Foreword The Operator's Manual
SERVICE MANUAL
You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand. Treat the Operator's Manual as part of the machine. Keep it clean and in good condition. Replace the Operator's Manual immediately if it is lost, damaged or becomes unreadable.
BACKHOE LOADER
1CX, 1CXT
Contents 01 - Machine 03 - Attachments, Couplings and Load Handling 06 - Body and Framework 09 - Operator Station 12 - Heating, Ventilating Conditioning (HVAC) 15 - Engine 18 - Fuel and Exhaust System 21 - Cooling System
EN - 9813/6050 - ISSUE 2 - 07/2018
24 - Brake System 27 - Driveline 30 - Hydraulic System
This manual contains original instructions, verified by the manufacturer (or their authorized representative).
33 - Electrical System 72 - Fasteners and Fixings 75 - Consumable Products 78 - After Sales
Copyright 2018 Š JCB SERVICE All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
www.jcb.com
and
Air-
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Spine Cards
SERVICE MANUAL
SERVICE MANUAL
1CX, 1CXT
1CX, 1CXT
EN 9813/6050
EN 9813/6050
SERVICE MANUAL
SERVICE MANUAL
1CX, 1CXT
1CX, 1CXT
EN 9813/6050
EN 9813/6050
Volume 1
Volume 3
Volume 2
Volume 4
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01 - Machine Contents
Page No.
Acronyms Glossary .................................................................................................................................... 01-2 01-03 Safety 01-03-03 Safety - Yours and Others ............................................................................................... 01-3 01-03-06 Safety Warnings ............................................................................................................... 01-4 01-03-09 General Safety ................................................................................................................. 01-5 01-03-12 Maintenance Safety ......................................................................................................... 01-6 01-03-18 Operating Safety .............................................................................................................. 01-8 01-03-21 Worksite Safety .............................................................................................................. 01-11 01-03-24 Risk Assessment ............................................................................................................ 01-12 01-03-27 Maintenance Positions ................................................................................................... 01-13 01-06 About this Manual 01-06-03 Model and Serial Number .............................................................................................. 01-17 01-06-06 Using the Manual ........................................................................................................... 01-18 01-33 Cleaning 01-33-00 General ........................................................................................................................... 01-21
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Acronyms Glossary PIL
Parts Identification List
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01 - Machine
03 - Safety
03 - Safety Contents 01-03-03 01-03-06 01-03-09 01-03-12 01-03-18 01-03-21 01-03-24 01-03-27
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Page No. Safety - Yours and Others ............................................................................................... 01-3 Safety Warnings ............................................................................................................... 01-4 General Safety ................................................................................................................. 01-5 Maintenance Safety ......................................................................................................... 01-6 Operating Safety .............................................................................................................. 01-8 Worksite Safety .............................................................................................................. 01-11 Risk Assessment ............................................................................................................ 01-12 Maintenance Positions ................................................................................................... 01-13
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03 - Safety - Yours and Others
03 - Safety - Yours and Others Introduction All machinery can be hazardous. When a machine is correctly operated and maintained, it is a safe machine to work with. When it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. In this manual and on the machine you will find warning messages, you must read and understand them. They inform you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them. Safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking of what hazards there might be and how to avoid them. Do not work with the machine until you are sure that you can control it. Do not start any work until you are sure that you and those around you will be safe. If you are not sure of anything, about the machine or the work, ask someone who knows. Do not assume anything. Remember: • • •
Be careful Be alert Be safe.
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06 - Safety Warnings
06 - Safety Warnings Introduction In this manual there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury. The signal word 'WARNING' indicates a hazardous situation which, if not avoided, could result in death or serious injury. The signal word 'CAUTION' indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The signal word 'Notice' indicates a hazardous situation which, if not avoided, could result in machine damage. The safety alert system symbol (shown) also helps to identify important safety messages in this manual. When you see this symbol your safety is involved, carefully read the message that follows. Figure 1. The safety alert system symbol
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09 - General Safety
Lifting Equipment
Introduction Training To operate the machine safely you must know the machine and have the skill to use it. You must abide by all relevant laws, health and safety regulations that apply to the country you are operating in. The operator's manual instructs you on the machine, its controls and its safe operation; it is not a training manual. Ensure that you receive the correct training before operating any machinery. Failing to do so will result in incorrect operation of the machine and you will be putting yourself and others at risk. In some markets, and for work on certain jobsites, you may be required to have been trained and assessed in accordance with an operator competence scheme. Make sure that you and your machine comply with relevant local laws and jobsite requirements – it is your responsibility. 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.
You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations. Raised Equipment Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped). Make sure that no-one goes near the machine while you install or remove the mechanical device. Raised Machine Never position yourself or any part of your body under a raised machine which is not correctly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed. Lightning
Clothing
Lightning can kill you. Do not use the machine if there is lightning in your area.
You can be injured if you do not wear the correct clothing. Loose clothing can get caught in the machinery. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and personal jewellery.
This machine is manufactured in compliance with prevailing legislative requirements. It must not be altered in any way which could affect or invalidate its compliance. For advice consult your JCB dealer.
Alcohol and Drugs
Machine Modifications
It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines which can cause drowsiness. 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. Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious injury. Switch off and do not use your mobile phone when refuelling the machine.
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12 - Maintenance Safety
Hydraulic Pressure
Introduction Raised Machine Never position yourself or any part of your body under a raised machine which is not correctly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed. Air Conditioning Maintenance The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person. You can be severely frostbitten or injured by escaping refrigerant. Compressed Air Compressed air is dangerous. Wear personal protective equipment. Never point a compressed air jet at yourself or others. Springs Always wear personal protective equipment when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidentally flying out. Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper drift to remove and install metal pins. Always wear personal protective equipment. 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. Repairs If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result in an accident or affect your health. Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer.
Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open. 'O' rings, Seals and Gaskets Badly installed, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals. Arc Welding To prevent the possibility of damage to electronic components, disconnect the battery and the alternator before arc-welding on the machine or attached implements. If the machine is equipped with sensitive electrical equipment, i.e. amplifier drivers, electronic control units (ECUs), monitor displays, etc., then disconnect them before welding. Failure to disconnect the sensitive electrical equipment could result in irreparable damage to these components. Parts of the machine are made from cast iron, welds on cast iron can weaken the structure and break. Do not weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine. Always connect the welder earth (ground) cable to the same component that is being welded to avoid damage to pivot pins, bearings and bushes. Attach the welder earth (ground) cable a distance from the part being welded no more than 0.6 m. Counterweights Your machine may be installed with counterweights. They are extremely heavy. Do not attempt to remove them. Accumulators The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on systems incorporating accumulators, the system pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may cause serious injury or death. Hot Components Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit. Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground.
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Working Under the Machine Make the machine safe before getting beneath it. Make sure that any attachments on the machine are correctly attached. Engage the park brake, remove the ignition key, disconnect the battery. If the machine has wheels use blocks to prevent unintentional movement. Lifting the Machine Under no circumstances must the engine be run with the transmission in gear and only one driving wheel jacked clear of the ground, since the wheel on the ground will move the machine. Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton®, FluorelTM and Technoflon®. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. This acid can severely burn. New fluoroelastomeric components at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose temperatures have not exceeded 300 °C ( 571.6 °F) require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions. Do not touch component or surrounding area. Used fluoroelastomeric components subjected to temperatures greater than 300 °C ( 571.6 °F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains. Thoroughly wash contaminated area with detergent and water. Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations. Do not burn fluoroelastiometric materials. Hydraulic Hoses Never re-use hydraulic hose end crimps or use reusable hose end crimps. Personal Protective Equipment Use the appropriate personal protective equipment before performing maintenance on the machine, otherwise you could be injured. Working at Height Use appropriate access equipment such as ladders or a working platform if it is necessary to work at height to perform maintenance tasks on the machine. If you do not use suitable access equipment there is a risk of falling, resulting in personal injury or death.
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exhaust extractor. If you begin to feel drowsy, stop the machine at once and get into fresh air.
Introduction
Worksites
Training Make sure that you have had adequate training and that you are confident in your ability to operate the machine safely before you use it. Practice using the machine and its attachments until you are completely familiar with the controls and what they do. With a careful, well trained and experienced operator, your machine is a safe and efficient machine. With an inexperienced or careless operator, it can be dangerous. Do not put your life, or the lives of others, at risk by using the machine irresponsibly. Before you start to work, tell your colleagues what you will be doing and where you will be working. On a busy site, use a signalman. Before doing any job not covered in this manual, find out the correct procedure. Your local JCB distributor will be glad to advise you.
Fuel Fuel is flammable, keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions.
Machine Condition A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this manual are completed before using the machine.
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 or additional equipment.
Engine/Steering Failure If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected.
Exhaust Gases Machine exhaust gases can harm and possibly kill you or bystanders if they are inhaled. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, install an 01 - 8
Worksites can be hazardous. Examine the site before working on it. You could be killed or injured if the ground gives way under your machine or if piled material collapses onto it. Check for potholes and hidden debris, logs, ironwork etc. Any of these could cause you to lose control of your machine. Check for utilities such as electric cables (overhead and underground), gas and water pipes etc. Mark the positions of the underground cables and pipes. Make sure that you have enough clearance beneath overhead cables and structures.
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. Worksites can be noisy, do not rely on spoken commands.
Parking An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Manual to park the machine correctly.
Banks and Trenches Banked material and trenches can collapse. Do not work or drive too close to banks and trenches where there is danger of collapse.
Safety Barriers Unguarded machines in public places can be dangerous. In public places, or where your visibility is reduced, place barriers around the work area to keep people away.
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.
Hazardous Atmospheres This machine is designed for use in normal out door atmospheric conditions. It must 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 dealer.
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Regulations Obey all laws, worksite and local regulations which affect you and your machine.
clearly. Modification of the machine's configuration by the user (e.g. the fitting of large and nonapproved attachments) may result in a restriction of the machine visibility.
Electrical Power Cables
Hands and Feet
You could be electrocuted or badly burned if you get the machine or its attachments too close to electrical power cables. You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near electric power lines. Before you start using the machine, check with your electricity supplier if there are any buried power cables on the site. There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier.
Keep your hands and feet inside the machine. When using the machine, keep your hands and feet clear of moving parts. Keep your hands and feet within the operator compartment while the vehicle is in motion.
Working Platform
Passengers
Using the machine as a working platform is hazardous. You can fall off and be killed or injured. Never use the machine as a working platform unless with approved man-basket or man-crate (if applicable).
Passengers in or on the machine can cause accidents. Do not carry passengers.
Machine Safety Stop work at once if a fault develops. Abnormal sounds and smells can be signs of trouble. Examine and repair before resuming work.
Hot Components Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit.
Travelling at High Speeds Travelling at high speeds can cause accidents. Always travel at a safe speed to suit working conditions.
Hillsides
Controls You or others can be killed or seriously injured if you operate the control levers from outside the machine. Operate the control levers only when you are correctly seated.
Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the correct machine location until you need to use it. Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible.
Roll Over Protection If the machine starts to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll over, do not try and jump from the cab. Stay in the cab, with your seat belt fastened.
Confined Areas Pay extra attention to proximity hazards when operating in confined areas. Proximity hazards include buildings, traffic and bystanders.
Operating the machine on hillsides can be dangerous if the correct precautions are not taken. Ground conditions can be changed by rain, snow, ice etc. Check the site carefully. When applicable, keep all attachments low to the ground.
Safe Working Loads
Visibility
Lightning
Accidents can be caused by working in poor visibility. Use your lights to improve visibility. Keep the road lights, windows, mirrors and cameras clean (when fitted). Do not operate the machine if you cannot see
If you are inside the machine during a lightning storm stay in the machine until the storm has passed. If you are outside of the machine during a lightning storm stay away from the machine until the storm
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Overloading the machine can damage it and make it unstable. Study the specifications in the Operator's Manual before using the machine.
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has passed. Do not attempt to mount or enter the machine. If the machine is struck by lightning do not use the machine until it has been checked for damage and malfunction by trained personnel.
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21 - Worksite Safety Introduction WARNING You or others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practise away from the worksite on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely. WARNING There could be dangerous materials such as asbestos, poisonous chemicals or other harmful substances buried on the site. If you uncover any containers or you see any signs of toxic waste, stop the machine and advise the site manager immediately.
An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a collection of rules and procedures that coordinates the machines and people that work together in the same area. Examples of worksite organisation include: • • •
Restricted areas Controlled patterns of machine movement A system of communication.
You and/or your company could be legally liable for any damage you may cause to public utilities. It is your responsibility to make sure that you know the locations of any public utility cables or pipes on the worksite which could be damaged by your machine.
WARNING Before you start using the machine, check with your local gas company if there are any buried gas pipes on the site. If there are buried gas pipes we recommend that you ask the gas company for any specific advice regarding the way you must work on the site. Some modern gas pipes cannot be detected by metal detectors, so it is essential that an accurate map of buried gas pipes is obtained before any excavation work commences. Hand dig trial holes to obtain precise pipe locations. Any cast iron pipes found must be assumed to be gas pipes until contrary evidence is obtained. Older gas pipes can be damaged by heavy vehicles driving over the ground above them. Leaking gas is highly explosive. If a gas leak is suspected, contact the local gas company immediately and warn all personnel on the site. Ban smoking, make sure that all naked lights are extinguished and switch off any engines which may be running. 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. CAUTION Before you start using the machine, check with your local public water supplier if there are buried pipes and drains on the site. If there are, obtain a map of their locations and follow the advice given by the water supplier. You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near buried pipes and drains. CAUTION If you cut through a fibre optic cable, Do not look into the end of it, your eyes could be permanently damaged.
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24 - Risk Assessment
Loading/Unloading Area •
Introduction
•
It is the responsibility of the competent people that plan the work and operate the machine to make a judgement about the safe use of the machine, they must take into account the specific application and conditions of use at the time. It is essential that a risk assessment of the work to be done is completed and that the operator obeys any safety precautions that the assessment identifies. If you are unsure of the suitability of the machine for a specific task, contact your JCB dealer who will be pleased to advise you. The following considerations are intended as suggestions of some of the factors to be taken into account when a risk assessment is made. Other factors may need to be considered. A good risk assessment depends on the training and experience of the operator. Do not put your life or the lives of others at risk.
Personnel •
• •
Are all persons who will take part in the operation sufficiently trained, experienced and competent? Are they fit and sufficiently rested? A sick or tired operator is a dangerous operator. Is supervision needed? Is the supervisor sufficiently trained and experienced? As well as the machine operator, are any assistants or lookouts needed?
• • • • •
The Route to be Travelled •
•
How solid is the ground, will it provide sufficient traction and braking? Soft ground will affect the stability of the machine and this must be taken into account. How steep are any slopes, up/down/across? A cross slope is particularly hazardous, is it possible to detour to avoid them?
Weather • •
The Machine • • • •
Is it level? Any slope of more than 2.5% (1 in 40) must be carefully considered. Is more than one direction of approach to the load possible? Approaching across the slope must be avoided, if possible. Is the ground solid? Will it support the weight of the machine when loaded? How rough is the ground? Are there any sharp projections which could cause damage, particularly to the tyres? Are there any obstacles or hazards in the area, for example, debris, excavations, manhole covers, power lines? Is the space sufficient for safe manoeuvring? Are any other machines or persons likely to be in or to enter the area while operations are in progress?
How windy is it? High wind will adversely affect the stability of a loaded machine, particularly if the load is bulky. Is it raining or is rain likely? The ground that was solid and smooth when dry will become uneven and slippery when wet, and it will not give the same conditions for traction, steering or braking.
Is it in good working order? Have any reported defects been corrected? Have the daily checks been carried out? Are the tyres still at the correct pressure and in good condition and is there sufficient fuel to complete the job (if applicable)?
The Load • • • •
How heavy is it? Is it within the capabilities of the machine? How bulky is it? The greater the surface area, the more affected it will be by wind speeds. Is it an awkward shape? How is the weight distributed? Uneven loads are more difficult to handle. Is there a possibility of the load shifting while being moved?
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27 - Maintenance Positions
Introduction
Introduction .................................................... 01-13 Health and Safety .......................................... 01-15
Make the machine safe before you start a maintenance procedure. You can complete most of the maintenance procedures with the lift arm lowered. Unless a maintenance procedure instructs you differently, you must lower the lift arm.
Lift Arm Lowered Figure 2.
6. If necessary, put chocks against the two sides of the wheels before you get below the machine.
1. Park the machine on level, solid ground. 2. Lower the lift arm. 3. Put the attachment flat on the ground.
Lift Arm Raised
4. Stop the engine and remove the ignition key.
If you raise the lift arm to get access for maintenance, you must install the maintenance strut on the lift arm.
5. Disconnect the battery to prevent accidental operation of the engine.
Figure 3.
Installing the Lift Arm Safety Strut
3. Release the strut. 3.1. Release the fastener.
Install the lift arm safety strut before you work underneath the raised lift arms. 1. Empty the shovel and raise the lift arms fully.
3.2. Remove the strut from the stowage bracket. 4. Install the strut.
2. Stop the engine and remove the ignition key. 01 - 13
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4.1. Push the strut over the ram piston rod. 01 - 13
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4.2. Secure the strut in position with strap.
2. Stop the engine and remove the ignition key.
5. Lower the lift arm onto the strut.
3. Remove the strut.
5.1. Start the engine and slowly lower the lift arms onto the safety strut, stop the movement immediately when the weight of the lift arms are supported by the safety strut.
3.1. Loosen the strap. 3.2. Remove the strut from the ram piston rod. 4. Stow the strut. 4.1. Secure the strut in the stowage position with the fastener. Refer to Figure 4.
Removing the Lift Arm Safety Strut 1. Fully raise the lift arms to take the weight off the safety strut. Figure 4.
D C
B A
A Fastener- unlock position C Strap
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B Fastener- lock position D Safety strut
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Health and Safety WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level ground. To prevent anyone starting the engine, remove the ignition key. Disconnect the battery (by means of the battery isolator if installed) when you are not using electrical power. If you do not take these precautions you could be killed or injured. WARNING Make the machine safe before getting beneath it. Make sure that any attachments on the machine are correctly attached. Engage the park brake, remove the ignition key, disconnect the battery.
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06 - About this Manual Contents
Page No.
01-06-03 Model and Serial Number .............................................................................................. 01-17 01-06-06 Using the Manual ........................................................................................................... 01-18
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03 - Model and Serial Number
03 - Model and Serial Number Introduction This manual provides information for the following model(s) in the JCB machine range: Model From: To: 1CX 1050000 1051999 1298000 1299999 1743000 1CXT 2416351
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06 - About this Manual 06 - Using the Manual
06 - Using the Manual Introduction Information in this manual conforms to a standard JCB service manual format. The format uses section headings taken from a PIL (Parts Identification
List). These headings are assigned numerical identification references.
Table 1. Example
Section
PIL reference Heading
33 Electrical System
Main Assembly / Heading 03 Battery
Information within each PIL reference is included under a set of standard headings such as Introduction, Health and Safety, Technical Data and Operation for example. Where additional relevant
Component / Sub-heading 03 Isolator Switch
information is contained within another PIL reference a cross reference is provided. The main systems information is contained in the manual as follows.
Table 2. System Hydraulic System Electrical System
Electronic Diagnostic
PIL Reference PIL 30-00-50 PIL 33-03-03 PIL 33-09-00 PIL 33-00-50 PIL 33-57-00
Machine Variants
•
Where information is different depending on machine variant, the applicable information sets are included within the same PIL reference. Headings are included to identify which information is for which variant. Make sure you use the correct information.
Diagnostics Information in this manual can help you diagnose machine faults. Before attempting to diagnose possible faults check the following. • • • •
Make sure that the operator understands the machine controls, functions and use. Refer to the applicable Operator Manual. Check that the maintenance record complies with the applicable schedule for the operating environment. Check that the fluids in use comply with the standards specified. Make sure that the machine electronic set-up is applicable. Use the applicable Servicemaster vehicle set-up tool.
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Heading Schematic Circuit Battery - Isolator Switch Power Distribution (including fuses and relays) Schematic Circuit Electronic Diagnostic (including Servicemaster) Use the applicable Servicemaster diagnostics tools.
Torque Tightening When you replace components, always tighten the applicable fixings to the correct torque value. Use the torque tightening values contained in the individual procedures (Remove and Install, Disassemble and Assemble etc.). If no torque values are specified, use the standard torque tightening values. For the torque setting to be effective, do the following before you install the fixings. Refer to PIL 72-00-00. • •
•
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Make sure that all the applicable component assemblies are correct. Make sure that the applicable fixings are to the correct specification. If necessary discard the original fixings and replace them with new ones. The relevant procedures indicate when this is necessary. Make sure that the applicable fixings and threaded holes are free from contamination. This includes dirt, debris, old sealants and compounds, fluids and lubricants.
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33 - Cleaning Contents
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01-33-00 General ........................................................................................................................... 01-21
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01 - Machine
33 - Cleaning 00 - General
00 - General
Introduction WARNING When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions.
Introduction .................................................... 01-21 Preparation .................................................... 01-22
CAUTION To avoid burning, wear personal protective equipment when handling hot components. To protect your eyes, wear goggles when using a brush to clean components. Notice: Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents. Notice: 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. Notice: Never use water or steam to clean inside the operator station. The use of water or steam could damage the machine electrics and render the machine inoperable. Remove dirt using a brush or damp cloth. Clean the product with water and/or steam. Do not let mud, debris etc. to collect on the product. Before you do any service procedures that require components to be removed: •
The cleaning must be done either in the area of components to be removed, or in the case of major work, or work on the fuel system, the whole engine and the surrounding product must be cleaned. When cleaning is complete, move the product away from the wash area or alternatively, remove the material washed from the product.
•
When you remove components, be aware of exposure to dirt and debris. Cover any open ports and remove the deposits before proceeding.
Detergents Do not use a full strength detergent. Always dilute the detergents as per the manufacturer's recommendations, or damage to the paint finish can occur. Always obey the local regulations regarding the disposal of debris created from cleaning the product.
Pressure Washing and Steam Cleaning CAUTION When using a steam cleaner, wear safety glasses or a face shield as well as protective clothing. Steam can cause personal injury. 01 - 21
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01 - Machine
33 - Cleaning 00 - General
Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine is to be washed using a high pressure system. Make sure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. Do not aim the water jet directly at bearings, oil seals or the engine air induction system.
Preparation 1. Make the machine safe. Stop the machine and let it cool for at least one hour. Do not try to clean any part of the machine while it is running. 2. Make sure that all of the electrical connectors are correctly coupled. 3. If the connectors are open, attach the correct caps or seal with waterproof tape.
Use a low pressure water jet and brush to remove dried mud or dirt. Use a pressure washer to remove soft dirt and oil. The product must always be greased (if appropriate) after pressure washing or steam cleaning.
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03 - Attachments, Couplings and Load Handling Contents
Page No.
Acronyms Glossary .................................................................................................................................... 03-2 03-00 Attachments 03-00-00 General ............................................................................................................................. 03-3 03-03 Direct-Mounted Attachments 03-03-00 General ............................................................................................................................. 03-7 03-09 Lift Arm Quickhitch 03-09-00 General ........................................................................................................................... 03-11 03-10 Excavator End Quickhitch 03-10-00 General ........................................................................................................................... 03-15 03-10-03 Mechanical Quickhitch ................................................................................................... 03-17 03-24 Auxiliary Circuit 03-24-00 General ........................................................................................................................... 03-21 03-24-06 Handheld Hydraulic Tool ................................................................................................ 03-24 03-27 Bucket 03-27-00 General ........................................................................................................................... 03-33 03-27-90 Teeth ............................................................................................................................... 03-37 03-30 Shovel 03-30-00 General ........................................................................................................................... 03-41 03-30-09 4-in-1 .............................................................................................................................. 03-45 03-33 Fork 03-33-00 General ........................................................................................................................... 03-49 03-33-09 Manure ........................................................................................................................... 03-51 03-33-12 Pallet .............................................................................................................................. 03-55 03-48 Rockbreaker 03-48-00 General ........................................................................................................................... 03-59
9813/6050-2 2018-05-02
Acronyms Glossary HP
High Pressure
SWL
Safe Working Load
9813/6050-2 2018-05-02
03 - Attachments, Couplings and Load Handling 00 - Attachments
00 - Attachments Contents
Page No.
03-00-00 General ............................................................................................................................. 03-3
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Notes:
03 - 2
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03 - 2
03 - Attachments, Couplings and Load Handling 00 - Attachments 00 - General
00 - General
Introduction
Introduction ...................................................... 03-3 Health and Safety ........................................... 03-4
A wide range of optional attachments are 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. Some attachments are supplied complete with instructions on safety, installing and removing, operation and maintenance. Read and fully understand the information before fitting, using and servicing the attachment. If there is anything you do not understand, ask your JCB Distributor. Before using any attachment, read Working With The Machine in the Operator Manual and consider how the attachment is going to affect operational safety. With the attachment installed, there may be changes in the machine's centre of gravity or overall dimensions. This could have an effect on, for example, machine stability, the gradients on which it is safe to operate or the safe distance from power lines. Practice using attachments off the job before working with them for the first time. 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 and any other legislative compliance may be affected by the use of non JCB approved attachments. If your machine needs the hydraulic system adapting to facilitate the use of auxiliary attachments, you must consult your distributor. Only suitably qualified personnel must reroute hydraulic hoses. All optional attachments will have limits on their operation. i.e. lifting capacity, speeds, hydraulic flow rates, etc. Always check in the literature supplied with the attachment or in the Specification section of this manual. Some specification limits may also be displayed on the attachments Data/Rating Plate. Important: Do not operate or work with attachments until the machine hydraulic oil has reached its normal working temperature.
03 - 3
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03 - Attachments, Couplings and Load Handling 00 - Attachments 00 - General
Health and Safety Attachments Use only the JCB approved attachments that are specified for your machine. Operating with nonspecified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yourself or others. The use of non-approved attachments could invalidate your warranty and cause damage to both machine and attachments. Attachments If you have an attachment which is not covered in the Operator's Manual do not install it, use it or remove it until you have obtained, read and understood the pertinent information. Install attachments only on the machines for which they were designed. WARNING! Load and unload on firm, level ground. Always be alert for possible hazards. Take special care when turning or reversing. DANGER! Before lowering the attachments to the ground, make sure that the machine and the area around it are clear of other people. Anyone on or close to the machine could fall and be crushed by the attachments, or get caught in the linkages. DANGER! Using the forks alone as a working platform is hazardous; you can fall off and be killed or injured. Never use the forks as a working platform.
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03 - Attachments, Couplings and Load Handling
03 - Direct-Mounted Attachments
03 - Direct-Mounted Attachments Contents
Page No.
03-03-00 General ............................................................................................................................. 03-7
03 - 5
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Notes:
03 - 6
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03 - Attachments, Couplings and Load Handling
03 - Direct-Mounted Attachments 00 - General
00 - General
Introduction
Introduction ...................................................... 03-7 Remove and Install ......................................... 03-8
The Rockbreaker and Earth Auger for example use an attachment frame for installation on to the machine.
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03 - Attachments, Couplings and Load Handling
03 - Direct-Mounted Attachments 00 - General
Remove and Install
Figure 6.
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.
Install 1. Keep the attachment on level ground. Refer to Figure 5. Figure 5.
C
B A
C Quickhitch lever D Locking pins
D
Remove 1. The removal procedure is the opposite of the installation procedure. A Attachment frame B Lip of the frame 2. Drive the machine squarely up to the attachment frame. 3. Lower the lift arm. 4. Tilt the quickhitch plate forwards. 5. Make sure that the top of the quickhitch plate is lower than the lip of the attachment frame. 6. Drive the machine until it touches the attachment frame. 7. Slowly tilt the plate backwards until it engages the attachment frame lip. 8. Raise the lift arm until the frame is in contact with the quickhitch plate, top and bottom. 9. Push the quickhitch levers fully inwards, to engage the locking pins and secure the attachment frame.
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03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch
09 - Lift Arm Quickhitch Contents
Page No.
03-09-00 General ........................................................................................................................... 03-11
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Notes:
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03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 00 - General
00 - General
Introduction
Introduction .................................................... 03-11 Health and Safety .......................................... 03-12 Lubricate ........................................................ 03-12
Quickhitches are used on machines to allow the rapid change of buckets, shovels and other attachments on the machine. Quickhitches do not normally have a specific function themselves in that they do not carry out handling or digging operations, but when installed on a machine they become a part of the overall machine system. They are usually mounted on the machine by means of pins that would otherwise be the mountings for the shovel or attachment.
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03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 00 - General
Health and Safety
Lubricate
WARNING Do not lean out of the cab to operate the quickhitch levers. If the controls are moved accidentally you could be killed or injured.
There are 6 grease points for the lubrication of the lift arm quickhitch. Refer to Figure 7.
WARNING Always install the quickhitch latch hook locking pin (mechanical only). Failure to install the pin will result in possible failure of the latching mechanism. Such a failure could result in the sudden release of an attachment from the machine and you or others could be killed or seriously injured.
Figure 7.
1
WARNING The attachment will move when released. Stand clear and to one side when releasing the attachment.
2
WARNING Attachments that are installed with the use of loader or excavator quickhitches must not be used to transport or lift persons if the machine is not designed and equipped to do so.
3 4
CAUTION When the quickhitch is attached to the machine, allowance must be made for the weight of the quickhitch on the rated operating load. The mass of the Quickhitch is stamped on the data plate.
6
5
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03 - Attachments, Couplings and Load Handling 10 - Excavator End Quickhitch
10 - Excavator End Quickhitch Contents
Page No.
03-10-00 General ........................................................................................................................... 03-15 03-10-03 Mechanical Quickhitch ................................................................................................... 03-17
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Notes:
03 - 14
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03 - Attachments, Couplings and Load Handling 10 - Excavator End Quickhitch 00 - General
00 - General
Introduction
Introduction .................................................... 03-15 Health and Safety .......................................... 03-16 Check (Condition) .......................................... 03-16
Quickhitches are used on machines to allow the rapid change of buckets, shovels and other attachments on the machine. Quickhitches do not normally have a specific function themselves in that they do not carry out handling or digging operations, but when installed on a machine they become a part of the overall machine system. They are usually mounted on the machine by means of pins that would otherwise be the mountings for the shovel or attachment.
03 - 15
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03 - Attachments, Couplings and Load Handling 10 - Excavator End Quickhitch 00 - General
Health and Safety
Check (Condition)
WARNING Do not lean out of the cab to operate the quickhitch levers. If the controls are moved accidentally you could be killed or injured. WARNING Always install the quickhitch latch hook locking pin (mechanical only). Failure to install the pin will result in possible failure of the latching mechanism. Such a failure could result in the sudden release of an attachment from the machine and you or others could be killed or seriously injured. WARNING The attachment will move when released. Stand clear and to one side when releasing the attachment.
1. Check the condition of the quickhitch for damaged or missing parts. 2. Remove any debris from the latch hook locking mechanism. 3. When you clean the quickhitch with HP (High Pressure) water, make sure you grease the latch hook pivot pin after cleaning. 4. Grease the latch hook pivot pin at the specified duration Duration: 7 d
WARNING Attachments that are installed with the use of loader or excavator quickhitches must not be used to transport or lift persons if the machine is not designed and equipped to do so. CAUTION When the quickhitch is attached to the machine, allowance must be made for the weight of the quickhitch on the rated operating load. The mass of the Quickhitch is stamped on the data plate.
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03 - Attachments, Couplings and Load Handling 10 - Excavator End Quickhitch 03 - Mechanical Quickhitch
03 - Mechanical Quickhitch
Introduction
Introduction .................................................... 03-17 Remove and Install ....................................... 03-18
The operation of the mechanical quickhitch is done, usually by the use of tools, at the quickhitch. The operator needs to leave the operator's station to go to the end of the work equipment in order to effect the release of the bucket or attachment, and to do the same in order to attach the next bucket or attachment to be used.
03 - 17
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03 - 17
03 - Attachments, Couplings and Load Handling 10 - Excavator End Quickhitch 03 - Mechanical Quickhitch
Remove and Install
Figure 8.
CAUTION When the quickhitch is installed and its attachment attached, It is possible to strike the cab and the underside of the boom or dipper with some attachments. Use great care with the boom and dipper to keep the attachment away from the operator cab.
K A
H
CAUTION When the quickhitch is attached to the machine, allowance must be made for the weight of the quickhitch on the rated operating load. The mass of the Quickhitch is stamped on the data plate.
E J B
C
F
Install G
1. Make the machine safe.
D
Refer to: PIL 01-03. 2. Make sure that the tipping lever locking bolt assembly is attached with the nut 1. 3. Put the quickhitch on hard and level ground. 4. Use suitable lifting equipment to move the quickhitch. 5. Position the machine so that the dipper arm and quickhitch are correctly aligned. 6. Engage the dipper.
K A B C D E F G H J K
Hole 1 Hole 2 Pivot pin 1 Nut 2 Hole 3 Hole 4 Pivot pin 2 Bolt 1 Bolt 2 Nut 3
6.1. Operate the controls to line up hole 1 in the dipper arm with the holes 2 in the quickhitch.
Remove
6.2. Insert the pivot pin 1.
1. The removal procedure is the opposite of the installation procedure.
6.3. Install the bolt 1 and nut 2. 7. Engage the tipping link. 7.1. Operate the controls to line up hole 3 in the tipping link with hole 4 in the quickhitch. 7.2. Insert the pivot pin 2. 7.3. Install the bolt 2 and nut 3.
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03 - Attachments, Couplings and Load Handling 24 - Auxiliary Circuit
24 - Auxiliary Circuit Contents
Page No.
03-24-00 General ........................................................................................................................... 03-21 03-24-06 Handheld Hydraulic Tool ................................................................................................ 03-24
03 - 19
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Notes:
03 - 20
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03 - Attachments, Couplings and Load Handling 24 - Auxiliary Circuit 00 - General
00 - General
Introduction
Introduction .................................................... 03-21 Health and Safety .......................................... 03-22 Discharge and Pressurise ............................. 03-22
The location of the auxiliary control switch can vary, depending on the machine model. If pressure is not discharged fully before you remove the coupling, pressure may remain in the attachment. This can prevent the reconnection of the attachment to the machine. Make sure the auxiliary attachments are in the closed position before you connect or disconnect the quick release couplings, failure to do so can build up residual pressure.
03 - 21
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03 - Attachments, Couplings and Load Handling 24 - Auxiliary Circuit 00 - General
Health and Safety
Discharge and Pressurise
CAUTION When using an attachment for example a hydraulic breaker, where the risk of flying debris is present, a protective layer (e.g. safety glasses or screen guard must be attached to the front of the cab) to protect the operator from flying debris which could cause injury.
For Excavator Auxiliary Circuit Discharge 1. Warm up the machine to make sure that the accumulators are charged. 2. Make sure the auxiliary attachments are in the closed position before you connect or disconnect the quick release couplings. This can build up the residual pressure. 3. Make the machine safe with lift arm lowered. Refer to: PIL 01-03. 4. Make sure that the seat is locked and faces rearwards. 5. Turn the ignition key to the ON position. 6. Press the auxiliary switch to ON position. 7. Press the selector switch to excavator position. 8. Slowly operate the auxiliary control switch three times fully in forward and then reverse direction. 8.1. Make a note that the location of the auxiliary control switch can vary, depending on the machine model. 9. Turn the ignition key to the OFF position. 10. Connect or necessary.
disconnect
the
couplings
as
10.1. If pressure is not discharged fully before you remove the coupling, pressure may remain in the attachment. This can prevent the reconnection to the machine to the attachment. 11. Make a note that when you do the discharge procedure, the movement of the attachments may be limited.
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03 - Attachments, Couplings and Load Handling 24 - Auxiliary Circuit 00 - General
Figure 9. A
11. Make a note that when you do the discharge procedure, the movement of the attachments may be limited.
AUX
Figure 10. C
B
A
C A Auxiliary switch B Selector switch - Excavator C Auxiliary control
B
AUX
For Lift Arm Auxiliary Circuit Discharge 1. Warm up the machine to make sure that the accumulators are charged.
A Auxiliary switch B Selector switch - Lift arm C Auxiliary control
2. Make sure the auxiliary attachments are in the closed position before you connect or disconnect the quick release couplings. This can build up the residual pressure. 3. Make the machine safe with lift arm lowered. Refer to: PIL 01-03. 4. Make sure that the seat is locked and faces forwards. 5. Turn the ignition key to the ON position. 6. Press the auxiliary switch to ON position. 7. Press the selector switch to lift arm position. 8. Slowly operate the auxiliary control switch three times fully in forward and then reverse direction. 8.1. Make a note that the location of the auxiliary control switch can vary, depending on the machine model. 9. Turn the ignition key to the OFF position. 10. Connect or necessary.
disconnect
the
couplings
as
10.1. If pressure is not discharged fully before you remove the coupling, pressure may remain in the attachment. This can prevent the reconnection to the machine to the attachment. 03 - 23
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03 - Attachments, Couplings and Load Handling 24 - Auxiliary Circuit
06 - Handheld Hydraulic Tool
06 - Handheld Hydraulic Tool Introduction .................................................... Operation ....................................................... Diagram ......................................................... Remove and Install .......................................
03 - 24
Introduction 03-24 03-25 03-25 03-26
The oil supply for the optional hand tool circuit is taken from the excavator valve auxiliary circuit feed lines.
9813/6050-2
03 - 24
03 - Attachments, Couplings and Load Handling 24 - Auxiliary Circuit
06 - Handheld Hydraulic Tool
Operation
Diagram Figure 11.
When the auxiliary circuit is selected by the foot pedal, oil is fed via the manual valve to the flow regulator valve. The flow regulator spool controls the flow to the hand tool circuit, it dumps excess oil back to tank via the return line of the excavator auxiliary circuit. Return oil from the hand tool circuit is fed directly back to tank. A relief Valve prevents pressure in the hand tool circuit from rising too far. The manual valve is turned off to isolate the hand tool circuit when the excavator auxiliary circuit is being used for other applications.
T 1 2 3 3a 3b 4 5
03 - 25
9813/6050-2
Tank Excavator valve block auxiliary lines Manual valve Flow regulator valve Flow regulator spool Relief valve Hand tool connection Return line from brake valve
03 - 25
03 - Attachments, Couplings and Load Handling 24 - Auxiliary Circuit
06 - Handheld Hydraulic Tool
Remove and Install Figure 14.
This procedure explains how to install the handheld hydraulic tool components on to the machine.
Install 1. Assemble the low flow regulator valve block. Figure 12.
C
A C Chassis
5. Install the pins (x4) and plain washers (x4). 6. Connect the hoses to the valve block. Refer to Figure 15. Figure 15.
A Low flow valve block 2. Install the low flow regulator valve block on the bracket 1.
335/ A2137
P
LOWFLOW REGULATOR
A
T
R
FWD
335/ A2146
B
L1 Forward pum p
10SPOOL VALVEBLOCK
T2
B 1
A1
34AP/ BA076
Figure 13.
33AP/ PP224
335/ A2148
GEARPUM P
F QR COUPLI NG RETURN
A Low flow valve block B Bracket 1 3. Install the pins (x2), washers (x4) and locknuts (x2). 4. Install the low flow valve block and bracket on the chassis.
03 - 26
M QR COUPLI G N FLO W
MAI NPUMP
7. Apply Loctite 243 to the port 1, port 2 and port 3. Refer to (PIL 75-10). 8. Tighten the hose connectors to the correct torque value.
9813/6050-2
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03 - Attachments, Couplings and Load Handling 24 - Auxiliary Circuit
06 - Handheld Hydraulic Tool
Figure 18.
Figure 16. D
J E F H
H Hose connector 4 J Hose connector 5
D Hose connector 1 E Hose connector 2 F Hose connector 3 9. Install the elbow adaptor on to the valve block.
16. Connect the hose to the return port on the regulator valve block. 16.1. Connect the opposite end to the quick release coupling on the rear frame.
10. Make sure that the elbow faces towards the front of the machine.
16.2. Mark the end of the hose to be installed to the rear frame with a letter M.
11. Apply Loctite 243 on the elbow. 12. Tighten the elbow to the correct torque value. Figure 17.
17. Apply Loctite 243 on the hose connectors. 18. Tighten the hose connectors to the correct torque value. Figure 19.
G
K G Elbow 13. Connect the hoses to the valve block.
K Return port
14. Apply Loctite 243 on the hose connectors. 15. Tighten the hose connectors to the correct torque value.
03 - 27
19. Connect the hose from the pressure port on the regulator valve block to the top of the gear pump. 20. Install the O-ring on the flange fitting.
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03 - Attachments, Couplings and Load Handling 24 - Auxiliary Circuit
06 - Handheld Hydraulic Tool
Figure 21.
Figure 20.
M L
L Pressure port hose
M Tie rods
21. Secure the hoses with tie rods.
22. Install the link lead to the ignition barrel. 23. Install the electrical harness (333/ V8288) to the regulator valve block. 24. Make sure that the electrical harness is routed around the rear frame and the switch console. 25. Remove the wire from the pin 5 of the ignition plug and replace with wire-A. 26. Install the removed wire from the pin 5 of the ignition plug into the terminal-B. 27. Install the terminal-B into the wire-100 on the hand held tool circuit connector. Figure 22. AD AC
AA
AE
AB
AF N
P
N Q AB AD
Wire-A Hand held tool circuit connector Connect standard relay Connect to battery
03 - 28
Q
P AA AC AE 9813/6050-2
Terminal-B Fuse Connect terminal in wire-100 Connect to reduced flow valve 03 - 28
03 - Attachments, Couplings and Load Handling 24 - Auxiliary Circuit
06 - Handheld Hydraulic Tool
AF Connect to hand held tool circuit on rear frame Figure 25.
28. Install the bracket 2 to the rear frame with a clamp plate. Figure 23.
T R T
T Bulkhead fittings 32. Apply Loctite 243 to the quick fit adaptors.
R Bracket 2 29. Install the clamp plate on the inside of the rear frame leg. Figure 24.
33. Install the male quick fit adaptor and female quick fit adaptor at their correct position. Refer to Figure 26. 34. Tighten the quick-fit adaptors to the correct torque value. Figure 26. U
S
V
S Clamp plate 30. Install the bulkhead fittings (x2) to the bracket 2.
U Male quick-fit adaptors V Female quick-fit adaptors
31. Install the nut and star washer on the inside.
35. Connect the hoses to the quick release couplings. 36. Apply Loctite 243 to the bulkhead fittings. 37. Connect the F-marked hose to the bottom fitting and the M-marked hose to the top fitting. 38. Tighten the hoses to the correct torque value.
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03 - Attachments, Couplings and Load Handling 24 - Auxiliary Circuit
06 - Handheld Hydraulic Tool
Remove
Figure 27.
1. The removal procedure is the opposite of the installation procedure.
W
Table 3. Torque Values Item D E F G H J K U V W X
X
W F-marked hose X M-marked hose 39. Install the electrical harness. 40. Install the cable ties.
Nm 89 135 135 89 89 135 69 81 81 69 69
41. Install the switch to the bracket 2. Make sure that the switch faces downwards. Figure 28.
Z
Y
Y Electrical harness Z Switch top 42. Install the switch top. 43. Install the switch cover. Figure 29.
AG
AG Switch cover
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03 - Attachments, Couplings and Load Handling 27 - Bucket
27 - Bucket Contents
Page No.
03-27-00 General ........................................................................................................................... 03-33 03-27-90 Teeth ............................................................................................................................... 03-37
03 - 31
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Notes:
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03 - Attachments, Couplings and Load Handling 27 - Bucket
00 - General
00 - General
Introduction
Introduction .................................................... 03-33 Health and Safety .......................................... 03-34 Remove and Install ....................................... 03-34
A bucket can be installed on many different types of excavating machines. The bucket can be directly mounted on to an excavator arm assembly or mounted to the excavator arm via a quickhitch assembly. There are a vast amount and size of buckets used for numerous applications. Excavator buckets are made of solid steel and generally have teeth protruding from the cutting edge.
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03 - Attachments, Couplings and Load Handling 27 - Bucket
00 - General
Health and Safety
Remove and Install
CAUTION Stand clear and to one side of the bucket while you remove the pivot pins. With the pins removed, the bucket could roll over. WARNING The bucket selected must be the correct width to suit the hole/trench to be excavated. However, if the hole width demands a larger bucket, consideration must be given to the density/weight of the material to be moved affecting the stability of the machine especially if working on a slope. If there is danger of the machine's stability being compromised, then select a smaller bucket or reposition the machine.
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. CAUTION Do not use your fingers through the holes to align the links. CAUTION Stand clear and to one side of the bucket while you remove the pivot pins. With the pins removed, the bucket could roll over.
For Non-Quickhitch Models Remove 1. Position the boom. 1.1. Rotate the boom. 1.2. Make sure that the boom is straight in front of the machine. 1.3. Rest the bucket on level ground. Make sure that the dipper is approximately vertical and the bucket is flat to the ground. 1.4. Block the bucket to prevent its movement. 2. Remove the lynch pin and pivot pins. 3. Disconnect the bucket. 4. Carefully lift the dipper clear of the bucket. 5. Remove the bucket. Figure 30.
B
A
A Lynch pin B Pivot pins
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03 - Attachments, Couplings and Load Handling 27 - Bucket
00 - General
Install
6. Remove the tommy bar from the quickhitch.
Make a note that two people can do this easily. One person to operate the controls and one to line up the pivots.
7. Rest the bucket on level ground.
1. Position the boom.
8. Slowly roll the quickhitch back and simultaneously raise the dipper arm to release the bucket front pivot pin. Refer to Figure 32. Figure 32.
1.1. Position the bucket flat on level ground with suitable lifting equipment. 2. Connect the dipper. 2.1. If necessary, move the machine to align the pivot pin holes. 2.2. Carefully align the holes in the dipper and bucket link with the bucket. 2.3. Install the lynch pin and pivot pins.
For Quickhitch Models Remove You must deposit the quickhitch attachments on firm level ground whenever possible. This will make installation easy and safe. 1. Make the machine safe. Refer to (PIL 01-03). 2. Position the bucket so that it is at approximately the specified distance above the ground.
Install 1. Position the bucket. 1.1. Use suitable lifting equipment to position the bucket flat on level ground.
Distance: 150 mm 3. Remove the lynch pin and locking pins. 4. Insert the tommy bar into the latch hook hole.
2. Position the machine. 2.1. Make sure that the quickhitch and bucket are correctly aligned for connection.
5. Apply a downward pressure on the bar to release the rear pivot pin from the latch hook. Refer to Figure 31.
2.2. Use the excavator controls to engage the quickhitch jaw with the pivot pin 1.
Figure 31.
2.3. Use the excavator controls to roll the quickhitch in the direction shown, until the latch hook is fully engaged with the pivot pin 2.
A C
2.4. Due to the light weight of some buckets it may be necessary to apply a load on the bucket teeth to achieve quickhitch connection.
E
2.5. Alternatively, use the tommy bar to lever the latch off. This allows the attachment pivot pin 2 to locate in the quickhitch jaw 2. D A C D E 03 - 35
3. Install the lynch pin and locking pins.
Lynch pin Locking pins Tommy bar Latch hook 9813/6050-2
03 - 35
03 - Attachments, Couplings and Load Handling 27 - Bucket
00 - General
Figure 33. F
B E D
A B C D E F
03 - 36
A
C
Quickhitch jaw Pivot pin 1 Latch hook Pivot pin 2 Locking pin Lynch pin
9813/6050-2
03 - 36
03 - Attachments, Couplings and Load Handling 27 - Bucket 90 - Teeth
90 - Teeth
Introduction
Introduction .................................................... 03-37 Remove and Install ....................................... 03-38
Excavator buckets generally have teeth protruding from the cutting edge, to disrupt hard material and avoid wear and tear of the bucket. Bucket teeth are available in a wide range of sizes and profiles.
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03 - 37
03 - Attachments, Couplings and Load Handling 27 - Bucket 90 - Teeth
Remove and Install Standard Teeth Remove 1. Make the machine safe. Refer to: PIL 01-03-27. 2. Put the bucket flat on level ground. 3. Stop the engine. 4. Remove the ignition key. 5. Discharge the hydraulic pressure. Refer to: PIL 30-00-00. 6. Remove the nut and bolt. 7. Remove the relevant tooth. Figure 34.
B A
A Tooth B Nut and bolt
Installation 1. Put the tooth in position. 2. Install the nuts and bolts to secure the tooth in position.
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03 - 38
03 - Attachments, Couplings and Load Handling 30 - Shovel
30 - Shovel Contents
Page No.
03-30-00 General ........................................................................................................................... 03-41 03-30-09 4-in-1 .............................................................................................................................. 03-45
03 - 39
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03 - 39
Notes:
03 - 40
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03 - 40
03 - Attachments, Couplings and Load Handling 30 - Shovel
00 - General
00 - General
Introduction
Introduction .................................................... 03-41 Health and Safety .......................................... 03-42 Remove and Install ....................................... 03-43
A shovel can be installed on many different types of earthmoving machines. The shovel can be directly mounted on to a lift arm assembly or mounted to the lift arm via a quickhitch assembly. There are a vast amount and size of shovels used for numerous applications. A shovel can be used to scoop up loose material from the ground, such as dirt, sand or gravel, and move it from one place to another without pushing the material across the ground. It is commonly used to move stockpiled material from ground level and deposited into a dump truck or into an open trench excavation.
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03 - 41
03 - Attachments, Couplings and Load Handling 30 - Shovel
00 - General
Health and Safety CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.
03 - 42
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03 - 42
03 - Attachments, Couplings and Load Handling 30 - Shovel
00 - General
Remove and Install Lifting Equipment
3. Remove the bolt (x2), washer (x2) from the pivot pin that attaches the shovel and lift arm.
You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations.
4. Remove the pivot pins (x4) from the shovel. Refer to: PIL 06-30-00. 5. Disconnect the shovel from the shovel lever and lift arm with suitable lifting equipment.
Remove
6. Inspect the condition of the bushes and seals at the pivot pin joints.
1. Make the machine safe with the lift arm lowered.
7. Replace worn or damaged bushes and/or seals. Use a press to remove and install the bushes and seals.
Refer to: PIL 01-03-27. 2. Remove the bolt (x2), washer (x2) from the pivot pin that attaches the shovel and the shovel link.
Figure 35.
B E
A F
D
A Shovel C Lift arm E Nut
03 - 43
C
B Shovel link D Bolt F Pivot pin
9813/6050-2
03 - 43
03 - Attachments, Couplings and Load Handling 30 - Shovel
00 - General
Install 1. The installation procedure is the opposite of the removal procedure.
03 - 44
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03 - 44
03 - Attachments, Couplings and Load Handling 30 - Shovel 09 - 4-in-1
09 - 4-in-1
Introduction
Introduction .................................................... 03-45 Operation ....................................................... 03-47 Lubricate ........................................................ 03-47
The 4-in-1 shovel allows you to load, dig, grab, grade, doze and spread without changing the attachments. It is similar to a normal shovel except that it has an opening clam. The clam is operated by hydraulic rams mounted on the bucket frame. You must practice using the 4-in-1 shovel off the job before you start working with it for the first time. You must close the clam before you move the machine. The loader control levers control the lift, lower, open and close movements of the 4-in-1 shovel. The right side control lever operates the shovel clam. Always operate the controls slowly and carefully. Drive slowly and carefully when the bucket is loaded. Keep the shovel low to the ground when moving, this increases your visibility and makes the machine more stable.
Loading and Digging With the clam closed, the shovel can be used as a conventional shovel. For higher dumping, open the clam instead of rolling the shovel. Refer to Figure 36. Figure 36.
Grabbing Open the clam and set the shovel directly above the object to be grabbed. To grab the object, lower the shovel and close the clam. Refer to Figure 37.
03 - 45
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03 - 45
03 - Attachments, Couplings and Load Handling 30 - Shovel 09 - 4-in-1
Figure 37.
discharge an even layer of material as it goes. Refer to Figure 40. Figure 40.
Grading To grade, open the clam and drag the shovel backwards. When the shovel is full, roll it back and close the clam. Refer to Figure 38. Figure 38.
Dozing To doze, open the clam and drive the machine forward. Refer to Figure 39. Figure 39.
Spreading Load the shovel with the material to be spread. Set the clam opening to suit the size of material and rate of flow. Drag the shovel backwards, allowing it to 03 - 46
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03 - Attachments, Couplings and Load Handling 30 - Shovel 09 - 4-in-1
Operation
Lubricate
On machines installed with a 4 in 1 clam shovel, the thumb switch on the loader lever operates the service.
There are 4 grease points for the lubrication of the 4-in1 shovel, two grease points on either side. Refer to Figure 42.
Make sure that the seat is locked and faces forwards.
Figure 42.
To enable the thumb switch, press the auxiliary circuit switch. The thumb switch must be isolated before travelling on the road, or when not in use, press the auxiliary switch to the OFF position. • •
1
Open Clam - To open the clam, push the switch forward. Close Clam - To close the clam, pull the switch backward. Figure 41.
B C
2
A
AUX
A Auxiliary circuit switch B Open Clam C Close Clam
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03 - Attachments, Couplings and Load Handling 33 - Fork
33 - Fork Contents
Page No.
03-33-00 General ........................................................................................................................... 03-49 03-33-09 Manure ........................................................................................................................... 03-51 03-33-12 Pallet .............................................................................................................................. 03-55
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03 - Attachments, Couplings and Load Handling 33 - Fork
00 - General
00 - General
Introduction
Introduction .................................................... 03-49 Health and Safety .......................................... 03-50
Forks can be installed on many different types of agricultural or construction machines. Forks can be directly mounted on to a lift arm or carriage or mounted to a lift arm via a quickhitch assembly. There are a vast amount and size of forks used for numerous applications. Forks can be used to lift, raise and carry heavy things and stack them where required.
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03 - Attachments, Couplings and Load Handling 33 - Fork
00 - General
Health and Safety DANGER Using the forks alone as a working platform is hazardous; you can fall off and be killed or injured. Never use the forks as a working platform. WARNING Loads can fall off incorrectly spaced forks. Always space the forks correctly for the load. Make sure the forks are completely under the load before lifting. WARNING If the fork/locking pin is not fully engaged, the fork could become unintentionally disengeged. WARNING Do not try to correct the alignment of the fork tips by bending the forks or adding shims. Never repair damaged forks by heating or welding. Forks are made of special steel using special procedures. Always replace the damaged forks. WARNING Overloaded scaffolding can collapse. Never load scaffolding beyond the regulation capacity. WARNING The forks project in front of the machine. Make sure there is enough clearance for the forks when making turns. CAUTION A load lifted on one fork can slip off. Never lift a load with one fork. CAUTION Never unload the forks by stopping the machine suddenly. Follow the procedures in the Operator Manual for unloading. CAUTION The forks are heavy. Make sure suitable lifting equipment is used to support and transport them. CAUTION Do not exceed the total rated load capacity of the forks being used. Forks can break resulting in a loss of load and possible injury. CAUTION Loads stacked on uneven ground can topple. Never stack loads on uneven ground.
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03 - Attachments, Couplings and Load Handling 33 - Fork
09 - Manure
09 - Manure Introduction .................................................... Operation ....................................................... Check (Condition) .......................................... Remove and Install .......................................
03 - 51
Introduction 03-51 03-52 03-53 03-54
The manure fork is installed with a top grab as standard which gives extra security to the pay load when you move the machine. The hydraulic ram mounted on the fork frame opens and closes the grab.
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03 - 51
03 - Attachments, Couplings and Load Handling 33 - Fork
09 - Manure
Operation Practice using the manure / silage fork off the job before working with it for the first time. The lift, lower and tilt movements of the fork are controlled by the loader control lever. The grab is operated by the right hand control lever. Refer to the operator manual for more information.
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03 - Attachments, Couplings and Load Handling 33 - Fork
09 - Manure
Check (Condition) 1. Check for damage.
2. Check for signs of hydraulic leaks.
1.1. Make sure the tines are secure and in good condition.
3. Grease the pivot points shown.
Figure 43.
1
2
3
4
5
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03 - Attachments, Couplings and Load Handling 33 - Fork
09 - Manure
Remove and Install The Manure Fork remove and install procedure is similar to the Bucket removal procedure. Refer to Standard Bucket, Remove and Install (PIL 03-27). Make sure that you disconnect all the hydraulic hoses from the manure fork before removal.
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03 - 54
03 - Attachments, Couplings and Load Handling 33 - Fork
12 - Pallet
12 - Pallet Introduction .................................................... Operation ....................................................... Adjust ............................................................ Remove and Install .......................................
03 - 55
Introduction 03-55 03-56 03-56 03-57
The pallet fork frame includes a rating plate which gives its weight and its SWL (Safe Working Load). The forks must always be used in pairs as supplied. Each fork is stamped with its part number and SWL.
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03 - 55
03 - Attachments, Couplings and Load Handling 33 - Fork
12 - Pallet
Operation
Adjust
Practice using the forks off the job before working with it for the first time.
1. Make the machine safe. Refer to (PIL 01-03).
The lift, lower and tilt movements of the fork are controlled by the loader control lever. Refer to the operator manual for more information.
2. Position the forks until they are just clear of the ground. 3. Move the spring loaded locking lever to the vertical position and slide the fork along the rail. 4. When the fork is in the required position return the spring loaded locking lever to the horizontal position. 5. Make sure that the locking pin is fully engaged in the slot in the rail. Figure 44. A
B B
A Vertical position B Horizontal position
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03 - 56
03 - Attachments, Couplings and Load Handling 33 - Fork
12 - Pallet
Remove and Install The pallet forks are attached to the machine with a quickhitch assembly. Refer to Quickhitch - Operation, (PIL 03-09).
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03 - Attachments, Couplings and Load Handling 48 - Rockbreaker
48 - Rockbreaker Contents
Page No.
03-48-00 General ........................................................................................................................... 03-59
03 - 58
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03 - 58
03 - Attachments, Couplings and Load Handling 48 - Rockbreaker 00 - General
00 - General
Introduction
Introduction .................................................... 03-59 Health and Safety .......................................... 03-60
A hydraulic rockbreaker (also called hammer, breaker, pecker, hoe ram or hoe rammer) is a powerful attachment installed to the excavator for demolishing concrete structures or rocks. It is powered by the auxiliary hydraulic system from the excavator, which is installed with a valve for this purpose.
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03 - 59
03 - Attachments, Couplings and Load Handling 48 - Rockbreaker 00 - General
Health and Safety WARNING The rockbreaker must be positioned correctly before attempting to release it from the quickhitch. if incorrectly positioned, the rockbreaker could swing or fall suddenly from the machine when releasing the quickhitch latch hook. CAUTION When using an attachment for example a hydraulic breaker, where the risk of flying debris is present, a protective layer (e.g. safety glasses or screen guard must be attached to the front of the cab) to protect the operator from flying debris which could cause injury. Notice: Every breaker has its own flow requirement. If the machine is not preset to deliver the correct flow for the breaker installed, either the breaker will not function correctly or the machine may be damaged. Whenever a breaker is installed, it is essential that the engine speed is correctly preset to suit the breaker. Have your JCB dealer reset the engine speed before using the machine with a new breaker installed. This is a specialist job and the machine can be seriously damaged if it is not done correctly. WARNING The attachment will move when released. Stand clear and to one side when releasing the attachment. WARNING Always install the quickhitch latch hook locking pin (mechanical only). Failure to install the pin will result in possible failure of the latching mechanism. Such a failure could result in the sudden release of an attachment from the machine and you or others could be killed or seriously injured.
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06 - Body and Framework Contents
Page No.
Acronyms Glossary .................................................................................................................................... 06-2 06-00 Body and Framework 06-00-00 General ............................................................................................................................. 06-3 06-06 Moveable Panel and Cover 06-06-00 General ............................................................................................................................. 06-9 06-06-03 Battery Compartment ..................................................................................................... 06-10 06-06-06 Engine Compartment ..................................................................................................... 06-11 06-12 Lift Arm 06-12-00 General ........................................................................................................................... 06-13 06-15 Excavator End 06-15-00 General ........................................................................................................................... 06-19 06-15-03 Boom .............................................................................................................................. 06-22 06-15-06 Dipper ............................................................................................................................. 06-23 06-15-09 Dipper Wear Pad Outer ................................................................................................. 06-26 06-15-10 Dipper Wear Pad Inner .................................................................................................. 06-28 06-27 Transportation Lock 06-27-00 General ........................................................................................................................... 06-31 06-30 Pivot Pins 06-30-00 General ........................................................................................................................... 06-33 06-36 Kingpost 06-36-00 General ........................................................................................................................... 06-37 06-42 Stabiliser 06-42-00 General ........................................................................................................................... 06-43 06-42-03 Leg ................................................................................................................................. 06-45 06-63 Identification Label 06-63-00 General ........................................................................................................................... 06-49 06-63-03 Machine .......................................................................................................................... 06-50 06-63-06 Engine ............................................................................................................................ 06-51 06-66 Tools 06-66-00 General ........................................................................................................................... 06-53 06-69 Maintenance Strut 06-69-00 General ........................................................................................................................... 06-57 06-75 Fire Extinguisher 06-75-00 General ........................................................................................................................... 06-59
9813/6050-2 2018-04-06
Acronyms Glossary PIN
Product Identification Number
VIN
Vehicle Identification Number
9813/6050-2 2018-04-06
06 - Body and Framework
00 - Body and Framework
00 - Body and Framework Contents
Page No.
06-00-00 General ............................................................................................................................. 06-3
06 - 1
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06 - 1
Notes:
06 - 2
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06 - 2
06 - Body and Framework
00 - Body and Framework 00 - General
00 - General Health and Safety ........................................... Repair .............................................................. Clean ............................................................... Check (Condition) ............................................
Health and Safety 06-3 06-4 06-5 06-7
Lifting Equipment You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations. Raised Equipment Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped). Make sure that no-one goes near the machine while you install or remove the mechanical device. WARNING! Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Do not start the engine with loose or open hose connections.
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06 - 3
06 - Body and Framework
00 - Body and Framework 00 - General
Repair In the event of a weld failure, it is recommended that the affected area may be inspected as per the sample defect sheet, before any attempt to rectify/ repair the weld joint on the site. Make sure that the paint is removed before you inspect the weld joint. The services of a professional/weld repair shop of a prominent electrode manufacturer are to be used for corrective repair. The welding production are currently using Advani Oerlikon CITOFIL ER70S-6 1.2 mm diameter MS (Mild Steel) copper- coated wire conforming to AWS
(American Welding Society) classification 5.18.79 with tensile strength of 700 bar ( 10,144.9 psi). For field repair of factory welding, the recommended equivalent is low hydrogen basic coated "Supercito X Plus 7018 " electrode for root-run and 3.15 mm diameter overcord electrode conforming to AWS 6013 for filling the final run/ overlays. The effects of current, arc length, and travel speed on covered electrode beads are illustrated. Refer to Figure 45.
Figure 45. J
K H
B
C
E
D
F
G
H A A C E G J
B
C
Correct current, arc length and travel speed Amperage too high Arc length too long Travel speed too fast Spatter
06 - 4
E
D B D F H K
F
G
Amperage too low Too short an arc length Travel speed too slow Base metal Undercut
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06 - 4
06 - Body and Framework
00 - Body and Framework 00 - General
Clean Pay particular attention to:
2. Around twin slew rams. Refer to Figure 46.
1. Excavator hoses passing through mainframe. Refer to Figure 46.
3. Twin ram slew recess in chassis (centremount). Refer to Figure 47.
Figure 46.
A C B
A Excavator hoses C Twin slew rams recess
B Twin slew rams
4. Kingpost slide rails (sideshift). Refer to Figure 47.
6. Recess between slew ram and kingpost casting. Refer to Figure 47.
5. Kingpost hose tray and bottom shelf (sideshift). Refer to Figure 47.
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06 - 5
06 - Body and Framework
00 - Body and Framework 00 - General
Figure 47.
A
C
B
A Kingpost slide rails C Recess between slew ram and chassis kingpost
06 - 6
B Kingpost hose tray and bottom shelf
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06 - 6
06 - Body and Framework
00 - Body and Framework 00 - General
Check (Condition) 1. Make sure that all of the guards and protective devices are in position, secured by their locking devices and free from damage. 2. Inspect all of the steelwork for damage. Include the following:
6. Check that all of the attachment teeth are undamaged and correctly attached. 7. Check that all of the safety and instructional labels are undamaged and in position. Install new labels where necessary.
2.1. Examine all of the lifting point welds.
8. Note any damaged paintwork for future repair.
2.2. Examine all of the pivot point welds.
9. Inspect the machine for broken or loose fasteners.
2.3. Examine the condition of all the pivot pins. 2.4. Check that the pivot pins are correctly in position and secured by their locking devices. 3. Check the steps and handrails are undamaged and correctly attached. 4. Check for broken, cracked or crazed window glass and mirrors. Replace the damaged items. 5. Check that the lamp lenses are undamaged.
Boom Lock Engagement Functional Test 1. Position the excavator in central protruding position. 2. Raise the boom fully. 3. Deactivate the excavator controls. 4. Visually check the boom lock is engaged.
Figure 48. A
A Boom raise
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06 - Body and Framework
06 - Moveable Panel and Cover
06 - Moveable Panel and Cover Contents
Page No.
06-06-00 General ............................................................................................................................. 06-9 06-06-03 Battery Compartment ..................................................................................................... 06-10 06-06-06 Engine Compartment ..................................................................................................... 06-11
06 - 8
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06 - 8
06 - Body and Framework
06 - Moveable Panel and Cover 00 - General
00 - General Introduction Access panels provide easy access to the machine major components test and service points and other parts which require routine testing, servicing, adjusting, replacement or repair. Before you operate the machine, make sure that all of the access panels are in their operation position and secure.
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06 - 9
06 - Body and Framework
06 - Moveable Panel and Cover 03 - Battery Compartment
03 - Battery Compartment Open and Close Open 1. Make the machine safe. Refer to (PIL 01-03). 2. Remove the screws (x3). 3. Lift the battery compartment cover. Figure 49.
B
A
A Battery compartment cover B Screws (x3)
Close 1. Position the battery compartment cover in the correct position. 2. Install the screws (x3).
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06 - Body and Framework
06 - Moveable Panel and Cover 06 - Engine Compartment
06 - Engine Compartment
Side Panels
Open and Close
Open
WARNING The engine has exposed rotating parts. Switch off the engine before working in the engine compartment. Do not use the machine with the engine cover open.
1. Make the machine safe. Refer to (PIL 01-03). 2. Stop the engine. 3. Remove the ignition key. 4. Open the engine compartment top cover.
Top Cover
5. Remove the screws.
Open 1. Make the machine safe. Refer to (PIL 01-03).
6. Lift the engine compartment side panel upwards and outwards. Figure 51.
2. Stop the engine. 3. Remove the ignition key. 4. Insert the key into the engine cover lock and turn the key clockwise to the specified angle. Angle: 90 ° 5. Open the engine cover until the latch gets engaged. Figure 50.
D C C Screws D Engine compartment side panel
B
Close
A
1. Carefully move the engine compartment side panel into the correct position. 2. Install the screws. 3. Close the engine compartment top cover.
A Engine compartment top cover B Key
Close 1. Release the latch. 2. Lower the engine cover. 3. Insert the key into the engine cover lock and turn the key anticlockwise to specified angle. Angle: 90 °
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06 - Body and Framework 12 - Lift Arm
12 - Lift Arm Contents
Page No.
06-12-00 General ........................................................................................................................... 06-13
06 - 12
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06 - 12
06 - Body and Framework 12 - Lift Arm
00 - General
00 - General Introduction .................................................... Health and Safety .......................................... Check (Condition) .......................................... Lubricate ........................................................ Remove and Install .......................................
06 - 13
Introduction 06-13 06-14 06-14 06-15 06-16
The lift arm or loader assembly is a fabricated steel construction. It usually has a front mounted shovel connected to the end of two lift arms. The lift arm assembly is permanently mounted to the machine. The shovel can be replaced with other devices or tools for example, forks to lift heavy pallets or shipping containers, and a hydraulically opening clam shovel allows the lift arm to act as a light dozer or scraper.
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06 - Body and Framework 12 - Lift Arm
00 - General
Health and Safety
Check (Condition)
Lifting Equipment
1. Make sure that the bushes and the pivot pins are within the permitted tolerances. Replace the pivot pin or bushes as necessary.
You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations. WARNING! Do not work under raised lift arms unless they are adequately supported by stands and/or slings.
2. Examine the lift arm structure for wear, damage or corrosion. Replace as necessary. 3. Examine the pivot levers for wear, damage or corrosion. Replace as necessary.
CAUTION! The lift arm pivot levers are potentially dangerous, when pivoting about their centre they form a scissor point with the lift arm. Make sure the pivot levers are securely blocked when working in the lift arm area. CAUTION! This component is heavy. It must only be removed or handled using a suitable lifting method and device.
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06 - Body and Framework 12 - Lift Arm
00 - General
Lubricate Make the machine safe. Refer to (PIL 01-03). There are a total of 22 grease points (11 grease points each side).
For each grease point shown there is another on the other side of the machine. Note: Grease point 11 is at the lift ram / chassis pivot.
Figure 52.
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06 - Body and Framework 12 - Lift Arm
00 - General
Remove and Install Consumables Description EP Hammer Grease
Part No. 4003/2107 4003/2106
Size 0.4 kg 12.5 kg
CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.
8. Put a label on the hoses to help installation. 9. Plug all the open ports and hoses to prevent contamination. 10. Remove the bolts from the lift ram eye end pivot pin. 11. Make sure that the weight of the lift arm is supported at the front end.
Remove
12. Support the lift rams.
1. Make the machine safe. Refer to (PIL 01-03).
13. Use the slide hammer kit to remove the lift ram eye end pivot pin. Refer to (PIL 06-30).
2. Remove all the attachments. Refer to (PIL 03-00). 3. Raise the lift arm so that the lift ram eye end pivot pin is clear of the machine structure. 4. Support the equipment.
lift
arm
with
suitable
lifting
5. Stop the engine. 6. Discharge the hydraulic pressure. Refer to (PIL 30-00). 7. Disconnect the auxiliary hoses and the crowd ram hoses.
14. Allow the rams to rest on the bodywork. 15. Lower the lift arm to the ground. 16. Remove the locking pins for the lift arm pivots and compensating arm pivots. 17. Use the slide hammer kit to remove the lift arm and compensating arm pivot pins. Refer to (PIL 06-30). 18. Move the lift arm clear of the machine. 19. Position the lift arm on a clean dry surface.
Figure 53.
C
B A
A Lift ram eye end pivot pin C Compensating arm pivots
06 - 16
B Lift arm pivots
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06 - Body and Framework 12 - Lift Arm
00 - General
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Apply specified grease to all pins and securing bolts. Consumable: EP Hammer Grease 3. Shims are available in two thicknesses. Install the shims, as necessary, on the left side of the lift arm pivot to eliminate end float. 4. Bleed the hydraulic system. Refer to (PIL 30-00).
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06 - Body and Framework 15 - Excavator End
15 - Excavator End Contents 06-15-00 06-15-03 06-15-06 06-15-09 06-15-10
06 - 18
Page No. General ........................................................................................................................... Boom .............................................................................................................................. Dipper ............................................................................................................................. Dipper Wear Pad Outer ................................................................................................. Dipper Wear Pad Inner ..................................................................................................
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06-19 06-22 06-23 06-26 06-28
06 - 18
06 - Body and Framework 15 - Excavator End 00 - General
00 - General
Introduction
Introduction .................................................... 06-19 Component Identification ............................... 06-20 Lubricate ........................................................ 06-21
The excavator arm is a fabricated steel construction. The excavator arm comprises a bucket, dipper and boom assembly attached to a kingpost. The excavator arm is pivoted on the kingpost to enable right and left movement. The bucket, dipper and boom are connected through pivots to enable a full range of bucket and other attachment options.
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06 - Body and Framework 15 - Excavator End 00 - General
Component Identification Figure 54.
B
C
A
D
A Boom C Tipping linkage
B Dipper D Bucket
Note: Figure shows a typical boom and dipper arrangement.
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06 - 20
06 - Body and Framework 15 - Excavator End 00 - General
Lubricate Consumables Description Special HP Grease
Part No. 4003/2020 4003/2017 4003/2006 4003/2005
Size 0.5 kg 0.4 kg 12.5 kg 50 kg
1. Make the machine safe. Refer to: PIL 01-03-27. 2. Apply grease to all the points and linkages. Total 22 grease points. Consumable: Special HP Grease
Figure 55. A B C X W
D E
V S
F
R
G
U
H
Q T T P
J
T N K
M
L
Note: Figure shows a typical boom and dipper arrangement. 06 - 21
9813/6050-2
06 - 21
06 - Body and Framework 15 - Excavator End 03 - Boom
03 - Boom
11. Move the boom clear of the machine. 12. Position the boom on a clean dry surface.
Remove and Install Consumables Description EP Hammer Grease
Part No. 4003/2107 4003/2106
Figure 57. Size 0.4 kg 12.5 kg
B
CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.
Remove 1. Make the machine safe. Refer to (PIL 01-03).
C
2. Remove the dipper from the machine. Refer to (PIL 06-15).
B Boom ram eye end pivot pin C Boom pivot pin
3. Disconnect the hydraulic hoses.
Install
4. Put a label on the hoses to help installation. 5. Plug all the open ports and hoses to prevent contamination.
1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Apply specified grease to all pins and securing bolts.
Figure 56.
Consumable: EP Hammer Grease 3. Bleed the hydraulic system. Refer to (PIL 30-00).
A
A Hydraulic hoses 6. Remove the bolt that retains the boom ram eye end pivot pin B. 7. Support the ram, use a drift to drive out the boom ram eye end pivot pin. 8. Remove the bolt from the boom pivot pin. 9. Support the boom with suitable lifting equipment. 10. Use the slide hammer kit to remove the boom pivot pin. Refer to (PIL 06-30). 06 - 22
9813/6050-2
06 - 22
06 - Body and Framework 15 - Excavator End 06 - Dipper
06 - Dipper
Lubricate
Lubricate ........................................................ 06-23 Remove and Install ....................................... 06-24
Consumables Description Waxoyl
Part No. 4004/0501A 4004/0502 4004/0505
Size 0.4 L 5L 200 L
1. Extend the dipper. 2. Coat the runners with Waxoyl. Consumable: Waxoyl Figure 58.
06 - 23
9813/6050-2
06 - 23
06 - Body and Framework 15 - Excavator End 06 - Dipper
Remove and Install Consumables Description EP Hammer Grease
Part No. 4003/2107 4003/2106
8. Remove the hose bracket from the dipper.
Size 0.4 kg 12.5 kg
9. Remove the bolt from the dipper ram eye end pivot pin. 10. Support the dipper rams.
Remove
11. Use the slide hammer kit to remove the dipper ram eye end pivot pin. Refer to (PIL 06-30).
1. Make the machine safe. Refer to (PIL 01-03).
12. Allow the rams to rest on the boom.
2. Remove all the attachments. Refer to (PIL 03-00). 3. Stop the engine.
13. Remove the locking pins (x2) from the dipper pivot pin.
4. Discharge the hydraulic pressure. Refer to (PIL 30-00).
14. Use the slide hammer kit to remove the dipper arm pivot pin. Refer to (PIL 06-30).
5. Disconnect the hydraulic hoses.
15. Move the lift arm clear of the machine.
6. Put a label on the hoses to help installation.
16. Keep the lift arm on a clean dry surface.
7. Plug all the open ports and hoses to prevent contamination. Figure 59. B
A
C
A Auxiliary hose bracket C Dipper pivot pin
06 - 24
B Dipper ram eye end pivot pin
9813/6050-2
06 - 24
06 - Body and Framework 15 - Excavator End 06 - Dipper
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Apply specified grease to all pins and securing bolts. Consumable: EP Hammer Grease 3. Bleed the hydraulic system. Refer to (PIL 30-00).
06 - 25
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06 - 25
06 - Body and Framework 15 - Excavator End
09 - Dipper Wear Pad Outer
09 - Dipper Wear Pad Outer
Introduction
Introduction .................................................... 06-26 Check (Condition) .......................................... 06-27
The dipper wear pads are installed with bolts and are replaceable items. They support and guide the inner dipper section's extension and retraction. There is a set of left side and right side wear pads, each set has top wear pads (outer) and bottom wear pads (inner). The outer wear pads are not adjustable and must be replaced with new pads once they have worn to their limit. The inner wear pads are adjustable and take up the wear on both the top and bottom pads. They must also be replaced with new pads when the outer pads are changed.
06 - 26
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06 - 26
06 - Body and Framework 15 - Excavator End
09 - Dipper Wear Pad Outer
Check (Condition) 1. Make the machine safe. Refer to (PIL 01-03). 2. Position the boom and dipper as shown. Refer to Figure 60. 3. Retract the dipper. 4. Make sure that the bucket is clear of the ground and the dipper is supported. 5. Stop the engine. 6. Remove the ignition key. 7. Check the condition of the wear pads. Figure 60.
C B
A
D
A B C D
Outer wear pads Inner wear pads Nut Dipper
7.1. Replace the wear pads, if they are worn down to the depth of the chamfer. 7.2. If the wear pads are worn near to their limit, inspect them more frequently than recommended in the maintenance schedules. Refer to (PIL 78-24). 7.3. To avoid damage to the dipper or wear pad, make sure the pads are installed the correct way around. Table 4. Torque Values Item C
06 - 27
Description Nut
Nm 50
9813/6050-2
06 - 27
06 - Body and Framework 15 - Excavator End
10 - Dipper Wear Pad Inner
10 - Dipper Wear Pad Inner Check (Condition) Consumables Description Waxoyl
Part No. 4004/0501A 4004/0502 4004/0505
3. Retract the dipper.
Size 0.4 L 5L 200 L
4. Make sure that the bucket is clear of the ground and the dipper is supported. 5. Stop the engine. 6. Remove the ignition key.
1. Make the machine safe. Refer to (PIL 01-03). 2. Position the boom and dipper as shown. Refer to Figure 61.
7. Check the condition of the wear pads.
Figure 61.
K L
A G
D
A Outer wear pads D Dipper K Locknut
B Inner wear pads G Gap ( 1.5 mm) L Adjuster
7.1. Remove any grease or dirt from the sliding faces. 7.2. Visually inspect the gap between the inner dipper and the outer wear pad. 7.3. Make sue that the gap between inner dipper and outer wear pad is less than the specified. Dimension: 1.5 mm 8. If the gap is greater than the specified limit, do as follows: 06 - 28
9813/6050-2
8.1. Remove the adjuster locknuts. 8.2. Tighten the adjusters equally on both sides to achieve the specified gap. Dimension: 1.5 mm 8.3. Apply Loctite 243 on the locknut threads. 8.4. Install the locknuts. 8.5. Tighten the locknuts to the correct torque value. 8.6. Visually inspect the gap between the inner dipper and the outer wear pad. 06 - 28
06 - Body and Framework 15 - Excavator End
10 - Dipper Wear Pad Inner
9. Make a note of the following: 9.1. You must alternate sides each time you do the adjustment. 9.2. When all the threads on the adjuster are flush with the locknut and the clearance is greater than the specified, you must replace the wear pads. 9.3. Make sure that the wear pads must be set and installed by a qualified service engineer. 10. When the adjustments are completed, apply Waxoyl to the runners of the inner dippers. Consumable: Waxoyl Table 5. Torque Values Item K
06 - 29
Description Locknut
Nm 50
9813/6050-2
06 - 29
06 - Body and Framework
27 - Transportation Lock
27 - Transportation Lock Contents
Page No.
06-27-00 General ........................................................................................................................... 06-31
06 - 30
9813/6050-2
06 - 30
06 - Body and Framework
27 - Transportation Lock 00 - General
00 - General Introduction Make sure that all machine locks are in the transport position before you transport the machine.
06 - 31
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06 - 31
06 - Body and Framework 30 - Pivot Pins
30 - Pivot Pins Contents
Page No.
06-30-00 General ........................................................................................................................... 06-33
06 - 32
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06 - 32
06 - Body and Framework 30 - Pivot Pins 00 - General
00 - General
Introduction
Introduction .................................................... 06-33 Remove and Install ....................................... 06-34
Pivot pins are a short shaft or pin that supports something that turns. Pivot pins are installed in numerous positions on the machine. There is usually a greasing point associated with the pivot pin. Make sure that the pivot points are greased at regular intervals. Refer to the Machine Maintenance Schedules. Refer to: PIL 78-24.
Slide Hammer Kit The slide hammer kit is used to remove pivot pins that must be extracted, i.e. cannot be 'knocked through'. The purpose of this description is to explain how the kit and the various components are used to remove the pivot pins. The adaptors that form part of the kit have a screwed thread at each end. One of the threads will always be M20 size, this is to accommodate the end stops. The other end of the adaptor will have varying thread sizes to suit the different size of threads in the pivot pins.
06 - 33
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06 - 33
06 - Body and Framework 30 - Pivot Pins 00 - General
Remove and Install Special Tools Description Slide Hammer Kit
Part No. 993/68100
Figure 62. Typical Machine Qty. 1
C
Make a note that the illustration shows a typical pivot pin. The actual pivot pin installed on the machine may look different. 1. Prepare the pivot pin for removal, remove the locking device e.g. pivot pin retaining bolt. 2. Prepare the slide hammer kit. Special Tool: Slide Hammer Kit (Qty.: 1) 2.1. Install the slide hammer onto the slide bar. 2.2. Determine the thread size of the pivot pin and then install the appropriate adaptor. Use the spanner flats to securely install the adaptor. 2.3. Install an end stop onto the other end of the adaptor (M20 thread size), make sure that the adaptor threads are fully engaged.
A B C D E F
Adaptor End stop End stop Spanner flats Slide bar Slide hammer
2.4. Install the slide bar into the end stop. Make sure that the threads are fully engaged. 2.5. Finally install the other end stop at the end of the slide bar. The slide hammer kit is now ready to use. 3. To extract the pivot pin, slide the hammer along the bar until it contacts the end stop. Repeat this step until the pivot pin is released. 4. To remove the slide hammer kit, reverse steps 2 to 3.
06 - 34
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06 - 34
06 - Body and Framework 36 - Kingpost
36 - Kingpost Contents
Page No.
06-36-00 General ........................................................................................................................... 06-37
06 - 35
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06 - 35
Notes:
06 - 36
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06 - 36
06 - Body and Framework 36 - Kingpost 00 - General
00 - General
Introduction
Introduction .................................................... 06-37 Check (Condition) .......................................... 06-38 Remove and Install ....................................... 06-39
The kingpost is the large kingpin that connects the boom to the chassis in an excavating machine.
06 - 37
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06 - 37
06 - Body and Framework 36 - Kingpost 00 - General
Check (Condition) 1. Examine the kingpost, pivot bushes, and the pivot pins for wear or damage. Replace the pivot pins and/or pivot bushes as necessary. 2. Examine the kingpost structure for wear, damage or corrosion. Replace as necessary.
06 - 38
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06 - 38
06 - Body and Framework 36 - Kingpost 00 - General
Remove and Install Consumables Description EP Hammer Grease JCB Gear Oil HP JCB Multi-Gasket JCB Threadlocker and Sealer (High Strength)
Part No. 4003/2107 4003/2106 4000/0505 4000/0503 4102/1212 4101/0550 4101/0552
Size 0.4 kg 12.5 kg 20 L 200 L 0.05 L 0.01 L 0.2 L
CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.
1. Make the machine safe. Refer to (PIL 01-03). 2. Remove the swing cylinder ram. Refer to (PIL 30-15). 3. Make a note that unless the kingpost is to be replaced, it is not necessary to remove the boom and dipper to release the kingpost from the machine. 4. If necessary, remove the boom. Refer to (PIL 06-15). 5. If necessary, remove the dipper. Refer to (PIL 06-15).
06 - 39
8. Plug all the open ports and hoses to prevent contamination. 9. Place a suitable container underneath the kingpost to catch the any oil. 10. Remove the capscrew 2. 11. Lift off the thrust cap with the filler tube assembly. 12. Remove the capscrews 3 from the pinion. 13. Support the equipment.
kingpost
with
suitable
lifting
14. Remove the bolt.
Remove
6. Disconnect the hydraulic hoses.
7. Put a label on the hoses to help installation.
15. Remove the pivot pin from the kingpost. 16. Lift the excavator assembly up with lifting equipment. 16.1. This will free the pinion from the carriage base. 17. Pull the excavator assembly back away from the carriage. 18. If installed, collect the shim. 19. Remove the pinion and thrust washer from the kingpost. 20. Remove the anti-roll pin. 21. Remove the rack.
9813/6050-2
06 - 39
06 - Body and Framework 36 - Kingpost 00 - General
Figure 63. G E K J
F R N
S
M
L
C
H D U
T P Q B A C E G J L N Q S U
Capscrew 1 Rack seal Capscrew 2 Filler tube assembly Bolt Shim Thrust washer O-ring Bush 2 Plungers
06 - 40
B D F H K M P R T
A Swing cylinder ram Rack Thrust cap Capscrews 3 Pivot pin Pinion Anti-roll pin Bush 1 Bush 3
9813/6050-2
06 - 40
06 - Body and Framework 36 - Kingpost 00 - General
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. If you replace the bushes, apply the specified multi-gasket before you install them. Consumable: JCB Multi-Gasket 3. Lubricate the pinion and rack with gear oil. Consumable: JCB Gear Oil HP 4. Apply the specified grease to the pivot pin. Consumable: EP Hammer Grease 5. Apply threadlocker to the threads of the capscrews 3. Consumable: JCB Threadlocker and Sealer (High Strength) 6. Tighten the capscrews to the correct torque value. 7. Fill the slew housing with the correct oil. Refer to (PIL 75-03). Table 6. Torque Values Item A E H
06 - 41
Description Capscrew 1 Capscrew 2 Capscrew 3
Nm 300 159 395
9813/6050-2
06 - 41
06 - Body and Framework 42 - Stabiliser
42 - Stabiliser Contents
Page No.
06-42-00 General ........................................................................................................................... 06-43 06-42-03 Leg ................................................................................................................................. 06-45
06 - 42
9813/6050-2
06 - 42
06 - Body and Framework 42 - Stabiliser 00 - General
00 - General
Introduction
Introduction .................................................... 06-43 Health and Safety .......................................... 06-44 Clean ............................................................. 06-44
The stabilisers are a safety device to stop the machine tipping over when the excavator arm is used. There are two stabiliser legs located behind the rear wheels. The stabiliser legs can be deployed by controls in the cab, to give the machine added stability when the machine is stationary.
06 - 43
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06 - 43
06 - Body and Framework 42 - Stabiliser 00 - General
Health and Safety
Clean
WARNING The stability of the machine can be reduced when you use the excavator without stabilisers. Before using the excavator make sure the stabilisers and the loader shovel are set on stable ground.
Make sure that Stabiliser cavities are kept clean, they can become clogged when operating in soft/ wet ground conditions. Remove and clean away all debris that may have built up.
WARNING You must be sitting in the driving seat when operating the stabiliser controls. Do not operate any machine controls from outside the machine. You or others could be injured or killed by movement of the machine or its working tools or attachments. The stabilisers must be down when you use the excavator, or the machine will rock violently. Each stabiliser has its own control lever and can be operated independently. Lower each stabiliser to level the machine and take the weight off of the rear tyres. The loader shovel should be used along with the stabilisers to level and steady the machine. WARNING Bystanders could be crushed and obstacles could be damaged if they are beneath the stabilisers while they are being lowered. Before lowering the stabilisers, make sure any bystanders are clear of the machine. Also make sure that there are no obstacles beneath the stabilisers. Notice: Before you extend the boom make sure that the stabiliser legs are deployed to the ground and the weight of the machine is supported.
06 - 44
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06 - 44
06 - Body and Framework 42 - Stabiliser 03 - Leg
03 - Leg Remove and Install Special Tools Description Slide Hammer Kit
Part No. 993/68100
7. Install the locknut and bolt.
Qty. 1
8. Place a block of wood underneath the stabiliser leg.
CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.
Remove 1. Make the machine safe with lift arm lowered. Refer to (PIL 01-03). 2. Lower the stabiliser leg until the pads are clear of the ground. Do not let it raise or support the weight of the machine.
9. Remove the circlips and drive out the top pivot pin with the spacing collars. 10. Start the engine. 11. Slowly extend the stabiliser cylinder ram. Make sure that the dump end of the ram protrudes from the top of the outer leg section. 12. Support the ram with suitable lifting equipment. Refer to Figure 64. 13. Switch off the engine.
3. Remove the stabiliser leg bottom locknut and bolt.
14. Operate the stabiliser control levers to release the stored hydraulic pressure.
4. Use the slide hammer kit to remove the bottom pivot pin and spacers. Refer to (PIL 06-30).
15. Disconnect the stabiliser hoses.
Special Tool: Slide Hammer Kit (Qty.: 1)
16. Put a label on the hoses to help installation.
5. Allow the stabiliser foot to fall clear.
17. Plug all the open ports and hoses to prevent contamination.
6. Lift the inner leg and install the pivot pin through the inner leg and ram.
18. Remove the inner leg assembly from the machine.
06 - 45
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06 - 45
06 - Body and Framework 42 - Stabiliser 03 - Leg
Figure 64.
J H
G
H
F
K
L M
B
A
D
E A C E G J L
Locknut Pivot pin Stabiliser foot Pivot pin Lifting equipment Stabiliser hose 2
06 - 46
B D F H K M
C
Bolt Spacer Circlips Collar Stabiliser hose 1 Inner leg
9813/6050-2
06 - 46
06 - Body and Framework 42 - Stabiliser 03 - Leg
Install 1. The installation procedure is the opposite of the removal procedure.
06 - 47
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06 - 47
06 - Body and Framework
63 - Identification Label
63 - Identification Label Contents
Page No.
06-63-00 General ........................................................................................................................... 06-49 06-63-03 Machine .......................................................................................................................... 06-50 06-63-06 Engine ............................................................................................................................ 06-51
06 - 48
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06 - 48
06 - Body and Framework
63 - Identification Label 00 - General
00 - General Introduction The machine has identification plates that contain important information relating to the specific machine details, for example VIN or PIN number and engine serial number. These serial numbers can help you identify exactly what equipment has been installed on the machine.
06 - 49
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06 - 49
06 - Body and Framework
63 - Identification Label 03 - Machine
03 - Machine
Item
Identification number (For example)
Introduction Your machine has an identification plate mounted. Refer to Figure 65. The serial numbers of the machine and its major units are stamped on the identification plate. The PIN (Product Identification Number) or VIN (Vehicle Identification Number) indicates the machine model and build specification. The serial number of each major unit is also stamped on the unit itself. If you replace any major unit, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered. The machine and engine serial numbers can help identify exactly the type of equipment you have. Figure 65.
6
E
7
751601
Details 6 = 2006 7 = 2007 Manufacturer location (E = England) Machine serial number
Table 8. PIN numbering system Item
Details
1
Identification number (For example) JCB
2
1CXWS
3
L
4
01299167
1CXWS = 1CX wheeled standard The check letter is used to verify the authenticity of a machine PIN Machine Each maserial num- chine has a ber (8 Dig- unique seriits) al number
A
A Machine identification label
World manufacturer identification (3 Digits) Machine type and model (5 Digits). Check letter (1 Digit)
JCB = UK Build
Table 7. VIN numbering system Item 1
Identification number (For example) SLP
2 3
1CX S
4
B
5
6
06 - 50
Details World manufacturer identification Machine model Steer type (S = Standard, H = High Flow) Build type (A = Canopy, B = Cab) Year of manufacture 2 = 2002 3 = 2003 4 = 2004 5 = 2005 9813/6050-2
06 - 50
06 - Body and Framework
63 - Identification Label 06 - Engine
06 - Engine Introduction The engine identification label is located on the crankcase at position. The engine identification includes the engine identification number. Figure 66.
A Engine identification label Table 9. PIN numbering system Item
1
Identification number (For example) RE
2
50261
3
U
4
500405
5
P
06 - 51
Details
Engine type GN = Naturally aspirated (Tier 3) GP = Turbocharged (Tier 3) HP = Naturally aspirated (Tier 2) RG = Turbocharged (Tier 2) Build num- ber Country of U = United manufacKingdom ture Engine ser- ial number Year of Each maManufacchine has a ture unique serial number 9813/6050-2
06 - 51
06 - Body and Framework 66 - Tools
66 - Tools Contents
Page No.
06-66-00 General ........................................................................................................................... 06-53
06 - 52
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06 - 52
06 - Body and Framework 66 - Tools
00 - General
00 - General
Introduction
Introduction .................................................... 06-53 Component Identification ............................... 06-54
When you carry tools onto the machine, you must keep three points of contact with the machine at all times. If necessary, lift the tools on to the machine in intervals. Put the tools down before you adjust your grips on the machine. Do not try to adjust your grips on the machine while holding tools.
06 - 53
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06 - 53
06 - Body and Framework 66 - Tools
00 - General
Component Identification Figure 67.
B A
A Engine cover (Tools inside) B Engine cover lock
06 - 54
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06 - 54
06 - Body and Framework 69 - Maintenance Strut
69 - Maintenance Strut Contents
Page No.
06-69-00 General ........................................................................................................................... 06-57
06 - 55
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06 - 55
Notes:
06 - 56
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06 - 56
06 - Body and Framework 69 - Maintenance Strut 00 - General
00 - General Introduction Before you start any service procedures on the machine, make sure that the relevant maintenance strut is installed in its correct position and secure. Refer to: PIL 01-03-27.
06 - 57
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06 - 57
06 - Body and Framework 75 - Fire Extinguisher
75 - Fire Extinguisher Contents
Page No.
06-75-00 General ........................................................................................................................... 06-59
06 - 58
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06 - 58
06 - Body and Framework 75 - Fire Extinguisher 00 - General
00 - General Introduction In addition to the operator check the extinguisher must be serviced every 12 months by a suitably qualified person. 1. Examine the fire extinguisher for damage and leaks. 2. Make sure the fire extinguisher is correctly attached. 3. Make sure that the gauge indicates that the extinguisher is charged i.e. the needle is in the green segment 3.1. If the needle is in or very near the red segment at either end of the gauge, the extinguisher must be serviced or replaced. 4. Make sure the safety pin is correctly installed. Figure 68. B
A
A Gauge B Safety Pin
06 - 59
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06 - 59
Notes:
06 - 60
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06 - 60
09 - Operator Station Contents
Page No.
Acronyms Glossary .................................................................................................................................... 09-2 09-00 Operator Station 09-00-06 Operator Protective Structure .......................................................................................... 09-3 09-09 Window 09-09-00 General ............................................................................................................................. 09-7 09-12 Operator Seat 09-12-00 General ........................................................................................................................... 09-15 09-15 Seat Belt 09-15-00 General ........................................................................................................................... 09-17 09-18 Door 09-18-00 General ........................................................................................................................... 09-21 09-18-03 Lock ................................................................................................................................ 09-24 09-18-06 Latch ............................................................................................................................... 09-25 09-27 Controls 09-27-36 Accelerator Pedal ........................................................................................................... 09-29 09-27-40 Multi-Purpose Joystick ................................................................................................... 09-32 09-33 Safety Label/Chart 09-33-00 General ........................................................................................................................... 09-35 09-78 Floor plate 09-78-00 General ........................................................................................................................... 09-39
9813/6050-2 2018-04-06
Acronyms Glossary FOPS
Falling Object Protective Structure
ROPS
Roll-Over Protective Structure
9813/6050-2 2018-04-06
09 - Operator Station
00 - Operator Station
00 - Operator Station Contents
Page No.
09-00-06 Operator Protective Structure .......................................................................................... 09-3
09 - 1
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09 - 1
Notes:
09 - 2
9813/6050-2
09 - 2
09 - Operator Station
00 - Operator Station
06 - Operator Protective Structure
06 - Operator Protective Structure Health and Safety ........................................... 09-3 Check (Condition) ............................................ 09-4
Health and Safety WARNING You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS/FOGS. If the ROPS/FOPS/ FOGS has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS/FOGS certification. WARNING When replacing or repairing the ROPS/FOPS/FOGS structure you must replace the fixings. Never re-use fixings. Use only new genuine JCB fixings tightened to the torque figures specified in the operator's manual.
09 - 3
9813/6050-2
09 - 3
09 - Operator Station
00 - Operator Station
06 - Operator Protective Structure
Check (Condition) 1. Check the structure for damage. 2. Check that all the ROPS (Roll-Over Protective Structure)/FOPS (Falling Object Protective Structure) mounting bolts are undamaged and correctly installed. 3. Make sure that the ROPS/FOPS mounting bolts are tightened to the correct torque value. Figure 69.
A
A
A A
A
A
A Mounting bolts Table 10. Torque Values Item A
09 - 4
Nm 135
9813/6050-2
09 - 4
09 - Operator Station
09 - Window
09 - Window Contents
Page No.
09-09-00 General ............................................................................................................................. 09-7
09 - 5
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09 - 5
Notes:
09 - 6
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09 - 6
09 - Operator Station
09 - Window 00 - General
00 - General
Introduction
Introduction ...................................................... 09-7 Health and Safety ........................................... 09-8 Preparation ...................................................... 09-8 Remove and Install ....................................... 09-10
The service procedures, explain how to correctly remove and install panes of glass that are directly bonded to the cab frame apertures. When you carry out any service procedure, you must always refer to the relevant safety precautions, Health and Safety. Refer to: PIL 09-09-00. 1. Always wear safety glasses during removal and replacement. 2. Use protective gloves - heavy duty leather gauntlet type gloves when cutting out the broken glass, non-slip type gloves when handling/ moving panes of glass, surgical type gloves when you use the polyurethane adhesives. 3. Wear protective overalls. 4. Do not smoke - the activators and primers used in the procedures are highly flammable. 5. Do not attempt to handle or move panes of glass unless you are using glass lifters. Several special tools are required to successfully complete the removal and replacement procedures. Reference is made to the tools in the procedures. The majority of these tools can be obtained locally and the remainder from JCB Service. The work must only be carried out in a dry, frost free environment. A protective canopy may be required or the machine/frame must be moved to a sheltered area. In damp or wet conditions, hinged doors and window frames can be removed from the machine and taken to a more suitable (dry) environment. Glass should not be replaced at temperatures below 5 °C ( 41.0 °F).
09 - 7
9813/6050-2
09 - 7
09 - Operator Station
09 - Window 00 - General
Health and Safety
Preparation
CAUTION Laminated glass must be handled with extra care to prevent breakage. Wherever possible, store and handle it in a vertical attitude. When placing or lifting the glass in a horizontal attitude it must be supported over its whole area, not just at the edges. WARNING Always wear safety glasses when removing or installing screen glass. Never use a power operated knife when removing the sealant around a toughened glass screen. The action of the knife could cause particles of glass to be thrown with sufficient force to cause serious injury, even when safety glasses are being worn. Use only hand operated tools when working with toughened glass.
Special Tools Description Glass Lifter Folding Stand Cartridge Gun Rubber Spacer Blocks Mobile Oven (12V) Static Oven (240V)
Part No. 892/00842 892/00843 892/00845 926/15500 992/12300 992/12400
Qty. 2 1 1 4 1 1
Consumables Description Black Primer/Activator Polyurethane Adhesive Surface Cleaning Fluid
Part No. 4104/2304 4103/2110 4103/1204
Size 0.1 L 0.31 L 1L
Operator Station Aperture 1. If damp or wet, dry the aperture area using a hot air gun (sourced locally). 2. Use surface cleaning fluid to thoroughly clean and prime the trimmed sealant. Use a lint free cloth to apply the cleaner, allow to dry. Duration: 5 min Consumable: Surface Cleaning Fluid Note: Do not use any other type of cleaning fluids, otherwise they may be absorbed into the old sealant and ultimately prevent the new glass from bonding.
New Glass 1. Make sure that the new glass correctly fits the frame aperture. 1.1. Put two spacer blocks on to the bottom part of the frame aperture. Special Tool: Rubber Spacer Blocks (Qty.: 2) 1.2. Install the new glass on the spacer blocks - Always use glass lifters. Check that there is an equal sized gap all round the edge of the glass. Note: The spacer blocks are rectangular in section to give two common gap widths. If necessary they can be trimmed to a smaller size to give an equal sized gap around the glass. Important: The glass edges must not touch the frame, otherwise movement of the frame will chip and eventually break the newly installed glass. Special Tool: Glass Lifter (Qty.: 2)
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09 - Operator Station
09 - Window 00 - General
Figure 70.
Figure 72.
4. Clean the glass. 4.1. Use surface cleaner to thoroughly clean and prime the black ceramic ink band printed on the glass (see Note). Use a lint free cloth to apply the cleaner, allow to dry. Important: Do not touch the glass after cleaning with the surface cleaner.
A Frame aperture B Spacer blocks C Glass lifters 2. After checking for size, remove the new glass and place it on a purpose made glass stand. Small panes of glass will need locating on a 600 x 700 mm x 15 to 19 mm thick plywood board, sourced locally to fit the glass stand. It is recommended that an access hole is cut in the board to accommodate the glass lifter, making it easier and safer to handle small panes of glass. The board should be covered with felt or carpet to give an anti-scratch surface. Resting the glass on four spacer blocks will ensure clearance of the cartridge nozzle tip during application of the polyurethane sealant.
Duration: 5 min Consumable: Surface Cleaning Fluid 4.2. If the glass does not have a black ceramic ink band, paint a band on the glass using Black Primer. Make sure that the band measures the correct width and that the edge is a neat straight line. Dimension: 25 mm Consumable: Black Primer/Activator Figure 73.
Special Tool: Rubber Spacer Blocks (Qty.: 4) Special Tool: Folding Stand (Qty.: 1) Figure 71.
5. Install the Ultra Fast Adhesive cartridge into a suitable applicator gun: Special Tool: Static Oven (240V) (Qty.: 1) Special Tool: Mobile Oven (12V) (Qty.: 1) Special Tool: Cartridge Gun (Qty.: 1) Consumable: Polyurethane Adhesive 3. Make sure the glass is positioned on the stand the correct way up (i.e. with the black ceramic ink band upwards) ready for application of primer etc.
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5.1. Remove the aluminium disc cover from the base of the cartridge and discard the dessicant capsule. 5.2. Make sure that the rolled edge of the cartridge is not damaged - if necessary, the edges should be pressed flat, otherwise it 09 - 9
09 - Operator Station
09 - Window 00 - General
will be difficult to remove the cartridge from the applicator gun. 5.3. Pierce the front nozzle end of the cartridge to its maximum diameter. 5.4. Install the pre-cut nozzle. 5.5. Install the cartridge in the applicator gun. Note: Cold material will be very difficult to extrude. The cartridges must be pre-heated in a special oven for 1 hour to a temperature of 80°C (176°F). Pre-heating the cartridges makes the adhesive more workable and also brings the curing time down to 30 minutes. Figure 74.
Remove and Install Special Tools Description Glass Lifter Glass Extractor (Handles Only) Nylon Spatula Wire Starter Braided Cutting Wire Rubber Spacer Blocks Cut-Out Knife 'L' Blades Consumables Description Black Polyurethane Sealant Black Primer/Activator Glass Replacement Kit Hand Cleaner JCB Glass Cleaner Surface Cleaning Fluid
A
B A 12.5 mm B 9 mm 6. Apply the pre-heated adhesive to the glass (do not start in a corner). Keep the nozzle guide against the edge of the glass and make sure that the adhesive forms a continuous pyramid' shape. Note: Once the pre-heated adhesive has been applied to the glass, install the glass in the aperture as soon as possible. If you wait too long then the sealant will form a skin, this will prevent the glass from bonding. Duration: 10 min
Part No. 892/00842 892/00846
Qty. 2 1
892/00847 892/00848 892/00849 926/15500 992/12800 992/12801
1 1 1 2 1 1
Part No. 4102/2310
Size 0.31 L
4104/2304 993/55701 4104/1310 4006/3175 4103/1204
0.1 L 0.75 L 1L
Removal 1. Position the machine on level ground and apply the park brake. Stop the engine. Put protective covers over the cab seat and control pedestals. 2. If a laminated pane breaks it will stay in one piece even though the glass is cracked. A toughened pane will shatter and fall apart. The method of removal of the glass depends upon which type it is. 2.1. Laminated glass - leave installed until the old sealant has been cut away, after which it will be possible to lift the broken screen away from its frame housing in one piece.
Figure 75.
2.2. Toughened glass - remove as much of the shattered glass as possible prior to cutting out the old sealant. 3. Cut out the old sealant, leaving approximately 1 to 2 mm on the cab frame. There are several tools and techniques for doing this: A Nozzle guide 7. After applying the adhesive, leave a small amount of sealant protruding from the nozzle. This will prevent any adhesive left in the cartridge from curing.
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3.1. Pneumatic Knife - This provides one of the easiest methods of removing the sealant around laminated glass. The tool, powered by compressed air, should be sourced locally. Press the handle to start the knife blade oscillating. Important: This tool must not be used on toughened glass. Insert the knife blade into the sealant. Slowly move the knife along the sealant with the blade positioned as close to the glass as possible. 09 - 10
09 - Operator Station
09 - Window 00 - General
Figure 77.
Do not allow the knife blade to overheat or the sealant will melt. Figure 76.
3.2. Braided Cutting Wire and Handles - This method uses a 3-core wire, a wire starter tube and two handles. Insert the steel tube into the old sealant on the inside of the glass. Insert the braided cutting wire down the centre of the steel tube. If necessary, from the outside, cut out local sealant at the point of the tube to gain access to the wire. Using suitable pliers, pull the cutting wire through the sealant to the outer side of the glass. Secure the end of the braided cutting wire (found on the outer side of the glass) in the special handle. Slowly remove the steel tube. Secure the second end of the braided cutting wire in the special handle. Move the cutting wire backwards and forwards in a sawing motion and at the same time gently push or pull the wire to cut through the old sealant. Special Tool: Wire Starter (Qty.: 1) Special Tool: Glass Extractor (Handles Only) (Qty.: 1) Special Tool: Braided Cutting Wire (Qty.: 1)
A B C D
Wire starter Braided cutting wire Glass extractor (handles) Glass extractor (handles)
3.3. Cut-out Knife - The cut-out knife can be used as a left handed or right handed tool. Insert the knife blade into the sealant. Make sure that the blade of the knife is against the glass. Use the 'pull-handle' to pull the knife along and cut out the old sealant. Special Tool: 'L' Blades (Qty.: 1) Special Tool: Cut-Out Knife (Qty.: 1) Figure 78.
A Glass 3.4. Craft Knife - The blades are replaceable. Insert the knife blade into the sealant. Pull the knife along and cut out the old sealant.
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09 - Window 00 - General
Figure 79.
glass. Make sure the two spacer blocks are in position. Refer to Preparation - New Glass 2. Install the glass in the frame aperture: 2.1. Always use the glass lifting tools when moving the glass. Use a lifting strap to hold large panes of glass in position. Special Tool: Glass Lifter (Qty.: 2) Figure 81. Typical Machine
A Blades 3.5. Glass Replacement Kit - This kit is designed for removal of one pane of glass. The kit comprises: Cartridge Polyurethane Adhesive (310ml), Primer/Activator (10ml), Surface Cleaner Wipe, Abrasive Pad, Applicator Nozzle, Wool Dauber, Cutting Wire, Rubber Blocks. Consumable: Glass Replacement Kit 4. Laminated glass - lift out the broken pane using glass lifters. Toughened glass - remove the cut off sealant and all remaining particles of shattered glass.
