JCB JZ70 TRACKED EXCAVATOR Service Repair Manual Instant Download

Open front screen 1 2 3 General Information Care & Safety Routine Maintenance R A B C D E F J K Attachments Body & Framework Service Manual Electrics Controls JZ 70 From machine no.834000 Hydraulics Transmission PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE: CHEADLE ROAD, UTTOXETER STAFFORDSHIRE, ST14 7BS, ENGLAND Tel. (01889) 590312 PRINTED IN ENGLAND Track & Running Gear Engine Publication No. 9803/6030 Issue 0

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 2 3 = = = General Information - includes torque settings and service tools. Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. 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 B = = Attachments 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 . 9803/6030 Issue 1

General Information Section 1 Section 1 i i Contents Page No. Bolt and Nut Torque Specifications 1 - 1 General Torque Settings 1 - 2 Service Tools Section B - Body and Framework Section C - Electrics Section E - Hydraulics 3 - 1 4 - 1 5 - 1 Sealing and Retaining Compounds 9 - 1 9803/6030 Issue 1

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General Information Section 1 Section 1 Bolt and Nut Torque Specifications 1 - 1 1 - 1 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 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 8 Shoe 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 Note: Use JCB Threadlocker and Sealer (High Strength) on those marked and tighten to the torque listed in the above table. 9803/6030 Issue 1

General Information Section 1 Section 1 General Torque Settings 1 - 2 1 - 2 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 9803/6030 Issue 1

General Information Section 1 Section 1 3 - 1 3 - 1 Service Tools Body and Framework (Section B) S186240 S186270 Hand Cleaner - special blend for the removal of polyurethane adhesives. Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc. 4104/1310 (454g; 1lb tub) 892/00845 ' S186250 12V Mobile Oven - 1 cartridge capacity - required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket (715/04300). S186280 Folding Stand for Holding Glass - essential for preparing new glass prior to installation. 892/00843 992/12300 S186260 S186300 240V Static Oven - available with 2 or 6 cartridge capacity - required to pre-heat adhesive prior to use. No plug supplied. Note: 110V models available upon request - contact JCB Technical Service Glass Lifter - minimum 2 off - essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage. 992/12400 - 2 cartridge x 240V 992/12600 - 6 cartridge x 240V 892/00842 9803/6030 Issue 1

General Information Section 1 Section 1 3 - 2 3 - 2 Service Tools (cont d) Body and Framework (Section B) (cont d) S186310 S186340 Wire Starter - used to access braided cutting wire (below) through original polyurethane seal. Cut-out Knife - used to remove broken glass. 992/12800 892/00848 ' S186350 S186320 'L' Blades - 25mm (1in.) cut - replacement blades for cut-out knife (above). Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass. 992/12801 (unit quantity = 5 off) 892/00846 S1863 S186360 Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool (above). Long Knife - used to give extended reach for normally inaccessible areas. 892/00849 (approx 25m length) 892/00844 9803/6030 Issue 1

General Information Section 1 Section 1 3 - 3 3 - 3 Service Tools (cont d) Body and Framework (Section B) (cont d) S186470 S186550 Nylon Spatula - general tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge. Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame. 926/15500 (unit quantity = 500 off) 892/00847 9803/6030 Issue 1

General Information Section 1 Section 1 4 - 1 4 - 1 Service Tools SECTION C - ELECTRICS Electrical Test Equipment 1 892/00283 Tool Kit Case 2 892/00281 AVO Meter 3 892/00286 Surface Temperature Probe 4 892/00284 Microtach Digital Tachometer 5 892/00282 Shunt - open type 6 892/00285 Hydraulic Oil Temperature Probe 7 892/00298 Fluke 85 Multimeter (not illustrated) 892/01033 Data Link Adaptor A360250 9803/6030 Issue 1

General Information Section 1 Section 1 5 - 1 5 - 1 Service Tools (continued) SECTION E - HYDRAULICS Hydraulic Pressure Test Gauges and Connections 1 892/00346 2 892/00898 3 892/00279 4 892/00280 5 892/00347 6 892/00254 Pressure Gauge 0-70 bar (0-1000 lbf/in2) Pressure Gauge 0-100 bar (0-1500 lbf/in2) Pressure Gauge 0-400 bar (0-6000 lbf/in2) Pressure Gauge 0-600 bar (0-8500 lbf/in2) Connector Hose 5 6 1/2/3/4 Pressure Test T Adapters Pressure Test Adapters 892/00262 816/55038 816/55040 892/00263 892/00264 892/00265 892/00266 892/00267 1/4 in BSP x 1/4 in F BSP x Test Point 3/8 in BSP x 3/8 in F BSP x Test Point 1/2 in BSP x 1/2 in F BSP x Test Point 5/8 in BSP x 5/8 in F BSP x Test Point 3/4 in BSP x 3/4 in F BSP x Test Point 1 in M BSP x 1 in F BSP x Test Point 1,1/4 in M BSP x 1,1/4 in F BSP x Test Point 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point 892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261 1/4 in BSP x Test Point 3/8 in BSP x Test Point 1/2 in BSP x Test Point 5/8 in BSP x Test Point 3/4 in BSP x Test Point 1 in BSP x Test Point 1,1/4 in BSP x Test Point 5/8 in UNF x Test Point 9803/6030 Issue 1

