General Information 1
Care & Safety 2
R
Routine Maintenance 3
Attachments A
Service Body & Framework
B
Manual Electrics C
JS130
from machine no. 758000
Hydraulics E
JS160 Transmission F
from machine no. 702000
Brakes G
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE: ©
WORLD PARTS CENTRE
UTTOXETER, STAFFORDSHIRE, ST14 7BS,
ENGLAND
Track & Running Gear J
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9803/6410
Issue 1
Engine K
,Introduction
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training
by JCB Technical Training Department.
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated
with the maintenance and repair of hydraulic earthmoving equipment.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of
course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe
connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all
else SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools.
2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for the whole machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for
example:
A = Attachments
B = Body & Framework ...etc
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later
issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.
‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.
Note: In this manual the term ‘swing’ may sometimes be used in place of ‘slew’ and the term ‘arm’ may sometimes be used in
place of ‘dipper’.
9803/6410 Issue 1
,Section 1 General Information Section 1
i i
Contents Page No.
Bolt and Nut Torque Specifications 1-1
Torque Settings 1-2
Service Tools
* Section B - Body and framework 3-1
Section C - Electrics 4-1
Section E - Hydraulics 5-1
* Section F - Transmission 6-1
*Sealing and Retaining Compounds 7-1
9803/6410 Issue 2*
, Section 1 General Information Section 1
1-1 Bolt and Nut Torque Specifications 1-1
JS130/JS160 and Variants
Tighten the bolts and nuts according to the table. Before and after daily work, check the bolts and nuts for looseness and
for those missing. Tighten if loose and renew if missing.
Tighten the bolts and nuts after the first 50 hours of the running-in stage and every 250 hours thereafter.
Tightening Torque Table
JS130/JS160
No Tightening Point Bolt Diameter Wrench Tightening Torque
mm Nm kgf m lbf ft
1† Travel Motor M16 24 270~310 27.6~31.8 200~230
2† Drive Sprocket M16 24 220~310 27.6~31.8 200~230
3† Idler Wheel M16 24 270~310 27.6~31.8 200~230
4† Upper (Carrier) Roller M16/M20 24/30 270~310/520~608 27.6~31.8/53.2~62.2 200~230/385~450
5† Lower (Track) Roller M16 24 270~310 27.6~31.8 200~230
6† Track Guard M16 24 270~310 27.6~31.8 200~230
* 7 Shoe Bolt M16 24 310~360/640~750 32~37/65~76.5 229~266/472~553
8 Counter weight M27 41 845~980 86~100 622~723
9† Turntable Bearing (Undercarriage) M16/M20 24 280~310/475~550 28.4~31.8/48.4~55.3 205~230/350~400
10† Turntable Bearing (Slew Frame) M16/M20 24 280~310/475~550 28.4~31.8/48.4~55.3 205~230/350~400
11† Slew Equipment M16/M20 24 280~310/475~550 28.4~31.8/48.4~55.3 205~230/350~440
12† Engine (Engine Mount) M16 24 265~310 27~32 195~230
13† Engine Bracket M10 17 65~75 6.5~7.6 47~55
14 Radiator M12 19 60~70 6.2~7.2 45~52
15† Hydraulic Pump M10 17 65~75 6.5~7.6 47~55
16† Hydraulic Oil Tank M16 24 205~285 21~29 152~210
17† Fuel Tank M16 24 225~285 22.4~29 162~210
18† Control Valve M16 24 270~310 27.6~31.8 200~230
19† Rotary Coupling M12 19 110~125 11.1~13.0 80~94
20 Cab M16 24 127~137 13~14 94~101
21 Battery M10 17 20~30 2.1~2.9 15~21
* Note: Use JCB Threadlocker and Sealer (High Strength) (adhesive) on those marked † and tighten to the torque listed in the
above table.
The tightening torques for the bolts and nuts not listed above are as follows:
Bolt Diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench mm 10 13 17 19 22 24 27 30
Hex. bolt Nm 6.9 15.7 32.3 58.8 98.0 137.2 196.0 274.4
Tightening
kgf m 0.7 1.6 3.2 5.9 9.8 13.7 19.6 27.4
Torque
lbf ft 5 12 24 43 72 101 145 202
Wrench mm 5 6 8 10 12 14 14 17
Hex. socket head Nm 8.8 21.6 42.1 78.4 117.6 176.4 245.0 343.0
Tightening
bolt kgf m 0.88 2.2 4.2 7.8 11.8 17.6 24.5 34.3
Torque
lbf ft 6.5 16 31 58 87 130 181 253
9803/6410 Issue 2*
Care & Safety 2
R
Routine Maintenance 3
Attachments A
Service Body & Framework
B
Manual Electrics C
JS130
from machine no. 758000
Hydraulics E
JS160 Transmission F
from machine no. 702000
Brakes G
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE: ©
WORLD PARTS CENTRE
UTTOXETER, STAFFORDSHIRE, ST14 7BS,
ENGLAND
Track & Running Gear J
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9803/6410
Issue 1
Engine K
,Introduction
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training
by JCB Technical Training Department.