2.2. Sit the bottom edge of the glass on the spacer blocks. Special Tool: Rubber Spacer Blocks (Qty.: 2)
5. If necessary, trim off the remaining old sealant to leave approximately 1 to 2 mm on the upright face of the cab frame aperture.
Figure 82.
Figure 80.
A
A 1.5 mm 6. Apply a coat of Black Primer to the paintwork if: Consumable: Black Primer/Activator 6.1. Paintwork was damaged or scratched during the glass/sealant removal procedures.
2.3. Make sure that the glass is correctly positioned, then gently press around the edges of the glass and ensure full adhesive contact is achieved. Do not press too hard or too much adhesive will squeeze out.
6.2. The old sealant was inadvertently cut back to the cab frame during the glass/sealant removal procedures.
3. Make the inside seal smooth:
Installing new Glass 1. If the internal trim strip is damaged, renew it (cut to length as required) before installing the new 09 - 12
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3.1. Wearing surgical gloves, dip your finger in a soapy water solution. 09 - 12
09 - Operator Station
09 - Window 00 - General
3.2. Use your finger to make the inside seal smooth. 4. All exposed edges must be sealed using Black Polyurethane Sealant. Important: Use extreme caution when wiping the inside of the new glass - pushing too hard on the inside of the glass will affect the integrity of the bonded seal. Special Tool: Nylon Spatula (Qty.: 1) Consumable: Black Polyurethane Sealant 5. Clean the glass after installation: 5.1. Small amounts of sealant can be cleaned from the glass using the surface cleaner. Consumable: Surface Cleaning Fluid 5.2. Large amounts of excess sealant should be left to cure and then cut off with a sharp knife. Note: On completion of the glass replacement procedures, the sealant curing time is 30 minutes. This means that the machine can be driven and used after 30 minutes, but it must not be used during the curing period of 30 minutes. 5.3. Clean the glass using a purpose made glass cleaner. Consumable: Hand Cleaner Consumable: JCB Glass Cleaner 6. On completion of the glass procedures tidy the work area:
installation
6.1. Remove all broken glass from the cab area. 6.2. Remove the protective covers from the cab seat and control pedestals. 6.3. Renew all safety and instructional labels so that the new installation conforms with the original cab installation.
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09 - Operator Station
12 - Operator Seat
12 - Operator Seat Contents
Page No.
09-12-00 General ........................................................................................................................... 09-15
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09 - Operator Station
12 - Operator Seat 00 - General
00 - General Check (Condition) 1. Check that the seat adjustments operate correctly. 2. Check the seat is undamaged. 3. Check the seat mounting bolts are undamaged, correctly installed and tight. 4. Make sure the seat is clear from unwanted materials and hazards at all times.
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09 - Operator Station 15 - Seat Belt
15 - Seat Belt Contents
Page No.
09-15-00 General ........................................................................................................................... 09-17
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09 - Operator Station 15 - Seat Belt
00 - General
00 - General
Health and Safety
Health and Safety .......................................... 09-17 Check (Condition) .......................................... 09-18
WARNING When a seat belt is installed on your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. WARNING Operating the machine without a seat belt can be dangerous. Before starting the engine, make sure your seat belt is fastened. Check the tightness and condition of the seat belt securing bolts regularly.
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09 - Operator Station 15 - Seat Belt
00 - General
Check (Condition) WARNING When a seat belt is installed on your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. WARNING If the seat belt does not 'lock' when you check if the seat belt is operating correctly, do not drive the machine. Get the seat belt repaired or replaced immediately. 1. Make sure the seat belt can be adjusted. 2. Examine the seat belt for signs of fraying and stretching. 3. Check that the stitching is not loose or damaged. 4. Check that the belt mounting bolts undamaged, correctly installed and tight.
are
5. Check that the buckle assembly is undamaged and operates correctly.
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09 - Operator Station
18 - Door
18 - Door Contents
Page No.
09-18-00 General ........................................................................................................................... 09-21 09-18-03 Lock ................................................................................................................................ 09-24 09-18-06 Latch ............................................................................................................................... 09-25
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Notes:
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09 - Operator Station
18 - Door
00 - General
00 - General Remove and Install Consumables Description Special HP Grease
Part No. 4003/2020 4003/2017 4003/2006 4003/2005
Size 0.5 kg 0.4 kg 12.5 kg 50 kg
2. Remove the hinge pin from the upper and lower hinge. 3. Lift the door off its hinges and move to a safe place. 4. If worn, replace the bushes. 5. If necessary, replace the hinge pins.
Remove 1. Make the machine safe with the lift arm lowered. Refer to (PIL 01-03).
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09 - Operator Station
18 - Door
00 - General
Figure 83.
A D
C
B
G J H
E F
A C E G J
Hinge pins Bushes Latch cover Door handle - inner Gasket
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B D F H
Door Hinge brackets Door latch Door handle - outer
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09 - Operator Station
18 - Door
00 - General
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Apply a thin layer of grease to the hinge pins. Consumable: Special HP Grease
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09 - Operator Station
18 - Door 03 - Lock
03 - Lock Remove and Install For the Door Lock, Remove and Install procedure, refer to Door Latch, Remove and Install, refer to (PIL 09-22).
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09 - Operator Station
18 - Door 06 - Latch
06 - Latch Remove and Install Remove
3. Remove the door latch and inside door handle.
1. Make the machine safe with lift arm lowered. Refer to (PIL 01-03).
4. Remove the outside door handle.
2. Remove the inside door latch cover.
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5. Remove the door handle gasket from the door.
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09 - Operator Station
18 - Door 06 - Latch
Figure 84.
A D
C
B
G J H
E F
A C E G J
Hinge pins Bushes Latch cover Inside door handle Gasket
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B D F H
Door Hinge brackets Door latch Outside door handle
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09 - Operator Station
18 - Door 06 - Latch
Install 1. The installation procedure is the opposite of the removal procedure.
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09 - Operator Station 27 - Controls
27 - Controls Contents
Page No.
09-27-36 Accelerator Pedal ........................................................................................................... 09-29 09-27-40 Multi-Purpose Joystick ................................................................................................... 09-32
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09 - Operator Station 27 - Controls
36 - Accelerator Pedal
36 - Accelerator Pedal Remove and Install Removal 1. Make the machine safe with lift arm lowered. Refer to (PIL 01-03). 2. Loosen the adjustment nut 1 from the foot throttle cable. 3. Make sure that the foot throttle cable moves freely. 4. Use a pair of pliers to push the clevis pin 1 off the foot throttle cable. 5. Remove the foot throttle cable from the accelerator pedal.
6. Carefully remove the return spring from the accelerator pedal. 7. Loosen the adjustment nut 2 from the hand throttle cable. 8. Remove the hand throttle cable out of the accelerator pedal. 9. Use a pair of pliers to push the clevis pin 2 off the hand throttle cable. 10. Remove the nuts, washers and bolts. 11. Remove the accelerator pedal out of the machine. 12. Remove the accelerator pedal from the bracket.
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09 - Operator Station 27 - Controls
36 - Accelerator Pedal
Figure 85.
L H,J,K
D
C
K A
M
B G E
A C E G J L
Adjustment nut 1 Clevis pin 1 Adjustment nut 2 Clevis pin 2 Washers Bracket
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B D F H K M
F
Foot throttle cable Return spring Hand throttle cable Nuts Bolts Accelerator pedal
9813/6050-2
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09 - Operator Station 27 - Controls
36 - Accelerator Pedal
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Operate the foot throttle controls and the hand throttle controls to make sure that they function correctly.
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09 - Operator Station 27 - Controls
40 - Multi-Purpose Joystick
40 - Multi-Purpose Joystick Introduction Refer to Hydraulic System, Flow Control Valve, Joystick (PIL 30-60-15).
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09 - Operator Station
33 - Safety Label/Chart
33 - Safety Label/Chart Contents
Page No.
09-33-00 General ........................................................................................................................... 09-35
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Notes:
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09 - Operator Station
33 - Safety Label/Chart 00 - General
00 - General
Introduction
Introduction .................................................... 09-35 Health and Safety .......................................... 09-36
The safety labels are strategically placed around the product to remind you of possible hazards. If you need eye-glasses for reading, make sure you wear them when reading the safety labels. Do not over-stretch or put yourself in dangerous positions to read the safety labels. If you do not understand the hazard shown on the safety label, then refer to Safety Label Identification. Keep all of the safety labels clean and readable. Replace a lost or damaged safety label. Make sure the replacement parts include the safety labels where necessary. Each safety label has a part number printed on it, use this number to order a new safety label from your JCB dealer.
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09 - Operator Station
33 - Safety Label/Chart 00 - General
Health and Safety WARNING Safety labels on the machine warn you of particular hazards. You can be injured if you do not obey the safety instructions shown.
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09 - Operator Station
78 - Floor plate
78 - Floor plate Contents
Page No.
09-78-00 General ........................................................................................................................... 09-39
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Notes:
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09 - Operator Station
78 - Floor plate 00 - General
00 - General Remove and Install Remove 1. Remove the bolts from the floor mat. 2. Carefully remove the floor mat from the left side of the operator station. 2.1. Make a note that the floor mat is split at the right side to make removal easier. 3. Remove the bolts from the floorplate. 4. Remove the floorplate from the machine.
Install 1. The installation procedure is the opposite of the removal procedure.
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Notes:
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12 - Heating, Ventilating and Air-Conditioning (HVAC) Contents
Page No.
Acronyms Glossary .................................................................................................................................... 12-2 12-00 Heating, Ventilating and Air-Conditioning (HVAC) 12-00-00 General ............................................................................................................................. 12-3 12-03 HVAC Unit 12-03-00 General ............................................................................................................................. 12-7 12-18 Filter 12-18-06 Fresh Air ........................................................................................................................ 12-11 12-18-09 Recirculation ................................................................................................................... 12-12
9813/6050-2 2017-07-27
Acronyms Glossary HVAC
Heating Ventilation Air Conditioning
9813/6050-2 2017-07-27
12 - Heating, Ventilating and Air-Conditioning (HVAC)
00 - Heating, Ventilating and Air-Conditioning (HVAC)
00 - Heating, Ventilating and Air-Conditioning (HVAC) Contents
Page No.
12-00-00 General ............................................................................................................................. 12-3
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Notes:
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12 - Heating, Ventilating and Air-Conditioning (HVAC)
00 - Heating, Ventilating and Air-Conditioning (HVAC) 00 - General
00 - General
Introduction
Introduction ...................................................... 12-3 Health and Safety ........................................... 12-4 Check (Leaks) ................................................. 12-5
To maintain optimum operator comfort in warm climates or during seasons of high ambient temperature, the air conditioning system delivers cool, dehumidified air into the cab. Cooling is provided by passing the warm ambient air, together with recirculated air, over an evaporator matrix in the air conditioning unit. The air conditioning system is a closed circuit through which the refrigerant is circulated, its state changing from gas to liquid and back to gas again, as it is forced through the system. The major components of the system are the: • • • • •
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Compressor Condenser matrix Receiver drier Expansion valve Evaporator matrix
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12 - Heating, Ventilating and Air-Conditioning (HVAC)
00 - Heating, Ventilating and Air-Conditioning (HVAC) 00 - General
Health and Safety
• •
Air Conditioning Maintenance The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person. You can be severely frostbitten or injured by escaping refrigerant.
•
Air Conditioning Refrigerant Do not operate the air conditioning system when there is no refrigerant in the system, otherwise the compressor will be damaged. Welding Do not carry out welding operations close to the air conditioning refrigerant circuit. A poisonous gas is produced when refrigerant comes into contact with naked flames. Do not smoke or allow naked flames close to the refrigerant circuit. CAUTION! Polyalkylene Glycol (PAG) type oil is an irritant. It can cause skin irritation. Breathing PAG vapour can cause irritation of the eyes, nose and lungs. Prolonged inhalation can cause drowsiness.
•
• •
DO NOT steam clean refrigerant system components. When charging or discharging the refrigerant system, no smoking or naked flames should be allowed in the immediate vicinity. The refrigerant does not give off a poisonous odour, however, when it comes into contact with a naked flame, a poisonous gas is produced. When handling refrigerant, rubber gloves and goggles should be worn. Operators should ensure no refrigerant comes into contact with the skin. Particular care should be taken when connecting or disconnecting charging hoses or pressure switches. When these components are connected to the system, a short release of refrigerant occurs. This results in a high velocity, very cold gas being emitted from the connection point. Use caution when working near exposed evaporator fins. Painful cuts can be inflicted by the edges of the fins. Also, damage to the fins will reduce the efficiency of the system. Make sure pressure cylinders are not over filled, particularly when recovering refrigerant. Disconnect battery before doing any work.
WARNING! Polyalkylene Glycol (PAG) type oil vapour is extremely flammable. Do not smoke or eat near PAG contaminated material. Exercise caution when working around hot and moving engine parts. CAUTION! When working on the HVAC System gloves, eye protection and protective clothing must be worn. Refrigerant may be released which can be harmful to your skin or eyes.
Safety Procedures The air conditioning system includes a pressurised closed circuit containing a non-CFC, environmentally friendly refrigerant, Type R-134a. Any service procedure which breaks into the closed circuit and therefore requires discharging of the system, must only be carried out by service personnel with specialist knowledge of air conditioning systems. The following guidelines should be adhered to by all personnel servicing the air conditioning system: •
• •
It is critical that the correct refrigerant (R-134a) is used and that charging is done only by qualified personnel. It is illegal to discharge the refrigerant into the atmosphere but as a precaution in case of accidental leakage, discharging and charging of the vehicle refrigerant system must be conducted in a wellventilated area. Containers of refrigerant should be stored in a cool environment away from direct sunlight. DO NOT perform welding operations close to refrigerant hoses (maintain a distance of at least 0.5m from hoses).
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12 - Heating, Ventilating and Air-Conditioning (HVAC)
00 - Heating, Ventilating and Air-Conditioning (HVAC) 00 - General
Check (Leaks) The refrigerant is heavier than air and will leak downwards from the defective component. Check in still conditions but in a well ventilated area. Hose or pipe connections are likely leakage points of any refrigerant circuit. It is essential that an electronic leak detector is used to locate leaks accurately. However, if a leak detector is not available, an approximate source can be found by applying a soap solution to the suspect area. To test for leaks in the high pressure side of the system i.e. from the compressor output to the expansion valve, run the air conditioning for a few minutes then switch off the engine and test for leakage using an electronic leak detector or soapy water. To test for leakage in the low pressure side of the system, switch off the air conditioning and leave for a few minutes before testing.
Leaking Hoses The refrigerant hoses have crimped ferrule end fittings. The hose connectors have an O-ring seal which compresses when the connection is tight, creating an air tight seal. Hoses are used to connect the inlets and outlets of the compressor, condenser, receiver drier and expansion valve (the evaporator coil is connected to the expansion valve within the air conditioning unit using rigid pipes). If leakage is detected from a hose connector, either by means of an electronic leak detector or soapy water, tighten the connector up and repeat the leakage test. If leakage is still evident, it will be necessary to discharge the system and renew the connector O-ring seal. Refer to: PIL 12-00-00.
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12 - Heating, Ventilating and Air-Conditioning (HVAC) 03 - HVAC Unit
03 - HVAC Unit Contents
Page No.
12-03-00 General ............................................................................................................................. 12-7
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12 - Heating, Ventilating and Air-Conditioning (HVAC) 03 - HVAC Unit 00 - General
00 - General Remove and Install Remove
6. Drain the HVAC system. Refer to (PIL 12-00).
1. Make the machine safe. Refer to (PIL 01-03).
7. Remove the cable ties as necessary.
2. Discharge the HVAC (Heating Ventilation Air Conditioning) system. Refer to (PIL 12-00).
8. Remove all the pipes.
3. Disconnect the battery. Refer to (PIL 33-03). 4. Remove the bolts (x4) and washers (x4) from the HVAC cover. 5. Remove the HVAC cover.
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9. Disconnect the electrical connectors. 10. Remove the screws from inside the operator station. 11. Remove the HVAC unit from the machine.
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12 - Heating, Ventilating and Air-Conditioning (HVAC) 03 - HVAC Unit 00 - General
Figure 86.
E D D F
A,B C
D
A Bolts (x4) C HVAC cover E Pipes
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B Washers (x4) D HVAC unit F Screws
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12 - Heating, Ventilating and Air-Conditioning (HVAC) 03 - HVAC Unit 00 - General
Install 1. The installation procedure is the opposite of the removal procedure. 2. Recharge the HVAC system. Refer to (PIL 12-00).
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12 - Heating, Ventilating and Air-Conditioning (HVAC) 18 - Filter
18 - Filter Contents
Page No.
12-18-06 Fresh Air ........................................................................................................................ 12-11 12-18-09 Recirculation ................................................................................................................... 12-12
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12 - Heating, Ventilating and Air-Conditioning (HVAC) 18 - Filter
06 - Fresh Air
06 - Fresh Air Clean 1. Make the machine safe. Refer to (PIL 01-03). 2. Open the battery access cover. Refer to (PIL 06-06). 3. Remove the air filter. Refer to Figure 87. Figure 87.
A A Air filter 4. Shake the air filter to remove the loose dust. 5. Clean the air filter with a low pressure jet of compressed air. 6. Install the air filter. 7. Close the battery access cover. Refer to (PIL 06-06).
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12 - Heating, Ventilating and Air-Conditioning (HVAC) 18 - Filter
09 - Recirculation
09 - Recirculation Clean 1. Make the machine safe. Refer to (PIL 01-03). 2. Remove the re-circulation filter. Figure 88.
B
B Re-circulation filter 3. Shake the re-circulation filter to remove the loose dust. 4. Clean the re-circulation filter with a low pressure jet of compressed air. 5. Install the re-circulation filter.
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Acronyms Glossary .................................................................................................................................... 15-3 15-00 Engine 15-00-00 General ............................................................................................................................. 15-3 15-03 Crankcase 15-03-00 General ........................................................................................................................... 15-25 15-06 Cylinder Head 15-06-00 General ........................................................................................................................... 15-29 15-12 Crankshaft 15-12-00 General ........................................................................................................................... 15-35 15-12-03 Main Bearing .................................................................................................................. 15-39 15-12-06 Front Oil Seal ................................................................................................................. 15-43 15-12-09 Rear Oil Seal ................................................................................................................. 15-44 15-12-12 Pulley .............................................................................................................................. 15-45 15-12-24 Wear Sleeve ................................................................................................................... 15-46 15-15 Camshaft 15-15-00 General ........................................................................................................................... 15-49 15-18 Engine Belt 15-18-00 General ........................................................................................................................... 15-59 15-18-03 Drive Belt ....................................................................................................................... 15-61 15-21 Oil Filter 15-21-00 General ........................................................................................................................... 15-67 15-24 Air Filter 15-24-00 General ........................................................................................................................... 15-73 15-24-09 Dust Valve ...................................................................................................................... 15-77 15-30 Valve 15-30-00 General ........................................................................................................................... 15-79 15-30-12 Valve Spring ................................................................................................................... 15-89 15-30-15 Valve Guide .................................................................................................................... 15-90 15-30-24 Stem Seal ...................................................................................................................... 15-91 15-33 Connecting Rod 15-33-00 General ........................................................................................................................... 15-93 15-33-06 Big-End Bearing ............................................................................................................. 15-97 15-36 Piston 15-36-00 General ......................................................................................................................... 15-103 15-36-03 Piston Ring ................................................................................................................... 15-115 15-39 Manifold 15-39-00 General ......................................................................................................................... 15-119 15-42 Rocker and Fittings 15-42-00 General ......................................................................................................................... 15-121 15-42-01 Rocker Arm .................................................................................................................. 15-129 15-42-03 Rocker Shaft ................................................................................................................ 15-130 15-42-06 Rocker Cover ............................................................................................................... 15-131 15-42-09 Push Rod ..................................................................................................................... 15-133 9813/6050-2 2018-07-02
15-42-21 Tappet ........................................................................................................................... 15-45 Oil Sump 15-45-00 General ......................................................................................................................... 15-51 Timing Gear 15-51-00 General ......................................................................................................................... 15-51-21 Front Case ................................................................................................................... 15-54 Flywheel 15-54-00 General ......................................................................................................................... 15-54-03 Housing ........................................................................................................................ 15-60 Oil Pump 15-60-00 General ......................................................................................................................... 15-60-06 Pressure Relief Valve ................................................................................................... 15-69 Oil Cooler 15-69-00 General ......................................................................................................................... 15-72 Alternator 15-72-00 General ......................................................................................................................... 15-75 Starter Motor 15-75-00 General ......................................................................................................................... 15-80 Glow Plug 15-80-00 General ......................................................................................................................... 15-84 Sensor 15-84-33 Coolant Temperature .................................................................................................... 15-86 Solenoid 15-86-00 General ......................................................................................................................... 15-86-03 Engine Shut-off Solenoid (ESOS) ................................................................................ 15-87 Switch 15-87-00 General ......................................................................................................................... 15-87-03 Engine Oil Pressure ..................................................................................................... 15-87-18 Air Filter Vacuum .......................................................................................................... 15-90 Air Intake 15-90-00 General ......................................................................................................................... 15-96 Pipe 15-96-00 General .........................................................................................................................
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15-135 15-139 15-143 15-146 15-153 15-158 15-163 15-171 15-175 15-179 15-187 15-195 15-201 15-205 15-206 15-211 15-212 15-215 15-219 15-221
Acronyms Glossary BDC
Bottom Dead Centre
CAN
Controller Area Network
DC
Direct Current
DTI
Dial Test Indicator
ECM
Engine Control Module
ECU
Electronic Control Unit
ESOS
Engine Shut-Off Solenoid
FEAD
Front End Accessory Drive
RPM
Revolutions Per Minute
TDC
Top Dead Centre
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Notes:
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15-00-00 General ............................................................................................................................. 15-3
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Introduction
Introduction ...................................................... 15-3 Health and Safety ........................................... 15-4 Technical Data ................................................. 15-5 Component Identification ................................. 15-6 Operation ......................................................... 15-8 Fault-Finding .................................................. 15-12 Drain and Fill ................................................. 15-15 Clean ............................................................. 15-16 Check (Leaks) ............................................... 15-17 Check (Pressure) .......................................... 15-18 Remove and Install ....................................... 15-19 Store and Recommission .............................. 15-20
This section contains information about the complete engine assembly. For specific engine technical information refer to the technical data section. Make sure that the correct engine service tools, consumables and torque figures are used when you perform service procedures. Replacement of oil seals, gaskets, etc., and any component that show signs of wear or damage, is expected as a matter of course. It is expected that components will be cleaned and lubricated where required, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid, engine oil and ingress of dirt.
Basic Description The Perkins 400 series engines are indirect injection engines. The engines are controlled with a mechanically actuated fuel injection pump. The engine cylinders are arranged in-line. The cylinder head assembly has one inlet valve and one exhaust valve for each cylinder. Each cylinder valve has a single valve spring. The crankshaft for the engine has main bearing journals. End play is controlled by the thrust washers that are located on the rear main bearing. The timing gears are stamped with timing marks in order to ensure the correct assembly of the gears. When the No. 1 piston is at top centre compression stroke, the teeth that are stamped on the crankshaft gear and the camshaft gear will be in alignment with the idler gear. The crankshaft gear turns the idler gear which then turns the camshaft gear and the gear for the engine oil pump. The fuel injection pump is mounted in the crankcase. The fuel injection pump is operated by lobes on the camshaft. The fuel transfer pump is located on the right hand side of the crankcase. The fuel transfer pump is also operated by lobes on the camshaft. The fuel injection pump conforms to requirements for emissions. If any adjustments to the fuel injection pump timing and high idle are required you must refer to a Perkins distributor or a Perkins dealer. Some fuel injection pumps have mechanical governors that control the engine rpm. Some fuel injection pumps have a governor that is electrically controlled. A gerotor oil pump is located in the centre of the idler gear. The engine oil pump sends lubricating oil to the 15 - 3
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main oil gallery through a pressure relief valve and an engine oil filter. The rocker arms receive pressurized oil through an externally located oil line that runs from the main oil gallery to the cylinder head. Coolant from the bottom of the radiator passes through the belt driven centrifugal cooling pump. The coolant is cooled by the radiator and the temperature is regulated by a water temperature regulator. Engine efficiency, efficiency of emission controls, and engine performance depend on adherence to correct operation and maintenance recommendations. Engine performance and efficiency also depend on the use of recommended fuels, lubrication oils, and coolants. Refer to: PIL 78-24.
Health and Safety Hot Components Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit. Turning the Engine Do not try to turn the engine by pulling the fan or fan belt. This could cause injury or premature component failure. Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine is to be washed using a high pressure system. Make sure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. Do not aim the water jet directly at bearings, oil seals or the engine air induction system. WARNING! To bleed the injectors you must turn the engine. When the engine is turning, there are parts rotating in the engine compartment. Before starting this job make sure that you have no loose clothing (cuffs, ties etc) which could get caught in rotating parts. When the engine is turning, keep clear of rotating parts. Notice: Clean the engine before you start engine maintenance. Obey the correct procedures. Contamination of the fuel system will cause damage and possible failure of the engine. Notice: Do not exceed the maximum level of engine oil in the sump. If the maximum is exceeded, the excess must be drained to the correct level. An excess of engine oil could cause the engine speed to increase rapidly without control. WARNING! The engine has exposed rotating parts. Switch off the engine before working in the engine compartment. Do not use the machine with the engine cover open. WARNING! Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer. Notice: A drive belt that is loose can cause damage to itself and/or other engine parts. WARNING! Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. CAUTION! It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in
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accordance with local regulations. Use authorised waste disposal sites.
Technical Data Table 11. Description Engine type
Data GN 404D-22
Emission compliance Number of cylinders Nominal bore size Stroke Cylinder arrangement Combustion Cycle Firing order Compression ratio Swept volume Valve clearance (cold) Idling speed
Tier 3
Data HP 404C-22, Naturally aspirated Tier 3
4
4
88 mm
84 mm
102 mm Vertical In-line
100 mm Vertical In-line
4-stroke
4-stroke
1-3-4-2 23.3:1
1-3-4-2 23.3:1
2.216 L 0.2 mm
2.216 L 0.2 mm
1400 RPM (Revolutions Per Minute) 2800 RPM
1075 RPM
34 kW at 2600 RPM -
38 kW at 3000 RPM 3.5 –4.5 bar ( 50.7 –65.2 psi) 0.29 bar ( 4.2 psi)
Maximum noload speed Power output
Lubricating oil pressure relief valve Lubricating oil pressure switch located on top cover Lubricating oil pressure switch located on cylinder block oil rail
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2800 RPM
0.98 bar ( 14.2 psi)
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Component Identification External The following identifies the main components of a typical engine assembly visible from the exterior. Some variants may differ in detail. Figure 89. Front and right side view
B
C
A
M
D L E K
F J H G
A C E G J L
Fuel shutoff solenoid Water pump Throttle lever Engine oil level gauge Engine oil filter Transfer pump
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B D F H K M
Number one fuel injector Lower engine oil filler cap Cover plate for the accessory drive Engine oil cooler Fuel injection pump Fuel filter
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Figure 90. Front and left side view Q
P
N
R S T U
V
AD
W X
AC AB
Y Z AA
N Q S U W Y AA AC
Top engine oil filler cap Rear Lifting eye Valve mechanism cover Water temperature regulator housing Electric starting motor Engine oil pan Fan drive belt Coolant temperature switch
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P R T V X Z AB AD
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Crankcase breather Air inlet elbow Turbocharger Starting motor solenoid Alternator Engine oil drain plug Crankshaft pulley Cooling fan
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Operation The Four Cylinder Cycle
Firing Order
This section describes the cycle sequence for the 4 cylinder engine.
A cylinder is said to be firing, when the fuel/air mixture ignites and the piston is about to start its power stroke.
With the crankshaft positioned as shown, the pistons in numbers 1 and 4 cylinders are at top dead centre and pistons in numbers 2 and 3 cylinders are at bottom dead centre. It is important to note that number 1 cylinder is firing and about to start its Power stroke. Rotating the crankshaft a further full rotation would position the pistons as described but the engine would be at a different stage in its four stroke cycle, with number 1 cylinder about to start its Induction stroke.
From the stages described, it can be seen that number 1 cylinder will be next to fire. Number 3 cylinder is starting its compression stroke and is next in the cycle, followed by cylinders 4 and 2. The firing order is therefore; 1, 3, 4, 2. The stages in the four stroke cycle for each cylinder are as follows:
Table 12. The Four Stroke Cycle Cylinder number 1 2 3 4
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Piston operation The piston is at the top of its Compression stroke and is about to start its Power stroke. The piston is at the bottom of its Power stroke and is about to start its Exhaust stroke. The piston is at the bottom of its Induction stroke and is about to start its Compression stroke. The piston is at the top of its Exhaust stroke and is about to start its Induction stroke.
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Valve operation Inlet and exhaust valves closed Inlet valves closed, exhaust valves about to open Exhaust valves closed, inlet valves about to close. Valve Operation Exhaust valves about to close, inlet valves about to open
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CYL1
Figure 91. Typical Four Cylinder Engine CYL2
1
CYL3
CYL4
2
5
A C
B
C G
B
C
B
H
C
B
J
K 4
3
F
745620 745620
G
H
J
K
C
A C
CYL1 CYL3 A C 1 3 5
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B
A B
A
B
C
A
C
B
Cylinder number 1 Cylinder number 3 Camshaft Camshaft lobe - Exhaust valve operation Exhaust valves Crankshaft Camshaft drive gear
CYL2 CYL4 B F 2 4
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Cylinder number 2 Cylinder number 4 Camshaft lobe - Inlet valve operation Front of engine Inlet valves Crankshaft gear
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Four Stroke Cycle Induction
The temperature rises to a point at which the fuel/air mixture ignites. A cylinder is said to be firing when the fuel/air mixture ignites.
As the piston travels down the cylinder, it draws filtered air at atmospheric pressure and ambient temperature through an air filter and inlet valves into the cylinder.
This combustion causes a very rapid rise in both temperature and pressure. The high pressure generated propels the piston downwards turning the crankshaft and producing energy.
Compression
Exhaust
When the piston reaches the bottom of its stroke, the inlet valves close. The piston then starts to rise up the cylinder compressing the air trapped in the cylinder. This causes the temperature and pressure of the air to rise. Fuel is injected into the cylinder when the piston is near to TDC (Top Dead Centre).
Once the piston has reached the bottom of its travel, the exhaust valves open and momentum stored in the flywheel forces the piston up the cylinder expelling the exhaust gases.
Power
In a running engine, these four phases are continuously repeated. Each stroke is half a revolution of the crankshaft, thus, in one cycle of a four stroke engine, the crankshaft revolves twice.
The piston continues to rise after the start of fuel injection, causing a further increase in pressure and temperature. Figure 92.
3
2
B
C
4
1
746030
1 3 A C TDC
Induction stroke Power stroke Camshaft Camshaft lobe - Exhaust valve operation TDC
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2 4 B BDC
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Compression stroke Exhaust stroke Camshaft lobe - Inlet valve operation Bottom dead centre
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Figure 93.
717620
1
2
3
4
B
C
A
C
A
B
A
B
A
C
B
C
1 3 A C
Induction stroke Power stroke Camshaft Camshaft lobe - Exhaust valve operation
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2 Compression stroke 4 Exhaust stroke B Camshaft lobe - Inlet valve operation
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Fault-Finding Fault Warning YELLOW light turn on The engine does not start Engine starts but stops RPM (Revolutions Per Minute) instability at idle speed Low idle speed Blue smoke Excessive fuel consumption Inadequate performance Slow acceleration Engine jerking Engine overheats Table 13. Warning YELLOW light turn on Cause ECM (Engine Control Module)has detected malfunctions Table 14. The engine does not start Cause Sulphated/corroded battery terminals Battery voltage too low Low fuel level Frozen fuel Clogged fuel filter Air suction in fuel system Clogged air filter Clogged pipes Open fuse Intake or exhaust system clogged Table 15. Engine starts but stops Cause Inefficient electrical connections Sulphated battery terminals Clogged fuel filter Clogged fuel pipes
Table 13. Table 14. Table 15. Table 16. Table 17. Table 18. Table 19. Table 20. Table 21. Table 22. Table 23.
Contact JCB Service
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Remedy
Remedy Clean the battery terminals Recharge or replace the battery Refuel Contact JCB Service Replace the filter Contact JCB Service Replace the filter Contact JCB Service Replace with a new fuse, if the problem persists, contact JCB Service Contact JCB Service Remedy Clean the electrical contacts, if the problem persists, contact JCB Service Clean the battery terminals Replace the filter and clean the tank Contact JCB Service
Table 16. RPM (Revolutions Per Minute) instability at idle speed Cause Remedy Clogged fuel pipes Contact JCB Service Table 17. Low idle speed Cause Clogged fuel pipes Poor quality fuel
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Remedy Contact JCB Service Clean the tank and refuel with quality fuel
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Table 18. Blue smoke High oil sump level
Cause
Clogged air filter Table 19. Excessive fuel consumption Cause Clogged air filter High oil sump level Table 20. Inadequate performance Cause Clogged air filter Clogged fuel pipes Poor quality fuel High oil sump level Clogged fuel filter Air or water in the fuel supply circuit The tank cap vent hole is clogged Piston rings worn or sticking Worn cylinder Crankshaft/Connecting rod bearings worn out Damaged cylinder head gasket Defective timing system Damaged injector Damaged high-pressure fuel injection pump Wrong injector IMA codes Table 21. Slow acceleration Cause Clogged fuel filter Table 22. Engine jerking Cause Clogged fuel pipes Table 23. Engine overheats Cause Piston rings worn or sticking Worn cylinder Damaged cylinder head gasket Defective timing system
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Remedy Replace the engine oil, if the problem persists, contact JCB Service Replace the filter Remedy Replace the filter Replace the engine oil, if the problem persists, contact JCB Service Remedy Replace the filter Contact JCB Service Clean the tank and refuel with quality fuel Replace the engine oil, if the problem persists, contact JCB Service Replace the filter and clean the tank Drain the fuel system and clean the tank, If the problem persists, contact JCB Service Clean the cap Replace the piston rings, If the problem persists, contact JCB Service Contact JCB Service Replace the bearings, If the problem persists, contact JCB Service Replace the gasket, If the problem persists, contact JCB Service Correct the timing system, If the problem persists, contact JCB Service Replace the injector Replace the fuel injection pump Contact JCB Service
Replace the fuel filter
Contact JCB Service
Remedy
Remedy
Remedy Replace the piston rings, If the problem persists, contact JCB Service Contact JCB Service Replace the gasket, If the problem persists, contact JCB Service Correct the timing system, If the problem persists, contact JCB Service 9813/6050-2
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Damaged injector
Cause
Insufficient coolant level High oil sump level Clogged radiator Defective thermostatic valve Defective or worn coolant pump
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Remedy Replace the injector, If the problem persists, contact JCB Service Fill up to the level Replace the engine oil, if the problem persists, contact JCB Service Clean the radiator, if the problem persists, contact JCB Service Replace the thermostatic valve Replace the coolant pump
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Drain and Fill
Figure 94.
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.
C
WARNING! Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer.
D
CAUTION! Keep your face away from the drain hole when removing the drain plug. CAUTION! The oil filter canister will contain some oil which could spill out when you remove the canister. CAUTION! Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug.
Drain Engine oil replacement must be completed in accordance with the service schedules. Failure to replace the oil replacement at the recommended interval could cause serious engine failure.
E
B A
A B C D E
Drain plug O-ring Filter mounting face Seal Filter canister
Fill 1. Clean and install the drain plug with a new O-ring. 2. Tighten the plug to the correct torque value.
Drain the oil when the engine is warm as contaminants held in suspension will then be drained with the oil.
3. Through one of the filler points, fill the engine with the recommended oil to the MAX mark on the dipstick. The oil must be added slowly.
1. Make the machine safe.
4. Wipe off any spilt oil. 5. Apply a thin layer of oil around the seal on the filter canister.
Refer to: PIL 01-03-27. 2. Get access to the engine. 3. Place a container of suitable size beneath the drain plug. 4. Remove the filter cap. 5. Remove the oil filler canister. If necessary use a chain or strap wrench. 6. Remove the oil dipstick. 7. Put a suitable container beneath the drain plug. 8. Remove the oil sump drain plug and O-ring from both sides of the oil sump. 9. Drain the engine oil.
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6. Install the filler canister. Tighten the filter canister with hand then an additional one quarter turn. 7. Install the filter cap. 8. Operate the engine, until the oil pressure low warning light has extinguished. 9. Check for oil leakage. 10. When the oil has cooled, check the oil level again, and if necessary top up with clean engine oil. Table 24. Torque Values Item A
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Description Drain plug
Nm 35
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Clean Notice: Clean the engine before you start engine maintenance. Obey the correct procedures. Contamination of the fuel system will cause damage and possible failure of the engine. Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine is to be washed using a high pressure system. Make sure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. Do not aim the water jet directly at bearings, oil seals or the engine air induction system.
9. When the pressure washing is complete, move the machine away from the wash area, or alternatively, clean away the material washed from the machine. 10. Before working on specific areas of the engine, use a compressed air jet to dry off any moisture. When the area is dry, use a soft clean brush to remove any sand or grit particles that remain. 11. When removing components, be aware of any dirt or debris that may be exposed. Cover any open ports and clean away the deposits before proceeding. Additional cleaning must be carried out prior to working on the high pressure fuel system. Refer to Fuel System, General, Clean.
Before carrying out any service procedures that require components to be removed, the engine must be properly cleaned. Cleaning must be carried out either in the area of components to be removed or, in the case of major work, or work on the fuel system, the whole engine and surrounding machine must be cleaned. Stop the engine and allow it to cool for at least one hour. DO NOT attempt to clean any part of the engine while it is running. 1. Make sure that the electrical system is isolated. 2. Make sure that all electrical connectors are correctly connected. If connectors are open install the correct caps or seal with water proof tape. 3. Cover the alternator with a plastic bag to prevent water ingress. 4. Seal the engine air intake, exhaust and breather system. 5. Make sure that the oil filler caps and dipstick are correctly installed. 6. Use a low pressure water jet and brush to soak off mud or dirt. 7. Apply an approved cleaning and degreasing agent with a brush. Obey the manufacturers instructions. 8. Use a pressure washer to remove the soft dirt and oil. Important: DO NOT aim the water jet directly at oil seals or electrical and electronic components such as the engine electronic control unit (ECU), alternator or fuel injectors. DO NOT place the jet nozzle closer than the specified distance to any part of the engine. Distance: 600 mm 15 - 16
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Check (Leaks)
Refer to: PIL 18-00-00.
The walk-around inspections should be performed before starting the machine. It can help to prevent machine damage and ensure your safety. A walkaround inspection should only take a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided. Inspect the engine for leaks and for loose connections:
9. Inspect the piping for the air intake system and the elbows for cracks and for loose clamps. Refer to: PIL 15-24-00. 10. Make sure that the hoses and the tubes are not contacting other hoses, tubes, wiring harnesses, etc. 11. Inspect the engine drive belt for cracks, breaks or other damage. Refer to: PIL 15-18-03.
1. Do a thorough inspection of the engine compartment before starting the engine.
11.1. For applications that require multiple drive belts, replace the belts in matched sets. Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched. The additional load on the new belt could cause the new belt to break.
2. Look for the following items and do the repair as necessary. 2.1. Oil leaks. 2.2. Coolant leaks. 2.3. Loose bolts.
12. Drain the water and the sediment from the fuel tank on a daily basis in order to make sure that only clean fuel enters the fuel system.
2.4. Worn belts. 2.5. Loose connections. 2.6. Build up of dirt. 3. Make sure that the guards are in the correct place. Repair the damaged guards or replace the missing guards, if any. 4. Wipe all the caps and the plugs before the engine is serviced to reduce the chances of system contamination. 4.1. If any leaks are found, clean up the fluid. 4.2. Find the source and correct the leak. 4.3. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted. 4.4. Make a note that accumulated grease and/ or oil on an engine is a fire hazard. Remove the accumulated grease and oil.
13. Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires. Refer to: PIL 33-12-00. 14. Inspect the ground/earth strap for a good connection and for good condition. 15. Disconnect any battery chargers that are not protected against the current drain of the starter motor. Check the condition and the electrolyte level of the batteries, unless the engine is equipped with a maintenance free battery. Refer to: PIL 33-03-00. 16. Check the condition of the gauges. Replace any gauges that are cracked. Replace any gauge that cannot be calibrated.
5. Make sure that the cooling system hoses are correctly clamped and the cooling system hoses are tight. Check for leaks. Check the condition of all pipes. Refer to: PIL 21-00-00. 6. Inspect the cooling pump for coolant leaks. Refer to: PIL 21-09-00. 7. Inspect the lubrication system for leaks at the front oil seal, the rear oil seal, the oil sump, the oil filters and the rocker cover. 8. Inspect the fuel system for leaks. Look for loose fuel line clamps and/or tie-wraps. 15 - 17
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Check (Pressure) Special Tools Description Pressure Gauge (0-40 Bar) Digital Hydraulic Pressure Test Kit
Oil Pressure Test Part No. 892/00278
Qty. 1
998/11051
1
Important: You must use a suitable pressure gauge that measures the oil pressure in the engine. An oil pressure gauge that has a defect can indicate low oil pressure. 1. Make sure that the engine is filled to the correct oil level.
Compression test Important: Compression tests should only be used to compare pressures between cylinders of an engine. If one or more cylinders vary more than 3.5 bar ( 50.7 psi) then those cylinders may be damaged. The cylinder compression test should not be the only test for determining the condition of an engine.
2. Connect the pressure gauge to a pressure test point location for engine oil. Special Tool: Digital Hydraulic Pressure Test Kit (Qty.: 1) Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) 3. Start the engine. Allow the engine to obtain normal operating temperature.
The following conditions can affect the result of the cylinder compression test, make sure you check the following points before starting the test:
4. Keep the oil temperature constant with the engine at the rated RPM. Read the pressure gauge.
• • • • •
5. Check the engine oil pressure is correct. Refer to Table 26.
The battery is in good condition. The battery is fully charged. The starter motor operates correctly. The valve lash adjustment is set correctly. The compression gauge is accurate.
Table 26.
1. Remove the fuel injector from the cylinder to measure the compression for that cylinder. 2. Connect a suitable compression gauge to the cylinder. 3. Disconnect Solenoid).
the
ESOS
(Engine
Oil Pressure Oil pressure at high idle 1.96 –4.41 bar ( 28.4 – 63.9 psi) Oil pressure at low idle 0.49 bar ( 7.1 psi) (1)
Shut-Off
(1) The 011 temperature must be 80 –110 °C ( 175.9 –229.8 °F)
4. Operate the starter motor and record the pressure on the compression gauge. 5. Repeat step 1 to step 4 for each cylinder. 6. Repair the engine if the compression is lower than the repair limit. Refer to Table 25. Important: Make sure that you measure the compression on all of the cylinders. If all of the cylinders are not checked an improper diagnosis may result. The compression pressure will vary with the change in engine RPM (Revolutions Per Minute). It is necessary to keep the engine RPM constant for all cylinders when you are taking a compression reading. Table 25. Compression (1) pressure
Standard at Repair limit assembly 29.4 bar ( 426.1 24.5 bar ( 355.1 psi) psi)
(1) The compression pressure is taken at 250 RPM. 15 - 18
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15 - 18
15 - Engine
00 - Engine 00 - General
Remove and Install The lifting equipment used must be an approved type and capable of lifting the engine safely. The recommended lifting equipment is shown. Use a spreader bar when lifting the engine. Never attempt to manually lift heavy components on your own. Always use lifting equipment, or obtain the help of an assistant. Inspect the lifting brackets for signs of damage. The brackets must be correctly torqued to the crankcase. Make sure the lifting equipment does not damage any of the engine dressing and the rocker cover. There will be some component differences depending on the machine variant. Before attempting to remove the engine ensure that all the necessary components have either been removed, or safely disconnected from the engine.
9. Disconnect the fuel supply line at the fuel lift pump and the spill line at the fuel injection pump. Cap all hoses and ports to prevent ingress of dirt. 10. Disconnect the electrical harness at the engine harness. 11. Ensure that all relevant harnesses and hoses are unclipped from the engine and tied out of the way. 12. Disconnect and plug the hoses at the hydraulic pump. 13. Disconnect the wiring to the hydraulic pump. 14. Attach slings to the engine lifting eyes. Figure 95.
Before Removal 1. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 2. Make the machine safe. A
Refer to: PIL 01-03.
B
3. Discharge the hydraulic pressure. Refer to: PIL 30-00-00.
C
4. Get access to the engine.
Remove 1. Disconnect the battery. Refer to: PIL 33-03-00. 2. Drain the engine oil.
A Engine B Sling C Lifting eye
Refer to: PIL 15-21. 3. Drain the engine coolant and remove the cooling pack. Refer to: PIL 21-00-00. 4. Disconnect the exhaust system. 5. Label the cab heater hoses at the engine crankcase. Release the hose clips and remove the hoses. 6. Disconnect the wiring connections from the starter motor. 7. Disconnect the wiring connections from the alternator. 8. Disconnect the wiring connections from the engine sensors and actuators. 15 - 19
15. Take the weight of the engine on the hoist and remove the engine mounting bolts. 16. Withdraw the engine in a level attitude until it is clear of the chassis. Raise the engine to lift it clear of the machine. 17. Lower the engine into a suitable stand that is capable of supporting the weight of the engine.
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps.
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15 - Engine
00 - Engine 00 - General
2. Fill the cooling system with the correct mix of coolant fluid. Refer to: PIL 21-00-00. 3. Fill and check the hydraulic fluid level. 4. Fill and check the engine oil level. Refer to: PIL 15-21. 5. On completion, check hydraulic and cooling system for leakage and levels. 6. Check the function of all drive and hydraulic services. Table 27. Torque Values Item C
Nm 25
Store and Recommission Consumables Description Cleaner/Degreaser - General purpose solvent based parts cleaner
Part No. 4104/1557
Size 0.4 L
If the engine is not started for several weeks, the lubricating oil will drain from the cylinder walls and from the piston rings. This forms the rust on the cylinder walls. The rust on the cylinder walls will cause increased engine wear and a reduction in engine service life. If an engine is out of operation and if use of the engine is not planned, special precautions should be made. If the engine is stored for more than one month, a complete protection procedure is recommended. When you protect the engine in accordance with the following procedure, it makes sure that no corrosion will occur. 1. Before you store the engine make sure that: 1.1. The environment is not humid or exposed to bad weather. 1.2. The storage place is not near an electric panel. 1.3. Prevent storing the engine in direct contact with the ground.
Lubrication System 1. Drain the fuel system completely and refill the system with preservative fuel. 1.1. The "1772204 POWERPART Lay-Up 1" can be mixed with the normal fuel in order to change the fuel into preservative fuel. 1.2. If preservative fuel is not available, the fuel system can be filled with normal fuel. This fuel must be discarded at the end of the storage period together with the fuel filter elements. 2. Operate the engine until the engine reaches the normal operating temperature. 3. Stop any leaks from fuel, lubricating oil or air systems. 4. Stop the engine and drain the lubricating oil from the oil sump. 5. Replace the lubricating oil filter.
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15 - Engine
00 - Engine 00 - General
6. Fill the oil sump to the Full Mark on the engine oil level gauge with new, clean lubricating oil. 6.1. Add "1762811 POWERPART Lay-Up 2" to the oil in order to protect the engine against corrosion. 6.2. If "1762811 POWERPART Lay-Up 2" is not available, use a preservative of the correct specification instead of the lubricating oil. 6.3. If a preservative is used, this must be drained completely at the end of the storage period and the oil sump must be refilled to the correct level with normal lubricating oil.
11. Fill the cooling system with an approved antifreeze mixture because this gives protection against corrosion. Certain corrosion inhibitors could cause damage to some engine components. Contact your JCB dealer for details. 12. Operate the engine for a short period to circulate the coolant in the engine. 13. Disconnect the battery. Refer to: PIL 33-03-00. 14. Apply the "1734115 POWERPART Lay-Up 3" to protect the battery terminal from corrosion.
Cooling System
15. Put the battery into safe storage in a fully charged condition.
1. Make the machine safe.
16. If installed, clean the crankcase breather and seal the end of the pipe.
Refer to: PIL 01-03-27. 2. Remove the filler cap of the cooling system. 3. Remove the drain plug from the side of the crankcase. Figure 96.
17. Remove the fuel injectors and spray "1762811 POWERPART Lay-Up 2" for specified duration into each cylinder bore with the piston at BDC (Bottom Dead Centre). 18. Slowly rotate the crankshaft for one complete revolution and then install the fuel injectors.
Induction System 1. Remove the air filter assembly. 2. If necessary, remove the fuel pipes that are installed between the air filter assembly and the turbocharger. 3. Spray "1762811 POWERPART Lay-Up 2" into the turbocharger. The duration of the spray is printed on the container.
A
4. Seal the turbocharger with waterproof tape.
Exhaust System 1. Remove the exhaust pipe.
4. Make sure that the drain hole is not restricted.
2. Spray "1762811 POWERPART Lay-Up 2" into the turbocharger. The duration of the spray is printed on the container.
5. Drain the engine.
3. Seal the turbocharger with waterproof tape.
6. Open the tap or remove the drain plug at the bottom of the radiator. If the radiator does not have a tap or a drain plug, disconnect the hose at the bottom of the radiator.
General Items
7. Drain the radiator.
2. If the lubricating oil filler cap is not installed on the valve mechanism cover, remove the valve mechanism cover.
A Drain plug
8. Flush the cooling system with clean water. 9. Fit the drain plugs and the filler cap. 10. Close the tap or connect the radiator hose. 15 - 21
1. If the lubricating oil filler is installed on the valve mechanism cover, remove the filler cap.
3. Spray "1762811 POWERPART Lay-Up 2" around the rocker shaft assembly. 9813/6050-2
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15 - Engine
00 - Engine 00 - General
4. Install the filler cap or the valve mechanism cover. 5. Seal the vent of the fuel tank or the fuel filler cap with waterproof tape. 6. Remove the alternator drive belts and put the drive belts into storage. 7. In order to prevent corrosion, spray the engine with "1734115 POWERPART Lay-Up 3". Do not spray the area inside the alternator.
Engine Starting After Storage 1. Remove the protective sheet. 2. Use a cloth soaked in degreasing fluid to remove the protective treatment from the external parts. Consumable: Cleaner/Degreaser purpose solvent based parts cleaner
General
3. Inject lubricating oil (not more than 2cm³) into the intake ducts. 4. Adjust the alternator belt tension. Refer to: PIL 15-18-00. 5. Refuel the machine. 6. Make sure that the oil and the coolant are up to the maximum level. 7. Start the engine and run at idle speed for the specified duration. Duration: 2 min 8. Bring the engine to 75% of the maximum rated speed for the specified duration. Duration: 5 –10 min 9. Stop the engine. 10. While the oil is still hot, drain the protective oil into a suitable container. 11. Put new oil up to the maximum level. 12. Replace the filters (air, oil and fuel). 13. Drain the cooling system completely and put new coolant up to the maximum level. Refer to: PIL 21-00-00. Important: Over an amount of time, lubricants and filters lose their properties, so it is important to consider whether they need replacing, also based on the criteria mentioned in the maintenance schedules. If the engine is not to be used for an extended period, the protective treatment procedure must be repeated within 730 d of the previous one. 15 - 22
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15 - Engine
03 - Crankcase
03 - Crankcase Contents
Page No.
15-03-00 General ........................................................................................................................... 15-25
15 - 23
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Notes:
15 - 24
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15 - 24
15 - Engine
03 - Crankcase 00 - General
00 - General
Introduction
Introduction .................................................... 15-25 Technical Data ............................................... 15-26 Check (Condition) .......................................... 15-26
The crankcase is the housing for the crankshaft. The enclosure forms the largest cavity in the engine and is located below the cylinders. It is integral with the cylinder bank and forms an engine block. It has an opening in the bottom to which an oil sump is attached with a gasket and bolted joint. The crankcase protects the crankshaft and connecting rods from foreign objects it also keeps the engine oil contained and allows the oil to be pressurised and also provide the rigid structure with which to join the engine to the transmission. Figure 97.
B
A A Crankcase B Crankshaft
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9813/6050-2
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15 - Engine
03 - Crankcase 00 - General
Technical Data
Check (Condition)
Table 28. Cylinder bore data Description Diameter of bore Bore service limit Flatness of the top of the cylinder Service limit for the flatness Clearance between the tappet and the tappet bore (Maximum) Clearance between the tappet and the tappet bore (Service limit)
Data 84 –84.019 mm 84.2 mm Less than 0.05 mm
1. Check the six positions for flatness with a straight edge and a feeler gauge. Refer to Figure 99. Figure 99. B
A
0.12 mm 0.058 mm C
0.08 mm
Figure 98.
3
1 5
A Crankcase B Straight edge C Feeler gauge A
B
2
6
4
2. Inspect the top of the crankcase for cracks, damage and warping. 3. Inspect each cylinder bore. 3.1. Make sure that there are no signs of scoring or corrosion.
A Tappet B Tappet bore
3.2. Measure each cylinder bore with a suitable gauge. 3.3. Measure the area of each cylinder bore that is in contact with the top, middle and bottom piston rings. 3.4. Make sure that you measure each cylinder bore at right angles to the crankshaft. 3.5. Do NOT use the flex-hone process on this engine. 4. Make sure that the cylinder bore dimensions do not exceed the specified service limits. Refer to: PIL 15-03-00. 5. If the service limit for the crankcase is exceeded, you must replace the crankcase.
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15 - Engine
06 - Cylinder Head
06 - Cylinder Head Contents
Page No.
15-06-00 General ........................................................................................................................... 15-29
15 - 27
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15 - 27
Notes:
15 - 28
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15 - 28
15 - Engine
06 - Cylinder Head 00 - General
00 - General Introduction .................................................... Technical Data ............................................... Check (Condition) .......................................... Calibrate ........................................................ Remove and Install .......................................
15 - 29
Introduction 15-29 15-30 15-30 15-31 15-32
The cylinder head is located above the cylinders on top of the crankcase. It closes in the top of the cylinder, forming the combustion chamber. This joint is sealed by a cylinder head gasket. The cylinder head also provides the space for the passages that feed air and fuel to the cylinder and allow the exhaust to escape. The cylinder head is also used to mount the valves and fuel injectors.
9813/6050-2
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15 - Engine
06 - Cylinder Head 00 - General
Technical Data
Check (Condition)
Table 29. Cylinder head gasket Piston height below top face of crankcase + 0.35 mm to + 0.5 mm + 0.5 mm to + 0.6 mm
Refer to: PIL 01-03.
Gasket Thickness 1.2 mm 1.3 mm
Table 30. Distortion of the cylinder head Description Distortion of the cylinder head Maximum service limit Maximum limit for regrinding the cylinder head
1. Make the machine safe.
Data 0 –0.05 mm
2. Get access to the engine. Refer to: PIL 06-06-06. 3. Remove the cylinder head bolts in the reverse numerical order. This will prevent distortion of the cylinder head. Refer to Figure 100. Figure 100.
0.12 mm 0.15 mm
12
4
5
8
16
1
7
15
13 9
2
11
3
17
10
6
18
14
4. Remove the cylinder head from the engine. 5. Clean the cylinder head thoroughly. 6. Make sure that the contact surface of the cylinder head and the contact surface of the crankcase are clean, smooth and flat. 7. Inspect the bottom surface of the cylinder head for pitting, corrosion and cracks. 8. Inspect the area around the valve seats and the holes for the fuel injectors. 9. Put the cylinder head on a suitable support. Figure 101. A
B A Cylinder head B Support 10. Use a straight edge and a feeler gauge to check the six positions for distortion. Refer to Figure 102. 15 - 30
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15 - Engine
06 - Cylinder Head 00 - General
Calibrate
Figure 102.
•
1 4
3 5
6
•
2
The dowel pins in the crankcase hold the cylinder head gasket in the correct position when the cylinder head is installed. Refer to Figure 103. The stamped marking on the cylinder head gasket must face upward. This makes sure that the cylinder head gasket is installed correctly. Refer to Figure 103. Figure 103. A
•
B
C
A Dowel pins B Gasket C Stamped marking Before you tighten the bolts, apply clean engine oil on the threads of the bolts. The bolts must be tightened to the torque of 101 N·m in the specified numerical sequence only. Refer to Figure 104. Figure 104. 12
4 8
16
11
13
1
7
15
•
5 9
2
3
17
10
18
6
14
Use a straight edge and a feeler gauge to check the six positions for distortion. Refer to Figure 105. Figure 105.
1 4
3 5
6 2
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15 - Engine
06 - Cylinder Head 00 - General
•
If you grind the cylinder head, check the valve depth below the cylinder head face. Refer to: PIL 15-30-00.
Remove and Install CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.
Remove 1. Make the machine safe. Refer to: PIL 01-03-27. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Remove the exhaust manifold. Refer to: PIL 18-24-04. 4. Remove the fuel filter. Refer to: PIL 18-09-00. 5. Remove the fuel injectors. Refer to: PIL 18-18-03. 6. Remove the glow plugs. Refer to: PIL 15-80-00. 7. Remove the rocker shaft and the push rods. Refer to: PIL 15-42-00. 8. Remove the cooling pump. Refer to: PIL 21-09-00. 9. Drain the cooling system. Refer to: PIL 21-00-00. 10. Gradually loosen the bolts in reverse numerical order. This will prevent distortion of the cylinder head. Refer to Figure 106. Figure 106. 12
4
5
8
16
1
7
15
11
13 9
2
3
17
10
6
18
14
11. Remove the bolts from the cylinder head. 12. Carefully lift the cylinder head off the crankcase with a suitable lifting device. 13. Make sure of the following. 13.1. Do not use a lever to separate the cylinder head from the crankcase. 15 - 32
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15 - Engine
06 - Cylinder Head 00 - General
13.2. Take care not to damage the machined surfaces of the cylinder head. 13.3. Avoid contamination of the cylinder bores with coolant or with debris.
2. Make sure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.
13.4. Place the cylinder head on a surface that will not scratch the face of the cylinder head.
3. Inspect the mating surface of the cylinder head for distortion. If the mating surface of the cylinder head is distorted beyond the maximum permitted limits, replace the cylinder head.
14. Remove the cylinder head gasket. Retain the old gasket to help identification.
4. Inspect dowels for damage. If necessary, replace the dowels in the crankcase.
15. Make a note of the position of the dowels. Do not remove the dowels unless they are damaged.
5. Install the guide bolts to the crankcase.
16. If necessary, remove the thermostat from the cylinder head. Refer to: PIL 21-12-00. Figure 107.
6. Make sure that the new gasket is of the same thickness as the old gasket. 7. Align the gasket with the guide bolt and the dowels. Install the gasket onto the crankcase. 8. Lift the cylinder head with a suitable lifting device.
A
9. Align the cylinder head with the guide bolts on the crankcase. Install the cylinder head onto the crankcase. 10. Make sure that the cylinder head is correctly positioned on the dowels. 11. Remove the guide bolts. 12. Install the bolts to the cylinder head. 13. Tighten the bolts to the correct torque value in the specified numerical sequence only. Refer to Figure 106. B
14. If removed, install the thermostat to the cylinder head. Refer to: PIL 21-12-00.
A Bolt B Cylinder head
15. Install the cooling pump. Refer to: PIL 21-09-00.
Figure 108. D
C
16. Install the rocker shaft and the push rods. Refer to: PIL 15-42-00.
D C
17. Install the glow plugs. Refer to: PIL 15-80-00. 18. Install the fuel injectors. Refer to: PIL 18-18-03. 19. Install the fuel filter. Refer to: PIL 18-09-00.
C Dowel D Guide bolt (M11 by 100 mm)
20. Install the exhaust manifold. Refer to: PIL 18-24-04.
Install 1. Clean the mating surfaces of the cylinder head and the crankcase.
15 - 33
Table 31. Torque Values Item A
9813/6050-2
Description Bolt
Nm 100 15 - 33
15 - Engine
12 - Crankshaft
12 - Crankshaft Contents 15-12-00 15-12-03 15-12-06 15-12-09 15-12-12 15-12-24
15 - 34
Page No. General ........................................................................................................................... Main Bearing .................................................................................................................. Front Oil Seal ................................................................................................................. Rear Oil Seal ................................................................................................................. Pulley .............................................................................................................................. Wear Sleeve ...................................................................................................................
9813/6050-2
15-35 15-39 15-43 15-44 15-45 15-46
15 - 34
15 - Engine
12 - Crankshaft 00 - General
00 - General Introduction .................................................... Technical Data ............................................... Component Identification ............................... Check (Condition) .......................................... Remove and Install .......................................
15 - 35
Introduction 15-35 15-36 15-36 15-37 15-37
The crankshaft is housed inside the crankcase. It is connected to the piston via a connecting rod, they form a simple mechanism that converts reciprocating motion into rotating motion. Refer to: PIL 15-00-00.
9813/6050-2
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15 - Engine
12 - Crankshaft 00 - General
Technical Data
Component Identification Figure 111.
Table 32. Description
Data Standard 2.95 –3 mm
Service limit 0.5 mm
Thrust washer thickness Crankshaft end 0.1 –0.3 mm play •
0.5 mm
Make sure that the oil grooves of all of the thrust washers are toward the crankshaft. Figure 109. B
B
A
D
A A Crankcase B Crankshaft
C
•
A Crankshaft B Main bearing holder bolt C Thrust washer D Top thrust washer If the crankshaft end play exceeds the service limit, check the thrust washers for wear. Figure 110. F E
A A Crankshaft E Allen head screw F Retaining bolt Table 33. Torque Values Item B E F 15 - 36
Description Main bearing holder bolt Allen head screw Retaining bolt
Nm 52 27 52 9813/6050-2
15 - 36
15 - Engine
12 - Crankshaft 00 - General
Check (Condition)
Remove and Install
1. Check the main bearing surfaces for damage and excessive wear. 2. Measure the crankshaft diameters to confirm they are within service limits. Refer to: PIL 15-12-00.
CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.
Remove 1. Remove the engine oil pressure relief valve.
3. Check that the oilway cross drillings in the crankshaft are clear and free from debris. Blocked or restricted oilways will cause oil starvation at the big end bearings.
Refer to: PIL 15-60-06. 2. Remove the crankshaft rear seal. Refer to: PIL 15-12-09. 3. Remove the engine oil pump and the suction pipe. Refer to: PIL 15-60-00. 4. Remove the pistons and the connecting rods. Refer to: PIL 15-36-00. 5. Mount the engine in a suitable stand with the rear end facing upwards. 6. Remove the bolts from the crankcase. 7. Remove the allen screws from the crankcase. 8. Attach a suitable lifting device to the crankshaft assembly. 9. Carefully lift the crankshaft assembly from the crankcase. 10. If necessary, gently tap the nose of the crankshaft with a soft faced hammer. 11. Install the nut for the crankshaft pulley to protect the nose of the crankshaft. Do not scratch the finished surfaces of the crankshaft.
15 - 37
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15 - Engine
12 - Crankshaft 00 - General
Figure 112.
3. Tighten the bolts and the screws to the correct torque value.
C D
4. Check the crankshaft end play.
B
4.1. Push the crankshaft towards the front of the engine. 4.2. Install a DTI (Dial Test Indicator) to the crankcase and the rear face of the crankshaft. 4.3. Push the crankshaft toward the rear of the engine. 4.4. Measure the crankshaft end play with the DTI. 4.5. Make sure that the end play does not exceed the maximum permissible crankshaft end play. Refer to: PIL 15-12-00.
A A B C D
Table 34. Torque Values
Crankshaft Crankcase Bolt Allen screw
Item C D
Description Bolt Allen screw
Nm 52 27
Figure 113. E
A
B
A Crankshaft B Crankcase E Lifting device
Install 1. Installation is the opposite of the removal procedure. Additionally do the following steps. 2. Before installation make sure that all the components are clean and free from damage.
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9813/6050-2
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15 - Engine
12 - Crankshaft
03 - Main Bearing
03 - Main Bearing
Introduction
Introduction .................................................... 15-39 Check (Condition) .......................................... 15-40 Remove and Install ....................................... 15-41
In a piston engine, the main bearings are the bearings on which the crankshaft rotates. The bearings hold the crankshaft in place and prevent the forces created by the piston and transmitted to the crankshaft by the connecting rods from dislodging the crankshaft, instead forcing the crank to convert the reciprocating movement into rotation. Figure 114. A
B
A Main bearing B Crankshaft
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15 - Engine
12 - Crankshaft
03 - Main Bearing
Check (Condition)
Figure 115.
Check the condition of the main bearings by measuring the clearance between the two bearing halves. If the crankshaft journals and the bores for the crankcase and connecting rods were measured, no further checks are necessary. If the bearing clearance measurement is necessary, the use of the plastic gauge is an acceptable method. The plastic gauge is less accurate on journals with small diameters if the clearances are less than 0.1 mm. When you use the plastic gauge make a note of the following: • • •
Make sure that the backs of the bearings and the bores are clean and dry. Make sure that the bearing locking tabs are properly seated in the tab grooves. The crankshaft must be free of oil at the contact points of the plastic gauge. Table 35. Plastic Gauges
Colour code Green Red Blue Yellow
A
B A Plastic gauge B Bearing 7. Measure the width of plastic gauge while the plastic gauge is in the bearing cap or on the crankshaft journal. 8. Remove all of plastic gauges before you install the bearing cap.
Dimensions 0.025 –0.076 mm 0.051 –0.152 mm 0.102 –0.229 mm 0.23 –0.51 mm
Measurement Procedure 1. Put the plastic gauge on the crown of the bearing that is in the cap. 2. Do not allow the plastic gauge to extend over the edge of the bearing. 3. Use the correct torque-turn specifications in order to install the bearing cap. 4. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. 5. Do not turn the crankshaft when the plastic gauge is installed. 6. Carefully remove the cap, but do not remove the plastic gauge.
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15 - Engine
12 - Crankshaft
03 - Main Bearing
Remove and Install Remove
5. Remove the upper main bearing and the lower main bearing from the upper main bearing cap and the lower main bearing cap respectively.
1. Remove the crankshaft. Refer to: PIL 15-12-00.
6. Keep the main bearings with the respective bearing caps.
2. Make sure that the bearing caps are marked for orientation and the correct position.
7. Do not remove the dowels from the main bearing caps.
3. Remove the bolt and the upper main bearing cap from the lower main bearing cap.
8. Remove the front bearing with the driver tool.
4. Remove the thrust washer 1 and the thrust washer 2. Figure 116. A
A
B
C
D
B
E F
F G
G H
A C E G
Bolt Thrust washer 1 Lower main bearing Thrust washer 2
15 - 41
B D F H
Upper main bearing cap Upper main bearing Lower main bearing cap Dowel
9813/6050-2
15 - 41
15 - Engine
12 - Crankshaft
03 - Main Bearing
Figure 117. K
J
11. Install the thrust washer 1 and thrust washer 2
L
12. Make sure that the thrust washers are aligned correctly and the oil grooves are facing the crankshaft.
M
13. Install the bolt and tighten to the correct torque value. J
14. Install the front bearing with the driver tool as follows: 14.1. Make sure that the oil supply hole is aligned with the oil gallery in the crankcase.
N
14.2. Make sure that the joint is facing upwards. J K L M N
14.3. Make sure that the chamfer faces towards the crankcase.
Front bearing Joint Chamfer Oil supply hole Driver tool
15. Install the crankshaft. Refer to: PIL 15-12-00.
Install 1. Clean the crankshaft thoroughly. Check the condition of the crankshaft. Refer to: PIL 15-12-00. 2. Clean all the bearings and thrust washers. Inspect all the components for wear or damage. 3. Install the upper main bearing to the upper main bearing cap. 4. Make sure that the locating tab for the upper main bearing is seated in the slot in the upper main bearing cap. 4.1. The upper bearing has a groove. 5. Install the lower main bearing to the lower main bearing cap. 6. Make sure that the locating tab for the lower main bearing is seated in the slot in the lower main bearing cap. 6.1. The lower bearing is a plain bearing that has oil holes. 7. Lubricate the main bearings with clean engine oil. 8. Keep the upper and the lower main bearing cap in position on the crankshaft. 9. Make sure that the bearing caps are installed in the correct location and orientation. The locating tabs for the upper and the lower bearings should be on the same side of the engine. 10. Make sure that the dowels are in the correct position. This is to make sure that the two halves of the main bearing caps are aligned. 15 - 42
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15 - Engine
12 - Crankshaft
06 - Front Oil Seal
06 - Front Oil Seal
Alternative Removal Procedure 1. Remove the crankshaft pulley.
Remove and Install Special Tools Description Slide Hammer Kit
Refer to: PIL 15-12-12.
Part No. 993/68100
2. Remove the timing gear front case.
Qty. 1
Refer to: PIL 15-51-21. 3. Press the front oil seal with a suitable mandrel and remove it from the front case.
Remove 1. Make the machine safe.
4. Support the front case to prevent damage to the front case.
Refer to: PIL 01-03-27.
Install
2. Remove the crankshaft pulley. Refer to: PIL 15-12-12. 3. Do not damage the crankshaft during the removal process of the crankshaft front oil seal.
1. Make sure that the bore in the front case and the nose of the crankshaft are clean and free from damage.
4. Drill the front oil seal with a specified sized drill bit.
2. Lubricate the lip of the new crankshaft front seal with clean engine oil. 3. Position the front oil seal in the bore of the front case.
Dimension: 4 mm Figure 118.
4. Make sure that the lip of the front oil seal that is spring loaded is facing toward the inside of the front case and that it is square with the bore of the case for the front oil seal. 5. Install the front oil seal to the front case.
A
Figure 119.
A B C D A Front case B Front oil seal C Slide hammer 4.1. Make sure that the main lip is used to remove the front oil seal. 4.2. Do not damage the edge of the housing for the front oil seal.
A Front case B Front oil seal D Soft hammer 6. If necessary, hit the front oil seal with a soft hammer. 7. If removed, install the timing gear front case. Refer to: PIL 15-51-21.
5. Remove the front oil seal with a slide hammer.
8. Install the crankshaft pulley.
Special Tool: Slide Hammer Kit (Qty.: 1) 6. Alternate the position of the slide hammer puller from one hole to another hole. This will allow you to evenly remove the front oil seal from the front case. 15 - 43
B
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Refer to: PIL 15-12-12.
15 - 43
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
09 - Rear Oil Seal
3. Make sure that the crankshaft flange is clean and free from damage. It is possible to reclaim a crankshaft flange that has a worn seal surface or a damaged seal surface by installing a wear sleeve.
Remove and Install Consumables Description Clear Silicone Sealant
Part No. 4102/0901
Size 0.31 L
Remove
4. Apply clean engine lubricating oil to the flange of the crankshaft around the running surface of the rear oil seal. 5. Align the new rear oil seal with the flange of the crankshaft.
1. Make the machine safe.
6. Carefully install the rear oil seal onto the crankshaft flange.
Refer to: PIL 01-03-27. 2. Remove the flywheel.
7. Apply a continuous bead of Silicone Adhesive to the rear face of the crankcase around the edge of the rear oil seal and the plug.
Refer to: PIL 15-54-00. 3. Remove the bolt. 4. Remove the flywheel housing and the back plate from the crankcase. Refer to: PIL 15-54-03.
Consumable: Clear Silicone Sealant 8. Align the flywheel housing and the back plate to the dowels. 9. Install the flywheel housing and the back plate.
5. Remove and discard the rear oil seal.
Refer to: PIL 15-54-03.
Figure 120. G
10. Install the bolt to the crankcase. 11. Tighten the bolt to the correct torque value. A
12. Install the flywheel.
B
Refer to: PIL 15-54-00.
D
Table 36. Torque Values Item C
E
A B C D E F G
F
Description Bolt
Nm 25
C
Rear oil seal Back plate Bolt Dowel Crankcase Crankshaft flange Silicone Adhesive
Install 1. Make sure that the mating surface of the crankcase, back plate and the flywheel housing are clean and free from damage. 2. Inspect the dowels. If the dowels are damaged, replace them. 15 - 44
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15 - Engine
12 - Crankshaft 12 - Pulley
12 - Pulley
Figure 122. A
Remove and Install
B
Remove 1. Make the machine safe. Refer to: PIL 01-03-27.
C
D
2. Remove the engine drive belt. 3. Loosen the nut. Do not remove the nut at this time. 4. Install the puller on the pulley with the bolt (x3). Figure 121.
B
A B C D
Woodruff key Pulley Nut Crankshaft
Install 1. Make sure that all the components are clean and free from damage.
E
2. Replace any components that are damaged. 3. Make sure that the taper of the crankshaft and the bore of the crankshaft pulley are clean and dry.
F
4. Install the woodruff key to the crankshaft.
B Pulley E Puller F Bolt (x3)
5. Install the pulley to the crankshaft.
5. Pull out the pulley from the crankshaft with the puller. 6. Remove the bolt (x3) and the puller from the pulley.
6. Lubricate the nut with clean engine oil and install it. 7. Tighten the nut to the correct torque value. 8. Install the engine drive belt.
7. Remove the loosened nut.
Table 37. Torque Values
8. Remove the pulley from the crankshaft. 9. Remove the woodruff key from the crankshaft.
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Item C
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Description Nut
Nm 304
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15 - Engine
12 - Crankshaft
24 - Wear Sleeve
24 - Wear Sleeve
Figure 124.
Remove and Install
C
A
The wear sleeves are used to reclaim worn seal surfaces or damaged seal surfaces. The wear sleeves are not original equipment. C
Remove 1. Make the machine safe.
A Wear sleeve C Liquid gasket
Refer to: PIL 01-03-27. 2. Remove the rear oil seal. Refer to: PIL 15-12-09. 3. Mark a deep score line across the crankshaft wear sleeve with a sharp tool. 3.1. Take care not to damage the crankshaft. Figure 123.
3. Apply a bead of liquid gasket at the specified distance from the flange end of the crankshaft wear sleeve. Distance: 5 mm 4. Align the wear sleeve with the crankshaft. 5. Position the installation tool that is provided with the wear sleeve over the crankshaft.
A
6. Drive the wear sleeve on the crankshaft with a slide hammer. 7. Make sure that the distance from the edge of the wear sleeve to the rear face of the crankshaft is the same as specified. Refer to Figure 125. Distance: 2.5 Âą 0.1 mm
B
Figure 125. A
A Wear sleeve B Crankshaft
B
4. Insert a thin blade between the wear sleeve and the crankshaft below the scored line. The crankshaft wear sleeve will separate along the line.
E
5. Remove and discard the wear sleeve from the crankshaft.
A B D E
Install 1. Make sure that the crankshaft is thoroughly clean and dry. Remove any areas of raised damage. 2. Apply a small continuous bead of liquid gasket to the inner surface of the wear sleeve at the specified position. Refer to Figure 124.
D
Wear sleeve Crankshaft Installation tool Distance from the edge of the wear sleeve to the rear face of the crankshaft ( 2.5 Âą 0.1 mm)
8. Remove the installation tool. 9. Make sure that the wear sleeve has no rough edges. 10. Install the new rear oil seal. Refer to: PIL 15-12-09.
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15 - Engine
15 - Camshaft
15 - Camshaft Contents
Page No.
15-15-00 General ........................................................................................................................... 15-49
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Notes:
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15 - Engine
15 - Camshaft 00 - General
00 - General Introduction .................................................... Technical Data ............................................... Component Identification ............................... Operation ....................................................... Check (Condition) .......................................... Remove and Install ....................................... Disassemble and Assemble ..........................
Introduction 15-49 15-50 15-51 15-52 15-53 15-54 15-56
The relationship between the rotation of the camshaft and the rotation of the crankshaft is of critical importance. Since the valves control the flow of the air/fuel mixture intake and exhaust gases, they must be opened and closed at the appropriate time during the stroke of the piston. For this reason, the camshaft is connected to the crankshaft through a gear mechanism. When the engine runs the crankshaft drives the camshaft through the gears. The camshaft opens and closes the inlet and exhaust valves through the push rods in time with the four stroke cycle.
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15 - Camshaft 00 - General
Technical Data
Figure 128.
Table 38. Description
D
Data Standard Service limit 34.453 –34.507 33.7 mm mm
Height of the camshaft lobe for the inlet and exhaust valves Height of the 41.94 –42.06 camshaft lobe mm for the fuel injection pump Height of the 31.9 –32 mm camshaft lobe for the fuel priming pump
E
41.8 mm
30 mm F
D Actual camshaft lobe lift E Height of the camshaft lobe F Base circle
Figure 126. A
3. Subtract the base circle diameter (1) from the height of the camshaft lobe (2). The difference is the actual camshaft lobe lift.
C B A Camshaft lobe for the inlet and exhaust valves B Camshaft lobe for the fuel injection pump C Camshaft lobe for the fuel priming pump
Table 39. Torque Values Item G
Description Setscrew
Nm 11
Figure 127. G
J H G Setscrew H Retainer plate J Camshaft gear To determine the lobe lift use the following procedure: 1. Measure the height of the camshaft lobe. 2. Measure the base circle.
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15 - Camshaft 00 - General
Component Identification Figure 129.
B
A
C D E
A Camshaft C Bearing E Gear
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B Woodruff key D Spacer
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15 - Engine
15 - Camshaft 00 - General
Operation As the crankshaft rotates the camshaft also rotates, driven by a gear on the crankshaft. The inlet and exhaust valves are opened by lobes on the camshaft in time with the cycle.
during the cycle it follows that the camshaft is driven at half crankshaft (engine) speed.
The diagrams show the position of the camshaft at each part of the four stroke cycle, refer to EngineGeneral, Operation. Refer to: PIL 15-00-00.
Oil is fed from the main gallery via a drilling to the camshaft bearing. A groove around the diameter of the bearing and connecting the cross drilling ensures that oil is always fed to the centre drilling. Oil is then transferred to the remaining camshaft bearings by further cross drillings in the shaft. The cam lobes and tappets are 'splash' lubricated.
It can be seen that for a complete cycle the camshaft revolves once. Since the crankshaft revolves twice
Lubrication
Figure 130.
1 Main gallery 3 Groove 15 - 52
2 Camshaft bearing 4 Centre drilling 9813/6050-2
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15 - Engine
15 - Camshaft 00 - General
Check (Condition) 1. Inspect the camshaft gear teeth for signs of damage or excessive wear. 2. Inspect the cam lobes, the camshaft journals, and the cam bearing surfaces inside the crankcase for signs of excessive wear, or scoring. Make sure that the dimensions are within the service limits. 3. Inspect the bearing surfaces of the tappets for signs of excessive wear or damage. Check that the dimensions are within service limits. 4. Inspect the tappet bores inside the crankcase for signs of excessive wear or damage. Check that the dimensions are within service limits. 5. If any of the camshaft journals or lobes are worn or damaged then the relative oil feed galleries in the crankcase and camshaft may be blocked. Make sure all oil ways are clear and free from debris. Refer to: PIL 15-03-00.
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15 - Camshaft 00 - General
Remove and Install Remove
6. Remove the bolt 1 and then bolt 2.
1. Remove the valve tappet.
7. Remove the camshaft retainer.
Refer to: PIL 15-42-21.
8. Rotate the crankshaft until the timing marks are aligned on the following gears:
2. Remove the timing gear front case.
8.1. Crankshaft gear
Refer to: PIL 15-51-21.
8.2. Camshaft gear
3. If installed, remove the mechanical fuel transfer pump. Refer to: PIL 18-21-00.
8.3. Idler gear 9. Carefully remove the camshaft assembly from the crankcase.
4. Remove the slider from the camshaft gear. 5. Rotate the camshaft gear to align the access hole in the camshaft gear with the fastener.
10. Make sure that the lobes of the camshaft and the camshaft bearings are not damaged.
Figure 131. A B
A
C
B
C
D A
E E D F A C E G
Bolt 1 Slider Camshaft retainer Crankshaft gear
15 - 54
G
B Bolt 2 D Camshaft gear F Idler gear
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15 - Engine
15 - Camshaft 00 - General
Figure 132.
H
H Camshaft assembly
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Before installation, lubricate the bearings of the camshaft with clean engine oil. 3. Tighten the bolts to the correct torque value. Table 40. Torque Values Item A B
15 - 55
Description Bolt 1 Bolt 2
Nm 10 10
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15 - Engine
15 - Camshaft 00 - General
Disassemble and Assemble Disassemble
4. Remove the spacer and the woodruff key from the camshaft.
1. Remove the camshaft assembly.
5. Remove the bearing from the camshaft with the combination puller.
Refer to: PIL 15-15-00. 2. Remove the gear with a combination puller. 3. Keep the gear in the correct position on a suitable support to prevent damage to the governor flyweights.
6. Make a note of the orientation of the bearing to help installation.
Figure 133.
B
A
C D E
A Camshaft C Bearing E Gear
15 - 56
B Woodruff key D Spacer
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15 - Engine
15 - Camshaft 00 - General
Assemble 1. Make sure that all of the components of the camshaft assembly are clean and free from damage. 2. Lubricate the nose of the camshaft with clean engine oil. 3. Install the bearing to the camshaft with a suitable press. 3.1. Make sure that you install the bearing in the correct orientation. 3.2. Make sure that you press the camshaft bearing squarely onto the camshaft or damage to the bearing may occur. 3.3. Do not press on the outer race of the bearing. 4. Install the spacer and the woodruff key to the camshaft. 5. Align the gear with the woodruff key. 6. Install the gear to the nose of the camshaft with a suitable press. 7. Install the camshaft assembly. Refer to: PIL 15-15-00.
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15 - Engine
18 - Engine Belt
18 - Engine Belt Contents
Page No.
15-18-00 General ........................................................................................................................... 15-59 15-18-03 Drive Belt ....................................................................................................................... 15-61
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15 - Engine
18 - Engine Belt
00 - General
00 - General
Introduction
Introduction .................................................... 15-59 Health and Safety .......................................... 15-60 Technical Data ............................................... 15-60
A crankshaft pulley is used to drive a FEAD (Front End Accessory Drive) belt. The belt drives the coolant pump. Depending on the machine application, the belt is configured to drive engine mounted accessories, such as the alternator, cooling fan and air conditioning compressor. Some applications have a second pulley on the crankshaft which drives a dedicated fan belt. The belt drives an engine mounted cooling fan.
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15 - Engine
18 - Engine Belt
00 - General
Health and Safety
Technical Data
Turning the Engine Do not try to turn the engine by pulling the fan or fan belt. This could cause injury or premature component failure. WARNING! The engine has exposed rotating parts. Switch off the engine before working in the engine compartment. Do not use the machine with the engine cover open.
Table 41. Belt tension chart Description Initial belt tension
(1)
Used belt tension
(2)
Gauge reading 400 –489 N 267 –356 N
(1) Initial belt tension refers to a new belt. (2) Used belt tension refers to a belt that has been in operation for 30 min or more at the rated speed.
Notice: A drive belt that is loose can cause damage to itself and/or other engine parts.
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15 - Engine
18 - Engine Belt
03 - Drive Belt
03 - Drive Belt Health and Safety .......................................... Check (Condition) .......................................... Adjust ............................................................ Remove and Install .......................................
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Health and Safety 15-61 15-62 15-63 15-64
Notice: A drive belt that is loose can cause damage to itself and/or other engine parts.
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15 - Engine
18 - Engine Belt
03 - Drive Belt
Check (Condition) At the recommended service interval, visually inspect the drive belt for damage. 1. Make the machine safe. Refer to: PIL 01-03-27. 2. Stop the engine and let it cool down. 3. Replace the drive belt if it has cracks or if it is frayed or has pieces of material missing.
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18 - Engine Belt
03 - Drive Belt
Adjust CAUTION Make sure the engine cannot be started. Disconnect the battery before doing this job, otherwise you could be injured.
5. Make sure that the drive belt deflects to specified distance. Distance: 7 mm
1. Make the machine safe.
6. To adjust the drive belt tension, do as follows:
Refer to: PIL 01-03.
6.1. Loosen the alternator mounting bolts.
2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work.
6.2. Loosen the tension adjustment bolt and move the alternator. 7. Make sure of the following:
3. Open the engine cover.
7.1. Excessive fan belt slack may result in damage to the engine timing cover.
Refer to: PIL 06-06-06. 4. Press the drive belt at the centre between the crankshaft pulley and the alternator pulley with a force of 5 kgf.
7.2. Any leverage required to position the alternator must be applied at the drive end only. If necessary, use only a wooden lever. 8. Tighten the bolts in the sequence given below:
Figure 134. D
E
E F
C A B
A Drive belt C Alternator E Alternator mounting bolt
B Crankshaft pulley D Fan F Tension adjustment bolt
8.1. Tension adjustment bolt. 8.2. Rear alternator mounting bolt. 8.3. Front alternator mounting bolt.
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15 - Engine
18 - Engine Belt
03 - Drive Belt
Remove and Install Remove
Refer to: PIL 33-03-00. 4. Loosen the alternator mounting bolts and the tension adjustment bolt.
1. Make the machine safe. Refer to: PIL 01-03-27.
5. If necessary, remove the fan.
2. Get access to the drive belt.
6. Remove the drive belt.
3. Disconnect the battery.
Figure 135. D
E
E F
C A B
A Drive belt C Alternator E Alternator mounting bolt
15 - 64
B Crankshaft pulley D Fan F Tension adjustment bolt
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15 - Engine
18 - Engine Belt
03 - Drive Belt
Install 1. Installation is the opposite of the removal procedure. Additionally do the following steps. 2. Make sure of the following: 2.1. For applications that require multiple drive belts, replace the belts in matched sets. Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched. The additional load on the new belt could cause the new belt to break. 3. When new belts are installed, check the belt tension again after 20 hours of engine operation. 4. Tighten the bolts in the sequence given below: 4.1. Tension adjustment bolt 4.2. Rear alternator mounting bolt 4.3. Front alternator mounting bolt
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15 - Engine
21 - Oil Filter
21 - Oil Filter Contents
Page No.
15-21-00 General ........................................................................................................................... 15-67
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15 - Engine
21 - Oil Filter
00 - General
00 - General Introduction .................................................... Health and Safety .......................................... Component Identification ............................... Check (Level) ................................................ Remove and Install .......................................
15 - 67
Introduction 15-67 15-68 15-68 15-69 15-69
The oil filter is a spin on type which screws on to the filter head. The oil filter and cooler are incorporated in a housing that is bolted to the side of the crankcase. The housing allows transfer of lubricating oil from the crankcase to the oil cooler and the oil filter head.
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15 - Engine
21 - Oil Filter
00 - General
Health and Safety
Component Identification
Oil
Figure 136.
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. CAUTION! It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. CAUTION! Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug.
C A
B
A Oil cooler B Adaptor C Oil filter
CAUTION! The oil filter canister will contain some oil which could spill out when you remove the canister.
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21 - Oil Filter
00 - General
Check (Level)
Remove and Install
Notice: Do not exceed the maximum level of engine oil in the sump. If the maximum is exceeded, the excess must be drained to the correct level. An excess of engine oil could cause the engine speed to increase rapidly without control. 1. Make the machine safe.
Important: Use of an oil filter not recommended by JCB could result in severe engine damage to the engine bearings, crankshaft, etc., as a result of the larger waste particles from unfiltered oil entering the engine lubricating system. Use only JCB recommended oil filters.
Remove
Refer to: PIL 01-03-27. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Wait for the oil to drain back into the engine sump before you take a reading. If not, a false low reading may be recorded which can cause the engine to be overfilled. 4. Open the engine compartment cover. Refer to: PIL 06-06-06.
1. Drain the engine oil. Refer to: PIL 15-00-00. 2. Remove the oil filter with a suitable tool. 3. Use a suitable container to recover any residual oil. 4. Inspect the oil filter as follows. The steps 4.1 to 4.5 can be carried out as a preventive maintenance. 4.1. Cut the oil filter open with a suitable tool.
5. Remove and clean the dipstick.
4.2. Break apart the pleats and check the oil filter for metal debris. An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure.
6. Replace the dipstick. 7. Remove the dipstick. 8. Check the oil level. The oil should be between the two marks on the dipstick.
4.3. Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element.
9. If necessary, add more oil.
4.4. The ferrous metals indicate wear on the steel and cast iron parts of the engine.
Refer to: PIL 15-00-00. 10. Close the engine compartment cover.
4.5. Non-ferrous metals indicate wear on the aluminum parts, brass parts or bronze parts of the engine. These affected parts include the following items:
Refer to: PIL 06-06-06. • • • •
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Main bearings Connecting Rod bearings Turbocharger bearings Cylinder heads
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15 - Engine
21 - Oil Filter
00 - General
Figure 137.
C A
B
A Oil cooler B Adaptor C Oil filter
Install 1. Clean the sealing surface of the oil cooler. 2. Apply clean engine oil to the new oil filter seal. 3. Do not fill the oil filters with oil before installing them. This oil would not be filtered and could be contaminated. Contaminated oil can cause accelerated wear to engine components. 4. Install the oil filter. Tighten the oil filter by hand. Do not overtighten the oil filter.
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24 - Air Filter
24 - Air Filter Contents
Page No.
15-24-00 General ........................................................................................................................... 15-73 15-24-09 Dust Valve ...................................................................................................................... 15-77
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Notes:
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24 - Air Filter
00 - General
00 - General Introduction .................................................... Health and Safety .......................................... Component Identification ............................... Check (Condition) .......................................... Remove and Install .......................................
Introduction 15-73 15-74 15-74 15-75 15-75
Introduction Engine performance and durability will be severely affected if the quality of the air intake is poor. A dirty and blocked air filter will reduce the amount of air entering the combustion chamber which can cause engine misfiring, black smoke and low output power. A dirty and blocked air filter can also lead to abrasion of the cylinder bores and valves (referred to as dusting). This will cause excessive oil consumption, black smoke, low output power and a reduced engine life. This is a dry-type air filter with a replaceable paper filter cartridge.
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24 - Air Filter
00 - General
Health and Safety
Component Identification
Notice: Do not run the engine when the element has been removed.
Figure 138.
Notice: The outer element must be renewed immediately if the warning light on the instrument panel illuminates.
A F D
B E A B C D E F G
15 - 74
C
G
Air filter Mounting bracket Adaptor elbow Vacuum Switch Inlet Outlet Dust exhaust valve
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15 - Engine
24 - Air Filter
00 - General
Check (Condition)
Remove and Install
The air filter element (s) should be changed at the recommended service interval, refer to the Maintenance Schedules. Refer to: PIL 78-24.
Remove
Check all the hose connections for loose installations and damaged hose clamps, look specifically for splits or cracks in the hoses. Pay particular attention to the connections on the air intake to turbo compressor and on the crossover tube. Renew any damaged components. In addition, most air filter housings will be installed with a vacuum switch. The switch will detect if there is a restriction on the air intake, and activate warning indicators such as an audible alarm and/or a visual indicator.
1. Make the machine safe. Refer to: PIL 01-03-27. 2. Open the engine compartment cover. Refer to: PIL 06-06-06. 3. Disconnect the induction hose and plug the open end to prevent dust from entering the engine manifold. 4. Release the retaining clips from the filter cover and remove the outer filter element. 5. Do not tap or knock the element as you remove it and remove the inner element. 6. Clean the inside of the canister and dust valve. Figure 139. A
E
C D
B
F A B C D E F
Induction hose Filter cover Outer filter element Inner filter element Canister Dust valve
Install 1. Clean the inside of the canister and dust valve. 2. Apply grease on the seal on the end of the element. 3. Insert the inner filter element into the canister temporarily and make sure that it is at its correct location.
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24 - Air Filter
00 - General
4. Remove the inner filter element and check that there is a continuous witness mark around the canister base. This shows that the canister has not been distorted which would allow unfiltered air to bypass the element. 5. Repeat the step 2 to step 4 for the outer filter element. 6. Install the inner and outer filter elements. 7. Install the filter cover. 8. Install the induction hose. 9. Check the condition and security of all air hoses.
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24 - Air Filter
09 - Dust Valve
09 - Dust Valve Clean 1. Make the machine safe. Refer to (PIL 01-03). 2. Open the engine compartment cover. Refer to (PIL 06-06). 3. Remove the dust valve. 4. Make sure that the dust valve is not blocked. 5. Inspect the rubber flaps for cuts and nicks. 6. Make sure that the rubber has not perished. If necessary, replace it. Figure 140.
A
B A Air filter B Dust valve
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30 - Valve
30 - Valve Contents 15-30-00 15-30-12 15-30-15 15-30-24
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Page No. General ........................................................................................................................... Valve Spring ................................................................................................................... Valve Guide .................................................................................................................... Stem Seal ......................................................................................................................
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15-79 15-89 15-90 15-91
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30 - Valve
00 - General
00 - General Introduction .................................................... Technical Data ............................................... Component Identification ............................... Operation ....................................................... Check (Condition) .......................................... Adjust ............................................................ Remove and Install .......................................
Introduction 15-79 15-80 15-82 15-82 15-83 15-85 15-87
The valve train system opens and closes the valves with correct timing in relation to the piston movements. The valve train system controls the flow of air into the cylinders and out of the cylinders during engine operation. The cylinder head assembly has two valves for each cylinder. Each valve has one valve spring. The ports for the inlet valve and the exhaust valve are on the left side of the cylinder head. Each push rod has one end in a valve tappet and the other end under a rocker arm. The valves extend through the cylinder head. The valves are made from a special metal to provide a long service life. Damaged or worn valves cannot be lapped or reground and must be replaced with new ones. Each valve stem has an oil seal. The Valve seat inserts are pressed into the cylinder head. The seat inserts are also made from a special metal to provide for a long service life. Damaged or worn valve seat inserts can be removed and replaced with new ones. The valve moves along a steel valve guide. These valve guides are installed in the cylinder head and can be replaced.
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30 - Valve
00 - General
Technical Data
Description
Table 42. Description
Data Inlet valve 1
Number of valves per cylinder Valve lash 0.2 mm Valve guide Black garter seal spring with a label "EX" Valve seat an- 45 ° gle Refer to Figure 145.
Exhaust valve 1
Data Standard Service limit 1.94 –2.16 mm 2.5 mm
Contact face exhaust valve Refer to Figure 145. Contact face in- 1.5 –2 mm let valve Refer to Figure 145.
0.2 mm Silver garter spring
Figure 141. A
45 °
C
B D
Table 43. Description Valve spring free length Valve spring test force Valve spring length under test force Clearance between the exhaust valve and the valve guide Refer to Figure 142. Clearance between the inlet valve and the valve guide Refer to Figure 142. Diameter of the exhaust valve stem Diameter of the inlet valve stem Thickness of the valve head Refer to Figure 143. Valve depth below the cylinder head face Refer to Figure 144.
15 - 80
2.5 mm
Data Standard 35 mm
Service limit 33.5 mm
79 N
68.6 N
30.4 mm
-
0.05 –0.075 mm
0.25 mm
0.03 –0.06 mm 0.2 mm
6.94 –6.955 mm
6.84 mm
6.955 –6.97 mm 0.925 –1.075 mm
6.89 mm
E
G
A B C D E F G H
F
H
Valve spring Exhaust valve guide seal Inlet valve guide seal Valve spring recesses Exhaust valve guide Inlet valve guide Exhaust valve stem Inlet valve stem
0.5 mm
0.65 –0.95 mm 1.8 mm
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Figure 145.
Figure 142.
L M
J
L Valve seat angle M Contact face
J Valve - valve guide clearance Figure 143.
N N Valve head thickness Figure 144.
K
K Valve depth
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Component Identification
Operation
Figure 146.
The inlet valve and the exhaust valve are opened and closed by the rotation and movement of the following components:
B
A
D
C
F
E H
J
L G A B C D E F G H J K L
Collets Valve spring retainer Valve spring Valve seal Valve guide Cylinder head Cylinder head gasket Push-rod Tappet Exhaust valve Inlet valve
K
• • • • • • •
Crankshaft Idler gear Camshaft Valve tappets Push-rods Rocker arms Valve springs
The camshaft drive gear is driven by the idler gear at half the speed of the crankshaft. The camshaft gear, the idler gear and the crankshaft gear are timed together. The camshaft lobes, two for each cylinder, (operating exhaust and inlet valves) actuate the valve tappets. When the camshaft rotates the cam lobes act on the tappets. The push rods act on the rockers which pivot on the camshaft. Each valve has a compression spring. The function of the spring is to close the valve and at the same time return the rocker arm and push rod to ensure that the tappets follow the camshaft lobes. The spring is located on the valve stem by a retainer and collets. The illustration shows a four cylinder engine - but the operation is the same for the three cylinder version. Figure 147. B
A
D
C
F
E H
J
L G A B C D E 15 - 82
K
Collets Valve spring retainer Valve spring Valve seal Valve guide
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F G H J K L
Cylinder head Cylinder head gasket Push-rod Tappet Exhaust valve Inlet valve
Check (Condition) Valve Lash Setting The valve lash setting given below is applicable only when the engine is cold. Table 44. Inlet valve Exhaust valve
0.2 ± 0.05 mm 0.2 ± 0.05 mm
Valve Lash Inspection If the valve lash requires adjustment several times in a short period of time, excessive wear exists in a different part of the engine. You must repair the problem to prevent further damage to the engine. Not enough valve lash can cause rapid wear of the camshaft and the valve tappets. Not enough valve lash can indicate that the valve seats are worn. The valves become worn due to the following causes: • • • •
Incorrect operation of the fuel injectors. Excessive dirt and oil are present in the inlet air filter. Incorrect fuel settings on the fuel injection pump. The load capacity of the engine is frequently exceeded.
The excessive valve lash can cause broken valve stems, springs and the spring retainers. This excessive valve lash can be an indication of the following problems: • • • • •
Worn camshaft and valve tappets. Worn rocker arms. Bent push-rods. Broken socket on the upper end of a push-rod. Loose the adjustment screw for the valve lash.
1. If the camshaft and valve tappets show rapid wear, look for fuel in the lubrication oil or dirty lubrication oil as a possible cause. 2. The valve lash is measured between the top of the valve stem and the rocker arm lever. 3. Remove the rocker cover and perform the adjustment procedure to adjust the valve lash. Refer to: PIL 15-30-00. 4. Inspect the valves for the cracks and other damage. 5. Check the valve stems for wear. 6. Check that the valve springs are the correct length under the test force. 15 - 83
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Refer to: PIL 15-30-00.
Valve Depth Check 1. Use the DTI (Dial Test Indicator) with the DTI holder to check the depths of the inlet valves and the exhaust valves below the face of the cylinder head. 2. Use the cylinder head face to zero the DTI. 3. Position the DTI holder and the DTI and measure the valve depth. Figure 148. A B
A DTI B DTI holder 4. Measure the depth of the inlet valve and the exhaust valve before the valve springs are removed. 5. Make sure that the valve depth is within the specified limits. Refer to: PIL 15-30-00. 5.1. If the valve depth below the cylinder head face exceeds the service limit, replace the valve and check the valve depth. 5.2. If the valve depth still exceeds the service limit, renew the cylinder head or if installed, renew the valve seat inserts.
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Adjust Valve Lash Adjustment
4.1. The "Single dot" on the crankshaft pulley is the reference point for the TDC (Top Dead Centre) position of No. 1 and No. 4 cylinders.
1. Make the machine safe. Refer to: PIL 01-03-27.
4.2. The "Middle dot" on the crankshaft pulley is the TDC reference point for No. 2 and No. 3 cylinders.
2. Remove the timing gear front case. Refer to: PIL 15-51-21. 3. Rotate the crankshaft in a clockwise direction (viewed from the front of the engine).
5. Check the valve lash of the inlet valve and the exhaust valve of the No. 1 cylinder.
4. When the inlet valve of the No. 4 cylinder has started to open and the exhaust valve of the No. 4 cylinder has not completely closed, make sure that the "Top" mark on the timing case aligns with the "Single dot" on the crankshaft pulley.
6. If necessary, make an adjustment as follows:
Figure 149.
E
6.1. Loosen the locknut from the adjustment screw. 6.2. Place the appropriate feeler gauge between the rocker arm and the valve.
F
E Single dot on crankshaft pulley F Middle dot on crankshaft pulley
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Figure 150. B C D
A
A Feeler gauge C Locknut
B Adjusting screw D Rocker arm
6.3. Hold the locknut and turn the adjustment screw. 6.4. Adjust the valve lash until the correct specification is achieved. 6.5. After each adjustment, hold the adjusting screw and tighten the locknut. 7. Rotate the crankshaft in a clockwise direction to the specified angle. Angle: 180 ° 8. When the inlet valve of the No. 2 cylinder has started to open and the exhaust valve of the No. 2 cylinder has not completely closed, make sure that the "Top" mark on the timing case aligns with "Middle dot" on the crankshaft pulley. 9. Check the valve lash of the inlet valve and the exhaust valve of the No. 3 cylinder. If necessary, do the step 6
12. Check the valve lash of the inlet valve and the exhaust valve of the No. 4 cylinder. If necessary, do the step 6 13. Rotate the crankshaft in a clockwise direction to the specified angle. Angle: 180 ° 14. When the inlet valve of the No. 3 cylinder has started to open and the exhaust valve of the No. 3 cylinder has not completely closed, make sure that the "Top" mark on the timing case aligns with "Middle dot" on the crankshaft pulley. 15. Check the valve lash of the inlet valve and the exhaust valve of the No. 2 cylinder. If necessary, do the step 6. 16. Install the timing gear front case. Refer to: PIL 15-51-21.
10. Rotate the crankshaft in a clockwise direction to the specified angle. Angle: 180 ° 11. When the inlet valve of the No. 1 cylinder has started to open and the exhaust valve of the No. 1 cylinder has not completely closed, make sure that the "Top" mark on the timing case aligns with "Single dot" on the crankshaft pulley.
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Remove and Install WARNING Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tools to release the spring force. WARNING The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Make sure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves.
5. Check the depth of the valves below the face of the cylinder head before you remove the valve springs. 6. Mark the heads of the valves to help installation. Do not stamp the heads of the valves, this can cause the valves to fracture. 7. Compress the valve spring with the valve spring compressor tool. 8. Make sure that you compress the valve spring squarely or damage to the valve stem may occur. 9. Remove the valve keepers. 10. Do not compress the valve spring so that the valve spring retainer touches the valve stem seal.
Remove 1. Make the machine safe.
11. Remove the valve spring compressor tool.
Refer to: PIL 01-03-27. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Remove the cylinder head.
12. Remove the valve spring retainer. 13. Remove the valve spring. 14. Remove the valve. 15. Remove the valve stem seal.
Refer to: PIL 15-06-00.
16. Do the step 7 to step 15 for the remaining valves.
4. Clean the bottom face of the cylinder head.
Figure 151. A
A B
B G
C
C
D
F
E
A C E G
Valve keeper Valve spring Valve Valve spring compressor tool
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B Spring retainer D Valve stem seal F Cylinder head
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Install 1. Clean all components of the cylinder head assembly. 2. Make sure that all ports, all coolant passages and all lubrication passages in the cylinder head are free from debris. 3. Do the step 3.1 to step 3.5 to inspect the components of the cylinder head assembly. Replace any components that are worn or damaged. 3.1. Check the condition of the cylinder head. Refer to: PIL 15-06-00.
8. Check the depth of the valve below the face of the cylinder head. 9. Install the valve spring into the cylinder head. Position the valve spring retainer on the valve spring. 10. Compress the valve spring with the valve spring compressor tool. 11. Make sure that you compress the valve spring squarely or damage to the valve stem may occur. 12. Install the valve keepers. 13. Remove the valve spring compressor tool. 14. Do the step 7 to step 13 for the remaining valves.
3.2. Check the condition of the valve seats.
15. Keep the cylinder head on a suitable support.
3.3. Check the condition of the valve guide.
16. Make sure that the heads of the valves are not obstructed.
Refer to: PIL 15-30-15. 3.4. Check the condition of the valves. 3.5. Check the condition of the valve spring. Make sure that its length is correct. 4. Make sure that the outer face of the valve guide is clean and dry.
17. Gently hit the top of the valves with a soft hammer and make sure that the valve keepers are correctly installed. 18. Install the cylinder head.
5. Install the new valve stem seals on each of the valve guides with the valve stem seal installation tool.
Refer to: PIL 15-06-00.
Figure 152.
H
D
D Valve stem seal H Valve stem seal installation tool 6. Lubricate the valve stem with clean engine oil. 7. Install the valve in the correct position in the cylinder head.
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12 - Valve Spring
12 - Valve Spring
6. Compress the valve spring with the tool 1 and remove the valve keepers.
Remove and Install
7. Do not turn the crankshaft when the valve springs are removed.
WARNING Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tools to release the spring force. WARNING The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Make sure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves.
8. Slowly release the pressure on the tool 1. 9. Remove the valve spring retainer and remove the valve spring. 10. Remove the tool1 and the tool 2. Figure 153. A B D
Remove
C
E
1. Make the machine safe. Refer to: PIL 01-03-27. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Remove the rocker shaft assembly. Refer to: PIL 15-42-00. 4. Make sure that the appropriate piston is at TDC (Top Dead Centre) before you remove the valve spring. 5. Position the appropriate piston at TDC as follows:
A B C D E
Valve keepers Spring retainer Valve spring Tool 1 Tool 2
Install 1. The installation procedure is the opposite of the removal procedure.
5.1. Install the tool1 and tool 2 in position on the cylinder head to compress the valve spring. 5.2. Compress the valve spring with the tool 1 and open the valve slightly. 5.3. Do not compress the spring so that the valve spring retainer touches the valve stem seal. 5.4. Rotate the crankshaft carefully until the piston touches the valve. 5.5. Do not use excessive force to turn the crankshaft. The use of force can bend the valve stems. 5.6. Continue to rotate the crankshaft and gradually release the pressure on tool 1 until the piston is at TDC. The valve is now held in position that allows the valve spring to be safely removed. 5.7. Make sure that you compress the valve spring squarely or you may damage the valve stem. 15 - 89
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15 - Valve Guide
15 - Valve Guide
9.1. Make sure that the clearance of the valve in the valve guide is within the specified limit.
Check (Condition)
Refer to: PIL 15-30-00. 9.2. If the clearance of the valve in the valve guide is within the specified limit, replace the valve guide.
1. Make the machine safe. Refer to: PIL 01-03-27. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work.
Refer to: PIL 15-30-15.
3. Remove the cylinder head. Refer to: PIL 15-06-00. 4. Place a new valve in the valve guide. 5. Place the DTI (Dial Test Indicator) with the magnetic base on the face of the cylinder head. 6. Lift the edge of the valve head to the specified distance. Length/Dimension/Distance: 15 mm 7. Move the valve in a radial direction away from the DTI. 7.1. Make sure that the valve moves away from the DTI as far as possible. Figure 154. A D
E B C
A B C D E
Valve guide Radial movement of the valve in the valve guide Valve stem DTI Valve head
7.2. Position the contact point of the DTI on the edge of the valve head. 7.3. Set the position of the needle of the DTI to zero. 8. Move the valve in a radial direction towards the DTI as far as possible. 9. Make a note of the distance of movement which is indicated on the DTI.
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24 - Stem Seal
24 - Stem Seal Remove and Install The removal and installation procedure for one valve and valve stem seal is exactly the same. Refer to: PIL 15-30-00.
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Page No.
15-33-00 General ........................................................................................................................... 15-93 15-33-06 Big-End Bearing ............................................................................................................. 15-97
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00 - General Introduction .................................................... Technical Data ............................................... Component Identification ............................... Calibrate ........................................................ Remove and Install ....................................... Disassemble and Assemble ..........................
