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Service Manual Tracked Excavators JS81 Service Manual - JS81 Section 1 - General Information Section 2 - Operator’s Manual Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/2000-02

World Class Customer Support Copyright © 2007 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 India Limited, 23/7, Mathura Road, Ballabgarh - 121004, Haryana (India), Tel 0129 4299000 Fax 0129 2309051

Section 1 General Information Service Manual - JS81 Section 1 - General Information Section 2 - Operator’s Manual Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/2000-02

Section 1 - General Information

Notes:

1-0

9813/2000-02

1-0

Section 1 - General Information Contents Page No. Introduction About this Manual ...................................................................................... 1-1 Machine Description .................................................................................. 1-2 Identifying Your Machine ........................................................................... 1-7 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-9 Hydraulic Connections ............................................................................. 1-13 Service Tools Numerical List .......................................................................................... 1-17 Tool Detail Reference .............................................................................. 1-20 Service Consumables Sealing and Retaining Compounds ......................................................... 1-41 Terms and Definitions Colour Coding .......................................................................................... 1-43

1-i

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 K Fig 1. ( T 1).

â&#x20AC;&#x201C; JCB JS81 from serial number 1480500 to 1481999. â&#x20AC;&#x201C; JCB JS81 from serial number 1798936 to 1799936.

â&#x20AC;&#x201C; JCB JS81 from serial number 2426501 to 2427000.

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.

A T017280-2

Fig 1.

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 1).

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

9813/2000-02

Introduction Machine Description

Machine Description The JCB Tracked Excavator The JCB Tracked Excavator is a self propelled machine comprising a tracked undercarriage and a revolving upper structure which incorporates a boom, dipper, bucket and swing mechanism. It is mainly used for digging below ground level with bucket motions towards the machine. The upper structure can swing 360 degrees and discharge material while the tracked undercarriage remains stationary.

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 in areas with dust containing asbestos, special safety regulations must be followed and the machine must be equipped for use in these environments. The machine is primarily designed for excavating with a bucket, without movement of the undercarriage during the work cycle. An excavator work cycle normally comprises excavating, elevating, swinging and discharging of material. An excavator can also be used for object or material handling/transportation provided it meets the lifting regulations.

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Introduction Machine Description

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Introduction Machine Description

Main Component Locations

Fig 2. Item

Description

Bucket

Bucket link

Bucket ram

Dipper

Dipper tank

Dipper ram

Boom

Boom ram

Operators cab

Counterweight

Undercarriage

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Introduction Identifying Your Machine

Identifying Your Machine Machine Identification Plate JCB MANUFACTURING LTD. TALEGAON, DIST PUNE-410507 INDIA

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

MADE IN INDIA

The machine serial number is also inscribed at the baseplate of the rear frame.

Fig 4. Item A

Description Identification plate

Fig 3. Item

Description

Identification plate (location)

Serial number (inscribed)

The machine model and build specification are indicated by the PIN. The PIN has 17 digits and must be read from left to right. JCB

Digit

JS102

Table 1. Typical PIN L XXXXXX

Table 2. Explanation of the PIN Description

1 to 3

World manufacturer identification. (JCB)

4 to 8

Machine type and model. For example, JS102 = JS330 Tracked.

Random check letter. The check letter is used to verify the authenticity of a machine's PIN.

10 to 17

Machine serial number.

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Introduction Identifying Your Machine

Component Identification Plate Engine The engine data labels are attached to the cylinder block.

ENGINE TYPE RATING kW/hp RATING STD.

RPM Enriching Lives

GOVERNING CLASS ENGINE NO.

E TYPE ENGIN p RATING kW/h

rpm

RATINGSTD. G CLASS GOVERNIN E No. ENGIN

S LTD R OIL ENGINE KIRLOSKA INDIA

KIRLOSKAR OIL ENGINES INDIA LTD

P041680-53

Fig 5.

9813/2000-02

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 3. Fastener Types ( T 1-7).

Torque settings are given for the following conditions:

Fastener Type

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

Condition 1 – Un-lubricated fasteners

Table 3. Fastener Types Colour Part No. Suffix

– Zinc fasteners

Zinc and Yellow

Golden finish

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

Dacromet

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

– Yellow plated fasteners

Condition 2

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.

– Zinc flake (Dacromet) fasteners – 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 6. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

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1-7

Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. 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 5. 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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1-8

Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. 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 7. 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

1-9

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1-9

Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 8. 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 9. 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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1-10

Section 1 - General Information Torque Settings Hydraulic Connections

Hydraulic Connections T11-003

'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45Â° seat machined into the face of the tapped port. Table 10. 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 11. 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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1-11

Section 1 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors

Fig 7. Hoses 7-B screwed into adaptors 7-A seal onto an `O' ring 7-C which is compressed into a 45Â° seat machined into the face of the adaptor port.

BSP Hose Size in.

1-12

Note: Dimension 7-D will vary depending upon the torque applied.

Table 12. 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

9813/2000-02

kgf m

lbf ft

1-12

Section 1 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 13. 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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1-13

Section 1 - General Information Torque Settings Hydraulic Connections

'Torque Stop' Hose System

Fig 8. `Torque Stop' Hoses 8-B screwed into adaptors 8-A seal onto an 'O' ring 8-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 8-D, which acts as a physical stop. Note: Minimum dimension 8-E fixed by shoulder 8-D.

Table 14. 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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1-14

Section 1 - General Information Service Consumables Sealing and Retaining Compounds

Service Consumables Sealing and Retaining Compounds T11-001_4

Table 15. 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

1-41

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1-41

Section 1 - General Information Service Consumables Sealing and Retaining Compounds

Page left intentionally blank

1-42

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1-42

Section 1 - General Information

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

Part Number

details of all tools, including the content of kits and sets, refer to Tool Detail Reference, Section 1. 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.

Description

See Section

993/68100

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

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

892/00842

Glass Lifter

892/00843

Folding Stand for Holding Glass

892/00845

Cartridge Gun

892/00846

Glass Extractor (Handles)

892/00847

Nylon Spatula

892/00848

Wire Starter

892/00849

Braided Cutting Wire

926/15500

Rubber Spacer Blocks

992/12300

12V Mobile Oven

992/12400

240V Static Oven (2 Cartridge)

992/12800

Cut-Out Knife

992/12801

'L' Blades

4104/1310

Hand Cleaner

892/00281

AVO Meter (not illustrated)

892/00298

Fluke Meter

892/00285

Hyd. Oil Temperature Probe

892/00284

Digital Tachometer

892/01174

DLA Kit

331/22966

Pump Drive Alignment Tool (not illustrated)

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

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

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

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

'T' Adaptors - see Tool Detail Reference (Section 1)

1-43

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1-43

Section 1 - General Information Service Tools Numerical List Part Number

Description

See Section

Female Blanking Caps - see Tool Detail Reference (Section 1)

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

Female Connectors - see Tool Detail Reference (Section 1)

Bonded Washers - see Tool Detail Reference (Section 1)

Ram Protection Sleeves - see Tool Detail Reference (Section 1)

892/00334

Ram Seal Fitting Tool

Hexagon Spanners - see Tool Detail Reference (Section 1)

892/01027

Piston Seal Assembly Tool

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

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

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

992/10100

Spool Clamp

892/00039

Spool Clamp

992/02800

ARV Extractor

331/31069

Test Block for A.R.V.

892/00891

Valve Spool Seal Fitting Tool

892/00346

Gauge

892/00279

Gauge

892/00280

Gauge

892/00347

Connector

892/00254

Hose

Ram Jigs - see Tool Detail Reference (Section 1)

Ram Piston Nut Spanners - see Tool Detail Reference (Section 1)

Socket Box Wrench

Nut Adapter

Seal Ring Tool

Stopper

Bearing Rig

Inserting Seal Ring and Correction Jig - see Tool Detail Reference (Section 1)

Jig for Pulling Out, Press-fitting Bushing - see Tool Detail Reference (Section 1)

Jig for Press-fitting Wiper Ring - see Tool Detail Reference (Section 1)

Jig for Inserting Cylinder Head - see Tool Detail Reference (Section 1)

Seal Ring and Connector Jig - see Tool Detail Reference (Section 1)

Bush Removal Jig - see Tool Detail Reference (Section 1)

Bush Fitting Jig - see Tool Detail Reference (Section 1)

Wiper Ring Fitting Jig - see Tool Detail Reference (Section 1)

892/00041

De-glazing Tool

1-44

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Section 1 - General Information Service Tools Tool Detail Reference

Tool Detail Reference Section B - Body and Framework Note: Not all service tools are illustrated.

Fig 9. 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 10. Rivet Nut Tool

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 11. 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 14. 892/00846 Glass Extractor (Handles) Used with braided cutting wire to cut out broken glass. K Fig 17. ( T 1-47).

Fig 15. 892/00847 Nylon Spatula

Fig 12. 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 16. 892/00848 Wire Starter Used to access braided cutting wire through original polyurethane seal. K Fig 17. ( T 1-47).

Fig 13. 892/00845 Cartridge Gun Hand operated. Essential for the application of sealants, polyurethane materials etc.

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 17. 892/00849 Braided Cutting Wire

Fig 20. 992/12400 Static Oven 240V

Consumable heavy duty cut-out wire used with the glass extraction tool. K Fig 14. ( T 1-46). 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 18. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.

Fig 21. 992/12800 Cut-Out Knife Used to remove broken glass.

Fig 19. 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).

1-47

Fig 22. 992/12801 'L' Blades 25 mm (1 in.) cut. Replacement blades for cut-out knife. K Fig 21. ( T 1-47). Unit quantity = 5 off.

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 23. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub).

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Section 1 - General Information Service Tools Tool Detail Reference

Section C - Electrics Note: Not all service tools are illustrated.

Fig 24. 892/00298 Fluke Meter

Fig 25. 892/00285 Hydraulic Temperature Probe

Fig 26. 892/00284 Venture Microtach Digital Tachometer

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Section 1 - General Information Service Tools Tool Detail Reference

Section E - Hydraulics Note: Not all service tools are illustrated. 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. 1604/0004A 1/2 in. x 1/2 in.

Fig 27. Male Adaptors

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

1/2 in. x 3/8 in.

Fig 28. Pressure Test Adapters

892/00258

5/8 in. BSP x Test Point

816/15118

3/4 in. BSP x Test Point

892/00259

1 in BSP x Test Point

892/00260

1.1/4 in. BSP x Test Point

892/00261

5/8 in. UNF x Test Point

816/55045

1/4 in. M BSP x 1/4 in. F BSP x Test Point

816/55038

3/8 in. M BSP x 3/8 in. F BSP x Test Point

816/55040

1/2 in. M BSP x 1/2 in. F BSP x Test Point

892/00263

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

892/00264

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

892/00265

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

892/00266

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

892/00267

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

Fig 29. Pressure Test 'T' Adapters

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 30. '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 31. 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 32. 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 33. Female Connectors

Fig 34. Bonded Washers

1-51

1406/0021

3/4 in. BSP

1406/0029

1.1/4 in. BSP

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 35. 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 36. 892/00334 Ram Seal Fitting Tool 5mm

m 3m

110mm 175mm 3o

Fig 37. 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

1-52

1.4

Fig 38. 892/01027 Piston Seal Assembly Tool

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Section 1 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11046 JCB ServiceMaster Flow Test Kit. K Fig 40. ( T 1-53).

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 39. 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 40. 998/11046 JCB ServiceMaster Flow Test Kit

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Section 1 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit. K Fig 42. ( T 1-54).

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 41. 892/ 00253 Hydraulic Circuit Pressure Test Kit

Fig 42. 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit

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Section 1 - General Information Service Tools Tool Detail Reference 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)

Fig 43. Hand Pump Equipment

Fig 44. Spool Clamps 892/00039

Spool Clamp

992/10100

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

992/02800

ARV Extractor

Fig 45. 331/31069 - Test Block for A.R.V.

Fig 46. 892/00881 Valve Spool Seal Fitting Tool 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. Hydraulic Circuit Test Gauges and Connections

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Section 1 - General Information Service Tools Tool Detail Reference

JS07050

Fig 48. Ram Piston Nut Removal/Fitting Spanner

1-56

993/99512

Spanner 55 mm A/F

993/99513

Spanner 60 mm A/F

993/99514

Spanner 65 mm A/F

993/99515

Spanner 70 mm A/F

993/99516

Spanner 75 mm A/F

993/99517

Spanner 85 mm A/F

993/99518

Spanner 90 mm A/F

993/99519

Spanner 100 mm A/F

993/99520

Spanner 110 mm A/F

993/99521

Spanner 115 mm A/F

SSP0046

Spanner 80 mm A/F

SSP0047

Spanner 95 mm A/F

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Section 1 - General Information Service Tools Tool Detail Reference

A408900

Fig 49. Socket Box Wrench Note: For disassembly and assembly of slew motor gearbox. This tool can not be ordered from JCB.

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Section 1 - General Information Service Tools Tool Detail Reference

A408860

Fig 50. Nut Adapter Note: For disassembly and assembly of slew motor gearbox. This tool can not be ordered from JCB.

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Section 1 - General Information Service Tools Tool Detail Reference

A408880-C1

Fig 51. Seal Ring Tool Note: For assembly and disassembly of slew motor gearbox seal. This tool can not be ordered from JCB.

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Section 1 - General Information Service Tools Tool Detail Reference

A408890

Fig 52. Stopper Note: For assembly of slew motor gearbox. This tool can not be ordered from JCB.

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Section 1 - General Information Service Tools Tool Detail Reference

A408870-C1

Fig 53. Bearing Rig Note: For removal of slew motor bearing. This tool can not be ordered from JCB.

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Section 1 - General Information Service Tools Tool Detail Reference Inserting Seal Ring and Correction Jig WDB 2052

Bucket

120mm Cylinder inner diameter

WDB 2054

Boom

125mm Cylinder inner diameter

WDB 2164

Boom

130mm Cylinder inner diameter

WDB 2056

Arm

150mm Cylinder inner diameter

Jig for Pulling Out, Press-fitting Bushing WDB 2166

Bucket

80mm Piston Rod diameter

WDB 2167

Boom

85mm Piston Rod diameter

WDB 2170

Arm

100mm Piston Rod diameter

WDB 2168

Bucket

90mm Piston Rod diameter

WDB 2168

Boom

90mm Piston Rod diameter

WDB 2171

Arm

105mm Piston Rod diameter

WDB 2166-1

Bucket

80mm Piston Rod diameter

WDB 2167-1

Boom

85mm Piston Rod diameter

WDB 2170-1

Arm

100mm Piston Rod diameter

Jig for Press-fitting Wiper Ring

WDB 2168-1

Bucket

90mm Piston Rod diameter

WDB 2168-1

Boom

90mm Piston Rod diameter

WDB 2171-1

Arm

105mm Piston Rod diameter

WDB 2174

Bucket

80mm Piston Rod inner diameter

WDB 2175

Boom

85mm Piston Rod inner diameter

Jig for Inserting Cylinder Head

WDB 2178

Arm

100mm Piston Rod inner diameter

WDB 2176

Bucket

90mm Piston Rod inner diameter

WDB 2176

Boom

90mm Piston Rod inner diameter

WDB 2179

Arm

105mm Piston Rod inner diameter

Seal Ring and Connector Jig WDB 2052

Seal Ring insert and connection jig set

Note: The above Part no. is applicable to a tube diameter of 120mm

Bush Removal Jig WDB 2166

1-62

Bush removal jig

9813/2000-02

1-62

Section 1 - General Information Service Tools Tool Detail Reference WDB 2166-1

Retainer

Note: The above Part no. is applicable to a rod diameter of 80mm

Bush Fitting Jig WDB 2166 WDB 2166-1

Bush press fitting jig Retainer

Note: The above Part no. is applicable to a rod diameter of 80mm

Wiper Ring Fitting Jig WDB 2166-1

Wiper Ring fitting

Note: The above Part no. is applicable to a rod diameter of 80mm

Wiper Ring Fitting Jig WDB 2174

Cylinder Head insertion guide jig

Note: The above Part no. is applicable to a rod diameter of 80mm

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Section 1 - General Information Service Tools Tool Detail Reference

Section K - Engine

Fig 54. 892/00041 - De-glazing Tool for Cylinder Bores To assist bedding-in of new piston rings.

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Section 1 - General Information Service Tools Tool Detail Reference

Page left intentionally blank

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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

1-66

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).

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Section 1 - General Information Terms and Definitions Colour Coding

Page left intentionally blank

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Section 2 Operator’s Manual Service Manual - JS81 Section 1 - General Information Section 2 - Operator’s Manual Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/2000-02

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

Notes:

2-0

9813/2000-02

2-0

Foreword The Operator's Manual

OPERATOR'S MANUAL JS81

WARNING You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand. Treat the Operator's Manual as part of the machine. Keep it clean and in good condition. Replace the Operator's Manual immediately if it is lost, damaged or becomes unreadable.

Machine Delivery and Installation 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.

EN - 9821/9600 - ISSUE 1A - 10/2014

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 (included in this manual) has not yet been completed with you. Your local JCB Dealer is

This manual contains original instructions, verified by the manufacturer (or their authorized representative).

Copyright 2014 ÂŠ JCB SERVICE All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

www.jcb.com

Notes:

9821/9600-1A

Table of Contents

Contents

Page No.

Acronyms Glossary ........................................................................................................................................ vii Introduction About this Manual Model and Serial Number ..................................................................................................................... Using the Manual .................................................................................................................................. Left-Hand Side, Right-Hand Side ......................................................................................................... Cross References ................................................................................................................................. Safety Safety - Yours and Others .................................................................................................................... Safety Warnings .................................................................................................................................... General Safety ...................................................................................................................................... Clothing and Personal Protective Equipment (PPE) ............................................................................

1 1 1 1 2 2 2 3

About the Product Introduction General .................................................................................................................................................. 5 Name and Address of the Manufacturer .............................................................................................. 5 Product Compliance .............................................................................................................................. 5 Description General .................................................................................................................................................. 6 Intended Use ......................................................................................................................................... 6 Log Moving/Object Handling ................................................................................................................. 6 Optional Equipment and Attachments .................................................................................................. 6 Danger Zone ......................................................................................................................................... 6 Main Component Locations .................................................................................................................. 7 Product and Component Identification Machine ................................................................................................................................................. 8 Engine ................................................................................................................................................... 9 Safety Labels General ................................................................................................................................................ 10 Safety Label Identification ................................................................................................................... 10 Operator Station Component Locations ......................................................................................................................... 12 Console Switches General ................................................................................................................................................ 13 Work Lights ......................................................................................................................................... 13 Control Locks ...................................................................................................................................... 13 Slew Lock ........................................................................................................................................... 13 Window Wipers ................................................................................................................................... 13 Two Speed Range .............................................................................................................................. 14 Power Mode ........................................................................................................................................ 14 Interior Switches Ignition Switch ..................................................................................................................................... 15 Cab Interior Light ................................................................................................................................ 15 Operation Introduction General ................................................................................................................................................ 17 Operating Safety General ................................................................................................................................................ 18 i

9821/9600-1A

Table of Contents

Worksite Safety ................................................................................................................................... Risk Assessment ................................................................................................................................ Walk-Around Inspection General ................................................................................................................................................ Entering and Leaving the Operator Station General ................................................................................................................................................ Emergency Exit ................................................................................................................................... Doors Operator Door ..................................................................................................................................... Windows Front Window ...................................................................................................................................... Side Window ....................................................................................................................................... Sun Visor/Sunblind Sunblind .............................................................................................................................................. Before Starting the Engine General ................................................................................................................................................ Operator Seat General ................................................................................................................................................ Suspension Seat ................................................................................................................................. Seat Ventilation Controls .................................................................................................................... Seat Belt General ................................................................................................................................................ Inertia Reel Seat Belt ......................................................................................................................... Static Seat Belt ................................................................................................................................... Mirrors General ................................................................................................................................................ Starting the Engine General ................................................................................................................................................ Warming Up ........................................................................................................................................ Stopping and Parking General ................................................................................................................................................ Preparing for Travel General ................................................................................................................................................ Preparing for Worksite Travel ............................................................................................................. Locks General ................................................................................................................................................ Control Lock ........................................................................................................................................ Drive Controls Track Controls ..................................................................................................................................... Travel Speed Selector ........................................................................................................................ Instruments Instrument Panel ................................................................................................................................. Getting the Machine Moving General ................................................................................................................................................ Driving the Machine General ................................................................................................................................................ Towing Other Equipment .................................................................................................................... Operating Levers/Pedals General ................................................................................................................................................ Control Layouts ................................................................................................................................... Excavator Arm Controls ...................................................................................................................... ii

9821/9600-1A

20 20 22 23 24 25 26 27 28 29 30 30 31 32 32 33 36 40 40 42 43 43 44 44 46 47 48 50 53 53 55 55 55 ii

Table of Contents

iii

Dozer Blade Controls ......................................................................................................................... Auxiliary Circuit Controls ..................................................................................................................... Lifting and Loading General ................................................................................................................................................ Working with the Excavator Arm General ................................................................................................................................................ Preparing to Use the Excavator Arm ................................................................................................. Lifting With the Excavator Arm ........................................................................................................... Digging ................................................................................................................................................ Changing the Bucket Linkage ............................................................................................................ Working with the Dozer Blade General ................................................................................................................................................ Dozing and Grading ............................................................................................................................ Scraping and Cutting .......................................................................................................................... Backfilling ............................................................................................................................................ Slopes General ................................................................................................................................................ Driving on Slopes ............................................................................................................................... Working on Slopes ............................................................................................................................. Heating, Ventilating and Air-Conditioning (HVAC) General ................................................................................................................................................ Air-Conditioning Controls .................................................................................................................... Face Level Fan ................................................................................................................................... Power Sockets Auxiliary Power Socket ....................................................................................................................... Battery Isolator General ................................................................................................................................................ Fire Extinguisher General ................................................................................................................................................ Moving a Disabled Product General ................................................................................................................................................ Getting the Machine Unstuck ............................................................................................................. Jump-Starting the Engine ................................................................................................................... Retrieval .............................................................................................................................................. Excavator Arm (Emergency Operation) .............................................................................................. Lifting the Product General ................................................................................................................................................ Transporting the Product General ................................................................................................................................................ Loading the Product onto the Transporting Vehicle/Trailer ................................................................. Unloading the Product from the Transporting Vehicle/Trailer ............................................................. Operating Environment General ................................................................................................................................................ Operating in Low Temperatures ......................................................................................................... Operating in High Temperatures ......................................................................................................... Cab Filters ........................................................................................................................................... Refuelling General ................................................................................................................................................ Low Fuel Levels .................................................................................................................................. Filling the Tank ....................................................................................................................................

58 58

93 93 93

9821/9600-1A

iii

60 61 61 61 62 66 68 68 68 68 70 70 72 74 74 75 76 77 78 80 80 81 82 82 84 86 86 89 91 91 91 92

Table of Contents

Attachments Working with Attachments Introduction .......................................................................................................................................... 95 Attachments for your Product ............................................................................................................. 95 Connecting/Disconnecting Hydraulic Hoses ....................................................................................... 96 Impact Protection ................................................................................................................................ 99 Direct-Mounted Attachments General .............................................................................................................................................. 100 Buckets General .............................................................................................................................................. 103 Bucket Teeth ..................................................................................................................................... 103 Preservation and Storage Cleaning General .............................................................................................................................................. Preparation ........................................................................................................................................ Checking For Damage General .............................................................................................................................................. Storage General .............................................................................................................................................. Put into Storage ................................................................................................................................ During Storage .................................................................................................................................. Take out of Storage .......................................................................................................................... Security General .............................................................................................................................................. LiveLink ............................................................................................................................................. Maintenance Introduction General .............................................................................................................................................. Owner/Operator Support ................................................................................................................... Service/Maintenance Agreements .................................................................................................... Obtaining Spare Parts ...................................................................................................................... Maintenance Safety General .............................................................................................................................................. Fluids and Lubricants ....................................................................................................................... Maintenance Schedules General .............................................................................................................................................. How to Use the Maintenance Schedules ......................................................................................... Maintenance Intervals ....................................................................................................................... Pre-start Cold Checks, Service Points and Fluid Levels .................................................................. Functional Tests and Final Inspection .............................................................................................. Maintenance Positions General .............................................................................................................................................. Maintenance Position (Excavator Arm Lowered) ............................................................................. Service Points General .............................................................................................................................................. Access Apertures General .............................................................................................................................................. Battery Cover .................................................................................................................................... Engine Compartment Cover ............................................................................................................. Hydraulic Compartment Cover ......................................................................................................... iv

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111 111 111 112 113 114 118 118 118 120 123 125 125 126 132 132 132 133 iv

Table of Contents

Tools General .............................................................................................................................................. Toolbox .............................................................................................................................................. Lubrication General .............................................................................................................................................. Preparation ........................................................................................................................................ Attachments General ............................................................................................................................................. Body and Framework General ............................................................................................................................................. Slew Ring Bearings .......................................................................................................................... Pivot Pins .......................................................................................................................................... Operator Station General ............................................................................................................................................. Seat ................................................................................................................................................... Seat Belt ........................................................................................................................................... Controls ............................................................................................................................................. Engine General ............................................................................................................................................. Oil ...................................................................................................................................................... Drive Belt .......................................................................................................................................... Air Filter General ............................................................................................................................................. Pre-Cleaner ....................................................................................................................................... Dust Valve ........................................................................................................................................ Fuel System General ............................................................................................................................................. Tank .................................................................................................................................................. Fuel Filter .......................................................................................................................................... Water Separator ............................................................................................................................... Cooling System General ............................................................................................................................................. Coolant .............................................................................................................................................. Cooling Pack .................................................................................................................................... Tracks General ............................................................................................................................................. Steel .................................................................................................................................................. Idler Wheels ...................................................................................................................................... Rollers ............................................................................................................................................... Track Gearbox Oil ...................................................................................................................................................... Hydraulic System General ............................................................................................................................................. Services ............................................................................................................................................ Oil ...................................................................................................................................................... Cylinder Rams .................................................................................................................................. Electrical System General ............................................................................................................................................. Battery ............................................................................................................................................... Battery Isolator ................................................................................................................................. Fuses ................................................................................................................................................ v

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Table of Contents

Relays ............................................................................................................................................... 160 Window Washer ................................................................................................................................ 161 Technical Data Static Dimensions Dimensions ........................................................................................................................................ Weights ............................................................................................................................................. Performance Dimensions Excavator Arm Dimensions and Performance .................................................................................. Driving Performance ......................................................................................................................... Fluids, Lubricants and Capacities General .............................................................................................................................................. Coolant .............................................................................................................................................. Torque Values General .............................................................................................................................................. Electrical System General .............................................................................................................................................. Fuses ................................................................................................................................................. Relays ............................................................................................................................................... Tracks General ..............................................................................................................................................

