JCB Backhoe Loader 3DX, 4DX India Service Manual - PDF DOWNLOAD by www.heydownloads.com

Service Manual 3DX / 4DX Backhoe Loader Service Manual - 3DX / 4DX Backhoe Loader Section 1 - General Information Section 2 - Operator’s Manual Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering

Publication No.

9813/2050-5

World Class Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Section 1 General Information Service Manual - 3DX / 4DX Backhoe Loader Section 1 - General Information Section 2 - Operator’s Manual Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine

Publication No.

9813/2050-5

Section 1 - General Information

Notes:

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9813/2050-5

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Section 1 - General Information Contents Page No. Introduction About this Publication ................................................................................ 1-1 Machine Nomenclature .........................................................................1-1 Machine Identification Machine Identification Plate ....................................................................... 1-3 Typical Engine Identification Number ....................................................1-3 Rear Axle Serial Plate ...........................................................................1-4 Front Axle Serial Plate ...........................................................................1-4 Synchro Shuttle Gearbox Serial Plate ...................................................1-5 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-7 Introduction ............................................................................................1-7 Bolts and Screws ...................................................................................1-7 Hydraulic Connections ............................................................................. 1-11 'O' Ring Face Seal System .................................................................. 1-11 'Torque Stop' Hose System .................................................................1-14 `Quick-Connect' Pilot Hoses .................................................................... 1-15 Disconnecting ......................................................................................1-15 Connecting ..........................................................................................1-15 Service Tools Numerical List .......................................................................................... Section B ................................................................................................. Section C ................................................................................................. Section E ................................................................................................. Section F ................................................................................................. Section H ................................................................................................. Section K .................................................................................................

1-17 1-20 1-24 1-25 1-33 1-42 1-43

Service Aids Sealing and Retaining Compounds ......................................................... 1-45 Terms and Definitions Colour Coding .......................................................................................... 1-47 Hydraulic Schematic Colour Codes .....................................................1-47

1-i

Introduction About this Publication This publication is designed for the benefit of JCB Dealer Service Engineers who are receiving, or have received, training by JCB India Product Support Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earth moving equipment. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST

for dry threads, hence for lubricated threads the figures may be reduced by one third. 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing for wards.

Machine Nomenclature In this Service Manual, reference is made to machine models,e.g. 3DX.3DX.Super and 3DXL these are Indian model names.

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:

Table 1. Attachments

Body and Framework etc.

Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. All sections are listed on the front cover Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are

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Introduction About this Publication

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Section 1 - General Information Machine Identification Machine Identification Plate

Machine Identification Machine Identification Plate Your machine has an identification plate mounted on the loader tower K Fig 1. ( T 1-3). The serial numbers of the machine and its major units are stamped on the plate. The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered.

Typical Engine Identification Number Engine data labels A are located on the cylinder block at position C and rocker cover D (if fitted). The data label contains important engine information and includes the engine identification number E. A typical engine identification number is explained as follows:

The machine and engine serial numbers can help identify exactly the type of equipment you have.

320/40001

00001

1 JCB MACHINE SERIAL NO.

Engine Type

MONTH & YR OF MFG.

ENGINE SERIAL NO.

FRONT AXLE SERIAL NO.

HYDRAULIC PUMP SERIAL NO.

REAR AXLE SERIAL NO.

CHASSIS NO.

GEAR BOX SERIAL NO.

SA = naturally aspirated. SB = turbocharged. SC = turbocharged and intercooled. SD = turbocharged.

JCB INDIA LIMITED 23/7 MATHURA ROAD BALLABGARH-12004 (INDIA)

SE = electronic common turbocharged and intercooled.

rail

fuel

injection,

SF = turbocharged and intercooled. 2

Engine part number

Country of manufacture

D026260

Fig 1. To December 2012

U = United Kingdom

PRODUCT IDENTIFICATION NO.

MONTH & YR OF MFG.

JCB MACHINE SERIAL NO.

FRONT AXLE SERIAL NO.

ENGINE SERIAL NO.

REAR AXLE SERIAL NO.

HYDRAULIC PUMP SERIAL NO.

GEAR BOX SERIAL NO.

CHASSIS NO.

Engine Serial Number

Year of Manufacture

The last three parts of the engine identification number are stamped on the cylinder block at position B.

JCB INDIA LIMITED 23/7 MATHURA ROAD BALLABGARH-12004 (INDIA)

00001

D026260-1

Fig 2. From January 2013

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Section 1 - General Information Machine Identification Machine Identification Plate

Front Axle Serial Plate

D B

Fig 5.

The front axle serial number is stamped on a plate mounted on the axle K Fig 5. ( T 1-4).

Fig 3. Engine

Rear Axle Serial Plate

Fig 4. Rear Axle The rear axle serial number is stamped on plate mounted to the front face of the axle, as shown K Fig 4. ( T 1-4)

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Section 1 - General Information Machine Identification Machine Identification Plate

Synchro Shuttle Gearbox Serial Plate The Synchro Shuttle serial number is stamped on a label which is mount adjacent to the Suction strainerK Fig 6. ( T 1-5).

Fig 6.

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Section 1 - General Information Machine Identification Machine Identification Plate

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

Torque Settings Zinc Plated Fasteners and Dacromet Fasteners T11-002

Introduction

Bolts and Screws

Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.

Use the following torque setting tables only where no torque setting is specified in the text.

The two types of fasteners can be readily identified by colour and part number suffix. K Table 2. Fastener Types ( T 1-7).

Torque settings are given for the following conditions:

Fastener Type

Table 2. Fastener Types Colour Part No. Suffix

Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate.

Condition 1 – Un-lubricated fasteners – Zinc fasteners – Yellow plated fasteners

Zinc and Yellow

Golden finish

'Z' (e.g. 1315/3712Z)

Dacromet

Mottled silver finish 'D' (e.g. 1315/3712D)

Condition 2 – Zinc flake (Dacromet) fasteners

Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener. Note: A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt.

– Lubricated zinc and yellow plated fasteners – Where there is a natural lubrication. For example, cast iron components

Verbus Ripp Bolts

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. Note: Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.

1-7

Fig 7. 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 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 3. 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 4. Torque Settings - Metric Grade 8.8 Fasteners Hexagon (A/F) Condition 1

Bolt Size ISO Metric Thread

5.8

9.9

24.0

M10

47.0

1-8

Condition 2

kgf m

Condition 2

lbf ft

kgf m

lbf ft

0.6

4.3

5.2

0.5

3.8

1.0

7.3

9.0

0.9

6.6

2.4

17.7

22.0

2.2

16.2

4.8

34.7

43.0

4.4

31.7

M12

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 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 5. 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 6. 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 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 7. 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 8. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size

1-10

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 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 9. Torque Settings - BSP Adaptors BSP Adaptor Hexagon (A/F) Size

1-11

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 10. 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 Torque Settings Hydraulic Connections Hoses Screwed into Adaptors

Fig 8. Hoses 8-B screwed into adaptors 8-A seal onto an `O' ring 8-C which is compressed into a 45Â° seat machined into the face of the adaptor port.

BSP Hose Size in.

1-12

Note: Dimension 8-D will vary depending upon the torque applied.

Table 11. 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

1-12

Section 1 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 12. BSP Adaptors with Bonded Washers - Torque Settings BSP Size

1-13

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 Torque Settings Hydraulic Connections

'Torque Stop' Hose System

Fig 9. `Torque Stop' Hoses 9-B screwed into adaptors 9-A seal onto an 'O' ring 9-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 9-D, which acts as a physical stop. Note: Minimum dimension 9-E fixed by shoulder 9-D.

Table 13. BSP `Torque Stop' Hose - Torque Settings BSP Hose Size Hexagon (A/F)

1-14

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 Torque Settings `Quick-Connect' Pilot Hoses

`Quick-Connect' Pilot Hoses Some pilot hoses have quick-connect couplings. This type of coupling requires a special tool to release it.

B Fig 10.

Disconnecting 1

Push on the pilot hose A in the direction shown, and insert the correct tool B. See Service Tools.

Push on the hose, and at the same time use the tool as a lever to release the coupling.

Connecting 1

Make sure that the hose coupling is clean and the Orings are not damaged. Apply some clean hydraulic fluid to the O-rings.

Align the coupling directly to the hydraulic port. Push the coupling into the port as far as it will go. The coupling will click when it is fully engaged.

Pull on the hose to verify that the coupling is fully engaged. If the connection is not good the coupling will release very easily.

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Section 1 - General Information Torque Settings `Quick-Connect' Pilot Hoses

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Section 1 - General Information Service Tools Numerical List

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. Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.

Part Number

Description

Tool Detail Reference - see Section:

AVO Test Kit - see tool detail reference for content

Bonded Washers - see tool detail reference for content

Female Cone Blanking Plugs - see tool detail reference for content

Female Connectors - see tool detail reference for content

Hydraulic Flow Test Equipment - see tool detail reference for content

Hydraulic Hand Pump Equipment - see tool detail reference for content

Male Adaptors - BSP x BSP - see tool detail reference for content

Male Adaptors - BSP x NPT (USA only) - see tool detail reference for content

Male Cone Blanking Caps - see tool detail reference for content

Pressure Test Points - `T' Adaptors - see tool detail reference for content

Pressure Test Points - Adaptors - see tool detail reference for content

Rivet Nut Tool - see tool detail reference for content

825/10053

Pilot hose release tool - for quick-connect hose fittings

892/01160

Engine lifting bracket (2-off)

4104/1310

Hand Cleaner

460/15708

Flow test adaptor - Powershift - Other components required, see tool detail

716/30313

Test relay - with LED indicator

721/10885

Interconnecting cable - use with 892/01033

825/10035

Adaptor plate spanner - viscous cooling fan

825/10036

Fan coupling spanner - viscous cooling fan

892/00011

Spool Clamp

892/00167

Ram Protection Sleeve for 90 mm Rod Diameter

892/00180

Seal Fitting Tool - Hydraulic Steer Unit

892/00181

Replacement Plastic Boss for 892/00180

892/00252

Test Block for Loader Valve A.R.V. (214e & 3C Machines Only)

892/00253

Hydraulic Pressure Test Kit - see tool detail reference for content

E, F

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Section 1 - General Information Service Tools Numerical List Part Number

Description

892/00268

Flow monitoring unit - Other components required, see tool detail

892/00301

Flow test adaptor - Synchro Shuttle - Other components required, see tool detail

892/00309

A.R.V. Pressure Test Kit - see tool detail reference for content

892/00334

Ram Seal Fitting Tool

892/00812

Drive coupling spanner

892/00822

Splined bolt socket

892/00842

Glass Lifter

892/00843

Folding Stand for Holding Glass

892/00844

Long Knife

892/00845

Cartridge Gun

892/00846

Glass Extractor (Handles)

892/00847

Nylon Spatula

892/00848

Wire Starter

892/00849

Braided Cutting Wire

892/00881

Valve Spool Seal Fitting Tool

892/00913

Grease gun attachment - Use where access to the grease nipple is restricted E.g. F Axle driveshaft universal joints

892/00964

Test point 1/8 BSP Powershift

892/00965

Test point 3/8 BSP Powershift

892/00966

Test point 1/4 BSP Synchro Shuttle

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

892/01033

Electronic service tool kit - also requires 721/10885

892/01042

Nitrogen Charging Tool Kit

892/01094

Transmission jack - support plates also required, see tool detail

892/01096

Speed sensor test harness - Powershift

892/01110

Torque converter alignment tool

1-18

Tool Detail Reference - see Section:

9813/2050-5

1-18

Section 1 - General Information Service Tools Numerical List Part Number

Description

Tool Detail Reference - see Section:

926/15500

Rubber Spacer Blocks

992/04000

Torque Multiplier

992/09100

Excavator Spool Clamp

992/09300

Hexagon Spanner 55mm A/F

E, H

992/09400

Hexagon Spanner 65mm A/F

E, H

992/09500

Hexagon Spanner 75mm A/F

E, H

992/09600

Hexagon Spanner 85mm A/F

E, H

992/09700

Hexagon Spanner 95mm A/F

E, H

992/09900

Hexagon Spanner 115mm A/F

E, H

992/10000

Hexagon Spanner 125mm A/F

E, H

992/12300

12V Mobile Oven

992/12400

24V Static Oven (2 Cartridge)

992/12600

24V Static Oven (6 Cartridge)

992/12800

Cut-Out Knife

992/12801

`L' Blades

993/68100

Slide Hammer Kit - see tool detail reference for content

993/85700

Battery Tester

998/11051

Digital Pressure Test Set (1)

(1) Only required for Joystick Control (Servo) machines.

1-19

9813/2050-5

1-19

Section 1 - General Information Service Tools Section B

Section B Note: Not all service tools are illustrated.

Fig 11. 993/68100 Slide Hammer Kit 1

993/68101

Slide Hammer

993/68107

Bar - M20 x M20 X 800 mm

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 12. Rivet Nut Tool

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9813/2050-5

1-20

Section 1 - General Information Service Tools Section B

Fig 13. 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 16. 892/00846 Glass Extractor (Handles) Used with braided cutting wire to cut out broken glass. K Fig 19. ( T 1-22).

Fig 17. 892/00847 Nylon Spatula

Fig 14. 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 18. 892/00848 Wire Starter Used to access braided cutting wire through original polyurethane seal. K Fig 19. ( T 1-22).

Fig 15. 892/00845 Cartridge Gun Hand operated. Essential for the application of sealants, polyurethane materials etc.

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9813/2050-5

1-21

Section 1 - General Information Service Tools Section B

Fig 19. 892/00849 Braided Cutting Wire

Fig 22. 992/12400 Static Oven 240V

Consumable heavy duty cut-out wire used with the glass extraction tool. K Fig 16. ( T 1-21). 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 20. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.

Fig 23. 992/12800 Cut-Out Knife Used to remove broken glass.

Fig 21. 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).

1-22

Fig 24. 992/12801 'L' Blades 25 mm (1 in.) cut. Replacement blades for cut-out knife. K Fig 23. ( T 1-22). Unit quantity = 5 off.

9813/2050-5

1-22

Section 1 - General Information Service Tools Section B

Fig 25. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub).

1-23

9813/2050-5

1-23

Section 1 - General Information Service Tools Section C

Section C

Fig 29. 993/85700 Battery Tester

Fig 26. 892/00298 Fluke Meter

Fig 27. 892/00285 Hydraulic Temperature Probe

Fig 30. 998/11051 Digital Pressure Test Set

Fig 28. 892/00284 Venture Microtach Digital Tachometer

1-24

9813/2050-5

1-24

Section 1 - General Information Service Tools Section E

Section E 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 31. 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

1/2 in. x 3/8 in.

Fig 32. Pressure Test Adapters

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

Fig 33. Pressure Test 'T' Adapters

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1-25

Section 1 - General Information Service Tools Section E

Fig 34. '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 35. 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 36. 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 37. Female Connectors

Fig 38. Bonded Washers

1-26

1406/0021

3/4 in. BSP

1406/0029

1.1/4 in. BSP

9813/2050-5

1-26

Section 1 - General Information Service Tools Section E

Fig 39. 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 40. 892/00334 Ram Seal Fitting Tool 5mm

m 3m

110mm 175mm 3o

Fig 41. 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

1-27

1.4

Fig 42. 892/01027 Piston Seal Assembly Tool

9813/2050-5

1-27

Section 1 - General Information Service Tools Section E Note: No longer available, refer to 998/11046 JCB ServiceMaster Flow Test Kit. K Fig 56. ( T 1-34).

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 43. 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

1606/0012

Adapter 1 in M x 3/4 in M BSP

816/20013

Adapter 3/4 in F x 1 in M BSP

998/11047

600 LPM Flow Turbine with Loading Valve

998/11048

1-7/8" UNF x1 - 1/4" BSP Flow Block Adaptors x2

998/11049

Carrying Case for Flow Test Kit

998/11050

Temperature Sensor (125Â°C Max)

Fig 44. 998/11046 JCB ServiceMaster Flow Test Kit

1-28

9813/2050-5

1-28

Section 1 - General Information Service Tools Section E Note: No longer available, refer to 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit. K Fig 46. ( T 1-29).

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

998/11052

Hand Held 4-Channel ServiceMaster Unit

998/11053

SensoWin Software Kit and PC Cable

998/11054

Equiment Case SCC-750

998/11055

0-600 Bar Pressure Transduce x2

998/11056

0-100 Bar pressureTransducer x2

998/11057

RPM Tachometer (includes fixed cable, 2 meters)

998/11058

5 Meter Connecting Cable

998/11059

M16 Metric Adaptors for Test Points x4

998/11060

400mm Test Hose 90Â° HSP to M16 x2

998/11061

400mm Test Hose Straight HSP to M16 x2

Fig 45. 892/ 00253 Hydraulic Circuit Pressure Test Kit

Fig 46. 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit

1-29

9813/2050-5

1-29

Section 1 - General Information Service Tools Section E 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

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)

892/00280

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

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

Fig 47. Hand Pump Equipment

Fig 48. Hydraulic Circuit Test Gauges and Connections

Fig 50. Spool Clamps 992/09100

Excavator Spool Clamp

892/00011

Spool Clamp

Fig 49. 892/00881 Valve Spool Seal Fitting Tool

1-30

9813/2050-5

1-30

Section 1 - General Information Service Tools Section E

Fig 51. 892/00252 Test Block for Loader Valve A.R.V. (214e)

Fig 53. 892/00309 A.R.V. Pressure Test Kit For 4CX Variable Flow machines use 25/201103 1

892/00340 Test Block Body

892/00341 Setting Body

993/68300 Adjusting Pin

892/00343 Spanner

892/00345 Anti-cavitation Lock Out Bung

892/00335 A.R.V. Cartridge Removal Tool

Fig 52. 892/01042 Nitrogen Charging Tool Kit 892/01043

1-31

Connector

9813/2050-5

1-31

Section 1 - General Information Service Tools Section E

Fig 54. 825/10053 Pilot Hose Release Tool 892/01043

1-32

Connector

9813/2050-5

1-32

Section 1 - General Information Service Tools Section F

Section F Note: Not all service tools are illustrated.

1-33

9813/2050-5

1-33

Section 1 - General Information Service Tools Section F Note: No longer available, refer to 998/11046 JCB ServiceMaster Flow Test Kit. K Fig 56. ( T 1-34).

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 55. 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

1606/0012

Adapter 1 in M x 3/4 in M BSP

816/20013

Adapter 3/4 in F x 1 in M BSP

998/11047

600 LPM Flow Turbine with Loading Valve

998/11048

1-7/8" UNF x1 - 1/4" BSP Flow Block Adaptors x2

998/11049

Carrying Case for Flow Test Kit

998/11050

Temperature Sensor (125Â°C Max)

Fig 56. 998/11046 JCB ServiceMaster Flow Test Kit

1-34

9813/2050-5

1-34

Section 1 - General Information Service Tools Section F Note: No longer available, refer to 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit. K Fig 46. ( T 1-29).

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

998/11052

Hand Held 4-Channel ServiceMaster Unit

998/11053

SensoWin Software Kit and PC Cable

998/11054

Equiment Case SCC-750

998/11055

0-600 Bar Pressure Transduce x2

998/11056

0-100 Bar pressureTransducer x2

998/11057

RPM Tachometer (includes fixed cable, 2 meters)

998/11058

5 Meter Connecting Cable

998/11059

M16 Metric Adaptors for Test Points x4

998/11060

400mm Test Hose 90Â° HSP to M16 x2

998/11061

400mm Test Hose Straight HSP to M16 x2

Fig 57. 892/ 00253 Hydraulic Circuit Pressure Test Kit

Fig 58. 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit

1-35

9813/2050-5

1-35

Section 1 - General Information Service Tools Section F

3 4 6 5

Fig 60. 892/00301 Flow Test Adaptor Note: Components listed as follows also required

Item

Description

892/00920 Adaptor

892/00302 Adaptor

A313250-C1

Fig 59. 460/15708 Flow Test Adaptor Note: Components listed below also required Item

Description

460/15707 Banjo bolt

2401/0222 O-ring

2403/0110 O-ring

2403/0108 O-ring

1604/0004 Adaptor - 2 off

1406/0018 Sealing washer - 2 off

1-36

9813/2050-5

1-36

Section 1 - General Information Service Tools Section F

Fig 64. 892/00913 Grease Gun Attachment

Fig 61. 892/00812 Drive Coupling Spanner

Fig 62. 892/00822 Splined Bolt Socket

Fig 65. 892/00964 Test Point 1/8 BSP

Fig 63. 992/04000 Torque Multiplier

Fig 66. 892/00965 Test Point 3/8 BSP

Fig 67. 892/00966 Test Point 1/4 BSP

1-37

9813/2050-5

1-37

Section 1 - General Information Service Tools Section F

E F

A406130-C2

Fig 70. 721/10885 Interconnecting Cable Use with 892/01033

A406130-C1

Fig 68. 892/01033 Electronic Test Kit Note: Also requires 721/10885 interconnecting cable Item

Description

Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and laptop PC loaded with the applicable ShiftMaster diagnostics software

Interconnecting cable, DLA to laptop PC. Several cables are included to enable compatibility with different PC port types

Kit carrying case

711300-C1

Fig 69. 892/01096 Speed Sensor Test Harness

1-38

9813/2050-5

1-38

Section 1 - General Information Service Tools Section F

A402680

Fig 71. 892/01094 Transmission Jack When removing the Powershift gearbox use of a special transmission jack is strongly recommended. This jack can also be used when removing Synchro Shuttle gearboxes. Note: The jack must be used with special support plates. Manufacture the plates locally, refer to Figs 72,73 and 74. Rear Jack Plate - 4 and 6 speed Powershift - Manufacture locally from 5 mm thick mild steel plate.

A706940-C1

Fig 72.

1-39

9813/2050-5

1-39

Section 1 - General Information Service Tools Section F Front Jack Plate - 6 speed Powershift - Manufacture locally from 5 mm thick mild steel plate.

A706940-C2

Fig 73. Front Jack Plate - 4 speed Powershift - Manufacture locally from 5 mm thick mild steel plate.

A706940-C3

Fig 74.

1-40

9813/2050-5

1-40

Section 1 - General Information Service Tools Section F

370.0

65.0

185.0

A 171.0 0.3 X 2 DOWELS 8 x 32 LONG PRESS FIT

SECTION

A-A

TYP

30.2 30.1

X 8.0 REF 2 DOWELS

10.0

1.0

10.0

12.0

0.3

43.4 43.3

10.0

3 x 35(25)

x 45

57.0 5

TYP

342.0

A436700

Fig 75. 892/01110 Torque Converter Alignment Tool Note: Use with 12" and W300 torque converters

1-41

9813/2050-5

1-41

Section 1 - General Information Service Tools Section H

Section H

Fig 77. Hexagon Spanners For ram pistons and end caps Fig 76. 892/00180 - Seal Fitting Tool Seal Fitting Tool for fitting 'O' ring and back-up ring to Danfoss Orbitrol Unit. 892/00181 - Replacement Plastic Boss

1-42

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

9813/2050-5

1-42

Section 1 - General Information Service Tools Section K

Section K

Fig 78. 892/01160 Lifting Bracket (2-off)

Fig 79. Spanners for Viscous Cooling Fan 825/10035 - Adaptor Plate Spanner 825/10036 - Fan Coupling Spanner

1-43

9813/2050-5

1-43

Section 1 - General Information Service Tools Section K

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1-44

9813/2050-5

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Section 1 - General Information Service Aids Sealing and Retaining Compounds

Service Aids Sealing and Retaining Compounds T11-001_4

Table 14. Type

Description

JCB Multi-Gasket

A medium strength sealant suitable for all sizes of 4102/1212 gasket flanges, and for hydraulic fittings of 25-65 mm diameter.

50 ml

JCB High Strength Threadlocker

A high strength locking fluid for use with threaded 4102/0551 components. Gasketing for all sizes of flange where the strength of the joint is important.

50 ml

JCB Retainer (High Strength)

For all retaining parts which are unlikely to be dismantled.

4101/0601

10 ml

4101/0651

50 ml

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

4101/0250

10 ml

4101/0251

50 ml

JCB Threadlocker and Sealer (High Strength)

A high strength locking fluid for sealing and retaining 4101/0550 nuts, bolts, and screws up to 50 mm diameter, and 4101/0552 for hydraulic fittings up to 25 mm diameter.

10 ml 200 ml

JCB Threadseal

A medium strength thread sealing compound.

4102/1951

50 ml

JCB Activator

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

4104/0251

200 ml (Aerosol)

4104/0253

1 ltr (Bottle)

JCB Cleaner/Degreaser

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

4104/1557

400 ml (Aerosol)

Direct Glazing Kit

For one pane of glass; comprises of:

993/55700

JCB Threadlocker and Sealer

Part No.

Quantity

– 1 x Ultra Fast Adhesive (310 ml) – 1 x Active Wipe 205 (30 ml) – 1 x Black Primer 206J (30 ml) – plus applicator nozzle etc. Ultra Fast Adhesive

For direct glazing.

4103/2109

310 ml

Active Wipe 205

For direct glazing.

4104/1203

250 ml

Black Primer 206J

For direct glazing.

4201/4906

30 ml

Clear Silicone Sealant

To seal butt jointed glass.

4102/0901

Plastic to Metal Bonder

To seal plastic to metal joints.

4103/0956

50 g

Black Polyurethane Sealant

To finish exposed edges of laminated glass.

4102/2309

310 ml

1-45

9813/2050-5

1-45

Section 1 - General Information Service Aids Sealing and Retaining Compounds

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1-46

9813/2050-5

1-46

Section 1 - General Information

Terms and Definitions Colour Coding Hydraulic Schematic Colour Codes T11-006

The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications.

Red

Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and MRV operating pressure.

Pink

Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red.

Orange

Blue

Green

Light Green

Yellow

1-47

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

Neutral: Neutral circuit pressure.

Exhaust

Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).

Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).

9813/2050-5

1-47

Section 1 - General Information Terms and Definitions Colour Coding

Page left intentionally blank

1-48

9813/2050-5

1-48

Section 2 Operator’s Manual Service Manual - 3DX / 4DX Backhoe Loader Section 1 - General Information Section 2 - Operator’s Manual Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine

Publication No.

9813/2050-5

Section 2 - Operatorâ&#x20AC;&#x2122;s Manual

Notes:

2-0

9813/2050-5

2-0

Dear JCB Customer Even if you have operated this type of equipment before, it is very important that your new machines operations and functions are explained to you by a JCB Dealer Representative following delivery of your new machine.

Your Local JCB Dealer is:

Following the installation you will know how to gain maximum productivity and performance from your new product. Please contact your local JCB dealer if the Installation Form has not yet been completed with you.

OPERATOR MANUAL THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

BACKHOE LOADER - 3DX, 3DX XTRA, 3DX SUPER, 4DX WITH JCB ECOMAX ENGINE ENGLISH - 9821/0000 - ISSUE 9 - JULY 2014 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.

A4-2-BHL - Printed In England

Notes:

9821/0000

Contents Page No. Safety Notices Important Information .................................................................................... 1 The Operator Manual ............................................................................... 1 Safety Warnings ....................................................................................... 1 Introduction About This Manual ......................................................................................... 3 Machine Model and Serial Number .......................................................... 3 Using this Manual ..................................................................................... 3 Left Side, Right Side ................................................................................. 3 Cab/Canopy ............................................................................................. 3 Cross References ..................................................................................... 3 Machine Description ...................................................................................... 4 The JCB Backhoe Loader ........................................................................ 4 Intended Use ............................................................................................ 4 Component List ........................................................................................ 4 Safety Check List ........................................................................................... 5 Safety - Yours and Others ........................................................................ 5 General Safety ......................................................................................... 5 Operating Safety ...................................................................................... 7 Maintenance Safety ................................................................................ 10 Identifying Your Machine ............................................................................. 15 Machine Identification Plate ................................................................... 15 Machine Identification Plate ................................................................... 15 Typical Product Identification Number (PIN) ........................................ 16 Component Identification Plates ............................................................. 17 Typical Engine Identification Number .................................................. 17 Transmission Identification Numbers ..................................................... 17 Axles .................................................................................................... 17 Hydraulic Pump Serial Plate ................................................................ 17 Gearbox ............................................................................................... 18 Operation Introduction .................................................................................................. 20 Before Entering the Cab .............................................................................. 21 Entering and Leaving the Cab ..................................................................... 22 Doors and Windows .................................................................................... 23 Opening and Closing the Door ............................................................... 23 Opening and Closing the Side Windows ................................................ 23 Opening and Closing the Rear Window ................................................. 24 Seat Controls ............................................................................................... 25 Introduction ............................................................................................. 25 Seat Control ........................................................................................... 26 For 3DX ............................................................................................... 26 For 3DX XTRA, 3DX SUPER, 4DX ..................................................... 27 Seat Belt ...................................................................................................... 28 Static Seat Belt ....................................................................................... 28 Fasten the Seat Belt ............................................................................ 28 Release the Seat Belt .......................................................................... 28 Adjusting the Seat Belt ........................................................................ 28 Cab Layout .................................................................................................. 29 From Serial Number ............................................................................... 29 Component Key From Serial Number .................................................. 30 From Serial Number ............................................................................... 31 Component Key From Serial Number .................................................. 33

Contents

Contents Page No. Drive Controls, Switches and Instruments ................................................... 34 Drive Controls ......................................................................................... 34 Steering Wheel .................................................................................... 34 Accelerator Pedal ................................................................................ 34 Hand Throttle Lever ............................................................................. 34 Foot Brake Pedals ............................................................................... 34 Park Brake Lever ................................................................................. 35 Transmission Lever (4-Speed Syncro Shuttle Transmission) .............. 35 Gear Lever (Syncro Shuttle Transmission) .......................................... 37 Transmission Dump Switch ................................................................. 37 Switches .............................................................................................. 38 Instruments ............................................................................................. 44 Front Console ...................................................................................... 44 Side Console ....................................................................................... 45 Air-Conditioning ........................................................................................... 48 General ................................................................................................... 48 Air-Conditioning Controls ....................................................................... 48 Operating Levers ......................................................................................... 49 Introduction ............................................................................................. 49 Control Layouts ...................................................................................... 49 Loader Controls ...................................................................................... 50 Manual Controls ................................................................................... 50 Excavator Controls ................................................................................. 53 From Serial Number ............................................................................ 53 Manual Controls - JCB Diagonal (X) Pattern ....................................... 53 Servo Excavator Controls ....................................................................... 56 From Serial Number ............................................................................ 56 Stabiliser Controls (Non-Servo Machines) ............................................. 59 From Serial Number ............................................................................ 59 Lever Controls ..................................................................................... 59 Stabiliser Controls (Servo Machines) ..................................................... 61 From Serial Number ............................................................................ 61 Lever Controls ..................................................................................... 61 Stabiliser indicator lights ...................................................................... 62 Auxiliary Controls ................................................................................... 63 6-in-1 Clamshovel ................................................................................ 63 Open Bucket ........................................................................................ 63 Close Bucket ........................................................................................ 63 Travel Speed modes .................................................................................... 64 Economy Mode ...................................................................................... 64 Power Mode ........................................................................................... 64 Safety Equipment ........................................................................................ 65 Boom and Slew Locks ............................................................................ 65 Boom Lock ........................................................................................... 65 Slew Lock ............................................................................................ 66 Beacon (if fitted) ..................................................................................... 67 Before Starting the Engine ........................................................................... 68 Starting The Engine ..................................................................................... 70 Starting the Engine in Cold Climate ........................................................ 71 Warning Lights ..................................................................................... 71

Contents

Contents Page No. Preparing The Machine For Travel .............................................................. 72 Backhoe Attachments ............................................................................ 72 Tucked In Travel Position ....................................................................... 72 Central Protruding Travel Position .......................................................... 73 Road Travel Position .............................................................................. 73 Site Travel Position ................................................................................. 74 Getting The Machine Moving ....................................................................... 75 Operating Practices ................................................................................ 75 Stopping and Parking the Machine .............................................................. 77 Working With The Machine ......................................................................... 79 Operating Practices and Site Safety ...................................................... 79 Clothing and Safety Equipment .............................................................. 79 Danger Zone .......................................................................................... 79 Log Moving/Handling .............................................................................. 79 Safety Practices ..................................................................................... 79 Working With The Loader ....................................................................... 81 Introduction .......................................................................................... 81 Hydraulic Speed Control (HSC) (if fitted) ............................................. 81 Filling the Loader Shovel ..................................................................... 82 Loading a Truck ................................................................................... 82 Back filling ............................................................................................ 83 6 in 1 Bucket ........................................................................................... 83 Dozing/Grading .................................................................................... 83 Loading and Digging ............................................................................ 84 Grabbing .............................................................................................. 84 Dozing .................................................................................................. 86 Lifting and Loading Operations ............................................................ 87 Risk Assessment ................................................................................. 88 Working With The Excavator .................................................................. 90 Introduction .......................................................................................... 90 Preparing to Use the Backhoe ............................................................. 91 Kingpost Clamps .................................................................................. 92 Changing a Bucket .............................................................................. 93 Digging ................................................................................................. 94 Moving the Machine while Digging Down Hill ...................................... 94 Sideshifting The Backhoe .................................................................... 95 Getting the Machine Unstuck ................................................................. 96 Operating Environment ................................................................................ 97 Operating in Low Temperatures ............................................................. 97 Operating in High Temperatures ............................................................ 97 Operating in Dusty or Sandy Areas ........................................................ 97 Operating in Coastal Regions ................................................................ 97 Operating on Wet or Soft Ground ........................................................... 97 Refuelling the Machine ................................................................................ 98 Low Fuel Levels ..................................................................................... 98 Filling the Tank ....................................................................................... 98 Moving A Disabled Machine ........................................................................ 99 Towing and Retrieval .............................................................................. 99 Running Engine Procedure ................................................................ 100 Disabled Engine Procedure ............................................................... 100 Transporting The Machine ......................................................................... 101 Lifting A Machine ....................................................................................... 103

iii

Contents

Contents Page No. Storage of the Machine ............................................................................. 106 Introduction ........................................................................................... 106 Storage Area ........................................................................................ 106 Prepare the Machine for Storage ......................................................... 106 Put the Machine into Storage ............................................................... 106 During Storage ..................................................................................... 106 Take the Machine Out of Storage ......................................................... 107 Machine Security ....................................................................................... 108 General ................................................................................................. 108 Security Locks ...................................................................................... 108 LiveLink ................................................................................................ 108 Routine Maintenance Service Requirements ............................................................................... 110 Introduction ........................................................................................... 110 Owner/Operator Support ...................................................................... 110 Service/Maintenance Agreements ....................................................... 110 Initial Service and Inspection ................................................................ 110 Health and Safety ...................................................................................... 111 Lubricants ............................................................................................. 111 Introduction ........................................................................................ 111 Hygiene .............................................................................................. 111 Storage .............................................................................................. 111 Waste Disposal .................................................................................. 111 Handling ............................................................................................. 111 First Aid - Oil ...................................................................................... 112 Spillage .............................................................................................. 112 Fires ................................................................................................... 112 Service Schedules ..................................................................................... 113 Introduction ........................................................................................... 113 How to Use the Service Schedules ...................................................... 113 Pre-start Cold Checks, Service Points and Fluid Levels ...................... 114 Functional Test and Final Inspection .................................................... 117 Fluids, Lubricants and Capacities .............................................................. 119 Coolant Mixtures .................................................................................. 120 Fuels ..................................................................................................... 121 Acceptable and Unacceptable Fuels ................................................. 121 Sulphur Content ................................................................................. 123 Effects of Fuel Contaminates ............................................................. 123 Tools .......................................................................................................... 124 Toolbox ................................................................................................. 124 Carrying Tools onto the Machine .......................................................... 124 Prepare the Machine for Maintenance ...................................................... 125 Introduction ........................................................................................... 125 How to Make the Machine Safe (Loader Arm Lowered) ...................... 126 How to Make the Machine Safe (Loader Arm Lifted) ........................... 126 Installing the Loader Arm Safety Strut ............................................... 126 Removing the Loader Arm Safety Strut ............................................. 127 Cleaning the Machine ................................................................................ 128 Introduction ........................................................................................... 128 Detergents ......................................................................................... 128 Pressure Washing and Steam Cleaning ............................................ 128 Preparing the Machine for Cleaning ..................................................... 128 Cleaning the Machine ........................................................................... 129

Contents

Contents Page No. Checking for Damage ................................................................................ 132 Check the Machine Body and Structure ............................................... 132 Check the Tyres ................................................................................... 132 Check the Seat and Seat Belt .............................................................. 132 Check the Hydraulic Hoses and Fittings .............................................. 133 Check the Electrical Circuits ................................................................. 133 Checking The ROPS/FOPS Structure .................................................. 133 Greasing .................................................................................................... 135 Introduction ........................................................................................... 135 Preparing the Machine for Greasing .................................................... 135 Loader Arms ......................................................................................... 136 Backhoe and Quickhitch (Optional) ...................................................... 137 Front Axle (2WD) .................................................................................. 138 Front Axle (4WD) .................................................................................. 138 Driveshafts ........................................................................................... 139 Front Driveshaft ................................................................................. 139 Rear Driveshaft .................................................................................. 139 Stabilisers (Centremount Machines) .................................................... 139 Kingpost ............................................................................................... 140 Access Panels ........................................................................................... 141 Introduction ........................................................................................... 141 Engine Cover ........................................................................................ 141 Cab Machines .................................................................................... 141 Front Grille ............................................................................................ 142 Side Panels .......................................................................................... 142 Air Conditioning ......................................................................................... 144 Cleaning the Cab Air Conditioning Filter .............................................. 144 Receiver Drier .................................................................................... 144 Brakes ....................................................................................................... 145 Park Brake ............................................................................................ 145 Introduction ........................................................................................ 145 Testing the Park Brake ....................................................................... 145 Park Brake Adjustment ...................................................................... 146 Foot Brake ............................................................................................ 146 Checking the Foot Brake Fluid Level ................................................. 146 Electrical System ....................................................................................... 148 Battery .................................................................................................. 148 Battery Disconnection/Connection ..................................................... 148 Battery Warning Indicator .................................................................. 148 Checking the Electrolyte Level .......................................................... 148 Jump Starting The Engine .................................................................... 150 Fuses .................................................................................................... 151 Relays .................................................................................................. 153 Engine ....................................................................................................... 154 Oil and Filter ......................................................................................... 154 Checking the Oil Level ....................................................................... 154 ........................................................................................................... 154 Changing the Oil and Filter ................................................................ 155 Cooling System .................................................................................... 156 Checking the Coolant Level (Reservoir fitted Machines) ................................................................ 156 Checking the Coolant Level

Contents

Contents Page No. (Non Reservoir fitted Machines) ........................................................ 156 Front End Accessory Drive Belt ........................................................... 157 Introduction ........................................................................................ 157 Inspecting the Drive Belt .................................................................... 158 Changing the Drive Belt ..................................................................... 158 Engine Air Filter .................................................................................... 159 Cleaning the Air Filter Scavenge Pipe ............................................... 159 Changing the Elements ..................................................................... 159 Fuel System ............................................................................................... 160 Introduction ........................................................................................... 160 Water Separator and Engine Fuel Filter ............................................... 160 Introduction ........................................................................................ 160 Draining the Water Separator and Engine Fuel Filter ........................ 161 Changing the Water Separator Pre-Filter .......................................... 163 Cleaning Water Separator Pump ....................................................... 164 Changing the Secondary Fuel Filter .................................................. 165 Bleeding the System ............................................................................ 166 Mechanical Fuel Injection System ..................................................... 166 Hydraulic System ....................................................................................... 167 Introduction ........................................................................................... 167 Releasing the Hydraulic Pressure ........................................................ 167 Hydraulic Tank Filler Cap ..................................................................... 168 Fit the Cap ......................................................................................... 168 Remove the Cap ................................................................................ 168 Oil and Filter ......................................................................................... 168 Checking the Fluid Level ................................................................... 168 Changing the Filter Element .............................................................. 169 Changing the Suction Strainer ........................................................... 170 Transmission ............................................................................................. 171 Gearbox ................................................................................................ 171 Checking the Oil Level ....................................................................... 171 Changing the Oil and Filter ................................................................ 172 Axles (Two Wheel Steer Machines) ...................................................... 173 Checking the Oil Level ....................................................................... 173 Changing the Oil ................................................................................ 174 Tyres and Wheels ...................................................................................... 175 Tyre Inflation ......................................................................................... 175 Introduction ........................................................................................ 175 Procedure .......................................................................................... 175 Wheel Nuts ........................................................................................... 176 Checking the Wheel Nut Torques ...................................................... 176 Checking the Wheel Nut Torques ...................................................... 176 Wear Pads ................................................................................................. 177 Stabiliser Legs (Sideshift Machines Only) ............................................ 177 Wear Pad Adjustment ........................................................................ 177 Windscreen Washer (If fitted) .................................................................... 178 Checking the Level ............................................................................... 178 Optional Attachments Introduction ................................................................................................ 180 Attachments For Your Machine ................................................................. 181

Contents

Contents Page No. Connecting/Disconnecting Hydraulic Hoses .............................................. 182 Introduction ........................................................................................... 182 Connecting the Hydraulic Hoses .......................................................... 182 Disconnecting the Hydraulic Hoses ...................................................... 183 Quick Release Couplings ..................................................................... 184 Essential Do's .................................................................................... 184 Essential Don'ts ................................................................................. 184 Connecting Quick Release Couplings ............................................... 185 Disconnecting Quick Release Couplings ........................................... 185 Directly Mounted Excavator Attachments .................................................. 186 Installing Directly Mounted Excavator Attachments ............................. 186 Shovel - Forks (If Fitted) ............................................................................ 187 Safety and Control ................................................................................ 187 Driving Up and Down Gradients ........................................................ 187 Preparing the Forks for Use ................................................................. 187 Preparing For Road Travel ................................................................... 188 Preparing For Site Travel ..................................................................... 188 Adjust The Fork Spacing ...................................................................... 188 Daily Maintenance ................................................................................ 188 Tool Carrier and Forks (If Fitted) ................................................................ 189 Safety and Control ................................................................................ 189 Driving Up and Down Gradients ........................................................ 189 Preparing the Forks for Use ................................................................. 189 Adjust the Fork Spacing ....................................................................... 190 Preparing for Road Travel .................................................................... 190 Preparing for Site Travel ....................................................................... 190 Preparing for Shovel Operation ............................................................ 190 Daily Maintenance ................................................................................ 190 Work Platforms .......................................................................................... 191 Specifications Lifting Regulations and Safe Working Loads ............................................. 192 Introduction ........................................................................................... 192 Lifting (Object Handling) Regulations ................................................ 192 Safe Working Loads ........................................................................... 192 Loader Unit ........................................................................................... 192 Static Dimensions ...................................................................................... 193 3DX, 3DX Super, 3DX Xtra .................................................................. 193 4DX ...................................................................................................... 195 Performance Dimensions .......................................................................... 197 3DX, 3DX Super, 3DX Xtra .................................................................. 197 4DX ...................................................................................................... 199 Hydraulic Hose Burst Pressures ................................................................ 201 Introduction ........................................................................................... 201 Old Type Hose ...................................................................................... 201 New Type Hose .................................................................................... 202

vii

Safety Notices Important Information T1-042

The Operator Manual

Safety Warnings

!MWARNING You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator Manual. You must understand and follow the instructions in the Operator Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. INT-1-4-2

Do not operate the machine without an Operator Manual, or if there is anything on the machine you do not understand. Treat the Operator Manual as part of the machine. Keep it clean and in good condition. Replace the Operator Manual immediately if it is lost, damaged or becomes unreadable.

This safety alert system identifies important safety messages in this manual. When you see this symbol, be alert, your safety is involved, carefully read the message that follows, and inform other operators. In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.

!MDANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured. INT-1-2-1

!MWARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-2

!MCAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine. INT-1-2-3

9821/0000-09

Safety Notices Important Information

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9821/0000-09

Introduction About This Manual Machine Model and Serial Number

Left Side, Right Side

This manual provides information for the following model(s) in the JCB machine range:

In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine.

P2-1002_2

– 3DX from 1855501 to 1899999

This is so whether you are facing the loader (front) or the backhoe (rear).

– 3DX Xtra from 1491201 to 1502999 – 3DX Super from 1491201 to 1502999 – 4DX from 1415101 to 1416999

Using this Manual T1-044

This manual is arranged to give you a good understanding of the machine and its safe operation. It also contains maintenance information and specification data. Read this manual from front to back before using the machine for the first time. Particular attention must be given to all the safety aspects of operating and maintaining the machine.

If there is anything you are not sure about, ask your JCB distributor or employer. Do not guess, you or others could be killed or seriously injured. General warnings in this chapter are repeated throughout the book, as well as specific warnings. Read all the safety statements regularly, so you do not forget them. Remember that the best operators are the safest operators. The illustrations in this manual are for guidance only. Where the machines differ, the text and or the illustration will specify. This manual contains original instructions, verified by the manufacturer (or their authorised representative). The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication.

A C003690-1

Fig 1.

Cab/Canopy T1-003_2

This manual frequently makes references to the cab. For instance, 'do not operate the machine without a manual in the cab'. It should be noted that these statements also apply to canopy build machines.

Cross References T1-004_2

In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The number of the page upon which the subject begins, is indicated within the brackets. For example: K Cross References ( T 3).

All optional equipment included in this manual may not be available in all territories.

9821/0000-09

Introduction Machine Description

Machine Description The JCB Backhoe Loader P2-1001_3

The Backhoe Loader is a self propelled wheeled machine with a main frame designed to carry both front mounted equipment and rear mounted backhoe equipment with stabilisers. When used in the backhoe mode, the machine is stationary and normally digs below ground level. A backhoe work cycle normally comprises excavating, elevating, swinging and discharging material When used in the loader mode (bucket use), the machine loads through forward motion. A loader work cycle normally comprises filling, elevating, transporting and discharge of material.

in areas with dust containing asbestos, special safety regulations must be followed and the machine must be equipped for use in these environments.

Component List 1

Loader arm

Cab

Hydraulic oil tank

Battery compartment

Boom

Fuel tank

Stabilisers

Kingpost

Dipper

Intended Use The machine is intended to be used under normal conditions for the applications described in this manual. If the machine is used for other purposes or in dangerous environments, for example in a flammable atmosphere or

2 5 9

6 1

D026650

Fig 2.

9821/0000-09

Introduction Safety Check List

Safety Check List P2-1005_3

Safety - Yours and Others

General Safety INT-1-3-1_3

All machinery can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. In this manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB distributor to explain them. But safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them.

!MWARNING

T1-043

To operate the machine safely you must know the machine and have the skill to use it. You must abide by all relevant laws, health and safety regulations that apply to the country you are operating in. The Operator Manual instructs you on the machine, its controls and its safe operation; it is not a training manual. If you are a new operator, get yourself trained in the skills of using a machine before trying to work with it. If you don't, you will not do your job well, and you will be a danger to yourself and others. INT-1-4-1

!MWARNING

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

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

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

INT-1-3-5

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

!MWARNING Clothing You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, earprotectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and personal jewellery. INT-1-3-6_2

!MWARNING Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines which can cause drowsiness. INT-1-3-9_2

9821/0000-09

Introduction Safety Check List

!MWARNING

!MDANGER

Feeling Unwell Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself and those you work with.

Lightning Lightning can kill you. Do not use the machine if there is lightning in your area. 5-1-1-2

8-1-2-4

!MWARNING

!MWARNING Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious injury.

Machine Modifications This machine is manufactured in compliance with legislative and other requirements. It should not be altered in any way which could affect or invalidate any of these requirements. For advice consult your JCB Distributor. INT-1-3-10_2

Switch off and do not use your mobile phone when refuelling the machine. INT-3-3-9

!MWARNING Lifting Equipment You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations. INT-1-3-7_2

!MWARNING Raised Equipment Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped). Make sure that no-one goes near the machine while you install or remove the mechanical device. 13-2-3-7_3

!MWARNING Raised Machine NEVER position yourself or any part of your body under a raised machine which is not properly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed. INT-3-3-7_1

9821/0000-09

Introduction 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

9821/0000-09

Introduction 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

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

9821/0000-09

Introduction Safety Check List

!MDANGER

!MWARNING

Working Platform Using the machine as a working platform is hazardous; you can fall off and be killed or injured. Never use the machine as a working platform.

High Loads A high load can block your view and reduce the machine's stability. Travel with the load low to the ground. Travel slowly and with caution over rough, muddy or loose surfaces.

5-1-5-9

5-1-3-2

!MWARNING Machine Safety Stop work at once if a fault develops. Abnormal sounds and smells can be signs of trouble. Inspect and repair before resuming work. 8-1-2-3

!MWARNING Slopes When transporting a load on a slope, drive slowly and keep the load uphill of the machine. This will increase stability. 5-1-4-1

!MWARNING Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit. 10-1-1-40

!MWARNING Travelling at High Speeds Travelling at high speeds can cause accidents. Do not reverse in a high gear with full throttle. Always travel at a safe speed to suit working conditions.

!MWARNING Hillsides Operating the machine on hillsides can be dangerous if proper precautions are not taken. Ground conditions can be changed by rain, snow, ice etc. Check the site carefully. Operate in first gear on hillsides, when applicable, keep all attachments low to the ground. Never coast down a hill with the engine off or the transmission in neutral. INT-2-2-7

!MWARNING

INT-5-3-3

!MWARNING The engine has exposed rotating parts. Switch OFF the engine before working in the engine compartment. Do not use the machine with the engine cover open.

Visibility Accidents can be caused by working in poor visibility. Use your lights to improve visibility. Keep the road lights, windows and mirrors clean. Do not operate the machine if you cannot see clearly. 5-1-4-7

5-2-6-5

!MWARNING

You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protection Structure (ROPS)/Falling Objects Protection Structure (FOPS) has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification.

Keep Your Hands and Feet Inside the Vehicle When using the machine, keep your hands and feet clear of moving parts. Keep your hands and feet within the operator compartment while the vehicle is in motion. 13-1-1-17

INT-2-1-9_6

9821/0000-09

Introduction Safety Check List

!MWARNING

Maintenance Safety

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

!MWARNING

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

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

INT-2-2-2_1

INT-3-1-5

0179_2

!MCAUTION

!MWARNING

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

Repairs If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result in an accident or affect your health. Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer.

Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use selfcontained breathing apparatus.

GEN-1-5_2

!MWARNING

INT-3-2-7_2

!MWARNING Should the machine start to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll over, do not try and jump from the cab. Stay in the cab, with your seat belt fastened.

Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper pin to remove and fit metal pins. Always wear safety glasses. INT-3-1-3_2

!MWARNING

INT-2-1-12

Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4

9821/0000-09

Introduction Safety Check List

!MWARNING

!MCAUTION

Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses and gloves. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.

It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. INT-3-2-14

!MWARNING

INT-3-1-10_3

!MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open. INT-3-1-11_2

Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground. INT-3-2-4

!MWARNING Always wear safety glasses when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidentally flying out. GEN-6-2

!MWARNING Fuel Fuel is flammable; keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions.

!MCAUTION Rams The efficiency of the rams will be affected if they are not kept free of solidified dirt. Clean dirt from around the rams regularly. When leaving or parking the machine, close all rams if possible to reduce the risk of weather corrosion. INT-3-2-10

INT-3-2-2_3

!MCAUTION

!MWARNING Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin. INT-3-2-3

Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents. INT-3-2-11

!MWARNING When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions. GEN-1-9

9821/0000-09

Introduction Safety Check List

!MCAUTION

!MWARNING

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

Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton®, FluorelTM and Technoflon®. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN.

INT-3-2-12

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

!MWARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly. Do not use the machine if a hose or hose fitting is damaged. INT-3-3-2_4

!MCAUTION Waxoyl contains turpentine substitute which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.

Used fluoroelastomeric components whose temperatures have not exceeded 300°C (572°F) require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA. Used fluoroelastomeric components subjected to temperatures greater than 300°C (572°F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: 1

Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.

Thoroughly wash contaminated detergent and water.

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

5-3-1-9

!MWARNING Working Under the Machine Make the machine safe before getting beneath it. Ensure that any fitments on the machine are secure; engage the park brake, remove the starter key, disconnect the battery. INT-3-3-8_2

area

with

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

!MWARNING Protect your eyes when grinding metal. Wear safety glasses or goggles. Remove or protect any combustible materials from the area which could be ignited by sparks. GEN-1-12

9821/0000-09

Introduction Safety Check List

!MWARNING

To avoid burning wear personal protective equipment (PPE) when handling hot components. To protect your eyes, wear personal protective equipment (PPE) when using a brush to clean components.

Accumulators The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on systems incorporating accumulators, the system pressure must be exhausted by a JCB distributor, as the sudden release of the hydraulic fluid or gas may cause injury.

HYD-1-3_3

!MWARNING

INT-3-1-17

Arc Welding To prevent the possibility of damage to electronic components, disconnect the battery and the alternator before arc-welding on the machine or attached implements. If the machine is equipped with sensitive electrical equipment, i.e. amplifier drivers, electronic control units (E.C.U.s), monitor displays, etc., then disconnect them before welding. Failure to disconnect the sensitive electrical equipment could result in irreparable damage to these components. Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine. 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.

!MWARNING Petrol Do not use petrol in this machine. Do not mix petrol with the diesel fuel; in storage tanks the petrol will rise to the top and form flammable vapours. INT-3-1-6

!MCAUTION Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. INT-3-1-14

!MWARNING 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

INT-3-1-15_2

!MWARNING

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

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

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

0147_1

9821/0000-09

Introduction Safety Check List

!MDANGER

!MWARNING

Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear personal protective equipment (PPE).

Wheels and tyres are heavy. Take care when lifting or moving them.

INT-3-2-1_4

13-3-1-7_1

Store with care to ensure that they cannot fall and cause injury.

!MWARNING

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

Asbestos Asbestos dust can damage your lungs. Some engine gaskets contain asbestos. Do not dismantle the engine or exhaust system; get these jobs done by a qualified person who has a copy of the engine service manual.

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

5-1-6-1

When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9

!MWARNING An exploding tyre can kill. Inflated tyres can explode if over-heated or over-inflated. Follow the instructions given when inflating the tyres. Do not cut or weld the rims. Use a tyre/wheel specialist for all repair work. 2-3-2-7_2

!MWARNING Jacking A machine can roll off jacks and crush you unless the wheels have been blocked. Always block the wheels at the opposite end of the machine that is to be jacked. Do not work underneath a machine supported only by jacks. Always support a jacked-up machine on axle stands before working underneath it. INT-3-2-8

!MWARNING Under no circumstances must the engine be run with the transmission in gear and only one driving wheel jacked clear of the ground, since the wheel on the ground will move the machine. INT-3-1-16

9821/0000-09

Introduction Identifying Your Machine

Identifying Your Machine Machine Identification Plate Your machine has an identification plate mounted as shown. The serial numbers of the machine and its major units are stamped on the plate. The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered.

PRODUCT IDENTIFICATION NO.

MONTH & YR OF MFG.

JCB MACHINE SERIAL NO.

FRONT AXLE SERIAL NO.

ENGINE SERIAL NO.

REAR AXLE SERIAL NO.

HYDRAULIC PUMP SERIAL NO.

GEAR BOX SERIAL NO.

CHASSIS NO.

JCB INDIA LIMITED 23/7 MATHURA ROAD BALLABGARH-12004 (INDIA)

The machine and engine serial numbers can help identify exactly the type of equipment you have. D026260-1 JCB MACHINE SERIAL NO.

Fig 4. From January 2013

MONTH & YR OF MFG.

ENGINE SERIAL NO.

FRONT AXLE SERIAL NO.

HYDRAULIC PUMP SERIAL NO.

REAR AXLE SERIAL NO.

CHASSIS NO.

GEAR BOX SERIAL NO.

Machine Identification Plate Your machine has an identification plate mounted as shown. The serial numbers of the machine and its major units are stamped on the plate.

JCB INDIA LIMITED 23/7 MATHURA ROAD BALLABGARH-12004 (INDIA)

The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered. D026260

Fig 3. To December 2012

The machine and engine serial numbers can help identify exactly the type of equipment you have.

9821/0000-09

Introduction Identifying Your Machine Typical Product Identification Number (PIN) JCB MACHINE SERIAL NO.

MONTH & YR OF MFG.

ENGINE SERIAL NO.

FRONT AXLE SERIAL NO.

HYDRAULIC PUMP SERIAL NO.

REAR AXLE SERIAL NO.

CHASSIS NO.

GEAR BOX SERIAL NO.

HA R 3 DX PC C 1 2 3 4 5 6 7 8 D067390

Fig 7.

JCB INDIA LIMITED 23/7 MATHURA ROAD BALLABGARH-12004 (INDIA)

World Manufacturer Identification (3 Digits)

Machine Model (5 Digits)

Check Letter (1 Digit) The Check Letter is used to verify the authenticity of a machine's PIN.

D026260

Fig 5. To December 2012

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

PRODUCT IDENTIFICATION NO.

MONTH & YR OF MFG.

JCB MACHINE SERIAL NO.

FRONT AXLE SERIAL NO.

ENGINE SERIAL NO.

REAR AXLE SERIAL NO.

HYDRAULIC PUMP SERIAL NO.

GEAR BOX SERIAL NO.

CHASSIS NO.

JCB INDIA LIMITED 23/7 MATHURA ROAD BALLABGARH-12004 (INDIA)

D026260-1

Fig 6. From January 2013

9821/0000-09

Introduction Identifying Your Machine

Component Identification Plates

Transmission Identification Numbers

Typical Engine Identification Number

Axles

Each JCB Engine has a unique identification number stamped on the main engine block, as shown A.

The rear axle has a serial number stamped on a data plate as shown.

When ordering replacement parts, always quote the complete engine serial number. K Fig 8. ( T 17).

RATIO

JCB INDIA LTD. SERIAL No.

XXX / XXXX / XX / XXXXX

D021990

Fig 8.

Fig 9. Rear Axle

xxxxx

Hydraulic Pump Serial Plate

Fig 10.

9821/0000-09

Introduction Identifying Your Machine Gearbox The gearbox has a serial number stamped on a data plate as shown.

RATIO

JCB INDIA LTD. SERIAL No.

RATIO

JCB INDIA LTD. SERIAL No.

XXX / XXXX / XX / XXXXX Fig 11. Synchro Shuttle Transmission

9821/0000-09

Operation Introduction T2-006_2

The aim of this part of the manual is to guide the operator step-by-step through the task of learning how to operate the machine efficiently and safely. Read the Operation section through from beginning to end. Before you start the machine, you must know how the machine operates. Use your manual to identify each control lever, switch, gauge, button and pedal. Do not guess. If there is anything you do not understand, ask your JCB distributor. The operator must always be aware of events happening in or around the machine. Safety must always be the most important factor when you operate the machine. When you understand the operating controls, gauges and switches, practice using them. Drive the machine in an open space, clear of people. Get to know the 'feel' of the machine and its driving controls. Finally, do not rush the job of learning, make sure you fully understand everything in the Operation section. Take your time and work efficiently and safely. Remember BE CAREFUL BE ALERT BE SAFE

9821/0000-09

Operation Before Entering the Cab

Before Entering the Cab T2-025_4

The following checks should be made each time you return to the machine after leaving it for any period of time. We advise you also to stop the machine occasionally during long work sessions and do the checks again.

d Inspect the windows for cracks and damage. Glass splinters can blind. e

Check for oil, fuel and coolant leakages underneath the machine.

All these checks concern the serviceability of the machine. Some concern your safety. Get your service engineer to check and correct any defects.

!MWARNING

You could be killed or injured if a machine tyre bursts. Do not use the machine with damaged, incorrectly inflated or excessively worn tyres.

Walking or working under raised attachments can be hazardous. You could be crushed by the attachments or get caught in the linkages.

2-2-1-2

Check for cut rubber and penetration by sharp objects. Do not use a machine with damaged tyres.

Lower the attachments to the ground before doing these checks. If you are new to this machine, get an experienced operator to lower them for you. If there is nobody to help you, study this manual until you have learned how to lower the attachments. Also make sure that the park brake is engaged before doing these checks.

Make sure the tyres are correctly inflated.

Make sure that all of the filler caps are installed correctly.

Make sure that all of the access panels are closed and secure.

2-2-1-1

Note: If the filler caps and access panels are fitted with locks, we recommend that you lock them to prevent theft or tampering.

Check for cleanliness. a

Clean the windows, light lenses and rear view mirrors.

b Remove dirt and debris, especially from around the linkages, rams, pivot points and radiator. c

Make sure the cab step(s) and handholds are clean and dry.

d Clean all safety and instructional labels. Replace any that are missing or cannot be read. 2

Check for damage. a

Inspect the machine generally for damaged and missing parts.

b Make sure that the attachment is secure and in good condition. c

Make sure that all pivot pins are secured correctly in place.

9821/0000-09

Operation Entering and Leaving the Cab

Entering and Leaving the Cab

!MWARNING Entering/Leaving Entering or leaving the cab or canopy must only be made where steps and handrails are provided. Always face the machine when entering and leaving. Make sure the step(s), handrails and your boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls as handholds, use the handrails. INT-2-1-7_1

Make sure the machine is stopped and correctly parked before entering or leaving the cab. If necessary, refer to Stopping and Parking the Machine. When you get on and off the machine always maintain a three point contact with the handrails and step. Do not use the machine controls or steering wheel as handholds.

805130-2

Fig 1.

9821/0000-09

Operation Doors and Windows

Doors and Windows Opening and Closing the Door

Opening and Closing the Side Windows

To open a door from the outside, unlock it with the key and pull the handle A. The door is fitted with an assister which will spring it open and hold it open.

To open a side window, unlock latch E. Pull lever C towards the operator seat, while pushing window outwards, until it latches down. To close the window, first pull the lever towards the front of the machine then pull the window inwards, lower the lever C and E to latch it.

Close the door from the inside by pulling it firmly; it will latch itself.

The window can be opened fully and secured to the door. Open the window then pull lever C forward a little way to unhook it from its pin on the frame.

To open the door from the inside, operate lever B. Note: Do not drive the machine with the door unlatched.

Swing the window right round to meet the outside of the door. The window will latch to the door. To close the window, move handle D, swing the window closed and set lever C back on its pin. Close the window as described above. Note: Do not drive the machine with the side windows open.

770810-3

Fig 2.

D026290

Fig 3.

9821/0000-09

Operation Doors and Windows

Opening and Closing the Rear Window

!MCAUTION The rear window is heavy. Take care when raising and lowering it. If necessary, slide the seat towards the loader end to give you more room when moving the window. 2-2-1-5

!MCAUTION

To open the rear window, press locking levers A. Take a firm grip on the handrails, move the window towards the front of the machine and up as far as it will go. Secure the window in its open position by releasing locking levers A, make sure the window is locked in position. It is recommended that the rear window is closed before travelling. Note: When closing the window, make sure that the window wiper lead does not get trapped.

On sideshift machines the rear window, when being closed or opened, can contact the bucket teeth. With the backhoe stowed across the back of the machine and the bucket closed its possible that the window can hit the bucket teeth when being closed or opened. 2-2-1-11

When the backhoe is stowed across the back of the machine and the bucket closed, the rear window can hit the bucket teeth. If the backhoe is in the position shown, move the bucket clear before closing or opening the rear window. K Fig 4. ( T 23).

A Fig 5.

271380-1

Fig 4.

9821/0000-09

Operation Seat Controls

Seat Controls Introduction

!MWARNING

T2-007_3

Seat Position the seat so that you can comfortably reach the machine controls. Do not adjust the seat while the machine is moving. You could have an accident if you operate the machine with the seat in the wrong position. 13-1-1-9_1

The operator's seat can be adjusted for your comfort. A correctly adjusted seat will reduce operator fatigue. Position the seat so that you can comfortably reach the machine controls. For driving the machine, adjust the seat so that you can depress the pedals fully with your back against the seat back.

9821/0000-09

Operation Seat Controls

Seat Control For 3DX

B A

D026620

Fig 6. A

Swivel To swivel pull the lever backwards, swivel the seat all the way around to face the opposite direction then release lever. Make sure the seat fully latches into the locked position.

Fore and Aft To move the seat fore and aft, lift the lever and slide the seat to the position you want, release the lever to lock the seat. Make sure the seat is locked in position.

Weight Whilst seated, turn the weight adjustment dial until your weight is shown in the scale just beside the knob. This will set the seat to the most suitable support for your weight. The dial is calibrated in kilograms (kg).

9821/0000-09

Operation Seat Controls For 3DX XTRA, 3DX SUPER, 4DX

C B

A P1063040-5

Fig 7. A

Fore and Aft To move the seat fore and aft, lift the lever and slide the seat to the position you want, release the lever to lock the seat. Make sure the seat is locked in position.

Recline To move the backrest to the required angle, lift the lever and adjust the backrest position as required, release the lever to lock the backrest. Make sure the backrest is locked in position.

Swivel To swivel pull the lever backwards, swivel the seat all the way around to face the opposite direction then release lever. Make sure the seat fully latches into the locked position.

9821/0000-09

Operation Seat Belt

Seat Belt Static Seat Belt

!MWARNING

T2-002

If you do not wear your seat belt you could be thrown about inside the machine, or thrown out of the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine. 8-2-9-2_1

!MWARNING 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.

Fig 8.

2-3-1-7_1

Adjusting the Seat Belt Fasten the Seat Belt Make sure the belt is across your hips and not over your stomach.

Sit correctly in the seat.

Push the male fitting A into the buckle B until it latches into position. Make sure the seat belt is not twisted and that it is over your hips not your stomach.

To adjust the male fitting A: 1

!MWARNING

Pull toggle D down the strap by the required distance. a

If the seat belt does not 'lock' when you check if the seat belt is operating correctly, do not drive the machine. Get the seat belt repaired or replaced immediately.

To make the strap longer, pull end E as far as it will go.

b To make the strap shorter, pull end F as far as it will go.

2-2-2-1

Release the Seat Belt

!MWARNING Release the seat belt only after switching off the engine. 2-2-1-10

Press button C and pull the male fitting A from the buckle B. Fig 9.

9821/0000-09

Operation Cab Layout

Cab Layout From Serial Number – 3DX from 1855501 to 1899999 – 3DX Xtra from 1491201 to 1502999 – 3DX Super from 1491201 to 1502999 – 4DX from 1415101 to 1416999

18 9 14 19

6 10 17

13 D026660

Fig 10.

9821/0000-09

Operation Cab Layout Component Key From Serial Number 1

K Steering Wheel ( T 33).

K Accelerator Pedal ( T 33).

K Foot Brake Pedals ( T 33)

K Transmission Lever (4-Speed Syncro Shuttle Transmission) ( T 34)

K Park Brake Lever ( T 34).

K Instruments ( T 43)

Front Console Switches K Switches ( T 37).

K Multi-Purpose Steering Column Switch ( T 41).

K Loader Controls ( T 49).

K Starter Switch ( T 39).

Side Console Switches K Switches ( T 37).

K Stabiliser Controls (Servo Machines) ( T 60).

K Excavator Controls ( T 52).

K Speedometer ( T 44).

K Front Console Warning Lights ( T 43)

K Hand Throttle Lever ( T 33)

K Toolbox ( T 123)

K Gear Lever (Syncro Shuttle Transmission) ( T 36)

K Auxiliary Controls ( T 62)

9821/0000-09

Operation Cab Layout

From Serial Number – 3DX Xtra from 1491201 to 1502999 – 3DX Super from 1491201 to 1502999 – 4DX from 1415101 to 1416999 Note: The illustration shows a servo and AC machine.

9821/0000-09

Operation Cab Layout

4 3 9 19 17

5 11

6 17

10 16 12

13 P040520-01

Fig 11.

9821/0000-09

Operation Cab Layout Component Key From Serial Number 1

K Steering Wheel ( T 33).

K Accelerator Pedal ( T 33).

K Foot Brake Pedals ( T 33)

K Transmission Lever (4-Speed Syncro Shuttle Transmission) ( T 34)

K Park Brake Lever ( T 34).

K Instruments ( T 43)

Front Console Switches K Switches ( T 37).

K Multi-Purpose Steering Column Switch ( T 41).

K Loader Controls ( T 49).

K Starter Switch ( T 39).

Side Console Switches K Switches ( T 37).

K Stabiliser Controls (Servo Machines) ( T 60).

K Excavator Controls ( T 52).

K Speedometer ( T 44).

K Front Console Warning Lights ( T 43)

K Hand Throttle Lever ( T 33)

K Toolbox ( T 123)

K Gear Lever (Syncro Shuttle Transmission) ( T 36)

K Auxiliary Controls ( T 62)

K Air Conditioning ( T 143)

9821/0000-09

Operation Drive Controls, Switches and Instruments

Drive Controls, Switches and Instruments

!MWARNING

Drive Controls Steering Wheel T2-048

Turn the steering wheel in the direction you want to go.

2-2-2-3

Accelerator Pedal

!MWARNING

You and others can be killed or injured if the brake pedal locking bar is not engaged as recommended. If only one brake is applied for a quick stop, the machine could swerve out of control.

T2-031

When driving the machine, use only the accelerator pedal to control the engine speed. Do not use the hand throttle lever to set the engine speed while driving.

Lock the pedals together when driving on the road in any gear. Separate the pedals only when driving in 1st or 2nd gear (1 or 2) off the road.

2-2-2-2

Push this pedal down to increase engine speed. Let the pedal up to reduce engine speed. With your foot off the pedal the engine will idle.

Hand Throttle Lever

!MWARNING When driving the machine, use only the accelerator pedal to control the engine speed. Do not use the hand throttle lever to set the engine speed while driving. 2-2-2-2

Move this lever to increase or decrease the engine speed as required when working with the excavator. Pull this lever towards the seat to increase engine speed. Push the lever fully away from the seat for idling speed.

D005030

Fig 12.

Foot Brake Pedals Push down on the brake pedals to slow or stop the machine. Use the brakes to prevent overspeeding down a slope. The stop lights should come on when the brakes are applied. Do not drive the machine unless both stop lights work correctly. Machines with Two Brake Pedals The left rear brake is operated by the left pedal. The right rear brake is operated by the right pedal. The pedals can be locked together by a steel locking bar A. K Fig 12. ( T 33).

9821/0000-09

Operation Drive Controls, Switches and Instruments Park Brake Lever

Transmission Lever (4-Speed Syncro Shuttle Transmission)

Use this lever to engage the park brake before leaving the machine. With the parking brake engaged the Indicator will light and the machine will not move either in forward or reverse as this operation disconnects the forward reverse solenoid electrically.

T2-023_3

Functions

To engage the parking brake, pull the lever up, check that the indicator light comes on. To release the parking brake, lower the lever as far as it will go. Check that the indicator light goes out.

!MCAUTION The park brake must not be used to slow the machine from travelling speed, except in an emergency, otherwise the efficiency of the brake will be reduced. Whenever the park brake has been used in an emergency, always renew both brake pads.

S240120-8

Fig 13. F/N/R K Drive Selection ( T 34) K Horn ( T 35)

4-2-1-1_2

Drive Selection

!MWARNING You and others can be killed or injured if you operate the forward/reverse lever while you travel. The machine will immediately reverse direction without warning to others. Follow the recommended procedure for proper use of this selector. 2-2-2-4_2

Stop the machine before moving the lever. To select forward (F), reverse (R) or neutral (N), 'lift' and move the lever to the required position. All four gears are available in forward and reverse. When reverse is selected an alarm will sound. The engine will only start if the lever is at neutral. The lever has 'detent' positions in forward, reverse and neutral. To move the lever from the detent position pull the lever towards you. Procedure for reversing direction:

Stop the machine: keep the foot brakes applied.

Let the engine speed drop to idle.

Select the new direction.

Release the foot brakes and accelerate away.

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Operation Drive Controls, Switches and Instruments Note: If the park brake is engaged when forward/reverse is selected, the Park Brake Engaged Indicator will come on and the warning buzzer will sound. Horn The horn button X is at the end of the forward/reverse lever. Push the button to operate the horn. It functions only with the starter switch set to on.

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Operation Drive Controls, Switches and Instruments Gear Lever (Syncro Shuttle Transmission) To select a gear, move the lever A as shown on the shift pattern. When the machine is stationary, make sure that forward/reverse lever is at neutral (N) and the engine at idle, before selecting a gear. The machine can be moved off in any gear, depending on the ground conditions. To change gear on the move: 1

Press the transmission dump switch B.

Select the new gear.

Release the transmission dump switch B.

Use the accelerator to produce a smooth gear change.

765300-2

Fig 14.

Transmission Dump Switch Depress and hold the switch on the gear lever to disconnect the drive while changing gear on the move. The dump switch on the lift and shovel control lever can be used to momentarily dump the transmission pressure to improve the hydraulic performance and reduce engine load.

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Operation Drive Controls, Switches and Instruments Switches

Instrument Panel Switches

Introduction

Side Lights and Headlights SW-001_2

Three position rocker switch with backlight. The switch functions operate when the starter switch is in the ON and OFF positions.

The installed switches and their positions can change according to the specification of the machine. Each switch has a graphic symbol A to show the function of the switch. Before you operate a switch, make sure that you understand its function.

Position 1: OFF (Backlight OFF) 340151-1

Position 2 (starter switch in the ON position): Headlights ON (Backlight ON)

The rocker switches have two or three positions (as shown). If the switch has a backlight, then the graphic symbol A comes on when the ignition switch or side lights are in the ON position. The light bar B comes on to show that the switch function is active.

Position 3: Side Lights ON (Backlight ON)

Position 2 (starter switch in the OFF position): Side Lights ON (Backlight ON) Machines without headlights or side lights are designed for site use. You may be breaking local laws if you travel on the road without headlights or side lights. Hazard Warning Lights Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON and OFF positions. Position 1: OFF (Backlight OFF). 339861-1

Position 2: ON (Backlight ON). A light on the instrument panel flashes with the outside lights.

Beacon (If fitted) Two position rocker switch. The switch functions operate when the starter switch is in the ON and OFF positions.

T042100-1

Fig 15.

Position 1: OFF Position 2: ON 339711-1

Before you operate the switch, refer to Beacon.

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Operation Drive Controls, Switches and Instruments Four Wheel Drive Selector (4WD machine only)

Servo Control (Servo machines only)

Three position rocker switch. The switch functions operate when the starter switch is in the ON position.

Two position rocker switch, spring loaded to position 1. The switch functions operate when the starter switch is in the ON position.

Position 1: 2-wheel drive - Two wheel braking D026770

Position 1: OFF

Position 2: 4-wheel drive - All wheel braking

Position 2: Servo Control ON.

Position 3: 2-Wheel drive - All wheel braking

To operate the servo system when facing the excavator end, press the switch once to position 2.

To operate the servo system when facing the loader end, press the switch once to position 2. The servo system will activate for 30 seconds . To continue, again press the switch for next 30 seconds.

Emergency lowering (boom/dipper/ bucket or slew) in case of engine failure:

Before you operate the switch, refer to Getting the Machine Moving.

!MWARNING Do not drive on the road with the work lights switched on. You can interfere with other drivers visibility and cause an accident. 2-2-2-5_1

Front Work Lights

Two position rocker switch. The switch functions operate when the starter switch is in the ON position.

Switch on the ignition.

Position 1: OFF

b Press the servo switch once to position 2. The servo system will activate for 30 seconds.

Position 2: Work Lights ON

340100-1

Note: The work lights work independently of the main lights circuit.

Operate the excavator end to lower the boom/dipper/bucket or slew.

Note: The accumulator actuates with limited pressure available to actuate the servo.

Rear Work Lights Three position rocker switch. The switch functions operate when the starter switch is in the ON position.

Kingpost Clamps

Position 1: OFF

Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON position.

Position 3: Outer Worklights ON

Position 1: OFF (Backlight OFF)

340090-1

Position 2: ON (Backlight ON)

Position 2: Inner and Outer Worklights ON

339970-2

Note: The work lights work independently of the main lights circuit.

Before you operate the switch, refer to Working with the Excavator.

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Operation Drive Controls, Switches and Instruments Starter Switch

Hydraulic Speed Control (If fitted)

T2-019_2

Two position rocker switch. The switch functions operate when the starter switch is in the ON position. Position 1: OFF (Backlight OFF)

This is operated by the starter key. It has four positions. The key can be removed only with the switch set to 0. 0

Turn the key to this position to stop the engine. Make sure the transmission is in neutral, the attachments have been lowered and the park brake is engaged before stopping the engine.

Putting the switch to this position connects the battery to all the electrical circuits except the position, tail lights and the hazard warning circuit. (The lights and hazard warning circuits are permanently live.) The starter key will spring back to this position when it is released from II or III.

This position is not used in this application

III

Operates the starter motor to turn the engine.

Position 2: ON (Backlight ON) 339920-3

Before you operate the switch, refer to Hydraulic Speed Control. Air Conditioning (If fitted) Two position rocker switch. The switch functions operate when the starter switch is in the ON position. Position 1: OFF (Backlight OFF) Position 2: ON (Backlight ON) P040540-03

Before you operate the switch, refer to Air Conditioning. Auto Engine Stop Deactivate Switch (Servo Machines)

A STOP

Note: Do not operate the starter motor for more than 10 seconds without the engine firing. If the engine fires but does not fully start, do not operate the starter motor for more than 40 seconds. Let the starter motor cool for at least two minutes between starts.

Two position rocker switch. The switch functions operate when the starter switch is in the ON position. Position 1: OFF. Engine will stop automatically if operator is not present on the operatorâ&#x20AC;&#x2122;s seat for 30 seconds. Position 2: ON (Auto engine stop deactivation). Use this switch position for maintenance purpose only.

H04432-4

Fig 16.

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Operation Drive Controls, Switches and Instruments Cab Interior Light The interior light G is located in cab roof near the door. To turn it on, press the right hand side of the light.To extinguish press the left hand side of the light to return it to the centre position. The lamp is also switched by a door operated switch. The light will remain lit for five seconds after the door has closed, then it will dim down until it is fully extinguished.

P040540-07

Fig 17.

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Operation Drive Controls, Switches and Instruments Multi-Purpose Steering Column Switch 1

Windscreen Wiper

Rotate the barrel 1 as follows to switch the windscreen wiper ON and OFF. Functions only with the ignition switch is ON or 1 position as well as the wiper motor K Fig 18. ( T 41).

J = Not used. O = Windscreen off. Note that the wiper does self-park. 2

Push button: Not used

Direction Indicators

D000582A

Fig 18.

Pull the lever towards you to indicate a right turn. Push the lever away from you to indicate a left turn. Switch the indicators off when you have completed the turn. Functions only with the starter switch at IGNITION ON Position i.e. at 1 position. 4

2 - 4 Wheel Drive Select Switch This is a three position rocker switch that allows the operator to select the status of the drive/brake system. Note: The three modes are:

Headlights With the headlights switched on push the lever down (away from you) for main beam. The centre position is dipped beam.

