JCB JS130W JS145W JS160W JS175W WHEELED EXCAVATOR Service Repair Manual Instant Download

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R Se
rvice Manual JS130W JS145W JS160W
JS175W PUBLISHED BY THE TECHNICAL PUBLICATIONS
DEPARTMENT OF JCB SERVICE UTTOXETER,
STAFFORDSHIRE, ST14 7BS, ENGLAND Tel. ROCESTER
[phone] PRINTED IN ENGLAND Publication
No. 9803/6310 Issue 5
General Information
2
Care Safety
3
Routine Maintenance
A
Attachments
B
Body Framework
C
Electrics
D
Controls
E
Hydraulics
F
Transmission
G
Brakes
K
Engine
2
Section 1 General Information Section 1
i i
Contents Page No.
Machine and Axle Identification 1 - 1
Torque Settings 2 - 1
Service Tools Body and Framework (Section B) 4 - 1
Electrics (Section C) 5 - 1
Hydraulics (Section E) 6 - 1
Transmission (Section F) 7 - 1
Axles (Section F) 8 - 1
Sealing and Retaining Compounds 9 - 1
Issue 1
3
Section 1
General Information
Section 1
1 - 1
1 - 1
Machine and Axle Identification
Machine Serial Plates Each machine has a Data
Plate, located to the rear left, inside the cab
as shown at A. The machine serial number is
inscribed at B and the engine number at C.
A
If the engine is replaced by a new one, the data
plate serial number will be wrong. Either stamp
the new number on the plate or stamp out the old
one. This will prevent the wrong number being
quoted when ordering replacement parts.
B
JS06050
??
JS06060

• Axle Serial Plate
• The axle serial number is stamped on a plate
  mounted to the rear face of the axle, as shown.
• When replacement parts are required, always
  ensure that the correct parts are obtained, e.g.
  in the case of gear replacements, always check
  the part number stamped on the gear, and the
  number of teeth.
• When ordering replacement parts, quote the
  details on the serial plate as shown.

S156570
Issue 1
4
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Section 1
General Information
Section 1
2 - 1
2 - 1
Torque Settings
Torque Settings Note 1 The figures quoted are
for non-plated fasteners and are to be used only
when there is no torque setting specified in the
relevant procedure in this service manual. Note
2 The 4T grade settings DO NOT APPLY to
fasteners used on the engine. If any 4T
specification fasteners are found on the engine,
these must be tightened to the figure quoted in
the relevant engine manual.

Bolt Size Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud
Nm 4T kgf m lbf ft Nm 8.8 kgf m lbf ft Nm 10.9 kgf m lbf ft Nm 12.9 kgf m lbf ft
M3 0.39 0.04 0.28 - - - - - - - - -
M4 0.78 0.08 0.57 - - - - - - - - -
M5 1.67 0.17 1.2 - - - - - - - - -
M6 2.84 0.29 2.1 8.04 0.82 5.9 11.3 1.15 8.3 - - -
M8 7.06 0.72 5.2 19.6 2.00 14.5 27.7 2.82 20.4 48.0 4.9 35
M10 14.0 1.43 10.3 39.1 3.99 28.8 55.0 5.61 40.6 94.0 9.6 69
M12 24.6 2.51 18.1 68.5 6.98 50.5 96.2 9.81 71 166 16.9 122
M16 61.9 6.31 45.7 173 17.6 127.6 242 24.7 178.5 400 40.8 295
M20 122 12.4 90 337 34.4 249 475 48.4 350 - - -
M22 167 17.0 123 464 47.3 342 652 66.5 481 - - -
M24 210 21.4 155 584 59.5 431 821 83.7 606 - - -
M27 311 31.7 229 864 88.1 637 1220 124 900 - - -
M30 420 42.8 310 1170 119 863 1650 168 1217 - - -
M33 576 58.7 425 1600 163 1180 2260 230 1667 - - -
M36 736 75.1 543 2050 209 1512 2880 294 2124 - - -
M39 961 98.0 709 2680 273 1977 3760 383 2773 - - -
M42 1190 121 878 3300 336 2434 4640 473 3422 - - -
M45 1490 152 1099 4140 422 3054 5820 593 4293 - - -
M48 1780 182 1312 4960 506 3659 6970 711 5141 - - -
Note All bolts are high tensile and must not
be replaced by bolts of a lesser tensile
specification.
9803/6310
Issue 2
6
Section 1
General Information
Section 1
4 - 1
4 - 1
Service Tools Body and Framework (Section B)
S186270 Cartridge Gun - hand
operated - essential for the application of
sealants, polyurethane materials etc. 892/00845
S186240 Hand Cleaner -
special blend for the removal of polyurethane
adhesives. 4104/1310 (454g 1lb tub)
S186250 12V Mobile Oven - 1
cartridge capacity - required to pre-heat
adhesive prior to use. It is fitted with a male
plug (703/23201) which fits into a female socket
(715/04300). 992/12300
' S186280 Folding Stand for Holding
Glass - essential for preparing new glass prior
to installation. 892/00843
S186300 Glass Lifter - minimum 2
off - essential for glass installation, 2
required to handle large panes of glass. Ensure
suction cups are protected from damage during
storage. 892/00842
S186260 240V Static Oven -
available with 2 or 6 cartridge capacity -
required to pre-heat adhesive prior to use. No
plug supplied. Note 110V models available upon
request - contact JCB Technical
Service 992/12400 - 2 cartridge x 240V 992/12600
- 6 cartridge x 240V
Issue 1
7
Section 1
General Information
Section 1
4 - 2
4 - 2
Service Tools (contd) Body and Framework
(Section B) (contd)
S186340 Cut-out Knife - used
to remove broken glass. 992/12800
S186310 Wire Starter - used
to access braided cutting wire (below) through
original polyurethane seal. 892/00848
'
S186320 Glass Extractor
(Handles) - used with braided cutting wire
(below) to cut out broken glass. 892/00846
S186350 'L' Blades - 25mm
(1in.) cut - replacement blades for cut-out knife
(above). 992/12801 (unit quantity 5 off)
S186330 Braided Cutting Wire -
consumable heavy duty cut-out wire used with the
glass extraction tool (above). 892/00849 (approx
25m length)
S186360 Long Knife - used to
give extended reach for normally inaccessible
areas. 892/00844
Issue 1
8
Section 1
General Information
Section 1
4 - 3
4 - 3
Service Tools (contd) Body and Framework
(Section B) (contd)
S186550 Rubber Spacer Blocks -
used to provide the correct set clearance between
glass edge and cab frame. 926/15500 (unit
quantity 500 off)
S186470 Nylon Spatula -
general tool used for smoothing sealants - also
used to re-install glass in rubber glazing
because metal tools will chip the glass
edge. 892/00847
Issue 1
9
Section 1
General Information
Section 1
5 - 1
5 - 1
Service Tools SECTION C - ELECTRICS

