Section 3: Publication No

Section 3
Maintenance
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section D - Controls
Section E - Hydraulics
Section F - Gearboxes
Section J - Track and Running Gear
Section K - Engine
717260
Publication No.
9803/9410-4
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 1 - General Information
Notes:
1-0 9803/9410-4 1-0

Contents
Contents Page No.

Routine Maintenance
Service Requirements ............................................................................... 3-1
Introduction ............................................................................................3-1
Owner/Operator Support .......................................................................3-1
Service/Maintenance Agreements ........................................................3-1
Fit for Purpose Tests for Lifting Equipment ............................................3-1
Obtaining Replacement Parts ................................................................3-1
Health and Safety ...................................................................................... 3-3
Lubricants ..............................................................................................3-3
Battery ...................................................................................................3-5
Service Schedules ..................................................................................... 3-7
Introduction ............................................................................................3-7
How to Use the Service Schedules .......................................................3-7
Calendar Equivalents ............................................................................3-8
Pre Start Cold Checks, Service Points and Fluid Levels .......................3-9
Functional Test and Final Inspection ................................................... 3-11
Fluids, Lubricants and Capacities ............................................................ 3-12
Coolant Mixtures .................................................................................3-13
Fuels ....................................................................................................3-14
Tools ........................................................................................................ 3-17
Toolbox (if fitted) ..................................................................................3-17
Carrying Tools onto the Machine .........................................................3-17
Prepare the Machine for Maintenance .................................................... 3-18
Introduction ..........................................................................................3-18
How to Make the Machine Safe (Excavator Lowered) ........................3-18
Cleaning the Machine .............................................................................. 3-19
Introduction ..........................................................................................3-19
Preparing the Machine for Cleaning ....................................................3-19
Cleaning the Machine ..........................................................................3-20
Cleaning the Tracks .............................................................................3-20
Checking for Damage .............................................................................. 3-22
Check the Machine Body and Structure ..............................................3-22
Check the Seat and Seat Belt .............................................................3-22
Check the Hydraulic Hoses and Fittings .............................................3-22
Check the Electrical Circuits ................................................................3-23
Checking the ROPS/FOPS Structure ..................................................3-24
Checking the Ram Piston Rods ..........................................................3-24
Greasing .................................................................................................. 3-25
Introduction ..........................................................................................3-25
Pivot Pins ............................................................................................3-26
Slew Ring Bearings .............................................................................3-27
Slew Ring Gear Teeth .........................................................................3-28
Access Panels ......................................................................................... 3-29
Introduction ..........................................................................................3-29
Engine Cover .......................................................................................3-29
Hydraulic Bay Cover ............................................................................3-30
Electrical System ..................................................................................... 3-31
Battery .................................................................................................3-31
Fuses ...................................................................................................3-35
Engine ..................................................................................................... 3-37
Oil and Filter ........................................................................................3-37
Cooling System ...................................................................................3-39
Fan Belt ...............................................................................................3-41
Air Filter ...............................................................................................3-42
3-i 3-i
Contents
Contents Page No.

Fuel System ............................................................................................. 3-44
Introduction ..........................................................................................3-44
Water Separator and Engine Fuel Filter ..............................................3-45
Bleeding the System ...........................................................................3-48
Hydraulic System ..................................................................................... 3-49
Introduction ..........................................................................................3-49
Releasing the Hydraulic Pressure .......................................................3-50
Oil and Filter ........................................................................................3-51
Tracks and Running Gear ....................................................................... 3-53
Tracks ..................................................................................................3-53
Fire Extinguisher (if fitted) ........................................................................ 3-56
Checking the Fire Extinguisher ...........................................................3-56
3-ii 3-ii
Routine Maintenance
Service Requirements
Routine Maintenance
Introduction You will have been given the names of the relevant service
T3-095
contacts at your Distributor when the machine was
Your machine has been designed and built to give installed.
maximum performance, economy and ease of use under a
wide variety of operating conditions. Prior to delivery, your To get the most from your Distributor please help them to
machine was inspected both at the Factory and by your satisfy you by:
Distributor to ensure that it reaches you in optimum
condition. To maintain this condition and ensure trouble 1 Giving your name, address and telephone number.
free operation it is important that the routine services, as
specified in this Manual, are carried out by an approved 2 Quoting your machine model and serial number.
JCB Distributor at the recommended intervals.
3 Date of purchase and hours of work.
This section of the Manual gives full details of the service
requirements necessary to maintain your JCB machine at 4 Nature of the problem.
peak efficiency.
Remember, only your JCB Distributor has access to the
A Service Manual for your machine is available from your vast resources available at JCB to help support you. In
JCB Distributor. The Service Manual contains information addition, your Distributor is able to offer a variety of
on how to repair, dismantle and assemble your machine programmes covering Warranty, Fixed Price Servicing,
correctly. Safety Inspections, including weight tests, covering both
legal and insurance requirements.
It can be seen from the Service Schedules on the following
pages that many essential service checks should only be Service/Maintenance Agreements
carried out by a JCB trained specialist. Only JCB
Distributor Service Engineers have been trained by JCB to To help plan and spread the costs of maintaining your
carry out such specialist tasks, and only JCB Distributor machine, we strongly recommend you take advantage of
Service Engineers are equipped with the necessary the many Service and Maintenance Agreements your
special tools and test equipment to perform such tasks, Distributor can offer. These can be tailor made to meet
thoroughly, safely, accurately and efficiently. your operating conditions, work schedule etc.
JCB regularly updates its Distributors advising them of any Please consult your JCB Distributor for details.
product developments, changes in specifications and
procedures. Therefore only a JCB Distributor is fully able Fit for Purpose Tests for Lifting
to maintain and service your machine.
Equipment
T3-097
A Service Record Sheet or Book is provided which will
All lifting equipment (for example forks, lifting hooks and
enable you to plan your service requirements and keep a
shackles) need regular inspection and testing by a
service history record. It should be dated, signed and
competent person to ensure they are fit for purpose.
stamped by your Distributor each time your machine is
serviced.
This may be needed every six months or at least annually
in some countries to meet and comply with legislation and
Remember, if your machine has been correctly
for insurance purposes.
maintained, not only will it give you improved reliability but
its resale value will be greatly enhanced.
Check with your local JCB distributor for further advice.
Owner/Operator Support Obtaining Replacement Parts
T3-096
JCB together with your Distributor wants you to be
If you use non-genuine JCB parts or consumables, then
completely satisfied with your new JCB machine. If you do
you can compromise the health and safety of the operator
encounter a problem however, you should contact your
and cause machine failure
Distributor's Service Department who are there to help
you!
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.
3-1 9803/9410-4 3-1

Routine Maintenance
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 9803/9410-4 3-2

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

T3-060_3
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 9803/9410-4 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 with 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 9803/9410-4 3-4