Introduction 15-93 15-94 15-95 15-95 15-96 15-96
The connecting rod connects the piston to the crankshaft. They form a simple mechanism that converts reciprocating motion into rotating motion. Connecting rods are usually made of high strength steel. They are not rigidly fixed at either end, so that the angle between the connecting rod and the piston can change as the rod moves up and down and rotates around the crankshaft. The small end of the connecting rod attaches to the piston pin which is a press fit into the connecting rod. The big end of the connecting rod connects to the bearing journal on the crank throw, they run on replaceable bearing shells that are accessible via the connecting rod bolts which hold the bearing cap on to the big end. There is a pinhole bored through the bearing and the big end of the connecting rod so that pressurised lubricating engine oil squirts out on to the thrust side of the cylinder wall to lubricate the travel of the pistons and piston rings.
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Technical Data
Figure 155.
Table 45. Diameter of connecting rod bearing journal Journals Standard
Diameter 51.964 –51.975 mm Undersize 0.25 51.714 –51.725 mm mm Undersize 0.5 51.464 –51.475 mm mm
Service limit 51.9 mm
B
51.65 mm A
51.4 mm
D
If the diameter of the connecting rod bearing journal is less than the maximum undersize service limit, then the crankshaft must be replaced. Table 46. Clearances Description
Data Standard clearance 0.035 –0.085 mm
Clearance between the connecting rod bearing and the connecting rod bearing journal Clearance be- 0.01 –0.025 tween the pis- mm ton pin and the piston pin bearing Clearance be- 0.1 –0.3 mm tween the connecting rod bore and the connecting rod bearing
Service limit 0.2 mm
0.1 mm
C
E
0.7 mm
A B C D E
Connecting rod Piston pin bearing Connecting rod bearing Bolt Nut Table 47. Torque Values Item D
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Description Bolt
Nm 52
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33 - Connecting Rod 00 - General
Component Identification Figure 156.
Calibrate This procedure determines the characteristics of the connecting rod: • •
following
The distortion of the connecting rod. The parallel alignment of the bores of the connecting rod.
1. Make sure that you use the correct gauges and measuring pins to measure the distances for the connecting rod.
F
2. Remove the connecting rod bearing before you take the measurements. 3. Measure the connecting rod for distortion and parallel alignment between the bores.
A
3.1. The measurements must be taken at a specified distance from the connecting rod. Refer to Figure 158.
G H
Distance: 100 mm Figure 158.
A F G H
Piston Connecting rod Piston pin Piston pin retainer
E
G
F
F
G
D
Figure 157. F D E F G
K L
Connecting rod Measuring pins Distance from the connecting rod ( 100 mm) Length (Should not be more than 0 ± 0.08 mm)
3.2. The total difference in measurements of length from each side should not vary more than the specified. Length: 0 ± 0.08 mm M
4. Inspect the piston pin bearing and the piston pin for wear and other damage. 5. Measure the clearance of the piston pin in the piston pin bearing.
N F K L M N
Connecting rod Connecting rod bearing (Upper half) Connecting rod bearing (Lower half) Connecting rod cap Nut
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Remove and Install
Disassemble and Assemble
The removal and installation procedure for one piston and connecting rod assembly is exactly the same.
The disassemble and assemble procedure for one piston and connecting rod assembly is exactly the same. Refer to: PIL 15-36-00.
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33 - Connecting Rod 06 - Big-End Bearing
06 - Big-End Bearing
Introduction
Introduction .................................................... 15-97 Check (Condition) .......................................... 15-98 Remove and Install ....................................... 15-98
In a piston engine, the big-end bearings are the bearings at the big-end of the connecting rod.
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Check (Condition)
Remove and Install
1. Check the bearing shell surfaces for signs of damage and excessive wear.
If all of the connecting rod bearings require replacement on a four cylinder engine, the procedure can be carried out two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders:
Refer to: PIL 15-33-00. 2. Measure the crank pin diameters to confirm they are within service limits. Refer to: PIL 15-12-00. 3. Renew any parts that are worn or not within the specified tolerances.
• •
1 and 4 cylinders. 2 and 3 cylinders.
Make sure that both pairs of the connecting rod bearings are installed before changing from one pair of cylinders to another pair of cylinders. On three cylinder engines perform this procedure on each cylinder at a time. The connecting rod and the connecting rod cap should have matching identification numbers. If necessary, make a temporary mark on the connecting rod and on the connecting rod cap.
Remove (Connecting rods in position) 1. Remove the suction pipe. Refer to: PIL 15-60-00. 2. Rotate the crankshaft until the piston is at the BDC (Bottom Dead Centre). 3. Remove the nuts and the connecting rod cap from the connecting rod. 4. Remove the lower connecting rod bearing from the connecting rod cap. 5. Carefully push the connecting rod into the cylinder bore. 6. Remove the upper connecting rod bearing from the connecting rod. 7. Apply tape or rubber tubing on the connecting rod bolts to protect the crankshaft journals. The sharp edges of the connecting rod bolts could damage the crankshaft journals.
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Figure 159.
10. Install the lower connecting rod bearing to the connecting rod cap. 11. Lubricate the pin of the crankshaft and the lower connecting rod bearing with clean engine oil.
A
12. Install the connecting rod cap.
B
13. Install the nuts. Tighten the nuts to the correct torque value.
C
14. Make sure that the installed connecting rod assembly has tactile side play. Carefully rotate the crankshaft in order to ensure that there is no binding.
D G
15. Install the suction pipe. Refer to: PIL 15-60-00. E A B C D E F G
F
Install (Connecting rods off the position) 1. Check the clearance between the connecting rod bearing and the connecting rod bearing journal of the crankshaft. Install the connecting rod bearings dry when the clearance checks are made.
Connecting rod Connecting rod bolt Upper connecting rod bearing Lower connecting rod bearing Connecting rod cap Nut Identification mark
2. Clean the bearing surface of the connecting rod and the connecting rod cap.
Install (Connecting rods in position) 1. Inspect the pins of the crankshaft for damage. If the crankshaft is damaged, replace the crankshaft or recondition the crankshaft. Refer to: PIL 15-12-00. 2. Make sure that the connecting rod bearings are clean and free from wear or damage. If necessary, replace the connecting rod bearings. Refer to: PIL 15-33-06. 3. Clean the bearing surface of the connecting rod and the connecting rod cap. 4. Make sure that the identification number on the connecting rod cap aligns with the identification number on the connecting rod. 5. Install the upper connecting rod bearing to the connecting rod. 6. Lubricate the bearing surface of the connecting rod bearing with clean engine oil. 7. Carefully pull the connecting rod against the crankshaft pin. 8. Apply tape or rubber tubing on the connecting rod bolts to protect the crankshaft journals. The sharp edges of the connecting rod bolts could damage the crankshaft journals. 9. Clean the connecting rod cap. 15 - 99
3. Make sure that the identification number on the connecting rod cap aligns with the identification number on the connecting rod. 4. Clean the upper connecting rod bearing and lubricate the bearing face with clean engine oil. 5. Clean the lower connecting rod bearing and lubricate the bearing face with clean engine oil. 6. Align the tabs on the back of the connecting rod bearings with the tab grooves in the connecting rod and the tab grooves on the connecting rod cap. 7. Install the upper connecting rod bearing to the connecting rod. 8. Position the crankshaft.
connecting
rod
against
the
9. Install the lower connecting rod bearing in the connecting rod cap. 10. Install the connecting rod cap in position on the connecting rod and install the nuts to the connecting rod bolts. 11. Tighten the nuts to the correct torque value. 12. Make sue that the identification marks must face to the right of the engine for the correct installation. 13. Install the suction pipe.
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Refer to: PIL 15-60-00. 14. Install the engine oil sump. Refer to: PIL 15-45-00. Table 48. Torque Values Item F
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Description Nut
Nm 52
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36 - Piston Contents
Page No.
15-36-00 General ......................................................................................................................... 15-103 15-36-03 Piston Ring ................................................................................................................... 15-115
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Notes:
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00 - General Introduction .................................................. Technical Data ............................................. Component Identification ............................. Calibrate ...................................................... Remove and Install ..................................... Disassemble and Assemble ........................
Introduction 15-103 15-104 15-106 15-108 15-110 15-112
The piston is acted upon by the pressure of the expanding combustion gases in the combustion chamber space at the top of the cylinder. This force then acts downwards through the connecting rod and on to the crankshaft. The pistons are cast from aluminium alloys for increased strength and improved fatigue life. The connecting rod is attached to the piston by a swivelling piston pin. This pin is mounted within the piston, The pin itself is of hardened steel and is fixed in the piston, but free to move in the connecting rod. The pins are prevented from moving sideways and the ends of the pin digging into the cylinder wall by circlips.
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Technical Data Table 49. Top piston ring Description
Table 51. Oil control ring
Data Standard Service limit Curved Refer to Figure 160. Barrel face
Shape of ring Naturally aspirated Turbocharged Half keystone Clearance be- 0.07 –0.11 mm tween piston ring groove and top piston ring Gap of top pis- 0.2 –0.35 mm ton ring
0.25 mm
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Clearance between piston ring groove and oil control ring Gap of oil con- 0.25 –0.5 mm trol ring
0.1 mm
Description
0.1 mm
Data Standard Service limit Taper Refer to Figure 160. 0.04 –0.08 mm 0.25 mm
Shape of ring Clearance between piston ring groove and intermediate piston ring Gap of interme- 0.2 –0.4 mm diate piston ring
Data Standard Service limit 0.02 –0.06 mm 0.15 mm
Table 52. Piston
Table 50. Intermediate ring Description
Description
0.1 mm
Data Standard Service limit Diameter of the 83.948 –83.963 83.7 mm piston skirt mm Clearance of 0.038 –0.072 0.25 mm the piston skirt mm to the cylinder wall Diameter of the 27.994 –28 mm 27.98 mm piston pin Clearance be- - 0.001 mm to + 0.02 mm tween the hole 0.011 mm for the piston pin and the piston pin
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Figure 160. A B
C
B D
C E D
A Piston C Intermediate ring E Spring
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B Top ring D Oil control ring
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Component Identification Figure 161.
F
A G H
A F G H
Piston Connecting rod Piston pin Piston pin retainer
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Figure 162. A B
C
B D
C E D
A Piston C Compression ring2 E Spring
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B Compression ring1 D Oil control ring
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Calibrate
3.2. Place each piston ring in the cylinder bore. 3.3. Measure the piston ring end gap with a suitable feeler gauge.
Piston Ring Groove - Inspection
3.4. You must remove the coil spring from the oil control ring before you measure the gap of the oil control ring.
1. Inspect the piston and the piston rings as follows: Figure 163.
Piston Height- Inspection
B
The correct piston height must be maintained in order to ensure that the engine conforms to the standards for emissions. If the height of the piston above the crankcase is not within the tolerance specified, the bearing for the piston pin must be checked. Refer to: PIL 15-15.
A
If any of the following components are replaced or re-machined, the piston height above the crankcase must be measured:
A Piston ring B Feeler gauge 1.1. Check the piston for wear and other damage. 1.2. Check that the piston rings are free to move in the grooves and that the rings are not broken. 2. Inspect the clearance of the piston ring as follows: 2.1. Remove the piston rings and clean the grooves and the piston rings. 2.2. Install the new piston rings into the piston grooves.
• • • •
Crankshaft Cylinder head Connecting rod Bearing for the piston pin
The top of the piston must not be machined. If the original piston is installed, be sure that the original piston is assembled to the correct connecting rod and installed in the original cylinder only. 1. Use the dial gauge and the dial gauge holder to measure the piston height above the crankcase. 2. Use the crankcase face to zero the dial gauge. Figure 165.
2.3. Check the clearance for the piston ring with a feeler gauge.
D
3. Inspect the piston ring end gap as follows: 3.1. Clean all carbon from the top of the cylinder bores.
E
Figure 164. B
A
D Dial gauge E Dial gauge holder
C
3. Rotate the crankshaft until the piston is at the approximate top centre. A Piston ring B Feeler gauge C Piston ring groove 15 - 108
4. Position the dial gauge holder and the dial gauge to measure the piston height above the crankcase. 9813/6050-2
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15 - Engine
36 - Piston
00 - General
5. Slowly rotate the crankshaft in order to determine when the piston is at the highest position. Record this dimension. 6. Compare this dimension with the dimensions that are given in Cylinder Head- Technical Data. Refer to: PIL 15-06-00.
Connecting Rod Bearings- Inspection 1. Check the connecting rod bearings and the connecting rod bearing journal for wear or other damage. 2. The connecting rod bearings are available with a smaller inside diameter than the original size bearings. These bearings are for crankshafts that have been ground.
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36 - Piston
00 - General
Remove and Install Remove
5. Mark the connecting rod and the connecting rod cap to help to identify the cylinder number.
1. Remove the cylinder head.
5.1. The connecting rod and the connecting rod cap should have an etched number on the side. The number on the connecting rod and the connecting rod cap must match.
Refer to: PIL 15-06-00. 2. Remove the suction pipe. Refer to: PIL 15-60-00.
5.2. Make sure that the connecting rod and the connecting rod cap are marked for the correct location.
3. Position the piston at the BDC (Bottom Dead Centre) position. 4. Remove the carbon from the inner surface of the cylinder bore with the ridge reamer.
5.3. Do not stamp the connecting rod assembly. 6. Remove the nut and the connecting rod cap from the connecting rod.
Figure 166. A B C
F
E
D
A Nut C Connecting rod bearing E Piston
B Connecting rod cap D Connecting rod F Etched number
7. Put tape or rubber tubing on the threads of the connecting rod bolts to protect the crankshaft journals. The sharp edges of the connecting rod bolts can damage the crankshaft journals.
12. Do the step 3 to step 11 to remove the remaining pistons and connecting rods.
8. Carefully push the piston and the connecting rod assembly out of the cylinder bore.
1. Clean all the components thoroughly.
9. Lift the piston out of the top of the crankcase. 10. Make an identification mark below the piston on the pin boss to identify the position on the piston to help installation. Always mark the front pin boss. 11. Keep the connecting rod bearings with the respective connecting rod and cap.
15 - 110
Install 2. Apply clean engine oil to the cylinder bore, piston rings, outer surface of the piston and the connecting rod bearings. 3. If you check the clearance at the connecting rod bearing, install them dry. Apply clean engine oil only when you install the connecting rod bearing. 4. Rotate the crankshaft until the crankshaft pin is at the BDC position.
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36 - Piston
00 - General
5. Lubricate the crankshaft pin with a clean engine oil. Figure 167. G
E D
A B
F A Nut D Connecting rod F Etched number
B Connecting rod cap E Piston G Piston ring compressor
6. Make sure that the gaps for the piston rings are at specified degrees away from each other.
14. Install the suction pipe.
Angle: 120 °
Refer to: PIL 15-60-00. 15. Install the cylinder head.
7. Install piston ring compressor on the piston.
Refer to: PIL 15-06-00.
7.1. Use tape or rubber tubing on the connecting rod bolts to protect the crankshaft journals. 7.2. Make sure that the piston ring compressor is installed correctly and the piston can easily slide from it. 7.3. Make sure that the piston and the connecting rod assembly are installed in the correct cylinder. 7.4. Align etched numbers on the side of the connecting rod to the right side of the crankcase. The right side is determined from the flywheel end of the engine. 8. Carefully push the piston and the connecting rod assembly into the cylinder bore and on the crankshaft pin. 9. Install the connecting rod cap on the connecting rod. 10. Make sure that the etched number on the connecting rod cap matches etched number on the connecting rod. 11. Install the nut and tighten it to the correct torque value. 12. Do the step 2 to step 11 to remove the remaining pistons and connecting rods. 13. Make sure that the installed connecting rod assembly has tactile side play. Carefully rotate the crankshaft to ensure that there is no binding. 15 - 111
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36 - Piston
00 - General
Disassemble and Assemble Disassemble
Figure 168.
1. Remove the piston and the connecting rod. Refer to: PIL 15-36-00. 2. Mark the components of the piston and connecting rod assembly. 2.1. This will ensure that the components of each piston and connecting rod assembly can be reinstalled in the original cylinder only.
F
2.2. Mark the front of the piston and the front of the connecting rod also.
A
2.3. Do not interchange the components. 3. Keep the piston and connecting rod assembly on a suitable surface with the connecting rod facing upwards.
G H
4. Remove the retaining rings with the retaining ring pliers. Refer to Figure 168. A F G H
Piston Connecting rod Piston pin Retaining ring
5. Remove the piston pin and the connecting rod from the piston. Refer to Figure 168. 5.1. If you cannot remove the piston pin by hand then heat the piston to the specified temperature and remove the piston pin. Temperature: 45 ± 5 °C ( 112.9 ± 41.0 °F) 5.2. DO NOT use the torch to heat the piston. 6. Keep the piston on a suitable surface with the crown facing upwards. 7. Make a note of the orientation of the piston rings to help installation. Refer to Figure 169.
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36 - Piston
00 - General
Figure 169. A B
C
B D
C E D
A Piston C Compression ring 2 E Spring
B Compression ring 1 D Oil control ring
8. Remove the compression rings and the oil control ring from the piston with the ring expander tool. Refer to Figure 170. Figure 170.
J
J Ring expander tool 9. Remove the nut and the connecting rod cap from the connecting rod. Refer to Figure 171.
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36 - Piston
00 - General
Figure 171.
2.5. Install the compression ring 2 into the second groove in the piston with the ring expander tool. Refer to Figure 170.
F
2.6. Make sure that the letter “T” and the chamfer on the inner face of the compression ring 2 is facing upwards.
K
2.7. Install the compression ring 1 into the top groove in the piston with the ring expander tool. Refer to Figure 170.
L
2.8. Make sure that the letter “T” is facing upwards. 2.9. Position the piston ring gaps at the specified angle from each other. Angle: 120 °
M
3. Lubricate the bush in the connecting rod and lubricate the bore for the piston pin in the piston with a clean engine oil.
N F K L M N
4. Keep the piston on a suitable surface with the crown facing downwards.
Connecting rod Connecting rod bearing (Upper half) Connecting rod bearing (Lower half) Connecting rod cap Nut
10. Remove the lower half of the connecting rod bearing from the connecting rod cap.
5. Install the connecting rod and the piston pin to the piston. Make sure that the name "Shibaura" inside the piston must align with the stamped number on the connecting rod. 5.1. If you cannot install the piston pin by hand then heat the piston to the specified temperature and install the piston pin.
11. Remove the upper half of the connecting rod bearing from the connecting rod.
Temperature: 45 ± 5 °C ( 112.9 ± 41.0 °F)
12. Keep the bearing shells together. 13. Check the condition of the connecting rod for wear or damage. If necessary, replace the connecting rod or the bush of the piston pin.
Assemble 1. Make sure that all the components are clean and free from wear or damage. If necessary, replace the worn or damaged components.
5.2. DO NOT use the heating torch to heat the piston. 6. Make sure that the orientation of the connecting rod in the piston is correct. 7. Install the retaining rings to the piston pin bore in the piston with the retaining ring pliers. 8. Make sure that the retaining rings are seated in the grooves in the correct piston.
2. Install the piston rings on the piston as follows: Refer to Figure 169.
9. Install the upper half of the connecting rod bearing to the connecting rod.
2.1. Keep the spring at the correct position for the oil control ring into the oil ring groove in the piston.
10. Install the lower half of the connecting rod bearing to the connecting rod cap.
2.2. Make sure that the central wire is located inside the end of the spring.
11. Install the piston and the connecting rod. Refer to: PIL 15-36-00.
2.3. Install the oil control ring over the spring with the ring expander tool. Refer to Figure 170. 2.4. Make sure that the central wire is at specified angle from the ring gap. Angle: 180 °
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36 - Piston
03 - Piston Ring
03 - Piston Ring
Introduction
Introduction .................................................. 15-115 Technical Data ............................................. 15-116 Calibrate ...................................................... 15-116
Gas sealing inside the piston is achieved by the use of piston rings. The rings are loosely installed into grooves in the piston. The rings are split at a point in the rim, to allow them to press against the cylinder with a light spring pressure. Two types of ring are used: - Upper rings have solid faces and provide gas sealing - Lower rings have narrow edges and have a Ushaped profile, to act as oil scrapers.
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36 - Piston
03 - Piston Ring
Technical Data
Calibrate
Refer to Piston-Technical Data PIL 15-36-00 .
Piston Rings End Gap 1. Insert a seal ring in the cylinder and measure the ring end gap which a thickness gauge. 2. Do step 1 for all the seal rings. 3. If the ring end gap values are not within the specified range, replace the seal rings. Refer to: PIL 15-36-00. 4. Make sure you replace the seal rings as a set.
Seal Ring Seat Clearance 1. Measure the clearance of each seal ring in its seat with a thickness gauge. 2. If the clearance values are not within the specified range, replace the seal rings and the piston. Refer to: PIL 15-36-00.
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39 - Manifold
39 - Manifold Contents
Page No.
15-39-00 General ......................................................................................................................... 15-119
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Notes:
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39 - Manifold 00 - General
00 - General Introduction Refer to: PIL 18-24.
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42 - Rocker and Fittings
42 - Rocker and Fittings Contents 15-42-00 15-42-01 15-42-03 15-42-06 15-42-09 15-42-21
15 - 120
Page No. General ......................................................................................................................... Rocker Arm .................................................................................................................. Rocker Shaft ................................................................................................................ Rocker Cover ............................................................................................................... Push Rod ..................................................................................................................... Tappet ...........................................................................................................................
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15-121 15-129 15-130 15-131 15-133 15-135
15 - 120
15 - Engine
42 - Rocker and Fittings 00 - General
00 - General Introduction .................................................. Technical Data ............................................. Component Identification ............................. Operation ..................................................... Check (Condition) ........................................ Remove and Install ..................................... Disassemble and Assemble ........................
15 - 121
Introduction 15-121 15-122 15-123 15-124 15-125 15-125 15-127
The rocker assembly is an indirect valve actuating system consisting of rocker arms and a shaft. The rocker arm is an oscillating lever that conveys radial movement from the cam lobe into linear movement at the poppet valve to open it. One end is raised and lowered by a rotating lobe of the camshaft via a tappet and push rod while the other end acts on the bridge piece which is connected to the valve stem.
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42 - Rocker and Fittings 00 - General
Technical Data
Table 54. Torque Values
Table 53. Description Diameter of the rocker shaft Service limit for the rocker shaft diameter Rocker arm clearance on the rocker shaft (Minimum) Rocker arm clearance on the rocker shaft (Maximum)
A
Data 14.95 –14.97 mm
Item A B D E
Description Setscrew Nut Stud Locknut
Nm 10 33 56 14
14.87 mm 0.03 –0.093 mm 0.2 mm
Figure 172. B
A Setscrew B Nut Figure 173. D C
C Rocker shaft D Stud Figure 174. E
F C C Rocker shaft E Locknut F Rocker arm 15 - 122
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42 - Rocker and Fittings 00 - General
Component Identification Figure 175. L
H J
K
M
R N
P S
Q H J K L M N P Q R S
Adjustment screw Nut Rocker arm Spring Washer Rocker shaft O-ring seal Base Recesses Hole
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42 - Rocker and Fittings 00 - General
Operation When the camshaft lobe raises the push-rod, the push-rod pushes the rocker arm up. Due to this the rocker arm presses down on the valve stem to open the valve. When the rocker arm returns due to the camshafts rotation, the valve spring closes the valve.
Lubrication Oil is fed from the main gallery through a drilling which passes up through the crankcase and cylinder
head to a small transfer gallery under the rocker shaft pedestal. The oversize rocker shaft fixing bolt hole allows oil to pass into a drilling in the centre of the rocker shaft. Further cross drillings transfer oil to each of the rocker pivot bushes. A cross drilling in each rocker transfers oil to the top of the rocker where it flows by gravity along a groove to the rocker tip.
Figure 176.
1 3 5 7 9
Main gallery Shaft pedestal Centre rocker shaft drilling Rocker pivot bushes Groove
15 - 124
2 4 6 8
Small transfer gallery Rocker shaft fixing bolt hole Cross drillings Cross drilling
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42 - Rocker and Fittings 00 - General
Check (Condition)
Remove and Install
1. Check the rocker shaft and rocker bushings for signs of damage and excessive wear. Measure the rocker shaft diameter and rocker bearing bushes to confirm they are within service limits. Refer to Technical Data. Note: The rocker bearing bushes are not renewable. If a rocker bearing bush is damaged or worn the rocker must be renewed as a complete assembly.
Remove
Refer to: PIL 15-42. 2. Make sure that all oil-ways and cross drillings in the rocker shaft, rocker arms and pedestals are clear and free from debris. Use an air line to blow through cross drillings.
1. Make the machine safe. Refer to: PIL 01-03. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Remove the engine pipe. Refer to: PIL 15-96-00. 4. Remove the rocker cover. Refer to: PIL 15-42-06. 5. Loosen the nut 1 and the adjustment screw from all the rocker arms. 6. Remove the bolt and nut 2 from the rocker shaft assembly. 7. Remove the rocker shaft assembly from the cylinder head. 8. Mark the caps identification.
and
push
rods
to
help
9. Remove the push rod from the cylinder head. 10. Remove the cap from the valve stem. 11. Remove the joint from the base of the rocker shaft assembly. Figure 177. B A
E
C
D
F
A B C D E F
15 - 125
Bolt Nut 2 Rocker shaft assembly Adjustment screw Cap Push rod
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42 - Rocker and Fittings 00 - General
Figure 178.
Refer to: PIL 15-96-00.
C
G
C Rocker shaft assembly G Joint
Install 1. Make sure that all the components are clean and free from wear or damage. 2. Install a new joint to the base of the rocker shaft assembly. 3. Apply clean engine lubricating oil to both ends of the push rods. 4. Install the push-rods to the engine with the cup facing upwards. 5. Make sure that the push rods are installed correctly in the socket of the valve tappets. 6. Lubricate the top of the valve stems with clean engine oil. 7. Install the cap to the valve stem. 8. Install the rocker shaft assembly to the cylinder head. 9. Make sure that the end of the adjustment screw correctly seats on the push rod. 10. Install the nut 2. Use a deep socket to tighten the nuts. Begin at the centre of the rocker shaft and work outwards. 11. Install the bolt. 12. Tighten the bolt and the nut 2 to the correct torque value. 13. Adjust the valves. Refer to: PIL 15-30-00. 14. Install the rocker cover. Refer to: PIL 15-42-06. 15. Install the engine pipe. 15 - 126
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42 - Rocker and Fittings 00 - General
Disassemble and Assemble
Figure 179. L
H
WARNING Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tools to release the spring force.
J
K
M
Disassemble 1. Remove the rocker shaft assembly. Refer to: PIL 15-42-00.
R
2. Mark each of the rocker arms to help identification.
N
P
3. Install a suitable bolt into the end of the rocker shaft.
S
4. Pull the bolt to remove the rocker shaft from the base. 5. Remove the rocker arm, washer and the spring. 6. Remove the O-ring seal from the rocker shaft. 7. Remove the adjustment screw and the nut from the rocker arm.
Q H J K L M N P Q R S
Adjustment screw Nut 1 Rocker arm Spring Washer Rocker shaft O-ring seal Base Recesses Hole
Assemble 1. Make sure that you install all the components in their original locations only. DO NOT interchange components. Make sure that all the components are clean and free from wear or damage. If necessary, replace the worn or damaged components. 2. Lubricate the adjustment screw with clean engine oil. 3. Install the adjustment screw and the nut to the rocker arm. 4. Install a new O-ring seal onto the rocker shaft. 5. Lubricate the rocker shaft with clean engine oil. 6. Position the end of the rocker shaft into the bore in the base. 15 - 127
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42 - Rocker and Fittings 00 - General
7. Align the recesses on the rocker shaft with the holes in the base. 8. Gradually insert the rocker shaft into the base. 9. Install the rocker arm. 10. Continue to insert the rocker shaft and install the rocker arm, washer, spring and washer to the rocker shaft. Make sure that the rocker shaft is fully engaged into the base. 11. Check that the recesses on the rocker shaft are aligned with the holes in the base. 12. Install the rocker shaft assembly. Refer to: PIL 15-42-00.
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42 - Rocker and Fittings 01 - Rocker Arm
01 - Rocker Arm Remove and Install Refer to Rocker Assembly-Remove and Install. Refer to: PIL 15-42-00.
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42 - Rocker and Fittings 03 - Rocker Shaft
03 - Rocker Shaft Remove and Install Refer to Rocker Assembly- Disassemble-Assemble. Refer to: PIL 15-42-00.
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42 - Rocker and Fittings 06 - Rocker Cover
06 - Rocker Cover Remove and Install Remove
5. Remove the bolt 1 from the rocker cover.
1. Make the machine safe.
6. Make sure that you loosen the bolt 1 evenly to avoid distortion of the rocker cover.
Refer to: PIL 01-03. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Loosen the hose clamps and disconnect the hose from the connection. 4. Remove the nuts and the washers from the rocker cover.
7. Remove the rocker cover from the base. 8. Remove the joint from the rocker cover. 9. If necessary, remove the bolt 2 and the connection from the rocker cover. 10. Remove the gasket. 11. If necessary, remove the crankcase breather.
Figure 180.
E F
D B
C
G H
J A
A C E G J
Bolt 2 Gasket Nut Rocker cover Joint
15 - 131
B D F H
Connection Bolt 1 Washer Base
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42 - Rocker and Fittings 06 - Rocker Cover
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Make sure that the rocker cover is clean and free from damage. Clean the mating surface of the base. 3. Tighten the fasteners to the correct torque value. Table 55. Torque Values Item A D E
15 - 132
Description Bolt 2 Nut Bolt 1
Nm 14 10 14
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15 - Engine
42 - Rocker and Fittings 09 - Push Rod
09 - Push Rod
Introduction
Introduction .................................................. 15-133 Remove and Install ..................................... 15-134
Push rods are used in a reciprocating engine to open and close the valves. They are moved by the cams on the camshaft. One end is pushed up by the cam and the other end makes contact with the rocker arms which rotates and pushes the valve open.
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15 - Engine
42 - Rocker and Fittings 09 - Push Rod
Remove and Install Refer to Rocker Assembly- Remove and Install. Refer to: PIL 15-42-00.
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42 - Rocker and Fittings 21 - Tappet
21 - Tappet Introduction .................................................. Technical Data ............................................. Component Identification ............................. Remove and Install .....................................
15 - 135
Introduction 15-135 15-136 15-136 15-137
Mechanical Tappet The tappets are also known as cam followers or lifters. The tappets run on the camshaft and are made to move vertically by the action of the rotating cam. In an overhead valve engine, the tappet is installed low down in the crankcase. From there it drives the push rod up to the top of the engine, above the cylinder head. Here the rockers, arranged on a rocker shaft beneath the rocker cover, reverse the direction of the valve movement to press the valves downwards to open them.
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15 - Engine
42 - Rocker and Fittings 21 - Tappet
Technical Data
Component Identification Figure 182.
Table 56. Description Clearance between the tappet and the tappet bore (Maximum) Clearance between the tappet and the tappet bore (Service limit)
Data 0.058 mm
C B
0.08 mm A
Figure 181.
A
B
A Tappet B Crankcase C Telescopic magnet
A Tappet B Tappet bore
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42 - Rocker and Fittings 21 - Tappet
Remove and Install
Figure 184.
Remove 1. Make the machine safe. A
Refer to: PIL 01-03-27.
B
2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Remove the cylinder head.
A Tappet B Crankcase
4. Clean the bottom face of the cylinder head. Refer to: PIL 15-06-00.
3. Check the condition of the tappets as follows:
5. Remove the tappet from the crankcase with the telescopic magnet.
3.1. Inspect the seat of the push rod in the tappet for wear or damage. Make sure that the oil holes in the tappet are not restricted.
6. Mark the tappets to help to identify the correct location for installation.
3.2. Inspect the shank of the tappet for wear or damage.
7. Do the step 5 and 6 for the remaining tappets.
3.3. Inspect the face of the tappet that runs on the camshaft for wear or damage.
Figure 183.
4. Lubricate the tappet with clean engine oil.
C
5. Install the tappets into the crankcase. B
6. Make sure that the tappets are free to rotate. If the tappets have been used, make sure that the tappets are installed in their original positions.
A
7. Install the cylinder head.
A Tappet C Telescopic magnet
Install 1. It is strongly recommended that all tappets are replaced when a new camshaft is installed. 2. Clean all the tappets.
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15 - Engine
45 - Oil Sump
45 - Oil Sump Contents
Page No.
15-45-00 General ......................................................................................................................... 15-139
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15 - Engine
45 - Oil Sump 00 - General
00 - General Introduction .................................................. Technical Data ............................................. Component Identification ............................. Remove and Install .....................................
15 - 139
Introduction 15-139 15-140 15-140 15-141
The lubrication system is supplied by the oil sump that forms the lower part of the engine. Oil is taken from the sump by the gear pump and it is passed through an oil filter. The oil is then delivered under pressure through a system of passages drilled through the engine.
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15 - Engine
45 - Oil Sump 00 - General
Technical Data
Component Identification Figure 185.
Table 57. Oil sump capacity (Mini- 8.9 L mum) Oil sump capacity (Max- 10.6 L imum)
B A
C
D
A B C D E
15 - 140
E
Oil sump Joint Bolt Sealing washer Drain plug
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15 - Engine
45 - Oil Sump 00 - General
Remove and Install
2. Make sure that the engine oil sump is clean and free from damage. Clean the mating surface of the crankcase.
Remove
3. Tighten the fasteners to the correct torque value.
1. Make the machine safe.
Table 58. Torque Values
Refer to: PIL 01-03-27. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work.
Item C E
Description Bolt Drain plug
Nm 11 34
3. Drain the oil from the engine. Refer to: PIL 15-00-00. 4. Remove the sealing washer from the drain plug. 5. Remove the bolt from the engine oil sump. 6. Remove the engine oil sump from the engine. 7. Remove the joint. Figure 186.
B A
C
D
A B C D E
E
Engine oil sump Joint Bolt Sealing washer Drain plug
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 15 - 141
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51 - Timing Gear
51 - Timing Gear Contents
Page No.
15-51-00 General ......................................................................................................................... 15-143 15-51-21 Front Case ................................................................................................................... 15-146
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15 - Engine
51 - Timing Gear 00 - General
00 - General Introduction .................................................. Technical Data ............................................. Component Identification ............................. Check (Condition) ........................................
Introduction 15-143 15-144 15-145 15-145
The timing gears are located inside a casing at the front end of the engine. The engine must be timed so that the camshaft operates the valves at the correct time relative to the crankshaft position. Valve timing is achieved by ensuring that the camshaft drive gear is meshed to the crankshaft gear at their correct angular positions, Refer to EngineGeneral, Operation, The Four Stroke Cycle for more information about valve timing.
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51 - Timing Gear 00 - General
Technical Data
Engine
Table 59. Injection timing Engine 402D-05 Industrial engine
403D-07 Industrial engine 403D-11 Industrial engine
403D-15 Industrial engine
403D-15T Industrial engine
403D-17 Industrial engine 404D-15 Industrial engine 404D-22 Industrial engine
404D-22 with balancer 404D-22T Industrial engine
15 - 144
Maximum rated engine speed 2800 RPM (Revolutions Per Minute) 3000 RPM 3600 RPM 2800 RPM 3000 RPM 3600 RPM 2200 RPM 2600 RPM 2800 RPM 3000 RPM 3400 RPM 3600 RPM 2200 RPM 2400 RPM 2600 RPM 2800 RPM 3000 RPM 2200 RPM 2400 RPM 2600 RPM 2800 RPM 3000 RPM 2400 RPM 2600 RPM 2800 RPM 3000 RPM 2200 RPM 2400 RPM 2600 RPM 2800 RPM 3000 RPM 2800 RPM DERATE 3000 RPM DERATE 2800 RPM
Injection tim(1) ing (BTDC)
2600 RPM 2800 RPM 3000 RPM
19 ± 1 ° 20 ± 1 ° 20 ± 1 °
18 ± 1 °
404D-22T with balancer 404D-22TA Industrial engine
Maximum rated engine speed 2600 RPM
Injection tim(1) ing (BTDC)
2800 RPM
23 ± 1 °
19 ± 1 °
(1) Before Top Dead Center Table 60. Backlash for all gears
20 21 18 20 21 23 24 24 24 23 23 22 22 22 22 22 17 17 17 17 17 20 20 22 22 19 19 20 20 20 20
±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1° ±1°
Minimum Maximum
0.08 mm 0.25 mm
20 ± 1 ° 20 ± 1 °
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15 - Engine
51 - Timing Gear 00 - General
Component Identification
Check (Condition)
Figure 187.
1. Inspect the gears for wear or damage. If one or more of the gears are worn or damaged, replace them. 2. Measure the backlash of the gears with a feeler gauge. Refer to Figure 188.
A
Figure 188. D C
A B C D
Camshaft gear Crankshaft gear Idler gear Timing mark
B
3. Make sure that the backlash is within the specified limits. Refer to Timing gear, Technical data. Refer to: PIL 15-51-00. 3.1. If the backlash measurement is greater than the maximum, install new gears.
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15 - Engine
51 - Timing Gear 21 - Front Case
21 - Front Case
Calibrate
Calibrate ...................................................... 15-146 Remove and Install ..................................... 15-147 Disassemble and Assemble ........................ 15-149
1. Adjust the fuel governor and install the DTI (Dial Test Indicator), DTI holder and the crankcase adaptor in place. Refer to: PIL 18-18. 2. Do not move the position of the DTI, DTI holder and the crankcase adaptor. 3. Pull the plunger of the DTI until the plunger has reached the fully out position. 4. Retain the plunger in position with a suitable clip. 5. Remove the fuel injection pump. Refer to: PIL 18-18-15. 6. Remove the original front case. Refer to: PIL 15-51-21. 7. Disassemble the original front case. Refer to: PIL 15-51-21. 8. Assemble the new front case with the parts that were removed from the original front case. Install a new fuel screw and a new locknut. Refer to: PIL 15-51-21. 9. Remove the Allen head screw from the original front case. Install it to the new front case. Tighten the Allen head screw to the correct torque value. 10. Remove the calibration spring from the original front case. Install it to the new front case. 11. Install the new front case. Refer to: PIL 15-51-21. 11.1. Do not install a gasket. 12. Install the fuel injection pump. Refer to: PIL 18-18-15. 12.1. Install the original shim. 13. Remove the clip from the plunger of the DTI.
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15 - 146
15 - Engine
51 - Timing Gear 21 - Front Case
Remove and Install Remove
J K L M
1. Make the machine safe.
Install
Refer to: PIL 01-03.
Bolt 1 Bolt 2 Washer 2 Washer 1
1. Make sure that the front housing assembly and the nose of the crankshaft are clean and free from damage.
2. Remove the fuel injection pump. Refer to: PIL 18-18-15.
2. Clean the mating surface of the plate.
3. Remove the crankshaft pulley. Refer to: PIL 15-12-12. 4. If the turbocharger is installed, disconnect the hose from the connection.
3. Install the seal protector tool on the nose of the crankshaft. Figure 190.
5. Remove the nut 1, bolt 1 and the washer 1. Q
6. Remove the cover and the O-ring seal. 7. Remove the nut 2, bolt 2 and the washer 2. 8. Identify the position of the different fasteners to help installation. 9. Carefully remove the front housing from the plate.
P
10. Make sure that the pin remains in the front housing. The front housing is aligned to the plate and to the crankcase with the dowels.
N N Oil pump cover P Idler gear assembly Q Seal protector tool
11. Remove the joint. Figure 189. A
B
4. Align the pin with the hole in the oil pump cover.
L
K C
M D
E
F G
A B C D E F G H
J
H
Connection Pin Nut 2 Nut 1 Plate Front housing O-ring seal Cover
15 - 147
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15 - Engine
51 - Timing Gear 21 - Front Case
Table 61. Torque Values
Figure 191. Item C D
R
Description Nut 2 Nut 1
Nm 10 50
B
B Pin R Hole 5. Make sure that the oil pump cover is concentric to the idler gear assembly. 6. Install a new joint to the plate. 7. Guide the linkage for the fuel injection pump into position so that the link is free to move inside the aperture on the crankcase for the fuel injection pump. 8. Align the front housing to the dowels in the plate. 9. Install the front housing to the plate. 10. Install the bolt 2, washer 2 and the nut 2. Tighten the nut 2 to the correct torque value. 11. Remove the seal protector tool from the nose of the crankshaft. 12. Install a new O-ring seal to the front housing. 13. Position the cover on the front housing and install the nut 1, bolt 1 and the washer 1. 14. Tighten the nut 1 to the correct torque value. 15. If the turbocharger is installed, connect the hose to the connection. 16. Install the crankshaft pulley. Refer to: PIL 15-12-12. 17. Install the fuel injection pump. Refer to: PIL 18-18-15. 15 - 148
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15 - 148
15 - Engine
51 - Timing Gear 21 - Front Case
Disassemble and Assemble Consumables Description JCB Threadlocker and Sealer (Medium Strength)
Part No. 4101/0250 4101/0251
Figure 193. Size 0.01 L 0.05 L
C A
WARNING Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tools to release the spring force.
E
Disassemble
F
1. Record the governor settings. 2. Remove the timing gear front case. Refer to: PIL 15-51-21.
A C E F
3. Remove the spring from the arm on the throttle control assembly. Refer to Figure 192. Figure 192.
Throttle control assembly Front case Bolt Joint
6. Remove the shaft 1 from the front case. Refer to Figure 194. 7. Remove the lever assembly 1 from the front case. Refer to Figure 194.
A B
Figure 194. C
G
C D R A B C D R
Throttle control assembly Arm Front housing Spring Fuel screw
H
4. Remove the bolt and the throttle control assembly from the front case. Refer to Figure 193. 5. Remove the joint. Refer to Figure 193.
C G H J
J
Front case Lever assembly 1 Sealing washer 1 Shaft 1
8. Remove the sealing washer 1 from the shaft 1. Refer to Figure 194. 9. If installed, remove the adjuster unit from the lever assembly 1. Refer to Figure 195.
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15 - Engine
51 - Timing Gear 21 - Front Case
Figure 197.
Figure 195.
L
M G
C
K
G Lever assembly 1 K Adjuster unit 10. Disconnect the spring from the front case. Refer to Figure 196.
Q
11. Remove the nut and the sealing washer 2 from the front case. Refer to Figure 196.
R
Figure 196.
C L M Q R
M
C
L
Front case Lever assembly 2 Spring Shaft 2 Fuel screw
13. Remove the spring assembly and the sealing washer 3 from the front case. Refer to Figure 198. Figure 198.
N
P
C
S
R
T C L M N P
Front case Lever assembly 2 Spring Sealing washer 2 Nut
12. Remove the shaft 2 and the lever assembly 2 from the front case. Refer to Figure 197.
V
U
W
C R S T U V W
Front case Fuel screw Spring assembly Sealing washer 3 Sealing washer 4 Locknut Cap
13.1. The position of the fuel screw controls the emissions of the engine. 13.2. Do not remove the fuel screw unless a different front case will be installed. 13.3. Do not adjust the fuel screw. 15 - 150
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15 - 150
15 - Engine
51 - Timing Gear 21 - Front Case
14. If necessary, remove the cap, locknut and the sealing washer 4 from the front case. Refer to Figure 198. 15. Remove the fuel screw.
10. Connect the spring to the front case. Refer to Figure 197. 11. If removed, install the adjuster unit as follows. 11.1. Apply threadlocker on the first two threads of the adjuster unit.
Assemble
Consumable: JCB Threadlocker Sealer (Medium Strength)
1. Make sure that all the components are clean and free from contamination.
and
11.2. Install the adjuster unit to the lever assembly. Refer to Figure 195.
Figure 199.
11.3. Tighten the adjuster unit to the correct torque value.
C
11.4. Make sure that the threadlocker does not contaminate the plunger assembly of the adjuster unit. Contamination of the plunger assembly will make the adjuster unit inoperative. 12. Install a new sealing washer1 to the shaft 1. Refer to Figure 194. 13. Place the lever assembly 1 in position in the front case and install shaft1. 14. Tighten the shaft 1 to the correct torque value.
R
15. Make sure that the lever assembly 1 is in the correct orientation.
C Front case R Fuel screw 2. Make sure that the fuel screw is adjusted correctly. 3. If you install the new front case, do the following steps. Refer to Figure 198. 3.1. Install the fuel screw to the front case. 3.2. Install a new sealing washer 4 to the fuel screw. 3.3. Loosely install the locknut to the fuel screw. 3.4. Install a new emissions label on the front case. 4. Install a new sealing washer 3 to the spring assembly. Refer to Figure 198. 5. Loosely install the spring assembly to the front case. 6. Place the lever assembly 2 in position in the front case and install the shaft 2. Refer to Figure 197. 7. Make sure the correct orientation of the lever assembly 2. 8. Install a new sealing washer 2 and the nut to the front case. Refer to Figure 196. 9. Tighten the nut to the correct torque value. 15 - 151
16. Position a new joint and throttle control assembly onto the front case. Refer to Figure 193. 17. Install the bolts and tighten to the correct torque value. 18. Install the spring. Refer to Figure 192. 19. If the position of the fuel screw has been altered, the fuel screw must be reset. 20. Install the timing gear front case. Refer to: PIL 15-51-21. 21. Set the position of the spring assembly. Refer to Figure 198. 22. Tighten the spring assembly to the correct torque value. 23. Install a new cap to the nut. Refer to Figure 198. Table 62. Torque Values Item E J K P S
9813/6050-2
Description Bolt Shaft 1 Adjuster unit Nut Spring assembly
Nm 11 16 6 6 34
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15 - Engine
54 - Flywheel
54 - Flywheel Contents
Page No.
15-54-00 General ......................................................................................................................... 15-153 15-54-03 Housing ........................................................................................................................ 15-158
15 - 152
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15 - 152
15 - Engine
54 - Flywheel 00 - General
00 - General Introduction .................................................. Technical Data ............................................. Check (Condition) ........................................ Calibrate ...................................................... Remove and Install .....................................
Introduction 15-153 15-154 15-155 15-155 15-156
Flywheels are used to provide continuous energy in systems, where the energy source is not continuous. In such cases, the flywheel stores energy when torque is applied by the energy source, and it releases stored energy when the energy source is not applying torque to it. In a reciprocating engine, a flywheel is used to maintain constant angular velocity of the crankshaft. The flywheel, which is mounted on the crankshaft, stores energy when torque is exerted on it by a firing piston, and it releases energy to its mechanical loads when no piston is exerting torque on it.
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15 - Engine
54 - Flywheel 00 - General
Technical Data Table 63. Description Maximum flywheel runout
Data 0.2 mm
Figure 200.
E
B
A
D
C
A Flywheel C Back plate E Back plate setscrew
B Ring gear D Flywheel setscrew
Table 64. Torque Values Item D E
15 - 154
Description Flywheel setscrew Back plate setscrew
Nm 74 25
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15 - 154
15 - Engine
54 - Flywheel 00 - General
Check (Condition)
Calibrate
1. Make the machine safe.
Alignment Check of the Flywheel Face
Refer to: PIL 01-03-27. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work.
1. Install the DTI (Dial Test Indicator). Refer to Figure 201. Figure 201.
3. Clean the flywheel thoroughly. 4. Inspect the flywheel visually for cracks and/or damage. 5. Check the alignment of the flywheel face. Refer to: PIL 15-54-00. 6. Check the flywheel face run-out. Refer to: PIL 15-54-00.
A
6.1. Make sure that the flywheel run-out is not more than the specified. Refer to: PIL 15-54-00.
A DTI 2. Set the pointer of the DTI to show the zero reading. 3. Turn the flywheel. Read the DTI for every specified rotation angle. 3.1. During the check, keep the crankshaft pressed towards the front of the engine to remove any end clearance. 4. Calculate the difference between the lowest measurement and the highest measurement of the four locations. This difference must not be greater than 0.03 mm for every 25 mm of the radius of the flywheel. The radius of the flywheel is measured from the axis of the crankshaft to the contact point of the DTI.
Flywheel Run-out Check 1. Install the DTI. Refer to Figure 202.
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15 - 155
15 - Engine
54 - Flywheel 00 - General
Remove and Install
Figure 202.
Special Tools Description Static Oven (240V)
Part No. 992/12400
Qty. 1
CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device. CAUTION To avoid burning, wear personal protective equipment when handling hot components. To protect your eyes, wear goggles when using a brush to clean components. A
Remove
A DTI 2. Set the pointer of the DTI to show the zero reading. 3. Turn the flywheel. Read the DTI for every specified rotation angle. 3.1. During the check, keep the crankshaft pressed towards the front of the engine to remove any end clearance.
1. Make the machine safe. Refer to: PIL 01-03. 2. Remove the starter motor. Refer to: PIL 15-75-00. 3. Install the lifting bracket on the flywheel and install a suitable lifting device. 3.1. Support the weight of the housing. The weight of the flywheel housing is approximately
4. Calculate the difference between the lowest measurement and the highest measurement of the four locations. 5. Make sure that the difference is not greater than the specified. Dimension: 0.2 mm
Weight: 42 kg 4. Remove the bolt 1 (x2) from the flywheel. 5. Install the guide stud (M10 x 1.25 mm by 80 mm) in the positions of the bolt 1 on the flywheel. Figure 203.
D
C A
A B C D 15 - 156
9813/6050-2
B Flywheel Bolt 1 (x2) Bolt 2 Lifting bracket 15 - 156
15 - Engine
54 - Flywheel 00 - General
Figure 205.
6. Remove the bolt 2 (x4). 7. Remove the flywheel. 8. Inspect the ring gear and the flywheel for wear or damage. If the ring gear or the flywheel is worn or damaged, it must be replaced. 9. If necessary, remove the ring gear from the flywheel as follows:
A E G
9.1. Keep the flywheel on a suitable support to remove the ring gear from the flywheel. Figure 204.
A Flywheel E Ring gear G Chamfered side of the gear teeth 1.3. Heat the ring gear in an oven to a maximum specified temperature.
A
Temperature: 150 °C ( 301.8 °F) Special Tool: Static Oven (240V) (Qty.: 1) 1.4. Do not use a heat torch to heat the ring gear. 1.5. Make sure that the orientation of the ring gear is correct and quickly install the ring gear onto the flywheel. F
E
2. Clean the flywheel housing thoroughly.
A Flywheel E Ring gear F Punch
3. Inspect the rear oil seal for leaks. If necessary, replace the rear oil seal.
9.2. Remove the ring gear from the flywheel with a hammer and a punch.
Install 1. If removed, install the ring gear to the flywheel as follows: 1.1. Identify the orientation of the new ring gear to install the ring gear correctly onto the flywheel. 1.2. Make sure that the chamfered side of the gear teeth are facing towards the starter motor when the flywheel is installed. This is to make sure that the starter motor engages correctly.
Refer to: PIL 15-12-09. 4. Install the guide stud (M10 x 1.25 mm by 80 mm) at the positions of bolt1 in the crankshaft. Refer to Figure 203. 5. Install the lifting bracket and a suitable lifting device to the flywheel. 6. Position the flywheel onto the guide studs. 7. Install the bolt 2 (x4) and finger tighten them. 8. Remove the guide studs and install the bolt 1 (x2). 9. Use a suitable tool to prevent the flywheel from rotating. 10. Tighten the bolts to the correct torque value. 11. Remove the lifting bracket and the lifting device from the flywheel. 12. Install the starter motor. Refer to: PIL 15-75-00. Table 65. Torque Values Item B C
15 - 157
9813/6050-2
Description Bolt 1 Bolt 2
Nm 75 75 15 - 157
15 - Engine
54 - Flywheel 03 - Housing
03 - Housing
Calibrate
Calibrate ...................................................... 15-158 Remove and Install ..................................... 15-159
Face Run-out (Axial Eccentricity) 1. Fasten the DTI (Dial Test Indicator) to the flywheel so the anvil of the DTI is in contact with the face of the flywheel housing. Refer to Figure 206. Figure 206.
A
A DTI 2. Put a force on the crankshaft towards the rear before the DTI is read at each point. 3. Set the pointer of the DTI to show the zero reading. 4. Turn the flywheel as shown. Read the DTI at the specified four locations. Refer to Figure 207. Figure 207. TOP
3
4
2
1 BOTTOM
4.1. For SAE5 flywheel housing - The difference between the lower measurements and the higher measurements that are performed at all four points must not be more than the specified. Dimension: 0.2 mm 4.2. For SAE4 flywheel housing - The difference between the lower measurements and the higher measurements that are performed at 15 - 158
9813/6050-2
15 - 158
15 - Engine
54 - Flywheel 03 - Housing
all four points must not be more than the specified.
Remove and Install CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.
Dimension: 0.23 mm These measurements are the maximum permissible face run-out (axial eccentricity) of the flywheel housings.
Bore Run-out (Radial Eccentricity)
Remove 1. Make the machine safe. Refer to: PIL 01-03.
1. Fasten the DTI to the flywheel so that the anvil of the DTI is in contact with the bore of the flywheel housing. Refer to Figure 206.
2. Remove the flywheel.
2. Put a force on the crankshaft towards the rear before the DTI is read at each point.
3. Support the engine.
3. Set the pointer of the DTI to show the zero reading.
4. Install a suitable lifting device to the flywheel housing.
4. Turn the flywheel as shown. Read the DTI at the specified four locations. Refer to Figure 207.
4.1. Support the weight of the housing. The weight of the flywheel housing is approximately
4.1. For SAE5 flywheel housing - The difference between the lower measurements and the higher measurements that are performed at all four points must not be more than the specified. Dimension: 0.2 mm 4.2. For SAE4 flywheel housing - The difference between the lower measurements and the higher measurements that are performed at all four points must not be more than the specified. Dimension: 0.23 mm These measurements are the maximum permissible bore run-out (axial eccentricity) of the flywheel housings.
Refer to: PIL 15-54-00.
Weight: 30 kg 5. Remove the bolt 1 and bolt 4 from the flywheel housing. 6. Remove the bolt 2 from each side of the crankcase. 7. Remove the bolt 3 from the back plate. 8. Remove the nut from the back plate. 9. Remove the flywheel housing from the back plate and the dowels. 10. Remove the flywheel housing with a suitable lifting device. Figure 208. A E
B C
F D G H A B C D E 15 - 159
Bolt 3 Back plate Bolt 1 Bolt 4 Nut
9813/6050-2
15 - 159
15 - Engine
54 - Flywheel 03 - Housing
Table 66. Torque Values
F Bolt 2 G Dowels H Flywheel housing
Item A C D F
Figure 209.
Description Bolt 3 Bolt 1 Bolt 4 Bolt 2
Nm 25 25 25 25
H
H Flywheel housing
Install 1. Make sure that the mating surfaces of the flywheel housing are clean and free from damage. 2. Inspect the crankshaft rear oil seal for leaks. If necessary, replace the crankshaft rear oil seal. Refer to: PIL 15-12-09. 3. Inspect the dowels for damage. If the dowels are damaged, replace them. 4. Align the flywheel housing to the dowels and install the flywheel housing. Use a suitable lifting device to lift the flywheel housing. 4.1. Support the weight of the housing. The weight of the flywheel housing is approximately Weight: 30 kg 5. Install the flywheel housing to the back plate. 6. Remove the nut from the back plate. 7. Remove the bolt 3 and the bolt 4 from the back plate. 8. Remove the bolt 2 from each side of the crankcase. 9. Remove the bolt1 from the flywheel housing. 10. Tighten all the bolts to the correct torque value. 11. Install the flywheel. Refer to: PIL 15-54-00. 15 - 160
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15 - 160
15 - Engine
60 - Oil Pump
60 - Oil Pump Contents
Page No.
15-60-00 General ......................................................................................................................... 15-163 15-60-06 Pressure Relief Valve ................................................................................................... 15-171
15 - 161
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15 - 161
Notes:
15 - 162
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15 - Engine
60 - Oil Pump 00 - General
00 - General Introduction .................................................. Technical Data ............................................. Component Identification ............................. Operation ..................................................... Check (Condition) ........................................ Remove and Install .....................................
15 - 163
Introduction 15-163 15-164 15-165 15-166 15-166 15-168
The oil pump is a rotor type pump. The pump is driven by the crankshaft. The pump consists of two rotors, one running inside the other. The outer rotor has one lobe more than the inner rotor, and turns on a different axis.
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15 - Engine
60 - Oil Pump 00 - General
Technical Data
Figure 211. M
Table 67. Description
K
Data Standard Gerotor pump 4
Service limit Pump type Number of lobes on inner rotor Number of 5 lobes on outer rotor Clearance be- 0.01 –0.15 mm 0.25 mm tween inner and outer rotor (Refer to Figure 211. ) Distance be0.1 –0.15 mm 0.2 mm tween the face of oil pump cover and the face of the idler gear (Refer to Figure 212. )
F
H
F H K M
Inner rotor Outer rotor Idler gear Clearance between inner and outer rotor Figure 212. E K
Figure 210. A
B
A B C D E F G H J K L
D
Circlip Collar Spring Shim Oil pump cover Inner rotor Spring Outer rotor Bushing Idler gear Thrust washer
15 - 164
G
E
C
F
H
J
K
L
N
P
E Oil pump cover K Idler gear N Distance between the face of oil pump cover and the face of the idler gear P Dial indicator The distance between the face of oil pump cover and the face of the idler gear Refer to Figure 212. can be adjusted with the shims. The following sizes of shims are available. • • • •
9813/6050-2
0.1 mm 0.15 mm 0.2 mm 0.5 mm
15 - 164
15 - Engine
60 - Oil Pump 00 - General
Component Identification
Figure 215. E
Figure 213. A
D
B
A B C D E F G H J K L
E
C
F
K G
H
J
K
L N
Circlip Collar Spring Shim Oil pump cover Inner rotor Spring Outer rotor Bushing Idler gear Thrust washer
P
E Oil pump cover K Idler gear N Distance between the face of oil pump cover and the face of the idler gear P Dial indicator
Figure 214. M K
H
F H K M
F
Inner rotor Outer rotor Idler gear Clearance between inner and outer rotor
15 - 165
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15 - 165
15 - Engine
60 - Oil Pump 00 - General
Operation
Check (Condition)
The pressure for the lubrication system is supplied by an engine oil pump which uses rotors. The oil pump is part of the idler gear. The idler gear is driven by the crankshaft gear.
If any part of the engine oil pump is worn enough in order to affect the performance of the engine oil pump, the engine oil pump must be replaced. Do the following steps to inspect the engine oil pump.
The oil pump has an inner rotor and an outer rotor. The axes of rotation of the rotors are off-centre relative to each other. There is a pin that is inserted through a hole in the oil pump cover into the outer rotor. The pin functions as a key in order to keep the outer rotor in a fixed position with the idler gear.
1. Make the machine safe.
The outer rotor is pressed into the bush. The bush is pressed into the idler gear.
3. Remove the timing gear front case.
The inner rotor has four lobes which mesh with the five lobes of the outer rotor. When the outer lobe rotates, the distance increases between the lobes of the outer rotor and the lobes of the inner rotor to create suction. Then, the space between the lobes is filled with oil. When the distance decreases between the lobes, pressure is created. This pressure forces the oil into the chamber for the engine oil relief valve.
Refer to: PIL 01-03-27. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. Refer to: PIL 15-51-21. 3.1. If the front case is not installed, do not turn the crankshaft. Damage to the engine may occur. 4. Disassemble the oil pump. Refer to: PIL 15-60-00. 4.1. Do not remove the bushing from the idler gear unless there is damage. Figure 216. A
D
B
A B C D E F G H J K L
G
E
C
F
H
J
K
L
Circlip Collar Spring Shim Oil pump cover Inner rotor Spring Outer rotor Bushing Idler gear Thrust washer
5. Clean all of the parts and inspect the parts for cracks in the metal or other damage. 6. Look for wear on the components. Make sure that the bushing is not loose in the idler gear. 7. Install the idler gear and the inner rotor on the shaft. Measure the clearance between the inner rotor and the outer rotor. 7.1. Make sure that the clearance is within the specified limit. Refer to: PIL 15-60-00. 15 - 166
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15 - 166
15 - Engine
60 - Oil Pump 00 - General
Figure 217.
Refer to: PIL 15-60-00. 9. Install the components of the engine oil pump and the front case on the crankcase.
M
10. Make sure that both the dowels align with the bushing, the outer rotor and the holes in the idler gear.
K
11. Align the timing marks. Refer to: PIL 15-60-00.
F
H
F H K M
Inner rotor Outer rotor Idler gear Clearance between inner and outer rotor
8. Measure the distance between the circlip and the collar with a feeler gauge. 8.1. Make sure that the distance between the circlip and the collar, when the components of the engine oil pump are installed on the front housing: 8.2. For new components, the distance should be within the specified range: Distance: 0.1 –0.15 mm 8.3. For used components, the distance should be less than the specified: Distance: 0.2 mm Figure 218.
Y Y Feeler gauge 8.4. The distance between the circlip and the collar can be adjusted with the shims. 15 - 167
9813/6050-2
15 - 167
15 - Engine
60 - Oil Pump 00 - General
Remove and Install WARNING Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tools to release the spring force.
4. Remove the suction pipe as follows. Refer to Figure 220. 4.1. Remove the oil sump. Refer to: PIL 15-45-00. Figure 220.
WARNING: Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Remove
K
1. Make the machine safe. Refer to: PIL 01-03.
M
2. Remove the timing gear front case.
K L M N
Refer to: PIL 15-54-00. 2.1. If the front case is not installed, do not turn the crankshaft. Damage to the engine may occur.
4.4. Remove the crankcase.
Figure 219.
A B C D E F G H J
suction
pipe
from
the
4.5. Remove the O-ring seal from the suction pipe.
C D
O-ring seal Oil tube assembly Bolt 1 Oil strainer
4.3. Inspect the oil strainer for damage. If damaged, replace the oil strainer.
3.1. Remove the C-clip that retains the idler gear on the idler hub.
B
N
4.2. Remove the bolt 1 and the oil strainer from the crankcase.
3. Remove the oil pump from the idler hub as follows. Refer to Figure 219.
A
L
5. Remove the idler hub as follows. Refer to Figure 221. E
F
5.1. Remove the camshaft. G
H
Refer to: PIL 15-15-00. J
5.2. Remove the bolt 2 and the plate from the crankcase.
Idler hub Thrust washer Idler gear Inner rotor Oil pump cover Shim Spring Collar Retaining ring
3.2. Remove the collar, spring, shim and the oil pump cover. 3.3. Remove the idler gear. 3.4. Remove the inner rotor. 3.5. Remove the thrust washer. 15 - 168
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60 - Oil Pump 00 - General
Q
Figure 221.
1.4. Hit the guide plate of the alignment tool with a hammer. 1.5. Drive the idler hub into the crankcase until the guide plate contacts the front of the crankcase.
P R
1.6. Remove the alignment tool. 1.7. Install the crankshaft.
S
Refer to: PIL 15-12-00. 1.8. Position a new joint on the crankcase. Refer to Figure 221. T
P Q R S T
1.9. Align the plate with the dowels in the crankcase. 1.10. Install the plate.
Plate Joint Camshaft Bolt 2 Crankshaft
1.11. Install the bolt 2 and tighten to the correct torque value. 1.12. Install the camshaft. Refer to: PIL 15-15-00.
5.3. Remove the joint.
2. Install the engine oil pump as follows. Refer to Figure 219.
5.4. Remove the crankshaft. Refer to: PIL 15-12-00. 5.5. Remove the idler hub from the crankcase with a hammer and a suitable drift. Align the drift to the rear face of the hub and drive the hub from the inside of the crankcase outwards. Refer to Figure 222.
Install 1. Install the idler hub as follows. Refer to Figure 222.
2.1. Install the thrust washer. 2.2. Lubricate the thrust washer with clean engine oil. 2.3. Apply grease to the faces of the inner rotor and to the vanes of the idler gear. 2.4. Align the timing marks on the idler gear with the respective timing marks on gear 1 and gear 2. Refer to Figure 223. Figure 223.
1.1. Install the pin of the alignment tool to the crankcase.
U
Figure 222. W
X
W
X
C
V
A A Idler hub W Alignment tool 1.2. Install the idler hub into the guide plate of the alignment tool. 1.3. Align the guide plate of the alignment tool with a pin of the alignment tool. 15 - 169
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C U V X
Idler gear Gear 1 Gear 2 Timing mark
2.5. Install the idler gear onto the idler hub. 15 - 169
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60 - Oil Pump 00 - General
2.6. Install the inner rotor to the idler gear. 2.7. Install the collar, spring, shim and the oil pump cover. Refer to Figure 219. 2.8. Install the retaining ring on the idler hub. 2.9. Measure the end play of the engine oil pump with a feeler gauge. Refer to Figure 224. Refer to: PIL 15-60-00. Figure 224.
Y Y Feeler gauge 3. If removed, install the suction pipe as follows. Refer to Figure 220. 3.1. Install a new O-ring seal on the oil tube assembly. 3.2. Install the oil suction pipe in the crankcase. 3.3. Install the oil strainer to the crankcase. 3.4. Tighten the bolt 1 to the correct torque value. 4. Install the front case. Refer to: PIL 15-54-00. 4.1. If the front case is not installed, do not turn the crankshaft. Damage to the engine may occur. 5. Install the oil sump. Refer to: PIL 15-45-00. Table 68. Torque Values Item M S
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Description Bolt1 Bolt2
Nm 10 11
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15 - Engine
60 - Oil Pump
06 - Pressure Relief Valve
06 - Pressure Relief Valve
Introduction
Introduction .................................................. 15-171 Remove and Install ..................................... 15-172
The oil pressure relief valve is used to control the oil pressure of the engine. Oil pressure can build up due to an engine malfunction, low volume of oil, instrument or equipment failure. The relief valve is designed or set to open at a predetermined set pressure to protect pressure vessels and other equipment from being subjected to pressures that exceed their design limits. When the set pressure is exceeded, the relief valve becomes the path of least resistance, as the valve is forced open and a portion of the fluid is diverted through the auxiliary route.
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60 - Oil Pump
06 - Pressure Relief Valve
Remove and Install
Table 69. Torque Values Item B
Remove
Description Oil pressure relief valve
Nm 64
1. Make the machine safe. Refer to: PIL 01-03-27. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Remove the oil pressure relief valve from the crankcase. 4. Remove the O-ring seal from the oil pressure relief valve. Figure 225. A B
A O-ring seal B Oil pressure relief valve
Install 1. Make sure that all the components are clean and free from damage. 2. Install a new O-ring seal to oil pressure relief valve. 3. Lubricate the oil pressure relief valve with a clean engine oil. 4. Install the oil pressure relief valve into the crankcase. 5. Tighten the oil pressure relief valve to the correct torque value. 15 - 172
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69 - Oil Cooler
69 - Oil Cooler Contents
Page No.
15-69-00 General ......................................................................................................................... 15-175
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Notes:
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69 - Oil Cooler 00 - General
00 - General Introduction .................................................. Component Identification ............................. Operation ..................................................... Remove and Install .....................................
15 - 175
Introduction 15-175 15-176 15-176 15-177
The oil cooler and filter are incorporated in a housing that is bolted to the side of the crankcase. The housing allows transfer of lubricating oil from the crankcase to the oil cooler and filter head.
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69 - Oil Cooler 00 - General
Component Identification
Operation
Figure 226. A
The oil cooler housing allows transfer of lubricating oil from the crankcase to the oil cooler and filter head. The cooled and filtered oil then passes back into the main oil gallery into the crankcase. B C D
F
A B C D E F
E
Hoses Hose clamps Oil cooler Adaptor Oil filter element O-ring seal
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69 - Oil Cooler 00 - General
Remove and Install
Install
Remove
1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps.
1. Make the machine safe.
2. Tighten the adaptor to the correct torque value.
Refer to: PIL 01-03-27. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work.
3. Fill the cooling system. Refer to: PIL 21-00-00. 4. Fill the engine oil.
3. Drain the cooling system.
Refer to: PIL 15-00-00.
Refer to: PIL 21-00-00.
Table 70. Torque Values
4. Drain the engine oil.
Item D
Refer to: PIL 15-00-00.
Description Adaptor
Nm 34
5. Remove the oil filter element with a strap wrench (if required). 6. Loosen the hose clamps and disconnect the hoses. 7. Make a note of the positions of the coolant inlet and the coolant outlet to help installation. 8. Remove the adaptor. 9. Remove the oil cooler from the crankcase. 10. Mark the oil cooler to show its orientation to help installation. 11. Remove the O-ring seal from the oil cooler. Figure 227. A
B C D F
A B C D E F
E
Hoses Hose clamps Oil cooler Adaptor Oil filter element O-ring seal
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72 - Alternator
72 - Alternator Contents
Page No.
15-72-00 General ......................................................................................................................... 15-179
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15 - Engine
72 - Alternator 00 - General
00 - General Introduction .................................................. Health and Safety ........................................ Technical Data ............................................. Component Identification ............................. Check (Condition) ........................................ Remove and Install .....................................
15 - 179
Introduction 15-179 15-180 15-181 15-182 15-182 15-184
The alternator is a three phase generator having a rotating field winding and static power windings. When the ignition switch is turned on, the current from the battery flows by way of the No Charge warning light to the field winding. This creates a magnetic field which supplements the residual magnetism in the rotor poles. As the engine is started, the FEAD (Front End Accessory Drive) belt drives the rotor and the alternating current is generated in the power windings as they are cut by the rotating magnetic field. Output is controlled by a solid state regulator which varies the field current in accordance with electrical demand.
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72 - Alternator 00 - General
Health and Safety • •
•
•
•
Ensure that the battery negative terminal is connected to the earthing cable. Never make or break connections to the battery or alternator, or any part of the charging circuit whilst the engine is running. Disregarding this instruction will result in damage to the regulator or rectifying diodes. Main output cables are 'live' even when the engine is not running. Take care not to earth connectors in the moulded plug if it is removed from the alternator. During arc welding on the machine, protect the alternator by removing the moulded plug (or if separate output cables installed, remove the cables). If slave starting is necessary, connect the second battery in parallel without disconnecting the vehicle battery from the charging circuit. The slave battery may then be safely removed after a start has been obtained. Take care to connect batteries positive to positive, negative to negative.
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72 - Alternator 00 - General
Technical Data Table 71. Voltage Current Direction of rotation Polarity Output voltage
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12 V 85 A Clockwise (viewed from the pulley) Negative ground to the case 13.5 –14.5 V
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Component Identification Figure 228.
A
Check (Condition) Charging Circuit Test 1. Make sure that all the battery and alternator connections are in place, secure and making good metal - to - metal contact, especially the earth connections to chassis and engine. 2. Adjust the alternator drive belt tension if necessary and make sure that the battery is well charged. 3. Turn the ignition switch to the ON position. Oil pressure and ''No Charge'' warning lights should glow. If any light fails, re-check the connections.
A Alternator
4. Start the engine; all warning lights should extinguish rapidly. If the ''No Charge'' warning light remains ON, re-check the alternator drive belt tension and that the battery is charged. If the oil pressure warning remains on stop the engine Immediately and investigate the engine lubrication system.
Check 1 With the ignition switch ON, check that the heater motor and screen wiper will operate. If they operate normally, check the warning light bulb for a blown filament. Simultaneous failure of all items indicates a fault at the ignition switch. Check for cable disconnection before condemning the switch itself. If the 'No Charge' warning bulb is in good order, withdraw the triple plug from the back of the alternator. Make a temporary connection between the small terminal in the plug and earth as shown below. If the 'No Charge' warning bulb still fails to light, check the cable for continuity. If the bulb now lights, check the alternator for a defective regulator. Figure 229.
Check 2 The following checks should be made using an analogue (moving pointer) type Multimeter. 15 - 182
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72 - Alternator 00 - General
1. Stop the engine and turn the ignition switch to OFF. 2. Withdraw the alternator plug and connect the Multimeter between the large terminals and earth. With the Multimeter set to measure,
4. Alternatively, operate the starter for a few moments with the ESOS (Engine Shut-Off Solenoid) fuse removed. 5. Install an open type shunt between the battery positive lead and the battery positive terminal.
Voltage: 12 V
Current: 100 A Figure 230.
6. Connect a Multimeter positive lead to machine side of the shunt and negative lead to battery side of the shunt. 7. Connect the leads to the Multimeter and set the Multimeter to the relevant range as follows. 8. AVO 2002 8.1. Red lead to volts (middle) socket on Multimeter. 8.2. Black lead to negative on Multimeter.
2.1. The Multimeter voltage.
should
show
8.3. Right side slider to DC (Direct Current) voltage.
battery
2.2. If the reading is zero, check the cables for continuity, particularly at the starter terminals.
8.4. Left side slider,Refer to Figure 231. 9. AVO 2003
3. If the voltage is correct, check the alternator.
9.1. Red lead to amps socket (A) on the Multimeter.
Alternator Charging Test
9.2. Black lead to negative on Multimeter. 9.3. Right side slider to DC voltage
Figure 231.
9.4. Left side slider to 200 Shunt 10. FLUKE 85 10.1. Red lead to volts socket (V ) on Multimeter. 10.2. Black lead to COM socket on Multimeter. 10.3. Set dial to mV. 11. Start the engine and run at maximum speed (see Technical Data). Multimeter should show maximum alternator output in Amps (see Technical Data). The Multimeter reading should be taken as soon as possible after starting the engine, as the charging current will fall rapidly.
1. Make sure that all battery and alternator connections are in place, secure and making good metal to metal contact, especially the earth connections to chassis and engine.
12. A zero reading indicates failure of the alternator and may be caused by one of the following conditions. These are listed in the order of probability. 12.1. Defective suppression capacitor.
2. Make sure that the alternator drive belt tension is correctly adjusted.
12.2. Dirty slip rings or worn brushes.
3. If the battery is in a fully charged condition, before commencing the test switch on the working lights for
12.4. Defective rectifier.
Duration: 3 min 15 - 183
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12.3. Defective regulator. 12.5. Open or short circuited field (rotor) windings.
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72 - Alternator 00 - General
12.6. Open or short circuited power (stator) windings. 13. To check for a fault, disconnect the capacitor and repeat the charging test. Renew the capacitor if necessary. 14. To check for faults with the slip rings, bushes or regulator, remove the regulator and brush box assembly. Check the condition of the brushes and, if necessary, clean the slip rings using extrafine glass paper. The regulator may only be renewed. 15. Faults with the rectifier, rotor and stator may be checked only by removing and dismantling the alternator for further testing.
Remove and Install Remove 1. Make the machine safe. Refer to: PIL 01-03. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Remove the engine drive belt. Refer to: PIL 15-18-03. 4. Disconnect the battery. 5. Mark the connections of the harness assembly to help installation. 6. Disconnect the electrical harness from the alternator. 7. Remove the bolt1 and washer 1 from the alternator. 8. Remove the washer 2 and nut. 9. Remove the bolt 2 and alternator from the mounting bracket. 10. If necessary, remove the bolt 3 and remove the adjusting link. Figure 232. C
A
D E
B
H
F
A B C D E
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G
Bolt 3 Adjusting link Washer 1 Bolt 1 Alternator
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72 - Alternator 00 - General
F Nut G Washer 2 H Bolt 2
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Make sure that the alternator pulley is aligned with the crankshaft pulley.
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75 - Starter Motor
75 - Starter Motor Contents
Page No.
15-75-00 General ......................................................................................................................... 15-187
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75 - Starter Motor 00 - General
00 - General Introduction .................................................. Health and Safety ........................................ Technical Data ............................................. Component Identification ............................. Check (Condition) ........................................ Remove and Install .....................................
Introduction 15-187 15-188 15-188 15-189 15-189 15-191
The electric starter motor is either a permanentmagnet or a series-parallel wound direct current electric motor with a starter solenoid mounted on to it. When the current from the battery is applied to the solenoid, through the key-operated ignition switch, the solenoid engages a lever that pushes out the drive pinion on the starter driveshaft and meshes the pinion with the starter ring gear on the flywheel of the engine. The solenoid also closes high current contacts for the starter motor, which begins to turn. Once the engine starts, the key-operated ignition switch is opened, a spring in the solenoid assembly pulls the pinion gear away from the ring gear, and the starter motor stops. The starter motor pinion is clutched to the drive shaft through an overrunning clutch which permits the pinion to transmit drive in only one direction. Drive is then transmitted through the pinion to the flywheel ring gear, but if the pinion remains engaged (as for example because the operator fails to release the key as soon as the engine starts, or if there is a short and the solenoid remains engaged), the pinion will spin independently of the drive shaft, this prevents the engine driving the starter. The starter motor is only designed for intermittent use, the electrical components are designed only to operate for a time period of 20 s before overheating.
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75 - Starter Motor 00 - General
Health and Safety
Technical Data
WARNING Make the machine safe before working on it. Park the machine on level ground and lower the loader arm. Stop the engine and remove the ignition key. Make sure the park brake is engaged. Disconnect the battery to prevent the engine being started. Block all four wheels. Notice: Before carrying out arc welding on the machine, disconnect the battery and alternator to protect the circuits and components. The battery must still be disconnected even if a battery isolator is installed. Notice: Do not isolate the machine electrics when the engine is running, this may cause damage to the machine electrics.
Table 72. Description Power rating Minimum average cranking RPM (Revolutions Per Minute) Solenoid pull-in current Solenoid hold-in current Maximum cable resistance (at 20 °C ( 68.0 °F) and at 12 V)
Data 2 kW 130 RPM 54.5 A 10.5 A 0.04 Ω
Table 73. No load conditions at 25 °C ( 77.0 °F) Description Data No load RPM 4000 to 6000 RPM Maximum current 540 A Current draw with no 130 A load Voltage 11.5 V Rated voltage 12 V Figure 233. C
E
B A
D
A B C D E
Starter motor Solenoid Battery terminal nut Switch terminal nut Starter mounting bolt Table 74. Torque Values Item C D E
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Description Battery terminal nut Switch terminal nut Starter mounting bolt
Nm 15 1.2 50
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75 - Starter Motor 00 - General
Check (Condition)
Component Identification Figure 234.
Before carrying out the multimeter tests, check the battery condition and make sure that all the applicable electrical connections are clean and tight. Make sure that the starter motor fixing bolts are tightened to the correct torque. B
A
A Starter motor B Starter motor solenoid
To prevent the engine starting during the tests make sure that the applicable engine stop fuse is removed. Check the readings in the following sequence using a multimeter. Unless otherwise stated, the readings must be taken with the ignition switch held in the start position (HS) and the controls set to enable the starter motor. The readings are shown for both 12 V and 24 V systems. The highest values are for machines with 24 V systems. Identify the applicable system before carrying out the tests. Do not operate the starter motor for more than 20 s at one time. Let the starter motor cool for at least 2 min between starts. 1. Connect the multimeter across the battery terminals. Figure 235.
1.1. Reading in start position approximately Voltage: 10 V Voltage: 20 V 1.2. Minimum permissible reading in start position Voltage: 9.5 V Voltage: 18 V 1.3. A low reading probably indicates a fault in the starter motor. 2. Connect the multimeter between the starter main terminal and the commutator end bracket. In the start position, the reading should not be below the reading obtained in 1 by any more than Voltage: 0.5 V Voltage: 1 V 15 - 189
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75 - Starter Motor 00 - General
Figure 238.
Figure 236.
A Starter main terminal B Commutator end bracket (Starter earth connection)
A B C D E H
2.1. Minimum permissible reading in start position Voltage: 9 V Voltage: 17 V
Starter main terminal Starter earth connection Solenoid terminal Start relay feed Start relay switched output Battery positive and solenoid connection
4.1. If the reading is less than specified, connect the multimeter between the start relay feed and earth.
2.2. If the reading is within this limit, continue to 3. If the reading is outside the limit, proceed to 4.
4.2. A faulty start relay or a fault in the feed to the relay solenoid is indicated if the voltage increases to
3. Connect the multimeter between the solenoid terminal and a good earth. Minimum permissible reading in start position
Voltage: 8 V Voltage: 16 V
Voltage: 8 V Voltage: 16 V
4.3. Check also the solenoid earth connection. The fault must be in either the starter switch or in the wiring between the solenoid, starter switch, and the start relay, if the reading between terminal and earth is less than
Figure 237.
Voltage: 8 V Voltage: 16 V 5. Connect the multimeter between battery negative and starter earth connection. The reading in the start position should be practically zero, maximum permissible reading Voltage: 0.25 V Figure 239.
C Solenoid terminal 4. If the reading is less than specified, connect the multimeter between the start relay switched output and earth. A fault is indicated with the wiring from the start relay to the solenoid if the reading increases to Voltage: 8 V Voltage: 16 V
B Starter earth connection 15 - 190
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75 - Starter Motor 00 - General
5.1. If the reading is above the maximum permissible voltage, a high resistance in the earth lead or connections is indicated. 6. Connect the voltmeter between battery positive and the starter main terminal. With the starter switch off, the voltmeter should indicate battery voltage, but it should fall to practically zero when the switch is turned to the on position, maximum permissible reading Voltage: 0.25 V Figure 240.
Remove and Install Remove 1. Make the machine safe. Refer to: PIL 01-03. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Disconnect the battery. 4. Remove the nut 1 and the washer from the starter motor solenoid. 5. Remove the electrical harness from the starter motor. 6. Support the starter motor and remove the nut 2 (x2) and the bolt (x2). 7. Disengage the pinion from the flywheel gear teeth and remove the stater motor. Figure 242.
A Starter main terminal
F
7. If the reading is above the maximum permissible voltage, a high resistance is present in the insulated lead or in the solenoid. Connect the multimeter between the battery positive and solenoid connection. If the multimeter now reads zero with the switch closed, the fault is in the solenoid.
C G
E D
Figure 241.
H Battery positive and solenoid connection 8. Finally install the engine stop fuse.
B
A B C D E F G
A
Starter motor Starter motor solenoid Nut 2 Bolt Washer Nut 1 Electrical harness
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Tighten the fasteners to the correct torque value.
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75 - Starter Motor 00 - General
Table 75. Torque Values Item D F
15 - 192
Description Bolt Nut 1
Nm 50 15
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15 - Engine
80 - Glow Plug
80 - Glow Plug Contents
Page No.
15-80-00 General ......................................................................................................................... 15-195
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Notes:
15 - 194
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15 - Engine
80 - Glow Plug 00 - General
00 - General Introduction .................................................. Component Identification ............................. Check (Operation) ....................................... Remove and Install .....................................
Introduction 15-195 15-196 15-196 15-197
A glow plug is a heating device used to help start diesel engines. In cold weather, diesel engines can be difficult to start because the mass of the crankcase and cylinder head absorb the heat of compression, preventing ignition due to the higher surface to volume ratio. The glow plug is a pencil shaped piece of metal with a heating element at the tip. The heating element, when electrified, heats due to its electrical resistance and begins to emit light, hence the term glow plug. The fuel injector spray pattern then acts directly upon the hot tip of the glow plug during the injection of fuel at TDC (Top Dead Centre). This enables the fuel to ignite even when the engine is insufficiently hot for normal operation. This reduces the cranking time needed to start the diesel engine.
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80 - Glow Plug 00 - General
Component Identification
Check (Operation) Special Tools Description Digital Multimeter
Figure 243.
Part No. 892/00298
Qty. 1
Continuity Test 1. Connect a suitable test light between a ground and the terminal of the glow plug.
A B
C
2. Choose the glow plug that is farthest away from the battery. 3. Turn the ignition switch to the ON position. 3.1. If the circuit is correct, the test light should turn on.
D
3.2. If the test light does not turn on, inspect the circuit for loose connections, broken wires and other damage. 4. Loosen the nut on each glow plug and then disconnect the connectors from the glow plugs.
A B C D
Nut Washer Connector Glow plug
5. Measure the resistance between the electrical terminal of the glow plug and the ground with a suitable digital multimeter. Special Tool: Digital Multimeter (Qty.: 1) 5.1. The point for the ground should be as close to the glow plug as possible. 5.2. The maximum resistance for the glow plugs is Resistance: 0.0139 Ί 6. Connect the test light to the positive terminal of the battery and to the electrical terminal of the glow plug. 6.1. If the light turns on, the continuity in the glow plug is correct. 6.2. If the light does not turn on, replace the glow plug. 6.3. Repeat this step for each glow plug. 7. Install the connector on each glow plug and tighten the nut.
Glow plug circuit 1. Disconnect the power supply cable from the connector. 2. Loosen the nut and remove the connector from the electrical terminal of the glow plug. 3. Connect the leads of a suitable ammeter between the power supply cable and the terminal of a glow plug and then connect the leads of 15 - 196
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80 - Glow Plug 00 - General
the digital multimeter between the terminal of the glow plug and a ground. 4. Turn on the ignition switch. 5. Observe the amperage reading of the ammeter and the voltage reading on the multimeter. Refer to Table 76. 6. Make sure that the voltage should not drop more than the specified Voltage: 0.5 V
Remove and Install Remove 1. Make the machine safe. Refer to: PIL 01-03-27. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work.
6.1. If the multimeter reading is below the specified value, replace the glow plug.
3. Disconnect the battery.
6.2. If there is no reading, replace the glow plug.
4. Remove the nut and the washer from the bus bar.
6.3. If the voltage reading of the multimeter is zero, inspect the ignition switch and the power supply for faulty components and loose connections.
Refer to: PIL 33-03-00.
5. Remove the bus bar from the glow plug. 6. Remove the glow plug from the cylinder head. Figure 244.
7. Install the connector to the terminal of each of the glow plug and tighten the nut. 8. Connect the cable for the power supply to the glow plugs.
A
Table 76.
B
Maximum current 110 A through the glow plug Current through the glow 11.5 Âą 1.5 A plug after 6 s C
A B C D
D
Nut Washer Connector Glow plug
Install 1. Installation is the opposite of the removal procedure. Additionally do the following steps. 2. Make sure that the threads of the glow plugs are clean and free from damage. Replace the damaged glow plugs. 3. Tighten the glow plug and the nut to the correct torque value. 15 - 197
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80 - Glow Plug 00 - General
Table 77. Torque Values Item A D
15 - 198
Description Nut Glow plug
Nm 1.2 18
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15 - Engine
84 - Sensor
84 - Sensor Contents
Page No.
15-84-33 Coolant Temperature .................................................................................................... 15-201
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Notes:
15 - 200
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15 - Engine
84 - Sensor
33 - Coolant Temperature
33 - Coolant Temperature
Introduction
Introduction .................................................. 15-201 Check (Operation) ....................................... 15-202 Remove and Install ..................................... 15-202
The coolant temperature sensor is a device used to measure the coolant temperature inside the engine. The sensor is installed on the coolant thermostat housing.
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84 - Sensor
33 - Coolant Temperature
Check (Operation)
Remove and Install
The operational check of the coolant temperature sensor must be done when the engine is running.
Remove
1. Use a suitable digital multimeter to measure the resistance of the coolant temperature sensor. 2. When the temperature of the coolant is less than the specified, disconnect the wire connector from the coolant temperature sensor. Temperature: 50 °C ( 121.9 °F)
1. Drain the cooling system. Refer to: PIL 21-00-00. 2. Disconnect the harness from the coolant temperature sensor. 3. Remove the coolant temperature sensor from the thermostat housing.
3. Place one lead of the multimeter on the connector of the coolant temperature sensor. Place the other lead of the multimeter on a ground for the coolant temperature sensor.
Figure 245.
4. Measure the resistance. Make sure that the resistance is within the specified limit.
A
Resistance: 54 ± 2 Ω 5. Repeat the step 3 and 4 when the temperature of the coolant is approximately specified.
B
Temperature: 120 °C ( 247.8 °F) 6. Measure the resistance. Make sure that the resistance is not less than the specified value. Resistance: 15 Ω 7. If the resistance through the coolant temperature sensor is not within the given resistances, replace the coolant temperature sensor.
A Coolant temperature sensor B Thermostat housing
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. If you install a used coolant temperature sensor, apply a thin layer of pipe sealant to the threads. 3. Tighten the coolant temperature sensor to the correct torque value. Table 78. Torque Values Item A
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Description Coolant temperature sensor
Nm 27
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86 - Solenoid
86 - Solenoid Contents
Page No.
15-86-00 General ......................................................................................................................... 15-205 15-86-03 Engine Shut-off Solenoid (ESOS) ................................................................................ 15-206
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Notes:
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86 - Solenoid 00 - General
00 - General Introduction A solenoid refers to a variety of transducer devices that convert energy into linear motion. The term also refers to a solenoid valve, which is an integrated device containing an electromechanical solenoid which actuates a hydraulic valve, or a solenoid switch.
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86 - Solenoid
03 - Engine Shut-off Solenoid (ESOS)
03 - Engine Shut-off Solenoid (ESOS) Introduction .................................................. 15-206 Check (Operation) ....................................... 15-207 Remove and Install ..................................... 15-208
Introduction The ESOS (Engine Shut-Off Solenoid) is attached to the engine fuel injection pump. The ESOS is a solenoid operated fuel valve. When the solenoid energises, by means of an engine run / stop switch for example, the fuel supply is connected to the fuel injection pump and the engine can run. When the solenoid de-energises the fuel supply to the engine fuel injection pump is isolated. If the engine is running it will stop, it cannot re-start until the solenoid energises again.
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86 - Solenoid
03 - Engine Shut-off Solenoid (ESOS)
Check (Operation)
3.3. Make sure that the current is within the specified limit. If the current is not within this tolerance, replace the ESOS.
1. Remove the ESOS (Engine Shut-Off Solenoid) from the engine.
Current: 1 Âą 0.1 A 4. Install the ESOS to the engine.
Refer to: PIL 15-86-03. 2. Connect the ESOS to an external power source.
Refer to: PIL 15-86-03.
Figure 246. A
B E
D C
A B C D E
Positive lead Electrical connector Plunger ESOS body Negative terminal
2.1. Use a specified battery as a power source. Voltage: 12 V 2.2. Connect the lead from the battery positive terminal to one of the pins in the electrical connector on the ESOS. 2.3. Connect the lead from the battery negative terminal to the remaining pin in the electrical connector on the ESOS. 2.4. The plunger on the ESOSwill extend the maximum distance when the leads are connected. 2.5. If the plunger does not move or if the plunger does not extend the maximum distance, replace the ESOS. 3. Measure the current through the ESOS. 3.1. Use a suitable digital multimeter. 3.2. Connect the battery, the ESOS and the leads of the multimeter in series.
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86 - Solenoid
03 - Engine Shut-off Solenoid (ESOS)
Remove and Install Remove 1. Make the machine safe. Refer to: PIL 01-03-27. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Disconnect the battery. Refer to: PIL 33-03-00. 4. Mark the connections of the harness assembly to help installation. 5. Disconnect the electrical harness from the electrical connector. 6. Rotate the ESOS (Engine Shut-Off Solenoid) in a counterclockwise direction and remove from the fuel injection pump housing. 7. Remove the sealing washer from the ESOS. Figure 247.
B A
C A ESOS B Washer C Electrical connector
Install 1. Installation is the opposite of the removal procedure. Additionally do the following step. 2. Tighten the ESOS to the correct torque value. Table 79. Torque Values Item A
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Description ESOS
Nm 17
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87 - Switch
87 - Switch Contents
Page No.
15-87-00 General ......................................................................................................................... 15-211 15-87-03 Engine Oil Pressure ..................................................................................................... 15-212 15-87-18 Air Filter Vacuum .......................................................................................................... 15-215
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Notes:
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15 - Engine
87 - Switch
00 - General
00 - General Introduction The engine electrical switches will send a signal to the instrument panel to alert the operator if the switches are outside the specified limits. After removal from the engine, protect the switches from knocks, dampness and any high temperature sources. The switches are not serviceable, therefore they must be replaced in the event of damage.
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15 - Engine
87 - Switch
03 - Engine Oil Pressure
03 - Engine Oil Pressure
Introduction
Introduction .................................................. 15-212 Check (Operation) ....................................... 15-213 Remove and Install ..................................... 15-213
The engine oil pressure switch is a device to alert the operator if the pressure inside the engine is outside the set limits. The switch is mounted on the engine crankcase or the rocker cover.
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87 - Switch
03 - Engine Oil Pressure
Check (Operation)
Remove and Install
1. Turn the ignition switch ON, but do not start the engine.
The engine oil pressure switch can be found in two positions.
2. Make sure that the warning light for the low engine oil pressure turns on. If the warning light does not turn on, do the following steps:
• •
2.1. Check the electrical circuit to the warning light and the engine oil pressure switch for a short circuit or an open circuit.
On the rocker cover. On the crankcase.
Refer to Oil Pressure Switch - Tech data for details. Refer to: PIL 15-87. Figure 248.
2.2. Check the bulb for the warning light for damage.
A
2.3. If the circuit is correct, replace the engine oil pressure switch. 2.4. Do the step 2 again. 3. Remove the engine oil pressure switch. Refer to: PIL 15-87-03. 4. Connect the engine oil pressure switch to the power source. 4.1. Use a specified battery as a power source. Voltage: 12 V 4.2. Connect the battery terminal, oil pressure switch and a digital multimeter in series.
B
5. Measure the current through the engine oil pressure switch. 5.1. Make sure that the current is within the specified limit. Current: 0.3 –0.4 A 5.2. Replace the engine oil pressure switch if the current value is more than the specified. Current: 0.42 A
A Engine oil pressure switch (Located on the rocker cover) B Engine oil pressure switch (Located on the crankcase)
Remove 1. Disconnect the harness assembly from the engine oil pressure switch. 2. If the engine oil pressure switch is located on the rocker cover, remove the engine oil pressure switch from the rocker cover. 3. If the engine oil pressure switch is located on the crankcase, do the following steps: 3.1. Remove the engine oil pressure switch and the adaptor as an assembly from the oil pipe. 3.2. Remove the washers. 3.3. Remove the engine oil pressure switch from the adaptor.
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87 - Switch
03 - Engine Oil Pressure
Figure 249.
C
E
D
A,B A Engine oil pressure switch (Located on the rocker cover) B Engine oil pressure switch (Located on the crankcase) C Oil pipe D Washers E Adaptor
Install 1. If you install the used engine oil pressure switch, apply a thin layer of pipe sealant to the threads of the engine oil pressure switch. 2. If the engine oil pressure switch is located on the rocker cover, install the engine oil pressure switch. 3. If the engine oil pressure switch is located on the crankcase, do the following steps: 3.1. Install the engine oil pressure switch to the adaptor. 3.2. Tighten the adaptor to the correct torque value. 3.3. Position the new washers on the oil pipe. 3.4. Install the assembly of the engine oil pressure switch and adaptor to the crankcase. 4. Tighten the oil pressure switch to the correct torque value. 5. Connect the harness assembly to the engine oil pressure switch. Table 80. Torque Values Item A B E 15 - 214
Nm 11 11 23 9813/6050-2
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15 - Engine
87 - Switch
18 - Air Filter Vacuum
18 - Air Filter Vacuum Introduction .................................................. Component Identification ............................. Diagram ....................................................... Remove and Install .....................................
Introduction 15-215 15-216 15-216 15-217
The air filter vacuum switch is installed on the engine air filter. When the filter is blocked the vacuum increases and triggers the air filter vacuum switch and the ECM (Engine Control Module) input becomes grounded. This causes a CAN (Controller Area Network) message to be transmitted to the instrument panel ECU (Electronic Control Unit) which then illuminates the air filter warning lamp. The message "AIR FILTER" is displayed and the internal buzzer is sounded. If the air filter input goes open circuit then all the warnings are turned off.
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87 - Switch
18 - Air Filter Vacuum
Diagram
Component Identification Figure 250.
Figure 251.
A 1
1
2
B-53
B
ECU
2
A A Air filter vacuum switch B Electrical connector
B
A ECM (Engine Control Module) B Air filter vacuum switch Table 81. Harness Connector - C026MF
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Connectors C026MF E001
Pins 1 -
2 1
B
53
-
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Details Earth Stud 1 and 2. Refer to: PIL 33-12. ECM
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15 - Engine
87 - Switch
18 - Air Filter Vacuum
Remove and Install Remove 1. Make the machine safe. Refer to: PIL 01-03-27. 2. Disconnect the battery. Refer to: PIL 33-03-00. 3. Disconnect the electrical connector from the air filter vacuum switch. 4. Remove the vacuum switch from the air filter. Figure 252.
B
A
A Air filter vacuum switch B Air filter
Install 1. The installation procedure is the opposite of the removal procedure.
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15 - Engine
90 - Air Intake
90 - Air Intake Contents
Page No.
15-90-00 General ......................................................................................................................... 15-219
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15 - Engine
90 - Air Intake 00 - General
00 - General Check (Condition) Refer to: PIL 15-24-00.
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15 - Engine
96 - Pipe
96 - Pipe Contents
Page No.
15-96-00 General ......................................................................................................................... 15-221
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15 - Engine
96 - Pipe
00 - General
00 - General
Figure 254.
Remove and Install
A E
Remove 1. Make the machine safe. Refer to: PIL 01-03-27.
F
2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Loosen the nut that attaches the clip on the oil line to the fuel injection pump. 4. Remove the banjo bolt 1 and remove the washers1 from the crankcase.
A Oil line E Banjo bolt 2 F Washers 2
Figure 253. A
6. Remove the oil line from the engine.
Install B
1. Installation is the opposite of the removal procedure. Additionally do the following steps. 2. Before installation, make sure that all the components are clean and free from damage. 3. Tighten the banjo bolts and the nut to the correct torque value. Table 82. Torque Values Item B C E
Description Nut Banjo bolt 1 Banjo bolt 2
Nm 15 12 12
C D A B C D
Oil line Nut Banjo bolt 1 Washers 1
5. Remove the banjo bolt 2 and remove the washers 2 from the crankcase.
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Notes:
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18 - Fuel and Exhaust System Contents
Page No.
Acronyms Glossary .................................................................................................................................... 18-2 18-00 Fuel and Exhaust System 18-00-00 General ............................................................................................................................. 18-3 18-03 Tank 18-03-00 General ........................................................................................................................... 18-15 18-09 Filter 18-09-00 General ........................................................................................................................... 18-19 18-12 Water Separator 18-12-00 General ........................................................................................................................... 18-25 18-12-04 Water in Fuel Sensor ..................................................................................................... 18-27 18-18 Injection 18-18-00 General ........................................................................................................................... 18-33 18-18-03 Injector ............................................................................................................................ 18-36 18-18-15 Pump .............................................................................................................................. 18-41 18-21 Fuel Pump 18-21-00 General ........................................................................................................................... 18-47 18-24 Exhaust 18-24-00 General ........................................................................................................................... 18-53 18-24-03 Inlet Manifold .................................................................................................................. 18-55 18-24-04 Outlet Manifold ............................................................................................................... 18-57 18-24-18 Catalyst .......................................................................................................................... 18-62 18-35 Turbocharger 18-35-00 General ........................................................................................................................... 18-67 18-35-05 Compressor .................................................................................................................... 18-75 18-35-06 Wastegate Valve ............................................................................................................ 18-77 18-96 Fuel Pipe 18-96-00 General ........................................................................................................................... 18-81
9813/6050-2 2018-04-16
Acronyms Glossary DEF
Diesel Exhaust Fluid
DTI
Dial Test Indicator
EGR
Exhaust Gas Recirculation
ESOS
Engine Shut-Off Solenoid
ISO
International Organization for Standardization
MECU
Machine Electronic Control Unit
NOx
Nitrogen Oxide
RPM
Revolutions Per Minute
SAE
Society of Automotive Engineers
SCR
Selective Catalytic Reduction
9813/6050-2 2018-04-16
18 - Fuel and Exhaust System
00 - Fuel and Exhaust System
00 - Fuel and Exhaust System Contents
Page No.
18-00-00 General ............................................................................................................................. 18-3
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Notes:
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18 - Fuel and Exhaust System
00 - Fuel and Exhaust System 00 - General
00 - General
Introduction
Introduction ...................................................... 18-3 Health and Safety ........................................... 18-4 Technical Data ................................................. 18-4 Component Identification ................................. 18-6 Operation ......................................................... 18-7 Clean ............................................................... 18-8 Check (Condition) .......................................... 18-10 Check (Leaks) ............................................... 18-10 Check (Operation) ......................................... 18-11 Bleed ............................................................. 18-12
The engines use a direct fuel injection system controlled with a mechanically actuated fuel injection pump. The fuel injection pump is mounted in the crankcase. The fuel injection pump is operated by lobes on the camshaft. The fuel transfer pump is located on the right hand side of the crankcase. The fuel transfer pump is also operated by lobes on the camshaft. The fuel injection pump conforms to requirements for emissions. No adjustments to the fuel injection pump timing and high idle are permitted. Some fuel injection pumps have mechanical governors that control the engine rpm. Some fuel injection pumps have a governor that is electronically controlled.
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00 - Fuel and Exhaust System 00 - General
Health and Safety
Technical Data
Fuel Fuel is flammable, keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions.
Fuel System Table 83. Fuel Injection Pump Description Type Direction of rotation
Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear personal protective equipment. Hold a piece of cardboard close to suspected leaks and then examine the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.
Figure 255. A
Notice: The high pressure fuel system is extremely susceptible to damage if it is contaminated. Always clean the engine using the correct procedures before carrying out maintenance. Contamination of the fuel system can cause catastrophic failure of the engine. Notice: Running the engine with air in the system could damage the fuel injection pump. After maintenance, the system must be bled to remove any air.
B E
WARNING! Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. Notice: Do not allow dirt to enter the fuel system. Before disconnecting any part of the fuel system, thoroughly clean around the connection. When a component has been disconnected, for example a fuel pipe, always install protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt entering the fuel system. Dirt in the fuel system will seriously damage the fuel injection equipment and could be expensive to repair.
Data In-line cassette Clockwise (viewed from the drive end)
C
D A B C D E
Fuel injection pump Nut 1 Shim Bolt 1 Delivery valve holder
The shim adjusts the timing of the fuel injection pump. A thicker shim retards the timing. A thinner shim advances the timing. The timing changes 1 ° for each 0.1 mm difference in the thickness of the shim.
Notice: Clean the engine before you start engine maintenance. Obey the correct procedures. Contamination of the fuel system will cause damage and possible failure of the engine. CAUTION! It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites.
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00 - Fuel and Exhaust System 00 - General
Table 84. Torque Values
Figure 256. Item B D E F K Q R
H F
G
K
F G H J K
Description Nut 1 Bolt 1 Delivery valve holder Adjustment screw Bolt 2 Nut 2 Setscrew
Nm 15 15 42 2.5 6 25 25
J
Adjustment screw Fuel priming pump Flange O-ring Bolt 2
The fuel inlet for the fuel priming can be rotated 360 °. The fuel inlet is adjustable in 15 ° increments. The flange of the fuel priming pump has two sets of locating holes. This allows the fuel priming pump to be mounted in four positions for the outlet connection.
Exhaust System Figure 257. L
M
N
P
R Q L M N P Q R
Cylinder head Stud Gasket Exhaust manifold Nut 2 Setscrew
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18 - Fuel and Exhaust System
00 - Fuel and Exhaust System 00 - General
Component Identification Figure 258.
G H
F
B
C
D
E
A A C E G
Fuel tank Sediment/water trap Fuel filter Fuel injectors
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B D F H
Hand primer Fuel priming pump Fuel injection pump Fuel return line from the fuel injection pump and the fuel injectors to the fuel tank
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00 - Fuel and Exhaust System 00 - General
Operation When the engine is running, the fuel is pulled from the fuel tank by the fuel priming pump. An optional sediment/water trap may be installed between the fuel tank and the fuel priming pump. The fuel priming pump forces the fuel through the fuel filter to the fuel injection pump.
• • • • • •
The fuel filter is changed The low pressure fuel line is removed The fuel injection pump is removed The fuel injectors are removed The fuel tank is drained A leak exists in the low pressure side of the fuel system
The fuel filter also functions as a water separator. The fuel filter can be drained through a valve that is located at the bottom of the filter housing. The fuel injection pump sends fuel at high pressure to each fuel injector. The fuel injector sprays fuel into a pre-combustion chamber which slows the rate of combustion in the cylinder. The following will result from reducing the rate of fuel combustion: • • •
Prevention of engine knock Reduction of noise Reduction of emissions
The fuel injector injects fuel into the pre-combustion chamber at different angles during two phases. Refer to Figure 259. The most of the fuel is injected when the valve is fully open. This process is called indirect fuel injection. The results are more even combustion and complete combustion of the fuel at a reduced temperature. The improved fuel combustion will increase power output while reducing emissions and reducing fuel consumption. Figure 259.
A
A Closed valve B Open valve C Fully open valve
B
C
The excess fuel from the fuel injectors and the fuel injection pump flows through the fuel return line and back to the fuel tank. The excess fuel aids the cooling of the fuel injectors. Also, the fuel return line removes any air that is trapped in the fuel injectors and the fuel injection pump. The fuel injection pump needs fuel for lubrication. If the precision parts of the pump are not adequately lubricated, the components may be easily damaged. The engine must not be started until the fuel injection pump is full of fuel and free of air. The system must be bled when any part of the system is drained of fuel: 18 - 7
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00 - Fuel and Exhaust System 00 - General
Clean
These contaminants can appear during manufacture, assembly, operation and maintenance.
Cleanliness Requirements
The fuel filter is rated at 5 micron = 0.005mm (0.0002in). Listed are a few typical comparisons of micron size:
Important: Additional cleaning must be carried out prior to working on the high pressure fuel system. It is extremely important the high pressure fuel components and the adjacent parts of the engine are meticulously cleaned before any components are removed. Refer to: Effects of Contamination.
Figure 260.
Before starting work on the high pressure fuel system, make sure that the working environment is suitable. Refer to: Maintenance Environment, Common Rail Fuel Injection. 1. Obey all fuel information.
system
health
and
3. Clean the engine. 4. Remove the hoses, electrical harnesses and ancillaries to improve access and expose any remaining trapped dirt close to the relevant high pressure components. 5. Wash away any remaining dirt or debris and then dry the area using a compressed air jet. When the area is dry use a soft clean brush to remove sand or grit particles that remain.
Effects of Contamination While the requirement for a good level of cleanliness is well known and common practice, the introduction of high pressure common rail fuel injection necessitates working to new levels of cleanliness. Once inside the system, fuel circuit contaminants greatly affect the performance and life of the fuel injection equipment. For example, contaminants in the fuel pump will develop internal wear to cause internal leakage and hence lower discharges. Use of poor quality fuels and poor maintenance could also lead to contaminants entering the fuel injectors. There is a possibility of catastrophic equipment failure if debris should prevent the injectors from fully closing. The main contaminants can be classified as follows:
• •
Solid Particles - sand, fibres, metallic particles, welding scale, sealing materials and wear particles etc. Liquid - usually water and incompatible oils and greases. Gases - Air, sulphur dioxide etc. which can create corrosive compounds if dissolved in the fluid.
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B
safety
2. Clean the machine, prior to completing any maintenance work.
•
C
A A 8 microns B 70 microns C 100 microns • • • •
Red Blood Cell = 8 microns (0.008mm, 0.000315in). Human Hair = 70 microns (0.07mm, 0.00275in). Grain of Salt = 100 microns (0.1mm, 0.00394in). The smallest particle visible to the naked eye is 40 microns (0.00157in) approximately.
The fuel filter must be changed in accordance with the applicable service schedule and procedures. The water in fuel sensor must be maintained to make sure of correct operation at all times. The potential for engine damage due to fuel contamination is much greater when using common rail injection technology than with mechanical injection systems. This is because common rail requires components with smaller manufacturing tolerances, especially the fuel injectors. In addition, common rail operates at much higher fuel pressures, over five times that of mechanical systems. Similar pressures are used by commercial water jet cutting machines to cut metal. Fortunately clean diesel fuel has lubricating qualities that prevents erosion of components but it is obvious that contaminated fuel will cause serious damage at such high pressures.