• Electrical Test Equipment
• 892/00283 Tool Kit Case
• 892/00281 AVO Meter
• 892/00286 Surface Temperature Probe
• 892/00284 Microtach Digital Tachometer
• 892/00282 Shunt - open type
• 892/00285 Hydraulic Oil Temperature Probe
• 892/00298 Fluke 85 Multimeter

A360250
892/01033
Data Link Adaptor Used with AMS Machines Only
Issue 2
10
Section 1
General Information
Section 1
6 - 1
6 - 1
Service Tools (continued) SECTION E -
HYDRAULICS Hydraulic Pressure Test Gauges and
Connections
1 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2)
2 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2)
3 892/00347 Connector
4 892/00254 Hose
5 892/00280 Pressure Gauge 0-600 bar (0-9000 lbf/in2)
1/2/5
Pressure Test T Adapters Pressure Test T Adapters Pressure Test Adapters Pressure Test Adapters
892/00262 1/4 in BSP x 1/4 in F BSP x Test Point 892/00255 1/4 in BSP x Test Point
816/55038 3/8 in BSP x 3/8 in F BSP x Test Point 892/00256 3/8 in BSP x Test Point
816/55040 1/2 in BSP x 1/2 in F BSP x Test Point 892/00257 1/2 in BSP x Test Point
892/00263 5/8 in BSP x 5/8 in F BSP x Test Point 892/00258 5/8 in BSP x Test Point
892/00264 3/4 in BSP x 3/4 in F BSP x Test Point 816/15118 3/4 in BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point 892/00259 1 in BSP x Test Point
892/00266 1,1/4 in M BSP x 1,1/4 in F BSP x Test Point 892/00260 1,1/4 in BSP x Test Point
892/00267 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point 892/00261 5/8 in UNF x Test Point
Issue 2
11
Section 1
General Information
Section 1
6 - 2
6 - 2
Service Tools (continued) SECTION E - HYDRAULICS
Hand Pump Equipment Hand Pump Equipment
892/00223 Hand Pump
892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
892/00706 Test Probe
892/00278 Gauge 0 - 40 bar (0 - 600 lb/in2) 816/50005 1/2 in BSP (A) x 1/2 in BSP (B)
892/00279 Gauge 0 - 400 bar (0 - 6000 lb/in2) 816/60096 3/4 in BSP (A) x 3/4 in BSP (B)
892/00280 Gauge 0 - 600 bar (0 - 8500 lb/in2) 816/00018 1 in BSP (A) x 1 in BSP (B)
Female Cone Blanking Plug
Male Cone Blanking Plug
892/00055 1/4 in BSP 816/00294 1/4 in BSP
892/00056 3/8 in BSP 816/00189 3/8 in BSP
892/00057 1/2 in BSP 816/00190 1/2 in BSP
892/00058 5/8 in BSP 816/00197 5/8 in BSP
892/00059 3/4 in BSP 816/00196 3/4 in BSP
892/00060 1 in BSP 816/00193 1 in BSP
Issue 1
12
Section 1
General Information
Section 1
6 - 3
6 - 3
Service Tools (continued) SECTION E - HYDRAULICS
JS07050
Ram Piston Nut Removal/Fitting Spanner
993/99512 993/99513 993/99514 993/99515 993/99516
993/99517 993/99518 993/99519
Spanner 55 mm A/F Spanner 60 mm A/F Spanner 65 mm
A/F Spanner 70 mm A/F Spanner 75 mm A/F Spanner
85 mm A/F Spanner 90 mm A/F Spanner 100 mm A/F
Ram Piston Nut Removal/Fitting Rig
993/99525 Rig Assembly (not including spanners and 993/99520 Spanner 110 mm A/F
993/99522 ram) Anchor Side Plate (supplied loose unwelded) 993/99521 SSP0046 Spanner 115 mm A/F Spanner 80 mm A/F
993/99523 Anchor Cross Member (supplied loose SSP0047 Spanner 95 mm A/F
unwelded)
993/99524 Ram Eye End Modification Plate Assembly
556/43400 Lift Ram
545/18000 Lynch Pin
811/50232 1,1/4 Pivot Pin
Issue 2
13
Section 1
General Information
Section 1
6 - 4
6 - 4
Service Tools (contd) Hydraulics (Section E)
(contd) Slew Motor Unit - JS130W/145W
ø61.- 0.2 (2.40"- 0.008)
ø38.- 0.2 (1.50"- 0.008)
ø70 (2.76")
30o
2 (0.079") 14 (0.55")
155 (6.10")
4 (0.16")
Seal Fitting Tool (Oil Seal 2)
JS07110
15 o 100 (3.94") 110 (4.33") Fitting Tool
for Inner Ring of Taper Roller Bearing 3 JS07120
(ø1.27- 0.004)
(ø1.40- 0.004)
ø42 (1.65")
ø32.2.- 0.1
ø35.5.- 0.1
5 o 50 (1.97") 80 (3.15") JS07130 Sea
l Protector Heat polyvinyl tube in hot water and
form to required shape.
50 (1.97") 60 (2.36") JS07140 Fitting
Tool for Inner Ring 1
ø38 (1.50")
ø40 (1.57") ø31.4- 0.1 (1.24"- 0.004)
Issue 2
14
Section 1
General Information
Section 1
6 - 5
6 - 5
Service Tools (contd) Hydraulics (Section E)
(contd)

Slew Motor Unit - JS160W/JS175W
2 x ø9 (0.35")
40 (1.57")
40 (1.57")
100 (3.94")
200 (9.84")
Inner diameter ø11 (0.43")
10 (0.39")
M10 180 (7.09") 240 (9.45")
JS07100
Puller for Brake Piston Stud is threaded M10 on
both ends for 20 mm (0.8 in) and fitted with two
M10 nuts.
Issue 2
15
Section 1
General Information
Section 1
6 - 6
6 - 6
Service Tools (contd) Hydraulics (Section E)
(contd)

