jcb JS 200 Series User manual

Service
Manual
JS200
from machine no. 705001
JS210
from machine no. 705648
JS220
from machine no. 705001
JS240
from machine no. 708001
JS260
from machine no. 708501
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; ©
WATERLOO PARK, UTTOXETER,
STAFFORDSHIRE, ST14 5PA, ENGLAND
Tel. ROCESTER [phone]
PRINTED IN ENGLAND
Publication No. 9803/6400
R
General Information
Care & Safety
Routine Maintenance
Attachments
Body & Framework
Electrics
1
2
3
A
B
C
Hydraulics E
F
Transmission
G
Brakes
J
Track & Running Gear
K
Engine
Issue 2

9803/6400 Issue 1
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 = Optional Equipment
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.
Page cross references are generally made by presenting the subject title printed in bold, followed by the title of the section
containing the subject. For example:
“24 If the axle is still on the machine, fit the brake calipers (see Brake Caliper Removal and Replacement, Section G).”
Note: If only the subject title in bold is given, i.e. no section title, the cross reference is to another part of the same section.
Use the contents list at the beginning of each section to find the exact page number.
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.

Contents Page No.
Bolt and Nut Torque Specifications 1 - 1
Service Tools
Section C - Electrics 4 - 1
Section E - Hydraulics 5 - 1
Section F - Transmission 6 - 1
Sealing and Retaining Compounds 7 - 1
i
General Information
9803/6400
i
Issue 2*
Section 1 Section 1
*
*
*

1 - 1
Section 1 General Information
9803/6400
Section 1
1 - 1
Issue 3*
*
Bolt and Nut Torque Specifications
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 replace 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
Note: Use Loctite 262 (adhesive) on those marked † and tighten to the torque listed in the above table.
The tightening torque for the bolts and nuts not listed above are as follows:
JS200/210/220/240/260
No Tightening Point Bolt Diameter Wrench Tighten Torque
Nm kgf m lbf ft
1† Travel Motor M16 24mm
270~310 27.2~31.8 200~230
2† Drive Sprocket M16 24mm
270~310 27.2~31.8 200~230
3† Idler Wheel M16 24mm 270~310 27.2~31.8 200~230
4† Upper (Carrier) Roller M20 30mm 520~608 53.2~62.2 385~450
5† Lower (Track) Roller M18 27mm
370~430 37.8~44.1 275~315
6† Track Guard M18 27mm 380~440 38.7~45.2 280~325
7Shoe Bolt M16 24mm 380~450 38.7~46.0 275~330
8Counter weight M27/M30 41/46mm
1058~1235/1335~1545 1
08~126/136~158 780~910/985~1140
9† Turntable Bearing (Undercarriage) M20/M24 30/36mm 475~550/780~910 48.4~55.3/80~93 350~400/575~670
10† Turntable Bearing (Slew Frame) M20/M24 30/36mm 475~550/780~910 48.4~55.3/80~93 350~400/575~670
11† Slew Equipment M20/M24 30/36mm
525~605/785~910 53.1~62/80~93 390~440/580~670
12† Engine (Engine Mount) M16 24mm 265~310 27.0~32 195~230
13† Engine Bracket M10 17mm 65~75 6.6~7.6 47~55
14 Radiator M16 24mm
150~175 15~18 108~130
15† Hydraulic Pump M10 17mm 65~75 6.6~7.6 47~55
16† Hydraulic Oil Tank M16 24mm 235~285 23.7~29.5 175~210
17† Fuel Tank M16 24mm
255~285 25.7~29.5 185~210
18† Control Valve M16 24mm 270~310 27.6~31.8 200~230
19† Rotary Coupling M12 19mm 110~125 11.1~13 80~94
20 Cab M16 24mm
127~135 13~14 94~101
21 Battery M10 17mm 20~30 2.1~2.9 15~21
Bolt Diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench mm 10 13 17 19 22 24 27 30
Hex. bolt Tightening Nm 6.9 15.7 32.3 58.8 98.0 137.2 196.0 274.4
Torque kgf m 0.7 1.6 3.2 5.9 9.8 13.7 19.6 27.4
lb ft 5 12 24 43 72 101 145 202
Wrench mm 5 6 8 10 12 14 14 17
Hex. socket head Tightening Nm 8.8 21.6 42.1 78.4 117.6 176.4 245.0 343.0
bolt Torque kgf m 0.8 2.2 4.2 7.8 11.8 17.6 24.5 34.3
lb ft 6.5 16 31 58 87 130 181 253