Maintenance Environment, Common Rail Fuel Injection Depending on circumstances engine maintenance may be required in various working environments. Obviously procedures are best carried out in a
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00 - Fuel and Exhaust System 00 - General
dedicated workshop equipped with a suitable clean room, but in practice this is not always possible. Maintenance procedures requiring removal or replacement of fuel system components, particularly high pressure components, require special precautions to make the working environment suitable, reducing the risk of contamination to an absolute minimum. Use the following guidelines to make sure you reduce the chances of fuel system contamination when working in different environments: Worksite - Open to weather
• •
Vehicle Maintenance Workshop Unless the workshop has a dedicated `sealable clean room' work bay, precautions must still be taken. •
This repair site is not an acceptable location. Only in extreme circumstances should a machine be repaired on an open site. Use the guidelines below:
• •
•
•
• • •
• •
• •
Clean the engine. If the machine is on hard standing, clean away the material washed from the engine. Place suitable clean boards on the ground around the machine. Erect clean plastic sheeting to shelter the engine from wind and rain. Wear a new disposable environmental type suit when working on the fuel system. If the suit becomes contaminated with mud, move away from the engine and change into a new suit. Use clean latex gloves (non-powdered). Before you start work make sure that all the required replacement parts and tools are on site. Make sure that the replacement parts are still sealed inside their packaging. Put caps on all exposed ports and orifices immediately. Do not leave them open. High pressure fuel pipes MUST BE RENEWED if any pipe joint is loosened or disconnected. DO NOT re-use the original pipe.
site. Make sure that the replacement parts are still sealed inside their packaging. Put caps on all exposed ports and orifices immediately. Do not leave them open. High pressure fuel pipes MUST BE RENEWED if any pipe joint is loosened or disconnected. DO NOT re-use the original pipe.
• • •
• •
Clean the engine. Clean the engine in the dedicated area and then move it to the workshop. Clean the floor area around the machine. Erect clean plastic sheeting to shelter the engine from any wind and the possibility of debris such as dirt and dust falling from above. Make sure that workshop doors to the outside are kept closed. A gust of wind through an open door will easily blow sand particles into the air. Make sure your work wear is clean, non-flocking and lint free. If in doubt wear a new disposable environmental type suit. Use clean latex gloves (non-powdered). Before you start work make sure that all the required replacement parts and tools are on site. Make sure that the replacement parts are still sealed inside their packaging. Put caps on all exposed ports and orifices immediately. Do not leave them open. High pressure fuel pipes MUST BE RENEWED if any pipe joint is loosened or disconnected. DO NOT re-use the original pipe.
Worksite - Closed to weather from above This repair site is the least acceptable condition, if possible move the machine to a more suitable environment. Use the guidelines below: • • • •
• •
Clean the engine. Clean the floor of all material washed from the engine. Place suitable clean boards on the ground around the machine. Erect clean plastic sheeting to shelter the engine from the wind and the possibility of debris such as dirt and dust falling from above. Wear a new disposable environmental type suit when working on the fuel system. If it becomes contaminated with mud, move away from the engine and change into a new suit. Use clean latex gloves (non-powdered). Before you start work make sure that all the required replacement parts and tools are on
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00 - Fuel and Exhaust System 00 - General
Check (Condition)
Check (Leaks)
1. Determine if water is present in the fuel, as follows:
1. Make the machine safe.
1.1. Check the water separator for the presence of water. 1.2. If necessary, drain the water separator. Refer to: PIL 18-12-00. 1.3. Make a note that a full fuel tank minimizes the potential for overnight condensation.
Refer to: PIL 01-03-27. 2. Open the engine compartment cover. Refer to: PIL 06-06-06. 3. Check the engine compartment, fuel pipes and the area below for leaks. 4. Start the engine.
1.4. Make a note that the water separator can appear to be full of fuel when the water separator is actually full of water.
5. While the engine is running, check the engine compartment, fuel lines and the area below for leaks.
2. Determine if the contaminants are present in the fuel, as follows:
6. If necessary, repair or replace any damaged components.
2.1. Remove a sample of fuel from the bottom of the fuel tank. 2.2. Visually inspect contaminants.
the
fuel
sample
for
2.3. The colour of the fuel is not necessarily an indication of fuel quality. However, fuel that is black, brown, and/or similar to sludge can be an indication of the growth of bacteria or oil contamination. 2.4. In cold temperatures, cloudy fuel indicates that the fuel may not be suitable for the operating conditions. 3. If the fuel quality is still suspected as a possible cause of problems regarding engine performance, do the following: 3.1. Disconnect the fuel inlet line. 3.2. Operate the engine temporarily from a separate source of fuel that is known to be good. 3.3. This will determine if the problem is caused by fuel quality. If fuel quality is determined to be the problem, drain the fuel system and replace the fuel filters. 4. The engine performance can also be affected by the following characteristics: 4.1. Octane number of the fuel. 4.2. Air in the fuel. 4.3. Other fuel characteristics.
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Check (Operation) The operation check of the fuel system checks for air in the fuel system. The procedure also helps to find the source of the air in the system. 1. Examine the fuel system for leaks. 2. Make sure that the fuel pipe fittings are properly tightened.
9. If excessive air is not seen at the inlet to the fuel pump, air is entering the system after the fuel pump. 10. If excessive air is seen at the inlet to the fuel pump, air is entering through the suction side of the fuel system. 11. Pressurize the fuel tank to the specified pressure. Pressure: 0.35 bar ( 5.1 psi) 11.1. Do not use more than the specified pressure to pressurize the fuel tank, to avoid damage.
2.1. Air can enter the fuel system on the suction side between the fuel pump and the fuel tank.
Pressure: 0.55 bar ( 8.0 psi)
3. Check the fuel level in the fuel tank.
11.2. Check for leaks in the fuel lines between the fuel tank and the fuel pump.
4. Install a suitable fuel flow tube with a visual sight gauge in the fuel return line.
11.3. Repair any leaks that are found.
5. When possible, install the sight gauge in a straight section of the fuel line that is at least as long as the specified length. Length: 304.8 mm 6. Do not install the sight gauge near the following devices that create turbulence:
11.4. Check the fuel pressure to make sure that the fuel transfer pump is operating properly. 12. If the source of the air is not found, disconnect the supply line from the fuel tank and connect an external fuel supply to the inlet of the fuel pump. 13. If this corrects the problem, repair the fuel tank or the stand pipe in the fuel tank.
6.1. Elbows. 6.2. Relief valves.
Figure 261.
6.3. Check valves. 7. Observe the fuel flow during engine cranking.
A
Acceptable
B
Acceptable
7.1. Look for air bubbles in the fuel. 7.2. If there is no fuel present in the sight gauge, bleed the fuel system. Refer to: PIL 18-00-00. 7.3. If the engine starts, check for air in the fuel at varying engine speeds. 7.4. When possible, operate the engine under the conditions which have been suspect.
C
Not Acceptable
8. If excessive air is seen in the sight gauge in the fuel return line, install a second sight gauge at the inlet to the fuel pump. 8.1. If a second sight gauge is not available, move the sight gauge from the fuel return line and install the sight gauge at the inlet to the fuel pump. 8.2. Observe the fuel flow during engine cranking. 8.3. Look for air bubbles in the fuel. 8.4. If the engine starts, check for air in the fuel at varying engine speeds.
18 - 11
9813/6050-2
18 - 11
18 - Fuel and Exhaust System
00 - Fuel and Exhaust System 00 - General
Table 85. Air in Fuel Acceptable Conditions Condition A - Acceptable Refer to Figure 261.
B - Acceptable Refer to Figure 261.
C - Not Acceptable Refer to Figure 261.
Description A steady stream of small bubbles with a diameter of approximately 1.6 mm is an acceptable amount of air in the fuel Bubbles with a diameter of approximately 1.6 mm are also acceptable, if there is 2 –3 s intervals between the bubbles Excessive air bubbles in the fuel are not acceptable
Bleed 1. Make the machine safe. Refer to: PIL 01-03-27. 2. Open the applicable access cover. Refer to: PIL 06-06. 3. Loosen the bleed screw on the fuel filter. 4. Turn on the ignition until fuel with no air flows freely from the valve, then close the bleed screw. 5. Check the engine for smooth running. 6. If the engine continues to run roughly, again bleed the fuel system. Figure 262. A
A Bleed screw
18 - 12
9813/6050-2
18 - 12
18 - Fuel and Exhaust System 03 - Tank
03 - Tank Contents
Page No.
18-03-00 General ........................................................................................................................... 18-15
18 - 13
9813/6050-2
18 - 13
Notes:
18 - 14
9813/6050-2
18 - 14
18 - Fuel and Exhaust System 03 - Tank
00 - General
00 - General
Introduction
Introduction .................................................... 18-15 Remove and Install ....................................... 18-16
The fuel tank is a safe container for storing flammable fluids, from here the fuel is pumped into the engine. There can be condensation in a partially filled fuel tank. Therefore, you must fill the fuel tank after you operate the engine. Drain the water and sediment from any fuel storage tank at the recommended service intervals.
18 - 15
9813/6050-2
18 - 15
18 - Fuel and Exhaust System 03 - Tank
00 - General
Remove and Install
Figure 263.
A
Remove 1. Make the machine safe. Refer to (PIL 01-03). 2. Disconnect the battery. Refer to (PIL 33-03). 3. Drain the fuel from the fuel tank. 3.1. Put a suitable clean container underneath the fuel tank.
E D
3.2. Remove the drain plug.
C
4. Disconnect the hoses from the fuel tank.
F
B
5. Put a label on the hoses to help installation. 6. Plug all the open ports and hoses to prevent contamination. 7. Remove the locknut, washers and spindles. 8. Remove the fuel tank from the machine. 9. Remove the clamp plate.
A B C D E F
Fuel tank Locknut (x4) Washer (x4) Spindle Clamp plate Left side fender
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Prime the fuel system. Refer to (PIL 18-00).
18 - 16
9813/6050-2
18 - 16
18 - Fuel and Exhaust System 09 - Filter
09 - Filter Contents
Page No.
18-09-00 General ........................................................................................................................... 18-19
18 - 17
9813/6050-2
18 - 17
Notes:
18 - 18
9813/6050-2
18 - 18
18 - Fuel and Exhaust System 09 - Filter
00 - General
00 - General
Component Identification
Component Identification ............................... 18-19 Drain and Fill ................................................. 18-21 Remove and Install ....................................... 18-22
Figure 264.
A
B
C
D E
F
G
A B C D E F G
18 - 19
Filter base Bolt Tube assemblies Clamps Hose Plug Filter element
9813/6050-2
18 - 19
18 - Fuel and Exhaust System 09 - Filter
00 - General
Figure 265.
C D E M K H J
F J
B J G
L A A C E G J L
Drain plug Bolt O-Ring Base Seals O-Ring
18 - 20
B D F H K M
Sediment bowl Washer Filter element O-Ring Filter head Screw
9813/6050-2
18 - 20
18 - Fuel and Exhaust System 09 - Filter
00 - General
Drain and Fill Drain
4. If any water is present in the bowl. Allow it to drain.
1. Stop the engine.
5. Install the tap.
2. Open the engine compartment cover.
6. If there is sediment in the bowl, replace the filter element.
Refer to: PIL 06-06-06. 3. Open the tap.
Figure 266.
C D
J
E B
M K
J G
H J L F A
A C E G J L
Tap Bolt O-ring 1 Base Seals 1 (x3) Seal 2
18 - 21
B D F H K M
Bowl Washer Filter element O-ring 2 Head Bleed screw
9813/6050-2
18 - 21
18 - Fuel and Exhaust System 09 - Filter
00 - General
Remove and Install
1. Make sure that the fuel filer base is clean and free from damage.
Obey all fuel system health and safety information. Refer to: PIL 18-00-00.
2. If necessary, replace the fuel filter base.
Remove 1. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 2. Thoroughly clean the outside of the filter housing and around the filter head.
3. If removed, install new rubber olives on the tube assemblies. 4. Install the tube assemblies on the filter base. 5. Make sure that the orientation of the tube assemblies is correct. Tighten the tube assemblies to the correct torque value. 6. Install the plug.
3. Loosen the hose clamp and disconnect the hoses.
7. Instal the bolt and tighten to the correct torque value.
4. Put caps on the fuel pipes to prevent contamination.
8. If necessary, install the new filter element.
5. Remove the filter element from the filter base. 6. Remove the bolt and remove the filter base from the mounting bracket. 7. If necessary, remove the tube assemblies and the rubber olives from the filter base.
9. Connect the hoses and tighten the clamps. 10. Make sure that the hoses do not touch any other engine component. 11. Bleed the fuel system. Refer to: PIL 18-00-00.
Figure 267.
A
B
C
D E
F
G
A B C D E F G
Filter base Bolt Tube assemblies Clamps Hose Plug Filter element
Install Important: If the engine is equipped with a hand priming pump, the hand priming pump is mounted on the fuel filter base. The assembly of the fuel filter base and the hand priming pump is not serviceable. 18 - 22
9813/6050-2
18 - 22
18 - Fuel and Exhaust System 12 - Water Separator
12 - Water Separator Contents
Page No.
18-12-00 General ........................................................................................................................... 18-25 18-12-04 Water in Fuel Sensor ..................................................................................................... 18-27
18 - 23
9813/6050-2
18 - 23
Notes:
18 - 24
9813/6050-2
18 - 24
18 - Fuel and Exhaust System 12 - Water Separator 00 - General
00 - General
Introduction
Introduction .................................................... 18-25 Drain and Fill ................................................. 18-26 Remove and Install ....................................... 18-26
The water separator is designed to separate water and dirt from the fuel using a special chemically treated paper filter element. A bowl installed in the bottom of the trap collects the water removed from the fuel. The bowl is installed with an electric probe which senses when the water is above a preset level. The probe enables a suitable alarm/indicator device. Water can be drained off by means of the drain screw installed in the base of the bowl. It is essential that the water trap is drained regularly. Water must be drained immediately if the probe signals an alarm.
18 - 25
9813/6050-2
18 - 25
18 - Fuel and Exhaust System 12 - Water Separator 00 - General
Drain and Fill
Remove and Install
Drain
Refer to Fuel and Exhaust system - Filter - Pre-Filter Element. Refer to: PIL 18-09.
1. Make the machine safe. Refer to: PIL 01-03-27. 2. Get access to the water separator. 3. Examine the water separator bowl for sediment. Refer to Figure 268. 3.1. If there is water but no sediment, open the tap to drain the water. 3.2. If there is any sediment in the bowl, replace the fuel filter element. Figure 268. Water Separator
B
A A Tap B Bowl
18 - 26
9813/6050-2
18 - 26
18 - Fuel and Exhaust System 12 - Water Separator
04 - Water in Fuel Sensor
04 - Water in Fuel Sensor Introduction .................................................... Component Identification ............................... Diagram ......................................................... Remove and Install .......................................
18 - 27
Introduction 18-27 18-28 18-29 18-30
The water in fuel sensor operates to indicate the presence of water in the fuel. The water in fuel sensor is Integral with the pre-filter assembly. The water in fuel sensor detects presence of water above a pre-determined level in the pre-filter bowl. Its electrical resistance range changes when the sensor probe is submerged in water.
9813/6050-2
18 - 27
18 - Fuel and Exhaust System 12 - Water Separator
04 - Water in Fuel Sensor
Component Identification Figure 269.
C
B
A A B C D
D
Drain tap Water separator bowl Filter unit Water in fuel sensor
18 - 28
9813/6050-2
18 - 28
18 - Fuel and Exhaust System 12 - Water Separator
04 - Water in Fuel Sensor
Diagram Figure 270. ECU
D
B
A
F C
E -VE
+VE
D Fuse F MECU (Machine Electronic Control Unit) 2
E Water in fuel sensor
Table 86. Harness Connector C098MF Connec- Pins tors C098MF A E001MF -
C047SB C075SB- 6 A
18 - 29
Details B -
C 1
15 -
-
Earth Stud 1 and 2. Refer to: PIL 33-12. MECU 2 Fusebox A. Refer to: PIL 33-09.
9813/6050-2
18 - 29
18 - Fuel and Exhaust System 12 - Water Separator
04 - Water in Fuel Sensor
Remove and Install
2. Bleed the fuel system. Refer to: PIL 18-00-00.
Important: The water in fuel sensor is a non serviceable part. If faulty, the water in fuel sensor must be replaced.
Remove 1. Obey all fuel information.
system
health
and
safety
Refer to: PIL 18-00-00. 2. Make the machine safe. Refer to: PIL 01-03. 3. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 4. Get access to the fuel pre-filter assembly. 5. Disconnect the electrical connector. 6. Drain any fuel or water mix from the water separator. 7. Remove the drain tap and water in fuel sensor assembly from the fuel pre-filter assembly. Figure 271.
C
B
A A B C D
D
Drain tap Water separator bowl Filter unit Water in fuel sensor
Install 1. Installation is the opposite of the removal procedure. Additionally do the following steps: 18 - 30
9813/6050-2
18 - 30
18 - Fuel and Exhaust System 18 - Injection
18 - Injection Contents
Page No.
18-18-00 General ........................................................................................................................... 18-33 18-18-03 Injector ............................................................................................................................ 18-36 18-18-15 Pump .............................................................................................................................. 18-41
18 - 31
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18 - 31
Notes:
18 - 32
9813/6050-2
18 - 32
18 - Fuel and Exhaust System 18 - Injection 00 - General
00 - General Introduction .................................................... Component Identification ............................... Operation ....................................................... Calibrate ........................................................
18 - 33
Introduction 18-33 18-34 18-34 18-35
Refer to Fuel and Exhaust System- General, Introduction. Refer to: PIL 18-00-00.
9813/6050-2
18 - 33
18 - Fuel and Exhaust System 18 - Injection 00 - General
Component Identification
Operation
Refer to Fuel and Exhaust System- General, Component Identification. Refer to: PIL 18-00-00.
Refer to Fuel and Exhaust System- General, Operation. Refer to: PIL 18-00-00.
18 - 34
9813/6050-2
18 - 34
18 - Fuel and Exhaust System 18 - Injection 00 - General
Calibrate Important: Fuel injection timing is set in the factory. Fuel injection timing cannot change during operation. If a fuel injection pump is removed, replace the old shims with new shims of the same thickness. DO NOT reuse the old shims. If the thickness of the shim is 0.5 mm or below, install the beaded shims. If the shim thickness is above 0.5 mm, install the non-beaded shim and then install the beaded shim. Make sure that the beading on the beaded shim faces upwards, towards the bottom of the fuel injection pump. Select the correct combination of shims. Refer to Table 87. Table 87. Shim thick(1) ness 0.2 mm 0.3 mm 0.4 mm 0.5 mm 0.5 mm
Perkins Part Number
Beaded
131437490 131437500 131437510 131437520 131437530
Yes Yes Yes Yes No
(1) If the original shim thickness cannot be determined, contact your JCB dealer.
18 - 35
9813/6050-2
18 - 35
18 - Fuel and Exhaust System 18 - Injection 03 - Injector
03 - Injector Introduction .................................................... Component Identification ............................... Clean ............................................................. Check (Operation) ......................................... Check (Pressure) .......................................... Remove and Install .......................................
Introduction 18-36 18-37 18-37 18-38 18-39 18-40
The sealing washer helps to prevent blow-by gases. The sealing washer also sets the projection of the fuel injector into the pre-combustion chamber. This projection affects the time that is required for combustion in the cylinder. If the projection is excessive, engine knock can occur at high RPM (Revolutions Per Minute). When a fuel injector is installed in the cylinder head, a new sealing washer should be installed. The operating pressure of the fuel injector is set and tested at the factory. During operation, extra fuel is used as a coolant and lubricant for components of the fuel injector. Figure 272. A
B A Fuel injector B Sealing washer
18 - 36
9813/6050-2
18 - 36
18 - Fuel and Exhaust System 18 - Injection 03 - Injector
Component Identification Figure 273.
Clean 1. Remove the fuel injector from the engine. Refer to: PIL 18-18-03.
A B
2. Remove any loose carbon from the tip of the fuel injector. 3. Do not use abrasives or a wire brush to clean the fuel injector. 4. Remove all the dirt or contamination from the fuel injector. 4.1. Take extra care when you handle the fuel injector to prevent damage to the tip of the fuel injector. 4.2. A scratch or a burr could cause needle leakage or spray distortion.
C
4.3. Dirt in the orifices of the nozzle tip can damage engine components.
A Fuel injector B Sealing washer C Tooling bead
18 - 37
4.4. Dirt can distort the spray pattern of the nozzle.
9813/6050-2
18 - 37
18 - Fuel and Exhaust System 18 - Injection 03 - Injector
Check (Operation) Special Tools Description Hand Pump Pressure Test
Part No. 892/00223
Figure 274.
Qty. 1
C
A B D
WARNING: Make sure that you wear the eye protection at all times during testing. When the fuel injectors are tested, test fluids travel through the orifices of the nozzle tip with high pressure. Under this amount of pressure, the test fluid can pierce the skin and cause serious injury to the operator. Always keep the tip of the fuel injector pointed away from the operator and into the fuel collector and extension. You must correct the pressure adjustment before you test the spray pattern. Check the spray pattern as follows:
E
1. Connect the hand pump.
A B C D E F
Special Tool: Hand Pump Pressure Test (Qty.: 1) 1.1. The spray from the fuel injector must be directed into the extension and the fuel collector.
F
Adaptor Fuel injector Tube assembly Extension Fuel collector Filter
2. Close the gauge protector valve and the shut-off valve. 3. Open the pump isolator valve. 4. Quickly pump the nozzle tester and look at the spray pattern when the fluid begins to flow through the orifices of the fuel injector. 5. The spray flows around the tip of the nozzle. A difference in the nozzle spray patterns indicates that the fuel injector is faulty. Refer to Figure 275. Figure 275. Phases of operation and spray pattern of the fuel Injector
A
C
B
A Closed valve C Fully open valve
B Open valve
6. Observe the following characteristics of the spray: 6.1. Drops of fuel should not be in the spray. 6.2. Fuel should be sprayed in the shape of a cone around the nozzle. 18 - 38
6.3. Fuel should be sprayed evenly in a circular pattern around the nozzle. 7. Make sure that the gauge protector valve is closed before the fuel injector is removed from the nozzle tester. Closing the valve will prevent damage to the pressure gauge.
9813/6050-2
18 - 38
18 - Fuel and Exhaust System 18 - Injection 03 - Injector
Check (Pressure) Special Tools Description Hand Pump Pressure Test
5. Operate the nozzle tester and flush the fuel injector. Part No. 892/00223
5.1. Operate the nozzle tester for 10 to 15 strokes at a rate of approximately sixty strokes per minute.
Qty. 1
6. Open the gauge protector valve.
Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear personal protective equipment. Hold a piece of cardboard close to suspected leaks and then examine the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.
7. Slowly increase the pressure until the valve in the fuel injector opens. 8. Make a note of the highest pressure indication on the gauge before the pointer moves to zero.
1. Connect the hand pump. Special Tool: Hand Pump Pressure Test (Qty.: 1) 1.1. The spray from the fuel injector must be directed into the extension and the fuel collector.
8.1. This highest pressure indication is the opening pressure of the fuel injector. The opening pressure occurs when the valve needle is lifted from the nozzle seat. 8.2. If the opening pressure is not within the range of the setting, the fuel injector must be replaced. Refer to: PIL 18-18-00.
1.2. Use a clean calibration fluid when the fuel injectors are tested. The calibration fluid should be equivalent to SAE (Society of Automotive Engineers) J-967 (ISO (International Organization for Standardization) 4113) oil. 2. Close the gauge protector valve. Figure 276. C
A B D
E A B C D E F
F
Adaptor Fuel injector Tube assembly Extension Fuel collector Filter
3. Close the shut-off valve. 4. Open the pump isolator valve. 18 - 39
9813/6050-2
18 - 39
18 - Fuel and Exhaust System 18 - Injection 03 - Injector
Remove and Install Consumables Description JCB Threadseal
Part No. 4102/1951
4.1. 402D-05 and 403D-07 engines have two seat washers. The seat washers are different diameters. The 403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA engines have one seat washer.
Size 0.05 L
The following procedure is for one injector, the procedure is identical for all the injectors.
Remove
5. Apply a bead of threadsealer to the first two threads of the fuel injector that engage into the cylinder head. Consumable: JCB Threadseal
1. Make the machine safe.
6. Make sure that the threadsealer does not cover the body of the fuel injector below the threads.
Refer to: PIL 01-03. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Remove the high pressure fuel pipes.
7. Install the fuel injector into the cylinder head. 8. Tighten the fuel injector to the correct torque value with the deep socket. 9. Install the high pressure fuel pipes.
Refer to: PIL 18-96-00.
Refer to: PIL 18-96-00.
4. Remove the fuel injector from the cylinder head with the deep socket. 5. Remove the seat washer from the cylinder head. 6. Put caps on all the openings immediately to prevent contamination.
Table 88. Torque Values Item A
Nm 64
Figure 277. A B
C A Fuel injector B Washer C Tooling bead
Install 1. Clean the bore of the fuel injector. 2. Make sure that no debris enters the cylinder. 3. Clean the threads on the fuel injector. 4. Install the new washer into the bore for the fuel injector in the cylinder head. 18 - 40
9813/6050-2
18 - 40
18 - Fuel and Exhaust System 18 - Injection 15 - Pump
15 - Pump Introduction .................................................... Technical Data ............................................... Component Identification ............................... Operation ....................................................... Remove and Install .......................................
Introduction 18-41 18-42 18-42 18-43 18-43
The ESOS (Engine Shut-Off Solenoid) must be energized for fuel to flow through the system. The fuel injection pump is a cassette type pump. The cassette type pump contains the following components: • • •
Fuel delivery valves. Fuel rack. Push-rods.
The fuel injection pump is installed directly into the crankcase. The part number and code letters for the fuel injection pump are stamped on the front of the pump.
18 - 41
9813/6050-2
18 - 41
18 - Fuel and Exhaust System 18 - Injection 15 - Pump
Technical Data
Component Identification Figure 278.
Refer to Fuel System- Technical Data PIL 18-00-00 .
A B
C D E
F
A Fuel pipe to the fuel Injectors B Fuel delivery valve C Nuts and setscrews for mounting the fuel injection pump to the crankcase D Shim E Vent screw for the fuel injection pump F Fuel flow from the fuel transfer pump
18 - 42
9813/6050-2
18 - 42
18 - Fuel and Exhaust System 18 - Injection 15 - Pump
Operation
Remove and Install
The fuel injection pump is a pressurized system that is totally enclosed. The pump sends the correct amount of fuel under high pressure at the correct time through the fuel injectors to the individual cylinders. The fuel injection occurs near the end of the compression stroke. The fuel injection pump regulates the amount of fuel that is delivered to the fuel injectors. This action controls the engine RPM (Revolutions Per Minute) by the governor setting or the position of the throttle control.
Remove 1. Obey all fuel information.
system
health
and
safety
Refer to: PIL 18-00-00. 2. Remove the ESOS (Engine Shut-Off Solenoid). Refer to: PIL 15-86-03. 3. Remove the fuel pipes.
Figure 279.
Refer to: PIL 18-96-00. 4. Gradually loosen the bolt and nut from the fuel injection pump.
A B
5. Carefully raise the fuel injection pump and remove the clip. 6. Remove the fuel injection pump from the crankcase. 7. Remove the shims from the mounting face of the crankcase.
C
8. Make a note of the thickness and the number of the shims to help installation. The fuel injection timing is determined by the thickness of the shim pack between the fuel injection pump and the mounting face on the crankcase.
D E
F
A Fuel line to the fuel Injectors B Fuel delivery valve C Nuts and setscrews for mounting the fuel injection pump to the crankcase D Shim E Vent screw for the fuel injection pump F Fuel flow from the fuel transfer pump
Figure 280. A
C
The camshaft is driven by the idler gear in the timing case. Lobes on the camshaft cause the push-rod for each cylinder to reciprocate. The reciprocating motion first draws the fuel. The reciprocating motion then pressurizes the fuel. The fuel delivery valve for each cylinder acts as a check valve to prevent a loss of pressure to the fuel injector. The correct operation of the fuel injection pump requires the pump to be completely full of fuel and empty of air. When the vent screw is loosened, air can escape from the fuel injection pump. The fuel injection pump will lubricate the components during operation.
18 - 43
B
D A B C D
Fuel injection pump Nut Shims Bolt
9813/6050-2
18 - 43
18 - Fuel and Exhaust System 18 - Injection 15 - Pump
Figure 281. E F
G
E Fuel rack control F Link G Clip
Install 1. Clean the mating surfaces of the crankcase and the fuel injection pump. 2. Install the new shims. Make sure that you install the correct number and correct thickness of shims. 3. Position the fuel injection pump close to the mounting face of the crankcase. 4. Connect the link and the rack control with the clip. 5. Align the fuel injection pump with the studs on the crankcase. 6. Install the fuel injection pump. 7. Install the bolt and nut. 8. Install the fuel pipes. Refer to: PIL 18-96-00. 9. Install the ESOS. Refer to: PIL 15-86-03. Table 89. Torque Values Item B D
18 - 44
Description Nut Bolt
Nm 15 15
9813/6050-2
18 - 44
18 - Fuel and Exhaust System
21 - Fuel Pump
21 - Fuel Pump Contents
Page No.
18-21-00 General ........................................................................................................................... 18-47
18 - 45
9813/6050-2
18 - 45
Notes:
18 - 46
9813/6050-2
18 - 46
18 - Fuel and Exhaust System
21 - Fuel Pump 00 - General
00 - General Introduction .................................................... Component Identification ............................... Operation ....................................................... Remove and Install .......................................
18 - 47
Introduction 18-47 18-48 18-49 18-49
The fuel lift pumps function is to raise the level of fuel up through the system into the fuel injection system.
9813/6050-2
18 - 47
18 - Fuel and Exhaust System
21 - Fuel Pump 00 - General
Component Identification Figure 282.
C B
A D
A Fuel lift pump C Hose (outlet)
18 - 48
B Hose (inlet) D Hydraulic tank
9813/6050-2
18 - 48
18 - Fuel and Exhaust System
21 - Fuel Pump 00 - General
Operation
Remove and Install
Refer to Fuel System - General, Operation.Refer to: PIL 18-00-00.
Observe all the health and safety information. Refer to Fuel system - Health and Safety.Refer to: PIL 18-00-00.
Electrical Fuel Pump Remove 1. Make the machine safe. Refer to: PIL 01-03. 2. Open the rear access cover. Refer to (PIL 06-06). 3. Turn the fuel supply to the OFF position. 4. Disconnect the electrical connector from the fuel pump. 5. Plug all the open ports and hoses to prevent contamination. 6. Loosen the clamps and disconnect the hoses. 7. Put a label on the hoses to help installation. 8. Remove the bolt1 (x2) and remove the fuel pump. Figure 283. B
A E
A B C D E
C D
D
E
Electrical connectors Bolt 1 (x2) Fuel pump (Electrical) Clamps Hoses
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Make sure that the electric transfer pump is clean and free from damage. 3. Bleed the fuel system. Refer to: PIL 18-00-00.
Mechanical pump Remove 1. Make the machine safe. 18 - 49
9813/6050-2
18 - 49
18 - Fuel and Exhaust System
21 - Fuel Pump 00 - General
Refer to: PIL 01-03. 2. Open the rear access cover. Refer to (PIL 06-06). 3. Turn the fuel supply to the OFF position. 4. Disconnect the electrical connector from the fuel pump. 5. Plug all the open ports and hoses to prevent contamination. 6. The fuel transfer pump can be oriented in two positions. Before you remove the fuel pump from the crankcase, note the orientation of flange on the fuel pump for installation.
3. Make sure that the fuel pump is orientated in the correct position. 4. Install the new O-ring seal to the fuel pump. 5. Lubricate the operating plunger of the fuel pump with clean engine oil. 6. Position the fuel pump on the crankcase. 7. Make sure that the operating plunger is positioned correctly on the camshaft lobe. 8. Install the bolt3. 9. Tighten the bolt3 to the correct torque value.
7. Loosen the clamps and disconnect the hoses.
10. Connect the hoses to the fuel pump.
8. Put a label on the hoses to help installation.
11. Tighten the hose clamps.
9. Loosen the bolt and remove the fuel pump from the crankcase.
12. The inlet for the fuel pump can be rotated to the specified angle by loosening bolt 2.
9.1. If necessary, rotate the crankshaft until the operating plunger of the fuel pump is not under pressure to remove the fuel pump.
12.1. The fuel inlet is adjustable to the specified degree increments.
Angle: 360 °
Angle: 15 °
10. Remove the O-ring seal from the fuel pump.
12.2. If adjustment is made to the position of the fuel inlet, tighten bolt 2 to the correct torque value.
Figure 284.
F
13. Turn the fuel supply to the ON position.
G
14. Bleed the fuel system.
H
Refer to: PIL 18-00-00. Table 90. Torque Values Item B G J
J K
F G H J K
Description Bolt 1 Bolt 2 Bolt 3
Nm 9 2.5 6
Fuel pump (Mechanical) Bolt 2 O-ring seal Bolt 3 Flange
Install 1. Clean the mating surfaces of the crankcase and the flange on the fuel pump. 2. Make sure that the camshaft lobe for the fuel pump is at the minimum lift before the fuel pump is installed. 18 - 50
9813/6050-2
18 - 50
18 - Fuel and Exhaust System 24 - Exhaust
24 - Exhaust Contents 18-24-00 18-24-03 18-24-04 18-24-18
18 - 51
Page No. General ........................................................................................................................... Inlet Manifold .................................................................................................................. Outlet Manifold ............................................................................................................... Catalyst ..........................................................................................................................
9813/6050-2
18-53 18-55 18-57 18-62
18 - 51
Notes:
18 - 52
9813/6050-2
18 - 52
18 - Fuel and Exhaust System 24 - Exhaust 00 - General
00 - General
Introduction
Introduction .................................................... 18-53 Health and Safety .......................................... 18-54 Check (Condition) .......................................... 18-54
The exhaust system is used to guide exhaust gases away from the controlled combustion inside the engine by means of an exhaust pipe. Depending on the machine design, the exhaust gas may flow through the following components: • • • •
•
Cylinder head and exhaust manifold. Turbocharger to increase the engine power (if installed). A catalytic converter or EGR (Exhaust Gas Recirculation) system to reduce air pollution (if installed). SCR (Selective Catalytic Reduction) (if installed). In SCR system exhaust gases pass through the DEF (Diesel Exhaust Fluid) injection chamber to lower the NOx (Nitrogen Oxide) concentration in the exhaust gases. A silencer or muffler to reduce noise (if installed).
The exhaust pipe carries the toxic and noxious gases away from the users of the machine. Note machines or generators that work indoors can quickly fill an enclosed space with carbon monoxide or other poisonous exhaust gases if they are not properly vented to the outdoors.
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18 - Fuel and Exhaust System 24 - Exhaust 00 - General
Health and Safety
Check (Condition)
Exhaust Gases Machine exhaust gases can harm and possibly kill you or bystanders if they are inhaled. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, install an exhaust extractor. If you begin to feel drowsy, stop the machine at once and get into fresh air. 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.
Excessive smoke from the exhaust stack combined with a complaint of low power could be as a result of: •
• •
Dirt or dust (unfiltered air) ingested directly into the engine, resulting in damage to the cylinder bores, there will also be a possible increase in oil consumption. Air leaks from the air hose connections. Exhaust manifold leaks.
Hazardous Atmospheres This machine is designed for use in normal out door atmospheric conditions. It must 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 dealer. Hot Components Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit. WARNING! The engine has exposed rotating parts. Switch off the engine before working in the engine compartment. Do not use the machine with the engine cover open.
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18 - Fuel and Exhaust System 24 - Exhaust
03 - Inlet Manifold
03 - Inlet Manifold
Introduction
Introduction .................................................... 18-55 Check (Condition) .......................................... 18-56 Remove and Install ....................................... 18-56
On compression ignition (diesel) engines, the inlet manifold (also called the intake manifold) is the part of the air intake system that distributes air for combustion to the cylinders via each inlet port in the cylinder head. The design of the manifold is important to make sure that air is distributed as evenly as possible under all engine speed and load conditions.
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18 - Fuel and Exhaust System 24 - Exhaust
03 - Inlet Manifold
Check (Condition)
Remove and Install
1. Check the manifold mating faces for signs of damage and distortion.
(For: Perkins T3 404D-22 Nat Asp)
2. Check the manifold casting for signs of cracks.
Before Removal
3. Renew the manifold if there are any signs of defect.
1. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 2. Get access to the engine.
Remove 1. Disconnect the breather hose at the manifold connection. 2. Disconnect the air inlet hose. 3. Remove the bolts that attach the inlet manifold to the cylinder head. 4. Lift the inlet manifold from the cylinder head. Discard the gasket. 5. Cap the inlet ports with blanking caps to prevent ingress of dirt.
Install 1. Replacement is a reversal of the removal procedure. 2. Renew the manifold gasket. 3. Loosely assemble the manifold, together with the new inlet gasket to the cylinder head, use the two bolts (one at each end). 4. With the manifold and gasket in position, install the remaining bolts. 5. Tighten the bolts to the correct torque value.
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18 - Fuel and Exhaust System 24 - Exhaust
04 - Outlet Manifold
04 - Outlet Manifold Introduction .................................................... Component Identification ............................... Check (Condition) .......................................... Remove and Install .......................................
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Introduction 18-57 18-58 18-59 18-60
The exhaust outlet manifold collects the exhaust gases from the multiple cylinders and delivers it to the turbocharger or the exhaust pipe.
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18 - Fuel and Exhaust System 24 - Exhaust
04 - Outlet Manifold
Component Identification Figure 285. B
A
C
E A Cylinder head C Gasket E Nut
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D
F
B Stud D Exhaust manifold F Bolt
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18 - Fuel and Exhaust System 24 - Exhaust
04 - Outlet Manifold
Check (Condition) 1. Check the manifold mating faces for signs of damage and distortion. 2. Check the manifold casting for signs of cracks. 3. Renew the manifold if there are any signs of defect. 4. Visually inspect for leaks at the exhaust manifold. Make sure all gaskets are in good condition, replace as required.
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18 - Fuel and Exhaust System 24 - Exhaust
04 - Outlet Manifold
Remove and Install Remove
5. Remove the nuts and the bolts.
1. Make the machine safe.
6. Identify the bolts of different length so that you can install them to their correct position.
Refer to: PIL 01-03-27. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. If installed, remove the turbocharger. 4. Loosen the nuts and the bolts. Make sure that the you loosen the outer fasteners first to avoid the distortion of the exhaust manifold.
7. Remove the exhaust manifold from the cylinder head. Make a note of the orientation of the exhaust manifold to help installation. 8. Remove the gasket from the cylinder head. 9. If necessary, remove the exhaust manifold studs from the cylinder head.
Figure 286. B
A
C
E A Cylinder head C Gasket E Nut
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D
F
B Stud D Exhaust manifold F Bolt
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18 - Fuel and Exhaust System 24 - Exhaust
04 - Outlet Manifold
Install 1. Make sure that the all parts are clean and free from contamination. 2. Make sure that the mating surfaces of the exhaust manifold and the cylinder head are clean and free from damage. 3. If removed, install the exhaust manifold stud on to the cylinder head. 4. Install the new gasket on the cylinder head. 5. Align the exhaust manifold with the studs and install the exhaust manifold to the cylinder head. 6. Make sure that the exhaust manifold is installed in its correct position. 7. Install the nut and the bolt and loosely tighten. 8. Make sure that the bolts of different length are installed in their correct position. 9. Tighten the bolts to the correct torque value. 10. Make sure that you tighten the inner bolts first. 11. If removed, install the turbocharger. Table 91. Torque Values Item F
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Description Bolt
Nm 25
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18 - Fuel and Exhaust System 24 - Exhaust
18 - Catalyst
18 - Catalyst Introduction .................................................... Operation ....................................................... Check (Condition) .......................................... Remove and Install .......................................
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Introduction 18-62 18-63 18-64 18-64
The catalytic converter also called a catalyst is a vehicle emissions control device that converts toxic pollutants in exhaust gas to less toxic pollutants by catalyzing a reaction (oxidation or reduction).
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18 - Fuel and Exhaust System 24 - Exhaust
18 - Catalyst
Operation The catalytic converter consists of a monolith honeycomb substrate coated with platinum group metal catalyst. This honeycomb structure is then covered in a stainless steel container. The honeycomb structure with many small parallel channels presents a high catalytic contact area to exhaust gases. As the hot gases contact the
catalyst, several exhaust pollutants are converted into harmless substances. The diesel oxidation catalyst is designed to oxidize carbon monoxide, gas phase hydrocarbons, and the Soluble Organic Fraction (SOF) of diesel particulate matter to CO2 and H2O:
Figure 287.
Diesel exhaust contains sufficient amounts of oxygen, necessary for the above chemical reactions. The concentration of O2 in the exhaust gases from diesel engine varies between 3 –17 %, depending on the engine load. The catalyst activity increases with temperature. A minimum exhaust temperature of about 200 °C ( 391.7 °F) is necessary for the catalyst to "light off". At higher temperatures, conversions depend on the catalyst size and design and can be higher than 90 %. The catalytic oxidation of SOF results in reduction of diesel particulate matter emission. The particulate matter conversion efficiency can range widely, depending on the SOF contents of the particulates and sulphur level in the fuel.
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18 - Fuel and Exhaust System 24 - Exhaust
18 - Catalyst
Check (Condition)
Remove and Install
A catalyst converter may reach the end of its life prematurely if on the receiving end of a badly performing engine. Catalytic converters are free from moving components and require little to no maintenance. Therefore, what wears out or damages a catalytic converter is external and not an issue caused by the unit itself.
Remove
What damages a catalytic converter can vary, but here's a few examples: •
•
•
•
Out-of-tune engine - Catalytic converters are designed to work when the engine is running optimally. This could be due to incorrect fuel mixture, incorrect engine timing etc. Including potential damage to the catalytic converter, such issues may cause damage to the engine itself. Excessive fuel - If your vehicle is using excessive fuel, it won't get burnt and make your machine go faster. It's simply unused and rerouted through the exhaust. As a result, this unused fuel will enter the catalytic converter. The converters operate at high temperatures and can ignite the fuel as it enters, this renders the catalytic converter at super-hot temperatures, even causing it to melt down. Oil - Oil entering the exhaust will ultimately travel though the catalytic converter, clogging the internals of the catalytic converter and preventing it from working efficiently. This can cause excessive heat to accumulate within the converter and other engine components. Physical damage - The catalytic converter being located where it is, can receive damage from road debris such as rocks. Although the catalytic converter is protected, a strike from a heavy piece of debris may damage the internals.
Important •
•
Use only the specified fuel. Low S.A.P.S. technology (fuel with low Sulphate, Phosphorous, Sulphur content) keeps catalyst in working conditions. The presence of sulfate, phosphorus and sulfur ashes causes with time the catalyst clogging and its consequent inefficiency. Do not run the engine at idle for more than 10 min.
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1. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 2. The catalyst can be hot even after the engine has cooled. Let the catalytic converter cool even if the engine has cooled. 3. Remove the nuts and bolt that attach the catalyst to the front exhaust pipe. Figure 288.
A
B
C
F
E
D
G A B C D E F G
Strap Nut (x3) Gasket Front exhaust pipe Bolt Catalyst Mounting bracket
4. Remove the gasket between the catalyst and the front exhaust pipe. 5. Only loosen the strap of the catalyst from the catalyst mounting bracket at this stage. 6. Remove the nuts that attach the catalyst to the turbocharger support flange.
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18 - Fuel and Exhaust System 24 - Exhaust
18 - Catalyst
Table 92. Torque Values
Figure 289. Item A B H
Nm 10 24 24
K J F F H J K
H
Catalyst Nut (x3) Gasket Turbocharger support flange
7. Remove the gasket between the catalyst and the support flange. 8. Release the strap completely from the catalyst. 9. Carefully remove the catalyst from the engine with a soft mallet. 10. Remove the thermal blanket from the catalyst.
Install 1. Make sure that the catalyst is clean and not damaged. 2. Make sure you always use new gaskets. 3. Put the thermal blanket on the catalyst. 4. Put the catalyst in position against the mounting bracket. 5. Attach the strap. Do not tighten it at this stage. 6. Put the gasket on the support flange studs. 7. Put the catalyst mounting flange on the turbocharger support flange. 8. Install the nuts to attach the catalyst to the turbocharger support flange. 9. Put the gasket between the catalyst and the front exhaust pipe. 10. Attach the front exhaust pipe to the catalyst with the bolts and nuts. 11. Tighten all of the nuts to the correct torque value. 12. Tighten the strap to the correct torque value.
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18 - Fuel and Exhaust System
35 - Turbocharger
35 - Turbocharger Contents
Page No.
18-35-00 General ........................................................................................................................... 18-67 18-35-05 Compressor .................................................................................................................... 18-75 18-35-06 Wastegate Valve ............................................................................................................ 18-77
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35 - Turbocharger 00 - General
00 - General Introduction .................................................... Component Identification ............................... Operation ....................................................... Check (Condition) .......................................... Check (Operation) ......................................... Remove and Install ....................................... Store and Recommission ..............................
Introduction 18-67 18-68 18-69 18-69 18-70 18-71 18-74
A turbocharger increases the temperature and the density of the air sent to the engine cylinder. This condition causes a lower temperature of ignition to develop earlier in the compression stroke. The compression stroke is also timed in a more accurate way with the fuel injection. The surplus air lowers the temperature of combustion. This surplus air also provides internal cooling. A turbocharger improves the following aspects of engine performance: • • •
Power output is increased. Engine torque is increased. Engine efficiency is increased. Figure 290. A
B
G
D
C
F E
H
J
K L A B C D E F G H J K L
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Air intake Compressor housing Compressor wheel Bearing Oil inlet port Bearing Turbine housing Turbine wheel Exhaust outlet Oil outlet port Exhaust inlet
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35 - Turbocharger 00 - General
Component Identification Figure 291. A
G
E
H
W
E
B
T V
B
F
J
D
Q N
U
S P A C E G J L N Q S U W
Air inlet hose Screw Turbocharger Banjo bolt Tube clips Tube assembly 1 Bolt 2 Joint 1 Bolt 3 Gasket 2 Tube connector
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R
M
L
C
K
B D F H K M P R T V
Hose clamp Exhaust elbow Gasket 1 Washer Bolt1 O-ring Tube assembly 2 Joint 2 Nut Stud
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35 - Turbocharger 00 - General
Operation
Check (Condition)
The turbocharger is installed between the exhaust manifold and the intake manifold. The turbocharger is driven by exhaust gases which flow through the exhaust inlet. The energy of the exhaust gas turns the turbine wheel. Then, the exhaust gas flows out of the turbine housing through the exhaust outlet.
1. Inspect the compressor and turbine for damage.
The turbine wheel and the compressor wheel are installed on the same shaft. Therefore, the turbine wheel and the compressor wheel rotate at the same RPM (Revolutions Per Minute). The compressor wheel is enclosed by the compressor housing. The compressor wheel compresses the intake air. The intake air flows into the engine cylinders through the inlet valves of the cylinders.
4. Before you install the turbocharger, make sure that the code of the component is correct for the type of engine, as installation of the wrong turbocharger can damage the turbo and engine and void the warranty.
2. Make sure that the compressor blades do not rub on the housing and rotate freely. It is normal to detect a bit of play on the blades. 3. Make sure that the shaft rotates freely.
The oil from the main gallery of the crankcase flows through the oil inlet port to lubricate the turbocharger bearings (Bearing1 and bearing2). The pressurised oil passes through the bearing housing of the turbocharger. The oil is returned through the oil outlet port to the oil pan. The turbocharger has a wastegate. The wastegate is controlled by the boost pressure. This allows some of the exhaust gases to bypass the turbine wheel at higher engine speeds. The wastegate is a type of flapper valve that automatically opens at a preset level of boost pressure in order to allow the exhaust gas to flow around the turbine. The wastegate allows the design of the turbocharger to be more effective at lower engine speeds.
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35 - Turbocharger 00 - General
Check (Operation) To maximise the duration of the turbocharger follow the rules described below.
Start-up Start the engine and keep it at idle speed for about a minute. The oil operating pressure is reached within a few seconds, but it is useful to allow the moving parts to warm up in good lubrication conditions. Immediately increasing the engine speed after start up will result in the turbocharger running at high rpm with less than optimal lubrication. This may lead to premature failure of the turbocharger.
After maintenance When carrying out maintenance on the engine or turbocharger, pre-lubricate the oil inlet of the turbocharger by adding clean lubricant until it is completely full. After pre-lubrication, let the engine run via the starter motor without firing (engine / fuel pump stop out) to allow the oil to circulate through the complete system under pressure. Upon engine start-up, make it run at idle speed for a few minutes, allowing the oil and bearings system to work satisfactorily.
Low temperature air or engine inactivity If the engine has been inactive for a certain period of time or the air temperature is very low, start the engine and then let it run at idle speed. This enables the oil to go into the lubrication system before applying high loads and speeds to the engine and turbocharger.
Engine shutdown Before switching the engine off after intense activity, you must allow the turbocharger to cool down, let the engine run at idle speed for at least 2 minutes to allow the turbocharger to cool.
Engine at idle speed Avoid running the engine at idle speed for long periods (above 20-30 minutes). Idle operation leads to low pressure values in the turbocharger, which may cause oil leaks from the seals at the ends of the turbo bearing shaft. Even if this does not cause damage, it can cause blue smoke from the exhaust when the engine speed and load are increased.
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18 - Fuel and Exhaust System
35 - Turbocharger 00 - General
Remove and Install Remove 1. Make sure you obey the special instructions on handling, operation and installation of the turbocharger. Refer to: PIL 18-35. 2. Make the machine safe.
9. Remove the bolt 1 and remove the tube assembly 1 from the crankcase. 10. Remove and discard the O-ring. 11. Remove the bolt 2 and disconnect the tube assembly 2 from the turbocharger. 12. Remove and discard the joint 1.
Refer to: PIL 01-03. 3. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 4. Loosen the hose clamp and remove the air inlet hose. 5. Remove the screw and remove the exhaust elbow. 6. Remove the gasket 1. 7. Remove the banjo bolt and the washer. 8. Remove the fasteners and spacers from the tube clips.
13. If necessary, remove the bolt 3 and remove the tube assembly 2 from the crankcase. 14. Remove and discard the joint 2. 15. Remove the nut and the turbocharger from the exhaust manifold. 16. Remove and discard the gasket 2 from the exhaust manifold. 17. If necessary, remove the stud from the exhaust manifold. Important: Do not use the actuator rod of the wastegate to lift the turbocharger.
Figure 292. A
G
E
H
W
E
B
T V
B
F
J
D
Q N
U
S P A C E G J L N Q S U
Air inlet hose Screw Turbocharger Banjo bolt Tube clips Tube assembly 1 Bolt2 Joint 1 Bolt 3 Gasket 2
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R
M
L
C
K
B D F H K M P R T V
Hose clamp Exhaust elbow Gasket 1 Washer Bolt1 O-ring Tube assembly 2 Joint 2 Nut Stud
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18 - Fuel and Exhaust System
35 - Turbocharger 00 - General
W Tube connector
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35 - Turbocharger 00 - General
Install 1. Make sure that all the parts are clean and free from contamination. 2. Check the turbocharger for wear or damage. If the turbocharger is worn, replace the complete turbocharger. 3. Check the actuator for correct operation. 4. If the actuator is damaged or does not operate within the specified limits, replace the complete turbocharger. 5. Clean the mating surfaces of the exhaust manifold. 6. If removed, install the studs to the exhaust manifold. 7. Tighten the studs to the correct torque value.
22. Keep the tube assembly 1 at its correct position on the turbocharger. 23. Install the tube clips with the fasteners and spacers. 24. Tighten the banjo bolt to the correct torque value. 25. Make sure that the tube assemblies do not touch any other components. 26. Clean the mating surfaces of the exhaust elbow. 27. Keep the new gasket 1 and exhaust elbow at its correct position on the turbocharger. 28. Install the screw and tighten to the correct torque value. 29. Make sure that the inlet hoses are clean and free from the defects or restrictions.
8. Install the new gasket 2 on the studs.
30. Loosely install the hose clamps on the air inlet hose.
9. Keep the turbocharger on the exhaust manifold at its correct position.
31. Install the inlet hose and then tighten the hose clamps.
10. Install the nuts and tighten to the correct torque value.
Table 93. Torque Values
11. Make sure that the tube assembly 1 and tube assembly 2 are clean and free from damage. If necessary, replace the tube assemblies. 12. If removed, keep the new joint 2 at its correct position on the crankcase with the tube assembly 2. 13. Install the bolt 3 and tighten to the correct torque value.
Item C G K N S T V
Description Screw Banjo bolt Bolt 1 Bolt 2 Bolt 3 Nut Stud
Nm 32 18 10 10 10 25 18
14. Keep the new joint 1 at its correct position on the tube assembly 2. Align the tube assembly 2 with the bottom of the turbocharger. 15. Install the bolt 2 and tighten to the correct torque value. 16. Lubricate the bearings of the turbocharger with the clean engine oil through the oil inlet port. 17. Rotate the shaft of the turbocharger to distribute the oil. 18. Install the new O-ring on the tube assembly 1. 19. Keep the tube assembly 1 at its correct position on the crankcase. 20. Install the bolt 1 and tighten to the correct torque value. 21. Install the new washer and banjo bolt to the tube assembly 1. 18 - 73
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35 - Turbocharger 00 - General
Store and Recommission
allowing the oil and bearings system to work satisfactorily.
What to do • • • • • • • • • •
Before assembling the turbocharger, make sure that the protection caps are installed on all openings of the turbocharger. Make sure that the packaging is correct before storing the turbocharger to be assembled. Make sure the turbocharger is pre-lubricated. Periodically check that the joints are sealed against oil and air. Use only the specified lubricating oil. Check the engine oil level. Before switching the engine off after use, let it run at idle speed for around 1 minute. Check the condition of the air and oil filter regularly as per the maintenance schedules. Make sure that the engine maintenance intervals are observed. Make sure that the engine and equipment are used in a way that is not harmful to the life of the turbocharger.
3. Low temperature air or engine inactivity: If the engine has been inactive for a certain period of time or the air temperature is very low, start the engine and then let it run at idle speed. This enables the oil to go into the lubrication system before applying high loads and speeds to the engine and turbocharger. 4. Engine shutdown: Before switching off the engine after intense use allow the turbocharger to cool down. Therefore run the engine at idle speed for at least 2 minutes that allow the turbocharger to cool down. 5. Engine at idle speed: Do not run the engine at idle speed for more than 20-30 minutes at a time. It may cause oil leaks from the seals at the end of the engine shaft or it can cause blue smoke from the exhaust when the engine speed and load are increasing.
What not to do • • • • • • •
Do not store the turbochargers in stacks. Do not store the turbochargers in damp or wet conditions. Do not expose the turbochargers to dust and dirt. Do not lift the turbocharger by holding the actuator rod. Do not increase the engine speed immediately after start-up. Do not run the engine at idle speed for more than 20-30 minutes at a time. Do not change the actuator settings.
Practical operating rules 1. Start-up: Start the engine and keep it at idle speed for about a minute. The oil operating pressure is reached within a few seconds, but it is useful to allow the moving parts to warm up in good lubrication conditions. Immediately increasing the engine speed after start up will result in the turbocharger running at high RPM (Revolutions Per Minute) with less than optimal lubrication. This may lead to premature failure of the turbocharger. 2. After maintenance: When carrying out maintenance on the engine or on the turbocharger, pre-lubricate the oil inlet of the turbocharger by adding clean lubricant until it is completely full. After pre-lubrication, let the engine run via the starter motor without firing, to allow the oil to circulate through the complete system under pressure. Upon engine start-up, make it run at idle speed for a few minutes, 18 - 74
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35 - Turbocharger 05 - Compressor
05 - Compressor
Introduction
Introduction .................................................... 18-75 Remove and Install ....................................... 18-76
The compressor increases the mass of intake air entering the combustion chamber. The compressor is made up of an impeller, a diffuser and a volute housing.
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18 - Fuel and Exhaust System
35 - Turbocharger 05 - Compressor
Remove and Install This part is not serviceable. If damaged replace the complete turbocharger assembly.
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35 - Turbocharger
06 - Wastegate Valve
06 - Wastegate Valve Introduction .................................................... Operation ....................................................... Check (Condition) .......................................... Check (Pressure) ..........................................
Introduction 18-77 18-78 18-78 18-79
The wastegate is a valve that diverts exhaust gases away from the turbine in the turbocharged engine. Diversion of exhaust gases regulates the turbine speed, which in turn regulates the rotating speed of the compressor. The primary function of the wastegate is to regulate the maximum boost pressure in turbocharger systems, to protect the engine and the turbocharger.
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18 - Fuel and Exhaust System
35 - Turbocharger
06 - Wastegate Valve
Operation
Check (Condition)
The wastegate controls the amount of exhaust gas that is allowed to bypass the turbine side of the turbocharger. This valve then controls the RPM (Revolutions Per Minute) of the turbocharger. When the engine operates in conditions of low boost, a spring presses against a diaphragm in the canister. The actuating rod will move and the wastegate will close. Then, the turbocharger can operate at maximum performance. When the boost pressure increases against the diaphragm in the canister, the wastegate will open. The RPM of the turbocharger becomes limited. The RPM is limited because a portion of the exhaust gases bypass the turbine wheel of the turbocharger.
WARNING Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer. Important: The turbocharger is a non-serviceable item. The pressure for the wastegate can be checked but not adjusted. Refer to: PIL 18-35-06. Before you check the condition of the wastegate, make sure that the inlet air and exhaust system restrictions are within the specified limits. 1. The following levels of boost pressure indicate a problem with the wastegate: 1.1. Too high in full load conditions. 1.2. Too low in all low boost conditions. 2. The boost pressure controls the maximum RPM (Revolutions Per Minute) of the turbocharger, because the boost pressure controls the position of the wastegate. The following factors also affect the maximum RPM of the turbocharger: 2.1. The engine rating. 2.2. The horsepower demand on the engine. 2.3. The high idle RPM 2.4. Inlet air restriction. 2.5. Exhaust system restriction.
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18 - Fuel and Exhaust System
35 - Turbocharger
06 - Wastegate Valve
Check (Pressure) Make sure you obey the special instructions on handling, operation and installation of the turbocharger. Refer to: PIL 18-35-00. 1. Make the machine safe. Refer to: PIL 01-03. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Get access to the turbocharger. 4. Remove the heatshield from the turbocharger. 5. Remove the guard for the wastegate. 6. Remove the boost line from the wastegate. 7. Connect an air supply to the wastegate that can be adjusted accurately. 8. Install a DTI (Dial Test Indicator) to the turbocharger so that the end of the actuator rod is in contact with the plunger of the DTI. This will measure the axial movement of the actuator rod. 9. Slowly apply air pressure to the wastegate so that the actuator rod moves to the specified distance. Distance: 1 mm 9.1. Make sure that the air pressure applied is within the specified limit. Pressure: 0.52 bar ( 7.5 psi) 10. Make sure that the DTI returns to zero when the air pressure is released. 11. Repeat the test several times to make sure that you get an accurate reading. 12. If the wastegate does not operate correctly, contact your JCB dealer.
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18 - Fuel and Exhaust System 96 - Fuel Pipe
96 - Fuel Pipe Contents
Page No.
18-96-00 General ........................................................................................................................... 18-81
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18 - Fuel and Exhaust System 96 - Fuel Pipe 00 - General
00 - General
Health and Safety
Health and Safety .......................................... 18-81 Remove and Install ....................................... 18-82
WARNING Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. Notice: Do not allow dirt to enter the fuel system. Before disconnecting any part of the fuel system, thoroughly clean around the connection. When a component has been disconnected, for example a fuel pipe, always install protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt entering the fuel system. Dirt in the fuel system will seriously damage the fuel injection equipment and could be expensive to repair.
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18 - Fuel and Exhaust System 96 - Fuel Pipe 00 - General
Remove and Install
Figure 294. C
Remove
E F
1. Make the machine safe.
G
Refer to: PIL 01-03. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Turn the fuel supply to the OFF position. 4. Remove the nut 1 from the fuel injector pipe. 5. Remove the fuel injection pipes from the engine.
D
6. Cap all the open ports of the pump immediately.
H
7. Remove the banjo bolt and washer 1. 8. Remove the nut 2 from the fuel injector. 9. Make sure that the fuel pipes are not distorted when you loosen the nut. 10. Remove the fuel return pipes and the washer 2 from the fuel injector. 11. Cap all the open fuel injector ports to prevent contamination. Figure 293.
C D E F G H
Return line Banjo bolt Nut 2 Washer 1 Fuel injector Washer 2
Install 1. Installation is the opposite of the removal procedure. Additionally do the following steps: 2. Tighten the nuts to the correct torque value.
A
3. Use a special tool to tighten the nut 1 at the fuel injector. Refer to Table 94. 4. Bleed the fuel system. Refer to: PIL 18-00-00.
B
Table 94. Special tool C D
Part number Part name Qty.
27610294 Injector pipe nut tool 1 Table 95. Torque Values
A B C D
Nut 1 Fuel Injector pipes Fuel return pipes Banjo bolt
18 - 82
Item A E
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Nm 23 27
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21 - Cooling System Contents
Page No.
Acronyms Glossary .................................................................................................................................... 21-2 21-00 Cooling System 21-00-00 General ............................................................................................................................. 21-3 21-03 Cooling Pack 21-03-03 Radiator .......................................................................................................................... 21-13 21-06 Expansion Tank 21-06-00 General ........................................................................................................................... 21-15 21-09 Pump 21-09-00 General ........................................................................................................................... 21-17 21-12 Thermostat 21-12-00 General ........................................................................................................................... 21-23 21-12-03 Housing .......................................................................................................................... 21-27 21-93 Hose 21-93-00 General ........................................................................................................................... 21-29
9813/6050-2 2018-02-12
Acronyms Glossary EGR
Exhaust Gas Recirculation
RPM
Revolutions Per Minute
9813/6050-2 2018-02-12
21 - Cooling System
00 - Cooling System
00 - Cooling System Contents
Page No.
21-00-00 General ............................................................................................................................. 21-3
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Notes:
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21 - Cooling System
00 - Cooling System 00 - General
00 - General
Introduction
Introduction ...................................................... 21-3 Health and Safety ........................................... 21-4 Technical Data ................................................. 21-4 Component Identification ................................. 21-5 Drain and Fill ................................................... 21-6 Check (Condition) ............................................ 21-7 Check (Leaks) ................................................. 21-8 Check (Level) .................................................. 21-9 Check (Pressure) .......................................... 21-10
During the working cycle of the engine a great deal of heat is generated. It is important that the engine is kept at its normal operating temperature to achieve maximum efficiency. It is the function of the cooling system to allow the engine to reach this temperature quickly and then maintain it.
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21 - Cooling System
00 - Cooling System 00 - General
Health and Safety
Technical Data
CAUTION The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system. CAUTION Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze.
Table 96. Opening temperature of the thermostat Fully open temperature of the thermostat Engine coolant
80 –84 °C ( 175.9 – 183.1 °F) 95 °C ( 202.9 °F) JCB Antifreeze HP Coolant/Water
Figure 295. Thermostat
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21 - Cooling System
00 - Cooling System 00 - General
Component Identification Figure 296. Typical Cooling System
K
L
G J H
F
E D
A
C
B
A C E G J L
Water pump Return from expansion tank Coolant cylinder head Expansion tank Coolant to radiator Coolant into radiator
21 - 5
B D F H K
Coolant intake Coolant cylinder EGR (Exhaust Gas Recirculation) cooler coolant Vent line to expansion tank Vent line from radiator to expansion tank
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21 - Cooling System
00 - Cooling System 00 - General
Drain and Fill
Fill
Consumables Description Antifreeze HP/ Coolant ASTM D6210 Concentrate
1. Install the drain plug on the engine.
Part No. 4006/1101 4006/1120 4006/1103
Size 5L 20 L 200 L
CAUTION The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system.
Drain
2. Install the drain plug on the radiator. 3. Fill the system with a specified coolant. Consumable: Antifreeze HP/Coolant ASTM D6210 Concentrate 3.1. Do not fill the cooling system faster than the specified flow rate. Flowrate: 5 L/min 4. Do not install the cooling system filler cap. 5. Run the engine.
1. Make the machine safe.
5.1. Start the engine.
Refer to: PIL 01-03.
5.2. Run the engine at low idle. 5.3. Increase the engine RPM (Revolutions Per Minute) to high idle.
2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work.
5.4. Run the engine at high idle for specified duration to purge the air from the cavities of the engine crankcase.
3. Get access to the engine. Refer to: PIL 06-06-06. 4. Loosen the cooling system filler cap slowly to relieve the pressure and then remove the cooling system filler cap.
Duration: 1 min 5.5. Stop the engine. 6. Check the coolant level.
5. Remove the drain plug on the radiator.
6.1. Maintain the coolant level within specified depth below the bottom of the pipe for filling.
6. Remove the drain plug on the engine.
Distance: 13 mm
7. Allow the coolant to drain in a suitable container.
Flush 1. Flush the cooling system with a clean water to remove any debris. 2. Install the drain plug on the engine.
6.2. Maintain the coolant level in the expansion tank at the correct level. 7. Clean the cooling system filler cap. 8. Inspect the gasket that is on the cooling system filler cap. 9. Inspect the cooling system for leaks and for correct operating temperature.
3. Install the drain plug on the radiator. 4. Fill the cooling system with clean water. 4.1. Do not fill the cooling system faster than the specified flow rate. Flowrate: 5 L/min 5. Install the cooling system filler cap. 6. Start and run the engine at low idle until the coolant reaches to specified temperature. 7. Stop the engine and allow the engine to cool. 8. Again drain the engine. 9. Again flush the cooling system with a clean water. 21 - 6
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21 - Cooling System
00 - Cooling System 00 - General
Check (Condition)
debris, dirt, or deposits will restrict the flow of coolant through the radiator. 5.3. Check for debris or damage between the fins of the radiator core. The debris between the fins of the radiator core restricts air flow through the radiator core.
High coolant temperatures can be caused by many conditions. Use the following procedure to determine the cause of higher coolant temperatures: 1. Check the coolant level in the cooling system. Refer to: PIL 21-00-00. 1.1. If the coolant level is too low, air will get into the cooling system. Refer to steps 3.1 to 3.5. 2. Check the coolant for contamination. 2.1. If contamination is suspected, drain the cooling system and fill with new clean coolant. Refer to: PIL 21-00-00.
6. Check the filler cap. 6.1. The pressure drop in the cooling system can cause the boiling point to be lower. This can cause the cooling system to boil. 7. Check the fan and the fan shroud. 7.1. Make sure that the fan shroud is the correct size and the fan shroud is positioned correctly. 8. Check for loose drive belts. 8.1. A loose fan drive belt will cause a reduction in the air flow across the radiator.
3. Check for air in the cooling system. Air can enter the cooling system in different ways.
8.2. Check the fan drive belt for correct belt tension.
3.1. The most common causes of air in the cooling system is by not filling the cooling system correctly and combustion gas leakage into the cooling system. 3.2. The combustion gas can get into the system through inside cracks, a damaged cylinder head, or a damaged cylinder head gasket. 3.3. Air in the cooling system will cause a reduction in coolant flow and bubbles in the coolant.
8.3. If necessary, adjust the tension of the fan drive belt. 9. Check the cooling pump for correct operation. Refer to: PIL 21-09-00. 10. Check the cooling pump for damage. If necessary, replace the pump. Refer to: PIL 21-09-00.
3.4. The air bubbles will keep the coolant away from the engine parts, which will prevent the transfer of heat to the coolant. 3.5. A low coolant level is caused by leaks or incorrectly filling of the expansion tank.
10.1. A cooling pump with a damaged impeller does not pump enough coolant for correct engine cooling. 11. Check the cooling system hoses and clamps. 11.1. Damaged hoses with leaks can normally be seen.
4. Check the coolant sender unit. 4.1. The temperature sensor in the engine sends signals to the sender unit. The sender unit converts these signals to an electrical impulse which is used by the coolant gauge.
11.2. The hoses that have no visual leaks can soften during operation. The soft areas of the hose can become kinked or crushed during operation. These areas of the hose can cause a restriction in the coolant flow.
4.2. If the sender unit malfunctions, the gauge can show an incorrect reading.
11.3. The hoses become soft and get cracks after a period of time. The inside of a hose can deteriorate and the loose particles of the hose can cause a restriction of the coolant flow.
4.3. If the electric wire unit breaks or if there is a short circuit, the gauge can show an incorrect reading.
12. Check for a restriction in the air inlet system.
5. Check the radiator. 5.1. Check the radiator for a restriction to coolant flow. 5.2. Check the radiator for debris, dirt, or deposits on the inside of the core. The 21 - 7
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12.1. The restriction of the air that is coming into the engine can cause high cylinder temperatures. The high cylinder temperatures require higher than 21 - 7
21 - Cooling System
00 - Cooling System 00 - General
the normal temperatures in the cooling system. 13. Check for a restriction in the exhaust system. 13.1. The restriction of the air that is coming out of the engine can cause high cylinder temperatures. 13.2. Make a visual inspection of the exhaust system. 13.3. Check for damage to the exhaust piping. 13.4. Check for damage to the exhaust elbow. 13.5. If no damage is found, check the exhaust system for a restriction.
Check (Leaks) Special Tools Description Hand Pump Pressure Test
Part No. 892/00223
Qty. 1
1. Make the machine safe. Refer to: PIL 01-03. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Loosen the filler cap. 4. Allow the pressure to release from the cooling system and then remove the filler cap.
14. Check the thermostat. Refer to: PIL 21-12-00. 14.1. A thermostat that does not open, or a thermostat that only opens part of the way can cause overheating.
5. Make sure that the coolant covers the top of the radiator core. 6. Put a suitable pressure pump onto the radiator. Special Tool: Hand Pump Pressure Test (Qty.: 1)
15. Consider the high outside temperatures. 15.1. When outside temperatures are too high for the rating of the cooling system, there is not enough of a temperature difference between the outside air and coolant temperatures.
7. Use the pressure pump to increase the pressure to a specified amount, more than the operating pressure of the filler cap.
15.2. The maximum temperature of the ambient air that enters the engine should not exceed the specified.
9. Check all the connections and the hoses of the cooling system for leaks.
Temperature: 50 °C ( 121.9 °F)
8. Check the radiator for leakage on the outside.
10. The radiator and the cooling system do not have leakage if all of the following conditions exist:
16. Consider the load that is applied on the engine.
10.1. You do not observe any leakage after the specified time.
16.1. When the load on the engine is too large, the engine RPM (Revolutions Per Minute) does not increase with an increase of fuel. This lower engine RPM causes a reduction in coolant flow through the system. 16.2. The combination of less air and less coolant flow during high input of fuel will cause above normal heating.
Duration: 5 min 10.2. The reading on the pressure gauge remains at a constant value beyond the specified time. Duration: 5 min 11. The inside of the cooling system has leakage only if the following conditions exist:
17. The timing of the engine which is incorrect may also cause overheating of the engine. Adjust the valve timing as necessary. 17.1. Late timing creates more heat in the engine.
11.1. The reading on the pressure gauge goes down. 11.2. You do not observe any outside leakage.
17.2. Early timing creates less heat in the engine. 17.3. If the timing of the engine is incorrect, the exhaust valves may be burned and damage to the exhaust manifold may occur. 21 - 8
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21 - Cooling System
00 - Cooling System 00 - General
Check (Level) CAUTION The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system. 1. Make the machine safe. Refer to: PIL 01-03. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Open the engine compartment. Refer to: PIL 06-06-06. 4. Get access to the expansion tank. 5. Check the level of coolant in the radiator and in the expansion tank. 6. If necessary, fill the cooling system with the correct coolant. Refer to: PIL 21-00-00.
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21 - Cooling System
00 - Cooling System 00 - General
Check (Pressure) Special Tools Description Hand Pump Pressure Test
Part No. 892/00223
Make a note that the temperature and pressure work together. When a diagnosis is made of a cooling system problem, the temperature and pressure must be checked. The cooling system pressure will have an effect on the cooling system temperature. Refer to Figure 297.
Qty. 1
Figure 297. Cooling system pressure at specific altitudes and boiling points of water
ALTITUDE METERS
FEET
4300
14,000
3700
12,000
3000
10,000
2400
8000
1800
6000
1200
4000
0
14
25
40
35
70
85
95
k Pa
0
2
4
6
8
10
12
14
PSI
2000
SEA LEVEL
0 82
88
93
99
104
110
115
121
180
190
200
210
220
230
240
250
1. Make the machine safe.
5. Make sure that the coolant is at the correct level.
Refer to: PIL 01-03.
Refer to: PIL 21-00-00.
2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work.
6. Inspect the filler cap carefully.
3. Loosen the filler cap.
6.1. The pressure loss in the cooling system can be caused by the faulty seal on the filler cap. 6.2. Look for damage to the seal.
4. Allow the pressure to release from the cooling system and then remove the filler cap.
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21 - Cooling System
00 - Cooling System 00 - General
Figure 298.
A
A Sealing surface between the filler cap and the radiator 6.3. Look for damage to the surface that seals. 6.4. Remove any debris on the cap, the seal or the sealing surface. 6.5. Clean the filler cap carefully. 7. Install the filler cap on a suitable pressure pump. Special Tool: Hand Pump Pressure Test (Qty.: 1) 8. Observe the exact pressure that opens the filler cap. 9. Compare the pressure to the pressure rating that is found on the top of the filler cap. 10. If the filler cap is damaged, replace the filler cap.
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21 - Cooling System
03 - Cooling Pack
03 - Cooling Pack Contents
Page No.
21-03-03 Radiator .......................................................................................................................... 21-13
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21 - Cooling System
03 - Cooling Pack 03 - Radiator
03 - Radiator Clean If the radiator tubes or fins get clogged the radiator will be less efficient. Follow the procedure below to clean the radiator. 1. Make the machine safe. Refer to (PIL 01-03). 2. Open the engine compartment cover. Refer to (PIL 06-06). 3. Blow out debris from the engine cover grille and radiator. 4. Make sure that the loosened material is removed from the cooling pack enclosure.
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21 - Cooling System
06 - Expansion Tank
06 - Expansion Tank Contents
Page No.
21-06-00 General ........................................................................................................................... 21-15
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21 - Cooling System
06 - Expansion Tank 00 - General
00 - General Introduction The expansion tank retains coolant that has been forced out of the machines radiator under pressure. As the machine runs, the temperature of the coolant circulating around the system increases, this causes an increase of pressure in the cooling system. When the pressure builds to a high enough point, the radiator cap allows that pressure to escape into the coolant tank through a rubber overflow tube that is connected from the neck of the radiator to the expansion tank. Most of the coolant that is forced into the expansion tank returns to the radiator naturally when the engine is cold.
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21 - Cooling System
09 - Pump
09 - Pump Contents
Page No.
21-09-00 General ........................................................................................................................... 21-17
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21 - Cooling System
09 - Pump
00 - General
00 - General Introduction .................................................... Component Identification ............................... Check (Operation) ......................................... Remove and Install .......................................
21 - 17
Introduction 21-17 21-18 21-19 21-20
The coolant pump is a centrifugal type located in the front of the crankcase, driven by the engine drive belt. The impeller rotates to circulate the coolant through the cooling system. The pump shaft bearing and seal are not renewable.
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21 - Cooling System
09 - Pump
00 - General
Component Identification Figure 299. A
A
D
B E
C F
G A C E G
Pump Bolt Hose clamps Fasteners
21 - 18
B Alternator bracket D Joint F Hose
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21 - Cooling System
09 - Pump
00 - General
Check (Operation) A failed cooling pump may cause severe engine overheating problems that could result in the following conditions: • • •
Cracks in the cylinder head A piston seizure Other potential damage to the engine
1. Visually inspect the cooling pump for leaks. 1.1. The water pump seal is lubricated by the coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and parts contract. 2. Replace the cooling pump seal or the cooling pump if there is an excessive leakage of coolant. Refer to: PIL 21-09-00.
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21 - Cooling System
09 - Pump
00 - General
Remove and Install Remove
6. Drain the cooling system. Refer to: PIL 21-00-00.
1. Make the machine safe.
7. Loosen the clamp and disconnect the hoses from the cooling pump.
Refer to: PIL 01-03. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work.
8. Remove the bolt and the alternator bracket from the pump. 9. Remove the fasteners and then remove the cooling pump from the engine. If necessary, slowly tap the pump with a soft hammer to loosen the pump.
3. Remove the drive belt. 4. Remove the cooling fan. 5. Remove the alternator.
10. Remove the joint from the crankcase.
Refer to: PIL 15-72-00.
Figure 300. A
A
D
B E
C F
G A C E G
Cooling pump Bolt Hose clamps Fasteners
21 - 20
B Alternator bracket D Joint F Hose
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21 - Cooling System
09 - Pump
00 - General
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Tighten the fasteners to the correct torque value. Table 97. Torque Values Item G
21 - 21
Description Fasteners
Nm 10
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21 - Cooling System
12 - Thermostat
12 - Thermostat Contents
Page No.
21-12-00 General ........................................................................................................................... 21-23 21-12-03 Housing .......................................................................................................................... 21-27
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21 - Cooling System
12 - Thermostat 00 - General
00 - General Introduction .................................................... Component Identification ............................... Check (Condition) .......................................... Check (Operation) ......................................... Remove and Install .......................................
Introduction 21-23 21-24 21-24 21-25 21-25
The thermostat is installed on the cylinder head. It is located between the engine and the radiator in the cooling circuit. The function of the thermostat is to block the flow of coolant to the radiator until the engine has warmed up to a sufficient temperature. When the engine is cold, no coolant flows through the engine. Once the engine reaches its operating temperature, refer to Cooling System - Technical Data, the thermostat opens. By letting the engine warm up as quickly as possible, the thermostat reduces engine wear, deposits and emissions. Refer to: PIL 21-00-00.
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21 - Cooling System
12 - Thermostat 00 - General
Component Identification
Check (Condition)
Figure 301. A
B
C
1. If the thermostat is suspected of being faulty, perform a thermostat test, to confirm its serviceability. 2. Note that the thermostat is a non-serviceable item. If the thermostat is faulty or damaged it must be renewed. 3. Inspect the seal for damage or splits. If necessary replace the seal. Make sure that the seal is correctly installed.
D
E
A B C D E
Bolt Outlet connection Joint Thermostat Thermostat housing
21 - 24
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21 - Cooling System
12 - Thermostat 00 - General
Check (Operation)
Remove and Install
WARNING: Personal injury can result from the escaping fluid under pressure. If a pressure indication is shown on the indicator, push the release valve to relieve pressure before removing any hose from the radiator.
Remove 1. Drain the cooling system. Refer to: PIL 21-00-00. 2. Remove the bolts.
1. Remove the thermostat from the engine.
3. Remove the outlet connection.
Refer to: PIL 21-12-00. 2. Heat the water in a pan until the temperature of the water is equal to the fully open temperature of the thermostat. 2.1. Stir the water in the pan. This will distribute the temperature throughout the pan. Figure 302.
4. Identify the orientation of the outlet connection to help installation. 5. Remove the joint. 6. Remove the thermostat from the thermostat housing. Figure 303. A
B
C
3. Hang the thermostat in the pan of water. The thermostat must be below the surface of the water. The thermostat must be away from the sides and the bottom of the pan.
D
4. Keep the water at the correct temperature for the specified time. Duration: 10 min 5. Remove the thermostat.
E
6. Immediately measure the opening of the thermostat. 7. Make sure that the opening distance is within the specified limit. If not, replace the thermostat. A B C D E
Bolt Outlet connection Joint Thermostat Thermostat housing
Install 1. Inspect the thermostat for wear, damage and correct operation. 21 - 25
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21 - Cooling System
12 - Thermostat 00 - General
Refer to: PIL 21-12-00. 2. Make sure that the mating surfaces of the outlet connection and the thermostat housing are clean and free from damage. 3. Instal the thermostat to the thermostat housing. 4. Install a new joint. 5. Install the outlet connection to the thermostat housing. 6. Make sure the correct orientation of the outlet connection. 7. Install the bolt and tighten to the correct torque value. 8. Fill the cooling system to the correct level. Refer to: PIL 21-00-00. Table 98. Torque Values Item A
21 - 26
Description Bolt
Nm 14
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21 - Cooling System
12 - Thermostat 03 - Housing
03 - Housing
Refer to: PIL 21-12-00. 9. Fill the cooling system.
Remove and Install
Refer to: PIL 21-00-00. Table 99. Torque Values
Remove
Item C
1. Drain the cooling system.
Description Nut
Nm 10
Refer to: PIL 21-00-00. 2. Loosen the hose clamp and disconnect the hose from the thermostat housing. 3. Remove the bolt and the nut. 4. Remove the thermostat housing from the cylinder head. 5. Remove the joint from the cylinder head. 6. If necessary, remove the thermostat. Refer to: PIL 21-12-00. Figure 304. A
B C D
E A B C D E F
F
Joint Thermostat housing Nut Bolt Clamp Hose
Install 1. Make sure that the mating surfaces of the cylinder head and the thermostat housing are clean and free from damage. 2. Install a new joint to the cylinder head. 3. Install thermostat housing to the cylinder head. 4. Install the bolt and the nut. 5. Tighten the nut to the correct torque value. 6. Connect the hose to thermostat housing. 7. Tighten the hose clamp. 8. If removed, install the thermostat. 21 - 27
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21 - Cooling System
93 - Hose
93 - Hose Contents
Page No.
21-93-00 General ........................................................................................................................... 21-29
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21 - Cooling System
93 - Hose
00 - General
00 - General Introduction .................................................... Health and Safety .......................................... Component Identification ............................... Check (Condition) ..........................................
21 - 29
Introduction 21-29 21-30 21-31 21-33
The engine cooling hoses are essential parts of the cooling system. They carry the liquid coolant between the engine and the radiator/cooling pack.
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21 - Cooling System
93 - Hose
00 - General
Health and Safety CAUTION The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system.
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21 - Cooling System
93 - Hose
00 - General
Component Identification Figure 305. Typical Cooling System
A
B
A Coolant outlet hose
21 - 31
B Coolant inlet hose
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21 - Cooling System
93 - Hose
00 - General
Figure 306.
C
D
C Oil cooler inlet hose
21 - 32
D Oil cooler outlet hose
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21 - Cooling System
93 - Hose
00 - General
Check (Condition) 1. Visually inspect the engine and related cooling components for: 1.1. Leaks. 1.2. Cracked, burnt or perished hoses. 1.3. Hose clips are in good condition and tightened to the correct torque value.
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Notes:
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24 - Brake System Contents
Page No.
24-00 Brake System 24-00-00 General ............................................................................................................................. 24-3 24-18 Park Brake 24-18-00 General ............................................................................................................................. 24-7
9813/6050-2 2015-10-01
Notes:
9813/6050-2 2015-10-01
24 - Brake System
00 - Brake System
00 - Brake System Contents
Page No.
24-00-00 General ............................................................................................................................. 24-3
24 - 1
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Notes:
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24 - Brake System
00 - Brake System 00 - General
00 - General
Introduction
Introduction ...................................................... 24-3 Health and Safety ........................................... 24-4 Preparation ...................................................... 24-4
The brake system components of this machine are an integral part of the wheel drive motors. Refer to (PIL 27-32).
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24 - Brake System
00 - Brake System 00 - General
Health and Safety
Preparation
WARNING Before testing the park brake make sure the area around the machine is clear of people. WARNING Non approved modifications to drive ratios, machine weight or wheel and tyre sizes may adversely affect the performance of the park brake. WARNING Be careful, if the park brake is not functioning and the drive controls are in neutral the machine will roll down the slope. To stop the machine engage drive controls.
When you stop the engine, the brakes are locked ON. You must do the following procedure, before you move a disabled machine. It is only possible to tow or winch the machine for short distances at a slow speed in a straight line. This is because the steering system is inoperative unless the machine is being self-propelled. If at all possible repair the disabled machine where it stands. If the machine needs to be returned to the workshop for repair, it must be winched onto a trailer or lifted onto a truck for transportation. 1. Block the wheels to prevent accidental movement when you release the brakes. 2. Remove the floor plates. Refer to (PIL 09-78). 3. Press in the by-pass plungers on the charge check valves (x4) underneath the pump. Refer to Figure 307. Figure 307.
A
A
A
A
A By-pass plungers 3.1. This will open the valves and allow oil from the motors to flow freely through the pump. 3.2. The valves will stay open until the machine is next started when charge pressure will automatically close the valves. 4. Remove the motor outer covers. 5. Remove the plug on each motor end cover.
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24 - Brake System
00 - Brake System 00 - General
Figure 308.
B
B Plugs 6. Use locally made pullers to jack out the brake piston to release the brake. Figure 309.
C
C M12 bolt 6.1. The pullers must be constructed so that they rest on the outer edge of the motor case and have a central bolt to screw into the tapped hole in the brake piston. 6.2. Do not rest the puller against the central part of the motor end cover to prevent it from damage. 7. Install the M12 bolt. 8. Turn a further one complete turn to release the brake. 9. If necessary, use washers under the bolt head to give correct thread engagement. 10. Remove the wheel blocks only when the machine is hitched up ready for towing/winching. 11. Keep personnel clear of the machine.
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24 - Brake System
18 - Park Brake
18 - Park Brake Contents
Page No.
24-18-00 General ............................................................................................................................. 24-7
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24 - Brake System
18 - Park Brake 00 - General
00 - General
Introduction
Introduction ...................................................... 24-7 Check (Operation) ........................................... 24-8
Make sure that you obey all health and safety precautions before you test or adjust the park brake. If you have any queries about the park brake test or adjustment procedures, contact your local JCB dealer.
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24 - Brake System
18 - Park Brake 00 - General
Check (Operation)
5.4. Make sure that the machine does not move.
WARNING Do not use a machine with a faulty park brake.
5.5. If the machine does start to move, immediately use the drive controls to hold the machine in position. 5.6. Repair or adjust the park brake as necessary.
1. Make the machine safe. Refer to (PIL 01-03). 2. Fasten the seat belt. 3. Park the machine on a suitable slope. Refer to Figure 310. Figure 310.
A A Slope ( 15 °) 4. Hold the machine safely in place with the drive controls. 5. Apply the park brake. 5.1. Press the rocker switch. Figure 311. P
B
B Rocker switch 5.2. Make sure illuminated.
that
the
switch
light
is
5.3. Release the drive control levers. 24 - 8
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27 - Driveline Contents
Page No.
Acronyms Glossary .................................................................................................................................... 27-2 27-00 Driveline 27-00-00 General ............................................................................................................................. 27-3 27-27 Hub 27-27-00 General ........................................................................................................................... 27-11 27-29 Wheel 27-29-00 General ........................................................................................................................... 27-21 27-29-15 Wheel Nuts .................................................................................................................... 27-24 27-31 Wheel Drive Pump 27-31-00 General ........................................................................................................................... 27-27 27-31-03 Coupling ......................................................................................................................... 27-37 27-32 Wheel Drive Motor 27-32-00 General ........................................................................................................................... 27-41 27-33 Tyre 27-33-00 General ........................................................................................................................... 27-65 27-36 Track 27-36-00 General ........................................................................................................................... 27-69 27-36-06 Rubber Track ................................................................................................................. 27-81 27-36-12 Gearbox Sprocket .......................................................................................................... 27-86 27-36-15 Frame ............................................................................................................................. 27-87 27-36-18 Idler Wheel ..................................................................................................................... 27-89 27-36-24 Bottom Roller ................................................................................................................. 27-91 27-36-27 Tensioner/Recoil unit ...................................................................................................... 27-93 27-37 Track Drive Pump 27-37-00 General ........................................................................................................................... 27-99 27-38 Track Drive Motor 27-38-00 General ......................................................................................................................... 27-111
9813/6050-2 2018-05-02
Acronyms Glossary ESOS
Engine Shut-Off Solenoid
HP
High Pressure
HPRV
High Pressure Relief Valve
LP
Low Pressure
RPM
Revolutions Per Minute
9813/6050-2 2018-05-02
27 - Driveline
00 - Driveline
00 - Driveline Contents
Page No.
27-00-00 General ............................................................................................................................. 27-3
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Notes:
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27 - Driveline
00 - Driveline 00 - General
00 - General Introduction ...................................................... Health and Safety ........................................... Technical Data ................................................. Operation ......................................................... Diagram ........................................................... Fault-Finding .................................................... Check (Level) ..................................................
27 - 3
Introduction 27-3 27-4 27-4 27-5 27-5 27-6 27-8
The main hydraulic pump provides the power to drive the machine. Refer to Hydraulic System, Operation (PIL 30-00).
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27 - Driveline
00 - Driveline 00 - General
Health and Safety
Technical Data
Working Under the Machine Make the machine safe before getting beneath it. Make sure that any attachments on the machine are correctly attached. Engage the park brake, remove the ignition key, disconnect the battery. If the machine has wheels use blocks to prevent unintentional movement. WARNING! A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the machine being started while you are beneath it.
Table 100. Hydraulic Motors Description Type Displacement Maximum working pressure Maximum speed Maximum flow
Data MCR03 328 cmÂł/rev 414 bar ( 6,000.0 psi) continuous 237 RPM (Revolutions Per Minute) continuous 84 L/min continuous
WARNING! Before disconnecting any propshaft, make sure you block both sides of all wheels to prevent machine movement. The park brake will become ineffective or may only operate on 2 wheels (depending on machine specification). WARNING! If a 4 wheel drive machine is to be raised and the engine/transmission run, make sure all four wheels are raised off the ground. Make sure the machine is correctly supported by the correct axle stands. If only one pair of wheels is raised, the machine could move and fall off the stands. WARNING! Under no circumstances must the engine be run with the transmission in gear and only one driving wheel jacked clear of the ground, since the wheel on the ground will move the machine.
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00 - Driveline 00 - General
Operation
Diagram Figure 312.
The flushing circuit type drive motor is installed on this machine. This is used to cool the motors during operation.
C
To save efficiency losses, flushing is taken off through an orifice on the low pressure side of the motor circuit.
B
A
Although the motors operate in both forward and reverse they are expected to operate in the forward direction for 90 % of the time so flushing is taken off the return line. This is the normal flushing rate. When the motors are in reverse mode there is a higher pressure in the B-port and also through the orifice, so the flow rate is higher in this mode. It is important, when you check the flushing circuit flow, you must measure the flow rate in forward drive only.
27 - 5
E D A B C D E
Pump Motor HP (High Pressure) LP (Low Pressure) Tank
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27 - Driveline
00 - Driveline 00 - General
Fault-Finding For: 1CX [T3], 1CXT [T3] ............ Page 27-6 For: Wheeled .............................. Page 27-7
(For: 1CX [T3], 1CXT [T3]) Fault Hydrostatic Transmission
Table 101.
Table 101. Hydrostatic Transmission Cause No oil in hydrostatic system Seat isolator not operating correctly Tyres worn or pressure incorrect Charge pressure incorrect No or low pump output
A high pressure loop relief valve/tow valve open/set incorrectly Pump neutral position set incorrectly Pump servos incorrectly set Feed hose failure No hydraulic feed to joystick No hydraulic feed from joystick to pump Brake hose failure Brake release pressure incorrect Electrical failure (brake valve circuit) Brake valve inoperative Brakes not released Mechanical brake failure Motor leakage
Joystick inoperative Chain tension Motor failure Chain/sprocket damage Pump/engine drive coupling failure
27 - 6
Page 27-6
Remedy Check supply of oil to pump. Make sure that the seat isolator is operating correctly. Check the electrical wiring and switch as required. Check the tyre pressures and condition. The charge pressure relief valve controls the charge pressure. Carry out a flow check. Check the pump. Do the wheel speed check. If one pump suspect, swop motor feed hoses and notice if problem changes sides. If yes, pump related fault; if no, motor related fault. Replace the relief valve. Adjust the servo neutral position. Adjust the servos Check the motor feed hoses. Check for feed to joystick. Check for feed from joystick to pump. Check the condition of the brake hoses. Check the charge/brake pressure. Check the brake valve electrical circuit. Check the valve (sticking spool, etc.) Inspect motor brakes for seal damage. Repair as required. Check the brake components (worn plates, spring damage, etc.). Check motor case drain for confirmation of internal leakage (compare one motor with the other). Pulsing leakage indicates piston ring damage; continuous leakage, possibly more in one direction than the other, indicates distributor seal damage. On wheeled machines, check for shaft seal leakage by checking chain case oil level - increase in oil level indicates possible leakage. Check the joystick (plunger movement, leaking seals, etc.) Check the chain tension. Inspect the motor for damage. Check the screen for sign of damage. Repair as required. Inspect the chain and sprocket. Repair as required. Check the coupling.
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27 - Driveline
00 - Driveline 00 - General
Internal damage
Cause
Remedy Noise once per revolution indicates piston damage. Noise eight times per revolution indicates cam damage. Repair as required. Inspect the motor for damage or incorrect timing. Check the charge pressure. Repair as required. Inspect the motor for dirt or damage. Repair as required. Transmission cut-off valve sticking or the electrical system.
Timing incorrect or stop pin damaged Dirt or fault in motor flushing circuit No Drive in any direction
(For: Wheeled) Fault Machine veers to one side
Table 102.
Table 102. Machine veers to one side Cause The pressure of one tyre may be low or one or both tyres on one side of the machine may be new and the other tyres worn. In both these cases the rolling circumference of the tyres will be unequal causing the machine to veer to one side. Chains which are tensioned unequally will cause the machine to veer to one side. Always adjust the tension on all four chains, never just one. Check that the joystick spools are not sticking and are correctly operated by the lever.
27 - 7
Page 27-7
Remedy Check the tyre pressures and condition.
Check the chain tension. Check the servo joystick.
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27 - Driveline
00 - Driveline 00 - General
Check (Level) (For: Wheeled) 1. Make the machine safe. Refer to (PIL 01-03). 2. Open the inspection plug. 3. Make sure that the oil is level with the bottom of the aperture. 4. If necessary, top up the oil level. Refer to (PIL 27-00). 5. Wipe up any oil spillage. 6. Check the condition of the washer on the plug. If necessary, replace it. 7. Clean the plug and its aperture. 8. Install the plug. Do not overtighten the plug. 9. Do the steps 2 to 8 on the right side of the machine. Figure 313.
A
A Plug
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27 - Driveline
27 - Hub
27 - Hub Contents
Page No.
27-27-00 General ........................................................................................................................... 27-11
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Notes:
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27 - Driveline
27 - Hub
00 - General
00 - General Introduction .................................................... Component Identification ............................... Check (Condition) .......................................... Remove and Install ....................................... Disassemble and Assemble ..........................
Introduction 27-11 27-12 27-13 27-14 27-17
The hub is the part of the axle where the wheel is mounted and where the axle shaft (if installed) passes through. Some hubs are not driven and rotate due to motion of the machine and some driven hubs may also have reduction gearing installed. The hub may also be designed to allow steering of the wheels and/or incorporate brakes.
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27 - Hub
00 - General
Component Identification Figure 314. M N
L
C A E
B
N F
M K
D J
P
G H
A C E G J L N
Bolts 1 Spacer Front stub axle Bearing cap Case Drain plug Bolt 2
27 - 12
B D F H K M P
Sprockets Rear stub axle Bearing Shaft seal O-ring Nut Hub face
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27 - Hub
00 - General
Check (Condition) Thoroughly clean and dry all components. Examine the bearings, axle shaft and casing for wear or damage. Renew as necessary.
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27 - Driveline
27 - Hub
00 - General
Remove and Install Consumables Description Clear Silicone Sealant Special HP Grease
Part No. 4102/0901 4003/2020 4003/2017 4003/2006 4003/2005
Figure 315.
Size 0.31 L 0.5 kg 0.4 kg 12.5 kg 50 kg
Q
Remove 1. Make the machine safe. Refer to (PIL 01-03). 2. Remove the wheels from the machine. Refer to (PIL 27-29). 3. Remove the drain plug.
Q Bar 10. Remove the spider. Refer to (PIL 27-27).
4. Drain the oil from the chain case.
11. Lift the appropriate chain from the drive sprocket. Make a note that the inner chain drives the front hub, therefore lift the rear chain first.
5. Loosen the nut. 6. Remove the bolts 2 (x4).
12. Remove the nut.
7. Remove the hub adjustment bolt and nut. 8. Swing the hub assembly towards the centre of the machine so that the drive chain is at its slackest position. 9. Use a suitable bar to wedge the hub. Refer to Figure 315.
13. Remove the hub assembly. 14. Remove the chain from the sprocket. 15. Remove the hub assembly from the chassis. 16. Remove and discard the O-ring.
9.1. If the front hub is to be removed, both hubs on that side must be rotated to slacken both chains.
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27 - Driveline
27 - Hub
00 - General
Figure 316. M N
L
C A E
B
N F
M K
D J
P
G H
A C E G J L N
Bolts 1 Spacer Front stub axle Bearing cap Case Drain plug Bolt 2
27 - 15
B D F H K M P
Sprockets Rear stub axle Bearing Shaft seal O-ring Nut Hub face
9813/6050-2
27 - 15
27 - Driveline
27 - Hub
00 - General
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Apply a thin layer of silicon sealer to the groove before you install the new O-ring. Consumable: Clear Silicone Sealant 3. Apply a layer of the specified grease to the hub mounting face and O-ring. Consumable: Special HP Grease 4. Adjust the drive chains as follows: 4.1. Install the hub onto the machine. 4.2. Install the nut. 4.3. Position the adjustment bolt and nut into the slot in the adjustment bracket as shown at position 1. Refer to Figure 317. Figure 317. R
R Position 1 4.4. Use the bolt to push the hub away from the centre of the machine. This will tighten the chain. 4.5. Rotate the sprocket so that one side of the chain is tight. 4.6. Position the hub to give the specified slackness on the opposite side of the chain at the midway point. Dimension: 25 mm 4.7. When the correct tension is achieved, install the bolts 2. 4.8. Tighten the bolts 2 and nut to the correct torque value. Table 103. Torque Values Item M N
27 - 16
Nm 244 244
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27 - 16
27 - Driveline
27 - Hub
00 - General
Disassemble and Assemble Consumables Description Cleaner/Degreaser - General purpose solvent based parts cleaner JCB Retainer (High Strength) Special HP Grease
Part No. 4104/1557
2. Make a note that the spacer is only installed to the front hubs.
Size 0.4 L
3. Remove the bolts 1 (x6) and drive sprocket. 4. Support the assembly on the hub face.
4101/0602
0.05 L
4003/2020 4003/2017 4003/2006 4003/2005
0.5 kg 0.4 kg 12.5 kg 50 kg
5. Press out the stub axle assembly. 6. The bearing 1 will remain in the case. If necessary, remove it separately. 7. The cap of the bearing 2 will also be left in the case. If necessary, remove the cap of the bearing 2.
Disassemble
8. Remove and discard the shaft seal.
1. Use the alphabetical sequence shown on the illustration as a guide to disassembly.
9. Inspect the stub axle and case for wear or damage.
27 - 17
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27 - Hub
00 - General
Figure 318. M N
L
C A E
B
N F
M K
D J
P
G H
A C E G J L N
Bolts 1 Spacer Front stub axle Bearing 2 Case Drain plug Bolt 2
27 - 18
B D F H K M P
Sprockets Rear stub axle Bearing 1 Shaft seal O-ring Nut Hub face
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27 - 18
27 - Driveline
27 - Hub
00 - General
Assemble 1. The assembly procedure is the opposite of the disassembly procedure. Additionally do the following step. 2. Lubricate all the bearings and seals with the specified grease. Consumable: Special HP Grease 3. Clean the mating faces of the sprocket and hub with the specified cleaner. Consumable: Cleaner/Degreaser purpose solvent based parts cleaner
General
4. Place the sprocket onto the stub axle. 5. Apply a single run of the specified retainer to each bolt hole in the stub axle. Consumable: JCB Retainer (High Strength) 6. Apply three runs of the specified retainer to each bolt 1. Consumable: JCB Retainer (High Strength) 7. Install the bolts. 8. Tighten the bolts evenly to the correct torque value in a diagonal sequence while you rotate the hub to seat the bearings. 9. Make sure that the torque value required to rotate the hub after assembly must not be more than the specified value. Torque: 30 N¡m Table 104. Torque Values Item A
27 - 19
Nm 405
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29 - Wheel
29 - Wheel Contents
Page No.
27-29-00 General ........................................................................................................................... 27-21 27-29-15 Wheel Nuts .................................................................................................................... 27-24
27 - 20
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27 - Driveline
29 - Wheel
00 - General
00 - General Introduction .................................................... Health and Safety .......................................... Technical Data ............................................... Remove and Install .......................................
27 - 21
Introduction 27-21 27-22 27-22 27-23
On new machines, and whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct. Every day, before starting work, check that the wheel nuts are tight. Tighten the wheel nuts (in a diagonal sequence) to the correct torque value, refer to Technical Data.
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27 - Driveline
29 - Wheel
00 - General
Health and Safety
Technical Data
WARNING If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged. WARNING Wheels and tyres are heavy. Take care when lifting or moving them. Store with care to ensure that they cannot fall and cause injury. Use suitable lifting equipment if necessary.
Table 105. Description Wheel nut torque
Data 390 N¡m
WARNING An exploding tyre can kill. Inflated tyres can explode if over-heated or over-inflated. Follow the instructions given when inflating the tyres. Do not cut or weld the rims. Use a tyre/ wheel specialist for all repair work. WARNING Deflate the tyre you wish to change before removing the wheel from the machine. Air pressure in the tyres can cause the tyre and rim sections to explode causing serious injury or death. Never loosen the nuts that hold the inner and outer wheel halves together when there is air pressure in the tyre. Always wear safety glasses. WARNING Wheels installed with semi-solid tyres are heavy. Removing and installing them requires special equipment and training. Have the work carried out by your JCB dealer or a tyre specialist. WARNING Do not install pneumatic tyres on a wheel made for a solid tyre. Do not install a solid tyre on a wheel made for a pneumatic tyre. If you are unsure of the correct specification for your machine, contact your local JCB dealer or a trained specialist. DANGER Run flat inserts may be installed in the rear wheels. These must remain installed to the rear wheels to ensure machine stability is not compromised in the event of a deflated tyre. Make sure that all tyres are inflated to the correct pressure and have run flat inserts as required. Where run flat inserts have been specified for use, ensure that replacement wheels also have run flat inserts to ensure the machine stability.
27 - 22
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27 - Driveline
29 - Wheel
00 - General
Remove and Install Use the same procedure for all four wheels.
Remove 1. Make the machine safe. Refer to (PIL 01-03). 2. Loosen the nuts. Figure 319.
A A Nut 3. Raise and support the ends of the machine on blocks. Figure 320.
B B Block 4. Remove the road wheel.
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Tighten the nuts to the correct torque value. Table 106. Torque Values Item A
27 - 23
Nm 244
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27 - Driveline
29 - Wheel
15 - Wheel Nuts
15 - Wheel Nuts Check (Condition) Checking the Wheel Nut Torques On new machines, and whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct. Every day, before starting work, check that the wheel nuts are tight. Tighten the wheel nuts (in a diagonal sequence) to the torque value given in Technical Data.
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31 - Wheel Drive Pump
31 - Wheel Drive Pump Contents
Page No.
27-31-00 General ........................................................................................................................... 27-27 27-31-03 Coupling ......................................................................................................................... 27-37
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Notes:
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31 - Wheel Drive Pump 00 - General
00 - General Introduction .................................................... Preparation .................................................... Adjust ............................................................ Remove and Install ....................................... Disassemble and Assemble ..........................
27 - 27
Introduction 27-27 27-28 27-30 27-32 27-34
The transmission pump consists of two pump units, one for each drive motor, mounted in tandem on a common drive shaft which is driven by the engine.
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31 - Wheel Drive Pump 00 - General
Preparation Special Tools Description Pressure Gauge (0-40 Bar)
Part No. 892/00278
2. Place the machine safely on the blocks. Make sure that all four wheels are clear of the ground.
Qty. 1
3. Make sure that the machine is stable.
You must follow this procedure, when you start up a new installation or when you start an installation after removal of the pump or motor from the system.
4. Knock the hose connection at the rear main pump to make sure that the pump inlet line from the hydraulic filter to the pump unit is filled with oil.
If a new or rebuilt pump is installed, fill the pump with filtered oil before you start the machine. Use the correct oil. Refer to (PIL 75-03).
5. Install a specified pressure gauge applicable pressure test point. Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
1. Jack up the machine with a suitable jack. Figure 321.
A
A Pressure test point 5.1. Make a note that the location of the pressure test point may differ for different machine models.
the engine starts and runs at the lowest possible speed. 6.5. As air leaves the system, the charge pressure (as indicated on the gauge) must rise to a minimum of the specified value.
6. Check the pressure gauge reading. 6.1. Remove the ESOS (Engine Shut-Off Solenoid) fuse to prevent the engine from starting. 6.2. Keep the drive control lever at neutral position. 6.3. Turn the engine with the starter motor. The pressure gauge should show a small rise in pressure as the engine turns. 6.4. If so, install the ESOS fuse and operate the starter motor. At the same time slowly increase the throttle lever setting until
Pressure: 7 bar ( 101.4 psi) 6.6. If the charge pressure is incorrect, shutdown the machine and find the cause. 7. Once the correct charge pressure is established, operate the drive system 10 times in all directions with the engine at idle then slowly increase the engine speed, at the same time continue to operate the system. 8. Operate the system in all directions several times with the engine running at the maximum speed. 9. Switch off the engine.
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31 - Wheel Drive Pump 00 - General
10. Remove the pressure gauge. 11. Check the system oil level and top up as necessary. Refer to (PIL 27-00), (PIL 75-00).
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31 - Wheel Drive Pump 00 - General
Adjust
Adjustment
Special Tools Description Hand Pump Pressure Test
1. Jack up the machine with a suitable jack.
Part No. 892/00223
Qty. 1
2. Place the machine safely on the blocks. Make sure that all four wheels are clear of the ground. 3. Make sure that the machine is stable.
Before Adjustment The incorrect neutral setting of the servo piston causes the movement of the machine when the joystick is still in neutral position. To correct this fault you must adjust the wheel drive motor. Before you adjust the wheel drive motor, do the following:
4. Position the operator seat facing forwards so that the brakes are released. 5. Identify the adjustment.
pump
section
that
requires
Figure 322.
1. Check the condition of the tyres and tyre pressure.
C
D
1.1. The pressure of one tyre may be low or one/ both tyres on one side of the machine may be new and the other tyres worn. In both cases the rolling circumference of the tyres will be unequal. This causes the machine to change direction suddenly. 2. Check the chain tension. 2.1. Chains that have unequal tension will cause the machine to change direction to one side. 2.2. You must adjust the tension on all four chains. Do not adjust any one chain. A
3. Check the brake release pressure and the condition of seals.
B
3.1. Low pressure or faulty seals can cause the brake to drag on one side.
A B C D
3.2. Check the pressure at the anti-stall valve. 3.3. Use the hand pump to release the brake to check condition of the seal. Make sure that the seal holds the pressure.
5.1. If the machine moves to the left, either the right side wheels moving forward or the left side wheels moving in reverse.
