jcb JCB 8061 Mini Excavator Service Repair Manual – PDF Download by www.heydownloads.com

Service Manual 8061 Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track and Running Gear Section K - Engine

Publication No.

9813/1750-1

World Class Customer Support Copyright Â© 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 Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track and Running Gear Section K - Engine

Publication No.

9813/1750-1

Section 1 - General Information

Notes:

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9813/1750-1

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Section 1 - General Information Contents Page No. Introduction About this Publication ...............................................................................1 - 1 Schematic Codes .....................................................................................1 - 2 Identification Plates Identifying Your Machine ..........................................................................1 - 3 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ......................................1 - 5 Hydraulic Connections ..............................................................................1 - 9 Service Tools Numerical List .........................................................................................1 - 13 Tool Detail Reference .............................................................................1 - 16 Service Consumables Sealing and Retaining Compounds ........................................................1 - 29

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Section 1 - General Information Contents

1 - ii

Page No.

1 - ii

Section 1 - General Information

Introduction About this Publication This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department.

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

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.

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.

Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST!

'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards. This Service Manual covers the following machines: JCB 8061 China - Serial numbers 2068385 Onwards

The manual is compiled in sections, the first three are numbered and contain information as follows: 1

General Information - includes torque settings and service tools.

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

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

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

Attachments

Body & Framework...etc.

The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual. Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.

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Section 1 - General Information Introduction Schematic Codes

Schematic Codes Colour Codes 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

1-2

Servo: Oil pressure used in controlling a device (servo).

Neural: 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).

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Section 1 - General Information

Identification Plates Identifying Your Machine Machine Identification Plate

SHA = Shanghai China Build.

Your machine has an identification plate mounted as shown. The Product Identification Number (PIN), weight, engine power, year of manufacture and serial number of the machine are shown on the plate.

Note: The machine model and build specification is indicated by the PIN. Refer to Typical Product Identification Number (PIN).

If the engine is replaced by a new one, the serial number on the identification plate will be wrong. Either get a replacement identification plate from your JCB Dealer or simply remove 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.

World Manufacturer Identification (3 Digits).

Machine Type and Model (5 Digits). 08061 = 8061. Random Check Letter (1 Digit). The Check Letter is used to verify the authenticity of a machineâ&#x20AC;&#x2122;s PIN.

Machine Serial Number (8 Digits). Each machine has a unique serial number.

Component Identification Typical Engine Identification Number If the engine is replaced by a new one, the data plate serial number will be wrong. Either stamp the new number on the plate or stamp out the old one. This will prevent the wrong number being quoted when you order replacement parts. a

50316

000001

Engine Type

b Engine Parts List c

Country of Manufacture

d Engine Serial Number e

Year of Manufacture

772890-2

Fig 1.

Typical Product Identification Number (PIN) 1

SHA

08061

2068385

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1-3

Section 1 - General Information Identification Plates Identifying Your Machine ROPS, TOPS and FOGS

!MWARNING Modified and wrongly repaired ROPS, TOPS & FOGS Structures are dangerous. Do not modify the TOPS Structure. Do not attempt to repair the ROPS, TOPS & FOGS Structure. If the ROPS, TOPS & FOGS Structure has been in an accident, do not use the machine until the structure has been inspected and repaired. This must be done by a qualified person. For assistance, contact your JCB dealer. Failure to take precautions could result in death or injury to the operator. 5-3-1-7_2

Machines built to ROPS and TOPS standards have an identification label fitted to the cab. K Fig 2. ( T 1-4). A bolt on falling object guard is available which also carries a certified label. This label certifies the cab to FOGS standard. K Fig 3. ( T 1-4). When a machine is used in an application with the risk of falling objects, the machine must be equipped with the optional FOGS guard. This guard is compliant to ISO10262 level 1 and is intended for protection from small objects, e.g. small rocks, small debris and other small objects encountered in operations such as highway maintenance, landscaping and other construction site services.

Fig 2.

Fig 3.

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Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners

Standard 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 1-5).

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.

1-5

Fig 1. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

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Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Hexagon (A/F) Condition 1

Bolt Size in.

in.

kgf m

lbf ft

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

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

1-6

Condition 2

kgf m

Condition 2

lbf ft

kgf m

lbf ft

5.8

0.6

4.3

5.2

0.5

3.8

9.9

1.0

7.3

9.0

0.9

6.6

24.0

2.4

17.7

22.0

2.2

16.2

M10

47.0

4.8

34.7

43.0

4.4

31.7

M12

83.0

8.5

61.2

74.0

7.5

54.6

M16

205.0

20.9

151.2

184.0

18.8

135.7

M20

400.0

40.8

295.0

360.0

36.7

265.5

M24

690.0

70.4

508.9

621.0

63.3

458.0

M30

1372.0

139.9

1011.9

1235.0

125.9

910.9

M36

2399.0

244.6

1769.4

2159.0

220.0

1592.4

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Section 1 - General Information Standard 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

kgf m

Condition 2 lbf ft

kgf m

lbf ft

8.1

0.8

6.0

7.3

0.7

5.4

13.9

1.4

10.2

12.5

1.3

9.2

34.0

3.5

25.0

30.0

3.0

22.1

M10

67.0

6.8

49.4

60.0

6.1

44.2

M12

116.0

11.8

85.5

104.0

10.6

76.7

M16

288.0

29.4

212.4

259.0

26.4

191.0

M20

562.0

57.3

414.5

506.0

51.6

373.2

M24

971.0

99.0

716.9

874.0

89.1

644.6

M30

1930.0

196.8

1423.5

1737.0

177.1

1281.1

M36

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

kgf m

lbf ft

kgf m

lbf ft

9.8

1.0

7.2

8.8

0.9

6.5

16.6

1.7

12.2

15.0

1.5

11.1

40.0

4.1

29.5

36.0

3.7

26.5

M10

80.0

8.1

59.0

72.0

7.3

53.1

M12

139.0

14.2

102.5

125.0

12.7

92.2

M16

345.0

35.2

254.4

311.0

31.7

229.4

M20

674.0

68.7

497.1

607.0

61.9

447.7

M24

1165.0

118.8

859.2

1048.0

106.9

773.0

M30

2316.0

236.2

1708.2

2084.0

212.5

1537.1

M36

4049.0

412.9

2986.4

3644.0

371.6

2687.7

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Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread

kgf m

lbf ft

1.2

0.1

0.9

3.0

0.3

2.0

6.0

0.6

4.5

10.0

1.0

7.5

24.0

2.5

18.0

M10

48.0

4.9

35.5

M12

82.0

8.4

60.5

Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size

1-8

ISO Metric Thread

kgf m

lbf ft

2.0

0.2

1.5

6.0

0.6

4.5

11.0

1.1

8.0

19.0

1.9

14.0

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

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Section 1 - General Information Standard 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 45Â° seat machined into the face of the tapped port. Table 8. Torque Settings - BSP Adaptors BSP Adaptor Hexagon (A/F) Size

1-9

in.

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

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

kgf m

lbf ft

7/16 - 20

15.9

20.0 - 28.0

2.0 - 2.8

16.5 - 18.5

9/16 - 18

19.1

46.0 - 54.0

4.7 - 5.5

34.0 - 40.0

3/4 - 16

22.2

95.0 - 105.0

9.7 - 10.7

69.0 - 77.0

7/8 - 14

27.0

130.0 - 140.0

13.2 - 14.3

96.0 - 104.0

1 1/16 - 12

31.8

190.0 - 210.0

19.4 - 21.4

141.0 - 155.0

1 5/16 - 12

38.1

290.0 - 310.0

29.6 - 31.6

216.0 - 230.0

1 5/8

47.6

280.0 - 380.0

28.5 - 38.7

210.0 - 280.0

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Section 1 - General Information Standard 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 45Â° seat machined into the face of the adaptor port.

BSP Hose Size in.

1 - 10

Note: Dimension 2-D will vary depending upon the torque applied.

Table 10. BSP Hose - Torque Settings Hexagon (A/F) mm

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

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

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kgf m

lbf ft

1 - 10

Section 1 - General Information Standard Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size

1 - 11

in.

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

203.0

20.7

150.0

1 1/4

305.0

31.0

225.0

1 1/2

305.0

31.0

225.0

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Section 1 - General Information Standard 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 45Â° 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 - 12

in.

kgf m

lbf ft

1/8

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

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

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Section 1 - General Information

Service Tools Numerical List The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools are available from JCB Service. Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full details of all tools, including the content of kits and sets,

see the relevant section in this manual. K Tool Detail Reference ( T 1-16). 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

See Section

Bonded Washers - see Tool Detail Reference (Section 1) for content

Female Cone Blanking Plugs - see Tool Detail Reference (Section 1) for content

Female Connectors - see Tool Detail Reference (Section 1) for content

Hydraulic Flow Test Equipment - see Tool Detail Reference (Section 1) for content

Hydraulic Hand Pump Equipment - see Tool Detail Reference (Section 1) for content

Male Adapters - BSP x BSP - see Tool Detail Reference (Section 1) for content

Male Adapters - BSP x NPT (USA only) - see Tool Detail Reference (Section 1) for content

Male Cone Blanking Caps - see Tool Detail Reference (Section 1) for content

Pressure Test Points - Adaptors - see Tool Detail Reference (Section 1) for content

Pressure Test Points - 'T' Adaptors - see Tool Detail Reference (Section 1) for content

Rivet Nut Tool - see Tool Detail Reference (Section 1) for content

331/22966

Pump Drive Alignment Tool

331/31069

Test Block for A.R.V.

4104/1310

Hand Cleaner

892/00039

Spool Clamp

892/00041

De-glazing Tool

892/00137

Micro-Bore Hose

892/00223

Hand Pump

892/00253

Hydraulic Circuit Pressure Test Kit - see Tool Detail Reference (Section 1) for content

892/00254

Hose

892/00271

Adapter

892/00272

Adapter

892/00273

Adapter

892/00274

Adapter

892/00275

Adapter

1 - 13

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1 - 13

Section 1 - General Information Service Tools Numerical List Part Number

Description

892/00276

Adapter

892/00277

Adapter

892/00279

Gauge

892/00280

Gauge

892/00281

AVO Meter

892/00284

Digital Tachometer

892/00285

Hyd. Oil Temperature Probe

892/00298

Fluke Meter

892/00334

Ram Seal Fitting Tool

892/00346

Gauge

892/00347

Connector

892/00706

Test Probe

892/00842

Glass Lifter

892/00843

Folding Stand for Holding Glass

892/00845

Cartridge Gun

892/00846

Glass Extractor (Handles)

892/00847

Nylon Spatula

892/00848

Wire Starter

892/00849

Braided Cutting Wire

892/01016

Ram Protection Sleeve for 25 mm Rod Diameter

892/01017

Ram Protection Sleeve for 30 mm Rod Diameter

892/01018

Ram Protection Sleeve for 40 mm Rod Diameter

892/01019

Ram Protection Sleeve for 50 mm Rod Diameter

892/01020

Ram Protection Sleeve for 50 mm Rod Diameter (slew ram)

892/01021

Ram Protection Sleeve for 60 mm Rod Diameter

892/01022

Ram Protection Sleeve for 60 mm Rod Diameter (slew ram)

892/01023

Ram Protection Sleeve for 65 mm Rod Diameter

892/01024

Ram Protection Sleeve for 70 mm Rod Diameter

892/01025

Ram Protection Sleeve for 75 mm Rod Diameter

892/01026

Ram Protection Sleeve for 80 mm Rod Diameter

892/01027

Piston Seal Assembly Tool

926/15500

Rubber Spacer Blocks

992/02800

ARV Extractor

992/04000

Torque Multiplier

992/09300

Hexagon Spanner 55mm A/F

992/09400

Hexagon Spanner 65mm A/F

992/09500

Hexagon Spanner 75mm A/F

1 - 14

See Section

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1 - 14

Section 1 - General Information Service Tools Numerical List Part Number

Description

See Section

992/09600

Hexagon Spanner 85mm A/F

992/09700

Hexagon Spanner 95mm A/F

992/09900

Hexagon Spanner 115mm A/F

992/10000

Hexagon Spanner 125mm A/F

992/10100

Spool Clamp

992/12300

12V Mobile Oven

992/12400

24V Static Oven (2 Cartridge)

992/12800

Cut-Out Knife

992/12801

'L' Blades

993/68100

Slide Hammer Kit - see Tool Detail Reference (Section 1) for content

1 - 15

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1 - 15

Section 1 - General Information Service Tools Tool Detail Reference

Tool Detail Reference Section B - Frame and Bodywork

Fig 1. 993/68100 Slide Hammer Kit 1

993/68101

Slide Hammer

993/68107

Bar - M20 x M20 X 800 mm

2 3

993/68102

End Stops

993/68108

Adaptor - M20 x 7/8" UNF

993/68103

Adaptor - M20 x 5/8" UNF

993/68109

Adaptor - M20 x M12

993/68104

Adaptor - M20 x 1" UNF

993/68110

Adaptor - M20 x 5/8" UNF (Shoulder)

993/68105

Adaptor - M20 x M20

993/68111

Adaptor - M20 x 1/2" UNF

993/68106

Adaptor - M20 x M24 1

826/01099

M6 x 16 mm Rivet Nut

826/01101

M6 x 19 mm Rivet Nut

826/01102

M8 x 18 mm Rivet Nut

826/01103

M8 x 21 mm Rivet Nut

826/01104

M10 x 23 mm Rivet Nut

826/01105A M10 x 26 mm Rivet Nut 2

Installation Tool available from: Bollhoff Fastenings Ltd (www.bollhof.com)

Fig 2. Rivet Nut Tool

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 3. 892/00842 Glass Lifter Minimum 2 off - Essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.

Fig 6. 892/00846 Glass Extractor (Handles) Used with braided cutting wire to cut out broken glass. K Fig 9. ( T 1-18).

Fig 7. 892/00847 Nylon Spatula

Fig 4. 892/00843 Folding Stand

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

Essential for preparing new glass prior to installation.

Fig 8. 892/00848 Wire Starter Used to access braided cutting wire through original polyurethane seal. K Fig 9. ( T 1-18).

Fig 5. 892/00845 Cartridge Gun Hand operated. Essential for the application of sealants, polyurethane materials etc.

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 9. 892/00849 Braided Cutting Wire

Fig 12. 992/12400 Static Oven 240V

Consumable heavy duty cut-out wire used with the glass extraction tool. K Fig 6. ( T 1-17). Approx 25 m length.

Required to pre-heat adhesive prior to use. No plug supplied. Note: 110V models available upon request - contact JCB Technical Service.

Fig 10. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.

Fig 13. 992/12800 Cut-Out Knife Used to remove broken glass.

Fig 11. 992/12300 Mobile Oven 12V 1 cartridge capacity. Required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket (715/04300).

1 - 18

Fig 14. 992/12801 'L' Blades 25 mm (1 in.) cut. Replacement blades for cut-out knife. K Fig 13. ( T 1-18). Unit quantity = 5 off.

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 15. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub).

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Section 1 - General Information Service Tools Tool Detail Reference

Section C - Electrics

Fig 16. 892/00298 Fluke Meter

Fig 17. 892/00284 Venture Microtach Digital Tachometer

Fig 18. 892/00285 Hydraulic Temperature Probe

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Section 1 - General Information Service Tools Tool Detail Reference

Section E - Hydraulics Male Adapters - BSP x BSP 1606/2052

3/8 in. x 1/4 in.

1604/0003A 3/8 in. x 3/8 in. 892/00071

3/8 in. x 3/8 in. taper

1606/0004

1/2 in. x 1/4 in.

1606/0007A 1/2 in. x 3/8 in. Fig 19. Male Adaptors

1604/0004A 1/2 in. x 1/2 in. 1606/0017

5/8 in. x 1/2 in.

1606/0008

3/4 in. x 3/8 in.

Male Adapters - BSP x NPT (USA only)

1606/0009

3/4 in. x 1/2 in.

816/00439

3/8 in. x 1/4 in.

1604/2055

3/4 in. x 3/4 in.

816/00440

1/2 in. x 1/4 in.

1606/0012

3/4 in. x 1 in.

816/15007A 3/8 in. x 3/8 in.

1606/0014

3/4 in. x 1.1/4 in.

816/15008

1606/0015

1 in. x 1.1/4 in.

892/00255

1/4 in. BSP x Test Point

892/00256

3/8 in. BSP x Test Point

892/00257

1/2 in. BSP x Test Point

892/00258

5/8 in. BSP x Test Point

816/15118

3/4 in. BSP x Test Point

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

816/55045

1/4 in. M 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

892/00263

5/8 in. M BSP x 5/8 in. F BSP x Test Point

892/00264

3/4 in. M BSP x 3/4 in. F BSP x Test Point

892/00265

1 in. M BSP x 1 in. F BSP x Test Point

892/00266

1.1/4 in. M BSP x 1.1/4 in. F BSP x Test Point

892/00267

1.1/4 in. M BSP x 1.1/2 in. F BSP x Test Point

1/2 in. x 3/8 in.

Fig 20. Pressure Test Adapters

Fig 21. Pressure Test 'T' Adapters

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 22. 'T' Adapters

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)

892/00049

5/8 in. BSP (A) x 1/4 in. BSP (B)

816/50043

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

892/00051

1 in. BSP (A) x 1/4 in. BSP (B)

816/50005

1/2 in. BSP (A) x 1/2 in. BSP (B)

816/60096

3/4 in. BSP (A) x 3/4 in. BSP (B)

816/00017

1 in. BSP (A) x 1 in. BSP (B)

892/00055A 1/4 in. BSP 892/00056A 3/8 in. BSP 892/00057

1/2 in. BSP

892/00058A 5/8 in. BSP 892/00059A 3/4 in. BSP Fig 23. Female Blanking Caps

892/00060

1 in. BSP

816/90045

1/4 in. BSP

816/00189A 3/8 in. BSP 816/00190A 1/2 in. BSP

Fig 24. Male Cone Blanking Caps

816/90022

5/8 in. BSP

816/90274

3/4 in. BSP

816/90205

1 in. BSP

892/00074

3/8 in. BSP x 3/8 in. BSP

892/00075

1/2 in. BSP x 1/2 in. BSP

892/00076

5/8 in. BSP x 5/8 in. BSP

892/00077

3/4 in. BSP x 3/4 in. BSP

1406/0011

1/4 in. BSP

1406/0018

1/2 in. BSP

1406/0014

5/8 in. BSP

Fig 25. Female Connectors

Fig 26. Bonded Washers

1 - 22

1406/0021

3/4 in. BSP

1406/0029

1.1/4 in. BSP

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 27. Ram 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

7mm 11o 20mm

10mm

Fig 28. 892/00334 Ram Seal Fitting Tool 5mm

m 3m

110mm 175mm 3o

Fig 29. Hexagon Spanners for Ram Pistons and End Caps 992/09300

55mm A/F

992/09400

65mm A/F

992/09500

75mm A/F

992/09600

85mm A/F

992/09700

95mm A/F

992/09900

115mm A/F

992/10000

125mm A/F

1 - 23

1.4

Fig 30. 892/01027 Piston Seal Assembly Tool

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1 - 23

Section 1 - General Information Service Tools Tool Detail Reference 892/00268

Flow Monitoring Unit

892/00269

Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)

892/00273

Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min)

892/00293

Connector Pipe

892/00270

Load Valve

1406/0021

Bonded Washer

1604/0006A Adapter 3/4 in M x 3/4 in M BSP

Fig 31. Flow Test Equipment

1612/2054

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

892/00277

Adapter 3/8 in F x 3/4 in M BSP

1606/0015

Adapter 1.1/4 in M BSP x 1 in M BSP

892/00078

Connector 1 in F x 1 in F BSP

1604/0008

Adapter 1 in M x 1 in M BSP

1604/0008

Adapter 1 in M x 3/4 in M BSP

816/20013

Adapter 3/4 in F x 1 in M BSP

892/00201

Replacement Gauge 0-20 bar (0-300 lbf/in2)

892/00202

Replacement Gauge 0-40 bar (0-600 lbf/in2)

892/00203

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

892/00254

Replacement Hose

993/69800

Seal Kit for 892/00254 (can also be used with probe 892/00706)

892/00706

Test Probe

892/00347

Connector - Hose to gauge

Fig 32. 892/ 00253 Hydraulic Circuit Pressure Test Kit

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Section 1 - General Information Service Tools Tool Detail Reference 892/00279

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

892/00346

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

892/00347

Connector

892/00254

Hose

892/00280

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

892/00223

Hand Pump

892/00137

Micro-bore Hose 1/4 in BSP x 3 metres

892/00274

Adapter 1/4 in M BSP x 3/8 in M BSP Taper

Fig 33. Hydraulic Circuit Test Gauges and Connections

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 34. Hand Pump Equipment

Fig 35. Spool Clamps 892/00039

Spool Clamp

992/10100

Spool Clamp - Diameter 19mm (3/4 in)

992/02800

ARV Extractor

1 - 25

Fig 36. 331/31069 - Test Block for A.R.V.

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 37. 331/22966 Pump Drive Alignment Tool

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Section 1 - General Information Service Tools Tool Detail Reference

Section K - Engine

Fig 38. 892/00041 - De-glazing Tool for Cylinder Bores To assist bedding-in of new piston rings. For details of other engine service tools refer to: – Publication No. 9806/2100 English – Publication No. 9806/2101 French – Publication No. 9806/2102 German – Publication No. 9806/2103 Spanish – Publication No. 9806/2104 Italian

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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

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Section 1 - General Information Service Consumables Sealing and Retaining Compounds

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Section 2 Care and Safety Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track and Running Gear Section K - Engine

Publication No.

9813/1750-1

Section 2 - Care and Safety

Notes:

2-0

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Section 2 - Care and Safety Contents Page No. Safety Notices Safety Check List ......................................................................................2 - 1 Safety Labels .......................................................................................... 2 - 11

2-i

Section 2 - Care and Safety Contents

2 - ii

Page No.

2 - ii

Section 2 - Care and Safety

Safety Notices Safety Check List P11-1010_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

2-1

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Section 2 - Care and Safety Safety Notices Safety Check List

!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.

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-1-3-9_2

INT-3-3-7_1

!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

2-2

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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

2-3

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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

2-4

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

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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.

Machines with a TOPS structure are equipped with a seat belt. The TOPS structure is designed to give you protection in an accident. If you do not wear the seat belt you could be thrown off the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine.

5-1-5-9

!MWARNING

2-2-1-9

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

!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. When applicable, keep all attachments low to the ground.

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.

8-1-1-1

10-1-1-40

Visibility Accidents can be caused by working in poor visibility. Use your lights to improve visibility. Keep the road lights, windows and mirrors clean.

!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

Do not operate the machine if you cannot see clearly. 5-1-4-7

!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.

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.

5-2-6-5

13-1-1-17

!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.

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. 0179_2

INT-2-1-9_6

2-5

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Section 2 - Care and Safety Safety Notices Safety Check List

!MCAUTION

!MWARNING

Passengers Passengers in or on the machine can cause accidents. Do not carry passengers.

Machine Safety Stop work at once if a fault develops. Abnormal sounds and smells can be signs of trouble. Inspect and repair before resuming work.

INT-2-2-2_1

8-1-2-3

!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. 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.

!MWARNING Machines with a TOPS structure are equipped with a seat belt. The TOPS structure is designed to give you protection in an accident. If you do not wear the seat belt you could be thrown off the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine. 2-2-1-9

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. INT-2-1-12

!MWARNING Seat Belt Operating the machine without a seat belt can be dangerous. Before starting the engine, make sure your seat belt is fastened. Check the tightness and condition of the seat belt securing bolts regularly (see maintenance schedules). INT-2-1-8_1

!MWARNING Safe Working Loads Overloading the machine can damage it and make it unstable. Study the specifications in the Operator Manual before using the machine. 7-1-1-8_2

2-6

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

Maintenance Safety

!MWARNING Communications Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing. Before starting the engine make sure the others are clear of the danger areas; examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken. INT-3-1-5

!MWARNING 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. GEN-1-5_2

!MWARNING 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.

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

!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

!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

INT-3-1-3_2

!MWARNING

!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

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

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Section 2 - Care and Safety Safety Notices Safety Check List

!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.

'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.

INT-3-2-14

INT-3-2-12

!MWARNING

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

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-3-2-4

INT-3-3-2_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

!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

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

!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

!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

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

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

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.

To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a brush to clean components.

New fluoroelastomeric components at ambient temperature require no special safety precautions.

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.

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.

Thoroughly wash contaminated detergent and water.

area

with

Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.

DO NOT BURN FLUOROELASTOMERIC MATERIALS. INT-3-3-5_4

HYD-1-3_2

!MWARNING

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. 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. INT-3-1-15_2

!MWARNING Counterweights Your machine may be fitted with counterweights. They are extremely heavy. Do not attempt to remove them. INT-3-2-5

!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.

Compressed air is dangerous. Wear suitable eye protection and gloves. Never point a compressed air jet at yourself or others.

GEN-1-12

0147_1

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

!MDANGER

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.

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 safety glasses. INT-3-2-1_3

!MWARNING

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.

Battery Terminals The machine is negatively earthed. Always connect the negative pole of the battery to earth. When connecting the battery, connect the earth (-) lead last.

INT-3-1-6

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

!MCAUTION

INT-3-1-9

Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged.

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.

INT-3-1-14

!MWARNING 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. 0125

!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

!MCAUTION

8-3-4-8

!MWARNING 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. 5-1-6-1

!MDANGER Before removing the boom from the machine, ensure that the counterweight is adequately supported as in certain ground conditions the machine could tip backwards. Never travel or transport the machine with the boom removed. BF-6-3

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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.

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Section 2 - Care and Safety Safety Notices Safety Labels

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Section 3 Maintenance Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track and Running Gear Section K - Engine

Publication No.

9813/1750-1

Section 3 - Maintenance

Notes:

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Section 3 - Maintenance Contents Page No. Routine Maintenance Service Requirements ..............................................................................3 - 1 Introduction ..........................................................................................3 - 1 Owner/Operator Support .....................................................................3 - 1 Service/Maintenance Agreements ......................................................3 - 1 Fit for Purpose Tests for Lifting Equipment ..........................................3 - 1 Obtaining Replacement Parts ..............................................................3 - 2 Health and Safety .....................................................................................3 - 3 Lubricants ............................................................................................3 - 3 Battery .................................................................................................3 - 5 Service Schedules ....................................................................................3 - 7 Introduction ..........................................................................................3 - 7 How to Use the Service Schedules .....................................................3 - 7 Calendar Equivalents ..........................................................................3 - 8 Pre-Start Cold Checks, Service Points and Fluid Levels .....................3 - 9 Functional Test and Final Inspection ................................................. 3 - 11 Fluids, Lubricants and Capacities ...........................................................3 - 12 Coolant Mixtures ...............................................................................3 - 12 Fuels ..................................................................................................3 - 14 Tools .......................................................................................................3 - 17 Carrying Tools onto the Machine .......................................................3 - 17 Toolbox ..............................................................................................3 - 17 Prepare the Machine for Maintenance ...................................................3 - 18 Introduction ........................................................................................3 - 18 How to Make the Machine Safe (Excavator Lowered) ......................3 - 18 Cleaning the Machine .............................................................................3 - 19 Introduction ........................................................................................3 - 19 Preparing the Machine for Cleaning ..................................................3 - 19 Cleaning the Machine ........................................................................3 - 20 Cleaning the Tracks ...........................................................................3 - 20 Checking for Damage .............................................................................3 - 22 Check the Machine Body and Structure ............................................3 - 22 Check the Seat and Seat Belt ...........................................................3 - 22 Check the Hydraulic Hoses and Fittings ...........................................3 - 22 Check the Electrical Circuits ..............................................................3 - 23 Checking the ROPS/FOPS Structure ................................................3 - 24 Checking the Ram Piston Rods ........................................................3 - 24 Greasing .................................................................................................3 - 25 Introduction ........................................................................................3 - 25 Pivot Pins ..........................................................................................3 - 25 Every 50 Hours ..................................................................................3 - 27 Every 1000 Hours ..............................................................................3 - 28 Access Panels ........................................................................................3 - 29 Introduction ........................................................................................3 - 29 Engine Side Cover ............................................................................3 - 29 Rear Hydraulic Cover ........................................................................3 - 31 Electrical System ....................................................................................3 - 32 Battery Cover ....................................................................................3 - 32 Battery ...............................................................................................3 - 32 Jump Starting the Engine ..................................................................3 - 34 Primary Fuses ...................................................................................3 - 36 Secondary Fuses ..............................................................................3 - 37

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Section 3 - Maintenance Contents

Contents Page No. Engine ....................................................................................................3 - 38 Checking the Oil Level ......................................................................3 - 38 Changing the Oil and Filter ................................................................3 - 40 Changing the Air Filter Elements .......................................................3 - 41 Checking the Coolant Level ..............................................................3 - 42 Changing the Coolant ........................................................................3 - 42 Adjusting the Fan Belt .......................................................................3 - 43 Adjusting the Compressor Belt ..........................................................3 - 44 Fuel System ............................................................................................3 - 45 Introduction ........................................................................................3 - 45 Draining the Fuel Filters/Sedimenters ...............................................3 - 46 Replacing the Fuel Filter Elements ...................................................3 - 47 Bleeding the System .........................................................................3 - 47 Hydraulic System ....................................................................................3 - 49 Introduction ........................................................................................3 - 49 Releasing the Hydraulic Pressure .....................................................3 - 50 Oil and Filter ......................................................................................3 - 51 Tracks and Running Gear ......................................................................3 - 53 Checking the Track Gearbox Oil Level ..............................................3 - 53 Changing the Track Gearbox Oil .......................................................3 - 54 Checking the Track Tension ..............................................................3 - 55 Adjusting the Track Tension ..............................................................3 - 55

3 - ii

Section 3 - Maintenance

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.

Giving your name, address and telephone number.

Quoting your machine model and serial number.

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.

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.

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.

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.

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Section 3 - Maintenance Routine Maintenance Service Requirements 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.

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Section 3 - Maintenance 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.

Avoid prolonged, excessive or repeated skin contact with used oil.

Apply a barrier cream to the skin before handling used oil. Note the following when removing engine oil from skin:

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.

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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.

3-3

Section 3 - Maintenance Routine Maintenance Health and Safety 3

Avoid skin contact with oil soaked clothing.

Don't keep oily rags in pockets.

Wash dirty clothing before re-use.