4 - 1
Section 1 General Information
9803/6400
Section 1
4 - 1
Issue 2*
Service Tools
SECTION C - ELECTRICS
Electrical Test Equipment
1892/00283 Tool Kit Case
2892/00281 AVO Meter
3892/00286 Surface Temperature Probe
4892/00284 Microtach Digital Tachometer
5892/00282 Shunt - open type
6892/00285 Hydraulic Oil Temperature Probe
7892/00298 Fluke 85 Multimeter
993/85700 Battery Tester
*

Service Tools (continued)
SECTION E - HYDRAULICS
5 - 1
Section 1 General Information
9803/6400
Section 1
5 - 1
Issue 1
Pressure Test ‘T’ Adapters
892/00262 1/4 in BSP x 1/4 in F BSP x Test Point
816/55038 3/8 in BSP x 3/8 in F BSP x Test Point
816/55040 1/2 in BSP x 1/2 in F BSP x Test Point
892/00263 5/8 in BSP x 5/8 in F BSP x Test Point
892/00264 3/4 in BSP x 3/4 in F BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point
892/00266 1,1/4 in M BSP x 1,1/4 in F BSP x Test Point
892/00267 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point
Pressure Test Adapters
892/00255 1/4 in BSP x Test Point
892/00256 3/8 in BSP x Test Point
892/00257 1/2 in BSP x Test Point
892/00258 5/8 in BSP x Test Point
816/15118 3/4 in BSP x Test Point
892/00259 1 in BSP x Test Point
892/00260 1,1/4 in BSP x Test Point
892/00261 5/8 in UNF x Test Point
Hydraulic Pressure Test Gauges and Connections
1892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2)
2892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2)
3892/00347 Connector
4892/00254 Hose
1/2
34

5 - 2
Section 1 General Information
9803/6400
Section 1
5 - 2
Issue 1
Service Tools (continued)
SECTION E - HYDRAULICS
Hand Pump Equipment
892/00223 Hand Pump
892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
892/00706 Test Probe
892/00278 Gauge 0 - 40 bar (0 - 600 lb/in2)
892/00279 Gauge 0 - 400 bar (0 - 6000 lb/in2)
892/00280 Gauge 0 - 600 bar (0 - 8500 lb/in2)
816/50005 1/2 in BSP (A) x 1/2 in BSP (B)
816/60096 3/4 in BSP (A) x 3/4 in BSP (B)
816/00018 1 in BSP (A) x 1 in BSP (B)
Female Cone Blanking Plug
892/00055 1/4 in BSP
892/00056 3/8 in BSP
892/00057 1/2 in BSP
892/00058 5/8 in BSP
892/00059 3/4 in BSP
892/00060 1 in BSP
Male Cone Blanking Plug
816/00294 1/4 in BSP
816/00189 3/8 in BSP
816/00190 1/2 in BSP
816/00197 5/8 in BSP
816/00196 3/4 in BSP
816/00193 1 in BSP

5 - 3
Section 1 General Information
9803/6400
Section 1
5 - 3
Issue 1
Service Tools (continued)
SECTION E - HYDRAULICS
Slew Motor Jig
SST0033 Oil Seal Jig
SST0034 Taper Bearing Ring Jig
SST0035 Inner Ring Jig
SST0036 Seal Press Fit Jig
(All dimensions are in mm.)
4
2
ø31
ø40
50
60
ø50
ø99.8
ø124
ø158
3
3015915
15°
SST0033
SST0034
SST0035
SST0036

5 - 4
Section 1 General Information
9803/6400
Section 1
5 - 4
Issue 1
Service Tools (continued)
SECTION E - HYDRAULICS
Ram Dismantling and Assembly
Ram Piston Head Nut (Rig Assembly - Section E, page 75 - 10)
Item Part Number Description Quantity
1 993/99525 Rig assembly (not including spanners and ram) 1
2 993/99522 Anchor side plate (supplied loose unwelded) 1
3 993/99523 Anchor cross member (supplied loose unwelded) 1
4 993/99524 Ram eye end modification 1
5 556/43400 Lift ram 1
6 545/18000 Lynch pin 1
7 811/50232 11/4in Pivot pin 1
Spanner Requirements
JS200/JS200LC/JS220/JS220LC
993/99518 Bucket ram 90 mm A/F Nut
SSP0047 Boom ram 95 mm A/F Nut
993/99519 Dipper ram 100 mm A/F Nut
JS240/JS240LC/JS260/JS260LC
993/99519 Bucket ram 100 mm A/F Nut
993/99519 Boom ram 100 mm A/F Nut
993/99521 Dipper ram 115 mm A/F Nut
Note: All spanners have operating centres of 500 mm.