Hydraulic Tank - JS130W/JS145W/JS160W/JS175W
A Dia. 40 mm (1.57 in)
B Dia. 26 mm (1.02 in)
C 40 mm (1.47 in)
D 50 mm (1.97 in)
E Dia. 10 mm (0.39 in)
F 550 mm (21.7 in)
G 9 mm (0.35 in)
H 24 mm (0.94 in)
I Dia. 81 mm 0 (3.91 in 0 ) -0.1 -0.004
J Dia. 76 mm 0 (2.99 in 0 ) -0.1 -0.004
K 24 mm (0.94 in)
L 95 mm (3.74 in)
M Radius 0.7 mm (0.028 in)
N 120 mm (16.5 in)
O 4.0 mm (0.157 in)
P 3.0 mm (0.118 in)
Q 15
O-ring G75
A B
C
D
E
F
N
G
Q
O
H
P
J I K
JS07150
Blank for Suction Strainer
Issue 2
16
Section 1
General Information
Section 1
6 - 7
6 - 7
Service Tools (contd) Hydraulics (Section E)
(contd)

Remote Control Valve - JS130W/JS145W/JS160W/JS175W
ø26.5 23.5
13
1
50
ø19 ø28
65
2
42
25 17
19
ø21 ø25 ø30
JS07160
Joint Removal Tool
15
Items 1 and 2 are assembled with an interference
fit.
Issue 2
17
Section 1
General Information
Section 1
6 - 8
6 - 8
Service Tools (contd) Hydraulics (Section E)
(contd) Hydraulic Pump
140 20
ø12
M12 x 1.75 Guide Rods
220
15
10
7
ø11.5
ø18.5
20
ø30
ø5
M8 M8
10
7 8
M8
Rear Shaft Protection Tool
Swash Plate Levelling Tool
ø75 -.005 ø75 0.15 0.1
ø34.9 -0.1
15
10

90
7
ø56
ø90
R2
ø18.5
ø30
ø5
ø8

3 - 0.1 150
11
Oil Seal Insertion Tool
Front Shaft Protection Tool
ø37 ø44 ø50
6
100
JS07980
Bearing Insertion Tool
Issue 1
18
Section 1
General Information
Section 1
6 - 9
6 - 9
Service Tools (contd) Hydraulics (Section E)
(contd) Hydraulic Rams Reconditioning
Bush Removal/Assembly Jig
Seal Ring Insertion Jig (Inner)
Bush Removal/Assembly Jig
Seal Ring Bedding Jig
Cylinder Head Insertion Jig
Wiper Ring Installation Jig
Seal Ring Insertion Jig (Outer)
Issue 1
19
Section 1
General Information
Section 1
7 - 1
7 - 1
Service Tools (contd) Transmission (Section F)

Slew Gearbox - JS130W/145W
5 o 60 (2.36") 100
(3.94") JS07180 Seal Protector Heat
polyvinyl tube in hot water and form to the
required shape on the pinion shaft
ø50 (1.97")
(1.18")
30
ø65 (2.56")
15 (0.59")
(0.236")
6
14 (0.55")
3 (0.118")
15 o
ø94.5 0.2
-
- 0.008) ø120 (4.72") ø130 (5.43")
(3.72"
JS07170
Seal Fitting Jig

Slew Gearbox - JS160W/175W
ø100 (ø3.937") JS07190 Bearing and
Oil Seal assembly Jig
ø155 (ø6.094") ø149 (ø5.866") JS07200 S
eal Fitting Jig
(3.15"0.012" )
2.5 (0.098")
800.3
-0
-0

Issue 2
20
Section 1
General Information
Section 1
7 - 2
7 - 2
Service Tools (contd) Transmission (Section F)
(contd)

Slew Gearbox - JS160W/175W (contd)
ø50 3 ø99.8 ø124 ø158 JS07210 Seal Fitting
Jig
100 110 JS07230 Jig for Taper
Roller Bearing Inner Ring
30
(ø46.5 -0.1)
ø30.5.- 0.1
ø36 (ø50)
15
9
15
30o
ø49.5
ø75
80
2
16
155
4
JS07220
Seal Fitting Jig (SST0033)
Issue 2
21
Section 1
General Information
Section 1
7 - 3
7 - 3
Service Tools (contd) Transmission (Section F)
(contd) Drive Gearbox
892/00223 892/00346 SSP0027/SSP0028
SSP0029/SSP0030/SSP0031 SSP0035 SSP0050 SSP0051
SSP0052 SST0011 SST0013 SST0018 SST0019 SST0020
SST0032
Hand Pump Pressure Gauge (0 - 70 bar)
Striker/Internal Puller Puller Assembly
Installer Fitting Tool Handle Fitting
Tool Measuring Cover Installer Sleeve Hydraulic
Connector Pressure Sleeve Clutch Jig Driver
Issue 1
22
Section 1
General Information
Section 1
8 - 1
8 - 1
Service Tools (cont'd) Axles (Section F)
992/07606 Measuring Cup - Pinion
Bearing
992/07604
Replacer - Crownwheel Bearing and Differential
Bearing Cones
992/07609 Adapter - Steer/Drive Axle Pinion Bearing Cone Adapter - Steer/Drive Axle Pinion Bearing Cone Adapter - Steer/Drive Axle Pinion Bearing Cone
892/00817 17 mm A/F x 3/4 in square drive
892/00818 22 mm A/F x 3/4 in square drive
892/00819 15 mm A/F x 1/2 in square drive
992/07607 Spacer - Pinion Bearing Preload 892/00333 19 mm A/F x 3/4 in square drive
992/07614 Adapter Set - Bull Pinion
Bearing Remover/Replacer
892/00182 Bearing Pad Driver
992/07601 Spanner for Half Shaft Nuts
992/07603 Replacer - Pinion Head
Bearing Cup
Issue 1
23
Section 1
General Information
Section 1
8 - 2
8 - 2
Service Tools (cont'd) Axles (Section F) (contd)
992/04000 Torque Multiplier (use in
conjunction with a torque wrench to give a 51
multiplication when tightening pinion
nuts) S197030
892/00822 Splined Bolt Socket for
driveshafts S197060
892/00174 Measuring Cup - Pinion Head Bearing
S190770
S197070 892/00224 Impulse Extractor Set
for Hub Bearing Seals
892/00334 Gland Seal Fitting tool
892/00812 Drive Coupling Spanner for axle yoke
couplings S196720
992/00800 Extractor for removing axle
pivot pin
Issue 1
24
Section 1
General Information
Section 1
8 - 3
8 - 3
Service Tools (cont'd) Axles (Section F) (contd)
993/59500 Adapter - Impulse
Extractor
892/00833 Annulus Removal Tool