Routine Maintenance
Health and Safety
Battery
T3-061
!MCAUTION
!MWARNING Damaged or spent batteries and any residue from fires
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 a hydrometer or
battery, take off the earth (-) lead first. voltmeter.
INT-3-1-8
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 9803/9410-4 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 9803/9410-4 3-6

Routine Maintenance
Service Schedules
Service Schedules
Introduction How to Use the Service Schedules

T3-036_3 T3-012_4
!MWARNING In the example shown, A shows all service requirements to

be carried out every 10 hours and B shows the
Maintenance must be done only by suitably qualified requirements to be carried out every 500 hours.
and competent persons.
Important: Services should be carried out at either the
Before doing any maintenance make sure the machine hourly interval or calendar interval, whichever occurs first.
is safe, it should be correctly parked on level ground. Refer to Calendar Equivalents.
To prevent anyone starting the engine, remove the Important: The intervals given in the schedules must not
starter key. Disconnect the battery when you are not be exceeded. If the machine is operated under severe
using electrical power. If you do not take these conditions (high temperature, dust, water, etc.), shorten
precautions you could be killed or injured. the intervals.
8-3-1-1
A badly maintained machine is a danger to the operator

and the people working around him. Make sure that the
regular maintenance and lubrication jobs listed in the
service schedules are done to keep the machine in a safe
and efficient working condition.
Apart from the daily jobs, the schedules are based on

machine running hours. Keep a regular check on the
hourmeter readings to correctly gauge service intervals.
When there is no hourmeter fitted, use the calendar
equivalents to determine the service intervals. Refer to
Calendar Equivalents. Do not use a machine which is
due for a service. Make sure any defects found during the
regular maintenance checks are rectified immediately.
795390-1
3-7 9803/9410-4 3-7

Routine Maintenance
Service Schedules
Calendar Equivalents
T3-098
Every 10 Hours = Daily
Every 50 Hours = Weekly
Every 500 Hours = Six Months
Every 1000 Hours = Yearly
Every 2000 Hours = 2 Years
3-8 9803/9410-4 3-8

Routine Maintenance
Service Schedules
Pre Start Cold Checks, Service Points and Fluid Levels
Operation 10 50 500 1000 2000

ENGINE
Oil level - Check
Oil and Filter - Change
Air Cleaner Element (Dusty Conditions only) - Change
Air Cleaner Outer Element - Change
Air Cleaner Inner Element - Change
Air Cleaner Hose Security - Check and Adjust
Air Filter Dust Valve - Check and Clean
Fuel Injectors(1) - Clean and Test
Coolant Quality/Level - Check
Coolant - Change
Fuel Lift Pump - Clean
Fuel Sedimenter - Drain and Clean
Fuel Filter/Sedimenter Element - Change
Primary Fuel Filter - Check
Fuel Pre Filter - Check
Fan Belt Tension/Condition - Check and Adjust
Valve Clearances(1) - Check and Adjust
Cylinder Head Bolts for Tightness - Check and Adjust
Engine Mounting Bolts for Tightness - Check and Adjust
Exhaust System Security - Check and Adjust
Radiator - Clean and Check
TRANSMISSION
Security of Mounting Bolts and Nuts
- Track Wheel Motor to Undercarriage Bolts - Check
- Drive Sprocket Bolts - Check
- Slew Gearbox Bolts - Check
Track Gearbox Oil - Change
HYDRAULICS
Oil Level - Check
3-9 9803/9410-4 3-9

Routine Maintenance
Service Schedules
Operation 10 50 500 1000 2000

Oil Change
Rams - Chrome Condition - Check
Hoses and Pipework - Damage/Leaks - Check
Return Filter Element - Change
Suction Strainer - Clean
Security of Mounting Bolts on Major Assemblies - Check
ELECTRICS
Battery Electrolyte Level (if applicable) - Check
Starter Motor and Alternator Brush Gear - Check
Wiring for Chaffing/Routing - Check
Battery Terminals for Condition and Tightness - Check
UNDERCARRIAGE
Track Rollers Bolts - Check
Track Rollers Oil and Seals - Change
Idler Wheels Oil and Seals - Change
Track Plate Condition and Bolt Torque - Check
Track Tension - Check
BODYWORK AND CAB
Cab Mounting Bolts Security - Check and Adjust
All Pivot Pins - Grease
Visual inspection of structure for damage including - Check
welds around lifting points and excavator end main
pivots K Checking for Damage ( T 3-22).
Kingpost - kingpin retaining plate bolts torque - Check
Slew Ring Bearing - Grease
Slew Ring Mounting Bolts - Check
Slew Ring Pinion and Gear Teeth - Grease
Door/Window Hinges - Lubricate
Windscreen Washer Fluid Level - Check
Machine Generally - Check and Clean
ATTACHMENTS
Quick Hitch - Grease
OPTIONAL EQUIPMENT
As Required - Check
(1) Jobs which should only be done by a specialist.
3-10 9803/9410-4 3-10

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

ENGINE
Idle and Maximum Speed(1) - Check and Adjust
Exhaust Smoke (excessive) - Check
Fuel System - Leaks and Contamination - Check
HYDRAULICS
Operation All Services - Excavator, Dozer etc. - Check
Hoses and Pipework - Damage/Leaks - Check
Main Relief Valve Pressure(1) - Check and Adjust
Auxiliary Relief Valve Pressure (1) - Check and Adjust
Slew Cross Line Relief Valve Pressure(1) - Check and Adjust
Servo Relief Valve Pressure (1) - Check and Adjust
ELECTRICS
All Electrical Equipment Operation, (e.g. warning
lights, beacon, alarms, horn, wipers etc.)
- Check
Hourmeter Operation - Check
UNDERCARRIAGE
Track and Running Gear Operation - Check
BODYWORK AND CAB
Excavator Lever and Swing Pedal Locks - Check
LIFTING EQUIPMENT
Fit for Purpose Test(2) - Complete
(1) Jobs which should only be done by a specialist.