Special Tool: Hand Pump Pressure Test (Qty.: 1)
5.2. Make a note that the pump P1 drives the left side motor and pump P2 drives the right side motor.
4. Check the drive joystick. 4.1. Make sure that the joystick spools do not stick. 4.2. Make sure that joystick levers operates correctly. If any of the above checks or adjustment cannot rectify the fault, then either the pump or motor could be faulty. To further identify the fault, interchange the motor feed hoses at the pump. If the machine now moves in the opposite direction then the pump is faulty. If the machine continues to move in the same direction the motor is faulty.
27 - 30
Locknut Adjusting screw Pump P1 (left side motor) Pump P2 (right side motor)
6. Stop the engine. 7. Remove the floor plates. Refer to (PIL 09-78). 8. Loosen the locknut. 9. Turn the neutral adjusting screw through the specified angle in the required direction.
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Angle: 36 ° 9.1. If the wheels are abnormally moving forward, turn the adjusting screw in a clockwise direction (looking underneath the pump). If the wheels are abnormally moving in reverse, turn the screw anticlockwise. 27 - 30
27 - Driveline
31 - Wheel Drive Pump 00 - General
9.2. Make a note that this adjustment is very sensitive. 9.3. You must turn the adjusting screw through only the specified angle at one time and check again. Angle: 36 ° 9.4. A slight movement when the wheels are raised is acceptable, there should be no movement when the machine is on the ground. 10. Tighten the locknut. 11. Start the engine. 12. Make sure that the wheels are stationary. 13. Tighten the locknut to the correct torque value. 14. Take care to retain the set position of the adjusting screw. 15. Check the wheels for movement again. Table 107. Torque Values Item A
27 - 31
Description Locknut
Nm 23
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27 - Driveline
31 - Wheel Drive Pump 00 - General
Remove and Install CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.
Remove
7. Loosen the bolt 2 from the rear sight side of the operator seat. Do not remove the bolt 2. 8. Rotate the operator seat towards the rear of the machine.
1. Make the machine safe. Refer to (PIL 01-03).
9. Disconnect the wiring harness and battery lead from the front seat mounting rail.
2. Disconnect the battery. Refer to (PIL 33-03).
10. Remove the seat mounting rail.
3. Remove the front floor plates. Refer to (PIL 09-78).
11. Disconnect all the hoses.
4. Drain the hydraulic tank. Refer to (PIL 30-00). 5. Disconnect the microswitch at the base of the seat. 6. Remove the bolts 1 (x2) from the front and left rear side of the operator seat.
12. Put a label on the hoses to help installation. 13. Plug all the open ports and hoses to prevent contamination. 14. Remove the bolts 3. 15. Remove the wheel drive pump from the machine.
Figure 323. B
C B
A Wheel drive pump C Bolts 3
27 - 32
A
B Hoses
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31 - Wheel Drive Pump 00 - General
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Tighten the bolts 3 to the correct torque value. 3. Fill the pump and hoses with clean oil before you install them. 4. Tighten the hydraulic connectors to the specified torque value. Torque: 45 –50 N¡m 5. Prime the pump. Refer to (PIL 30-11). Table 108. Torque Values Item C
27 - 33
Description Bolts 3
Nm 77
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27 - 33
27 - Driveline
31 - Wheel Drive Pump 00 - General
Disassemble and Assemble
Figure 324.
After you do a complete rebuild of the pump, it is necessary to set up the pump on a dynamic test jig. It is recommended that you must not disassemble the pump beyond that covered in the following procedures.
Shaft Seal Disassemble 1. Press shaft into the body against the spring force. 2. Remove the circlip.
D
2.1. When you remove the circlip, the seal carrier will move out by specified approximately distance due to spring force.
E C
Distance: 6 mm 3. Lightly tap the end of the shaft with a soft faced hammer.
F
4. Remove the seal carrier. 4.1. Make a note that after you remove the seal carrier, the shaft and bearing assembly are free to rotate in the body. You must not remove the shaft as this could cause loss of alignment of the pump internals. This could lead to total strip and rebuild requirement of the pump. 5. Remove and discard the O-ring 1. 6. Use a suitable press to press out the lip seal from the seal carrier. 7. Remove and discard the lip seal.
A
B
A B C D E F
Circlip Shaft Seal carrier Bearing O-ring 1 Seal
Assemble 1. Check the condition of the seal carrier for damage. 2. Check the condition of the sealing area on the shaft for signs of rust, wear or contamination. 3. If necessary, polish the sealing area on the shaft. 4. Apply suitable sealant on the outside diameter of the new lip seal. 5. Press the lip seal into the shaft bearing side of the seal carrier. 6. Make sure that the lip of the lip seal faces the shaft bearing. 7. Take care not to damage the lip seal. 8. Lubricate the inside diameter of the lip seal with petroleum jelly. 9. Install new O-ring 5 onto the seal carrier 3 and lubricate with petroleum jelly. 10. Wrap the splined end of the shaft with a thin plastic to prevent damage to the lip seal during installation.
27 - 34
9813/6050-2
27 - 34
27 - Driveline
31 - Wheel Drive Pump 00 - General
11. Slide the seal carrier over the shaft.
Assemble
12. Press the seal carrier into position in the pump body recess.
1. Check the condition of theHPRV and mating seat in plug 1 for damage. If necessary, replace them.
13. Press shaft into the body against the spring force.
2. Install the new O-rings 2 and back-up ring on the plug 1.
14. Install the circlip.
3. Make sure that the conical spring is correctly retained on the HPRV.
Charge Check and HPRV
4. Install the HPRV in the pump body.
The charge check valve and HPRV (High Pressure Relief Valve) are identical. The procedure given below is for disassembly and assembly of the HPRV, the procedure for the charge valve is the similar.
5. Install the plug 1.
Disassemble
Charge/Anti-stall Valve
1. Remove the plug 1.
6. Tighten the plug 1 to the correct torque value.
Disassemble
2. Remove the HPRV assembly. 3. Make a note that the smaller end of the conical spring is crimped to retain it on the HPRV. 4. Make a note that the HPRV is factory set and cannot be repaired. 5. Remove and discard the O-rings 2 and back-up ring.
1. Mark the pump components to help assembly. 2. Loosen the locknut. 3. Remove the plug 2 from the pump body. 4. Remove and discard the O-ring 3. 5. Remove the spring and poppet from the pump body.
Figure 325.
Figure 326.
M Q H L
J
J G G H J L
Plug 1 HPRV O-ring 2 back-up ring
27 - 35
J
P K
H L J
N
G
K M N P Q
Plug 2 Poppet Locknut O-ring 4 Spring
9813/6050-2
27 - 35
27 - Driveline
31 - Wheel Drive Pump 00 - General
Assemble 1. Check the condition of the poppet and mating seat in the pump body for damage. If necessary, replace them. 2. Install the new O-ring 3 on plug 2. 3. Install the poppet and spring into the pump body. 4. Install the plug 2 complete with the locknut into the pump body. 5. Make sure that all the parts are correctly aligned. 6. Tighten the locknut. 7. Check the charge pressure. If necessary, do the adjustment. Table 109. Torque Values Item G
27 - 36
Description Plug 1
Nm 68
9813/6050-2
27 - 36
27 - Driveline
31 - Wheel Drive Pump 03 - Coupling
03 - Coupling
Introduction
Introduction .................................................... 27-37 Component Identification ............................... 27-38
The wheel drive pump coupling is a gear type flexible coupling. It has the following components: •
An outer coupling attached to the engine drive plate An inner coupling attached to the pump input shaft
•
The outer and inner couplings are contained within the case and the wheel drive pump is attached to this case. All capscrews must be coated with JCB Threadlocker and Sealer, and tightened to the correct torque value. Table 110. Torque Values Item D E
27 - 37
9813/6050-2
Description Capscrew for inner coupling Capscrew for outer coupling
Nm 47 28
27 - 37
27 - Driveline
31 - Wheel Drive Pump 03 - Coupling
Component Identification Figure 327.
C
E B D
A
A B C D E
Outer coupling Inner coupling Case Capscrew Capscrews (x4)
27 - 38
9813/6050-2
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27 - Driveline
32 - Wheel Drive Motor
32 - Wheel Drive Motor Contents
Page No.
27-32-00 General ........................................................................................................................... 27-41
27 - 39
9813/6050-2
27 - 39
Notes:
27 - 40
9813/6050-2
27 - 40
27 - Driveline
32 - Wheel Drive Motor 00 - General
00 - General Introduction .................................................... Component Identification ............................... Remove and Install ....................................... Disassemble and Assemble ..........................
Introduction 27-41 27-42 27-47 27-52
The transmission drive motor has a gearwheel set connected by a valve drive to a disc valve. The gearwheel set consists of a toothed internal gear and a fixed external gear rim, The rollers form the teeth of external gear rim. The internal gear is free to rotate in a circular orbit within the gear rim. The disc valve is arranged to create a series of inlets and outlets which, as the gear rotates, always align precisely with the chambers formed between the internal gear teeth and the gear rim rollers. Oil under pressure passes through the disc valve inlets to the inter-tooth chambers on one side of the gearwheel set. These chambers are so shaped that the oil pressure within them creates an imbalance of forces which causes the internal gear to rotate. As the gear rotates the oil in the chambers is progressively connected to the disc valve outlets, from where it returns to tank. A cardan shaft connects the inner gear to the output shaft. The brake pack has a series of alternate friction plates and brake pads. The spring force holds the brake in the ON position and hydraulic pressure releases the brakes.
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32 - Wheel Drive Motor 00 - General
Component Identification For: Series 2 ............................. Page 27-42 For: Series 1 ............................. Page 27-43
(For: Series 2) Figure 328.
F
E D C A B
A Output shaft C Cardan shaft E Valve drive
27 - 42
B Brake pack D Gearwheel set F Disc valve
9813/6050-2
27 - 42
27 - Driveline
32 - Wheel Drive Motor 00 - General
(For: Series 1) Figure 329. For machines up to serial no. 751011 C D
X
Z B
A
N
AA
P Q
M
G
Y
H
AB
AD L
AS
AC
AF
AR
AG
J K
E
AH
AJ
AK F
R
AW
AL
AM
AN AP T
AE
U
S V
AQ
AU AV AT
W
A C E G J L N
Capscrew Bolts 1 Channel plate Balance plate Seal Disc valve O-ring
27 - 43
B D F H K M P 9813/6050-2
Washer Housing 1 Guide pin Spacer Valve drive Pin O-ring 27 - 43
27 - Driveline
32 - Wheel Drive Motor 00 - General
Q S U W Y AA AC AE AG AJ AL AN AQ AS AU AW
Seal Gear wheel set O-ring Hydraulic port Housing 2 Seal Shaft Friction discs O-ring Spring Circlip
27 - 44
R T V X Z AB AD AF AH AK AM AP AR AT AV
9813/6050-2
O-ring Inner gear Outer gear Bolts 2 O-ring Bearing Friction plate O-ring Spring Shaft seal Bearing
27 - 44
27 - Driveline
32 - Wheel Drive Motor 00 - General
Figure 330. For machines from serial no. 751012 to 807172 B
A
D C
H
J
K
G
E
F
J
H Q
U U
M
P S
AE
R
N
AD L AB
T V
AC W
AP
AL
AF
X AH
AN AG
AK
Y AM
A C E G J L N Q S U W Y AA AC AE
Shaft Bearing Cylinder block Piston Retaining rings Rear case Stop pin Seal ring Seal ring O-ring Brake housing Brake piston Plug Inner plates Shims
27 - 45
B D F H K M P R T V X Z AB AD AF 9813/6050-2
Z
AJ
AA
Front case Shaft seal Rollers Circlips Cam Distributor ring Seal ring O-ring Capscrews Shaft End cover Shims Gasket 27 - 45
27 - Driveline
32 - Wheel Drive Motor 00 - General
AG AJ AL AN
Seal O-ring Capscrew Spacer
27 - 46
AH AK AM AP
9813/6050-2
Seal Capscrew Spring disc Washer
27 - 46
27 - Driveline
32 - Wheel Drive Motor 00 - General
Remove and Install 2. Remove the floor plate. Refer to (PIL 09-78).
For: Series 2 ............................. Page 27-47 For: Series 1 ............................. Page 27-49
3. Remove the bolts (x6) and washers (x6) from inside of the chassis.
(For: Series 2)
4. Remove the cover.
Consumables Description JCB Retainer (High Strength) JCB Threadlocker and Sealer (Medium Strength)
Part No. 4101/0602
Size 0.05 L
4101/0250 4101/0251
0.01 L 0.05 L
The removal procedure for the wheel drive motor is divided into two sections: • •
Removal of wheel drive motors. Removal of drive sprocket and chains.
5. Remove and discard the gasket. 6. Turn both the stub axles until the drive chains are at their slackest position. Refer to (PIL 27-27). 7. If installed, remove the spider as follows: 7.1. Remove the bolts. 7.2. Remove the spider. 8. Remove the sprocket. 9. Remove and discard the oil seal. 10. Check the condition of the bearing. Do not remove the bearing until you replace it.
Remove Drive Sprocket 1. If necessary, remove the wheels from the machine. Refer to (PIL 27-29).
Figure 331.
F B
A
H G
J F D
A Bolts 1 C Cover E Bolts 2 27 - 47
C
B Washers D Gasket F Spider 9813/6050-2
27 - 47
27 - Driveline
32 - Wheel Drive Motor 00 - General
G Sprocket J Bearing
27 - 48
H Oil seal
9813/6050-2
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27 - Driveline
32 - Wheel Drive Motor 00 - General
Motor
3. Remove the capscrews (x4).
1. Remove the motor cover.
4. Remove the motor from the machine.
2. Disconnect the hydraulic hoses. Figure 332.
J
K
K Hoses
L Capscrews
Install
(For: Series 1)
1. The installation procedure is the opposite of the removal procedure. Additionally do the following step.
Consumables Description JCB Retainer (High Strength) JCB Threadlocker and Sealer (Medium Strength)
2. Apply specified threadlocker to the bolt 2. Consumable: JCB Threadlocker and Sealer (Medium Strength) 3. Apply the specified retainer to the capscrews. Consumable: JCB Retainer (High Strength) 4. Tighten the fasteners to the correct torque value. 5. Adjust the drive chain tension. Refer to (PIL 27-63). Table 111. Torque Values Item A E K L L L L
Description Bolts 1 Bolts 2 Hydraulic connections Capscrews (M10 x 30) Capscrews (M12 x 30) Capscrews (M14 x 35) Capscrews (M14 x 35)
Nm 28 56 47 56 98 220 220
Part No. 4101/0602
Size 0.05 L
4101/0250 4101/0251
0.01 L 0.05 L
The removal procedure for the wheel drive motor is divided into two sections: • •
Removal of wheel drive motors. Removal of drive sprocket and chains.
Remove Drive Sprocket 1. Make the machine safe. Refer to (PIL 01-03). 2. If necessary, remove the wheels from the machine. Refer to (PIL 27-29). 3. Remove the floor plate. Refer to (PIL 09-78). 4. Remove the bolts (x6) and washers (x6) from inside of the chassis. 5. Remove the cover. 6. Remove and discard the gasket.
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27 - Driveline
32 - Wheel Drive Motor 00 - General
7. Turn both stub axles until the drive chains are at their slackest position. Refer to (PIL 27-27). 8. If installed, remove the spider as follows:
9. Remove the sprocket. 10. Remove and discard the oil seal. 11. Check the condition of the bearing. Do not remove the bearing until you replace it.
8.1. Remove the bolts. 8.2. Remove the spider.
Figure 333.
F B
A
H G
J F D
A C E G J
Bolts 1 Cover Bolts 2 Sprocket Bearing
27 - 50
B D F H
C
Washers Gasket Spider Oil seal
9813/6050-2
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27 - Driveline
32 - Wheel Drive Motor 00 - General
Motor
3. Remove the capscrews (x4).
1. Remove the motor cover.
4. Remove the motor from the machine.
2. Disconnect the hydraulic hoses. Figure 334.
J
K Hydraulic hoses
K
L Capscrews
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Apply the specified threadlocker to the bolt 2. Consumable: JCB Threadlocker and Sealer (Medium Strength) 3. Apply the specified retainer to the capscrews. Consumable: JCB Retainer (High Strength) 4. Tighten the fasteners to the correct torque value. 5. Adjust the drive chain tension. Refer to (PIL 27-63). Table 112. Torque Values Item A E K L L L L
27 - 51
Description Bolts 1 Bolts 2 Hydraulic connections Capscrews (M10 x 30) Capscrews (M12 x 30) Capscrews (M14 x 35) Capscrews (M14 x 35)
Nm 28 56 47 56 98 220 220
9813/6050-2
27 - 51
27 - Driveline
32 - Wheel Drive Motor 00 - General
Disassemble and Assemble For: Series 2 ............................. Page 27-52 For: Series 1 ............................. Page 27-55
20. Support the front case and cam assembly on blocks.
(For: Series 2) Consumables Description Extreme Performance Moly Grease JCB Threadlocker and Sealer (Medium Strength)
19. Separate the rear case out from the front case and cam assembly.
Part No. 4003/1327 4003/1326 4101/0250 4101/0251
Size 0.4 kg 12.5 kg 0.01 L 0.05 L
21. Separate the cam assembly out from the front case. 22. Remove and discard the O-ring 2 and O-ring 3. 23. Tap the rear case lightly with a soft faced hammer to release the distributor ring. 24. Make a note of the position of the stop pin in the slot in the rear case.
Disassemble 1. Remove the wheel drive motor. Refer to (PIL 27-32). 2. Drain the oil from the wheel drive motor. Refer to (PIL 27-32). 3. Put a mark on the front case, rear case and brake housing to help installation.
25. Remove the stop pin. 26. Make a note that the slots in the rear case are identified L or R to make sure that the motor rotation is correct after assembly. 27. Remove and discard the seal rings (x3) from the distributor ring. 28. Remove the springs from their bores in the distributor ring.
4. Remove the capscrews 1. 5. Remove the end cover from the brake housing. 6. Remove and discard the gasket.
29. Separate the crankcase from the cam.
7. Remove the spring disc.
30. Remove the circlips and retaining rings from the crankcase.
8. Use LP (Low Pressure) compressed air to remove the brake piston from the brake housing.
31. Remove the pistons and the rollers from the crankcase.
9. Take care to collect the piston as it gets ejected.
31.1. If necessary, use the LP compressed air at the ports in the crankcase.
10. Remove and discard the seal 1 from the brake piston. 11. Remove the capscrews 2.
32. Remove and discard the O-rings 4 from the pistons.
12. Remove the washers 1.
33. Use a soft steel drift to remove the split ring and washer 2.
13. Separate the brake housing out from the rear case.
34. Support the front case on blocks and press the shaft out of the bearings.
14. Remove and discard the O-ring 1.
35. Remove the cone from the bearing 1.
15. Remove the seal 2 from inside of the brake housing.
36. Use a soft steel drift to remove the bearing 1 and bearing 2 cups from the front case.
16. Remove the brake pack from the brake housing.
37. Remove the bearing 2 cone from the shaft with a puller. If the bearing cone is damaged, replace the bearing.
17. If installed, remove the shim 1 and shim 2. 18. Remove the capscrews 3.
27 - 52
38. Remove and discard the shaft seal from the front case.
9813/6050-2
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32 - Wheel Drive Motor 00 - General
Figure 335. U
AP
AN AM AK AJ
AD
AE T AG AC AH AF AE
AL
AD
V S
W X AB AA
Z Y R
P Q
K J
N
M
H
F L
C A
G E
A C E G J L N Q S U
Capscrews 1 Gasket Brake piston Seal 2 Shims 1 Capscrews 2 Brake housing Capscrews 3 O-ring 2 Front case
27 - 53
B D F H K M P R T V 9813/6050-2
D
B
End cover Spring disc Seal 1 Brake pack Shims 2 Washer 1 O-ring 1 Rear case Cam O-ring 3 27 - 53
27 - Driveline
32 - Wheel Drive Motor 00 - General
W Y AA AC AE AG AJ AL AN
Distributor ring Stop pin Seal ring 2 Crankcase Retaining ring Rollers Split ring Shaft Shaft seal
27 - 54
X Z AB AD AF AH AK AM AP
9813/6050-2
Springs Seal ring 1 Seal ring 3 Circlip Piston O-ring 4 Washer 2 Bearing 1 Bearing 2
27 - 54
27 - Driveline
32 - Wheel Drive Motor 00 - General
Assemble
22. The remaining assembly procedure is the opposite of the disassembly procedure. Additionally do the following steps.
1. Clean all components with hydraulic oil. 2. Apply petroleum jelly on all the O-rings and seals. 3. Heat the bearing 2 cone and press onto the shaft with a bench press. 4. Press the shaft seal into the front case with a bench press.
23. Check the condition of the pistons and their bores in the crankcase for signs of damage. If necessary, replace them. 24. Inspect the springs for signs of damage or distortion. If necessary, replace them.
5. Take care not to damage the seal.
25. Clean the capscrews 2, capscrews 3 and mating parts thoroughly.
6. Fill grease in the space between the lips of the seal.
26. Apply the capscrews.
specified
threadlocker
to
the
7. Press the bearing 2 cup into the front case with a bench press.
Consumable: JCB Threadlocker and Sealer (Medium Strength)
8. Turn the front case over and press the bearing 1 cup into the front case with a bench press.
27. Inspect the brake plates for signs of wear or damage.
9. Cover the splines of the shaft with tape to protect the shaft seal.
27.1. You must not replace the brake plates individually, the entire brake plate pack must be replaced.
10. Install the front case assembly to the shaft assembly.
27.2. If you install the new brake plate pack, the overall length of the clamped pack must be within the specified dimension.
11. Check that the shaft seal is not damaged.
Dimension: 28.1 –28.3 mm
12. Remove the tape from the shaft splines.
27.3. You can achieve the desired dimension with the shims installed between the end of the brake plate pack and the rear case.
13. Heat the bearing 1 cone and press onto the shaft with a bench press to the specified load. You must rotate the front case when you install the bearing 1 cone.
27.4. If necessary, use the additional one or two brake plates to reduce the number of shims.
Force: 4 t 14. Use a bench press to apply specified pre-load to the bearing 1 cone while rotating the front case.
27.5. Apply a layer of specified grease to the contact surfaces of spring disc.
Force: 1.5 t
Consumable: Extreme Performance Moly Grease
15. Install the split ring onto the shaft. 16. Measure the gap between the bearing 1 and the split ring. 17. Remove the split ring. 18. Install the washer 2 with a thickness of between the specified value greater than the measured gap. Length/Dimension/Distance: 0.05 –0.1 mm
Item A L Q
Nm 15 73.5 119.5
(For: Series 1) For machines up to serial no. 751011
19. Install the split ring. 20. Remove the pre-load. 21. Check that the shaft runs freely and without binding, but with a slight stiffness, in the front case.
27 - 55
Table 113. Torque Values
Later wheel drive motors are installed with Eslock type bolts 1 which are wire locked. When early motors are disassembled the later type bolts must be installed and wire locked. The bolts must always be replaced whenever a motor is disassembled. New bolts and lock wire are supplied as part of the replacement seal kit.
9813/6050-2
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32 - Wheel Drive Motor 00 - General
To gain access to the brake only, remove bolts 2, do not disturb the bolts 1.
Disassemble 1. Use the alphabetical sequence shown on the illustration as a guide to disassembly. 2. After you remove the plug and washer, hold the unit in a suitable tool or jig. Make sure that the housing 1 faces upwards. 3. Put a mark on the positions of the housings 1, housing 2 and outer gear to help installation. 4. Remove the housing 1 and channel plate together. 5. Remove the guide pin before you separate the channel plate from the housing. 6. Remove the balance plate from the housing 1 as follows:
6.3. Press a mandrel into the hole and force out the balance plate. 7. Before you remove the inner gear, put a mark on its position in the outer gear to make sure that it is returned the same way on assembly. 8. Keep all parts of the gearwheel set together after removal. 9. Do not mix gearwheel parts from different motors. 10. Before you disassemble the brake assembly, seal the hydraulic port to prevent ingress of dirt. 11. Put a mark on the position of the flanges to help installation. 12. Keep the brake friction plates and discs together as a set. 13. Discard all the seals and O-rings.
6.1. Remove the spacer.
14. If you remove any bearings, replace them.
6.2. Fill the hole with grease to act as a hydraulic piston.
15. Clean all the parts in low aromatic kerosene.
27 - 56
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27 - Driveline
32 - Wheel Drive Motor 00 - General
Figure 336. For machines up to serial no. 751011 C D
X
Z B
A
N
AA
P Q
M
G
Y
H
AB
AD L
AS
AC
AF
AR
AG
J K
E
AH
AJ
AK F
R
AW
AL
AM
AN AP T
AE
U
S V
AQ
AU AV AT
W
A C E G J L N Q S
Plug Bolts 1 Channel plate Balance plate Seal 1 Disc valve O-ring 1 Seal 2 Gear wheel set
27 - 57
B D F H K M P R T 9813/6050-2
Washer Housing 1 Guide pin Spacer Valve drive Pin O-ring 2 O-ring 3 Inner gear 27 - 57
27 - Driveline
32 - Wheel Drive Motor 00 - General
U W Y AA AC AE AG AJ AL AN AQ AS AU AW
O-ring 4 Hydraulic port Housing 2 Seal 3 Shaft Friction discs O-ring 7 Spring Circlip
27 - 58
V X Z AB AD AF AH AK AM AP AR AT AV
9813/6050-2
Outer gear Bolts 2 O-ring 5 Bearing Friction plate O-ring 6 Spring Shaft seal Bearing
27 - 58
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32 - Wheel Drive Motor 00 - General
Assemble
Figure 337.
1. The assembly procedure is the opposite of the disassembly procedure. Additionally do the following step.
L
2. Soak the new brake plates in oil for the specified duration.
BC
Duration: 1 h
BD
3. Lubricate all the parts with oil.
K
4. Apply grease to all seals.
BB
5. Apply petroleum jelly to all the O-rings. 6. Make sure that the bearing is pressed fully onto the shoulder of the shaft.
T
7. When you install the bolts 2, tighten them in sequence to avoid tilting the bearing.
BA
8. Do the following procedure to make sure of the correct alignment of the gearwheel set components:
K L T BA BB BC BD
8.1. Put a mark 1 on any spline peak on the inner gear that lies across a valley of the lobes. 8.2. Put a mark 2 on the bottom of a spline tooth on the valve drive. 8.3. On the disc valve select a trough aligning with any outer hole and put a mark 3 the next peak to the left.
Valve drive Disc valve Inner gear Mark 1 Mark 2 Mark 3 Outer hole
8.4. When the disc valve, valve drive and inner gear are assembled, all marks must align. 8.5. If you do not follow the above procedure, it may result in the wrong direction motor driving. 9. When you assemble the outer gear to the housing 2, make sure that the holes are aligned. 10. Use petroleum jelly on the spacer to prevent it from dropping out during assembly. 11. When you install the bolts 1, tighten them initially to the specified value then slacken one half turn before you tighten to the correct torque value. Torque: 145 –155 N¡m 12. Wire lock the bolts in pairs as shown. Refer to Figure 338.
27 - 59
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32 - Wheel Drive Motor 00 - General
Table 114. Torque Values
Figure 338. Item A C Z AJ Port plugs
Torque Value 30 –60 N·m 135 –145 N·m 31 –39 N·m 31 –39 N·m 5 –10 N·m
For machines from serial no. 751012 to 807172 Disassemble 1. Use the alphabetical sequence shown on the illustration as a guide to disassembly.
27 - 60
9813/6050-2
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32 - Wheel Drive Motor 00 - General
Figure 339. For machines from serial no. 751012 to 807172 B
A
D C
H
J
K
G
E
F
J
H Q
U U
M
P S
AE
R
N
AD L AB
T V
AC W
AP
AL
AF
X AH
AN AG
AK
Y AM
A C E G J L N Q S U W Y AA AC AE
Shaft Bearing Cylinder block Piston Retaining rings Rear case Stop pin Seal ring Seal ring O-ring Brake housing Brake piston Plug Inner plates Shims
27 - 61
B D F H K M P R T V X Z AB AD AF 9813/6050-2
Z
AJ
AA
Front case Shaft seal Rollers Circlips Cam Distributor ring Seal ring O-ring Capscrews Shaft End cover Shims Gasket 27 - 61
27 - Driveline
32 - Wheel Drive Motor 00 - General
AG AJ AL AN
Seal O-ring Capscrew Spacer
27 - 62
AH AK AM AP
9813/6050-2
Seal Capscrew Spring disc Washer
27 - 62
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32 - Wheel Drive Motor 00 - General
Assemble 1. The assembly procedure is the opposite of the disassembly procedure.
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33 - Tyre
33 - Tyre Contents
Page No.
27-33-00 General ........................................................................................................................... 27-65
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33 - Tyre
00 - General
00 - General
Introduction
Introduction .................................................... 27-65 Health and Safety .......................................... 27-66 Check (Condition) .......................................... 27-66
Tyres provide a flexible cushion that absorb shocks, while keeping the wheel in close contact with the ground. Tyre materials are usually synthetic rubber, natural rubber, fabric and wire, along with other compound chemicals. They consist of a tread and a body. The tread provides traction while the body ensures support. Make sure that the tyres are kept in good condition.
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33 - Tyre
00 - General
Health and Safety
Check (Condition)
DANGER Make sure that all tyres are inflated to the correct pressure. Refer to the machine operator manual. WARNING An exploding tyre can kill. Inflated tyres can explode if over-heated or over-inflated. Follow the instructions given when inflating the tyres. Do not cut or weld the rims. Use a tyre/ wheel specialist for all repair work. WARNING Wheels and tyres are heavy. Take care when lifting or moving them. Store with care to ensure that they cannot fall and cause injury. Use suitable lifting equipment if necessary. WARNING Do not use the machine with damaged, incorrectly installed, incorrectly inflated or excessively worn tyres. Recognise the speed limitation of the tyres installed and do not operate at more than their recommended maximum speed. WARNING Running tyres outside recommended guidelines may result in failure of the tyres which at high speeds may endanger life. WARNING Deflate the tyre you wish to change before removing the wheel from the machine. Air pressure in the tyres can cause the tyre and rim sections to explode causing serious injury or death. Never loosen the nuts that hold the inner and outer wheel halves together when there is air pressure in the tyre. Always wear safety glasses. WARNING Do not install pneumatic tyres on a wheel made for a solid tyre. Do not install a solid tyre on a wheel made for a pneumatic tyre. If you are unsure of the correct specification for your machine, contact your local JCB dealer or a trained specialist. WARNING When ordering tyres, you must specify not only the tyre size but also the speed designation. The correct tyres for the machine are shown in the Operator's Manual. On no account should you use tyres of other designations without first gaining approval from the machine manufacturer. WARNING Remove the valve core to make sure the tyre is fully deflated. If the tyre is not fully deflated, unseen damage to the wheel and / or tyre could cause the assembly to explode.
Always drive with consideration for the condition of the tyres. Incorrect tyre pressures will affect the stability of the machine. Check the tyres daily for the correct tyre pressure and signs of damage. For example: • • •
Signs of distortion (bulges). Cuts or wear. Embedded objects (nails, etc.).
Install the valve caps firmly to prevent dirt from entering the valve. Inspect for leaks when you check the tyre pressures. Inspect the tyre valve for leaks, when you check the tyre pressures.
Tyre Inflation Always try to maintain the tyre pressure to the recommended settings. Using a machine with underinflated tyres means: • • • • •
Decreasing the machines stability. Higher tyre temperatures. Excessive strain of the tyre fabric. Causes bulging of the sidewalls. Shortens the tyres life.
Using the machine with over-inflated tyres is dangerous: •
It causes excessive tensile loads in the fabric: this makes a tyre more susceptible to cuts and punctures.
Do not cut or weld on the rim of an inflated tyre. After checking or amending the tyre pressure always replace and secure the valve cap. Always deflate the tyre before removing foreign obstacles from the tread.
Procedure These instructions are for adding air to a tyre which is already inflated. If the tyre has lost all its air pressure, call in a qualified tyre mechanic. The tyre mechanic should use a tyre inflation cage and the correct equipment to do the job. 1. Prepare the wheel. Before you add air to the tyre, make sure it is correctly installed on the machine or installed in a tyre inflation cage.
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Figure 340.
2. Prepare the equipment. 2.1. Use only an air supply system which includes a pressure regulator. Set the regulator no higher than 1.38 bar (20 psi) above the recommended tyre pressure. 2.2. Use an air hose fitted with a self-locking air chuck and remote shut-off valve. 3. Add the air. 3.1. Make sure that the air hose is correctly connected to the tyre valve. Clear other people from the area. Stand behind the tread of the tyre while adding the air. 3.2. Inflate the tyre to the recommended pressure. Do not over-inflate.
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36 - Track Contents 27-36-00 27-36-06 27-36-12 27-36-15 27-36-18 27-36-24 27-36-27
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Page No. General ........................................................................................................................... Rubber Track ................................................................................................................. Gearbox Sprocket .......................................................................................................... Frame ............................................................................................................................. Idler Wheel ..................................................................................................................... Bottom Roller ................................................................................................................. Tensioner/Recoil unit ......................................................................................................
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27-69 27-81 27-86 27-87 27-89 27-91 27-93
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00 - General Introduction .................................................... Health and Safety .......................................... Component Identification ............................... Fault-Finding .................................................. Check (Condition) .......................................... Adjust ............................................................
Introduction 27-69 27-70 27-71 27-73 27-77 27-80
The track assemblies are mounted on each side of the machine chassis in place of the wheel hubs. The machine sits on rollers which run inside the rubber track. A front idler wheel slides in grooves in the track frame and locates against the spring loaded tensioner which protects the track against shock loadings. A grease filled hydraulic cylinder inside the recoil unit provides a facility for the correct tensioning of the track. The rear idler wheel gives an additional secure location for the track. The track is rotated by a hydraulic motor mounted on the track frame. The sprocket on the output shaft of the motor locates in holes in the track.
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Health and Safety Raised Machine Never position yourself or any part of your body under a raised machine which is not correctly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed. CAUTION! The following operations must only be undertaken by persons familiar with track changing operations and who are qualified to perform the operations. All persons must keep clear of the machine driven sprocket. CAUTION! Ensure that all persons are clear of the track and especially of the driven sprocket during the following operations. Notice: When converting a machine from steel tracks to rubber tracks, the track guides must be removed. When converting from rubber tracks to steel tracks the track guides must be installed. Damage to the tracks may result if this is not carried out. WARNING! Recoil unit servicing must only be carried out by JCB dealers. You could be killed or injured if you tamper with it. CAUTION! The recoil unit spring can cause serious injury if suddenly released. Take great care when removing and replacing the spring retaining nut. Scrap recoil units must be dismantled before transfer from the workshop. Do not use flame cutting equipment unless precautions are taken to release the spring pressure slowly.
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Component Identification F Hydraulic motor G Sprocket H Track frame
Figure 341. B
H
E A B C D E
G
F
A
D
C
Rollers Rubber Track Front idler wheel Grease Tensioner (Spring loader recoil unit) Rear idler wheel
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Figure 342.
C D G
F
H
A A D F H
Rollers Grease Tensioner (Spring loader recoil unit) Hydraulic motor Track frame
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E C Front idler wheel E Rear idler wheel G Sprocket
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Fault-Finding Fault Core Bar (Separation) Core Bars (Breaking in the middle) Core Bars (Breaking on the wings) Core Bars (Fast Abrasion) Core Bars (Oxidation (Rusting) Steel Cord (Breaking) Steel Cord (Separation) Steel Cord (Exposure) Steel Cord (Sticking Out) Outer Track Rubber - Tearing/Cuts Outer Track Rubber (Fast Abrasion) Outer Track Rubber (Cracks) Outer Track Rubber (Longitudinal Cracks) Inner Track Rubber (Tearing/Cuts) Inner Track Rubber (Cracks) Miscellaneous (Not Engaging Correctly) Miscellaneous (Detracking)
Table 115. Table 116. Table 117. Table 118. Table 119. Table 120. Table 121. Table 122. Table 123. Table 124. Table 125. Table 126. Table 127. Table 128. Table 129. Table 130. Table 131.
Table 115. Core Bar (Separation) Cause Low track tension, the core bars are likely to hit the running gear components and lead to separation from the track Hard material (stone, metal) stuck between the top of the two core bars Sprocket teeth badly worn (hook-shaped)
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Remedy Check the track tension regularly (as recommended in service schedules)
Clean the tracks regularly as recommended, particularly after operation in clay soil When installing a track on a machine, always make sure that the sprocket is in good condition. If the sprocket is damaged it must be changed Oxidation (rusting) of the core bars Regularly clean and grease the components If one or more core bars are separated from the track Replace the track
Table 116. Core Bars (Breaking in the middle) Cause Excessive track tension together with a shock load, for example, climbing pavement edges Hard material (stone, metal) stuck between the sprocket and the core bar with excessive track tension Abrasion of the teeth Idler spring ineffective
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Remedy Check the track tension regularly (as recommended in service schedules) Clean the tracks regularly as recommended, particularly after operation in clay soil The track is not appropriate for the sprocket. Make sure that the sprocket is not excessively worn and is in good condition Clean the spring if it is clogged (with clay, for instance) and make sure that it is in working order
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Table 117. Core Bars (Breaking on the wings) Cause Only one side of the track is in contact with the ground, for instance, sitting astride a trench, or passing over pavement edges at an angle. If one or more core bars are broken If the core bars break on the wings
Table 118. Core Bars (Fast Abrasion) Cause The sprocket is not correct for the track The teeth of the sprocket are worn (hook shaped) Operating environment is extremely abrasive Core bars are worn out
Table 119. Core Bars (Oxidation (Rusting) Cause Operating in an environment which increases likelihood of oxidation (rusting), for example newly spread compost ground could increase acidic or alkali values Prolonged exposure to detergents, paint, solvents or fuel If the core bars are slightly rusted
Table 120. Steel Cord (Breaking) Cause The sprocket is not appropriate for the track (the pitch does not fit). Hard material (stone, metal) stuck between the track and the sprocket with excessive track tension The steel cord has been exposed and rusted The steel cord is broken Table 121. Steel Cord (Separation) Cause Excessive tension of the track (during installation, excessive tension plus a foreign body, shearing sharp bend on hard surface) The sprocket is not appropriate for the track
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Remedy Always operate the machine on both tracks. Use a ramp to mount and dismount from pavement edges Replace the track The track can still be used but note that eventually long term damage will occur unless the track is replaced Remedy Make sure that the sprocket is genuine JCB. Make sure the sprocket is in good condition Replace the sprocket. When new tracks are installed, the sprockets should always be checked (and renewed if necessary). Clean the tracks with fresh water The track must be replaced (The track does not have to be replaced if the core bar abrasion is below approximately 20%) Remedy Clean the tracks with fresh water after operation. Make sure that the visible metallic components of the track are greased Clean the tracks with fresh water after operation in areas where chemicals can attack the tracks The track can be used. However, the propagation of rust under the rubber should be monitored, otherwise it is possible that the core bar will separate from the rubber Remedy Make sure that the sprocket is genuine JCB. Make sure the sprocket is in good condition. Check the tension regularly. Clean the tracks regularly as recommended, particularly after operation in clay soil As soon as you see small cracks on the lug side, clean with water and repair immediately The track must be replaced. As a preventive measure always check the tension Remedy Check the tension regularly Make sure that the sprocket is genuine JCB. Make sure the sprocket is in good condition
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Table 122. Steel Cord (Exposure) Cause Stones and sharp material can tear the rubber and expose the steel cord
Individual strands of steel cord sticking out of the track does not necessarily mean the track needs to be replaced Table 123. Steel Cord (Sticking Out) Cause Strands of the steel cord may sometimes stick out of the rubber track. This is caused by the friction of the sprocket against the edges of the track sprocket holes
Remedy The life expectancy of a track is greatly reduced by working on a site where sharp and pointed materials are numerous. Operate the machine with attention to the ground surface in rough terrain, e.g. demolition sites, rocky ground etc. Individual strands can be cut off (the number of steel cord strands is always over specified), however exposed strands should be repaired immediately (see recommended repair procedures) Remedy Individual strands of steel cord sticking out of the track does not necessarily mean the track needs to be replaced. Individual strands can be cut off (the number of steel cord strands is always over specified), however exposed strands should be repaired immediately (see recommended repair procedures
Table 124. Outer Track Rubber - Tearing/Cuts Cause Cuts on the lug are often due to particularly sharp materials such as stones, the problem is particularly evident if using sharp driving techniques on demolition type ground (e.g. stones, debris etc.)
Remedy The life expectancy of a track is greatly reduced by working on a site where sharp and pointed materials are numerous. Operate the machine with attention to the ground's surface in rough terrain, e.g. demolition sites, rocky ground etc. The life expectancy of a track is greatly reduced by Operate the machine with attention to the ground's working on a site where sharp and pointed materials surface in rough terrain, e.g. demolition sites, rocky are numerous ground etc.
Table 125. Outer Track Rubber (Fast Abrasion) Cause Sharp driving on hard and abrasive surfaces, for example concrete, asphalt etc. Operation on surfaces where the temperature is unusually high, for instance, travelling over freshly laid asphalt A track can still be used if the lug is higher than 5mm Table 126. Outer Track Rubber (Cracks) Cause Bending fatigue of the rubber after excessive use Long storage (a few months) outside in the sunlight The track can be used as long as the cracks do not reach the metallic components of the track
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Remedy Operate the machine with care, avoid making quick and repeated turns Do not stay too long on very hot surfaces. On the other hand, the track is safe if you just go across this area. If less than 5mm, the track must be replaced. Refer also to warranty pro-rata use scale Remedy Make sure cracks do not reach the metallic components of the track Tracks must be stored indoors or under cover away from direct sunlight and bad weather When the cracks expose the steel cords, the track must be replaced or repaired
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Table 127. Outer Track Rubber (Longitudinal Cracks) Cause Remedy The edges of the rubber track are often deformed Operate the machine with care, avoid concrete largely due to a bumpy ground surface, stones pavements and big rocks and other objects, which cause intensive stress on the edges resulting in damage. Especially when a machine drives over concrete pavements, this type of damage easily occurs Table 128. Inner Track Rubber (Tearing/Cuts) Cause Remedy Stones and sharp material can tear the rubber at the The life expectancy of a track is greatly reduced by edges of the track working on a site where sharp and pointed materials are numerous. Operate the machine with attention to the ground's surface in rough terrain, e.g. demolition sites, rocky ground etc. Driving close to pavement edges and ridges Drive the machine carefully, avoid driving over causing the edges to be forcefully bent against the projections, prevent the track edges from contacting track frame ridges etc. The track can be used as long as the cuts do not When the cracks expose the steel cords, the track reach the metallic components must be replaced or repaired Table 129. Inner Track Rubber (Cracks) Cause Excessive tension of the rubber Excessive vibration whilst the machine remains stationary, for example using an auxiliary attachment such as a hammer The track can be used as long as the cuts do not reach the metallic components
Remedy Check the tension regularly Do not let the machine sit too long in the same position when operating in these conditions. Move the machine from time to time so that the pressure of the vibrations is not always felt on the same place of the track When the cracks expose the steel cords, the track must be replaced or repaired
Table 130. Miscellaneous (Not Engaging Correctly) Cause Remedy Excessive abrasion of the sprocket teeth Make sure that the sprocket is genuine JCB. Make sure the sprocket is in good condition Excessive tension of the track leading to incorrect Check the track tension regularly (as recommended track pitch in service schedules) Table 131. Miscellaneous (Detracking) Cause Low track tension The rollers are worn out and the track is not correctly guided Sharp bends (shearing stress) Machine working following a hillside which weathers or is soft
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Remedy Check the tension regularly Check the rollers and running gear components in accordance with the recommended service intervals Drive carefully on hard surfaces like concrete, asphalt etc. Make sure that the ground is firm when working along a hillside and drive carefully
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Check (Condition)
Figure 345. Core Bars (Fast Abrasion)
Rubber tracks are used in numerous operating environments / applications, it is therefore possible that damage may occur to the track. The damage may be superficial and the track can continue to be used or repaired, but sometimes it may be necessary to replace the track to avoid damage to the track running gear. Below are some examples of typical failures, refer to the fault finding tables for possible causes, prevention and corrective actions.
Figure 346. Core Bars (Oxidation)
Figure 343. Core Bars (Separation)
Figure 347. Steel Cord (Breaking)
Figure 344. Core Bars (Breaking)
Figure 348. Steel Cord (Separation)
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Figure 349. Steel Cord (Exposure)
Figure 351. Outer Track Rubber (Tearing/Cuts)
Figure 352. Outer Track Rubber (Fast Abrasion) Figure 350. Steel Cord (Sticking Out)
Figure 353. Outer Track Rubber (Cracks)
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Figure 354. Outer Track Rubber (Longitudinal Cracks)
Figure 356. Inner Track Rubber (Cracks)
Figure 355. Inner Track Rubber (Tearing/Cuts)
B A
A Cut B Tear
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Adjust
Figure 358. B
Correct track tension is important for good performance and to prevent the tracks from dismounting. The forward idler which is attached to a grease filled hydraulic cylinder controls the track tension. The track tension should be checked as follows:
C A
1. Make the machine safe. Refer to (PIL 01-03). 2. Clean the track. 3. Make sure that all debris is removed from around the sprocket and rollers. 4. Drive the machine backwards and forwards while cleaning.
A Bolts B Access plate C Plug
5. Lift the tracks off the ground to the specified distance with the bucket in dump position and the rear stabiliser legs up.
9.3. To tighten the track, pump grease into the nipple with a grease gun.
Distance: 150 mm
9.4. To loosen the track, carefully remove the hexagon plug and allow the grease to flow into a suitable container.
6. Make sure that the track is completely clear of the ground. 7. Put a ruler between the two middle rollers and measure the distance from the machine frame to the track. 8. Make sure that the gap is as specified.
10. When the correct adjustment is achieved, install the cover plate. 11. Do the steps 6 to 9.4 for the opposite track.
Dimension: 103 mm Figure 357. X
E D D E F X
F
Ground clearance ( 150 mm) Bucket dumped Stabiliser leg Distance between frame and track ( 103 mm)
9. If necessary, adjust the gap as follows: 9.1. Remove the bolts. 9.2. Remove the access plate. 27 - 80
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06 - Rubber Track
06 - Rubber Track Introduction .................................................... Fault-Finding .................................................. Repair ............................................................ Remove and Install .......................................
Introduction 27-81 27-82 27-82 27-84
Track Construction The structure of the rubber track consists of core bar and steel cord encased in the rubber track. The core bar and steel cord give the track its internal strength and ensure engagement of the sprocket whilst the rubber provides flexibility. Compared to steel tracks, the characteristics of the materials used for the rubber tracks bring about significant improvements. They do not damage paved and fragile surfaces, they offer more comfort to the user and are quieter than steel tracks. Figure 359.
L
N
M
L Rubber track M Core bar N Steel cord
Serial Number Location and Production Date The track is embossed with the production date and serial number.
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Figure 360.
Fault-Finding Refer to Track-Fault Finding (PIL 27-36).
Repair Minor cuts which occur between the lugs can be repaired with a suitable repair kit. Cuts no longer than 30 mm and no deeper than 10 mm do not need to be repaired. Cuts beyond these dimensions should be repaired as detailed. Note, if steel is evident (irrespective of cut size), then a repair should be completed to prevent oxidation (rusting) and subsequent long term damage. Specialist rubber compounds for cold vulcanisation can be purchased from various outlets. The procedures below describe typical good practice repair procedures. Always check the manufacturer's instructions. 1. Use a brush or compressed air to clean the cut thoroughly to make sure of the correct adhesion of the bonding agents. If oil is evident, a cleaning solution should be used to make sure the area is dry.
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Figure 361.
4. Mix the rubber compound. Note, the repair rubber is usually supplied as two separate compounds which are mixed together in equal quantities. Follow the manufacturers instructions. Figure 364.
2. Use sandpaper or a clean wire brush to roughen the area in and around the cut to make sure of good bonding adhesion. Make sure that the area is roughened approximately 30 to 40 mm wider than the cut. Clean the area using a suitable air compressor. Figure 362.
5. Make sure that the adhesive applied in 3 has completely dried and then apply another adhesive layer. When the second adhesive layer is almost dry (sticky to the touch) the rubber compound should be firmly applied to the cut. The compound should be higher than the original rubber track by Length/Dimension/Distance: 2 mm 6. Allow to harden. Approximate curing times: Table 132. Curing Time (Hours) 24 48 72
3. Apply the adhesive. Figure 363.
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Temperature 30 °C ( 86.0 °F) 40 °C ( 103.9 °F) - 45 ( 112.9 ) 50 °C ( 121.9 °F) - 60 ( 139.9 )
If the cut is on the track edge, this is more difficult to repair. In some instance, it is possible to repair with a strong bonding adhesive.
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Remove and Install
Figure 366.
Lifting Equipment
C
You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations.
D
Remove 1. Position the machine on a firm, level surface. 2. Raise the machine on the side to be worked on as follows: 2.1. Place a block of wood under one end of the shovel and fully lower and tilt the shovel onto the block so as to raise the front of the machine.
C Sling D Steel bar 5. Use the hoist to lift the track clear of the sprocket. 6. Unscrew the sprocket retaining bolts and remove the sprocket. Figure 367.
2.2. Position blocks under the front and rear of the chassis then raise the shovel to lower the machine so that the chassis sits on the blocks. Alternatively use a suitable jack to raise the machine, take care not to damage the chassis.
E F
3. Remove the access cover and unscrew the grease adjuster to release the track tension. Collect and discard the grease. Use a lever to push the front idler wheel fully in. Figure 365. B
A
E Bolt F Sprocket 7. Position a support under the track to take up the sag at the bottom. 8. Manoeuvre the track off the rear idler and away from the machine.
Install
A Access cover B Grease adjuster 4. Thread a sling through holes in the track between the rear idler and the sprocket. Insert a suitable round section steel bar between the sling and the track. Use a hoist to raise the bar so as to rotate the track slightly until the bar is positioned at the top of the sprocket.
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1. Position the track so that it locates under the bottom rollers and around the front and rear idler wheels. Position a support under the track to take up the sag at the bottom. 2. Place a steel bar under the track adjacent to the sprocket and support the weight of the track. 3. Assemble the sprocket to the motor flange and tighten the securing bolts. Operate the track
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motor to rotate the sprocket as necessary to locate its teeth into the grooves of the track. 4. Lower the track onto the sprocket and remove the hoist and bar. 5. Pump grease into the adjuster to extend the front idler wheel ensuring that the track is correctly located on the idler wheels and guide rollers. 6. Lower the machine to the ground and adjust the track tension. 7. Replace the access cover. Recheck the track adjustment after the machine has been driven for a while. Table 133. Torque Values Item F
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Description Sprocket
Nm 300
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12 - Gearbox Sprocket
12 - Gearbox Sprocket
3. Install the track (PIL 27-36-06) Refer to: PIL 27-36-06.
Remove and Install Special Tools Description Grease Gun Attachment Grease Gun Consumables Description Special HP Grease
4. Pump grease into the grease tensioner to extend the front idler wheel to make sure that the track is correctly located on the idler wheels and guide rollers.
Part No. 892/00913
Qty. 1
992/11300
1
Part No. 4003/2020 4003/2017 4003/2006 4003/2005
Size 0.5 kg 0.4 kg 12.5 kg 50 kg
Special Tool: Grease Gun (Qty.: 1) Special Tool: Grease Gun Attachment (Qty.: 1) Consumable: Special HP Grease 5. Lower the machine to the ground and adjust the track tension. Recheck the track adjustment after the machine has been driven. Table 134. Torque Values Item E
Removal
Nm 300
1. Position the machine on a firm, level surface. 2. Remove the track (PIL 27-36-06). Refer to: PIL 27-36-06. 3. Remove the sprocket retaining bolts and remove the sprocket. Figure 368.
E F
E Retaining bolts F Sprocket
Install 1. Installation is a reversal of the removal procedure. Note the following: 2. Assemble the sprocket to the motor flange and tighten the retaining bolts. Operate the track motor to rotate the sprocket as necessary to locate its teeth into the grooves of the track. 27 - 86
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15 - Frame
15 - Frame
Figure 369.
Remove and Install Lifting Equipment You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations. Notice: Do not pull the frame too far away otherwise the hoses will rip off.
Remove 1. Position the machine on a firm, level surface. 2. Raise the machine on the side to be worked on as follows: 2.1. Place a block of wood under one end of the shovel and fully lower and tilt the shovel on to the block so as to raise the front of the machine.
6. Remove the bolts from the front mounting. Figure 370.
B
2.2. Position blocks under the front and rear of the chassis then raise the shovel to lower the machine so that the chassis sits on the blocks. Alternatively use a suitable jack to raise the machine, taking care not to damage the chassis.
A
3. Remove the track. Refer to (PIL 27-36). Refer to: PIL 27-36-06. 4. Mark the hoses to aid installation, disconnect the motor feed and return hoses. 5. Put a sling around the track frame and support the weight using a suitable hoist.
A Front mounting bolts B Rear mounting bolts 7. Remove the bolts from the rear mounting. It will be necessary to release the top two bolts gradually whilst easing the frame away from the machine. 8. Once access has been gained, disconnect the motor drain and brake hoses, mark the hoses to aid installation. 9. Manoeuvre the track frame away from the machine.
Install 1. Replacement is a reversal of the removal procedure. 2. Tighten the bolts to the correct torque value. 27 - 87
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15 - Frame
Table 135. Torque Values Item A B
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Nm 220 220
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18 - Idler Wheel
18 - Idler Wheel
Remove and Install
Remove and Install ....................................... 27-89 Disassemble and Assemble .......................... 27-90
Remove This component can be removed without removing the track frame from the machine. Figure 371.
A
A Rear idler wheel 1. Make the machine safe, refer to (PIL 01-03). 2. Remove the track, refer to (PIL 27-36). 3. Remove the bolts that secure the rear idler wheel 4. Remove the rear idler wheel.
Install Installation is a reversal of the removal procedure.
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18 - Idler Wheel
Disassemble and Assemble When dismantling this assembly, check components for wear and renew if necessary.
the
Figure 372.
1 4 5
2
6
3
7 8
1 3 5 7
Rim Bracket Plug O-ring
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2 4 6 8
Seal Bearing Shaft Bracket
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24 - Bottom Roller
24 - Bottom Roller
Remove and Install
Remove and Install ....................................... 27-91 Disassemble and Assemble .......................... 27-92
Remove These components can be removed without removing the track frame from the machine. Figure 373.
A
B A Roller 1. Make the machine safe. refer to (PIL 01-03). 2. Remove the track. (refer to (PIL 27-36). 3. Remove the bolts that secure the roller. 4. Remove the roller assembly.
Install 1. Installation is a reversal of the removal procedure.
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24 - Bottom Roller
Disassemble and Assemble When dismantling this assembly, check components for wear and renew if necessary.
the
Figure 374.
7
6
5
1 2 3
4
1 2 3 4 5 6 7
Bracket Seal Plug Circlip Shaft Centre bracket Bracket
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36 - Track
27 - Tensioner/Recoil unit
27 - Tensioner/Recoil unit Health and Safety .......................................... Technical Data ............................................... Remove and Install ....................................... Disassemble and Assemble ..........................
27 - 93
Health and Safety 27-93 27-94 27-94 27-95
WARNING Recoil unit servicing must only be carried out by JCB dealers. You could be killed or injured if you tamper with it. CAUTION The recoil unit spring can cause serious injury if suddenly released. Take great care when removing and replacing the spring retaining nut. Scrap recoil units must be dismantled before transfer from the workshop. Do not use flame cutting equipment unless precautions are taken to release the spring pressure slowly.
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36 - Track
27 - Tensioner/Recoil unit
Technical Data
Remove and Install
Table 136. Component Front idler wheel and recoil unit Rear idler wheel Guide roller
Weight 60.5 kg 32.2 kg 27.8 kg
CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.
Remove These components can be removed without removing the track frame from the machine. Figure 375.
A
B
A Idler wheel B Grease tensioner 1. Position the machine on a firm, level surface. 2. Raise the machine on the side to be worked on as follows: 2.1. Place a block of wood under one end of the shovel and fully lower and tilt the shovel onto the block so as to raise the front of the machine. 2.2. Position blocks under the front and rear of the chassis then raise the shovel to lower the machine so that the chassis sits on the blocks. Alternatively use a suitable jack to raise the machine, taking care not to damage the chassis. 3. Remove the track, refer to (PIL 27-36). 4. Remove the Idler wheel and grease tensioner assembly. 27 - 94
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36 - Track
27 - Tensioner/Recoil unit
Disassemble and Assemble
Install Replacement is a reversal of the removal procedure.
CAUTION The recoil unit spring can cause serious injury if suddenly released. Take great care when removing and replacing the spring retaining nut. Scrap recoil units must be dismantled before transfer from the workshop. Do not use flame cutting equipment unless precautions are taken to release the spring pressure slowly. The Illustration shows the complete recoil unit/Idler wheel assembly. We recommend that the recoil unit is not disassembled, replace this assembly. Figure 376.
A B C
A Idler wheel B Recoil unit C Spring retaining nut When dismantling the Idler wheel assembly, check the components for wear and renew if necessary.
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27 - Tensioner/Recoil unit
Figure 377.
1 8
2 3 4 5
6 7
9
8
1
2 5 1 2 3 4 5 6 7 8 9
Idler wheel Bracket left Plug Circlip Shaft Bearing Seal Bracket right O-ring
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37 - Track Drive Pump
37 - Track Drive Pump Contents
Page No.
27-37-00 General ........................................................................................................................... 27-99
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Notes:
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37 - Track Drive Pump 00 - General
00 - General
Introduction
Introduction .................................................... 27-99 Preparation .................................................. 27-100 Adjust .......................................................... 27-102 Remove and Install ..................................... 27-104 Disassemble and Assemble ........................ 27-106
The transmission pump consists of two pump units, one for each drive motor, mounted in tandem on a common drive shaft which is driven by the engine.
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37 - Track Drive Pump 00 - General
Preparation Special Tools Description Pressure Gauge (0-40 Bar)
Part No. 892/00278
2. Place the machine safely on the blocks. Make sure that all four wheels are clear of the ground.
Qty. 1
3. Make sure that the machine is stable.
You must follow this procedure, when you start up a new installation or when you start an installation after removal of the pump or motor from the system.
4. Knock the hose connection at the rear main pump to make sure that the pump inlet line from the hydraulic filter to the pump unit is filled with oil.
If a new or rebuilt pump is installed, fill the pump with filtered oil before you start the machine. Use the correct oil. Refer to (PIL 75-03).
5. Install a specified pressure gauge applicable pressure test point. Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
1. Jack up the machine with a suitable jack. Figure 378.
A
A Pressure test point 5.1. Make a note that the location of the pressure test point may differ for different machine models.
6.5. As air leaves the system, the charge pressure (as indicated on the gauge) must rise to a minimum of the specified value. Pressure: 7 bar ( 101.4 psi)
6. Check the pressure gauge reading. 6.1. Remove the ESOS fuse to prevent the engine from starting. 6.2. Keep the drive control lever at neutral position. 6.3. Turn the engine with the starter motor. The pressure gauge should show a small rise in pressure as the engine turns. 6.4. If so, install the ESOS fuse and operate the starter motor. At the same time slowly increase the throttle lever setting until the engine starts and runs at the lowest possible speed. 27 - 100
6.6. If the charge pressure is incorrect, shutdown the machine and find the cause. 7. Once the correct charge pressure is established, operate the drive system 10 times in all directions with the engine at idle then slowly increase the engine speed, at the same time continue to operate the system. 8. Operate the system in all directions several times with the engine running at the maximum speed. 9. Switch off the engine. 10. Remove the pressure gauge.
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37 - Track Drive Pump 00 - General
11. Check the system oil level and top up as necessary. Refer to (PIL 27-00), (PIL 75-00).
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37 - Track Drive Pump 00 - General
Adjust
Adjustment
Special Tools Description Hand Pump Pressure Test
1. Jack up the machine with a suitable jack.
Part No. 892/00223
Qty. 1
2. Place the machine safely on the blocks. Make sure that all four wheels are clear of the ground. 3. Make sure that the machine is stable.
Before Adjustment The incorrect neutral setting of the servo piston causes the movement of the machine when the joystick is still in neutral position. To correct this fault you must adjust the wheel drive motor. Before you adjust the wheel drive motor, do the following:
4. Position the operator seat facing forwards so that the brakes are released. 5. Identify the adjustment.
pump
section
that
requires
Figure 379.
1. Check the condition of the tyres and tyre pressure.
C
D
1.1. The pressure of one tyre may be low or one/ both tyres on one side of the machine may be new and the other tyres worn. In both cases the rolling circumference of the tyres will be unequal. This causes the machine to change direction suddenly. 2. Check the chain tension. 2.1. Chains that have unequal tension will cause the machine to change direction to one side. 2.2. You must adjust the tension on all four chains. Do not adjust any one chain. A
3. Check the brake release pressure and the condition of seals.
B
3.1. Low pressure or faulty seals can cause the brake to drag on one side.
A B C D
3.2. Check the pressure at the anti-stall valve. 3.3. Use the hand pump to release the brake to check condition of the seal. Make sure that the seal holds the pressure.
5.1. If the machine moves to the left, either the right side wheels moving forward or the left side wheels moving in reverse.
Special Tool: Hand Pump Pressure Test (Qty.: 1)
5.2. Make a note that the pump P1 drives the left side motor and pump P2 drives the right side motor.
4. Check the drive joystick. 4.1. Make sure that the joystick spools do not stick. 4.2. Make sure that joystick levers operates correctly. If any of the above checks or adjustment cannot rectify the fault, then either the pump or motor could be faulty. To further identify the fault, interchange the motor feed hoses at the pump. If the machine now moves in the opposite direction then the pump is faulty. If the machine continues to move in the same direction the motor is faulty.
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Locknut Adjusting screw Pump P1 (left side motor) Pump P2 (right side motor)
6. Stop the engine. 7. Remove the floor plates. Refer to (PIL 09-78). 8. Loosen the locknut. 9. Turn the neutral adjusting screw through the specified angle in the required direction.
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Angle: 36 ° 9.1. If the wheels are abnormally moving forward, turn the adjusting screw in a clockwise direction (looking underneath the pump). If the wheels are abnormally moving in reverse, turn the screw anticlockwise. 27 - 102
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37 - Track Drive Pump 00 - General
9.2. Make a note that this adjustment is very sensitive. 9.3. You must turn the adjusting screw through only the specified angle at one time and check again. Angle: 36 ° 9.4. A slight movement when the wheels are raised is acceptable, there should be no movement when the machine is on the ground. 10. Tighten the locknut. 11. Start the engine. 12. Make sure that the wheels are stationary. 13. Tighten the locknut to the correct torque value. 14. Take care to retain the set position of the adjusting screw. 15. Check the wheels for movement again. Table 137. Torque Values Item A
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Description Locknut
Nm 23
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37 - Track Drive Pump 00 - General
Remove and Install CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.
Remove
7. Loosen the bolt 2 from the rear sight side of the operator seat. Do not remove the bolt 2. 8. Rotate the operator seat towards the rear of the machine.
1. Make the machine safe. Refer to (PIL 01-03).
9. Disconnect the wiring harness and battery lead from the front seat mounting rail.
2. Disconnect the battery. Refer to (PIL 33-03).
10. Remove the seat mounting rail.
3. Remove the front floor plates. Refer to (PIL 09-78).
11. Disconnect all the hoses.
4. Drain the hydraulic tank. Refer to (PIL 30-00). 5. Disconnect the microswitch at the base of the seat. 6. Remove the bolts 1 (x2) from the front and left rear side of the operator seat.
12. Put a label on the hoses to help installation. 13. Plug all the open ports and hoses to prevent contamination. 14. Remove the bolts 3. 15. Remove the wheel drive pump from the machine.
Figure 380. B
C B
A Wheel drive pump C Bolts 3
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A
B Hoses
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37 - Track Drive Pump 00 - General
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Tighten the bolts 3 to the correct torque value. 3. Fill the pump and hoses with clean oil before you install them. 4. Tighten the hydraulic connectors to the specified torque value. Torque: 45 –50 N¡m 5. Prime the pump. Refer to (PIL 30-11). Table 138. Torque Values Item C
27 - 105
Description Bolts 3
Nm 77
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37 - Track Drive Pump 00 - General
Disassemble and Assemble
Figure 381.
After you do a complete rebuild of the pump, it is necessary to set up the pump on a dynamic test jig. It is recommended that you must not disassemble the pump beyond that covered in the following procedures.
Shaft Seal Disassemble 1. Press shaft into the body against the spring force. 2. Remove the circlip.
D
2.1. When you remove the circlip, the seal carrier will move out by specified approximately distance due to spring force.
E C
Distance: 6 mm 3. Lightly tap the end of the shaft with a soft faced hammer.
F
4. Remove the seal carrier. 4.1. Make a note that after you remove the seal carrier, the shaft and bearing assembly are free to rotate in the body. You must not remove the shaft as this could cause loss of alignment of the pump internals. This could lead to total strip and rebuild requirement of the pump. 5. Remove and discard the O-ring 1. 6. Use a suitable press to press out the lip seal from the seal carrier. 7. Remove and discard the lip seal.
A
B
A B C D E F
Circlip Shaft Seal carrier Bearing O-ring 1 Seal
Assemble 1. Check the condition of the seal carrier for damage. 2. Check the condition of the sealing area on the shaft for signs of rust, wear or contamination. 3. If necessary, polish the sealing area on the shaft. 4. Apply suitable sealant on the outside diameter of the new lip seal. 5. Press the lip seal into the shaft bearing side of the seal carrier. 6. Make sure that the lip of the lip seal faces the shaft bearing. 7. Take care not to damage the lip seal. 8. Lubricate the inside diameter of the lip seal with petroleum jelly. 9. Install new O-ring 5 onto the seal carrier 3 and lubricate with petroleum jelly. 10. Wrap the splined end of the shaft with a thin plastic to prevent damage to the lip seal during installation.
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37 - Track Drive Pump 00 - General
11. Slide the seal carrier over the shaft.
Assemble
12. Press the seal carrier into position in the pump body recess.
1. Check the condition of theHPRV and mating seat in plug 1 for damage. If necessary, replace them.
13. Press shaft into the body against the spring force.
2. Install the new O-rings 2 and back-up ring on the plug 1.
14. Install the circlip.
3. Make sure that the conical spring is correctly retained on the HPRV.
Charge Check and HPRV
4. Install the HPRV in the pump body.
The charge check valve and HPRV are identical. The procedure given below is for disassembly and assembly of the HPRV, the procedure for the charge valve is the similar.
5. Install the plug 1.
Disassemble
Charge/Anti-stall Valve
1. Remove the plug 1.
6. Tighten the plug 1 to the correct torque value.
Disassemble
2. Remove the HPRV assembly. 3. Make a note that the smaller end of the conical spring is crimped to retain it on the HPRV. 4. Make a note that the HPRV is factory set and cannot be repaired. 5. Remove and discard the O-rings 2 and back-up ring.
1. Mark the pump components to help assembly. 2. Loosen the locknut. 3. Remove the plug 2 from the pump body. 4. Remove and discard the O-ring 3. 5. Remove the spring and poppet from the pump body.
Figure 382.
Figure 383.
M Q H L
J
J G G H J L
Plug 1 HPRV O-ring 2 back-up ring
27 - 107
J
P K
H L J
N
G
K M N P Q
Plug 2 Poppet Locknut O-ring 4 Spring
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37 - Track Drive Pump 00 - General
Assemble 1. Check the condition of the poppet and mating seat in the pump body for damage. If necessary, replace them. 2. Install the new O-ring 3 on plug 2. 3. Install the poppet and spring into the pump body. 4. Install the plug 2 complete with the locknut into the pump body. 5. Make sure that all the parts are correctly aligned. 6. Tighten the locknut. 7. Check the charge pressure. If necessary, do the adjustment. Table 139. Torque Values Item G
27 - 108
Description Plug 1
Nm 68
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38 - Track Drive Motor
38 - Track Drive Motor Contents
Page No.
27-38-00 General ......................................................................................................................... 27-111
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Notes:
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38 - Track Drive Motor 00 - General
00 - General Introduction .................................................. Component Identification ............................. Remove and Install ..................................... Disassemble and Assemble ........................
Introduction 27-111 27-112 27-113 27-115
The transmission drive motor has a gearwheel set connected by a valve drive to a disc valve. The gearwheel set consists of a toothed internal gear and a fixed external gear rim, The rollers form the teeth of external gear rim. The internal gear is free to rotate in a circular orbit within the gear rim. The disc valve is arranged to create a series of inlets and outlets which, as the gear rotates, always align precisely with the chambers formed between the internal gear teeth and the gear rim rollers. Oil under pressure passes through the disc valve inlets to the inter-tooth chambers on one side of the gearwheel set. These chambers are so shaped that the oil pressure within them creates an imbalance of forces which causes the internal gear to rotate. As the gear rotates the oil in the chambers is progressively connected to the disc valve outlets, from where it returns to tank. A cardan shaft connects the inner gear to the output shaft. The brake pack has a series of alternate friction plates and brake pads. The spring force holds the brake in the ON position and hydraulic pressure releases the brakes.
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Component Identification Figure 384.
F
E D C A B
A Output shaft C Cardan shaft E Valve drive
27 - 112
B Brake pack D Gearwheel set F Disc valve
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38 - Track Drive Motor 00 - General
Remove and Install Consumables Description JCB Retainer (High Strength) JCB Threadlocker and Sealer (Medium Strength)
Part No. 4101/0602
Size 0.05 L
4101/0250 4101/0251
0.01 L 0.05 L
The removal procedure for the wheel drive motor is divided into two sections: • •
2. Remove the floor plate. Refer to (PIL 09-78). 3. Remove the bolts (x6) and washers (x6) from inside of the chassis. 4. Remove the cover. 5. Remove and discard the gasket. 6. Turn both the stub axles until the drive chains are at their slackest position. Refer to (PIL 27-27). 7. If installed, remove the spider as follows:
Removal of wheel drive motors. Removal of drive sprocket and chains.
7.1. Remove the bolts. 7.2. Remove the spider.
Remove
8. Remove the sprocket.
Drive Sprocket 1. If necessary, remove the wheels from the machine. Refer to (PIL 27-29).
9. Remove and discard the oil seal. 10. Check the condition of the bearing. Do not remove the bearing until you replace it.
Figure 385.
F B
A
H G
J F D
A C E G J
Bolts 1 Cover Bolts 2 Sprocket Bearing
27 - 113
B D F H
C
Washers Gasket Spider Oil seal
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38 - Track Drive Motor 00 - General
Motor
3. Remove the capscrews (x4).
1. Remove the motor cover.
4. Remove the motor from the machine.
2. Disconnect the hydraulic hoses. Figure 386.
J
K Hoses
K
L Capscrews
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Apply specified threadlocker to the bolt 2. Consumable: JCB Threadlocker and Sealer (Medium Strength) 3. Apply the specified retainer to the capscrews. Consumable: JCB Retainer (High Strength) 4. Tighten the fasteners to the correct torque value. 5. Adjust the drive chain tension. Refer to (PIL 27-63). Table 140. Torque Values Item A E K L L L L
27 - 114
Description Bolts 1 Bolts 2 Hydraulic connections Capscrews (M10 x 30) Capscrews (M12 x 30) Capscrews (M14 x 35) Capscrews (M14 x 35)
Nm 28 56 47 56 98 220 220
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38 - Track Drive Motor 00 - General
Disassemble and Assemble Consumables Description Extreme Performance Moly Grease JCB Threadlocker and Sealer (Medium Strength)
Part No. 4003/1327 4003/1326 4101/0250 4101/0251
Size 0.4 kg 12.5 kg 0.01 L 0.05 L
20. Support the front case and cam assembly on blocks. 21. Separate the cam assembly out from the front case. 22. Remove and discard the O-ring 2 and O-ring 3. 23. Tap the rear case lightly with a soft faced hammer to release the distributor ring.
Disassemble 1. Remove the wheel drive motor. Refer to (PIL 27-32). 2. Drain the oil from the wheel drive motor. Refer to (PIL 27-32). 3. Put a mark on the front case, rear case and brake housing to help installation. 4. Remove the capscrews 1. 5. Remove the end cover from the brake housing. 6. Remove and discard the gasket.
24. Make a note of the position of the stop pin in the slot in the rear case. 25. Remove the stop pin. 26. Make a note that the slots in the rear case are identified L or R to make sure that the motor rotation is correct after assembly. 27. Remove and discard the seal rings (x3) from the distributor ring. 28. Remove the springs from their bores in the distributor ring. 29. Separate the crankcase from the cam.
7. Remove the spring disc. 8. Use LP (Low Pressure) compressed air to remove the brake piston from the brake housing.
30. Remove the circlips and retaining rings from the crankcase.
9. Take care to collect the piston as it gets ejected.
31. Remove the pistons and the rollers from the crankcase.
10. Remove and discard the seal 1 from the brake piston.
31.1. If necessary, use the LP compressed air at the ports in the crankcase.
11. Remove the capscrews 2. 12. Remove the washers 1.
32. Remove and discard the O-rings 4 from the pistons.
13. Separate the brake housing out from the rear case.
33. Use a soft steel drift to remove the split ring and washer 2.
14. Remove and discard the O-ring 1.
34. Support the front case on blocks and press the shaft out of the bearings.
15. Remove the seal 2 from inside of the brake housing. 16. Remove the brake pack from the brake housing. 17. If installed, remove the shim 1 and shim 2. 18. Remove the capscrews 3. 19. Separate the rear case out from the front case and cam assembly.
27 - 115
35. Remove the cone from the bearing 1. 36. Use a soft steel drift to remove the bearing 1 and bearing 2 cups from the front case. 37. Remove the bearing 2 cone from the shaft with a puller. If the bearing cone is damaged, replace the bearing. 38. Remove and discard the shaft seal from the front case.
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38 - Track Drive Motor 00 - General
Figure 387. U
AP
AN AM AK AJ
AD
AE T AG AC AH AF AE
AL
AD
V S
W X AB AA
Z Y R
P Q
K J
N
M
H
F L
C A
G E
A C E G J L N Q S U
Capscrews 1 Gasket Brake piston Seal 2 Shims 1 Capscrews 2 Brake housing Capscrews 3 O-ring 2 Front case
27 - 116
B D F H K M P R T V 9813/6050-2
D
B
End cover Spring disc Seal 1 Brake pack Shims 2 Washer 1 O-ring 1 Rear case Cam O-ring 3 27 - 116
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38 - Track Drive Motor 00 - General
W Y AA AC AE AG AJ AL AN
Distributor ring Stop pin Seal ring 2 Crankcase Retaining ring Rollers Split ring Shaft Shaft seal
27 - 117
X Z AB AD AF AH AK AM AP
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Springs Seal ring 1 Seal ring 3 Circlip Piston O-ring 4 Washer 2 Bearing 1 Bearing 2
27 - 117
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38 - Track Drive Motor 00 - General
Assemble
22. The remaining assembly procedure is the opposite of the disassembly procedure. Additionally do the following steps.
1. Clean all components with hydraulic oil. 2. Apply petroleum jelly on all the O-rings and seals. 3. Heat the bearing 2 cone and press onto the shaft with a bench press. 4. Press the shaft seal into the front case with a bench press.
23. Check the condition of the pistons and their bores in the crankcase for signs of damage. If necessary, replace them. 24. Inspect the springs for signs of damage or distortion. If necessary, replace them.
5. Take care not to damage the seal.
25. Clean the capscrews 2, capscrews 3 and mating parts thoroughly.
6. Fill grease in the space between the lips of the seal.
26. Apply the capscrews.
specified
threadlocker
to
the
7. Press the bearing 2 cup into the front case with a bench press.
Consumable: JCB Threadlocker and Sealer (Medium Strength)
8. Turn the front case over and press the bearing 1 cup into the front case with a bench press.
27. Inspect the brake plates for signs of wear or damage.
9. Cover the splines of the shaft with tape to protect the shaft seal.
27.1. You must not replace the brake plates individually, the entire brake plate pack must be replaced.
10. Install the front case assembly to the shaft assembly.
27.2. If you install the new brake plate pack, the overall length of the clamped pack must be within the specified dimension.
11. Check that the shaft seal is not damaged.
Dimension: 28.1 –28.3 mm
12. Remove the tape from the shaft splines.
27.3. You can achieve the desired dimension with the shims installed between the end of the brake plate pack and the rear case.
13. Heat the bearing 1 cone and press onto the shaft with a bench press to the specified load. You must rotate the front case when you install the bearing 1 cone.
27.4. If necessary, use the additional one or two brake plates to reduce the number of shims.
Force: 4 t 14. Use a bench press to apply specified pre-load to the bearing 1 cone while rotating the front case.
27.5. Apply a layer of specified grease to the contact surfaces of spring disc.
Force: 1.5 t
Consumable: Extreme Performance Moly Grease
15. Install the split ring onto the shaft. 16. Measure the gap between the bearing 1 and the split ring. 17. Remove the split ring. 18. Install the washer 2 with a thickness of between the specified value greater than the measured gap.
Table 141. Torque Values Item A L Q
Nm 15 73.5 119.5
Length/Dimension/Distance: 0.05 –0.1 mm 19. Install the split ring. 20. Remove the pre-load. 21. Check that the shaft runs freely and without binding, but with a slight stiffness, in the front case.
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30 - Hydraulic System Contents
Page No.
Acronyms Glossary .................................................................................................................................... 30-2 30-00 General 30-00-00 General ............................................................................................................................. 30-3 30-00-49 Schematic Symbols ........................................................................................................ 30-14 30-00-50 Schematic Circuit ........................................................................................................... 30-18 30-03 Tank 30-03-00 General ........................................................................................................................... 30-69 30-03-12 Suction Strainer .............................................................................................................. 30-70 30-03-24 Breather .......................................................................................................................... 30-71 30-04 Filter 30-04-00 General ........................................................................................................................... 30-73 30-04-03 Main ................................................................................................................................ 30-74 30-04-09 Return Line .................................................................................................................... 30-75 30-11 Gear Pump 30-11-00 General ........................................................................................................................... 30-77 30-15 Cylinder / Ram 30-15-00 General ........................................................................................................................... 30-91 30-15-21 Swing .............................................................................................................................. 30-97 30-15-99 Seal Kit ......................................................................................................................... 30-103 30-50 Excavator Control Valve Block 30-50-00 General ......................................................................................................................... 30-107 30-51 Lift Arm Control Valve Block 30-51-00 General ......................................................................................................................... 30-121 30-51-03 Main Relief Valve (MRV) .............................................................................................. 30-139 30-51-06 Auxiliary Relief Valve (ARV) ......................................................................................... 30-144 30-51-36 Load Hold Check Valve ............................................................................................... 30-150 30-60 Directional Control Valve 30-60-00 General ......................................................................................................................... 30-155 30-60-03 Brake ............................................................................................................................ 30-157 30-60-15 Joystick ......................................................................................................................... 30-160 30-60-25 Power Management System (PMS) ............................................................................. 30-173 30-60-39 Lift Arm ......................................................................................................................... 30-178 30-60-44 Transmission ................................................................................................................ 30-182 30-60-96 Control Pattern Selector ............................................................................................... 30-187 30-68 Pressure Reduction Valve 30-68-00 General ......................................................................................................................... 30-191 30-93 Hose 30-93-00 General ......................................................................................................................... 30-201 30-97 Connectors 30-97-00 General ......................................................................................................................... 30-205 30-97-03 Quick Release Coupling .............................................................................................. 30-208 30-97-18 O-Ring Face Seal (ORFS) ........................................................................................... 30-210
9813/6050-2 2018-04-09
Acronyms Glossary ARV
Auxiliary Relief Valve
HP
High Pressure
ISO
International Organization for Standardization
LHCV
Load Hold Check Valve
MRV
Main Relief Valve
ORFS
O-Ring Face Seal
PMS
Power Management System
PTFE
Polytetrafluoroethylene
QRC
Quick Release Coupling
RPM
Revolutions Per Minute
SAE
Society of Automotive Engineers
9813/6050-2 2018-04-09
30 - Hydraulic System
00 - General
00 - General Contents
Page No.
30-00-00 General ............................................................................................................................. 30-3 30-00-49 Schematic Symbols ........................................................................................................ 30-14 30-00-50 Schematic Circuit ........................................................................................................... 30-18
30 - 1
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Notes:
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30 - Hydraulic System
00 - General 00 - General
00 - General
Introduction
Introduction ...................................................... 30-3 Health and Safety ........................................... 30-4 Technical Data ................................................. 30-5 Operation ......................................................... 30-8 Discharge and Pressurise ............................. 30-11 Clean ............................................................. 30-11 Check (Level) ................................................ 30-13
The hydraulic system is a power transmission system that uses the force of flowing liquids to transmit power to specific components in a machine. To help you trace specific hydraulic problems to a faulty unit (valve, actuator, ram etc.), refer to Fault finding. Refer to: PIL 30-00-00. Once you have traced the faulty unit, refer to the relevant section for removal, disassembly and checking instructions. To help identify circuits, valves, rams etc. mentioned in the fault finding procedures. Refer to the hydraulic schematic diagrams. Refer to: PIL 30-00-50. • • • •
•
Before you begin fault finding, read the Health and Safety Information. Refer to: PIL 30-00-00. Make simple checks before you remove or disassemble a major component. Make sure that the hydraulic fluid is at the correct working temperature 50 °C ( 121.9 °F). Whatever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary. Refer to Hydraulic fluid quality in this procedure and Hydraulic System - Clean. Refer to: PIL 30-00-00. Make sure you remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit.
Hydraulic Fluid Quality This machine uses a large volume of fluid in the hydraulic system for power transmission, equipment lubrication, rust prevention and sealing. According to a survey conducted by a pump manufacturer, seventy per cent of the causes of problems in hydraulic equipment were attributable to inadequate maintenance of the quality of the hydraulic fluid. Therefore, it is obvious that control of the quality of the hydraulic fluid helps prevent hydraulic equipment problems and greatly improves safety and reliability. Furthermore from an economic angle it extends the life of the hydraulic fluid if quality is maintained.
Hydraulic Contamination Once inside the system, hydraulic circuit contaminants greatly affect the performance and life of hydraulic equipment. For example, contaminants in a hydraulic pump develop internal wear to cause internal leakage and hence lower discharges. Wear particles generated will circulate with the hydraulic fluid to cause further deterioration in the performance of this and other equipment. Contaminants also enter principal sliding sections of the equipment causing temporary malfunction, scuffing, sticking 30 - 3
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and leakage and can lead to major problems. The main contaminants can be classified as follows:
Health and Safety
1. Solid Particles - Sand, fibres, metallic particles, welding scale, sealing materials and wear particles etc.
Hydraulic Pressure
2. Liquid - Usually water and incompatible oils and greases. 3. Gases - Air, sulphur dioxide etc. which can create corrosive compounds if dissolved in the fluid. These contaminants can appear manufacture, assembly and operation.
during
Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the machine cannot be started while the hoses are open. WARNING! Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of pressurised fluid and wear protective glasses. If fluid penetrates your skin, get medical help immediately. WARNING! Take care when disconnecting hydraulic hoses and fittings as the oil will be hot. WARNING! Damaged hoses can cause fatal accidents. Examine the hoses regularly. Do not use the machine if a hose or hose fixture is damaged. Notice: Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid. The fluid can harm your skin. Wear rubber gloves. Cover cuts or grazes. Notice: Do not allow dirt to enter the system. Before disconnecting any part of the system, thoroughly clean around the connection. When a component has been disconnected, always install protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt entering the system. Dirt in the system will seriously damage the systems components and could be expensive to repair. CAUTION! The temperature of the hydraulic oil will be high soon after stopping the machine. Wait until it cools before beginning maintenance. Notice: Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid. The fluid can harm your skin. Wear rubber gloves. Cover cuts or grazes.
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Technical Data For: Series 2 ............................... Page 30-5 For: Series 1 ............................... Page 30-6
(For: Series 2)
Description Data Output Characteristics- Dual Lever Drive Control Transmission control 5.5 bar ( 79.7 psi) at 15 spools % stroke Loader control spools 3.5 bar ( 50.7 psi) at 15 % stroke
Table 142. Auxiliary Pump - Standard Description Type Flowrate
Data Gear type 48 L/min at 3000 RPM (Revolutions Per Minute) Maximum working pres- 185 –192 bar ( 2,681.1 – sure 2,782.6 psi) Maximum speed 3200 RPM Maximum input torque 121 N·m Table 143. Auxiliary Pump - High Flow Description Type Flowrate - Front section Flowrate - Rear section Maximum working pressure Maximum speed Maximum input torque
Description Type Displacement Maximum working pressure Maximum speed Maximum flow
Data MCR03 328 cm³/rev 414 bar ( 6,000.0 psi) continuous 237 RPM continuous 84 L/min continuous
Table 147. Relief Valve Operating Pressures
Data Tandem Gear type 90 L/min at 3600 RPM 57 L/min at 3600 RPM 185 –192 bar ( 2,681.1 – 2,782.6 psi) 3600 RPM 121 N·m
Table 144. Main Pump - 2 off Description Type
Data Tandem axial piston Series 42 M28 Displacement 28 cm³/rev Control Servo non-feedback proportional, 15 bar ( 217.4 psi) to give maximum pump displacement. Maximum working pres- 350 bar ( 5,072.4 psi) sure Maximum speed 3900 RPM Charge pressure (Oil 11.5 bar ( 166.7 psi) at temperature at 50 °C engine idle ( 121.9 °F)) 23.5 –24 bar ( 340.6 – 347.8 psi) at 3000 RPM Table 145. Servo Joysticks Description Data Output Characteristics - Single Lever Drive Control Transmission for3.5 bar ( 50.7 psi) at 15 ward/reverse (spools 2 % stroke & 4) Transmission left/right 5.5 bar ( 79.7 psi) at 15 (spools 1 & 3) % stroke Loader 3.5 bar ( 50.7 psi) at 15 % stroke 30 - 5
Table 146. Hydraulic Motors
Description Operating Pressure MRV (Main Relief Valve) 207 bar ( 3,000.0 psi) at 1500 RPM ARV (Auxiliary Relief Valve) - Loader Shovel crowd 235 bar ( 3,405.8 psi) Shovel dump 100 –103 bar ( 1,449.3 – 1,492.7 psi) Lift ram raise 241 bar ( 3,492.7 psi) ARV - Excavator Slew ram 241 bar ( 3,492.7 psi) Boom raise 241 bar ( 3,492.7 psi) Boom lower 241 bar ( 3,492.7 psi) Dipper in 241 bar ( 3,492.7 psi) Dipper out 241 bar ( 3,492.7 psi) Bucket crowd 241 bar ( 3,492.7 psi) Bucket dump 241 bar ( 3,492.7 psi) Auxiliary spool (optional) 241 bar ( 3,492.7 psi) (1) - Both ports Optional hand tool circuit 138 bar ( 2,000.0 psi) (1) The return line ARV must be set to zero when a Rockbreaker is installed. The ARV must return to the correct setting when the Rockbreaker is removed. Table 148. Solenoid Brake Valve Description Type Electrics
Data 3 position, 4 way directional control 12 V
Table 149. Hydraulic filter Description Type Suction strainer
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Data HP (High Pressure) Spin On - 5 micron 125 micron 30 - 5
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Table 150. Cylinder Ram Dimensions Cylinder ram description Lift Shovel Boom Dipper Bucket Stabilizer
Data Bore diameter 60 mm 60 mm 70 mm 70 mm 70 mm 60 mm
Rod diameter 30 mm 30 mm 40 mm 40 mm 40 mm 30 mm
Table 154. Main Pump - 2 off Description Type
Data Tandem axial piston Series 42 M28 Displacement 28 cm³/rev Control Servo non-feedback proportional, 15 bar ( 217.4 psi) to give maximum pump displacement. Maximum working pres- 350 bar ( 5,072.4 psi) sure Maximum speed 3900 RPM Charge pressure (Oil 7.5 bar ( 108.7 psi) at temperature at 50 °C engine idle ( 121.9 °F)) 19.5 bar ( 282.6 psi) at 3000 RPM
Stroke length 500 mm 500 mm 600 mm 500 mm 400 mm 500 mm
Table 151. Cylinder Ram Torque Setting Description Piston head Lift rams Shovel rams (Crowd) 6 in 1 ram Boom ram Stabilizer ram Dipper ram Bucket ram End cap Lift rams Shovel rams (Crowd) 6 in 1 ram Boom ram Stabilizer ram Dipper ram Bucket ram
Torque value 300 N·m 300 N·m 405 N·m 405 N·m 300 N·m 405 N·m 405 N·m
Table 155. Servo Joysticks Description Output Characteristics - Transmission control spools
Data 5 bar ( 72.5 psi) at 15 % stroke 15 bar ( 217.4 psi) at 95 % stroke Output Characteristics - 3.3 –3.7 bar ( 47.8 –53.6 Loader control spools psi) at 15 % stroke 14.5 –16.5 bar ( 210.1 –239.1 psi) at 95 % stroke
450 N·m 450 N·m 678 N·m 678 N·m 450 N·m 678 N·m 678 N·m
Table 156. Hydraulic Motors
(For: Series 1) Table 152. Auxiliary Pump - Standard Description Type Flowrate Maximum working pressure Maximum speed Maximum input torque
Data Gear type 48 L/min at 3000 RPM 185 –192 bar ( 2,681.1 – 2,782.6 psi) 3200 RPM 121 N·m
Table 153. Auxiliary Pump - High Flow Description Type Flowrate - Front section Flowrate - Rear section Maximum working pressure Maximum speed Maximum input torque 30 - 6
Data Tandem Gear type 90 L/min at 3600 RPM 57 L/min at 3600 RPM 185 –192 bar ( 2,681.1 – 2,782.6 psi) 3600 RPM 121 N·m
Description Type Displacement Maximum working pressure Maximum speed Maximum flow
Data MCR03 328 cm³/rev 414 bar ( 6,000.0 psi) continuous 237 RPM continuous 84 L/min continuous
Table 157. Relief Valve Operating Pressures Description MRV at 1500 RPM ARV - Loader Shovel crowd Shovel dump Lift ram raise ARV - Excavator Slew ram Boom raise Boom lower Dipper in Dipper out Bucket crowd
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Operating Pressure 207 bar ( 3,000.0 psi) 235 bar ( 3,405.8 psi) 100 –103 bar ( 1,449.3 – 1,492.7 psi) 241 bar ( 3,492.7 psi) 241 bar ( 3,492.7 psi) 241 bar ( 3,492.7 psi) 241 bar ( 3,492.7 psi) 241 bar ( 3,492.7 psi) 241 bar ( 3,492.7 psi) 241 bar ( 3,492.7 psi) 30 - 6
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Description Bucket dump Auxiliary spool (optional) (1) - Both ports Optional hand tool circuit
Operating Pressure 241 bar ( 3,492.7 psi) 241 bar ( 3,492.7 psi) 138 bar ( 2,000.0 psi)
(1) The return line ARV must be set to zero when a Rockbreaker is installed. The ARV must return to the correct setting when the Rockbreaker is removed. Table 158. Pressure Reducing Solenoid Valve Description Maximum inlet pressure Regulated pressure Minimum rated flow Maximum leakage Oil temperature range Solenoid valve Reducing valve Electrics
Description End cap Lift rams Shovel rams (Crowd) Extending dipper ram Boom ram Stabilizer ram Dipper ram Bucket ram
Torque value 450 N·m 450 N·m 500 N·m 678 N·m 450 N·m 678 N·m 678 N·m
Data 207 bar ( 3,000.0 psi) 24 bar ( 347.8 psi) 10 L/min 25 cm³/min at 210 bar ( 3,043.5 psi) and 10 centistokes -40 –106 °C ( -39.9 – 222.7 °F) 3 Position, 3 Port cartridge valve Cartridge type 12 V
Table 159. Hydraulic filter Description Type Suction strainer
Data HP Spin On - 5 micron 125 micron
Table 160. Cylinder Ram Dimensions Cylinder ram description Lift Shovel Boom Dipper Bucket Stabilizer Extending dipper
Data Bore diameter 60 mm 60 mm 70 mm 70 mm 70 mm 60 mm 50 mm
Rod diameter 30 mm 30 mm 40 mm 40 mm 40 mm 30 mm 25 mm
Stroke length 500 mm 500 mm 600 mm 500 mm 400 mm 500 mm 530 mm
Table 161. Cylinder Ram Torque Setting Description Piston head Lift rams Shovel rams (Crowd) Extending dipper ram Boom ram Stabilizer ram Dipper ram Bucket ram 30 - 7
Torque value 300 N·m 300 N·m 405 N·m 405 N·m 300 N·m 405 N·m 405 N·m 9813/6050-2
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Operation For: Series 2 ............................... Page 30-8 For: Series 1 ............................... Page 30-9
(For: Series 2) The main components of the hydraulic circuit are as follows: • • • • • • • • •
Tank. Pumps. Drive motors. Servo operated loader and drive control circuits. Manually operated excavator valves. Filters. Coolers. Rams. Solenoid brake valve.
The engine drives the tandem mounted hydraulic pumps. The pumps deliver pressurised oil to the valves and motors. A servo joystick in the case of the loader/drive circuits or a manual control lever for the excavator circuit operate the valves are operated. When a valve is operated, it delivers the oil to one end of the appropriate ram or to the pump servo-controls depending on which control is operated. The pressurised oil forces the cylinder ram piston along the bore of the cylinder ram or operates
30 - 8
the pump servo controls, which changes the flow direction to the motors and hence the direction of rotation. The relief valves prevent system pressure from rising too far. The solenoid brake valve (together with its associated electrical circuitry) acts as a safety device. The safety function makes sure that the machine loader and transmission controls cannot be operated without the operator being seated correctly and the door properly closed and latched.
Machine Neutral Circuit The auxiliary pump draws oil from the tank through a suction strainer. The auxiliary pump delivers pressurised oil through a non-return valve to the loader control valve. Oil flows through the loader control valve and onto the excavator control valve then through the filter to the main pumps. Oil from main pump 1 and main pump 2 is returned through the cooler to the tank. The oil feed for the servo controls is taken from the main pump charge circuit through the solenoid brake valve. The solenoid brake valve acts as a safety device. It prevents the oil supply to the loader and transmission servo controls until the operator is seated correctly and the door properly closed and latched. The solenoid brake valve also allows the transmission brakes to be manually applied.
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Figure 388. B
A
E
F
J L
K
H
C D
G A C E G J L
B D F H K
Loader control valve Excavator control valve Cooler Suction strainer Main pump 1 Auxiliary pump
(For: Series 1) The main components of the hydraulic circuit are as follows: • • • • • • • • •
Tank. Pumps. Drive motors. Servo operated loader and drive control circuits. Manually operated excavator valves. Filters. Coolers. Rams. Solenoid brake valve.
The engine drives the tandem mounted hydraulic pumps. The pumps deliver pressurised oil to the valves and motors. A servo joystick in the case of the loader/drive circuits or a manual control lever for the excavator circuit operate the valves are operated. When a valve is operated, it delivers the oil to one end of the appropriate ram or to the pump servo-controls depending on which control is operated. 30 - 9
Non return valve Solenoid brake valve Tank Filter Main pump 2
The pressurised oil forces the cylinder ram piston along the bore of the cylinder ram or operates the pump servo controls, which changes the flow direction to the motors and hence the direction of rotation. A pressure reducing solenoid valve maintains the required pressure at various components and relief valves prevent system pressure from rising too far. The pressure reducing solenoid valve together with its associated electrical circuit is designed to both limit the pressure in the circuit and act as a safety device. The safety function makes sure that the machine controls cannot be operated without the operator being seated correctly in his seat and the door properly closed and latched.
Machine Neutral Circuit The auxiliary pump draws oil from the tank through a suction strainer. The auxiliary pump delivers pressurised oil to the pressure reducing solenoid valve. If the solenoid valve is in the energised position, the pressurized oil is delivered to the loader control valve. In the de-energised position, solenoid valve returns the oil to the hydraulic tank. This makes
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sure that there is insufficient pressure available to operate the 5 bar ( 72.5 psi) check valve. If the solenoid valve is in the energised position, the pressurized oil is delivered to the loader control valve. Oil then flows through the excavator valve
and then through the filter to the main pumps. Oil from the main pumps is returned through the cooler to the tank. The pressure reducing solenoid valve also allows the transmission brakes to be manually applied.
Figure 389. A
B E
F
K
L
J
H
C
G D
A C E G J L
Loader control valve Excavator control valve Cooler Suction strainer Main pump 1 Auxiliary pump
30 - 10
B D F H K
Non return valve Pressure reducing solenoid valve Tank Filter Main pump 2
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Discharge and Pressurise
Clean
Discharge
Special Tools Description Hydraulic Flushing Rig
1. Make the machine safe. Refer to (PIL 01-03). 2. Operate the controls to remove the hydraulic pressure from the service hose lines. 2.1. For manually operated services, operate the controls several times of the service to be disconnected. 3. Clean the top of the tank around the filler cap. 4. Slowly remove the filler cap to allow the system to vent fully and prevent oil being forced out of the filler neck. 5. Check that the seal is in good condition and correctly installed in the cap. If necessary, replace it.
Part No. 892/01255
Qty. 1
Cleaning Operation The purpose of cleaning oil is to remove contaminants of all types and sludge by filtering hydraulic fluid through a cleaning unit. Follow the instructions in the Hydraulic flushing rig instruction manual.
Procedure 1. Connect the Hydraulic flushing rig in place of the hydraulic filter. Special Tool: Hydraulic Flushing Rig (Qty.: 1) 2. Run the system for sufficient time to pump all the hydraulic fluid through the unit. 3. Disconnect the cleaning unit and reconnect the filter. 4. Top up the system with clean hydraulic fluid as required. Figure 390.
A
A Hydraulic flushing rig
Contaminant Standards Dirt that damages your system is in many cases too small to be seen with the eye. The particle size is measured in microns (1 micron = 0.001 mm (0.0000394 in). Listed below are a few typical comparisons: 30 - 11
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• • •
Red Blood Cell = 8 microns (0.008 mm, 0.000315 in) Human Hair = 70 microns (0.07 mm, 0.00275 in) Grain of Salt = 100 microns (0.1 mm, 0.00394 in)
The smallest particle visible to the naked eye is 40 microns (0.00157) approximately. Standards will often be quoted to ISO (International Standards Organisation) for which literature can be obtained.
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Check (Level) Notice: If the fluid is cloudy, then water or air has contaminated the system. This could damage the hydraulic pump. Contact your JCB dealer immediately.
1. Make the machine safe. Refer to (PIL 01-03). 2. Look at the fluid level in the sight glass. The level should be at the red mark.
Figure 391.
A
A Hydraulic oil sight glass 3. If the oil level is low, remove the hydraulic oil tank filler cap and fill with recommended hydraulic oil as required. Refer to (PIL 75-03). Figure 392.
B B Hydraulic oil tank filler cap
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49 - Schematic Symbols
49 - Schematic Symbols
Introduction
Introduction .................................................... 30-14 Diagram ......................................................... 30-15
Complex hydraulic components and circuits can be described to the engineer by using graphical symbols. The tables illustrate and give a brief description for some of the more common symbols used. There are many symbols in use and it would be impossible to include them all here. However it should be noted that most are only variations or refinements on the basic principles explained here. If more detailed information is required you are recommended to obtain a copy of BS2917 or IS01219. Once familiar with the symbols, the engineer can use hydraulic circuit diagrams as an aid to fault finding. It will be possible to see the complete hydraulic circuit and decipher the relationship between hydraulic components.
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49 - Schematic Symbols
Diagram
Table 165. Directional control valves Symbol Table 162. General
Symbol
Description Spring Flow restriction affected by viscosity Direction of flow Indication of rotation Indication of direction and paths of flow Variable control
Table 163. Cylinder Rams Symbol
Description Used to enclose several valves indicating they are supplied as one unit 3-Position, 4-port spring centered pilot operated valve 3-position, 6-port spring centered manually operated valve 3-Position, 4-port spring centered solenoid & pilot pressure operated valve 3-Position, 4-port spring centered detent hand operated valve Non-return valve Non-return valve with back pressure spring
Description Single acting
Pilot operated non-return valve
Double acting One way restrictor
Double ended Double acting with damping at rod area end
Throttling orifice - normally closed
Table 164. Pumps and Motors Symbol
High pressure selector (shuttle valve)
Description Variable capacity pump two directions of flow
Throttling orifice - normally open
Fixed capacity motor one direction of flow
Relief valve
Fixed capacity motor two directions of flow Variable capacity motor one direction of flow
Variable restrictor
Variable capacity motor two directions of flow
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Table 166. Energy Transmissions and Conditioning Symbol
Symbol
Description Working line, return or feed Pilot control Drain lines Flexible pipe
Description Filter or strainer Water trap
Cooler - with no indication of coolant flow Cooler - indicating direction of coolant flow
Line junction
Heater
Crossing lines
Table 167. Control Mechanisms Symbol
Description Rotating shaft - one direction Rotating shaft - two directions Detent
Air bleed
Locking device
Line plugged, also pressure test point Line plugged with takeoff line QRC (Quick Release Coupling) - connected QRC - disconnected Tank - return line above fluid level Tank - return line below fluid level
Over centre device Simple linkage General control Push button operated Lever operated Pedal operated Stem operated
Header tank
Spring operated Pressure sealed tank
Roller operated
Accumulator
Roller trip operated (one directional) Solenoid one winding Solenoid two windings
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49 - Schematic Symbols
Symbol M
Description Electric motor operated Internal pressure pilot operated External pressure pilot operated Pressure operated spring release Pilot operated by solenoid pilot valve Pilot operated by a solenoid or separate pilot valve Pressure gauge Pressure switch
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50 - Schematic Circuit
50 - Schematic Circuit
Introduction
Introduction .................................................... 30-18 Diagram ......................................................... 30-19
A schematic wiring diagram is a simplified pictorial representation of the machines hydraulic circuit. It shows the components of the circuit as simplified hydraulic symbols, and the connections between the different components. The schematic diagram is used to troubleshoot problems and to make sure that all the connections have been made and that everything is present. Detailed schematics for individual systems are given in the relevant PIL section.
