Service Manual 1CX Service Manual - 1CX Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section J - Tracks Section K - Engine
Publication No.
9803/9960-4
World Class Customer Support Copyright Š 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section 1 General Information Service Manual - 1CX Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section J - Tracks Section K - Engine
Publication No.
9803/9960-3
World Class Customer Support Copyright Š 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section 1 - General Information
Notes:
1-0
9803/9960-3
1-0
Section 1 - General Information Contents
Contents Page No. Introduction About This Manual ..................................................................................... 1-1 Machine Model and Serial Number .......................................................1-1 Using the Service Manual .....................................................................1-1 Section Numbering ................................................................................1-1 Cab/Canopy ..........................................................................................1-1 Left Side, Right Side ..............................................................................1-1 Identifying Your Machine ........................................................................... 1-3 Machine Identification Plate ..................................................................1-3 Component Identification Plates ............................................................1-4 Typical Engine Identification Number ....................................................1-5 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-7 Introduction ............................................................................................1-7 Bolts and Screws ...................................................................................1-7 Hydraulic Connections ............................................................................. 1-11 'O' Ring Face Seal System .................................................................. 1-11 'Torque Stop' Hose System .................................................................1-14 Service Tools Numerical List Section B - Body and Framework .................................... Tool Detail Reference Section B - Body and Framework ........................ Numerical List Section C - Electrics ........................................................ Tool Detail Reference Section C - Electrics ............................................. Numerical List Section E- Hydraulics ...................................................... Tool Detail Reference Section E- Hydraulics ...........................................
1-15 1-16 1-20 1-21 1-22 1-25
Service Consumables Sealing and Retaining Compounds ......................................................... 1-29 Terms and Definitions Colour Coding .......................................................................................... 1-31 Hydraulic Schematic Colour Codes .....................................................1-31
1-i
1-i
Section 1 - General Information Contents
Contents
1-ii
Page No.
1-ii
Section 1 - General Information
Introduction About This Manual Machine Model and Serial Number
Finally, please remember above all else safety must come first!
This manual provides information for the following model(s) in the JCB machine range:
Section Numbering T11-005
The manual is compiled in sections, the first three are numbered and contain information as follows:
– 1CX (series 1) from 751600 – 1CX (series 2) from 1743153
Using the Service Manual
1
General Information - includes torque settings and service tools.
2
Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3
Maintenance - includes service schedules and recommended lubricants for all the machine.
T11-004
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication.
1-1
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: A
Attachments
B
Body and Framework, etc.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.
Cab/Canopy T1-003_2
This manual frequently makes references to the cab. For instance, 'do not operate the machine without a manual in the cab'. It should be noted that these statements also apply to canopy build machines.
Left Side, Right Side P2-1002
In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. This is so whether you are facing the loader (front) or the backhoe (rear).
9803/9960-3
1-1
Section 1 - General Information Introduction About This Manual
A
B
A
B C003690
Fig 1.
1-2
9803/9960-3
1-2
Section 1 - General Information Introduction Identifying Your Machine
Identifying Your Machine Machine Identification Plate Your machine has an identification plate mounted as shown. K Fig 2. ( T 1-3). The serial numbers of the machine and its major units are stamped on the plate. Note: The machine model and build specification is indicated by the VIN (earlier machines) or PIN (later machines). A detailed description of the VIN/PIN numbering system is included later in this section. The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, 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.
S203651
Fig 2.
1-3
9803/9960-3
1-3
Section 1 - General Information Introduction Identifying Your Machine
Component Identification Plates
Typical Product Identification Number (PIN)
Typical Vehicle Identification Number (VIN) 1
2
SLP 1CX
3
4
5
6
7
S
B
6
E
751601
1
World Manufacturer Identification.
2
Machine Model.
3
Steer Type (S = Standard, H = High Flow).
4
Build Type (A = Canopy, B =Cab).
5
Year of Manufacture: 2 = 2002
1
2
3
4
JCB
1CXWS
L
01299167
1
World Manufacturer Identification (3 Digits). JCB = UK Build.
2
Machine Type and Model (5 Digits). 1CXWS = 1CX Wheeled Standard.
3
Check Letter (1 Digit). The check letter is used to verify the authenticity of a machine's PIN.
4
3 = 2003
Machine Serial Number (8 Digits). Each machine has a unique serial number.
4 = 2004 5 = 2005 6 = 2006 7 = 2007 6
Manufacturer Location (E = England).
7
Machine Serial Number.
1-4
9803/9960-3
1-4
Section 1 - General Information Introduction Identifying Your Machine
Typical Engine Identification Number The engine data label is located on the cylinder block at position A. K Fig 3. ( T 1-5). The data label includes the engine identification number. A typical engine identification number is explained as follows: RE
50261
U
500405
P
1
2
3
4
5
1
Engine Type GN = Naturally aspirated (Tier 3). GP = Turbocharged (Tier 3). HP = Naturally aspirated (Tier 2). RG = Turbocharged (Tier 2).
2
Build Number
3
Country of manufacture U = United Kingdom
4
Engine Serial Number
5
Year of Manufacture
T017650-1
Fig 3.
1-5
9803/9960-3
1-5
Section 1 - General Information Introduction Identifying Your Machine
Page left intentionally blank
1-6
9803/9960-3
1-6
Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners
Torque Settings Zinc Plated Fasteners and Dacromet Fasteners T11-002
Introduction
Bolts and Screws
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.
Use the following torque setting tables only where no torque setting is specified in the text.
The two types of fasteners can be readily identified by colour and part number suffix. K Table 1. Fastener Types ( T 1-7).
Torque settings are given for the following conditions:
Fastener Type
Table 1. Fastener Types Colour Part No. Suffix
Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate.
Condition 1 – Un-lubricated fasteners – Zinc fasteners – Yellow plated fasteners
Zinc and Yellow
Golden finish
'Z' (e.g. 1315/3712Z)
Dacromet
Mottled silver finish 'D' (e.g. 1315/3712D)
Condition 2 – Zinc flake (Dacromet) fasteners
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. Note: 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.
– Lubricated zinc and yellow plated fasteners – Where there is a natural lubrication. For example, cast iron components
Verbus Ripp Bolts
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. Note: 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.
1-7
Fig 1. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.
9803/9960-3
1-7
Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Hexagon (A/F) Condition 1
Bolt Size in.
mm
in.
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
1/4
6.3
7/16
11.2
1.1
8.3
10.0
1.0
7.4
5/16
7.9
1/2
22.3
2.3
16.4
20.0
2.0
14.7
3/8
9.5
9/16
40.0
4.1
29.5
36.0
3.7
26.5
7/16
11.1
5/8
64.0
6.5
47.2
57.0
5.8
42.0
1/2
12.7
3/4
98.00
10.0
72.3
88.0
9.0
64.9
9/16
14.3
13/16
140.0
14.3
103.2
126.0
12.8
92.9
5/8
15.9
15/16
196.0
20.0
144.6
177.0
18.0
130.5
3/4
19.0
1 1/8
343.0
35.0
253.0
309.0
31.5
227.9
7/8
22.2
1 15/16
547.0
55.8
403.4
492.0
50.2
362.9
1
25.4
1 1/2
814.0
83.0
600.4
732.0
74.6
539.9
1 1/8
31.7
1 7/8
1181.0
120.4
871.1
1063.0
108.4
784.0
1 1/4
38.1
2 1/4
1646.0
167.8
1214.0
1481.0
151.0
1092.3
Table 3. Torque Settings - Metric Grade 8.8 Fasteners Hexagon (A/F) Condition 1
Bolt Size ISO Metric Thread
mm
M5
5
8
5.8
M6
6
10
9.9
M8
8
13
24.0
M10
10
17
47.0
1-8
Condition 2
mm
Nm
kgf m
Condition 2
lbf ft
Nm
kgf m
lbf ft
0.6
4.3
5.2
0.5
3.8
1.0
7.3
9.0
0.9
6.6
2.4
17.7
22.0
2.2
16.2
4.8
34.7
43.0
4.4
31.7
M12
12
19
83.0
8.5
61.2
74.0
7.5
54.6
M16
16
24
205.0
20.9
151.2
184.0
18.8
135.7
M20
20
30
400.0
40.8
295.0
360.0
36.7
265.5
M24
24
36
690.0
70.4
508.9
621.0
63.3
458.0
M30
30
46
1372.0
139.9
1011.9
1235.0
125.9
910.9
M36
36
55
2399.0
244.6
1769.4
2159.0
220.0
1592.4
9803/9960-3
1-8
Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Hexagon (A/F) Condition 1
Bolt Size ISO Metric Thread
mm
mm
Nm
kgf m
Condition 2 lbf ft
Nm
kgf m
lbf ft
M5
5
8
8.1
0.8
6.0
7.3
0.7
5.4
M6
6
10
13.9
1.4
10.2
12.5
1.3
9.2
M8
8
13
34.0
3.5
25.0
30.0
3.0
22.1
M10
10
17
67.0
6.8
49.4
60.0
6.1
44.2
M12
12
19
116.0
11.8
85.5
104.0
10.6
76.7
M16
16
24
288.0
29.4
212.4
259.0
26.4
191.0
M20
20
30
562.0
57.3
414.5
506.0
51.6
373.2
M24
24
36
971.0
99.0
716.9
874.0
89.1
644.6
M30
30
46
1930.0
196.8
1423.5
1737.0
177.1
1281.1
M36
36
55
3374.0
344.0
2488.5
3036.0
309.6
2239.2
Table 5. Metric Grade 12.9 Fasteners Hexagon (A/F) Condition 1
Bolt Size
Condition 2
ISO Metric Thread
mm
mm
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
M5
5
8
9.8
1.0
7.2
8.8
0.9
6.5
M6
6
10
16.6
1.7
12.2
15.0
1.5
11.1
M8
8
13
40.0
4.1
29.5
36.0
3.7
26.5
M10
10
17
80.0
8.1
59.0
72.0
7.3
53.1
M12
12
19
139.0
14.2
102.5
125.0
12.7
92.2
M16
16
24
345.0
35.2
254.4
311.0
31.7
229.4
M20
20
30
674.0
68.7
497.1
607.0
61.9
447.7
M24
24
36
1165.0
118.8
859.2
1048.0
106.9
773.0
M30
30
46
2316.0
236.2
1708.2
2084.0
212.5
1537.1
M36
36
55
4049.0
412.9
2986.4
3644.0
371.6
2687.7
1-9
9803/9960-3
1-9
Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread
mm
Nm
kgf m
lbf ft
M3
3
1.2
0.1
0.9
M4
4
3.0
0.3
2.0
M5
5
6.0
0.6
4.5
M6
6
10.0
1.0
7.5
M8
8
24.0
2.5
18.0
M10
10
48.0
4.9
35.5
M12
12
82.0
8.4
60.5
Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size
1-10
ISO Metric Thread
Nm
kgf m
lbf ft
M3
2.0
0.2
1.5
M4
6.0
0.6
4.5
M5
11.0
1.1
8.0
M6
19.0
1.9
14.0
M8
46.0
4.7
34.0
M10
91.0
9.3
67.0
M12
159.0
16.2
117.0
M16
395.0
40.0
292.0
M18
550.0
56.0
406.0
M20
770.0
79.0
568.0
M24
1332.0
136.0
983.0
9803/9960-3
1-10
Section 1 - General Information Torque Settings Hydraulic Connections
Hydraulic Connections T11-003
'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port. Table 8. Torque Settings - BSP Adaptors BSP Adaptor Hexagon (A/F) Size
1-11
in.
mm
Nm
kgf m
lbf ft
1/4
19.0
18.0
1.8
13.0
3/8
22.0
31.0
3.2
23.0
1/2
27.0
49.0
5.0
36.0
5/8
30.0
60.0
6.1
44.0
3/4
32.0
81.0
8.2
60.0
1
38.0
129.0
13.1
95.0
1 1/4
50.0
206.0
21.0
152.0
Table 9. Torque Settings - SAE Connections SAE Port Hexagon (A/F)
SAE Tube Size
Thread Size
mm
Nm
kgf m
lbf ft
4
7/16 - 20
15.9
20.0 - 28.0
2.0 - 2.8
16.5 - 18.5
6
9/16 - 18
19.1
46.0 - 54.0
4.7 - 5.5
34.0 - 40.0
8
3/4 - 16
22.2
95.0 - 105.0
9.7 - 10.7
69.0 - 77.0
10
7/8 - 14
27.0
130.0 - 140.0
13.2 - 14.3
96.0 - 104.0
12
1 1/16 - 12
31.8
190.0 - 210.0
19.4 - 21.4
141.0 - 155.0
16
1 5/16 - 12
38.1
290.0 - 310.0
29.6 - 31.6
216.0 - 230.0
20
1 5/8
47.6
280.0 - 380.0
28.5 - 38.7
210.0 - 280.0
9803/9960-3
1-11
Section 1 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors
Fig 2. Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring 2-C which is compressed into a 45° seat machined into the face of the adaptor port.
BSP Hose Size in.
1-12
Note: Dimension 2-D will vary depending upon the torque applied.
Table 10. BSP Hose - Torque Settings Hexagon (A/F) mm
Nm
1/8
14.0
14.0 - 16.00
1.4 - 1.6
10.3 - 11.8
1/4
19.0
24.0 - 27.0
2.4 - 2.7
17.7 - 19.9
3/8
22.0
33.0 - 40.0
3.4 - 4.1
24.3 - 29.5
1/2
27.0
44.0 - 50.0
4.5 - 5.1
32.4 - 36.9
5/8
30.0
58.0 - 65.0
5.9 - 6.6
42.8 - 47.9
3/4
32.0
84.0 - 92.0
8.6 - 9.4
61.9 - 67.8
1
38.0
115.0 - 126.0
11.7 - 12.8
84.8 - 92.9
1 1/4
50.0
189.0 - 200.0
19.3 - 20.4
139.4 - 147.5
1 1/2
55.0
244.0 - 260.0
24.9 - 26.5
180.0 - 191.8
9803/9960-3
kgf m
lbf ft
1-12
Section 1 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size
1-13
in.
Nm
kgf m
lbf ft
1/8
20.0
2.1
15.0
1/4
34.0
3.4
25.0
3/8
75.0
7.6
55.0
1/2
102.0
10.3
75.0
5/8
122.0
12.4
90.0
3/4
183.0
18.7
135.0
1
203.0
20.7
150.0
1 1/4
305.0
31.0
225.0
1 1/2
305.0
31.0
225.0
9803/9960-3
1-13
Section 1 - General Information Torque Settings Hydraulic Connections
'Torque Stop' Hose System
Fig 3. `Torque Stop' Hoses 3-B screwed into adaptors 3-A seal onto an 'O' ring 3-C which is compressed into a 45° seat machined in the face of the adaptor port. To prevent the 'O' ring being damages as a result of over tightening, 'Torque
Stop' Hoses have an additional shoulder 3-D, which acts as a physical stop. Note: Minimum dimension 3-E fixed by shoulder 3-D.
Table 12. BSP `Torque Stop' Hose - Torque Settings BSP Hose Size Hexagon (A/F)
1-14
in.
mm
Nm
kgf m
lbf ft
1/8
14.0
14.0
1.4
10.0
1/4
19.0
27.0
2.7
20.0
3/8
22.0
40.0
4.1
30.0
1/2
27.0
55.0
5.6
40.0
5/8
30.0
65.0
6.6
48.0
3/4
32.0
95.0
9.7
70.0
1
38.0
120.0
12.2
89.0
1 1/4
50.0
189.0
19.3
140.0
1 1/2
55.0
244.0
24.9
180.0
9803/9960-3
1-14
Section 1 - General Information
Service Tools Numerical List Section B - Body and Framework The tools listed in the table are special tools required for removal and replacement of Body and Framework parts. These tools are available from JCB Service.
Note: 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.
Part Number
Description
Tool Detail Reference
4104/1310
Hand Cleaner
K Fig 1. ( T 1-16)
826/01099
Rivet Nut
K Fig 15. ( T 1-19)
826/01101
Rivet Nut
K Fig 15. ( T 1-19)
826/01102
Rivet Nut
K Fig 15. ( T 1-19)
826/01103
Rivet Nut
K Fig 15. ( T 1-19)
826/01104
Rivet Nut
K Fig 15. ( T 1-19)
826/01105
Rivet Nut
K Fig 15. ( T 1-19)
892/00842
Glass Lifter
K Fig 6. ( T 1-16)
892/00843
Folding Stand
K Fig 4. ( T 1-16)
892/00844
Long Knife
K Fig 12. ( T 1-18)
892/00845
Cartridge Gun
K Fig 2. ( T 1-16)
892/00846
Glass Extractor (Handles)
K Fig 9. ( T 1-17)
892/00847
Nylon Spatula
K Fig 13. ( T 1-18)
892/00848
Wire Starter
K Fig 7. ( T 1-17)
892/00849
Braided Cutting Wire
K Fig 11. ( T 1-18)
926/15500
Rubber Spacer Blocks
K Fig 14. ( T 1-18)
992/12300
12V Mobile Oven
K Fig 3. ( T 1-16)
992/12400
Static Oven - 2 Cartridge
K Fig 5. ( T 1-16)
992/12600
Static Oven - 6 Cartridge
K Fig 5. ( T 1-16)
992/12800
Cut-Out Knife
K Fig 8. ( T 1-17)
992/12801
"L" Blades
K Fig 10. ( T 1-17)
1-15
9803-9960-3
1-15
Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework
Tool Detail Reference Section B - Body and Framework
Fig 1. Hand Cleaner - special blend for the removal of polyurethane adhesives. JCB part number - 4104/1310 (454g; 1 lb tub)
Fig 2. Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc. JCB part number - 892/00845
Fig 3.
Fig 4. 12V Mobile Oven - 1 cartridge capacity - required to pre-heat Folding Stand for holding glass - essential for preparing adhesive prior to use. It is fitted with a male plug (703/23201) new glass prior to installation. which fits into a female socket (715/04300). JCB part number - 992/12300 JCB part number - 892/00843
Fig 5.
1-16
Fig 6.
9803-9960-3
1-16
Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework 240V Static Oven - available with 2 or 6 cartridge capacity - Glass Lifter - minimum 2 off - essential for glass installation, required to pre-heat adhesive prior to use. No plug supplied. 2 required to handle large panes of glass. Ensure suction Note: 110V models available upon request - contact JCB cups are protected from damage during storage. Technical Service. JCB part number: JCB part number - 892/00842 992/12400 - 2 Cartridge x 240V9 992/12600 - 6 Cartridge x 240V
Fig 7.
Fig 8. Wire Starter - used to access braided cutting wire (below) Cut-Out Knife - used to remove broken glass. through original polyurethane seal. JCB part number - 892/00848 JCB part number - 992/12800
Fig 10.
Fig 9. Glass Extractor (Handles) - used with braided cutting wire 'L' Blades - 25 mm (1 in) cut - replacement blades for cut-out (below) to cut out broken glass. knife (above). JCB part number - 892/00846 JCB part number - 992/12801 (unit quantity = 5 off)
1-17
9803-9960-3
1-17
Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework
Fig 11.
Fig 12. Braided Cutting Wire - consumable heavy duty cut-out wire Long Knife - used to give extended reach for normally used with the glass extraction tool (above). inaccessible areas. JCB part number - 892/00849 (approx 25 m length) JCB part number - 892/00844
Fig 13.
Fig 14. Nylon Spatula - general tool used for smoothing sealants - Rubber Spacer Blocks - used to provide the correct set also used to re-install glass in rubber glazing because metal clearance between glass edge and cab frame. tools will chip the glass edge. JCB part number - 892/00847 JCB part number - 926/15500 (unit quantity = 500 off)
1-18
9803-9960-3
1-18
Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework
Fig 15. Rivet Nuts 826/01099 M6 x 16mm Rivet Nut 826/01101 M6 x 19mm Rivet Nut 826/01103 M8 x 18mm Rivet Nut 826/01102 M8 x 21mm Rivet Nut 826/01104 M10 x 23mm Rivet Nut 826/01105 M10 x 26mm Rivet Nut Installation Tool Available from: Bollhoff Fastenings Ltd. Midacre The Willenhall Estate Rose Hill Willenhall West Midlands, WV13 2JW
1-19
9803-9960-3
1-19
Section 1 - General Information Service Tools Numerical List Section C - Electrics
Numerical List Section C - Electrics The tools listed in the table are special tools required for testing electrics. These tools are available from JCB Service.
Note: 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.
Part Number
Description
Tool Detail Reference
721/10885
Interconnecting Cable (part of 892/01033)
K Fig 17. ( T 1-21)
892/01033
Electronic Service Tool Kit
K Fig 16. ( T 1-21)
1-20
9803-9960-3
1-20
Section 1 - General Information Service Tools Tool Detail Reference Section C - Electrics
Tool Detail Reference Section C - Electrics
3 D
C
B
A
J
E F
H
D
C
B
G
A
J
E F
H
G
4 A408030
Fig 17. Interconnecting Cable 721/10885
Interconnecting cable, DLA to machine ECU diagnostics socket (part of 892/ 01033 Kit).
1 2
A406130-1
Fig 16. Electronic Service Tool Kit 892/01033 Tool Kit comprises: 1
Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable diagnostics software.
2
Interconnecting cable, DLA to laptop PC. Several cables are included to enable compatibility with different PC port types.
3
Interconnecting cable, DLA to machine ECU diagnostics socket.
4
Kit carrying case.
1-21
9803-9960-3
1-21
Section 1 - General Information Service Tools Numerical List Section E- Hydraulics
Numerical List Section E- Hydraulics The tools listed in the table are special tools required for testing, removing and replacing hydraulics. These tools are available from JCB Service.
Note: 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.
Part Number
Description
Tool Detail Reference
1406/0011
Bonded Washer
K Fig 23. ( T 1-26)
1406/0018
Bonded Washer
K Fig 23. ( T 1-26)
1406/0021
Bonded Washer
K Fig 23. ( T 1-26)
1406/0029
Bonded Washer
K Fig 23. ( T 1-26)
1604/0003
Adapter
K Fig 24. ( T 1-26)
1604/0004
Adapter
K Fig 24. ( T 1-26)
1604/0006
Adapter
K Fig 24. ( T 1-26)
1606/0003
Adapter
K Fig 24. ( T 1-26)
1606/0004
Adapter
K Fig 24. ( T 1-26)
1606/0007
Adapter
K Fig 24. ( T 1-26)
1606/0008
Adapter
K Fig 24. ( T 1-26)
1606/0009
Adapter
K Fig 24. ( T 1-26)
1612/0006
Adapter
K Fig 21. ( T 1-25)
816/00189
Blanking Cap
K Fig 26. ( T 1-26)
816/00190
Blanking Cap
K Fig 26. ( T 1-26)
816/00193
Blanking Cap
K Fig 26. ( T 1-26)
816/00196
Blanking Cap
K Fig 26. ( T 1-26)
816/00197
Blanking Cap
K Fig 26. ( T 1-26)
816/00294
Blanking Cap
K Fig 26. ( T 1-26)
816/15118
Pressure Test Adapter
K Fig 20. ( T 1-25)
816/50043
'T' Adapter
K Fig 27. ( T 1-27)
816/55038
Pressure Test 'T' Adapter
K Fig 19. ( T 1-25)
816/55040
Pressure Test 'T' Adapter
K Fig 19. ( T 1-25)
816/60096
'T' Adapter
K Fig 27. ( T 1-27)
892/00047
'T' Adapter
K Fig 27. ( T 1-27)
892/00048
'T' Adapter
K Fig 27. ( T 1-27)
892/00055
Blanking Plug
K Fig 25. ( T 1-26)
892/00056
Blanking Plug
K Fig 25. ( T 1-26)
892/00057
Blanking Plug
K Fig 25. ( T 1-26)
892/00059
Blanking Plug
K Fig 25. ( T 1-26)
892/00060
Blanking Plug
K Fig 25. ( T 1-26)
1-22
9803-9960-3
1-22
Section 1 - General Information Service Tools Numerical List Section E- Hydraulics Part Number
Description
Tool Detail Reference
892/00074
Female Connector
K Fig 28. ( T 1-27)
892/00075
Female Connector
K Fig 28. ( T 1-27)
892/00077
Female Connector
K Fig 28. ( T 1-27)
892/00137
Hose
K Fig 22. ( T 1-26)
892/00167
Ram Seal Protection Sleeve
K Fig 32. ( T 1-28)
892/00223
Hand Pump
K Fig 22. ( T 1-26)
892/00253
Pressure Test Kit
K Fig 18. ( T 1-25)
892/00255
Pressure Test Adapter
K Fig 20. ( T 1-25)
892/00256
Pressure Test Adapter
K Fig 20. ( T 1-25)
892/00257
Pressure Test Adapter
K Fig 20. ( T 1-25)
892/00258
Pressure Test Adapter
K Fig 20. ( T 1-25)
892/00259
Pressure Test Adapter
K Fig 20. ( T 1-25)
892/00260
Pressure Test Adapter
K Fig 20. ( T 1-25)
892/00261
Pressure Test Adapter
K Fig 20. ( T 1-25)
892/00262
Pressure Test 'T' Adapter
K Fig 19. ( T 1-25)
892/00263
Pressure Test 'T' Adapter
K Fig 19. ( T 1-25)
892/00264
Pressure Test 'T' Adapter
K Fig 19. ( T 1-25)
892/00265
Pressure Test 'T' Adapter
K Fig 19. ( T 1-25)
892/00268
Flow Monitoring Unit
K Fig 21. ( T 1-25)
892/00269
Sensor Head
K Fig 21. ( T 1-25)
892/00270
Load Valve
K Fig 21. ( T 1-25)
892/00271
Adapter
K Fig 21. ( T 1-25)
892/00272
Adapter
K Fig 21. ( T 1-25)
892/00274
Adapter
K Fig 22. ( T 1-26)
892/00275
Adapter
K Fig 21. ( T 1-25)
892/00276
Adapter
K Fig 21. ( T 1-25)
892/00277
Adapter
K Fig 21. ( T 1-25)
892/00278
Gauge
K Fig 22. ( T 1-26)
892/00279
Gauge
K Fig 22. ( T 1-26)
892/00334
Ram Seal Fitting Tool
K Fig 31. ( T 1-28)
892/00706
Test Probe
K Fig 22. ( T 1-26)
892/01016
Ram Seal Protection Sleeve
K Fig 32. ( T 1-28)
892/01017
Ram Seal Protection Sleeve
K Fig 32. ( T 1-28)
892/01018
Ram Seal Protection Sleeve
K Fig 32. ( T 1-28)
892/01019
Ram Seal Protection Sleeve
K Fig 32. ( T 1-28)
892/01020
Ram Seal Protection Sleeve
K Fig 32. ( T 1-28)
892/01021
Ram Seal Protection Sleeve
K Fig 32. ( T 1-28)
1-23
9803-9960-3
1-23
Section 1 - General Information Service Tools Numerical List Section E- Hydraulics Part Number
Description
Tool Detail Reference
892/01022
Ram Seal Protection Sleeve
K Fig 32. ( T 1-28)
892/01023
Ram Seal Protection Sleeve
K Fig 32. ( T 1-28)
892/01024
Ram Seal Protection Sleeve
K Fig 32. ( T 1-28)
892/01025
Ram Seal Protection Sleeve
K Fig 32. ( T 1-28)
892/01026
Ram Seal Protection Sleeve
K Fig 32. ( T 1-28)
992/09300
Spanner
K Fig 29. ( T 1-27)
992/09400
Spanner
K Fig 29. ( T 1-27)
992/09500
Spanner
K Fig 29. ( T 1-27)
992/09600
Spanner
K Fig 29. ( T 1-27)
992/09700
Spanner
K Fig 29. ( T 1-27)
992/09900
Spanner
K Fig 29. ( T 1-27)
992/10000
Spanner
K Fig 29. ( T 1-27)
The following parts are replacement items for kits and would normally be included in the kit numbers quoted above. Table 1. Replacement items for kit no. 892/00253 Part Number
Description
Tool Detail Reference
892/00201
Replacement Gauge
K Fig 18. ( T 1-25)
892/00202
Replacement Gauge
K Fig 18. ( T 1-25)
892/00203
Replacement Gauge
K Fig 18. ( T 1-25)
892/00254
Replacement Hose
K Fig 18. ( T 1-25)
1-24
9803-9960-3
1-24
Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics
Tool Detail Reference Section E- Hydraulics 892/00263 5/8 in BSP x 5/8 in F BSP x Test Point 892/00264 3/4 in BSP x 3/4 in F BSP x Test Point 892/00265 1 in M BSP x 1 in F BSP x Test Point
Fig 20. Pressure Test Adapters 892/00255 1/4 in BSP x Test Point 892/00256 3/8 in BSP x Test Point
Fig 18. Hydraulic Circuit Pressure test Kit 892/00253 Pressure Test Kit
892/00257 1/2 in BSP x Test Point
892/00201 Replacement gauge 0-20 bar (0-300 lbf/in2)
892/00258 5/8 in BSP x Test Point
892/00202 Replacement gauge 0-40 bar (0-600 lbf/in2)
816/15118 3/4 in BSP x Test Point
892/00203 Replacement gauge 0-400 bar (0-6000 lbf/ in2) 892/00254 Replacement Hose
892/00259 1 in BSP x Test Point 892/00260 1,1/4 in BSP x Test Point 892/00261 5/8 in UNF x Test Point
Fig 21. Flow Test Equipment Fig 19. Pressure Test `T' Adapters 892/00262 1/4 in BSP x 1/4 in F BSP x Test Point 816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point 816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point
1-25
892/00268 Flow Monitoring Unit 892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/ min) 892/00270 Load Valve 1406/0021 Bonded Washer
9803-9960-3
1-25
Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics 1604/0006 Adapter 3/4 in M x 3/4 in M BSP 1612/0006 Adapter 3/4 in F x 3/4 in M BSP 892/00271 Adapter 3/4 in F x 5/8 in M BSP 892/00272 Adapter 5/8 in F x 3/4 in M BSP 816/20008 Adapter 3/4 in F x 1/2 in M BSP 892/00275 Adapter 1/2 in F x 3/4 in M BSP 892/00276 Adapter 3/4 in F x 3/8 in M BSP
Fig 24. Male Adapters - BSP x BSP
892/00277 Adapter 3/8 in F x 3/4 in M BSP
1606/0003 3/8 in x 1/4 in 1604/0003 3/8 in x 3/8 in 1606/0004 1/2 in x 1/4 in 1606/0007 1/2 in x 3/8 in 1604/0004 1/2 in x 1/2 in 1606/0008 3/4 in x 3/8 in 1606/0009 3/4 in x 1/2 in 1604/0006 3/4 in x 3/4 in
Fig 22. Hand Pump Equipment 892/00223 Hand Pump 892/00137 Micro-bore Hose 1/4 in BSP x 5 metres 892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 892/00706 Test Probe 892/00278 Gauge 0 - 40 bar (0 - 600 lbf/in2) 892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in2)
Fig 25. Female Cone Blanking Plug 892/00055 1/4 in BSP 892/00056 3/8 in BSP 892/00057 1/2 in BSP 892/00059 3/4 in BSP 892/00060 1 in BSP'T'
Fig 23. Bonded Washers 1406/0011 1/4 in BSP 1406/0018 1/2 in BSP 1406/0021 3/4 in BSP 1406/0029 1.1/4 in BSP
Fig 26. Male Cone Blanking Plug
1-26
9803-9960-3
1-26
Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics 816/00294 1/4 in BSP 816/00189 3/8 in BSP 816/00190 1/2 in BSP 816/00197 5/8 in BSP 816/00196 3/4 in BSP 816/00193 1 in BSP
Fig 29. Hexagon Spanners for Ram Pistons and End Caps 992/09300 55 mm A/F 992/09400 65 mm A/F 992/09500 75 mm A/F 992/09600 85 mm A/F 992/09700 95 mm A/F 992/09900 115 mm A/F Fig 27. `T' Adapters
992/10000 125 mm A/F
892/00047 3/8 in BSP (A) x 1/4 in BSP (B) 892/00048 1/2 in BSP (A) x 1/4 in BSP (B) 816/50043 3/4 in BSP (A) x 1/4 in BSP (B) 816/60096 3/4 in BSP (A) x 3/4 in BSP (B)
7mm 11o 20mm
10mm
5mm
m
R
3m
110mm 175mm
Fig 28. Female Connectors 892/00074 3/8 in BSP x 3/8 in BSP
3o
892/00075 1/2 in BSP x 1/2 in BSP
R
1.4
mm
892/00077 3/4 in BSP x 3/4 in BSP
Fig 30. Piston Seal Assembly Tool 892/01027
1-27
9803-9960-3
1-27
Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics
Fig 31. Ram Seal Fitting Tool 892/00334
Fig 32. Ram Seal Protection Sleeves 892/01016 For 25 mm Rod Diameter 892/01017 For 30 mm Rod Diameter 892/01018 For 40 mm Rod Diameter 892/01019 For 50 mm Rod Diameter 892/01020 For 50 mm Rod Diameter (slew ram) 892/01021 For 60 mm Rod Diameter 892/01022 For 60 mm Rod Diameter (slew ram) 892/01023 For 65 mm Rod Diameter 892/01024 For 70 mm Rod Diameter 892/01025 For 75 mm Rod Diameter 892/01026 For 80 mm Rod Diameter 892/00167 For 90 mm Rod Diameter
1-28
9803-9960-3
1-28
Section 1 - General Information Service Consumables Sealing and Retaining Compounds
Service Consumables Sealing and Retaining Compounds T11-001_4
Table 1. Type
Description
JCB Multi-Gasket
A medium strength sealant suitable for all sizes of 4102/1212 gasket flanges, and for hydraulic fittings of 25-65 mm diameter.
50 ml
JCB High Strength Threadlocker
A high strength locking fluid for use with threaded 4102/0551 components. Gasketing for all sizes of flange where the strength of the joint is important.
50 ml
JCB Retainer (High Strength)
For all retaining parts which are unlikely to be dismantled.
4101/0601
10 ml
4101/0651
50 ml
A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter.
4101/0250
10 ml
4101/0251
50 ml
JCB Threadlocker and Sealer (High Strength)
A high strength locking fluid for sealing and retaining 4101/0550 nuts, bolts, and screws up to 50 mm diameter, and 4101/0552 for hydraulic fittings up to 25 mm diameter.
10 ml 200 ml
JCB Threadseal
A medium strength thread sealing compound.
4102/1951
50 ml
JCB Activator
A cleaning primer which speeds the curing rate of anaerobic products.
4104/0251
200 ml (Aerosol)
4104/0253
1 ltr (Bottle)
JCB Cleaner/Degreaser
For degreasing components prior to use of anaerobic adhesives and sealants.
4104/1557
400 ml (Aerosol)
Direct Glazing Kit
For one pane of glass; comprises of:
993/55700
JCB Threadlocker and Sealer
Part No.
Quantity
– 1 x Ultra Fast Adhesive (310 ml) – 1 x Active Wipe 205 (30 ml) – 1 x Black Primer 206J (30 ml) – plus applicator nozzle etc. Ultra Fast Adhesive
For direct glazing.
4103/2109
310 ml
Active Wipe 205
For direct glazing.
4104/1203
250 ml
Black Primer 206J
For direct glazing.
4201/4906
30 ml
Clear Silicone Sealant
To seal butt jointed glass.
4102/0901
Plastic to Metal Bonder
To seal plastic to metal joints.
4103/0956
50 g
Black Polyurethane Sealant
To finish exposed edges of laminated glass.
4102/2309
310 ml
1-29
9803/9960-3
1-29
Section 1 - General Information Service Consumables Sealing and Retaining Compounds
Page left intentionally blank
1-30
9803/9960-3
1-30
Section 1 - General Information
Terms and Definitions Colour Coding Hydraulic Schematic Colour Codes T11-006
The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications.
Red
Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and MRV operating pressure.
Pink
Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red.
Orange
Blue
Green
Light Green
Yellow
1-31
Servo: Oil pressure used in controlling a device (servo).
Neutral: Neutral circuit pressure.
Exhaust
Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).
Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).
9803/9960-3
1-31
Section 1 - General Information Terms and Definitions Colour Coding
Page left intentionally blank
1-32
9803/9960-3
1-32
Section 2 Care and Safety Service Manual - 1CX Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section J - Tracks Section K - Engine
Publication No.
9803/9960-3
World Class Customer Support Copyright © 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section 2 - Care and Safety
Notes:
2-0
9803/9960-3
2-0
Section 2 - Care and Safety Contents Page No. Safety Notices Important Information ................................................................................ 2-1 The Operator Manual ............................................................................2-1 Safety Warnings ....................................................................................2-1 Safety Check List ....................................................................................... 2-2 Safety - Yours and Others .....................................................................2-2 General Safety ......................................................................................2-2 Operating Safety ...................................................................................2-4 Maintenance Safety ...............................................................................2-7 Safety Labels ........................................................................................... 2-12 Introduction ..........................................................................................2-12
2-i
2-i
Section 2 - Care and Safety Contents
2-ii
Page No.
2-ii
Section 2 - Care and Safety
Safety Notices Important Information T1-042
The Operator Manual
Safety Warnings
!MWARNING You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator Manual. You must understand and follow the instructions in the Operator Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. INT-1-4-2
Do not operate the machine without an Operator Manual, or if there is anything on the machine you do not understand. Treat the Operator Manual as part of the machine. Keep it clean and in good condition. Replace the Operator Manual immediately if it is lost, damaged or becomes unreadable.
This safety alert system identifies important safety messages in this manual. When you see this symbol, be alert, your safety is involved, carefully read the message that follows, and inform other operators. In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.
!MDANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured. INT-1-2-1
!MWARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-2
!MCAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine. INT-1-2-3
2-1
9803/9960-3
2-1
Section 2 - Care and Safety Safety Notices Safety Check List
Safety Check List P2-1005_3
Safety - Yours and Others
General Safety INT-1-3-1_3
All machinery can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. In this manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB distributor to explain them. But 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 what hazards there might be and how to avoid them.
!MWARNING
T1-043
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 Manual instructs you on the machine, its controls and its safe operation; it is not a training manual. If you are a new operator, get yourself trained in the skills of using a machine before trying to work with it. If you don't, you will not do your job well, and you will be a danger to yourself and others. INT-1-4-1
!MWARNING
Do not work with the machine until you are sure that you can control it.
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.
Do not start any job until you are sure that you and those around you will be safe.
INT-1-3-5
If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE
!MWARNING Clothing You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, earprotectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and personal jewellery. INT-1-3-6_2
!MWARNING Alcohol and Drugs 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. INT-1-3-9_2
2-2
9803/9960-3
2-2
Section 2 - Care and Safety Safety Notices Safety Check List
!MWARNING
!MDANGER
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.
Lightning Lightning can kill you. Do not use the machine if there is lightning in your area. 5-1-1-2
8-1-2-4
!MWARNING
!MWARNING 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.
Machine Modifications This machine is manufactured in compliance with legislative and other requirements. It should not be altered in any way which could affect or invalidate any of these requirements. For advice consult your JCB Distributor. INT-1-3-10_2
Switch off and do not use your mobile phone when refuelling the machine. INT-3-3-9
!MWARNING 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. INT-1-3-7_2
!MWARNING 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. 13-2-3-7_3
!MWARNING Raised Machine NEVER position yourself or any part of your body under a raised machine which is not properly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed. INT-3-3-7_1
2-3
9803/9960-3
2-3
Section 2 - Care and Safety Safety Notices Safety Check List
!MWARNING
Operating Safety
!MWARNING 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. INT-2-1-2_2
!MWARNING Machine Limits Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications. INT-2-1-4
!MWARNING 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.
Work Sites Work sites can be hazardous. Inspect 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. INT-2-2-1_2
!MWARNING Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands. INT-2-2-3
!MWARNING
INT-2-1-5
!MWARNING Exhaust Gases Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, fit an exhaust extension. If you begin to feel drowsy, stop the machine at once and get into fresh air. INT-2-1-10_2
Parking An incorrectly parked machine can move without an operator. Follow the instructions in the Operator Manual to park the machine correctly. INT-2-2-4_2
!MWARNING 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. INT-2-2-5
!MWARNING 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. INT-2-2-8
2-4
9803/9960-3
2-4
Section 2 - Care and Safety Safety Notices Safety Check List
!MDANGER
!MWARNING
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.
Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls. If that happens you could lose control of the machine. 2-2-3-6
!MWARNING
INT-2-2-10
!MWARNING Hazardous Atmospheres This machine is designed for use in normal out door atmospheric conditions. It should not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor.
Electrical Power Cables 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.
INT-2-1-14
!MCAUTION Regulations Obey all laws, work site and local regulations which affect you and your machine.
There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier.
INT-1-3-3
2-2-5-4
!MWARNING
!MCAUTION
Practise You or others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practise away from the work site on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely.
If you have an attachment which is not covered in the Operator 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. 5-5-1-1_2
INT-2-1-1
!MWARNING
!MWARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when fitted). Inspect these areas frequently and clean at the beginning of each work shift or more often if required. Before opening the engine cover, ensure that the top is clear of debris. 5-3-1-12_3
2-5
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. 2-4-5-2_1
9803/9960-3
2-5
Section 2 - Care and Safety Safety Notices Safety Check List
!MDANGER
!MWARNING
Working Platform 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.
High Loads A high load can block your view and reduce the machine's stability. Travel with the load low to the ground. Travel slowly and with caution over rough, muddy or loose surfaces.
5-1-5-9
5-1-3-2
!MWARNING Machine Safety Stop work at once if a fault develops. Abnormal sounds and smells can be signs of trouble. Inspect and repair before resuming work. 8-1-2-3
!MWARNING Slopes When transporting a load on a slope, drive slowly and keep the load uphill of the machine. This will increase stability. 5-1-4-1
!MWARNING 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. 10-1-1-40
!MWARNING Travelling at High Speeds Travelling at high speeds can cause accidents. Do not reverse in a high gear with full throttle. Always travel at a safe speed to suit working conditions.
!MWARNING Hillsides Operating the machine on hillsides can be dangerous if proper precautions are not taken. Ground conditions can be changed by rain, snow, ice etc. Check the site carefully. Operate in first gear on hillsides, when applicable, keep all attachments low to the ground. Never coast down a hill with the engine off or the transmission in neutral. INT-2-2-7
!MWARNING
INT-5-3-3
!MWARNING 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.
Visibility Accidents can be caused by working in poor visibility. Use your lights to improve visibility. Keep the road lights, windows and mirrors clean. Do not operate the machine if you cannot see clearly. 5-1-4-7
5-2-6-5
!MWARNING
!MWARNING
You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protection Structure (ROPS)/Falling Objects Protection Structure (FOPS) 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 certification.
Keep Your Hands and Feet Inside the Vehicle 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. 13-1-1-17
INT-2-1-9_6
2-6
9803/9960-3
2-6
Section 2 - Care and Safety Safety Notices Safety Check List
!MWARNING
Maintenance Safety
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.
!MWARNING
Passengers Passengers in or on the machine can cause accidents. Do not carry passengers.
Communications Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing. Before starting the engine make sure the others are clear of the danger areas; examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken.
INT-2-2-2_1
INT-3-1-5
0179_2
!MCAUTION
!MWARNING
!MWARNING
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.
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.
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. Firefighters should use selfcontained breathing apparatus.
GEN-1-5_2
!MWARNING
INT-3-2-7_2
!MWARNING Should the machine start 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.
Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper pin to remove and fit metal pins. Always wear safety glasses. INT-3-1-3_2
!MWARNING
INT-2-1-12
Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4
2-7
9803/9960-3
2-7
Section 2 - Care and Safety Safety Notices Safety Check List
!MWARNING
!MCAUTION
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 protective glasses and gloves. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.
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. INT-3-2-14
!MWARNING
INT-3-1-10_3
!MWARNING Hydraulic Pressure 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. INT-3-1-11_2
Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground. INT-3-2-4
!MWARNING Always wear safety glasses when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidentally flying out. GEN-6-2
!MWARNING 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.
!MCAUTION Rams The efficiency of the rams will be affected if they are not kept free of solidified dirt. Clean dirt from around the rams regularly. When leaving or parking the machine, close all rams if possible to reduce the risk of weather corrosion. INT-3-2-10
INT-3-2-2_3
!MCAUTION
!MWARNING Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin. INT-3-2-3
Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents. INT-3-2-11
!MWARNING When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions. GEN-1-9
2-8
9803/9960-3
2-8
Section 2 - Care and Safety Safety Notices Safety Check List
!MCAUTION
!MWARNING
'O' rings, Seals and Gaskets Badly fitted, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals.
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.
INT-3-2-12
New fluoroelastomeric components at ambient temperature require no special safety precautions.
!MWARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly. Do not use the machine if a hose or hose fitting is damaged. INT-3-3-2_4
!MCAUTION 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.
Used fluoroelastomeric components whose temperatures have not exceeded 300°C (572°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 (572°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: 1
Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.
2
Thoroughly wash contaminated detergent and water.
3
Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.
5-3-1-9
!MWARNING Working Under the Machine Make the machine safe before getting beneath it. Ensure that any fitments on the machine are secure; engage the park brake, remove the starter key, disconnect the battery. INT-3-3-8_2
area
with
DO NOT BURN FLUOROELASTOMERIC MATERIALS. INT-3-3-5_4
!MWARNING Protect your eyes when grinding metal. Wear safety glasses or goggles. Remove or protect any combustible materials from the area which could be ignited by sparks. GEN-1-12
2-9
9803/9960-3
2-9
Section 2 - Care and Safety Safety Notices Safety Check List
!MWARNING
!MWARNING
To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a brush to clean components.
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 exhausted by a JCB distributor, as the sudden release of the hydraulic fluid or gas may cause injury.
HYD-1-3_2
!MWARNING 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 (E.C.U.s), 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.
INT-3-1-17
!MWARNING Petrol Do not use petrol in this machine. Do not mix petrol with the diesel fuel; in storage tanks the petrol will rise to the top and form flammable vapours. INT-3-1-6
!MCAUTION Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. INT-3-1-14
!MWARNING
Always connect the welder earth (ground) cable to the same component that is being welded, i.e. boom or dipper, to avoid damage to pivot pins, bearings and bushes. Attach the welder earth (ground) cable no more than 0.6 metres (2 feet) from the part being welded.
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.
INT-3-1-15_2
0125
!MWARNING
!MWARNING
Counterweights Your machine may be fitted with counterweights. They are extremely heavy. Do not attempt to remove them.
Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use an approved battery tester.
INT-3-2-5
!MWARNING Compressed air is dangerous. Wear suitable eye protection and gloves. Never point a compressed air jet at yourself or others.
INT-3-1-8_2
0147_1
2-10
9803/9960-3
2-10
Section 2 - Care and Safety Safety Notices Safety Check List
!MDANGER
!MWARNING
Electrolyte 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 personal protective equipment (PPE).
Wheels and tyres are heavy. Take care when lifting or moving them.
INT-3-2-1_4
13-3-1-7_1
Store with care to ensure that they cannot fall and cause injury.
!MWARNING
!MWARNING
Battery Terminals The machine is negatively earthed. Always connect the negative pole of the battery to earth.
Asbestos Asbestos dust can damage your lungs. Some engine gaskets contain asbestos. Do not dismantle the engine or exhaust system; get these jobs done by a qualified person who has a copy of the engine service manual.
When connecting the battery, connect the earth (-) lead last.
5-1-6-1
When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9
!MWARNING 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. 2-3-2-7_2
!MWARNING Jacking A machine can roll off jacks and crush you unless the wheels have been blocked. Always block the wheels at the opposite end of the machine that is to be jacked. Do not work underneath a machine supported only by jacks. Always support a jacked-up machine on axle stands before working underneath it. INT-3-2-8
!MWARNING 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. INT-3-1-16
2-11
9803/9960-3
2-11
Section 2 - Care and Safety Safety Notices Safety Labels
Safety Labels Introduction
!MWARNING
T1-014_2
Safety Labels Safety labels on the machine warn you of particular hazards. You can be injured if you do not obey the safety instructions shown. INT-1-3-11
Safety labels are strategically placed around the machine 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 place 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. Note: The illustration(s) show a typical machine model. Your machine may look different from the model shown. Keep all safety labels clean and readable. Replace lost or damaged safety labels. Make sure replacement parts include 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 distributor.
2-12
9803/9960-3
2-12
Section 3 Maintenance Service Manual - 1CX Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section J - Tracks Section K - Engine
Publication No.
9803/9960-3
World Class Customer Support Copyright Š 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section 3 - Routine Maintenance
Notes:
3-ii
9803/9960-3
3-ii
Section 3 - Routine Maintenance Contents
Contents Page No. Routine Maintenance Service Requirements ............................................................................... 1-1 Introduction ............................................................................................1-1 Owner/Operator Support .......................................................................1-1 Service/Maintenance Agreements ........................................................1-1 Initial Service and Inspection .................................................................1-1 Fit for Purpose Tests for Lifting Equipment ............................................1-2 Obtaining Replacement Parts ................................................................1-2 Health and Safety ...................................................................................... 1-3 Lubricants ..............................................................................................1-3 Battery ...................................................................................................1-5 Service Schedules ..................................................................................... 1-7 Introduction ............................................................................................1-7 How to Use the Service Schedules .......................................................1-7 Calendar Equivalents ............................................................................1-7 Pre-start Cold Checks, Service Points and Fluid Levels .......................1-8 Functional Test and Final Inspection ................................................... 1-11 Fluids, Lubricants and Capacities ............................................................ 1-13 Coolant Mixtures .................................................................................1-14 Fluid Recommendations (Fuel Specification) ......................................1-14 Diesel Fuel Characteristics - Perkins Recommendation .....................1-16 Tools ........................................................................................................ 1-22 Carrying Tools onto the Machine .........................................................1-22 Tool Locations .....................................................................................1-22 Prepare the Machine for Maintenance .................................................... 1-23 Introduction ..........................................................................................1-23 How to Make the Machine Safe (Loader Arms Lowered) ....................1-24 How to Make the Machine Safe (Loader Arms Lifted) .........................1-25 Cleaning the Machine .............................................................................. 1-27 Introduction ..........................................................................................1-27 Preparing the Machine for Cleaning ....................................................1-27 Cleaning the Machine ..........................................................................1-28 Checking for Damage .............................................................................. 1-30 Check the Machine Body and Structure ..............................................1-30 Check the Tyres ..................................................................................1-30 Check the Seat and Seat Belt .............................................................1-30 Check the Hydraulic Hoses and Fittings .............................................1-30 Check the Electrical Circuits ................................................................1-31 Checking the ROPS/FOPS Structure ..................................................1-31 Greasing .................................................................................................. 1-32 Introduction ..........................................................................................1-32 Preparing the Machine for Greasing ...................................................1-32 Every 10 Hours ....................................................................................1-32 Oiling ....................................................................................................... 1-36 Oil the Control Levers ..........................................................................1-36 Oil the Door Hinges (Cab machines only) ...........................................1-36 Slew Oil Level Check ..........................................................................1-37 Access Panels ......................................................................................... 1-38 Introduction ..........................................................................................1-38 Battery Cover ......................................................................................1-38 Engine Cover .......................................................................................1-38 Engine Side Panels .............................................................................1-39 Floor Plates .........................................................................................1-39
3-iii
3-iii
Section 3 - Routine Maintenance Contents
Contents Page No. Heater and Air Conditioning .................................................................... 1-40 Cleaning the Fresh Air Filter. ...............................................................1-40 Cleaning the Re-circulation Filter. .......................................................1-40 Brakes ..................................................................................................... 1-41 Park Brake (Wheeled or Tracked Machines) .......................................1-41 Electrical System ..................................................................................... 1-42 Battery .................................................................................................1-42 Jump Starting the Engine ....................................................................1-44 Fuses ...................................................................................................1-45 Relays .................................................................................................1-47 Engine ..................................................................................................... 1-48 Oil and Filter ........................................................................................1-48 Cooling System ...................................................................................1-51 Alternator Drive Belt ............................................................................1-53 Air Filter ...............................................................................................1-54 Fuel System ............................................................................................. 1-56 Introduction ..........................................................................................1-56 Drain the Fuel Filter .............................................................................1-57 Changing the Fuel Filter Element ........................................................1-58 Hydraulic System ..................................................................................... 1-59 Introduction ..........................................................................................1-59 Releasing the Hydraulic Pressure .......................................................1-59 Hydraulic Oil and Filter ........................................................................1-60 Transmission ........................................................................................... 1-62 Tracked Machines ...............................................................................1-62 Wheeled Machines ..............................................................................1-62 Tyres and Wheels (1CXW Only) .............................................................. 1-63 Tyre Inflation ........................................................................................1-63 Checking the Wheel Nut Torques ........................................................1-64 Tracks ...................................................................................................... 1-65 Track Adjustment .................................................................................1-65 Wear Pads ............................................................................................... 1-67 Extending Dipper Wear Pads ..............................................................1-67 Windscreen Washer ................................................................................ 1-69 Fire Extinguisher (if fitted) ........................................................................ 1-70 Checking the Fire Extinguisher ...........................................................1-70
3-iv
3-iv
Routine Maintenance Service Requirements Introduction
Owner/Operator Support T3-095
Your machine has been designed and built to give maximum performance, economy and ease of use under a wide variety of operating conditions. Prior to delivery, your machine was inspected both at the Factory and by your Distributor to ensure that it reaches you in optimum condition. To maintain this condition and ensure trouble free operation it is important that the routine services, as specified in this Manual, are carried out by an approved JCB Distributor at the recommended intervals.
JCB together with your Distributor wants you to be completely satisfied with your new JCB machine. If you do encounter a problem however, you should contact your Distributor's Service Department who are there to help you!
This section of the Manual gives full details of the service requirements necessary to maintain your JCB machine at peak efficiency.
To get the most from your Distributor please help them to satisfy you by:
You will have been given the names of the relevant service contacts at your Distributor when the machine was installed.
1
Giving your name, address and telephone number.
2
Quoting your machine model and serial number.
3
Date of purchase and hours of work.
It can be seen from the Service Schedules on the following pages that many essential service checks should only be carried out by a JCB trained specialist. Only JCB Distributor Service Engineers have been trained by JCB to carry out such specialist tasks, and only JCB Distributor Service Engineers are equipped with the necessary special tools and test equipment to perform such tasks, thoroughly, safely, accurately and efficiently.
4
Nature of the problem.
JCB regularly updates its Distributors advising them of any product developments, changes in specifications and procedures. Therefore only a JCB Distributor is fully able to maintain and service your machine.
Service/Maintenance Agreements
A Service Manual for your machine is available from your JCB Distributor. The Service Manual contains information on how to repair, dismantle and assemble your machine correctly.
A Service Record Sheet or Book is provided which will enable you to plan your service requirements and keep a service history record. It should be dated, signed and stamped by your Distributor each time your machine is serviced. Remember, if your machine has been correctly maintained, not only will it give you improved reliability but its resale value will be greatly enhanced.
1
Remember, only your JCB Distributor has access to the vast resources available at JCB to help support you. In addition, your Distributor is able to offer a variety of programmes covering Warranty, Fixed Price Servicing, Safety Inspections, including weight tests, covering both legal and insurance requirements.
To help plan and spread the costs of maintaining your machine, we strongly recommend you take advantage of the many Service and Maintenance Agreements your Distributor can offer. These can be tailor made to meet your operating conditions, work schedule etc. Please consult your JCB Distributor for details.
Initial Service and Inspection T3-005_2
To further protect your machine's performance it is essential your JCB Distributor carries out an initial service and inspection when the machine is one month old or when it has completed 100 hours of operation (whichever
9803/9960-4
1
Routine Maintenance Service Requirements occurs first). You should notify your Distributor in advance to allow the necessary arrangements to be made.
Fit for Purpose Tests for Lifting Equipment T3-097
All lifting equipment (for example forks, lifting hooks and shackles) need regular inspection and testing by a competent person to ensure they are fit for purpose. This may be needed every six months or at least annually in some countries to meet and comply with legislation and for insurance purposes. Check with your local JCB distributor for further advice.
Obtaining Replacement Parts T3-096
If you use non-genuine JCB parts or consumables, then you can compromise the health and safety of the operator and cause machine failure A Parts Book for your machine is available from your JCB Distributor. The Parts Book will help you identify parts and order them from your JCB distributor. Your dealer will need to know the exact model, build and serial number of your machine. See Identifying Your Machine (Introduction section). The data plate also shows the serial numbers of the engine, transmission and axle(s), where applicable. But remember if any of these units have been changed, the serial number on the data plate may be wrong. Check on the unit itself.
