jcb JS70 User manual

Service
Manual
JS70
from machine no. 695501
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE: ©
ROCESTER, STAFFORDSHIRE, ST14 5LS,
ENGLAND
Tel. ROCESTER [phone]
PRINTED IN ENGLAND
Publication No. 9803/6020
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 0

9803/6020 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 = 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’.

Contents Page No.
Bolt and Nut Torque Specifications 1 - 1
General Torque Settings 1 - 2
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
9803/6020
i
Issue 1
Section 1 Section 1

1 - 1
Section 1 General Information
9803/6020
Section 1
1 - 1
Issue 1
Bolt and Nut Torque Specifications
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 renew if missing.
Tighten the bolts and nuts after the first 50 hours of the running-in stage and every 250 hours thereafter.
Torque Tightening Table
Note: Use JCB Threadlocker and Sealer (High Strength) on those marked †and tighten to the torque listed in the above
table.
No Tightening Point Bolt Diameter Wrench Tightening Torque
mm Nm kgf m lbf ft
1† Travel Motor M16 24
268~312 27.2~31.8 197~230
2† Drive Sprocket M14 22 173
~202 17.6~20.6 128~149
3† Idler Wheel M10 17 63
~73 6.9~7.4 46~54
4† Upper (Carrier) Roller M16 24 267~312 27.2~31.8 197~230
5† Lower (Track) Roller M12 19 109 ~127 11~13 80~94
6† Grease Cylinder M12 19 109
~127 11~13 80~94
7† Track Guard M12 19 109~127 11~13 80~94
8Shoe Bolt U1/2 - 38 19 196 ~235 20~24 145~173
9† Counterweight M24 36 660
~770 67.3~78.5 487~568
10† Turntable Bearing (Undercarriage) M16 24 252~283 25.7~28.9 186~209
11† Turntable Bearing (Slew Frame) M16
24 252~283 25.7~28.9 186~209
12† Slew Equipment M16 24 273~318 27.8~32.4 201~235
13† Engine (Engine Mount) M16 24 167~216 17~22 123~159
14† Engine Bracket M10/M16 17/24
65~75/167~216 6.6~7.7/17~22 48~55/123~159
15 Radiator M10 17 30 ~35 3.1~3.6 22~26
16† Hydraulic Pump M10/M12 17/19 63~73/109~127 6.4~7.4/11~13 46~54/80~94
17† Hydraulic Oil Tank M16 24
160~172 16.3~17.5 118~127
18† Fuel Tank M16 24 160~172 16.3~17.5 118~127
19† Control Valve M12 19 53
~65 5.4~6.6 39~48
20
† Rotary Coupling M10 17 63 ~73 6.4~7.4 46~54
21 Cab M16 24 79~88 8~9 58~65
22 Battery M10 17 20~30 2~3 15~22

1 - 2
Section 1 General Information
9803/6020
Section 1
1 - 2
Issue 1
General Torque Settings
General Torque Settings
Note 1: The figures quoted are for non-plated fasteners and are to be used only when there is no torque setting specified in
the relevant procedure in this service manual.
Note 2: The 4T grade settings DO NOT APPLY to fasteners used on the engine. If any 4T specification fasteners are found on
the engine, these must be tightened to the figure quoted in the relevant engine manual.
Bolt
Size Strength Grade of Bolt or Stud
4T 8.8 10.9
Nm kgf m lbf ft Nm kgf m lbf ft Nm kgf m lbf ft
M3 0.39 0.04 0.28 - - - - - -
M4 0.78 0.08 0.57 - - - - - -
M5 1.67 0.17 1.2 - - - - - -
M6 2.84 0.29 2.1 8.04 0.82 5.9 11.3 1.15 8.3
M8 7.06 0.72 5.2 19.6 2.00 14.5 27.7 2.82 20.4
M10 14.0 1.43 10.3 39.1 3.99 28.8 55.0 5.61 40.6
M12 24.6 2.51 18.1 68.5 6.98 50.5 96.2 9.81 71
M16 61.9 6.31 45.7 173 17.6 127.6 242 24.7 178.5
M20 122 12.4 90 337 34.4 249 475 48.4 350
M22 167 17.0 123 464 47.3 342 652 66.5 481
M24 210 21.4 155 584 59.5 431 821 83.7 606
M27 311 31.7 229 864 88.1 637 1220 124 900
M30 420 42.8 310 1170 119 863 1650 168 1217
M33 576 58.7 425 1600 163 1180 2260 230 1667
M36 736 75.1 543 2050 209 1512 2880 294 2124
M39 961 98.0 709 2680 273 1977 3760 383 2773
M42 1190 121 878 3300 336 2434 4640 473 3422
M45 1490 152 1099 4140 422 3054 5820 593 4293
M48 1780 182 1312 4960 506 3659 6970 711 5141