(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.
3-11 9803/9410-4 3-11

Routine Maintenance
Fluids, Lubricants and Capacities
Table 1.
Item Capacity Fluid / Lubricant JCB Part No Container
Litres (Gal) Size (1)
Fuel Tank 36.5 (8) Diesel Oil - -
Engine (Oil) (2) 4.5 (1.0) JCB Engine Oil HP 15W/40 (above -10°C, 4001/1505 20 Litres
14°F)
JCB Cold Climate Engine Oil EP 5W40 (-20°C 4001/2705 20 Litres
to +50°C, -4°F to 122°F)
Engine Coolant 8.5 (1.9) JCB Antifreeze HP/Coolant/Water K Coolant 4006/1120 20 Litres
Mixtures ( T 3-13).
Track Gearbox (each) 0.8 (0.2) JCB Engine Oil HP SAE 30 (Not Multigrade) 4001/0305 20 Litres
Track Idler Wheels 0.08 (0.02) JCB HD90 Gear Oil 4000/0305 20 Litres
Track Rollers (top) 0.03 (0.01) JCB HD90 Gear Oil 4000/0305 20 Litres
Track Rollers (bottom) 0.08 (0.02) JCB HD90 Gear Oil 4000/0305 20 Litres
Hydraulic Tank 40 (8.8) JCB Hydraulic Fluid HP32 (Up to 30°C, 86°F) 4002/1025 20 Litres
JCB Hydraulic Fluid HP46 (Over 30°C, 86°F) 4002/0805 20 Litres
Slew Ring Bearings - JCB HP Grease 4003/2017 400g
Slew Ring Gear Teeth - JCB Special Slew Pinion Grease 4003/1619 400g
All Other Grease - JCB MPL-EP Grease 4003/1501 400g
(1) For information about the different container sizes that are available (and their part numbers), contact your local JCB
dealer.
(2) Caution - Do not use ordinary Engine Oil.
3-12 9803/9410-4 3-12

Routine Maintenance
Coolant Mixtures
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

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

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.
The correct concentration of antifreeze protects the engine

against frost damage in winter and provides year round
protection against corrosion.
The protection provided by JCB High Performance

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

Protects against damage down to -40 °C (-39 °F)
60% Concentration (Extreme Conditions Only)

Protects against damage down to -56 °C (-68 °F)
Important: Do not exceed a 60% concentration, as the

freezing protection provided reduces beyond this point.
If you use any other brand of antifreeze:
– Ensure that the antifreeze complies with International

Specification ASTM D6210.
– Always read and understand the manufacturer's
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).
3-13 9803/9410-4 3-13

Routine Maintenance
Fuels !MCAUTION
Acceptable and Unacceptable Fuels Consult your fuel supplier or JCB distributor about the
T3-048_2
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 2.
Fuel Specification Applicable Engines Service Requirements
EN590 Diesel fuel types - Auto/C0/C1/C2/ All Obey the usual routine
C3/C4 maintenance schedules and
BS2869 Class A2 procedures.
ASTM D975-076 2-D, US DF1, US DF2, US

DFA
JIS K2204 Grades 1, 2, 3 and Special Grade
3
ASTM D975-076 1-D All Obey the usual routine
MIL T38219 JP7 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(1).
K Additives ( T 3-15).
AVTURFSII, NATO F34, JP8, MIL T83133, All 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(1). K Additives ( T 3-15).
service life.
NATO F35, JET A1, DEF STAN 91-91,
DERD 2494, XF63
AVCAT, NATO F43 (obsolete), JP5 without
additives
JET A (ASTM D1655)
ASTM D3699 Kerosene
B5 Biodiesel - RME content blended with Tier 3 only(2). You must obey special routine
mineral derived diesel (5% maximum) - maintenance schedules and
ASTM D6751, DIN 51606, ISO 14214 procedures. K Warranty ( T 3-15).
AVTAG (obsolete) These fuels are not acceptable with
AVTAG FSII (obsolete), NATO F40, JP4, or without additives. Engines must
DERD 2454 not be operated with these fuels.
JET B (ASTM D1655)

BS MA100
JIS K2203 No.2
Unmodified vegetable oils
(1) Use a fuel additive (where instructed) to make sure that the fuel meets the minimum lubricity requirement.
(2) Refer to Typical Engine Identification Number.
3-14 9803/9410-4 3-14

Routine Maintenance
Additives tank (or the storage tank). Water will encourage mico-
bacterial growth.
The additives listed below are advertised as being suitable – Make sure that the fuel pre-filter is drained daily.
for bringing the lubricity levels of kerosene/low sulphur
– Only Tier 3 engines (factory filled with CH4 oil) - this
fuels up to those of diesel fuels. They must be used as
is not approved with other manufacturers.
specified by your fuel supplier who will understand the
concentration level necessary. – Use heater kits in low ambient temperature territories.
– The biodiesel must meet the following standards:
Important: The lubricity wear scar diameter must not be ASTM D6751, DIN 51606, ISO 14214
more than 460 microns, as tested on a high frequency
reciprocating rig at 60°C (140°F). Refer to ISO 12156-1. 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
least 2 x tank fills) to EN590 specification and relevant stall
– Paradyne 7505 (from Infineum). Dosage 500 ppm
speeds recorded prior to making the report.
(0.05%).
Warranty
Note: These products are given as examples only. The
information is derived from the manufacturers data. The
JCB have shown a commitment to support the
products are not recommended or endorsed by JCB.
environment by approving the use of biodiesel blended
fuels.
Service Requirements for use of B5 Biodiesel
Using a B5 blend of biodiesel requires caution and
– The engine oil must be a grade CH4 as minimum
additional servicing of the engine is required. K Service
specification.
Requirements for use of B5 Biodiesel ( T 3-15).
– Do not leave unused B5 biodiesel in the fuel tank for
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 engine
excessive unburnt fuel content, water or wear workmanship and therefore will not be supported by JCB
particles. 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
3-15 9803/9410-4 3-15

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 3. Sulphur Content ( T 3-16). 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 3. 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
3-16 9803/9410-4 3-16

Routine Maintenance
Tools
Tools
Toolbox (if fitted)

The machine has a lockable tool storage container A
below the seat.
A
T034120-1
Fig 1.
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.
3-17 9803/9410-4 3-17

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

P11-3001 (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 dozer.
using electrical power. If you do not take these
precautions you could be killed or injured. 3 Lower the excavator so the attachment is flat on the
8-3-1-1 ground.
Make the machine safe before you start a maintenance 4 Stop the engine and remove the starter key.
procedure.
5 Disconnect the battery to prevent accidental
Unless a maintenance procedure instructs you differently, operation of the engine.
you must lower the Excavator. Refer to How to Make the
Machine Safe (Excavator Lowered).
717260-4
Fig 2.
3-18 9803/9410-4 3-18