2
9803/9960-4
2
Routine Maintenance Health and Safety
Health and Safety Lubricants T3-060_3
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.
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.
Handling
!MWARNING Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin. INT-3-2-3
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
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:
Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers.
1
Avoid prolonged, excessive or repeated skin contact with used oil.
2
Apply a barrier cream to the skin before handling used oil. Note the following when removing engine oil from skin:
Waste Disposal
!MCAUTION 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. INT-3-2-14
All waste products should be disposed of in accordance with all the relevant regulations.
3
9803/9960-4
a
Wash your skin thoroughly with soap and water.
b Using a nail brush will help. c
Use special hand cleansers to help clean dirty hands.
d Never use petrol, diesel fuel, or paraffin for washing.
3
Routine Maintenance Health and Safety 3
Avoid skin contact with oil soaked clothing.
4
Don't keep oily rags in pockets.
5
Wash dirty clothing before re-use.
6
Throw away oil-soaked shoes.
First Aid - Oil 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 with sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.
Fires
!MWARNING Do not use water to put out an oil fire. This will only spread it because oil floats on water. Extinguish oil and lubricant fires with carbon dioxide, dry chemical or foam. Fire fighters should use self contained breathing apparatus. 7-3-1-3_1
4
9803/9960-4
4
Routine Maintenance Health and Safety
!MCAUTION
Battery
!MWARNING
T3-061
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 personal protective equipment (PPE). 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.
Damaged or spent batteries and any residue from fires or spillage should be put in a closed acid proof receptacle and must be disposed of in accordance with local environmental waste regulations. INT-3-1-12
!MWARNING Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use an approved battery tester. INT-3-1-8_2
Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up. When reconnecting, fit the positive (+) lead first. 5-3-4-12_2
!MCAUTION Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. INT-3-1-14
!MWARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4
!MDANGER Electrolyte 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 personal protective equipment (PPE). INT-3-2-1_4
5
9803/9960-4
5
Routine Maintenance Health and Safety Warning Symbols
First Aid - Electrolyte
The following warning symbols may be found on the battery.
Do the following if electrolyte: Gets into your eyes
Symbol
Meaning
Immediately flush with water for 15 minutes, always get medical help.
Keep away from children.
Is swallowed A289230-1
Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help.
Shield eyes.
Gets onto your skin
A289260-1
No smoking, no naked flames, no sparks. Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help. A289280
Explosive Gas.
A289250
Battery acid.
A289240
Note operating instructions.
A289270
6
9803/9960-4
6
Routine Maintenance Service Schedules
Service Schedules Introduction
How to Use the Service Schedules
!MWARNING
T3-036_3
Maintenance must be done only by suitably qualified and competent persons.
T3-012_4
In the example shown, A shows all service requirements to be carried out every 10 hours and B shows the requirements to be carried out every 500 hours.
Before doing any maintenance make sure the machine is safe, it should be correctly parked on level ground.
Important: Services should be carried out at either the hourly interval or calendar interval, whichever occurs first. Refer to Calendar Equivalents.
To prevent anyone starting the engine, remove the starter key. Disconnect the battery when you are not using electrical power. If you do not take these precautions you could be killed or injured.
Important: 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.
8-3-1-1
A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition. Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings to correctly gauge service intervals. When there is no hourmeter fitted, use the calendar equivalents to determine the service intervals. Refer to Calendar Equivalents. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately.
795390-1
Calendar Equivalents Every 10 Hours = Daily
T3-098
Every 50 Hours = Weekly Every 500 Hours = Six Months Every 1000 Hours = Yearly Every 2000 Hours = 2 Years
7
9803/9960-4
7
Routine Maintenance Service Schedules
Pre-start Cold Checks, Service Points and Fluid Levels Note: More frequent checks of engine components than the engine manufacturer recommends do not invalidate emissions warranty. Operation
10
50
100
500
1000 2000
ENGINE Engine and Pump Mount Security Oil and Filter (1)
- Check - Drain and Refill
Coolant Level and Antifreeze Strength
- Check
Coolant
- Change
Air Cleaner Dust Valve
- Clean
Air Cleaner Outer Element (2)
- Change
Air Cleaner Inner Element
- Change
Cylinder Head Nuts
- Change
Valve Clearances - Check and Adjust
- Change
Fan Belt Tension/Condition
- Check
Fan Belt
- Change
Fuel Sedimenter - Drain
- Drain
Fuel Filter - Change
- Change
Radiator Hose - Condition
- Clean
Air Cleaner Hose Security
- Check
Fuel System for Leaks and Contamination
- Check
External Oil Leaks
- Check
Clean Radiator Matrix
- Inspect
TRANSMISSION Motor Mounting Bolts - Tightness
- Check
Wheel Nut Security
- Check
Hub Mounting Bolt Security
- Check
Tyre Pressures
- Check
Drive Chain Case Oil Level
- Check
Drive Chain Case Oil Drive Chain Tension
8
- Change - Check and Adjust
9803/9960-4
8
Routine Maintenance Service Schedules Operation
10
50
100
500
1000 2000
HYDRAULICS Oil - Sample/Change (Clean Suction Strainer) Oil Level
- Check
Oil Filter
- Sample, Change
Ram Piston Rods for Damage/Leaks
- Change
Hoses - Damage or Leaks
- Check
Pipework - Damage or Leaks
- Check
Breather(3)
- Clean
(3)
Change
Breather
- Sample/Change
ELECTRICS Battery Electrolyte Level (If applicable)
- Check
Battery Charge Condition
- Check
Battery Terminals for Condition and Tightness
- Check
Wiring for Chafing
- Check
BODY AND FRAMEWORK All Pivot Pins
- Check and Grease - Check
Visual inspection of structure for damage including welds around lifting points and excavator end main pivots K Checking for Damage ( T 30). All Hinges
- Lubricate
All Linkages
- Lubricate
Slew Oil Level
- Check
General Damage including ROPS/FOPS
- Check
Seat Belt - Condition/Security
- Check
Windscreen Washer Level (if fitted)
- Check
Quickhitch Locking Peg Housings
- Clean
Extending Dipper
- Adjust and Waxoyl
TRACKS AND RUNNING GEAR Track Tension
- Check
Sprocket Torque
- Check
CAB - Clean
Cab re-circulation filter - Clean(4)
- Clean
(4)
Fresh air intake filter - Clean
9
9803/9960-4
9
Routine Maintenance Service Schedules (1) (2) (3) (4)
10
Oil and filter change at 500 hours, (provided CH4 oil is used) The Air Cleaner Outer Element should be changed every 100 hours if the machine is working in dusty conditions. The Hydraulic Tank Breather should be changed more frequently if the machine is working in dusty conditions. More regularly if used in dusty conditions.
9803/9960-4
10
Routine Maintenance Service Schedules
Functional Test and Final Inspection Note: More frequent checks of engine components than the engine manufacturer recommends do not invalidate emissions warranty. Operation
10
50
100
500
1000 2000
ENGINE Idle Speed(1)
- Check and Adjust
Maximum No-load Speed(1)
- Check and Adjust
Exhaust System - Security/Fouling
- Check
Exhaust for Excessive Smoke
- Check
Throttle System and Control Cable
- Check
TRANSMISSION Transmission Stall Pressure
- Check
HYDRAULICS Operation All Services
- Check and Adjust
MRV 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
- Check
- Check
Starter Motor
- Check
Alternator
- Check
Gauges and Warning Lights
- Check
Front Wiper Motor (if fitted)
- Check
Cab Switches - Operation
- Check
Horn Operation
- Check
Heater (if fitted)
- Check
Reverse Alarm (if fitted)
- Check
Lights and Indicators (if fitted)
- Check
Operate all Electrical Equipment
- Check
Hydraclamp Operation BRAKES Parking Brake - Operation ELECTRICS
11
9803/9960-4
11
Routine Maintenance Service Schedules Operation
10
50
100
500
1000 2000
- Check
- Check
- Check
Check
ATTACHMENTS Attachment Condition and Operation PAINTWORK Condition GENERAL Check for Fluid Leaks (e.g. coolant, engine oil, hydraulic oil, etc. LIFTING EQUIPMENT Fit for Purpose Test(2)
(1) Jobs which should only be done by a specialist (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.
12
9803/9960-4
12
Routine Maintenance Fluids, Lubricants and Capacities
Fluids, Lubricants and Capacities Table 1. CAPACITY
Container Size (1)
ITEM
Litres
UK Gal FLUID/LUBRICANT
Fuel Tank
45
17.6
Diesel Oil. K Fluids, Lubricants and Capacities ( T 13)
Engine (Oil) (2) 1CXWS
10.5
2.3
JCB Engine Oil EP 15W40 (-10°C to +50°C 4001/1805 (14°F to 122°F) API CH-4/SJ, ACEA E5/E3/ B3/A3
20 Litres
JCB Cold Climate Engine Oil EP 5W40(4001/2705 20°C to +50°C (-4°F to 122°F) API CH-4/CG4/CF-4/CF/SJ, ACEA E2/B3/A3
20 Litres
JCB Engine Oil EP 15W40 (-10°C to +50°C 4001/1805 (14°F to 122°F) API CH-4/SJ, ACEA E5/E3/ B3/A3
20 Litres
JCB Cold Climate Engine Oil EP 5W40(4001/2705 20°C to +50°C (-4°F to 122°F) API CH-4/CG4/CF-4/CF/SJ, ACEA E2/B3/A3
20 Litres
Engine (Oil) (3) 1CXT
9.3
2.0
JCB PART NO -
-
Engine (Coolant)(4)
11
2.4
JCB Antifreeze HP Coolant/Water K Coolant Mixtures ( T 14).
4006/1120
20 Litres
Hydraulic System 1CXWS
80
17.6
JCB Optimum Performance Hydraulic Oil
4002/2805
20 Litres
Hydraulic System 1CXT
80
17.6
JCB Ultra Performance Hydraulic Oil
4002/2805
20 Litres
Grease Points
---
---
JCB Special HP Grease
4003/2017
400g
4003/1501
400g
(6)
JCB Waxoyl
4004/0502
5 Litres
JCB Special MPL-EP Grease Extending Dipper
---
---
(5)
Chain Case
Fill to level plug
JCB Engine Oil HP 10W30
4001/1705
20 Litres
Slew Oil
Fill to level plug
JCB Engine Oil HP 10W30
4001/1705
20 Litres
(1) (2) (3) (4)
For information about the different container sizes that are available (and their part numbers), contact your JCB dealer Caution - Do not use ordinary Engine Oil. Caution - Do not use ordinary Engine Oil. 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. (5) JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing must be carried out more frequently. (6) WARNING: Waxoyl contains turpentine substitute, which is inflammable. 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. Note: No warranty liability will be accepted for engine failures where unacceptable fuel grades (or their equivalent) have been used at any stage.
13
9803/9960-4
13
Routine Maintenance Fluids, Lubricants and Capacities
Coolant Mixtures T3-009_4
Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period. Replace the coolant mixture according to the intervals shown in the machine's Service Schedule.
Fluid Recommendations (Fuel Specification) General Information
!MWARNING
Note: Every attempt is made to provide accurate, up to date information. By use of this document you agree that Perkins Engines Company Limited is not responsible for errors or omissions.
Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze.
Note: These recommendations are subject to change without notice. Contact your local Perkins distributor for the most up to date recommendations.
7-3-4-4_1
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.
Diesel Fuel Requirements Satisfactory engine performance is dependent on the use of a good quality fuel. The use of a good quality fuel will give the following results: long engine life and acceptable exhaust emissions levels. The fuel must meet the minimum requirements that are stated in the tables K Table 2. ( T 15), K Table 3. ( T 17), K Table 4. ( T 17). Note: The footnotes are a key part of the Perkins Specification for Distillate Diesel Fuel Table . Read ALL of the footnotes.
50% Concentration (Standard) Protects against damage down to -40 °C (-39 °F) 60% Concentration (Extreme Conditions Only) Protects against damage down to -56 °C (-68 °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: – Ensure that the antifreeze complies with International Specification ASTM D6210. – Always read and understand the manufacturer's instructions. – Ensure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used. – Ensure that the antifreeze is ethylene glycol based and does not use Organic Acid Technology (OAT).
14
9803/9960-4
14
Routine Maintenance Fluids, Lubricants and Capacities Table 2. Perkins Specification for Distillate Diesel Fuel(1) Property
UNITS
Requirements
"ASTM" Test
"ISO" Test
Aromatics
%Volume
35% maximum
D1319
"ISO"3837
Ash
%Wieght
0.02% maximum
D482
"ISO"6245
Carbon Residue on 10% Bottoms
%Weight
0.35% maximum
D524
"ISO"4262
Cetane Number(2)
-
40 minimum
D613/D6890
"ISO"5165
Cloud Point
°C
The cloud point must not exceed the lowest D2500 expected ambient temperature.
"ISO"3015
Copper Strip Corrosion
-
No. 3 maximum
D130
"ISO"2160
Density at 15 °C (59 °F)(3)
Kg / M3
801 minimum and 876 maximum
No equivalent "ISO"3675, test "ISO" 12185
Distillation
°C
10% at 282 °C (539.6 °F) maximum 90% at D86 360 °C (680 °F) maximum
"ISO"3405
Flash Point
°C
Legal limit
"ISO"2719
Thermal Stability
-
Minimum of 80% reflectance after aging for D6468 180 minutes; at 150 °C (302 °F)
No equivalent test
Pour Point
°C
6°C (42.8 °F) Minimum below ambient temperature
D97
"ISO"3016
Sulfur(1)(4)
%mass
The level of sulfur that is in the fuel is controlled by emissions regulations. Refer to the tables K Table 3. ( T 17), K Table 4. ( T 17) for more information.
D5453/ D26222
"ISO"20846 "ISO" 20844
Kinematic Viscosity(5)
"MM"2" / S (cSt)"
The viscosity of the fuel that is delivered to the fuel injection pump. "1.4 minimum/4 .5 maximum
D445
"ISO"3405
Water and sedimant
% Weight
0.1% Maximum
D1796
"ISO"3734
Water
% Weight
0.1 % Maximum
D1744
No equivalent test
% Weight
0.05% Maximum
D473
"ISO"3735
mg/100 mL
10 mg per 100 mL
D381
"ISO"6246
0.46 maximum
D6079
"ISO"12156-1
Sediment (6)
Gums and Resins
mm Lubricity corrected wear scar diameter at 60 °C (140 °F).(7)
D93
(1) This specification includes the requirements for Ultra Low Sulfur Diesel (ULSD). ULSD fuel will have <= 15 ppm (0.0015%) sulfur. Refer to "ASTM D5453", "ASTM D2622", or "ISO 20846, ISO 20884" test me1thods. This specification includes the requirements for Low Sulfur Diesel (LSD). LSD fuel will have <= 500 ppm (0.05%) sulfur. Refer to following:"ASTM 5453, ASTM D2622", "ISO 20846", and "ISO 20884 test methods". (2) A fuel with a higher cetane number is recommended in order to operate at a higher altitude or in cold weather. (3) "Via standards tables, the equivalent API gravity for the minimum density of 801 kg I m3 (kilograms per cubic meter) is 45 and for the maximum density of 876 kg I m3 is 30".
15
9803/9960-4
15
Routine Maintenance Fluids, Lubricants and Capacities (4) Regional regulations, national regulations or international regulations can require a fuel with a specific sulfur limit. Consult all applicable regulations before selecting a fuel for a given engine application. Perkins fuel systems and engine components can operate on high sulfur fuels in territories that are non-emissions regulated. Fuel sulfur levels affect exhaust emissions. High sulfur fuels also increase the potential for corrosion of internal components. Fuel sulfur levels above 0.5% may significantly shorten the oil change interval. For additional information, refer to this manual, "Fluid recommendations (General lubricant Information)". (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 째C (104 째F) 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 cSt 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 cSt at the fuel injection pump. (6) Follow the test conditions and procedures for gasoline (motor). (7) The lubricity of a fuel is a concern with low sulfur and ultra low sulfur 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, consult your fuel supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in the fuel system. Note: Operating with fuels that do not meet the Perkins recommendations 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, and reduced service life of the engine.
Diesel Fuel Characteristics - Perkins Recommendation 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. Cetane numbers in excess of 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 that can have a low cetane value. A minimum cetane value of 40 is required during average starting conditions. A higher cetane value may be required for operations at high altitudes or in cold weather operations.Fuel with a low cetane number can be the root cause of problems during cold start.
Viscosity
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. This is generally quoted in the following kg/ m at 15 째C, (59 째F).Perkins recommends a value of density of 841 kg/m in order to obtain the correct power output. Lighter fuels are acceptable but these fuels will not produce the rated power.
Sulfur
Viscosity is the property of a liquid of offering resistance to shear or flow. Viscosity decreases with increasing temperature. This decrease in viscosity follows a logarithmic relationship for normal fossil fuel. The common reference is to kinematic viscosity. This is the quotient of
16
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 cSt 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.Perkins recommends kinematic viscosities of 1.4 and 4.5 mm2/sec that is delivered to the fuel injection pump.
The level of sulfur is governed by emissions legislations. Regional regulation, national regulations or international regulations can require a fuel with a specific sulfur limit. The sulfur content of the fuel and the fuel quality must comply with all existing local regulations for emissions.The
9803/9960-4
16
Routine Maintenance Fluids, Lubricants and Capacities Tables K Table 2. ( T 15), K Table 3. ( T 17) list the guidelines for the correct sulfur level for specific territories. Consult all applicable regulations before selecting the fuel for a given engine application.
Territory
Table 3. Fuel Requirements From 2007
EPA
Low sulfur (500 ppm) maximum
EC
Sulfur / Power
Low sulfur (300 ppm) maximum for less than or equal to 19 kW
Sulfur (1000 ppm) maximum for greater than 19 kW
Models
402D-05 and 403D07
403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T, and 404D22TA
NonRegulated Territories
Table 4. Fuel Requirements From 2010
EPA
Low sulfur (15 ppm) maximum
EC
Sulfur / Power
Models
NonRegulated Territories
Lubricity
Low sulfur (10 ppm) maximum for less than or equal to 37 kW
Sulfur (300 ppm) maximum for greater than 37 kW
402D-05 403D-07 403D-11 403D-15 403D-15T 403D-17 404D-15
404D-22 404D-22T, and 404D22TA
Sulfur limit of less than 4000 ppm
By using the test methods "ASTM D5453, ASTM D2622, or ISO 20846 ISO 20884", the content of sulfur in low sulfur
17
In some parts of the world and for some applications, high sulfur fuels above 0.5% by mass might only be available. Fuel with very high sulfur content can cause engine wear. High sulfur fuel will have a negative impact on emissions of particulates. High sulfur fuel can be used provided that the local emissions legislation will allow the use. High sulfur fuel can be used in countries that do not regulate emissions. When only high sulfur 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. Refer to this Operation and Maintenance Manual, "Fluid Recommendations (Genernal Lubrication Information)" for information on sulfur in fuel.
Sulfur limit of less than 4000ppm
Territory
diesel (LSD) fuel must be below 500 PPM 0.05%. By using the test methods "ASTM D5453, ASTM D2622, or ISO 20846 ISO 20884", the content of sulfur in ultra low sulfur (ULSD) fuel must be below 15 PPM 0.0015%. The lubricity of these fuels must not exceed wear scar diameter of 0.46 mm (0.0181 inch). The fuel lubricity test must be performed on a HFRR, operated at 60 °C (140 °F). Refer to "ISO 12156-1 ".
This is the capability of the fuel to prevent pump wear. The fluid 's lubricity describes the ability of the fluid to reduce the friction between surfaces that are under load. This ability reduces the damage that is caused by friction. Fuel injection systems rely on the lubricating properties of the fuel. Until fuel sulfur limits were mandated, the fuel's lubricity was generally believed to be a function of fuel viscosity. The lubricity has particular significance to the current low viscosity fuel, low sulfur 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 (140 °F). Refer to "ISO 12156 part 1 and CEC document F06-A-96" for the test method. Lubricity wear scar diameter of 0.46 mm (0.0181 inch) MUST NOT be exceeded. The fuel lubricity test must be performed on a HFRR, operated at 60 °C (140 °F). Refer to "ISO 12156-1 ".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
9803/9960-4
17
Routine Maintenance Fluids, Lubricants and Capacities and for the proper level of treatment. Refer to "Fuel Additive" for more information.
Classification of the Fuels Diesel engines have the ability to burn a wide variety of fuels. These fuels are divided into four general groups: Ref to table 3.
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.
Table 5. Fuel Groups Classification Group 1
Preferred fuels
Full life of the product
Group 2
Permissible fuels
These fuels MAY cause reduced engine life and performance
Group 3
Aviation fuels
These fuels WILL cause reduced engine life and performance
Group 4
Biodiesel
Group 1 Specification (Preferred Fuels) This group of fuel specifications is considered acceptable: – EN590 DERV Grade A, B, C, E, F, Class, 0, 1, 2, 3, and 4 – "ASTM D975", Grade 2D S15, and Grade 2D S500 – "JIS K2204 Grades 1,2,3 and Special Grade 3" This grade of fuel must meet the minimum lubricity requirements that are stated in table 1. – "BS2869 Class A2" Off-Highway Gas Oil Red Diesel Note: BS2869 can only be used if the sulfur level meets the specifications that are listed in the tables K Table 3. ( T 17), K Table 4. ( T 17). An analysis of a sample of fuel must be conducted in order to check the sulfur level. Note: The use of LSD fuel and the use of ULSD fuel is acceptable provided that the fuels meet the minimum requirements that are stated in thet tables K Table 2. ( T 15), K Table 3. ( T 17), K Table 4. ( T 17). The lubricity of these fuels must not exceed wear scar diameter of 0.46 mm (0.0181 inch). The lubricity test must be performed on a HFRR, operated at 60 °C (140 °F). Refer to "ISO 12156-1". By using the test methods "ASTM D5453, ASTM D2622, or ISO 20846 ISO 20884", the content of sulfur in LSD fuel must be below 500 PPM 0.05%. By using the test methods "ASTM D5453, ASTM D2622,or ISO 20846 ISO 20884", the content of sulfur in ULSD fuel must be below 15 PPM 0.0015%.
18
9803/9960-4
18
Routine Maintenance Fluids, Lubricants and Capacities Group 2 Specifications (Permissible Fuels) This group of fuel specifications is considered acceptable, but these fuels MAY reduce the engine life and performance. – "ASTM 0975", Grade 10 S15, and Grade 10 S500 – "JP7 (MIL-T-38219)" – "NATO F63" Note: JP7 and NATO F63 can only be used if the sulfur level meets the specifications that are listed in the tables K Table 2. ( T 15), K Table 3. ( T 17). An analysis of a sample of fuel must be conducted in order to check the sulfur level.
Group 3 Specifications (Aviation Fuels) This group of fuel specification must be used only with the appropriate fuel additive. This fuel WILL reduce engine life and performance. – "NATO F34 (MIL-OTL-83133E)""NATO F35 (MILOTL-83133E)""NATO JP8 (MIL-OTL83133E)""NATO F-44 (MIL-OTL-5624U)""NATO JP5 (M IL-OTL-5624U)""Jet A (ASTM 01655)""Jet A1 (ASTM 0 1655)" Note: All the above fuels can ONLY be used if the sulfur level meets the specifications that are listed in the tables K Table 2. ( T 15), K Table 3. ( T 17). An analysis of a sample of fuel must be conducted in order to check the sulfur level. Note: These fuels are only acceptable provided that these fuels are used with an appropriate fuel additive. These fuels must meet the requirements that are stated in the tables K Table 2. ( T 15), K Table 3. ( T 17), K Table 4. ( T 17). Fuel samples should be analyzed for the compliance. These fuels MUST NOT exceed lubricity wear scar diameter of 0.46 mm (0.0181 inch). The fuel lubricity test must be performed on a HFRR, operated at 60 °C (140 °F). Refer to "ISO 12156-1 ".Fuels must have minimum viscosity of 1.4 centistokes that is delivered to the fuel injection pump. Fuel cooling may be required in order to maintain minimum viscosity of 1.4 centistokes that is delivered to the fuel injection pump.
Group 4 Biodiesel
variety of feedstock. The most commonly available biodiesel in europe is Rape Methyl Ester (REM). This biodiesel is derived from rapeseed oil. Soy Methyl Ester (SME) is the most common biodiesel in the United States. This biodiesel is derived from soybean oil. Soybean oil or rapeseed oil are the primary feedstocks. These fuels are together known as Fatty Acid Methyl Esters (FAME). Raw pressed vegetable oils are NOT acceptable for use as a fuel in any concentration in compression engines. Without esterification, these oils gel in the crankcase and the fuel tank. These fuels may not be compatible with many of the elastomers that are used in engines that are manufactured today. In original forms, these oils are not suitable for use as a fuel in compression engines. Alternate base stocks for biodiesel may include animal tallow, waste cooking oils, or a variety of other feedstocks. In order to use any of the products that are listed as fuel, the oil must be esterified. Note: Engines that are manufactured by Perkins are certified by use of the prescribed Environmental Protection Agency (EPA) and European Certification fuels. Perkins does not certify engines on any other fuel. The user of the engine has the responsibility of using the correct fuel that is recommended by the manufacturer and allowed by the EPA and other appropriate regulatory agencies. Recommendation for the use of biodiesel The neat biodiesel must conform to "EN14214" or "ASTM 0675" regulations. A maximum of 10% mixture of biodiesel can be used in mineral diesel fuel. The mineral diesel fuel must conform to "EN590", "ASTM 0975" or "8S2869 Grade A2" regulations. In North America, biodiesel and mixtures of biodiesel must be purchased from the 809000 authorized manufacturers and 809000 certified distributors. In other areas of the world, the use of biodiesel that is authorized and certified by an appropriate biodiesel quality body is required. Note: When biodiesel, or any blend of biodiesel is used, the user has the responsibility for obtaining the proper local exemptions, regional exemptions, and/or national exemptions that are required for the use of biodiesel in any Perkins engine that is regulated by emissions standards. Biodiesel that meets "EN14214" is acceptable. The biodiesel must be blended with an acceptable distillate diesel fuel at the maximum stated percentages. However, the following operational recommendations must be followed:
Biodiesel is a fuel that can be defined as mono-alkyl esters of fatty acids. Biodiesel is a fuel that can be made from a
19
9803/9960-4
19
Routine Maintenance Fluids, Lubricants and Capacities – The oil change interval can be affected by the use of biodiesel. Use Services Oil Analysis in order to monitor the condition of the engine oil. Use Services Oil Analysis also in order to determine the oil change interval that is optimum. – Confirm that biodiesel is acceptable for use with the manufacturer of the fuel filters. – In a comparison of distillate fuels to biodiesel, biodiesel provides less energy per gallon by 5% to 7%. Do NOT change the engine rating in order to compensate for the power loss. This will help avoid engine problems when the engine is converted back to 100 percent distillate diesel fuel. – The compatibility of the elastomers with biodiesel is being monitored. The condition of seals and hoses should be monitored regularly. – Biodiesel may pose low ambient temperature problems for both storage and operation. At low ambient temperatures, fuel may need to be stored in a heated building or a heated storage tank. The fuel system may require heated fuel lines, filters, and tanks. Filters may plug and fuel in the tank may solidify at low ambient temperatures if precautions are not taken. Consult your biodiesel supplier for assistance in the blending and attainment of the proper cloud point for the fuel. – Biodiesel has poor oxidation stability, which can result in long term problems in the storage of biodiesel. The poor oxidation stability may accelerate fuel oxidation in the fuel system. This is especially true in engines with electronic fuel systems because these engines operate at higher temperatures. Consult the fuel supplier for oxidation stability additives. – Biodiesel is a fuel that can be made from a variety of feedstock. The feedstock that is used can affect the performance of the product. Two of the characteristics of the fuel that are affected are cold flow and oxidation stability. Contact your fuel supplier for guidance. – Biodiesel or biodiesel blends are not recommended for engines that will operate occasionally. This is due to poor oxidation stability. If the user is prepared to accept some risk, then limit biodiesel to a maximum of B5. Examples of applications that should limit the use of biodiesel are the following: Standby Generator sets and certain emergency vehicles.
effectiveness of conventional anti-microbial additives in biodiesel is not known. Consult your supplier of fuel and additive for assistance. – Care must be taken in order to remove water from fuel tanks. Water accelerates microbial contamination and growth. When biodiesel is compared to distillate fuels, water is naturally more likely to exist in the biodiesel.
Fuel for Cold Weather Operation The European standard "EN590" contains climate dependant requirements and a range of options. The options can be applied differently in each country. There are 5 classes that are given to arctic climates and severe winter climates. 0, 1, 2, 3, and 4.Fuel that complies with "EN590" CLASS 4 can be used at temperatures as low as -44 °C (-47.2 °F). Refer to "EN590" for a detailed discretion of the physical properties of the fuel. The diesel fuel "ASTM 0975 Grade 1-D S15 or SSOO" that is used in the united states of america may be used in very cold temperatures that are below -18 °C (-0.4 °F).In extreme cold ambient conditions, you may also use fuels that are listed in the table 5. These fuels are intended to be used in temperatures that can be as low as - 54 °C (-65.2 °F). Table 6. Light Distillate Fuels(1) Specification
Grade
"MIL-DTL-5624U"
JP-5
"MIL-DTL-83133E"
JP-8
"ASTM D1655"
Jet-A-1
(1) The use of these fuels is acceptable with an appropriate fuel additive and the fuels must meet minimum requirements that are stated in the tables. Fuel samples should be analyzed for the compliance. Fuels MUST NOT exceed 0.46 mm lubricity wear scar diameter that is tested on a HFFR The test must be performed at 60 °C. Refer to "ISO 12156-1". Fuels must have minimum viscosity of 1.4 centistokes that is delivered to the fuel injection pump. Fuel cooling may be required in order to maintain minimum viscosity of 1.4 centistokes that is delivered to the fuel injection pump.
– Biodiesel is an excellent medium for microbial contamination and growth. Microbial contamination and growth can cause corrosion in the fuel system and premature plugging of the fuel filter. The use of conventional anti-microbial additives and the
20
9803/9960-4
20
Routine Maintenance Fluids, Lubricants and Capacities
!MWARNING Mixing alcohol or gasoline with diesel fuel can produce an explosive mixture in the engine crankcase or the fuel tank. Alcohol or gasoline must not be used in order to dilute diesel fuel. Failure to follow this instruction may result in death or personal injury. ENG-8-21
There are many other diesel fuel specifications that are published by governments and by technological societies. Usually, those specifications do not review all the requirements that are addressed in the tables K Table 2. ( T 15), K Table 3. ( T 17), K Table 4. ( T 17). To ensure optimum engine performance, a complete fuel analysis should be obtained before engine operation. The fuel analysis should include all of the properties that are stated in the tables K Table 2. ( T 15), K Table 3. ( T 17), K Table 4. ( T 17).
Fuel Additive Supplemental diesel fuel additives are not generally recommended. This is due to potential damage to the fuel system or the engine. Your fuel supplier or the fuel manufacturer will add the appropriate supplemental diesel fuel additives. Perkins recognizes the fact that additives may be required in some special circumstances. Fuel additives need to be used with caution. The additive may not be compatible with the fuel. Some additives may precipitate. This action causes deposits in the fuel system. The deposits may cause seizure. Some additives may be corrosive, and some additives may be harmful to the elastomers in the fuel system. Some additives may raise fuel sulfur levels above the maximum that is allowed by the EPA or the other regulatory agencies. Contact your fuel supplier for those circumstances when fuel additives are required. Your fuel supplier can recommend the appropriate fuel additive and the correct level of treatment. Note: For the best results, your fuel supplier should treat the fuel when additives are required. The treated fuel must meet the requirements that are stated in the tables K Table 2. ( T 15), K Table 3. ( T 17), K Table 4. ( T 17).
21
9803/9960-4
21
Routine Maintenance Tools
Tools Carrying Tools onto the Machine When you carry tools onto the machine you must maintain three points of contact with the machine at all times. Lift tools onto the machine in intervals if necessary. Place the tools down before you adjust your grips on the machine. Do not try to adjust your grips on the machine while holding tools.
Tool Locations The Grease Gun and Wheel brace are located inside the lockable engine cover A. All tools must be secured in their correct positions when not in use.
A
T036670
Fig 1.
22
9803/9960-4
22
Routine Maintenance Prepare the Machine for Maintenance
Prepare the Machine for Maintenance Introduction
A
!MWARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it should be correctly parked on level ground. To prevent anyone starting the engine, remove the starter key. Disconnect the battery when you are not using electrical power. If you do not take these precautions you could be killed or injured. 8-3-1-1
Make the machine safe before you start a maintenance procedure. You can complete most of the maintenance procedures with the loader arms lowered (Position A). Unless a maintenance procedure instructs you differently, you must lower the arm. Refer to How to Make the Machine Safe (Loader Arms Lowered).
B
If you lift the loader arms to get access for maintenance (Position B), you must install the maintenance strut on the arm. Refer to How to Make the Machine Safe (Loader Arms Lifted).
T019810
Fig 2.
23
9803/9960-4
23
Routine Maintenance Prepare the Machine for Maintenance
How to Make the Machine Safe (Loader Arms Lowered) Important: You can complete most of the maintenance procedures with the arm lowered. Unless a maintenance procedure instructs you differently, you must lower the arm. 1
Park the machine on level, solid ground. If necessary, refer to Stopping and Parking the Machine in the Operator Manual.
2
Lower the Loader arms.
3
Put the attachment flat on the ground.
4
Stop the engine and remove the starter key.
5
Disconnect the battery operation of the engine.
6
If necessary, put chocks against the two sides of the wheels before you get below the machine.
24
to
prevent
accidental
9803/9960-4
24
Routine Maintenance Prepare the Machine for Maintenance
How to Make the Machine Safe (Loader Arms Lifted)
!MWARNING 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).
Installing the Maintenance Strut Before fitting the safety strut remove any load on the forks empty and remove buckets or attachments. 1
Park the machine on level, solid ground. If necessary, refer to Stopping and Parking the Machine in the Operator Manual.
2
Empty the shovel or attachment and remove it. Raise the arm just far enough to install the strut.
Make sure that no-one goes near the machine while you install or remove the mechanical device.
3
Stop the engine and remove the starter key.
13-2-3-7_3
4
Remove the strut A from its stowage position C.
5
Place the strut A around the lift ram piston rod. Secure it in position with the strap B. K Fig 3. ( T 26).
6
To prevent any chance of the arm creeping down and trapping your fingers, the arm should be lowered onto the strut.
!MCAUTION You will have to climb onto the machine to fit or remove the strut. Take care, especially if the machine is wet. Remove mud and oil before climbing onto the machine. Do not use the exhaust as a handhold. It can burn you. 5-3-1-4_1
Note: If you lift the arm to get access for maintenance, you must install the maintenance strut on the loader arms.
25
Note: Lower the arm carefully, to prevent possible damage to the strut. Stop as soon as the weight of the arm is on the strut. 7
Disconnect the battery operation of the engine.
8
If necessary, put chocks against the two sides of the wheels before you get below the machine.
9803/9960-4
to
prevent
accidental
25
Routine Maintenance Prepare the Machine for Maintenance Removing the Maintenance Strut 1
Park the machine on level, solid ground. If necessary, refer to Stopping and Parking the Machine in the Operator Manual.
2
Raise the arm to take the weight off of the strut.
3
Stop the engine and remove the starter key.
4
Remove the strut.
5
Secure the strut in its stowage position C.
T006020-1
Fig 3.
S202720-1
Fig 4.
26
9803/9960-4
26
Routine Maintenance Cleaning the Machine
Cleaning the Machine
!MCAUTION
Introduction T3-062_3
Clean the machine using water and or steam. Do not allow mud, debris etc. to build upon the machine. Before carrying out any service procedures that require components to be removed: 1
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.
The engine or certain components could be damaged by high pressure washing systems; special precautions must be taken if the engine is to be washed using a high pressure system. Ensure that the engine air intake, alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. ENG-3-3_2
When cleaning is complete move the machine away from the wash area, or alternatively, clean away the material washed from the machine.
Important: Do not aim the water jet directly at bearings, oil seals, the engine air intake or electrical and electronic components such as the engine electronic control unit (ECU), alternator or fuel injectors.
Important: 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.
Use a low pressure water jet and brush to soak off caked mud or dirt.
Detergents
Use a pressure washer to remove soft dirt and oil.
Avoid using full strength detergent - always dilute detergents as per the manufacturer's recommendations, otherwise damage to the paint finish may occur.
Note: The machine must always be greased after pressure washing or steam cleaning.
2
Always adhere to local regulations regarding the disposal of debris created from machine cleaning.
Preparing the Machine for Cleaning 1
Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.
Pressure Washing and Steam Cleaning Important: 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.
!MWARNING When using a steam cleaner, wear safety glasses or a face shield as well as protective clothing. Steam can cause serious personal injury.
2
Make sure that all electrical connectors are correctly coupled. If connectors are open fit the correct caps or seal with water proof tape.
3
Remove the undershield.
13-3-2-10_2
When cleaning around the engine and radiator, debris will be released more easily if the undershields are removed. Refer to Access Panels, Undershield.
27
9803/9960-4
27
Routine Maintenance Cleaning the Machine
Cleaning the Machine
b Do not aim the jet wash directly at the fuel injector seals.
!MWARNING
c
To avoid burning wear personal protective equipment (PPE) when handling hot components. To protect your eyes, wear personal protective equipment (PPE) when using a brush to clean components. HYD-1-3_3
Do not wash any part of the: i
Fuel injection pump.
ii
Cold start device.
iii Electrical shut off solenoid (ESOS).
!MWARNING
iv Electrical connections.
Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when fitted). Inspect these areas frequently and clean at the beginning of each work shift or more often if required. Before opening the engine cover, ensure that the top is clear of debris.
d Ensure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by high pressure cleaning system. 6
5-3-1-12_3
Make sure the radiator grille is not clogged up. a
!MCAUTION Never use water or steam to clean inside the cab. The use of water or steam could damage the on-board computer and render the machine inoperable. Remove dirt using a brush or damp cloth.
Remove outer radiator grille by unscrewing fastener D and lifting off the grille.
D
8-3-4-8
Pay particular attention to the following areas: 1
Backhoe hoses passing through mainframe.
2
Kingpost slide rails (sideshift).
3
Kingpost hose tray and bottom `shelf' (sideshift).
4
Recess between slew system and kingpost casting (sideshift).
5
Do not allow mud to build up on the engine and transmission. The engine or certain components could be damaged by high pressure washing systems, special precautions must be taken if the engine is to be washed using a high pressure system. Do not attempt to clean any part of the engine while it is running. Stop the engine and allow it to cool for at least one hour. a
28
Disconnect the battery.
T020000-2
Fig 5. b Use compressed air to remove debris from the radiator E. c
Use a brush to remove any further debris.
d Inspect the radiator for damage.
9803/9960-4
28
Routine Maintenance Cleaning the Machine e
Refit the outer radiator grille, screwing fastener D hand tight, and close the bonnet.
E
T021910-1
Fig 6. 7
29
Stabiliser cavities can become clogged when operating in soft/wet ground conditions. Remove and clean away all debris that may have built up.
9803/9960-4
29
Routine Maintenance Checking for Damage
Checking for Damage Check the Machine Body and Structure T3-063_5
Make sure that all guards and protective devices are in place, attached by their locking devices and free from damage. Inspect all steelwork for damage. Pay particular attention to the following:
– 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.
– Inspect all lifting point welds. – Inspect all pivot point welds.
Check the Seat and Seat Belt
– Inspect the condition of all pivot pins. – Check pivot pins are correctly in place and secured by their locking devices. Check steps and handrails are undamaged and secure. Check for broken, cracked or crazed window glass and mirrors. Replace damaged items.
!MWARNING
T3-008_2
When a seat belt is fitted to 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. Fit a new seat belt every three years. 2-3-1-7_1
Check all lamp lenses for damage. Check all attachment teeth are undamaged and secure. Check all safety and instructional labels are in place and undamaged. Fit new labels where necessary.
Check that the belt mounting bolts are undamaged, correctly fitted and tightened.
Note damaged paintwork for future repair.
Check the Tyres
!MWARNING
Inspect the seat belt for signs of fraying and stretching. Check that the stitching is not loose or damaged. Check that the buckle assembly is undamaged and works correctly.
T3-065_2
Check seats are undamaged and secure. Check seat adjustments for correct operation.
Check the Hydraulic Hoses and Fittings
You could be killed or injured if a machine tyre bursts. Do not use the machine with damaged, incorrectly installed, incorrectly inflated or excessively worn tyres. Recognise the speed limitation of the tyres fitted and do not operate at more than their recommended maximum speed. 13-2-1-2_2
!MWARNING
T3-072
Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly. Do not use the machine if a hose or hose fitting is damaged. INT-3-3-2_4
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:
30
Inspect the hoses regularly for:
9803/9960-4
30
Routine Maintenance Checking for Damage – Damaged hose ends
2
Make sure that all the ROPS/FOPS mounting bolts A are in place and are undamaged.
3
Make sure that the ROPS/FOPS mounting bolts A are tightened to the correct torque setting.
– Chafed outer covers – Ballooned outer covers – Kinked or crushed hoses – Embedded armouring in outer covers – Displaced end fittings
Bolts
Do not use the machine if a hose or hose fitting is damaged. Replace damaged hoses before you use the machine again.
A
Table 7. Torque Setting Nm
lbf ft
135
99.5
Replacement hoses must be of the same size and standard.
Check the Electrical Circuits T3-099
Inspect the electrical circuits regularly for: – Damaged connectors
A
– Loose connections – Chafing on wiring harnesses – Corrosion – Missing insulation
A
– Incorrect routing of harness
A
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.
Checking the ROPS/FOPS Structure
A A A
!MWARNING
T037800
You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protection Structure (ROPS)/Falling Objects Protection Structure (FOPS) 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 certification.
Fig 7.
INT-2-1-9_6
For assistance, contact your JCB distributor. Failure to take these precautions could result in death or injury to the operator. 1
31
Check the structure for damage.
9803/9960-4
31
Routine Maintenance Greasing
Greasing Introduction
Preparing the Machine for Greasing T3-028_2
You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Refer to the Service Schedule for the correct intervals. Note: The machine must always be greased after pressure washing or steam cleaning. Greasing should be done with a grease gun. Normally, two strokes of the gun should be sufficient. Stop greasing when fresh grease appears at the joint. Use only the recommended type of grease. Do not mix different types of grease, keep them separate. In the following illustrations, the grease points are numbered. Count off the grease points as you grease each one. Refit the dust caps after greasing.
Make the machine safe before you start a greasing procedure. Refer to Prepare the Machine for Maintenance. Important: You can complete most of the greasing procedures with the boom lowered. If you lift the boom to get access for greasing, you must install the maintenance strut on the boom.
Every 10 Hours Quickhitch Pivot Points 6 Grease Points Make the machine safe. K How to Make the Machine Safe (Loader Arms Lowered) ( T 24).
Note: Where applicable, refer to the manufacturers manual for instructions on the maintenance of optional attachments.
!MCAUTION 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. 5-3-1-9
S203960-1
Fig 8.
32
9803/9960-4
32
Routine Maintenance Greasing Loader Arm Pivot Points
For each grease point shown there is another on the other side of the machine.
Make the machine safe. K How to Make the Machine Safe (Loader Arms Lowered) ( T 24).
Note: Grease point 11 is at the lift ram/chassis pivot.
Total 22 grease points (11 grease points each side)
S203481
Fig 9.
33
9803/9960-4
33
Routine Maintenance Greasing Backhoe Pivot Points
Grease point 5 is at dipper ram eye end.
Make the machine safe. K How to Make the Machine Safe (Loader Arms Lowered) ( T 24).
Grease point 14 is on end of dipper. Lubricate the kingpost mounting rails and stabiliser legs with diesel oil or Waxoyl.
14 Grease Points
8
10
S203491-1
Fig 10.
34
9803/9960-4
34
Routine Maintenance Greasing 4-in-1 Clamshovel
Extending Dipper
!MWARNING
!MCAUTION
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 protective glasses and gloves. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.
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.
INT-3-1-10_3
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. 5-3-1-9
Total of 4 grease points. (1 and 2 as illustrated, 3 and 4 at opposite end.)
Extend the dipper. Coat the runners with Waxoyl. K Fig 12. ( T 35).
1
2 Fig 11.
Fig 12.
35
9803/9960-4
35
Routine Maintenance Oiling
Oiling The following points should be lightly lubricated with engine oil every 100 operating hours.
Oil the Door Hinges (Cab machines only) Oil the door hinges B sparingly.
!MWARNING You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started. Make sure the park brake is engaged.
B B
Block all four wheels before getting under the machine. 2-3-2-1
Oil the Control Levers Oil the clevis A at the bottom of each backhoe control lever.
T020790-1
Fig 14.
S202740-1
Fig 13.
36
9803/9960-4
36
Routine Maintenance Oiling
Slew Oil Level Check 1
Park the machine on level ground and stop the engine.
2
Remove plug D and check that oil is visible on the plug spigot.
3
If the level is low, remove plug D (if not already removed) and fill with new oil until oil runs from the hole. K Fluids, Lubricants and Capacities ( T 13).
4
Refit plug D.
5
Operate the slew service fully in each direction five times.
6
Remove plug D and re-check oil level. If level is low, repeat steps 3 to 5 until all air is expelled.
D T059020
Fig 15.
37
9803/9960-4
37
Routine Maintenance Access Panels
Access Panels Introduction
Engine Cover T3-100
When placed in their maintenance position, the access panels give you access to parts or areas of the machine that are not required during machine operation.
Opening and Closing 1
Park the machine on firm level ground, engage the park brake and set the transmission to neutral.
Before you operate the machine, make sure that all of the access panels are in their operation position and secure.
Battery Cover
!MWARNING 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.
Removal and Replacement
5-2-6-5
1
Park the machine on firm level ground, engage the park brake and set the transmission to neutral.
2
Remove the three screws A and lift of the cover B.
A J
B
S203571-1
Fig 17. T021520
2
Switch OFF the engine and remove the starter key.
3
To release the engine cover, insert key J into the engine cover lock and turn 90° clockwise.
4
Open the engine cover until the latch is engaged.
5
To close the engine cover, release the latch and lower the engine cover.
6
To lock the engine cover, insert key J into the engine cover lock and turn 90° anticlockwise.
Fig 16.
38
9803/9960-4
38
Routine Maintenance Access Panels
Engine Side Panels
Floor Plates
Removal and Replacement
Removal and Replacement
1
To carry out various servicing procedures, you must remove some of the floor plates.
Stop the engine and remove the starter key.
Note: It is easier to remove the panel either with the shovel resting on the ground or with the arms fully raised (See Loader Arm Safety Strut). 2
Raise the engine cover (See Opening and Closing the engine cover).
3
Remove the side panel by unscrewing fastener A and lifting the side panel upwards and outwards.
4
To fit the side panel, carefully slot the side panel into position, then tighten fastener A hand tight. Lower and lock the engine cover. K Engine Cover ( T 38).
1
Remove the bolts that hold the floor mat in position.
2
Carefully feed the mat out from the left hand side of the cab (the mat is split at the right hand side to make this easier).
3
Remove the bolts holding the required section of floor plate.
S203781
Fig 18.
39
9803/9960-4
39
Routine Maintenance Heater and Air Conditioning
Heater and Air Conditioning Cleaning the Fresh Air Filter.
Cleaning the Re-circulation Filter.
1
Park the machine on firm level ground and set the park brake to ON and the engine to OFF. Make the machine safe. K Prepare the Machine for Maintenance ( T 23)
1
Park the machine on firm level ground and set the park brake to ON and the engine to OFF. Make the machine safe. K Prepare the Machine for Maintenance ( T 23)
2
Remove the right hand side battery box access panel. K Access Panels ( T 38)
2
Enter the cab and remove filter B by pulling it through the aperture. Shake the filter to remove loose dust.
3
Remove the air filter A by pulling through the aperture and shake the filter to remove loose dust.
3
Clean the filter with a low pressure jet of compressed air.
4
Clean the filter with a low pressure jet of compressed air.
4
Refit the filter.
5
Refit the filter.
6
Replace the access panel.
B
A
T070470-8 T070470-8
Fig 20.
Fig 19.
40
9803/9960-4
40
Routine Maintenance Brakes
Brakes
!MWARNING
Park Brake (Wheeled or Tracked Machines)
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.
Introduction
!MWARNING
T3-071
0149
If the machine moved during the test, drive the machine to a suitable flat location and contact your JCB distributor to inspect the brake.
Do not use a machine with a faulty park brake. 3-2-3-10_2
!MWARNING Non approved modifications to drive ratios, machine weight or wheel and tyre sizes may adversely affect the performance of the park brake.
A
3-2-3-11
Make sure that you obey all health and safety precautions before you test or adjust the park brake. If you have any queries concerning the park brake test or adjustment procedures, consult your local JCB distributor.
15°
Testing the Park Brake
!MWARNING P
Before testing the park brake make sure the area around the machine is clear of people.
B
2-2-4-5
1
Make sure your seat belt is securely fastened.
2
Position the machine Position the machine on a suitable slope as shown at A. Make sure the machine is safely `held' in position using the drive controls.
3
Engage the park brake Press the rocker switch B, the switch light should be illuminated. Release hold of the drive control levers, the machine should not move. If the machine does start to move immediately use the drive controls to `hold' the machine in position. S202854-3
Fig 21.
41
9803/9960-4
41
Routine Maintenance Electrical System
Electrical System Battery
Checking the Electrolyte Level
Battery Disconnection/Connection
Low maintenance batteries used in normal temperate climate applications should not need topping up. However, in certain conditions (such as prolonged operation at tropical temperatures or if the alternator overcharges) the electrolyte level should be checked as described below.
T3-020_3
!MWARNING
T3-019_4
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 burnt. 5-2-2-4_2
1
Get access to the battery. See Access Panels.
2
Disconnect and remove battery. See Battery Disconnection/Connection.
Disconnection
!MWARNING
1
Get access to the battery. See Access Panels.
2
If the machine has a battery isolator, move the switch to the OFF position then remove the key.
3
Remove the leads. Disconnect the earth (-) terminal first.
Do not top the battery up with acid. The electrolyte could boil out and burn you. 2-3-4-6
3
Connection 1
Remove covers A. Look at the level in each cell. The electrolyte should be 6 mm (1/4 in) above the plates. Top up if necessary with distilled water or de-ionized water.
Check the battery. a
If the terminal is dirty, clean the post.
Fig 22. b If the terminal post is corroded and generates white powder wash the terminal with hot water. If considerable corrosion is detected, clean with a wire brush or abrasive paper.
4
Refit battery.
c
5
Close and lock the access panels.
After cleaning, apply a thin coat of petroleum jelly to the terminal.
2
Re-connect the leads. Connect the earth (-) terminal last.
3
If the machine has a battery isolator, move the switch to the ON position.
4
Close and lock the access panels.
42
Fig 23. Typical Battery
9803/9960-4
42
Routine Maintenance Electrical System Battery Isolator To disconnect the battery from the machine electrics a battery isolator switch has been installed in the battery cover.
A
!MCAUTION Except in an emergency, do not use the battery isolator to switch OFF the engine. Failure to comply may result in damage to the electrical circuits. INT-3-2-13
!MCAUTION 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 fitted. INT-3-1-13
At the end of a working cycle or if the machine is being left unattended, provided the lights are not required, the battery must be isolated. Before attempting to start the engine or use the machine electrics the battery isolator key must be fitted and switched on. To disconnect the machine electrics: 1
Turn the battery isolation switch A to the off position and remove the isolation key.
T036660
Fig 24.
To connect the machine electrics: 1
43
Turn the battery isolation switch A to the on position.
9803/9960-4
43
Routine Maintenance Electrical System
Jump Starting the Engine
!MWARNING
T3-023
Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery fully charged. Do not try to charge a frozen battery or jump-start and run the engine, the battery could explode. Batteries produce a flammable gas, which is explosive; do not smoke when checking the electrolyte levels.
Important: The machine has a 12 Volt electrical system. Using a booster (slave) supply with a higher voltage will damage the machine's electrical system. 1
The park brake should have been engaged when the machine was last parked. If it is not engaged, engage it now. The engine will not start unless the park brake is on.
2
Set all switches in the cab to off.
3
Connect the booster cables as follows: a
b Connect the positive booster cable to the positive (+) terminal on the machine battery. Connect the other end of this cable to the positive (+) terminal of the booster supply.
When jump-starting from another vehicle, make sure that the two vehicles do not touch each other. This prevents any chance of sparks near the battery. Set all the machine switches to their OFF positions before connecting the external power supply. Even with the starter switch set to off some circuits will be energised when the external power supply is connected. Do not connect the booster (slave) supply directly across the starter motor. Doing this by-passes the neutral gear safety switch. If the machine is in gear, it may 'runaway' and kill or injure bystanders. Use only sound jump leads with securely attached connectors. Connect one jump lead at a time. The machine has a negative earth electrical system. Check which battery terminal is positive (+) before making any connections. Keep metal watch straps and jewellery away from the jump lead connectors and the battery terminals - an accidental short could cause serious burns and damage equipment.
Unlock and open the battery cover.
c
Connect the negative (-) booster cable to a good frame earth on the machine, away from and below the battery.
Note: A good frame earth is part of the main frame, free from paint and dirt. Do not use a pivot pin for an earth. d Connect the other end of this cable to the negative (-) terminal on the booster supply. 4
Do the Pre-Start Checks.
5
Start the engine.
!MWARNING When the engine is running, there are rotating parts in the engine compartment. Before disconnecting the cables, make sure that you have no loose clothing (cuffs, ties etc.) which could get caught in rotating parts. 2-2-4-3
Make sure you know the voltage of the machine. The booster (slave) supply must not be higher than that of the machine. Using a higher voltage supply will damage your machine's electrical system. If you do not know the voltage of your booster (slave) supply, then contact your JCB dealer for advice. Do not attempt to jump-start the engine until you are sure of the voltage of the booster (slave) supply. 4-2-2-3_1
44
6
Disconnect the negative booster cable from the machine frame earth. Then disconnect it from the booster supply. Disconnect the positive booster cable from the positive (+) terminal on the battery. Then disconnect it from the booster supply.
7
9803/9960-4
Close and lock the battery cover.
44
Routine Maintenance Electrical System
Fuses
Internal Fuses
Introduction
The internal relays listed below are located behind the panel H.
!MCAUTION 10 9 8 7 6
Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage.
B
7.5
10
10
10
5
5 4
3 2 1
15
5
20
5
15
8-3-3-5
The electrical circuits are protected by fuses. The internal fuses are located behind the panel H. If a fuse ruptures, find out why and rectify the fault before fitting a new one.
A
10 9 8 7 6
5 4
3 2 1
15
5
5
10
7.5
10
7.5
Note: All the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown.
5
15
10
262020-5
Fig 26. Table 8. Fuse No. Circuit A1
Park Brake
10
A2
Aux Hyd Switch, Float Switch & Joystick Switch
15
A3
High-flow Hydraulics
5
A4
Hazard Switch, HeadLight Sw, Front WorkLight Sw, Heater Sw, Beacon Sw, Wash/Wipe Sw, Indicator Sw, Aux Hyd Sw, Illumination Feed, Buzzer, Water Temp, Hyd Oil Temp, Air Filter, Air Temperature Lamp Feed & Hour Meter Feed.
5
A5
Engine speed ind, ESOS, Fuel pump feed
5
A6
Heater Motor
10
A7
Rear Wiper
7.5
A8
Front / Rear Horn
7.5
A9
Beacon, Interior Light & face fan
10
A10
Hazard switch illumination
15
B1
Dip Beam
15
B2
L.H. Side Lights front and rear & rear number plate
5
B3
R.H. Side Lights front & rear
5
B4
Front Work Lights
20
B5
Rear Work Lights
15
B6
Power socket
7.5
H T0200010-1
Fig 25.
45
Rating(A)
9803/9960-4
45
Routine Maintenance Electrical System Fuse No. Circuit
Rating(A)
B7
2 Speed, Aux/Ext Dipper, Multifunction Attachment & Servo Harness
10
B8
Front Wash/wipe
10
B9
Reverse Alarm, Brake Lights
10
B10
Hazard lights
7.5
External Fuses The external relays are located in the battery compartment on the right hand side of the machine.