Headlight flash Pull the lever upwards towards you. Functions only with the starter switch at IGNITION ON Position, i.e. at 1 position.

Important: Do not drive on the road with the work lights switched on. You can dazzle other drivers and cause an accident.

- Two Wheel Drive-All Wheel Braking when the machine is driven on public highways. Front wheel braking is via the drive to the front axle (there are no 'brakes' in the front axle). When Position 3 is selected, the machine is in 2-wheel drive. However, when the brakes are applied, a microswitch operated by the movement of the brake pedals automatically engages 4wheel drive. This has the effect of 'all wheel braking'. - Two Wheel Drive-Two Wheel Braking - Four Wheel Drive-All Wheel Braking Use this position when operating in heavy duty site conditions, for instance, deep mud, undulating surfaces, slurry etc.

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Operation Drive Controls, Switches and Instruments Auxiliary Power Socket

Face Level Fan (If Fitted)

The socket X supplies a 12 Volt DC power supply to electrical accessories (from the battery). Only connect items which are compatible with the power rating of the socket (Refer to Electrical System, Fuses) and have the correct plug.

Toggle switch E to switch on the face level fan. Functions only with 'ignition' on.

T2-036_2

Always operate the engine during prolonged use of electrical accessories, otherwise the battery can discharge. Make sure that the socket cap is closed when the socket is not in use.

218140-3

Fig 19.

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Operation Drive Controls, Switches and Instruments

Instruments

3. Front Work Light Lights up when the front work lights are switched ON

The driving indicators are located on the front console. There are additional instruments and gauges located at the side of the driver's seat. D026320

All instruments power down when the starter switch is set to O, apart from the hazard warning lights indicator.

4. Master Warning Light Lights when any of the warning lights come on.

Front Console On the front console, the master warning light (and buzzer) 3 will illuminate when any of the following warning lights on the side console are illuminated: K Fig 20. ( T 43). Air Filter Blocked; Water Temperature; Transmission Oil Temperature; Engine Oil Pressure; Park Brake Engaged; Transmission Oil Pressure.

D026380

5. Rear Work Light Lights when the rear work lights are switched ON.

There are also additional warning lights mounted in the front console. The master warning light 3 is also linked with the front console lights.

6. Direction Indicators

Front Console Warning Lights

D026330

Flashes with the direction indicators. Use the indicators to signal before turning the machine.

5 D026340

7. Hazard Warning Lights

Lights when the Hazard switch is ON.

9 D026390

Fig 20. D026350

1. Main Beam Lights when the headlight main beams are switched ON. Switch the main beams off for oncoming vehicles.

8. Four Wheel Steer (Optional) Lights when the drive option is selected. The switch functions operate when the starter switch is in the ON position.

D026300 D026360

2. Side Light Lights when side lights are switched ON.

Before you operate the switch, refer to K Getting The Machine Moving ( T 74)

D026310

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Operation Drive Controls, Switches and Instruments Speedometer

Side Console

Indicates the road speed in Kilometres per hour (km/h).

The side console is located at the side of the drivers seat, for indicator and gauge positions. K Fig 22. ( T 44). Side Instrument Panel The instruments and indicator lights are grouped together on an instrument panel. Instruments provided are a tachometer, hourmeter, a coolant temperature gauge and a fuel level gauge. There are warning lights for various fault conditions. When a warning light comes on an alarm will sound. The only way to cancel the alarm is to set the starter to 'off'. Do not use the machine if it has a fault condition, or you might damage the engine and/or the transmission. All instruments and indicators will be turned off when the starter switch is set to off. The hazard warning indicator will still operate if the hazard warning lights are switched on.

D026400

Fig 21.

A B

K J

Fig 22.

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Operation Drive Controls, Switches and Instruments A

Table 1. No Charge

Transmission Oil Temperature High Lights if the transmission oil Temperature is high.

Audible/Visual. Lights if the battery charging circuit fails while the engine is running. The light should go out a few seconds after the engine is started. I B

Water In Fuel Lights if water is detected in fuel. Empty the water separator.

Analog RPM Meter

Indicates the engine speed in revolutions per minute (RPM). The RPM is shown on the outer ring. Each division is 100 RPM. A green band on the scale indicates the RPM which gives fuel economy. Operate within that band whenever possible K Fig 23. ( T 45), K Fig 24. ( T 45). Refer to the optimum engine rpm table while operating the backhoe. K Table 2. Optimum Engine RPM ( T 89).

Air Filter Blocked Lights if engine air filter blocks up.

15 10 D

Park Brake Engaged Audible/Visual. Lights when the park brake is engaged with the machine in forward (F) or reverse (R). The alarm will sound. The light and the alarm should go out when the parking brake switch is turned off. Always switch on the parking brake before leaving the machine, in case the engine is running.

rpmx100

D018600

Fig 23.

Transmission Oil Pressure Low Lights if the transmission oil pressure drops too far. The light should go out a few seconds after the engine is started.

Coolant Temperature Red Light and Audible Alarm. Lights if the engine temperature is above normal.

K D026460

Fig 24. G

Engine Oil Pressure Low

Indicates the working temperature condition of the engine coolant. Do not run the machine if the indicator needle goes into the red area. K Fig 22. ( T 44), K Fig 24. ( T 45)

Audible/Visual. Lights if the engine oil pressure is below normal. The light should go out when the engine is started. L

Coolant Temperature Gauge

9821/0000-09

Fuel Level Gauge

Operation Drive Controls, Switches and Instruments Indicates the level of diesel fuel in the tank. Do not let the tank run dry, or air will enter the fuel system. Do not run the machine if the indicator needle goes into the red area.K Fig 22. ( T 44), K Fig 24. ( T 45). 1st segment of fuel gauge blinks to show reserve capacity.

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Operation Air-Conditioning

Air-Conditioning General The operator must experiment with the controls to get the best possible working environment in the operator station. Poor ventilated air can cause tiredness. Do not operate the machine for long periods without ventilation or with the operator station fully closed and the fan turned off.

Air-Conditioning Controls The air conditioning is controlled by a two position rocker switch A. The switch functions operate when the starter switch is in the ON position.

Turn the control knob B clockwise to increase the speed of the air conditioning fan. Turn the control knob B counterclockwise to decrease the speed of the air conditioning fan. p040540-06

Fig 26. Six air conditioning vents C are located in the roof panel and can be adjusted to direct air flow in the cab.

P040540-01

Fig 25.

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Operation Operating Levers

Operating Levers Introduction

Control Layouts

!MWARNING

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.

Control lever/switch action may vary on machines, instructional labels near the levers/switches show by symbols, which levers/switches cause what actions. Before operating control levers/switches check the instructional label to make sure you select the desired action.

0179_2

5-2-2-9_2

!MWARNING

Control levers and switches may vary on machines.

Loader Controls K Loader Controls ( T 49). Note: Make sure the seat is locked in the front facing position when operating the loader controls. â&#x20AC;&#x201C; Manual Controls Backhoe Controls K Excavator Controls ( T 52).

Before you start using the machine, check with your electricity supplier if there are any buried power cables on the site. There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier.

Note: Make sure the seat is locked in the rear facing position when operating the backhoe controls. â&#x20AC;&#x201C; Manual Controls - JCB Diagonal (X) Pattern

2-2-5-4

!MWARNING Make sure it is clear overhead before raising the boom. Keep an adequate safe distance from all electrical power lines. Contact your local power company for safety procedures. 5-2-1-5_1

9821/0000-09

Operation Operating Levers

Loader Controls Manual Controls Introduction On Manual Control machines the loader shovel is operated from a single control lever A. Pressing the transmission dump push button B on the lever knob quickly disconnects the transmission from the engine. This gives more power to the loader.

For individual loader movements (raise, lower, roll forward, roll back) the lever is moved in a '+' pattern. Combined movements can be selected by moving the lever in directions between the four main ones. For example, the shovel is raised by pulling the lever straight back; while to roll the shovel back the lever must be moved to the left. So if you pull the lever diagonally back-and-left the shovel will both rise and roll back.

The speed of loader actions depends on how far you move the lever. The further you move it the faster the action. The lever is spring-loaded to its central (hold) position. The loader will stay in any position until you move it with the control lever except for Float and Return To Dig operations.

D026570

Fig 27.

A decal, located beside the control lever, shows by symbols what lever movements cause which loader actions. The symbols, lever movements and loader actions are described on the following pages.

9821/0000-09

Operation Operating Levers Raise

Roll Forward

To raise the shovel A, pull the lever straight back. As the shovel rises, it will stay at the same angle to the ground. This is due to the parallel linkages on the loader arms.

To roll the bucket forward C, push the lever to the right.

Lower

To roll the bucket back D, pull the lever to the left.

Roll Back

To lower the shovel B, push the lever forward. The shovel will stay at the same angle to the ground as described in Raise.

A C

D B

T065030-2

Fig 29.

A T065030-1

Fig 28.

9821/0000-09

Operation Operating Levers Float

!MWARNING If Float is selected with the loader raised, the loader will descend to ground level and 'float' across it as you travel. You will not have control over the rate of fall. 2-2-2-7

Always lower the loader before selecting Float. To make the shovel 'float' across the ground, push the lever forwards as far as it will go and leave it there. You will feel a slight pressure on the lever as it passes through the Lower position.

T065030-3

Fig 30.

9821/0000-09

Operation Operating Levers

Excavator Controls

From Serial Number – 3DX Xtra from 1491201 to 1502999 – 3DX Super from 1491201 to 1502999 – 4DX from 1415101 to 1416999

Manual Controls - JCB Diagonal (X) Pattern

!MWARNING Do not operate the excavator controls from outside the machine, or you could be crushed by the excavator. 2-2-3-1

D026670

Fig 31.

On machines with JCB Diagonal ('X') Pattern control, there are two backhoe control levers. The left hand lever A operates the boom and slew. The right hand lever B operates the dipper and bucket. For operation of the Controls (Servo stabilisers. K Stabiliser Machines) ( T 60). Both levers move in a 'X' pattern for individual backhoe actions. Combined actions can be selected by moving the levers in directions between the four main ones. Both levers can be operated at the same time, for more efficient operation. The speed of the backhoe action depends on how far you move the levers. The further you move a lever, the faster the action. Both levers are spring-loaded to their central (hold) positions. The backhoe will stay in any position until you move it with the levers. A decal near the controls shows, by symbols, what lever movements cause which backhoe actions. The symbols, lever movements and backhoe actions are explained on the following pages.

9821/0000-09

Operation Operating Levers Raise Boom

Slew Left

To raise the boom A, pull the lever diagonally left and towards you. Before raising the boom check that it is clear overhead.

To slew the boom to your left C, push the lever diagonally left and away from you. Note: Some backhoe buckets and attachments may collide with the stabiliser legs if slewed too far round. Check this before using different attachments.

Lower Boom To lower the boom B, push the lever diagonally right and away from you.

Slew Right To slew the boom to your right D, pull the lever diagonally right and towards you.

A B

D C

A D

D026470

Fig 32.

D026480

Fig 33.

9821/0000-09

Operation Operating Levers Dipper In

Close Bucket

To bring the dipper in E, pull the lever diagonally right and towards you.

To close the bucket G pull the lever diagonally to your left. Open Bucket

Note: Some backhoe attachments may collide with the boom if brought too far in. Check this before using different attachments.

To open the bucket H push the lever diagonally to your right.

Dipper Out To push the dipper out F, push the lever diagonally left and away from you. If the boom is already up, check that it is clear overhead before swinging the dipper out.

D026500

Fig 35.

D026490

Fig 34.

9821/0000-09

Operation Operating Levers

Servo Excavator Controls

From Serial Number – 3DX Xtra from 1491201 to 1502999 – 3DX Super from 1491201 to 1502999 – 4DX from 1415101 to 1416999

!MWARNING Do not operate the excavator controls from outside the machine, or you could be crushed by the excavator. 2-2-3-1

When not in use the excavator controls can be put in the stowed position. To move the controls into the excavating postion press the foot pedal C down and engage the excavator joystick into the locked position.

The joystick is returned to the stowed position by pressing the foot pedal C and moving the excavator control until it locks in the stowed position. K Fig 36. ( T 55). K Fig 37. ( T 55). On machines with JCB ('+') Pattern control, there are two backhoe control levers. The left hand lever A operates the boom and slew. The right hand lever B operates the dipper and bucket. For operation of the stabilisers. K Stabiliser Controls (Servo Machines) ( T 60).

P040540-05

Fig 36.

Both levers move in a '+' pattern for individual backhoe actions. Combined actions can be selected by moving the levers in directions between the four main ones.

Both levers can be operated at the same time, for more efficient operation. The speed of the backhoe action depends on how far you move the levers. The further you move a lever, the faster the action. Both levers are spring-loaded to their central (hold) positions. The backhoe will stay in any position until you move it with the levers. A decal near the controls shows, by symbols, what lever movements cause which backhoe actions. The symbols, lever movements and backhoe actions are explained on the following pages.

P040540-12

Fig 37. 4DX Machines with Servo and AC

9821/0000-09

Operation Operating Levers Raise Boom

Slew Left

To raise the boom A, pull the lever towards you. Before raising the boom check that it is clear overhead.

To slew the boom to your left C, push the lever left. Note: Some backhoe buckets and attachments may collide with the stabiliser legs if slewed too far round. Check this before using different attachments.

Lower Boom To lower the boom B, push the lever away from you.

Slew Right To slew the boom to your right D, pull the lever right.

A B

C D

P040680-1

Fig 38. P040680-2

Fig 39.

9821/0000-09

Operation Operating Levers Dipper In

Close Bucket

To bring the dipper in E, pull the lever towards you.

To close the bucket G pull the lever to your left.

Note: Some backhoe attachments may collide with the boom if brought too far in. Check this before using different attachments.

Open Bucket To open the bucket H push the lever to your right.

Dipper Out To push the dipper out F, push the lever away from you. If the boom is already up, check that it is clear overhead before swinging the dipper out.

F E G

P040680-4

Fig 41.

P040680-3

Fig 40.

9821/0000-09

Operation Operating Levers

Stabiliser Controls (Non-Servo Machines)

Raise Stabilisers To raise the stabilisers A and C, push the levers towards the rear of the machine.

From Serial Number

Lower Stabilisers

â&#x20AC;&#x201C; 3DX Xtra from 1491201 to 1502999 â&#x20AC;&#x201C; 3DX Super from 1491201 to 1502999

To lower the stabilisers B and D, pull the levers towards the front of the machine.

â&#x20AC;&#x201C; 4DX from 1415101 to 1416999

Lever Controls

!MWARNING Stabilisers Bystanders could be crushed and obstacles could be damaged if they are beneath the stabilisers while they are being lowered. Before lowering the stabilisers, make sure any bystanders are clear of the machine. Also make sure that there are no obstacles beneath the stabilisers.

2-2-2-10

405090-1

Fig 42. Manual Controls

The stabilisers must be down when you use the excavator, or the machine will rock violently. Each stabiliser has its own control lever and can be operated independently. Lower each stabiliser to level the machine and take the weight off of the rear tyres. The loader shovel should be used along with the stabilisers to level and steady the machine. 2-2-2-8_1

Before travelling, fully raise both stabiliser legs. On sideshift machines, when stabiliser leg has fully raised, the top of the stabiliser leg can be seen through the hole E. If the stabiliser leg has not been fully raised the stabiliser leg will not be visible as shown at F.

338901-2

Fig 43.

Use the stabiliser control levers that are applicable to your machine.

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Operation Operating Levers

366080

Fig 44. Occasionally there may be a need for fully extending one or both stabiliser legs and rams in order to level the machine on steep slopes. In these conditions it may be necessary to use the boom to apply a down force to enable the stabiliser to fully extend, also raising the shovel off the ground can help.

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Operation Operating Levers

Stabiliser Controls (Servo Machines)

Raise Stabilisers

From Serial Number

To raise the stabilisers A and C, push the levers towards the rear of the machine.

â&#x20AC;&#x201C; 3DX Xtra from 1491201 to 1502999

Lower Stabilisers

â&#x20AC;&#x201C; 3DX Super from 1491201 to 1502999 â&#x20AC;&#x201C; 4DX from 1415101 to 1416999

To lower the stabilisers B and D, pull the levers towards the front of the machine.

Lever Controls

!MWARNING You must be sitting in the driving seat when operating the stabiliser controls. Do not operate the stabilisers from outside the machine. Otherwise you could be crushed when the machine moves. The stabilisers must be down when you use the excavator, or the machine will rock violently. Each stabiliser has its own control lever and can be operated independently.

P040680-5

Fig 45. Manual Controls

Lower each stabiliser to level the machine and take the weight off of the rear tyres. The loader shovel should be used along with the stabilisers to level and steady the machine. 2-2-2-8_1

338901-2

Fig 46.

9821/0000-09

Operation Operating Levers

366080

Fig 47. Occasionally there may be a need for fully extending one or both stabiliser legs and rams in order to level the machine on steep slopes. In these conditions it may be necessary to use the boom to apply a down force to enable the stabiliser to fully extend, also raising the shovel off the ground can help.

Stabiliser indicator lights Some machines are fitted with optional stabiliser indicator lights. The lights will illuminate when both stabiliser legs are in the down position and the weight of the machine is supported. If fitted, ensure both indicator lights illuminate when the stabiliser legs are in the down position. If the lights do not illuminate do not use the machine until the fault is investigated and corrected.

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Operation Operating Levers

Auxiliary Controls 6-in-1 Clamshovel On machines fitted with a 6-in-1 clamshovel there is a second control lever next to the standard one. On these machines, the standard lever operates as described earlier. The second lever operates the clam on the clamshovel. The two levers can be operated at the same time to produce combined loader actions. The lever movements and their effects on the shovel are shown on a plastic decal located close to the lever.

Open Bucket

To open the clam F, push the lever forward.

Close Bucket To close the clam G, pull the lever back.

d052250

Fig 48.

9821/0000-09

Operation Travel Speed modes

Travel Speed modes All the 3DX machines built after 1855501 will have the following travel speed modes as standard option. â&#x20AC;&#x201C; Economy Mode â&#x20AC;&#x201C; Power Mode

Economy Mode The machines are pre-built with the economy mode where the maximum travel speed is restricted to 36 KPH and the engine speed varies between 1950 and 2050 RPM. The performance of the machine has been optimized for this position to give the best balance of output with increased fuel economy.

Power Mode To activate the power mode, remove the bracket A from the fuel pump. Travel speed of 40 KPH can be achieved by this mode and the engine speed is reset by 2320 to 2420 RPM. Productivity will be increased with an associated increase in fuel consumption. Note: Ensure the safe custody of the bracket and the mount for the future fitment.Any adjustment or modification should not be attempted on the fuel pump as this will invalidate the emissions certification of the engine.

Fig 49.

9821/0000-09

Operation Safety Equipment

Safety Equipment Boom and Slew Locks Boom Lock We recommend that the boom lock and the slew lock be engaged before travelling on the road. Check on a daily basis that the boom lock fully engages and secures the boom. If the lock does not fully engage (or disengage) the boom stop A may need adjusting (consult your JCB Distributor).

!MWARNING B

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

It is recommended that the slew lock is engaged before fitting the boom lock. Note: The illustration shows a centremount boom and slew lock arrangement. Sideshift machines stow the slew lock pin in the toolbox.

Engage the Boom Lock 1

Set the backhoe straight behind the machine, rest the boom on the ground.

Make sure that the boom lock B is fully raised. D0551250

Fig 50.

Close the boom ram (raise the boom).

Lower the boom lock B, make sure that the lock is fully engaged in the boom lugs.

Lower the boom a little to tighten the lock.

Disengage the Boom Lock 1

Raise the boom a little to release the lock.

Raise the boom lock B.

9821/0000-09

Operation Safety Equipment Slew Lock

Remove the lock pin G and put it in the tool box.

We recommend that the boom lock and the slew lock be engaged before travelling on the road.

!MWARNING 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

!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

Empty the bucket/attachment.

Slew the backhoe into the required position. Make sure that hole E (in the kingpost) aligns with hole F (in the mainframe). Stop the engine.

D0551260

Fig 51.

!MWARNING Do not attempt to install or remove the slew lock pin when sat in the cab, you will be leaning over the backhoe control levers. You or others can be killed or seriously injured if the control levers are accidently operated. 2-2-3-10_1

Remove the slew lock pin G from the tool box and fit it into the aligned holes.

Disengage the Slew Lock 1

Stop the engine.

9821/0000-09

Operation Safety Equipment

Beacon (if fitted) In certain territories you will be breaking the law if you do not fit a rotating beacon before you travel on public highways - make sure you are complying with local laws. Note: Be careful when you operate the machine with a beacon. The total height of the machine is increased when the beacon is in the operating position. 1

Put the beacon A on the cab roof.

Note: The beacon is held in position by a magnetic base. 2

Put the plug B into the cab roof socket C.

Use the switch D to operate the beacon. The indicator light in the switch comes ON when the beacon is operating.

In some territories, to meet legislative requirements, a beacon extension mount E must be fitted, or the beacon must be mounted on the dipper. Consult your JCB Distributor for advice. Do not climb on the machine to fit the beacon on the dipper. Fully extend and lower the boom and dipper so that it is possible to fit the beacon whilst standing on the ground.

227600-3

Fig 52.

9821/0000-09

Operation Before Starting the Engine

Before Starting the Engine Note: Read Operating Environment in Operation section if you will be using the machine in very cold or very hot climates. Note: If the fuel tank has been empty or if any part of the fuel system has been drained or disconnected, the fuel system must be primed before attempting to start the engine. See Bleeding the System, Maintenance section. 1

!MWARNING 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

The park brake should have been engaged when the machine was last parked. But if it is not already engaged, engage it now.

Remove oil, grease and mud from the pedals, control levers and the steering wheel.

d Make sure that your hands and shoes are clean and dry.

!MDANGER

!MWARNING

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.

Loose articles can fall and strike you or roll on the floor. You could be knocked unconscious, or the controls could get jammed. If that happens you could lose control of the machine. 2-2-3-7_1

2-2-3-4

Remove or secure all loose articles in the cab such as lunch boxes, tools etc.

Inspect the ROPS/FOPS structure for damage. Get your JCB Distributor to repair any damage. Make sure all its securing bolts are fitted and correctly tightened.

Make sure that the attachment is on the ground.

!MCAUTION On machines fitted with hose burst protection valves the attachments cannot be lowered with the engine stopped. On these machines start the engine and lower the attachments before doing the walk round inspection.

g Check around the cab for loose or missing bolts, screws etc. Replace or tighten where necessary.

2-2-3-5

h Inspect the seat belt and its mountings for damage and excessive wear.

For your own safety (and others) and for a maximum service life of your machine, do a pre-start inspection before starting the engine. a

If you haven't already done it, do a walk round inspection of the outside of the machine. See Before Entering the Cab. Also, complete the daily checks as detailed in the Service Schedules.

b Remove dirt and rubbish from the cab interior, specially around the pedals and control levers.

Check that the following are in working order: Lights, Warning Lights, Horn, Indicator Lights, All Switches, Direction Indicators, Hazard Warning Lights, Windscreen Washer and Wipers (if fitted).

9821/0000-09

Operation Before Starting the Engine 4

Adjust the seat so that you can comfortably reach all the driving controls. You should be able to apply full brake pedal travel with your back against the seat back.

If fitted, adjust the armrest so that you can reach and operate the controls without stretching.

If fitted, set the rear view mirror(s) to give you a good view close behind the machine when you are correctly seated.

Fasten the seat belt.

9821/0000-09

Operation Starting The Engine

Starting The Engine 1

Read and comply with Before Starting The Engine.

Put the Forward, Reverse lever in neutral.

The engine will not start unless the forward, reverse lever A is in neutral. 3

Put the gear lever in neutral.

Note: The gear lever B is only fitted to machines equipped with Synchro Shuttle (manual) transmission. 4

Set the hand throttle lever to minimum. Make sure that hand throttle lever C is set at the minimum engine revolution position.

D026680

Fig 53. Manual Controls 6

Normal engine start. a

Release the starter key as soon as the engine starts. The switch will return to `IGN' position I.

!MWARNING

Slightly depress the accelerator pedal D.

b Turn the starter switch E to position III and hold it there until the engine starts.

Do not use ether or other starting fluids to assist cold starting. Using these fluids may result in an explosion causing possible injury and/or damage to the engine. 3-2-1-9

Ease off on the accelerator pedal to reduce engine speed.

Once the engine has started, check that all the warning lights have gone off. Do not race the engine until the oil pressure low light has gone out. Racing the engine too soon could damage the turbo-charger due to under lubrication. Check that the audible alarm is silent.

Note: The engine noise and or tone may be louder than usual when cold. This is normal and is due to the fuel injection pump being advanced. The engine will become

9821/0000-09

Operation Starting The Engine quieter when the engine reaches normal operating temperature.

Note: If any warning lights fail to go off, or come on while the engine is running, stop the engine as soon as it is safe to do so. 9

Operate the backhoe a few times to help warm up the hydraulic system. Do not operate attachments until the hydraulic oil has reached its normal working temperature.

Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).

Note: Do not attempt to move the machine if the Service Brake warning light does not go off. Contact your JCB dealer.

Starting the Engine in Cold Climate

D070490

Fig 54.

Cold climate engine start (If fitted), -6ºC (21ºF) 1

Turn the starter switch C to position I, the cold start inlet manifold heater warning light will come ON.

Fully depress the accelerator pedal to the floor.

When the warning light goes OFF, turn the starter switch C to the ‘start’ position III and hold it there until the engine starts.

Position I

Heater illumination ON - LED

Starter switch

Note: Do not operate the starter motor for than 10 seconds without the engine firing. If the engine fires but does not fully start, do not operate the starter motor for more than 40 seconds. Let the starter motor cool for at least two minutes between starts.

Warning Lights With the starter switch in position I, if the outside air temperature is -6ºC (21ºF) or below the light will illuminate indicating that the manifold heater is ON. When the light extinguishes, the engine is ready to start.

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Operation Preparing The Machine For Travel

Preparing The Machine For Travel When travelling on the road or on site there are usually local rules and safety regulations for the machine travelling position. The 'Road Travelling Position' and 'Site Travelling Position' described on the following pages are recommendations that should help you meet the requirements of these regulations; they are not necessarily the applied law: PLEASE MAKE SURE THAT BEFORE TRAVELLING ON THE ROAD OR ON SITE, YOU AND YOUR MACHINE COMPLY WITH ALL THE RELEVANT LOCAL LAWS - IT IS YOUR RESPONSIBILITY. Whether driving on the road or on site, there are two possible travelling positions: 1

The 'tucked-in' position, i.e. the backhoe is placed across the back of the machine. K Fig 55. ( T 71). The 'central protruding' position, i.e. the backhoe is placed central and protruding from the back of the All centremount machine. K Fig 56. ( T 71). machines must travel in the 'central protruding' position.

Choosing the correct travelling position will depend on; the type of machine you are operating and the type of equipment you have fitted to the backhoe.

182290-1

Fig 56. Central Protruding Position

Backhoe Attachments We recommend that all backhoe attachments be removed before travelling on the road. However, if the machine IS driven on the road with attachments fitted, then the conditions listed under the headings Tucked-In Travel Position and Central Protruding Travel Position should be maintained.

Tucked In Travel Position 1

The attachments must not cause the maximum overall machine width to exceed 2.5m (8.2ft). If any part protrudes beyond the outer edge of the rear frame, it must be marked with red and white stripes to warn that a hazard exists.

The boom lock and slew lock must be securely fitted. K Boom and Slew Locks ( T 64).

In certain territories, it will be necessary to fit a bucket crowd ram safety strut.

The attachments must not protrude from the back of the machine by more than 1m (3.28ft). If the attachments do protrude by more than 1m (3.28ft) then a rear protrusion plate/light must be fitted. If the attachment is removed, then the tipping link must be secured.

182280-1

Fig 55. Tucked In Position

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Operation Preparing The Machine For Travel 5

Machine stability must be maintained.

The rear stop, tail, indicator lights (both sides) must be clearly visible from the rear of the machine.

The hydraulic clamps (kingpost clamps) must be engaged.

Important: Whilst this information is believed to be correct, JCB can not be aware of all circumstances in which JCB machines may be operated on a Public Highway and it is the responsibility of the user to ensure compliance with the regulations. 4

Set the backhoe, there are two possible positions.

Central Protruding Travel Position

Engage the boom and slew locks.

The attachments must not affect machine stability. For instance there must be at least 20% of the total machine weight acting on the front axle.

If the backhoe is set central to the rear frame, attach a protrusion plate/light to the dipper. Ensure that the plate light is plugged in.

The backhoe must be set centrally on the rear frame and hydraulic clamping engaged (applicable to sideshift machines only).

If any attachments are fitted, make them safe, for example, fit tooth guards etc. If forks are fitted, put them in the fork stowage position.

The boom lock and slew lock must be securely fitted. K Boom and Slew Locks ( T 64).

In certain territories, it will be necessary to fit a bucket crowd ram safety strut.

Note: In certain territories you will be breaking the law if you do not fit a tooth guard to the loader shovel, even if the teeth are not fitted. Make sure you are complying with local laws.

A protrusion plate/light must be fitted. If the attachment is removed, then the tipping link must be secured and the rear protrusion plate/light must still be fitted.

Road Travel Position Read and understand the information given on Preparing The Machine For Travel. The recommendations given below ARE NOT necessarily the applied law, please make sure you are complying with the relevant local laws.

On machines with dual brake pedals, lock the pedals together when driving on the road in any gear. The stop lights should come on when the brakes are applied.

Make sure the stabilisers are fully up.

Note: Make sure the stabiliser legs are clean and free from debris before retracting. 10

Note: Machines without headlights and sidelights are designed for site use, you may be breaking local laws if you travel on the road without headlights or sidelights. 1

Secure any additional backhoe bucket inside the front loader shovel. If fitted, use the shovel mounted hanger bracket; the bucket MUST BE secured before travelling on the road.

Roll the shovel fully back. Position it to clear the road surface by 300 mm (1ft in).

Always assess your route for overhead structures such as bridges which could be damaged by your machine.

Select the following drive (depending on machine type):

steer

positions

2 Wheel Steer Machines - select 'Two Wheel Drive - All Wheel Braking'.

b 4 Wheel Steer Machines - select 'Two Wheel Steer'. 11

9821/0000-09

Check that the road lamps are all in working order and clearly visible. Do not drive the machine unless both stop lights work correctly.

Operation Preparing The Machine For Travel

Site Travel Position Read and understand the information given on Preparing The Machine For Travel. The recommendations given below ARE NOT necessarily the applied law, please make sure you are complying with the relevant local laws. 1

Machines without smooth ride system, roll the shovel fully back. Position it to clear the surface by 300 mm (12 in), as shown at F.

F 762410-1

Fig 57. 2

Set the backhoe, there are two possible positions. K Tucked In Travel Position ( T 71), K Central Protruding Travel Position ( T 72).

If any attachments are fitted, make them safe. Unless you are using the forks to carry a load, put the forks in the stowage position.

Engage the boom and slew locks. K Boom and Slew Locks ( T 64).

Make sure the stabilisers are fully up. K Stabiliser Controls (Servo Machines) ( T 60).

4 Wheel Steer Machines Only: Select the mode of steering most suitable for the terrain and the work you are doing.

Select the drive and brake mode most suitable for the terrain and the work you are doing.

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Operation Getting The Machine Moving

Getting The Machine Moving Operating Practices The machine can be put in motion in any gear. But do not over work the engine unnecessarily by using too high a gear for example, on a hill. Operating in too high a gear will overheat the torque converter fluid. When moving the machine, keep it under control at all times. Stay alert for obstructions and possible hazards.

Note: Do not use 4-wheel drive on the road or hard surfaces, as it will cause excessive tyre wear and fuel consumption.

!MWARNING In 4-wheel steer, the back end of the machine will swing out when you make a turn. Check for clearance before making a turn. 5-2-3-3

Do not use the brake pedals as footrests. 3

Engage a gear using gear lever G K Fig 58. ( T 75).

Do not coast the machine in neutral, you will not have full control. Also, coasting the machine will damage the transmission.

!MWARNING

Select the necessary gear before starting down a slope. Use the same gear you would use to go up the slope. Do not change gear on the slope.

You and others can be killed or injured if you operate the forward/reverse lever while you travel. The machine will immediately reverse direction without warning to others. Follow the recommended procedure for proper use of this selector.

If the load will be pushing the machine on a down slope, select first gear (1) before starting downhill. Use the brake pedal to prevent overspeeding down a slope. Approach deep mud in first gear (1) with the front wheels straight.

2-2-2-4_2

!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. INT-5-3-3

The front and rear axles are fitted with axle breathers. If the machine is to be driven into deep water (i.e. above the level of the breather), care should be taken to ensure that water does not enter the breather.

Select Forward or Reverse and move off a

UNDER NO CIRCUMSTANCES must the rear axle breather be blanked off, as this could cause a reduction in brake efficiency.

b Push the brake pedal(s) D hard down c

After you have warmed up the engine and tested the park brake, make sure the service brake warning light has gone off, then move off as described below. 1

Check your seat belt and seat. a

Check that the attachments are in one of their travel positions.

Lift the forward/reverse lever E from its detent position and select forward or reverse.

Note: When forward or reverse drive is selected, an audible alarm will sound and a warning light will show to remind you that the park brake is still engaged.

Make sure that your seat belt is correctly fastened.

d Release the park brake F.

b Make sure that the seat is correctly adjusted. 2

Select 2 or 4 wheel drive K Switches ( T 37).

9821/0000-09

Operation Getting The Machine Moving

!MWARNING

When driving the machine, use only the accelerator pedal to control the engine speed. Do not use the hand throttle lever to set the engine speed while driving.

2-2-2-2

Make sure it is safe to move off, then release the brake pedals and push down on the accelerator pedal. The machine will move smoothly away.

!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. INT-2-1-5

While the machine is travelling slowly, check the steering and brakes. Do not drive the machine unless the steering and brakes are working correctly. If you are not sure, assume they are faulty.

Fig 58.

9821/0000-09

Operation Stopping and Parking the Machine

Stopping and Parking the Machine Stop the machine on dry and level ground where the machine will not be a hazard or danger. It is recommended that the backhoe is extended when parking, make sure there is enough room.

Lower the loader arms and backhoe assembly to the ground. It is recommended that the backhoe is positioned with the bucket fully open, boom and dipper fully extended. K Fig 59. ( T 76).

!MWARNING 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

Fig 59. 1

Ease up on the accelerator pedal A and down on the brake pedals B to bring the machine to a smooth stop. Keep the foot brakes on until the park brake has been pulled on.

If you are leaving the machine, make sure that all switches are set to off. If necessary, leave the hazard warning and/or side lights switched on. Remove the starter key D.

4-2-1-1_2

Pull the park brake lever C fully up. Make sure that the park brake indicator lights up. Release the foot brakes.

!MWARNING Do not dismount a moving machine. 3-2-3-12

Set the forward/reverse lever E to neutral. Make sure the lever is in its detent position.

Lower the stabiliser legs until they just touch the ground.

!MDANGER

D026550

Fig 60. Manual Controls 7

Use the handholds and step when you climb down from the machine. If you are leaving the machine, close and latch all windows and lock both doors. Make sure that the filler cap is locked on.

2-2-3-4

9821/0000-09

Operation Stopping and Parking the Machine

At the end of a working cycle or if the machine is being left unattended, provided the lights are not required remove the battery isolator key (if fitted).

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Operation Working With The Machine

Working With The Machine Operating Practices and Site Safety T2-057_2

This section explains some techniques and procedures for efficient and safe use of the machine and its attachments. Attention is also drawn to the various safety aspects of operating on site. Read and understand this section before you start working with the machine. Make sure that you have had adequate training and that you are confident in your ability to operate the machine safely before you use it. Practice using the machine and its attachments until you are completely familiar with the controls and what they do. With a careful, well trained and experienced operator, your machine is a safe and efficient machine. With an inexperienced or careless operator, it can be dangerous. Do not put your life, or the lives of others, at risk by using the machine irresponsibly. Before you start to work, tell your work mates what you will be doing and where you will be working. On a busy site, use a signalman.

applicability of these notes must be determined by the person seeking to apply them, on the basis of his/her own judgement, in the light of the conditions in which use is intended and subject to all relevant statutory requirements. The information in this section is given in good faith and in light of the best information available, JCB can accept no responsibility for the recommendations, advice, statements, opinions and conclusions expressly or by implication and gives no warranty or representation of assurance in respect of the accuracy of the same. Remember that your machine is mobile. Whenever possible, manoeuvre it into a position which combines safety and efficiency. But if you have to choose, always remember that: Safety must come first.

Clothing and Safety Equipment T2-069

Do not wear loose clothing or jewellery that can get caught on controls or moving parts. Wear protective clothing and personal safety equipment issued or called for by the job conditions, local regulations or as specified by your employer.

Danger Zone Appropriate job site organisation is required in order to minimise hazards that are caused by restricted visibility. Job site organisation is a collection of rules and procedures that coordinates machines and people that work together in the same area. Examples of job site organisation include: â&#x20AC;&#x201C; Restricted areas

Before performing maintenance tasks make the machine safe. Refer to Make the Machine Safe.

â&#x20AC;&#x201C; Controlled patterns of machine movement â&#x20AC;&#x201C; A system of communication

Log Moving/Handling

You and/or your company could be legally liable for any damage you may cause to public utilities. It is your responsibility to make sure that you know the locations of any public utility cables or pipes on the site which could be damaged by your machine. Before doing any job not covered in this manual, find out the correct procedure. Your local JCB distributor will be glad to advise you. There are a wide variety of situations in which your machine may be used. Consequently, in all cases, the

T2-046_2

The danger zone means any zone within and/or around machinery in which a person is subject to a risk to his health or safety. During operation of the machine, keep all persons out of the danger zone. Persons in the danger zone could be injured. Refer to Specifications.

T2-047

Do not use the machine to move or handle logs unless it has been fitted with adequate log protection. You could cause serious injury to yourself and damage the machine. Contact your JCB dealer.

Safety Practices P2-2019_3

Read Operating Safety (Introduction Section), plus the following information.

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Operation Working With The Machine

!MWARNING

Reworking Old Sites There could be dangerous materials such as asbestos, poisonous chemicals or other harmful substances buried on the site. If you uncover any containers or you see any signs of toxic waste, stop the machine and advise the site manager immediately.

Underground Gas Pipes Before you start using the machine, check with your local gas company if there are any buried gas pipes on the site.

2-2-5-5

!MWARNING Water Supplies and Drains Before you start using the machine, check with your local public water supplier if there are buried pipes and drains on the site. If there are, obtain a map of their locations and follow the advice given by the water supplier.

If there are buried gas pipes we recommend that you ask the gas company for any specific advice regarding the way you should work on the site. Some modern gas pipes cannot be detected by metal detectors, so it is essential that an accurate map of buried gas pipes is obtained before any excavation work commences. Hand dig trial holes to obtain precise pipe locations. Any cast iron pipes found should be assumed to be gas pipes until contrary evidence is obtained.

You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near buried pipes and drains.

Older gas pipes can be damaged by heavy vehicles driving over the ground above them.

2-2-5-6

Leaking gas is highly explosive.

!MWARNING Fibre Optic Cables If you cut through a fibre optic cable, Do not look into the end of it, your eyes could be permanently damaged. 8-2-9-20

If a gas leak is suspected, contact the local gas company immediately and warn all personnel on the site. Ban smoking, ensure that all naked lights are extinguished and switch off any engines which may be running. You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near buried gas pipes. 2-2-6-1_1

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Operation Working With The Machine

Working With The Loader Introduction To use the JCB Backhoe Loader efficiently and safely you must know the machine and have the skill to use it. This manual instructs you on the machine, its controls and its safe operation. It is not a training manual on the art of loading. If you are a new operator, get yourself trained in the skills of using a JCB Backhoe Loader 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. Remember that you will be driving the machine while you are using the loader. Keep alert for bystanders and possible hazards. Stay in the correct driving position. Keep your seat belt fastened. When working with the loader, set the backhoe straight behind the machine, as for road travel.

Keep the loader shovel low to the ground when travelling. This increases your visibility and makes the machine more stable.

812080

Whenever possible, travel in reverse when you are carrying a loaded shovel downhill. Travel forward when you are going uphill. With heavily loaded shovels, do not travel faster than 8 km/h (5 m.p.h.). If Smooth Ride System is fitted and selected ON the loader can not power down. For duties other than light handling the system should be selected OFF.

!MWARNING Do not attempt to use the lugs on the top of a loader shovel for lifting equipment, towing or using as tie down points. The lugs have not been designed for these purposes. 2-4-5-8

Loader shovels without forks fitted, lugs A must not be used for lifting, towing or tie down points under any circumstances.

Fig 61.

Hydraulic Speed Control (HSC) (if fitted) The HSC switch is located on the instrument panel and loader control lever. By operating this switch, the HSC Solenoid valve is energised thereby dumping one pump flow to tank. There are two main applications for this operation: â&#x20AC;&#x201C; More tractive force can be applied to the loader end when entering a stock pile. â&#x20AC;&#x201C; More power can be made available from the engine whilst the machine is travelling on the highway. Operating this switch will also lead to better fuel economy while roading.

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Operation Working With The Machine Filling the Loader Shovel

Loading a Truck T2-004_2

!MWARNING When loading with material from a high bank or pile, remove any overhang first. Watch out for sliding material. If overhanging material falls, you and your machine could be buried. 2-2-6-3

On hard surfaces, select Float. As the shovel enters the pile, start rolling the shovel back while raising it at the same time. This will sweep the shovel up the pile, gathering material as it goes. When entering a stockpile, pressing the hydraulic flow rate selector switch to LO will give more tractive force to the loader. Pressing the transmission dump switch will give more power to the loader and speed the operation. Try to fill the shovel in one pass. Half full shovels are less productive.

Put the truck(s) at an angle of about 45Â° to the pile, as shown. This cuts out unnecessary manoeuvring. Allow enough distance for the shovel to reach its unloading height while you are travelling, without slowing down. Keep the wind on your back. This keeps dust away from you and your machine. Move your machine as close as possible to the truck before unloading. If the truck body is about as long as a shovel's width, tip the load into the centre of the truck. If the truck is two shovelwidths long or more, load the front of the truck first. Do not dump the material in one sudden movement. Roll the shovel forward in stages until it is empty. Use the control lever to rock the shovel back and forth to loosen any sticky material.

When moving the load, roll the shovel right back to prevent spillage. When you are loading from a pile of loose material, start at the bottom and follow up the face as shown. Approach the pile with the shovel level and skimming the ground. In tightly packed material, start at the top and work down. When removing material from a stockpile, start at a shovel's height from the base. Once the height of the stockpile has been reduced, begin loading from the base. 145500-2

Fig 63.

145491-1

Fig 62.

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Operation Working With The Machine Back filling

6 in 1 Bucket

When back filling on a slope, pile the material on the high side of the trench if possible.

Dozing/Grading

Set the shovel level to the ground.Select a shovel height and gear speed which will give maximum depth of cut without over loading the engine. Work at right angles to the trench, filling a shovel's width at a time K Fig 64. ( T 82). Leave any spillage until the trench is filled. Use the spillage to finish the job by driving the length of the trench with the shovel low to the ground.

Keep the bottom of the shovel parallel to the ground when using the machine as a dozer or for grading. When grading a site, use forward travel to remove high spots. Use the soil collected this way to fill in the troughs when reversing K Fig 65. ( T 82). Do not use excessive down pressure on the shovel, or the machine could lose traction. In hard material, use the shovel teeth K Fig 65. ( T 82).

D000611

Fig 64.

D000613

Fig 65.

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Operation Working With The Machine Loading and Digging

Grabbing

The 6 in 1 clam shovel allows you to load, dig, grab, grade, doze and spread without changing attachments. With the clam closed, the shovel can be used as a conventional shovel as described in Using the Loader. For higher dumping, open the clam instead of rolling the shovel K Fig 66. ( T 83).

Open the clam and set the shovel directly above the object to be grabbed. To grab the object, lower the shovel and close the clam K Fig 67. ( T 83).

D000616

Fig 67. Grading

D000614

Fig 66.

To grade, open the clam and drag the shovel backwards. When the shovel is full, roll it back and close the clam K Fig 68. ( T 84).

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Operation Working With The Machine

D000617

Fig 68.

9821/0000-09

Operation Working With The Machine Dozing To doze, open the clam and drive the machine forward K Fig 69. ( T 85).

0 5 10 15

D000618

Fig 69. Spreading Load the shovel with the material to be spread. The indicator A shows the clam opening in centimetres. K Fig 70. ( T 85).

D000619

Fig 70. Set the clam opening to suit the size of material and rate of flow. Drag the shovel backwards, allowing it to discharge an even layer of material as it goes K Fig 71. ( T 85).

D000621

Fig 71.

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Operation Working With The Machine Lifting and Loading Operations P5-2067

Ensure that all local and national legislation governing operations such as lifting and loading are fully satisfied before operating the machine. This should include the selection of the correct model of machine for the operation, and the planning of the lifting operation itself.

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Operation Working With The Machine Risk Assessment

!MDANGER

P2-2025

Factors affecting machine stability include size and type of load, angle of elevation, the distance the boom is extended, ground condition and wind speed and direction. It is the responsibility of the operator to assess the wind conditions and size of load before operating the machine. It is the responsibility of the operator to assess the terrain, surface roughness, firmness of ground (remember that when wet, the ground will not support the same loads as when dry) before operating the machine.

and that the operator is satisfied that no part of the operation is outside the scope of his/her training and experience. Traffic routes should be of consolidated firm ground with no gradient more severe than the following: Maximum up slope :

15% (1 in 7)

Maximum down slope:

15% (1 in 7)

Maximum lateral slope:

15% (1 in 7)

These figures apply only to the machine in it's normal travelling mode, that is with the upper surface of the heels of the fork arms not more than 500mm (20in) above mean ground level, and travelling no faster than walking pace. Particularly in the case of a lateral slope, some form of restraint on the load may be necessary.

0074

It is the responsibility of the competent people planning the job and operating the machine to make judgement as to the safe use of the machine, having taken into account the specific application and conditions of use at the time.

Observe the maximum wading depth of this machine. Water can enter the engine and axles, and the cooling fan can be damaged if the machine is operated in deeper water. Personnel

It is essential that a risk assessment of the work to be done is completed and that the operator complies with any safety precautions that the assessment identifies. If you are unsure of the suitability of the machine for a specific task, contact your JCB distributor who will be pleased to advise you. The following considerations are intended as suggestions of some of the factors to be taken into account when making a risk assessment. Other factors may need to be considered. Important: An adequate risk assessment depends on the training and experience of the operator. Do not put your life or the lives of others at risk. General An area selected as a loading/unloading area should be large enough to accommodate all the wheels of the machine and stabilisers (if fitted). It should not be necessary for the machine to make tight turns with an elevated load.

– Are all persons who are going to take part in the operation adequately trained, experienced and competent? Are they fit and adequately rested? A sick or tired operator is a dangerous operator. – Is supervision needed? Is the supervisor adequately trained and experienced? – As well as the machine operator, are any assistants or lookouts needed? The machine – Is it in good working order? – Have any reported defects been rectified? – Have the daily checks been carried out? – Are the tyres still at the correct pressure and in good condition and is there sufficient fuel to complete the job?

However, your machine may safely be used for loading/ unloading operations in areas which are not substantially level provided that its design capabilities are not exceeded

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Operation Working With The Machine The load – How heavy is it? Is it within the capabilities of the machine? – How bulky is it? The greater the surface area, the more affected it will be by wind speeds. – Is it an awkward shape? How is the weight distributed? Uneven loads are more difficult to handle. – Is there a possibility of the load shifting whilst being moved? If so, can it be secured on the forks? Loading/unloading area – Is it level? Any gradient of more than 2.5% (1 in 40) should be carefully considered. – Is more than one direction of approach to the load possible? Approaching across the gradient should be avoided, if possible. – Is the ground firm? Will it support the weight of the machine when loaded? – How rough is the ground? Are there any sharp projections which could cause damage, particularly to the tyres? – Are there any obstacles or hazards in the vicinity, for example, debris, excavations, man-hole covers, power lines? – Is the space adequate for safe manoeuvring? – Are any other vehicles or persons likely to be in or to enter the area whilst operations are in progress? The route to be traversed – How firm is the ground, will it provide adequate traction and braking? – How steep are any gradients, up/down/across? Cross gradients are particularly hazardous, is it possible to detour to avoid them? Weather – How windy is it? High wind will adversely affect the stability of a loaded machine, particularly if the load is bulky. – Is it raining or is rain likely? The ground that was firm and smooth when dry will become uneven and slippery when wet, and it will not offer the same conditions for traction, steering or braking.

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Operation Working With The Machine

Working With The Excavator Introduction

!MWARNING Before you start using the excavator, you must convert the machine into a safe and stable working platform. See Preparing to Use the Backhoe (Operation Section) for details. 2-2-6-4_2

To use the JCB Backhoe Loader efficiently and safely you must know the machine and have the skill to use it. This manual instructs you on the machine, its controls and its safe operation. It is not a training manual on the art of excavating. If you are a new operator, get yourself trained in the skills of using a JCB Backhoe Loader 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. If you will be working with a labourer, make sure you both understand what each other will be doing. Learn and use the recognised signalling procedures. Do not rely on shouting - he will not hear you. Make sure the correct bucket for the job is fitted. Instructions for removing and installing buckets are given on the following pages. For best fuel economy when using the backhoe refer the optimum engine rpm table give below. Table 2. Optimum Engine RPM 3DX 3DX Xtra 3DX 4DX Super Low Idle 950-1000 950-1000

950-1000 950-1000

Hand Throttle (+/- 50)

1750

1550

1750

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Operation Working With The Machine Preparing to Use the Backhoe P2-2021_2

When choosing a digging position, avoid digging downhill if possible. Whenever possible, dump the load on the uphill side of the excavation. Both these precautions will help to keep the machine stable. 1

When the machine is in the desired position on the site, roll the shovel forward, then lower it to take the weight off the front tyres. If Smooth Ride System is fitted, switch OFF the system then lower the shovel in order to take the weight off the front tyres.

!MWARNING The machine will drop suddenly if the Smooth Ride System is selected ON when the machine is supported on the loader shovel. 2-2-6-9

763520-5

Fig 72.

Note: On tarmac surfaces, do not roll the shovel fully forward. Keep the bottom of the shovel flat on the ground. This will minimise damage to the surface. When a Clamshovel is fitted, do not put weight on the fork carriers. 2

Set the transmission to the neutral position. Make sure the lever is in its detent position.

Engage the park brake.

Turn the seat to face the backhoe. Make sure the seat locks in position.

Then lower the stabilisers to raise the rear tyres just clear of the ground. Adjust the stabiliser positions until the machine is level. K Fig 72. ( T 90). In soft ground, put heavy duty planks beneath the stabilisers. This will spread the weight and prevent sinking.

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Operation Working With The Machine Kingpost Clamps On sideshift machines only, the kingpost assembly must be clamped to the cross rails before starting any excavation work. For detailed instructions on how to move the kingpost and backhoe assembly across the rails. K Sideshifting The Backhoe ( T 94). Release Clamps To release the clamps, press switch B on, switch light illuminated. Tighten Clamps To enable the clamps to tighten, press switch B off.

B T039550-55

Fig 73.

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Operation Working With The Machine Changing a Bucket

!MWARNING

P2-2023_2

Removing a Bucket 1

Position the backhoe, set the backhoe straight behind the machine. Rest the bucket on level ground, with the bucket flat as shown. 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

Remove the lock nut A, nut B and spacer C. Remove the bolt D from the pivot pin. Then remove the pivot pin E.

Remove the lock nut F, nut G and spacer H. Remove the bolt J from the pivot pin. Then remove the pivot pin K. Withdraw the dipper, using the controls, carefully lift the dipper clear of the bucket.

H G F

Installing a Bucket

Position the bucket, set the bucket flat on level ground as shown, using a suitable lifting device.

Reverse the machine while aligning the dipper end with the bucket hinge area.

Engage the dipper, carefully operate the controls to line up the holes in the dipper and tipping link with the holes in the bucket. Fit the pivot pin K. Insert the bolt J. Fit the spacer H, nut G and secure by tightening the lock nut F. After the dipper pivot pin has been locked in, fit the tipping link pivot pin E, bolt D, spacer C, nut B and lock nut A.

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C B A D0551270

Fig 74.

Operation Working With The Machine Digging P2-2001

To start the dig, reach out with the boom and dipper and position the bucket. K Fig 75. ( T 93).

Fig 77. Note: Do not use the side of the excavation to stop the bucket. This could damage the machine. Fig 75. Slowly close the bucket and at the same time bring the dipper in. Make sure the bucket stays at the same angle to the ground while it travels. If necessary, at the same time apply a downward pressure on the boom, to increase the digging force on the bucket. When the bucket is full, close it fully and at the same time move the dipper out a little way. K Fig 76. ( T 93). This will keep soil from building up under the machine.

Backfill the excavation by loading the bucket with soil from the pile. Do not push the soil with the side of the bucket.

Moving the Machine while Digging Down Hill Note: When moving the machine downhill make sure you are in the correct driving position. Keep the attachments low to the ground. To move the machine when digging down a hill, raise the excavator stabilisers and shovel and carefully drive the machine to its next position in first gear (1).

Fig 76. Swing the bucket towards the dump area. K Fig 77. ( T 93). Start dumping as the bucket approaches the pile. Do not waste time by dumping too far from the excavation. Dump close to the start dig position. Swing the bucket back to the excavation and start the next dig.

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Operation Working With The Machine Digging near Walls

Sideshifting The Backhoe

Note: When digging near a wall, take care not to undermine the foundations. The wall could collapse.

Manual Sideshift

Position the machine close to the wall as shown. Set the front wheels in line with the wall, pointing in the direction of dig K Fig 78. ( T 94).

Note: Before sideshifting the backhoe, make sure that the kingpost rails are clear of debris. 1

Use the stabilisers to set the machine level and stable, with the kingpost A vertical.

Rest the bucket on the ground, straight behind the machine.

Release the clamps, press the rocker switch B to the 'ON' position, the switch light should be illuminated.

D000637

Fig 78. Digging on Slopes To dig a trench across a slope, use the stabilisers and loader shovel to level the machine. On steeper slopes, cut a level base to work from. Dump the trench material on the uphill side of the trench, far enough away to prevent it falling back into the trench K Fig 79. ( T 94). Note: Do not use the machine to push loads, push out tree trunks, demolition work in case the ARV is not fitted in the bucket circuit. Please check with your JCB Dealer for fitment of ARV in bucket circuit.

D000638

Fig 79.

208710-6

Fig 80. 4

Loosen the kingpost on its rails, operate the boom up and down a few times.

Raise and slew the backhoe directly to one side of the machine. Slew to the left if you want to sideshift to the right. Slew to the right if you want to sideshift to the left. Set the bucket on the ground, with the dipper at 90Â° to the boom as shown.

Open the bucket. As the bucket opens, the kingpost will be pushed across the back of the machine. If the kingpost A sticks in mid-travel, raise or lower the boom slightly to keep the kingpost vertical to the rails.

Once the kingpost is in the required position, tighten the clamps by pressing rocker switch B to the 'OFF' position.

Note: Pressure generated in the backhoe services will ensure the clamps fully engage. Before operating the

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Operation Working With The Machine backhoe, move the bucket control lever to fully crowd the bucket, hold the lever in this position for a minimum of five seconds (engine at 1500 r.p.m.).

Getting the Machine Unstuck P2-2024

If the machine gets stuck in the trench, use the shovel to free it: set the drive in neutral, then roll the shovel forward as shown. Then select shovel Lower to raise the front wheels. When the front wheels are free, slowly roll the shovel back, to push the machine backwards. When the front wheels are on firm ground, select reverse and drive clear.

145411

Fig 81.

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Operation Operating Environment

Operating Environment Operating in Low Temperatures

In low temperature situations, take the following precautions. They will make for easier starting and prevent possible damage to your machine.

Keep the radiator/oil cooler clean, regularly remove dirt and debris from the radiator/oil cooler and the engine.

Check the fan belt regularly.

Use the correct viscosity engine lubricating oil.

Check the air vents. Make sure that the air vents to and from the engine compartment are not blocked.

Use the correct viscosity hydraulic oil.

Check the engine pre-cleaner regularly (if fitted).

If available use a low temperature diesel fuel.

Check the battery electrolyte level.

Use the correct coolant mixture.

Keep the battery at full charge.

Fill the fuel tank at the end of each work period. This will help to prevent condensation forming on the tank walls.

Protect the machine when not in use. Park the machine inside a building or cover it with a tarpaulin.

T3-069_3

Operating in Dusty or Sandy Areas 1

Securely tighten the hydraulic oil tank filler cap to prevent sand and dust from entering the hydraulic system.

Operating in Coastal Regions

Install a cold weather starting aid. In very low temperatures, -18Â°C (0Â°F) and below, additional starting aids may be needed. Examples are fuel, oil and coolant heaters. Ask your JCB distributor for advice.

Important: Do not connect two batteries in series to give 24 volts for starting as this can cause damage to the electrical circuits. 9

After daily operations, wash the machine thoroughly and take special care when cleaning the electrical devices and hydraulic cylinders to prevent salt entry and eventual corrosion.

Operating on Wet or Soft Ground 1

Remove snow from the engine compartment before starting otherwise snow could get into the air filter.

Clean the Machine. Moisture or mud will cause the paint, wiring and metallic parts to deteriorate. When operating the machine keep it as dry as possible and regularly grease the machine.

Operating in High Temperatures T3-070

In high temperature situations, take the following precautions to prevent possible damage to the machine. 1

Use the correct viscosity engine lubricating oil.

Use the correct coolant mixture.

Check the coolant system regularly, keep the coolant at the correct level. Make sure there are no leaks.

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Operation Refuelling the Machine

Refuelling the Machine Low Fuel Levels

Filling the Tank

If you operate the machine on very low fuel levels, then air can enter the fuel system. To prevent the entry of air, always add more fuel when the fuel gauge shows a low level of fuel.

Important: Before you add the fuel to the machine, refer to Fluids, Lubricants and Capacities, Fuels. If you use the incorrect type of fuel or fuel which is contaminated, then damage to the fuel injection system can occur.

If air enters the fuel system, the engine speed will vary dramatically and low power will be experienced. The symptoms may be made worse when the machine operates on steep gradients.

At the end of every working day, fill the tank with the correct type of fuel. This will prevent overnight condensation from developing in the fuel.

Note: If you Increase the engine speed or load while there is air in the fuel system, then subsequent damage to the engine can occur. If the fuel supply contains air, you must stop the engine, fill the fuel tank then bleed the fuel system to remove the air. Refer to Routine Maintenance, Fuel System.

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

Remove all unwanted material from around the filler cap A. K Fig 82. ( T 97).

Remove the filler cap A. a

Important: You must bleed the fuel system after a fuel filter change.

Insert the key and unlock the filler cap.

b Rotate and pull the cap Note: The cap A incorporates a side mounted barrel lock that is operated by the ignition / door key. 4

Add the fuel through the filler neck, as necessary.

Install the filler cap.

Note: The key MUST be inserted in the cap when removing and fitting.

A D026590

Fig 82.

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Operation Moving A Disabled Machine

Moving A Disabled Machine Towing and Retrieval Important: Do not tow a machine unless there is no alternative. Remember that further damage might be caused to the machine by towing it. If at all possible repair the machine where it stands. If the machine must be towed, follow the procedure below.

Wrap the towing slings A around the front axle just inside the steering linkages, avoid any sharp edges, use rubber protectors B if necessary. K Fig 83. ( T 98). Note: Maximum Permissible Towing Force - 154kN.

!MDANGER If the engine is not running, there will not be enough pressure to apply the service brakes. Carefully follow the precautions on this page before moving the machine or there may be a serious accident. 13-2-4-4

Important: Towing a machine too far or too fast can damage the transmission or structural members. Do not tow the machine further than necessary. Move the machine at a speed of 2mph (3kph) or less to a convenient location for repair or access to a trailer for transportation.

Important: If towing is the only alternative, one towing machine must be coupled to the front of the disabled machine. Another towing machine must be coupled to the rear of the disabled machine, to provide braking power.

Important: Always transport the machine on a suitable trailer if long distance moving is required. – Before towing, make sure that both towing slings have the correct strength for the vehicle that is to be towed, this must be 1.5 times more than the gross machine weight per sling.

T033440-1

Fig 83.

– It is advised to use shielding on both machines to protect the operators if the tow line breaks. – Keep the tow line angle to a minimum. Do not exceed a 20 degree angle from the straight ahead position. – Prevent any quick machine movement. This could overload the tow line, gradual and steady movements will be required for a safe retrieval. – Make sure that the towing machine has enough weight, power and braking capacity to perform the towing procedure safely. Note: Block the loader arms before attaching the towing slings.

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Operation Moving A Disabled Machine Running Engine Procedure

Disabled Engine Procedure

Note: All scenarios cannot be listed, due to the vastly different situations that could occur, dependent on the problem and the reason for towing. It is advised you contact your JCB dealer for help and advice on the correct and safest procedure for machine preparation before attempting to move the machine.

Engage the park brake.

Raise all attachments off the ground.

Set the gear lever to neutral (synchro shuttle machines only) or forward/reverse lever to neutral on powershift machines.

All attachments must be raised into their transport positions and secured, move the appropriate control lever to the raise position when performing this procedure. Ensure the control lever is returned to its neutral position after lifting.

The machine is now ready for towing. Make sure you understand what the towing driver will be doing. Obey his instructions and all relevant regulations.

Set the gear lever to neutral (Synchro shuttle machines only) or forward/reverse lever to neutral on powershift machines.

Release the park brake to allow the machine to move.

The machine is now ready for towing. Make sure you understand what the towing driver will be doing. Obey his instructions and all relevant regulations.

Release the park brake to allow the machine to move.

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Operation Transporting The Machine

Transporting The Machine

T001280-2

Fig 84.

!MWARNING

The safe transit of the load is the responsibility of the transport contractor and driver. Any machine, attachments or parts that may move during transit must be adequately secured.

Before moving the machine onto the trailer, make sure that the trailer and ramp are free from oil, grease and ice. Remove oil, grease and ice from the machine tyres. Make sure the machine will not foul on the ramp angle. See Static Dimensions in SPECIFICATION section for the minimum ground clearance of your machine.

5-2-5-9

Note: Before transporting the machine make sure you will be obeying the rules and laws of all the areas that the machine will be carried through. Make sure that the transporting vehicle is suitable. Refer to Specifications section, Static Dimensions and Machine Weight for the relevant information of your machine.

100

2-2-7-5_1

Place blocks at the front and rear of the trailer wheels.

Make sure the ramps are correctly in place and secure.

Set the loader shovel and backhoe. K Preparing The Machine For Travel ( T 71).

Engage the boom and slew locks. K Boom Lock ( T 64), K Slew Lock ( T 65).

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100

Operation Transporting The Machine 5

If the machine has an extendable dipper make sure that the locking pin is securely in place.

Carefully move the machine onto the trailer. a

When the machine is safely in position, engage the park brake and set the drive to neutral.

b When the machine is safely in position, engage the park brake and set the drive to neutral, lower the loader shovel and backhoe onto the trailer bed. c

On sideshift machines, lower the stabilisers to the trailer bed and remove the starter key.

Note: If for any reason the slew or boom lock cannot be engaged, then the bucket must be securely lashed to the trailer bed, if no bucket is fitted, then secure the dipper end to the trailer bed. d Lock all doors and access panels. e

Cover the exhaust opening.

Measure the maximum height of the machine from the ground. Make sure the truck driver knows the clearance height before he drives away.

Put blocks at the front and rear of all four tyres. Make sure they are securely in place.

Secure the machine to the trailer bed with chains. Use the tie down points indicated by the safety decal. Tension the chain as close to 45 degrees as possible. K Fig 85. ( T 101).

T033270-1

Fig 85. Note: Refer to safety decal A to identify the correct positions to secure your machine during transportation. K Fig 84. ( T 100).

101

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101

Operation Lifting A Machine

Lifting A Machine

Note: Weights may vary with different attachments, therefore none standard attachments i.e.: hammer, brush etc. must be removed before attempting to lift the machine. Only lift the machine with a standard shovel and bucket fitted. Note: The correct lifting points are marked on the machine by this decal.

T033280

Fig 86. 1

Remove all attachments (except bucket and shovel) from the machine.

Position the crane for a level machine lift.

Make sure there are no loose items in the cab or on the machine. Stow all loose items in a lockable container.

Use correctly adjusted spreader bars to avoid contact between the lifting gear and the machine. K Fig 87. ( T 102).

102

T033430-1

Fig 87. 5

On Sideshift machines make sure that the excavator carriage is in the centre position.

Set the loader shovel and backhoe. K Preparing The Machine For Travel ( T 71).

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102

Operation Lifting A Machine 7

Engage the boom and slew locks. K Boom Lock ( T 64), K Slew Lock ( T 65).

If the machine has an extendable dipper make sure that the locking pin is securely in place.

Engage the Park Brake, Set the gear lever to Neutral

Switch OFF the engine, remove the starter key, shut the doors and windows and vacate the machine.

Use correctly rated slings A either side of the front axle. Use rubber protectors B beneath the axle.

T033450

Fig 89. Sideshift machine

b The lifting eyes on Centremount machines. Note: When using the lifting eyes, suitably rated D links must be used.

T033440

Fig 88. 12

For the rear lifting points, use: a

The top of the rear frame on side shift machines. K Fig 89. ( T 103). T033460

Fig 90. Centremount machine

103

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103

Operation Lifting A Machine 13

Make sure the area is clear of personnel before attempting to lift the machine.

Lift the machine slightly, check the balance of the machine.

104

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104

Operation Storage of the Machine

Storage of the Machine Introduction

Put the Machine into Storage T2-074

If you will not use the machine for an extended period, you must store the machine correctly. If you prepare the machine carefully and apply on-going care you can prevent deterioration and damage to the machine while it is in storage.

T2-077

Park the machine on level, solid ground. Park the machine in a position where the machine is easy to get access (in case the machine does not start at the end of the storage period).

Note: JCB Dealers must check stock monthly.

Place suitable timbers under the machine to eliminate direct contact with the ground.

Storage Area 2

Retract all rams and lower the attachments to the ground.

-40째C to 54째C (-40째F to 129째F).

Vent the hydraulic system.

When possible, you must keep the machine in a dry building or shelter.

Remove the starter key.

Apply a thin layer of grease or petroleum jelly to all exposed ram piston rods.

Remove the battery. Charge the battery.

The machine can be stored in a temperature range of:

If only an outdoor storage area is available, look for a storage area with good drainage. If the machine is to be out of use for an extended period, careful preparation and on-going care will minimise the possibility of deterioration and damage while in storage.

Keep the battery in warm, dry conditions. Charge the battery periodically. 7

Prepare the Machine for Storage

If you keep the machine outdoors, cover the machine with tarpaulins or plastic sheets.

T2-076

Clean the machine to remove all unwanted material and corrosive products.

During Storage T2-078

Dry the machine to remove solvents and moisture. 2

Apply grease to the moving parts. Refer to Greasing the Machine.

Examine the machine for worn or damaged parts. Replace if necessary.

Fill the fuel tank to prevent a build up of condensation in the tank.

Examine the coolant condition. Replace if necessary.

Examine all fluid levels. Top up if necessary.

105

Operate the machine functions each week to prevent a build up of rust in the engine and hydraulic circuits, and to minimise deterioration of the hydraulic seals. 1

Clean the machine to remove all unwanted material and corrosives. Remove the grease or petroleum jelly from the ram piston rods.

Install a charged battery.

Examine all fluid levels. Top up if necessary.

Start the engine.

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105

Operation Storage of the Machine 5

Operate the hydraulic controls. Make sure that the hydraulic functions operate correctly.

Prepare the machine for storage. Refer to Put the Machine into Storage.

Take the Machine Out of Storage T2-079

Examine the coolant condition. Replace If necessary

Examine all fluid levels. Top up if necessary.

Clean the machine to remove unwanted material and corrosives. Remove the grease or petroleum jelly from the ram piston rods.

Install a charged battery.

Start the engine.

Operate the hydraulic controls. Make sure that the hydraulic functions operate correctly.

106

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106

Operation Machine Security

Machine Security General

LiveLink

Vandalism and the theft of unattended machines is an ever increasing problem and JCB is doing everything possible to help stop this.

Your JCB machine may be installed with LiveLink, JCBs advanced machine monitoring system. LiveLink monitors a range of information about your machine and sends it via cellular and satellite communication back to JCB's secure monitoring centre. Machine owners and JCB dealers can then view that information via the LiveLink website, by email and even via text message. If you want to know how LiveLink can help manage your JCB machines, contact your local dealer for more information.

T1-052

Your JCB dealer will be pleased to provide information on any of these sensible precautions. Act Now!

Security Locks Safety hooks are positioned on both cab doors to be used with padlocks to provide extra security.

P040630-01

Fig 91.

107

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107

Operation Machine Security

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108

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108

Routine Maintenance Service Requirements

Routine Maintenance Service Requirements Introduction 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. This section of the Manual gives full details of the service requirements necessary to maintain your JCB machine at peak efficiency. 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. 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. 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. 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.

You will have been given the names of the relevant service contacts at your Distributor when the machine was installed. To get the most from your Distributor please help them to satisfy you by: 1

Giving your name, address and telephone number.

Quoting your machine model and serial number.

Date of purchase and hours of work.

Nature of the problem.

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.

Service/Maintenance Agreements To help plan and spread the costs of maintaining your machine, we strongly recommend you take advantage of the many Service and Maintenance Agreements your Distributor can offer. These can be tailor made to meet your operating conditions, work schedule etc. Please consult your JCB Distributor for details.

Initial Service and Inspection T3-005_2

To further protect your machine's performance it is essential your JCB Distributor carries out an initial service and inspection when the machine is one month old or when it has completed 100 hours of operation (whichever occurs first). You should notify your Distributor in advance to allow the necessary arrangements to be made.

Remember, if your machine has been correctly maintained, not only will it give you improved reliability but its resale value will be greatly enhanced.

Owner/Operator Support 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!

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109

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

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.

110

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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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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Routine Maintenance Service Schedules

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

100(1)

500

- Check



1000 2000 6000

ENGINE Coolant Quality and Level. Cooling System.

- Drain / Refill

Oil level. Oil and Filter

- Check (2)(3)



K Oil and Filter ( T 153).

- Change

Air Cleaner Inner Element (4).

- Change - Drain

Water Separator Fuel Filter.

- Change

Engine Fuel Filter(5).

- Change

Front End Accessory Drive (FEAD) Belt Condition K Inspecting the Drive Belt ( T 157). Front End Accessory Drive (FEAD) Belt K Changing the Drive Belt ( T 157).



 



 

- Change

Air Cleaner Outer Element (4)

Water Separator and Engine Fuel Filter.



- Check

       

        



- Change

Engine Mounting Bolts for Tightness

- Check

All Hoses - Condition K Check the Hydraulic Hoses and Fittings ( T 132).

- Check

Radiator(4) K Cleaning the Machine ( T 128).

- Clean

Breather Gauze

- Clean

        

 



   

Valve Clearances(5)

- Check / Adjust

Oil Filler and Dipstick Seals(5) K Oil and Filter ( T 153).

- Check / Adjust

   

Rocker Cover and Injector Seals(5)

- Change



Injectors(5)

- Change

Injector(s) Leak Off Rail(5)

- Change

High Pressure Fuel Lines(5)

- Inspect

   



 

TRANSMISSION, AXLES AND STEERING Transmission Oil Level.

- Check



Transmission Oil(6) K Changing the Oil and Filter ( T 171).

- Change



Transmission Filter K Changing the Oil and Filter ( T 171)

- Change



- Check



- Change

 



 

Axle Oil Level (incl. Hubs when applicable) Front(7)(8) Axle Oil (incl. Hubs when applicable) Rear (7)(8) Tyre Pressures and Condition K Tyre Inflation ( T 174).

- Check



Wheel Nut Security.

- Check



Front Hub Bearings

- Check

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Routine Maintenance Service Schedules Operation

100(1)

Transmission Strainer K Changing the Oil and Filter ( T 171).

- Clean



Steer Axle Movement and Shimming(5)

- Check

 

(9)

Steer Axle Pivots and Linkages K Greasing ( T 134).

Drive Shafts(9) K Greasing ( T 134). Front Axle Main Pivot K Greasing ( T 134).

- Grease

500

1000 2000 6000



 

- Security and Grease



- Grease



- Check



     

HYDRAULICS Oil Level(10) K Oil and Filter ( T 167).

Rams - Chrome Condition

- Check

Hydraulic Oil Cooler

- Clean

Hydraulic Oil Strainer K Changing the Suction Strainer ( T 169).

- Clean

    

Hydraulic Tank Filler Cap (with integral filter) K Hydraulic Tank Filler Cap ( T 167).

- Check



Oil K Oil and Filter ( T 167). Oil Filter K Oil and Filter ( T 167).

Servo Joystick Lever Bush (5)

- Sample, Change

 

- Change

  



  

- Check/Grease

BRAKES Brake Fluids Level

- Check

Brake Fluids Level

- Change

Park Brake K Park Brake ( T 144).

- Check / Adjust

ELECTRICS Battery Electrolyte Level (if applicable) K Checking the Electrolyte Level ( T 147).

- Check



Wiring for Chaffing/Routing K Check the Electrical Circuits ( T 132).

- Check



Battery Terminals for Condition and Tightness K Battery Disconnection/Connection ( T 147).

- Check



   

    

BODYWORK AND CAB All Pins and Bushes K Greasing ( T 134).

- Check / Grease

Door/Window Hinges

- Lubricate

All Cables

- Lubricate

Cab Heater Fresh Air Filter (if applicable)(4) Air Conditioner Condensor (4)

114

- Clean / Change - Clean

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

114

Routine Maintenance Service Schedules Operation Cab Air Conditioning Recirculation Filter (if fitted) (4) .

- Clean/Change

Kingpost clamp .

- Check / Adjust

Door - Fit and Catches

- Check

Cab Seat - Operation K Check the Seat and Seat Belt ( T 131)

- Check

Windscreen Washer Fluid Level (if fitted)

- Check

Condition of Paintwork K Check the Machine Body and Structure ( T 131).

- Check

100(1)



500

1000 2000 6000



  



 



Stabiliser Legs (Sideshift) K Stabiliser Legs (Sideshift Machines Only) ( T 176).

- Check / Adjust

Machine Generally K Cleaning the Machine ( T 127).

- Check / Clean



- Grease



Wear Pads (with Extended Dipper) (if fitted) K Greasing ( T 134).

(1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) If operating under arduous conditions, change the engine oil and filter every 250 hours. (3) The oil service interval will be affected if there is a high sulphur content in the fuel. Refer to Fuel System for more information. (4) If operating in dusty working environments, change more frequently. Change the inner element whenever the outer element is being changed. (5) Jobs which should only be done by a specialist. (6) After a major transmission repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil and filter after a further 100 hours if the oil was heavily contaminated because of, or from the failure (e.g. water contamination). (7) Check for leaks every 50 hours, check level if leaking. (8) After a hub repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil again after a further 100 hours to remove any bedding-in wear. This is particularly important if new brake plates have been fitted. (9) The axles and driveshafts are factory greased with a high performance grease, if during service a standard grease is used, then the interval must be reduced to every 50 hours, contact your JCB Distributor for advice. (10) Check the hydraulic fluid level with the loader and backhoe in the travel position.

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Routine Maintenance Service Schedules

Functional Test and Final Inspection Operation

100(1)

500

1000 2000 6000

     

ENGINE - Check and Adjust

Idle Speed(2) (2)

- Check and Adjust

Exhaust Smoke (excessive)

- Check

Maximum No-Load Speed



- Check

(2)

Exhaust System Security Air Inlet System Security

- Check

Throttle System and Control Cable

(2)

- Check

TRANSMISSION, AXLES AND STEERING Steer Mode - Operation/Phasing

- Check

2WD/4WD Selection

- Check

Wheel Nuts Torque

- Check

Forward/Reverse and Gear Change Operation

- Check

Hydraulic Flow Control - Operation (if fitted)

- Check

Steer Circuit Pressure(2)

- Check

Transmission Main Line Pressure(2)

- Check

Transmission Dump Operation

- Check

Neutral Start Operation

- Check



 



 

  

      

    



- Check

(2)

Clutch Pack Pressures HYDRAULICS

- Check and Adjust

MRV Pressure(2) Operation All Services

- Check

Hose Burst Protection Valves (if fitted)

- Check



- Check and Adjust

Unloader Valve Pressure(2) (2)

Auxiliary Circuit & Pressures

- Check and Adjust

BRAKES Foot Brake - Operation

- Check



Park Brake - Operation

- Check



 

ELECTRICS Starter Motor

- Check

Alternator - Output

- Check

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Routine Maintenance Service Schedules Operation

100(1)

500

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

- Check



Operation of Stop Control/E.S.O.S.

- Check



Servo Actuator Switch

- Check

Accumulator System

- Check

Engine Auto Stop Switch

- Check

   

  



1000 2000 6000

BODYWORK AND CAB Teeth and Side Cutters

- Check

Doors and Windows - Fitment/Leaks

- Check

Seat / Seat Belts

- Check

LIFTING EQUIPMENT Fit for Purpose Test (3)

- Complete

(1) First 100 Hours Service Only, to be completed by your JCB Distributor. (2) Jobs which should only be done by a specialist. (3) 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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Routine Maintenance Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities ITEM

CAPACITY Litres

UK Gal

128

Min.

2.64

Max.

3.3

Fuel Tank Engine (Oil)

Table 1. FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION

Diesel Oil

ASTM D975-66T Nos. 1D, 2D

JCB Engine Oil Max

15W40CI4+

(-10°C to +50°C (14°F to 122°F) ! CAUTION: DO NOT USE ORDINARY ENGINE OIL

17.5

3.85 Wet JCB Ready to use Coolant K Coolant Mixtures ( T 119).

18.5

4.07 Dry

3.2 Dry

Housing (2WS)

2.86

Hubs (x2)

2.0

0.44

Rear Axle (2WS)

Engine (Coolant)

(1)

Synchro Shuttle (2WD)

(2)

Front Axle (4WD)

ASTM D6210

JCB Transmission Oil JCB Gear Oil (without LSD)

API-GL-5

JCB Gear Oil HP Plus (with LSD)

API-GL-4

4.61

JCB Rear Axle Oil

API-GL-4

Brake System

1.4

0.3

JCB HVI HYDRAULIC OIL

HVI

Hydraulic System

130

28.6

JCB HVI Hydraulic Oil

HVI 46

(Above 38 °C, 100 °F) Grease Points

---

JCB Special Grease

Lithium complex NLGI No.2 consistency including extreme pressure additives

or JCB Special MPL-EP Grease(3)

Lithium based NLGI No.2 consistency including extreme pressure additives

Extending Dipper

---

Waxoyl(4)

Electrical connections

---

As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly.

