitted, JS200-
220)
1 Get access to the drive belt. Refer to Front End
Accessory Drive Belt, Introduction.
Changing the Filter Element
2 Use a 16mm (5/8 in.) socket located on the hexagon
The filter element must be changed at the recommended
spigot nut D, carefully rotate the tensioner against the
interval.
spring force in direction E. Do not use excessive force
or the tensioner will be damaged.
1 Get access to the filter case.
3 Keep holding the tensioner against the spring force
and lift the belt off the tensioner pulley F.
4 Slowly release the spring force by rotating the

tensioner unit in the opposite direction.
5 Before fitting a new belt, check that the tensioner

roller and fan pulley rotate smoothly and that there is A
no play in the bearings.
6 Fit the new drive belt around the pulleys.
7 Use a 16mm (5/8 in.) socket located on the hexagon

spigot nut D, carefully rotate the tensioner against the
spring force in direction E. Do not use excessive force
or the tensioner will be damaged.
8 Keep holding the tensioner against the spring force B,C

and lift the belt around the tensioner pulley F. D
2 Twist and remove the top half of the filter case A to

access the filter.
3 Lift out the filter element B and discard it.
4 Clean the inside of the filter housing C. Remove all oil

and sludge contamination.
5 Make sure that the oil drain in the bottom of the filter
housing is not blocked with sludge. If necessary
remove the drain pipe D at the engine. Make sure that
the drain pipe non-return ball valve at the bottom of
the filter housing is fitted and free to move.
6 Fit a new filter element B.
Note: Important: Install the correct type of filter element.
7 Install the top half of the filter case A.
3-58 9813/1000 3-58

Routine Maintenance
Fuel System
Fuel System
Introduction Draining Fuel Tank Impurities
!MWARNING 1 Stop the engine and remove the key.
Fuel 2 Get access to the fuel tank. Refer to Introduction

Fuel is flammable; keep naked flames away from the Section, Component Location.
fuel system. Stop the engine immediately if a fuel leak
is suspected. Do not smoke while refuelling or 3 Remove screws and take off the cover plate from
working on the fuel system. Do not refuel with the below the fuel tank.
engine running. Completely wipe off any spilt fuel
which could cause a fire. There could be a fire and 4 Position a suitable container under the drain.
injury if you do not follow these precautions.
INT-3-2-2_3 Note: The machine is fitted with a self sealing drain plug X.
!MWARNING
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of pressurised
fluid and wear protective glasses. If fluid penetrates
your skin, get medical help immediately.
0177
!MCAUTION
Do not allow dirt to enter the system. Before
disconnecting any part of the system, thoroughly
clean around the connection. When a component has
been disconnected, always fit protective caps and
plugs to prevent dirt ingress.
Failure to follow these instructions will lead to dirt

entering the system. Dirt in the system will seriously
damage the systems components and could be
expensive to repair. Fig 36.
INT-3-3-12
5 Remove the self sealing drain plug outer threaded
!MCAUTION cover.
Running the engine with air in the system could 6 Fit the self sealing drain kit threaded union with
damage the fuel injection pump. After maintenance, attached pipe Y. Drain water and deposits until clean
the system must be bled to remove any air. diesel oil flows.
2-3-3-11
7 Remove the self seal drain kit, clean and refit the
outer cover. Do not over tighten the cover.
3-59 9813/1000 3-59

Routine Maintenance
Fuel System
Draining the Primary Fuel Filter/

Sedimenter
If there is water in the fuel or if the cab warning light
illuminates, drain the water separators and engine filter as
detailed.
1 Get access to the primary fuel filter/sedimenter. Refer

to Introduction Section, Component Location.
2 Drain off any water in the water separator bowl A by

turning tap B. Do not disconnect the electrical
connector C (if fitted).
3 If there is sediment in the bowl after draining, support

the bowl and release the locking ring D.
4 Wash the bowl in clean fuel.

E
5 Refit the bowl, secure in position with locking ring D.
D
Important: Ensure the seal E is seated correctly before
refitting the bowl. A
6 Make sure that the electrical connector C is correctly B
fitted (if fitted). C
C007030-6
Fig 37.
3-60 9813/1000 3-60

Routine Maintenance
Fuel System
Changing the Primary Fuel Filter/

Sedimenter Element
1 Get access to the primary fuel filter/sedimenter. Refer
2 Drain and remove the water separator bowl C. Refer

to Draining the Primary Filter/Sedimenter.
3 To remove the filter element A, release locking ring B

and discard element.
4 Fit new element and secure in position with locking

ring B.
5 Refit the bowl, secure in position with locking ring.
Important: Ensure the seal D is seated correctly before

refitting the bowl.
6 Make sure that the electrical connector E is correctly

fitted (if fitted).
C007030-5
Fig 38.
3-61 9813/1000 3-61

Routine Maintenance
Fuel System
Draining the Main Fuel Filter/Sedimenter

If there is water in the fuel or if the cab warning light
illuminates, drain the water separators and engine filter as
detailed.
1 Get access to the main fuel filter/sedimenter. Refer to

Introduction Section, Component Location.
2 Drain off any water in the water separator bowl A by

turning tap B. Do not disconnect the electrical
connector C (if fitted).
3 If there is sediment in the bowl after draining, support

the bowl and release the locking ring D.
4 Wash the bowl in clean fuel.
5 Refit the bowl, secure in position with locking ring D. E