A B C
P1062940-4A
Fig 27. Table 9. Fuse No. Circuit
46
Rating(A)
A
Fuse C1 (Innermost) Auxiliary OPPS switch feed
5
B
Fuse C3 (Middle) Power Management ECU, PMS warning light, PMS Torque & Power MNG SET
20
C
Fuse C2 (Outermost) Servo circuit feed
25
9803/9960-4
46
Routine Maintenance Electrical System
Relays
External Relays
Internal Relays
The external relays are located in the battery compartment on the right hand side of the machine.
The internal relays listed below are located behind the panel H.
1
2
3
4
5
6
7
A
B
C
D
E
F
262020-4
Fig 28. Table 10. Relay No.
Circuit
R1
Ignition 2
R2
Isolator
R3
Ignition 1
R4
Alarm Buzzer
R5
Indicator Flasher
R6
Park Brake
R7
Horn
P1062940-4C
Fig 29. Table 11.
47
Relay No.
Circuit
A
Ign 2
B
Dig
C
Load
D
ISO1
E
Dig 1
F
Load 1
9803/9960-4
47
Routine Maintenance Engine
Engine Oil and Filter Checking the Oil Level 1
Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance.
2
Get access to the engine. Refer to Access Panels, Engine Cover.
3
Check that the oil level is between the maximum and minimum marks on the dipstick A.
!MWARNING Do not exceed the correct level of engine oil in the sump. If there is too much engine oil, the excess must be drained to the correct level. An excess of engine oil could cause the engine speed to increase rapidly without control. GEN-1-18
4
If necessary, add the recommended oil through filler B to the maximum level. K Fluids, Lubricants and Capacities ( T 13).
5
Fit filler cap and dipstick, make sure that they are fully inserted and tightened.
B
A Fig 30.
48
9803/9960-4
48
Routine Maintenance Engine Changing the Oil and Filter Drain the oil when the engine is warm as contaminants held in suspension will then be drained with the oil. 1
Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance.
2
Get access to the engine. Refer to Access Panels, Engine Cover.
3
Disconnect the battery.
4
Remove Blanking plate X.
5
Place a container of suitable size beneath the sump drain plug hose C.
!MCAUTION Oil will gush from the hole when the drain plug is removed. Hot oil and engine components can burn you. Keep to one side when you remove the plug. S262150
13-3-1-15
Fig 31.
6
Remove the drain plug C to allow oil to flow into the container. K Fig 31. ( T 49).
7
After emptying the sump, replace the drain plug C. Position the drain hose back inside the chassis and replace blanking plate X.
8
Change the filter: a
Unscrew the filter canister D. Remember that it will be full of oil.
b Clean the filter head E. K Fig 32. ( T 50). c
Add clean engine lubricating oil to the new filter canister. Allow enough time for the oil to pass through the filter element.
d Smear the seal F on the new filter with oil. Screw in the new filter canister - hand tight only. 9
Fill the engine, to the MAX mark on the dipstick, with new oil through the filler. See the chart in this Section for recommended oil grades. Wipe off any spilt oil. Make sure the filler cap is correctly refitted.
Note: Add the oil at a rate of no faster than two litres per minute.
49
10
Make sure the engine will not start by removing the engine shut-off solenoid (stop) fuse. Turn the engine using the starter key until the oil pressure warning light is extinguished.
9803/9960-4
49
Routine Maintenance Engine 11
Refit the engine shut-off solenoid fuse and start the engine. Check for leaks. When the engine has cooled, check the oil level and, if necessary, top up with clean engine oil.
Fig 32.
50
9803/9960-4
50
Routine Maintenance Engine
Cooling System Checking the Coolant Level
!MWARNING 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. 9-3-3-1_2
Visually check the coolant level daily. Check the quality of the antifreeze mixture every year before the cold weather starts. Change it every two years. Important: Water in the expansion bottle A and not in the radiator indicates expansion bottle tube leaking or a nonsealing radiator pressure cap. 1
Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance.
2
Get access to the engine. Refer to Access Panels, Engine Cover.
3
Check that the expansion bottle is 2/3 full of coolant.
S263130-1
Fig 33.
Note: If the level in the expansion bottle is low, then continue with steps 4 to 6. 4
Top-up the expansion bottle, through the filler cap B. The bottle should be 2/3 full.
5
Refit the filler cap, make sure it is tight.
6
Run the engine for a while to raise the coolant to working temperature and pressure. Stop the engine and check for leaks.
S262140-1
Fig 34.
51
9803/9960-4
51
Routine Maintenance Engine Changing the Coolant
8
Refit the filler cap B, make sure the cap is tight.
!MWARNING
9
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.
Run the engine for a while, to raise the coolant to working temperature and pressure. Stop the engine. Check for leaks.
10
Check the coolant level and top up if necessary. K Checking the Coolant Level ( T 51).
9-3-3-1_2
1
Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance.
2
Get access to the engine. Refer to Access Panels, Engine Cover.
3
Carefully loosen filler cap B.
!MCAUTION Keep your face disconnecting it.
away
from
the
hose
while
5-3-3-1
S255870
Fig 36. 4
Remove plug C from the drain hose and let the coolant drain out.
5
Flush the system, if necessary. Use clean water.
6
Refit drain plug C.
S262140-1
Fig 35. 7
52
Fill the system, use the necessary mix of clean, soft water and antifreeze. K Fluids, Lubricants and Capacities ( T 13).
9803/9960-4
52
Routine Maintenance Engine
Alternator Drive Belt Adjusting the Alternator Drive Belt At the recommended service interval, visually inspect the belt for damage.
!MWARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5
!MWARNING 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. 0094
1
Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance.
2
Get access to the engine. Refer to Access Panels, Engine Cover.
3
Loosen adjustment link and fastening bolt A and pivot fastening bolt B.
4
Position the alternator so that there is 7 mm (0.28 in) slack at point W.
5
Secure the alternator, tighten bolts A and B.
Fig 37.
Note: If a new belt is fitted, the belt tension must be checked again after the first 20 hours of operation.
53
9803/9960-4
53
Routine Maintenance Engine
Air Filter Cleaning the Air Filter Dust Valve Important: Do not run the engine with the dust valve K removed. K Fig 38. ( T 54). 1
Check the dust valve K is not blocked.
2
Inspect the rubber flaps for cuts and nicks and check that the rubber is not perished. Renew if necessary.
K 332260-1
Fig 38.
54
9803/9960-4
54
Routine Maintenance Engine Changing the Elements
5
Test the seating of seals: Insert the new elements in canister C.
C
J
H
G
Remove the elements and check for witness marks on the inside base of the canister. 6
If the seals are secure, re-insert the new inner element.
7
Insert the new outer element.
8
Refit the induction hose (if disconnected). Make sure that the wire to the Air Filter Blocked switch is attached to the spade connector.
D 332-r6314-7-s1
Fig 39.
!MCAUTION The outer element must be renewed immediately if the warning light on the instrument panel illuminates. 2-3-3-1
!MCAUTION
Note: Do not run the engine with the dust valve D removed. Note: In dusty conditions, the outer element can be cleaned by blowing through in the reverse direction with clean dry compressed air. If the element is damaged, it must be replaced. A new inner element must be fitted at least every third time the outer element is changed. As a reminder, mark the inner element with a felt tipped pen each time the outer element is changed.
Do not run the engine when the outer element has been removed. 16-3-3-1
Note: In a dusty working environment, the outer element may have to be renewed more frequently than the service schedule recommendation. A new inner element must be fitted at least every other time the outer element is changed. As a reminder, mark the inner element with a felt tipped pen each time the outer element is changed. Do not attempt to wash or clean the elements - they must only be renewed. 1
Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance.
2
Get access to the engine. Refer to Access Panels, Engine Cover.
3
Unlatch the clips H. Remove the filter cap and outer element G. Take care not to tap or knock the element.
4
Clean inside the canister C and dust valve D.
55
9803/9960-4
55
Routine Maintenance Fuel System
Fuel System Introduction
Location
!MWARNING
The fuel filter X is located at the front left hand side of the engine compartment.
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.
P
32/401102
INT-3-2-2_3
!MWARNING 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.
X
0177
329160-2
Fig 40.
!MCAUTION 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 fit 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. INT-3-3-12
!MCAUTION 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. 2-3-3-11
56
9803/9960-4
56
Routine Maintenance Fuel System
Drain the Fuel Filter 1
Stop the engine.
2
Open the bonnet.
C D
3
Drain off any water in the bowl B by opening tap A.
E
4
Re-tighten tap A. K Fig 41. ( T 57).
5
If there is sediment in the bowl B change the element F. See Changing the Fuel Filter Element.
M K H J
F J
B J G
L A S255820-B3
Fig 41.
57
9803/9960-4
57
Routine Maintenance Fuel System
Changing the Fuel Filter Element 1
Stop the engine.
2
Open the bonnet.
3
Place a receptacle under the filter to catch any fuel. Slacken tap A.
4
Support the bowl B and unscrew bolt C. Remove the bolt C, remove and discard washer D and 'O' ring E.
5
Remove filter element F, bowl B and base G as a unit.
6
Discard 'O' ring H.
7
Separate element F, bowl B and base G.
8
Remove and discard seals J (3 off), discard 'O' ring L.
9
Lubricate all seals and 'O' rings with clean fuel oil.
10
Fit new seals J (3 off) to base G, bowl B and element F, fit 'O' ring H to the centre of the element F.
11
Fit element F, bowl B, base G, to the head K.
12
Insert centre bolt C after fitting new washer D and 'O' ring E. Tighten the bolt C carefully by hand to ensure that all seals are correctly seated. Fit new 'O' ring L to tap A and insert tap into base G.
13
Tighten bolt C to 8-11 Nm (6-8 lbf ft, 0.8-1.1 kgf m).
14
Prime the Filter.
15
Slacken bleed screw M, turn on the ignition to operate the priming pump P until fuel spurts from the loosened screw with no entrapped air. K Fig 40. ( T 56).
16
Tighten the bleed screw, turn off the ignition, check the filter for leaks. Tighten connections or change seals as required.
58
9803/9960-4
58
Routine Maintenance Hydraulic System
Hydraulic System
!MCAUTION
Introduction
!MWARNING The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools (less than 40°C) before beginning maintenance. 8-3-4-10
!MWARNING 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 protective glasses and gloves. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. INT-3-1-10_3
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 fit 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. INT-3-3-12
Releasing the Hydraulic Pressure 1
Make the machine safe. K Prepare the Machine for Maintenance ( T 23).
2
Operate the controls to remove the hydraulic pressure from the service hose lines.
!MWARNING
a
Hydraulic Pressure 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.
For manually operated services, operate the controls (several times) of the service to be disconnected.
b For Easy Control servo machines, switch off engine, turn key to buzzer position 1 and operate services to lower services and release pressure. 3
Clean the top of the tank around the filler cap.
INT-3-1-11_2
!MCAUTION
!MCAUTION 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.
Allow the hydraulic fluid temperature to cool before removing the hydraulic tank filler cap. Open the cap slowly to prevent oil being forced out of the filler neck. 5-3-4-8
!MCAUTION
2-3-5-1_2
Do not run the engine with the hydraulic tank filler cap removed. 5-3-4-1
4
5
59
Check that the seal in good condition and correctly
9803/9960-4
Slowly remove filler cap to allow the system to vent fully and prevent oil being forced out of the filler neck. installed in the cap. Replace if necessary.
59
Routine Maintenance Hydraulic System
Hydraulic Oil and Filter Checking the Fluid Level 1
Position the machine on level ground. Set the loader shovel on the ground. Raise the loader arm, swing in the dipper and close the bucket. Stop the engine. Remove the starter key.
2
Look at the fluid level in the sight glass A. The level should be at the red mark.
B T070470-1
Fig 43.
A
203771
Fig 42.
!MCAUTION If the fluid is cloudy, then water or air has contaminated the system. This could damage the hydraulic pump. Contact your JCB Distributor immediately. 12-5-1-4
3
60
If the oil level is low, remove filler cap B and replenish with recommended hydraulic oil as required.
9803/9960-4
60
Routine Maintenance Hydraulic System Changing the Hydraulic Filter(s)
Hydraulic Oil Filter tightening torque
D F
E
B
Note: Machines fitted with the High-Flow hydraulic system have a second filter E which must also be changed. The two filter canisters, although visually similar, are different and must not be mixed. 6
If fitted, before removing the High-Flow filter E, take suitable precautions to catch any oil and unscrew the old High-Flow filter canister, using a chain wrench if necessary and dispose of the old filter and any waste material according to local regulations.
7
Lubricate the seal on the new filter canister with the correct clean hydraulic oil. Tighten to the correct torque.
8
Screw on the new filter canister and tighten to the correct torque.
C E
35 nm (26 Ib-ft)
Hi-Flow Hydraulic Oil Filter 35 nm (26 Ib-ft) tightening torque 9
Add the correct hydraulic oil through filler point B. K Fluids, Lubricants and Capacities ( T 13).
10
Refit cap B, run the engine for a few minutes, then recheck the fluid level.
9803/9960-4
61
T070470-2
Fig 44. 1
Stop the engine and wait for 5 minutes and release hydraulic pressure. K Releasing the Hydraulic Pressure ( T 59)
2
Loosen the hydraulic tank filler cap B and allow all pressure to dissipate. Remove the filler cap. K Fig 44. ( T 61).
3
Take suitable precautions to catch any oil and unscrew the old filter canister C, using a chain wrench if necessary, and dispose of the old filter and any waste material according to local regulations.
4
Lubricate seal D on the filter canister with the correct clean hydraulic oil. Tighten to the correct torque.
5
Screw on the new filter canister and tighten to the correct torque.
61
Routine Maintenance Transmission
Transmission Tracked Machines On tracked machines, a hydraulic motor mounted on each side of the machine drives each track directly. Tracked machines do not have drive chains.
Wheeled Machines The final drive to the wheels is by chains. A chain casing on each side of the machine houses two chains, one to the front wheel and one to the rear wheel. The chains run in an oil bath.
A
Checking the Oil Levels (Wheeled Machines Only) 1
Park the machine on level ground.
2
Stop the engine.
3
On the left side of the machine, remove inspection plug A and check that the oil level is up to the bottom of the aperture.K Fig 45. ( T 62)
4
If necessary, top up through the aperture using the recommended oil. (See Fluids, Capacities and Lubricants.) Wipe up any oil spillage.
5
Check that the washer on plug A is undamaged. Renew if necessary.
6
Clean plug A and its aperture before refitting. Do not overtighten or you could strip the threads in the housing.
7
Repeat steps 3 to 6 on the right side of the machine.
62
T021440-1
Fig 45. Note: This diagram shows the location of the chain casing plugs on the left side of the machine. The right side casing is a mirror image of the left side casing.
9803/9960-4
62
Routine Maintenance Tyres and Wheels (1CXW Only)
Tyres and Wheels (1CXW Only) Tyre Inflation
in a qualified tyre mechanic. The tyre mechanic should use a tyre inflation cage and the correct equipment to do the job.
Introduction
!MWARNING
T3-066
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. 2-3-2-7_2
1
Prepare the wheel. Before you add air to the tyre, make sure it is correctly fitted on the machine or installed in a tyre inflation cage. K Fig 46. ( T 63).
2
Prepare the equipment. a
!MWARNING Wheels and tyres are heavy. Take care when lifting or moving them. Store with care to ensure that they cannot fall and cause injury.
b Use an air hose fitted with a self-locking air chuck and remote shut-off valve.
13-3-1-7_1
Always try to maintain your tyre pressure to the recommended settings. Using your machine with underinflated tyres means:
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. For recommended tyres and pressures for your machine, see Specifications, Tyre Sizes and Pressures.
3
– Decreasing the machines stability – Higher tyre temperatures
Add the air. a
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.
– Excessive strain of the tyre fabric b Inflate the tyre to the recommended pressure. Do not over-inflate.
– More 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 T3-067_2
These instructions are for adding air to a tyre which is already inflated. If the tyre has lost all its air pressure, call
63
9803/9960-4
A089570-1
Fig 46.
63
Routine Maintenance Tyres and Wheels (1CXW Only)
Checking the Wheel Nut Torques
!MWARNING 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. 2-3-2-8
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. The correct torques are shown in the table below. Table 12. Front
64
Rear
Nm
lbf ft
Nm
lbf ft
390
288
390
288
9803/9960-4
64
Routine Maintenance Tracks
Tracks Track Adjustment
9
When both checks / adjustments are complete, lower the tracks to the ground and park the stabiliser legs and bucket normally.
Correct track tension is important for good performance and to prevent the tracks from dismounting. The track tension is controlled by the forward idler which is attached to a grease filled hydraulic cylinder. The track tension should be checked as follows: 1
Position machine on a smooth, flat and firm surface
2
Thoroughly clean the track, making sure that all debris are removed from around the sprocket and rollers. Drive the machine backwards and forwards while cleaning.
X
!MWARNING Raised Machine NEVER position yourself or any part of your body under a raised machine which is not properly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed.
E F
D
T055250-3
Fig 47.
INT-3-3-7_1
3
Lift the tracks of the ground approximately 150 mm (6 in) (D) using dumped bucket E and the rear stabiliser legs F. Make sure the track to be adjusted is completely clear of the ground.
4
Position the ruler between the 2 middle rollers and measure the distance X from the machine frame to the track. The gap should be 103mm (4 in). K Fig 47. ( T 65).
5
If adjustment is required, unscrew bolts A and remove access plate B. K Fig 48. ( T 66).
6
To tighten the track, pump grease into the nipple using a grease gun. To loosen the track, carefully unscrew hexagon plug C and allow the grease to flow into a suitable container.
7
When correct adjustment is achieved, replace the cover plate.
8
Repeat for the opposite track.
65
9803/9960-4
65
Routine Maintenance Tracks
C B A
T055570-2
Fig 48.
66
9803/9960-4
66
Routine Maintenance Wear Pads
Wear Pads Extending Dipper Wear Pads
Inspecting the Top Wear Pads
The extending dipper wear pads are bolt-on replaceable items. They support and guide the inner dipper section during extension and retraction. The following procedures explain how to inspect, and where applicable, adjust the pads. There is a set of Left hand and Right hand wear pads, each set comprises top wear pads A and bottom wear pads B. The top wear pads A are not adjustable and must be replaced with new pads once they have worn to their limit. K Inspecting the Top Wear Pads ( T 67).
C
The bottom wear pads B are adjustable and take up the wear on both the top and bottom pads. They must also be replaced with new pads when the top pads are changed. K Adjusting the Bottom Wear Pads ( T 68). New wear pads A and B must be replaced as a set and nuts C tightened to the correct torque value shown with Loctite 243 applied to threads and fitted by a qualified service engineer.
T062090
Fig 49. 1
Park the machine on level ground. Engage the park brake and put the transmission in neutral. Position the boom and dipper. K Fig 49. ( T 67). Retract the extending dipper D. Make sure that the bucket is clear of the ground and the dipper is supported.
2
Stop the engine and remove the starter key.
3
Renew the pads when, or before, they are worn down to the depth of the chamfer. If the pads are worn near to their limit then inspect them more frequently than recommended in the Service Schedules. To avoid damage to the dipper or wear pad make sure the pads are fitted the correct way round.
Item C
67
9803/9960-4
Table 13. Torque Values Nm (lbf ft) 50 (37)
67
Routine Maintenance Wear Pads Adjusting the Bottom Wear Pads
T062090-1
Fig 50. 1
Park the machine on level ground. Engage the park brake and put the transmission in neutral. Support the boom and dipper. K Fig 50. ( T 68). Stop the engine.
2
Clean the sliding faces of the inner dipper with a suitable solvent.
3
Start the engine. Retract the extending dipper D. Make sure that the bucket is clear of the ground and the dipper is supported. Stop the engine.
4
With grease, mud etc. removed from the sliding faces visually check the gap between inner dipper and top wear pad A, as shown at G. The gap should be no greater than 1.5 mm (1/16 inch).
c
Note: Remember to alternate sides each time an adjustment is made. When all the threads on the adjuster L are flush with locknut K and the clearance is greater than 1.5 mm (1/16 inch), then wear pads A and B must be replaced as a set and fitted by a qualified service engineer. 6
When the adjustments have been completed, apply Waxoyl to the runners of the inner dipper.
Item 5
If the gap is greater than 1.5mm (1/16 inch) then adjust as follows: a
Tighten locknuts K to the correct torque value shown with Loctite 243 applied to threads. Visually re-check the gap is no greater than 1.5mm (1/16 inch) as shown at G.
K
Table 14. Torque Values Nm (lbf ft) 50 (37)
Undo adjuster locknuts K.
b Screw in adjusters L equally on both sides to achieve a 1.5mm (1/16 inch) gap.
68
9803/9960-4
68
Routine Maintenance Windscreen Washer
Windscreen Washer 1
Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance.
2
Get access to the engine. Refer to Access Panels, Engine Cover.
3
Fill the windscreen washer bottle D with a suitable liquid. The liquid should contain a de-icing fluid to prevent freezing. Do not use engine coolant antifreeze.
S263120
Fig 51.
69
9803/9960-4
69
Routine Maintenance Fire Extinguisher (if fitted)
Fire Extinguisher (if fitted) T3-022
Checking the Fire Extinguisher Check the fire extinguisher for damage, security and signs of leaking. Check that the gauge A indicates that the extinguisher is charged i.e. the needle is in the GREEN segment. Note: If the needle is in or very near the RED segment at either end of the gauge, the extinguisher must be serviced or replaced. Make sure the safety pin B is fitted and secure. The extinguisher should be serviced every 12 months by a suitably qualified person.
Fig 52.
70
9803/9960-4
70
Routine Maintenance Fire Extinguisher (if fitted)
Page left intentionally blank
71
9803/9960-4
71
Section A Attachments Service Manual - 1CX Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section J - Tracks Section K - Engine
Publication No.
9803/9960-3
World Class Customer Support Copyright Š 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section A - Attachments
Notes:
A-0
9803/9960-3
A-0
Section A - Attachments Contents
Contents Page No. Service Procedures Introduction ............................................................................................... A-1 Attachments for your Machine .................................................................. A-2 Impact Protection ...................................................................................... A-3 Removing Excavator Auxiliary Residual Pressure ................................... A-4 Removing Loader Auxiliary Residual Pressure ........................................ A-5 Connecting/Disconnecting Hydraulic Hoses ............................................. A-6 Introduction ........................................................................................... A-6 Connecting the Hydraulic Hoses .......................................................... A-6 Disconnecting the Hydraulic Hoses ...................................................... A-7 Quick Release Couplings ..................................................................... A-8 Maintenance 4-in-1 Clamshovel .................................................................................... A-11 Introduction ..........................................................................................A-11 Using the 4 in-1 Shovel .......................................................................A-11 Operation ............................................................................................ A-13 Pallet Forks ............................................................................................. A-14 Safety ................................................................................................. A-14 Fitting/Removing Pallet Forks ............................................................ A-14 Road Travel ........................................................................................ A-14 Adjust the Fork Spacing ..................................................................... A-14 Daily Maintenance .............................................................................. A-14 Manure/Silage Fork with Top Grab ......................................................... A-15 Safety ................................................................................................. A-15 Operation ............................................................................................ A-15 Control ................................................................................................ A-15 Preparing for Travel ............................................................................ A-15 Installing and Removing ..................................................................... A-15 Using the Manure/Silage Fork ............................................................ A-15 Daily Maintenance .............................................................................. A-15 Attachment Frame .................................................................................. A-16 Installing/Removing the Attachment Frame ........................................ A-16 Excavator Quickhitch .............................................................................. A-17 Introduction ......................................................................................... A-17 Installation .......................................................................................... A-17 Removal ............................................................................................. A-17 Maintenance ....................................................................................... A-18 Buckets ................................................................................................... A-19 Bucket Selection ................................................................................. A-19 Removing a Bucket - Non Quickhitch Models .................................... A-20 Installing a Bucket - Non Quickhitch Models ...................................... A-21 Removing a Bucket from a Quickhitch ............................................... A-21 Installing a Bucket on a Quickhitch .................................................... A-23 Replacing Bucket Teeth ...................................................................... A-24
A-i
A-i
Section A - Attachments Contents
Contents
A-ii
Page No.
A-ii
Section A - Attachments
Service Procedures Introduction T4-002_3
!MWARNING
Practice using attachments off the job before working with them for the first time.
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. 2-4-5-2_1
!MCAUTION If you have an attachment which is not covered in the Operator 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. 5-5-1-1_2
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. This part of the manual includes general information on attachment operation and instructions for installation and removal of attachments.
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.
!MCAUTION Some attachments may contact parts of the machine when in the fully folded position. Take extra care to avoid damage to the machine. 3-4-1-4
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 again Working With The Machine in the Operation section and consider how the attachment is going to affect operational safety. With the attachment fitted, 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.
A-1
9803/9960-3
A-1
Section A - Attachments Service Procedures Attachments for your Machine
Attachments for your Machine
!MCAUTION Some attachments (e.g. muck fork/push-off) can cause damage to the front tyres when the boom is lowered and the carriage is tilted forward. Exercise caution when lowering the boom with the carriage tilted forward when a muck fork/push-off type attachment is fitted.
For other attachments, please refer to the manufacturer's manual for the attachment (if supplied). General installation and removal procedures for other attachments are, however, included here. Important: Do not operate attachments until the hydraulic oil has reached its normal working temperature. Note: Do not use this machine with a sweeper or sweeper/ collector unless the attachment is connected to optional high flow equipment auxiliary connections. Allow the hydraulic system to cool for 30 minutes between each period of use.
5-5-1-9
Note: The JCB 1CX can accept 803 series buckets. However, because of the different geometry of these buckets, the auxiliary pipework must be removed from the boom before fitting, or damage to the pipework may result.
382971-1
Fig 1.
!MCAUTION If you have an attachment which is not covered in the Operator 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. 5-5-1-1_2
All standard machines are fitted with a Q-Fit carriage. Attachments will help increase the productivity of your machine, for more information contact your JCB Distributor. Remember, do not operate attachments until you have read and fully understand the attachment operating instructions.
A-2
9803/9960-3
A-2
Section A - Attachments Service Procedures Impact Protection
Impact Protection
!MWARNING When using an attachment for example a hydraulic breaker, where the risk of flying debris is present, a protective layer or screen guard must be attached to the front of the cab to protect the operator from flying debris which could cause injury. 8-5-1-5
The decal A states that the machine is not fitted with glass protection.
A
332/V3761
Fig 2.
A-3
9803/9960-3
A-3
Section A - Attachments Service Procedures Removing Excavator Auxiliary Residual Pressure
Removing Excavator Auxiliary Residual Pressure
!MWARNING
Note: The location of the auxiliary controls will vary according to the specification of the machine.
Hydraulic Pressure 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. INT-3-1-11_2
Note: Make sure the machine is warmed up before removing residual pressure to make sure the accumulators are charged.
7
Turn the ignition OFF.
8
Connect or Disconnect the couplings as required.
Note: During the venting procedure, limited movement of the attachment is likely to occur. Note: Failure to fully vent the attachment before removal of the couplings will store pressure within the attachment which may prevent subsequent reconnection to the machine.
Note: Make sure the Auxiliary attachments are in the closed position before you connect or disconnect quick release couplings otherwise residual pressure can build up. 1
Make the Machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.
2
Make sure the seat is locked in the rear facing position.
3
Turn the key to the 'ON' position (position 1).
AUX H
X
A T060200-19
Fig 4.
Fig 3. 4
Press the auxiliary switch X to ON position.
5
Press the switch H to excavator position.
6
Operate the auxiliary control switch A in forward then reverse direction, slowly and fully three times. Refer to Auxiliary Controls, Operation Section.
A-4
9803/9960-3
A-4
Section A - Attachments Service Procedures Removing Loader Auxiliary Residual Pressure
Removing Loader Auxiliary Residual Pressure
!MWARNING
Note: The location of the auxiliary controls will vary according to the specification of the machine.
Hydraulic Pressure 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. INT-3-1-11_2
Note: Make sure the machine is warmed up before removing residual pressure to make sure the accumulators are charged.
7
Turn the ignition OFF.
8
Connect or Disconnect the couplings as required.
Note: During the venting procedure, limited movement of the attachment is likely to occur. Note: Failure to fully vent the attachment before removal of the couplings will store pressure within the attachment which may prevent subsequent reconnection to the machine.
Note: Make sure the Auxiliary attachments are in the closed position before you connect or disconnect quick release couplings otherwise residual pressure can build up. 1
Make the Machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.
2
Make sure the seat is locked in the forward facing position.
3
Turn the key to the 'ON' position (position 1).
A
Fig 5.
H
4
Press the auxiliary switch X to ON position.
5
Press the switch H to Loader position.
6
Operate the auxiliary control switch A in forward then reverse direction, slowly and fully three times. Refer to Auxiliary Controls, Operation Section.
A-5
AUX X
9803/9960-3
T060200-1
Fig 6.
A-5
Section A - Attachments Service Procedures Connecting/Disconnecting Hydraulic Hoses
Connecting/Disconnecting Hydraulic Hoses T4-004_2
Introduction
Connecting the Hydraulic Hoses
!MWARNING 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 protective glasses and gloves. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.
1
Make the machine safe. Refer to Routine Maintenance, Prepare the Machine for Maintenance.
2
Vent the hydraulic system. Refer to Routine Maintenance, Releasing the Hydraulic Pressure.
3
If necessary, remove the blanking caps.
4
Check the hoses and adaptors for damage. Refer to Routine Maintenance, Checking for Damage.
5
Connect the hoses.
INT-3-1-10_3
!MWARNING Hydraulic Pressure 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.
If the hoses have quick releases couplings, refer to Quick Release Couplings. a
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.
INT-3-1-11_2
Some attachments are hydraulically powered. The following procedures show how to connect and disconnect the hydraulic hoses safely.
T037400
Fig 7. b Make sure that the hose does not touch hot parts. High ambient temperatures can cause the hose to fail. c
Make sure that the hose does not touch parts which can rub or cause abrasion.
d Use the hose clamps (where possible) to support long hose runs and keep the hoses away from moving parts, etc.
A-6
9803/9960-3
A-6
Section A - Attachments Service Procedures Connecting/Disconnecting Hydraulic Hoses
Disconnecting the Hydraulic Hoses 1
Make the machine safe. Refer to Routine Maintenance, Prepare the Machine for Maintenance.
2
Vent the hydraulic system. Refer to Routine Maintenance, Releasing the Hydraulic Pressure.
3
Disconnect the hoses.
T037420
Fig 8. To allow for length changes when the hose is pressurised, do not clamp at the bend. The curve absorbs the change.
If the hoses have quick releases couplings, then refer to Quick Release Couplings. 4
Check the hoses and adaptors for damage. Refer to Routine Maintenance, Checking for Damage.
5
If necessary, install the blanking caps
6
Check for leaks. a
Start the engine.
b Operate the related control to increase the pressure in the hydraulic system. c
T037410
Fig 9. 6
Stop the engine then remove the starter key.
d Check for indications of leakage at the hose connections. Correct, as necessary.
Check for leaks. a
Start the engine.
b Operate the related control to increase the pressure in the hydraulic system. c
Stop the engine then remove the starter key.
d Check for indications of leakage at the hose connections. Correct, as necessary.
A-7
9803/9960-3
A-7
Section A - Attachments Service Procedures Connecting/Disconnecting Hydraulic Hoses
Quick Release Couplings
by dirt in the coupling or physical damage due to abuse.
!MWARNING The external surfaces of the couplings must be clean before connecting or disconnecting. Ingress of dirt will cause fluid leaks and difficulty in connecting or disconnecting. You could be killed or seriously injured by faulty Quick Release Couplings. 2-4-1-15
Flat face quick release couplings allow the operator to remove and install attachments swiftly and efficiently. Generally, your machine pipework will be fitted with a female coupling A and a male coupling B. The optional attachment hoses will also be fitted with a female coupling A and a male coupling B. K Fig 10. ( T A-9). The quick release couplings should be trouble free and relatively easy to connect and disconnect, provided they are kept clean and used correctly. The recommendations listed below should always apply when using flat face quick release couplings. Finally, please read the correct fitting and releasing procedures before you install or remove any optional attachment fitted with quick release couplings.
Essential Do's – 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. – 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. Ensure the locking ball and notch in the locking sleeve are aligned, pull back the sleeve and twist the couplings apart. Sticking is normally caused
A-8
– Connect and disconnect 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 fitting 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. – Periodically lubricate the internal locking balls on the female half of the coupling with silicone grease.
Essential Don'ts – Never attempt 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 vehicle or otherwise crushed - this will distort the sleeve and prevent connection and disconnection. – Never try to turn the sleeve when the coupling is disconnected since 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 should be replaced with a new one. See coupling guides for a reference. – Never hit the centre poppet of the coupling to try and release locked in pressure. This can cause irreparable damage to the coupling and serious injury. – When fitting 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 reduce the life of the coupling or cause failure. – Never allow the torsional forces transmitted from hoses to unscrew/screw together 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.
9803/9960-3
A-8
Section A - Attachments Service Procedures Connecting/Disconnecting Hydraulic Hoses Connecting Quick Release Couplings 1
Remove any residual hydraulic pressure trapped in the service line hose.
2
Wipe the two faces of the male and female couplings and make sure they are clean.
3
Make sure that ball C in the female coupling is located in one of its slots.
4
Fit the male coupling into the female coupling.
5
Where applicable, rotate sleeve E half a turn and make sure that the locking ball C does not align with the slot D.
Disconnecting Quick Release Couplings 1
Remove any residual hydraulic pressure trapped in the service line hose.
2
Where applicable, align the slot D with ball C.
3
Pull back sleeve E to release the coupling.
C007100-1
Fig 10.
A-9
9803/9960-3
A-9
Section A - Attachments Service Procedures Connecting/Disconnecting Hydraulic Hoses
Page left intentionally blank
A-10
9803/9960-3
A-10
Section A - Attachments
Maintenance 4-in-1 Clamshovel Introduction
Loading and Digging
The 4-in-1 shovel allows you to load, dig, grab, grade, doze and spread without changing attachments.
With the clam closed, the shovel can be used as a conventional shovel as described in Working with the Loader. For higher dumping, open the clam instead of rolling the shovel.
It is similar to a normal shovel except that it has an opening clam which is operated by hydraulic rams mounted on the bucket frame.
Safety Obey all the safety instructions given in the main part of this book, plus those given in this section.
Operation Practice using the 4-in-1 shovel off the job before working with it for the first time. Fig 1.
Preparing for Travel Grabbing Close the clam then treat as a standard shovel. 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.
Control The lift, lower, open and close movements of the 4-in-1 shovel are controlled by the loader control levers. The shovel clam is operated by the right hand control lever.
Using the 4 in-1 Shovel 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.
Fig 2.
A-11
9803/9960-3
A-11
Section A - Attachments Maintenance 4-in-1 Clamshovel Grading
Spreading
To grade, open the clam and drag the shovel backwards. When the shovel is full, roll it back and close the clam.
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 discharge an even layer of material as it goes.
Fig 3.
Dozing Fig 5. To doze, open the clam and drive the machine forward.
Fig 4.
A-12
9803/9960-3
A-12
Section A - Attachments Maintenance 4-in-1 Clamshovel
Operation F
On machines fitted with a 4 in 1 clamshovel, the thumb switch on the loader lever operates the service.
G
Ensure the seat is locked in the forward facing position. To enable the thumb switch, press the auxiliary circuit switch X. The thumb switch should be isolated before roading or when not in use, press the auxiliary switch to the OFF position. K Fig 7. ( T A-13). F
Open Clam - To open the clam F, push the switch forward.
G
Close Clam - To close the clam G, pull the switch backwards.
X
AUX
T060200
Fig 6.
A-13
Fig 7.
9803/9960-3
A-13
Section A - Attachments Maintenance Pallet Forks
Pallet Forks The pallet fork frame includes a Rating Plate which gives its weight and its Safe Working Load. The forks should always be used in pairs as supplied. Each fork is stamped with its Part Number and Safe Working Load.
Adjust the Fork Spacing 1
Position the forks until they are just clear of the ground.
2
Move the spring-loaded locking lever to the vertical position A and slide the fork along the rail.
Safety
A
Obey all the safety instructions given in the main part of this book, plus the ones given in this section. An optional Load Guard can be purchased, see your JCB Distributor for details.
B B
!MCAUTION Fork Spacing 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. 5-1-4-2
Fitting/Removing Pallet Forks
Fig 8. 3
See Quickhitch Control (OPERATION section).
Operation
When the fork is in the required position return the spring-loaded locking lever to the horizontal position B, ensuring that the locking pin is fully engaged in a slot in the rail.
Practice using the forks off the job before working with them for the first time.
Daily Maintenance
Control
1
Oil the spring loaded locking lever.
The forks are operated by the loader control lever (see Loader Controls (OPERATION section).
2
Grease top rail slots.
3
Clean with the rest of the machine.
Operate the control carefully when using the forks.
Road Travel
!MWARNING The Quick-Hitch forks must not be fitted for road travel. Failure to comply may render the operator vulnerable to criminal prosecution. If the machine has to travel on public roads the forks must be removed. 2-4-5-4
A-14
9803/9960-3
A-14
Section A - Attachments Maintenance Manure/Silage Fork with Top Grab
Manure/Silage Fork with Top Grab The Manure/Silage fork is fitted with a top grab as standard which gives extra security to the pay load when moving the machine.
To unload the fork, raise it to a suitable height, open the top grab and tilt down.
Daily Maintenance The grab is opened and closed by a hydraulic ram mounted on the fork frame.
1
Clean with the rest of the machine.
Safety
2
Check for damage
Obey all the safety instructions given in the main part of this book, plus those given in this section.
Make sure the tines are secure and in good condition. 3
Check for signs of hydraulic leaks.
Operation Practice using the Manure/Silage fork off the job before working with it for the first time.
Control The lift, lower and tilt movements of the fork are controlled by the loader control lever (see Loader Controls OPERATION section).
!MWARNING 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 protective glasses and gloves. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. INT-3-1-10_3
The grab is operated by the right hand control lever.
4
Preparing for Travel
Grease Total of 5 grease points.
Close the grab; then treat as a standard shovel.
Installing and Removing
1
2
3
4
Apart from connecting and disconnecting the hydraulic hoses, the Manure/Silage fork is installed like a standard bucket. See Quickhitch Control in OPERATION section. Close the grab before removing it.
Using the Manure/Silage Fork
5
Always operate the controls slowly and carefully. Drive slowly and carefully when the Manure/Silage fork is loaded. Keep the fork low to the ground when moving, this increases your visibility and makes the machine more stable.
Fig 9.
Open the top grab before loading the fork. Close the top grab on the load before moving the machine.
A-15
9803/9960-3
A-15
Section A - Attachments Maintenance Attachment Frame
Attachment Frame Some attachments, e.g. Hammermaster and Earth Drill, utilise an attachment frame for installing on a Skid Steer Loader. Use the following procedure for Installing/ Removing the attachment frame.
Installing/Removing the Attachment Frame 1
Stand the attachment frame on level ground as shown at A. Drive the Skid Steer Loader squarely up to the frame and stop.
Fig 11. 3
Drive the machine forward until the Quickhitch plate touches the attachment frame then stop.
4
Slowly tilt the plate backwards until it engages the attachment frame lip. Raise the loader arm until the frame is in contact with the Quickhitch plate, top and bottom.
5
Push Quickhitch levers fully in, as at position E, to engage locking pins F and secure the attachment frame.
6
Removal is the reversal of steps 1 to 5 above.
7
Refer to the Owners Manual of the particular attachment for full instructions concerning its installation/removal from the attachment frame.
Fig 10. 2
Lower the loader arm and tilt forward Quickhitch plate B so that the top of the plate is lower than the lip C of the attachment frame.Move Quickhitch levers (one each side of hitch plate) fully out, as at position D.
!MWARNING Do not lean out of the cab to operate the Quickhitch levers. If the controls are moved accidentally you could be killed or injured. 3-4-1-8
A-16
9803/9960-3
A-16
Section A - Attachments Maintenance Excavator Quickhitch
Excavator Quickhitch Introduction
3
Position the machine so that the dipper arm and Quickhitch are correctly aligned as shown.
The Excavator Quickhitch, which is attached to the dipper permits fast removal and installation of the bucket (and other attachments).
4
Engage the dipper: Operate the controls to line up hole A in the dipper arm with the holes B in the Quickhitch.
The Quickhitch is mechanically operated and does not require hydraulic connections.
Insert the pivot pin C and secure with fasteners H and D.
!MCAUTION When the Quick-Hitch is installed and its attachment fitted, there is a danger of the attachment hitting the underside of the boom. Operate the boom and dipper carefully when the Quick-Hitch and its attachment are fitted.
5
Engage the tipping link: Operate the controls to line up hole E in the tipping link with hole F in the Quickhitch. Insert the pivot pin G and secure with fasteners J and K.
2-4-4-2
Note: To prevent premature wear, failure and breakage, the Quickhitch assembly must be used with a rockbreaker for short periods only. If the machine is to be used for rock breaking for a long period of time, it is recommended that the rockbreaker is installed directly on the machine. When using a rockbreaker, it must be curled towards the machine (as a typical digging operation). Do not use the rockbreaker as a lever as this causes excessive loads on the locking mechanism.
K A H E
B
!MCAUTION
J
When the Quickhitch is fitted 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
C
8-4-5-7
G D K
Installation Note: This operation is easier done by two people - one person to operate the controls and one to line up the pivots. 1
2
Before the Quickhitch is installed, make sure that the tipping lever locking bolt assembly is attached with the nut at position K. K Fig 12. ( T A-17).
F
Fig 12.
Removal The removal of the Quickhitch is a reversal of the installation procedure. Pay particular attention to safety notices.
Put the Quickhitch on hard, level ground. Use the safe and correct lifting equipment to move the Quickhitch.
A-17
9803/9960-3
A-17
Section A - Attachments Maintenance Excavator Quickhitch
Maintenance Examine the Quickhitch daily for broken or missing parts. Remove any debris from the latch hook locking mechanism. If the Quickhitch is cleaned by high pressure water, always grease the latch hook pivot pin. Always grease the latch hook pin every week.
A-18
9803/9960-3
A-18
Section A - Attachments Maintenance Buckets
Buckets Bucket Selection
!MWARNING The bucket selected should be the correct width to suit the hole/trench to be excavated. However, if the hole width demands the larger bucket, consideration should 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. 8-2-9-45
A-19
9803/9960-3
A-19
Section A - Attachments Maintenance Buckets
Removing a Bucket - Non Quickhitch Models
3
P11-4002
1
Position the Boom
Withdraw the Dipper Using the controls, carefully lift the dipper clear of the bucket.
Slew the boom so that it is straight in front of the machine. Rest the bucket on level ground, with the dipper approximately vertical and the bucket flat to the ground. Block the bucket to prevent its movement.
!MWARNING Stand clear and to one side of the bucket while you remove the pivot pins. With the pins removed, the bucket could roll over. 2-2-6-6
2
Detach the Bucket Remove the lynch pin A and the pivot pins B.
B
A Fig 13.
!MWARNING 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. B-2-1-8
A-20
9803/9960-3
A-20
Section A - Attachments Maintenance Buckets
Installing a Bucket - Non Quickhitch Models
1
Position the bucket so that it is approximately 150mm (6 in) above the ground.
See Bucket Selection. Note: This job is easier done by two people - one to operate the controls and one to line up the pivots. 1
Park the machine on firm level ground.
Position the Bucket
!MWARNING The attachment will roll forward when released. Stand clear and to one side when releasing the attachment. 2-4-4-1
Set the bucket flat on level ground, using a suitable lifting device.
!MWARNING
2
Remove lynch pin A, and locking pin B.
3
Insert the tommy bar C into the hole D of the latch hook.
Do not use your fingers through the holes to align the links.
A
8-2-9-32
2
Engage the Dipper
B
If necessary move the machine to align the pivot pin holes. Carefully align the holes in the dipper and bucket link with the bucket. Fit the pivot pins B and lynch pin A. K Fig 13. ( T A-20)
Z
B D
C
Fig 15.
A
4
Apply a downward pressure on the bar to release the buckets' rear pivot pin from the latch hook, K Fig 15. ( T A-21) at Z. Remove the tommy bar from the Quickhitch.
5
Rest the bucket on the ground.
6
Slowly roll the Quickhitch back and simultaneously raise the dipper arm to release the buckets' front pivot pin, K Fig 16. ( T A-22) at Y.
Fig 14.
Removing a Bucket from a Quickhitch P11-4003
Note: Deposit Quickhitch attachments on firm level ground whenever possible. This will make later refitting easy and safe.
A-21
Note: Quickhitch procedure applies to most attachments. See your attachments instructions for specific procedures.
9803/9960-3
A-21
Section A - Attachments Maintenance Buckets
Y
Fig 16.
A-22
9803/9960-3
A-22
Section A - Attachments Maintenance Buckets
!MCAUTION
Installing a Bucket on a Quickhitch
Make sure that the latch hook has fully engaged.
See Bucket Selection.
2-4-4-3
1
Position the Bucket d Fit the latch hook locking pin F and secure with lynch pin G.
Set the bucket on firm level ground. Use safe and correct lifting equipment to move the bucket. 2
!MWARNING
Position the machine a
Position the machine so that the Quickhitch and bucket are correctly aligned for connection as shown.
b Use the excavator controls to engage jaw A of the Quickhitch with the pivot pin B of the bucket.
Always fit the Quickhitch latch hook locking pin. Failure to fit the pin will result in possible failure of the latching mechanism. Such a failure would result in the sudden release of an attachment from the machine; you or others could be killed or seriously injured. 3-4-1-9
!MCAUTION When the Quick-Hitch is installed and its attachment fitted, there is a danger of the attachment hitting the underside of the boom. Operate the boom and dipper carefully when the Quick-Hitch and its attachment are fitted.
G
2-4-4-2
B F C
D
E
A
Fig 17. c
Use the excavator controls to roll the Quickhitch in the direction of arrow C until the latch hook D has fully engaged the pivot pin E on the bucket. Due to the light weight of some bucket it may be necessary to apply a load on the bucket teeth to achieve Quickhitch connection. Alternatively, use the tommy bar to lever the latch off, allowing the attachment pivot pin E, to locate in jaw D of the Quickhitch.
A-23
9803/9960-3
A-23
Section A - Attachments Maintenance Buckets
Replacing Bucket Teeth P11-4001
1
Position the Bucket Make sure that the bucket is resting flat on the ground
2
Switch off the Engine Remove the starter key.
3
Remove a Tooth Remove the nut and bolt B and the tooth A.
4
Install a Tooth Position the tooth A and fit the bolts B.
B A Fig 18.
A-24
9803/9960-3
A-24
Section B Body and Framework Service Manual - 1CX Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section J - Tracks Section K - Engine
Publication No.
9803/9960-3
World Class Customer Support Copyright © 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section B - Body and Framework
Notes:
B-0
9803/9960-3
B-0
Section B - Body and Framework Contents
Contents Page No. Service Procedures Rivet Nuts ................................................................................................. B-1 Fitting Procedure .................................................................................. B-2 Slide Hammer Kit ...................................................................................... B-3 Fitting Procedure .................................................................................. B-3 Glazing ..................................................................................................... B-4 Direct Glazing ....................................................................................... B-4 Loader Loader Arm .............................................................................................. B-11 Removal ..............................................................................................B-11 Replacement ...................................................................................... B-12 Excavator Dipper ..................................................................................................... B-13 Removal ............................................................................................. B-13 Replacement ...................................................................................... B-14 Boom ...................................................................................................... B-15 Removal ............................................................................................. B-15 Replacement ...................................................................................... B-15 Kingpost Assembly ................................................................................. B-16 Removal and Replacement up to machine no. 807225 ..................... B-16 Cab/Canopy Door Removal and Replacement .................................................................... B-19 Removal ............................................................................................. B-19 Replacement ...................................................................................... B-19 Locks and Handles ................................................................................. B-20 Removal ............................................................................................. B-20 Replacement ...................................................................................... B-20 Foot Throttle Pedal Removal and Replacement .................................................................... B-23 Removal ............................................................................................. B-23 Replacement ...................................................................................... B-23 Stabiliser Legs Removal and Replacement .................................................................... B-25 Removal ............................................................................................. B-25 Replacement ...................................................................................... B-25 Fuel Tank Removal and Replacement .................................................................... B-27 Removal ............................................................................................. B-27 Replacement ...................................................................................... B-27 Air Conditioning Unit (If fitted) Removal and Replacement .................................................................... B-29 Removal ............................................................................................. B-29 Replacement ...................................................................................... B-29
B-i
B-i
Section B - Body and Framework Contents
Contents
B-ii
Page No.
B-ii
Section B - Body and Framework
Service Procedures Rivet Nuts TB-001_2
A 'Rivet Nut' is a one piece fastener installed 'blind' from one side of the machine body/framework. The rivet nut 1A is compressed so that a section of its shank forms an 'upset' against the machine body/framework, leaving a durable thread 1-B.
Table 1. Specifications Rivet Nut Rivet Nut Material Rivet Thread Outside Thickness Length Diameter Diameter (Total)
Drill Hole Dia.
M5
7.10
7
M6
9
M8
11
M10
13
0.25 - 3.00
14.00
3.00 - 5.50
17.00
0.50 - 3.00
16.00
3.00 - 5.50
19.00
0.50 - 3.00
18.00
3.00 - 5.50
21.00
1.00 - 3.50
23.00
3.50 - 6.00
26.00
9.10 11.10 13.10
Note: All dimensions in mm Fig 1. Rivet nuts are fitted 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 rivet nuts are available. K Table 1. Specifications ( T B-1) to determine the size of rivet nut to be used for particular applications. If for any reason a new rivet nut requires fitting, then the correct installation procedure must be followed. K Fitting Procedure ( T B-2). Note: In an emergency, and if no installation tool is available, it is possible to fit a rivet nut by using a nut and bolt the same thread diameter as the rivet nut being installed. However, this is not the recommended method.
B-1
9803/9960-2
B-1
Section B - Body and Framework Service Procedures Rivet Nuts
Fitting Procedure
(smooth bulge) seating itself against the body/ framework 4-E.
1
Drill a hole in the machine body/framework where the rivet nut is to be fitted. De-burr hole edges.
2
Screw the rivet nut onto the mandrel of the installation tool. The bottom of the mandrel should be in line with the bottom of the rivet nut 2-A.
Note: The thread of the rivet nut must not be stripped, take care when 'upsetting' the rivet nut.
Fig 4. Fig 2. 3
6
Remove the installation tool.
Wind the body of the installation tool down the threaded mandrel until it touches the head of the rivet nut 3-B.
Fig 3. 4
Insert the rivet nut (assembled to the tool) into the hole drilled in step 1.
5
Hold handle 4-C and at the same time draw the mandrel into the installation tool by turning nut 4-D. The rivet nut will contract in length and form an 'upset'
B-2
9803/9960-2
B-2
Section B - Body and Framework Service Procedures Slide Hammer Kit
Slide Hammer Kit TB-003
Fig 5. Typical M/c. Installation 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 5-A 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, items 5-B and 5-C. The other end of the adaptor will have varying thread sizes to suit the different size of threads in the pivot pins.
3
Fit an end stop 5-B onto the other end of the adaptor (M20 thread size), make sure that the adaptor threads are fully engaged.
4
Fit the 'slide bar' 5-E into the end stop. Again make sure that the threads are fully engaged.
5
Fit the 'slide hammer', item 5-F, onto the slide bar as shown.
6
Finally, fit another end stop, item 5-C, at the end of the slide bar, as shown. The slide hammer kit is now ready to use.
Fitting Procedure 1
Prepare the pivot pin, for instance, if fitted, remove the pivot pin retaining bolt.
7
2
Determine the thread size of the pivot pin and then fit the appropriate adaptor 5-A as shown. Use the spanner flats 5-D to securely fit the adaptor.
To extract the pivot pin, slide the hammer along the bar until it contacts end stop 5-C. Repeat this step until the pivot pin is released.
8
To remove the slide hammer kit, reverse steps 2 to 7.
B-3
9803/9960-2
B-3
Section B - Body and Framework Service Procedures Glazing
Glazing Direct Glazing
Removing the Broken Glass and Old Sealant TB-002_6
The following procedures explain how to correctly remove and install panes of glass that are directly bonded to the cab frame apertures. When carrying out the procedures, relevant safety precautions must be taken. 1
Always wear safety glasses during both removal and replacement.
2
Use protective gloves - heavy duty leather gauntlet type gloves when cutting out the broken glass; 'nonslip' type gloves when handling/moving panes of glass; surgical type gloves when using 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.
!MWARNING 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. BF-2-3_1
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. a
Several special tools are required to successfully complete the removal and replacement procedures. Reference is made to the tools in the text. The majority of these tools can be obtained locally and the remainder from JCB Service (see Service Tools). 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.
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.
b 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
Glass should not be replaced at temperatures below 5°C (41°F).
!MWARNING
Pneumatic Knife. K Fig 6. ( T B-5). This provides one of the easiest methods of removing the sealant around laminated glass. The tool, powered by compressed air, should be sourced locally.
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. BF-1-8_1
B-4
9803/9960-2
B-4
Section B - Body and Framework Service Procedures Glazing ii
Insert the braided cutting wire B 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.
iii Using suitable pliers, pull the cutting wire through the sealant to the outer side of the glass. Fig 6. Pneumatic Knife i
iv Secure the end of the braided cutting wire (found on the outer side of the glass) in the special handle C.
Press the handle to start the knife blade oscillating.
v
Important: This tool must not be used on toughened glass. ii
vi Secure the second end of the braided cutting wire in the special handle D.
Insert the knife blade into the sealant.
vii 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.
iii Slowly move the knife along the sealant with the blade positioned as close to the glass as possible. Do not allow the knife blade to overheat or the sealant will melt. b Braided Cutting Wire and Handles. K Fig 7. ( T B-5). This method uses a 3-core wire, a wire starter tube and two handles. i
Slowly remove the steel tube A.
c
Cut-out Knife. K Fig 8. ( T B-5). The cut-out knife can be used as a left handed or right handed tool.
Insert the steel tube A into the old sealant on the inside of the glass.
Fig 8. Cut-out Knife Insert the knife blade into the sealant.
ii
Make sure that the blade of the knife is against the glass A. K Fig 8. ( T B-5).
iii Use the 'pull-handle' to pull the knife along and cut out the old sealant.
Fig 7. Braided Cutting Wire and Handles
B-5
i
9803/9960-2
B-5
Section B - Body and Framework Service Procedures Glazing d Craft Knife. K Fig 9. ( T B-6). The blades A are replaceable. i
Insert the knife blade into the sealant.
ii
Pull the knife along and cut out the old sealant.
Preparing the Cab Frame Aperture 1
If damp or wet, dry the aperture area using a hot air gun (sourced locally).
2
Use 'Active Wipe 205' to thoroughly clean and 'prime' the trimmed sealant. Use a lint free cloth to apply the 'Active Wipe 205', allow 5 minutes flash off (drying) time.
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.
Preparing the New Glass
!MWARNING Fig 9. Craft Knife 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.
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. K Fig 10. ( T B-6).
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. BF-1-8_1
1
Make sure that the new glass correctly fits the frame aperture A. K Fig 11. ( T B-7). a
Put two spacer blocks B onto the bottom part of the frame aperture.
b Install the new glass on the spacer blocks Always use glass lifters C. Check that there is an equal sized gap all round the edge of the glass.
1-2 mm
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.
Fig 10. 6
Apply a coat of 'Black Primer 206J' to the paintwork if: a
Paintwork was damaged or scratched during the glass/sealant removal procedures.
b The old sealant was inadvertently cut back to the cab frame during the glass/sealant removal procedures.
B-6
9803/9960-2
B-6
Section B - Body and Framework Service Procedures Glazing
Fig 13.
Fig 11. 2
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.
4
Clean the glass a
After checking for size, remove the new glass and place it on a purpose made glass stand. K Fig 12. ( T B-7).
Use 'Active Wipe 205' to thoroughly clean and 'prime' the black ceramic ink band printed on the glass (see Note). Use a lint free cloth to apply the 'Active Wipe 205', allow 5 minutes flash off (drying) time.