(1) It is recommended that the cooling system be filled at a maximum rate of 10 litres per minute. If the fill rate is any higher than this there is a possibility of air becoming trapped in the system. (2) The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system. Figures quoted within 1.0 litre (0.22 U.K. gal). (3) JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing must be carried out more frequently. (4) WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.

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Routine Maintenance Fluids, Lubricants and Capacities

Coolant Mixtures T3-009_4

Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period. Replace the coolant mixture according to the intervals shown in the machine's Service Schedule.

!MWARNING Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze. 7-3-4-4_1

You must dilute full strength antifreeze with clean water before use. Use clean water of no more than a moderate hardness (pH value 8.5). If this cannot be obtained, use de-ionized water. For further information advice on water hardness, contact your local water authority. The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion. As an example, the protection provided by JCB High Performance Antifreeze and Inhibitor is given below. 50% Concentration (Standard) Protects against damage down to -40 °C (-39 °F) 60% Concentration (Extreme Conditions Only) Protects against damage down to -56 °C (-68 °F) Important: Do not exceed a 60% concentration, as the freezing protection provided reduces beyond this point. If you use any other brand of antifreeze: – Ensure that the antifreeze complies with International Specification ASTM D6210. – Always read and understand the manufacturer's instructions. – Ensure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used. – Ensure that the antifreeze is ethylene glycol based and does not use Organic Acid Technology (OAT).

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Routine Maintenance Fluids, Lubricants and Capacities

!MCAUTION

Fuels Acceptable and Unacceptable Fuels T3-031

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

Service Requirements

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

Obey the maintenance procedures.

BS2869 Class A2

usual routine schedules and

ASTM D975-91 Class 2, US DF1, US DF2, US DFA JIS K2204 (1992) Grades 1, 2, 3 and Special Grade 3 ASTM D975-91 Class 1DA MIL T38219 XF63 NATO F63 French EN590 (RME5) with 5% maximum

All Dieselmax engines.

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. K Additives ( T 121).

AVTURFSII, NATO F34, JP8, MIL T83133, All Dieselmax engines. 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, JP7

Obey the usual routine maintenance schedules and procedures. Fuel additives must be used. K Additives ( T 121).

AVCAT, NATO F43 (obsolete), JP5 without additives JET A (ASTM D1655) ASTM D3699 Kerosene B20 Biodiesel - RME content blended with Dieselmax engines mineral derived diesel (20% maximum) - from 2007 on only(1). ASTM D6751, DIN 51606, ISO 14214

manufactured You must obey special routine maintenance schedules and procedures. K Warranty ( T 121).

AVTAG (obsolete)

These fuels are not acceptable with or AVTAG FSII (obsolete), NATO F40, JP4, 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) The year of manufacture is part of the engine serial number. Refer to Typical Engine Identification Number.

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Routine Maintenance Fluids, Lubricants and Capacities Additives

and factory filled with CH4 oil) - this is not approved with other manufacturers.

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. – 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 B20 Biodiesel – The engine oil must be a grade CH4 as minimum specification. – Do not leave unused B20 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.

– 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 B20 blend of biodiesel requires caution and additional servicing of the engine is required. K Service Requirements for use of B20 Biodiesel ( T 121). 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 JCB Dieselmax 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 tank (or the storage tank). Water will encourage micobacterial growth. – Make sure that the fuel pre-filter is drained daily (not every week as currently advised). – Only JCB engines built after Jan. 2007 are applicable (i.e. engines with 07 on the end of their serial number

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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 122).

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

122

– 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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Routine Maintenance Tools

Tools Toolbox

Carrying Tools onto the Machine

All tools must be kept in the toolbox A (If fitted) when not in use.

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.

P041110-01

Fig 1.

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Routine Maintenance Prepare the Machine for Maintenance

Prepare the Machine for Maintenance Introduction

!MWARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it should be correctly parked on level ground. To prevent anyone starting the engine, remove the starter key. Disconnect the battery when you are not using electrical power. If you do not take these precautions you could be killed or injured. 8-3-1-1

Make the machine safe before you start a maintenance procedure. You can complete most of the maintenance procedures with the loader arm lowered (Position A). Unless a maintenance procedure instructs you differently, you must lower the loader arm. Refer to How to Make the Machine Safe (Loader Arm Lowered).

T024630-1

Fig 2.

If you lift the loader arm to get access for maintenance (Position B), you must install the maintenance strut on the loader arm. Refer to How to Make the Machine Safe (Loader Arm Lifted).

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Routine Maintenance Prepare the Machine for Maintenance

How to Make the Machine Safe (Loader Arm Lowered) Important: You can complete most of the maintenance procedures with the loader arm lowered. Unless a maintenance procedure instructs you differently, you must lower the loader arm. 1

b Remove strut C from its stowage bracket. 4

Push strut C over the ram piston rod.

b Secure the strut in position with strap B.

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

Retract then lower the loader arm.

Put the attachment flat on the ground.

Stop the engine and remove the starter key.

Disconnect the battery operation of the engine.

If necessary, put chocks against the two sides of the wheels before you get below the machine.

prevent

Install the strut. a

Park the machine on level, solid ground.

Release fastener A.

Lower the arm onto the strut. To prevent any chance of the loader arms creeping down and trapping your fingers, the loader arms should be carefully lowered onto the safety strut as shown. Start the engine and slowly lower the loader arms onto the safety strut, stop the movement immediately the weight of the loader arms is supported by the safety strut.

accidental

Note: When lowering the loader, operate the control lever carefully. 'Feather' the lever to lower the loader very slowly.

How to Make the Machine Safe (Loader Arm Lifted)

Installing the Loader Arm Safety Strut Install the loader arm safety strut as detailed below before working underneath raised loader arms.

D026630

Empty the shovel and raise the loader arms fully.

Stop the engine and remove the starter key.

Release the strut.

125

Fig 3.

9821/0000-09

125

Routine Maintenance Prepare the Machine for Maintenance Removing the Loader Arm Safety Strut 1

Fully raise the loader arms to take the weight off the safety strut.

Stop the engine and remove the starter key.

Remove the strut. a

Undo the strap B.

b Remove the strut C from the ram piston rod. 4

Stow the strut. Secure the strut in its stowage position with fastener A.

D026630

Fig 4.

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Routine Maintenance Cleaning the Machine

Cleaning the Machine

!MCAUTION

Introduction T3-062_3

Clean the machine using water and or steam. Do not allow mud, debris etc. to build upon the machine. Before carrying out any service procedures that require components to be removed: 1

Cleaning must be carried out either in the area of components to be removed or, in the case of major work, or work on the fuel system, the whole engine and surrounding machine must be cleaned.

The engine or certain components could be damaged by high pressure washing systems; special precautions must be taken if the engine is to be washed using a high pressure system. Ensure that the engine air intake, alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. ENG-3-3_2

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

Important: Do not aim the water jet directly at bearings, oil seals, the engine air intake or electrical and electronic components such as the engine electronic control unit (ECU), alternator or fuel injectors.

Important: When removing components be aware of any dirt or debris that may be exposed. Cover any open ports and clean away the deposits before proceeding.

Use a low pressure water jet and brush to soak off caked mud or dirt.

Detergents

Use a pressure washer to remove soft dirt and oil.

Avoid using full strength detergent - always dilute detergents as per the manufacturer's recommendations, otherwise damage to the paint finish may occur.

Note: The machine must always be greased after pressure washing or steam cleaning.

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

Preparing the Machine for Cleaning 1

Make the machine safe with the loader arm lifted. Refer to Prepare the Machine for Maintenance.

Pressure Washing and Steam Cleaning Important: Stop the engine and allow it to cool for at least one hour. Do not attempt to clean any part of the engine while it is running.

!MWARNING When using a steam cleaner, wear safety glasses or a face shield as well as protective clothing. Steam can cause serious personal injury.

13-3-2-10_2

127

9821/0000-09

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

127

Routine Maintenance Cleaning the Machine

Cleaning the Machine

Note: Machines with air conditioning have a condenser matrix fitted in front of the oil cooler, the fins of the condenser matrix may get clogged. In this case, clean the tubes/fins of the condenser matrix as described above.

!MWARNING To avoid burning wear personal protective equipment (PPE) when handling hot components. To protect your eyes, wear personal protective equipment (PPE) when using a brush to clean components. HYD-1-3_3

!MCAUTION Never use water or steam to clean inside the cab. The use of water or steam could damage the on-board computer and render the machine inoperable. Remove dirt using a brush or damp cloth. 8-3-4-8 711790-2

Fig 5.

Pay particular attention to: 1

Cooling Pack

Do not allow mud to build up on the engine and transmission. Pay particular attention to the exhaust area, remove all combustible material.

The cooling pack is located in front of the engine, the pack consists of the engine cooling radiator, hydraulic oil cooler, intercooler and air-conditioning condenser (optional). If the cooler tubes/fins get clogged (by dirt and flies etc.) the radiator and coolers will be less efficient. a

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.

Remove the front grille.

b Brush off all debris from the cooler tubes and fins. Make sure the loosened material is brushed out of the cooler enclosure.

Important: Do not place the jet nozzle closer than 600mm (24 in) to any part of the engine.

Note: When cleaning the matrix make sure that the brush follows the same direction as the fins are to avoid damaging them. Damaged fins will reduce the cooling efficiency of the matrix. c

128

Engine

Do not attempt to clean any part of the engine while it is running. Stop the engine and allow it to cool for at least one hour. a

Disconnect the battery.

b Do not aim the jet wash directly at the fuel injector seals A. K Fig 6. ( T 129).

Refit the radiator grille.

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Routine Maintenance Cleaning the Machine 4

Backhoe Pay particular attention to:

Backhoe hoses passing through mainframe.

b Around twin slew rams. c

Twin ram slew recess in chassis (centremount).

Fig 6. c

Do not wash any part of the: i

Fuel injection pump.

Cold start device.

iii Electrical shut off solenoid (ESOS). iv Electrical connections. d Ensure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by high pressure cleaning system. 3

Stabiliser cavities can become clogged when operating in soft/wet ground conditions. Remove and clean away all debris that may have built up.

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C006700-3

Fig 7. d Kingpost slide rails (sideshift). e

Kingpost hose tray and bottom 'shelf' (sideshift).

129

Routine Maintenance Cleaning the Machine

e d T066400-2

Fig 8. f

Recess between slew ram and kingpost casting (sideshift).

f C006720-1

Fig 9.

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Routine Maintenance Checking for Damage

Checking for Damage Check the Machine Body and Structure T3-063_5

Make sure that all guards and protective devices are in place, attached by their locking devices and free from damage. Inspect all steelwork for damage. Pay particular attention to the following:

– Signs of distortion (bulges) – Cuts or wear – Embedded objects (nails, etc.) Install the valve caps firmly to prevent dirt from entering the valve. Inspect for leaks when you check the tyre pressures. Inspect the tyre valve for leaks, when you check the tyre pressures.

– Inspect all lifting point welds. – Inspect all pivot point welds.

Check the Seat and Seat Belt

– Inspect the condition of all pivot pins. – Check pivot pins are correctly in place and secured by their locking devices. Check steps and handrails are undamaged and secure. Check for broken, cracked or crazed window glass and mirrors. Replace damaged items.

!MWARNING

T3-008_2

When a seat belt is fitted to your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. Fit a new seat belt every three years. 2-3-1-7_1

Check all lamp lenses for damage. Check all attachment teeth are undamaged and secure. Check all safety and instructional labels are in place and undamaged. Fit new labels where necessary.

Check that the belt mounting bolts are undamaged, correctly fitted and tightened.

Note damaged paintwork for future repair.

Check the Tyres

!MWARNING

Inspect the seat belt for signs of fraying and stretching. Check that the stitching is not loose or damaged. Check that the buckle assembly is undamaged and works correctly.

T3-065_2

Check seats are undamaged and secure. Check seat adjustments for correct operation.

You could be killed or injured if a machine tyre bursts. Do not use the machine with damaged, incorrectly installed, incorrectly inflated or excessively worn tyres. Recognise the speed limitation of the tyres fitted and do not operate at more than their recommended maximum speed. 13-2-1-2_2

Always drive with consideration for the condition of the tyres. Incorrect tyre pressures will affect the stability of the machine. Check the tyres daily for the correct tyre pressure and signs of damage. For example:

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Routine Maintenance Checking for Damage

Check the Hydraulic Hoses and Fittings

!MWARNING

Checking The ROPS/FOPS Structure

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 the hoses regularly for: – Damaged hose ends

!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

– Chafed outer covers

Check the structure for damage. Check that the mounting bolts are installed and undamaged. Check the bolt torques. K Torque Settings ( T 132). Tighten them to the correct torque if necessary.

– Ballooned outer covers – Kinked or crushed hoses – Embedded armouring in outer covers – Displaced end fittings Do not use the machine if a hose or hose fitting is damaged. Replace damaged hoses before you use the machine again. Replacement hoses must be of the same size and standard.

Remove the rear wheels to gain access to the rear mounting bolts A.

Remove the covers C and external trim panels D to gain access to the front mounting bolts B.

Bolts A and B

Table 4. Torque Settings 205 Nm (150 lbf ft)

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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Routine Maintenance Checking for Damage

D B

Fig 10.

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Routine Maintenance Greasing

Greasing Introduction

Preparing the Machine for Greasing T3-028_2

You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Refer to the Service Schedule for the correct intervals. Note: The machine must always be greased after pressure washing or steam cleaning.

Make the machine safe before you start a greasing procedure. Refer to Prepare the Machine for Maintenance. Important: You can complete most of the greasing procedures with the loader arm lowered. If you lift the loader arm to get access for greasing, you must install the maintenance strut on the loader arm.

Greasing should be done with a grease gun. Normally, two strokes of the gun should be sufficient. Stop greasing when fresh grease appears at the joint. Use only the recommended type of grease. Do not mix different types of grease, keep them separate. In the following illustrations, the grease points are numbered. Count off the grease points as you grease each one. Refit the dust caps after greasing. Note: Where applicable, refer to the manufacturers manual for instructions on the maintenance of optional attachments.

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Routine Maintenance Greasing

Loader Arms

1,2 15,16 3,4 5,6 7,8 9,10 11,12 13,14

18,17 19,20 21,22 Fig 11. For each grease point shown, there is another on the other side of the machine. Total 22 grease points.

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Routine Maintenance Greasing

Backhoe and Quickhitch (Optional)

13 8

12 10

6 4 9

1 21

2 Fig 12.

22 Grease Points Note: Figure shows arrangement.

136

typical

boom

and

dipper

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136

Routine Maintenance Greasing

Front Axle (2WD)

Note: Grease point 5 is a remote grease point mounted on the side of the mainframe chassis (near the left front wheel).

9 Grease Points

9 260200-1

Fig 13.

Front Axle (4WD)

Note: Grease point 5 is a remote grease point mounted on the side of the mainframe chassis (near the left front wheel).

5 Grease Points

1,2

3,4 3

260220-1

Fig 14.

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Routine Maintenance Greasing

Driveshafts Front Driveshaft

3 Grease Points

3 2

1 1

Fig 17.

157500-1

Fig 15.

Rear Driveshaft 3 Grease Points

157511-1

Fig 16.

Stabilisers (Centremount Machines) 3 grease points on each stabiliser Total 6 Grease Points

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Routine Maintenance Greasing

Kingpost 8 Grease Points Note: Figure shows a centremount kingpost, greasing is same for sideshift kingpost. Note: It is recommended that grease points 2 and 3 are lubricated using a hand grease gun. The use of a power grease gun may result in the mounting plate being distorted.

1 2 3 4 5

8 P040540-13

Fig 18.

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Routine Maintenance Access Panels

Access Panels Introduction 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.

Engine Cover Cab Machines

Opening and Closing

!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.

D0551240

Fig 19.

10-1-1-40

Important: Before you stop the engine, you must allow the engine to operate at low idle for four minutes. The delay allows the coolant temperatures to stabilise before you open the engine cover. 1

Make the machine safe with the loader arm lifted. Refer to Prepare the Machine for Maintenance.

To release the engine cover, pull handle A, the cover will automatically open and will be supported on gas struts.

To close the engine cover, pull the cover down by means of the cable B, push the cover down, make sure it is locked in place.

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Routine Maintenance Access Panels

Front Grille

Make the machine safe with the loader arm lifted. Refer to Prepare the Machine for Maintenance.

Use the starter key to unlock the front grille.

To install the side panels. Align the side panel G with the front chassis H and grille housing J.

Note: Press the top part of grille B if the key is difficult to turn. 3

Remove the front grille B, lift the grille upwards and outwards.

Fit the front grille, carefully slot the grille into position. Use the starter key to lock and secure the front grille

B J F H D068300

Fig 21. 5

Tighten the Bolts F to secure the side panels.

Close the engine cover.

T011190-3

Fig 20.

Side Panels 1

Open the engine cover. Refer to Access Panels, Routine Maintenance.

Remove the bolts F fitted on the engine side panels G on both sides.

Remove the side panels.

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Routine Maintenance Access Panels

F H D068300-1

Fig 22.

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142

Routine Maintenance Air Conditioning

Air Conditioning Cleaning the Cab Air Conditioning Filter Important: In dusty conditions the filter will require cleaning/changing more often than detailed in the service schedule.

!MCAUTION The filter may be filled with dust. Wear goggles and a face mask when removing the filter. 2-3-3-6

Make the machine safe with the loader arm lowered.

Remove the cover retaining screws (4 off) and then remove the cover, item A.

Knock loose dust off the filter B.

Wash the filter in clean warm water.

Dry the filter.

Install the filter into the housing.

Receiver Drier

Refit the cover A and secure with the retaining screws (4 off).

If the sight glass D on receiver drier C is clear, it indicates the correct level of charge.

Fig 23.

C Fig 24.

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Routine Maintenance Brakes

Brakes Park Brake

Testing the Park Brake

!MWARNING

Introduction

!MWARNING

T3-071

Before testing the park brake make sure the area around the machine is clear of people. 2-2-4-5

Do not use a machine with a faulty park brake. 3-2-3-10_2

â&#x20AC;&#x201C; The park brake must be fully engaged when the lever is vertical.

!MWARNING Non approved modifications to drive ratios, machine weight or wheel and tyre sizes may adversely affect the performance of the park brake.

A339340

â&#x20AC;&#x201C; The park brake warning light must come on when the park brake is engaged and forward or reverse is selected (starter switch at I).

3-2-3-11

Make sure that you obey all health and safety precautions before you test or adjust the park brake. If you have any queries concerning the park brake test or adjustment procedures, consult your local JCB distributor.

Enter the machine. Fasten your seat belt (if fitted) and park the machine on a level dry surface.

Fully apply park brake.

Start the engine and raise the attachments to the appropriate travel position.

Select fourth gear.

Push down hard on foot brake pedal.

Select forward drive. The park brake warning light must illuminate.

!MWARNING If the machine starts to move during the following test, immediately apply the foot brake and reduce the engine speed. 2-2-5-1

Test the park brake as follows: a

Move the park brake lever fractionally forward until the park brake warning light is just extinguished.

b Slowly release the foot brake pedal. c

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If the machine has not moved, use the accelerator to gradually increase the engine speed to approximately 1500 RPM. The machine should not move.

144

Routine Maintenance Brakes Park Brake Adjustment

Note: Do not do this test for longer than 20 seconds.

!MWARNING

d Reduce engine speed to idle and select neutral.

Return the park brake lever to the fully on position.

Lower attachments and stop the engine.

Over adjustment of the park brake could result in the park brake not fully releasing. 0011

If the machine moved during the test, adjust the park brake and repeat the test. Refer to Park Brake Adjustment.

Disengage the park brake (lever horizontal).

Note: Failure to disengage the park brake fully will result in excessive wear of the handbrake mechanism. 2

Pull and turn handle grip A clockwise, half a turn.

Test the park brake.

If the brake fails the test, repeat steps 1, 2 and 3. If there is no more adjustment and pin B is at the end of its travel get the brake checked by your JCB dealer.

T065030-7

Fig 25.

Foot Brake Checking the Foot Brake Fluid Level

!MWARNING Faulty brakes can kill. If you have to top up the brake reservoir frequently, get the brake system checked by your JCB Dealer. Do not use the machine until the fault has been put right. 2-3-2-5_1

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Routine Maintenance Brakes

B 1

Make the machine safe with loader arm lowered. Refer to K How to Make the Machine Safe (Loader Arm Lowered) ( T 125).

Open the engine cover and remove the side panel.

Visually check the level. The correct fluid level is marked on the reservoir B.

If necessary to add fluid, raise the loader arms and fit the safety strut. Make the safe with the loader arm lifted. Refer to K How to Make the Machine Safe (Loader Arm Lifted) ( T 125).

Remove the reservoir cap A. If the system has fallen a long way below the MAX mark, get the system checked by your JCB dealer.

Carefully pour the recommended fluid until it reaches the correct level.

Refit the reservoir cap. Wipe up any spillage.

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Routine Maintenance Electrical System

Electrical System Battery Battery Disconnection/Connection

!MWARNING

T3-019_4

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

Close and lock the access panels.

Battery Warning Indicator

Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metal work. If it happens you can get burnt.

All battery have a indicator on the top, which shows various warning for the battery. The warnings are: Green colour indicates that battery is OK

5-2-2-4_2

Disconnection 1

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.

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

Blue colour indicates that battery is OK

White colour indicates that battery needs charging

Connection 1

Check the battery. a

In the event of the indicator showing red, open service plugs with the help of a coin and top up with pure distilled water or call any authorised battery dealer. Do not use screw driver for opening the plugs.

If the terminal is dirty, clean the post.

Note: The green colour is applicable for Exide make batteries and blue colour for Tata green make batteries.

Checking the Electrolyte Level

Fig 26. 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.

Maintenance free 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. 1

Get access to the battery. See Access Panels.

Disconnect and remove battery. See Battery Disconnection/Connection.

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

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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 service plugs 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. K Fig 27. ( T 148)

A B A089660-11

Fig 27. 4

Refit battery.

Close and lock the access panels.

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Routine Maintenance Electrical System

Jump Starting The Engine

The park brake should have been engaged when the machine was last parked. If it is not engaged, engage it now.

Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery fully charged.

Set all switches in the cab to off.

Do not try to charge a frozen battery or jump-start and run the engine, the battery could explode.

!MWARNING

T3-053

Batteries produce a flammable gas, which is explosive; do not smoke when checking the electrolyte levels.

!MDANGER

2-2-3-4

Set all the machine switches to their OFF positions before connecting the external power supply. Even with the starter switch set to off some circuits will be energised when the external power supply is connected.

Lower the loader shovel to the ground, if it is not already there. It will lower itself under its own weight when you operate the lever. Operate the lever carefully to control the rate of descent. If your machine is fitted with hose burst protection valves you will not be able to lower the shovel. In this case install the safety strut.

Do not connect the booster (slave) supply directly across the starter motor. Doing this by-passes the neutral gear safety switch. If the machine is in gear, it may 'runaway' and kill or injure bystanders.

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.

Connect the negative (-) booster cable to a suitable point on the engine.

Use only sound jump leads with securely attached connectors. Connect one jump lead at a time.

Start the engine.

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.

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.

!MWARNING When the engine is running, there are rotating parts in the engine compartment. Before disconnecting the cables, make sure that you have no loose clothing (cuffs, ties etc.) which could get caught in rotating parts. 2-2-4-3

Disconnect the negative booster cable from the engine. Then disconnect it from the booster supply.

Disconnect the positive booster cable from the positive (+) terminal on the battery. Then disconnect it from the booster supply.

If you do not know the voltage of your booster (slave) supply, then contact your JCB dealer for advice. Do not attempt to jump-start the engine until you are sure of the voltage of the booster (slave) supply. 4-2-2-3_1

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Routine Maintenance Electrical System

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 fuses. The fuses are located in the side console. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

D053400

Fig 29.

To get acess to the fuses:

2 3

Make the machine safe.

Remove all four knobs A.

Remove the cover plate B.

Now the fuses C should be visible. .

4 5 6

D026690

Fig 28.

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Routine Maintenance Electrical System Table 5. Fuse Circuit No.

Fuse Rating

EGR (OPT.)

Relay Coil

Stop Lamp

10A

Parking Light LH

7.5A

Front Work Light

20A

Hydraclamp

15A

Side Indicators

Cluster

Hazard

10A

Parking Light RH

Rear Work Light

15A

Acc Supply

10A

4WB

10A

Horn

10A

Light SW.

10A

Dipper

15A

Rear Work Light

15A

Face Fan

10A

Dump Relay

20A

Lights

15A

Wiper

10A

Main

20A

ESOS Cold Start

10A

Radio

15A

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Routine Maintenance Electrical System

Relays

A B

C D D026700

Fig 30. Table 6. 1A

Horn

Parking Light

Front Working Lights

Forward Reverse

Not Used

KIngpost Clamps

Dipper HI LOw

Rear Working Lights

Starter SW. Position 1

Starter SW. Position 2

Starter SW. Position 3

Side Indicators

Warning Buzzer

Revers Horn

Move the instrument cluster plate B.

Now the relays C should be visible. .

The relay C are behind the instrument cluster B. K Fig 31. ( T 152). To get access to the relays: 1

Make the machine safe.

Remove all screws A.

152

D053360

Fig 31.

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152

Routine Maintenance Engine

Engine Oil and Filter Checking the Oil Level

!MWARNING Do not exceed the correct level of engine oil in the sump. If there is too much engine oil, the excess must be drained to the correct level. An excess of engine oil could cause the engine speed to increase rapidly without control.

GEN-1-18

Make the machine safe with the loader arm lifted. Refer to Prepare the Machine for Maintenance.

Allow the engine to cool.

Check that the oil level is between the maximum and minimum marks on the dipstick A.

If necessary, add the recommended oil through filler B to the maximum level.

Fit filler cap and dipstick, make sure that they are fully inserted and tightened. Fig 32.

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Routine Maintenance Engine Changing the Oil and Filter

Loosen and remove the filter housing drain plug E and its 'O' ring J. Let the oil fully drain, then clean and refit the drain plug with a new 'O' ring. Torque the drain plug to 40-60Nm (30-44lbf ft).

T3-030_2

Drain the oil when the engine is warm as contaminants held in suspension will then be drained with the oil. 1

Get access to the engine. Refer to Access Panels, Engine Cover.

Unscrew the filter canister F, use a chain wrench if necessary.

Place a container of suitable size beneath the sump drain plug C.

Clean the seal face of the filter head G.

Smear the seal H on the new filter canister F with clean engine oil.

Screw the filter on until it just contacts the filter head.

Turn the filter at least a further 3/4 of a turn.

Through the top filler point, fill the engine with the recommended oil to the MAX mark on the dipstick. Refer to Checking the Oil Level. Wipe off any spilt oil, refit the filler cap and make sure it is secure.

Operate the engine until the oil pressure low warning light has extinguished. Check for oil leakage. When the oil has cooled, check the oil level again, and if necessary top up with clean engine oil.

!MCAUTION Oil will gush from the hole when the drain plug is removed. Hot oil and engine components can burn you. Keep to one side when you remove the plug. 13-3-1-15

Drain the engine oil. a

Machine with a sump plug, remove the sump drain plug C and its 'O' ring D. Let the oil drain out, then clean and refit the drain plug with a new 'O' ring. Torque the drain plug to 40-60Nm (30-44lbf ft).

b Machines with a drain valve, remove the dust cap K from the sump drain port. Attach drain tube L. With the free end of the tube in an oil container, screw in the drain tube assembly to open the valve. When all the oil has drained, unscrew the drain tube assembly and fit the dust cap K.

C012110-1

Fig 33. 4

C012110-5

Fig 34.

Place a container of suitable size under drain plug E to catch the oil. K Fig 34. ( T 154).

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Routine Maintenance Engine

Cooling System

Checking the Coolant Level (Reservoir fitted Machines) Visually check the coolant level daily. Check the quality of the antifreeze mixture every year before the cold weather starts. Change the coolant as per prescribed in service schedule. 1

Get access to the engine. Refer to Access Panels, Engine Cover.

The coolant level should be between the MIN and the MAX marks on coolant reservoir.

MAX

Note: If the level in the expansion bottle is low, then continue with steps 3 to 4. 3

MIN

Carefully loosen cap A on the coolant reservoir. Let any pressure escape before removing the cap. Fill with pre-mixed water/antifreeze until it reaches the correct level.

Note: To prevent air becoming trapped in the cooling system, do not exceed the maximum fill-rate shown. Refer to Fluids, Lubricants and Capacities. 4

Run the engine for a while to raise the coolant to working temperature and pressure. Stop the engine and checks for leaks. D026710

Fig 35.

Checking the Coolant Level (Non Reservoir fitted Machines) Important: Never attempt to open the radiator cap when the machine is running, engine is in hot condition. Do not run the engine without the radiator cap installed. Visually check the coolant level daily. Check the quality of the antifreeze mixture every year before the cold weather starts. Change the coolant as per prescribed in service schedule.

155

Get access to the engine. Refer to Access Panels, Engine Cover.

Let the engine cool down.

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Routine Maintenance Engine 3

Carefully loosen the radiator cap. Let any pressure escape before removing the cap.

Remove the radiator cap.

Check the coolant level.

Introduction

If the level is low, fill with JCB coolant until it reaches the correct level. 6

Front End Accessory Drive Belt

Always replace the cap with correct PSI JCB radiator caps.

The front end accessory drive belt (FEAD) drives the alternator, water pump and the air conditioning compressor (if fitted). The belt is automatically kept in tension so will not need to be adjusted.

!MWARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5

!MWARNING Turning the Engine Do not try to turn the engine by pulling the fan or fan belt. This could cause injury or premature component failure. 0094

To get access to the drive belt for maintenance: 1

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9821/0000-09

Open the engine cover. Refer to Access Panels, Engine Cover.

156

Routine Maintenance Engine Inspecting the Drive Belt

Changing the Drive Belt T3-029

At the recommended service interval, visually inspect the belt for damage.

Get access to the drive belt. Refer to Front End Accessory Drive Belt, Introduction.

Inspect the belt for cracks A, fraying B or missing pieces C. K Fig 36. ( T 157).

Use a 16mm (5/8 in.) socket located on the hexagon spigot nut D, carefully rotate the tensioner against the spring force in direction E. Do not use excessive force or the tensioner will be damaged.

Keep holding the tensioner against the spring force and lift the belt off the tensioner pulley F.

Slowly release the spring force by rotating the tensioner unit in the opposite direction.

Before fitting a new belt, check that the tensioner roller and fan pulley rotate smoothly and that there is no play in the bearings.

Fit the new drive K Fig 36. ( T 157).

Use a 16mm (5/8 in.) socket located on the hexagon spigot nut D, carefully rotate the tensioner against the spring force in direction E. Do not use excessive force or the tensioner will be damaged.

Keep holding the tensioner against the spring force and lift the belt around the tensioner pulley F.

Fit a new belt as required. Refer to Changing the Drive Belt.

belt

around

the

pulleys.

763440-2

Fig 36.

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Routine Maintenance Engine

Engine Air Filter

Remove cover A. K Fig 37. ( T 158).

Cleaning the Air Filter Scavenge Pipe

Remove outer element B. If necessary, remove the inner element C.

Important: Do not run the engine with the hose K removed. K Fig 37. ( T 158).

Note: Take care not to tap or knock the element.

JCB Ecomax engine has an exhaust scavenge pipe installed in the air induction system. This arrangement ensures heavy dust particles inside the air filter assembly is scavenged due to the low pressure in the exhaust muffler.

Clean the inside of cover A and canister D.

Carefully insert the new inner element C into the canister. Make sure it seats correctly. Check seal is fully seated.

Please check the hose K regularly.

Insert a new outer element into the canister, check seal is fully seated. Fit cover A with hose K at the bottom. Push the cover firmly into position and make sure it is secured.

Check all hoses for condition and tightness.

Inspect the hose for cuts and nicks and check that the rubber is not perished. Renew if necessary for effective functioning of the scavenging.

Changing the Elements

Note: Never try to replace hose K with any other pipe/ hose. The machine can catch fire if incorrect parts are fitted. Contact JCB service dealer for details.

!MCAUTION The outer element must be renewed immediately if the warning light on the instrument panel illuminates. 2-3-3-1

!MCAUTION Do not run the engine when the outer element has been removed. 16-3-3-1

Note: when the air filter blocked warning comes on, the air filter outer element must cleaned with dry compressed air only. Never attempt to clean the inner element. After every cleaning of outer element check the element for cuts and tears.

844430-50

Fig 37.

Note: The air filters must be replaced every 1000 hours or whenever the outer element has been cleaned twice whichever occurs earlier Note: In a dusty environment, the outer element may have to be changed more frequently than the service schedule recommendation. 1

Stop the engine and remove the starter key.

Open the engine cover. K Engine Cover ( T 140).

Identify the air filter.

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Routine Maintenance Fuel System

Fuel System Introduction

Water Separator and Engine Fuel Filter

!MWARNING

Introduction

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.

To get access to the water separator A, engine fuel filter B and C for maintenance: 1

Open the engine cover. Refer to Access Panels, Engine Cover.

INT-3-2-2_3

!MWARNING Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of pressurised fluid and wear protective glasses. If fluid penetrates your skin, get medical help immediately.

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.

D026720

Fig 38.

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

D026720

Fig 39.

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Routine Maintenance Fuel System Draining the Water Separator and Engine Fuel Filter T3-075

If there is water in the fuel or if the cab warning light illuminates, drain the water separator and engine filter as detailed. Drain every 50 hours of machine operation as indicated on the warning decal and in operator handbook, when water is visible in the filter bowls (as indicated by the red float) or immediately whenever the water in fuel warning illuminates.

Wash the bowl in clean fuel.

Refit the bowl, secure in position with locking ring F.

Important: Ensure the seal is seated correctly before refitting the bowl. Refer to Changing the Water Separator Pre-Filter. 7

Make sure that the electrical connector E is correctly fitted.

Draining the filters regularly also removes dirt particles and increases filter life reducing filter costs. Its also recommended to drain Fuel Filter, water separator all together. 1

Get access to the Water Separator and Engine Fuel Filter. Refer to Water Separator and Engine Fuel Filter, Introduction.

Drain off any water in the element A by turning tap B.

C040110-1

Fig 41. 8

K Fig 42. ( T 161) Drain by unscrewing the knob G.

C048590-1

Fig 40. 3

Drain off any water in the water separator bowl C by turning tap D. Do not disconnect the electrical connector E (if fitted).

If there is sediment in the bowl after draining, support the bowl and release the locking ring F.

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Routine Maintenance Fuel System

F G D022740

Fig 42.

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Routine Maintenance Fuel System Changing the Water Separator Pre-Filter T3-076

Get access to the Water Separator. Refer to Water Separator and Engine Fuel Filter, Introduction.

Drain and remove the water separator bowl C. Refer to Draining the Water Separator and Engine Fuel Filter.

To remove the filter element A, release locking ring B and discard element.

Fit new element and secure in position with locking ring B.

Refit the bowl, secure in position with locking ring B.

Important: Ensure the seal D is seated correctly before refitting the bowl. 6

Make sure that the electrical connector E is correctly fitted.

C007030-5

Fig 43.

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Routine Maintenance Fuel System Cleaning Water Separator Pump T3-077

If the priming pump does not operate or if a fuel blockage is suspected, the hand priming pump can be removed and the pump and sedimenter cleaned. Note: To carry out this procedure you will need a strap wrench to loosen and tighten locking ring A. 1

Get access to the Water Separator. Refer to Water Separator and Engine Fuel Filter, Introduction.

Thoroughly clean the outside of the filter housing and around the filter head.

To remove the pump assembly, using a suitable strap wrench release locking ring A, keep the assembly pressed down to contain the spring once the locking ring is free.

Carefully remove the pump assembly, take care not to lose spring B.

Pull out diaphragm C and clean as required using clean fuel.

Remove any debris in the water sedimenter and inlet connectors as required.

Make sure seal D is positioned correctly, lubricate diaphragm C with clean engine oil. Taking care not to damage diaphragm C, refit diaphragm and spring B.

Secure assembly in position, taking care not to cross thread locking ring A, tighten to finger tight.

With strap wrench, tighten locking ring A a further 1/4 of a turn.

Bleed the system and check for leaks. Refer to Bleeding the System.

A B C D

812300

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Fig 44.

163

Routine Maintenance Fuel System Changing the Secondary Fuel Filter T3-078

Get access to the Engine Fuel Filter. Refer to Water Separator and Engine Fuel Filter, Introduction.

Thoroughly clean the outside of the filter housing and around the filter head.

Loosen the drain tap A and allow the fuel to drain into a suitable container.

Mark the pipes prior to removal to ensure they are refitted in the correct position. Press fuel coupling release button B and disconnect fuel lines C and D.

Release the filter strap retaining screw E and lift the filter clear.

Install new filter element F. Make sure that the black dot G is aligned with the locating hole H in the strap. Torque tighten the filter strap retaining screw E to 24 Nm (17.7 lbf ft).

Reconnect the fuel lines C and D.

Bleed the fuel system. Refer to Bleeding the System.

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C007090

Fig 45.

164

Routine Maintenance Fuel System

Bleeding the System Mechanical Fuel Injection System To bleed the engine fuel filter A carry out the following: 1

Disconnect the fuel line B at the injection pump.

Operate the fuel lift pump priming button C until air free fuel exits from the fuel filter outlet.

Reconnect fuel line B.

The engine is now ready to start. If the engine runs smoothly for a short time and then begins to run roughly, leave at idle until it runs smoothly.

After manually priming the fuel system, use the fuel injection pump to bleed the remaining air from the system. The best way to help the injection pump bleed air is by running the engine at idle and blipping the throttle between idle and half speed for approximately 2 minutes. If this is done, all the chambers in the fuel pump will be operated and they will purge the majority of the remaining air from the system.

763990-3

Fig 46.

Important: The engine should never be run at full speed or full load until the fuel system has been properly bled of air. If the engine continues to run roughly, check again for air in the fuel system. If the fault persists contact your nearest JCB dealer.

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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. INT-3-1-10_3

Do not allow dirt to enter the system. Before disconnecting any part of the system, thoroughly clean around the connection. When a component has been disconnected, always fit protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt entering the system. Dirt in the system will seriously damage the systems components and could be expensive to repair. INT-3-3-12

Releasing the Hydraulic Pressure P2-3006

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

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

!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.

b For electrical and servo operated services, turn the starter key to the ON position. c

INT-3-1-11_2

!MCAUTION

166

Press the relevant console switch (to make the relevant service active). Refer to Operation Section. Operate the controls (several times) of the service(s) to be disconnected.

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

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

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. Refer to Hydraulic Tank Cap.

Install the hydraulic tank filler cap.

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166

Routine Maintenance Hydraulic System

Hydraulic Tank Filler Cap

Oil and Filter

The hydraulic tank breather (and filter) forms an integral part of the hydraulic tank filler cap B. Replace the cap (and breather filter) with a new one at the recommended interval.

Checking the Fluid Level 1

Make the machine safe with the loader arm lowered. K Prepare the Machine for Maintenance ( T 124).

The cap incorporates a side mounted barrel lock that is operated by the ignition/door key. It is important to note that seal C must be in good condition and correctly installed in the cap.

Park the machine in travel position.

Look at the fluid level in the sight glass A. The level should be half (or above). K Fig 48. ( T 167).

!MCAUTION

Fit the Cap Insert the key and turn anticlockwise D, screw the cap on until resistance is felt then turn a further quarter of a turn, turn the key clockwise E and remove the key. With the key removed the cap will rotate and can not be undone.

If the fluid is cloudy, then water or air has contaminated the system. This could damage the hydraulic pump. Contact your JCB Distributor immediately. 12-5-1-4

Remove the Cap 4 Insert the key and turn anticlockwise D, unscrew the cap.

If the fluid level is low, remove filler cap B and replenish with recommended hydraulic oil as required.

Note: The key must be inserted in the cap when removing and fitting.

329760-3

Fig 47.

Fig 48.

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Routine Maintenance Hydraulic System Changing the Filter Element

!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

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

Remove the hydraulic tank filler cap.

Remove the nuts C, cover plate D and seal E.

Remove the complete element assembly F and the seal.

Remove the nut and spring K.

Remove the filter element L from the spindle and clean magnets J.

Install the new element L and the new seals G and H.

Put the cover plate D in position, then tighten the nuts C.

Add the recommended hydraulic fluid to the correct level.

Attach the filler cap and make sure its tight.

G H D E L F

K Fig 49.

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Routine Maintenance Hydraulic System Changing the Suction Strainer 1

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

Remove hydraulic tank filler cap.K Hydraulic Tank Filler Cap ( T 167).

Place a container beneath the hydraulic tank to catch the oil, remove drain plug and drain the hydraulic tank. Make sure the container is large enough to hold the tank contents. K Fluids, Lubricants and Capacities ( T 118).

Undo clips A and disconnect the hydraulic suction hose.

Using a 65mm A/F spanner unscrew suction strainer B and discard.

Fit a new filter assembly B, torque tighten to 15-20 Nm (11-15 lbf ft).

Reconnect suction hose. Make sure the clips A are positioned 180Â° apart.

Refit drain plug, torque tighten to 100 Nm (74 lbf ft).

Refill hydraulic tank, fit and tighten the filler cap. K Hydraulic Tank Filler Cap ( T 167).

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A 334050-2

Fig 50.

169

Routine Maintenance Transmission

Transmission Gearbox Checking the Oil Level 1

Start then operate the engine at low idle for four minutes. The delay allows the oil to fill the filter, pump, torque converter, oil cooler and hoses.

Switch OFF the engine and remove the starter key.

Open the engine cover. Refer to Access Panels, Engine Cover. Before you complete a check of the oil level, you must wait as shown on the instructional label A.

Note: The instructional label shows the time in seconds. 4

Check that the oil level is between the end of the dipstick and maximum mark on the dipstick B.

Add oil as necessary. Fill through the dipstick tube to maximum dipstick level. Use only the recommended oil. C007000-2

Fig 51.

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Routine Maintenance Transmission Changing the Oil and Filter Synchro Shuttle Transmission The transmission oil should be drained through the suction strainer aperture to flush out any particles which fall off the strainer during its removal. 1

Get access to the engine. Refer to Access Panels, Engine Cover.

Disconnect the battery. K Battery Disconnection/ Connection ( T 147).

!MCAUTION When the strainer is removed, oil will gush out. Keep to one side when you remove the strainer. 2-3-4-1

Place a container, of suitable size beneath the suction strainer. Remove bolts D. Pull out the strainer E and its gasket F. Allow the oil to drain into the container. Be aware that the oil may be hot.

Clean the strainer with a suitable solvent. Follow the solvent manufacturer's instructions on safety.

Fit the strainer E and a new gasket F. Apply JCB Thread locker and Sealer to bolts D before fitting and tightening them. Torque tighten the bolts to 10 Nm (7 lbf ft).

Unscrew and remove the filter B. Fit the new filter: a

D C

Smear seal C with transmission oil. Fig 52.

b Screw the filter on until it just contacts the filter head. c 7

Turn the filter at least another 3/4 of a turn.

Fill the system with new oil through the dipstick/filler. Do not fill past the top mark on the dipstick.

Note: Fit only a genuine supplied JCB filter, otherwise damage to the system may be incurred through contamination.

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Routine Maintenance Transmission

Axles (Two Wheel Steer Machines) Checking the Oil Level

!MCAUTION

The oil level must be checked with the machine level, otherwise a false indication of the amount of oil will be given. 16-3-5-3_2

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

Clean the area around fill/level plug A, then remove the plug and its sealing washer. Oil should be level with the bottom of the hole. Add recommended oil if necessary.

Fig 54. Rear axle

Clean and refit the plug and its washer.

A B

Fig 53. Front Axle (4WD)

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Routine Maintenance Transmission

!MCAUTION

Changing the Oil The axle oil is also used to lubricate the brake components and cool the brake plates in the rear axle.

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

It is important that the oil is changed regularly as specified in the service schedule - the lubricating properties of the oil will reduce as a result of brake wear.

Remove the drain plug B. Allow the oil to drain out. The drain plug is magnetic. Wipe it clean. (Metallic particles should be carefully removed). Clean and refit the drain plug B.

Remove the fill level plug A. Fill the axle with the specified quantity and recommended type of oil. Clean and refit fill level plug A.

Fill the front hub with the specified quantity and recommended type of oil.

Consult your JCB dealer for advice if necessary. 1

Park the machine on level ground so that the 'OIL LEVEL' mark on one hub is at the bottom. K Fig 55. ( T 173). Engage the park brake. Set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

Start the machine.

b Lift the front axle by lowering the loader arm fully down until the front wheels are clear off the ground. c

Rotate the hub. Make sure the â&#x20AC;&#x2DC;OIL LEVELâ&#x20AC;&#x2122; mark is paralell to the ground. K Fig 56. ( T 173).

d Fill the hub with specified recommended type of oil. e

quantity

and

Clean and install the plug C.

Fig 55. 2

Place a container of suitable size beneath fill level plug C to catch the oil. Remove the fill level plug C from the hub. Allow the oil to drain out. The drain plug is magnetic. Wipe it clean. (Metallic particles should be carefully removed). Clean and refit the hub fill level plug C.

Position the other wheel of the rear axle so that the 'OIL LEVEL' mark on its hub is at the bottom. Repeat step 2.

Place a container of suitable size beneath the drain plug B to catch the oil.

Fig 56.

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Routine Maintenance Tyres and Wheels

Tyres and Wheels Tyre Inflation

in a qualified tyre mechanic. The tyre mechanic should use a tyre inflation cage and the correct equipment to do the job.

Introduction

!MWARNING

T3-066

An exploding tyre can kill. Inflated tyres can explode if over-heated or over-inflated. Follow the instructions given when inflating the tyres. Do not cut or weld the rims. Use a tyre/wheel specialist for all repair work. 2-3-2-7_2

Prepare the wheel. Before you add air to the tyre, make sure it is correctly fitted on the machine or installed in a tyre inflation cage. K Fig 57. ( T 174).

Prepare the equipment. a

!MWARNING Wheels and tyres are heavy. Take care when lifting or moving them. Store with care to ensure that they cannot fall and cause injury.

b Use an air hose fitted with a self-locking air chuck and remote shut-off valve.

13-3-1-7_1

Always try to maintain your tyre pressure to the recommended settings. Using your machine with underinflated tyres means:

Use only an air supply system which includes a pressure regulator. Set the regulator no higher than 1.38 bar (20 psi) above the recommended tyre pressure. For recommended tyres and pressures for your machine, see Specifications, Tyre Sizes and Pressures.

– Decreasing the machines stability – Higher tyre temperatures

Add the air. a

Make sure that the air hose is correctly connected to the tyre valve. Clear other people from the area. Stand behind the tread of the tyre while adding the air.

– Excessive strain of the tyre fabric b Inflate the tyre to the recommended pressure. Do not over-inflate.

– More bulging of the sidewalls – Shortens the tyres life. Using the machine with over inflated tyres is dangerous: – It causes excessive tensile loads in the fabric: this makes a tyre more susceptible to cuts and punctures. Do not cut or weld on the rim of an inflated tyre. After checking or amending the tyre pressure always replace and secure the valve cap. Always deflate the tyre before removing foreign obstacles from the tread.

Procedure T3-067_2

These instructions are for adding air to a tyre which is already inflated. If the tyre has lost all its air pressure, call

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A089570-1

Fig 57.

174

Routine Maintenance Tyres and Wheels

Wheel Nuts Checking the Wheel Nut Torques

!MWARNING If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged. 2-3-2-8

On new machines, and whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct. Every day, before starting work, check that the wheel nuts are tight. Tighten the wheel nuts (in a diagonal sequence) to the torque value shown.

Checking the Wheel Nut Torques T3-014_3

!MWARNING

If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged. 2-3-2-8

175

Front

Rear

Nm (lbf ft)

680 (500)

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175

Routine Maintenance Wear Pads

Wear Pads Stabiliser Legs (Sideshift Machines Only) The wear pads support and guide the inner leg section. They ensure that during extension and retraction the inner leg is kept central and has a minimum amount of 'float'.

Note: Over-tightening the adjustable pad B will lock the pad in position, it will not be possible to back the pad off. If this should happen, operate the stabiliser leg as normal but be aware that pads B and C will wear more rapidly.

Upper wear pads A (4 off) are fitted to the top of the inner leg as shown. The upper pads are available in 3 sizes and are colour coded; 5mm (green); 6mm (red) and 7mm (blue). Lower wear pads comprise adjustable pads B (2 off) and fixed pads C (2 off). When pads A and C have worn to a minimum thickness of 0.5 mm (0.020 in.) they must be replaced with new ones. To replace the pads, the stabiliser inner leg must be removed (contact your JCB Distributor). It is important to note that lower pads C are designed to take most of the 'loading' during stabiliser leg operation, as a consequence these pads must be checked regularly for wear. When replacing pads, it is recommended that the complete lower set of pads are replaced (items B and C). The top pads should be inspected and replaced as required.

Wear Pad Adjustment Note: It is very important that the wear pads are adjusted at the correct service intervals, as the inner leg could contact the outer leg and scoring could occur. Scoring will dramatically reduce wear pad life. 1

Remove and clean away all debris that may have built up in stabiliser cavities.

As a guide, there should be approximately 1mm (0.039 in.) float between the stabiliser inner and outer leg.

Before adjusting the clearance make sure that the leg is raised clear of the ground but not fully retracted.

To adjust the clearance, screw pad B fully in until it just touches the inner leg and then back the pad off by one quarter of a turn.

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273120-5

Fig 58.

176

Routine Maintenance Windscreen Washer (If fitted)

Windscreen Washer (If fitted) Checking the Level 1

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

Open the engine cover. K Access Panels ( T 140)

Remove the washer bottle cap A. K Fig 59. ( T 177).

Fill the windscreen washer bottle with a suitable liquid. The liquid should contain a de-icing fluid to prevent freezing. Do not use engine coolant antifreeze.

Install the washer bottle cap A.

Fig 59.

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Routine Maintenance Windscreen Washer (If fitted)

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Optional 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.

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Optional 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. Note: Patch Planer is NOT suitable for use with this machine.

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Optional 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 1. 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.

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Optional 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 2. 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 3. 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.

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Optional 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 4. ( T 184). 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

183

– 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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Optional 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 4.

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Optional Attachments Directly Mounted Excavator Attachments

Directly Mounted Excavator Attachments Installing Directly Mounted Excavator Attachments Various auxiliary attachments can be used to increase the productivity and versatility of your machine. The same principles apply to all attachments. Your JCB Distributor will gladly answer any queries. The descriptions below describe how to install attachments directly mounted to the excavator. The removal procedure is a reversal of the installation procedure.

!MWARNING

B-2-1-8

Note: This job is easier done by two people - one to operate the controls and one to line up the pivots. 1

Set the attachment flat on level ground as shown. Use safe and correct lifting equipment to move the attachment.

Position the machine: a

H G C

Fig 5.

Position the machine so that the attachment mounting area on the dipper aligns with the attachment.

Fit the hoses. K Connecting/Disconnecting Hydraulic Hoses ( T 181).

b Engage the park brake. c

Disengage the drive.

Operate the controls to line up hole A in the dipper with holes B on the attachment. Insert pivot pin K, fit washer G and secure it with lynch pin D. K Fig 5. ( T 185).

Operate the controls to line up the hole F in the tipping link with the remaining pair of holes in the attachment. Insert pivot pin C, fit washer K and secure it with nuts G and C.

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Optional Attachments Shovel - Forks (If Fitted)

Shovel - Forks (If Fitted) Safety and Control

Preparing the Forks for Use

!MWARNING Each fork weighs approximately 26 kg (57 lb). Take care when swinging them over the shovel.

Position the 6-in-1 shovel approximately 150 mm (6 in) off the ground and slightly rolled forward.

Remove lynch pin B and fork retaining pin A and slide the forks to the ends of the fork mounting rails. K Fig 6. ( T 186).

The forks project in front of the machine. Drive carefully when the forks are in the operating position. If you use the forks and the loader shovel at the same time you could overload the front of the machine. Do not use the forks while there is material in the shovel. If the forks are tilted downwards, the load can slip off and cause an accident. Keep loaded forks tilted upwards. 2-4-2-4_2

The forks are operated by the loader control lever. Always operate the controls slowly and carefully when using the forks. Space the forks as wide as possible for the load. Drive slowly and carefully when the forks are loaded. Keep the forks low to the ground and tilted up at the front when travelling with a load.

Driving Up and Down Gradients To ensure maximum traction do the following when driving on a gradient. Drive an unladen machine forward down a gradient and in reverse up a gradient. Drive a laden machine forward up a gradient and in reverse down a gradient.

Fig 6.

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Optional Attachments Shovel - Forks (If Fitted)

!MWARNING Each fork weighs approximately 26kg (57lb). Take care when swinging them over the shovel.

Roll the loader shovel forward so that the forks are allowed to hang freely. K Fig 7. ( T 187).

Adjust the width setting of the forks to suit the load.

2-4-2-11

Daily Maintenance 3

Manually lift the forks over the shovel until the fork carriage plate rests on the shovel. Keep a grip on the fork arm, allow the arm to lower under its own weight until the heel of the fork rests against the clam blade.

Clean with the rest of the machine.

Check for damage.

Grease (if necessary) the fork mounting rails D. Use JCB MPL Grease. K Fig 7. ( T 187).

Fit fork retaining pins A and lynch pins B. K Fig 6. ( T 186).

Note: Fork retaining pin A and lynch pin B must be fitted before using the forks (as shown at C), otherwise, in extreme positions, it is possible for the fork heels to be trapped in the clam.

!MWARNING With the forks locked in the 'ready for use' position, opening the clam and rolling the shovel back quickly will throw the forks over the back of the shovel. Do not use the clam and shovel to throw the forks over the back of the shovel, otherwise you could cause injury and/or damage to personnel and equipment. Always manually lift the forks over the shovel. When using the forks, operate the controls slowly and carefully.

Fig 7.

2-4-2-12

Preparing For Road Travel 1

Remove the lynch pins B and retaining pins A.

Swing each fork back over the shovel and engage it in its stowage bracket.

Fit the retaining pins A and the lynch pins B. K Fig 7. ( T 187).

Preparing For Site Travel Unless using the forks to carry a load, put the forks in the stowage position as detailed above.

Adjust The Fork Spacing 1

Raise or lower the loader arms to bring the forks approximately horizontal.

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Optional Attachments Tool Carrier and Forks (If Fitted)

Tool Carrier and Forks (If Fitted)

!MWARNING

Safety and Control The forks are operated by the loader control lever.

Forks are heavy. Take care when spacing forks or folding back the forks.

Always operate the controls slowly and carefully when using the forks. Space the forks as wide as possible for the load. Drive slowly and carefully when the forks are loaded. Keep the forks low to the ground and tilted up at the front when travelling with a load.

0002

Manually lift the forks over until the fork carriage plate rests on the ground. To prevent loss, replace retaining pin B and locking pin A.

Driving Up and Down Gradients

Remove locking pin D and retaining pin C, roll the hitch back, fit fork retaining pin C and locking pin D to lock the forks in position. K Fig 9. ( T 188).

To ensure maximum traction do the following when driving on a gradient. Drive an unladen machine forward down a gradient and in reverse up a gradient.

Drive a laden machine forward up a gradient and in reverse down a gradient.

Preparing the Forks for Use 1

Remove the shovel.

Roll the hitch forward, remove locking pin A and fork retaining pin B. K Fig 8. ( T 188). Fig 9.

Fig 8.

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Optional Attachments Tool Carrier and Forks (If Fitted)

Adjust the Fork Spacing

Preparing for Road Travel

Raise or lower the loader arms to bring the forks approximately horizontal. K Fig 10. ( T 189).

Roll the hitch forward so that the forks are allowed to hang freely.

Loosen clamp F, adjust the width setting of the forks to suit the load, then tighten clamp.

Remove locking pin D and fork retaining pin C. K Fig 9. ( T 188).

!MWARNING Forks are heavy. Take care when spacing forks or folding back the forks. 0002

Swing each fork back. To prevent loss, replace retaining pin C and locking pin D.

Roll the hitch forward, remove locking pin A and fork retaining pin B. K Fig 8. ( T 188).

Position the forks until they align with the stow brackets, manually lift the forks over until in the stow position.

Fit fork retaining pin B and locking pin A.

Preparing for Site Travel Unless using the forks to carry a load, put the forks in the road travel position as detailed above.

Preparing for Shovel Operation Put the forks in the road travel position as detailed above. Fig 10.

Fit the shovel.

Daily Maintenance

189

Clean with the rest of the machine.

Check for damage.

Grease (if necessary) the fork mounting rails. Use JCB MPL Grease.

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Optional Attachments Work Platforms

Work Platforms P5-4006_3

!MDANGER Forks/Working Platform Using the forks alone as a working platform is hazardous; you can fall off and be killed or injured. Never use the forks as a working platform. 5-1-5-3

The use of work platforms with this machine is subject to legislation which varies from territory to territory. It is the responsibility of the owner/operator and supplier of the work platform to ensure compliance with the relevant legislation in the relevant territory. In the case of uncertainty, guidance should be sought from the relevant local or government authority. JCB supply integrated work platforms solely for use in Europe which comply with the requirements of European Directive 2006/42/EC. Contact your dealer for further details. Health and safety legislation also varies from territory to territory. Customers should check the latest health and safety legislation for the territory in which the work platform is to be used prior to operation.

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Specifications Lifting Regulations and Safe Working Loads Introduction Lifting (Object Handling) Regulations T2-045

The owner and/or operator must ensure that he fully understands the laws and regulations concerning the use of the JCB Excavator as an earthmover and for lifting. Consult your JCB Distributor for further information. Note: In certain countries Safety Regulations in force call for the application of specific safety factors. Consult your JCB distributor for information.

Safe Working Loads

!MWARNING

P11-5001_3

The safe working load shown on lifting accessories (for example chains, etc.) is not the safe working load of the machine. M0002

The maximum load which may be lifted depends on the equipment fitted to the machine and the laws and regulations in force at the time and in the country in which the machine is being used. If your machine is equipped to be operated under 'Exemption Certificate' rules, your Exemption Certificate will specify the Safe Working Loads.

Loader Unit In all cases the maximum load to be lifted by the loader unit when used as a crane is 1000kg (1 tonne, 2205lb). The maximum safe working load of the fork lift attachment is 1060kg (1.06 tonne, 2336lb) at 600mm (23.5in) load centres. The maximum safe working load of the fork lift mounted crane hook attachment is 1000kg (1 tonne, 2205lb).

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Specifications Static Dimensions

Static Dimensions 3DX, 3DX Super, 3DX Xtra

H G

D B

K J

Fig 1. Table 1. Machine Dimensions 3DX 3DX Super

3DX Xtra

G.P. Shovel

6 in 1 Clam Shovel

1.1 cu m G.P. Shovel

Overall length

6.10 m

Wheelbase

2.17 m

2.24 m

2.17 m

Slew centre to rear axle centre

1.32 m

Minimum ground clearance

0.36 m

Slew ground clearance

0.53 m

Height to top of cab

2.87 m

Overall height

3.90 m

Track width-rear

1.73 m

Track width-Front

1.86 m

1.91 m

1.86 m

Width over bucket

2.35 m

2.23 m

2.35 m

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Specifications Static Dimensions

D026800

Fig 2. Table 2. Turning Circle

3DX(1)

3DX Super(1)

3DX Xtra(1)

Inner wheels braked A

Outside loader bucket

8.64 m

10.40 m

9.70 m

Outside Wheels

6.20 m

7.21 m

6.20 m

Inner wheels not braked A

Outside loader bucket

11.40 m

11.50 m

11.00 m

Outside Wheels

8.94 m

8.32 m

8.94 m

(1) Machines with standard bucket in travel position.

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Specifications Static Dimensions

4DX

H G

D B

K J

D026780

Fig 3. Table 3. Machine Dimensions Long/Short Dig Depth A

Overall length

6.35 m

Wheelbase

2.34 m

Slew centre to rear axle centre

1.19 m

Minimum ground clearance

0.28 m

Slew ground clearance

0.33 m

Height to top of cab

2.87 m

Overall height

3.95 / 4.21 m

Track width-rear

1.73 m

Track width-Front

Width over bucket

â&#x20AC;&#x201C; 1.86-2WD â&#x20AC;&#x201C; 1.91-4WD

194

2.44 m

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Specifications Static Dimensions

D026800

Fig 4. Table 4. Turning Circle

4DX(1)

Inner wheels braked A

Outside loader bucket

Outside Wheels

10.20 m - 2WD / 10.70 m - 4WD 7.61 m - 2WD / 8.06 m - 4WD

Inner wheels not braked A

Outside loader bucket

Outside Wheels

11.70 m - 2WD / 12.45 m - 4WD 9.11m - 2WD / 9.80 m - 4WD

(1) Machines with standard bucket in travel position.

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Specifications Performance Dimensions

Performance Dimensions 3DX, 3DX Super, 3DX Xtra

G T

B A

Fig 5.

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Specifications Performance Dimensions Table 5. Loader End 3DX G.P. Shovel 2.74 m

3DX SUPER

3DX Xtra

6 in 1 Clam Shovel 2.9 m

G.P. Shovel

Dump Height

2.90 m

Load over height

3.23 m

3.40 m

Pin height

3.45 m

3.60 m

Pin forward reach

0.36 m

0.41 m

0.40 m

Reach at ground

1.42 m

1.60 m

Max. reach at full height

1.20 m

Reach at full height - Bucket dumped

0.83 m

0.90 m

0.93 m

Below ground level dig depth

0.07 m

0.15 m

0.12 m

Rollback at ground

45°

43°

Dump angle

43°

41°

Bucket break-out force

6010 kgf

6600 kgf

6070 kgf

Pay Load

1800 kgf

1650 kgf

1800 kgf

Shovel Capacity

1.1 cu m

1.0 cu m

1.1 cu m

Table 6. Excavator End (Standard Dipper) 3DX

3DX SUPER

3DX Xtra

Max. dig depth

4.77 m

5.10 m

Reach-ground level to rear wheel centre

6.72 m

6.90 m

Reach-ground level to slew centre

5.40 m

5.60 m

5.6 m

Reach at full height to slew centre

2.74 m

3.10 m

Side reach to centre line of machine

6.02 m

6.10 m

Max working height

5.97 m

6.00 m

Max. load over height

4.18 m

4.4 m

King post travel

1.06 m

Bucket rotation - power

185°

Bucket tear out force

5700 kgf

6324 kgf

Dipper tear out force

3010 kgf

3217 kgf

Lift capacity to bucket pivot at full reach (no bucket fitted) Standard dipper

1490 kgs

1584 kgs

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Specifications Performance Dimensions

4DX

D026790

Fig 6.

198

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Specifications Performance Dimensions Table 7. Loader End Long/Short Dig Depth M

Dump Height

2.90 m

Load over height

3.40 m

Pin height

3.60 m

Reach at ground

1.60 m

Max. reach at full height

1.20 m

Reach at full height - Bucket dumped

0.93 m

Below ground level dig depth

0.13 m

Rollback at ground

43째

Dump angle

41째

Bucket break-out force

6010 kgf

Pay Load

1800 kgf

Shovel Capacity

1.2 cu m Table 8. Excavator End Long Dig Depth

Short Dig Depth

Max. dig depth

5.36 m

4.95 m

Reach-ground level to rear wheel centre

7.57 m

7.11 m

Reach-ground level to slew centre

6.38 m

5.92 m

Reach at full height to slew centre

2.18 m

1.98 m

Side reach to centre line of machine

3.91 m

Max working height

6.25 m

5.69 m

Max. load over height

3.96 m

3.66 m

Reach over side from stabliser

4.44 m

3.96 m

Bucket rotation - power

185째

Bucket tear out force

6125 kgf

Dipper tear out force

3963 kgf

Lift capacity to bucket pivot at full reach (no 2323 kgs bucket fitted) Standard dipper

2200 kgs

199

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Specifications Hydraulic Hose Burst Pressures

Hydraulic Hose Burst Pressures Introduction The information is included to advise the machine operator of the hydraulic hose burst pressures for all hoses used on this machine.

The heading at the top of the left-hand column is 'JCB Prefix Number', this number can be found stamped on the swaged end of a hose immediately behind the hose nut. The JCB prefix is the 2 or 3 digit prefix of the JCB part number, e.g., 612/21100 or 34AP/BA130.

Old Type Hose JCB PREFIX

BORE SIZE

Table 9. 3 Digit JCB Part Number Prefix RANGE MAXIMUM WORKING PRESSURE

MINIMUM BURST PRESSURE

607/

19.05 mm

Medium Pressure

235 bar

950 bar

611/

6.35 mm

High Pressure

400 bar

1600 bar

612/

9.525 mm

High Pressure

330 bar

1320 bar

613/

12.7 mm

High Pressure

275 bar

1100 bar

614/

15.875 mm

High Pressure

250 bar

1000 bar

615/

19.05 mm

High Pressure

275 bar

1100 bar

629/

5 mm

SAE 100 R7 (or 3/16 in)

207 bar

827 bar

631/

6.35 mm

Low Pressure

190 bar

760 bar

632/

9.525 mm

Low Pressure

155 bar

620 bar

633/

12.7 mm

Low Pressure

140 bar

550 bar

634/

15.875 mm

Low Pressure

100 bar

415 bar

635/

19.05 mm

Low Pressure

85 bar

345 bar

637/

25.4 mm

Low Pressure

70 bar

275 bar

200

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Specifications Hydraulic Hose Burst Pressures

New Type Hose Table 10. 2 Digit JCB Part Number Prefix (From Serial number 2006051) BORE SIZE TYPE / RANGE MAXIMUM WORKING MINIMUM BURST PRESSURE PRESSURE 1st Digit 2nd Digit JCB PREFIX

6.4 mm

Pilot Servo Hose

103 bar

412 bar

9.5 mm

Pilot Servo Hose

103 bar

412 bar

6.4 mm

Low Pressure Hose

190 bar

760 bar

9.5 mm

Low Pressure Hose

155 bar

620 bar

12.7 mm

Low Pressure Hose

140 bar

560 bar

15.9 mm

Low Pressure Hose

100 bar

400 bar

19.1 mm

Low Pressure Hose

85 bar

340 bar

25.4 mm

Low Pressure Hose

70 bar

280 bar

31.8 mm

Low Pressure Hose

40 bar

160 bar

38.1 mm

Low Pressure Hose

35 bar

140 bar

50.8 mm

Low Pressure Hose

25 bar

100 bar

6.4 mm

High Pressure Hose

350 bar

1400 bar

9.5mm

High Pressure Hose

330 bar

1320 bar

12.7mm

High Pressure Hose

275 bar

1100 bar

15.9mm

High Pressure Hose

275 bar

1100 bar

19.1mm

High Pressure Hose

275 bar

1100 bar

25.4mm

High Pressure Hose

275 bar

1100 bar

31.8mm

High Pressure Hose

210 bar

840 bar

6.4mm

High Pressure Static Hose

350 bar

1400 bar

9.5mm

High Pressure Static Hose

330 bar

1320 bar

12.7mm

High Pressure Static Hose

275 bar

1100 bar

15.9mm

High Pressure Static Hose

275 bar

1100 bar

19.1mm

High Pressure Static Hose

275 bar

1100 bar

25.4mm

High Pressure Static Hose

275 bar

1100 bar

31.8mm

High Pressure Static Hose

210 bar

840 bar

19.1mm

Extra High Pressure Hose

350 bar

1400 bar

25.4mm

Extra High Pressure Hose

350 bar

1400 bar

31.8mm

Extra High Pressure Hose

350 bar

1400 bar

201

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Specifications Hydraulic Hose Burst Pressures

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Section A Attachments Service Manual - 3DX / 4DX Backhoe Loader Section 1 - General Information Section 2 - Operator’s Manual Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine

Publication No.

9813/2050-5

Section A - Attachments

Notes:

A-0

9813/2050-5

A-0

Section A - Attachments Contents Page No. Hammer Master 360 Technical Data .......................................................................................... A-1 Hammer Master Identification ................................................................... A-2 Major Components ................................................................................... A-3 Basic Operation ........................................................................................ A-4 Start-Up ................................................................................................ A-4 Raising the Piston ................................................................................ A-5 Piston Stroke ........................................................................................ A-6 Torque Settings ........................................................................................ A-7 External Components ........................................................................... A-7 Internal Components ............................................................................ A-8 Lubricants ................................................................................................. A-9 External Components ........................................................................... A-9 Internal Components .......................................................................... A-10 Service Schedules ................................................................................... A-11 Every 2-4 Hours ..................................................................................A-11 Daily ....................................................................................................A-11 Weekly .................................................................................................A-11 Initial 50-100 Hour Service ..................................................................A-11 Every 500 Hours or Yearly .................................................................. A-12 Service Procedures ................................................................................ A-13 Tool Bushings ..................................................................................... A-13 Side Plates ......................................................................................... A-13 Hydraulic Pressure Testing ................................................................. A-14 Lower Tool Bushing and Tools ................................................................ A-15 Checking For Excessive Wear (Monthly) ........................................... A-15 Lower Tool Bushing ............................................................................ A-16 Side Plates ............................................................................................. A-17 Removal ............................................................................................. A-17 Swivel Couplings .................................................................................... A-18 Removal and Dismantling .................................................................. A-18 Assembly and Replacement ............................................................... A-18 Accumulators .......................................................................................... A-19 Removal and Replacement ................................................................ A-19 Dismantling and Assembly ................................................................. A-20 Charging ............................................................................................. A-21 Pressure Adjusting Valve ........................................................................ A-22 Dismantling and Assembly ................................................................. A-22 Adjustment ......................................................................................... A-23 Tie Rods ................................................................................................. A-24 Removal and Replacement ................................................................ A-24 Inspection ........................................................................................... A-24 Valve Body .............................................................................................. A-25 Removal and Dismantling .................................................................. A-25 Assembly and Replacement ............................................................... A-25 Cylinder .................................................................................................. A-26 Removal and Replacement ................................................................ A-26 Front Head ............................................................................................. A-27 Dismantling and Assembly ................................................................. A-27 Charging Procedure ............................................................................... A-28

A-i

Section A - Attachments Contents

Contents

A-ii

Page No.

A-ii

Section A - Attachments Hammer Master 360 Technical Data

Hammer Master 360 Technical Data Working weight (including tool and side plates)

405 kg (891 lbs.)

Impact Energy

730 Joules

Impact Rate

600 - 1800 blows / min.

Operating pressure

100 - 130 bars (1450 - 1885 lbf/ in)

Pressure relief setting limits of carrier ARV

130 - 220 bar (1885 - 3190 lbf / in)

Oil supply

50 - 150 l min. (11 - 33 gal/ min.)

Return line back pressure (max.)

30 bar (435 lbf / in)

Input power (max.)

40 kW

Output power (max.)

22 kW

Port adapters - Hammer master/ connecting hoses Pressure line

3/4” BSP (male)

Return line

1" BSP (male)

Connecting hose inner diameters Pressure line

19 mm

Return line

25 mm

Oil temperature range

- 20 °C to + 80 °C

Carrier weight

5 - 8. 5 T

Tools (Moil Point and Chisel) Length

730 mm

Weight

20 kg

Shank diameter (new)

70 mm

Shank diameter (minimum allowable)

68 mm

Bushings Diameter (new)

70 mm

Diameter (max. allowable)

72 mm

Accumulator charging pressure Low pressure accumulator

12 bar

High pressure accumulator

40 bar

A-1

9813/2050-5

A-1

Section A - Attachments Hammer Master 360 Hammer Master Identification

Hammer Master Identification The equipment serial number is stamped on plate A located on the left hand side plate of Hammer Master 360 as shown.

Fig 1.

A-2

9813/2050-5

A-2

Section A - Attachments Hammer Master 360 Major Components

Major Components K Fig 2. ( T A-3) Table 1. A

Side plate

Low pressure accumulator

High pressure accumulator

Distributor valve

Pressure adjusting valve

Valve body

Cylinder

Piston

Tie rod

Piston seal

Wiper

Front head

Thrust ring

Upper ring

Tool retaining pin

Cap screws

Lower tool bushing

Dust seal

Tool

Fig 2.

A-3

9813/2050-5

A-3

Section A - Attachments Hammer Master 360 Basic Operation

Basic Operation Start-Up When the hammer cycle begins the high and low pressure circuits are common circuits to each other and separate from tank line. The entire hammer is under low pressure, which keeps the piston P and distributor D in their lowest position K Fig 3. ( T A-4). The oil flows into the low pressure accumulator A and acts on the Z end of the spool S. An increase in pressure compresses the spring and the adjusting valve spool moves to a pre - adjusted setting and closes the flow path between high pressure circuit and the low pressure circuits (which now precharge). Pressure increase in the high pressure circuit and a normal hammer cycle begins.

Fig 3.

A-4

9813/2050-5

A-4

Section A - Attachments Hammer Master 360 Basic Operation

Raising the Piston The high pressure oil acts on the lower outer shoulder area of DL. The distributor then moves to its most upward position.This allows the top area of piston PT access to tank line. High pressure oil acting on piston shoulder PS lifts piston. As the piston rises, the upper piston area PU forces oil into the low pressure accumulator A, storing energy K Fig 4. ( T A-5).

Fig 4.

A-5

9813/2050-5

A-5

Section A - Attachments Hammer Master 360 Basic Operation

Piston Stroke In the upper position the piston shoulder PS opens high pressure circuit to distribution area DA through a pilot channel. The force acting on distributor area DA forces the distributor to its lowest position, connecting inlet pressure to piston top PT. This balances forces on piston shoulder PS allowing low pressure piston downward K Fig 5. ( T A-6). During the piston stroke, high pressure acting on upper distributor area DA is greater than the force acting on lower distributor area DL with high pressure. As the piston moves downwards the upper area of the piston PU and the pilot channel are connected and deliver low pressure to the upper distributor area DA. Due to the high pressure at the lower distributor area DL, the distributor moves upward and piston starts another cycle.

Fig 5.

A-6

9813/2050-5

A-6

Section A - Attachments Hammer Master 360 Torque Settings

Torque Settings External Components K Fig 6. ( T A-7) Table 2. Item

Description

Quantity

Ibf ft

Side plate mounting bolts/nuts (earlier models)

580

428

Side plate mounting screws (Later models)

580

428

Side plate mounting screws

580

428

Side plate mounting screws

340

250

Side plate mounting screws (upper) M24 x 50

580

430

Side plate mounting screws (lower) M24 x 90

580

430

Fig 6.

A-7

9813/2050-5

A-7

Section A - Attachments Hammer Master 360 Torque Settings

Internal Components K Fig 7. ( T A-8) Table 3. Item

Description

Quantity

lbf ft

Mounting screw - LP accumulator

175

129

Filter plug - LP accumulator

Cover mounting screw - LP accumulator

175

129

Tie rods (plus 600)

500

369

Plug - pressure adjusting valve

150

110

Spring housing - pressure adjusting valve

340

251

Filler plug - HP accumulator

Mounting screw - HP accumulator

175

129

Cover mounting screw - HP accumulator

175

129

Accumulator blanking plugs

150

110

Fig 7.

A-8

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A-8

Section A - Attachments Hammer Master 360 Lubricants

Lubricants External Components K Fig 8. ( T A-9) Table 4. Item

Function

Product Description

Lubricate threads

JCB Special MPL Moly Grease

Grease pivot pin bushes

JCB Special MPL Grease

Fig 8.

A-9

9813/2050-5

A-9

Section A - Attachments Hammer Master 360 Lubricants

Internal Components K Fig 9. ( T A-10) Table 5. Item

Function

Product Description

Grease tool shank and inside of tool bushing

JCB Special hammer Grease

Coat grease inside of accumulator membrane

Silicone Grease

Lubricate threads

JCB Special Moly Grease

Anti- friction coating for mating machine faces

JCB chain Lubricant

Grease `o' rings

Silicone Grease

Lubricate hydraulic parts and seals

JCB Special hydraulic Fluid

Anti - corrosion coating

Cold galvanising spray

Thread locking

Locking Fluid (high locking force)

Seal gap between tie- rods and top face of front head

Silicone compound

Pack spring housing of pressure adjusting valve

Petroleum Jelly

Fig 9.

A-10

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A-10

Section A - Attachments Hammer Master 360 Service Schedules

Service Schedules Maintenance must only be done by competent personnel.

Weekly

Every 2-4 Hours

Do the 2-4 hour and Daily jobs plus:

(Depending on operating conditions).

Check (engine stopped)

Grease

The lower tool bushing for excessive wear.

The tool shank for excessive wear.

The hydraulic hoses - renew if necessary.

The tool bushing via the grease nipple(s).

Important: The grease must be a Molydenium Disulphide or Graphite grease with no dropping point and a maximum working temperature level of 150 Â°C. it must also be water resistant.

Initial 50-100 Hour Service Note: Applies to a new Hammer Master only.

Daily

Check (engine stopped) Do the 2 - 4 hour jobs plus: 1

Torque tightness of bracket/side plate securing hanger bolts.

All hydraulic connections.

Clean 1

The Hammer Master, its tools and its hoses.

Grease

Check (engine running)

For hoses rubbing against carrier (throughout range of rotation of the Hammer Master).

The Hammer Master pivots.

Check (engine stopped) 1

Hammer Master operating pressure.

For damage to the Hammer Master, its tools and its hoses. Tighten loose fasteners and connection.

Hydraulic operation.

The torque tightness of the hanger bracket/ side plate securing bolts.

Hammer Master efficiency, impact rate and evenness of operation.

oil

temperature

during

continuous

Observe (Hammer Master operating) Change 1

Operating pressure, hydraulic oil temperature, blow efficiency and evenness of operation.

A-11

9813/2050-5

The carrier hydraulic filter(s).

A-11

Section A - Attachments Hammer Master 360 Service Schedules

Every 500 Hours or Yearly Note: Whichever interval occurs first. This annual service is best carried out by the JCB distributor. 1

Overhaul the Hammer Master.

With the tester unit installed in place of the hammer, measure the circuit oil flows, back pressure and pressure relief setting.

Replace hydraulic filter (s) of carrier.

Check all hydraulic hoses and replace if necessary.

Check operating pressure, hydraulic oil temperature blow efficiency and evenness of operation.

Replace Hammer Master warning decals.

Replace all seals.

Replace diaphragm.

Check all parts for wear and replace if necessary. That includes carrying out crack tests on the breaker tie rods.