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Diagram For: Series 2 ............................. Page 30-19 For: Series 1 ............................. Page 30-33
(For: Series 2) Figure 393. ISO Machines - 333-R1564................................................................................ Page 30-21 Figure 394. SAE Machines - 333-R5885............................................................................... Page 30-25 Figure 395. ISO/SAE Changeover Circuit - 333-R5917......................................................... Page 30-29
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Notes:
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Page 30-22
Page 30-23
Figure 393. ISO Machines - 333-R1564 13
12
17
11
18
15 14
16
20
1
2 19 5
10 3
7 9
30 - 21
4
21
8 6
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50 - Schematic Circuit Page 30-22
Page 30-23
Figure 393. (Part 1 of 2)
13
12
17
11
15 14
16
1
Page 30-23
2
5
10 3
7
4
8 6
9
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Figure 393. (Part 2 of 2)
17
11
18 20
Page 30-22
19
21
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Page 30-26
Page 30-27
Figure 394. SAE Machines - 333-R5885
12
17
13
15
14
1
11
18
20
16
2 19
5 10 3
7
21
4
8 9
30 - 25
6
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Page 30-27
Figure 394. (Part 1 of 2)
12
17
13
15
14
1
11
16
Page 30-27
2 5 10 3
7
4
8 6
9
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Figure 394. (Part 2 of 2)
17
11
18
Page 30-26
20
19
21
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Figure 395. ISO/SAE Changeover Circuit - 333-R5917
11
EXTENDI NG DI PPER OPTI ON
LOADER
P1
P4
P3
P3
P1
SV1
13
17
P5
P5
P2
18
EXTENDI NG DI PPER / AUX CHANGEOVER VALVE OPTI ON
P2
20
STAB LEGS
LOADER AUX
BUCKET 2.5MM RESTRI CTOR
HBCV
1.4MM 2MM
1
1A
3500
1B
2MM
2A
3500
3500
2B
3B
3A
3500
3500
4B
4A
3500
3500
5A
5B
6A
6B
7A
3500
7B
3500
8A
1450
8B
3500
9A
3500
9B
10A
16
10B
LOADER CHANGEOVER VALVE
PG BW CLAMP PORT
YG
3500
SV6
DI PPER
P4 P6
KI NGPOST CLAMP
SHOVEL
RACK AND PI NI ON SLEW BOOM
AUX P6
PW YW
10 SPOOL VALVE BLOCK 3200
SV5
12 15 14
1.4MM
Page 30-31
BR
OB
CLAMP VALVE DRAIN PORT
OO OO
SV4
Page 30-30
OW O SV3
O
GR BH. BUCKET
BH. SLEW
BH. DIPPER
STAB
STAB
L. BOOM
L. BUCKET
BH. AUX
L. AUX
OUTLET
GG GG
SV2
BH. BOOM
INLET
GW
A2 B2 C2 D2
CHANGEOVER VALVE SWI TCHES OPERATI ON OF BOOM AND DI PPER BETWEEN I SO AND SAE MODE
G
G SV1
HYDRAULI C CI RCUI T I S SHOWN I N I SO MODE
T
I SO/ SAE CHANGEOVER VALVE OPTI ON
B5
B6
B7
B8
J1
2
SV7
D1
3
TRANSMI SSI ON CHANGEOVER VALVE
LS1
SV6
SV5
A1 B1 C1
SV8 LS4
J2 LS2
LS3
P5
30 - 29
P6
P7
P8
T
J4
J3
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Page 30-30
11
Figure 395. (Part 1 of 2)
EXTENDI NG DI PPER OPTI ON
12 15 14
1.4MM
LOADER
13
RACK AND PI NI ON SLEW BOOM
DI PPER
KI NGPOST CLAMP
SHOVEL
17
STAB LEGS
LOADER AUX
BUCKET 2.5MM RESTRI CTOR
HBCV
1.4MM 2MM
1
1A
3500
1B
2MM
2A
3500
3500
2B
3B
3A
3500
3500
4B
4A
3500
3500
5A
5B
6A
6B
7A
3500
7B
3500
8A
1450
8B
3500
9A
3500
9B
10A
16
10B
CLAMP PORT
3500
10 SPOOL VALVE BLOCK 3200 CLAMP VALVE DRAIN PORT
BH. BOOM
BH. BUCKET
BH. SLEW
BH. DIPPER
STAB
STAB
L. BOOM
L. BUCKET
BH. AUX
L. AUX
OUTLET
Page 30-31
INLET
A2 B2 C2
B5
B6
B7
B8
J1
2
TRANSMI SSI ON CHANGEOVER VALVE
LS1
SV6
SV5
SV7
A1 B1 C1
SV8 LS4
J2 LS2
LS3
P5
30 - 30
P6
P7
P8
T
J4
J3
9813/6050-2
30 - 30
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-30
11
Figure 395. (Part 2 of 2) EXTENDI NG DI PPER OPTI ON
AUX P6
1.4MM
P4 P6
P1
P4
P3
P3
P1
SV1
KI NGPOST CLAMP
17
P5
P5
P2
18
EXTENDI NG DI PPER / AUX CHANGEOVER VALVE OPTI ON
P2
20
LOADER CHANGEOVER VALVE
PG YG
SV6
BW CLAMP PORT
YW
SV5
PW BR
OB
CLAMP VALVE DRAIN PORT
SV4
OO OO
OW O SV3
O
GR SV2
GG GG
GW
A2 B2 C2 D2
G
CHANGEOVER VALVE SWI TCHES OPERATI ON OF BOOM AND DI PPER BETWEEN I SO AND SAE MODE
G SV1
Page 30-30
HYDRAULI C CI RCUI T I S SHOWN I N I SO MODE
T
I SO/ SAE CHANGEOVER VALVE OPTI ON
A1 B1 C1
30 - 31
D1
3
9813/6050-2
30 - 31
Page 30-31
30 - Hydraulic System
00 - General
50 - Schematic Circuit
Item 11
Table 168. Component Key Item 1 2 3 4 5 6 7 8 9 10
30 - 32
Description 10 Spool excavator valve block Transmission changeover valve PMS valve Excavator pilot pressure valve Drive control joystick Hydraulic tank Wheel motor left side Wheel motor right side Transmission pump Hydraulic filter
12 13 14 15 16 17 18 19 20 21
9813/6050-2
Description Extending dipper (Option) Loader ram Shovel ram Stabiliser legs Slew ram Loader auxiliary Hydraclamp Extending dipper auxiliary changeover valve (Option) Loader joystick Loader changeover valve High flow valve option
30 - 32
30 - Hydraulic System
00 - General
50 - Schematic Circuit
(For: Series 1) Figure 396. Standard Machines - Single Lever Drive Control (From machine No. 751012 to 752462)................................................................................................................................... Page 30-35 Figure 397. Standard Machines - Single Lever Drive Control (From machine No. 752463)................................................................................................................................... Page 30-39 Figure 398. Standard Machines - Dual Lever Drive Control (From machine No. 751012 to 752462)................................................................................................................................... Page 30-43 Figure 399. Standard Machines - Dual Lever Drive Control (From machine No. 752463)..... Page 30-47 Figure 400. High Flow Machines - Single Lever Drive Control (From machine No. 751012 to 752462)................................................................................................................................... Page 30-51 Figure 401. High Flow Machines - Single Lever Drive Control (From machine No. 752463)................................................................................................................................... Page 30-55 Figure 402. High Flow Machines - Duel Lever Drive Control (From machine No. 751012 to 752462)................................................................................................................................... Page 30-59 Figure 403. High Flow Machines - Duel Lever Drive Control (From machine No. 752463)................................................................................................................................... Page 30-63
30 - 33
9813/6050-2
30 - 33
Notes:
30 - 34
9813/6050-2
30 - 34
30 - Hydraulic System
00 - General
50 - Schematic Circuit
Figure 396. Standard Machines Single Lever Drive Control (From machine No. 751012 to 752462)
Page 30-36
Page 30-37
52
32
5
7
37 4
2 12
2F
2H
6 4A
2J
38
4J
2G
2E
36
51
T
2D
4K 4B
2X
2B
2A
4L
2C 50 4M 4C 34
F1 1
3 4D
11
35
4N 4E
2Y 9
4P
P3
4Q 4F 8 2Z
8A
8B
8C
4R
10
8D
33
4S 4G
P1
P2 4T
M1
M2 4H 30
C
T
30 - 35
S1
9813/6050-2
30 - 35
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-36
Page 30-37
Figure 396. (Part 1 of 2) 52 5 2 12
2F
2H
6
2G
2E
2J 2D
2X
2B
2A
2C
F1 1
3
Page 30-37
11
2Y 9 P3
8 2Z
8A
P1 M1
8B
8C
10
8D
P2 M2 C
T
30 - 36
9813/6050-2
30 - 36
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-36
Figure 396. (Part 2 of 2) 32 7
37 4
12
36
38
4J
6 4A
51
T 4K 4L
4B
50 4M 4C 34
4D Page 30-36
35
4N 4E
4P 4Q 4F
4R
10
33
4S 4G
4T 4H 30
S1
30 - 37
9813/6050-2
30 - 37
Page 30-37
30 - Hydraulic System
00 - General
50 - Schematic Circuit
30 - 38
9813/6050-2
30 - 38
30 - Hydraulic System
00 - General
50 - Schematic Circuit
Page 30-40
Page 30-41
Figure 397. Standard Machines - Single Lever Drive Control (From machine No. 752463) 52
32
5
7
37 4
2 12
2F
2H
4A
2J
38
4J
6
2G
2E
36
51
T
2D
4K 4B
2X
2B
2A
4L
2C 50 4M 4C 34
F1 1
3 4D
11
35
4N X
4E
2Y
9
4P
P3
T
4Q 4F 8 2Z
8A
8B
8C
10
8D
4R
33
4S 4G
P1
P2 4T
M1
M2 4H 30
C
T
30 - 39
S1
9813/6050-2
30 - 39
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-40
Page 30-41
Figure 397. (Part 1 of 2) 52 5 2 12
2F
2H
6
2G
2E
2J
T
2D
2X
2B
2A
2C
F1 1
3
Page 30-41
11
2Y
9
P3
8 2Z
8A
P1 M1
8B
8C
10
8D
P2 M2 C
T
30 - 40
9813/6050-2
30 - 40
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-40
Figure 397. (Part 2 of 2) 32 7
37 4
12
36
38
4J
6 4A
51
T 4K 4L
4B
50 4M 4C 34
4D
Page 30-40
35
4N X
4E
4P
T
4Q 4F
10
4R
33
4S 4G
4T 4H 30
S1
30 - 41
9813/6050-2
30 - 41
Page 30-41
30 - Hydraulic System
00 - General
50 - Schematic Circuit
30 - 42
9813/6050-2
30 - 42
30 - Hydraulic System
00 - General
50 - Schematic Circuit
Figure 398. Standard Machines Dual Lever Drive Control (From machine No. 751012 to 752462)
Page 30-44
52
5
Page 30-45 32
7 4
2 2F
12
2H
6
4A
2G
2E
2J
37
36
38
4J 51
T
2D
4K
2X
2B
2A
4B
2C
4L
50 4M 4C
34
F1 1
11
3
8
4D
2Y
4E
9
35 4N
4P P3 4F
4Q
4R 2Z
4G 10 P1
M1
4H C
T
30 - 43
33
4T
P2 M2
4S
30
S1
9813/6050-2
30 - 43
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-44
Page 30-45
Figure 398. (Part 1 of 2) 52
5 2 2F
12
2H 2G
2E
2J 2D
2X
2B
2A
2C
F1 1
8
Page 30-45
11
3
2Y
9
P3
2Z
10 P1 M1
P2 M2
C
T
30 - 44
9813/6050-2
S1
30 - 44
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-44
Figure 398. (Part 2 of 2) 32
7 4 12
6
37
36
38
4J
4A
51
T 4K 4L
4B
50 4M 4C
8
34
Page 30-44
4D
35 4N
4E
4P 4Q
4F
4R 4S
4G
33
4T 4H
30
S1
30 - 45
9813/6050-2
30 - 45
Page 30-45
30 - Hydraulic System
00 - General
50 - Schematic Circuit
30 - 46
9813/6050-2
30 - 46
30 - Hydraulic System
00 - General
50 - Schematic Circuit
Page 30-48
Figure 399. Standard Machines - Dual Lever Drive Control (From machine No. 752463)
Page 30-49
52
32
5
7
37 4
2 12
2F
6
2H
4A
2J
38
4J
2G
2E
36
51
T
2D
4K 4B
2X
2B
2A
4L
2C 50 4M 4C 34
F1 1
3
8
4D
11
35
4N
2Y
4E
X
4P P3
T
4Q
9
4F
4R
33
4S
2Z
4G
10 P1 M1
4T
P2 4H
M2
30
C
T
30 - 47
S1
9813/6050-2
30 - 47
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-48
Page 30-49
Figure 399. (Part 1 of 2) 52 5 2 12
2F
2H 2G
2E
2J 2D
2X
2B
2A
2C
F1 1
3
8
Page 30-49
11
2Y
P3 9
2Z
10 P1 M1
P2 M2 C
T
30 - 48
9813/6050-2
S1
30 - 48
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-48
Figure 399. (Part 2 of 2) 32 7
37 4
12
36
38
4J
6 4A
51
T 4K 4B
4L
50 4M 4C 34
8
4D
Page 30-48
35
4N 4E
X
4P
T
4Q 4F
4R
33
4S 4G
4T 4H 30
S1
30 - 49
9813/6050-2
30 - 49
Page 30-49
30 - Hydraulic System
00 - General
50 - Schematic Circuit
30 - 50
9813/6050-2
30 - 50
30 - Hydraulic System
00 - General
50 - Schematic Circuit
Figure 400. High Flow Machines Single Lever Drive Control (From machine No. 751012 to 752462)
Page 30-52
Page 30-53
52
32
5
7
37 4
2 12
2F
2H
4A
2J
38
4J
6
2G
2E
36
51
T
2D
4K 4B
2X
2B
2A
4L
2C 50 4M 4C 34
F1 1
3
8
4D
11
35
4N
2Y
4E
X
4P P3
T
4Q
9
4F
4R
33
4S
2Z
4G
10 P1 M1
4T
P2 4H
M2
30
C
T
30 - 51
S1
9813/6050-2
30 - 51
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-52
Page 30-53
Figure 400. (Part 1 of 2) 52 5 2 12
2F
2H 2G
2E
2J 2D
2X
2B
2A
2C
F1 1
3
8
Page 30-53
11
2Y
P3 9
2Z
10 P1 M1
P2 M2 C
T
30 - 52
9813/6050-2
S1
30 - 52
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-52
Figure 400. (Part 2 of 2) 32 7
37 4
12
36
38
4J
6 4A
51
T 4K 4B
4L
50 4M 4C 34
8
4D
Page 30-52
35
4N 4E
X
4P
T
4Q 4F
4R
33
4S 4G
4T 4H 30
S1
30 - 53
9813/6050-2
30 - 53
Page 30-53
30 - Hydraulic System
00 - General
50 - Schematic Circuit
30 - 54
9813/6050-2
30 - 54
30 - Hydraulic System
00 - General
50 - Schematic Circuit
Page 30-56
Figure 401. High Flow Machines - Single Lever Drive Control (From machine No. 752463)
Page 30-57
52
32
5
7
37 4
2 12
2F
6
2H
4A
2J
38
4J
2G
2E
36
51
T
2D
4K 4B
2X
2B
2A
4L
2C 50 4M 4C 34
F1 1
3
8
4D
11
35
4N
2Y
4E
X
4P P3
T
4Q
9
4F
4R
33
4S
2Z
4G
10 P1 M1
4T
P2 4H
M2
30
C
T
30 - 55
S1
9813/6050-2
30 - 55
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-56
Page 30-57
Figure 401. (Part 1 of 2) 52 5 2 12
2F
2H 2G
2E
2J 2D
2X
2B
2A
2C
F1 1
3
8
Page 30-57
11
2Y
P3 9
2Z
10 P1 M1
P2 M2 C
T
30 - 56
9813/6050-2
S1
30 - 56
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-56
Figure 401. (Part 2 of 2) 32 7
37 4
12
36
38
4J
6 4A
51
T 4K 4B
4L
50 4M 4C 34
8
4D
Page 30-56
35
4N 4E
X
4P
T
4Q 4F
4R
33
4S 4G
4T 4H 30
S1
30 - 57
9813/6050-2
30 - 57
Page 30-57
30 - Hydraulic System
00 - General
50 - Schematic Circuit
30 - 58
9813/6050-2
30 - 58
30 - Hydraulic System
00 - General
50 - Schematic Circuit
Figure 402. High Flow Machines - Duel Lever Drive Control (From machine No. 751012 to 752462)
Page 30-60
52
5
Page 30-61 32
7 4
2 2F
12
2H
6
4A
2G
2E
2J
37
36
38
4J 51
T
2D
4K
2X
2B
2A
4B
2C
4L
50 4M 4C
34
F1 1
11
3
8
4D
2Y
4E
35 4N
2W 14B 9
4P
14C
P3 14
15
14
F2
4F
14A 2Z
M1
P2 M2
4H 10
S1
4S
33
4T
C
T
30 - 59
4R 4G
13
P1
4Q
30
S2
9813/6050-2
30 - 59
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-60
Page 30-61
Figure 402. (Part 1 of 2) 52
5 2 2F
12
2H 2G
2E
2J 2D
2X
2B
2A
2C
F1 1
8
Page 30-61
11
3
2Y 2W 14B 9
14C
P3 14
14 14A
2Z
13
P1 M1
P2
C M2
10
T
30 - 60
9813/6050-2
S1
30 - 60
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-60
Figure 402. (Part 2 of 2) 32
7 4 12
6
37
36
38
4J
4A
51
T 4K 4L
4B
50 4M 4C
34
Page 30-60
4D
35 4N
4E
14B
4P
14C
15
14
F2
4Q
4F
14A
4R 4S
4G
13
4T
C 4H
S1
30 - 61
33
30
S2
9813/6050-2
30 - 61
Page 30-61
30 - Hydraulic System
00 - General
50 - Schematic Circuit
30 - 62
9813/6050-2
30 - 62
30 - Hydraulic System
00 - General
50 - Schematic Circuit
Page 30-64
Page 30-65
Figure 403. High Flow Machines - Duel Lever Drive Control (From machine No. 752463)
52
32
5
7
37 4
2 12
2F
6
2H
4A
2J
38
4J
2G
2E
36
51
T
2D
4K 4B
2X
2B
2A
4L
2C 50 4M 4C 34
F1 3
8
1
4D
11
35
4N
2Y
X
4E 2W 14B 14 P3
4P
14C
9
14
F2
T
4Q
15 4F
14A 4R 4G
13
P1 M1
4T
P2
C 4H
M2
30
10
T
30 - 63
33
4S
2Z
S1
S2
9813/6050-2
30 - 63
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-64
Page 30-65
Figure 403. (Part 1 of 2) 52 5 2 12
2F
2H 2G
2E
2J 2D
2X
2B
2A
2C
F1 3
8
1
Page 30-65
11
2Y 2W 14B 14 P3 9
14C 14 14A
2Z 13
P1 M1
P2
C M2 10
T
30 - 64
9813/6050-2
S1
30 - 64
30 - Hydraulic System
00 - General
50 - Schematic Circuit Page 30-64
Figure 403. (Part 2 of 2) 32 7
37 4
12
36
38
4J
6 4A
51
T 4K 4L
4B
50 4M 4C 34
8
4D
Page 30-64
35
4N X
4E
14B
4P
14C
4Q
15 14
F2
T
4F
14A 4R
33
4S 4G
13
4T C 4H 30
S1
30 - 65
S2
9813/6050-2
30 - 65
Page 30-65
30 - Hydraulic System
00 - General
50 - Schematic Circuit
Table 169. Component Key Item C F1 P1 P2 P3 M1 M2 S1 T 1 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2X 2Y 2Z
3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 30 - 66
Description Cooler Filter Main pump (Run in tandem with P2) Main pump (Run in tandem with P1) Auxiliary gear pump Left side drive motor Right side drive motor Suction strainer Tank Loader joystick Loader valve block Crowd spool Lift spool Auxiliary spool MRV (Main Relief Valve) Crowd ram rod side ARV (Auxiliary Relief Valve) Crowd ram head side ARV Lift ram head side ARV Auxiliary ARV Auxiliary ARV Pressure test point (MRV) Pressure test point (Transmission charge pressure) Pressure test point (Brake pressure) & Hand pump connector (Manual brake release) Check valve ( 8 bar ( 115.9 psi)) Excavator valve block Slew spool Boom spool Stabiliser spool Stabiliser spool Dipper spool Bucket spool Auxiliary spool Hydraclamp valve Slew ARV Slew ARV Boom ram head side ARV Boom ram rod side ARV
Item 4N 4P 4Q 4R 4S 4T 5 6 7 8 8A 8B 8C 8D 9 10 11 12 30 32 33 34 35 36 37 38 50 51 52
9813/6050-2
Description Dipper ram rod side ARV Dipper ram head side ARV Bucket ram rod side ARV Bucket ram head side ARV Auxiliary ARV Auxiliary ARV Crowd rams Manually operated dump valve Lift rams Drive control joystick Reverse spool Left turn spool Forward spool Right turn spool Pressure reducing solenoid valve Check valve ( 2 bar ( 29.0 psi)) Filter By-pass valve ( 3 bar ( 43.5 psi)) Auxiliary feeds Hydraclamp Stabiliser ram Stabiliser ram Slew ram Slew ram Boom ram Dipper ram Bucket ram Bi-restrictor Bi-restrictor One-way restrictor
30 - 66
30 - Hydraulic System
03 - Tank
03 - Tank Contents
Page No.
30-03-00 General ........................................................................................................................... 30-69 30-03-12 Suction Strainer .............................................................................................................. 30-70 30-03-24 Breather .......................................................................................................................... 30-71
30 - 67
9813/6050-2
30 - 67
Notes:
30 - 68
9813/6050-2
30 - 68
30 - Hydraulic System
03 - Tank
00 - General
00 - General Introduction The hydraulic tank holds excess hydraulic oil to accommodate volume changes due to the following. • • •
Cylinder ram extension and contraction. Temperature driven expansion and contraction. Hydraulic oil leaks.
The tank is also designed to aid in the separation of air from the fluid and it also acts as a heat accumulator to cover losses in the system when peak power is used. The tank also houses filters or strainers that help to separate dirt and other particulates from the oil. The cleanliness of this component is critical. Refer to: PIL 30-00-00.
30 - 69
9813/6050-2
30 - 69
30 - Hydraulic System
03 - Tank
12 - Suction Strainer
12 - Suction Strainer Introduction The suction strainer is a component used for trapping large and coarse particles, preventing them entering the hydraulic system. The strainer is usually located inside the hydraulic tank, at the hydraulic pump suction port.
30 - 70
9813/6050-2
30 - 70
30 - Hydraulic System
03 - Tank
24 - Breather
24 - Breather Introduction The hydraulic tank breather allows air in and out of the tank. This smooths out the pressure fluctuations in the hydraulic tank as hydraulic fluid is rapidly drawn out from, or returned to the tank. The breather also prevents contaminants like moisture and particles from entering the tank when air is drawn in. Contaminates can easily corrode, wear out or otherwise reduce the fluid performance of a hydraulic system. When air is expelled from the tank the breather prevents hydraulic fluid spillage.
30 - 71
9813/6050-2
30 - 71
30 - Hydraulic System 04 - Filter
04 - Filter Contents
Page No.
30-04-00 General ........................................................................................................................... 30-73 30-04-03 Main ................................................................................................................................ 30-74 30-04-09 Return Line .................................................................................................................... 30-75
30 - 72
9813/6050-2
30 - 72
30 - Hydraulic System 04 - Filter
00 - General
00 - General Introduction Hydraulic filters are an important part of the machines hydraulic system. Metal particles are continually produced by mechanical components and need to be removed along with other contaminants. The hydraulic filter assemblies are designed to filter all the contamination that is generated through use to the required level of cleanliness. Filters are positioned in many different locations. Refer to the relevant hydraulic filter for the location and removal procedure. The filters must be serviced to the requirements of the machine maintenance schedules. To ensure optimum performance and reliability it is important that the machine's hydraulic system is serviced periodically in accordance with the manufacturers requirements.
30 - 73
9813/6050-2
30 - 73
30 - Hydraulic System 04 - Filter 03 - Main
03 - Main
Install 1. Make the machine safe. Refer to (PIL 01-03)
Remove and Install
2. Lubricate O-Ring on the filter canister with the correct clean hydraulic oil. Tighten to the correct torque.
Remove 1. Make the machine safe. Refer to (PIL 01-03). 2. Discharge the hydraulic pressure. Refer to (PIL 30-00). 3. Loosen the hydraulic oil tank filler cap and allow all pressure to dissipate. Remove the filler cap. 4. Take suitable precautions to catch any oil. Remove the old filter canister, use a chain wrench if necessary, and dispose of the old filter and any waste material according to local regulations. 5. Repeat 3 to 4 for the high flow hydraulic oil filter if installed. Figure 404.
3. Screw on the new filter canister and tighten to the correct torque. 4. Repeat 1 to 3 for the high flow hydraulic oil filter if installed. 5. Fill the hydraulic oil tank using the correct hydraulic oil through filler point. 6. Install hydraulic oil tank filler cap. Run the engine for a few minutes, then check the fluid level, top up as required. Table 170. Torque Values Item C E
Nm 35 35
D F
E
B C E
B C D E F
Filler cap Hydraulic oil filter O-Ring Hydraulic oil filter (High flow) Oil filter cover
30 - 74
9813/6050-2
30 - 74
30 - Hydraulic System 04 - Filter
09 - Return Line
09 - Return Line Remove and Install Remove 1. Discharge the hydraulic pressure. Refer to (PIL 30-00). 2. Remove the battery compartment cover. Refer to (PIL 06-06). 3. Remove the hydraulic filler cap. 4. Drain the hydraulic tank. Refer to (PIL 30-00). 4.1. Drain the hydraulic oil to below the level of the filter return connection. 5. Disconnect the filter hoses. 6. Plug all the open ports and hoses to prevent contamination. 7. Remove the bolts. 8. Remove the filter assembly from the machine. Figure 405. A B
B
C
A Filter assembly B Hoses C Bolts
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Start and run the engine for a few minutes then check for leaks. 3. Top up as necessary with the correct oil. Refer to (PIL 30-00), (PIL 75-00).
30 - 75
9813/6050-2
30 - 75
30 - Hydraulic System
11 - Gear Pump
11 - Gear Pump Contents
Page No.
30-11-00 General ........................................................................................................................... 30-77
30 - 76
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30 - Hydraulic System
11 - Gear Pump 00 - General
00 - General Introduction .................................................... Component Identification ............................... Operation ....................................................... Check (Condition) .......................................... Remove and Install ....................................... Disassemble and Assemble ..........................
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Introduction 30-77 30-78 30-81 30-81 30-82 30-84
The auxiliary hydraulic pump is a gear type pump.
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11 - Gear Pump 00 - General
Component Identification For: Standard Flow .................... Page 30-78 For: High Flow .......................... Page 30-79
(For: Standard Flow) Figure 406. L
B
M
D
C L
K N
K
H
F E G
A A C E G K M
Bolts 1 Body Drive gear Bearing 2 Backup rings Coupling
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B D F H L N
Flange Idler gear Bearing 1 Cover Seals Mounting bolt
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11 - Gear Pump 00 - General
(For: High Flow) Figure 407. B
G Y
F
D
H
J
C
K
AA
E
Z
L S
R M
P T
U
V
N X
W
Q
A A C E G J L N Q
Bolts Body 1 Gear 2 Seal 1 Seal 2 Gasket 2 Body 3 Gear 4
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B D F H K M P R 9813/6050-2
Flange Gear 1 Bearing block 1 Bearing block 2 Gasket 1 Body 2 Gear 3 Bearing block 3 30 - 79
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11 - Gear Pump 00 - General
S U W Y AA
Seal 3 Seal 4 Cover Extended bush Row X (Within 10 mm of the flange)
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T V X Z
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Bearing block 4 Gasket 3 Gasket 4 Plug
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11 - Gear Pump 00 - General
Operation
Check (Condition)
The working principle of a gear pump depends on the meshing of two spur gears. Gears pick oil up on the suction side of the pumps. Oil is then carried round between the gear teeth and the pump body. As the gears come into mesh the oil is forced out through the outlet port.
1. Disassemble the gear pump. Refer to (PIL 30-11).
Some oil is allowed to circulate behind the bearings to hold them against the gears and minimise oil slippage. Lubrication oil is drawn through the recess and around the counter bore. Oil then flows along the scrolled grooves in the bushes, induced by the viscous drag of the rotating shaft.
4. Make a note that it is normal for the gears to have cut a slight track in the body bore on the inlet side.
2. Clean all the components. 3. Immediately apply hydraulic oil on all the components to prevent them from moisture.
5. The gear track wear cannot be measured accurately but will be related to bearing wear. 6. Check the condition of the bores of the bearing blocks. 6.1. Bearing blocks are coated with a grey PTFE (Polytetrafluoroethylene). Check the condition of the PTFE coating for wear. 6.2. Replace the pump, if the bronze base is visible. It indicated that the PTFE coating is worn. 7. Replace the pump, if faces of the bearing blocks are scored or if side faces of the gears are chipped or damaged. 8. Do not use any abrasives on the bearing blocks or gears. 9. Assemble the gear pump. Refer to (PIL 30-11).
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11 - Gear Pump 00 - General
Remove and Install Remove 1. Make the machine safe. Refer to (PIL 01-03).
7. Loosen the bolt 2 from the rear right side of the operator seat. Do not remove the bolt 2.
2. Disconnect the battery. Refer to (PIL 33-03).
8. Rotate the operator seat towards the rear of the machine.
3. Remove the front floor plates. Refer to (PIL 09-78).
9. Disconnect the wiring harness and battery lead from the front seat mounting rail.
4. Drain the hydraulic tank. Refer to (PIL 30-00).
10. Remove the seat mounting rail.
5. Disconnect the microswitch at the base of the seat.
11. Disconnect the gear pump hoses and plug the exposed connections to prevent contamination.
6. Remove the bolts 1 (x2) from the front and left rear side of the operator seat.
12. Remove the bolts 3. 13. Remove the gear pump from the machine.
Figure 408.
D A
B
A Auxiliary gear pump C Main pump
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C
B Bolts 3 D Bolts 4
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11 - Gear Pump 00 - General
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Tighten the bolts 3 to the correct torque value. 3. Fill the pump and hoses with clean oil before you install them. 4. Tighten the hydraulic connectors to the specified torque value. Torque: 45 –50 N¡m 5. Prime the pump. Refer to (PIL 30-11). Table 171. Torque Values Item B
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Description Bolts 3
Nm 77
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11 - Gear Pump 00 - General
Disassemble and Assemble 2. Use the alphabetical sequence shown on the illustration as a guide to disassembly.
For: Standard Flow .................... Page 30-84 For: High Flow .......................... Page 30-85
3. If installed, remove the coupling.
(For: Standard Flow) Consumables Description EP Hammer Grease JCB Threadlocker and Sealer (Medium Strength)
Part No. 4003/2107 4003/2106 4101/0250 4101/0251
4. Hold the body in a soft jawed vice with the mounting flange facing upwards.
Size 0.4 kg 12.5 kg 0.01 L 0.05 L
5. Mark all parts to help assembly. 6. Discard all seals and sealing rings. 7. Clean all parts in light aromatic kerosene. Check all the parts for damage and wear. replace as necessary.
Disassemble 1. Remove the gear pump from the machine. Refer to (PIL 30-11).
Figure 409. B
M
L N
D C
P
L
K
H
K F E
G
A A C E G K M P
Bolts Body Drive gear Bearing Pressure loading ring/backing ring Coupling Mounting bolt
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B D F H L N
Cover Driven gear Bearing Cover Sealing ring Bearing recesses
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11 - Gear Pump 00 - General
Assemble 1. The assembly procedure is the opposite of the disassembly procedure. Additionally do the following step. 2. Install the pressure loading ring/backing ring and sealing rings to the flange and cover. Apply the specified grease in the grooves. Consumable: EP Hammer Grease
15. Install the gear pump to the machine. Refer to (PIL 30-11). Table 172. Torque Values Item A X Y P
Description Bolts Inlet adaptor Outlet adaptor Mounting bolts
3. Hold the flange in a soft jawed vice with the sealing rings facing upwards.
(For: High Flow)
4. Make sure that the body cut-in track corresponds to the inlet side of the flange.
Consumables Description EP Hammer Grease
5. Assemble the gear/bearing pack components separately. It is important to return the flange end bearing to the flange end of the unit, otherwise internal leakage can occur due to bedding in. 6. Make sure that the bearing face recesses are adjacent to the gear faces and that the relieved radii are both towards the pump outlet. 7. Lightly lubricate the body bore and bearings. 8. Push the gear/bearing pack into the body. 9. Install the cover. Make sure that the inlet side is in the correct position. 10. Tighten the bolts to the correct torque value. 11. If the inlet adaptor is disturbed, install a new Oring. 12. Tighten the inlet adaptor the correct torque value. Do not overtighten. 13. If the outlet adaptor is disturbed, clean the threads and apply Threadlocker to two of the threads. Consumable: JCB Threadlocker and Sealer (Medium Strength) 14. Tighten the outlet adaptor the correct torque value. Do not overtighten.
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JCB Threadlocker and Sealer (Medium Strength)
Nm 65 130 95 77
Part No. 4003/2107 4003/2106 4101/0250 4101/0251
Size 0.4 kg 12.5 kg 0.01 L 0.05 L
Before you remove and disassemble the pump, check flow and pressure. If either of these are low, replacement of components such as gears, bearings and housings will not give a permanent cure. If the pump output is satisfactory but there is external leakage, the pump may be removed and disassembled for re-sealing only.
Disassemble 1. Remove the gear pump from the machine. Refer to (PIL 30-11). 2. Use the alphabetical sequence shown on the illustration as a guide to disassembly. 3. Mark the housings and covers to help assembly. 4. Keep the bearing blocks and gears together in sets to make sure the correct installation of the bearing blocks in their original positions. 5. The extended bush in the bearing block 1 is a light push fit in flange. Do not remove the plug as it is an interference fit and assembled to a critical dimension.
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11 - Gear Pump 00 - General
Figure 410. B
G Y
F
D
H
J
C
K
AA
E
Z
L S
R M
P T
U
V
N X
W
Q
A A C E G J L N Q S U
Bolts Body 1 Gear 2 Seal 1 Seal 2 Gasket 2 Body 3 Gear 4 Seal 3 Seal 4
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B D F H K M P R T V 9813/6050-2
Flange Gear 1 Bearing block 1 Bearing block 2 Gasket 1 Body 2 Gear 3 Bearing block 3 Bearing block 4 Gasket 3 30 - 86
30 - Hydraulic System
11 - Gear Pump 00 - General
W Cover Y Extended bush AA Row X (Within 10 mm of the flange)
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X Gasket 4 Z Plug
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11 - Gear Pump 00 - General
Assemble 1. Replace all the seals. Hold them in position with grease. Consumable: EP Hammer Grease 2. Make sure that the ends of seals do not overhang the bearing blocks to become trapped in the housings. Bearings must be assembled with cast recesses and not in seal grooves, against gear faces and with seal ends towards the inlet side of the pump. 3. Lightly lubricate threads of bolts. 4. Install the bolts and tighten by hand. 5. Hold the flange in a vice. 6. Apply specified force to the body at position indicated by row X. Refer to Figure 410. Force: 200 –250 N 7. Tighten the bolt to the correct torque value in a diagonal sequence. This procedure is necessary to make sure correct metal to metal contact between the front bearing lobes and inlet side of body. 8. If the inlet adaptor is disturbed, install a new Oring. 9. Tighten the inlet adaptor to the correct torque value. Do not overtighten. 10. If the outlet adaptor is disturbed, clean the threads and apply Threadlocker to two of the threads. Consumable: JCB Threadlocker and Sealer (Medium Strength) 11. Tighten the outlet adaptor to the correct torque value. Do not overtighten. 12. Install the gear pump to the machine. Refer to (PIL 30-11). Table 173. Torque Values Item A X Y
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Description Bolts Inlet adaptor Outlet adaptor
Nm 65 130 95
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30 - Hydraulic System
15 - Cylinder / Ram
15 - Cylinder / Ram Contents
Page No.
30-15-00 General ........................................................................................................................... 30-91 30-15-21 Swing .............................................................................................................................. 30-97 30-15-99 Seal Kit ......................................................................................................................... 30-103
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Notes:
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15 - Cylinder / Ram 00 - General
00 - General Introduction .................................................... Health and Safety .......................................... Technical Data ............................................... Disassemble and Assemble ..........................
Introduction 30-91 30-92 30-93 30-94
A hydraulic cylinder ram is a mechanical actuator that is used to give a single directional force through a single action stroke. It is used in many applications, the cylinder gets the power from pressurised hydraulic oil. The hydraulic cylinder consists of a cylinder barrel, in which a piston connected to a piston rod moves back and forth. The barrel is closed on one end by the cylinder cap and the other end by the cylinder head where the piston rod comes out of the cylinder. The piston has sliding rings and seals. The piston divides the inside of the cylinder into two chambers, the bottom chamber (cap end) and the piston rod side chamber (rod end / head end).
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Health and Safety
Caution During Use 1. Use only under designated conditions.
Hydraulic Pressure
1.1. If hydraulic oil other than the designated oil is used, the seals quickly degenerate and become damaged. If the relief valve is set at a value higher than specified, it may cause ram damage and is dangerous.
Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open.
1.2. In high temperature environments (approx. 90°C and above) or low temperature environments (below -20°C), seals quickly become damaged. Special seal materials are necessary so check to see if the ram that you are using is suitable or not.
Lifting Equipment You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations. WARNING! A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the machine being started while you are beneath it.
1.3. The number one cause of ram oil leakage is rod damage. Be careful not to damage the rod. 2. Warm up sufficiently before beginning work. 2.1. In cold conditions the rod seals may be frozen, so if the ram is operated at maximum pressure and maximum speed, the seals will be damaged. 2.2. There is a large amount of air in a new ram or one which has been left for a long time, so the ram will not operate smoothly. Also, if pressure is applied suddenly without bleeding the air, high temperatures will be generated due to adiabatic compression and the seals may burn.
Precautions for Installation 1. Precautions when installing the ram on the machine. 1.1. When installing and removing from the machine, suspend the ram safely. 1.2. Suspending the ram by the piping is not only dangerous, but can also cause damage to the cylinder. 1.3. Secure the piston rod with a band. It is very dangerous if the rod extends unexpectedly. Also, the rod can be damaged and become unusable.
2.3. Before beginning work, always move the ram at full stroke with no load and expel air from the cylinder. 3. When stopping or storing, do it at a safe and fixed position. 3.1. The installed ram cannot maintain the same position for a long period of time, because the oil inside the ram may leak and the hydraulic oil volume decreases as it cools. Stop or store the machine in a safe and fixed position.
2. Welding after installing the ram may result in damage. 2.1. If electric welding is done even at a point away from the ram, there may be sparking inside the ram and it will become necessary to replace the ram with a new one.
Maintenance, Inspection Points 1. Carry out daily maintenance and inspection.
3. When painting the machine, mask the ram. If paint adheres to the rod surface or to the wiper ring and the ram is operated, the wiper ring will not function properly and foreign matter and paint can easily enter the ram. This will cause damage to the seals, drastically shortening the life of the ram. 4. Install the ram only when it is clean.
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1.1. The key point for correct long-term ram function is daily maintenance and inspection. Carry out maintenance and inspection so that the ram functions fully at all times. Always remove any mud, water, dust or oil film adhering to the rod and keep it in normal condition. However, when cleaning the wiper ring and seals, do not get them wet with water but wipe clean with a rag. To prevent rust forming during storage, the amount of exposed ram piston rod 30 - 92
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15 - Cylinder / Ram 00 - General
should be kept to a minimum. If leaving for more than one week, apply a light coating of suitable grease or petroleum jelly to the exposed part of the ram piston rod.
Technical Data Table 174. Drilling Details for Piston Head Retention
2. Use genuine JCB parts when replacing parts. 2.1. If parts other than genuine JCB parts are used, the desired results may not be obtained. Use only genuine JCB parts. 3. Caution during dismantling and reassembly. 3.1. Dismantling the ram while it is still installed on the machine can be dangerous as unexpected movements of the machine can occur. Remove the ram from the machine and then dismantle.
Cylinder Ram Size (mm) Dowel Size (mm) Guide Drill Diameter Guide Drill Depth Dowel Drill Diameter (X) Dowel Drill Depth (Y)
50 x 25, 60 x 30, 70 x 40, 80 x 50 20 x 6 4 mm 19 mm 6.02-6.1mm 22-23mm
3.2. If reassembled with dirty hands, foreign matter can enter the ram causing a shorter life span and also the other hydraulic equipment may be damaged. Reassemble in a clean state. 3.3. Follow the instructions in the diagrams regarding torque tightening for screwed parts. If the torque is too high or too low, it can cause damage.
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Disassemble and Assemble Consumables Description Cleaner/Degreaser - General purpose solvent based parts cleaner JCB Activator
Part No. 4104/1557
Size 0.4 L
4104/0251 4104/0253
0.2 L 1L
Description JCB Threadlocker and Sealer (Medium Strength)
Part No. 4101/0250 4101/0251
Size 0.01 L 0.05 L
The numerical sequence shown on the illustration is intended as a guide to disassembly.
Figure 411. Typical Cylinder Ram
1 3 5 7
End cap Seal Locking dowel Piston rod
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2 4 6 8 9813/6050-2
Seal Seal Piston head O-ring 30 - 94
30 - Hydraulic System
15 - Cylinder / Ram 00 - General
9 11
10 12
Inner rod seal O-ring
Disassemble 1. Disassemble the cylinder ram assembly in numerical sequence.
Outer rod seal Piston eye bush
2. Remove all swarf and contamination. Insert a dowel into the drilled hole, make sure that the tapped extractor hole is to the outside. Figure 412.
2. Discard all seals and 'O' rings
Assemble 1. The assembly procedure is the opposite of the disassembly procedure. 2. Thoroughly clean the threads of piston head, piston rod, end cap and the cylinder with a wire brush. 3. Use new seals and O-rings throughout the assembly. Refer to the cylinder ram sealing procedure. Make sure that all threads are free from grease, hydraulic oil and old locking fluids, use JCB Cleaner/Degreaser. Allow solvent to dry for 15 minutes before applying JCB Activator. Consumable: Cleaner/Degreaser purpose solvent based parts cleaner Consumable: JCB Activator
5 Locking dowel X Drill diameter Y Drill depth
General
4. Make sure that all lubricants used during assembly do not come into contact with the locking fluids. 5. Apply JCB Activator to the threads of the piston head 6. Allow to dry for 15 minutes before bringing into contact with JCB Threadlocker. Note: Threadlocker and Activator must not contact seals, bearing rings or 'O' rings. 6. Apply JCB Threadlocker & Sealer (High Strength) to all threads of the piston rod. Install and tighten the piston head to the correct torque value. Consumable: JCB Threadlocker and Sealer (Medium Strength) 7. Install the locking dowel to the piston head/rod as follows:
New Rod and Piston Head If both are required, the following procedure should be followed: 1. Use a drill to make a hole through the piston head into the piston rod. Use an undersized diameter drill first as a guide and then use the correct size diameter drill to suit, refer to Drilling head retention, Technical Data (PIL 30-15).
New Piston Head Installed to a Pre-drilled Piston Rod 1. Use a drill to make a hole through the piston head and the piston rod at 90° from the existing drilled dowel hole in the piston rod. Follow the procedure, New Rod and Piston Head. New Piston Head Installed to a Pre-drilled Piston Head Use the pre-drilled hole in the piston head. Care must be taken not to elongate the existing hole in the piston head. 1. Use a drill of the same diameter as the pre-drilled hole in the piston head to make a centre mark in the piston rod. Do not drill the piston rod at this stage. 2. Use an undersized diameter drill as a guide and drill into the piston rod to the required depth. Refer to Drilling details for piston head retention, Technical Data (PIL 30-15). Make sure that the drill has centred correctly on the centre mark made in step 1. 3. Use the correct size diameter drill to suit the dowel and drill to the required depth. Refer to Drilling details for piston head retention, Technical Data (PIL 30-15). 4. Remove all swarf and contamination. Insert the dowel into the drilled hole, make sure that the tapped extractor hole is to the outside.
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15 - Cylinder / Ram 00 - General
5. Take care to retain the end cap at the furthest end of the piston rod from the cylinder, coat the thread of the cylinder with JCB Activator. Next apply JCB Threadlocker to the thread of the end cap. Wait 15 minutes before bringing the two together and then torque-tighten the end cap into the cylinder. Consumable: JCB Activator Consumable: JCB Threadlocker and Sealer (Medium Strength) Note: If hydraulic oil contacts uncured Threadlocker, a weakening of the bond will result. Cure times vary according to the ambient temperature. Allow approximately 1 hour at 20 °C between assembly and filling the cylinder ram with oil. When installing cylinder and piston eye bushes, make sure that the split in the bush is set at 90° to the longitudinal centreline of the cylinder. When operating in cold conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working.
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15 - Cylinder / Ram 21 - Swing
21 - Swing
Drain and Fill
Drain and Fill ................................................. 30-97 Remove and Install ....................................... 30-98 Disassemble and Assemble ........................ 30-101
You must follow this procedure when you fill the swing ram, to make sure that all the air is expelled from the swing ram.
Fill 1. Remove the plug 1. 2. Fill with clean oil to the level of the plug 1. 3. Install the plug 1. 4. Remove the plug 2. 5. Fill the breather tube with the clean oil to half level. 6. Install the plug 2. 7. Start the engine. 8. Operate the swing service until the oil level rises in the breather tube. 9. Stop the engine. 10. Remove the plug 1 to release the air. 11. Install the plug 1. 12. Remove the plug 2. 13. Fill the breather tube with clean oil to half level. 14. Do the steps 1 to 13 until all air is expelled. 15. Make sure that the oil is level with the mark in the breather tube. Figure 413. B
C
A A Plug 1 B Plug 2 C Breather tube 30 - 97
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15 - Cylinder / Ram 21 - Swing
Remove and Install Remove
6. Remove the capscrew 1.
1. Make the machine safe. Refer to (PIL 01-03).
7. Place a suitable container underneath the kingpost to catch any oil.
2. Discharge the hydraulic pressure. Refer to (PIL 30-00). 3. Disconnect the hydraulic hoses from the swing cylinder ram.
8. Remove the swing cylinder ram from the machine. 8.1. Turn the excavator assembly to one side and then remove the other swing cylinder ram. This will push off each swing cylinder ram.
4. Put a label on the hoses to help installation. 5. Plug all the open ports and hoses to prevent contamination.
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9. Remove the rack seals.
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15 - Cylinder / Ram 21 - Swing
Figure 414. G E K J
F R N
S
M
L
C
H D U
T P Q B A C E G J L N Q S U
Capscrew 1 Rack seal Capscrew 2 Filler tube assembly Bolt Shim Thrust washer O-ring Bush 2 Plungers
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B D F H K M P R T
A Swing cylinder ram Rack Thrust cap Capscrews 3 Pivot pin Pinion Anti-roll pin Bush 1 Bush 3
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15 - Cylinder / Ram 21 - Swing
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Install the new rack seals and O-ring. 3. Fill the swing assembly with the correct grade of oil. Refer to (PIL 75-03). 4. Bleed the hydraulic system. Refer to (PIL 30-00). 5. Check the oil level. Refer to (PIL 30-00). Table 175. Torque Values Item A
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Description Capscrew 1
Nm 300
9813/6050-2
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15 - Cylinder / Ram 21 - Swing
Disassemble and Assemble Disassemble
7. Make a note that oil will flow out of the swing housing when the cylinder is removed.
1. Make the machine safe. Refer to (PIL 01-03).
8. Place a suitable container underneath the swing housing to catch the oil.
2. Discharge the hydraulic system. Refer to (PIL 30-00).
9. Disconnect the hydraulic hoses.
3. Swing the excavator fully around so that the cylinder to be worked on faces rearwards.
10. Remove the capscrews.
4. Install the boom lock.
11. Remove the cylinder ram.
5. Stop the engine.
12. Remove the seals from the rack.
6. Operate the swing control levers to discharge the residual hydraulic pressure. Figure 415.
E
D
G C
A
F
B A C E G
Hydraulic hose Cylinder ram End damping plunger O-ring
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B Capscrews D Seals F Spring
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15 - Cylinder / Ram 21 - Swing
Assemble 1. The assembly procedure is the opposite of the disassembly procedure. Additionally do the following step. 2. Check that the seal grooves are clean and free from burrs. 3. Check the condition of the end damping plunger. 4. Make sure that the end damping plunger moves freely in its bore and returns by the force of the spring. 5. Lubricate the new seals with clean engine oil. 6. Install the seals to the rack. 7. Tighten the capscrews to the correct torque value. 8. Fill the swing assembly with hydraulic oil. Table 176. Torque Values Item B
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Description Capscrews
Nm 300
9813/6050-2
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15 - Cylinder / Ram 99 - Seal Kit
99 - Seal Kit
Figure 416.
Remove and Install Special Tools Description Ram Protection Sleeve (90mm rod diameter) Ram Seal Installation Tool Ram Protection Sleeve (25mm rod diameter) Ram Protection Sleeve (30mm rod diameter) Ram Protection Sleeve (40mm rod diameter) Ram Protection Sleeve (50mm rod diameter) Ram Protection Sleeve - Slew (50mm rod diameter) Ram Protection Sleeve (60mm rod diameter) Ram Protection Sleeve - Slew (60mm rod diameter) Ram Protection Sleeve (65mm rod diameter) Ram Protection Sleeve (70mm rod diameter) Ram Protection Sleeve (75mm rod diameter) Ram Protection Sleeve (80mm rod diameter) Ram Seal Assembly Tool
Part No. 892/00167
Qty. 1
892/00334
1
892/01016
1
892/01017
1
892/01018
1
892/01019
1
892/01020
1
892/01021
1
892/01022
1
892/01023
1
892/01024
1
892/01025
1
892/01026
1
892/01027
1
A Ram seal installation tool B Pins 1.2. Open the seal installation tool and insert the new rod seal. Install the seal behind the two front pins but in front of the rear pin as shown. Figure 417.
A Rod seal 1.3. Later ram end caps and piston heads have metric threads. The seals are also different, make sure that the correct seals are installed. On metric threaded rams, make sure that the seals are installed the correct way around, as shown. Figure 418.
Remove 1. Remove and discard the old seals. Refer to: PIL 30-15-00.
Install 1. Install new rod seals: 1.1. Use the ram seal installation tool to install rod seals, the size (diameter) and position of pins is determined by the diameter and radial width of the rod seal being installed. The pins are screwed into threaded holes in the tool body, the spacing of the holes is designed to suit small or large diameter rod seals.
A Inner seal B Outer seal 1.4. Close the tool. The seal must form a reniform (kidney shape).
Special Tool: Ram Seal Installation Tool (Qty.: 1) 30 - 103
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15 - Cylinder / Ram 99 - Seal Kit
Figure 419.
Special Tool: Ram Protection Sleeve - Slew (60mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (65mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (70mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (75mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (80mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (90mm rod diameter) (Qty.: 1)
1.5. Before you install the rod seals, check that the seal grooves are free of contamination and sharp edges.
Figure 421.
1.6. Locate the seal in the end cap groove. When the seal is in position, open the tool to release the seal. Make sure the seal is correctly installed in its grooved and remove the tool. Figure 420.
A Protection Sleeve (various sizes) 2. Install new head piston seals.
1.7. Install the rod wiper seal into the seal groove. Make sure that the seal is correctly installed as shown. Note: Some rod wipers, i.e. power track rod, may use a metal encased seal which is pressed into the housing. Care must be taken to make sure that the seal is square before it is pressed in.
2.1. Use the Piston seal assembly tool to lever the inner seal into the piston head seal groove. Do not let the seal twist. There are identification marks on the outer diameter of the seal, make sure that the marks are visible and the seal is free to rotate, if not remove the seal and retry. Special Tool: Ram Seal Assembly Tool (Qty.: 1) Figure 422.
1.8. A special sleeve must be used to protect the rod seals from damage, when installing the end cap on to the piston rod. There are various sizes of sleeve, make sure you use the correct size sleeve and also make sure that the hexagon on the end cap is towards the eye end of the rod. Special Tool: Ram Protection Sleeve (25mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (30mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (40mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (50mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve - Slew (50mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (60mm rod diameter) (Qty.: 1) 30 - 104
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A Piston seal assembly tool B Inner seal C Outer seal
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30 - Hydraulic System
15 - Cylinder / Ram 99 - Seal Kit
2.2. Use the same procedure to install the outer seal as stated for the inner seal. Check that the external grooves are visible. 2.3. Make sure that the O-ring is installed into the internal seal groove on the piston head. Screw the piston head on to the thread of the piston rod and tighten to the correct torque value. Refer to: PIL 30-15-00. 2.4. Install the piston head retaining dowel. Refer to: PIL 30-15-00. 2.5. Install wear rings, rotate the wear rings so that the piston retention dowel is covered by the wear ring, not as shown at C. Figure 423.
A Outer wear ring B Inner wear ring C Incorrect installation 3. Install the piston rod and head assembly into the cylinder. 3.1. Insert the piston/rod assembly into the cylinder ram. Align the rod and head assembly until parallel with the cylinder ram then push the assembly into the cylinder. 3.2. Install the end cap and assemble the ram assembly. Refer to: PIL 30-15-00.
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50 - Excavator Control Valve Block
50 - Excavator Control Valve Block Contents
Page No.
30-50-00 General ......................................................................................................................... 30-107
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30 - Hydraulic System
50 - Excavator Control Valve Block 00 - General
00 - General Introduction .................................................. Component Identification ............................. Operation ..................................................... Fault-Finding ................................................ Remove and Install ..................................... Disassemble and Assemble ........................
30 - 107
Introduction 30-107 30-108 30-109 30-115 30-117 30-118
The excavator control valve block is made of many sections. Each section controls a different hydraulic service. The number of valve sections is dependent on the hydraulic services and options installed on the machine.
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50 - Excavator Control Valve Block 00 - General
Component Identification Figure 424.
K
J
H
G
F
E
D
B
A C
A C E G J
Excavator control valve block Load hold check valve Boom spool Stabiliser spool Bucket spool
30 - 108
B D F H K
Inlet port Slew spool Stabiliser spool Dipper spool Auxiliary spool
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50 - Excavator Control Valve Block 00 - General
Operation Oil from the loader valve enters the excavator valve through inlet port. Oil then flows through the neutral gallery and around the waists of the solid spools. It also fills the parallel gallery but is not at a high enough pressure to open the LHCV (Load Hold Check Valve)s.
Neutral Circuit All the excavator services operate in a similar manner. The boom service is shown as an example. When you select the boom spool for lift, initially back
pressure exceeds system pressure which closes the LHCV. When pressure in the feed line exceeds back pressure, the LHCV opens and oil is allowed to flow to the boom ram piston. This pressure causes the boom ram to lift. Oil from the other side of the piston returns to the exhaust line through the control valve. The system pressure also opens the remaining LHCVs but the galleries are dead-ended because the spools are in neutral. When lower is selected, the spool directs the flow in the reverse direction.
Figure 425.
E
C L
C LHCV L Parallel gallery
30 - 109
E Boom spool
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50 - Excavator Control Valve Block 00 - General
Excavator Operation
Valve
-
Bi-Restrictor
Due to the weight of the excavator end, it may take over the control when the boom lower operation is selected. The falling boom will tend to push the oil out
of the ram faster than the head side is being filled. Consequently, when the excavator has reached the ground, there will be a time lapse while the ram is filled with oil before the service will operate again. To prevent this, the boom service is installed with a bi-restrictor.
Figure 426. E
M
E Boom spool
30 - 110
M Bi-restrictor
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50 - Excavator Control Valve Block 00 - General
Slew Operation The illustration shows the right side slew selected. The spool pressurises the lower port. Oil flows from the parallel gallery, out past ARV (Auxiliary Relief Valve) 2 to the left side of the slew actuator. The boom therefore slews to the right side. The displaced
oil from the right side of the slew actuator flows back through the upper service port and back to tank. When the actuator reaches the end of its travel, the damper piston contacts the end of the slew pot and is pushed into the slew rack. This restricts the flow of oil and slows down the slew action.
Figure 427.
D N
R
S L
Q P D N Q S
Slew spool ARV 1 Lower port Damper piston
30 - 111
L Parallel gallery P ARV 2 R Upper service port
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50 - Excavator Control Valve Block 00 - General
Slew ARV and Anti-Cavitation Operation The slew spool is in neutral but the momentum of the slewing excavator end creates back pressure in
the right side slew cylinder. This opens ARV 1 and dumps oil to exhaust. At this point the left side slew cylinder cavitates and exhaust oil pressure causes ARV 2 to open. This allows oil from the exhaust gallery to fill the left side cylinder.
Figure 428. D
N
P D Slew spool P ARV 2
30 - 112
N ARV 1
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50 - Excavator Control Valve Block 00 - General
ARV Operation
When this pressure reaches the setting of ARV 3, the ARV 3 opens. This relieves the pressure into the exhaust gallery. Cavitation occurs in the rod side of the dipper service.
When the bucket spool is selected to operate the service against an immovable object, it forces the dipper away from the obstruction and pressurises the head side of the dipper ram.
Figure 429. J
H
T
V
W
H Dipper spool T ARV 4 V ARV 5
30 - 113
U
J Bucket spool U ARV 3 W ARV 6
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50 - Excavator Control Valve Block 00 - General
ARV Pressure Relief Operation
Pilot Valve Opens
ARV at Rest
As the service pressure reaches the pilot setting of the ARV, pilot poppet 2 lifts. This allows oil to escape into cavity 1 and pass down the sides of the sleeve into the exhaust gallery.
The ARVs are positioned in the excavator valve block in order to relieve excessive pressure in the services.
Main Poppet Opens
When the service is in neutral and there are no excessive forces acting on the equipment, service pressure will act on the lower face of poppet 1. The service pressure will also be felt inside the valve through hollow piston.
As the service pressure continues to rise and oil escapes from cavity 2, the pressure differential between the upper and lower surfaces of the hollows piston causes this piston to rise and seat on the point of pilot poppet 2.
The force of the spring 1 and spring 2, combined with the service pressure acting on the upper faces of poppet 1 and hollow piston, keeps poppet 1 and poppet 2 tightly seated. The force of the spring 2 is adjustable to suit the relevant service by means of adjuster screw and locknut.
Oil continues to escape from cavity 2 but the incoming flow to the cavity has been cut off. This produces a pressure drop above poppet 1, causing the poppet 1 to lift and release service pressure into exhaust gallery.
Figure 430. AG AF
AE
AF
AL
AH AE AD AC
AE
AD
AJ
AC AB
AK
AK
AK
AB
X Z AB AD AF AH AK
AA
AA
AA
X
Y
Z
ARV at rest Main poppet opens Poppet 1 Spring 1 Spring 2 Cavity 1 Exhaust gallery
30 - 114
Y AA AC AE AG AJ AL
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Pilot valve opens Service pressure Hollow piston Poppet 2 Locknut Sleeve Cavity 2
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50 - Excavator Control Valve Block 00 - General
Fault-Finding Fault A spool is sticking A spool does not move over its full stroke The dipper/boom falls under load with the spool in neutral System pressure does not rise at all Relief pressure is unstable Oil leak Table 177. A spool is sticking Cause Oil temperature abnormally high The hydraulic oil is dirty The service pipe connection is over tightened The valve housing was twisted during installation Pressure too high A spool is bent A return spring is broken A return spring or cap is out of alignment Temperature distribution within control valve not uniform
Table 177. Table 178. Table 179. Table 180. Table 181. Table 182.
Page 30-115 Page 30-115 Page 30-115 Page 30-115 Page 30-115 Page 30-116
Remedy Check correct oil. Check oil cooler and grille for blockage. Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system. Check tightening torque. Loosen retaining bolts and tighten to correct torque values. Check system pressure. Replace the control valve section. Replace as necessary. Remove the cap, check that the spring is in the correct position. Install the cap and tighten bolts to the correct torque value. Warm the entire system up before using service.
Table 178. A spool does not move over its full stroke Cause Remedy Dirt is clogging the inside of the valve Remove the dirt (flush out the valve). Table 179. The dipper/boom falls under load with the spool in neutral Cause Remedy Oil is leaking past the ram/boom piston seals Replace the piston seal. Oil is bypassing dipper/boom spool Replace control valve section. Oil is leaking past dipper/boom ARV (Auxiliary Relief Remove ARV and clean housing seat and relief valve Valve) seat. Install ARV. Table 180. System pressure does not rise at all Cause Remedy The main poppet, check valve poppet or pilot poppet Remove MRV (Main Relief Valve) and dismantle. is sticking open, or dirt is caught in the valve seat Inspect and clean all parts. Assemble MRV, ensuring that all parts slide freely. Install the MRV. Table 181. Relief pressure is unstable Cause Remedy The pilot poppet seat is scratched or the pilot piston Remove MRV and disassemble. Inspect and clean is sticking with the main poppet or the parts are worn all parts. Renew damaged parts or remove scratches out with very fine emery cloth. Assemble MRV and make sure that all the parts are slide freely. Install the MRV. The lock nut and adjusting screw are loose Tighten the lock nut and reset MRV pressure.
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50 - Excavator Control Valve Block 00 - General
Table 182. Oil leak Worn O-rings
30 - 116
Cause
Remedy Remove MRV and replace the O-rings.
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50 - Excavator Control Valve Block 00 - General
Remove and Install CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.
Remove 1. Make the machine safe. Refer to (PIL 01-03). 2. Remove the floor plate. Refer to (PIL 09-78). 3. Discharge the hydraulic system. Refer to (PIL 30-00). 4. Disconnect all the hoses. 5. Disconnect the electrical connectors. 6. Put a label on the hoses and electrical connectors to help installation. 7. Plug all the open ports and hoses to prevent contamination. 8. Remove the nuts. 9. Remove the excavator control valve block from the machine.
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Tighten the nuts to the correct torque value. Torque: 56 N¡m
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50 - Excavator Control Valve Block 00 - General
Disassemble and Assemble Use the numerical sequence shown on the illustration as a guide to disassembly. Refer to Figure 431.
The assembly procedure is the opposite of the disassembly procedure.
Figure 431.
25
24
4Q 4F
26 27 3 1A
4S
4N 4E
4L 4D
4C
4B
4A
4J
2
4G 4
7
9
8
10 4W 1B
4M
5
19
4R
18 17
6
4K
4P
21 4T
16 20
15 14 12
13
11 Additionally note the following points: • • •
•
Each spool has an identical LHCV (Load Hold Check Valve). The condition of the seating face of the check valve on the poppet and on the mating face in the valve block must be satisfactory. All the valve block adapters are torqued to 81 N·m.
30 - 118
• • •
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The valve operational spools are identical but must not be interchanged as they are matched to their bores. The slew spool is different in design from all other spools. All the spools has the same centring and sealing components. You must hold the rod through the eye end of the spool to prevent the spool rotation. 30 - 118
30 - Hydraulic System
50 - Excavator Control Valve Block 00 - General
•
You must lubricate new seals with clean hydraulic oil to prevent them from damage before installation. Table 183. Torque Values Item 1A 1B 11 13
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Nm 19 45 6.8 10.2
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51 - Lift Arm Control Valve Block
51 - Lift Arm Control Valve Block Contents 30-51-00 30-51-03 30-51-06 30-51-36
30 - 120
Page No. General ......................................................................................................................... Main Relief Valve (MRV) .............................................................................................. Auxiliary Relief Valve (ARV) ......................................................................................... Load Hold Check Valve ...............................................................................................
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30-121 30-139 30-144 30-150
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51 - Lift Arm Control Valve Block 00 - General
00 - General Introduction .................................................. Technical Data ............................................. Component Identification ............................. Operation ..................................................... Diagram ....................................................... Fault-Finding ................................................ Remove and Install ..................................... Disassemble and Assemble ........................
30 - 121
Introduction 30-121 30-122 30-124 30-126 30-130 30-131 30-134 30-135
The lift arm control valve block is made of many sections. Each section controls a different hydraulic service. The number of valve section is dependent on the hydraulic services and options installed on the machine.
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51 - Lift Arm Control Valve Block 00 - General
Technical Data (For: Series 2) Table 184. Relief Settings Section
MRV (Main Relief Valve)
Port A Item Refer to Figure 432.
IN
Inlet
D
1
BH Boom
A
2
BH Bucket
A
3
BH Dipper
B
4
BH Swing
A
5 6 7
Stabilizer Stabilizer Loader arms
-
8
Loader shovels
C
9
BH auxiliary A
10
Loader aux- F iliary Outlet -
OUT
Port B Item Refer to Figure 432.
Pressure
Flow rate
19 L/min
-
-
-
2 L/min
B
10 L/min
2 L/min
A
10 L/min
A
2 L/min
A
-
A
100 bar ( 1,449.3 psi) 240 bar ( 3,478.2 psi) Option
56 L/min
C
2 L/min
A
Option
F
240 bar ( 3,478.2 psi) 240 bar ( 3,478.2 psi) 240 bar ( 3,478.2 psi) 240 bar ( 3,478.2 psi) 240 bar ( 3,478.2 psi) 240 bar ( 3,478.2 psi) 240 bar ( 3,478.2 psi) Option
-
-
-
-
-
Pressure 220 bar ( 3,188.4 psi) 220 bar ( 3,188.4 psi) 240 bar ( 3,478.2 psi) 240 bar ( 3,478.2 psi) 240 bar ( 3,478.2 psi) 240 bar ( 3,478.2 psi) -
Flow rate
(1)
2 L/min 2 L/min 2 L/min 2 L/min 10 L/min 2 L/min Option
(1) Based on a pump delivering 45 L/min.
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51 - Lift Arm Control Valve Block 00 - General
Figure 432. B
A
A
A
A
A
B
A
A
B
A
F
C
A
F
E
D
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51 - Lift Arm Control Valve Block 00 - General
Component Identification For: Series 1 ........................... Page 30-124 For: Series 2 ........................... Page 30-125
(For: Series 1) Figure 433.
G
A
H B D H
E
H
F J C A C E G J
Lift arm control valve block Outlet to excavator valve block Lift spool Main relief valve Outlet to tank
30 - 124
B D F H
Inlet Crowd spool Auxiliary spool Auxiliary relief valve
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51 - Lift Arm Control Valve Block 00 - General
(For: Series 2) Figure 434.
BL BD DI SL
LR LC
GP
EPD
IP
CP WP BR BC DO SR
IP WP OP BR BC DO SR LL LD
Inlet port Work port (x20) Outlet port Boom raise Bucket crowd Dipper out Slew right Lift arm lower Loader shovel dump
30 - 125
LL LD
GP PP EPD BL BD DI SL LR LC
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OP
PP
Gauge port Pilot port (x14) External clamp port drain Boom lower Bucket dump Dipper in Slew left Lift arm raise Loader shovel crowd
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51 - Lift Arm Control Valve Block 00 - General
Operation Neutral circuit Oil from the pump enters the lift arm control valve block. When all the spools are in the neutral position, the oil passes around the waisted central position of the spools and flows on to feed the excavator control valve block through outlet line. Oil trapped in the lines prevents movement of the cylinder rams. Oil also fills the parallel gallery.
Lift Ram Operation 1
Initially, the weight of the loaded shovel causes a higher pressure in the service line than in the parallel gallery. This pressure differential causes the load hold check valve to close. The load hold check valve is a spring loaded nonreturn valve operating across the pressure feed from the parallel gallery. The load hold check valve prevents reverse flow from the cylinder rams into the pressure feed line. It maintains the ram pressure until the system pressure is exceeded. This prevents the load from dropping.
The illustration shows the lift ram spool is selected to raise the loader lift arm. Figure 435.
C A B
A Lift ram spool C Load hold check valve
30 - 126
B Parallel gallery
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51 - Lift Arm Control Valve Block 00 - General
Lift Ram Operation 2 The central land of the selected spool blocks the neutral circuit, then the pressure in the parallel gallery increases until it is greater than that in the service line. At this point the load hold check valve opens. This allows oil to flow from the parallel gallery into the service line and operate the lift ram to raise the loader
arms. As the arms rise, oil from the other side of the ram returns to the exhaust line through the control valve and returns to tank. When the pressure in the feed line rises above the set pressure, the ARV (Auxiliary Relief Valve) will lift and dump pressure to tank. Make a note that the loader arm lowering operation is a opposite of the above procedure.
Figure 436.
D B A
A Lift ram spool D Lift ram
30 - 127
B Parallel gallery
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51 - Lift Arm Control Valve Block 00 - General
Crowd Ram Operation Shovel Lift (Crowd) The load hold check valve controls and operates the crowd spool. The crowd spool operation is similar to the lift spool operation. When the crowd spool
is selected for lift, pressure acts on the crowd ram piston and the shovel crowds or lifts. Oil from the other side of the ram returns to the exhaust line through the control valve. The ARV protects both the feed and return lines from overpressure.
Figure 437. E F
E Crowd spool
30 - 128
F Crowd ram piston
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51 - Lift Arm Control Valve Block 00 - General
Shovel Open
Figure 439.
This is the opposite of the shovel lift procedure.
Relief Valve Operation Main Relief Valve The MRV (Main Relief Valve) is located in the loader valve block. It provides control of both loader and excavator pressures. As the service pressure reaches the pilot setting of the MRV, the pilot poppet lifts. This allows oil to escape into cavity and pass down the sides of a sleeve into the exhaust gallery. Refer to Figure 438.
G
L
Figure 438. M
K
H
G K L M N
G J
Pilot poppet Exhaust gallery Cavity Piston Poppet
Oil continues to escape from the cavity but the incoming flow to the cavity has been cut off. This produces a pressure drop above the poppet, causing the poppet to lift and release service pressure into the exhaust gallery.
Auxiliary Relief Valve
K
G H J K
N
The ARV functions in exactly the same manner as the MRV although the operating pressures are different.
Pilot poppet Cavity Sleeve Exhaust gallery
As the service pressure continues to rise and oil escapes from cavity, the pressure differential between the upper and lower surfaces of piston causes this piston to rise and seat on the point of the pilot poppet. Refer to Figure 439.
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51 - Lift Arm Control Valve Block 00 - General
Diagram (For: Series 2) Figure 440.
IN
IN 2 4 6 8 10
1
Inlet port Bucket Slew Stabiliser Shovel Lift arm auxiliary
30 - 130
2
3
4
5
6
7
1 3 5 7 9 OUT
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8
9
10
OUT
Boom Dipper Stabiliser Lift arm Excavator auxiliary Outlet/return
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51 - Lift Arm Control Valve Block 00 - General
Fault-Finding Fault Lack of power in all loader functions All hydraulic cylinder rams slow to operate One hydraulic service fails to operate or is slow to operate Engine tends to stall when hydraulics are under load. Valve spool sticking Cylinder ram creep Hydraulic oil becomes too hot Boom judders when used while machine is moving Table 185. Lack of power in all loader functions Cause Insufficient hydraulic fluid Leaks in the hydraulic system MRV (Main Relief Valve) setting is incorrect Low loader pump flow Charge filter by-pass valve leaking Charge pressure incorrect Piston rod bent Oil temperature abnormally high
Table 185. Table 186. Table 187. Table 188. Table 189. Table 190. Table 191. Table 192.
Page 30-131 Page 30-131 Page 30-132 Page 30-132 Page 30-132 Page 30-133 Page 30-133 Page 30-133
Remedy Check for leaks and top up as necessary. Check the hoses. If necessary, replace them. Check and adjust the MRV as necessary. Check the pump flow. If necessary, repair or replace the pump. Check condition of the hydraulic filter. Check operation of the by-pass valve. Check the relief valve or charge pump. Replace the piston rod. Check the pressure setting of MRV. Make sure that the pivot pins are greased correctly. Check for correct fluid. Check the oil cooler and grille for blockage.
Table 186. All hydraulic cylinder rams slow to operate Cause Remedy MRV setting incorrect Check and adjust the MRV as necessary. Low loader pump flow Check the pump flow. If necessary, repair or replace the pump. Charge pressure incorrect Check the relief valve or charge pump. Servo pressure low Do the charge pressure check. Check for blocked service feed hose or faulty joystick. Neutral circuit or low pressure lines leaking, Check the pipe lines. If necessary, replace them. damaged, trapped or kinked Restriction in the neutral circuit lines Check the hoses and pipes. If necessary, replace them. Service pipe lines leaking, damaged, trapped or Check the hoses and pipes If necessary, replace kinked them.
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Table 187. One hydraulic service fails to operate or is slow to operate Cause Remedy Service pipe lines leaking, damaged, trapped or Check the hoses and pipes If necessary, replace kinked them. Cylinder ram or pipe lines from the cylinder ram are Check and repair as necessary. leaking Valve spool not operating Check and repair as necessary. Make sure that the spool lock-out is operating. Check the spool lockout for faulty wiring, solenoid sticking, burr on spool, etc. Make sure that the load hold check valve is operating. On servo machines, check operation of the joystick and feed hoses. On manual machines, check that the control lever and linkage is operating the spool. Repair as necessary. Valve spool not moving fully from neutral to full Make sure that the spool movement is as specified. selection On servo machines, check the servo charge pressure. Dimension: 5.5 mm Check for the contamination. Repair as necessary. Check the engine performance.
Valve spool leaking Poor engine performance
Table 188. Engine tends to stall when hydraulics are under load. Cause Remedy MRV setting incorrect Check and adjust the MRV as necessary. Oil temperature abnormally high Check for correct fluid. Check the oil cooler and grille for blockage. Poor engine performance Check the engine performance. Table 189. Valve spool sticking Cause Dirty hydraulic oil Valve housing twisted during installation Bent spool Spool return spring broken Spool return spring or cap out of alignment Temperature distribution within control valve not uniform
30 - 132
Remedy Clean the tank strainer. If strainer is clogged, drain and flush the hydraulic system then fill with clean hydraulic oil. Loosen the bolts and tighten to correct torque. Disassemble the control valve. If necessary, replace the spools. Check the condition of the spring. Id necessary, replace it. Remove the cap. Check that the spring is in correct position. Install the cap and tighten the bolts to the correct torque value. Warm up the complete system before you use the service.
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51 - Lift Arm Control Valve Block 00 - General
Table 190. Cylinder ram creep Cause Piston rod bent Valve spool not operating
Table 191. Hydraulic oil becomes too hot Cause Hydraulic filter is clogged Charge filter by-pass valve leaking Air in hydraulic system Service pipe connection over tightened
Remedy Replace the piston rod. Check the pressure setting of of MRV. Make sure that the pivot pins are greased correctly. Check and repair as necessary. Make sure that the spool lock-out is operating. Check the spool lockout for faulty wiring, solenoid sticking, burr on spool, etc. Make sure that the load hold check valve is operating. On servo machines, check operation of the joystick and feed hoses. On manual machines, check that the control lever and linkage is operating the spool. Repair as necessary. Remedy Change hydraulic filter. Check the condition of the hydraulic filter. Check the operation of the by-pass valve. Bleed the hydraulic system. Refer to (PIL 30-00). Check the tightness.
Table 192. Boom judders when used while machine is moving Cause Remedy Loader pump flow low Check the flowrate. Restriction in neutral circuit lines Check the condition of the hoses and pipes. If necessary, replace them. Service pipe lines leaking, damaged, trapped or Check the hoses and pipes If necessary, replace kinked them.
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51 - Lift Arm Control Valve Block 00 - General
Remove and Install CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.
Remove 1. Make the machine safe. Refer to (PIL 01-03). 2. Remove the floor plate. Refer to (PIL 09-78). 3. Discharge the hydraulic system. Refer to (PIL 30-00). 4. Disconnect all the hoses. 5. Disconnect the electrical connectors. 6. Put a label on the hoses and electrical connectors to help installation. 7. Plug all the open ports and hoses to prevent contamination. 8. Remove the nuts. 9. Remove the lift arm control valve block from the machine.
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Tighten the nuts to the correct torque value. Torque: 56 N¡m
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51 - Lift Arm Control Valve Block 00 - General
Disassemble and Assemble Disassemble
14.1. Do not mix the parts between individual valve sections.
1. Remove the lift arm control valve block from the machine. Refer to (PIL 30-51).
15. Remove and discard the O-rings 2 (x4).
2. Make sure that you work on a clean and dirt free surface.
16. Carefully push the check valve and spring 2 outwards.
3. Remove the plug 1 from the port.
17. Push the spool outwards. 17.1. The following procedure is for the valve section 1. The procedure for the other valve sections is similar.
4. Remove the capscrews 1 from the end caps. 5. Remove and discard the O-ring 1. 6. Carefully remove the spring seat and spring 1 from each end cap.
18. Remove the ARV (Auxiliary Relief Valve) (x2). 18.1. Make a note that there are two ARVs on the valve section 1 and one ARV on the valve section 2.
7. Keep all parts of each end cap together. 7.1. Make a note that the all the end caps are identical.
19. Remove the plugs 2 (x2).
7.2. Do not mix the parts between individual end caps.
19.1. There are two plugs on the valve section 2 and one plug on the valve section 3.
8. Remove the capscrews 2.
20. Remove and discard the O-rings 4 (x3).
9. Remove the solenoids (x2).
21. Remove the MRV (Main Relief Valve) from the inlet valve section.
10. Remove the nuts 1 (x2) and washers 1 (x2).
22. Remove and discard the O-ring 5.
11. Remove the tie rod 1.
23. Remove the test connector from the inlet valve section.
12. Remove the nuts 2 (x4) and washer 2 (x4). 13. Remove the tie rods 2 (x2).
24. Remove and discard the O-ring 6.
14. Carefully separate the valve inlet section, valve section 1, valve section 2, valve section 3 and the valve outlet section.
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25. Clean all the parts in kerosene. 26. Check the condition of all the parts. If necessary, replace them.
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 00 - General
Figure 441. L L
H X
M
J
M
Y AC
AB
AA
T
S
Z C
D
AE
E
B
AF AG
V AD K
W
N
R
J
Q
H
30 - 136
F
G
L
L
Capscrews 1 O-ring 1 Spring 1 Solenoid (x2) Washers 1 (x2) Nuts 2 (x4) Tie rods 2 Check valve
T
N M
M
A C E G J L N Q
A
U
T
P
B D F H K M P R 9813/6050-2
End caps Spring seat Capscrews 2 Nuts 1 (x2) Tie rods 1 Washers 2 (x4) O-ring 2 Spring 2 30 - 136
30 - Hydraulic System
51 - Lift Arm Control Valve Block 00 - General
S U W Y AA AC AE AG
Spool O-ring 3 O-ring 4 O-ring 5 O-ring 6 Valve inlet section Valve section 1 Valve section 3
30 - 137
T V X Z AB AD AF
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ARV Plug 2 MRV Test connector Port Valve outlet section Valve section 2
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 00 - General
Assemble 1. The assembly procedure is the opposite of the disassembly procedure. Additionally do the following step. 2. Lubricate all the parts with clean hydraulic oil before you assemble. 3. Lubricate all the O-rings and seals with petroleum jelly. 4. Make sure that the spools are inserted with their larger waisted sections towards the bottom.
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 03 - Main Relief Valve (MRV)
03 - Main Relief Valve (MRV) Introduction .................................................. Check (Pressure) ........................................ Remove and Install ..................................... Disassemble and Assemble ........................
30 - 139
Introduction 30-139 30-140 30-141 30-143
The MRV (Main Relief Valve) is located in the lift arm valve block. The MRV sets the maximum operating pressure for the lift arm hydraulic services.
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 03 - Main Relief Valve (MRV)
Check (Pressure) Special Tools Description Pressure Gauge (0-400 Bar)
5.2. Loosen the locknut and turn the MRV adjuster in or out as required. Part No. 892/00279
Figure 442.
Qty. 1
B
Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear personal protective equipment. Hold a piece of cardboard close to suspected leaks and then examine the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.
A
1. Discharge the hydraulic system pressure. Refer to: PIL 30-00-00.
A Locknut B MRV adjuster
2. Connect the specified gauge to the test point at lift arm control valve block.
5.3. Make a note that when you turn the MRV adjuster inwards, it increases the pressure and when you turn the MRV adjuster outwards, it decreases the pressure.
Special Tool: Pressure Gauge (0-400 Bar) (Qty.: 1) 3. Start the engine and run at idle RPM (Revolutions Per Minute).
5.4. Tighten the locknut and do the steps 2 to step 4.8 again.
4. Operate the machine to normal specified operating temperature and check the following. Temperature: 50 °C ( 121.9 °F) 4.1. Select the boom lower service and hold the ram fully closed.
Table 193. Torque Values Item A C
Description Locknut Dome nut (If installed)
Nm 6.8 6.8
4.2. Increase the engine speed to maximum RPM. 4.3. Check the pressure gauge reading. Make sure that the gauge reading is as specified in Technical Data. Refer to: PIL 30-00-00. 4.4. If the pressure exceeds the specified data before maximum RPM is reached, return the control lever to the neutral position and reduce the engine speed to idle. 4.5. Make the machine safe with the lift arm raised. Refer to: PIL 01-03. 4.6. Switch off the engine. 4.7. Discharge the hydraulic system pressure. Refer to: PIL 30-00-00. 4.8. Adjust the MRV (Main Relief Valve). Refer to step 5. 5. Do the following steps to adjust the MRV. 5.1. If installed, remove the dome nut. 30 - 140
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 03 - Main Relief Valve (MRV)
Remove and Install Remove
3. Remove the floor plate. Refer to (PIL 09-78).
1. Make the machine safe. Refer to (PIL 01-03).
4. Turn the nut with a suitable tool.
2. Discharge the hydraulic system. Refer to (PIL 30-00).
5. Remove the MRV (Main Relief Valve). 6. Discard all the O-rings.
Figure 443.
A B
B D
D
D
E
F
A MRV C Nut E Locknut
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C
B ARV (Auxiliary Relief Valve) D O-rings F Adjusting screw
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 03 - Main Relief Valve (MRV)
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Lubricate the part with hydraulic oil before installation. 3. Tighten the nut to the correct torque value. 4. Check the MRV pressure. If necessary, adjust it. Refer to (PIL 30-51). Table 194. Torque Values Item C
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Description Nut
Nm 44.75
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 03 - Main Relief Valve (MRV)
Disassemble and Assemble It is not recommended to replace individual MRV (Main Relief Valve) components. You must replace the complete MRV, if any of the parts are damaged.
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 06 - Auxiliary Relief Valve (ARV)
06 - Auxiliary Relief Valve (ARV)
Introduction
Introduction .................................................. Check (Pressure) ........................................ Remove and Install ..................................... Disassemble and Assemble ........................
The ARV (Auxiliary Relief Valve) protects hydraulic circuits not in use against back pressures.
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30-144 30-145 30-147 30-149
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 06 - Auxiliary Relief Valve (ARV)
Check (Pressure) Special Tools Description Hand Pump Pressure Test Pressure Gauge (0-400 Bar) Test Block for Loader Valve ARV
Part No. 892/00223
Qty. 1
892/00279
1
892/00923
1
Special Tool: Test Block for Loader Valve ARV (Qty.: 1) 3. Connect the specified hand pump to the test block. Special Tool: Hand Pump Pressure Test (Qty.: 1) 4. Install the specified pressure gauge to the hand pump. Special Tool: Pressure Gauge (0-400 Bar) (Qty.: 1)
Removed ARV You can test the ARV (Auxiliary Relief Valve) when removed from the valve block with the use of a test block and the hand pump. The advantage of using this method are as follows:
5. Pressurise the hand pump until oil begins to escape from the drain hole. At this point the gauge will indicate the crack pressure of the ARV.
• •
6. Check the pressure gauge reading. Make sure that the gauge reading is as specified in Technical Data.
•
This method is more accurate. No need to disconnect the hoses from the valve block. No need to connect gauges and install the caps.
1. Remove the required ARV from the valve block. Refer to: PIL 30-51-00.
Refer to: PIL 30-00-00. 7. If necessary, adjust the ARV as follows. 7.1. If installed, remove the domenut.
2. Install the ARV into the specified test block.
7.2. Loosen the locknut and turn the cap in or out as required. Figure 444.
A B
A Locknut
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B Cap
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 06 - Auxiliary Relief Valve (ARV)
Installed ARV If the test block or the hand pump are not available then the ARV can be tested as installed. The ARV's which are set below the MRV (Main Relief Valve) pressure can be tested simply by operating the relevant service. For the tilt ram ARV which are set above the MRV pressure, the MRV should be temporarily set at 260 bar ( 3,768.1 psi). 1. Operate the machine to normal operating temperature before you do the following steps. 1.1. With the pressure gauge connected to test point, run the engine at idle and operate the service to full travel. 1.2. The engine must not be run at maximum speed as a significant increase in pressure will be recorded. 1.3. Hold the service to full travel and check the maximum gauge reading. 1.4. Make sure that the gauge reading is equal to the ARV operating pressure. 1.5. Stop the engine. 1.6. Turn the ignition key to the ON position. 1.7. Discharge the hydraulic system pressure. Refer to: PIL 30-00-00. 1.8. Adjust the ARV as required. 1.9. Check the MRV pressure again. Table 195. Torque Values Item A C
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Description Locknut Dome nut (If installed)
Nm 6.8 6.8
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 06 - Auxiliary Relief Valve (ARV)
Remove and Install Remove
3. Remove the floor plate. Refer to (PIL 09-78).
1. Make the machine safe. Refer to (PIL 01-03).
4. Turn the nut with a suitable tool.
2. Discharge the hydraulic system. Refer to (PIL 30-00).
5. Remove the ARV (Auxiliary Relief Valve). 6. Discard all the O-rings.
Figure 445.
A B
B D
D
D
E
F
A MRV (Main Relief Valve) C Nut E Locknut
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C
B ARV D O-rings F Adjusting screw
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 06 - Auxiliary Relief Valve (ARV)
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Lubricate the parts with hydraulic oil before installation. 3. Tighten the nut to the correct torque value. 4. Check the ARV pressure. If necessary, adjust it. Refer to (PIL 30-51). Table 196. Torque Values Item C
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Description Nut
Nm 44.75
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 06 - Auxiliary Relief Valve (ARV)
Disassemble and Assemble It is not recommended to replace individual ARV (Auxiliary Relief Valve) components. You must replace the complete ARV, if any of the parts are damaged.
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 36 - Load Hold Check Valve
36 - Load Hold Check Valve Introduction .................................................. Component Identification ............................. Check (Condition) ........................................ Adjust ..........................................................
30 - 150
Introduction 30-150 30-151 30-151 30-152
The check valve allows flow in one direction, it prevents the load falling back if the load pressure is greater than the pump pressure.
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 36 - Load Hold Check Valve
Check (Condition)
Component Identification Figure 446.
1. Make the machine safe. Refer to (PIL 01-03). 2. Make sure that the operator seat faces forwards. 3. Run the engine at 1000 RPM (Revolutions Per Minute). C B
A A B C D
Plug Spring Poppet Valve body
D
4. Make sure that the hydraulic oil is at the correct working temperature. 5. Check the MRV (Main Relief Valve) pressure. Refer to (PIL 30-00). 6. Check the brake pressure. Refer to (PIL 24-00). 7. Compare the pressure difference between the MRV pressure and brake pressure. 8. Make sure that the pressure difference is equal to the specified opening pressure of the LHCV (Load Hold Check Valve). Pressure: 5 bar ( 72.5 psi) 9. If necessary, adjust the LHCV opening pressure. Refer to (PIL 30-00).
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30 - Hydraulic System
51 - Lift Arm Control Valve Block 36 - Load Hold Check Valve
Adjust 1. Turn the plug in or out as required. 2. Make a note that when you turn the plug inwards, it increases the pressure and when you turn the plug outwards, it decreases the pressure. 3. Make a note that the LHCV (Load Hold Check Valve) opening pressure is as specified. Pressure: 5 bar ( 72.5 psi) Figure 447.
C
D
B A A B C D
Plug Spring Poppet Valve body
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30 - Hydraulic System
60 - Directional Control Valve
60 - Directional Control Valve Contents 30-60-00 30-60-03 30-60-15 30-60-25 30-60-39 30-60-44 30-60-96
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Page No. General ......................................................................................................................... Brake ............................................................................................................................ Joystick ......................................................................................................................... Power Management System (PMS) ............................................................................. Lift Arm ......................................................................................................................... Transmission ................................................................................................................ Control Pattern Selector ...............................................................................................
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30-155 30-157 30-160 30-173 30-178 30-182 30-187
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Notes:
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30 - Hydraulic System
60 - Directional Control Valve 00 - General
00 - General Introduction Flow Control Valves
Figure 451.
Control valves are usually represented by one or more square boxes. The number of boxes indicates the number of possible valve operating positions, (3 boxes, 3 positions etc). Figure 448.
1 Position 1 (P1 - P2, P3 - P4) 3 Position 3 (P1 - P4, P2 - P3) In circuit diagrams the pipework is usually shown connected to the box which represents the unoperated condition. (Hydraulic circuit diagrams are usually shown in the unoperated condition).
It must be noted that not all spools are of the same type. Their operating designs can be seen by following the path the flow arrows take in their respective operating squares.
Figure 449.
Three typical JCB style spools are known as 'D' spools, 'F' spools and 'N' spools. The 'D' spools generally control rams because when in the neutral position the outlet ports are blocked, preventing ram movement.
A valve described as a 3-position, 4-port control valve. Port describes the openings to and from the valve by which the hydraulic fluid enters or leaves. In an unoperated condition all ports are blocked.
'F' spools are often shown as four position spools with the three normal positions for neutral and service control; and the forth position, which has a detent, connects both sides of the ram together to allow the service to 'float'.
Figure 450.
Figure 452.
2 Position 2 (all 4 ports blocked) If the valve spool was moved to Position 1, movement of the spool would connect Port P1 to Port P2, and Port P3 to Port P4.
'N' spools are sometimes used to control hydraulic motors, and it can be seen from the flow arrows, that in neutral position both service ports are connected to the exhaust oil port
If the valve spool was moved to Position 3, movement of the spool would connect Port P1 to Port P4, and Port P3 to Port P2.
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Figure 453.
30 - 155
30 - Hydraulic System
60 - Directional Control Valve 00 - General
Figure 454. Simple Schematic Circuit Example
A
B
C
D
E
G
F
A C E G
B Strainer D Relief valve F One way valve
Hydraulic tank Fixed displacement pump Spool Double acting hydraulic ram
Some of the symbols described on the preceding pages have been arranged into a simple schematic circuit. The hydraulic tank is a pressurised tank with an internally mounted strainer on the suction line to the fixed displacement pump. System pressure is limited to the setting of relief valve. The valve spool is an open-centre spool that is in neutral position; flow from the pump passes through the spool and returns to the hydraulic tank. If the lever operated spool is moved away from neutral position hydraulic fluid is directed to either head side or rod side of hydraulic ram. Notice that the fluid must first open one way valve before flowing to the ram.
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30 - Hydraulic System
60 - Directional Control Valve 03 - Brake
03 - Brake
Check (Condition)
Check (Condition) ........................................ 30-157 Disassemble and Assemble ........................ 30-158
If damage to any component or distortion of the spool is evident the complete valve assembly must be renewed. Great care should be taken when dismantling and assembling the valve to avoid the following: • • •
Contamination Damage to spools Damage to seal grooves
Any of the above may result in possible problems with the operation of the valve.
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30 - Hydraulic System
60 - Directional Control Valve 03 - Brake
Disassemble and Assemble Consumables Description JCB Threadlocker and Sealer (Medium Strength)
Part No. 4101/0250 4101/0251
Figure 455. Size 0.01 L 0.05 L
It is not normally recommended to remove the spool from the valve body. None of the component parts of the valve assembly can be renewed individually. The extent of permissible servicing is cleaning and the consequential renewal of O-ring seals. Refer to Check Condition.
Disassemble 1. Remove the surface mounted O-rings 1. 2. Unscrew the knurled nut and remove O-ring 3, withdraw the solenoid and O-ring 5. 3. Hold the solenoid valve body in a vice, using the spanner flats, remove spindle and O-ring 8. 4. Pull out the actuating pin, spring, spring retainer and spool. 5. Dismantle the opposite solenoid in the same sequence as described above. 6. Inspect the spool and spool bore for signs of wear, nicks scratches etc.
1 2 3 4 5 6 7 8 9 10 11 12 A
O-rings Knurled nut O-ring Solenoid O-ring Solenoid valve body Spindle O-ring Actuating pin Spring Spring retainer Spool Spanner flats
Assemble 1. Renew all O-rings. 30 - 158
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30 - 158
30 - Hydraulic System
60 - Directional Control Valve 03 - Brake
2. Lightly lubricate all parts with clean transmission fluid before assembling. 3. Apply a small quantity of JCB Threadlocker and Sealer to the threads in the knurled nut before installation. Consumable: JCB Threadlocker and Sealer (Medium Strength) Table 197. Torque Values Item 2
30 - 159
Nm 12.5
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30 - Hydraulic System
60 - Directional Control Valve 15 - Joystick
15 - Joystick Component Identification ............................. Diagram ....................................................... Remove and Install ..................................... Disassemble and Assemble ........................
30 - 160
Component Identification 30-160 30-165 30-166 30-168
For: Series 1 ........................... Page 30-161 For: Series 2 ........................... Page 30-163
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30 - 160
30 - Hydraulic System
60 - Directional Control Valve 15 - Joystick
(For: Series 1) Figure 456. Joystick - For machines up to serial number 807146
C D K A
P B E
H
J F N
G
M L
A C E G J
Gaiter Handle assembly Retaining plate Screws Seal
30 - 161
B D F H K
Cap head screws Regulator valve Valve body Spacer block Seal
9813/6050-2
30 - 161
30 - Hydraulic System
60 - Directional Control Valve 15 - Joystick
L Valve N Seal
M Seal P Valve unit Figure 457. Joystick - For machines from serial number 807147 to 1743152
F
B
K
G
C
H L M N
J
P
A V
E
W
D
Q
U S T R
A C E G J L N Q S U W
Pin Gaiter Screw Shims Valve body Plungers Spacer Spring Valve base Seal Pin
30 - 162
B D F H K M P R T V
Handle Nut Cam plate Retaining plate Cover Shim Screw Screw Seal Seal
9813/6050-2
30 - 162
30 - Hydraulic System
60 - Directional Control Valve 15 - Joystick
(For: Series 2) Figure 458. Servo joystick from machine serial number 1743153
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30 - Hydraulic System
60 - Directional Control Valve 15 - Joystick
CE P2 P4 TP
Cable exit hole Port 2 Port 4 Tank port
30 - 164
P1 Port 1 P3 Port 3 PP Pressure port
9813/6050-2
30 - 164
30 - Hydraulic System
60 - Directional Control Valve 15 - Joystick
Diagram (For: Series 2) Figure 459.
P3 P2 P1 P2 P3 P4 PP TP
P1
PP TP
P4
Port 1 Port 2 Port 3 Port 4 Pressure port Tank port
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30 - 165
30 - Hydraulic System
60 - Directional Control Valve 15 - Joystick
Remove and Install The following procedure is for the right side joystick, the procedure for the left side joystick is similar.
Remove 1. Make the machine safe. Refer to (PIL 01-03). 2. Discharge the hydraulic pressure. Refer to (PIL 30-00). 3. Put a mark on the joystick flange and support flange to help correct installation. 4. Disconnect the hydraulic hose. 5. Disconnect the electrical connector. 6. Plug all the open ports and hoses to prevent contamination. 7. Remove the bolts (x4). 8. Remove the joystick from the machine. Figure 460.
A
D
C
B A B C D
Joystick Hydraulic hose connector Electrical connector Bolts (x4)
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step.
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30 - Hydraulic System
60 - Directional Control Valve 15 - Joystick
Table 198. Torque Values Item B D
30 - 167
Nm 30 12
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30 - Hydraulic System
60 - Directional Control Valve 15 - Joystick
Disassemble and Assemble For: Series 1 ........................... Page 30-168 For: Series 2 ........................... Page 30-172
2. Remove the handle assembly as follows: 2.1. Lift the gaiter upwards. 2.2. Remove the capscrews (x4).
(For: Series 1) Consumables Description JCB Threadlocker and Sealer (High Strength)
Part No. 4101/0550 4101/0552
Size 0.01 L 0.2 L
For machines up to serial number 807146
2.3. Separate the handle assembly from the valve body. 3. Make sure that the components of the valve units are kept together as sets and returned to their original locations in the body. Do not mix components from different valve units.
Disassemble 1. Use the alphabetical sequence shown on the illustration as a guide to disassembly.
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30 - Hydraulic System
60 - Directional Control Valve 15 - Joystick
Figure 461. Joystick - For machines up to serial number 807146
C D K A
P B E
H
J F N
G
M L
A C E G J L N
Gaiter Handle assembly Retaining plate Screws Seal Valve Seal
30 - 169
B D F H K M P
Capscrews Regulator valve Valve body Spacer block Seal Seal Valve unit
9813/6050-2
30 - 169
30 - Hydraulic System
60 - Directional Control Valve 15 - Joystick
Assemble 1. The assembly procedure is the opposite of the disassembly procedure. Additionally do the following step. 2. Lubricate all the parts with hydraulic oil. 3. Apply a thin layer of petroleum jelly on all the Orings. Table 199. Torque Values Item B G
30 - 170
Description Capscrews Screws
For machines from serial number 807147 to 1743152 Disassemble 1. Use the alphabetical sequence shown on the illustration as a guide to disassembly. 2. Make sure that the components of the valve units are kept together as sets and returned to their original locations in the body. Do not mix components from different valve units.
N¡m 12 12
9813/6050-2
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30 - Hydraulic System
60 - Directional Control Valve 15 - Joystick
Figure 462. Joystick - For machines from serial number 807147 to 1743152
F
B
K
G
C
H L M N
J
P
A V
E
W
D
Q
U S T R
A C E G J L N Q S U W
Pin Gaiter Screw 1 Shims 1 Valve body Plungers Spacer Spring Valve base Seal Pin
30 - 171
B D F H K M P R T V
Handle Nut Cam plate Retaining plate Cover Shim Screw 2 Screw 3 Seal Seal
9813/6050-2
30 - 171
30 - Hydraulic System
60 - Directional Control Valve 15 - Joystick
Assemble 1. The assembly procedure is the opposite of the disassembly procedure. Additionally do the following step. 2. Lubricate all the parts with hydraulic oil. 3. Apply a thin layer of petroleum jelly on all the Orings. 4. Make sure that the valve units are returned to their original bores in the valve body. 5. Select the shims 1 so that there is a small clearance between cam plate and the tops of the plungers when the lever is in the neutral position. 6. Apply threadlocker on the threads of the screw 1. Consumable: JCB Threadlocker and Sealer (High Strength) Table 200. Torque Values Item D E R
Description Nut Screws 1 Screws 2
N¡m 30 40 50
(For: Series 2) The illustration shows a typical joystick. Slight variations may occur depending on the application. This assembly part is not to be dismantled. Replace the complete assembly if faulty.
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30 - Hydraulic System
60 - Directional Control Valve
25 - Power Management System (PMS)
25 - Power Management System (PMS) Introduction .................................................. Technical Data ............................................. Component Identification ............................. Diagram ....................................................... Remove and Install .....................................
30 - 173
30-173 30-174 30-175 30-176 30-177
Introduction The PMS (Power Management System) combination valve is located underneath of the floor plate inside the operator station.
9813/6050-2
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30 - Hydraulic System
60 - Directional Control Valve
25 - Power Management System (PMS)
Technical Data Table 201. Operating Conditions Maximum flow 20 L/min Maximum working pres- 30 bar ( 434.8 psi) sure Table 202. Torque Values CT Number CT1 CT2 CT3 CT4 CT5 CT6
30 - 174
Description Solenoid cartridge Solenoid cartridge Proportional pressure reducer Proportional pressure reducer Proportional pressure reducer Proportional pressure reducer
Torque Values 20 N路m 20 N路m 30 N路m 45 N路m
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30 - Hydraulic System
60 - Directional Control Valve
25 - Power Management System (PMS)
Component Identification Figure 463.
PA
C
P
BR A
P2
P1 T
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30 - Hydraulic System
60 - Directional Control Valve
25 - Power Management System (PMS)
Diagram Figure 464.
PA
BRU
CT1 1
P1U
CT4 4
CT2 2
P2U
CT5 5
CT3 3
CT6 6
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30 - Hydraulic System
60 - Directional Control Valve
25 - Power Management System (PMS)
Remove and Install Remove 1. Make the machine safe with the lift arm lowered. Refer to (PIL 01-03). 2. Remove the floor mat. Refer to (PIL 09-48). 3. Remove the floor plate. Refer to (PIL 09-78). 4. Disconnect all the hoses. 5. Disconnect the electrical connectors. 6. Put a label on the hoses and electrical connectors to help installation. 7. Plug all the open ports and hoses to prevent contamination. 8. Support the PMS (Power Management System) combination valve. 9. Remove the bolts. 10. Remove the PMS combination valve from the machine.
Install 1. The installation procedure is the opposite of the removal procedure.
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30 - Hydraulic System
60 - Directional Control Valve 39 - Lift Arm
39 - Lift Arm Introduction .................................................. Component Identification ............................. Diagram ....................................................... Remove and Install .....................................
30 - 178
Introduction 30-178 30-179 30-180 30-181
The lift arm changeover valve is located under the floor plate in the operator station. Table 203. Operating Conditions Nominal flow Normal pressure Maximum working pressure Solenoid coil
9813/6050-2
5 L/min 40 bar ( 579.7 psi) 65 bar ( 942.0 psi) 20.16 W 12 V
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30 - Hydraulic System
60 - Directional Control Valve 39 - Lift Arm
Component Identification Figure 465.
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30 - Hydraulic System
60 - Directional Control Valve 39 - Lift Arm
Diagram Figure 466.
DIODE WIRING DIAGRAM 1 + VE
2 -VE
GW^
G^
T^
SV1
SV1
Solenoid valve 1 Solenoid valve 3 Solenoid valve 5
30 - 180
GR^
O^
OW^
GG^
SV2
OB^
OO^
SV4
SV3
SV2 G^
SV1 SV3 SV5
GG^
O^
SV3
SV4
SV2 SV4 SV6
YG^
PW^
SV5 OO^
9813/6050-2
YW^
PG^
SV SV6 BW^
BR^
SV5
SV SV6
Solenoid valve 2 Solenoid valve 4 Solenoid valve 6
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30 - Hydraulic System
60 - Directional Control Valve 39 - Lift Arm
Remove and Install Remove 1. Make the machine safe with lift arm lowered. Refer to (PIL 01-03). 2. Remove the floor mat. Refer to (PIL 09-48). 3. Remove the floor plate. Refer to (PIL 09-78). 4. Disconnect all the hoses. 5. Disconnect the electrical connectors. 6. Put a label on the hoses and electrical connectors to help installation. 7. Plug all the open ports and hoses to prevent contamination. 8. Support the lift arm changeover valve. 9. Remove the bolts. 10. Remove the lift arm changeover valve from the machine.
Install 1. The installation procedure is the opposite of the removal procedure.
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30 - Hydraulic System
60 - Directional Control Valve 44 - Transmission
44 - Transmission Introduction .................................................. Technical Data ............................................. Component Identification ............................. Diagram ....................................................... Remove and Install .....................................
Introduction 30-182 30-183 30-184 30-185 30-186
The transmission changeover valve is located under the floor plate in the operator station. The solenoid valve when de-energised allows oil flow from port 3 to 2 and from port 4 to 1. When energised the cartridge spool shifts to allow the oil flow from port 2 to 1 and from port 3 to 4. The solenoid coil is an integral part of the valve and is not serviceable.
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30 - Hydraulic System
60 - Directional Control Valve 44 - Transmission
Technical Data Table 204. Operating Conditions Nominal flow Maximum flow Normal pressure Maximum working pressure Maximum tank line pressure Solenoid coil
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5 L/min 30 L/min 20 bar ( 289.9 psi) 35 bar ( 507.2 psi) 3 bar ( 43.5 psi) 20.16 W 12 V
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30 - Hydraulic System
60 - Directional Control Valve 44 - Transmission
Component Identification Figure 467.
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30 - Hydraulic System
60 - Directional Control Valve 44 - Transmission
Diagram Figure 468.
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30 - Hydraulic System
60 - Directional Control Valve 44 - Transmission
Remove and Install Remove 1. Make the machine safe with the lift arm lowered. Refer to (PIL 01-03). 2. Remove the floor mat. Refer to (PIL 09-48). 3. Remove the floor plate. Refer to (PIL 09-78). 4. Disconnect all the hoses. 5. Disconnect the electrical connectors. 6. Put a label on the hoses and electrical connectors to help installation. 7. Plug all the open ports and hoses to prevent contamination. 8. Support the transmission changeover valve. 9. Remove the bolts. 10. Remove the transmission changeover valve from the machine.
Install 1. The installation procedure is the opposite of the removal procedure.
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30 - Hydraulic System
60 - Directional Control Valve 96 - Control Pattern Selector
96 - Control Pattern Selector
Introduction
Introduction .................................................. 30-187 Remove and Install ..................................... 30-188
The ISO (International Organization for Standardization)/SAE (Society of Automotive Engineers) changeover valve is located underneath of the floor plate inside the operator station.
Figure 469.
A
A ISO/SAE changeover valve
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30 - Hydraulic System
60 - Directional Control Valve 96 - Control Pattern Selector
Remove and Install Remove 1. Make the machine safe with the lift arm lowered. Refer to (PIL 01-03). 2. Remove the floor mat. Refer to (PIL 09-48). 3. Remove the floor plate. Refer to (PIL 09-78). 4. Disconnect all the hoses. 5. Disconnect the electrical connectors. 6. Put a label on the hoses and electrical connectors to help installation. 7. Plug all the open ports and hoses to prevent contamination. 8. Support the ISO (International Organization for Standardization)/SAE (Society of Automotive Engineers) changeover valve. 9. Remove the bolts. 10. Remove the ISO/SAE changeover valve from the machine.
Install 1. The installation procedure is the opposite of the removal procedure.
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30 - Hydraulic System
68 - Pressure Reduction Valve
68 - Pressure Reduction Valve Contents
Page No.
30-68-00 General ......................................................................................................................... 30-191
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Notes:
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30 - Hydraulic System
68 - Pressure Reduction Valve 00 - General
00 - General Introduction .................................................. Component Identification ............................. Operation ..................................................... Diagram ....................................................... Remove and Install ..................................... Disassemble and Assemble ........................
30 - 191
Introduction 30-191 30-192 30-193 30-194 30-195 30-196
The pressure reduction valve supplies hydraulic oil at reduced pressure to operate the joystick and the automatic park brake. The seat position switch, override switch and park brake switch controls the pressure reduction valve. It contains a reducing valve cartridge and a 3 position, 3 port cartridge solenoid valve.
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30 - Hydraulic System
68 - Pressure Reduction Valve 00 - General
Component Identification Figure 470. G
B
E
C
E A
D F
A C E G
Pressure reducing solenoid valve Solenoid cartridge valve Solenoids (x2) Orifice
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B Bolts (x2) D Pressure reducing cartridge valve F Coil retaining nut
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30 - Hydraulic System
68 - Pressure Reduction Valve 00 - General
Operation When you first enter the machine and the starter switch is in the OFF position, there is no hydraulic pressure as the auxiliary hydraulic pump is not running and the solenoid valve is in position as there is no electrical supply. If the park brake is ON and the seat faces forward, start the engine and move the solenoid valve to position 1 to energise the isolation relay and solenoid 2. In this position the valve directs hydraulic power through the loader joystick to the loader valve and other circuits, but the brake pressure is still dumped to tank.
the solenoid valve to move to position 3, directing hydraulic power through the loader joystick as before, but also pressurising the brake circuit. If the seat is rotated to face the rear of the machine, the seat switch opens and de-energises the relay. The solenoid 1 and solenoid 2 de-energise, and the solenoid valve returns to position 1. In this condition, pressure from the auxiliary pump is dumped to tank and the brakes ON and no hydraulic pressure available at the loader joystick. When the override switch is closed, the seat switch is bypassed allowing the loader to be used with the seat facing rearwards.
Operation of the park brake switch de-energises solenoid 1 and energises solenoid 2. This causes Figure 471. C A
B
D J
H
G
F E
A C E G J
Pressure reducing solenoid valve Pressure inlet Brake Position 1 Solenoid valve
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B D F H
Joystick loader Tank Position 2 Position 3
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30 - Hydraulic System
68 - Pressure Reduction Valve 00 - General
Diagram Figure 472.
C
D E
G
F A
B
A C E G
Park brake switch Operation solenoid Override switch Seat switch
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B Park brake solenoid D Park brake solenoid F Isolation relay
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30 - Hydraulic System
68 - Pressure Reduction Valve 00 - General
Remove and Install Remove 1. Make the machine safe. Refer to (PIL 01-03). 2. Discharge the hydraulic system. Refer to (PIL 30-00). 3. Disconnect all the hoses. 4. Disconnect the electrical connectors. 5. Put a label on the hoses and electrical connectors to help installation. 6. Plug all the open ports and hoses to prevent contamination. 7. Remove the bolts (x2). 8. Remove the pressure reduction valve from the machine.
Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Tighten the bolts to the correct torque value. Torque: 12 N¡m
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30 - Hydraulic System
68 - Pressure Reduction Valve 00 - General
Disassemble and Assemble Disassemble
5.2. Remove the solenoids.
1. Remove the pressure reduction valve from the machine. Refer to (PIL 30-68). 2. Hold the pressure reduction valve in a suitable soft jaw vice. 3. Remove the pressure reduction cartridge valve. 4. Remove the solenoid cartridge valve. 5. If necessary, remove the solenoids as follows:
6. Remove and discard all the O-rings. 7. Do not disassemble the cartridges. If damage or excessive wear is found, a cartridge must be replaced as a complete unit. 8. Inspect the machined orifice for wear. Do not remove it, unless to be replaced. 9. Inspect the wiring for damage or chafing. If necessary, replace it.
5.1. Loosen the coil retaining nut. Figure 473. G
B
E
C
E A
D F
A C E G
Pressure reducing solenoid valve Solenoid cartridge valve Solenoids (x2) Orifice
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B Bolts (x2) D Pressure reducing cartridge valve F Coil retaining nut
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30 - Hydraulic System
68 - Pressure Reduction Valve 00 - General
Assemble
Figure 475.
1. The assembly procedure is the opposite of the disassembly procedure. Additionally do the following step. 2. Install the new O-ring seals. 3. Check the pressure reducing valve cartridge setting. If necessary, adjust it. 4. Replace solenoid cartridge valve.
H
5. Tighten the coil retaining nut to the correct torque value.
Pressure Reducing Adjustment
Valve
Cartridge
Do not disassemble the pressure reducing valve cartridge. If damaged, you must replace it. 1. Make sure the hydraulic oil is at its correct working temperature. 2. Connect a pressure gauge to the test point.
H Test point 3. Make sure that the seat faces forwards. 4. Start the engine. 5. Run the engine at maximum speed.
2.1. On machines, up to serial no. 751715, the test point is located under the throttle pedal plate. Refer to Figure 474. Figure 474.
6. Operate the arms lower service until the rams are fully closed to blow off the MRV (Main Relief Valve). 7. Check the pressure gauge reading. The reading should show the regulated pressure. Refer to Hydraulic System, Technical Data - (PIL 30-00). 8. If the setting is incorrect, do the following:
H
8.1. Stop the engine. 8.2. Remove the cartridge dust cover. 8.3. Adjust the screw to achieve the required pressure. Figure 476.
K H Test point 2.2. On machines, from serial no 751716, the test point is located at the rear of the left hand side of the engine. Refer to Figure 475.
J L
J Dust cover K Adjust screw L Pressure reducing valve 8.4. Install the dust cover.
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30 - Hydraulic System
68 - Pressure Reduction Valve 00 - General
8.5. Check the pressure again otherwise oil will leak from the valve. Table 205. Torque Values Item D F
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Nm 25.5 6
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30 - Hydraulic System
93 - Hose
93 - Hose Contents
Page No.