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
3-19 9803/9410-4 3-19

Routine Maintenance
Cleaning the Machine Cleaning the Tracks

P11-3003
!MWARNING !MWARNING
To avoid burning, wear protective gloves when If two people are doing this job make sure that the
handling hot components. To protect your eyes, wear person operating the controls is a competent operator.
goggles when using a brush to clean components. If the wrong control lever is moved, or if the controls
HYD-1-3_2 are moved violently, the other person could be killed
or injured.
!MWARNING If you will be working with another person, make sure
Airborne particles of light combustible material such that you both understand what is to be done. Learn
as straw, grass, wood shavings, etc. must not be and use the recognised signalling procedures. Do not
allowed to accumulate within the engine compartment rely on shouting - he will not hear you.
or in the propshaft guards (when fitted). Inspect these
areas frequently and clean at the beginning of each To clean the tracks, you must turn them. When the
work shift or more often if required. Before opening tracks are turning, keep clear of rotating parts. Before
the engine cover, ensure that the top is clear of debris. starting this job, make sure that you have no loose
5-3-1-12_3 clothing (cuffs, ties etc.) which could get caught in
moving parts. Keep people not involved with this job
!MCAUTION well away!
MD-3-3-2
Never use water or steam to clean inside the cab. The
use of water or steam could damage the on-board 1 Park the machine on level ground.
computer and render the machine inoperable. Remove
dirt using a brush or damp cloth. 2 Operate the controls to slew the cab around across
8-3-4-8 the tracks. Lower the bucket to the ground.
Pay particular attention to the following: 3 Operate the controls to push the boom down so that
the track nearest the bucket is lifted clear of the
1 Remove debris and loose articles from inside the cab. ground.
2 If the radiator tubes/fins get clogged the radiator will

be less efficient.
!MWARNING
Rotating the tracks off the ground may cause stones
Brush off all debris from the cooler tubes and fins and other debris to be thrown with considerable force.
using a soft bristle brush. Make sure the loosened If you are on the outside, keep well clear. Keep other
material is brushed out of the cooler enclosure. people well clear.
8-3-5-8
3 Debris can collect under the boom. Remove
especially all combustible material. 4 Operate the controls to rotate the track which is off the
ground. Rotate it one way and then the other to shake
4 Do not allow debris to accumulate around the engine, off the mud. If necessary the person outside may use
pay particular attention to the exhaust area, remove water from a hose to help loosen sticky material.
all combustible material.
5 When the track is clean stop the rotation.
5 Thoroughly dry piston rams and protect with clean
transmission or hydraulic oil if necessary. 6 Inspect the track, rollers sprockets and idler wheels
for damage or oil leaks. Replace any damaged parts.
If in doubt consult your JCB Dealer.
7 Operate the controls slowly to lower the track to the

ground.
3-20 9803/9410-4 3-20

Routine Maintenance
8 Operate the controls to position the bucket on the
other side of the machine so that steps 2 to 7 can be
repeated for the other track.
3-21 9803/9410-4 3-21

Routine Maintenance
Checking for Damage
Checking for Damage
Check the Machine Body and Structure Check the Hydraulic Hoses and Fittings
T3-063_5 T3-072
Make sure that all guards and protective devices are in

place, attached by their locking devices and free from
!MWARNING
damage. Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the
Inspect all steelwork for damage. Pay particular attention hoses regularly. Do not use the machine if a hose or
to the following: hose fitting is damaged.
INT-3-3-2_4
– Inspect all lifting point welds.
– Inspect all pivot point welds. Inspect the hoses regularly for:
– Inspect the condition of all pivot pins.
– Damaged hose ends
– Check pivot pins are correctly in place and secured by
– Chafed outer covers
their locking devices.
– Ballooned outer covers
Check steps and handrails are undamaged and secure. – Kinked or crushed hoses
– Embedded armouring in outer covers
Check for broken, cracked or crazed window glass and
mirrors. Replace damaged items. – Displaced end fittings
Check all lamp lenses for damage. Do not use the machine if a hose or hose fitting is
damaged. Replace damaged hoses before you use the
Check all attachment teeth are undamaged and secure. machine again.
Check all safety and instructional labels are in place and Replacement hoses must be of the same size and
undamaged. Fit new labels where necessary. standard.
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.
Check seats are undamaged and secure. Check seat

adjustments for correct operation.
3-22 9803/9410-4 3-22

Routine Maintenance
Checking for Damage
Check the Electrical Circuits

T3-099
Inspect the electrical circuits regularly for:
– Damaged connectors
– Loose connections
– Chafing on wiring harnesses
– Corrosion
– Missing insulation
– Incorrect routing of harness
Do not use the machine if one or more of these faults are

found. You must make sure that the electrical circuit is
repaired immediately.
3-23 9803/9410-4 3-23

Routine Maintenance
Checking for Damage
Checking the ROPS/FOPS Structure
!MWARNING
You could be killed or seriously injured if you operate
a machine with a damaged or missing ROPS/FOPS. If
the Roll Over Protection Structure (ROPS)/Falling
Objects Protection Structure (FOPS) has been in an
accident, do not use the machine until the structure
has been renewed. Modifications and repairs that are
not approved by the manufacturer may be dangerous
and will invalidate the ROPS/FOPS certification.
INT-2-1-9_6
For assistance, contact your JCB distributor. Failure to

take these precautions could result in death or injury to the
operator.
1 Check the structure for damage.
2 Make sure that all the ROPS/FOPS mounting bolts

are in place and are undamaged.
3 Make sure that the ROPS/FOPS mounting bolts are

tightened to the correct torque setting.
Checking the Ram Piston Rods

Extend each ram fully, one at a time and visually examine
for score marks, dents or similar defects. If a ram piston
appears defective contact your service engineer or JCB
dealer.
3-24 9803/9410-4 3-24

Routine Maintenance
Greasing
Greasing
Introduction
T3-028_2
You must grease the machine regularly to keep it working

efficiently. Regular greasing will also lengthen the
machine's working life. Refer to the Service Schedule for
the correct intervals.
Note: The machine must always be greased after

pressure washing or steam cleaning.
Greasing should be done with a grease gun. Normally, two

strokes of the gun should be sufficient. Stop greasing when
fresh grease appears at the joint. Use only the
recommended type of grease. Do not mix different types of
grease, keep them separate.
In the following illustrations, the grease points are

numbered. Count off the grease points as you grease each
one. Refit the dust caps after greasing.
Note: Where applicable, refer to the manufacturers

manual for instructions on the maintenance of optional
attachments.
!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
3-25 9803/9410-4 3-25

Routine Maintenance
Greasing
Pivot Pins A Dipper ram pivot pins

B Bucket ram pivot pins
!MWARNING C Bucket pivot pins
You will be working close into the machine for these D Boom ram pivot pins
jobs. Lower the attachments if possible. Remove
E Kingpost ram pivot pins
starter key and disconnect the battery. This will
prevent the engine being started. F Swing ram pivot pins
8-3-1-3 G Dozer ram pivot pins
For the types of grease to use at each point, K Fluids, H Dozer arm pivot pins
Lubricants and Capacities ( T 3-12). Do not mix different
types of grease, keep them separate.
A
A
8
0
4
0
ZTS
B
D
E F
D
B
C
E
C C
F
H
G H
Fig 3.
3-26 9803/9410-4 3-26

Routine Maintenance
Greasing
Slew Ring Bearings
!MWARNING
Do not overgrease the slew ring as this will result in
the displacement of the grease seal.
8-2-9-35
Ensure the slew ring is kept full of grease. With the cab in
the straight ahead position as shown, the grease point A is
located near the front of the slew ring.
To ensure full distribution of the grease, use the following

procedure:
1 Grease in, using 4 strokes of the grease gun. Rotate

180°.
2 Grease in, using 4 strokes of the grease gun. Rotate

180°.
3 Grease in using 4 strokes of the grease gun.
C031400
x4
Fig 4.
3-27 9803/9410-4 3-27

Routine Maintenance
Greasing
Slew Ring Gear Teeth 7 Repeat steps 4 to 6 as necessary.
!MWARNING 8 Refit the plate B using bolts A.
Slew Pinion Grease 9 Lower the machine to the ground.