A-12

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A-12

Section A - Attachments Hammer Master 360 Service Procedures

Service Procedures Tool Bushings

Side Plates

Greasing (Every 2-4 Hours)

Checking Bolt Tightness (Daily)

Position the Hammer Master vertically as shown, with its weight on the tool. Make sure the carrier parking brake is engaged, the drive is in neutral and the engine stopped. Remove the starter key.

It is important that the eight screws A and two nuts/bolts B are checked for torque tightness. The correct torque tightness is 580 Nm (428 Ibf ft) K Fig 11. ( T A-13).

Inject JCB Special Hammer Grease through grease point (s) A using the grease gun supplied. Ten - to - fifteen shots should normally be enough K Fig 10. ( T A-13).

Note: The eight screws A thread directly into the body of the Hammer Master, fours on each side. On early models bolts B reach through side plate spacers to be secured by nuts on the opposite side. On later models screw B thread into tapped holes in the spacers between the side plates.

Note: Make sure that the tool is kept fully up in its housing during greasing, to prevent grease filling the cavity between the piston and the tool. The actual frequency of this job will depend on operating conditions and the material being worked. If inspection reveals that the greasing has been insufficient, grease more often.

Fig 11.

Fig 10.

A-13

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A-13

Section A - Attachments Hammer Master 360 Service Procedures

Hydraulic Pressure Testing Pressure testing should be performed with the Hammer Master installed on the carrier.

!MWARNING Make the machine safe before connecting the pressure gauge. Stop the engine, remove the starter key and relieve system pressure. B-3-2-4

Switch off the carrier engine and remove the starter key. Operate the carrier auxiliary control a few times to relieve system pressure (refer to carrier operating instructions) K Fig 12. ( T A-14).

Remove blanking plug A Connect in its place a glycerine damped high pressure gauge (250 bar).

Start the carrier engine and lower the Hammer Master tool onto a thick steel plate.

Fig 12.

!MCAUTION The next part of the test is extremely noisy. Protect your hearing by wearing ear defenders. Warn other people in the area to wear ear defenders also. B-3-2-3

Adjust the carrier engine speed according to the carrier operating instruction and operate the Hammer Master.

Read off the gauge the average operating pressure which should be as set at factory. This should not need adjusting. Table 6. Average Operating Pressure

Range Hammer master 360

bar 110 - 130

If the pressure is incorrect, refer to Pressure Adjusting Valve in appropriate Servicing section.

Disconnect the pressure gauge. Refit plug A and tighten to a torque of 33 Nm (24 lbf ft).

At the completion of pressure testing repeat step 1.

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A-14

Section A - Attachments Hammer Master 360 Lower Tool Bushing and Tools

Lower Tool Bushing and Tools Checking For Excessive Wear (Monthly) 1

Remove the tool.

The original tool shank diameter is D1. If the diameter D2 at any point is less than that listed (see table below), obtain a new tool K Fig 13. ( T A-15).

The original inside diameter of the lower tool bushing is D3. Note that tool bushings tend to wear oval as shown is the maximum internal diameter D4 exceeds that listed, the bushing should be renewed.

If the grease grove in the lower bushing has worn beyond the 40 mm area marked on the bottom illustration, the bushing should be renewed.

Renew the lower bushing as described.

Smear the tool's shank and bushing with JCB Special Hammer Grease before installing the tool.

Dimension

Table 7. Minimum Acceptable Value

70 mm

68 mm

70 mm

72 mm Fig 13.

A-15

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A-15

Section A - Attachments Hammer Master 360 Lower Tool Bushing and Tools

Lower Tool Bushing Removal 1

Remove the tool.

Remove the two roll pins A by knocking them into the cavity normally occupied by the tool. Withdraw the lower tool bushing B and remove it's internal seal C. K Fig 14. ( T A-16)

Replacement 1

Fit a new internal seal C into the Bushing (see diagram B for correct way to fit).

Apply MoS2 spray to the contact surfaces of the bushing and the front head.

Install the bushing by reversing step 2 of the Removal procedure, taking care to align the holes in the bushing with the retaining pin apertures visible through the side plates.

Smear the tool's shank and the lower tool bushing with JCB Special Hammer Grease before installing the tool.

Checking For and Removing Burrs 1

Remove the tool.

Check for burrs on the tools shank and the retaining pins.

Fig 14.

Carefully remove all burrs. Do not overheat the tool.

!MCAUTION Protect yourself when removing burrs. Wear safety glasses and industrial gloves. B-3-1-4_1

Smear the tools shank and the bushing with JCB Special Hammer Grease before installing the tool.

A-16

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A-16

Section A - Attachments Hammer Master 360 Side Plates

Side Plates Removal 1

Mount the Hammer Master on the rock breaker support stand. Support each side plate on lifting hooks inserted in the pivot pin holes K Fig 15. ( T A-17).

Remove the two sets of pivot plate securing nuts A. washers B,C and Bolts D.Remove and retain spacers F.

Remove the eight securing screws E and washers B, one side at a time.

Remove the side plates. taking care not to damage the swivel couplings.

Installing Important: Clean all parts before installing. Installing is a reversal of the removal procedure. Ensure that the spacers F are in place and that the washers B face towards each other as shown. Finger-tighten the nuts A and screws E and then insert two pivot pins in to the pivot pin bushes (to ensure correct side plate alignment). Torque tighten the nuts and screws. Evenly and in stages, to 580 Nm (428 lbf ft). Finally, remove the two pivot pins.

Fig 15.

A-17

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A-17

Section A - Attachments Hammer Master 360 Swivel Couplings

Swivel Couplings Removal and Dismantling

Assembly and Replacement

Note: Only remove the swivel coupling assembly if there is evidence of oil leakage, and then only if you have a replacement seal kit.Otherwise do not disturb.

Assemble in reverse order to step 4 of the Removal and Dismantling procedure. making sure that swivels E and F are not interchanged. Fit new seals, washers and circlips from the seal kit.

Tighten each flange plug G, if removed, to a torque setting of 150 Nm (110 lbf ft).

Select the appropriate seals and washers from the seal kit and install manifold B using banjo bolts A.

Tighten the banjo bolts to a torque of 450 Nm (330lbf ft).

Remove the side plate K Fig 16. ( T A-18).

Remove the two banjo bolts A while supporting manifold B.

Lift the manifold away form the Hammer Master. Discard the exposed seals and washers, making a note of where they fit and what they look like.

Remove the circlips C and washers D which retain swivels E and F. Remove the swivels.

Note: The swivels are not identical. E having a 3/4 in BSP thread.

Fig 16. 5

Discard the seals O - rings and circlips. making a note of where they fit and what they look like.

Flange plugs G need only be removed if there is a blockage in the manifold.

A-18

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A-18

Section A - Attachments Hammer Master 360 Accumulators

Accumulators Removal and Replacement Removal 1

Remove the side plates. K Fig 17. ( T A-19).

Remove the protective plugs A and B from the accumulators.

!MWARNING Use only nitrogen gas to charge accumulators. The use of any other gas can cause the accumulators to explode. Remember that although nitrogen is not poisonous you can be killed by suffocation if it displaces the air in your workplace. Do not allow excessive quantities of nitrogen to be discharged into the atmosphere.

Position accumulator J on top of the valve body and remove the lifting ring.

Grease the threads of the 12 socket head screws H. fit them with locking washers (two per screw) and install. Tighten to a torque of 175 Nm (129 lbf ft).

Coat the mating surfaces of valve body K and accumulator M with Mos2 spray.

Position accumulator M on the valve body.

Grease the threads of the socket head screws. Fit them with locking washers (two per screw) and install. Tighten to a torque of 175 N (129 lbf ft).

B-3-1-6

Carefully open low pressure accumulator filling plug C and let the nitrogen escape. When there is no more pressure in the accumulator, remove plug C and Usit ring D.

Carefully open high pressure accumulator filling plug E and let the nitrogen escape.When there is no more pressure in the accumulator, remove plug E and Usit ring F.

Release the residual pressure in the hammer by opening pressure measuring plug G.

Install lifting ring in the hole vacated by plug A. Remove the 12 socket head screws H and their locking washers. Liift the low pressure accumulator J clear of valve body K.

Remove the four socket head screws L and their locking washers. Remove high pressure accumulator M.

Replacement

Fig 17.

Charge the accumulators.

Coat the mating surfaces of valve body K and accumulator J with MoS2 spray.

A-19

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A-19

Section A - Attachments Hammer Master 360 Accumulators

Dismantling and Assembly

Assembly

The dismantling and assembling procedures below apply to both low pressure (LP) and high pressure (HP) accumulators. Detailed differences are indicated.

Secure cover F upside down on bolts held in a bench vice.

Coat the inside of cover F and the gas side of a new diaphragm E with silicone grease. Install the diaphragm in the cover.

Install accumulator base D.

Grease the threads of socket head screws B (LP-8 off, HP- 4 off) and fit them with locking washers C (two per screw).

Install the screws and tighten evenly and progressively to a torque off 175 Nm (129 lbf ft).

Dismantling 1

Remove `O' ring A from accumulator base D K Fig 18. ( T A-20),

Secure the accumulator upside down by locking cover F on bolts held in bench vice.

Remove socket head screws B (LP-8 off. HP-4 off) and their locking washers C (two per screw).

Remove the accumulator base D and diaphragm E.

Fig 18.

A-20

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A-20

Section A - Attachments Hammer Master 360 Accumulators

Charging

Fit a new protective plug E over the filler plug and tighten to a torque of 150 Nm (110 lbf ft).

Note: This procedure applies to both the low pressure and the high pressure accumulators.

Fit a new Usit-ring A and filler plug B.

Connect nitrogen accumulator.

Via the charging device, open filler plug B by three turns as at D K Fig 19. ( T A-21).

Open the discharge valve of the charging device. Carefully open the nitrogen gas bottle valve and confirm that the nitrogen gas flows freely. Shut the gas bottle valve and the discharge valve of the charging device.

Carefully open the gas bottle valve and charging valve and watching the gauge, allow nitrogen to flow until the pressure reading reaches 5 bar (72.5 lb in2) above the recommended pressure given below. Close the gas bottle valve.

Wait 10 minutes to dissipate the heat generated during charging.

Adjust the pressure in the accumulator to the recommended pressure by carefully opening and closing the discharge valve of the charging device. Via the charging device, shut the filler plug B and tighten to a torque off 20 Nm (15 lbf ft).

Release the pressure from the gas bottle hose by opening the discharge valve of the charging device. Disconnect the charging device from the accumulator.

Check the gas - tightness of filler plug B by pouring some oil around it.

A-21

charging

device

the

9813/2050-5

Fig 19.

A-21

Section A - Attachments Hammer Master 360 Pressure Adjusting Valve

Pressure Adjusting Valve The pressure adjusting valve is located in the valve body adjacent to the swivel couplings banjo securing bolts.With the side plates removed. it can be dismantled individually without disturbing any other components.

Assembly 1

Dismantling and Assembly

Check all pans for damage. Carefully remove minor blemishes. Renew parts which are badly damaged. Clean all hydraulic parts and coat with clean Hydraulic oil before installation.

Dismantling

Install a new seal F in its groove in the valve body, making sure it is fitted correctly K Fig 20. ( T A-23).

Insert spool E, making sure it is the right way round. Do not insert too deeply.

Install plug D and tighten to a torque of 150 Nm (110lbf ft).

!MWARNING Do not dismantle the pressure adjusting valve until the hydraulic oil pressure has been released from the Hammermaster. B-3-2-1

Remove spring housing A followed by shim plates B and spring C. (Do not lose the shim plates).

Install spring C, original shim plates B and spring housing A.

Remove plug D and push out spool E through the aperture vacated by D.

Check the spring pre-load as described in Adjustment below.

Remove seal F from the valve body.

Fill spring housing A with grease and tighten to a torque of 340 Nm (250 lbf ft).

A-22

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A-22

Section A - Attachments Hammer Master 360 Pressure Adjusting Valve

Adjustment Adjustment of the pre-load on spring C is the means by which the hammer operating pressure can be varied. This will have been pre-adjusted at the factory and should not need to be altered. However if pressure adjustment is found to be necessary the correct spring pro-load can be restored by adding or removing shim plates increases operating pressure. and vice-versa. To adjust the pre-load, tighten spring housing A until spring pressure can just be felt. At this point spring C is not loaded. Measure the gap X which should be1.5 mm (0.058 in). Add or remove shim plates B to adjust the gap.

Fig 20.

A-23

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A-23

Section A - Attachments Hammer Master 360 Tie Rods

Tie Rods Removal and Replacement Removal 1

Remove the accumulators.

Remove rubber ring A and locking plate B from each the rod K Fig 21. ( T A-24)

Identify each tie rod C with its nuts D.

Use a wrench to loosen each tie rod. Evenly and progressively unscrew the tie rods and remove them.

Take out the nuts D using and M8 screw, making note of which way up they are fitted.

Remove washers E from the valve body.

Replacement 1

Grease the tie rod threads and the contact surfaces of the tie rods and the valve body.

Spray cold galvanising fluid onto the portion of each tie rod which is located inside the valve body.

Insert washers E in the valve body with their grooves facing upwards.

Use an M8 screw to insert the nuts D, making sure they are the same way up as they were originally.

Install the four tie rods, making sure each one is used with its original nut.

Used a torque wrench to tighten the four tie rods progressively and evenly, first to a torque of 250Nm (185lbf ft) and finally to 500 Nm (369 lbf ft).

Inspection

Tighten each tie rod by a further 60 degree.

Install a locking plate B followed by a rubber ring A to each tie rod.

Clean the tie rods and use crack detecting equipment to inspect them. If cracks are found, or if other damage is evident, replace the all affected tie rod and its nut.

Fill the gaps between the tie rods and top of the front head (point F) with silicone compound.

Install the accumulators.

Fig 21.

A-24

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A-24

Section A - Attachments Hammer Master 360 Valve Body

Valve Body Removal and Dismantling 1

Remove the accumulator and tie rods.

Mark the relative positions of valve body A and cylinder H K Fig 22. ( T A-25).

Install eye ring into two diametrically opposite threaded holes intended for the low pressure accumulator mounting bolts. Lift valve body A away from cylinder H.

Remove steering bush B and discard the `O' rings C and internal seal D.

Remove slide ring E, distributor F and assembly ring G.

Assembly and Replacement 1

Check all parts for damage. Carefully remove minor blemishes. Renew parts which are badly damaged. Clean all hydraulic parts and coat with clean hydraulic oil before assembly.

Grease and fit new `O' rings C (2 off) and seal D to steering bush B.

Install assembly ring G, distributor F and slide ring E into valve body A. Check that the distributor moves freely.

Install steering bush B.

Coat the mating surfaces of valve body A and cylinder H with MoS2 spray.

Lift the valve body onto the cylinder, making sure the marks made previously are aligned.

Install the tie rods and accumulator.

A-25

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Fig 22.

A-25

Section A - Attachments Hammer Master 360 Cylinder

Cylinder Removal and Replacement Removal 1

Remove the accumulators, the tie rods and valve body.

Remove the six `O' rings A and two `O' rings B from the top of cylinder E K Fig 23. ( T A-26).

Remove locating pin C and extract piston D (noting which way round it fits).

Mark relative positions of cylinder E and the front head.

Remove the cylinder from the front head and discard wiper F and seal G.

Replacement 1

Check all parts for damage. Carefully remove minor blemishes. Renew parts which are badly damaged. Clean all hydraulic parts and coat with clean hydraulic oil before installation.

Fit a new seal G and wiper F to cylinder E.

Coat the mating surface of the cylinder and the front head with MoS2 spray.

Lift the cylinder onto the front head, making sure the marks made previously are aligned.

Coat piston D with clean hydraulic oil and install in cylinder E, making sure it is the right way round (see step 3 of Removal).

install six new `O' rings A and to new `O' rings B, followed by locating pin C.

Install the valve body, the tie rods and the accumulators.

A-26

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Fig 23.

A-26

Section A - Attachments Hammer Master 360 Front Head

Front Head Dismantling and Assembly Dismantling 1

Removing the accumulator, the tie rods, the valve body and the cylinder.

Remove thrust ring A.

Remove upper tool bushing B using a suitable puller. If the bushing is tight apply heat to the lower end of front head D. Remove locating pin C.

Check all parts for damage. Carefully remove minor blemishes K Fig 24. ( T A-27).

Check the upper tool bushing for excessive wear if the internal diameter at any point exceeds 70 mm, renew the bushing.

Fig 24.

Assembly 1

Insert upper tool bushing B into front head D.

Install thrust ring A and locating pin C.

Install the cylinder, the valve body, the tie rods and the accumulators.

A-27

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A-27

Section A - Attachments Hammer Master 360 Charging Procedure

Charging Procedure 1

Remove protective plug from top of accumulator.

Remove charging screw and replace Usit-ring.

Connect the nitrogen charging kit to the accumulator.

Via the charging device, open the filler plug by 3 turns.

Open the discharge valve on the charging device.

Carefully open the nitrogen gas bottle valve and confirm that the nitrogen flows freely. Shut the gas bottle valve and the discharge valve on the charging device.

Carefully open the gas bottle valve, and watching the gauge, allow the nitrogen to flow until the pressure reading reaches 5 bar above the required setting.

Close the gas bottle valve.

Wait for 5 minutes for the temperature of the gas and the accumulator body to equalise. Usually a slight drop in pressure is noticed on the gauge during this time.

Adjust the pressure in the accumulator by carefully opening and closing the discharge valve on the charging device.

Via the charging device, close the filler plug and tighten to torque setting of 20 Nm (15lb/ft).

Release the pressure from the gas bottle hose by opening the discharge valve on the charging device.

Disconnect the accumulator.

Check the gas-tightness of the filler plug by pouring a small amount of oil around the plug.

Insert the protective plug and tighten to 150 Nm (110lb/ft K Fig 25. ( T A-28)).

A-28

charging

device

from

Fig 25.

the

9813/2050-5

A-28

Section B Body and Framework Service Manual - 3DX / 4DX Backhoe Loader Section 1 - General Information Section 2 - Operator’s Manual Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine

Publication No.

9813/2050-5

Section B - Body and Framework

Notes:

B-0

9813/2050-5

B-0

Section B - Body and Framework Contents Page No. Service Procedures Glazing ..................................................................................................... B-1 Direct Glazing ....................................................................................... B-1 Service Tools Slide Hammer Kit ...................................................................................... B-7 Fitting Procedure .................................................................................. B-7 Rivet Nuts ................................................................................................. B-9 Fitting Procedure ................................................................................ B-10 Body and Framework Welding .................................................................................................... B-11 Cab Seat Removal and Replacement .................................................................... B-13 Cab Mountings Removal and Replacement .................................................................... B-15 Removal, Front Mountings ................................................................. B-15 Removal, Rear Mountings .................................................................. B-16 Replacement ...................................................................................... B-17 Air Conditioning Unit ............................................................................................................... B-19 Operation Overview ................................................................................ B-21 System Operation ............................................................................... B-21 System Controls ................................................................................. B-22 Safety Procedures .................................................................................. B-23 Service Checks ....................................................................................... B-24 Off-Season Operation ........................................................................ B-24 Fault Finding ........................................................................................... B-25 Fault Indications ................................................................................. B-25 System Diagnosis using Test Gauges ................................................ B-27 Test Procedures ...................................................................................... B-37 Leak Testing ....................................................................................... B-37 Tightening Leaking Hoses .................................................................. B-37 Refrigerant Charge Level ................................................................... B-37 Refrigerant .............................................................................................. B-39 R134a Refrigerant .............................................................................. B-39 PAG Type Refrigerant Oil ................................................................... B-39 Refrigerant Charging and Discharging ............................................... B-39 Air Conditioning Condenser Cleaning ................................................................................................. B-45 Removal and Replacement .................................................................... B-46 Removal ............................................................................................. B-47 Replacement ...................................................................................... B-47 Fuel Tank Removal and Replacement .................................................................... B-49 Fuel Level Sender .............................................................................. B-51 Hydraulic Tank Removal and Replacement .................................................................... B-53 Fluid Level Sight Glass ....................................................................... B-55

B-i

Section B - Body and Framework Contents

Contents Page No. Stabiliser Legs Sideshift Machines ................................................................................. B-57 Removal and Replacement ................................................................ B-57 Loader and Excavator Arms Loader Arms ........................................................................................... B-59 Removal ............................................................................................. B-60 Replacement ...................................................................................... B-60 Boom .................................................................................................. B-62 Removal and Replacement ................................................................ B-63 Dipper ..................................................................................................... B-64 Removal and Replacement ................................................................ B-65 Clearances ............................................................................................. B-66 Clearance on Backhoe, Loader and Mainframe ................................. B-66 Excavator Kingpost and carriage ............................................................................. B-67 Removal and Replacement ................................................................ B-67 Kingpost ............................................................................................. B-68 Sideshift Carriage ............................................................................... B-70

B-ii

Section B - Body and Framework

Service Procedures Glazing

!MWARNING

Direct Glazing TB-002_6

The following procedures explain how to correctly remove and install panes of glass that are directly bonded to the cab frame apertures. When carrying out the procedures, relevant safety precautions must be taken.

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.

Always wear safety glasses during both removal and replacement.

BF-1-8_1

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.

Removing the Broken Glass and Old Sealant

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.

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).

!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 park 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.

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.

b Toughened glass - remove as much of the shattered glass as possible prior to cutting out the old sealant.

Glass should not be replaced at temperatures below 5Â°C (41Â°F).

B-1

Laminated glass - leave installed until the old sealant has been cut away, after which it will be possible to lift the broken screen away from its frame housing in one piece.

9813/2050-5

Cut out the old sealant, leaving approximately 1 to 2 mm on the cab frame. There are several tools and techniques for doing this:

B-1

Section B - Body and Framework Service Procedures Glazing a

Pneumatic Knife. K Fig 1. ( T B-2). This provides one of the easiest methods of removing the sealant around laminated glass. The tool, powered by compressed air, should be sourced locally.

Fig 1. Pneumatic Knife i

Press the handle to start the knife blade oscillating.

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

Fig 2. Braided Cutting Wire and Handles

Insert the knife blade into the sealant.

iii Slowly move the knife along the sealant with the blade positioned as close to the glass as possible. Do not allow the knife blade to overheat or the sealant will melt.

iii Using suitable pliers, pull the cutting wire through the sealant to the outer side of the glass.

b Braided Cutting Wire and Handles. K Fig 2. ( T B-2). This method uses a 3-core wire, a wire starter tube and two handles. i

Insert the braided cutting wire B down the centre of the steel tube. If necessary, from the outside, cut out local sealant at the point of the tube to gain access to the wire.

iv Secure the end of the braided cutting wire (found on the outer side of the glass) in the special handle C.

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

Slowly remove the steel tube A.

vi Secure the second end of the braided cutting wire in the special handle D. vii Move the cutting wire backwards and forwards in a sawing motion and at the same time gently push or pull the wire to cut through the old sealant. c

B-2

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Cut-out Knife. K Fig 3. ( T B-3). The cut-out knife can be used as a left handed or right handed tool.

B-2

Section B - Body and Framework Service Procedures Glazing 5

If necessary, trim off the remaining old sealant to leave approximately 1 to 2 mm on the upright face of the cab frame aperture. K Fig 5. ( T B-3).

1-2 mm

Fig 3. Cut-out Knife

Fig 5.

Insert the knife blade into the sealant.

Make sure that the blade of the knife is against the glass A. K Fig 3. ( T B-3).

iii Use the 'pull-handle' to pull the knife along and cut out the old sealant. d Craft Knife. K Fig 4. ( T B-3). The blades A are replaceable. i

Insert the knife blade into the sealant.

Pull the knife along and cut out the old sealant.

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

Preparing the Cab Frame Aperture 1

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

Fig 4. Craft Knife 4

Laminated glass - lift out the broken pane using glass lifters. Toughened glass - remove the cut off sealant and all remaining particles of shattered glass.

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Section B - Body and Framework Service Procedures Glazing 1

Make sure that the new glass correctly fits the frame aperture A. K Fig 6. ( T B-4). a

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

b Install the new glass on the spacer blocks Always use glass lifters C. Check that there is an equal sized gap all round the edge of the glass. 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 7. Glass Stand

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

Small panes of glass will need locating on a 600 x 700 mm x 15 to 19 mm thick plywood board, sourced locally to fit the glass stand. K Fig 8. ( T B-4). It is recommended that an access hole is cut in the board to accommodate the glass lifter, making it easier and safer to handle small panes of glass. The board should be covered with felt or carpet to give an antiscratch surface. Resting the glass on four spacer blocks will ensure clearance of the cartridge nozzle tip during application of the polyurethane sealant.

Fig 6. 2

Fig 8.

After checking for size, remove the new glass and place it on a purpose made glass stand. K Fig 7. ( T B-4).

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

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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.

B-4

Section B - Body and Framework Service Procedures Glazing 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 9. ( T B-5).

Fig 10. 6

Apply the pre-heated adhesive to the glass (do not start in a corner). Keep the nozzle guide A against the edge of the glass and make sure that the adhesive forms a continuous 'pyramid' shape. K Fig 11. ( T B-5)

Fig 9. 5

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

Fig 11. 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

d Fit the pre-cut nozzle. K Fig 10. ( T B-5). e

Install the cartridge in the applicator gun.

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'.

Installing the New Glass

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.

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-3) - step 1.

Install the glass in the frame aperture: a

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Always use the special lifting tools when moving the glass. Use a lifting strap to hold large panes of glass in position. K Fig 12. ( T B-6).

B-5

Section B - Body and Framework Service Procedures Glazing 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

Fig 12. Typical M/c. Installation

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.

b Sit the bottom edge of the glass on the spacer blocks. K Fig 13. ( T B-6)

Note: On completion of the glass replacement procedures, the sealant 'curing' time is 30 minutes. This means that the machine can be driven and used after 30 minutes, but it must not be used during the curing period of 30 minutes. 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 safety and instructional labels so that the new installation conforms with the original cab installation.

Fig 13. 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.

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Section B - Body and Framework

Service Tools Slide Hammer Kit TB-003

Fig 14. Typical M/c. Installation The slide hammer kit is used to remove pivot pins that must be extracted, i.e. cannot be 'knocked through'. The purpose of this description is to explain how the kit and the various components are used to remove the pivot pins. The adaptors 14-A that form part of the kit have a screwed thread at each end. One of the threads will always be M20 size, this is to accommodate the end stops, items 14-B and 14-C. The other end of the adaptor will have varying thread sizes to suit the different size of threads in the pivot pins.

Fitting Procedure 1

B-7

Prepare the pivot pin, for instance, if fitted, remove the pivot pin retaining bolt.

Determine the thread size of the pivot pin and then fit the appropriate adaptor 14-A as shown. Use the spanner flats 14-D to securely fit the adaptor.

Fit an end stop 14-B onto the other end of the adaptor (M20 thread size), make sure that the adaptor threads are fully engaged.

Fit the 'slide bar' 14-E into the end stop. Again make sure that the threads are fully engaged.

Fit the 'slide hammer', item 14-F, onto the slide bar as shown.

Finally, fit another end stop, item 14-C, at the end of the slide bar, as shown. The slide hammer kit is now ready to use.

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Section B - Body and Framework Service Tools Slide Hammer Kit 7

To extract the pivot pin, slide the hammer along the bar until it contacts end stop 14-C. Repeat this step until the pivot pin is released.

To remove the slide hammer kit, reverse steps 2 to 7.

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Section B - Body and Framework Service Tools Rivet Nuts

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 15A is compressed so that a section of its shank forms an 'upset' against the machine body/framework, leaving a durable thread 15-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 15. 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-9) 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-10). 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 Tools Rivet Nuts

Fitting Procedure

(smooth bulge) seating itself against the body/ framework 18-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 16-A.

Note: The thread of the rivet nut must not be stripped, take care when 'upsetting' the rivet nut.

Fig 18. Fig 16. 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 17-B.

Fig 17. 4

Insert the rivet nut (assembled to the tool) into the hole drilled in step 1.

Hold handle 18-C and at the same time draw the mandrel into the installation tool by turning nut 18-D. The rivet nut will contract in length and form an 'upset'

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Section B - Body and Framework

Body and Framework Welding In the event of a weld failure, it is recommended that the affected area may be inspected as per the sample defect sheet prior to any attempt to rectify/repair the weld joint on the site. Ensure that the paint is removed prior to inspection of weld joint K Fig 19. ( T B-12). The services of a professional/weld repair shop of a prominent electrode manufacturer are to be used for corrective repair. The Welding production are currently using Advani Oerlikon CITOFIL ER70S-6 1.2 mm Dia. MS CopperCoated Wire conforming to AWS classification5.18.79 with Tensile Strength of 70 N/sq. mm. For field repair of factory welding the recommended equivalent is Low Hydrogen Basic Coated "Supercito X Plus 7018 "Electrode for Root-Run and 3.15 mm Dia. OVERCORD Electrode conforming to AWS 6013 for filling the Final Run/ Overlays. The effects of current, arc length, and travel speed on covered electrode beads. 1

A - Correct current, arc length and travel speed.

B - Amperage too low .

C - Amperage too high.

D - Too short an arc length.

E - Arc length too long.

F- Travel speed too slow.

G - Travel speed too fast.

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Section B - Body and Framework Body and Framework Welding

Fig 19.

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Section B - Body and Framework

Cab Seat Removal and Replacement Removal 1

Lower the loader to the ground. Engage the park brake, stop the engine and remove the starter key.

Undo the 4 fixing boltsA and lift the seat assembly clear of the machine.

Replacement Replacement is the reverse of removal but note the following: Torque tighten bolts A. Table 2. Torque Settings Nm kgf m

Item A

lbf ft 22.1

A Fig 20.

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Section B - Body and Framework Cab Seat Removal and Replacement

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Section B - Body and Framework

Cab Mountings Removal and Replacement Removal, Front Mountings Important: Do not remove the front mountings A and rear mountings B at the same time. Remove the 2 front mountings OR the 2 rear mountings as required. 1

Remove the covers C and external trim panels D to gain access to the front mountings K Fig 21. ( T B-15).

Undo the nut E and remove the lower mount F from each front mounting. Withdraw the bolt G from each mounting from inside the cab K Fig 21. ( T B-15).

Place a suitable jack between the cab frame and the machine chassis. Raise the cab sufficiently to remove the upper mounts H. Record the positions of the cab mounts to ensure correct replacement K Fig 21. ( T B-15).

Important: Be sure to jack the steel cab frame. DO NOT locate the jack on the composite cab floor. Important: Block the cab using suitable supports. DO NOT work under the cab supported only by a jack or lifting equipment.

H F

E G

D C

Fig 21.

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Section B - Body and Framework Cab Mountings Removal and Replacement

Removal, Rear Mountings Important: Do not remove the front mountings A and rear mounts B at the same time. Remove the 2 front mountings OR the 2 rear mountings as required. 1

Remove the rear wheels to gain access to the rear mountings B. Block the machine using suitable supports. Do not work under a machine supported by its stabilisers under any circumstances.

E B F

D C

Make sure that no-one goes near the machine while you install or remove the mechanical device. 13-2-3-7_3

Undo the nut C and remove the lower mount D and bolt E from each rear mounting K Fig 22. ( T B-16).

Place a suitable jack between the cab frame and the machine chassis. Raise the cab sufficiently to remove the upper mounts F. Record the positions of the cab mounts to ensure correct replacement.

Fig 22.

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Section B - Body and Framework Cab Mountings Removal and Replacement

Replacement Replacement is the reversal of removal but note the following: Although the front and rear cab mount components are similar in appearance they are not the same. Make sure that you fit them in their correct locations. If the mounts are to be renewed make sure you identify the new components correctly. Refer to the relevant parts information. Torque tighten the fixing nuts 21E and 22C.

Item

Table 3. Torque Settings Nm kgf m

lbf ft

205

151

205

151

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Section B - Body and Framework Cab Mountings Removal and Replacement

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Section B - Body and Framework Air Conditioning Unit

Air Conditioning Unit

C B

D070920-02

Fig 23. Item

Description

Item

Description

Compressor

Air conditioning unit

Condensor

Receiver drier

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Section B - Body and Framework Air Conditioning Unit

C E X B

A D070920-03

Fig 24. Item

Description

Compressor

Condensor

Receiver drier

Expansion valve

Evaporator matrix

Charging connector (High pressure)

Charging connector (Low pressure)

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Section B - Body and Framework Air Conditioning Unit Operation Overview

Operation Overview System Operation Refer Component identification K Fig 23. ( T B-19) and circuit diagram K Fig 24. ( T B-20). To maintain optimum operator comfort in warm climates or during seasons of high ambient temperature, the air conditioning system delivers cool, dehumidified air into the cab. Cooling is provided by passing the warm ambient air, together with recirculated air, over an evaporator matrix in the air conditioning unit. The air conditioning system is a closed circuit through which the refrigerant is circulated, its state changing from gas to liquid and back to gas again, as it is forced through the system. The major components of the system are the compressor A, condenser matrix B, receiver drier C, expansion valve D and evaporator matrix E.

The high temperature, high pressure refrigerant is forced by compressor action into the expansion valve D, 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 matrix E by the suction of the compressor. The temperature of refrigerant is now considerably below that of the air being drawn across the evaporator matrix 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 matrix and is drained away via condensate. Cool de-humidified air is emitted through air vents into the cab.

To operate the air conditioning, press switch A to switch the system on. Rotate the knob B to select the desired fan speed of the air conditioning fan. Refer K Fig 25. ( T B-22).

The low temperature, low pressure, high heat content refrigerant gas, is now drawn by suction back to the compressor, where the cycle is completed.

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.

Service connection points X and Y adjacent to the compressor are provided for connecting the pressure gauge manifold, when charging or testing the refrigerant. Connection X high pressure (red) and connection Y low pressure (blue).

The compressor A 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 B. Ambient air is drawn across the condenser by the engine driven cooling fan. 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 C, 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.

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Section B - Body and Framework Air Conditioning Unit Operation Overview

System Controls The air conditioning is controlled by a two position rocker switch A. The switch functions operate when the starter switch is in the ON position. Turn the control knob B clockwise to increase the speed of the air conditioning fan. Turn the control knob B counterclockwise to decrease the speed of the air conditioning fan.

P040540-01

Fig 25.

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Section B - Body and Framework Air Conditioning Unit Safety Procedures

Safety Procedures The air conditioning system includes a pressurised closed circuit containing a non-CFC, environmentally friendly refrigerant, Type R-134a.

When charging or discharging the refrigerant system, no smoking or naked flames should be allowed in the immediate vicinity.

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 refrigerant does not give off a poisonous odour, however, when it comes into contact with a naked flame, a poisonous gas is produced.

When handling refrigerant, rubber gloves and goggles should be worn.

Operators should ensure no refrigerant comes into contact with the skin. Particular care should be taken when connecting or disconnecting charging hoses or pressure switches.

When these components are connected to the system, a short release of refrigerant occurs. This results in a high velocity, very cold gas being emitted from the connection point.

Use caution when working near exposed evaporator fins.

Painful cuts can be inflicted by the edges of the fins. Also, damage to the fins will reduce the efficiency of the system.

Make sure pressure cylinders are not over filled, particularly when recovering refrigerant.

Disconnect battery before doing any work.

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. 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. It is illegal to discharge the refrigerant into the atmosphere but as a precaution in case of accidental leakage, discharging and charging of the vehicle refrigerant system must be conducted in a wellventilated area. Containers of refrigerant should be stored in a cool environment away from direct sunlight.

!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.

!MWARNING PAG type oil is an irritant.It can cause skin irritation. Breathing PAG vapour can cause irritation of the eyes, nose and lungs. Prolonged inhalation can cause drowsiness. BF-1-11

!MWARNING PAG oil vapour is extremely flammable. Do not smoke or eat near PAG contaminated material. Exercise caution when working around hot and moving engine parts. BF-1-12

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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Section B - Body and Framework Air Conditioning Unit Service Checks

Service Checks The air conditioning system needs to be checked regularly to ensure efficient and safe operation. Before commencing any service operations, carry out a basic service check as described below: 1

Start the engine and operate at fast idle speed (1000 RPM).

Switch on the air conditioning and set to maximum cooling.

Note: The cab temperature needs to be above 20°C. At low ambient temperatures it may be necessary to operate the heating system to prevent the air conditioning system switching off. 3

Operate the engine at operating temperature for five to ten minutes.

Close the cab door and windows and allow the internal temperature to stabilise.

Measure the temperature at the evaporator outlets. The temperature should change as the compressor clutch cycles in and out. The outlet temperature with the clutch engaged should be significantly below ambient (4°C to 10°C) rising by 6°C to 8°C when the clutch disengages.

Stop the engine when the tests are complete.

Off-Season Operation During the off-season, the air conditioning system should be operated for at least five minutes every month to circulate the oil in the system to lubricate the fittings and seals. When operating the system, ensure that: 1

Engine idle speed is greater than 1000 RPM.

Ambient temperature is greater than 0°C.

Cab temperature is greater than 20°C.

The engine is at normal operating temperature.

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Section B - Body and Framework Air Conditioning Unit Fault Finding

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

Fault Poor Performance.

Table 4. General Fault Indications Possible Cause

Action

Low system pressure.

Evacuate and recharge system.

Condenser matrix air flow restricted.

Remove debris from around matrix using compressed air or low pressure water.

Air filter blocked.

Remove and replace.

Compressor drive belt slipping.

Check condition of front end accessory drive belt (FEAD) and auto tensioner mechanism.

Warm or slightly cool air emitted from unit.

Expansion valve stuck open or closed.

Renew expansion valve.

Blower operates on fan speed 3 only.

Blower resistor failed.

Renew resistor.

Blower motor failed.

Renew complete blower unit.

Blower does not operate.

Fuse blown.

Replace fuse and retest.

Compressor clutch continually cuts out.

Condenser matrix blockage.

Remove debris from around matrix or renew condenser.

Overcharging of refrigerant system.

Evacuate and recharge system.

Blocked expansion valve or condenser.

Clear blocked component.

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. If the air conditioning does not work use the tables to help identify system faults: K Table 5. No Air Conditioning ( T B-26)

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Section B - Body and Framework Air Conditioning Unit Fault Finding Check

Table 5. No Air Conditioning Action

Are the controls set correctly, i.e. air conditioning selected, YES: Check 2. thermostat switch set to coldest position and blower NO: Reset controls and retest. switched on?

Is the air conditioning (evaporator) blower working?

YES: Check 3. NO:

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

YES: Check 9. NO:

Is the air conditioning fuse(s) blown? For details of the electrical circuit and connections.

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

Renew the compressor clutch and retest.

Does the clutch engage with thermostat switch bypassed? YES: Renew thermostat switch and retest. NO: Are blower switch and wiring OK? Is sight glass indication OK?

Check 11.

YES: Clean filter and, if necessary the evaporator. NO:

B-26

Charge check required by refrigeration engineer or suitably trained person.

YES: Clean condenser and radiator. NO:

11 Is evaporator air flow blocked?

Renew switch or wiring.

YES: Check 10. NO:

10 Is condenser air flow blocked?

Check all electrical connections.

YES: Renew blower unit complete. NO:

Check 7.

Does the compressor clutch engage with pressure switch YES: Replace pressure switch assembly. assembly bypassed? NO:

Check 8.

YES: Check 6. NO:

Check 5.

YES: Renew fuse(s) and retest. NO:

Check 4.

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Call in refrigeration engineer, or suitably trained person.

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Section B - Body and Framework Air Conditioning Unit Fault Finding

System Diagnosis using Test Gauges

LOW SIDE (Blue)

This section gives an overview of the following system conditions: 1

Functioning K Normally System ( T B-27).

K Low R-134a Charge ( T B-29).

K Poor Refrigerant Circulation ( T B-30).

K No Refrigerant Circulation ( T B-31).

K Insufficient Cooling of Condenser Refrigerant Overcharge ( T B-32).

K Air in System ( T B-33).

K Expansion Valve Improperly Mounted Defective (Opening Too Wide) ( T B-34).

K Compressor Malfunction ( T B-35).

K Some Moisture in the System ( T B-36).

Air

Conditioning

HIGH SIDE (Red)

Normal

Normal 2

LOW SIDE: 2.0 bar (2.0 kgf/cm ; 29 lbf/in2) HIGH SIDE: 14.8 bar (15.1 kgf/cm2; 215 lbf/in2)

Normally Functioning Air Conditioning System Gauge Readings: Low Side Gauge - Normal. High Side Gauge - Normal. Other Indications: Sight Glass - Clear. Discharge Air - Cold. The pressures displayed on the manifold gauges at 25 Â°C with the engine at 1500 RPM, the blower on maximum and the thermostat set to maximum, should be as shown (i.e. typically, the high pressure is nominally 6 to 8 times greater than the low pressure). K Fig 26. ( T B-28) 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. Note: The gauge hoses are normally colour coded, `Blue' for low side and `Red' for high side gauges.

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Section B - Body and Framework Air Conditioning Unit Fault Finding

200 250

350

50 100

0 110 00 1

30 40 5 20 0

70 80 90

5 30 3

500 45

0 1 0

D070920-04

Fig 26. Component Key:

Component Key:

High pressure and high temperature gas.

Low pressure and low temperature gas.

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High pressure liquid.

B-28

Section B - Body and Framework Air Conditioning Unit Fault Finding Low R-134a Charge Gauge Readings: Low Side Gauge - Low. High Side Gauge - Low.

LOW SIDE (Blue)

HIGH SIDE (Red)

Low

Low 2

LOW SIDE: 0.76 bar (0.77 kgf/cm ; 11 lbf/in2) HIGH SIDE: 8.3 bar (8.5 kgf/cm2; 121 lbf/in2)

Other symptoms:

350

50 100

0 110 00 1

30 40 5 20

0 1 0

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

200 250

Diagnosis:

0 30

70 80 90

Sight Glass - Bubbles continuously visible.

5 30 3

500 45

incorrect charge. Correction: 1

Leak test system.

Evacuate the air conditioning system.

Repair system leaks.

Charge system with R-134a.

Operate system and check performance.

A268030

Fig 27.

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Section B - Body and Framework Air Conditioning Unit Fault Finding Poor Refrigerant Circulation

LOW SIDE (Blue)

HIGH SIDE (Red)

Zero to negative

Gauge Readings:

Low 2

LOW SIDE: -1.0 bar (-1.1 kgf/cm ; -15 lbf/in2)

Low Side Gauge - Zero to negative.

HIGH SIDE: 5.4 bar (5.5 kgf/cm2; 78 lbf/in2)

High Side Gauge - Low. Other symptoms:

70 80

350 40 0

50 100

0 110 00 1

30 40 5

0 1 0

Diagnosis:

200 250 0

to evaporator unit.

Receiver Drier - Frost on tubes from receiver drier

5 30 3

500 45

Refrigerant flow obstructed by dirt, receiver drier clogged. Correction: 1

Evacuate the air conditioning system.

Replace receiver drier.

Charge system with R-134a.

Operate system and check performance.

A268040

Fig 28.

B-30

9813/2050-5

B-30

Section B - Body and Framework Air Conditioning Unit Fault Finding No Refrigerant Circulation

LOW SIDE (Blue)

HIGH SIDE (Red)

Zero to negative

Gauge Readings:

Low 2

LOW SIDE: -1.0 bar (-1.1 kgf/cm ; -15 lbf/in2)

Low Side Gauge - Zero to negative.

HIGH SIDE: 5.4 bar (5.5 kgf/cm2; 78 lbf/in2)

Other symptoms: 70 80

350

50 100

0 110 00 1

30 40 5 20 0 1 0

Diagnosis:

200 250

and after receiver drier.

0 30

Receiver Drier - Frost or moisture on tubes before

40 0

High Side Gauge - Low.

5 30 3

500 45

Refrigerant flow obstructed by dirt, moisture or gas leakage from expansion valve heat sensing tube. Correction: 1

Evacuate the air conditioning system.

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

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

Replace receiver drier.

Charge system with R-134a.

Operate system and check performance.

B-31

Fig 29.

9813/2050-5

B-31

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

LOW SIDE (Blue)

HIGH SIDE (Red)

High

High 2

LOW SIDE: 3.0 bar (3.0 kgf/cm ; 43 lbf/in2)

Gauge Readings:

HIGH SIDE: 22.1 bar (22.5 kgf/cm2; 320 lbf/in2)

Low Side Gauge - High. High Side Gauge - High.

70 80

350 0 40

50 100

30 40 5

12 0 110 00 1

engine RPM.

200 250 0

Sight Glass - No bubbles visible even at lower

Other symptoms:

5 30 3

500 45

0 1 0

Diagnosis: Refrigerant overcharge, condenser cooling fins clogged with dirt or cooling fans malfunctioning. Correction: 1

Clean condenser cooling fins.

Check cooling fan operation.

Evacuate the air conditioning system.

Charge system with R-134a.

Operate system and check performance. Fig 30.

B-32

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B-32

Section B - Body and Framework Air Conditioning Unit Fault Finding Air in System Gauge Readings: Low Side Gauge - High. High Side Gauge - High.

LOW SIDE (Blue)

HIGH SIDE (Red)

High

High 2

LOW SIDE: 2.8 bar (2.8 kgf/cm ; 40 lbf/in2) HIGH SIDE: 22.1 bar (22.5 kgf/cm2; 320 lbf/in2)

Other symptoms:

350 0 40

50 100

30 40 5

12 0 110 00 1

Pipes - Low pressure pipes are hot to the touch.

200 250 0

operation.

70 80 90

Sight Glass - Bubbles visible during system

5 30 3

500 45

0 1 0

Diagnosis: Air is present in the system, possibly from inadequate evacuation procedure. Correction: 1

Evacuate the air conditioning system.

Check compressor oil for contamination. Check compressor for proper oil amount. Correct if necessary.

Charge system with R-134a.

Operate system and check performance.

B-33

Fig 31.

9813/2050-5

B-33

Section B - Body and Framework Air Conditioning Unit Fault Finding Expansion Valve Improperly Mounted or Defective (Opening Too Wide)

LOW SIDE (Blue)

HIGH SIDE (Red)

High

High 2

LOW SIDE: 3.5 bar (3.5 kgf/cm ; 50 lbf/in2)

Gauge Readings:

HIGH SIDE: 22.1 bar (22.5 kgf/cm2; 320 lbf/in2)

Low Side Gauge - High. High Side Gauge - High.

70 80

350

50 100

0 110 00 1

side pipes.

200 250

Pipes - Large amount of frost or moisture on low

0 30

30 40 5 20 0

Other symptoms:

5 30 3

500 45

0 1 0

Diagnosis: Excessive refrigerant in low side pipes possibly from expansion valve being opened too wide. Correction: 1

Leak test system.

Evacuate the air conditioning system.

Repair system leaks.

Charge system with R-134a.

Operate system and check performance. Fig 32.

B-34

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B-34

Section B - Body and Framework Air Conditioning Unit Fault Finding Compressor Malfunction

Low Side Gauge - High. High Side Gauge - Low.

HIGH SIDE (Red)

High

Low 2

LOW SIDE: 4.9 bar (5.0 kgf/cm ; 71 lbf/in2) HIGH SIDE: 8.3 bar (8.5 kgf/cm2; 121 lbf/in2)

Diagnosis:

Repair or replace compressor.

Charge system with R-134a.

Operate system and check performance.

350

50 100

0 110 00 1

30 40 5 20 0 0 1 0

Evacuate the air conditioning system.

200 250

Correction:

0 30

mechanically broken.

70 80

Internal compressor leak or compressor

Gauge Readings:

LOW SIDE (Blue)

5 30 3

500 45

Fig 33.

B-35

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B-35

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

LOW SIDE (Blue)

HIGH SIDE (Red)

Normal to low

Gauge Readings:

Normal to high 2

Low Side Gauge - Normal, then sometimes drops to below zero.

LOW SIDE: -2.1 bar (-2.1 kgf/cm ; -30 lbf/in2) HIGH SIDE: 14.8 bar (15 kgf/cm2; 214 lbf/in2)

High Side Gauge - Normal, then sometimes goes high. 50 100

0 110 00 1

40 0

350

30 40 5 20 0 1 0

cycle, normal system operation returns when ice

Moisture in system freezes, temporarily stopping

200 250

Diagnosis:

70 80

5 30 3

500 45

melts. Correction: 1

Evacuate the air conditioning system.

Replace receiver drier.

Remove moisture by repeatedly evacuating system.

Charge system with R-134a.

Operate system and check performance.

Fig 34.

B-36

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B-36

Section B - Body and Framework Air Conditioning Unit Test Procedures

Test Procedures Leak Testing

!MWARNING

TB-004

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

valve (the evaporator coil is connected to the expansion valve within the air conditioning unit using rigid pipes). If leakage is detected from a hose connector, either by means of an electronic leak detector or soapy water, tighten the connector up and repeat the leakage test. If leakage is still evident, it will be necessary to discharge the system and renew the connector 'O' ring seal.

Refrigerant Charge Level 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 A.

It is essential that an electronic leak detector is used to locate leaks accurately. However, if a leak detector is not available, an approximate source can be found by applying soap solution to the suspect area.

To test for leaks in the high pressure side of the system i.e. from the compressor output to the expansion valve, run the air conditioning for a few minutes then switch off the engine and test for leakage using an electronic leak detector or soapy water. To test for leakage in the low pressure side of the system, switch off the air conditioning and leave for a few minutes before testing.

Tightening Leaking Hoses D070920-05

!MWARNING

Fig 35.

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.

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. Recharging of the system should be carried out by an air conditioning engineer. Check refrigerant charge level as follows:

4-3-4-1_2

The refrigerant hoses have crimped ferrule end fittings. The hose connectors have an 'O' ring seal which compresses when the connection is tight, creating an air tight seal.

Note: When R-134a refrigerant is used slight bubbling will be seen at the system sight glass. This is normal for this type of refrigerant. If the system is not providing adequate cooling K Fault Finding ( T B-25). 1

Hoses are used to connect the inlets and outlets of the compressor, condenser, receiver drier and expansion

B-37

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Park the machine on firm, level ground. Lower the backhoe and loader to the ground.

B-37

Section B - Body and Framework Air Conditioning Unit Test Procedures 2

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

Check the refrigerant charge level at the receiver drier sight glass A. K Fig 35. ( T B-37).

B-38

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B-38

Section B - Body and Framework Air Conditioning Unit Refrigerant

Refrigerant R134a Refrigerant

Refrigerant Charging and Discharging TB-006

TB-005

Refrigerants are the basic ingredient of all air conditioning systems and are used to transfer the heat energy around the system. Refrigerant type R134a is used in the air conditioning system. It's full chemical name is:

Note: The procedures for refrigerant charging and discharging must only be carried out by qualified service personnel who have received specialist training on the air conditioning system.

!MWARNING

1, 1, 1, 2-Tetraflouroethane (CH2FCF2) R134a is a HFC (HydrFlouroCarbon) and is non-toxic, non-flammable and non-explosive at normal atmospheric temperature and pressure. It can be flammable under certain pressure and air mixtures. Due to environmental concerns, the use of ozone depleting chlorofluorocarbons (CFCs) in the air conditioning systems is being gradually phased out. The R-12 refrigerant used in some systems contains CFCs. Air conditioning systems using R-134a refrigerant are not compatible with systems using R-12 refrigerant. No attempt should be made to charge R-134a systems with R12 refrigerant. Important: Refer to the safety procedures within this section before handling refrigerants. Good installation practice is required to avoid the release of refrigerant into the atmosphere. Refrigerant R134a contains no chlorine and has an Ozone Depleting Potential (ODP) of zero, and a Global Warming Potential (GWP) of 0.1.

Refrigerant Recovery The recovery process clears the system refrigerant prior to servicing or for refrigerant renewal. Note: Do not re-use refrigerant unless you are aware of its purity. Note: The JCB recommended 'Javac' unit only recovers refrigerant as a gas. Other units can recover refrigerant as a liquid and/or gas. Always check manufacturers instructions before using. 1

Ensure that the engine is OFF and the starter key removed.

Connect the manifold to the system as shown, with the blue hose 36-A connected to the system low pressure port. Do Not connect the red hose 36-B. Make sure that both valves are closed.

Connect the yellow hose 36-C to the 'Javac' unit filter 36-D.

Connect the filter 36-D to the 'Javac' unit 36-E.

Connect the 'Javac' unit 36-E to an empty receiver bottle 36-F. Weigh the bottle before and after filling to assess system capacity.

PAG Type Refrigerant Oil TB-007

The system requires a PAG type refrigerant oil to lubricate the compressor. The oil mixes with the refrigerant and is carried around the system. It is important that the recommended grade of refrigerant oil is used. Mineral oil is not suitable for R134a refrigerant systems. Do not mix oil types. The compressor is supplied with an oil charge, but additional oil will be required when the receiver drier is replaced. The oil is added to the compressor through the oil filling plug before the evacuation procedure is started. Only use fresh, unused oil. Oil that has been exposed to the air will have absorbed water.

B-39

Note: Do not fill the receiver bottle to more than 80% by weight.

9813/2050-5

B-39

Section B - Body and Framework Air Conditioning Unit Refrigerant 6

Switch on 'Javac' unit 36-E and open the low pressure manifold valve.

Note: If the high pressure warning light on the `Javac' unit comes on, throttle back the manifold low pressure valve to provide a restriction. 7

The 'Javac' unit 36-E will automatically switch off when a pressure balance exists between the system and the receiver bottle. Switch off 'Javac' at main switch, but leave the system connected. Switch on after 10 minutes, the 'Javac' will restart if residual pressure remains.

Close valves and remove equipment.

Fig 36. Refrigerant Recovery

B-40

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B-40

Section B - Body and Framework Air Conditioning Unit Refrigerant Evacuating (Vacuuming) This procedure follows on from the 'Recovery' process and is necessary to ensure proper refilling of the system with refrigerant. To avoid leakage in the vacuum system itself, Do not use extensions to the yellow hose (use standard 2 metre length). 1

Recover all refrigerant from K Refrigerant Recovery ( T B-39).

the

system.

Close all valves and connect the manifold as shown. Connect the blue hose 37-A to the system low pressure port and the red hose 37-B to the high pressure port.

Connect the yellow hose 37-C to the vacuum pump 37-D.

Fig 37. Evacuating

Note: If the Electronic Vacuum Gauge 37-E is used Vacuum connected as shown. K Electronic Gauge ( T B-42), for further information. 4

Open manifold valves.

Switch on the vacuum pump 37-D until 740mm (29 in) mercury vacuum reads on both gauges.

Note: Achievable vacuum will vary with altitude. Maximum gauge reading will be 25mm (1 in) less for every 305 metres (1000 feet) above sea level. 6

Maintain suction for approximately 30 minutes.

Note: If the vacuum falls rapidly the system is leaking. Check all connections and reseal. If the point of leakage is not obvious, recharge the system and test again. 7

Close valves and remove equipment.

B-41

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B-41

Section B - Body and Framework Air Conditioning Unit Refrigerant Electronic Vacuum Gauge

ATM/BAT

Normal atmospheric pressure reading. Battery condition.

15"/510mbar

381mm (15 in)Hg. Partial vacuum Vacuum system is operating.

29"/980mbar

736mm (29 in)Hg. No vacuum drawn Possible system leakage.

8000

8.0mm (0.31 in)Hg. Partial vacuum - If the reading does not progress the system may have a slow leak.

1000

1.0mm (0.039 in)Hg. Deeper vacuum.

600

0.6mm (0.023 in)Hg. Deep vacuum.

400

0.4mm (0.015 in)Hg. Deep vacuum.

200

0.2mm (0.0078 in)Hg. Deep vacuum.

0.025mm (0.00098 in)Hg. Pump Test. Maximum sustainable vacuum.

A396790

Fig 38. The CPS VG100 vacuum gauge is an electronic type using LED's to indicate various states of vacuum. It is used in place of or to supplement the gauge on the vacuum pump. Before connecting into the system switch on to check that the first LED lights to show that the battery is in good condition. Note: The indicator lights show pressure in inches of mercury (Hg) and vacuum in microns (0.001mm Hg).

B-42

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B-42

Section B - Body and Framework Air Conditioning Unit Refrigerant Relubricating Pre-lubrication is essential after recovering system refrigerant, vacuuming and component flushing. The system should be evacuated to a vacuum of 740mm (29 in) of mercury before re-lubricating. 1

Ensure that the engine is OFF and the starter key is removed.

Close all valves and connect the manifold as shown, with the blue hose 39-A connected to the oil injector 39-E and the red hose 39-B to the system high pressure port.

Connect the yellow hose 39-C to the vacuum pump 39-D.

Connect the other end of the oil injector 39-E to the system low pressure point 39-F.

Switch on the vacuum pump 39-D and open the high pressure side valve.

Unscrew the oil injector cap and add the specified quantity of refrigerant oil.

When 740mm (29 in) mercury shows on the vacuum gauge, open the oil injector valve to allow the oil into the system.

If more oil is needed repeat the above procedure. The quantity of oil should be the same as that taken out during the 'Recovery' procedure.

F Fig 39. Relubricating

Note: Use only PAG oil in R-134a systems.

B-43

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B-43

Section B - Body and Framework Air Conditioning Unit Refrigerant Charging This procedure is industry recommended practice for refilling air conditioning systems with refrigerant. Evacuate the system beforehand to 740mm (29 in) of mercury. 1

Close all valves and connect the manifold as shown. Connect the blue hose 40-A to system low pressure and the red hose 40-B to system high pressure. Connect the yellow hose 40-C to the refrigerant cylinder 40-D.

Invert single valve cylinder on the scales 40-E and zero the scale reading

Note: Some refrigerant cylinders have separate valves for gas and liquid. Be sure to connect to the liquid port when following the above procedure. Note: Refrigerant can be used either in gas or liquid form. If recharging with gas follow the manufacturers instructions and recharge only via the low pressure port. Do not use liquid refrigerant at the low pressure port. 3

Fig 40. Charging

Slowly open the high pressure valve and allow the vacuum to draw-in refrigerant to the specified weight for the system. Refer to Technical Data. Add refrigerant until the scales 40-E indicate the specified weight for the system or the weight obtained when the system refrigerant was previously recovered.

Note: To speed up the process a thermostatically controlled thermal blanket 40-F can be used around the replenishing cylinder. 4

Close all valves and remove the equipment.

B-44

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B-44

Section B - Body and Framework

Air Conditioning Condenser Cleaning It is likely that over a period of time, because of the machine's working environment, the airflow around the condenser matrix 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. High pressure cut-out can also be caused by an internal blockage of the condenser matrix. 1

Remove the condenser without disconnecting the air and conditioning hoses. K Removal Replacement ( T B-46)

!MWARNING Compressed air is dangerous. Wear suitable eye protection and gloves. Never point a compressed air jet at yourself or others. 0147_1

Important: To avoid damaging the condenser, compressed air used for cleaning purposes must not exceed 2 bar (30 lbf/in2). 2

With the condenser fully supported, use compressed air or low pressure water to backflow through the matrix fins. Take care not to damage the condenser fins or tubes. Damaged fins must be straightened out to ensure a good airflow through the matrix.

B-45

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B-45

Section B - Body and Framework Air Conditioning Condenser Removal and Replacement

Removal and Replacement

F A

D070920-01

Fig 41. The condenser matrix is mounted onto the cooling pack in the engine compartment behind the front grille. If the condenser is being removed only to gain access to the cooling pack, this can be done without disconnecting the air conditioning hoses i.e. with the system fully charged.

Removal of the condenser matrix will require the assistance of a refrigeration engineer or suitably trained person since the refrigerant must be discharged from the system.

Note: Before disconnecting air conditioning system hoses, discharge the system. K Refrigerant Charging and Discharging ( T B1-27).

B-46

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B-46

Section B - Body and Framework Air Conditioning Condenser Removal and Replacement

Removal

â&#x20AC;&#x201C; Torque tighten the securing bolts. K Table 6. Torque Settings ( T B-47)

Park the machine and make it safe. Obey the General Safety procedures. Refer to Section 2 - General Procedures.

â&#x20AC;&#x201C; After replacement recharge the K Refrigerant Charging Discharging ( T B1-27).

Lift the engine cover and remove the grille.

Remove the front grille housing.

system. and

â&#x20AC;&#x201C; Run the air conditioning and check the hose connections for leaks. In the cab. Set the air conditioning to maximum cooling and check that cooled air is emitted from the vents.

Item A

Table 6. Torque Settings Nm Kgf m 18

8.2

lbf ft 59.7

4-3-4-1_2

Make sure that the air conditioning system is fully discharged. K Refrigerant Charging and Discharging ( T B1-27). Disconnect the air conditioning hoses at the pipe stubs B and F on the condenser. Label the hoses before disconnecting to ensure correct replacement. Plug the hose ends to prevent ingress of dirt and loss of fluid.

Note: To avoid damaging the condenser when removing or installing the hoses, it is essential that the hexagon flats on the pipe stubs B and F must be held with a spanner whilst loosening or tightening the hose nuts. When removing components or hoses, retain any lubricant within the component/hose and replenish the system with the same amount of clean lubricant (PAG Oil). 5

Remove screws A (8 off in total), and carefully lift the condenser matrix G from the machine.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

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B-47

Section B - Body and Framework Air Conditioning Condenser Removal and Replacement

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B-48

Section B - Body and Framework Fuel Tank Removal and Replacement

Fuel Tank Removal and Replacement

!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

Renew the O-ring on the drain plug A, and apply JCB Thread locker and Sealer to the threads before fitting. Torque tighten the plug. Apply JCB High Strength Thread locker to the threads of mounting bolts H before fitting. Torque tighten the bolts. Refill the tank with clean fuel. Make sure all connections are tight and check for leaks. On completion, prime the fuel system, see Section 3, Routine Maintenance.

Removal 1

Disconnect the battery.

Working underneath the RH side of the machine, carefully remove the drain plug A and drain the fuel tank contents into a suitable clean container. When empty disconnect suction hose B K Fig 42. ( T B-50).

Remove the plastic trim C below the front RH corner of the cab to gain access to the top of the fuel level sender D. Uncouple the electrical harness from connector E and disconnect the fuel return pipe from pipe stub F K Fig 42. ( T B-50).

Remove bolts G securing the rear fender extension (if fitted).

Support the fuel tank with suitable lifting equipment, then unscrew mounting bolts H and carefully lift the tank away from the machine.

Replacement Replacement is a reversal of the removal sequence, but note the following: If a new fuel tank is being fitted, remove the fuel level sender D from the old tank and fit to the new tank. .

B-49

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B-49

Section B - Body and Framework Fuel Tank Removal and Replacement

A B

Fig 42.

Item

Table 7. Torque Settings Nm lbf ft

85 - 100

63 - 74

8.7 - 10.2

8.5

B-50

kgf m

9813/2050-5

B-50

Section B - Body and Framework Fuel Tank Removal and Replacement

Fuel Level Sender

Removal 1

Note that in order to lift out the fuel level sender the tank must first be lowered from the machine, see Fuel Tank - Removal K Fig 43. ( T B-51).

Undo bolts K and carefully lift the fuel level sender out of the tank aperture.

Replacement Replacement is a reversal of the removal sequence, but note the following: Inspect the gasket L to make sure it is clean and in good condition. If in doubt, renew the gasket. When refitting the fuel level sender, make sure the float arm M is orientated towards the front of the machine K Fig 43. ( T B-51).

Apply JCB Thread locker and Sealer to the threads of bolts K. Torque tighten the bolts.

Fig 43.

Item K

B-51

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Table 8. Torque Settings Nm lbf ft 7

kgf m 0.7

B-51

Section B - Body and Framework Fuel Tank Removal and Replacement

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B-52

Section B - Body and Framework Hydraulic Tank Removal and Replacement

Hydraulic Tank Removal and Replacement

!MWARNING

If the filter cover plate H is removed for any reason, use a new o-ring and sealing washers.

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

Use a new O-ring on the drain plug A, and tighten. Torque tighten the plug. Apply JCB High Strength Thread locker to the threads of mounting bolts F before fitting. Torque tighten the bolts. When refitting the suction hose D make sure it is correctly fitted and phased on the tank spigot. There must be at least 12 mm (0.5 in) clearance between the hose and the gearbox casing. Phase the two clips C 180o apart.

Removal 1

Operate the control levers back and forth several times to vent residual hydraulic pressure. Remove the hydraulic tank filler cap. Working underneath the LH side of the machine, carefully remove the drain plug A and drain the hydraulic tank contents into a suitable clean container K Fig 44. ( T B-54). At the rear of the tank, disconnect and plug the hydraulic return hoses B K Fig 44. ( T B-54).

Refill the tank with clean hydraulic fluid, see Section 3, Routine Maintenance. On completion, operate the machine to bring the hydraulic fluid up to normal working temperature (50 oC, 122 oF). Stop the engine and check for leaks.

Item

Table 9. Torque Settings Am lbw ft

85 - 100

62 - 74

8.6 - 10.2

0.5

8.5

kegs m

Note: Some machine variants may have different return hose configurations at the tank to those illustrated. Be sure to disconnect all hoses. 4

Loosen the two clips C and pull off the suction hose D.

Support the hydraulic tank with suitable lifting equipment, then unscrew mounting bolts F and carefully lift the tank away from the machine.

Replacement Replacement is a reversal of the removal sequence, but note the following: Inspect the fluid level sight glass G to make sure it is clean and in good condition. If in doubt, renew the sight glass. K Fluid Level Sight Glass ( T B-55).

B-53

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B-53

Section B - Body and Framework Hydraulic Tank Removal and Replacement

E F

G F

F F

Fig 44.

B-54

9813/2050-5

B-54

Section B - Body and Framework Hydraulic Tank Removal and Replacement

Fluid Level Sight Glass

Replacement

Removal

Replacement is a reversal of the removal sequence, but note the following:

Before removing the sight glass, the tank must first be drained until the fluid level is below the tank aperture, see Hydraulic Tank - Removal.

Carefully unscrew the sight glass G from the tank aperture K Fig 45. ( T B-55).

Replacement

Make sure the filter cover plate H and hydraulic tank surface is clean K Fig 46. ( T B-55). Use new sealing washers K and gasket L. Apply JCB Thread seal to the threads of screws J before fitting. Torque tighten the screws.

Replacement is a reversal of the removal sequence, but note the following:

J K

Use a new O-ring on the sight glass G, and apply Thread sealent on the threads before fitting. Torque tighten the sight glass.

H L

Fig 45.

Item G

Table 10. Torque Settings (From 1855501 to 1899999) Nm lbf ft 9 - 10

6.6 - 7.3

C032500-2

Fig 46.

kgf m 0.9 - 1.0 Item

Filter Cover Plate

Table 11. Torque Settings Nm lbf ft 21

15.4

kgf m 2.1

Removal 1

Remove the screws J and filter cover plate H.

Remove the sealing washers K and gasket L and discard them K Fig 46. ( T B-55).

Note: If the screws have plain washers, these should be replaced with sealing washers K.

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B-55

Section B - Body and Framework Hydraulic Tank Removal and Replacement

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B-56

Section B - Body and Framework

Stabiliser Legs Sideshift Machines Removal and Replacement Removal 1

Park the machine on firm level ground. Engage the parking brake and set the transmission to neutral.

Lower the loader shovel to the ground.

Make sure that the backhoe assembly is set central to the mainframe as shown. If necessary 'side shift' the backhoe into a central position.

Remove the stabiliser foot and ram, refer to Section E Hydraulic Rams, Removal and Replacement Stabiliser Ram.

Remove the inner leg: a

Locate a suitable jack underneath the inner leg.

b Use the jack to lift the inner leg until the top wear pads A protrude from the top of the outer leg section K Fig 47. ( T B-58). c

Remove the wear pads and attach suitable lifting gear through the wear pad locating holes.

d Use suitable lifting equipment, lift the inner leg clear. Replacement Replacement is a reversal of the removal sequence. Select suitable size upper pads A to achieve a maximum permissible float of 1mm (0.039 in.) Make sure that the bottom pads C are held in position before guiding the inner leg into position. If the lower pads are not secured then the inner leg could dislodge the pads during assembly. When the inner leg is in position adjust the bottom pads, refer to.

B-57

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B-57

Section B - Body and Framework Stabiliser Legs Sideshift Machines

Fig 47.

B-58

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B-58

Section B - Body and Framework Loader and Excavator Arms Loader Arms

Loader and Excavator Arms Loader Arms

Fig 48.

B-59

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B-59

Section B - Body and Framework Loader and Excavator Arms Loader Arms

Removal

Park the machine on firm level ground. Engage the parking brake and set the transmission to neutral.

Note: To gain access to bolts D and F and their retaining nuts, remove Silencer. To gain access to bolts E and G and their retaining nuts, remove the Air Cleaner.

Remove loader end attachment (such as a shovel) if fitted. If the attachment is hydraulically operated, disconnect attachment hoses and plug/cap immediately. Vent residual hydraulic pressure prior to removing hoses by operating the control levers with the engine switched off.

Remove pivot pin retaining bolts D, E, F and G.

Sling the loader arms as shown at Y. Make sure that the sling is wrapped around the loader arms only and not the level links.

Remove nut and bolt (shown as Clip H) Remove retaining ring and shim K.

!MWARNING Do not work under raised loader arms unless they are adequately supported by stands and/or slings. BF-3-1

!MWARNING Road Wheel Alignment At the start of each working period, and at least once a day, or if having difficulty in steering, check and, if necessary, re-align the road wheels.

!MWARNING The loader arm interlevers are potentially dangerous, when pivoting about their centre they form a 'scissor' point with the loader arm. Make sure the interlevers are securely blocked when working in the loader arm area. BF-2-1

Secure the inter lever linkage as shown at Z, otherwise with level link pivot pin L removed, the inter lever linkage could pivot about its centre and cause injury and/or damage.

Use extractor tool and remove pivot pin L.

Repeat steps 11 to 13 for the opposite level link pivot pin.

Switch off the engine and vent residual hydraulic pressure from the loader end by operating the loader controls back and forth several times.

Remove nut and bolt T and retaining ring R and shims.

Use extractor tool and remove pivot pin U.

Remove the lift ram pivot pins A.

Repeat steps 15 and 16 for the opposite loader arm pivot pin.

When all four pivot pins have been removed, carefully reverse the machine clear of the loader arms

2-1-1-10

Raise the loader arms to give access to the lift ram pivot pins A.

Sling the loader arms as shown at X. Make sure that the slings are taut and therefore holding the weight of the loader arms.

Note: Care must be taken when removing the lift ram pivot pin, once the pin is removed the ram will drop. Either hold the ram using a sling or have a second person hold the ram before removing the pin.

Replacement 7

Lower the loader arms to the ground using the slings, it may be necessary to retract the lift rams to enable the loader arms to rest fully on the ground. Make sure the lift rams do not foul when retracted. Make sure residual hydraulic pressure has been vented. Disconnect the shovel ram and auxiliary (if fitted) hoses, shown at B. Plug and cap the hoses immediately.

B-60

Replacement is a reversal of the removal sequence but note the following. 1

Fit pivot pins with the extraction hole on the outside of the machine.

Apply grease to all mainframe bores.

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Section B - Body and Framework Loader and Excavator Arms Loader Arms 3

Apply rust inhibiting oil to all pivot pins before assembly in to rams and mainframe.

All clip ring installations to have a maximum end float of to mm (0.078 in).

Fit new liner bearings in the loader arms and/or the level link using a shouldered mandrel as shown.

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Section B - Body and Framework Loader and Excavator Arms Loader Arms

Boom

G E

B L

J C

Fig 49.

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B-62

Section B - Body and Framework Loader and Excavator Arms Loader Arms

Removal and Replacement

Remove lock nut and bolt, spacers J (one fitted each side) and pivot pin L. Mark the spacers so that they can be replaced in the same position.

Hoist the boom clear of the king post assembly.

K Fig 49. ( T B-62) Removal The procedures describe the removal of the boom with the boom and dipper rams still installed. If required, these items can be removed separately before removing the boom, refer to the appropriate removal and replacement procedure. 1

Remove the backhoe bucket and place the backhoe in the position shown at A.

Lower the stabilisers.

Stop the engine and disconnect the battery (to prevent the engine being started).

Operate the backhoe control levers back and forth several times to release pressure trapped in the hydraulic hoses.

Replacement Replacement is generally a reversal of the installation procedure. The boom pivot pin G must be retained using two M12 thin nuts. Fit the first thin nut with zero torque, fit the second thin nut and torque to 98 Nm (72 lbf ft).

When fitting the boom to the king post assembly, make sure that spacers J are refitted in their original positions. Replace all pivot pin seals as required.

INT-3-1-11_2

Disconnect the hydraulic hoses from the bulkhead plate B. Always label hydraulic hoses before disconnecting them, this will ensure that they are correctly reconnected. Plug and cap all hose open ends to prevent ingress of dirt and loss of hydraulic fluid.

Remove the dipper, see Dipper - Removal and Replacement.

Wrap a sling around the boom as shown at D. Make sure the weight of the boom is held by the sling before removing pivot pins etc.

Place a suitable support underneath the boom ram C.

Remove two thin nuts E, bolt F and pivot pin G.

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Section B - Body and Framework Loader and Excavator Arms Dipper

Dipper

Fig 50.

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B-64

Section B - Body and Framework Loader and Excavator Arms Dipper

!MWARNING

Removal and Replacement Removal The procedures describe the removal of the dipper with the extrading (if fitted) and the bucket ram still installed. If required, these items can be removed separately before removing the dipper, refer to the appropriate removal and replacement procedure. 1

Remove the backhoe bucket and place the backhoe in the position shown at A K Fig 50. ( T B-64).

Replacement 2

Lower the stabilizers.

Stop the engine and disconnect the battery (to prevent the engine being started).

Operate the backhoe control levers back and forth several times to release pressure trapped in the hydraulic hoses.

Replacement is generally a reversal of the installation procedure. The boom to dipper pivot pin K must be retained using two M12 thin nuts. Fit the first thin nut with zero torque, fit the second thin nut and torque to 98Nm (72 lbf ft). When fitting the dipper to the boom, make sure that shim, item L is installed as shown.

Replace all pivot pin seals as required.

INT-3-1-11_2

Disconnect the hydraulic hoses, as shown at B. Always label hydraulic hoses before disconnecting them, This will ensure that they are correctly reconnected. Plug and cap all hose open ends to prevent ingress of dirt and loss of hydraulic fluid.

Place a suitable support underneath the dipper ram as shown at C.

Wrap a sling around the dipper as shown at D. Make sure the weight of the dipper is held by the sling before removing pivot pins etc.

Remove nut E, bolt F and pivot pin G.

Remove two thin nuts H, bolt J and pivot pin K.

Note: It is important to use two thin nuts, this arrangement allows the pivot pin retaining bolt to be secured without inducing a lateral tension. 10

Hoist the dipper clear of the boom.

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Section B - Body and Framework Loader and Excavator Arms Clearances

Clearances

Clearance on Backhoe, Loader and Mainframe 1

Table 12. Leg and foot maintaining gap (spacer fitment on top side

Shimming gap at boom mounting pin and spacer.

3 mm max./ 1.5mm min.

Clearance between retaining nut and pivot boss at boom and dipper pivot pin retention.

1 mm max.

Shimming gap between tipping link and tipping lever

2 mm max.

Shimming boom and dipper mounting fitment gap.

1.5 mm max.

Shimming loader arm assembling mounting gap.

2.0 mm max.

Hydra clamp gap between piston housing and king post.

2 - 4 mm

Tightening torque of side cutters and bucket teeth

70 kg-mtrs

Gap between inner and outer stabiliser legs(when leg fully etracted)

Specified maximum gap (X1+X2)

5.65 mm

Specified maximum gap (X1+X2)

2.45 mm

Specified maximum gap (Y1+Y2)

3.1 mm

Specified maximum gap (Y1+Y2)

0.4 mm

1.0 mm.

Gap between inner and outer stabiliser legs(when leg fully extemded) e

Specified maximum gap (X1+X2)

4.46 mm

Specified maximum gap (X1+X2)

1.26 mm

Specified maximum gap (Y1+Y2)

3.1 mm

Specified maximum gap (Y1+Y2)

0.4 mm

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Section B - Body and Framework Excavator Kingpost and carriage

Excavator Kingpost and carriage Removal and Replacement Before removing the king post/carriage, slew the kingpost to dead centre and remove the boom and dipper, see Boom and Dipper - Removal and Replacement.

Fig 51.

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Section B - Body and Framework Excavator Kingpost and carriage

Kingpost Removal 1

Carefully lift the king post away from the rear frame. Take care to retrieve the thrust washers N. Label the thrust washers to ensure they are returned to their original positions on assembly.

Inspection

Remove bolt J, washer K, and spacer L, then withdraw the king post bottom pivot pin M.

K Fig 51. ( T B-67) Make sure that the slew lock pin A is in its stowage position (i.e. not fitted in the `slew lock' position.

!MWARNING

Working from the bottom up, disconnect the backhoe hydraulic hoses from the king post bulkhead plate. Label the hoses before disconnecting to ensure correct replacement. Plug and cap all open hydraulic connections to prevent loss of fluid and ingress of dirt. Remove thin lock nuts B (2-off per pivot pin) and pivot pin retaining bolts C (2-off), then using a suitable drift knock out the slew ram (eye end) pivot pins D (2-off). Note that there may be shims fitted under the circlip. Take care to retrieve any shims and keep them together with their respective pivot pin.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Attach suitable lifting straps to the king post casting E as shown, and support its weight with a suitable hoist. The weight of the king post casting is approximately 130 kg (287 lbs).

Disconnect the boom lock cable, then remove the boom lock, see Section D, Boom Lock Cable Removal and Replacement.

With the king post securely supported on the hoist, remove thin lock nuts F (2-off) and retaining bolt G, then withdraw the king post top pivot pin H.

B-68

Inspect the nickel bronze liner bearings P, Q and R for signs of damage, wear, scores or nicks etc. Ensure that grease holes in the bearings align with the appropriate holes in the casting. Note: The liner bearings need only be removed if they are damaged and are required to be renewed. Use a suitable close fitting shouldered mandrel (manufactured locally) to facilitate removal of the bearings if required. To ensure the mandrel is manufactured to the correct size, the bearing dimensions are shown on the illustration. Note that the dimensions are NOMINAL figures only and should not be used to manufacture bearings. Note also that bearing P could be one of two different sizes, see the illustration.

