JCB JS160 TRACKED EXCAVATOR Service Repair Manual (SN JS160-702000 Onwards)

Open front screen

General Information

1

Care & Safety

2

Routine Maintenance

3

Attachments

A

Service Manual

Body & Framework

B

Electrics

C

JS130

Hydraulics

E

Transmission

F

R

from machine no. 758000

JS160 from machine no. 702000

Brakes PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE: © WORLD PARTS CENTRE UTTOXETER, STAFFORDSHIRE, ST14 7BS, ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND Publication No. 9803/6410 Issue 1

Track & Running Gear Engine

G J K

Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training

by JCB Technical Training Department.

These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment.

Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 1 2 3

= = =

General Information - includes torque settings and service tools.

Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.

Routine Maintenance - includes service schedules and recommended lubricants for the whole machine.

The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: A B

= =

Attachments Body & Framework ...etc

The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual.

Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.

All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference.

Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third.

‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.

Note: In this manual the term ‘swing’ may sometimes be used in place of ‘slew’ and the term ‘arm’ may sometimes be used in place of ‘dipper’.

9803/6410

Issue 1

Section 1

General Information

Section 1

i

i

Contents

9803/6410

Page No.

Bolt and Nut Torque Specifications

1-1

Torque Settings

1-2

Service Tools * Section B - Body and framework Section C - Electrics Section E - Hydraulics * Section F - Transmission

3-1 4-1 5-1 6-1

*Sealing and Retaining Compounds

7-1

Issue 2*

Section 1

General Information

Section 1

Bolt and Nut Torque Specifications

1-1

1-1

JS130/JS160 and Variants 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.

Tightening Torque Table JS130/JS160 No

Tightening Point

Bolt Diameter Wrench

Tightening Torque kgf m

lbf ft

1† Travel Motor

M16

mm 24

270~310

27.6~31.8

200~230

2† Drive Sprocket

M16

24

220~310

27.6~31.8

200~230

3† Idler Wheel

M16

24

270~310

27.6~31.8

200~230

4† Upper (Carrier) Roller

*

M16/M20

24/30

270~310/520~608

27.6~31.8/53.2~62.2

200~230/385~450

5† Lower (Track) Roller

M16

24

270~310

27.6~31.8

200~230

6† Track Guard

M16

24

270~310

27.6~31.8

200~230

M16

24

310~360/640~750

32~37/65~76.5

229~266/472~553

7

Shoe Bolt

8

Counter weight

M27

41

845~980

86~100

622~723

9† Turntable Bearing (Undercarriage)

M16/M20

24

280~310/475~550

28.4~31.8/48.4~55.3

205~230/350~400

10† Turntable Bearing (Slew Frame)

M16/M20

24

280~310/475~550

28.4~31.8/48.4~55.3

205~230/350~400

11† Slew Equipment

M16/M20

24

280~310/475~550

28.4~31.8/48.4~55.3

205~230/350~440

12† Engine (Engine Mount)

M16

24

265~310

27~32

195~230

13† Engine Bracket

M10

17

65~75

6.5~7.6

47~55

14 Radiator

*

Nm

M12

19

60~70

6.2~7.2

45~52

15† Hydraulic Pump

M10

17

65~75

6.5~7.6

47~55

16† Hydraulic Oil Tank

M16

24

205~285

21~29

152~210

17† Fuel Tank

M16

24

225~285

22.4~29

162~210

18† Control Valve

M16

24

270~310

27.6~31.8

200~230

19† Rotary Coupling

M12

19

110~125

11.1~13.0

80~94

20 Cab

M16

24

127~137

13~14

94~101

21 Battery

M10

17

20~30

2.1~2.9

15~21

Note: Use JCB Threadlocker and Sealer (High Strength) (adhesive) 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) Wrench Hex. bolt Tightening Torque Wrench Hex. socket head bolt

Tightening Torque

9803/6410

M6

M8

M10

M12

M14

M16

M18

M20

mm

10

13

17

19

22

24

27

30

Nm

6.9

15.7

32.3

58.8

98.0

137.2

196.0

274.4

kgf m

0.7

1.6

3.2

5.9

9.8

13.7

19.6

27.4

lbf ft

5

12

24

43

72

101

145

202

mm

5

6

8

10

12

14

14

17

Nm

8.8

21.6

42.1

78.4

117.6

176.4

245.0

343.0

kgf m

0.88

2.2

4.2

7.8

11.8

17.6

24.5

34.3

lbf ft

6.5

16

31

58

87

130

181

253

Issue 2*

Section 1

General Information

Section 1

Torque Settings

1-2

1-2

Torque Settings Note 1: The figures quoted are for non-plated fasteners and are to be used only when there is no torque setting specified in the relevant procedure in this service manual.

Note 2: The 4T grade settings DO NOT APPLY to fasteners used on the engine. If any 4T specification fasteners are found on the engine, these must be tightened to the figure quoted in the relevant engine manual.

Bolt Size

Strength Grade of Bolt or Stud 4T

9803/6410

8.8

10.9

Nm

kgf m

lbf ft

Nm

kgf m

lbf ft

Nm

kgf m

lbf ft

M3

0.39

0.04

0.28

-

-

-

-

-

-

M4

0.78

0.08

0.57

-

-

-

-

-

-

M5

1.67

0.17

1.2

-

-

-

-

-

-

M6

2.84

0.29

2.1

8.04

0.82

5.9

11.3

1.15

8.3

M8

7.06

0.72

5.2

19.6

2.00

14.5

27.7

2.82

20.4

M10

14.0

1.43

10.3

39.1

3.99

28.8

55.0

5.61

40.6

M12

24.6

2.51

18.1

68.5

6.98

50.5

96.2

9.81

71

M16

61.9

6.31

45.7

173

17.6

127.6

242

24.7

178.5

M20

122

12.4

90

337

34.4

249

475

48.4

350

M22

167

17.0

123

464

47.3

342

652

66.5

481

M24

210

21.4

155

584

59.5

431

821

83.7

606

M27

311

31.7

229

864

88.1

637

1220

124

900

M30

420

42.8

310

1170

119

863

1650

168

1217

M33

576

58.7

425

1600

163

1180

2260

230

1667

M36

736

75.1

543

2050

209

1512

2880

294

2124

M39

961

98.0

709

2680

273

1977

3760

383

2773

M42

1190

121

878

3300

336

2434

4640

473

3422

M45

1490

152

1099

4140

422

3054

5820

593

4293

M48

1780

182

1312

4960

506

3659

6970

711

5141

Issue 1

Section 1

General Information

Section 1

3-1

3-1

Service Tools (SECTION B) BODY AND FRAMEWORK

S186240

S186270

Hand Cleaner - special blend for the removal of polyurethane adhesives.

Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc.

4104/1310 (454g; 1lb tub)

892/00845

'

S186250

12V Mobile Oven - 1 cartridge capacity - required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket (715/04300).

Folding Stand for Holding Glass - essential for preparing new glass prior to installation.