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Table of Contents

Acronyms Glossary DECU

Display Electronic Control Unit

DEF

Diesel Exhaust Fluid

ECU

Electronic Control Unit

FOPS

Falling-Object Protective Structure

HVAC

Heating Ventilation Air Conditioning

Product Identification Number

PPE

Personal Protective Equipment

ROPS

Roll-Over Protective Structure

SWL

Safe Working Load

vii

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Notes:

viii

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viii

Introduction About this Manual

Introduction

About this Manual Model and Serial Number This manual provides information for the following model(s) in the JCB machine range: Model From: To: JS81 02426501 02427000

Using the Manual

This operator's manual is arranged to give you a good understanding of the product and its safe operation. It also contains maintenance and technical data. Read this manual from the front to the back before you use the product for the first time. Particular attention must be given to all the safety aspects of operating and maintaining the product. If there is anything you are not sure about, ask your JCB dealer or employer. Do not guess, you or others could be killed or seriously injured. The general and specific warnings in this section are repeated throughout the manual. 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 are different, the text and or the illustration will specify. The manufacturer's policy is one of continuous improvement. The right to change the specification of the product without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the product and the descriptions contained in this manual. All of the optional equipment included in this manual may not be available in all territories

Left-Hand Side, Right-Hand Side In this manual, 'left' and 'right' mean your left and right when you are seated correctly in the machine. Figure 1.

A A B

Left Right

Cross References In this manual, cross references are made by presenting the subject title in blue (electronic copy only). The number of the page upon which the subject begins is indicated within the brackets. For example: Refer to: Introduction > About this Manual > Cross References (Page 1).

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Introduction Safety

Safety Safety - Yours and Others All machinery can be hazardous. When a product is correctly operated and maintained, it is a safe product to work with. When it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. In this manual and on the product you will find warning messages, read and understand them. They inform you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them. Safety is not just a matter of responding to the warnings. All the time you are working on or with the product you must be thinking of what hazards there might be and how to avoid them. Do not work with the product until you are sure that you can control it. Do not start any work until you are sure that you and those around you will be safe. If you are not sure of anything, about the product or the work, ask someone who knows. Do not assume anything. Remember: â&#x20AC;˘ â&#x20AC;˘ â&#x20AC;˘

Be careful Be alert Be safe.

Safety Warnings In this manual and on the product, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury. The signal word 'WARNING' indicates a hazardous situation which, if not avoided, could result in death or serious injury. The signal word 'CAUTION' indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The signal word 'Notice' indicates a hazardous situation which, if not avoided, could result in product damage. The safety alert system (shown) also helps to identify important safety messages in this manual and on the product. When you see this symbol, be alert, your safety is involved, carefully read the message that follows, and inform other operators. Figure 2. The safety alert system

General Safety Training To operate the machine safely you must know the machine and have the skill to use it. You must abide by all relevant laws, health and safety regulations that apply to the country you are operating in. The operator's manual instructs you on the machine, its controls and its safe operation; it is not a training manual. 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.

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Introduction Safety

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. Clothing You can be injured if you do not wear the correct clothing. Loose clothing can get caught in the machinery. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and personal jewellery. 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. Feeling Unwell Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself and those you work with. Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious injury. Switch off and do not use your mobile phone when refuelling the machine. Lifting Equipment You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations. Raised Equipment Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped). Make sure that no-one goes near the machine while you install or remove the mechanical device. Raised Machine Never position yourself or any part of your body under a raised machine which is not correctly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed. Lightning Lightning can kill you. Do not use the machine if there is lightning in your area. Machine Modifications This machine is manufactured in compliance with legislative and other requirements. It must not be altered in any way which could affect or invalidate any of these requirements. For advice consult your JCB dealer.

Clothing and Personal Protective Equipment (PPE) 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.

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Notes:

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About the Product Introduction

General Before you start using the product, you must know how the product operates. Use this part of the 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 dealer.

Name and Address of the Manufacturer JCB India Limited, Heavyline - India Business Unit, Talegaon, Pune - 410507, India.

Product Compliance Your JCB product was designed to comply with the laws and regulations applicable at the time of its manufacture for the market in which it was first sold. In many markets, laws and regulations exist that require the owner to maintain the product at a level of compliance relevant to the product when first produced. Even in the absence of defined requirements for the product owner, JCB recommend that the product compliance be maintained to ensure safety of the operator and exposed persons and to ensure the correct environmental performance. Your product must not be altered in any way which could affect or invalidate any of these requirements. For advice consult your JCB dealer. For its compliance as a new product, your JCB and some of its components may bear approval numbers and marking's, and may have been supplied with a Declaration/Certificate of Conformity. These marking's and documents are relevant only for the country/region in which the product was first sold to the extent that the laws and regulations required them. Re-sales and import/export of products across territories with different laws and regulations can cause new requirements to become relevant for which the product was not originally designed or specified. In some cases, pre owned products irrespective of their age are considered new for the purposes of compliance and may be required to meet the latest requirements which could present an insurmountable barrier to their sale/use. Despite the presence of any compliance related marking's on the product and components, you should not assume that compliance in a new market will be possible. In many cases it is the person responsible for import of a pre owned product into a market that becomes responsible for compliance and who is also considered the manufacturer. JCB may be unable to support any product compliance related enquiry for a product which has been moved out of the legislative country/region where it was first sold, and in particular where a product specification change or additional certification would have been required in order for the product to be in compliance.

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About the Product Description

Description General The JCB Tracked Excavator is a self propelled machine with a tracked undercarriage and a revolving upper structure which has a boom, dipper, bucket and swing mechanism. The excavator is mainly used to dig below ground level with bucket motions towards the machine. The upper structure can slew 360Â° and discharge material when the tracked undercarriage is stationary.

Intended Use The machine is intended to be used in normal conditions for the applications described in this manual. If the machine is used for other applications or in dangerous environments, for example in a flammable atmosphere or in areas with dust containing asbestos, special safety regulations must be obeyed and the machine must be equipped for use in these environments. The machine is primarily designed for excavating with a bucket, without movement of the undercarriage during the work cycle. A normal excavator work cycle consists of, digging, elevating, swinging and the discharging of material. An excavator can also be used for object or material handling/transportation if it meets the lifting regulations. Refer to: Operation > Lifting and Loading (Page 60).

Log Moving/Object Handling Do not use the machine to move or handle logs unless sufficient log protection is installed. You could cause serious injury to yourself and damage to the machine. For more information, contact your JCB dealer.

Optional Equipment and Attachments A wide range of optional attachments are available to increase the versatility of your machine. Only the JCB approved attachments are recommended for use with your machine. Contact your JCB dealer for the full list of approved attachments available.

Danger Zone The danger zone is any zone within and/or around the machinery in which a person is subject to a risk to their health or safety. During operation of the product, keep all persons out of the danger zone. Persons in the danger zone could be injured. Refer to: Technical Data (Page 162). Before you do a maintenance task, make the product safe. Refer to: Maintenance > Maintenance Positions (Page 125).

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About the Product Description

Main Component Locations Figure 3. H J

G F

D A B C D E F G H J K L

Bucket Bucket link Bucket ram Dipper Dipper link Dipper ram Boom Boom ram Operators cab Counterweight Undercarriage

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About the Product Product and Component Identification

Product and Component Identification Machine Your machine has an identification plate. The PIN (Product Identification Number), weight, engine power, year of manufacture and serial number of the machine are shown on the identification plate. The machine serial number is also inscribed at the baseplate of the rear frame. Figure 4.

B A

A B

Identification plate (location) Serial number (inscribed)

The machine model and build specification are indicated by the PIN. The PIN has 17 digits and must be read from left to right. Table 1. Typical PIN JCB

JS102

01536000

Table 2. Explanation of the PIN Digit 1 to 3 4 to 8 9 10 to 17

Description World manufacturer identification. (JCB) Machine type and model. For example, JS102 = JS330 Tracked. Random check letter. The check letter is used to verify the authenticity of a machine's PIN. Machine serial number.

9821/9600-1A

About the Product Product and Component Identification

Figure 5.

Identification plate

Engine The engine data label is attached to the cylinder block. Refer to Figure 6. Figure 6.

ENGINE TYPE RATING kW/hp RATING STD.

RPM Enriching Lives

GOVERNING CLASS ENGINE NO.

E TYPE ENGIN p RATING kW/h

rpm

RATINGSTD. G CLASS GOVERNIN E No. ENGIN

S LTD R OIL ENGINE KIRLOSKA INDIA

KIRLOSKAR OIL ENGINES INDIA LTD

9821/9600-1A

About the Product Safety Labels

Safety Labels General Warning! Safety labels on the machine warn you of particular hazards. You can be injured if you do not obey the safety instructions shown. The safety labels are strategically placed around the product to remind you of possible hazards. If you need eye-glasses for reading, make sure you wear them when reading the safety labels. Do not overstretch or put yourself in dangerous positions to read the safety labels. If you do not understand the hazard shown on the safety label, then refer to Safety Label Identification. Refer to: About the Product > Safety Labels > Safety Label Identification (Page 10). Keep all of the safety labels clean and readable. Replace a lost or damaged safety label. Make sure the replacement parts include the safety labels where necessary. Each safety label has a part number printed on it, use this number to order a new safety label from your JCB dealer.

Safety Label Identification Figure 7. B

9821/9600-1A

About the Product Safety Labels

Figure 8. J

K L

M Table 3. Safety Labels Item A

Part No. 817/18535

B C D E F G H J

817/18536 817/18537 817/18538 817/18566 817/18533 333/P5908 817/19470 JHP0134

K L

817/18527 817/18529

817/18532

Description Warning. Coolant under pressure. Warning, risk of severing of hands/ fingers in rotating parts. Warning, hot surfaces. Remove ignition key and refer to operator's handbook and maintenance manual. Burns to fingers and hands. Stay a safe distance away. Warning. High pressure and hot coolant/steam; Keep hands away. Warning. Risk of severing finger/hand in rotating parts; Keep hands away. Do not walk or place any body weight in this area. Warning. Risk of trapping fingers/hand in door; Keep hands away. Read the operatior's manual. The arm or bucket may move, keep clear. Warning. High pressure hydraulic system. 1, Stop the engine. 2, Unscrew the box nut. 3, Depress the pressure relief valve until all the tank pressure is released. 4, Remove filler plug/breather assembly as required. Diesel fuel warning, Flammable substance; No ignition source. Warning. Damage may occur when starting in cold temperatures, refer to the operator's manual. Warning. Risk of electrocution, maintain the minimum clearance recommended by your local electricity supplier. Risk of injury by crushing, do not lean out of the window. Warning. Risk of tripping, raise the control lock lever before exiting. Pressure hazard. Stop the engine, remove the ignition key and release the hydraulic pressure before you start maintenance work. Refer to Maintenance Section in the operator's manual. 9821/9600-1A

Qty. 1 1 1 1 1 1 1 1 1 1 1

About the Product Operator Station

Operator Station Component Locations Figure 9. B R C

F G

H STOP

L S

A B C D E F G H J K L M N P Q R S

Left hand track control, Refer to: Operation > Drive Controls > Track Controls (Page 46). Instruments, display monitor, Refer to: Operation > Instruments (Page 48). Right hand track control, Refer to: Operation > Drive Controls > Track Controls (Page 46). Optional circuit pedal, Refer to: Operation > Operating Levers/Pedals > Auxiliary Circuit Controls (Page 58). Right joystick, Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 55). Seat/console slide lever, Refer to: Operation > Operator Seat (Page 30). Throttle control lever Right switch console, Refer to: About the Product > Console Switches (Page 13). HVAC (Heating Ventilation Air Conditioning) controls,Refer to: Operation > Heating, Ventilating and Air-Conditioning (HVAC) (Page 74). Door lock release lever, Refer to: Operation > Doors (Page 25). Interior light switch, Refer to: About the Product > Interior Switches (Page 15). Left console, Refer to: About the Product > Console Switches (Page 13). Controls isolation lever, Refer to: Operation > Locks > Control Lock (Page 44). Left joystick, Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 55). Footrest Dozer control leverRefer to: Operation > Operating Levers/Pedals > Dozer Blade Controls (Page 58). Engine stop cable

9821/9600-1A

About the Product Console Switches

Console Switches General The installed switches and their positions can change according to the specification of the machine. Each switch has a graphic symbol to show the function of the switch. Before you operate a switch, make sure that you understand its function. The rocker switches have two or three positions (as shown). If the switch has a backlight, then the graphic symbol illuminates when the ignition switch or side lights are in the on position. The light bar illuminates to show that the switch function is active. Figure 10. 1

A B

Graphic symbol Light bar

Work Lights

Control Locks

Slew Lock

Three position rocker switch. The switch functions operate when the ignition switch is in the on and off positions. Position : 1 = Off Position : 2 = Boom and toolbox work lights on Position : 3 = Boom, toolbox and counterweight work lights on. Controls isolation switch. Two position momentary rocker switch. The switch functions when the engine is running, and the controls isolation lever is lowered. Press momentarily to isolate the controls, the switch light illuminates. Press momentarily again to enable the controls, the switch light extinguishes. Position : 1 = Rest position. Switch light illuminates when the controls are isolated Position : 2 = Momentary position. Two position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Slew available. Position : 2 = Slew locked.

Window Wipers Three position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Off Position : 2 = Upper wiper intermittent on Position : 3 = Upper wiper continuous on. 13

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About the Product Console Switches

Two Speed Range Two position rocker switch. The switch functions operate when the ignition switch is in the on position. Position 1: Low travel speed. Position 2: High travel speed.

Power Mode Two position rocker switch. The switch functions when the engine is running. Position 1: Economy mode active Position 2: Power mode active

9821/9600-1A

About the Product Interior Switches

Interior Switches Ignition Switch The ignition key operates the four-position ignition switch. The ignition key can only be inserted or removed in position 0. If the engine fails to start, the ignition key must be returned to position 0 before the starter motor is re-engaged. Do not operate the starter motor for more than 20s without the engine firing. If the engine fires but does not fully start, let the starter motor cool for at least 2min between starts. Figure 12. A

B A B

Ignition switch Ignition key Table 5. Switch Positions

Position 0 I II III

Function This position is not used. The ignition key can only be removed at this position. On: Turn the ignition key to this position to connect the battery to all of the electrical circuits. The ignition key will return to this position when it is released from position II or position III. This position is not used. Start: Turn the ignition key to this position to operate the starter motor and turn the engine. The ignition switch has an inhibitor to stop the ignition switch being turned on when the engine is running. There may be a delay of up to 1s between switch operation and engine cranking.

Cab Interior Light Press either end of the light unit to turn on the cab interior light. Press the other end of the light unit to turn off the cab interior light. Make sure the cab interior light is turned off when you intend to leave the machine for a long period of time. Figure 14.

Cab interior light

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Notes:

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Operation Introduction

Operation

Introduction General 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. 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. 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: â&#x20AC;˘ â&#x20AC;˘ â&#x20AC;˘

Be careful. Be alert. Be safe.

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Operation Operating Safety

Operating Safety General Fuel Fuel is flammable, keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions. Machine Condition A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this manual are completed before using the machine. Machine Limits Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications. Engine/Steering Failure If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected. Exhaust Gases 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, install an exhaust extension. If you begin to feel drowsy, stop the machine at once and get into fresh air. Worksites Worksites can be hazardous. Examine the site before working on it. You could be killed or injured if the ground gives way under your machine or if piled material collapses onto it. Check for potholes and hidden debris, logs, ironwork etc. Any of these could cause you to lose control of your machine. Check for utilities such as electric cables (overhead and underground), gas and water pipes etc. Mark the positions of the underground cables and pipes. Make sure that you have enough clearance beneath overhead cables and structures. Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Worksites can be noisy, do not rely on spoken commands. Parking An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Manual to park the machine correctly. Banks and Trenches Banked material and trenches can collapse. Do not work or drive too close to banks and trenches where there is danger of collapse. Safety Barriers Unguarded machines in public places can be dangerous. In public places, or where your visibility is reduced, place barriers around the work area to keep people away. Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust. Hazardous Atmospheres This machine is designed for use in normal out door atmospheric conditions. It must not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB dealer. Regulations Obey all laws, worksite and local regulations which affect you and your machine. 18

9821/9600-1A

Operation Operating Safety

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. There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier. 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 unless with approved man-basket or man-crate (if applicable). Machine Safety Stop work at once if a fault develops. Abnormal sounds and smells can be signs of trouble. Examine and repair before resuming work. Hot Components Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit. Travelling at High Speeds Travelling at high speeds can cause accidents. Do not reverse in a high gear with full throttle. Always travel at a safe speed to suit working conditions. Hillsides Operating the machine on hillsides can be dangerous if the correct precautions are not taken. Ground conditions can be changed by rain, snow, ice etc. Check the site carefully. When applicable, keep all attachments low to the ground. 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. Hands and Feet Keep your hands and feet inside the machine. When using the machine, keep your hands and feet clear of moving parts. Keep your hands and feet within the operator compartment while the vehicle is in motion. 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. Passengers Passengers in or on the machine can cause accidents. Do not carry passengers. Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the correct machine location until you need to use it. Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters must use self-contained breathing apparatus. Roll Over Protection If the machine starts to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll over, do not try and jump from the cab. Stay in the cab, with your seat belt fastened.

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Operation Operating Safety

Safe Working Loads Overloading the machine can damage it and make it unstable. Study the specifications in the Operator's Manual before using the machine.

Worksite Safety Warning! You or others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practise away from the worksite on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely. Warning! There could be dangerous materials such as asbestos, poisonous chemicals or other harmful substances buried on the site. If you uncover any containers or you see any signs of toxic waste, stop the machine and advise the site manager immediately. Warning! Before you start using the machine, check with your local gas company if there are any buried gas pipes on the site. If there are buried gas pipes we recommend that you ask the gas company for any specific advice regarding the way you must work on the site. Some modern gas pipes cannot be detected by metal detectors, so it is essential that an accurate map of buried gas pipes is obtained before any excavation work commences. Hand dig trial holes to obtain precise pipe locations. Any cast iron pipes found must be assumed to be gas pipes until contrary evidence is obtained. Older gas pipes can be damaged by heavy vehicles driving over the ground above them. Leaking gas is highly explosive. If a gas leak is suspected, contact the local gas company immediately and warn all personnel on the site. Ban smoking, make sure that all naked lights are extinguished and switch off any engines which may be running. You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near buried gas pipes. Caution! Before you start using the machine, check with your local public water supplier if there are buried pipes and drains on the site. If there are, obtain a map of their locations and follow the advice given by the water supplier. You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near buried pipes and drains. Caution! If you cut through a fibre optic cable, Do not look into the end of it, your eyes could be permanently damaged. An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a collection of rules and procedures that coordinates the machines and people that work together in the same area. Examples of worksite organisation include: â&#x20AC;˘ â&#x20AC;˘ â&#x20AC;˘

Restricted areas Controlled patterns of machine movement A system of communication.

You and/or your company could be legally liable for any damage you may cause to public utilities. It is your responsibility to make sure that you know the locations of any public utility cables or pipes on the worksite which could be damaged by your machine.

Risk Assessment It is the responsibility of the competent people that plan the work and operate the machine to make a judgement about the safe use of the machine, they must take into account the specific application and conditions of use at the time. It is essential that a risk assessment of the work to be done is completed and that the operator obeys any safety precautions that the assessment identifies. 20

9821/9600-1A

Operation Operating Safety

If you are unsure of the suitability of the machine for a specific task, contact your JCB dealer who will be pleased to advise you. The following considerations are intended as suggestions of some of the factors to be taken into account when a risk assessment is made. Other factors may need to be considered. A good risk assessment depends on the training and experience of the operator. Do not put your life or the lives of others at risk.

Personnel • • •

Are all persons who will take part in the operation sufficiently trained, experienced and competent? Are they fit and sufficiently rested? A sick or tired operator is a dangerous operator. Is supervision needed? Is the supervisor sufficiently trained and experienced? As well as the machine operator, are any assistants or lookouts needed?

The Machine • • • •

Is it in good working order? Have any reported defects been corrected? Have the daily checks been carried out? Are the tyres still at the correct pressure and in good condition and is there sufficient fuel to complete the job (if applicable)?

The Load • • • •

How heavy is it? Is it within the capabilities of the machine? How bulky is it? The greater the surface area, the more affected it will be by wind speeds. Is it an awkward shape? How is the weight distributed? Uneven loads are more difficult to handle. Is there a possibility of the load shifting while being moved?

Loading/Unloading Area • • • • • • •

Is it level? Any slope of more than 2.5% (1 in 40) must be carefully considered. Is more than one direction of approach to the load possible? Approaching across the slope must be avoided, if possible. Is the ground solid? Will it support the weight of the machine when loaded? How rough is the ground? Are there any sharp projections which could cause damage, particularly to the tyres? Are there any obstacles or hazards in the area, for example, debris, excavations, manhole covers, power lines? Is the space sufficient for safe manoeuvring? Are any other machines or persons likely to be in or to enter the area while operations are in progress?

The Route to be Travelled • •

How solid is the ground, will it provide sufficient traction and braking? How steep are any slopes, up/down/across? A cross slope is 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 solid and smooth when dry will become uneven and slippery when wet, and it will not give the same conditions for traction, steering or braking.

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Operation Walk-Around Inspection

Walk-Around Inspection General Warning! Walking or working under a raised boom and dipper is hazardous. You could be crushed by the boom and dipper or get caught in the linkages. Lower the boom and dipper before doing these checks. If you are new to this machine, get an experienced operator to lower the boom and dipper for you. If there is nobody to help you, study the Operator's Manual until you have learned how to lower the boom and dipper. The following checks must 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. All these checks concern the serviceability of the machine. Some concern your safety. Get your service engineer to check and correct any defects. 1. Check for cleanliness. 1.1. Clean the windows, light lenses and the rear view mirrors (where applicable). 1.2. Remove dirt and debris, especially from around the linkages, rams, pivot points and radiator. 1.3. Make sure the cab step and handrails are clean and dry. 1.4. Clean all of the safety and instructional labels. Replace any label that is missing or cannot be read. 2. Check for damage. 2.1. Examine the machine generally for damaged and missing parts. 2.2. Make sure that the attachment is correctly attached and in good condition. 2.3. Make sure that all of the pivot pins are correctly installed. 2.4. Examine the windows for cracks and damage. Glass splinters can blind. 2.5. Check for oil, fuel and coolant leakages below the machine. Warning! You could be killed or injured with damaged tracks. Do not use the machine with damaged or excessively worn tracks. 3. Check the tracks. Refer to: Maintenance > Tracks (Page 151). 4. Make sure that all of the filler caps are installed correctly. 5. Make sure that all of the access panels are closed correctly. Refer to: Maintenance > Access Apertures (Page 132). 6. If the filler caps and access panels are installed with locks, we recommend that you lock them to prevent theft or tampering.

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Operation Entering and Leaving the Operator Station

Entering and Leaving the Operator Station General General Warning! For safety reasons, machines installed with single access canopies from new must not have the barrier removed. The machine must always be entered/exited with the left hand isolator raised via the left hand side. Warning! Do not enter or exit the cab unless the arm rest is raised or controls isolation lever is fully engaged. Caution! Entering or leaving the operator station 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.

Standard Cab Machines Entering the Cab 1. Open the cab door and if necessary, latch it in the open position. Refer to: Operation > Doors > Operator Door (Page 25). 2. Make sure that the controls lock lever is in the raised position. Refer to: Operation > Locks > Control Lock (Page 44). 3. Hold the two handrails (one each side of the cab entrance), then climb onto the top of the track. Refer to Figure 15. Figure 15.

A B

Handrails Track

4. Keep hold of the left handrail, then climb into the cab and swing yourself into the operators seat. 5. Close the cab door. Leaving the Cab 1. Park the machine on solid, level ground with the upper structure parallel to the undercarriage. 2. Lower the attachment. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 55). 3. Stop the engine. 4. Turn the ignition key to the on position.

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Operation Entering and Leaving the Operator Station

5. Operate the hydraulic controls several times to release any residual hydraulic pressure in the system. Refer to: Operation > Moving a Disabled Product > Excavator Arm (Emergency Operation) (Page 82). 6. Turn the ignition key to the off position. 7. Raise the controls lock lever. 8. Open the cab door and latch it in the open position. 9. Hold the left handrail and turn your back towards the track. Refer to Figure 16. Figure 16.

A B

Handrails Track

10. Hold both of the handrails and use the track climb down backwards from the cab onto the ground. 11. Close the cab door.

Emergency Exit Standard Cab Figure 17.

A A

Glazing breaker

In an emergency, if the door cannot be used: 1. Turn the backrest of the seat fully forward/down. 2. Use the glazing breaker to hit the rear window near the corner to shatter the window. 24

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Operation Doors

Doors Operator Door To open the door from the outside, unlock it with the key provided and press the lock barrel to release the latch. Pull the handle towards you. To open the door from inside, push the lever away from you. Figure 18. A

Lever

Close the door from the inside by pulling it towards you, it will latch itself.

Latch the Door in the Open Position To latch the door in the open position open the door until it latches correctly on the side of the cab. To release the door from the stowed position push the lever in the cab downwards. Figure 19.

A 25

Lever 9821/9600-1A

Operation Windows

Windows Front Window Opening and Closing the Front Upper Window Caution! Take care when raising and lowering the window. Lower your head as you pull the window back. Isolate the hydraulic controls before opening and closing the window. To open the window: 1. Hold the handles, and depress the buttons with your thumbs. 2. Use the handles to lift the window into a position parallel with the roof. 3. Release the buttons to hold the window in position. Make sure the window locates on the latches in the cab roof. Figure 20.