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

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Section 3 - Maintenance Routine Maintenance Health and Safety

!MCAUTION

Battery

!MWARNING

T3-061

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

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

!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 safety glasses. INT-3-2-1_3

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Section 3 - Maintenance 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

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Section 3 - Maintenance 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

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Section 3 - Maintenance Routine Maintenance Service Schedules

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

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Section 3 - Maintenance Routine Maintenance Service Schedules

Pre-Start Cold Checks, Service Points and Fluid Levels Operation

500

1000

2000

- Check

ENGINE Oil level Oil and Filter

- Change

Air Cleaner Element (Dusty Conditions only)

- Change

Air Cleaner Outer Element

- Change

Air Cleaner Inner Element

- Change

Air Cleaner Hose Security

- Check and Adjust

Air Filter Dust Valve

- Check and Clean

Fuel Injectors(1)

- Clean and Test

Coolant Quality/Level

- Check

Coolant Fuel Sedimenter

- Change - Drain and Clean

Fuel Pre-Filter/Sedimenter Element

- Change

Primary Fuel Filter

- Change

Electric Fuel Pump Gauze Filter

- Clean and Check

Fan Belt Tension/Condition

- Check and Adjust

HVAC Compressor Belt Tension/Condition

- Check and Adjust

Valve Clearances(1)

- Check and Adjust

Cylinder Head Bolts for Tightness

- Check and Adjust

Engine Mounting Bolts for Tightness

- Check and Adjust

Exhaust System Security

- Check and Adjust

Radiator

- Clean and Check

TRANSMISSION Security of Mounting Bolts and Nuts - Track Wheel Motor to Undercarriage Bolts

- Check

- Drive Sprocket Bolts

- Check

- Slew Gearbox Bolts

- Check

Track Gearbox Oil

- Change

HYDRAULICS Oil Level

3-9

- Check

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Section 3 - Maintenance Routine Maintenance Service Schedules Operation Oil

Change

Rams - Chrome Condition

- Check

Hoses and Pipework - Damage/Leaks

- Check

Return Filter Element

- Change

Suction Strainer

- Clean

Security of Mounting Bolts on Major Assemblies

- Check

500

1000

2000

ELECTRICS Battery Electrolyte Level (if applicable)

- Check

Starter Motor and Alternator Brush Gear

- Check

Wiring for Chaffing/Routing

- Check

Battery Terminals for Condition and Tightness

- Check

UNDERCARRIAGE Track Rollers Bolts

- Check

Track Rollers Oil and Seals

- Change

Idler Wheels Oil and Seals

- Change

Track Plate Condition and Bolt Torque

- Check

Track Tension

- Check

BODYWORK AND CAB Cab Mounting Bolts Security

- Check and Clean

- Grease

- Check

- Check and Adjust

All Pivot Pins

- Grease

Visual inspection of structure for damage including welds around lifting points and excavator end main pivots K Checking for Damage ( T 3-22).

- Check

Kingpost - kingpin retaining plate bolts torque

- Check

Slew Ring Bearing

- Grease

Slew Ring Mounting Bolts

- Check

Slew Ring Pinion and Gear Teeth Door/Window Hinges

- Grease - Lubricate

Windscreen Washer Fluid Level Machine Generally

- Check

ATTACHMENTS Quick Hitch OPTIONAL EQUIPMENT As Required (1) Jobs which should only be done by a specialist.

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Section 3 - Maintenance Routine Maintenance Service Schedules

Functional Test and Final Inspection Operation

500

1000

2000

ENGINE - Check and Adjust

Idle and Maximum Speed(1) Exhaust Smoke (excessive)

- Check

Fuel System - Leaks and Contamination

- Check

Operation All Services - Excavator, Dozer etc.

- Check

Hoses and Pipework - Damage/Leaks

- Check

HYDRAULICS

- Check and Adjust

Main Relief Valve Pressure(1) Auxiliary Relief Valve Pressure

(1)

Slew Cross Line Relief Valve Pressure(1) Servo Relief Valve Pressure

(1)

- Check and Adjust - Check and Adjust - Check and Adjust

ELECTRICS All Electrical Equipment Operation, (e.g. warning lights, beacon, alarms, horn, wipers etc.)

- Check

Hourmeter Operation

- Check

- Complete

UNDERCARRIAGE Track and Running Gear Operation BODYWORK AND CAB Excavator Lever and Swing Pedal Locks 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.

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Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities JCB recommend that you use the JCB lubricants shown as they have been verified by JCB for use on JCB machines. However, you could use other lubricants that are equivalent to the JCB standards and quality or offer the same machine component protection.

Item Fuel Tank Engine (Oil)

Table 1. Capacity Fluid / Lubricant Litres (Gal)

JCB Part No Container Size (1)

138 (30.36) Diesel Oil

4001/1505

20 Litres

JCB Cold Climate Engine Oil EP 5W40 (-20°C to 4001/2705 +50°C, -4°F to 122°F)

20 Litres

9 (1.98)

(2)

JCB Engine Oil HP 15W/40 (above -10°C, 14°F)

12.05 (2.65) JCB Antifreeze HP/Coolant/Water K Coolant Mixtures ( T 3-12).

Engine Coolant Track Gearbox (each)

0.8 (0.2)

4006/1120

20 Litres

JCB Engine Oil HP SAE 30 (Not Multigrade)

4001/0305

20 Litres

Track Idler Wheels

sealed unit

JCB HD90 Gear Oil

Track Rollers (top)

sealed unit

JCB HD90 Gear Oil

Track Rollers (bottom)

sealed unit

JCB HD90 Gear Oil

Hydraulic Tank

59 (12.98)

JCB Hydraulic Fluid HP32 (Up to 30°C, 86°F)

4002/1025

20 Litres

JCB Hydraulic Fluid HP46 (Over 30°C, 86°F)

4002/0805

20 Litres

Slew Ring Bearings

JCB HP Grease

4003/2017

400g

Slew Ring Gear Teeth

JCB Special Slew Pinion Grease

4003/1619

400g

All Other Grease

JCB MPL-EP Grease

4003/1501

400g

(1) For information about the different container sizes that are available (and their part numbers), contact your local JCB dealer. (2) Caution - Do not use ordinary Engine Oil.

Coolant Mixtures T3-009_3

Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period.

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.

Replace the coolant mixture according to the intervals shown in the machine's Service Schedule.

The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion.

!MWARNING

The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below.

Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze.

50% Concentration (Standard) Protects against damage down to -40 °C (-39 °F)

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

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Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities 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).

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Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities

!MCAUTION

Fuels Acceptable and Unacceptable Fuels T3-048_2

Important: No warranty liability whatsoever will be accepted for failure of fuel injection equipment where the failure is attributed to the quality and grade of the fuel used.

Fuel Specification

Consult your fuel supplier or JCB distributor about the suitability of any fuel you are unsure of. GEN-9-2

Table 2. Applicable Engines

EN590 Diesel fuel types - Auto/C0/C1/C2/ All C3/C4

Service Requirements Obey the maintenance procedures.

BS2869 Class A2

usual routine schedules and

ASTM D975-076 2-D, US DF1, US DF2, US DFA JIS K2204 Grades 1, 2, 3 and Special Grade 3 ASTM D975-076 1-D MIL T38219 JP7 NATO F63 French EN590 (RME5) with 5% maximum

All

Obey the usual routine maintenance schedules and Important: Engines operated with procedures. Fuel additives are these fuels may have a reduced recommended for use with low service life. sulphur fuels(1). K Additives ( T 3-15).

AVTURFSII, NATO F34, JP8, MIL T83133, All DERD 2463, DEF STAN 91-87 AVCAT FSII, NATO F44, JP5, MIL T5624, Important: Engines operated with these fuels may have a reduced DERD 2452, AVTOR service life. NATO F35, JET A1, DEF STAN 91-91, DERD 2494, XF63

Obey the usual routine maintenance schedules and procedures. Fuel additives must be used(1). K Additives ( T 3-15).

AVCAT, NATO F43 (obsolete), JP5 without additives JET A (ASTM D1655) ASTM D3699 Kerosene B5 Biodiesel - RME content blended with Tier 3 only(2). mineral derived diesel (5% maximum) ASTM D6751, DIN 51606, ISO 14214

You must obey special routine maintenance schedules and procedures. K Warranty ( T 3-15).

AVTAG (obsolete)

These fuels are not acceptable with AVTAG FSII (obsolete), NATO F40, JP4, or without additives. Engines must not be operated with these fuels. DERD 2454 JET B (ASTM D1655) BS MA100 JIS K2203 No.2 Unmodified vegetable oils (1) Use a fuel additive (where instructed) to make sure that the fuel meets the minimum lubricity requirement. (2) Refer to Typical Engine Identification Number.

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Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities Additives

tank (or the storage tank). Water will encourage micobacterial growth.

The additives listed below are advertised as being suitable for bringing the lubricity levels of kerosene/low sulphur fuels up to those of diesel fuels. They must be used as specified by your fuel supplier who will understand the concentration level necessary. Important: The lubricity wear scar diameter must not be more than 460 microns, as tested on a high frequency reciprocating rig at 60°C (140°F). Refer to ISO 12156-1. – Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%), specifically for Indian Superior Kerosene (SKO) but may be applicable to other fuels. – Lubrizol 539N. Dosage (on Swedish low sulphur fuel) 250 ppm. – Paradyne 7505 (from Infineum). Dosage 500 ppm (0.05%). Note: These products are given as examples only. The information is derived from the manufacturers data. The products are not recommended or endorsed by JCB. Service Requirements for use of B5 Biodiesel – The engine oil must be a grade CH4 as minimum specification. – Do not leave unused B5 biodiesel in the fuel tank for extended periods (top up each day). – Make sure that 1 in 5 fuel tank fills use standard diesel to EN590 specification, this will help to prevent 'gumming'. – Make sure regular oil sampling is completed (look for excessive unburnt fuel content, water or wear particles.

– Make sure that the fuel pre-filter is drained daily. – Only Tier 3 engines (factory filled with CH4 oil) - this is not approved with other manufacturers. – Use heater kits in low ambient temperature territories. – The biodiesel must meet the following standards: ASTM D6751, DIN 51606, ISO 14214 Note: If necessary use a test kit to confirm the fuel specification. Testing kits are available (not from JCB currently), use the internet as a source for the kits. Note: If performance related issues are to be reported to JCB Service, and the engine has been run on biodiesel, then the fuel system must be filled with standard diesel (at least 2 x tank fills) to EN590 specification and relevant stall speeds recorded prior to making the report. Warranty JCB have shown a commitment to support the environment by approving the use of biodiesel blended fuels. Using a B5 blend of biodiesel requires caution and additional servicing of the engine is required. K Service Requirements for use of B5 Biodiesel ( T 3-15). Failure to follow the additional recommended service requirements may lead to a warranty claim being declined. Failures resulting by the incorrect use of biodiesels or other fuel additives are not defects of the engine workmanship and therefore will not be supported by JCB Warranty.

– Change the engine oil and filter more frequently (as a minimum half the recommended intervals), or as indicated by oil sampling. – Change the fuel filters more frequently (as a minimum half the recommended intervals), or if there are engine performance related issues. – Make sure the fuel is stored correctly, care must be taken to make sure no water enters the machine fuel

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Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities Sulphur Content

Effects of Fuel Contaminates T3-032

T3-033

High sulphur content can cause engine wear. (High sulphur fuel is not normally found in North America, Europe or Australia.) If you have to use high sulphur fuel you must change the engine oil more frequently. K Table 3. Sulphur Content ( T 3-16).

The effect of dirt, water and other contaminants in diesel can be disastrous for injection equipment:

Low sulphur fuels must have the appropriate fuel lubricity additives, these lubricity improvers must not create residual deposits that block the fuel system, e.g. injectors, filters etc. Contact your fuel Supplier.

!MCAUTION A combination of water and sulphur will have a corrosive chemical effect on fuel injection equipment. It is essential that water is eradicated from the fuel system when high sulphur fuels are used. ENG-3-2

Table 3. Sulphur Content Percentage of sulphur in Oil Change Interval the fuel (%) Less than 0.5

Normal

0.5 to 1.0

0.75 of normal

More than 1.0

0.50 of normal

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– Dirt - A severely damaging contaminant. Finely machined and mated surfaces such as delivery valves and distributor rotors are susceptible to the abrasive nature of dirt particles - increased wear will almost inevitably lead to greater leakage, uneven running and poor fuel delivery. – Water - Water can enter fuel through poor storage or careless handling, and will almost inevitably condense in fuel tanks. The smallest amounts of water can result in effects that are just as disastrous to the fuel injection pump as dirt, causing rapid wear, corrosion and in severe cases, even seizure. It is vitally important that water is prevented from reaching the fuel injection equipment. The filter/water trap must be drained regularly. – Wax - Wax is precipitated from diesel when the ambient temperature falls below that of the fuel's cloud point, causing a restriction in fuel flow resulting in rough engine running. Special winter fuels may be available for engine operation at temperatures below 0°C (32°F). These fuels have a lower viscosity and limit wax formation.

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Section 3 - Maintenance 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.

Toolbox The machine has a lockable tool storage container below the seat.

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Section 3 - Maintenance Routine Maintenance Prepare the Machine for Maintenance

Prepare the Machine for Maintenance Introduction

!MWARNING

P11-3001

How to Make the Machine Safe (Excavator Lowered) P11-3002

Maintenance must be done only by suitably qualified and competent persons.

Important: Unless a maintenance procedure instructs you differently, you must lower the Excavator. 1

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.

If necessary, refer to Stopping and Parking the Machine in the Operator Manual. 2

Lower the dozer.

Lower the excavator so the attachment is flat on the ground.

Stop the engine and remove the starter key.

Disconnect the battery operation of the engine.

8-3-1-1

Make the machine safe before you start a maintenance procedure.

Park the machine on level, solid ground.

Unless a maintenance procedure instructs you differently, you must lower the Excavator. Refer to How to Make the Machine Safe (Excavator Lowered).

prevent

accidental

717260-4

Fig 1.

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Section 3 - Maintenance Routine Maintenance Cleaning the Machine

Cleaning the Machine

!MCAUTION

Introduction T3-062_2

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. When cleaning is complete move the machine away from the wash area, or alternatively, clean away the material washed from the machine.

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.

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 alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. ENG-3-3

Important: Do not aim the water jet directly at bearings, oil seals or electrical and electronic components such as the engine electronic control unit (ECU), alternator or fuel injectors. Use a low pressure water jet and brush to soak off caked mud or dirt. Use a pressure washer to remove soft dirt and oil.

Detergents 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.

Preparing the Machine for Cleaning P11-3004

Always adhere to local regulations regarding the disposal of debris created from machine cleaning.

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.

Make the machine safe with the excavator lowered. Refer to Prepare the Machine for Maintenance.

Make sure that all electrical connectors are correctly coupled. If connectors are open fit the correct caps or seal with water proof tape.

13-3-2-10_2

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Section 3 - Maintenance Routine Maintenance Cleaning the Machine

Cleaning the Machine

Cleaning the Tracks

!MWARNING

To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a brush to clean components.

If two people are doing this job make sure that the person operating 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.

HYD-1-3_2

!MCAUTION

If you will be working with another person, make sure that you both understand what is to be done. Learn and use the recognised signalling procedures. Do not rely on shouting - he will not hear you. To clean the tracks, you must turn them. When the tracks are turning, keep clear of rotating parts. Before starting this job, make sure that you have no loose clothing (cuffs, ties etc.) which could get caught in moving parts. Keep people not involved with this job well away! MD-3-3-2

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.

Park the machine on level ground. Operate the controls to slew the cab around across the tracks. Lower the bucket to the ground.

Operate the controls to push the boom down so that the track nearest the bucket is lifted clear of the ground.

8-3-4-8

Pay particular attention to the following: 1

Remove debris and loose articles from inside the cab.

If the radiator tubes/fins get clogged the radiator will be less efficient. Brush off all debris from the cooler tubes and fins using a soft bristle brush. Make sure the loosened material is brushed out of the cooler enclosure.

Debris can collect under the boom. Remove especially all combustible material.

Do not allow debris to accumulate around the engine, pay particular attention to the exhaust area, remove all combustible material.

!MWARNING Rotating the tracks off the ground may cause stones and other debris to be thrown with considerable force. If you are on the outside, keep well clear. Keep other people well clear. 8-3-5-8

Operate the controls to rotate the track which is off the ground. Rotate it one way and then the other to shake off the mud. If necessary the person outside may use water from a hose to help loosen sticky material.

When the track is clean stop the rotation. Inspect the track, rollers sprockets and idler wheels for damage or oil leaks. Replace any damaged parts. If in doubt consult your JCB Dealer.

Operate the controls slowly to lower the track to the ground.

Thoroughly dry piston rams and protect with clean transmission or hydraulic oil if necessary.

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Section 3 - Maintenance Routine Maintenance Cleaning the Machine 6

Operate the controls to position the bucket on the other side of the machine so that steps 2 to 5 can be repeated for the other track.

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Section 3 - Maintenance Routine Maintenance Checking for Damage

Checking for Damage Check the Machine Body and Structure

Check the Hydraulic Hoses and Fittings

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:

!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

– Inspect all lifting point welds. Inspect the hoses regularly for:

– Inspect all pivot point welds. – Inspect the condition of all pivot pins.

– Damaged hose ends

– Check pivot pins are correctly in place and secured by their locking devices.

– Chafed outer covers – Ballooned outer covers

Check steps and handrails are undamaged and secure. Check for broken, cracked or crazed window glass and mirrors. Replace damaged items.

– Kinked or crushed hoses – Embedded armouring in outer covers – Displaced end fittings

Check all attachment teeth are undamaged and secure.

Do not use the machine if a hose or hose fitting is damaged. Replace damaged hoses before you use the machine again.

Check all safety and instructional labels are in place and undamaged. Fit new labels where necessary.

Replacement hoses must be of the same size and standard.

Check all lamp lenses for damage.

Note damaged paintwork for future repair.

Check the Seat and Seat Belt

!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

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. Check that the belt mounting bolts are undamaged, correctly fitted and tightened. Check seats are undamaged and secure. Check seat adjustments for correct operation.

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Section 3 - Maintenance Routine Maintenance Checking for Damage

Check the Electrical Circuits T3-099

Inspect the electrical circuits regularly for: – Damaged connectors – Loose connections – Chafing on wiring harnesses – Corrosion – Missing insulation – Incorrect routing of harness 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.

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Section 3 - Maintenance Routine Maintenance Checking for Damage

Checking the ROPS/FOPS Structure

!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. 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

Check the structure for damage.

Make sure that all the ROPS/FOPS mounting bolts are in place and are undamaged.

Make sure that the ROPS/FOPS mounting bolts are tightened to the correct torque setting.

Checking the Ram Piston Rods Extend each ram fully, one at a time and visually examine for score marks, dents or similar defects. If a ram piston appears defective contact your service engineer or JCB dealer.

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Section 3 - Maintenance Routine Maintenance Greasing

Greasing Introduction 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.

Boom pivot pin

Dozer ram pivot pin, Dozer pivot pin

Boom ram pivot pin

Boom/Dipper pivot pin

Dipper ram pivot pin

Dipper/Tipping link pivot pin

Tipping link pivot pin

Dipper/Bucket pivot pin

Tipping link/Bucket pivot pin

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. Note: Where applicable, refer to the manufacturers manual for instructions on the maintenance of optional attachments.

Pivot Pins

!MWARNING You will be working close into the machine for these jobs. Lower the attachments if possible. Remove starter key and disconnect the battery. This will prevent the engine being started. 8-3-1-3

Dipper ram pivot pin

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Section 3 - Maintenance Routine Maintenance Greasing A

D E

C K K

Fig 2.

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Section 3 - Maintenance Routine Maintenance Greasing

Every 50 Hours Slew Ring Bearings

!MWARNING Do not overgrease the slew ring as this will result in the displacement of the grease seal. 8-2-9-35

Ensure the slew ring is kept full of grease. With the cab in the straight ahead position as shown, the grease point A is located on the front of the slew ring. To ensure full distribution of the grease, use the following procedure: 1

Grease in, using 4 strokes of the grease gun. Rotate 180Â°.

Grease in using 4 strokes of the grease gun.

A x4

Fig 3.

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Section 3 - Maintenance Routine Maintenance Greasing

Every 1000 Hours Slew Ring Gear Teeth

!MWARNING Slew Pinion Grease JCB Slew Pinion Grease is harmful as it contains bitumen compounds 2811. Excessive contact may lead to dermatitis or skin cancer. Always use a barrier cream or wear gloves; wash contaminated skin thoroughly with soap and water. In the event of eye contact, immediately wash with plenty of water and seek medical advice.

8-1-1-7

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

Fig 4. 7

Repeat step 4 as necessary.

Refit the plate B using bolts A.

Lower the machine to the ground.

INT-3-2-4

!MWARNING Jacking A machine can roll off jacks and crush you. Do not work under a machine supported only by jacks. 8-3-5-7

Raise the machine and support the undercarriage.

Stop the engine and remove the starter key.

Remove bolts A and plate B in the underside of the undercarriage. K Fig 4. ( T 3-28)

Apply the grease to the pinion using the applicator. K Fluids, Lubricants and Capacities ( T 3-12).

Start the engine and rotate the mainframe fully twice.

Stop the engine and remove the key.

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Section 3 - Maintenance Routine Maintenance Access Panels

Access Panels Introduction

Engine Side 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. Before you operate the machine, make sure that all of the access panels are in their operation position and secure.

!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. 5-2-6-5

!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

To open the engine side cover: 1

Make the Machine safe with the excavator lowered. Refer to Prepare the Machine for Maintenance.

Unlock the cover using the starter key. Release the latch by pushing button A and pulling up handle B at the same time. K Fig 6. ( T 3-31). The cover is supported on a gas strut.

To close the side engine cover:

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Push the engine cover down..

Make sure it is locked in place.

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Section 3 - Maintenance Routine Maintenance Access Panels

A B V019001-2

Fig 5. Engine Side Cover

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Section 3 - Maintenance Routine Maintenance Access Panels

Rear Hydraulic Cover To open the rear hydraulic bay cover: 1

Unlock the cover using the starter key.

Release the latch by pushing button A and pulling up handle B at the same time. K Fig 5. ( T 3-30). The cover will automatically open and be supported on a gas strut.

To close the rear hydraulic bay cover: 1

Push the cover down.

Make sure it is fastened.

Make sure it is locked in place.

B V019004-2

Fig 6. Rear Hydraulic Cover

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Section 3 - Maintenance Routine Maintenance Electrical System

Electrical System Battery Cover

Connection

The battery A is located under the battery cover B inside the rear hydraulic cover. K Fig 7. ( T 3-32).

Check the battery. a

If the terminal is dirty, clean the post.

Fig 8. 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. c

After cleaning, apply a thin coat of petroleum jelly to the terminal.

T063330-2

Fig 7.

Re-connect the leads. Connect the earth (-) terminal last.

If the machine has a battery isolator, move the switch to the ON position.

Close and lock the access panels.

Battery Battery Disconnection/Connection

!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 burned.

Checking the Electrolyte Level T3-020_3

Disconnection

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.

Get access to the battery. See Access Panels.

If the machine has a battery isolator, move the switch to the OFF position then remove the key.

Disconnect and remove battery. See Battery Disconnection/Connection.

Remove the leads. Disconnect the earth (-) terminal first.

5-2-2-4

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Section 3 - Maintenance Routine Maintenance Electrical System

!MWARNING Do not top the battery up with acid. The electrolyte could boil out and burn you. 2-3-4-6

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.

Fig 9. Typical Battery 4

Refit battery.

Close and lock the access panels.

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Section 3 - Maintenance Routine Maintenance Electrical System

!MDANGER

Jump Starting the Engine

!MWARNING In temperatures below freezing, the battery electrolyte may freeze if the battery is discharged or poorly charged. Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge.

Before lowering the attachments to the ground, make sure that the machine and the area around it are clear of other people. Anyone on or close to the machine could fall and be crushed by the attachments, or get caught in the linkages. 2-2-3-4

If you try to charge a frozen battery or jump-start and run the engine, the battery could explode.

Lower the excavator bucket and dozer to the ground, if they are not already there. They will lower themselves under their own weight when you operate the control. Operate the control carefully to control the rate of descent.

Batteries produce a flammable gas, which is explosive; do not smoke when checking the electrolyte levels. 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 switches in the cab to 'OFF'.

Gain access to the battery. a

Switch off all circuits which are not controlled by the starter switch. Do not connect the booster (slave) supply directly across the starter motor.

8-2-7-4

Connect the Booster Cables a

Note: A good frame earth is part of the machine frame, free from paint and dirt. Do not use a pivot pin for an earth. 5

Do the pre-start checks. See Before Starting the Engine, Operation Section. Start the engine. See Starting the Engine, Operation Section.

Disconnect the Booster Cables a

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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.

b Connect the negative (-) booster cable to a good frame earth on the machine, away from and below the battery.

Note: Follow the instructions on this and the following page to start the engine using booster cables. Your machine has a 12V starting system. The negative (-) terminal on the battery is connected to frame earth.

Open the engine cover.

b The battery is located on the right side of the engine compartment.

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. 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 jumpstart the engine until you are sure of the voltage of the booster (slave) supply.

Lower the Attachments to the Ground.

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Disconnect the cable from the machine frame earth, then disconnect if from the booster supply.

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Section 3 - Maintenance Routine Maintenance Electrical System b Disconnect the positive booster cable from the positive (+) terminal on the battery, then disconnect it from the booster supply. 8

Close the engine cover.

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Section 3 - Maintenance Routine Maintenance Electrical System

Primary Fuses

!MCAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5

The electrical circuits are protected by three primary fuses. The primary fuse box A is located under the rear hydraulic cover K Fig 10. ( T 3-36). If a fuse blows, find out why before fitting a new one. Fuse Circuit

Rating

PF1

Ignition I, Glow Plugs, Ignition III

50A

PF2

Condenser Fan Relay

30A

PF3

Blower, A/C, Boom Light

50A

T063330-1

Fig 10.

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Section 3 - Maintenance Routine Maintenance Electrical System

Secondary Fuses

Fuse Circuit

!MCAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5

Rating

E.S.O.S

Servo Control, Instruments, Two Speed Tracking

Windscreen Wiper

15A

Work Lights

7.5A

Blower, A/C

20A

The electrical circuits are protected by secondary fuses.

Boom Light

25A

The secondary fuse box A is located on the left hand side of the seat base K Fig 11. ( T 3-37). If a fuse blows, find out why before fitting a new one.

Glow Plugs

Horn, Interior Light, Aux. Power Socket

10A

Beacon

10A

5 0 60 70 8 0 40 120 150

Fig 11.

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Section 3 - Maintenance Routine Maintenance Engine

Engine Checking the Oil Level

level will show the oil at the top of the hatched area of the dipstick.

Park the machine on level ground. Lower the excavator and dozer to the ground.

Stop the engine and remove starter key.

Maximum fill rate = 2 litres (0.44 UK Gal) per minute.

Open the engine cover. Allow time for the oil to drain back into the engine sump before taking a reading. If insufficient time is given a false low reading may be recorded which will result in overfilling the engine.

DO NOT insert the container neck Z completely into the filler hole. K Fig 13. ( T 3-38). Allow oil to flow down from the filler to the crankcase.

Withdraw the dipstick A and wipe clean, re-insert fully into tube and withdraw to check level. The correct

Replace filler cap B securely. Use only the recommended oil. K Fluids, Lubricants and Capacities ( T 3-12).

If necessary add oil slowly through the filler B.

Fig 12. Fig 13.

Z Z

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Section 3 - Maintenance Routine Maintenance Engine

!MCAUTION The engine has a closed ventilation system, (a hose connects the ventilation system and the inlet manifold). When oil is added through the oil filler it is important that the oil is added slowly. If the oil is added too rapidly it will enter the cylinders through the hose and intake manifold and cause serious engine damage. 8-3-5-10

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Section 3 - Maintenance Routine Maintenance Engine

Changing the Oil and Filter

!MWARNING Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer. 8-3-1-4

!MCAUTION Keep your face away from the drain hole when removing the drain plug. 2-3-3-4

Remove the engine skid plate to gain access to the engine drain plug (if necessary).

Place a container beneath the engine (to catch the oil). K Fluids, Lubricants and Capacities ( T 3-12), for capacity. Remove the drain plug. Let the oil drain out, then clean and refit the drain plug.

T001480-4

Fig 14. 3

!MCAUTION

Smear the seal on the new filter canister with oil. Screw in the new canister - hand tight and then one quarter turn.

The oil filter canister will contain some oil which could spill out when you remove the canister. MD-3-2-1

Unscrew the filter canister A. If necessary use a chain or strap wrench. Clean the filter mounting face.

Fill the engine with new oil through the filler B. DO NOT insert the container neck Z completely into the filler hole. K Fig 13. ( T 3-38). Allow oil to flow down from the filler to the crankcase. Replace filler cap securely. Use only the recommended oil. K Fluids, Lubricants and Capacities ( T 3-12) Maximum fill rate = 2 litres (0.44 UK Gal) per minute.

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Wipe off any spilt oil. Check for leaks. Make sure that the filler cap is correctly refitted

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Section 3 - Maintenance Routine Maintenance Engine

Changing the Air Filter Elements

Stop the engine and remove starter key.

Open the engine cover.

To prevent dust entering the engine inlet manifold, disconnect induction hose A and plug or cover the open end.

Undo the two retaining clips holding the cover B and remove the element C. Do not tap or knock the element as you remove it.

Remove the inner element D.

Clean the inside of canister E and dust valve F.

Prior to fitting the new element, smear the seal on the end of the element D with grease. Temporarily insert the filter element into the canister ensuring its correct location. Withdraw the element and check that there is a continuous grease witness mark around the base of the canister. This shows that the canister has not been distorted which would allow unfiltered air to bypass the element. Repeat the operation for the outer element C

C B

F T001250-2

Fig 15.

Refit the cover B. Remove the plug from the induction hose and check all air hoses for condition and security.

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Section 3 - Maintenance Routine Maintenance Engine

Checking the Coolant Level

Changing the Coolant

!MWARNING

!MCAUTION

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.

Keep your face away from the cylinder block tap and the radiator drain plug when you drain the system.

9-3-3-1_2

Park the machine on level ground, stop the engine and remove the starter key. Open the engine cover and allow the engine to cool.

Carefully and slowly remove the radiator cap B allowing any trapped pressure to escape.

Observe the coolant fluid in the expansion bottle, the bottle A should be full of coolant to the MAX mark.

Disconnect the bottom radiator hose from the radiator and let the coolant drain out.

Flush the system with clean water if necessary.

Top up the system, if required by carefully removing the expansion bottle cap B, top up the level to the MAX mark.

MD-3-1-6

Refit the filler cap B making sure that it is tight.

Fig 17. 5

Refit the bottom radiator hose.

Fill the system. Use the correct mix of clean, soft water and anti-freeze. K Coolant Mixtures ( T 3-12).

Refit the filler cap B making sure that it is tight.

Run the engine for a while, to raise the coolant to working temperature and pressure. Stop the engine. Check for leaks.

Fig 16. Note: Water in the expansion bottle and not in the radiator indicates expansion bottle tube leaking or a non-sealing radiator pressure cap.

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Section 3 - Maintenance Routine Maintenance Engine

Adjusting the Fan Belt 1

Raise the engine cover

Depress the fan belt A at the centre between the alternator pulley and the crankshaft pulley with a finger force of 49Nm, (11lbf - 5kgf) approx. The belt deflection should be 10 mm (0.4in) approx.

To alter the fan belt tension loosen the alternator mountings B.

Note: Any leverage required to position the alternator must be applied at the drive end using a wooden lever 4

Secure the alternator mounting bolts.

B A

B Fig 18.

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Section 3 - Maintenance Routine Maintenance Engine

Adjusting the Compressor Belt 1

Raise the engine cover

Depress the compressor belt A at the centre between the compressor pulley and the crankshaft pulley with a finger force of 49Nm, (11lbf - 5kgf) approx. The belt deflection should be 6-10 mm (0.24 - 0.40 in) approx.