Note: Do not touch the glass after cleaning with the 'Active Wipe 205'. b If the glass does not have a black ceramic ink band, paint a band on the glass using 'Black Primer 206J'. The band should be approximately 25mm (1in) wide, and the edge should be a neat straight line. K Fig 14. ( T B-7).
Fig 12. 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. K Fig 13. ( T B-7). 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 antiscratch surface. Resting the glass on four spacer blocks will ensure clearance of the cartridge nozzle tip during application of the polyurethane sealant.
B-7
Fig 14. 5
9803/9960-2
Install the Ultra Fast Adhesive cartridge (see Sealing and Retaining Compounds, Section 1 and Note) into a suitable applicator gun:
B-7
Section B - Body and Framework Service Procedures Glazing a
Remove the aluminium disc cover from the base of the cartridge and discard the 'dessicant capsule'.
b Make sure that the rolled edge of the cartridge is not damaged - if necessary, the edges should be pressed flat, otherwise it will be difficult to remove the cartridge from the applicator gun. c
Pierce the front 'nozzle' end of the cartridge to its maximum diameter.
Note: Once the pre-heated adhesive has been applied to the glass, install the glass in the aperture as soon as possible. After approximately 10 minutes the sealant will form a 'skin', this will prevent the glass from bonding. 7
Installing the New Glass 1
If the internal trim strip is damaged, renew it (cut to length as required) before fitting the new glass. Make sure the two spacer blocks are in position. K Preparing the New Glass ( T B-6) - step 1.
2
Install the glass in the frame aperture:
d Fit the pre-cut nozzle. K Fig 15. ( T B-8). e
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.
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'.
a
Always use the special lifting tools when moving the glass. Use a lifting strap to hold large panes of glass in position. K Fig 17. ( T B-8).
Fig 15. 6
Apply the pre-heated adhesive to the glass (do not start in a corner). Keep the nozzle guide A against the edge of the glass and make sure that the adhesive forms a continuous 'pyramid' shape. K Fig 16. ( T B-8)
Fig 17. Typical M/c. Installation b Sit the bottom edge of the glass on the spacer blocks. K Fig 18. ( T B-9)
Fig 16.
B-8
9803/9960-2
B-8
Section B - Body and Framework Service Procedures Glazing minutes, but it must not be used during the curing period of 30 minutes. c
6
Clean the glass using a purpose made glass cleaner
On completion of the glass installation procedures tidy the work area: a
Remove all broken glass from the cab area.
b Remove the protective covers from the cab seat and control pedestals. c
Renew all safety and instructional labels so that the new installation conforms with the original cab installation.
Fig 18. c
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.
Make the inside seal smooth: a
Wearing surgical gloves, dip your finger in a soapy water solution.
b Use your finger to make the inside seal smooth. 4
All exposed edges must be sealed using Black Polyurethane Sealant (see Sealing and Retaining Compounds, Section 1).
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. 5
Clean the glass after installation: a
Small amounts of sealant can be cleaned from the glass using the 'Active Wipe 205'.
b 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
B-9
9803/9960-2
B-9
Section B - Body and Framework Service Procedures Glazing
Page left intentionally blank
B - 10
9803/9960-2
B - 10
Section B - Body and Framework
Loader Loader Arm
205440-B1
Fig 1.
!MWARNING
Removal
!MWARNING 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. INT-1-3-7_2
Ensure that all attachments are removed from the loader arm and park the machine on clean level ground. Raise the loader arm so that the lift ram eye end pivot pin is clear of the machine structure. Support the weight of the loader arm using suitable lifting equipment. Stop the engine and vent hydraulic pressure from the system (see Venting Hydraulic Pressure).
B-11
Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication. HYD-1-5
Disconnect and plug the auxiliary hoses and the crowd ram hoses on both sides. Mark the hoses to ensure correct reconnection. Remove the bolts retaining the lift ram eye end pivot pin A from both sides. Ensuring that the weight of the loader arm is supported at the front end, and also supporting the lift rams, drift out the lift ram eye end pivot pins from both sides. Allow the rams to rest on the bodywork. Lower the loader arm to the ground.Remove the locking pins for the lift arm pivots B and compensating arm pivots C on both sides. Supporting the weight of the loader arm, drift out the
9803/9960-1
B-11
Section B - Body and Framework Loader Loader Arm lift arm and compensating arm pivot pins. The loader arm can now bemanoeuvered from the machine using the lifting equipment. Place the loader arm on a clean dry surface.
Replacement Replacement is a reversal of the removal procedure. Grease all pins and securing bolts with JCB Special MPL grease. Shims are available in two thicknesses (2 mm and 3 mm) and should be fitted as required on the left hand side of the loader arm pivot to eliminate end float. Reconnect all hoses and bleed the hydraulic system.
B-12
9803/9960-1
B-12
Section B - Body and Framework
Excavator Dipper
205450-B1
Fig 1.
Removal
plug the crowd ram feed and return hoses, marking the hoses to ensure correct reconnection.
Remove the bucket or other attachment from the machine and park the machine on clean level ground. Place the excavating end in the position shown. Stop the engine and vent hydraulic pressure from the system (see Venting Hydraulic Pressure).
Remove the bolt retaining the dipper ram eye end pivot pin B. Supporting the ram, drift out the dipper ram eye end pivot pin. Allow the ram to rest on the boom.
!MWARNING
!MWARNING
Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.
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.
HYD-1-5
INT-1-3-7_2
Disconnect and plug the auxiliary hoses, marking the hoses to ensure correct reconnection. Remove the auxiliary hose bracket A from the dipper. Disconnect and
Remove the locking pins (2 off) for the dipper pivot pin C. Supporting the weight of the dipper, drift out the pivot pin. The dipper can now be manoeuvered from the machine using the lifting equipment. Place the dipper on a clean dry surface.
B-13
9803/9960-1
B-13
Section B - Body and Framework Excavator Dipper
Replacement Replacement is a reversal of the removal procedure. Grease all pins and securing bolts with JCB Special MPL grease. Reconnect all hoses and bleed the hydraulic system.
B-14
9803/9960-1
B-14
Section B - Body and Framework Excavator Boom
Boom
!MWARNING
Removal It is assumed that the dipper has been removed. K Dipper ( T B-13)
!MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication. HYD-1-5
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. INT-1-3-7_2
Remove the bolt retaining the boom pivot pin C. Supporting the weight of the boom, drift out the pivot pin. The boom can now be manoeuvered from the machine using the lifting equipment. Place the boom on a clean dry surface.
205460-B1
Fig 3.
204260-B1
Fig 2.
Replacement Disconnect and plug the auxiliary hoses, marking the hoses to ensure correct reconnection (see Connecting/ Disconnecting Hoses). Disconnect and plug the feed and return hoses A (6 off), marking the hoses to ensure correct reconnection.
Replacement is a reversal of the removal procedure. Grease all pins and securing bolts with JCB Special MPL grease. Reconnect all hoses and bleed the hydraulic system.
Remove the bolt retaining the boom ram eye end pivot pin B. Supporting the ram, drift out the boom ram eye end pivot pin.
B-15
9803/9960-1
B-15
Section B - Body and Framework Excavator Kingpost Assembly
Kingpost Assembly Removal and Replacement up to machine no. 807225
S242442
Fig 4. K Slew Cylinder - Removal ( T B-17)
B-16
9803/9960-1
B-16
Section B - Body and Framework Excavator Kingpost Assembly Slew Cylinder - Removal
dipper have been removed, place the sling around the kingpost.)
K Fig 4. ( T B-16) Remove locking bolt 9 and kingpost pivot pin 10. Position the machine on firm level ground, rest the front shovel on the ground and position the excavator bucket just above the ground. Stop the engine. Operate the excavator controls to vent residual hydraulic pressure.
Using the crane, lift the excavator assembly up which will free the pinion from the carriage base then pull the assembly back away from the carriage, taking care to collect shim 11.
Release the hydraulic connections to the slew cylinders. Note: Shim 11 is not fitted to later machines. Unscrew and remove capscrews 1 from each slew cylinder 2. Position an oil tray underneath the kingpost to catch any oil lost during dismantling.
Remove pinion 12 and thrust washer 13 from the kingpost. Remove the anti-rotation pin 14 and withdraw the rack 4.
Kingpost - Replacement Withdraw the cylinders by manually swinging the excavator assembly to one side and then the other. This will push off each cylinder in turn.
Repacement is a reversal of the removal procedure.
Remove rack seals 3 as each side of the rack 4 is exposed.
If bushes 16,17 or 18 are to be renewed, coat outside diameter with JCB Multi-Gasket before pressing into position.
Kingpost - Removal If required, remove the boom and dipper. Note: Unless the kingpost is to be renewed, it is not necessary to remove the boom and dipper to release the kingpost from the machine.
Note: On later machines, bush 18 was changed to a flanged type and is fitted with a thrust washer as shown at X. The flanged type bush may be fitted to earlier machines provided the thrust washer is also fitted.
!MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.
347390-B1
Fig 5. Lubricate the pinion and rack with gear oil before assembly.
HYD-1-5
At the kingpost, disconnect and plug the hydraulic hoses, marking the hoses to ensure correct reconnection (see Connecting/Disconnecting Hydraulic Hoses).
Apply JCB Special MPL grease to pivot pin 10. Check that shim 11 is the latest steel type; replace if not.
Position an oil tray underneath the kingpost to catch any oil lost during dismantling. Remove capscrews 5 and lift off the thrust cap 6 complete with filler tube assembly 7.
Note: Shim 11 is not fitted to later machines; the pinion flange is machined 3 mm deeper. The shim should be discarded if the later pinion is fitted to earlier machines.
Slacken and remove the pinion capscrews 8. Support the backhoe by placing a sling from a crane around the boom ram to kingpost pivot. (If the boom and
B-17
Clean threads of capscrews 8 and apply JCB Threadlocker and Sealer. Tighten to correct torque.
9803/9960-1
B-17
Section B - Body and Framework Excavator Kingpost Assembly After replacement, refill the slew housing with the appropriate grade of oil (see Routine Maintenance, Section 3 for correct procedure).
Slew Cylinder - Replacement Fit new seals 3 to rack 4. Ensure that plungers A move freely in their bores without sticking. Assemble cylinders 2 using new `O' ring 15. Reconnect hydraulic pipework. After replacement, refill the slew housing with the appropriate grade of oil (see Routine Maintenance, Section 3 for correct procedure). When assembly is complete, operate excavator services fully to bleed the hydraulic system then check the hydraulic level. Torque Settings Item
Nm
kgf m
lbf ft
1
300
30.6
221
5
159
16.2
117
8
395
40.3
291
B-18
9803/9960-1
B-18
Section B - Body and Framework
Cab/Canopy Door Removal and Replacement Removal 1
Make the machine safe with the loader arm lowered. Refer to Section 3 Maintenance, Prepare the Machine for Maintenance.
2
Remove the hinge pin 1 from the upper and lower hinges.
3
Lift the door 2 off its hinges and move to a safe place.
4
If worn, the bushes 3 can be removed from the hinge brackets 4 on the door 2 and replaced.
5
If hinge pins 1 are worn, replace. K Fig 1. ( T B-21).
Renew any worn or damaged components.
Replacement Replacement is a reversal of the removal procedure. Apply a smear of grease to the hinge pins 1.
B-19
9803/9960-3
B-19
Section B - Body and Framework Cab/Canopy Door Locks and Handles
Locks and Handles Removal 1
Make the machine safe with the loader arm lowered. Refer to Section 3 Maintenance, Prepare the Machine for Maintenance.
2
Remove the inside door latch cover 5.
3
Remove the door latch 6 and door handle 7.
4
Remove the door handle 8.
5
Remove the door handle gasket 9 from the door 2. K Fig 1. ( T B-21).
Replacement 1
Make the machine safe with the loader arm lowered. Refer to Maintenance, Prepare the Machine for Maintenance.
2
Replacement is a reversal of the removal procedure.
B-20
9803/9960-3
B-20
Section B - Body and Framework Cab/Canopy Door Locks and Handles
1 4
3
2
7 9 8
5 6 P029730-01
Fig 1.
B-21
9803/9960-3
B-21
Section B - Body and Framework Cab/Canopy Door Locks and Handles
Page left intentionally blank
B-22
9803/9960-3
B-22
Section B - Body and Framework
Foot Throttle Pedal Removal and Replacement Removal 1
Park the machine on firm level ground, apply the parking brake.
2
Lower the loader arms and excavator to the ground.
3
Switch off the engine and remove the starter key.
4
Loosen the foot throttle cable adjusting nuts A and make sure the cable B moves freely.
5
Use the pliers to push the foot throttle cable clevis pin C and remove the foot throttle cable B from the pedal assembly.
6
Carefully remove the foot throttle pedal return spring D.
7
Loosen the hand throttle cable adjusting nuts E and remove the hand throttle cable F out from the pedal assembly.
8
Use the pliers to push the hand throttle cable clevis pin G from the pedal assembly.
9
Remove the nuts H, washers J and bolts K securing the pedal assembly.
10
Remove the pedal assembly L away from the machine.
11
Remove the pedal M from its mounting bracket. K Fig 1. ( T B-24).
Replacement 1
Make the machine safe and prepare the machine for maintenance.
2
Replacement is a reversal of the removal procedure.
3
After the installation, operate the foot and hand throttle controls and make sure they function correctly.
B-23
9803/9960-3
B-23
Section B - Body and Framework Foot Throttle Pedal Removal and Replacement
L
D C
H,J,K K A
M
B G
E F
P029760-06
Fig 1.
B-24
9803/9960-3
B-24
Section B - Body and Framework Stabiliser Legs Removal and Replacement
Stabiliser Legs Removal and Replacement
!MWARNING
Removal 1
Park the machine on the firm level ground.
This component is heavy. It must only be removed or handled using a suitable lifting method and device.
2
Engage the park brake and set the transmission to neutral.
BF-4-1_1
14 3
Lower the loader end to the ground.
4
Lower the stabiliser leg until the pads are approximately off the ground. Do not let it raise or support the weight of the machine.
Use a suitable lifting equipment to remove the inner leg assembly M (along with the ram) clear off the machine. K Fig 1. ( T B-26).
Replacement Replacement is a reversal of the removal sequence.
5
Remove the stabiliser leg bottom lock nut A and bolt B.
6
Remove the bottom pivot pin C, spacers D and allow the stabiliser foot E to fall clear.
7
Lift the inner leg and re-install the pivot pin C through the inner leg and ram using the lock nut A and bolt B.
8
Place a block of wood underneath the stabiliser leg.
9
Remove the circlips F and drive out the top pivot pin G with the spacing collars H.
10
Start the engine and slowly extend the stabiliser ram so that the dump end of the ram protrudes from the top of the outer leg section.
11
Attach a suitable lifting equipment to the ram as shown. Make sure the weight of the ram is supported by the sling J.
!MWARNING 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 protective glasses and gloves. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. INT-3-1-10_3
Use suitable lifting equipments to locate the stabiliser inner leg M. After replacing or lifting the inner leg M, connect the hydraulic pipes, make sure that the ram and leg operate freely and do not foul. K Fig 1. ( T B-26).
!MWARNING Hydraulic Pressure 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. INT-3-1-11_2
12
Make sure the engine is switched off. Operate the stabiliser control levers to release the stored hydraulic pressure.
13
Loosen and remove the stabiliser hoses K, L, label the hoses before removing (to help installation). Plug all open ports to prevent loss of fluid and ingress of dirt.
B-25
9803/9960-3
B-25
Section B - Body and Framework Stabiliser Legs Removal and Replacement
J
H
G
H
F
K
L M
B
A
D
E
C P029760-5
Fig 1.
B-26
9803/9960-3
B-26
Section B - Body and Framework
Fuel Tank Removal and Replacement
!MWARNING
Replacement
Make the machine safe before working underneath it. Park the machine on level ground, lower the attachments to the ground. Apply the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels.
Replacement is a reversal of the removal sequence. On completion, prime the fuel system, see Section 3, Routine maintenance.
Disconnect the battery, to prevent the engine being started while you are beneath the machine.
A
GEN-4-1_1
Removal 1
Disconnect the battery.
2
Drain the fuel from the fuel tank A into a suitable clean container.
3
Attach a label to the fuel feed and return hoses to help the installation.
D
Disconnect the fuel feed and return hoses.
C
E
4
B
!MWARNING 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. INT-3-2-2_3
5
Working below the LH fender remove the lock nuts B, washers C and spindles D.
6
Lift the fuel tank A away from the machine.
7
Remove the clamp plate E from the fuel tank A. K Fig 1. ( T B-27).
B-27
9803/9960-3
P029820-01
Fig 1.
B-27
Section B - Body and Framework Fuel Tank Removal and Replacement
Page left intentionally blank
B-28
9803/9960-3
B-28
Section B - Body and Framework
Air Conditioning Unit (If fitted) Removal and Replacement Note: Before you remove the HVAC - Air Conditioning Unit, discharge the system. Note: Removal of the HVAC unit will require the assistance of a refrigeration engineer or suitably trained person since the refrigerant needs to be drained from the system.
Replacement Replacement is the reversal of removal procedure.
Removal 1
Make the machine safe. Refer to Section 3 Maintenance - Prepare the Machine for Maintenance.
2
Disconnect the battery.
3
Remove the bolt A (x4) and washer B (x4) that attach the air conditioning cover C.
4
Remove the air conditioning cover C.
!MWARNING 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. 4-3-4-1_2
5
Drain the refrigerant from the air conditioning system.
6
Check around the top of the air conditioning unit D, rear and bottom side. Remove the cable ties and remove all the pipe work E.
7
Disconnect the electrical connections.
8
Working inside the cab, remove the screws F that attach the air conditioning unit D to the cab.
9
Remove the unit K Fig 1. ( T B-30).
B-29
D
from
the
machine.
9803/9960-3
B-29
Section B - Body and Framework Air Conditioning Unit (If fitted) Removal and Replacement
E D
F D C A,B
D
P029760-3
Fig 1.
B-30
9803/9960-3
B-30
Section C Electrics Service Manual - 1CX Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section J - Tracks Section K - Engine
Publication No.
9803/9960-3
World Class Customer Support Copyright Š 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section C - Electrics
Notes:
C-0
9803/9960-3
C-0
Section C - Electrics Contents
Contents Page No. Technical Data Electrical System ...................................................................................... C-1 Light Bulbs ............................................................................................ C-1 Sensing Switches ................................................................................. C-1 General Using a Multimeter .................................................................................... C-3 Measuring DC Voltage ......................................................................... C-4 Measuring Resistance .......................................................................... C-4 Measuring Continuity ............................................................................ C-5 Measuring Frequency ........................................................................... C-5 Testing a Diode or a Diode Wire ........................................................... C-6 Battery ...................................................................................................... C-7 Maintenance ......................................................................................... C-7 Testing .................................................................................................. C-7 Specific Gravity Testing ........................................................................ C-9 Alternator ................................................................................................ C-10 General Description ............................................................................ C-10 Service Precautions ........................................................................... C-10 Charging Circuit Test .......................................................................... C-10 Alternator Charging Test ..................................................................... C-11 Starter Motor ........................................................................................... C-13 Starting Circuit Test ............................................................................ C-13 Wiring Harness Repair ........................................................................... C-15 Introduction ......................................................................................... C-15 Repair Procedure ............................................................................... C-15 Alternator Removal and Replacement .................................................................... C-19 100 and 400 series Engines ............................................................... C-19 Dismantling and Assembly ..................................................................... C-20 Dismantling ......................................................................................... C-21 Assembly ............................................................................................ C-21 Electrical Circuit Diagrams From machine no. 751600 to 752370 ..................................................... C-23 Main Components .............................................................................. C-24 From machine no. 752371 to 752675 ..................................................... C-26 Main Components .............................................................................. C-27 From machine no. 752676 ...................................................................... C-29 Main Components .............................................................................. C-30 Series 2 Machines From SN 1743570 .................................................... C-32 Harness Data Wire and Harness Number Identification ................................................ C-41 Introduction ......................................................................................... C-41 Wire Numbers and Functions ............................................................. C-42 Harness Interconnections and Drawings ................................................ C-43 Harnesses .......................................................................................... C-43 Drawings ............................................................................................ C-43 Servo Hydraulics (Early Machines) .................................................... C-44 Servo Hydraulics (Later Machines) .................................................... C-47 Joystick Controls ................................................................................ C-48
C-i
C-i
Section C - Electrics Contents
Contents Page No. Control Systems Description .............................................................................................. C-49 Auxiliary ECU ..................................................................................... C-49 Power Management System (PMS) ................................................... C-50 Power Management System (PMS) ....................................................... C-51 Update PMS Settings ......................................................................... C-51 Fault Finding ........................................................................................... C-53 Auxiliary System Faults ...................................................................... C-53 Power Management System Faults ................................................... C-54
C-ii
C-ii
Section C - Electrics
Technical Data Electrical System Type
12 Volts, negative earth
Battery Cold crank amps for 1 minute to 1.4 VPC at -18 째C (0 째F)
420 to 585 according to battery type
Reserve capacity (minutes) for 25 Amp load
170 to 230 according to battery type
Alternator XUD Engines
12V, 50 Amp output
100 and 400 Series Engines
12V, 55 or 65 Amp output
Light Bulbs Working Lights
55W (Halogen)
Indicator Lights
21W
Warning Lights
1.2W
Beacon (if fitted)
70W
Interior Light (if fitted)
10W
Side Lights (if fitted)
5W
Number Plate Light (if fitted)
5W
Sensing Switches A
Transmission Charge Pressure Switch. K Fig 1. ( T C-2)
Normally closed, opens at 2-3.4 bar (30-50 lbf/in2) falling.
B
Transmission Oil Temperature Switch K Fig 2. ( T C-2)
Normally open, closes at 107-113 째C (225-235 째F) rising.
C
Reverse Alarm Pressure Switches.K Fig 2. ( T C-2)
Normally open, closes at 7 bar (100 lbf/in2) rising.
D
Brake Light Pressure Switches. K Fig 2. ( T C-2)
Normally open, closes at 4 bar (58 lbf/in2) rising.
C-1
9803/9960-3
C-1
Section C - Electrics Technical Data Electrical System
422990-B1
Fig 1.
423000-B1
Fig 2.
C-2
9803/9960-3
C-2
Section C - Electrics
General Using a Multimeter TC-002
In order to obtain maximum benefit from the fault finding information contained in Section C 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 multimeters.
Fig 2. AVO 2003
Fig 1. FLUKE 85
Fig 3. A Typical Analogue Meter
C-3
9803/9960-3
C-3
Section C - Electrics General Using a Multimeter 1
2
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 "立". When making measurements ensure 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.
Measuring Resistance 1
Make sure there is no power to the part of the circuit you are about to measure.
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. a
3
When measuring voltage: Make sure that the correct range is selected, that is set the selector to a 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.
On the FLUKE 85. i
b On the AV0 2003.
Measuring DC Voltage
i 1
Select the correct range on the multimeter. a
Turn the switch to position 1-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 1-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.
On the FLUKE 85. c
Turn the switch to position 1-B.
On an analogue meter. i
b On the AV0 2003.
Move the right hand slider switch to position 2B, and the left hand slider switch to the appropriate Ohms (立) range.
Move the dial to the appropriate Ohms (立) range.
Move the right slider switch to position 2-A, and the left hand slider switch to the appropriate range. c
On an analogue meter. Turn the dial to the appropriate DC Volts range.
2
C-4
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.
9803/9960-3
C-4
Section C - Electrics General Using a Multimeter
Measuring Continuity
Measuring Frequency
1
Make sure there is no power to the part of the circuit you are checking for continuity.
The AVO 2003 and the analogue meter are not capable of measuring frequency, therefore a Fluke 85 digital multimeter must be used.
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.
3
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 1-J.
3
Turn the selector switch to position 1-A and depress 1-G repeatedly until 1-F is highlighted on the top row of the display.
4
Press button 1-H once.
5
Touch or connect the red probe to the frequency source to be measured. Press and hold button if an average reading is required.
Select the correct range on the multimeter. a
On the FLUKE 85. Turn the switch to position 1-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 1-F in the meter drawing. If there is continuity in the circuit, the beeper will sound. If there is no continuity (open circuit), the beeper will not sound.
b On the AV0 2003. Move the right hand slider switch to position 2-B, and the left hand slider switch to position 2-C. If there is continuity (i.e. very low resistance) between two points the buzzer will sound. c
On an analogue meter. Turn the dial to the lowest Ohms (Ί) 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.
C-5
9803/9960-3
C-5
Section C - Electrics General Using a Multimeter
Testing a Diode or a Diode Wire
c
A diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end. The diode is sealed in heatshrink sleeving. 1
On an analogue meter. i
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.
To test a Diode or a Diode Wire a
On the FLUKE 85. i
Turn the switch to position 1-D.
ii
Press the HOLD button and check that the H sign appears at the top right hand side of the display window.
iii 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.
Select the Ohms 1000s (1k) range.
ii
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.
iv 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. v
Press the HOLD button and check that the H sign disappears from the right hand side of the display window.
b On the AV0 2003. i
Move the right hand slider to position 2-A, and the left hand slider switch to position 2-C.
ii
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. If the Avometer does not buzz the diode is faulty.
iii 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 Avometer does not read "1" the diode is faulty.
C-6
9803/9960-3
C-6
Section C - Electrics General Battery
Battery TC-001_5
!MWARNING
Maintenance To ensure that the battery provides optimum performance the following steps should be observed: 1
Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion.
2
When applicable - never allow the electrolyte level to fall below the recommended level - 6 mm (1/4 in) above the plates. Use only distilled water for topping up.
3
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: – Never boost-charge a maintenance free battery (if fitted). – Never charge a battery at a voltage in excess of 15.8 Volts. – Never continue to charge a battery after it begins to gas.
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 personal protective equipment (PPE). 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 five minutes before connecting it up. When reconnecting, fit the positive (+) lead first. 5-3-4-12_2
Testing This test is to determine the electrical condition of the battery and to give an indication of the remaining useful 'life'. Before testing ensure that the battery is at least 75% charged (SG of 1.23 to 1.25 for ambient temperature up to 27°C). Ensure that the battery is completely disconnected from the vehicle. Connect up the battery tester as follows:
C-7
1
Set the CHECK/LOAD switch 4-A to OFF.
2
Set rocker switch 4-B to the battery voltage (12V).
3
Connect the red flying lead to the battery positive (+) terminal and the black flying lead to the battery negative (-) terminal.
9803/9960-3
C-7
Section C - Electrics General Battery 4
Set the CHECK/LOAD switch 4-A to CHECK to read the battery no-load voltage which should be at least 12.4 volts.
5
Set the CHECK/LOAD switch 4-A to LOAD and hold down for 5-10 seconds until the meter reading stabilises. The reading should be at least 9 volts.
Note: Do not hold the switch in the LOAD position for more than 10 seconds. 6
K Table 1. Fault Diagnosis ( T C-8), if the foregoing tests are unsatisfactory.
Battery Tester Readings 1
Fig 4. Battery Tester
Table 1. Fault Diagnosis Remedy
CHECK: 0 - 12.6 Volts
Renew battery
LOAD: less than 6 Volts 2
CHECK: 6 - 12.4 Volts
Recharge and re-test. If tests still unsatisfactory renew battery.
LOAD: less than 9 Volts and falls steadily but remains in yellow zone. 3
CHECK: less than 10 Volts
Indicates battery has been over-discharged and unlikely to recover. Renew battery.
LOAD: less than 3 Volts 4
CHECK: more than 11 Volts
Charge battery which will probably recover.
LOAD: 6 - 10 Volts steady
C-8
9803/9960-3
C-8
Section C - Electrics General Battery
Specific Gravity Testing 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.
Table 2. Specific Gravity at 15°C (60°F) Fully Charged Half Discharged
Fully Discharged
Ambient temperature up to 27°C (80°F)
1.270 - 1.290
1.190 - 1.210
1.110 - 1.130
Ambient temperature above 27°C (80°F)
1.240 - 1.260
1.170 - 1.190
1.090 - 1.110
C-9
9803/9960-3
C-9
Section C - Electrics General Alternator
Alternator TC-006_2
General Description
Charging Circuit Test
The alternator is a three phase generator having a rotating field winding and static power windings.
1
Ensure 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.
2
Adjust the alternator drive belt tension if necessary and make sure that the battery is well charged.
3
Turn the start switch to the ON position.
When the start switch is turned on, 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 fan belt drives the rotor and 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. Servicing is restricted to periodic inspection of slip ring brushes. Bearings are 'sealed for life'.
'Oil pressure' and 'No charge' warning lights should glow. If any light fails, K Check 1 ( T C-10). 4
If the 'No charge' warning light remains ON, K Check 2 ( T C-11).
Service Precautions 1
Ensure that the battery negative terminal is connected to the earthing cable.
2
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.
3
4
5
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 fitted, remove the cables). If jump starting starting is necessary, connect the second battery in parallel without disconnecting the vehicle battery from the charging circuit. The second battery may then be safely removed after a start has been obtained. Take care to connect batteries positive to positive, negative to negative.
C-10
Start the engine; all warning lights should extinguish rapidly.
If the oil pressure warning remains on stop engine Immediately and investigate the engine lubrication system.
Check 1 With start switch 'ON' try the heater motor and screen wiper. If they operate normally, check the warning light bulb/LED is not defective. Simultaneous failure of all items indicates a fault at the start switch. Check for cable disconnection before condemning the switch itself. If the 'No charge' warning bulb/LED 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/LED still fails to light, check the cable for continuity. If the bulb/LED now lights, check the alternator for a defective regulator. K Alternator Charging Test ( T C-11).
9803/9960-3
C-10
Section C - Electrics General Alternator
Alternator Charging Test
Fig 5.
Check 2 Note: The following checks should be made using an analogue (moving pointer) type meter. 1
Stop the engine and turn the starter switch to OFF.
2
Withdraw the alternator plug and connect the test meter between the large terminals and 'earth'. With the meter set to measure 12V DC, the meter should show battery voltage. If the reading is zero, check the cables for continuity, particularly at the starter terminals.
Fig 7. 1
Ensure 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.
2
Make sure that the alternator drive belt tension is correctly adjusted.
3
If the battery is in a fully charged condition, switch on the working lights for 3 minutes before commencing the test. Alternatively, operate the starter for a few moments with the engine stop fuse removed (See Fuse Identification).
4
Install a 100 amp open - type shunt between the battery positive lead and the battery positive terminal.
5
Connect a multimeter positive lead to machine side of the shunt and negative lead to battery side of the shunt.
6
Connect the leads to the meter and set the meter to the relevant range as follows.
Fig 6. If the voltage is correct, check the alternator. K Alternator Charging Test ( T C-11).
C-11
9803/9960-3
C-11
Section C - Electrics General Alternator AVO 2002
11
Faults d, e, and f may be checked only by removing and dismantling the alternator for further testing.
9803/9960-3
C-12
– Red lead to volts (middle) socket on meter. – Black lead to negative on meter. – RH slider to DC voltage. – LH slider. K Fig 7. ( T C-11).
AVO 2003
– Red lead to amps socket (marked A) on the meter. – Black lead to negative on meter. – RH slider to DC voltage – LH slider to 200 Shunt
FLUKE 85
– Red lead to volts socket (marked V ) on meter. – Black lead to COM socket on meter. – Set dial to mV.
7
Start the engine and run at maximum speed (see Technical Data). Meter should show maximum alternator output in Amps (see Technical Data).
Note: The meter reading should be taken as soon as possible after starting the engine, as the charging current will fall rapidly. 8
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. a
Defective suppression capacitor.
b Dirty slip rings or worn brushes. c
Defective regulator.
d Defective rectifier. e
Open or short - circuited field (rotor) windings.
f
Open or short - circuited power (stator) windings.
9
To check for fault a, disconnect the capacitor and repeat the charging test. Renew the capacitor if necessary.
10
To check for faults b and c, remove the regulator and brush box assembly. Check the condition of the brushes and, if necessary, clean the slip rings using extra-fine glass paper. The regulator may only be checked by substitution.
C-12
Section C - Electrics General Starter Motor
Starter Motor TC-005_2
Starting Circuit Test
than 0.5V below the reading obtained in Step 1. Minimum permissible reading in 'start' position 9.0V.
Before carrying out the voltmeter tests, check the battery condition and ensure that all connections are clean and tight.
If the reading is within this limit, continue to Step 3. If the reading is outside the limit, proceed to Step 4 and Step 5.
To prevent the engine starting during the tests ensure that the engine stop fuse is removed, (refer to Fuse Identification page). Check the readings in the following sequence using a voltmeter. Unless otherwise stated, the readings must be taken with the starter switch held in the 'start' position and the transmission forward/reverse selector in neutral. Note: Do not operate the starter motor for more than 20 seconds at one time. Let the starter motor cool for at least two minutes between starts. 1
Connect the voltmeter across the battery terminals. K Fig 8. ( T C-13). Reading in 'start' position: 10.0V approximately. Minimum permissible reading in 'start' position 9.5V.
Fig 9. 3
A low reading probably indicates a fault in the starter motor.
Connect the voltmeter between the solenoid terminal 10-C and a good earth. Minimum permissible reading in 'start' position: 8.0V.
Fig 10.
Fig 8. 2
Connect the voltmeter between the starter main terminal 9-A and the commutator end bracket 9-B. In the 'start' position, the reading should not be more
C-13
9803/9960-3
a
If the reading is less than specified, connect the voltmeter between the neutral start relay terminal 11-D and earth. An increase in reading to 8.0V indicates a fault in the wiring from the start relay to the solenoid.
C-13
Section C - Electrics General Starter Motor b If the reading between terminal 11-D and earth is below 8.0V, connect the voltmeter between terminal 11-E and earth. An increase in the reading to 8.0V indicates either a faulty start relay or a fault in the feed from the transmission selector switch to the relay solenoid. Check also the solenoid earth connection.
5
Connect the voltmeter between battery positive and the starter main terminal 13-A. 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 0.25V.
If the reading between 11-E and earth is less than 8.0V, the fault must be in either the starter switch or in the wiring between the solenoid, starter switch, and the start relay.
Fig 13. If the reading is above 0.25V, a high resistance is present in the insulated lead or in the solenoid. Connect the voltmeter between the battery positive and solenoid connection 14-H. If the voltmeter now reads zero with the switch closed, the fault is in the solenoid.
Fig 11. 4
Connect the voltmeter between battery negative and starter earth connection 12-B. The reading in the 'start' position should be practically zero, maximum permissible reading 0.25V. If the reading is above 0.25V, a high resistance in the earth lead or connections is indicated.
Fig 14. 6
Finally refit the engine stop fuse.
Fig 12.
C-14
9803/9960-3
C-14
Section C - Electrics General Wiring Harness Repair
Wiring Harness Repair TC-004
!MCAUTION
Introduction Instances do 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.
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.
To ensure 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 International Protection rating of 67 (I.P.67).
ELEC-2-3
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.
!MCAUTION 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.
Repair Procedure Part No.
Table 3. Tools Required Description
892/00350
Butane Heater assembly
1
892/00349
Crimp tool
1
892/00351
Splice 0.5-1.5 mm (Red)
50
892/00352
Splice 1.5-2.5 mm (Blue)
50
892/00353
Splice 3.0-6.0 mm (Yellow)
50
1
Qty
Cut the wire and remove the protective insulation for a suitable distance dependent upon the size of wire and splice to be used. For the splices detailed in K Table 3. ( T C-15), the dimension is 7mm.
ELEC-2-1
!MWARNING 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.
Fig 15.
ELEC-2-2
2
C-15
9803/9960-3
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. K Fig 15. ( T C-15). Note that each of the splices detailed is colour-coded to make size and range
C-15
Section C - Electrics General Wiring Harness Repair 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. 3
With the Butane heater assembly, connection. K Fig 16. ( T C-16). a
seal
the
Remove the cap 17-A from the end of the disposable gas cartridge 17-B.
Fig 18. d Turn the small ring 19-E so that the air holes at 19F are completely closed. Fig 16. b Before assembling the gas cartridge to the reflector element 18-C, turn the red ring 18-D to the left, (in the direction of the minus sign marked on the ring).
Fig 19. e Fig 17. c
C-16
Position the tube hanging down from inside the reflector assembly into the hole at the top of the gas cartridge. Then press the gas cartridge up into the reflector assembly as far as possible until the two elements are clasped firmly together. K Fig 18. ( T C-16). A click will be heard.
Turn the red ring 20-D 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.
9803/9960-3
C-16
Section C - Electrics General Wiring Harness Repair i
Side wings 22-G down, reflector head completely open. In this mode the infra-red heat waves are dominant (recommended for the light coloured plastic splices).
Fig 20. f
Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown. Fig 22. 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 21-E until the air holes at 21-F are completely open. The tool is ready for use.
ii
Side wings 23-G up, reflector head opening reduced. In this mode the heating is done only by the hot gas (use for dark coloured plastic splices).
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.
Fig 23. h To switch off the heater, turn the red ring 23-D to the left (in the direction of the minus sign). Fig 21. g The heater can be used in two modes:
C-17
9803/9960-3
C-17
Section C - Electrics General Wiring Harness Repair
Page left intentionally blank
C-18
9803/9960-3
C-18
Section C - Electrics
Alternator Removal and Replacement 100 and 400 series Engines
!MWARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5
Disconnect the battery negative lead. Disconnect the wiring from the rear of the alternator.Loosen the pivot bolt A and the adjustment bolt B. Reposition the alternator to release the tension then slip the drive belt from the pulleys. Remove the adjustment bolt B. Swivel the alternator outwards, remove the pivot bolt A and lift it from the engine. Examine the drive belt for wear. Replacement is a reversal of the removal procedure. Position the alternator until belt deflection at X is approximately 10 mm (3/8 in) then tighten bolts A and B.
S255830-B1
Fig 1.
C-19
9803/9960-3
C-19
Section C - Electrics Alternator Dismantling and Assembly
Dismantling and Assembly
S213570
Fig 2. K Dismantling ( T C-21)
C-20
9803/9960-3
C-20
Section C - Electrics Alternator Dismantling and Assembly
Dismantling
Torque Settings
K Fig 2. ( T C-20) Remove suppressor 2 (if fitted) by removing nut 1 anddisconnecting lead E from terminal F.Unscrew bolts 3 and disconnect lead G from terminal H to remove the brush box and regulator assembly 4. If the brush length is less than 5mm (0.2in) [new length 17mm (0.67in)], or if spring pressure is less than 1.3 N , the brush box and regulator assembly must be renewed.
Item
Nm
kgf m
lbf ft
8
3.4
0.35
2.5
7
5.4
0.55
4
12
60
6.1
44
Remove nuts and washers 5, bolts 6 and nuts 7. Remove slip ring end bracket 8. Carefully remove rectifier 10 and stator 11 as an assembly. Unsolder the interconnecting wires at X, Y, and Z only if renewing either of these components. Remove nut and washer 12 using an 8mm Allen key in the shaft hexagon hole to prevent rotation. If necessary, use a press to remove rotor 19 from the drive end bracket 17. Check the rotor poles and the inner faces of the stator for signs of rubbing, which indicates worn bearings. The drive end bearing is part of bracket 17 and cannot be removed separately. If requiring renewal, needle roller bearing 20 should be pressed out in the direction of the arrow.
Assembly K Fig 2. ( T C-20) Reverse the dismantling procedure, but note the following: Ensure that spacers 14, 16 and 18 are correctly positioned as shown. Ensure that the slip rings J are clean and smooth, using extra fine glasspaper to rectify slight imperfections. Ensure that insulation bushes 9 and washer 5 are positioned as shown. Take care not to damage the brushes when fitting the brush box and regulator assembly. Torque Settings Item
Nm
kgf m
lbf ft
3
2.7
0.28
2
6
4.1
0.41
3
C-21
9803/9960-3
C-21
Section C - Electrics Alternator Dismantling and Assembly
Page left intentionally blank
C-22
9803/9960-3
C-22
9803/9960-3
C-23 K Main Components ( T C-24)
3
C-23
BATTERY
1 4
THERMOSTART
GLOW PLUGS
5 STARTERMOTOR
N/START RELAY
STARTERSOLENOID
2
6
NEUTRAL START RELAY
9
P. BRAKE
7 SWITCH P. BRAKE 8 RELAY
10
FUSE A1
OPERATIONAL SOLENOID PARKBRAKE SOLENOID
OVERRIDE 11SWITCH
FUSE A2
SEAT
ISOLATORRELAY
14 AUX. SWITCH
12 ISOLATION RELAY
13
16
AUX. HYD. FWD (FRONT)
JOYSTICK
15 AUX. HYD. REV (FRONT)
17
18
20
HI FLOW SWITCH
SEAT SWITCH
FUSE A3
21
HI-FLOW HYDRAULICS
19 LATCHING RELAY HOURMETER
HYD. OIL TEMP. ENGINE OIL PRESS. AIRFILTER CHARGE PUMP PRESS.
ENGINEWATERTEMP. HYD. OIL TEMP. ENGINE OIL PRESSURE AIRFILTER CHARGE PUMP PRESSURE E.S.O.S.
30
INTERIORLIGHT
REARHORN FRONT HORN
35
INTERIORLIGHT
36
BEACON
Fig 1.
106
111
115
117
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 L.H. FRONT WORK LIGHT R.H. FRONT WORK LIGHT L.H. REARWORK LIGHT R.H. REARWORK LIGHT
L.H. FRONT INDICATR L.H. REARINDICATOR
44
From machine no. 751600 to 752370
ALTERNATOR
ALTERNATOR
BEACON SWITCH
IGN. RELAY
109 110
FUSE B2
113 FRONT WORKLIGHT
40
41
119
HAZARD SWITCH
121
R.H. FRONT INDICATR R.H. REARINDICATOR FLASHERUNIT
Electrical Circuit Diagrams
23
22 24
BUZZER
100
FUSE A4
25 26 27 28 29
WATERTEMP.
101 102 103 104 105
FUSE A8
31 32
33
FUSE A5
34 FUSE B10
37
107 108
FUSE B1 ROAD LIGHT SWITCH
39
112
FUSE B3 WORKING LIGHT
38 RELAY
114
FUSE B4
116
FUSE B5
REARWORKLIGHT
118 INDICATORSWITCH
42
120 FUSE A7
FUSE A6
43 FLASHER UNIT WASH/WIPE SWITCH
47
46
WASHERMOTOR FRONT WIPERMOTOR
48 49
FUSE A9
REARWIPERMOTOR
50
HEATER MOTOR
FAST
51
FUSE A10
SLOW
53
52 55
FUSE B6
HEATERMOTOR
55
REVERSE ALARM
54 BRAKE LIGHT TIMERUNIT
122
10 SECOND TIMER
56
56
57 123
FUSE B7
58
L.H. BRAKE LIGHT R.H. BRAKE LIGHT HAND HELD ATTACHMENT SOLENOID
59 H/H ATTACHMENT SOLENOID
FLOAT SWITCH PRESS. SWITCH
60
61
852-95001-1
852/95001/1
LATCHING RELAY
62 FLOAT SOLENOID
63
FUSE B8
FACE LEVEL FAN
65
64
66
FUSE B9
JUNCTION BOX
From machine no. 751600 to 752370
Electrical Circuit Diagrams
Section C - Electrics
Section C - Electrics Electrical Circuit Diagrams From machine no. 751600 to 752370
Main Components
26
Hydraulic Oil Temperature Switch
K Fig 1. ( T C-23)
27
Engine Oil Pressure Switch
1
Battery
28
Air Cleaner Warning Switch
2
Starter Switch
29
Charge Pump Pressure Switch
3
Neutral Start Relay
30
Engine Shut Off Solenoid
4
Glow Plugs
31
Rear Horn (when fitted)
5
Starter Motor
32
Front Horn
6
Starter Solenoid
33
Horn Relay
7
Park Brake Switch
34
Horn Pushbutton
8
Park Brake Relay
35
Interior Light and Switch
9
Operational Solenoid
36
Beacon Switch
10
Park Brake Solenoid
37
Ignition Relay
11
Override Switch
38
Working Light Relay
12
Isolator Relay
39
Road Lights Switch
13
Auxiliary Attachments Switch
40
Front Worklight Switch
14
Seat Switch
41
Rear Worklight Switch
15
Joystick Switch
42
Hazard Warning Switch
16
Auxiliary Hydraulics - Forward Solenoid
43
Flasher Unit
17
Auxiliary Hydraulics - Reverse Solenoid
44
Indicator Switch & Warning Light
18
High-flow Hydraulic Switch
45
Intentionally Blank
19
Latching Relay
46
Wash/Wipe Switch & Warning Light
20
Seat Switch
47
Washer Motor
21
High-flow Hydraulic Solenoid
48
Front Wiper Motor
22
Hourmeter
49
Rear Wiper MotorRear Wiper Switch
23
Alternator
50
Heater Blower Switch
24
Warning Buzzer
51
Heater Blower Resistor
25
Engine Coolant Temperature Switch
52
Heater Blower
C-24
9803/9960-3
C-24
Section C - Electrics Electrical Circuit Diagrams From machine no. 751600 to 752370 53
Reverse Alarm
Lamps
54
Reverse Alarm Switches
118
L. H. Headlight Dip
119
R. H. Headlight Dip
55
Brake Light Switches
120
Number Plate Light
56
Brake Light Timer
121
L. H. Rear Side Light
122
L. H. Front Side Light
57
Hand Held Attachment Switch & Warning
123
R. H. Rear Side Light
58
Hand Held Attachment Solenoid
59
Hydraulic Float Switch
60
Hydraulic Float Pressure Switch
61
Latching Relay
62
Hydraulic Float Solenoid
63
Face Level Fan
64
Face Level Fan Switch
65
Junction Box
Fuses See Section 3
Bulbs K Light Bulbs ( T C-1)
Lamps 100
Alternator Warning
101
Engine Coolant Temperature Warning
102
Hydraulic Oil Temperature Warning
103
Engine Oil Pressure Warning
104
Air Cleaner Warning
105
Charge Pump Pressure Warning
106
R. H. Front Side Light
107
Left Hand Front Worklight
108
Right Hand Front Worklight
109
Left Hand Rear Worklight
110
Right Hand Rear Worklight
111
L. H. Front Direction Indicator
112
L. H. Rear Direction Indicator
113
R. H. Front Direction Indicator
114
R. H. Rear Direction Indicator
115
L. H. Rear Brake Light
116
R. H. Rear Brake Light
117
Beacon Light
C-25
9803/9960-3
C-25
C-26
BATTERY
THERMOSTART
GLOW PLUGS
STARTERMOTOR N/START RELAY
17 50a
004
5
842
6
P/BRAKE SWITCH
938A
1
938B
7
5
3 815
1
STARTERSOLENOID 600V
2
5
5
2
NEUTRAL START RELAY OPERATION SOLENOID PARK BRAKE SOLENOID P/BRAKE SWITCH ILLUM.
8
7
11
810
600HC
865B
1
15
14
2 886
4
865
865A
12 13
3
5
125D
600HB F
600HX
971 A B
OVERRIDE SWITCH SEAT POSITION SWITCH
AUX. HYD. FWD. (FRONT)
17
5 1 8
JOYSTICK
873A
16
6
C 600HY
AUX. HYD. REV. (FRONT)
18
9
600GN
TUV SEAT SWITCH (GERMAN BUILD ONLY)
866A
ISOLATION RELAY 125E
125
7 125B 3
001
972
2 10
600GV 600CP
10
10
4
4
122A
3 1
4
P/BRAKE RELAY 122
9 815A
122B
9
K Main Components ( T C-27)
1
003E
3
19 30
810
15/54
FUSE A1
2
200B 200C
9803/9960-3 FUSE A2
C-26 887
23
600JU
810A
AUX. SWITCH ILLUM.
810C 810B
877A
HIGH-FLOW SWITCH
SEAT SWITCH
22
4 877C 2
5
877B
874
2
881 4
21
129
877
3
LATCHING RELAY
10
600CU 600DH
877E
HIGH-FLOW HYDRAULICS
19
9
600DD
1
5
7
3 5
4
20
FUSE A3 IGN. RELAY 205A
002
600DE
877D
1
001A
600W
2
106T
1
600HR
2
24
23
26
600HS
IGNITION RELAY
HOURMETER
'W'
25
28
407B
X
407A
ALTERNATOR
411
80
27
23
BUZZER 434
434B
81 82
29
414A
434A
415A 403C
ALTERNATOR
83 84 85
414
414B
HYD. OIL TEMP.
406
WATERTEMP.
X 600JT
30 31 32 33
403
403B
415
415B
X
ENGINEWATERTEMP. SWITCH HYD. OIL TEMP. SWITCH ENGINE OIL PRESS. SWITCH
CHARGE PUMP PRESS. SWITCH
600CS
AIRFILTERSWITCH
600CF
34
X
E.S.O.S. FLOAT SWITCH ILLUM.
3
PRESSURE SWITCH
7 2
35
Fig 2.
FLOAT SWITCH 1
ENGINE SPEED INDICATORUNIT
412
3
407 3
HOURMETER 106C
106AA
106
402
AIRFILTER
ENGINE OIL PRESS.
CHARGE PUMP PRESS.
105
101AR
FUSE A6
6 8 9
LATCHING RELAY
10
36
2
4
1
5
FLOAT SOLENOID
37
38
3
600BD
39
834B
40
834A
834
829C 829
829D
LH SIDE LIGHT
91
830B
RH TAIL LIGHT
92
RH SIDE LIGHT 600DW
93
855B
855
600AS
94
855A
10
600AR
41 861
95
1
861B
96
42
ROADLIGHT SWITCH
RH FRONT WORKLIGHT FRONT WORKLIGHT SWITCH
600CJ
RH REARWORKLIGHT REARWORKLIGHT SWITCH
99
44
43
806B
806E
100
45 46
47
871B
600H 600BL
600EY
871
48
600AJ
101
600AP
102
894
LH FRONT WORKLIGHT
LH REARWORKLIGHT
600AY 600AV 600CK
98
7
806H
49a 31
49
1
HAZARD SWITCH ILLUM. LH FRONT INDICATOR LH REARINDICATOR
600G
805C
1 805B
10 805G 808C
802
5
10
9
600DX
97
5
9
803B 805 806P
6
2
300
FLASHER UNIT
HAZARD SWITCH
600EL
INTERIORLIGHT
600DY
RH FRONT INDICATOR RH REARINDICATOR FLASHERUNIT
FRONT HORN REARHORN INTERIORLIGHT BEACON
49
BEACON SWITCH ILLUM.
50
BEACON SWITCH
800CC
800
5
800B
1
SLOW
52
10
600BH
800D
WASH/WIPE SWITCH 839
4
800GR
HEATERMOTOR
600EB
54
51
HEATERRESISTOR HEATER SWITCH
JUNCTION BOX
FAST
53
101
FUSE B8
3 8
106R
REARWIPERMOTOR LH DIP BEAM
LH TAIL LIGHT
90
830
830D
1
NO. PLATE LIGHT
89
FUSE B2
828
829E
828M
FUSE B3
10
RH DIP BEAM
88
2
205D
87
9
106K
86
5
116
5
117
861A
10
803A 10
1 3
5 8
104
FUSE A10 312
FUSE A8
871A
HORN SWITCH
102
FUSE B7
From machine no. 752371 to 752675
ENGINE SPEED INDICATOR UNIT 2
1
106D 200 200A
FUSE A4
106AB 106AC 106AD 106AE 106AF
FUSE A5
114
FUSE A7
FUSE B1 833
3 6
9
106L
855C
FUSE B4
FUSE B5
9
106M
805E
IND. SWITCH
803 7
106F
FUSE B10
303
FUSE A9
303A 205B
303G 106N
103
FUSE B8
600BG
WASHERMOTOR
2 5
7
840
800AK
10
600ED
56
807A
58
127A
55
106H
8
REVERSE SWITCHES
FUSE B9
807B
600CD
WIPERMOTOR W/WIPE SWITCH ILLUM.
816L
869A
816D
816
60
60
59
816E
BRAKE LIGHT TIMERUNIT LH BRAKE LIGHT
104
103
852-95001-2
57
852/95001/2
REVERSE ALARM
57 600AW
127C
10 SEC. TIMER
BRAKE SWITCHES 127B
RH BRAKE LIGHT
From machine no. 752371 to 752675
Electrical Circuit Diagrams
Section C - Electrics
Section C - Electrics Electrical Circuit Diagrams From machine no. 752371 to 752675
Main Components
26
Engine Speed Indicator Unit
K Fig 2. ( T C-26)
27
Warning Buzzer
1
Battery
28
Alternator
2
Glow Plugs
29
Engine Coolant Temperature Switch
3
Starter Motor
30
Hydraulic Oil Temperature Switch
4
Starter Solenoid
31
Engine Oil Pressure Switch
5
Neutral Start Relay
32
Air Cleaner Warning Switch
6
Starter Switch
33
Charge Pump Pressure Switch
7
Park Brake Relay
34
Engine Shut Off Solenoid
8
Park Brake Switch
35
Hydraulic Float Pressure Switch
9
Operational Solenoid
36
Hydraulic Float Switch
10
Park Brake Solenoid
37
Latching Relay
11
TUV Seat Switch (German machines only)
38
Hydraulic Float Solenoid
12
Override Switch
39
Rear Wiper Motor
13
Seat Switch
40
Road Lights Switch
14
Isolator Relay
41
Front Worklight Switch
15
Auxiliary Attachments Switch
42
Rear Worklight Switch
16
Joystick Switch
43
Indicator Switch & Warning Light
17
Auxiliary Hydraulics - Forward Solenoid (Front)
44
Hazard Warning Switch
18
Auxiliary Hydraulics - Reverse Solenoid (Front)
45
Flasher Unit
19
High-flow Hydraulic Solenoid
46
Horn Switch
20
Latching Relay
47
Front Horn
21
Seat Switch
48
Rear Horn (when fitted)
22
High-flow Hydraulic Switch
49
Beacon Switch
23
Diode
50
Junction Box
24
Ignition Relay
51
Heater Blower Switch
25
Hourmeter
52
Heater Blower Resistor
C-27
9803/9960-3
C-27
Section C - Electrics Electrical Circuit Diagrams From machine no. 752371 to 752675 53
Heater Blower
Fuses
54
Washer Motor
See Section 3
55
Wiper Motor
Bulbs
56
Wash/Wipe Switch & Warning Light
K Light Bulbs ( T C-1)
57
Reverse Alarm Switches
58
Reverse Alarm
59
Brake Light Timer
60
Brake Light Switches
Lamps 80
Alternator Warning
81
Engine Coolant Temperature Warning
82
Hydraulic Oil Temperature Warning
83
Engine Oil Pressure Warning
84
Air Cleaner Warning
85
Charge Pump Pressure Warning
86
L. H. Headlight Dip
87
R. H. Headlight Dip
88
Number Plate Light
89
L. H. Tail Light
90
L. H. Side Light
91
R. H. Tail Light
92
R. H. Side Light
93
Left Hand Front Worklight
94
Right Hand Front Worklight
95
Left Hand Rear Worklight
96
Right Hand Rear Worklight
97
L. H. Front Direction Indicator
98
L. H. Rear Direction Indicator
99
R. H. Front Direction Indicator
100
R. H. Rear Direction Indicator
101
Interior Light and Switch
102
Beacon Light
103
L. H. Rear Brake Light
104
R. H. Rear Brake Light
C-28
9803/9960-3
C-28
9803/9960-3
C-29
003E
GLOW PLUGS
3
19
50a
004
5
3
6
842
1
810
STARTERMOTOR
5
N/START RELAY
17
30
STARTERSOLENOID
4
4 15/54
2
600V
106AK
600GN P/BRAKE SWITCH
P/BRAKE RELAY +8
122
122A
5
3
815
-7 1
1
936B
600GV
2
1
122B
3
NEUTRAL START RELAY P/BRAKE SWITCH ILLUM OPERATION SOLENOID
936A 600CP
8
2
PARKBRAKE SOLENOID
7
10
2
TUV SEAT SWITCH (GERMAN BUILD ONLY)
866A 810
5
O/R 865B
600HC
3 SEAT
1
125D
600HB
2 866
865
13
4
F
865A
15
600JU
OVERRIDE SWITCH SEAT POSITION SWITCH AUX SWITCH ILLUM
-7
1
600HX
971
1
17
2
125B
A
3 4
873A
B
2
AUX HYD FWD (FRONT)
JOYSTICK
16
6 +8
12
125
AUXILIARY SWITCH 10
106AR
001
5
125C
14
ISOL RELAY 125E
FUSE A2
9
FUSE A1
4
11
K Main Components ( T C-27)
1 THERMOSTART
BATTERY
2
200B 200C
C-29 C 600HY
972
18
867 810A
AUX HYD REV (FRONT)
810C 810B
877A
23
HI FLOW SWITCH
SEAT SWITCH
-7 1
+8
877D
129
877B
881
21
2
4
600CU
600DD
2 1
874
HI FLOW HYDRAULICS
600DH
877E
877
5
19
22
3
3
5
002
LATCHING RELAY
877C
6
3
5
20
FUSE A3
IGN RELAY 200D
600DE
2
1 001A
600W 1
106T
2
600HR
23
26
24
2
4
ENGINE SPEED INDICATOR UNIT
3
600HS
4
0
X
407A
IGNITION RELAY
27
23
81 82
29
80
23
434 434A
X
600JT
83 84 85
30 31 32 33
414 403
402 415B
415
X 600CF 600CS
34
105
X
ENGINEWATERTEMP SWITCH HYD. OIL TEMP SWITCH ENGINE OIL PRESS SWITCH AIRFILTERSWITCH CHARGE PUMP PRESS SWITCH E.S.O.S. FLOAT SWITCH ILLUM
36
FLOAT SWITCH
FUSE A6
101AR
6
8
37
23
2
4
38
Fig 3.