A B C

Handles Buttons Latches

To close the window: 1. Hold the handles, and depress the buttons with your thumbs. 2. Use the handles to pull the window into a vertical position. 3. Release the buttons to hold the window in position. Make sure the window locates on the latches in the cab front.

Opening and Closing the Front Lower Window The front lower window can be opened in two positions: To open the front lower window: 1. For a small amount of ventilation pinch the locks between finger and thumb and move the window down until the locks locate in the lower latch positions. 2. For a larger amount of ventilation pinch the locks between finger and thumb and push the window up until the locks locate in the upper latch positions. 26

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Operation Windows

Figure 21.

A A

Locks

To close the front lower window: 1. Pinch the locks between finger and thumb and return the window to the closed position at the front of the cab.

Side Window The side window is held closed by a latch operated from inside the cab. To open the window, operate the latch and slide the window to the required position and secure it using the lock. To close the window, slide the window fully shut and check that the latch has located into position. Figure 22.

A B A B

Latch Lock

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Operation Sun Visor/Sunblind

Sun Visor/Sunblind Sunblind Optional Figure 23. B

A B C

Handle Upper hooks Lower hooks

The sunblind is installed in the cab roof and can be secured in two positions: 1. Use the handle in the centre of the sunblind lower edge to pull the sunblind forward. 2. Attach both sides of the sunblind edge on to the upper hooks or lower hooks. 3. To release the sunblind, hold the handle, release the bottom edge of the sunblind from the hooks and let the sunblind slowly rewind back into the stowed position.

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Operation Before Starting the Engine

Before Starting the Engine General Danger! Before lowering the attachments to the ground, make sure that the machine and the area around it are clear of other people. Anyone on or close to the machine could fall and be crushed by the attachments, or get caught in the linkages. 1. Read the Operating in Low Temperatures or Operating in High Temperatures procedures in the Operation section if you will be using the machine in very cold or very hot climates. Refer to: Operation > Operating Environment (Page 91). 2. If the fuel tank was empty or if any part of the fuel system has been drained or disconnected, the fuel system must be primed before you try to start the engine. Refer to: Maintenance > Fuel System > General > Bleed (Page 145). 3. Lower the excavator bucket to the ground, if they are not already there. They will lower themselves under their own weight when you operate the controls. Operate the controls carefully to control the rate of descent. Refer to: Operation > Operating Levers/Pedals (Page 55). 4. For your own safety (and others) and for the maximum service life of your machine, do a pre-start inspection before you start the engine. 4.1. If you have not done it, do a walk-around inspection of the outside of the machine. Refer to: Operation > Walk-Around Inspection (Page 22). 4.2. Remove any dirt and rubbish from the cab interior, specially around the pedals and control levers. 4.3. Remove any oil, grease and mud from the pedals and control levers. 4.4. Make sure that your hands and shoes are clean and dry. 4.5. Remove or stow all loose articles in the cab, for example tools. 4.6. Check around the cab for loose or missing bolts, screws etc. Replace or tighten where necessary. 4.7. Check the excavator lever gaiters are not damaged or loose, replace or attach as required with new fasteners. 4.8. Examine the seat belt and its mountings for damage and excessive wear. Refer to: Maintenance > Operator Station > Seat Belt > Check (Condition) (Page 140). 4.9. Make sure that the following operate correctly: lights, horn, all switches, front window washer and wipers (if installed). Refer to: Maintenance > Electrical System (Page 158). 5. Adjust the seat so that you can comfortably reach all the driving controls. You must be able to operate the control pedal with your back against the seat back. Make sure the seat locking lever has fully engaged. Refer to: Operation > Operator Seat (Page 30). 6. Adjust the rear view mirrors (where applicable) to give you a good view close behind the machine, when you are correctly seated. 7. Fasten the seat belt.

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Operation Operator Seat

Operator Seat General Caution! 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. The operator's seat can be adjusted for your comfort. A correctly adjusted seat will decrease the operator fatigue. Adjust the seat so that you can comfortably reach the machine controls. For driving the machine, adjust the seat so that you can push the pedals fully down when your back is against the seat back.

Suspension Seat Seat Adjustments Seat Fore/Aft Lift the seat fore/aft lever and slide the seat into the required position. Release the lever. Make sure the seat is locked in position. Weight Turn the suspension adjuster to increase or decrease the suspension of the seat to match the operator weight. Check the indicator. Backrest Lift the backrest lever and move the backrest to the required angle. Release the lever. Backrest Extension Height Move the backrest extension up or down to adjust its position. The backrest extension can be removed if necessary. Armrest Turn the hand-wheel to change the angle of the armrest when its lowered. Do not apply pressure to the armrest during this step.

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Operation Operator Seat

Figure 24.

B A

C F

D A B C D E F G

Hand-wheel (armrest adjustment) Document pouch Lever (backrest angle adjustment) Weight adjuster Backrest extension Weight indicator Lever - seat fore/aft

Seat Ventilation Controls A switch on the left console operates the ventilated seat. Refer to: About the Product > Console Switches (Page 13). . When the ventilated seat is on, the adjustment of the seat weight may not be possible.

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Operation Seat Belt

Seat Belt General Warning! Operating the machine without a seat belt can be dangerous. Before starting the engine, make sure your seat belt is fastened. Check the tightness and condition of the seat belt securing bolts regularly. Warning! 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. Warning! When a seat belt is installed on your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. Install a new seat belt every three years.

Inertia Reel Seat Belt Fasten the Seat Belt Warning! 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. 1. Sit correctly in the seat. 2. Pull the seat belt and the tongue from the inertia reel holder in one continuous movement. 3. Push the tongue into the latch. Make sure the seat belt is not twisted and that it is over your hips not your stomach. 3.1. If the seat belt 'locks' before the tongue is engaged, let the seat belt retract into the inertia reel holder then try again. The inertia mechanism can lock if you pull the seat belt too quickly or if the machine is parked on an slope. Figure 25.

A B

Tongue Latch

Warning! If the seat belt does not 'lock' when you check if the seat belt is operating correctly, do not drive the machine. Get the seat belt repaired or replaced immediately. 4. To make sure the seat belt operates correctly, hold the middle of the seat belt as shown at and pull. The seat belt should 'lock'.

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Operation Seat Belt

Figure 26.

C D

Seat belt Button

Release the Seat Belt Warning! Release the seat belt only after switching off the engine and engaging the park brake (if applicable). 1. Push the button and pull the tongue from the latch. 2. Carefully let the seat belt retract into the inertia reel holder.

Static Seat Belt Fasten the Seat Belt Warning! 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. 1. Sit correctly in the seat. 2. Push the tongue into the latch. Make sure the seat belt is not twisted and that it is over your hips not your stomach.

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Operation Seat Belt

Figure 27. B

A A B

Tongue Latch

Adjust 1. Move the toggle the required distance down the strap. 2. To make the strap longer, pull the end as far as it will go. 3. To make the strap shorter, pull the end as far as it will go. Figure 28. D A

A B C D

Tongue Toggle Strap (pull here to lengthen) Strap (pull here to shorten)

Release the Seat Belt Warning! Release the seat belt only after switching off the engine and engaging the park brake (if applicable). 1. Push the button and pull the tongue from the latch.

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Operation Seat Belt

Figure 29. B C

A B C

Tongue Latch Button

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Operation Mirrors

Mirrors General Installation Introduction When they operate the machine, the operator must continually survey their field of vision. It is important that the mirrors are securely installed and give maximum vision around the machine. When a mirror is provided to supplement the operators direct field of vision, it must be adjusted to serve as an aid to the operator in seeing people or obstacles around the machine. The mirror provides indirect vision to hidden areas and improves the effectiveness of the machines usage. A

A B

Figure 30.

Mirror position (option) Mirror position (option)

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Operation Mirrors

Cab Mirrors (Option) Secure the mirror to the handrail: 1. Secure the mirror support to the handrail with the cap-screws and nuts. 2. Remove the protective cap from the back of the mirror and tighten the nut to secure the mirror to the support. 3. Replace the protective cap after the adjustment. Do not fully tighten the fittings until the mirrors are adjusted correctly. Figure 31.

D,E F

D E F

Cap-screw Nut Protective cap

Adjusting the Mirrors 1. Adjust the seat to suit the operator. 2. Adjust the mirror(s) to suit your specific working requirements before you drive or operate the machine. 3. Check the field of vision.

Checking the Field of Vision Cab Mirrors 1. Adjust the seat to suit the operator. 2. Adjust the mirrors. The field of vision shall be such that the operator can see, using the mirrors, at least a flat portion bounded on the left and right of the machine, starting at the rear end of the machine at a height of 1m above ground level and a width of 0.75m, continuing to a width of 3.5m at ground level, 30m behind the rear end of the machine.

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Operation Mirrors

Figure 32. Side Mirror Y A

V B

X C

A B C D T V X Y Z

T Field of vision Filament position centre point Outer borderline Inner borderline Measurement at ground level Measurement at 1m above ground level 3.5m 30m 750mm

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Operation Mirrors

Rear Mirror (Option) 1. Adjust the seat to suit the operator. 2. Adjust the mirror. The field of vision shall be such that the operator can see, using the mirror the area of ground directly behind the machine.

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Operation Starting the Engine

Starting the Engine General Warning! Thoroughly warm the hydraulic oil before operating the excavator services. Before selecting boom up, check there are no overhead obstructions or electric power cables. The engine noise and or tone may be louder than usual when cold. The engine will become quieter when the engine reaches normal operating temperature. 1. Make sure that the machine is ready to start. Refer to: Operation > Before Starting the Engine (Page 29). Figure 34. 0

1 2

0 1 2 3

Ignition off/engine stop position Ignition on position Not used Start position

2. Correct any critical faults before starting the engine. 3. Sound the horn as a warning. 4. Turn the ignition key to the start position and hold it there until the engine starts. Do not operate the starter motor for more than: Duration: 15s 5. If the engine does not start, turn the ignition key to the off position. 6. Let the starter motor cool for a few minutes before you repeat the steps 4 and 5. 7. When the engine has started, check instrument panel for critical faults. If any critical faults are displayed, stop the engine as soon as it is safe to do so. 8. Warm the engine and hydraulics. Refer to: Operation > Starting the Engine > Warming Up (Page 40).

Warming Up Before starting work in temperatures below 20Â°C, the hydraulic fluid must be warmed. 1. Warm up the engine. 1.1. Start the engine. 1.2. Set the throttle lever to the medium position and run the engine. Duration: 5â&#x20AC;&#x201C;10min 1.3. Do not operate any services. 40

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Operation Starting the Engine

2. After the warm up period make sure that everyone is clear of the machine. 3. Warm up the hydraulic oil. 3.1. Warm up the hydraulic oil by repeatedly selecting bucket crowd by moving the right hand lever to the left for: Duration: 5s 3.2. Repeat for several minutes. 4. Warm up the hydraulic circuit. 4.1. Decrease the machine power to medium. 4.2. Raise and lower the boom from ground level to full height, five times. 4.3. Move the dipper fully in both directions, five times. 4.4. Rotate the bucket fully in both directions, five times. 4.5. Slew the upper structure clockwise for one revolution and stop. 4.6. Slew the upper structure counterclockwise for one revolution and stop. 4.7. Repeat step 4.3 three times. 5. If the operation still appears slow, then repeat the steps 4.2 and 4.3.

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Operation Stopping and Parking

Stopping and Parking General Stopping and Parking Danger! Before lowering the attachments to the ground, make sure that the machine and the area around it are clear of other people. Anyone on or close to the machine could fall and be crushed by the attachments, or get caught in the linkages. 1. Stop the machine. Refer to: Operation > Drive Controls > Track Controls (Page 46). 2. Lower the attachment. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 55). 3. If applicable, lower the dozer blade. Refer to: Operation > Operating Levers/Pedals > Dozer Blade Controls (Page 58). 4. Stop the engine. 4.1. Pull the engine stop cable. Refer to: About the Product > Operator Station > Component Locations (Page 12). 4.2. Turn the ignition key to the 0 position. 5. If you are going to leave the machine, remove the ignition key and make sure that all unnecessary switches are set to off. 6. Leave and secure the machine: 6.1. Lift the controls isolation lever. Refer to: Operation > Locks > Control Lock (Page 44). 6.2. If you are leaving the machine for a long period, close and latch the window(s) and lock the door. 6.3. Use the handrails and steps to leave the cab. Refer to: Operation > Entering and Leaving the Operator Station > General (Page 23). 6.4. Make sure that the fuel filler cap is locked (if a lock is installed). Caution! Entering or leaving the operator station 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.

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Operation Preparing for Travel

Preparing for Travel General When you travel on the road or on site there are usually local rules and safety regulations for the machine travel position. This publication contains recommendations that may help you meet the requirements of these regulations, they are not necessarily the applied law. Make sure that before you travel on site, you and your machine comply with all the relevant local laws - it is your responsibility.

Preparing for Worksite Travel 1. Start the beacon, if installed. Refer to: Operation > Preparing for Travel > Beacon (Page

2. Move the cab so that it faces forward over the dozer blade. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 55). 3. If applicable, lift the dozer blade. Refer to: Operation > Operating Levers/Pedals > Dozer Blade Controls (Page 58). 4. Uneven worksite conditions: Lower the boom so that the bucket or attachment is clear of the ground. Figure 35.

B A B

Beacon 150mm

5. Level worksite conditions: 5.1. Fold the attachment as shown, so that the attachment is a sufficient distance from the ground. Distance: 500mm Figure 36.

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Operation Locks

Locks General Warning! The boom/slew lock must be engaged when travelling on road or trailer, otherwise the boom could swing to one side and cause injury or death. The requirement for controls isolation varies according to local legislation. You must comply with local legislation at all times. The controls lock is designed to isolate the control(s) in the neutral position. You must isolate the controls before you travel on public roads.

Control Lock Isolate the Hydraulic Controls There are two methods of isolating the machines hydraulic controls: 1. Raise the controls isolation lever. Refer to: Operation > Locks > Control Lock (Page 44). 2. Push the controls isolation switch. Refer to: About the Product > Console Switches > Control Locks (Page 13). If either of the two methods of isolating the hydraulic controls is used, the other method cannot be used to reactivate the controls. Warning! Use the controls isolation switch when you are not operating the machine, to avoid accidentally operating the controls and causing a dangerous movement of the machine. Before adjusting the cab environment, e.g. opening the windows or adjusting the seat, you must always isolate the controls using the servo isolator switch.

Enable the Controls To enable the machines hydraulic controls: 1. If the controls isolation lever is raised to isolate the controls, lower it to enable the controls. 2. Push the controls isolation switch after lowering the controls isolation lever to enable the controls. If the controls isolation switch was pushed to isolate the controls, push it a second time to enable the controls.

Controls Isolation Lever Raise the controls isolation lever to isolate the hydraulic controls. The isolation of the controls is an integral part of the safety procedure for leaving the cab. Lower the controls isolation lever to enable the hydraulic controls.

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Operation Locks

Figure 37. A

Controls isolation lever

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Operation Drive Controls

Drive Controls Track Controls Warning! When the cab is swung around so that it is facing the track motor end of the undercarriage, the action of the track controls is reversed. Take extra care! The two levers/foot pedals at the front of the cab control the travel. The left travel lever and pedal are connected, so are the right travel lever and pedal. To control the travel either can be used. Each travel lever/pedal controls the track on the same side. For example the left travel lever controls the left track when the cab faces forwards, (towards the recoil units). Before a travel lever/pedal is moved, check if the undercarriage faces forwards or backwards. Figure 38. B A

A B C D

Left travel lever Right travel lever Right travel pedal Left travel pedal

Do not travel with the track motors in front, particularly on hard or rocky ground. The recoil units will not be able to absorb the shocks and damage can be caused to the track running gear. When the machine is not travelling, do not put your feet on the travel pedals. Push the left and right travel levers slowly forwards, to travel forwards or pull them towards you, to travel backwards.

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Operation Drive Controls

Figure 39.

To turn the machine to the right, push the left travel lever forwards. To turn the machine to the left, push the right travel lever forwards. If the travel speed selector is set to fast speed and the travel levers are operated quickly, the machine will start quickly. Refer to: Operation > Drive Controls > Travel Speed Selector (Page 47). The simultaneous movement of the left and right travel levers, moved in the opposite directions will cause the machine to turn around its centre. To move the machine backwards in a straight line pull both levers in a backwards motion equally. Both tracks will operate in a reverse direction.

Travel Speed Selector The travel speed of the machine can be changed between fast and slow using the two speed switch. Refer to: About the Product > Console Switches (Page 13). A

A B

Figure 40.

Fast (hare) Slow (tortoise)

Use the high/fast travel speed mode when the ground is level. Use the low/slow travel speed mode when climbing or descending a slope or when the ground is rough.

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Operation Instruments

Instruments Instrument Panel The instrument panel is located at the front of the cab in the line of sight from the operator's seat. The gauges, warning and indicator lamps are grouped together on the instrument cluster. Figure 41.

A D B

A B C D E

Hourmeter Coolant temperature gauge Fuel gauge Warning symbols Mode status

Hourmeter: The digital hourmeter displays the machine working hours. Coolant temperature gauge: The needle position shows the current temperature of the engine coolant. Do not let the needle rise into the red danger zone of the gauge. Fuel gauge: The needle position shows the current level of fuel in the tank. Do not let the tank run dry, or air can enter the fuel system. Warning symbols: The warning symbols illuminate and a buzzer will sound when there is a fault in the machine. All the symbols will go off when the ignition key is turned to the off position. (But the direction indicator, roadlights, main-beam and hazard warning indicators will continue to operate if their related functions are switched on.) Do not use the machine if it has a fault condition, or you can damage the engine and/or the transmission. Mode status: The mode status shows the current speed mode of the machine. You can select different speed modes using the power mode switch. Refer to: About the Product > Console Switches (Page 13).

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Operation Instruments

Warning and Notification Symbols Figure 42. A

Lamp test (daily): Turn the ignition key to the on position to do a start-up cycle. Only the symbols shown should illuminate during the start-up cycle. Do not use the machine if any of the warning symbols do not illuminate, contact your JCB dealer. Do not use the machine if it has a fault condition, or you may damage the machine. Table 6. A

Engine coolant temperature (red)

Hydraulic oil temperature (red)

Engine oil pressure (red)

D E

Engine intake air filter (red) Battery charging condition (red)

Coolant level (red)

Slew lock ON (red)

Servo isolator ON (red)

Water separator (red)

Visual only. Illuminates if the engine coolant temperature rises too high. Put the engine into low idle and wait until the temperature is normal. Visual only. Illuminates if the hydraulic fluid temperature rises too high. Visual only. Illuminates if the engine oil pressure is low. The lamp should go off when the engine is started. If the lamp flashes, this indicates a fault with this function. Visual only. Illuminates when the air filter is blocked. Visual only. Illuminates if the alternator is not charging. If the lamp has been on for 30s, when the engine is running the buzzer will sound. The lamp should go off a few seconds after the engine is started. Visual only. Illuminates if the engine coolant level drops too low. Visual only. Illuminates when the machine slew lock is engaged. Visual only. Illuminates when the machine's servo isolator is engaged. Visual only. Illuminates if water level reaches the maximum mark in the water separator.

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Operation Getting the Machine Moving

Getting the Machine Moving General Moving the Machine 1. Prepare the machine. Refer to: Operation > Preparing for Travel (Page 43). 2. Check the area around the machine, then sound the horn to warn other personnel of a machine operation. 3. Use the track controls to move the machine in the required direction. Refer to: Operation > Drive Controls > Track Controls (Page 46). 4. Do not change the travel speed when the machine is moving. Stop the machine, then change the travel speed. Refer to: Operation > Drive Controls > Travel Speed Selector (Page 47).

Stability Pull the dig end close when you travel, to improve the stability of the machine.

Decreasing the Machine Wear When you travel on level ground keep the drive sprockets at the rear. If the drive sprockets are at the front, the tracks could wear prematurely. Figure 54.

If you travel with the track raised on one side, it increases the load on the other side of the undercarriage. If possible to decrease the wear, travel on level ground. Figure 55.

If you travel while using the dig end, it increases the load on the undercarriage and increases its wear.

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Operation Getting the Machine Moving

Figure 56.

When a track comes off the ground, the track will loosen and the track rollers may come off their links. On hard surfaces the shock forces are larger and have an adverse effect on the undercarriage. Always keep the correct track tension. Figure 57.

When the machine is operated on muddy ground, the tracks will fill with mud. If the machine travels in this condition it will cause wear to the tracks. To decrease the wear, lift one track off of the ground at a time and turn the track to remove the mud. Figure 58.

If the machine travels over obstacles for example tree stumps and rocks, the track shoes may bend and a high load will be applied to the individual track pins. Figure 59.

If the machine must travel over such obstacles, drive the centre of the track shoes over the obstacles.

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Operation Getting the Machine Moving

Figure 60.

When you travel over a mound, always support the chassis with the dig end to prevent shock loads. Figure 61.

Figure 62.

When the machine travels for long distances heat is generated in the undercarriage, which causes increased wear. When possible, stop the machine and let it cool down. Figure 63.

If the track comes off the ground, the track will loosen. When you slew the machine, if the track is too loose the track roller can ride up on the link. Always keep the correct track tension. Figure 64.

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Operation Driving the Machine

Driving the Machine General Warning! When the cab is swung around so that it is facing the track motor end of the undercarriage, the action of the track controls is reversed. Take extra care! Caution! Drive the machine smoothly. Spin turn manoeuvres, zig-zag driving or turning too fast can cause the vehicle to overturn. The track controls operate as described when the excavator is positioned about the dozer. If the excavator is at the opposite end to the dozer, the lever operation will be reversed. Always travel the machine with the excavator positioned at the same end as the dozer, especially on hard and rocky ground. Ensure you have complete field of vision when driving the machine. To move the machine forward, push both levers forward. Release the levers to stop. Track motor braking occurs automatically when the levers are released. To move the machine backward, pull both levers backward. Release the levers to stop. Track motor braking occurs automatically when the levers are released. Figure 65. A

A B

Forward travel Backward travel

To turn the machine while you travel, move the lever back towards the central position on the side towards which direction you want to go, for example, move the left lever back to turn left. This causes one of the tracks to move slower than the other. The faster moving track will push the machine around. Release the lever to stop. Figure 66.

C D

Turn right Turn left

To spin the machine around through 360Â°, without moving it, operate one lever, in a forward position and the other in a reverse position. This will cause the tracks to drive in opposite directions and hence push the machine around. Figure 67. E

E F

Spin right Spin left

Towing Other Equipment A light duty tow eye is attached to the undercarriage. The maximum tow capacity of the tow eye is 25% of the machine weight. Do not exceed the maximum tow capacity of the tow eye. 53

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Operation Driving the Machine

Use the minimum force to move the equipment slowly (not greater than 2km/h) smoothly and without shocks. Do not use the tow eye to retrieve the machine, as this will cause damage.

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Operation Operating Levers/Pedals

Operating Levers/Pedals General Warning! 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. Caution! 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.

Control Layouts Warning! 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. The control levers and switches may vary on machines.

Excavator Arm Controls Introduction Notice: Do not excavate on hard or rocky ground with the boom positioned diagonally across the undercarriage. The resulting rocking motion could cause damage to the track gearbox sprockets and tracks. Notice: When carrying out deep digging with the superstructure swung to any position other than in line with the undercarriage, it is possible that part of the boom structure may contact the machine. Take extra care when digging, to avoid damaging the machine. The excavating is controlled mainly by the movements of the left and right excavator joystick controllers. Many of the excavating movements are a combination of two (or more) movements at the same time, which requires practice. Practice the movements singly at first and then in combination, until you are completely familiar with the effects of all the controls. Before you start to excavate, make sure that the controls isolation lever is down and the slew lock switch is off. Use the label on the front window to remind you of the operating patterns when you move the excavator joystick controllers. When the engine has stopped, there will be sufficient pressure available for a limited time to enable the boom/ dipper to be lowered to a safe position.

ISO Controls This machine's operation conforms to the ISO operating method. The operating pattern is shown on a label on the front window. ISO Pattern Right Joystick Notice: In some instances it may be possible to hit the cab with the bucket or attachment. To prevent damage care should be taken when operating with the bucket/ attachment close to the cab. The right hand joystick controls the movements of the excavator arm and the bucket. When released, the joystick returns to the neutral position. The excavator arm will move within its limits for as long as you hold the joystick forward or backwards. It will stop automatically when you release the joystick. To raise the excavator arm, pull the joystick backwards (position 1). To lower the excavator arm, push the joystick forwards (position 2).

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Operation Operating Levers/Pedals

If the engine stops and will not re-start, to lower the attachment the ground: 1. Make sure the ignition is on. 2. Make sure the controls isolation lever is down. Refer to: Operation > Locks > Control Lock (Page 44). 3. Push the joystick forwards (position 2). The bucket will move within its limits for as long as you hold the joystick to one side. It will stop automatically when you release the joystick. To fill the bucket, move the joystick to the left (position 3). To empty the bucket, move the joystick to the right (position 4). Press the horn switch to sound the horn, to give a signal before the machine is started or before you engage travel or slew. Figure 68. 1

4 1 2 3 4 5

Backward: Raise the boom arm Forward: Lower the boom arm Left: Fill the bucket Right: Empty the bucket Horn

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Operation Operating Levers/Pedals

Left Joystick The left hand joystick controls the slew of the superstructure and the movements of the dipper. When released, the joystick returns to the neutral position. The superstructure will slew within its limits for as long as you hold the joystick over to one side. It will stop automatically when you release the joystick due to the application of the slew brake. When the joystick is returned to neutral, the machine will still not stop moving immediately because of inertia. Remember this when you do a slew operation. The operation of the bucket attachment is reversed when it is installed in the reverse position, be careful. To move the dipper inwards, move the joystick backwards (position 1). To move the dipper outwards, move the joystick forwards (position 2). The dipper will move within its limits as long as you hold the joystick forward or backwards. It will stop automatically when you release the joystick. To slew to the left, move the joystick to the left (position 3). To slew to the right, move the joystick to the right (position 4). Press and hold the excavator arm priority switch to change the priority from slew to boom raise. Release the switch to deselect boom priority. Select the excavator arm raise priority option during a simultaneous slew and boom operation to decrease the flow to the slew motor and increase the flow to the boom raise operation. Press the horn switch to sound the horn, to give a signal before the machine is started or before you engage travel or slew. Figure 69.