General Information Section 1 Section 1 5 - 2 5 - 2 Service Tools (continued) SECTION E - HYDRAULICS Hand Pump Equipment 892/00223 892/00137 892/00274 892/00262 892/00706 892/00278 892/00279 892/00280 Hand Pump Micro-bore Hose 1/4 in BSP x 5 metres Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1/4 in M BSP x 1/4 in F BSP x Test Point Test Probe Gauge 0 - 40 bar (0 - 600 lb/in2) Gauge 0 - 400 bar (0 - 6000 lb/in2) Gauge 0 - 600 bar (0 - 8500 lb/in2) 816/50005 816/60096 816/00018 1/2 in BSP (A) x 1/2 in BSP (B) 3/4 in BSP (A) x 3/4 in BSP (B) 1 in BSP (A) x 1 in BSP (B) Female Cone Blanking Plug Male Cone Blanking Plug 892/00055 892/00056 892/00057 892/00058 892/00059 892/00060 1/4 in BSP 3/8 in BSP 1/2 in BSP 5/8 in BSP 3/4 in BSP 1 in BSP 816/00294 816/00189 816/00190 816/00197 816/00196 816/00193 1/4 in BSP 3/8 in BSP 1/2 in BSP 5/8 in BSP 3/4 in BSP 1 in BSP 9803/6030 Issue 1

General Information Section 1 Section 1 5 - 3 5 - 3 Service Tools (continued) SECTION E - HYDRAULICS JS07050 JS07050 Ram Piston Nut Removal/Fitting Spanner JS07050 993/99512 993/99513 993/99514 993/99515 993/99516 993/99517 993/99518 993/99519 993/99520 993/99521 SSP0046 SSP0047 Spanner 55mm A/F Spanner 60mm A/F Spanner 65mm A/F Spanner 70mm A/F Spanner 75mm A/F Spanner 85mm A/F Spanner 90mm A/F Spanner 100mm A/F Spanner 110mm A/F Spanner 115mm A/F Spanner 80mm A/F Spanner 95mm A/F Ram Piston Nut Removal/Fitting Rig 993/99525 Rig assembly (not including spanners and ram) Anchor Side Plate (suppied loose unwelded) Anchor cross Member (suppied loose unwelded) Ram Eye End Modification Plate Assembly Lift Ram Lynch Pin 1,1/4 in. Pivot Pin 993/99522 993/99523 993/99524 556/43400 545/18000 811/50232 9803/6030 Issue 1

General Information Section 1 Section 1 9 - 1 9- 1 Sealing and Retaining Compounds JCB Multi-Gasket A medium strength sealant suitable for all sizes of gasket 4102/1212 flanges, and for hydraulic fittings of 25-65 mm diameter. 50 ml JCB Threadlocker For threads of 50 mm diameter upwards, e.g. suction strainer. 4101/0451 50 ml JCB Threadlocker (High Strength) A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important. 4102/0551 50 ml 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 nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. 10 ml 50 ml 4101/0251 JCB Threadlocker and Sealer (High Strength) A high strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. 4101/0550 4101/0552 10 ml 200 ml JCB Threadseal A medium strength thread sealing compound. 4102/1951 50 ml JCB Activator A cleaning primer which speeds the curing rate of anaerobic products. 4104/0251 4104/0253 Aerosol (1 ltr) Bottle (200 ml) JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic adhesives and sealants. 4104/1557 Aerosol (400 ml) Anti-Seize Paste A compound used for assembly and prevention of parts seizure. 4003/0211 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 9803/6030 Issue 1

Care & Safety Section 2 Section 2 i i Contents Page No. Safety Notices 1 - 1 General Safety 2 - 1 Operating Safety 3 - 1 Maintenance Safety 4 - 1 9803/6030 Issue 1

Care & Safety Section 2 Section 2 1 - 1 1 - 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 9803/6030 Issue 1

Care & Safety Section 2 Section 2 2 - 1 2 - 1 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. 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 WARNING Care and Alertness 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 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 ! Raised Equipment !WARNING ! !WARNING Clothing Raised equipment can fall and injure you. Do not walk or work under raised equipment unless safely supported. 13-1-1-6 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 !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 9803/6030 Issue 1