992/12300

892/00843

S186280

S186260

240V Static Oven - available with 2 or 6 cartridge capacity - required to pre-heat adhesive prior to use.

No plug supplied. Note: 110V models available upon request - contact JCB Technical Service 992/12400 - 2 cartridge x 240V 992/12600 - 6 cartridge x 240V

9803/6410

S186300

Glass Lifter - minimum 2 off - essential for glass installation, 2 required to handle large panes of glass.

Ensure suction cups are protected from damage during storage.

892/00842 Issue 1

Section 1

General Information

Section 1

3-2

3-2

Service Tools (cont’d) (SECTION B) BODY AND FRAMEWORK

S186310

S186340

Wire Starter - used to access braided cutting wire (below) through original polyurethane seal.

Cut-out Knife - used to remove broken glass.

992/12800

892/00848

'

S186350

S186320

Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass.

'L' Blades - 25mm (1in.) cut - replacement blades for cut-out knife (above).

892/00846

992/12801 (unit quantity = 5 off)

S186330 S186360

Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool (above).

Long Knife - used to give extended reach for normally inaccessible areas.

892/00849 (approx 25m length)

892/00844

9803/6410

Issue 1

Section 1

General Information

3-3

Section 1 3-3

Service Tools (cont’d) (SECTION B) BODY AND FRAMEWORK

S186470

Nylon Spatula - general tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge.

892/00847

9803/6410

S186550

Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame.

926/15500 (unit quantity = 500 off)

Issue 1

Section 1

General Information

Section 1

4-1

4-1

Service Tools SECTION C - ELECTRICS

Electrical Test Equipment

993/85700

9803/6410

1

892/00283

Tool Kit Case

2

892/00281

AVO Meter

3

892/00286

Surface Temperature Probe

4

892/00284

Microtach Digital Tachometer

5

892/00282

Shunt - open type

6

892/00285

Hydraulic Oil Temperature Probe

7

892/00298

Fluke 85 Multimeter

Battery Tester

Issue 2*

Section 1

General Information

Section 1

5-1

5-1

Service Tools (continued) SECTION E - HYDRAULICS

Hydraulic Pressure Test Gauges and Connections 1

892/00279

Pressure Gauge 0-400 bar (0-6000 lbf/in2)

2

892/00346

Pressure Gauge 0-70 bar (0-1000 lbf/in2)

3

892/00347

Connector

4

892/00254

Hose

5

892/00280

Pressure Gauge 0-600 bar (0-9000 lbf/in2)

3 4

1/2/5

Pressure Test ‘T’ Adapters

Pressure Test Adapters

892/00262 816/55038 816/55040 892/00263 892/00264 892/00265 892/00266 892/00267

892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261

9803/6410

1/4 in BSP x 1/4 in F BSP x Test Point 3/8 in BSP x 3/8 in F BSP x Test Point 1/2 in BSP x 1/2 in F BSP x Test Point 5/8 in BSP x 5/8 in F BSP x Test Point 3/4 in BSP x 3/4 in F BSP x Test Point 1 in M BSP x 1 in F BSP x Test Point 1,1/4 in M BSP x 1,1/4 in F BSP x Test Point 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point

1/4 in BSP x Test Point 3/8 in BSP x Test Point 1/2 in BSP x Test Point 5/8 in BSP x Test Point 3/4 in BSP x Test Point 1 in BSP x Test Point 1,1/4 in BSP x Test Point 5/8 in UNF x Test Point

Issue 2*

Section 1

General Information

Section 1

5-2

5-2

Service Tools (continued) SECTION E - HYDRAULICS

Hand Pump Equipment 892/00223 892/00137 892/00274 892/00262 892/00706 892/00278 892/00279 892/00280

Hand Pump Micro-bore Hose 1/4 in BSP x 5 metres Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1/4 in M BSP x 1/4 in F BSP x Test Point Test Probe Gauge 0 - 40 bar (0 - 600 lb/in2) Gauge 0 - 400 bar (0 - 6000 lb/in2) Gauge 0 - 600 bar (0 - 8500 lb/in2)

816/50005 816/60096 816/00018

1/2 in BSP (A) x 1/2 in BSP (B) 3/4 in BSP (A) x 3/4 in BSP (B) 1 in BSP (A) x 1 in BSP (B)

Female Cone Blanking Plug

Male Cone Blanking Plug

892/00055 892/00056 892/00057 892/00058 892/00059 892/00060

816/00294 816/00189 816/00190 816/00197 816/00196 816/00193

9803/6410

1/4 in BSP 3/8 in BSP 1/2 in BSP 5/8 in BSP 3/4 in BSP 1 in BSP

1/4 in BSP 3/8 in BSP 1/2 in BSP 5/8 in BSP 3/4 in BSP 1 in BSP

Issue 1

Section 1

General Information

Section 1

5-3

5-3

Service Tools (continued) SECTION E - HYDRAULICS

JS07050

Ram Piston Nut Removal/Fitting Spanner

Ram Piston Nut Removal/Fitting Rig 993/99525 993/99522 993/99523 993/99524 556/43400 545/18000 811/50232

9803/6410

Rig Assembly (not including spanners and ram) Anchor Side Plate (supplied loose unwelded) Anchor Cross Member (supplied loose unwelded) Ram Eye End Modification Plate Assembly Lift Ram Lynch Pin 1,1/4� Pivot Pin

993/99512 993/99513 993/99514 993/99515 993/99516 993/99517 993/99518 993/99519 993/99520 993/99521 SSP0046 SSP0047

Spanner 55 mm A/F Spanner 60 mm A/F Spanner 65 mm A/F Spanner 70 mm A/F Spanner 75 mm A/F Spanner 85 mm A/F Spanner 90 mm A/F Spanner 100 mm A/F Spanner 110 mm A/F Spanner 115 mm A/F Spanner 80 mm A/F Spanner 95 mm A/F

Issue 1

Section 1

General Information

Section 1

5-4

5-4

Service Tools (continued) SECTION E - HYDRAULICS

30

¿70 (2.76")

¿38.+- 0.2 (1.50"+-0.008)

¿61.+- 0.2 (2.40"+-0.008)

Slew Motor Unit - JS130

o

2 (0.079") 14 (0.55")

155 (6.10")

4 (0.16") Seal Fitting Tool (Oil Seal 2)

¿32.2.+- 0.1 (¿1.27+-0.004)

¿35.5.+- 0.1 (¿1.40+-0.004)

¿42 (1.65")

JS07110

100 (3.94") 110 (4.33")

5o

¿31.4+-0.1 (1.24"+-0.004)

JS07120

¿40 (1.57")

¿38 (1.50")

Fitting Tool for Inner Ring of Taper Roller Bearing 3

50 (1.97") 80 (3.15")

50 (1.97") 60 (2.36") JS07130

JS07140

Seal Protector Heat polyvinyl tube in hot water and form to required shape.

