JZ70 Operators Manual

www.WorkshopManuals.co.
uk
Operator Handbook
JZ70
From Serial Number 834000 Onwards
! THIS HANDBOOK MUST BE KEPT IN THE MACHINE AT ALL TIMES !
Publication Number 9801/6740 Nov 01 Issue 3
Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

i SAFETY NOTICES i
! WARNING
Study this Handbook Before Starting the Machine
You must understand and follow the instructions in this handbook. You must observe
all relevant laws and regulations. If you are unsure about anything, ask your JCB
Distributor or employer. Do not guess, you or others could be killed or seriously
injured.
INT-1-1-1
In this handbook and on the machine there are safety notices. Each notice starts
with a signal word. The meanings of the signal words 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
MACHINE SECURITY
Vandalism and theft of unattended machines is an ever increasing problem and
JCB is doing everything possible to help combat this.
JCB PLANTGUARD is a comprehensive package available to help you

safeguard your machine. It includes such devices as vandal proof covers,
window etching, immobiliser, concealed serial number, battery isolator, Tracker
security system and much more.
Remember that the fitting of any one of these security devices will help to
minimise not only the damage or loss of your machine but also subsequent lost
productivity. It could also result in reduced insurance premiums.
Your JCB Distributor or Dealer will be pleased to provide information on any of

these sensible precautions. ACT NOW!
INT-1-2-4
6740-1

ii
SAFETY NOTICES ii
! CAUTION
A wide range of optional attachments is available to increase the versatility of your
machine. Only JCB approved attachments are recommended for use with your
machine. Consult your JCB Distributor for the full list of approved attachments
available.
JCB attachments are designed and manufactured specifically to suit the machine’s
hydraulic system, mounting arrangements and safe load requirements. Attachments
which are not designed for use with this machine may cause damage and create
safety hazards for which JCB cannot be held responsible. In addition the machine’s
warranty, “CE” and other legislative compliance may be affected by the use of non-
JCB approved attachments.
2-4-1-13/2
! CAUTION
This machine is manufactured in compliance with legislative and other requirements.
It should not be altered in any way which could affect or invalidate any of these
requirements. For advice consult your JCB Distributor.
Reference should also be made to Optional Attachments section where appropriate.

INT-1-3-10
6740-1

iii CONTENTS iii
INTRODUCTION Tracking Controls

Tracking Levers/Foot Pedals 38
Travel Speed Range Change Switch 38
About this Handbook
Moving Straight Ahead 39
Machine Description 1
Reversing 39
Machine and Serial Numbers 1
Turning Left 40
Using this Handbook 1
Turning Right 40
Using the Machine 1
Spin Turns 41
Left and Right Hand Convention 1
Units of Measurement. 1
Excavating Controls
Service Contract 1
Excavating 42
Operation 42
Safety First - Yours and Other People's 2
Boom and Bucket 43
Superstructure and Dipper 44
Safety First - Check List
General Safety 2
Other Controls
Operating Safety 3
Horn Button 45
Maintenance Safety 4
One Touch Idle Switch 45
Dozer Blade Lever 45
Safety Decals 6
Offset Boom Control Switch 46
Identifying Your Machine 8
Before Starting the Engine 47
Starting the Engine

OPERATION Normal Conditions 48
Cold Conditions 48
Introduction 21
Jump Starting the Engine 49
Before Entering the Cab 21
Engine Warm-up
Cab Door After Starting 50
Opening/Closing the Door 22 Warming-up Procedure 50
Entering and Leaving the Cab 23 Cold Climate Warm-up 50
Cab Windows Stopping the Engine

Opening/Closing the Upper Front Window 24 Routine Stopping 51
Opening/Closing the Lower Front Window 25 Stopping Following Overheating 51
Emergency Exit 25
Opening/Closing the Sunblind 25 Parking the Machine 51
Using the Attachments and Site Safety 52

Adjusting the Seat 26
Operating Precautions
Heater Controls 27 In Low Temperatures 54
In High Temperatures 54
Cab Radio 28 In Dusty or Sandy Areas 54
Cab Interior Lights 28 In Coastal Regions 54
Cab Layout 29 Transporting the Machine 55
Switches and Controls Using your Machine

Right Console 30 Installing a Bucket 57
Left Console 32 Removing a Bucket 58
Monitor Panel 33 Connecting Hydraulic Hoses 59
Bucket Teeth 60
Servo Controls Immobilisation 37 Removing Bucket Teeth 61
Fitting Bucket Teeth 61
Digging 62
Digging Near Walls 63
Digging on Slopes 63
6740-1

iv CONTENTS iv
Using your Machine (cont’d) Engine Oil and Filter

Dumping into a Truck 63 Checking the Oil Level 94
Backfilling 63 Changing the Oil and Filter 94
Dozing/Grading 63
Scraping and Cutting 63 Engine Cooling System
Lifting 64 Checking the Coolant Level 95
Pulling Out From Soft Ground 65 Coolant Mixtures 95
Changing the Coolant 96
Refuelling Cleaning the Radiator and Oil Cooler 96
Fuel Level 66 Checking Fan Belt Tension 97
Filling the Tank 66 Fitting a New Fan Belt 97
Refuelling Pump (optional) 66
Fuel System
Storage 67 Types of Fuel 98
Filling the Tank 98
Draining Fuel Tank Impurities 99
MAINTENANCE Draining the Water Separator 99
Cleaning the Water Separator 99
Service Contracts 81 Changing the Filter Element 100
Cleaning the Lift Pump Strainer 100
Regular Maintenance and Lubrication Schedules Bleeding the Fuel System 101
Initial Precautions for New Machine Usage 81
Every 10 Operating Hours or Daily 82 Hydraulic System
Every 50 Operating Hours or Weekly 82 Checking the Fluid Level 102
Every 100 Operating Hours or 2-Weekly 82 Releasing Tank Pressure 102
Every 250 Operating Hours or Monthly 83 Topping-up Fluid Level 102
Every 500 Operating Hours or 3-Monthly 83 Changing the Fluid 103
Every 1000 Operating Hours or 6-Monthly 83 Changing the Return Filter Element 104
Every 2000 Operating Hours or Yearly 83 Cleaning/Changing the Suction Strainer 104
Every 4000 Operating Hours or 2 Years 83 Changing the Nephron Filter 105
Every 5000 Operating Hours or 2 Years 6 Months 84 Changing the Air Breather Element 106
Draining Tank Impurities 106
Revised Service Schedules - Rockbreaker Usage 85 Changing the Servo Oil Filter 107
Changing the Breaker In-line Filter (if fitted) 108
Bolt and Nut Torque Specifications 86 Air Bleeding Procedures 109
Lubricants - Health and Safety Gearboxes

First Aid - Oil 87 Replenishing Slew Gearbox Grease 111
Hygiene 87 Checking the Track Gearbox Oil Level 111
Storage 87 Changing the Track Gearbox Oil 111
Handling 87
Waste Disposal 87 Tracks and Running Gear
Spillage 87 Clean the Tracks 112
Checking/Adjusting the Track Tension 113
Cleaning the Machine 88 Checking the Track Shoes 114
Checking the Rollers and Idler Wheels for
Checking for Damage 88 Oil Leaks 114
Greasing Electrical System

Slew Ring Teeth and Slew Pinion 89 Fuses 115
Slew Ring Bearing 89
Excavator End (Standard Boom) 90 Battery
Excavator End (Offset Boom) 91 First Aid - Electrolyte 116
Checking the Electrolyte Level 116
Engine Air Filter Warning Symbols 117
Changing the Outer Element 92
Changing the Inner Element 93 Windscreen Washer 118
Obtaining Replacement Parts 118
6740-1

v CONTENTS v
Lubricants and Capacities 119
Trouble Shooting
Engine and Related Area 120
Operating Controls 122
Hydraulic Pump 122
Working Attachments 122
Travelling 123
Slewing 123
Hydraulic Rams 123
Component Location Diagrams 124
SPECIFICATIONS
Lifting (Craning) Regulations and
Safe Working Loads 141
Static Dimensions 142
Shipping Weights (Approximate)

Standard Boom 143
Offset Boom 143
Dig Depth Chart 144
Noise and Vibration Data 145
6740-1


1 INTRODUCTION 1
ABOUT THIS HANDBOOK
Machine Description Using the Machine

JZ70 is a self-propelled tracked excavator with an upper The Tracked Excavator can do many jobs. If these jobs are
structure capable of 360° rotation. It excavates, elevates, to be done well and safely, you must know the machine
swings and discharges material by the action of a bucket and have the skill to use it. This handbook instructs you on
fitted to the boom and dipper, without moving the the machine, its controls, and its safe operation. It is not a
undercarriage during any part of the working cycle of the training manual on the art of excavating. If you are a new
machine. operator, get yourself trained in the skills of using a
Tracked Excavator before attempting to use the machine.
Machine and Serial Numbers If you attempt to use the machine without the necessary
skills, you will be a danger to yourself and others.
This handbook covers the following machines:
Left and Right Hand Convention
JCB JZ70 from Product Identification Number (PIN)
834000. In this handbook, left and right refer to the left and right
when you are correctly seated in the machine, with the
The machine is available with either a monoboom or an superstructure facing the correct way, i.e. with the track
offset boom. motors to the rear.
Using this Handbook Units of Measurement

The illustrations in this handbook are for guidance only. In this handbook, the units of measurement are metric with
Where the machines differ, the text and/or the illustration imperial following in brackets, e.g. 10 mm (0.4 in).
will specify.
Service Contract
This handbook is arranged to give you a good
understanding of the machine and its safe operation. It In order to keep your machine working efficiently, it is
also contains maintenance information and specification essential that it is properly and regularly maintained in
data. Read this handbook from front to back before using accordance with the service schedules included in this
the machine for the first time. Particular attention must be handbook.
given to all the safety aspects of operating and maintaining
the machine. Your distributor will already have discussed your service
requirements. When the distributor service has been
General warnings in this chapter are repeated throughout completed, you are strongly advised to take advantage of a
the book, as well as specific warnings. Read all the safety regular service contract.
statements regularly, so you do not forget them.
Remember that the best operators are the safest
operators.
Finally, treat this handbook as part of the machine. Keep it

clean and in good condition. Do not operate the machine
without a handbook in the cab. If there is anything you are
not sure about, ask your JCB distributor or employer. Do
not guess, you or others could be killed or seriously
injured.
The manufacturer’s policy is one of continuous

improvement. The right to change the specification of the
machine without notice is reserved. No responsibility will
be accepted for discrepancies which may occur between
specifications of the machine and the descriptions
contained in this publication.
INT-1-2-5/1
6740-1

2 INTRODUCTION 2
SAFETY FIRST - YOURS AND OTHER PEOPLE’S
All construction and agricultural equipment can be Do not work with the machine until you are sure that you
hazardous. When a JCB Excavator is correctly operated can control it.
and properly maintained, it is a safe machine to work with.
But when it is carelessly operated or poorly maintained it Do not start any job until you are sure that you and those
can become a danger to you (the operator) and others. around you will be safe.
In this handbook and on the machine you will find warning
If you are unsure of anything, about the machine or the job,
messages. Read and understand them. They tell you of
ask someone who knows. Do not assume anything.
potential hazards and how to avoid them. If you do not
fully understand the warning messages, ask your employer
Remember
or JCB distributor to explain them.
BE CAREFUL
But safety is not just a matter of responding to the BE ALERT
warnings. All the time you are working on or with the BE SAFE
machine you must be thinking what hazards there might be INT-1-3-1/1
and how to avoid them.
SAFETY CHECK LIST

General Safety
! WARNING
! WARNING
Clothing
Handbook
You and others can be injured if you operate or You can be injured if you do not wear the proper
maintain the machine without first studying this clothing. Loose clothing can get caught in the
handbook. Read the safety instructions before machinery. Wear protective clothing to suit the job.
operating the machine. If you do not understand Examples of protective clothing are: a hard hat, safety
anything, ask your employer or JCB distributor to shoes, safety glasses, a well fitting overall, ear-
explain it. Keep this handbook clean and in good protectors and industrial gloves. Keep cuffs fastened.
condition. Do not operate the machine without a Do not wear a necktie or scarf. Keep long hair
handbook in the cab, or if there is anything on the restrained.
INT-1-3-6
machine you do not understand.
INT-1-3-2
Operating Safety
! WARNING ! WARNING
Decals
You can be injured if you do not obey the decal safety Practice
instructions. Keep decals clean. Replace unreadable You or others can be killed or seriously injured if you
or missing decals with new ones before operating the do unfamiliar operations without first practising them.
machine. Make sure replacement parts include Practice away from the work site on a clear area. Keep
warning decals where necessary. other people away. Do not perform new operations
INT-1-3-4 until you are sure you can do them safely.
INT-2-1-1
! WARNING ! WARNING
Care and Alertness Machine Condition
All the time you are working with or on the machine, A defective machine can injure you or others. Do not
take care and stay alert. Always be careful. Always be operate a machine which is defective or has missing
alert for hazards. parts. Make sure the maintenance procedures in this
INT-1-3-5
handbook are completed before using the machine.
! WARNING INT-2-1-2
Alcohol and Drugs

It is extremely dangerous to operate machinery when ! CAUTION
under the influence of alcohol or drugs. Do not If you have an attachment which is not covered in this
consume alcoholic drinks or take drugs before or handbook, don’t install it, use it or remove it until you
whilst operating the machine or attachments. Be have obtained, read and understood the pertinent
aware of medicines which can cause drowsiness. information. Install attachments only on the machines
INT-1-3-9 for which they were designed.
! WARNING 5-5-1-1
Feeling Unwell
Do not attempt to operate the machine if you are
feeling unwell. By doing so you could be a danger to
yourself and those you work with.
8-1-2-4
6740-1

3 INTRODUCTION 3
SAFETY CHECK LIST

(continued)
Operating Safety (continued)
! WARNING ! WARNING
Electrical Power Cables
Machine Limits
You could be electrocuted or badly burned if you get
Operating the machine beyond its design limits can
the machine or its attachments too close to electrical
damage the machine, it can also be dangerous. Do not
power cables.
operate the machine outside its limits. Do not try to
upgrade the machine performance with unapproved You are strongly advised to make sure that the safety
modifications. arrangements on site comply with the local laws and
INT-2-1-4
regulations concerning work near electric power lines.
! DANGER Buried Electric Power Cables
Sparks Before you start using the machine, check with your
Explosions and fire can be caused by sparks from the electricity supplier if there are any buried power cables
exhaust or the electrical system. Do not use the on the site.
machine in closed areas where there is flammable Overhead Electric Power Cables
material, vapour or dust. There is a minimum clearance required for working
INT-2-2-10 beneath overhead power cables. You must obtain
! WARNING details from your local electricity supplier.
Engine 2-2-5-4
The engine has exposed rotating parts. Do not open ! CAUTION
the engine cover while the engine is running. Do not With certain combinations of bucket or attachment and
use the machine with the cover open. boom/dipper configuration, it is possible for the bucket
INT-2-1-6/1 teeth or attachment extremities to contact and cause
! WARNING damage to the structure of the machine. Check the
Passengers limit of free movement as the dipper is brought in
towards the machine.
Passengers in or on the machine can cause accidents.
8-2-5-2
The JCB Excavator is a one man machine. Do not
carry passengers.
! WARNING
Hazardous Atmospheres
INT-2-2-2
This machine is designed for use in normal outdoor
! WARNING atmospheric conditions. It should not be used in an
Safe Working Loads enclosed area without adequate ventilation. Do not use
Overloading the machine can damage it and make it the machine in a potentially explosive atmosphere, i.e.
unstable. Study the lifting and/or digging combustible vapours, gas or dust, without first
specifications in this handbook before using the consulting your JCB Distributor.
attachment. INT-2-1-14
INT-2-2-11/1
! WARNING ! WARNING
Urban Worksites Raised Attachments
Make sure the worksite is cordoned off to keep out Raised attachments can fall and injure you. Do not
pedestrians. If traffic flow is affected provide a walk or work under raised attachments unless they are
watchman to prevent accidents and keep traffic safely blocked.
INT-1-3-8
moving.
8-1-2-5
! WARNING ! DANGER
Lifting Equipment Boom Removal
You can be injured if you use faulty lifting equipment. Never remove the boom from the machine as this
Make sure that lifting equipment is in good condition. would severely upset the machine's balance so that in
Make sure that lifting tackle complies with all local certain ground conditions it could tip backwards.
regulations and is suitable for the job. Make sure that 8-2-8-4/2
lifting equipment is strong enough for the job.

INT-1-3-7 ! WARNING
Controls
! WARNING You or others can be killed or seriously injured if you
Drive Safety operate the control levers from outside the cab.
Drive the machine smoothly. Avoid repeated start/stop Operate the control levers only when you are correctly
or spin turn manoeuvres. Avoid unnecessary zig-zag seated inside the cab.
driving. INT-2-1-3
8-1-2-
6740-1

4 INTRODUCTION 4
SAFETY CHECK LIST

(continued)
Maintenance Safety ! WARNING

Fires
! WARNING If your machine is equipped with a fire extinguisher,
Modifications and Welding make sure it is checked regularly. Keep it in the
Non-approved modifications can cause injury and operator’s cab until you need to use it.
damage. Parts of the machine are made from cast
iron; welds on cast iron can weaken the structure and Do not use water to put out a machine fire, you could
break. Do not weld cast iron. Contact your JCB spread an oil fire or get a shock from an electrical fire.
distributor for advice before modifying the machine. Use carbon dioxide, dry chemical or foam
INT-3-1-2/1 extinguishers. Contact your nearest fire department
as quickly as possible. Firefighters should use self-
! WARNING contained breathing apparatus.
INT-3-2-7/1
Electrical Circuits
Understand the electrical circuit before connecting or ! WARNING
disconnecting an electrical component. A wrong
Hot Coolant
connection can cause injury and/or damage.
The cooling system is pressurised when the engine is
INT-3-1-4
hot. Hot coolant can spray out when you remove the
! WARNING filler cap. Let the system cool before removing the
Diesel Fuel filler cap. To remove the cap; turn it to the first notch
Diesel fuel is flammable; keep naked flames away and let the steam pressure escape, then remove
from the machine. Do not smoke while refuelling the the cap.
machine or working on the engine. Do not refuel with INT-3-2-9/1
the engine running. There could be a fire or injury if

you do not follow these precautions. ! CAUTION
INT-3-2-2
Cleaning
! WARNING Cleaning metal parts with incorrect solvents can cause
Oil corrosion. Use only recommended cleaning agents
Oil is toxic. If you swallow any oil, do not induce and solvents.
vomiting, seek medical advice. Used engine oil INT-3-2-11
contains harmful contaminants which can cause skin ! WARNING
cancer. Do not handle used engine oil more than
Soft Ground
necessary. Always use barrier cream or wear gloves to
A machine can sink into soft ground. Never work
prevent skin contact. Wash skin contaminated with oil
under a machine on soft ground.
thoroughly in warm soapy water. Do not use petrol,
INT-3-2-4
diesel fuel or paraffin to clean your skin.
INT-3-2-3
! CAUTION
! WARNING Rams
The efficiency of the rams will be affected if they are
Hydraulic Fluid
not kept free of solidified dirt. Clean dirt from around
Fine jets of hydraulic fluid at high pressure can
the rams regularly. When leaving or parking the
penetrate the skin. Do not use your fingers to check
machine, close all rams if possible to reduce the risk
for hydraulic fluid leaks. Do not place your face close
of weather corrosion.
to suspected leaks. Hold a piece of cardboard close to
INT-3-2-10
suspected leaks and then inspect the cardboard for
signs of hydraulic fluid. If hydraulic fluid penetrates ! WARNING
the skin, get medical help immediately. Hydraulic Hoses
INT-3-1-10/1 Damaged hoses can cause fatal accidents.
Inspect the hoses regularly for:
! WARNING Damaged end fittings
Hydraulic Pressure Chafed outer covers
Hydraulic fluid at system pressure can injure you. Ballooned outer covers
Before disconnecting or connecting hydraulic hoses, Kinked or crushed hoses
stop the engine and operate the controls to release Embedded armouring in outer covers
pressure trapped in the hoses. Make sure the engine Displaced end fittings.
INT-3-3-2
cannot be started while the hoses are open.
INT-3-1-11/1
6740-1