To alter the compressor belt tension loosen the compressor mountings B.

Note: Any leverage required to position the alternator must be applied at the drive end using a wooden lever 4

Secure the compressor mounting bolts.

B B

B A Fig 19.

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Section 3 - Maintenance Routine Maintenance Fuel System

Fuel System Introduction

!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. 0177

!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

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Section 3 - Maintenance Routine Maintenance Fuel System

Draining the Fuel Filters/Sedimenters 1

Locate the dual sedimenter under the rear hydraulic cover.

Look in the bowls A. If there is any sediment in the bowls replace the fuel filter element. K Replacing the Fuel Filter Elements ( T 3-47). If there is water but no sediment, drain off the water by opening tap B.

50 h

Fig 20.

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Section 3 - Maintenance Routine Maintenance Fuel System

Replacing the Fuel Filter Elements

Bleeding the System

!MCAUTION

If the bowl A contains sediment carry out the following: 1

Open the rear hydraulic cover.

Disconnect the battery.

Drain the sediment bowl A. K Draining the Fuel Filters/Sedimenters ( T 3-46).

Unscrew the filter and sediment bowl from the filter head B.

Unscrew the sediment bowl A from the filter C and wash the bowl. Use clean fuel.

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

!MWARNING To bleed the injectors you must turn the engine. When the engine is turning, there are parts rotating in the engine compartment. Before starting this job make sure that you have no loose clothing (cuffs, ties etc) which could get caught in rotating parts. When the engine is turning, keep clear of rotating parts. 2-3-3-8

Open the engine cover.

To bleed air from the filter, slacken bleed screw A. Operate hand primer B until air free fuel flows from the union.

The fuel injection pump is self bleeding as the engine is cranked.

C A

Fig 21. 6

Re-assemble new filter to bowl and refit to filter head B.

Bleed the system. System ( T 3-47).

3 - 47

K Bleeding

the

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Section 3 - Maintenance Routine Maintenance Fuel System

B A

Fig 22.

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Section 3 - Maintenance 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 40Â°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.

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

INT-3-1-10_3

!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. 2-3-5-1_2

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Section 3 - Maintenance Routine Maintenance Hydraulic System

Releasing the Hydraulic Pressure 1

Make the machine safe with the excavator lowered. Refer to Prepare the Machine for Maintenance.

Operate the controls to remove the hydraulic pressure from the service hose lines: a

For manually operated services, operate the controls (several times) of the service(s) to be disconnected.

b For electrical services, turn the starter key to the ON position. Operate the controls (several times) of the service(s) to be disconnected. Set the starter switch to the OFF position then remove the starter key. c

Press the relevant console switch (to make the relevant service active). Refer to Operation Section.

Important: To release the hydraulic pressure from the electrical and servo operated services the battery must be connected while you operate the controls. 3

Carefully remove the hydraulic tank filler cap to vent residual tank hydraulic pressure.

Install the hydraulic tank filler cap.

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Section 3 - Maintenance Routine Maintenance Hydraulic System

Oil and Filter

Checking and Adjusting the Fluid Level 1

Prepare the Machine

Park the machine on firm level ground with the rams positioned as shown. K Fig 23. ( T 3-51). Stop the engine and remove the starter key.

T063500-5

Fig 23. 2

Fig 24.

Check the Level Open the engine cover and check the level indicator A.

Top up fluid level if necessary Remove filler cap B, add fluid. Ensure that only correct grade of fluid is used. K Fluids, Lubricants and Capacities ( T 3-12).

Refit the filler cap.

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Section 3 - Maintenance Routine Maintenance Hydraulic System Replacing the Hydraulic Filter 1

Raise the rear cover.

Remove the screws retaining the filter cap C. K Fig 24. ( T 3-51)

Remove the filter element.

Fit new filter and seals, replace cap.

Top up hydraulic fluid level through filter. K Fluids, Lubricants and Capacities ( T 3-12).

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Section 3 - Maintenance Routine Maintenance Tracks and Running Gear

Tracks and Running Gear Checking the Track Gearbox Oil Level 1

Position the machine on firm level ground. Ensure that the gearbox plugs A and B are positioned as shown. Stop the engine and remove starter key.

Clean the area around the fill/level plug A and remove the plug, oil should be seen to be level with the hole.

Top up as necessary. K Fluids, Lubricants and Capacities ( T 3-12). Clean and refit the plug, make sure it is tight.

A B

Fig 25.

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Section 3 - Maintenance Routine Maintenance Tracks and Running Gear

Changing the Track Gearbox Oil 1

Position the machine on firm level ground.

Place a suitable container beneath the drain plug B to collect the oil.

!MCAUTION Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug. 2-3-4-2

Remove level/filler plug A. Remove the drain plug B. Allow the oil to drain out. Wipe the drain plug clean. Make sure that you remove all metal particles. Refit the drain plug. Make sure it is tight.

Fill with new oil through the fill/level plug hole until oil runs from the hole. K Fluids, Lubricants and Capacities ( T 3-12).

Run the machine, operate the track controls and then make sure there are no leaks.

A B

Fig 26.

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Section 3 - Maintenance Routine Maintenance Tracks and Running Gear

Checking the Track Tension

Park the machine on level ground. Raise the track to be checked using the attachment. K Fig 27. ( T 3-55)

Rotate the track several times.

Check that the tension measurement at A is 3.4 in (85 mm) for rubber tracks and 5.0 in (125 mm) for steel tracks.

!MCAUTION Always make sure that the track tension measurement is not less than specified or severe strain to the track will result. 8-3-3-3

T063500-6

Fig 27.

Adjusting the Track Tension

If the Track is Too Slack

!MCAUTION Recoil unit servicing must only be carried out by JCB distributors. You could be killed or injured if you tamper with it. 8-3-3-4

Ensure adjusting screw B is tight. Connect a grease gun to nipple C and add grease until the correct tension is achieved. NEVER LOOSEN GREASE NIPPLE C

Check the track tension. K Checking the Track Tension ( T 3-55).

If the Track is Too Tight 1

Release the adjusting screw B to obtain the correct clearance. NEVER LOOSEN GREASE NIPPLE C K Fig 27. ( T 3-55)

Check the track tension. K Checking the Track Tension ( T 3-55).

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Section 3 - Maintenance Routine Maintenance Tracks and Running Gear

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Section A Attachments Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track and Running Gear Section K - Engine

Publication No.

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Section A - Attachments

Notes:

A-0

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A-0

Section A - Attachments Contents Page No. Attachments Introduction .............................................................................................. A - 1 Attachments For Your Machine ............................................................... A - 2 Impact Protection ..................................................................................... A - 3 Connecting/Disconnecting Hydraulic Hoses ............................................ A - 4 Quickhitch Assembly ............................................................................... A - 8 Buckets .................................................................................................. A - 10 Quickhitch Rockbreaker ........................................................................ A - 16

A-i

Section A - Attachments Contents

A - ii

Page No.

A - ii

Section A - Attachments

Attachments Introduction T4-002_3

!MWARNING

Practice using attachments off the job before working with them for the first time.

!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

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A-1

Section A - Attachments Attachments Attachments For Your Machine

Attachments For Your Machine 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. Important: Do not operate or work with attachments until the machine hydraulic oil has reached its normal working temperature.

A-2

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A-2

Section A - Attachments Attachments 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 warns the operator against the risk of flying debris when using an attachment. The attachment must not be used if a protective layer or screen guard has not been fitted to the machine. K Fig 1. ( T A-3). Make sure that the attachment for example a hydraulic breaker B is positioned in front of the cab, before it is operated. Do not swing the boom to the side during operation of the attachment. Consult your JCB dealer for further information.

732000-4

Fig 1.

A-3

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A-3

Section A - Attachments Attachments Connecting/Disconnecting Hydraulic Hoses

Connecting/Disconnecting Hydraulic Hoses T4-004_2

Introduction

Connecting the Hydraulic Hoses

Make the machine safe. Refer to Routine Maintenance, Prepare the Machine for Maintenance.

Vent the hydraulic system. Refer to Routine Maintenance, Releasing the Hydraulic Pressure.

If necessary, remove the blanking caps.

Check the hoses and adaptors for damage. Refer to Routine Maintenance, Checking for Damage.

Connect the hoses.

INT-3-1-10_3

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 2. 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-4

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Section A - Attachments Attachments Connecting/Disconnecting Hydraulic Hoses

Disconnecting the Hydraulic Hoses 1

Make the machine safe. Refer to Routine Maintenance, Prepare the Machine for Maintenance.

Vent the hydraulic system. Refer to Routine Maintenance, Releasing the Hydraulic Pressure.

Disconnect the hoses.

T037420

Fig 3. 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.

If necessary, install the blanking caps

Check for leaks. a

Start the engine.

b Operate the related control to increase the pressure in the hydraulic system. c

T037410

Fig 4. 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-5

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A-5

Section A - Attachments Attachments 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 5. ( T A-7). 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-6

– 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.

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A-6

Section A - Attachments Attachments Connecting/Disconnecting Hydraulic Hoses Connecting Quick Release Couplings 1

Remove any residual hydraulic pressure trapped in the service line hose.

Wipe the two faces of the male and female couplings and make sure they are clean.

Make sure that ball C in the female coupling is located in one of its slots.

Fit the male coupling into the female coupling.

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.

Where applicable, align the slot D with ball C.

Pull back sleeve E to release the coupling.

C007100-1

Fig 5.

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A-7

Section A - Attachments Attachments Quickhitch Assembly

Quickhitch Assembly Introduction

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).

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.

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

!MCAUTION

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

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.

Fig 6.

Removal 1

Before the Quickhitch is installed, make sure that the tipping lever locking bolt assembly is attached with the nut at position K. K Fig 6. ( T A-8). Put the Quickhitch on hard, level ground. Use the safe and correct lifting equipment to move the Quickhitch.

A-8

The removal of the Quickhitch is a reversal of the installation procedure. Pay particular attention to safety notices.

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A-8

Section A - Attachments Attachments Quickhitch Assembly

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-9

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A-9

Section A - Attachments Attachments 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

!MCAUTION When buckets 750 mm (29.5 in) or wider are fitted to the machine, use extreme caution in operation to avoid contact with the cab. 0122_1

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Section A - Attachments Attachments Buckets

Removing a Bucket - Non Quickhitch Models

P11-4002

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

Detach the Bucket Remove the lynch pin A and the pivot pins B.

A Fig 7.

!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

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Section A - Attachments Attachments Buckets

Installing a Bucket - Non Quickhitch Models

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

Remove lynch pin A, and locking pin B.

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.

8-2-9-32

Engage the Dipper

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 7. ( T A-11)

B D

Fig 9.

Apply a downward pressure on the bar to release the buckets' rear pivot pin from the latch hook, K Fig 9. ( T A-12) at Z. Remove the tommy bar from the Quickhitch.

Rest the bucket on the ground.

Slowly roll the Quickhitch back and simultaneously raise the dipper arm to release the buckets' front pivot pin, K Fig 10. ( T A-13) at Y.

Fig 8.

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 - 12

Note: Quickhitch procedure applies to most attachments. See your attachments instructions for specific procedures.

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A - 12

Section A - Attachments Attachments Buckets

Fig 10.

A - 13

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A - 13

Section A - Attachments Attachments Buckets

!MCAUTION

Installing a Bucket on a Quickhitch

Make sure that the latch hook has fully engaged.

See Bucket Selection.

2-4-4-3

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

2-4-4-2

B F C

Fig 11. 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 - 14

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A - 14

Section A - Attachments Attachments Buckets

Replacing Bucket Teeth P11-4001

Position the Bucket Make sure that the bucket is resting flat on the ground

Switch off the Engine Remove the starter key.

Remove a Tooth Remove the nut and bolt B and the tooth A.

Install a Tooth Position the tooth A and fit the bolts B.

B A Fig 12.

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A - 15

Section A - Attachments Attachments Quickhitch Rockbreaker

Quickhitch Rockbreaker

!MWARNING

Introduction The standard machine has a single-acting hydraulic circuit for use with the applicable single-acting hydraulic attachments. The attachments that need double-acting hydraulics for example the JCB Augers must have additional (optional) pipework installed, for more information contact your JCB Distributor. For details of the installation of the attachments refer to the Attachment Handbook, for more information contact your JCB Distributor.

Removing a Quickhitch Breaker

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

Stop the engine.

Turn the starter key to the 'I' position.

Operate the auxiliary attachment control pedal, this will release any hydraulic pressure trapped in the system.

Disconnect the hydraulic hoses.

2-4-4-2

Note: When possible, put the Quickhitch attachments on hard, level ground to make the installation procedure safe and easier. 1

Park the machine on firm level ground.

!MWARNING

!MCAUTION The rockbreaker must be positioned correctly before attempting to release it from the Quickhitch. if incorrectly positioned, the rockbreaker could swing or fall suddenly from the machine when releasing the Quickhitch latch hook.

Remove lynch pin H, and locking pin F.

Insert the tommy bar J into the hole K of the latch hook.

Apply a downward pressure on the bar to release the breakers rear pivot pin from the latch hook, allowing the breaker to swing forward as shown at Z. Remove the tommy bar from the Quickhitch.

Refit the locking pin F and lynch pin H. Failure to refit the pin will result in the breaker re-latching as it is lowered to the ground. Make sure that the hydraulic hoses do not become trapped under the breaker.

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A - 16

Position the breaker just clear of the ground and at an angle such that the breaker does not detach from the front pivot pin when the Quickhitch is unlatched. Typically shown at V. K Fig 13. ( T A-17)

A - 16

2-4-4-1

8-2-9-36

The attachment will roll forward when released. Stand clear and to one side when releasing the attachment.

Section A - Attachments Attachments Quickhitch Rockbreaker 11

Start the engine and carefully lower the breaker to the ground as shown at Y.

F J

732000-2

Fig 13.

A - 17

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A - 17

Section A - Attachments Attachments Quickhitch Rockbreaker

Installing a Quickhitch Breaker

Operation

!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.

2-4-4-2

Position the breaker: Set the bucket on firm level ground. Use safe and correct lifting equipment to move bucket a

Set the engine to operate at full throttle.

Position the machine.

Slowly push the throttle forward until a change in engine speed is heard.

b Use the excavator controls to engage the jaw of the Quickhitch with the pivot pin of the breaker. c

The engine speed when using the attachment must be reduced to 2000 engine rpm:

Use the excavator controls to roll the Quickhitch in until the latch hook has fully engaged the pivot pin on the breaker. It may be necessary to apply a load on the bucket teeth to achieve Quickhitch connection.

Move the throttle forward approximately 50 mm (2 in.). The throttle is now set at the correct speed. 2

Alternatively, use the tommy bar to lever the latch off, allowing the breaker pivot pin to locate in jaw of the Quickhitch.

The attachment is operated by a floor mounted pedal: Push the pedal at A to operate the single-acting attachments. Push the pedal at B to operate the double-acting attachments.

!MCAUTION

B A

Make sure that the latch hook has fully engaged. 2-4-4-3

d Fit the latch hook locking pin and secure with lynch pin.

!MWARNING 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

790140-2

Fig 14.

A - 18

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A - 18

Section B Body and Framework Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track and Running Gear Section K - Engine

Publication No.

9813/1750-1

Section B - Body and Framework

Notes:

B-0

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B-0

Section B - Body and Framework Contents Page No. Technical Data Static Dimensions .................................................................................... B - 1 Performance Dimensions ........................................................................ B - 3 General Description ................................................................................. B - 4 Air Conditioning Description ............................................................................................... B - 5 Safety Procedures ................................................................................... B - 8 Inspection ................................................................................................ B - 9 Fault Finding .......................................................................................... B - 10 Service Procedures ............................................................................... B - 17 Service Procedures Rivet Nuts .............................................................................................. B - 19 Glazing .................................................................................................. B - 21 Bucket Ram Pivot and Linkage Removal and Replacement ................................................................... B - 27 Dipper Removal and Replacement ................................................................... B - 29 Boom Removal and Replacement ................................................................... B - 31 Dozer Removal and Replacement ................................................................... B - 33 Slew Ring Removal and Replacement ................................................................... B - 35

B-i

Section B - Body and Framework Contents

B - ii

Page No.

B - ii

Section B - Body and Framework Technical Data Static Dimensions

Technical Data Static Dimensions O I

H J

N K

Fig 1. 8061 H

Overall Height

2704 mm (8 ft 11 in)

Overall Length

5604 mm (18 ft 3 in)

Slew Clearance

651 mm (2 ft 2 in)

Sprocket Idler Centres

2006 mm (6 ft 7 in)

Under Carriage Length

2531 mm (8 ft 4 in)

Tail Swing

1405 mm (4 ft 7 in)

Dozer Height

447 mm (1 ft 6 in)

Dozer Width

2012 mm (6 ft 7 in)

Super Structure Width

1800 mm (5 ft 11 in)

Width Over Tracks

2000 mm (6 ft 7 in)

Min. Clean Up to Dozer Ground Level

548 mm (1 ft 10 in)

B-1

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B-1

Section B - Body and Framework Technical Data Static Dimensions Table 1. Machine Weights 8061 kg (lbs) Operating Weight (Steel Tracks)

6125 (16415)

(1)

6050 (16209)

(2)

Transport Weight

(1) Operating weight includes cab, steel tracks, standard dipper, 600 mm (24 in) bucket, full fuel tanks and a 75 kg (165 lb.) operator (2) Transport weight is operating weight less a 75 kg (165 lb.) operator

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B-2

Section B - Body and Framework Technical Data Performance Dimensions

Performance Dimensions

A B F G D

E Fig 2. 8061

B-3

Max. digging height

5767 mm (18 ft 11 in)

Max. dumping height

4059 mm (13 ft 4 in)

Max. vertical digging depth

2512 mm (8 ft 3 in)

Max. digging depth (dozer up)

3960 mm (13 ft 0 in)

Max. reach (ground level)

6085 mm (20 ft 0 in)

Blade cut above ground

342 mm (1 ft 1 in)

Blade cut below ground

470 mm (1 ft 6 in)

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B-3

Section B - Body and Framework Technical Data General Description

General Description The Excavator body and framework is of fabricated steel construction and comprises the upper structure and front attachment. The upper structure comprises a fabricated steel base that provides housing and mounting for the machine controls and services. The machine cab is mounted on the floorplate. The engine is mounted behind the cab. The front attachment comprises a bucket, dipper and boom assembly attached to the front of the upper structure through a fixed kingpost. The bucket dipper and boom are connected through pivots enabling a full range of bucket, or other attachment operations

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Section B - Body and Framework

Air Conditioning Description General To maintain optimum operator comfort in warm climates or during seasons of high ambient temperature, the air conditioning system recirculates, clean, dehumidified air into the cab. Cooling is provided by passing the recirculated air, over an evaporator coil in the air conditioning unit. The air conditioning system is a closed circuit through which the refrigerant is circulated, its state changing from gas to liquid and back to gas again, as it is forced through the system. The major components of the system are:

The high temperature, high pressure refrigerant is forced by compressor action into the expansion valve 5, which meters the amount of refrigerant entering the evaporator. In the expansion valve the refrigerant instantaneously expands to become a low pressure, low temperature liquid. The refrigerant is drawn through the evaporator coil by the suction of the compressor. The temperature of refrigerant is now considerably below that of the air being drawn across the evaporator coil by the blowers. Heat is transferred from the ambient, and recirculated air, to the refrigerant, causing the low pressure liquid to vaporise and become a low pressure gas. Moisture in the air condenses on the evaporator coil and is drained away via condensate. Cool de-humidified air is emitted through air vents into the cab. The low temperature, low pressure, high heat content refrigerant gas, is now drawn by suction back to the compressor, where the cycle is completed.

– Compressor (1) – Condenser (2) – Receiver-drier (3) – Evaporator coil (4) – Expansion valve (5) Air conditioning system power is generated from the engine, via an electromagnetic clutch to the compressor. Three switches, connected in series, are included in the clutch supply line, all must be closed for the clutch and therefore the air conditioning system to operate.

Note: In dusty conditions, it is recommended that air is recirculated within the cab, otherwise the filter may become clogged. Two air vents A are located in the cab rear panel. Two air vents B are located in the right hand front corner of the cab.

The compressor 1 draws in low pressure refrigerant gas from the suction line (evaporator to compressor) and increases refrigerant pressure through compression. This process also increases the refrigerant temperature. High pressure refrigerant is forced from the compressor to the condenser 2, which is mounted on top of the cab. Ambient air is drawn across the condenser by two fans. In the condenser, the refrigerant changes state to a high pressure, high temperature liquid but with a lower heat content. The refrigerant passes through the receiver drier 3 , which contains a desiccant to remove moisture from the system. The receiver drier serves as a reservoir for refrigerant and also includes a filter to remove foreign particles from the system.

B-5

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B-5

Section B - Body and Framework Air Conditioning Description

1 B

3 4

5 Fig 1.

B-6

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B-6

Section B - Body and Framework Air Conditioning Description

Control Control of the system is achieved by the cyclic action of the compressor's electromagnetic clutch. When current is fed to the field coil of the compressor's clutch, a magnetic field develops between the field coil and the armature which pulls the field coil, complete with clutch assembly, onto the compressor's rotor. Because the clutch assembly is turned constantly by the crankshaft pulley drive belt, the compressor armature turns, starting the refrigeration cycle. Current is fed to the field coil through three series switches whose contacts are controlled by the following: 1

The manual switch in the cab.

The thermostat switch monitoring the evaporator temperature.

The high and low level pressure switch.

The switch in the cab will start the refrigeration cycle provided that the ambient temperature in the cab is greater than 0Â°C and the refrigerant pressure remains within the specified limits. The thermostat has its sensor inserted in the evaporator coil. It controls the refrigeration cycle by switching the compressor clutch on and off to prevent freezing of the condensate on the evaporator coil. The pressure level switch is housed in a common assembly located on the Receiver Drier. If the refrigerant pressure exceeds the upper pressure limit specified or falls below the lower limit, the contacts will open and the clutch will disengage, closing down the refrigeration cycle.

Pressures Switch Settings High pressure switch 28 kgf/cm2 or 27.5 bar Low pressure switch 2 kgf/cm2 or 2 bar

B-7

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B-7

Section B - Body and Framework Air Conditioning Safety Procedures

Safety Procedures The air conditioning system includes a pressurised, closed circuit containing a non-CFC, environmentally friendly refrigerant, Type R-134a. Any service procedure which breaks into the closed circuit and therefore requires discharging of the system, must only be carried out by service personnel with specialist knowledge of air conditioning systems. The following guidelines should be adhered to by all personnel servicing the air conditioning system.

!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.

When charging or discharging the refrigerant system, refrain from smoking. Naked flames must not be allowed in the immediate vicinity. The refrigerant does not give off a poisonous odour, however, when it comes into contact with a naked flame, a poisonous gas is produced. When handling refrigerant, rubber gloves and goggles should be worn. Operators should ensure that no refrigerant comes into contact with the skin. Particular care should be taken when connecting or disconnecting charging hoses or pressure switches. When these components are connected to the system, a short release of refrigerant occurs. This results in a high velocity, very cold gas being emitted from the connection point.

4-3-4-1_2

!MCAUTION Do not operate the air conditioning system when there is no refrigerant in the system, otherwise the compressor will be damaged. 4-3-4-4

It is critical that the correct refrigerant (R-134a) is used and that charging is done only by qualified personnel. As a precaution, in case of accidental leakage, discharging and charging of the vehicle refrigerant system must be conducted in a well ventilated area. Containers of refrigerant should be stored in a cool environment away from direct sunlight.

!MWARNING Do not carry out welding operations close to the air conditioning refrigerant circuit. A poisonous gas is produced when refrigerant comes into contact with naked flames. Do not smoke or allow naked flames close to the refrigerant circuit. BF-1-9

Do NOT perform welding operations close to refrigerant hoses (maintain a distance of at least 0.5m from hoses). Do NOT steam clean refrigerant system components.

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B-8

Section B - Body and Framework Air Conditioning Inspection

Inspection The following checks are visual inspection items that can be carried out without the need for specialist equipment or the need to open the air conditioning circuit.

NOT attempt to remove any hoses from a charged air conditioning system.

Compressor and Drive Belt

The compressor is mounted on a bracket secured to the engine. 1

Check that the compressor is securely mounted on its bracket and that the bracket is secure on the engine.

Check that the compressor clutch assembly and drive pulley are secure.

Check that the drive belt is in good condition. The belt should not show signs of excessive wear nor be frayed and should be correctly tensioned. Frayed or badly worn belts should be replaced. Belts that are obviously incorrectly tensioned should be adjusted. Refer to Adjusting the Compressor Belt, Maintenance Section.

Check the belt run between the compressor clutch pulley and the engine drive pulley. The belt run should form a straight line parallel to the engine timing cover.

4-3-4-1_2

The visual checks are to be carried out without the engine running unless specifically stated.

Condenser The condenser is located on top of the cab of the machine. 1

Check that the condenser is free from leaves, debris, mud or built up dirt deposits. The condenser needs to be relatively clean in order to function efficiently as a heat exchanger. If the condenser obviously needs cleaning K Condenser ( T B-17).

Hoses and Fittings 2

While inspecting the condenser, check the hose connections. Condenser failure can be caused by loose hoses. Hose movement can cause a fatigue failure of the condenser tubing adjacent to the fittings. Make sure that the hoses are securely clamped.

Check all visible hoses and fittings. Look for places where the hoses flex or are fastened, clamped, connected, bent or pass through panels. All these places are potential wear and damage points. Any suspect hoses should be noted and rectified only as detailed in Service Procedures. Do not attempt to remove any hoses from a charged air conditioning system.

For any hoses that appear to require tightening K Tightening Leaking Hoses ( T B-17)

Receiver Drier The receiver drier is located in the engine compartment. 1

Clean the sight glass on the top housing of the receiver drier.

Check the sight glass, in a normal operating system the sight glass should be clear.K Sight Glass Indications ( T B-12)

Check the hose connections to the receiver drier for signs of cracks or wear due to being insecurely clamped. Any suspect hoses should be noted and rectified only as detailed in Service Procedures. Do

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B-9

Section B - Body and Framework Air Conditioning Fault Finding

Fault Finding Procedures that require charging or discharging the system are not given in this manual as they require special equipment that is usually held only by trained refrigeration engineers. Fault indications are given K General Fault Indications ( T B-11) The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment. It is recommended that, to locate faults on the system accurately and quickly, an electronic leak detector and a refrigerant pressure gauge should be used. However, leaks can be detected on the system by using soapy water applied to the suspected leak area and system pressure can be assessed by the state of refrigerant passing through the receiver drier sight glass. The following pages of the manual deal with the major components of the air conditioning system and give further fault finding and maintenance information.

B - 10

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B - 10

Section B - Body and Framework Air Conditioning Fault Finding

General Fault Indications There are several indications that may help to determine the fault area on a system not working efficiently:

Poor performance

Table 1. Low system pressure

Evacuate and recharge system

Condenser coil air flow restricted

Remove debris from around coil using compressed air or low pressure water

Air filters blocked

Clean with detergent and water

Compressor drive belt too slack

Adjust to correct tension.

Warm or slightly cool air emitted from Expansion valve stuck open or closed unit Renew expansion valve. Blower does not operate Compressor clutch continually cuts out

B - 11

Fuse blown

Replace fuse (20A) and retest.

Circuit faultFault

Fault find and repair.

Condenser coil blockage

Remove debris from around coil/renew condenser.

Overcharging of refrigerant system

Evacuate and recharge system.

Blocked expansion valve/condenser

Clear blocked component

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B - 11

Section B - Body and Framework Air Conditioning Fault Finding

Sight Glass Indications

Clear

An approximate indication of the condition of the refrigerant can be seen through the receiver/drier sight glass when the compressor is running. Refer also to Checking Refrigerant Charge Level

Clear

Fig 4. Desiccant breakdown in the receiver-drier Note: Sight glass indications cannot always give a positive identification of a problem. Further diagnosis, preferably by a refrigeration engineer using pressure gauges, is advisable before reaching a definite conclusion.

Fig 2. No fault indicated unless the system is unable to provide cool air. The indication then is that the system is completely discharged of refrigerant.

Foam or Bubbles

Fig 3. Refrigerant low and in need of charging. (Some slight bubbling is to be expected when R134a refrigerant is used.)

B - 12

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B - 12

Section B - Body and Framework Air Conditioning Fault Finding

Fault Finding - No Air Conditioning 1

Are the controls set correctly, i.e. air conditioning selected, thermostat switch set to coldest position and blower switched on?

YES

Check 2.

Reset controls and retest.

Is the air conditioning (evaporator) blower YES working?

Check 3.

Check 4. Check 9.

Is the compressor running (visual check of pulley/clutch)?

YES NO

Check 5.

Is the air conditioning fuse(s) blown?

YES

Renew fuse(s) and retest.

Check 8.

YES

Check 6.

Check 7.

Is there a 12V supply to the pressure switch harness?

Does the compressor clutch engage with YES pressure switch assembly bypassed?

Does the clutch engage with thermostat switch bypassed?

8 9

10 11

B - 13

Are blower switch and wiring OK? Is sight glass indication OK?

Is condenser air flow blocked? Is evaporator air-flow blocked?

Replace pressure switch assembly.

Renew the compressor clutch and retest.

YES

Renew thermostat switch and retest.

Check all electrical connections.

YES

Renew blower unit complete.

Renew switch or wiring.

YES

Check 10.

Charge check required by refrigeration engineer.

YES

Clean condenser and radiator.

Check 11.

YES

Clean filter and, if necessary the evaporator.

Call in refrigeration engineer.

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B - 13

Section B - Body and Framework Air Conditioning Fault Finding

System Diagnosis

Poor Refrigerant Circulation

Normal gauge readings will depend on system components and ambient conditions, make sure that the valves are closed and the readings are stable and that the system has a full charge. The pressures on the manifold at 25 Â°C, with the engine a 1500 rev/min, the blower on maximum and the thermostat set to maximum, should be approximately:

Gauge Readings: Low Side Gauge

Zero to negative

High Side Gauge

Low

Other Symptoms: Receiver-drier

Contact JCB Service for the correct pressure settings.

Frost on tubes from receiver-drier to evaporator

Diagnosis Typically, the high pressure is 6 - 8 times the low pressure

Refrigerant flow obstructed by dirt, receiver-drier clogged Correction:

Normally Functioning A/C System

1. Evacuate A/C System. 2. Replace receiver-drier.

Gauge Readings: Low Side Gauge

Normal

3. Charge System with R-134a.

High Side Gauge

Normal

4. Operate System and Check Performance.

Other Symptoms: Sight Glass

Clear

Discharge Air Normal Recharge Weight:

No Refrigerant Circulation

Cold 1575 grammes

Low R-134a Charge

Gauge Readings: Low Side Gauge

Zero to negative

High Side Gauge

Low

Other Symptoms: Receiver-drier

Gauge Readings: Low Side Gauge

Low

High Side Gauge

Low

Other Symptoms: Sight Glass

Bubbles Continuously Visible

Frost or moisture on tubes before and after receiver-drier

Diagnosis Refrigerant flow obstructed by dirt, moisture or gas leakage from expansion valve heat sensing tube. Correction:

Diagnosis

1. Evacuate A/C system.

System slightly low on R-134a, due to leak or incorrect charge.