A272520
892/00891
Oil Seal Insertion Tool
Issue 2
25
Section 1
General Information
Section 1
9 - 1
9 - 1
Sealing and Retaining Compounds
JCB Multi-Gasket A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter. 4102/1212 50 ml
JCB Threadlocker For threads of 50 mm diameter upwards, 4101/0451 50 ml
e.g. suction strainer.
JCB Threadlocker (High Strength) A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where 4102/0551 50 ml
the strength of the joint is important.
JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/0651 50 ml
JCB Threadlocker and Sealer A medium strength locking fluid for sealing and retaining 4101/0250 10 ml
nuts, bolts, and screws up to 50 mm diameter, and 4101/0251 50 ml
for hydraulic fittings up to 25 mm diameter.
JCB Threadlocker and Sealer A high strength locking fluid for sealing and retaining 4101/0550 10 ml
(High Strength) nuts, bolts, and screws up to 50 mm diameter, and for 4101/0552 200 ml
hydraulic fittings up to 25 mm diameter.
JCB Threadseal A medium strength thread sealing compound. 4102/1951 50 ml
JCB Activator A cleaning primer which speeds the curing rate of 4104/0251 Aerosol (1 ltr)
anaerobic products. 4104/0253 Bottle (200 ml)
JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic 4104/1557 Aerosol (400 ml)
adhesives and sealants.
Anti-Seize Paste A compound used for assembly and prevention of 4003/0211
parts seizure.
Direct Glazing Kit For one pane of glass comprises items marked below
plus applicator nozzle etc.
Ultra Fast Adhesive For direct glazing 4103/2109 310 ml
Active Wipe 205 For direct glazing 4104/1203 250 g
Black Primer 206J For direct glazing 4201/4906 30 ml
Clear Silicone Sealant To seal butt jointed glass. 4102/0901
Issue 2
26
Care Safety
Section 2
Section 2
i
i
Contents Safety Notices
Page No. 1 - 1
General Safety
2 - 1
Operating Safety
3 - 1
Maintenance Safety
4 - 1
Issue 1
27
Section 2
Care Safety
Section 2
1 - 1
1 - 1
In this publication and on the machine, there are
safety notices. Each notice starts with a signal
word. The signal word meanings are given
below. 8 DANGER Denotes an extreme hazard
exists. If proper precautions are not taken, it
is highly probable that the operator (or others)
could be killed or seriously injured. INT-1-2-1
8 WARNING Denotes a hazard exists. If proper
precautions are not taken, the operator (or
others) could be killed or seriously
injured. INT-1-2-2 8 CAUTION Denotes a reminder
of safety practices. Failure to follow these
safety practices could result in injury to the
operator (or others) and possible damage to the
machine. INT-1-2-3
Issue 2
28
Section 2
Care Safety
Section 2
2 - 1
2 - 1
All construction and agricultural equipment can
be hazardous. When a JCB Excavator is correctly
operated and properly maintained, it is a safe
machine to work with. But when it is carelessly
operated or poorly maintained it can become a
danger to you (the operator) and others. Do not
work with the machine until you are sure that you
can control it. Do not start any job until you
are sure that you and those around you will be
safe. If you are unsure of anything, about the
machine or the job, ask someone who knows. Do not
assume anything.
Note This section includes a certain amount of
operating safety information. But remember that
whenever you drive the machine or operate its
controls, you are in effect a machine operator.
Therefore you should read and understand the
information given in the Operator Handbook before
driving the machine or operating its controls.
Remember BE CAREFUL BE ALERT BE SAFE
GEN-1-6
As well as the warnings in the following pages,
specific warnings are given throughout the book.
This section is designed to give a safety code
for use of the machine generally and for
operation and maintenance practices.
General Safety
8 WARNING Care and Alertness All the time you are
working with or on the machine, take care and
stay alert. Always be careful. Always be alert
for hazards. INT-1-3-5
8 WARNING Lifting Equipment You can be injured if
you use faulty lifting equipment. Make sure that
lifting equipment is in good condition. Make sure
that lifting tackle complies with all local
regulations and is suitable for the job. Make
sure that lifting equipment is strong enough for
the job. INT-1-3-7
8WARNING Raised Equipment Raised equipment can
fall and injure you. Do not walk or work under
raised equipment unless safely supported. 13-1-1-6
8WARNING Clothing You can be injured if you do
not wear the proper clothing. Loose clothing can
get caught in the machinery. Wear protective
clothing to suit the job. Examples of protective
clothing are a hard hat, safety shoes, safety
glasses, a well fitting overall, ear-protectors
and industrial gloves. Keep cuffs fastened. Do
not wear a necktie or scarf. Keep long hair
restrained. INT-1-3-6
8 DANGER Before removing the boom from the
machine, ensure that the counterweight is
adequately supported as in certain ground
conditions the machine could tip backwards. Never
travel or transport the machine with the boom
removed. BF 6-3
8 WARNING Alcohol and Drugs It is extremely
dangerous to operate machinery when under the
influence of alcohol or drugs. Do not consume
alcoholic drinks or take drugs before or whilst
operating the machine or attachments. Be aware of
medicines which can cause drowsiness. INT-1-3-9
Issue 2
29
Section 2
Care Safety
Section 2
3 - 1
3 - 1
Operating Safety 8WARNING Engine The engine has
rotating parts. Do not open the engine cover
while the engine is running. Do not use the
machine with the cover open. INT-2-1-6
8WARNING Ramps and Trailers Water, mud, ice,
grease and oil on ramps or trailers can cause
serious accidents. Make sure ramps and trailers
are clean before driving onto them. Use extreme
caution when driving onto ramps and
trailers. INT-2-2-6
8WARNING Entering/Leaving Always face the machine
when entering and leaving the cab. Use the
step(s) and handrails. Make sure the step(s),
handrails and your boot soles are clean and dry.
Do not jump from the machine. Do not use the
machine controls as handholds, use the
handrails. INT-2-1-7
8WARNING Communications Bad communications can
cause accidents. Keep people around you informed
of what you will be doing. If you will be working
with other people, make sure any hand signals
that may be used are understood by everybody.
Work sites can be noisy, do not rely on spoken
commands. INT-2-2-3
8WARNING Controls You or others can be killed or
seriously injured if you operate the control
levers from outside the cab. Operate the control
levers only when you are correctly seated inside
the cab. INT-2-1-3
8 DANGER Sparks Explosions and fire can be caused
by sparks from the exhaust or the electrical
system. Do not use the machine in closed areas
where there is flammable material, vapour or
dust. INT-2-2-10
8WARNING Visibility Accidents can be caused by
working in poor visibility. Keep windows clean
and use your lights to improve visibility. Do not
operate the machine if you cannot see
properly. INT-2-1-11
8WARNING Controls Keep the machine controls clean
and dry. Your hands and feet could slide off
slippery controls. If that happens, you will lose
control of the machine. 2-2-3-6
8WARNING Machine Limits Operating the machine
beyond its design limits can damage the machine,
it can also be dangerous. Do not operate the
machine outside its limits. Do not try to upgrade
the machine performance with unapproved
modifications. INT-2-1-4
8WARNING Hazardous Atmospheres This machine is
designed for use in normal outdoor atmospheric
conditions. It should not be used in an enclosed
area without adequate ventilation. Do not use the
machine in a potentially explosive atmosphere,
i.e. combustible vapours, gas or dust, without
first consulting your JCB Distributor. INT-2-1-14
8WARNING Exhaust Gases Breathing the machine