30-93-00 General ......................................................................................................................... 30-201
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Notes:
30 - 200
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30 - Hydraulic System
93 - Hose
00 - General
00 - General
Introduction
Introduction .................................................. 30-201 Disconnect and Connect ............................. 30-202 Check (Condition) ........................................ 30-203
Hydraulic hoses are used to connect different components in the hydraulic circuit. The hoses are graded by pressure, temperature, and fluid compatibility. Hoses are built up with rubber and steel layers. A rubber interior is surrounded by multiple layers of woven wire and rubber. The exterior is designed for abrasion resistance. The bend radius of a hydraulic hose is carefully designed into the machine, since hose failures can be deadly, and violating the hose's minimum bend radius will cause failure. Hydraulic hoses generally have steel fittings swaged on the ends.
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30 - Hydraulic System
93 - Hose
00 - General
Disconnect and Connect
Figure 479.
Some attachments are hydraulically powered. The following procedures show how to connect and disconnect the hydraulic hoses safely.
Connecting the Hydraulic Hoses 1. Make the machine safe. Refer to: PIL 01-03. 2. Discharge the hydraulic system pressure. Refer to: PIL 30-00-00. 5. Check for leaks:
3. Check the hoses and adaptors for damage.
5.1. Start the machine.
4. Connect the hoses:
5.2. Operate the related controls to increase the pressure in the hydraulic system.
4.1. Make sure that the hose is not twisted. Pressure applied to a twisted hose can cause the hose to fail or the connections to loosen.
5.3. Stop the machine then remove the key. 5.4. Check for indications of leakage at the hose connections. Correct, as necessary.
Figure 477.
Disconnecting the Hydraulic Hoses 1. Make the machine safe. Refer to: PIL 01-03. 2. Discharge the hydraulic system pressure. Refer to: PIL 30-00-00. 3. Disconnect the hoses. 4.2. Make sure that the hose does not touch hot parts. High ambient temperatures can cause the hose to fail.
4. Check the hoses and adaptors for damage.
4.3. Make sure that the hose does not touch parts which can rub or cause abrasion.
6. Check for leaks:
5. If necessary, install the blanking caps.
4.4. Use the hose clamps (where possible) to support long hose runs and keep the hoses away from moving parts, etc.
6.1. Start the machine. 6.2. Operate the related controls to increase the pressure in the hydraulic system. 6.3. Stop the machine then remove the key.
Figure 478.
6.4. Check for indications of leakage at the hose connections. Correct, as necessary.
4.5. To allow for length changes when the hose is pressurised, do not clamp at the bend. The curve absorbs the change.
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30 - Hydraulic System
93 - Hose
00 - General
Check (Condition) Hydraulic Hoses WARNING Damaged hoses can cause fatal accidents. Examine the hoses regularly. Do not use the machine if a hose or hose fixture is damaged. WARNING Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear personal protective equipment. Hold a piece of cardboard close to suspected leaks and then examine the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. Examine the hoses for: • • • • • • •
Damaged hose ends Worn outer covers Ballooned outer covers Kinked or crushed hoses Exposed armouring in the outer covers Displaced hose end fittings. Worn cover sheathing or hose burst protection covering
Replace a damaged hose before you use the machine again. The replacement hoses must be of the same size, standard and pressure rating. If necessary, for more information contact your JCB dealer.
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30 - Hydraulic System
97 - Connectors
97 - Connectors Contents
Page No.
30-97-00 General ......................................................................................................................... 30-205 30-97-03 Quick Release Coupling .............................................................................................. 30-208 30-97-18 O-Ring Face Seal (ORFS) ........................................................................................... 30-210
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30 - 204
30 - Hydraulic System
97 - Connectors 00 - General
00 - General Technical Data O-Ring Face Seal UNF Threads on the ORFS Fittings Table 206. Torque Settings - ORFS UNF Thread Size inch x pitch 9/16 x 18 11/16 x 16 13/16 x 16 1 x 14 1 3/16 x 12 1 5/16 x 12 1 7/16 x 12 1 11/16 x 12 2 x 12
Torque Value N·m 24 –27 N·m 40 –44 N·m 55 –60 N·m 60 –66 N·m 90 –99 N·m 115 –126 N·m 125 –138 N·m 170 –187 N·m 200 –220 N·m
Table 207. Torque Settings - BSP Adaptors
30 - 205
BSP Adaptor Size mm 6.35 9.525 12.7 15.875
Hexagon (A/F) mm 19 mm 22 mm 27 mm 30 mm
Torque Value N·m 18 N·m 31 N·m 49 N·m 60 N·m
BSP Adaptor Size mm 19.05 25.4 31.75
Hexagon (A/F) mm 32 mm 38 mm 50 mm
Torque Value N·m 81 N·m 129 N·m 206 N·m
Table 208. Torque Settings - SAE Connections
Adaptors Connected into Valve Blocks
BSP Adaptor Size Inch 1/4 3/8 1/2 5/8
BSP Adaptor Size Inch 3/4 1 1 1/4
SAE Hose SAE Port Dash Size Thread Size inch x pitch 4 7/16 x 20 6 9/16 x 18 8 3/4 x 16
Hexagon (A/F)
Torque Value
mm
N·m
15.9 mm 19.1 mm 22.2 mm
10
7/8 x 14
27 mm
12
1 1/16 x 12 31.8 mm
16
1 5/16 x 12 38.1 mm
20
1 5/8
20 –28 N·m 46 –54 N·m 95 –105 N·m 130 –140 N·m 190 –210 N·m 290 –310 N·m 280 –380 N·m
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47.6 mm
30 - 205
30 - Hydraulic System
97 - Connectors 00 - General
Hoses installed into Adaptors Figure 480. D
B C A
B
A Adaptor C O-ring
C
A
B Hose D Dimension will vary depending upon the torque applied.
Hoses installed into adaptors seal onto an `O' ring which is compressed into a 45 ° seat machined into the face of the adaptor port. Table 209. BSP Hose - Torque Settings BSP Hose Size in 1/8 1/4 3/8 1/2 5/8 3/4 1 1 1/4 1 1/2
Hexagon (A/F) mm 14.0 19.0 22.0 27.0 30.0 32.0 38.0 50.0 55.0
Nm
kgf m
lbf ft
14.0 - 16.00 24.0 - 27.0 33.0 - 40.0 44.0 - 50.0 58.0 - 65.0 84.0 - 92.0 115.0 - 126.0 189.0 - 200.0 244.0 - 260.0
1.4 - 1.6 2.4 - 2.7 3.4 - 4.1 4.5 - 5.1 5.9 - 6.6 8.6 - 9.4 11.7 - 12.8 19.3 - 20.4 24.9 - 26.5
10.3 - 11.8 17.7 - 19.9 24.3 - 29.5 32.4 - 36.9 42.8 - 47.9 61.9 - 67.8 84.8 - 92.9 139.4 - 147.5 180.0 - 191.8
Adaptors into Component Connections with Bonded Washers Table 210. BSP Adaptors with Bonded Washers - Torque Settings BSP Hose Size in 1/8 1/4 3/8 1/2 5/8 3/4 1 30 - 206
Nm
kgf m
lbf ft
20.0 34.0 75.0 102.0 122.0 183.0 203.0
2.1 3.4 7.6 10.3 12.4 18.7 20.7
15.0 25.0 55.0 75.0 90.0 135.0 150.0
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30 - Hydraulic System
97 - Connectors 00 - General
BSP Hose Size in 1 1/4 1 1/2
Nm
kgf m
lbf ft
305.0 305.0
31.0 31.0
225.0 225.0
Torque Stop Hose System Figure 481. D
B C A
B
C
A
A Adaptor C O-ring E Minimum dimension fixed by shoulder.
B Hose D Shoulder
Torque-Stop hoses installed into adaptors seal onto an `O' ring which is compressed into a 45 ° seat machined into the face of the adaptor port. To prevent
the 'O' ring being damaged as a result of over tightening, Torque-Stop hoses have an additional shoulder, which acts as a physical stop.
Table 211. BSP `Torque Stop' Hose - Torque Settings BSP Hose Size in. 1/8 1/4 3/8 1/2 5/8 3/4 1 1 1/4 1 1/2
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Hexagon (A/F) mm 14.0 19.0 22.0 27.0 30.0 32.0 38.0 50.0 55.0
Nm
kgf m
lbf ft
14.0 27.0 40.0 55.0 65.0 95.0 120.0 189.0 244.0
1.4 2.7 4.1 5.6 6.6 9.7 12.2 19.3 24.9
10.0 20.0 30.0 40.0 48.0 70.0 89.0 140.0 180.0
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30 - Hydraulic System
97 - Connectors
03 - Quick Release Coupling
03 - Quick Release Coupling
Introduction
Introduction .................................................. 30-208 Disconnect and Connect ............................. 30-209
The flat face quick release couplings allow the operator to remove and install attachments swiftly and efficiently. Generally, your machine pipework will have female couplings installed, and the optional attachment hoses will have male couplings installed. The quick release couplings will be trouble free and relatively easy to connect and disconnect, if they are kept clean and used correctly. The recommendations listed below must always apply when using flat face quick release couplings. Read the correct connecting and releasing procedures before you install or remove any optional attachment connected with quick release couplings. Figure 482. A
B
A Female coupling B Male coupling
Essential Do's •
• • • •
•
• •
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Before connecting or removing any hydraulic hose, the residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing the hoses. Always wipe the two mating faces clean before connecting. Use caps and plugs when the couplings are disconnected. Always align the external locking ball (if used) with the notch in the locking sleeve and then pull the locking sleeve back fully to disconnect. If a coupling sticks, first check that pressure has been released. Make sure the locking ball and notch in the locking sleeve are aligned, pull back the sleeve and twist the couplings apart. Sticking is normally caused by dirt in the coupling or physical damage due to abuse. Connect and disconnect the new couplings two or three times to work the PTFE seals. Sometimes a new coupling will stick if the seal has not been worked. When connecting the couplings, only apply the spanner or grips to the hexagon and nowhere else. Avoid damage to the coupling faces. Burrs and scratches cause damage to the seals and cause leaks. They can also impede connection and disconnection of the couplings.
30 - 208
30 - Hydraulic System
97 - Connectors
03 - Quick Release Coupling
•
Periodically lubricate the internal locking balls on the female half of the coupling with silicone grease.
Essential Don'ts •
•
•
• •
• • • • •
Never try to reconnect using a damaged half coupling as this will destroy the seals in the mating half and necessitate replacement of both halves. Do not leave the coupling where it may be run over by a machine or otherwise crushed, this will distort the sleeve and prevent connection and disconnection. Never try to turn the sleeve when the coupling is disconnected as this will cause the locking ball to jam under the locking sleeve and damage the coupling. Never try to strip the coupling down, there are no user serviceable parts. If the coupling is damaged it must be replaced with a new one. Never hit the centre poppet of the coupling to try and release the locked in pressure. This can cause irreparable damage to the coupling and serious injury. When connecting the couplings, never clamp on the sleeve of the female or nose of the male, this will cause distortion and/or damage. Never subject the couplings to external forces, especially side load. This can decrease the life of the coupling or cause failure. Never allow the torsional forces transmitted from the hoses to unscrew/screw together the couplings. Never use a coupling as a plug. Do not connect and disconnect with pressure in the line unless the coupling type is specifically designed to do so.
Disconnect and Connect Some attachments are hydraulically powered. The following procedures show how to connect and disconnect the hydraulic hoses safely.
Connect 1. Make the machine safe. Refer to: PIL 01-03. 2. Discharge the hydraulic pressure. Refer to: PIL 30-00-00. 3. Wipe the two faces of the male and female couplings and make sure they are clean. 4. Make sure that the ball in the female coupling is located in one of its slots. 5. Connect the male coupling into the female coupling. 6. Where applicable, rotate the sleeve half a turn and make sure that the locking ball does not align with the slot.
Disconnect 1. Make the machine safe. Refer to: PIL 01-03. 2. Discharge the hydraulic pressure. Refer to: PIL 30-00-00. 3. Where applicable, align the slot with the ball. 4. Pull back the sleeve to release the coupling. Figure 483. D E C
C Ball D Slot E Sleeve
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30 - Hydraulic System
97 - Connectors
18 - O-Ring Face Seal (ORFS)
18 - O-Ring Face Seal (ORFS)
Introduction
Introduction .................................................. 30-210 Remove and Install ..................................... 30-211
The ORFS (O-Ring Face Seal) type fittings are adaptors that are screwed into valve blocks, they seal on to an O-ring which is compressed into a 45° seat machined into the face of the tapped port.
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30 - Hydraulic System
97 - Connectors
18 - O-Ring Face Seal (ORFS)
Remove and Install
Figure 486.
The hose fittings are for flat face components for resistance over torque. The ORFS (O-Ring Face Seal) offers 100% reliability. When you remove or install components, make sure all of the hydraulic fittings are tightened to the correct torque value during the assembly procedure. 4 Swivel nut - Hand tight 5 Swivel nut - Torque tightened
To prevent damage to the ORFS during the assembly procedure it is important to use the double-spanner method to tighten the fittings.
Figure 487.
Figure 484.
A
B C D
1 Torque spanner 2 Open ended combination spanner
Install 1. Always coat the ORFS with hydraulic oil before installation. 2. The rubber ORFS is compressed into a precision machined groove in the adaptor to form a tight seal against a flat surface of the sleeve. Figure 485.
A B C D
3
Nut Sleeve ORFS Adaptor
3 ORFS 3. Use the swivel nut line marking. Tighten the nut to the correct torque value to compress the fitting. Refer to Technical Data.
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Notes:
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33 - Electrical System Contents
Page No.
Acronyms Glossary .................................................................................................................................... 33-2 33-00 Electrical System 33-00-00 General ............................................................................................................................. 33-3 33-00-50 Schematic Circuit ............................................................................................................. 33-6 33-00-90 Earth Point ..................................................................................................................... 33-56 33-03 Battery 33-03-00 General ........................................................................................................................... 33-59 33-03-03 Isolator Switch ................................................................................................................ 33-65 33-09 Power Distribution 33-09-00 General ........................................................................................................................... 33-69 33-09-03 Fuse ............................................................................................................................... 33-71 33-09-06 Relay .............................................................................................................................. 33-74 33-12 Harness 33-12-00 General ........................................................................................................................... 33-77 33-12-23 Servo Hydraulic .............................................................................................................. 33-87 33-12-26 Joystick Controls ............................................................................................................ 33-95 33-40 Bulb 33-40-00 General ........................................................................................................................... 33-97 33-45 Control Module 33-45-07 Power Management System (PMS) ............................................................................... 33-99 33-45-38 Auxiliary Circuits ........................................................................................................... 33-103 33-54 Window Washer/Wipe 33-54-00 General ......................................................................................................................... 33-107 33-54-03 Tank .............................................................................................................................. 33-108 33-57 Electronic Diagnostic 33-57-90 Fault Codes .................................................................................................................. 33-111
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Acronyms Glossary ECU
Electronic Control Unit
LED
Light Emitting Diode
PMS
Power Management System
PWM
Pulse Width Modulation
RPM
Revolutions Per Minute
9813/6050-2 2018-06-01
33 - Electrical System
00 - Electrical System
00 - Electrical System Contents
Page No.
33-00-00 General ............................................................................................................................. 33-3 33-00-50 Schematic Circuit ............................................................................................................. 33-6 33-00-90 Earth Point ..................................................................................................................... 33-56
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Notes:
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33 - Electrical System
00 - Electrical System 00 - General
00 - General Introduction ...................................................... Health and Safety ........................................... Technical Data ................................................. Check (Condition) ............................................ Check (Operation) ...........................................
33 - 3
Introduction 33-3 33-4 33-4 33-5 33-5
It is important that the electrical system on the machine is in a sound state of repair. Make sure that all the health and safety warnings in this section are followed. The machine must be safe with the battery isolated before you attempt to disconnect any electrical connections or work in the engine compartment.
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33 - Electrical System
00 - Electrical System 00 - General
Health and Safety
Technical Data
Arc Welding To prevent the possibility of damage to electronic components, disconnect the battery and the alternator before arc-welding on the machine or attached implements. If the machine is equipped with sensitive electrical equipment, i.e. amplifier drivers, electronic control units (ECUs), monitor displays, etc., then disconnect them before welding. Failure to disconnect the sensitive electrical equipment could result in irreparable damage to these components. Parts of the machine are made from cast iron, welds on cast iron can weaken the structure and break. Do not weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine. Always connect the welder earth (ground) cable to the same component that is being welded to avoid damage to pivot pins, bearings and bushes. Attach the welder earth (ground) cable a distance from the part being welded no more than 0.6 m. Notice: Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. CAUTION! Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.
33 - 4
Table 212. Description Battery type Cold crank amps for 1 min1 minute to 1.4 VPC at -18 °C ( -0.4 °F) Reserve capacity for 25 A load Alternator XUD engines 100 and 400 series engines
Data 12 V, Negative earth 420 –585 A according to battery type 170 –230 A according to battery type 12 V, 50 A output 12 V, 55 A or 65 A output
Table 213. Light Bulbs Description Working lights Indicator lights Warning lights Beacon lights Interior lights Side lights Number plate lights
Data 55 W (Halogen) 21 W 1.2 W 70 W 10 W 5W 5W
Table 214. Sensor Switches Description Transmission charge pressure switch
Data Normally closed, opens at 2 –3.4 bar ( 29.0 – 49.3 psi) falling Transmission oil temper- Normally open, closes ature switch at 107 –113 °C ( 224.5 –235.2 °F) rising Reverse alarm pressure Normally open, closes at switches 7 bar ( 101.4 psi) rising Brake light pressure Normally open, closes at switches 4 bar ( 58.0 psi) rising
9813/6050-2
33 - 4
33 - Electrical System
00 - Electrical System 00 - General
Check (Condition)
Check (Operation)
Examine the electrical circuits regularly for:
Make sure that all the electrical equipment listed below operate correctly.
• • • • • •
Damaged connectors. Loose connections. Chafing on the wiring harnesses. Corrosion. Missing insulation. Incorrect routing of the wiring harnesses.
Do not use the machine if one or more of these faults are found. You must make sure that the electrical circuit is repaired immediately.
• • • • • • • • •
Switches Warning lights Beacon Alarms Horn Wipers Hourmeter Battery Lights
All defective equipment must be repaired before the machine is used.
33 - 5
9813/6050-2
33 - 5
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
50 - Schematic Circuit
Introduction
Introduction ...................................................... 33-6 Diagram ........................................................... 33-9
A schematic wiring diagram is a simplified pictorial representation of the machines electrical circuit. It shows the components of the circuit as simplified electrical symbols, and the power and signal connections between the devices. The wiring diagram is used to troubleshoot problems and to make sure that all the connections have been made and that everything is present. Use the schematics together with the correct electrical harness drawings to reference the connector pin details. This section may contain more than one set of electrical schematics for different machine variants.
Understanding Electrical Schematics Use the applicable schematic set to trace wires and connections between electrical devices. In most cases it will be necessary to trace wires across more than one schematic sheet. The example identifies the information contained on the diagrams. It also shows how to follow wires from one diagram sheet to another. The harness inter-connector codes and device harness connector codes are the same as used on the applicable harness drawings. Splices are not normally accessible. Splices are inside the harness sheath and not visible on the outside. Wires are welded together at a splice, there are no individual connector components.
33 - 6
9813/6050-2
33 - 6
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
Figure 488. 3 /7.B4 TO SWITCH:MAIN WIPER C116
-S012
0.50 mm² 1009A
TO
#1996
C A FROM SPLICE:BACKLIGHTING S012 /3.D1
#1996
FROM
/9.B5 TO MOTOR:WIPER-UPPER C058
7236/0002
-C058
TO
#1783
6/6
2/6
2/6
RED
YELLOW -B8 1/6
WHITE
A C E G J L
0.75 mm² 8006
8
2/10
2
-IC08_M 21/21
J
5/6
BLACK
7
7/10
1
D
3
3/10
4 0.75 mm² 8006
5/10
D GD
5 6
4/10 6/10
E
9 5/6
1.00 mm² 8006
5/20
5/20
0.75 mm² 8006
FROM
#1783
/7.B4 FROM SWITCH:MAIN WIPERS C116
GREEN 3/6
3/6
BROWN 4/6
4/6
B D F H K
Wire size (area) and number Device description Device internal schematic Harness inter-connector symbol Destination reference number Destination (diagram sheet and grid)
To help locate a wire destination from other diagram sheets use the grid reference. This identifies the applicable location zone on the sheet in a similar way to a map reference.
33 - 7
F
21/21
8/10
MOTOR:WIPER UPPER
6/6
1/6
F -IC08_M
-SW5 701/E0089 SWITCH: MAIN WIPER
B
0.50 mm² 8100J
H
K
-C116
0.50 mm² 1009A
-S011
L
7219/0013
7
Device harness connector code Connector pin number (wire location / total) Harness inter-connector codes Splice code and symbol Destination (harness connector code)
Due to space limitations, the grid is sometimes omitted.
9813/6050-2
33 - 7
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
Figure 489. Grid reference example (D4) 1
F
E
RC012:6 /15.C5
FROM
RC011:1 /13.A4
FROM
RC007:2 /13.B4
FROM
RC009:1 /12.F6
FROM
2
GROUND
1.00 mm² 601SP
GROUND
1.00 mm² 601AV
GROUND
1.00 mm² 601AX
GROUND
2.00 mm² 601AR
GROUND
1.50 mm² 600WP
GROUND
2.00 mm² 601AW
RC18:2 /12.C6 RC004:1 /12.E6
FROM
RC003:2 /14.F7
FROM
RC005:2 /13.C7
FROM
RC008:2 /13.C7
FROM
GROUND
2.00 mm² 601DG
GROUND
2.00 mm² 601KG
6.00 mm² 601RC2
-SRC6
0.75 mm² 699CE
HYD ECU SENSOR GND
1.00 mm² 699SK
HYD ECU SENSOR GND
1.00 mm² 699CH
SP44 /25.C5
FROM
FROM
FROM
HYD ECU SENSOR GND
P095:6 /26.D1
FROM
0.75 mm² 699CB
HYD ECU SENSOR GND
0.75 mm² 699CC
P091:2 /29.E5 P092:2 /29.E5
FROM
HYD ECU SENSOR GND
0.75 mm² 699CD
HYD ECU SENSOR GND
1.00 mm² 699CG
HYD ECU SENSOR GND
0.75 mm² 699CF
P087:2 /21.B7 SP2 /27.E4 P111:2 /29.B6
P070:15 /21.C6
FROM
FROM
FROM
CAN SHLD
FROM
2.00 mm² 600P
CAN SHLD
2.00 mm² 601BU
CAN SHLD
2.00 mm² 601AL
CAN SHLD
2.00 mm² SCR
P055:1 /12.B6
FROM
FROM
P130:4 /13.D7
FROM
SPMC12 /17.C3
FROM
2.00 mm² SCR
CAN SHLD
1.00 mm² 600H
FROM
P034:2 /7.C2
FROM
-SP42
1.50 mm² 699CA
10.00 mm² 600
-SP61
CAN SHLD
SVMC15 /17.D5
5
6
HYD ECU SENSOR GND FROM
/22.B7 SC9 / P039:F7
0.75 mm² 601HB
CAN SHLD
0.75 mm² 601EK
CAN SHLD
0.75 mm² 601HK
CAN SHLD
0.75 mm² 601HL
/3.D2
FROM
P006:10
/3.D2
FROM
P007:10
/3.C2
FROM
P007:5
/3.C2
FROM
P008:10
/3.A2
FROM
P008:5
/3.B2
FROM
P101:10
/8.D4
FROM
P014:1 /13.F1
M10
CAN SHLD
P006:5
CAN SHLD
7
8
0.75 mm² 601JJ
CAN SHLD
1.00 mm² 601TS
CAN SHLD
0.75 mm² 601LH
CAN SHLD
0.75 mm² 601SH
CAN SHLD
1.00 mm² 601RD
CAN SHLD
1.00 mm² 601LL
/9.C5
FROM
CAN SHLD
0.75 mm² 601SY
P112:2 /14.C4
FROM
CAN SHLD
0.75 mm² 601JB
P020:7 /11.D3
FROM
FROM
P014:5 /13.E1
FROM
P058:4 /15.E2
FROM
P013:5
FROM
/8.C1
0.75 mm² 601X
CAN SHLD
P016:5 /11.E6
FROM
P016:10 /11.E6
FROM
-SP3
3.00 mm² 601JC
E
P072:17
-P035
M10
B
CAN SHLD
1.00 mm² 601DE
CAN SHLD
1.00 mm² 601HT
CAN SHLD
0.75 mm² 601AD
CAN SHLD
1.00 mm² 601HP
CAN SHLD
1.00 mm² 601C
CAN SHLD
1.00 mm² 601DZ
CAN SHLD
0.75 mm² 601NS
P063:7
CAN SHLD
0.75 mm² 601BL
P073:A /17.D1
FROM
P036:7 /25.D2
FROM
P010:5 /4.E2
FROM
P011:5 /10.F6
FROM
CAN SHLD
1.00 mm² 601FV
CAN SHLD
1.00 mm² 601KP
CAN SHLD
1.00 mm² 601V
CAN SHLD
1.00 mm² 601AC
CAN SHLD
1.00 mm² 601AC
CAN SHLD
1.00 mm² 601KK
P067:10 /14.D4
FROM
P015:10 /14.D5
FROM
P013:10 /10.B1
FROM
P015:5 /14.D3
FROM
P017:7 /14.C5
FROM
P062:7 /27.E4
FROM
P40:10
/9.A3
FROM
P066:11 /8.B7
FROM
-SP29
/9.F7
CAN SHLD
0.50 mm² 601P
CAN SHLD
1.00 mm² Y
CAN SHLD
0.75 mm² 601BF
CAN SHLD
1.00 mm² 601DC
CAN SHLD
1.00 mm² 601AC
CAN SHLD
1.00 mm² 601AY
P017:7 /25.E3
FROM
CAN SHLD
1.00 mm² 601KA
P021:7 /12.F3
FROM
CAN SHLD
1.00 mm² 601AL
P022:7 /12.E3
FROM
CAN SHLD
1.00 mm² 601BL
P065:2 /15.B5
FROM
P027:7 /21.B4
FROM
P042-A /28.E2
FROM
P024:7 /10.C1
FROM
P023:7 /10.F2
FROM
P026:7 /13.F3
FROM
P028:7 /13.B2
FROM
P029:7 /13.E3
FROM
P061:7 /16.F2
FROM
P052:7 /14.B5
FROM
FROM
-SP11
3.00 mm² 601JE
D
-SP62
3.00 mm² 601JH
1.50 mm² 606TR
CAN SHLD
P130:3 /13.D7
-RC06
1.00 mm² 699SJ
HYD ECU SENSOR GND FROM
10.00 mm² 601RC
-SRC7
HYD ECU SENSOR GND
SP43 /30.E6
P095:3 /26.D1
C
6.00 mm² 601RC1
2.00 mm² 601FK
GROUND
4
F
-SRC5
FROM
D
3
CAN SHLD
2.00 mm² 601TR
CAN SHLD
1.00 mm² 601DD
CAN SHLD
1.00 mm² 610ACF
P070:16 /21.C6
FROM
P052:1 /14.E7
FROM
P013:5 /14.E2
FROM
-SP6
10.00 mm² 600
-P030
M10
C
2.00 mm² 601JD
P018:7 /30.F2
CAN SHLD
1.00 mm² 601BB
CAN SHLD
1.00 mm² 601BH
CAN SHLD
1.00 mm² 601DX
CAN SHLD
1.00 mm² 601KC
CAN SHLD
1.00 mm² 601N
CAN SHLD
0.75 mm² 601AK
CAN SHLD
1.00 mm² 601EN
FROM
B 2.00 mm² 601JF
-SP28
A
A
1
33 - 8
2
3
4
9813/6050-2
5
6
7
8
33 - 8
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
Diagram For: Series 1 ............................... Page 33-9 For: Series 2 ............................. Page 33-24
(For: Series 1) Figure 490. From Machine No. (751600 to 752370).............................................................. Page 33-11 Figure 491. .............................................................................................................................Page 33-15 Figure 492. .............................................................................................................................Page 33-21
33 - 9
9813/6050-2
33 - 9
Notes:
33 - 10
9813/6050-2
33 - 10
33 - 11 WORKING LIGHT
IGN. RELAY
9813/6050-2 FUSEA6
FUSEA7
38 RELAY
37
HAZARD SWITCH
FUSEB9
FUSEB8
FUSEB7
FUSEB6
56
43
66
50
48
57
65
LATCHING RELAY
PRESS . SWITCH
H/H ATTACHMENT SOLENOID
10 SECOND TIMER
55
52
SLOW
62
61
FAST
64
59
63
123
53
121
122
49
47
120
117
115
113
111
119
116
114
118
54
112 FUSEB3
109
107
21
17
16
31 32
25 26 27 28 29
23
10
9
106
108
35
110
FUSEB1
INTERIORLIGHT
30
JOYSTICK
14
SEAT
IDE 11OVERR SWITCH
5
FUSEB2
WASH/WIPE SWITCH
55
46
44
15
6
THERMOSTART
19 LATCHING RELAY
24
INDICATORSWITCH
33
CHARGE PUMP PRESS .
AIRFILTER
ENGINE OIL PRESS .
HYD. OIL TEMP.
FLOAT SWITCH
58
HEATER MOTOR
60
56
51
FLASHER UNIT
REARWORKLIGHT
41
40
FRONT WORKLIGHT
BUZZER
WATERTEMP.
ALTERNATOR
ROAD LIGHT SWITCH
36
39
BEACON SWITCH
34
101 102 103 104 105
22
20
SEAT SWITCH
12 ISOLATION RELAY
P. BRAKE
7 SWITCH
4 GLOW PLUGS
JUNCTION BOX
FACE LEVEL FAN
FLOAT SOLENOID
HAND HELD ATTACHMENT SOLENOID
L.H.BRAKE LIGHT R.H.BRAKE LIGHT
BRAKE LIGHT TIMERUNIT
REVERSEALARM
HEATER MOTOR
REARWIPERMOTOR
FRONT WIPERMOTOR
WASHERMOTOR
R.H.FRONT INDICATR R.H.REARINDICATOR FLASHERUNIT
L.H.FRONT INDICATR L.H.REARINDICATOR
L.H.REARWORK LIGHT R.H.REARWORK LIGHT
L.H.FRONT WORK LIGHT R.H.FRONT WORK LIGHT
L.H.DIP BEAM R.H.DIP BEAM NO. PLATE LIGHT L.H.TAIL LIGHT L.H.SIDE LIGHT R.H.TAIL LIGHT R.H.SIDE LIGHT
BEACON
INTERIORLIGHT
REARHORN FRONT HORN
CHARGE PUMP PRESS URE E.S.O.S.
AIRFILTER
ENGINE OIL PRESS URE
ENGINEWATERTEMP. HYD. OIL TEMP.
ALTERNATOR
HOURMETER
HI-FLOW HYDRAULICS
AUX. HYD. REV (FRONT)
AUX. HYD. FWD (FRONT)
ISOLATORRELAY
PARKBRAKE SOLENOID
OPERATIONAL SOLENOID
NEUTRAL START RELAY
STARTERSOLENOID
STARTERMOTOR
Figure 490. From Machine No. (751600 to 752370)
FUSEA10
FUSEA9
42
FUSEB5
FUSEB4
FUSEB10
FUSEA5
18
HI FLOW SWITCH
100
AUX. SWITCH
13
P. BRAKE 8 RELAY
3
1
Page 33-12
FUSEA8
FUSEA4
FUSEA3
FUSEA2
FUSEA1
2
N/START RELAY
BATTERY
33 - Electrical System 00 - Electrical System 50 - Schematic Circuit
Page 33-13
852/95001/1
852-95001-1
33 - 11
33 - 12
9813/6050-2 37
IGN. RELAY
Page 33-13
FUSEB10
FUSEA5
FUSEA8
FUSEA4
FUSEA3
FUSEA2
FUSEA1
2
18
WATERTEMP.
33
CHARGE PUMP PRESS .
AIRFILTER
24
33 - 12
FUSEB2
INTERIORLIGHT
LATCHING RELAY
15
6
THERMOSTART
19
4
FUSEB1
ENGINE OIL PRESS .
HYD. OIL TEMP.
ROAD LIGHT SWITCH
36
39
BEACON SWITCH
34
101 102 103 104 105
BUZZER
22
20
SEAT SWITCH
12 ISOLATION RELAY
P. BRAKE
7 SWITCH
1
ALTERNATOR
HI FLOW SWITCH
100
AUX. SWITCH
13
N/START RELAY
. BRAKE 8 PRELAY
3
BATTERY
110
109
107
21
17
16
31 32
25 26 27 28 29
23
10
9
106
108
35
30
JOYSTICK
14
SEAT
IDE 11OVERR SWITCH
5
L.H.DIP BEAM R.H.DIP BEAM NO. PLATE LIGHT
BEACON
INTERIORLIGHT
REARHORN FRONT HORN
CHARGE PUMP PRESS URE E.S.O.S.
AIRFILTER
ENGINE OIL PRESS URE
ENGINEWATERTEMP. HYD. OIL TEMP.
ALTERNATOR
HOURMETER
HI-FLOW HYDRAULICS
AUX. HYD. REV (FRONT)
AUX. HYD. FWD (FRONT)
ISOLATORRELAY
PARKBRAKE SOLENOID
OPERATIONAL SOLENOID
NEUTRAL START RELAY
STARTERSOLENOID
STARTERMOTOR
GLOW PLUGS
33 - Electrical System 00 - Electrical System 50 - Schematic Circuit Page 33-12 Page 33-13
Figure 490. (Part 1 of 2)
33 - 13 FUSEA6
FUSEA7
WORKING LIGHT
38 RELAY
37 IGN. RELAY
Page 33-12
9813/6050-2 FUSEB9
FUSEB8
56
60
56
51
66
WASH/WIPE SWITCH
44
50
48
57
55
65
LATCHING RELAY
PRESS . SWITCH
H/H ATTACHMENT SOLENOID
10 SECOND TIMER
SLOW
52
62
61
FAST
64
59
63
123
53
121
122
49
47
120
117
115
113
111
109
107
119
116
114
118
54
112
FUSEB3
INDICATORSWITCH
55
46
FLOAT SWITCH
58
HEATER MOTOR
43 FLASHER UNIT
REARWORKLIGHT
41
40
110
108
FUSEB2
FUSEB1
JUNCTION BOX
FACE LEVEL FAN
FLOAT SOLENOID
HAND HELD ATTACHMENT SOLENOID
L.H.BRAKE LIGHT R.H.BRAKE LIGHT
BRAKE LIGHT TIMERUNIT
REVERSEALARM
HEATER MOTOR
REARWIPERMOTOR
FRONT WIPERMOTOR
WASHERMOTOR
R.H.FRONT INDICATR R.H.REARINDICATOR FLASHERUNIT
L.H.FRONT INDICATR L.H.REARINDICATOR
L.H.REARWORK LIGHT R.H.REARWORK LIGHT
L.H.FRONT WORK LIGHT R.H.FRONT WORK LIGHT
L.H.DIP BEAM R.H.DIP BEAM NO. PLATE LIGHT L.H.TAIL LIGHT L.H.SIDE LIGHT R.H.TAIL LIGHT R.H.SIDE LIGHT
BEACON
Figure 490. (Part 2 of 2)
FUSEB7
FUSEB6
FUSEA10
FUSEA9
42 HAZARD SWITCH
FUSEB5
FUSEB4
FRONT WORKLIGHT
39
ROAD LIGHT SWITCH
106
33 - Electrical System 00 - Electrical System 50 - Schematic Circuit Page 33-12
852/95001/1
852-95001-1
33 - 13
Page 33-13
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 100 102 104 106 108 110 112 114 116 118 120 122
Battery Neutral start relay Starter motor Park brake switch Operational solenoid Override switch Auxiliary attachments switch Joystick switch Auxiliary hydraulics - Reverse solenoid Latching relay High - flow hydraulic solenoid Alternator Engine coolant temperature switch Engine oil pressure switch Charge pump pressure switch Rear horn (When installed) Horn relay Interior light and switch Ignition relay Road lights switch Rear worklight switch Flasher unit Intentionally blank Washer motor Rear wiper motor / Rear wiper switch Heater blower resistor Reverse alarm Brake light switches Hand held attachment switch and warning Hydraulic float pressure switch Latching relay Face level fan Junction box Alternator warning Hydraulic oil temperature warning Air cleaner warning RH Front side light RH Front work light RH Rear worklight LH Rear direction indicator RH Rear direction indicator RH Rear brake light LH Headlight dip Number plate light LH Front side light
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 101 103 105 107 109 111 113 115 117 119 121 123
Stater switch Glow plugs Starter solenoid Park brake relay Park brake solenoid Isolator relay Seat switch Auxiliary hydraulics - Forward solenoid High - flow hydraulic switch Seat switch Hourmeter Warning buzzer Hydraulic oil temperature switch Air cleaner warning switch Engine shut off solenoid Front horn Horn pushbutton Beacon switch Working light relay Front worklight switch Hazard warning switch Indicator switch and warning light Wash / Wipe switch and warning light Front wiper motor Heater blower switch Heater blower Reverse alarm switches Brake light timer Hand held attachment solenoid Hydraulic float pressure switch Hydraulic float solenoid Face level fan switch Lamps Engine coolant temperature warning Engine oil pressure warning Charge pump pressure warning LH Front work light LH Rear worklight LH Front direction indicator RH Front direction indicator LH Rear brake light Beacon light RH Headlight dip LH Rear side light RH Rear side light
Fuses See section 3
From Machine No. (752371 to 752675)
33 - 14
9813/6050-2
33 - 14
33 - 15 205B
24
9813/6050-2 127B
49 127C
10
5
10 SEC. TIMER
56
57
57
869A
8
7
2
SLOW
816
840
839
807B
HEATER RESISTOR
800D
816E
816D
55
816L
4
WASH/WIPE SWITCH
800
FAST
600BH 600EB
58
BRAKE SWITCHES
807A
51
REVERSESWITCHES
5 10
52
127A
HEATER SWITCH
101 54
FUSEB9
3
50
8
800B
102
106H
106R
1
894
53
103
102
BEACON SWITCH
10
1
871B 871A
INTERIORLIGHT
808C
806E
47
FUSEB8
FUSEB7
101
9
5
871
806B
806H
48
FUSEB8
303G
46 HORN SWITCH
45
106N
303A
43
303
312
FLASHER UNIT
7 10 805G
99
FUSEA9
HAZARD SWITCH
49a 31 49
9
5
100
FUSEA8
FUSEA10
802
44 6
803A
600CK
600AW
600CD
600ED
800AK
600BG
800GR
800CC
600DY
RH BRAKE LIGHT
LH BRAKE LIGHT
BRAKE LIGHT TIMER UNIT
REVERSEALARM
W/WIPE SWITCH ILLUM.
WIPERMOTOR
WASHERMOTOR
HEATER MOTOR
JUNCTION BOX
BEACON SWITCH ILLUM.
BEACON
INTERIORLIGHT
REARHORN
600AP
600AJ
FRONT HORN
FLASHERUNIT
RH FRONT INDICATOR RH REARINDICATOR
HAZARD SWITCH ILLUM. LH FRONT INDICATOR LH REAR INDICATOR
REARWORKLIGHT SWITCH
RH REARWORKLIGHT
LH REARWORKLIGHT
600EL
600BL
600H
600G
600DX
RH FRONT WORKLIGHT FRONT WORKLIGHT SWITCH
600EY
98
2
803B
40 805 806P
42
1 3
805C
600AV
600AY
ROADLIGHT SWITCH
RH SIDE LIGHT
RH TAIL LIGHT
LH FRONT WORKLIGHT
Figure 491.
300
104
10
1 805B
97
5 8
7
IND. SWITCH
35 805E
861A
861B
600CJ
600AR
600AS
LH SIDE LIGHT
LH TAIL LIGHT
NO. PLATE LIGHT
RH DIP BEAM
LH DIP BEAM
REARWIPERMOTOR
FLOAT SOLENOID
FLOAT SWITCH ILLUM.
E.S.O.S.
CHARGE PUMP PRESS . SWITCH 600CS
X
AIRFILTERSWITCH
ENGINE OIL PRESS . SWITCH
HYD. OIL TEMP. SWITCH
ENGINEWATERTEMP. SWITCH
ALTERNATOR
HOURMETER
ENGINE SPEED INDICATOR UNIT
IGNITION RELAY
HIGH-FLOW HYDRAULICS
AUX. SWITCH ILLUM.
AUX. HYD. REV. (FRONT)
AUX. HYD. FWD. (FRONT)
SEAT POSITION SWITCH
OVERRIDE SWITCH
P/BRAKE SWITCH ILLUM.
PARK BRAKE SOLENOID
OPERATION SOLENOID
NEUTRAL START RELAY
STARTERSOLENOID
600CF
X
600JT
X
X
600DW
96
FUSEB10
106F
10
861
855A
95
803
9
1
41
106M
10
855B
830D
830B
829E
829D
829C
834A
834B
600W 600HR
600HS
600BD
94
5
9
830
829
834
93
117
106L
1
2 3
415
403
414
91
855
855C
FUSEB3
FUSEB2
FUSEB1
5
4
LATCHING RELAY
PRESS URE SWITCH
'W'
600DH
600CU
600JU
600HY
600HX
600HB
600HC
600GN
600CP
600DE
92
1
10
833
828M
828
10
6
36 6
3
9
8
3
37
90
5
1
7 2
415B
402
39
89
116
105
CHARGE PUMP PRESS .
414B
406
403B
34
88
FUSEB5
FUSEB4
106AF
AIR FILTER
FLOAT SWITCH
83 84 85 106AE
ENGINE OIL PRESS .
HYD. OIL TEMP.
WATERTEMP.
411
434B
407
877E
F
87
9
2
106AD
434
877
600DD
412
414A
86
106K
81 82 106AC
434A
BUZZER
407A
407B
3
1
2
LATCHING RELAY
5
881 4
JOYSTICK C
415A 403C
38
205D
80
106AB
ALTERNATOR
27
30 31 32 33
114
25 106C
HOURMETER
3
2
3
2
B
A
865A
29
FUSEA7
106AA
1
ENGINE SPEED INDICATOR UNIT
26 23
101AR
23 106D
1
873A 972
865
600V
600GV
GLOW PLUGS STARTERMOTOR
Page 33-16
FUSEA6
106
877D
877B
SEAT SWITCH
21
28
FUSEA5
FUSEA4
106T
7
874
4 877C
2
10
1 2 886
865B
19
200 200A
1
22 9
3
16
5
887
971
4
5
ISOLATION RELAY
TUV SEAT SWITCH (GERMAN BUILD ONLY)
20
2
129
15 HIGH-FLOW SWITCH
9
2
6
8
1
5
7
125D
125E
1 10
938B 938A
7
18
4
FUSEA3
23 877A
3
9 815A
5
14
10
7 125B
866A
815
842
P/BRAKE SWITCH
17
001A
002
810B
2
1
1 2
12 13
810C
810A
3
3
8
125
810
4
5
5 4
5
122B
122A
810
P/BRAKE RELAY
4 11
3
6 10
FUSEA2
122
004
9
5
50a
1
FUSEA1
15/54
N/START RELAY
THERMOSTART
3
IGN. RELAY
30
17
BATTERY
2
205A
001
200B 200C
19
003E
33 - Electrical System 00 - Electrical System 50 - Schematic Circuit
Page 33-17
103
104
59
60
60
852/95001/2
852-95001-2
33 - 15
33 - 16
9813/6050-2 4 2
Page 33-17
80 81 82 106AD
106AF
105
9
8
10
6
3
24
33 - 16
4
2
LATCHING RELAY
414A
7 2
1
PRESS URE SWITCH
402 415B
AIR FILTER CHARGE PUMP PRESS .
403B
ENGINE OIL PRESS .
415A 403C
FLOAT SWITCH
83 84 85 106AE
414B
HYD. OIL TEMP.
434B
407
412
877E
'W'
415
403
414
23
106AC
434
411
406
434A
BUZZER
407A
407B
WATERTEMP.
ALTERNATOR
27
106AB
2 3
3
2
877
600DD
LATCHING RELAY
3
1
2
F
600CU
600JU
600HY
600HX
600HB
600HC
X
600CS
600CF
X
600JT
X
X
600HS
600HR
600W
600DE
600DH
29
101AR
25
106C
HOURMETER
ENGINE SPEED INDICATOR UNIT
26
106AA
1
1
10
21
28
FUSEA6
106
23 106D
9
5
881 4
C
JOYSTICK
A
865A
19
FUSEA5
FUSEA4
106T
877D
874
B
865
865B
600GN
600CP
600GV
600V
FLOAT SWITCH ILLUM.
E.S.O.S.
CHARGE PUMP PRESS . SWITCH
AIR FILTER SWITCH
ENGINE OIL PRESS . SWITCH
HYD. OIL TEMP. SWITCH
ENGINEWATERTEMP. SWITCH
ALTERNATOR
HOURMETER
ENGINE SPEED INDICATOR UNIT
IGNITION RELAY
HIGH-FLOW HYDRAULICS
AUX. SWITCH ILLUM.
AUX. HYD. REV. (FRONT)
AUX. HYD. FWD. (FRONT)
SEAT POSITION SWITCH
OVERRIDE SWITCH
P/BRAKE SWITCH ILLUM.
PARK BRAKE SOLENOID
OPERATION SOLENOID
NEUTRAL START RELAY
STARTERSOLENOID
STARTER MOTOR
GLOW PLUGS
Figure 491. (Part 1 of 2)
200 200A
001A
002
22
7
2
SEAT SWITCH 877B
972
873A
16
5
4 877C
2 886
1
20
1
15 HIGH-FLOW SWITCH
887
4
5
ISOLATION RELAY
TUV SEAT SWITCH (GERMAN BUILD ONLY)
18
3
129
23 877A
9
2
6
971
3
1 10
938B 938A
7
12 13
8
1
5
7
125D
125E
14
FUSEA3
810B
3
9 815A
5
17
10
7 125B
866A
815
P/BRAKE SWITCH
842
11
810C
1 2
2
1
8
810A
3
3
4
125
810
4
5
4
5
10
5
6 5
122B
122A
P/BRAKE RELAY
810
9
FUSEA2
122
004
1
FUSEA1
15/54
50a
N/START RELAY
THERMOSTART
3
IGN. RELAY
30
17
BATTERY
2
205A
001
200B 200C
19
003E
33 - Electrical System 00 - Electrical System 50 - Schematic Circuit Page 33-16 Page 33-17
30 31 32 33 34 35
36
33 - 17
9813/6050-2 205B
127B
49 127C
10 SEC. TIMER
56
57
57
869A
10
5
816
840
839
807B
HEATER RESISTOR
800D
816E
816D
55
816L
4
SLOW
FAST
600BH 600EB
58
BRAKE SWITCHES
807A
51
REVERSESWITCHES
8
7
2
WASH/WIPE SWITCH
800
52
127A
HEATER SWITCH
5 10
101 54
FUSEB9
3
50
8
800B
53
106H
106R
1
INTERIORLIGHT
102
103
102
101
894
871B 871A
47
FUSEB8
FUSEB7
FUSEB8
BEACON SWITCH
10
1
871
808C
806E
48
9
5
303A
45 HORN SWITCH
46
106N
303G
49a 31
49
FLASHER UNIT
43
303
HAZARD SWITCH
806H
806B
99
FUSEA9
312
2
7 10 805G
100
FUSEA8
300
802
44 805 806P
40
6
42
1 3
9
5
805C
805E
35
803B
803A
1 805B
97
5 8
10
IND. SWITCH
861A
861B
600AY 600AV
600AW
600CD
600ED
800AK
600BG
800GR
800CC
600DY
600AP
RH BRAKE LIGHT
LH BRAKE LIGHT
BRAKE LIGHT TIMER UNIT
REVERSEALARM
W/WIPE SWITCH ILLUM.
WIPER MOTOR
WASHER MOTOR
HEATER MOTOR
JUNCTION BOX
BEACON SWITCH ILLUM.
BEACON
INTERIORLIGHT
REARHORN 600AJ
FRONT HORN
FLASHER UNIT
RH FRONT INDICATOR RH REAR INDICATOR
HAZARD SWITCH ILLUM. LH FRONT INDICATOR LH REAR INDICATOR
REARWORKLIGHT SWITCH
RH REARWORKLIGHT
600EL
600BL
600H
600G
600DX
600CK
LH REARWORKLIGHT
FRONT WORKLIGHT SWITCH
RH FRONT WORKLIGHT
LH FRONT WORKLIGHT
ROADLIGHT SWITCH
RH SIDE LIGHT
RH TAIL LIGHT
LH SIDE LIGHT
LH TAIL LIGHT
NO. PLATE LIGHT
RH DIP BEAM
LH DIP BEAM
REARWIPER MOTOR
FLOAT SOLENOID
FLOAT SWITCH ILLUM.
600EY
98
FUSEA10
104
7
861
95
FUSEB10
106F
1 10
600CJ
600AR
600AS
600DW
96
803
9
41 5
855A
93
117
10
855B
830D
830B
829E
829D
94
106M
9
855
834A 829C
91
106L
1
830
829
834
834B
600BD
92
5
1
2 3
90
116
855C
FUSEB3
FUSEB2
FUSEB1
5
4
LATCHING RELAY
89
10
833
36 828M
828
6 10
PRESS URE SWITCH
87
6
3
9
8
3
39 88
9
2
1
7 2
FLOAT SWITCH
37 86
106K
114
101AR
38
205D
FUSEA7
FUSEA6
Figure 491. (Part 2 of 2)
FUSEB5
FUSEB4
Page 33-16
33 - Electrical System 00 - Electrical System 50 - Schematic Circuit Page 33-16
104
103
59
60
60
852/95001/2
852-95001-2
33 - 17
Page 33-17
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 81 83 85 87 89 91 93 95 97 99 101 103
Battery Starter motor Neutral start relay Park brake relay Operational solenoid TUV Seat switch (German machines only) Seat switch Auxiliary attachments switch Auxiliary hydraulics - Forward solenoid (Front) High - flow hydraulic solenoid Seat switch Diode Hourmeter Warning buzzer Engine coolant temperature switch Engine oil pressure switch Charge pump pressure switch Hydraulic float pressure switch Latching relay Rear wiper motor Front worklight switch Indicator switch and warning light Flasher unit Front horn Beacon switch Heater blower switch Heater blower Wiper motor Reverse alarm switches Brake light timer Lamps Engine coolant temperature warning Engine oil pressure warning Charge pump pressure warning RH Headlight dip LH Tail light RH Tail light LH Front worklight LH Rear worklight LH Front direction indicator RH Front direction indicator Interior light and switch LH Rear brake light
33 - 18
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 80 82 84 86 88 90 92 94 96 98 100 102 104
9813/6050-2
Glow plugs Starter solenoid Starter switch Park brake switch Park brake solenoid Override switch Isolator relay Joystick switch Auxiliary hydraulics - Reverse solenoid (Front) Latching relay High - flow hydraulic switch Ignition relay Engine speed indicator unit Alternator Hydraulic oil temperature switch Air cleaner warning switch Engine shut off solenoid Hydraulic float switch Hydraulic float solenoid Road lights switch Rear worklight switch Hazard warning switch Horn switch Rear horn (If installed) Junction box Heater blower resistor Washer motor Wash / Wipe switch and warning light Reverse alarm Brake light switches Alternator warning Hydraulic oil temperature warning Air cleaner warning LH Headlight dip Number plate light LH Side light RH Side light RH Front worklight RH Rear worklight LH Rear direction indicator RH Rear direction indicator Beacon light RH Rear break light
33 - 18
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
From Machine No. 752676
33 - 19
9813/6050-2
33 - 19
Notes:
33 - 20
9813/6050-2
33 - 20
205B
001
33 - 21
9813/6050-2
816L
10 SEC TIMER
57
869A
5 +8
2
6
61 5
4
57
59
3
60 60
127D
WASH/WIPE SWITCH
3
-7 1
SLOW
816
807B
800D
M
816E
816D
M
M
600EB
600BH
55
2
1 4
2
BRAKE LIGHT TIMERRELAY
839
840
FAST
HEATERRESISTOR
58
BRAKE SWITCHES
REVERSESWITCHES 807A
2
1
800B
800
56
127B
106H
102A
840A
6
54
127C
127A
1 3 4
52
53
FUSEB9
2
-7
M
806C
806E
102
103
49 1
51
5
46 2
+10
50
102A
HEATER SWITCH
871B 871A INTERIORLIGHT
805B 806B
805C
48
FUSEB8
106R
894
+3
101
102
2
BEACON SWITCH
3
-7
2
-7 +1
47
FUSEB7
101
44 1
871
43
303A
2
1
100
2
+8
HORN SWITCH
803A
8
805E
99
FUSEB6
45 303G
806P
805 803
106AP
IND SWITCH
98
106N
HAZARD SWITCH
5 17 18
FLASHER UNIT
97
303
106AP
+8
31
803B
49a
49
96
FUSEA9
106F
802
42
2
-10
95
3
2
861B 861A
94
312
300
1
861
REARWORKLIGHT SWITCH
3
-7
600W 600HR
ROADLIGHT SWITCH
600DW
FLASHERUNIT INDICATORSWITCH LH FRONT INDICATOR LH REARINDICATOR
600G
BRAKE LIGHT TIMERUNIT
600H
600G
RH BRAKE LIGHT
BRAKE LIGHT TIMERRELAY LH BRAKE LIGHT
600AW
600MJ
REVERSEALARM
600CD
WASHERMOTOR
WIPERMOTOR
600AK
600BG
W/WIPE SWITCH ILLUM
600ED
HEATER MOTOR
600CC
600GR
BEACON
JUNCTION BOX
600AP
INTERIORLIGHT BEACON SWITCH ILLUM
FRONT HORN REARHORN
600DY
600AJ
600EL
600H
600EY
RH FRONT INDICATOR RH REARINDICATOR
HAZARD SWITCH ILLUM 600BL
600LA
600DX
REARWORKLIGHT SWITCH LH REARWORKLIGHT RH REARWORKLIGHT 600AV
RH FRONT WORKLIGHT
600AY
LH FRONT WORKLIGHT
600AS 600AR
600CK
FRONT WORKLIGHT SWITCH
600CJ
RH SIDE LIGHT
RH TAIL LIGHT
LH SIDE LIGHT
LH TAIL LIGHT
No PLATE LIGHT
RH DIP BEAM
LH DIP BEAM
REARWIPERMOTOR
FLOAT SOLENOID
FLOAT SWITCH ILLUM
E.S.O.S.
CHARGE PUMP PRESSSWITCH
AIRFILTERSWITCH
ENGINE OIL PRESSSWITCH
HYD. OIL TEMP SWITCH
ENGINEWATERTEMP SWITCH
ALTERNATOR
HOURMETER
ENGINE SPEED INDICATOR UNIT
IGNITION RELAY
600BD
X
600CS
600CF
X
600JT
X
X
600HS
HI FLOW HYDRAULICS
Figure 492.
FUSEA8
FUSEA10
24 104
2
1
855B 855A
93
FUSEB10
2
41
+8
855
23 FRONT WORKLIGHT SWITCH
830D
830B
829E
92
117
3
830
829D
91
106M
2
-7
40 1
FUSEB3
829
834B 834A 829C
600CU
90
2
+8
855C
828M
FUSEB2
834
M
415
89
116
2
828
FUSEB1
414 403
600HX
AUX HYD REV (FRONT)
AUX SWITCH ILLUM AUX HYD FWD (FRONT)
600JU
600HY
OVERRIDE SWITCH SEAT POSITION SWITCH
600HC
600HB
OPERATION SOLENOID PARKBRAKE SOLENOID
600GV
600DH
600DE
88
ROADLIGHT SWITCH
+3
833
'W'
87
106L
2
6
-7
2
3
1
23
86
200F
1
5
4
LATCHING RELAY
PRESS URE SWITCH
415B
402
37
5
8+
3
6
10
406 414B 403B
35
9
8
411
434B
F
877E
JOYSTICK
34
200N
1
36
2
7
434
407
877
600DD
412
3
1
2
O/R
SEAT
39
106K
83 84 85
FLOAT SWITCH
105
CHARGE PUMP PRESS
AIRFILTER
407A
5
4
LATCHING RELAY
C
A
865A
865B
STARTERSOLENOID NEUTRAL START RELAY P/BRAKE SWITCH ILLUM
600CP
38
114
WATERTEMP
ENGINE OIL PRESS
HYD OIL TEMP
434A
407B
B
865
30 31 32 33
FUSEA7
101AR
81 82 106AF
80
106AE
3
27
106AD
25 ALTERNATOR
106C BUZZER
3
21
23
106AC
0
2 3
881
874
23
106AB
4
HOURMETER
4
2
SEAT SWITCH
972
873A
2 866
1
3
TUV SEAT SWITCH (GERMAN BUILD ONLY)
29
FUSEA6
FUSEA5
23 106AA
1
ENGINE SPEED INDICATOR UNIT
877C
877B
ISOL RELAY
936A
936B
600V 600GN
STARTERMOTOR
GLOW PLUGS
Page 33-22
FUSEB5
FUSEA4
23 106D
1
2
6
3
-7 1
4
5
3
-7 1
26
28
FUSEB4
200 200A
106T
22 5
867
971
125D
125E
2
1
20
2
+8
HI FLOW SWITCH
6
4
3
1
-7
2
+8
16 19
2
877D
877A
2
1
AUXILIARY SWITCH
866A
815
P/BRAKE SWITCH
18
4
002
810C
5
125C +8
2
10
7 125B
1
3
2
106AK
842
17
129
810B
810A
810
5
4
2
1
15
FUSEA3
125
122B
122A
P/BRAKE RELAY
4
3
THERMOSTART
13
1
3
FUSEA2
122
810
5
BATTERY
14
IGN RELAY
106AR
6 FUSEA1
004
N/START RELAY
5 8 12
5
15/54
50a
003E
4 11
001A
200D
30
17
1 10
414A
9 415A
3 406A
2
403C
200B 200C
19
33 - Electrical System 00 - Electrical System 50 - Schematic Circuit
Page 33-23
103
104
3
1
347381
347381
33 - 21
001
200 200A
9813/6050-2 101AR
5
106T
877D
877A
5
125C +8
2
10
125B
4
1
3
2
23
23 80 81 82 106AF
1
1
4
403B
414B
406
434B
10
6
3
105
24
33 - 22
877
407
412
3
600DD 1
C
A
865A
2
37 2
3
1
865
865B
O/R
F
'W'
877E
JOYSTICK
SEAT
34
5
4
LATCHING RELAY
PRESS URE SWITCH
415B
434
411
LATCHING RELAY
5
4
CHARGE PUMP PRESS
407A
881
874
B
402
434A
407B
SEAT SWITCH
972
873A
2 866
1
3
TUV SEAT SWITCH (GERMAN BUILD ONLY)
35
9
8
3
2
3
2
877C
877B
ISOL RELAY
936A
936B
AIRFILTER
ENGINE OIL PRESS
HYD OIL TEMP
36
2
7
3
106C BUZZER
WATERTEMP
FLOAT SWITCH
83 84 85 1
0 HOURMETER
4
6
ENGINE SPEED INDICATOR UNIT
2
ALTERNATOR
25
27
106AE
5
3
-7 1
4
5
3
-7 1
23
106AD
2
+8
867
971
125D
125E
2
1
P/BRAKE SWITCH
21
415
403
414
23
106AC
6
4
3
1
-7
HI FLOW SWITCH
2
1
2
+8
842
28
106AB
106AA
106D
866A
815
106AK
AUXILIARY SWITCH
2
1
THERMOSTART
600V
SEAT POSITION SWITCH AUX SWITCH ILLUM AUX HYD FWD (FRONT)
600JU
600HX
600CU
600DE 600W
X
600CS
600CF
X
600JT
X
X
600HS
600HR
FLOAT SOLENOID
FLOAT SWITCH ILLUM
E.S.O.S.
CHARGE PUMP PRESSSWITCH
AIRFILTERSWITCH
ENGINE OIL PRESSSWITCH
HYD. OIL TEMP SWITCH
ENGINEWATERTEMP SWITCH
ALTERNATOR
HOURMETER
ENGINE SPEED INDICATOR UNIT
IGNITION RELAY
HI FLOW HYDRAULICS
AUX HYD REV (FRONT)
OVERRIDE SWITCH
600HC
600HB
600HY
OPERATION SOLENOID PARKBRAKE SOLENOID
600GV
NEUTRAL START RELAY P/BRAKE SWITCH ILLUM
STARTERSOLENOID
STARTERMOTOR
GLOW PLUGS
600CP
600GN
600DH
29
FUSEA6
FUSEA5
129
810B
810C
810A
810
122B
122A
P/BRAKE RELAY
4
3
22
26
Page 33-23
FUSEA4
FUSEA3
125
122
810
5
N/START RELAY
15 16
2
002
106AR
FUSEA2
FUSEA1
004
7 20
4
3
50a
6 14 13 19
1
17
5 8 12
5
15/54
19
4 11 18
001A
200D
30
1 10
IGN RELAY
200B 200C
BATTERY
9 406A
33 - 22 3 17
415A
2
414A
Figure 492. (Part 1 of 2)
403C
003E
33 - Electrical System 00 - Electrical System 50 - Schematic Circuit Page 33-22 Page 33-23
30 31 32 33
38
23
33 - 23 205B
9813/6050-2 816L
6
61 5
4
57
59
3
60 60
127D
57
869A
2
3
-7 1
807B
M
816E
816D
M
600EB
600BH
55
2
1 4
2
BRAKE LIGHT TIMERRELAY
816
839
840
M
58
BRAKE SWITCHES
10 SEC TIMER
+8
1
56
127B
REVERSESWITCHES 807A
5
2
FAST
800D
54
127C
127A
106H
WASH/WIPE SWITCH
840A
SLOW
HEATERRESISTOR
53
FUSEB9
103
800B
800
52
6
102A
M
806C
806E
805C
102
FUSEB8
2
3
51 4
50
5
1
-7
46 2
49 1
894
871B 871A INTERIORLIGHT
805B 806B
48
102A
HEATER SWITCH
+10
BEACON SWITCH
3
+3
-7 +1
101
102
106R
2
1
-7
871
2
1
47
FUSEB7
101
44 303A
8
2
43
2
+8
HORN SWITCH
106AP
803A
99
FUSEB6
45 303G
806P
803B
805E
97
106N
HAZARD SWITCH
805 803
802
IND SWITCH
100
303
106AP
+8
17 18
5
2
-10
98
FUSEA9
106F
3
2
95
312
300
1
FLASHER UNIT
861A
861B
96
FUSEA8
FUSEA10
104
31
42 49a
49
861
REARWORKLIGHT SWITCH
3
-7
93
2
1
855A
855B
94
FUSEB10
2
+8
41
117
23 FRONT WORKLIGHT SWITCH
855
91
106M
2
3
830D
830B
829E
829D
92
FUSEB5
2
-7
40
1
830
829
89
855C
FUSEB3
FUSEB2
829C
87
828M
828
834B 834A
90
116
+8
+3
834
M
88
ROADLIGHT SWITCH
2
833
FUSEB1
3
1
ROADLIGHT SWITCH
FLASHERUNIT INDICATORSWITCH LH FRONT INDICATOR LH REARINDICATOR
600G
600H
600G
600MJ
RH BRAKE LIGHT
BRAKE LIGHT TIMERRELAY LH BRAKE LIGHT
BRAKE LIGHT TIMERUNIT
WASHERMOTOR
600BG
REVERSEALARM
WIPERMOTOR
600AK
600AW
W/WIPE SWITCH ILLUM
600ED
600CD
HEATER MOTOR
JUNCTION BOX
600CC
600GR
BEACON
600AP
600DY
INTERIORLIGHT BEACON SWITCH ILLUM
600EL
600AJ
FRONT HORN REARHORN
600EY
600H
RH FRONT INDICATOR RH REARINDICATOR
HAZARD SWITCH ILLUM 600LA
600BL
RH REARWORKLIGHT 600AV
600DX
REARWORKLIGHT SWITCH LH REARWORKLIGHT
RH FRONT WORKLIGHT
600AR
600CK
LH FRONT WORKLIGHT
600AS
600AY
FRONT WORKLIGHT SWITCH
600CJ
RH SIDE LIGHT
RH TAIL LIGHT
LH SIDE LIGHT
LH TAIL LIGHT
No PLATE LIGHT
RH DIP BEAM
LH DIP BEAM
REARWIPERMOTOR
600BD
600DW
FLOAT SOLENOID
Figure 492. (Part 2 of 2)
106L
2
6
-7
5
37
2
LATCHING RELAY 4
86
200F
1
10
23
5
8+
8
PRESS URE SWITCH
35
9
3
6
39
200N
114
1
2
7
38
106K
FUSEA7
101AR
36
FUSEB4
Page 33-22
33 - Electrical System 00 - Electrical System 50 - Schematic Circuit Page 33-22
104
103
3
1
347381
347381
33 - 23
Page 33-23
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 81 83 85 87 89 91 93 95 97 99 101 103
Battery Starter motor Neutral start relay Park brake relay Operational solenoid TUV Seat switch (German machines only) Seat switch Auxiliary attachments switch Auxiliary hydraulics - Forward solenoid (Front) High - flow hydraulic solenoid Seat switch Diode Hourmeter Warning buzzer Engine coolant temperature switch Engine oil pressure switch Charge pump pressure switch Hydraulic float pressure switch Latching relay Rear wiper motor Front worklight switch Indicator switch and warning light Flasher unit Front horn Beacon switch Heater blower switch Heater blower Wiper motor Reverse alarm switches Brake light timer Lamps Engine coolant temperature warning Engine oil pressure warning Charge pump pressure warning RH Headlight dip LH Tail light RH Tail light LH Front worklight LH Rear worklight LH Front direction indicator RH Front direction indicator Interior light and switch LH Rear brake light
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 80 82 84 86 88 90 92 94 96 98 100 102 104
Glow plugs Starter solenoid Starter switch Park brake switch Park brake solenoid Override switch Isolator relay Joystick switch Auxiliary hydraulics - Reverse solenoid (Front) Latching relay High - flow hydraulic switch Ignition relay Engine speed indicator unit Alternator Hydraulic oil temperature switch Air cleaner warning switch Engine shut off solenoid Hydraulic float switch Hydraulic float solenoid Road lights switch Rear worklight switch Hazard warning switch Horn switch Rear horn (If installed) Junction box Heater blower resistor Washer motor Wash / Wipe switch and warning light Reverse alarm Brake light switches Alternator warning Hydraulic oil temperature warning Air cleaner warning LH Headlight dip Number plate light LH Side light RH Side light RH Front worklight RH Rear worklight LH Rear direction indicator RH Rear direction indicator Beacon light RH Rear break light
(For: Series 2) Series 2 Machines From SN 1743570
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
Page 33-26
33 - 25
Figure 493. Series 2 Machines From SN 1743570
9813/6050-2
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33 - 25
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-26
Page 33-27
Page 33-27
Figure 493. (Part 1 of 2)
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-26
Page 33-26
Figure 493. (Part 2 of 2)
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Page 33-27
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
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Figure 494.
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-30
Page 33-31
Page 33-31
Figure 494. (Part 1 of 2)
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-30
Page 33-30
Figure 494. (Part 2 of 2)
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Page 33-31
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
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33 - 33
Figure 495.
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33 - 33
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-34
Page 33-35
Page 33-35
Figure 495. (Part 1 of 2)
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-34
Page 33-34
Figure 495. (Part 2 of 2)
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Page 33-35
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
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33 - 37
Figure 496.
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33 - 37
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-38
Page 33-39
Page 33-39
Figure 496. (Part 1 of 2)
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-38
Page 33-38
Figure 496. (Part 2 of 2)
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Page 33-39
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
Page 33-42
33 - 41
Figure 497.
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33 - 41
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-42
Page 33-43
Page 33-43
Figure 497. (Part 1 of 2)
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-42
Page 33-42
Figure 497. (Part 2 of 2)
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Page 33-43
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
33 - 44
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
Page 33-46
33 - 45
Figure 498.
9813/6050-2
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33 - 45
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-46
Page 33-47
Page 33-47
Figure 498. (Part 1 of 2)
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-46
Page 33-46
Figure 498. (Part 2 of 2)
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Page 33-47
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
Page 33-50
33 - 49
Figure 499.
9813/6050-2
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33 - 49
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-50
Page 33-51
Page 33-51
Figure 499. (Part 1 of 2)
33 - 50
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33 - 50
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-50
Page 33-50
Figure 499. (Part 2 of 2)
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Page 33-51
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
33 - 52
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit
Page 33-54
33 - 53
Figure 500.
9813/6050-2
Page 33-55
33 - 53
33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-54
Page 33-55
Page 33-55
Figure 500. (Part 1 of 2)
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33 - Electrical System
00 - Electrical System 50 - Schematic Circuit Page 33-54
Page 33-54
Figure 500. (Part 2 of 2)
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Page 33-55
33 - Electrical System
00 - Electrical System 90 - Earth Point
90 - Earth Point Introduction The ground or earth refers to the reference point in an electrical circuit from which voltages are measured, a common return path for electrical current, or a direct physical connection to earth. Electrical circuits may be connected to ground or earth to prevent user contact with dangerous voltage if the electrical insulation fails. Earth points can be useful when tracing electrical faults typically when several electrical devices are malfunctioning.
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33 - Electrical System 03 - Battery
03 - Battery Contents
Page No.
33-03-00 General ........................................................................................................................... 33-59 33-03-03 Isolator Switch ................................................................................................................ 33-65
33 - 57
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Notes:
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33 - 58
33 - Electrical System 03 - Battery
00 - General
00 - General Introduction .................................................... Health and Safety .......................................... Fault-Finding .................................................. Disconnect and Connect ............................... Check (Condition) .......................................... Charge ...........................................................
Introduction 33-59 33-60 33-61 33-61 33-63 33-64
Batteries used in normal temperate climate applications should not need topping up. However, in certain conditions (such as prolonged operation in high ambient temperatures or if the alternator overcharges) the electrolyte level should be checked frequently and topped up as necessary. The electrolyte level should be checked in accordance with the routine maintenance schedule. Shorter maintenance intervals are required if the machine is operating at high ambient temperatures or continuously for long periods. Later Machines may have the new type batteries installed which include a sight glass to check the condition of the battery. New batteries should be used as replacements if replacing the battery on earlier machines. Figure 501.
A Maintenance free battery
Maintenance To make sure that the battery provides optimum performance the following steps should be observed: • •
•
Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion. When applicable - never allow the electrolyte level to fall below the recommended level of 6 mm above the plates. Use only distilled water for topping up. Keep the battery at least three quarters charged, otherwise the plates may become sulphated (hardened) - this condition makes recharging the battery very difficult.
Extra precautions must be taken when bench charging maintenance free batteries, they are more prone to damage by overcharging than the standard type of battery: •
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Never boost charge a maintenance free battery (if installed).
33 - 59
33 - Electrical System 03 - Battery
00 - General
• •
Never charge a battery at a voltage in excess of 15.8 V. Never continue to charge a battery after it begins to gas.
Quiescent Current Drain If the machine has no permanently live circuits there should be zero quiescent current drain, when the key-switch is off and all the lights are switched off. It should be noted that some permanently live circuits will place a quiescent drain on the battery. Typically the quiescent drain will be in the range of 10–20 mA. If the quiescent drain measures 40 mA or more, there is a problem with the wiring insulation or the accessories, if the fault is not rectified it will continue to drain the battery.
Health and Safety DANGER Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. 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, zips etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches to off before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first. Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait 5 min before connecting it up. When reconnecting, attach the positive (+) lead first. WARNING Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metal work. If it happens you can get burned. WARNING 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. WARNING Do not top the battery up with acid. The electrolyte could boil out and burn you. CAUTION Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. Notice: Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. CAUTION 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. DANGER If you try to charge a frozen battery, or jump start and run the engine, the battery could explode. Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge. CAUTION Damaged or spent batteries and any residue from fires or spillage must be put in a
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33 - Electrical System 03 - Battery
00 - General
suitable closed receptacle and must be disposed of in accordance with local environmental waste regulations. Notice: Before carrying out arc welding on the machine, disconnect the battery and alternator to protect the circuits and components. The battery must still be disconnected even if a battery isolator is installed.
Fault-Finding The most obvious sign of a battery problem is a machine not being able to start. However, because the battery is part of a larger electrical system connected to other parts of the machine, a flat battery may indicate another problem. If something else is going wrong in the electrical system, for example, a weak alternator, corrosion or loose connections, cold weather starting, electrical equipment being left on without the engine running, interrogate the cause of the problem. The best way to test the condition of the battery is with an electronic battery tester. Refer to BatteryCheck Condition. When the machine is not in use, make sure that the electrical system is not causing a drain on the battery. On machines with electronically controlled engines check the operation of the power hold relay. Refer to PIL 33-09-06.
Disconnect and Connect Notice: Before you install a pair of batteries to a machine, make sure you know the machines voltage. Some machines require two batteries but have a 12 V electrical system. This means the batteries need to be connected in parallel. For 24 V machines, the batteries must be connected in series. Incorrect voltage may result in serious damage to the electrical system.
Disconnect 1. Make the machine safe. Refer to: PIL 01-03. 2. Get access to the battery. Refer to: PIL 06-06. 3. If the machine has a battery isolator, move the switch to the OFF position, then remove the key. 4. Disconnect the negative battery lead first. 5. Disconnect the positive battery lead and store away from the battery. 6. Disconnect and remove the battery leads.
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33 - Electrical System 03 - Battery
00 - General
Figure 502. 12V Battery Connection (Example)
2.1. Connect the positive lead then the negative lead. 3. If the machine has a battery isolator, move the switch to the ON position. 4. Close and lock the access panels.
_
+ A
C
B
12 V A Battery B Positive lead C Negative lead
Connect 1. Check the battery as follows: 1.1. If any terminals are dirty, clean them. 1.2. If the terminal is corroded and has white powder, wash the terminal with hot water. Make sure the water does not enter the battery cells. 1.3. If considerable corrosion is found, then clean with a wire brush or abrasive paper. Make sure you use eye and hand protection. Refer to Figure 503. Figure 503.
1.4. After cleaning, apply a thin coat of petroleum jelly to the terminals. 2. Connect the leads. 33 - 62
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33 - Electrical System 03 - Battery
00 - General
Check (Condition)
Table 215. Fault Diagnosis
Battery Test This test is to determine the electrical condition of the battery and to give an indication of the remaining useful life. Before you test the battery, make sure that the battery is at least 75% charged (Specific Gravity of 1.23 to 1.25 for ambient temperature up to 27°C). Make sure that the battery disconnected from the vehicle.
is
completely
Figure 504.
Battery Tester Readings CHECK: 0 -12.6 Volts: LOAD: less than 6 Volts CHECK: 6 -12.4 Volts: LOAD: less than 9 Volts and falls steadily but remains in yellow zone CHECK: less than 10 Volts: LOAD: less than 3 Volts
Remedy Renew battery Recharge and re-test. If tests are still unsatisfactory renew battery
Indicates battery has been over-discharged and unlikely to recover. Renew battery CHECK: more than 11 Charge battery which Volts: LOAD: 6 - 10 Volts will probably recover steady
Specific Gravity Test The specific gravity of the electrolyte gives an idea of the state of charge of the battery. Readings should be taken using a hydrometer, when the electrolyte temperature is 15°C (60°F). If the battery has recently been on charge, wait approximately one hour (or slightly discharge the battery) to dissipate the surface charge before testing. Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell. If the electrolyte temperature is other than 15°C (60°F) a 'correction factor' must be applied to the reading obtained. Add 0.07 per 10°C (18°F) if the temperature is higher than 15°C (60°F) and subtract the same if the temperature is lower.
A Battery voltage switch B Check load switch Connect up the battery tester as follows:
Table 216. Specific Gravity at 15°C (60°F))
1. Set the Check Load switch to OFF. 2. Set the battery voltage switch to 12V. 3. Connect the red flying lead to the battery positive (+) terminal and the black flying lead to the battery negative (-) terminal. 4. Set the Check/Load switch to CHECK to read the battery no-load voltage which should be at least 12.4 volts.
Ambient Temperature degrees C (degrees F) Below 27 ( 80 ) Above 27 ( 80 )
Fully Charged
Half Discharged
Fully Discharged
1.270-1.290 1.190-1.210 1.110-1.130 1.240-1.260 1.170-1.190 1.090-1.110
5. Set the Check/Load switch to LOAD and hold down for 5-10 seconds until the meter reading stabilises. The reading should be at least 9 volts. 6. If the tests are unsatisfactory, refer to the fault diagnosis table.
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33 - Electrical System 03 - Battery
00 - General
Charge Precautions Before Charging Follow all the precautions described below, to prevent damage to the alternator and battery. 1. Make the machine safe. Refer to: PIL 01-03. 2. Make sure that the battery negative terminal is connected to the earth cable. 3. Do not connect or disconnect the battery or alternator connections, or any part of the charging circuit while the engine is in operation. If you disregard this instruction, the regulator or rectifying diodes will be damaged. 4. Main output cables are always in an active state of current flow even when the engine is not in operation. If the alternator connector is removed, do not earth the moulded plug. 5. When you do arc welding on the machine, remove the moulded plug (or if the separate output cables are installed, remove the cables) to protect the alternator. 6. If it is necessary to jump start the battery, do the following steps. 6.1. Connect a secondary battery in parallel without disconnecting the vehicle battery from the charging circuit. 6.2. Connect the batteries using suitable jump leads. Connect the positive lead to the positive terminals of both batteries. Connect the negative lead to the negative terminals of both batteries. 6.3. After the jump start, safely disconnect the jump leads and remove the secondary battery.
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33 - Electrical System 03 - Battery
03 - Isolator Switch
03 - Isolator Switch
Introduction
Introduction .................................................... 33-65 Disconnect and Connect ............................... 33-66
The battery isolator switch is used to disconnect the battery from the machine electrics. The switch must be turned to the OFF position if any maintenance work is to be performed on the machine. Some machine systems perform shut down cycles after the engine stops. Wait until shut down cycles are complete before setting the battery isolator switch to the OFF position. For more information refer to Disconnect and Connect. Refer to: PIL 33-03-00.
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33 - Electrical System 03 - Battery
03 - Isolator Switch
Disconnect and Connect Disconnect 1. Make the machine safe. Refer to (PIL 01-03). 2. Open the battery cover. Refer to (PIL 06-06). 3. Turn the battery isolation switch to the OFF position. 4. Remove the isolation key. Figure 505.
A
A Isolator switch
Connect 1. Install the isolation key. 2. Turn the battery isolation switch to the ON position. 3. Close battery cover. Refer to (PIL 06-06).
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33 - Electrical System
09 - Power Distribution
09 - Power Distribution Contents
Page No.
33-09-00 General ........................................................................................................................... 33-69 33-09-03 Fuse ............................................................................................................................... 33-71 33-09-06 Relay .............................................................................................................................. 33-74
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Notes:
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33 - Electrical System
09 - Power Distribution 00 - General
00 - General
Introduction
Introduction .................................................... 33-69 Health and Safety .......................................... 33-70
The electrical circuits are protected by fuses. If a fuse blows, find out why and rectify the fault before installing a new one. A full up to date list of fuses and relays and their locations can be found in the relevant operator manual, maintenance section.
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33 - Electrical System
09 - Power Distribution 00 - General
Health and Safety Notice: Always replace fuses with ones of correct ampere rating to avoid electrical system damage. Notice: When installing auxiliary electrical components always ensure that the additional load rating is suitable for that particular circuit. It is unacceptable to simply increase the fuse rating as this can cause overloading and consequential failure of wiring, along with failure of integral circuit components, which the fuse is protecting.
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33 - Electrical System
09 - Power Distribution 03 - Fuse
03 - Fuse Technical Data Figure 506. For Standard Machines
33 - 71
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
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33 - Electrical System
09 - Power Distribution 03 - Fuse
Figure 507. For Servo Machines B10
A10
B9
A9
B8
B7
B6
B5
B4
B3
B2
B1
A8
A7
A6
A5
A4
A3
A2
A1
C3
C2
C1
Table 217. Fuse A1 A2 A3 A4
A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8
(1)
33 - 72
Circuit(s) Protected Park brake switch supply Aux Hydraulic Switch, Float Switch & Joystick Switch Feed High Flow Switch Feed Hazard Switch, HeadLight Switch, Front WorkLight Switch, Heater Switch, Beacon Switch, Wash/Wipe Switch, Indicator Switch, Aux Hydraulic Switch, Illumination Feed, Buzzer, Water Temp, Hydraulic Oil Temp, Air Filter, Air Temperature Lamp Feed & Hour Meter Feed. Engine Speed Ind, ESOS, Fuel Pump Feed Heater Switch Feed Rear Wiper Feed Horn Feed Beacon Switch, Interior Light & Face Fan Feed Hazard Switch Illumination Feed Front Road lights Dip feed Left hand side lights Front/Rear & Number plate Right hand side lights Front/Rear Front Work lights Feed Rear Work lights Feed Power Socket Feed 2 Speed, Aux/Ext Dipper, Multifunction Attachment and Servo Harness
Amperage 10 A 15 A 5A 5A
Front Washer/Wiper Switch
10 A 9813/6050-2
5A 10 A 7.5 A 7.5 A 10 A 15 A 15 A 5A 5A 20 A 15 A 7.5 A 10 A
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33 - Electrical System
09 - Power Distribution 03 - Fuse
Fuse B9 B10 C1 C3 C2
Circuit(s) Protected Reverse Alarm Switch, Brake Light Switch and Brake Light Relay Hazard Switch Feed AUX OPPS Switch Feed Power MNG ECU4, PMS Warning Light, PMS Torque and Power MNG SET Servo Circuit Feed
Amperage 10 A 7.5 A 5A 20 A 25 A
(1) Fuse used on extending dipper option only.
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33 - Electrical System
09 - Power Distribution 06 - Relay
06 - Relay Technical Data Figure 508. For Standard Machines
R7
33 - 74
R6
R5
R3
R4
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R2
R1
33 - 74
33 - Electrical System
09 - Power Distribution 06 - Relay
Figure 509. For Servo Machines
R9
R8
R7
R6
R5
R4
R3
R2
R1
Table 218. Relay number R1 R2 R3 R4 R5 R6 R7 R8 R9
33 - 75
Circuit(s) Ignition 2 Isolator Ignition 1 Alarm buzzer Indicator flasher Park brake Horn Load relay 1 Load relay 2
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33 - Electrical System
12 - Harness
12 - Harness Contents
Page No.
33-12-00 General ........................................................................................................................... 33-77 33-12-23 Servo Hydraulic .............................................................................................................. 33-87 33-12-26 Joystick Controls ............................................................................................................ 33-95
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33 - Electrical System
12 - Harness 00 - General
00 - General Introduction .................................................... Health and Safety .......................................... Component Identification ............................... Repair ............................................................ Check (Condition) ..........................................
33 - 77
Introduction 33-77 33-78 33-79 33-81 33-83
Harness Drawings Drawings are reproduced from production electrical harness drawings. Each harness drawing includes tables showing wire connections and destinations for all the connectors on the harness. To identify the correct harness drawing for a particular machine refer to the relevant Harness Interconnection page for the machine serial number range.
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33 - Electrical System
12 - Harness 00 - General
Health and Safety Notice: When installing auxiliary electrical components always ensure that the additional load rating is suitable for that particular circuit. It is unacceptable to simply increase the fuse rating as this can cause overloading and consequential failure of wiring, along with failure of integral circuit components, which the fuse is protecting.
Harness Repair (Butane Heater) WARNING In addition to the warnings incorporated into this procedure, extreme care should be taken when handling the gas heating tool to ensure that the flame does not damage or set fire to any items in the vicinity of the repair, i.e. other wires, floor panels, floor mats, sound proofing, paintwork, etc. This tool should not be used in any restricted location prohibiting the use of "Naked Flames" or where risk of explosive gas or similar safety parameters apply. No other heat source should be used to attempt a sealed joint. CAUTION When the heater is in use, the reflector and the air coming out are extremely hot. Keep away to avoid accidental burns. Do not touch the reflector until it has had time to cool down after switching off. If flame reappears at the reflector when the heater is in use, the catalytic element is damaged or used up. Stop work immediately and replace the heater.
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33 - Electrical System
12 - Harness 00 - General
Component Identification Wire and Harness Number Identification This section details the allocation of wire numbers and the identification of wires in the wiring harness. Figure 510.
The illustration shows a typical connector and wires. Each wire has an individual identification number permanently marked on it, at regular intervals along it's length. The number stamped on the wire identifies the following:
Identification Number 819
Table 219. Wire and Harness Number Identification Identification Number # B
Description
9/371
The # indicates the start of the identification number. It is always printed to the left of the identification number. If applicable - The colour of the flying lead that the harness wire should mate with. For instance, if wire 819 from harness 719/37100 mated with a flying lead coloured black (colour code B) then the number printed on the wire would be B-819 9/371.
Description The wire's unique identification number. The wire functions and numbers allocated to them are consistent through out the JCB range of products. Refer to Wire Numbers and Functions. If applicable - The part number of the harness that the wire originates from. If the harness part number is 719/37100, the number printed on the harness wires will be 9/371 (71 and 00 are common numbers and therefore deleted).
Wire Numbers and Functions Table 220. Wires 000-199, 1000-1999 (These numbers are reserved for ignition feeds, heater start circuits and start circuits) Wire Number Wires 000 - 099 Wires 100 - 199 and 1000 -1999
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Description Unfused ignition feeds Fused ignition feeds (feeds via ignition relays are also classed as ignition feeds). Power supplies output by a control module.
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Table 221. Wires 200-399, 2000-3999 (These numbers are reserved for battery feeds) Wire Number Wires 200-299 and 2000-2999 Wires 300-399 and 3000-3999
Description Unfused battery feeds. Power supplies output by a control module. Fused battery feeds. Power supplies output by a control module.
Table 225. Wires In Splices Wire Number Various
Table 222. Wires 400-599, 4000-5999 Wire Number Wires 400-599 and 1000-5999
Description The main input wire is allocated with a wire number and a suitable description, i.e. Wire 640 earth splice to earth. The additional wires in the splice are allocated the same wire number and a postfix, i.e. 640A, 640B, etc. Figure 512.
Description These numbers are reserved for instruments, sensors and variable input/output signal wires used in electronic systems. CAN wires also use numbers in this series.
Table 223. Wires 600-799, 6000-7999 Wire Number Wires 600-799 and 6000-7999
Description These numbers are used for earth wires. When the number is printed on to a wire it is prefixed by the Earth symbol. This symbol is printed onto the wire, it may however be omitted from harness drawings. Where a load is switched negative, the wire number from the load to the switch shall be different to that of the wire from the switch to the earth. Figure 511.
General Points 1. Wires continue to have the same number even after passing through a connector block to another harness. 2. The descriptions are applicable to JCB specification wiring harnesses. The machine may be installed with some wiring that does not conform to the JCB specifications, typically when it is part of equipment supplied by other manufacturers.
600 Table 224. Wires 800-999, 8000-9999 Wire Number Wires 800-999 and 8000-9999
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Description These numbers are reserved for switched supplies to electrical loads, i.e. to lights, etc. Power supplies output by a control module.
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12 - Harness 00 - General
Repair Special Tools Description Wiring Crimp Tool Butane Heater Consumables Description Wiring Splice (0.5-1.5mm Red, contains 50 off) Wiring Splice (1.5-2.5mm Blue, contains 50 off) Wiring Splice (3-6mm Yellow, contains 50 off)
Part No. 892/00349 892/00350
Qty. 1 1
Part No. 892/00351
Size -
892/00352
-
892/00353
-
2. Using the correct sized splice, attach the new section of wire required or auxiliary flying lead to the existing harness and secure using the crimp tool. Note that each of the splices detailed is colour-coded to make size and range readily visible. They are secured using the corresponding size and matching colour-coded jaws of the crimp tool to ensure joint security. This tool also incorporates a ratchet closing mechanism which will not release until the splice is fully closed to the correct compression size. Consumable: Wiring Splice (0.5-1.5mm Red, contains 50 off) Consumable: Wiring Splice (1.5-2.5mm Blue, contains 50 off) Consumable: Wiring Splice (3-6mm Yellow, contains 50 off)
Instances occur where it is necessary to incorporate auxiliary electrical components into existing electrical circuits and although unlikely with present wiring harnesses, repair or replace specific individual wires within a harness. This will also apply to other machines in addition to those of manufacture.
3. With the Butane heater assembly, seal the connection.
To make sure that either the inclusion of an auxiliary electrical component or a repair within a harness is completed to an acceptable standard it is strongly recommended that the following tools, equipment and procedures are always used. Note that JCB harnesses have an Ingress Protection rating of 67 (I.P.67). The sheath covering of the recommended splice is heat shrunk onto the original wire insulation. This results in a seal and corresponding joint to IP 67 specifications.
Procedure 1. Cut the wire and remove the protective insulation for a suitable distance dependent upon the size of wire and splice to be used.
Special Tool: Butane Heater (Qty.: 1) 3.1. Remove the cap from the end of the disposable gas cartridge. Figure 514. A
B A Cap B Gas cartridge 3.2. Before assembling the gas cartridge to the reflector element, turn the red ring to the left, (in the direction of the minus sign marked on the ring). Figure 515.
Special Tool: Wiring Crimp Tool (Qty.: 1) Figure 513. A
C Reflector element D Red ring 3.3. Position the tube hanging down from inside the reflector assembly into the hole at the top of the gas cartridge. Then press the gas
A Distance for splice (check size) 33 - 81
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12 - Harness 00 - General
cartridge up into the reflector assembly as far as possible until the two elements are clasped firmly together. An audible click will be heard.
Figure 518.
Figure 516.
D Red ring
3.4. Turn the small ring so that the air holes are completely closed. Figure 517.
3.6. Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown. Hold the heater vertically for 1 to 2 minutes until the catalytic reaction occurs. This is indicated when the blue flame fades and the ceramic element glows red. Then turn the small ring until the air holes at are completely open. The tool is ready for use. Note: The fact that the sound of liquid cannot be heard when the cartridge is shaken does not mean it is empty. No sound will be heard even when the cartridge is full. Figure 519.
E Small ring F Air holes 3.5. Turn the red ring to the right (in the direction of the plus sign) in order to turn on the gas. Important: Before turning the heater on, make sure that the cartridge is not hotter than the reflector element. This may occur if the cartridge is held in the hand for a long time. The temperature difference between the cartridge and the reflector element may cause long yellow flames to appear on ignition.
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E Small ring F Air holes 3.7. The heater can be used in two modes: 3.8. Side wings down, reflector head completely open. In this mode the infra-red heat waves are dominant (recommended for the light coloured plastic splices).
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Check (Condition)
Figure 520.
This section describes how to use electrical measuring devices that are used in electrical fault finding.
Use of Multimeters
G Side wings 3.9. Side wings up, reflector head opening reduced. In this mode the heating is done only by the hot gas (use for dark coloured plastic splices). Figure 521.
In order to obtain the maximum benefit from the fault finding information contained in the Electrical Section, it is important that the technician fully understands the approach to fault finding and the use of the recommended test equipment, in this case a FLUKE 85 or AVO 2003 digital multimeter, or a moving pointer analogue multimeter. The approach is based on a fault finding check list. In tracing the fault from the symptoms displayed you will be directed to make measurements using a multimeter. These instructions are intended to cover the use of the recommended meters. 1. Make sure that the test leads are plugged into the correct sockets. The black test lead should be plugged into the black socket (sometimes, this socket is also marked by a -, or E or marked as COMMON or COM). The red test lead should be plugged into the red socket marked with +, V or Ί. 2. When you make a measurement, make sure that the test probes have a good clean contact with bare metal, free from grease, dirt, and corrosion as these can cause a false reading.
D Red ring G Side wings
3. When you measure a voltage, make sure that the correct range is selected, that it is set to the selector value equal to or greater than that you are about to measure. e.g. If asked to measure 12 Volts, set the selector to the 12V range. If there is no 12V range, set the selector to the next range higher, 20V for instance. If the meter is set to a range that is too low, it may be damaged. e.g. setting to the 2V range to measure 12V.
Measuring DC Voltage 1. Select the correct range on the multimeter. 1.1. On the digital multimeter, turn the switch to position B.
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Figure 523. AVO 2003 Multimeter
Figure 522. Fluke 85 Multimeter
1.2. On the AV0 meter, move the right slider switch to position A, and the left hand slider switch to the appropriate range.
1.3. On an analogue meter, turn the dial to the appropriate DC Volts range. Figure 524. Typical Analogue Multimeter
2. Connect the black probe to the nearest available suitable earth point, usually this will be the starter motor earth, the battery negative, or the chassis. Connect the red probe to the wire or contact from which you are measuring the voltage.
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Measuring Resistance
Measuring Frequency
1. Make sure that there is no power to the part of the circuit you are about to measure.
The AVO meter and the analogue meter are not capable of measuring frequency, therefore a digital multimeter must be used.
2. Connect one probe at one end of the component or wire to be checked and the other probe at the other end. It does not matter which way round the two probes are placed. 3. Select the correct range on the multimeter. 3.1. On the digital multimeter. Turn the switch to position C and check that the W sign at the right hand side of the display window is on. If the F sign is on instead, press the blue button G to change the reading to 立. Touch the meter lead probes together and press the REL3 key on the meter to eliminate the lead resistance from the meter reading. 3.2. On the AV0 meter, move the right hand slider switch to position B, and the left hand slider switch to the appropriate Ohms (立) range. 3.3. On an analogue meter, move the dial to the appropriate Ohms (立) range.
Measuring Continuity 1. Make sure that there is no power to the part of the circuit you are checking for continuity.
1. Insert the black plug into the COM socket on the meter and attach the probe to the nearest suitable earth point on the chassis, for example, the battery negative terminal. 2. Insert the red probe into socket J. 3. Turn the selector switch to position A and depress G repeatedly until F is highlighted on the top row of the display. 4. Press button H once. 5. Touch or connect the red probe to the frequency source to be measured. Press and hold the button if an average reading is required.
Testing a Diode or a Diode Wire A diode wire is a diode with male connector installed on one end and a female connector installed on the other end. The diode is sealed in heatshrink sleeving. To test a Diode or a Diode Wire. 1. On the digital multimeter: 1.1. Turn the switch to position D.
2. Connect one probe to one end of the component or wire to be checked and the other probe to the other end. It does not matter which way round the two probes are placed.
1.2. Press the HOLD button and check that the H sign appears at the top right hand side of the display window. 1.3. Connect the black probe to the end of the diode with a band or to the male connector of the diode wire. Connect the red probe to the other end of the diode or diode wire. If the beeper does not sound the diode or diode wire is faulty.
3. Select the correct range on the multimeter. 3.1. On the digital multimeter, turn the switch to position C and check that the beeper symbol appears at the left hand side of the display window. If the F sign is on instead, press the button labelled F. If there is continuity in the circuit, the beeper will sound. If there is no continuity (open circuit), the beeper will not sound.
1.4. Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. If the beeper sounds or the meter does not read O.L., the diode or diode wire is faulty.
3.2. On the AV0 meter, move the right hand slider switch to position B, and the left hand slider switch to position C. If there is continuity (i.e. very low resistance) between two points the buzzer will sound. 3.3. On an analogue meter, turn the dial to the lowest Ohms (立) range. If there is continuity (i.e. very low resistance) between two points the needle will move across fully (or almost fully) to the right hand side of the scale.
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1.5. Press the HOLD button and check that the H sign disappears from the right hand side of the display window. 2. On the AV0 meter:
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2.1. Move the right hand slider to position A, and the left hand slider switch to position C. 2.2. Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe should be connected to the other end of the 33 - 85
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diode or diode wire. If the Avo meter does not buzz the diode is faulty. 2.3. Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. If the Avo meter does not read 1 the diode is faulty. 3. On an analogue meter: 3.1. Select the Ohms 1000s (1k) range, connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe should be connected to the other end of the diode or diode wire. The meter should read 20-400 kΊ, if it reads more than this the diode is faulty. 3.2. Select the Ohms 100s range, connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. The meter should read 300-400Ί, if it reads less than this the diode is faulty.
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12 - Harness
23 - Servo Hydraulic
23 - Servo Hydraulic Diagram For: Series 2 ............................. Page 33-87 For: Series 1 ............................. Page 33-91
(For: Series 2) Figure 525. 333/U1474 Issue 1 (Sheet 1 of 4)
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33 - Electrical System
12 - Harness
23 - Servo Hydraulic
Figure 526. 333/U1474 Issue 1 (Sheet 2 of 4)
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12 - Harness
23 - Servo Hydraulic
Figure 527. 333/U1474 Issue 1 (Sheet 3 of 4)
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12 - Harness
23 - Servo Hydraulic
Figure 528. 333/U1474 Issue 1 (Sheet 4 of 4)
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12 - Harness
23 - Servo Hydraulic
(For: Series 1) Figure 529. 333/T7366 Issue 2 (Sheet 1 of 4)
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12 - Harness
23 - Servo Hydraulic
Figure 530. 333/T7366 Issue 2 (Sheet 2 of 4)
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12 - Harness
23 - Servo Hydraulic
Figure 531. 333/T7366 Issue 2 (Sheet 3 of 4)
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33 - Electrical System
12 - Harness
23 - Servo Hydraulic
Figure 532. 333/T7366 Issue 2 (Sheet 4 of 4)
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12 - Harness
26 - Joystick Controls
26 - Joystick Controls Diagram Figure 533. 333/T9226 Issue 1 (Sheet 1)
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33 - Electrical System 40 - Bulb
40 - Bulb Contents
Page No.
33-40-00 General ........................................................................................................................... 33-97
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33 - Electrical System 40 - Bulb
00 - General
00 - General Introduction Make sure the bulbs are replaced with the same type and rating as the damaged bulb.
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45 - Control Module
45 - Control Module Contents
Page No.
33-45-07 Power Management System (PMS) ............................................................................... 33-99 33-45-38 Auxiliary Circuits ........................................................................................................... 33-103
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33 - Electrical System
45 - Control Module
07 - Power Management System (PMS)
07 - Power Management System (PMS)
Component Identification
Component Identification ............................... 33-99 Check (Operation) ....................................... 33-100 Calibrate ...................................................... 33-101 Figure 534. PMS (Power Management System)
Table 226. PMS Connection Pin Details Pin 1 2 3 4 5 6 7 8
9 10 11 12
33 - 99
Configuration Earth Earth Earth Low side output Analogue Analogue
Function 0 V supply Not connected Not connected Diagnostic lamp Not connected Signal, angle sensor Frequency input Alternator input Switch input PMS (Power Management System) override Switch input Calibrate High side out- PMS valve put High side out- Not connected put Supply 12 V ignition supply 9813/6050-2
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33 - Electrical System
45 - Control Module
07 - Power Management System (PMS)
Check (Operation) Hydraulic pressure will not adjust during setting procedure: • • •
Faulty PMS (Power Management System) control switch. PMS solenoid valve failure. Main PMS ECU (Electronic Control Unit)fault.
Hydraulic pressure adjusts throughout setting procedure but settings are not stored on completion: This fault will prevent the wheel speed changing when the PMS control switch is adjusted. •
No RPM signal to PMS ECU Check W terminal is connected on alternator.
Table 227. PMS Fault blink codes Blink Code 1 2 3 4
33 - 100
Fault Code Description 1 Long flash 1 Short Signal from alternaflash tor W terminal absent or incorrect 1 Long flash 2 Short Sensitivity control flashes not working / fitted (torque screw) 1 Long flash 3 Short Dump valve soleflashes noid short circuit 1 Long flash 4 Short Dump valve soleflashes noid open circuit
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Test Method Comments Remove W terminal Fault code permanently on Disconnect twist pot Fault code correct Short to Earth Disconnect
Fault code does not work Fault code correct
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07 - Power Management System (PMS)
Calibrate
Figure 537.
Special Tools Description Pressure Gauge (0-40 Bar) Digital Tachometer Consumables Description Clear Silicone Sealant
Part No. 892/00278
Qty. 1
892/00284
1
Part No. 4102/0901
Size 0.31 L
C
1. Install reflective tape onto the pulley on the front of the engine. Figure 535.
C Blanking plug 6. Install the horn button to the connector. 7. Turn the PMS (Power Management System) switch fully clockwise.
A
8. Hold the red horn button. Figure 538.
A Reflective tape 2. Install a T-piece and a test point to the excavator pressure valve. D
3. Install the pressure gauge to the test point. Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) Figure 536.
D Red horn button 9. Turn the ignition on until the red light on the instrument panel flashes.
B
10. Release the button.
B Test point 4. Find the plug with two wires (No. 508/144C) in the fusebox. 5. Remove the blanking plug. 33 - 101
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45 - Control Module
07 - Power Management System (PMS)
Figure 539.
27. Put the ignition switch in OFF position, at least for the specified duration. The PMS is now set. Duration: 5 s 28. Remove the red horn button. 29. Install the plug. 30. Remove the loop wire. Figure 540.
E
E Red light on instrument panel 11. Start the engine. 12. Use a tachometer to take readings from the pulley with the reflected tape installed. Special Tool: Digital Tachometer (Qty.: 1)
F
13. Increase the engine RPM (Revolutions Per Minute) to 2460. At the same time, check the pressure gauge reading.
F Loop wire
14. Turn the PMS switch counterclockwise. 15. Press the red horn button when the pressure gauge shows the specified reading.
31. Install the blanking plug. 31.1. Apply silicon sealant to the plug to form a watertight fit.
Pressure: 10 bar ( 144.9 psi)
Consumable: Clear Silicone Sealant
16. Turn the PMS switch fully clockwise. 17. Use a tachometer to take readings from the pulley with the reflected tape installed. 18. Increase the engine RPM to 3440. At the same time, check the pressure gauge reading. 19. Turn the PMS switch counter clockwise. 20. Press the red horn button when you pressure gauge shows specified reading. Pressure: 20 bar ( 289.9 psi)
32. Make sure that the PMS works correctly. 33. Turn the PMS switch fully counterclockwise. 34. Hold the engine throttle on full RPM position. 35. Check the reading on the pressure gauge. Make sure that the pressure gauge shows the specified value. Pressure: 20 bar ( 289.9 psi)
21. Turn the PMS switch fully clockwise.
36. Continue to hold the engine throttle on full RPM position and turn the PMS switch fully clockwise.
22. Use a tachometer to take readings from the pulley with the reflected tape installed.
37. Make sure that the pressure gauge shows the specified value.
23. Maintain the engine RPM to 3440. At the same time, check the pressure gauge reading.
38. Slowly turn the PMS switch counterclockwise.
24. Turn the PMS switch counterclockwise. 25. Press the red horn button when the pressure gauge shows the specified reading. Pressure: 10 bar ( 144.9 psi) 26. Stop the engine.
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Pressure: 10 bar ( 144.9 psi)
39. Check the reading on the pressure gauge. Make sure that the reading on the pressure gauge slowly rises to the specified range. Pressure: 10 –20 bar ( 144.9 –289.9 psi) 40. Remove the pressure gauge from the test point.
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45 - Control Module 38 - Auxiliary Circuits
38 - Auxiliary Circuits
Component Identification
Component Identification ............................. 33-103 Check (Operation) ....................................... 33-104 Figure 541. Auxiliary ECU
Table 228. Auxiliary ECU Connection Pin Details Pin 1 2 3 4 5 6 7 8 9 10
11 12
33 - 103
Configuration Earth Earth Earth
Function 0 V supply 0 V common 0 V common thumbwheel Low side output Indication LED (Light Emitting Diode) 0 V Analogue Control solenoid 0 V Analogue 0 –5 V input from thumbwheel Switch input 12 V constant flow set input Not used Not used 5 V input 5 V reference input High side out- PWM (Pulse put Width Modulation) forward SOL output High side out- PWM reverse put SOL output + V Supply 12 V/ 24 V ignition supply
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45 - Control Module 38 - Auxiliary Circuits
Check (Operation) Auxiliary services not working in either directions •
• •
Figure 542. A
Thumb-stick control switch out of tolerance. This fault will generate a blink code on the switch panel as soon as the ignition is switched on. CT4/CT5 failure. Auxiliary ECU (Electronic Control Unit) fault.
C
Auxiliary services work in one direction only
B
D E
A blink code will be generated when the thumb-stick is moved in the non-operating direction. • •
CT4/CT5 failure. Auxiliary ECU fault.
Make sure that the thumb-stick centre position voltage is within 2.3 –2.7 V range.
A B C D E
CT2 brake solenoid CT1 servo isolator (feeds loader joystick pilot) CT5 auxiliary solenoid CT4 auxiliary solenoid CT3 PMS (Power Management System) solenoid/transmission
Table 229. Auxiliary Fault Blink Codes Blink Code 1
Fault Code 1 long flash 1 short flash
2
1 long flash 2 short flashes
3
1 long flash 3 short flashes 1 long flash 4 short flashes 1 long flash 5 short flashes 1 long flash 6 short flashes
4 5 6
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Description Joystick thumb wheel not in centre position Joystick thumb wheel reading high or low
Test Method Held thumb wheel out of position
Comments Fault code correct
Short pin 5 to pin 7 of thumb wheel
Auxiliary 5 V supply High value Right solenoid open circuit Right solenoid short or over temperature Left solenoid short or over temperature
5 V to pin B of voltage reg Solenoid 1 open circuit Solenoid 1 short circuit Solenoid 2 = CT4 short
Fault code correct for low, does not work for high (flashes code 3) Fault code correct
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Solenoid 1 = CT5 fault code correct Fault code correct Fault code correct
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33 - Electrical System
54 - Window Washer/Wipe
54 - Window Washer/Wipe Contents
Page No.
33-54-00 General ......................................................................................................................... 33-107 33-54-03 Tank .............................................................................................................................. 33-108
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Notes:
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33 - Electrical System
54 - Window Washer/Wipe 00 - General
00 - General Introduction The wash/wipe system is used to remove rain and debris from the front or rear window. The main components of the system are: • • • • • • • •
Wiper Arm. Wiper Blade. Nozzle (jet). Wiper Motor Mechanism. Tank (reservoir). Washer Pump. Wash/Wipe Switch. Multifunction Switch (intermittent settings).
speed
The wiper assembly consists of an arm, pivoting at one end with a long rubber blade attached to the other. The blade is swung back and forth over the glass, pushing water from its surface. The speed is normally adjustable, with several continuous speeds and often one or more intermittent settings. Some machines may use two wiper arms. The wipers operate together with the washer system. The washer pump supplies a mixture of water, alcohol, and detergent (washer fluid) from a tank to the windows through a hose. The fluid is dispensed through small nozzles mounted below the screen. It is essential the correct washer fluid is used as an incorrect fluid could freeze in colder climates and damage the pump. Although antifreeze is chemically similar to windscreen wiper fluid, it should not be used because it can damage the paintwork.
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33 - Electrical System
54 - Window Washer/Wipe 03 - Tank
03 - Tank Drain and Fill Consumables Description JCB Screenclear
Part No. 4006/0504
Size 1L
Drain 1. Make the machine safe. Refer to: PIL 01-03. 2. Get access to the window wash tank. Refer to: PIL 06-06-06. 3. Disconnect the electrical connection to the washer/wipe pump. 4. Disconnect the washer hose and allow the fluid to drain into a suitable container..
Fill 1. The fill procedure is the opposite of the drain procedure. 2. Fill the tank with the recommended washer fluid. Important: Do not use antifreeze. Consumable: JCB Screenclear
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33 - Electrical System
57 - Electronic Diagnostic
57 - Electronic Diagnostic Contents
Page No.