PRESSURE SWITCH
2
35
3
1 7
LATCHING RELAY
10 9
1
FLOAT SOLENOID
5 3
114
39
FUSE A7
M
600BD
600DW
86
834B 106K
8+
-7
1
FUSE B1
834A
834
5
829
829D
REARWIPERMOTOR ROADLIGHT SWITCH RH DIP BEAM LH TAIL LIGHT
40
90
829E
23
LH SIDE LIGHT
91
830B
830
RH TAIL LIGHT
92
830D -7
1
RH SIDE LIGHT
LH FRONT WORKLIGHT
600AS
FRONT WORKLIGHT SWITCH
600CJ
2
93
855
3
855B
600AR
855A
41
94
FRONT WORKLIGHT SWITCH
LH REARWORKLIGHT
600AY
861B
REARWORKLIGHT SWITCH
600CK
95
861
3
42
96
44
49a
FLASHER UNIT
600BL
HAZARD SWITCH ILLUM
600DX
97
106AP
8
1
805C
-7 +1
600G
98
803A
805B 806B
2
43
+3
45
99
806E
100 47
101
46
871A INTERIORLIGHT
600H
LH REARINDICATOR
RH FRONT INDICATOR RH REARINDICATOR
REARHORN
600EL
FRONT HORN
600AJ
-7
1
600EY
48
+8
303G
FLASHERUNIT INDICATORSWITCH LH FRONT INDICATOR
600LA 805E
-10
IND SWITCH
803B
805 803
5 17 18
2
871 HORN SWITCH
303A
303
106N
RH FRONT WORKLIGHT
RH REARWORKLIGHT
600AV
861A
-7
1
2
2
1
No PLATE LIGHT
89
FUSE B2
828
+3
88
833
6
829C
2
828M FUSE B3
855C
+8
116
+8
117
31
49
104
3
806P
806C
871B 312
FUSE A9
LH DIP BEAM
87
200N
200F
2
ROADLIGHT SWITCH
106L FUSE B4
2
106M FUSE B5
REARWORKLIGHT SWITCH 2
FUSE B10
802
2
300 FUSE A10
+8
106F
HAZARD SWITCH 106AP
FUSE A8
205B
From machine no. 752676
434B
ALTERNATOR
106AB
AIRFILTER
CHARGE PUMP PRESS
FUSE A5
ALTERNATOR
411
406
WATERTEMP
106AA
106AF
HOURMETER
'W'
407
3
28
25
4
407B
414B
HYD OIL TEMP
106AC
106AE
ENGINE SPEED INDICATORUNIT
412
2
1
106D
3
HOURMETER
200 200A 106C BUZZER
FUSE A4
403B
ENGINE OIL PRESS
106AD
414A
415A
406A
403C
600DY
INTERIORLIGHT BEACON SWITCH ILLUM
2
894
3
600AP
M
BEACON
BEACON SWITCH
49
50
102
2
FUSE B6
600CC
101
+10
102
-7
1
JUNCTION BOX
51
106R FUSE B7
1
600BH
2
52
102A
3
HEATER SWITCH
800
4 5
HEATERRESISTOR 800D
600GR
600EB
FAST -7 1
1 840A
WIPERMOTOR
600AK
W/WIPE SWITCH ILLUM
600ED
2
M
56
54
839
6
600BG
M
2
57
57
807B
BRAKE LIGHT TIMERRELAY LH BRAKE LIGHT
600MJ
BRAKE LIGHT TIMERUNIT
600AW
REVERSE ALARM
600CD
58
3
4
1
2
816D
1 816E
4
347381
2
816
600G
104
127D
103
347381
60
60
59
3
5
61
10 SEC TIMER
869A
WASHERMOTOR
55
REVERSE SWITCHES 807A
127C
816L
HEATERMOTOR
53
800B
2
103
5 +8
127A
M
SLOW 6
102A
FUSE B8
840
3
WASH/WIPE SWITCH 106H
FUSE B9
127B
BRAKE SWITCHES
BRAKE LIGHT TIMERRELAY
600H
RH BRAKE LIGHT
From machine no. 752676
Electrical Circuit Diagrams
Section C - Electrics
Section C - Electrics Electrical Circuit Diagrams From machine no. 752676
Main Components
26
Engine Speed Indicator Unit
K Fig 2. ( T C-26)
27
Warning Buzzer
1
Battery
28
Alternator
2
Glow Plugs
29
Engine Coolant Temperature Switch
3
Starter Motor
30
Hydraulic Oil Temperature Switch
4
Starter Solenoid
31
Engine Oil Pressure Switch
5
Neutral Start Relay
32
Air Cleaner Warning Switch
6
Starter Switch
33
Charge Pump Pressure Switch
7
Park Brake Relay
34
Engine Shut Off Solenoid
8
Park Brake Switch
35
Hydraulic Float Pressure Switch
9
Operational Solenoid
36
Hydraulic Float Switch
10
Park Brake Solenoid
37
Latching Relay
11
TUV Seat Switch (German machines only)
38
Hydraulic Float Solenoid
12
Override Switch
39
Rear Wiper Motor
13
Seat Switch
40
Road Lights Switch
14
Isolator Relay
41
Front Worklight Switch
15
Auxiliary Attachments Switch
42
Rear Worklight Switch
16
Joystick Switch
43
Indicator Switch & Warning Light
17
Auxiliary Hydraulics - Forward Solenoid (Front)
44
Flasher Unit
18
Auxiliary Hydraulics - Reverse Solenoid (Front)
45
Hazard Warning Switch
19
High-flow Hydraulic Solenoid
46
Horn Switch
20
Latching Relay
47
Front Horn
21
Seat Switch
48
Rear Horn (when fitted)
22
High-flow Hydraulic Switch
49
Beacon Switch
23
Diode
50
Junction Box
24
Ignition Relay
51
Heater Blower Switch
25
Hourmeter
52
Heater Blower Resistor
C-30
9803/9960-3
C-30
Section C - Electrics Electrical Circuit Diagrams From machine no. 752676 53
Heater Blower
Lamps
54
Wiper Motor
104
55
Washer Motor
Fuses
56
Wash/Wipe Switch & Warning Light
See Section 3
57
Reverse Alarm Switches
Bulbs
58
Reverse Alarm
K Light Bulbs ( T C-1)
59
Brake Light Timer
60
Brake Light Switches
61
Brake Light Timer Relay
R. H. Rear Brake Light
Lamps 80
Alternator Warning
81
Engine Coolant Temperature Warning
82
Hydraulic Oil Temperature Warning
83
Engine Oil Pressure Warning
84
Air Cleaner Warning
85
Charge Pump Pressure Warning
86
L. H. Headlight Dip
87
R. H. Headlight Dip
88
Number Plate Light
89
L. H. Tail Light
90
L. H. Side Light
91
R. H. Tail Light
92
R. H. Side Light
93
Left Hand Front Worklight
94
Right Hand Front Worklight
95
Left Hand Rear Worklight
96
Right Hand Rear Worklight
97
L. H. Front Direction Indicator
98
L. H. Rear Direction Indicator
99
R. H. Front Direction Indicator
100
R. H. Rear Direction Indicator
101
Interior Light and Switch
102
Beacon Light
103
L. H. Rear Brake Light
C-31
9803/9960-3
C-31
Section C - Electrics Electrical Circuit Diagrams Series 2 Machines From SN 1743570
Series 2 Machines From SN 1743570
Fig 4. 333-T7417-1 Sheet 1 of 8
C-32
9803/9960-3
C-32
Section C - Electrics Electrical Circuit Diagrams Series 2 Machines From SN 1743570
Fig 5. 333-T7417-1 Sheet 2 of 8
C-33
9803/9960-3
C-33
Section C - Electrics Electrical Circuit Diagrams Series 2 Machines From SN 1743570
Fig 6. 333-T7417-1 Sheet 3 of 8
C-34
9803/9960-3
C-34
Section C - Electrics Electrical Circuit Diagrams Series 2 Machines From SN 1743570
Fig 7. 333-T7417-1 Sheet 4 of 8
C-35
9803/9960-3
C-35
Section C - Electrics Electrical Circuit Diagrams Series 2 Machines From SN 1743570
Fig 8. 333-T7417-1 Sheet 5 of 8
C-36
9803/9960-3
C-36
Section C - Electrics Electrical Circuit Diagrams Series 2 Machines From SN 1743570
Fig 9. 333-T7417-1 Sheet 6 of 8 (Servo Option Mk2)
C-37
9803/9960-3
C-37
Section C - Electrics Electrical Circuit Diagrams Series 2 Machines From SN 1743570
Fig 10. 333-T7417-1 Sheet 7 of 8 (Multifunction Option)
C-38
9803/9960-3
C-38
Section C - Electrics Electrical Circuit Diagrams Series 2 Machines From SN 1743570
Fig 11. 333-T7417-1 Sheet 8 of 8
C-39
9803/9960-3
C-39
Section C - Electrics Electrical Circuit Diagrams Series 2 Machines From SN 1743570
Page left intentionally blank
C-40
9803/9960-3
C-40
Section C - Electrics Harness Data Wire and Harness Number Identification
Harness Data Wire and Harness Number Identification TC-003_2
Introduction This section details the allocation of wire numbers and the identification of wires in the wiring harness.
Fig 1. Typical Wire and Harness Number K Fig 1. ( T C-41). 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:
Table 1. Wire and Harness Number Identification Ident. No.
Description
#
The # indicates the start of the identification number. It is always printed to the left of the identification number.
B
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.
819
The wire's unique identification number. The wire functions and numbers allocated to them are consistent through out the JCB range of products. K Wire Numbers and Functions ( T C-42).
9/371
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).
C-41
9803-9960-3
C-41
Section C - Electrics Harness Data Wire and Harness Number Identification
Wire Numbers and Functions
Wires 800-999
Wires 000-199
These numbers are reserved for switched supplies to electrical loads, i.e. to lights, etc.
These numbers are reserved for ignition feeds, heater start circuits and start circuits. These can be further categorised by:
Wires In Splices
– Wires 000 - 099 are allocated to unfused ignition feeds. – Wires 100 - 199 are allocated to fused ignition feeds. Note: Feeds via ignition relays are classed as ignition feeds.
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. K Fig 3. ( T C-42). Note: The letters I, O, Q and S are not used.
Wires 200-399 These numbers are reserved for battery feeds, They can be further categorised by: – Wires 200 - 299 are allocated to unfused battery feeds. – Wires 300 - 399 are allocated to fused battery feeds.
Wires 400-599 These numbers are reserved for instruments, i.e. alternators to tachos, temperature switches to warning lights, etc. and signal wires used in electronic systems. Fig 3.
Wires 600-799 General Points These numbers are used for earth wires. When the number is printed onto a wire A it is prefixed by the Earth symbol B. K Fig 2. ( T C-42). This symbol is printed onto the wire, it may however be omitted from harness drawings.
1
Wires continue to have the same number even after passing through a connector block to another harness.
2
If all the numbers in a category have been allocated, then the category is re-used with an additional prefix '1', i.e. 1832.
Fig 2. 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.
C-42
9803-9960-3
C-42
Section C - Electrics Harness Data Harness Interconnections and Drawings
Harness Interconnections and Drawings Harnesses Harness No. 1
Issue Remarks K 333-T7366-1 (Sheet 1 of 3) ( T C-44)
Servo Hydraulics (Early Machines) 333/T7366
Drawing
1
K 333-T7366-1 (Sheet 2 of 3) ( T C-45) K 333-T7366-1 (Sheet 3 of 3) ( T C-46)
2
Servo Hydraulics (Later Machines) 333/U1474
3
1
K 333-U1474-1 (Sheet 1 of 1) ( T C-47)
1
K 333-T9226-1 (Sheet 1 of 1) ( T C-48)
Joystick Controls 333/T9226
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.
C-43
9803-9960-3
C-43
Section C - Electrics Harness Data
Servo Hydraulics (Early Machines)
Fig 4. 333-T7366-1 (Sheet 1 of 3)
Harness Interconnections and Drawings
C-44
9803-9960-3
C-44
Section C - Electrics Harness Data
Fig 5. 333-T7366-1 (Sheet 2 of 3)
Harness Interconnections and Drawings
C-45
9803-9960-3
C-45
Section C - Electrics Harness Data Harness Interconnections and Drawings
Fig 6. 333-T7366-1 (Sheet 3 of 3)
C-46
9803-9960-3
C-46
Section C - Electrics Harness Data
Servo Hydraulics (Later Machines)
Fig 7. 333-U1474-1 (Sheet 1 of 1)
Harness Interconnections and Drawings
C-47
9803-9960-3
C-47
Section C - Electrics Harness Data
Joystick Controls
Fig 8. 333-T9226-1 (Sheet 1 of 1)
Harness Interconnections and Drawings
C-48
9803-9960-3
C-48
Section C - Electrics
Control Systems Description Auxiliary ECU
T065390
Fig 1. Auxiliary ECU Pin
Configuration
Fuction
1
Ground
0V Supply
2
Ground
0V Common
3
Ground
0V Common Thumbwheel
4
Low side output
Indication LED 0V
5
Analogue
Control Solenoids 0V
6
Analogue
0-5V Input from Thumbwheel
7
Switch Input
+12 V constant Flow Set Input
8
Not Used
Not Used
9
5V Input
5V Ref Input
10
High Side output
PWM Forward SOL Output
11
High Side output
PWM Reverse SOL Output
12
+V Supply
12/24V Ingnition Supply
C-49
9803/9960-3
C-49
Section C - Electrics Control Systems Description
Power Management System (PMS)
A
A
T065400
Fig 2. Power Management System (PMS) Pin
Configuration
Fuction
1
Ground
0V Supply
2
Ground
Not Connected
3
Ground
Not Connected
4
Low side output
Diagnostic Lamp
5
Analogue
Not Connected
6
Analogue
Signal - Angle Sensor
7
Frequency input
Alternator Input
8
Switch Input
PMS Overide
9
Switch Input
Calibrate
10
High Side output
PMS Valve
11
High Side output
Not Connected
12
Supply
12V Ingnition Supply
C-50
9803/9960-3
C-50
Section C - Electrics Control Systems Power Management System (PMS)
Power Management System (PMS) Update PMS Settings 1
Fit reflective tape A onto the pulley on the front of the engine.
A
C Fig 5. 4
Remove blanking plug C and fit a horn button D to the connector.
Fig 3. 2
Fit T piece and test point B to the excavator pressure valve. Once installed fit a pressure guage to the test point.
D
B
Fig 6. 5
Rotate the PMS switch fully clockwise.
6
Hold down the red horn button D, turn on the ignition until the red light E on the instrument panel flashes, then release the button.
Fig 4. 3
Where the fuses are fitted find the plug C with 2 wires No. 508/144C.
C-51
9803/9960-3
C-51
Section C - Electrics Control Systems Power Management System (PMS)
E F
Fig 7. 7
Start the engine and using a tachometer take readings from the pulley with the reflected tape fitted. Increase revs up to 2460 rpm. At the same time check the pressure guage fitted at B. Rotate the PMS switch counter clockwise. When 10 bar is achieved press the red horn button D.
15
Check to see if the PMS is working.
16
Rotate the PMS switch fully counter clockwise. Hold revs on full flight and using the pressure guage the reading should be showing 20 bar.
17
Continue to hold revs on full flight and rotate the PMS switch fully clockwise. The pressure guage should read 10 bar.
18
With the PMS switch fully clockwise and the revs on full flightt slowly rotate the PMS switch counter clockwise. Check the pressure guage at the same time. The pressure should slowly rise from 10 bar, up to 20 bar when the switch is fully counter clockwise.
19
Once the test is complete remove the pressure guage fitted at test point B.
9803/9960-3
C-52
8
Rotate the PMS switch fully clockwise.
9
Using a tachometer take readings from the pulley with the reflected tape fitted. Increase revs up to 3440 rpm. At the same time check the pressure guage fitted at B. Rotate the PMS switch counter clockwise. When 20 bar is achieved press the red horn button D.
10
Rotate the PMS switch fully clockwise.
11
Using a tachometer take readings from the pulley with the reflected tape fitted. Maintain revs at 3440 rpm. At the same time check the pressure guage fitted at B. Rotate the PMS switch counter clockwise. When 10 bar is achieved press the red horn button D.
12
Stop the engine and leave the ignition off for at least 5 seconds. The PMS is now set.
13
Remove red horn button D and refit the blanking plug C.
14
Remove loop wire F and fit a blanking plug. Silicone grease must be used to form a watertight fit.
C-52
Fig 8.
Section C - Electrics Control Systems Fault Finding
Fault Finding Auxiliary System Faults
A
Auxiliary services not working (in both directions):
B
– 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. K Table 1. Aux Fault Blink Codes ( T C-53) – CT4/CT5 Failed. K Fig 9. ( T C-53)
Check
Blink
code.
– Auxiliary ECU fault.
C
Auxiliary services work in ONE direction only:
D E
A blink code will be generated when the Thumb-stick is moved in the non-operating direction. Fig 9. Combi-Valve – CT4/CT5 Failed. K Fig 9. ( T C-53)
Check
Blink
code.
– Auxiliary ECU fault. Note: Thumb-stick 'centre position' voltage should be in the range - 2.3V to 2.7V.
Blink Code
Fault Code
A
CT2 Brake Solenoid
B
CT1 Servo Isolator (feeds loader joystick pilot)
C
CT5 Aux Solenoid
D
CT4 Aux Solenoid
E
CT3 PMS Solenoid / Transmission
Table 1. Aux Fault Blink Codes Description Test Method
Comments
1
1 Long Flash 1 Joystick thumb wheel not in Short Flash centre position
Held thumb wheel out of position
Fault code correct
2
1 Long Flash 2 Joystick thumb wheel High or Short Flashes Low reading
Short pin 5 to pin 7 of thumb wheel
Fault code correct for low, does not work for high (flashes code 3)
3
1 Long Flash 3 Aux 5V supply High value Short Flashes
12V to pin B of voltage reg
Fault code correct
4
1 Long Flash 4 Right solenoid open circuit Short Flashes
Solenoid 1 open circuit
Solenoid 1 = CT5 fault code correct
5
1 Long Flash 5 Right solenoid short or over Short Flashes temperature
Solenoid 1 short circuit
Fault code correct
6
1 Long Flash 6 Left solenoid short or over Short Flashes temperature
Solenoid 2 = CT4 short
Fault code correct
C-53
9803/9960-3
C-53
Section C - Electrics Control Systems Fault Finding
Power Management System Faults
Hydraulic pressure adjusts throughout setting procedure but settings are not stored on completion:
Hydraulic pressure will not adjust during setting procedure: – Faulty PMS control switch. – PMS solenoid valve failure (CT3). K Table 2. PMS Fault Blink Codes ( T C-54)
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.
– Main PMS ECU fault.
Blink Code
Fault Code
Table 2. PMS Fault Blink Codes Description Test Method
1
1 Long Flash 1 Signal from alternator W Short Flash terminal absent or incorrect
2
1 Long Flash 2 Sensitivity control not working / Disconnect twist pot Short Flashes fitted (torque screw)
Fault code correct
3
1 Long Flash 3 Dump valve solenoid short Short Flashes circuit
Short to earth
Fault code does not work
4
1 Long Flash 4 Dump valve solenoid open Short Flashes circuit
Disconnect
Fault code correct
C-54
Remove W terminal
Comments
9803/9960-3
Fault code permanently on
C-54
Section E Hydraulics Service Manual - 1CX Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section J - Tracks Section K - Engine
Publication No.
9803/9960-3
World Class Customer Support Copyright Š 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section E - Hydraulics
Notes:
E-0
9803/9960-3
E-0
Section E - Hydraulics Contents
Contents Page No. Technical Data Up to machine number 752462 ................................................................ E-1 From machine number 752463 ................................................................ E-4 General Connecting/Disconnecting Hydraulic Hoses ............................................. E-7 Introduction ........................................................................................... E-7 Releasing the Hydraulic Pressure ........................................................ E-7 Hydraulic Contamination .......................................................................... E-8 Hydraulic Fluid Quality ......................................................................... E-8 Effects of Contamination ...................................................................... E-8 Cleaning Operation .............................................................................. E-8 Contaminant Standards ........................................................................ E-9 Filters .................................................................................................... E-9 Operation General Description up to machine no. 752462 ...................................... E-11 Machine Neutral Circuit .......................................................................E-11 General Description from machine no. 752463 ...................................... E-13 Machine Neutral Circuit ...................................................................... E-13 Auxiliary Pump ........................................................................................ E-15 Loader Valve ........................................................................................... E-16 Neutral Circuit ..................................................................................... E-16 Lift Ram Operation 1 .......................................................................... E-17 Lift Ram Operation 2 .......................................................................... E-18 Crowd Ram Operation ........................................................................ E-19 Relief Valve Operation ........................................................................ E-20 Excavator Valve ...................................................................................... E-21 Neutral Circuit ..................................................................................... E-21 Operation ............................................................................................ E-22 Excavator Valve - Bi-Restrictor Operation .......................................... E-23 Slew Operation ................................................................................... E-24 Slew A.R.V. and Anti-Cavitation Operation ........................................ E-25 A.R.V. Operation ................................................................................. E-26 A.R.V. Pressure Relief Operation ....................................................... E-27 Pressure Reducing Solenoid Valve ........................................................ E-28 From machine no. 751600 ................................................................. E-28 Drive Motor ............................................................................................. E-30 Transmission in Neutral .......................................................................... E-32 Transmission in Forward Drive ............................................................... E-34 Schematic Circuits Standard Machines - Single Lever Drive Control .................................... E-37 From Machine no. 751012 to 752462 ................................................ E-37 From Machine no. 752463 ................................................................. E-39 Standard Machines - Dual Lever Drive Control ...................................... E-41 From Machine no. 751012 to 752462 ................................................ E-41 From Machine no. 752463 ................................................................. E-43 High Flow Machines - Single Lever Drive Control .................................. E-45 From Machine no. 751012 to 752462 ................................................ E-45 From Machine no. 752463 ................................................................. E-47 High Flow Machines - Dual Lever Drive Control ..................................... E-49 From Machine no. 751012 to 752462 ................................................ E-49 From Machine no. 752463 ................................................................. E-51
E-i
E-i
Section E - Hydraulics Contents
Contents Page No. Series 2 Machines from SN 1743570 ..................................................... E-53 ISO Machines ..................................................................................... E-53 ISO / SAE Changeover Circuit ........................................................... E-56 SAE Machines .................................................................................... E-58 Optional Hand Tool Circuit ...................................................................... E-61 Description ......................................................................................... E-61 Fault Finding Hydrostatic Transmission ....................................................................... E-63 Machine veers to one side when travelling ........................................ E-65 Loader Circuit ......................................................................................... E-66 Pressure Testing Main Relief Valve (M.R.V.) - In Situ ........................................................ E-69 Torque Settings .................................................................................. E-69 Auxiliary Relief Valve (A.R.V.'s) - Using Hand Pump .............................. E-71 Torque Settings .................................................................................. E-71 Check Valve ............................................................................................ E-72 Pressure Reducing Valve Cartridge ....................................................... E-73 Charge Pressure Checking and Adjustment .......................................... E-74 Pumps Removal and Replacement .................................................................... E-77 Removal ............................................................................................. E-77 Replacement ...................................................................................... E-78 Pump/Engine Coupling ........................................................................... E-79 Start-up Procedure ................................................................................. E-80 Hydrostatic Pump from machine no. 751012 ......................................... E-82 Dismantling and Assembly ................................................................. E-82 Shaft Seal ........................................................................................... E-82 Charge Check and High Pressure Relief Valves ................................ E-83 Charge/Anti-stall Valve ....................................................................... E-84 Pump Neutral Adjustment .................................................................. E-85 Auxiliary Pump (Standard machines) ..................................................... E-87 Removal and Replacement ................................................................ E-87 Dismantling and Assembly ................................................................. E-87 Auxiliary Pump (High-flow machines) ..................................................... E-89 Dismantling and Assembly ................................................................. E-89 Valves (Series 1 Machines) Loader Valve ........................................................................................... E-91 Removal ............................................................................................. E-91 Replacement ...................................................................................... E-92 Dismantling and Assembly ................................................................. E-93 Main Relief Valve and Auxiliary Relief Valves .................................... E-95 Excavator Valve ...................................................................................... E-96 Dismantling and Assembly ................................................................. E-97 Pressure Reducing Solenoid Valve (to serial no. 752462) ................... E-100 Removal ........................................................................................... E-100 Replacament .................................................................................... E-100 Dismantling ....................................................................................... E-100 Assembly .......................................................................................... E-101 Brake Valve from serial no. 752463 ...................................................... E-102 Dismantling ....................................................................................... E-102 Assembly .......................................................................................... E-102
E-ii
E-ii
Section E - Hydraulics Contents
Contents Page No. Valves (Series 2 Machines) Main Servo Valve Block (10 Spool) ...................................................... E-103 Description ....................................................................................... E-103 Removal ........................................................................................... E-108 Replacement .................................................................................... E-108 Loader Changeover Valve .................................................................... E-109 Description ....................................................................................... E-109 Removal ............................................................................................ E-111 Replacement ..................................................................................... E-111 Transmission Changeover Valve ........................................................... E-112 Description ........................................................................................E-112 Removal ............................................................................................E-114 Replacement .....................................................................................E-114 PMS Combination Valve ........................................................................ E-115 Description ........................................................................................E-115 Removal ............................................................................................E-118 Replacement .....................................................................................E-118 ISO/SAE Changeover Valve .................................................................. E-119 Description ........................................................................................E-119 Removal ........................................................................................... E-121 Replacement .................................................................................... E-121 Solenoid Valve ...................................................................................... E-122 Description ....................................................................................... E-122 Removal ........................................................................................... E-123 Replacement .................................................................................... E-123 Drive Motors Removal and Replacement .................................................................. E-125 Removal of the Drive Sprocket ......................................................... E-125 Removal of Motor ............................................................................. E-126 Replacement .................................................................................... E-126 Dismantling and Assembly to machine no. 751011 .............................. E-128 Dismantling ....................................................................................... E-128 Assembly .......................................................................................... E-128 Dismantling and Assembly from machine no. 751012 to 807172 ........ E-131 Dismantling ....................................................................................... E-132 Assembly .......................................................................................... E-132 Later Type Motor with Twin Bearing Output Shaft. ........................... E-133 Dismantling and Assembly from machine number 807173 .................. E-135 Dismantling ....................................................................................... E-136 Assembly .......................................................................................... E-136 Servo Joysticks All Joysticks .......................................................................................... E-139 Removal and Replacement .............................................................. E-139 Joystick up to machine number 807146 ............................................... E-140 Dismantling ....................................................................................... E-141 Assembly .......................................................................................... E-141 Joystick from machine number 807147 ................................................ E-143 Dismantling ....................................................................................... E-144 Assembly .......................................................................................... E-144 Servo Joystick from machine number 1743153 ................................... E-145 Dismantling ....................................................................................... E-147
E-iii
E-iii
Section E - Hydraulics Contents
Contents Page No. Rams Typical Ram (with dowelled piston head) ............................................. E-148 Dismantling and Assembly ............................................................... E-149 Slew Cylinder ........................................................................................ E-153 Re-seal ............................................................................................. E-153 Filling Procedure .............................................................................. E-154 Filtration Suction Strainer .................................................................................... E-156 Return Filter .......................................................................................... E-157 Removal and Replacement .............................................................. E-157 Hand Held Tool Circuit Assembly .............................................................................................. E-159
E-iv
E-iv
Section E - Hydraulics
Technical Data Up to machine number 752462 Note: System Cleanliness is to be to ISO 16/13 Auxiliary Pump - Standard Type
Gear
Displacement
48 l/min (10.5 UK gal/min, 12.7 US gal/min) at 3000 rev/ min
Maximum Working Pressure
185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2)
Maximum Speed
3200 rpm
Maximum Input Torque
121 Nm (89 lbf ft, 12 kgf m)
Auxiliary Pump - High Flow Type
Tandem Gear
Displacement - Front Section
90 l/min (19.8 UK gal/min, 23.8 US gal/min) at 3600 rev/ min
Displacement - Rear Section
57 l/min (12.5 UK gal/min, 15 US gal/min) at 3600 rev/ min
Maximum Working Pressure
185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2)
Maximum Speed
3600 rpm
Maximum Input Torque
121 Nm (89 lbf ft, 12 kgf m)
Main Pump (2 off) Type
Tandem axial piston Series 42 M28
Displacement
28 cc/rev (1.71 in3/rev)
Control
Servo non-feedback proportional, 15 bar (218 lbf/in2) to give max pump displacement.
Maximum Working Pressure
350 bar (5076 lbf/in2)
Maximum Speed
3900 rpm
Charge Pressure (oil temperature at 50° C)
7.5 bar (109 lb/in2) at engine idle; 19.5 bar (283 lb/in2) at 3000 rev/min
Servo Joysticks Output Characteristics - Transmission control spools
5 bar (72 lb/in2) at 15% stroke. 15 bar (217.5 lb/in2) at 95% stroke.
Output Characteristics - Loader control spools
3.3 - 3.7 bar (48 - 53 lb/in2) at 15% stroke. 14.5 - 16.5 bar (210 - 239 lb/in2) at 95% stroke.
E-1
9803/9960-3
E-1
Section E - Hydraulics Technical Data Up to machine number 752462 Hydraulic Motors Type
MCR03
Displacement
328 cc/rev (20 in3/rev)
Maximum Working Pressure
414 bar (6000 lbf/in2) continuous
Maximum Speed
237 rpm continuous
Maximum Flow
84 l/min (18.5 UK gal/min, 24 US gal/min) continuous
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) at 1500 rev/min
207
211
3006
Shovel Crowd
235
240
3410
Shovel Dump
100-103
102-105
1450-1494
Lift Ram Raise
235
240
3410
241
246
3500
Auxiliary Relief Valves (A.R.V.) Loader
Excavator Slew Rams Boom Raise
241
246
3500
Boom Lower
241
246
3500
Dipper In
241
246
3500
Dipper Out
241
246
3500
Bucket Crowd
241
246
3500
Bucket Dump
241
246
3500
Auxiliary Spool (optional) - both ports (see note)
241
246
3500
138
141
2001
Optional Hand Tool Circuit Note: The return line auxiliary A.R.V. should be set to zero when a Rockbreaker is fitted (Refer to Technical
Information 1/011). The A.R.V. must be returned to the correct setting when the Rockbreaker is removed.
Pressure Reducing Solenoid Valve Maximum Inlet Pressure
207 Bar (3006 lbf/in2), 211 kgf/cm2)
Regulated Pressure
24 Bar (348 lbf/in2), 24.47 kgf/cm2)
Minimum Rated Flow
10 l/min (2.2 UK gal/min, 2.64 US gal/min)
Maximum Leakage
25 cc/min (1.52 in3/min) at 210 Bar (3045 lbf/in2) and 10 cSt
Oil Temperature Range
- 40 °C to +106 °C
Solenoid Valve (including Diodes)
3 Position, 3 Port Cartridge Valve
Reducing Valve
Cartridge Type
Electrics
12 Volt
E-2
9803/9960-3
E-2
Section E - Hydraulics Technical Data Up to machine number 752462 Filter Type
High Pressure Spin On - 5 micron
Suction Strainer
125 micron
Rams
Bore
Rod Dia
Stroke
mm
in
mm
in
mm
in
Lift
(60 x 30)
60
2.36
30
1.18
500
19.69
Shovel
(60 x 30)
60
2.36
30
1.18
500
19.69
Boom
(70 x 40)
70
2.75
40
1.57
600
23.62
Dipper
(70 x 40)
70
2.75
40
1.57
500
19.69
Bucket
(70 x 40) (Long and Short Dipper)
70
2.75
40
1.57
400
15.75
Stabilizer
(60 x 30)
60
2.36
30
1.18
500
19.69
Extending Dipper
(50 x 25)
50
1.97
25
0.98
530
20.87
Ram Torque Settings
Nm
lbf ft
Kgf m
Lift Rams
300
222
30.7
Shovel Rams (Crowd)
300
222
30.7
Boom Ram
405
300
41.5
Stabiliser Rams
300
222
30.7
Dipper Ram
405
300
41.5
Bucket Ram
405
300
41.5
Extending Dipper Ram
405
300
41.5
Lift Rams
450
332
45.9
Shovel Rams (Crowd)
450
332
45.9
Boom Ram
678
500
69.2
Stabiliser Rams
450
332
45.9
Dipper Ram
678
500
69.2
Bucket Ram
678
500
69.2
Extending Dipper Ram
500
369
51.2
Piston Head
End Cap
E-3
9803/9960-3
E-3
Section E - Hydraulics Technical Data From machine number 752463
From machine number 752463 Note: System Cleanliness is to be to ISO 16/13 Auxiliary Pump - Standard Type
Gear
Displacement
48 l/min (10.5 UK gal/min, 12.7 US gal/min) at 3000 rev/ min
Maximum Working Pressure
185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2)
Maximum Speed
3200 rpm
Maximum Input Torque
121 Nm (89 lbf ft, 12 kgf m)
Auxiliary Pump - High Flow Type
Tandem Gear
Displacement - Front Section
90 l/min (19.8 UK gal/min, 23.8 US gal/min) at 3600 rev/ min
Displacement - Rear Section
57 l/min (12.5 UK gal/min, 15 US gal/min) at 3600 rev/ min
Maximum Working Pressure
185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2)
Maximum Speed
3600 rpm
Maximum Input Torque
121 Nm (89 lbf ft, 12 kgf m)
Main Pump (2 off) Type
Tandem axial piston Series 42 M28
Displacement
28 cc/rev (1.71 in3/rev)
Control
Servo non-feedback proportional, 15 bar (218 lbf/in2) to give max pump displacement.
Maximum Working Pressure
350 bar (5076 lbf/in2)
Maximum Speed
3900 rpm
Charge Pressure (oil temperature at 50° C) up to machine number 807734
7.5 bar (109 lb/in2) at engine idle; 19.5 bar (283 lb/in2) at 3000 rev/min
Note: Earlier machines may be adjusted to the higher pressure if there is a requirement to raise the lift arms at engine idle. Charge Pressure (oil temperature at 50° C) from machine number 807735
11.5 bar (167 lb/in2) at engine idle; 23.5 - 24 bar (340 348 lb/in2) at 3000 rev/min
Servo Joysticks up to machine no. 807146 Output Characteristics - Transmission control spools
5 bar (72 lb/in2) at 15% stroke. 15 bar (217.5 lb/in2) at 95% stroke.
Output Characteristics - Loader control spools
3.3 - 3.7 bar (48 - 53 lb/in2) at 15% stroke. 14.5 - 16.5 bar (210 - 239 lb/in2) at 95% stroke.
E-4
9803/9960-3
E-4
Section E - Hydraulics Technical Data From machine number 752463 Servo Joysticks from machine no. 807147 Output Characteristics - Single Lever Drive Control Transmission for/rev (spools 2 & 4)
3.5 bar (51 lb/in2) at 15% stroke.
Transmission left/right (spools 1 & 3)
5.5 bar (80 lb/in2) at 15% stroke.
Loader
3.5 bar (51 lb/in2) at 15% stroke.
Output Characteristics- Dual Lever Drive Control Transmission control spools
5.5 bar (80 lb/in2) at 15% stroke.
Loader control spools
3.5 bar (51 lb/in2) at 15% stroke.
Hydraulic Motors Type
MCR03
Displacement
328 cc/rev (20 in3/rev)
Maximum Working Pressure
414 bar (6000 lbf/in2) continuous
Maximum Speed
237 rpm continuous
Maximum Flow
84 l/min (18.5 UK gal/min, 24 US gal/min) continuous
Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) at 1500 rev/min
207
211
3006
Auxiliary Relief Valves (A.R.V.) Loader Shovel Crowd
235
240
3410
Shovel Dump
100-103
102-105
1450-1494
Lift Ram Raise
235
240
3410
Excavator Slew Rams
241
246
3500
Boom Raise
241
246
3500
Boom Lower
241
246
3500
Dipper In
241
246
3500
Dipper Out
241
246
3500
Bucket Crowd
241
246
3500
Bucket Dump
241
246
3500
Auxiliary Spool (optional) - both ports (see note)
241
246
3500
138
141
2001
Optional Hand Tool Circuit Note: The return line auxiliary A.R.V. should be set to zero when a Rockbreaker is fitted (Refer to Technical Information 1/011). The A.R.V. must be returned to the correct setting when the Rockbreaker is removed.
E-5
9803/9960-3
E-5
Section E - Hydraulics Technical Data From machine number 752463 Solenoid Brake Valve Type
3 position, 4 way Directional Control
Electrics
12 Volt
Filter Type
High Pressure Spin On - 5 micron
Suction Strainer
125 micron
Rams
Bore
Rod Dia
Stroke
mm
in
mm
in
mm
in
Lift
(60 x 30)
60
2.36
30
1.18
500
19.69
Shovel
(60 x 30)
60
2.36
30
1.18
500
19.69
Boom
(70 x 40)
70
2.75
40
1.57
600
23.62
Dipper
(70 x 40)
70
2.75
40
1.57
500
19.69
Bucket
(70 x 40) (Long and Short Dipper)
70
2.75
40
1.57
400
15.75
Stabilizer
(60 x 30)
60
2.36
30
1.18
500
19.69
Ram Torque Settings
Nm
lbf ft
Kgf m
Lift Rams
300
222
30.7
Shovel Rams (Crowd)
300
222
30.7
Piston Head
6 in 1 Shovel
405
300
41.5
Boom Ram
405
300
41.5
Stabiliser Rams
300
222
30.7
Dipper Ram
405
300
41.5
Bucket Ram
405
300
41.5
Lift Rams
450
332
45.9
Shovel Rams (Crowd)
450
332
45.9
End Cap
E-6
6 in 1 Shovel
678
500
69.2
Boom Ram
678
500
69.2
Stabiliser Rams
450
332
45.9
Dipper Ram
678
500
69.2
Bucket Ram
678
500
69.2
9803/9960-3
E-6
Section E - Hydraulics
General Connecting/Disconnecting Hydraulic Hoses
!MCAUTION
Introduction
!MWARNING The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools (less than 40°C) before beginning maintenance. 8-3-4-10
!MWARNING 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 protective glasses and gloves. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. INT-3-1-10_3
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 fit 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. INT-3-3-12
Releasing the Hydraulic Pressure 1
Make the machine safe. Refer to Prepare the Machine for Maintenance, Section 3.
2
Operate the controls to remove the hydraulic pressure from the service hose lines.
!MWARNING
a
Hydraulic Pressure 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. INT-3-1-11_2
!MCAUTION
3
For manually operated services, operate the controls (several times) of the service to be disconnected.
Clean the top of the tank around the filler cap.
!MCAUTION Allow the hydraulic fluid temperature to cool before removing the hydraulic tank filler cap. Open the cap slowly to prevent oil being forced out of the filler neck. 5-3-4-8
!MCAUTION
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.
Do not run the engine with the hydraulic tank filler cap removed.
2-3-5-1_2
5-3-4-1
E-7
4
Slowly remove filler cap to allow the system to vent fully and prevent oil being forced out of the filler neck.
5
Check that the seal in good condition and correctly installed in the cap. Replace if necessary.
9803/9960-3
E-7
Section E - Hydraulics General Hydraulic Contamination
Hydraulic Contamination TE-002_3
Hydraulic Fluid Quality
Procedure
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.
Connect the cleaning unit in place of the hydraulic filter. K Fig 1. ( T E-8). Run the system for sufficient time to pump all the hydraulic fluid through the unit. Disconnect the cleaning unit and reconnect the filter. Top up the system with clean hydraulic fluid as required.
Effects of Contamination Once inside the system, hydraulic circuit contaminants greatly effect 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 and leakage and can lead to major problems.The main contaminants can be classified as follows: 1
Solid Particles - sand, fibres, metallic particles, welding scale, sealing materials and wear particles etc.
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.
S168050-1
Fig 1. Cleaning Unit
These contaminants can appear during manufacture, assembly and operation.
Cleaning Operation The purpose of cleaning oil is to remove contaminants of all types and sludge by filtering hydraulic fluid through a cleaning unit. K Fig 1. ( T E-8). General Bulletin 011 also refers.
E-8
9803/9960-3
E-8
Section E - Hydraulics General Hydraulic Contamination
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: â&#x20AC;&#x201C; Red Blood Cell = 8 microns (0.008 mm, 0.000315 in) â&#x20AC;&#x201C; Human Hair = 70 microns (0.07 mm, 0.00275 in) â&#x20AC;&#x201C; Grain of Salt = 100 microns (0.1 mm, 0.00394 in) 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.
Filters The filter assembly fitted to all product ranges is designed to filter all the contamination that is generated through use to the required level of cleanliness. The filter must be serviced to the requirements of the machine Service Schedules. To ensure optimum performance and reliability it is important that the machines hydraulic system is serviced periodically in accordance with the manufacturers requirements.
E-9
9803/9960-3
E-9
Section E - Hydraulics General Hydraulic Contamination
Page left intentionally blank
E-10
9803/9960-3
E-10
Section E - Hydraulics
Operation General Description up to machine no. 752462 The main components of the hydraulic circuit are the tank, pumps, drive motors, the servo operated loader and drive control circuits, the manually operated excavator valves, filters, cooler, rams and pressure reducing solenoid valve. The pumps are driven by the engine and are mounted in tandem. They deliver pressurised oil to the valves and motors.
If valve 9 is energised, oil is permitted to flow to the loader control valve 2. After passing through the loader valve, the oil flows through the excavator valve 4 and then via the filter F1 to the main pumps P1 and P2. Oil from P1 and P2 is returned via the cooler C to the tank T. Valve 9 also allows the transmission brakes to be manually applied.
The valves are operated by either a servo joystick in the case of the loader or drive circuits, or a manual control lever for the excavator circuit. 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 ram's piston along the bore of the 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 circuitry) is designed to both limit the pressure in the circuit and act as a safety device. The safety function ensures 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 K Fig 1. ( T E-12) This description should also be read in conjunction with the the Schematic Circuits. K Schematic Circuits ( T E-37) Oil is drawn from the tank T by the auxiliary pump P3 via a suction strainer S1. The pump P3 delivers pressurised oil to the pressure reducing solenoid valve 9 and, providing that solenoid valve 9 is in the energised position, to the loader control valve 2. In the de-energised position, valve 9 returns the oil to the hydraulic tank. This ensures that there is insufficient pressure available to operate the 5 bar check valve 3.
E-11
9803/9960-3
E-11
Section E - Hydraulics Operation General Description up to machine no. 752462
204361-B1
Fig 1. K ( T E-11)
E-12
9803/9960-3
E-12
Section E - Hydraulics Operation General Description from machine no. 752463
General Description from machine no. 752463 The main components of the hydraulic circuit are the tank, pumps, drive motors, the servo operated loader and drive control circuits, the manually operated excavator valves, filters, cooler, rams and solenoid brake valve. The pumps are driven by the engine and are mounted in tandem. They deliver pressurised oil to the valves and motors. The valves are operated by either a servo joystick in the case of the loader or drive circuits, or a manual control lever for the excavator circuit. 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 ram's piston along the bore of the ram or operates the pump servo controls, which changes the flow direction to the motors and hence the direction of rotation. 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 ensures 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 K Fig 2. ( T E-14) This description should also be read in conjunction with the the Schematic Circuits. K Schematic Circuits ( T E-37) Oil is drawn from the tank T by the auxiliary pump P3 via a suction strainer S1. The pump P3 delivers pressurised oil via non return valve 3 to the loader control valve 2. Oil flows through the loader valve and onto the excavator valve 4 then via the filter F1 to the main pumps P1 and P2. Oil from P1 and P2 is returned via the cooler C to the tank T. The oil feed for the servo controls is taken from the main pump charge circuit via the solenoid brake valve 9. The solenoid brake valve 9 acts as a safety device by preventing the oil supply to the loader and transmission servo controls until the operator is seated correctly and the door properly closed and latched. The brake valve also allows the transmission brakes to be manually applied.
E-13
9803/9960-3
E-13
Section E - Hydraulics Operation General Description from machine no. 752463
316840-B1
Fig 2. K ( T E-13)
E-14
9803/9960-3
E-14
E-15
9803/9960-3
Some oil is allowed to circulate behind the bearings C to hold them against the gears and minimise oil
The auxiliary pump is a gear type pump. The working principle of a gear pump depends on the meshing of two spur gears A and B. Oil is picked up on the suction side of the pump by the gears and 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.
slippage. Lubrication oil is drawn through the recess D and around the counter bore. The oil then flows along the scrolled grooves E in the bushes, induced by the viscous drag of the rotating shaft.
Fig 3.
Auxiliary Pump
C072110
Section E - Hydraulics Operation
Auxiliary Pump
E-15
E-16
Oil from the pump enters the valve at 1. When all the spools are in the neutral position as shown, the oil passes around the waisted central position of the spools and flows on to feed the excavator valve via outlet line 2. Oil trapped in the lines prevents movement of the rams. Oil also fills the parallel gallery X.
Neutral Circuit Auxiliary spool Main relief valve Auxiliary relief valves Outlet to tank (via filter)
5 6 7 8
Loader valve block Inlet Outlet to excavator valve block Crowd spool Lift spool
A 1 2 3 4
Fig 4.
Component Key
Component Key
Loader Valve
205110-B1
Section E - Hydraulics Operation
Loader Valve
9803/9960-3
E-16
E-17
9803/9960-3
The load hold check valve Y is a spring-loaded nonreturn valve operating across the pressure feed from the parallel gallery X. It prevents reverse flow from the rams into the pressure feed line, so maintaining ram
Initially, the weight of the loaded shovel, as indicated by the arrows, causes a higher pressure in the service line than in the parallel gallery X. This pressure differential causes the load hold check valve Y to close.
The illustration shows `Loader Arm Raise' being selected by the lift ram spool 1. K Fig 5. ( T E-17)
Lift Ram Operation 1
pressure until exceeded by system pressure, thus preventing the load from dropping.
Fig 5.
C072120
Section E - Hydraulics Operation
Loader Valve
E-17
E-18
9803/9960-3
At this point, the load hold check valve opens, allowing oil to flow from the parallel gallery into the service line and operate the lift ram 2 and so raise the loader arms. As the arms rise, oil from the other side of the ram returns to the exhaust line via the control valve and returns to tank.
As the neutral circuit has been blocked by the central lands of the selected spool 1, the pressure in parallel gallery X increases until it is greater than that in the service line.
Lift Ram Operation 2
`Loader Arm Lower' is a reverse of the above procedure.
Should the pressure in the feed line rise above the set pressure, the auxiliary relief valve will lift and dump pressure to tank.
Fig 6.
C072130
Section E - Hydraulics Operation
Loader Valve
E-18
E-19
9803/9960-3
The crowd spool operates, and is controlled by a load hold check valve, in a similar manner to that described for the lift spool. When the crowd spool 1 is selected for lift, pressure acts on the crowd ram piston 2 and the shovel 'crowds' or lifts. Oil from the other side of the ram returns to the exhaust line via the control valve.
Shovel Lift (Crowd)
Crowd Ram Operation
This is the reverse of the Shovel Lift procedure.
Shovel Open
Both feed and return lines are protected from overpressure by auxiliary relief valves.
Fig 7.
C072140
Section E - Hydraulics Operation
Loader Valve
E-19
Section E - Hydraulics Operation Loader Valve
Relief Valve Operation
C072180
Fig 8.
Main Relief Valve The main relief valve (M.R.V.) 6 is situated in the loader valve block. K Fig 4. ( T E-16) It provides control of both loader and excavator pressures.
Oil continues to escape from the cavity E but the incoming flow to the cavity has been cut off. This produces a pressure drop above poppet G, causing the poppet to lift and release service pressure into the exhaust gallery D.
Auxiliary Relief Valve View X As service pressure reaches the pilot setting of the valve, pilot poppet A lifts, allowing oil to escape into cavity B and pass down the sides of sleeve C into the exhaust gallery D.
The auxiliary relief valves work in exactly the same manner as the main relief valve although the operating pressures are different.
View Y. As service pressure continues to rise and oil escapes from cavity E, the pressure differential between the upper and lower surfaces of piston F causes this piston to rise and seat on the point of pilot poppet A.
E-20
9803/9960-3
E-20
E-21
9803/9960-3
Stabiliser Spool
Stabiliser Spool
Dipper Spool
Bucket Spool
4C
4D
4E
4F
Auxiliary Spool
Boom Spool
4B
4G
Slew Spool
4A
Component Key (JCB 'X' Control Pattern)
Neutral Circuit
Oil from the loader valve enters the excavator valve at A and flows through the neutral gallery and around the waists of the solid spools. It also fills the parallel gallery X but is not at a high enough pressure to open the load hold check valves B.
Fig 9. Note: Machines with ISO control pattern have the boom and dipper spools interchanged.
Excavator Valve
C072150
Section E - Hydraulics Operation
Excavator Valve
E-21
Section E - Hydraulics Operation Excavator Valve
Operation
C072160
Fig 10. The excavator services all operate in a similar manner. The boom service is shown as an example. When the boom spool 4B is selected for lift, initially back pressure exceeds system pressure which closes the load hold check valve Y. When pressure in the feed line exceeds back pressure, the load check valve Y opens and oil is allowed to flow to the boom ram piston, as shown, and the pressure causes the boom ram to lift. Oil from the other side of the piston returns to the exhaust line via the control valve. The remaining load hold check valves are also opened by system pressure 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.
E-22
9803/9960-3
E-22
Section E - Hydraulics Operation Excavator Valve
Excavator Valve - Bi-Restrictor Operation
C072170
Fig 11. Because of its weight, the excavator end could take over control when boom lower was selected. The falling boom would tend to push oil out of the ram faster than the head side was being filled. Consequently, when the excavator had reached the ground, there would be a time lapse while the ram filled with oil before the service would operate again. To prevent this from happening, the boom service is fitted with bi-restrictor E.
E-23
9803/9960-3
E-23
Section E - Hydraulics Operation Excavator Valve
Slew Operation
C072190
Fig 12. The illustration shows right hand slew selected. The lower port C has been pressurised by the spool. Oil flows from the parallel gallery X, out past A.R.V. 4K to the left hand side of the slew actuator. The boom therefore slews to the right as seen from the operators viewpoint. Displaced oil from the right hand side of the slew actuator flows back through the upper service port D and back to tank. When the actuator is approaching the end of its travel, the damper piston P contacts the end of the slew pot and is pushed into the slew rack. This causes the flow of oil to be restricted, so slowing down the slew action.
E-24
9803/9960-3
E-24
Section E - Hydraulics Operation Excavator Valve
Slew A.R.V. and Anti-Cavitation Operation
C072200
Fig 13. The spool 4A is in neutral but the momentum of the slewing excavator end creates back pressure in the right hand slew cylinder. This opens A.R.V. 4J and dumps oil to exhaust. At this point the left hand slew cylinder cavitates and exhaust oil pressure causes A.R.V. 4K to open, allowing oil from the exhaust gallery to fill the left hand cylinder.
E-25
9803/9960-3
E-25
E-26
The illustration shows the bucket spool 4F selected to operate the service against an immovable object. K Fig 14. ( T E-26) This forces the dipper away from the obstruction and pressurises the head side of the dipper ram.
A.R.V. Operation
9803/9960-3
When this pressure reaches the setting of A.R.V. 4P, this valve opens, relieving the pressure into the exhaust gallery. Cavitation occurs in the rod side of the dipper service. K A.R.V. Pressure Relief Operation ( T E-27)
Fig 14.
C072210
Section E - Hydraulics Operation
Excavator Valve
E-26
Section E - Hydraulics Operation Excavator Valve
A.R.V. Pressure Relief Operation
C072220
Fig 15.
1 Valve at Rest
2 Pilot Valve Opens
A.R.V's are positioned in the excavator valve block in order to relieve excessive pressure in the services. K A.R.V. Operation ( T E-26)
As service pressure reaches the pilot setting of the valve, pilot poppet E lifts, allowing oil to escape into cavity H and pass down the sides of sleeve J into the exhaust gallery K.
When the service is in neutral and there are no excessive forces acting on the equipment, service pressure at A will be acting on the lower face of poppet B and will also be felt inside the valve via hollow piston C.
3 Main Poppet Opens
The force of springs D and F, combined with the service pressure acting on the upper faces of poppet B and piston C, keeps poppets B and E tightly seated. The force of spring F is adjustable to suit the relevant service by means of adjuster screw and locknut G.
E-27
As service pressure continues to rise and oil escapes from cavity L, the pressure differential between the upper and lower surfaces of piston C causes this piston to rise and seat on the point of pilot poppet E. Oil continues to escape from cavity L but the incoming flow to the cavity has been cut off. This produces a pressure drop above poppet B, causing the poppet to lift and release service pressure into exhaust gallery K.
9803/9960-3
E-27
Section E - Hydraulics Operation Pressure Reducing Solenoid Valve
Pressure Reducing Solenoid Valve
A204763-B1
Fig 16.
From machine no. 751600
power via the loader joystick as before, but also pressurising the brake circuit B (brakes OFF).
This valve supplies hydraulic oil at reduced pressure to operate the loader joystick and the automatic parking brake. It is controlled by the seat position switch, the override switch and the park brake switch. It contains a reducing valve cartridge and a 3 position, 3 port cartridge solenoid valve. The relevant sections of the circuits are shown on the illustrations. Hydraulic K Fig 16. ( T E-28). Electrical K Fig 17. ( T E-29)
If the seat is rotated to face the rear of the machine, seat switch 14 opens, de-energising relay 12. Both solenoids 9 and 10 de-energise, and the solenoid valve returns to position X. In this condition, pressure from the auxiliary pump is dumped to tank (brakes ON and no hydraulic pressure available at the loader joystick).
When first entering the machine, assuming the starter switch is OFF, there is no hydraulic pressure as the auxiliary pump is not running and the solenoid valve is in position X as there is no electrical supply.
When the override switch 11 is closed, the seat switch 14 is by-passed allowing the loader to be used with the seat facing rearwards.
If the parking brake is ON (switch 7 in the position shown) and the seat facing forward (seat switch 14 closed), starting the engine energises the isolation relay 12 and solenoid 9, moving the solenoid valve to position Y. In this position the valve directs hydraulic power via the loader joystick A to the loader valve and other circuits, but the brake pressure is still dumped to tank T. Operation of the parking brake switch 7 de-energises solenoid 9 and energises solenoid 10. This causes the solenoid valve to move to position Z, directing hydraulic
E-28
9803/9960-3
E-28
Section E - Hydraulics Operation Pressure Reducing Solenoid Valve Key to Electrical Schematic 7
Parking Brake switch
8
Parking Brake Solenoid
9
Operation Solenoid
10
Parking Brake Solenoid
11
Override Switch
12
Isolation Relay
14
Seat Switch
A204763-B2
Fig 17.