Care & Safety Section 2 Section 2 3 - 1 3- 1 Operating Safety ! !WARNING Engine ! Ramps and Trailers !WARNING The engine has exposed rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open. INT-2-1-6/1 ! 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 ! 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 ! 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 ! 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 ! 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 ! 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 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 ! 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 ! 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 ! 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 !WARNING !WARNING !WARNING !DANGER !WARNING !WARNING !WARNING !WARNING !WARNING 9803/6030 Issue 1

Care & Safety Section 2 Section 2 4 - 1 4 - 1 Maintenance Safety ! !WARNING Soft Ground ! !WARNING Fires A machine can sink into soft ground. Never work under a machine on soft ground. INT-3-2-4 ! 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 ! 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 ! 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 ! 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 ! 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 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. !WARNING 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 ! 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 ! 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 ! Battery Terminals The machine is negatively earthed. Always connect the negative pole of the battery to earth. !WARNING !WARNING !WARNING !WARNING !WARNING !WARNING When connecting the battery, connect the earth (-) lead last. When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9 ! 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 ! Do not disconnect the alternator, the battery, or any part of the charging circuit with the engine running. 8-3-4-1 !WARNING !WARNING !CAUTION 9803/6030 Issue 1

Care & Safety Section 2 Section 2 4 - 2 4 - 2 Maintenance Safety (cont d) ! !CAUTION ! Hydraulic Fluid !WARNING 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 ! 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. 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 ! 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 ! Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents. INT-3-2-11 ! '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 ! 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 ! 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 ! Compressed Air When using compressed air, wear safety glasses and gloves. Do not direct compressed air at your skin. 8-3-4-2 !CAUTION !CAUTION 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. !CAUTION 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 ! 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 ! 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 ! 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 !CAUTION !WARNING !WARNING !CAUTION !WARNING !WARNING 9803/6030 Issue 1

Routine Maintenance Section 3 Section 3 i i Contents Page No. Fluids and Lubricants Lubricants - Health and Safety 1 - 1 1 - 2 Service Schedules Service Intervals for Hydraulic Oil and Filters when using a Breaker Operating Hours Schedule 2 - 1 2 - 2 Greasing Slew Ring Teeth and Slew Pinion Slew Ring Bearing Excavator End (Standard Boom) Excavator End (Offset Boom) 3 - 1 3 - 1 3 - 2 3 - 3 Battery 4 - 1 Fuses See Section C Hydraulics Air Bleeding Procedures Bleeding Air from the Hydraulic Pump Bleeding Air from the Slew Motor Bleeding Air from the Rams Checking the Fluid Level Releasing Tank Pressure Topping up Fluid Level Changing the Fluid Changing the Return Filter Element Cleaning/Changing the Suction Strainer Changing the Nephron Filter Changing the Air Breather Element Draining Tank Impurities Changing the Servo Oil Filter Changing the Breaker In-line Filter (If fitted) 5 - 1 5 - 1 5 - 2 5 - 2 5 - 3 5 - 3 5 - 3 5 - 4 5 - 5 5 - 5 5 - 6 5 - 7 5 - 7 5 - 8 5 - 9 Transmission Slew Gearbox Grease Checking Track Gearbox Oil Level Changing the Track Gearbox Oil 6 - 1 6 - 1 6 - 1 Tracks and Running Gear Cleaning the Tracks Checking/Adjusting the Track Tension Checking the Track Shoes Checking the Rollers and Idler Wheels for Oil Leaks 7 - 1 7 - 2 7 - 3 7 - 3 9803/6030 Issue 1

Routine Maintenance Section 3 Section 3 ii ii Contents Page No. Engine Changing the Air Filter Elements Checking the Oil Level Changing the Oil and Filter Checking the Coolant Level Coolant Mixtures Changing the Coolant Cleaning the Radiator and Oil Cooler Checking the Fan Belt Tension Fitting a New Fan Belt Draining Fuel Tank Impurities Draining the Water Separator Cleaning the Water Separator Changing the Fuel Filter Element Cleaning the Lift Pump Strainer Bleeding the Fuel System 8 - 1 8 - 3 8 - 3 8 - 4 8 - 4 8 - 5 8 - 5 8 - 6 8 - 6 8 - 7 8 - 7 8 - 7 8 - 8 8 - 8 8 - 9 Component Locations 9 - 1 9803/6030 Issue 1