Important: Ensure the seal E is seated correctly before D
refitting the bowl.
A
6 Make sure that the electrical connector C is correctly
fitted (if fitted). B
C
C007030-6
Fig 39.
3-62 9813/1000 3-62

Routine Maintenance
Fuel System
Changing the Main Fuel Filter/

Sedimenter Element
1 Get access to the main fuel filter/sedimenter. Refer to
2 Drain and remove the water separator bowl C. Refer

to Draining the Primary Filter/Sedimenter.
3 To remove the filter element A, release locking ring B

and discard element.
4 Fit new element and secure in position with locking

ring B.
5 Refit the bowl, secure in position with locking ring.
Important: Ensure the seal D is seated correctly before

refitting the bowl.
6 Make sure that the electrical connector E is correctly

fitted (if fitted).
C007030-5
Fig 40.
3-63 9813/1000 3-63

Routine Maintenance
Fuel System
Draining the Engine Fuel Filter/ Changing the Engine Fuel Filter/
Sedimenter Sedimenter Element
If there is water in the fuel or if the cab warning light 1 Get access to the engine fuel filter/sedimenter. Refer
illuminates, drain the water separators and engine filter as to Introduction Section, Component Location.
detailed.
2 Thoroughly clean the outside of the filter housing and
1 Get access to the engine fuel filter/sedimenter. Refer around the filter head.
3 Loosen the drain tap B and allow the fuel to drain into
2 Drain off any water in the element A by turning tap B. a suitable container.
4 Remove the low pressure fuel lines C and E. Mark the

pipes prior to removal to ensure they are refitted in the
correct position.
5 Release the filter strap retaining screw D and lift the

filter clear.
6 Install new filter element A. Make sure that the filter is

in the correct position to enable connection of the fuel
lines. Torque tighten the filter strap retaining screw D
to 24 Nm (17.7 lbf ft).
7 Reconnect the fuel lines C and E.
8 Bleed the fuel system. Refer to Bleeding the

A System.
C E
B
C040110-2 D
Fig 41.
3-64 9813/1000 3-64

Routine Maintenance
Fuel System
Bleeding the System

Electronic Fuel Injection System
The engine installation features an electrically operated

fuel lift pump on top of the primary fuel filter/sedimenter.
The system is designed to bleed automatically when the lift
pump is operated. Make sure that as much air is removed
from the fuel as possible before starting the engine.
!MWARNING
Do not open the high pressure fuel system with the
engine running. Engine operation causes high fuel
pressure. High pressure fuel spray can cause serious
injury or death.
13-3-2-16
Important: Do not attempt to bleed the high pressure fuel

system by loosening high pressure pipe connections even
when the engine is not running. To bleed the fuel system
follow the correct procedure.
Bleed the system as follows:
1 Turn on the starter switch to start the fuel lift pump. Do

not start the engine. Allow the pump to run for 30
seconds.
2 Turn off the starter switch to stop the fuel lift pump.
Wait 10 seconds and then turn the starter switch to
start the pump. Do not start the engine. Allow the
pump to run for 30 seconds.
3 Repeat step 2 twice more before starting the engine.
4 Start the engine and make sure it runs smoothly.
3-65 9813/1000 3-65

Routine Maintenance
Hydraulic System
Hydraulic System
Introduction !MCAUTION
Do not allow dirt to enter the system. Before
!MWARNING disconnecting any part of the system, thoroughly
The temperature of the hydraulic oil will be high soon clean around the connection. When a component has
after stopping the engine. Wait until it cools (less than been disconnected, always fit protective caps and
40°C) before beginning maintenance. plugs to prevent dirt ingress.
8-3-4-10
Failure to follow these instructions will lead to dirt
entering the system. Dirt in the system will seriously
!MWARNING damage the systems components and could be
Fluid Under Pressure expensive to repair.
Fine jets of fluid at high pressure can penetrate the INT-3-3-12
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of fluid. If
fluid penetrates your skin, get medical help
immediately.
INT-3-1-10_3
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
!MCAUTION
Using incorrect fluid could damage the system. See
Fluids, Capacities and Lubricants for the correct fluid.
The fluid can harm your skin. Wear rubber gloves.
Cover cuts or grazes.
2-3-5-1_2
3-66 9813/1000 3-66

Routine Maintenance
Hydraulic System
Releasing Tank Pressure Releasing the Hydraulic Pressure
!MWARNING Use the procedure below to release the hydraulic

pressure. You must release the hydraulic pressure before
Do not remove the hydraulic tank filler cap or cover carrying out maintenance on the machine for example.
plate when the engine is running. The hydraulic
system is under pressure. You or others could be 1 Park the machine on hard, level ground and lower the
injured. First stop the engine and then release the attachment.
pressure.
8-3-4-4 2 Stop the engine.
1 Prepare the machine. K Prepare the Machine for 3 Turn the ignition to the 'ON' position.
4 Lower the control lock lever.
2 Release tank pressure.
5 Operate the hand controllers in all directions to
Get access to the hydraulic tank breather. Refer to release pressure in the hydraulic system.
6 Turn the ignition to the 'OFF' position.
Depress rubber boot A, to release the pressure from
the tank. 7 Remove the starter key.
8 Release the hydraulic oil tank pressure, refer to