exhaust gases can harm and possibly kill you. Do
not operate the machine in closed spaces without
making sure there is good ventilation. If
possible, fit an exhaust extension. If you begin
to feel drowsy, stop the machine at once. Get out
of the cab into fresh air. INT-2-1-10
8WARNING Boom Removal Never remove the boom from
the machine as this would severely upset the
machines balance so that in certain ground
conditions it could tip backwards. 8-2-8-4/2
8WARNING Front Axle Lock DO NOT travel on the
road unless the front axle is free to pivot. Lock
the axle only while excavating or
lifting. 8-2-9-1/1
Issue 2
30
Section 2
Care Safety
Section 2
4 - 1
4 - 1
Maintenance Safety 8WARNING Soft Ground A machine
can sink into soft ground. Never work under a
machine on soft ground. INT-3-2-4
8WARNING Fires If your machine is equipped with a
fire extinguisher, make sure it is checked
regularly. Keep it in the operator's cab until
you need to use it.
8WARNING Metal Splinters You can be injured by
flying metal splinters when driving metal pins in
or out. Use a soft faced hammer or drift to
remove and fit metal pins. Always wear safety
glasses. INT-3-1-3
Do not use water to put out a machine fire, you
could spread an oil fire or get a shock from an
electrical fire. Use carbondioxide, dry chemical
or foam extinguishers. Contact your nearest fire
department as quickly as possible. Fire fighters
should use self-contained breathing
apparatus. INT-3-2-7/1
8WARNING Battery A battery with frozen
electrolyte can explode if it is used or charged.
Do not use a machine with a frozen battery. To
help prevent the battery from freezing, keep the
battery fully charged. INT-3-1-7
8WARNING Communications Bad communications can
cause accidents. If two or more people are
working on the machine, make sure each is aware
of what the others are doing. Before starting the
engine, make sure the others are clear of the
danger areas examples of danger areas are the
rotating blades and belt on the engine, the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or
injured if these precautions are not
taken. INT-3-1-5
8WARNING Battery Gases Batteries give off
explosive gases. Keep flames and sparks away from
the battery. Do not smoke close to the battery.
Make sure there is good ventilation in closed
areas where batteries are being used or charged.
Do not check the battery charge by shorting the
terminals with metal use a hydrometer or
voltmeter. INT-3-1-8
8WARNING Diesel Fuel Diesel fuel is flammable
keep naked flames away from the machine. Do not
smoke while refuelling the machine or working on
the engine. Do not refuel with the engine
running. There could be a fire and injury if you
do not follow these precautions. INT-3-2-2
8WARNING Battery Terminals The machine is
negatively earthed. Always connect the negative
pole of the battery to earth.
8WARNING Petrol Do not use petrol in this
machine. Do not mix petrol with the diesel fuel
in storage tanks the petrol will rise to the top
and form flammable vapours. INT-3-1-6
When connecting the battery, connect the earth
(-) lead last.
When disconnecting the battery, disconnect the
earth (-) lead first. INT-3-1-9
8WARNING 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
8WARNING Oil Oil is toxic. If you swallow any
oil, do not induce vomiting, seek medical advice.
Used engine oil contains harmful contaminants
which can cause skin cancer. Do not handle used
engine oil more than necessary. Always use
barrier cream or wear gloves to prevent skin
contact. Wash skin contaminated with oil
thoroughly in warm soapy water. Do not use
petrol, diesel fuel or paraffin to clean your
skin. INT-3-2-3
8 CAUTION Never use water or steam to clean
inside the cab. The use of water or steam could
damage the on-board computer and render the
machine inoperable. Remove dirt using a brush or
damp cloth. 8-3-4-8
Issue 2
31
Section 2
Care Safety
Section 2
4 - 2
4 - 2
Maintenance Safety (contd) 8 CAUTION Arc
Welding Before carrying out any arc welding on
the machine, completely remove the Control
Computer to avoid damage to the circuits also
disconnect the alternator plug and battery leads.
8 CAUTION Rams The efficiency of the rams will be
affected if they are not kept free of solidified
dirt. Clean dirt from around the rams regularly.
When leaving or parking the machine, close all
rams if possible to reduce the risk of weather
corrosion. INT-3-2-10
When welding items to the mainframe make sure
that the earth clamp is positioned on the
mainframe and when welding to the undercarriage
make sure that the earth clamp is positioned on
the undercarriage. If you earth one and weld the
other, you may cause severe damage to the slew
ring.
8 CAUTION Cleaning Cleaning metal parts with
incorrect solvents can cause corrosion. Use only
recommended cleaning agents and
solvents. INT-3-2-11
Always connect the earth clamp to any other
component being welded, i.e. boom or dipper, to
avoid damage to pivot pins and bushes. 8-1-2-6/1
8 CAUTION 'O'-rings, Seals and Gaskets Badly
fitted, damaged or rotted 'O'-rings, seals and
gaskets can cause leakages and possible
accidents. Renew whenever disturbed unless
otherwise instructed. Do not use Trichloroethane
or paint thinners near 'O' rings and
seals. INT-3-2-12
8WARNING Hydraulic Hoses Damaged hoses can cause
fatal accidents. Inspect the hoses regularly
for Damaged end fittings Chafed outer covers
Ballooned outer covers Kinked or crushed
hoses Embedded armouring in outer covers
Displaced end fittings. INT-3-3-2
8WARNING Hot Coolant The cooling system is
pressurised when the engine is hot. Hot coolant
can spray out when you remove the radiator cap.
Let the system cool before removing the radiator
cap. To remove the cap turn it to the first
notch and let the system pressure escape, then
remove the cap. INT-3-2-9
8WARNING DO NOT remove the hydraulic tank filler
cap or cover plate when the engine is running.
The hydraulic system is under pressure. You or
others could be injured. First stop the engine
and then release the pressure. 8-3-4-4/1
8WARNING Protect your eyes when grinding metal.
Wear safety glasses or goggles. Remove or protect
any combustible materials from the area which
could be ignited by sparks. GEN-1-12
8WARNING Hydraulic Pressure Hydraulic fluid at
system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop
the engine and operate the controls to release
pressure trapped in the hoses. Make sure the
engine cannot be started while the hoses are
open. INT-3-1-11/1
8WARNING Hydraulic Fluid Fine jets of hydraulic
fluid at high pressure can penetrate the skin. Do
not use your fingers to check for hydraulic fluid
leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to
suspected leaks and then inspect the cardboard
for signs of hydraulic fluid. If hydraulic fluid
penetrates your skin, get medical help
immediately. INT-3-1-10/1
Issue 2
32
Section 3 Routine Maintenance Section 3
i i
Contents Page No.
Lubricants and Capacities 1 - 1
Lubricants - Health and Safety 1 - 3
Service Schedules 2 - 1
Greasing Slew Ring Teeth and Slew Pinion 3 - 1
Slew Ring Bearing 3 - 1
Greasing (50 hours) 3 - 2
Greasing (General) 3 - 4
Battery 4 - 1
Fuses See Section C
Tyres and Wheels Tyre Inflation 5 - 1
Checking the Wheel Nut Tightness 5 - 1
Hydraulics Checking the Fluid Level Releasing
Tank Pressure Topping-up Fluid Level Changing the
Fluid Changing the Return Filter Element Flushing
Filters Cleaning/Changing the Suction Strainer
Changing the Plexus Filter Changing the Air
Breather Element Draining Tank Impurities Changing
the Servo Oil Filter Changing the Drain Line
Filter Element Changing the Steering Line Filter
Element Changing the Breaker In-line Filter (if
fitted) Air Bleeding Procedures
7 - 1 7 - 1 7 - 1 7 - 2 7 - 3 7 - 3 7 - 4 7 - 5 7
- 7 7 - 7 7 - 8 7 - 9 7 - 9 7 - 10 7 - 11