Section 3 Section 3 Routine Maintenance Fluids and Lubricants 1 - 1 1 - 1 CAPACITIES AND SPECIFICATIONS Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load). Item Fluid/Lubricant International Specification Capacity ENGINE See separate chart - 6.8 litres (1.49 UK gal) (1.79 US gal) TRACK GEARBOXES JCB Gear Oil HD90 API-GL-5, MIL-L-2105C 2 x 1.7 litres (0.37 UK gal) (0.44 US gal) TRACK ROLLERS AND IDLER WHEEL Engine Oil (see separate chart) - - HYDRAULIC SYSTEM JCB Special Hydraulic Fluid HP46 Vickers 35VQ25/V104C: Sundstrand, Denison and FZG Approval Tests 92 litres (20.26 UK gal) (24.33 US gal) SLEW RING - BEARINGS - GEAR TEETH JCB HP Grease JCB HP Grease Lithium Complex (NLGI 2) inc. extreme measure additives - 3.2 kg (7.14 lb) ALL OTHER GREASE POINTS Lithium Complex (NLGI 2) inc. extreme measure additives JCB HP Grease COOLING SYSTEM See Coolant Mixtures ASTM D3306-74 10.1 litres (2.22 UK gal) (2.66 US gal) FUEL TANK See Fuel System, Types of Fuel ASTM D975-66T Nos 1D, 2D 140 litres (30.8 UK gal) (37.0 US gal) Engine Lubrication Chart Use according to ambient temperature ( C) -30 -20 -10 0 10 20 30 40 JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F JCB SUPER 10W/30 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F 9803/6030 Issue 1

Section 3 Section 3 Routine Maintenance Lubricants - Health and Safety 1 - 2 1 - 2 It is most important that you read and understand this information and the publications referred to. Make sure that all of your colleagues who are concerned with lubricants read it too. First Aid - Oil Handling Swallowing If oil is swallowed you should not induce vomiting. Get medical advice. New Oil There are no special precautions needed for the handling or use of new oil, beside normal care and hygiene practices. Used Oil Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer. Here are precautions to protect your health when handling used engine oil: Skin In the case of excessive skin contact you should wash with soap and water. Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention. 1. Avoid prolonged, excessive or repeated skin contact with used engine oils. 2. Apply a barrier cream to the skin before handling used engine oil. Fires Extinguish with carbon dioxide, dry chemical or foam. Fire- fighters should use self contained breathing apparatus. ! 3. Note the following when removing engine oil from skin: a. Wash your skin thoroughly with soap and water. ! WARNING b. Using a nail brush will help. Do not use water to put out an oil fire. This will only spread it because oil floats on water. c. Use special hand cleansers to help clean dirty hands. d. Never use petrol, diesel fuel or gas oil. 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 e. Avoid skin contact with oil soaked clothing. f. Don't keep oily rags in pockets. g. Wash dirty clothing before re-use. Hygiene h. Throw away oil-soaked shoes. JCB lubricants are not a health risk when used properly for their intended purposes. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation. Low viscosity oils are more likely to do this, therefore particular care is necessary in handling used oils which can be diluted with fuel contamination. Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, and note the following: Waste Disposal All waste products should be disposed of in accordance with all the relevant regulations. The collection and disposal of used engine oil should be in accordance with any local regulations. Never pour used engine oil into sewers or drains. Spillage Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area. Storage Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers. 9803/6030 Issue 1

Section 3 Section 3 Routine Maintenance Service Schedules 2 - 1 2 - 1 Service Intervals for Hydraulic Oil and Filters when using a Breaker When using a breaker, contamination and degradation of the hydraulic oil occurs much more quickly than in normal excavating use. If the machine is used with increasingly degrading oil it can cause problems in the control valve, premature wear of the hydraulic pump and damage to the hydraulic system as a whole. Servicing of the hydraulic oil and filters must be done more frequently according to the percentage of total operating hours involving use of the breaker. When a breaker is fitted, ensure that the oil and filters are changed at the intervals shown in the table below. The hydraulic oil must be sampled and checked for contamination and degradation at the intervals shown. Use Frequency 100% Use Frequency 40% Use Frequency 20% Use Frequency 10% Item Time (hrs) 10 100 600 10 300 1500 10 600 3000 10 800 4000 Hydraulic Oil ! ! ! ! ! ! ! ! ! ! ! ! Return Filter ! ! ! ! ! ! ! ! Suction Filter ! ! ! ! Drain Filter ! ! ! ! Servo Filter ! ! ! ! Nephron Filter ! ! ! ! Breaker In-Line Filter ! ! ! ! Hydraulic Oil Sampling Every 200 hrs Every 300 hrs Every 600 hrs Every 800 hrs ! ! Check oil level and top up as required ! Change ! Clean Note: The filters must be changed whenever the period of breaker use exceeds 100hrs, regardless of the total number of hours the machine has worked. 9803/6030 Issue 1