E-29
9803/9960-3
E-29
Section E - Hydraulics Operation Drive Motor
Drive Motor
S167740
Fig 18. K Table 1. Component Key ( T E-31)
E-30
9803/9960-3
E-30
Section E - Hydraulics Operation Drive Motor A
Table 1. Component Key Output Shaft
B
Brake Pack
C
Cardan Shaft
D
Gearwheel Set
E
Valve Drive
F
Disc Valve
When the motors are in reverse mode there is higher pressure in the B port and also through the orifice, so the flow rate is higher in this mode. It is important, when checking the flushing circuit flow, to take the measurement in forward drive only.
Note: On the illustration the main parts of the motor are shown slightly separated for purposes of explanation. K Fig 18. ( T E-30) Basically, this type of motor comprises a gearwheel set D which is connected by a valve drive E to a disc valve F. The gearwheel set consists of a toothed internal gear (the rotating part) and a fixed external gear rim whose 'teeth' are formed by rollers. 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. 423040-B1
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.
Fig 19.
A cardan shaft C connects the inner gear to the output shaft A. Brake pack B comprises a series of alternate friction plates and brake pads. The brake is normally held 'on' by spring force and released by hydraulic pressure. From machine no. 751818, a different type motor is fitted which has a flushing circuit. K Fig 19. ( T E-31) This is used to cool the motors during operation. To save efficiency losses the flushing is taken off through an orifice on the low pressure side of the motor circuit. Although the motors operate in both forward and reverse they are expected to operate in the forward direction for 90% of the time so the flushing is taken off the return line (port B when in forward). This is the normal flushing rate.
E-31
9803/9960-3
E-31
E-32
9803/9960-3
Pressure Relief Valve Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank
Pe M1 M2 S1 T
Filter
Main Pump
Main Pump
Auxiliary Gear Pump
Charge Valve
Pressure Relief Valve
Pressure Relief Valve
F1
P1
P2
P3
Pa
Pb
Pc
8a
8e
4
C
8d 8
P3
2
T
S1
3
A242320
valve 4 and filter F1 to main pumps P1 and P2. A small amount of oil flows through the charge valve Pa, enters the pump casing and is returned via line z to tank T.Oil is also fed from pump P3 to the transmission servo joystick 8 but, because the joystick is not operated, the oil is blocked by the spools 8a, 8b, 8c and 8d and therefore no servo pressure is applied to operate the swash plates of pumps P1 and P2.As the pump swash plates are spring loaded to the neutral position there is no delivery from either pump and the machine remains stationary.The motor brakes x and y are released whenever the engine is running by oil fed through the pressure reducing valve 9.
8b 8c
With the engine running but no drive selected, oil from pump P3 is fed through the loader valve 2, excavator
Pressure Relief Valve
Pd
Fig 20.
Cooler
Pe
y
M2
C
Pd
Pa
P2
z
Key
P1
Pc
11
F1
Key
2X
x
M1
Pb
9
2Y
Transmission in Neutral
Section E - Hydraulics Operation
Transmission in Neutral
E-32
Section E - Hydraulics Operation Transmission in Neutral However the machine is prevented from moving by oil locked up in the pump/motor circuit.
E-33
9803/9960-3
E-33
E-34
9803/9960-3
Tank Loader Valve
T 2
Auxiliary Gear Pump
Charge Valve
Pressure Relief Valve
P3
Pa
Pb
Pressure Test Point
Suction Strainer
S1
Main Pump
P2
2X
Right Hand Drive Motor
M2
Main Pump
P1
Pressure Relief Valve
Left Hand Drive Motor
M1
Filter
F1
Pc
Pressure Relief Valve
Pe
8d
8c
8b
8a
8
4
3
2Y
Pressure Relief Valve
Pd
Cooler
Fig 21.
8e
C
Pe
y
M2
8b 8c
Key
Pd
Pa
P2
z
8a
Key
P1
Pc
11
F1
Key
2X
x
M1
Pb
9
2Y
Transmission in Forward Drive
4
C
8
P3
Joystick Control Spool
Joystick Control Spool
Joystick Control Spool
Joystick Control Spool
Drive Control Joystick
Excavator Valve
Check Valve (5 bar)
Pressure Test Point
8d
2
T
S1
3
A242330
Section E - Hydraulics Operation
Transmission in Forward Drive
E-34
Section E - Hydraulics Operation Transmission in Forward Drive Key 8e
Shuttle Valves
9
Pressure Reducing Solenoid Valve
11
Filter By-pass Valve
When the joystick 8 is moved to select forward drive spool 8b is operated allowing oil from pump P3 to pass via shuttle valves 8e to the swash plate servos on pumps P1 and P2. The swash plates are tilted causing flow to pass to the motors M1 and M2 and the machine moves forward. Return oil from the motors flows back into the main pumps. Any excess oil from the pump casing is fed back to tank via cooler C. Shuttle valves 8e prevent servo pressure from being fed into other servo circuits.
E-35
9803/9960-3
E-35
Section E - Hydraulics Operation Transmission in Forward Drive
Page left intentionally blank
E-36
9803/9960-3
E-36
E-37
Loader Joystick
Loader Valve Block
Crowd Spool
Lift Spool
Auxiliary Spool
Main Relief Valve (MRV)
Crowd Ram Rod Side ARV
Crowd Ram Head Side ARV
Lift Ram Head Side ARV
Auxiliary ARV
Auxiliary ARV
Pressure Test Point (Main Relief Valve)
Pressure Test Point (Transmission Charge Pressure)
1
2
2A
2B
2C
2D
2E
2F
2G
2H
2J
2X
2Y
M1
Tank
Left Hand Drive Motor
P3
T
Auxiliary Gear Pump
P2
Suction Strainer
Main Pump (Run in Tandem with P1)
P1
S1
Main Pump (Run in Tandem with P2)
F1
Right Hand Drive Motor
Filter
C
M2
Table 1. Component Key Cooler
K Fig 1. ( T E-38)
From Machine no. 751012 to 752462 Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release) Check Valve (8 bar) 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 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
2Z
3 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S 4T 5 6 7 8
Forward Spool
8C
9803/9960-3
One-way Restrictor
Bi-restrictor
Bi-restrictor
Bucket Ram
Dipper Ram
Boom Ram
Slew Ram
Slew Ram
Stabiliser Ram
Stabiliser Ram
Hydraclamp
Auxiliary Feeds
Filter By-pass Valve (3 bar)
Check Valve (2 bar)
Pressure Reducing Solenoid Valve
Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.
52
51
50
38
37
36
35
34
33
32
30
12
11
10
9
Right Turn Spool
Left Turn Spool
8B 8D
Reverse Spool
8A
Standard Machines - Single Lever Drive Control
Schematic Circuits
Section E - Hydraulics Schematic Circuits
Standard Machines - Single Lever Drive Control
E-37
E-38
9803/9960-3
P1
P2
2X
2D
M2
1
2E
2A
3
2F
8A
2
8B
8
2G
2B
52
8C
P3
8D
2J
2C
2H
T
C
12
10
6
T
S1
7
4H
4G
4F
4E
4D
4C
4B
4A
4
4T
4S
4R
4Q
4P
4N
4M
4L
4K
4J
Fig 1. Standard Machines - Single Lever Drive Control From Machine no. 751012 to 752462
9
K Table 1. Component Key ( T E-37)
M1
2Z
2Y
11
F1
5
50
51
36
33
35
34
32
30
37 38
A243002A
Section E - Hydraulics Schematic Circuits
Standard Machines - Single Lever Drive Control
E-38
E-39
Crowd Ram Head Side ARV
Lift Ram Head Side ARV
Auxiliary ARV
Auxiliary ARV
Pressure Test Point (Main Relief Valve)
Pressure Test Point (Transmission Charge Pressure)
Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release)
Check Valve (8 bar)
Excavator Valve Block
Slew Spool
2F
2G
2H
2J
2X
2Y
2Z
3
4
4A
Loader Valve Block
2
Crowd Ram Rod Side ARV
Loader Joystick
1
2E
Tank
T
Main Relief Valve (MRV)
Suction Strainer
S1
2D
Right Hand Drive Motor
M2
Auxiliary Spool
Left Hand Drive Motor
M1
2C
Auxiliary Gear Pump
P3
Lift Spool
Main Pump (Run in Tandem with P1)
P2
2B
Main Pump (Run in Tandem with P2)
P1
Crowd Spool
Filter
F1
2A
Table 2. Component Key Cooler
C
K Fig 2. ( T E-40)
From Machine no. 752463 Stabiliser Spool
4D
9803/9960-3
Filter By-pass Valve (3 bar) Auxiliary Feeds
11 12
33
32
Stabiliser Ram
Stabiliser Ram
Hydraclamp
Check Valve (2 bar)
30
Brake Valve
10
Right Turn Spool
Forward Spool
Left Turn Spool
Reverse Spool
Drive Control Joystick
Lift Rams
Manually Operated Dump Valve
Crowd Rams
Auxiliary ARV
Auxiliary ARV
Bucket Ram Head Side ARV
Bucket Ram Rod Side ARV
Dipper Ram Head Side ARV
Dipper Ram Rod Side ARV
Boom Ram Rod Side ARV
Boom Ram Head Side ARV
Slew ARV
Slew ARV
Hydraclamp Valve
Auxiliary Spool
Bucket Spool
9
8D
8C
8B
8A
8
7
6
5
4T
4S
4R
4Q
4P
4N
4M
4L
4K
4J
4H
4G
4F
Dipper Spool
Stabiliser Spool
4C 4E
Boom Spool
4B
Return line fitted from machine no. 807226
One-way Restrictor (1)
Bi-restrictor
Bi-restrictor
Bucket Ram
Dipper Ram
Boom Ram
Slew Ram
Slew Ram
Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.
(1) On machines fitted with a Husco Loader Valve, Oneway Restrictor 52 is deleted. On these machines a restrictor is incorporated in the Valve Block.
X
52
51
50
38
37
36
35
34
Section E - Hydraulics Schematic Circuits
Standard Machines - Single Lever Drive Control
E-39
E-40
9803/9960-3
P1
P2
2X
9
K Table 2. Component Key ( T E-39)
M1
2Z
2Y
11
F1
5
2D
2A
3
8A
8B
8
2G
2B
8C
P3
8D
2J
2C
2H
T
C
12
10
6
T
S1
7
4H
4G
4F
4E
4D
4C
4B
4A
4
Fig 2. Standard Machines - Single Lever Drive Control From Machine no. 752463
M2
1
2E
2F
2
52
4T
4S
4R
4Q
4P
4N
4M
4L
4K
4J
50
51
36
33
X
35
34
32
30
T
37 38
316741
Section E - Hydraulics Schematic Circuits
Standard Machines - Single Lever Drive Control
E-40
E-41
Table 3. Component Key Cooler
Filter
Main Pump (Run in Tandem with P2)
Main Pump (Run in Tandem with P1)
Auxiliary Gear Pump
Left Hand Drive Motor
Right Hand Drive Motor
Suction Strainer
Tank
Left Hand Joystick
Loader Valve Block
Crowd Spool
Lift Spool
Auxiliary Spool
Main Relief Valve (MRV)
Crowd Ram Rod Side ARV
Crowd Ram Head Side ARV
Lift Ram Head Side ARV
Auxiliary ARV
Auxiliary ARV
Pressure Test Point (Main Relief Valve)
Pressure Test Point (Transmission Charge Pressure)
Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release)
C
F1
P1
P2
P3
M1
M2
S1
T
1
2
2A
2B
2C
2D
2E
2F
2G
2H
2J
2X
2Y
2Z
K Fig 3. ( T E-42)
From Machine no. 751012 to 752462 Slew Spool
4A
9803/9960-3
Auxiliary Feeds
12
Hydraclamp
Filter By-pass Valve (3 bar)
11 30
Check Valve (2 bar)
Pressure Reducing Solenoid Valve
Right Hand Joystick
Lift Rams
Manually Operated Dump Valve
Crowd Rams
Auxiliary ARV
Auxiliary ARV
Bucket Ram Head Side ARV
Bucket Ram Rod Side ARV
Dipper Ram Head Side ARV
Dipper Ram Rod Side ARV
Boom Ram Rod Side ARV
Boom Ram Head Side ARV
Slew ARV
Slew ARV
Hydraclamp Valve
Auxiliary Spool
Bucket Spool
Dipper Spool
Stabiliser Spool
Stabiliser Spool
10
9
8
7
6
5
4T
4S
4R
4Q
4P
4N
4M
4L
4K
4J
4H
4G
4F
4E
4D
4C
Boom Spool
Excavator Valve Block
4 4B
Check Valve (8 bar)
3
One-way Restrictor
Bi-restrictor
Bi-restrictor
Bucket Ram
Dipper Ram
Boom Ram
Slew Ram
Slew Ram
Stabiliser Ram
Stabiliser Ram
Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.
52
51
50
38
37
36
35
34
33
32
Standard Machines - Dual Lever Drive Control
Section E - Hydraulics Schematic Circuits
Standard Machines - Dual Lever Drive Control
E-41
E-42
9803/9960-3
M1
2Z
2Y
P1
P2
2X
M2
9
1
2D
3
2E
2A
10
P3
2F
2
2G
52
2B
C
T
2J
2C
2H
8
12
S1
6
T
7
4H
4G
4F
4E
4D
4C
4B
4A
4
Fig 3. Standard Machines - Dual Lever Drive Control From Machine no. 751012 to 752462
K Table 3. Component Key ( T E-41)
11
F1
5
4T
4S
4R
4Q
4P
4N
4M
4L
4K
4J
50
51
36
33
35
34
32
30
37 38
A243003A
Section E - Hydraulics Schematic Circuits
Standard Machines - Dual Lever Drive Control
E-42
E-43
Crowd Ram Head Side ARV
Lift Ram Head Side ARV
Auxiliary ARV
Auxiliary ARV
Pressure Test Point (Main Relief Valve)
Pressure Test Point (Transmission Charge Pressure)
Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release)
Check Valve (8 bar)
Excavator Valve Block
Slew Spool
2F
2G
2H
2J
2X
2Y
2Z
3
4
4A
Loader Valve Block
2
Crowd Ram Rod Side ARV
Left Hand Joystick
1
2E
Tank
T
Main Relief Valve (MRV)
Suction Strainer
S1
2D
Right Hand Drive Motor
M2
Auxiliary Spool
Left Hand Drive Motor
M1
2C
Auxiliary Gear Pump
P3
Lift Spool
Main Pump (Run in Tandem with P1)
P2
2B
Main Pump (Run in Tandem with P2)
P1
Crowd Spool
Filter
F1
2A
Table 4. Component Key Cooler
C
K Fig 4. ( T E-44)
From Machine no. 752463 Stabiliser Spool
4D
9803/9960-3
Slew Ram
34
37
36
Dipper Ram
Boom Ram
Slew Ram
Stabiliser Ram
33 35
Hydraclamp Stabiliser Ram
32
Auxiliary Feeds
Filter By-pass Valve (3 bar)
Check Valve (2 bar)
Brake Valve
Right Hand Joystick
Lift Rams
Manually Operated Dump Valve
Crowd Rams
Auxiliary ARV
Auxiliary ARV
Bucket Ram Head Side ARV
Bucket Ram Rod Side ARV
Dipper Ram Head Side ARV
Dipper Ram Rod Side ARV
Boom Ram Rod Side ARV
Boom Ram Head Side ARV
Slew ARV
Slew ARV
Hydraclamp Valve
Auxiliary Spool
Bucket Spool
30
12
11
10
9
8
7
6
5
4T
4S
4R
4Q
4P
4N
4M
4L
4K
4J
4H
4G
4F
Dipper Spool
Stabiliser Spool
4C 4E
Boom Spool
4B
Return line fitted from machine no. 807226
One-way Restrictor (1)
Bi-restrictor
Bi-restrictor
Bucket Ram
Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.
(1) On machines fitted with a Husco Loader Valve, Oneway Restrictor 52 is deleted. On these machines a restrictor is incorporated in the Valve Block.
X
52
51
50
38
Section E - Hydraulics Schematic Circuits
Standard Machines - Dual Lever Drive Control
E-43
E-44
9803/9960-3
M1
2Z
2Y
P1
P2
9
2X
K Table 4. Component Key ( T E-43)
11
F1
5
M2
3
2A
10
P3
2F 2G
2B
C
T
2J
2C
2H
8
12
S1
6
T
7
4H
4G
4F
4E
4D
4C
4B
4A
4
Fig 4. Standard Machines - Dual Lever Drive Control From Machine no. 752463
1
2D
2E
2
52
4T
4S
4R
4Q
4P
4N
4M
4L
4K
4J
50
51
36
33
X
35
34
32
30
T
37 38
316761
Section E - Hydraulics Schematic Circuits
Standard Machines - Dual Lever Drive Control
E-44
E-45
Table 5. Component Key Cooler
Filter
High Flow Filter
Main Pump (Run in Tandem with P2)
Main Pump (Run in Tandem with P1)
Auxiliary Gear Pump
Left Hand Drive Motor
Right Hand Drive Motor
Suction Strainer
High Flow Suction Strainer
Tank
Loader Joystick
Loader Valve Block
Crowd Spool
Lift Spool
Auxiliary Spool
Main Relief Valve (MRV)
Crowd Ram Rod Side ARV
Crowd Ram Head Side ARV
Lift Ram Head Side ARV
Auxiliary ARV
Auxiliary ARV
Pressure Test Point (High-flow Relief Valve)
Pressure Test Point (Main Relief Valve)
C
F1
F2
P1
P2
P3
M1
M2
S1
S2
T
1
2
2A
2B
2C
2D
2E
2F
2G
2H
2J
2W
2X
K Fig 5. ( T E-46)
From Machine no. 751012 to 752462
9803/9960-3
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
4N 4P 4Q 4R 4S 4T 5 6 7 8
Reverse Spool
Boom Ram Rod Side ARV
4M
8A
Boom Ram Head Side ARV
4L
Bucket Spool
4F
Slew ARV
Dipper Spool
4E
4K
Stabiliser Spool
4D
Slew ARV
Stabiliser Spool
4C
4J
Boom Spool
4B
Hydraclamp Valve
Slew Spool
4A
4H
Excavator Valve Block
4
Auxiliary Spool
Check Valve (8 bar)
3
4G
Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release)
Pressure Test Point (Transmission Charge Pressure)
2Z
2Y
One-way Restrictor
Bi-restrictor
Bi-restrictor
Bucket Ram
Dipper Ram
Boom Ram
Slew Ram
Slew Ram
Stabiliser Ram
Stabiliser Ram
Hydraclamp
Attachment Motor
High-flow Circuit Relief Valve
High-flow Control Valve
High-flow Pilot Valve
High-flow Valve
High Flow Pump
Auxiliary Feeds
Filter By-pass Valve (3 bar)
Check Valve (2 bar)
Pressure Reducing Solenoid Valve
Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.
52
51
50
38
37
36
35
34
33
32
30
15
14C
14B
14A
14
13
12
11
10
9
Right Turn Spool
Forward Spool
8C 8D
Left Turn Spool
8B
High Flow Machines - Single Lever Drive Control
Section E - Hydraulics Schematic Circuits
High Flow Machines - Single Lever Drive Control
E-45
E-46
9803/9960-3
P1
P2
2X
9
M2
1
10
2E
2A
3
2F
8A
2
8B
14
2B
8
2G
52
8C
P3
8D
14C
2W
2J
14A
14B
2C
2H
T
C
12
F2
6
15
T
S1
13
7
S2
4H
4G
4F
4E
4D
4C
4B
4A
4
4T
4S
4R
4Q
4P
4N
4M
4L
4K
4J
Fig 5. High Flow Machines - Single Lever Drive Control From Machine no. 751012 to 752462
2D
K Table 5. Component Key ( T E-45)
M1
2Z
2Y
11
F1
5
50
51
36
33
35
34
32
30
37 38
A243003B
Section E - Hydraulics Schematic Circuits
High Flow Machines - Single Lever Drive Control
E-46
E-47
Main Relief Valve (MRV)
Crowd Ram Rod Side ARV
Crowd Ram Head Side ARV
Lift Ram Head Side ARV
Auxiliary ARV
Auxiliary ARV
Pressure Test Point (High-flow Relief Valve)
Pressure Test Point (Main Relief Valve)
Pressure Test Point (Transmission Charge Pressure)
2D
2E
2F
2G
2H
2J
2W
2X
2Y
Tank
T
Auxiliary Spool
High Flow Suction Strainer
S2
2C
Suction Strainer
S1
Lift Spool
Right Hand Drive Motor
M2
2B
Left Hand Drive Motor
M1
Crowd Spool
Auxiliary Gear Pump
P3
2A
Main Pump (Run in Tandem with P1)
P2
Loader Valve Block
Main Pump (Run in Tandem with P2)
P1
2
High Flow Filter
F2
Loader Joystick
Filter
F1
1
Table 6. Component Key Cooler
C
K Fig 6. ( T E-48)
From Machine no. 752463
9803/9960-3
Pressure Reducing Solenoid Valve
8D 9
Forward Spool Right Turn Spool
8C
Left Turn Spool
Reverse Spool
8A 8B
Lift Rams
Manually Operated Dump Valve
6
Drive Control Joystick
Crowd Rams
5
8
Auxiliary ARV
4T
7
Auxiliary ARV
4S
Slew ARV
4K
Bucket Ram Head Side ARV
Slew ARV
4J
4R
Hydraclamp Valve
4H
Bucket Ram Rod Side ARV
Auxiliary Spool
4G
4Q
Bucket Spool
4F
Dipper Ram Head Side ARV
Dipper Spool
4E
4P
Stabiliser Spool
4D
Dipper Ram Rod Side ARV
Stabiliser Spool
4C
4N
Boom Spool
4B
Boom Ram Rod Side ARV
Slew Spool
4A
4M
Excavator Valve Block
4
Boom Ram Head Side ARV
Check Valve (8 bar)
3
4L
Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release)
2Z Auxiliary Feeds
12
Return line fitted from machine no. 807226
One-way Restrictor(1)
Bi-restrictor
Bi-restrictor
Bucket Ram
Dipper Ram
Boom Ram
Slew Ram
Slew Ram
Stabiliser Ram
Stabiliser Ram
Hydraclamp
Attachment Motor
High-flow Circuit Relief Valve
High-flow Control Valve
High-flow Pilot Valve
High-flow Valve
Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.
(1) On machines fitted with a Husco Loader Valve, Oneway Restrictor 52 is deleted. On these machines a restrictor is incorporated in the Valve Block.
X
52
51
50
38
37
36
35
34
33
32
30
15
14C
14B
14A
14
High Flow Pump
Filter By-pass Valve (3 bar)
11 13
Check Valve (2 bar)
10
Section E - Hydraulics Schematic Circuits
High Flow Machines - Single Lever Drive Control
E-47
E-48
9803/9960-3
M1
2Z
2Y
P1
P2
9
2X
K Table 6. Component Key ( T E-47)
11
F1
5
3
2A
10
P3
2G
2B
C
T
2J
2C
2H
8
12
S1
6
T
7
4H
4G
4F
4E
4D
4C
4B
4A
4
Fig 6. High Flow Machines - Single Lever Drive Control From Machine no. 752463
M2
1
2D
2E
2F
2
52
4T
4S
4R
4Q
4P
4N
4M
4L
4K
4J
50
51
36
33
X
35
34
32
30
T
37 38
316761
Section E - Hydraulics Schematic Circuits
High Flow Machines - Single Lever Drive Control
E-48
E-49
Table 7. Component Key Cooler
Filter
High Flow Filter
Main Pump (Run in Tandem with P2)
Main Pump (Run in Tandem with P1)
Auxiliary Gear Pump
Left Hand Drive Motor
Right Hand Drive Motor
Suction Strainer
High Flow Suction Strainer
Tank
Left Hand Joystick
Loader Valve Block
Crowd Spool
Lift Spool
Auxiliary Spool
Main Relief Valve (MRV)
Crowd Ram Rod Side ARV
Crowd Ram Head Side ARV
Lift Ram Head Side ARV
Auxiliary ARV
Auxiliary ARV
Pressure Test Point (High-flow Relief Valve)
Pressure Test Point (Main Relief Valve)
C
F1
F2
P1
P2
P3
M1
M2
S1
S2
T
1
2
2A
2B
2C
2D
2E
2F
2G
2H
2J
2W
2X
K Fig 7. ( T E-50)
From Machine no. 751012 to 752462
9803/9960-3
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 Right Hand Joystick
4N 4P 4Q 4R 4S 4T 5 6 7 8
Pressure Reducing Solenoid Valve
Boom Ram Rod Side ARV
4M
9
Boom Ram Head Side ARV
4L
Bucket Spool
4F
Slew ARV
Dipper Spool
4E
4K
Stabiliser Spool
4D
Slew ARV
Stabiliser Spool
4C
4J
Boom Spool
4B
Hydraclamp Valve
Slew Spool
4A
4H
Excavator Valve Block
4
Auxiliary Spool
Check Valve (8 bar)
3
4G
Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release)
Pressure Test Point (Transmission Charge Pressure)
2Z
2Y
High Flow Pump
One-way Restrictor
Bi-restrictor
Bi-restrictor
Bucket Ram
Dipper Ram
Boom Ram
Slew Ram
Slew Ram
Stabiliser Ram
Stabiliser Ram
Hydraclamp
Attachment Motor
High-flow Circuit Relief Valve
High-flow Control Valve
High-flow Pilot Valve
High-flow Valve
Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.
52
51
50
38
37
36
35
34
33
32
30
15
14C
14B
14A
14
13
Auxiliary Feeds
Filter By-pass Valve (3 bar)
11 12
Check Valve (2 bar)
10
High Flow Machines - Dual Lever Drive Control
Section E - Hydraulics Schematic Circuits
High Flow Machines - Dual Lever Drive Control
E-49
E-50
9803/9960-3
M1
2Z
2Y
P1
P2
2X
M2
10
9
1
2D
3
2E
2A
P3
2F
2
2G
52
2B
T
2J
14
2C
2H
14C
2W
8
S1
13
14A
14
14B
12
C
6
F2
S2
T
7
15
4H
4G
4F
4E
4D
4C
4B
4A
4
Fig 7. High Flow Machines - Dual Lever Drive Control From Machine no. 751012 to 752462
K Table 7. Component Key ( T E-49)
11
F1
5
4T
4S
4R
4Q
4P
4N
4M
4L
4K
4J
50
51
36
33
35
34
32
30
37 38
A243004
Section E - Hydraulics Schematic Circuits
High Flow Machines - Dual Lever Drive Control
E-50
E-51
Main Relief Valve (MRV)
Crowd Ram Rod Side ARV
Crowd Ram Head Side ARV
Lift Ram Head Side ARV
Auxiliary ARV
Auxiliary ARV
Pressure Test Point (High-flow Relief Valve)
Pressure Test Point (Main Relief Valve)
Pressure Test Point (Transmission Charge Pressure)
2D
2E
2F
2G
2H
2J
2W
2X
2Y
Tank
T
Auxiliary Spool
High Flow Suction Strainer
S2
2C
Suction Strainer
S1
Lift Spool
Right Hand Drive Motor
M2
2B
Left Hand Drive Motor
M1
Crowd Spool
Auxiliary Gear Pump
P3
2A
Main Pump (Run in Tandem with P1)
P2
Loader Valve Block
Main Pump (Run in Tandem with P2)
P1
2
High Flow Filter
F2
Left Hand Joystick
Filter
F1
1
Table 8. Component Key Cooler
C
K Fig 8. ( T E-52)
From Machine no. 752463
9803/9960-3
High Flow Pump
Auxiliary Feeds
12 13
Filter By-pass Valve (3 bar)
11
Check Valve (2 bar)
Brake Valve
9 10
Lift Rams
Manually Operated Dump Valve
6
Right Hand Joystick
Crowd Rams
5
8
Auxiliary ARV
4T
7
Auxiliary ARV
4S
Slew ARV
4K
Bucket Ram Head Side ARV
Slew ARV
4J
4R
Hydraclamp Valve
4H
Bucket Ram Rod Side ARV
Auxiliary Spool
4G
4Q
Bucket Spool
4F
Dipper Ram Head Side ARV
Dipper Spool
4E
4P
Stabiliser Spool
4D
Dipper Ram Rod Side ARV
Stabiliser Spool
4C
4N
Boom Spool
4B
Boom Ram Rod Side ARV
Slew Spool
4A
4M
Excavator Valve Block
4
Boom Ram Head Side ARV
Check Valve (8 bar)
3
4L
Pressure Test Point (Brake Pressure) & Hand Pump Connector (Manual Brake Release)
2Z High-flow Control Valve
14B
Return line fitted from machine no. 807226
One-way Restrictor(1)
Bi-restrictor
Bi-restrictor
Bucket Ram
Dipper Ram
Boom Ram
Slew Ram
Slew Ram
Stabiliser Ram
Stabiliser Ram
Hydraclamp
Attachment Motor
Note: Excavator services shown here are to the JCB 'X' control pattern. For ISO '+' control pattern, components 36 and 37 are swapped over.
(1) On machines fitted with a Husco Loader Valve, Oneway Restrictor 52 is deleted. On these machines a restrictor is incorporated in the Valve Block.
X
52
51
50
38
37
36
35
34
33
32
30
15
High-flow Circuit Relief Valve
High-flow Pilot Valve
14A 14C
High-flow Valve
14
Section E - Hydraulics Schematic Circuits
High Flow Machines - Dual Lever Drive Control
E-51
E-52
9803/9960-3
M1
2Z
2Y
P1
P2
9
2X
K Table 8. Component Key ( T E-51)
11
F1
5
M2
3
2A
P3
2G
2B
T
2J
14
2C
2H
14C
2W
8
S1
13
14A
14
14B
12
C
6
F2
S2
T
7
15
4H
4G
4F
4E
4D
4C
4B
4A
4
Fig 8. High Flow Machines - Dual Lever Drive Control From Machine no. 752463
10
1
2D
2E
2F
2
52
4T
4S
4R
4Q
4P
4N
4M
4L
4K
4J
50
51
36
33
X
35
34
32
30
T
37 38
316771
Section E - Hydraulics Schematic Circuits
High Flow Machines - Dual Lever Drive Control
E-52
Section E - Hydraulics Schematic Circuits Series 2 Machines from SN 1743570
Series 2 Machines from SN 1743570 ISO Machines K Fig 9. ( T E-54), K Fig 10. ( T E-55).
1
Table 9. Component Key 10 Spool Excavator Valve Block
2
Transmission Changeover Valve
3
PMS Valve
4
Excavator Pilot Pressure Valve
5
Drive Control Joystick
6
Hydraulic Tank
7
Wheel Motor LH
8
Wheel Motor RH
9
Transmission Pump
10
Hydraulic Filter
11
Extending Dipper (Option)
12
Loader Ram
13
Shovel Ram
14
Stabiliser Legs
15
Slew Ram
16
Loader Auxiliary
17
Hydraclamp
18
Extending Dipper Auxiliary Changeover Valve (Option)
19
Loader Joystick
20
Loader Changeover Valve
21
High Flow Valve Option
E-53
9803/9960-3
E-53
Section E - Hydraulics Schematic Circuits Series 2 Machines from SN 1743570
A B EXTENDING DIPPER OPTION
13
12
11 17
LOADER
KINGPOST CLAMP
SHOVEL
15 14
C
RACK AND PINION SLEW DIPPER
BOOM
D E F
STAB LEGS
16
LOADER AUX
BUCKET HBCV
1.4MM
1
2.5MM RESTRICTOR
1A
3500
1B
2MM
3500
2B
2A
3500
3A
3500
3500
2MM
3B
3500
4B
4A
3500
5A
5B
6A
6B
7A
3500
7B
8A
3500
8B
1450
9A
3500
9B
3500
10A
G
CLAMP PORT
10B
3500
10 SPOOL VALVE BLOCK 3200 CLAMP VALVE DRAIN PORT
H I BH. BOOM
INLET
BH. BUCKET
BH. SLEW
BH. DIPPER
L. BOOM
STAB
STAB
L. BUCKET
OUTLET
L. AUX
BH. AUX
J K L M N B5
B7
B6
B8
2
J1
O
TRANSMISSION CHANGEOVER VALVE
LS1
SV6
SV5
SV7
SV8
LS4 LS2
TRANSMISSION JOYSTICK
LS3
P5
P8
P7
P6
T
J4
J3
3
2
1
P
T
4
5
P Q
10 FILTER
R
ACCUMULATOR P1
BR
PA CT1
CT4
CT2
P2 CT5
PMS VALVE
3
EXC. PILOT PRESSURE VALVE
4
CT3
C
T
A
SERVICE PUMP
P
S
7 LEFT HAND WHEEL MOTOR TRANSMISSION PUMP
9
8
T
RIGHT HAND WHEEL MOTOR U
FOR HIGH FLOW OPTION TANK RETURN FROM VALVE GOES INTO COOLER AND TANK RETURN FROM TRANSMISSION PUMP GOES STRAIGHT TO TANK
6 HYDRAULIC TANK
V W X Y
333/R1564-1
Fig 9. ISO Circuit sheet 1 of 2
E-54
9803/9960-3
E-54
Section E - Hydraulics Schematic Circuits Series 2 Machines from SN 1743570
A B AUX 1.4MM
P6
P6
P1
P1
P4 P4
18
P3
P3
SV1
C
P5
P5
P2
EXTENDING DIPPER / AUX CHANGEOVER VALVE OPTION
P2
20
D E F
LOADER CHANGEOVER VALVE
G
PG BW SV6
YG PW
SV5
YW
BR
OB OO SV4
OO OW
H
O SV3
O I GR J
GG
L M
GW
N
G
G SV1
K
SV2
GG
T O
19
LOADER JOYSTICK
3
2
1
P
T
4
P Q R
HIGH FLOW VALVE OPTION
21
FEED
RETURN
Ps M1 M1
S
M2 M2
P
T
PP
T DR
U
V
SERVICE PUMP 2
DRAIN
W X Y
333/R1564-1
Fig 10. ISO Circuit sheet 2 of 2
E-55
9803/9960-3
E-55
Section E - Hydraulics Schematic Circuits Series 2 Machines from SN 1743570
ISO / SAE Changeover Circuit K Fig 11. ( T E-57).
1
Table 10. Component Key 10 Spool Excavator Valve Block
2
Transmission Changeover Valve
3
ISO /SAE Changeover Valve (Option)
11
Extending Dipper (Option)
12
Loader Ram
13
Shovel Ram
14
Stabiliser Legs
15
Slew Ram
16
Loader Auxiliary
17
Hydraclamp
18
Extending Dipper Auxiliary Changeover Valve (Option)
20
Loader Changeover Valve
E-56
9803/9960-3
E-56
9803/9960-3
P5
B5
10 SPOOL VALVE BLOCK
1
SV5
P6
B6
SV6
INLET
3200
P7
3500
1A
SV7
BH. BOOM
B7
2.5MM RESTRICTOR
BOOM
3500
2A
P8
B8
BH. BUCKET
2MM
3500
1B
DIPPER
SV8
T
3A
3500
BH. DIPPER
3500
2B
J4
LS4
3500
4A
LS3
J3
J1
3500
BH. SLEW
2MM
3B
BUCKET
LS1
3500
4B
LS2
1.4MM
STAB
5A
J2
2
STAB
6A
HBCV 6B
L. BOOM
7A
3500
7B
TRANSMISSION CHANGEOVER VALVE
5B
STAB LEGS
RACK AND PINION SLEW
12 15 14
LOADER
L. BUCKET
1450
8A
3500
8B
BH. AUX
3500
9B
L. AUX
10A
OUTLET
16
10B
LOADER AUX
CLAMP PORT
CLAMP VALVE DRAIN PORT
A1
A2
C2
B1 C1
B2
17
D1
D2
P6 P1
P1
P5
P6
P5
P2
P4
P4 P3
P2
P3
SV1
AUX
18
EXTENDING DIPPER / AUX CHANGEOVER VALVE OPTION
3
ISO/SAE CHANGEOVER VALVE OPTION
CHANGEOVER VALVE SWITCHES OPERATION OF BOOM AND DIPPER BETWEEN ISO AND SAE MODE
HYDRAULIC CIRCUIT IS SHOWN IN ISO MODE
Fig 11. ISO/SAE Changeover Circuit
3500
9A
13 SHOVEL
KINGPOST CLAMP
1.4MM
EXTENDING DIPPER OPTION
PG
G
GW
GG
GR
O
OW
OO
OB
YW
PW
YG
T
G
GG
O
OO
BR
BW
20 SV6 SV5 SV4 SV3 SV2
E-57 SV1
11
333/R5917
LOADER CHANGEOVER VALVE
Section E - Hydraulics Schematic Circuits
Series 2 Machines from SN 1743570
E-57
Section E - Hydraulics Schematic Circuits Series 2 Machines from SN 1743570
SAE Machines K Fig 12. ( T E-59), K Fig 13. ( T E-60).
1
Table 11. Component Key 10 Spool Excavator Valve Block
2
Transmission Changeover Valve
3
PMS Valve
4
Excavator Pilot Pressure Valve
5
Drive Control Joystick
6
Hydraulic Tank
7
Wheel Motor LH
8
Wheel Motor RH
9
Transmission Pump
10
Hydraulic Filter
11
Extending Dipper (Option)
12
Loader Ram
13
Shovel Ram
14
Stabiliser Legs
15
Slew Ram
16
Loader Auxiliary
17
Hydraclamp
18
Extending Dipper Auxiliary Changeover Valve (Option)
19
Loader Joystick
20
Loader Changeover Valve
21
High Flow Valve Option
E-58
9803/9960-3
E-58
Section E - Hydraulics Schematic Circuits Series 2 Machines from SN 1743570 A B EXTENDING DIPPER OPTION
12
LOADER
13
RACK AND PINION SLEW BOOM
15 14
DIPPER
KINGPOST CLAMP
SHOVEL
C
D E F
STAB LEGS
16
LOADER AUX
BUCKET HBCV
1.4MM
1
2.5MM RESTRICTOR
1A
3500
1B
2MM
3500
2A
2B
3500
3A
3500
3500
2MM
3B
3500
4B
4A
3500
5A
5B
6A
6B
11 17
7B
7A
3500
8A
3500
8B
1450
9A
3500
9B
3500
10A
G
CLAMP PORT
10B
3500
10 SPOOL VALVE BLOCK 3200 CLAMP VALVE DRAIN PORT
H
I BH. BOOM
INLET
BH. BUCKET
BH. SLEW
BH. DIPPER
STAB
L. BOOM
STAB
L. BUCKET
OUTLET
L. AUX
BH. AUX
J K L M N B5
B7
B6
B8
J1
2
O
TRANSMISSION CHANGEOVER VALVE
LS1
SV6
SV5
SV7
SV8
LS4 LS2
TRANSMISSION JOYSTICK
LS3
P5
P8
P7
P6
T
J4
J3
3
2
1
P
T
4
5
P Q
10 FILTER
R
ACCUMULATOR P1
BR
PA CT1
CT4
CT2
P2 CT5
3
PMS VALVE
EXC. PILOT PRESSURE VALVE
4
CT3
C
T
A
SERVICE PUMP
P
S
7 LEFT HAND WHEEL MOTOR TRANSMISSION PUMP
9
8
T
RIGHT HAND WHEEL MOTOR U
FOR HIGH FLOW OPTION TANK RETURN FROM VALVE GOES INTO COOLER AND TANK RETURN FROM TRANSMISSION PUMP GOES STRAIGHT TO TANK
6
V W X
HYDRAULIC TANK
Y
333/R5885sheet1
Fig 12. SAE Circuit sheet 1 of 2
E-59
9803/9960-3
E-59
Section E - Hydraulics Schematic Circuits Series 2 Machines from SN 1743570 A B 1.4MM
AUX P6
P6
P1
18
P1 P4 P3 P4
P3
SV1
C
P5
P5
P2
EXTENDING DIPPER / AUX CHANGEOVER VALVE OPTION
P2
D E F LOADER CHANGEOVER VALVE
G
20
PG BW SV6
YG PW
SV5
YW
BR
OB OO SV4
OO OW
H
O SV3
O I GR GG
N
G
GG SV2
J K L M
GW SV1
G
T O
19
LOADER JOYSTICK
3
2
1
P
T
4
P Q R
HIGH FLOW VALVE OPTION
Ps
21
FEED
RETURN
M1 M1
S
M2 M2
P
T
PP
T DR
U
V
SERVICE PUMP 2
DRAIN
W X Y
333/R5885sheet2
Fig 13. SAE Circuit sheet 2 of 2
E-60
9803/9960-3
E-60
Section E - Hydraulics Schematic Circuits Optional Hand Tool Circuit
Optional Hand Tool Circuit Description The oil supply for the optional hand tool circuit is taken from the excavator valve auxiliary circuit feed lines. When the auxiliary circuit is selected by the foot pedal, oil is fed via the Manual Valve 2 to the Flow Regulator Valve 3. Flow Regulator Spool 3a controls the flow to the hand tool circuit 4, dumping excess oil back to tank via the return line of the excavator auxiliary circuit. Return oil from the hand tool is fed directly back to tank. Relief Valve 3b prevents pressure in the hand tool circuit from rising too far. Manual Valve 2 is turned off to isolate the hand tool circuit when the excavator auxiliary circuit is to be used for other applications.
Component Key T
Tank
1
Excavator Valve Block Auxiliary Lines
2
Manual Valve
3
Flow Regulator Valve
3a
Flow Regulator Spool
3b
Relief Valve
4
Hand Tool Connection
5
Return Line from Brake Valve
E-61
303930
Fig 14.
9803/9960-3
E-61
Section E - Hydraulics Schematic Circuits Optional Hand Tool Circuit
Page left intentionally blank
E-62
9803/9960-3
E-62
Section E - Hydraulics
Fault Finding Hydrostatic Transmission Key to Cause
Table 1. Remedy
1
No oil in hydrostatic system
Check supply of oil to pump.
2
Seat isolator not operating correctly
Ensure the seat isolator is operating correctly, check electrical wiring and switch as required.
3
Tyres worn or pressure incorrect
Check tyre pressures and condition.
4
Charge pressure incorrect
Charge pressure is controlled by the Charge Pressure Relief Valve. Carry out flow check.
5
No or low pump output
Check pump - carry out 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.
6
A high pressure `loop' relief valve/tow valve Replace relief valve and re-check. open/set incorrectly
7
Pump neutral position set incorrectly
Adjust servo neutral position.
8
Pump servos incorrectly set
Adjust servos
9
Feed hose failure
Check motor feed hoses.
10
No hydraulic feed to joystick
Check for feed to joystick.
11
No hydraulic feed from joystick to pump
Check for feed from joystick to pump.
12
Brake hose failure
Inspect brake hoses.
13
Brake release pressure incorrect
Check charge/brake pressure.
14
Electrical failure (brake valve circuit)
Check brake valve electrical circuit.
15
Brake valve inoperative
Check valve (sticking spool, etc.)
16
Brakes not released
Inspect motor brakes for seal damage. Repair as required.
17
Mechanical brake failure
Check brake components (worn plates, spring damage, etc.).
18
Motor leakage
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.
19
Joystick inoperative
Check joystick (plunger movement, leaking seals, etc.)
20
Chain tension
Check chain tension.
21
Motor failure
Inspect motor for damage. Check the screen for sign of damage. Repair as required.
22
Chain/sprocket damage
Inspect chain and sprocket. Repair as required.
E-63
9803-9960-3
E-63
Section E - Hydraulics Fault Finding Hydrostatic Transmission Key to Cause
Remedy
23
Pump/engine drive coupling failure
Check coupling.
24
Internal damage
Noise once per revolution indicates piston damage. Noise eight times per revolution indicates cam damage. Repair as required.
25
Timing incorrect or stop pin damaged
Inspect motor for damage or incorrect timing. Check charge pressure. Repair as required.
26
Dirt or fault in motor flushing circuit
Inspect motor for dirt or damage. Repair as required.
27
No Drive in any direction
Transmission cut off valve sticking or the electrical system.
E-64
9803-9960-3
E-64
Section E - Hydraulics Fault Finding Hydrostatic Transmission
Machine veers to one side when travelling This condition may be corrected by adjusting the pump servo units or manual controls but before attempting this, carry out the following preliminary checks. Check tyre pressures and condition
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.
Check chain tension
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 the servo joystick
Check that the joystick spools are not sticking and are correctly operated by the lever.
E-65
9803-9960-3
E-65
Section E - Hydraulics Fault Finding Loader Circuit
Loader Circuit The purpose of this section is to help you trace hydraulic problems to a faulty unit (valve, actuator, ram etc.). Once you have traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the manual. To help identify circuits, valves, rams etc. mentioned in the problem solving procedures, refer to hydraulic schematic diagrams.
– Before you begin problem solving, read the Safety Information at the beginning of this manual. – Make simple checks before say, stripping a major component. – Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F). – Whatever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary. – Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit.
PROBLEM
CAUSE
Lack of power in all loader functions.
1, 2, 3, 4, 6, 7,18, 20
All hydraulic rams slow to operate.
3, 4, 7, 8, 10, 11, 13
One hydraulic service fails to operate or is slow to operate.
13, 14, 15, 16, 17, 19
Engine tends to stall when hydraulics are under load.
3, 19, 20
Valve spool sticking.
21, 23, 24, 25, 26, 27, 28, 29
Ram creep.
15, 18
Hydraulic oil becomes too hot.
5, 6, 12, 22
Boom judders when used while machine is moving.
9, 11, 13
Key to Cause
Remedy
1
Insufficient hydraulic fluid.
Check for leaks and top up as required.
2
Hydraulic leaks in system.
Check hoses, replace as required.
3
Main relief valve (MRV) setting incorrect.
Check and adjust as required.
4
Low loader pump flow.
Check pump flow, if necessary service or replace pump.
5
Hydraulic filter clogged.
Change hydraulic filter.
6
Charge filter by-pass valve leaking.
Check condition of hydraulic filter.
7
Charge pressure incorrect.
Check relief valve or charge pump
8
Servo pressure low
Carry out charge pressure check.
Check operation of by-pass valve.
Check for blocked service feed hose or faulty joystick. 9
Loader pump flow low.
Check flow rate.
10
Neutral circuit or low pressure lines leaking, damaged, trapped or kinked.
Check pipe lines and replace as required.
11
Restriction in neutral circuit lines.
Check hoses and pipes, replace as necessary.
12
Air in hydraulic system
Bleed System
13
Service pipe lines leaking, damaged, trapped Check hoses and pipes, replace as required. or kinked.
E-66
9803-9960-3
E-66
Section E - Hydraulics Fault Finding Loader Circuit Key to Cause
Remedy
14
Ram or pipe lines from ram leaking.
Check and rectify as required.
15
Valve spool not operating.
Check for leaks, rectify as required. Make sure that spool lock-out is operating (check for faulty wiring, solenoid sticking, burr on spool, etc.) Make sure that associated load hold check valve is operating. On servo machines, check operation of joystick and feed hoses. On manual machines, check that control lever and associated linkage is operating the spool, rectify as required.
16
Valve spool not moving fully from neutral to full selection.
Spool movement should be 5.5 mm (0.22 in) On servo machines, check servo (charge) pressure.
17
Valve spool leaking
Rectify, check for contamination.
18
Piston rod bent.
Replace piston rod. Check pressure setting of MRV.
19
Poor engine performance.
Check engine performance.
20
Oil temperature abnormally high.
Check for correct fluid. Check oil cooler and grille for blockage.
21
Hydraulic fluid dirty.
Clean tank strainer. If strainer badly clogged, drain and flush hydraulic system then fill with clean hydraulic fluid.
22
Service pipe connection over tightened.
Check tightness.
23
Valve housing twisted during installation.
Loosen retaining bolts and tighten to correct torque.
24
Bent spool.
Dismantle control valve. Renew spool as necessary.
25
Spool return spring broken.
Renew as necessary.
26
Spool return spring or cap out of alignment.
Remove cap, check that spring is in correct position.
Check that associated pivot pins are adequately greased.
Refit cap and torque tighten bolts. 27
E-67
Temperature distribution within control valve not uniform.
Warm up entire system before using service.
9803-9960-3
E-67
Section E - Hydraulics Fault Finding Loader Circuit
Page left intentionally blank
E-68
9803-9960-3
E-68
Section E - Hydraulics
Pressure Testing Main Relief Valve (M.R.V.) - In Situ Connect a 0 - 400 bar (0 - 6000 lb/in2, 0 - 422 kg/cm2) pressure gauge to test connector A located on the righthand end of the loader valve block. K Fig 1. ( T E-70) With the engine running at 1500 rev/min, check the M.R.V. setting by lowering the loader arm until the rams are fully closed and noting the maximum gauge reading. Keep clear of the loader arm. The maximum pressure should be as stated in Technical Data. K Technical Data ( T E-1) If the pressure is incorrect, remove dome nut B, slacken locknut C and adjust screw D. Turn it clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut. Note: The pressure setting is stamped on the body of the valve.
Torque Settings Item
Nm
kgfm
lbf ft
B
5.4 - 8.2
0.55 - 0.83
4-6
C
5.4 - 8.2
0.55 - 0.83
4-6
E-69
9803/9960-3
E-69
Section E - Hydraulics Pressure Testing Main Relief Valve (M.R.V.) - In Situ
205160-B1
Fig 1.
E-70
9803/9960-3
E-70
Section E - Hydraulics Pressure Testing Auxiliary Relief Valve (A.R.V.'s) - Using Hand Pump
Auxiliary Relief Valve (A.R.V.'s) - Using Hand Pump Insert the A.R.V. into the test block, part no. 892/00252. Connect hand pump 892/00223 and a 0 - 400 bar (0 - 6000 lb/in2, 0 - 422 kg/cm2) pressure gauge. Plug the two large diameter (3/4 inch B.S.P.) ports of the test block using blanking plugs (892/00059) and bonded washers (1406/0021).
The pressure should be as given in Technical Data. If required, adjust the pressure by removing dome nut A, slackening locknut B and turning screw C.
Torque Settings
Pressurise until oil begins to escape from the drain hole D. At this point the gauge will indicate the crack pressure of the A.R.V.
Item
Nm
kgfm
lbf ft
A
5.4 - 8.2
0.55 - 0.83
4-6
B
5.4 - 8.2
0.55 - 0.83
4-6
S221130-C1
Fig 2.
E-71
9803/9960-3
E-71
Section E - Hydraulics Pressure Testing Check Valve
Check Valve The check valve consists of a plug A, plus a poppet and spring B in a body C. K Fig 3. ( T E-72)
seat facing forward and the engine running at 1000 rev/ min. The difference in the two pressures should equal the opening pressure of the check valve.
Opening pressure is 5 bar (75 lbf/in2). To check the opening pressure, compare the difference between the recorded pressures at the MRV test point and the brake pressure test point. These should be checked with the hydraulic oil at correct working temperature, the
To adjust the opening pressure, screw plug A in or out of the body C as required. If the valve is damaged or worn replace as a unit. Do not fit parts from other valves.
205160-B1
Fig 3.
E-72
9803/9960-3
E-72
Section E - Hydraulics Pressure Testing Pressure Reducing Valve Cartridge
Pressure Reducing Valve Cartridge This cartridge should not be dismantled. If it malfunctions it should be replaced by a new one. Before checking the setting make sure the hydraulic oil is at its correct working temperature. To check the setting, connect a pressure gauge to the test point as follows:
348890-B1
Fig 5. Ensure that the seat is facing forward then start the engine and run at maximum speed. Operate the arms lower service until the rams are fully closed to `blow off' the M.R.V. Check the gauge reading which should show the regulated pressure. K Technical Data ( T E-1) 204330-B1
Fig 4. â&#x20AC;&#x201C; On machines up to serial no. 751715 the test point is located under the throttle pedal plate as shown at E. â&#x20AC;&#x201C; From serial no 751716 the test point is located at the rear of the left hand side of the engine as shown at F.
If the setting is incorrect, stop the engine. Remove the cartridge dust cover C and adjust screw D to achieve the required pressure. Replace dust cover C before restarting the engine to recheck the pressure otherwise oil will leak from the valve.
205000-B1
Fig 6.
E-73
9803/9960-3
E-73
Section E - Hydraulics Pressure Testing Charge Pressure Checking and Adjustment
Charge Pressure Checking and Adjustment 1
Stop engine. Connect a 0 - 40 bar (0 - 600 lb/in2, 0 42 kg/cm2) pressure gauge into the test point which up to machine no. 751715 is situated underneath the pump as shown at X. K Fig 7. ( T E-74) From serial no. 751716 the test point is positioned at the rear of the left hand side of the engine as shown at Y. K Fig 8. ( T E-74).
348890-B3
Fig 8. 2
Start engine and check pressure is as specified. K Technical Data ( T E-1).
3
If the pressure is not as specified, stop the engine. Unscrew locknut 2 and turn adjuster Z 1/4 turn at a time (clockwise to increase pressure) then re-tighten locknut. K Fig 9. ( T E-75) Start engine and re-check pressure. Continue procedure until pressure is correct then remove pressure gauge.
S246240-B2
Fig 7.
E-74
9803/9960-3
E-74
Section E - Hydraulics Pressure Testing Charge Pressure Checking and Adjustment
S244920-B1
Fig 9.
E-75
9803/9960-3
E-75
Section E - Hydraulics Pressure Testing Charge Pressure Checking and Adjustment
Page left intentionally blank
E-76
9803/9960-3
E-76
Section E - Hydraulics
Pumps Removal and Replacement
206350-B1
Fig 1. Note: The illustration shows an early pump but although later pumps are visually different the same procedure applies.
If the auxiliary pump is to be removed, disconnect the auxiliary pump hoses and plug exposed connections. Remove bolts A and lift out the pump.
Removal
If the main pump assembly is to be removed, do not disconnect the auxiliary pump hoses but remove bolts A and lift the pump off the main pump assembly and secure to the rear seat mounting rail with cable ties or similar.
Disconnect the battery. Remove the front floor plates. See Section 3. Drain the hydraulic tank. Disconnect the microswitch at the base of the seat. Remove the two front and the left hand rear bolts securing the seat. Slacken but do not remove the right hand rear bolt. The seat can now be rotated towards the rear of the machine. Unclip the wiring loom and battery lead from the front seat mounting rail. Remove the seat mounting rail.
E-77
Remove and plug all connections to the main pump assembly and the servo units. Detach the electrical wiring from the left hand side of the pump by cutting the cable ties. Slacken the pump
9803/9960-3
E-77
Section E - Hydraulics Pumps Removal and Replacement mounting bolts B and support the weight of the pump using suitable lifting equipment. Remove two bolts B and ease the unit away from the engine.Once the pump unit coupling has separated from the engine, the unit can be lifted clear.
Replacement Using suitable lifting equipment, ease the pump unit into position, making sure that the pump unit/engine couplings engage smoothly and completely. Refit flange bolts B. Refit all connections to the main pump. Refit the auxiliary pump if this has been removed, then refit and torque tighten connections. Refill the pumps with filtered, clean oil via the pump outlets before finally tightening the outlet connections. See Fluids, Lubricants and Capacities, Section 3. Refill the hydraulic tank. See Fluids, Lubricants and Capacities, Section 3. Prime the system. K Start-up Procedure ( T E-80) Refit the front floor plates.
Torque Settings Item
Nm
kgf m
lbf ft
A
77
7.9
57
B
77
7.9
57
Hydraulic Connections
45 - 50
4.6 - 5.1
33 - 37
E-78
9803/9960-3
E-78
Section E - Hydraulics Pumps Pump/Engine Coupling
Pump/Engine Coupling This is a gear type flexible coupling comprising an outer coupling B, bolted to the engine drive plate, and an inner coupling A clamped to the input shaft of the pump unit. Both are contained within casing C, to which the pump unit is bolted. The outer coupling B is bolted to the engine with four capscrews E. The inner section A is tightened onto the pump shaft spline with cap screw D. Coat threads of capscrew D with JCB Threadlocker and Sealer and torque tighten to 47 Nm (35 lbf ft, 4.8 kgf m). Coat threads of capscrews E with JCB Threadlocker and Sealer and torque tighten to 28 Nm (21 lbf ft, 2.8 kgf m).
205410-B1
Fig 2.
E-79
9803/9960-3
E-79
Section E - Hydraulics Pumps Start-up Procedure
Start-up Procedure
A168042-B2
Fig 3. The following start-up procedure should always be followed when starting up a new installation or when restarting an installation in which either a pump or motor has been removed from the system. Note: If a new or rebuilt pump is being fitted always refill the pump with filtered oil prior to start up via a 10 micron filter (no by-pass).. Use the correct oil. See Fluids, Lubricants and Capacities, Section 3.