5 INTRODUCTION 5
Maintenance Safety (cont’d)
! WARNING ! WARNING
Communications Arc Welding
Bad communications can cause accidents. If two or Before carrying out any arc welding on the machine,
more people are working on the machine, make sure completely remove the Control Computer to avoid
each is aware of what the others are doing. Before damage to the circuits; also disconnect the alternator
starting the engine make sure the others are clear of and battery leads.
the danger areas; examples of danger areas are: the
When welding items to the mainframe make sure that
rotating blades and belt on the engine, the
the earth clamp is positioned on the mainframe and
attachments and linkages, and anywhere beneath or
when welding to the undercarriage make sure that the
behind the machine. People can be killed or injured if
earth clamp is positioned on the undercarriage. If you
these precautions are not taken.
INT-3-1-5
earth one and weld the other, you may cause severe
damage to the slew ring.
! WARNING Always connect the earth clamp to any other
Counterweights component being welded, i.e. boom or dipper, to avoid
Your machine may be fitted with counterweights. They damage to pivot pins and bushes.
are extremely heavy. Do not attempt to remove them. 8-1-2-6/1
INT-3-2-5
! CAUTION
! WARNING 'O' rings, Seals and Gaskets
Exhaust Gases Badly fitted, damaged or rotted 'O' rings, seals and
Breathing the machine exhaust gases can harm and gaskets can cause leakages and possible accidents.
possibly kill you. Do not operate the machine in closed Renew whenever disturbed unless otherwise
spaces without making sure there is good ventilation. instructed. Do not use Trichloroethane or paint
If possible, fit an exhaust extension. If you begin to thinners near 'O' rings and seals.
feel drowsy, stop the machine at once. Get out of the INT-3-2-12
cab into fresh air.
INT-2-1-10
! 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
Repairs
Do not try to do repairs or any other type of
maintenance work you do not understand. Get a
Service Manual from your JCB distributor, or get the
work done by a specialist engineer.
INT-3-1-1
! 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
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
6740-1

6 INTRODUCTION 6
SAFETY DECALS
! WARNING ! WARNING
Decals on the machine warn you of particular hazards. If you need eye-glasses for reading, make sure you
Each decal is attached close to a part of the machine wear them when reading the safety decals. Decals are
where there is a possible hazard. Read and make sure strategically placed around the machine to remind you
you understand the safety message before you work of possible hazards. Do not over-stretch or place
with or on that part of the machine. yourself in dangerous positions to read the decals.
INT-3-3-4
Keep all decals clean and readable. Replace lost or

damaged decals. The decals and their attachment
points are shown on the following pages. Each decal
has a part number printed on it, use this number of
order a new decal from your JCB distributor.
INT-3-3-3
6740-1

7 INTRODUCTION 7
SAFETY DECALS
(continued)
WARNING WARNING
DO NOT OPERATE OR WORK ON THIS MACHINE
UNLESS YOU HAVE READ AND UNDERSTAND THE
INSTRUCTIONS AND WARNINGS IN THE OPERATION
AND MAINTENANCE MANUAL. FAILURE TO FOLLOW
THE INSTRUCTIONS OR HEED THE WARNINGS FAILURE TO USE SEAT BELTS AND
COULD RESULT IN INJURY OR DEATH.
CONTACT ANY J.C.B. DEALER FOR REPLACEMENT JUMPING FROM A MACHINE THAT IS
COPIES. PROPER CARE IS YOUR RESPONSIBILITY. OVERTURNING CAN CAUSE
INJURY OR DEATH ! JHP0200
817/01639
24 V
JS08450
Some of the labels illustrated are in English only. Your JCB Distributor will advise on the availability of labels in other
languages.
Note: The decals shown are representative and vary according to each machine. Consult your Parts Book for the correct part
when ordering a replacement.
6740-1

8 INTRODUCTION 8
IDENTIFYING YOUR MACHINE
Your machine has a Data Plate, located inside the cab as

shown A. The Product Identification Number (PIN) is
JCB - HEAVY PRODUCTS LTD.
inscribed at B and the engine number at C. UTTOXETER, STAFFS,
ST14 8TL, ENGLAND A
If the engine is replaced by a new one, the data plate serial
number will be wrong. Either stamp the new number on the
V I N Vehicle Identification Number
plate or stamp out the old one. This will prevent the wrong Product
number being quoted when you order replacement parts. Identification
Number
B
JHP00
JS08192
A335250
6740-1

21 OPERATION 21
INTRODUCTION
This chapter is arranged to guide you step-by-step through Move on to the boom and dipper controls only when you
the task of learning how to operate the machine. Read it can drive the machine confidently and safely. When you
through from beginning to end. By the end of the chapter have learned where the boom and dipper controls are and
you should have a good understanding of the machine and what they do, practise using them but take great care at
how to operate it. the same time. Practise in an open space clear of other
people.
Pay particular attention to all safety messages. They are to
warn you of possible danger. Do not just read them; think Do not jerk the controls; operate them slowly until you
about what they mean. Understand the dangers and how understand the effect they have on the machine.
to avoid them. If there is anything you do not understand,
Finally, do not rush the job of learning. Take your time and
ask your JCB distributor. He will be pleased to advise you.
take it safely.
When you have learned where the track driving controls
Remember
are and what they do, practise using them. Practise driving
the machine in a safe, open space clear of other people.
BE CAREFUL
Get to know the 'feel' of the machine and its controls.
BE ALERT
BE SAFE
INT-1-3-1/1
BEFORE ENTERING THE CAB
2 Check for Damage

The following checks should be made each time you return
to the machine after leaving it for any period of time. We a Inspect the machine generally for damaged and
advise you also to stop the machine occasionally during missing parts.
long work sessions and do the checks again. All these
checks concern the serviceability of the machine. Some b Make sure that all pivot pins are secured in place.
concern your safety. Get your service engineer to check
and correct any defects. c Inspect the windows for cracks and other damage.
! WARNING d Check for oil, fuel and coolant leakages beneath

Walking or working under a raised boom and dipper is the machine.
hazardous. You could be crushed by the boom and
dipper or get caught in the linkages. Lower the boom 3 Check for Security
and dipper before doing these checks. If you are new
to this machine, get an experienced operator to lower a Check the security of the hinged covers on the
the boom and dipper for you. engine compartment and hydraulic compartment.
If there is nobody to help you, study this handbook b Make sure that the hydraulic fluid and diesel fuel
until you have learned how to lower the boom and filler caps are both tightly closed. (We also
dipper. recommend that you lock the filler caps.)
8-2-1-1
1 Check for Cleanliness
a Clean the windows, light lenses and rear view

mirrors.
b Remove dirt and debris, especially from around

the linkages, rams, pivot pins and radiator grille.
c Make sure the cab step and handholds are clean

and dry.
6740-1

22 OPERATION 22
CAB DOOR
Opening/Closing The Door

To open the door from the outside unlock it with the key
provided and press the lock barrel. Once the door latch
has been released swing the door open.
Once in the cab (see Entering and Leaving the Cab),

close and secure the door by pulling with the bar until the
latch clicks shut. To open the door from the inside, pull the
lever to the rear.
The door can be secured in the fully open position. Swing

the door fully open until the spigot on the door locates
securely in the socket on the side of the cab. To release
the door when it is secured fully open, pull lever A
upwards.
A
! CAUTION
Do not drive the machine with the door unlatched. It
must be correctly closed or secured fully open.
8-2-1-2
Always lock the cab when leaving the machine.

A296862
6740-1

23 OPERATION 23
ENTERING AND LEAVING THE CAB
! CAUTION ! WARNING
Always face the machine when entering (and leaving) Do not use the machine controls as handholds when
the cab. Make sure your shoes and hands are clean entering (or leaving) the machine.
and dry. Otherwise you could slip and fall. 2-2-1-4
2-2-1-3
Leaving the Cab

Entering the Cab
1. Stop the engine and, with the Starter Switch set to
1. Open the cab door and, if necessary, secure it in the ON, operate the hydraulic controls several times to
fully open position (see Doors and Windows, release any residual hydraulic pressure in the system.
Opening and Closing the Door). Turn the Starter Switch OFF.
2. Check that the Controls Lock Lever (see Switches 2. Open the cab door and, if necessary, secure it in the
and Controls) is raised. fully open position (see Doors and Windows,
Opening and Closing the Door).
3. Holding the two handrails (one each side of the cab
entrance), climb onto the top of the track (as at A). 3. Ensure that the Isolator Switch (see Right Console)
is in the OFF position.
4. Retaining hold of the left handrail, step into the cab
and swing yourself into the operator’s seat (as at B). 4. Raise the Controls Lock Lever (see Switches and
Controls).
5. Leave the cab by reversing instructions 3 and 4 of

Entering the Cab.
A B
JS08251
6740-1

24 OPERATION 24
DOORS AND WINDOWS
Opening and Closing the Front Upper

Window E F
1. Opening
To open the front window, hold the left and right handles
A, B and depress the catches C, D with your thumbs. Pull
the handles backwards and swing the front window
upwards until it locates on the catches E, F in the ceiling.
2. Closing
To close the front window, hold the left and right handles
A, B and depress the catches C, D with your thumbs. Pull
the handles downwards and swing the front window until
it locates in the closed position.
C D
A B
A296800
6740-1

25 OPERATION 25
DOORS AND WINDOWS

(continued)
Opening and Closing The Front Lower

Window
The front lower window can be opened in two positions:
For a small amount of ventilation pinch the locks G, H

between finger and thumb and push the window down until
the locks locate on the lower catch positions.
G H
For a larger amount of ventilation pinch the locks G, H
between finger and thumb and push the window up until
the locks locate on the top catch positions.
To close the front lower window pinch the locks G, H

between finger and thumb and return the window to the
closed position. A296810
Emergency Exit
In an emergency, if the door cannot be used; using the
emergency glazing breaker J which is stowed behind the
seat, strike the rear window near the corner, this will
shatter the window which can then be kicked out.
J A296630
Opening and Closing the Sunblind

The sunblind is located at the top of the cab front window
and can be placed in three positions. M M
Pull the sunblind down using the handle K in the centre of
the blind lower edge. Locate both sides of the sunblind
lower edge on to the hooks L as shown.
The sunblind can also be located on the hooks positioned
on the cab ceiling M.
To release the sunblind, hold the handle K, disengage the
bottom edge of the sunblind from the locating hooks and
K
let the sunblind slowly rewind back into the stowed
position. L L
L LA296820
6740-1

26 OPERATION 26
ADJUSTING THE SEAT
Operators Seat
The operator's seat can be adjusted for your comfort. A
correctly adjusted seat will reduce operator fatigue. Adjust
the seat so that you can comfortably reach all the driving
controls. You should be able to apply full travel to the
track control levers while leaning against the seat
backrest.
7
Fore/Aft
Lift handle 1 and slide the seat into the required position.
Release lever 1. Make sure the seat is locked in position.
Weight
6
Turn adjuster 2 until the operator's weight on scale 3 is
adjacent to the pointer.
Cushion Height/Angle
Sit in the seat, press or lift lever 4 and use your weight to
position the height of the front and rear of the cushion as
required. Release lever 4.
3
Backrest
5 2
Raise lever 5, position the backrest to the required angle.
Release lever 5.
Headrest (if fitted) 1 4 A335161
Raise/lower and adjust the angle as required. ENSURE

THAT THE HEADREST IS BEHIND THE HEAD, NOT THE
NECK.
Armrest
To position the armrests, turn the adjuster 6 on the

underside of each armrest.
The Operator Handbook and Parts Book are located in

the pouch 7 on the rear of the seat.
6740-1

27 OPERATION 27
HEATER CONTROLS
(continued)
Heater/Air Conditioning Controls

Located on the Left side of the Rear Panel, the heater/air
conditioning controls A are used in conjunction with the
heater fan controls.
Fresh Air/Recirculated Air
1 0
3 2
A
Turn rotary switch B fully anti-clockwise for fresh air, turn it
fully clockwise for recirculated air. (Intermediate positions
give a mixture of fresh and recirculated air.)
A353240
Heater Fan
Turn rotary switch C clockwise to turn on the heater fan.

The volume of air from the heater increases by rotating the
switch further clockwise.
Temperature 1 0
3 2
Turn rotary switch D fully anti-clockwise for minimum
temperature, turn it fully clockwise for maximum E C
temperature. (Intermediate positions give intermediate
temperatures.)
Cigar Lighter
B
To operate the lighter E, press it fully into its socket. When
it has heated up sufficiently it will spring forward a little way
out of its socket. It can then be removed for use.
REMEMBER IT WILL BE HOT. Return the lighter to its
socket after use.
Air Conditioning Controls (if fitted)

D
Air conditioning ON/OFF control (see Left Console) - this
two position rocker switch is used to select or deselect the
facility. When the ‘snow flake’ icon is pressed to switch air
conditioning ON, the switch illuminates. A353210
Using the Air Conditioning
b. Set control B fully clockwise so as to avoid drawing

1. In hot weather to produce comfortable working
damp air in from outside the cab.
conditions.
c. Set control D fully clockwise to heat the de-

a. Close the door and windows.
humidified conditioned air, de-mist the screen and
generally de-humidify the cab air.
b. Set control B fully clockwise so as to avoid drawing
hot air in from outside the cab.
c. Set control D fully anti-clockwise to avoid re-

heating the de-humidified conditioned air. If the in-
cab temperature drops too low adjust clockwise the
setting of the heat control to remedy the situation.
2. In cold/damp weather, to minimise misting.
a. Close the door and windows.
6740-1

28 OPERATION 28
CAB RADIO
Radio
The radio X, located on the rear left hand panel, operates
only with the Starter Switch ON. It has the following
controls:
A Tone control
B On/off switch and volume control

1 0
3 2
Tuning display (waveband, memory number,
frequency) X
D Waveband/frequency select buttons
E Pre-set memory store/select buttons

A353240
F Cassette loading/control features
Removal
Insert the bows as shown, lock the bows in and press F

outwards to release the retaining catches. Remove the A
radio.
Replacement
Push in the radio until it engages the retaining catches.

C
B E D
JS03900
Cab Interior Lights H

a. The interior light H is located on the cab back wall.
b. To turn it on, press the right hand side of the light.
To extinguish press the left hand side of the light.
A353280
6740-1

29 OPERATION 29
CAB LAYOUT
7 6 4
3
8 5
9 2
1
!
A335535
1 Right Console 7 Left Hand Track Control

(see Switches and Controls) (see Tracking Controls)
2 Right Excavator Joystick Control 8 Travel Speed Range Change Switch

(see Excavating Controls) (see Tracking Controls)
3 Monitor Panel 9 Left Excavator Joystick Control

(see Switches and Controls) (see Excavating Controls)
4 Dozer Blade Lever 10 Control Lock Lever

(see Other Controls) (see Left Console)
5 Foot Rest 11 Left Console

(see Switches and Controls)
6 Right Hand Track Control
(see Tracking Controls) 12 Door Lock Release Lever
(see Cab Door)
6740-1

30 OPERATION 30
SWITCHES AND CONTROLS
Right Console
1 ST
AR
T
ONF
OF
T
H EA
0
2
3 4 5 6 7 8 A335444
1 Starter Switch 3 Quick hitch (option)

When a quick hitch system is fitted, press to release
This key operated rotary switch has four positions. The the hitch. (This switch needs to be operated in
key can only be inserted or removed in the OFF conjunction with the quick hitch, item 6 on the left
position. The positions are: console. A buzzer will sound when the switch is
selected (only if item 6 on the left console is selected).
OFF - Isolates all electrics. Press again to re-apply the quick hitch.
Turning key to this position stops the engine and, if 4 Servo Isolator
appropriate, silences the warning buzzer. Press to isolate the servo system. The monitor will
display “ISOLATOR” acknowledgement message.
HEAT: For manual pre-heating of air intake during When pressed the controls are isolated and no
cold weather, key must be held in this position. machine movement is possible.
Returns to OFF when key is released. The monitor will
display ‘PREHEAT’ when the key is in the HEAT 5 Slew lock
position. Press the switch to apply the slew lock The monitor
will display “SWING LOCK” acknowledgement
ON - Switch position for normal running. message. Press again to release the slew lock.
START: Key held in this position cranks the starter 6 Beacon (option)
motor for starting the engine. Release the key when When a beacon is fitted, press the switch to activate
the engine starts and the switch returns to ON. the beacon. The switch gives power to the jack
socket into which the rotating beacon or the service
2 Throttle Dial inspection lamp is plugged.
This rotary control provides progressive engine speed 7 Wiper

control over the full range. Press to operate the wiper continuously. Press again
to de-activate the wiper.
6740-1

31 OPERATION 31

(continued)
8 Light Switch
The ignition must be ON for the lights to illuminate.