Section 3 Section 3 Routine Maintenance Service Schedules 2 - 2 2 - 2 Every 10 Operating Hours or Daily Whichever occurs first Every 100 Operating Hours or 2-Weekly Whichever occurs first 1 Do a 50 hour service plus: 1 Clean a Machine generally. 2 Clean a Battery terminals. 2 Grease (If operating in very wet or severe conditions) Fuel lift pump strainer . b Bucket/dipper pivot points. a 3 Change a Engine oil main filter element . 3 Check (Engine Stopped) a Generally for damage. Engine oil . b Servo oil filter element . c For oil and coolant leakage. b Engine oil filter by-pass element . d Security of bolts and nuts . c Return filter element . e Drain filter element . f For disconnected or shorted wiring, loose terminals. d Track gearbox oil . g Hydraulic fluid level. e Fuel filter element . h Engine oil level. f 4 Check (Engine Stopped) Hoses and pipework for chafing or damage. a Track tension. g Condition of ram piston. b Windscreen washer fluid level. h Bucket pivot pin grease seals . c Fuel system for leaks. j Track plate condition. d k Fuel level. Track and running gear. e Top and bottom track rollers for oil leaks . f The auxiliary circuit hydraulic oil filter visual indicator (if using a rockbreaker) l Track idler wheels for oil leaks . g Security of major unit mounting bolts and nuts . If loose, tighten to specified torque. h Tapping with a hammer will identify any loose nuts and bolts which should then be tightened to the specified torque. Wiring for chafing. i 4 Check (Engine Running) a Operation of warning lights and audible alarm. Fan belt adjustment . j Accumulator operation. k Operation of other electrical equipment. b Radiator for damage. l Exhaust for excessive smoke. c m Oil cooler for damage. Battery electrolyte level . n Excavator operation. d Exhaust system security . p Transmission operation. e Teeth and sidecutters . r Operation of track and slew brakes. f 5 Check (Engine Running) Operation of hour meter. Operation of throttle system . g a Operation of overload warning . b Every 50 Operating Hours or Weekly Whichever occurs first Operation of stop control . c These procedures are only to be carried out after the first 100 hours use of a new machine. Thereafter they are to be carried out as detailed in the following periodic checks. 1 Do the daily jobs plus: 2 Clean a Drain water and sediment from fuel tank. Drain fuel water separator. b 3 Grease a All pivot pins. 9803/6030 Issue 1

Section 3 Section 3 Routine Maintenance Service Schedules 2 - 3 2 - 3 Every 250 Operating Hours or Monthly Whichever occurs first Every 1000 Operating Hours or 6-Monthly Whichever occurs first 1 Do a 100 hour service plus: 1 Do a 500 hour service plus: 2 Clean a 2 Clean a Fuel lift pump strainer. Drain water and deposits from hydraulic oil tank. Hydraulic fluid suction strainer. b Air cleaner dust valve. b 3 Change (Engine Stopped) a Engine air filter element (outer). 3 Grease a Door and canopy hinges. Hydraulic tank air breather element. b Slew ring bearing. b Track gearbox oil. c 4 Change a Engine oil. Return filter element. d Engine oil full flow filter element. Nephron filter. b e Servo oil filter element. f 5 Check (Engine Stopped) a Battery electrolyte level. Drain filter. g Security of major unit mounting bolts and nuts. If loose, tighten to specified torque. b 4 Check (Engine Stopped) a Track wear. Track gearbox oil level. c Every 2000 Operating Hours or Yearly Whichever occurs first Fan belt adjustment. d Air inlet system security e 1 Do a 1000 hour service plus: 2 Check (Engine Stopped) a Sample hydraulic oil and replace if necessary. Every 500 Operating Hours or 3-Monthly Whichever occurs first 3 Grease a Slew gearbox 1 Do a 250 hour service plus: 2 Clean a 4 Change a Hydraulic fluid suction strainer. Radiator, grille and oil cooler fins. 3 Grease a Slew ring teeth. Engine air filter element (inner). b Every 4000 Operating Hours or 2 Years Whichever occurs first 4 Change a Fuel filter element. 5 Check (Engine Stopped) a Exhaust system security. 1 Do a 2000 hour service plus: 2 Change a Top and bottom track roller oil Top and bottom track rollers for oil leaks. b Track idler wheels for oil leaks. c Long life coolant. b Hydraulic oil (check the degradation and cleanliness by sampling). d Fuel hose (fuel tank - engine). c Fuel hose (fuel filter - injection pump). d Seat belt condition and security. e Hydraulic pump exit hose (pump - operation valve). e Teeth and sidecutters. f Boom ram line hose. f 6 Check (Engine Running) a Operation of throttle system. Dipper ram line hose. g Bucket ram line hose. h Operation of overload warning. b Refer to Service Intervals for Hydraulic Oil and Filters when using a Breaker. Operation of stop control. c 9803/6030 Issue 1