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated
with the maintenance and repair of hydraulic earthmoving equipment.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of
course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe
connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all
else SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools.
2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for the whole machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for
example:
A = Attachments
B = Body & Framework ...etc
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later
issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.
‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.
Note: In this manual the term ‘swing’ may sometimes be used in place of ‘slew’ and the term ‘arm’ may sometimes be used in
place of ‘dipper’.
9803/6410 Issue 1
,Section 1 General Information Section 1
i i
Contents Page No.
Bolt and Nut Torque Specifications 1-1
Torque Settings 1-2
Service Tools
* Section B - Body and framework 3-1
Section C - Electrics 4-1
Section E - Hydraulics 5-1
* Section F - Transmission 6-1
*Sealing and Retaining Compounds 7-1
9803/6410 Issue 2*
, Section 1 General Information Section 1
1-1 Bolt and Nut Torque Specifications 1-1
JS130/JS160 and Variants
Tighten the bolts and nuts according to the table. Before and after daily work, check the bolts and nuts for looseness and
for those missing. Tighten if loose and renew if missing.
Tighten the bolts and nuts after the first 50 hours of the running-in stage and every 250 hours thereafter.
Tightening Torque Table
JS130/JS160
No Tightening Point Bolt Diameter Wrench Tightening Torque
mm Nm kgf m lbf ft
1† Travel Motor M16 24 270~310 27.6~31.8 200~230
2† Drive Sprocket M16 24 220~310 27.6~31.8 200~230
3† Idler Wheel M16 24 270~310 27.6~31.8 200~230
4† Upper (Carrier) Roller M16/M20 24/30 270~310/520~608 27.6~31.8/53.2~62.2 200~230/385~450
5† Lower (Track) Roller M16 24 270~310 27.6~31.8 200~230
6† Track Guard M16 24 270~310 27.6~31.8 200~230
* 7 Shoe Bolt M16 24 310~360/640~750 32~37/65~76.5 229~266/472~553
8 Counter weight M27 41 845~980 86~100 622~723
9† Turntable Bearing (Undercarriage) M16/M20 24 280~310/475~550 28.4~31.8/48.4~55.3 205~230/350~400
10† Turntable Bearing (Slew Frame) M16/M20 24 280~310/475~550 28.4~31.8/48.4~55.3 205~230/350~400
11† Slew Equipment M16/M20 24 280~310/475~550 28.4~31.8/48.4~55.3 205~230/350~440
12† Engine (Engine Mount) M16 24 265~310 27~32 195~230
13† Engine Bracket M10 17 65~75 6.5~7.6 47~55
14 Radiator M12 19 60~70 6.2~7.2 45~52
15† Hydraulic Pump M10 17 65~75 6.5~7.6 47~55
16† Hydraulic Oil Tank M16 24 205~285 21~29 152~210
17† Fuel Tank M16 24 225~285 22.4~29 162~210
18† Control Valve M16 24 270~310 27.6~31.8 200~230
19† Rotary Coupling M12 19 110~125 11.1~13.0 80~94
20 Cab M16 24 127~137 13~14 94~101
21 Battery M10 17 20~30 2.1~2.9 15~21
* Note: Use JCB Threadlocker and Sealer (High Strength) (adhesive) on those marked † and tighten to the torque listed in the
above table.
The tightening torques for the bolts and nuts not listed above are as follows:
Bolt Diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench mm 10 13 17 19 22 24 27 30
Hex. bolt Nm 6.9 15.7 32.3 58.8 98.0 137.2 196.0 274.4
Tightening
kgf m 0.7 1.6 3.2 5.9 9.8 13.7 19.6 27.4
Torque
lbf ft 5 12 24 43 72 101 145 202
Wrench mm 5 6 8 10 12 14 14 17
Hex. socket head Nm 8.8 21.6 42.1 78.4 117.6 176.4 245.0 343.0
Tightening
bolt kgf m 0.88 2.2 4.2 7.8 11.8 17.6 24.5 34.3
Torque
lbf ft 6.5 16 31 58 87 130 181 253
9803/6410 Issue 2*