The light switch has three positions, the first is OFF,
the second switches the cab front lights ON. The third
switches ON the boom and rear lights and the front
lights.).
9 One Touch Idle Switch
Pressing this switch instantly changes the engine rpm

back and forth between that selected for working and a
‘low idling’ speed. When ‘low idling’ has been selected
the message ‘ENG. IDLING’ is displayed on the
Monitor Panel.
10 Auxiliary Circuit Switch
This three-position rocker switch, spring loaded to the

central OFF position, provides bi-directional flow for
relevant attachments, e.g. weedcutter, grab rotate.
Press and hold the switch to the right or left, as
appropriate, for as long as the attachment is to be
used. Release the switch to turn off the attachment.
6740-1

32 OPERATION 32

(continued)
Left Console
1
8 4
2 5 6 7
A335462
1 Hammer/Auxiliary Switch
4 Tilt Handle
Press the switch to start the hammer/auxiliary. The
Turn the tilt handle anti-clockwise to unlock the
engine speed will automatically reduce to the correct
console which can then be hinged up and down.
preset level for optimum efficiency. When the switch is
Raising the console provides a method of isolating the
pressed again, the hammer/auxiliary will stop and the
hydraulic controls (in addition to operating the Servo
engine speed should automatically change to the level
Isolator Switch (on the Right Console) or raising the
set by the volume knob.
Control Lock Lever) and is an integral part of the
2 Horn Switch procedure for vacating the cab. Release the handle
and lower the console to the operating position where
When you press the switch, located on top of the left it locks.
hand joystick the horn will sound.
5 Air Conditioning Switch
3 Control Lock Lever
Air conditioning ON/OFF control 5 - this two position
Raising the lever provides a method of isolating the rocker switch is used to select or deselect the facility.
hydraulic controls (in addition to raising the Left When the ‘snow flake’ icon is pressed to switch air
Console or operating the Servo Isolator Switch) and conditioning ON, the switch illuminates.
is an integral part of the procedure for vacating the
cab. Lower the lever to activate the hydraulic controls. 6 Quick Hitch Switch
The quick hitch switch must be engaged to allow the
quick hitch switch on the Right Console to release the
quick hitch. This is a safety device to avoid accidental
release of the bucket.
7 Hammer/Auxiliary Control Switch
Press the switch to change the additional hydraulic
3 circuit from hammer (reduced flow) circuit to auxiliary
(full flow) circuit.
8 Offset Boom Switch
The offset boom switch changes the left hand
joystick, which normally controls swing. When
selected the joystick controls the offset boom. If the
switch is press a second time the control revets back
to swing.
6740-1

33 OPERATION 33

(continued)
Monitor Panel
1 Display Panel
The EMS instrument panel is located at the front of the
cab in the line of sight from the operator’s seat. It
provides the interface with the machines system. The
LCD has 20 segment bar graph gauges for fuel,
hydraulic and water temperatures, a clock, gear,
power, mode and hours run meter. The panel also has POWER
MODE
an eleven character message area.
1
2 Mode Switch
Press to select working mode. The machine will be in
S mode when started. Each press cycles through the
modes as follows: 2
S !L!S
Select the appropriate work mode suitable for the work 3 5
to be carried out:
S - STANDARD MODE
Mode for general digging and loading work. 4 6
L - LIGHT MODE
for precise or light duty work (3/4 Throttle)
3 Set Switch 7
Press the SET switch to access the monitor menu. The
menu can be scrolled through using the Scroll Up and
Scroll Down switches.
4 ACK Switch A335120

Press to acknowledge warnings shown on the display.
This will clear the message but will not put out the
warning lamps. Indicates that machine hours are displayed top
left of the display.
5 Scroll Up Switch
6 Scroll Down Switch

Indicates that time is displayed top right of the
7 Warning lamps display.
Eighteen tell tale warning light indicators are included
on the monitor, (not all the warning lights are used).
Indicates that transmission information is

displayed top left of the display.
! CAUTION
All the warning lights should go out when the engine
is started. Rectify any faults immediately.
4-2-1-4
6740-1

34 OPERATION 34

(continued)
Monitor Panel (cont’d)

Warning Lights
High Engine Coolant Temperature Low Hydraulic Oil Level (Not Used)
Illuminates if the engine coolant temperature Wheeled machine only.
rises to high.
Low Engine Oil Pressure Direction Indicator (Not used)

Illuminates if the engine oil pressure drops too Wheeled machine only.
far. The light should go out when the engine is
started.
Charging System Fault Hazard Warning Lamps Indicator (Not used)

Illuminates when the battery voltage is low. Wheeled machine only.
Service Required Main Beam Indicator (Not used)

If lit, contact your JCB Distributor. Wheeled machine only.
Low Air Pressure (Not used) Dozer Mode Indicator (Not used)
Only used on JS 330 and JS 450 machines Wheeled machine only.
High Hydraulic Oil Temperature Park Brake ON (Not used)

Illuminates if the hydraulic fluid temperature Wheeled machine only.
rises too high.
Low Coolant Level (Not used) Offset Mode

Illuminates if the engine coolant level drops too Illuminates when offset mode is energised.
low.
Engine Oil Filter Blocked (Not used)

Illuminates if the engine oil filter is blocked.
Slew Lock ON
Illuminates when the machine slew lock is
engaged.
Servo Isolator ON
Illuminates when the machines servo isolator is
engaged.
Engine Air Filter Blocked (Not used)

Illuminates if the engine air filter is blocked.
6740-1

35 OPERATION 35

(continued)

Set Switch
Press set switch to access the monitor menu. This allows the operator to change the settings of some of the machine’s
functions. The menu can be scrolled through using the scroll up and scroll down switches.
Set clock - Use to adjust the displayed time.

CLOCK
ACK
12/24? Use scroll keys to change 12h or 24h clock
ACK
12:10 Use scroll keys to change time
ACK
Language - Used to change the language of the display messages.
Date - Used to adjust to date

DATE
ACK
02-10-1999 Use scroll keys to change date
ACK
SET Return to normal display
6740-1

36 OPERATION 36

(continued)
Message Display Meaning
ALT VOLTS Alternator output voltage
BAT VOLTS Battery voltage
CALIBRATE Calibrate throttle control (set up engine speeds)
CLOCK To set time
DATE To set date
DEG C Degrees centigrade
ENGINE HOUR Total engine running hours
ENGLISH Language name
FUEL LEVEL Fuel tank level (Ohms)
HRDWARE VER Hardware (controller) version
HYD OIL TMP Hydraulic oil temperature (ºC)
HYD TEMP Hydraulic oil temperature too high
ID Identification
LANGUAGE Language name that the system is displaying
LIMP MODE Emergency mode if controller fails
LOW BAT Low battery voltage
LOW FUEL Low fuel level in fuel tank
LOW IDLE Engine at low idle
NO THROTTLE No throttle control
OHMS Resistance in ohms
OIL PRESS Low oil pressure
OVER-RIDE Solenoid over-ride system for test
PERC Percent
PILOT SWITCH Pilot pressure switch
PREHEAT Engine preheat on (Glow plugs)
RES FUEL Reserve level in fuel tank
SENSOR VOLT Sensor voltage
SERIAL NO Machine serial number
SERVICE OFF Switch off service required warning lamp
SFTWARE VER Software version
SWING BRAKE Swing brake on
SWING LOCK Swing lock on
THROTTL PWM Throttle system Pulse Width Modulation value
THRTTLE POT Throttle volume potentiometer voltage (from throttle dial in cab)
VOLTS Voltage
WATER TEMP Engine water temperature (ºC)
TVOL MIN Throttle volume minimum
TVOL MAX Throttle volume maximum
TSENS Throttle sensor
MODE Swing mode
MODE Offset mode
VER Software / Hardware version
SWING OFF Swing mode off
SWING ON Swing mode on
ERROR Error
ELECT FAULT Electrical fault open circuit/short circuit/no volts
6740-1

37 OPERATION 37
SERVO CONTROLS IMMOBILISATION
There are Three means of immobilising the machine

working servo controls:
1 Raising the left console (see Tilt Handle, Left

Console).
2 Raising the Control Lock Lever (see Left Console).
3 Pressing the Servo Isolator Switch (see Right

Console).
6740-1

38 OPERATION 38
TRACKING CONTROLS
1 Tracking Levers/Foot Pedals

Travel is controlled by the two levers/foot pedals A
and B at the front of the cab. When the cab is facing
forwards (towards the recoil units C), each lever
controls the track on the same side, i.e. the left lever
controls the left track. Before operating the travel E
lever, confirm whether the undercarriage is facing
forwards or backwards.
! WARNING A B
When the cab is swung around so that it is facing the
track motor end D of the undercarriage, the action of
the tracking controls is reversed. Take extra care!
8-2-8-1
Note: When not travelling, do not place your feet on the

travel pedals.
! WARNING
Do not travel with the track motors leading, particularly
on hard or rocky ground. The recoil units will not be
able to absorb the shocks and damage could be A335535
caused to the track running gear. Track chain wear

could also be greatly increased.
8-2-2-3-/3
2 Travel Speed Range Change Switch

At ignition switch-on the range change circuit defaults
to the low range. To change from one range to the
other, press foot operated switch E.
Choose the speed range to suit the working

conditions. When the ‘high’ speed range is selected
the ‘hare’ icon illuminates. When the ‘low’ speed
range is selected the ‘hare’ icon is not illuminated.
A353220
Speed Range Working Conditions C D
General work, when the ground is level.
High
Low When greatest power and low speed is

required or when the ground is rough.
Note: Do not change the mode while travelling. Stop the
machine to select a different speed range.
6740-1

39 OPERATION 39
TRACKING CONTROLS
(continued)
Moving Straight Ahead Reversing

To move straight ahead, tilt both levers/foot pedals forward To move in a straight line backwards, tilt both levers/foot
equally as shown by A and B. Both tracks will revolve in a pedals backwards equally as shown by C and D. Both
forward direction. tracks will revolve in a rearwards direction.
! WARNING
Make sure that there are no other people, equipment or
other obstacles behind you before you move.
8-2-2-4
A B
C D
C D
A B
JS08550 JS08560
6740-1

40 OPERATION 40
TRACKING CONTROLS
(continued)
By tilting one lever/foot pedal further forward than the Turning Right
other, the machine will turn away from the side on which
you press furthest. The machine will turn right if you tilt the left lever/foot pedal
A furthest forward.
Turning Left
The machine will turn left if you tilt the right lever/foot pedal
B furthest forward.
A B A B
A B A B JS08580
JS08570
6740-1

41 OPERATION 41
TRACKING CONTROLS
(continued)
Spin Turns
By tilting one lever/foot pedal forward and tilting the other
backwards, you can make the machine spin round while
standing in the same place.
The illustration shows a spin turn to the right. Operating the

levers/foot pedals in the opposite directions will spin the
machine to the left.
A D
s D
6740-1

42 OPERATION 42
EXCAVATING CONTROLS
Excavating
Excavating is controlled mainly by the movements of the
left A and right B Excavator Joystick Controls. Other
associated controls are the Work Mode Selection (see
Monitor Panel) and One Touch Idle switches (see Right
Console) and the Slew Lock and Servo Isolator switches
(see Right Console).
A B
Many excavating movements are a combination of two (or
more) movements at the same time, which requires
practice. Practise the movements singly at first and then in
combination until you are completely familiar with the
effects of all the controls. Use the cab decal to remind you
of the movements when you are operating.
! WARNING
When you are excavating DO NOT rest your feet on the
foot pedals. Even light pressure on the pedals can
cause the brakes to be released.
8-2-2-5
! WARNING
A335535
Never excavate directly beneath the machine itself.

Excavating beneath the machine can weaken the Operation
ground and cause the machine to tip over.
8-2-9-10 Before starting to excavate make sure that the Control
Lock Lever (see Right Console) is down and the Slew
! WARNING Brake and Servo Isolator switches (see Right Console)
When the cab is swung round so that it is facing the are OFF (not illuminated). Set the Work Mode Selection
rear of the undercarriage, the action of the steering Switch (see Monitor Panel) to suit the work to be done.
and transmission direction will be reversed. Take extra
care! Note: Following engine failure or stalling with the
8-2-9-11 attachment raised, it is still possible to lower the load to a
safe position. With the ignition switched ON, the hydraulic
! CAUTION circuit accumulators will provide sufficient pressure for a
Do not excavate on hard or rocky ground with the limited period to enable the boom/dipper to be lowered by
boom positioned diagonally across the undercarriage. operating the relevant control(s) as described in the
The resulting rocking motion could cause damage to following pages.
the track gear box sprockets.
8-2-2-6
! CAUTION
When carrying out deep digging it is possible that part
of the boom structure may contact the undercarriage.
Take extra care when digging, to avoid damaging the
machine.
8-2-8-2/2
6740-1

43 OPERATION 43
EXCAVATING CONTROLS
(continued)
Boom and Bucket

The right hand joystick controls movements of the boom
and the bucket. When released the joystick returns to the
neutral position.
The boom will move within its limits for as long as you hold
the joystick forward or backwards. It will stop automatically
when you release the joystick.
1 To raise the boom
Pull the joystick backwards.
2 To lower the boom

1
Push the joystick forwards.
The bucket will move within its limits for as long as you
hold the joystick to one side. It will stop automatically when
you release the joystick.
3 To fill the bucket
Move the joystick to the left.
4 To empty the bucket
Move the joystick to the right.
2
3
4
1 3
A350820
6740-1

44 OPERATION 44
EXCAVATING CONTROLS
(continued)
Superstructure and Dipper

The left hand joystick controls the slewing of the The dipper will swing within its limits as long as you hold
superstructure and the movements of the dipper. When the joystick forward or backwards. It will stop automatically
released the joystick returns to the neutral position. when you release the joystick.
The superstructure will slew within its limits for as long as 3 To swing the dipper outwards
you hold the joystick over to one side. It will stop
automatically when you release the joystick, due to Push the joystick forward.
application of the slew brake.
4 To swing the dipper inwards
1 To slew to the left
Pull the joystick backwards.
Move the joystick to the left.
2 To slew to the right
Move the joystick to the right.
3
4
1
2
2
4
A350830 1 A336920
6740-1

45 OPERATION 45
OTHER CONTROLS
1 Horn Button
The horn push button is located on the left Excavator B

Joystick (see Left Console).
2 One Touch Idle Switch
Push-button A, located on top of the right Excavator

Joystick Control, provides a means of instantly
switching engine speed from working to idling and
vice-versa by one push on the button.
A
3 Dozer Blade Lever
The dozer blade is lowered and raised by means of

the Dozer Blade Lever B. Move the lever forward to
lower the dozer blade. Move the lever rearward to
raise the dozer blade.
A335535
6740-1

46 OPERATION 46
OTHER CONTROLS
(continued)
Offset Boom Control (If fitted)

Machines with the optional offset boom incorporate a
single position ram. The ram is connected between the two
main sections of the boom. This enables the boom and
dipper assembly to be correctly positioned for road travel
and also allows a wider range of boom positions for A
digging.
To enable the offset boom, press button A. Light D is

illuminated and icon C is displayed on the monitor display
for 5 seconds.
To return to swing mode, press button A, the swing icon B

is then displayed on the monitor.
A350990
6740-1

47 OPERATION 47
BEFORE STARTING THE ENGINE
Note: Read Operating Precautions if you will be using 1 If you haven't already done it, do a walkround
the machine in very cold or very hot climates, in dusty or inspection of the outside of the machine (See Before
sandy areas or in coastal regions. Entering the Cab).
Do a Pre-Start Inspection 2 Remove dirt and rubbish from the cab interior,
especially around the pedals and other controls.
For your own safety (and others’) and for maximum service
life of your machine, do a pre-start inspection before
starting the engine. ! WARNING
Keep the machine controls clean and dry. Your hands
and feet could slide off slippery controls. If that
! WARNING happens you will lose control of the machine.
Walking or working under a raised boom and dipper is 2-2-3-6
hazardous. You could be crushed by the boom and

dipper or get caught in the linkages. Lower the boom 3 Remove oil, grease and mud from the pedals and
and dipper before doing these checks. If you are new other controls.
to this machine, get an experienced operator to lower
the boom and dipper for you. 4 Make sure that your hands and shoes are clean and
dry.
If there is nobody to help you, study the handbook
until you have learned how to lower the boom and 5 Remove or secure all loose articles in the cab - such
dipper. as lunch boxes, tools etc.
8-2-1-1
! WARNING
! CAUTION Loose articles can fall and strike you or roll on the
On machines fitted with hose burst protection valves floor. You could be knocked unconscious, or the
the attachments cannot be lowered with the engine controls could get jammed. If that happens you will
stopped. On these machines start the engine and lose control of the machine.
lower the attachments before doing the walk round 2-2-3-7/1
inspection.
2-2-3-5
6 Adjust the seat so that you can comfortably reach all
the driving controls (see Adjusting the Seat). You
should be able to apply full travel to the track control
levers while leaning against the seat backrest.
6740-1

48 OPERATION 48
STARTING THE ENGINE
Normal Conditions
1 Turn the Throttle Control to just below half way (see
Right Console).
2 Set the Servo Isolator Switch (see Right Console) to
OFF.
3 Turn the Starter Switch to ON (see Right Console).
Do not crank the starter motor.
If the ambient temperature is below a preset level the
Preheat Indicator (see Monitor Panel) illuminates
and the buzzer sounds to indicate that preheating is in
progress. The indicator goes out and the buzzer stops
when preheating is complete.
Note: If the engine is not started within 5 seconds of the
Starter Switch being turned ON or within 5 seconds of the
completion of preheating, a buzzer sounds to alert you.
Switch OFF or start the engine (see below) to silence the
buzzer.
4 Turn the Starter Switch to START. Hold there until the
engine starts and then release the key. The Starter
Switch will return to ON. If the engine is difficult to
start, turn the Throttle Control a few degrees
clockwise and try again.
Note: In normal conditions do not hold the key in the
START position for more than 20 seconds. If this period
has expired allow the starter motor to cool down for at least
2 minutes before trying again.
5 After the engine starts carry out the Warming-up
Procedure (see Engine Warm-up).
Note: The JZ70 has an auto warm up procedure.
When starting the machine and the water temperature is
below 40ºC the machine will only run in L mode.
When the machines water temperature reaches 40º C then
S mode can be selected and full engine speed is available.
Cold Conditions
1 Carry out steps 1 to 3 above.
2 Turn the Starter Switch to HEAT and hold there for 15
to 30 seconds. The message PREHEAT is shown on
the Monitor Panel to confirm that the warm-up
procedure is in progress. When warm-up is complete
the message is extinguished and the buzzer sounds.
Note: In cold conditions do not hold the key in the START
position for more than 30 seconds. If this period has
expired allow the starter motor to cool down before trying
again.
3 Carry out steps 4 and 5 above.
6740-2

49 OPERATION 49
JUMP STARTING THE ENGINE
! WARNING
If you try to charge a frozen battery, or jump-start and
run the engine, the battery could explode. 3 Do the Pre-Start Checks
Do not use a battery if its electrolyte is frozen. To See Before Starting the Engine.
prevent the battery electrolyte from freezing, keep the
battery at full charge. 4 Start the Engine
Batteries give off a flammable gas that can explode. See Starting the Engine.
Do not smoke when checking the battery electrolyte 5 Disconnect the Booster Cables
levels. When starting from another machine, make
sure the two machines do not touch. This prevents any a Disconnect the negative booster cable from the
chance of sparks near the battery. Sparks could ignite machine frame earth. Then disconnect it from the
the battery gas. If that happens the battery will booster supply.
explode.
b Disconnect the positive booster cable from the
Use only booster cables which are in good condition,
positive (+) terminal on the battery. Then
with securely attached connectors. Connect both ends
disconnect it from the booster supply.
of one booster cable before connecting the other one.
8-2-3-4
c Refit and secure the metal plate above the battery.
Note: You will need a 24 Volt booster supply to start your Replace the battery compartment cover.
machine. The booster supply should not be higher than 24
Volts. Using a higher voltage supply will damage your
machines electrical system.
1 Set all Switches in the Cab to Off
2 Connect the Booster Cables
Connect the booster cables as follows:
a Remove the battery compartment cover and then

remove the bolts securing the metal plate above
the battery. Remove the plate.
! WARNING
Keep metal watchbands, and any metal fasteners on
your clothes clear of the positive (+) battery terminal.
Such items can short between the terminal and nearby A336951
metalwork. If that happens you could get burned.
Make sure that the fuel filler cap is tightly fitted. Clean
up any spilt hydraulic fluid in the battery area.
8-2-3-5
b Connect the positive booster cable to the positive

(+) terminal on the machine battery. Connect the
other end of this cable to the positive (+) terminal
of the booster supply.
c Connect the negative booster cable to a good

frame earth on the machine, away from and below
the battery.
Note: A good frame earth is part of the main frame, free

from paint and dirt. Do not use a pivot pin for an earth.
d Connect the other end of this cable to the negative

(-) terminal on the booster supply.
6740-1

50 OPERATION 50
ENGINE WARM-UP
After Starting
Check that neither the Oil Pressure Low nor the 4 Set the Servo Isolator Switch (see Right Console) to
Charging Circuit Malfunction icons (see Monitor Panel) ON to enable the hydraulic servo controls to be
are illuminated. If either is illuminated, stop the engine and operated.
investigate the cause.
5 Operate the bucket control (see Excavating Controls)
Warming-up Procedure slowly until it reaches one end of its travel and leave it
there for 30 seconds.
1 Turn the Throttle Control to mid-range and make sure
the Work Mode Selection Switch is set to S (see 6 Operate the bucket control slowly to the other end of
Monitor Panel). its travel and leave it there for 30 seconds.
2 Press the One Touch Idle Switch (see Right 7 Repeat steps 5 and 6 for 10 minutes to warm up the
Console). hydraulic circuit.
3 Run the engine until the Coolant Temperature gauge 8 Now operate the excavating controls three to five
(see Monitor Panel) reads within the normal (green) times in each direction to distribute warm hydraulic oil
range. around the system.
COLD CLIMATE WARM-UP
6 Repeat Steps 4 and 5 Five Times

