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

Maintenance must be done only by suitably qualified
and competent persons.
Before doing any maintenance make sure the machine
is safe, it should be correctly parked on level ground.
be carried out every 10 hours and B shows the
requirements to be carried out every 500 hours.
Important: Services should be carried out at either the
hourly interval or calendar interval, whichever occurs first.
Refer to Calendar Equivalents.

To prevent anyone starting the engine, remove the
starter key. Disconnect the battery when you are not
using electrical power. If you do not take these
precautions you could be killed or injured.
8-3-1-1
Important: The intervals given in the schedules must not
be exceeded. If the machine is operated under severe
conditions (high temperature, dust, water, etc.), shorten
the intervals.

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

Calendar Equivalents
T3-037
Every 10 Hours = Daily
Every 50 Hours = Weekly
Every 500 Hours = Six Months
Every 1000 Hours = Yearly
Every 2000 Hours = 2 Years
Every 8000 Hours = 8 Years

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 Routine Maintenance
Service Schedules

Pre-start Cold Checks, Service Points

and Fluid Levels
Note: More frequent checks of engine components than
the engine manufacturer recommends do not invalidate
emissions warranty.

Table 10. Engine

Operation 10 50 100(1) 500 1000 2000
Oil - Level and condition Check      
Coolant - Level Check      
Air intake piping(2) Check      
Cooling fan(2) Check      
Crankcase breather tubes Check      
Drive belts(2) Check      
Fuel sedimenter/Water seperator Drain      
Charge air cooler and piping(3) Clean/Check      
Air cleaned restriction meter Check    
Air cleaner primary/outer element(4) Change  
Air cleaner secondary/inner element(10) Change 
Fuel system for leaks and contamination Check      
Fuel sedimenters/water separators Drain      
Fuel filter cum water separator (10 micron) Change   
Fuel filter element (2 micron) Change   
Fuel filter three layer element (2 micron) Change  
Radiator and hoses(2)(5) Clean/Check
Radiator pressure cap (6) Check    
Oil and filter(7) Change   
Coolant - Strength and condition Check    
Drive belt - Condition(2) Check    
Drive belts Replace  
Automatic belt tensioner Check   
Compressor discharge lines (8) Clean 
Coolant Change 
Crankcase breather element(8) Change 
Vibration damper Check 
Engine - Steam clean Clean 
Air filter elements(9) Change
Overhead-set (10) Check/Adjust

(1) First 100 Hours Service only, to be completed by your JCB Dealer.
(2) Check for wear, damage and security, replace if necessary.

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 Routine Maintenance
Service Schedules
(3) Check for cracks, holes and other damage.
(4) Change the outer element more frequently in dusty operating environments.
(5) Check every 250 hours.
(6) Make sure the cap is the correct type, either normal duty (15 psi) or light duty (7 psi).
(7) In arduous conditions change the oil and filter after every 250 hours or three months (whichever comes first).
(8) To be done by your local JCB Dealer.
(9) A change is dependant on the Air Cleaner Restrictor. Change the secondary element every other time the primary
element is changed.
(10) Every 5000 hour or four years.

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 Routine Maintenance
Service Schedules
Table 11. Transmission and Axles
Operation 10 50 100(1) 500 1000 2000
Transmission oil - level Check      
Tyres - pressures and condition Check      
Wheel nut - security Check      
Driveshaft, universal joints and rear axle pivot Grease(2)    
Transmission mounts security Check   
Axle breathers(3) Clean/Check    
Axle mount and driveshaft - security Check   
Bevel ring gear - deflection plunger Check  
Transmission oil (4) Change   
Transmission filter (5) Change    
Axle and hub oil Check      
Axle and hub oil Change   

(1) First 100 Hours Service only, to be completed by your JCB Dealer.
(2) Grease more frequently when the machine is operated in arduous conditions.
(3) Replace if necessary
(4) At every oil change, it is recommended to carry out AEB calibration i.e. automatic filling procedure for clutch using
AEB Calibration tool.
(5) At every oil change, transmission filter must be changed.

Table 12. Hydraulics

Operation 10 50 100(1) 500 1000 2000
Oil level Check      
Hydraulic tank breather Check   
Oil Sample   
Oil filter Change    
Hoses, rams and pipe-work - Damage Check      
Oil and hydraulic tank breather Change 
Suction strainers (x2) Clean 

(1) First 100 Hours Service only, to be completed by your JCB Dealer.