6 - 1
Section 1 General Information
9803/6400
Section 1
6 - 1
Issue 1
Service Tools (continued)
SECTION F - TRANSMISSION
Track Motor Jig
SST0028 Inner Rail Press Jig
SST0029 Snap Ring Jig
SST0030 Oil Seal Jig
SST0031 Case Fixing Jig
SST0032 Bearing Jig
(All dimensions are in mm.)
ø49.5
100
ø40.5
70
ø59.5
10
ø40
SST0028 SST0029
SST0030 SST0031
SST0032
ø115
ø65
185
140
ø61.5
ø45
180
ø54
ø50.5

6 - 2
Section 1 General Information
9803/6400
Section 1
6 - 2
Issue 1
Service Tools (continued)
SECTION F - TRANSMISSION
Track Gearbox Jig
SST0037 Re-sealing Tool
SST0038 Main Bearing Tool
SST0039 Main Bearing Tool
(All dimensions are in mm.)
SST0037
SST0038
SST0039
24
21
ø315
ø270
ø304
ø306
14
M10
62
52
20
Ø230
Ø182.5
Ø44
10
220
72°
72°
Ø240
Ø250
195
Chamfer 1 x 45° Chamfer 1 x 45°
R40

6 - 3
Section 1 General Information
9803/6400
Section 1
6 - 3
Issue 1
Service Tools (continued)
SECTION F - TRANSMISSION
Track Gearbox Jig
SST0040 Ring Nut Tool
SST0041 Planet Gear Tool
(All dimensions are in mm.)
SST0040
SST0041
ø233.5
ø248
ø265
30
8
90
30
38.1sq
ø9.7
11
1.5x45°
ø9.5 no.4 dowel
M4x4 no.4 screw
1x45°
30
20
8
R2
Ø35
Ø56
Ø46
1.5X4.5°
R.8

7 - 1
Section 1 General Information
9803/6400
Section 1
7 - 1
Issue 2*
*Sealing and Retaining Compounds
JCB Multi-Gasket A medium strength sealant suitable for all sizes of gasket 4102/1212 50 ml
flanges, and for hydraulic fittings of 25-65 mm diameter.
JCB Threadlocker For threads of 50 mm diameter upwards, 4101/0451 50 ml
e.g. suction strainer.
JCB Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml
(High Strength) components. Gasketing for all sizes of flange where
the strength of the joint is important.
JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/0651 50 ml
JCB Threadlocker and Sealer A medium strength locking fluid for sealing and retaining 4101/0250 10 ml
nuts, bolts, and screws up to 50 mm diameter, and 4101/0251 50 ml
for hydraulic fittings up to 25 mm diameter.
JCB Threadlocker and Sealer A high strength locking fluid for sealing and retaining 4101/0550 10 ml
(High Strength) nuts, bolts, and screws up to 50 mm diameter, and for 4101/0552 200 ml
hydraulic fittings up to 25 mm diameter.
JCB Threadseal A medium strength thread sealing compound. 4102/1951 50 ml
JCB Activator A cleaning primer which speeds the curing rate of 4104/0251 Aerosol (1 ltr)
anaerobic products. 4104/0253 Bottle (200 ml)
JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic 4104/1557 Aerosol (400 ml)
adhesives and sealants.
Anti-Seize Paste A compound used for assembly and prevention of 4003/0211
parts seizure.
Direct Glazing Kit For one pane of glass; comprises items marked †below
plus applicator nozzle etc.
† Ultra Fast Adhesive For direct glazing 4103/2109 310 ml
† Active Wipe 205 For direct glazing 4104/1203 250 g
† Black Primer 206J For direct glazing 4201/4906 30 ml
Clear Silicone Sealant To seal butt jointed glass. 4102/0901

Contents Page No.
Safety Notices 1 - 1
General Safety 2 - 1
Operating Safety 3 - 1
Maintenance Safety 4 - 1
4 - 2
i
Care & Safety
9803/6400
i
Issue 1
Section 2 Section 2