Before starting work in temperatures below -15 °C, the
hydraulic oil must be warmed. 7 Repeat step 4.
1 Warm up the Engine 8 Swing the Dipper Outwards
Carry out steps 1 to 4 of Warming-up Procedure (see Push forward on the left hand joystick for a maximum
Engine Warm-up). DO NOT operate any services. of two seconds.
After the warm-up period make sure that everyone is
clear of the machine. 9 Repeat Step 8 Three Times
Note: During the following steps you will have to operate 10 Swing the Dipper Inwards
the machine controls. See Excavating Controls for full
Pull back (or push forward) on the left joystick until the
details.
dipper ram is about half open. Then pull back on the
2 Lower the Boom joystick until the dipper is fully in. Hold for two
seconds.
Push the right excavator joystick forward for a
maximum of two seconds. You may feel the machine 11 Repeat Step 10 Five Times
rise slightly.
12 Operate the Bucket (as if to fill)
3 Repeat Step 2 Three Times
Move the right excavator joystick to the left for a
4 Raise the Boom maximum of two seconds.
Pull back the right excavator joystick until the boom 13 Repeat Step 12 Three Times
rams are about half open.
14 Operate the Bucket (as if to empty)
5 Lower the Boom
Move the right excavator joystick to the right, until the
Push forward the right excavator joystick until you feel bucket reaches the end of its travel. Hold for two
the machine lift slightly. seconds.
15 Repeat Step 14 Five Times
6740-1

51 OPERATION 51
STOPPING THE ENGINE
The engine is fitted with a turbocharger which runs at

temperatures in excess of 700 °C (1300 °F) and can be
damaged if the engine is stopped too soon.
Routine Stopping Stopping Following Overheating

1 Operate the Servo Isolator Switch (see Right 1 Operate the Servo Isolator Switch (see Right
Console). Console).
2 Press the One Touch Idle Switch (see Right 2 Press the One Touch Idle Switch (see Right
Console) to select the low idling speed as indicated by Console) to select the low idling speed as indicated by
the illuminated icon adjacent to the Throttle Control the illuminated icon adjacent to the Throttle Control
(see Right Console). (see Right Console).
3 Let the engine run at this speed for at least 5 minutes 3 Let the engine run at this speed until the Coolant
to allow the turbocharger to cool down. Temperature Gauge reading begins to fall (see
Monitor Panel).
4 Turn the Starter Switch to OFF.
4 Turn the Starter Switch to OFF.
PARKING THE MACHINE
3 Operate the Slew Brake Switch

! WARNING
Parking See Right Console.
An incorrectly parked machine can move without an
operator. Follow the instructions in this handbook to 4 Stop the Engine
park the machine correctly.
INT-2-2-4
See Routine Stopping.
Whenever possible, park the machine on dry and level
5 Remove the Starter Key
ground.
If you are going to leave the machine, remove the
1 Stop the Machine
starter key.
Ensure the machine is stopped in a suitable parking
place with the Servo Isolator Switch (see Right 6 Switch Off All Unnecessary Switches
Console) OFF, and the Control Lock Lever lowered
(see Left Console). If you are leaving the machine, make sure that all
switches, including the Servo Isolator Switch are set
to OFF. Raise the Control Lock Lever.
! DANGER
Before lowering the attachments to the ground, make 7 Leave and Secure the Machine
sure that the machine and the area around it are clear
of other people. Anyone on or near the machine could Close and latch all windows. Leave the cab (see
fall and be crushed by the attachments, or get caught Entering and Leaving the Cab) and lock the door.
in the linkages. Make sure that the fuel filler cap is locked on.
2-2-3-4
2 Lower the Bucket/Attachment to the Ground
Operate the excavator joystick to lower the

bucket/attachment to the ground. Once it is on the
ground, operate the joystick a little further so that it
begins to take the weight of the machine.
6740-1

52 OPERATION 52
USING THE ATTACHMENTS AND SITE SAFETY
This section explains some techniques for efficient and safe ! WARNING
use of the machine and its attachments. Attention is also You could be electrocuted or badly burned if you get
drawn to the various safety aspects of operating on site. the machine or its attachments too close to electrical
Read and understand this section before you start working power cables.
with the machine. Practise using the attachments until you
are completely familiar with the controls and what they do. You are strongly advised to make sure that the safety
arrangements on site comply with the local laws and
Before you start using the machine, tell your work mates regulations concerning work near electric power lines.
what you will be doing and where you will be working. On a
busy site, use a signalman. Buried Electric Power Cables
Before you start using the machine, check with your
Remember that your machine is mobile. Whenever possible, electricity supplier if there are any buried power cables
manoeuvre your machine into a position which combines on the site.
safety with efficiency. If you have to choose, remember that:
Overhead Electric Power Cables
SAFETY MUST COME FIRST There is a minimum clearance required for working
beneath overhead power cables. You must obtain
Choose the correct attachment for the job. Do not use an details from your local electricity supplier.
oversize shovel for rocky material. It could overload the 2-2-5-4
system and shorten service life.
! WARNING
Reworking Old Sites
! WARNING There could be dangerous materials such as asbestos,
Work sites can be hazardous. Inspect the site before poisonous chemicals or other harmful substances
working on it. Look for potholes, weak ground, hidden buried on the site. If you uncover any containers or you
rocks etc. Check for utilities such as electric cables see any signs of toxic waste, stop the machine and
(overhead and underground), gas and water pipes etc. advise the site manager immediately.
Mark the positions of the underground cables and pipes. 2-2-5-5
Make sure that you have enough clearance beneath
overhead cables and structures.
! WARNING
INT-2-2-1
Water Supplies and Drains
Before you start using the machine, check with your
! WARNING local public water supplier if there are buried pipes and
Before you start using the machine, inspect the job site. drains on the site. If there are, obtain a map of their
You could be killed or injured if the ground gives way locations and follow the advice given by the water
under your machine or if piled material collapses onto it. supplier.
Check for potholes and hidden debris, logs, ironwork
etc. Any of these could cause you to lose control of your You are strongly advised to make sure that the safety
machine. arrangements on site comply with the local laws and
2-2-5-2 regulations concerning work near buried water pipes
and drains.
! CAUTION 2-2-5-6
You and/or your company could be legally liable for any
damage you may cause to public utilities. It is your ! WARNING
responsibility to make sure that you know the locations Communications
of all public utility cables or pipes on the site which Bad communications can cause accidents. Keep people
could be damaged by your machine. around you informed of what you will be doing. If you
2-2-5-3 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
6860-1

53 OPERATION 53
USING THE ATTACHMENTS AND SITE SAFETY

(continued)
! WARNING ! WARNING
Underground Gas Pipes Banks and Trenches
Before you start using the machine, check with your Banked material and trenches can collapse. Do not work
local gas supplier if there are any buried gas pipes on or drive too close to banks and trenches where there is
the site. danger of collapse.
INT-2-2-5
If there are buried gas pipes we recommend that you
ask the gas company for any specific advice regarding ! WARNING
the way you should work on the site.
Safety Barriers
Unguarded machines in public places can be dangerous.
Some modern gas pipes cannot be detected by metal
In public places, or where your visibility is reduced,
detectors, so it is essential that an accurate map of
place barriers around the work area to keep people away.
buried gas pipes is obtained before any excavation work
INT-2-2-8
commences.
Hand dig trial holes to obtain precise pipe locations. ! CAUTION

Any cast iron pipes found should be assumed to be gas With certain combinations of bucket or attachment and
pipes until contrary evidence is obtained. boom/dipper configuration, it is possible for the bucket
teeth or attachment extremities to contact and cause
Older gas pipes can be damaged by heavy vehicles damage to the structure of the machine. Check the limits
driving over the ground above them. of free movement as the dipper is brought in towards the
machine.
LEAKING GAS IS HIGHLY EXPLOSIVE. 8-2-5-2
If a gas leak is suspected, contact the local gas ! WARNING

company immediately and warn all personnel on the If you will be working with a mate make sure you both
site. Ban smoking, ensure that all naked lights are understand what the other will be doing. Learn and use
extinguished and switch off any engines which may be the recognised signalling procedures. Do not rely on
running. shouting - he will not hear you.
8-2-5-1
You are strongly advised to make sure that the safety

arrangements on site comply with the local laws and
regulations concerning work near buried gas pipes. ! WARNING
2-2-6-1/1 When you are excavating DO NOT rest your feet on the
foot pedals. Even light pressure on the pedals can cause
! WARNING the brake to be released.
8-2-2-5
Hillsides
Operating the machine on hillsides can be dangerous if
proper precautions are not taken. Ground conditions ! WARNING
can be changed by rain, snow, ice etc. Check the site Hard and rocky ground
carefully. Do not travel with the track motors leading, particularly
on hard or rocky ground. The recoil units will not be able
Going uphill, reverse when unloaded or travel forwards to absorb the shocks and damage could be caused to
when loaded. Going downhill, travel forwards when the track running gear.
unloaded or reverse when loaded.
Do not excavate on hard or rocky ground with the boom
Take special care when moving across a slope. If the positioned diagonally across the undercarriage. The
slope is too steep your machine could roll over. If you resulting rocking motion could cause damage to the
must drive across a slope, keep the attachments close track gearbox sprockets.
to the ground. 8-1-1-6
3-1-1-4/1
6860-1

54 OPERATION 54
OPERATING PRECAUTIONS
In Low Temperatures In High Temperatures

In low temperature situations, take the following In high temperature situations, take the following
precautions. They will make for easier starting and prevent precautions to prevent possible damage to the machine.
possible damage to your machine.
1 Use the correct viscosity engine oil
1 Use the correct viscosity engine lubricating oil
See Lubricants and Capacities in MAINTENANCE
See Lubricants and Capacities in MAINTENANCE section.
section.
2 Use the correct coolant mixture
2 Use a low temperature diesel fuel if available
See Engine Cooling System in MAINTENANCE
See Fuel System in MAINTENANCE section. section.
3 Use the correct coolant mixture 3 Check the coolant system regularly
See Engine Cooling System in MAINTENANCE Keep the coolant at the correct level. Make sure there
section. are no leaks.
4 Make sure the machine is properly warmed-up 4 Keep the radiator clean
See Cold Climate Warm-Up. Regularly remove dirt and debris from the radiator and
the engine.
5 Protect the Battery
5 Check the fan belt regularly
Keep the battery at full charge. Remove from the
machine and store in a warm place when the machine See Engine Cooling System in MAINTENANCE
is to be left outside for more than 12 hours. section.
6 Fill the fuel tank at the end of each work period

In Dusty or Sandy Areas
See Refuelling.
1 Air Cleaner
7 Clean the machine on completion of work:
Frequently check the air cleaner elements and, if
a Remove accumulated mud from the machine. necessary, replace the elements regardless of the
inspection interval.
b Thoroughly clean and dry the ram cylinder rods.
Frozen water droplets can damage the cylinder 2 Securely tighten the hydraulic oil tank filler cap to
seals. prevent sand and dust from entering the hydraulic
system.
c Open the fuel tank drain cock to release water
accumulated in the fuel tank. 3 Always keep lubricated parts (e.g. pins and bushings)
clean. Thoroughly clean grease nipples before
d Open the drain plug on the fuel system water applying grease.
separator.
8 Protect the machine when not in use

In Coastal Regions
Put the machine inside a building or cover it with a
tarpaulin. 1 Check that all the plugs, bolts and fasteners are
tightened properly.
9 Install cold weather starting aids
2 After daily operations, wash the machine thoroughly
In very low temperatures, of say -18 °C (0 °F) and and take special care when cleaning the electrical
below, additional starting aids may be needed. devices and hydraulic cylinders to prevent salt entry
Examples are fuel, oil and coolant heaters and extra and eventual corrosion.
batteries. Ask your local JCB distributor for advice.
6740-1

55 OPERATION 55
TRANSPORTING THE MACHINE
The safe transit of the load is the responsibility of the

transport contractor and driver. Any machine,
attachments or parts that may move during transit
must be adequately secured.
5-2-5-9
Note: Before transporting the machine, make sure you will

be obeying the rules and laws of all the areas that the
machine will be carried through.
Make sure that the transporting vehicle is suitable. See

SPECIFICATION section for the dimensions and weight of
A345950
your machine. The bed of the trailer should have a wood
surface to aid stability.
! WARNING
Before moving the machine onto the trailer, make sure
that the trailer and ramp are free from oil, grease and
ice. Also remove oil, grease and ice from the machine
tracks.
8-2-4-2
1 Block the Transporter Wheels
Place blocks at the front and rear of the trailer wheels.
Note: Before moving the machine on to the trailer, make

sure that the machine will not foul on the ramp/trailer
angle.
2 Move the Machine onto the Trailer
Note: Machines equipped with the 2.18 m dipper should

be loaded with the dozer blade towards the rear of the
trailer and the boom/dipper towards the front. This
eliminates the possibility of the bucket fouling the dozer at
step f.
a Make sure the ramps are correctly in place and

secure. The ramp angle should not exceed 15 °.
b Slew the cab to make sure the excavating

equipment is in a position where it will not interfere
with your view of the ramp and trailer. Fully raise
the dozer blade.
c Slowly and carefully drive the machine onto the

trailer.
d When the machine is safely in position, slew the

cab to face forwards.
e Place wooden blocks on the trailer in front of the

machine.
f Crowd the bucket/attachment and swing in the

dipper. Lower the boom until the dipper rests on
the wooden blocks. Lower the dozer blade.
6740-1

56 OPERATION 56
TRANSPORTING THE MACHINE

(continued)
! CAUTION
If you do not crowd the bucket/attachment the cab
could be damaged as the dipper is swung in.
8-2-8-5
! CAUTION
Do not transport the machine with any of the rams fully
extended. A fully extended ram could suffer damage
due to road shocks.
8-2-8-6 A
g Turn the Servo Isolator Switch (see Right
Console) to OFF.
h Stop the engine (see Stopping the Engine).
j Secure the cab.
k Cover the exhaust stack.
3 Secure the Machine to the Trailer
Fasten the undercarriage to the trailer using chains at

four positions A (two each side) as illustrated. Make
sure the chains are strong enough for the purpose.
Chain the dipper arm to the trailer using either the

hook, shackle or link as appropriate (item B).
4 Measure the Machine Height
Measure the maximum height of the machine from the

ground. Make sure that the transporter driver knows
the clearance height before he drives away.
5 Unloading the Machine from the Trailer
Unloading is a reversal of the procedures described in

steps 2 and 3.
A A
JS08423
6740-1

57 OPERATION 57
USING YOUR MACHINE

(continued)
Installing a Bucket ! WARNING

Note: This job is easier done by two people - one to driving metal pins in or out. Use a soft faced hammer
operate the controls and one to line up the pivots. or drift to remove and fit metal pins. Always wear
safety glasses.
1 Position the Bucket INT-3-1-3
Set the bucket flat on level ground as shown, using a 3 Engage the Dipper
suitable lifting device. Block the bucket to prevent its
movement. Carefully operate the controls to line up hole A in the
dipper with hole B in the bucket.
2 Drive the Machine Squarely Up to the Bucket
Insert pivot pin C and secure with linch pin D.
! WARNING 4 Engage the Tipping Link
If two people are doing this job make sure that the
person working the controls is a competent operator. If Operate the bucket ram to align the tipping link E with
the wrong control lever is moved, or if the controls are hole F on the bucket. Insert pivot pin G and secure
moved violently, the other person could be killed or with linch pin H.
injured.
2-2-6-5
A
E
B
F
H
JS03960
6740-1

58 OPERATION 58
USING YOUR MACHINE

(continued)
Removing a Bucket
1 Position the Boom ! WARNING
Swing the boom straight in front of the machine. Rest driving metal pins in or out. Use a soft faced hammer
the bucket on level ground, with the dipper or drift to remove and fit metal pins. Always wear
approximately vertical and the bucket flat as shown. safety glasses.
Block the bucket to prevent its movement. INT-3-1-3
2 Remove the Pivot Pins

! WARNING
Stand clear and to one side of the bucket while you Remove linch pin A. Withdraw tipping link pivot pin B.
remove the pivot pins. With the pins removed, the Then remove linch pin C. Withdraw dipper pivot pin D.
bucket could roll over.
2-2-6-6
3 Withdraw the Dipper
! WARNING Using the controls, carefully lift the dipper clear of the
If two people are doing this job make sure that the bucket.
person working the controls is a competent operator. If
the wrong control lever is moved, or if the controls are
moved violently, the other person could be killed or
injured.
2-2-6-5
JS03970
6740-1

59 OPERATION 59
USING YOUR MACHINE

(continued)
Connecting Hydraulic Hoses

Many dipper mounted attachments are hydraulically
powered. These use the auxiliary hydraulic pipes (if fitted)
mounted on each side of the dipper.
1 Stop The Engine
! WARNING
Hydraulic Fluid
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 A
signs of hydraulic fluid. If hydraulic fluid penetrates
your skin, get medical help immediately.
INT-3-1-10/1
! 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 JS06720
pressure trapped in the hoses. Make sure the engine
cannot be started while the hoses are open.
INT-3-1-11/1
Note: Only one of the hydraulic pipes is shown. The pipe
2 Relieve System Pressure on the opposite side of the dipper is a mirror image of that
shown.
Operate the machine controls to relieve pressure in
the hydraulic circuits.
Switch OFF and remove the starter key.
3 Vent hydraulic tank pressure (see Releasing Tank

Pressure in MAINTENANCE section).
4 Connect the Hoses
Remove end caps A and connect the hoses, after first

making sure the connectors are clean. Make sure you
fit the hoses the right way round, if appropriate (the
pipe on the right side of the dipper is the feed for uni-
directional attachments). Tighten the hose fittings fully.
6740-1

60 OPERATION 60
USING YOUR MACHINE

(continued)
Bucket Teeth
A wide range of 'Super V' teeth is available for your
machine. This means that you can cater for all digging
conditions. The 'Super V' system consists of: 3
1 Adaptor
1
2 Tooth
3 Locking pin
2
The adaptor remains fitted to the bucket and the teeth can
be easily and quickly changed by one man. The method of
fitting is the same for all types of teeth. See Fitting Bucket
Teeth. A272410
For details of current and future availability, see your JCB

distributor.
6740-1

61 OPERATION 61
USING YOUR MACHINE

(continued)
Removing Bucket Teeth Fitting Bucket Teeth

1 Position the Bucket 1 Do Steps 1 and 2 of Removing Bucket Teeth.
Make sure that the bucket is securely supported off the 2 Fit the Tooth
ground to leave sufficient space for removal of the
locking pin. a Fit the tooth over the adaptor by reversing step 4
of Removing Bucket Teeth.
2 Switch Off the Engine b Insert a new locking pin as shown at C. Make sure
that the locking pin is the right way round, i.e. the
Remove the starter key. arrow pointing downwards on the outside edge.
3 Remove Tooth Locking Pin c Carefully tap in the locking pin with a hammer until
it is flush with its guide and locks in position, as
Using a hammer and suitable drift, knock the locking shown at D.
pin down and out of its guide, as shown at A. Discard
the locking pin which should not be re-used.
4 Remove the Tooth
Take it off the nose as shown at B.
A B
C D
A272420
6740-1