4 1

4 3 1 2 3 4 57

Backward: Move the dipper inwards Forward: Move the dipper outwards Left: Slew to the left Right: Slew to the right 9821/9600-1A

Operation Operating Levers/Pedals

Dozer Blade Controls Notice: Before operating the dozer blade, make sure that large rocks or other objects are not between it and the tracks that can jam the mechanism. The dozer blade is operated by a single control lever on the right side of the cab. The control lever is spring loaded to the central position. In this position the dozer blade will not move. To lift the dozer blade, pull the control lever backwards. At the required position release the control lever. To lower the dozer blade, push the control lever forward until an increased resistance is felt and the dozer blade moves. At the required position release the control lever. Figure 70.

A B C

Control lever Forward: Lower the dozer blade Backward: Lift the dozer blade

Auxiliary Circuit Controls Warning! Before operating the auxiliary control system make sure that you are aware of all safety notices that apply to the attachment you are using. Also make sure you have installed the attachment correctly.

General The auxiliary controls are on the excavator arm controls. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 55). There is also an auxiliary control pedal option, push the pedal to operate a full flow auxiliary circuit. For more information, refer to the operator manual supplied with the attachment.

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Operation Operating Levers/Pedals

Figure 71.

A A

Auxiliary control pedal

Attachment Systems Rockbreaker Circuit This system supplies a one-way, regulated hydraulic flow to operate a rockbreaker. The flow to the rockbreaker is controlled by a pedal at the operator's feet.

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Operation Lifting and Loading

Lifting and Loading General Warning! 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. Warning! When transporting a load on a slope, drive slowly and keep the load uphill of the machine. This will increase stability. Warning! Do not use the machine for object handling unless it is equipped for this purpose. Without the relevant devices the machine can become unstable and tip over. You and others could be seriously injured or killed. Warning! Before you lift a load with the machine, you must read and understand this section. Failure to take the precautions shown can result in death or injury. If your machine is not installed with a lifting point (for example a hook or shackle), hose burst check valves, load charts and an overload warning system then it must not be used for object handling. If your machine is not installed with this equipment you must only use the machine for earthmoving purposes.

Lifting (Object Handling) Regulations The owner and/or operator must make sure that they fully understand the laws and regulations concerning the use of the JCB machine as an earthmover and for lifting. Consult your JCB dealer for more information. In certain countries safety regulations in force call for the application of specific safety factors. Consult your JCB dealer for more information. All figures and lift capacities (if applicable) in this publication are based on the machine being on level, solid ground.

Safe Working Loads The maximum load which may be lifted depends on the equipment attached 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.

Fit for Purpose Tests for Lifting Equipment All lifting equipment (for example forks, lifting hooks and shackles) needs regular inspections and testing by a competent person to make sure they are fit for purpose. These may be needed every six months or at least annually in some countries to meet and comply with legislation and for insurance purposes. Refer to: Maintenance > Maintenance Schedules > Functional Tests and Final Inspection (Page 123). Check with your local JCB dealer for further advice.

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Operation Working with the Excavator Arm

Working with the Excavator Arm General Warning! When using the boom and dipper fully extended, take the following precautions, otherwise the machine could get damaged or become unstable and become a danger to you and other people. Make sure you do not exceed the working capacity of the boom at maximum reach. Swing the boom slowly to prevent any chance of the machine becoming unstable. For the same reason avoid dumping downhill if possible. Warning! Care must be taken with machines installed with an extra long dipper as it may affect the stability of the machine. Before you start using the excavator, you must convert the machine into a safe and stable working platform. Refer to: Operation > Working with the Excavator Arm > Preparing to Use the Excavator Arm (Page 61). To use the excavator 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 the excavator 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 or she will not hear you. Make sure the correct bucket for the job is installed. Refer to: Attachments > Buckets (Page 103).

Preparing to Use the Excavator Arm When choosing a digging position, avoid digging downhill if possible. When possible, dump the load on the uphill side of the excavation. Both of these precautions will help to keep the machine stable. When the machine is in the required position on the worksite, lower the dozer blade to the ground. Ensure you have complete field of vision before using the excavator arm.

Lifting With the Excavator Arm Use a signalman when lifting with the excavator. Make sure you both understand and use the recognised signals. Keep all persons clear of the load and machine when the load is on the excavator. A bucket must be installed when lifting with the excavator to prevent the bucket link from swinging. Make sure that the load is not more than the SWLfor the bucket. If a hook is installed a shackle may not be required. Refer to: Technical Data > Static Dimensions (Page 162). If a lug is installed a shackle is required. The lifting shackle must be removed when excavating to prevent the possibility of damage. Refer to: Technical Data > Static Dimensions (Page 162). If your machine is not installed with this equipment there will be a label in the operators cab to indicate this and you must use the machine for earth moving purposes only. 1. Where possible lifting should be carried out with the bucket closed in order to increase visibility, move the sharp objects away from the lifting chains and prevent any obstruction or deflection of the lifting chains away from the vertical position. 2. Attach the lifting chains to the shackle or hook. Keep the chain length as short as possible, to prevent swinging. Always use lifting tackle which is strong enough and in good condition. Check the load weight before choosing the lifting chains. 3. Attach a handline to the load. Make sure the person holding the handline stands clear of the load and machine. 4. Test the load by lifting it: Distance: 25â&#x20AC;&#x201C;50mm 61

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Operation Working with the Excavator Arm

5. If the load is to be lifted to a height where it is not possible to prevent the bucket obstructing or deflecting the lifting chains then the lifting chains must only be guided by the back wall of the bucket and not by any other parts of the machine. Figure 73. B

6. Slowly manoeuvre the load across the ground with the excavator controls. Lower the load to the ground if you feel any instability of the load or the machine. When you are using the dipper movement to lift, always lift by moving the dipper away from you, as shown, not towards you. This is because hose burst check valves (if installed) are provided only on the 'dipper-in' side.

Digging Warning! When you are excavating do not rest your feet on the foot pedals. Even light pressure on the pedals can cause the machine to move.

Decreasing the Machine Wear Do not use the weight of the machine to dig. The shock load will cause stress to the dig end and the chassis. Use the machines hydraulic force to dig. Figure 86.

If impact force is used to do a task, it will cause damage to the dig end. An impact force will also create high pressures inside the cylinders, which will cause the cylinders to swell. Figure 87.

The cylinders are designed with a cushion mechanism which will gradually release any back pressure. If an impact force is applied at the end of the cylinder stroke, the piston will hit the head or bottom end and cause damage.

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Operation Working with the Excavator Arm

Figure 88.

Stability A machine which is stable during operation, increases productivity, extends the life of the machine and makes sure of operator safety. Figure 89.

The dig point effects stability, if the dig point is too far away the machine can become unstable. Figure 90.

Keep the dig point close to the machine to improve stability and increase the dig force. Figure 91.

When the dig end is used, always keep the drive sprockets at the rear. The stability of the machine is improved and wear to the drive is decreased.

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Operation Working with the Excavator Arm

Figure 92.

Where practical work with the tracks pointing forwards, to improve the stability of the machine. When working with the tracks pointing to the sides exercise caution due to reduced stability. Figure 93.

Digging on a Slope Before you dig a vertical trench on a slope, if possible cut-out a level base to work from. Refer to: Operation > Slopes > Working on Slopes (Page 72). Dump the trench material on the uphill side of the trench, far enough away to prevent it falling back into the trench.

Machine Efficiency When the bucket cylinder and link, and the arm cylinder and dipper are both at 90Â° to each other, the force of each cylinder is at a maximum and the efficiency of the operation is increased. Figure 94.

90 90

When you dig with the dipper, keep the dipper angle within a range of 45Â° to the front and 30Â° to the rear. In this range if the boom and bucket are also used, the efficiency of the operation is increased.

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Operation Working with the Excavator Arm

Figure 95.

Backfilling When you backfill on a slope, pile the material on the high side of the trench if possible. 1. Move the bucket level to the ground. 2. Select a bucket height and excavating speed which will give you a maximum depth of cut, without overloading the machine. 3. Work at right angles to the trench and fill a buckets width at a time. Leave any spillage until the trench is filled. 4. Use the spillage to finish the job by driving the length of the trench with bucket low to the ground.

Travelling With a Load (Pick and Carry) Warning! Do not use the machine for object handling unless it is equipped for this purpose. Without the relevant devices the machine can become unstable and tip over. You and others could be seriously injured or killed. If your machine is not fitted with a lift point (for example a hook or shackle), hose burst check valves, load charts and a overload warning system then it must not be used for object handling. 1. Stop the machine on solid, level ground. 2. Align the undercarriage with the upper structure. Refer to: Operation > Operating Levers/Pedals (Page 55). 3. Make sure that the load is within the capacity of the machine. Refer to the lift chart in the machine cab. 4. When possible the load should be attached to the machine frame to prevent the load from swinging and causing instability. 5. Important: All of the lifting equipment, including the hook and/or the shackle and any chains/slings/webs between the machine and the load, will need regular inspections and testing by a competent person to make sure they are fit for purpose. 6. Select slow speed travel. Maintain slow travel speed at all times. Refer to: Operation > Drive Controls > Travel Speed Selector (Page 47). 7. Suspend the load as low to the ground as possible. The load must be visible at all times by the operator or an appropriately trained person who is in contact with the operator at all times. 8. When you travel with the load, do not apply sharp adjustments to the controls.

Dumping Into a Truck 1. To prevent unnecessary manoeuvring, put the truck(s) in position, as shown. Refer to Figure 96.

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Operation Working with the Excavator Arm

Figure 96.

2. Do not dump the material in one sudden movement. Roll the bucket forward in stages until it is empty. Refer to Figure 97. 3. Use the joystick to move the bucket backwards and forwards to loosen any sticky material. 4. Keep the wind on your back. This keeps the dust away from you and your machine. 5. If the truck body is about as long as a buckets width, dump the load into the centre of the truck. If the truck is two bucket widths long or more, fill the front of the truck first. 6. When you lift a large, heavy load: 6.1. Dump the load close to the bed of the truck. 6.2. Do not dump the load from height, this will damage the bed of the truck. 6.3. Put soil into the bed of the truck first to act as a cushion for the loads. 7. Move the truck into a position where it can easily be seen by the operator and lift multiple loads. This will increase the operating efficiency and improve safety. Figure 97. 3

3 1 2

1 1 2 3

Changing the Bucket Linkage It is possible to compensate for the lateral wear which causes the sideways play of the bucket. The regular use of this compensating procedure leads to less wear on the bucket swivel pin and the dipper bushes.

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Operation Working with the Excavator Arm

Figure 98.

A B C

Swivel pin Dipper bush Clearance

1. Park the machine on solid, level ground. 2. Set the bucket as shown.Refer to Figure 99. Figure 99.

3. Turn the bucket slightly to the left and adjust it so that the arm end is pressed to the side which is not to be adjusted. 4. Stop the engine and remove the ignition key. 5. Measure the clearance. Refer to Figure 98. 5.1. The distance should be approximately: Distance: 0.8mm 6. If the clearance is incorrect, contact your JCB dealer.

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Operation Working with the Dozer Blade

Working with the Dozer Blade General When you work with the dozer blade, remember that you will be driving the machine. Keep alert for bystanders, animals and possible hazards. When you work with the dozer blade, make sure the slew lock is engaged. When possible, do not slew the machine to do a dozer blade task. If you must slew the machine to do a dozer blade task, use a smooth slew action and make sure there are no obstacles. When the machine is slewed to do a dozer blade task, it will create large side loads on the dig end and this will cause twisting and bending. Figure 100.

Dozing and Grading Keep the bottom of the dozer blade parallel to the ground. When grading a site remove the high spots first, then use this soil to fill in troughs. Do not use excessive downward pressure on the dozer blade or machine traction could be lost. When you work with the dozer blade, move the excavator straight with the machine, as for worksite travel. Refer to: Operation > Preparing for Travel > Preparing for Worksite Travel (Page 43). Keep the dozer blade high during travel as this increases the machines ground clearance.

Scraping and Cutting If a deep cut is to be made, do it in steps of about 50mm. Do not forget to adjust the height of the dozer blade when the machines tracks enter the cut.

Backfilling When you backfill on a slope, pile the material on the high side of the trench when possible. Move the dozer blade level to the ground. Work at right angles to the trench, fill a dozer blades width at a time. Leave any spillage until the trench is filled. Use the spillage to finish the job by driving the length of the trench with the dozer blade low to the ground.

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Operation Working with the Dozer Blade

Figure 101.

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Operation Slopes

Slopes General Warning! Make sure that you have been trained and are familiar with the use of machines on slopes, and understand the adverse affects that slopes and site conditions can have on stability. Never use the machine on a slope if you do not understand the recommended practices for the use of machines in such applications. There are a number of factors which can adversely affect the stability of the machine and the safety of the machine and operator when used on a slope. 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.

Driving on Slopes Introduction Warning! 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. Going uphill, reverse when unloaded or travel forwards when loaded. Going downhill, travel forwards when unloaded or reverse when loaded. Take special care when moving across a slope. If the slope is too steep your machine could roll over. If you must drive across a slope, keep the attachments close to the ground. The machine can operate without affecting its systems on slopes of up to 35Â°. On slopes greater than 10Â° the operator must use his discretion and continue with extreme caution.

Driving Down a Slope When you drive down a slope, make sure that the bucket is set 250 Âą 50mm above the ground (in the position shown) and drive at a low speed. Refer to Figure 102. Figure 102.

When you drive down a slope always keep the drive sprockets at the front. If the drive sprockets are at the rear, the tracks will be loose and there is a danger the machine could move unexpectedly after it stops. Keep the dig end in a position that makes sure the machine is stable and at the same time where it is possible, to use the dig end to stop the machine in an emergency. The steering speed is quite fast when you drive down a steep slope. If it is necessary to change direction, stop the machine and turn the track backward on the side to which the machine will turn. This will improve safety when you turn on a slope. Refer to Figure 103.

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Operation Slopes

Figure 103.

Driving Up a Slope When you drive up a slope, make sure that the bucket is set 250 Âą 50mm above the ground (in the position shown). Refer to Figure 104. Figure 104.

When you drive up a steep slope, make sure that the bucket is set 250 Âą 50mm above the ground (in the position shown). Refer to Figure 105. Figure 105.

When you drive up a slope, always keep the drive sprockets at the rear. If the drive sprockets are at the front, the tracks will be loose and the drive will be decreased.

Driving Across a Slope Never drive across or turn on a steep slope, always drive to level ground before you do this. Be careful when you open or close the door on a slope, make sure the door is locked in the open or closed position. 71

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Operation Slopes

Working on Slopes The illustrations show a typical model. Your machine may look different to the model shown. It is dangerous to operate the machine on a slope. Where possible, use a platform or a level cut-out to keep the machine horizontal when in use. Refer to Figure 106. Figure 106.

If it is necessary to stop on a slope, dig the bucket into the surface of the ground and put blocks under the tracks. Refer to Figure 107. Figure 107.

When you stop on a steep slope for a long period with the engine running, there is a risk that the oil cannot circulate around the engine correctly. This can cause damage to the engine. If necessary, stop with the machine facing down the slope. Refer to Figure 108. Figure 108.

When you drive over ditches or holes, it is safer if the work equipment is used to help the machine.

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Operation Slopes

Figure 109. 3

When you climb a ramp, it is easier and safer if the work equipment is used to help the machine. Figure 110. 1

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Operation Heating, Ventilating and Air-Conditioning (HVAC)

Heating, Ventilating and Air-Conditioning (HVAC) General The operator must set the controls to obtain the best 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 Air Conditioning Controls (Option) Introduction Air-conditioning reduces moisture from the air and can be used to demist windows quickly in damp weather. B

2 A 1 2 B C D 3 4

Figure 111.

Air conditioning switch Air conditioning switch - position 1 Air conditioning switch - position 2 3-speed fan switch Temperature control switch Recirculation switch Recirculation switch - position 1 Recirculation switch - position 2

The air conditioning control panel is installed on the trim panel to the right side of the operator seat. The temperature is adjusted by the recirculation switch, a fan switch and the temperature control switch. Adjust the air vents to direct the air flow to the front window (for demisting) and/or the cab floor. To obtain the best results from the air conditioning system make sure that all doors and windows are closed. Before starting the engine make sure the air conditioning is switched off. Air Conditioning Control Turn the air conditioning switch to position 1 to switch off the air conditioning system. Turn the air conditioning switch to position 2 to switch on the air conditioning system. 3-Speed Fan Control Turn the fan speed switch to adjust the speed of the fan. This functions only when the ignition key is in position I. Temperature Control Turn the temperature control switch clockwise to increase the temperature. 74

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Operation Heating, Ventilating and Air-Conditioning (HVAC)

Turn the temperature control switch counterclockwise to decrease the temperature. Air Control Turn the recirculation switch to position '1' to let fresh air enter the cab. Turn the recirculation switch to position '2' to recirculate the air, this should be used when you operate in a dusty working environment.

Face Level Fan Figure 112.

Switch - fan on/off

The face level fan is installed on the rear side panel behind the operator seat. Press the switch to turn on/off the face level fan.

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Operation Power Sockets

Power Sockets Auxiliary Power Socket Your machine may be fitted with one or more 12V auxiliary power sockets, which can be used for mobile phone chargers or other 12V powered devices. Refer to: About the Product > Operator Station > Component Locations (Page 12). Only connect items which are compatible with the power rating of the socket and have the correct plug. Always operate the engine during the prolonged use of the electrical accessories, or the battery can discharge. Make sure that the socket cap is closed when the socket is not in use.

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Operation Battery Isolator

Battery Isolator General Notice: Before carrying out arc welding on the machine, disconnect the battery and alternator to protect the circuits and components. The battery must still be disconnected even if a battery isolator is installed.

Disconnect the Machine Electrics: 1. Turn the ignition key to the off position. 2. Get access to the battery isolator. Refer to: Maintenance > Service Points > General (Page 126). 3. Turn the battery isolator key in a counter-clockwise direction and remove.

Connect the Machine Electrics: 1. Make sure the ignition is switched off. 2. Insert the battery isolator key and turn in a clockwise direction.

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Operation Fire Extinguisher

Fire Extinguisher General Location (If installed) The fire extinguisher is stowed in a bracket behind the operator seat. Keep the fire extinguisher in the bracket until you need to use it. Figure 114.

Fire extinguisher

Operation Warning! Do not use the fire extinguisher in a confined space. Make sure that the area is well ventilated during and after using the fire extinguisher. Warning! After any use, the extinguisher must be replaced or serviced. Make sure that you understand how to use the fire extinguisher. If necessary, refer to the instructions found on the fire extinguisher. Only try to extinguish a fire if the circumstances permit and your safety is not endangered. If necessary, contact your nearest fire department. Using the fire extinguisher: 1. Move the machine to a safe area to prevent the fire from spreading. 2. Remove the fire extinguisher from its bracket. 3. Remove the safety pin. 4. Aim directly at the fire from an upwind position, if possible. 5. Squeeze the trigger to operate the fire extinguisher, release the trigger to stop the flow.

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Operation Fire Extinguisher

Figure 115. B

A B

Safety pin Trigger

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Operation Moving a Disabled Product

Moving a Disabled Product General If the machine becomes disabled, the machine must be made safe, lifted onto a transporter and moved to a location where it can be repaired. You must contact your nearest JCB dealer before you try to tow, winch or push the machine. Towing, winching or pushing the machine without following the correct procedure will damage the hydraulic pumps. If possible, repair the disabled machine where it stands.

Getting the Machine Unstuck Pulling the Machine Out of Soft Ground If the machine gets bogged down in soft ground, the excavator controls can be used to help get the machine moving again. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 55). To free the machine it is necessary to put something below the track(s) to provide grip. 1. One Track is Bogged Down. Refer to Figure 116. 1.1. Slew the boom towards the side to be freed and stop it at the required angle to the track (the correct angle is shown ): Angle: 90Â° 1.2. Set the dipper angle (the correct angle is shown) to the boom and crowd the bucket: Angle: 90Â° 1.3. Lower the boom until the bucket touches the ground. If necessary, put a board or something else with a broad ground contact, under the bucket. 1.4. Lower the boom further and lift the bogged down track off the ground. 1.5. Put a mat, board or log, etc below the track and raise the boom until the track rests on it. 1.6. Drive the machine away. Figure 116.

2. Both of the Tracks are Bogged Down. Refer to Figure 117. Do steps 1.1 to 1.5 of the One Track is Bogged Down procedure for each track, then drive the machine away or do the following procedure: 2.1. Drive a heavy stake into the ground directly in front of the machine. 2.2. Set the boom and dipper as if to dig, then hook the bucket onto the stake. 2.3. Use the excavator controls to draw in the dipper and the track controls to drive the machine forward and drag it out of the soft ground.

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Operation Moving a Disabled Product

Figure 117.

Jump-Starting the Engine Warning! In temperatures below freezing, the battery electrolyte may freeze if the battery is discharged or poorly charged. Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge. If you try to charge a frozen battery or jump-start and run the engine, the battery could explode. Batteries produce a flammable gas, which is explosive. Do not smoke when checking the electrolyte levels. 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. Switch off all circuits which are not controlled by the ignition key. Do not connect the booster (slave) supply directly across the starter motor. Use only sound jump leads with securely attached connectors. Connect one jump lead at a time. The machine has a negative earth electrical system. Check which battery terminal is positive (+) before making any connections. Keep metal watch straps and jewellery away from the jump lead connectors and the battery terminals - an accidental short could cause serious burns and damage equipment. Make sure you know the voltage of the machine. The booster (slave) supply must not be higher than that of the machine. Using a higher voltage supply will damage your machine's electrical system. If you do not know the voltage of your booster (slave) supply, then contact your JCB dealer for advice. Do not attempt to jump-start the engine until you are sure of the voltage of the booster (slave) supply. The negative (-) terminal on the battery is connected to frame earth. 1. Lower the excavator bucket and dozer blade to the ground, if they are not already there. They will lower themselves under their own weight when you operate the controls. Operate the controls carefully to control the rate of descent. Refer to: Operation > Operating Levers/Pedals (Page 55). 2. Set all switches in the cab to their off positions. 3. Get access to the battery. Refer to: Maintenance > Access Apertures (Page 132). 4. Connect the booster cables: 4.1. 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. 4.2. Connect the negative (-) booster cable to a good frame earth on the machine, away from and below the battery. A good frame earth is a part of the machine frame, free from paint and dirt. Do not use a pivot pin for an earth. 4.3. Connect the other end of this cable to the negative (-) terminal on the booster supply. 5. Do the pre-start checks. 6. Start the engine. 7. Disconnect the booster cables: 81

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Operation Moving a Disabled Product

7.1. Disconnect the negative booster cable from the machine frame earth. Then disconnect if from the booster supply. 7.2. Disconnect the positive booster cable from the positive (+) terminal on the battery. Then disconnect it from the booster supply.

Retrieval Notice: It is not recommended to tow a disabled machine. Permanent damage to the track motors of the disabled machine may occur if the machine is towed. If the machine cannot be moved to a safe area, then attach wire ropes or chains which are capable of pulling the machine to the lower frame, as shown. Refer to Figure 118. Notice: Do not use the tow eye or tie down points (if installed) to tow the machine, as this will cause damage to the machine. Figure 118.

Tow eye

Use the minimum force necessary to slowly move the machine (not greater than 2km/h) smoothly and without shocks). Tow the machine the minimum distance (not to exceed 20m) to a safe area for recovery by lifting. Refer to: Operation > Lifting the Product > General (Page 84). Do not use the tow eye or tie down points (if installed) to tow the machine, as this will cause damage. When the machine is recovered, a qualified person must inspect the track motors for damage.

Excavator Arm (Emergency Operation) The excavator has an accumulator installed. The accumulator stores a limited amount of hydraulic pressure for use in an emergency (engine failure for example). This hydraulic pressure must be used to move the dipper and lower the boom into a safe position. Do not try to operate other machine functions as this will deplete the hydraulic pressure in the accumulator and it may then not be possible to move the dipper and lower the boom. If an emergency occurs: 1. Turn the ignition key to the on position. 82

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Operation Moving a Disabled Product

2. Enable the controls. Refer to: Operation > Locks > Control Lock (Page 44). 3. Use the right and left control levers to move the dipper and lower the boom. 4. Vent the hydraulics. Refer to: Maintenance > Hydraulic System > General > Discharge (Page 155). 5. Turn the ignition key to the off position.

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Operation Lifting the Product

Lifting the Product General Figure 119.

A C

75 D

B A B C D

Spacer bars Lifting platform Lifting-hook height Angle = 75Â°

Danger! Do not stand underneath the raised load during the lowering procedure. Stand clear and to one side until the load has been safely lowered. Make sure that the area is clear of other people before lowering the load. If you do not follow these precautions you or others could be killed or seriously injured. 1. Park the machine on a suitable lifting platform with the attachment in the position shown. Refer to Figure 119. Refer to: Operation > Operating Levers/Pedals > General (Page 55). 2. Stop the engine. 3. Push the controls isolation switch. Refer to: Operation > Locks > Control Lock (Page 44). 4. Turn the ignition key to the 'off' position. 5. Make sure there are no loose items in the cab or on the machine. 6. Check the unladen weight and the height of the machine. Refer to: Technical Data > Static Dimensions > Dimensions (Page 162). 7. Make sure the lifting equipment complies with all of the local regulations, is suitable and strong enough for the task. 8. Use spacer bars are of sufficient length and strength to prevent the cables from touching the machine and causing damage. 9. Maintain the correct lifting angle between the engine cover and the sling. Refer to: Technical Data > Static Dimensions > Dimensions (Page 162). 10. Maintain the correct height to the lifting-hook. Refer to: Technical Data > Static Dimensions > Dimensions (Page 162). 84

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Operation Lifting the Product

11. Lift the machine slightly to check the balance of the machine and the installation of the lifting equipment. If the machine does not lift horizontally, adjust the length of the slings. Proceed slowly and evenly until the lift is complete. 12. Keep the machine horizontal during the lift. The centre of gravity of the machine is approximately above the slew centre.