Section 3 Section 3 Routine Maintenance Service Schedules 2 - 4 2 - 4 Every 5000 Operating Hours or 2 Years 6 Months Whichever occurs first 1 Do a 1000 hour service plus: 2 Change a Hydraulic oil. Hydraulic tank air breather element. b Hydraulic fluid suction strainer. c Refer to Service intervals for Hydraulic Oil and Filters when using a Breaker. 9803/6030 Issue 1

Section 3 Section 3 Routine Maintenance Greasing 3 - 1 3 - 1 You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Do not mix different types of grease. Keep them separate. ! WARNING Greasing should be done with a grease gun. Normally, two strokes of the gun should be enough. Stop greasing when fresh grease appears at the joint. You will be working close into the machine for these jobs. Lower the attachments if possible. Remove starter key and disconnect the battery. This will prevent the engine being started. 8-3-1-3 For the type of grease to use at each point, see Fluids and Lubricants - Capacities and Specifications. Slew Ring Teeth and Slew Pinion Ensure slew ring is kept full of grease. Always grease whenever the machine has been steam-cleaned. For location of the slew ring gear refer to Component Locations at the end of this section. 1 Make the Machine Safe Stop the engine and remove the starter key. 2 Grease the Slew Ring Remove cover A and discharge port plug B. a Apply grease to the slew ring via aperture C. b 3 Slew the Machine B Start the engine and slew the machine a few degrees. Stop the engine, remove the starter key and apply grease again. C A Repeat until the whole ring is greased. Check that grease exudes around the entire circumference. 4 Refit the Cover JS08211 Refit discharge port plug B and cover A. Slew Ring Bearing Three grease nipples are mounted on the slew ring D D D A353220 9803/6030 Issue 1

Section 3 Section 3 Routine Maintenance Greasing (continued) 3 - 2 3 - 2 ! WARNING Excavator End (Standard Boom) (50 hours) You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started. 8-3-1-3 Read general information about greasing at the beginning of this section. Each arrow highlights one grease point. 19 Grease points 5 5 5 5 4 4 1 1 4 4 2 2 6 6 3 3 6 6 4 4 6 6 3 3 3 3 3 3 A351020 1 2 3 A343930 4 5 6 A343940 9803/6030 Issue 1

Section 3 Section 3 Routine Maintenance 3 - 3 3 - 3 ! WARNING Excavator End (Offset Boom) (50 hours) You will be working close into the machine for these jobs. Lower the attachments if possible. Remove starter key and disconnect the battery. This will prevent the engine being started. 8-3-1-3 Read general information about greasing at the beginning of this section. Each arrow highlights one grease point. 27 Grease points 5A 1 5A 5A 5A 5B 5A 5B 5B 5A 4 4 2 6 6 3 3 A351120 6 3 1 2 3 4 6 5A A353321 5B A343940 A353310 9803/6030 Issue 1

Section 3 Section 3 Routine Maintenance Battery 4 - 1 4 - 1 First Aid - Electrolyte Checking the Electrolyte Level Maintenance free batteries used in normal temperate climate applications should not need topping up. However, in certain conditions (such as prolonged operation at tropical temperatures or if the alternator overcharges) the electrolyte level should be checked as described below. EYES FLUSH WITH WATER FOR 15 MINUTES. GET MEDICAL HELP FAST. IF SWALLOWED DO NOT INDUCE VOMITING. DRINK LARGE QUANTITIES OF WATER OR MILK. Then drink milk of magnesia, beaten egg or vegetable oil. A A SKIN FLUSH WITH WATER. REMOVE AFFECTED CLOTHING. ! WARNING Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and naked flames. A351020 1 Remove the Battery Compartment Cover A Remove the bolts securing the metal plate above the batteries. Remove the plate. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to prevent spillage. 2 Check the Level Remove cover B. Look at the level in each cell. The electrolyte should be 6 mm (0.25 in) above the plates. Top up if necessary with distilled water or de-ionized water. ! WARNING Do not top the battery up with acid. The electrolyte could boil out and burn you. 2-3-4-6 Keep metallic items (watches, rings, zippers etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches in the cab to OFF before disconnecting the battery. When disconnecting the battery, take off the earth (-) lead first. When reconnecting, fit the positive (+) lead first. 3 Check the Connections 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. 5-3-4-3 Make sure that the terminals are tight and clean. Coat them with petroleum jelly to prevent corrosion. ! CAUTION Do not disconnect the alternator, the battery, or any part of the charging circuit with the engine running. 8-3-4-1 B A336951 9803/6030 Issue 1