Maintenance, Releasing Tank Pressure.
Fig 42.
3-67 9813/1000 3-67

Routine Maintenance
Hydraulic System
Oil and Filters Topping-up Fluid Level
Checking the Fluid Level 1 Prepare the machine. K Prepare the Machine for
Maintenance ( T 3-25). 2 Release tank pressure. K Releasing Tank
Pressure ( T 3-67)
Position the machine on level ground with the bucket
and dipper rams fully extended and the boom lowered 3 Add Fluid.
to rest the attachment on the ground, as at A.
a Remove plate B.
Fig 43.
b Refill oil through the filler port using a suitable
2 Check the level. Look at the fluid level in the sight tundish.
tube B. The level should be between the two marks
on the tube. If the fluid is cloudy, water or air has c Check the level through the level gauge on the
entered the system. side of the tank.
Water or air in the system could damage the hydraulic d Refit plate B.
pump. Contact your JCB distributor if the fluid is
cloudy.
3-68 9813/1000 3-68

Routine Maintenance
Hydraulic System
Changing the Fluid 4 Renew the suction strainer D and return filter E.
K Cleaning/Changing the Suction
1 Prepare the machine. K Prepare the Machine for Strainer ( T 3-70). K Changing the Return
Maintenance ( T 3-25). Filter ( T 3-70)).
2 Release tank pressure. K Releasing Tank 5 Tighten the drain plug C securely.
Pressure ( T 3-67)
6 Refill the tank with the specified oil to the specified
level. K Fluids, Lubricants and
Capacities ( T 3-16).
A
7 Seal the System. Install the O-ring B and filler port
B cover A.
Note: If the O-ring is damaged, replace it with a new one.
8 Bleed air from the hydraulic components. K Air

Bleeding Procedures ( T 3-75).
9 Start the engine and run it for 5 minutes without load.

Slowly operate the rams several times and then put
the machine in the hydraulic oil checking position.
10 Check that the hydraulic oil is within the proper range.
E
D
C
Fig 44.
3 Remove the oil.
a Remove cover A and O-ring B.
b Use a pump and discharge the hydraulic oil into

an empty container.
c Remove the drain plug C on the bottom of the tank

and drain the remaining oil from the tank.
Note: Have a drain pan ready.
3-69 9813/1000 3-69

Routine Maintenance
Hydraulic System
Cleaning/Changing the Suction Strainer Changing the Return Filter
1 Prepare the machine. K Prepare the Machine for 1 Prepare the machine. K Prepare the Machine for
Maintenance ( T 3-25). Maintenance ( T 3-25).
2 Get access to the suction strainer. Refer to 2 Get access to the return filter. Refer to Introduction
Introduction Section, Component Location. Section, Component Location.
3 Release the tank pressure. K Releasing Tank 3 Release Tank Pressure. K Releasing Tank
Pressure ( T 3-67). Pressure ( T 3-67).
A
B
Fig 45. Fig 46.
4 Remove the suction strainer. 4 Remove the element
a Remove the filler port cover A and O-ring B. a Remove the cover A and O-ring B.
b Remove the suction strainer C from the tank and b Remove spring C, valve D and return filter E from
renew. the tank.
5 Fit the suction strainer. Fitting is a reversal of removal. 5 Fit a new element. Re-assemble in reverse order
When changing the suction strainer, fit a new O-ring using a new filter element E and a new cover O-ring
seal to the filler port cover A and secure the fasteners. B.
6 Check the hydraulic oil level.
3-70 9813/1000 3-70

Routine Maintenance
Hydraulic System
Changing the Plexus Filter

2 Get access to the plexus filter. Refer to Introduction


Pressure ( T 3-67). Fig 48.
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. K Topping-up Fluid
C B Level ( T 3-68)
Fig 47.
4 Remove the plexus filter A.
a Close the two filter case cocks B and C by turning

them to position X.
3-71 9813/1000 3-71

Routine Maintenance
Hydraulic System
Changing the Hydraulic Tank Breather Element 5 Refit the filter cover C
1 Prepare the machine. K Prepare the Machine for Adjust the cover so that it fits over the stud, and
Maintenance ( T 3-25). install hexagonal nut B and rubber boot A.

Pressure ( T 3-67).
3 Get access to the hydraulic tank breather element.

Refer to Introduction Section, Component
Location.
4 Replace the hydraulic tank breather element
a Remove the rubber boot A, locking nut B and

cover C.
F C
E
D
Fig 49.
Note: The cover C can only fit in one of two positions

because of the slot F in the cover which locates over a
similar shaped protrusion on the mounting stud.
b Remove the old filter element D together with the

sponge packing E.
c Replace the old filter element D, with a new one.