2. Check heat sensing tube at expansion valve. Replace expansion valve if necessary.

Correction: 1. Leak test system.

3. Remove expansion valve and attempt removal of dirt. If dirt cannot be removed, replace expansion valve.

2. Evacuate A/C system.

4. Replace receiver drier.

3. Repair system Leaks.

5. Charge system with R-134a.

4. Charge system with R-134a.

6. Operate system and check performance.

5. Operate system and check performance.

B - 14

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Section B - Body and Framework Air Conditioning Fault Finding Insufficient Cooling of Condenser or Refrigerant Overcharge

Gauge Readings:

Expansion Valve Improperly Mounted or Heat Sensing Tube Defective (Opening Too Wide)

Gauge Readings:

Low Side Gauge

High

Low Side Gauge

High

High Side Gauge

High

High Side Gauge

High

Other Symptoms: Sight Glass

Other Symptoms: No bubbles visible even at lower engine speeds.

Pipes

Diagnosis Refrigerant overcharge, condenser cooling fins clogged with dirt or cooling fans malfunctioning.

Large amount of frost or moisture on low side pipes.

Diagnosis

Correction:

Excessive refrigerant in low side pipes possibly from expansion valve being opened too wide.

1. Clean condenser cooling fins.

Correction:

2. Check cooling fan operation.

1. Leak test system.

3. Evacuate A/C system.

2. Evacuate A/C system.

4. Charge system with R-134a.

3. Repair system leaks.

5. Operate system and check performance.

4. Charge system with R-134a. 5. Operate system and check performance.

Air in System Compressor Malfunction Gauge Readings: Low Side Gauge

High

Gauge Readings:

High Side Gauge

High

Low Side Gauge

High

High Side Gauge

Low

Other Symptoms: Sight Glass Pipes

Bubbles visible during system operation. Low pressure pipes are hot to the touch.

Diagnosis Internal compressor leak or compressor mechanically broken. Correction:

Diagnosis

1. Evacuate A/C system.

Air is present in the system, possibly from inadequate evacuation procedure.

2. Repair or replace compressor.

Correction:

4. Operate system and check performance.

3. Charge system with R-134a.

1. Evacuate A/C system. 2. Check compressor oil for contamination. Check compressor for proper oil amount. Correct if necessary. 3. Charge system with R-134a. 4. Operate system and check performance.

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B - 15

Section B - Body and Framework Air Conditioning Fault Finding Some Moisture in the System

Gauge Readings: Low Side Gauge

Normal, then sometimes drops to below zero.

High Side Gauge

Normal, then sometimes goes high.

Diagnosis Moisture in system freezes, temporarily stopping cycle, normal system operation returns when ice melts. Correction: 1. Evacuate A/C system. 2. Replace receiver drier. 3. Remove moisture by repeatedly evacuating system. 4. Charge system with R-134a. 5. Operate system and check performance.

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B - 16

Section B - Body and Framework Air Conditioning Service Procedures

Service Procedures Checking Refrigerant Charge Level

and test for leakage using an electronic leak detector or soapy water.

Normal Recharge Weight: 1575 grammes The pressure in the system, i.e. the refrigerant charge level, can be determined by checking the state of refrigerant at the receiver drier sight glass. The receiver drier is mounted on the central rear counterweight, close to the air conditioning condenser. If the level of charge is correct, the sight glass will be clear. If the charge is low, bubbles will be seen. Bubbles may also be an indication of inadequate cooling, due to a restriction of air flow around the condenser coil. (Some slight bubbling is to be expected when R134a refrigerant is used.) Recharging of the system should be carried out by an air conditioning engineer. Check refrigerant charge level as follows: 1

Park the machine on firm, level ground. Lower the excavator arms to the ground. Engage the parking brake.

Open the engine cover.

Start the engine and run at idle. Switch the air conditioning ON to circulate refrigerant.

Check refrigerant charge level at sight glass.

To test for leakage in the low pressure side of the system, switch off the air conditioning and leave for a few minutes before testing.

Tightening Leaking Hoses

The refrigerant hoses have crimped ferrule end fittings. The hose connectors have an 'O' ring seal which compresses when the connection is tight, creating an airtight seal. Hoses are used to connect the inlets and outlets of the compressor, condenser, receiver drier and expansion valve (the evaporator coil is connected to the expansion valve within the air conditioning unit using rigid pipes). If leakage is detected from a hose connector, either by means of an electronic leak detector or soapy water, tighten the connector and repeat the leakage test. If leakage is still evident, it will be necessary to de-gas the system and renew the connector 'O' ring seal.

Leak Testing

!MWARNING Leak testing in Air Conditioning systems should be carried out only in a well ventilated area.

Condenser

BF-1-2

Note: The refrigerant is heavier than air and will leak downwards from the defective component. Check in still conditions but in a well ventilated area. Hose or pipe connections are likely leakage points of any refrigerant circuit. To test for leaks in the high pressure side of the system, i.e. from the compressor output to the expansion valve, run the air conditioning for a few minutes then switch off the engine

B - 17

It is likely that over a period of time, because of the machine's working environment, the airflow around the condenser will become restricted due to a build up of airborne particles. If the build up of particles is severe, heat dissipation from the refrigerant to the air will be significantly reduced, resulting in poor air conditioning performance. In extreme cases, over pressurisation of the system occurs, causing the high pressure cut out switch to operate and switch off the system.

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B - 17

Section B - Body and Framework Air Conditioning Service Procedures High pressure cut out can also be caused by an internal blockage of the condenser coil.

Condenser Cleaning Take care not to damage the condenser fins or tubes. Damaged fins must be straightened to ensure a good airflow through the condenser. The condenser is located on top of the cab. 1

Position the machine on level ground and apply the parking brake. Stop the engine.

Remove the starter key.

Use compressed air or low pressure water to backflow through the coil fins. Take care not to damage the fins.

Run the air performance.

B - 18

conditioning

and

check

cooling

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B - 18

Section B - Body and Framework Service Procedures Rivet Nuts

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.

7.10

M10

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-19) 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-20). 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.

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Section B - Body and Framework Service Procedures Rivet Nuts

Fitting Procedure

(smooth bulge) seating itself against the body/ framework 4-E.

Drill a hole in the machine body/framework where the rivet nut is to be fitted. De-burr hole edges.

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

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.

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'

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Section B - Body and Framework Service Procedures Glazing

Glazing Direct Glazing

Removing the Broken Glass and Old Sealant TB-002_3

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.

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.

Wear protective overalls.

Do not smoke - the activators and primers used in the procedures are highly flammable.

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

Position the machine on level ground and apply the parking brake. Stop the engine. Put protective covers over the cab seat and control pedestals.

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 5Â°C (41Â°F).

!MWARNING

Pneumatic Knife. K Fig 5. ( T B-22). 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

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Section B - Body and Framework Service Procedures Glazing ii

Insert the braided cutting wire 6-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 5. Pneumatic Knife i

iv Secure each end of the braided cutting wire in the special handles 6-C.

Press the handle to start the knife blade oscillating.

v Important: This tool must not be used on toughened glass. ii

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.

Insert the knife blade into the sealant. c

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.

Cut-out Knife. K Fig 7. ( T B-22). The cut-out knife can be used as a left handed or right handed tool.

b Braided Cutting Wire and Handles. K Fig 6. ( T B-22). This method uses a 3-core wire, a wire starter tube and two handles. i

Insert the steel tube 6-A into the old sealant on the inside of the glass.

Fig 7. Cut-out Knife i

Insert the knife blade into the sealant.

Make sure that the blade of the knife is against the glass 7-A.

iii Use the 'pull-handle' to pull the knife along and cut out the old sealant. d Craft Knife. K Fig 8. ( T B-23). The blades 8-A are replaceable. Fig 6. Braided Cutting Wire and Handles

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Insert the knife blade into the sealant.

Pull the knife along and cut out the old sealant.

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Section B - Body and Framework Service Procedures Glazing Preparing the Cab Frame Aperture

Fig 8. Craft Knife Note: There are other tools available to cut out the old sealant. For example, there is a long handle type craft knife to give extended reach. Refer to Service Tools, for details of this and any other tools. 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.

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 9. ( T B-23)

If damp or wet, dry the aperture area using a hot air gun (sourced locally).

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 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

Make sure that the new glass correctly fits the frame aperture 10-A. a

1-2 mm

Put two spacer blocks 10-B onto the bottom part of the frame aperture.

b Install the new glass on the spacer blocks Always use glass lifters 10-C. Check that there is an equal sized gap all round the edge of the glass. Note: The spacer blocks are rectangular in section to give two common gap widths. If necessary they can be trimmed to a smaller size to give an equal sized gap around the glass. Fig 9.

Apply a coat of 'Black Primer 206J' to the paintwork if: a

Important: The glass edges must not touch the frame, otherwise movement of the frame will chip and eventually break the newly installed glass.

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.

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Section B - Body and Framework Service Procedures Glazing

Fig 12.

Fig 10. 2

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.

Clean the glass a

After checking for size, remove the new glass and place it on a purpose made glass stand. K Fig 11. ( T B-24).

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 13. ( T B-24).

Fig 11. Glass Stand Small panes of glass will need locating on a 600 x 700 mm x 15 to 19 mm thick plywood board 12-A, sourced locally to fit the glass stand. It is recommended that an access hole is cut in the board to accommodate the glass lifter, making it easier and safer to handle small panes of glass. The board should be covered with felt or carpet to give an anti-scratch surface. Resting the glass on four spacer blocks will ensure clearance of the cartridge nozzle tip during application of the polyurethane sealant.

B - 24

Fig 13. 5

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Install the Ultra Fast Adhesive cartridge (see Sealing and Retaining Compounds, Section 1 and Note) into a suitable applicator gun:

B - 24

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-23) - step 1.

Install the glass in the frame aperture:

d Fit the pre-cut nozzle. K Fig 14. ( T B-25). 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 80Â°C (176Â°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'.

Always use the special lifting tools when moving the glass. Use a lifting strap to hold large panes of glass in position. K Fig 16. ( T B-25)

Fig 14. 6

Apply the pre-heated adhesive to the glass (do not start in a corner). Keep the nozzle guide 15-A against the edge of the glass and make sure that the adhesive forms a continuous 'pyramid' shape. K Fig 15. ( T B-25)

Fig 16. Typical M/c. Installation b Sit the bottom edge of the glass on the spacer blocks. K Fig 17. ( T B-26)

Fig 15.

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Section B - Body and Framework Service Procedures Glazing minutes, but it must not be used during the curing period of 30 minutes. c

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 'warning' and 'information' decals so that the new installation conforms with the original cab installation.

Fig 17. c

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 - 26

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B - 26

Section B - Body and Framework Bucket Ram Pivot and Linkage Removal and Replacement

Bucket Ram Pivot and Linkage Removal and Replacement Removal

Inspection

Remove the bucket.

Remove the self-locking nuts A and bolts B. Support the links D and E. Drive out the pivot pins C. Retract the piston rod end of the bucket ram F clear of the link E. Remove the links D and E.

Clean all old grease from the links E and D and pivot pins C.

Check that the link bushes and the pivot pin are within permitted tolerances. Renew pivot pin and/or remove and replace link bushes as necessary. Table 1. Tolerances Pivot pin

Pivot bush

Reference value

44.9 mm dia.

45 mm I/D

Allowable limit

43.9 mm dia.

46 mm I/D

Replacement

!MWARNING

Do not use your fingers through the holes to align the links. 8-2-9-32

Grease the pivot pins C K Fluids, Lubricants and Capacities ( T 3-12).

Locate the fork end of the link E onto the dipper, the correct way up as shown. Fit the pivot pin C through both sides of the link and dipper. Secure using bolt B and new self-locking nut A.

Locate the rod end of the bucket ram F into the fork of the link E. Fit the pivot pin C through both links and the ram end. Secure using bolt B and new self-locking nut A.

Grease the linkage through the grease nipple on the ram end boss.

C F

D Fig 1.

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Section B - Body and Framework Bucket Ram Pivot and Linkage Removal and Replacement

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Section B - Body and Framework Dipper Removal and Replacement

Dipper Removal and Replacement Removal 1

Remove the bucket.

If necessary remove the bucket ram.

Remove the locknut A and bolt B. Drive out the dipper ram pivot pin C. Separate the dipper ram eye end D from the dipper pivot E. Position a block of timber on which to rest the dipper ram eye end.

Attach suitable lifting equipment through the dipper ram pivot pin location and support the dipper J.

Remove the locknut F and the bolt G. Drive out the pivot pin H.

Using suitable lifting equipment, remove the dipper from the machine.

Fig 1.

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B - 29

Section B - Body and Framework Dipper Removal and Replacement

Inspection 1

Check that the dipper pivot bushes and the pivot pin are within permitted tolerances. Renew pivot pin and/ or remove and replace dipper pivot bushes as necessary. Table 1. Tolerances Pivot pin

Pivot bush

Reference value

44.9 mm dia.

45 mm I/D

Allowable limit

43.9 mm dia.

46 mm I/D

Replacement K Fig 1. ( T B-29). 1

Using suitable lifting equipment, locate the dipper J onto the boom.

Fit the pivot pin H and secure with bolt G and a new locknut F.

Locate the dipper ram end D into the dipper pivot E. Fit the pivot pin C and secure with the bolt B and new locknut A.

Fit the bucket ram.

Fit the bucket.

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B - 30

Section B - Body and Framework Boom Removal and Replacement

Boom Removal and Replacement Note: The boom weighs 106 kg (233.7 lb). Take care when lifting or handling it.

Removal 1

Remove the bucket, bucket link and dipper.

Remove the dipper and boom rams.

Disconnect the hydraulic hoses at the base of the boom. Blank off the open ends of hoses and pipes.

Disconnect the boom working light harness.

Attach suitable lifting equipment to the boom A and take up the slack.

Remove the locknut B. Remove the bolt C and drive out the pivot pin D. Remove the boom from the kingpost

Inspection 1

Check that the boom pivot bushes and the pivot pin are within permitted tolerances. Renew pivot pin and/ or boom pivot bushes as necessary.

Examine the boom structure for wear, damage or corrosion. Renew as necessary. Table 1. Tolerances Pivot pin

Pivot bush

Reference value

44.9 mm dia.

45 mm I/D

Allowable limit

43.9 mm dia.

46 mm I/D

Replacement 1

Using suitable lifting equipment, locate the boom A onto the kingpost.

Fit the pivot pin D and secure with the bolt C and a new locknut B.

Fit the dipper and boom rams.

Fit the dipper, bucket link and bucket.

Remove the blanks and connect the hydraulic hoses at the base of the dipper.

Restore the hydraulic supply and set up the hydraulic circuit.

Connect the boom working lights.

Fig 1.

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Section B - Body and Framework Boom Removal and Replacement

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Section B - Body and Framework Dozer Removal and Replacement

Dozer Removal and Replacement Removal

Inspection

Park the machine on level ground with the dozer blade lowered on to the ground and the cab slewed to give access.

Remove the self-locking nuts A and the bolts B. Support the ram. Drive out the pivot pin C. Lower the cylinder end of the dozer ram to the ground.

Remove the self-locking nut D and the bolt E on each pivot. Support the dozer arms. Drive out the pivot pins F. Remove the dozer. Clean all old grease from the dozer and pivot pins F.

B - 33

Check that the dipper pivot bushes and the pivot pin are within permitted tolerances. Renew pivot pin and/ or remove and replace dipper pivot bushes as necessary. Table 1. Tolerances Pivot pin

Pivot bush

Reference value

44.9 mm dia.

45 mm I/D

Allowable limit

43.9 mm dia.

46 mm I/D

Replacement 1

Apply grease to the pivot pins C and F

Locate the ends of the dozer into the fork of the pivots. Align the pivots and fit the pivot pins F into the pivots. Retain with bolts E and self-locking nuts D.

Locate the rod end of the dozer ram into the fork of the undercarriage.

Fit the pivot pin C through both links and the ram end. Secure using bolt B and new self-locking nut A.

Grease the pivots through the grease nipple on the ram end boss.

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B - 33

Section B - Body and Framework Dozer Removal and Replacement

E D E

B A

Fig 1.

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B - 34

Section B - Body and Framework Slew Ring Removal and Replacement

Slew Ring Removal and Replacement Removal

Note: The removal and replacement of the slew ring requires major elements of the machine being removed from the slewframe, and the slewframe and undercarriage separated. The procedures and safety precautions required to disassemble a machine to this point, must be clearly understood before starting work. The correct lifting and support equipment must be used, along with a clean regime when disconnecting hydraulic components.

Secure the slew ring to the undercarriage in this position, by torque tightening opposing bolts to ensure the slew ring is seated correctly.

The following text is intended to give the setting procedure for correct installation of a new slew ring only. 1

With the slewframe mounted on a tilting table, offer the slew ring to the slewframe, ensuring the 'S' mark on the outer race is at 90Â° to the front and rear of the machine.

Secure the outer slew ring C loosely with four equally spaced bolts and washers F, (the ring should be able to rotate under pressure, to allow alignment).

Refit the slew motor and rotate the inner slew ring D until the 'Green/Blue' shaded teeth are aligned with the slew motor pinion. Measure the back lash between pinion and slew ring, this should read 4.6mm (0.18 in.).

To adjust the backlash, rotate the loosely mounted slew ring until the required 4.6mm (0.18 in.) dimension is achieved. With the backlash set, secure the slew ring to the slewframe, adding the remaining bolts and washers, and torque tighten in sequence.

Rotate the inner slew ring, until the 'soft spot' (stamped 'S') is opposite the 'S' mark on the outer race. Check the clearance between the slew motor and slew ring teeth:-

Max

0.4mm

Min:

0.2mm

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Section B - Body and Framework Slew Ring Removal and Replacement

B A

Fig 1.

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Section B - Body and Framework Slew Ring Removal and Replacement

Checking Slew Bearing Backlash

Fig 2. 1

Set bucket 1mtr (40 in) above ground with dipper fully extended.

Stop the machine.

Attach dial test indicator to lower half of slew bearing and set needle to bolt head on top half of slew bearing.

By hand push bucket fully to one side and hold whilst dial test indicator is set to zero.

By hand push bucket fully to other side and record measurement on dial test indicator.

By hand push bucket fully to other side and hold, make a further mark on bottom half of bearing (which is in line with original mark on top half of bearing).

Record measurement.

Contact JCB Service for correct backlash limit of use.

Alternatively 1

Set bucket 1mtr (40 in) above ground with dipper fully extended.

Stop machine.

By hand push bucket fully to one side and hold whilst a mark is made across the two halves of slew bearing.

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Section B - Body and Framework Slew Ring Removal and Replacement

Checking Slew Bearing Vertical Lift

Fig 3. 1

Fig 5.

First set the Dipper in a perpendicular position and position the bucket 200 mm (9 in) above the ground, stop the engine.

Start the engine and lift the main body with the bucket, when the bottom of the shoe is 100 mm (4 in) above the ground, note the reading on the dial gauge. The needle will turn in the counter clockwise direction. This value becomes L1, lower the body to the ground and confirm the needle reads zero.

Fig 4. 2

Install a dial gauge and set the needle to the Zero Point

Fig 6. 4

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Then rotate the main body 180Â° and repeat the procedure, this time the needle will rotate clockwise. This value becomes L3.

B - 38

Section B - Body and Framework Slew Ring Removal and Replacement Note: Always stop the engine when installing or removing the dial gauge or reading the dial gauge.

Fig 7. 5

Next, place the dial gauge on the rear of the vehicle and repeat the two above procedures to obtain L2 and L4.

Fig 8. 6

The average lateral movement is shown as the result of the equation L1+L2+L3+L4 2

Contact JCB Service for correct vertical lift limit of use.

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Section B - Body and Framework Slew Ring Removal and Replacement

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Section C Electrics Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track and Running Gear Section K - Engine

Publication No.

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Section C - Electrics

Notes:

C-0

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C-0

Section C - Electrics Contents Page No. Technical Data General Electrical Data ............................................................................ C - 1 Service Procedures Using a Multimeter ................................................................................... C - 3 Alternator ................................................................................................. C - 7 Starter Motor .......................................................................................... C - 10 Battery ................................................................................................... C - 12 Wiring Harness Repair .......................................................................... C - 15 Alternator Removal and Replacement ................................................................... C - 19 Starter Motor Removal and Replacement ................................................................... C - 21 Schematic Circuits 8061 ...................................................................................................... C - 23 Harness Data Wire and Harness Number Identification ............................................... C - 27 Harness Drawings ................................................................................. C - 29

C-i

Section C - Electrics Contents

C - ii

Page No.

C - ii

Section C - Electrics Technical Data General Electrical Data

Technical Data General Electrical Data Battery Type

Voltage

12 V

Cold Crank Current

750 A

Capacity

110 ampere/hour

Starter Motor

2.2kW

Alternator Type

AAK4323

Output

14 Volts, 80A

Polarity

Negative earth

C-1

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Section C - Electrics Technical Data General Electrical Data

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Section C - Electrics Service Procedures Using a Multimeter

Service Procedures 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

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Section C - Electrics Service Procedures Using a Multimeter 1

Make sure that the test leads are plugged into the correct sockets. The black test lead should be plugged into the black socket (sometimes, this socket is also marked by a "-", or "E" or marked as "COMMON" or "COM"). The red test lead should be plugged into the red socket marked with "+", "V" or "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.

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.

Select the correct range on the multimeter. a

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.

Connect the black probe to the nearest available suitable earth point, usually this will be the starter motor earth, the battery negative, or the chassis. Connect the red probe to the wire or contact from which you are measuring the voltage.

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Section C - Electrics Service Procedures Using a Multimeter

Measuring Continuity

Measuring Frequency

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.

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.

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.

Insert the red probe into socket 1-J.

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.

Press button 1-H once.

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 (ÎŠ) range. If there is continuity (i.e. very low resistance) between two points the needle will move across fully (or almost fully) to the right hand side of the scale.

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Section C - Electrics Service Procedures Using a Multimeter

Testing a Diode or a Diode Wire

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 kÎŠ, 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.

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.

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 300-400ÎŠ, 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.

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.

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Section C - Electrics Service Procedures Alternator

Alternator TC-006

General Description

Charging Circuit Test

The alternator is a three phase generator having a rotating field winding and static power windings.

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.

Adjust the alternator drive belt tension if necessary and make sure that the battery is well charged.

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-7). 4

If the 'No charge' warning light remains ON, K Check 2 ( T C-8).

Service Precautions 1

Ensure that the battery negative terminal is connected to the earthing cable.

Never make or break connections to the battery or alternator, or any part of the charging circuit whilst the engine is running. Disregarding this instruction will result in damage to the regulator or rectifying diodes.

Main output cables are 'live' even when the engine is not running. Take care not to earth connectors in the moulded plug if it is removed from the alternator. During arc welding on the machine, protect the alternator by removing the moulded plug (or if separate output cables fitted, remove the cables). If slave starting is necessary, connect the second battery in parallel without disconnecting the vehicle battery from the charging circuit. The slave battery may then be safely removed after a start has been obtained. Take care to connect batteries positive to positive, negative to negative.

C-7

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 for blown filament. 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 is in good order, withdraw the triple plug from the back of the alternator. Make a temporary connection between the SMALL terminal in the plug and earth as shown below. If the 'No charge' warning bulb still fails to light, check the cable for continuity. If the bulb now lights, check the alternator for a defective regulator. K Alternator Charging Test ( T C-8).

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Section C - Electrics Service Procedures Alternator

Alternator Charging Test

Fig 4.

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.

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 6. 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.

Make sure that the alternator drive belt tension is correctly adjusted.

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 shut off solenoid (ESOS) fuse removed (See Fuse Identification).

Install a 100 amp open - type shunt between the battery positive lead and the battery positive terminal.

Connect a multimeter positive lead to machine side of the shunt and negative lead to battery side of the shunt.

Connect the leads to the meter and set the meter to the relevant range as follows.

Fig 5. If the voltage is correct, check the alternator. K Alternator Charging Test ( T C-8).

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Section C - Electrics Service Procedures Alternator AVO 2002

Faults d, e, and f may be checked only by removing and dismantling the alternator for further testing.

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– Red lead to volts (middle) socket on meter. – Black lead to negative on meter. – RH slider to DC voltage. – LH slider. K Fig 6. ( T C-8).

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.

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.

Open or short - circuited power (stator) windings.

To check for fault a, disconnect the capacitor and repeat the charging test. Renew the capacitor if necessary.

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-9

Section C - Electrics Service Procedures Starter Motor

Starter Motor TC-005

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 ('HS') 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 7. ( T C-10). Reading in 'start' position: 10.0V approximately. Minimum permissible reading in 'start' position 9.5V.

Fig 8. 3

A low reading probably indicates a fault in the starter motor.

Connect the voltmeter between the solenoid terminal 9-C and a good earth. Minimum permissible reading in 'start' position: 8.0V.

Fig 9.

Fig 7. 2

Connect the voltmeter between the starter main terminal 8-A and the commutator end bracket 8-B. In the 'start' position, the reading should not be more

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If the reading is less than specified, connect the voltmeter between the neutral start relay terminal 10-D and earth. An increase in reading to 8.0V indicates a fault in the wiring from the start relay to the solenoid.

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Section C - Electrics Service Procedures Starter Motor b If the reading between terminal 10-D and earth is below 8.0V, connect the voltmeter between terminal 10-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.

Connect the voltmeter between battery positive and the starter main terminal 12-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 10-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 12. 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 13-H. If the voltmeter now reads zero with the switch closed, the fault is in the solenoid.

Fig 10. 4

Connect the voltmeter between battery negative and starter earth connection 11-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 13. 6

Finally refit the engine stop fuse.

Fig 11.

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Section C - Electrics Service Procedures Battery

Battery TC-001_3

!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.

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.

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:

Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches in the cab 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.

– Never boost-charge a maintenance free battery. – Never charge a maintenance free battery at a voltage in excess of 15.8 Volts. – Never continue to charge a maintenance free battery after it begins to gas.

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

First Aid - Electrolyte Do the following if electrolyte:

GETS INTO YOUR EYES Immediately flush with water for 15 minutes, always get medical help.

IS SWALLOWED Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help.

GETS ONTO YOUR SKIN Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help. 5-3-4-3_1

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Section C - Electrics Service Procedures Battery

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 27Â°C).

Set the CHECK/LOAD switch 14-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-13), foregoing tests are unsatisfactory.

the

Ensure that the battery is completely disconnected from the vehicle. Connect up the battery tester as follows: 1

Set the CHECK/LOAD switch 14-A to OFF.

Set rocker switch 14-B to the battery voltage (12V).

Connect the red flying lead to the battery positive (+) terminal and the black flying lead to the battery negative (-) terminal.

Set the CHECK/LOAD switch 14-A to CHECK to read the battery no-load voltage which should be at least 12.4 volts.

Fig 14. Battery Tester

Battery Tester Readings 1

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

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Section C - Electrics Service Procedures 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

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Section C - Electrics Service Procedures 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

892/00349

Crimp tool

892/00351

Splice 0.5-1.5 mm (Red)

892/00352

Splice 1.5-2.5 mm (Blue)

892/00353

Splice 3.0-6.0 mm (Yellow)

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

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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

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Section C - Electrics Service Procedures 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

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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.

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Section C - Electrics Service Procedures 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.

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:

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Section C - Electrics Service Procedures Wiring Harness Repair

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Section C - Electrics

Alternator Removal and Replacement Removal

Replacement

Raise the engine cover.

Put the alternator in position and install the mounting bolts, Do not tighten the bolts.

Disconnect the battery. Disconnect the earth lead first.

Put the fan belt on to the pulley.

Depress the fan belt C at the centre between the alternator pulley and the crankshaft pulley with a finger force of 49Nm, (11lbf - 5kgf) approx. The belt deflection should be 10 mm (0.4in) approx.

Connect the electrical connections.

Reconnect the battery.

Important: Connect the earth lead last.

Close the engine cover.

A Fig 24. 3

Loosen the alternator mounting bolt A located underneath the alternator and B and on the adjusting bracket. Remove the fan belt C from the alternator drive pulley.

Disconnect the electrical connections from the alternator.

Support the alternator and remove the mounting bolts.

Remove the alternator.

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Section C - Electrics Alternator Removal and Replacement Page left intentionally blank

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Section C - Electrics Starter Motor Removal and Replacement

Starter Motor Removal and Replacement Removal

Replacement

Park the machine on firm level ground and remove the starter key.

Put the starter motor in position and align the pinion in the flywheel gear teeth.

Raise the engine cover

Fit and tighten the securing bolts B.

Disconnect the starter electrical connections.

Connect the electrical connections.

Support the starter motor A, loosen and remove the securing bolts B.

Connect the battery terminals.

Disengage the pinion from the flywheel gear teeth and remove the starter motor.

Important: Connect the earth terminal last. 5

Refit the bulkhead access plate.

Close the engine cover.

Fig 1.

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Section C - Electrics Starter Motor Removal and Replacement

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Schematic Circuits 8061 The electrical circuits are shown. K Fig 1. ( T C-24), K Fig 2. ( T C-25), K Fig 3. ( T C-26).

Interior Light

Horn

Component Key

Accessory Socket

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Ignition Switch

Battery Isolator

Primary Fuses

Starter Motor

Glow Plug Timer and Relay

Fuel Pump

Buzzer

Alternator

Two Speed Switch

Temperature Sensor

Left Hand Arm Servo Isolation Switch

Glow Plugs

Wiper Motor Switch

E.S.O.S

Ignition Relay

Water Temperature Switch

A/C Switch

Engine Oil Pressure Switch

Freeze Switch

Air Filter Switch

Condenser Fan Relay 1

Fuel Sedimentor

Condenser Fan Relay 2

Instrument Panel

Compressor Clutch

Fuel Sender

Rear Work Lights

Two Speed Solenoid

Beacon Switch

Servo Solenoid

Horn Switch

Wiper Motor

Work Lights Switch

Washer Pump

Heater Switch

Excitation Resistor

Heater Motor

Condenser Fan 1

GPS Unit

Condenser Fan 2

Immobiliser Relay

Boom Light

Front Work Lights

Section C - Electrics

Schematic Circuits

Beacon

Battery

8061

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27 1

C - 24

3 2

29 5 30 28

6 7 4 8

19 9813/1750-1

9 10 11 12 14

Fig 1. 853/20040 issue 1 (Sheet 1 of 1) K Component Key ( T C-23).

8061

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Schematic Circuits

Section C - Electrics

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18 46 45 37

36 20

38 39

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44 22 23 41

25 24 27

Fig 2.

8061

C - 25

K Component Key ( T C-23).

Schematic Circuits

Section C - Electrics

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Section C - Electrics

K Component Key ( T C-23).

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8061

Schematic Circuits

Fig 3.

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-27). 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.

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-28).

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).

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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-28). 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-28). This symbol is printed onto the wire, it may however be omitted from harness drawings.

Wires continue to have the same number even after passing through a connector block to another harness.

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.

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Section C - Electrics Harness Data Harness Drawings

Harness Drawings 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.

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Mainframe Harness

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Section C - Electrics

K Fig 6. ( T C-32), Sheet 4 of 4: K Fig 7. ( T C-33).