4 - 1
Section 1 General Information
9803/6020
Section 1
4 - 1
Issue 1
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
239510

Service Tools (continued)
SECTION E - HYDRAULICS
5 - 1
Section 1 General Information
9803/6020
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
1892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2)
2892/00898 Pressure Gauge 0-100 bar (0-1500 lbf/in2)
3892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2)
4892/00280 Pressure Gauge 0-600 bar (0-8500 lbf/in2)
5892/00347 Connector
6892/00254 Hose
6
1/2/3/4
5

5 - 2
Section 1 General Information
9803/6020
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
9803/6020
Section 1
5 - 3
Issue 1
Service Tools (continued)
SECTION E - HYDRAULICS
Ram Piston Nut Removal/Fitting Rig
993/99525 Rig assembly (not including spanners and
ram)
993/99522 Anchor Side Plate (suppied loose unwelded)
993/99523 Anchor cross Member (suppied loose
unwelded)
993/99524 Ram Eye End Modification Plate Assembly
556/43400 Lift Ram
545/18000 Lynch Pin
811/50232 1,1/4 in. Pivot Pin
Ram Piston Nut Removal/Fitting Spanner
993/99512 Spanner 55mm A/F
993/99513 Spanner 60mm A/F
993/99514 Spanner 65mm A/F
993/99515 Spanner 70mm A/F
993/99516 Spanner 75mm A/F
993/99517 Spanner 85mm A/F
993/99518 Spanner 90mm A/F
993/99519 Spanner 100mm A/F
993/99520 Spanner 110mm A/F
993/99521 Spanner 115mm A/F
SSP0046 Spanner 80mm A/F
SSP0047 Spanner 95mm A/F
JS07050
JS07050
JS07050

5 - 4
Section 1 General Information
9803/6020
Section 1
5 - 4
Issue 1
Service Tools (continued)
SECTION E - HYDRAULICS
Seal press-fit jig
Seal protector

5 - 5
Section 1 General Information
9803/6020
Section 1
5 - 5
Issue 1
Service Tools (continued)
SECTION E - HYDRAULICS
Jig to press fit the taper roller
bearing inner rings
Barrel pulling out jig
Hanger assembling jig
More than 140
Approximate
Hexagon socket head set screw
M12 x100 (Full dog point)

6 - 1
Section 1 General Information
9803/6020
Section 1
6 - 1
Issue 1
Work Bench
Hub 1/ spindle 2 Securing jig
Special tool I
To Remove spring 114 from cylinder block 104.
To insert spring 114, washer 110 and snap ring 145
into the cylinder block 104.
Special Tool II
For removing the deep groove ball bearing race 149
from shaft 102.
Special tool III
for pressing the oil seal 132 into the spindle.
Special tool IV
Use to locate the outer race of the bearing 22 and tap
to secure the bearing to the crankshaft.
Main bearing pre-load adjusting jig.
Eye bolts
A - Facilitates lifting of cover 8 from hub 1.
B - Use to hoist track gearbox, spindle 2 and hub 1.
AB
Service Tools (continued)
SECTION F - TRANSMISSIONS