33-57-90 Fault Codes .................................................................................................................. 33-111
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Notes:
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33 - Electrical System
57 - Electronic Diagnostic 90 - Fault Codes
90 - Fault Codes Technical Data This machine has no diagnostic capability and therefore there are no fault codes.
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Notes:
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72 - Fasteners and Fixings Contents
Page No.
72-00 Fasteners and Fixings 72-00-00 General ............................................................................................................................. 72-3 72-03 Screws 72-03-00 General ............................................................................................................................. 72-7 72-06 Bolts 72-06-00 General ........................................................................................................................... 72-11 72-18 Bearings 72-18-00 General ........................................................................................................................... 72-15 72-21 Clips 72-21-03 Worm Drive .................................................................................................................... 72-17 72-36 Threaded Insert 72-36-00 General ........................................................................................................................... 72-23
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Notes:
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72 - Fasteners and Fixings
00 - Fasteners and Fixings
00 - Fasteners and Fixings Contents
Page No.
72-00-00 General ............................................................................................................................. 72-3
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Notes:
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72 - 2
72 - Fasteners and Fixings
00 - Fasteners and Fixings 00 - General
00 - General
Fastener Type Colour
Introduction
Zinc Nickel black Zinc flake black
JCB Fasteners (Before September 2017) Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines. The two types of fasteners can be readily identified by colour and part number suffix. Refer to Table 1. Fastener Types. Table 230. Fastener Type Colour Zinc and Yellow Golden Finish Dacromet
Mottled Silver Finish
Torque and Angle Tightening Insufficient pre-load of a bolted joint can cause major problems, such as cylinder head warp, leaking gasket joints etc. There are several methods of achieving an accurate pre-load of a bolted joint, the two main methods used on the JCB engine are: •
Part Number Suffix Z (e.g. 1315/3712Z) D (e.g. 1315/3712D)
Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener.
•
A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt. All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.
JCB Fasteners (After September 2017) Table 231. Fastener Type Colour
Part Number Suffix D (e.g. 1315/3712D)
Zinc flake-silver White aluminium (silver-grey), Dull Zinc and heavy Silver (Bright iri- V (e.g. trivalent passi- descent) 1315/3712V) vated with seal Zinc Nickel - sil- Dark, dull silver Not assigned ver/grey grey 72 - 3
Black, chalky texture Black, slight gloss
Part Number Suffix N (e.g. 1315/3712N) B (e.g. 1315/3712B)
Torque Control Tightening - Using a torque meter to control the torque is the most popular means of controlling pre-load, and in the majority of instances this method is adequate. It should be noted that with this process, the majority of the torque is used to overcome friction, therefore slight variations in the frictional conditions can lead to large changes in the bolt pre-load. Angle Control Tightening - Where a more precise pre-load is required, the torque and angle tightening method is used. The bolt is tightened to a predetermined torque (this may be done in stages), and then as a final sequence, the bolt is tightened to a predetermined angle - this method of tightening the bolts results in a smaller variation in the final pre-load. It is critical that the predetermined tightening angle is accurately achieved, failure to tighten accurately to the specified angle could result in the bolt pre-load being incorrect - this will lead to eventual failures. It is good practice to replace all bolts that have been tightened using the torque + angle procedure.
Tightening Method The following example explains the recommended torque and angle procedure. A torque angle gauge should be used for accuracy, but as a visual check, the bolts can be match marked as described below. 1. Tighten the bolt to the specified torque (specified torque values will be detailed in the relevant PIL sections). 2. Mark a line across the centre of the bolt, and a second line on the part to be clamped - the two lines should be aligned. Refer to Figure 543.
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Figure 543.
0°
3. Mark a third line at the specified torque angle - in this instance the additional torque angle is 90°. This line must be marked the specified angle in a clockwise direction (to further tighten the bolt). Refer to Figure 544. Figure 544.
+90°
4. In some instances, angle torque tightening can be specified in two stages, for instance in this example, the first angle quoted is 90° and then a second angle of 180°. The additional 180° angle is from the LAST tightened position. Refer to Figure 545. Figure 545.
+180°
+90°
5. Tighten the bolt so that the line on the bolt aligns with the angle(s) marked on the item to be clamped - remember, to ensure complete accuracy an angle gauge should be used.
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72-03-00 General ............................................................................................................................. 72-7
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03 - Screws 00 - General
00 - General
Introduction
Introduction ...................................................... 72-7 Technical Data ................................................. 72-8
Use the torque setting tables (Technical Data) only where no torque setting is specified in the text. Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate. Torque settings are given for the following conditions: Table 232. Up to September 2017 Type no coating 2 (obsolete from September 2017). 3, 4 (obsolete from September 2017).
Condition 1 Condition 2 Unlubricated fas- Zinc flake silver teners (Dacromet) fasteners. Zinc fasteners Lubricated zinc and yellow plated fasteners. Yellow plated fas- Where there is teners a natural lubrication. For example, cast iron components.
Table 233. From September 2017 Type no coating 1 5 7 8 9
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Condition 1 Unlubricated fasteners Zinc flake - silver Zinc and heavy trivalent with seal Zinc nickel - silver Zinc nickel - black Zinc flake - black
Condition 2 Dacromet) fasteners. Zinc flake silver (Dacromet) fasteners.
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72 - Fasteners and Fixings
03 - Screws 00 - General
Technical Data Table 234. Torque Settings - Internal Hexagon Headed Capscrews (Zinc) Bolt Size mm 3 4 5 6 8 10 12 16 18 20 24
72 - 8
N·m 2 6 11 19 46 91 159 395 550 770 1,332
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72-06-00 General ........................................................................................................................... 72-11
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Notes:
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00 - General
00 - General
Introduction
Introduction .................................................... 72-11 Technical Data ............................................... 72-12
Use the torque setting tables (Technical Data) only where no torque setting is specified in the text. Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate. Torque settings are given for the following conditions: Table 235. Up to September 2017 Type no coating 2 (obsolete from September 2017). 3, 4 (obsolete from September 2017).
Condition 1 Condition 2 Unlubricated fas- Zinc flake silver teners (Dacromet) fasteners. Zinc fasteners Lubricated zinc and yellow plated fasteners. Yellow plated fas- Where there is teners a natural lubrication. For example, cast iron components.
Table 236. From September 2017 Type no coating 1 5 7 8 9
Condition 1 Unlubricated fasteners Zinc flake - silver Zinc and heavy trivalent with seal Zinc nickel - silver Zinc nickel - black Zinc flake - black
Condition 2 Dacromet) fasteners. Zinc flake silver (Dacromet) fasteners.
Verbus-Ripp Bolts Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings. Figure 546.
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00 - General
Technical Data
Table 239. Torque Settings Coarse Metric Grade 8.8 Fasteners
From JCB standard STD00019 issue 15. 1. This information does not apply to:1.1. Hydraulic fittings (i.e. BSP, SAE O-ring boss, UNF, four bolt split flange and JIC). 1.2. Locking type fasteners (those with a nylon insert, or with distorted thread nuts such as Cleveloc). 2. For information on fastener conditions, refer to fasteners and fixings, bolts, general, introduction. Table 237. Torque Settings - UNF S Fasteners Bolt Size in (1/4 in) (5/16 in) (3/8 in) (7/16 in) (1/2 in) (9/16 in) (5/8 in) (3/4 in) (7/8 in) (1 in) (1 1/8 in) (1 1/4 in)
Treads Hexaper Inch gon (A/ F) in in 28 7/16 24 1/2 24 9/16 20 5/8 20 3/4 18 13/16 18 15/16 16 1 1/8 14 1 15/16 12 1 1/2 12 1 7/8 12 2 1/4
Condition 1
Condition 2
N·m 11.2 22.3 40 64 98 140 196 343 547 814 1,181 1,646
N·m 10 20 36 57 88 126 177 309 492 732 1,063 1,481
in (1/4 in) (5/16 in) (3/8 in) (7/16 in) (1/2 in) (9/16 in) (5/8 in) (3/4 in) (7/8 in) (1 in) (1 1/8 in) (1 1/4 in)
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Treads Hexaper Inch gon (A/ F) in in 28 7/16 24 1/2 24 9/16 20 5/8 20 3/4 18 13/16 18 15/16 16 1 1/8 14 1 15/16 12 1 1/2 12 1 7/8 12 2 1/4
Tread Pitch
mm 4 5 6 8 10 12 14 16 20 24 30 36
mm 0.7 0.8 1 1.25 1.5 1.75 2 2 2.5 3 3.5 4
Hexagon (A/ F) mm 7 8 10 13 17 19 22 24 30 36 46 55
Condition 1
Condition 2
N·m 2.9 5.8 9.9 24 47 83 132 205 400 690 1,372 2,399
N·m 2.6 5.2 9 22 43 74 119 184 360 621 1,235 2,159
Table 240. Torque Settings - Coarse Metric Grade 10.9 Fasteners
Table 238. Torque Settings - UNF X Fasteners Bolt Size
Bolt Size
Condition 1
Condition 2
N·m 17.6 35.2 64 101 155 221 310 542 864 1,285 1,865 2,598
N·m 15.9 31.6 57 91 139 199 279 488 777 1,156 1,679 2,339
Bolt Size
Thread Pitch
mm 4 5 6 8 10 12 14 16 20 24 30 36
mm 0.7 0.8 1 1.25 1.5 1.75 2 2 2.5 3 3.5 4
Hexagon (A/ F) mm 7 8 10 13 17 19 22 24 30 36 46 55
Condition 1
Condition 2
N·m 4 8.1 13.9 34 67 116 185 288 562 971 1,930 3,374
N·m 3.6 7.3 12.5 30 60 104 167 259 506 874 1,737 3,036
Table 241. Torque Settings - Coarse Metric Grade 12.9 Fasteners Bolt Size
Thread Pitch
mm 4 5 6 8 10 12 14 16
mm 0.7 0.8 1 1.25 1.5 1.75 2 2
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Hexagon (A/ F) mm 7 8 10 13 17 19 22 24
Condition 1
Condition 2
N·m 4.8 9.8 16.6 40 80 139 223 345
N·m 4.4 8.8 15 36 72 125 200 311 72 - 12
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00 - General
Bolt Size
Thread Pitch
mm 20 24 30 36
mm 2.5 3 3.5 4
Hexagon (A/ F) mm 30 36 46 55
Condition 1
Condition 2
N·m 674 1,165 2,316 4,049
N·m 607 1,048 2,084 3,644
Table 242. Torque Settings - Rivet Nuts / Bolts Bolt Size mm 3 4 5 6 8 10 12
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N·m 1.2 3 6 10 24 48 82
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18 - Bearings 00 - General
00 - General Check (Condition) 1. Carefully inspect all rollers, cages and cups for wear, chipping, or nicks to determine the condition of the bearings for further use. 2. Do not replace a bearing cone or cup individually. Replace the mating cup and the cone at the same time. 3. After inspection, lubricate the bearings with a suitable clean oil. 4. Wrap the bearings in clean lint free cloth or paper to protect them until you install the bearings again.
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72-21-03 Worm Drive .................................................................................................................... 72-17
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21 - Clips
03 - Worm Drive
03 - Worm Drive
Introduction
Introduction .................................................... 72-17 Technical Data ............................................... 72-18 Component Identification ............................... 72-21
Plain Worm Drive Clips There are three types of plain worm drive clips. • • •
Standard worm drive clip Heavy duty worm drive clip Spring assisted worm drive clip
Spring assisted worm drive clip contains a spring insert on the inside of the band to provide compensation against hose compression set. Use the torque setting tables (Technical Data) only where no torque setting is specified in the text.
Constant Torque Worm Drive Clips Your machine may be installed with constant torque worm drive clips. Use the torque setting tables (Technical Data) only where no torque setting is specified in the text.
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Technical Data Dimensions Figure 547. Plain Worm Drive Clips
C
J
H
K
A
B D Table 243. A Clamping range
B Band thickness
C Housing width
D Band width
H Hex size across flats
Standard worm drive clips and spring assisted worm drive clips 8 –16 mm 0.7 mm 13 mm 9 mm 7 mm 12 –22 mm 16 –27 mm up 0.8 mm 14.6 mm 12 mm to 60 –80 mm 70 –90 mm up to 160 –180 mm
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J Bolt and housing length
K Bolt and housing overall height
21 mm 21 mm 30 mm
11 mm 12.5 mm
36 mm
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03 - Worm Drive
A Clamping range
B Band thickness
C Housing width
D Band width
H Hex size across flats
J Bolt and housing length
Heavy duty worm drive clips 172 –206 mm 0.7 mm
K Bolt and housing overall height
23.1 mm
16 mm
7 mm
37 mm
13 mm
Figure 548. Constant Torque Worm Drive Clips
A
B Table 244. A Clamping range 14 –27 mm 25 –45 mm 32 –54 mm 45 –67 mm 54 –79 mm 70 –92 mm 83 –105 mm 95 –118 mm
B Band Width 14.2 mm 15.7 mm 15.7 mm 15.7 mm 15.7 mm 15.7 mm 15.7 mm 15.7 mm
Torque Values Table 245. Standard Worm Drive Clip Clamping range 8 –16 mm 12 –22 mm 16 –27 mm 72 - 19
Part number
Torque values
2201/0001 2201/0003 2201/0005
2 -0/+0.5 N·m 3 -0/+0.5 N·m 5 -0/+0.5 N·m
Clamping range 20 –32 mm 25 –40 mm 35 –50 mm 40 –60 mm 50 –70 mm 60 –80 mm
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Part number
Torque values
2201/0006 2201/0007 2201/0008 2201/0010 2201/0012 2201/0013
5 5 5 5 5 5
-0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m 72 - 19
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03 - Worm Drive
Clamping range 70 –90 mm 80 –100 mm 90 –110 mm 100 –120 mm 120 –140 mm 130 –150 mm 150 –170 mm 160 –180 mm
Part number
Torque values
2201/0014 2201/0015 2201/0016 2201/0021 2201/0017 2201/0018 2201/0019 2201/0020
5 5 5 5 5 5 5 5
-0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m
Table 246. Heavy Duty Worm Drive Clip Clamping range 172 –194 mm 184 –206 mm
Part number
Torque values
2201/0022 2201/0023
10 -0/+0.5 N·m 10 -0/+0.5 N·m
Table 247. Spring Assisted Worm Drive Clip Clamping range 16 –27 mm 20 –32 mm 25 –40 mm 30 –45 mm 35 –50 mm 40 –60 mm 50 –70 mm 60 –80 mm 70 –90 mm
Part number
Torque values
2206/1627 2206/2032 2206/2540 2206/3045 2206/3550 2206/4060 2206/5070 2206/6080 2206/7090
5 5 5 5 5 5 5 5 5
-0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m -0/+0.5 N·m
Table 248. Constant Torque Worm Drive Clips Clamping range 14 –27 mm 25 –45 mm 32 –54 mm 45 –67 mm 54 –79 mm 70 –92 mm 83 –105 mm 95 –118 mm
72 - 20
Part number
Torque values
334/J4514 334/J9549 333/K2259 OR 400/P2870 821/10236 821/10191 821/10192 332/K3479 332/S8033
5 N·m 10 N·m 10 N·m 10 N·m 10 N·m 10 N·m 10 N·m 10 N·m
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03 - Worm Drive
Component Identification
Figure 551. Spring Assisted Worm Drive Clip A B
Figure 549. Standard Worm Drive Clip A
B
C
C
D G D
F
E E F
A B C D E F
A B C D E F G
Screw support flange Asymmetric housing Asymmetric extension Short housing saddle Stamped inside Identification of material/clamping range
Screw support flange Asymmetric housing Asymmetric extension Short housing saddle Stamped inside Spring insert Identification of material/clamping range
Figure 552. Constant Torque Worm Drive Clips B
A
Figure 550. Heavy Duty Worm Drive Clip
F A
D
C
E
C
B
A Extended bridge B Band width ( 16 mm) C Identification of clamping range 72 - 21
A B C D E F
Housing Screw Belleville spring Saddle Liner Band
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36 - Threaded Insert
36 - Threaded Insert Contents
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72-36-00 General ........................................................................................................................... 72-23
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36 - Threaded Insert 00 - General
00 - General
Introduction
Introduction .................................................... 72-23 Technical Data ............................................... 72-24 Remove and Install ....................................... 72-24
A threaded insert also known as a rivet nut is a one piece fastener installed blind from one side of the machine body/framework. The threaded insert is compressed so that a section of its shank forms an upset against the machine body/framework, leaving a durable thread. Figure 553.
A Threaded insert B Durable thread Threaded inserts are installed to various parts of the machine body and framework. They are used in a number of applications, for instance, hose clamp and hydraulic valve retention etc. Various sized threaded inserts are available, refer to technical data to determine the correct size of threaded insert to be used for particular applications. If for any reason a new threaded insert is required, the correct installation procedure must be followed. Refer to: PIL 72-36-00.
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36 - Threaded Insert 00 - General
Technical Data
Remove and Install
Table 249. Specifications Thread Diameter mm M5 M5 M6 M6 M8 M8 M10 M10
Outside Diameter mm (inch) 7 7 9 9 11 11 13 13
Material Thickness mm (inch) 0.25 –3 3 –5.5 0.5 –3 3 –5.5 0.5 –3 3 –5.5 1 –3.5 3.5 –6
Total Rivet Length mm (inch) 14 17 16 19 18 21 23 26
Drill Hole Diameter mm (inch) 7.1 7.1 9.1 9.1 11.1 11.1 13.1 13.1
Consumables Description Part No. Threaded Insert (M10 x 826/01104 23mm) Threaded Insert (M10 x 826/01105A 26mm) Threaded Insert (M6 x 826/01099 16mm) Threaded Insert (M6 x 826/01101 19mm) Threaded Insert (M8 x 826/01102 18mm) Threaded Insert (M8 x 826/01103 21mm)
Size -
The threaded insert installation tool is available from Bolhoff Fastenings Ltd. www.bolhoff.com.
Install 1. Drill a hole in the machine body/framework where the threaded insert is to be installed, refer to technical data for the correct size. 2. De-burr the hole edges. 3. Screw the threaded insert on to the mandrel of the installation tool. The bottom of the mandrel should be in line with the bottom of the threaded insert. Consumable: Threaded Insert (M6 x 16mm) Consumable: Threaded Insert (M6 x 19mm) Consumable: Threaded Insert (M8 x 18mm) Consumable: Threaded Insert (M8 x 21mm) Consumable: Threaded Insert (M10 x 23mm) Consumable: Threaded Insert (M10 x 26mm) Figure 554.
A Threaded insert 4. Wind the body of the installation tool down the threaded mandrel until it touches the head of the threaded insert. 72 - 24
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36 - Threaded Insert 00 - General
Figure 555.
B Head of threaded insert 5. Insert the threaded insert (assembled to the tool) into the hole drilled in step 1. 6. Hold handle and at the same time draw the mandrel into the installation tool by turning nut. The threaded insert will contract in length and form an upset (smooth bulge) seating itself against the body/ framework. Note: The thread of the threaded insert must not be stripped, take care when upsetting the threaded insert. Figure 556.
C Handle D Nut E Body/Framework 7. Remove the installation tool.
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Notes:
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75 - Consumable Products Contents
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Acronyms Glossary .................................................................................................................................... 75-2 75-00 Consumable Products 75-00-00 General ............................................................................................................................. 75-3 75-00-03 Parts List .......................................................................................................................... 75-8 75-03 Oil 75-03-00 General ........................................................................................................................... 75-11 75-03-03 Engine ............................................................................................................................ 75-12 75-03-21 Refrigerant ...................................................................................................................... 75-14 75-06 Grease 75-06-00 General ........................................................................................................................... 75-17 75-09 Fluids 75-09-00 General ........................................................................................................................... 75-21 75-09-03 Antifreeze ....................................................................................................................... 75-22 75-10 Locking Fluids 75-10-00 General ........................................................................................................................... 75-25 75-14 Solvents and Primers 75-14-00 General ........................................................................................................................... 75-29 75-15 Adhesive 75-15-00 General ........................................................................................................................... 75-33 75-16 Sealant 75-16-00 General ........................................................................................................................... 75-39 75-18 Fuel 75-18-00 General ........................................................................................................................... 75-47
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Acronyms Glossary DEF
Diesel Exhaust Fluid
ISO
International Organization for Standardization
PTFE
Polytetrafluoroethylene
SAE
Society of Automotive Engineers
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75-00-00 General ............................................................................................................................. 75-3 75-00-03 Parts List .......................................................................................................................... 75-8
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00 - General
Introduction
Introduction ...................................................... 75-3 Health and Safety ........................................... 75-4 Technical Data ................................................. 75-6
JCB recommend that you use the JCB lubricants shown as they have been verified by JCB for use on JCB machines. However, you could use other lubricants that are equivalent to the JCB standards and quality or offer the same machine component protection. Before you start work, make sure that: • • •
All safety precautions are observed in accordance with the information contained within the relevant support documentation. The consumables are used in accordance with the manufacturer's recommendations. The consumables shown are available in the correct quantity.
Consumables other than those listed may be required. It is expected that general consumables will be available in any well equipped workshop or be available locally.
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Health and Safety 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.
Waste Disposal CAUTION It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. CAUTION Damaged or spent batteries and any residue from fires or spillage must be put in a suitable closed receptacle and must be disposed of in accordance with local environmental waste regulations.
Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear personal protective equipment. Hold a piece of cardboard close to suspected leaks and then examine the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. Fuel Fuel is flammable, keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions.
Hygiene JCB lubricants are not a health risk when used correctly for their intended purposes. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation. Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination. Whenever you are handling oil products you must 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, plus the following.
All waste products must be disposed of in accordance with all the relevant regulations. The collection and disposal of used oil must be in accordance with any local regulations. Never pour used engine oil into sewers, drains or on the ground.
Handling CAUTION The temperature of the hydraulic oil will be high soon after stopping the machine. Wait until it cools before beginning maintenance.
New Oil There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices.
Used Oil Used engine crankcase lubricants contain harmful contaminants. Here are precautions to protect your health when handling used engine oil: • •
Storage
•
Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers. • • • 75 - 4
Avoid prolonged, excessive or repeated skin contact with used oil Apply a barrier cream to the skin before handling used oil. Note the following when removing engine oil from skin:
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Wash your skin thoroughly with soap and water • Using a nail brush will help • Use special hand cleansers to help clean dirty hands • Never use petrol, diesel fuel, or paraffin for washing Avoid skin contact with oil soaked clothing Don't keep oily rags in pockets Wash dirty clothing before re-use 75 - 4
75 - Consumable Products
00 - Consumable Products 00 - General
•
Battery
Throw away oil-soaked shoes
Warning Symbols The following warning symbols may be found on the battery. Figure 557. A
B
C
D
E
F
A Keep away from children C No smoking, no naked flames, no sparks E Battery acid
B Shield eyes D Explosive gas F Note operating instructions
First Aid - Oil
Swallowing
Eyes
Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help.
In the case of eye contact, flush with water for 15min. If irritation persists, get medical attention.
Swallowing If oil is swallowed do not induce vomiting. Get medical advice.
Skin In the case of excessive skin contact, wash with soap and water.
Spillage Absorb with sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.
Fires 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.
First Aid - Electrolyte
Skin Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.
First Aid - DEF (if applicable) Do not drink or inhale DEF (Diesel Exhaust Fluid). If large quantities of DEF have been swallowed a doctor should be called immediately. Do not induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to an unconscious person. Avoid prolonged or repeated skin contact. After contact with skin wash thoroughly with plenty of soap and water. If irritation develops seek medical advice. Avoid contact with eyes, skin and clothing. Wear chemical resistant gloves, overalls and safety goggles complying with an approved standard. If in contact with eyes, rinse immediately with plenty of clean water. If irritation occurs seek medical attention. Always wash hands and arms thoroughly after handling before eating, drinking, smoking or using the lavatory.
Eyes In the case of eye contact, flush with water for 15 min. always get medical attention.
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Technical Data CAUTION Waxoyl contains turpentine substitute which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.
JCB recommend that you use the JCB lubricants shown as they have been verified by JCB for use on JCB machines. However, you could use other lubricants that are equivalent to the JCB standards and quality or offer the same machine component protection. No warranty liability will be accepted for engine failures where unacceptable fuel grades (or their equivalent) have been used at any stage.
Table 250. Item
Capacity
Fluid/Lubricant
Fuel tank Engine (oil) (2) 1CXWS
45 L 10.5 L
Diesel oil JCB engine oil EP 5W/40 20 °C ( 68.0 °F) to 50 °C ( 121.9 °F)
Engine (oil) (2) 1CXT
9.3 L
Engine (coolant)
(3)
11 L
Hydraulic system 80 L 1CXWS Hydraulic system 80 L 1CXT Grease points
Extending dipper
75 - 6
JCB Part Number
Con- Specification tainer (1) Size
4001/2705 20 L API CH-4/CG-4, CF-4,CF,SJ. ACEA, E2, B3, A3 JCB engine oil EP 15W/40 -10 4001/1805 API CH-4/SJ, ACEA °C ( 14.0 °F) to 50 °C ( 121.9 °F) E5, E3, B3, A3 JCB engine oil EP 5W/40 20 °C 4001/2705 20 L API CH-4/CG-4, ( 68.0 °F) to 50 °C ( 121.9 °F) CF-4,CF,SJ. ACEA, E2, B3, A3 JCB engine oil EP 15W/40 -10 4001/1805 API CH-4/SJ, ACEA °C ( 14.0 °F) to 50 °C ( 121.9 °F) E5, E3, B3, A3 JCB antifreeze HP coolant/ water 4006/1120 20 L ASTM D3306, ASTM D4985, ASTM D6210, SAE (Society of Automotive Engineers) J1034, BS6580 (1992), AFNOR NF R15601 JCB Optimum Performance Hy4002/2805 20 L draulic Oil JCB Ultra Performance Hydraulic 4002/2805 20 L Oil JCB special HP grease 4003/2017 0.4 kg (4) 4003/1501 0.4 JCB special MPL-EP grease kg JCB waxoyl 4004/0502 5 L
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75 - Consumable Products
00 - Consumable Products 00 - General
Item
Capacity
Chain case
Fill to level JCB engine oil HP 10W/30 plug Fill to level JCB engine oil HP 10W/30 plug
Slew oil
Fluid/Lubricant
JCB Part Number
Con- Specification tainer (1) Size 4001/1705 20 L 4001/1705 20 L
(1) For information about the different container sizes that are available (and their part numbers), contact your JCB dealer. (2) Caution - Do not use ordinary engine oil. (3) It is recommended that the cooling system be filled at a maximum rate of 10 litres per minute. If the fill rate is any higher than this there is a possibility of air becoming trapped in the system. (4) JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing must be carried out more frequently.
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75 - Consumable Products
00 - Consumable Products 03 - Parts List
03 - Parts List
Introduction
Consumables
Description Antifreeze HP/Coolant ASTM D6210 Concentrate
Black Polyurethane Sealant Black Primer/Activator Cleaner/Degreaser - General purpose solvent based parts cleaner Clear Silicone Sealant EP Hammer Grease Extreme Performance Moly Grease Glass Replacement Kit Hand Cleaner JCB Activator JCB Autogrease JCB Gear Oil HP JCB Glass Cleaner JCB Multi-Gasket JCB Retainer (High Strength) JCB Screenclear JCB Threadlocker and Sealer (High Strength) JCB Threadlocker and Sealer (Medium Strength) JCB Threadseal Polyurethane Adhesive Special HP Grease
Special Hammer Grease Special MPL-EP Grease
Special Slew Pinion Grease Special Slide Grease Surface Cleaning Fluid Threaded Insert (M10 x 23mm) Threaded Insert (M10 x 26mm) Threaded Insert (M6 x 16mm) Threaded Insert (M6 x 19mm) Threaded Insert (M8 x 18mm) Threaded Insert (M8 x 21mm)
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Part No. 4006/1101 4006/1120 4006/1103 4102/2310 4104/2304 4104/1557 4102/0901 4003/2107 4003/2106 4003/1327 4003/1326 993/55701 4104/1310 4104/0251 4104/0253 4003/2305 4000/0505 4000/0503 4006/3175 4102/1212 4101/0602 4006/0504 4101/0550 4101/0552 4101/0250 4101/0251 4102/1951 4103/2110 4003/2020 4003/2017 4003/2006 4003/2005 4003/1119 4003/1501 4003/1506 4003/1510 4003/1619 4003/1115 4103/1204 826/01104 826/01105A 826/01099 826/01101 826/01102 826/01103
Size 5L 20 L 200 L 0.31 L 0.1 L 0.4 L 0.31 L 0.4 kg 12.5 kg 0.4 kg 12.5 kg 0.2 L 1L 0.5 kg 20 L 200 L 0.75 L 0.05 L 0.05 L 1L 0.01 L 0.2 L 0.01 L 0.05 L 0.05 L 0.31 L 0.5 kg 0.4 kg 12.5 kg 50 kg 0.4 kg 0.4 kg 12.5 kg 50 kg 0.4 kg 0.4 kg 1L -
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75 - Consumable Products
00 - Consumable Products 03 - Parts List
Waxoyl
Description
Part No. 4004/0501A 4004/0502 4004/0505 892/00351 892/00352 892/00353
Wiring Splice (0.5-1.5mm Red, contains 50 off) Wiring Splice (1.5-2.5mm Blue, contains 50 off) Wiring Splice (3-6mm Yellow, contains 50 off)
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Size 0.4 L 5L 200 L -
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75 - Consumable Products 03 - Oil
03 - Oil Contents
Page No.
75-03-00 General ........................................................................................................................... 75-11 75-03-03 Engine ............................................................................................................................ 75-12 75-03-21 Refrigerant ...................................................................................................................... 75-14
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75 - Consumable Products 03 - Oil
00 - General
00 - General Introduction New Oil There are no special precautions needed for the handling or use of new oil, besides the normal health and safety practices mentioned in the relevant section of this service manual.
Used Oil Used engine crankcase lubricants contain harmful contaminants. Here are precautions to protect your health when handling used engine oil: 1. Avoid prolonged, excessive or repeated skin contact with used oil. 2. Apply a barrier cream to the skin before handling used oil. 3. Note the following when removing engine oil from skin: 3.1. Wash your skin thoroughly with soap and water. 3.2. Using a nail brush will help. 3.3. Use special hand cleansers to help clean dirty hands. 3.4. Never use petrol, diesel fuel, or paraffin for washing. 4. Avoid skin contact with oil soaked clothing. 5. Don't keep oily rags in pockets. 6. Wash dirty clothing before re-use. 7. Throw away oil-soaked shoes.
First Aid EYES - In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention. SWALLOWING - If oil is swallowed do not induce vomiting. Get medical advice. SKIN - In the case of excessive skin contact, wash with soap and water. SPILLAGE - Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area. FIRES - Extinguish with carbon dioxide, dry chemical or foam. Firefighters should use self-contained breathing apparatus. 75 - 11
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75 - Consumable Products 03 - Oil
03 - Engine
03 - Engine
Introduction
Introduction .................................................... 75-12 Technical Data ............................................... 75-13
New engines DO NOT require a running-in period. The engine/machine 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). The choice of lubricant viscosity should be made based on the lowest ambient temperature at which the machine will be started and the maximum ambient temperature at which it will operate. The technical data section provides guidance as to the temperature range that can be accommodated by standard oil viscosities and can be used to select an appropriate grade. When selecting the oil viscosity grade, make sure that the oil conforms with or exceeds the recommended specification.
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75 - Consumable Products 03 - Oil
03 - Engine
Technical Data Table 251. Engine Code SA, SB, SC, SK, SG, SD, SE, SF, DA, DB, DC, DE, DG, DD, DK, DF, EC, EE, EF, EK
Oil API Specification CF/ CH-4 CH-4 CH-4 CH-4
Viscosity SAE 5W30 SAE 15W40 SAE 10W40 SAE 5W40
Minimum Temperature °C ( °F) -30 °C ( -22.0 °F) -5 °C ( 23.0 °F) -15 °C ( 5.0 °F) -30 °C ( -22.0 °F)
Maximum Temperature °C ( °F) 30 °C ( 86.0 °F) 50 °C ( 121.9 °F) 46 °C ( 114.7 °F) 46 °C ( 114.7 °F)
Minimum Temperature °C ( °F) -30 °C ( -22.0 °F) -30 °C ( -22.0 °F) -5 °C ( 23.0 °F)
Maximum Temperature °C ( °F) 46 °C ( 114.7 °F) 46 °C ( 114.7 °F) 50 °C ( 121.9 °F)
Minimum Temperature °C ( °F) -30 °C ( -22.0 °F) -30 °C ( -22.0 °F) -15 °C ( 5.0 °F)
Maximum Temperature °C ( °F) 46 °C ( 114.7 °F) 30 °C ( 86.0 °F) 46 °C ( 114.7 °F)
Table 252. Engine Code SL, SH, DH, DM
Oil API Specification CH-4 CJ-4 CH-4
Viscosity SAE 5W40 SAE 5W40 SAE 15W40 Table 253.
Engine Code SJ, DJ, FL, FN
Oil API Specification CJ-4 CJ-4 CJ-4
Viscosity SAE 5W40 SAE 5W30 SAE 10W30 Table 254. Capacity
Engine Code SA, SB, SC, SK, SG, SD, SE, SF, DA, DB, DC, DE, DG, DD, DK, DF, SL, SH, DH, SJ, DJ, DM EC, EE, EF, EK FL, FN
Minimum 11.5 L
Maximum 14 L
20 L 12.3 L
24 L 14.5 L
For information on how to identify the correct engine code. Refer to (PIL 06-63-06)
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75 - Consumable Products 03 - Oil
21 - Refrigerant
21 - Refrigerant
Introduction
Introduction .................................................... 75-14 Health and Safety .......................................... 75-15
Refrigerants are the basic ingredient of all air conditioning systems and are used to transfer the heat energy around the system. Refrigerant type R134a is used in the air conditioning system. It's full chemical name is: 1, 1, 1, 2 - Tetrafluoroethane (CH²FCF²). R134a is a HFC (Hydrofluorocarbon) and is nontoxic, non-flammable and non-explosive at normal atmospheric temperature and pressure. It can be flammable under certain pressure and air mixtures. Due to environmental concerns, the use of ozone depleting chlorofluorocarbons (CFCs) in the air conditioning systems is being gradually phased out. The R-12 refrigerant used in some systems contains CFCs. Air conditioning systems using R-134a refrigerant are not compatible with systems using R-12 refrigerant. No attempt should be made to charge R-134a systems with R- 12 refrigerant. Important: Refer to the safety procedures within the Air conditioning section before handling refrigerants. Good installation practice is required to avoid the release of refrigerant into the atmosphere. Refrigerant R134a contains no chlorine and has an Ozone Depleting Potential (ODP) of zero, and a Global Warming Potential (GWP) of 0.1.
PAG Type Refrigerant Oil The system requires a PAG type refrigerant oil to lubricate the compressor. The oil mixes with the refrigerant and is carried around the system. It is important that the recommended grade of refrigerant oil is used. Mineral oil is not suitable for R134a refrigerant systems. Do not mix oil types. The compressor is supplied with an oil charge, but additional oil will be required when the receiver drier is replaced. The oil is added to the compressor through the oil filling plug before the evacuation procedure is started. Only use fresh, unused oil. Oil that has been exposed to the air will have absorbed water.
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75 - Consumable Products 03 - Oil
21 - Refrigerant
Health and Safety CAUTION Polyalkylene Glycol (PAG) type oil is an irritant. It can cause skin irritation. Breathing PAG vapour can cause irritation of the eyes, nose and lungs. Prolonged inhalation can cause drowsiness. WARNING Polyalkylene Glycol (PAG) type oil vapour is extremely flammable. Do not smoke or eat near PAG contaminated material. Exercise caution when working around hot and moving engine parts.
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75 - Consumable Products
06 - Grease
06 - Grease Contents
Page No.
75-06-00 General ........................................................................................................................... 75-17
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75 - Consumable Products
06 - Grease 00 - General
00 - General
5. JCB Autogrease
Introduction
6. JCB EP Hammer Grease
Consumable: JCB Autogrease
Special Tools Description Grease Gun Attachment Grease Gun Consumables Description EP Hammer Grease Extreme Performance Moly Grease JCB Autogrease Special HP Grease
Special Hammer Grease Special MPL-EP Grease Special Slew Pinion Grease Special Slide Grease
Consumable: EP Hammer Grease
Part No. 892/00913
Qty. 1
992/11300
1
Part No. 4003/2107 4003/2106 4003/1327 4003/1326 4003/2305 4003/2020 4003/2017 4003/2006 4003/2005 4003/1119
Size 0.4 kg 12.5 kg 0.4 kg 12.5 kg 0.5 kg 0.5 kg 0.4 kg 12.5 kg 50 kg 0.4 kg
4003/1501 4003/1506 4003/1510 4003/1619
0.4 kg 12.5 kg 50 kg 0.4 kg
4003/1115
0.4 kg
7. JCB Special Hammer Grease Consumable: Special Hammer Grease 8. JCB Special Slew Pinion Grease
There are various greasing points on the machine. You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. You must grease the machine as stated in the maintenance schedule. Refer to: PIL 78-24. JCB grease is manufactured to provide significant load protection for your machine. It is recommended to use only JCB grease on your machine because they are specifically designed for the particular application. The list of JCB greases comprises: 1. JCB Special HP Grease Consumable: Special HP Grease 2. JCB Special MPL-EP Grease Consumable: Special MPL-EP Grease 3. JCB Extreme Performance Moly Grease Consumable: Grease
Extreme
Performance
4. JCB Special Slide Grease Consumable: Special Slide Grease 75 - 17
Moly
Consumable: Special Slew Pinion Grease
Greasing Procedure 1. Make the machine safe. Refer to: PIL 01-03. 2. If necessary, install articulation struts.
any
maintenance
or
3. Make a note of the following: 3.1. The machine must always be greased after pressure washing or steam cleaning. 3.2. Greasing must be done with a grease gun. Normally, two strokes of the gun should be sufficient. Special Tool: Grease Gun (Qty.: 1) Special Tool: Grease Gun Attachment (Qty.: 1) 3.3. Stop greasing when fresh grease appears at the joint. 3.4. Use only the recommended type of grease. 3.5. Do not mix different types of grease, keep them separate. 4. Count off the grease points as you grease each one. 5. Install the dust caps after greasing (if installed).
JCB Special HP Grease JCB Special HP grease is a premium quality, extreme pressure grease. It is recommended for use in arduous operating conditions, such as high temperatures, excessive loading and extensive exposure to water. The sophisticated additive package combines with excellent adhesive properties to give high performance protection to your machine. Table 255. JCB Special HP Grease Properties Description Colour Soap type
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Data Blue Lithium complex
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75 - Consumable Products
06 - Grease 00 - General
Description Drop point Working temperature range
Table 258. JCB Special Slide Grease Properties
Data 245 °C ( 472.7 °F) -20 –150 °C ( -4.0 – 301.8 °F)
JCB Special MPL-EP Grease JCB Special MPL-EP grease is a true multipurpose grease. It is recommended for a wide range of lubricating applications, such as pivot pins and wheel bearings, where excellent anti wear and anti rust performance is required. Its EP additive makes it particularly suitable for the shock load and vibrating conditions found on machines. Table 256. JCB Special MPL-EP Grease Properties Description Colour Soap type Drop point Working temperature range
Data Brown Lithium 180 °C ( 355.7 °F) -20 –130 °C ( -4.0 – 265.8 °F)
JCB Autogrease JCB Autogrease is for use with the automatic greasing system. It is a mineral oil based paste. It contains an aluminium complex soap and solid lubricants. It is suitable for use under water or in high ambient temperatures. The specially designed cartridges screw into the automatic greasing system installed on the machine.
Table 259. JCB Autogrease
JCB Extreme Performance Moly grease is an advanced performance, multipurpose grease. It is recommended for heavily loaded bearing surfaces and in particular where limited or oscillating motion causes fretting. The addition of molybdenum disulphide provides extra protection against scoring and wear. This grease is ideal for automotive, industrial, agricultural and earthmoving equipment. Table 257. JCB Extreme Performance Moly Grease Properties Data Grey Black Lithium 185 °C ( 364.7 °F) -20 –120 °C ( -4.0 – 247.8 °F)
Description Colour Soap type Drop point Working temperature range
Data Black Aluminium complex, solid lubricants 260 °C ( 499.6 °F) -20 –110 °C ( -4.0 – 229.8 °F)
JCB EP Hammer Grease JCB EP Hammer grease is a unique formulation aluminium complex grease for use where extremes of pressure and temperature are likely to be encountered. It is suitable for the hammer applications where resistance to water washing and migration may be critical. Table 260. JCB EP Hammer Grease
JCB Special Slide Grease JCB Special Slide grease is formulated to provide excellent protection under heavy load and extreme pressure, where water and dirt are prevalent. It maintains a film of lubrication on slow moving slides. It has an excellent resistance to squeeze out and superb corrosion resistance.
75 - 18
Data Dark grey Lithium 180 °C ( 355.7 °F) -20 –120 °C ( -4.0 – 247.8 °F)
The clear cartridge allows the operator to easily monitor the grease usage from inside of the operator station.
JCB Extreme Performance Moly Grease
Description Colour Soap type Drop point Working temperature range
Description Colour Soap type Drop point Working temperature range
Description Colour Soap type Drop point Working temperature range
Data Black Aluminium complex 250 °C ( 481.6 °F) -20 –160 °C ( -4.0 – 319.8 °F)
JCB Special Hammer Grease JCB Special Hammer grease provides a highly effective lubricant on slow moving slides and an excellent corrosion resistant property. It combines the self healing action of oils and the resistance to drip of viscous compounds.
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75 - Consumable Products
06 - Grease 00 - General
Table 261. JCB Special Hammer Grease Description Colour Soap type Drop point Working temperature range
Data Dark grey Lithium 185 °C ( 364.7 °F) -15 –120 °C ( 5.0 –247.8 °F)
JCB Special Slew Pinion Grease JCB Special Slew Pinion grease is a soft, black and tenacious grease. It is designed specifically for the lubrication of large and heavy duty open gears. It has an excellent corrosion protection and load carrying properties throughout a large temperature range. Table 262. JCB Special Slew Pinion Grease Description Colour Soap type Working temperature range
75 - 19
Data Black Organically modified clay -40 –100 °C ( -39.9 – 211.9 °F)
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75 - Consumable Products
09 - Fluids
09 - Fluids Contents
Page No.
75-09-00 General ........................................................................................................................... 75-21 75-09-03 Antifreeze ....................................................................................................................... 75-22
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75 - Consumable Products
09 - Fluids
00 - General
00 - General Introduction It is most important that you read and understand this information and the publications referred to. Make sure all your colleagues who are concerned with lubricants read it too.
Hygiene JCB lubricants are not a health risk when used properly for their intended purposes. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation. Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination. Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following.
Storage Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers.
Waste Disposal All waste products should be disposed of in accordance with all the relevant regulations. The collection and disposal of used oil should be in accordance with any local regulations. Never pour used engine oil into sewers, drains or on the ground.
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75 - Consumable Products
09 - Fluids
03 - Antifreeze
03 - Antifreeze
Introduction
Introduction .................................................... 75-22 Health and Safety .......................................... 75-23 Technical Data ............................................... 75-23
Coolant Mixtures Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period. Do not use solutions of more than 60% or damage to the engine may occur. Replace the coolant mixture according to the intervals shown in the machine's maintenance schedule. You must dilute full strength antifreeze with clean water before use. Use clean water of no more than a moderate hardness (pH value 8.5). If this cannot be obtained, use de-ionized water. For further information advice on water hardness, contact your local water authority. The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion. Always renew the antifreeze every two years. The protection provided by High Performance Antifreeze and Inhibitor is shown below. If any other antifreeze is used, refer to the manufacturer's instructions and make sure that a corrosion inhibitor is included. Table 263. Solution 50% Concentration (Standard) 60% Concentration (Standard)
Maintains circulation down to: -33 °C ( -27.4 °F)
Protects against damage down to: -40 °C ( -39.9 °F)
-42 °C ( -43.5 °F)
-56 °C ( -68.7 °F)
Important: Do not exceed a 60% concentration, as the freezing protection provided reduces beyond this point. If you use any other brand of antifreeze: • • • •
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Make sure that the antifreeze complies with International Specification ASTM D6210. Always read and understand the manufacturer's instructions. Make sure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used. Make sure that the antifreeze is ethylene glycol based and does not use Organic Acid Technology (OAT).
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75 - Consumable Products
09 - Fluids
03 - Antifreeze
Health and Safety
Technical Data
CAUTION The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system. CAUTION Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze.
Table 264. Description Capacity Specification JCB Part Number
Data 11 L Antifreeze HP/Coolant ASTM D6210 Concentrate 4006/1120
Coolant Mixtures 1. Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period. 2. Replace the coolant mixture as per the maintenance schedule. Refer to (PIL 78-24). 3. You must dilute full strength antifreeze with clean water before use. Use clean water of no more than a moderate hardness (pH value 8.5). If this cannot be obtained, use de-ionized water. For further information advice on water hardness, contact your local water authority. The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion. As an example, the protection provided by JCB High Performance Antifreeze and Inhibitor is given below. • •
50 % concentration (Standard) protects against damage down to -40 °C ( -39.9 °F). 60 % concentration (Extreme Conditions Only) protects against damage down to -40 °C ( -39.9 °F).
Do not exceed a 60 % concentration, as the freezing protection provided reduces beyond this point. If you use any other brand of antifreeze, do the following: 1. Make sure that the antifreeze complies with international specification ASTM D6210. 2. Always read and understand the manufacturer's instructions. 3. Make sure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used. 4. Make sure that the antifreeze is ethylene glycol based and does not use OAT (Organic Acid Technology).
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75 - Consumable Products
10 - Locking Fluids
10 - Locking Fluids Contents
Page No.
75-10-00 General ........................................................................................................................... 75-25
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75 - Consumable Products
10 - Locking Fluids 00 - General
00 - General
Introduction
Introduction .................................................... 75-25 Technical Data ............................................... 75-26
All locking fluids should be used at all times in line with the manufacturer’s recommendations. Locking fluids are used for the locking of threaded fasteners and for the retention of ball & roller bearings and similar cylindrical items on to shafts and into housings. These fluids consist of an anaerobic resin in a liquid form which hardens when confined between closely fitting metal to metal and many metal to non-metal surfaces. The fluids available possess a wide span of break-loose strengths, viscosities and gap filling properties and are marketed for a variety of locking and retaining purposes requiring different strength grades. Some of the sealants in use in JCB are also of anaerobic resin type and only differ from the locking fluids in respect of viscosity and other technical details.
Strength grades Various strength grades of fluid are available, the highest strength type for permanent locking where disassembly is unlikely, medium strength for permanent locking but allowing disassembly with ordinary tools and low strength for locking of components where frequent adjustment or easy dismantling is required. It is recommended that trials be carried out before scheduling locking fluids for any new type of application that has not been already proved as satisfactory in production or when use at elevated temperatures is intended. Additional technical information is normally available from the product manufacturers.
Approved locking fluids The table shown in Technical Data shows the approved locking fluids available to use on JCB machines. The table also provides basic details to help with selection of locking fluids. More up to date information can be found on the manufacturer’s website.
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10 - Locking Fluids 00 - General
Technical Data Table 265. Locking Fluids Approved Product Information Subsection High strength
Commer- Product Colour cial name Number Loctite 4101/0100 Green (1) fluores270 cent R.A.S. Red threadlock (1) for studs High Loctite 4101/1400 Green, strength 638 UV fluorescent
Shelf Strength life 365 80 –120 bar d ( 1,159.4 – 1,739.1 psi) breakaway strength
For the retention of threads up to M20 diameter where disassembly is unlikely and for locking bearings etc. onto shafts and into housing. Has a maximum gap fill of 0.05 mm.
365 d
Maximum gap fill of 0.25 mm. Maximum strength at room temperature.
High Perstrength mabond (1) A115 Loctite 262
4101/0500 Red, flu- 365 oresd cent
High Loctite strength 648(1) Permabond A118
4101/0600 Green, 365 fluores- d cent
High Loctite strength 2701
4101/1700 Green
365 d
Medium Loctite to high 243
4101/1100
Blue
365 d
Medium Perstrength mabond (1) A119
4101/0900 Blue
365 d
Medium Loctite strength 640
4101/1200 Green, 365 fluores- d cent
75 - 26
More than 250 bar ( 3,623.2 psi) compressive shear strength 100 – 150 bar ( 1,449.3 – 2,173.9 psi) prevailing strength More than 250 bar ( 3,623.2 psi) compressive shear strength 260 – 500 bar ( 3,768.1 – 7,246.3 psi) breakaway torque 140 – 340 bar ( 2,029.0 – 4,927.5 psi) breakaway torque 80 –120 bar ( 1,159.4 – 1,739.1 psi) static shear strength 150 – 330 bar ( 2,173.9 – 4,782.6 psi) static shear strength
9813/6050-2
Comments
Fast curing ( 10 –15 min) thread locking up to M20, especially for use on oily surfaces, plated and clean parts.
Designed for holding gears and sprockets onto gearbox shafts and rotors on electric motor shafts.
Designed for permanent locking and sealing of threaded fasteners. Particularly suited for use on inactive substrates and/or where maximum resistance to hot oil is required. Suitable for all nuts, bolts, screws up to M36.
Maximum gap fill of 0.25 mm. Handling strength in 10 –15 min.
Product has a slow cure rate, used on parts unlikely to be disassembled.
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75 - Consumable Products
10 - Locking Fluids 00 - General
Subsection Medium strength
Commer- Product cial name Number Loctite 4101/0200 (1) 242 Permabond A1042 Permabond A113
Colour
Shelf Strength life Blue, 365 80 –120 bar fluores- d ( 1,159.4 – cent 1,739.1 psi) static shear strength
Low Loctite strength 222
4101/0300 Purple, 365 fluores- d cent
Low Perstrength mabond A1098
4101/1500 Blue
365 d
Low Loctite strength 567
4101/1600 Offwhite
365 d
Very low Loctite strength 932(1) Permabond A011
4101/0400 Brown/ red
365 d
Comments
Suitable for all nuts, bolts and screws up to M36 and hydraulic fittings up to 25mm in diameter. Permabond A113 and A1042 are the preferred choices. The difference between A113 and A1042 is timing for handling and working strength. A113 handling time 10 –25 min, working strength 1 h. A1042 handling time 5 –10 min, working strength 30 min. 15 –40 bar For screwed fasteners up to M20 that re( 217.4 – quire easy disassembly or frequent ad579.7 psi) justment. Maximum gap fill of 0.05 mm. Achieves handling strength in 10 –30 min. 120 bar Allows dismantling of parts for mainte( 1,739.1 nance. Suitable for sealing small hydraulic psi) shear and pneumatic fittings. Handling strength in strength 5 –10 min. 17 bar For the locking and sealing of metal ta( 246.4 psi) pered threads and fittings. High lubricatbreakaway ing properties prevent galling on stainless torque steel, aluminium and all other metal pipe threads and fittings. 7 –18 bar Can be disassembled with hand tools. 10 ( 101.4 –30 min cure time for handling strength. –260.9 Used on large diameter screw threads bigpsi) averger than 50mm. age shear strength
(1) This is a non preferred product.
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14 - Solvents and Primers
14 - Solvents and Primers Contents
Page No.
75-14-00 General ........................................................................................................................... 75-29
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75 - Consumable Products
14 - Solvents and Primers 00 - General
00 - General
Introduction
Introduction .................................................... 75-29 Technical Data ............................................... 75-30
This section contains information on primers, solvents, cleaning solutions etc. that are in use at JCB. All primers and solvents should be used at all times in line with the manufacturer’s recommendations.
Approved primers and solvents The table shown in Technical Data shows the approved primers and solvents available to use on JCB machines. The table also provides basic details to help with the selection of primers and solvents. More up to date information can be found on the manufacturer’s website.
75 - 29
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14 - Solvents and Primers 00 - General
Technical Data Table 266. Primers and Solvents Approved Product Information Subsec- Commer- Product Colour tion cial name Number Activa- Loctite 332/U7901 Colourtor/Primer 770 less
Shelf life 365 d
Activator Loctite 7455
4104/1700 Clear amber
730 d
Activator Loctite 7471 Permabond A905 Water Loctite proofing water proofing Solvent Loctite 7063
4104/0200 Colour- 365 less d
Cleaning Loctite fluid 7070
4101/2200 Colour- 365 less d
4104/0500 -
-
4104/1500 Colour- 365 less d
Cleaning Simple 332/E9240 fluid green extreme Applica- A4GBCJCB4104/3300 tion fluid Gasket Loctite 4104/3200 cleaner 7200
Colour- 365 less d Blue
730 d Colour- 730 less d
Hand cleaner
Loctite 7855
Hand cleaner
Sika hand 4104/1300 Off cleaner white
75 - 30
-
4104/3100 Light grey
540 d
-
Drying Comments Time Less than 5 Used to make low energy surfaces suits able for bonding with cyanocrylate adhesives. It is recommended for polyethylene, polypropylene, PTFE and thermoplastic rubber materials. Can be used with Loctite 406 (332/U7899). Apply and HIGHLY FLAMMABLE. Organic acceleraleave to dry tor, non CFC solvent based surface activafor 30 s be- tor. Designed to promote the speed of cure fore apply- of cyanoacrylic adhesives. ing adhesive 1 –3 min Used with anaerobic products it increases cure speed. Recommended for inert surfaces and large bond gaps. A water proofing solution for protecting joints made using cyanoacrylate adhesive. Apply to Loctite 495 (4103/0900). 1 min at 20 HIGHLY FLAMMABLE, cleaner and de°C ( 68.0 greaser. Removes grease, oil and dirt from °F) electrical parts, tools and precision equipment. No wipe Cleaning treatment to remove most greas5 –10 min, es, oils, lubrication fluids and metal cuttings post wipe 1 –2 min An all purpose cleaner and degreaser used diluted in water for direct, spray and dip tank procedures. Vinyl labels application fluid for use with the insignia/livery labels. Allow 10 – This is a product to aid the removal of 15 min for cured chemical gaskets. Apply for time gasket, 30 specified and remove gasket with soft min for sil- scraper. icone gasket. Is a heavy duty hand cleaner, specially formulated for the most difficult to remove soils like polyurethane, paints, primers, adhesives etc. The product is free from silicone and harsh solvents. Can be used without water. A non-abrasive hand cleaner for use when using direct glazing materials.
9813/6050-2
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14 - Solvents and Primers 00 - General
Subsection Direct glazing
Commer- Product Colour cial name Number Sika acti- 4104/2100 Clear vator
Shelf life 365 d
Drying Time 10 min minimum drying time
Direct glazing
Sika re4104/1900 mover 208 (use 4104/3600) Sika 4104/1200 cleaner 205 (use 4104/3600) Sika 4104/2300 primer 209 (use 4104/3500)
Transparent
-
-
Clear
-
-
Black
270 d
Direct glazing Direct glazing
Direct glazing
Active wipe for surface Direct glazing
Cleaner
75 - 31
Application temperature 10 –35 °C ( 50.0 –95.0 °F) Sika akti- 4104/2400 Clear 365 10 min at vator d more than 15 °C ( 59.0 °F) or 30 min at less than 15 °C ( 59.0 °F) Tero4104/3400 Colour- 270 Minimum stat 8560 less d 30 s and AC-25 maximum 1 h Terostat 4102/3500 Black 0.1 L Approx. 2 8519 P bot- min tle = 365 d. 0.01 L and 0.035 L bottle = 540 d Teroson 4104/3600 Clear 730 DependFL cleand ing on coner ditions between 2 – 10 min.
9813/6050-2
Comments HIGHLY FLAMMABLE. A cleaning and activating agent specifically formulated for the treatment of bonded faces in direct glazing applications prior to applying the direct glazing adhesive. A cleaning agent for removing contaminates on painted surfaces and glass. A cleaning agent for removing contaminates on painted surfaces and glass. Used to prime painted surfaces and plastic substrates prior to bonding with Sikaflex products. Used to clean and give improved adhesion on glass, ceramic-coated glass, the cut face of old polyurethane adhesive beads, polyurethane coated windows glass and paints. Applied with a clean cloth to the surface, the adhesive may then be applied after the drying time. Applied to glass or ceramic coating but only in the bonding area. Used to promote adhesion in direct glazing to glass and glass ceramics.
Used for degreasing and cleaning of substrates prior to application of adhesives and sealants.
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15 - Adhesive
15 - Adhesive Contents
Page No.
75-15-00 General ........................................................................................................................... 75-33
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15 - Adhesive 00 - General
00 - General
Introduction
Introduction .................................................... 75-33 Technical Data ............................................... 75-34
All adhesives should be used at all times in line with the manufacturer’s recommendations. Adhesives are used for the bonding of a number of engineering materials used in production at JCB. Many types are available on the market but in the interests of variety reduction and economy only a limited selection is purchased for regular use.
Types of adhesive Various types of adhesive are covered by JCB Standards: 1. General purpose adhesives for laminated plastics, wood, rubber themselves and to each other.
bonding etc. to
2. The more expensive cyanoacrylate adhesives for use where high strength, resistance to many chemicals and fast cure times are required. 3. Adhesives specially developed for bonding of foam rubber to painted metal surfaces.
Additional health cyanoacrylates
and
safety
for
These adhesives require very careful handling on account of their exceptional properties. They bond together strongly and rapidly to most surfaces including body tissue, the curing process being initiated by surface moisture. For further information on cyanoacrylates refer to the Manufacturer’s recommendations.
Approved adhesives The tables shown in Technical Data are the approved adhesives available to use on JCB machines. The tables also provide basic details to help with the selection of adhesives. More up to date information can be found on the manufacturer’s website.
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15 - Adhesive 00 - General
Technical Data Table 267. Adhesives Approved Product Information Subsection High strength
Commer- Product Colour cial name Number Per4103/3100 Mixed mabond grey 5002
Shelf Technical life data 730 d 3 –5 min for handling strength
High Loctite strength 601
4103/1000 Green 365 d fluorescent
Cyanoacrylate
Loctite 424
4103/3500 Colour- less to straw
Cyanoacrylate
Loctite 401
4103/2300 Colour- 180 d less
Cyanoacrylate
Loctite 406
332/U7899 Colour- 180 d less
Cyanoacrylate
Loctite 410
4103/2400 Black
120 d
Cyanoacrylate
Loctite 480
4103/3800 Black
-
Cyanoacrylate
Two part adhesive mixed in equal parts. A toughened adhesive system which bonds metals, plastics, wood, glass, ceramics and composites; even plated or coated surfaces can be securely fastened. 16 –30 bar This product is a single component anaero( 231.9 – bic adhesive. Used to bond cylindrical fitting 434.8 psi) parts, particularly where low viscosity is restatic shear quired. Maximum gap fill is 0.15 mm. strength 18 –26 bar Suitable for most materials including plastic ( 260.9 and rubber. Takes 30 s to cure to working –376.8 strength. psi) shear strength 18 –26 bar Designed for general purpose use. For use ( 260.9 – on acidic and porous surfaces, reaching 376.8 psi) handling strength in seconds. Materials intensile clude plated metals, composite materials, strength wood, cork, foam, leather and paper. 18 –26 bar Designed for bonding of plastics and elas( 260.9 – tomeric materials where very fast fixturing 376.8 psi) is required. Can be used with Loctite 770 lap shear as a primer (332/U7901) strength 22 bar 0.2 mm, gap fill. A rubber toughened ethyl ( 318.8 psi) cyanoacrylate adhesive with enhanced relap shear sistance to peel and shock. Bonds rubber, strength metals and plastics for use in difficult conditions. 22 –30 bar A rubber toughened adhesive with in( 318.8 – creased flexibility and peel strength along 434.8 psi) with enhanced resistance to shock. lap shear strength 12 h maxi- High speed bonding, suitable for rubber to mum cure itself and other materials reaching handling time strength in a matter of seconds. Joint must be waterproofed with Loctite water proofing (4104/0500).
Loctite 4103/0900 Colour- 270 d 495 less Permabond C2 Low Dunlop 4103/1100 Clear 90 d strength 1727 to light straw British vita company VB 165 Acrylic 3M 4941P 4103/3900 Dark 730 d Peel adhefoam grey sion 350 strip adN/ 100 mm hesive
75 - 34
Comments
9813/6050-2
Sprayable adhesive, non-structural applications. For the bonding of flexible foam to themselves, wood, painted metal, chipboard, fibreglass, hessian, felt etc. High bond acrylic double sided foam tape. Its allows more complete bond contact area when bonding rigid or irregular materials due to its conformability. Its core adhesive composition makes the product well suited to many paints and primers. 75 - 34
75 - Consumable Products
15 - Adhesive 00 - General
Subsection General purpose gap filling material
Commer- Product Colour cial name Number Araldite 4103/1400 Clear / XD 580 cream
Shelf Technical life data 730 d 560 bar ( 8,115.9 psi) flexural strength
Methacry- Loctite late Speedbonder H3151
4103/3600 Cream to light yellow
Methacry- Plexus late MA420
4103/3700 Off365 d 186 – white or 206 bar blue ( 2,695.6 –2,985.5 psi) 332/S7420 Black 180 d -
Structur- Scotchal plastic weld structural plastic adhesive Non-pre- Evo-Stick 4103/0800 Noneferred 528 preadhesive ferred
Direct glazing
Direct glazing
Direct glazing
75 - 35
-
-
365 d HIGHLY FLAMMABLE
Sika 4103/2100 Black 250PC Sikatack Ultrafast (use 4103/4000 or 4102/4900) Sika 4103/2200 Black 255FC (use 4102/5000)
-
-
-
-
Sikaflex 4103/3200 Black 552 (use 4102/5000)
-
-
9813/6050-2
Comments Two part, equal parts by weight. Wear pad fixing to castings and telescopic components, alignments of fixings pads without expensive machining. This product is a general purpose gap-filling material. Cure time 2 h at 25 °C ( 77.0 °F). This is a sag resistant, two component, equal parts, methacrylate adhesive system formulated to bond automotive grade cold rolled steel without the use of an external primer. Suitable for bonding a wide variety of plastic and metal substrates. Provides a long open time ( 40 –60 min) for correct aligning of parts. Two part methacrylate adhesive for structural bonding of thermoplastic, metal and composite assemblies. Combined at 10:1 ratio. It has a working time of 4 –6 min. Two part acrylic based adhesive (10:1 ratio by vol.) that can bond many low surface energy plastics, including many grades of polypropylene, polyethylene and TPO’s without special surface preparation. A thin even film of adhesive should be applied to both surfaces being bonded and allowed to become touch dry. This is a contact adhesive and coated surfaces cannot therefore be slid into position since the bond forms on contact. It is often convenient to align the parts along an edge and then bring the two areas into contact. A one component polyurethane pre-polymer based adhesive. A mastic adhesive which reacts with atmospheric moisture to form a rubber like solid.
For bonding glass to cab frames. A mastic adhesive which reacts with atmospheric moisture to form a rubber like solid. When using this product ensure both surfaces are clean and dry. Use Sika cleaner 205 (4104/1200). A high performance, elastic, gap, filling one part structural adhesive cures on exposure to atmospheric moisture to form a durable elastomer. Contains no isocyanate.
75 - 35
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15 - Adhesive 00 - General
Subsection Industrial grade epoxy adhesive
Commer- Product cial name Number Loctite 333/Y7062 Hysol E-214 HP
Colour Light Grey Paste
Shelf Technical life data 307 bar ( 4,449.3 psi) tensile strength
Anaero- Scotchbic adweld hesive RT-20 (Dimethacrylate)
333/L9575 Green
365 d -
Direct glazing
Terostat 8597 CT
4102/4900 Black
Direct glazing
Teroson 939CT / Terostat MS939
4102/5000 Black, offwhite, grey, black
Direct glazing
Terostat 8900 HV
4103/4000 Black
540 d in original packaging 365 d in original packaging 180 d 80 bar ( 1,159.4 psi) tensile strength
Direct glazing
Tero4103/4100 Black stat 8594 HMLC
75 - 36
Comments Single component, heat activated formulation develops tough, strong, structural bonds which provide excellent peel resistance and impact strength. When fully cured, the product offers superior thermal shock resistance, excellent mechanical and electrical resistance properties and withstands exposure to a wide variety of solvents and chemicals. Bonds to a wide variety of materials, including metals, glass, ceramics and plastics. Cure at 120 °C ( 247.8 °F) or above until completely firm. Heat up to 150 °C ( 301.8 °F) for 2 h, to maximize properties. Single component anaerobic adhesives designed to secure cylindrical metal assemblies such as bearings on shafts, bushings, sleeves, housings, and keyways. Help prevent loosening, corrosion and leakage caused by shock and vibration. Full cure time 24 h. Temperature range = - 54 °C ( 129.1 °F) to 450 °C ( 841.4 °F). Not recommended for use on most plastics due to potential cracking of plastic parts. Cure rate: approx. 3 –4 mm/ 24 h. Glazing time: maximum 20 min (period of time between beginning of material application until inserting of the pane). Skin formation time: approx. 10 min. Cure rate: approx. 3 mm/ 24 h.
One component, pumpable adhesive/sealant based on polyurethane, which cures by reaction with moisture to an elastic rubber. The skin formation and curing time are dependent on humidity, temperature and depth of joint. High temperature and high moisture reduces curing time. Sag resistant, temperature range of - 40 °C ( 103.9 °F) to 90 °C ( 193.9 °F). 270 d 85 bar Single component, moisture curing, ad( 1,231.9 hesive/sealant for repair. Product with psi) tensile high shear modulus and low conductivity. strength Suitable for all applications that require very high electrical insulation of the adhesive used for the bonding of windows. Sag resistant.
9813/6050-2
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15 - Adhesive 00 - General
Subsection Direct glazing
Commer- Product Colour cial name Number Terostat 4103/4200 Black 8900 LV
Direct glazing
Sika 295 UV
75 - 37
4103/4300 Black, white
Shelf Technical life data 365 80 bar d in ( 1,159.4 car- psi) tensile tridges.strength 180 d in sausage pack. 180 d in hobbocks and drums 365 d -
9813/6050-2
Comments One component, pumpable adhesive/sealant based on polyurethane, which cures by reaction with moisture to an elastic rubber. The skin formation and curing time are dependent on humidity, temperature and depth of joint. High temperature and high moisture reduces curing time. Sag resistant, temperature range of - 40 °C ( 103.9 °F) to 90 °C ( 193.9 °F) short exposure (up to 1 h) of 130 °C ( 265.8 °F).
Direct glazing adhesive for plastic glazing panels. One component polyurethane adhesive of paste like consistency. 60 min tack free time, 1 d cure time ( 4 mm at 23 °C ( 73.4 °F)). Good UV, fresh water and seawater resistance. Do not apply below temperatures of 10 °C ( 50.0 °F) or above 35 °C ( 95.0 °F).
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16 - Sealant
16 - Sealant Contents
Page No.
75-16-00 General ........................................................................................................................... 75-39
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75 - Consumable Products
16 - Sealant 00 - General
00 - General
Introduction
Introduction .................................................... 75-39 Technical Data ............................................... 75-40
All sealants should be used at all times in line with the manufacturer’s recommendations. Sealants are used mainly for the sealing of screwed joints, sealing flanges and flat surfaces and where gap filling properties are required.
Types of Sealant Various types of sealant are specified in JCB Standards: 1. Those for the sealing of screwed joints. 2. Sealants for joining flanges and flat surfaces. (Flange size and likelihood of dismantling require consideration when selecting this type of sealant). 3. Sealants for use where gap filling properties are required. (The gap dimensions, joint movement if any, type of materials being joined and aesthetic appearance require consideration when selecting this type of sealant).
Approved Sealants The table shown in Technical Data are the approved sealants available to use on JCB machines. The table also provides basic details to help with selection of sealants. More up to date information can be found on the manufacturer’s website.
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16 - Sealant 00 - General
Technical Data Table 268. Sealants Approved Product Information Subsec- Comtion mercial name High Loctite strength 275(1) Permabond A140 High Forgestrength way (1) 240FC
Product Number
Medium Loctite to high 620 strength Medium strength
Medium strength
Colour
Shelf Technical life data
4102/0500 Green
730 d 250 bar Non drip formulation, used on larger fittings, ( 3,623.2 coarse threads. psi) torque strength (on M8)
4102/3100 Yellow
270 d 25 bar ( 362.3 psi) breaking strength
4102/3500 Green
-
More than 241 bar ( 3,492.7 psi) shear strength Loc4102/2000 Red, flu- 365 d 90 bar tite 518 ores( 1,304.3 Gasket cent psi) tensile Eliminastrength tor Loctite 4102/4100 Red gel, 80 bar 5182 fluores( 1,159.4 cent psi) shear strength
Medium Loctite strength 595
4102/2500 Clear
Medium Loctite 4102/1900 Yellow strength 577(1) Permabond A1044 Medium Loctite 4102/2700 Blue strength 2431
Can be painted over with some 2 pack paint. Maximum width of joint = 35 mm, minimum width = 2 mm, minimum depth = 2 mm. Recommended depth of joint = width of joint. Used for locating pins in radiator assemblies, sleeves into pump housings and bearings in auto transmissions. Not suitable for plastics. Diametrical clearance: up to 0.2 mm Typically used as form-in-place gasket on rigid flanged connections.
It is manufactured to minimise air bubbles in the package. Used to seal gaskets, housings, cases and covers. It can also be used to repair and replace cut gaskets (up to 0.08 mm in thickness). 365 d 6 mm gap Formulated to withstand weathering and filling extreme temperature cycling. Used for potting, coating and sealing. Can be applied horizontal, vertical and overhead. 365 d 170 bar A fast curing thread sealant used on coarse ( 2,463.8 threads and pipe fittings up to 75 mm psi) break- thread size. Clearance for gap filling 0.8 away mm. torque
365 d 140 – 340 bar ( 2,029.0 –4,927.5 psi) breakaway torque Low Clayton 4102/2200 White 12 h Maximum strength Dewanopaque full seal presdre air cure sure 29 brake bar ( 420.3 sealant psi) SC1252 Low Red 4102/0800 Resistant strength Herto oil metite 75 - 40
Comments
9813/6050-2
Taper thread sealant, non-fluorescing to see oil leaks. Suitable for all taper fittings up to M36.
Seals pipes and plugs against leakage of air, fuels, lubricants and coolants. Hardens to a tough seal resistant to shock and vibration. Easily dismantled. Non-hardening paste jointing for joints regularly opened for servicing. 75 - 40
75 - Consumable Products
16 - Sealant 00 - General
Subsec- ComProduct tion mercial Number name Low Loctite 4102/1100 strength 572
Colour
Shelf Technical life data
Comments
White 730 d 40 –100 opaque bar ( 579.7 –1,449.3 psi) breakaway torque GasLoc4102/3200 Blue to 0.2 72 h full keting tite 509 green mm strength on medium Gasket gap steel strength Elimifilling nator Flange Sealant GasLoctite 4102/1200 Red 730 d 2 h working (1) keting strength 574 medium Perstrength mabond
Used where slow cure is required to permit component alignment. PTFE (Polytetrafluoroethylene) filler.
Sealant for gaskets
Used to dress new or worn gaskets. Dries slowly, sets to pliable film for easy dismantling.
Rubber jointing compound
Epoxy resin
75 - 41
A136 Loctite 4102/2600 Black FAG 2 / Loctite 5922
365 d Resists pressures up to 345 bar ( 5,000.0 psi) Dow 4102/0900 Clear or 270 d 16.7 bar corning translu( 242.0 781 cent psi) tensile strength Loctite superflex clear RTV3 EVOstick standard industrial clear silicone sealant Dunlop high modulus silicone sealant DP2205 Loc4102/2400 Slightly tite fast coloured / epoxy transsealant parent
9813/6050-2
Easy disassembly, used as form-in-place gasket.
Does not creep or relax after curing, no bolt re-tightening is required. Oil resistant. Ideal for formed in-situ gaskets.
A synthetic rubber joint sealant suitable for joints between non-porous surfaces such as glass and metal, metal and metal where relatively large gap filling properties are required. Suitable for vertical and overhead applications under normal atmospheric conditions. Joint movement approx.+/-12.5%. Cure time to 6 mm depth in 24 h.
0.05 L container requires special bi-mixer (gun) so it is mixed as dispensed, 0.024 L is mixed by hand.
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16 - Sealant 00 - General
Subsec- Comtion mercial name Room Loctite tempera- 5910, ture vul- Flange canising sealant, RTV Silicon Room Loctite tempera- 5970 ture vulcanising
Product Number
Colour
4102/3400 Metal- lic black paste
4102/4200 Black
Room temperature vulcanising
Loc4102/2900 Black tite superflex black silicone Room Loctite 4102/3700 Grey tempera- 5901 ture vulcanising Room temperature vulcanising Room temperature vulcanising
Shelf Technical life data
Dry to Designed for flange sealing, good resistouch in 40 tance to oils and allows high joint movemin ment.
730 d 18 bar ( 260.9 psi) tensile strength
Used for gaskets. Excellent resistance to engine oils. Typical applications include stamped sheet metal covers (timing covers and oil sumps) where good oil resistance and the ability to withstand high joint-movement are required. 270 d 16 bar Thixotropic allowing easy application, hori( 231.9 zontal, vertical and overhead. Seals against psi) tensile water and many solvents. strength 730 d 14 bar ( 202.9 psi) shear strength
Loctite 5368
4102/3900 Black paste
730 d
Loctite 5366
4102/4000 Clear paste
730 d
Room Hylomar 332/D5695 Black tempera- 607 paste ture vulcanising
540 d
Joining Loctite oil pan to 5900 bedplate
730 d
4102/3800 Black paste
Anti-cor- To mil- 4102/4300 Yellow rosive itary spec TTP-1757B 1CY
75 - 42
Comments
-
Designed specifically for on line, low pressure tests carried out before product begins to cure. Product exhibits excellent resistance to automotive engine oils. Primarily for flange sealing, it withstands high jointmovement requirements. 20 bar Generally used for sealing applications, but ( 289.9 also for bonding and for high temperature psi) tensile protection. strength 20 bar Designed specifically for use as a bond( 289.9 ing agent to ensure perfect sealing, as psi) shear well as bonding and protection. Examples strength are sealing side windows in trains, sealing heat sources (heat exchangers and water heaters) and for protection/insulation of electrical boxes. 40 bar A special purpose adhesive and sealant ( 579.7 that can be used for a variety of applicapsi) tensile tions. It has good resistance to oils and strength aqueous anti-freeze agents, and is particularly suitable for high strength applications in odour sensitive environments. 14 bar JCB Service ONLY. Introduced for joining ( 202.9 the oil pan to the bedplate face during serpsi) shear vice. High resistance to engine oils. The strength joint should be clamped to spread the adhesive and allowed to cure for 7 d before heavy service duty. Type 1 Used to coat surfaces of dissimilar metals Class C prior to assembly to prevent corrosion. Zinc chromate containing substance ideal for application to joints between aluminium and steel to prevent corrosion and seizure. FOR USE ON MILITARY VEHICLES ONLY.
9813/6050-2
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16 - Sealant 00 - General
Subsec- ComProduct Colour Shelf Technical tion mercial Number life data name GasBondloc 4102/4500 Clear/ Full cure keting B555 Opaque time 24 medium h. 50 bar strength ( 724.6 psi) tensile strength Seam Terolan 4102/4600 Light 90 d sealant 3412 grey AA-25
Direct glazing
Sikaflex 4102/2800 Yellow 221 (use 4102/4800) Sikaflex 4102/2300 Black 252 (use (1) 4102/4700)
-
-
-
-
Direct glazing
Teroson 4102/4700 PU92 CT
Direct glazing
930 4102/4800 Yellow JCB Branded yellow CT
365 d in original packaging 365 d in original packaging
Direct glazing
Terostat 4102/4900 Black 8597 CT
Direct glazing
75 - 43
-
-
9813/6050-2
Comments B555 is an anaerobic gasket sealant. It seals close fitting joints between rigid metal faces and flanges. Tensile strength to ISO 6922. Serves as a seam sealant between sheet metal butt and overlap joints (interior seems) on vehicle bodies. Can be cured at temperatures of minimum 140 °C ( 283.8 °F) (effective metal temperature) for 15 min. The material is applied to electro-dip coated steel sheets. Direct glazing one component polyurethane based adhesive and sealant compound. Tack free time of 50 min. A one component polyurethane pre-polymer based sealant. For sealing glass to frames. A mastic sealant which reacts with atmospheric moisture to form a rubber like solid. The substrates must be clean, dry, oil and grease free. Skin formation time: approx. 20 min Cure rate: approx. 4 mm/ 24 h
The substrates must be clean, dry, oil and grease free. It can be necessary to roughen the surface or to use a primer/adhesion promoter to provide optimum adhesion. When manufacturing of plastics, external release agents are often used; these agents must be absolutely removed prior. Skin formation time : approx. 20 min Cure rate : approx. 4 mm/ 24 h Isocyanate free solution. Designed for use without primer or activator. When you use this sealant on operator station, it should be used with Teroson PU 8519P black primer (and Teroson 450 clear adhesion promoter when specified specially). Cross compatible with all OEM / OES / AAM DGX sealants, including MS and PU chemistry (any remaining bead must be fully cured before application).
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16 - Sealant 00 - General
Subsec- Comtion mercial name Silicone Sisealant - ka/EverHeat re- build sistant Heat Mate GasLoctite ket and 510 sealing
Product Number
Colour
Shelf Technical life data
Comments
-
-
4102/6100 Opaque pink
-
High modulus permanently flexible 100 % silicone. Temperature resistant up to 300 °C ( 571.6 °F). Ideal for sealing industrial and high performance gaskets, oven doors etc. Introduced for Heavy products India (swing motor/ gearbox face).
4102/5100 Black
(1) This is a non preferred product.
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18 - Fuel
18 - Fuel Contents
Page No.
75-18-00 General ........................................................................................................................... 75-47
75 - 45
9813/6050-2
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Notes:
75 - 46
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75 - Consumable Products
18 - Fuel
00 - General
00 - General
Introduction
Introduction .................................................... 75-47 Health and Safety .......................................... 75-50
(For: Perkins T3 404D-22 Nat Asp) The quality of the fuel is very important for satisfactory engine performance, long engine service life and acceptable exhaust emission levels. The fuel must meet the minimum requirements. Refer to Table 269. and Refer to Table 270. If you operate the machine with fuels that do not meet the recommendations below, it can cause the following effects: • • • • • •
Starting difficulty Poor combustion Deposits in the fuel injectors Reduced service life of the fuel system Deposits in the combustion chamber Reduced service life of the engine.
Table 269. Perkins Specification for Distillate Diesel Fuel Property
ASTM Test
Maximum 35 % by volume Ash Maximum 0.02 % by weight Carbon residue on 10 % Maximum 0.35 % by bottoms weight (2) 40 minimum Cetane number Cloud point The cloud point must not exceed the lowest expected ambient temperature. Copper strip corrosion No. 3 maximum Density at 15 °C ( 59.0 801 kg/M³ minimum, 876 (3) kg/M³ maximum °F)
D1319
ISO (International Organization for Standardization) Test ISO 3837
D482
ISO 6245
D524
ISO 4262
D613/D6890
ISO 5165
D2500
ISO 3015
D130 No equivalent test
ISO 2160 ISO 3675, ISO 12185
D86
ISO 3405
Flash point Thermal stability
D93 D6468
ISO 2719 No equivalent test
D97
ISO 3016
D5453/D26222
ISO 20846, ISO 20844
Requirements
(1)
Aromatics
Distillation
Pour point sulphur
(1, 4)
75 - 47
10 % at 282 °C ( 539.2 °F) minimum, 90 % at 360 °C ( 679.5 °F) maximum Legal limit Minimum of 80 % reflectance after aging for 180 min, at 150 °C ( 301.8 °F) 6 °C ( 42.8 °F) minimum below ambient temperature The emissions regulations control the level of sulphur in the fuel. Refer to Table 270.
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75 - Consumable Products
18 - Fuel
00 - General
Property
Requirements
ASTM Test
The viscosity of the fuel that is delivered to the fuel injection pump. 1.4 centistokes minimum and 4.5 centistokes maximum Maximum 0.1 % by weight Maximum 0.1 % by weight Maximum 0.05 % by weight 0.00001 kg per 0.1 L
D445
ISO (International Organization for Standardization) Test ISO 3405
D1796
ISO 3734
D1744
No equivalent test
D473
ISO 3735
D381
ISO 6246
0.46 mm maximum
D6079
ISO 12156-1
(1)
Kinematic viscosity
(5)
Water and sedimant Water Sediment Gums and resins Lubricity corrected wear scar diameter at 60 °C (7) ( 139.9 °F) (6)
(1) This specification includes the requirements for Ultra Low sulphur Diesel (ULSD). ULSD fuel will have less than or equal to 15 ppm ( 0.0015 %) sulphur. Refer to ASTM D5453, ASTM D2622, or ISO 20846, ISO 20884 test methods. This specification includes the requirements for Low sulphur Diesel (LSD). LSD fuel will have less than or equal to 500 ppm ( 0.05 %) sulphur. (2) A fuel with a higher Cetane number is recommended in order to operate at a higher altitude or in cold weather. (3) As per the standards tables, the equivalent API gravity for the minimum density of 801 kg/M³ is 45 and maximum density of 876 kg/M³ is 30. (4) Regional regulations, national regulations or international regulations can require a fuel with a specific sulphur limit. Contact all applicable regulations before you select a fuel for a given engine application. The Perkins fuel systems and engine components can operate on high sulphur fuels in territories that are nonemissions regulated. Fuel sulphur levels affect exhaust emissions. High sulphur fuels also increase the potential for corrosion of internal components. Fuel sulphur levels above 0.5 % may significantly shorten the oil change interval. (5) The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscosity requirement and the fuel should meet the maximum viscosity requirements at 40 °C ( 103.9 °F) of either the ASTM D445 test method or the ISO 3104 test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain 1.4 centistokes or greater viscosity at the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to lower the viscosity to 4.5 centistokes at the fuel injection pump. (6) Follow the test conditions and procedures for motor gasoline. (7) The lubricity of a fuel is a concern with low sulphur and ultra low sulphur fuel. To determine the lubricity of the fuel, use the ISO 12156-1 or ASTM D6079 High Frequency Reciprocating Rig (HFRR) test. If the lubricity of a fuel does not meet the minimum requirements, contact your fuel supplier. Some additives are not compatible. These additives can cause problems in the fuel system.
Diesel Fuel Characteristics Cetane Number Fuel that has a high Cetane number will give a shorter ignition delay. This will produce a better ignition quality. Cetane numbers are derived for fuels against proportions of Cetane and heptamethylnonane in the standard CFR engine. Refer to ISO 5165 for the test method. The Cetane numbers greater than 45 are normally expected from current diesel fuel. However, a Cetane number of 40 may be experienced in some territories. The United States of America is one of the territories 75 - 48
that can have a low Cetane value. A minimum Cetane value of 40 is necessary, when you start the engine in average starting conditions. A higher Cetane value may be necessary for operations at high altitudes or in cold weather operations. Fuel with a low Cetane number can be the root cause of problems in cold starting conditions.
Viscosity Viscosity is the property of a liquid of offering resistance to shear or flow. Viscosity decreases with increase in temperature. This decrease in viscosity follows a logarithmic relationship for normal fossil fuel. The common reference is to kinematic viscosity.
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75 - Consumable Products
18 - Fuel
00 - General
This is the quotient of the dynamic viscosity that is divided by the density. The determination of kinematic viscosity is normally by readings from gravity flow viscometers at standard temperatures. Refer to ISO 3104 for the test method. The viscosity of the fuel is significant because fuel serves as a lubricant for the fuel system components. Fuel must have sufficient viscosity in order to lubricate the fuel system in both extremely cold temperatures and extremely hot temperatures. If the kinematic viscosity of the fuel is lower than 1.4 centistokes at the fuel injection pump damage to the fuel injection pump can occur. This damage can be excessive scuffing and seizure. Low viscosity may lead to difficult hot restarting, stalling and loss of performance. High viscosity may result in seizure of the pump. The recommends kinematic viscosities are 1.4 centistokes minimum and 4.5 centistokes maximum.
Density Density is the mass of the fuel per unit volume at a specific temperature. This parameter has a direct influence on engine performance and a direct influence on emissions. This determines the heat output from a given injected volume of fuel. The recommended a value of density is 841 kg/M³ in order to obtain the correct power output. Lighter fuels are acceptable but these fuels will not produce the rated power.
sulphur The emissions regulations control the level of sulphur in the fuel. Regional regulation, national regulations or international regulations can require a fuel with a specific sulphur limit. The sulphur content of the fuel and the fuel quality must comply with all existing local regulations for emissions. Contact all applicable regulations before you select a fuel for a given engine application.
Table 270. Fuel Requirements Territory EPA EC
Non regulated territories
Requirements Low sulphur (15 ppm ( 0.0015 %)) maximum sulphur/Power 10 ppm sulphur maximum for less than or equal to 37 kW Models 402D-05, 403D-07, 403D-11, 403D-15, 403D-15T, 403D-17, 404D-15 sulphur limit of less than 4000 ppm
In some parts of the world and for some applications, high sulphur fuels above 0.5 % by mass might only be available. Fuel with very high sulphur content can cause engine wear. High sulphur fuel will have a negative impact on emissions of particulates. High sulphur fuel can be used provided that the local emissions legislation will allow the use. High sulphur fuel can be used in countries that do not regulate emissions. When only high sulphur fuels are available, it will be necessary that high alkaline lubricating oil is used in the engine or that the lubricating oil change interval is reduced.
Lubricity This is the capability of the fuel to prevent pump wear. The lubricity of fluid describes the ability of the fluid to reduce the friction between surfaces that are under load. This ability reduces the friction damages. Fuel injection systems rely on the lubricating properties of the fuel. Until fuel sulphur limits were mandated, the lubricity of fuel was generally believed to be a function of fuel viscosity. 75 - 49
300 ppm sulphur maximum for greater than 37 kW 404D-22, 404D-22T and 404D-22TA
The lubricity has particular significance to the current low viscosity fuel, low sulphur fuel and low aromatic fossil fuel. These fuels are made in order to meet stringent exhaust emissions. A test method for measuring the lubricity of diesel fuels has been developed and the test is based on the HFRR method that is operated at 60 °C ( 139.9 °F). Do not exceed the lubricity wear scar diameter of 0.46 mm. The fuel lubricity test must be performed on a HFRR, operated at 60 °C ( 139.9 °F). Fuel additives can enhance the lubricity of a fuel. Contact your fuel supplier for those circumstances when fuel additives are required. Your fuel supplier can make recommendations for additives to use and for the proper level of treatment.
Distillation This is an indication of the mixture of different hydrocarbons in the fuel. A high ratio of light weight hydrocarbons can affect the characteristics of combustion.
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75 - Consumable Products
18 - Fuel
00 - General
Health and Safety Fuel Fuel is flammable, keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions. WARNING! Do not use petrol in this machine. Do not mix petrol with the diesel fuel. In storage tanks the petrol will form flammable vapours.
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78 - After Sales Contents
Page No.
Acronyms Glossary .................................................................................................................................... 78-2 78-24 Maintenance Schedules 78-24-00 General ............................................................................................................................. 78-3 78-24-03 Maintenance Intervals ...................................................................................................... 78-4 78-24-06 Pre-start Cold Checks, Service Points and Fluid Levels .................................................. 78-5 78-24-09 Functional Tests and Final Inspection .............................................................................. 78-7 78-81 Clothing and Personal Protective Equipment (PPE) 78-81-00 General ........................................................................................................................... 78-11 78-93 Special Tools 78-93-00 General ........................................................................................................................... 78-13 78-93-03 Parts List ........................................................................................................................ 78-14 78-96 Units of Measurement 78-96-00 General ........................................................................................................................... 78-29
9813/6050-2 2017-11-23
Acronyms Glossary FOPS
Falling Object Protective Structure
MRV
Main Relief Valve
ROPS
Roll-Over Protective Structure
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78 - After Sales
24 - Maintenance Schedules
24 - Maintenance Schedules Contents 78-24-00 78-24-03 78-24-06 78-24-09
78 - 1
Page No. General ............................................................................................................................. Maintenance Intervals ...................................................................................................... Pre-start Cold Checks, Service Points and Fluid Levels .................................................. Functional Tests and Final Inspection ..............................................................................
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78 - 1
Notes:
78 - 2
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78 - After Sales
24 - Maintenance Schedules 00 - General
00 - General Introduction The schedules show the service tasks which must be done and their intervals. The services must be done at either the hourly interval or the calendar equivalent, whichever occurs first. The intervals given in the schedules must not be exceeded. If the machine is operated under severe conditions (high temperature, dust, water, etc.) shorten the intervals. Table 271. Service task can be completed by a competent operator. Details of how to complete the service task are given in the Operator's Manual. We recommend that a Service Engineer completes the service task. Details of how to complete the service task are given in the Service Manual.
78 - 3
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24 - Maintenance Schedules 03 - Maintenance Intervals
03 - Maintenance Intervals Introduction Table 272. Interval (h) 10 50 500 1000 2000
78 - 4
Calendar Equivalent Daily Weekly Six months Yearly Two years
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24 - Maintenance Schedules
06 - Pre-start Cold Checks, Service Points and Fluid Levels
06 - Pre-start Cold Checks, Service Points and Fluid Levels Technical Data Table 273. Component
Task
10
Engine Engine and pump mount security Check Oil and filter
Drain and refill
Coolant level and Antifreeze strength Coolant
Check
Air cleaner dust valve
Clean
(1)
Replace
Air cleaner inner element
Replace
Cylinder head nuts
Replace
Valve clearance
Check and adjust
Fan belt condition and tension
Check
Fan belt
Replace
Fuel sediment
Drain
Fuel filter
Replace
Radiator hose
Clean
Air cleaner hose security
Check
Fuel system for leaks and contamination External oil leaks
Check
Clean radiator matrix
Inspect
Transmission Motor mounting bolt tightness
Check
Wheel nut security
Check
Hub mounting bolt security
Check
Tyre pressures
Check (Condition)
Drive chain case oil level
Check
Drive chain case oil
Replace
Drive chain tension
Check and Adjust
Hydraulics Oil
Sample/Replace
Oil level
Check
Oil filter
Sample/Change
Ram piston rods for Damage/Leaks
Change
78 - 5
100
(1)
500
1000
2000
Replace
Air cleaner outer element
(2)
50
Check
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78 - After Sales
24 - Maintenance Schedules
06 - Pre-start Cold Checks, Service Points and Fluid Levels
Component
Task
Hoses - Damage or leaks
Check
Pipework - Damage or leaks
Check
Breather
Clean
Breather
Change
(3) (3)
10
50
100
(1)
500
1000
2000
Electrics Battery electrolyte level (If applic- Check able) Battery charge condition Check Battery terminals for condition and tightness Wiring for chafing Body and Framework All pivot pins Visual inspection of structure for damage including welds around lifting points and excavator end main pivots All hinges
Check Check Check and Grease Check
Lubricate
All linkages
Lubricate
Slew oil level
Check
General damage including ROPS Check (Roll-Over Protective Structure)/FOPS (Falling Object Protective Structure) Seat belt - Condition and security Check Windscreen washer fluid level (If installed) Quickhitch locking peg housing
Check
Extending dipper
Adjust and Waxoyl
Tracks and Running Gear Track tension
Clean
Check
Sprocket torque
Check
Operator station Recirculation filter
Clean
Fresh air filter
Clean
(1) Oil and filter change at 500 hours, (provided CH4 oil is used). (2) The Air Cleaner Outer Element should be changed every 100 hours if the machine is working in dusty conditions. (3) The Hydraulic Tank Breather should be changed more frequently if the machine is working in dusty conditions. (4) More regularly if used in dusty conditions.
78 - 6
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24 - Maintenance Schedules
09 - Functional Tests and Final Inspection
09 - Functional Tests and Final Inspection Technical Data Table 274. Component Engine
Task
10
50
100
500
1000
2000
Check and adjust
Idle speed
(1)
Maximum no load speed
Check and adjust
Exhaust smoke (excessive)
Check
Exhaust system security
Check
(1)
Throttle system and control cable Check Transmission Transmission stall pressure
Check
Hydraulics Operation all services
Check and Adjust
MRV (Main Relief Valve) pressure Check and adjust Auxiliary circuit
Check and adjust
Control isolation
Check
Pressure reducing valve
Check and adjust
Excavator valve and controls
Check and adjust
Hydraclamp operation
Check
Brakes Park brake - operation
Check
Electrics Starter motor
Check
Alternator
Check
Gauges and warning lights
Check
Front wiper motor (If installed)
Check
Cab switches - Operation
Check
Horn - Operation
Check
Heater (If installed)
Check
Reverse alarm (If installed)
Check
Lights and Indicators (If installed) Check Operate all electrical equipments Attachments Attachment condition and operation Paint work Condition
Check Check Check
General 78 - 7
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78 - After Sales
24 - Maintenance Schedules
09 - Functional Tests and Final Inspection
Component Task Check for fluid leaks (for example, Check coolant, engine oil, hydraulic oil, etc.) Lifting equipment (2) Check Fit for purpose test
10
50
100
500
1000
2000
(1) Jobs which should only be done by a specialist only. (2) This may be required every six months or at least annually in some countries to meet and comply with legislation and for insurance purposes.
78 - 8
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78 - After Sales
81 - Clothing and Personal Protective Equipment (PPE)
81 - Clothing and Personal Protective Equipment (PPE) Contents
Page No.
78-81-00 General ........................................................................................................................... 78-11
78 - 9
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Notes:
78 - 10
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78 - After Sales
81 - Clothing and Personal Protective Equipment (PPE) 00 - General
00 - General Introduction Do not wear loose clothing or jewellery that can get caught on controls or moving parts. Wear protective clothing and personal safety equipment issued or called for by the job conditions, local regulations or as specified by your employer.
78 - 11
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93 - Special Tools
93 - Special Tools Contents
Page No.
78-93-00 General ........................................................................................................................... 78-13 78-93-03 Parts List ........................................................................................................................ 78-14
78 - 12
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78 - After Sales
93 - Special Tools 00 - General
00 - General Introduction The tools shown are the special tools required for completing the procedures described in this manual. These tools are available from JCB Service or in some instances can be manufactured locally. The tools are divided into three categories: • • •
Special Tool = Only available from JCB. Recommended Tool = Available from JCB but other tool manufacturers/suppliers may offer a tool with the same characteristics. General Tool = A tool which is widely available.
Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier. Before you start work, make sure that all safety precautions are observed in accordance with the information contained within the relevant support documentation.
78 - 13
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93 - Special Tools 03 - Parts List
03 - Parts List
Introduction
Introduction .................................................... 78-14 Component Identification ............................... 78-17
06 - Body and Framework Tool Category Special Tool
Part No. 993/68100
Description Slide Hammer Kit
Qty. 1
Comments
Tool Category Recommended Tool Recommended Tool Recommended Tool Recommended Tool
Part No. 892/00842 892/00843 892/00845 892/00846
Qty. 2 1 1 1
Comments
Recommended Tool Recommended Tool Recommended Tool Recommended Tool General Tool General Tool Recommended Tool Recommended Tool
892/00847 892/00848 892/00849 926/15500 992/12300 992/12400 992/12800 992/12801
Description Glass Lifter Folding Stand Cartridge Gun Glass Extractor (Handles Only) Nylon Spatula Wire Starter Braided Cutting Wire Rubber Spacer Blocks Mobile Oven (12V) Static Oven (240V) Cut-Out Knife 'L' Blades
Description Pressure Gauge (0-40 Bar) Digital Multimeter Static Oven (240V) Slide Hammer Kit Digital Hydraulic Pressure Test Kit
Qty. 1
Part No. 892/00223
Description Hand Pump Pressure Test
Qty. 1
Comments
Part No. 892/00223
Description Hand Pump Pressure Test
Qty. 1
Comments
09 - Operator Station
1 1 1 4 1 1 1 1
15 - Engine Tool Category Special Tool
Part No. 892/00278
General Tool General Tool Special Tool Special Tool
892/00298 992/12400 993/68100 998/11051
Comments
1 1 1 1
18 - Fuel and Exhaust System Tool Category Special Tool
21 - Cooling System Tool Category Special Tool
78 - 14
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93 - Special Tools 03 - Parts List
27 - Driveline Tool Category Special Tool
Part No. 892/00223
Special Tool
892/00278
Recommended Tool
892/00913
General Tool
992/11300
Description Hand Pump Pressure Test Pressure Gauge (0-40 Bar) Grease Gun Attachment Grease Gun
Qty. 1
Description Ram Protection Sleeve (90mm rod diameter) Hand Pump Pressure Test Pressure Gauge (0-400 Bar) Ram Seal Installation Tool Test Block for Loader Valve ARV Ram Protection Sleeve (25mm rod diameter) Ram Protection Sleeve (30mm rod diameter) Ram Protection Sleeve (40mm rod diameter) Ram Protection Sleeve (50mm rod diameter) Ram Protection Sleeve - Slew (50mm rod diameter) Ram Protection Sleeve (60mm rod diameter) Ram Protection Sleeve - Slew (60mm rod diameter) Ram Protection Sleeve (65mm rod diameter) Ram Protection Sleeve (70mm rod diameter) Ram Protection Sleeve (75mm rod diameter) Ram Protection Sleeve (80mm rod diameter) Ram Seal Assembly Tool Hydraulic Flushing Rig
Qty. 1
Comments
1 1 1
30 - Hydraulic System Tool Category Special Tool
Part No. 892/00167
Special Tool
892/00223
Special Tool
892/00279
Special Tool
892/00334
Special Tool
892/00923
Special Tool
892/01016
Special Tool
892/01017
Special Tool
892/01018
Special Tool
892/01019
Special Tool
892/01020
Special Tool
892/01021
Special Tool
892/01022
Special Tool
892/01023
Special Tool
892/01024
Special Tool
892/01025
Special Tool
892/01026
Special Tool
892/01027
Special Tool
892/01255
78 - 15
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Comments
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
78 - 15
78 - After Sales
93 - Special Tools 03 - Parts List
33 - Electrical System Tool Category Special Tool
Part No. 892/00278
General Tool General Tool General Tool
892/00284 892/00349 892/00350
Description Pressure Gauge (0-40 Bar) Digital Tachometer Wiring Crimp Tool Butane Heater
Qty. 1
Description Grease Gun Attachment Grease Gun
Qty. 1
Comments
1 1 1
75 - Consumable Products Tool Category Recommended Tool
Part No. 892/00913
General Tool
992/11300
78 - 16
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Comments
1
78 - 16
78 - After Sales
93 - Special Tools 03 - Parts List
Component Identification Special Tool - 892/00167 - Ram Protection Sleeve (90mm rod diameter)
Special Tool - 892/00223 - Hand Pump Pressure Test
Special Tool - 892/00278 - Pressure Gauge (0-40 Bar)
Special Tool - 892/00279 - Pressure Gauge (0-400 Bar)
78 - 17
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78 - After Sales
93 - Special Tools 03 - Parts List
General Tool - 892/00284 - Digital Tachometer
General Tool - 892/00298 - Digital Multimeter
Special Tool - 892/00334 - Ram Seal Installation Tool
General Tool - 892/00349 - Wiring Crimp Tool
78 - 18
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78 - After Sales
93 - Special Tools 03 - Parts List
General Tool - 892/00350 - Butane Heater
Recommended Tool - 892/00842 - Glass Lifter
Essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.
Recommended Tool - 892/00843 - Folding Stand
Essential for preparing new glass prior to installation.
Recommended Tool - 892/00845 - Cartridge Gun
Hand operated. Essential for the application of sealants, polyurethane materials etc.
78 - 19
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78 - After Sales
93 - Special Tools 03 - Parts List
Recommended Tool - 892/00846 - Glass Extractor (Handles Only)
Used with braided cutting wire to cut out broken glass. Refer to special tool 892/00849 (Braided Cutting Wire)
Recommended Tool - 892/00847 - 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.
Recommended Tool - 892/00848 - Wire Starter
Used to access braided cutting wire through original polyurethane seal. Refer to special tool 892/00849 (Braided Cutting Wire)
Recommended Tool - 892/00849 - Braided Cutting Wire
Consumable heavy duty cut-out wire used with the glass extraction tool. Length: Approximately 25m. Refer to special tool 892/00846 (Glass Extractor (Handles Only))
Recommended Tool - 892/00913 - Grease Gun Attachment
78 - 20
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78 - After Sales
93 - Special Tools 03 - Parts List
Special Tool - 892/00923 - Test Block for Loader Valve ARV
Special Tool - 892/01016 - Ram Protection Sleeve (25mm rod diameter)
Special Tool - 892/01017 - Ram Protection Sleeve (30mm rod diameter)
Special Tool - 892/01018 - Ram Protection Sleeve (40mm rod diameter)
78 - 21
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93 - Special Tools 03 - Parts List
Special Tool - 892/01019 - Ram Protection Sleeve (50mm rod diameter)
Special Tool - 892/01020 - Ram Protection Sleeve - Slew (50mm rod diameter)
Special Tool - 892/01021 - Ram Protection Sleeve (60mm rod diameter)
Special Tool - 892/01022 - Ram Protection Sleeve - Slew (60mm rod diameter)
78 - 22
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93 - Special Tools 03 - Parts List
Special Tool - 892/01023 - Ram Protection Sleeve (65mm rod diameter)
Special Tool - 892/01024 - Ram Protection Sleeve (70mm rod diameter)
Special Tool - 892/01025 - Ram Protection Sleeve (75mm rod diameter)
Special Tool - 892/01026 - Ram Protection Sleeve (80mm rod diameter)
78 - 23
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93 - Special Tools 03 - Parts List
Special Tool - 892/01027 - Ram Seal Assembly Tool
7m m 11o 20m m
10m m
5m m mm R3
110m m 175m m 3o R
1.
4m
m
Special Tool - 892/01255 - Hydraulic Flushing Rig
Recommended Tool - 926/15500 - Rubber Spacer Blocks
Used to provide the correct set clearance between glass edge and cab frame. Unit quantity: 500 off.
78 - 24
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78 - After Sales
93 - Special Tools 03 - Parts List
General Tool - 992/11300 - Grease Gun
General Tool - 992/12300 - Mobile Oven (12V)
General Tool - 992/12400 - Static Oven (240V)
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). Cartridge capacity: 1.
Required to pre-heat adhesive prior to use. No plug supplied. Cartridge capacity: 2.
Recommended Tool - 992/12800 - Cut-Out Knife
Used to remove broken glass. Refer to special tool 992/12801 ('L' Blades)
Recommended Tool - 992/12801 - 'L' Blades
Refer to special tool 992/12800 (Cut-Out Knife) 25 mm (1 in.) cut. Replacement blades for cut-out knife. Unit quantity = 5 off.
78 - 25
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93 - Special Tools 03 - Parts List
Special Tool - 993/68100 - Slide Hammer Kit
Item 1 2 3
Part No. 993/68101 993/68102 993/68103
4
993/68104
5
993/68105
6
993/68106
7
993/68107
8
993/68108
9
993/68109
10
993/68110
11
993/68111
Special Tool - 998/11051 - Digital Hydraulic Pressure Test Kit
78 - 26
Item 1
Part No. 998/11052
2
998/11053
3 4
998/11054 998/11055
5
998/11056
9813/6050-2
Description Slide hammer End Stops Adaptor (M20 x 5/8" UNF) Adaptor (M20 x 1" UNF) Adaptor (M20 x M20) Adaptor (M20 x M24) Bar (M20 x M20 X 800mm) Adaptor (M20 x 7/8" UNF) Adaptor (M20 x M12) Adaptor (M20 x 5/8" UNF - Shoulder) Adaptor (M20 x 1/2" UNF)
Qty. 1 3 1
Description Hand Held 4-Channel ServiceMaster Unit SensoWin Software Kit and PC Cable Equipment Case 0-600 Bar Pressure Transducer 0-100 Bar PressureTransducer
Qty. 1
1 1 1 1 1 1 1 1
1 1 2 2
78 - 26
78 - After Sales
93 - Special Tools 03 - Parts List
78 - 27
Item 6
Part No. 998/11057
7
998/11058
8
998/11059
9
998/11060
10
998/11061
9813/6050-2
Description Qty. RPM Tachometer 1 (includes fixed cable, 2 metres) 5 Metre Connecting 1 Cable M16 Metric 4 Adaptors for Test Points 400mm Test Hose 2 90° HSP to M16 400mm Test Hose 2 Straight HSP to M16
78 - 27
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96 - Units of Measurement
96 - Units of Measurement Contents
Page No.
78-96-00 General ........................................................................................................................... 78-29
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78 - After Sales
96 - Units of Measurement 00 - General
00 - General
Table 280. Flow
Technical Data The standard units of measurement used by JCB are listed below together with the formula for conversion for countries using non metric standards.
Table 275. Force Convert to
Multiply by
Kilogram force (kgf) Pound force (lbf)
0.102
Multiply by 0.0394 3.281 1.094 0.621
Convert to
Multiply by
Ounce (oz) Pound (lb) Ton
0.035 2.205 0.984
Measurement (unit) Newton metre (Nm)
Convert to
Measurement (unit) Bar
Measurement (unit) Kilometre/Litre (km/l)
Millilitre (ml) Litre (l) 78 - 29
Convert to
3.281
Multiply by
Cubic Inch (in³) 0.061 Cubic Foot (ft³) Cubic Yard (yd³) Fluid ounce (fl oz) UK Gallon US Gallon
Multiply by
Square Inch (in²) Square Foot (ft²) Square Yard (yd²)
0.0015 10.764 1.196
35.315 1.308 0.035 0.220 0.264
Convert to
Multiply by
Pound force foot (lb f ft)
0.7376
Convert to
Multiply by
Pound force/ inch² (psi)
14.5
Convert to
Multiply by
Miles/Gallon (mpg) Miles/ US Gallon
2.825 2.352
Table 285. Temperature Measurement (unit) Degrees Celsius (°C)
Table 279. Volume Measurement (unit) Cubic Centimetre (cm³) Cubic Metre (m³)
Convert to
Table 284. Fuel Consumption
Multiply by
mile/hour (mph) 0.621 feet/second (ft/ s)
0.264
Table 283. Pressure
Table 278. Speed Measurement (unit) Kilometre/Hour (km/h) Metre/Second (m/s)
0.220
Table 282. Torque
Table 277. Mass Measurement (unit) Gram (g) Kilogram (kg) Tonne
Measurement (unit) Square Millimetre (mm²) Square Metre (m²)
0.225
Table 276. Length Measurement Convert to (unit) Millimetre (mm) Inch (in) Metre (m) Feet (ft) Yard (yd) Kilometre (km) Mile (mile)
Multiply by
Table 281. Area
Standard Units Measurement (unit) Newton (N)
Measurement Convert to (unit) Litre/Minute (L/ UK Galm) lon/Minute US Gallon/Minute
Convert to
Formula
Degrees Multiply by 9, Fahrenheit (°F) Divide by 5, Add 32 Table 286. Power
Measurement (unit) KiloWatt (kW)
Convert to
Multiply by
Horsepower (hp)
1.341
Table 287. Time Measurement (unit) Second (s) Minute (min) Hour (h) 9813/6050-2
78 - 29
78 - After Sales
96 - Units of Measurement 00 - General
Table 288. Current Measurement (unit) Ampere (A) Table 289. Voltage Measurement (unit) Volt (V) Table 290. Noise Levels Measurement (unit) Sound pressure level (LpA) Sound power level (LwA)
78 - 30
9813/6050-2
78 - 30