JCB Slew Pinion Grease is harmful as it contains
bitumen compounds 2811. Excessive contact may
lead to dermatitis or skin cancer. Always use a barrier
cream or wear gloves; wash contaminated skin
thoroughly with soap and water. In the event of eye
contact, immediately wash with plenty of water and
seek medical advice.
8-1-1-7
!MWARNING
Soft Ground
A machine can sink into soft ground. Never work
under a machine on soft ground.
INT-3-2-4
!MWARNING
Jacking
A machine can roll off jacks and crush you. Do not
work under a machine supported only by jacks.
8-3-5-7
1 Raise the machine and support the undercarriage.
2 Stop the engine and remove the starter key.
3 Remove bolts A and plate B in the underside of the

undercarriage. K Fig 5. ( T 3-28)
4 Apply the grease to the pinion using the applicator.

K Fluids, Lubricants and Capacities ( T 3-12).
5 Start the engine and rotate the mainframe fully twice.
6 Stop the engine and remove the key.
C031400
Fig 5.
3-28 9803/9410-4 3-28

Routine Maintenance
Access Panels
Access Panels
Introduction
T3-100
When placed in their maintenance position, the access

panels give you access to parts or areas of the machine
that are not required during machine operation.
Before you operate the machine, make sure that all of the
access panels are in their operation position and secure.
Engine Cover
Opening the Cover
!MWARNING A
The engine has exposed rotating parts. Switch OFF the
engine before working in the engine compartment. Do B
not use the machine with the engine cover open.
5-2-6-5
Fig 6.
!MWARNING
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
cool before servicing the unit.
10-1-1-40
1 Make the machine safe with the excavator lowered,

Refer to Prepare the Machine for Maintenance.
2 Unlock the cover using the starter key. Release the

latch by pushing button A and pulling up handle B at
the same time.
The cover will automatically open and be supported

on a gas strut.
Closing the Cover
1 Make sure that the hydraulic bay cover is closed.
2 Push the engine cover down.
3 Make sure it is locked in place.
3-29 9803/9410-4 3-29

Routine Maintenance
Access Panels
Hydraulic Bay Cover

Opening the Cover

2 Get access to the engine. Refer to Access Panels,

Engine Cover.
3 Locate handle H which is positioned in the top right

hand corner of the engine bay, above the air filter.
K Fig 6. ( T 3-29)
4 Pull the handle H to release the catch and lift the

cover by its bottom edge while the handle is held in
the release position.
Closing the Cover
1 Push the cover down.
2 Make sure it is fastened.
3-30 9803/9410-4 3-30

Routine Maintenance
Electrical System
Electrical System
Battery
!MCAUTION
Do not disconnect the battery while the engine is
running, otherwise the electrical circuits may be
damaged.
INT-3-1-14
Battery Access

2 Remove the 4 bolts A.
3 Remove the lower trim panel B.
JCB POWERMASTER
BATTERY
T058960
Fig 7.
3-31 9803/9410-4 3-31

Routine Maintenance
Electrical System
Battery Disconnection/Connection 4 Close and lock the access panels.
!MWARNING Checking the Electrolyte Level

T3-020_2
Keep metal watch straps and any metal fasteners on Maintenance free batteries used in normal temperate
your clothes, clear of the positive (+) battery terminal. climate applications should not need topping up. However,
Such items can short between the terminal and nearby in certain conditions (such as prolonged operation at
metal work. If it happens you can get burned. tropical temperatures or if the alternator overcharges) the
5-2-2-4 electrolyte level should be checked as described below.
Disconnection 1 Get access to the battery. K Battery

Access ( T 3-31).
1 Get access to the battery. K Battery
Access ( T 3-31). 2 Disconnect and remove battery. See Battery
Disconnection/Connection.
2 If the machine has a battery isolator, move the switch
to the OFF position then remove the key. K Battery
Isolator (if fitted) ( T 3-33).
!MWARNING
Do not top the battery up with acid. The electrolyte
3 Remove the leads. Disconnect the earth (-) terminal could boil out and burn you.
first. 2-3-4-6
Connection 3 Remove covers A. Look at the level in each cell. The

electrolyte should be 6 mm (1/4 in) above the plates.
1 Get access to the battery. K Battery Top up if necessary with distilled water or de-ionized
Access ( T 3-31), Check the battery. water.
a If the terminal is dirty, clean the post.
Fig 8.
b If the terminal post is corroded and generates

white powder wash the terminal with hot water. If
considerable corrosion is detected, clean with a
wire brush or abrasive paper. Fig 9.
c After cleaning, apply a thin coat of petroleum jelly 4 Refit battery.

to the terminal.
5 Close and lock the access panels.
2 Re-connect the leads. Connect the earth (-) terminal
last.
3 If the machine has a battery isolator, move the switch

to the ON position.
3-32 9803/9410-4 3-32

Routine Maintenance
Electrical System
Battery Isolator (if fitted) Jump Starting the Engine
To disconnect the battery from the machine electrics a

battery isolator switch has been installed.
!MWARNING
In temperatures below freezing, the battery electrolyte
!MCAUTION may freeze if the battery is discharged or poorly
charged. Do not use a battery if its electrolyte is
Before carrying out arc welding on the machine, frozen. To prevent the battery electrolyte from
disconnect the battery and alternator to protect the freezing, keep the battery at full charge.
circuits and components. The battery must still be
disconnected even if a battery isolator is fitted. If you try to charge a frozen battery or jump-start and
INT-3-1-13 run the engine, the battery could explode.
To disconnect the machine electrics: Batteries produce a flammable gas, which is

explosive; do not smoke when checking the
1 Open the tool storage cover. K Toolbox (if electrolyte levels.
fitted) ( T 3-17).
When jump-starting from another vehicle, make sure
2 Insert the key A, then turn the battery isolation switch that the two vehicles do not touch each other. This
to the off position. K Fig 10. ( T 3-33). prevents any chance of sparks near the battery.
To connect the machine electrics: Switch off all circuits which are not controlled by the
starter switch.
1 Turn the battery isolation switch A to the on position
and remove the key. Do not connect the booster (slave) supply directly
across the starter motor.
2 Close the tool storage cover.
Use only sound jump leads with securely attached
connectors. Connect one jump lead at a time.
The machine has a negative earth electrical system.