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Operation Transporting the Product

Transporting the Product General Warning! 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. Warning! Make sure that the ramp incline does not exceed the machine's operational limits. Caution! 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 tracks. Make sure the machine will not foul on the ramp angle. Check the condition of the transport vehicle before the machine is loaded on to its trailer. Make sure that the transport trailer is suitable for the dimensions and weight of your machine. Refer to: Technical Data > Static Dimensions (Page 162). The bed of the trailer should have a wood surface to aid stability. Before transporting the machine make sure you will be obeying the local rules and laws regarding machine transportation of all the areas that the machine will be carried through.

Loading the Product onto the Transporting Vehicle/Trailer Caution! The machine must be securely tied down to the transport vehicle to prevent lateral movement, foreand-aft movement, and slewing of the superstructure. Failure to do so could cause injury to yourself or others. 1. Stop the transport vehicle on solid, level ground. 2. Apply the park brakes. 3. Lower any stability jacks. 4. Put blocks at the front and rear of the wheels on the transport trailer. 5. Make sure the ramps are in their correct positions and angle, then secure them. The ramps should not be at more than the specified angle: Angle: 15Â° Figure 120.

A A

Angle of the ramp

6. Before the machine is driven on to the transport trailer, make sure that the machine will not catch on the ramp/trailer angle. Refer to Figure 120. 7. Start the machine. Refer to: Operation > Starting the Engine (Page 40). 8. Slew the cab to make sure the excavating equipment is in a position where it will not interfere with your view of the ramp and the transport trailer. Refer to: Operation > Operating Levers/Pedals (Page 55). 9. Lift the bucket/attachment. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 55). 86

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Operation Transporting the Product

10. If applicable, lift the dozer blade. Refer to: Operation > Operating Levers/Pedals > Dozer Blade Controls (Page 58). 11. Slowly and carefully drive the machine onto the transport trailer. Be careful when the machine leaves the ramp and goes onto the transport trailer, because its centre of gravity will move suddenly. Refer to: Operation > Drive Controls (Page 46). 12. When the machine is safely in position, slew the cab to face forwards. 13. Engage the slew lock. Refer to: About the Product > Console Switches > Slew Lock (Page 13). 14. On a triple articulating boom machine, put the boom, dipper and bucket in the positions shown. Refer to Figure 121. Figure 121.

B A B

Undercarriage securing method Dipper arm securing method

15. Put suitable wooden blocks on the transport trailer at the front of the machine. 16. Crowd the bucket/attachment and move in the dipper. 17. Lower the boom until the dipper rests on the wooden blocks. Be careful, if you do not crowd the bucket/ attachment the cab could be damaged when the dipper is moved in. 18. Do not transport the machine with any of the rams fully extended. A fully extended ram could be damaged because of road shocks. 19. Isolate the controls. Refer to: Operation > Locks > Control Lock (Page 44). 20. Check that the overall height of the load is within the regulations. Adjust if necessary. 21. Stop the engine. 22. Secure the cab. 23. Put the cover on the exhaust stack. 24. Attach suitable tying-down accessories to the left and right side of the machine to secure the undercarriage to the transport trailer, as shown. Make sure the tying down accessories are strong enough for the purpose and tensioned correctly.Refer to Table 7.

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Operation Transporting the Product

Figure 122. D

A A

B E

A B C D E F

45Â° Minimum 50.6Â° Minimum 50.6Â°Minimum Tying-down accessory - Right side of machine Tying-down accessory - Left side of machine Centre line of machine

24.1.Make sure that both sides of the machine are restrained using the angles shown. Where he tracks are not shown, this is done for clarity. You do not need to remove the tracks to secure the machine. 25. Use either the hook, shackle or link as applicable, to secure the dipper arm to the transport trailer, as shown. Refer to Figure 121. 26. The correct tie down positions are identified on the machine by their labels. Refer to Figure 123. Figure 123.

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Operation Transporting the Product

27. Lift any stability jacks. 28. Measure the maximum height of the machine from the ground. Make sure that the transporter driver knows the maximum height before he drives away. Table 7. Tying-Down Accessories Restraint Specification Lashing capacity Minimum lashing breaking force

N 57,000 115,000

Unloading the Product from the Transporting Vehicle/Trailer Warning! If the dozer blade is to the rear, the track controls will be reversed. Use extreme caution when tracking off the trailer. 1. Stop the transport vehicle on solid, level ground. 2. Apply the park brakes. 3. Lower any stability jacks. 4. Before the machine is driven off the transport trailer, make sure that the machine will not catch on the ramp/ trailer angle. Refer to Figure 124. 5. Make sure the ramps are in their correct positions and angle, then secure them. The ramps should not be at more than the specified angle: Angle: 15Â° Figure 124.

A A

Angle of the ramp

6. Remove the cover from the exhaust stack. 7. Remove the tying-down accessories and blocks from the machine and stow them. 8. Start the machine. Refer to: Operation > Starting the Engine (Page 40). 9. Enable the controls. Refer to: Operation > Locks > Control Lock (Page 44). 10. Disengage the slew lock. Refer to: About the Product > Console Switches > Slew Lock (Page 13). 11. Slew the cab to make sure the excavating equipment is in a position where it will not interfere with your view of the ramp and the transport trailer. Refer to: Operation > Operating Levers/Pedals (Page 55). 12. Lift the bucket. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 55). 89

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Operation Transporting the Product

13. If applicable, lift the dozer blade. Refer to: Operation > Operating Levers/Pedals > Dozer Blade Controls (Page 58). 14. Drive the machine slowly to the ramps. 15. Continue to drive the machine until the tracks are over the ramps. 16. Slowly drive the machine onto the ramps and off the transport trailer.

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Operation Operating Environment

Operating Environment General In low and high temperature conditions, take the following precautions. They will make it easier to start and prevent possible damage to your machine.

Operating in Low Temperatures Notice: Do not connect two batteries in series to give 24V for starting as this can cause damage to the electrical circuits. 1. Use the correct viscosity engine lubricating oil. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 164). 2. If available, use a low temperature diesel fuel. 3. Use the correct coolant mixture. 4. Keep the battery at full charge. 5. Fill the fuel tank at the end of each work period, this will help to prevent condensation forming on the tank walls. 6. Protect the machine when its not in use. Park the machine inside a building or cover it with a tarpaulin. 7. Install a cold weather starting aid. In very low temperatures (less than the value shown) additional starting aids may be needed. For example are fuel, oil and coolant heaters. Ask your JCB dealer for advice. Temperature: -20Â°C 8. Before the engine is started, remove any snow from the engine compartment or snow could get into the air filter.

Operating in Extremely Low Temperatures In extremely low temperatures (below 0Â°C) special care must be taken. Extend the warm up time and cover the front faces of the radiator and oil cooler. After warm up, remove the covers. 1. Until the machine is thoroughly warmed up never try to slew quickly or operate the travel system, or damage can occur. 2. Before the machine is operated after a warm up, make sure that the boom, dipper bucket, slew and travel services all operate correctly. A time lag may occur when selecting these services if the hydraulic oil is not sufficiently warm. 3. If the machine will be left outside for more than one day without being used, remove the battery and take it indoors. 4. Drain the water collected in the fuel system to prevent it freezing. 5. Clean the machine after use and put it on wooden blocks. Keep the rams as fully retracted as possible. Remove any water from the exposed portion of the piston rods. 6. Additional low temperature fuel and lubricants and batteries may be required. Contact your local JCB dealer for advice.

Operating in High Temperatures 1. Use the correct viscosity engine lubricating oil. 2. Use the correct coolant mixture. 3. Check the coolant system regularly, keep the coolant at the correct level. Make sure there are no leaks.

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Operation Operating Environment

4. Keep the cooling pack and engine clean, regularly remove dirt and debris from the cooling pack and the engine. 5. Check the fan belt regularly. 6. Check the air vents. Make sure that the air vents to and from the engine compartment are not blocked. 7. Check the engine pre-cleaner regularly (if installed). 8. Check the battery electrolyte level.

Cab Filters Cab Filters There are two different filters available for the cab heater unit/air-conditioning unit. The cab is not air tight or pressurised. The cab filter is provided for comfort only, it does not provide complete protection against the environment in which the machine is used. The appropriate PPE (Personal Protective Equipment) must be worn if the machine is used in hazardous environments.

Standard Filter A solid particle filter used for general applications which do not require special filtration.

Carbon Filter A solid particle, odour filter used for general applications which do not require special filtration.

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Operation Refuelling

Refuelling General Caution! Spilt fuel may cause skidding and therefore accidents. Clean any spilt fuel immediately. Do not use fuel to clean the machine. When filling with fuel, choose a well aired and ventilated area. Notice: Consult your fuel supplier or JCB dealer about the suitability of any fuel you are unsure of.

Low Fuel Levels 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. 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 slopes. If you increase the engine speed or load when there is air in the fuel system, then 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: Maintenance > Fuel System > General > Bleed (Page 145). You must bleed the fuel system after changing the fuel filter(s).

Filling the Tank Refuelling the Machine Filling the Tank Before you add the fuel to the machine, Refer to: Maintenance > Maintenance Safety > Fluids and Lubricants (Page 114). If you use the incorrect type of fuel or fuel which is contaminated, then damage to the fuel injection system can occur. Warning! 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. 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 tank. Locate the fuel tank. Refer to: About the Product > Description (Page 6). 1. Park the machine on solid, level ground. 2. Lower the bucket to the ground. 3. Stop the engine. 4. Remove the ignition key. 5. Remove the fuel filler cap. 6. Add diesel through the filler point. 7. Replace the fuel filler cap. 8. We recommend that you lock the fuel filler cap to prevent theft and tampering.

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Operation Refuelling

Figure 127. A

Fuel filler cap

Fuel Level The amount of fuel in the tank is shown on the fuel gauge. Be alert for the red warning indicator on the gauge. Refer to: Operation > Instruments > General (Page ). You should fill the tank at the earliest opportunity when the red warning indicator comes on.

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Attachments Working with Attachments

Attachments

Working with Attachments Introduction Attachments Use only the JCB approved attachments that are specified for your machine. Operating with non-specified 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. Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper drift to remove and install metal pins. Always wear personal protective equipment. Attachments If you have an attachment which is not covered in the Operator's Manual do not install it, use it or remove it until you have obtained, read and understood the pertinent information. Install attachments only on the machines for which they were designed. Some attachments are supplied with the instructions on the safety, installation, removal, operation and maintenance procedures. Read and fully understand these procedures before the attachment is installed, used and serviced. If there is anything you do not understand, ask your JCB dealer. Before you use an attachment, make sure you understand how the attachment will affect the operational safety. When an attachment is installed, there may be changes in the machines centre of gravity or overall dimensions. These change can effect for example, the machine stability, the gradients on which it is safe to operate or the safe distance from power lines. Practice with an attachment off the job before you work with it for the first time. A JCB attachment is designed and manufactured specifically to suit the machines hydraulic system, mounting components and safe load requirements. An attachment which is not designed for use with the machine can cause damage and create a safety hazard for which JCB cannot be held responsible. Also the machines warranty and any other legislative compliance can be affected by the use of non JCB approved attachments. If your machine needs the hydraulic system adapting to use an auxiliary attachment, you must consult your JCB dealer. Only suitably qualified personnel must re-route the hydraulic hoses. All optional attachments will have limits on their operation for example, the lifting capacity, speeds, hydraulic flow rates. Always check the instructions supplied with the attachment or in the Specification section of this manual. Some specification limits may also be shown on the data/rating plate on the attachment. This section of the Operator's Manual includes general information on the operation of the attachment and the procedures for the installation and removal of the attachment.

Attachments for your Product Caution! Operation of this machine with an earth drill or breaker attached will alter machine stability. Attachments will help increase the productivity of your machine, for more information contact your JCB dealer. Remember, do not operate an attachment until you have read and fully understand the attachment operating instructions. Do not operate or work with attachments until the machine hydraulic oil has reached its normal working temperature.

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Attachments Working with Attachments

Notice: Some attachments may contact parts of the machine when in the fully folded position. Take extra care to avoid damage to the machine.

Connecting/Disconnecting Hydraulic Hoses Warning! Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear personal protective equipment. Hold a piece of cardboard close to suspected leaks and then examine the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. Warning! Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open. Some attachments are hydraulically powered. The following procedures show how to connect and disconnect the hydraulic hoses safely.

Connecting the Hydraulic Hoses 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Vent the hydraulic system. Refer to: Maintenance > Hydraulic System > General > Discharge (Page 155). 3. Check the hoses and adaptors for damage. Refer to: Maintenance > Hydraulic System > General > Check (Condition) (Page 155). 4. Connect the hoses: 4.1. Make sure that the hose is not twisted. Pressure applied to a twisted hose can cause the hose to fail or the connections to loosen. Figure 128.

4.2. Make sure that the hose does not touch hot parts. High ambient temperatures can cause the hose to fail. 4.3. Make sure that the hose does not touch parts which can rub or cause abrasion. 4.4. Use the hose clamps (where possible) to support long hose runs and keep the hoses away from moving parts, etc. Figure 129.

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Attachments Working with Attachments

4.5. To allow for length changes when the hose is pressurised, do not clamp at the bend. The curve absorbs the change. Figure 130.

5. Check for leaks: 5.1. Start the engine. 5.2. Operate the related controls to increase the pressure in the hydraulic system. 5.3. Stop the engine then remove the ignition key. 5.4. Check for indications of leakage at the hose connections. Correct, as necessary.

Disconnecting the Hydraulic Hoses 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Vent the hydraulic system. Refer to: Maintenance > Hydraulic System > General > Discharge (Page 155). 3. Disconnect the hoses. 4. Check the hoses and adaptors for damage. Refer to: Preservation and Storage > Checking For Damage (Page 107). 5. If necessary, install the blanking caps. 6. Check for leaks: 6.1. Start the engine. 6.2. Operate the related controls to increase the pressure in the hydraulic system. 6.3. Stop the engine then remove the ignition key. 6.4. Check for indications of leakage at the hose connections. Correct, as necessary.

Quick Release Couplings Warning! 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. The flat face quick release couplings allow the operator to remove and install attachments swiftly and efficiently. Generally, your machine pipework will be installed with a female coupling and a male coupling. The optional attachment hoses will also be installed with a female coupling and a male coupling.

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Attachments Working with Attachments

Figure 131. A

A B

Female coupling Male coupling

The quick release couplings will be trouble free and relatively easy to connect and disconnect, if they are kept clean and used correctly. The recommendations listed below must always apply when using flat face quick release couplings. Read the correct connecting and releasing procedures before you install or remove any optional attachment connected with quick release couplings. Essential do's: • • • • • • • • •

Before connecting or removing any hydraulic hose, the residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing the hoses. Always wipe the two mating faces clean before connecting. Use caps and plugs when the couplings are disconnected. Always align the external locking ball (if used) with the notch in the locking sleeve and then pull the locking sleeve back fully to disconnect. If a coupling sticks, first check that pressure has been released. Make sure the locking ball and notch in the locking sleeve are aligned, pull back the sleeve and twist the couplings apart. Sticking is normally caused by dirt in the coupling or physical damage due to abuse. Connect and disconnect the new couplings two or three times to work the PTFE seals. Sometimes a new coupling will stick if the seal has not been worked. When connecting the couplings, only apply the spanner or grips to the hexagon and nowhere else. Avoid damage to the coupling faces. Burrs and scratches cause damage to the seals and cause leaks. They can also impede connection and disconnection of the couplings. Periodically lubricate the internal locking balls on the female half of the coupling with silicone grease.

Essential don'ts: • • • • • • • • • •

Never try to reconnect using a damaged half coupling as this will destroy the seals in the mating half and necessitate replacement of both halves. Do not leave the coupling where it may be run over by a machine or otherwise crushed, this will distort the sleeve and prevent connection and disconnection. Never try to turn the sleeve when the coupling is disconnected as this will cause the locking ball to jam under the locking sleeve and damage the coupling. Never try to strip the coupling down, there are no user serviceable parts. If the coupling is damaged it must be replaced with a new one. Never hit the centre poppet of the coupling to try and release the locked in pressure. This can cause irreparable damage to the coupling and serious injury. When connecting the couplings, never clamp on the sleeve of the female or nose of the male, this will cause distortion and/or damage. Never subject the couplings to external forces, especially side load. This can decrease the life of the coupling or cause failure. Never allow the torsional forces transmitted from the hoses to unscrew/screw together the couplings. Never use a coupling as a plug. Do not connect and disconnect with pressure in the line unless the coupling type is specifically designed to do so.

Connecting Quick Release Couplings 1. Remove any residual hydraulic pressure trapped in the service line hose. 2. Wipe the two faces of the male and female couplings and make sure they are clean. 98

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Attachments Working with Attachments

3. Make sure that ball in the female coupling is located in one of its slots. 4. Connect the male coupling into the female coupling. 5. Where applicable, rotate the sleeve half a turn and make sure that the locking ball does not align with the slot. Figure 132. D E C

C D E

Ball Slot Sleeve

Disconnecting Quick Release Couplings 1. Remove any residual hydraulic pressure trapped in the service line hose. 2. Where applicable, align the slot with ball. 3. Pull back the sleeve to release the coupling.

Impact Protection Caution! When using an attachment for example a hydraulic breaker, where the risk of flying debris is present, a protective layer or screen guard must be attached to the front of the cab to protect the operator from flying debris which could cause injury. The safety label warns the operator against the risk of flying debris when they use an attachment. The attachment must not be used if a protective layer or screen guard has not been installed on the machine. Make sure that the attachment, for example a hydraulic breaker is positioned in front of the cab before it is operated. Do not swing the boom to the side during operation of the attachment. Consult your JCB dealer for further information. Figure 133. A

332/V3761-1

A B

Safety label Hydraulic breaker

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Attachments Direct-Mounted Attachments

Direct-Mounted Attachments General Removal 1. Move the boom straight in front of the machine. Refer to: Operation > Operating Levers/Pedals (Page 55). 2. Put the bucket on level ground, with the dipper approximately vertical and the bucket flat. 3. Put blocks around the bucket to prevent its movement. 4. Stop the engine. 5. Remove the ignition key. Caution! Stand clear and to one side of the bucket while you remove the pivot pins. With the pins removed, the bucket could roll over. Warning! 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. 6. At the bucket tipping-link, remove the locking pin from the pivot pin. Refer to Figure 134. 7. At the dipper tipping-link, remove the locking pin from the pivot pin. Figure 134.

20mm A B

Bucket tipping-link: Pivot pin Dipper tipping-link: Pivot pin

8. Lift the bucket from the ground by the specified distance. Distance: 20mm 9. Use the bucket ram to adjust the position of the bucket tipping-links, until there is no load on its pivot pin. 10. Use a hard wood, nylon or copper drift to remove the pivot pin from the bucket tipping-links. If necessary, the drift can be hit with a hammer. 11. Retract the bucket ram so that the bucket tipping-links are away from the bucket, then remove the O-ring seals. 100

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100

Attachments Direct-Mounted Attachments

12. Use the boom rams to carefully lower the dipper nose until there is no load on the pivot pin in the dipper tipping-links. 13. Use the drift to remove the pivot pin. 14. Move the dipper nose away from the bucket, then remove the O-ring seals.

Installation The installation procedure is not the reverse of the removal procedure. 1. Clean the pivot pins and the bores in the bucket bosses. 2. Make sure that the pivot pins slide through the bucket bosses. 3. Move the bucket in-line and in front of the machine. 4. Roll the two dipper tipping-link O-ring seals over the outside diameter of the inner bucket bosses. 5. Retract the bucket ram. 6. Move the nose of the dipper link between the bucket plates and align their bores, as shown at position 'C'. Refer to Figure 135. 7. Insert a solid steel bar with the specified diameter through the bores at position 'C'. Dimension: 50mm 7.1. The dipper should be approximately vertical. 8. Align the bucket link bores with the bucket bores, as shown at position 'D'. 9. Insert a solid steel bar with the specified diameter through the bores at position 'D'. Dimension: 50mm 10. Lift the boom until the bucket is off the ground hanging on the steel bars. Figure 135.

C D

101

Position 'C' Position 'D'

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101

Attachments Direct-Mounted Attachments

11. Move the bucket to the dump position so that the dipper link and the bucket bores are closely aligned (as shown at position 'C'), with the bucket teeth/toe plate above the ground by the specified distance. Distance: 20mm 11.1. In this position the bucket will be at a point of balance and will be suspended on the steel bar at position 'D', only through the tipping-link. 12. Remove the steel bar from position 'C', then push the pivot pin through. 13. Align the locking pin holes in the pivot pin and the boss, then install the locking pin. 14. Put the bucket flat on the ground in a suitable position. 15. Remove the second steel bar from position 'D'. 16. Swing the bucket link out and hold the O-ring seals in position. Refer to Figure 136. 17. Carefully move the bucket link forwards into alignment with the bucket bosses, as shown at position 'D'. 18. Push the pivot pin through the bores at position 'D'. Be careful, do not to put your fingers in a position where they can get trapped. 19. Align the locking pin holes in the pivot pin and the boss, then install the locking pin. 20. Make sure that the O-ring seals are in their correct positions. 21. Grease the pivot pins. Figure 136.

O-ring seals

Reversal 1. Do the bucket removal procedure. 2. Slightly lift the dipper, then turn the bucket by the specified angle. Angle: 180Â° 3. Do the bucket installation procedure.

102

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102

Attachments Buckets

Buckets General Warning! The bucket selected must be the correct width to suit the hole/trench to be excavated. However, if the hole width demands a larger bucket, consideration must be given to the density/weight of the material to be moved affecting the stability of the machine especially if working on a slope. If there is danger of the machine's stability being compromised, then select a smaller bucket or reposition the machine. Use the heavy duty bucket for maximum penetration when digging in hard, rocky or clay soils. Use the general purpose bucket for bulk shifting light or loose materials.

Bucket Teeth Introduction This bucket teeth information relates only to the buckets supplied by JCB. If a bucket from another source is used, refer to the relevant manufacturers manual. A wide range of bucket teeth is available for your machine, which are suitable for all digging conditions. The bucket teeth consists of an adaptor, tooth and locking pin. Refer to Figure 137. The adaptor remains attached to the bucket and the teeth can be easily and quickly changed by one man. The method of removal/installation is the same for all types of teeth.

Removal 1. Make the machine safe. 2. Move the bucket into position. 2.1. Make sure the bucket is supported off the ground with sufficient space for the removal of the locking pin. 3. Stop the engine. 4. Remove the ignition key. 5. Remove the locking pin. Refer to Figure 137. 5.1. Use a hammer and suitable drift, to knock the locking pin down and out of its guide. 5.2. Discard the locking pin. 6. Remove the tooth from the adaptor. Refer to Figure 137.

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Figure 137.

C A B C

Adaptor Locking pin Tooth

Installation 1. Install the tooth over the adaptor. Refer to Figure 137. 2. Install a new locking pin. Make sure that the locking pin is in the correct position. Refer to Figure 137. 3. Carefully hit the locking pin with a hammer until it is flush with its guide and locks in position.

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General Warning! When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions. Caution! To avoid burning, wear personal protective equipment when handling hot components. To protect your eyes, wear goggles when using a brush to clean components. Notice: Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents. Notice: The efficiency of the rams will be affected if they are not kept free of solidified dirt. Clean dirt from around the rams regularly. When leaving or parking the machine, close all rams if possible to reduce the risk of weather corrosion. Notice: Never use water or steam to clean inside the 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. Clean the product with water and/or steam. Do not let mud, debris etc. to collect on the product. Before you do any service procedures that require components to be removed: â&#x20AC;˘

The cleaning must be done either in the area of components to be removed, or in the case of major work, or work on the fuel system, the whole engine and the surrounding product must be cleaned. When cleaning is complete, move the product away from the wash area or alternatively, remove the material washed from the product.

â&#x20AC;˘

When you remove components, be aware of exposure to dirt and debris. Cover any open ports and remove the deposits before proceeding. Refer to the individual clean procedures throughout the Maintenance section. Refer to: Maintenance > Maintenance Schedules (Page 118).

Detergents Do not use a full strength detergent. Always dilute the detergents as per the manufacturer's recommendations, or damage to the paint finish can occur. Always obey the local regulations regarding the disposal of debris created from cleaning the product.

Pressure Washing and Steam Cleaning Caution! When using a steam cleaner, wear safety glasses or a face shield as well as protective clothing. Steam can cause serious personal injury. Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine is to be washed using a high pressure system. Make sure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. Do not aim the water jet directly at bearings, oil seals or the engine air induction system. Use a low pressure water jet and brush to remove dried mud or dirt. Use a pressure washer to remove soft dirt and oil. The product must always be greased (if appropriate) after pressure washing or steam cleaning.

Preparation 1. Make the product safe. Refer to: Maintenance > Maintenance Positions (Page 125). 105

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2. Stop the engine and let it cool for at least one hour. Do not try to clean any part of the engine while it is running. 3. Make sure that all of the electrical connectors are correctly coupled. If the connectors are open, attach the correct caps or seal with water proof tape.

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Preservation and Storage Checking For Damage

Checking For Damage General Refer to the individual condition checks throughout the Maintenance section. Refer to: Maintenance > Maintenance Schedules (Page 118).

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

Storage Area The product can be stored in a temperature range of: -40Â°C to 54Â°C If the product uses DEF (Diesel Exhaust Fluid) and is to be stored with DEF (or other fluids present), check the relevant fluid storage requirements as they may affect the applicable storage temperature range, see: Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 164). When possible, you must keep the product in a dry building or shelter. If only an outdoor storage area is available, look for a storage area with good drainage.

Prepare the Product for Storage 1. Clean the product to remove all unwanted material and corrosive products. 2. Dry the product to remove solvents and moisture. 3. Apply grease to the moving parts (if applicable). 4. Examine the product for worn or damaged parts. Replace if necessary. 5. Fill the fuel tank to prevent a build up of condensation in the tank (if applicable). 6. Examine the coolant condition. Replace if necessary. 7. Examine all fluid levels. Top up if necessary.