When installing the new filter element D place the
sponge packing E on the element.
3-72 9813/1000 3-72

Routine Maintenance
Hydraulic System
Changing the Pilot Oil Filter Table 22. Torque Settings
Item Nm kgf m lbf ft
1 Prepare the machine. K Prepare the Machine for A 24.4 to 34.3 2.5 to 3.5 18.07 to 25.5
2 Release tank pressure. K Releasing Tank Note: When refitting the pilot filter bowl after changing the
Pressure ( T 3-67). filter element, it is important that the filter bowl is tightened
carefully to avoid damaging the threads in the filter
3 Get access to the pilot oil filter. Refer to Introduction housing.
4 Dismantle the filter:
Fig 50.
a Using a wrench on the case, unscrew the filter

case A from the filter head B.Take care not to spill
the oil it contains.
b Remove and discard the 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 oil and

locate in the filter head B.
b Coat the seal area of the new element C and

install it in the filter case A.
c Screw the filter case A to the head B and torque

tighten with the wrench.
3-73 9813/1000 3-73

Routine Maintenance
Hydraulic System
Changing the Breaker In-line Filter Changing the Drain Line Filter
Note: This filter should be changed at the intervals stated 1 Prepare the machine. K Prepare the Machine for
in Service Schedules or when the visual indicator X has Maintenance ( T 3-25).
popped up. Do not use the breaker with a blocked filter.
1 Prepare the machine. K Prepare the Machine for Pressure ( T 3-67).
3 Get access to the drain line filter. Refer to
2 Release tank pressure. K Releasing Tank Introduction Section, Component Location.
Pressure ( T 3-67).
4 Unscrew and remove filter A from head B.
3 Get access to the breaker in-line filter. Refer to
Introduction Section, Component Location. 5 Fit the new filter. Coat the seal of the new filter with
4 Unscrew and remove filter A from head B. and tighten. Check and top up the hydraulic oil level.
5 Fit the new filter. Coat the seal of the new filter with
and tighten. Check and top up the hydraulic oil level.
Fig 52.
Fig 51.
3-74 9813/1000 3-74

Routine Maintenance
Hydraulic System
Draining Water and Sediment from the Air Bleeding Procedures

Hydraulic Tank
After replacing the hydraulic oil or repairing or replacing
1 Prepare the machine. K Prepare the Machine for hydraulic components or removing hydraulic pipes, bleed
Maintenance ( T 3-25). air from the hydraulic circuit
2 Release tank pressure. K Releasing Tank Bleeding Air from the Hydraulic Pump
Pressure ( T 3-67).
3 Draining the water and sediment. Carefully loosen the Maintenance ( T 3-25).
drain plug C on the bottom of the tank and drain the
sediment and water accumulated at the bottom of the 2 Get access to the hydraulic pump. Refer to
tank. Introduction Section, Component Location.
Note: Have a drain pan ready. The task is complete when 3 Temporarily loosen the hose connection at A to check
clean hydraulic oil flows out. that oil does not come out of the pump.
4 Seal the system. Tighten the drain plug C. 4 If oil comes out re-tighten the connection, if it does not
come out remove the hose and pour hydraulic oil into
the pump case through the port. When oil comes out
of the port refit the hose connection.
5 Run the machine at idle for five minutes.
Fig 53.
3-75 9813/1000 3-75

Routine Maintenance
Hydraulic System
Air Bleeding from Rams Air Bleeding from the Slew Motor
If air is not bled from the rams when replaced or repaired, If air is not completely bled from the slew motor the motor
the piston and/or seals may be damaged. bearing or other parts may be damaged.
1 Prepare the machine. Idle the engine at low speed 1 Prepare the machine. K Prepare the Machine for
and extend and retract each ram 5 times, stopping the Maintenance ( T 3-25).
ram 100 mm before the end of each stroke.
2 Get access to the slew motor. Refer to Introduction
2 Bleeding. Operate each ram 4 times for the full stroke Section, Component Location.
to completely bleed the air.
3 Checking oil procedure.
a Loosen the air bleeding plug B and check that oil

seeps out from the air bleeding port.
b If no oil comes out, remove the air bleeding plug

B, and fill the motor case with Hydraulic Oil.
c Tighten the air bleeding plug B.
Fig 54.
4 Sealing the system. Idle the engine at low speed and

slowly slew the machine left to right evenly, two times.
3-76 9813/1000 3-76

Routine Maintenance
Slew Gearbox
Slew Gearbox
Checking the Slew Gearbox Oil Level Changing the Slew Gearbox Oil
1 Prepare the machine. K Prepare the Machine for 1 Prepare the machine. K Prepare the Machine for
Maintenance ( T 3-25). Maintenance ( T 3-25).
2 Get access to the slew gearbox. Refer to 2 Drain the oil.

a Remove the drain plug, located under the valve
3 Check the level. block. Allow the oil to drain out.
a Remove the dipstick A, wipe it clean and re-fit. b Wipe the drain plug clean. Remove any metallic
particles.
b Remove the dipstick again and check that the oil
level is within the min -max range. c Refit the drain plug. Make sure it is tight.
c If necessary, top up through filler port B. 3 Fill with recommended oil through filler port B.
K Fluids, Lubricants and Capacities ( T 3-16) K Fluids, Lubricants and Capacities ( T 3-16).
If there is no separate filler port fitted, top up 4 Check the level.