Transmission Checking the Slew Gearbox Oil Level
Changing the Slew Gearbox Oil Replenishing Slew
Gearbox Grease Checking the Drive Gearbox Oil
Level Changing the Drive Gearbox Oil Checking the
Front Axle Differential Oil Level Changing the
Front Axle Differential Oil Checking the Front
Axle Hub Oil Level Changing the Front Axle Hub
Oil Checking the Rear Axle Differential/Hub Oil
Level Changing the Rear Axle Differential/Hub Oil
8 - 1 8 - 1 8 - 2 8 - 3 8 - 3 8 - 4 8 - 4 8 - 5 8
- 5 8 - 6 8 - 6
Issue 4
33
Routine Maintenance
Section 3
Section 3
ii
ii
Contents Engine Changing the Air Filter Outer
Element Changing the Air Filter Inner Element
Checking the Oil Level Changing the Oil and
Filters Checking the Coolant Level Coolant
Mixtures Changing the Coolant Cleaning the
Radiator and Oil Cooler Adjusting the Fan
Belt Fitting a New Fan Belt Draining Fuel Tank
Impurities Draining the Fuel System Water
Separator Changing the Fuel Filter
Element Cleaning the Fuel Lift Pump Strainer
Bleeding the Fuel System
Page No.
9 - 1 9 - 2 9 - 3 9 - 3 9 - 4 9 - 4 9 - 5 9 - 5 9
- 6 9 - 6 9 - 7 9 - 7 9 - 8 9 - 8 9 - 9
Component Location Diagrams
10 - 1