Harness Data

Sheet 2 of 4: K Fig 5. ( T C-31), Sheet 3 of 4

Harness Drawings

C - 30

Fig 4. 333/T8338 issue 1 (Sheet 1 of 4)

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Section C - Electrics

K Fig 6. ( T C-32), Sheet 4 of 4: K Fig 7. ( T C-33).

Harness Data

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Sheet 1 of 4: K Fig 4. ( T C-30), Sheet 3 of 4

Harness Drawings

Fig 5. 333/T8338 issue 1 (Sheet 2 of 4)

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Section C - Electrics

K Fig 5. ( T C-31), Sheet 4 of 4: K Fig 7. ( T C-33).

Harness Data

Sheet 1 of 4: K Fig 4. ( T C-30), Sheet 2 of 4

Harness Drawings

C - 32

Fig 6. 333/T8338 issue 1 (Sheet 3 of 4)

C - 33 9813/1750-1

Section C - Electrics

K Fig 5. ( T C-31), Sheet 3 of 4: K Fig 6. ( T C-32).

Harness Data

Sheet 1 of 4: K Fig 4. ( T C-30), Sheet 2 of 4

Harness Drawings

C - 33

Fig 7. 333/T8338 issue 1 (Sheet 4 of 4)

Section C - Electrics Harness Data Harness Drawings

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Section D Controls Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track and Running Gear Section K - Engine

Publication No.

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Section D - Controls

Notes:

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Section D - Controls Contents Page No. Controls Controls Identification .............................................................................. D - 1 Servo Hand Controllers Introduction .............................................................................................. D - 3 Operation ................................................................................................. D - 4 Inspection ................................................................................................ D - 5 Dismantling and Assembly ...................................................................... D - 6 Fault Finding ............................................................................................ D - 9 Track Levers Operation ............................................................................................... D - 11 Controls Dozer Control Lever .............................................................................. D - 13

D-i

Section D - Controls Contents

D - ii

Page No.

D - ii

Section D - Controls Controls Controls Identification

Controls Controls Identification 1

8 9 7

11 Fig 1. 1

Left Track Control Lever

Right Track Control Lever

Auxiliary Pedal (if fitted)

Dozer Lever

Right Hand Controller

Left Hand Controller

Switch Pack Cluster

Hand Throttle Lever

Warning Lights

Starter Switch

Auxiliary Power Socket

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Section D - Controls Controls Controls Identification

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Section D - Controls Servo Hand Controllers Introduction

Servo Hand Controllers Introduction This section deals with the Remote Control Valve which provides pilot pressure for the hydraulic control valve and electrical switching to flow-control solenoids. The remote control valve is a pressure reduction valve used to control the pilot pressure operated system. Four pressure reduction valves used to control the pilot pressure are located in the main housing. Direction of the output pilot pressure is controlled by selective movement of the control lever. The valves and control levers are mounted in the arm rests on both sides of the operator's seat.

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Section D - Controls Servo Hand Controllers Operation

Operation The pressure reduction unit comprises spools 26, pressure control springs 18, return springs 13 and spring seats 17. The spools 26 are held against the plungers 16 by the return springs 13. The lower end of the main body 21 contains the main inlet port P fed from the pump, exhaust port T connected to tank and the pilot pressure outlet ports 1, 2, 3 and 4. The pilot pressure controls the stroke and direction of the main control valve spools. Oil supplied by the hydraulic pilot pump enters at port P and the function of the spools 16 is to direct oil from the inlet port P to the output ports 1, 2, 3 and 4 or alternatively, to the exhaust port T to tank. The pressure control springs 18 act on the spools 26 to determine pressure at each port. Plungers 16 slide in the guides 15 to vary the compression in the springs 18. The control handle, fixed to the adjusting nut 10 and circular rocker plate 11 is operated to move the plungers 16. The control handle is able to rotate 360Â° around the knuckle joint 9. The return springs 13 operate between the casing 21 and the seats 17, regardless of the outlet pilot pressure, returning the plungers 16 to their outer positions, ensuring the spools 26 return to their neutral (closed) positions. The springs 13 also provide a resistive force, giving the operator a `tactile feel' of the controls. The control handles contain electrical push button and rocker switches which are used to operate auxiliary services. When the control handle is tilted, the plungers 16 move down, depressing the return spring seats 17, simultaneously compressing the pressure control springs 18, moving the spool, allowing hydraulic oil to flow to the designated pilot port.

Fig 1.

If the handle is held in the tilted position, the pressure in the outlet ports rises to equal the force of pressure control spring 18; the oil pressure and spring force become balanced. If the outlet pressure exceeds the set pressure, the spool moves to allow port T to open. If the outlet pressure falls below the set pressure, port T is closed and port P is opened.

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Section D - Controls Servo Hand Controllers Inspection

Inspection Note: Ensure that `O'-rings and other seals are renewed during re assembly. If the body assembly screw 19 is loosened, always renew the `O'-ring 20. K Fig 3. ( T D-7).

Plunger Replace if the tip is worn more than 1 mm (0.039 in).

Leakage Amount ø7mm ø(0.276”)

Replace if the leakage exceeds 1.0 litre/min (0.22 UK gal/ min, 0.26 US gal/min) with the handle in the neutral position or 2.0 litre/min (0.44 UK gal/min, 0.5 US gal/min) during operation.

1mm (0.039”)

Condition:

Fig 2. – Primary pressure 26 bar (377 lbf/in2).

Loose Movement in the Operating Controls

– Oil viscosity 23 cSt.

Spool Replace when the sliding contact faces are worn more than 0.01 mm (0.0004 in) or more than the non-sliding contact faces. Note: The conditions are approximately the same as for the leakage above.

D-5

Replace the parts if the wear in the pin and joint produces free travel of more than 2 mm (0.079 in).

Actuation Stability Investigate if abnormal noises, jerky operation or drops in primary pressure are experienced during operation. Replace the valve if the problem cannot be solved.

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Section D - Controls Servo Hand Controllers Dismantling and Assembly

Dismantling and Assembly Dismantling

Clean the valve exterior using approved solvent and using soft metal pads for protection, clamp the valve body into a vice.

If the return springs 13 are weak, the sliding resistance of the seal 14 will cause the guides 15 to stick in the casing. Using a screw driver, carefully ease out the guides 15 and plungers 16.

K Fig 3. ( T D-7). Note: All parts are precision made and require the utmost care when being handled. Note: During dismantling, do not use excessive force to separate components which could cause scratches or burrs on bearing surfaces. Failure to observe this instruction will cause oil leaks leading to poor performance.

Note: Care must be taken to prevent damage to the guides when removing. Ensure the guides do not fly out due to the force of the return springs.

Note: Label all parts during dismantling to ensure correct assembly.

Note: Storing the valve when dismantled could cause rusting of parts. Ensure they are suitably protected by antirust treatment.

Note: Identify each set of parts and their locations for assembly.

Push down upper section of gaiter 5 and remove roll pin 6.

Slacken and remove body assembly screws 19. Remove and discard â&#x20AC;&#x2DC;O'rings 20.

Separate upper and lower body sections 21 and 22. Remove dowel pins 23 and bush 24.

Remove and discard â&#x20AC;&#x2DC;O'ring 25.

Hold spool 26 firmly, depress spring seat 17 and flex spring 18 to allow the spring seat to slide sideways and be removed from the spool via the larger aperture.

Remove control handle 5A from mounting knuckle 7.

Note: Take care when removing handle to avoid damage to wiring loom and switches. These should be removed by separating the line connectors in the control handle and below the valve body. 3

Remove gaiter 5 from valve housing.

Slacken locknut 8 and remove mounting knuckle 7.

Slacken and remove joint nut 10 and rocker plate 11.

Note: Avoid scratching the surface of the spools. Do not depress the spring seats more than 6 mm (0.24 in). 14

Separate spools 26, spring seats 17, springs 18 and washers 27.

Remove plungers 16 from guides 15.

Remove seals 28 and 14 from guides 15 and discard.

Important: When unscrewing the knuckle joint 9, ensure retaining plate 12 is held firmly against the force of springs 13 to make sure parts do not fly out and cause injury. 6

Remove spring seats 17, return springs 13, pressure control springs 18 and spools 26.

Note: Leave all parts to soak in suitable solvent until dirt is loosened. Using clean solvent, wash all parts and allow to air dry. Apply rust inhibitor to all parts.

Unscrew knuckle joint 9, releasing retaining plate 12.

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Section D - Controls Servo Hand Controllers Dismantling and Assembly

Fig 3. K Dismantling ( T D-6). K Assembly ( T D-8).

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D-7

Section D - Controls Servo Hand Controllers Dismantling and Assembly

Assembly K Fig 3. ( T D-7). Note: During assembly, ensure all parts are clean and free from burrs and scratches. Remove minor damage by lapping. Note: Renew all `O' rings, seals and back-up rings. Take care to install seals the correct way around. Note: During assembly apply hydraulic oil to `O' rings and seals. Note: Ensure all screws and bolts are tightened to the torque settings given. Reverse the dismantling procedure, noting the following details: 1

Locate retaining plate 12 onto plunger guides 15 and screw knuckle joint 9 into position. Torque tighten to 4. 6 Nm (0.5 kgf m, 40 lbf in).

Locate rocker plate 11 and tighten until it makes contact with the plungers 16. Ensure the plungers are not depressed at this stage.

Holding the rocker plate 11 in this position, screw down joint nut 10. Torque tighten to 6.7 Nm (0.7 kgf m, 60 lbf in).

When fitting the body assembly screws 19, torque tighten to 1.9 Nm (0.2 kgf m, 17 lbf in).

Ensure the switch cable is free from obstruction and the line connectors are securely fastened.

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Section D - Controls Servo Hand Controllers Fault Finding

Fault Finding Symptom

Table 1. Possible cause

Primary pressure is low.

Check servo pressure maintenance valve.

Spring 18 is damaged. K Fig 3. ( T D-7).

Renew the spring.

Clearance between the spool and seating is too large.

Renew the remote control valve assembly.

The handle unit is loose.

Dismantle, reassemble or renew the handle unit.

Low secondary pressure.

Unstable secondary pressure.

High secondary pressure.

D-9

Remedy

Sliding parts are sticking.

Release the sticking part.

Fluctuations in the tank line pressure.

Check return line and filter for blockage.

Air is trapped in the piping.

Operate the valve several times to remove the air.

The tank line pressure is too high.

Check return line and filter for blockage.

Sliding parts are sticking.

Release the sticking part.

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Section D - Controls Servo Hand Controllers Fault Finding

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D - 10

Section D - Controls Track Levers Operation

Track Levers Operation Track Controls

!MWARNING

Make sure that all persons are clear before moving. MD-2-1-4

The two tracks are controlled by a pair of control levers A in front of the seat. Each lever controls one track and is spring-loaded to a central position. In this position the track does not operate. The left side lever controls the left track. The right side lever controls the right track. The two levers can be operated individually or together as necessary to move the machine as required. This can be done using one hand or both, or by using the pedals C.

Fig 2. An increase in speed can be achieved by operating the two speed tracking push button switch B located in the dozer lever.

!MWARNING The track controls operate as described when the dozer is located in front of the windscreen. If the dozer is positioned behind the cab, the lever operation will be reversed. It is advisable when tracking to always position the dozer to the front of the machine. 8-2-9-26

!MWARNING

Low speed must always be selected when unloading the machine from a vehicle or tracking down steep slopes. The machine will take longer to stop when the levers are released if high speed is selected. 0076

Forward P11-2001

To move the machine forward, push both levers forward. Release the levers to stop. Fig 1.

Reverse To move the machine backward, pull both levers backward. Release the levers to stop.

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D-11

Section D - Controls Track Levers Operation Turn To turn the machine when travelling, move the lever back towards the central position on the side towards which you want to go e.g. move the left lever back to turn left. This causes one of the tracks to move slower than the other. The faster moving track will push the machine around. Release the lever to stop.

Spin To spin the machine around though 360Â°, without moving it, operate one lever, in a forward position and the other in a reverse position. This will cause the tracks to drive in opposite directions and hence push the machine around.

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D-12

Section D - Controls Controls Dozer Control Lever

Controls Dozer Control Lever Removal

locknuts H. Care must be taken not to twist the outer cable when tightening the locknuts.

Remove all mud and debris from the cab floor mat.

Remove cab floor mat.

Remove bolts A securing the cab floor plate.

Manoeuvre the lever gaiter C out of the floor plate and slide up to the top of the lever.

Remove the nuts F and the bolts G and remove the dozer control lever B.

Lift the cab floor plate out of the way to give access to the control cable D.

Disconnect the control cable D from the dozer control lever E.

Disconnect electrical harness L.

Manoeuvre the lever gaiters C down the levers through the floor plate and slide the cab floor plate upward, off of the dozer control lever and remove it.

Remove the nuts and bolts K and remove the dozer control lever.

Connect the control cable D and check the settings.

Adjust as necessary.

Connect electrical harness.

Test the dozer control system.

Test the two-speed track system.

Fit and secure the cab floor plate.

Note: Apply Loctite to threads of cable prior to fitting to spool .

Inspection 1

Check all linkages for security and excessive movement.

Remove and replace defective components.

Replacement 1

Grease the lever pivots.

Replace the control lever in reverse order of disassembly

Set the dozer control lever. Slacken locknuts H and adjusting bolt J until the control lever is set at 90Â° in both planes, to the line of the floor. Tighten the

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D - 13

Section D - Controls Controls Dozer Control Lever

C K F

A D

Fig 1.

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D - 14

Section E Hydraulics Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track and Running Gear Section K - Engine

Publication No.

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Section E - Hydraulics

Notes:

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E-0

Section E - Hydraulics Contents Page No. Technical Data 8061 ........................................................................................................ E - 1 Basic System Operation Introduction to Hydraulic Schematic Symbols ......................................... E - 5 Schematic Circuits 8061 .......................................................................................................E - 11 Circuit Description Neutral Circuit ........................................................................................ E - 13 Servo Circuit .......................................................................................... E - 14 Fault Finding Hydraulic System ................................................................................... E - 15 Slew Motor and Gearbox ....................................................................... E - 17 Hydraulic Contamination General .................................................................................................. E - 19 Hydraulic Pump Description ............................................................................................. E - 21 Checking and Setting Procedures ......................................................... E - 30 Removal and Replacement - Pump ....................................................... E - 38 Removal and Replacement - Pump Drive ............................................. E - 39 Dismantling and Assembly .................................................................... E - 41 Control Valve General Description ............................................................................... E - 45 Removal and Replacement ................................................................... E - 48 Dismantling, Inspection and Assembly .................................................. E - 49 Valve Section ......................................................................................... E - 51 Main Relief Valve Removal and Replacement ................................................................... E - 53 Adjustment ............................................................................................ E - 54 Auxiliary Relief Valves Removal, Dismantling, Inspection and Assembly .................................. E - 55 Pressure Testing .................................................................................... E - 57 Pressure Maintenance Valve and Dual Solenoid Valve Description ............................................................................................. E - 59 Removal and Replacement ................................................................... E - 60 Adjustment ............................................................................................ E - 61 Track Motor/Gearbox Description ............................................................................................. E - 63 Removal and Replacement ................................................................... E - 70 Dismantling and Assembly .................................................................... E - 71 Port Identification ................................................................................... E - 78 Slew Motor/Gearbox Description ............................................................................................. E - 81 Removal and Replacement ................................................................... E - 88

E-i

Section E - Hydraulics Contents

Contents Page No. Dismantling and Assembly .................................................................... E - 89 Fault Finding ........................................................................................ E - 100 Rotary Coupling Description ........................................................................................... E - 102 Removal and Replacement ................................................................. E - 104 Dismantling and Assembly .................................................................. E - 106 Hose Locations (port numbers stamped on joint) ................................ E - 107 Hydraulic Oil Cooler Removal and Replacement ................................................................. E - 108 Hydraulic Rams Precautions During Use ........................................................................E - 110 Removal and Replacement ..................................................................E - 112 Dismantling and Assembly ...................................................................E - 116

E - ii

Section E - Hydraulics Technical Data 8061

Technical Data 8061 Pump Model

REXROTH A10VO

Type

Single variable displacement, flow on demand piston pump, fully load sensed.

Max flow

140l/min, 30.7 UK gal/min, 36.5 gal/min

Weight

33kg

Flow Rates

Variable displacement, return to idle pump. All measured flows corrected to engine speed of 2500 rev/min. with hydraulic oil at approx. 50Â°C. Flow and pressure measured at auxiliary circuit.

Pressure

Flow

100 bar (1450 lbf/in )

140 l/min. 30.8 UK gal/min.

125 bar (1813 lbf/in2)

138 l/min. 30.4 UK gal/min.

150 bar ( 2176 lbf/in2)

115 l/min. 25.3 UK gal/min.

175 bar ( 2538 lbf/in ) 2

200 bar (2901 lbf/in )

94 l/min. 20.7 UK gal/min. 78 l/min 17.1 UK gal/min

Relief Valve Operating Pressures

bar

lbf/in2

Load Sense Relief Valve

213

3089

Servo Pressure Maintenance Valve

435

Boom rod and head side

280

4061

Dipper rod and head side

280

4061

280

4061

Auxiliary Relief Valves (A.R.V)

Bucket rod and head side Swing rod and head side Dozer head side Dozer head side

E-1

Anti-cavitation valve 280

4061

Anti-cavitation valve

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E-1

Section E - Hydraulics Technical Data 8061 Slew Motor and Gearbox Type Motor Displacement Working Pressure Gear Ratio Output Torque Working Temperature

SG025E-127 45.5 cc/rev 200 kgf/cm2 (0.28 psi) 15.5 : 1 1853 Nm (11367 lbf ft) @ 200 kgf/cm2 (0.28 psi) -30°C to +80°C

Weight

67 kg

Grease

150cc from empty

Pinion Teeth - Total

Track Motor and Gearbox Motor Displacement Low speed

44.1cm3/rev

High speed

23.5cm3/rev

Gear Ratio

53: 1

Max Pressure

230 bar

Max Flow

75 L/min

Max Pressure to release parking brake

13 bar

Max Motor Output Torque Low speed

161 Nm

High speed

86 Nm

Max Motor Output Speed Low speed

1701rpm at 75 l/min

High speed

3191rpm at 75 l/min

Max Gearbox Output Torque Low speed

8556 Nm

High speed

4559 Nm

Max Gearbox Output Speed Low speed

60 rpm

High speed

32 rpm

Check Valve Cracking Pressure 2 Speed Control Pressure Total Weight

E-2

<0.3 bar High To Low 205 +/- 15 bar with Ps = 36.5 bar 65 kg +/- 10%

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E-2

Section E - Hydraulics Technical Data 8061 Bore

Rod Dia

Stroke

Weight

Rams

(lb)

Boom

110

4.3

2.4

676

26.6

71.5

Dipper

100

3.9

2.4

701

27.6

63.5

Bucket

3.5

2.4

546

21.5

42.75

19.5

Swing

3.5

2.0

473

18.6

42.25

Dozer

110

4.3

2.4

190

7.5

40.5

18.5

Filtration Main Bypass pressure

1.5 bar (22 lbf/in2)

Torque Settings

Kgf

lbf ft

Ram Piston head

405

299

Ram Endcap

678

500

Track Motors to Undercarriage

137

101

Slew Motor to Slew Frame

350

258

Hydraulic Pump Mounting Bolts

244

180

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Section E - Hydraulics Technical Data 8061

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Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols

Basic System Operation Introduction to Hydraulic Schematic Symbols TE-001

General (Basic and Functional Symbols) Complex hydraulic components and circuits can be described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used.

Table 2. Rams Single acting

Double acting There are many symbols in use and it would be impossible to include them all here. However it should be noted that most are only variations or refinements on the basic principles explained here. If more detailed information is required you are recommended to obtain a copy of BS2917 or IS01219. Once familiar with the symbols, the engineer can use hydraulic circuit diagrams as an aid to fault finding. It will be possible to see the complete hydraulic circuit and decipher the relationship between hydraulic components. Table 1. General

Double ended

Double acting with damping at rod area end

Table 3. Pumps and Motors Variable capacity pump two directions of flow

Spring Flow restriction affected by viscosity

Fixed capacity motor one direction of flow

Direction of flow Fixed capacity motor two directions of flow

Indication of rotation

Variable capacity motor one direction of flow

Indication of direction and paths of flow

Variable capacity motor two directions of flow

Variable control

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Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols Table 4. Control Valves Used to enclose several valves indicating they are supplied as one unit

Throttling orifice - normally closed

3-Position, 4-port spring centered pilot operated valve

Throttling orifice - normally open

3-position, 6-port spring centered pilot operated valve Relief valve

3-Position, 4-port spring centered solenoid & pilot pressure operated valve 3-Position, 4-port spring centered detent hand operated valve

Variable restrictor

Non-return valve

Non-return valve with back pressure spring

Pilot operated non-return valve

One way restrictor

High pressure selector (shuttle valve)

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Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols Table 5. Energy Transmissions and Conditioning Working line, return or feed

Reservoir - return line below fluid level

Pilot control Drain lines Header tank Flexible pipe

Pressure sealed tank Line junction

Accumulator

Crossing lines

Filter or strainer

Water trap Air bleed

Line plugged, also pressure test point Line plugged with take off line

Cooler - with no indication of coolant flow

Cooler - indicating direction of coolant flow

Quick release couplings connected Heater Quick release couplings disconnected

Reservoir - return line above fluid level

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Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols Table 6. Control Mechanisms Solenoid one winding

Rotating shaft - one direction

Solenoid two windings

Rotating shaft - two directions

Detent

Locking device

Electric motor operated

Internal pressure pilot operated

Over centre device External pressure pilot operated Simple linkage Pressure operated spring release General control Pilot operated by solenoid pilot valve Push button operated Pilot operated by a solenoid or seperate pilot valve Lever operated Pressure guage Pedal operated Pressure switch Stem operated

Spring operated

Roller operated

Roller trip operated (one directional)

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E-8

Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols

Control Valves Control valves are usually represented by one or more square boxes. K Fig 1. ( T E-9) shows a control valve represented by three boxes. The number of boxes indicates the number of possible valve operating positions, (3 boxes - 3 positions etc).

Fig 4. Fig 1. K Fig 2. ( T E-9) - In circuit diagrams the pipework is usually shown connected to the box which represents the unoperated condition. (Hydraulic circuit diagrams are usually shown in the unoperated condition).

It must be noted that not all spools are of the same type. Their operating designs can be seen by following the path the flow arrows take in their respective operating squares. Three typical JCB style spools are known as 'D' spools, 'F' spools and 'N' spools. The 'D' spools generally control rams because when in the neutral position the outlet ports are blocked, preventing ram movement. K Fig 4. ( T E-9) shows a 'D' type spool.

Fig 2. K Fig 4. ( T E-9) shows a valve described as a 3-position, 4-port control valve. Port describes the openings to and from the valve by which the hydraulic fluid enters or leaves. In the fig shown, Position 2 indicates that in an unoperated condition all 4 ports are blocked.

K Fig 5. ( T E-9) - 'F' spools are often shown as four position spools with the three normal positions for neutral and service control; and the forth position, which has a detent, connects both sides of the ram together to allow the service to 'float'.

Fig 5. K Fig 6. ( T E-9) - 'N' spools are sometimes used to control hydraulic motors, and it can be seen from the flow arrows, that in neutral position both service ports are connected to the exhaust oil port

Fig 3. If the valve spool was moved to Position 1, movement of the spool would connect Port P1 to Port P2, and Port P3 to Port P4. K Fig 4. ( T E-9). If the valve spool was moved to Position 3, movement of the spool would connect Port P1 to Port P4, and Port P3 to Port P2. K Fig 4. ( T E-9).

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Fig 6.

E-9

Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols

Example of Schematic Circuit

Fig 7. Simple Schematic Circuit Some of the symbols described on the preceding pages have been arranged into a simple schematic circuit. K Fig 7. ( T E-10). Hydraulic tank 7-A is a pressurised tank with an internally mounted strainer 7-B on the suction line to the fixed displacement pump 7-C. System pressure is limited to the setting of relief valve 7-D. Valve spool 7-E is an open-centre spool that is in neutral position; flow from the pump passes through the spool and returns to the hydraulic tank.

Example Circuit Key 7-A

Hydraulic Tank

7-B

Strainer

7-C

Fixed Displacement Pump

7-D

Relief Valve

7-E

Spool

7-F

One Way Valve

7-G

Double Acting Hydraulic Ram

If the lever operated spool is moved away from neutral position hydraulic fluid is directed to either head side or rod side of hydraulic ram 7-G. Notice that the fluid must first open one way valve 7-F before flowing to the ram.

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Section E - Hydraulics Schematic Circuits 8061

Schematic Circuits 8061 Item

Description

Hydraulic pump â&#x20AC;&#x201C; variable flow

Hydraulic tank

Excavator valve block

Manifold Block

Track valve

Pressure maintenance valve

Boom ram

Dipper ram

Bucket ram

Dozer ram

Hydraulic oil cooler

Return filter

LH excavator controller

RH excavator controller

LH track motor

RH track motor

Auxiliary Attachments (Single and Double Acting)

Rotary coupling

Slew motor

Ball Valve

E - 11

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E - 12

3 9813/1750-1

8 18 P

10 15

Fig 1. 333/u3500-2 (Standard 8 spool machine)

8061

E - 12

Schematic Circuits

Section E - Hydraulics

Section E - Hydraulics Circuit Description Neutral Circuit

Circuit Description Neutral Circuit Refer K Fig 1. ( T E-12). The engine driven variable flow hydraulic pump P is mounted on the engine flywheel housing and connects to the engine flywheel via a plastic drive coupling. When the engine is running with no service selected, there is no demand signal from the valve block and the variable flow system shuts down to minimum (see Pump Operation), only delivering sufficient oil through the circuit to maintain system cooling levels. With a service selected, the pump P senses the demand and oil is drawn from the hydraulic tank T via suction strainer 1 and suction line 2. Pressurised oil from the pump flows to the valve block 13 via neutral circuit hoses and pipes. Servo pressure is tapped off this pressure line and is supplied to the servo pressure maintenance valve 4. Here it is reduced to the required value by pressure reducing valve 5, with the isolator solenoid valve 6 energised, servo pressure is available at the excavator controllers 11 and 12. The second solenoid valve 7 energises high speed tracking. Exhaust oil returning to tank T from valve block 13 , flows through oil cooler 50 and into the tank mounted return filter 52. The cooler pressure sensitive bypass 51 operates to protect the cooler from excess pressure, particularly when the oil is cold. A 4 bar (60 lbf/in2) exhaust back pressure valve maintains a positive pressure in the hydraulic return line back to the valve block 13 to ensure that the dipper, boom and slew crossline anti-cavitation valves operate correctly.

E - 13

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Section E - Hydraulics Circuit Description Servo Circuit

Servo Circuit Refer K Fig 1. ( T E-12). The servo pressure maintenance valve 4 is fitted with a single pressure reducing valve 5 and a solenoid valve 6 for servo isolation. A second solenoid valve 7 is fitted for a servo pressure selected high speed tracking operation. The servo system is supplied from a signal line tapped into the main hydraulic pump feed to the valve block 13. The pressure reducing valve 5 controls incoming pump pressure, this screw pressure adjustable valve reduces and maintains servo pressure by opening and allowing excess pressure to escape to tank. Down stream of the pressure reducing valve are located the servo accumulator 10 with its non return valve. The accumulator traps and stores servo pressure to enable the excavator spools to be operated for a limited period with a stopped engine. This allows the excavator end to be lowered safely to the ground should the engine stop. The servo isolator solenoid 7 is energised by a microswitch located under the LH arm rest. When the arm rest is raised, the micro switch opens and solenoid 7 is spring returned to the closed position. With the arm rest down, micro switch closes and energises the isolator solenoid, allowing servo pressure to become available at the excavator controllers 11 and 12. A selector switch mounted in the control knob of the dozer lever energises the two speed tracking solenoid 7. When selected the energised solenoid opens a route for servo pressure to operate the high speed selector 48 in the track motors 43 and 44 via the rotary coupling 42.

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Section E - Hydraulics Fault Finding Hydraulic System

Fault Finding Hydraulic System Before carrying out the following checks, ensure that where applicable: 1

The correct hydraulic fluid is used and the system is filled to the correct level.

The hydraulic fluid, filter and suction strainer are clean.

There are no visible leaks in the system.

Engine maximum speed and condition is as specification.

General Fault Diagnosis 1

ALL:Check 2. ONE:Check 6. 2

Hydraulic pressures for each service are correct to specification.

If all the hydraulic services are at fault start at check 1.

If servo controllers only are at fault start at check 13.

If tracking services only are at fault start at check 16.

If slew service only is at fault start at check 21.

Are the hydraulics inoperative or lacking in power? INOPERATIVE:Check 4. POOR PERFORMANCE: Check 3.

Is the servo pressure to specification? YES:Check 4.

If possible the machine should be operated to identify the fault and to bring the systems to their normal working temperature. After completing these initial checks, proceed as follows:

Is the fault in all services or one only?

NO:Adjust. 4

Is the pump operating correctly? YES:Check M.R.V's. NO:Check 5.

Is the pump noisy in operation? YES:Purge air from pump casing. NO:Check 6.

Is the pump drive broken? YES:Renew NO:Check 7.

Is one service only down on pressure? YES:Check 8. NO:Check 9.

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Section E - Hydraulics Fault Finding Hydraulic System 8

Is the cable adjustment correct? (Tracks, dozer & auxiliary services only)

YES:Check 9.

ONE:Swap hoses between pumps P2 & P3, If the fault changes to other track, service pump. If fault stays check 18. Check for sticking motor counterbalance spool.

NO:Adjust cable. 9

Is the tracking fault in one track in one or both directions?

Is the control valve spool sticking? BOTH:Check 18. YES:Overhaul valve block section. 18

Is the fault in one track only and in both directions?

NO:Check 10. 10

YES:With track stalled measure lubrication return to tank flow (1) at top of rotary joint and (2) out of track motor.

Is the service A.R.V. operating correctly? YES:Check 11.

If (1) high and (2) normal service rotary joint. If (1) high and (2) high check track motor.

NO:Reset or renew. 11

Is the valve block section cracked?

Is high speed engaging?

YES:Renew section and check valve block mounting

YES:Check 20.

Are the rams faulty?

NO:Check operation of high speed solenoid valve, rotary joint seals or motor high speed selector spool.

YES:Overhaul or renew. 20 13

Is the fault in all servo operated services or only one? ALL:Check servo isolator microcircuit, check servo solenoid valve, check 14.

Is the track motor high speed selector servo hose crossed with motor lubrication drain hose? YES:Correct connections

Is the slew motor performance/braking poor?

ONE: Check 15. 14

YES:Check for correct pressure settings of cross line relief valves. Check slew motor anti-cavitation check valves are closing.

Is the servo system operating correctly? YES: Check 15. 22 NO:Check servo pressure maintenance valve.

Is the hand controller plunger leaking/sticking?

Does the slew motor performance improve if bucket service stalled? YES:Check servo pressure maintenance valve non return valves are closing.

YES: Service hand controller, K Inspection ( T D-5). 16

Is the tracking fault in both tracks and in one or both directions? ONE:Check control linkage, check 17. BOTH:Check 4.