Table 13. Brakes

Operation 10 50 100(1) 500 1000 2000
Park brake - Operation Check      
Foot brake - Operation Check      

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 Routine Maintenance
Service Schedules

Operation 10 50 100(1) 500 1000 2000

Brake wear (2) Check 

(1) First 100 Hours Service only, to be completed by your JCB Dealer.
(2) Check every 1500 hours.

Table 14. Electrics

Operation 10 50 100(1) 500 1000 2000
Instrument panel - Operation Check      
Battery - Electrolyte level (If applicable) Check    
Battery terminals - Condition and tightness Check    
Battery - Charge and condition Check   
Wiring - Chaffing and routing Check   

(1) First 100 Hours Service only, to be completed by your JCB Dealer.

Table 15. Bodywork and Cab

Operation 10 50 100(1) 500 1000 2000
Machine Condition - General Check     
Autolube reservoir level (Option) (2) Check      
Window washer fluid - Level Check      
Seat/Seat belt - Condition and security Check      
Check the machine for leaks (For example engine oil and Check      
hydraulic fluid)
All pivot-pins, loader arms, centre pivot, rear axle pivots, Grease(3)    
steer rams and the Quickhitch locking-pins (Option)
Autolube reservoir filler filter (Option) Change   
Hinges Lubricate   
Cab heater intake filter(s) Clean(4)   
ROPS/FOPS Check  

(1) First 100 Hours Service only, to be completed by your JCB Dealer.
(2) Top-up as necessary.
(3) Grease more frequently when operating in arduous conditions.
(4) Clean more frequently when the machine is operated in a dusty operating environment.

Table 16. Lifting Equipment

Operation 10 50 100(1) 500 1000 2000
Fit for purpose test(2) Complete   

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 Routine Maintenance
Service Schedules

(1) First 100 Hours Service only, to be completed by your JCB Dealer.
(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.

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 Routine Maintenance
Service Schedules

Functional Test and Final Inspection

Table 17. Engine
Operation 10 50 100(1) 500 1000 2000
Exhaust system - Security Check    
Air inlet system - Security Check    
Idle speed Check   
Torque converter - Stall speed Check   
Maximum no load speed Check   
Throttle system Check   
Exhaust smoke Check   
Combined stall speed Check  

(1) First 100 Hours Service only, to be completed by your JCB Dealer.

Table 18. Transmission, Axles and Steering

Operation 10 50 100(1) 500 1000 2000
Transmission - Operation Check      
Forward/reverse/speed range - Operation Check      
Neutral start - Operation Check      
Steering - Operation Check      
Oil cooler and pipe-work Check   

(1) First 100 Hours Service only, to be completed by your JCB Dealer.

Table 19. Hydraulics

Operation 10 50 100(1) 500 1000 2000
Piston rods and gland seals Check    

(1) First 100 Hours Service only, to be completed by your JCB Dealer.

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 Routine Maintenance
Service Schedules
Table 20. Electrics
Operation 10 50 100(1) 500 1000 2000
Gauges and warning lights Check      
Wiper motors Check      
Cab switches - Operation Check      
Horn Check      
Heater (Option) Check      
Reverse alarm (Option) Check      
Lights and indicators (Option) Check      
Proximity sensor - Operation Check      
Starter motor and alternator - Connections Check  

(1) First 100 Hours Service only, to be completed by your JCB Dealer.

Table 21. Bodywork and Cab

Operation 10 50 100(1) 500 1000 2000
Air conditioning (Option) Check      
Tool kit and operator manual Check      
Paintwork - Condition Check   
Doors and hinges Check 

(1) First 100 Hours Service only, to be completed by your JCB Dealer.

Table 22. Attachments

Operation 10 50 100(1) 500 1000 2000
Attachment - Condition and operation Check     

(1) First 100 Hours Service only, to be completed by your JCB Dealer.

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 Routine Maintenance
Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities

Specifications

JCB recommend that you use the JCB lubricants shown as they have been verified by JCB for use on JCB machines.
However, you could use other lubricants that are equivalent to the JCB standards and quality or offer the same machine
component protection.