62 OPERATION 62
USING YOUR MACHINE

(continued)
Digging
1 When choosing a digging position, avoid digging
downhill if possible. Whenever possible, dump the load
on the uphill side of the excavation. Both these
precautions will help to keep the machine stable.
To start the dig, reach out with the boom and dipper
and position the bucket as shown.
JS08390
2 Slowly close the bucket and at the same time bring the
dipper in. Make sure the bucket stays at the same
angle to the ground while it travels. If necessary, at the
same time apply a downward pressure on the boom,
to increase the digging force on the bucket.
When the bucket is full, close it fully and at the same

time move the dipper out a little way. This will keep soil
from building up under the machine.
JS08401
3 Swing the bucket towards the dump area. Start

dumping as the bucket approaches the pile. Do not
waste time by dumping too far from the excavation.
Dump close to the start dig position. Swing the bucket
back to the excavation and start the next dig.
Note: Do not use the side of the excavation to stop the

bucket. This could damage the machine.
Backfill the excavation by loading the bucket with soil

from the pile. Do not push the soil with the side of the
bucket.
JS08411
6740-1

63 OPERATION 63
USING YOUR MACHINE

(continued)
Digging near Walls Backfilling
! WARNING When backfilling on a slope, pile the material on the high

When digging near a wall, take care not to undermine side of the trench if possible.
the foundations. The wall could collapse.
2-2-7-1 Set the bucket level to the ground. Select a bucket height
and excavating speed which will give you maximum depth
of cut without overloading the machine. Work at right
Digging on Slopes angles to the trench, filling a bucket's width at a time.
Leave any spillage until the trench is filled. Use the spillage
To dig a vertical trench on a slope, if possible cut a level to finish the job by driving the length of the trench with
base to work from. Dump the trench material on the uphill bucket low to the ground.
side of the trench, far enough away to prevent it falling
back into the trench. Dozing/Grading
For dozing or coarse grading, lower the dozer blade to
Dumping into a Truck ground level and drive the machine forward.
Position the truck(s) as shown to cut out unnecessary As an alternative means of dozing or for fine grading, use
manoeuvring. the bucket, keeping the bottom parallel to the ground.
When grading a site, use forward travel to remove high
Do not dump the material in one sudden movement. Roll spots. Use the soil collected this way to fill in the troughs
the bucket forward in stages until it is empty. Use the when reversing.
joystick to rock the bucket back and forth to loosen any
sticky material. Do not use excessive down pressure on the bucket, or the
machine could lose traction. Use the bucket teeth in hard
Keep the wind on your back. This keeps the dust away material.
from you and your machine.
Scraping and Cutting
If the truck body is about as long as a bucket's width, tip
the load into the centre of the truck. If the truck is two If a deep cut is to be made, do it in steps of about 50 mm
bucket-widths long or more, load the front of the truck first. (2 in).
During the final cut, do not make fine adjustments by

altering the bucket height. Adjust by altering the bucket
angle, or the bucket may leave ruts in the surface.
JS03890
6740-1

64 OPERATION 64
USING YOUR MACHINE

(continued)
Lifting
Before using this machine for lifting purposes, read Lifting When you are using the dipper movement to lift, always lift
(Craning) Regulations and Safe Working Loads in the by moving the dipper away from you, as shown at C, not
SPECIFICATIONS section of this handbook. towards you. This is because hose burst protection valves
(if fitted) are provided only on the dipper out side.
! CAUTION
Before lifting a load read the following: Inside the cab are the Load Charts which refer to lift
capacities relevant to machine specification when
Always use lifting tackle which is strong enough and equipped with an approved JCB tipping link, shackle and
in good condition. Check the load weight before bucket ram.
choosing the lifting chains. Weights of buckets, slings and auxiliary devices must be
deducted from these capacities. Care must be taken to
A bucket should be fitted when lifting. Check that the ensure that these loads are not exceeded.
load is not greater than the safe working load for the
bucket. Note: In certain countries Safety Regulations in force call
for the application of specific safety factors. Consult your
Use a signalman when lifting. Make sure you both JCB distributor for information.
understand and use the recognised signals. Attach a
handline to the load. Make sure the person holding the
handline stands clear of the load and the machine.
Test the load by lifting it 25-50mm (1or 2 inches) and
slowly manoeuvring it across the ground with the
controls.
Keep all persons clear of the load and machine while

the load is on.
Lower the load to the ground if you feel any instability

of the load or the machine.
Failure to take these precautions could result in death

or injury.
8-2-6-4
When the excavator is being used as a crane, the correct

JCB lifting shackle A must be fitted. The bucket ram must
be fully extended as at B. A bucket must be fitted to
prevent the link swinging.
Note: The lifting shackle must be removed when

excavating to prevent the possibility of damage.
C
A
JS04100
JS08261
6740-1

65 OPERATION 65
USING YOUR MACHINE

(continued)
Pulling Out From Soft Ground

If the machine gets bogged down in soft ground, the
excavator controls can be used to assist in getting moving
again.
To free the machine it is necessary to put something

underneath the track(s) to provide grip. Proceed as follows:
1 One Side Bogged Down
a Swing the boom towards the side to be freed and

stop it when at 90° to the track.
b Set the dipper at 90° to the boom and crowd the

bucket.
c Lower the boom until the bucket touches the

ground. If necessary place a board, or something
else with broad ground contact, under the bucket.
d Lower the boom further so as to lift the bogged

down track off the ground.
e Place a mat, board or log, etc. beneath the track

and raise the boom until the track rests on it.
f Drive the machine away.
2 Both Sides Bogged Down
Carry out the steps a to e of One Side Bogged Down

for both sides of the machine. Then drive the machine
away.
Alternatively proceed as follows:
a Set the boom and dipper as if to dig, and lower the

bucket teeth into the ground directly in front of the
machine.
b Then, at the same time, draw in the dipper and

drive the machine forward.
c The machine will be dragged out of the soft

ground.
6740-1

66 OPERATION 66
REFUELLING
Fuel Level
The amount of fuel in the tank is indicated on the Fuel
Gauge (see Display Monitor). You should fill the tank at
the earliest opportunity when the gauge reading A
approaches E.
Filling the Tank
For location of the fuel tank filler cap refer to Component
Location Diagram at the end of MAINTENANCE section.
Use the correct fuel (see Fuel System in MAINTENANCE
section).
! WARNING
Do not use petrol in this machine. Do not mix petrol
with the diesel fuel. In storage tanks the petrol could
rise to the top and form flammable vapours.
INT-3-1-6 A343420
! WARNING
Diesel fuel is flammable. Keep flames away from the
machine. Do not smoke while fuelling 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
Fill through filler cap A.

At the end of every working day, fill the tank with the
correct type of fuel. This will prevent overnight
condensation from developing in the tank.
Note: When filling the fuel tank take care that the filler
nozzle does not damage the gauze filter inside the filler
tube.
We recommend that you lock the fuel cap to prevent theft
and tampering.
Refuelling Pump (Optional)
If a pumped supply of fuel is not available, you may refuel
from cans or drums using the optional refuelling pump.
Maximum pump operating time is 30 minutes. Allow the
B
pump to cool before re-using.
! CAUTION
Do not allow the pump to run dry for more than 30
seconds.
8-2-7-2
Using the Refuelling Pump

Remove the fuel tank filler cap A to let the air escape. C
Check the suction end of the hose B is clean. If dirty, use
a small container of fuel to clean the suction end. Place
the suction end of the refuel pump hose B into the fuel
supply, either fuel can or barrel.
To fill the fuel tank, lift switch C, to start the refuel pump.
The fuel level can be monitored using the fuel gauge
mounted on the side of the tank. Care must be taken not
to overfill the fuel tank. When the switch is released it will 367661
automatically revert to the OFF position.
The speed of the refuel pump is 30 litres/min.
6740-2

67 OPERATION 67
STORAGE
If the machine is to be out of use for an extended period, During Storage

careful preparation and on-going care will minimise the
possibility of deterioration and damage while in storage. At least once a week, operate the machine functions to
prevent rust forming in the engine and hydraulic circuits,
Storage Sites and to minimise deterioration of the hydraulic seals.
Ideally the machine should be stored inside a dry building 1 Clean off Anti-rust Oil
or shelter.
Remove the anti-rust oil from all ram piston rods.
If only outdoor storage is available, look for a well drained,
well ventilated site. 2 Install a Fully Charged Battery
Preparing for Storage 3 Start the Engine
1 Wash the Machine Allow the engine to warm up (see Engine Warm-Up).
2 Grease Moving Parts 4 Operate the Hydraulic Controls
See Greasing in MAINTENANCE section. Check that the hydraulic functions are operating
correctly.
3 Check the Engine Oil
5 Prepare for Re-storage
Top up if necessary (see Engine Oil and Filter in
MAINTENANCE section). See Putting into Storage.
4 Check the Coolant Level Taking Out of Storage

Top up if necessary (see Engine Cooling System in 1 Check the Engine Oil Level
MAINTENANCE section).
See Engine Oil and Filter in MAINTENANCE section.
Putting into Storage
2 Check the Coolant Level
1 Indoors and Outdoors
See Engine Cooling System in MAINTENANCE
a Close the dipper and bucket rams. Lower the section.
boom to rest the bucket on the ground (onto
wooden blocks if outdoors). 3 Clean off Anti-rust Oil
b Protect the exposed parts of all ram piston rods by Remove the anti-rust oil from all ram piston rods.
coating with anti-rust oil.
4 Install a Fully Charged Battery
c Stop the engine and then vent the hydraulic
pressure by operating the excavating controls a 5 Start the Engine
few times.
Allow the engine and hydraulic oil to warm up (see
d Remove the battery, charge and store separately. Engine Warm-Up).
2 Outdoors 6 Operate the Machine Controls
a Place suitable timbers under the tracks to Check the tracking, slew and excavator functions
eliminate direct contact with the ground. (including offset boom, if fitted) several times to verify
their correct operation.
b Cover the machine with tarpaulins or plastic
sheets.
6740-1


81 MAINTENANCE 81
SERVICE CONTRACTS
To make sure that your machine keeps working to We strongly advise you to take advantage of a regular
maximum efficiency, it is essential that it is properly and service contract. Consult your JCB distributor for full
regularly maintained in accordance with the service details.
schedules included in this handbook.
REGULAR MAINTENANCE AND LUBRICATION SCHEDULES
A poorly maintained machine is a hazard. Doing the Initial Precautions for New Machine
regular maintenance and lubrication jobs listed in these Usage
schedules will help keep the machine in safe running
order.
! CAUTION
Apart from the daily jobs, the schedules are based on If the machine is operated at full load before its initial
machine running hours. Keep a regular check on the run-in procedure is complete it may cause scuffing
hourmeter reading. Do not use a machine which is due for and seizing which can adversely affect the life of the
a regular service. Rectify any defects found during regular machine.
maintenance before clearing the machine for use. 8-3-1-5
Note: Use of a rockbreaker attachment will necessitate A new machine is only dispatched when all inspection
more frequent servicing of the hydraulic circuit of the procedures are complete, but operating it too hard before it
machine. The actual servicing frequency will depend on is run-in will affect its performance and shorten its service
what percentage of overall use involves the rockbreaker. life. During the running-in period pay particular attention to
Refer to page 85 for full details. the following:
1 Carry out the daily inspection procedure.

! WARNING
Maintenance must be done only by suitably qualified 2 Always warm up the machine (see Engine Warm-up
and competent persons. or Cold Climate Warm-up as appropriate).
Before doing any maintenance make sure the machine 3 Check that the machine is running normally.
is safe, it should be correctly parked on level ground.
4 Avoid running or slewing the machine rapidly.
To prevent anyone starting the engine, remove the
starter key. Disconnect the battery when you are not 5 Avoid sudden shocks e.g. suddenly stopping the boom
using electrical power. If you do not take these when lowering.
precautions you could be killed or injured.
8-3-1-1 6 Where applicable, grease the front pins daily.
7 Carry out the initial (100 hrs) service.

A Service History Record Book is supplied with every
machine to enable you to plan your service
requirements and keep a service history record. This
record book should be dated, signed and stamped by
your Distributor at machine installation and each time
your machine is serviced.
2-3-1-9
6740-1

82 MAINTENANCE 82
SERVICE SCHEDULES
Every 10 Operating Hours or Daily Every 100 Operating Hours or 2-Weekly

Whichever occurs first Whichever occurs first
1 Clean 1 Do a 50 hour service plus:
a Machine generally.
2 Clean
2 Grease a Battery terminals.
(If operating in very wet or severe conditions)
b Fuel lift pump strainer†.
a Bucket/dipper pivot points.
3 Change
3 Check (Engine Stopped) a Engine oil main filter element †.
a Generally for damage. b Engine oil †.
b For oil and coolant leakage. c Servo oil filter element †.
d Engine oil filter by-pass element †.
c Security of bolts and nuts ††.
e Return filter element†.
d For disconnected or shorted wiring, loose
f Drain filter element †.
terminals.
g Track gearbox oil†.
e Hydraulic fluid level.
h Fuel filter element†.
f Engine oil level.
4 Check (Engine Stopped)
g Track tension. a Hoses and pipework for chafing or damage.
h Windscreen washer fluid level. b Condition of ram piston.
j Fuel system for leaks. c Bucket pivot pin grease seals†.

d Track plate condition.
k Fuel level.
e Track and running gear.
l The auxiliary circuit hydraulic oil filter visual f Top and bottom track rollers for oil leaks †.
indicator (if using a rockbreaker)
g Track idler wheels for oil leaks †.
†† Tapping with a hammer will identify any loose nuts and
h Security of major unit mounting bolts and nuts†.
bolts which should then be tightened to the specified
If loose, tighten to specified torque.
torque.
i Wiring for chafing.
4 Check (Engine Running)
a Operation of warning lights and audible alarm. j Fan belt adjustment†.
k Accumulator operation.
b Operation of other electrical equipment.
l Radiator for damage.
c Exhaust for excessive smoke.
m Oil cooler for damage.
d Excavator operation. n Battery electrolyte level†.
e Transmission operation. p Exhaust system security†.

r Teeth and sidecutters†.
f Operation of track and slew brakes.
5 Check (Engine Running)
g Operation of hour meter.
a Operation of throttle system†.
Every 50 Operating Hours or Weekly b Operation of overload warning†.
Whichever occurs first c Operation of stop control†.
1 Do the daily jobs plus: † These procedures are only to be carried out after the
first 100 hours use of a new machine. Thereafter they are
2 Clean to be carried out as detailed in the following periodic
a Drain water and sediment from fuel tank. checks.
b Drain fuel water separator.
3 Grease
a All pivot pins.
6740-1

83 MAINTENANCE 83
SERVICE SCHEDULES
(continued)
Every 250 Operating Hours or Monthly Every 1000 Operating Hours or 6-Monthly
Whichever occurs first Whichever occurs first
1 Do a 100 hour service plus: 1 Do a 500 hour service plus:
2 Clean 2 Clean
a Drain water and deposits from hydraulic oil tank. a Fuel lift pump strainer.
b Air cleaner dust valve. b Hydraulic fluid suction strainer.
3 Grease 3 Change (Engine Stopped)

a Door and canopy hinges. a Engine air filter element (outer).
b Slew ring bearing. b Hydraulic tank air breather element.

c Track gearbox oil.
4 Change
a Engine oil. d Return filter element.†††
b Engine oil full flow filter element. e Nephron filter.†††
5 Check (Engine Stopped) f Servo oil filter element.†††
a Battery electrolyte level.
g Drain filter.†††
b Security of major unit mounting bolts and nuts.
If loose, tighten to specified torque.
a Track wear.
c Track gearbox oil level.
Every 2000 Operating Hours or Yearly
d Fan belt adjustment. Whichever occurs first
e Air inlet system security 1 Do a 1000 hour service plus:
Every 500 Operating Hours or 3-Monthly
a Sample hydraulic oil and replace if necessary.
Whichever occurs first
1 Do a 250 hour service plus: 3 Grease
a Slew gearbox
2 Clean
a Radiator, grille and oil cooler fins. 4 Change
a Hydraulic fluid suction strainer.
3 Grease
a Slew ring teeth. b Engine air filter element (inner).
4 Change Every 4000 Operating Hours or 2 Years

a Fuel filter element. Whichever occurs first
5 Check (Engine Stopped) 1 Do a 2000 hour service plus:
a Exhaust system security.
2 Change
b Top and bottom track rollers for oil leaks. a Top and bottom track roller oil
c Track idler wheels for oil leaks. b Long life coolant.
d Hydraulic oil (check the degradation and c Fuel hose (fuel tank - engine).
cleanliness by sampling).
d Fuel hose (fuel filter - injection pump).
e Seat belt condition and security.
e Hydraulic pump exit hose (pump - operation valve).
f Teeth and sidecutters.
f Boom ram line hose.
6 Check (Engine Running) g Dipper ram line hose.
a Operation of throttle system.
h Bucket ram line hose.
b Operation of overload warning.
†††If using a breaker, see page 85 for revised servicing
c Operation of stop control. schedules.
6740-1

84 MAINTENANCE 84
SERVICE SCHEDULES
(continued)
Every 5000 Operating Hours or 2 Years

6 Months
Whichever occurs first
1 Do a 1000 hour service plus:
2 Change
a Hydraulic oil.
b Hydraulic tank air breather element.
c Hydraulic suction filter.†††
††† If using a breaker, see page 85 for revised servicing

schedules.
6740-1

85 MAINTENANCE 85
REVISED SERVICE SCHEDULES - ROCKBREAKER USAGE
Note: The following servicing intervals should be adopted

instead of those called for in the Service Schedules when
a rockbreaker is used regularly.
Servicing Intervals (hours)

Servicing Operation
100% usage 40% usage 20% usage 10% usage
Hydraulic Oil - check level 10 10 10 10

- change 600 1500 3000 4000
Return Filter Element - change+ 100 300 600 800
Suction Strainer - clean 100 300 600 800

- change 600 1500 3000 4000
Servo Oil Filter - change 100 300 600 800
Drain Filter - change 100 300 600 800
Nephron Filter - change 100 300 600 800
Breaker In-line Filter - change 100 300 600 800
Hydraulic Oil - sampling 200 300 600 800
+ It is recommended that oil samples are taken and

analysed immediately prior to each Return Filter
Element change.
6740-1

86 MAINTENANCE 86
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 24 270~310 27.6~31.8 200~230
2* Drive Sprocket M14 22 165~215 17~22 120~160
3* Idler Wheel M10 17 62~73 6.4~7.4 45~55
4* Upper (Carrier) Roller M16 24 270~310 27.6~31.8 200~230
5* Lower (Track) Roller M12 19 110~130 11~13 80~95
6* Grease Cylinder M12 19 110~130 11~13 80~95
7* Track Guard M12 19 110~130 11~13 80~95
8 Shoe Bolt M12 19 195~235 20~24 140~175
9* Counterweight M24 36 660~770 65~80 485~570
10* Turntable Bearing (Undercarriage) M16 24 250~285 25~29 180~210
11* Turntable Bearing (Slew Frame) M16 24 250~285 25~29 180~210
12* Slew Equipment M16 24 270~320 27~33 200~235
13* Engine (Engine Mount) M16 24 165~215 17~22 120~160
14* Engine Bracket M10/M16 17/24 65~75/165~215 6.5~7.6/17~22 47~55/120~160
15* Radiator M10 17 30~35 3.1~3.6 22~26
16* Hydraulic Pump M10/M12 17/19 65~75/110~130 6.5~7.6/11~13 47~55/80~95
17* Hydraulic Oil Tank M16 24 160~170 16.3~17.5 118~125
18* Fuel Tank M16 24 160~170 16.3~17.5 118~125
19* Control Valve M12 19 53~65 5.4~6.6 39~48
20* Rotary Coupling M10 17 62~73 6.4~7.4 45~55
21 Cab M16 24 75~90 8~9 55~66
22 Battery M10 17 20~30 2~3 15~21
Note: Use JCB Threadlocker and Sealer (High Strength) on those marked * and tighten to the torque listed in the above table.
The tightening torques for the bolts and nuts not listed above are as follows:
Bolt Diameter (size) M6 M8 M10 M12 M14 M16 M18 M20