1 - 1
Section 2 Care & Safety
9803/6400
Section 2
1 - 1
Issue 2*
In this publication and on the machine, there are safety notices. Each notice starts
with a signal word. The signal word meanings are given below.
!!DANGER
Denotes an extreme hazard exists. If proper precautions are not taken, it is
highly probable that the operator (or others) could be killed or seriously
injured.
INT-1-2-1
!!WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator (or
others) could be killed or seriously injured.
INT-1-2-2
!!CAUTION
Denotes a reminder of safety practices. Failure to follow these safety
practices could result in injury to the operator (or others) and possible damage
to the machine.
INT-1-2-3

2 - 1
All construction and agricultural equipment can be
hazardous. When JCB Excavator is correctly operated and
properly maintained, it is a safe machine to work with. But
when it is carelessly operated or poorly maintained it can
become a danger to you (the operator) and others.
Do not work with the machine until you are sure that you can
control it.
Do not start any job until you are sure that you and those
around you will be safe.
If you are unsure of anything, about the machine or the job,
ask someone who knows. Do not assume anything.
Remember
BE CAREFUL
BE ALERT
BE SAFE
GEN-1-6
As well as the warnings in the following pages, specific
warnings are given throughout the book. This section is
designed to give a safety code for use of the machine
generally and for operation and maintenance practices.
General Safety
!!
WARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment. Make
sure that lifting equipment is in good condition. Make sure
that lifting tackle complies with all local regulations and is
suitable for the job. Make sure that lifting equipment is
strong enough for the job.
INT-1-3-7
!!WARNING
Clothing
You can be injured if you do not wear the proper clothing.
Loose clothing can get caught in the machinery. Wear
protective clothing to suit the job. Examples of protective
clothing are: a hard hat, safety shoes, safety glasses, a well
fitting overall, ear-protectors and industrial gloves. Keep
cuffs fastened. Do not wear a necktie or scarf. Keep long
hair restrained.
INT-1-3-6
Note: This section includes a certain amount of operating
safety information. But remember that whenever you drive
the machine or operate its controls, you are in effect a
machine operator. Therefore you should read and
understand the information given in the Operator Handbook
before driving the machine or operating its controls.
!!
WARNING
Care and Alertness
All the time you are working with or on the machine, take
care and stay alert. Always be careful. Always be alert for
hazards.
INT-1-3-5
!!WARNING
Raised Equipment
Raised equipment can fall and injure you. Do not walk or
work under raised equipment unless safely supported.
13-1-1-6
!!DANGER
Before removing the boom from the machine, ensure that the
counterweight is adequately supported as in certain ground
conditions the machine could tip backwards. Never travel or
transport the machine with the boom removed.
BF6-3
Section 2 Care & Safety
9803/6400
Section 2
2 - 1
Issue 2*

3 - 1
Operating Safety
!!WARNING
Engine
The engine has rotating parts. Do not open the engine cover
while the engine is running. Do not use the machine with the
cover open.
INT-2-1-6
!!WARNING
Entering/Leaving
Always face the machine when entering and leaving the cab.
Use the step(s) and handrails. Make sure the step(s),
handrails and your boot soles are clean and dry. Do not
jump from the machine. Do not use the machine controls as
handholds, use the handrails.
INT-2-1-7
!!WARNING
Controls
You or others can be killed or seriously injured if you operate
the control levers from outside the cab. Operate the control
levers only when you are correctly seated inside the cab.
INT-2-1-3
!!WARNING
Visibility
Accidents can be caused by working in poor visibility. Keep
windows clean and use your lights to improve visibility. Do
not operate the machine if you cannot see properly.
INT-2-1-11
!!WARNING
Machine Limits
Operating the machine beyond its design limits can damage
the machine, it can also be dangerous. Do not operate the
machine outside its limits. Do not try to upgrade the machine
performance with unapproved modifications.
INT-2-1-4
!!WARNING
Exhaust Gases
Breathing the machine exhaust gases can harm and possibly
kill you. Do not operate the machine in closed spaces
without making sure there is good ventilation. If possible, fit
an exhaust extension. If you begin to feel drowsy, stop the
machine at once. Get out of the cab into fresh air.
INT-2-1-10
!!WARNING
Hazardous Atmospheres
This machine is designed for use in normal outdoor
atmospheric conditions. It shoul not be used in an enclosed
area without adequate ventilation. Do not use the machine in
a potentially explosive atmosphere, i.e. combustible vapours,
gas or dust, without first consulting your JCB Distributor.
INT-2-1-14
!!WARNING
Ramps and Trailers
Water, mud, ice, grease and oil on ramps or trailers can
cause serious accidents. Make sure ramps and trailers are
clean before driving onto them. Use extreme caution when
driving onto ramps and trailers.
INT-2-2-6
!!WARNING
Communications
Bad communications can cause accidents. Keep people
around you informed of what you will be doing. If you will be
working with other people, make sure any hand signals that
may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands.
INT-2-2-3
!!DANGER
Sparks
Explosions and fire can be caused by sparks from the
exhaust or the electrical system. Do not use the machine in
closed areas where there is flammable material, vapour or
dust.
INT-2-2-10
!!WARNING
Controls
Keep the machine controls clean and dry. Your hands and
feet could slide off slippery controls. If that happens, you will
lose control of the machine.
2-2-3-6
Section 2 Care & Safety
9803/6400
Section 2
3- 1
Issue 1