Put into Storage 1. Park the machine on solid, level ground. 1.1. Park the machine in an area where it is easy to access. (In case the machine does not start at the end of the storage period). 1.2. Put suitable timbers under the machine to eliminate direct contact with the ground. 2. Retract all of the rams and lower the attachment to the ground. 3. Vent the hydraulic system. 4. Remove the ignition key. 5. Apply a thin layer of grease or petroleum jelly to all of the exposed ram piston rods. 6. Remove the battery. 6.1. Keep the battery in warm, dry conditions. 6.2. Charge the battery periodically. 7. If you keep the machine outdoors, cover the machine with tarpaulins or plastic sheets.

During Storage Operate the machine functions each week to prevent a build up of rust in the engine and hydraulic circuits, and to minimise the deterioration of the hydraulic seals. 1. Remove the grease or petroleum jelly from the ram piston rods. 108

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2. Examine all fluid levels. If necessary, add more fuel. 3. Install a charged battery. 4. Start the engine. 5. Operate the hydraulic controls. Make sure that the hydraulic functions operate correctly. 6. Prepare the machine for storage.

Take out of Storage 1. Examine the coolant condition. Replace if necessary. 2. Examine all fluid levels. If necessary, add more fluid. 3. Remove the grease or petroleum jelly from the ram piston rods. 4. Install a charged battery. 5. Start the engine. 6. Operate the hydraulic controls. Make sure that the hydraulic functions operate correctly.

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Security General Vandalism and the theft of unattended machines is an ever increasing problem and JCB is doing everything possible to help stop this. Your JCB dealer will be pleased to provide information on any of these sensible precautions. Act now!

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

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General Your product 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 product was inspected both at the factory and by your dealer to make sure that it reaches you in optimum condition. To maintain this condition and trouble free operation it is important that the routine services, as specified in this manual, are done by an approved JCB dealer at the recommended intervals. This section of the manual gives full details of the service requirements necessary to maintain your JCB product at peak efficiency. A service manual for your product is available from your JCB dealer. The service manual contains information on how to repair, disassemble and assemble your product correctly. It can be seen from the service schedules on the following pages that many essential service checks must only be done by a JCB trained specialist. Only the JCB dealer service engineers have been trained by JCB to do such specialist tasks, and only the JCB dealer service engineers are equipped with the necessary special tools and test equipment to do such tasks, thoroughly, safely, accurately and efficiently. JCB regularly updates its dealers to advise them of any product developments, changes in specifications and procedures. Therefore only a JCB dealer is fully able to maintain and service your product. A service record sheet or book is provided which will enable you to plan your service requirements and keep a service history record. It must be dated, signed and stamped by your dealer each time your product is serviced. Remember, if your product 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 dealer wants you to be completely satisfied with your new JCB product. However, if you do have a problem, you can contact your dealers service department who are there to help you! You will have been given the names of the relevant service contacts at your dealer when the product was supplied. To get the most from your dealer please help them to satisfy you by: 1. Giving your name, address and telephone number. 2. Quoting your product model and serial number. 3. Date of purchase and hours of work. 4. Nature of the problem. Remember, only your JCB dealer has access to the vast resources available at JCB to help support you. In addition, your dealer 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 product, we strongly recommend you take advantage of the many service and maintenance agreements your dealer can offer. These can be tailor made to meet your operating conditions, work schedule etc. Please consult your JCB dealer for details.

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Obtaining Spare Parts If you use non-genuine JCB parts or consumables, then you can compromise the health and safety of the operator and cause machine failure. A parts book for your machine is available from your JCB dealer. The parts book will help you identify parts and order them from your JCB dealer. Your dealer will need to know the exact model, build and serial number of your machine. Refer to: About the Product > Product and Component Identification (Page 8). The data plate also shows the serial numbers of the engine, transmission and axle(s), where applicable. Remember, if any of these units have been changed, the serial number on the data plate may be wrong. Check on the unit itself.

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Maintenance Safety General Compressed Air Compressed air is dangerous. Wear personal protective equipment. Never point a compressed air jet at yourself or others. Springs Always wear personal protective equipment when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidentally flying out. Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper drift to remove and install metal pins. Always wear personal protective equipment. Communications Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing. Before starting the engine make sure the others are clear of the danger areas. Examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken. Repairs If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result in an accident or affect your health. Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer. Hydraulic 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. 'O' rings, Seals and Gaskets Badly installed, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals. Arc Welding To prevent the possibility of damage to electronic components, disconnect the battery and the alternator before arc-welding on the machine or attached implements. If the machine is equipped with sensitive electrical equipment, i.e. amplifier drivers, electronic control units (ECUs), monitor displays, etc., then disconnect them before welding. Failure to disconnect the sensitive electrical equipment could result in irreparable damage to these components. Parts of the machine are made from cast iron, welds on cast iron can weaken the structure and break. Do not weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine. Always connect the welder earth (ground) cable to the same component that is being welded to avoid damage to pivot pins, bearings and bushes. Attach the welder earth (ground) cable a distance from the part being welded no more than 0.6m. Counterweights Your machine may be installed with counterweights. They are extremely heavy. Do not attempt to remove them. Accumulators The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on systems incorporating accumulators, the system pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may cause injury. 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.

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Hot Components Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit. Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground. Working Under the Machine Make the machine safe before getting beneath it. Make sure that any attachments on the machine are correctly attached. Engage the park brake (if installed), remove the ignition key, disconnect the battery. If the machine has wheels use blocks to prevent unintentional movement. Lifting the Machine Under no circumstances must the engine be run with the transmission in gear and only one driving wheel jacked clear of the ground, since the wheel on the ground will move the machine. Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton®, FluorelTM and Technoflon®. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. This acid can severely burn. New fluoroelastomeric components at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose temperatures have not exceeded 300°C 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 (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains. Thoroughly wash contaminated area with detergent and water. Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations. Do not burn fluoroelastiometric materials. Hydraulic Hoses Never re-use hydraulic hose end crimps or use reusable hose end crimps.

Fluids and Lubricants 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. Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear personal protective equipment. Hold a piece of cardboard close to suspected leaks and then examine the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. Fuel Fuel is flammable, keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions.

Hygiene JCB lubricants are not a health risk when used correctly for their intended purposes. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation. Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination. 114

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

Storage Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers.

Waste Disposal Caution! It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. Caution! Damaged or spent batteries and any residue from fires or spillage must be put in a closed acid proof receptacle and must be disposed of in accordance with local environmental waste regulations. All waste products must be disposed of in accordance with all the relevant regulations. The collection and disposal of used oil must be in accordance with any local regulations. Never pour used engine oil into sewers, drains or on the ground.

Handling 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: • •

• • • •

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: • Wash your skin thoroughly with soap and water • Using a nail brush will help • Use special hand cleansers to help clean dirty hands • Never use petrol, diesel fuel, or paraffin for washing Avoid skin contact with oil soaked clothing Don't keep oily rags in pockets Wash dirty clothing before re-use Throw away oil-soaked shoes

Battery Warning Symbols The following warning symbols may be found on the battery.

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D Keep away from children Shield eyes No smoking, no naked flames, no sparks Explosive gas Battery acid Note operating instructions

A B C D E F

Figure 138. B

First Aid - Oil Eyes In the case of eye contact, flush with water for 15min. If irritation persists, get medical attention.

Swallowing If oil is swallowed do not induce vomiting. Get medical advice.

Skin In the case of excessive skin contact, wash with soap and water.

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

Fires Warning! Do not use water to put out an oil fire. This will only spread it because oil floats on water. Extinguish oil and lubricant fires with carbon dioxide, dry chemical or foam. Fire fighters must use self contained breathing apparatus.

First Aid - Electrolyte Eyes In the case of eye contact, flush with water for 15min. always get medical attention.

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

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Skin Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.

Maintenance Caution! 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. Caution! The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools before beginning maintenance.

First Aid - DEF (if applicable) If large quantities of DEF (Diesel Exhaust Fluid) have been swallowed a doctor should be called immediately. Do not induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to an unconscious person. Avoid prolonged or repeated skin contact. After contact with skin wash thoroughly with plenty of soap and water. If irritation develops seek medical advice. Avoid contact with eyes, skin and clothing. Wear chemical resistant gloves, overalls and safety goggles complying with an approved standard. If in contact with eyes, rinse immediately with plenty of clean water. If irritation occurs seek medical attention. Always wash hands and arms thoroughly after handling before eating, drinking, smoking or using the lavatory. DEF is corrosive to some metals such as copper and its alloys. Make sure DEF does not come in to contact with electrical connections. Use only recommended storage and dispensing systems. DEF solution is very polluting to surface water and groundwater. DEF may not be removed by oil separators so it is important to isolate drainage from the dispensing area to prevent pollution in the event of a spill. Keep container closed in a segregated, approved and labelled area. Store below 30Â°C.

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Maintenance Schedules General Warning! Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level ground. To prevent anyone starting the engine, remove the ignition key. Disconnect the battery when you are not using electrical power. If you do not take these precautions you could be killed or injured. A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication tasks listed in the service schedules are done to keep the machine in a safe and efficient working condition. Apart from the daily tasks, the schedules are based on the machine running hours. Keep a regular check on the hourmeter readings to correctly gauge the service intervals. When there is no hourmeter installed, use the calendar equivalents to determine the service intervals. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are corrected immediately. More frequent checks of engine components than the engine manufacturer recommends do not invalidate emissions warranty.

How to Use the Maintenance Schedules The schedules show the service tasks which must be done and their intervals. The services must be done at either the hourly interval or the calendar equivalent, whichever occurs first. The intervals given in the schedules must not be exceeded. If the machine is operated under severe conditions (high temperature, dust, water, etc.) shorten the intervals. Table 8. Service task can be completed by a competent operator. Details of how to complete the service task are given in the Operator's Manual. We recommend that a Service Engineer completes the service task. Details of how to complete the service task are given in the Service Manual.

Maintenance Intervals General Table 9. Interval (h) 10 50 250 500 1000 2000 4000 8000

Calendar Equivalent Daily Weekly Monthly Three months Six months Yearly Two years Four Years

Attachments When using a breaker, crusher or pulveriser, contamination and degradation of the hydraulic oil occurs much more quickly than in normal excavating use. If the machine is used with increasingly degrading oil it can cause problems in the control valve, premature wear of the hydraulic pump and damage to the hydraulic system as a whole. 118

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The servicing of the hydraulic oil and filters must be done more frequently according to the percentage of total operating hours involving use of the breaker, crusher or pulverizer. When a breaker, crusher or pulverizer is installed, make sure that the oil and filters are changed at the intervals shown in the table below. The hydraulic oil must be sampled and checked for contamination and degradation at the intervals shown. Contact your JCB dealer who will have the facilities to do these tasks and make sure that the hydraulic system is correctly maintained. Table 10. Check the oil level, add more oil as required Change Clean Table 11. Item

Use Frequency Greater than 75% 50-75% 25-50% 10-25% Less than 10% 10h 100h 600h 10h 200h 1,000h 10h 300h 1,500h 10h 600h 3,000h 10h 800h 4,000h

Hydraulic oil Return filter

(1)

Suction filter Drain filter

(1)

Drain filter

(1)

Breaker in-line (1) filter Hydraulic oil Every 200 hrs sampling

Every 200 hrs

Every 300 hrs

Every 600 hrs

Every 800 hrs

(1) The filters must be changed whenever the period of breaker/crusher/pulverizer use exceeds 100hrs, regardless of the total number of hours the machine has worked

Periodic Replacement of Safety Related Components Routinely replace the important components concerned with safety. It is difficult to determine by a visual inspection or from operation the service life of specific components, so routinely replace them as important components every 2 years. If any abnormality is found with any of these components before the replacement time, repair or replace them as you would normally do. When you replace the hoses, if the hose clamps are deformed or cracked, replace the hose clamps at the same time as the hoses. Regarding the hoses not included in the routine replacement of safety components, do the inspection described. Tighten, replace, etc, when any abnormality is found. Refer to Table 14. Replace the O-rings, gaskets at the same time as the hoses. Contact your JCB dealer for the replacement of the safety components. Do an inspection of the hydraulic hoses and the fuel hoses at the routine inspection described. Refer to Table 14. Table 12. Important Parts Fuel hose (Fuel tank - engine) Fuel hose (Fuel filter - injection pump)

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Replacement Interval Every 2 years or every 4000 hours, whichever comes first.

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Table 13. Important Parts Pump exit hose (Pump - operation valve) Boom ram line hose Dipper ram line hose Bucket ram line hose

Replacement Interval Every 2 years or every 4000 hours, whichever comes first.

Table 14. Inspection Classification Start-up inspection Special independent inspection (Monthly inspection) Special independent inspection (Yearly inspection)

Inspection Item Fuel, hydraulic hose connections, oil leakage from caulked parts. Fuel, hydraulic hose connections, oil leakage from caulked parts. Fuel, hydraulic hose damage (cracks, wear, picking) Fuel, hydraulic hose connections, oil leakage from caulked parts. Fuel, hydraulic hose interference, squeezing, aging, twisting, damage (cracks, wear, picking)

Pre-start Cold Checks, Service Points and Fluid Levels Table 15. Component Task Attachments/Optional Equipment As required Lubricate As required

250

500 1,000 2,000 4,000

Check (Condition)

Engine speed in breaker mode Check (Operation) Body and Framework General

Clean

General

Check (Condition)

Slew ring bearing

Lubricate

Slew ring pinion and gear teeth Pivot pins (except boom base and dipper) Pivot pins (boom base and dipper) Pivot pins (wet or severe conditions - except boom base and dipper pins) Operator Station Operator protective structure

Lubricate

Seat belt

Check (Condition)

Engine Oil

Check (Leaks)

Oil

Check (Level)

Oil Drive belt

Replace

Drive belt

Replace

(4)

Lubricate Lubricate

Check (Condition)

Check (Condition) (10)

120

Lubricate

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Component Valves

Task Check (Condition)

Engine mounts

Check (Condition)

Air inlet security

Check (Condition)

Exhaust system security

Check (Condition)

Fuel tank water and sediment

Clean

Fuel level

Check (Level)

Fuel filler cap

Clean

Fuel filler cap (dusty conditions) Air Filter

Clean

(2)

Air filter (outer)

(5)

Replace

Pre cleaner (if installed)

Clean

Fuel System Fuel system

Check (Leaks)

Main fuel filter/sedimenter

Replace

Main fuel filter/sedimenter

Clean

Engine fuel filter Engine fuel filter

Replace

Primary fuel filter

Replace

Primary fuel filter

Clean

Water separator

Drain

Water separator

Clean

250

500 1,000 2,000 4,000

Drain/Clean

Replace

Fuel injectors

(2, 11)

High pressure fuel lines Cooling System Coolant

Replace

Coolant

Check (Condition)

Coolant

Check (Level)

Coolant

Replace

Cooling pack

Check (Condition)

Gearbox Track gearbox security

Check (Condition)

Slew gearbox security

Check (Condition)

Track gearbox oil

Check (Level)

Slew gearbox oil

Check (Level)

(2, 11)

(3)

Check (Leaks)

Track gearbox oil

Replace

Slew gearbox oil

Replace

Tracks Track plate condition and bolt torque

Check (Condition)

(3, 8)

121

Replace

Air filter (inner)

(4)

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Component Idler wheels oil and seals

Task Check (Condition)

Track tension

Check (Condition)

Track roller oil and seals

Check (Condition)

Hydraulics Hose and pipework

Check (Leaks)

Oil

Check (Level)

Oil (Biodegradable and nonbiodegradable) Oil (Biodegradable)

Sample

Oil (Non-biodegradable) Oil cooler

Replace

(10)

Rams

Check (Condition)

Hydraulic oil filter

Replace

Drain filter

Replace

Suction strainer

Clean

Suction strainer

Replace

Cushion valve filter

Clean

Cushion valve filter

Replace

Security of the mounting bolts (7) on major components

Check (Condition)

(3)

Servo filter element

Replace

Pump line exit hose

Replace

Boom ram hoses

Replace

Dipper line ram hoses

Replace

Bucket line ram hoses

Replace

Electrics Wiring

Check (Condition)

Battery

Clean

Battery electrolyte level (if applicable) Battery isolator

Check (Level)

Starter motor

Check (Condition)

Alternator

Check (Condition)

(3, 6)

122

250

500 1,000 2,000 4,000

Clean Replace

(3, 6)

Replace

Hydraulic tank breather (6, 12)

Check (Operation)

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Component Miscellaneous Fire extinguisher

Task

250

500 1,000 2,000 4,000

Check (Condition)

(1) Dusty conditions only. (2) Tasks which must be done by a specialist. (3) These procedures are only to be done at the first 500 hours of use. Then sample/replace every 1000 hours. (4) Replace every 400 hours. If operating under arduous conditions, do an engine oil flush (use the normal recommended engine oil) every 250 hours and replace the engine oil and filter. Service times may depend on fuel used. (5) If operating in dusty condition do these tasks more frequently. (6) If using a breaker, crusher or pulveriser, refer to the service intervals for attachments in this manual. (7) Tighten the bolts and nut after the first 50 hours of first use and then every 250 hours. (8) Sample/replace every 500 hours if the tracking hours is greater than 20% machine hours. (9) Replace every 3000 hours. (10) Replace every 5000 hours. (11) Replace every 8000 hours. (12) First 100 hours service only, to be completed by your JCB dealer.

Functional Tests and Final Inspection Table 16. Component Body and Framework Excavator lever and pedal locks Doors and locks

Task

Seat and seat belt

Check (Condition)

Seat and seat belt

Check (Operation)

Engine Maximum no-load speed

Check (Operation)

Throttle calibration

Check (Operation)

Engine Stop

Check (Operation)

General

Check (Condition)

Cooling System Coolant

Check (Condition)

Hydraulics Hydraulic tank - water and sediment

250

500 1,000 2,000 4,000

Check (Operation) Check (Condition)

Drain/Clean

Relief valves

Check (Condition)

Services

Check (Operation)

(2)

Accumulator (engine stopped) Check (Condition) Fuel System Fuel system

Check (Leaks)

Transmission Slew brake

Check (Operation)

Electrics General

Check (Operation)

Alternator - output

Check (Condition)

Miscellaneous 123

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Maintenance Maintenance Schedules

Component Fit for purpose test

Task Check (Operation)

Optional Equipment Overload warning system

Check (Operation)

Refuel pump

Check (Operation)

(2)

250

500 1,000 2,000 4,000

(1) Dusty conditions only. (2) Tasks which must be done by a specialist.

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Maintenance Maintenance Positions

Maintenance Positions General Danger! Your machine may be fitted with a hydraulically raised cab. Do not, under any circumstances enter or work underneath an un-supported cab in the raised position. Warning! A machine can sink into soft ground. Never work under a machine on soft ground. Warning! Make the machine safe before getting beneath it. Make sure that any attachments on the machine are correctly attached. Engage the park brake (if installed), remove the ignition key, disconnect the battery. Make the machine safe before you start a maintenance procedure. Unless a maintenance procedure instructs you differently, you must lower the arm and lower the hydraulically raised cab (if fitted). Refer to: Maintenance > Maintenance Positions (Page 125).

Maintenance Position (Excavator Arm Lowered) 1. Park the machine on solid, level ground, with the upper structure parallel to the undercarriage.. Refer to: Operation > Stopping and Parking (Page 42). 2. If necessary, lower the dozer blade. Refer to: Operation > Operating Levers/Pedals > Dozer Blade Controls (Page 58). 3. Lower the excavator so the dipper is flat on the ground. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 55). Figure 139.

Excavator lowered with the dipper flat on the ground

4. Stop the engine. 5. Remove the ignition key. 6. Release the hydraulic pressure and the tank pressure. Refer to: Maintenance > Hydraulic System > General > Discharge (Page 155). 7. Isolate the battery to prevent the accidental operation of the engine. Refer to: Maintenance > Electrical System > Battery Isolator > Check (Operation) (Page 159).

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Maintenance Service Points

Service Points General Caution! Make sure the steps, handrails, and your footwear soles are clean and dry before climbing onto the machine. Always face the machine when climbing on and off it.

Upper Structure A

Figure 140. C D

E F G

H J K A B C D E F G H J K

126

Tool box Fuel filler cap Hydraulic oil filler cap Hydraulic tank breather Engine oil filter Engine oil dipstick Engine fuel filters Engine oil filler cap Radiator cap Expansion bottle

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Maintenance Service Points

Access to the Upper Structure Figure 141.

Figure 142.

JCB

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Maintenance Service Points

Figure 143.

1. Make the machine safe. 2. Hold the handrail with both hands, then use the step between the top and bottom tracks to climb onto the top of the track. Keep three points of contact with the machine at all times.Refer to Figure 141. 3. Keep hold of the handrail and use the steps on the toolbox to climb up to the top of the upper structure. Keep two points of contact with the machine at all times. Refer to Figure 143.

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Maintenance Service Points

Battery Compartment Figure 144.

A B C

A B C D

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Air filter Radiator Expansion bottle Battery

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Maintenance Service Points

Hydraulic Compartment Figure 145.

A B C D

130

Main fuel filter Water separator Hydraulic oil filter Hydraulic oil level indicator

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Maintenance Service Points

Undercarriage Figure 146.

A B

131

Track rollers Track tensioners

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Maintenance Access Apertures

Access Apertures General When moved to 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 correctly in their closed or installed positions.

Battery Cover Open 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 125). 2. Use the ignition key to unlock the cover. 3. Pull the handle to release the latch. 4. Open the cover until it latches in position. Figure 147. C A

A B C

Lock Handle Cover

Close 1. To release the latch pull it up. 2. Close the cover. 3. Make sure the cover is closed correctly. 4. Use the ignition key to lock the cover.

Engine Compartment Cover Open 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 125). 132

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Maintenance Access Apertures

2. Use the ignition key to unlock the cover. 3. Pull the handle to release the latch. The cover opens automatically and is supported on a gas strut. 4. Ensure the support bar has fully engaged. Figure 148. A

C A B C

Lock Handle Cover

Close 1. Hold the weight of the cover and pull the support bar towards you. 2. Push the cover down. 3. Make sure the cover is closed correctly. 4. Use the ignition key to lock the cover.

Hydraulic Compartment Cover Open 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 125). 2. Use the ignition key to unlock the cover. 3. Pull the handle to release the latch. 4. Open the cover until it latches in position.

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Maintenance Access Apertures

Figure 149.

A C B A B C

Lock Handle Cover

Close 1. To release the latch pull it up. 2. Close the cover. 3. Make sure the cover is closed correctly. 4. Use the ignition key to lock the cover.

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Maintenance Tools

Tools General When you carry tools onto the machine, you must keep three points of contact with the machine at all times. If necessary, lift the tools on to the machine in intervals. Put the tools down before you adjust your grips on the machine. Do not try to adjust your grips on the machine while holding tools.

Toolbox The grease gun is stowed in the toolbox. The toolbox can be locked with the key. Figure 150.

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Toolbox

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Maintenance Lubrication

Lubrication General Caution! Waxoyl contains turpentine substitute which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Refer to the individual condition checks throughout the Maintenance section. Refer to: Maintenance > Maintenance Schedules > Pre-start Cold Checks, Service Points and Fluid Levels (Page 120). The machine must always be greased after pressure washing or steam cleaning. Greasing must be done with a grease gun. Normally, two strokes of the grease gun is 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. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 164). Attach the dust caps after greasing (if installed).

Preparation Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 125). You can complete the greasing procedures with the excavator lowered.

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Maintenance Attachments

Attachments General Lubricate Where applicable, refer to the specific manufacturers manual for instructions on the lubrication of optional attachments.

Check (Condition) Where applicable, refer to the specific manufacturers manual for instructions on the maintenance of optional attachments.

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Maintenance Body and Framework

Body and Framework General Clean Debris can collect under the boom. Remove all debris from under the boom. Thoroughly dry the piston rams and protect them with clean transmission or hydraulic oil if necessary.

Check (Condition) 1. Make sure that all of the guards and protective devices are in position, secured by their locking devices and free from damage. 2. Inspect all of the steelwork for damage. Include the following: 2.1. Examine all of the lifting point welds. 2.2. Examine all of the pivot point welds. 2.3. Examine the condition of all the pivot pins. 2.4. Check that the pivot pins are correctly in position and secured by their locking devices. 3. Check the steps and handrails are undamaged and correctly attached. 4. Check for broken, cracked or crazed window glass and mirrors. Replace the damaged items. 5. Check that the lamp lenses are undamaged. 6. Check that all of the attachment teeth are undamaged and correctly attached. 7. Check that all of the safety and instructional labels are undamaged and in position. Install new labels where necessary. 8. Note any damaged paintwork for future repair. 9. Inspect the machine for broken or loose fasteners.

Slew Ring Bearings Lubricate Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 125). The slew ring bearings have three grease nipples distributed equally around the slew ring. Make sure that grease extrudes from under the seal around all of the circumference. It is not possible to add too much grease. Figure 151.

D D

138

Grease nipples

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Maintenance Body and Framework

Pivot Pins Lubricate Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 125). Grease the pivot pins. Figure 152. C B

G A B C D E F G

F E

Boom base pin Boom ram, eye and pin Dipper ram, dump end pin Dipper ram, eye end pin Boom to dipper, connecting pin Bucket ram, dump end pin Boom ram, dump end pin Figure 153. P

M L M N P

139

Bucket ram to bucket linkage pin Bucket linkage to bucket pin Dipper to bucket pin Dipper to bucket linkage pin

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Maintenance Operator Station

Operator Station General Clean Notice: Never use water or steam to clean inside the cab. The use of water or steam could damage the on-board computer and render the machine inoperable. Remove dirt using a brush or damp cloth. Remove debris and loose articles from inside the cab.

Seat Check (Condition) Check that the seat adjustments operate correctly. Check the seat is undamaged. Check the seat mounting bolts are undamaged, correctly installed and tight. Make sure the seat is clear from unwanted materials and hazards at all times.

Seat Belt Check (Condition) Warning! When a seat belt is installed on your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. Install a new seat belt every three years. Warning! If the seat belt does not 'lock' when you check if the seat belt is operating correctly, do not drive the machine. Get the seat belt repaired or replaced immediately. Make sure the seat belt can be adjusted. Examine the seat belt for signs of fraying and stretching. Check that the stitching is not loose or damaged. Check that the belt mounting bolts are undamaged, correctly installed and tight. Check that the buckle assembly is undamaged and operates correctly.