!MWARNING
!MWARNING 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 protective glasses and gloves. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. INT-3-1-10_3
The following procedure requires the machine to be disabled (wheels raised off the ground, attachment disconnected etc.) while the work is carried out.
Place the machine safely onto blocks, so that all four wheels are clear of the ground. Ensure that the machine is stable.
HYD-8-1_2
Check that the pump inlet line from the hydraulic filter to the pump unit is filled with fluid, by 'cracking' the hose connection at the rear main pump.
!MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication. HYD-1-5
E-80
Install a 0 - 35 bar (0 - 500 lb/in2, 0 - 35 kgf/cm2) pressure gauge in the charge pressure gauge port A, to monitor the charge pressure. After machine serial no. 751012 a test point is provided which, up to serial no. 751715, is positioned under the pump as shown at B. K Fig 4. ( T E-81)
9803/9960-3
E-80
Section E - Hydraulics Pumps Start-up Procedure From serial no. 751716 this test point is positioned at the rear of the left hand side of the engine as shown at C K Fig 5. ( T E-81).
whilst slowly increasing the throttle lever setting until the engine starts and runs atthe lowest possible speed. As air leaves the system, the charge pressure (as indicated on the gauge) should rise to a minimum of 7 bar (7 kgf/cm2 100 lb/in2).If the charge pressure is incorrect, shut-down and determine the cause. Once the correct charge pressure has been established, operate the drive system 10 times in all directions with the engine at idle then slowly increase the engine speed whilst continuing to operate the system. Finally operate the system in all directions several times with the engine running at maximum speed. Shut down engine and remove the pressure gauge. Check the system fluid level and top up as necessary.
S246240-B1
Fig 4.
348890-B2
Fig 5. Remove the ESOS fuse to prevent the engine from starting. With the Drive Control Lever (in the cab) at Neutral, 'jog' the engine using the starter. The pressure gauge should show a small rise in pressure as the engine turns. If so, replace theESOS fuse and operate the starter
E-81
9803/9960-3
E-81
Section E - Hydraulics Pumps Hydrostatic Pump from machine no. 751012
Hydrostatic Pump from machine no. 751012 Dismantling and Assembly Note: Following a complete rebuild of this pump it is necessary for it to be set up on a dynamic test jig. Because of this it is recommended that no dismantling work is carried out beyond that covered in this manual.
8
Install new O-ring 5 onto seal carrier 3 and lubricate with petroleum jelly.Wrap the splined end of shaft 2 with thin plastic to prevent damage to the lip seal during installation.Slide seal carrier 3 over shaft 2 and press into position in the pump body recess.
9
Holding inward pressure against shaft 2, refit circlip 1 to secure the assembly.
Shaft Seal Removal and Replacement 1
Remove circlip 1.
Note: It may be necessary to press shaft 2 into the body against spring force before the circlip can be removed. When the circlip is removed, seal carrier 3 will move out approximately 6 mm (0.25 in.) due to spring force. 2
Lightly tap the end of shaft 2 with a rubber mallet and remove seal carrier 3.
Note: After the seal carrier has been removed, the shaft 2 and bearing assembly 4 are free in the body. Under no circumstances should the shaft be removed as this could cause loss of alignment of the pump internals necessitating a total strip and rebuild. Such a procedure is outside the scope of this Service Manual. 3
Remove O-ring 5 from seal carrier 3. Discard the Oring.
4
Using a suitable press, press out lip seal 6 from the seal carrier. Discard the lip seal.
5
Inspect seal carrier 3 for damage, and the sealing area on shaft 2 for signs of rust, wear or contamination. Polish the sealing area on the shaft if necessary.
6
Coat the outside diameter of new lip seal 6 with suitablesealant. Press the lip seal into the shaft bearing side of seal carrier 3, ensuring that the seal lip faces the shaft bearing. Take care not to damage the lip seal.
7
Lubricate the inside diameter of lip seal 6 with petroleum jelly.
E-82
9803/9960-3
S244910-B1
Fig 6.
E-82
Section E - Hydraulics Pumps Hydrostatic Pump from machine no. 751012
Charge Check and High Pressure Relief Valves Dismantling and Assembly The charge check and high pressure relief valves are identical. The procedure for dismantling and assembly is therefore the same for both valves. 1
Unscrew plug 1 from the pump body.
2
Remove the relief valve assembly 2 from the body. The smaller end of the conical spring is crimped to retain it on the relief valve.
Note: The High Pressure Relief Valve is factory set and cannot be repaired. 3
Remove and discard O-rings 3 and 4, and back-up ring 5 from plug 1.
4
Inspect relief valve 2 and mating seat in plug 1 for damage. Replace if necessary.
5
Install a new outer O-ring 3, new back-up ring 5 and new inner O-ring 4 on plug 1.
6
Check that the conical spring is correctly retained on relief valve and install the valve in the pump body.
S244930-B1
Fig 7.
Note: The conical spring must be correctly retained on the relief valve to ensure satisfactory pump operation. 7
Refit plug 1 and torque tighten to 68 Nm (50 lbf ft).
E-83
9803/9960-3
E-83
Section E - Hydraulics Pumps Hydrostatic Pump from machine no. 751012
Charge/Anti-stall Valve Dismantling and Assembly 1
Mark the plug 1, locknut 2 and the pump body so as to maintain approximately the original adjustment.
2
Loosen locknut 2 and unscrew plug 1 from pump body. Remove O-ring 3 from plug 1 and discard Oring.
3
Remove spring 4 and poppet 5 from pump body.
4
Inspect poppet 5 and mating seat in pump body for damage. Renew as necessary.
5
Install a new O-ring 3 on plug 1.
6
Fit poppet 5 and spring 4 into pump body.
7
Screw plug 1 complete with locknut 2 into pump body to align with the marks made during disassembly. Tighten the locknut.
8
Check the charge pressure and adjust as necessary.K Charge Pressure Checking and Adjustment ( T E-74) S244920-B1
Fig 8.
E-84
9803/9960-3
E-84
Section E - Hydraulics Pumps Hydrostatic Pump from machine no. 751012
Pump Neutral Adjustment
Position the operator's seat facing forwards so that the brakes are released.
This procedure may be carried out if the machine creeps when the drive joystick is in the neutral position. This fault may be due to an incorrect neutral setting of the servo piston. Before attempting any adjustment, carry out the following preliminary checks. 1
1
Identify which pump section requires adjustment. If the machine veers to the left this could be caused by either the right hand wheels moving forward or the left hand wheels moving in reverse. Remember that pump P1 drives the left hand motor and pump P2 drives the right hand motor.
Check tyre pressures and condition. 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.
2
Check chain tension. 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.
3
Check brake release pressure, seal failure. Low pressure or faulty seals may cause the brake to drag on one side. Check the pressure at theanti-stall valve. Check the seal by using a hand pump to release the brake and see if the pressure holds.
4
Check the drive joystick Check that the joystick spools are not sticking and are correctly operated by the lever.
Note: If the fault cannot be rectified by any of the above checks or adjustment, then either the pump or motor could be faulty. To identify which, swop the motor feed hoses at the pump. If the machine now veers in the opposite direction then the pump is faulty. If the machine continues to veer in the same direction the the motor is faulty.
Adjustment procedure
S244940-B1
Fig 9. 2
Stop the engine.
3
Remove the floor plates.
4
Loosen locknut A and turn the `neutral' adjusting screw B 1/10 of a turn in the required direction then re-tighten the locknut.
!MWARNING
If the wheels are creeping forward, turn the adjusting screw in a clockwise direction (looking underneath the pump). If the wheels are creeping in reverse, turn the screw anti-clockwise.
The following procedure requires the machine to be disabled (wheels raised off the ground, attachment disconnected etc.) while the work is carried out. HYD-8-1_2
Place the machine safely onto blocks, so that all four wheels are clear of the ground. Ensure that the machine is stable.
E-85
Note: This adjustment is very sensitive. Turn the adjusting screw 1/10 of a turn at a time and re-check. A slight movement when the wheels are raised is acceptable
9803/9960-3
E-85
Section E - Hydraulics Pumps Hydrostatic Pump from machine no. 751012 provided that no movement occurs when the machine is resting on the ground. 5
Start the engine and check that the wheels are stationary.
6
Finally tighten locknut A to 23 Nm (17 lbf ft), taking care to retain the set position of adjusting screw B.
7
Re-check for wheel movement.
E-86
9803/9960-3
E-86
Section E - Hydraulics Pumps Auxiliary Pump (Standard machines)
Auxiliary Pump (Standard machines)
S167751-V1
Fig 10.
Removal and Replacement
Dismantling
Remove bolts X and lift the pump away from the main pump unit.
Remove coupling A if still fitted.
On replacement, torque tighten the bolts to 77 Nm (57 lbf ft, 7.9 kgf m).
Hold the body in a soft jawed vice with the mounting flange uppermost. Mark all parts to ensure correct alignment when assembling. Discard all seals and sealing rings.
Dismantling and Assembly
Clean all parts in light aromatic kerosene, examine for damage and wear.
The numerical sequence shown on the illustration is intended as a guide to dismantling. K Fig 10. ( T E-87)
Damaged or worn parts must be renewed.
For assembly the sequence should be reversed.
Inspection It is normal for the gears to have cut a slight track in the body bore on the inlet side. The gear track wear can not bemeasured accurately but will be related to bearing wear.
E-87
9803/9960-3
E-87
Section E - Hydraulics Pumps Auxiliary Pump (Standard machines) Examine the bearing bores C which are coated during manufacture with PTFE. If the grey PTFE is worn through so that the bronze base is visible, the complete pump must be renewed. K Fig 11. ( T E-88)
If the inlet adapter is disturbed, fit a new `O' ring and tighten to 115 - 145 Nm (85 - 107 lbf ft, 11.7 - 14.8 kgf m). Do not overtighten. If the outlet adapter is disturbed, clean the threads and apply JCB Threadlocker and Sealer to two of the threads. Tighten to 95 Nm (70 lbf ft, 9.7 kgf m). Do not overtighten. When refitting the auxiliary pump to the Hydrostatic pump, tighten mounting bolts to 77 Nm (57 lbf ft, 7.9 kgf m).
Testing Install the pump onto a suitable test rig and test as follows. K Table 1. Test Data ( T E-88)
Oil Viscosity
Table 1. Test Data 40 - 45 cSt at 50 deg C, (122 deg F)
Oil Temperature
45 - 50 deg C (113 - 122 deg F) at pump inlet
Test Speed
1500 rev/min nominal
139690-V1
Fig 11. Renew the pump if the bearings are scored or if the gear side faces are chipped or damaged. DO NOT use anyabrasives on the bearings or gears as this would destroy critical manufacturing dimensions.
Run pump initially off load and check for leaks. Increase pressure in stages of 40 bar (600 lb/in2, 40 kg/cm2) and allow to run for 1 minute at each stage. This will allow components to readjust and flow readings will indicate if rebuild is correct. Check pump output under the following conditions.K Table 2. ( T E-88)
Assembly Pressure Fit the pressure loading ring/backing ring 10 and sealing rings 11 to the flange 2 and cover 8. A little grease (JCB MPL Grease) in the grooves will help retain them.
Minimum Flow
Table 2. 230 bar (3335 lb/in2, 230 kg/cm2) 22 l/min (4.8 UK gal/min, 5.8 US gal/min)
Hold the flange 2 in a soft jawed vice with the sealing rings facing upwards and assemble the body 3. Ensure that the body cut-in track corresponds to the inlet side of the flange. Assemble the gear/bearing pack components 4, 5, 6 and 7 separately. It is important to return the flange end bearing 6 to the flange end of the unit, otherwise internal leakage can occur due to bedding in. Ensure that the bearing face recesses B are adjacent to the gear faces and that the relieved radii are both towards the pump outlet. Lightly lubricate the body bore and bearings, then push the gear/bearing pack into the body. Fit the cover 8, ensuring the inlet side is in the correctposition. Torque tighten bolts 1 to 61 - 68 Nm (45 50 lbf ft, 6.2 - 7.0 kgf m).
E-88
9803/9960-3
E-88
Section E - Hydraulics Pumps Auxiliary Pump (High-flow machines)
Auxiliary Pump (High-flow machines) Dismantling and Assembly Note: Before removing and dismantling the pump, check flow and pressure. If either of these is low, renewal of components such as gears, bearings and housings will not effect a permanent cure. If the pump output is satisfactory but there is external leakage, the pump may be removed and dismantled for re-sealing only. The numerical sequence shown on the illustration is intended as a guide to dismantling. K Fig 12. ( T E-90) For assembly the sequence should be reversed.
When Dismantling Mark housings and covers to ensure correct re-assembly. Keep bearing blocks 6, 8, 16, 18 and gears 4, 5, 14 and 15 together in sets to ensure refitting of the bearing blocks in their original positions.
Hold flange 2 in a vice and apply a force of 200-250 N (4555 lbf) to body 3 at position indicated by arrow X (within 10 mm [0.4 in] of the flange). Whilst maintaining this force, torque tighten bolts 1 in a diagonal sequence. This procedure is necessary to ensure metal to metal contact between front bearing lobes and inlet side of body. Torque tighten bolts 1 to 61 - 68 Nm (45 - 50 lbf ft, 6.2 - 7.0 kgf m). If the inlet adapters are disturbed, fit new `O' rings and tighten to 115 - 145 Nm (85 - 107 lbf ft, 11.7 - 14.8 kgf m). Do not overtighten. If the outlet adapters are disturbed, clean the threads and apply JCB Threadlocker and Sealer to two of the threads. Tighten to 95 Nm (70 lbf ft, 9.7 kgf m). Do not overtighten.
Extended bush A in bearing block 6 is a light push fit in flange 2. DO NOT remove plug B as it is an interference fit, assembled to a critical dimension.
Inspection Wash all components then apply hydraulic oil immediately afterwards to prevent moisture from collecting. It is normal for the gears to have cut a slight track in the body bore on the inlet side. The gear track wear cannot be measured accurately but will be related to bearing wear. Examine the bores of the bearing blocks 6, 8, 16 and 18 which are coated during manufacture with PTFE. If the grey PTFE is worn through so that the bronze base is visible, the complete pump must be renewed. Renew pump if faces of bearing blocks are scored or if side faces of gears are chipped or damaged. DO NOT use any abrasives on the bearing blocks or gears as this would destroy critical manufacturing dimensions.
When Assembling Renew all seals. Hold them in position with grease duringassembly. Ensure that the ends of seals 7, 9, 17 and 19 do not overhang the bearing blocks to become trapped in the housings. Bearings must be assembled with cast recesses (not seal grooves) against gear faces and with seal ends towards theinlet side of the pump. Lightly lubricate threads of bolts 1 and finger tighten only.
E-89
9803/9960-3
E-89
Section E - Hydraulics Pumps Auxiliary Pump (High-flow machines)
291090-V1
Fig 12.
E-90
9803/9960-3
E-90
Section E - Hydraulics
Valves (Series 1 Machines) Loader Valve
205110-B2
Fig 1.
!MWARNING
Removal Remove rear floor plates. See Floorplates, Section 3.
Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication. HYD-1-5
Before working on the hydraulic system ensure that the engine is switched off and the starter key removed.
E-91
9803/9960-3
E-91
Section E - Hydraulics Valves (Series 1 Machines) Loader Valve Vent the hydraulic pressure. K Releasing the Hydraulic Pressure ( T E-7) Drain the hydraulic tank. Disconnect all hydraulic hoses from the valve ports (one check valve at inlet A, six work ports B, four servo connections C (two on the opposite side), one high pressure carry over D and one outlet E). Cover exposed connections to prevent ingress of dirt. Mark the hoses to ensure correct reconnection. Disconnect the electrical connectors to the solenoids. Markthe connectors to ensure correct reconnection. Remove the securing nuts from mounting lugs F and lift the valve block from the machine.
Replacement Replacement is a reversal of the removal procedure. Ensure all hoses and ports are clean and free from dirt. securing nuts to 56 Nm (5.7 kg fm, 42 lbf ft)
E-92
9803/9960-3
E-92
Section E - Hydraulics Valves (Series 1 Machines) Loader Valve
Dismantling and Assembly
Ensure that the spools are inserted with their larger waisted sections towards the bottom.
K Fig 2. ( T E-94)
Dismantling
Lubricate all parts with hydraulic oil before assembly and all 'O' rings and seals with vaseline.
Always work on a clean, dirt free surface.
Torque Settings
1
Remove the plug from port B.
Nm
kgf m
lbf ft
Tie Rod 10
(1 off)
44.75
4.6
33.0
Tie Rod 13
(2 off)
20.0
2.0
14
A.R.V. 18
(3 off)
44.75
4.6
33.0
M.R.V. 22
(1 off)
44.75
4.6
33.0
Note: The four end caps 2 are identical. Do not mixparts between individual end caps.
Plug 20
(3 off)
44.75
4.6
33.0
Plug B
(1 off)
9.5
1.0
7.0
3
Remove cap screws 6 from the solenoids 7, then remove the solenoids (2 off).
Cap screws 1 (6 off) &6
34.0
3.5
25.0
4
Remove nuts 8 (2 off) and washers 9 (2 off) from tie rod 10, withdraw tie rod 10.
5
Remove nuts 11 (4 off) and washer 12 (4 off) from tie rods 13 (2 off), withdraw tie rods 13.
6
Carefully separate inlet section C, operation sections E, F, G and outlet section D. Discard the 'O' rings 14 (4 off) from between the sections.
2
Item
Remove the cap screws 1 from the end caps 2. Carefully remove the 'O' ring 3, spring seat 4 and spring 5 from each end cap 2. Keep all parts of each end cap together. Discard 'O' ring 3.
Note: Work on the operation sections E, F, G individually. Do not interchange parts from individual sections. 7
Carefully push out the check valve 15 and spring 16. Push out the spool 17. (Only spool E is described, but F and G are similar.)
8
Remove the auxiliary relief valves 18 (2 from E, 1 from F).
9
Remove plugs 20 (1 from F, 2 from G), remove and discard 'O' rings 21 (3 off).Remove the main relief valve 22 from the inlet section C. Remove and discard 'O' ring 23.
10
Remove the test connector 24 from the inlet section. Remove and discard 'O' ring 25.
11
Clean all parts in kerosene, inspect and check for damage.
Damaged sections should be replaced complete.
Assembly Assembly is a reversal of the dismantling procedure. Renew all seals and 'O' rings.
E-93
9803/9960-3
E-93
Section E - Hydraulics Valves (Series 1 Machines) Loader Valve
205140
Fig 2.
E-94
9803/9960-3
E-94
Section E - Hydraulics Valves (Series 1 Machines) Loader Valve
Main Relief Valve and Auxiliary Relief Valves
205090-B1
Fig 3. Note: The M.R.V. X and loader valve A.R.V.'s Y are identical in design.
Renew all 'O' rings. Lubricate parts with Hydraulic Fluid before assembly.The M.R.V. can be tested/adjusted in situ . The A.R.V's are tested/adjusted on a bench.
Removal Replacement Remove rear floor plates. See Floorplates, Section 3. Replacement is a reversal of the removal procedure. Ensure that the engine is stopped and hydraulic pressure released from the system. Each valve is removed by unscrewing nut 1.
Dismantling and Assembly
Torque Settings Item
Nm
kgfm
lbf ft
1
44.75
4.6
33
The manufacturers do not recommend renewing individual components of the M.R.V. or A.R.V.'s. Each valve should be renewed as a unit if a component is defective.
E-95
9803/9960-3
E-95
Section E - Hydraulics Valves (Series 1 Machines) Excavator Valve
Excavator Valve
205170
Fig 4. K Dismantling and Assembly ( T E-97)
E-96
9803/9960-3
E-96
Section E - Hydraulics Valves (Series 1 Machines) Excavator Valve
Dismantling and Assembly
Relief Valves
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Ensure that A.R.V's 4J to 4T are correctly adjusted and fitted in their specified positions.
K Fig 4. ( T E-96)
Torque tighten A.R.V's to 41 - 68 Nm (30 - 50 lbf ft, 4.15 6.9 kgf m).
For assembly the sequence should be reversed. The manufacturers do not recommend renewing individual components of the A.R.V.'s. Each valve should be renewed as a unit if a component is defective.
Check Valves Each spool has an identical load hold check valve which can be removed as shown at 4W. Note: Only 4W shown on illustration. Ensure good condition of seating face on poppet 10 and on the mating face in the valve block. Note: All valve block adapters are torqued to 81 Nm (60 lbf ft; 8.3 kgf m).
Spools
Renew all 'O' rings. Lubricate parts with Hydraulic Fluid before assembly. The A.R.V's are tested/adjusted on a bench. K Auxiliary Relief Valve (A.R.V.'s) - Using Hand Pump ( T E-71)
Hydraclamp Valve The numerical sequence shown on the illustration is intended as a guide to dismantling. K Fig 5. ( T E-98)
Spools 4B, 4C, 4D, 4E, 4F and 4G are identical but must not be interchanged as they are matched to their bores. Slew spool 4A is different in design from the above spools.
For assembly the sequence should be reversed.
All spools have the same centring and sealing components items 11 to 19 and 24 to 27. To completely dismantle a spool, follow the sequence 11 to 19 and 24 to 27. To prevent spool rotation when turning screw 13, hold a rod through the eye end of the spool. Lubricate new seals with Hydraulic Fluid and take care to prevent them from being damaged by the sharp edges of the spool. Apply JCB Lock and Seal to threads of screw 13. Torque Settings Item
Nm
1A
17.6 - 20.4 1.76- 2.04 13 - 15
1B
41 - 49
4.2 - 5
11
6.1 - 7.5
0.62 - 0.76 4.5 - 5.5
13
9.5 - 10.9
0.97 - 1.11 7 - 8
E-97
kgfm
lbf ft 30 - 36
9803/9960-3
E-97
Section E - Hydraulics Valves (Series 1 Machines) Excavator Valve
S175600
Fig 5.
E-98
9803/9960-3
E-98
Section E - Hydraulics Valves (Series 1 Machines) Excavator Valve When Dismantling Plug hose 1 to prevent loss of oil and entry of dirt. When Assembling Note: View 'A' shows the clamp in the OFF position. K Fig 5. ( T E-98) Ensure that orifice X is clear. Lubricate new seals with Hydraulic Fluid. Ensure that plug 7 locates in groove Y of rotary spool 9. Torque nut 5 finger-tight before locking lever 4. Ensure that spool 9 rotates freely after tightening nuts 5 and 3. Torque Settings Item
Nm
kgfm
lbf ft
3
55 - 67
5.6 - 6.84
40.5 - 49.5
7
3.3 - 4.7
0.35 - 0.49 2.5 - 3.5
14
21.3 - 26.7 2.22 - 2.78 16 - 20
E-99
9803/9960-3
E-99
Section E - Hydraulics Valves (Series 1 Machines) Pressure Reducing Solenoid Valve (to serial no. 752462)
Pressure Reducing Solenoid Valve (to serial no. 752462)
204990-B1
Fig 6.
Removal
Remove bolts X (2 off) and remove the valve.
!MWARNING
Replacament
Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.
Reconnect the connections.
solenoid
valves
and
all
hydraulic
Dismantling
HYD-1-5
Before working on the hydraulic system ensure that the engine is switched off and the starter key removed.Vent the hydraulic pressure. K Releasing the Hydraulic Pressure ( T E-7) Remove and plug all hydraulic hoses. Plug exposed connections in the valve body 1. Disconnect the solenoid electrical cables.
E-100
Replace bolts X and torque tighten to 12 Nm (9 lbf ft, 1.2 kgf m).
K Fig 6. ( T E-100) Secure the valve body 1 into a suitable soft jaw vice or fixture. Remove the pressure reducing cartridge valve 2 and the solenoid cartridge valve 3. Solenoids A and B can be removed if necessary by unscrewing the coil retaining nut 4.
9803/9960-3
E-100
Section E - Hydraulics Valves (Series 1 Machines) Pressure Reducing Solenoid Valve (to serial no. 752462) All seals and 'O' rings should be discarded. Do not dismantle the cartridges. If damage or excessive wear is found a cartridge should be replaced as a complete unit. The machined orifice 5 should be examined for wear but not removed unless being renewed. Examine wiring for damage or chafing; replace as necessary.
Assembly Assembly is a reversal of the dismantling procedure. Fit new 'O' ring seals. Torque tighten to 23-28 Nm (17 - 21 lbf ft, 2.3 - 2.9 kgf m).Check (and if necessary adjust) the setting of cartridge valve 2. K Pressure Reducing Valve Cartridge ( T E-73) Replace solenoids on cartridge 3, torque tighten the coil retaining nut 4 to 5 - 7 Nm (3.7 - 5.2 lbf ft, 0.5 - 0.7 kgf m).
E-101
9803/9960-3
E-101
Section E - Hydraulics Valves (Series 1 Machines) Brake Valve from serial no. 752463
Brake Valve from serial no. 752463 Dismantling Unscrew the knurled nut 2 and remove `O' ring 3, withdraw the solenoid 4 and `O' ring 5. Hold the solenoid valve body 6 in a vice, using the spanner flats A, remove spindle 7 and `O' ring 8. Pull out actuating pin 9, spring 10, spring retainer 11 and spool 12. Inspect the spool and spool bore for signs of wear, nicks, scratches, etc.
Assembly Assembly is the reversal of the dismantling procedure. Renew all `O' rings. Lightly lubricate all parts with clean hydraulic fluid before assembling. Check that the flying leads are secure and that the connectors are intact.
Torque Settings Item
Nm
kgfm
lbf ft
2
10 to 15
1 to 1.5
8 to 10
161590-B1
Fig 7.
E-102
9803/9960-3
E-102
Section E - Hydraulics
Valves (Series 2 Machines) Main Servo Valve Block (10 Spool) Description
An electrically operated servo cut-off valve is fitted in the servo feed circuit. This is operated by the isolator switch to allow spool movement only when the switch is closed.
The cleanliness of this component is critical and must conform to JCB standard 9993/0003. The main servo valve block is located under the cab floor plate. The valve block consists of ten hydraulic servo operated spools controlling loader arm lift and excavator functions. A main relief valve controls the maximum pressure generated in the loader circuits. When no service is selected the oil passes straight through the neutral gallery of the valve block. When a service is selected the neutral gallery is blocked by the selected spool and oil is directed past the load hold check valve and on to the ram to operate the service. Return oil from the ram is fed back through the spool into the valve block exhaust gallery and back to tank. Note that loader raise and lower return oil is fed back to the neutral gallery.
IN 1
2
3
4
5
6
Item
Table 1. Valve sections Description
IN
Inlet
1
BH Boom
2
BH Bucket
3
BH Dipper
4
BH Slew
5
Stabiliser
6
Stabiliser
7
Loader Arms
8
Loader Shovel
9
BH Auxiliary
10
Loader Auxiliary
OUT
Outlet
7
8
9
10 OUT
Fig 1.
E-103
9803-9960-3
E-103
Section E - Hydraulics Valves (Series 2 Machines) Main Servo Valve Block (10 Spool) Table 2. Relief Settings Port A
Section Item Bar (psi) Main Relief Valve
Flow (Litre/min)
Port B (1)
Item Bar (psi)
Flow (Litre/min)
220 (3190)
IN
Inlet
D
220 (3190)
19
-
-
-
1
BH Boom
A
240 (3480)
2
B
240 (3480)
10
2
BH Bucket
A
240 (3480)
2
A
240 (3480)
2
3
BH Dipper
B
240 (3480)
10
A
240 (3480)
2
4
BH Slew
A
240 (3480)
2
A
240 (3480)
2
5
Stabiliser
-
-
-
-
-
-
6
Stabiliser
-
-
-
-
-
-
7
Loader Arms
-
-
-
A
240 (3480)
2
8
Loader Shovel
C
100 (1450)
56
C
240 (3480)
10
9
BH Auxiliary
A
240 (3480)
2
A
240 (3480)
2
10
Loader Auxiliary
F
Option
Option
F
Option
Option
-
-
-
-
OUT Outlet
(1) Based on a pump delivering 45 Litres / minute.
T065350-1
Fig 2.
E-104
9803-9960-3
E-104
Section E - Hydraulics Valves (Series 2 Machines) Main Servo Valve Block (10 Spool)
IN
1
2
3
4
5
6
7
8
9
10
OUT T065350-2
Fig 3. Schematic
Port
Table 3. Valve Port Description
IN
Inlet
1
BH Boom
2
BH Bucket
3
BH Dipper
4
BH Slew
5
Stabiliser
6
Stabiliser
7
Loader Arms
8
Loader Shovel
9
BH Auxiliary
10
Loader Auxiliary
OUT
Outlet/Return
E-105
9803-9960-3
E-105
Section E - Hydraulics Valves (Series 2 Machines) Main Servo Valve Block (10 Spool)
BL BD DI SL
LR LC
GP
EPD
IP
CP WP BR BC DO SR
LL LD
OP
PP T065360-2
Fig 4. Main Valve Block Ports
Port
Table 4. Valve Ports Description
IP
Inlet Port
GP
Gauge Port
WP
Work Port (x 20)
PP
Pilot Port (x 14)
OP
Outlet Port
EPD
External Clamp Port Drain
BR
Boom Raise
E-106
Port
Description
BL
Boom Lower
BC
Bucket Crowd
BD
Bucket Dump
DO
Dipper Out
DI
Dipper In
SR
Slew Right
SL
Slew Left
LL
Loader Arms Lower
9803-9960-3
E-106
Section E - Hydraulics Valves (Series 2 Machines) Main Servo Valve Block (10 Spool) Port
Description
LR
Loader Arms Raise
LD
Loader Shovel Dump
LC
Loader Shovel Crowd
E-107
9803-9960-3
E-107
Section E - Hydraulics Valves (Series 2 Machines) Main Servo Valve Block (10 Spool)
Removal
!MWARNING 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 starter key. Make sure the park brake is engaged. Disconnect the battery to prevent the engine being started. Block all four wheels. 3-3-1-2
!MWARNING Hydraulic Pressure 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. INT-3-1-11_2
1
Make the machine safe with the loader arm lowered. Refer to Maintenance, Prepare the Machine for Maintence.
2
Remove the floor mat.
3
Remove the bolts that secure the floor plates, remove the floor plates to reveal the hydraulic valves.
4
Mark all hoses to ensure correct replacement. K Table 3. Valve Port ( T E-105).
5
Remove the hoses and cap the ends with blanking caps to prevent loss of fluid and ingress of dirt.
6
Support the valve block and remove the bolts.
7
Remove the valve block, cap the ports with blanking caps to prevent loss of fluid and ingress of dirt.
Replacement 1
Replacement is a reversal of the removal procedure.
2
Ensure all hoses and ports are clean and free from dirt.
3
Make sure all bolts are correctly torque tightened.
E-108
9803-9960-3
E-108
Section E - Hydraulics Valves (Series 2 Machines) Loader Changeover Valve
Loader Changeover Valve Description
Table 5. Operating Conditions Nominal Flow 5 Litres / min
The cleanliness of this component is critical and must conform to JCB standard 9993/0003.
Normal pressure
40 Bar
Maximum working pressure
65 Bar
The loader changeover valve is located under the cab floor plate.
Solenoid Coil
20.16 Watts / 12 Volts
DIODE WIRING DIAGRAM 1 +VE
2 -VE
G^
T^
GW^
SV1
GG^
GR^
SV1
OW^
GG^
SV2
OB^
OO^
SV4
SV3
SV2 G^
O^
O^
SV3
YW^
PW^
SV5 OO^
SV4
YG^
SV SV6 BW^
BR^
SV5
PG^
SV SV6
T065330-1
Fig 5.
Item
Table 6. Description
SV1
Solenoid Valve 1
SV2
Solenoid Valve 2
E-109
Item
Description
SV3
Solenoid Valve 3
SV4
Solenoid Valve 4
SV5
Solenoid Valve 5
9803-9960-3
E-109
Section E - Hydraulics Valves (Series 2 Machines) Loader Changeover Valve Item
Description
SV6
Solenoid Valve 6
T065330-2
Fig 6.
E-110
9803-9960-3
E-110
Section E - Hydraulics Valves (Series 2 Machines) Loader Changeover Valve
Removal
!MWARNING 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 starter key. Make sure the park brake is engaged. Disconnect the battery to prevent the engine being started. Block all four wheels. 3-3-1-2
!MWARNING Hydraulic Pressure 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. INT-3-1-11_2
1
Make the machine safe with the loader arm lowered. Refer to Maintenance, Prepare the Machine for Maintence.
2
Remove the floor mat.
3
Remove the bolts that secure the floor plates, remove the floor plates to reveal the hydraulic valves.
4
Mark all hoses and electrical connections to ensure correct replacement.
5
Remove the hoses, cap the ends with blanking caps to prevent loss of fluid and ingress of dirt.
6
Support the valve and remove the bolts.
7
Remove the valve , cap the ports with blanking caps to prevent loss of fluid and ingress of dirt.
Replacement 1
Replacement is a reversal of the removal procedure.
2
Ensure all hoses and ports are clean and free from dirt.
3
Make sure all bolts are correctly torque tightened.
E-111
9803-9960-3
E-111
Section E - Hydraulics Valves (Series 2 Machines) Transmission Changeover Valve
Transmission Changeover Valve Description
The coil is an integral part of the valve and is not serviceable.
The cleanliness of this component is critical and must conform to JCB standard 9993/0003.
Table 7. Operating Conditions Nominal Flow 5 Litres / min
The transmission changeover valve is located under the cab floor plate.
Maximum Flow Normal pressure
20 Bar
The solenoid valve when de-energised allows oil flow from port 3 to 2 and from port 4 to 1. When energised the cartidge spool shifts to allow the oil flow from port 2 to 1 and from port 3 to 4.
Maximum working pressure
35 Bar
30 Litres / min
Maximum tank line pressure 3 Bar Solenoid Coil
20.16 Watts / 12 Volts
T065370-2
Fig 7.
E-112
9803-9960-3
E-112
Section E - Hydraulics Valves (Series 2 Machines) Transmission Changeover Valve
T065370-1
Fig 8. Schematic
E-113
9803-9960-3
E-113
Section E - Hydraulics Valves (Series 2 Machines) Transmission Changeover Valve
Removal
!MWARNING 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 starter key. Make sure the park brake is engaged. Disconnect the battery to prevent the engine being started. Block all four wheels. 3-3-1-2
!MWARNING Hydraulic Pressure 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. INT-3-1-11_2
1
Make the machine safe with the loader arm lowered. Refer to Maintenance, Prepare the Machine for Maintence.
2
Remove the floor mat.
3
Remove the bolts that secure the floor plates, remove the floor plates to reveal the hydraulic valves.
4
Mark all hoses and electrical connections to ensure correct replacement.
5
Remove the hoses, cap the ends with blanking caps to prevent loss of fluid and ingress of dirt.
6
Support the valve and remove the bolts.
7
Remove the valve , cap the ports with blanking caps to prevent loss of fluid and ingress of dirt.
Replacement 1
Replacement is a reversal of the removal procedure.
2
Ensure all hoses and ports are clean and free from dirt.
3
Make sure all bolts are correctly torque tightened.
E-114
9803-9960-3
E-114
Section E - Hydraulics Valves (Series 2 Machines) PMS Combination Valve
PMS Combination Valve Description The cleanliness of this component is critical and must conform to JCB standard 9993/0003. The PMS combination valve is located under the cab floor plate. Table 8. Operating Conditions Maximum Flow 20 Litres / min Maximum working pressure
30 Bar
Table 9. CT No
Description
Torque Value
CT1
Solenoid Cartridge
20Nm
CT2
Solenoid Cartridge
20Nm
CT3
Proportional Pressure Reducer
30Nm
CT4
Proportional Pressure Reducer
-
CT5
Proportional Pressure Reducer
-
CT6
Proportional Pressure Reducer
45Nm
E-115
9803-9960-3
E-115
Section E - Hydraulics Valves (Series 2 Machines)
E-116
9803-9960-3
A
BR
P2
PA
C
P1
P
T
PMS Combination Valve
E-116
Section E - Hydraulics Valves (Series 2 Machines) PMS Combination Valve T065340-1
Fig 9. PMS Combination Valve
PA
BRU CT1 1
P1U CT4 4
CT2 2
P2U CT5 5
CT3 3 CT6 6
Fig 10. Schematic
E-117
9803-9960-3
E-117
Section E - Hydraulics Valves (Series 2 Machines) PMS Combination Valve
Removal
!MWARNING 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 starter key. Make sure the park brake is engaged. Disconnect the battery to prevent the engine being started. Block all four wheels. 3-3-1-2
!MWARNING Hydraulic Pressure 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. INT-3-1-11_2
1
Make the machine safe with the loader arm lowered. Refer to Maintenance, Prepare the Machine for Maintence.
2
Mark all hoses and electrical connections to ensure correct replacement.
3
Remove the floor mat.
4
Remove the bolts that secure the floor plates, remove the floor plates to reveal the hydraulic valves.
5
Remove the hoses, cap the ends with blanking caps to prevent loss of fluid and ingress of dirt.
6
Support the valve block and remove the bolts.
7
Remove the valve block, cap the ports with blanking caps to prevent loss of fluid and ingress of dirt.
Replacement 1
Replacement is a reversal of the removal procedure.
2
Ensure all hoses and ports are clean and free from dirt.
3
Make sure all bolts are correctly torque tightened.
E-118
9803-9960-3
E-118
Section E - Hydraulics Valves (Series 2 Machines) ISO/SAE Changeover Valve
ISO/SAE Changeover Valve Description
The ISO/SAE changeover valve is located under the cab floor plate.
The cleanliness of this component is critical and must conform to JCB standard 9993/0003.
T065380-1
Fig 11.
E-119
9803-9960-3
E-119
Section E - Hydraulics Valves (Series 2 Machines) ISO/SAE Changeover Valve
T065380-2
Fig 12.
E-120
9803-9960-3
E-120
Section E - Hydraulics Valves (Series 2 Machines) ISO/SAE Changeover Valve
Removal
!MWARNING 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 starter key. Make sure the park brake is engaged. Disconnect the battery to prevent the engine being started. Block all four wheels. 3-3-1-2
!MWARNING Hydraulic Pressure 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. INT-3-1-11_2
1
Make the machine safe with the loader arm lowered. Refer to Maintenance, Prepare the Machine for Maintence.
2
Remove the floor mat.
3
Remove the bolts that secure the floor plates, remove the floor plates to reveal the hydraulic valves.
4
Mark all hoses to ensure correct replacement.
5
Remove the hoses, cap the ends with blanking caps to prevent loss of fluid and ingress of dirt.
6
Support the valve block and remove the bolts.
7
Remove the valve block, cap the ports with blanking caps to prevent loss of fluid and ingress of dirt.
Replacement 1
Replacement is a reversal of the removal procedure.
2
Ensure all hoses and ports are clean and free from dirt.
3
Make sure all bolts are correctly torque tightened.
E-121
9803-9960-3
E-121
E-122 B
The PMS combination valve is located under the cab floor plate.
Maximum inlet pressure
The cleanliness of this component is critical and must conform to JCB standard 9993/0003.
9803-9960-3
Fig 13. Solenoid Valve
A
Table 11. Torque Values Coil Retaining Nut 5 Nm
100 Bar
Table 10. Operating Conditions Maximum Flow 20 Litres / min
Description
Solenoid Valve 20 Nm
A
Note: Do not overtighten the coil retaining nut.
Cartridge Valve
T065320-1
Section E - Hydraulics
Valves (Series 2 Machines) Solenoid Valve
E-122
Section E - Hydraulics Valves (Series 2 Machines) Solenoid Valve
Removal
!MWARNING 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 starter key. Make sure the park brake is engaged. Disconnect the battery to prevent the engine being started. Block all four wheels. 3-3-1-2
!MWARNING Hydraulic Pressure 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. INT-3-1-11_2
1
Make the machine safe with the loader arm lowered. Refer to Maintenance, Prepare the Machine for Maintence.
2
Remove the floor mat.
3
Remove the bolts that secure the floor plates, remove the floor plates to reveal the hydraulic valves.
4
Mark all hoses and electrical connections to ensure correct replacement.
5
Remove the hoses, cap the ends with blanking caps to prevent loss of fluid and ingress of dirt.
6
Support the valve block and remove the bolts.
7
Remove the valve block, cap the ports with blanking caps to prevent loss of fluid and ingress of dirt.
Replacement 1
Replacement is a reversal of the removal procedure.
2
Ensure all hoses and ports are clean and free from dirt.
3
Make sure all bolts are correctly torque tightened.
E-123
9803-9960-3
E-123
Section E - Hydraulics Valves (Series 2 Machines) Solenoid Valve
Page left intentionally blank
E-124
9803-9960-3
E-124
Section E - Hydraulics
Drive Motors Removal and Replacement
205150-B1
Fig 1.
!MWARNING Clothing You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, earprotectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and personal jewellery. INT-1-3-6_2
E-125
The removal of the drive motors can be divided into two sections: removal of the motors themselves and removal of the drive sprockets and chains.
Removal of the Drive Sprocket On machines up to serial number 751817, remove the roadwheels. See Road Wheel Removal and Replacement, Section F. Remove the front floorplates. See Floorplates, Section 3. From the inside of the chassis, remove bolts 1 (6 off) and washers 2 (6 off). Take off cover 3, remove and discard
9803/9960-3
E-125
Section E - Hydraulics Drive Motors Removal and Replacement gasket 4. Turn both stub axles until the drive chains are at their slackest. See Wheel Hub Removal and Replacement, Section F.
Replacement
On machines up to serial number 751817, remove bolts 5 and withdraw spider 6. Draw out sprocket 7, then remove and discard oil seal 8. Examine the condition of bearing 9. Do not remove it unless it is to be renewed.
Note: The motors fitted from machine number 751012 are constructed differently for left and right hand operation and this is indicated on the serial number plate. Due to the installation on this machine the actual position may be opposite to that indicated on the motor, i.e. a motor marked for left hand operation would be fitted to the right hand side of the machine and vice versa. However on machines built around May 1997 onwards the motors are correctly marked. Refer to the parts catalogue for the correct motor.
On machines from serial number 751818 the spider assembly is no longer fitted, the sprocket being splined directly onto the motor shaft.
Removal of Motor On machines up to serial number 751817, remove the drive sprocket as previously described. On machines from serial number 751818 the sprocket is splined directly onto the motor shaft therefore it is not necessary to remove the sprocket or disturb the hubs and chains.
Replacement is the reversal of the removal procedure.
Renew all seals and 'O' rings. Apply JCB Threadlocker and Sealer to bolts 5 before fitting. Apply JCB High Strength Retainer to capscrews B before fitting. Note: On machines after serial number 751476 capscrews B are increased in size to M12. Earlier machines may be fitted with the larger capscrews if required, see Technical Information Bulletin 1/008. On machines after serial number 751818 capscrews B are further increased in size to M14. These have since been changed to M14 setscrews with hardened plain washers and no spring washer. The setscrews and hardened washers may be fitted as complete sets to earlier machines in place of the M14 cap screws, plain and spring washers. On machines up to serial number 751817, adjust the drivechain tension before fitting motor cover 3. See Section 3.
Torque Settings
S246250-B2
Fig 2. Remove the motor cover. Disconnect the hydraulic hoses A from the motor. Plug exposed connections. Withdraw capscrews B (4 off). The motors can now be lifted clear.
E-126
Item
Description
kgf m
lbf ft
1
Bolts M8 x 16 28 (6 off)
2.9
21
5
Cap screw 56 M10 x 100 (3 off)
5.8
42
A
Hydraulic Connections
44-50
4.6-5.1
33-37
B
Cap screw M10 x 30 (8 off)
56
5.8
42
B
Cap screw M12 x 30 (8 off)
98
10
72
9803/9960-3
Nm
E-126
Section E - Hydraulics Drive Motors Removal and Replacement Item
Description
Nm
kgf m
lbf ft
B
Cap screw M14 x 35 (8 off)
220
22.4
162
B
Setscrew M14 x 35 (8 off)
220
22.4
162
E-127
9803/9960-3
E-127
Section E - Hydraulics Drive Motors Dismantling and Assembly to machine no. 751011
Dismantling and Assembly to machine no. 751011 The numerical sequence shown is a guide to dismantling. For assembly the sequence should be reversed. K Fig 5. ( T E-130)
Note: Fretting between the housing flanges is accept able provided that components are assembled in the same relative positions.
Dismantling
Assembly
Note: Later motors are fitted with Eslock type bolts 3 which are wirelocked. When early motors are dismantled the later type bolts must be fitted and wirelocked. The bolts must always be renewed whenever a motor is dismantled. New bolts and lockwire are supplied as part of the replacement seal kit.
Note: Note: Soak new brake plates in oil for 1 hour before assembly.
Note: To gain access to the brake only, remove bolts 24, do not disturb bolts 3. After removing plug 1 and washer 2, place the unit in a holding tool or jig with housing 4 uppermost. Mark relative positions of housings 4 and 25 and outer gear 20 to ensure correct position on re-assembly.
Before assembling, lubricate all parts with oil. Grease all seals and 'O' rings with Vaseline. Ensure bearing 44 is pressed fully onto the shoulder of shaft 29. When fitting bolts 24, tighten them in sequence to avoid tilting the bearing 28. Do the following to ensure correct alignment of the gearwheel set components:
Housing 4 and channel plate 5 should be removed together and placed on a clean area of the bench. Remove guide pin 6 before separating the channel plate from the housing. To remove the balance plate 7 from housing 4, first remove spacer 8, then fill the hole with grease (to act as a hydraulic piston). Press a mandrel into the hole and force out the balance plate. Before removing inner gear 18 mark its position in the outer gear 20 to ensure that it is returned the same way upon assembly. Keep all parts of the gearwheel set 17 together after removal. Do not mix gearwheel parts from different motors. Before dismantling the brake assembly, seal the hydraulic port 23 to prevent ingress of dirt. Mark the position of the flanges to ensure correct assembly. Keep brake friction plates 30 and discs 31 together as a set. Discard all seals and 'O' rings. Any bearings removed must be renewed. Clean all parts in low aromatic kerosene.
E-128
9803/9960-3
S167730A
Fig 3.
E-128
Section E - Hydraulics Drive Motors Dismantling and Assembly to machine no. 751011 1
Mark any spline peak on the inner gear 18 that lies across a valley of the lobes as at F.
2
Mark the bottom of a spline tooth on the valve drive 10 as at G.
3
4
On disc valve 11 select a trough aligning with any outer hole (eg. H) and mark the next peak to the left as at J. When the disc valve 11, valve drive 10 and inner gear 18 are assembled, all marks must align.
Fill the assembled motor with the correct oil (see Lubricants and Capacities in Section 3) before fitting to the machine. After fitting to the machine, run the motor for a few minutes with the wheels raised off the ground. This is to circulate oil through the motor prior to operation under load. If the motor is to be stored, or fitted but not connected for any length of time, it is advisable to fit plugs to the brake and motor connection ports.
Torque Settings Note: Note: Failure to follow the above procedure could result in the motor driving in the wrong direction.
Item
Nm
kgf m
lbf ft
30 - 60
3-6
22 - 44
When assembling outer gear 20 to housing 25 ensure thatholes A are aligned.
1
1 off
3
(see text) 4 off 135 - 145
13.8 - 14.8 99.5 - 107
Using Vaseline on spacer 8 will prevent it dropping out during assembly.
33
4 off
31 - 39
3.2 - 4.0
23 - 29
24
8 off
31 - 39
3.2 - 4.0
23 - 29
Port plugs 4 off
5 - 10
0.5 - 1.0
3.7 - 7.4
When fitting bolts 3, torque tighten initially to 145 - 155 Nm (107 - 114 lbf ft; 14.8 - 15.8 kgf m) then slacken one half turn before tightening to the correct torque specified below. Wirelock bolts in pairs as shown at B. K Fig 4. ( T E-129)
S167730B-B1
Fig 4.
E-129
9803/9960-3
E-129
Section E - Hydraulics Drive Motors Dismantling and Assembly to machine no. 751011
167730
Fig 5. K Dismantling and 751011 ( T E-128)
E-130
Assembly
to
machine
no.
9803/9960-3
E-130
Section E - Hydraulics Drive Motors Dismantling and Assembly from machine no. 751012 to 807172
Dismantling and Assembly from machine no. 751012 to 807172
S243720
Fig 6. K ( T E-132)
E-131
9803/9960-3
E-131
Section E - Hydraulics Drive Motors Dismantling and Assembly from machine no. 751012 to 807172
Dismantling
K Fig 6. ( T E-131)
Note: To ensure that motor rotation is correct on reassembly, the slots in the rear case are identified `L' or `R'. Note that the actual position of the motor may be opposite to that indicated on the serial plate (see parts catalogue).
Mark the relative positions of the front case 2, rear case 21 and brake housing 60.
Remove seal rings 26, 27, and 28 from distributor ring 22. Discard the seal rings.
Remove capscrews 33 and separate the rear case and brake housing assembly from the front case and cam assembly.
Remove springs 24 from their bores in distributor ring 22.
Drain the oil from the motor.
Support the front case and cam assembly on blocks.
Unscrew plug 65 from end cover 64. Remove and discard `O' ring 73. Unscrew capscrews 74 in a progressive manner then remove end cover 64 from brake housing 60. Remove and discard gasket 70.
Separate cam 20 from front case 2. Note: On later motors the output shaft is supported by two taper roller bearings which are preloaded. The dismantling and assembly of this part of the motor is covered on the next page. Press shaft 1 out of bearing 7. Note that on later motors, shaft1 has a male end, not female as shown. Using a suitable puller, remove bearing 7 from front cover 2.
Withdraw spring disc 78 from brake housing 60. Insert a suitable bolt in the tapped hole in brake piston 62 and withdraw the brake piston from brake housing 60.Remove seal 71 from brake piston 62. Discard the seal.Unscrew capscrews 75 and separate brake housing 60 from rear case 21. Remove and discard `O'-ring 31.
Remove O-ring 32 from front case 2. Discard the O-ring.
Remove seal 72 from interior of brake housing 60. Withdraw brake pack comprising inner plates 67 and outer plates 66 from brake housing 60, together with shims 68 and 69 (if fitted).
Separate cylinder block 15 from cam 20.
Assembly
Remove circlips 18 and retaining rings 19 from cylinder block 15.
Assembly is a reversal of the dismantling procedure.
Remove shaft seal 11 from front case 2. Discard the shaft seal.
Withdraw pistons 17 and rollers 16 from cylinder block 15. If difficulty is experienced, low pressure air can be applied to the ports in the cylinder block.
Inspect the inner plates 67 and outer plates 66 for signs of wear or damage. Plates should not be renewed individually, the entire plate pack should be renewed.
Remove and discard the O-rings fitted to pistons 17.
Clean all components and oil before assembly. All new seals and O-rings should be greased with petroleum jelly.
Withdraw brake shaft 61 from rear case and brake housing assembly.
The space between the lips of shaft seal 11 should be filled with JCB HP Grease.
Tap rear case 21 lightly with a rubber mallet to release distributor ring 22.
The contact surfaces of spring disc 78 should be coated with JCB Special MPL Moly grease.
Remove O-ring 32 from rear case 21. Discard the O-ring. Make a note of the position of stop pin 23 in the slot in rear case 21 then remove the stop pin.
E-132
9803/9960-3
E-132
Section E - Hydraulics Drive Motors Dismantling and Assembly from machine no. 751012 to 807172
Later Type Motor with Twin Bearing Output Shaft. Dismantling Drain the oil from the motor and mark the relative positions of the front and rear cases. Separate the front case 2 from the rear case as detailed on the previous page. K Dismantling and Assembly from machine no. 751012 to 807172 ( T E-131)
S243870-B1
Fig 7. If a new plate pack is to be fitted, the overall plate pack dimension X (when clamped) must be between 28.1 and 28.3 mm. The desired dimension should be achieved using shims 68 and 69 fitted between the end of the plate pack and the rear case 21 as shown. One or two additional outer plates 66 may be used to reduce the number of shims if required. Thoroughly degrease capscrews 75 and 33 and mating parts, then assemble using JCB Threadlocker and Sealer. Examine pistons 17 and their bores in cylinder block 15 for signs of damage. Replace as necessary. Inspect springs 24 for signs of damage and/or distortion. Replace as necessary.
S276770A-B1
Fig 8. Remove split ring 3 using a soft steel drift to separate. Remove shim washer 4.Support the front casing on blocks and press out shaft 1. Remove bearing cone 7 from the assembly. Remove bearing cup 7 from the front case using a puller. Carefully remove seal 11 from the front case. Remove bearing cup 8 from the front case and the conefrom the shaft. Use a puller or soft steel drift.
Torque Settings Item
Nm
kgf m
lbf ft
33
117 - 122
11.9 - 12.4
86 - 90
74
14 - 16
1.4 - 1.6
10 - 12
75
70 - 77
7.1 - 7.8
52 - 57
The remainder of the dismantling procedure is as described on the previous page. K Dismantling and Assembly from machine no. 751012 to 807172 ( T E-131)
Assembly Carefully press bearing cup 8 into the front casing. Insert seal 11 into the front case. Grease lips of seal with JCB HP Grease. Carefully press bearing cup 7 into the front casing.
E-133
9803/9960-3
E-133
Section E - Hydraulics Drive Motors Dismantling and Assembly from machine no. 751012 to 807172 Position drive shaft 1 vertically on a press. Warm bearing cone 8 and press into position on the shaft. Pack the front bearing cone with JCB HP Grease and assemble the front cover onto the shaft, taking care not to damage the lips of seal 11 on the splines of the shaft. Warm bearing cone 7 and press onto the shaft to a load of 5 tonnes. Rotate the front case during this process. Allow assembly to cool. Using a press, apply a preload of 1.5 tonnes to bearing 7. Rotate the front casing during this process. With the preload still applied, fit split ring 3 onto the shaft. Using a feeler gauge, measure the gap between bearing 7 and the split ring. Remove the split ring and fit washer 4 with thickness 0.05 -0.2 mm (0.002 - 0.008 in) greater than the measured gap. Refit the split ring and remove the load. Check that the shaft rotates in the front casing. The remainder of the assembly procedure is as described on the previous page. K Dismantling and Assembly from machine no. 751012 to 807172 ( T E-131)
E-134
9803/9960-3
E-134
Section E - Hydraulics Drive Motors Dismantling and Assembly from machine number 807173
Dismantling and Assembly from machine number 807173
387340-B1
Fig 9. K Dismantling ( T E-136)
E-135
9803/9960-3
E-135
Section E - Hydraulics Drive Motors Dismantling and Assembly from machine number 807173
Dismantling
Withdraw pistons 30 and rollers 31 from cylinder block 27. If difficulty is experienced, low pressure air can be applied to the ports in the cylinder block.
Drain the oil from the motor.
Remove and discard `O' rings 32 fitted to pistons 30. Using a soft steel drift, remove split ring 33 and washer 34.
K Fig 9. ( T E-135) Mark the relative positions of the front case 19, rear case 16 and brake housing 13.
Support the front case on blocks and press shaft 35 out of bearings 36 and 38.
Unscrew capscrews 1 in a progressive manner then remove end cover 2 from brake housing 13. Remove and discard gasket 3. Withdraw spring disc 4.
Remove the cone from bearing 36. Using a soft steel drift, remove bearing cups 36 and 38 from front casing 19.
Remove the brake piston 5 from brake housing 13 using low pressure compressed air. Take care to collect piston as it is being ejected.
Remove bearing cone 38 from shaft 35 using a puller. This action may damage the bearing cone, in which case it should be replaced.
Remove and discard seal 6 from the brake piston.
Remove and discard shaft seal 37 from front casing 19.
Unscrew capscrews 11 and remove with washers 12 then separate brake housing 13 from rear case 16. Remove anddiscard `O' ring 14.
Assembly
Remove seal 7 from interior of brake housing 13. Withdraw brake pack 8 from brake housing 13 together with shims 9 and 10 (if fitted). Remove capscrews 15 and separate the rear case 16 fromthe front case and cam assembly. Support the front case and cam assembly on blocks. Separate cam assembly 18 from front case 19. Remove and discard `O' rings 17 and 20. Tap rear case 16 lightly with a rubber mallet to release distributor ring 21. Make a note of the position of stop pin 23 in the slot in rear case 16 then remove the stop pin. Note: To ensure that motor rotation is correct on reassembly, the slots in the rear case are identified `L' or `R'. Remove seal rings 24, 25, and 26 from distributor ring 21. Discard the seal rings. Remove springs 22 from their bores in distributor ring 21.
