General Information 1

Care & Safety 2

R
Routine Maintenance 3
Attachments A
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Body & Framework
B
Service
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Manual Electrics C
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D
ca

Controls
JS130W
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JS145W
JS160W Hydraulics E
JS175W
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
Transmission F
OF JCB SERVICE: ©
UTTOXETER, STAFFORDSHIRE, ST14 7BS,
ENGLAND
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Brakes G
Publication No. 9803/6310
Issue 5
Engine K
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

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9803/6310 Issue 1
Section 1 General Information Section 1
1-1 Machine and Axle Identification 1-1

Machine Serial Plates

Each machine has a Data Plate, located to the rear left,
inside the cab as shown at A. The machine serial number is A
inscribed at B and the engine number at C.

If the engine is replaced by a new one, the data plate serial

number will be wrong. Either stamp the new number on the
plate or stamp out the old one. This will prevent the wrong
number being quoted when ordering replacement parts.

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JS06050
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JS06060

Axle Serial Plate

The axle serial number is stamped on a plate mounted to the

rear face of the axle, as shown.

1 When replacement parts are required, always ensure

that the correct parts are obtained, e.g. in the case of
gear replacements, always check the part number
stamped on the gear, and the number of teeth.

2 When ordering replacement parts, quote the details on

the serial plate as shown.

S156570

9803/6310 Issue 1
 Section 1 General Information Section 1
2-1 Torque Settings 2-1

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

* Bolt
Size Strength Grade of Bolt or Stud

4T 8.8 10.9 12.9

Nm kgf m lbf ft Nm kgf m lbf ft Nm kgf m lbf ft Nm kgf m lbf ft

M3 0.39 0.04 0.28 - - - - - - - - -

m
M4 0.78 0.08 0.57 - - co - - - - - - -

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 - - -

s.
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
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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
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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 - - -
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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 - - -
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M30 420 42.8 310 1170 119 863 1650 168 1217 - - -

M33 576 58.7 425 1600 163 1180 2260 230 1667 - - -

M36 736 75.1 543 2050 209 1512 2880 294 2124 - - -

M39 961 98.0 709 2680 273 1977 3760 383 2773 - - -

M42 1190 121 878 3300 336 2434 4640 473 3422 - - -

M45 1490 152 1099 4140 422 3054 5820 593 4293 - - -

M48 1780 182 1312 4960 506 3659 6970 711 5141 - - -

* Note: All bolts are high tensile and must not be replaced by bolts of a lesser tensile specification.

9803/6310 Issue 2*
Section 1 General Information Section 1
4-1 4-1

Service Tools
Body and Framework (Section B)

S186240 S186270

m
Hand Cleaner - special blend for the removal of Cartridge Gun - hand operated - essential for the
polyurethane adhesives. application of sealants, polyurethane materials etc.
co
4104/1310 (454g; 1lb tub) 892/00845
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S186250

12V Mobile Oven - 1 cartridge capacity - required to

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pre-heat adhesive prior to use. It is fitted with a male S186280

plug (703/23201) which fits into a female socket Folding Stand for Holding Glass - essential for
(715/04300). preparing new glass prior to installation.

992/12300 892/00843

S186260
S186300
240V Static Oven - available with 2 or 6 cartridge
capacity - required to pre-heat adhesive prior to use. Glass Lifter - minimum 2 off - essential for glass
No plug supplied. Note: 110V models available upon installation, 2 required to handle large panes of glass.
request - contact JCB Technical Service Ensure suction cups are protected from damage
during storage.
992/12400 - 2 cartridge x 240V
992/12600 - 6 cartridge x 240V 892/00842

9803/6310 Issue 1
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