9803/6410

Fitting Tool for Inner Ring 1

Issue 1

Section 1

General Information

Section 1

5-5

5-5

Service Tools (continued) SECTION E - HYDRAULICS Slew Motor Unit - JS160

40 (1.57")

2 x ¿9 (0.35")

200 250 (9.84")

100 (3.94")

40 (1.57")

10 (0.39")

Inner diameter ¿11 (0.43")

M10 180 (7.09") 240 (9.45") JS07100

Puller for Brake Piston Stud is threaded M10 on both ends for 20 mm (0.8 in) and fitted with two M10 nuts.

9803/6410

Issue 1

Section 1

General Information

Section 1

5-6

5-6

Service Tools (continued) SECTION E - HYDRAULICS Hydraulic Tank - JS130, JS160

A

Dia. 40 mm (1.57 in)

B

Dia. 26 mm (1.02 in)

C

40 mm (1.47 in)

D

50 mm (1.97 in)

E

Dia. 10 mm (0.39 in)

F

550 mm (21.7 in)

G

9 mm (0.35 in)

H

24 mm (0.94+0in)

I

Dia. 81 mm

J

Dia. 76 mm

K

24 mm (0.94 in)

L

95 mm (3.74 in)

M

Radius 0.7 mm (0.028 in)

A

N

120 mm (16.5 in)

B

O

4.0 mm (0.157 in)

P

3.0 mm (0.118 in)

Q

15°

O-ring

G75

+0 -0.004

-0.1

+0 (3.91 -0.1

in

) +0 -0.004

(2.99 in

)

C

D

E

F

N G M

Q

O

H

L P J I K

JS07150

Blank for Suction Strainer

9803/6410

Issue 1

Section 1

General Information

Section 1

5-7

5-7

Service Tools (continued) SECTION E - HYDRAULICS Remote Control Valve - JS130, JS160

13

¿26.5 23.5

1

2

19

17

25

42

50

65

¿19 ¿28

¿21 ¿25 ¿30

JS07160

Joint Removal Tool

15

Items 1 and 2 are assembled with an interference fit.

9803/6410

Issue 1

Section 1

General Information

5-8

Section 1 5-8

Service Tools (continued) SECTION E - HYDRAULICS Hydraulic Pump

Guide Rods

Rear Shaft Protection Tool Swash Plate Levelling Tool

Oil Seal Insertion Tool

Front Shaft Protection Tool

Bearing Insertion Tool

9803/6410

Issue 1

Section 1

General Information

5-9

Section 1 5-9

Service Tools (continued) SECTION E - HYDRAULICS Hydraulic Rams Reconditioning

Bush Removal/Assembly Jig

Seal Ring Insertion Jig (Inner)

Bush Removal/Assembly Jig

Seal Ring Bedding Jig

Cylinder Head Insertion Jig

Wiper Ring Installation Jig

Seal Ring Insertion Jig (Outer)

9803/6410

Issue 1

Section 1

General Information

Section 1

6-1

Service Tools (continued) SECTION F - TRANSMISSION Slew Gearbox - JS130

15 o ø94.5 +- 0.2 (3.72" +- 0.008) ø120 (4.72")

ø65 (2.56")

5o

60 (2.36")

3 (0.118")

14 15 (0.55") 6 (0.59") 30 (0.236") (1.18")

ø50 (1.97")

100 (3.94")

JS07180

ø130 (5.43") JS07170

Seal Protector Heat polyvinyl tube in hot water and form to the required shape on the pinion shaft

Seal Fitting Jig

Slew Gearbox - JS160

ø100 (ø3.937")

2.5 (0.098")

ø155 (ø6.094")

80 +0.3 -0 (3.15"+0.012" ) -0

*

6-1

ø149 (ø5.866") JS07200

JS07190

Bearing and Oil Seal assembly Jig

9803/6410

Seal Fitting Jig

Issue 2*

Section 1

General Information

Section 1

6-2

6-2

Service Tools (continued) SECTION F - TRANSMISSION Slew Gearbox - JS160 (continued)

3

ø30.5.+- 0.1 (ø46.5 +-0.1)

15

9

15

ø36 (ø50)

30

ø50

100

ø99.8

110

ø124 ø158

JS07230 JS07210

Jig for Taper Roller Bearing Inner Ring

Seal Fitting Jig

o

80

ø49.5

ø75

30

2 16

155 4 JS07220

Seal Fitting Jig (SST0033)

9803/6410

Issue 1

Section 1

General Information

Section 1

7-1

7-1

Sealing and Retaining Compounds JCB Multi-Gasket

A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings 25-65 mm diameter.

4102/1212

A high strength locking fluid for use with threaded components.

4102/0551

JCB Retainer (High Strength)

For retaining parts which are unlikely to be dismantled.

4101/0651

JCB Threadlocker and Sealer

A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter.

4101/0251

A locking fluid for use on threads larger than 50 mm diameter.

4101/0451

JCB Threadlocker and Sealer (High Strength)

A medium to high strength locking fluid for retention and sealing of ram piston heads.

4101/0552

JCB Activator

A cleaning primer which speeds the curing rate of anaerobic products.

4104/0251 4104/0253

Aerosol Bottle

JCB Cleaner/Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants.

4104/1557

Aerosol

Anti-Seize Paste

A compound used for assembly and prevention of parts seizure.

JCB High Strength Threadlocker

JCB Threadlocker

50ml

4003/0211

Direct Glazing Kit

For one pane of glass; comprises items marked † below plus applicator nozzle etc.

† Ultra Fast Adhesive

For direct glazing

4103/2109

310 ml

† Active Wipe 205

For direct glazing

4104/1203

250 g

† Black Primer 206J Clear Silicone Sealant

For direct glazing To seal butt jointed glass.

4201/4906 4102/0901

30 ml

The part numbers and descriptions of sealing and retaining compounds available from JCB Service have been revised with effect from January 1997 (see MI 563/H, 507/HA, 511/E).

References to these products on subsequent pages in this service manual will be progressively updated, but for convenience a cross reference table is shown below.

Old Description

Old Part Number

New Description

New Part Number

JCB High Strength Threadlocker

4102/0502

JCB High Strength Threadlocker

4102/0551

JCB High Strength Retainer

4101/0602

JCB Retainer (High Strength)

4101/0651

JCB Lock & Seal

4101/0202

JCB Threadlocker & Sealer

4101/0251

Loctite 243

4101/1101

Use 4101/0251

JCB Multi-Gasket

4102/1204

JCB Multi-Gasket

4102/1212

High Strength Lock and Seal

4104/0502

JCB Threadlocker & Sealer (High Strength)

4101/0552

JCB Threadlocker

4101/0402

JCB Threadlocker

4102/0451

Loctite Activator N

4104/0101 Aerosol 4104/0102 Bottle

JCB Activator

4104/0251 4104/0253

Super Clean Safety Solvent

4104/0601 Aerosol

No longer available, Replaced by

4104/1557

JCB Cleaner & Degreaser

4104/1538 Aerosol

JCB Cleaner/Degreaser

4104/1557

Note: High Strength Threadlocker was previously called High Strength Gasketing (4102/0502).