Table 23.
Item Capacity Fluid/Lubricant JCB Part
(Litres) Number
Fuel System 310 Diesel, Refer to K Fuels ( T 120)
Fuel Additive (1) 90ml per 80 FAST Exocet X01236D 4005/0801
litres of fuel
Engine - Oil 28 Engine Oil CI 4+ (-10 to 50ºC) 4001/3200
Cold Climate (-20ºC+) 10W40 4001/2000
Engine - Coolant 37 JCB Antifreeze HP Coolant 229/01233
JIS K2234 class II (Non Aminic) 4006/1115
4006/1110
Transmission(2) 38 UTTO oil (JCB gear oil HP Plus) 4000/2200
JCB rear axle oil 4000/4600
JCB HP Universal ATF 4000/2300
ZF TE-MIL 06, 11, 12, 14
API-GL-3 SAE 10W30
Cold Climate (JCB EP gear oil plus) 4000/4200
API-GL-4 SAE 10W30
Axles 70 UTTO oil (JCB gear oil HP Plus) 4000/2200
JCB rear axle oil
JCB HP Universal ATF
ZF TE-MIL 06, 11, 12, 14
API-GL-3 SAE 10W30
Hydraulic System(3) 180 HVI Hydraulic Oil 229/00024
Cold climate grade 32 4002/1000
Grease Points JCB Special HP Grease(4) 4003/2000
Lithium complex NLGI 2 4003/2017
Auto Greasing System (Option) JCB special HP Grease 4003/2000

(1) Fuel additive must be added in fuel for cold climate region machines (below -20ºC)
(2) The figure shown is the total capacity of the system. Use the maximum and the minimum marks on the dipstick when
you fill the system.
(3) The total capacity of the hydraulic system depends on the equipment being used. Fill the system with all of the rams
closed and monitor the level in the sight gauge.
(4) If JCB Special MPL Grease is used for normal greasing, all of the 100 hour greasing operations must be done at ten
(10) hour intervals.

Note: No warranty liability will be accepted for engine equivalent) have been used at any stage.
failures where unacceptable fuel grades (or their

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 Routine Maintenance
Fluids, Lubricants and Capacities

Anti-Corrosion Additives If you use any other brand of antifreeze:

!MWARNING – Ensure that the antifreeze complies with International

Specification ASTM D6210.
Antifreeze can be harmful. Obey the manufacturer's – Always read and understand the manufacturer's
instructions when handling full strength or diluted instructions.
antifreeze. – Ensure that a corrosion inhibitor is included. Serious
7-3-4-4_1 damage to the cooling system can occur if corrosion
inhibitors are not used.
To provide sufficient corrosion protection, Supplemental
– Ensure that the antifreeze is ethylene glycol based
Coolant Additive (SCA) must be added to the coolant
and does not use Organic Acid Technology (OAT).
mixture. The coolant filter provides the required amount of
SCA, provided the filter is replaced at regular intervals.
Fuels
Coolant Mixtures
Acceptable and Unacceptable Fuels
T3-009_4

Check the strength of the coolant mixture at least once a

Important: No warranty liability will be accepted for engine
year, preferably at the start of the cold period.
failures where unacceptable fuel grades (or their
equivalent) have been used at any stage.
Replace the coolant mixture according to the intervals
shown in the machine's Service Schedule.
Fuel Groups

!MWARNING The major world fuels standards are divided into four
categories. Those that are fully accepted as suitable fuels,
Antifreeze can be harmful. Obey the manufacturer's
those that are acceptable from a "warranty" point of view,
instructions when handling full strength or diluted
but may have undesirable affects on the expected life of
antifreeze.
the engine performance changes from original
7-3-4-4_1
specification, those that will lead to reduce the expected
life, and lastly those that are viewed as unacceptable for
You must dilute full strength antifreeze with clean water
use. (Note: fuels shown on the same line as each other are
before use. Use clean water of no more than a moderate
considered equivalents).
hardness (pH value 8.5). If this cannot be obtained, use
de-ionized water. For further information advice on water
The lists below are not exhaustive of all diesel fuel
hardness, contact your local water authority.
standards encountered in the marketplace. If comment is
required on the suitability of fuel standards not on the list,
The correct concentration of antifreeze protects the engine
requests with, if possible, specification details showing at
against frost damage in winter and provides year round
least the key characteristics described above should be
protection against corrosion.
forwarded to JCB Service for assessment and comment.
As an example, the protection provided by JCB High
Performance Antifreeze and Inhibitor is given 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.

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