through the dipstick port.
a Remove the dipstick A, wipe it clean and re-fit.
4 Refit the dipstick.
b Remove the dipstick again and check that the oil
level is within the min-max range.
A
B c If necessary, top up through filler port B.
K Fluids, Lubricants and Capacities ( T 3-16).
5 Refit the dipstick.
6 Check for leaks. Run the machine, operate the slew

controls and make sure there are no leaks.
Fig 55.
3-77 9813/1000 3-77

Routine Maintenance
Tracks and Running Gear
Tracks !MWARNING
Checking/Adjusting the Track Tension When opening the check valve always stand to one
side and loosen a little at a time until grease starts to
1 Prepare the Machine. K Prepare the Machine for come out. If you over-loosen too much grease could
Maintenance ( T 3-25). spurt out or the valve cover fly out and cause serious
injury.
Position the machine on level ground. Run it 8-3-4-5
backwards and forwards several times. Stop after
running it forwards. !MWARNING
Carry out steps 1 to 3 of Cleaning the Tracks. Block Under no circumstances must the check valve be
up the undercarriage frame. Finish track rotation by dismantled or any attempt made to remove the grease
running the track forwards. Stop the engine and nipple from the check valve.
remove the starter key 8-3-4-9
If a gap C exists between the idler wheel shaft and

!MWARNING the track frame, you may use pressure to apply the
Raised Machine grease. If there is no gap C after the application of
NEVER position yourself or any part of your body grease, then the necessary repairs must be carried
under a raised machine which is not properly out by your JCB distributor.
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be
killed.
INT-3-3-7_1
2 Check the Tension.
Measure gap A in line with the third roller from the

front and between the lower surface of the track frame
and the upper surface of the shoe.
Table 23.
Machine Dimension A (Hard Ground
Conditions)
JS115/JS130/ 235-255mm
JS145/JS160
JS180/JS200/ 275-295mm
JS210/JS220
3 Adjust the Track Tension.

Fig 56.
Adjustment is made by either injecting or releasing
Note: Excessive tension can cause the track rail to wear
grease from the check valve B. Inject grease to
the drive rollers and sprocket, insufficient tension can
reduce the gap (increase the tension) or open to
cause wear to the drive sprocket and track rail.
release grease and increase the gap.
3-78 9813/1000 3-78

Routine Maintenance
4 Lower the Track. Track Plate Inspection
Remove the blocks from beneath the undercarriage 1 Prepare the machine. K Prepare the Machine for
and lower the track to the ground using the boom and Maintenance ( T 3-25).
dipper controls.
Note: If a shoe bolt is used when it is loose, it may be
5 Repeat for the Opposite Track. broken. Immediately tighten the shoe bolts whenever they
are found to be loose.
Slew the boom round to the other side and repeat
steps 1 to 4 above. 2 Check and Tighten.
Checking Rollers and Idler Wheels for Oil Leaks
1 Prepare the Machine. K Prepare the Machine for

Carry out steps 1 to 3 of Cleaning the Tracks. Block

up the undercarriage frame.
!MWARNING
Raised Machine
NEVER position yourself or any part of your body
under a raised machine which is not properly
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be
killed.
INT-3-3-7_1
2 Look for Oil Leaks. Fig 57.
Check the top and bottom rollers and the idler wheels Torque tighten the bolts in the sequence shown and
for oil leaks. If leaks are found contact your JCB check that the nuts and shoe are closely fitted to the
distributor for service. link joining surface. K Bolt and Nut Torque
Specifications ( T 3-43).
!MCAUTION 3 Repeat the Procedure.

Do not run the machine if you discover oil leaks in the
top or bottom rollers or idler wheels. Failure to rectify a Start the engine and move the machine forwards
such leaks could cause damage to the machine. or backward. Stop the engine.
8-3-4-6
b Repeat the above procedure until the whole track
3 Lower the Track. is tightened.
Remove the blocks from beneath the undercarriage

and lower the track to the ground using the boom and
dipper controls.
4 Repeat for the Opposite Track.
Slew the boom to the other side and repeat steps 1 to

3 above.
3-79 9813/1000 3-79

Routine Maintenance
Running Gear !MCAUTION

Checking the Track Gearbox Oil Level Oil will gush from the hole when the drain plug is
removed. Keep to one side when you remove the plug.
1 Prepare the machine. K Prepare the Machine for 2-3-4-2
b Remove filler/level plug A and drain plug B. Allow
Position the machine on level ground with the level the oil to drain out.
and drain plugs as illustrated. K Fig 58. ( T 3-80).
c Wipe the plugs clean. Make sure you remove all
metal particles.
d Wrap seal tape on the drain plug B and refit.

Torque tighten to 37Nm.
3 Fill with new oil for oil type and volume. K Fluids,
Lubricants and Capacities ( T 3-16) .
a Pour new oil through filler/level plug A until oil

runs out of plug A.
b Check the condition of the o-ring, renew if it is

damaged. Refit filler/level plug. Torque tighten to
37Nm.
4 Change the oil on the other side.