Controls Check (Operation) Check the operation of the non-hydraulic and non-electrical operator station controls.

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Maintenance Engine

Engine General Check (Condition) Start the engine and check for: • • • • • •

Excessive smoke Excessive vibration Excessive noise Overheating Performance Unusual smells.

Oil Check (Leaks) Before you start the product, do a check for oil leaks: 1. Make the product safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Get access to the engine compartment (if applicable) Refer to: Maintenance > Access Apertures (Page 132). 3. Check the engine and the area below for oil leaks. 4. Close the engine cover (if applicable). 5. If necessary, contact your JCB dealer.

Check (Level) Notice: 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. 1. Make the product safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Wait for the oil to drain back into the engine sump before you take a reading. If not, a false low reading may be recorded which can cause the engine to be overfilled. 3. Get access to the engine compartment (if applicable). Refer to: Maintenance > Access Apertures (Page 132). 4. Remove and clean the dipstick. Refer to: Maintenance > Service Points (Page 126). 5. Replace the dipstick. 6. Remove the dipstick. 7. Check the oil level. The oil should be between the two marks on the dipstick. 8. If necessary, add more oil: 8.1. Remove the filler cap. Refer to: Maintenance > Service Points (Page 126). 141

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Maintenance Engine

8.2. Add the recommended oil slowly through the filler point Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 164). 8.3. Replace the dipstick. 8.4. Remove the dipstick. 8.5. Check the oil level, if necessary add more oil. 8.6. Replace the dipstick 8.7. Replace the filler cap. 9. Close and secure the engine cover (if applicable).

Replace Notice: 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. Warning! Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer. Caution! It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Get access to the engine compartment. Refer to: Maintenance > Access Apertures (Page 132). 3. Remove the oil filler cap. Refer to: Maintenance > Service Points (Page 126). 4. Remove the engine oil drain plug. Drain the oil in to a suitable container. Refer to: Maintenance > Service Points (Page 126). 5. Clean the drain plug. Install the drain plug. Tighten the drain plug to the correct torque value. Refer to: Technical Data > Torque Values (Page 166). 6. Remove the cap from the oil filter housing (if applicable). 7. Remove and discard the oil filter cartridge. 8. Fit a new filter with new gaskets. 9. Fit and tighten the cover on the oil filter housing (if applicable). Tighten the cover to the correct torque value. Refer to: Technical Data > Torque Values (Page 166). 10. Add the correct specification and quantity of oil. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 164). 11. Check the oil level. Refer to: Maintenance > Engine > Oil > Check (Level) (Page 141). 12. Install the oil filler cap. 13. Close and secure the engine cover.

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Maintenance Engine

14. Operate the engine at idle speed until the oil pressure low warning light has extinguished and the new filter has primed before the engine speed is increased above idle speed. 15. Check for leaks. 16. Check the oil level when the oil has cooled. 16.1.Fill with clean engine oil, if necessary.

Drive Belt Check (Condition) The drive belt is self tensioning. If the tensioner is adjusted to its maximum position the drive belt tension will be correct. Renew the belt if it has cracks or if it is frayed or has pieces of material missing.

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Maintenance Air Filter

Air Filter General Check (Condition) Notice: Do not modify or fit non JCB approved components to the engine induction system, otherwise the engine emissions will be compromised. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Get access to induction system. Refer to: Maintenance > Access Apertures (Page 132). 3. Check the system hoses for: 3.1. Condition. 3.2. Damage. 3.3. Security. 4. Replace the system hoses if necessary.

Pre-Cleaner Clean Refer to the pre-cleaner manufacturers instructions for specific maintenance/cleaning instructions.

Dust Valve Check (Condition) • • • •

144

Check the dust valve for rips/tears. Check there are no obstructions. Check that the dust valve is free of dirt and dust. Check that the dust valve securely attached to the air filter housing.

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Maintenance Fuel System

Fuel System General Bleed Figure 154.

A B

Fuel lift pump Bleed screw

1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Open the engine cover. Refer to: Maintenance > Access Apertures (Page 132). 3. Loosen the bleed screw, located on the fuel filter.Refer to Figure 154. 4. Operate the fuel lift pump lever until all of the air has been released. 5. Tighten the bleed screw. 6. Loosen the connecting union nuts at the injectors. 7. Crank the engine until all of the air has been released. 8. Check all the O-ring seals and connections. 9. Tighten the connecting union nuts to the correct value. Refer to: Technical Data > Torque Values (Page 166). 10. Close the engine cover. 11. Start the engine. 12. Make sure the engine operates smoothly and does not stop. If necessary, do the steps 1 to 10 again.

Check (Leaks) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 145

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Maintenance Fuel System

2. Get access to the engine compartment (if applicable). Refer to: Maintenance > Access Apertures (Page 132). 3. Check the engine compartment (if applicable), fuel lines and the area below for leaks. 4. Start the engine. 5. While the engine is running check the engine compartment (if applicable), fuel lines and the area below for leaks. 6. If necessary, contact your JCB dealer.

Tank Clean Draining Fuel Tank Impurities 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 125). 2. Remove the cover plate from below the fuel tank. 3. Put a suitable container below the self sealing drain plug. 4. Remove the outer threaded cover from the self sealing drain plug. 5. Connect the self sealing drain kit threaded union with attached pipe. Drain the water and deposits until there is clean diesel. 6. Remove the self seal drain kit. 7. Clean and install the outer threaded cover. Do not over tighten the cover. 8. Install the cover plate. Figure 155.

A B A B

Self sealing drain kit Pipe

Clean the Filler Cap 1. Make the machine safe.

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Maintenance Fuel System

Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 125). 2. Get access to the fuel filler cap. Refer to: Maintenance > Service Points > General (Page 126). 3. Clean the exterior of the cap with a clean cloth. 4. Remove the fuel filler cap. 5. Clean the interior of the fuel filler cap with a clean cloth. 6. Install the fuel filler cap.

Fuel Filter Replace Figure 157.

A A

Fuel filters

1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Open the hydraulic compartment cover. 3. Get access to the fuel filter. Refer to: Maintenance > Access Apertures (Page 132). 4. Loosen the drain plug located at the bottom of the filter bowl.Refer to Figure 157. 5. Drain and remove the fuel filter. 6. Replace the fuel filter. 7. Bleed the fuel system. Refer to: Maintenance > Fuel System (Page 145). 8. Close the hydraulic compartment cover. 147

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Maintenance Fuel System

9. Start the engine. Make sure the engine operates smoothly and does not stop.

Water Separator Clean Figure 158.

A A B

Main fuel filters Water separator

1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Open the hydraulic compartment cover. Refer to: Maintenance > Access Apertures (Page 132). 3. Loosen the drain plug to remove sediments from the fuel filters. Refer to Figure 158. 4. Loosen the center bolts and remove the filters. 5. Clean the bowls with diesel oil. 6. Check the condition of O-rings and if required, replace with new O-rings. 7. Install the fuel filters. 8. Tighten the center bolts to the correct torque value. Refer to: Technical Data > Torque Values (Page 166). 9. Close the hydraulic compartment cover. 10. Bleed the fuel system. Refer to: Maintenance > Fuel System (Page 145). 11. Start the engine. Make sure the engine operates smoothly and does not stop.

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Maintenance Cooling System

Cooling System General Check (Leaks) Before you start the machine, inspect the system for leaks: 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Get access to the cooling pack. Refer to: Maintenance > Access Apertures (Page 132). 3. Check the cooling system for leaks. 4. If necessary, contact your JCB dealer.

Coolant Check (Condition) Refer to: Technical Data > Fluids, Lubricants and Capacities > Coolant (Page 164).

Check (Level) Caution! The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system. 1. Make the machine safe. Refer to: Operation > Stopping and Parking (Page 42). 2. Let the engine cool. 3. Get the access to the coolant expansion bottle. Refer to: Maintenance > Service Points (Page 126). 4. Check the fluid level in the expansion bottle, if the fluid level is low: 4.1. Carefully loosen the cap on the expansion bottle and let the pressure release from the system. Refer to: Maintenance > Service Points (Page 126). 4.2. Remove the cap from the expansion bottle. 4.3. Add the recommended coolant up to the maximum mark. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 164). 4.4. Manipulate the top radiator hose to make sure that there are no air locks in the system. 4.5. Replace the cap. 5. Start the engine. 6. Turn the slew lock on. Refer to: Operation > Operating Levers/Pedals (Page 55). 7. Stall the 'dipper in' service until the coolant reaches the specified temperature. Temperature: 90Â°C Refer to: Operation > Instruments (Page 48). 8. Stop the engine. 9. Remove the ignition key. 149

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Maintenance Cooling System

10. Let the engine cool. 11. Check the level of coolant in the expansion bottle. If necessary, add more coolant.

Cooling Pack Clean 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Let the engine cool. 3. Get access to the radiator. Refer to: Maintenance > Access Apertures (Page 132). 4. If necessary, use a soft bristle brush or compressed air to remove all debris from the radiator.

Check (Condition) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Let the engine cool. 3. Get access to the cooling pack. Refer to: Maintenance > Access Apertures (Page 132). 4. Check the condition of the hoses, radiator and fan for: 4.1. Condition. 4.2. Damage. 4.3. Security. 5. Replace the system hoses/radiator if necessary.

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Maintenance Tracks

Tracks General Clean Warning! If two people are doing this job make sure that the person operating the controls is a competent operator. If the wrong control lever is moved, or if the controls are moved violently, the other person could be killed or injured. If you will be working with another person, make sure that you both understand what is to be done. Learn and use the recognised signalling procedures. Do not rely on shouting - he will not hear you. To clean the tracks, you must turn them. When the tracks are turning, keep clear of rotating parts. Before starting this job, make sure that you have no loose clothing (cuffs, ties etc.) which could get caught in moving parts. Keep people not involved with this job well away! Caution! Rotating the tracks off the ground may cause stones and other debris to be thrown with considerable force. If you are on the outside, keep well clear. Keep other people well clear. 1. Stop the machine on solid, level ground. 2. Open the bucket. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 55). 3. Slew the boom until it is at the specified angle to the track. Angle: 90Â° 4. Lower the bucket to the ground. 5. Operate the controls to push the boom down so that the track nearest the bucket is lifted clear of the ground. Refer to Figure 159. Figure 159.

6. When it is safe to do so and you are sure that everyone is clear of the machine, operate the controls to turn the track which is off the ground. 7. Turn the track one way and then the other to shake off the mud. If necessary, the person outside can use water from a hose to help loosen the sticky material. 8. When the track is clean, stop the movement. 9. Examine the track, roller sprockets and idler wheels for damage or oil leaks. Replace any damaged parts. If in doubt contact your JCB dealer. 10. Operate the controls slowly to lower the track to the ground. 11. Operate the controls to slew the boom to the other side of the machine, then repeat the steps 2 to 10 and clean the other track.

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Maintenance Tracks

Steel Check (Operation) Warning! Recoil unit servicing must only be carried out by JCB dealers. You could be killed or injured if you tamper with it. Notice: Always make sure that the track tension measurement is not less than specified or severe strain to the track will result.

Check/Adjust the Track Tension 1. Stop the machine on solid, level ground. 2. Move the machine backwards and forwards several times, then move the machine forwards and stop it on level ground. 3. Stop the engine. 4. Check the track tension. Figure 160. A

Track tension - measurement

4.1. Place a long, stiff and straight piece of steel or wood on top of the tracks touching above the front idler and the top roller. 5. Make sure the track tension is within the specified limits. Refer to: Technical Data > Tracks (Page 170). 6. If necessary, adjust the track tension. 6.1. To adjust the track tension, inject or release grease from the check valve. 6.2. Inject grease to increase the tension. 6.3. Release grease to decrease the tension. 6.4. When you open the check valve, always stand to one side and loosen it a slowly until the grease starts to release. 6.5. Do not loosen the check valve too much, grease can spurt out or the cover of the check valve can come off and cause serious injury. 7. Never attempt to disassemble the check valve or try to remove the grease point from the check valve. 8. If there is a clearance between the idler wheel shaft and the track frame, use pressure to apply the grease. 9. If there is no clearance after the application of grease, then contact your JCB dealer for any service requirements. 152

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Maintenance Tracks

10. Do not tension the tracks too much, this will cause the track rail to wear the drive rollers and sprocket. 11. Always make sure you adjust the track tension to the specified limits. Incorrect tension can cause wear to the drive sprocket and the track rail. Refer to: Technical Data > Tracks (Page 170). 12. Repeat the procedure for the other track.

Check (Condition) Check the condition of the track plates. Check the track plate bolt torques. Refer to: Technical Data > Torque Values (Page 166).

Idler Wheels Check (Condition) 1. Stop the machine on solid, level ground. 2. Do the steps 2 to 12 of Check/Adjust the Track Tension. Refer to: Maintenance > Tracks > Steel > Check (Operation) (Page 152). 3. Check the top and bottom rollers for oil leaks. If leaks are found contact your JCB dealer 4. Repeat the steps 2 to 3 for the other track.

Rollers Check (Condition) 1. Stop the machine on solid, level ground. 2. Do the steps 2 to 12 of Check/Adjust the Track Tension. Refer to: Maintenance > Tracks > Steel > Check (Operation) (Page 152). 3. Check the idler wheels for oil leaks. If leaks are found contact your JCB dealer. 4. Repeat the steps 2 to 3 for the other track.

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Maintenance Track Gearbox

Track Gearbox Oil Check (Level) 1. Make the machine safe, with the fill/level and drain plugs in the positions shown. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 125). A

Figure 161.

A B

Fill\level plug Drain plug

2. Clean the area around the fill/level plug. 3. Remove the fill/level plug. 4. Make sure that the oil inside the gearbox is level with the fill/level plug. 5. If necessary, add the recommended oil through the fill/level plug hole. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 164). 6. Clean the fill/level plug. 7. Install the fill/level plug. Tighten the fill/level plug to the correct torque value. Refer to: Technical Data > Torque Values (Page 166). 8. Check the oil level on the other side. Repeat the steps 1 to 7.

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Maintenance Hydraulic System

Hydraulic System General Discharge 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 125). 2. Turn the ignition key to the on position. 3. Lower the controls isolation lever and push the controls isolation switch. Refer to: Operation > Locks > Control Lock (Page 44). 4. Operate the hand controllers in all directions to release the pressure from the hydraulic system. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 55). 5. Turn the ignition key to the off position. 6. Remove the ignition key. 7. Push the rubber boot on the hydraulic tank breather to release the pressure from the tank. Refer to: Maintenance > Service Points (Page 126).

Check (Condition) Hydraulic Hoses Warning! Damaged hoses can cause fatal accidents. Examine the hoses regularly. Do not use the machine if a hose or hose fixture is damaged. Examine the hoses for: • • • • • •

Damaged hose ends Worn outer covers Ballooned outer covers Kinked or crushed hoses Embedded armouring in the outer covers Displaced hose end fittings.

Replace a damaged hose before you use the machine again. The replacement hoses must be of the same size and standard. If necessary, for more information contact your JCB dealer.

Accumulator 1. Stop the machine on solid, level ground. 2. Raise the boom and extend the dipper. Refer to: Operation > Operating Levers/Pedals (Page 55). 3. Stop the engine. Do not raise the controls isolation lever. Refer to: Operation > Locks (Page 44). 4. Lower the boom. Stop the boom several metres from the ground. 5. Lower the boom to the ground. There must be sufficient pressure stored in the accumulator to lower the boom to the ground in two stages. If this is not possible, contact your JCB dealer. 155

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Maintenance Hydraulic System

Check (Leaks) Notice: If the fluid is cloudy, then water or air has contaminated the system. This could damage the hydraulic pump. Contact your JCB dealer immediately. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Open the access covers. Refer to: Maintenance > Access Apertures (Page 132). 3. Check the hydraulic hoses for damage. Refer to: Maintenance > Hydraulic System > General > Check (Condition) (Page 155). 4. Close the access covers. 5. If necessary, contact your JCB dealer.

Services Check (Operation) Check the operation of all the hydraulic services. Check for: • • • •

Speed of operation Strength of operation Juddering Abnormal noises.

Do not use the machine if one or more of these faults are found. You must make sure that the hydraulic service is repaired immediately.

Oil Check (Level) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Look at the hydraulic fluid in the sight tube. If the hydraulic fluid is cloudy, water or air is in the system. Water or air in the system can damage the hydraulic pump. Contact your JCB dealer if the hydraulic fluid is cloudy. Refer to: Maintenance > Service Points (Page 126). 3. The level of hydraulic fluid should be between the two marks on the sight tube. 4. If necessary, add the recommended hydraulic fluid: Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 164). 4.1. Release the pressure from the hydraulic tank. Refer to: Maintenance > Hydraulic System > General > Discharge (Page 155). 4.2. Get safe access to the hydraulic filler port. Refer to: Maintenance > Service Points (Page 126). 4.3. Remove its cover plate to access the hydraulic filler port. 4.4. Use a suitable container to add the hydraulic fluid through the filler port. 4.5. Check the level of hydraulic fluid. 156

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Maintenance Hydraulic System

4.6. Attach the cover plate.

Cylinder Rams Check (Condition) Extend each ram fully, one at a time and visually examine for score marks, dents or similar defects. Make the machine safe before inspecting each ram. If a ram piston appears defective, contact your service engineer or JCB dealer.

157

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Maintenance Electrical System

Electrical System General Check (Operation) Make sure all of the electrical equipment operates correctly, for example: • • • • • • • • •

Switches Warning lights Beacon Alarms Horn Wipers Hourmeter/display Battery Lights

All defective equipment must be repaired before the machine is used.

Check (Condition) Warning! Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses. Warning! Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal. Use a hydrometer or voltmeter. Caution! Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. Examine the electrical circuits regularly for: • • • • • •

Damaged connectors Loose connections Chafing on the wiring harnesses Corrosion Missing insulation Incorrect routing of the wiring harnesses.

Do not use the machine if one or more of these faults are found. You must make sure that the electrical circuit is repaired immediately.

Battery Clean Warning! Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metal work. If it happens you can get burned. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Get access to the battery. Refer to: Maintenance > Access Apertures (Page 132). 3. If the terminal posts are corroded and covered with white powder wash them with hot water. If there is considerable corrosion, clean the terminal posts with a wire brush or abrasive paper. Refer to Figure 162.

158

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158

Maintenance Electrical System

Figure 162.

4. Apply a thin layer of petroleum jelly to the terminal posts.

Connect Caution! The machine is negatively earthed. Always connect the negative pole of the battery to earth. When connecting the battery, connect the earth (-) lead last. When disconnecting the battery, disconnect the earth (-) lead first. 1. Get access to the batteries. Refer to: Maintenance > Electrical System > Battery > Disconnect (Page 159). 2. Connect the battery leads. Connect the earth (-) terminal last. 3. If the machine has a battery isolator, move the switch to the on position. Refer to: Operation > Battery Isolator (Page 77).

Disconnect Caution! The machine is negatively earthed. Always connect the negative pole of the battery to earth. When connecting the battery, connect the earth (-) lead last. When disconnecting the battery, disconnect the earth (-) lead first. Notice: Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Get access to the batteries. Refer to: Maintenance > Access Apertures (Page 132). 3. If the machine has a battery isolator, move the switch to the off position then remove the key. Refer to: Operation > Battery Isolator (Page 77). 4. Disconnect the battery leads. Disconnect the earth (-) terminal first.

Battery Isolator Check (Operation) Notice: Do not isolate the machine electrics when the engine is running, this may cause damage to the machine electrics.

159

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Maintenance Electrical System

1. Isolate the machine electrics. Refer to: Operation > Battery Isolator (Page 77). 2. Make sure that the machine electrics are isolated. A defective isolator must be repaired before the machine is used. For more information, contact your JCB dealer.

Fuses Replace Notice: Always replace fuses with ones of correct ampere rating to avoid electrical system damage. The electrical circuits are protected by fuses. If a fuse blows, find out why before a new one is installed. For more information on the individual fuses: Refer to: Maintenance > Electrical System > Fuses (Page 160). Fuse - Cab The fuses are installed to the right side of the operator seat on the side lower panel. Open the cover to get access to the fuses. For fuse identification, a label is attached to the rear of cover. Figure 163.

Fuses

Relays Replace Introduction For more information on the individual relays: Refer to: Technical Data > Electrical System > Relays (Page 168). Relays - Cab The relays are installed to the right side of the operator seat on the side lower panel. Open the cover to get access to the relays. For relay identification, a label is attached to the rear of cover. Refer to: Technical Data > Electrical System > Relays (Page 168).

160

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Maintenance Electrical System

Figure 164.

Relays

Window Washer Check (Level) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 125). 2. Get access to the front window washer bottle. Refer to: Maintenance > Service Points > General (Page 126). 3. Remove the filler cap. 4. Fill the washer bottle with clean water. The liquid should contain a de-icing fluid to prevent it freezing. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 164). 5. Replace the filler cap. Do not use engine coolant antifreeze. Do not use the window washer when there is no liquid in the washer bottle as it will cause damage to the motor.

161

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Technical Data Static Dimensions

Technical Data

Static Dimensions Dimensions Figure 165. E H

Table 17. A B C D

Description Track length on ground Undercarriage overall length Track gauge Width over tracks

Length 2,244mm 2,817mm 1,700mm 2,150mm Table 18.

Dipper lengths E Transport length F Transport height

1,950mm 6,226mm 2,768mm Table 19.

G H I J K L M

Description Counterweight clearance Tailswing radius Width of superstructure Height over cab Height over grab rail Ground clearance Track height

Length 775mm 1,866mm 2,228mm 2,722mm 2,722mm 365mm 666mm

Weights Shipping Weight An approximate weight when the machine has a monoboom, medium length dipper, bucket, operator and a full fuel tank. Table 20. Track shoe width 450mm

162

Dozer Dozer

Weight 8,400kg

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Technical Data Performance Dimensions

Performance Dimensions Excavator Arm Dimensions and Performance Digging Monoboom Figure 166. A B

C 7

Metres

C F

Metres

Table 21. Boom length Dipper length A Maximum digging reach B Maximum digging reach (on ground) C Maximum digging depth D Maximum digging height E Maximum dumping height F Maximum vertical wall cut depth G Maximum swing radius

3,700mm 1,740mm 6,314mm 6,062mm 3,940mm 7,094mm 5,401mm 3,675mm 1,841mm

Driving Performance The maximum travel speed of all JS Tracked Excavators is no more than 5.1km/h.

163

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Technical Data Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities General JCB recommend that you use the JCB lubricants shown as they have been verified by JCB for use on JCB machines. However, you could use other lubricants that are equivalent to the JCB standards and quality or offer the same machine component protection. Table 22. Fluids, Lubricants and Capacities Item Fuel Tank Engine (Oil)

(2)

Cooling System Track Gearbox (each) Slew Gearbox Track Rollers and Idler Wheels Recoil Spring Cylinder Hydraulic System Slew Ring Bearings Slew Ring Gear Teeth All Other Grease

Capacity

Fluid/Lubricant

164L 14L

Diesel Above -10°C: JCB Engine MAX 15W40 C14+ Castrol Antifreeze HP/Coolant JCB HD90 Gear Oil JCB HD90 Gear Oil JCB HD90 Gear Oil

16L 1.7L 3.5L

92L As required 17kg As required

JCB Special HP Grease JCB Hydraulic Fluid HP32-10°C to 30°C JCB Special HP Grease JCB Special HP Grease JCB Special HP Grease

JCB Part Number 4001/3200 229/01233 4000/0300 4000/0300 4000/0300 4003/2000 229/00024 4003/2000 4003/2000 4003/2000

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

Coolant Caution! Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze. 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. 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. The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below. Table 23. Concentration 50% (Standard) 60% (Extreme Conditions Only)

Level of protection Protects against damage down to -40°C Protects against damage down to -56°C

Do not exceed a 60% concentration, as the freezing protection provided reduces beyond this point. If you use any other brand of antifreeze: • • •

164

Make sure that the antifreeze complies with International Specification ASTM D6210 Always read and understand the manufacturer's instructions Make sure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used 9821/9600-1A

164

Technical Data Fluids, Lubricants and Capacities

â&#x20AC;˘

165

Make sure that the antifreeze is ethylene glycol based and does not use Organic Acid Technology (OAT).