9803/6410

Issue 1

Section 2

Care & Safety

Section 2

i

i

Contents

9803/6410

Page No.

Safety Notices

1-1

General Safety

2-1

Operating Safety

3-1

Maintenance Safety

4-1

Issue 1

Section 2

Care & Safety

1-1

Section 2 1-1

In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.

! DANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured.

INT-1-2-1

! WARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured.

INT-1-2-3

! CAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine.

INT-1-2-3

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Care & Safety

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All construction and agricultural equipment can be hazardous. When a JCB Excavator is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others.

Do not work with the machine until you are sure that you can control it.

Note: This section includes a certain amount of operating safety information. But remember that whenever you drive the machine or operate its controls, you are in effect a machine operator. Therefore you should read and understand the information given in the Operator Handbook before driving the machine or operating its controls.

Do not start any job until you are sure that you and those around you will be safe.

If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything.

Remember BE CAREFUL BE ALERT BE SAFE GEN-1-6

As well as the warnings in the following pages, specific warnings are given throughout the book. This section is designed to give a safety code for use of the machine generally and for operation and maintenance practices.

General Safety !

WARNING

!

WARNING

Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job.

Care and Alertness All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards.

INT-1-3-5

INT-1-3-7

!WARNING !WARNING Clothing You can be injured if you do not wear the proper clothing.

Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, ear-protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained.

INT-1-3-6

9803/6410

Raised Equipment Raised equipment can fall and injure you. Do not walk or work under raised equipment unless safely supported.

13-1-1-6

! DANGER Before removing the boom from the machine, ensure that the counterweight is adequately supported as in certain ground conditions the machine could tip backwards. Never travel or transport the machine with the boom removed.

BF6-3

Issue 1

Section 2

Care & Safety

Section 2

3-1

3- 1

Operating Safety !WARNING

!WARNING

Engine The engine has rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open.

Ramps and Trailers Water, mud, ice, grease and oil on ramps or trailers can cause serious accidents. Make sure ramps and trailers are clean before driving onto them. Use extreme caution when driving onto ramps and trailers.

INT-2-1-6

!WARNING Entering/Leaving Always face the machine when entering and leaving the cab.

Use the step(s) and handrails. Make sure the step(s), handrails and your boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls as handholds, use the handrails.

INT-2-1-7

!WARNING Controls You or others can be killed or seriously injured if you operate the control levers from outside the cab. Operate the control levers only when you are correctly seated inside the cab.

INT-2-1-3

!WARNING Visibility Accidents can be caused by working in poor visibility. Keep windows clean and use your lights to improve visibility. Do not operate the machine if you cannot see properly.

INT-2-1-11

!WARNING

INT-2-2-6

!WARNING Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands.

INT-2-2-3

! DANGER Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust.

INT-2-2-10

!WARNING Controls Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls. If that happens, you will lose control of the machine.

2-2-3-6

Machine Limits Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications.

INT-2-1-4

!WARNING Exhaust Gases Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, fit an exhaust extension. If you begin to feel drowsy, stop the machine at once. Get out of the cab into fresh air.

INT-2-1-10

!WARNING Hazardous Atmospheres This machine is designed for use in normal outdoor atmospheric conditions. It shoul not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor.

INT-2-1-14

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Maintenance Safety !WARNING

!WARNING

Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground.

Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the operator's cab until you need to use it.

INT-3-2-4

!WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or drift to remove and fit metal pins. Always wear safety glasses.

Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbondioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Fire fighters should use self-contained breathing apparatus.

INT-3-1-3

INT-3-2-7/1

!WARNING Communications Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing. Before starting the engine, make sure the others are clear of the danger areas; examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken.

INT-3-1-5

!WARNING Diesel Fuel Diesel fuel is flammable; keep naked flames away from the machine. Do not smoke while refuelling the machine or working on the engine. Do not refuel with the engine running.

There could be a fire and injury if you do not follow these precautions.

INT-3-2-2

!WARNING Petrol Do not use petrol in this machine. Do not mix petrol with the diesel fuel; in storage tanks the petrol will rise to the top and form flammable vapours.

INT-3-1-6

!WARNING Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin.

INT-3-2-3

!WARNING Battery A battery with frozen electrolyte can explode if it is used or charged. Do not use a machine with a frozen battery. To help prevent the battery from freezing, keep the battery fully charged.

INT-3-1-7

!WARNING Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery.

Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter.

INT-3-1-8

!WARNING Battery Terminals The machine is negatively earthed. Always connect the negative pole of the battery to earth.

When connecting the battery, connect the earth (-) lead last.

When disconnecting the battery, disconnect the earth (-) lead first.

INT-3-1-9

!WARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.

INT-3-1-4

! CAUTION Do not disconnect the alternator, the battery, or any part of the charging circuit with the engine running.

8-3-4-1

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Section 2

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4-2

Maintenance Safety (cont’d) ! CAUTION

!WARNING

Never use water or steam to clean inside the cab. The use of water or steam could damage the on-board computer and render the machine inoperable. Remove dirt using a brush or damp cloth.

Hydraulic Fluid Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immediately.

8-3-4-8

! CAUTION

Arc Welding Before carrying out any arc welding on the machine, completely remove the Control Computer to avoid damage to the circuits; also disconnect the alternator plug and battery leads.

When welding items to the mainframe make sure that the earth clamp is positioned on the mainframe and when welding to the undercarriage make sure that the earth clamp is positioned on the undercarriage. If you earth one and weld the other, you may cause severe damage to the slew ring.

Always connect the earth clamp to any other component being welded, i.e. boom or dipper, to avoid damage to pivot pins and bushes.

8-1-2-6/1

INT-3-1-10/1

! CAUTION Rams The efficiency of the rams will be affected if they are not kept free of solidified dirt. Clean dirt from around the rams regularly. When leaving or parking the machine, close all rams if possible to reduce the risk of weather corrosion.

INT-3-2-10

! CAUTION Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents.

INT-3-2-11

!WARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: Damaged end fittings Chafed outer covers Ballooned outer covers Kinked or crushed hoses Embedded armouring in outer covers Displaced end fittings.

INT-3-3-2

!WARNING DO NOT remove the hydraulic tank filler cap or cover plate when the engine is running. The hydraulic system is under pressure. You or others could be injured. First stop the engine and then release the pressure.

! CAUTION 'O'-rings, Seals and Gaskets Badly fitted, damaged or rotted 'O'-rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Trichloroethane or paint thinners near 'O' rings and seals.

INT-3-2-12

!WARNING Hot Coolant The cooling system is pressurised when the engine is hot.

Hot coolant can spray out when you remove the radiator cap. Let the system cool before removing the radiator cap.

To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap.

INT-3-2-9

! CAUTION

8-3-4-4/1

!WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open.

INT-3-1-11/1

If the machine is operated at full load, before its initial run-in procedure is complete, it may cause scuffing and seizing which can adversely effect the service life of the machine.

8-3-1-5

!WARNING Compressed Air When using compressed air, wear safety glasses and gloves.

Do not direct compressed air at your skin.