Fig 58.
Repeat steps 1 to 3.
2 Check the level on one side.
5 Check for Leaks.
Clean the area around filler/level plug A and remove
Run the machine, operate the tracking controls and
it. Oil should be level with plug A. Top up through plug
then make sure there are no leaks.
A if necessary for oil types. K Fluids, Lubricants
and Capacities ( T 3-16)
3 Clean and refit the plug. Torque tighten to 37Nm.
4 Check the level on the other side.
Repeat steps 1 to 3.
Changing the Track Gearbox Oil
1 Prepare the machine. K Checking the Track

Gearbox Oil Level ( T 3-80)
2 Drain the oil on one side.
a Place a container below the drain plug to catch the

oil. The container must be large enough to hold
the maximum gearbox capacity. K Fluids,
Lubricants and Capacities ( T 3-16)
3-80 9813/1000 3-80

Routine Maintenance
Bucket
Bucket
Checking/Adjusting For Side Play 2 Measure the Clearance at C.
It is possible to compensate for lateral wear which leads to The clearance should be approximately 0.8 mm
sideways play of the bucket. Regular use of this K Fig 59. ( T 3-81).
compensating facility leads to less wear on the bucket
swivel pin A and the dipper bushes B. 3 Check the clearance.
Fig 59.

JS03353
Fig 60.
Position the machine on level ground. Set the bucket

as shown K Fig 60. ( T 3-81). Turn it slightly to the
left and position it so that the arm end is pressed to
the side which is not to be adjusted. Stop the engine,
remove the starter key.
3-81 9813/1000 3-81

Routine Maintenance
Windscreen Washer
Windscreen Washer
Checking the Level

Locate the front window washer bottle A and fill with clean
water. The liquid should contain a de-icing fluid to prevent
it freezing. Do not use engine coolant antifreeze.
Note: Do not use the washer when there is no liquid in the

bottle as it will damage the motor.
Fig 62. JS200/JS210/JS220
Fig 61. JS115-JS180
3-82 9813/1000 3-82

Routine Maintenance
Fire Extinguisher (If fitted)
Fire Extinguisher (If fitted)
The fire extinguisher should be inspected daily.
!MWARNING
Do not use the fire extinguisher in a confined space.
Make sure that the area is well ventilated during and
after using the fire extinguisher.
4-2-3-1
The fire extinguisher is located in the cab behind the

drivers seat at A. Ensure the extinguisher is only used as
directed on the canister.
Fig 64. Machines Built After December 2011
!MWARNING
After any use, the extinguisher should be replaced or
serviced.
4-2-3-2
Fig 63. Machines Built Up To December 2011
3-83 9813/1000 3-83

Routine Maintenance
Troubleshooting
Troubleshooting
To extend the service life and improve the operation of the If trouble occurs, search for the cause in the items below
machine, daily inspection and lubrication are necessary as and make adjustments, repairs, etc. as necessary. If the
well as immediately isolating any problem found and cause cannot be isolated, contact your JCB distributor.
dealing with it. If the machine is operated with the problem
uncorrected, it may lead to larger trouble and possibly to a
big accident.
Engine and Related Area

Table 24. Engine does not start
Cause Remedy
Defective starter switch Connect, repair connection
Defective rotation of starter (Starter rotates slowly) Discharged battery, starter problems, contaminated or loose
wiring connection
Improper viscosity of engine oil Inspect and replace as necessary
Excessive cooling of engine (Cold weather) Preheat with air heater. Warm up the coolant (add hot water)
Possible seizure in engine Repair(1)
Incomplete air bleeding of fuel system Completely bleed air
No fuel in fuel tank Refill
Fuel quality unsuitable Inspect and replace as necessary
Fuel filter clogged Clean or replace
Low compression Repair(1)
Defective fuel injection system Repair(1)
Table 25. Engine stops during operation

Cause Remedy
No fuel in fuel tank Refill
Fuel filter clogged Clean and replace
Air is mixed in the fuel system Retighten fuel pipe connections and bleed system
Table 26. Low oil pressure

Cause Remedy
Low oil Refill
Defective oil pressure switch Replace(1)
Oil filter clogged Replace element
Low oil viscosity Replace with oil of viscosity matching temperature
Improper operation of oil pump Replace parts(1)
Oil leakage at connections Tighten connections
3-84 9813/1000 3-84

Routine Maintenance
Troubleshooting
Table 27. Exhaust gas from engine is white or blue
Cause Remedy
Excessive oil consumption Disassemble and repair, replace parts(1)
Excessively low oil viscosity Replace with correct oil
Excessive cooling by radiator Adjust
Improper fuel injection timing Adjust or replace if necessary(1)
Low compression Disassemble and repair, replace parts(1)
Table 28. Exhaust gas from engine is black or dark grey

Cause Remedy
Improper fuel Replace with correct fuel
Improper valve clearance Adjust
Defective fuel injection pump Adjust or replace if necessary(1)
Insufficient air intake (air cleaner clogged) Clean or replace the element
Table 29. Excessive fuel consumption

Cause Remedy
Defective fuel injection pump Replace(1)
Improper spray from fuel injection nozzle Replace(1)
Improper fuel injection timing Adjust or replace if necessary(1)
Improper fuel Replace with correct fuel
Insufficient air intake Clean or replace element
Table 30. Excessive engine oil consumption

Cause Remedy
Excessive oil Drain oil to proper level
Low oil viscosity Replace with oil of viscosity matching temperature
Oil leakage Retighten and replace parts if necessary
Worn cylinder piston rings Disassemble and repair, replace parts(1)
Table 31. Abnormal noise (fuel or mechanical)