Section 3 Section 3 Routine Maintenance Battery 4 - 2 4 - 2 ! CAUTION Warning Symbols Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. INT- 3- 1-14 ! WARNING Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4 ! DANGER 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 ! CAUTION Damaged or spent batteries and any residue from fires or spillage should be put in a closed acid proof receptacle and must be disposed of in accordance with local environmental waste regulations. INT-3-1-12 ! WARNING 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 The following warning symbols may be found on the battery. Symbol Meaning Keep away from children. . A289230 Shield eyes. A289260 No smoking, no naked flames, no sparks. A289280 Explosive Gas A289250 Battery acid. A289240 Note operating instructions. A289270 9803/6030 Issue 1

Routine Maintenance Section 3 Section 3 Hydraulics 5 - 1 5 - 1 Air Bleeding Procedures After replacing the hydraulic oil or repairing or replacing hydraulic components or removing hydraulic pipes, bleed air from the hydraulic circuit. A Bleeding Air from the Hydraulic Pump If the air is not completely bled, the life of the pump will be reduced or serious trouble can occur. 1 Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key. 2 Locate the Hydraulic Pump A353350 Refer to Component Locations at the end of this section. 3 Temporarily loosen air bleeding plug A. 4 If oil comes out, re-tighten the plug. If oil does not come out, remove the air bleeding plug A and prime the pump by pouring hydraulic oil into the pump case through the air bleeding port. 5 Temporarily tighten air bleeding plug A. Start the engine and idle at low speed. Slightly loosen air bleeding plug A and continue to run the engine until oil exudes from the air bleeding port. 6 Tighten the air bleeding plug firmly. 7 Stop the engine and allow any bubbles in the system to make their way through the hydraulic tank. 9803/6030 Issue 1

Routine Maintenance Section 3 Section 3 Hydraulics (continued) 5 - 2 5 - 2 Air Bleeding Procedures (continued) Bleeding Air from the Rams If air is not bled from the rams when replaced or repaired, the piston and/or seals may be damaged. 1 Prepare the Machine Idle the engine at low speed and extend and retract each ram 4 or 5 times, stopping the ram 100 mm before the end of each stroke. 2 Bleeding Operate each ram 3 or 4 times over the full stroke in both directions to completely bleed the air. Bleeding Air from the Slew Motor If air is not completely bled from the slew motor the motor bearing or other parts may be damaged. 1 Prepare the Machine Position the machine on level ground. Stop the Engine. 2 Locate the Slew Motor A Refer to Component Locations at the end of this section. 3 Bleeding the Slew Motor a Start the engine and idle at low speed. b Loosen air bleeding plug A and check that oil seeps out (the illustration right shows the top of the slew motor with the arrow indicating the front of the machine). Note: Do not operate any other equipment . c If no oil seeps out, stop the engine and remove air bleeding plug A. Fill the motor case with hydraulic oil. d Temporarily tighten air bleeding plug A. e Idle the engine at low speed again. Slightly loosen air bleeding plug A and continue to run until oil runs out of the port. 4 Sealing the System a Tighten air bleeding plug A firmly. b Idle the engine at low speed and slowly slew the machine left to right evenly, two or more times. 5 Stop the engine and allow any bubbles in the system to make their way through the hydraulic tank. 9803/6030 Issue 1

Routine Maintenance Section 3 Section 3 Hydraulics (continued) 5 - 3 5 - 3 For location of hydraulic oil tank refer to Component Locations at the end of this section. D ! WARNING Hydraulic Fluid C E 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 Checking the Fluid Level A 1 Prepare the Machine Position the machine on level ground with the bucket and dipper rams fully extended and the boom lowered to rest the attachment on the ground, as at A. 2 Check the Level Look at the fluid level in the sight tube B. The level should be between the two marks on the tube. If the fluid is cloudy, water or air has entered the system. Water or air in the system could damage the hydraulic pump. Contact your JCB distributor if the fluid is cloudy. B Releasing Tank Pressure ! 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 A336931 1 Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key. Topping-up Fluid Level 2 Locate Breather C on Top of the Hydraulic Oil Tank 1 Prepare the Machine 3 Release Tank Pressure Position the machine on level ground. Stop the engine. Remove the starter key. Remove cap D. Press and hold the projection revealed until all pressure has been released. 2 Release Tank Pressure See Releasing Tank Pressure. 3 Add Fluid Remove the hydraulic tank filler port cover E and add fluid to the required level as indicated on the sight tube B. See Fluids and Lubricants - Capacities and Specifications for type of fluid to use. 4 Refit filler port cover E. 9803/6030 Issue 1