Wrench mm 10 13 17 19 22 24 27 30
Hex. bolt Nm 6.9 15.7 32.3 58.8 98.0 137.2 196.0 274.4
Tightening
kgf m 0.7 1.6 3.2 5.9 9.8 13.7 19.6 27.4
Torque
lbf ft 5 12 24 43 72 101 145 203
Wrench mm 5 6 8 10 12 14 14 17
Hex. socket head Nm 8.8 21.6 42.1 78.4 117.6 176.4 245.0 343.0
Tightening
bolt kgf m 0.88 2.2 4.2 7.8 11.8 17.6 24.5 34.3
Torque
lbf ft 6.5 16 31 58 87 130 180 253
6740-1

87 MAINTENANCE 87
LUBRICANTS - HEALTH AND SAFETY
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. New Oil
If oil is swallowed you should not induce vomiting. Get There are no special precautions needed for the handling
medical advice. or use of new oil, beside normal care and hygiene
practices.
Skin
In the case of excessive skin contact you should wash with Used Oil
soap and water. Used engine crankcase lubricants contain harmful
contaminants. In laboratory tests it was shown that used
Eyes engine oils can cause skin cancer.
In the case of eye contact, flush with water for 15 minutes.
If irritation persists, get medical attention. Here are precautions to protect your health when handling
used engine oil:
Fires
Extinguish with carbon dioxide, dry chemical or foam. 1 Avoid prolonged, excessive or repeated skin contact
Firefighters should use self contained breathing apparatus. with used engine oils.
Hygiene 2 Apply a barrier cream to the skin before handling used

engine oil.
JCB lubricants are not a health risk when used properly for
their intended purposes. 3 Note the following when removing engine oil from skin:
However, excessive or prolonged skin contact can remove a Wash your skin thoroughly with soap and water.
the natural fats from your skin, causing dryness and b Using a nail brush will help.
irritation. c Use special hand cleansers to help clean dirty
hands.
Low viscosity oils are more likely to do this, therefore d Never use petrol, diesel fuel or gas oil.
particular care is necessary in handling used oils which e Avoid skin contact with oil soaked clothing.
can be diluted with fuel contamination. f Don't keep oily rags in pockets.
g Wash dirty clothing before re-use.
Whenever you are handling oil products you should h Throw away oil-soaked shoes.
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 Waste Disposal
authority, and note the following:
All waste products should be disposed of in accordance
Storage with all the relevant regulations.
Always keep lubricants out of the reach of children. The collection and disposal of used engine oil should be in
accordance with any local regulations. Never pour used
Never store lubricants in open or unlabelled containers. 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.
6740-1

88 MAINTENANCE 88
CLEANING THE MACHINE
Exterior Interior
Clean the exterior of the machine using water and/or ! CAUTION
steam. If steam is used the machine must be completely Never use water or steam to clean inside the cab. The
greased afterwards. See Greasing. use of water or steam could damage the on-board
computer and render the machine inoperable. Remove
Pay particular attention to the cab windows. Make sure that dirt using a brush or damp cloth.
the radiator grille is not blocked. 8-3-4-1
CHECKING FOR DAMAGE
Check all bucket teeth for damage and security.

Inspect steelwork for damage. Note damaged paintwork for
future repair.
Check all lamp lenses for damage.
Make sure all pivot pins are correctly in place and secured
Check that all safety decals are in place and undamaged.
by their locking devices.
Fit new decals where necessary.
Ensure that the steps and handrails are undamaged and
secure.
Check for broken, cracked or crazed window glass.

Replace damaged items.
6740-1

89 MAINTENANCE 89
GREASING
You must grease the machine regularly to keep it working Do not mix different types of grease. Keep them separate.
efficiently. Regular greasing will also lengthen the
machine's working life. ! WARNING
You will be working close into the machine for these
Greasing should be done with a grease gun. Normally, two jobs. Lower the attachments if possible. Remove
strokes of the gun should be enough. Stop greasing when starter key and disconnect the battery. This will
fresh grease appears at the joint. prevent the engine being started.
8-3-1-3
For the type of grease to use at each point, see
Lubricants and Capacities.
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

Location Diagrams at the end of this section.
1 Make the Machine Safe
Stop the engine and remove the starter key.
2 Grease the Slew Ring
a Remove cover A and discharge port plug B.
b Apply grease to the slew ring via aperture C.
3 Slew the Machine
Start the engine and slew the machine a few degrees.

Stop the engine, remove the starter key and apply
B
grease again.
C
Repeat until the whole ring is greased. Check that A
grease exudes around the entire circumference.
4 Refit the Cover
Refit discharge port plug B and cover A.
Slew Ring Bearing

Three grease nipples are mounted on the slew ring D
D
A353220
6740-1

90 MAINTENANCE 90
GREASING
(continued)
Excavator End (Standard Boom) ! WARNING

(50 hours) You will be working close into the machine for these
jobs. Lower the attachments if possible. Remove the
Read general information about greasing at the beginning starter key and disconnect the battery. This will
of this section. prevent the engine being started.
8-3-1-3
Each arrow highlights one grease point.
19 Grease points
5
1 4
4
2 6 3
6 6 4
3 33 A351020
1 2 3
A343930
4 5 6
A343940
6740-1

91 MAINTENANCE 91
GREASING
(continued)
Excavator End (Offset Boom) ! WARNING

(50 hours) You will be working close into the machine for these
jobs. Lower the attachments if possible. Remove
Read general information about greasing at the beginning starter key and disconnect the battery. This will
of this section. prevent the engine being started.
8-3-1-3
Each arrow highlights one grease point.
27 Grease points
5A
5A
1 5A
5A
5A 5B
5B 5B
5A
2 6 4 4
6 3
3
A351120
6 3
1 2 3
4 5A 6
A353321
5B A343940
A353310
6740-1

92 MAINTENANCE 92
ENGINE AIR FILTER
Changing the Outer Element 1 Stop the engine.
2 Press clips A and lift off cover B. Remove outer

! CAUTION element C. Take care not to tap or knock the element.
The outer element must be renewed immediately if the
warning light on the instrument panel illuminates. 3 Clean the inside of cover B and canister D.
2-3-3-1
4 Insert a new element into the canister, check seal E is

Note: Do not attempt to wash or clean the elements - they fully seated. Fit cover B with dust valve F at the
must only be renewed. bottom. Push the cover firmly into position and make
sure it is secured by clips A.
Note: Do not run the engine with the dust valve F removed.
5 Make sure that the wire is connected to the Air Filter
Note: Change the outer element more frequently if Blocked switch.
operating in dusty conditions. A new inner element must be
fitted at least every third time the outer element is changed. 6 Check all hoses for condition and tightness.
As a reminder, mark the inner element with a felt tipped pen
each time the outer element is changed.
A
A336941
F
6740-1

93 MAINTENANCE 93
ENGINE AIR FILTER

(continued)
Changing the Inner Element

4 Clean the inside of cover B and canister D.
Note: Do not attempt to wash or clean the elements - they
must only be renewed. 5 Carefully insert the new inner element G into the
canister. Make sure it seats correctly. Check seal H is
Note: Do not run the engine with the dust valve F removed. fully seated
Note: A new inner element must be fitted at least every 6 Insert a new outer element C into the canister, check
third time the outer element is changed. As a reminder, seal E is fully seated. Fit cover B with dust valve F at
mark the inner element with a felt tipped pen each time the the bottom. Push the cover firmly into position and
outer element is changed. make sure it is secured by clips A.
1 Stop the engine. 7 Make sure that the wire is connected to the Air Filter
Blocked switch.
2 Press clips A and lift off cover B. Remove outer
element C. 8 Check all hoses for condition and tightness.
3 Lift up pulls J and remove inner element G.
G
H
C
J
A
A336941
F
6740-1

94 MAINTENANCE 94
ENGINE OIL AND FILTER
Checking the Oil Level

1 Prepare the Machine 4 Fill the System
Park the machine on level ground. Lower the bucket to Fill the engine with new oil through the filler B. See
the ground. Lubricants and Capacities for type and amount.
2 Stop the Engine Wipe off any spilt oil. Check for leaks. Make sure the
filler cap is correctly refitted.
3 Open the Engine Compartment 5 Check for Leaks
4 Check the Oil Level Start the engine and go through the warming-up
procedure (see Engine Warm-Up).
Remove dipstick A. Oil should be between H and L
marks. Add oil if necessary, through filler B. Use only When warming-up is complete, stop the engine and
the recommended oil, see Lubricants and check for leaks.
Capacities. Make sure that the dipstick and filler cap
are secure.
Changing the Oil and Filter

1 Do steps 1 to 3 of Checking the Oil Level B
2 Drain the Oil
Place an oil collecting container of suitable size

beneath the engine sump drain point.
a All machines except for German market
Remove the drain plug at C and allow the oil to

drain completely. Clean the drain plug and its
aperture in the sump, refit and tighten firmly. Do A
not overtighten or the threads could be
stripped.
C
b German machines only
A335250
Obtain from the tool box the drain tube. Remove
the sump drain valve dust cover from location C.
In its place, after locating the drain tube inside the
oil collecting container, firmly attach the drain tube
to the adapter. The oil will automatically drain
once the tube is connected. When the oil has
drained completely, remove the tube and clean
D
the drain valve and the valve dust cover. Refit the
dust cover.
3 Change the Filter
a Unscrew the filter canister D. Remember that the

filter will be full of oil.
b Clean the filter head. JS08770
c Smear the seal on the new filter with oil.
d Tighten the filter until the seal bites onto the filter
housing.
e Tighten the filter a minimum of one more full turn.
6740-2

95 MAINTENANCE 95
ENGINE COOLING SYSTEM
Checking the Coolant Level

1 Park the Machine on Level Ground
Stop the engine and let it cool down. Open the engine
compartment.
! WARNING A
The cooling system is pressurised when the coolant is
hot. Hot coolant will burn you. Make sure that the
engine is cool before checking the coolant level or
draining the system.
2-3-3-3
2 Release System Pressure
For location of engine cooling radiator, refer to

Component Location Diagrams at the end of this JS04410
section.
Carefully slacken cap A. Let any pressure escape.

Remove the cap.
3 Check the Level
The level should be between the FULL and LOW

marks on the expansion bottle B. Top up the bottle
with pre-mixed water/antifreeze if necessary. See
Coolant Mixtures.
4 Refit the Pressure Cap A
Make sure it is tight.

Note: Check the quality of the antifreeze mixture every
year - before the cold weather starts. Change it every two
years.
Coolant Mixtures
To prevent the coolant freezing in cold conditions,
antifreeze must be added. JCB Four Seasons Antifreeze
and Summer Coolant will give protection down to the
temperatures shown in the table.
Antifreeze Solution Starts to freeze at
55% -36 °C (-33 °F)

Never use less than a 50% solution otherwise there will not
be enough corrosion protection.
B
A336961
Never use more than 60% solution otherwise the cooling

system may be damaged.
Leave the antifreeze in all the year round as it gives
protection against corrosion.
Check the strength of antifreeze solution at least once a
year, preferably at the start of the cold period. Always
renew the antifreeze every two years.
A 50% antifreeze mixture should be used even if frost

protection is not needed. This gives protection against
corrosion and raises the coolant's boiling point.
6740-1

96 MAINTENANCE 96
ENGINE COOLING SYSTEM

(continued)
Changing the Coolant

1 Do Steps 1 and 2 of 'Checking the Coolant Level'
2 Drain the System
Open the radiator drain tap, on the bottom of the

radiator. Remove the cylinder block drain plug B.
Remove the expansion bottle cap (see Checking the
Coolant Level). Let the coolant drain out.
B
! CAUTION
Keep your face away from the drain hole when
removing the drain plug.
2-3-3-4
A335250
3 Flush the System
If necessary. Use clean water.
4 Refit the Drain Plug
Clean and refit the drain plug, making sure it is tight.

Close the radiator drain tap.
5 Fill the System
Using the necessary mix of clean, soft water and

antifreeze, (see Coolant Mixtures) fill via the
expansion bottle cap until the level in the bottle is
between the FULL and LOW marks.
6 Refit the Radiator Pressure Cap
7 Refit the Expansion Bottle Cap
8 Check for Leaks
Run the engine for a while to raise the coolant to

working temperature and pressure. Stop the engine.
Check for leaks. Re-check the level in the expansion
bottle and top up if necessary.
Cleaning the Radiator and Oil Cooler

A clogged radiator and/or oil cooler can lead to engine
overheating. Regularly check for a build-up of dirt and
debris and, if necessary, use compressed air to clean-out
the grille. At the same time check all hoses for damage or
perishing, and replace if necessary.
6740-1

97 MAINTENANCE 97
ENGINE
Checking Fan Belt Tension
! WARNING
Make sure that the engine cannot be started.
Disconnect the battery before doing this job.
2-3-3-5 E
1 Prepare the Machine
Put the machine on level ground, lower the bucket to
the ground.
2 Stop the Engine

Remove the starter key.
3 Check the Fan Belt Tension

D
There must be 10 mm (0.4 in) slack on the fan belt C
midway between the alternator A and water pump B.
A344070
4 Loosen the Alternator

Slacken bolts D.
5 Adjust the Fan Belt

a Use adjusting bolt E to re-position the alternator so
as to adjust the fan belt tension.
Note: If the fan belt is stretched so much that it cannot be

adjusted correctly, fit a new belt. B
b When correct tension is achieved fully tighten D A C
and E.
Fitting a New Fan Belt

1 Prepare the Machine and Stop the Engine
Carry out steps 1 and 2 of Checking Fan Belt
Tension.
2 Loosen the Alternator

Slacken bolts D and then adjust bolt E to loosen fan
belt C, so that it can be removed.
3 Fit a new Fan Belt

Remove the fan belt C and replace it with a new one.
Make sure the ‘V’ profile locates in the pulleys
correctly.
Note: It may be necessary to apply leverage to the new

belt to get it over the pulleys.
4 Adjust the Fan belt

Carry out steps 4 and 5 of Checking Fan Belt
Tension.
5 Re-check the Fan Belt Tension

Check after running the machine for 1 hour.
6740-1

98 MAINTENANCE 98
FUEL SYSTEM
Types of Fuel Advice
Use good quality diesel fuel to get the correct power and Consult your fuel supplier or JCB distributor concerning the
performance from your engine. The recommended fuel suitability of any fuel you are not sure about. If you have to
specification is given below. use non-standard fuels, contact your JCB distributor for
advice on engine adjustments and oil change periods.
Cetane Number: 45 (minimum)
Viscosity: 2.5/4.5 centistokes at 40°C (104°F) Petrol
Density: 0.836/0.866 kg/litre (1.046/1.084
lb/pint) ! WARNING
Sulphur: 0.5% of mass (maximum)
Distillation: 85% at 350°C (662°F) Do not use petrol in this machine. Do not mix petrol
with the diesel fuel, in storage tanks the petrol could
Cetane Number rise to the top and form flammable vapours.
INT-3-1-6
Indicates ignition performance. Fuel with a low cetane
number can cause cold start problems and affect
combustion.
Filling the Tank
Viscosity
This is the resistance to flow. If this is outside limits, the Refer to Refuelling in OPERATION section.
engine performance can be affected.
Density
Lower density will reduce engine power. Higher density
will increase both engine power and exhaust smoke.
Sulphur
High sulphur content can cause engine wear. (High
sulphur fuel is not normally found in North America,
Europe or Australia). If you have to use a high sulphur fuel
you must also use a highly alkaline engine lubricating oil;
or change the normal oil more frequently.
Distillation
This indicates the mixture of different hydrocarbons in the
fuel. A high ratio of lightweight hydrocarbons can affect
the combustion characteristics.
Low Temperature Fuels
Special winter fuels may be available for engine operation
at temperatures below 0°C (32°F). These fuels have a
lower viscosity. They also limit wax formation in the fuel at
low temperatures. (Wax forming in the fuel can stop the
fuel flowing through the filter).
Flow improvers may also be available. These can be
added to the fuel to reduce wax formation.
Fatty Acid Methyl Ester Fuels as a replacement for
Diesel Fuels
Fuel resources such as Rape Methyl Ester and Soybean

Methyl Ester, collectively known as Fatty Acid Methyl
Esters are being used as alternatives and extenders for
mineral oil.
Fatty Acid Methyl Esters must conform to certain

standards to be of acceptable quality, just as mineral oils
do at present.
Consult your JCB distributor for advice about the use of

Fatty Acid Methyl Ester fuels, as improper application may
impair engine performance.
6740-1

99 MAINTENANCE 99
FUEL SYSTEM
(continued)
Draining Fuel Tank Impurities

Stop the engine and remove the key.
Remove screws A and take off cover B.
Loosen the drain tap C on the underside of the fuel tank.

Drain the water and deposits until clean diesel oil flows out.
Close the drain tap firmly and refit cover B.
! WARNING
Fuel oil is highly inflammable. Completely wipe off any
spilt fuel which could cause a fire.
8-3-4-3
A A
B JS08371
Draining the Water Separator

The water separator should be drained at least every 50
hours, but more often if necessary.
1. Stop the engine and remove the key.
2. Drain off any water in the bowl by turning tap D.
3. Make sure tap D is turned off and secure.
A351020
Cleaning the Water Separator

If the bowl E contains sediment carry out the following:
1. Hold the bowl E and unscrew the domed nut G.
2. Remove the bowl, wash the bowl in clean fuel. G
3. Clean strainer F.
4. Refit the bowl. Make sure the gasket is in good
condition and positioned correctly. F
E
5. Retighten the nut G, take care not to over tighten.
6. Bleed the fuel system. D
6740-1

100 MAINTENANCE 100
FUEL SYSTEM
(continued)
Changing the Filter Element

1 Stop the Engine
Stop the engine and remove the key.
2 Disconnect the Battery
3 Open the Engine Compartment
Locate the fuel filter element A.
4 Remove the Element

A
Using a chain wrench, unscrew the filter element from
the filter head. Avoid spilling the fuel retained in the
element.
5 Fit the New Element
Smear the new filter element sealing ring with fuel oil
and hand tighten onto filter head. Use a chain wrench
to tighten by a further 2/3 turn.
Cleaning the Lift Pump Strainer

1 Stop the Engine
Switch off the engine and remove the key.
2 Disconnect the battery

B
Locate the priming pump B.
4 Remove the Pump Strainer
Unscrew banjo bolt C and remove complete with

strainer D.
5 Clean the Strainer

D
! WARNING
C
JS08470
When using compressed air, wear safety glasses and
gloves. Do not direct compressed air at your skin.
8-3-4-2
Blow clean with compressed air and then rinse in

clean fuel oil.
6 Refit the Pump Strainer
Insert the clean strainer into the banjo bolt and refit the
bolt to secure the pump feed pipe. Do not overtighten.
6740-1

101 MAINTENANCE 101
FUEL SYSTEM
(continued)
Bleeding the Fuel System

Air in the fuel system could cause misfiring or failure to
start. Air will enter the system if any part of it is
disconnected or emptied.
Note: Running the engine with air in the system could

damage the fuel injection pump. After maintenance,
remove air from the fuel system as detailed below. A
1 Stop the Engine
Switch off the engine and remove the key.
2 Disconnect the Battery
Remove the negative lead to chassis.
Locate bleed plug A and priming pump C.
4 Prepare for Bleeding
Loosen bleed plug A on the fuel filter head. Release

knob B on the priming pump C by turning it anti-
clockwise. The knob will be lifted by spring pressure.
5 Bleed the System
Operate the priming pump knob B until there are no air

bubbles at bleed plug A.
6 Restore the System to Normal
Tighten bleed plug A. Depress knob B and turn

clockwise to lock into priming pump C.
B
7 Check for Leaks C

! WARNING
Fuel oil is highly inflammable. Completely wipe off any
spilt fuel which could cause a fire.
8-3-4-3
Wipe up any spilled fuel. Then start the engine and

check for leaks. JS08480
6740-1

102 MAINTENANCE 102
HYDRAULIC SYSTEM
(continued)
For location of hydraulic oil tank refer to Component

Location Diagrams at the end of this section.
! WARNING
Hydraulic Fluid D
penetrate the skin. Do not use your fingers to check C
for hydraulic fluid leaks. Do not put your face close to E
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

Position the machine on level ground with the bucket A
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.
Releasing Tank Pressure B

! 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
1 Prepare the Machine A336931
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
3 Release Tank Pressure
Remove cap D. Press and hold the projection revealed Remove the starter key.
until all pressure has been released.
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 Lubricants and Capacities for type of fluid to
use.
4 Refit filler port cover E.