Replacement Replacement is generally a reversal of the removal sequence, but note the following: To assist with the identification of 15ft 6in and 17ft centreleft king posts the number 6 is stamped on the king post to identify 60 mm diameter bores. If fitting new liner bearings, assemble with a close fitting shouldered mandrel, see Inspection. If necessary, use oil or suitable lubricant to facilitate pressing-in bearings - to minimise scoring of mating face. Bearings Q and R have `lead-in' diameters (noticeable with a slight step), always install the smaller diameter first into the pivot bore. Make sure that the liner bearings Q are fully engaged in the boom pivot bores. There must be a recess of 5mm (3/16 inch) to allow for installation of the seals S. Make sure that the liner bearings R are fully engaged in the king post pivot bores. There must be a recess of 6mm (1/ 4 inch) to allow for installation of the seals T. Seals S and T are lip seals, on re assembly make sure that the seal lips face outward (shown in insets on the king post pivot). When assembling, check for and remove any burrs and sharp edges on the pivot bores, liner bearings and pivot

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Section B - Body and Framework Excavator Kingpost and carriage pins to minimise assembly damage. Make sure that all pivot bores and pivot pins are clean and smeared with greased. When fully assembled, apply grease at each grease nipple BEFORE operating the machine. Note that thrust washers N come in different sizes to allow for variations of castings. Make sure that thin lock nuts, items B and F are `just' free when locked into position. Before fitting bolt J, clean the threads and then apply JCB Thread locker and Sealer. Torque tighten the bolt. If the slew ram trunnion plate bolts X have been removed for any reason, make sure they are re tightened to the correct torque value. Check the operation of the boom lock. If a new king post casting has been fitted, the boom lock cable and boom stop will need to be adjusted, see Section D, Boom Lock Cable - Removal and Replacement.

Item J X

Table 13. Torque Settings Nm lbf ft 98

kgf m

565

(1)

417

57.5

510

(2)

376

(1) Un-plated Fasteners (2) Plated Fasteners

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Section B - Body and Framework Excavator Kingpost and carriage

Sideshift Carriage

ensure they are refitted in their original positions on assembly.

The following procedure assumes that the king post has already been removed. Note however that it is possible to remove the side shift carriage with the king post still fitted, providing all the necessary hoses are first disconnected at the king post bulkhead plate.

Carefully manoeuvre the carriage off the clamp bolts E and lift the carriage away from the rear frame.

Remove the clamp bolts E and clamp plates F from the rear frame rail.

Removal 1

Powered side shift only: Disconnect the chains from the carriage. Tie the chains out of the way, see Service Procedures, Powered Side shift - Chain Adjustment.

Powered side shift only: These machines also have wear pads (not shown) in addition to the clamp plates.

Inspection

Remove the slew rams, see Section E, Hydraulic Rams - Removal and Replacement.

Inspect the nickel bronze liner bearings X for signs of damage, wear, scores or nicks etc. Ensure that grease holes in the bearings align with the appropriate holes in the casting.

Note: If required, the side shift carriage can be removed with the slew rams still fitted, providing the hoses to the slew rams are disconnected.

Note: The liner bearings need only be removed if they are damaged and are required to be renewed.

K Fig 52. ( T B-71) Disconnect and remove all the feed hoses to the hydra clamp units A. Plug and cap all open ports to prevent loss of fluid and ingress of dirt. Label each hose before disconnecting to ensure correct replacement.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device.

Powered side shift only: Inspect the wear pads to ensure they are in good condition. If in doubt, renew the wear pads, see Service Procedures, Powered Side shift Wear Pad Renewal.

Replacement Replacement is a reversal of the reversal sequence, but note the following: If fitting new liner bearings X, assemble with a close fitting shouldered mandrel, for more details, see King post Replacement. On completion, adjust the clamp nuts D to set the correct hydra clamp clearance Y, see Service Procedures, Side shift - Hydra clamp Clearance Setting. Powered side shift only: Reconnect and adjust the chains, see Service Procedures, Powered Side shift Chain Adjustment. Apply grease at each wear pad grease nipple BEFORE operating the machine.

BF-4-1_1

Attach suitable lifting straps to the carriage casting B and support its weight with a suitable hoist.

With the carriage securely supported on the hoist, bend back the lock washer tabs C, unscrew clamp nuts D and carefully remove each hydra clamp unit in turn. Label the hydra clamp units before removing, to

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Section B - Body and Framework Excavator Kingpost and carriage

D070840-11

Fig 52.

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Section B - Body and Framework Excavator Kingpost and carriage

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Section C Electrics Service Manual - 3DX / 4DX Backhoe Loader Section 1 - General Information Section 2 - Operator’s Manual Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine

Publication No.

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Section C - Electrics

Notes:

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C-0

Section C - Electrics Contents Page No. Service Procedure Using a Multimeter .................................................................................... C-1 Measuring DC Voltage ......................................................................... C-2 Measuring Resistance .......................................................................... C-2 Measuring Continuity ............................................................................ C-3 Measuring Frequency ........................................................................... C-3 Testing a Diode or a Diode Wire ........................................................... C-4 Battery ...................................................................................................... C-5 Maintenance ......................................................................................... C-5 Testing .................................................................................................. C-5 Specific Gravity Testing ........................................................................ C-7 Alternator .................................................................................................. C-8 General Description .............................................................................. C-8 Service Precautions ............................................................................. C-8 Charging Circuit Test ............................................................................ C-8 Alternator Charging Test ....................................................................... C-9 Starter Motor ........................................................................................... C-11 Starting Circuit Test ............................................................................ C-11 Circuit Schematics Electrical Circuit - 3DX ............................................................................ C-13 From Serial Number ........................................................................... C-13 From Serial Number ........................................................................... C-20 Electrical Circuit - 3DX Xtra, 3DX Super and 4DX ................................. C-22 From Serial Number ........................................................................... C-22 Harness Data - 3DX ............................................................................... C-30 From Serial Number ........................................................................... C-30 Harness Data - 3DX Xtra, 3DX Super and 4DX ..................................... C-37 From Serial Number ........................................................................... C-37 Fuses ............................................................................................................... C-45 Fuses ...................................................................................................... C-46 Fuses (3DX Standard without Livelink) .............................................. C-46 Fuses (3DX Xtra, Super and 4DX with Livelink) ................................. C-47 Relays .................................................................................................... C-48 Relays (3DX Standard) ....................................................................... C-48 Relays (3DX Xtra, Super and 4DX with Livelink, Servo and Engine Auto Stop) ................................................................................................... C-48 Livelink Removal and Replacement .................................................................... C-49 Removal ............................................................................................. C-49 Replacement ...................................................................................... C-49 VIN Flashing ........................................................................................... C-50 Diagnostics Process ............................................................................... C-51

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Section C - Electrics Contents

C-ii

Page No.

C-ii

Section C - Electrics

Service Procedure 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

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Section C - Electrics Service Procedure 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.

C-2

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

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Section C - Electrics Service Procedure 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 Procedure 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 Procedure Battery

Battery TC-001_5

!MWARNING

Maintenance To ensure that the battery provides optimum performance the following steps should be observed: 1

Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion.

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

Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear personal protective equipment (PPE). Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first. Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up. When reconnecting, fit the positive (+) lead first. 5-3-4-12_2

Testing This test is to determine the electrical condition of the battery and to give an indication of the remaining useful 'life'. Before testing ensure that the battery is at least 75% charged (SG of 1.23 to 1.25 for ambient temperature up to 27°C). Ensure that the battery is completely disconnected from the vehicle. Connect up the battery tester as follows:

C-5

Set the CHECK/LOAD switch 4-A to OFF.

Set rocker switch 4-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.

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Section C - Electrics Service Procedure Battery 4

Set the CHECK/LOAD switch 4-A to CHECK to read the battery no-load voltage which should be at least 12.4 volts.

Set the CHECK/LOAD switch 4-A to LOAD and hold down for 5-10 seconds until the meter reading stabilises. The reading should be at least 9 volts.

Note: Do not hold the switch in the LOAD position for more than 10 seconds. 6

K Table 1. Fault Diagnosis ( T C-6), if the foregoing tests are unsatisfactory.

Battery Tester Readings 1

Fig 4. Battery Tester

Table 1. Fault Diagnosis Remedy

CHECK: 0 - 12.6 Volts

Renew battery

LOAD: less than 6 Volts 2

CHECK: 6 - 12.4 Volts

Recharge and re-test. If tests still unsatisfactory renew battery.

LOAD: less than 9 Volts and falls steadily but remains in yellow zone. 3

CHECK: less than 10 Volts

Indicates battery has been over-discharged and unlikely to recover. Renew battery.

LOAD: less than 3 Volts 4

CHECK: more than 11 Volts

Charge battery which will probably recover.

LOAD: 6 - 10 Volts steady

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Section C - Electrics Service Procedure 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 Procedure Alternator

Alternator TC-006_2

General Description

Charging Circuit Test

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

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-8). 4

If the 'No charge' warning light remains ON, K Check 2 ( T C-9).

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.

C-8

Start the engine; all warning lights should extinguish rapidly.

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

If the oil pressure warning remains on stop engine Immediately and investigate the engine lubrication system.

Check 1 With start switch 'ON' try the heater motor and screen wiper. If they operate normally, check the warning light bulb/LED is not defective. Simultaneous failure of all items indicates a fault at the start switch. Check for cable disconnection before condemning the switch itself. If the 'No charge' warning bulb/LED is in good order, withdraw the triple plug from the back of the alternator. Make a temporary connection between the SMALL terminal in the plug and earth as shown below. If the 'No charge' warning bulb/LED still fails to light, check the cable for continuity. If the bulb/LED now lights, check the alternator for a defective regulator. K Alternator Charging Test ( T C-9).

9813/2050-5

C-8

Section C - Electrics Service Procedure Alternator

Alternator Charging Test

Fig 5.

Check 2 Note: The following checks should be made using an analogue (moving pointer) type meter. 1

Stop the engine and turn the starter switch to OFF.

Withdraw the alternator plug and connect the test meter between the large terminals and 'earth'. With the meter set to measure 12V DC, the meter should show battery voltage. If the reading is zero, check the cables for continuity, particularly at the starter terminals.

Fig 7. 1

Ensure that all battery and alternator connections are in place, secure and making good metal - to - metal contact, especially the 'earth' connections to chassis and engine.

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 stop 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 6. If the voltage is correct, check the alternator. K Alternator Charging Test ( T C-9).

C-9

9813/2050-5

C-9

Section C - Electrics Service Procedure Alternator AVO 2002

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

9813/2050-5

C-10

– Red lead to volts (middle) socket on meter. – Black lead to negative on meter. – RH slider to DC voltage. – LH slider. K Fig 7. ( T C-9).

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-10

Section C - Electrics Service Procedure 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 8. ( T C-11). Reading in 'start' position: 10.0V approximately. Minimum permissible reading in 'start' position 9.5V.

Fig 9. 3

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

Connect the voltmeter between the solenoid terminal 10-C and a good earth. Minimum permissible reading in 'start' position: 8.0V.

Fig 10.

Fig 8. 2

Connect the voltmeter between the starter main terminal 9-A and the commutator end bracket 9-B. In the 'start' position, the reading should not be more

C-11

9813/2050-5

If the reading is less than specified, connect the voltmeter between the neutral start relay terminal 11-D and earth. An increase in reading to 8.0V indicates a fault in the wiring from the start relay to the solenoid.

C-11

Section C - Electrics Service Procedure Starter Motor b If the reading between terminal 11-D and earth is below 8.0V, connect the voltmeter between terminal 11-E and earth. An increase in the reading to 8.0V indicates either a faulty start relay or a fault in the feed from the transmission selector switch to the relay solenoid. Check also the solenoid earth connection.

Connect the voltmeter between battery positive and the starter main terminal 13-A. With the starter switch 'off', the voltmeter should indicate battery voltage, but it should fall to practically zero when the switch is turned to the 'on' position, maximum permissible reading 0.25V.

If the reading between 11-E and earth is less than 8.0V, the fault must be in either the starter switch or in the wiring between the solenoid, starter switch, and the start relay.

Fig 13. If the reading is above 0.25V, a high resistance is present in the insulated lead or in the solenoid. Connect the voltmeter between the battery positive and solenoid connection 14-H. If the voltmeter now reads zero with the switch closed, the fault is in the solenoid.

Fig 11. 4

Connect the voltmeter between battery negative and starter earth connection 12-B. The reading in the 'start' position should be practically zero, maximum permissible reading 0.25V. If the reading is above 0.25V, a high resistance in the earth lead or connections is indicated.

Fig 14. 6

Finally refit the engine stop fuse.

Fig 12.

C-12

9813/2050-5

C-12

C-13

Circuit Schematics Electrical Circuit - 3DX From Serial Number – 1888500 - 1899999

-C2

-FU11

-BAT1 335/A1781

7208/1107

-VE

-C1

+VE +VE

+VE

-FU10

20A

-FU9

10A

LUG

-VE

10A

7208/1102

+VE

LUG

3.00 mm† 2000J

1.00 mm† 3000

BATT

1.50 mm† 3110

BATT

1.50 mm† 3030

BATT

TO HAZARD SW:3 /5.E3

-FU3

TO HEAD LT SW:2 /5.D1

-FU2

TO SPLICE IP_SP340 /1.A1

-FU1

2.50 mm† 2000E BATT

TO INSTRUMENT CLUSTER:12 /2.F2

-FU4 -FU24

7212/0060

-MF_MF2

-T6 8.00 mm† 2000B

-FU2

-IP_C12

IGN

1.00 mm† 1340

IGN

1.50 mm† 1010

IGN

TO SPLICE IP_SP282 /7.B2

GND

TO HAZARD SW:1 /5.E3 TO SPLICE IP_SP070 /3.B3 TO SPLICE IP_SP040 /3.F1 TO SPLICE IP_SP330 /4.D4 -FU7

TO SPLICE IP_SP300 /4.C1

0.50 mm† 1330A

3.00 mm† 2000H

TO SPLICE IP_SP282 /7.B2

GND

0.50 mm† 6000B

-IP_SP410

3.00 mm† 0007C

-FU5

1/2

-IP_C27 7241/0058

-IP_C26 7241/0058

9813/2050-5

15A

2.50 mm† 2000P

-IP_SP110

-FU19

2.00 mm† 3309

15A

2.50 mm† 2000N 35

-FU20

7211/0026

7241/0062

-T2

-FU27

60A

-C7

-MF_MF1

8.00 mm† 2030

1/1

1/2

IGN TO

-IP_SP060

-IP_SP050

2.50 mm† 1100

1.00 mm† 1180A

IGN

0.50 mm† 1180B

IGN

1.50 mm† 1100C

IGN

1.00 mm† 1100B

IGN

TO SPLICE IP_SP030 /2.C2 TO 4WD & HORN RELAY:10 /3.D3 TO 4WD & HORN RELAY:8 /3.D4 TO RH COLUMN SW:3 /5.F1

-FU22

2.00 mm† 3090

BATT

2.00 mm† 3100

BATT

BATT TO

7219/0005

7219/0006

TO RH COLUMN SW:7 /5.F1

-IP_C41

-CB_C41

-CB_SP130

1.00 mm† 1140

2.00 mm† 1140

3/14 1.00 mm† 1330P

IGN

0.50 mm† 1330C

IGN

0.50 mm† 1330D

IGN

0.50 mm† 1330E

IGN

1.00 mm† 1140A

TO RR WL SW:2 /5.C1

TO TL08 BATT FUSE:1 /6.B1

2/2

-B6

TO SPLICE CB_SP121 /7.D5

1.00 mm† 6000G GND

1/2

2/2

TO FR WL LT SW:2 /6.F1

TO FR WLT RELAY:5 /6.F3

FACE FAN

-CB_C10 1.00 mm† 1140B

3/14

1/2

TO HEAD LT SW:5 /5.D1

TO RR W LT RELAY:5 /5.C3

7232/0023

10A

-IP_SP080

TO RR W LT RELAY:10 /5.C3

BATT TO

TO RADIO:5 /6.E1

TO RR WL SW:5 /5.C1

7211/0025

-IP_C11

8.00 mm† 2030

1.00 mm† 2000Q

7207/1323

BATT

39 20A

2.50 mm† 2000M 36

8.00 mm† 2000A

1.00 mm† 1180

0.50 mm† 1330B

1.00 mm† 0007A

-FU18 8.00 mm† 2010

1/2

1.00 mm† 1060

15A

3.00 mm† 0007

15 10A

-FB1 7241/0063

1/2

11 10

3.00 mm† 0002C

-FU6

-IP_SP010 B

0.50 mm† 6000A

2/2

60A

3.00 mm† 2000G

-R5 716/30148 IGN RELAY - 2

-IP_SP100

2/2

8.00 mm† 2010

ZUKEN ISSUE SPLICE S2 IS ADDED

2.00 mm† 1070

8.00 mm† 2020

70.00 mm† BLACK

-S2

2/2

-C9

60A

332/E9928 8.00 mm† 2020

7241/0062

-FU1

-R4 716/30148 IGN RELAY - 1

(ADD 16.00 Sqmm WIRE)

7207/1323

IGN

15A

1.50 mm† 0002B

IGN

1.00 mm† 1260

1.00 mm† 0002D

TO HEAD LT HI/LO RELAY /5.B1

1.00 mm† 1040

6 20A

3.00 mm† 0002 0.75 mm† 2000K BATT

7 10A

7207/1304

-T5

1.00 mm† 1330

-IP_SP090

7232/0023

1/1

-FU23

15A

1.50 mm† 2000F

-IP_SP290

1.50 mm† 3040

MOBILE CHARGER

-IP_C40 1.00 mm† 3040B

2/2

1.00 mm† 3040B

1/2

-B30

7219/0005

-IP_C41

TO HEAD LT HI/LO RELAY:10 /5.A1

BATT

2.00 mm† 2000

-CB_C41

1.00 mm† 3040A

TO RADIO:5 /6.E1

BATT TO

8/14

-IP_C9

-B5

1/4

3/4

1/4

TO SPLICE IP_SP040 /3.F1

IGN TO

2/4

2.50 mm† 0001

-IP_C20 5/6

-FU17

2.50 mm† 0001B

7/6

1.00 mm† 0001A

1.00 mm† 1330

1.00 mm† 1050

10A

7219/0005

7219/0006

-IP_C14

-CH_C14

BATT

1.00 mm† 1050

7212/0060

TO SPLICE IP_SP200 /4.C1 TO SPLICE IP_SP282 /7.B2

0.50 mm† 6000C

A B

-IP_C17

-CH_C6

1/2

-IP_SP170 0.50 mm† 8100

7207/1317

332/E9928

-CH_C17

1/2

3.00 mm† 8420

TO SPLICE CH_SP030 /4.B1

IGN

0.50 mm† 8100B

FROM

ST SOL

TO LH COLUMN SW:5 /3.D3

-B1

7207/1417 GND FROM

7208/1018

2.00 mm† 6110

-T4

1/1

M10

70.00 mm† BLACK

-GND1 GND

7208/1018

-T3

70.00 mm† RED

1/1

M10

7219/0006

-IP_C41

-CB_C41

7204/0408

-CB_C13

2/14

-B1

7204/0408

-CB_C14

1/1

1.00 mm† 6000F

7207/1514

TO SPLICE CB_SP120 /7.B5

GND TO

1/1

1.50 mm† 3030A

2/14

7214/0068

WIPER MOTOR

-IP_C52 FROM FUSE FU9:21 /1.F3

BATT FROM

1.50 mm† 3030

FROM RH COLUMN SW /5.F1

2/4

1/4 #14 FROM

C-13

3/4

1.00 mm† 9820

#13 FROM

FROM RH COLUMN SW:4 /5.F1

TO INSTRUMENT CLUSTER /2.C5

ALT W

0.50 mm† 4120

ALT D+

0.50 mm† 4070

2/4 3/4

1.00 mm† 8400

TO SPLICE IP_SP310 /2.E6

-B3 1/4

1.50 mm† 3030B

-IP_SP340

B+

M10

INTERIOR LIGHT 1/1

1.00 mm† 3030A

16.00 mm† 2000

7219/0005

4/4

1.00 mm† 6000P

GND TO

TO SPLICE IP_SP280 /7.E2

4/4

7219/0005

7219/0006

-IP_C14

-CH_C14 8/14

4/14

7207/1405

ALTERNATOR

-CH_C3

-B27

1/1

ALT B+

1/1

ALT W

1/1

ALT D+

7207/2005 1.00 mm† 4120

8/14

-CH_C7

-CH_C4 7207/2005

1.00 mm† 4070

-CH_C5

-GND2

335-Y3467-1

Fig 1. 335/Y3467 (Sheet 1 of 7)

Electrical Circuit - 3DX

FROM SPLICE CH_SP070 /2.C7

-CH_C33

Circuit Schematics

-IP_C28 7241/0058

STARTER MOTOR 1/1

TO DUMP & PARK RELAY:8 /3.E1

IGN

0.50 mm† 8100A

2.50 mm† 8420

Section C - Electrics

GND TO

3/14

-R6 716/30148 NEUTRAL START RELAY 3.00 mm† 0004

TO SPLICE IP_SP282 /7.B2

2/4

3/14

3.00 mm† 0004

7/6

-B29

-IP_SP270

5/6

IGN

GND

7236/0003

IGNITION SW 1/4

1/4

0.50 mm† 8290

1.00 mm† 6000ZZ

3/4 4/4

1.00 mm† 1070E

4/4

-FU8

-IP_C21

TO SPLICE IP_SP281 /7.D2

ACC SUPPLY

7214/0001 1.00 mm† 3040C

7234/0003

1/2

7219/0006

8/14

6.00 mm† 2000L

GND

1.00 mm† 6000Q

2/2

-FB2 7241/0063

C-14

INSTRUMENT CLUSTER 7219/0005 2/36

-IP_C25

1.00 mm† 4050

6/14

7213/0031

-IP_C14 13/36

FROM SPLICE IP_SP040 /3.F1

IGN FROM

3/6

2/6

3/6

GND

1.00 mm† 6000W

1/6

-IP_C16

SPEED SENSOR 2/2

-B23

0.50 mm† 4120A

GND

1.00 mm† 6000K

1.00 mm† 4060B

WATER TEMP

1.00 mm† 4060E

WATER TEMP

1.00 mm† 4120D

ALT W

A/3

ALT W FROM

ALT W

1.00 mm† 4120B

-IP_SP370

-CH_C11

FROM FUSE FU15:31 /5.F7

IGN FROM

FROM SPLICE CB_SP060 /5.E5

IGN TO

IGN FROM

GND

1.00 mm† 6000D

GND

1.00 mm† 6000B

GND

1.00 mm† 6000Z

GND

TO SPLICE IP_SP021 /7.F7

2/2

AIR CLEANER -B3 2/2

1/2

1.00 mm† 4020

2/14

1/2

TO SPLICE CH_SP021 /7.F7

2/2

1.00 mm† 8300H

0.50 mm† 8300A

7212/0030

-IP_C14 22/36

0.50 mm† 8300F

7219/0006

7219/0005

-CB_C41

-IP_C41

1.00 mm† 8300

-CH_C21

-CH_C14

0.50 mm† 4040

7/14

7213/0031

-CH_C2 FROM

PARK

4/36

0.75 mm† 4010

FROM

23/36

4/36

0.75 mm† 1897A

-IP_SP380

0.75 mm† 1897B

8/8

9813/2050-5

16/36

TO SPLICE CH_SP020 /7.D7

-B5 C/3

B/3

TO SPLICE CH_SP021 /7.F7

C/3

B/3

TO LIVELINK CONN /6.A7 TO SPLICE IP_SP390 /6.A4

GND

0.75 mm† 6110C

WATER IN FUEL SW.

A/3

8/8

WATER IN FUEL

1.00 mm† 1897

2/2 2/2

A/3

1.00 mm† 1050D

1.00 mm† 1897B

23/36

-B4

1/2

11/14

FROM SPLICE CH_SP030 BATT /4.A1 -IP_C16 -CH_C16

TRANS OIL TEMP SW 1/2

1.00 mm† 4040

22/36

0.50 mm† 8300

11/14

FROM DUMP & PARK RELAY:10 /3.E2

-CH_C13

-CH_C14

2/14

2/2

TO LIVELINK CONNECTOR:1 /6.B7

0.50 mm† 4020

21/36

TO HAZARD SW:8 /5.E3 FROM HEAD LT SW:8 /5.D3

-IP_C14 21/36

0.50 mm† 8300E

-B6

1/2

7212/0013 IGN

1.00 mm† 6000C

ENG. OIL PRE. SW 1/2

1/14

ENG. OIL PRE.

1.00 mm† 4030B

TO SPLICE CH_SP060 /7.E5

TO EGR ECU /4.F1

1.00 mm† 4030A

1/14

C/3

FROM ALTERNATOR ALT W /1.A5

-CH_C14

0.50 mm† 4030A

10/36

C/3

TO LIVELINK CONNECTOR:3 /6.B7

7212/0030 0.50 mm† 4030

-IP_C14

-B2

B/3

TO TL09 ENG RUN FUSE:1 /6.B5

0.50 mm† 4120

TO SPLICE SP020 /7.D7

10/36

GND

TO SPLICE CH_SP020 /7.E7

TO ERG ECU:8 /4.F1

1/2

TO 4WD SW:8 /3.A3

1.00 mm† 6000E

B/3

-IP_SP310

15/36

1/2

2/2

5/8

5/14

7/36

15/36

7212/0128 1.00 mm† 9740

5/8

5/14

-IP_SP320

7/36

0.50 mm† 8300C

4/6

-CH_C19

-CH_C16

0.50 mm† 8300D

1.00 mm† 4060

18/36

-IP_SP210

4/6

1/6

GND

WATER TEMP SENSOR

A/3 1.00 mm† 4060A

TO SPLICE IP_SP280 /7.E2 18/36

7218/0002

10/14

2/6

1.00 mm† 9740

7218/0001

10/14 0.50 mm† 4060A

-B2

-CH_C28 1.00 mm† 4090

SPEEDOMETER

0.50 mm† 1070D

-CH_C14

0.50 mm† 4090

13/36

-IP_C51

1.00 mm† 6000J

2/2

-B6

12/36

7216/0052

TRANS. OIL PR. SW -B1 1/2 2/2

1/2

12/36

0.75 mm† 2000K

FROM

-CH_C18

-CH_C14

0.50 mm† 4050

2/36

FROM SPLICE IP_SP100 BATT /1.F3

7212/0030

7219/0006

-IP_C14

7239/0031

16/36 28/36

ALT D+

0.50 mm† 4070

FROM

FROM ALTERNATOR D+ /1.A5

28/36 20/36

0.50 mm† 4080

-IP_C14

IGN FROM

1.00 mm† 1060

1.00 mm† 1060X

IGN TO

1.00 mm† 4080A

11/14 1/14

TO LIVELINK CONNECTOR:8 /6.B7

0.50 mm† 4080B

-CH_C26

-CH_C14

0.50 mm† 4080A

20/36

FROM FUSE FU7:15 /1.F7

FUEL SENDER TO

B GND F

FROM SPLICE IP_SP200 /4.B1

IGN FROM

1/2

1.00 mm† 6110A

2.00 mm† 6110

TO BATTERY EARTH /1.B5

-CH_SP070

WARNING CLUSTER 1/14

0.50 mm† 8290F

-B25

1/14

9/36

FROM SPLICE IP_SP220 HIGH BEAM /5.A5

E J

TO SPLICE IP_SP390 /6.B5

-IP_C49 9/36

0.75 mm† 1060A

BUZ

FROM

GND

TO LIVELINK CONN:9 /6.B7

7219/0005

0.50 mm† 1060C

-IP_SP030 1.00 mm† 4110

2/2

-B7

1/2

BUZZERD

C IGN

2/2

GND

FUEL SENDER

11/14

-R1 704/10000 BUZZER A

1.00 mm† 6110B

7212/0044

-IP_SP400

FROM

2/14

0.50 mm† 8370B

2/14

FROM SPLICE IP_SP240 /6.F5

FR WL

0.50 mm† 8550B

#115

0.50 mm† 8040B

FROM

4/14 4/14

-IP_C30 7241/0058

FROM SPLICE IP_SP140 /5.F3

FROM

5/14 5/14

-IP_SP120 11/36

0.75 mm† 4110A

FROM SPLICE IP_SP160 /5.F3

PH IND

0.50 mm† 8060B

LH IND

0.50 mm† 8050B

RR WL

0.50 mm† 8610A

FROM

6/14 6/14

11/36 FROM

7/14 7/14

FROM SPLICE IP_SP250 /5.C4

FROM

11/14 11/14 8/14

0.50 mm† 4110B

3/14

8/14

0.50 mm† 6000AA

GND TO

TO SPLICE IP_SP280 /7.F2

3/14

14/14

C-14

Electrical Circuit - 3DX

335-Y3467-2

Fig 2. 335/Y3467 (Sheet 2 of 7)

Circuit Schematics

14/14

0.50 mm† 1060B

Section C - Electrics

FROM SPLICE IP_SP150 /5.F3

C-15

-R9 332/C3148 FWD & REV RELAY

-R7 332/C3148 DUMP & PARK RELAY 1 2

FROM ACC SUPPLY:4 /1.D5

IGN 1.00 mm† 1070E

FROM

FROM FUSE FU1:5 /1.F5

2.00 mm† 1070C

IGN 2.00 mm† 1070

FROM

0.50 mm† 1070A

1.50 mm† 8520

1.00 mm† 8520A

1.00 mm† 8120

0.50 mm† 8090

0.50 mm† 6000G

IGN TO

-CH_C16

2/8

7212/0030

-CH_C23

2/8

GND TO

IGN FROM

0.50 mm† 8100A

-CH_C16

0.75 mm† 4010

PARK

0.50 mm† 6000L GND

TO INSTRUMENT CLUSTER:4 /2.C2

TO SPLICE IP_SP282 /7.C2

GND

0.50 mm† 6000H

1.50 mm† 8110

0.50 mm† 8080

-IP_C32 7241/0060

7212/0001

-IP_C16

1.00 mm† 8470

1.00 mm† 6000F

1.00 mm† 8110A

-IP_C41

2/2

GND

1.00 mm† 6000V

6/14

TO SPLICE IP_SP281 /7.D2

TO SPLICE CH_SP020 /7.D7

REAR HORN 1/2

7/8

GND

-B15

2/2

1/2

1.00 mm† mm 6000V

GND TO

TO SPLICE CH_SP020 /7.E7

2/2

TO SPLICE IP_SP282 /7.B2

7219/0006

-CB_C41

REVERSE TO

TO SPLICE CB_SP030 /5.F5

6/14

LH COLUMN SW.

7219/0005

-IP_C53

2/2

1/2

-CH_C32

-CH_C16

1.00 mm† 8470

1.00 mm† 8110

-B26

GND

TO SPLICE CH_SP020 /7.D7

-IP_C31 7241/0058

7219/0005

PARK BRAKE SW. 1/2

1.00 mm† 6000M

2/2

7/8

-IP_SP180

1.50 mm† 8110C

GND

-R2 716/21100 REVERSE FLASHER RELAY

7212/0141

-IP_C13

REVERSE SOLENOID -B14 1/2 2/2

1/2

-IP_C34 7241/0060

1.00 mm† 9360

-CH_C22

3/8

1.00 mm† 8110B

FROM SPLICE IP_SP170 /1.C6

-IP_C16

1.00 mm† 6000N

2/2

7212/0030

7 10

1.50 mm† 8520

7218/0002 1.00 mm† 8110

-R10 332/C3148 FWD & REV RELAY

7 9

7218/0001

3/8

-R8 332/C3148 DUMP & PARK RELAY - 2

0.50 mm† 9360A

1/2

TO SPLICE IP_SP282 /7.B2

0.50 mm† 1070B

1.00 mm† 9360

FORWARD SOLENOID -B13 1/2 2/2

1.00 mm† 8120

-IP_C32 7241/0060

-IP_C34 7241/0060

0.50 mm† 1070D

7218/0002

-IP_C16

0.50 mm† 9340

-IP_SP040

TO SPEEDOMETER:3 /2.E1

7218/0001

-B23

9/14 9/14

7/14

0.50 mm† 8090

7/14

0.50 mm† 8080

11/14 4/14

0.50 mm† 1070B

1.00 mm† 6000AB

GND TO

TO SPLICE IP_SP280 /7.F2

11/14

4/14

TO SPLICE IP_SP170 /1.C6

IGN

5/14

0.50 mm† 8100B

5/14 8/14

0.50 mm† 9210

8/14

-R11 332/C3148 4WD & HORN RELAY 7

FROM SPLICE IP_SP060 /1.F7

IGN FROM

-IP_SP260

1.00 mm† 1180A

1.00 mm† 8140

0.50 mm† 9210B

0.50 mm† 1180B

-IP_C35 7241/0060

7218/0001

7218/0002

-IP_C16

-CH_C16

7212/0001

FROM

FROM SPLICE IP_SP060 /1.E7

1/8

1/2

-CH_C31

-CH_C14

0.50 mm† 9210A

9813/2050-5

DIODE-2

-IP_C39 2/4

-B12

1/4

2/4

0.50 mm† 9340

1/4

7219/0005

7219/0006

-IP_C14

-CH_C14

0.50 mm† 9340A

-FU12 1.00 mm† 9330

-IP_C41

-CB_C41

10A

1.00 mm† 8160

5/14

2/2

GND

1.00 mm† 6000H

GND

0.50 mm† 6000AC

GND

1.00 mm† 6000L

GND

TO SPLICE CH_SP020 /7.E7

2/2

TRANS DUMP 1/2

2/2

TO SPLICE CH_SP020 /7.E7

2/2

1/2 BRAKE

1.00 mm† 6000T

7212/0128

-CH_C25

7219/0006

GND

TO SPLICE CH_SP021 /7.E7

2/2

1/2

1.00 mm† 9340C

7219/0005

1.00 mm† 6000R

-CH_SP010

13/14

1.00 mm† 9330A

3/4

4/4

2/2

1/2 1.00 mm† 9340A

13/14 3/4

4/4

1.00 mm† 9133

GND

DUMP SW

-CH_C29 1.00 mm† 9340B

7214/0068

1.00 mm† 6000A

REAR HORN SW

1/2

14/14

7212/0128

0.50 mm† 9360A

2/2 2/2

1/2

1.00 mm† 9210A

14/14

-B12

1/2

7212/0001

-IP_C14

FRONT HORN

-CH_C1 1.00 mm† 8140

IGN

TO SPLICE CB_SP040 /5.D5

5/14

-R12 332/C3148 4WD & HORN RELAY

4WD SW

2 1.00 mm† 1260C

1.00 mm† 9330A

0.50 mm† 1260A

0.50 mm† 8770

7212/0141

5/10

1.00 mm† 1260B

-IP_C47

3/10 2/10

2/10

1.00 mm† 8530A

-IP_SP230

IGN FROM

FROM FUSE FU2:6 /1.F5

7218/0001

7218/0002

2/2

-IP_C16

-CH_C16

7212/0052

-CH_C20

TO SPLICE IP_SP280 /7.E2

6/8

4WD SOLENOID 1/2

1.00 mm† mm 8530B

6/8

2/2

-IP_C35 7241/0060

1.00 mm† 8530B

3/10 6/10

-B28

1/2 1.00 mm† 1260

7219/0013

1/2

0.50 mm† 8770

-IP_SP070

5/10

1.00 mm† 9133

BRAKE SW

-IP_C54

-B4

1/2

-B11

2/2

TO SPLICE CH_SP020 /7.E7

2/2

1.00 mm† 8530

6/10 0.50 mm† 8300E

IGN FROM

FROM SPLICE IP_SP210 /2.D2

8/10 7/10

0.50 mm† 6000K

GND TO

TO SPLICE IP_SP282 /7.C2

7/10

Electrical Circuit - 3DX

C-15

Circuit Schematics

335-Y3467-3

Fig 3. 335/Y3467 (Sheet 3 of 7)

Section C - Electrics

8/10

C-16

EGR ECU 1/18

320/09640

FROM SPLICE IP_SP310 /2.E6

ALT W

7216/0002

-IP_C15

-CH_C15

3/6

8/18

1.00 mm† 4060B

-CH_C15

6/18

6/6

4/6

2/6

4/6

GND

1.00 mm† 6000S

GND

TO SPLICE CH_SP021 /7.F7

6/6

1.00 mm† 4830

6/18

1.00 mm† 6000AC

4/6

-CH_C15

1.00 mm† 4830

8/18

2/6

1.00 mm† 4800

6/6

-IP_C15

FROM

1/6 1/6

1.00 mm† 4800

13/18

FROM SPLICE IP_SP320 WATER TEMP /2.E6

EGR VALVE

-CH_C8

3/6

-IP_C15 13/18

4/18

320/09642 1.00 mm† 4062

1/18 4/18

1.00 mm† 4120B

FROM

7216/0001 1.00 mm† 4062

-IP_C50

4/6

-IP_C16

6/6

-CH_C16

5/6

1.00 mm† 1340B

5/6

4/8

-B16

1.00 mm† 1340B

4/8

-B24

7214/0001

RS232

-IP_C3 17/18

1.00 mm† 4310

3/4

1.00 mm† 4310

18/18

-B8

3/4

17/18 1.00 mm† 4320

FROM FUSE FU4:8 /1.F5

IGN

1.00 mm† 1340

TO SPLICE CH_SP282 /7.C2

2/4

4/4

-IP_SP330

FROM

2/4

4/4

1.00 mm† 4320

18/18

1/4

1.00 mm† 1340A

1/4

7234/0008

-IP_C2

15/18

1.00 mm† 1010C

15/18

2/18

WARNING LAMP -B22

3/4

1.00 mm† 4605

2/18

1/4

1.00 mm† 1340C

2A/4

1A/4

-IP_C15 16/18

-CH_C15

1.00 mm† 8950A

16/18

9813/2050-5

12/18

2/6

GND

1.00 mm† 6000E

TO SPLICE IP_SP280 /7.E2

12/18

7219/0013

FROM FUSE FU24:48 /1.F5

IGN

-IP_SP300

1.50 mm† 1010

FROM

HYDRA CLAMP SW.

-IP_C23 2/10

1.00 mm† 1010A

3/10

2/10

FROM ACC SUPPLY:3 /1.D6

IGN

-IP_SP200

0.50 mm† 8290

FROM

3/10 8/10

0.50 mm† 8290E

7/10

8/10

TO FRONT WORKLIGHT SW /6.F1

IGN

FROM REAR WORKLIGHT SW:8 /5.C1 FROM FUSE FU16:32 /5.F7

IGN IGN IGN

12/14 0.50 mm† 6000AF

GND

0.50 mm† 6000T

GND

FROM

1.00 mm† 6000F

GND

TO O SPLICE CH_SP020 /7.D7

FROM RR WORK LT SW:7 /5.C3

0.50 mm† 8290A

4/14

1.00 mm† 1050A

COLD START ADVANCE SOL

7212/0140

-CH_C12 COLD START ADVANCE 2/2 1/2 -B18

-CH_C9 1.00 mm† 8950B

1/2

1.00 mm† 8950

-CH_SP050

1/2

-B20

2/2

TO SPLICE CH_SP021 /7.E7

2/2

1.00 mm† 1050D

7212/0013

ESOS

-CH_C27 1/2

1.00 mm† 1050B

1/2

-B21

2/2

1.00 mm† 6000W

GND TO

TO SPLICE CH_SP021 /7.F7

2/2

C-16

335-Y3467-4.

Fig 4. 335/Y3467 (Sheet 4 of 7)

Circuit Schematics

-CH_SP030 1.00 mm† 1050

Electrical Circuit - 3DX

BATT TO

GND

-IP_C41

1.00 mm† 8290A

2/2

TO WATER IN FUEL SW /2.D6

1.00 mm† 6000X

2/2

FROM FR WORK LT SW:7 /6.F3

7212/0052

BATT FROM

2/2

-B19

0.50 mm† 8290F

-CB_C41 4/14

FROM FUSE FU17 /1.C6

HYDRA CLAMP 1/2 1/2

12/14

Section C - Electrics

IGN TO

7212/0052

-CH_C30 1.00 mm† 9200

1.00 mm† 8290D

TO SPLICE CB_SP050 /5.B5

-CH_C14

0.50 mm† 8290C

FROM

TO WARNING CLUSTER:1 /2.B5

7219/0006

-IP_C14

7/10

0.50 mm† 8290B

7219/0005 1.00 mm† 9200

C-17

7219/0005

FROM SPLICE IP_SP050 /1.E7

RH COLUMN SW. 3/14

1.50 mm† 1100C

8/14

RH IND

TO WIPER MOTOR:3 /1.A3

#13 TO

TO WARNING CLUSTER:5 /2.B5

4/14

1.00 mm† 9820

7214/0068

-IP_SP140

#115

0.50 mm† 8040B

#14 TO

-B7

-IP_C41

14/14

LH IND

9/14

-IP_SP150

1.00 mm† 8050C

7/14

1/14

1/14 LH IND

5/10

1.00 mm† 8050A

11/14 12/14

1.00 mm† 8030

FROM SPLICE IP_SP180 /3.E6

REVERSE FROM

IGN 1.00 mm† 1040

3/10

IGN 0.50 mm† 8300A

FROM

IGN

1.00 mm† 8290D

IGN

TO SPLICE IP_SP210 /2.D2 TO SPLICE IP_SP200 /4.C1

-B4 REVERSE

1.00 mm† 6000Y

GND 10/10 8/10

5/6

BRAKE GND TAIL

6/6

RH IND

4/6 1.00 mm† 8300B

-CB_SP020

3/10

4/6

1.00 mm† 8160A

1/10

BATT 1.00 mm† 3000

FROM

1.00 mm† 8300H

REAR COMBI LAMP RH 2/6

1.00 mm† 8110A

1.00 mm† 8040A

1/10

FROM FUSE FU11:23 /1.F3 FROM SPLICE IP_SP210 /2.D2

31 7.5A

-CB_C11

-CB_SP030

1.00 mm† 8110

18/10 FROM

-FU16

17/10

-B8

18/10

1.00 mm† 8030A

FROM FUSE FU3:7 /1.F5

-FU15 1.50 mm† 8280

4/4

2/6

17/10

LH IND

5/10

-IP_SP130

12/14

FROM SPLICE IP_SP240 /6.F5

7216/0051

TO WARNING CLUSTER:7 /2.B5

HAZARD SW.

-IP_C46 11/14

FROM

1.00 mm† 8050

7219/0014

13/14 1.50 mm† 8027

7/14

0.50 mm† 8050B

13/14

FR WL

-IP_SP190

1.00 mm† 8050

10/14 0.50 mm† 8360

1.00 mm† 8280A

1.00 mm† 8060

9/14

10/14

0.50 mm† 8330

1.00 mm† 8550A

3/4 4/4

-CB_C41

1.00 mm† 8060

14/14

1.00 mm† 8400

3/4

1/4

1.00 mm† 8040

1/4 7/14

1.00 mm† 1100B

-B13

2/4 2/4

4/14 IGN FROM

DIODE-1

-IP_C38 1.00 mm† 806C

8/14

7/14

TO WIPER MOTOR:3 /1.A2

-IP_SP160

1.00 mm† 8060A

3/14

FROM SPLICE IP_SP050 /1.E7

TO WARNING CLUSTER:6 /2.B5

PH IND

0.50 mm† 8060B

-IP_C48 IGN FROM

1.00 mm† 8060B

0.50 mm† 6000X

7232/0023

10/10

TO SPLICE IP_SP210 /2.D2

8/10

1.00 mm† 6000R GND

TO SPLICE CB_SP120 /7.C5

1.00 mm† 6000M GND

TO SPLICE CB_SP121 /7.D5

1.00 mm† 6000L GND

TO SPLICE CB_SP121 /7.D5

1.00 mm† 6000H GND

TO SPLICE CB_SP120 /7.B5

1.00 mm† 6000P GND

TO SPLICE CB_SP120 /7.C5

1.00 mm† 6000J GND

TO SPLICE CB_SP120 /7.B5

1.00 mm† 6000N GND

TO SPLICE CB_SP120 /7.C5

1.00 mm† 6000K GND

TO SPLICE CB_SP120 /7.C5

1.50 mm† 6000A GND

TO SPLICE CB_SP121 /7.C5

1.50 mm† 6000E GND

TO SPLICE CB_SP121 /7.D5

3/6

6/6

TO SPLICE IP_SP280 /7.F2

GND

3/6

5/6

IGN TO

-CB_C18

-CB_SP060

1.00 mm† 8300

NO PLATE LAMP RH 1/2

1.00 mm† 8300C

2/10

-B7

2/2

1/2

2/2

2/10 7232/0023

-CB_C19

-R3 716/21100 FLASHER RELAY

NO PLATE LAMP LH 1/2

1.00 mm† 8300A

-B8

2/2

1/2

2/2

D A

1.00 mm† 8030B

1.00 mm† 8020

7216/0051

-CB_C12 REAR COMBI LAMP LH TO SPLICE IP_SP282 /7.B2

7219/0013

-IP_C45

1.00 mm† 6000D

3/10

-B9

6/10

2/6

1.00 mm† 8110B

FROM FUSE FU12:24 /3.C4

5/6

REVERSE -B5 BRAKE GND TAIL

6/6

LH IND

2/6 BRAKE FROM

1.00 mm† 8160

4/6

1.00 mm† 8160B

-CB_SP040

-IP_C29 7241/0058

HEAD LT SW. 6/10

1.50 mm† 8027

GND TO

4/6 1.00 mm† 8290

3/6

5/6

1.50 mm† 8280B

3/10

1.00 mm† 8050B

-CB_SP010

6/6

FROM FUSE FU10:22 /1.F3

BATT

2/10

1.50 mm† 3110

FROM

7/10

2/10

TO SPLICE IP_SP080 /1.E5

IGN

5/10

1.00 mm† 1330P

FROM

8/10

5/10

9813/2050-5

7219/0013

-IP_C24

FROM SPLICE IP_SP080 /1.D5

FROM

IGN 0.50 mm† 1330D

FROM

IGN TO

7219/0005

TO SPLICE IP_SP210 /2.D2

-IP_C41

REAR WORK LIGHT SW.

FROM FUSE FU19:39 /1.E3

BATT FROM

2.00 mm† 3090

3/10 5/10

0.50 mm† 8170

2.00 mm† 8610

0.50 mm† 6000M

14/14

0.50 mm† 8610A

-IP_C36 7241/0060

0.50 mm† 8117

RR WL TO

7/10

1.00 mm† 8610

GND TO

TO SPLICE IP_SP282 /7.C2 7212/0052

-IP_C41

-CB_C41

-CB_SP110

0.50 mm† 6000U

GND TO

LH RR WORK LT-I -B11 1/2 2/2

-CB_C20 1.00 mm† 8861B

2/2

RH RR WORK LT-II -B10 1/2

7212/0052

2/2

1/2

-R14 332/C3148 REAR WORK LT

TO SPLICE IP_SP281 /7.D2

-CB_C17 1.00 mm† 8861A

12/14

TO HYDRACLAMP SW /4.C4

7/10

8/10

2/2

1/2

1.00 mm† 8861

0.50 mm† 6000AF

1/2

-CB_C21

TO WARNING CLUSTER:11 /2.A5

12/14 8/10

RH RR WORK LT-1 -B9

1/2

14/14

6/10 IGN 0.50 mm† 8290C

-CB_C16 1.00 mm† 8610A

7212/0052

GND

3/10 6/10

FROM

-CB_SP100

1.00 mm† 8610B

-IP_SP250

-B16

5/10

TO SPLICE IP_SP200 /4.C1

7212/0052

7219/0006

-CB_C41

2.00 mm† 8610B

-R13 332/C3148 REAR WORK LT 2

2/10

IGN 0.50 mm† 1330E

0.50 mm† 8300F

8/10

2/10

FROM SPLICE IP_SP080 /1.D5

0.50 mm† 6000X

7/10

LH RR WORK LT-II -B12 1/2 2/2

2/2

1/2

FROM FUSE FU18:38 /1.E3

BATT FROM

2.00 mm† 3309

2.00 mm† 8861

0.50 mm† 8117

7216/0051

TO SPLICE IP_SP282 /7.C2

GND TO

0.50 mm† 6000N

-R15 332/C3148 HEAD LAMP HI & LO RLY 2

TO SPLICE IP_SP100 /1.F3

BATT FROM

2.50 mm† 2000E

-CB_C1 FROM SPLICE IP_SP200 /4.B1

-IP_C36 7241/0060 -FU13 25

2.00 mm† 1836

7219/0005

7219/0006

-IP_C41

-CB_C41

IGN FROM

10/14

2.00 mm† 8370

-CB_SP050 -CB_SP070

1/6 2/6 2/6 3/6

1.00 mm† 8340B

10/14

0.50 mm† 6000J

GND TO

SIDE LAMP -B2 HIGH BEAM GND LOW BEAM

4/6

3/6 5/6

1.00 mm† 8050A 0.50 mm† 8360

HEAD LAMP LH 1/6

1.00 mm† 8290B

1.00 mm† 8370B

2.00 mm† 8340

20A

1.00 mm† 8290A

TO SPLICE IP_SP282 /7.C2

LH IND

5/6

7216/0051

-R16 332/C3148 HEAD LAMP HI & LO RLY 7 FROM

2.00 mm† 2000

2.00 mm† 1833

0.50 mm† 8330

-IP_SP220

-IP_C41

2.00 mm† 8370A

0.50 mm† 6000Z

9/14

2.00 mm† 8340

0.50 mm† 8370B

-CB_SP080

9/14 HIGH BEAM TO

3/6

SIDE LAMP -B3 HIGH BEAM GND LOW BEAM

5/6

RH IND

2/6

1.00 mm† 8370

2/6 1.00 mm† 8340A

GND TO

HEAD LAMP RH 1/6

1/6

-CB_C41

2.00 mm† 8370A

TO WARNING CLUSTER:2 /2.B5 1.00 mm† 8060A

-IP_C37 7241/0060

4/6

3/6 5/6

335-Y3467-5

Fig 5. 335/Y3467 (Sheet 5 of 7)

C-17

Electrical Circuit - 3DX

TO SPLICE IP_SP282 /7.C2

BATT

WORKLIGHTS 4 X 55 W BULB -FU14 15A

Circuit Schematics

FROM SPLICE IP_SP090 /1.D3

-CB_C4 1.00 mm† 8300D

Section C - Electrics

-IP_C37 7241/0060

C-18

-R17 332/C3148 FRONT WORK LT 7219/0005

FROM FUSE FU20:40 /1.E3

FRONT WORK LT SW 7219/0013

FROM SPLICE IP_SP080 /1.E5

-IP_C22

IGN

2.00 mm† 3100

0.50 mm† 8016

2.00 mm† 8550C

GND

0.50 mm† 6000AE

TO SPLICE IP_SP280 /7.E2 0.50 mm† 8550B

FR WL

1.00 mm† 8550A

FR WL

GND

0.50 mm† 6000T

-CB_SP090

-CB_C2 1.00 mm† 8550A

13/14

7212/0052

-CB_C3 1.00 mm† 8550B

TO HYDRACLAMP SW:7 /4.C4

TO DIODE -I /5.F5

FRONT WORK LT LH-I -B13 1/2 2/2

1/2

TO WARNING CLUSTER:4 /2.B5

-IP_C33 7241/0060 7/10

FROM SPLICE IP_SP200 /4.C1

-CB_C41

2.00 mm† 8550C

3/10

2/10

7212/0052

7219/0006

-IP_C41

-IP_SP240 2.00 mm† 8550

13/14

3/10

2/10

0.50 mm† 1330C

FROM

-B15

BATT FROM

1.00 mm† 6000B

GND

1.00 mm† 6000D

GND

TO SPLICE IP_SP121 /7.D5

2/2

FRONT WORK LT RH-I -B14 1/2 2/2

1/2

TO SPLICE IP_SP121 /7.D5

2/2

7/10 IGN

8/10

0.50 mm† 8290B

FROM

8/10

7232/0023

RADIO FROM SPLICE IP_SP290 /1.D5 FROM SPLICE CB_SP130 /1.E7

BATT

5/8

1.00 mm† 3040A

FROM

5/8 BATT

8/8

1.00 mm† 1140A

FROM

-CB_C9 4/8

-B17

0.50 mm† 9010

4/8 3/8

1/2 0.50 mm† 8590

2/2

0.50 mm† 8590

3/8

8/8

-CB_C8 2/8

-B15

2/2 7232/0023 0.50 mm† 9020

0.50 mm† 9020

0.50 mm† 8600

2/8 1/8

LH SPEAKER 1/2

0.50 mm† 9010

RH SPEAKER 1/2

1/2

1/8 TO

2/2

-B16

2/2

TO CAB GND CB_C15 /7.B3

GND

7/8 7/8

9813/2050-5

7213/0015 7213/0015 A

-TL03 727/00002

-MC1:SH1

-IP_C8 A/3

0.50 mm† CAN HB

B/3

0.50 mm† CAN LB

-MC3:SH1

-IP_SP022 -IP_SP021 -IP_SP029

CAN SHLD

0.50 mm† CAN SB

0.50 mm† CAN SC

BATT

B/3

CAN SHLD

TL01 DIAGNSTIC SKT 2

0.50 mm† CAN SF

B/9

-B18

0.50 mm† CAN LG

0.50 mm† CAN SG

0.50 mm† CAN SA1

0.50 mm† CAN HG

TL02 LIVE LINK

7219/0018

-IP_C44

7219/0098 C/9

11/12 1/12 11/12

0.50 mm† CAN HA

C/9 D/9

2/12 NO CONNECTOR LEAD CUT

D/9

E/9

FROM

1.00 mm† 4120D

A/9

-IP_TL07 7241/0053

5/12

8/12

/2.D5 /2.E6

1.00 mm† 1060X

9/14

GND TO

IGN FROM

FROM SPLICE IP_SP030 /2.C3

8/12 9/12

1.00 mm† 6110B

9/14

FROM

7/12

5/12

-CH_C14

1.00 mm† 6110

FROM

7/12 1.00 mm† 6120

-IP_C14

WATER TEMP FROM SPLICE IP_SP320

3/12

1.00 mm† 4120C

-IP_TL09 7241/0053

-FU29 3A 1.00 mm† 6110A

ENG. OIL PRE. FROM SPLICE IP_SP370

1.00 mm† 4060E

FROM SPLICE CH_SP070 /2.C7

0.50 mm† 4080B

FUEL SENDER FROM SPLICE IP_SP400 FROM

/2.C5

9/12 12/12 10/12

1.00 mm† 6110B

1.00 mm† 1897

WATER IN FUEL FROM

FROM SPLICE IP_SP380 /2.C5

12/12

10/12 0.75 mm† 6110C

GND FROM

FROM INSTRUMENT CLUSTER:16 /2.C5 4/12

1.00 mm† 3050

4/12

335-Y3467-6

C-18

Fig 6. 335/Y3467 (Sheet 6 of 7)

Electrical Circuit - 3DX

-IP_SP390

ALT W

1.00 mm† 4030B

Circuit Schematics

FROM SPLICE IP_SP310 /2.E6

3/12

-FU30 3A

0.50 mm† CAN SA1

1.00 mm† 6110D

1/12 1/12

-C1 CUT END

1/1

A/9

-B10

2/12

0.50 mm† CAN LA

E/9

-C31 CUT END

Section C - Electrics

-IP_TL08 7241/0053

1/1

-MC6:SH1

CAN SHLD

-IP_C7

B/9

1.00 mm† 3050A

0.50 mm† CAN LA

-MC2:SH1

-FU28 3A 1.00 mm† 2000Q

-TL05 727/00002

NO CONNECTOR LEAD CUT

1/1

0.50 mm† CAN HA FROM

A/3

0.50 mm† CAN LF

-IP_SP020

CAN SHLD

0.50 mm† CANH HF

NO CONNECTOR LEAD CUT

CUT END

FROM SPLICE IP_SP110 /1.D3

-IP_SP027

0.50 mm† CAN LC

-C32

-IP_C10

-MC7:SH1

-IP_SP028

0.50 mm† CAN HC

C-19 FROM LH COLUMN SW:11 /3.D5 FROM HAZARD SW:10 /5.E4 FROM SPEEDOMETER:2 /2.E2 FROM WIPER MOTOR:4 /1.A3 FROM EGR ECU:12 /4.D4 FROM BRAKE SW:2 /3.B7

GND FROM

GND

1.00 mm† 6000D

GND

1.00 mm† 6000C

GND

1.00 mm† 6000AC

GND

1.00 mm† 6000F

GND

1.00 mm† 6000A

GND

1.00 mm† 6000V

GND

1.00 mm† 6000J

GND

1.00 mm† 6000T

GND

1.00 mm† 6000H

GND

1.00 mm† 6000R

GND

1.00 mm† 6000L

GND

1.00 mm† 6000N

GND

1.00 mm† 6000M

GND

1.00 mm† 6000X

GND

FROM FACE FAN:1 /1.E8

1.00 mm† 6000B

GND

FROM MOBILE CHARGER:1 /1.D6

FROM NO PLATE LAMP RH:2 /5.E8

1.00 mm† 6000K

GND

GND FROM

-CH_SP021

FROM REAR WORK LT 1&2 RLY:3 /5.C4 FROM DUMP & PARK RELAY:6 /3.E2

0.50 mm† 6000AC

0.50 mm† 6000AE

7212/0060

332/E9928

-IP_C17

-CH_C17

8.00 mm† 6000

1.00 mm† 6000E

FROM

FROM WATER TEMP SENSOR:C /2.F7

ADD WIRE OF 8.00 Sqmm OF WIRE NO:600U2

8.00 mm† 6000U1

2/2

GND

2/2

-CH_SP060

FROM 4WD SW:7 /3.A3 FROM HEAD LAMP HI & LW RLY:6 /5.A1 FROM HEAD LAMP HI & LW RLY:3 /5.B2 FROM FWD & REV RELAY:6 /3.E3 FROM FWD & REV RELAY:3 /3.F5

FROM FLASHER RELAY:6 /5.D3 FROM NEUTRAL START RELAY:6 /1.C4

FROM ACC SUPPLY /1.D6

1.00 mm† 6000L

GND

1.50 mm† 6000E

GND

1.00 mm† 6000D

GND

1.00 mm† 6000B

GND

1.50 mm† 6000A

GND

FROM

1.00 mm† 6000Q FROM

NEW SPLICE IS ADDED

1.00 mm† 6000S

FROM

-CB_SP121

0.50 mm† 6000L

0.50 mm† 6000K

1.00 mm† 6000R

GND

0.50 mm† 6000Z

1.00 mm† 6000P

GND

0.50 mm† 6000J

1.00 mm† 6000N

GND

0.50 mm† 6000H

1.00 mm† 6000K

GND

0.50 mm† 6000G

1.00 mm† 6000J

GND

1.00 mm† 6000F

1.00 mm† 6000H

GND

1.00 mm† 6000D

1.00 mm† 6000F

GND

0.50 mm† 6000C

GND

0.50 mm† 6000B

GND FROM

FROM

GND

0.50 mm† 6000A

GND

1.00 mm† 6000ZZ

FROM

-CH_SP020

FROM

FROM FRONT HORN:2 /3.D7 FROM REAR HORN:2 /3.E7 FROM TRANS. OIL OI PR. SW:2 /2.F7 FROM DUMP SW:2 /3.C7 FROM TRANS DUMP:2 /3.C7 FROM REAR HORN SW:2 /3.C7 FROM 4WD SOLENOID:2 /3.B7 FROM FORWARD SOLENOID:2 /3.F7 FROM REVERSE SOLENOID:2 /3.F7 FROM HYDRA CLAMP:2 /4.C7 FROM TRANS OIL TEMP SW:2 /2.D7 FROM SPEED SENSOR:1 /2.E2

FROM HEAD LAMP RH:4 /5.A8 FROM FRONT WORK LT RH-I:2 /6.F7 FROM FRONT WORK LT LH-I:2 /6.F7

CRIMP BOTH THE WIRE 600 & 600U2 ON RING TERMINAL M10 CH_C24

FROM HEAD LAMP LH:4 /5.B8

-CH_C24

GND

FROM

FROM COLD START ADVANCE SOL:2 /4.B7

7207/1510

GND

FROM

FROM EGR VALVE:4 /4.F7

FROM NO PLATE LAMP LH:2 /5.E8

1.00 mm† 6000V

0.50 mm† 6000M

FROM

0.50 mm† 6000U

0.50 mm† 6000N

FROM

GND

FROM

FROM ENG. OIL PRE. SW:2 /2.E7

M10

-GND4

-CB_SP120

FROM

FROM REAR COMBI LAMP RH:3 /5.E8 FROM RH RR WORK LT-1:2 /5.D8 FROM RH RR WORK LT-II:2 /5.C8 FROM LH RR WORK LT-II:2 /5.C8 FROM LH RR WORK LT-I:2 /5.C8 FROM REAR COMBI LAMP LH:3 /5.D8 FROM INTERIOR LIGHT:1 /1.B3

FROM MUSIC SYSTEM:7 /6.D3

FROM

GND ADD WIRE OF 1.00 Sqmm OF WIRE NO:600S

-IP_SP282 CRIMP BOTH THE WIRE 600 & 600S ON RING TERMINAL M6 CB_C15 M6

7207/1323

-CB_C15

-GND3

C-19

335-Y3467-7

Fig 7. 335/Y3467 (Sheet 7 of 7)

Electrical Circuit - 3DX

FROM IGN RELAY IP_C27:6 /1.E2

1.00 mm† 6000M

FROM

FROM AIR CLEANER:2 /2.D7

Circuit Schematics

FROM IGN RELAY IP_C26:6 /1.E4

GND

FROM

FROM WATER IN FUEL SW.:C /2.D7

Section C - Electrics

FROM REVERSE FLASHER RELAY:4 /3.E6

1.00 mm† 6000G

GND FROM

FROM

1.00 mm† 6000E

GND FROM

FROM

1.00 mm† 6000P

8.00 mm† 6000ZZ

FROM REAR WORK LT 1&2 RLY:6 /5.B3

GND

FROM

1.00 mm† 6000W

-IP_SP281

FROM

FROM ESOS:2 /4.A4

10.00 mm† 6000

9813/2050-5

FROM RS232:2 /4.E7

FROM

1.00 mm† 6000Y

3.00 mm† 6000YY

FROM PARK BRAKE SW:2 /3.E3

GND

FROM

1.00 mm† 6000AB

-IP_SP280

FROM

6.00 mm† 6000

FROM REAR WORK LIGHT SW:7 /5.C3

FROM

0.50 mm† 6000AA

3.00 mm† 6000XX

FROM FRONT WORK LT 1 & 2 RLY:3 /6.F4

GND FROM

GND

1.00 mm† 6000Z

2.50 mm† 6000AA

FROM WARNING CLUSTER:3 /2.A7

1.00 mm† 6000W

Section C - Electrics Circuit Schematics Electrical Circuit - 3DX

From Serial Number â&#x20AC;&#x201C; 1828001 to 1899999

Fig 8.

C-20

9813/2050-5

C-20

Section C - Electrics Circuit Schematics Electrical Circuit - 3DX

Fig 9.

C-21

9813/2050-5

C-21

C-22

Electrical Circuit - 3DX Xtra, 3DX Super and 4DX From Serial Number â&#x20AC;&#x201C;

1491201 to 1502999 (3DX Xtra / 3DX Super) and 1415101 to 1416999 (4DX)

9813/2050-5

Section C - Electrics

Circuit Schematics

Electrical Circuit - 3DX Xtra, 3DX Super and 4DX

C-22

D070880-01

Fig 10. 334/Y7150 sheet 1

C-23

9813/2050-5

Section C - Electrics Circuit Schematics D070880-02

C-23

Electrical Circuit - 3DX Xtra, 3DX Super and 4DX

Fig 11. 334/Y7150 sheet 2

C-24

9813/2050-5

Section C - Electrics Circuit Schematics D070880-03

C-24

Electrical Circuit - 3DX Xtra, 3DX Super and 4DX

Fig 12. 334/Y7150 sheet 3

C-25

9813/2050-5

Section C - Electrics Circuit Schematics D070880-04

C-25

Electrical Circuit - 3DX Xtra, 3DX Super and 4DX

Fig 13. 334/Y7150 sheet 4

C-26

9813/2050-5

Section C - Electrics Circuit Schematics D070880-05

C-26

Electrical Circuit - 3DX Xtra, 3DX Super and 4DX

Fig 14. 334/Y7150 sheet 5

C-27

9813/2050-5

Section C - Electrics Circuit Schematics D070880-06

C-27

Electrical Circuit - 3DX Xtra, 3DX Super and 4DX

Fig 15. 334/Y7150 sheet 6

C-28

9813/2050-5

Section C - Electrics Circuit Schematics D070880-07

C-28

Electrical Circuit - 3DX Xtra, 3DX Super and 4DX

Fig 16. 334/Y7150 sheet 7

C-29

9813/2050-5

Section C - Electrics Circuit Schematics D070880-08

C-29

Electrical Circuit - 3DX Xtra, 3DX Super and 4DX

Fig 17. 334/Y7150 sheet 8

Section C - Electrics Circuit Schematics Harness Data - 3DX

Harness Data - 3DX From Serial Number â&#x20AC;&#x201C; 1828001 to 1899999

C-30

9813/2050-5

C-30

Section C - Electrics Circuit Schematics Harness Data - 3DX Maxi Fuses Harness

Fig 18.

C-31

9813/2050-5

C-31

Section C - Electrics Circuit Schematics Harness Data - 3DX Chassis Harness

Fig 19. To 1828000

C-32

9813/2050-5

C-32

C-33

9813/2050-5

Fig 20. (1828001 to 1833426)

Section C - Electrics Circuit Schematics Harness Data - 3DX

C-33

Section C - Electrics Circuit Schematics Harness Data - 3DX Cab Harness - 2WD

Fig 21.

C-34

9813/2050-5

C-34

Section C - Electrics Circuit Schematics Harness Data - 3DX Panel Harness 4WD

Fig 22.

C-35

9813/2050-5

C-35

C-36

9813/2050-5

C-36

Harness Data - 3DX

Circuit Schematics

Section C - Electrics

Fig 23. (1828001 to 1833426)

C-37

Harness Data - 3DX Xtra, 3DX Super and 4DX From Serial Number â&#x20AC;&#x201C; 1486501 to 1502999 and 1414001 to 1416999

Chassis Harness

9813/2050-5

Section C - Electrics

Circuit Schematics

C-37

Harness Data - 3DX Xtra, 3DX Super and 4DX

D070870-01

Fig 24. 334/Y4606

C-38

Panel Harness

D070870-02

9813/2050-5

Fig 25. 334/Y4607

Section C - Electrics Circuit Schematics Harness Data - 3DX Xtra, 3DX Super and 4DX

C-38

C-39

D070870-06

9813/2050-5

Fig 26. 334/Y7355 (3DX Xtra Base)

Section C - Electrics Circuit Schematics Harness Data - 3DX Xtra, 3DX Super and 4DX D070870-07

C-39

Fig 27. 334/Y7356 (3DX Super)

C-40

9813/2050-5

D070870-08

Section C - Electrics Circuit Schematics

C-40

Harness Data - 3DX Xtra, 3DX Super and 4DX

Fig 28. 334/Y7358 (3DX Super Servo and AC)

C-41

Roof Harness

9813/2050-5

Section C - Electrics Circuit Schematics D070870-03

C-41

Harness Data - 3DX Xtra, 3DX Super and 4DX

Fig 29. 333/Y8485

C-42

Maxi Fuse Harness

9813/2050-5

D070870-04

Section C - Electrics Circuit Schematics

C-42

Harness Data - 3DX Xtra, 3DX Super and 4DX

Fig 30. 40/302817

C-43

Rear Horn Pigtail

Fig 31. 334/Y7733

D070870-05

9813/2050-5

Section C - Electrics Circuit Schematics Harness Data - 3DX Xtra, 3DX Super and 4DX

C-43

Section C - Electrics Circuit Schematics Harness Data - 3DX Xtra, 3DX Super and 4DX

Page left intentionally blank

C-44

9813/2050-5

C-44

C-45

Fuses

9813/2050-5

C-45

Fuses

Section C - Electrics

Fig 1.

Section C - Electrics Fuses Fuses

Fuses Fuses (3DX Standard without Livelink)

D071120-09

Fig 2.

C-46

9813/2050-5

C-46

Section C - Electrics Fuses Fuses

Fuses (3DX Xtra, Super and 4DX with Livelink)

D071120-08

Fig 3.

C-47

9813/2050-5

C-47

Section C - Electrics Fuses Relays

Relays Relays (3DX Standard)

D071120-10

Fig 4.

Relays (3DX Xtra, Super and 4DX with Livelink, Servo and Engine Auto Stop)

D071120-07

Fig 5.

C-48

9813/2050-5

C-48

Section C - Electrics

Livelink Removal and Replacement Removal 1

Park and make the machine safe in accordance with the machine handbook instructions. Stop the engine and let it cool down.

Remove the loader control cover assembly.

Get access to the livelink ECU unit B.

Remove all the electrical connection from the unit.

Remove the four bolts A that attaches the livelink unit B.

Remove the livelink ECU unit B.

A B

D071090-01

Fig 1.

Replacement Replacement is the reverse of the removal procedure.

C-49

9813/2050-5

C-49

Section C - Electrics Livelink VIN Flashing

VIN Flashing 1

Park and make the machine safe in accordance with the machine handbook instructions.

Turn the ignition key to ON position.

Connect the servicemaster to a laptop with a DLA cable.

Open servicemaster and click on the other tab A.

D071090-04

Fig 4. 7

To flash the actual 17 digit VIN number first click on the write button D and then on the read button E.

D071090-02

Fig 2. 5

Click on the livelink icon B.

D071090-05

Fig 5. 8

The servicemaster must read the VIN number and display the number in the VIN tab F. K Fig 5. ( T C-50).

Take a screen shot and store the screen shot, as a document.

Send the document to the head office of the livelink department.

9813/2050-5

C-50

D071090-03

Fig 3. 6

Click on the livelink 2 setup icon C.

C-50

Section C - Electrics Livelink Diagnostics Process

Diagnostics Process 1

Park and make the machine safe in accordance with the machine handbook instructions.

Turn the ignition key to ON position.

Connect the servicemaster to a laptop with a DLA cable.

Open servicemaster and click on the other tab A.

D071090-06

Fig 8. 7

Click on the start button D.

D071090-02

Fig 6. 5

Click on the livelink icon B.

D071090-07

Fig 9. 8

Check the firmware and firmware version E as FW7.0.0. or above. K Fig 9. ( T C-51).

Check the other informations F, such as VIN, machine battery voltage, LLECU serial number and backup battery charge. K Fig 9. ( T C-51).

Take a screen shot and store the screen shot, as a document.

9813/2050-5

C-51

D071090-03

Fig 7. 6

Click on the livelink 2 diagnostics icon C to open the diagnostic tool window. K Fig 8. ( T C-51).

C-51

Section C - Electrics Livelink Diagnostics Process 11

Click on the advanced parameter tab G and wait for five minutes to get the GPS fix.

D071090-08

Fig 10. 12

Green LED H will illuminate in the GPS parameters, when the machine get the GPS fix. K Fig 10. ( T C-52).

Check the all K Fig 10. ( T C-52).

Make sure the IP address in the GPRS parematers is 59.162.104.57.

Note down the VIN, IMSI, IMEI numbers and mail to JCB command center for the SAP updation.

Take a screen shot and store the screen shot, as a document.

Run the engine for minimum 15 minutes.

C-52

GRPS

parameters

9813/2050-5

C-52

Section D Controls Service Manual - 3DX / 4DX Backhoe Loader Section 1 - General Information Section 2 - Operator’s Manual Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine

Publication No.

9813/2050-5

Section D - Controls

Notes:

D-0

9813/2050-5

D-0

Section D - Controls Contents Page No. Controls Steering column ....................................................................................... D-1 Dismantling and Assembly ................................................................... D-2 Dismantle and Assemble .......................................................................... D-3 Loader Valve Controls .......................................................................... D-3 Excavator Valve Controls ..................................................................... D-5 Auxiliary Foot pedal Control ................................................................. D-7 Loader Control Knob ................................................................................ D-9 Dismantling and Assembly ................................................................... D-9 Stabiliser Controls Removal and Installation ........................................................................ D-11 Removal ............................................................................................. D-11 Installation .......................................................................................... D-12

D-i

Section D - Controls Controls Steering column

Controls Steering column

Fig 1.

D-1

9813/2050-5

D-1

Section D - Controls Controls Steering column

Dismantling and Assembly

Apply Lock and Seal to the threads of bolts 16 before fitting them.

The numerical sequence shown on the illustration is intended as a guide to dismantling K Fig 1. ( T D-1). For assembly the sequence should be reversed.

When Dismantling Remove the front instrument housing and the steering column pedestal cover to gain access to the steering column. Note the electrical connections before disconnecting the components mounted on the housing. Bend back retaining tabs to permit removal of upper bearing 14. To remove the steering column complete, remove bolts 11 and slacken nut 16. Then withdraw the column from the flexible coupling. When Assembling Note: To avoid excessive side loading on the steer valve, assemble the steering column 13, flexible coupling 26, extension shaft 24 and the steer valve with a minimum of misalignment before tightening securing bolts 11 and clamps 16 and 25. Press in bearing 15 until flush with end of outer column, and bearing 14 until it can be secured by the retaining tabs. Achieve minimum end-float (maximum permissible 2.0mm 0.08in.) by selecting groove in space 9 (see note). Fit additional spacing washers 19 above set pin 18, if necessary. Note: Tension pin 8 must be fitted offset so that one end engages with the direction indicator automatic cancel button. Make sure that the extension shaft 24 is correctly installed in the flexible coupling 26. The coupling bolt 25 must be engaged with the cut-out in the shaft, shown at B. Remove all dirt etc. from the spindle socket of steering valve A before fitting the column assembly. Install E-clip 23 as close as possible to the splines on extension shaft 24. Insert the extension shaft spline into the steer valve splined socket. Make sure that there is a 0.5 to 1.5 mm(0.020 to 0.060 in) gap between the splines shaft and socket, shown at C. The shaft must not touch the bottom of the splined socket.

D-2

9813/2050-5

D-2

Section D - Controls Controls Dismantle and Assemble

Dismantle and Assemble Loader Valve Controls

F X

D070930-04

Fig 2.

D-3

9813/2050-5

D-3

Section D - Controls Controls Dismantle and Assemble The illustration shows the control rods and linkages for a 3 spool loader control valve, and is intended as a guide to the dismantling and assembly.

Connect the battery, check the controls and transmission dump switch operate correctly.

Refit the console panels around the loader levers.

Dismantle 1

Park the machine on firm level ground, apply the parking brake. Lower the loader arms and excavator to the ground, switch OFF the engine and remove the starter key. Disconnect the battery K Fig 2. ( T D-3).

Working in the cab, remove the console panels surrounding the loader levers as shown at A.

Uncouple the transmission dump switch electrical connector and remove the wires from the connector. Use a screwdriver to release the wires and pins from the connector, alternatively cut the wires and resolder on assembly.

Remove the control lever knobs and gaiters.

Disconnect the control rods from the loader valve spools. Remove the bolts securing the complete lever assembly to the chassis and withdraw the control levers and mounting bracket through the floor aperture.

Note: Make sure there is an equal amount of thread at each end of the control rod. 1

Adjust the auxiliary controls rod H until the auxiliary lever E aligns with loader lever D, then tighten the control rod lock nuts.

Assembly Assembly is the reverse of the dismantling sequence. 1

Bolt the mount bracket A to the chassis.

Assemble the loader lever D and auxiliary lever E together, with washer and retaining clip as shown.

FIt the control rod F, G and H to the lever assembly.

Note: If necessary, loosen the lock nut and rotate the fitting to give equal amounts of adjustment (thread) at each end of the control rod. 4

Fit the lever assembly to the mounting plate A.

Adjust the control rods as necessary. After the control rods are adjusted fit the gaiters over the control levers.

Thread the transmission dump switch cable through the loader control lever and fit the wires/pins into the electrical connector to the chassis harness and fit the control lever knobs.

D-4

9813/2050-5

D-4

Section D - Controls Controls Dismantle and Assemble

Excavator Valve Controls

E C F F

C003210

Fig 3.

D-5

9813/2050-5

D-5

Section D - Controls Controls Dismantle and Assemble The illustration shows the control rods and linkages for the excavator control valve and is intended as a guide to the dismantling and assembly.

Dismantle 1

Park the machine on firm level ground, apply the parking brake. Lower the loader arms, side shift the excavator to the R.H. side of the machine and lower to the ground. Switch OFF the engine and remove the starter key. Disconnect the battery. Uncouple the rear horn switch electrical connector and remove the wires from the connector. Use a screwdriver to release the wires and pins from the connector, alternatively cut the wires and re-solder on assembly.

Note: Some machine variants may have additional switches in the control lever knobs which will also need to be uncoupled as above. 3

Working in the cab, remove the control lever knobs and gaiters. Lift off the cover A surrounding the excavator levers.

Disconnect the control rods from the excavator valve spools. Remove the bolts securing the complete lever assembly to the excavator valve mounting plate and withdraw the control levers and mounting bracket through the floor aperture.

be 395 mm (15.55 in) between hole centres, adjust as required. Feed the control rods through the rubber seal D and connect to the excavator levers. 4

Connect the control rods to the excavator valve spools with the clevis pins G.

Adjust the control rods if necessary. Refit the cover and the gaiters over the control levers.

Thread the rear horn switch cable through the control lever and fit the wires and pins into the electrical connector. Couple the connector to the chassis harness and fit the control lever knobs.

Connect the battery, check that the controls and rear horn switch operate correctly.

Adjustment Minor adjustment of the control rods may be necessary to align the levers, or to position the levers closer or further from the operator. After adjustment operate the levers and check that there is sufficient travel to give full movement of the excavator valve spools.

Assemble Assembly is the reverse of the dismantling sequence. 1

Bolt the mounting bracket B to the excavator valve mounting plate K Fig 3. ( T D-5).

Assemble the stabiliser levers C to the mounting bracket. Measure the stabiliser lever control rods (2 off) which should be 370 mm (14.57 in) between hole centres, adjust as required. Feed the control rods through the rubber seal D and connect to the stabiliser levers.

Note: If necessary, loosen the lock nuts and rotate the end fittings to give equal amounts of adjustment (thread) at each end of the control rod. 3

D-6

Assemble the excavator levers E to the mounting bracket together with the universal joints F. Measure the excavator lever control rods (4 off) which should

9813/2050-5

D-6

Section D - Controls Controls Dismantle and Assemble

Auxiliary Foot pedal Control

F G

G C

D B

D070930-05

Fig 4.

D-7

9813/2050-5

D-7

Section D - Controls Controls Dismantle and Assemble sufficient pedal travel to give full movement of the auxiliary valve spool.

The illustrations show the control rods and linkages for the auxiliary control valve and are intended as a guide to the dismantling and assembly.

Dismantle 1

Working at the rear of the machines at the auxiliary valve, remove the clevis clips A and disconnect the lower control rod B from the valve spool.

Undo the lock nut C disconnect the upper control rod from the lever D.