4 - 1
Maintenance Safety
!!WARNING
Soft Ground
A machine can sink into soft ground. Never work under a
machine on soft ground.
INT-3-2-4
!!WARNING
Metal Splinters
You can be injured by flying metal splinters when driving
metal pins in or out. Use a soft faced hammer or drift to
remove and fit metal pins. Always wear safety glasses.
INT-3-1-3
!!WARNING
Communications
Bad communications can cause accidents. If two or more
people are working on the machine, make sure each is
aware of what the others are doing. Before starting the
engine, make sure the others are clear of the danger areas;
examples of danger areas are: the rotating blades and belt
on the engine, the attachments and linkages, and anywhere
beneath or behind the machine. People can be killed or
injured if these precautions are not taken.
INT-3-1-5
!!WARNING
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from the
machine. Do not smoke while refuelling the machine or
working on the engine. Do not refuel with the engine
running. There could be a fire and injury if you do not follow
these precautions.
INT-3-2-2
!!WARNING
Petrol
Do not use petrol in this machine. Do not mix petrol with the
diesel fuel; in storage tanks the petrol will rise to the top and
form flammable vapours.
INT-3-1-6
!!WARNING
Oil
Oil is toxic. If you swallow any oil, do not induce vomiting,
seek medical advice. Used engine oil contains harmful
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier
cream or wear gloves to prevent skin contact. Wash skin
contaminated with oil thoroughly in warm soapy water. Do
not use petrol, diesel fuel or paraffin to clean your skin.
INT-3-2-3
!!WARNING
Fires
If your machine is equipped with a fire extinguisher, make
sure it is checked regularly. Keep it in the operator's cab
until you need to use it.
Do not use water to put out a machine fire, you could spread
an oil fire or get a shock from an electrical fire. Use
carbondioxide, dry chemical or foam extinguishers. Contact
your nearest fire department as quickly as possible. Fire
fighters should use self-contained breathing apparatus.
INT-3-2-7/1
!!WARNING
Battery
A battery with frozen electrolyte can explode if it is used or
charged. Do not use a machine with a frozen battery. To
help prevent the battery from freezing, keep the battery fully
charged.
INT-3-1-7
!!WARNING
Battery Gases
Batteries give off explosive gases. Keep flames and sparks
away from the battery. Do not smoke close to the battery.
Make sure there is good ventilation in closed areas where
batteries are being used or charged. Do not check the
battery charge by shorting the terminals with metal; use a
hydrometer or voltmeter.
INT-3-1-8
!!WARNING
Battery Terminals
The machine is negatively earthed. Always connect the
negative pole of the battery to earth.
When connecting the battery, connect the earth (-) lead last.
When disconnecting the battery, disconnect the earth (-) lead
first.
INT-3-1-9
!!WARNING
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
!!CAUTION
Never use water or steam to clean inside the cab. The use
of water or steam could damage the on-board computer and
render the machine inoperable. Remove dirt using a brush
or damp cloth.
8-3-4-8
Section 2 Care & Safety
9803/6400
Section 2
4 - 1
Issue 1