Clean all components and oil before assembly. All new seals and `O' rings should be greased with petroleum jelly.Warm bearing cone 38 and press onto shaft 35 using a bench press. Press shaft seal 37 into front case 19 using a bench press. Take care not to damage the seal. Fill the space between the lips of the seal with grease. Press bearing cup 38 into front case 19 using a bench press. Turn the front case over and press bearing cup 36 into the front casing using a bench press. Cover the splines of shaft 35 with tape to protect the shaftseal. Fit the completed front casing assembly to the shaft assembly. Check that the shaft seal 37 is undamaged then remove the tape from the shaft splines. Warm bearing cone 36 and, while rotating the front case, press onto shaft 35 using a bench press to a load of 4 tonnes.
Separate cylinder block 27 from cam 18.
Using a bench press, apply a pre-load of 1.5 tonnes to the bearing cone 36 while rotating the front case. Fit split ring 33 onto shaft 35 and measure the gap between bearing 36 and the split ring.
Remove circlips 28 and retaining rings 29 from cylinder block 18.
Remove split ring 33 and fit washer 34 with a thickness of between 0.05 to 0.1 mm (0.002 to 0.004 in.) greater than
E-136
9803/9960-3
E-136
Section E - Hydraulics Drive Motors Dismantling and Assembly from machine number 807173 the measured gap. Refit the split ring and remove the preload. Check that shaft 35 runs freely and without binding, but with a slight stiffness, in the front case. The remainder of the assembly is a reversal of the dismantling procedure. Examine pistons 31 and their bores in cylinder block 27 for signs of damage. Replace as necessary. Inspect springs 22 for signs of damage and/or distortion. Replace as necessary. Thoroughly degrease capscrews 15 and 11 and mating parts, then assemble using JCB Threadlocker and Sealer. Inspect the brake plates 8 for signs of wear or damage. Plates should not be renewed individually, the entire plate pack should be renewed. If a new plate pack is to be fitted, the overall length of the pack (when clamped) must be between 28.1 and 28.3 mm. The desired dimension should be achieved using shims 9 and 10 fitted between the end of the plate pack and the rear case 13. One or two additional brake outer plates may be used to reduce the number of shims if required. The contact surfaces of spring disc 4 should be coated with JCB Special MPL Moly grease.
Torque Settings Item
Nm
kgf m
lbf ft
1
14 - 16
1.4 - 1.6
10 - 12
11
70 - 77
7.1 - 7.8
52 - 57
15
117 - 122
11.9 - 12.4
86 - 90
E-137
9803/9960-3
E-137
Section E - Hydraulics Drive Motors Dismantling and Assembly from machine number 807173
Page left intentionally blank
E-138
9803/9960-3
E-138
Section E - Hydraulics
Servo Joysticks All Joysticks Removal and Replacement Removal Note: Only the right-hand joystick is shown in the illustration. K Fig 1. ( T E-139) The other joystick is removed and replaced in the same way. Ensure that the engine is stopped and all hydraulic pressure is released from the system. K Releasing the Hydraulic Pressure ( T E-7) Mark the joystick flange and supporting flange at 1 to ensure correct realignment on replacement. Remove the hydraulic flexible hoses at A, plug exposed connections to prevent ingress of dirt and water. Disconnect electrical connection B. Remove four bolts D and lift the joystick unit clear.
Replacement Replacement is a reversal of the removal procedure. Torque tighten hydraulic connections A to 30 Nm (22 lbf ft, 3 kgf m). Torque tighten bolts D (4 off) to 12 Nm (9 lbf ft, 1.2 kgf m).
S167960
Fig 1.
E-139
9803/9960-3
E-139
Section E - Hydraulics Servo Joysticks Joystick up to machine number 807146
Joystick up to machine number 807146
E-140
9803/9960-3
E-140
Section E - Hydraulics Servo Joysticks Joystick up to machine number 807146 S167950
Fig 2.
Dismantling The numerical sequence is intended as a guide to dismantling, assembly is the reverse of this sequence. K Fig 2. ( T E-141) To remove the handle assembly 3, lift up the gaiter 1 and remove the four cap head screws 2. This will allow the handle assembly to be separated from the valve body 6. Note: Ensure that the components of valve units 14 are kept together as sets and returned to their original locations in the body. Do not mix components from different valve units.
Assembly Lubricate all parts with hydraulic fluid before assembly. 'O' rings and seals should be lightly coated with petroleum jelly prior to assembly. See note in Dismantling procedure regarding valve units 14.
Torque Settings Item
Nm
kgfm
lbf ft
Bolts 2 (4 off) 12
1.2
9
Bolts 7 (2 off) 12
1.2
9
Handle Replacement The handles complete with switches can be replaced as a unit. Ensure that the correct assembly is used. K Table 1. ( T E-141) K Fig 3. ( T E-142)
A B
E-141
Table 1. Handle assembly used on the loader control joystick. Handle assembly used on direction control joystick.
9803/9960-3
E-141
Section E - Hydraulics Servo Joysticks Joystick up to machine number 807146
A168110 A168110-B1
Fig 3.
E-142
9803/9960-3
E-142
Section E - Hydraulics Servo Joysticks Joystick from machine number 807147
Joystick from machine number 807147
2
3 6
10
7 8
11
1 5
12
4
13
14 9 20 15 21 19 17 18 16 388480 388480
Fig 4.
E-143
9803/9960-3
E-143
Section E - Hydraulics Servo Joysticks Joystick from machine number 807147
Dismantling The illustration shows a typical joystick. Slight variations may occur depending on the application. K Fig 4. ( T E-143) The numerical sequence is intended as a guide to dismantling, assembly is the reverse of this sequence. Note: Ensure 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 and do not mix components between different joysticks.
Assembly Lubricate all parts with hydraulic fluid before assembly. 'O' rings and seals should be lightly coated with petroleum jelly prior to assembly. Ensure that valve units are returned to their original bores in the valve body. Select shims 7 so that there is a small clearance between cam plate 6 and the tops of plungers 11 when the lever is in the neutral position. Coat threads of item 5 with JCB Threadlocker and Sealer (High Strength) before assembly.
Torque Settings Item
Nm
kgfm
lbf ft
4
30
3.0
22
6
40
4.1
30
16
50
5.1
37
E-144
9803/9960-3
E-144
Section E - Hydraulics Servo Joysticks Servo Joystick from machine number 1743153
Servo Joystick from machine number 1743153
P3 P2
P1
PP TP
P4
P3
PP TP
P4 P2
CE P1 T065410
E-145
9803/9960-3
E-145
Section E - Hydraulics Servo Joysticks Servo Joystick from machine number 1743153 Fig 5. Table 2. Component Key P1
Port 1
P2
Port 2
P3
Port 3
P4
Port 4
PP
Pressure Port
TP
Tank Port
CE
Cable Exit Hole
E-146
9803/9960-3
E-146
Section E - Hydraulics Servo Joysticks Servo Joystick from machine number 1743153
Dismantling The illustration shows a typical joystick. Slight variations may occur depending on the application. This assembly part is not to be dimantled. Replace the complete assembly if faulty. K Fig 5. ( T E-146)
E-147
9803/9960-3
E-147
Section E - Hydraulics
Rams Typical Ram (with dowelled piston head)
140731-B1
Fig 1. K Dismantling and Assembly ( T E-149)
E-148
9803/9960-3
E-148
Section E - Hydraulics Rams Typical Ram (with dowelled piston head)
Dismantling and Assembly
Ensure that lubricants used during assembly do not come into contact with locking fluids.
Dismantling Place the ram assembly on a locally manufactured strip/ rebuild bench.
Use seal fitting tool (892/00334) to fit rod seals 9 and 10.The size (diameter) and position of pins A is determined by the diameter and radial width of the rod seal being fitted.
Slacken the end cap 1 using a special spanner (see Service Tools, Section 1) and remove the piston rod assembly from the cylinder. K Fig 1. ( T E-148)
!MWARNING If air or hydraulic pressure is used to force out the piston assembly, ensure that the end cap is securely fitted. Severe injury can be caused by a suddenly released piston rod. HYD-1-2
Position the piston rod assembly on the bench in place of the ram cylinder. Remove the piston head seals 2, 3 and 4. Extract dowel 5 from the piston head using a metric screw (M3) threaded into the extractor hole. Note: Any attempt to remove the piston head without removing the dowel will cause damage to both the piston head and rod.
161750X-B3
Fig 2. 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. 1
Open the tool as shown at B and insert the new rod seal, the seal must be fitted behind the two front pins but in front of the rear pin as shown.K Fig 2. ( T E-149)
Remove piston head 6 from rod 7 using a special spanner (see Service Tools, Section 1). Remove the piston head internal 'O' ring 8. Remove the end cap 1 from the piston rod and remove the inner and outer seals 9, 10 and 11. Ensure that all metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the inner rod and wiper seals.
P Q
Discard all seals and 'O' rings.
Assembly
153212-B1
Fig 3. Renew all seals and 'O' rings. Thoroughly clean the threads of the piston rod, piston head, end cap and cylinder using a wire brush. Use JCB Cleaner/Degreaser to ensure that all threads are free from grease, hydraulic oil and locking fluids. Allow 15 minutes for the solvent to dry before applying JCB Activator.
E-149
Note: Make sure the seals are fitted the correct way round, as shown at P and Q.K Fig 3. ( T E-149)
9803/9960-3
E-149
Section E - Hydraulics Rams Typical Ram (with dowelled piston head) Sleeve E must be used to protect the rod seals from damage when fitting end cap 1 onto the piston rod 7. There are various sizes of sleeve. (See Service Tools, Section 1.) Make sure the hexagon on the end cap is towards the eye end of the rod. Apply JCB Activator to the threads of the piston head 6. Allow to dry for 15 minutes before bringing into contact with JCB Threadlocker. 161750_Y-B2
Fig 4. 2
3
Note: Neither Threadlocker nor Activator must be allowed to contact seals, bearing rings or 'O' rings.
Close the tool as shown at C. The seal must form a reniform (kidney shape). Before fitting the rod seals check the seal grooves are free of contamination and sharp edges.
Apply JCB Threadlocker & Sealer (High Strength) to all threads of the piston rod. Fit and torque-tighten the piston head.
X
Y 5 S161750 Z-B1
Fig 5. 4
5
Locate the seal in the end cap groove, shown at D, when the seal is in position, open the tool to release the seal. Make sure the seal is correctly installed in its groove and remove the tool. Fit rod wiper seal 10 into seal groove. Make sure the seal is correctly installed as shown. K Fig 3. ( T E-149)
343030-B1
Fig 7. Fit the locking dowel 5 to the piston head/rod as follows: 1
New rod and piston head. If both are required, the following procedure should be followed: a
Drill through the piston head into the piston rod, as shown.K Fig 7. ( T E-150) Use an undersized diameter drill first as a guide and then drill using the correct size diameter drill to suit: refer to the table for drill diameters and depths. K Table 1. Drilling Details for Piston Head Retention (all dimensions in mm) ( T E-151)
187361-B1
Fig 6.
E-150
9803/9960-3
E-150
Section E - Hydraulics Rams Typical Ram (with dowelled piston head) b Remove all swarf and contamination. Insert dowel 5 into the drilled hole, making sure that the tapped extractor hole is to the outside. 2
New piston head fitted to a pre-drilled piston rod. a
3
Fit new wear rings J (2) and K (4). Rotate the wear rings so that the piston retention dowel is covered by the wear ring,NOT as shown at L.
Redrill and dowel BOTH the piston head and piston rod at 90° from the existing drilled dowel hole in the piston rod. Follow the procedure described in step 1.
K J
New piston rod fitted 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. a
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.
b Use an undersized diameter drill as a guide and drill into the piston rod to the required depth (see table), making sure that the drill has centred correctly on the 'centre mark' made in step 3a. c
L
338490-B1
Fig 8. Fit new piston head seals 3 as follows: 1
Use the correct size diameter drill to suit the dowel and drill to the required depth. K Table 1. Drilling Details for Piston Head Retention (all dimensions in mm) ( T E-151)
Using a blunt instrument (892/01027) as shown at F lever the inner seal G 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 the marks are visible and the seal is free to rotate, if not remove the seal and refit.
d Remove all swarf and contamination. Insert the dowel 5 into the drilled hole, making sure that the tapped extractor hole is to the outside. Table 1. Drilling Details for Piston Head Retention (all dimensions in mm) Ram Dowel Guide Guide Dowel Dowel Size Size Drill Ø Drill Drill Ø Drill Depth X Depth Y 50 x 25 20 x 6Ø 4
19
6.1/ 6.02
23/22
60 x 30 20 x 6Ø 4
19
6.1/ 6.02
23/22
70 x 40 20 x 6Ø 4
19
6.1/ 6.02
23/22
80 x 50 20 x 6Ø 4
19
6.1/ 6.02
23/22
E-151
338470
Fig 9. 2
9803/9960-3
Fit outer seal H using the same procedure as step 1. Check the external grooves are visible.
E-151
Section E - Hydraulics Rams Typical Ram (with dowelled piston head)
338480-V1
Fig 10. Position the cylinder on the bench and install the rod assembly into the cylinder. Taking care to retain the end cap 1 at the further 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. 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 ram with oil. Note: When fitting cylinder and piston eye bushes 12, ensure that the split in the bush is set at 90° to the longitudinal centreline of the cylinder. Note: Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working.
Torque Settings See Standard Torque Settings, Section 1.
E-152
9803/9960-3
E-152
Section E - Hydraulics Rams Slew Cylinder
Slew Cylinder Re-seal
215900-B1
Fig 11.
!MWARNING
Disconnect hydraulic feed pipe 1 from cylinder. Unscrew capscrews 2 and remove cylinder 3.
Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.
Remove seals 4 from rack. Check that seal grooves are clean and free from burrs. Check end damping plunger 5 which should move freely in its bore and be returned by the force of spring 6.
HYD-1-5
Lubricate new seals 4 with clean engine oil and fit to rack. Renew 'O' ring 7.
Position machine on firm level ground. Slew the excavator fully round so that the cylinder to be worked on is facing rearwards. Fit the boom lock and stop the engine. Operate slew control levers to vent residual hydraulic pressure.
Re-assemble components in reverse order. Tighten capscrews 2 to 300 Nm (221 lbf ft, 31 kgf m).
Oil will run out of the slew housing when the cylinder is removed. Position a container underneath to catch the oil.
Repeat for other slew cylinder if required then fill the slew housing with oil. K Filling Procedure ( T E-154)
E-153
9803/9960-3
E-153
Section E - Hydraulics Rams Slew Cylinder
Filling Procedure Whenever the slew housing is re-filled with oil the following procedure must be carried out to ensure that all air is expelled: 1
Remove plug A and fill with clean oil to the level of the plug. Replace the plug.
S203940-B1
Fig 12. 2
Remove plug B and half fill the breather tube C with clean oil.
3
Start the engine and operate the slew service until the oil level rises in the breather tube. Stop the engine.
4
Remove plug A to release the air then replace the plug. Top up the oil level in the breather tube.
5
Repeat the operation until all air is expelled.
6
Check that the oil level is up to the mark in the breather tube and replace plug B.
E-154
9803/9960-3
E-154
Section E - Hydraulics Rams Slew Cylinder
Page left intentionally blank
E-155
9803/9960-3
E-155
Section E - Hydraulics
Filtration Suction Strainer See Section 3, Routine Maintenance for renewal of the suction strainer.
E-156
9803/9960-3
E-156
Section E - Hydraulics Filtration Return Filter
Return Filter Removal and Replacement See Section 3, Routine Maintenance for renewal of the filter element.
!MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication. HYD-1-5
1
Vent the hydraulic pressure. K Releasing the Hydraulic Pressure ( T E-7).
2
Remove the battery compartment cover and the corresponding inside panel.
3
Remove the hydraulic filler cap.
4
Remove the hydraulic tank drain plug at the rear of the tank and drain the hydraulic oil to below the level of the filter return connection.
204350-B1
Fig 1.
Note: Always drain into a suitable container. 5
Disconnect and blank the connections to the filter.
6
Remove bolts A and withdraw filter assembly from machine.
Replacement is a reversal of the removal procedure. Start and run the engine for a few minutes then check for leaks. Top up as necessary with the correct fluid.
E-157
9803/9960-3
E-157
Section E - Hydraulics Filtration Return Filter
Page left intentionally blank
E-158
9803/9960-3
E-158
Section E - Hydraulics
Hand Held Tool Circuit Assembly 1
Sub assemble the low flow regulator valve block A.
R
3
Fasten the assembled valve block and bracket to the chassis at C, using four m8 x 20 pins and four m8 plain washers.
A
T
T2
P
C
Fig 1. 2
Fasten the assembled low flow regulator valve block A to bracket B as shown. Fit with two m8 x 110 pins, four m8 washers and two m8 locknuts.
Fig 3. 4
Fit hoses to the valve block. For hose numbers and port numbers, K Fig 4. ( T E-160).
Note: Fasten the valve block to the bracket before attaching the bracket to the machine.
A
B
Fig 2.
E-159
9803/9960-3
E-159
Section E - Hydraulics Hand Held Tool Circuit Assembly
T2
335/A2137
34AP/BA076
B1
A1
P
LOW FLOW REGULATOR
10SPOOL VALVE BLOCK
T2
T R
FWD
335/A2146
L1 Forward pump
P
T
33AP/PP224 335/A2148
GEAR PUMP
Fig 5. F QR COUPLING RETURN
M
6
Fit an elbow adaptor to port A1 on the 10 spool valve block. Phase the elbow towards the front of the machine, use loctite 243 and torque to 89 Nm.
QR COUPLING FLOW
MAIN PUMP
Fig 4. 5
Fit hoses to ports T, T2 and P. Use loctite 243 and torque hoses, K Table 1. Torque Figures ( T E-160).
T2
Table 1. Torque Figures 89 Nm
P
135 Nm
T
135 Nm
A1
Fig 6. 7
Fit hoses to ports A1 and B1. Use loctite 243 and torque hoses, K Table 2. Torque Figures ( T E-160).
A1 B1
E-160
9803/9960-3
Table 2. Torque Figures 89 Nm 135 Nm
E-160
Section E - Hydraulics Hand Held Tool Circuit Assembly
B1
A1 D
Fig 7. 8
Fig 9.
Fit hose to port R on the regulator valve block. Use loctite 243 and torque to 69 Nm. The opposite end will fit to the quick release coupling on the rear frame. Mark the end of the hose to be fitted to the rear frame with a letter M.
E R
Fig 10. 10
Fit the link lead to the ignition barrel. Fit harness 333/ V8288 to the regulator valve block, phase round to the rear frame and switch console.
11
Remove wire from pin 5 of the ignition plug and replace with wire as shown at A. Fit removed wire from pin 5 of ignition plug into terminal B. Fit terminal into wire No. 100 on HHTC harness as shown at C.
9803/9960-3
E-161
Fig 8. 9
Fit hose D from port P on the regulator valve block to the top of the gear pump. An O ring must be used on the flange fitting. Cable tie the hose to the 10 spool hoses at E to stop the filler tube being crushed.
E-161
Section E - Hydraulics Hand Held Tool Circuit Assembly
A
B
C
Fig 11.
D C
A
E
F
B Fig 12.
E-162
A
Fuse
B
Fit standard relay
C
Fit terminal in wire No. 100 on HHTC harness
D
Fit to battery
E
Fit to reduced flow valve
F
Fit to hand held tool circuit on rear frame
9803/9960-3
E-162
Section E - Hydraulics Hand Held Tool Circuit Assembly 12
Fit bracket A to the rear frame using a clamp plate to secure. The clamp plate fits on the inside of the rear frame leg. Fit as shown at B.
C
C A
Fig 15.
D
Fig 13.
E B
Fig 16. 14
When the rear frame is fitted to the machine connect the hoses to the quick release couplings. Fit hose marked F to the bottom fitting and the hose marked M to the top fitting. Use loctite 243 and torque to 69 Nm.
9803/9960-3
E-163
Fig 14. 13
Fit two bulkhead fittings C to the loader change over bracket. Fit with running nut and star washer on the inside. Fit a male D and female E quick fit adapter to the bulkhead fittings. Use loctite 243 and torque to 81 Nm.
E-163
Section E - Hydraulics Hand Held Tool Circuit Assembly
H
F
M
Fig 17. 15
Fig 19.
Fit harness J and secure with cable ties. Fit switch to the HHTC bracket. Fit with the tab on the switch facing down. Fit the switch top as shown at G. Fit the switch cover H.
G
J
Fig 18.
E-164
9803/9960-3
E-164
Section F Transmission Service Manual - 1CX Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section J - Tracks Section K - Engine
Publication No.
9803/9960-3
World Class Customer Support Copyright Š 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section F - Transmission
Notes:
F-0
9803/9960-3
F-0
Section F - Transmission Contents
Contents Page No. Wheels and Tyres Road Wheels ............................................................................................. F-1 Removal ................................................................................................F-1 Replacement .........................................................................................F-1 Wheel Hubs ............................................................................................... F-2 Removal ................................................................................................F-5 Replacement .........................................................................................F-5 Dismantling ............................................................................................F-5 Assembly ...............................................................................................F-6
F-i
F-i
Section F - Transmission Contents
F-ii
Page No.
F-ii
Section F - Transmission Wheels and Tyres Road Wheels
Wheels and Tyres Road Wheels
203750-B1
Fig 1.
Removal Procedure is the same for all four wheels. Slacken off the road wheel retaining bolts A. Then raise and support the ends of the machine on blocks. Remove the road wheels.
Replacement Replacement is a reversal of the removal procedure. Tighten road wheel retaining bolts to the correct torque. See Section 3, Routine Maintenance.
F-1
9803/9960-3
F-1
Section F - Transmission Wheels and Tyres Wheel Hubs
Wheel Hubs
F-2
9803/9960-3
F-2
Section F - Transmission Wheels and Tyres Wheel Hubs
S255770
Fig 2.
F-3
9803/9960-3
F-3
Section F - Transmission Wheels and Tyres Wheel Hubs K Removal ( T F-5)
F-4
9803/9960-3
F-4
Section F - Transmission Wheels and Tyres Wheel Hubs
Removal
Adjust the drive chain(s) as follows:
It is assumed that roadwheels are removed and the machine is correctly supported.
1
Mount the hub onto the machine and fit nut B finger tight only.K Fig 2. ( T F-3)
Drain the oil from the chain case via plug A. K Fig 2. ( T F-3) Slacken nut B and remove bolts C (4 off). Remove hub adjustment bolt and nut and swing the hub assembly towards the centre of the machine so that the drive chain is at its slackest. Use a suitable bar to wedge the hub as shown at X. K Fig 3. ( T F-5)
S255790-B1
Fig 4. 2
Position adjustment bolt and nut into the slot in the adjustment bracket as shown at Y. K Fig 4. ( T F-5)Use the bolt to push the hub away from the centre of the machine and so tighten the chain.
3
Rotate the sprocket so that one side of the chain is taut. Position the hub to give 25 mm (1 in) of slack on the opposite side of the chain at the midway point.
4
When the correct tension is achieved, fit and tighten bolts C and tighten nut B. K Fig 2. ( T F-3)
5
Finally torque tighten nut B and bolts C to 244 Nm (180 lbf ft, 25 kgf m).
S255780-B1
Fig 3. Note: If the front hub is to be removed, both hubs on that side must be rotated to slacken both chains. Remove the spider. See Drive Motor Removal, Section E. Lift off the appropriate chain from the drive sprocket. Note that the front hub is driven by the inner chain, therefore the rear chain will need to be lifted off first. Remove the nut B and pull the hub assembly out; remove the chain from the sprocket 2. Remove the hub assembly from the chassis. Remove and discard seal 9.
The numerical sequence is a guide to dismantling. K Fig 2. ( T F-3) Note: Stub axle 4 is fitted to rear hubs and 4A to front hubs. Spacer 3 is only fitted to front hubs.
Replacement Replacement is a reversal of the removal procedure. A new 'O' ring 9 must be fitted. Apply a thin smear of silicon sealer to the groove before fitting the `O' ring, this will retain the ring in the groove. Smear the hub mounting face and `O' ring with JCB HP Grease.
F-5
Dismantling
Remove bolts 1 (6 off) and drive sprocket 2. Support the assembly on face Z and press out the stub axle assembly 4 or 4A. Bearing 5 will remain in the casing 8 and can be removed separately if necessary. The bearing cap of bearing 6 will also be left in the casing and can be removed if necessary. Shaft seal 7 should be removed from the stub
9803/9960-3
F-5
Section F - Transmission Wheels and Tyres Wheel Hubs axle 4 and discarded. Examine the stub axle and casing forwear or damage.
Assembly The numerical sequence shown in the dismantling procedure should be reversed. K Fig 2. ( T F-3) Lubricate all bearings and seals with JCB Special HP Grease before assembly. Clean the mating faces of the sprocket and hub before assembly using JCB Cleaner/Degreaser. Place the sprocket onto the stub axle. Apply a single run of JCB Retainer (High Strength) to each bolt hole in the stub axle. Apply three runs of JCB Retainer (High Strength) to each bolt 1. Fit bolts and tighten evenly to the correct torque in a diagonal sequence whilst rotating the hub to seat the bearings. Note: The torque required to rotate the hub after assembly should be no more than 30 Nm (22 lbf ft, 3 kgf m).
Torque Settings Item
Nm
kgf m
lbf ft
1 (6 off)
405
4.1
298
F-6
9803/9960-3
F-6
Section G Brakes Service Manual - 1CX Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section J - Tracks Section K - Engine
Publication No.
9803/9960-3
World Class Customer Support Copyright Š 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section G - Brakes
Notes:
G-0
9803/9960-3
G-0
Section G - Brakes Contents
Contents Page No. Towing and Winching Preparation for Towing/Winching from machine no. 751012 .................... G-1 After Towing/Winching .......................................................................... G-2
G-i
G-i
Section G - Brakes Contents
Contents
G-ii
Page No.
G-ii
Section G - Brakes
Towing and Winching Preparation for Towing/Winching from machine no. 751012 started when charge pressure will automatically close the valves.
The braking system components on this machine are integral with the hydraulic drive motors. See Section E Hydraulics. Since the brakes are locked 'ON' whenever the engine is stopped, the following procedures should be followed before attempting to move a disabled machine. It is only possible to tow or winch the machine for short distances at slow speed in a straight line. This is because the steering function 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.
!MCAUTION Lifting the Machine When lifting the machine using the mainframe lifting points it is necessary to use a lifting frame to prevent the chains causing damage to the ROPS/FOPS structure GEN-9-1
S246230-B1
Fig 1.
!MCAUTION
4
Do not attempt to tow/winch the machine without first releasing the hydrostatic braking otherwise damage will occur to the hydraulic pumps.
Remove the motor outer covers and unscrew plug B on each motor end cover. K Fig 2. ( T G-2) Store the plugs in a safe place.
3-2-1-2
1
Block the wheels to prevent accidental movement when the brakes are released.
2
Remove the floor plates to gain access to the hydraulic pump assembly. See Floor Plates Section 3.
3
Press in the by-pass plungers on the four Charge Check valves A underneath the pump. K Fig 1. ( T G-1) This will open the valves and allow oil from the motors to flow freely through the pump. The valves will stay open until the machine is next
G-1
9803/9960-3
G-1
Section G - Brakes Towing and Winching Preparation for Towing/Winching from machine no. 751012 7
Remove the wheel blocks only when the machine is hitched up ready for towing/winching. Keep personnel clear of the machine while the blocks are removed.
After Towing/Winching Remove the brake piston pullers and refit plugs B. Refit the motor outer covers.
S243870-B2
Fig 2. 5
Using locally made pullers, jack out the brake piston to release the brake. The pullers must be constructed so that they rest on the outer edge of the motor casing and have a central bolt to screw into the tapped hole in the brake piston. K Fig 3. ( T G-2)
M12
A246440
Fig 3. Note: DO NOT rest the puller against the central part of the motor end cover or the cover will be distorted. 6
Screw the M12 bolt in finger tight and then turn a further one complete turn to release the brake. Use washers under the bolt head if necessary to give correct thread engagement.
G-2
9803/9960-3
G-2
Section J Tracks Service Manual - 1CX Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section J - Tracks Section K - Engine
Publication No.
9803/9960-4
World Class Customer Support Copyright © 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section J - Track and Running Gear
Notes:
J-0
9803/9960-4
J-0
Section J - Track and Running Gear Contents Page No. Basic System and Operation Description ................................................................................................. J-1 Running Gear Components ................................................................... J-1 Track Construction ................................................................................ J-3 Track Serial Number Location and Direction of Rotation ...................... J-3 Tracks Removal and Replacement ....................................................................... J-5 Removal ................................................................................................ J-5 Replacement ......................................................................................... J-6 Sprocket Removal and Replacement ....................................................................... J-7 Removal ................................................................................................ J-7 Replacement ......................................................................................... J-8 Track Frame Assembly Removal and Replacement ....................................................................... J-9 Removal ................................................................................................ J-9 Replacement ....................................................................................... J-10 Idler Wheels and Recoil Unit Front Idler Wheel and Recoil Unit ............................................................ J-11 Removal .............................................................................................. J-11 Replacement ....................................................................................... J-11 Dismantling and Assembly .................................................................. J-12 Rear Idler Wheel ...................................................................................... J-13 Removal .............................................................................................. J-13 Replacement ....................................................................................... J-13 Dismantling and Assembly .................................................................. J-14 Guide Roller ............................................................................................. J-15 Removal .............................................................................................. J-15 Replacement ....................................................................................... J-15 Dismantling and Assembly .................................................................. J-16 Track Damage Types of Rubber Track Damage .............................................................. J-17 Core Bars - Separation ........................................................................ J-18 Core Bars - Breaking ........................................................................... J-18 .................................................................. Core Bars - Fast Abrasion J-19 Core Bars - Oxidation (Rusting) .......................................................... J-20 ..........................................................................Steel Cord - Breaking J-20 .......................................................................Steel Cord - Separation J-21 Steel Cord - Exposure ......................................................................... J-21 Steel Cord - Sticking Out ..................................................................... J-22 Outer Track Rubber - Tearing/Cuts ..................................................... J-23 Outer Track Rubber - Fast Abrasion ................................................... J-23 Outer Track Rubber - Cracks .............................................................. J-24 ..........................................Outer Track Rubber - Longitudinal Cracks J-24 Inner Track Rubber - Tearing/Cuts ...................................................... J-25 ...............................................................Inner Track Rubber - Cracks J-26 .............................................Miscellaneous - Not Engaging Correctly J-26 Miscellaneous - Detracking ................................................................. J-26
J-i
J-i
Section J - Track and Running Gear Contents
Contents Page No. Track Repair Recommended Repair Procedures ......................................................... J-27 Additional Notes: ................................................................................. J-28
J-ii
J-ii
Section J - Track and Running Gear
Basic System and Operation Description Note: This section applies only to tracked versions of the machine.
Running Gear Components The track assemblies are mounted on each side of the machine chassis in place of the wheel hubs. The machine sits on rollers A which run inside the rubber track B. A front idler wheel C slides in grooves in the track frame and locates against the spring loaded recoil unit D 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. Rear idler wheel E gives an additional secure location for the track.
B
H
G
D F A
C
E T056000-20
Fig 1. The track is rotated by a hydraulic motor F mounted on the track frame H. Sprocket G on the output shaft of the motor locates in holes in the track.
J-1
9803/9960-4
J-1
Section J - Track and Running Gear Basic System and Operation Description
C D G
F
H
A
E T056010-20
Fig 2.
J-2
9803/9960-4
J-2
Section J - Track and Running Gear Basic System and Operation Description
Track Construction
Track Serial Number Location and Direction of Rotation
The structure of the rubber track consists of core bar M and steel cord N encased in the rubber track L. 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.
The track is embossed with the Name plate, direction of rotation and serial number as shown.
L
T070140-47
Fig 4. Serial number
N M 394181-1
Fig 3.
T070140-48
Fig 5. Name plate and Direction
J-3
9803/9960-4
J-3
Section J - Track and Running Gear Basic System and Operation Description
Page left intentionally blank
J-4
9803/9960-4
J-4
Section J - Track and Running Gear
Tracks Removal and Replacement Removal 1
Make the machine safe, refer to Section 3Maintenance, Prepare the Machine for Maintenance.
2
Raise the machine on the side to be worked on as follows: a
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.
b 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 access cover and unscrew the grease adjuster to release the track tension. Refer to Section 3, Tracks, Track Adjustment. Collect and discard the grease. Use a lever to push the front idler wheel fully in as shown at A.
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. Using a hoist, raise the bar so as to rotate the track slightly until the bar is positioned at the top of the sprocket as shown at B.
5
Using the hoist, lift the track clear of the sprocket.
6
Unscrew the sprocket retaining bolts and remove the sprocket as shown at C.
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.
J-5
9803/9960-4
J-5
Section J - Track and Running Gear Tracks Removal and Replacement 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 motor to rotate the sprocket as necessary to locate its teeth into the grooves of the track.
A
B
Item
Nm
Kgf m
lbf ft
Sprocket Mounting Bolts
300
30.6
221
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. Refer to Section 3, Tracks, Track Adjustment.
7
Replace the access cover.
Re-check the track adjustment after the machine has been driven for a while.
C
T057640-20
Fig 1.
Replacement 1
J-6
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.
9803/9960-4
J-6
Section J - Track and Running Gear
Sprocket Removal and Replacement Removal 1
Make the machine safe, refer to Section 3Maintenance, Prepare the Machine for Maintenance.
2
Raise the machine on the side to be worked on as follows: a
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.
b 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 access cover and unscrew the grease adjuster to release the track tension. Refer to Section 3, Tracks, Track Adjustment. Collect and discard the grease. Use a lever to push the front idler wheel fully in as shown at A.
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. Using a hoist, raise the bar so as to rotate the track slightly until the bar is positioned at the top of the sprocket as shown at B.
5
Using the hoist, lift the track clear of the sprocket.
6
Unscrew the sprocket retaining bolts and remove the sprocket as shown at C.
J-7
9803/9960-4
J-7
Section J - Track and Running Gear Sprocket Removal and Replacement 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 motor to rotate the sprocket as necessary to locate its teeth into the grooves of the track.
A
B
Item
Nm
Kgf m
lbf ft
Sprocket Mounting Bolts
300
30.6
221
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. Refer to Section 3, Tracks, Track Adjustment.
7
Replace the access cover.
Re-check the track adjustment after the machine has been driven for a while.
C
T057640-20
Fig 1.
Replacement 1
J-8
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.
9803/9960-4
J-8
Section J - Track and Running Gear
Track Frame Assembly Removal and Replacement Removal 1
Make the machine safe, refer to Section 3 Maintenance, Prepare the Machine for Maintenance.
2
Raise the machine on the side to be worked on as follows: a
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.
b 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. K Tracks ( T J-5).
T056050-20
Fig 1. 4
Disconnect the motor feed and return hoses having marked them for correct reconnection.
5
Sling the track frame as shown and support the weight using a suitable hoist.
B A
T057660-20
Fig 2. 6
J-9
9803/9960-4
Remove the 8 x bolts A from the front mounting.
J-9
Section J - Track and Running Gear Track Frame Assembly Removal and Replacement 7
Remove the bolts 8 x B from the rear mounting. It will be necessary to release the top two bolts gradually whilst easing the frame away from the machine.
!MCAUTION Do not pull the frame too far away otherwise the hoses will rip off. 0072
8
Once access has been gained, disconnect the motor drain and brake hoses having marked them for correct reconnection.
9
Manoeuvre the track frame away from the machine.
Replacement Replacement is a reversal of the removal procedure. Tighten front and rear mounting bolts to 220 Nm (162 lbf ft, 22.4 kgf m).
J-10
9803/9960-4
J-10
Section J - Track and Running Gear Idler Wheels and Recoil Unit Front Idler Wheel and Recoil Unit
Idler Wheels and Recoil Unit Front Idler Wheel and Recoil Unit Removal
4
These components can be removed without removing the track frame from the machine.
Replacement
Remove the Idler wheel and recoil unit assembly.
Replacement is a reversal of the removal procedure.
A
B
T056020
Fig 1. 1
Make the machine safe, refer to Section 3 Maintenance, Prepare the Machine for Maintenance.
2
Raise the machine on the side to be worked on as follows: a
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.
b 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. Replacement ( T J-5).
J-11
K Removal
and
9803/9960-4
J-11
Section J - Track and Running Gear Idler Wheels and Recoil Unit Front Idler Wheel and Recoil Unit
Dismantling and Assembly
1 8
2 3 4 5
6
7 9
Fig 2. Item
Description
1
Sprocket Front
2
Bracket Left
3
Plug
4
Circlip
5
Shaft
6
Bearing
7
Seal
8
Bracket Right
9
O-ring
Component weight
J-12
60.5 kg
9803/9960-4
J-12
Section J - Track and Running Gear Idler Wheels and Recoil Unit Rear Idler Wheel
Rear Idler Wheel Removal These components can be removed without removing the track frame from the machine.
A
Fig 3. 1
Make the machine safe, refer to Section 3 Maintenance, Prepare the Machine for Maintenance.
2
Remove the track. Replacement ( T J-5).
3
Remove the 2 x bolts securing the rear idler A.
4
Remove the rear idler.
K Removal
and
Replacement Replacement is a reversal of the removal procedure.
J-13
9803/9960-4
J-13
Section J - Track and Running Gear Idler Wheels and Recoil Unit Rear Idler Wheel
Dismantling and Assembly 1
4 5
2
6
3
7 8
T057510
Fig 4. Item
Description
1
Rim
2
Seal
3
Bracket
4
Bearing
5
Plug
6
Shaft
7
O-ring
8
Bracket
Component weight
J-14
32.2 kg
9803/9960-4
J-14
Section J - Track and Running Gear Idler Wheels and Recoil Unit Guide Roller
Guide Roller Removal These components can be removed without removing the track frame from the machine.
A T056040-20
Fig 5. 1
Make the machine safe, refer to Section 3 Maintenance, Prepare the Machine for Maintenance.
2
Remove the track. Replacement ( T J-5).
3
Remove the 2 x bolts securing the roller A.
4
Remove the roller assembly.
K Removal
and
Replacement Replacement is a reversal of the removal procedure.
J-15
9803/9960-4
J-15
Section J - Track and Running Gear Idler Wheels and Recoil Unit Guide Roller
Dismantling and Assembly
6
7
5 1 2 3
4
T057520
Fig 6. Item
Description
1
Bracket
2
Seal
3
Plug
4
Circlip
5
Shaft
6
Centre Bracket
7
Bracket
Component weight
J-16
27.8 kg
9803/9960-4
J-16
Section J - Track and Running Gear
Track Damage Types of Rubber Track Damage 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.
Refer to the quick reference table below, then to the corresponding paragraph for illustrated examples of the failures, possible causes, prevention and corrective actions. XX Main cause X Secondary cause
Item 1
2
Description
Type of Damage
Core Bar
Separation
X
XX
Breaking
X
X
Fast Abrasion
X
Steel Cord
Ground Condition
Maintenance/ Fitting
Operation
Running Gear X
XX
X XX
Oxidation
XX
Breaking
X
X
XX
X
Separation
X
X
XX
X
Exposure
XX
Sticking Out 3
Outer Track Rubber
Tearing/Cuts
XX
X
Fast abrasion
X
XX
Cracks Longitudinal Cracks 4 5
Inner Track Rubber
Tearing/Cuts Cracks
Miscellaneous
Faulty engaging
X X
X X
X XX
Detracking
J-17
XX
XX
XX
9803/9960-4
X
X
J-17
Section J - Track and Running Gear Track Damage Types of Rubber Track Damage
Core Bars - Separation
Core Bars - Breaking
Cause:
Breaking in the middle
1
Cause:
Low track tension - the core bars are likely to hit the running gear components and lead to separation from the track
1
Excessive track tension together with a shock load, for example, climbing pavement edges.
2
Hard material (stone, metal) stuck between the sprocket and the core bar with excessive track tension.
3
Abrasion of the teeth.
Prevention:
4
Idler spring ineffective.
1
Check the track tension regularly (as recommended in service schedules).
Prevention:
2
Clean the tracks regularly as recommended, particularly after operation in clay soil.
3
When fitting a track on a machine, always make sure that the sprocket is in good condition. If the sprocket is damaged it must be changed.
2
Hard material (stone, metal) stuck between the top of two core bars.
3
Sprocket teeth badly worn (hook-shaped).
4
Oxidation (rusting) of the core bars.
4
1
Check the track tension regularly (as recommended in service schedules).
2
Clean the tracks regularly as recommended, particularly after operation in clay soil.
3
The track is not appropriate for the sprocket. Make sure that the sprocket is not excessively worn and is in good condition.
4
Clean the spring if it is clogged (with clay, for instance) and make sure that it is in working order.
Regularly clean and grease the components.
Breaking on the wings Cause: 1
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.
Prevention: 1
Always operate the machine on both tracks. Use a ramp to mount and dismount from pavement edges.
Fig 1.
Additional Notes: If one or more core bars are separated from the track, the track must be replaced.
J-18
9803/9960-4
J-18
Section J - Track and Running Gear Track Damage Types of Rubber Track Damage
Core Bars - Fast Abrasion Cause: 1
The sprocket is not correct for the track.
2
The teeth of the sprocket are worn (hook shaped).
3
Operating environment is extremely abrasive
Prevention: 1
Make sure that the sprocket is genuine JCB, ensure sprocket is in good condition.
2
Replace sprocket. When new tracks are fitted, the sprockets should always be checked (and renewed if necessary).
3
Clean the tracks with fresh water.
Fig 2.
Additional Notes: If one or more core bars are broken, the track must be replaced. If the core bars break on the wings, the track can still be used but note that eventually long term damage will occur.
Fig 3.
Additional Notes: When the core bars are worn out, the track must be replaced. The track does not have to be replaced if the core bar abrasion is below approximately 20%.
J-19
9803/9960-4
J-19
Section J - Track and Running Gear Track Damage Types of Rubber Track Damage
Core Bars - Oxidation (Rusting)
Steel Cord - Breaking
Cause:
Cause:
1
1
The sprocket is not appropriate for the track (the pitch does not fit).
2
Hard material (stone, metal) stuck between the track and the sprocket with excessive track tension.
3
The steel cord has been exposed and rusted.
2
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.
Prevention:
Prevention:
1
Clean the tracks with fresh water after operation. Make sure that the visible metallic components of the track are greased.
1
Make sure that the sprocket is genuine JCB, ensure sprocket is in good condition.
2 2
Clean the tracks with fresh water after operation in areas where chemicals can attack the tracks.
Check the tension regularly. Clean the tracks regularly as recommended, particularly after operation in clay soil.
3
As soon as you see small cracks on the lug side, clean with water and repair immediately.
Fig 4.
Additional Notes: If the core bars are slightly rusted, 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.
J-20
Fig 5.
Additional Notes: When the steel cord is broken, the track must be replaced. As a preventive measure always check the tension.
9803/9960-4
J-20
Section J - Track and Running Gear Track Damage Types of Rubber Track Damage
Steel Cord - Separation
Steel Cord - Exposure
Cause:
Cause:
1
1
Excessive tension of the track
Stones and sharp material can tear the rubber and expose the steel cord.
- during fitting Prevention: - excessive tension plus a foreign body 1 - shearing (sharp bend on hard surface) 2
The sprocket is not appropriate for the track.
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.
Prevention: 1
Check the tension regularly.
2
Make sure that the sprocket is genuine JCB, ensure sprocket is in good condition.
Fig 7.
Additional Notes: Fig 6.
Additional Notes: When the steel cord separates from the rubber at the junction, the track must be replaced.
J-21
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).
9803/9960-4
J-21
Section J - Track and Running Gear Track Damage Types of Rubber Track Damage
Steel Cord - Sticking Out
Additional Notes:
Cause:
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).
1
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.
Fig 8.
Fig 9.
J-22
9803/9960-4
J-22
Section J - Track and Running Gear Track Damage Types of Rubber Track Damage
Outer Track Rubber - Tearing/Cuts
Outer Track Rubber - Fast Abrasion
Cause:
Cause:
1
1
Sharp driving on hard and abrasive surfaces, for example concrete, asphalt etc.
2
Operation on surfaces where the temperature is unusually high, for instance, travelling over freshly laid asphalt.
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.).
Prevention: 1
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.
Prevention: 1
Operate the machine with care, avoid making quick and repeated turns.
2
Do not stay too long on very hot surfaces. On the other hand, the track is safe if you just go across this area.
Fig 10.
Additional Notes: You can do less damage by driving slowly on hard surfaces. Small cuts on the lug do not prevent the track from being used. When the cut goes deeper down and reaches the steel cord or the core bar, the track must be repaired. If a lug is pulled out, the track can be used but the grip on muddy surfaces will be greatly reduced.
J-23
Fig 11.
Additional Notes: A track can still be used if the lug is higher than 5mm, otherwise the track must be replaced. Refer also to warranty pro-rata use scale.
9803/9960-4
J-23
Section J - Track and Running Gear Track Damage Types of Rubber Track Damage
Outer Track Rubber - Cracks
Outer Track Rubber - Longitudinal Cracks
Cause: Cause:
1
Bending fatigue of the rubber after excessive use.
2
Long storage (a few months) outside in the sunlight.
1
Prevention: 1
Ensure cracks do not reach the metallic components of the track.
2
Tracks must be stored indoors or under cover away from the direct sunlight and bad weather.
The edges of the rubber track are often deformed largely due to a bumpy ground surface, stones 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.
Prevention: 1
Operate the machine with care, avoid concrete pavements and big rocks.
Fig 12.
Additional Notes:
Fig 13.
The track can be used as long as the cracks do not reach the metallic components of the track. When the cracks expose the steel cords, the track must be replaced or repaired.
J-24
9803/9960-4
J-24
Section J - Track and Running Gear Track Damage Types of Rubber Track Damage
Inner Track Rubber - Tearing/Cuts
Fig 14. Cause: 1
Stones and sharp material can tear the rubber at the edges of the track.
2
Driving close to pavement edges and ridges - causing the edges to be forcefully bent against the track frame.
Prevention: 1
2
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. Drive the machine carefully, avoid driving over projections, prevent the track edges from contacting ridges etc.
J-25
Fig 15.
Additional Notes: The track can be used as long as the cuts do not reach the metallic components. When the cracks expose the steel cords, the track must be replaced or repaired.
9803/9960-4
J-25
Section J - Track and Running Gear Track Damage Types of Rubber Track Damage
Inner Track Rubber - Cracks
Miscellaneous - Not Engaging Correctly
Cause:
Cause:
1
Excessive tension of the rubber
1
Excessive abrasion of the sprocket teeth.
2
Excessive vibration whilst the machine remains stationary, for example using an auxiliary attachment such as a hammer.
2
Excessive tension of the track leading to incorrect track pitch.
Prevention: Prevention: 1
Check the tension regularly.
2
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.
1
Make sure that the sprocket is genuine JCB, ensure sprocket is in good condition.
2
Check the track tension regularly (as recommended in service schedules).
Miscellaneous - Detracking Cause: 1
Low track tension.
2
The rollers are worn out and the track is not correctly guided.
3
Sharp bends (shearing stress).
4
Machine working following a hillside which weathers or is soft.
Prevention: 1
Check the tension regularly.
2
Check the rollers and running gear components in accordance with the recommended service intervals.
3
Drive carefully on hard surfaces like concrete, asphalt etc.
4
Make sure that ground is firm when working along a hillside and in any case drive carefully.
Fig 16.
Additional Notes: The track can be used as long as the cracks do not reach the metallic components. When the cracks expose the steel cords, the track must be replaced or repaired.
J-26
9803/9960-4
J-26
Section J - Track and Running Gear
Track Repair Recommended Repair Procedures Minor cuts which occur between the lugs can be repaired with a suitable repair kit. Cuts no longer than 30mm and no deeper than 10mm 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
Clean the cut thoroughly to ensure correct adhesion of the bonding agents. Use a brush or compressed air. If oil is evident, a cleaning solution should be used, make sure the area is dry.
Fig 2. 3
Apply the adhesive.
Fig 1. Fig 3. 2
The area in and around the cut should be 'roughened' to ensure good bonding adhesion. Use sand paper or a clean wire brush. Make sure that the area is roughened approximately 30 to 40 mm wider than the cut. Clean the area using a suitable air compressor.
J-27
4
9803/9960-4
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.
J-27
Section J - Track and Running Gear Track Repair Recommended Repair Procedures
Fig 4. 5
Ensure that the adhesive applied in step 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 2 to 3 mm higher than the original rubber track.
6
Allow to harden. Approximate curing times: - 24 hours @ 30°C - 48 hours @ 40 - 45°C - 72 hours @ 50 - 60°C
Additional Notes: 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.
J-28
9803/9960-4
J-28
Section K Engine Service Manual - 1CX Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section J - Tracks Section K - Engine
Publication No.
9803/9960-3
World Class Customer Support Copyright Š 2004 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section K - Engine
Notes:
K-0
9803/9960-3
K-0
Section K - Engine Contents
Contents Page No. Technical Data 100 Series Engine up to machine no. 807552 .......................................... K-1 400 Series Engine from machine no. 807553 .......................................... K-2 404D-22 Series Engine from machine no. 1743153 ................................. K-3 Engine Unit Removal and Replacement ...................................................................... K-5 Removal ............................................................................................... K-5 Replacement ........................................................................................ K-6
K-i
K-i
Section K - Engine Contents
Contents
K-ii
Page No.
K-ii
Section K - Engine
Technical Data 100 Series Engine up to machine no. 807552 Type
4 cylinder in-line, compression ignition, naturally aspirated.
Bore (nominal)
84 mm (3.31 in)
Stroke
100 mm (3.94 in)
Swept Volume
2216 cm3 (135.2 in3)
Compression Ratio
22 : 1
Injection Sequence
1,3,4,2
Valve Clearance - Cold - Inlet and Exhaust
0.2 mm (0.0078 in)
Oil Pressure
2.6 - 3.5 bar (38 - 52 lbf/in2, 2.7 - 3.6 kgf/cm2)
Speeds Rated Speed
2800 rev/min
Idling Speed
850 - 950 rev/min
Fuel System Governing
Mechanical
Static Timing
19° - 21° BTDC
Injector Codes
PN: 130506140
Injector Setting Pressure
150 - 162 bar (2175 - 2350 lbf/in2, 153 - 165 kgf/cm2)
Cooling System Fan Type
Mechanical
Coolant Pressure
0.5 bar (7.25 lbf/in2, 0.5 kgf/cm2)
Thermostat operating temperature
82 - 94 °C (180 - 200 °F)
Temperature Warning Light operates at
97 - 103 °C (207 - 217 °F)
Note: If at anytime during the necessary to fit a new engine, operating hours a new engine oil the engine oil changed. Failure damage the engine.
life of a machine it is then after the first 50 filter must be fitted and to complete this could
Note: Should further details be required, refer to Engine Service Manual 9806/2100.
K-1
9803/9960-3
K-1
Section K - Engine Technical Data 400 Series Engine from machine no. 807553
400 Series Engine from machine no. 807553 Type
4 cylinder in-line, compression ignition, naturally aspirated.
Bore (nominal)
84 mm (3.31 in)
Stroke
100 mm (3.94 in)
Swept Volume
2216 cm3 (135.2 in3)
Injection Sequence
23.3 : 1
Injection Sequence
1,3,4,2
Valve Clearance - Cold - Inlet and Exhaust
0.2 mm (0.0078 in)
Oil Pressure
1 bar (15 lbf/in2) min
Speeds Rated Speed
2800 rev/min
Idling Speed
900 25 rev/min
Maximum No Load
2950 25 rev/min
Fuel System Governing
Mechanical
Static Timing
19° - 21° BTDC
Injector Codes
131 406 360
Injector Setting Pressure
147 bar (2133 lbf/in2)
Cooling System Fan Type
Mechanical
Coolant Pressure
1 bar (14.5 lbf/in2)
Thermostat operating temperature - opens at:
82 °C (180 °F)
- fully open at:
95 °C (202 °F)
Temperature Warning Light operates at Note: If at anytime during the necessary to fit a new engine, operating hours a new engine oil the engine oil changed. Failure damage the engine.
97 - 103 °C (207 - 217 °F)
life of a machine it is then after the first 50 filter must be fitted and to complete this could
Note: Should further details be required, refer to Engine Service Manual 9806/2190.
K-2
9803/9960-3
K-2
Section K - Engine Technical Data 404D-22 Series Engine from machine no. 1743153
404D-22 Series Engine from machine no. 1743153 Type
4 cylinder in-line, compression ignition, naturally aspirated.
Bore (nominal)
84 mm (3.31 in)
Stroke
100 mm (3.94 in)
Swept Volume
2216 cm3 (135.2 in3)
Injection Sequence
23.3 : 1
Injection Sequence
1,3,4,2
Valve Clearance - Cold - Inlet and Exhaust
0.2 mm (0.0078 in)
Oil Pressure
1 bar (15 lbf/in2) min
Speeds Rated Speed
3000 rev/min
Idling Speed
900 25 rev/min
Maximum No Load
2950 25 rev/min
Fuel System Governing
Mechanical
Static Timing
19° - 21° BTDC
Injector Codes
131 406 360
Injector Setting Pressure
147 bar (2133 lbf/in2)
Cooling System Fan Type
Mechanical
Coolant Pressure
1 bar (14.5 lbf/in2)
Thermostat operating temperature - opens at:
82 °C (180 °F)
- fully open at:
95 °C (202 °F)
Temperature Warning Light operates at Note: If at anytime during the necessary to fit a new engine, operating hours a new engine oil the engine oil changed. Failure damage the engine.
97 - 103 °C (207 - 217 °F)
life of a machine it is then after the first 50 filter must be fitted and to complete this could
Note: Should further details be required, refer to Engine Service Manual 9806/4450.
K-3
9803/9960-3
K-3
Section K - Engine Technical Data 404D-22 Series Engine from machine no. 1743153
Page left intentionally blank
K-4
9803/9960-3
K-4
Section K - Engine
Engine Unit Removal and Replacement Removal
9
Disconnect wiring connections from the starter motor and alternator, also water temperature and oil pressure senders from the engine.
1
Position the machine on firm level ground. Fully lower the lift arms and stop the engine.
10
Disconnect the engine/chassis earth strip.
2
Open the bonnet and remove engine compartment side panels.
11
Disconnect the engine oil cooler hose.
3
Disconnect and remove the battery.
12
Disconnect the throttle and stop controls at the fuel pump.
4
Remove the exhaust and air filter assembly.
13
5
Drain the cooling system, then disconnect the radiator top hose, air vent hose and bottom hose.
Disconnect the fuel supply line and spill line at the engine.
14
Disconnect and plug all hydraulic lines (11 off) at the hydraulic pump assembly.
15
Disconnect wiring connections from the pump assembly.
16
Attach slings to the engine lifting eyes.
6
Remove the coolant header tank and the bracket supporting it.
!MWARNING 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. INT-1-3-7_2
17
Take the weight of the engine on the hoist and remove mounting bolts A (4 off). K Fig 2. ( T K-6)
18
Withdraw the engine in a level attitude until the hydraulic pump is clear of the cab floor. Raise the engine to lift it clear of the machine.
9803/9960-3
K-5
204290-B1
Fig 1. 7
Support the weight of the cooling pack and remove the securing bolts E (4 off).
8
Lift the cooling pack clear.
K-5
Section K - Engine Engine Unit Removal and Replacement
205180-B1
Fig 2.
Replacement
Torque Settings
Replacement is a reversal of the removal procedure.
Item
Nm
kgf m
lbf ft
On completion, check hydraulic and cooling systems for leakage and level.
A
56
5.7
42
B
56
5.7
42
C
98
10
72
D
28
3
21
Note: If the mounting brackets are removed from the engine block it is necessary to use JCB Lock and Seal when reinstalling the mounting bolts B before torque tightening. Note: The metalastic flexible mounts can be removed by removing bolts C. Note: The front left hand engine mount also carries the alternator and is held by 3 x M8 bolt D as opposed to 2 x M10 bolt B.
K-6
9803/9960-3
K-6