6740-1

103 MAINTENANCE 103
HYDRAULIC SYSTEM
(continued)
Changing the Fluid

A
Position the machine on level ground.
engine. Remove the starter key.
Stop the
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 Identification of Machine
Components). 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.
D
5 Renew the Suction Strainer D and Return Filter E
C
(See Cleaning/Changing the Suction Strainer and
Changing the Return Filter.)
6 Tighten drain plug C securely.
7 Refill the tank with the specified oil to the specified

level (see Fluids and Lubricants).
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).
6740-1

104 MAINTENANCE 104
HYDRAULIC SYSTEM
(continued)
Changing the Return Filter Element

1 Prepare the Machine A
Position the machine on level ground. Stop the engine. B
Remove the starter key. C
2 Locate the Return Filter E
3 Release Tank Pressure D

(See Releasing Tank Pressure).
4 Remove the Element

E
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


F
2 Locate the Suction Strainer H
G
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.
6 Check the hydraulic oil level (see Checking the Fluid

Level) and top up if necessary (see Topping-up Fluid H
Level).
6740-1

105 MAINTENANCE 105
HYDRAULIC SYSTEM
(continued)
Changing the Nephron Filter J

E D
1. Prepare the Machine A
F
G
2. Locate the Nephron Filter
Refer to the Identification of Machine Components. H
3. Release Tank Pressure A
(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.
X
Take care not to drop any sediment.
B
5. Fit a New Element C
a Slowly immerse the new Nephron filter A. Install the
O-ring H, cover D, nuts G and bolts F and bolts E.
Y
b Torque tighten bolts E to 20Nm (14.75 lbf ft)
c Open the cocks B and C by turning them to position
Y.
6. Priming the Nephron Filter C
a Start the engine and set at low idling, loosen plug J,
then tighten the plug when hydraulic oil flows out.
B
b. Stop the engine, check the hydraulic oil level and
top-up if low. (See Checking the Fluid Level).
6740-1

106 MAINTENANCE 106
HYDRAULIC SYSTEM
(continued)
Changing the Air Breather Element

1 Prepare the Machine F
Position the machine on level ground. Stop the engine. A

Remove the starter key. B
G
(See Releasing Tank Pressure.) C
3 Locate the Air Breather W E

D W
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 JS03660

packing E.
c Install a new filter element D followed by new

sponge packing E.
5 Refit Filter Cover C
Rotate the cover so that it fits over the stud. Then, in X W

order, install seal washer B, hexagonal nut A and
cover F. Y
Draining Tank Impurities

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.
5 Top up the Hydraulic Oil Tank.

Z
(See Topping-up Fluid Level) and refit plate X/O-ring
Y.
6740-1

107 MAINTENANCE 107
HYDRAULIC SYSTEM
(continued)
Changing the Servo Oil Filter

Position the machine on level ground. Stop the engine

and operate all the hydraulic servo controls to release
system pressure. Turn the starter key to OFF and then
remove it.
See Releasing Tank Pressure.
3 Locate the Servo Oil Filter
Refer to Component Location Diagrams at the end

of this section.
4 Dismantle the Filter B

A351130
a Using a wrench on the case, unscrew filter case A
from filter head B. Take care not to spill the oil it D
contains.
b Remove and discard element C and 'O' ring D. C

5 Clean the Filter Base and Case
Discard any fluid in the filter case. Clean out the case
A
and the underside of the head.
6 Fit New Filter Components
a Coat the new 'O' ring D with hydraulic fluid and

locate in filter head B.
b Coat the seal area of the new element C and

install it in the filter case.
c Screw filter case A to filter head B and tighten with

the wrench.
7 Check the Hydraulic Oil Level
Check (see Checking the Fluid Level) and, if

necessary, top-up the hydraulic oil tank (see Topping-
up Fluid Level).
6740-1

108 MAINTENANCE 108
HYDRAULIC SYSTEM
(continued)
Changing the Breaker In-line Filter (if

fitted) X
Note: This filter should be changed at the intervals stated
in Service Schedules or when the visual indicator X has
popped up. DO NOT USE THE ROCKBREAKER OR
CRUSHER WITH A BLOCKED FILTER.

Remove the starter key. B
A
3 Locate the Filter

JS06700
4 Remove the Oil Filter
Unscrew and remove filter A from head B.
5 Fit the New Filter
Coat the seal of the new filter with clean hydraulic

fluid. Screw the new filter into head B and tighten.
6 Check (see Checking the Fluid Level) and top up

the hydraulic oil tank (see Topping-up Fluid Level).
6740-1

109 MAINTENANCE 109
HYDRAULIC SYSTEM
(continued)
Air Bleeding Procedures

After replacing the hydraulic oil or repairing or replacing
hydraulic components or removing hydraulic pipes, bleed A
air from the hydraulic circuit.
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.

A353350
2 Locate the Hydraulic Pump
Refer to Component Location Diagram 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.
6740-1

110 MAINTENANCE 110
HYDRAULIC SYSTEM
(continued)
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.
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.
Position the machine on level ground. Stop the

Engine.
2 Locate the Slew Motor
Refer to the Component Location Diagrams at the

A
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
6740-1

111 MAINTENANCE 111
GEARBOXES
Slew Gearbox Grease

The slew gearbox bearing is sealed for life and will not
require lubrication.
Checking the Track Gearbox Oil Level

A
Position the machine on level ground with the filler
and level plug A positioned as shown. B
2 Check the level on One Side
Clean the area around the filler and level plug and
remove the plug. Top up through hole A if necessary.
(Refer to Lubricants and Capacities for oil types.)
3 Fill with New Oil
3 Clean and Refit the Plugs
Refer to Lubricants and Capacities for oil type and
Make sure they are tight. volume.
4 Check the Level on the Other Side a Remove Filler/level plug A.
Repeat steps 1 to 3. b Pour new oil through filler/level plug A until oil runs
out of the filler/level plug hole.
Changing the Track Gearbox Oil c Clean and refit plug A , making sure it is tight.
1 Prepare the Machine 4 Drain the Oil on the Other Side
See Checking the Track Gearbox Oil Level. Repeat steps 1 to 3.
2 Drain the Oil on One Side 5 Check for Leaks
a Place a container below drain plug B to catch the Run the machine, operate the tracking controls and
oil. The container must be large enough to hold then make sure there are no leaks.
the maximum gearbox capacity (see Lubricants
and Capacities).
! CAUTION
Oil will gush from the hole when the drain plug is
removed. Keep to one side when you remove the drain
plug.
2-3-4-2
b Remove plugs A and B. Allow the oil to drain out.
c Wipe both the plugs clean. Make sure you remove

all metal particles.
d Refit drain plug B.
6740-1

112 MAINTENANCE 112
TRACKS AND RUNNING GEAR
Clean the Tracks
! WARNING
If two people are doing this job make sure that the
person working the controls is a competent operator. If
the wrong control lever is moved, or if the controls are
moved violently, the other person could be killed or
injured.
If you will be working with another person, make sure

you both understand what the other will be doing.
Learn and use the recognised signalling procedures.
Do not rely on shouting - he will not hear you.
To clean the tracks you must turn them. When the

tracks are turning, keep clear of rotating parts.
Before starting this job, make sure that you have no A343960
loose clothing (cuffs, ties, etc) which could get caught

in rotating parts.
Keep people not involved with the job well away! 4 Inspect the Track
8-3-3-1
Set the Servo Isolator Switch to OFF. Stop the
1 Prepare the Machine engine. Inspect the track rollers, sprockets and idler
wheels for damage and oil leaks.
Park the machine on level ground. Set the offset-boom
(if fitted) to its central position (see Other Controls in 5 Lower the Track
OPERATION section).
Operate the boom and dipper controls to lower the
Open the bucket and swing the boom until it is at 90° track to the ground.
to the track. Lower the bucket to the ground.
6 Repeat for the Opposite Track
2 Raise the Track
Swing the boom round to the other side and repeat
Operate the boom and dipper controls so that the track steps 2 to 5 inclusive for the other track.
on the side nearest the bucket is lifted up clear of the
ground.
3 Rotate the track
! WARNING
Rotating the tracks off the ground may cause stones
and other debris to be thrown with considerable force.
If you are on the outside, keep well clear. Keep other
people well clear.
8-3-3-2
When it is safe to do so and you are sure that

everyone is clear of the machine, operate the controls
to rotate the track which is off the ground. Rotate it first
one way and then the other to shake off the mud. If
necessary, the person outside may use water to get
the mud off.
6740-1

113 MAINTENANCE 113

(continued)
Checking/Adjusting the Track Tension

B
a Position the machine on firm and level ground.
! WARNING
NEVER position yourself or any part of your body
under a raised machine which is not properly
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be C
killed.
INT-3-3-7
b Raise the track to be measured off the ground

(see Cleaning the Tracks, steps 1 and 2). Block
the undercarriage.
c Rotate the track in forward direction only to ensure A

that the track is able to rotate freely.
A343970
d Stop the engine and remove the starter key.
2 Check the Tension

a If the track is too tight, release a small amount of
Measure dimension A (see table below), between grease from the tension unit, by loosening the
track plate and undercarriage, at the third roller check valve B on the tensioner.
counting from the idler wheel end.
Note: A maximum of 3 turns of the check valve should be
Note: In certain ground conditions, e.g. soft sand and sufficient.
sticky mud, the chain tension may increase as the machine b If the track is too slack, pump grease into the
is operated and material is packed between the chain and
tensioner.
sprocket/idler wheel. In this case, the tension should be
checked again after approximately 5 minutes tracking.
Note: If dimension C is (or becomes) zero before (or
during) tensioning, this indicates that the track and/or its
Dimension A (mm)
associated components require attention. Continued use
could cause further serious damage, so consult your JCB
Hard Ground 180 - 205
Distributor for service or repairs.
Soft Sand/Sticky Mud 250 - 275
4 Lower the Track
Remove the blocks from beneath the undercarriage

3 Adjust the Track Tension
and lower the track to the ground using the boom and
dipper controls.
! WARNING
When opening the check valve always stand to one 5 Repeat for the Opposite Track
side and loosen a little at a time until grease starts to
come out. It you over-loosen too much grease could Swing the boom round to the other side and repeat
spurt out or the valve cover fly out and cause serious steps 1 to 4.
injury.
8-3-4-5
Note: The machine shown is typical. The track rollers must
! WARNING be counted from the front, i.e. the idler end. The example
shows the measurement taken at track roller number three.
Under no circumstances must the check valve be
dismantled or any attempt made to remove the grease
nipple from the check valve.
8-3-4-9
6740-1

114 MAINTENANCE 114

(continued)
Checking the Track Shoes

A
Position the machine on level ground and switch off

the engine.
1 3
2 Inspect the Track Shoes
4 2
Check the shoes for wear and for loose mounting
bolts.
3 Carry out Repairs or Maintenance
a Replace any damaged or broken shoes.
b Tighten or re-tighten the shoe-mounting bolts in

the sequence shown at A to a torque of 197 - 236
Nm (145 - 174 lbf ft).
Checking the Rollers and Idler Wheels

for Oil Leaks
See Clean the Tracks, steps 1 to 3.
Block the undercarriage.

2 Look for Oil Leaks
Check the top and bottom rollers and the idler wheels
for oil leaks. If leaks are found contact your JCB
Distributor for service.
! CAUTION
Do not run the machine if you discover oil leaks in the
top or bottom rollers or idler wheels. Failure to rectify
such leaks could cause damage to the machine.
8-3-4-6
3 Lower the Track
Remove the blocks from beneath the undercarriege.
See Clean the Tracks, step 5.
4 Repeat for the Opposite Track
Swing the boom to the other side and repeat steps 1 to

3 above.
6740-1

115 MAINTENANCE 115
ELECTRICAL SYSTEM
! CAUTION
Fuses
Always replace fuses with ones of correct ampere rating
to avoid electrical system damage.
8-3-3-5
Fuses 1 0
3 2
A
The electrical circuits are protected by fuses. Some of the
fuses are located in fuse box A on the rear console to the
right behind the drivers seat.
A353240
If a fuse blows, find out why before fitting a new one.
Fuse Box A
1 2 3 4 5 6
Fuse Circuit(s) Protected Rating

A 7 5 10 15 5 10
A1 EMS ignition supply 7A
A2 Travel alarm, isolator 5A
A3 Horn, beacon, quickhitch 10A
A4 Shut down, washer 15A
B 20 10 20 15 10 2
A5 2 Speed travel, grab CW &CCW 5A
A6 Cab work lamp 10A
B1 Heater/air conditioner, auto fan 20A

B2 Radio, lighter, room lamp 10A C
B3 Refuel pump (if fitted), auxillary 1 & 2, wiper 20A

B4 Work lights, back lights 15A
B5 Key switch 10A
D
B6 EMS battery supply 2A
C1 Not used
C2 Not used
C3 Not used
C4 Not used
C5 Not used
C6 Not used
D1 Not used
D2 Not used
D3 Not used
D4 Not used
D5 Not used
D6 Not used
6740-1

116 MAINTENANCE 116
BATTERY
First Aid - Electrolyte Checking the Electrolyte Level

EYES Maintenance free batteries used in normal temperate
climate applications should not need topping up. However,
FLUSH WITH WATER FOR 15 MINUTES. GET MEDICAL in certain conditions (such as prolonged operation at
HELP FAST. tropical temperatures or if the alternator overcharges) the
electrolyte level should be checked as described below.
IF SWALLOWED
1 Remove the Battery Compartment Cover A
DO NOT INDUCE VOMITING. DRINK LARGE
QUANTITIES OF WATER OR MILK. Then drink milk of
magnesia, beaten egg or vegetable oil.
SKIN
A
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 A351020
battery away from sparks and naked flames.
Remove the bolts securing the metal plate above the
Battery electrolyte contains sulphuric acid. It can burn batteries. Remove the plate.
you if it touches your skin or eyes. Wear goggles.
Handle the battery carefully to prevent spillage. 2 Check the Level
Keep metallic items (watches, rings, zippers etc) away Remove cover B. Look at the level in each cell. The
from the battery terminals. Such items could short the electrolyte should be 6 mm (0.25 in) above the plates.
terminals and burn you. Top up if necessary with distilled water or de-ionized
water.
Set all switches in the cab to OFF before
disconnecting the battery. When disconnecting the ! WARNING
battery, take off the earth (-) lead first. Do not top the battery up with acid. The electrolyte
could boil out and burn you.
When reconnecting, fit the positive (+) lead first. 2-3-4-6
Re-charge the battery away from the machine, in a 3 Check the Connections
well-ventilated area. Switch the charging circuit off
before connecting or disconnecting the battery. When Make sure that the terminals are tight and clean. Coat
you have installed the battery in the machine, wait five them with petroleum jelly to prevent corrosion.
minutes before connecting it up.
5-3-4-3
! CAUTION
Do not disconnect the alternator, the battery, or any
part of the charging circuit with the engine running.
8-3-4-1
A336951
6740-1

117 MAINTENANCE 117
BATTERY
(continued)
Warning Symbols ! CAUTION

Do not disconnect the battery while the engine is
The following warning symbols may be found on the running, otherwise the electrical circuits may be
battery. damaged.
INT- 3- 1-14
! WARNING
Symbol Meaning Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
Keep away from children. INT-3-1-4
.
! DANGER
A289230 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.
Shield eyes. INT-3-2-1/3
A289260 ! CAUTION
Damaged or spent batteries and any residue from fires
No smoking, no naked flames, or spillage should be put in a closed acid proof
no sparks. receptacle and must be disposed of in accordance
with local environmental waste regulations.
INT-3-1-12
A289280
! WARNING
Explosive Gas 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
A289250
charged. Do not check the battery charge by shorting
the terminals with metal; use a hydrometer or
voltmeter.
Battery acid. INT-3-1-8
A289240
Note operating instructions.
A289270
6740-1

118 MAINTENANCE 118
WINDSCREEN WASHER
Fill the windscreen washer bottle A with clean water. In

freezing weather add a de-icing fluid. Do not use engine
coolant antifreeze.
A336970
OBTAINING REPLACEMENT PARTS
We recommend you fit only JCB Genuine Parts. A JCB HEAVY PRODUCTS LTD.
Tracked Excavator Parts Book will help you identify parts UTTOXETER, STAFFS,
and order them from your JCB distributor. ST14 8TL, ENGLAND
V I N Vehicle Identification Number

Your distributor will need to know the exact identity of your Product
machine. The Product Identification Number (PIN) B is
B
Identification
Number
stamped on a data plate at the front of the mainframe.
(See Identifying Your Machine in INTRODUCTION
section.) The data plate also shows the engine serial
number C. But remember if the engine has been changed C
the serial number on the data plate may be wrong. Check
on the engine itself. JHP00
JS08530
6740-1

119 MAINTENANCE 119
LUBRICANTS AND CAPACITIES
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 - 9.6 litres

(2.1 UK gal)
(2.5 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 Vickers 35VQ25/V104C: 92 litres

Fluid HP46 Sundstrand, Denison and (20.26 UK gal)
FZG Approval Tests (24.33 US gal)
SLEW RING
- BEARINGS JCB HP Grease Lithium Complex (NLGI 2) inc. -
- GEAR TEETH JCB HP Grease extreme measure additives 3.2 kg (7.14 lb)
ALL OTHER GREASE Lithium Complex (NLGI 2) inc.