4 - 2
Maintenance Safety (continued)
!!CAUTION
Arc Welding
Before carrying out any arc welding on the machine,
completely remove the Control Computer to avoid damage to
the circuits; also disconnect the alternator plug and battery
leads.
When welding items to the mainframe make sure that the
earth clamp is positioned on the mainframe and when
welding to the undercarriage make sure that the earth clamp
is positioned on the undercarriage. If you earth one and weld
the other, you may cause severe damage to the slew ring.
Always connect the earth clamp to any other component
being welded, i.e. boom or dipper, to avoid damage to pivot
pins and bushes.
8-1-2-6/1
!!WARNING
Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the
hoses regularly for:
Damaged end fittings
Chafed outer covers
Ballooned outer covers
Kinked or crushed hoses
Embedded armouring in outer covers
Displaced end fittings.
INT-3-3-2
!!WARNING
DO NOT remove the hydraulic tank filler cap or cover plate
when the engine is running. The hydraulic system is under
pressure. You or others could be injured. First stop the
engine and then release the pressure.
8-3-4-4/1
!!WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the engine
and operate the controls to release pressure trapped in the
hoses. Make sure the engine cannot be started while the
hoses are open.
INT-3-1-11/1
!!WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate the
skin. Do not use your fingers to check for hydraulic fluid
leaks. Do not put your face close to suspected leaks. Hold a
piece of cardboard close to suspected leaks and then inspect
the cardboard for signs of hydraulic fluid. If hydraulic fluid
penetrates your skin, get medical help immediately.
INT-3-1-10/1
!!CAUTION
Rams
The efficiency of the rams will be affected if they are not kept
free of solidified dirt. Clean dirt from around the rams
regularly. When leaving or parking the machine, close all
rams if possible to reduce the risk of weather corrosion.
INT-3-2-10
!!CAUTION
Cleaning
Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents and
solvents.
INT-3-2-11
!!CAUTION
'O'-rings, Seals and Gaskets
Badly fitted, damaged or rotted 'O'-rings, seals and gaskets
can cause leakages and possible accidents. Renew
whenever disturbed unless otherwise instructed. Do not use
Trichloroethane or paint thinners near 'O' rings and seals.
INT-3-2-12
!!WARNING
Hot Coolant
The cooling system is pressurised when the engine is hot.
Hot coolant can spray out when you remove the radiator cap.
Let the system cool before removing the radiator cap. To
remove the cap; turn it to the first notch and let the system
pressure escape, then remove the cap.
INT-3-2-9
!!CAUTION
If the machine is operated at full load, before its initial run-in
procedure is complete, it may cause scuffing and seizing
which can adversely effect the service life of the machine.
8-3-1-5
Section 2 Care & Safety
9803/6400
Section 2
4 - 2
Issue 1

Contents Page No.
Fluids and Lubricants 1 - 1
Lubricants - Health and Safety 1 - 2
Service Schedules 2 - 1
Greasing
Slew Ring Bearing 3 - 1
Slew Ring Teeth and Slew Pinion 3 - 1
Excavator End 3 - 2
Battery 4 - 1
Fuses See Section C
Hydraulics
Air bleeding procedures 5 - 1
Releasing tank pressure 5 - 1
Air bleeding from hydraulic pump 5 - 2
Air bleeding from ram 5 - 2
Air bleeding from the slew motor 5 - 3
Checking the fluid level 5 - 4
Topping up fluid level 5 - 4
Changing the hydraulic oil 5 - 5
Changing the Return Filter Element 5 - 6
Cleaning/Changing the Suction Strainer 5 - 7
Changing the Air Breather Element 5 - 8
Draining Tank Impurities 5 - 9
Changing the Pilot Oil Filter 5 - 9
Changing the Breaker In-line Filter 5 - 10
Changing the Drain Line Filter 5 - 10
Changing the Nephron Filter 5 - 11
Transmission
Checking Track Gearbox Oil Level 6 - 1
Changing the Track Gearbox Oil 6 - 1
Checking the Slew Gearbox Oil Level 6 - 2
Changing the Slew Gearbox Oil 6 - 2
Replenishing Slew Gearbox Grease 6 - 2
Tracks and Running Gear
Cleaning the Tracks 7 - 1
Checking/Adjusting the Track Tension 7 - 2
Checking the Shoe Plate 7 - 3
Checking the Rollers and Idler Wheels for Oil Leaks 7 - 3
i
Routine Maintenance
9803/6400
i
Issue 2*
Section 3 Section 3