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Section E - Hydraulics Fault Finding Slew Motor and Gearbox

Slew Motor and Gearbox Fault

Possible Cause

Action

Motor does not turn

Relief valve pressure too low or faulty

Renew the relief valve

Motor has too much internal leakage

Renew the motor assembly

Insufficient torque

Abnormal noise

Oil leakage at housing joint face Oil leakage at pinion gear Delay in starting Excessive heat generation

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Motor has burned inner parts

Renew the motor assembly

Reduction gears damaged

Renew the gears

Overload

Remove the overload

Relief valve pressure too low or faulty

Renew the relief valve

Motor has too much internal leakage

Renew the motor assembly

Motor has burned inner parts

Renew the motor assembly

Reduction gears damaged

Renew the gears

Bearings damaged

Renew the bearings

Cavitation noise due to insufficient flow

Check oil level and pipework

Motor has damaged sliding parts

Renew the motor assembly

Reduction gears damaged

Renew the gears

Bearings damaged

Renew the bearings

Pinion gear damaged

Renew pinion

Damaged `O' rings

Renew `O' rings

Loose bolts

Re-tighten

Damaged oil seal

Renew oil seal

Relief valve pressure too low or faulty

Renew the relief valve

Check valve internal leakage

Renew check valve

Motor has burned or damaged sliding parts

Renew the motor assembly

Reduction gears damaged

Renew the gears

Bearings damaged

Renew the bearings

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Section E - Hydraulics Fault Finding Slew Motor and Gearbox

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Section E - Hydraulics Hydraulic Contamination General

Hydraulic Contamination General TE-002_2

cleaning unit. K Fig 1. ( T E-19). General Bulletin 011 also refers.

Hydraulic Fluid Quality Construction machinery 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.

Procedure Connect the cleaning unit in place of the hydraulic filter. K Fig 1. ( T E-19). 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.

Liquid - usually water and incompatible oils and greases.

Gases - Air, sulphur dioxide etc. which can create corrosive compounds if dissolved in the fluid.

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

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Section E - Hydraulics Hydraulic Contamination General

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.

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Section E - Hydraulics

Hydraulic Pump Description The pump is a variable displacement axial piston type. Displacement of oil is achieved by the continuous operation of nine pistons. Pump fluid output volume is controlled by a tilting swashplate, the angle of which is regulated to ensure that only the amount of fluid necessary to satisfy load conditions is delivered. If a load condition is such that no flow is required, only sufficient fluid for cooling, lubrication and servo operation is provided. Main components of pump P are as follows: cylinder barrel 1 splined to drive shaft 2. This is held against valve plate 3 by spring 4. Assembled in the barrel are the axial pistons 5, each having an articulated slipper pad held in contact with the swashplate 6 by its attachment plate 7. The tilting action of the swashplate is achieved by a stroking piston 8 and a control piston 9, the latter fed by pilot pressure. Fitted to the pump casing is valve block 10, housing the pressure compensator valve 11 and flow compensator valve 12. Also fitted to the pump casing is a torque limiter (horsepower control) valve 13. Rotation of the cylinder barrel 1 causes linear movement of the piston 5 as its shoe slides up and down the ramp of the angled swashplate. As the piston is drawn out of the barrel, oil from the pump suction port fills the developing vacuum behind the piston via kidney shaped ports in valve plate 3. As the barrel continues to rotate the piston passes bottom dead centre of its linear travel. Its open end is masked as it passes over the dividing section between the kidney shaped ports on the valve plate. Once over bottom dead centre the piston begins to travel up the barrel. Its open end then synchronizing with a pressure kidney shape in the valve plate. This in turn connects to the pressure delivery port of the pump delivering pressurised oil into the hydraulic circuit of the machine. The stroke of the pistons and consequently the displacement volume of the pump is directly related to the swashplate angle. The swashplate is normally held in its maximum displacement angle by the spring and system pressure in the stroking piston 8.

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Section E - Hydraulics Hydraulic Pump Description

12 P 11 B

L 10

6 L1

Y X

2 S

L1 L

13 7

5 4

12 11

10 Fig 1.

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Section E - Hydraulics Hydraulic Pump Description Item

Description

Pump

Cylinder barrel

Drive shaft

Port plate

Spring

Axial pistons

Swashplate

Shoe plate

Stroking piston

Control piston

Pump control valve block

Pressure compensator valve

Flow compensator valve

Torque Limiter (Horsepower Control) valve

RED

Pressure Generated by Operation of a Service

GREEN

Exhaust

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Section E - Hydraulics Hydraulic Pump Description

Load Sensing - Maximum Flow When a service is operated, the load sensing signal pressure from the valve block 13 increases. This increase in pressure combined with the force of springs 6 moves spool 4 up allowing oil in control piston 7 to drain back to tank via gallery 10. The force of spring 1 on swash plate 2 is now sufficient to increase the angle. The increased angle of the swashplate increases the output of the pump. As the pump output pressure continues to rise, it will eventually lift flow-regulating spool 4 against the force of springs 6. Pump output pressure is now sensed via spools 4 and 3 through port A to control piston 7. This in turn overcomes return spring force 1 causing the swashplate angle to reduce and decrease pump output. Eventually the pressure in the load sense line LS and the force of springs 6 moves spool 4 down and the â&#x20AC;&#x2DC;meteringâ&#x20AC;&#x2122; cycle starts again. This up and down movement of the spool 4 keeps the pressure sensed at both ends of the spool equal. Spring 6 is equivalent to 15 bar (220 lbf/in2), therefore the pump pressure should be this amount greater than the signal pressure (except when at maximum system pressure). See Maximum Pressure (No Flow). RED

Pressure Generated by Operation of a Service

GREEN

Exhaust

PINK

Sensing Pressure

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Section E - Hydraulics Hydraulic Pump Description

8 12 7 T A

9 P 3

A B 11 6

10 4 5 Fig 2.

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Section E - Hydraulics Hydraulic Pump Description

Load Sensing - Stand-by Position Stand-by occurs when the engine is running and the control levers are in neutral, i.e. no services selected. There is no pressure or flow demand on the pump and therefore there is no pressure signal. With the engine stopped, spring 1 holds swashplate 2 at the maximum angle. When the engine is started and the pump begins to turn, oil begins to flow and pressure builds in the closed centre hydraulic system. The flow and pressure regulator spools receive this increasing pressure signal via port P. Which lifts pressure compensating spool 4 up against its springs and opens a flow path from port P to port A, allowing oil flow from the flow regulator valve to swash plate control piston 7. The control piston 7 now moves the swashplate 2 to the minimum angle, stopped by cross drillings 8. As the cross drillings are unmasked, oil pressure is allowed to vent into the pump casing. These cross drillings 8 also prevent excess pressure build up in the control piston 7, when the drillings are exposed, pump flow is insufficient to make up for the leakage and maintain the pressure behind the control piston 7. Therefore the piston moves back, partially covering the cross drilling. The minimum flow stop position ensures enough flow is available to cater for normal system leakage and to provide flow through the hydraulic cooler maintaining system temperature and establish a system stand-by pressure for servo control etc. RED

Pressure Generated by Operation of a Service

GREEN

Exhaust

PINK

Sensing Pressure

YELLOW

Trapped Oil

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Section E - Hydraulics Hydraulic Pump Description

8 12 7 T A

9 P 3

A B 11 6

10 4 5 Fig 3.

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Section E - Hydraulics Hydraulic Pump Description

Load Sensing - Maximum Pressure (No Flow) When a service ram reaches the end of its stroke or the operated service meets resistance (maximum tear out for instance), the signal pressure from the valve block 13 will be controlled by load sensing relief valve mounted in the hydraulic control valve. The force of spring 6 is sufficient to move spool 4 down. System pressure is also sufficient to move spool 3 up against the force of spring 12, this opens pump outlet to control piston 7 via port A. Control piston 7 decreases the angle of the swashplate 2 and hence pump output flow but pressure is maintained at maximum setting. There is now minimum flow but maximum system pressure. RED

Pressure Generated by Operation of a Service

GREEN

Exhaust

PINK

Sensing Pressure

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Section E - Hydraulics Hydraulic Pump Description

8 12 7 T A

9 P 3

A B 11 6

10 4 5 Fig 4.

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Section E - Hydraulics Hydraulic Pump Checking and Setting Procedures

Checking and Setting Procedures Pressure Testing All pump and valve block settings are factory set and should not normally require any adjustment, however it is necessary to check the machineâ&#x20AC;&#x2122;s performance after initial build or refit. Note: A high standard of hydraulic cleanliness is essential when working with the machine, all instrumentation used during testing must be well maintained and have a valid calibration label. Note: If you are unsure about any aspect of checking and setting the hydraulic system, advice should be sought from JCB Compact Products Ltd.

Initial Build Performance Check 1

Using a digital thermometer installed at the top of the hydraulic filter, warm up the machine until the hydraulic oil temperature is at 50Â°C (normal operating temperature). This can be achieved quickly by operating the tracks with the machine off the ground and simultaneously powering the dozer down to the end of ram stroke.

Using an optical tachometer check the engine max speed. It should read between 2800 and 2820 rpm. The engine fuel settings are factory set. If the speed is too low, then check the cable is fully operating the lever on the injection pump. Do not alter the adjustment screws on the engine because of exhaust emissions legislation.

Check the low idle speed is 1050 rpm. If necessary, adjust the throttle stop screw on the pump lever.

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Section E - Hydraulics Hydraulic Pump Checking and Setting Procedures

Hydraulic Valve Block Performance 1

Make a visible mark on each track.

Safely raise the tracks off the ground, with the engine at maximum speed, operate one track only.

Using a stopwatch, time how long it takes for the track to complete 10 revolutions. The time should be TBA seconds (high speed mode) or TBA seconds (low speed mode).

Minimum tolerance

TBA seconds.

Maximum tolerance

TBA seconds.

With both tracks operating in the air (in high speed mode) the time for 10 revolutions should be TBA seconds.

Minimum tolerance

TBA seconds.

Maximum tolerance

TBA seconds.

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Section E - Hydraulics Hydraulic Pump Checking and Setting Procedures

Pump Specification Check 1

Connect a flow meter and load control valve into the auxiliary line.

Connect bucket service head side supply hose into auxiliary line (tee into flow meter feed).

Operate auxiliary service and bucket service (engine at flight speed).

Progressively screw load control valve in and record pressure, flow and engine rpm.

Compare data against example K Fig 5. ( T E-33).

For control adjustment complete the following procedures in order: a

Check Hydraulic Valve Block Valve K Hydraulic Performance ( T E-31)

Performance Block

b Adjust flow/pressure control valve K Flow/ Pressure Controller Adjustment ( T E-34) c

Adjust Torque Limiter (Horsepower control) K Torque Limiter (Horsepower Control) Adjustment ( T E-36)

Check adjustments by repeating combined auxiliary and bucket service flow and pressure checks.

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Section E - Hydraulics Hydraulic Pump Checking and Setting Procedures 160

2470

140 1970

100

1470

C A

970

Engine Speed (RPM)

Pump Flow (ltrs./ min.)

120

B 40 470 20

-30 100

120

140

160

180

200

220

240

260

Pump Press ure (Bar) Fig 5.

Key A

Rexroth Theoretical Data

Test Machine 1

Test Machine 2

Graph Translation Pump Pressure (bar) Pump Flow (Litres/min) Engine Speed (RPM)

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Section E - Hydraulics Hydraulic Pump Checking and Setting Procedures

Flow/Pressure Controller Adjustment Item Part Number

Description

Qty

611/22100

Hose

816/50043

Tee piece

1604/2051

Adapter

892/00055A

Blanking plug 1/4"

Using the adapter from FR2 connect a second hose A to the front of port FR1, leave the other end free to atmosphere. Use a container to collect the discharged oil.

FR2 FR1

Connect the hose A (1/4 inch bore only approximately 500 mm long), to the return hose 1 using the Tee piece B. Connect the other end of the hose to the control valve at port M using adapter C.

MRV B

1 D

Fig 7.

M,C

Remove the 400 bar gauge and replace with a 40 bar (600 lbf/in2) pressure gauge to the pump pressure port on the servo pressure maintenance valve (PMV).

Unscrew the valve FR1 out to avoid the gauge being damaged and screw FR2 in fully.

Run the engine at 1500 rev/min

Adjust FR1 in until 20 bar (290 lbf/in2) is achieved.

Adjust FR2 until 15 bar (218 lbf/in2) is achieved

If the pressure will not adjust, remove the spool in FR1 or FR2 by removing the plug on the bottom and check for contamination.

Refit the adapter from FR1 to FR2 and replace the blanking cap and refit hose 2 to FR2 K Fig 6. ( T E-34).

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A Fig 6. 2

Remove the load sense hose 2 from FR2 and cap the hose with a blanking plug. Leave the port open to atmosphere. No oil should be discharged.

Remove blanking plug D from the front of port FR1.

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Section E - Hydraulics Hydraulic Pump Checking and Setting Procedures Final Operation Pressure MRV

230 bar (3335 lbf/in2)

215 bar (3118 lbf/in2)

FR1

20 bar (290 lbf/in2)

FR2

15 bar (218 lbf/in2)

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Section E - Hydraulics Hydraulic Pump Checking and Setting Procedures

Torque Limiter (Horsepower Control) Check

Torque Limiter (Horsepower Control) Adjustment

It may be necessary to check the pump torque settings if for instance the engine stalls easily under load or the machine services are slow in operation.

Note: Differences in oil temperature will affect this procedure. The adjustments must be conducted in a short period of time with the oil temperature range between 50ยบ to 70ยบ.

Connect the auxiliary and bucket service hoses together.

Item Part Number

Description

Qty

Using a 1 in. high pressure hose, loop the auxiliary hose on the dipper and install a flow meter with an adjustable restrictor into the loop.

611/22100

Hose

892/00055A

Blanking plug 1/4"

892/00059A

Blanking plug 3/4"

Connect a pressure gauge to the test point PT on the pressure maintenance valve.

816/50002

Tee adaptor

With the hydraulic oil at normal operating temperature, the engine running at maximum speed and the restrictor valve fully open, select the auxiliary service.

Disconnect the feed hose Z to the valve block. Connect the feed hose to a flow meter (Webster or similar) with a variable restrictor.

Disconnect the return hose 1 and cap with plug E.

Connect hose Y between the flow meter and point X.

Remove signal hose W from the M2 port and tee into pump pressure hose using tee adapter F.

Disconnect the hose from the pump port 5 and cap with plug D.

Connect hose A between the pump port and LS port.

Open the restrictor on the flow gauge (to start engine without load).

Loosen the lock nut 6 on torque limiter 7 on the pump.

Turn out the grub screw 8 three turns using an Allen key and re-tighten the lock nut 6.

Connect a tachometer to the machine.

Run the engine at maximum rev/min (typical 2250 rev/min).

Adjust restrictor on the flow meter to achieve 115 to 125 l/min. Approximately 110 bar will be seen on the flow meter pressure gauge.

Loosen the large lock nut 9, ensure lock nut 6 is tight. Adjust the large threaded shaft using the grub screw 8, (keeping flow 115 to 125 I/min) until the engine rev/

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Slowly close the restrictor valve until the pump pressure reaches 165 bar. At this pressure the flow should be between 88 and 92 lpm. Continue to close the restrictor valve until 230 bar is reached, the flow should be between 56 - 60 lpm.

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Section E - Hydraulics Hydraulic Pump Checking and Setting Procedures min reaches 2140+/-5 rev/min. Re-tighten the large lock nut 9. 14

Adjust restrictor on the flow meter to achieve 85 to 95 I/min. Approximately 165 bar will be seen on the flow meter pressure gauge.

Loosen the lock nut 6. Adjust the small grub screw 8 (keeping flow 85 to 95 I/min) until the engine rev/min reaches 2140 +/- 5 rev/min.

Lock the locknut 6 ensuring the settings do not change.

X E

Z M2

6 9

8 5

A LS Fig 8.

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Section E - Hydraulics Hydraulic Pump Removal and Replacement - Pump

Removal and Replacement - Pump Removal

Park the machine on level ground and lower the excavator end until the bucket is resting on the ground. Stop the engine.

Open and support the engine cover.

Fill the hydraulic tank to the correct level on the sight gauge with recommended JCB Hydraulic fluid.

Important: It is extremely important that the pump is primed prior to starting the engine, failure to prime the pump will result in irreparable damage to the pump.

Priming the Pump

!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

Drain the hydraulic fluid into a clean container.

Note the position of the pump hoses. Disconnect pump inlet and outlet hoses A and B respectively. Disconnect all other hoses.

Remove blanking plug C from the pump casing, when air free hydraulic oil flows from the open port replace plug C To ensure positive pressure in the hydraulic tank Operate all hydraulic services, stop engine. Remove breather/hydraulic tank cap. Start engine and operate all hydraulic services. Extend all excavator rams and swing ram to a maximum stroke. Stop engine, replace breather/tank cap. Start engine and operate machine normally.

Important: The hydraulic pump weighs 33 kg and will require supporting on a sling prior to removing mountings. Ensure sling is attached to a suitable lifting device. 5

Remove the pump to flywheel housing bolts D. Pull the pump clear of drive coupling and flywheel housing. Lift the pump clear of the machine.

Replacement 1

Replacement is generally a reversal of the removal

procedure.

Renew all â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; rings. Inspect the drive coupling and gear for signs of wear or damage. Renew if necessary.

Clean all old Loctite from mounting bolt threads using Loctite cleaner. Apply threadlock to bolt threads.

Carefully engage pump drive gear with coupling. Replace retaining bolts and remove lifting slings.

Connect hoses A and B to pump flanges.Connect all other hoses

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A Fig 9.

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Section E - Hydraulics Hydraulic Pump Removal and Replacement - Pump Drive

Removal and Replacement - Pump Drive Removal 1

Follow the pump removal sequence K Removal and Replacement - Pump ( T E-38)

Inspect the pump drive gear on pump shaft, renew if showing signs of damage, such as chipped or broken teeth.

To remove slacken pinch bolt 1 and slide gear 2 from the pump drive splines. Discard gear.

Use a sling to support the rear of the engine. Raise the engine to clear of the two rear engine mounts.

Remove the bolts and washers 4 securing the flywheel housing to the engine, remove the flywheel housing. Retain the bolts and washers.

Inspect the plastic drive gear 5 bolted to the engine flywheel. Remove the eight bolts, spring washers and plain washers 6. Discard the drive gear 5.

Replacement 1

Replacement is a reversal of the removal sequence, however care must be taken when bolting new drive gear 5 to flywheel.

Replace bolts and washers 6, add Loctite and progressively tighten them in sequence, working diagonally from bolt to bolt.

Replace the flywheel housing, torque set the bolts to the required setting. Lower the engine over the mounts and secure. Remove the sling.

Fit the pump drive gear 2 to the dimension quoted on the illustration. Torque set the pinch bolt 1.

Torque Settings

Flange to Flywheel

Pinch Bolt

Replace the pump to the engine K Removal and Replacement - Pump ( T E-38)

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Section E - Hydraulics Hydraulic Pump Removal and Replacement - Pump Drive

5 5

1 2

1 Fig 10.

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Section E - Hydraulics Hydraulic Pump Dismantling and Assembly

Dismantling and Assembly Before removing and dismantling the pump, make sure that it is the pump at fault. If the pump has recorded a significant number of working hours it may be more economic to replace the pump complete rather than attempt the following repair sequence. Complete all the necessary checks as detailed in this section. Make sure that the exterior of the pump and working area is thoroughly cleaned and free of possible sources of contamination. The variable displacement pump has matched components. Consequently, some items will only be available as a sub-assembly.

Remove control piston 7. Note that the control piston is mounted on the same side as the regulator valve.

Remove the stroking piston assembly 8.

Further dismantling of the pump is not recommended.

Inspecting Parts 1

Generally check all pump parts for damage and/or wear.

Any parts that are scored or damaged must be renewed.

The shaft ‘O’ ring grooves and all sealing faces must be free from burrs and scores. During assembly, make sure that the rotary piston group moves freely.

Renew all ‘O’ rings and seals.

All ‘O’ rings, seals and bearings are available in a kit form.

Dismantling K Renewing Pump Drive Shaft Seal ( T E-43) 1

Remove the steel bundy pipe fitted between pump control valves.

Assembly

Remove capscrews 1 and detach the regulator assembly 2 from the pump housing.

Assembly is generally a reversal of the dismantling procedure, but note the following.

Mark position of port plate 3 to pump housing 4.

Remove capscrews 5 and remove the port plate together with the valve plate 6, control piston 7 and stroking piston 8. Hold the plate in position during removal.

The mainshaft taper roller bearing must have a preload of 0.0 to 0.05mm (0.0 to 0.002in.). If the original bearing and shim is refitted, no preload adjustment is required.

If a new bearing is installed follow the preload adjustment instructions below.

Remove taper roller bearing 9 from the drive shaft 11.

Remove the rotary piston assembly 12 from the pump housing. Assembly includes shaft 11, bearing 15 and cradle 16.

Remove and discard port plate to pump housing ‘O’ ring 13.

Remove bearing shells 14 and ring 17.

If damaged and un-serviceable remove the outer bearing races (not shown) from the pump housing and port plate. Lift the valve plate 6 off the port plate, do not lose the dowel pins (not shown).

Remove and discard ‘O’ rings 18.

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Section E - Hydraulics Hydraulic Pump Dismantling and Assembly

16 11

15 13 4 14

5 18

9 17

7 6 12 A

B 18 1

2 Fig 11.

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Section E - Hydraulics Hydraulic Pump Dismantling and Assembly

Preload Adjustment

Renewing Pump Drive Shaft Seal

Install a setting spacer A of known thickness. The spacer should be manufactured to a tolerance of 0.01mm (0.0004in.). In this example the spacer thickness is 1.5mm. (see Note below).

Fit the port plate 3 with the capscrews finger tight only. It is important that the capscrews are tightened evenly and the port plate sits square.

Note: The following procedure describes renewal of the pump mainshaft oil seal. However this is not the normal sequence, the sealing ring would normally be assembled with the taper roller bearing from inside the pump casing to ensure a secure sealing condition. If the shaft seal is to be renewed in this manner, it is extremely important not to scratch or damage the drive shaft, otherwise leakage will occur.

Using feeler gauges measure the gap B between port plate and pump housing 4. Measure in more than one place to ensure port plate is fitted evenly. Illustrated example

(dimensions in mm)

Measured gap

1.26

Subtract preload

0.051.21

Known spacer thickness

1.50

Subtract calculated preload

1.21-

Shim thickness required

0.29

When the required shim thickness has been calculated, remove the setting spacer A and fit the required shim (in this example the thickness required is 0.29mm).

Remove retaining ring 1 and use a special rounded tool such as a ground screwdriver shank to remove the drive shaft sealing ring 2.

Examine the seal running area (driveshaft and housing) for wear or damage. Damage in these areas will require the pump to be dismantled further.

Lubricate the new seal with JCB Special MPL -EP Grease.

Install the new seal, it is advisable to use a tube or similar located over the driveshaft to ensure the seal enters the housing evenly. DO NOT push the seal too far into the housing. If the shaft seal touches the bearing, the seal will be damaged.

Assemble the retaining ring 1.

Note: Setting spacer A is not currently available as a service tool. The spacer (and the calculated shim) can be manufactured locally. Maintain a tolerance of 0.01mmm (0.0004in.). 5

The lubrication bore relief C on the cradle must be fitted to the pressure side of the pump.

Check that the control piston and stroking piston move smoothly.

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Section E - Hydraulics Hydraulic Pump Dismantling and Assembly

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Section E - Hydraulics

Control Valve General Description The excavator valve is mounted on a backing plate, located on the rear of the hydraulic tank, under the rear lockable cover. This sectionalized valve is an assembly of 8 spools, all of which are load-sensed pressure compensated valves. They control the volume, direction of the oil flow and maintain a constant flow regardless of the changing load pressures. The valve sections are designed to suit the various duties of the excavator and tracking services. Key A

'A' Service Ports (upper ports)

'B' service Ports (lower ports)

Compensator Valve (if fitted)

Mechanical Linkage Spools

Servo Operated Spools

Auxiliary Relief Valves

Load Sensing Valve

Load Sensing Port

Return to Tank

Pressure Port 1

Pressure Port 2

Check Valves

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Section E - Hydraulics Control Valve General Description

E L D

C G

H D J K F Fig 1.

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Section E - Hydraulics Control Valve General Description

Testing Compensator Shuttle Signal Network

at stall operate the malfunctioning spool section, if this section now operates correctly the shuttle in question is at fault.

The shuttle network can be easily checked. Start the engine and operate the hydraulic system until the oil has reached normal operating temperature.

If the spool section still malfunctions, the shuttle is NOT at fault.

With the engine at 1500 rev/min operate each service in turn starting with the service furthest from the pump as shown:

Shuttles may be removed; check the seals and the shuttle ball. Clean and refit or fit a new shuttle as required. 1

Track Left

Track Right

Slew

Dozer

When a compensator shuttle is suspect, complete the following check:

Dipper

Bucket

Stall a service that is situated nearer the pump than the suspect section. This should stall the whole system. While

Boom

Auxiliary

If one valve section function either fails to work or is slow to work in one or both directions, the compensator shuttle in that section may be at fault.

4 1

Fig 2.

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Section E - Hydraulics Control Valve Removal and Replacement

Removal and Replacement Removal

Replacement

!MWARNING

Disconnect the battery to prevent the engine being inadvertently started.

!MWARNING Hydraulic Pressure (Servo Machines) Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine. When the engine has stopped, turn the starter switch to on. Operate the controls to release pressure trapped in the hoses. Turn the starter switch to off. Make sure the engine cannot be started while the hoses are open. 5-1-7-1

Label for identification purposes and disconnect all service hydraulic hoses, plug hoses, and cap valve block ports to prevent ingress of dirt.

Label all servo hoses and disconnect from valve block. Plug hoses and cap valve block open ports to prevent ingress of dirt.

Disconnect control cable from track spools, dozer spool, swing spool and auxiliary service spool.

Install lifting sling around valve and attach to a suitable lifting device. Remove retaining bolts and lift valve block clear of machine.

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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. 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_2

Replacement is a reversal of the removal sequence

After replacement check auxiliary relief valve (ARV) pressure settings.

Note: All hydraulic adapters that are installed with a bonded sealing washer must also have JCB Threadseal applied to their threads prior to installation.

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Section E - Hydraulics Control Valve Dismantling, Inspection and Assembly

Dismantling, Inspection and Assembly Dismantling Important: Absolute cleanliness is essential stripping and assembling hydraulic components.

Inspection when

Note: It is not necessary to separate valve sections to remove valve spools, connections, relief valves etc. from the valve block. If spools are removed, label them to make sure they are assembled in their original positions and facing the correct direction as each one is machined to match its bore. 1

Remove the nuts A from one end of the valve tie rods.

Stand the valve vertically on the other end of the tie rods.

Withdraw the sections one by one, discarding the intersection `O' rings as you proceed. Note the position and orientation of the sections before removing them.

Check the mating faces of the valve sections for scratching, pitting, burrs and/or corrosion. Renew valve sections as necessary.

Check the â&#x20AC;&#x2DC;O' ring seatings and check valves for scratching, pitting, burrs and/or corrosion. Renew control valve sections or check valves as necessary.

Assembly Note: Use new seals and `O' rings, smeared with hydraulic fluid on assembly. Note: If a load check valve has been dismantled then when assembling check the valve poppet and seat for scratches, damage and cleanliness. Begin assembly with the poppet, followed by the spring and finally the plug. Screw the unit in by hand to feel for any misalignment or cross threading. Note: If a spool is removed, when assembling ensure that the `O' ring and wiper seal (if fitted) are correctly seated and not damaged. Pay particular attention to cleanliness and the smooth finish of the spool. Ensure that the spools are fitted in their correct positions.

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Ensure all sections are returned to their original location. Assembly must be carried out on a clean, smooth surface.

Screw the nuts to one end of each tie rod (to the end with the shortest length of thread).

Insert the tie rods into the first section of the valve. Place the section on the bench with the free length of the tie rod uppermost.

Lubricate the necessary `O' rings and place on the required seats. Add the elements to the tie rods ensuring that mating surfaces are thoroughly clean.

After all elements are installed screw the nuts into the tie rods and tighten to 50% of the required torque.

Tighten the tie rods to a torque of 25 Nm (18.5 lbf ft) using a torque wrench.

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Section E - Hydraulics Control Valve Dismantling, Inspection and Assembly

Fig 3.

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Section E - Hydraulics Control Valve Valve Section

Valve Section Spool Seal Assembly The spool seals must be installed using the procedure detailed below. 1

Lubricate the spool, bore and ‘0’ ring groove with hydraulic fluid. Move the spool to the position shown and install new ’O’ ring A in its groove.

Fig 6.

Fig 4. 2

Move the spool to the position shown and install new 'O’ ring B. IMPORTANT Do not move the spool beyond the positions shown as machined edge of spool C may damage the first fitted ‘O’ ring A.

C B

Fig 5. 3

Position the spool in the centre position as shown. Re-assemble the centring spring assembly and servo

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Section E - Hydraulics Control Valve Valve Section

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Section E - Hydraulics Main Relief Valve Removal and Replacement

Main Relief Valve Removal and Replacement Removal

The main relief valve A is located on the right hand side of the control valve:

Unscrew the M.R.V from the valve block, covering the port to prevent the ingress of dirt. Remove to a clean working area.

Replacement Note: Seals are made from special material, ensure correct replacements are used.

Note: Torque setting of the M.R.V. is very critical to ensure correct M.R.V. pressure and prevent oil leakage. The adjuster cap can removed and refitted once only using the existing washer and then tightened to 25 Nm (18 lbf ft). If the cap is removed and refitted again, a new washer must be fitted and the cap tightened to 22 Nm (16 lbf ft). 1

Screw the M.R.V. assembly into the valve block and tighten to 50 Nm (37 lbf ft).

Reconnect hydraulics and set the valve.

Refit the components removed to gain access to the valve(s).

Fig 1.

!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. 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_2

Relieve hydraulic pressure, if necessary disconnect and blank hydraulic hoses from the valve block.

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Section E - Hydraulics Main Relief Valve Adjustment

Adjustment 1

Park the machine safely on a level surface with the bucket resting on the ground. Relieve the pressure from the hydraulic system by operating the excavator controls.

Install a 400 bar (6000 lbf/in2) pressure gauge on the pump test port PT. This is located on the servo pressure maintenance valve which is next to the pump.

Run the engine at full throttle and dead end a service (i.e. bucket open) to raise MRV pressure.

Check the MRV pressure is 230 bar. If the value is not correct unscrew the relief valve A on the valve block, one turn, then screw it back in to obtain 230 bar.

Fig 3.

PT Fig 2.

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Section E - Hydraulics Auxiliary Relief Valves Removal, Dismantling, Inspection and Assembly

Auxiliary Relief Valves Removal, Dismantling, Inspection and Assembly Removal ARV's are located in the following sections of the main control valve:

– Boom – Bucket – Dipper – Dozer

Fig 1.

Obtain access to the control valve.

Relieve hydraulic pressure, disconnect and blank any hoses or pipes which may interfere with the removal of the relief valve(s).

Unscrew the auxiliary relief valve(s) A from the control valve and remove to a clean working area.

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Section E - Hydraulics Auxiliary Relief Valves Removal, Dismantling, Inspection and Assembly

Dismantling

Inspection

Prise off plastic locking cap.