7 - 1
Section 1 General Information
9803/6020
Section 1
7 - 1
Issue 1
Sealing and Retaining Compounds
JCB Multigasket A medium strength sealant suitable for all sizes of gasket
flanges and for hydraulic fittings of 25-65 mm diameter. 4102/1212
JCB High Strength Threadlocker A high strength locking fluid for use with threaded components. 4102/0551
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
JCB Threadlocker & Sealer A medium strength locking fluid for sealing and retaining nuts 4101/0251
bolts and screws up to 50mm diameter, and for hydraulic
fittings up to 25mm diameter.
JCB Threadlocker For threads of 50 mm diameter upwards, e.g. suction strainer. 4101/0451 50 ml
JCB Threadlocker & Sealer A medium to high strength locking fluid. 4101/0552
(High Strength)
JCB Threadseal Medium strength thread sealant (for patch bolts that are re-used). 4102/1951 50 ml
JCB Activator A cleaning primer which speeds the curing rate of anaerobic 4104/0251 Aerosol
products. 4104/0253 Bottle
JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic adhesives
and sealants. 4104/1557 Aerosol
Direct Glazing Kit For one pane of glass, comprises items marked †below plus
applicator nozzle etc. 993/55700
† 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. Also to seal hub planet gear carrier
when no 'O' ring is fitted 4102/0901
Black Polyurethane Sealant To finish exposed edges of laminated glass 4102/2309 310 ml

Contents Page No.
Safety Notices 1 - 1
General Safety 2 - 1
Operating Safety 3 - 1
Maintenance Safety 4 - 1
i
Care & Safety
9803/6020
i
Issue 1
Section 2 Section 2

1 - 1
Section 2 Care & Safety
9803/6020
Section 2
1 - 1
Issue 1
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-1-2-3
!!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 a 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
9803/6020
Section 2
2 - 1
Issue 1

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 should 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
9803/6020
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
Do not disconnect the alternator, the battery, or any part of
the charging circuit with the engine running.
8-3-4-1
Section 2 Care & Safety
9803/6020
Section 2
4 - 1
Issue 1

4 - 2
Maintenance Safety (cont’d)
!!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
!!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
!!WARNING
Compressed Air
When using compressed air, wear safety glasses and gloves.
Do not direct compressed air at your skin.
8-3-4-2
Section 2 Care & Safety
9803/6020
Section 2
4 - 2
Issue 1

Contents Page No.
Fluids and Lubricants 1 - 1
Lubricants - Health and Safety 1 - 2
Service Schedules
Service Intervals for Hydraulic Oil and Filters
when using a Breaker 2 - 1
Initial Precautions For New Machine Usage 2 - 2
Operating Hours Schedule 2 - 3
Greasing
Slew Ring Teeth and Slew Pinion 3 - 1
Slew Ring Bearing 3 - 1
Excavator End (Standard Boom) 3 - 2
Excavator End (Offset Boom) 3 - 3
Battery 4 - 1
Fuses See Section C
Hydraulics
Air bleeding procedures 5 - 1
Checking the fluid level 5 - 1
Releasing tank pressure 5 - 1
Topping up fluid level 5 - 1
Air bleeding from hydraulic pump 5 - 2
Air bleeding from the slew motor 5 - 3
Air bleeding from ram 5 - 3
Changing the Fluid 5 - 4
Changing the Return Filter Element 5 - 5
Cleaning/Changing the Suction Strainer 5 - 5
Changing the Nephron Filter 5 - 6
Changing the Air Breather Element 5 - 7
Draining Tank Impurities 5 - 7
Changing the Servo Oil Filter 5 - 8
Changing the Breaker In-line Filter (If fitted) 5 - 9
Transmission
Checking Track Gearbox Oil Level 6 - 1
Changing the Track Gearbox Oil 6 - 1
Replenishing Slew Gearbox Grease 6 - 2
Tracks and Running Gear
Cleaning the Tracks 7 - 1
Checking/Adjusting the Track Tension 7 - 2
Checking the Track Shoes 7 - 3
Checking the Rollers and Idler Wheels for Oil Leaks 7 - 3
i
Routine Maintenance
9803/6020
i
Issue 1
Section 3 Section 3