Check which battery terminal is positive (+) before
making any connections. Keep metal watch straps and
jewellery away from the jump lead connectors and the
battery terminals - an accidental short could cause
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
A 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
T034130
Fig 10.
Note: The machine has a 12 Volt electrical system. Using
a booster (slave) supply with a higher voltage will damage
the machine's electrical system. The negative (-) terminal
on the battery is connected to frame earth.
3-33 9803/9410-4 3-33

Routine Maintenance
Electrical System
!MDANGER
Before lowering the attachments to the ground, make
sure that the machine and the area around it are clear
of other people. Anyone on or close to the machine
could fall and be crushed by the attachments, or get
caught in the linkages.
2-2-3-4
1 Lower the attachments to the ground.
Lower the excavator bucket and dozer to the ground,

if they are not already there. They will lower
themselves under their own weight when you operate
the control. Operate the control carefully to control the
rate of descent.
2 Set all switches in the cab to 'OFF'.
3 Get access to the battery. K Battery

Access ( T 3-31).
4 Connect the booster cables.
a Connect the positive booster cable to the positive

(+) terminal on the machine battery. Connect the
other end of this cable to the positive (+) terminal
of the booster supply.
b Connect the negative (-) booster cable to a good

frame earth on the machine, away from and below
the battery.
Note: A good frame earth is part of the machine frame,

free from paint and dirt. Do not use a pivot pin for an earth.
c connect the other end of this cable to the negative

(-) terminal on the booster supply.
5 Do the pre-start checks.
6 Start the engine.
7 Disconnect the booster cables
a Disconnect the negative booster cable from the

machine frame earth. Then disconnect if from the
booster supply.
b Disconnect the positive booster cable from the

positive (+) terminal on the battery. Then
disconnect it from the booster supply.
3-34 9803/9410-4 3-34

Routine Maintenance
Electrical System
Fuses All Machines
Introduction
!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. If a fuse

blows, find out why before fitting a new one.
Two primary fuses A and B are located in the battery

compartment below the cab door. K Fig 11. ( T 3-35).
C
The secondary fuses are in the fuse box located below the 862330-3
operator's seat. K Fig 12. ( T 3-35). Fig 12.
Open panel C using the starter key. Pull off the cover to
gain access to the fuses.
A,B
Fig 11. Primary Fuses
3-35 9803/9410-4 3-35

Routine Maintenance
Electrical System
Table 4.
Fuse Circuit Rating
No. (Amps)
1 Engine Stop Solenoid 5
2 Instruments, Two-speed Circuit, 5
Servo Solenoid
3 Wash/Wipe Circuit 15
4 Slew/Swing Circuit, SAE Control 15
5 Boom Light 7.5
6 Work Lights 15
7 Interior Light, Horn, Radio, Accessory 15
Power Socket
8 Beacon 10
9 Heater Blower and Air Conditioning 20
A Primary fuse 60
B Primary fuse 60
3-36 9803/9410-4 3-36

Routine Maintenance
Engine
Engine
Oil and Filter 4 If necessary add oil slowly through the remote filler.
Checking the Oil Level Do not insert the container neck Z completely into the
remote filler hole. K Fig 14. ( T 3-37).
Engine Cover. Allow oil to flow down from the remote filler to the
crankcase.
2 Open the engine cover. Allow time for the oil to drain
back into the engine sump before taking a reading. If Replace filler cap securely. Use only the
insufficient time is given a false low reading may be recommended oil.
recorded which will result in overfilling the engine.
3 Withdraw dipstick and wipe clean, re-insert fully into

tube and withdraw to check level. The correct level Z Z
will show the oil at the top of the hatched area of the
dipstick A. K Fig 13. ( T 3-37).
Fig 14.
Fig 13.
!MCAUTION
The engine has a closed ventilation system, (a hose
connects the ventilation system and the inlet
manifold). When oil is added through the oil filler it is
important that the oil is added slowly. If the oil is added
too rapidly it will enter the cylinders through the hose
and intake manifold and cause serious engine
damage.
8-3-5-10
3-37 9803/9410-4 3-37

Routine Maintenance
Engine
Changing the Oil and Filter
!MWARNING
Hot oil and engine components can burn you. Make
A
sure the engine is cool before doing this job.
Used engine crankcase lubricants contain harmful

contaminants. In laboratory tests it was shown that
used engine oils can cause skin cancer.
8-3-1-4
!MCAUTION
Keep your face away from the drain hole when
removing the drain plug. B
2-3-3-4
1 Remove the engine skid plate to gain access to the

engine drain plug (if necessary).
Fig 15.
2 Place a container beneath the engine (to catch the
4 Fill the engine with new oil through the filler. DO NOT
oil). Remove the drain plug A. Let the oil drain out,
insert the container neck Z completely into the filler
then clean and refit the drain plug.
hole. K Fig 14. ( T 3-37).
K Fig 15. ( T 3-38).
5 Allow oil to flow down from the filler to the crankcase.
!MCAUTION Replace filler cap securely. Use only the
recommended oil.
The oil filter canister will contain some oil which could
spill out when you remove the canister.
Important: Oil must be added slowly.
MD-3-2-1
6 Wipe off any spilt oil. Check for leaks. Make sure that
3 Unscrew the filter canister B. If necessary use a chain
the filler cap is correctly refitted
or strap wrench. Clean the filter mounting face.
Smear the seal on the new filter canister with oil.

Screw in the new canister - hand tight and then one
quarter turn.
3-38 9803/9410-4 3-38

Routine Maintenance
Engine
Cooling System
Checking the Coolant Level
!MWARNING
The cooling system is pressurised when the coolant is
hot. When you remove the cap, hot coolant can spray
out and burn you. Make sure that the engine is cool
before you work on the cooling system.
9-3-3-1_2

Engine Cover. Allow the engine to cool.
2 Observe the coolant fluid in the expansion bottle, the

bottle A should be half full of coolant.
K Fig 16. ( T 3-39).
3 Top up the system, if required by carefully removing

the expansion tube filler cap B, top up the level to the
neck of the expansion tube.
4 Refit the filler cap B making sure that it is tight.
Fig 16.
3-39 9803/9410-4 3-39