Release adjuster lock nut 1 and remove adjuster screw 2.

Remove spring 3 and relief valve poppet 4.

Unscrew upper valve body 5 and remove poppet 6 and springs 7.

Check valve components for scratching, pitting, distortion and/or corrosion.

Note: If any part other than O-rings and washer are damaged the entire valve must be renewed. Note: Seals are made from special material, ensure correct replacements are used.

Assembly

1 2 3 4

Clean the valve body and components in an appropriate solvent.

Assemble in the reverse order of dismantling.

If the valve has been dismantled it should be pressure tested before refitting.

Fig 2.

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Section E - Hydraulics Auxiliary Relief Valves Pressure Testing

Pressure Testing 1

Remove the auxiliary relief valve from the control valve and plug the valve port.

Install the auxiliary relief valve into the test block B part number 331/31069.

Connect a 0 - 400 bar (0 - 6000lbf/in2) pressure gauge and hand pump, part number 892/00223, to test block.

Operate pump and adjust pressure setting plug C until valve opens at correct pressure, K Technical Data ( T E-1).

Lock the pressure setting plug with the locknut D and re-test. Remove auxiliary relief valve from test block and refit to control valve.

Fig 3.

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Section E - Hydraulics Auxiliary Relief Valves Pressure Testing

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Section E - Hydraulics Pressure Maintenance Valve and Dual Solenoid Valve Description

Pressure Maintenance Valve and Dual Solenoid Valve Description The pressure maintenance valve (PMV) supplies servo pressure where required throughout the hydraulic system (see Hydraulic Schematics). Pressure from the hydraulic pump is fed to port P1. Solenoid valve CT3 supplies servo pressure to the following: – Left Hand Controller – Right Hand Controller – Slew Motor – Track Valve – Swing/Auxiliary Change-over Valve Solenoid valve CT4 supplies speed control pressure (2 speed) to the track motors. CT1 shuts off the pump pressure supply should the pressure at inlet P1 rise too high, CT5 is the relief valve and CT2 closes if the inlet pressure falls, e.g. if the engine stops. This allows the pressure in the accumulator ACC to be used to bring the machine to a safe position.

PT T

Fig 2.

CT1

ACC

CT5 CT2 CT3

PV2

CT4

BV Fig 1.

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Section E - Hydraulics Pressure Maintenance Valve and Dual Solenoid Valve Removal and Replacement

Removal and Replacement Removal

Stop the machine on level ground with the bucket resting on the ground. Stop the engine and vent residual pressure from the servo accumulator by turning the ignition on and lowering the L.H. arm rest to the excavator operate position. Operate both excavator control levers in all directions until stored servo pressure in the accumulator has been exhausted.

Remove the key. Remove the left and right side skirts to gain access to the pressure maintenance valve.

Note: Note: It is possible to remove a valve cartridge for cleaning or re-sealing without removing the complete valve from the machine.

Replacement

To remove the valve, mark hoses for correct replacement and remove. Plug hoses to prevent the ingress of dirt. Disconnect the electrical connections A to the two solenoids.

Remove the two bolts B (one at far end not shown) holding the valve to the slew frame.

Replacement procedure.

the

reverse

the

removal

Note: If there is evidence of damage to the valve or its seat caused by debris then the cartridges will require renewing. If a cartridge or valve complete is renewed it is recommended that the filtered adapters in the feed ports of the valve are also renewed.

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Section E - Hydraulics Pressure Maintenance Valve and Dual Solenoid Valve Adjustment

Adjustment 1

Remove the blanking cap and connect a 0 - 40 bar (0 - 600 lbf/in2) pressure gauge to the test point PV2 on the pressure maintenance valve.

Slacken lock nut A and turn adjusting screw B clockwise to increase the pressure or anticlockwise to decrease.

b Tighten lock nut to 25 Nm (18 lbf ft). 4

Recheck the pressure as described in step 3.

Switch off engine. Remove pressure gauge and refit blanking cap.

CT1 PV2 Fig 3. 2

With the engine running at maximum speed and hydraulic fluid at normal working temperature, operate the dipper service and check the gauge reading.

Fig 4. 3

If the servo pressure is incorrect (see Technical Data), adjust CT1 as follows:

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Section E - Hydraulics Pressure Maintenance Valve and Dual Solenoid Valve Adjustment

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Section E - Hydraulics Track Motor/Gearbox Description

Track Motor/Gearbox Description

Fig 1. Note: The track motor shown is typical only. The motors fitted to this machine differ in detail. The track motors consist of two sections, a hydraulic motor section which is static and a rotary casing containing two stage epicyclic reduction gearbox to which is bolted the track drive sprocket. When hydraulic power is applied to the motor A, the motor output shaft B turns. This shaft is meshed to two sets of planetary gears. Drive is transmission through the gears in the train to the rotary section of the motor via an integral ring gear C, this transmitting motive power to the machine track.

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Section E - Hydraulics Track Motor/Gearbox Description

Epicyclic Reduction The reduction gearbox converts the high speed rotary input from the hydraulic motor to low speed high torque rotation of the case. A sun gear drives two sets of planet gears, these reduce the input speed in two stages and transmit drive to the ring gear which rotates the gearbox case and track drive sprocket.

Hydraulic Motor The hydraulic motor A is an axial piston type and converts the pump supplied hydraulic energy to rotary movement. This rotary movement is achieved by incoming pressure from the pump acting on the crowns of the pistons B pushing them down the barrel C. The sliding shoe D on the opposite end of the piston slides down the angled face of the swash plate E rotating the barrel and hence the connecting shaft F from motor to gearbox. The swash plate angle is supported on an eccentric trunnion J consisting of a pair of ball bearings mounted above the centre line of the motor shaft. This ensures the motor is set to full capacity for maximum torque, which translates into powerful machine tracking performance. With high-speed tracking selected, servo pressure fills chamber K between stopper ring L and cylinder barrel M. The swash plate rocks on its trunnion to a shallower angle reducing the hydraulic capacity of the motor. The same volume of oil from the pump now turns the motor faster increasing the tracking speed of the machine.

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Section E - Hydraulics Track Motor/Gearbox Description

M D

J L

E K J L

E B D

Fig 2.

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Section E - Hydraulics Track Motor/Gearbox Description

Counter Balance Operation When the machine is tracking down an incline, gravity helps the machine to travel. Under these conditions, it is possible for the motor to over speed and act as a pump, increasing outlet pressure while inlet pressure reduces. This pressure differential allows the counter balance spool to move back towards the neutral position. This restricts the flow of oil through the return to tank port of the motor, pressure develops in the exhaust side of the motor causing it to slow.

Braking When the operator releases the track levers, the motor pressure ports are connected to tank. Pressure sensed on both ends of counter balance plunger falls to this same tank pressure and spool is returned to the centre position by its springs. The metering notches on the spool progressively limit the escape of oil from the motor and the machine speed is smoothly reduced. Should the motor experience a violent deceleration crossline relief cartridges operate and the motor is again smoothly bought to rest. Note: Plug one drain port depending on left or right hand motor, change as required for installation. The drain port is the uppermost one.

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Section E - Hydraulics Track Motor/Gearbox Description

2 Speed Motor Operation

The swash plate 4 is supported by the two balls 6 which are fixed to the motor body 7, allowing movement of the swash plate.

B 7

On initial start up, surface A of the swash plate is pressed against the motor body by the force of spring 8. The swash angle is therefore at its maximum (Îą). This gives low speed with maximum torque. When high speed is selected, pressurised oil is fed into control chamber 9, driving piston 10. This moves the swash plate against spring pressure, pressing surface B against the body. The swash angle becomes Îą, giving higher speed but less torque.

6 A

When the engine stops, control chamber 9 is vented to tank and spring 8 again pushes surface A against the body. The track motor thus always starts in the low speed condition. Fig 3.

4 B 7

6 A 9 10 Fig 4.

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Section E - Hydraulics Track Motor/Gearbox Description

Parking Brake Section The parking brake holds the output shaft of hydraulic motor mechanically when the wheel motor is stopped. When ports A and B are not pressurised, brake piston 14 is pressed in the direction shown at A by the spring 15. Disc plates 16, which are fixed to the cylinder barrel 3, are held between steel plates 17, which are fixed to the motor body 7. As a result, the cylinder barrel 3 and the hydraulic motor are unable to rotate. When ports A and B are pressurised, pressurised oil is fed to chamber X. Brake piston 14 is moved in the direction shown at B against the force of spring 15. As a result, disc plates 16 are released from steel plates 17, and the cylinder barrel 3 can be rotated.

Fig 5.

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Section E - Hydraulics Track Motor/Gearbox Description

Auto Kick Down Function When the pilot switch for high speed is turned on, the pilot pressure for high speed is lead into chamber #1 of the auto kick down valve A, and force F1 is applied. Force F1 overcomes spring force F4, and shifts the auto kick down valve to the right, then the motor is switched to high speed mode. On the other hand, drive pressure of the hydraulic motor is lead into chambers #2 and #3, generating forces F2 and F3. At this point, force F3 is larger than force F2 due to the larger cross-sectional area. The difference between F2 and F3 becomes larger when higher pressure is applied. When the motor drive pressure exceeds the specified value to change the speed from high to low mode, the total force of F3 and F4 becomes larger than the total of F1 and F2, and the auto kick down spool shifts to the left, then the motor is switched to low speed mode.

Fig 6.

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Section E - Hydraulics Track Motor/Gearbox Removal and Replacement

Removal and Replacement Removal 1

Remove the track and if required, remove the driven sprocket.

Remove the bolts A and washers B. Remove the cover C.

Label and disconnect the hydraulic hoses D from the manifold E. Blank off the hoses and manifold ports.

Fig 8.

Replacement Replace in the reverse order of removal.

Item F

Table 1. Torque Settings Nm lbf ft 137

101

kgf m 14

Fig 7. 4

Drain the gearbox.

Attach suitable lifting equipment to the motor/gearbox assembly.

Note: The track gearbox and motor assembly weigh 65kg (143lb) 6

Remove the bolts F. Detach the motor/gearbox sprocket assembly from the machine. Remove the motor/gearbox/sprocket assembly to a clean working area.

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Section E - Hydraulics Track Motor/Gearbox Dismantling and Assembly

Dismantling and Assembly Track Motor Note: For assembly the sequence should be reversed.

Dismantling Cover all open orifices to prevent dirt entering the hydraulic system. The numerical sequence shown on the illustrations are intended as a guide to dismantling. Mark adjacent casing sections for ease of assembly. Layout components in a clean environment in order of dismantling. Discard 'O' rings and seals. Note: Some items will have been assembled at the factory by press fitting, these parts are not available separately, therefore do not attempt to dismantle.

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Section E - Hydraulics Track Motor/Gearbox Dismantling and Assembly

Fig 9.

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Section E - Hydraulics Track Motor/Gearbox Dismantling and Assembly Brake Valve Assembly When removing the valve spools, note their orientation; they must be refitted correctly or the valve will not operate properly. 1

Thoroughly clean each part with solvent before assembling. Keep parts free from debris and foreign material, any dirt trapped between components will cause accelerated wear and may cause seizure.

Take care to protect all mating and sealing parts, such as 'O' rings and oil seals from damage during assembly.

Replace counterbalance spool, spring seat ring and spring into valve housing. Renew 'O' ring on plug. Torque tighten plug to 220 Nm.

Replace Two speed tracking selector spool, ensuring it is fitted the correct way round, into the housing followed by its spring. Fit new 'O' ring to plug and torque plug to 48 Nm.

Insert shuttle spool into housing, renew 'O' rings, replace plugs, and torque to 18 Nm.

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Section E - Hydraulics Track Motor/Gearbox Dismantling and Assembly

Fig 10.

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Section E - Hydraulics Track Motor/Gearbox Dismantling and Assembly

Track Gearbox Dismantling K ( T E-76). 1

Remove the snap ring 1, cover 2 and `O' ring 3. Discard `O' ring 3.

Remove the thrust pad 4 and shaft 5.

Remove the carrier assembly 6 and thrust washer 7.

Note: All components of carrier assembly 6 are nonserviced parts (NSP). The carrier assembly need not be dismantled other than for inspection. If this is not required, ignore steps 4 and 5. 4

Remove snap ring 8 and sun gear 9 from the carrier 17.

Remove snap ring 10, thrust washer 11, needle bearings 12, gear 13 and thrust washer 14 from each of the shafts 16 on the carrier assembly.

Do not remove roll pins 15 or shafts 16.

Remove snap ring 18, thrust washer 19, gear 20, needle bearings 21, sleeve 22 and thrust washer 23 from each of the shafts B.

Remove snap ring 24 and separate the hydraulic motor 30 from the body 25.

Note: It may be necessary to clamp the hydraulic motor and body flanges together to relieve the load and allow removal of the snap ring. 9

Do not try to remove bearings 31 or 33 as they are NSP and a press would be required for removal and replacement.

Remove seal ring 26 and remove and discard `O' ring 27 from the hydraulic motor 30.

Remove seal ring 28 and remove and discard `O' ring 29 from the body 25.

Remove plugs 34 from cover 2.

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Section E - Hydraulics Track Motor/Gearbox Dismantling and Assembly

Fig 11.

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Section E - Hydraulics Track Motor/Gearbox Dismantling and Assembly Inspection 1

Clean and check the needle bearings for scoring, wear, pitting and corrosion.

Clean and check the condition of all gear wheel teeth and mating surfaces, especially for wear and corrosion.

Clean and examine all parts for wear, corrosion or damage.

Install the carrier assembly 6 and shaft 5 into the body 25 ensuring correct engagement of all teeth.

Lightly grease ‘O' ring 3 and install on the cover 2.

Fit the cover 2 to the body 25, taking care not to damage the ‘O' ring 3.

Secure cover 2 with snap ring 1.

Fit new `O' rings 35 to plugs 34.

Assembly K ( T E-76). 1

Lightly grease the new ‘O' ring 27 and seal ring 26 and install them on the hydraulic motor 30, using hand pressure only. Remove any excess grease.

Lightly grease the new ‘O' ring 29 and seal ring 28 and install them in the body 25 using hand pressure only. Remove any excess grease.

Install the hydraulic motor 30 into the body 25 and secure with snap ring 24.

Note: It may be necessary to clamp the hydraulic motor and body flanges together to allow fitting of the snap ring. The force used must not exceed 800 kgf (1764 lbf). 4

Fit thrust washers 23, sleeves 22 and gears 20.

Install needle bearings 21 between each gear 20 and each shaft B.

Fit a thrustwasher 19 over each shaft B and secure with a snap ring 18.

Fit a thrust washer 14 and gear 13 over each of the shafts 16.

Install needle bearings 12 between each gear 13 and shaft 16.

Fit a thrust washer 11 over each shaft 16 and secure with a snap ring 10.

Install sun gear 9 in the carrier 17 and secure with snap ring 8.

Install the thrust washer 7 over the sun gear 9.

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Section E - Hydraulics Track Motor/Gearbox Port Identification

Port Identification Important: Ensure the casing is filled to the correct level with the correct type and grade of oil. Never operate the track motors without the correct level and type of oil. Port Identification P1

Service Port

Two Speed Control Port

Drain Port

Note: The drain port is always the lower port, the top port is then blanked.

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Section E - Hydraulics Track Motor/Gearbox Port Identification

Ps T1

a1 a1

P1 a2 P2 T2

T2 T1

P2 P1

R/G

a1 Fig 12.

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Section E - Hydraulics Track Motor/Gearbox Port Identification

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Section E - Hydraulics

Slew Motor/Gearbox Description The slew motor consists of a reduction gearbox J, hydraulic motor K and hydraulic cross-line relief valve assembly L. The hydraulic motor is an axial piston type and converts hydraulic energy supplied from the hydraulic pump into a rotary motion. The hydraulic valve consists of cross-line relief valves, which in conjunction with a double acting spool fitted to the valve block ensures that the inertia produced when stopping the machine is absorbed through the cross-line relief valves producing a smooth machine stop also preventing the hydraulic motor becoming overloaded. The gearbox is a single step planetary type, the gearing converts high speed rotary motion from the hydraulic motor into low-speed high torque transmitted to the pinion shaft.

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Section E - Hydraulics Slew Motor/Gearbox Description

C D

L E A

C B

E F K

D L

K H J G H

Fig 1. Key K Fig 1. ( T E-82)

Hydraulic Motor

Air Vent

Cross-line Relief Valve Assembly

Pressure Testing Ports

Make-up Oil Port

Drain Port

Pressure port ‘A’

Pressure port ‘B’

Drain Port

Greasing Port

Reduction Gearbox

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Section E - Hydraulics Slew Motor/Gearbox Description

Fig 2.

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Section E - Hydraulics Slew Motor/Gearbox Description

Fig 3. Key K Fig 3. ( T E-84) A

A chamber

B chamber

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Section E - Hydraulics Slew Motor/Gearbox Description Key K Fig 2. ( T E-83)K Fig 3. ( T E-84) Item

Inspection and Maintenance Standards

Balance Plate 7

The crescent-shaped ports in the balance plate, which are in sliding contact with the end face of the cylinder assembly shaft, act to switch between high and low oil pressure. Any damage to the sliding contact face will increase leakage, causing a decrease in volumetric efficiency and an increase in slip. Any seizure of the sliding contact face causes a reduction in mechanical efficiency and can lead to further damage. If the grooves or marks depths are less than 0.03 mm (.001 in), the plate can be corrected using fine emery cloth. If the wear is greater than 0.03 mm (.001 in), the plate should be renewed. The plate should be renewed if it shows any sign of seizure.

Piston Assembly 18 slipper feet

Correct any damage to the sliding contact face of the slipper feet by using fine emery cloth. Renew the motor if the depth of any slipper foot oil groove is less than 0.45 mm (.018 in) or if the slipper foot surfaces are seriously damaged.

Piston Assembly 18 pistons

The external surfaces of the piston assemblies should be practically unworn. The motor should be renewed if a piston assembly shows any sign of seizure.

Cylinder Assembly 16 piston bores

The piston bores should be practically unworn. The motor should the bores show any sign of seizure or are badly damaged.

Hydraulic motor taper roller bearing 1. Needle bearing 3. Reduction Gear taper roller bearing 4,8.

The bearings should be renewed if any slight damage is noticed on the contact surfaces of the rollers or needles. It is recommended that all bearings be renewed on reassemble of the motor because bearings can be damaged when the motor is dismantled.

Hydraulic Motor/ Reduction gear oil seal 7.

Renew any oil seal if damage to the lip is apparent. New seals must be used when reassembling the motor.

Hydraulic motor â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122;-rings 6, 8, 25, 27, 30, 33 Renew any 'O'-ring that appears to be damaged. New 'O'-rings must be used when reassembling the motor. Hydraulic Motor back-up ring 24, 32.

The back-up rings must be renewed when reassembling the motor.

!MCAUTION

!MWARNING

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

8-3-1-5

INT-3-1-10_3

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Section E - Hydraulics Slew Motor/Gearbox Description

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Section E - Hydraulics Slew Motor/Gearbox Description

Crossline Relief Valves

spring force is overcome. Poppet A opens allowing excess pressure to vent through C.

When the operator returns the slew service to neutral, the momentum of the slewing superstructure turns the motor into a pump. This pressurised oil fills the open centre of poppet A and loads top of piston G which moves across compressing spring B. The momentum continues to increase the pressure load against poppet A until the

As the slewing superstructure slows, momentum induced pressure begins to reduce. The spring B returns piston and poppet to their respective seats and the escape path for the oil is closed. The machine is consequently brought progressively and smoothly to rest.

F Fig 4.

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Section E - Hydraulics Slew Motor/Gearbox Removal and Replacement

Removal and Replacement Note: It is not necessary to remove the motor/gearbox complete to service either the motor or the cross-line relief valve assembly.

Replacement 1

Remove protective cover from gearbox, position slew motor over gearbox, ensuring correct engagement of drive shaft splines.

Vent residual pressure from within the hydraulic tank by releasing the tank filler cap. Remove seat, floor matting and floor plates as required to gain access to the slew motor.

Align marks made prior to dismantling, fit capscrews and tighten to 103 Nm (76 lbf ft).

Label, then disconnect hydraulic hoses from the motor head.

Renew 'O'-ring seals, ensure valve is correctly positioned and fit housing to motor.

Plug hoses and blank open ports E and F to prevent the ingress of dirt.

Align marks made during removal and install cap screws.

Important: Lubrication drain hose is a direct connection to hydraulic tank, consequently it must be plugged immediately to prevent excessive oil loss.

Check relief valve setting (see Pressure Testing).

Removal 1

If removing the motor only mark gearbox casing J and motor casing K to aid re-assembly.

If removing motor only remove ring of capscrews locating motor casing to gearbox casing. If removing complete assembly remove gear box capscrews.

Lift motor/gearbox clear and remove to a clean area for dismantling.

If removing motor only protect open gearbox from ingress of dirt.

Cross Valve Relief Valve Assembly

Cross Valve Relief Valve Assembly 1

Mark adjacent housing to aid re-assembly.

Remove cap screws.

Lift off housing taking care that the valve plate fitted on top of the motor barrel is not displaced.

Move valve housing to a clean area for dismantling, cover open motor to prevent dirt ingress.

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Section E - Hydraulics Slew Motor/Gearbox Dismantling and Assembly

Dismantling and Assembly Dismantling Note: Refer to K Fig 2. ( T E-83) and K Fig 3. ( T E-84) as a guide to dismantling and assembling. Before attempting to dismantle the slew motor assembly, the inlet and outlet ports should be blanked and the outer surfaces washed down with a suitable solvent to remove all dirt and dust. Dry using compressed air. 1

Remove the relief assembly 23 using a 27 mm A/F hexagonal key and the by-pass valve assembly 31 with a 8 mm hex, socket.

Fig 6. 3

Loosen the bolts 34 with a 10 mm socket wrench, place the motor with the output shaft downwards and remove the cover 28.

Fig 5. 2

Before removing the motor from the reduction gear, it is advisable to make an alignment mark on the mating faces to facilitate re assembly.

Fig 7. 4

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Remove the snap ring 2 and remove the inner ring of the needle bearing 3 and balance plate 7. The inner ring of the needle bearing 3 is pressed into the male axis of the cover 28 and must be removed with a gear puller.

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Section E - Hydraulics Slew Motor/Gearbox Dismantling and Assembly

Remove the springs 14 from the brake piston 15.

Fig 8. Note: Record the relative positions of the parts to ensure correct re assembly. 5

Remove the O-ring 8.

Fig 10. Note: Keep the springs in the order in which they are to be re-inserted. 8 Fig 9. 6

Remove the bushings 11 with teflon rings 13 and the plate springs 12.

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It may be difficult to remove the brake piston 15 from housing 21 due to resistance caused by â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122;-rings 6 and 30. Remove brake piston 15 using the tapped M6 holes with a wrench A and a support block B as shown in the illustration.

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Section E - Hydraulics Slew Motor/Gearbox Dismantling and Assembly

Remove the friction plate 4 and the mating plate 5.

Fig 12. The outer ring of the taper roller bearing 1 remains in the housing. The end face C of the cylinder 16 is a sliding face and should be protected with a clean cloth to prevent it being damaged. Make alignment marks or write numbers on the piston bores of the cylinder 16 and the piston assemblies 18 so that the piston assemblies can be replaced in the same bores during re assembly. 11

Remove the outer rings D of the taper roller bearing 1 from the housing 21.

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Fig 11. 10

Hold the end of the cylinder 16 by hand and pull out the cylinder assembly from the housing 21.

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Section E - Hydraulics Slew Motor/Gearbox Dismantling and Assembly

Fig 13. Fig 15. 12

Attach a puller to the inner ring E of taper roller bearing 1 at two places and on the end of cylinder spline 16, then extract bearing inner ring 22.

Slide cam plate 20 from the sliding faces of the piston assemblies.

Fig 16. Fig 14. 13

Remove the cam plate 20, return plate 19 and piston assemblies 18 from the cylinder.

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Note: Take care not to damage the cam plate during handling. 15

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Remove the spring 17 from the cylinder 16.

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Section E - Hydraulics Slew Motor/Gearbox Dismantling and Assembly

Assembly Note: Refer to K Fig 2. ( T E-83) and K Fig 3. ( T E-84) as a guide to dismantling and assembling. Check all parts before assembly and remove any scratches with a fine oil stone or carborundum paper. Wash with a suitable solvent and blow dry. Replace all seals with new ones. Apply clean hydraulic oil to all sliding faces during assembly

!MCAUTION Fig 17.

Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents. INT-3-2-11

!MCAUTION '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. INT-3-2-12

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Lap the sliding contact faces of piston assemblies 18, balance plate 20 and swash plate 7 with very fine paste on a flat surface.

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Section E - Hydraulics Slew Motor/Gearbox Dismantling and Assembly

Fig 20. 4

Mount the piston assemblies 18 together with return plate 19 into cylinder 16.

Fig 18. 2

Apply grease to the curved part of cylinder 16 (contact face with spring 17) and mount spring 17.

Fig 21. Fig 19. 3

Position the piston assemblies 18 into the holes of retainer 19.

Note: Insert the piston assemblies into the same bores from which they were removed. Apply clean hydraulic oil to all cylinder 16 bores before reassembling. 5

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Apply clean hydraulic oil to piston assembly 18 shoe sliding surface and mount the cam plate 20.

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Section E - Hydraulics Slew Motor/Gearbox Dismantling and Assembly

Fig 22. 6

Mount The inner ring E of the taper roller bearing 1 on the cylinder 16 by hand and press using a press fitting jig F.

Fig 24. 8

Mount the inner ring 22 on the cylinder 16 using a press fitting jig F. Wipe off excess sealing material spilled between the inner ring 22 and the taper roller bearing.

Fig 23. Note: The end face of the cylinder should be protected by a soft cloth to prevent it from being damaged while pre fitting.

Fig 25. 9

Apply a thin coat of JCB Retainer G where the inner ring is mounted on motor output shaft 16.

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Mount the outer ring 1 of the taper roller bearing into the housing 21.

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Section E - Hydraulics Slew Motor/Gearbox Dismantling and Assembly that the cylinder end is approximately 7.5 mm (0.3 in) lower than the housing. 11

Mount friction plate 4 and mating plate 5.

Fig 26. 10

Apply grease to the lip of the oil seal. Hold the end of cylinder 16 by hand and carefully insert the cylinder assembly into housing 21. Use the seal protector on the splines.

Fig 28. Note: Apply hydraulic oil to both faces before mounting the plates. 12

Mount 'O'-ring 30 in housing 21 and 'O'-ring 6 on piston 15.

Fig 27. Fig 29. Note: The splines of the cylinder assembly protrude beyond the housing, so use a guide of 30-50 mm (1.2-1.9 in) on the lower part of the housing. Verify that spring 17 is inserted correctly into the back face of retainer 19. Confirm

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Note: Grease the 'O'-rings before mounting.

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Section E - Hydraulics Slew Motor/Gearbox Dismantling and Assembly 13

Apply hydraulic oil to the sliding surface around piston 15 and slide it into housing 21.

Mount the bushings 11 with Teflon rings 13 and the plate springs 12 and the balance plate 7 into the bushing holes in cover 28.

Fig 30. Note: It is difficult to insert piston 15 into the housing due to O'-rings 6 and 30. Hold the piston 15 horizontally and push it into the housing with one movement. 14

Insert the brake unit springs 14 back into brake piston 15.

Fig 32. Note: Apply a coating of grease to the end faces and peripheries of the bushings 11 and to the Teflon rings 13 before mounting them, as this helps prevent them from falling out when the cover is mounted onto the housing. When assembling balance plate 7 and cover 28, confirm alignment marks on the mating faces to facilitate re assembly 16

Press needle bearing 3 inner ring into cover 28 and attach snap ring 2.

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Fig 31. Note: Insert the springs 14 in the same order as they were found during dismantling.

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Section E - Hydraulics Slew Motor/Gearbox Dismantling and Assembly

Fig 35.

Fig 33. 17

Apply grease to the 'O'-ring and install 'O'-ring 8 to cover 28.

Lift the cover 28 and the balance plate 7 by hand and mount them carefully on the housing 21.

Fig 34. 18

To prevent oil leakage from the cover bolt holes apply JCB Multi-gasket H to the mating surface of the housing 21 and the cover 28.

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Fig 36. Take care that the balance plate 7 and bushings do not fall out while mounting cover 28. Align housing 21 and cover 28 alignment marks which were made before dismantling. 20

Tighten the bolts 34 (with 10 mm A/F hexagonal socket) which attach the cover 28 to the housing 21 to a torque of 103 Nm (76 lbf ft.).

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Section E - Hydraulics Slew Motor/Gearbox Dismantling and Assembly the drain port). Check that the drive shaft can be rotated smoothly for at least one full revolution by applying a torque of approx. 24.5 Nm (18.0 lbf ft). Note: If the shaft does not turn, the unit has not been assembled correctly so dismantle again and inspect.

Fig 37. Tighten and insert the relief assemblies 23 with a 27 mm A/F hexagonal socket) into the cover 28 to a torque of 39 Nm (29 lbf ft.). 21

Tighten and insert the by-pass valve assemblies 31 (with 8 mm A/F hexagonal socket) into the cover 28 to a torque of 39 Nm (29 lbf ft.).

Fig 38. 22

Final checks after assembling. Open the inlet and outlet ports and apply 39.2 bar (40 kgf/cm2)(569 lbf/in2) pilot pressure to the brake release port. (Take care as oil will be discharged from

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Section E - Hydraulics Slew Motor/Gearbox Fault Finding

Fault Finding Symptom Motor does not turn.

Excessive slip.

Abnormal heating.

Cause

Table 1. External Inspection

Repair

Internal damage to the motor.

Measure the oil drain volume.

High possibility of damage K Table 2. to the sliding surfaces if the ( T E-101) supply volume is approximately equal to the drain volume. Dismantle and inspect.

Internal damage to the motor.

Open the motor inlet and outlet ports and apply 39 bar (40 kgf/cm2) (569 lbf/in2) pilot pressure to the brake release port. Try to rotate the shaft with a torque of approx. 24.40 Nm (18 lbf ft).

High possibility of internal Renew damaged damage to the motor if the parts or renew the supply shaft does not rotate motor assembly. smoothly when this torque is applied. Dismantle and inspect.

Relief valve in circuit not set correctly.

Measure pressure.

Reset to the prescribed setting.

K Table 2. ( T E-101)

Wear or damage to the Measure the oil drain motor sliding surfaces or volume to the high-pressure seal

Leakage is too high if the oil K Table 2. drain volume exceeds 5 l/ ( T E-101) min (1.1 UK gal/min; 1.3 US gal/min). Dismantle and inspect.

Oil hot and excessive leakage in the motor.

Measure the oil temperature.

Reduce the oil temperature.

K Table 2. ( T E-101)

Seizure of motor sliding parts or circuit.

Check for any metallic matter deposited in motor drain oil or drain filter. Apply a 39 bar (40 kgf/cm2) (569 lbf/in2) pilot pressure to the brake release port and try to rotate the shaft with a torque of approx. 24.40 Nm (18 lbf ft).

If metallic matter is discovered or the supply shaft does not rotate smoothly when torque is applied, there is a high possibility of internal damage to the motor. Dismantle and inspect.