Falling Objects Protection Structure (FOPS)
Checking the FOPS structure
12 - 1
Issue 2
34
Section 3
Routine Maintenance
Section 3
1 - 1
1 - 1
Lubricants and Capacities
Note New engines DO NOT require a running-in
period. The engine should be used in a normal
work cycle immediately glazing of the piston
cylinder bores, resulting in excessive oil
consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine
be allowed to idle for extended periods (e.g.
warming-up without load).
Item Fluid/Lubricant International Specification Capacity Capacity
Item Fluid/Lubricant International Specification JS130W JS145W/JS160W
ENGINE See separate chart 12.1 litres (2.7 UK gal) 12.1 litres (2.7 UK gal)
SLEW GEARBOX JCB Gear Oil HD90 JCB HP Grease API-GL-5 MIL-L-2105C Lithium based, No. 2 consistency 5 litres (1.09 UK gal) 1 litre (0.22 UK gal) 5 litres (1.09 UK gal) 1 litre (0.22 UK gal)
HYDRAULIC SYSTEM JCB Special Hydraulic Fluid HP46 Vickers 35VQ25/V104C Sundstrand, Denison and FZG Approval Tests 124 litres (27.3 UK gal) 124 litres (27.3 UK gal)
SLEW RING BEARINGS GEAR TEETH JCB HP Grease JCB HP Grease Lithium based, No. 2 consistency - 17 kg (37.48 lb) - 17 kg (37.48 lb)
PROPSHAFTS JCB HP Grease Lithium based, No. 2 consistency
ALL OTHER GREASE POINTS JCB HP Grease Lithium based, No. 2 consistency
COOLING SYSTEM See Coolant Mixtures ASTM D3306-74 16.4 litres (3.6 UK gal) 17.2 litres (3.78 UK gal)
FUEL TANK See Fuel System, Types of Fuel in Operator Handbook ASTM D975-66T Nos 1D, 2D 240 litres (52.8 UK gal) 240 litres (52.8 UK gal)
FRONT AXLE DIFFERENTIAL HUB (x 2) JCB Special Gear Oil Plus JCB Special Gear Oil Plus API GL4 M2C-41B/134D, JD20C MGF M1135/M1141/M1143 18 litres (3.9 UK gal) 1.5 litres (0.33 UK gal) 18 litres (3.9 UK gal) 1.5 litres (0.33 UK gal)
REAR AXLE - DIFFERENTIAL AND HUBS (x 2) JCB Special Gear Oil Plus API GL4 M2C-41B/134D, JD20C MGF M1135/M1141/M1143 17.7 litres (3.9 UK gal) 17.7 litres (3.9 UK gal)
DRIVE GEARBOX JCB Super 15W/40 Multigrade Engine Oil API CF4/SG MIL-L-2104F 3.8 litres (0.83 Uk gal) 3.8 litres (0.83 UK gal)
Issue 2
35
Section 3
Routine Maintenance
Section 3
1 - 2
1 - 2
Lubricants and Capacities
Note New engines DO NOT require a running-in
period. The engine should be used in a normal
work cycle immediately glazing of the piston
cylinder bores, resulting in excessive oil
consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine
be allowed to idle for extended periods (e.g.
warming-up without load).
Item Fluid/Lubricant International Specification Capacity
Item Fluid/Lubricant International Specification JS175W
ENGINE See separate chart 21.5 litres (4.72 UK gal)
SLEW GEARBOX JCB Gear Oil HD90 API-GL-5 MIL-L-2105C 5 litres (1.09 UK gal)
HYDRAULIC SYSTEM JCB Special Hydraulic Fluid HP46 Vickers 35VQ25/V104C Sundstrand, Denison and FZG Approval Tests 124 litres (27.3 UK gal)
SLEW RING BEARINGS GEAR TEETH JCB HP Grease JCB HP Grease Lithium complex (NLGI) inc. extreme pressure additives - 17 kg (37.48 lb)
PROPSHAFTS JCB HP Grease Lithium complex (NLGI) inc. extreme pressure additives
ALL OTHER GREASE POINTS JCB HP Grease Lithium complex (NLGI) inc. extreme pressure additives
COOLING SYSTEM See Coolant Mixtures ASTM D3306-74 25.5 litres (5.6 UK gal)
FUEL TANK See Fuel System, Types of Fuel ASTM D975-66T Nos 1D, 2D 240 litres (52.8 UK gal)
FRONT AXLE
- DIFFERENTIAL JCB Special Gear API GL4 M2C-41B/134D, 18 litres
Oil Plus JD20C (3.9 Uk gal)
- HUB (x 2) JCB Special Gear MGF M1135/M1141/ 1.5 litres
Oil Plus M1143 (0.33 UK gal)
REAR AXLE - DIFFERENTIAL AND HUBS (x 2) JCB Special Gear Oil Plus API GL4 M2C-41B/134D JD20C, MGF M1135/M1141/ M1143 17.7 litres (3.9 UK gal)
DRIVE GEARBOX JCB Super 15W/40 Multigrade Engine Oil API CF4/SG MIL-L-2104F 3.8 litres (0.83 UK gal)
Issue 2
36
Section 3
Routine Maintenance
Section 3
1 - 3
1 - 3
Lubricants and Capacities (continued)
Engine Lubrication Chart - All Machines
Use according to ambient temperature
(C) 0 10 20 30 JCB SUPER 15W/40 MULTIGRADE
ENGINE OIL API CF4/SG MIL L-2104F
-30
-20
-10
40
50
JCB SUPER 10W/30 MULTIGRADE ENGINE OIL API CF4/SG
MIL L-2104F
Issue 2
37
Section 3
Routine Maintenance
Section 3
1 - 4
1 - 4
Lubricants - Health and Safety
It is most important that you read and understand
this information and the publications referred
to. Make sure that all of your colleagues who are
concerned with lubricants read it too.
First Aid - Oil Swallowing. If oil is swallowed
you should not induce vomiting. Get medical
advice.
Handling New Oil There are no special precautions
needed for the handling or use of new oil, beside
normal care and hygiene practices.
Skin In the case of excessive skin contact you
should wash with soap and water.
Used Oil Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin cancer.
Eyes In the case of eye contact, flush with water
for 15 minutes. If irritation persists, get
medical attention.
Here are precautions to protect your health when
handling used engine oil
Fires Extinguish with carbon dioxide, dry
chemical or foam. Firefighters should use self
contained breathing apparatus.
1 Avoid prolonged, excessive or repeated skin
contact with used engine oils.
2 Apply a barrier cream to the skin before
handling used engine oil.
Hygiene JCB lubricants are not a health risk when
used properly for their intended purposes.
3 Note the following when removing engine oil
from skin