Routine Maintenance Section 3 Section 3 Hydraulics (continued) 5 - 4 5 - 4 Changing the Fluid 1 Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key. A A B B 2 Locate Breather Mounting Plate A and Drain Plug C These are, respectively, on the top and bottom of the hydraulic oil tank (see Component Locations). 3 Release Tank Pressure E E (See Releasing Tank Pressure) 4 Empty the Tank a Remove plate A and O-ring B. b Use a pump to discharge the hydraulic oil into an empty container. c Remove drain plug C and drain the remaining oil from the tank into a suitable drain pan. 5 Renew the Suction Strainer D and Return Filter E D D (See Cleaning/Changing the Suction Strainer and Changing the Return Filter.) C C 6 Tighten drain plug C securely. 7 Refill the tank with the specified oil to the specified level (see Fluids and Lubricants - Capacities and Specifications). 8 To seal the system, install O-ring B and breather mounting plate A. Note: If the O-ring is damaged, fit a new one. 9 Bleed air from the hydraulic components (see Air Bleeding Procedures). 10 Start the engine and run it for about 5 minutes without load. Slowly operate the rams several times and then carry out step 1 above. 11 Check the hydraulic oil level (see Checking the Fluid Level) and top up if necessary (see Topping-up Fluid Level). 9803/6030 Issue 1

Routine Maintenance Section 3 Section 3 Hydraulics (continued) 5 - 5 5 - 5 Changing the Return Filter Element 1 Prepare the Machine A A Position the machine on level ground. Stop the engine. B B C C Remove the starter key. 2 Locate the Return Filter E D D 3 Release Tank Pressure (See Releasing Tank Pressure). E E 4 Remove the Element a Remove cover A and O-ring B. b Remove spring C, valve D and return filter E from the tank. 5 Fit a New Element Re-assemble in reverse order using a new filter element E and a new cover O-ring B. Cleaning/Changing the Suction Strainer 1 Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key. F F G G 2 Locate the Suction Strainer H 3 Release the Tank Pressure (See Releasing Tank Pressure.) 4 Remove the Suction Strainer a Remove breather mounting plate F and O-ring G. b Remove suction strainer H from the tank and clean with a suitable solvent or, if renewing, discard. 5 Fit the Suction Strainer Fitting is the reverse of removal. When changing the suction strainer, fit a new O-ring seal G to breather mounting plate F and secure the fasteners. H H 6 Check the hydraulic oil level (see Checking the Fluid Level) and top up if necessary (see Topping-up Fluid Level). 9803/6030 Issue 1

Routine Maintenance Section 3 Section 3 Hydraulics (continued) 5 - 6 5 - 6 Changing the Nephron Filter J E D A 1 Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key. F G H 2 Locate the Nephron Filter Refer to Component Locations. A 3 Release Tank Pressure (See Releasing Tank Pressure). 4 Remove the Nephron Filter a Close the two filter case cocks B and C by turning them to position X. b Remove bolts and washers E, c Slacken the nuts G and insert the screws F to lift off the cover D. d Remove the cover D and remove the O-ring H. e Lift up the Nephron filter A carefully and remove. Take care not to drop any sediment. X B C 5 Fit a New Element a Slowly immerse the new Nephron filter A. Install the O-ring H, cover D, nuts G and bolts F and bolts E. b Torque tighten bolts E to 20Nm (14.75 lbf ft) c Open the cocks B and C by turning them to position Y. Y C 6 Priming the Nephron Filter a Start the engine and set at low idling, loosen plug J, then tighten the plug when hydraulic oil flows out. b. Stop the engine, check the hydraulic oil level and top-up if low. (See Checking the Fluid Level). B 9803/6030 Issue 1

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Routine Maintenance Section 3 Section 3 Hydraulics (continued) 5 - 7 5 -7 Changing the Air Breather Element 1 Prepare the Machine F A Position the machine on level ground. Stop the engine. Remove the starter key. B G 2 Release Tank Pressure C (See Releasing Tank Pressure.) 3 Locate the Air Breather W E W D 4 Replace the Air Breather Element a Remove cover F, hexagonal nut A, seal washer B and cover C. Note: The cover C can only fit in one of two positions because of the slot G in the cover which locates over a similar shaped protrusion on the mounting stud. b Remove old filter element D together with sponge packing E. JS03660 c Install a new filter element D followed by new sponge packing E. 5 Refit Filter Cover C W W X X Rotate the cover so that it fits over the stud. Then, in order, install seal washer B, hexagonal nut A and cover F. Y Y Draining Tank Impurities 1 Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key. 2 Release Tank Pressure (See Releasing Tank Pressure.) 3 Remove Plate X/O-ring Y 4 Draining the Water and Sediment Loosen drain plug Z on the bottom of the tank and drain the sediment and water accumulated. The task is complete when clean hydraulic fluid flows out. Tighten drain plug Z. Z Z 5 Top up the Hydraulic Oil Tank. (See Topping-up Fluid Level) and refit plate X/O-ring Y. 9803/6030 Issue 1

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