Cause Remedy
Bad fuel Replace
Damage inside muffler Replace
3-85 9813/1000 3-85

Routine Maintenance
Troubleshooting
Table 32. Engine overheating (water temperature reads too high)
Cause Remedy
Low coolant Refill
Water leakage Repair
Elongated or oil dirtied belt Clean or replace
Defective radiator Repair or replace(1)
Broken fan Replace(1)
Incorrect mixture of anti-freeze solution Replace
Defective thermostat Replace(1)
Defective water pump Replace(1)
Defective water sensor Replace(1)
Table 33. Defective battery charge

Cause Remedy
Improper belt tension Adjust
Wiring trouble Repair
Defective battery Replace
Defective regulator Replace(1)
Defective alternator Replace(1)
(1) Indicates jobs which should be done by specialist.
3-86 9813/1000 3-86

Routine Maintenance
Troubleshooting
Monitor Display - Fault Messages

Note: For further information refer to Operation Section,
Instruments.
Table 34. Water and Hydraulic oil temperature

Message Cause Remedy
WATER TEMP Water leakage Repair
Belt elongation, soiled with oil Clean or replace
Defective radiator Repair or replace(1)
Broken fan Replace(1)
Improper anti-freeze mixture Replace
Defective thermostat Replace(1)
Defective water pump Replace(1)
Dirty oil cooler (clogged) Clean
Dirty radiator (clogged) Clean
Defective dust protection net (clogged) Clean
HYD TEMP Defective monitor Replace(1)
Table 35. Low oil pressure

OIL PRESS Low Engine oil Refill
Oil leakage at connections Repair
Defective engine oil pressure sensor Replace(1)
Engine oil viscosity low Replace with oil of viscosity matching the
temperature
Defective engine oil pump Adjust, clean, replace(1)
Defective monitor Replace(1)
Table 36. Air filter

AIR FILTER Air filter element clogged Clean, replace
Intake system clogged, foreign matter Clean
inside.
Table 37. Low fuel

LOW FUEL Fuel low Refill
Defective sensor Replace(1)
3-87 9813/1000 3-87

Routine Maintenance
Troubleshooting
Table 38. Alternator
ALTERNATOR Belt tension Adjust
Wiring fault Repair
Defective battery Replace
Defective regulator Replace (1)
Defective alternator Repair or replace(1)
Table 39. Low coolant

COOLANT LOW Coolant low Refill
Table 40. Engine oil filter

OIL FILTER Engine oil dirty Replace engine oil, oil filter
Table 41. Electrical fault

ELECT FAULT Short circuit, etc abnormalities Inspect, repair (1)
(1) Indicates jobs which should be done by a specialist.
Operations
Table 42. Operating controls hard to operate
Cause Remedy
Foreign matter caught on control valve spool Wash the control valve (1)
Valve sticking Repair or replace valve assembly(1)

Improper lubrication of lever link Grease
Lever link seizure Grease
3-88 9813/1000 3-88

Routine Maintenance
Troubleshooting
Hydraulic pump
Table 43. Oil not delivered by oil pump
Cause Remedy
Low hydraulic oil Refill
Clogged suction filter Repair
Table 44. Hydraulic pump does not build pressure

Cause Remedy
Oil leakage inside hydraulic pump Replace hydraulic pump(1)
Air inside the hydraulic pump Refill oil or check hose on suction side
Main relief valve pressure set too low Adjust pressure(1)
Table 45. Abnormal noise from hydraulic pump

Cause Remedy
Cavitation resulting from deformed hose on the suction side Replace filter, replace hydraulic oil if dirty
or suction filter clogged
Joint of the suction side is loose or hydraulic oil is low and Retighten or grease the joints. Check that oil is filled to
air is being sucked in proper level inside casing
Cavitation resulting from excessively high viscosity of Replace with hydraulic oil of suitable viscosity
hydraulic oil
Table 46. Oil leakage from hydraulic pump

Cause Remedy
Defective seal in hydraulic pump Replace seal or hydraulic pump(1)
3-89 9813/1000 3-89

Routine Maintenance
Troubleshooting
Working Attachments
Table 47. Overall low power
Cause Remedy
Insufficient engine output Refer to Engine Service Manual
Function drops due to wear of hydraulic pump Replace hydraulic pump(1)
Defective main relief valve Adjust the pressure or replace(1)
Low hydraulic oil Refill
Viscosity of hydraulic oil incorrect Replace with hydraulic oil of proper viscosity
Suction filter clogged Replace suction filter
Table 48. Defective operations

Cause Remedy
Hydraulic pump broken Replace hydraulic pump(1)
Hydraulic oil low Replace suction filter
Table 49. Insufficient work power

Cause Remedy
Set pressure for main or port relief valve is low or incorrect Adjust pressure or replace relief valve(1)
Damaged hydraulic ram seals Replace hydraulic ram seals(1)
Damaged hydraulic ram, cylinder Replace hydraulic ram/cylinder or the assembly(1)
Table 50. Attachment sinks down

Cause Remedy
Damaged hydraulic ram seals Replace hydraulic ram seals(1)
Damaged hydraulic ram, cylinder Replace hydraulic ram/cylinder or the assembly(1)
Oil leakage inside control valve Repair valve assembly, replace(1)
Oil leakage inside holding valve Repair valve assembly, replace(1)
Table 51. Abnormal noise from joints of the attachment