8-3-4-2

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

i

i

Contents Fluids and Lubricants Lubricants - Health and Safety

1-1 1-2

Service Schedules Service Intervals for Hydraulic Oil and Filters when using a Breaker or Crusher Initial Precautions For New Machine Usage Operating Hours Schedule

2-1 2-2 2-3

Greasing Slew Ring Bearing Slew Ring Teeth and Slew Pinion Excavator End

3-1 3-1 3-2

Battery

4-1

Fuses

*

9803/6410

Page No.

See Section C

Hydraulics Air bleeding procedures Releasing tank pressure Air bleeding from hydraulic pump Air bleeding from ram Air bleeding from the slew motor Checking the fluid level Topping up fluid level Changing the hydraulic oil Changing the Return Filter Element Flushing Filters Cleaning/Changing the Suction Strainer Changing the Air Breather Element Draining Tank Impurities Changing the Pilot Oil Filter Changing the Breaker In-line Filter Changing the Drain Line Filter Changing the Nephron Filter

5-1 5-1 5-2 5-2 5-3 5-4 5-4 5-5 5-6 5-6 5-7 5-8 5-9 5-9 5 - 10 5 - 10 5 - 11

Transmission Checking Track Gearbox Oil Level Changing the Track Gearbox Oil Checking the Slew Gearbox Oil Level Changing the Slew Gearbox Oil Replenishing Slew Gearbox Grease

6-1 6-1 6-2 6-2 6-2

Tracks and Running Gear Cleaning the Tracks Checking/Adjusting the Track Tension Checking the Shoe Plate Checking the Rollers and Idler Wheels for Oil Leaks

7-1 7-2 7-3 7-3

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Routine Maintenance

Section 3

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Contents

*

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Page No.

Engine Changing the Air Filter Elements Checking the Oil Level Changing the Oil and Filter(s) Checking the Coolant Level Coolant Mixtures Changing the Coolant Adjusting the Fan Belt Fitting a New Fan Belt Cleaning the Radiator and Oil Cooler Draining Fuel Tank Impurities Draining the Water Separator Changing the Fuel Filter Element Bleeding the Fuel System

8-1 8-2 8-2 8-3 8-3 8-4 8-5 8-5 8-6 8-7 8-7 8-7 8-8

Component Location Diagrams

9-1

Performance Evaluation

10 - 1

Falling Objects Protection Structure (FOPS) Checking the FOPS structure

12 - 1

Issue 2*

Section 3

Routine Maintenance

Section 3

Fluids and Lubricants

1-1

1-1

CAPACITIES AND SPECIFICATIONS Capacity

International Item

Lubricant

Specification

JS130

JS160

12.1 litres (2.7 UK gal) (3.2 US gal)

12.1 litres (2.7 UK gal) (3.2 US gal)

ENGINE

(see separate chart)

TRACK GEARBOX

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105

2 x 3.0 litres (2 x 0.66 UK gal) (2 x 0.79 US gal)

2 x 3.0 litres (2 x 0.66 UK gal) (2 x 0.79 US gal)

SLEW GEARBOX

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105

JCB Special HP Grease

Lithium based No. 2 consistency

5 litres (1.09 UK gal) (1.31 US gal) 1 litre (0.22 UK gal) (0.26 US gal)

5 litres (1.09 UK gal) (1.31 US gal) 1 litre (0.22 UK gal) (0.26 US gal)

TRACK ROLLERS IDLER WHEEL

JCB HD 90 Gear OIl

API-GL-5, MIL-L-2105

-

-

RECOIL SPRING CYLINDER

JCB Special HP Grease

Lithium based, No. 2 consistency

-

-

HYDRAULIC SYSTEM

JCB Hydraulic Fluid 46

ISO VG46

124 litres (27.3 UK gal) (32.8 US gal)

124 litres (27.3 UK gal) (32.8 US gal)

SLEW RING - BEARING

JCB Special HP Grease

-

-

- GEAR TEETH

JCB Special HP Grease

Lithium based No. 2 consistency Lithium based No. 2 consistency

11kg (24.25 lb)

17kg (37.48 lb)

-

-

ALL OTHER GREASE POINTS

JCB Special HP Grease

Lithium based No. 2 consistency

COOLING SYSTEM

see Coolant Mixtures

-

16.4 litres (3.6 UK gal) (4.3 US gal)

17.2 litres (3.78 UK gal) (4.5 US gal)

FUEL TANK

see Type of Fuel

-

240 litres (52.8 UK gal) (63.4 US gal)

240 litres (52.8 UK gal) (63.4 US gal)

*ENGINE LUBRICATION CHART - ALL COUNTRIES EXCEPT NORTH AMERICAN

-30

Use according to ambient temperature (°C) -10 0 10 20

-20

30

40

JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG JCB SUPER 10W/30 MULTIGRADE ENGINE OIL API CF4/SG *ENGINE LUBRICATION CHART - NORTH AMERICAN Use according to ambient temperature (°F) -22

-5

0

14

32

50

68

90

104

JCB 15W/40 MULTIGRADE ENGINE OIL API CF4/SG JCB 10W ENGINE OIL API CF4/SG 9803/6410

Issue 2*

Section 3

Routine Maintenance

Section 3

Lubricants - Health and Safety

1-2

1-2

It is most important that you read and understand this information and the publications referred to. Make sure that all of your colleagues who are concerned with lubricants read it too.

First Aid - Oil

Handling

Swallowing

New Oil

If oil is swallowed you should not induce vomiting. Get medical advice.

There are no special precautions need for the handling or use of new oil, beside normal care and hygiene practices.

Used Oil Skin In the case of excessive skin contact you should wash with soap and water.

Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer.

Eyes

Here are precautions to protect your health when handling used engine oil:

In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention.

1. Avoid prolonged, excessive or repeated skin contact with used engine oils.

Fires

2. Apply a barrier cream to the skin before handling used engine oil.

Extinguish with carbon dioxide, dry chemical or foam. Firefighters should use self contained breathing apparatus.

! WARNING Do not use water to put out an oil fire. This will only spread it because oil floats on water.

Extinguish oil and lubricant fires with carbon dioxide, dry chemical or foam. Fire fighters should use self contained breathing apparatus.

7-3-1-3/1

3. Note the following when removing engine oil from skin: a. Wash your skin thoroughly with soap and water. b. Using a nail brush will help. c. Use special hand cleansers to help clean dirty hands. d. Never use petrol, diesel fuel or gas oil. e. Avoid skin contact with oil soaked clothing. f. Don't keep oily rags in pockets.

Hygiene

g. Wash dirty clothing before re-use.

JCB lubricants are not a health risk when used properly for their intended purposes.

h. Throw away oil-soaked shoes.

Waste Disposal

However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.

All waste products should be disposed of in accordance with all the relevant regulations.

Low viscosity oils are more likely to do this, therefore particular care is necessary in handling used oils which can be diluted with fuel contamination.

The collection and disposal of used engine oil should be in accordance with any local regulations. Never pour used engine oil into sewers or drains.

Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, and note the following:

Spillage Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.

Storage Always keep lubricants out of the reach of children.

Never store lubricants in open or unlabelled containers.

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Routine Maintenance

Section 3

Service Schedules

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2-1

Service Intervals for Hydraulic Oil and Filters when using a Breaker or Crusher When using a breaker or crusher, contamination and degradation of the hydraulic oil occurs much more quickly than in normal excavating use. If the machine is used with increasingly degrading oil it can cause problems in the control valve, premature wear of the hydraulic pump and damage to the hydraulic system as a whole.

Servicing of the hydraulic oil and filters must be done more frequently according to the percentage of total operating hours involving use of the breaker or crusher. When a breaker or crusher is fitted, ensure that the oil and filters are changed at the intervals shown in the table below.

The hydraulic oil must be sampled and checked for contamination and degradation at the intervals shown.

Item

Time (hrs)

Hydraulic Oil

Use Frequency 100%

Use Frequency 40%

10

600

10

●

●

100

●

300

Use Frequency 20%

1500

10

●

●

●

800 4000

●

●

●

Suction Filter

¹

Drain Filter

●

●

●

●

Servo Filter

●

●

●

●

Nephron Filter

●

●

●

●

Breaker In-Line Filter

●

●

●

●

Hydraulic Oil Sampling

Every 200 hrs

Every 300 hrs

Every 600 hrs

Every 800 hrs

● Change

●

¹

●

10

Return Filter

● Check oil level and top up as required

●

600 3000

Use Frequency 10%

●

¹

● ●

¹

●

¹ Clean

Note: The filters must be changed whenever the period of breaker/crusher use exceeds 100hrs, regardless of the total number of hours the machine has worked.

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Section 3

Routine Maintenance

2-2

Service Schedules

Section 3 2-2

Initial Precautions for New Machine Usage ! CAUTION If the machine is operated at full load, before its initial run-in procedure is complete it may cause scuffing and seizing which can adversely effect the life of the machine.

8-3-1-5

A new machine is only dispatched when it has completed all its inspection procedures, but operating it under severe conditions from new will affect its performance and shorten its service life.

1

Carry out the Daily inspection procedure

2

Always warm up the machine sufficiently

3

Hold the engine speed to 80% of the maximum

4

Check to see if the machine is running normally

5

Avoid running or swinging the machine rapidly

6

Avoid sudden shocks e.g. suddenly stopping the boom when lowering

7

Where applicable, grease the front pins daily

8

At 50 hrs carry out servicing

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Routine Maintenance

Section 3

Service Schedules

2-3

2-3

Every 10 Operating Hours or Daily

Every 100 Operating Hours or 2-Weekly

Whichever occurs first

Whichever occurs first

1

Clean a Machine generally.

1

Do a 50 hour service plus:

2.

2

Grease (If operating in very wet conditions)

Clean a Battery terminals.†.

3

Check (Engine Stopped) a Generally for damage.

b Fuel lift pump strainer†.

3

b For oil and coolant leakage. c

b Engine oil main filter element †.

Security of bolts and nuts ††.

c

d For disconnected or shorted wiring, loose terminals. e

Change a Engine oil †.

d Engine oil filter by-pass element †.

Hydraulic fluid level.

e

f Engine oil level.

g Track and slew gearbox oil†.

h Windscreen washer fluid level.

l 4

h Fuel filter element†.

Fuel system for leaks.

k Fuel level.

4

c

d Excavator operation.

f

Operation of track and slew brakes.

Bucket pivot pin grease seals†.

d Track plate condition.

Exhaust for excessive smoke.

Transmission operation.

Hose and pipework for chafing or damage.

b Condition of ram piston.

b Operation of other electrical equipment.

e

Check (Engine Stopped) a

The breaker oil filter visual indicator (if using a rockbreaker).

Check (Engine Running) a Operation of warning lights and audible alarm.

c

Return filter element†.

f Drain filter element †.

g Track tension.

j

Servo oil filter element †.

e

Track and running gear.

f

Top and bottom track rollers for oil leaks †.

g Track idler wheels for oil leaks †. h Security of major unit mounting bolts and nuts†.

If loose, tighten to specified torque.

g Operation of hour meter.

Every 50 Operating Hours or Weekly Whichever occurs first

i

Wiring for chafing.

j

Fan belt tension†.

k

Accumulator operation.

l

Radiator for damage†.

1

Do the daily jobs plus:

2

Clean a Drain water and sediment from fuel tank.

n Battery electrolyte level†.

b Drain fuel water separator.

p Exhaust system security†.

Grease a All pivot pins.

r

3

m Oil cooler for damage†.

5

Check (Engine Running) a

††

Tapping with a hammer will identify any loose nuts and bolts which should then be tightened to the specified torque.

Operation of throttle system†.

b Operation of overload warning†. c †

9803/6410

Teeth and sidecutters†.

Operation of stop control†.

These procedures are only to be carried out after the first 100 hours use of a new machine. Thereafter they are to be carried out as detailed in the following periodic checks.

Issue 1

Section 3

Routine Maintenance

Section 3

Service Schedules

2-4

2-4

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 a Drain water and deposits from hydraulic oil tank.

2

Clean a Fuel lift pump strainer.

b Air cleaner dust valve. c 3

b

Pre-cleaner

3

Grease a Door and canopy hinges.

c

b Security of major unit mounting bolts and nuts.

If loose, tighten to specified torque.

e

Nephron filter. †††

f

Servo oil filter element. †††

g Drain filter. †††

Track and slew gearbox oil level.

4.

d Fan belt adjustment. e

Track and slew gearbox oil.

d Return filter element. †††

Check (Engine Stopped) a Battery electrolyte level.

c

Change (Engine Stopped) a Engine air filter element (outer). b Hydraulic tank air breather element.

b Slew ring bearing.

4

Hydraulic fluid suction strainer.

Check (Engine Stopped) a Track wear.

Air inlet system security

Every 2000 Operating Hours or Yearly Whichever occurs first

Every 500 Operating Hours or 3-Monthly Whichever occurs first

1

Do a 1000 hour service plus:

2

Change a Hydraulic fluid suction strainer.

1

Do a 250 hour service plus:

2

Clean a Radiator, grille and oil cooler fins.

3

Grease a Slew ring teeth.

4

Change a Engine oil.

Every 4000 Operating Hours or 2 Years

b Engine oil full flow filter element.

Whichever occurs first

c

1

Do a 2000 hour service plus:

2

Change a Long life coolant.

Fuel filter element.

d Engine oil by-pass filter element.

5

6

Check (Engine Stopped) a Exhaust system security.

b Engine air filter element (inner).

3 *

Check (Engine Stopped) a Sample hydraulic oil and replace if necessary.

b Fuel hose (fuel tank - engine).

b Top and bottom track rollers for oil leaks.

c

c

d Hydraulic pump exit hose (pump - operation valve).

Track idler wheels for oil leaks.