Renew damaged parts or renew the motor assembly.

Leakage from Damage or wear to the oil seals. seal lip.

Renew the oil seals.

Damage or wear of the shaft seal.

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Countermeasure

Repair the problem or renew the motor assembly.

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Section E - Hydraulics Slew Motor/Gearbox Fault Finding Symptom Insufficient torque

Abnormal noise

Oil leakage from mating surfaces.

Cause

External Inspection

Countermeasure

Repair

Wear or seizure of the motor sliding surfaces.

Open motor inlet and outlet ports and apply 39 bar 40 kgf/cm2 (569 lbf/in2) pilot pressure to the brake release port.Try to rotate the shaft with a torque of approx. 24.40 Nm (18 lbf ft).

High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect.

Inspect the parts and bearing according to K Table 2. ( T E-101) item a-e and renew any defective parts.

Relief valve in the circuit is not set correctly.

Measure relief pressure.

Reset to the prescribed setting.

Internal damage to the motor.

Check if any metallic matter High possibility of internal Repair or renew is deposited in motor drain damage to motor if metallic damaged parts. oil or drain filter. matter is discovered. Renew the motor assembly.

Large amount of air mixed in the oil.

Check the oil in the tank and Thoroughly bleed the air. motor casing.

Loosening of bolts or pipes.

Check if the piping connections, attachment mounting bolts, motor attachment bolts or other bolts are loose.

Tighten to the specified torque.

O-ring is damaged.

Renew O-rings

Seal face is damaged.

Repair seal face or renew

Bolts are loose.

Check the bolt tightness.

Tighten the bolts to the correct torque.

Table 2. Item

Part Inspected

Repair

Wear of the sliding surface of balance plate 7.

Repair or renew the part

Damage to sliding surface of cam plate 20.

Repair the part or renew the motor.

Damage to sliding surface of the piston assemblies 18. Repair the part or renew the motor.

External wear to the piston assemblies 18.

Repair the part or renew the motor.

Wear to piston bores in cylinder assembly 16.

Renew the motor.

Damage to Teflon ring 13.

Renew the part.

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Section E - Hydraulics Slew Motor/Gearbox Fault Finding

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Section E - Hydraulics Rotary Coupling Description

Rotary Coupling Description General The rotary coupling distributes hydraulic fluid under pressure, through transfer ports in the fixed inner core, to their associated port of the rotating outer shell. The outer shell A is machined from a type Fe 52 steel forging, which is phosphated after machining. The outer shell A has eight hydraulic fluid ports B arranged in two groups of four. All galleries on the inner surface of the outer shell, are sealed to the inner core with O-ring seals and back-up rings C. In addition, the inner surface of the outer shell, is fitted with top and bottom lip seals D which seal to the top and bottom of the inner core. The outer shell has four fixing lugs E welded to its outer surface, which are used for mounting the coupling to the machine undercarriage. The inner core F is a machined carbon steel component, with a hard chromed working surface, in which are machined the eight hydraulic fluid transfer ports. The core is fitted with an external top seal J and is retained within the outer shell with a hardened steel bottom retaining plate H, also sealed, which is bolted to the bottom of the core. A reaction peg K is welded to the top of the inner core, which locates in a slotted plate in the mainframe.

Operation When the outer shell A of the rotary coupling rotates around the fixed inner core, the transfer ports G of the inner core align with the ports of the outer shell B. Hydraulic fluid under pressure from the hydraulic pump, is then routed via a transfer port of the inner core, to the required service.

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Section E - Hydraulics Rotary Coupling Description

F K

J P2 B

P4 E

P3 B

P6 P5 P8

P7 C

P2 P1

P1 P6

E Fig 1.

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Section E - Hydraulics Rotary Coupling Removal and Replacement

Removal and Replacement Removal

clear of the machine and remove to a clean working surface.

K Fig 2. ( T E-105).

Replacement

Note: Before removing a suspected leaking coupling, ensure that the leak is from the coupling core and not a hose adaptor. Ensure all adaptors are tight.

K Fig 2. ( T E-105). Replace in reverse order of removal.

Reconnect hydraulic hoses using new lightly lubricated Orings.

INT-3-1-10_2

!MWARNING A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-1

Remove the floor plate

Disconnect the hydraulic hoses from the rotary coupling adaptors A, mark for correct replacement, blank off the hoses and adaptors.

Remove the undercarriage cover plate.

Disconnect the remaining hydraulic hose from the rotary coupling adaptors B. Blank off the hoses and adaptors.

Support the coupling from above and remove bolts, washers and nuts C securing the coupling flanges to the undercarrige.

Lower the coupling, allowing the reaction peg D to clear the slot in the mainframe floor continue to lower

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Section E - Hydraulics Rotary Coupling Removal and Replacement

D A

H B

C L

K Fig 2.

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Section E - Hydraulics Rotary Coupling Dismantling and Assembly

Dismantling and Assembly Dismantling 1

Mark the positions and remove the adaptors A and B from the coupling. Discard the O-rings.

Remove the two M10 inner core retaining bolts K, from the base of the coupling and remove the bottom retaining plate and seal.

From the top of the coupling, carefully withdraw the coupling core G from the shell H.

Remove and discard the inner core top and bottom V seal L and port O-rings and back-up rings M, from the inner surface of the outer shell.

Assembly 1

Assemble in reverse order of dismantling, fitting new O-rings, back-up rings and V seals. Lightly lubricate with hydraulic fluid, the inner core and all O-rings with hydraulic fluid.

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Section E - Hydraulics Rotary Coupling Hose Locations (port numbers stamped on joint)

Hose Locations (port numbers stamped on joint) Dozer ram – Head side to rotary joint port no.7 – Rod side to rotary joint port no.2 L.H. Track Motor – Port A to rotary joint port no. 3 – Port B to rotary joint port no. 5 – Top drain port to rotary joint port no.1 – Pilot port to rotary joint port no.8 R.H. Track Motor – Port A to rotary joint port no. 6 – Port B to rotary joint port no. 4 – Top drain port to rotary joint port no.1 – Pilot port to rotary joint port no.8

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Section E - Hydraulics Hydraulic Oil Cooler Removal and Replacement

Hydraulic Oil Cooler Removal and Replacement

!MWARNING

INT-3-1-10_2

Note: The hydraulic oil cooler is mounted next to the radiator, and under normal circumstances should require no attention. However, any debris collected on the cooler should be removed.

Removal 1

Position the machine on firm level ground with the bucket resting on the ground. Stop the engine and vent residual pressure from the system by fully operating all control levers.

Remove the hydraulic oil filler cap and drain the hydraulic tank.

Clean the areas around the top and bottom hose connections of the oil cooler to avoid possible contamination of the hydraulic fluid.

Disconnect the top and bottom hoses from the cooler.

A A

Fig 1. 5

Remove the 4 x bolts and washers A securing the oil cooler.

Replacement Replacement is a reversal of the removal procedure. On completion, fill the hydraulic tank, run the engine and check for leaks.

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Section E - Hydraulics Hydraulic Oil Cooler Removal and Replacement

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Section E - Hydraulics Hydraulic Rams Precautions During Use

Hydraulic Rams Precautions During Use TE-006

Installation 1

Precautions when installing the ram on the machine.

b Suspending the ram by the piping is not only dangerous, but can also cause damage to the cylinder. c

Secure the piston rod with a band. It is very dangerous if the rod extends unexpectedly. Also, the rod can be damaged and become unusable. 3

If electric welding is done even at a point away from the ram, there may be sparking inside the ram and it will become necessary to replace the ram with a new one.

If paint adheres to the rod surface or to the wiper ring and the ram is operated, the wiper ring will not function properly and foreign matter and paint can easily enter the ram. This will cause damage to the seals, drastically shortening the life of the ram.

Carry out daily maintenance and inspection. a

Install the ram only when it is clean.

Use only under designated conditions. a

If hydraulic oil other than the designated oil is used, the seals quickly degenerate and become damaged. If the relief valve is set at a value higher than specified, it may cause ram damage and is dangerous.

b In high temperature environments (approx. 90Â°C and above) or low temperature environments (below -20Â°C), seals quickly become damaged. Special seal materials are necessary so check to see if the ram that you are using is suitable or not. c

The number one cause of ram oil leakage is rod damage. Be careful not to damage the rod.

If parts other than genuine JCB parts are used, the desired results may not be obtained. Use only genuine JCB parts.

Caution during dismantling and reassembly. a

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The key point for correct long-term ram function is daily maintenance and inspection. Carry out maintenance and inspection so that the ram functions fully at all times. Always remove any mud, water, dust or oil film adhering to the rod and keep it in normal condition. However, when cleaning the wiper ring and seals, do not get them wet with water but wipe clean with a rag. To prevent rust forming during storage, the amount of exposed ram piston rod should be kept to a minimum. If leaving for more than one week, apply a light coating of suitable grease or petroleum jelly to the exposed part of the ram piston rod.

Use genuine JCB parts when replacing parts. a

Warm up sufficiently before beginning work.

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The installed ram cannot maintain the same position for a long period of time, because the oil inside the ram may leak and the hydraulic oil volume decreases as it cools. Stop or store the machine in a safe and fixed position.

Maintenance, Inspection Points

Caution During Use 1

Before beginning work, always move the ram at full stroke with no load and expel air from the cylinder.

When stopping or storing, do it at a safe and fixed position.

When painting the machine, mask the ram. a

When installing and removing from the machine, suspend the ram safely.

Welding after installing the ram may result in damage. a

In cold conditions the rod seals may be frozen, so if the ram is operated at maximum pressure and maximum speed, the seals will be damaged.

b There is a large amount of air in a new ram or one which has been left for a long time, so the ram will not operate smoothly. Also, if pressure is applied suddenly without bleeding the air, high temperatures will be generated due to adiabatic compression and the seals may burn.

Dismantling the ram while it is still installed on the machine can be dangerous as unexpected movements of the machine can occur. Remove the ram from the machine and then dismantle.

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Section E - Hydraulics Hydraulic Rams Precautions During Use b If reassembled with dirty hands, foreign matter can enter the ram causing a shorter life span and also the other hydraulic equipment may be damaged. Reassemble in a clean state. c

Follow the instructions in the diagrams regarding torque tightening for screwed parts. If the torque is too high or too low, it can cause damage.

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Section E - Hydraulics Hydraulic Rams Removal and Replacement

Removal and Replacement

!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

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Section E - Hydraulics Hydraulic Rams Removal and Replacement

!MWARNING

Boom, Dipper and Bucket Rams Removal 1

With the engine idling, set the machine with the bucket on the ground.

It is not possible to vent all residual pressure. Loosen the connection one full turn and allow the pressure to dissipate. Keep face and hands well clear of pressurised hydraulic oil and wear protective glasses. HYD-4-3

Support the excavator under the angle between the dipper and boom to ensure it will not move when the ram is removed.

On boom and bucket rams, remove the protection plate. Support the ram under the gland bearing and remove locknut A and bolt B from the pivot at the eye end of the ram. Drive out the pivot pin C.

Replacement

Support the ram and remove the locknut A and the bolt B from the pivot at the base of the piston. Drive out the pivot pin C. Disconnect the hoses. Remove the ram from the machine.

Locate the pivot point on the ram into the location on the machine structure. Fit the pivot pin C and secure using the bolt B and new locknut A.

Support the ram under the gland end of the cylinder, reconnect the hoses. With the engine idling, slowly extend the ram until the eye end locates correctly in the machine structure. Fit pin C. Secure using the bolt B and new locknut A.

Apply grease to the pivot points through the grease nipples. For grease specification K Fluids, Lubricants and Capacities ( T 3-12).

Connect the hoses to the cylinder, torque tighten.

On the bucket and boom rams, fit the protection plate and secure using the bolts.

Fig 1. 4

With the engine idling, gently retract the ram rod into the cylinder by operating the relevant service.

Run the engine at idle and with the servo isolator lock in the operate position, move the control lever rapidly in both directions to vent any trapped pressure. Stop the engine.

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Section E - Hydraulics Hydraulic Rams Removal and Replacement

Dozer Ram

Fig 2. 5

Removal 1

Set the machine in the posture shown with the dozer grounded onto suitable supports.

With the starter switch turned OFF, relieve residual hydraulic pressure by operating the hydraulic controls.

Disconnect the hydraulic hoses. Blank off the hoses and the open ports of the ram.

Remove locknut A and the bolt B from the pivot at the rod end of the ram. Support the ram and drive out the pin C. Lower the ram end onto a suitable support.

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Remove locknut D and bolt E. Support the ram and drive out pin F. Carefully remove the ram from the machine.

E - 114

Section E - Hydraulics Hydraulic Rams Removal and Replacement Replacement 1

Locate the pivot point on the base of the ram into the dozer frame.

Fit pivot pin F and secure with bolt E and new locknut D.

Fit the pivot point at the rod end of the ram to the machine.

Fit the pivot pin C and secure using the bolt B and new locknut A.

Apply grease to the pivot points through the grease nipples G.

Connect the hoses to the cylinder.

Note: K Standard Torque Settings ( T 1-5) and K Sealing and Retaining Compounds ( T 1-29) for torque tightening and sealant information.

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Section E - Hydraulics Hydraulic Rams Dismantling and Assembly

Dismantling and Assembly All Rams

bush for damage, scores or nicks. If damaged, the bush must be replaced as part of the end cap assembly.

!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

Dismantling The numerical sequence shown on the illustrations are intended as a guide to dismantling only. For assembly the sequence should be reversed. K Boom Ram ( T E-118)

Ensure that metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the seals.

Check the bore of the ram cylinder for damage.

Discard all seals and â&#x20AC;&#x2DC;O' rings.

Inspection Piston Rod Warp 1

Support the piston rod on a pair of 'V' blocks.

Set a dial test indicator (D.T.I.) at the approximate centre of the rod. Set the D.T.I. to zero.

Rotate the piston rod in its blocks, noting any variation in D.T.I. reading.

If warp (half the difference between maximum and minimum readings) exceeds 0.5 mm (0.02 in) the piston rod must be replaced.

K Dipper Ram ( T E-119) K Bucket Ram ( T E-120) K Dozer Ram ( T E-121) 1

Support ram assembly as shown.

Pivot Bush Clearances 1

Using an internal micrometer measure the internal diameter (I.D.) of the pivot pin bushes in the piston rod and cylinder ends.

Compare the readings with the permitted tolerances shown. Remove and replace pin bushes as necessary.

Fig 3. 2

Slacken end cap 1 using Hook spanner or spanner and remove the piston rod assembly 2 from the cylinder.

Position piston rod assembly on bench in place of ram cylinder. Remove seals 3 and wear rings from piston head.

Undo nut/locking pin and remove / unscrew piston head from rod.

Remove end cap 1 from piston rod and remove the remaining `O' rings and seals. Check the end cap

E - 116

Piston Rod/Rod Bush Clearances 1

Using internal and external micrometers, measure the piston rod outside diameter (O.D.) and the rod bush inside diameter (I.D.).

Compare the readings taken with the permitted clearances. If necessary, renew the piston rod and/or the rod bush.

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Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Pin Bush Clearances 1

Using internal and micrometers, measure the inside diameter (I.D.) of the pin bushes in the piston rod and cylinder ends.

Compare the readings taken with the permitted clearances. Remove and replace pin bushes as necessary.

Assembly 1

Completely remove oil, grease, dirt and hardened locking compound from all threads. Remove all traces of rust using a wire brush.

Apply JCB Activator to threads of piston rod and cylinder. Apply JCB Threadlocker and Sealer to threads of end cap 1. Wait 15 minutes before assembly, using correct torque figures. K Table 1. Torque Settings ( T E-117)

Use new seals and â&#x20AC;&#x2DC;O' rings, lubricated with hydraulic fluid before assembly.

Take care not to damage seals during assembly.

Apply JCB High Strength Threadlocker & Sealer to thread of lock nut / locking pin.

Allow one hour at 20*C before filling the ram with oil. Table 1. Torque Settings Piston Head End Cap

Boom Ram

408 Nm

678 Nm

Dipper Ram

408 Nm

678 Nm

Bucket Ram

450 Nm

678 Nm

Dozer Ram

TBA

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E - 117

Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Boom Ram

4 6 8

10 15 13 14

11 9 12

Fig 4.

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E - 118

Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Dipper Ram

7 8

9 10

1 11

12 13 15

Fig 5.

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E - 119

Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Bucket Ram

6 7

13 11 12

2 Fig 6.

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Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Dozer Ram

6 7

10 12

Fig 7.

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E - 121

Section F Gearboxes Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track and Running Gear Section K - Engine

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Section F - Gearboxs

Notes:

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Section F - Gearboxes Contents Page No. Technical Data General Description ..................................................................................F - 1

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Section F - Gearboxes Contents

F - ii

Page No.

F - ii

Section F - Gearboxes Technical Data General Description

Technical Data General Description This range of Excavators is fitted with three gearboxes, one providing drive for slewing of the upper structure and one each for the machine tracks. The gearboxes produce high speed reduction while maintaining high torque. The slew gearbox is mounted on the main frame of the upper structure and transmits drive to the slew ring. The track gearboxes are mounted onto flanges on the undercarriage side frames and are covered by guards. Drive to the track is transmitted through the gearbox output pinion to the track assembly driven sprocket For removal, replacement, dismantling and Inspection information refer to Section E.

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Section F - Gearboxes Contents

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Section J Track and Running Gear Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track and Running Gear Section K - Engine

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Section 1 - Track and Running Gear

Notes:

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1-2

Section J - Track and Running Gear Contents Page No. Technical Data General Description .................................................................................. J - 1 Steel Track Removal and Replacement ...................................................................... J - 2 Track Guides Introduction ............................................................................................... J - 3 Removal and Replacement ...................................................................... J - 4 Track Rollers (Lower) Removal and Replacement ...................................................................... J - 5 Dismantling and Assembly ....................................................................... J - 6 Track Rollers (Upper) Removal and Replacement ...................................................................... J - 7 Dismantling and Assembly ....................................................................... J - 8 Wear Limits ............................................................................................... J - 9 Track Rollers Track Roller Metallic Face Seals ............................................................ J - 11 Driven Sprocket Removal and Replacement .................................................................... J - 12 Idler and Recoil Unit Removal and Replacement .................................................................... J - 13 Dismantling and Assembly ..................................................................... J - 14

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Section J - Track and Running Gear Contents

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Page No.

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Section J - Track and Running Gear Technical Data General Description

Technical Data General Description P11-J001

The Excavator track and running gear comprises the tracks fitted to the machine, the associated sprockets that transmit drive from the track gearboxes to the tracks and the equipment that provides and maintains the tension of the tracks. The track and running gear is located on and within the machine undercarriage track boxes.

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J-1

Section J - Track and Running Gear Steel Track Removal and Replacement

Steel Track Removal and Replacement 1

Position the machine so that the master pin B is at the front of the track, as shown.

Remove the fastener A and drive out the master pin B.

Lay out the replacement track C, behind the machine. Drive the machine onto the new track, guiding the track over the idler wheel D and roller E, until the ends can be joined.

Fig 2. 5

Fit the master pin B and lock using a new fastener A.

Tension the track. Refer to Track Tensioning, Section 3.

Fig 1.

!MWARNING Ensure that all persons are clear of the track and especially of the driven sprocket during the following operations. TRACK-1-6

Slowly reverse the machine until the track is laid on the ground.

!MWARNING The following operations must only be undertaken by persons familiar with track changing operations and who are qualified to perform the operations. All persons must keep clear of the machine driven sprocket. TRACK-1-7

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Section J - Track And Running Gear Track Guides Introduction

Track Guides Introduction

Fig 1. Track guides are fitted to both sides of each track at the idler wheel position. At the drive hub position they are fitted to the outer side of the track.

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Section J - Track And Running Gear Track Guides Removal and Replacement

Removal and Replacement

Fig 2.

Removal Remove the bolts A securing the guide brackets B to the subframe, remove the bracket from the subframe.

Replacement Replace in the reverse order of removal.

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Section J - Track and Running Gear Track Rollers (Lower) Removal and Replacement

Track Rollers (Lower) Removal and Replacement Removal

Fig 2. 1

Set the machine in the posture shown. Fit suitable supports under the machine lower structure. If necessary adjust the track tension to allow the track to become clear of the rollers.

Replacement 1

Fit the rollers in the reverse sequence to removal. Torque tighten the fittings.

Refit and tension the track.

Remove the supports and lower the tracks to the ground.

Item

Table 1. Torque Settings Nm lbf ft

kgf m

244

180

244

180

Fig 1. 2

Remove the bolts C, D and washers E. Lower the roller assembly F from the machine.

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J-5

Section J - Track and Running Gear Track Rollers (Lower) Dismantling and Assembly

Dismantling and Assembly

Fig 3.

Dismantling

Remove semi circular clips 1 from grooves in end of shaft.

Remove 'Oâ&#x20AC;&#x2122; rings 2 from roller shaft 3 and remove shaft.

Pry off end caps 4 and drain roller of oil.

Maintain metallic face seals 5 in original pairs.

If necessary remove bearing bushes 6.

Check contact area of metallic face seals 5. K Track Roller Metallic Face Seals ( T J-11).

Assembly 1

Install bearing bushes 6 into roller shell.

Fit one pair of metallic face seals 5 to end cap and roller shell.

Replace roller shaft 3 through roller end cap. Renew 'O' rings 2 on roller shaft.

Replace semi circular clip 1 in roller shaft groove.

Remove filler plug 7 in end cap, fill roller casing with 160cc of JCB Special Gear Oil.

Inspection 1

Check that the roller diameters at the outer edges are within permitted limits. Re-new as necessary.

Check that the roller bearing bushes 6 are not marked or worn oval. Renew as necessary.

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Section J - Track and Running Gear Track Rollers (Upper) Removal and Replacement

Track Rollers (Upper) Removal and Replacement Removal

Fig 2. 1

Set the machine in the posture shown. Fit suitable supports under the machine lower structure. If necessary adjust the track tension to allow the track to become clear of the rollers.

Replacement 1

Fit the rollers in the reverse sequence to removal. Torque tighten the fittings.

Refit and tension the track.

Remove the supports and lower the tracks to the ground.

Item

Table 1. Torque Settings Nm lbf ft

kgf m

244

180

244

180

Fig 1. 2

Remove the bolts C, D and washers E. Lower the roller assembly F from the machine.

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J-7

Section J - Track and Running Gear Track Rollers (Upper) Dismantling and Assembly

Dismantling and Assembly

Fig 3.

Dismantling

Assembly

Remove semi circular clips 1 from grooves in end of shaft.

Install bearing bushes 6 into roller shell.

2 2

Remove 'Oâ&#x20AC;&#x2122; rings 2 from roller shaft 3 and remove shaft.

Fit one pair of metallic face seals 5 to end cap and roller shell.

3 3

Pry off end caps 4 and drain roller of oil.

Replace roller shaft 3 through roller end cap. Renew 'O' rings 2 on roller shaft.

Maintain metallic face seals 5 in original pairs.

Replace semi circular clip 1 in roller shaft groove.

If necessary remove bearing bushes 6.

Remove filler plug 7 in end cap, fill roller casing with 160cc of JCB Special Gear Oil.

Inspection 1

Check that the roller diameters at the outer edges are within permitted limits. Re-new as necessary.

Check that the roller bearing bushes 6 are not marked or worn oval. Renew as necessary.

Check contact area of metallic face seals 5. K Track Roller Metallic Face Seals ( T J-11).

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Section J - Track and Running Gear Track Rollers (Upper) Wear Limits

Wear Limits JS200 - 260 Nominal Pitch

190.00mm Dimension A (mm)

J-9

Wear

Normal Impact

120.00

10%

118.90

20%

117.70

30%

116.60

40%

115.40

50%

114.20

60%

113.10

70%

111.90

80%

110.90

90%

109.00

100%

107.20

110%

105.40

120%

103.50

Fig 4.

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Section J - Track and Running Gear Track Rollers (Upper) Wear Limits

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Section J - Track and Running Gear Track Rollers Track Roller Metallic Face Seals

Track Rollers Track Roller Metallic Face Seals P11-J002

When Removing

Inspection

!MCAUTION

Avoid skin contact with surface 'A' as corrosion may be caused.

If contact area A is undamaged, estimate remaining life wear as follows:

GEN-3-10

New seals- Contact area is a narrow band at outer edge.

Retain face seals in pairs when they are removed. Fit as matched pairs if suitable for further use.

Partly worn seals - Contact area is wider but does not extend full width. Scrap seals - Contact area is worn to full width. 2

Renew pair of seals if contact surface is scratched, pitted or corroded.

Examine outer edges B, housing ramp C and lip D. Carefully polish away light damage or corrosion.

When Replacing Note: Do not allow oil to come into contact with the 'O' rings or housings until the assembly is complete. Thoroughly clean and dry seals, 'O' rings and housings before fitting seals as follows: 1

Fit 'O' rings onto the seals, check that they seat evenly and are not twisted.

Press 'O' ring past lip D. Check that dimension is constant around the circumference of seal.

Immediately before final assembly, clean dust etc. from surface A and lightly coat with clean oil of the appropriate grade.

Fig 1.

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Section J - Track and Running Gear Driven Sprocket Removal and Replacement

Driven Sprocket Removal and Replacement Removal

Inspection

Set up the machine and remove the track. Clean off all dirt and accumulated debris.

Remove the bolts A.

Replacement

Remove driven sprocket C from the track gearbox D.

Install the driven sprocket C onto the track gearbox D.

Using locking fluid on the bolt threads, torque tighten the bolts A in a diagonal sequence K Table 1. Torque Settings ( T J-12).

Fit the track.

Check that the driven sprocket conforms to permitted tolerances.

Item A

Table 1. Torque Settings Nm lbf ft 137

101

kgf m 14

Fig 1.

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J - 12

Section J - Track and Running Gear Idler and Recoil Unit Removal and Replacement

Idler and Recoil Unit Removal and Replacement Removal

Set the machine to remove the track.

Undo the recoil adjusting valve nut B to relieve the grease pressure.

Replacement

Carefully raise and support the dozer clear of the track to give sufficient clearance for the removal of the idler wheel. Support the dozer ram and disconnect the dozer from the ram.

Lift the idler and recoil assembly clear of the machine undercarriage.

Install the idler and recoil assembly into the machine undercarriage.

Reconnect the dozer to the dozer ram.

Fit the track to the machine.

Set the track tension A. Refer to Track Tensioning, Section 3.

Fig 1.

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Section J - Track and Running Gear Idler and Recoil Unit Dismantling and Assembly

Dismantling and Assembly Dismantling

Note: If smooth faced idlers are to be rebuilt it is recommended that they are changed in pairs for the later sprocket type.

Inspection

Remove and discard the wiper seal W, spacer X and O ring Y.

Examine the spring U for cracks and distortion. Renew if necessary.

K Fig 2. ( T J-15). 1

Remove bolts B and spring washers C, separate the idler sprocket from yoke D.

Examine the cylinder Q for wear or damage. Renew if necessary.

Drive out the pins E.

Examine the cap V for wear or damage. Renew if necessary.

Remove the idler brackets F.

Remove the lip seals G and circlips H.

Remove the screw J with washer K.

!MWARNING The recoil unit spring can cause serious injury if suddenly released. Take great care when removing and replacing the spring retaining nut. Scrap recoil units must be dismantled before transfer from the workshop Do not use flame cutting equipment unless precautions are taken to release the spring pressure slowly. TRACK-1-9

Using a hide faced mallet, drive out the shaft L and one of the bearings M. Press the remaining bearing M from the idler sprocket N.

Withdraw the piston rod P from the cylinder Q.

Ensure all old grease is removed from the cylinder Q.

Slacken the locking bolt R from the nut T.

Using a 2.5 to 3.0 tonne press, compress the spring U and remove the nut T.

Carefully release the pressure on the unit. Remove the cap V and the spring U from the cylinder Q.

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Section J - Track and Running Gear Idler and Recoil Unit Dismantling and Assembly

D L

E M B

C R

K L F

L L

U Q

Y W

X Fig 2.

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J - 15

Section J - Track and Running Gear Idler and Recoil Unit Dismantling and Assembly

Assembly

Carefully push in the piston rod P until grease is emitted continuously from the valve orifice.

!MWARNING The recoil unit spring can cause serious injury if suddenly released. Take great care when removing and replacing the spring retaining nut.

Remove the grease nipple from the valve A and fit valve A into cylinder Q. Ensure that grease flows from valve A then fit the grease nipple to valve A.

Slide the spring U with plate V over the cylinder Q.

Scrap recoil units must be dismantled before transfer from the workshop

Use the 2.5 to 3.0 tonne press to compress the spring to a length as below at X. Check compression load

Do not use flame cutting equipment unless precautions are taken to release the spring pressure slowly.

Install the nut T and secure with the locking bolt R at the correct hole position in the cylinder.

TRACK-1-9

Note: There are two set positions for the locking bolt and nut. These are different for steel or rubber tracks. The nuts are marked R and S.

K Fig 2. ( T J-15). 1

Install the idler shaft L into the idler sprocket N.

Fit new bearings M in the idler sprocket N over the idler shaft L.

Secure the bearings M with the circlips H.

Fit new lip seals G to the idler sprocket N over the idler shaft L.

Fill the idler assembly with JCB gear oil HD90 through the capscrew J hole.

Fit a new bonded washer K and the capscrew J into the idler sprocket N.

Position the idler brackets F over the idler shaft Lwith the holes for the tension pin E aligned.

Drive in the tension pins E to secure the idler brackets to the idler shaft L.

Fit the yoke D to the idler brackets F with the bolts B and spring washers C.

Lubricate the new seal X, O-ring Y and new wiper seal W with MPL grease and install them in the cylinder Q.

Release the spring assembly from the press

Install the idler and recoil assembly into the machine undercarriage.

Reconnect the dozer to the dozer ram.

Fit the track to the machine.

Set the track tension. Table 1. Idler Recoil Spring length X 263 mm (10.5 in)

Fig 3. 23

Fully pack the cylinder Q with JCB MPL grease.

Slide the piston rod P in to the cylinder Q.

Prime the piston rod P with JCB MPL grease to ensure that there are no trapped air pockets.

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Secure nut T with a new cotter pin S.

J - 16

Section K Engine Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track and Running Gear Section K - Engine

Publication No.

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Section K - Engine

Notes:

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Section K - Engine Contents Page No. Technical Data General .................................................................................................... K - 1

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Section K - Engine Contents

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Page No.

K - ii

Section K - Engine Technical Data General

Technical Data General Model

ISUZU 4JG1PBW

Type

Vertical in-line, 4 cylinder, normally aspirated, 4 stroke, water cooled diesel.

Displacement

3.059 litres (3059cm3) (186.7in3)

Bore

95.4 mm (3.8 in)

Stroke

107 mm (4.2 in)

Firing order

1, 3, 4, 2

Power output

43.0 kW (57.7hp) @ 2200 rev/min

Valve clearance (cold)

0.40 mm (0.0157 in)

Compression ratio

18.6 : 1

Compression pressure

3.04 MPa (31kgf/cm2 ) (441psi)

Idling speed

1150 rev/min

Maximum no - load speed

2450rev/min

Rated speed

2200 rev/min

Note: For further details of the engine refer to Engine Service Manual 9806/2180.

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Section K - Engine Technical Data General

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