POINTS JCB HP Grease extreme measure additives
COOLING SYSTEM See Coolant Mixtures ASTM D3306-74 10.1 litres

(2.22 UK gal)
(2.66 US gal)
FUEL TANK See Fuel System, ASTM D975-66T 140 litres

Types of Fuel Nos 1D, 2D (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
6740-2

120 MAINTENANCE 120
TROUBLESHOOTING
To extend the service life and improve the operation of the machine, daily inspection and lubrication are necessary as well as
immediately isolating any problem found and dealing with it. If the machine is operated with the problem uncorrected, it may
lead to larger trouble and possibly to a big accident.
If trouble occurs, search for the cause in the items below and make adjustments, repairs, etc. as necessary. If the cause
cannot be isolated, contact your JCB Distributor.
* Indicates jobs which should be done by a specialist. Refer to Engine Service Manual.
Engine and Related Area
Problem Cause Remedy

•Defective starter switch (Starter does not run) Connect, repair connection
•Defective rotation of starter (Starter rotates slowly) Discharged battery, starter problems, contaminated
or loose wiring connection
•Improper viscosity of engine oil Inspect and replace as necessary
•Excessive cooling of engine (Cold weather) Preheat with air heater
Warm up the coolant (add hot water)
Engine does not start •Possible seizure in engine *Repair
•Incomplete air bleeding of fuel system Completely bleed air
•No fuel in fuel tank Refill
•Fuel quality unsuitable Inspect and replace as necessary
•Fuel filter clogged Clean or replace
•Low compression *Repair
•Defective fuel injection pump *Repair
•No fuel in fuel tank Refill

Engine stops during •Fuel filter clogged Clean and replace
operation •Air is mixed in the fuel system Retighten fuel pipe connections and bleed system
•Low oil Refill

•Defective oil pressure switch *Replace
Low oil •Oil filter clogged Replace element
pressure •Low oil viscosity Replace with oil of viscosity matching temperature
•Improper operation of oil pump *Replace parts
•Oil leakage at connections Tighten connections
•Excessive oil consumption *Disassemble and repair, replace parts

•Excessively low oil viscosity Replace with correct oil
Exhaust gas from engine •Excessive cooling by radiator Adjust
is white or blue •Improper fuel injection timing *Adjust or replace if necessary
•Low compression *Disassemble and repair, replace parts
•Improper fuel Replace with correct fuel

•Improper valve clearance Adjust
Exhaust gas from engine •Defective fuel injection pump *Adjust or replace if necessary
is black or dark grey •Low compression *Disassemble and repair, replace parts
•Insufficient air intake (air cleaner clogged) Clean or replace the element
•Defective fuel injection pump *Adjust or replace if necessary

•Improper spray from fuel injection nozzle *Adjust or replace if necessary
Excessive fuel •Improper fuel injection timing *Adjust or replace if necessary
consumption •Improper fuel Replace with correct fuel
•Low compression *Disassemble and repair, replace parts
•Insufficient air intake Clean or replace element
•Excessive oil Drain oil to proper level

Excessive engine oil •Low oil viscosity Replace with oil of viscosity matching temperature
consumption •Oil leakage Retighten and replace parts if necessary
•Worn cylinder piston rings *Disassemble and repair, replace parts
Abnormal noise.(Fuel •Bad fuel Replace

or mechanical) •Damage inside muffler Replace
6740-1

121 MAINTENANCE 121
TROUBLESHOOTING
(continued)
Engine and Related Area (cont’d)

•Low coolant Refill
•Water leakage Repair
•Elongated or oil dirtied belt Clean or replace
Engine overheating •Defective radiator *Repair or replace
(Water temperature •Broken fan *Replace
reads too high) •Incorrect mixture of anti-freeze solution Replace
•Defective thermostat *Replace
•Defective water pump *Replace
•Defective water sensor *Replace
•Improper belt tension Adjust

•Wiring trouble Repair
Defective battery charge •Defective battery Replace
•Defective regulator *Replace
•Defective alternator *Replace
6740-1

122 MAINTENANCE 122
TROUBLESHOOTING
(continued)
Operating Controls

•Foreign matter caught on control valve spool *Wash the control valve
Operating controls •Valve sticking *Repair or replace valve assembly
hard to operate •Improper lubrication of lever link Grease
•Lever link seizure Grease
Hydraulic Pump
Oil not delivered by •Low hydraulic oil Refill
oil pump •Clogged suction filter Repair
•Oil leakage inside hydraulic pump *Replace hydraulic pump

Hydraulic pump does •Air inside the hydraulic pump Refill oil or check hose on suction side
not build pressure •Main relief valve pressure set too low *Adjust pressure
•Cavitation resulting from deformed hose on the

suction side or suction filter clogged Replace filter, replace hydraulic oil if dirty
Abnormal noise from •Joint of the suction side is loose or hydraulic oil is Retighten or grease the joints
hydraulic pump low and air is being sucked in Check that oil is filled to proper level inside casing
•Cavitation resulting from excessively high
viscosity of hydraulic oil Replace with hydraulic oil of suitable viscosity
Oil leakage from hydraulic pump •Defective seal in hydraulic pump *Replace seal or hydraulic pump
Working Attachments
•Insufficient engine output Refer to Engine Service Manual
•Function drops due to wear of hydraulic pump *Replace hydraulic pump
•Defective main relief valve *Adjust the pressure or replace
Overall low power •Low hydraulic oil Refill
•Viscosity of hydraulic oil incorrect Replace with hydraulic oil of proper viscosity
•Suction filter clogged Replace suction filter
Defective operations •Hydraulic pump broken *Replace hydraulic pump

•Hydraulic oil low Replace suction filter
•Set pressure for main or port relief valve is low or *Adjust pressure or replace relief valve
incorrect
Insufficient work power •Damaged hydraulic ram seals *Replace hydraulic ram seals
•Damaged hydraulic ram, cylinder *Replace hydraulic ram/cylinder or the assembly
•Damaged hydraulic ram seals *Replace hydraulic ram seals

Attachment sinks down •Damaged hydraulic ram, cylinder *Replace hydraulic ram/cylinder or the assembly
•Oil leakage inside control valve *Repair valve assembly, replace
•Oil leakage inside holding valve *Repair valve assembly, replace
Abnormal noise from •Insufficient grease Grease

joints of the attachment •Connecting pin seizure Replace the bushing and/or pin
* Indicates jobs which should be done by a specialist. Refer to Service Manual.
6740-1

123 MAINTENANCE 123
TROUBLESHOOTING
(continued)
Travelling

•Pressure setting for main relief valve is too low *Adjust the pressure
Insufficient •Defective counterbalance valve *Replace the counterbalance valve
travel force •Performance reduction of travel motor *Replace travel motor
•Swivel joint packing damage *Replace swivel joint packing
•Performance reduction of hydraulic pump *Replace hydraulic pump
•Excessively tightened track Adjust to proper tension

•Stone or foreign matter caught in track Remove stone or foreign matter
Rough travel •Defective valve *Repair valve or replace
•Performance reduction of travel motor *Replace travel motor
•Air in travel motor Refill with oil
•Left and right tracks are not equally tightened Bleed air from left and right, adjust tracks to equal tension
•Performance reduction of hydraulic pump *Replace hydraulic pump
Crooked travel •Performance reduction of travel motor *Replace travel motor
•Oil leakage inside control valve *Replace valve housing assembly
•Swivel joint packing damage *Replace swivel joint packing
•Loose lever link Adjust
Slewing
Insufficient •Performance reduction of slew motor *Replace slew motor
slew force •Thermal seizure of slew shaft *Supply grease or replace the slew shaft
•Low setting of brake valve *Adjust the pressure

Poor braking •Clogged valve *Wash the valve
performance •Performance reduction of slew motor *Replace slew motor
•Internal oil leakage of control valve *Repair or replace valve assembly
•Low setting of brake valve or port relief valve *Adjust the pressure
Poor stopping •Clogged valve *Wash the valve
performance •Performance reduction of slew motor *Replace slew motor
•Internal oil leakage of control valve *Repair or replace valve assembly
Abnormal noise •Air in slew motor Refill with oil

during slew •Insufficient greasing of slew bearing Add grease
Hydraulic Rams
•Low pressure setting for the relief valve *Adjust the pressure
Insufficient force of •Oil leakage inside the hydraulic ram *Replace the ram seals
hydraulic ram •Damage of the hydraulic ram or rod *Replace the hydraulic ram or rod
•Oil leakage inside the control valve *Repair or replace the valve assembly
Oil leakage outside the •Defective hydraulic ram seals *Replace hydraulic ram seals
hydraulic ram •Hydraulic cylinder rod damage *Replace hydraulic ram rod
* Indicates jobs which should be done by a specialist. Refer to Service Manual.
6740-1

124 MAINTENANCE 124
COMPONENT LOCATION DIAGRAMS
A - Hydraulic Servo Oil Filter J - Engine Oil Sump Drain Plug
B - Fuel Filter K - Main Control Valve
C - Engine Oil Filter L - Hydraulic Oil Tank
D - Hydraulic Suction Filter M - Engine Cooling Radiator
E - Air Filter N - Fuel Tank Filler Cap
F - Hydraulic Oil Tank Filler Cap P - Nephron Filter
G - Hydraulic Oil Tank Air Breather Q - Hydraulic Pump
H - Slew Ring Gear/Slew Motor
A
E
M F D L
H N
B
Q
K
336820
6740-1

141 SPECIFICATIONS 141
LIFTING (CRANING) REGULATIONS AND SAFE WORKING LOADS
Lifting Regulations Safe Working Loads

The Factories Act Construction (Lifting Operations) ! WARNING
Regulations 1961 defines 'Excavators' as 'Lifting The safe working load indicated on lifting accessories
Appliances'. As such, the JCB Tracked Excavator is such as chains etc. is not the safe working load of the
subject to these regulations both when using the machine
machine.
as an earthmover, and specifically when using the machine 8-5-1-2/1
as a crane.
When loads are to be lifted by the excavator, a bucket
The owner and/or operator must make sure that he fully must be fitted.
understands the laws and regulations concerning the use
of the JCB Tracked Excavator as an earthmover and as a The maximum load which may be lifted depends on the
crane. Consult your JCB Distributor for further information. equipment fitted to the excavator and the laws and
regulations in force at the time and in the country in which
If your machine has not been fitted with an approved lifting the excavator is being used.
point such as hook or shackle then it must not be used as
a crane. Use the machine for earthmoving purposes only. If your machine is equipped to be operated under
If your machine is not equipped to be used as a crane "Exemption Certificate" rules, your Exemption Certificate
there will be a decal in the operator's cab which says: will specify the Safe Working Loads.
! WARNING
Do not use this Excavator as a 'crane'. Consult U.K.
Lifting Regulations.
8-5-1-1
Your machine may be used as a crane if it has been fitted

with an approved lifting point such as a hook or shackle, if
it has been tested, plated and certified for its safe working
load, and if all other regulation requirements have been
met (consult your JCB distributor).
6740-1

STATIC DIMENSIONS
L
D
F
E
G M
R
C N H
J
S A
K
B
P JS08421
A Tracked length on ground 2200 mm (7 ft 2 in)
B Undercarriage - overall length 2830 mm (9 ft 3 in)
C Tail height 767 mm (2 ft 6 in)
D Tailswing radius 1160 mm (3 ft 10 in)
E Tail length 1160 mm (3 ft 10 in)
F Superstructure width 2200 mm (7 ft 3 in)
G Height over cab 2625 mm (8 ft 7 in)
H Ground clearance 363 mm (1 ft 2 in)
J Track gauge 1700 mm (5 ft 8 in)
K Track width - 450 mm (18 in) shoes 2150 mm (7 ft 1 in)

- 600 mm (24 in) shoes 2300 mm (7 ft 7 in)
L Transport length - Standard boom (1.74 m dipper) 5430 mm (17 ft 10 in)

- Standard boom (2.18 m dipper) 5410 mm (17 ft 9 in)
- Offset Boom 5370 mm (17 ft 7 in)
M Transport height - Standard boom (1.74 m dipper) 2640 mm (8 ft 8 in)

- Standard boom (2.18 m dipper) 2930 mm (9 ft 7 in)
- Offset Boom 2740 mm (9 ft 0 in)
N Track height 663 mm (2 ft 2 in)
P Dozer blade width 2320 mm (7 ft 8 in)
R Dozer blade height 480 mm (1 ft 7 in)
S Dozer blade reach in front of tracks 516 mm (1 ft 8 in)
6740-1

SHIPPING WEIGHTS (APPROXIMATE)
Machine equipped with Boom; 1.74 m (5 ft 8 in) Dipper Arm, Dozer Blade, Standard Excavating Bucket, operator and full fuel
tank.
Standard Boom
Shoe Width Operating Weight Ground Bearing Pressure
450 mm (18 in) 7300 kg (16096 lb) 0.33 kgf/cm2 (4.69 lb/in2)
600 mm (24 in) 7500 kg (16537 lb) 0.25 kgf/cm2 (3.56 lbf/in2)
Offset Boom
Shoe Width Operating Weight Ground Bearing Pressure
450 mm (18 in) 7800 kg (17200 lb) 0.35 kgf/cm2 (4.97 lb/in2)
600 mm (24 in) 8000 kg (17640 lb) 0.27 kgf/cm2 (3.84 lbf/in2)
6740-1

DIG DEPTH CHART
A Max. digging reach

B Max. digging reach on ground G
C Max. digging depth
D Max. digging height
E Max. dumping height
F Max. vertical wallcut depth
G Max. swing radius
# Bucket rotation
D E
C F
JS09711
Standard Boom Offset Boom (1.74 m Dipper) Offset Boom (2.18 m Dipper)
Dim 1.74 m Dipper 2.18 m Dipper No Offset Max. Offset No Offset Max. Offset
A 6360 mm (20 ft 11 in) 6810 mm (22 ft 4 in) 6359 mm (20 ft 10 in) 5878 mm (19 ft 3 in) 6812 mm (22 ft 4 in) 6329 mm (20 ft 9 in)
B 6220 mm (20 ft 5 in) 6680 mm (21 ft 11 in) 6234 mm (20 ft 5 in) 5743 mm (18 ft 10 in) 6684 mm (21 ft 11 in) 6191 mm (20 ft 4 in)
C 4138 mm (13 ft 7 in) 4573 mm (15 ft 0 in) 4043 mm (13 ft 3 in) 3563 mm (11 ft 8 in) 4472 mm (14 ft 8in) 3989 mm (13 ft 1 in)
D 7237 mm (23 ft 9 in) 7667 mm (25 ft 2 in) 7189 mm (23 ft 7 in) 6801 mm (22 ft 4 in) 7680 mm (25 ft 2 in) 7280 mm (23 ft 11 in)
E 5157 mm (16 ft 11 in) 5567 mm (18 ft 2 in) 5123 mm (16 ft 10 in) 4735 mm (15 ft 6 in) 5603 mm (18 ft 5 in) 5213 mm (17 ft 1 in)
F 3483 mm (11 ft 5 in) 4053 mm (13 ft 4 in) 3173 mm (10 ft 5 in) 2717 mm (8 ft 11 in) 4073 mm (13 ft 4 in) 3553 mm (11 ft 8 in)
G 1750 mm (5 ft 9 in) 2050 mm (6 ft 9 in) 1918 mm (6 ft 3 in) 1680 mm (5 ft 6 in) 2264 mm (7 ft 5 in) 1937 mm (6 ft 4 in)
# 184° 184° 184° 184° 184° 184°
6740-1

NOISE AND VIBRATION DATA
NOISE
1 Noise Level at Operator's Ear (LpA) 76
2 External Noise Level (LwA) 101
VIBRATION All Models
3. Weighted rms acceleration: Whole body Tracking

Less than 0.75 m/sec2
4. Weighted rms acceleration: Hand/Arm All Duties
Less than 2.5 m/sec2
Item 1 above is determined in accordance with dynamic test conditions defined in ISO 6396.
Item 2 above is determined in accordance with dynamic test conditions defined in 2000/14/EC (Annex 5, 6).
Item 3 above is an 'Average Equivalent Value' determined from measurement on machines performing typical duties,
detailed below, with values weighted in accordance with ISO 2631.
Item 4 above measured at the steering control device when machine is travelling over rough terrain, with values weighted in
accordance with ISO 2631.
The Vibration values are determined from measurements in three perpendicular planes.
Values determined with standard excavator bucket fitted.
For information relating to this machine when used with other JCB approved attachments, please refer to the literature
accompanying the attachments.
Typical Duties for tracked excavators: Tracking (Rough Terrain)

Excavating
6740-2


REGISTRATION INFORMATION (Do not remove this portion from the Handbook) Issue 3 February 2000
English
Registration Date ............................................................... Dealer .............................................................................
P.I.N/Machine Serial Number !!!!!!!
S L P
V.I.N. !!!!!!!!!!!!!!!!! JCB Model ........................................................................... Installing Engineer ........................................................
Vehicle Registration Number !!!!!!! Eng. Ser. No. !!!!!!!!!!!!!!!!! Signature ....................................................................... #
DEALERS COPY U.K. and EIRE ONLY
Do NOT send back to JCB SERVICE A COPY OF THE REGISTRATION DETAILS TO BE SENT DIRECT TO:-
Dealer ....................................................................................................................... THE EQUIPMENT REGISTER LTD. (T.E.R.),

JCB Model ............................................................................................................... BATH & WEST BUILDINGS
LOWER BRISTOL ROAD
P.I.N/Machine Serial Number !!!!!!! BATH
V.I.N. S L P
!!!!!!!!!!!!!!!!! BA2 3EG
Vehicle Registration Number !!!!!!! Tel: 01225 464599 (24 Hour) Fax: 01225 317698
Engine Serial Number !!!!!!!!!!!!!!!!!
Customer's Name ...................................................................................................
Address ..................................................................................................................
....................................................................................................................................
............................................................................Postcode .....................................
Registration Date ....................................................................................................
Installing Engineer ..................................................................................................
P.D.I. Date ................................................................................................................
Owner's Plant Reference No. ...............................................................................
ALPHA • DOT SECURITY SYSTEM - YES/NO

" Please send details of:
"JCB Assetcare Machinery Protection Plan" !

#


*9801/6740*
9801/6740

JZ70 Operators Manual

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! THIS HANDBOOK MUST BE KEPT IN THE MACHINE AT ALL TIMES !

Publication Number 9801/6740 Nov 01 Issue 3

Purchased from www.WorkshopManuals.co.uk

Purchased from www.WorkshopManuals.co.uk

JCB PLANTGUARD is a comprehensive package available to help you

Your JCB Distributor or Dealer will be pleased to provide information on any of

Purchased from www.WorkshopManuals.co.uk

Reference should also be made to Optional Attachments section where appropriate.

Purchased from www.WorkshopManuals.co.uk

INTRODUCTION Tracking Controls

Starting the Engine

Entering and Leaving the Cab 23 Cold Climate Warm-up 50

Cab Windows Stopping the Engine

Using the Attachments and Site Safety 52

Cab Layout 29 Transporting the Machine 55

Switches and Controls Using your Machine

Purchased from www.WorkshopManuals.co.uk

Using your Machine (cont’d) Engine Oil and Filter

Lubricants - Health and Safety Gearboxes

Greasing Electrical System

Obtaining Replacement Parts 118

Purchased from www.WorkshopManuals.co.uk

Lubricants and Capacities 119

Component Location Diagrams 124

Static Dimensions 142

Shipping Weights (Approximate)

Dig Depth Chart 144

Noise and Vibration Data 145

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ABOUT THIS HANDBOOK

Machine Description Using the Machine

Using this Handbook Units of Measurement

Finally, treat this handbook as part of the machine. Keep it

The manufacturer’s policy is one of continuous

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SAFETY FIRST - YOURS AND OTHER PEOPLE’S

and how to avoid them.

SAFETY CHECK LIST

Alcohol and Drugs

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SAFETY CHECK LIST

lifting equipment is strong enough for the job.

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SAFETY CHECK LIST

Maintenance Safety ! WARNING

the engine running. There could be a fire or injury if

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Maintenance Safety (cont’d)

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Keep all decals clean and readable. Replace lost or

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IDENTIFYING YOUR MACHINE

Your machine has a Data Plate, located inside the cab as

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BEFORE ENTERING THE CAB

2 Check for Damage

! WARNING d Check for oil, fuel and coolant leakages beneath

1 Check for Cleanliness

a Clean the windows, light lenses and rear view

b Remove dirt and debris, especially from around

c Make sure the cab step and handholds are clean