Fuel hose (fuel filter - injection pump).

d Hydraulic oil (check the degradation and cleanliness by sampling).

e

Boom ram line hose.

f

Dipper ram line hose.

e

Seat belt condition and security.

g Bucket ram line hose.

f

Teeth and sidecutters.

Check (Engine Running) a

Operation of throttle system.

††† If using a breaker or crusher, see page 2 - 1 for revised servicing schedules.

b Operation of overload warning. c

Operation of stop control.

9803/6410

Issue 2*

Section 3 2-5

Routine Maintenance Service Schedules

Section 3 2-5

Every 5000 Operating Hours or 2 Years 6 Months Whichever occurs first 1

Do a 1000 hour service plus:

2

Change Hydraulic oil.

Hydraulic tank air breather element.

Hydraulic suction filter. †††

††† If using a breaker or crusher, see page 2 - 1 for revised servicing schedules.

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

Greasing

3-1

! WARNING

General Notes For the type of grease to use at each point, see Lubricants and Capacities.

Do not mix different types of grease. Keep them separate.

3-1

You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started.

8-3-1-3

Slew Ring Bearing 1

The three grease nipples are grouped together on the front of the machine.

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 .

1

Make the Machine Safe Stop the engine and remove the starter key.

2

Grease the Slew Ring a

Remove the Inspection port cover A (on the lower centre section).

b Remove the grease discharge port cover B (on the lower inner side). c

Remove contaminated grease.

d Replace the discharge port cover. e 3

Apply grease to the slew ring via aperture C.

Slew the Machine Start the engine and slew the machine a few degrees.

Stop the engine, remove the starter key and apply grease again.

Repeat until the whole ring is greased. Check that grease exudes around the entire circumference.

4

Refit the Cover

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Issue 1

Section 3

Routine Maintenance

Section 3

Greasing (continued)

3-2

3-2

! WARNING

Excavator End

You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started.

16 Grease Points

8-3-1-3

Greasing Points

(No.) Reference drawing

Boom Boom ram, eye end pin

3.

1

Dipper ram, dump end pin Boom ram, dump end pin

2.

2

2.

3

1.

1.

Dipper to Bucket pin

1.

Bucket ram, dump end pin

1.

Boom to Dipper, connecting pin

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Centralised greasing (total of 6 points)

2.

Dipper to Bucket Linkage pin

Dipper ram, eye end pin

}

1.

Bucket ram to Bucket linkage pin Bucket linkage to Bucket pin

Number of greasing points

4

1.

(total of 5 points)

(total of 3 points)

1.

Issue 1

Section 3 3-3

Routine Maintenance Greasing (continued)

Section 3 3-3

Excavator End

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Issue 1

Section 3

Routine Maintenance

Section 3

Battery

4-1

4-1

First Aid - Electrolyte

Check the Electrolyte Level

EYES

1

Open the Battery Compartment A

FLUSH WITH WATER FOR 15 MINUTES. GET MEDICAL HELP FAST.

IF SWALLOWED DO NOT INDUCE VOMITING. DRINK LARGE QUANTITIES OF WATER OR MILK. Then drink milk of magnesia, beaten egg or vegetable oil.

SKIN Remove the bolts securing the metal plate above the battery. Remove the plate.

FLUSH WITH WATER. REMOVE AFFECTED CLOTHING.

! WARNING Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and naked flames.

2

Remove covers and look at the level in each cell. The electrolyte should be 6 mm. (0.25 inch) above the plates. Top up if necessary with distilled water or de-ionized water.

Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles.

Handle the battery carefully to prevent spillage.

Keep metallic items (watches, rings, zippers etc) away from the battery terminals. Such items could short the terminals and burn you.

Set all switches in the cab to OFF before disconnecting the battery. When disconnecting the battery, take off the earth (-) lead first.

Check the Level

! WARNING Do not top the battery up with acid. The electrolyte could boil out and burn you.

2-3-4-6

3

Check the Connections Make sure that the terminals are tight and clean. Coat them with petroleum jelly to prevent corrosion.

When reconnecting, fit the positive (+) lead first.

Re-charge the battery away from the machine, in a wellventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up.

5-3-4-3

! CAUTION

Do not disconnect the alternator, the battery, or any part of the charging circuit with the engine running.

8-3-4-1

Charge Rate Depending on the Battery specific Gravity Temperature 20°C

0°C

-10°C

100% (satisfactory)

1.26

1.27

1.28

90% (satisfactory)

1.24

1.25

1.26

80% (charge)

1.22

1.23

1.24

Charge Rate

75% (charge) 1.21 1.22 1.23 If the battery is charged and the charge rate is less than 75%, replace the battery.

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Issue 1

Section 3

Routine Maintenance

Section 3

Hydraulics

5-1

5-1

Air Bleeding Procedures Air Bleeding Sequence

! WARNING

Air Bleeding Air Bleeding Air Bleeding from slew Check from pump from ram motor

Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open.

INT-3-1-11/1

Hydraulic oil or pump replacement

O

Ram replacement

O

O

O

O O

Slew motor replacement

O

O

Releasing Tank Pressure ! WARNING DO NOT remove the hydraulic tank filler cap or cover plate when the engine is running. The hydraulic system is under pressure. You or others could be injured. First stop the engine and then release the pressure.

8-3-4-4/1

! WARNING The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools down (less than 40°C) before beginning maintenance.

8-3-4-10

1

Prepare the Machine a

Position the machine on level ground. Stop the engine. Remove the starter key.

b

Locate the hydraulic oil tank filler cap A or filler plate.

c

Remove the box nut of the breather B on top of the hydraulic oil tank, press the projection and release the pressure from the tank.

A

B

A

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Issue 1

Section 3

Routine Maintenance

Section 3

Hydraulics (continued)

5-2

5-2

Air Bleeding from Hydraulic Pump ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open.

A

INT-3-1-11/1

1

Prepare the Machine a Position the Machine on level ground. Stop the engine. Remove the starter key. b Loosen the air bleeding plug A to check that oil comes from the air bleeding port. c

If oil does not come out, remove the air bleeding plug A and fill hydraulic oil into the pump case through the air bleeding port.

d Temporarily tighten the air bleeding plug A. e

Idle the engine at low speed, slightly loosen the air bleeding plug and continue to run the engine until oil comes out from the air bleeding port.

f

Completely tighten the air bleeding plug A.

g Stop the engine and allow the bubbles to make their way through the hydraulic tank.

Air Bleeding from Ram ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open.

INT-3-1-11/1

! WARNING

The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools down (less than 40°C) before beginning maintenance.

8-3-4-10

1

Prepare the Machine a

Position the Machine on level ground.

b Idle the engine at low speed and retract each ram 4 or 5 times without reaching the stroke end (about 100mm (4 in.) before the end of the ram. c

Operate each ram 3 or 4 times to the stroke end to completely bleed the air.

d Stop the engine and allow the bubbles to make their way through the hydraulic tank.

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Issue 1

Section 3

Routine Maintenance

Section 3

Hydraulics (continued)

5-3

Air Bleeding from the Slew Motor ! 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.