Routine Maintenance
Engine
Changing the Coolant 7 Refit the filler cap A making sure that it is tight.
!MCAUTION 8 Run the engine for a while, to raise the coolant to

working temperature and pressure. Stop the engine.
Keep your face away from the cylinder block tap and Check for leaks.
the radiator drain plug when you drain the system.
MD-3-1-6 Note: Manually squeeze the top and bottom radiator
hoses during filling to displace any trapped pockets of air
1 Get access to the engine. Refer to Access Panels, and to prevent air locks
Engine Cover. Allow the engine to cool.
2 Carefully and slowly remove the radiator cap allowing

any trapped pressure to escape.
3 Undo the plug B on the cylinder block and let the

coolant drain out. Remove the bottom radiator hose C
by unfastening at clip D and let the coolant drain out.
Make sure the drain hole is not blocked.
K Fig 17. ( T 3-40).
4 Flush the system with clean water if necessary.
B
Fig 17.
5 Refit the plug B. Refit bottom hose C and secure with

hose clip D.
6 Fill the system. Use the correct mix of clean, soft

water and anti-freeze. K Coolant
Mixtures ( T 3-13).
3-40 9803/9410-4 3-40

Routine Maintenance
Engine
Fan Belt
Adjusting the Fan Belt

Engine Cover.
2 Check that there is 5mm (0.2in) slack midway

between the alternator pulley and the crankshaft
pulley.
3 If necessary, adjust the fan belt as follows:
a Slacken lock nut B. K Fig 18. ( T 3-41).
b Turn screw C until there is 5mm (0.2in) slack

midway between the alternator pulley and the
crankshaft pulley.
c Tighten lock nut B.
Important: Excessive fan belt slack may result in damage

to the engine timing cover.
4 Close the engine cover.
Fig 18.
3-41 9803/9410-4 3-41

Routine Maintenance
Engine
Air Filter
Changing the Outer Element
1 Get access to the air filter. Refer to Access Panels,

Engine Cover and Access Panels, Hydraulic Bay
Cover.
2 Undo the two retaining clips holding the cover A and

remove the element B by twisting anti-clockwise. Do
not tap or knock the element as you remove it.
K Fig 19. ( T 3-42).
3 Clean the inside of canister and dust valve with a

vacuum cleaner.
4 Prior to fitting new element, smear the seal on the end

of the element with grease. Temporarily insert the
filter element into the canister ensuring its correct
location. Withdraw the element and check that there
is a continuous grease witness mark around the base
of the canister. This shows that the canister has not
been distorted which would allow unfiltered air to
bypass the element. Refit the element and cover.
Check all air hoses for condition and security.
B A
Fig 19.
3-42 9803/9410-4 3-42

Routine Maintenance
Engine
Changing the Inner Element
C035060
Fig 20.
1 Get access to the air filter. Refer to Access Panels,

Engine Cover.
2 To prevent dust getting into the engine, remove the

induction hose Y. Cover the hose to prevent rain and
dirt getting into the engine. K Fig 20. ( T 3-43).
3 Undo the two retaining clips holding the cover A and

remove the element B by twisting anti-clockwise.
4 Remove inner element G.
5 Clean inside of canister C and dust valve D with a

vacuum cleaner.
6 Smear the seal J of new inner element and carefully

insert into canister making sure that it seats correctly.
Withdraw element and check for continuous grease
witness mark on the canister base. Refit element.
7 Follow the same practice when fitting outer element,

this time smearing seal E with grease, inserting
element correctly, withdrawing and checking for
continuous grease witness mark. Refit element.
8 Remove cover from induction hose Y and refit. Check

security and condition of all air hoses.
Note: In a dusty working environment, the outer element

may have to be changed more frequently than the Service
Schedule recommendation. A new inner element must be
fitted at latest every third time the outer element is
changed. As a reminder, mark the inner element with a felt
tip pen each time the outer element is changed.
3-43 9803/9410-4 3-43

Routine Maintenance
Fuel System
Fuel System
Introduction
!MWARNING
Fuel
Fuel is flammable; keep naked flames away from the
fuel system. Stop the engine immediately if a fuel leak
is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel
which could cause a fire. There could be a fire and
injury if you do not follow these precautions.
INT-3-2-2_3
!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.
INT-3-3-12
!MCAUTION
Running the engine with air in the system could
damage the fuel injection pump. After maintenance,
the system must be bled to remove any air.
2-3-3-11
3-44 9803/9410-4 3-44

Routine Maintenance
Fuel System
Water Separator and Engine Fuel Filter

Draining the Fuel Filter/Sedimenter

Engine Cover.
2 Locate the sedimenter under the engine

compartment at the front in a central position.
3 If there is any sediment in the bowl replace the fuel

filter element. K Replacing the Fuel Filter
Element ( T 3-46). If there is water but no sediment,
drain off the water by opening tap B.
B
Fig 21.
3-45 9803/9410-4 3-45

Routine Maintenance
Fuel System
Replacing the Fuel Filter Element
If the bowl A contains sediment carry out the following:

Engine Cover.
2 Drain the sediment bowl A. K Draining the Fuel

Filter/Sedimenter ( T 3-45).
3 Unscrew the filter and sediment bowl from the filter

head B.
4 Unscrew the sediment bowl A from the filter C and

wash the bowl. Use clean fuel.
5 Re-assemble new filter to bowl and refit to filter head

B.
6 Bleed the system. K Bleeding the

System ( T 3-48).
Fig 22.
3-46 9803/9410-4 3-46

Routine Maintenance
Fuel System
Replacing the Fuel Pre Filter Element

Engine Cover.
2 Clamp the fuel hoses A. K Fig 23. ( T 3-47).
3 Disconnect the fuel hose clips B.
4 Remove the bolt C, Collect the washer, Remove the

fuel pre filter D.
5 Install new filter in reverse order.
6 Bleed the system. K Bleeding the

System ( T 3-48).
C B A
D B A
T016500
Fig 23.
3-47 9803/9410-4 3-47

Routine Maintenance
Fuel System
Bleeding the System 1 Get access to the engine. Refer to Access Panels,
Engine Cover.
!MWARNING 2 To bleed air from the filter, slacken bleed screw A.

To bleed the injectors you must turn the engine. When Switch ignition to ON position (This will start the
the engine is turning, there are parts rotating in the electric fuel pump). K Fig 24. ( T 3-48).
engine compartment.
3 Retighten bleed screw A when all air has been
Before starting this job make sure that you have no removed.
loose clothing (cuffs, ties etc) which could get caught
in rotating parts.
When the engine is turning, keep clear of rotating

parts.
2-3-3-8
T015790-2
Fig 24.
3-48 9803/9410-4 3-48

Routine Maintenance
Hydraulic System
Hydraulic System
Introduction !MCAUTION
!MWARNING Do not allow dirt to enter the system. Before
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
!MWARNING entering the system. Dirt in the system will seriously

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
3-49 9803/9410-4 3-49

Routine Maintenance
Hydraulic System
Releasing the Hydraulic Pressure

1 Make the machine safe with the boom lowered. Refer
to Prepare the Machine for Maintenance.
2 Operate the controls to remove the hydraulic

pressure from the service hose lines:
a For manually operated services, operate the

controls (several times) of the service(s) to be
disconnected.
b For electrical services, turn the starter key to the

ON position.
Operate the controls (several times) of the

service(s) to be disconnected. Set the starter
switch to the OFF position then remove the starter
key.
c Press the relevant console switch (to make the

relevant service active). Refer to Operation
Section.
Important: To release the hydraulic pressure from the

electrical and servo operated services the battery must be
connected while you operate the controls.
3 Carefully remove the hydraulic tank filler cap to vent

residual tank hydraulic pressure.
4 Install the hydraulic tank filler cap.
3-50 9803/9410-4 3-50

Routine Maintenance
Hydraulic System
Oil and Filter

Checking and Adjusting the Fluid Level
1 Make the machine safe with the boom lowered. Refer

to Prepare the Machine for Maintenance.
2 Check the Level
Open the engine cover and hydraulic bay cover.