Remove the lock nuts E (3 off) securing the foot pedal assembly in to the cab floor.

Working in the cab, withdraw the foot pedal assembly with the upper control rod attached from the aperture in the cab floor.

Assembly Assembly is the reverse of the dismantling sequence. When assembly check the lever D rotate freely on the pivot and is not seized. Adjust the control rods, After adjustment, operate the foot pedal and check that the auxiliary valve functions correctly. 1

Adjust the length of the lower control rod B so that the lever D is horizontal.

Note: If necessary, loosen the lock nuts and rotate the end fittings to give equal amounts of adjustment (thread) at each end of the control rod. 2

D-8

Screw the rod adjusting nut G to set the pedal travel. Depress the heel end of the pedal and check there is

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D-8

Section D - Controls Controls Loader Control Knob

Loader Control Knob Same machines are fitted with a microswitch, which energizes the transmission dump solenoid.

Dismantling and Assembly The numerical sequence show on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

When dismantling 1

To gain access to the micro switch gently prise off the top cover 1 K Fig 5. ( T D-9).

Disconnect the wiring harness 2.

Remove locknut 3 and shakeproof washer micro switch 4, adapter 5, and rubber cover 6 may now be withdrawn through the knob.

When Assembly Apply JCB lock and seal to micro switch adapter 5, prior to assembly. Note: Microswitch 5 is a non- service item and must be replaced as an assembly.

Fig 5.

D-9

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D-9

Section D - Controls Controls Loader Control Knob

Page left intentionally blank

D-10

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Section D - Controls Stabiliser Controls Removal and Installation

Stabiliser Controls Removal and Installation There are two control cables which operate the R.H. and L.H. stabiliser control valves on the excavator valve block.

D070920-18

Fig 6.

Removal 1

Park the machine on firm level ground, apply the parking brake. Lower the loader arms and excavator to the ground, switch OFF the engine and remove the starter key.

Working under the machine at the excavator valve, loosen the locknut A.

D-11

Remove the clevis pin to release the cable clevis B from the spool.

Working in the cab, remove the four bolts C that attaches the stabiliser mounting bracket D to the floor.

Pull the stabiliser controls E out and remove the three bolts F and nuts G from the stabiliser mounting bracket D.

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D-11

Section D - Controls Stabiliser Controls Removal and Installation 6

Remove the stabiliser controls E and the control cables H.

After fitting the cable(s), operate the controls and check that the stabilisers function correctly.

Installation Installation is the reverse of the removal sequence.

C G

F E C

B D070920-19

Fig 7.

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D-12

Section E Hydraulics Service Manual - 3DX / 4DX Backhoe Loader Section 1 - General Information Section 2 - Operator’s Manual Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine

Publication No.

9813/2050-5

Section E - Hydraulics

Notes:

E-0

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E-0

Section E - Hydraulics Contents Page No. Technical Data Machine Hydraulics .................................................................................. E-1 Hydraulic Pump Flow and System Pressure ............................................ E-2 Gear Pump ............................................................................................... E-3 Loader Valve Block ................................................................................... E-4 Main Relief Valve .................................................................................. E-4 Excavator Valve Block ............................................................................. E-5 Backhoe ............................................................................................... E-5 Gear Pump ............................................................................................... E-6 Loader Valve Block ................................................................................... E-7 Main Relief Valve .................................................................................. E-7 Excavator Valve Block ............................................................................. E-8 Backhoe ............................................................................................... E-8 Attachments ......................................................................................... E-9 Basic System Operation Introduction to Hydraulic Schematic Symbols ........................................ E-10 General (Basic and Functional Symbols) ........................................... E-10 Control Valves .................................................................................... E-14 Example of Schematic Circuit ............................................................ E-15 Component Location and Neutral Circuit Descriptions ........................... E-16 Gear Pump - Double Pump ................................................................ E-16 Hydraulic Schematics 3DX BSIII with JCB Ecomax Engine ...................................................... E-18 From Serial Number ........................................................................... E-18 From Serial Number ........................................................................... E-19 3DX Xtra, 3DX Super and 4DX .............................................................. E-21 From Serial Number ........................................................................... E-21 Hydraulic Pump Gear Pump - Operation .......................................................................... E-31 Single Pump - Operation .................................................................... E-31 Double Pump ...................................................................................... E-31 Machines from Serial no. 964125 (High Pressure) ............................ E-32 Unloader Valve ................................................................................... E-34 Main Relief Valve (MRV) - Operation ................................................. E-35 Main Relief Valve (MRV) .................................................................... E-37 Loader Valve - Neutral Circuits ............................................................... E-38 Neutral Circuit ..................................................................................... E-38 Unloader Operation (If fitted) .............................................................. E-39 Hydraulic Speed Control (HSC) .......................................................... E-41 Load Hold Check Valves .................................................................... E-43 Arms Lower Operation ....................................................................... E-45 Float ................................................................................................... E-45 Auxiliary Relief Valve .......................................................................... E-47 Main Relief Valve (MRV) Operation .................................................... E-49

E-i

Section E - Hydraulics Contents

Contents Page No. Excavator Valve ...................................................................................... E-52 Neutral Circuit ..................................................................................... E-52 Excavator Valve .................................................................................. E-54 One Way Restrictor ............................................................................ E-54 Excavator Valve - Slew Operation ...................................................... E-55 Slew Ram End Damping .................................................................... E-57 Slew A.R.V. and Anti-Cavitation Operation ........................................ E-58 Excavator Valve - A.R.V. Operation .................................................... E-59 Auxiliary Relief Valve Operation ......................................................... E-60 Auxiliary Relief Valve - Anti-Cavitation ............................................... E-61 Excavator Valve - Dipper Make-Up Check Valve and Anti-Cavitation Operation .................................................................................................... E-62 Hydraclamp (Sideshift Machines) ....................................................... E-63 Service Procedures Hydraulic Contamination ........................................................................ E-65 Hydraulic Fluid Quality ....................................................................... E-65 Effects of Contamination .................................................................... E-65 Cleaning Operation ............................................................................ E-65 Contaminant Standards ...................................................................... E-66 Filters .................................................................................................. E-66 Connecting/Disconnecting Hydraulic Hoses ........................................... E-67 Introduction ......................................................................................... E-67 Connecting the Hydraulic Hoses ........................................................ E-67 Disconnecting the Hydraulic Hoses .................................................... E-68 Quick Release Couplings ................................................................... E-69 Hydraulic Pump ...................................................................................... E-71 Flow and Pressure Testing ................................................................. E-71 Loader Valve (Unloader valve) ........................................................... E-73 Shovel Ram Rod Side A.R.V. Pressure Testing ................................. E-74 Removal and Replacement ................................................................ E-75 Dismantling, Inspection and Assemble .............................................. E-76 Loader Valve - Pressure Testing ............................................................. E-79 Main Relief Valve (M.R.V.) .................................................................. E-79 Unloader Valve ................................................................................... E-80 Hydraulic Speed Control (HSC) .......................................................... E-81 Auxiliary Relief Valves - Using Hand Pump ........................................ E-82 Excavator Valve - Pressure Testing ........................................................ E-87 Auxiliary Relief Valves - Using Hand Pump ........................................ E-87 Ram Creep Tests - All Services .............................................................. E-88 Valve Block Spool Seals ......................................................................... E-94 Seal Fitting - 3DX ............................................................................... E-94 Seal Fitting - 3DX ECO ...................................................................... E-97 Hydraclamp Valve - Dismantling and Assembly ............................... E-101 Hydraulic Adaptors (Positional Type) ................................................... E-103 Fitting Procedure .............................................................................. E-103 Loader Valve Removal and Replacement .................................................................. E-104 Removal ........................................................................................... E-104 Replacement .................................................................................... E-104

E-ii

Section E - Hydraulics Contents

Contents Page No. Dismantle and Assemble ...................................................................... E-106 Main Relief Valve (MRV) .................................................................. E-106 Auxiliary Relief Valves (ARV) and Load Hold Check Valves (LHCV) E-108 Unloader Valve ..................................................................................E-110 Standard Spool ..................................................................................E-112 Float Spool ........................................................................................E-114 Electric Detent Spool .........................................................................E-116 Loader Valve Component Identification ....................................................................... E-118 3DX Xtra and 4DX .............................................................................E-118 3DX Super .........................................................................................E-119 Removal and Installation ...................................................................... E-122 Removal ........................................................................................... E-122 Installation ........................................................................................ E-122 Dismantle and Assemble ...................................................................... E-123 Main Relief Valve (MRV) .................................................................. E-123 Unloader Valve ................................................................................. E-123 Open End Kit .................................................................................... E-123 Excavator Valve Removal and Replacement .................................................................. E-125 Dismantle and Assemble ...................................................................... E-127 Valve Block ....................................................................................... E-127 Auxiliary Relief Valves (ARV's) ......................................................... E-130 Hydraclamp Valve (Sideshift Machines) ........................................... E-132 Hoses and Pipes (Sideshift Valve) ................................................... E-134 Hoses and Pipes (Centremount Valve) ............................................ E-135 Excavator Valve Description ............................................................................................ E-137 For 3DX Xtra, 3DX Super (Base and AC) ........................................ E-137 For 3DX Xtra and 3DX Super (Servo) .............................................. E-139 4DX .................................................................................................. E-141 Removal and Replacement .................................................................. E-143 Sideshift Machine ............................................................................. E-143 Dismantle and Assemble ...................................................................... E-144 Valve Block ....................................................................................... E-144 Servo Joysticks Description and Operation .................................................................... E-149 Description ....................................................................................... E-149 Operation .......................................................................................... E-149 Removal and Replacement .................................................................. E-150 Removal ........................................................................................... E-150 Replacement .................................................................................... E-150 Hydraulic Rams Precautions During Use ........................................................................ E-153 Installation ........................................................................................ E-153 Caution During Use .......................................................................... E-153 Maintenance, Inspection Points ....................................................... E-153

E-iii

Section E - Hydraulics Contents

Contents Page No. Removal and Replacement .................................................................. E-155 Loader Shovel Ram .......................................................................... E-155 Loader Lift Ram ................................................................................ E-157 Bucket Crowd Ram .......................................................................... E-160 Dipper Ram ...................................................................................... E-162 Boom Ram ....................................................................................... E-164 Slew Ram ......................................................................................... E-166 Stabiliser Ram (Sideshift) ................................................................. E-169 Priority Valve .................................................................................... E-170 JCB Ram Sealing Procedure ........................................................... E-172 Assembly and Disassembly .................................................................. E-174 Typical Ram ...................................................................................... E-174 Slew Ram ......................................................................................... E-181 Fault Finding Introduction ........................................................................................... E-191

E-iv

Section E - Hydraulics Technical Data Machine Hydraulics

Technical Data Machine Hydraulics Machine

Table 1. 3DX BSIII and 3DX Xtra 3DX BSIII 3DX Xtra (1888500 (1494400 to to 1502999) 1899999)

Recommended Hydraulic Fluid

JCB Standard 4002/1000 or 4002/08000

Recommended Oil Charge Interval

2000 Hour - Tank oil and 4000 hrs Complete system oil

Recommended charge interval for filter Element

500 hours Maximum

ISO Cleanliness Standard on brand New System

16/13

Total System Capacity

120 litres (Tank - 70 litres)

Maximum allowable Water content

0.1%

By pass valve setting of return Line filter

1.5 Bar

Breather assembly - Outer valve Intlet

0.34 to 0.35 bar

Inlet valve

0.02 to 0.04 bar

Working temperature of Hydraulic Fluid Intermittent

1600 C Maximum

Continuous (in Excavation)

800 C Maximum

Recommended Engine RPM for Low Idle (+/- 50RPM)

900 RPM

Recommended Engine RPM for Hand Throttle (+/- 50RPM)

1550 RPM

Micron Rating of filter Element

10 microns

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E-1

Section E - Hydraulics Technical Data Hydraulic Pump Flow and System Pressure

Hydraulic Pump Flow and System Pressure Machine

Table 2. 3DX BSIII and 3DX Xtra 3DX BSIII (1888500 to 1899999)

3DX Xtra (1494400 to 1502999)

Model

Double pump

Steering pump

Seperate Steering pump

Main pump flow (P1:P2) CC

33:21 CC

29:29 CC

Pressure (P1/P2) Bar

227/207

250/227

Steering pump flow (CC) (i = 1.625)

14 CC

Steering pressure (Bar)

125

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E-2

Section E - Hydraulics Technical Data Gear Pump

Gear Pump Table 3. 3DX BSII

Hydraulic Pumps (Parker) Model/ Reference

Double Pump (9-81377-3DX)

Rotation

Anti-clockwise

Mounting

Chassis (driveshaft driven)

Flow at 2200 rev/mm and system pressure at 500 C

23:23 cc - 101 litres

Maximum Working Pressure

see- Relief valve Operating Pressures

Hydraulic Pumps (Parker)

3DX After 1855501

Table 4. 3DX BSIII 3DX Xtra To 1855500

3DX Super India

3DX Super Export

4DX

Model/ Reference

Double Pump (onwards)

Rotation

Anticlockwise

Mounting

Gearbox

29:21cc 110 litres

33:23 cc 123 litres

23:23 cc 101 litres

33:23 cc 123 litres

37:33 cc 154 litres

Flow at 2200 rev/mm and system 33:21cc pressure at 500C 118.8 litres Maximum Working Pressure

E-3

see- Relief valve Operating Pressures

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E-3

Section E - Hydraulics Technical Data Loader Valve Block

Loader Valve Block Main Relief Valve Operating Pressures @1500 RPM

Table 5. Bar

kg/cm2

lb/in2

3DX (upto9-815777)

207

211

3000

3DX (9-815777onwards)

228

233

3300

3DX Xtra

245

251

3600

4DX

228

233

3300

Unloader Valve

Table 6. Bar

kg/cm2

lb/in2

3DX BSII

207

211

3000

3DX BSIII

207

211

3000

3DX Xtra

221

226

3200

3DX Super

207

211

3000

4DX

207

211

3000

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Section E - Hydraulics Technical Data Excavator Valve Block

Excavator Valve Block Backhoe Table 7. Auxiliary Relief Valve (A.R.V.)

bar

kg/cm2

Ib/in2

Boom Ram Head Side

241-255

246-260

3500-3700

Boom Ram Rod Side

303-317

309-323

4400-4600

Bucket Ram Head Side

303-317

309-323

4400-4600

Bucket Ram Rod Side

241-255

246-260

3500-3700

Dipper Ram Head Side

241-255

246-260

3500-3700

Dipper Ram Rod Side

241-255

246-260

3500-3700

Slew Left and Right

255-269

260-274

3700-3900

Attachments

Extradig Ram Head Side

Table 8. *207-220

211-225

3000-3200

Jaw Bucket Ram Head Side

138-145

141-148

2000-2100

Jaw Bucket Ram Rod Side

207-214

211-218

3000-3100

Knuckle Ram Head Side

138-145

141-148

2000-2100

Knuckle Ram Rod Side

207-214

211-218

3000-3100

Hammermaster

207-214

211-218

3000-3100

Roadbreaker

*138-150

141-153

2000-2200

Sequence valve

300

Return Line Filter Table 9. By-Pass pressure - 3DX

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1.4

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E-5

Section E - Hydraulics Technical Data Gear Pump

Gear Pump Hydraulic Pumps (Parker)

Table 10. 3DX 3DX Xtra 3DX Super 4DX (1855501 to 189999) (Base + Servo + (Base + Servo + (Base + Servo + AC) AC) AC) (1491201 to (1491201 to (1415101 to 1502999) 1502999) 1416999) Standard and Servo

Model / Reference

Duble Pump

Rotation

Anticlock wise

Mounting

Gear box

Flow at 2200 rev/mm

33:21 cc 118.8 Litres

E-6

29:29 cc 127.6 Litres

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33 :21 cc 116.6 Litres

37:33 cc 154 Litres

E-6

Section E - Hydraulics Technical Data Loader Valve Block

Loader Valve Block Main Relief Valve Table 11. Machine Serial Number Range

bar

3DX

(1855501 to 189999)

3DX Xtra ( Base + Servo + AC )

(1491201 to 1502999)

3DX Super ( Base + Servo + AC ) 4DX ( Base + Servo + AC )

Relief Valve Pressure

Unloader Valve

kg/cm2

lb/in2

227

231

3292

250

255

3626

(1491201 to 1502999)

227

231

3292

(1415101 to 1416999)

227

231

3292

Table 12. Machine Serial Number bar Range

kg/cm2

lb/in2

3DX

(1855501 to 189999)

207

211

3002

3DX Xtra ( Base + Servo + AC )

(1491201 to 1502999)

225

229

3263

3DX Super ( Base + Servo + AC ) (1491201 to 1502999)

207

211

3002

4DX ( Base + Servo + AC )

207

211

3002

Auxiliary Relief Valve (A.R.V.)

(1415101 to 1416999) Table 13. 3DX Xtra

3DX Super

4DX

– Shovel Ram Head Side

174 bar (2524 lb/in ) 170 bar (2466 lb/in ) 172 bar (2495 lb/in2)

– Shovel Ram Rod Side

310 bar (4496 lb/in2) 310 bar (4496 lb/in2) 310 bar (4496 lb/in2)

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Section E - Hydraulics Technical Data Excavator Valve Block

Excavator Valve Block Backhoe Auxiliary Relief Valve (A.R.V.) Boom Ram Head Side

Table 14. 3DX Xtra (Base + Servo + AC) bar kg/cm2 260

265

Ib/in2 3771

Boom Ram Rod Side

350

357

5076

Bucket Ram Head Side

260

265

3771

Bucket Ram Rod Side

260

265

3771

Dipper Ram Head Side

260

265

3771

Dipper Ram Rod Side

260

265

3771

Slew Left and Right

260

265

3771

Auxiliary Relief Valve (A.R.V.)

Table 15. 3DX Super (Base + Servo + AC) bar kg/cm2

Ib/in2

Boom Ram Head Side

250

255

3626

Boom Ram Rod Side

310

316

4496

Bucket Ram Head Side

250

255

3626

Bucket Ram Rod Side

250

255

3626

Dipper Ram Head Side

250

255

3626

Dipper Ram Rod Side

250

255

3626

Slew Left and Right

260

265

3771

Auxiliary Relief Valve (A.R.V.)

Table 16. 4DX (Base + Servo + AC) bar kg/cm2

Ib/in2

Boom Ram Head Side

250

255

3626

Boom Ram Rod Side

350

357

5076

Bucket Ram Head Side

250

255

3626

Bucket Ram Rod Side

310

316

4496

Dipper Ram Head Side

250

255

3626

Dipper Ram Rod Side

250

255

3626

Slew Left and Right

260

265

3771

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E-8

Section E - Hydraulics Technical Data Excavator Valve Block

Attachments Extradig Ram Head Side

Table 17. *207-220

211-225

3000-3200

Jaw Bucket Ram Head Side

138-145

141-148

2000-2100

Jaw Bucket Ram Rod Side

207-214

211-218

3000-3100

Knuckle Ram Head Side

138-145

141-148

2000-2100

Knuckle Ram Rod Side

207-214

211-218

3000-3100

Hammermaster

207-214

211-218

3000-3100

Roadbreaker

*138-150

141-153

2000-2200

Sequence valve

300

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E-9

Section E - Hydraulics

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 19. 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 18. General

Double ended

Double acting with damping at rod area end

Table 20. 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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E-10

Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols Table 21. 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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E-11

Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols Table 22. 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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E-12

Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols Table 23. 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)

E-13

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E-13

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-14) 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-14) - 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-14) shows a 'D' type spool.

Fig 2. K Fig 4. ( T E-14) shows a valve described as a 3position, 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-14) - '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-14) - '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-14). 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-14).

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Fig 6.

E-14

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-15). 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.

E-15

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E-15

Section E - Hydraulics Basic System Operation Component Location and Neutral Circuit Descriptions

Component Location and Neutral Circuit Descriptions Gear Pump - Double Pump Oil is drawn from the hydraulic tank T by the hydraulic pump. The pump has two sections, P1 and P2 K Fig 8. ( T E-17). The hydraulic pump is mounted on the rear of the gearbox and is driven by the engine via a drive shaft. Oil from the larger section P1 flows direct to the loader valve 3. Oil from pump section P2, flows to steering priority valve 7, and in neutral circuit flows through the priority valve to the auxiliary valve 5 and then to join the flow from P1 at the loader valve. From the loader valve neutral gallery, oil flows via a high pressure carry-over line 1B to the excavator valve 4. Some of the exhaust oil flows directly back to the tank through an in-tank filter 6, and some of the exhaust oil returns to tank via the hydraulic oil cooler 26. To help prevent excavator dipper ram and loader lift ram cavitation, there is a check valve 13 fitted to the return line. The check valve raises approximately 5 bar (75 lbf/in2) of pressure in the line, which improves the operation of the respective anti-cavitation valves. On side shift machines only, hydra clamp exhaust hose 62 is fitted. The hose connects the hydra clamp spool directly into the exhaust circuit. This prevents the clamps from `locking-up' when the side shifting operation is required. Table 24. Component Key: T

Hydraulic Tank

Hydraulic Pump (main section)

Hydraulic Pump (secondary section)

High Pressure Carry-over

Loader Valve Block

Excavator Valve

Return Line Filter (inside hydraulic tank)

Steer Circuit Priority Valve

Return Line Check Valve

Hydraulic Oil Cooler

Hydra clamp exhaust hose

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E-16

Section E - Hydraulics Basic System Operation Component Location and Neutral Circuit Descriptions

Fig 8.

E-17

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E-17

E-18

Hydraulic Schematics 3DX BSIII with JCB Ecomax Engine From Serial Number â&#x20AC;&#x201C; 1888500 - 1899999

HYDRA CLAMP

SLEW RAM

SHOWEL RAM

LOADER RAM

262 bar

SLE W

3.8 mm 1B

1A 262 bar

3.8 mm

SLEW RAM 4.5 mm

207 bar 310 bar

Steer Cylinder

BOO M

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2B 248 bar

BOOM RAM

LIFT BUCK ET

Unloader

P2 STABILIZER

HPC O

STABILIZER RAM

STABILIZER 310 bar

172 bar

4B 125bar

STABILIZER RAM

227 bar

Steer Valve 200 cc DIPPE R 248 bar

33 cc

14 cc

5B 248 bar

i= 1

DIPPE R RAM

TANKCAP (BR EATHER) OUTLET

RETURNLINE FILTER 10 microns

SUCTION STRAINER 125 micron

HYDRAULIC TANK

E-18

P041950-951

Fig 9. Hydraulic Schematic

Hydraulic Schematics

BUCKET RAM

248 bar

HYDRAULIC OIL COOLER

Section E - Hydraulics

BUCKE T 248 bar

3DX BSIII with JCB Ecomax Engine

i = 1.625

21 cc

â&#x20AC;&#x201C; 1828001 to 1899999

E-19

From Serial Number

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Section E - Hydraulics Hydraulic Schematics

E-19

3DX BSIII with JCB Ecomax Engine

Fig 10.

E-20

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Section E - Hydraulics Hydraulic Schematics

E-20

3DX BSIII with JCB Ecomax Engine

Fig 11.

Section E - Hydraulics Hydraulic Schematics 3DX Xtra, 3DX Super and 4DX

3DX Xtra, 3DX Super and 4DX From Serial Number – 3DX Xtra from 1486501 to 1491201 – 3DX Super from 1486501 to 1491201 – 4DX from 1414001 to 1415101

10 9 30 29

28 6 8

7 12

27 21

23 26

4 26 5 25

14 cc

33 cc 21 cc

13 24

15 18

17 20

D070890-01

Fig 12. 3DX Super (Base)

E-21

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E-21

Section E - Hydraulics Hydraulic Schematics 3DX Xtra, 3DX Super and 4DX Item

Description

Boom Ram

Dipper Ram

Bucket Ram

Stabiliser Ram Left Hand

Stabiliser Ram Right Hand

Slew Ram

Lift Ram

Showel Ram

Hydra Clamp

Main Control Valve

Loader Control Valve

Main Gear Pump

Steering Pump

Hydraulic Oil Cooler

Steering Unit

Hydraulic Tank

Stainer

Pressurized Breather

Return Line Filter

Loader Valve Lift Spool

Loader Valve Bucket Spool

Loader Valve Auxiliary Spool

Bucket Spool

Dipper Spool

Stabilizer Spool

Boom Spool

Slew Spool

Neutral Passage

High Pressure Passage

E-22

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E-22

Section E - Hydraulics Hydraulic Schematics 3DX Xtra, 3DX Super and 4DX

10 9 20

12 30

37 6

22 36

16 26

14 cc

33 cc

21 cc

14 34

2 15 17 23

33 3

D070890-02

Fig 13. 3DX Super (Servo)

E-23

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E-23

Section E - Hydraulics Hydraulic Schematics 3DX Xtra, 3DX Super and 4DX Item

Description

Boom Ram

Dipper Ram

Bucket Ram

Stabiliser Ram Left Hand

Stabiliser Ram Right Hand

Slew Ram

Lift Ram

Showel Ram

Hydra Clamp

Excavator Valve Block

Loader Valve Block

Main Gear Pump

Steering Pump

Hydraulic Oil Cooler

Steering Unit

Hydraulic Tank

Hydrocontrol Joystick Right Hand

Hydrocontrol Joystick Left Hand

Accumulator

Stabiliser Lever Servo

Steer Cylinder

Stainer

Pressurized Breather

Return Line Filter

Boom Joystick

Slew Joystick

Bucket Joystick

Dipper Joystick

Loader Valve Lift Spool

Loader Valve Shovel Spool

Loader Valve Auxiliary Spool

Bucket Spool

Dipper Spool

Stabilizer Spool

Boom Spool

Slew Spool

E-24

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E-24

Section E - Hydraulics Hydraulic Schematics 3DX Xtra, 3DX Super and 4DX

10 9

28 6

12 27 22

1 23 26

26 5

18 25 14 cc

29 cc

14 24 3

15 17 19

D070890-03

Fig 14. 3DX Extra (Base)

E-25

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E-25

Section E - Hydraulics Hydraulic Schematics 3DX Xtra, 3DX Super and 4DX Item

Description

Boom Ram

Dipper Ram

Bucket Ram

Stabiliser Ram Left Hand

Stabiliser Ram Right Hand

Slew Ram

Lift Ram

Showel Ram

Hydra Clamp

Excavator Control Valve

Loader Control Valve

Main Gear Pump

Steering Pump

Hydraulic Oil Cooler

Steering Unit

Hydraulic Tank

Pressure Sensor

Stainer

Pressurized Breather

Return Line Filter

Loader Valve Lift Spool

Loader Valve Bucket Spool

Bucket Spool

Dipper Spool

Stabilizer spool

Boom spool

Slew Spool

E-26

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E-26

Section E - Hydraulics Hydraulic Schematics 3DX Xtra, 3DX Super and 4DX

10 9

30 31 36 6

35 16

34 34

i=1 i = 1.625 14 cc

29 cc

29 5

33 2

15 17 23

D070890-04

Fig 15. 3DX Extra (Servo)

E-27

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E-27

Section E - Hydraulics Hydraulic Schematics 3DX Xtra, 3DX Super and 4DX Item

Description

Boom Ram

Dipper Ram

Bucket Ram

Stabiliser Ram Left Hand

Stabiliser Ram Right Hand

Slew Ram

Lift Ram

Showel Ram

Hydra Clamp

Main Control Valve

Loader Control Valve

Main Gear Pump

Steering Pump

Hydraulic Oil Cooler

Steering Unit

Hydraulic Tank

Hydrocontrol Joystick Right Hand

Hydrocontrol Joystick Left Hand

Accumulator

Stabiliser Lever Servo

Pressure Sensor

Stainer

Pressurized Breather

Return Line Filter

Boom Joystick

Slew Joystick

Bucket Joystick

Dipper Joystick

Loader Valve Lift Spool

Loader Valve Shovel Spool

Bucket Spool

Dipper Spool

Stabilizer Spool

Boom Spool

Slew Spool

E-28

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E-28

E-29

9 26 27

32 5 31 13

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i = 1.625 14 cc

i=1 37 cc

33 cc

29 2

D070890-05

Fig 16. 4DX (Servo)

E-29

Section E - Hydraulics

Hydraulic Schematics

3DX Xtra, 3DX Super and 4DX

14 20

Section E - Hydraulics Hydraulic Schematics 3DX Xtra, 3DX Super and 4DX item

Description

Boom Ram

Dipper Ram

Bucket Ram

Stabiliser Ram Left Hand

Slew Ram

Lift Ram

Showel Ram

Main Control Valve

Loader Control Valve

Main Gear Pump

Steering Pump

Hydraulic Oil Cooler

Steering Unit

Hydraulic Tank

Hydrocontrol Joystick Right Hand

Hydrocontrol Joystick Left Hand

Accumulator

Stabiliser Lever Servo

Stainer

Pressurized Breather

Return Line Filter

Boom Joystick

Slew Joystick

Bucket Joystick

Dipper Joystick

Loader Valve Lift Spool

Loader Valve Shovel Spool

Bucket Spool

Dipper Spool

Stabilizer Spool

Boom Spool

Slew Spool

E-30

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E-30

Section E - Hydraulics Hydraulic Pump Gear Pump - Operation

Hydraulic Pump Gear Pump - Operation Double Pump K Fig 19. ( T E-33). Both sections P1 and P2 operate as described below: The basic principle of the gear pump depends on the meshing of two spur gears A, one of which is engine driven while the other is an idler. Oil is picked up by the gear teeth on the inlet side of the pump and carried around between the teeth and the pump body. As the gears come into mesh, the space carrying the oil is filled by a gear tooth on the mating gear, forcing the oil out of the space and the through the pump outlet.

Fig 17.

Single Pump - Operation K Fig 18. ( T E-31). The hydraulic pump is a gear type. The basic principle of the pump depends on the meshing of the two spur gears A and B, one of which is enginedriven whilst the other is an idler. Oil is picked up on the inlet side of the pump by the gears and carried round between the gear teeth and the pump body. As the gears come into mesh the oil is forced through the pump outlet. Lubrication is provided by the hydraulic oil which is directed around the unit, via special oil ways, by the motion of the meshing gears.

The wear plates B are loaded towards the gears by pressurised oil which is fed to the backs of the wear plates via channels C. This ensures that the clearance between the wear plates and gears is prevented from becoming excessive as outlet pressure rises. The side of each wear plate that faces the gears has two recesses D. The recess on the inlet side of the pump assists the flow of oil into the gear spaces, thus raising the cavitation threshold of the pump. The recess on the outlet side vents oil trapped between meshing gear teeth to prevent compression loads on the bearings. Table 25. Key to Oil Flow and Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation

Fig 18.

E-31

Lock Up

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E-31

Section E - Hydraulics Hydraulic Pump Gear Pump - Operation Table 26. Component Key: A

Spur Gears.

Wear Plates.

Channel.

Recess.

Main Section.

Secondary Section.

Machines from Serial no. 964125 (High Pressure) Relief Valve Pressures: K Fig 19. ( T E-33)

bar

kgf/cm2

lbf/in2

Main Relief Valve (M.R.V.)

248 - 252

253 - 256

3600 - 3650

Unloader Valve

224 - 231

228 - 235

3250 - 3350

Shovel Ram Head Side

172 - 179

176 - 183

2500 - 2600

Shovel Ram Rod Side

310 - 317

316 - 323

4500 - 4600

Auxiliary Relief Valves (A.R.V.)

Important: Relief valves fitted to machines prior to serial no. 964125 cannot be adjusted to the high pressure. Note: Instructions for pressure testing and adjustment are described in Service Procedures, Loader Valve Pressure Testing.

E-32

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E-32

Section E - Hydraulics Hydraulic Pump Gear Pump - Operation

7 9 12

13 10

Fig 19. Component Key: 1

Arms lift service

Unloader solenoid

Shovel service

Auxiliary relief valve

Auxiliary (optional)

Tank port

Pump section 1 - inlet

High pressure carry-over (HPCO) port

Pump section 2 - inlet

Service ports

Pressure test port

Load hold check valve assemblies

Unloader assembly

E-33

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E-33

Section E - Hydraulics Hydraulic Pump Gear Pump - Operation

Unloader Valve Make sure that the hydraulic oil is at working temperature, i.e. 50Â°C (122Â°F). Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure. Make sure that the `hydraulic speed control' and `smooth ride system' facilities are NOT switched on, otherwise the correct unloader valve pressure cannot be obtained. If the machine has a front-mounted roadbreaker, ensure that the roadbreaker control valve lever is in the 'off' position (lever down), otherwise the roadbreaker relief valve will operate and prevent unloader valve pressure from being reached. 1

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector A.

With the engine running at 1500 revs/min, slowly operate arms raise or lower.

Fig 20.

Note: The arms raise or lower service is specified because it has no auxiliary relief valve (A.R.V.). Selecting this service ensures that the pressure vents through the M.R.V. and not an A.R.V. 3

When the service reaches full travel, return the lever to the neutral position. Select the service again, very slowly, the pressure gauge will rise until a step or kick is seen in the rate of change in the pressure increase. This is the start of unloader operation. Keep selecting the service until a sudden sharp increase in pressure is observed with a change of engine sound, this point is the unloader setting and should be as specified in Technical Data.

If the pressure is incorrect, slacken locknut E and adjust cap F. Turn it clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut and check the pressure again. Adjust as required. If the correct pressure cannot be achieved, add or subtract shims as required, refer to Loader Valve - Fixed Flow, Dismantling and Assembly - Unloader Valve.

E-34

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E-34

Section E - Hydraulics Hydraulic Pump Gear Pump - Operation

Main Relief Valve (MRV) - Operation K Fig 21. ( T E-36). The main relief valve (M.R.V.) 3B, situated in the loader valve block, provides control of both loader and excavator pressures. 1

Valve at Rest

The illustration 1 shows a loader service selected by spool 3D causing pressure to rise in the service line and back through the loader valve to the pump via line 1A. The service is operating under light load and the pressure is not sufficient to cause any response in the M.R.V. The main plunger A is held on its seat B by the combined effect of spring C and the pump pressure which enters chamber D through the small drilling E. Pump pressure outside the chamber is not high enough to lift the plunger off its seat. 2

Pilot Valve Opens

If, as shown in view 2, pump pressure rises high enough to force the pilot valve F from its seat (against spring G), the pressure in chamber D is vented into the exhaust gallery H. Unless the pressure continues to rise, plunger A will remain on its seat. 3

Valve Moves off its seat

In view 3, pump pressure at 1A has risen to the setting of the main relief valve but pressure in chamber D has not risen because the seat orifice of pilot valve F is larger than small drilling E and oil is unable to fill the chamber as quickly as it is being exhausted. Pressure acting on the upper faces of main plunger A is therefore greater than the combined force of spring C and the pressure in chamber D. The plunger then moves off its seat, allowing pressure to be released to the exhaust gallery. As the pump pressure decreases, the pilot valve is able to reseat and pressure in chamber D assists spring C to force the main plunger A back onto its seat.

E-35

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E-35

Section E - Hydraulics Hydraulic Pump Gear Pump - Operation

Fig 21. See also K Table 25. Key to Oil Flow and Pressure ( T E-31).

E-36

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E-36

Section E - Hydraulics Hydraulic Pump Gear Pump - Operation

Main Relief Valve (MRV) Make sure that the hydraulic oil is at working temperature, i.e. 50Â°C (122Â°F). Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure. 1

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector A on the loader valve, (refer to Service Tools).

With the engine running at 1500 revs/min, check M.R.V. pressure by raising or lowering the loader arms until the rams are fully open or closed and noting the maximum gauge reading. CAUTION: Do not select 'float'. The maximum pressure should be as stated in Technical Data.

Fig 22.

Note: The rams must be 'held' open or closed when reading gauge. 3

If the pressure is incorrect, loosen locknut D and adjust screw C. Turn it clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut and check the pressure again. Adjust as required.

E-37

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E-37

Section E - Hydraulics Hydraulic Pump Loader Valve - Neutral Circuits

Loader Valve - Neutral Circuits Neutral Circuit K Fig 23. ( T E-40). The loader valve is mounted on the chassis frame, right hand side (when viewed from the rear). It includes the lift ram spool 3C, shovel ram spool 3D and auxiliary spool 3E. Linkage rods connect the spool ends to the control levers. In neutral circuit hydraulic oil from the pump section P2 enters the loader valve at 1C via the steering priority valve. On entering the valve block, oil flows around the waisted section of the unloader valve 3L, past check valve 3N and joins the flow from pump section P1. Oil from pump section P1 enters the loader valve at 1A. Combined oil flow from P1 and P2 passes the main relief valve (MRV) 3B and fills the parallel gallery B. From the parallel gallery the oil flows around the waisted central portions of spools 3C, 3D and 3E (all in neutral position) and flows on to feed the excavator valve via high pressure carry over line 1B K Table 27. ( T E-38). Table 27. Key to Oil Flow and Pressure Full Pressure. Pressure. Servo. Neutral. Exhaust. Cavitation. Lock Up.

E-38

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E-38

Section E - Hydraulics Hydraulic Pump Loader Valve - Neutral Circuits

Unloader Operation (If fitted) K Fig 24. ( T E-40). Unloader spool operation protects the engine from being overloaded if a service is being worked particularly hard, for example when using the excavator to tear out. It does this by dumping the oil from the pump section P2 to tank, allowing engine power to be applied fully to the main pump section P1. If the pressure in the inlet gallery C rises to the setting of the pilot valve 3M, this valve will open, allowing oil in spring cavity 3P to escape more quickly than it can be replaced by oil entering through the small drilling D. This creates a pressure differential between the spring cavity 3P and gallery C. Higher pressure in gallery C acts on the face of spool 3L causing the spool to be moved off its seat. Oil entering the valve block from pump section P2 now flows directly to tank T. High pressure in gallery C also holds check valve 3N firmly closed, preventing oil from pump section P1 from also being dumped. When pressure in inlet gallery C falls, for example if the excavator has stopped tearing out, pilot valve 3M will close. This means oil in spring cavity 3P will be at the same pressure as oil in gallery C, spring pressure will move spool 3L back onto its seat, closing pump section P2 connection to tank. Also refer K Table 27. ( T E-38).

E-39

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E-39

Section E - Hydraulics Hydraulic Pump Loader Valve - Neutral Circuits

3C 3M B

3D 3E

3L 1B

1C(P2) C 3Q 3B

1A(P1)

3N 3J A401150

A401150

Fig 23.

3M 3L

C P2 D

3N P1 A401160

A401160

Fig 24.

E-40

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E-40

Section E - Hydraulics Hydraulic Pump Loader Valve - Neutral Circuits

Hydraulic Speed Control (HSC) Solenoid valve 3Q allows the operator to control the unloader spool movement (to dump flow from the hydraulic pump section P2) using a switch in the cab. There are two main applications for this operation: 1

More tractive force can be applied to the loader end when entering a stock pile. This is because more power is available from the engine as flow from pump section P2 is being dumped directly to tank.

More power can be made available from the engine whilst the machine is travelling on the highway. Again, this is because flow from pump section P2 is being dumped directly to tank.

When the solenoid valve 3Q is de-energised its spool is moved by spring pressure. This spool movement makes a connection from the unloader spool chamber 3P to tank. Because the unloader chamber is now connected to tank, and so at exhaust pressure, pressure in gallery C (neutral shown) acts on the face of unloader spool 3L causing the spool to be moved off its seat. Oil entering the valve block from pump section P2 now flows directly to tank. When solenoid valve 3Q is energised its spool closes the connection from the unloader valve spool chamber to tank. Spool 3L is once again controlled by system pressure.

E-41

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E-41

Section E - Hydraulics Hydraulic Pump Loader Valve - Neutral Circuits

Fig 25. See also K Table 27. Key to Oil Flow and Pressure ( T E-38).

E-42

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E-42

Section E - Hydraulics Hydraulic Pump Loader Valve - Neutral Circuits

Load Hold Check Valves Operation 1 K Fig 26. ( T E-43) The illustration shows 'arms raise' being selected by the lift ram spool 3C. The weight of the loaded shovel, as indicated by the arrows, produces a higher pressure in service line D than in the parallel gallery B. This pressure differential causes load hold check valve 3J to close, thus preventing the load from dropping. For colour identification see the table.

Fig 26.

E-43

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E-43

Section E - Hydraulics Hydraulic Pump Loader Valve - Neutral Circuits Operation 2 K Fig 27. ( T E-44) As the neutral circuit has been blocked by the central land of the selected spool 3C, the pressure in parallel gallery B increases until it is greater than that in service line D. At this point, load hold check valve 3J opens, allowing oil to flow from the parallel gallery into the service line and operate the lift rams 33 and 34.

Fig 27.

E-44

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E-44

Section E - Hydraulics Hydraulic Pump Loader Valve - Neutral Circuits

Arms Lower Operation When a spool is selected as shown at 3C, the central land of the spool C blocks the neutral circuit. Oil from the pump, entering at 1A, is diverted into the parallel gallery B, opens the load hold check valve 3J, and flows around the waisted section of the spool D and out to the rod side of lift rams 33 and 34. The lower land of the selected spool E blocks the flow from the parallel gallery to the head side port and oil returning from the rams is diverted into the exhaust gallery K Fig 28. ( T E-46). For the colour Identification K Table 27. ( T E-38).

see

the

table

Float The float facility is provided to allow the arms to move up and down so that the shovel can follow the surface contours as the machine is driven over uneven ground. This is achieved by moving the lift spool 3C down beyond 'arms lower' into the 'float' detent, when the feed from the parallel gallery to the service ports is blocked and the neutral circuit is re-opened. Both service ports are connected to exhaust via the spool waists A. Oil can then be displaced from either end of the lift rams 33 and 34 into the exhaust gallery, allowing the rams to open and close as required K Fig 29. ( T E-46).

E-45

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E-45

Section E - Hydraulics Hydraulic Pump Loader Valve - Neutral Circuits

3C D 3J

1A C

33 34

A396390

Fig 28.

3C A

33 34

A396400 A396400

Fig 29.

E-46

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E-46

Section E - Hydraulics Hydraulic Pump Loader Valve - Neutral Circuits

Auxiliary Relief Valve K Fig 30. ( T E-48). Under normal operating conditions, with the shovel in the 'carry' position, the mechanical linkage keeps the shovel level as the arms are raised, to prevent spillage of the load. If, as illustrated, the shovel is fully tipped when the arms are being raised, the shovel is unable to tip further, producing back pressure in the head side of the shovel rams 31 and 32 and cavitation in the rod side. As the arms continue to rise, the back pressure increases until it reaches the setting of A.R.V. 3F. This A.R.V. then opens, allowing the excess back pressure to be dumped to exhaust and prevent the rams and linkage from being damaged. The rod side A.R.V. 3G senses a higher pressure in the exhaust gallery than in the service port and therefore opens to allow exhaust oil to overcome the cavitation. For the colour Identification K Table 27. ( T E-38).

E-47

see

the

table

9813/2050-5

E-47

Section E - Hydraulics Hydraulic Pump Loader Valve - Neutral Circuits

3C 3G

32 31 3F

A396370

Fig 30.

E-48

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E-48

Section E - Hydraulics Hydraulic Pump Loader Valve - Neutral Circuits

Main Relief Valve (MRV) Operation K Fig 31. ( T E-50). The main relief valve (MRV) 3B, housed in the loader valve block, sets the maximum operating pressure for both the loader and excavator hydraulic services. 1

Valve at Rest:

The view 1 shows a loader service selected by spool 3D, causing pressure to rise in the service line and back through the loader valve to the pump via line 1A. The service is operating under light load, therefore the pressure is not sufficient to cause any response in the MRV. The main plunger A is held on its seat B by the combined effect of spring C and the pump pressure which enters chamber D through the small drilling E. Pump pressure outside the chamber is not high enough to lift the plunger off its seat. 2

Pilot Valve Poppet Opens:

In view 2, pump pressure rises high enough to force the pilot valve F from its seat (against spring G), the pressure in chamber D is vented into the exhaust gallery H. Unless the pressure continues to rise, plunger A will remain on its seat. 3

Main Valve Opens:

E-49

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E-49

Section E - Hydraulics Hydraulic Pump Loader Valve - Neutral Circuits

A D H F G

B E 1A A D C 2 3B

D E A C F

1A 1A

1 A401180

3 Fig 31. See also K Table 27. Key to Oil Flow and Pressure ( T E-38). For a further detailed description of a typical pilot operated relief valve operation, see K Pilot Operated Main Relief Valve Operation ( T E-51).

E-50

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E-50

Section E - Hydraulics Hydraulic Pump Loader Valve - Neutral Circuits Pilot Operated Main Relief Valve Operation

E G F D C

F C B

B A

3 D070840-34

Fig 32. 1

Valve at Rest: Oil pressure in gallery A will be acting on the bottom face of the main poppet B, and will also be felt inside the valve through the drilling in the piston C.

the main poppet B, causing it to lift and vent oil pressure from gallery A directly into the exhaust gallery H.

Oil pressure on the top face of the main poppet B, combined with the force of the springs D and E, keep the main poppet and the pilot poppet F tightly seated. 2

Pilot Valve Poppet Opens: When the pressure in gallery A reaches the pilot setting of the valve, pilot poppet F lifts, allowing oil to escape through cavity G into the exhaust gallery H.

Main Poppet Opens: As the pressure in gallery A continues to rise and oil escapes through cavity G, the pressure differential between the top and bottom surfaces of piston C, causes the piston to lift and seat against the end of the pilot poppet F. The oil flow through cavity G is then closed off. This produces a pressure drop above

E-51

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E-51

Section E - Hydraulics Hydraulic Pump Excavator Valve

Excavator Valve Neutral Circuit

Fig 33. Oil from the loader valve enters the excavator valve at A and flows through the neutral gallery and around the waists of the solid spools. It also fills the parallel gallery B but is not at a high enough pressure to open the load hold check valves C K Fig 33. ( T E-52).

Component Key: 4F

Bucket Spool

Table 28. Component Key: A

Inlet

Parallel Galley

Load Hold Check Valve

Slew Spool

Boom Spool

Stabiliser Spool

Dipper Spool

E-52

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E-52

Section E - Hydraulics Hydraulic Pump Excavator Valve

Fig 34.

Fig 35.

E-53

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E-53

Section E - Hydraulics Hydraulic Pump Excavator Valve

Excavator Valve Operation 1 Flow to the service via a typical solid spool 4B is controlled by the load hold check valve 4S which is a spring-loaded non-return valve operating across the pressure feed from the parallel gallery B. The valve prevents reverse flow from the rams into the pressure feed line, so maintaining ram pressure until exceeded by system pressure. The illustration shows a service selected but back pressure D exceeds system pressure which closes the load hold check valve K Fig 34. ( T E-53). Operation 2 When pressure in the feed line exceeds the back pressure, the load check valve 4S opens and oil operates the ram. The remaining load hold check valves are also opened by system pressure but the galleries are dead-ended because the spools are in neutral K Fig 35. ( T E-53). Table 29. Component Key: B

Parallel Gallery

Service Line

Spool

Load Hold Check Valve

One Way Restrictor Because of its weight, the excavator end could take over control when boom lower was selected. The falling boom would tend to push oil out of the ram faster than the head side was being filled. Consequently, when the excavator had reached the ground, there would be a time lapse while the ram filled with oil before the service would operate again K Fig 36. ( T E-55). To prevent this from happening, the boom service is fitted with a one way restrictor. When the boom is being raised, the poppet in restrictor E is held off its seat by pressurised oil flow, therefore oil delivery to the boom ram rod side is unrestricted. When the boom is being lowered, the oil flow through the one way restrictor E re-seats the poppet, therefore the flow of oil is restricted through the small drilling in the base of the poppet. This slows the boom down to a controllable speed.

E-54

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E-54

Section E - Hydraulics Hydraulic Pump Excavator Valve

Fig 36.

Excavator Valve - Slew Operation The illustration shows R.H. slew selected. The lower port C has been pressurised by the spool. Oil flows from the parallel gallery B, out past A.R.V. 4H to both the head side of the L.H. slew ram and the rod side of the R.H. slew ram. The boom therefore slews to the right hand side of the machine. Displaced oil from the rod side of the L.H. slew ram and from the head side of the R.H. slew ram flows back through the upper service port D and back to tank K Fig 37. ( T E-56).

E-55

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E-55

Section E - Hydraulics Hydraulic Pump Excavator Valve

Fig 37.

E-56

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E-56

Section E - Hydraulics Hydraulic Pump Excavator Valve

Slew Ram End Damping As ram A nears the closed position, damping rod B seats in cone C, where it is held by spring D. Tapered flutes on the end of the rod produce a restricting orifice, thus restricting the speed of the oil being exhausted from the ram. This provides a cushioning effect between the piston and the dump end of the ram, effectively damping out the shock loads which would otherwise occur when the boom reaches the end of its slewing are K Fig 38. ( T E-57).

Fig 38. Table 30. A

Ram

Damping Rod

Cone Seat

Spring

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Section E - Hydraulics Hydraulic Pump Excavator Valve

Slew A.R.V. and Anti-Cavitation Operation The spool 4A is in neutral but the momentum of the slowing excavator end creates back pressure in the head side of the R.H. slew cylinder and in the rod side of the L.H.

slew cylinder. This opens A.R.V. 4J and dumps oil to exhaust. At this point the cylinders cavitate and exhaust oil pressure causes A.R.V. 4H to open, allowing oil from the exhaust gallery to fill the L.H. cylinder. Top picture of K Fig 39. ( T E-58).

Fig 39.

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Section E - Hydraulics Hydraulic Pump Excavator Valve

Excavator Valve - A.R.V. Operation

For a further detailed description, refer also Auxiliary Relief Valve Operation.

The illustration shows the bucket spool 4F selected to operate the service against an immovable object. This forces the dipper away from the obstruction and pressurises the head side of the dipper ram. Bottom picture of K Fig 40. ( T E-59).

Table 31. Component Key: 4A

Slew Spool

Dipper Spool

When this pressure reaches the setting of A.R.V. 4M, this valve opens, relieving the pressure into the exhaust gallery.

Bucket Spool

ARV

Cavitation occurs in the rod side of the dipper service until A.R.V 4N opens, allowing the higher pressure in the exhaust gallery to supplement that in the service line.

ARV

Fig 40.

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Section E - Hydraulics Hydraulic Pump Excavator Valve

Auxiliary Relief Valve Operation A.R.V's are positioned in the excavator valve block in order to relieve excessive pressure in the services as shown in the figure.

Valve at Rest

The ARV pressure setting is adjustable by means of spring D and adjusting screw E. Turning the screw clockwise compresses the spring and therefore, increases the pressure setting and conversely, turning the screw anticlockwise releases the spring which decreases the pressure.

Pilot Valve opens

Illustration 1 of shows the service is in neutral and there are no excessive forces acting on the equipment. The force of spring D acting through Collar C keeps the poppet B firmly held on its seat. Chamber J is connected to the exhaust gallery via small drilled holes H, this means the pressure in the chamber will always be at Exhaustive pressure.

Illustration 2 of K Fig 41. ( T E-60) shows the Pressure in the service gallery A has reached the setting of the ARV. The pressure on the service side of the poppet is high enough to overcome the force of spring D so poppet B lifts off its seat. Oil in the chamber J is displaced through small drilled holes H. Service pressure at A is now released into exhaust gallery K.

Fig 41.

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Section E - Hydraulics Hydraulic Pump Excavator Valve Illustration 2 of K Fig 42. ( T E-61) shows the service gallery cavitating.

Auxiliary Relief Valve - Anti-Cavitation When the service gallery is cavitating, the ARV anticavitation operation allows oil from the exhaust gallery to supplement the cavitating service line. Illustration 1 of K Fig 42. ( T E-61) shows the ARV subjected to normal operating pressure in Service gallery A. The force of spring F and the pressure in the service gallery acting on the bottom face of anti-cavitation cone G keep the cone firmly on its seat.

The pressure in exhaust gallery K is sufficient to overcome the force of spring F. The cone and its assembly move down allowing oil in the exhaust gallery to enter the service gallery and limit the effects of cavitation. When the service gallery is no longer cavitating, compressed spring F will return to its relaxed position and thus bring the anti-cavitation cone back onto its seat.

Fig 42.

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Section E - Hydraulics Hydraulic Pump Excavator Valve

Excavator Valve - Dipper Make-Up Check Valve and Anti-Cavitation Operation The illustration shows the dipper spool 4E fully selected to lower the loader bucket K Fig 43. ( T E-62). As the engine is running slowly, and the ram is opening quickly, the pressure in the parallel gallery B falls to a lower level than that in the exhaust gallery. This causes A.R.V. 4M to open but the flow past the A.R.V. is insufficient to keep the head side of dipper ram 55 filled with oil.

Additional flow from the exhaust gallery is therefore provided by means of the make-up check valve 4X which opens due to the pressure differential. The combined flow past A.R.V. and make-up check will ensure that sufficient oil is fed to the head side of the ram to maintain smooth operation of the service as the dipper goes past the vertical. The make-up check valve will open in the same way to prevent cavitation when other services are operated.

Fig 43.

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Section E - Hydraulics Hydraulic Pump Excavator Valve

Hydraclamp (Sideshift Machines)

Fig 44.

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Section E - Hydraulics Hydraulic Pump Excavator Valve Hydraclamp Operation (Sideshift Machines) K Fig 44. ( T E-63) The hydra clamp control valve 4G is positioned in the inlet end of the excavator valve block and is connected directly to the parallel gallery B. Sleeve C is connected to the clamp control lever by linkage D. 1 - Clamps Pressurised When the control lever is pulled upwards and an excavator service is operated, oil from the parallel gallery B is allowed to pressurise the clamps 62 as follows. Oil enters the hollow poppet E via grooves in plug L and exits via the small orifice F. Pressure acts on both ends of the poppet which is therefore `floating' in its bore. Pressure also acts on poppet G lifting it of its seat against spring pressure to allow oil to feed the clamps. 2 - Clamps Released When the control lever is lowered, the valve sleeve C is rotated so that radial holes H align with the metering cavities J in the valve bore. These cavities are connected to an external drain port X. 3 - Clamps Locked Up If no service is being operated, pressure in the parallel gallery falls to that of the neutral circuit (blue in the inset) and spring force assists poppet G to re-seat. Pressure is therefore trapped (yellow) in the line to the clamps, maintaining the excavator end in a securely clamped condition.

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Section E - Hydraulics

Service Procedures Hydraulic Contamination TE-002_3

cleaning unit. K Fig 45. ( T E-65). General Bulletin 011 also refers.

Hydraulic Fluid Quality This machine uses a large volume of fluid in the hydraulic system for power transmission, equipment lubrication, rust prevention and sealing. According to a survey conducted by a pump manufacturer, seventy per cent of the causes of problems in hydraulic equipment were attributable to inadequate maintenance of the quality of the hydraulic fluid. Therefore, it is obvious that control of the quality of the hydraulic fluid helps prevent hydraulic equipment problems and greatly improves safety and reliability. Furthermore from an economic angle it extends the life of the hydraulic fluid if quality is maintained.

Procedure Connect the cleaning unit in place of the hydraulic filter. K Fig 45. ( T E-65). 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.

S168050-1

Fig 45. Cleaning Unit 2

Liquid - usually water and incompatible oils and greases.

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

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 Service Procedures Hydraulic Contamination

Contaminant Standards Dirt that damages your system is in many cases too small to be seen with the eye. The particle size is measured in microns. 1 micron = 0.001 mm (0.0000394 in). Listed below are a few typical comparisons: â&#x20AC;&#x201C; Red Blood Cell = 8 microns (0.008 mm, 0.000315 in) â&#x20AC;&#x201C; Human Hair = 70 microns (0.07 mm, 0.00275 in) â&#x20AC;&#x201C; Grain of Salt = 100 microns (0.1 mm, 0.00394 in) Smallest particle visible to the naked eye is 40 microns (0.00157) approximately. Standards will often be quoted to ISO (International Standards Organisation) for which literature can be obtained.

Filters The filter assembly fitted to all product ranges is designed to filter all the contamination that is generated through use to the required level of cleanliness. The filter must be serviced to the requirements of the machine Service Schedules. To ensure optimum performance and reliability it is important that the machines hydraulic system is serviced periodically in accordance with the manufacturers requirements.

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Section E - Hydraulics Service Procedures 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 46. 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.

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Section E - Hydraulics Service Procedures 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 47. 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 48. 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.

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Section E - Hydraulics Service Procedures Connecting/Disconnecting Hydraulic Hoses

Quick Release Couplings

by dirt in the coupling or physical damage due to abuse.

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 49. ( T E-70). 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.

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Section E - Hydraulics Service Procedures 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 49.

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Section E - Hydraulics Service Procedures Hydraulic Pump

Hydraulic Pump Flow and Pressure Testing

Before removing the pump it is necessary to determine the source of any problem by measuring the output flow at system pressure from both of the pump outlet ports. To check flow it is necessary to fit flow meter A into the output line of each pump section in turn. If available, load valve B (service tool 892/00270) should also be installed (see Note 1). Make sure the flow meter is installed with its arrow pointing away from the pump and, if applicable, located between the pump and the load valve. Note: 1) If no load valve is available, ignore the references to the load valve in Fitting and Removing a Flow Meter and Load Valve below. An alternative method of determining flow is included in the Checking Flow procedures following.

Pump section 2 - disconnect hose D from the pump. Fit the flow meter and load valve (see Note 2) between hose D and the pump.

Note: 2) Make sure the load valve is in the open position, i.e. with the adjusting knob screwed fully out, before carrying out the Checking Flow procedure. Removing Removing is the reverse of fitting.

Checking the Pump Flow 1

Check the setting of the Main Relief Valve (MRV) as described in Loader Valve, Pressure Testing. Adjust if necessary.

Fitting and Removing a Flow Meter and Load Valve

Before fitting or removing a flow meter and load valve, switch off the machine and operate the loader and excavator controls a few times to vent system pressure.

!MWARNING

b If no load valve is available - fit a flow meter, as described in Fitting, to each pump output in turn.

!MWARNING TRANS-1-2

Fitting

E-71

Using a load valve - adjust the load valve so that the pressure gauge reading is just below the MRV setting.

b If no load valve is available - raise or lower the loader arms until the rams are fully open or closed. Continue to operate the raise or lower control so that system pressure builds up. Watch the flow meter and note its reading at the moment the MRV operates.

Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT.

Pump section 1 - disconnect hose C from the pump. Fit the flow meter and load valve (see Note 2) between hose C and the pump.

Start the engine and bring the hydraulics up to working temperature 50ยบC (122ยบF). Set the engine speed to 2200 rpm.

INT-3-1-11_2

Using a load valve - fit a flow meter and load valve, as described in Fitting, to each pump outlet in turn. Fit a 0-400 bar (0-6000 lbf/in2) pressure gauge to the load valve pressure test connector.

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The flow reading should be as listed in Technical Data.

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Section E - Hydraulics Service Procedures Hydraulic Pump

Fig 50.

D C

Fig 51.

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Section E - Hydraulics Service Procedures Hydraulic Pump

Loader Valve (Unloader valve)

Make sure that the hydraulic oil is at working temperature i.e. 50Â°C (122Â°F). Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure

If the pressure is incorrect, slacken locknut E and adjust cap F. Turn it clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut and check the pressure again. Adjust as required K Fig 53. ( T E-73). If the correct pressure cannot be achieved, add or subtract shims as required.

Make sure that the smooth ride system facility is NOT switched on, if fitted, otherwise the correct unloader valve pressure cannot be obtained. 1

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector A K Fig 52. ( T E-73).

With the engine running at 1500 revs/min., slowly operate arms raise or lower.

Fig 53.

Fig 52. Note: The arms raise or lower service is specified because it has no auxiliary relief valve (A.R.V.). Selecting this service ensures that the pressure vents through the M.R.V. and not an A.R.V. 3

When the service reaches full travel, return the lever to the neutral position. Select the service again, very slowly, the pressure gauge will rise until a step/kick is seen in the rate of change in the pressure increase. This is the start of unloader operation. Keep selecting the service until a sudden sharp increase in pressure is observed with a change of engine sound, this n Technical Data

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Section E - Hydraulics Service Procedures Hydraulic Pump

Shovel Ram Rod Side A.R.V. Pressure Testing Testing of A.R.V's on the machine should be avoided (use hand pump method). However, the procedure described below is a secondary checking method which can be used if no hand pump is available. The shovel ram rod side A.R.V. is set at a higher pressure than the M.R.V. (maximum system pressure). To raise the pressure in the shovel ram rod side service line above system pressure, it is necessary to disconnect/connect hoses (as shown in the following procedures) so that oil displaced from the LIFT ram (rod side) is fed through the A.R.V. Make sure that the hydraulic oil is at working temperature, i.e. 500C (1220F).

Fig 54.

Rest the shovel on the ground, stop the engine and vent all services. Disconnect hoses B and C from metal pipes B1 and C1 respectively, shown at K Fig 54. ( T E-74). Screw a tee piece fitted with a 0400 bar (0-6000 Ibf/in2) pressure gauge to metal pipe B1, shown at K Fig 55. ( T E-74). Pull the hose C down from behind the loader arm and fit to the other side of the tee piece as shown at V. Fit a cap to metal pipe C and fit a plug to hose B. Note: For reference, C1 is the service hose for the shovel ram, rod side. B is the service hose for the lift ram, rod side. With the engine running at 1000 revs/mm, select and operate slowly the loader arms lift service until the ram creeps, keep raising the arms slowly until a reading on the pressure gauge is obtained.

Fig 55.

The highest pressure value shown on the gauge will be the setting of the shovel ram rod side A.R.V. (see Technical Data). If necessary, adjust as detailed below. If the pressure is incorrect, the A.R.V. must be adjusted.

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Section E - Hydraulics Service Procedures Hydraulic Pump

Removal and Replacement The following Procedure describes replacement of a double section pump.

3 removal

and

Removal

Note: All hydraulic adaptors that are installed together with a bonded sealing washer must also have sealant JCB Threadseal applied to the threads of the adaptor. 4

Reconnect the pump inlet hose flange to the pump body with bolts B (4 off).

Fit the propshaft, refer to Section F, Transmission Propshafts - Removal and Replacement.

Fill the system to the correct level with recommended hydraulic fluid, see Section 3, Maintenance Lubricants and Capacities.

INT-3-3-8_2

Remove the propshaft, refer to Section F, Transmission, PropshaftRemoval and Replacement.

Drain the hydraulic fluid from the hydraulic tank.

Remove flange bolts B (4 off) and disconnect the pump inlet hose flange from the pump body. Blank off all exposed connections to prevent ingress of dirt.

Disconnect the pump outlet hoses C and D from the elbow fittings. Blank off all exposed connections to prevent ingress of dirt.

Reconnect the pump outlet hoses C and D to the elbow fittings.

Note: Replace the suction strainer and return line filter after fitting a new or serviced pump. 7

After fitting a new or serviced pump and before starting the engine screw the main relief valve out. Run the engine and check for leaks, also check the main relief valve (MRV) operating pressure. Refer to service procedures, pressure testing - M.R.V

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device.

E D

BF-4-1_1

Secure the pump using a sling around the pump body, remove the pump mounting bolts E and carefully withdraw the pump clear of the gearbox.

Replacement

Replacement is the reverse of the removal procedure. 1

Clean off all traces of gasket compound from the pump and gearbox mounting faces. Apply a thin bead of JCB Muligasket to the gearbox mounting face.

Locate the splined shaft of the pump into the gearbox. Apply JCB Thread locker and Sealer to bolts E and secure the pump flange to the gearbox mounting face.

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Fig 56.

E-75

Section E - Hydraulics Service Procedures Hydraulic Pump

Dismantling, Inspection and Assemble

pump should be removed and dismantled for re-sealing only.

Before removing and dismantling the pump, check flow and pressure. If either of these are low, the pump must be changed. Renewal of components such as gears, bearings and housing will not affect a permanent cure. If the pump output is satisfactory but there is external leakage, the

Before removing and dismantling the pump, make sure the exterior of the pump and working area is thoroughly cleaned and free of possible sources of contamination.

Fig 57.

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Section E - Hydraulics Service Procedures Hydraulic Pump Dismantle

mounting flange and all sealing faces must be free of burrs and scores which could result in seal damage and hence hydraulic oil leakage.

K Fig 57. ( T E-76) 2

Renew the pump if any of the following symptoms exist:

Remove the four bolts 3 and serrated washers 4 which clamp the units together.

Use a soft faced hammer to separate front body 5 and rear body 6 after first marking them to ensure correct re-assembly.

Remove spindle coupling 7 and O-rings 8. Discard the O-rings.

Use a soft faced hammer to separate end cover 9 from rear body 6, after first marking them to ensure correct re-assembly.

b The gear side faces are scored. Often contaminated fluid results in a distinct wear step coincident with the gear root diameter. This can normally be felt by drawing a sharp point across the gear side face from the journal towards the tip of the gear.

Remove drive gear 10 from its bore. Pushing it out of the rear body will also remove balance plate 11 complete with seal 12 and seal energiser 13. Discard the seal and seal energiser. Note the position of the drive shaft and the balance plate to ensure correct reassembly.

Discard O-ring 18.

Use a soft hammer to separate mounting flange 19 from front body 5, after first marking them to ensure correct re-assembly.

There is a noticeable wear groove on driveshaft 23 where seals 22 run.

d The balance plate faces are scored, particularly in the area adjacent to the gear root diameter.

Remove driven gear 14, followed by balance plate 15 complete with seal 16 and seal energiser 17. Discard the seal and seal energiser.

The PTFE coated bearings in the pump bodies, the mounting flange and the end cover are worn through to reveal the bronze backing.

The shaft splines are worn or severely fretted.

The gear `cut-in' area in the low pressure side of the pump body is deeper than 0.15 mm (0.006 in) or has a torn or pitted appearance.

Assemble

Remove circled 21 and shaft seals 22. Note which way round the seal lips are fitted to ensure correct fitting of new seals on re-assembly.

Remove drive shaft 23 from front body 5. Removal will also remove balance plate 28 complete with seal 29 and seal energiser 30. Discard the seal and seal energiser.

Remove driven gear 27 followed by balance plate 24, seal 25 and seal energiser 26. Discard the seal and seal energiser.

Discard O-ring 31.

Remove all sealant from the contact faces of the mounting flange, front body, end cover and rear body interfaces.

Wash all components and immediately apply a coating of hydraulic oil to prevent corrosion.

K Fig 57. ( T E-76) When carrying out the following procedure, renew all seals and O-rings. Lubricate using JCB Special Hydraulic Fluid. 1

Fit shaft seals 22 into mounting flange 19, making sure the seal lips are the correct way round as noted in dismantling. Fit circlip 21 into its groove in the flange. Coat the seal lips with high melting point grease.

Note: If the seal recess is scored, it is permissible to seal outside diameter with JCB Multigasket to prevent leakage. 2

Stand front body 5 on its rear face. Fit seal 25 and seal energiser 26 into balance plate 24.

Ensuring that the seals do not fall out, carefully feed the balance plate into the bores of the front body 5 with the two small holes through the balance plate to the low pressure side of the body (i.e. side with the large 4-bolt port pattern).

Insert driveshaft 23 and driven gear 27 into the original bores.

Fit balance plate 28 over the driveshaft and gear stub. Insert seal 29 and seal energiser 30 into the balance plate.

Inspection 1

Generally check all pump parts for damage and or wear. The O-ring grooves, the seal recess in the

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Section E - Hydraulics Service Procedures Hydraulic Pump 6

Fit O-ring 31 into the groove on mounting flange 19. Item

Apply a small amount of JCB Multi gasket to the face of front body 5 which seals with mounting flange 19 (i.e. the face containing the clamping bolt holes).

Carefully feed mounting flange 19 over driveshaft 23 in its original position, as marked earlier. Use a soft faced hammer to tap the flange onto its location spigot.

Support the front pump assembly on the mounting flange (but not the driveshaft). Fit O-rings 8 into the grooves on the rear face of the front body 5. Install splined coupling 7.

Fit rear body 6 onto front body 5 in its original position, as marked earlier, ensuring that it locates on the dowels and that the clamping bolt holes line up.

Fit seal 16 and seal energiser 17 into balance plate 15. Ensuring that the seals do not fall out, carefully feed the balance plate into rear body 6 with the two small holes through the balance plate to the low pressure side (i.e. side without a port).

Fit drive gear 10 so that it locates with splined coupling 7. Fit driven gear 14.

Fit balance plate 11 in its original position (i.e. with the two small holes to the low pressure side). Fit seal 12 and seal energiser 13 into the balance plate.

Fit O-ring 18 into end cover 9.

Apply a small amount of JCB Multigasket to the exposed face of rear body 6 (i.e. the face containing the clamping bolt holes).

Fit end cover 9 in its original position, as marked earlier.

Install the four bolts 3, each with a serrated washer 4, and tighten evenly and progressively. Torque tighten the bolts, K Table 32. Torque Settings ( T E-78).

Pour a small amount of clean JCB Special Hydraulic Fluid into the ports. Check that driveshaft 23 rotates without undue force. If excessive force is required it is possible that one or more of the balance plate seals are trapped, in which case it will be necessary to dismantle and assemble the pump again.

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Table 32. Torque Settings Nm kgf m 90 - 100

9.2 - 10.2

lbf ft 66 - 74

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Section E - Hydraulics Service Procedures Loader Valve - Pressure Testing

Loader Valve - Pressure Testing Main Relief Valve (M.R.V.) Make sure that the hydraulic oil is at working temperature, i.e. 50Â°C (122Â°F). Lower the excavator bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure. 1

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector A on the loader valve, (refer to Service Tools).

With the engine running at 1500 revs/min., check M.R.V. pressure by raising or lowering the loader arms until the rams are fully open or closed and noting the maximum gauge reading. CAUTION: Do not select 'float'. The maximum pressure should be as stated in Technical Data.

Fig 59. 3DX ECO

Note: The rams must be 'held' open or closed when reading gauge. 3

If the pressure is incorrect, loosen locknut D and adjust screw C. Turn it clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the recount and check the pressure again. Adjust as required.

Fig 58. 3DX

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Section E - Hydraulics Service Procedures Loader Valve - Pressure Testing

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector A.

With the engine running at 1500 revs/min. slowly operate arms raise or lower.

Fig 60.

Note: The arms raise or lower service is specified because it has no auxiliary relief valve (A.R.V.). Selecting this service ensures that the pressure vents through the M.R.V. and not an A.R.V. 3

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Section E - Hydraulics Service Procedures Loader Valve - Pressure Testing

Hydraulic Speed Control (HSC) The following procedure can be used to establish if the hydraulic speed control facility is working correctly. Make sure that the hydraulic oil is at working temperature, i.e. 50Â°C (122Â°F). Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure. 1

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to the hydraulic test point A at the loader valve as shown.

With the engine running at 1500 revs/min., slowly operate arms raise, the pressure should be approximately 138 bar (2000 lbf/in2).

Make sure that the HSC rocker switch (mounted on the console) is in the OFF position. Raise the arms slowly and select the rocker switch to ON, the arms should raise slower.

Make sure that the HSC rocker switch (mounted on the console) is in the OFF position. Raise the arms slowly and press the button on the loader control knob, the arms should raise slower.

If the loader arms fail to respond, then check the HSC hydraulic and electrical circuits for any faults.

Fig 61.

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E-81

Section E - Hydraulics Service Procedures Loader Valve - Pressure Testing

Auxiliary Relief Valves - Using Hand Pump To pressure test and re-set the auxiliary relief valves (A.R.V.'s), service kit 892/00309 must be used. The service kit comprises; a test block 1, a setting body 2 with adjusting pin 3, a special spanner 4, anti-cavitation lock out bung 5. A.R.V. cartridge removal tool 892/00335 comprises; an extractor cap 6 and a 'C' washer 7.

Fig 62. 1

Remove the complete A.R.V. assembly from the valve block. If the A.R.V. sub-assembly 7 remains in the valve block, proceed as follows: a

Fit extractor cap 11 over the A.R.V. subassembly 7, into the valve block E.

Fit 'C' washer 12 on top of the extractor cap, but under the anti-cavitation spring seat as shown.

Unscrew the extractor cap, - the A.R.V. subassembly will withdraw with the extractor cap.

Fig 63.

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E-82

Section E - Hydraulics Service Procedures Loader Valve - Pressure Testing 2

Use special spanner 4 located in cross holes A and separate the A.R.V. sub-assembly 7 from its cap 8.

Fig 64. 3

Install adjusting pin 3 into setting body 2.

Fig 65. 4

Install the A.R.V. sub-assembly into setting body 2. Make sure that the adjusting pin 3 correctly locates in adjusting screw 9. Make sure that the lock nut 10 correctly locates in the setting body socket - the anti-cavitation cone should still be closed, as shown at B.

Fig 66. 5

Install the A.R.V. sub-assembly and setting body into test block 1. Make sure that the assembly is installed in the port marked 'RV' (relief valve).

Fig 67.

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E-83

Section E - Hydraulics Service Procedures Loader Valve - Pressure Testing 6

Connect a hydraulic hand pump to port 'P' (pump) of the test block 1. Make sure that the hand pump is filled with JCB Hydraulic fluid. Connect a 0 to 400 bar (0 to 6000 lbf/in2) pressure test gauge to port 'G' (gauge) of the test block 1. Port 'T' (tank) can be left open when using a hydraulic hand pump.

Fig 68. 7

Raise the pressure at the valve inlet using the hydraulic hand pump, when the A.R.V. 'cracks' and oil escapes from the port marked 'T' the pressure gauge will indicate the A.R.V. setting. If the A.R.V. setting is correct, move to step 12. If the A.R.V. setting is not correct, move to step 8.

Fig 69. 8

Use the hand pump to raise approximately 172 bar (2500 lbf/in2) pressure at the valve inlet. Note: Raising the pressure at the valve inlet locks the anti-cavitation cone C onto its seat, this allows the A.R.V. adjusting screw lock nut 10 to be loosened (step 10). If the pressure is maintained move to step 10. If the pressure falls off rapidly, or if no pressure can be obtained it is possible that the anti-cavitation cone is not seating effectively, in this instance move to step 9.

Fig 70.

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E-84

Section E - Hydraulics Service Procedures Loader Valve - Pressure Testing 9

If no pressure can be raised (see step 8) at the valve inlet, remove the A.R.V. assembly and install anticavitation lock-out bung 6 in the port marked 'RV', make sure that the bung O-ring face seal D is facing out. Re-fit the A.R.V. assembly. Note: The anti-cavitation lock-out bung seals and locks the A.R.V. anti-cavitation function. The bung is only suitable for the test block application and must NEVER be fitted to the valve block. The bung can be extracted using a <FmNumerator>3/<FmDenominator>8 - 16 UNC threaded bolt.

Fig 71. 10

Release the A.R.V. adjusting screw lock nut (see note): Engage the nut at the end of setting body 2 using the slot in special spanner 4, turn the nut anticlockwise to release the A.R.V. adjusting screw lock nut. Note: Remember, it will not be possible to release the lock nut if there is not approximately 172 bar (2500 lbf/in2) pressure at the valve inlet.

Fig 72. 11

Insert an allen key into adjusting pin 3 (T-Bar type shown). Push the adjusting pin down and make sure it has engaged with the A.R.V. adjusting screw. Rotate the T-bar clockwise to increase the pressure setting and anti-clockwise to decrease the pressure setting. After adjustment, use the slot in spanner 4 to lock the A.R.V. adjusting screw lock nut (see note). Note: Remember, pressure must be maintained at the valve inlet to ensure the lock nut is tightened.

Fig 73.

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E-85

Section E - Hydraulics Service Procedures Loader Valve - Pressure Testing 12

When the correct A.R.V. setting has been attained, release the pressure in the test block. Remove the A.R.V. sub-assembly and its setting body from the test block. Separate the A.R.V. sub-assembly from its setting body. Install the A.R.V. sub-assembly into its cap.

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E-86

Section E - Hydraulics Service Procedures Excavator Valve - Pressure Testing

Excavator Valve - Pressure Testing Auxiliary Relief Valves - Using Hand Pump

Fig 74. The auxiliary relief valves found in the backhoe valve block are identical in design to those found in the loader valve block. For the correct pressure test procedures see Loader Valve - Pressure Testing. To pressure test and re-set the auxiliary relief valves (A.R.V.'s), service kit 892/00309 must be used. The service kit comprises; a test block 1, a setting body 2 with adjusting pin 3, a special spanner 4, anti-cavitation lock out bung 5. A.R.V. cartridge removal tool 892/00335 comprises; an extractor cap 6 and a 'C' washer 7.

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E-87

Section E - Hydraulics Service Procedures Ram Creep Tests - All Services

Ram Creep Tests - All Services If ram creep is suspected the following procedures must be carried out to define if the leakage is within tolerance. Ram creep can be caused by a number of reasons: cylinder or piston leakage, spool leakage or ARV leakage. The text and illustrations show a typical ram installation (in this instance the boom ram), the principle applies to all rams. Note: The procedures are not applicable for rams fitted with hose burst protection valves.

Fig 75.

INT-3-1-11_2

!MWARNING

Measure the actual piston rod movement over 10 minutes. Measure the movement by checking the pivot pin to pivot pin dimensions as at C. Alternatively mark the rod with a felt tip pen 150mm (5.9 in) from the end cap and check the movement after 10 minutes, this is not possible on the majority of boom extending dipper rams.

Using K Table 33. Creep Rates ( T E-90), check if the piston rod movement is within the recommended tolerance. If so, the ram creep is acceptable.

Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. TRANS-1-2

A 1

Test for Ram Creep Operate the machine to bring the hydraulic oil to a normal working temperature of 50Â°C (122Â°F) which can be measured using a hydraulic oil temperature probe (service tool 892/00285).

Fit an appropriate pressure gauge A to a tee piece in the service hose which is pressurised when the ram in question is supported, see K Fig 75. ( T E-88).

Operate the rams to ensure they are full of hot oil.

Apply a load to the suspect ram for example the boom ram by raising the dipper to the horizontal as at B.

E-88

Note: The table indicates the MAXIMUM permitted ram movement. 7

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If the rate of movement is unacceptable, identify if the fault is as a result of cylinder or piston leakage, or spool leakage at the control valve, see procedures B and C.

E-88

Section E - Hydraulics Service Procedures Ram Creep Tests - All Services B 1

loader auxiliary, stabilisers or to the bucket rod side service except when a Rockbreaker is fitted.

Test Cylinder or Piston Leakage Ensure that the oil temperature is at 50Â°C (122Â°F) by using the hydraulic oil temperature probe detailed in step A1. Take the weight off the ram to be tested, in this example, by positioning the backhoe with dipper vertical and bucket on the ground. Use a suitable pressure gauge A to blank off the supporting port of the ram K Fig 76. ( T E-89).