5-3

JS130

JS160

8-3-4-4/1

! WARNING The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools down (less than 40°C) before beginning maintenance.

8-3-4-10

1

Prepare the Machine a Position the machine on level ground.

A

A

b Idle the engine at low speed, loosen the air bleeding plug A and check that oil comes out from the air bleeding port.

DO NOT SLEW THE MACHINE. c If no oil comes out, stop the engine, remove the air bleeding plug A and fill the motor case with hydraulic oil. d Temporarily tighten the air bleeding plug. e

Idle the engine at low speed and continue to run until oil comes out from the air bleeding port.

f

Completely tighten the air bleeding plug.

g Idle the engine at low speed and slowly slew the machine left to right evenly more than 2 turns. h Stop the engine and allow the bubbles to make their way through the hydraulic tank.

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Issue 1

Section 3

Routine Maintenance

Section 3

Hydraulics (continued)

5-4

5-4

For location of hydraulic oil tank see Component Location Diagram.

! WARNING

Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin get medical help immediately.

A

INT-3-1-10/1

Checking the Fluid Level 1

Prepare the Machine Position the machine on level ground with the bucket and dipper rams fully extended and the boom lowered to rest the attachment on the ground, as at A.

2

Check the Level Look at the fluid level in the sight tube B. The level should be between the two marks on the tube. If the fluid is cloudy, water or air has entered the system.

Water or air in the system could damage the hydraulic pump.

B

Topping up Fluid Level ! 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 Position the Machine on level ground as at A. Stop the engine. Remove the starter key.

2

Locate the Hydraulic Oil Tank or Filler Plate See Component location Diagrams.

3

Release Tank Pressure See Releasing Tank Pressure.

4

Add Fluid. a Remove plug C. b Refill oil through the filler port using a suitable tundish. c Check the level through the level gauge on the side of the tank.

C

d Refit plug C.

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Issue 1

Section 3

Routine Maintenance

Section 3

Hydraulics (continued)

5-5

5-5

Changing the Hydraulic oil ! 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.

A

8-3-4-4/1

! WARNING Hydraulic Pressure Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin.

INT-3-2-3

1

Prepare the Machine Position the machine on level ground as at A. Stop the engine. Remove the starter key.

2

Locate the Hydraulic oil tank or Filler Plate. See Component Location Diagrams at the end of the section.

3

Release Tank Pressure See Releasing Tank Pressure. a

Remove the filler port cover B and 'O'-ring C.

b Use a pump and discharge the hydraulic oil into an empty waste container. c

Remove the drain plug D on the bottom of the Tank and drain the remaining oil from the tank (have a drain pan ready).

4

Replace the Suction Strainer E See Changing the Suction Strainer.

5

Replace the Return Filter F See Changing the Return Filter.

6

Seal the system a Refit Drain plug D. b Refill the Tank Refill the Tank with Hydraulic oil (See Lubricants and Capacities for the type of fluid) to the specified level see Checking the Fluid Level. c

Install the 'O'-ring C and filler port cover B.

Note: If the 'O'-Ring C is damaged, replace it with a new one.

7

Bleed the Hydraulic Components See Air Bleeding Procedures

8

Check for leaks a Start the engine and run it for around 5 minutes without load. b Slowly operate the Travel, slew and cylinders several times.

9

Check the fluid level See Checking the Fluid Level.

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Issue 1

Section 3 5-6

Routine Maintenance Hydraulics (continued)

5-6

Changing the Return Filter Element 1

C

Prepare the Machine Position the machine on level ground. Stop the engine.

Remove the starter Key.

2

Locate the Return filter. See Components Location Diagram at the end of this section.

3

Release Tank Pressure.

See Releasing Tank Pressure.

4

Section 3

A B

D E

Removing the Element a Remove the retaining bolts A and washers B and take off the cover plate C complete with its 'O'-ring seal.

F

b Remove the spring D, bypass valve E and element F.

*

5

Fit a New Element Re-assemble in reverse order, using a new filter element F and replace the 'O'-ring with a new one if the one removed is worn or damaged.

6

Seal the system Refit the cover plate C and secure with bolts A and washers B.

Flushing Filters A slave hydraulic flushing element can now be obtained for the machine. It is a mandatory requirement that the hydraulic system is flushed when: 1

The hydraulic system has become contaminated with debris.

2

Major hydraulic components such as pumps, valve blocks, ram, tanks, motors etc. are changed.

3

5

Run the machine as described below: The filter should be left in the machine for a minimum of 4 hours, during which time all hydraulic services must be operated a minimum of 20 times to ensure complete system cleanliness.

6

After the required flushing time has elapsed, stop the engine and vent hydraulic pressure (see Releasing Tank Pressure).

An oil sample report indicates that the system needs to be cleaned.

7

Remove flushing filter element and save in a clean condition until step 10 is completed.

The slave filter should be fitted in place of the main return filter during flushing only.

8

Fit new main hydraulic filter and refit tank cover.

1

9

Take oil sample and send for analysis.

10

If analysis shows that the oil is out of specification the flushing procedure should be repeated until analysis confirms that the oil is satisfactory.

Vent hydraulic tank pressure (see Releasing Tank Pressure) and then remove tank cover C, main hydraulic filter F, relief valve E and spring D.

2

Fit flushing filter element, relief valve G and spring D.

3

Refit tank cover C, ensuring that the ‘O’ ring is positioned correctly.

4

Start up machine and test for leaks.

9803/6410

Element Required SSP0061

All JS Machines up to and including JS160.

Issue 2*

Section 3 5-7

Routine Maintenance

Section 3

Hydraulics (continued)

5 -7

Cleaning/Changing the Suction Strainer 1

Prepare the Machine Position the machine on level ground.

Stop the engine. Remove the starter key.

2

Locate the Suction Strainer

3

Release Tank Pressure See Releasing Tank Pressure.

4

Remove the suction Strainer a Remove the retaining bolts A and washers D, lift off cover plate B. b Remove the suction strainer C and clean with a suitable solvent or, if renewing discard.

5

Fit the Suction Strainer Fitting is a reversal of removal.

6

Check the Hydraulic fluid Level See Checking the Fluid Level.

7

Seal the System Refit the cover plate B together with its 'O'-ring.

B

D

A

Note: Check the 'O'-ring, if it is worn or damaged replace it with a new one and secure with bolts A and washers B.

C

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

Hydraulics (continued)

5-8

5-8

Changing the Air Breather Element 1

Prepare the Machine Position the machine on level ground. Stop the engine.

Remove the starter key.

2

Release Tank Pressure See Releasing Tank Pressure.

3

Locate the Air Breather Cover A See illustration.

4

A

Replace the air Breather Element B a Remove the hexagonal nut D and sealing washer E. b Remove the cover A (note: slot). c

5

Replace the air breather element B, when installing re-fit the sponge packing F above element.

H

Re-fit Breather Cover A a Align the slot on the air breather cover A with the slot on the cover plate G. b Refit the sealing washer E, hexagonal nut D and nut cap C.

C D E slot A F B

G

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Issue 1

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