K Access Panels ( T 3-29).
Check the level indicator A. The fluid level should be

visible in the level indicator. K Fig 25. ( T 3-51).
3 Top up fluid level if necessary
Remove filler cap B, add fluid. Ensure that only

correct grade of fluid is used. K Fluids, Lubricants
and Capacities ( T 3-12).
4 Refit the filler cap.
Fig 25.
3-51 9803/9410-4 3-51

Routine Maintenance
Hydraulic System
Replacing the Hydraulic Filter
1 Open the engine cover and hydraulic bay cover.

K Access Panels ( T 3-29).
2 Unscrew cap B and spring C. K Fig 26. ( T 3-52).
3 Withdraw bypass valve D, cartridge filter E and seal

F.
4 Clean all metal parts. Reassemble using new

cartridge filter E and seal F.
5 Top up hydraulic fluid. K Checking and Adjusting

the Fluid Level ( T 3-51)
6 Replace bypass valve D, spring C and cap B.
Fig 26.
3-52 9803/9410-4 3-52

Routine Maintenance
Tracks and Running Gear
Tracks
Checking the Track Gearbox Oil Level

2 Ensure that the gearbox plugs A and B are positioned

as shown. Stop the engine and remove starter key.
3 Clean the area around the fill/level plug A and remove

the plug, oil should be seen to be level with the hole.
4 Top up as necessary. K Fluids, Lubricants and

Capacities ( T 3-12). Clean and refit the plug, make
sure it is tight.
B
717260-6
Fig 27.
3-53 9803/9410-4 3-53

Routine Maintenance
Changing the Track Gearbox Oil

2 Place a suitable container beneath the drain plug B to

collect the oil.
!MCAUTION
Oil will gush from the hole when the drain plug is
removed. Keep to one side when you remove the plug.
2-3-4-2
3 Remove level/filler plug A. Remove the drain plug B.

Allow the oil to drain out. Wipe the drain plug clean.
Make sure that you remove all metal particles. Refit
the drain plug. Make sure it is tight.
4 Fill with new oil through the fill/level plug hole until oil
runs from the hole. K Fluids, Lubricants and
Capacities ( T 3-12).
5 Run the machine, operate the track controls and then

make sure there are no leaks.
B
717260-6
Fig 28.
3-54 9803/9410-4 3-54

Routine Maintenance
Checking the Track Tension 3 Check the Tension:
!MCAUTION Check that the tension measurement at A is between

60mm (2.4in) and 65mm (2.6in) for rubber tracks and
Recoil unit servicing must only be carried out by JCB 120mm (4.8in.) for steel tracks. K Fig 29. ( T 3-55)
distributors. You could be killed or injured if you
tamper with it.
8-3-3-4
!MCAUTION
Always make sure that the track tension measurement
1 Prepare the Machine is not less than specified or severe strain to the track
will result.
Park the machine on level ground. Run it backwards 8-3-3-3
and forwards several times. Stop the machine after
running it forwards. 4 Adjust the track tension.
2 Set the machine in the posture shown with the track a To tighten the track:
to be checked raised from the ground and supported.
K Fig 29. ( T 3-55). Pump grease through nipple B in adjusting screw
C until track tension is correct. K Fluids,
Lubricants and Capacities ( T 3-12).
Fig 29.
Rotate track and re-check dimension A. 5 Refit the cover plate. Lower the track to the ground.
b To slacken the track: Note: Track tension will increase during rotation. Check
the track tension at its tightest point to avoid over
Slacken adjusting screw C until track tension is tensioning.
correct.
Rotate track and re-check dimension A.
3-55 9803/9410-4 3-55

Routine Maintenance
Fire Extinguisher (if fitted)
Fire Extinguisher (if fitted)

T3-022
Checking the Fire Extinguisher

Check the fire extinguisher for damage, security and signs
of leaking.
Check that the gauge A indicates that the extinguisher is

charged i.e. the needle is in the GREEN segment.
Note: If the needle is in or very near the RED segment at

either end of the gauge, the extinguisher must be serviced
or replaced.
Make sure the safety pin B is fitted and secure.
The extinguisher should be serviced every 12 months by a Fig 30.

suitably qualified person.
3-56 9803/9410-4 3-56

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Section 3

1-0 9803/9410-4 1-0

Contents Page No.

Contents Page No.

3-1 9803/9410-4 3-1

The data plate also shows the serial numbers of the

3-2 9803/9410-4 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 9803/9410-4 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 with sand or a locally approved brand of absorbent

Extinguish oil and lubricant fires with carbon dioxide,

3-4 9803/9410-4 3-4

Battery electrolyte contains sulphuric acid. It can burn

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

3-5 9803/9410-4 3-5

A289260-1 Gets onto your skin

Note operating instructions.

3-6 9803/9410-4 3-6

Introduction How to Use the Service Schedules

!MWARNING In the example shown, A shows all service requirements to

A badly maintained machine is a danger to the operator

Apart from the daily jobs, the schedules are based on

3-7 9803/9410-4 3-7

3-8 9803/9410-4 3-8

Pre Start Cold Checks, Service Points and Fluid Levels

Operation 10 50 500 1000 2000

3-9 9803/9410-4 3-9

Operation 10 50 500 1000 2000

(1) Jobs which should only be done by a specialist.

3-10 9803/9410-4 3-10

Functional Test and Final Inspection

Operation 10 50 500 1000 2000

(1) Jobs which should only be done by a specialist.

3-11 9803/9410-4 3-11

Fluids, Lubricants and Capacities

3-12 9803/9410-4 3-12

Check the strength of the coolant mixture at least once a

Replace the coolant mixture according to the intervals

You must dilute full strength antifreeze with clean water

The correct concentration of antifreeze protects the engine

The protection provided by JCB High Performance

50% Concentration (Standard)

60% Concentration (Extreme Conditions Only)

Important: Do not exceed a 60% concentration, as the

If you use any other brand of antifreeze:

– Ensure that the antifreeze complies with International

3-13 9803/9410-4 3-13

ASTM D975-076 2-D, US DF1, US DF2, US

JET B (ASTM D1655)

3-14 9803/9410-4 3-14