Cause Remedy
Insufficient grease Grease
Connecting pin seizure Replace the bushing and/or pin
3-90 9813/1000 3-90

Routine Maintenance
Troubleshooting
Travel
Table 52. Insufficient travel force
Cause Remedy
Pressure setting for main relief valve is too low Adjust the pressure(1)
Defective counterbalance valve Replace the counterbalance valve(1)
Performance reduction of travel motor Replace travel motor(1)
Swivel joint packing damage Replace swivel joint packing(1)
Performance reduction of hydraulic pump Replace hydraulic pump(1)
Table 53. Rough travel

Cause Remedy
Excessively tightened track Adjust to proper tension
Stone or foreign matter caught in track Remove stone or foreign matter
Defective valve Repair valve or replace(1)
Air in travel motor Refill with oil
Table 54. Crooked travel

Cause Remedy
Left and right tracks are not equally tightened Bleed air from left and right, adjust tracks to equal tension
Performance reduction of hydraulic pump Replace hydraulic pump(1)
Oil leakage inside control valve Replace valve housing assembly(1)
Swivel joint packing damage Replace swivel joint packing(1)
Loose lever link Adjust
3-91 9813/1000 3-91

Routine Maintenance
Troubleshooting
Slew
Table 55. Insufficient slew force
Cause Remedy
Performance reduction of slew motor Replace slew motor(1)
Thermal seizure of slew shaft Supply grease or replace the slew shaft(1)
Table 56. Idle slew during slew braking

Cause Remedy
Low setting of brake valve Adjust the pressure(1)
Clogged valve Wash the valve(1)
Internal oil leakage of control valve Repair or replace valve assembly(1)
Table 57. Idle slew during slew stopping

Cause Remedy
Low setting of brake valve or port relief Adjust the pressure (1)
Clogged valve Wash the valve(1)

Internal oil leakage of control valve Repair or replace valve assembly(1)
Table 58. Abnormal noise during slew

Cause Remedy
Air in slew motor Refill with oil
Insufficient greasing of slew bearing Add grease
Hydraulic ram
Table 59. Insufficient force of hydraulic ram
Cause Remedy
Low pressure setting for the relief valve Adjust the pressure(1)
Oil leakage inside the hydraulic ram Replace the ram seals(1)
Damage of the hydraulic ram or rod Replace the hydraulic ram or rod(1)
Oil leakage inside the control valve Repair or replace the valve assembly(1)
Table 60. Oil leakage outside the hydraulic ram

Cause Remedy
Defective hydraulic ram seals Replace hydraulic ram seals(1)
Hydraulic cylinder rod damage* Replace hydraulic ram rod(1)
3-92 9813/1000 3-92

4.section 3 - Routine Maintenance

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Section 3

3-0 9813/1000-3 3-0

Contents Page No.

Contents Page No.

Introduction Owner/Operator Support

Remember, if your machine has been correctly

3-1 9813/1000 3-1

Fit for Purpose Tests for Lifting

All lifting equipment (for example forks, lifting hooks and

This may be needed every six months or at least annually

Check with your local JCB distributor for further advice.

Obtaining Replacement Parts

If you use non-genuine JCB parts or consumables, then

A Parts Book for your machine is available from your JCB

The data plate also shows the serial numbers of the

3-2 9813/1000 3-2

Health and Safety

Lubricants The collection and disposal of used oil should be in

It is most important that you read and understand this Handling

3-3 9813/1000 3-3

4 Don't keep oily rags in pockets.

5 Wash dirty clothing before re-use.

6 Throw away oil-soaked shoes.

First Aid - Oil

In the case of eye contact, flush with water for 15 minutes.

If oil is swallowed do not induce vomiting. Get medical

In the case of excessive skin contact, wash with soap and

Absorb on sand or a locally approved brand of absorbent

Extinguish oil and lubricant fires with carbon dioxide,

3-4 9813/1000 3-4

Battery electrolyte contains sulphuric acid. It can burn

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

3-5 9813/1000 3-5

A289260-1 Gets onto your skin

Note operating instructions.

3-6 9813/1000 3-6

3-74 9813/1000 3-74

Pre Start Cold Checks, Service Points and Fluid Levels

Operation 10 50 250 500 1000 2000 3000 4000 5000 8000

3-8 9813/1000 3-8

Operation 10 50 250 500 1000 2000 3000 4000 5000 8000

3-9 9813/1000 3-9

Operation 10 50 250 500 1000 2000 3000 4000 5000 8000

3-10 9813/1000 3-10

Operation 10 50 250 500 1000 2000 3000 4000 5000 8000

3-11 9813/1000 3-11

Functional Test and Final Inspection

Operation 10 50 250 500 1000 2000 4000

3-12 9813/1000 3-12

Operation 10 50 250 500 1000 2000 4000

(1) These jobs must be done by a qualified engineer.

3-13 9813/1000 3-13

{ Check oil level and top up as required

3-14 9813/1000 3-14

Table 2. Fuel System

Table 3. Hydraulic System

3-15 9813/1000 3-15

Fluids, Lubricants and Capacities

JS115/JS130/JS145 and Variants

3-16 9813/1000 3-16

JS160/JS180 and Variants

3-17 9813/1000 3-17

JS200/JS210/JS220 and Variants