A.R.V.

Control Layout: JCB

ISO

- Right

- Left

- Rod

- Head

- Rod

- Head

- Rod

- Head

Slew

Boom

Dipper

Bucket

Note: Bucket ram rod side ARV only fitted to machines equipped with Rockbreakers.

Fig 76. 4

Disconnect the hose from the opposite port D and leave the port open to atmosphere.

Apply a load to the suspect ram for example the boom ram by raising the dipper to the horizontal as at B.

After the initial movement measure the pin to pin movement as at C and note the rod movement over 10 minutes.

If rod movement is evident the ram is defective.

Render the A.R.V.'s inoperative in the suspect service. This is achieved by removing the A.R.V. and replacing with a blanking plug (part no. 25/609901) and seal kit (25/610301).

Recheck the piston rod movement as described steps A1 to A6.

If the rod movement is now acceptable the A.R.V. must be at fault. The A.R.V. may only require cleaning and then resealing. If dirt is evident, the hydraulic tank should be drained and cleaned. It is recommended that when re-filling the hydraulic tank that new oil and filter be used to prevent further contamination. If the A.R.V. is worn it should be replaced.

Test Spool Leakage

Note: The following procedure applies only to services fitted with A.R.V.'s. Note A.R.V.'s are not fitted to loader lift,

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E-89

Section E - Hydraulics Service Procedures Ram Creep Tests - All Services

Fig 77. Table 33. Creep Rates Total Displacement - mm/10 minutes @ Ram

Cylinder Dia. Rod Dia. (mm) (mm)

69 bar (1000 lb/in2) 138 bar (2000 lb/in2) 207 bar (3000 lb/in2)

HEAD SIDE Backhoe: S/shift Jack Leg

Knuckle

100

Bucket

114

Bucket

100

Extending Dipper

Clam

Lift

Loader:

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E-90

Section E - Hydraulics Service Procedures Ram Creep Tests - All Services Total Displacement - mm/10 minutes @ Ram

Cylinder Dia. Rod Dia. (mm) (mm)

69 bar (1000 lb/in2) 138 bar (2000 lb/in2) 207 bar (3000 lb/in2)

ROD SIDE Backhoe: Boom

110

Boom

120

Boom

130

Boom

140

Dipper

100

Dipper

110

Extending Dipper

Loader: Shovel

Using the figures above, a graph can be plotted and the maximum amount of movement determined. See the next page for a working example. 1

Using the figures given in the table, plot a graph for the ram to be tested. Example: Boom Ram 110 x 60, see K Fig 78. ( T E-92).

Check the pressure in the ram (induced by the applied load). In this example the pressure on the gauge reads 107 bar; 1500 lb/in2.

Draw a vertical line from the pressure reading to the plotted graph line. Where the vertical line intercepts the graph line, draw a horizontal line and read the permitted ram displacement. In this example the permitted maximum displacement is 18 mm.

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E-91

Section E - Hydraulics Service Procedures Ram Creep Tests - All Services

100

52mm

40 Bo

MAXIMUM RAM MOVEMENT PERMITTED (MM)

120

26mm

18mm

8mm

69bar

100

107bar

150

138bar

200

207bar

250

PRESSURE (BAR) Fig 78. Note: For a blank graph sheet to copy and use as required, K Fig 79. ( T E-93).

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E-92

Section E - Hydraulics Service Procedures Ram Creep Tests - All Services

MAXIMUM RAM MOVEMENT PERMITTED (MM)

120

100

69bar

100

150

138bar

200

207bar

250

PRESSURE (BAR) Fig 79. Blank Graph Sheet

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E-93

Section E - Hydraulics Service Procedures Valve Block Spool Seals

Valve Block Spool Seals Seal Fitting - 3DX

debris, use a pressure washer to clean the valve block if available.

K Fig 80. ( T E-96) The following points MUST be avoided when dismantling and assembling the valve:

Remove the boot 4, retaining plate and breather 2, CLEAN around the top of the spool.

Undo cap screws 16 and remove end cap 15. Place a container underneath to catch the oil when the spool is removed, carefully remove the spool assembly.

– Contamination. – Damage to Spool. – Damage to Seal Grooves.

Note: If all spools on the valve block are being resealed, the above operation must be done one at time.

All or any of the above points may result in possible problems with the valve.

Remove the upper lip seal 5 and wiper seal 6 with a non sharp object and thoroughly CLEAN the spool seal cavity area. Pay particular attention to the outer seal contact area 7. Check the spools for signs of pitting or damage, i.e. scratches from previous damaged repairs. Replace as required.

Fit a new boot 4 to the seal retaining plate 2 and grease the bottom of the seal plate with red lithium grease, included in the kit.

Carefully fit the new lip seal 5 into the valve block. Ensure squareness of the lip seal and that it is in the correct orientation, seal lip inwards.

Fit wiper seal 6 on top of lip seal 5, grease the top of the valve seal plate contact area with red lithium grease.

Fit the new boot assembly with the breather groove 1 pointing to the rear of the valve block as illustrated, only finger tighten bolts 3 at this stage.

Note: A Valve Spool Reseal Kit is available for the following procedure: 1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the loader arms and boom to the ground. Switch OFF the engine, remove the starter key and disconnect the battery.

Operate the controls to vent hydraulic pressure.

Note: Take care not to damage the rear horn or wiring.

Note: If the lower wiper seal 9 requires changing, it is recommended the spring end mechanism 10 - 14 is removed from the spool assembly using spool clamp tool 992/10100. Insert the wiper seal onto the spool with the bottom flat face of the wiper seal pointing along the length of the spool. Fit the seal retaining plate 10 and spring end mechanism 11 - 14, apply JCB Thread locker and sealer to the thread of bolt 14 and torque tighten to 9.5 Nm (0.97 kgf m, 7.0 lbf ft).

Fit the lower lipseal 8 into the valve block. Ensure squareness of the lipseal and that it is in the correct orientation, wider lip to cavity base. Apply red lithium grease to bottom seal plate contact area.

Using clean hydraulic oil as a lubricant, from the bottom, insert spool through the valve block, do not use excessive force when fitting, a turning motion should ease the spool through the valve block.

Check that the tang end of the spool passes through the boot without dislodging or damaging the boot.

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E-94

INT-3-1-11_2

The control levers will need to be partially dismantled to gain access to the loader or excavator valves (see Control Rods and Linkage, Dismantling and Assembly).

Inspect ALL the fittings, hoses and connecting joints etc. to ensure and confirm the leakage is clearly coming from the valve spool seals.

Note: If a valve block is in a rusty or dirty condition, it is recommended that the complete valve block is removed, (see Loader Valve or Excavator Valve Removal and Replacement), and a complete spool valve kit is fitted. 6

Disconnect control linkages.

Before removing the boot, clean the entire valve block, make sure that all components are free of

E-94

Section E - Hydraulics Service Procedures Valve Block Spool Seals Ensure that the tang aligns with the control rod and that the boot is not distorted and is located in the spool land. 18

Fit end cap 15, torque tighten cap screws 16 to 9.5 Nm (0.97 kgf m, 7.0 lbf ft).

Torque tighten cap screws 3 to 9.5 Nm (0.97 kgf m, 7.0 lbf ft).

Operate the machine and check for leaks.

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E-95

Section E - Hydraulics Service Procedures Valve Block Spool Seals

Fig 80.

E-96

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E-96

Section E - Hydraulics Service Procedures Valve Block Spool Seals

Seal Fitting - 3DX ECO

Disconnect control linkages.

The following points MUST be avoided when dismantling and assembling the valve:

Before removing the boot, clean the entire valve block, make sure that all components are free of debris, use a pressure washer to clean the valve block if available.

Remove the boot 4, retaining plate and breather 2, CLEAN around the top of the spool.

Undo capscrews 16 and remove end cap 15. Place a container underneath to catch the oil when the spool is removed, carefully remove the spool assembly.

– Contamination – Damage to Spool – Damage to Seal Grooves All or any of the above points may result in possible problems with the valve. Note: A Valve Spool Reseal Kit is available for the following procedure: 1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral K Fig 81. ( T E-100).

Lower the loader arms and boom to the ground. Switch OFF the engine, remove the starter key and disconnect the battery.

Operate the controls to vent hydraulic pressure.

Note: If all spools on the valve block are being resealed, the above operation must be done one at time. 10

Fit a new boot 4 to the seal retaining plate 2 and grease the bottom of the seal plate with red lithium grease, included in the kit.

Carefully fit the new lipseal 5 into the valve block. Ensure squareness of the lipseal and that it is in the correct orientation, seal lip inwards.

Fit wiper seal 6 on top of lipseal 5, grease the top of the valve seal plate contact area with red lithium grease.

Fit the new boot assembly with the breather groove 1 pointing to the rear of the valve block as illustrated, only finger tighten bolts 3 at this stage.

The control levers will need to be partially dismantled to gain access to the loader or excavator valves (see Control Rods and Linkage, Dismantling and Assembly).

Note: Take care not to damage the rear horn or wiring. 5

Inspect ALL the fittings, hoses and connecting joints etc. to ensure and confirm the leakage is clearly coming from the valve spool seals.

E-97

Note: If the lower wiper seal 9 requires changing, it is recommended the spring end mechanism 10 - 14 is removed from the spool assembly using spool clamp tool 992/10100. Insert the wiper seal onto the spool with the bottom flat face of the wiper seal pointing along the length of the spool. Fit the seal retaining plate 10 and spring end mechanism 11 - 14, apply JCB Threadlocker and sealer to the thread of bolt 14 and torque tighten to 9.5 Nm (0.97 kgf m, 7.0 lbf ft). 15

Fit the lower lipseal 8 into the valve block. Ensure squareness of the lipseal and that it is in the correct

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E-97

Section E - Hydraulics Service Procedures Valve Block Spool Seals orientation, wider lip to cavity base. Apply red lithium grease to bottom seal plate contact area. 16

Check that the tang end of the spool passes through the boot without dislodging or damaging the boot. Ensure that the tang aligns with the control rod and that the boot is not distorted and is located in the spool land.

Fit end cap 15, torque tighten cap screws 16 to 9.5 Nm (0.97 kgf m, 7.0 lbf ft).

Torque tighten cap screws 3 to 9.5 Nm (0.97 kgf m, 7.0 lbf ft).

Operate the machine and check for leaks.

E-98

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E-98

Section E - Hydraulics Service Procedures Valve Block Spool Seals

E-99

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E-99

Section E - Hydraulics Service Procedures Valve Block Spool Seals Fig 81.

E-100

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E-100

Section E - Hydraulics Service Procedures Valve Block Spool Seals

Hydraclamp Valve - Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling K Fig 82. ( T E-102). For assembly the procedure should be reversed.

When Dismantling Plug hoses 1 to prevent loss of oil entry of dirt.

When Assembling Make sure that the orifice X is clear. Lubricate new seal with JCB hydraulic Fluid. Screw item 8 fully home into housing then back -off by no more then 1800 until the flats align with capscrew centre line as show at A K Fig 82. ( T E-102). Fit plate 6 in position shown and connect clevis 2. If necessary, adjust position of clevis 2 so that plate 6 can be operated over full extent of its travel.

E-101

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E-101

Section E - Hydraulics Service Procedures Valve Block Spool Seals

Fig 82.

E-102

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E-102

Section E - Hydraulics Service Procedures Hydraulic Adaptors (Positional Type)

Hydraulic Adaptors (Positional Type) Fitting Procedure On a typical machine, some hydraulic components may utilise `Positional Type' SAE Hydraulic Adaptors. When fitting `Positional Type' Hydraulic Adaptors it is important to adopt the following procedure. If this procedure is not followed correctly, damage to the `O' ring seal A can occur resulting in oil leaks. 1

Ensure the locknut B is screwed back onto the body of the adaptor as far as possible as shown.

Check the `O' ring backing washer C is a tight fit on the adaptor. Note that the washer should not move freely, if the washer is slack do not use the adaptor.

Check the `O' ring A is fitted and that it is free from damage or nicks. Before fitting the adaptor, smear the `O' ring with clean hydraulic fluid.

Note: The dimensions and shore hardness of the `O' ring is critical. Should it become necessary to replace the `O' ring, ensure that only JCB Genuine Parts are used. 4

Screw the adaptor into the port of the hydraulic component as far as possible, so that ALL the threads engage and the `O' ring is correctly seated against the sealing face.

Set the angular position of the adaptor as required, then secure by tightening the locknut B.

Note: When fitted correctly no more than one thread should be visible at Z as shown. 6

Torque tighten the locknut to 81 Nm (60 lbf ft).

Fig 83.

E-103

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E-103

Section E - Hydraulics

Loader Valve Removal and Replacement K Fig 84. ( T E-105).

Replacement

!MWARNING

Replacement is a reversal of the removal sequence.

Make the machine safe before working underneath it. Park the machine on level ground, lower the attachments to the ground. Apply the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

!MWARNING

After replacement check the main relief valve (M.R.V.) and auxiliary relief valve (A.R.V.) pressure settings. Note: All hydraulic adaptors that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adaptor.

INT-3-1-11_2

Removal 1

Operate the valve block levers back and forth to vent residual pressure.

Remove clevis pins A and nuts B to disconnect the control levers from the valve block spools.

Disconnect all hydraulic hoses from the valve block and plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct position when refitting.

Uncouple the dump solenoid electrical connector G. Uncouple the electric detent connector H (if fitted).

Loosen and remove the three fixing nuts J. Remove the loader valve and spacing washers C.

E-104

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E-104

Section E - Hydraulics Loader Valve Removal and Replacement

Fig 84.

E-105

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E-105

Section E - Hydraulics Loader Valve Dismantle and Assemble

Dismantle and Assemble Main Relief Valve (MRV)

Fig 85. The numerical sequence shown on the illustration is intended as a guide to dismantling K Fig 86. ( T E-107).

Adjust pressure setting as required, refer to Service Procedures, Loader Valve - Pressure Testing.

For assembly the sequence should be reversed. Item The following points MUST be avoided when dismantling and assembling the valve:

Table 34. Torque Settings Nm kgf m 5.4

0.6

lbf ft 4

– Contamination – Damage to spool – Damage to seal grooves All or any of the above points may result in possible problems with the valve.

Assemble Renew all 'O' rings and back-up rings. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. Make sure that the 'O' rings and back-up rings are fitted the correct way, items 10 and 11 K Fig 86. ( T E-107).

E-106

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E-106

Section E - Hydraulics Loader Valve Dismantle and Assemble

Fig 86. Main Relief Valve (MRV)

E-107

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E-107

Section E - Hydraulics Loader Valve Dismantle and Assemble

Auxiliary Relief Valves (ARV) and Load Hold Check Valves (LHCV) The numerical sequence shown on the illustration is intended as a guide to dismantling K Fig 87. ( T E-109).

Item

Table 35. Torque Settings Nm kgf m

lbf ft

6.6

2.5

8.3

For assembly the sequence should be reversed. The following points MUST be avoided when dismantling and assembling the valve: – Contamination – Damage to spool – Damage to seal grooves All or any of the above points may result in possible problems with the valve. The ARV's are identical in design but have different pressure settings, refer to Technical Data. The LHCV's are identical.

Dismantle When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the seal grooves. Discard ALL 'O' rings and back up rings. DO NOT use worn or damaged items. Dismantle sub-assembly 14 from item 1 using a special tool (see Service Tools). The special spanner locates in cross holes B. Make sure that small drilling A is not blocked. Ensure good condition of seating faces on poppet 18 and on the mating face of the valve block. Inspect the valve components for scratches, nicks or any other type of damage, replace with new if required.

Assemble Renew all 'O' rings and back-up rings. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. Fit back-up ring 13 on the upper side of 'O' ring 12. Fit flat face of sleeve 9 against shoulder of poppet 10. Torque tighten item 14 using the special tool (see Service Tools), until its shoulder seats firmly against item 1. Pressure test the relief valves, refer to Service Procedures, Loader Valve - Pressure Testing.

E-108

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E-108

Section E - Hydraulics Loader Valve Dismantle and Assemble

Fig 87. Auxiliary Relief Valve (ARV) and Load Hold Check Valve

E-109

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E-109

Section E - Hydraulics Loader Valve Dismantle and Assemble

Unloader Valve Item

Table 36. Torque Settings Nm kgf m

lbf ft

The numerical sequence shown on the illustration is intended as a guide to dismantling K Fig 88. ( T E-111).

6.7

0.7

2.8

For assembly the sequence should be reversed.

8.3

4.6

3.5

The following points MUST be avoided when dismantling and assembling the valve: – Contamination – Damage to spool – Damage to seal grooves All or any of the above points may result in possible problems with the valve.

Dismantle When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the seal grooves. Discard ALL 'O' rings and back up rings. DO NOT use worn or damaged items. Use a nylon rod to push out spool assembly item 23, DO NOT damage spool bore. Inspect the valve components for scratches, nicks or any other type of damage, replace with new if required.

Assemble Renew all 'O' rings and back-up rings.Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. Ensure that the small drilling through the centre of items 23, is clear. Shims 21 are intended to limit the maximum pressure setting, the specified pressure setting is achieved by adjusting capnut 15. If the specified pressure cannot be achieved under test, it is permissible to add shims as required. There MUST be at least one hardened shim next to the spring item 22. Do not over-tighten the solenoid assembly, it may effect the operation of the solenoid, use the spanner flats and torque tighten to figure indicated in the table below (items 1 and 5). Fit chamfered end of spring 22 against head of pilot poppet item 23. Check pressure setting after refitting, refer to Service Procedures, Loader Valve - Pressure Testing. Check the operation of the hydraulic speed control, refer to Service Procedures, Loader Valve - Pressure Testing.

E-110

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E-110

Section E - Hydraulics Loader Valve Dismantle and Assemble

Fig 88. Unloader Valve

E-111

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E-111

Section E - Hydraulics Loader Valve Dismantle and Assemble

Standard Spool

Torque tighten cap screws 1.

The numerical sequence shown on the illustration is intended as a guide to dismantling. See K Fig 89. ( T E-113).

When fitting bolt 9, clean the threads thoroughly using JCB Cleaner and Degreaser, leave it for 10 minutes then apply a small quantity of JCB Threadlocker and Sealer to the threads of the spool.

Make sure that all the parts move freely, check that item 10 does not interfere with item 13.

Renew 'O' ring 15. Make sure the 'O' ring is not trapped or damaged.

Fit seal 15 and seal plate 14 to the valve block section. Torque tighten capscrew 5 on completion.

Re-connect the lever mechanism to the tang (lever) end of the spool.

Dismantle

Run the engine and inspect the valve for external leaks.

Remove the lever linkage from the tang (lever) end of the spool.

Item

When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves, for instance, item 3, which is a wiper seal and is a press fit in the counterbore.

Table 37. Torque Settings Nm kgf m

lbf ft

9.5

0.96

9.5

0.96

9.5

0.96

Care must be taken to ensure that the spool 8 is not damaged when removing it from the valve block. Hold the spool in clamp 992/10100, unscrew bolt 9 and remove spring 12, spacer 10 and cups 11 and 13. Check for surface contamination on the under side of the seal plates 2 and 14. Clean if necessary. Check for the flatness of the seal plate. If found to be bent - replace with new (any work previously carried out on this valve may have resulted in the bending of the seal plate).

Assemble 1

Fit the boot 1A to the seal plate 2.

Fit a new lipseal 4 into the valve block, ensure square. Fit wiper 3 on top of lipseal.

Fit the seal plate and boot assembly to valve block section but do not torque tighten capscrews 1 at this stage. Ensure wiper locates into seal plate.

Use clean hydraulic oil as a lubricant. From the bottom, insert spool through the valve block, do not use excessive force when fitting, a turning motion should ease the spool through the valve block.

E-112

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E-112

Section E - Hydraulics Loader Valve Dismantle and Assemble

Fig 89. Standard Spool

E-113

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E-113

Section E - Hydraulics Loader Valve Dismantle and Assemble

Float Spool

that the boot is not distorted and is located in the spool land.

The numerical sequence shown on the illustration is intended as a guide to dismantling K Fig 90. ( T E-115).

Torque tighten cap screws 1.

For assembly the sequence should be reversed.

When fitting detent pin 20, clean the threads thoroughly using JCB Cleaner and Degreaser, leave it for 10 minutes then apply a small quantity of JCB Threadlocker and Sealer to the threads of the spool.

Apply grease liberally balls 10, this will help to hold the balls in position whilst assembling.

Renew 'O' ring 15. Make sure the 'O' ring is not trapped or damaged.

Fit seal 15 and seal plate 14 to the valve block section. Torque tighten capscrew 6 on completion.

Dismantle Remove the lever linkage from the tang (lever) end of the spool.

Re-connect the lever mechanism to the tang (lever) end of spool. Run the engine and inspect the valve for external leaks.

When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves, for instance, item 4, which is a wiper seal and is a press fit in the counterbore. Care must be taken to ensure that the spool 13 is not damaged when removing it from the valve block.

Item

Table 38. Torque Settings Nm kgf m

lbf ft

9.5

0.96

9.5

0.96

9.5

0.96

Carefully remove collar 9 and collect detent balls 10. Using tool 992/10100 to hold the spool, remove circlip 16, plug 17, ball 18 and spring 19. Unscrew detent pin 20 and remove spring 22 and cups 21 and 23. Check for surface contamination on the under side of the seal plates 3 and 14. Clean if necessary. Check for the flatness of the seal plate. If found to be bent - replace with new (any work previously carried out on this valve may have resulted in the bending of the seal plate).

Assemble 1

Fit the boot 2 to the seal plate 3.

Fit a new lipseal 5 into the valve block, ensure square. Fit wiper 4 on top of lipseal.

Fit the seal plate and boot assembly to valve block but do not torque tighten capscrews 1 at this stage. Ensure wiper locates into seal plate.

Use clean hydraulic oil as a lubricant. From the bottom, insert spool through the valve block, do not use excessive force when fitting, a turning motion should ease the spool through the valve block.

Check that the tang end of the spool passes through the boot without dislodging or damaging the boot. Ensure that the tang aligns with the control rod and

E-114

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E-114

Section E - Hydraulics Loader Valve Dismantle and Assemble

Fig 90. Float Spool

E-115

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E-115

Section E - Hydraulics Loader Valve Dismantle and Assemble

Electric Detent Spool

When fitting spool end 15, clean the threads thoroughly using JCB Cleaner and Degreaser, leave it for 10 minutes then apply a small quantity of JCB Threadlocker and Sealer to the threads of the spool.

For assembly the sequence should be reversed.

Make sure that the chamfer on item 14 faces away from the solenoid, item 6.

The following points MUST be avoided when dismantling and assembling the valve:

Renew lipseal 11. Make sure the lipseal is not trapped or damaged.

Fit lipseal 11 and seal plate 10 to the valve block section. Torque tighten capscrew 5 on completion.

The numerical sequence shown on the illustration is intended as a guide to dismantling K Fig 91. ( T E-117).

– Contamination – Damage to spool – Damage to seal grooves All or any of the above points may result in possible problems with the valve.

Check the operation of the solenoid 6 after assembly by connecting a 12V supply. The spool should be held when it is pushed into the detent position and returned when the supply is disconnected.

Dismantle Run the engine and inspect the valve for external leaks. When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves, for instance, item 3, which is a wiper seal and is a press fit in the counterbore. Care must be taken to ensure that the spool 12 is not damaged when removing it from the valve block.

Item

Table 39. Torque Settings Nm kgf m

lbf ft

9.5

0.96

9.5

0.96

9.5

0.96

Use tool 992/10100 to hold the spool, remove circlip 13 and 'clapper' 14. Unscrew spool end 15 and remove spring 17 with cups 16 and 18. Check for surface contamination on the under side of the seal plates 2, 8 and 10. Clean if necessary. Check for the flatness of the seal plate. If found to be bent - replace with new (any work previously carried out on this valve may have resulted in the bending of the seal plate).

Assemble 1

Fit the boot 1A to the seal plate 2.

Fit a new lipseal 4 into the valve block, ensure square. Fit wiper 3 on top of lipseal.

Fit the seal plate and boot assembly to valve block but do not torque tighten capscrews 1 at this stage. Ensure wiper locates into seal plate.

Use clean hydraulic oil as a lubricant. From the bottom, insert spool through the valve block, do not use excessive force when fitting, a turning motion should ease the spool through the valve block.

Torque tighten cap screws 1.

E-116

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E-116

Section E - Hydraulics Loader Valve Dismantle and Assemble

Fig 91. Electric Detent Spool

E-117

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E-117

Section E - Hydraulics

Loader Valve Component Identification 3DX Xtra and 4DX â&#x20AC;&#x201C; From serial number 1486501 to 1502999 and 1414001 to 1416999

E-118

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Section E - Hydraulics Loader Valve Component Identification

D1 D2

G HPCO

D070920-06

Fig 92. 3DX Xtra and 4DX Item

Description

Port

Description

Main Relief Valve

Intelt

Unloader Valve

Return to Tank

Load Hold Check Valve

HPCO

High Pressure Carry Over

Lift Spool

Lift Ram Head Side

Bucket

Lift Ram Rod Side

Gauge Port

Bucket Ram Head Side

Bucket Ram Rod Side

Port

Table 40. Description

Inlet

3DX Super â&#x20AC;&#x201C; From serial number 1415101 to 1416999

E-119

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Section E - Hydraulics Loader Valve Component Identification

C F E D D A

HPCO

P1 P2

D070920-09

Fig 93. 3DX Super

Item

Table 41. Description

Main Relief Valve

Load hold Check Valve

Auxiliary Relief Valve

E-120

Item

Description

Lift Spool

Bucket Spool

Aux. Spool

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E-120

Section E - Hydraulics Loader Valve Component Identification Port

Table 42. Description

Intelt

Lift Ram Head Side

Lift Ram Rod Side

Bucket Ram Head Side

Bucket Ram Rod Side

Aux. Ram Head Side

Aux. Ram Rod Side

Return to Tank

Gauge

E-121

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E-121

Section E - Hydraulics Loader Valve Removal and Installation

Removal and Installation

!MWARNING Make the machine safe before working underneath it. Park the machine on level ground, lower the attachments to the ground. Apply the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

Before commencing work, ensure that the exterior of the loader valve block and the working area are thoroughly cleaned and free of possible sources of contamination.

Removal 1

Park the machine and make it safe. Obey the care and safety procedures.

Vent the hydraulic pressure.

Disconnect the control rod linkages from the ends of the spools.

Put a suitable receptacle beneath the valve block to collect any hydraulic fluid spillage.

B D070920-13

Working beneath the machine, label and disconnect all the hydraulic hoses from the loader valve block.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Remove the three securing nuts A, then carefully lift the valve block away from the resilient mounts B.

E-122

Fig 94. Typical Valve

Installation Installation is a reversal of the removal procedure. During the replacement procedure do this work also: – Inspect the resilient mounts B for damage, cracking etc. If the mounts are not in good condition, replace them with new ones. – Apply JCB Threadlocker and Sealer to the threads of nuts A before fitting. – Make sure that the hoses are correctly installed, and phased in the same position as removal to prevent chafing. – On completion, run the engine and check for leaks.

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E-122

Section E - Hydraulics Loader Valve Dismantle and Assemble

Dismantle and Assemble Main Relief Valve (MRV)

Open End Kit

Main relief valve is a complete kit with desire pressure setting as per Machine model. Refer to Technical Data.

Assemble 1

Put the relief valve A in the appropriate cavity and torque the relief valve to 80 Nm. K Fig 95. ( T E-123).

Put the quad ring 1 in between the casting and the spool.

D071030-05

Fig 97. 2

Gently press the quad ring 1 to fit in the groove. K Fig 97. ( T E-123).

Install the spacer 2 with the wiper seal and gently press the spacer 2.

D071030-10

Fig 95.

Unloader Valve Unloader valve is a complete kit with desire pressure setting as per Machine model. Refer to Technical Data. Put the unloader valve B in the appropriate cavity and torque the relief valve to 60 Nm.

D071030-06

Fig 98. 4

Put the flange 3 over the each spacer 2.

D071030-11

Fig 96.

E-123

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E-123

Section E - Hydraulics Loader Valve Dismantle and Assemble

D071030-07

Fig 99. 5

Attach the flange 3 with the four screws 4 and torque the screws to 10 Nm.

4 5 3 Fig 100. 6

Put the rubber boot 5 in the groove of the center ring and the spool. K Fig 100. ( T E-124).

Dismantle Dismantle is a reversal of the assemble sequence.

E-124

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E-124

Section E - Hydraulics Excavator Valve Removal and Replacement

Excavator Valve Removal and Replacement

Remove clevis pins B to disconnect the control levers from the valve block spools.

Disconnect all hydraulic hoses from the valve block and plug all orifices to prevent ingress of dirt. Label each hose and note the phasing before disconnecting, this will ensure correct position when refitting.

Uncouple the electrical connection to the hydraclamp solenoid F (for side shift machine only).

Uncouple the electrical connection to the rear horn G ( for side shift machine only).

Loosen nuts H - do not completely remove the retaining nuts.

GEN-4-1_1

This component is heavy. It must only be removed or handled using a suitable lifting method and device.

INT-3-1-11_2

BF-4-1_1

Removal

Open the rear window. Wrap a suitable sling around the valve, make sure that the weight of the valve is supported by the sling.

Remove nuts H. Remove the rear horn G. Lower the valve block to the ground.

Operate the valve block levers back and forth to vent residual pressure.

Remove the rear valance.

In order to gain access for valve removal the excavator control console A must be removed, see Section D, Controls.

!MWARNING

Replacement Replacement is a reversal of the removal sequence. Hoses and pipes (when applicable) must be re-connected and phased in same position as removal. Refer to Dismantling and Assembly, Hoses and Pipes.

Note: All hydraulic adaptors that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adaptor.

D070860-09

Fig 101.

E-125

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E-125

Section E - Hydraulics Excavator Valve Removal and Replacement

!MWARNING

Adjust the control levers to the correct positions, see Section D, Controls.

After replacement check the auxiliary relief valve (ARV) pressure settings.

INT-3-1-10_3

S439000-C2

Fig 102.

Fig 103.

E-126

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E-126

Section E - Hydraulics Excavator Valve Dismantle and Assemble

Dismantle and Assemble Valve Block The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

Load Hold Check Valves

Auxiliary relief valve dismantling and assembly procedures are detailed separately, K Auxiliary Relief Valves (ARV's) ( T E-130). Note: All hydraulic adaptors that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adaptor.

Assemble

Each of the identical load hold check valves 4R to 4W can be removed as shown at 4W. Make-up check valve 4X is a smaller size but otherwise identical.

Fit the boot 10 to the seal plate 11.

Fit a new lipseal 12A into the valve block, ensure square. Fit wiper 12 on top of lipseal.

Fit the seal plate and boot assembly to valve block but do not torque tighten capscrews 9 at this stage. Ensure wiper locates into seal plate.

Use clean hydraulic oil as a lubricant. From the bottom, insert spool through the valve block, do not use excessive force when fitting, a turning motion should ease the spool through the valve block.

If only renewing the seals, dismantle as far as cap 14 then remove items 15 to 22 as an assembly.

Torque tighten cap screws 9, K Table 43. Torque Settings ( T E-128).

Lubricate new seals with JCB Hydraulic Fluid and take care to prevent them from being damaged by the sharp edges of the spool.

When fitting bolt 15, clean the threads thoroughly using JCB Cleaner and Degreaser, leave it for 10 minutes then apply a small quantity of JCB Threadlocker and Sealer to the threads of the spool.

Make sure that all the parts move freely, check that item 16 does not interfere with item 18.

Renew 'O' ring 21 and seal 20. Make sure the 'O' ring and wiper seal are not trapped or damaged.

Fit seal 20 and seal plate 19 to the valve block section. Torque tighten capscrew 13 on completion, K Table 43. Torque Settings ( T E-128).

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E-127

Ensure good condition of seating faces on poppets 4 and 8 and on the mating faces in the valve block.

Service Spools Spools 4A, 4B, 4E and 4F are identical but must not be interchanged as they are matched to their bores. Stabiliser spools 4C and 4D are identical to each other but different from the excavator spools. All spools have the same centring and sealing components items 9 to 21. To completely dismantle a spool, follow the sequence 9 to 21. To prevent spool rotation when turning screw 15, hold a rod through the eye end of the spool.

Apply JCB Threadlocker and Sealer to threads of screw 15.

Auxiliary Relief Valves A.R.V's 4H to 4P appear identical but have various pressure settings, refer to Technical Data. Ensure that they are correctly adjusted and fitted in their specified positions.

E-127

Section E - Hydraulics Excavator Valve Dismantle and Assemble Re-connect the lever mechanism to the tang (lever) end of the spool. Run the engine and inspect the valve for external leaks.

Item

Table 43. Torque Settings Nm kgf m

122

12.4

8.3

9.5

0.96

0.7

1.1

E-128

lbf ft

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E-128

Section E - Hydraulics Excavator Valve Dismantle and Assemble

Fig 104.

E-129

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E-129

Section E - Hydraulics Excavator Valve Dismantle and Assemble

Auxiliary Relief Valves (ARV's)

Dismantle

Eight A.R.V's are fitted at positions 4H to 4Q. These are identical in design but have various pressure settings, refer to Technical Data.

K Fig 105. ( T E-131). The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

Note: The bucket rod side A.R.V. 4Q is only fitted to machines equipped with a Rockbreaker.

Dismantle sub-assembly 14 from item 1 using a special tool (see Service Tools). The special spanner locates in cross holes B. Dismantle sub-assembly 14 into its component parts. Make sure that small drilling A is not blocked. Discard old and worn O-rings and back-up rings.

Assemble Renew all O-rings and back-up rings. Lubricate O-rings and back-up rings with JCB Hydraulic Fluid. Fit back-up ring 13 on the upper side of 'O' ring 12 as shown in the inset. Fit flat face of sleeve 9 against shoulder of poppet 10.

A.R.V. Position Key: Control Layout JCB

ISO

Case

Ford

Slew Right

Slew Left

Boom Rod

Boom Head

Dipper Rod

Dipper Head

Bucket Rod

Bucket Head

E-130

Torque tighten item 14 using the special tool (see Service Tools), until its shoulder seats firmly against item 1. Pressure test the relief valves, refer to Service Procedures, Excavator Valve - Pressure Testing.

Item

Table 44. Torque Settings Nm kgf m

lbf ft

6.6

2.5

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E-130

Section E - Hydraulics Excavator Valve Dismantle and Assemble

Fig 105. Auxiliary Relief Valve

E-131

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E-131

Section E - Hydraulics Excavator Valve Dismantle and Assemble

Hydraclamp Valve (Sideshift Machines) The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. The following points MUST be avoided when dismantling and assembling the valve:

Do not over-tighten the solenoid assembly, it may affect the operation of the solenoid, use the spanner flats and torque tighten to figure indicated in the table below (items 11 and 13). Check the operation of the electric hydraclamp, refer to Circuit Descriptions, Excavator Valve - Manual Control - Hydraclamp Valve Operation. Table 45. Torque Settings Nm kgf m

– Contamination

Item

– Damage to poppet and seat

13.5

1.4

– Damage to seal grooves

24.5

2.5

13.5

1.4

5.5

0.5

24.5

2.5

All or any of the above points may result in possible problems with the valve.

lbf ft

When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the seal grooves. Discard ALL 'O' rings DO NOT use worn or damaged items. Note that the hydraclamp comprises two separate valve assemblies; 1) the check valve assembly (items 1 to 8); 2) the solenoid assembly (items 11 to 14).

Dismantle Loosen nut 1 (turn anti-clockwise) and then remove the check valve assembly from the valve block. If required, the check valve assembly can be dismantled into its component parts (items 1 to 8). Inspect the valve components for scratches, nicks or any other type of damage, particularly on the poppet and seat faces. Replace with new if required.

Assemble Renew all 'O' rings. The parts microfiche will identify the correct seal kit part numbers for items 2, 2A, 4, 6, 10 and 14. Fit seal 2A with the recess towards `O' ring 2, as shown at A. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. Ensure that the small drilling through the centre of item 3, is clear.

E-132

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E-132

Section E - Hydraulics Excavator Valve Dismantle and Assemble

Fig 106.

E-133

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E-133

Section E - Hydraulics Excavator Valve Dismantle and Assemble

Hoses and Pipes (Sideshift Valve) Refer to K Removal and Replacement ( T E-125) for valve block removal and replacement procedure. Hoses and pipes (when applicable) must be re-connected and phased in same position as removal.

Fig 107. ISO Excavator Valve

Fig 108. JCB Excavator Valve

E-134

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E-134

Section E - Hydraulics Excavator Valve Dismantle and Assemble

Hoses and Pipes (Centremount Valve) Refer to K Removal and Replacement ( T E-125) for valve block removal and replacement procedure. Hoses and pipes (when applicable) must be re-connected and phased in same position as removal.

Fig 109. ISO Excavator Valve

Fig 110. JCB Excavator Valve

E-135

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E-135

Section E - Hydraulics Excavator Valve Dismantle and Assemble

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E-136

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Section E - Hydraulics Excavator Valve Description

Excavator Valve Description For 3DX Xtra, 3DX Super (Base and AC)

The cleanliness of this component is critical and must conform to JCB standard 9993/0003.

â&#x20AC;&#x201C; From serial number 1486501 to 1491201

The valve block consists of six spools which controls the slew, boom, stabilizer, dipper and the bucket.

K J H G F E D

CT T1

L M

D070920-10

Fig 111. 3DX Xtra, 3DX Super (Base and AC)

Item

Table 46. Description

Main Relief Valve

Connector Pin

Load Hold Check Valve

Auxiliary Relief Valve

Swing Spool

Boom Spool

Stabilizer Spool

E-137

Item

Description

Stabilizer Spool

Dipper Spool

Bucket Spool

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E-137

Section E - Hydraulics Excavator Valve Description

Port

Table 47. Description

Swing Ram Head Side

Swing Ram Rod Side

Boom Ram Head Side

Boom Ram Rod Side

Stabilizer Ram Head Side

Stabilizer Ram Rod Side

Stabilizer Ram Head Side

Stabilizer Ram Rod Side

Dipper Ram Head Side

Dipper Ram Rod Side

Bucket Ram Head Side

Bucket Ram Rod Side

Return to Tank

Clamp Tank

HP Passage

Neutral Passage

E-138

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E-138

Section E - Hydraulics Excavator Valve Description

For 3DX Xtra and 3DX Super (Servo) â&#x20AC;&#x201C; From serial number 1491201 to 1502999

B PRA

A D

F G H

D070920-11

Fig 112. 3DX Xtra, 3DX Super (Servo)

Item

Table 48. Description

Main Relief Valve

Load Hold Check Valve

Auxiliary Relief Valve

Slew Control Servo

Boom Control Servo

Stabilizer Spool

Dipper Control Servo

Bucket Control Servo

Port

Table 49. Description

A1 B1

E-139

Port

Description

Boom Ram Head Side

Boom Ram Rod Side

Stabilizer Ram Head Side

Stabilizer Ram Rod Side

Stabilizer Ram Head Side

Stabilizer Ram Rod Side

Dipper Ram Head Side

Dipper Ram Rod Side

Bucket Ram Head Side

Bucket Ram Rod Side

Return to Tank

Swing Ram Head Side

Clamp Tank

Swing Ram Rod Side

Clamp Port

Pilot Port 1

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E-139

Section E - Hydraulics Excavator Valve Description Port

Description

PRA

Pilot Port 2

HP Passage

Neutral Passage

E-140

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E-140

Section E - Hydraulics Excavator Valve Description

4DX â&#x20AC;&#x201C; 1415101 to 1416999

PR PRA H G C

E D F

K J

D070920-12

Fig 113. 4DX

Item

Table 50. Description

Port

Table 51. Description

Main Relief Valve

Swing Ram Head Side

Load Hold Check Valve

Swing Ram Rod Side

Auxiliary Relief Valve

Boom Ram Head Side

Slew Control Servo

Boom Ram Rod Side

Boom Control Servo

Stabilizer Ram Head Side

Stabilizer Spool

Stabilizer Ram Rod Side

Dipper Control Servo

Stabilizer Ram Head Side

Bucket Control Servo

E-141

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E-141

Section E - Hydraulics Excavator Valve Description Port

Description

Stabilizer Ram Rod Side

Dipper Ram Head Side

Dipper Ram Rod Side

Bucket Ram Head Side

Bucket Ram Rod Side

Return to Tank

Pilot Port 1

PRA

Pilot Port 2

Neutral Passage

HP Passage

E-142

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E-142

Section E - Hydraulics Excavator Valve Removal and Replacement

Removal and Replacement

!MWARNING

This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Support the weight of the valve block with suitable lifting equipment, then remove the securing nuts. Carefully lift the valve block away from the resilient mounts.

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

Sideshift Machine To improve access to the valve block, sideshift the excavator fully to the left, then lower to the ground.

Removal Fig 114. 1

Park the machine and make it safe. Obey the care and safety procedures.

Vent the hydraulic pressure.

Put a suitable receptacle beneath the valve block to collect any hydraulic fluid spillage.

Installation Installation is a reversal of the removal procedure. During the replacement procedure do this work also:

Machines with Manual Spools: Disconnect the control rod linkages from the ends of the spools.

Machines with Servo Spools: Working beneath the machine, label and disconnect all the hydraulic hoses from the excavator valve block. Note the phasing of the hoses.

Cap the open contamination.

– Inspect the resilient mounts for damage, cracking etc. If the mounts are not in good condition, replace them with new ones. – Apply JCB Threadlocker and Sealer to the threads of nuts before fitting. – Make sure that the hoses are correctly installed, and phased in the same position as removal to prevent chafing. – On completion, run the engine and check for leaks.

E-143

hoses

and

ports

prevent

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E-143

Section E - Hydraulics Excavator Valve Dismantle and Assemble

Dismantle and Assemble Valve Block

Put the assembled control valve on a flat surface table and check the alignment.

K Fig 115. ( T E-145). The numerical sequence shown on the illustration is intended as a guide to dismantling.

Torque the tie rod nut 1 to 40 Nm (outlet side), at the same time hold the inlet side tie rod nut 2 with a spanner.

Service Spools

Do the same step for the inlet side tie rod nut 2.

Dismantle

Note: Spool are NSP (non-serviceable parts) and noninterchange. Spool are designed precise for the particular section / functions.

For assembly the sequence should be reversed.

Place the valve perpendicularly with respect to the surface.

Keep the inlet section at the bottom and the outlet section must be at the top facing on surface table.

Loosen the tie rod nuts A on the outlet side, at the same time hold the tie rod nuts B on the inlet side with a spanner.

Remove the tie nut A and the split washer C.

Mark the valve block section for assembly aid.

Carefully remove each section one by one and arrange in the same configuration of the control valve.

Replace the damage section with the new section.

Note: Each valve section comes with pre-assembled spool and interface seals. Spools are NSP (nonserviceable parts). 8

Make sure that the interface seal is properly fits in the groove.

Assemble 1

Put the smaller thread length side of the tie rods in the inlet side of the valve.

Tighten the four tie rod nuts 2 and four washers 4 (inlet side).

Install all the section one after another in the same sequence as removed.

Install all the valve sections and tighten the tie rod nuts 1 with split washers 3 (outlet side).

E-144

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E-144

Section E - Hydraulics Excavator Valve Dismantle and Assemble

4 1

2 5 6 7 8 9 10 11 12 D071030-01

Fig 115.

Load Hold Check Valve Load check kit is a complete kit assembly as a spare. 1

Place the poppet along with spring and tighten the plug A on the load check valve ports.

D071030-09

Fig 116. 2

Torque the plug A to 130 Nm.

E-145

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E-145

Section E - Hydraulics Excavator Valve Dismantle and Assemble Auxiliary Relief Valves Dismantle ARV is a complete kit assembly and this is a drop-in cartridge type. A.R.V's appear identical but have various pressure settings, refer to Technical Data. Make sure that they are correctly adjusted and fitted in their specified positions. 1

Loosen the screw in the cap plug A and remove the ARV B. D071030-04

Fig 118. 3

Torque the plug to 40 Nm.

Open End Kit Assemble

B 1

Put the quad ring 1 in between the casting and the spool.

A B 2

Replace the damage ARV with new ARV.

Assemble 1

Check the spring C, for the anti-cavitation function is placed properly in lock nut of the ARV.

D071030-05

Fig 119. 2

Gently press the quad ring 1 to fit in the groove. K Fig 119. ( T E-146).

Install the spacer 2 with the wiper seal and gently press the spacer 2.

D071030-02

Fig 117. 2

Put the AVR cartridge B into the cavity and tighten the screw in the cap plug with O-ring.

E-146

9813/2050-5

E-146

Section E - Hydraulics Excavator Valve Dismantle and Assemble

4 5 3 Fig 122. D071030-06

Fig 120. 4

Put the flange 3 over the each spacer 2.

Put the rubber boot 5 in the groove of the center ring and the spool. K Fig 122. ( T E-147).

Dismantle Dismantle is a reversal of the assemble sequence.

D071030-07

Fig 121. 5

Attach the flange 3 with the four screws 4 and torque the screws to 10 Nm.

E-147

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E-147

Section E - Hydraulics Excavator Valve Dismantle and Assemble

Page left intentionally blank

E-148

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E-148

Section E - Hydraulics

Servo Joysticks Description and Operation Description The joysticks basically comprise of a control lever 5, four pressure adjustment valves and a housing 10. Each pressure adjustment valve comprises of a control spool 6, a control spring 7, a return spring 8 and a plunger 9.

Operation

When not actuated the control lever is held in zero position by the four return springs 8. The control ports 1, 2, 3, 4 are connected to the tank port T via the drilling 11.

With deflection of the control lever 5 the plunger 9 pushes against the return spring 8and the control spring 7. The control spring 7 firstly moves the control spool 6 downwards and closes the connection between the appropriate port and tank port T. At the same time the appropriate port is connected to the port P via the drilling 11. The control phase begins as soon as the control spool 6 has found its balance between the force of the control spring 7 and the force which results from the hydraulic pressure in the appropriate port ports 1, 2, 3 or 4.

8 7 10

Through the interaction of control spool 6 and control spring 7 the pressure in the appropriate ports is proportional to the stroke of the plunger 9 and thus the position of the control lever 5. A rubber boot 12 protects the mechanical components of the housing from contamination.

E-149

6 T057530

Fig 123.

Port

Table 52. Description

Supply

Tank

1,2,3,4

Control

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E-149

Section E - Hydraulics Servo Joysticks Removal and Replacement

Removal and Replacement Removal Note: Only the left-hand (L.H.) joystick is shown in the illustration K Fig 124. ( T E-151). The other joystick is removed and replaced in the same way. Ensure that the engine is stopped and all hydraulic pressure is released from the system.

!MWARNING 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

Remove the covers from around the joystick body.

Mark the joystick flange and supporting flange to ensure correct realignment on replacement.

Label then remove hydraulic hoses and plug exposed connections to prevent ingress of dirt and water.

Disconnect the electrical connection if fitted.

Remove four screws 1 and washers 2, lift the joystick unit clear.

Replacement 1

Replacement is a reversal of the removal procedure.

Torque tighten hydraulic connections to 30 Nm (22 lbf ft).

Torque tighten screws 1 (4 off) to 10 Nm (7 lbf ft).

Reconnect the electrical connection if fitted. Replace covers around the joystick body.

E-150

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E-150

Section E - Hydraulics Servo Joysticks Removal and Replacement

4 3

4 D070920-15

Fig 124.

E-151

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E-151

Section E - Hydraulics Servo Joysticks Removal and Replacement

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E-152

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E-152

Hydraulic Rams Precautions During Use TE-006

Installation 1

Special seal materials are necessary so check to see if the ram that you are using is suitable or not.

Precautions when installing the ram on the machine. a

When installing and removing from the machine, suspend the ram safely.

b Suspending the ram by the piping is not only dangerous, but can also cause damage to the cylinder. c

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.

When painting the machine, mask the ram.

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.

Welding after installing the ram may result in damage. a

Warm up sufficiently before beginning work. a

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.

The number one cause of ram oil leakage is rod damage. Be careful not to damage the rod.

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.

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. a

Install the ram only when it is clean.

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.

Caution During Use

Maintenance, Inspection Points

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.

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Carry out daily maintenance and inspection. a

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

153

Hydraulic Rams Precautions During Use 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. 2

Use genuine JCB parts when replacing parts. a

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

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.

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

154

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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154

Hydraulic Rams Removal and Replacement

Removal and Replacement Loader Shovel Ram

Remove kliprings B, shims C and spacers D.

Removal

Remove pivot pins E.

K Fig 125. ( T 156).

Replacement

!MWARNING

Replacement is a reversal of the removal sequence.

The loader arm interlevers are potentially dangerous, when pivoting about their centre they form a 'scissor' point with the loader arm. Make sure the interlevers are securely blocked when working in the loader arm area. BF-2-1

Park the machine on firm level ground. Engage the parking brake and set the transmission to neutral.

Rest the shovel flat on the ground.

!MWARNING

Coat pivot pins with anti-rust lubricant.

All klipring installations to have a maximum end float of 2mm (0.080 in). Make sure that each klipring is installed with a shim.

INT-3-1-11_2

Switch off the engine and vent residual hydraulic pressure from the loader end by operating the loader controls back and forth several times.

Label and then remove the shovel ram hoses A. Plug and cap all open orifices to prevent loss of fluid and ingress of dirt.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Fasten lifting straps to the shovel ram, make sure that the weight of the ram is supported by the sling.

155

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155

Hydraulic Rams Removal and Replacement

D070860-19

Fig 125. Boom Ram

156

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156

Hydraulic Rams Removal and Replacement

Loader Lift Ram

D070930-08

Fig 126. Loader Lift Ram

Removal K Fig 126. ( T 157).

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157

Hydraulic Rams Removal and Replacement

!MWARNING

Remove pivot pin retaining bolt D.

Remove klipring E and shim F from both sides of ram, use slide hammer kit (service tool 993/68100) to remove pivot pin G.

Remove the lift ram.

BF-2-1

Replacement 1

Park the machine on firm level ground. Engage the parking brake and set the transmission to neutral. Raise the loader arms to give access to the lift ram pivot pins C. The loader arms must be supported, use a tool as shown.

Switch off the engine and vent residual hydraulic pressure from the loader end by operating the loader controls back and forth several times.

Note: If a hose burst protection valve is fitted on the ram, the system will not vent. Extreme caution must be used when releasing hydraulic connections - release the connections one turn and allow the pressure to dissipate. 4

Label and then remove the lift ram hoses A. Plug and cap all open orifices to prevent loss of fluid and ingress of dirt.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device.

Replacement is a reversal of the removal sequence.

Coat pivot pins with anti-rust lubricant. Make sure that the head of item D is on the engine side. Coat mainframe bores with grease. Assembly sequence for shim F and klipring: 1st

shim

2nd

ram

3rd

shim (as required)

4th

klipring

Pivot pins with M24 pin extractor hole: 1st

spacer

2nd

ram

3rd

shim (as required)

4th

klipring

All klipring installations to have a maximum end float of 2mm (0.080 in).

BF-4-1_1

Fasten lifting straps to the lift ram, make sure that the weight of the ram is supported by the sling.

Remove pivot pin retaining bolt B and then remove the pivot pin C.

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158

Hydraulic Rams Removal and Replacement

D070930-09

Fig 127. Loader Shovel Ram

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159

Hydraulic Rams Removal and Replacement

Bucket Crowd Ram

Replacement

Removal

Replacement is a reversal of the removal sequence.

!MWARNING

K Fig 128. ( T 161). 1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the backhoe and loader end to the ground and stop the engine.

INT-3-1-11_2

Vent residual hydraulic pressure from the backhoe hoses by operating the backhoe controls back and forth several times.

Label and then remove the bucket crowd ram hoses A. Plug and cap all open orifices to prevent loss of fluid and ingress of dirt.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Fasten lifting straps to the bucket crowd ram, make sure that the weight of the ram is supported by the sling.

Remove the pivot pin retaining nut B and bolt C, remove the pivot pin D.

Remove the bucket crowd ram.

160

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160

Hydraulic Rams Removal and Replacement

D070860-20

Fig 128. Bucket Crowd Ram

161

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161

Hydraulic Rams Removal and Replacement

Dipper Ram

Replacement

Removal

Replacement is a reversal of the removal sequence.

!MWARNING

K Fig 129. ( T 163). 1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the backhoe and loader end to the ground and stop the engine.

INT-3-1-11_2

Vent residual hydraulic pressure from the backhoe hoses by operating the backhoe controls back and forth several times.

Label and then remove the dipper ram hoses A. Plug and cap all open orifices to prevent loss of fluid and ingress of dirt.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Fasten lifting straps to the dipper ram, make sure that the weight of the ram is supported by the sling.

Remove the pivot pin retaining nut B and bolt C, remove the pivot pin D.

Remove dipper ram.

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162

Hydraulic Rams Removal and Replacement

D070930-10

Fig 129. Dipper Ram

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163

Hydraulic Rams Removal and Replacement

Boom Ram Removal

Fasten lifting straps to the boom ram, make sure that the weight of the ram is supported by the sling.

Remove the pivot pin retaining nut F and bolt G remove the kingpost pivot pin H.

Remove the boom ram.

K Fig 130. ( T 165). 1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the backhoe and loader end to the ground and stop the engine.

Replacement Replacement is a reversal of the removal sequence.

Remove pivot pin retaining nut A and bolt B. Remove the pivot pin C.

!MWARNING

Remove the grease nipple from the eye end of the ram (through access hole D).

Use the machine hydraulics to SLOWLY retract the ram.

Remove the hose clamp.

!MWARNING

INT-3-1-10_3

Vent residual hydraulic pressure from the backhoe hoses by operating the backhoe controls back and forth several times.

It will be necessary to extend the ram to align and engage the boom pivot pin C. As the ram extends, the ram will tend to turn. For this reason it is recommended that a smaller diameter steel bar is used to locate the boom ram at the kingpost casting. The steel bar can be more readily removed to allow for re-alignment of the boom pivot pin C. When the boom pivot pin has been correctly aligned and fitted, then fit the correct pivot pin H at the kingpost.

Label and then remove the boom ram hoses E. Plug and cap all open orifices to prevent loss of fluid and ingress of dirt.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

164

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164

Hydraulic Rams Removal and Replacement

D070860-19

Fig 130. Boom Ram

165

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165

Hydraulic Rams Removal and Replacement

Slew Ram

Removal

Inspection

K Fig 131. ( T 168).

Inspect the liner bearings 7 (located in the trunnion retaining bracket 3) and liner bearing 8 for signs of damage, wear, scores or nicks etc. Replace as required.

Slew the backhoe to the left to remove the right hand slew ram and visa versa.

Lower the bucket to the ground and switch off the engine.

!MWARNING

Lift the slew ram assembly clear of the machine.

To remove the liner bearing 8 use a jack located against blanking plate 9. Shown in the inset at Y. To remove the bearing liner 7 from the trunnion bracket use flat faced bearing pullers.

Vent any residual hydraulic pressure by operating the backhoe and slew control levers.

Disconnect the hydraulic hoses 1 to the slew rams before disconnecting the hoses make sure that they are labelled (to assist with reassembly).

Plug and cap all open hydraulic connections to prevent ingress of dirt and loss of hydraulic fluid.

Loosen and remove trunnion bracket retaining nuts 2 and hardened washers 2A (see note).

Note: On assembly, the correct grade of nut (grade 12) and bolt (grade 10.9) must be used. Also, use hardened washers 2A - NOT ordinary washers. Using incorrect specification items could result in a reduction of clamping efficiency. 7

Remove the trunnion bracket 3.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Attach suitable lifting straps to the slew ram assembly. Note that the weight of the slew ram assembly is approximately 44 kg (97 lbs).

Remove thin nuts 4 (2 off per pivot pin) and remove the pivot pin retaining bolt 5. Use a 25 - 30 mm diameter bar to knock the pin out vertically.

Remove the slew ram (eye end) pivot pin 6 and swing the ram to clear the kingpost casting.

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166

Hydraulic Rams Removal and Replacement Replacement

Replacement is generally a reversal of the removal procedures, however note the following: The liner bearings 7 and 8 have a `lead-in' diameter (noticeable with a slight step), always install the smaller diameter first into the pivot bore. The bearings must be installed so that they sit flush. The eye end pivot pins 6 should be secured first - i.e. BEFORE the trunnion bracket retaining nuts 2, this will help to maximise ram assembly alignment. Make sure that the hydraulic hoses are correctly installed. Make sure that any new or reused bearings are clean and smeared with grease prior to reassembly of pins and trunnion journals.When fully assembled, apply grease at each grease nipple BEFORE operating the machine. Table 53. Torque Settings (Un-plated Fasteners) Item Nm lbf ft kgf m 2

565

417

57.5

Table 54. Torque Settings (Plated Fasteners) Item Nm lbf ft kgf m 2

167

510

376

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167

Hydraulic Rams Removal and Replacement

Fig 131. Slew Ram

168

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168

Hydraulic Rams Removal and Replacement

Stabiliser Ram (Sideshift)

Removal

Loosen and remove the stabiliser hoses L, label the hoses before removing (as an aid to assembly). Plug all open orifices to prevent loss of fluid and ingress of dirt.

K Fig 132. ( T 170). 1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the backhoe and loader end to the ground.

Lower the stabiliser legs until the pads are approximately 4 in. (100 mm) off the ground and stop the engine.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Remove the bottom locking nut A and bolt B. Drive out the bottom pivot pin C and allow the stabiliser foot D to fall clear. Lift the inner leg and temporarily refit the pivot pin C through inner leg and ram.

Place a block of wood underneath the stabiliser leg.

Remove circlips E and drive out top pivot pin F with spacing collars G.

Start the engine and slowly extend the stabiliser ram so that the dump end of the ram protrudes from the top of the outer leg section.

Attach suitable lifting gear to the ram as shown at H. Make sure that the weight of the ram is supported by the sling and remove the bottom pivot pin C.

Using suitable lifting equipment, lift the ram clear.

Replacement Replacement is a reversal of the removal sequence.

Use suitable lifting appliances to locate the stabiliser ram. After replacing or fitting the ram, connect the hydraulic pipes, make sure that the ram and leg operate freely and do not foul.

Make sure the engine is switched off, vent residual hydraulic pressure by moving the backhoe and stabiliser control levers back and forth.

Note: If a check valve is fitted on the ram, the system will not vent. Extreme caution must be used when releasing hydraulic connections - release the connections one turn and allow the pressure to dissipate.

169

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169

Hydraulic Rams Removal and Replacement

D070920-14

Fig 132. Stabiliser Ram (Sideshift)

Priority Valve Removal and Replacement

member, behind the hydraulic tank. It is attached to the chassis member by one bolt A, and is accessible from below K Fig 133. ( T 171).

The priority valve is mounted on the left hand side chassis

There are four connections to the valve as follows

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170

Hydraulic Rams Removal and Replacement P

- from hydraulic pump

to steering valve

to valve block

pilot connection from steering valve

port is plugged

For assembly the sequence should be reversed. When Dismantling Press out the spool item 14 using a nylon pin. Take care not to damage the bores of the valve. When Assembling

When replacing always renew sealing washers 2, 4, and 10.

Make sure that spring seat of spool 14 faces toward LS connection. Clean all parts in clean paraffin. Lubricate all parts with hydraulic fluid. Renew aluminium washers 8 and 12. Note: All hydraulic adaptors that are installed together with a bonded sealing washer must also have sealant (Loctite 577)applied to the threads of the adaptor.

Item

Table 55. Torque Settings Nm lbf ft

*To bleed the LS line, start the engine, loosen the connection on the valve, turn and hold the steering wheel fully in either direction. When bubble free oil flows from the joint, tighten the connection.

Fig 133. priority valve

Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling.

171

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171

Hydraulic Rams Removal and Replacement

JCB Ram Sealing Procedure TE-005_2

Fit new rod seals. Use seal fitting tool 134-A to fit rod seals, the size (diameter) and position of pins 134-B is determined by the diameter and radial width of the rod seal being fitted.

153212-1

Fig 136. b Close the tool. K Fig 137. ( T 172). The seal must form a reniform (kidney shape). S216250-1

Fig 134. Seal Fitting Tool The pins are screwed into threaded holes in the tool body, the spacing of the holes is designed to suit small or large diameter rod seals. a

Open the tool and insert the new rod seal 135-A. The seal must be fitted behind the two front pins but in front of the rear pin as shown.

S161750 Y-1

Fig 137. c

Before fitting the rod seals check the seal grooves are free of contamination and sharp edges.

d Locate the seal in the end cap groove. K Fig 138. ( T 172). When the seal is in position, open the tool to release the seal. Make sure the seal is correctly installed in its grooved and remove the tool.

S161750 X-1

Fig 135. Note: Later ram end caps and piston heads are metric threads. The seals are also different, make sure the correct seals are fitted. On metric threaded rams make sure the seals are fitted the correct way round, as shown at 136-A and 136-B. S161750 Z-1

Fig 138. e

172

9813/2050-5

Fit rod wiper seal 136-A into seal groove. Make sure the seal is correctly installed as shown.

172

Hydraulic Rams Removal and Replacement Note: Some rod wipers, i.e. power track rod, may use a metal encased seal which is pressed into the housing. Care must be taken to ensure the seal is square before it is pressed in.

b Fit outer seal 140-C using the same procedure as stated for seal 140-B. Check the external grooves are visible. c

Sleeve 139-A must be used to protect the rod seals from damage when fitting end cap onto the piston rod. There are various sizes of sleeve, see Service Tools, Section 1. Make sure the hexagon on the end cap is towards the eye end of the rod.

Ensure the O-ring is fitted into the internal seal groove on the piston head. Screw the piston head onto the thread of the piston rod, refer to the relevant section for torque figure and completion of ram assembly.

d Fit the piston head retaining dowel, refer to the relevant section for torque figure and completion of ram assembly. e

Fit wear rings 141-A and 141-B. Rotate the wear rings so that the piston retention dowel is covered by the wear ring, Not as shown at 141-C.

187361-1

Fig 139. 2

Fit new head piston seals. a

Use a blunt instrument 140-A (Part no. 892/ 01027) to lever the inner seal 140-B into the piston head seal groove. Do not let the seal twist. There are identification marks on the outer diameter of the seal, make sure the marks are visible and the seal is free to rotate, if not remove the seal and refit.

338490-1

Fig 141. 3

Fit the piston rod and head assembly into the cylinder. a

Insert the piston/rod assembly into the cylinder. Align the rod and head assembly until parallel with the cylinder then push the assembly into the cylinder.

b Fit the end cap, refer to the relevant section for torque figure and completion of ram assembly.

338480-1

Fig 140.

173

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173

Hydraulic Rams Assembly and Disassembly

Assembly and Disassembly Typical Ram The procedures described below are applicable for the following rams: – Loader Shovel Ram – Loader Lift Ram – Bucket Crowd Ram – Boom Ram – Dipper Ram

Disassembly The numerical sequence shown on the illustration is intended as a guide to dismantling. D070910-02

Fig 143.

For assembly the sequence should be reversed. 5

!MWARNING

Rotate and pull the piston rod B from the tube.

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

Clean the cylinder using good clean cloth. Ensure that dirt does not go inside through ports.

Hold the cylinder on a Bench vise firmly with proper support by using rexin on the outer surface to prevent any damage on the outer tube.

D070910-03

Fig 144. 6

Place the piston rod on a V-block.

Remove seal from the head end cover.

D070910-04

Fig 145. D070910-01

Fig 142. 4

Insert a pipe in the rod end C. K Fig 145. ( T 174).

Remove the snap ring D and the grub screw E. K Fig 146. ( T 175).

Open the head end cover A.

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174

Hydraulic Rams Assembly and Disassembly

D070910-05

Fig 146.

D070910-08

Fig 148. 9

Remove the piston bearing G. 11

Remove the piston nut J.

D070910-06

Fig 149. 12

Remove and disassemble the piston K.

D070910-07

Fig 147. 10

Open the grub screw H.

D070910-13

Fig 150.

175

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175

Hydraulic Rams Assembly and Disassembly 16

Remove the head end cover.

Use a bent screwdriver to remove the wiper seal L and the secondary rod seal M.

Remove the piston seal P.

D070910-11

Fig 153. 17

Remove the piston O-ring Q and the piston back up ring R.

D070910-09

Fig 151. 15

Remove the piston bearing N.

D070910-12

Fig 154. 18

Examine all the components and seals for damage.

D070910-10

Fig 152.

176

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176

Hydraulic Rams Assembly and Disassembly Assembly Clean all the components with Use JCB Cleaner and Degreaser to ensure that all threads are free from grease, hydraulic oil and sealant. Make sure that lubricants used during assembly do not come into contact with the JCB Threadlocker and Sealer (High Strength). For the correct method of fitting seals to the end cap and Ram Sealing piston head refer K JCB Procedure ( T 172). 1

Put the primary rod seal B in the head end cover A. D070910-15

Fig 156. 3

Put the secondary rod seal D and the wiper seal E.

D070910-14

Fig 155. 2

Put the rod seal guide ring C in the head end cover. K Fig 156. ( T 177).

D070910-16

Fig 157. 4

177

9813/2050-5

Put the piston O-rings F onto the piston.

177

Hydraulic Rams Assembly and Disassembly

D070910-19

Fig 160. 8

Clean the piston rod K.

D070910-17

Fig 158. 5

Put the piston seal G onto the piston.

D070910-20

Fig 161. 9

Install the retainer L.

D070910-21

Fig 162. 10

Put the head end cover on the piston rod A. K Fig 163. ( T 179).

9813/2050-5

178

D070910-18

Fig 159. 6

Make sure screw driver does not have sharp edges.

Put the piston O-ring H and the back ring J inside the piston head.

178

Hydraulic Rams Assembly and Disassembly

D070910-22

Fig 163. D070910-25

Lightly tap the head end cover with a rubber mallet to install the cover.

Fig 166. 15

Tighten the grub screw P and seal the joint.

Install the piston M.

D070910-23

Fig 164. 13

D070910-26

Fig 167.

Tighten the nylon nut N to the correct torque value. Refer to the torque table K Table 56. ( T 180).

D070910-27

D070910-24

Fig 168.

Fig 165. 14

Tighten the piston M.

179

Tighten the grub screw Q and assemble the snap ring R.

Install the piston bearing S and apply oil on the tube assembly. K Fig 169. ( T 180).

9813/2050-5

179

Hydraulic Rams Assembly and Disassembly

D070910-28

Fig 169. 18

Install the piston rod assembly into the tube.

D070910-31

Fig 172.

Ram D070910-29

Fig 170. 19

Tighten the head end cover A.

Loader Shovel Ram

Table 56. Torque Table Nm Kgfm 412-461

42-47

Loader Lift Ram 539-588

55-60

Bucket Crowd Ram

1078-1176

110-120

Boom Ram

1765-1961

180-200

Dipper Ram

1667-1863

170-190

Performance Check

D070910-30

Pull the piston rod and push it back to check the smoothness of assembly.

Mount the cylinder on the equipment and operate at low speed, check for any leakage.

Ensure that air is not trapped in the cylinder by operating the cylinder at low speed for 2 minutes.

Fig 171. 20

Seal the head end cover.

180

9813/2050-5

180

Hydraulic Rams Assembly and Disassembly

Slew Ram Disassembly The numerical sequence shown on the illustration is intended as a guide to dismantling. 1

Clean the cylinder with a clean cloth.

Position the cylinder in a bench vice. Use a soft jaws to prevent any damage on the outer tube.

D070910-34

Fig 175. 5

Remove the port cap 23.

D070910-32

Fig 173. 3

Mark a straight line on trunnion and tube for assembly aid.

D070910-35

Fig 176. 6

Remove the plunger 7 before removing the trunnion.

D070910-33

Fig 174. 4

Remove the hex socket set screw 10.

D070910-36

Fig 177.

181

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181

Hydraulic Rams Assembly and Disassembly 7

Loosen the trunnion 4 in counterclockwise direction with a rubber mallet or a nylon rod and hammer.

Remove the grub screw 11.

D070910-40

Fig 181. D070910-37

Fig 178. 8

Mark a straight line on the piston and the piston rod for assembly aid.

Remove the trunnion 4 along with the piston rod assembly 3 from the tube.

D070910-38

Fig 179. 9

D070910-41

Put the piston rod assembly on clean bench and remove the piston bearing strip 14.

Fig 182. 12

Hold the rod eye and loosen the piston.

D070910-42

Fig 183. D070910-39

Fig 180.

182

9813/2050-5

Remove the piston 2 from the piston rod 3.

182

Hydraulic Rams Assembly and Disassembly 16

Remove the trunnion O-ring 19 and back up ring 20 with a bend screw driver.

D070910-46

Fig 187. D070910-43

Remove the metal gland wiper 22.

Fig 184. 14

Remove the piston rod 3 from the trunnion 4.

D070910-47

Fig 188. D070910-44

Fig 185. 15

Remove the piston bearing strip 14.

Remove the snap ring 13 of metal gland wiper and rod seal 21 with a bend screw driver.

D070910-45

Fig 186.

183

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183

Hydraulic Rams Assembly and Disassembly Assembly 1

Assemble the rod seal 21.

D070910-48

Fig 189. 19

Remove the piston seal 15. K Fig 190. ( T 184).

Fig 192. 2

Put the trunnion O-ring 19 and the back ring 20.

D070910-49

Fig 190.

D070910-53

Fig 193. 20

Remove the piston O-ring 16. 3

Put the metal guard 22 and the snap ring 13.

D070910-54

Fig 194. 4

Make sure that the wiper and lips face against pressure side.

D070910-50

Fig 191. 21

Examine all the components and seals for damage.

184

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184

Hydraulic Rams Assembly and Disassembly

D070910-56

Fig 197. D070910-51

Fig 195. 5

Install the O-ring K Fig 196. ( T 185).

7 the

piston

grove.

Apply petroleum jelly on the head end cover or the trunnion O-ring and install the piston rod assembly 3 into the trunnion 4.

D070910-55

Fig 196. 6

Install the piston seal 15 on the O-ring. D070910-57

Fig 198. 8

185

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Install the piston 2 on piston rod assembly 3.

185

Hydraulic Rams Assembly and Disassembly

D070910-58

Fig 199. 9

Make sure that the cushion ring is in the centre. K Fig 200. ( T 186).

D070910-60

Fig 201. 11

Put the bearing strips 14 in grove of piston.

D070910-59

Fig 200. 10

Install the set screw 11 in the grove and seal the joint.

D070910-61

Fig 202.

186

The two piston bearing strips slot is in the opposite direction.

9813/2050-5

186

Hydraulic Rams Assembly and Disassembly

D070910-64

D070910-62

Fig 205.

Fig 203. 13

Apply hydraulic oil inside the tube 1 and install the piston rod assembly 3 inside the tube.

Tighten the head end cover or the trunnion and align with the mark.

D070910-63

D070910-65

Fig 204. 14

Fig 206.

Install the the head end cover or trunnion 4 on tube 1.

187

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Install and seal the hex set screw 10.

187

Hydraulic Rams Assembly and Disassembly

D070910-66

Fig 207. 17

Install the port cap 23 and the plunger 7.

D070910-67

Fig 208.

188

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188

189

1 8 7

23 4 10 20

22 13

2 5 9813/2050-5

6 3

189

Hydraulic Rams

D070910-68

Fig 209.

Assembly and Disassembly

Hydraulic Rams Assembly and Disassembly

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190

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190

Section E - Hydraulics

Fault Finding Introduction The purpose of this section is to help you trace hydraulic faults to a faulty unit (valve, actuator, ram etc). Once you have traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the hydraulics section. To help identify circuits, valves, rams etc. mentioned in the fault finding procedures, refer to the hydraulic schematic diagrams (near the beginning of the Hydraulics Section). 1

Before you begin fault finding, read the Safety information at the beginning of this manual.

Make simple checks before say, stripping a major component.

Make sure that the hydraulic fluid is at correct working temperature (50 0C, 122 0F).

What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.

Make any relevant electrical checks before moving on to the hydraulics.

Be sure to remove. ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit Replace any seals such as '0' rings before reassembling hydraulic components.

Replace any seals such as 'O' rings before reassembling hydraulic components.

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E-191

Section E - Hydraulics Fault Finding Introduction Table 57. Probable Cause

Fault

Action

Lack of power in all hydraulic functions. Insufficient hydraulic fluid.

Check for leaks and top up as required.

Hydraulic leaks in system.

Check hoses, replace as required.

Engine performance.

Check engine performance, see transmission section for stall speed test procedures.

Main relief valve (MRV) setting incorrect.

Check and adjust as required.

Low pump flow.

Check pump flow, if required service or replace pump.

Hydraulic tank breather.

Clean or replace the breather.

Tank filter by-pass valve.

Check condition of hydraulic filter.

Unloader valve pressure setting too high.

Check pressure setting of the unloader valve.

Table 58. Probable Cause

Fault

All hydraulic rams slow to operate. Neutral circuit or low pressure lines leaking, damaged, trapped or kinked.

Action Check pipe lines and replace as required.

Low pump flow.

Check pump flow, if required service or replace pump.

Main Relief Valve (MRV) setting incorrect.

Check and adjust as required.

Unloader valve.

Check if unloader valve is sticking, i.e. dumping flow from pump section P2.

Tank filter by-pass valve.

Check condition of hydraulic filter.

Hydraulic tank Breather.

Clean or replace the breather.

Fault

Table 59. Probable Cause

One hydraulic service fails to operate or is slow to operate.

Associated service pipe lines leaking, damaged, trapped or kinked.

Check hoses, replace as required.

Associated ram leaking.

Complete ram leakage check, replace seals as required.

Auxiliary relief valve (ARV) setting incorrect.

Check and adjust as required.

Action

Associated valve block section leaking Check for leaks, rectify as required. or not operating See also `Leaking Oil Seal (Control Valves)'. Check that the control lever and associated linkage is operating the spool, rectify as required. See also `A Spool is Sticking'.

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Section E - Hydraulics Fault Finding Introduction Fault

Probable Cause

Action

Check valve malfunctioning (if fitted), e.g. stabiliser circuit.

Test check valve, rectify as required.

Hose burst protection valve malfunctioning (if fitted).

Test HBPV, service as required.

Piston rod is bent.

Replace piston rod, check pressure settings of MRV and ARV. Check that associated pivot points are adequately greased.

Fault The engine tends to stall when hydraulics are under load.

Fault A spool is sticking.

Table 60. Probable Cause

Action

M.R.V setting incorrect.

Check and adjust as required.

Poor engine performance.

Check engine performance, see transmission section for stall speed test procedure.

Unloader valve pressure setting too high.

Check pressure setting of the unloader valve.

Table 61. Probable Cause

Action

Oil temperature abnormally high.

Check for correct fluid, see lubricants and capacities. Check oil cooler and grille for blockage.

The hydraulic fluid is dirty.

Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system. Fill with clean hydraulic fluid.

The service pipe connection is over tightened.

Check tightening torque.

The valve housing was twisted during installation.

Loosen retaining bolts and tighten to correct torque figures.

A control linkage is bent.

Disconnect the linkage. Repair the linkage if possible, or fit a new one.

A spool is bent.

Dismantle the control valve. Renew spool as necessary.

A return spring is broken.

Renew as necessary.

A return spring or cap is out of alignment.

Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts.

Temperature distribution within control Warm the entire system up before valve not uniform. servicing.

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Section E - Hydraulics Fault Finding Introduction Fault Leaking Oil Seal (Control Valves)

Fault Ram creep

Table 62. Probable Cause Paint or dirt on the seal face.

Remove the seal and clean.

The back pressure in the valve circuit is excessively high.

Check circuit pressures, adjust if possible. Otherwise investigate thoroughly.

Spool damaged.

Dismantle. Inspect all parts. Renovate or renew as necessary.

The seal is not secured.

Clean the seal and tighten the retaining bolts to the correct torque.

The seal is cut or damaged.

Fit a new seal.

Table 63. Probable Cause

Action

Associated ram or pipe lines from ram Check and rectify as required. leaking.

Fault Hydraulic oil becomes too hot.

Fault Steering fails to operate or stiff to operate.

Fault

Check valve malfunctioning (if fitted), e.g. stabiliser circuit.

Test check valve, rectify as required.

Associated valve section spools leaking.

Rectify, check for contamination.

Associated ARV leaking.

Rectify, check for contamination.

Table 64. Probable Cause

Action

Oil cooler obstructed.

Remove debris from cooler fins.

Restriction in neutral circuit lines.

Check hoses, replace as necessary.

Hydraulic filter clogged and by-pass valve not working.

Change hydraulic filter.

Table 65. Probable Cause

Action

Tyres not inflated to correct Pressure.

Inflate tyres to correct Pressure.

Insufficient hydraulic fluid.

Check for leaks and top up as required.

Low pump flow.

Check pump flow, if required service or replace pump.

Leak in the relevant hoses or component connection.

Check hoses and for connection for leaks.

Steer relief valve set incorrectly.

Check pressure setting of steer unit relief valve, adjust as required.

Table 66. Probable Cause

Steering fails to operate or stiff Priority valve not operating to operate (Cont.). correctly.

E-194

Action

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Action Check if the priority valve is sticking, rectify as required.

E-194

Section E - Hydraulics Fault Finding Introduction Fault

Probable Cause

Action Check the load sense line from the steer unit to the priority valve for signs for leaking or poor connection.

Steer mode valve not operating correctly.

Check if the spool is sticking, rectify as required.

Mechanical failure.

Check for damaged axle components, such as ram, track rods,linkages etc. Check for damaged axle components, such as ram, trackrods, linkages etc. Check for damaged steer unit components. Steering column and associated components not set correctly.

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Section E - Hydraulics Fault Finding Introduction

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Hydraulic Rams Assembly and Disassembly

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192

Hydraulic Rams Assembly and Disassembly

193

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193

Hydraulic Rams Assembly and Disassembly

194

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194

Hydraulic Rams Assembly and Disassembly

195

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195

Hydraulic Rams Assembly and Disassembly

196

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196

Hydraulic Rams Assembly and Disassembly

197

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197

Section E - Hydraulics

Before you begin fault finding, read the Safety information at the beginning of this manual.

Make simple checks before say, stripping a major component.

Make sure that the hydraulic fluid is at correct working temperature (50 0C, 122 0F).

What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.

Make any relevant electrical checks before moving on to the hydraulics.

Replace any seals such as 'O' rings before reassembling hydraulic components.

E-187

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E-187

Section E - Hydraulics Fault Finding Introduction Table 56. Probable Cause

Fault

Action

Lack of power in all hydraulic functions. Insufficient hydraulic fluid.

Check for leaks and top up as required.

Hydraulic leaks in system.

Check hoses, replace as required.

Engine performance.

Check engine performance, see transmission section for stall speed test procedures.