1. Wash your skin thoroughly with soap and water.
2. Using a nail brush will help.
3. Use special hand cleansers to help clean dirty
   hands.
4. Never use petrol, diesel fuel or gas oil.
5. Avoid skin contact with oil soaked clothing.
6. Don't keep oily rags in pockets.
7. Wash dirty clothing before re-use.
8. Throw away oil-soaked shoes.

However, excessive or prolonged skin contact can
remove the natural fats from your skin, causing
dryness and irritation.
Low viscosity oils are more likely to do this,
therefore particular care is necessary in
handling used oils which can be diluted with fuel
contamination.
Whenever you are handling oil products you should
maintain good standards of care and personal and
plant hygiene. For details of these precautions
we advise you to read the relevant publications
issued by your local health authority, and note
the following
Waste Disposal All waste products should be
disposed of in accordance with all the relevant
regulations.
Storage
The collection and disposal of used engine oil
should be in accordance with any local
regulations. Never pour used engine oil into
sewers or drains.
Always keep lubricants out of the reach of
children.
Never store lubricants in open or unlabelled
containers.
Spillage
Absorb on sand or a locally approved brand of
absorbent granules. Scrape up and remove to a
chemical disposal area.
38
Section 3
Routine Maintenance
Section 3
2 - 1
2 - 1
Service Schedules
Every 10 Operating Hours or Daily Whichever
occurs first 1 Clean
h Footbrake operation.
a Machine generally. (When steam cleaning do not
direct jet at grease nipples.)
j Steering operation.

k Parking brake operation.
2 Grease (If operating in very wet or severe
conditions).
l Operation of slew brake.
m Operation of hour meter.
a Bucket/dipper pivot points.

• 3 Check (Engine Stopped)
• Generally for damage.
• For oil and coolant leakage.
• Security of bolts and nuts .
• For disconnected or shorted wiring, loose
  terminals.
• Hydraulic fluid level.
• Engine oil level.
• Engine coolant level.
• Windscreen washer fluid level.
• Fuel system for leaks.

• Every 50 Operating Hours or Weekly
• Whichever occurs first
• Do the daily jobs plus
• Clean

a Drain water and sediment from fuel tank.
b Drain fuel water separator.
3 Grease a All pivot pins.

• p The auxiliary circuit hydraulic oil filter
  visual indicator (if using a rockbreaker or
  crusher).
• Tapping with a hammer will identify any loose
  nuts and bolts which should then be tightened to
  the specified torque.
• 4 Check (Engine Running)
• Operation of warning lights and audible alarm.
• Operation of brake lights and reversing lights.
• Operation of other electrical equipment.
• Exhaust for excessive smoke.
• Excavator operation.
• Dozer, stabiliser and attachment operation.
• Transmission operation.

Issue 2
39
Section 3
Routine Maintenance
Section 3
2 - 2
2 - 2
Service Schedules

• Every 100 Operating Hours or 2-Weekly
• Whichever occurs first
• Do a 50 hour service plus
• Clean

6 Check (Engine Running)

1. Operation of throttle system.
2. Operation of overload warning.
3. Operation of stop control.

1. Battery terminals.
2. Fuel lift pump strainer.

3 Grease
These procedures are only to be carried out
after the first 100 hours use of a new machine.
Thereafter they are to be carried out as detailed
in the following periodic checks.
a Slew ring bearing. b Axle pivot and steering
joints . c Propshafts.

• Every 250 Operating Hours or Monthly
• Whichever occurs first
• Do a 100 hour service plus
• Clean

4 Change

1. Engine oil main filter element .
2. Engine oil .
3. Servo oil filter element .
4. Engine oil filter by-pass element .
5. Return filter element .
6. Drain filter element .
7. Slew gearbox oil .
8. Front axle hub oil .

1. Drain water and deposits from hydraulic oil tank.
2. Air cleaner dust valve.
3. Pre-cleaner

• 3 Grease
• Door and canopy hinges.
• Slew ring bearing.

1. Rear axle hub/differential oil .
2. Drive gearbox oil .
3. Fuel filter element .

4 Check (Engine Stopped)

• Battery electrolyte level.
• Security of major unit mounting bolts and nuts.
• If loose, tighten to specified torque.
• Slew gearbox oil level.
• Fan belt adjustment.
• Front axle hub oil and differential oil levels.

5 Check (Engine Stopped)

• Hose and pipework for chafing or damage.
• Condition of ram piston rods.
• Bucket pivot pin grease seals .
• All grease seals.
• Tightness of engine mounting bolts.
• Security of major unit mounting bolts and nuts
  .
• If loose, tighten to specified torque.
• Wiring for chafing.
• Fan belt tension.
• j Accumulator operation.

1. Rear axle hub/differential oil level.
2. Drive gearbox oil level.
3. Air inlet system security.

1. Radiator for damage.
2. Oil cooler for damage.
3. Exhaust system security.
4. Teeth and sidecutters.

Issue 2
40
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41
Section 3
Routine Maintenance
Section 3
2 - 3
2 - 3
Service Schedules

• Every 500 Operating Hours or 3-Monthly
• Whichever occurs first
• Do a 250 hour service plus
• Clean

Every 1000 Operating Hours or 6-Monthly Whichever
occurs first

• Do a 500 hour service plus
• Clean
• Fuel lift pump strainer.
• Hydraulic fluid suction strainer.

a Radiator, grille and oil cooler fins.
3 Grease
3 Grease a Replenish slew gearbox grease.
a Slew ring teeth and slew pinion.
b Axle pivot and steering joints. (JCB HP
Grease should be used on all axle grease points.
If an alternative grease is used the service
interval must be reduced to 50 hours or weekly.)
4 Change (Engine Stopped)

• Engine air filter element (outer).
• Hydraulic tank air breather element.
• Slew gearbox oil.
• Return filter element .
• Nephron filter .
• Servo oil filter element .
• Drain filter .
• Front axle differential oil.
• j Steering line filter element .

• Change
• Engine oil.
• Engine oil full flow filter elements.
• Fuel filter element.
• Engine oil filter by-pass element.
• Front axle hub oil.
• Rear axle hub/differential oil.
• Check (Engine Stopped)
• Exhaust system security.
• b Propshaft .

5 Check (Engine Stopped) a Hub brake friction
plates for wear. Renew as necessry .

• Every 2000 Operating Hours or Yearly
• Whichever occurs first
• Do a 1000 hour service plus
• Clean

e Hydraulic oil (check the degradation and
cleanliness by sampling).
f Seat belt condition and security.

• a Injectors (and test) .
• 3 Check (Engine Stopped)
• Valve clearance and lubrication.
• b Sample hydraulic oil and replace if necessary.

• g Teeth and sidecutters.
• 6 Check (Engine Running)
• Operation of throttle system.
• Operation of overload warning.
• Operation of stop control.

4 Change

• Hydraulic fluid suction strainer.
• Engine air filter element (inner).
• Drive gearbox oil.
• If using a breaker or crusher, see Revised
  Service Schedules - Rockbreaker or Crusher Usage
  in this section.
• Indicates jobs which should be done by a
  specialist.

9803/6310
Issue 2
42
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