Main relief valve (MRV) setting incorrect.

Check and adjust as required.

Low pump flow.

Check pump flow, if required service or replace pump.

Hydraulic tank breather.

Clean or replace the breather.

Tank filter by-pass valve.

Check condition of hydraulic filter.

Unloader valve pressure setting too high.

Check pressure setting of the unloader valve.

Table 57. Probable Cause

Fault

All hydraulic rams slow to operate. Neutral circuit or low pressure lines leaking, damaged, trapped or kinked.

Action Check pipe lines and replace as required.

Low pump flow.

Check pump flow, if required service or replace pump.

Main Relief Valve (MRV) setting incorrect.

Check and adjust as required.

Unloader valve.

Check if unloader valve is sticking, i.e. dumping flow from pump section P2.

Tank filter by-pass valve.

Check condition of hydraulic filter.

Hydraulic tank Breather.

Clean or replace the breather.

Fault

Table 58. Probable Cause

One hydraulic service fails to operate or is slow to operate.

Associated service pipe lines leaking, damaged, trapped or kinked.

Check hoses, replace as required.

Associated ram leaking.

Complete ram leakage check, replace seals as required.

Auxiliary relief valve (ARV) setting incorrect.

Check and adjust as required.

Action

E-188

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E-188

Section E - Hydraulics Fault Finding Introduction Fault

Probable Cause

Action

Check valve malfunctioning (if fitted), e.g. stabiliser circuit.

Test check valve, rectify as required.

Hose burst protection valve malfunctioning (if fitted).

Test HBPV, service as required.

Piston rod is bent.

Replace piston rod, check pressure settings of MRV and ARV. Check that associated pivot points are adequately greased.

Fault The engine tends to stall when hydraulics are under load.

Fault A spool is sticking.

Table 59. Probable Cause

Action

M.R.V setting incorrect.

Check and adjust as required.

Poor engine performance.

Check engine performance, see transmission section for stall speed test procedure.

Unloader valve pressure setting too high.

Check pressure setting of the unloader valve.

Table 60. Probable Cause

Action

Oil temperature abnormally high.

Check for correct fluid, see lubricants and capacities. Check oil cooler and grille for blockage.

The hydraulic fluid is dirty.

Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system. Fill with clean hydraulic fluid.

The service pipe connection is over tightened.

Check tightening torque.

The valve housing was twisted during installation.

Loosen retaining bolts and tighten to correct torque figures.

A control linkage is bent.

Disconnect the linkage. Repair the linkage if possible, or fit a new one.

A spool is bent.

Dismantle the control valve. Renew spool as necessary.

A return spring is broken.

Renew as necessary.

A return spring or cap is out of alignment.

Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts.

Temperature distribution within control Warm the entire system up before valve not uniform. servicing.

E-189

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E-189

Section E - Hydraulics Fault Finding Introduction Fault Leaking Oil Seal (Control Valves)

Fault Ram creep

Table 61. Probable Cause Paint or dirt on the seal face.

Remove the seal and clean.

The back pressure in the valve circuit is excessively high.

Check circuit pressures, adjust if possible. Otherwise investigate thoroughly.

Spool damaged.

Dismantle. Inspect all parts. Renovate or renew as necessary.

The seal is not secured.

Clean the seal and tighten the retaining bolts to the correct torque.

The seal is cut or damaged.

Fit a new seal.

Table 62. Probable Cause

Action

Associated ram or pipe lines from ram Check and rectify as required. leaking.

Fault Hydraulic oil becomes too hot.

Fault Steering fails to operate or stiff to operate.

Fault

Check valve malfunctioning (if fitted), e.g. stabiliser circuit.

Test check valve, rectify as required.

Associated valve section spools leaking.

Rectify, check for contamination.

Associated ARV leaking.

Rectify, check for contamination.

Table 63. Probable Cause

Action

Oil cooler obstructed.

Remove debris from cooler fins.

Restriction in neutral circuit lines.

Check hoses, replace as necessary.

Hydraulic filter clogged and by-pass valve not working.

Change hydraulic filter.

Table 64. Probable Cause

Action

Tyres not inflated to correct Pressure.

Inflate tyres to correct Pressure.

Insufficient hydraulic fluid.

Check for leaks and top up as required.

Low pump flow.

Check pump flow, if required service or replace pump.

Leak in the relevant hoses or component connection.

Check hoses and for connection for leaks.

Steer relief valve set incorrectly.

Check pressure setting of steer unit relief valve, adjust as required.

Table 65. Probable Cause

Steering fails to operate or stiff Priority valve not operating to operate (Cont.). correctly.

E-190

Action

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Action Check if the priority valve is sticking, rectify as required.

E-190

Section E - Hydraulics Fault Finding Introduction Fault

Probable Cause

Action Check the load sense line from the steer unit to the priority valve for signs for leaking or poor connection.

Steer mode valve not operating correctly.

Check if the spool is sticking, rectify as required.

Mechanical failure.

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Section E - Hydraulics Fault Finding Introduction

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Section F Transmission Service Manual - 3DX / 4DX Backhoe Loader Section 1 - General Information Section 2 - Operator’s Manual Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine

Publication No.

9813/2050-5

Section F - Transmission

Notes:

F-0

9813/2050-5

F-0

Section F - Transmission Contents Page No. Basic Operation Front Axle .................................................................................................. F-1 Component Identification .......................................................................F-1 Transmission .........................................................................................F-2 Principal of Operation ............................................................................F-3 Torque Converter ....................................................................................... F-6 Component Identification .......................................................................F-6 Systems Description Operation ................................................................................................... F-7 Synchromesh ........................................................................................F-7 Synchro Shuttle Gearbox Synchromesh (Blocking Pin Type) ...............F-8 Synchromesh - Operation .....................................................................F-8 Synchro Shuttle Gearbox Service Procedures ................................................................................. F-13 Removal and Replacement .................................................................F-13 Removal ..............................................................................................F-13 Replacement .......................................................................................F-16 Dismantle, Inspection and Assembly ....................................................... F-18 Torque Convertor ..................................................................................... F-19 Removeal ............................................................................................F-19 Front Axle Service Procedure ................................................................................... F-21 Front Axle ............................................................................................F-21 Torque Converter Stall Test. ................................................................F-24 Front Axle ............................................................................................... F-26 Removing and Replacing ....................................................................F-26 Replacement .......................................................................................F-28 Torque Setting ....................................................................................F-28 Swivel and Drive shaft ........................................................................F-35 Selecting the spacer ...........................................................................F-40 Pinion Depth Setting ............................................................................F-41 Crown Wheel and Pinion Meshing ......................................................F-42 Hub End Torque ..................................................................................F-44 Rear Axle Service Procedures ................................................................................. F-47 Removal and Replacement .................................................................F-47 Fault Finding Gearbox ................................................................................................... F-59 Synchro Shuttle Gearbox ....................................................................F-59

F-i

Basic Operation Front Axle

Basic Operation Front Axle Component Identification

B A E G

H D070840-09

Fig 1. K Fig 1. ( T 1)

Table 1. Yoke connection to prop shaft

Pinion

Crown wheel

Differential unit

Drive shaft

Universal coupling

Reduction gear hub

Steer swivel trunion bearings

Axle pivot

Oil fill and Drain plug

9813/2050-5

Basic Operation Front Axle

Transmission

Fig 2.

9813/2050-5

Basic Operation Front Axle

Principal of Operation This illustration shows a typical JCB Synchro Shuttle gearbox which consists of a torque converter, hydraulic reverser unit, and integral manual 4-speed gearbox. The reverser unit A has a pair of hydraulically operated clutches giving forward - neutral - reverse drive.

Forward/reverse clutch unit

Hydraulic Pump mounting face

Torque converter relief valve

Oil Pressure switch

Hose connection - to cooler

Hose connection - from cooler

Oil flow is provided by a crescent type pump B driven at engine speed by the drive lugs of the torque converter. The oil pressure is controlled by maintenance valve D and clutch selection is achieved by means of an electric solenoid valve E K Fig 2. ( T 2). Drive is transferred from the reverser unit by helical gears to the main shaft F, which carries the 3rd /4th synchromesh unit G, and to the lay shaft H, which carries the 1st / 2nd synchromesh unit J. Synchromesh unit G and J are of the 'Blocking Pin' type, a full description of which is given in this section. Drive is transmitted finally via the output shaft K to the rear axle. If 4 wheel drive is selected, the front wheels are also driven via 4 wheel drive output yoke L. Drive shaft T is permanently driven by the engine and runs through the hollow forward / reverse unit shaft to the back of the gearbox. The shaft T drives the gearbox mounted machine main hydraulic pump. Gearbox oil is cooled by an air blast cooler. The cooler is part of the front mounted machine cooling pack.

Component Identification

Table 2. Forward/reverse clutch unit

Transmission oil pump

Torque converter pressure regulating valve

Oil pressure maintenance valve

Solenoid control valve

Main shaft

Synchromesh unit - 3rd/4th gears

Lay shaft

Synchromesh unit - 1st/2nd gears

Transfer gear, output shaft and yoke

4WD output yoke (if fitted)

2/4WD clutch unit (if fitted)

4WD Solenoid control valve (if fitted)

Oil Strainer

Oil filter

Gear selection turret assembly

Torque Converter

Drive shaft (drives machine main hydraulic pump

9813/2050-5

Basic Operation Front Axle

Fig 3.

9813/2050-5

Basic Operation Front Axle Hydraulic and Electrical Operation

Key

Oil from the pump B is fed through an internal passage via the filter to pressure maintenance valve D, which maintains pressure to the solenoid valve E for clutch selection. Excess oil from the maintenance valve flows back through the casing to the torque converter S. Oil enters the converter between the converter hub and the stator support, and leaves between the Reverser Shaft and Pump Drive Shaft. Pressure in the converter is controlled by a regulating valve C which dumps oil from the converter line back to the sump. Torque converter relief valve V acts as a safety valve should the system pressure suddenly rise above normal, protecting the torque converter from being damaged. Oil from the torque converter S flows out of the transmission to the external oil cooler Z, returning at the top of the transmission unit and pass through the drillings in the reverser shaft for clutch lubrication. Lubrication oil is also provided via a pump drain line to the forward/reverse front shaft bearing A4. The drain from pressure maintenance valve D also provides lubrication for idler gear bearing F.

Solenoid Valve) Operation Pressurised oil at the solenoid valve E is used to control the forward/reverse clutches A1 and A K Fig 3. ( T 4).

Table 3. Key

Description

Forward/Reverse Clutch unit

Forward Clutch

Reverse Clutch

Forward/Reverse front shaft

Forward/Reverse front shaft bearing

Transmission oil pump

Torque converter pressure regulating valve

Oil pressure maintenance valve

Solenoid control valve

Idler gear bearing

Output shaft bearing

4WD output yoke if fitted

2/4WD clutch unit if fitted

4WD solenoid control valve if fitted

Oil strainer

Oil filter

Torque converter

Torque converter relief valve

Oil cooler

Forward In the diagram, electrical solenoid E is energised by the forward / reverse control lever in the cab. Pressurised oil is diverted to the forward clutch A1 and forward is selected. A restrictor orifice in the feed to the solenoid valve modulates the pressure to the clutch to smooth engagement. At the same time oil from reverse clutch A2 is diverted back to the sump via solenoid valve E. Reverse When the reverse is selected electrical solenoid E2 is energised and pressurised oil is diverted to the reverse clutch A2. At the same time oil from clutch A1 is diverted back to the sump. Neutral When neutral is selected (via the control lever or the transmission dump button), the flow of the pressurised oil is blocked at the solenoid valve. No solenoids are energised and no clutches engaged. For a further detailed description refer to Forward/Reverse Clutch operation. The 2/4WD unit M is controlled by solenoid valve N. For a full description of 2/4WD Clutch operation refer to 2/4WD Clutch operation.

9813/2050-5

Basic Operation Torque Converter

Torque Converter Component Identification A

Impeller

Turbine

Reaction member

Drive plate

Engine flywheel

Drive to gearbox input shaft

Spline location for reaction member

Direct drive from the engine to the gearbox oil pump

Direction of oil flow

Because of the absence of a direct mechanical connection between the engine and the gearbox therefore, the flexibility of the torque converter drive greatly reduces wear on the transmission, absorbing shocks and torsional vibration from the engine. The engine cannot be stalled due to overload, as the fluid coupling slips.

Principle of Operation The torque converter is similar to a fluid coupling, which utilizes the centrifugal force exerted in the transmission oil to transmit power from the engine to the gearbox. It multiplies the torque from the engine and functions as a combined clutch and infinitely variable reduction gearbox. K Fig 4. ( T 6) The torque converter is enclosed in a casing and consists of three basic parts, the impeller A, reaction member C, and turbine B.

Impeller A is driven by the engine.Reaction member C does not rotate. Its hub engages with a splined tube on the gearbox oil pump and is held stationary. Turbine B is engaged with the splined end of the gearbox input shaft The impeller A, driven by the engine, forms one set of shaped blades, it can be likened to a centrifugal pump imparting energy to the transmission oil. This energy is transferred to another set of shaped blades, which form the turbine B. The turbine is connected to the gearbox and converts the energy back to a mechanical torque.

Fig 4.

When the impeller A is rotating faster than the turbine B, the fixed reaction member C causes some of the energy in the oil to be transferred back to the impeller A. This has the effect of multiplying the torque available. When the impeller A (input) is running much faster than the turbine B (output) there is a substantial circulation of transmission oil around the blades. The oil circulation is maximum when the turbine (output) is stalled, and is almost zero when the impeller and turbine speeds are equal i.e. the ratio is near 1:1. If the turbine (output) is stalled whilst the impeller (input) is revolving, all the power is dissipated as heat.

9813/2050-5

Systems Description Operation

Systems Description Operation Synchromesh A C B

E D G

J Fig 5.

9813/2050-5

Systems Description Operation

Synchro Shuttle Gearbox Synchromesh (Blocking Pin Type) The gearbox is fitted with 'Blocking Pin' synchromesh, comprising the following parts K Fig 6. ( T 8).

Synchro Hub A Hub A controls the operation of the synchromesh unit and gear selection, the selector fork fitting into the outer groove. Internal dog teeth link the selected gear to the drive shaft. Through the synchro hub centre are two sets of holes for the blocker pins C and the split energiser pins D, spaced alternately.

are 'collapsed. When selecting second gear the synchro hub A slides along the split energiser pins until the pin recess and the synchro hub flange are in line. At this point the split energiser pins open and the synchro rings are moved by the synchro hub pushing on the split energiser pin shoulder. Initial contact between the synchro ring and the synchro cup start to synchronise the speed of the shaft and second gear. The rotational force of the synchro ring is taken by the blocker pin against the edge of the synchro hub hole, as at G K Fig 6. ( T 8).

Synchro Rings B

As the axial load on the synchro hub increases, the split energiser pin'collapses' and the conical faces of the bloking pin and synchro hub hole come in to contact, as at H of K Fig 6. ( T 8).

Rings B are rigidly joined by the blocker pins, with the split energiser pins held, in counter bores, between the two synchro rings.

Further increases in the axial loads increases the frictional grip of the sentry ring and the synchro cup, causing the shaft and gear speeds to synchronise.

Blocker Pins C

As the speeds are synchronised the radial load on the blocker pin and the synchro hub is reduced. This allows the synchro hub to slide freely along the blocker pin and engage its dog teeth with second as at J K Fig 6. ( T 8).

Pins C have a narrow neck in the centre, against which the sentry hub transmits radial drive during gear changes. The edges of the blocker pin neck and their mating sentry hub holes are designed so that, as the radial loads are reduced, the sentry hub can slide over the shoulder of the blocker pin.

Split Energiser Pins D Pins D take the initial axial load of the sentry hub on the shoulder of the split energizer pin neck. As the axial load reaches approximately 400 N (40.8 kg; 90 lb) the internal springs allow the split energiser pin to collapse and the synchro hub to move axially.

Synchro Cups E Cups E take the frictional drive from the synchro ring on their inner faces. The synchro cups are splined to drive their respective gears whilst synchronisation is taking place.

Synchromesh - Operation Diagram F of K Fig 5. ( T 7) shows the gearbox with first gear engaged. Synchro ring B is in contact with synchro cup E and the synchro hub dog teeth are linking first gear to the shaft gear. In this position the split energiser pins D

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Fig 6.

Systems Description Operation Forward/Reverse Clutch Operation

Fig 7.

Synchro Shuttle Gearbox Forward/Reverse Clutch Operation

Clutch A2 is disengaged and no drive is transmitted to gear/plate carrier G2. The gear is also free to rotate on the input shaft assembly.

The forward/reverse clutch unit 1 transfers drive from the input shaft A3 to either gear G1 or gear G2 depending on which of the two clutches (A1 or A2) is engaged, giving forward or reverse drive. When neither clutch is engaged, neutral is selected K Fig 7. ( T 9). The clutches are of the wet, multi-plate type. The clutch housings and input shaft are a one piece assembly A3. The assembly is permanently driven by the engine via the torque converter. Clutch counter plates 3 are also permanently driven via meshing teeth inside the clutch housings. Clutch friction plates 4 are meshed with the gear/plate carriers (G1 and G2). In the diagram, clutch A1 is engaged. The counter plates 3 and friction plates 4 are pressed together by hydraulically actuated piston 5. Drive is then transmitted from the input shaft to the gear G1.

Actuation of the hydraulic pistons 10 and 5 is controlled via three position solenoid valve E. When neutral is selected, solenoids E1 and E2 are deactivated and the flow of pressurised oil to the clutches is blocked. Springs 8 and 9 move the pistons away from the clutch plates and oil from both pistons is vented to the sump. When either forward or reverse is selected, the solenoid valve E diverts pressurised oil via cross drillings inside the input shaft A3 to the appropriate clutch (piston 10 or 5) in the unit. Pressure from the other clutch is vented to the sump via the solenoid valve spool. Oil is prevented from leaking by seals 6 on the pistons and ring seals 7 on the input shaft A3. The valve E is shown using symbols.

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Systems Description Operation 2/4 Wheel Drive Clutch Operation

Fig 8.

Fig 9. Synchro Shuttle Gearbox 2/4 Wheel Drive Clutch Operation - Pressure ON/Spring OFF Type 4 Wheel Drive Operation This clutch is of the 'Pressure-ON (4WD)/Spring-OFF (2WD) type. The clutch is engaged and disengaged by introducing or dumping pressurised oil behind piston C via

a solenoid valve A. The solenoid valve is operated by a switch in the cab K Fig 8. ( T 10). When the switch is in the 4 wheel drive position, solenoid valve A is energised. The energised solenoid A1 causes the valve spool to move and form a connection between ports 3 and 2.

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Systems Description Operation Pressurised oil is directed to piston C via ports 3 and 2. The piston moves, against spring D, to press the friction/ counter plates of clutch pack B together, thus driving the output yoke E.

In the diagram, clutch A1 is engaged. The counter plates 3 and friction plates 4 are pressed together by hydraulically actuated piston 5. Drive is then transmitted from the input shaft to the gear G1.

Synchro Shuttle Gearbox Forward/Reverse Clutch Operation

Clutch A2 is disengaged and no drive is transmitted to gear/plate carrier G2. The gear is also free to rotate on the input shaft assembly.

2/4 Wheel Drive Clutch Operation

Fig 10.

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Systems Description Operation

Fig 11. Synchro Shuttle Gearbox 2/4 Wheel Drive Clutch Operation - Pressure ON/Spring OFF Type 4 Wheel Drive Operation

Because there is no pressure behind piston C, the friction/ counter plates of clutch pack B now freely rotate on the output shaft, thus disengaging drive to the front axle.

This clutch is of the 'Pressure-ON (4WD) / Spring-OFF (2WD) type. The clutch is engaged and disengaged by introducing or dumping pressurised oil behind piston C via a solenoid valve A. The solenoid valve is operated by a switch in the cab K Fig 8. ( T 10). When the switch is in the 4 wheel drive position, solenoid valve A is energised. The energised solenoid A1 causes the valve spool to move and form a connection between ports 3 and 2. Pressurised oil is directed to piston C via ports 3 and 2. The piston moves, against spring D, to press the friction/ counter plates of clutch pack B together, thus driving the output yoke E.

2 Wheel Drive Operation When the switch is in the 2 wheel drive position, solenoid valve A is de-energised. With the solenoid A1 deenergised, the valve spool moves under the force of the spring A2. The oil supply to the piston C is blocked (shown at port 3). At the same time oil vents from the back of piston C to the sump via ports 1 and 2 K Fig 9. ( T 10).

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Synchro Shuttle Gearbox Service Procedures

Synchro Shuttle Gearbox Service Procedures Removal and Replacement

Disconnect the front axle drive shaft bolts B.

Important: The gearbox is heavy. Unless it is safely supported during removal and replacement it could fall and cause injury. Make sure that you have access to suitable jacks and a gearbox locating `cradle' before attempting to remove the gearbox.

Drain the hydraulic tank and remove the main hydraulic pump (see Section E, Service Procedures and Main Hydraulic Pump). Tie the suction hose up clear of the gearbox.

Drain the gearbox oil, see Section 3, Routine Maintenance.

Remove the access plate at the bottom of the torque converter housing. Through the access hole, loosen and remove the torque converter to engine flywheel retaining bolts D.

At a later stage the gearbox and engine assembly is tilted to allow access to fixing bolts. To prevent damage as the engine is tilted components must have their fixings removed as follows:

Removal 1

Park the machine on firm level ground. The gearbox is heavy. If the ground is soft or uneven it will not be possible to remove the gearbox safely. Loosen the right side rear wheel nuts. Rest the shovel on the ground and lower the stabilisers to raise the rear of the machine. Check dimension X which must be at least 800 mm. This will allow the gearbox to be pulled clear. Block/support the machine K Fig 12. ( T 15).

Fuel sediment bowl assembly E (2 bolts).

Exhaust stack fixing bracket F (2 bolts).

Radiator fan cowl G (4 bolts). It is not necessary to remove these components, only release them from their fixings.

Support the gearbox using a suitable trolley jack and cradle. The gearbox must be securely located on the cradle as shown at Y.

Make sure that the weight of the gearbox is supported by the trolley jack and then remove the gearbox mounting bolts H.

Using the trolley jack, lower the gearbox and engine to gain access to the top torque converter housing to engine block retaining bolts J. Put a support under the engine as shown at Z to prevent it from dropping when the gearbox is removed.

Undo the four bolts J at the top of the torque converter housing. Note that the two outer most bolts have nuts instead of screwing into the engine block. Also note the position of the electrical earth straps.

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Note: Suitable lengths of steel channel can be used as safety struts between the stabliser feet and chassis, one at each stabiliser. 3

Remove the right hand side rear wheel.

Remove the bonnet.

Disconnect the gearshift from the top of the gearbox, as shown at A.

Remove the rear axle propshaft.

Synchro Shuttle Gearbox Service Procedures 16

Pull off the breather tube K. Undo the gearbox dipstick fixing nut L and then remove the dipstick tube.

Uncouple the forward/reverse solenoid valve connectors M, oil pressure sender N and temperature sender P (if fitted). Label the connectors for identification when refitting.

Disconnect the gearbox oil cooler hoses R.

On 4 wheel drive machines, uncouple the electrical connector at the 4WD solenoid S.

Remove the flywheel housing to engine bolts T.

Manoeuvre the gearbox with the torque convertor clear of the engine housing.

Lower the trolley jack and pull the gearbox and torque convertor clear of the machine.

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Synchro Shuttle Gearbox Service Procedures

J J

J M

J N P

E F G X

Y C006610

Fig 12.

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Synchro Shuttle Gearbox Service Procedures

Replacement Replacement is a reversal of the removal procedure but note the following: 1

Hydraulic Pump K Fig 14. ( T 17). Before replacing the gearbox remove circlip 5 and withdraw the pump drive shaft 6 together with its bearing 7 approximately 50 mm (2.0 in). The shaft can then be engaged after the gearbox has been fitted, making replacing the gearbox easier. Remember to engage the pump drive shaft, refit the bearing and circlip after the gearbox has been fitted.

Set the Torque converter as described in Torque Converter, Removal and Replacement.

Align the Torque Converter K Fig 13. ( T 17).

Item

Table 4. kgf m

4.5

237

175

J,T

lbf ft

It is vitally important that the torque converter is fitted at the gearbox and engine flywheel correctly. Failure to locate the converter correctly will result in damage to the gearbox oil pump on engine start up. Proceed as follows: Make sure that the torque converter drive dogs 1 are correctly engaged with the pump 2 on the gearbox. Temporarily tie the converter onto the gearbox. Use wire tied at a drive plate bolt hole to a convenient point on the outside of the gearbox. Take note of the flywheel and drive plate fixing hole phasing. The heads of the bolts 3 will foul the flywheel 4 if phasing is incorrect.Before bolting the torque converter housing to the engine make sure the mating faces are fully together (DO NOT USE FORCE). The drive plate 8 should also be mated close to the flywheel. Do not force the components together with the fixing bolts. Make sure that the torque converter is free to rotate slightly within the clearance of the location bolt holes. If you cannot rotate the converter it is trapped either by bolt heads 3 or by incorrectly located pump drive dogs. Make sure that all is well before tightening the bolts. 4

Fill the gearbox with the specified amount and type of oil. Leave hose N off until the filling operation is complete. After filling refit hose N.

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Synchro Shuttle Gearbox Service Procedures

7 5

A396890-C1

Fig 14.

A396460-C1

Fig 13.

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Synchro Shuttle Gearbox Dismantle, Inspection and Assembly

Dismantle, Inspection and Assembly The procedures for dismantling, inspection and assembly are described in a separate publication, see Transmissions Service Manual, Publication No. 9803- 8610, SEC E Manual Gearboxes ( SS 700) for full details. Make sure that you identify the gearbox correctly.

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Synchro Shuttle Gearbox Torque Convertor

Torque Convertor Removeal

only 3 bolts). Check the converter run out as shown at B, which should not exceed 0.38mm (0.015 in).

See the relevant gearbox removal procedure for torque converter removal.

When Replacing 1

Ensure that flywheel face, flexible drive plate, and hardware are clean and free from burrs or other surface imperfections.

Offer the flexible drive plate 1 to the torque converter.

Place the torque converter alignment tool A over the torque converter spigot. Note that the alignment tool is used one way round for the 12" and the other way round for W300 torque converters. Make sure that the tool locates in two of the converter bolt holes as shown. Fig 16. Note: In the unlikely event that the run-out exceeds 0.38 mm (0.015 in), remove the converter and check the spigot for burrs, remove the drive plate and rotate it 180Â° on the torque converter, repeat steps 2 to 4. 6

Remove the torque converter and drive plate assembly from the flywheel.

Install the torque converter with its drive plate assembly onto the transmission input shaft, make sure that the dogs on the converter pump drive shaft engage with the recesses in the pump, also take care not to damage the oil seal.Rotate the engine flywheel so that one bolt hole is in a six O' clock position.

Rotate the torque converter and drive plate assembly so that one bolt hole is in a six O' clock position.

Install the transmission and torque converter assembly to the engine. See the relevant gearbox replacement procedure. It is vitally important that the torque converter is fitted at the gearbox and engine flywheel correctly. Failure to locate the converter correctly will result in damage to the gearbox oil pump on engine start up.

Apply JCB Threadlocker and Sealer to flanged bolts 3. Remove the access plate from the bottom of the

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Fig 15. Note: It is important that the converter drive tube is protected against damage or contamination at all times. 4

Fit two of the flanged bolts 2 and torque tighten to 50 Nm (37 lbf ft). Remove the alignment tool and fit the remaining two retaining bolts 2.

Offer the torque converter and drive plate assembly to the flywheel, bolt the drive plate to the flywheel (use

Synchro Shuttle Gearbox Torque Convertor engine flywheel housing and through the access hole fit and hand tighten one flanged bolt (item 3) in the six 'O' clock position. 11

Rotate the flywheel until the next bolt hole is accessible, fit and hand tighten the next bolt 3. Repeat the operation until all bolts are fitted. Finally torque tighten bolts 3 to 44 Nm (32.5 lbf ft), rotating the flywheel each time to align bolts 3 with access hole. Refit access plate.

Item

Table 5. Torque Settings Nm kgf m

5.1

4.5

32.5

lbf ft

Fig 17.

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Front Axle Service Procedure Front Axle

b If necessary, progressively torque tighten the nut to a maximum of 300 Nm (221 lbf ft) to achieve correct rolling torque.

Renewing the Pinion Oil Seal The pinion oil seal 3 may be renewed without removing the axle from the machine.

Note: If the rolling torque figure (new pinion seal fitted) exceeds the reading recorded in step 1 by 1Nm (0.74 lbf ft; 0.1 kgf m) or more, or a minimum torque of 250 Nm (184 lbf ft) can not be achieved then the pinion assembly must be re-built using a solid spacer, see the appropriate axle assembly procedure.

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-1

K Fig 18. ( T 22) Remove the road wheels and uncouple the axle propshaft. Measure the axle rolling torque and record the reading. Mark the relative positions of the pinion shaft 4 and nut 2 with a scriber.

Using Service Tool 892/00812, remove the drive yoke 1 together with its stake nut 2.

Removal the seal 3 and fit new one. Be sure not to damage the seal housing. Pack between the lips of the new seal with the grease before fitting.

Fit the yoke and temporarily fit the old stake nut 2. Tighten the nut with a torque wrench, aligning the scriber marks. Note the tightening torque required for the same.

Remove and discard the old nut. Fit a new nut and tighten to the torque determined at step 5. a

Measure the rolling torque. The reading should be 0.5 to 1Nm (0.37 to 0.74 lbf ft; 0.05 to 0.1kgf m) more than that recorded in Step 1.

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Front Axle Service Procedure

Fig 18.

Rear Axle Renewing the Pinion Oil Seal The rear axle pinion oil seal is renewed using the same procedure as Front Axle but note the following: The rear axles are fitted with a brake disc/drive flange in place of the yoke on front axles.

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Front Axle Service Procedure

K J

L C A

D070930-13

Fig 19.

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Front Axle Service Procedure

Torque Converter Stall Test.

bar (0-300 lbf/in2) pressure gauge to test connector E (see Service Tools).

Ensure that the engine and transmission are at normal working temperature. Run engine at maximum speed and check the No Load Speed. See Engine Technical Data for correct figure, adjust if necessary.

Start engine and run at 1000 rev/min. The flowmeter will show the Pump Flow which should be as shown in Technical Data. A low reading indicates a worn pump or blocked suction strainer. The pressure gauge will show the Main Line Pressure (see Technical Data). A low reading can be caused by either a faulty pressure maintenance valve or a worn pump. A high reading indicates a faulty pressure maintenance valve or, if the pump flow is low, the oil cooler may be blocked.

Stop engine, remove flow test adaptors and refit filter. Connect pressure gauge and flowmeter into converter out line as shown at F. Run engine at 1000 rev/min with transmission in Neutral and note Converter Out Pressure and Oil Cooler Flow, which should be as shown in Technical Data. A high pressure together with low flow could be caused a blocked oil cooler (See also check 7) .

DO NOT stall the converter for longer than 10 seconds or the transmission fluid will overheat.

If engine speeds are below the stated figures, either the engine is losing power and should be serviced/overhauled or the torque converter reaction member clutch is slipping. To check the engine, select Neutral, open throttle fully and operate an excavator service to 'blow off' the main relief valve. Engine speed should fall slightly (50 - 100 RPM). If engine speed is correct the torque converter is faulty.

With parking brake and foot brake applied firmly, select. Forward and check flow reading, which should not fall by more than 4.5 litres per minute. A low reading indicates a high leakage rate in that particular clutch, which could be caused by worn or broken piston seals or shaft sealing rings. Select Reverse and repeat the test.

If the clutch leakage rate is high, the Clutch Pressures may be checked by connecting the pressure gauge into ports G and H and repeating test 4. A low reading (see Technical Data) would confirm a high leakage rate in the particular clutch selected.

Stop engine, connect the pressure gauge into port J in the transmission, and fit a load valve L in the converter outline

Start engine, run at 1000 rev/min and slowly screw down the load valve whilst observing the gauge reading, which should rise to the setting of the Converter Relief (Safety) Valve (see Technical Data).

DO NOT allow the pressure to exceed 10.3 bar (150 lbf/in2) or damage to the converter seals will be caused.

If the reading is higher than specified, the relief (safety) valve must be faulty. A low reading indicates

Apply parking brake and foot brake firmly, select 4th Speed Forward and open throttle fully. Engine speed should be as specified at Torque Converter Stall in Transmission Technical Data. Note: When fully engaged, the parking brake electrically disconnects the transmission drive, this prevents the machine from being driven with the park brake on. Therefore, to complete the test, move the park brake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the park brake will not be fully operational. Alternatively, disconnect the switch at the park brake.

Note: Max. Governed Speed is a datum figure only. It cannot be adjusted or checked with the engine installed in the machine.

Pressure and Flow Test Note: The tests must be carried out only in the following order, step by step.

!MWARNING Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. TRANS-1-2

K Fig 19. ( T 23) Stop engine, remove transmission filter and filter head adaptor. Fit adaptor A (892/ 00920) into the gearbox casing. Fit test adaptor B (892/00301) and secure with adaptor C (892/00302). Connect flowmeter D as shown and connect a 0-20

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Front Axle Service Procedure faulty relief (safety) valve, leaking converter 'piston ring' type seal or leaking pump seal. Stop engine and connect pressure gauge and flowmeter into return line from oil cooler to transmission as shown at K. Start engine, and with transmission in Neutral check flowmeter reading, which will show the Cooler Flow Rate (see Technical Data). The pressure gauge will show the Lubrication Pressure (see Technical Data). Low flow and pressure reading could be indicate a blocked oil cooler.

Towing Procedure Synchro Shuttle Gearbox If there is no transmission damage, the machine may be towed for a distance of approximately 1.5 kilometres (1 mile). Always use a rigid tow bar, ensure that the gear lever is in neutral (applicable to Synchro Shuttle machines only). Restrict towing speed to 25 k.p.h. (15 m.p.h.). If it is necessary to tow the machine for a distance in excess of 1.5 kilometres (1 mile), the propshafts should be disconnected to prevent damage to the transmission system. When towing is complete, block the wheels securely BEFORE removing the towbar and reconnecting the propshafts. Important: In some countries neither of the above procedures may be legally acceptable for towing on public highways.

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Front Axle Front Axle

Front Axle Removing and Replacing Removing Before removing propshafts always mark both companion flanges and also mark the sliding joints prior to removal.

Replacing Upon reassembly, after lubricating sliding joints with LCG2 grease, align the shafts against identification marks previously made or, in the case of a shaft being renewed, use the manufacturer's alignment markings.

Apply loctite to threads of all flange bolts.

C A

Retaining straps C stretch with use, therefore these straps must always be replaced with new ones. The propshaft must have both ends exactly on the same plane as shown at X. The yokes must not be at right angles as at Y or at an intermediate angle as at Z K Fig 20. ( T 26).

Item Nm

kgf m

75 - 85 7.7 - 8.7 55 - 63

118

Table 6. lbf ft

Fig 20.

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Front Axle Front Axle

B H F

E G D070930-14

Fig 21.

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Front Axle Front Axle Removal and Replacement

Remove pivot pin G seals and remove the pivot pin G and axle shims.

Lower the jack so that the axle is clear of the mounting.

Replacement Replacement is the reverse of the removal sequence. Note: Raised loader arms can drop a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged.

GEN-1-1

Note: Whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct.

Removal Note: Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut. 1

Unlock and remove the front grille.

Remove bolts A to disconnect the drive shaft from the axle K Fig 47. ( T 51).

Apply Loctite to the threads of bolts A. The front axle must be shimmed to give a maximum fore and aft movement of 0.5 mm (0.020 in). 1

Nylon shims must be fitted as follows: a

Fit a 5.0 mm thick master shim (coloured blue) between the rear of the axle and the yoke plate as shown at Y.

Disconnect the hydraulic pipes B from the steer rams, blank off all exposed connections.

Disconnect remote grease nipple hose H.

Loosen the wheel mounting nuts D.

Make sure that the rear wheels are blocked, use the loader arms to raise the front end of the machine.

Note: DO NOT fit more than 2 shims (including the master shim).

Prop the machine on each side as shown at C.

Note: To assist assembly, use the double sided tape ring to retain the shims on the yoke plate.

Remove the front wheels.

Position a jack underneath the balance point (see Note) of the axle and support the axle weight.

b Measure the fore and aft movement and subtract 0.5 mm to obtain the required shim thickness. Fit the correct thickness shim between the front of the axle and the yoke plate as shown at X.

Note: Because the Drive head assembly is offset, the balance point of the axle is not the centre of the axle. Attach a 'cradle' to the jack that will partially embrace the axle. 10

Remove nut E and pivot pin retaining bolt F.

Remove pivot pin G seals and remove the pivot pin G and axle shims.

Torque Setting Item

Table 7. kgf m

lbf ft

680

500

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Front Axle Front Axle

A258180-C1

Fig 22.

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Front Axle Front Axle Front Hub

Fig 23.

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Front Axle Front Axle Dismantling The following illustrations show the axle removed from the machine but the hubs may be dismantled without removing the axle. 1

Drain oil from the hub K Fig 23. ( T 30).

Remove screws 1.

Lever the planet gear carrier 2 off the bearing carrier. Remove and discard `O' ring 3. Remove planet gears 4 only if defective. Note that gears can only be removed as assemblies, which comprise the gear, the bearing 5 and two 'L' shaped circlips 6. To remove a planet gear, first remove the external circlip 7. Pull off the planet gear. The drive shaft thrust pad 8 is drilled and tapped M6 for removal purposes. Remove circlip 9 to allow the sun gear 29 to be slid off the drive shaft K Fig 24. ( T 31). To remove the `Verbus Ripp' bolts 11, it is necessary to remove the spacer 10. Revolve the spacer with a suitable drift to align the holes in the spacer 10 with the space between the bolts. Using two dowels and two heel bars, remove the spacer using the method shown at A. Remove the 'Verbus Ripp' bolts 11. These bolts are very tight and care must be taken not to distort the bolt heads. Use as short an extension bar as possible. Note: Fretting between the hub swivel 23 and annulus carrier 14 mating faces might be evident; this condition is normal, do not attempt to repair. If the hub swivel and annulus carrier are to be re-used, the carrier must be assembled in the same angular position it was removed; match mark the hub swivel and carrier before removing the carrier. Using 2 high grade M14 bolts B as jacking screws, remove the annulus carrier assembly. Shown at C. Remove circlip 15 to separate the annulus ring 16 from the annulus carrier 14. Fig 24.

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Front Axle Front Axle Note: The Bearing Puller is required throughout steps 13 to 17. Assemble the puller B, screwing the legs A onto, two diametrically opposite wheel studs and placing reaction tube C over the drive shaft. Note: Reaction Tube C, MUST be used, otherwise damage to the drive shaft and drive shaft bearings will occur. Screw in D slowly until the bearing carrier together with the outer bearing cone and its cup are released from the axle. If the wheel hub starts to turn use a suitable bar Y to prevent further rotation. Note: If D becomes to hard to turn, tap the back of the hub with a plastic hammer to help release the bearing. Remove and discard the outer part of combination seal 19 by cutting the outer seal with a sharp chisel X. Carefully force the inner seal fully on to the stub axle, taking CARE not to damage the seal seat on the stub axle. Assemble the puller B, with the inner bearing plate E clamped around the inner bearing 18, attach the puller rods F and reaction tube C over the drive shaft 26. Note: Reaction tube C, MUST be used, otherwise damage to the drive shaft and drive shaft bearings will occur. Slowly screw in D until the bearing 18 is released. Remove and discard the inner section of seal 19. Note: Do not attempt to remove the dirt shield 22 (if fitted).

Fig 25.

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Front Axle Front Axle Note: : The bearing press is required throughout steps 1 to 10. 1

Attach the bearing centre puller H to the centre of the hub 23 using the existing `Verbus Ripp' bolts 11 K Fig 25. ( T 32).

Note: When refitting the annulus carrier 14, NEW `Verbus Ripe' bolts must be used. 2

Install outer bearing race from bearing 17 into bearing carrier 12.

Install the inner bearing 18 into the bearing carrier 12. Fit a new combination oil seal 19 as follows: Do not lubricate before fitting. Use seal dolly M (892/00891) to fit the seal. Fit the seal over the dolly and then use a soft faced hammer to drive the seal squarely into the carrier until the dolly flange is up against the carrier.

Lightly oil the inner wheel bearing 18. Position the bearing carrier (complete with inner bearing) onto the stub over the centre puller H.

Slide the bearing fitting tube K over the centre bearing puller H (the wide opening towards the bearing). Make sure that the bearing and carrier are square to the shaft.

Attach the puller handle J to the bearing centre puller H, making sure that the thrust bearing is fitted between two thrust washers at L. Using the puller handle, screw in the bearing fitting tube K until the inner bearing 18 is pressed correctly into position.

Remove the puller handle J and bearing fitting tube K.

Install the outer bearing 17 in the bearing carrier 12.

Assemble the puller handle J and bearing fitting tube K onto the centre puller H.

Using the puller handle J, screw in the bearing fitting tube K until the outer bearing 17 is pressed correctly into position so as to remove most of the free play.

D070930-17

Fig 26.

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Front Axle Front Axle 11

Assemble the annulus ring 16 to the annulus carrier 14. Secure with the circlip 15. Make sure that dowels 13 are correctly located.

Fit annulus assembly in the same angular position as removal (see Note, Dismantling, step 11) using new 'Verbus Ripp' bolts 11. Do not fully tighten bolts but allow the bearing carrier to rock slightly. Measure seal drag rolling force - see step 13.

To measure seal drag rolling force: Refit the planet gear carrier 2 - DO NOT FIT THE SUN GEAR 29.

Fig 27.

Use a spring balance and cord wrapped around the planet carrier flange as shown.

Press the drive shaft thrust pad 8 (chamfered side lowermost) into the recess in the planet carrier 2.

Pull the spring balance so that the hub rotates, do several times to let the seal bed in and record the reading.

Fit new planet gears 4 in place of any that were removed See step 4 in 'Dismantling'). Secure with circlip.

Remove planet gear carrier.

Note: : When fitting the planet gear assemblies be sure to orientate them correctly. Fit the large radius end of inner bearing over the pin first as shown at A.

Tighten M14 Verbus Ripp bolts 11 to 320 Nm (236 lbf ft, 33 kgf m) and then measure rolling force - see step 15.

To measure rolling force: Refit the planet gear carrier - DO NOT FIT THE SUN GEAR. Use a spring balance and cord wrapped around the planet gear carrier flange as shown. Pull the spring balance so that the hub rotates and record the reading K Fig 27. ( T 34).

Note: The sun gear must be fitted with the 1.5 mm (0.060 in) x 45Â° chamfer inboard. Fit the planet carrier 2 onto the bearing carrier 12, ensuring that the two tapped holes are in line with those on the bearing carrier. Fit and torque tighten screws 1 to 56 Nm (41lbf ft; 5.7 kgf m) after applying JCB Lock and seal to threads.

To get the rolling force, subtract seal drag rolling force (see step 13) from reading obtained at this step, the result should be 2 to 22 Nm (1.5 to 16 lbf ft). If the resulting figure is outside these limits check: the seal is fitted correctly; and/or renew bearings if necessary; and/or new fitted components.

Fit spacer 10 and slide the sun gear 29 onto the drive shaft 26 and secure with circlip 9. Fit a new `O' ring 3 K Fig 28. ( T 35) .

Note: Do not strike the centre of the planet gear carrier when fitting as this may dislodge the drive shaft thrust pad 8 fitted at step 16. Re-fill hubs with the correct grade oil. Torque Setting Table 8.

Item

Kgf m

lbf ft

5.7

320

238

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Front Axle Front Axle

Swivel and Drive shaft Dismantling Note: The hub assembly must be removed before attempting to remove the hub swivel and drive shaft, see the axle hub removal procedure. 1

Disconnect the track rod and steering cylinder from the axle steer knuckles.

Note: The top and bottom trunnions are very similar (bottom trunnion not illustrated). 2

Mark position of top and bottom trunnions 20, remove bolts 21 and remove trunnions. Withdraw the hub swivel K Fig 29. ( T 36).

Note: Trunnions may be removed easily by pumping grease through the grease nipple. 3

Remove the top and bottom trunnion seals 24 and bearings 25 (only if they are to be renewed).

Remove drive shaft seal 27 and needle roller bearing 28 from the hub swivel.

Withdraw drive shaft 26 from the axle.

Prise out drive shaft inner oil seal 30 from the axle arm.

Remove circlip 31.

Remove bearing 32.

If there has been a component failure (bearing 32 for example), remove all traces of debris from the axle and clean the magnetic drain plug screws 1.

Assembly Note: The top and bottom trunnions are very similar (bottom trunnion not illustrated). 1

Tap the drive shaft inner bearing 32 into position in the axle casing.

Fit circlip 31 K Fig 29. ( T 36).

Fit new oil seal 30. Pack grease between the lips of the seal.

Fig 28.

9813/2050-5

Front Axle Front Axle 4

Tap the drive shaft outer bearing 28 into position in the hub swivel drive shaft bore.

Fit new oil seal 27. Pack grease between lips of seal.

Fit drive shaft 26, taking care to locate inner end into splines of differential gears.

Press new trunnion oil seals 24 into position followed by bearings 25. Grease bearing and oil seal before fitting to axle.

Drive Head

Note: In the following step, take care not to damage seal 24 when tightening the trunnion bolts. 8

Locate hub swivel 23 and fit top and bottom trunnions. Apply loctite to threads of trunnion bolts 21 (8-off). Finger tighten all bolts, then sequentially tighten them to bring the two trunnions together. Torque to 98 Nm (72 lbf ft, 10.0 kgf m).

Connect the track rod and steering cylinder to the axle steer knuckles. Fig 30. Drive Head - Dismantling

Fig 29.

Drain the oil from the drive head. Remove the propshaft K Fig 30. ( T 36).

To remove the drive head it is necessary to withdraw both drive shafts from the axle.

Remove the drive head carrier screws 1. Mark the installation position of drive head carrier 2 relative to the axle housing.

Remove the drive head carrier from the axle housing.

Pull out the roll pins 3 and remove the castle nuts 4. Remove the outer races of bearings 5 and 6 from the drive head carrier bores.

Remove inner bearing races of 5 and 6.

Remove differential assembly 8 from carrier.

9813/2050-5

Front Axle Front Axle 8

Loosen the differential case half bolts 7 and pull the case halves 8A and 8B apart. Remove the axle bevel gears 9, the differential bevel gears 10, trunnion pin 11 and thrust washers 12 from the case halves.

Remove the thrust washers 13 from both case haves.

Pull off the bearing 6 from case half 8A.

Remove the Verbus Ripp bolts 14 and separate the crown wheel 15 from the case half 8A.

Mark the position of the drive yoke on the splined shaft. Remove the drive yoke.

Drive pinion shaft 20 out of drive head carrier 2.

Prise shaft seal 19 out of the bore.

Remove taper roller bearing 21 and tap out the outer bearing race.

Tap out the outer race of bearing 22 from the opposite bearing housing and remove the drive pinion shim(s) 23.

Remove spacer 24 from drive pinion 20. Prise taper roller bearing 22 to raise it sufficiently to insert bearing pullers. Pull the bearing from the pinion shaft.

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Front Axle Front Axle Drive Head - Assembly

Fig 31.

9813/2050-5

Front Axle Front Axle The outline procedure below refers also to the following aspects of the drive head assembly, which are covered separately in detail as sub topics later in this section: – Crown Wheel and Pinion Meshing – Collapsible Spacer Assembly – Crown Wheel and Pinion Meshing Note: Both the Crown wheel 15 and pinion 20 and the bevel gears 9 and 10 are matched and should be renewed as sets if any of their components are damaged or excessively worn. The two differential housing halves 8A and 8B are also matched. Do not use unmatched halves. Make sure all bearings are lightly oiled before fitting and setting. Make sure bearings are rotated whilst being set. 1

Determine the correct thickness required for the shims 23, refer to Pinion Depth Setting K Fig 31. ( T 38).

Fit shims 23 behind new bearing cup 22.

Fit new pinion head bearing cone 22 onto pinion 20.

Install pinion and bearings into the drive head casing. Install largest available solid spacer 24 e.g (14.20 mm) and fit pinion tail bearing 21 (lightly oiled). Do not fit the oil seal 19 at this stage.

D070930-16

Fig 32. 7

Fit dial test indicator (DTI) F. Ensure that the DTI is mounted on the drive head and not on bracket D K Fig 32. ( T 39).

Set torque wrench G to 35 Nm (25.8 lbf ft) and measure the end float while rotating the shaft K Fig 33. ( T 39).

Note: : It should be noted that the axle is assembled using a solid spacer. However, in the absence of the special tools required or the correct size solid spacer 24 it is acceptable to fit a collapsible spacer, refer to Collapsible Spacer Assembly. 5

Fit special tool sleeve B and special pinion shaft adaptor C. Tighten adaptor C to approximately 50 Nm, making sure the pinion is free to rotate and there is end float, this will prevent any damage to the bearing. If the pinion is not free to rotate or there is no end float at this stage check the bearing is fitted correctly. Also check the correct size spacer has been fitted.

Fit special bracket D to the drive-head housing using two M10 x 30 nuts and bolts. Fit special tool support pillar E to bracket D so that the fork end engages in adaptor C. Ensure that fork E is centrally located on adaptor C. If necessary, re-align bracket D to suit. D070930-15

Fig 33.

9813/2050-5

Front Axle Front Axle

Selecting the spacer 1

To select the right size spacer 24, subtract the end float obtained at step 7 from the solid spacer size (14.20 mm). Also subtract 0.04 mm to allow for theoretical bearing tolerance and pre load. The result is the size of spacer to be fitted from the solid spacer. setting kit. If there is no spacer of this size, fit the next nearest size spacer, refer to Service Tools - Axles.

Note: The nut tightening torque can be increased to a maximum of 300 Nm provided that the pinion rolling torque does not exceed the maximum of 3.4 Nm.

Example: (all dimensions in millimeters).

Finally stake the nut 16 into the slot.

Temporary spacer size: 14.20.

Assemble the trunnion pin 11, bevel gears 9 and 10 and their thrust washers 12 and 13 into differential half case 8A.

Fit Crown wheel 15 using new Verbus Ripp bolts 14 tightened to 94 Nm (69 lbf ft, 9.59 kgf m).

Locate Crown wheel assembly (without bearings) into housing.

Drive bearing cones 5 and 6 onto differential case spigots. Lightly oil the bearings then fit their bearing cups and castle nuts 4 into drive head carrier 2. Do not fit the roll pins 3 at this stage.

Adjust castle nuts 4 to give an increase in input pinion rolling torque of between 1.36 - 2.5 Nm (12 - 22 lbf in) more than that recorded in Step 13.

Measure the backlash between crown wheel 15 and pinion 20, which should be 0.17 - 0.28 mm (0.006 0.010 in). Adjust castle nuts 4 by equal amounts when altering backlash. When backlash and preload are both correct, fit roll pins 3.

Check tooth marking to verify crown wheel and pinion are set correctly. Refer to Crown wheel and Pinion Meshing.

Apply Sealant to the mating faces of drive head carrier 2 and the axle casing. Fit the drive head carrier to the axle casing with the crown wheel towards the short drive shaft. Fit securing bolts 1 and tighten to 98 Nm (72 lbf ft, 10 kgf m).

9813/2050-5

Subtract end float: 0.25. Total:13.95. Subtract tolerance & pre load: 0.04. Result:13.91 Note: No spacer available this size, use next nearest size spacer i.e 13.900. 2

Remove sleeve B and temporary spacer. Fit correct size spacer from solid spacer setting kit. During removal take care to avoid damaging the outer bearing.

Fit sleeve B. Tighten adaptor C to no more than 50 Nm to protect against bearing damage while spacer selection is verified making sure the pinion is free to rotate. Check there is no end float and pinion is free to turn smoothly by hand. Remove adaptor C and fit nut 16. Then check that rolling torque is less than 2.0 Nm. If the rolling torque exceeds 2.0 Nm, check that the shaft has been assembled correctly.

Note: If the pinion is not free to rotate check the correct size spacer has been fitted. 4

Progressively torque tighten stake nut 16, occasionally rotating coupling yoke, up to 250 Nm. Provided, the correct size spacer has been selected, the rolling torque should be between 2.3 and 3.4 Nm including seal drag.

If rolling torque measured at step 10 is too high, fit the next larger size spacer. If rolling torque is too low, fit the next smallest size spacer. If a correct spacer is not available from the range, check that drive head is assembled correctly. Remove adaptor C and sleeve B. Fit new oil seal 19, grease between seal lips before fitting. Fit coupling yoke 18 and NEW stake nut 16.

Front Axle Front Axle 17

Reassemble both drive shafts and hub assemblies, refer to Axle Hub and Drive shaft - Dismantling and Assembly.

Re-fill the hubs and differential with the correct grade of oil.

Refit the propshaft, refer Removing and Replacing.

Propshafts

Pinion Depth Setting 1

Place new pinion head inner bearing assembly on a flat surface and position service tool 892/00174 over the bearing. Measure gap A (e.g. 0.20mm) and add this to the cup depth stamped on the tool (e.g. 30.01mm) to obtain the bearing depth K Fig 34. ( T 41).

From the face of the pinion, obtain the etched deviation figure B (e.g. + 2) which is in units of 0.01 mm. If positive, add this to the bearing depth; if negative, subtract from the bearing depth.

Obtain the deviation figure C (e.g. - 1) stamped on the differential housing bolt flange. If negative, add to bearing depth; if positive, subtract from bearing depth.

Subtract the total of the above figures from the standard value of 31.19 mm. The result will be the thickness of shims required behind the pinion head bearing cup. Example (all dimensions in millimeters). Cup depth 30.01 Gap A + 0.20 Bearing depth 30.21 Pinion deviation B (+ 2) + 0.02 Housing deviation C (- 1) +0.01 Total 30.24 Standard value31.19Less Total above 30.24 Shim Thickness 0.95 Fig 34.

Note: In the event that the setting data stamp has been omitted from the drive head casing, adopt the following setting procedure.

9813/2050-5

Front Axle Front Axle

Crown Wheel and Pinion Meshing

2 Wheel Drive

Meshing of the gears should be checked by marking three of the pinion teeth with engineers marking compound and rotating the pinion K Fig 35. ( T 42).

Dismantling The numerical sequence shown on the illustration is intended as a guide to dismantling.

The marking will then be transferred to the crown wheel teeth.

For assembly the sequence should be reversed.

Correct tooth marking

A suitable press will be required to remove and replace stub axle 22 K Fig 36. ( T 43).

Pinion too deeply in mesh.

When Assembling

Decrease the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel towards the pinion to correct the backlash.

Fit bushes 18 and 20 with open ends of grease grooves facing the axle beam.

Pinion too far out of mesh.

Add shims 16 as required to give zero to 0.1mm (0.004in) clearance between axle beam and bearing 15.

Increase the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel away from the pinion to correct the backlash.

Apply Loctite to threads of bolt 9. Pack LCG-2 Grease into hubs 5 and between lips of seals 7. Bed in bearings 6 and 8 by rotating hub in each direction whilst tightening nut 3. When correct torque setting has been achieved, back off one flat and fit split pin 2. Torque Settings

Item

Table 9. kgf m

lbf ft

Back off one flat before fitting split pin.

Fig 35.

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Front Axle Front Axle

Fig 36.

9813/2050-5

Front Axle Front Axle

Hub End Torque 1

Apply thin layer of grease on the wear sleeve A and insert the hub end assembly B into the stub axle C.

D071120-01

Fig 37.

D071120-03

Fig 39. 2

Make sure that the stub axle C does not hit the hub end B. K Fig 37. ( T 44). Install the the outer taper roller bearing D on the stub axle C.

Make sure that the stake nut turns freely.

Tighten the stake nut E with a pneumatic gun F but do not tighten fully.

D071120-04

Fig 40.

D071120-02

Make sure that the hub is seated properly on the stab axle.

Torque the stake nut to 70 Nm and mark the position on the stub axle and nut.

Rotate the hub two times and check for the marks.

Make sure the marks are align.

Fig 38. 4

Put the stake nut E on the stub axle C and turn at least three threads with hand.

9813/2050-5

Front Axle Front Axle 11

If not dot the step 8 to 10 again.

Loosen the stake nut by half turn.

Torque the stake nut again to 13 Nm with a fixed torque wrench and mark the position on the stub axle and nut.

Rotate the hub two times and check for the mark.

Make sure the marks are align, if not do the 9 to 13 again.

Stake the stake nut at two places on the stub as shown.

D071120-05

Fig 41. 17

The stake of the nut should be done by the assigned tool as per WI/PR/02.

Check the rolling torque at the two ends and note down the torque data.

D071120-06

Fig 42.

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Front Axle Front Axle

Page left intentionally blank

9813/2050-5

Rear Axle Service Procedures

Rear Axle Service Procedures Removal and Replacement

Jack the axle arm off the drive head, using the drive head securing bolts. Remove all traces of gasketing from the mating faces.

There are two counter plates B, one at each end of the brake pack, which are not secured to the plate carrier C. If the plates are to be re-used, note their positions and which way round they are then withdraw the brake pack.

Remove the circlip. If the brake pack is to be re-used, note the positions of the plates before removing them.

Removing 1

Remove bolts A to disconnect the drive shaft from the axle.

Disconnect the brake pipes from the brake piston housing, shown at H. Remove tee piece B retaining bolt and remove the tee piece. Blank off exposed connections.

Label and then disconnect hydraulic pipes D from the steer rams. blank off all exposed connections.

Loosen the road wheel retaining nuts E.

Make sure that the front wheels are blocked, use the stabiliser legs to raise the rear end of the machine.

Prop the machine on each side as shown at F.

Remove the rear road wheels.

Position a jack underneath the balance point (centre) of the axle and support the axle weight.

Remove nuts G. Bolts J and washers K.

Lower the jack and remove the axle.

Note: Attach a cradle to the jack that will partially embrace the axle. Brakes - Dismantling Note: 1 It is recommended that the axle be removed from the machine when dismantling the rear axle brakes. Note: 2 Although the drive shaft is shown removed in the following pictures, this job can be done without removing the swivel hub or the driveshaft. 1

Support the axle K Fig 43. ( T 48).

arm

and

remove

bolts

9813/2050-5

Rear Axle Service Procedures

Fig 44. 6

Remove the three reaction pins D. Inspect for damage K Fig 45. ( T 48).

Fig 45. Fig 43.

Note: The plate carrier has an internal chamfer at the end which faces away from the drivehead. 5

Carefully withdraw the brake piston E from its housing, if removal is necessary a hydraulic hand pump can be used to force the piston out of the housing.

Wear limit of friction plates is to the depth of circumferential grooves X. Check all plates for flatness and damage. (Some scoring of the counterplots is normal) Renew the brake pack complete if worn or damaged. Do not renew individual plates K Fig 44. ( T 48).

9813/2050-5

Rear Axle Service Procedures the chamfered end of the brake carrier C faces away from the drive head. Return re-used counterplates to their original positions. Push the brake pack fully home.

Fig 46. 8

Remove and discard seals F and G. Inspect the housing bore for damage and scoring. Nicks or cuts in the seals may be responsible for loss of brake fluid K Fig 46. ( T 49).

Apply JCB Multigasket to the mating face of the drive head. Locate the axle arm onto the drive head, with the embossed word `TOP' on the axle arm uppermost.

Fit bolts A and torque tighten to 244 Nm (176 lbf ft, 24.9 kgf m).

Note: Check the grade of bolts fitted. Grade 8.8 should be tightened to 244 Nm grade 12.9 should be tightened to 400 Nm. Hub and Drive Shaft Dismantling and assembly of the rear axle hub and driveshaft is the same as for the front axle hub and driveshaft. Component Key- PD70 Axle Hub Table 10.

Fig 47. Brakes - Assembly 1

Item

Description

Quantity per Hub

Planet Gear Carrier

`O' ring

Planet Gear

Bearing - planet gear

Circlip - `L' section

Circlip - internal

Fit new seals F and G. Make sure they seat squarely in their grooves K Fig 47. ( T 49).

Thrust Pad

Circlip - external

Carefully press the piston E all the way into its housing.

Verbus Ripp Bolts

Bearing Carrier

Assemble the friction plates and counterplates onto the carrier. K if the original brake pack is being reused, return the plates to their original positions (see 'Dismantling', Step 3) Soak new friction plates in JCB Special Axle Oil before assembly. Fit circlip.

Dowel

Annulus Carrier

Circlip - internal

Annulus Ring

Bearing - outer

Bearing - inner

Combination Oil Seal

Dirt Shield

Driveshaft

Locate the three reaction pins D into their grooves, securing them with grease. Push the pins fully into their location holes in the housing. Install one counterplate B into the housing, then the brake pack. then the other counterplate. Ensure that

9813/2050-5

Rear Axle Service Procedures

Fig 48.

Drivehead - Dismantling As the drivehead cannot be dismantled whilst fitted on the machine, we recommend that the complete axle is removed. K Removing ( T 47). The crownwheel and pinion are matched and should be renewed as a pair, if either one is damaged or excessively worn. The two differential case halves are also matched as are the differential side gears and planet gears, do not use unmatched have lves or gears. 1

Position the drive head as shown, with the crownwheel at the top. (For coupling removal see 'Renewing the Rear Axle Pinion Seal'. Remove capscrews A K Fig 49. ( T 50).

Fig 49. 2

9813/2050-5

Match - mark the brake piston housing B and drive head Pull off the brake piston housing K Fig 50. ( T 51).

Rear Axle Service Procedures

Fig 52. 5

Fig 50. 3

Drive out the differential side nut locking pin C, to allow readjustment on assembly. Remove the other brake piston housing only if damaged. But remove its locking pin C regardless (to allow sideload adjustment on assembly).

Using a soft faced hammer, hit the pinion end shaft until the pinion is free from its front bearing, then withdraw the pinion K Fig 52. ( T 51).

Fig 53. 6

Withdraw the pinion seal and outer bearing cone K Fig 53. ( T 51).

Fig 51. 4

Lift out the crown wheel / differentiaI assembly K Fig 51. ( T 51).

Note: If both brake piston housings are to be removed, put a mark on the crownwheel end of the drive head casing to ensure that the assembly is returned to its original position.

Fig 54. 7

9813/2050-5

If necessary, drive out the pinion inner bearing cup and shims. Discard the shims. Repeat for the outer

Rear Axle Service Procedures bearing cup if required. Note that there are no shims for the outer bearing cup K Fig 54. ( T 51).

Fig 58. 11 Fig 55. 8

Remove the differential gears and spherical washers. Pull off both differential bearing cones K Fig 58. ( T 52).

Remove the spacer. Pull off the bearing cone K Fig 55. ( T 52).

Fig 59. If required, remove the crownwheel to differential case half retaining bolts and remove the crownwheel K Fig 59. ( T 52).

Fig 56. 9

To dismantle the differential assembly, first remove bolts D K Fig 56. ( T 52).

Drivehead Assembly Determine the pinion follows:K Fig 60. ( T 53).

setting

Assemble the pinion inner bearing and its cup on a fiat surface.

Place Service Tool 892/00174 over the bearing assembly. Measure gap A. Add tool depth (30.01 mm) to gap A to give bearing depth.

Note the rnounting distance figure B etched on the pinion and the deviation figure C on the drive head housing. Both figures are in units of 0.01 mm.

Fig 57. 10

depth

Lift off the top half housing K Fig 57. ( T 52).

9813/2050-5

Rear Axle Service Procedures 4

If dimension B is positive, add it to the bearing depth. If dimension B is negative, subtract it from the bearing depth.

If dimension C is positive, subtract it from the total. If dimension C is negative, add it to the total.

Subtract the result from the standard value of 31.19 mm to give the required shim thickness.

Example (Dimension in mm) Dimension A

0.25

Add tool depth

+30.01

Total

30.26

Add dimension B if positive. (Subtract if negative).

+0.01

Total

30.27

Add dimension C if negative (Subtract if positive).

+0.01

Total

30.28

Standard Value

31.19

Less calculated total from above

-30.28

Drivehead Assembly (contd.)

SHIM THICKNESS

0.91

Note: The crownwheel and pinion are matched and should be renewed as a pair if either one is damaged or excessively worn K Fig 61. ( T 53).

Fig 61.

The two differential case halves are also matched as are the differential side gears and planet gears, do not use unmatched halves or gears K Fig 62. ( T 54). If required, fit a new crownwheel to the differential case half, torque tighten crownwheel retaining bolts to 166 Nm 122 lbf ft; 17 kgf m). Assemble the differential gears and their spherical washers into the boflom half housing. Fit the differential bearing cones.

Fig 60.

9813/2050-5

Rear Axle Service Procedures

Fig 64.

Fig 62. 2

Position the top half housing onto the differential, aligning the match mark letters (see Note above). Apply JCB Lock and Seal to the threads of bolts D, then fit and torque - tighten to 56 Nm (42 lbf ft, 6 kgf m). Check the gears for free rotation K Fig 63. ( T 54).

Fit the pinion bearing and the Service Spacer (14.20 mm K Fig 64. ( T 54).

Fig 65. 5

Insert the pinion into its bore. (Before inserting, ensure that the pinion matches the crownwheel. The code numbers etched on the pinion end face and the crownwheel perimeter should be the same K Fig 65. ( T 54).

Fig 63. 3

Fit the pinion inner bearing cup, together with the required thickness of shims to give correct pinion depth (See - Determine the pinion depth setting). To ensure the cup is fitted square, use a suitable puller assembly. Do not use a hammer. Fit the outer bearing cup.

Fig 66. 6

9813/2050-5

Fit the pinion outer bearing cone. Do not fit the Oil seal at this stage K Fig 66. ( T 54).

Rear Axle Service Procedures 7

Set torque wrench G to 35 Nm (25.8 lbf ft) and measure the end float while rotating the shaft K Fig 67. ( T 55).

To select the right size spacer, subtract the end float obtained at step 8 from the solid spacer size (14.20 mm). Also subtract 0.04 mm to allow for theoretical bearing tolerance and pre load. The result is the size of spacer to be fitted from the solid spacer setting kit. If there is no spacer of this size, fit the next nearest size spacer.

nut 16. Then check that rolling torque is less than 2.0 Nm. If the rolling torque exceeds 2.0 Nm, check that the shaft has been assembled correctly. Note: If the pinion is not free to rotate check the correct size spacer has been fitted.

Example: Temporary spacer size

4.20

Subtract end-float

0.25

Total

13.95

Subtract tolerance & preload

0.04

Result

13.91

(No spacer available this size, use next nearest size spacer i.e 13.900). 11

Remove sleeve B and temporary spacer. Fit correct size spacer from solid spacer setting kit, refer to Service Tools - Axles. During removal take care to avoid damaging the outer bearing.

9813/2050-5

Fig 67.

Rear Axle Service Procedures 13

If rolling torque measured at step 12 is too high, fit the next larger size spacer. If rolling torque is too low, fit the next smallest size spacer. If a correct spacer is not available from the range, check that drive head is assembled correctly.

Remove adaptor C and sleeve B. Fit a new oil seal, grease between seal lips before fitting. Fit the brake caliper bracket D. Apply loctite to the fixing bolts E. Fit the brake disc/coupling and a NEW stake nut 16.

Progressively torque tighten the stake nut, occasionally rotating coupling yoke, up to 250 Nm. Providing the correct size spacer has been selected the rolling torque should be between 2.3 and 3.4 Nm including seal drag.

Note: The nut tightening torque can be increased to a maximum of 300 Nm provided that the pinion rolling torque does not exceed the maximum of 3.4 Nm. 16

Finally stake the nut 16 into the slot.

If both brake piston housings were removed, fit the one at the opposite end to the crownwheel, using the procedure in Step 18. Then install the crown wheel / differential assembly into the drive head.

Apply sealant to the drive head mating face, then fit the brake piston housing. Ensure that the match marks made during dismantling are aligned. Fit cap screws. Torque - tighten to 56 Nm (42 lbf ft, 5.7 kgf m). (Applies to both piston housings K Fig 68. ( T 56).

Adjust differential side nuts to give a bearing preload of 1.13-2.26 Nm (0.8-1.6 lbf ft; 0.1-0.2 kgf m). (Measure the preload by taking another rolling torque reading and subtracting the torque figure measured at step 21. The difference is the bearing preload.

Fig 68.

9813/2050-5

Rear Axle Service Procedures 20

Measure the crownwheel backlash (see Note), which should be 0.17 - 0.28 mm (0.006 - 0.010 in). Adjust the differential side nuts by equal amounts when altering backlash. When backlash and preload are both correct, fit the sidenut locking pins 18 K Fig 69. ( T 57).

Pinion too far out of mesh. lncrease the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel away from the pinion to correct the backlash K Fig 70. ( T 57).

Verify crownwheel and pinion are set correctly, see 'Crownwheel and Pinion Adjustment'. Note: To measure the backlash, use a magnet drilled and tapped 6 mm to accept a length of rod threaded 6 mm on one end. Position the magnet in-between the crown wheel locking bolts as shown in the inset.

Fig 69.

Crownwheel and pinion Meshing Meshing of the gears should be checked by marking three of the pinion teeth with engineers marking compound and rotating the pinion. The marking will then be transferred to the crown wheel teeth. Pinion too deeply in mesh. Decrease the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel towards the pinion to correct the backlash.

Fig 70.

9813/2050-5

Rear Axle Service Procedures Collapsible Spacer Assembly When assembling the axle, if the special tools listed in the Service Tools - Axles section or if the correct size solid spacer is not available, it is acceptable to fit a collapsible spacer using the procedure below. The illustration shows a typical axle, note that rear axles are fitted with a brake disc, not the yoke 22 shown. 1

Smear output shaft inner bearing 27 with Grease before refitting. Fit bearing cup 28 over pinion shaft 23 and assemble into drive head casing K Fig 71. ( T 58).

Fit NEW collapsible spacer 24, after smearing with Grease, fit outer bearing 26 followed by a new oil seal 25. Grease between seal lips before fitting. Assemble Yoke 22 and NEW stake nut 20 with integral washer.

Tighten stake nut to achieve a rolling torque of 1.5 to 2.8 Nm (1.1 to 21. lbf ft.), inclusive of seal drag.

Note: If this figure is accidentally exceeded the output shaft must be dismantled and the collapsible spacer 24 renewed. 4

Finally stake nut into slot.

Fig 71.

9813/2050-5

Fault Finding Gearbox

Fault Finding Gearbox Synchro Shuttle Gearbox

If the transmission will not pull, start at check 12.

Before carrying out the checks listed hereunder, the machine should, if possible, be operated to determine the fault area (s), and bring the systems to their normal working temperatures.

If there is no drive in one or both directions, start at check 17.

If the transmission is jumping out of gear, start at check 29.

If the transmission is sticking in gear, start at check 39.

If ratios are 'crash changing', start at check 41.

Ensure that the correct quantity and grade of oil is used and that there are no obvious leaks. 1

If the transmission is noisy, start at check 1.

If the transmission is overheating, start at check 4. Table 11. Sr.No.

CHECK

ACTION

Is there noise when selecting direction?

Is there noise when running with direction selector in neutral and ratio selector in 1st

YES:

Check 3

NO:

Check 2

YES:

Check 9 Check 19

3 4

Is there air in the hydraulic system? Is the fluid level correct?

Are the oil passages restricted?

YES:

Continue running to expel air.

NO:

Check 4

YES:

Check 5

NO:

Check level only when machine is cold and top-up as required

YES:

Clear the restriction.

NO:

Check 6 Remove and clean strainer.

Is the suction strainer restricted?

YES: NO:

Check 7

Is pump pressure as specified?

YES:

Check 9

NO:

Check clutch press. Maintenance valve is free

YES:

Renew pump.

No:

Check converter sprag clutch for wear or slip.

YES:

Check 10

No:

Check 11

When flow testing pump, is output low?

Does the noise continue when direction selector is in forward or reverse?

9813/2050-5

Fault Finding Gearbox Sr.No.

CHECK

ACTION

Is transmission misaligned?

YES: No:

Check 'converter out' pressure and flow.

Are the pump bushes worn?

YES:

Renew

No:

Check converter for wear or

Is the transmission not pulling in one direction only YES:

Is the transmission not pulling in both Forward and YES: Reverse?

No:

No: 14

Is 'converter in' pressure as specified?

Is pump being driven by converter?

Are clutch sealing rings damaged?

Is there drive in one direction only?

Check 15

YES:

Check pump pressure

No:

Renew damaged parts.

YES:

Tap pressure gauge into clutch

No:

Check clutch plates for damage. feed lines to monitor pressure

YES:

Check18

No:

Check19

Is the fault only when the transmission is hot?

22 23

Is the noise a hiss, thump or bumping? Is the noise a squeal? Is the noise present when in neutral or when in gear? Is the countershaft or its bearings worn or damaged? Is there excessive backlash in the gears?

Check 16 Inspect converter relief valve for damage.

Check 13 Stall test machine, Check 14

YES:

Is the start switch in the run position and supplying YES: current to the neutral start relay.

Is the noise a growl, hum or grinding?

Check 16

No:

Renew mountings and check position.

Check19

No:

Rectify.

YES:

Dismantle solenoid and check components.

No:

Check microswitches, relay and wiring loom.

YES:

Check gears for damage or wear

No:

Check microswitches, relay and wiring loom.

YES:

Check bearings for damage or wear.

No:

NO:Check 21

YES:

Check free running gears for seizure.

No:

Check 23

NEUTRAL: Check 24 IN GEAR

Check 27

YES:

Renew damaged parts

No:

Check 25

YES:

Adjust by checking shaft end float

9813/2050-5

Fault Finding Gearbox Sr.No. 26 27 28 29 30

CHECK

ACTION

Is the mainshaft pilot bearing worn? Is the mainshaft rear bearing worn? Are the sliding gear teeth worn or damaged? Are the selector forks loose? Are the selector fork pads or grooves in gears worn?

Are the dog gear teeth worn?

Are the selector rod detent springs broken?

No:

Check 26

YES:

Renew.

No:

Check gear teeth for scuffing.

YES:

Renew.

No:

Check 28

YES:

Renew gears.

No:

Check 29

YES:

Tighten screws.

No:

Check 30

YES:

Renew worn parts.

No:

Check 31

YES:

Renew.

No:

Check 32

YES:

Renew.

No:

Check 33 Renew.

Are the selector rods worn or damaged?

YES: No:

Check 34

Are the selector fork pads out of position?

YES:

Reposition or renew (check interlock)

No:

Check 35

Is there excessive end float in gears or shafts

YES:

Adjust.

No:

Check thrust washers and mating faces.

Is the synchroniser bronze worn?

YES:

Renew synchro pack

No:

Check 37

YES:

Continue using, chips will either

No:

Check 38

YES:

Renew.

No:

Check free running gears for seizure or damage.

YES:

Free or renew.

No:

Check 40

YES:

Remove chips.

No:

Ensure that clutch is disengaged when pedal is pressed. Continue using, chips will either embed below bronze or be rejected.

39 40

Are steel chips embedded in the bronze? (embed below bronze or be rejected). Are the synchroniser components damaged?

Are the sliding gears tight on the splines? Are chips wedged between splines of shaft

Are steel chips embedded in the bronze?

YES: No:

Check 42

Are the synchroniser spring pins damaged?

YES:

Renew synchro

9813/2050-5

Fault Finding Gearbox Sr.No. 43

CHECK

ACTION

Is the synchroniser bronze worn?

No:

Check 43

YES:

Renew synchro.

No:

Check blocker pins.

Synchro Shuttle Gearbox - 2/4 Wheel Drive Clutch 4WD Cannot be Engaged.

Check that the 4-wheel drive external pipe work is not damaged and that the drive train is intact.

In normal operation the 2/4 wheel drive clutch is spring loaded off and therefore disengaged to give 2 wheel drive. The clutch must be pressurised to give 4 wheel drive. Before starting the more detailed fault finding procedures eliminate the obvious:

Check that all the electrical connections are clean and secure. Also check that the solenoid spool is not sticking (in the 2WD position).

Check that the mainline pressure is correct (see Low Mainline Pressure).

Check that the pump flow rate is correct.

Check that the transmission oil level is correct.

Check that the fuse for the 2/4WD circuit is intact. If the fault is not rectified after eliminating the obvious, check the following: Table 12.

Possible Cause

Remedy

Low mainline pressure

Identify if the fault is related to the 2/4WD disconnect:Disconnect the external pipe work to the 2/4WD clutch. Cap and plug open orifices check the mainline pressure if the pressure is correct, the fault must be within the 2/4WD (see step 8). If the reading is still low check the transmission in the normal manner.

Low mainline pressure (due to 2/ 4WD clutch): 2/4WD solenoid spool sticking

Strip, clean and re-assemble solenoid valve, renew valve if required.

2 /4WD solenoid spool O-ring failed

Renew O-ring.

Clutch shaft sealing rings leaking

Renew clutch shaft sealing rings.

Excessive clutch shaft end float.

Renew parts as required, reset end float (should not exceed 0.03 mm; 0.001 in).

Wrong type clutch piston fitted.

Fit correct type clutch piston (i.e. without bleed hole).

Clutch piston O-ring failed.

Replace clutch piston O-ring.

Defective 2/4WD clutch Wrong type clutch piston fitted.

Fit correct type clutch piston (i.e. without bleed hole).

Clutch piston O-ring failed.

Replace clutch piston O-ring.

Defective 2/4WD clutch: Worn friction/counter plates

Inspect friction/counter plates, renew as required.

Mechanical failure of 4WD unit

Strip and inspect 4WD unit. Check that the electrical and hydraulic circuits are functioning correctly.

Incorrect clutch pack end float.

Measure clutch pack end float (should be 1.0 to 2.3 mm). Correct as required.

9813/2050-5

Fault Finding Gearbox 2WD Cannot be Engaged No pressure is required to engage 2WD(spring loaded). Check that the solenoid spool is not sticking (in the 4WD position), then see below.

Possible Cause

Table 13. Remedy

Incorrect type of solenoid valve fitted.

Check solenoid. Note: Powershift and Synchro Shuttle machines Have different types of solenoid - check parts list

Non-return valve faulty (noticeable because 2WD cannot be engaged).

Check the non-return valve.

2/4WD solenoid permanently energised.

Check the 2/4WD relay and select switch, Replace, if necessary.

9813/2050-5

Fault Finding Gearbox

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9813/2050-5

Front Axle Front Axle setting kit. If there is no spacer of this size, fit the next nearest size spacer, refer to Service Tools - Axles.

Note: The nut tightening torque can be increased to a maximum of 300 Nm provided that the pinion rolling torque does not exceed the maximum of 3.4 Nm.

Example: (all dimensions in millimeters). 7