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Technical Data Torque Values

Torque Values General Before and after daily work, check for loose or missing nuts and bolts. Tighten if loose and replace if missing. Tighten the nuts and bolts after the first 50h of the running-in stage and then every 250h. Tighten the nuts and bolts, Refer to Table 24. Table 24. Tightening Point

Bolt Diameter

Wrench (mm)

Travel motor

M16

Tightening Torque N·m 259

Drive sprocket

M14

167

Idler wheel

M14

167

Upper (carrier) roller

M16

259

Lower (track) roller

M12

104

Track guard

M12

104

Shoe bolt M14 Counterweight M30 Turntable bearing (undercarriage) M16

22 46 24

250 1,930 259

Turntable bearing (revolving frame) Slew equipment

M16

259

M16

259

Slew motor Engine (engine mount)

M12 M16

19 24

125 259

Engine bracket

M12

125

Radiator Hydraulic pump

M8 M16

13 24

30 259

Hydraulic oil tank

M16

259

Fuel tank

M16

259

Control valve

M12

116

Battery

12.5

Rotary coupling

Rotary coupling Y bracket

M12

104

Rotary coupling bracket

M10

24 25

Cab mount to revolver

M10

Cab to floor plate

M16

259

(1)

6 7 8

(1)

11 12

(1)

14 15

(1)

(1) (1) (1)

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 25. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

166

mm N·m

M6 10 12.5

M8 13 30

M10 17 60

M12 19 104

M14 22 167

M16 24 259

M18 27 506

M20 30 874

mm N·m

5 15

6 36

8 72

10 125

12 200

14 311

16 -

17 607

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Technical Data Electrical System

Electrical System General Table 27. Item System voltage

Specification 12V

Fuses Fuses - Cab Figure 167. A

Table 28. Fuse Identification Fuse A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 C1 C2 C3 C4 C5 D1 D2 167

Circuit(s) Protected Spare fuse Starter Livelink Radio Spare fuse HVAC (if installed) Compressor (if installed) Power socket Spare fuse Radio Livelink ground Wiper Gauge coil Spare fuse Swing lock

Rating 5A 40A 3A 3A 10A 10A 5A 10A 40A 10A 3A 10A 10A 30A 10A 9821/9600-1A

167

Technical Data Electrical System

Fuse D3 D4 D5 E1 E2 E3 E4 E5 F1 F2 F3 F4 F5

Circuit(s) Protected Lever lock Horn Interior lamp Fuse puller Wiper Battery Fed Face fan Ignition I/P Fuse box label CWT Lamp Work / boom lamps Time relay - Auto idle relay Parking lights

Rating 5A 10A 5A 10A 40A 10A 30A 10A 30A 5A 5A

Relays Relays - Cab (Machines with HVAC) Figure 168. A

Table 29. Relay Identification Relay A B C D E F

168

Circuit(s) Horn and auto idle Timer Boom/work lights Hydraulic and wiper Starter Buzzer

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168

Technical Data Electrical System

Relays - Cab (Machines without HVAC) Figure 169. A

Table 30. Relay Identification Relay A B C D E F

169

Circuit(s) Horn and auto idle Buzzer Starter Boom/work lights Timer Hydraulic and wiper

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169

Technical Data Tracks

Tracks General Table 31. Track Tension (Hard Ground Conditions) Minimum Track Tension 13mm

Maximum Track Tension 24mm Table 32. Track Tension (Soft Ground Conditions)

Minimum Track Tension 40mm

170

Maximum Track Tension 50mm

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Section B Body & Framework Service Manual - JS81 Section 1 - General Information Section 2 - Operator’s Manual Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/2000-02

Section B - Body and Framework

Notes:

B-0

9813/2000-02

B-0

Section B - Body & Framework Contents

Contents Page No. Specifications Static Dimensions .................................................................................... B - 1 JS81 ................................................................................................... B - 1 Dig Depth Chart ....................................................................................... B - 2 JS81 ................................................................................................... B - 2 Shipping Weight ...................................................................................... B - 3 Static Dimensions (Serial Number - 24266501 to 2427000) ................... B - 4 JS81 ................................................................................................... B - 4 Dig Depth Chart (Serial Number - 24266501 to 2427000) ...................... B - 5 JS81 ................................................................................................... B - 5 Shipping Weight (Serial Number - 24266501 to 2427000) ...................... B - 6 Driving Performance ................................................................................ B - 7 Service Procedures Cab Structure .......................................................................................... B - 9 Direct Glazing ..................................................................................... B - 9 Checks ............................................................................................. B - 15 Air Conditioning (Optional) .............................................................................................................. B - 17 System Charging .............................................................................. B - 21 Refrigerant Leaks Detections ........................................................... B - 22 Lubrications ...................................................................................... B - 23 System Flushing ............................................................................... B - 25 Fault Finding Air Conditioning ..................................................................................... B - 27 System Initial Check Points .............................................................. B - 27 Temperature Pressure Data ............................................................. B - 27 System Diagnosis based on Pressures ............................................ B - 28 Gauges Reading Interpretation ........................................................ B - 29 Noise from A/C System .................................................................... B - 30 Unpleasant Odour from A/C System ................................................ B - 30 Cab Panels Cab Panel Removal ............................................................................... B - 31 Right Hand Cab Panels .................................................................... B - 31 Left Hand Cab Panels ...................................................................... B - 32 Wiper/Wash (Optional) .......................................................................... B - 33 Removal and Replacement .............................................................. B - 33 Replacement .................................................................................... B - 33

B-i

Section B - Body & Framework Specifications Static Dimensions

Specifications Static Dimensions JS81

G H I N

A B Fig 1. Table 1. Dimensions in millimetres (ft. in) A

Track length on ground

2200 (7-2)

Undercarriage overall length

2830 (9-3)

Counterweight Clearance

767 (5-6)

Tail swing radius

1580 (5-2)

Width of superstructure

2220 (7-3)

Table 2. Dipper lengths

2.4m* (7ft 10in)

Transport length with monoboom and without cab hand rail

5900 (19-4)

Transport height with monoboom and without cab hand rail

2690 (8-9)

Dimensions in millimetres (ft. in)

Table 3. Dozer Blade (Standard)

Height over cab

2625 (8-7)

Maximum height (Above ground)

375 (1-2)

Ground clearance

363 (1-2)

Dig Depth (Below ground)

235 (0-9)

Track gauge

1700 (5-6)

Approach Angle

26Â°

Width over Tracks (450 mm Shoes)

2150 (7-0)

Width

2320 (7-7)

Track Height

665 (2-2)

Height

460 (1-6)

Dozer blade width (back fill)

2320 (7-7)

Reach in Front of Tracks

480 (1-6)

B-1

9813/2000-02

B-1

Section B - Body & Framework Specifications Dig Depth Chart

Dig Depth Chart JS81

Fig 2. Table 4. m (ft in)

m (ft in)

Dipper

1.74 (5.85)

2.18 (7.18)

Maximum digging reach

6.36 (20-10)

6.81 (22-4)

Maximum digging reach (on ground)

6.22 (24 5)

6.68 (21-10)

Maximum digging depth

4.13 (15 10)

4.57 (14-12)

Maximum digging height

7.23 (28 1)

7.66 (25-1)

Maximum dumping height

5.15 (20)

5.56 (18-2)

Maximum vertical wall cut depth

3.48 (14)

4.05 (13-3)

Maximum swing radius

1.75 (8 7)

2.05 (6-8)

Dipper tearout

4000 Kgf

3500 Kgf

Bucket tear out

5700 Kgf

Bucket Rotation (deg)

184 °

B-2

9813/2000-02

B-2

Section B - Body & Framework Specifications Shipping Weight

Shipping Weight Approximate weight when equipped with monoboom, medium length dipper, bucket, operator and full fuel tank except where indicated otherwise.

Model

Table 5. Track shoe width

Weight

JS81

450mm

8100 kg

B-3

9813/2000-02

B-3

Section B - Body & Framework Specifications Static Dimensions (Serial Number - 24266501 to 2427000)

Static Dimensions (Serial Number - 24266501 to 2427000) JS81 E H

M L C

B P041950-52

Fig 3. Table 6. Dimensions

Length

Track length on ground

2,244mm

Undercarriage overall length

2,817mm

Track gauge

1,700mm

Width over tracks

2,150mm Table 7.

Dipper lengths

1,950mm

Transport length

6,226mm

Transport height

2,768mm

Description

Length

Counterweight clearance

775mm

Tailswing radius

1,866mm

Width of superstructure

2,228mm

Height over cab

2,722mm

Height over grab rail

2,722mm

Ground clearance

365mm

Track height

666mm

B-4

9813/2000-02

B-4

Section B - Body & Framework Specifications Dig Depth Chart (Serial Number - 24266501 to 2427000)

Dig Depth Chart (Serial Number - 24266501 to 2427000) JS81 A B C 7

D 3

Metres

C F

Metres

P041950-53

Fig 4. Table 8. Boom length

3,700mm

Dipper length

1,740mm

Maximum digging reach

6,314mm

Maximum digging reach (on ground)

6,062mm

Maximum digging depth

3,940mm

Maximum digging height

7,094mm

Maximum dumping height

5,401mm

Maximum vertical wall cut depth

3,675mm

Maximum swing radius

1,841mm

B-5

9813/2000-02

B-5

Section B - Body & Framework Specifications Shipping Weight (Serial Number - 24266501 to 2427000)

Shipping Weight (Serial Number - 24266501 to 2427000) Approximate weight when equipped with monoboom, medium length dipper, bucket, operator and full fuel tank except where indicated otherwise.

Model

Table 9. Track shoe width

Weight

JS81

450mm

8400 kg

B-6

9813/2000-02

B-6

Section B - Body & Framework Specifications Driving Performance

Driving Performance The maximum travel speed of all JS Tracked Excavators is not more than 3.5km/h (2.2mph).

B-7

9813/2000-02

B-7

Section B - Body & Framework Specifications Driving Performance

Page left intentionally blank

B-8

9813/2000-02

B-8

Section B - Body and Framework

Service Procedures Cab Structure

!MWARNING

Direct Glazing TB-002_4

The following procedures explain how to correctly remove and install panes of glass that are directly bonded to the cab frame apertures. When carrying out the procedures, relevant safety precautions must be taken. 1

Always wear safety glasses during both removal and replacement.

Use protective gloves - heavy duty leather gauntlet type gloves when cutting out the broken glass; 'nonslip' type gloves when handling/moving panes of glass; surgical type gloves when using the polyurethane adhesives.

Wear protective overalls.

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

Do not attempt to handle or move panes of glass unless you are using glass lifters.

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).

Laminated glass must be handled with extra care to prevent breakage. Wherever possible, store and handle it in a vertical attitude. When placing or lifting the glass in a horizontal attitude it must be supported over its whole area, not just at the edges. BF-1-8_1

Removing the Broken Glass and Old Sealant

!MWARNING Always wear safety glasses when removing or installing screen glass. Never use a power operated knife when removing the sealant around a toughened glass screen. The action of the knife could cause particles of glass to be thrown with sufficient force to cause serious injury, even when safety glasses are being worn. Use only hand operated tools when working with toughened glass. BF-2-3_1

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

If a laminated pane breaks it will stay in one piece even though the glass is cracked. A toughened pane will shatter and fall apart. The method of removal of the glass depends upon which type it is.

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-9

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.

9813/2000-02

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-9

Section B - Body and Framework Service Procedures Cab Structure a

Pneumatic Knife. K Fig 5. ( T B-10). 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 5. Pneumatic Knife i

Press the handle to start the knife blade oscillating.

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

Fig 6. 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 6. ( T B-10). This method uses a 3-core wire, a wire starter tube and two handles. i

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

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

B-10

9813/2000-02

Insert the braided cutting wire 6-B down the centre of the steel tube. If necessary, from the outside, cut out local sealant at the point of the tube to gain access to the wire.

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.

Cut-out Knife. K Fig 7. ( T B-11). The cut-out knife can be used as a left handed or right handed tool.

B-10

Section B - Body and Framework Service Procedures Cab Structure 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 9. ( T B-11)

1-2 mm

Fig 7. Cut-out Knife

Fig 9.

Insert the knife blade into the sealant.

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

iii Use the 'pull-handle' to pull the knife along and cut out the old sealant. d Craft Knife. K Fig 8. ( T B-11). The blades 8-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 8. 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.

B-11

9813/2000-02

B-11

Section B - Body and Framework Service Procedures Cab Structure 1

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

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

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

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

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

Fig 10. 2

Fig 12.

After checking for size, remove the new glass and place it on a purpose made glass stand. K Fig 11. ( T B-12).

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

B-12

9813/2000-02

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-12

Section B - Body and Framework Service Procedures Cab Structure Note: Do not touch the glass after cleaning with the 'Active Wipe 205'. b If the glass does not have a black ceramic ink band, paint a band on the glass using 'Black Primer 206J'. The band should be approximately 25mm (1in) wide, and the edge should be a neat straight line. K Fig 13. ( T B-13).

Fig 14. 6

Apply the pre-heated adhesive to the glass (do not start in a corner). Keep the nozzle guide 15-A against the edge of the glass and make sure that the adhesive forms a continuous 'pyramid' shape. K Fig 15. ( T B-13)

Fig 13. 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 15. 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 14. ( T B-13). 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-11) - step 1.

Install the glass in the frame aperture: a

B-13

9813/2000-02

Always use the special lifting tools when moving the glass. Use a lifting strap to hold large panes of glass in position. K Fig 16. ( T B-14)

B-13

Section B - Body and Framework Service Procedures Cab Structure 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 16. 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 17. ( T B-14)

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

Fig 17. c

Make sure that the glass is correctly positioned, then gently press around the edges of the glass and ensure full adhesive contact is achieved. Do not press too hard or too much adhesive will squeeze out.

Make the inside seal smooth: a

Wearing surgical gloves, dip your finger in a soapy water solution.

b Use your finger to make the inside seal smooth.

B-14

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B-14

Section B - Body and Framework Service Procedures Cab Structure

Checks Failure to take these precautions could result in death or injury to the operator. Check the structure for damage. Check that the six mounting bolts A are installed and undamaged. Check the bolt torques. Tighten them to the correct torque if necessary.

B-15

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B-15

Section B - Body and Framework Service Procedures Cab Structure

Page left intentionally blank

B-16

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B-16

Section B - Body and Framework

Air Conditioning (Optional)

C B

A P041530-22

Fig 18. Item

B-17

Description

Air Conditioning unit

Control panel

Receiver/Dryer

Dryer mounting bracket

Condensor

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B-17

Section B - Body and Framework Air Conditioning (Optional)

A P041680-69

Fig 19. AC Control Panel Item

B-18

Description

Air conditioning switch

Air conditioning switch - position 1

Air conditioning switch - position 2

3-speed fan switch

Temperature switch

Recirculation switch

Recirculation switch - position 1

Recirculation switch - position 2

9813/2000-02

B-18

B-19

CONTROL PANEL

AC UNIT VEHICLE CONNECTION

1 2

+12V

30 AMP

+A THERMOSTAT SB VARIABLE -C

RECIRC

SD -C +A

BLOWER

+1 -2

COMPRESSOR CLUTCH

GROUND 3 CLUTCH

HIGH PRESSURE SWITCH

POT AC 50K

OUT

RESISTOR

1 2 OUT

A/C SWITCH

LOW PRESSURE SWITCH OUT SP1

FR / RECIRC SWITCH

CLUTCH RELAY

9813/2000-02

C 3 2

BLOWER SWITCH

B-19

Air Conditioning (Optional)

P041680-70

Fig 20. AC Electrical Schematic (Sheet 1 of 2)

Section B - Body and Framework

B-20

(-) C1 BLOWER

HVAC UNIT

(+)

+12V A

C10 SIGNAL THERMOSTAT

B C

SP1

GROUND F E

C11 RECIRC ACTUATOR

GROUND SIGNAL

D C

SP1

B A

+12V

SP2

GROUND SIGNAL +12V

1 2 3 4 5 6

+12V CLUTCH OFF FR/RC SIGNAL TEMP SIGNAL

SP1

B A

SP2

K2 CLUTCH RELAY

NAME

C4 VEHICLE HARNESS

SP1

CAVITY LENGTH -

885

SP1

C9 PWM UNIT

175

SP1

C9 PWM UNIT

175

SP1

C1 BLOWER

355

SP1

K2 CLUTCH RELAY

805

SP1

C4 VEHICLE CONNECTOR

885

C9 PWM UNIT

C4 VEHICLE CONNECTOR

1060

C9 PWM UNIT

C1 BLOWER

530

C9 PWM UNIT

SP2

960

SP2

C8 WATER VALVE

380

SP2

C11 RECIRC ACTUATOR

550

GROUND

SP2

C4 VEHICLE CONNECTOR

100

K2 CLUTCH RELAY

C10 THERMOSTAT

500

K2 CLUTCH RELAY

C4 VEHICLE CONNECTOR

340

K2 CLUTCH RELAY

C4 VEHICLE CONNECTOR

340

SPEED 2

C8 WATER VALVE

SP3

295

SPEED 3

C8 WATER VALVE

C4 VEHICLE CONNECTOR

480

C11 RECIRC ACTUATOR

SP3

885

C11 RECIRC ACTUATOR

C4 VEHICLE CONNECTOR

650

SPPED 1

SP1

CAVITY

85 86

NAME

SP2

C10 THERMOSTAT

C4 VEHICLE CONNECTOR

580

C4 VEHICLE CONNECTOR

SP3

595

C9 PWM UNIT

SP3

525

SPEED1

RESISTOR

SPEED2 SPEED3

SP3

B-20

Air Conditioning (Optional)

P041680-71

Fig 21. (Sheet 2 of 2)

Section B - Body and Framework

9813/2000-02

87 87a

1 2 3 4

ITEM

D C

FROM

12V ACTUATOR & COMP

DEUTSCH 4 WAY CONNECTOR DTP-04-C012

F E

C8 WATER VALVE ACTUATOR

WIRE TABLE

DEUTSCH 6 WAY CONNECTOR DT04-6P-CL09

Section B - Body and Framework Air Conditioning (Optional) System Charging Refrigerant can be charged as liquid (through high pressure side and in A/C off condition) or vapour (through low pressure side and in A/C on condition) into the system. Normally the vapour method preferred and below is the detail procedure for the same.

System Charging Procedure (Vapour Charging) To charge the system with vapour refrigerant engine need to be running and A/C switched on. 1

Identify the system charge capacity.

Connect the gauges to the system charging ports.

Put the refrigerant cylinder on the electronic scales and connect the yellow hose from the gauges to the vapour valve on the cylinder.

Zero the electronic scales.

Open the vapour valve on the top of the cylinder and let the refrigerant go into yellow hose.

Bleed off a small amount of air from yellow hose at gauge manifold.

Open Blue valve ONLY on the gauges and let refrigerant vapour flow into the system.

When the system pressure equalises with the cylinder pressure, start the vehicle, switch on the AC and let the compressor pull in the required amount of refrigerant as shown on the digital display on scales.

Upon completion of vapour charging, shut the valve on top of refrigerant cylinder then blue valve on the gauges.

Remove the gauges; put the back cap on charging ports.

Charging Complete.

B-21

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B-21

Section B - Body and Framework Air Conditioning (Optional) Refrigerant Leaks Detections

Ultrasonic leak Detection

Refrigerant leaks must be found and rectified as a low refrigerant charge will cause system damage:

Ultrasonic leak detection kit is only now becoming affordable to the average ac service technician. The advantage of this equipment is that it can be used to identify leaking components in area which are Inaccessible with our basic equipment set up. This method of leak detection need skilled person to make a judgment.

â&#x20AC;&#x201C; Air and moisture can enter a system at the leak point and cause internal components to corrode and cause freezing in TXV. â&#x20AC;&#x201C; Compressor lubrication depends on refrigerant circulation. â&#x20AC;&#x201C; Refrigerant helps cool the compressor. Below are the various ways to detect the leak.

Visual Leak Detection When a refrigerant leak occurs, it is common in some cases for the lubricant oil to escape with the refrigerant. The presence of oil in encrusted dust around the hose fittings, joints and components can indicate a refrigerant leak is present.

Soap Solution A mixture of dishwashing liquid and water applied around the A/C system pipes and fittings will form bubbles if a leak is present.

Electronic Leak Detector Electronic leak detectors operate in various ways. The most common being that when the unit is turned on, a low ticking sound can be heard and once the probe locates a leak, the ticking sound increases to a high pitched noise. This can be achieved by moving the sensing tip slowly around the underside of components and fittings at a distance of approximately 5 mm. DO NOT allow the sensing tip to contact components or fittings as false readings and tip damage will occur.

Ultraviolet Fluroscent System A fluorescent coloured dye is injected into the A/C system and allowed to circulate, and then a specially designed ultraviolet lamp is passed over each component in the A/C system. If a leak is evident, the coloured dye glows bright. This method is exceptionally good for pin pointing a small leak.

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B-22

Section B - Body and Framework Air Conditioning (Optional) Lubrications

Compressor (New Replacement)

To keep the Compressor and the various seals in the system the lubrication is used in the a/c systems. The lubricating oil runs in the system along with the refrigerant.

Drain and measure the lubricating oil from removed compressor. Likewise, remove the oil from the new compressor, refill this new compressor with the same quantity of oil drained from the old compressor.

It is very important to maintain the desired level of the oil in system, as access oil effect the system performance and less oil increase the wear and tear of compressor and result in early failure. The new system comes with required amount of oil but in servicing while replacing any part the oil need to be topped up. Below are the details.

On compressors without inspection plugs, add oil to compressor through the discharge and suction ports, turn the compressor pulley several times by hand to make sure no oil is trapped in the compressor chambers. Use the new clean oil removed from the new compressor plus 10cc to allow for any internal oil. K Fig 23. ( T B-24).

Component Replacement During the replacement any of the system part checks vehicle service manual to find the amount of oil need to be added for various parts. Below are the are approximate values: Evaporator

40ml

Filter drier

30ml

Condenser

30ml

IRD Condensor

50ml

Hose assembly

20-40ml (depending on the length)

B-23

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B-23

Section B - Body and Framework Air Conditioning (Optional)

P041680-67

Fig 22. AC Compressor

P041680-68

Fig 23. AC Compressor Installation Item

Desription

Compressor

Mounting bracket

Mounting

Air Conditioning unit

B-24

9813/2000-02

B-24

Section B - Body and Framework Air Conditioning (Optional) System Flushing The reason we flush the air conditioning system is to remove any contamination which could arise from component failure, bad service and/or repair procedure, compressor seized or damaged, contaminated oil being found in the system. There are a number of options available but we must remember the objective of the exercise which is to remove contamination. Therefore, the recommended method would be to use a purpose built flushing system utilising the system refrigerant (R134a) as the flushing medium. If any flushing agents other than 134a are used, the system must be evacuated for an extensive period of time in an attempt to remove all the traces of the agent before re-charging the system with refrigerant before re-charging the system refrigerant. Improper flushing will lead to blockage in the condenser, filter drier or TXV and repeat component failure may occur. When flushing through the condenser and evaporator, some of the paths may remain blocked and this will affect the system performance. When this occurs, it may be a better option to replace the component. After finishing flushing, blowing the system with dry nitrogen is recommended.

B-25

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B-25

Section B - Body and Framework Air Conditioning (Optional)

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B-26

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B-26

Section B - Body and Framework

Fault Finding Air Conditioning System Initial Check Points

A/C On

Before servicing or diagnosing an A/C system there are preliminary checks that should take place. These include but not limited to:

Max Cold Top Blower Speed

– Check the all control knob positions. – Checking for visual hose damage and chaffing. – Ensure the condenser cooling fins are not blocked with obstructions such as insects, leaves or grass.

Fresh air position 7

Start engine, bring engine rpm to half of rated engine rpm then allow pressure gauge needles to stabilize.

Take pressure and temperature readings. Compare this to the manufacturers performance charts found in appropriate workshop manuals.

– Condenser fan operates and runs in correct direction. – Inspect drive belts for correct tension and damage. – Compressor cycles on and off. – Evaporator drain hose not blocked. – Heater turned off in the full cold mode position.

Note: Only take pressure and temperature readings when the compressor is engaged.

– Blower fan has all speeds operational. – Air mix door fully closed. – Dash vents open and close fully. – No air leaks between evaporator case and heater case.

Temperature Pressure Data 1

Park vehicle in a shaded area. Take note of ambient temperature.

Open both front windows and engine hood.

Connect both high and low pressure service hose coupling valves to the system charging ports.

Open all dash louvers and adjust to the straightahead position.

Insert thermometer probe approximately 50 mm into the centre vent louver.

B-27

Set the controls to:

Note: Compare these vent temp and the pressure reading with the manufacturer’s specifications on that particular ambient. If the readings are comparable then system working fine, If not then proceeds for the further diagnosis with the help of pressure gauges.

9813/2000-02

B-27

Section B - Body and Framework Fault Finding Air Conditioning

System Diagnosis based on Pressures The below two graphs are showing the values of suction and discharge pressure. Most of the system operates in this region but not all. It is always recommended to have these two charts for the every system and should be the part of vehicle service manual. Then during servicing the actual values need to be compared with individual system graphs. Note: Pressure gauge readings (low & high) depend on outside temperature.

B-28

9813/2000-02

B-28

Section B - Body and Framework Fault Finding Air Conditioning possible problem. Below table shows the possible causes associated with particular type of gauge reading;

Gauges Reading Interpretation

As we have mentioned before, correct pressure gauges reading may show particular problem associate to a Problem Low Pressure Gauge High Pressure Gauge No Cooling/ Normal Less Cooling

Normal or low

Probable Causes

Normal

Warm air infiltrated into the evaporating unit or passenger compartment.Warm water infiltrated in the heaterBlend door position or blend door failure.

Low

Normal situation if the ambient temperature is very low. Blockage in the HP branch between compressorand condenser-filter hose, but before the H.P. reading point,Check for leaksVery less refrigerant quantity . 70- 80 % less . Compressor faulty

High or Normal

High

Normal situation if the ambient temperature is very high. Excess refrigerant charge, 5-35% moreClogged condenser Air present in the A/C system Blockage in the H.P. branch between compressor and condenser filter hose, but after the H.P. reading pointsame

Same as HP

Same as LP

Compressor belt jumped, probably caused by misalignment of the pulleys. Compressor clutch not engaged. Compressor damaged

High

Normal or Low

Suction and discharge hoses reversed on compressor Clutch not engaged Compressor damaged

Low

B-29

Low or Normal

9813/2000-02

Filter saturated with moisture

B-29

Section B - Body and Framework Fault Finding Air Conditioning

Noise from A/C System Sometime due to various reasons some abnormal noise start coming from the system, below are some possible instances: S. No.

Causes

Solution

Belt worn or slipped of belt

Check the wear and tension of belt

Belt Idler Pulley noisy

Replace it

Electric clutch plate slipping

Make sure that the gap between the compressor pulley and clutch is 0.3-.05 mm

Vibration and resonance of the compressor support plate.

Make sure the bolts are tight and the plate is properly positioned.

Expansion valve whistles.

If the noise persists, replace the valve.

In some cases, any defective components of the A/C system may create an incorrect inlet and outlet pressure. This phenomenon causes noise in the compressor that is actually due to one of the causes listed below and NOT to the compressor itself: – Incorrect amount of refrigerant (30-35% more or 7075% less). – Expansion valve stuck shut or blocked. – Clogging in the A/C system circuit – Filter saturated with moisture. Note: Check all the above points and take corrective action accordingly.

Unpleasant Odour from A/C System Under certain conditions, moulds and bacteria (normally present in the air) may form on the surface of the evaporator core, causing an unpleasant odour inside the vehicle. – Use an antibacterial product to treat the evaporator. – Get the evaporator cleaned. – Advise the customer to turn off the A/C system a few minutes before shutting off the vehicle, leaving the blower fan running (this will dry the evaporator core from the moisture that encourages bacteria growth).

B-30

9813/2000-02

B-30

Section B - Body and Framework Cab Panels Cab Panel Removal

Cab Panels Cab Panel Removal TB-008

Remove the screws as shown in the following illustrations. Note: Care must be taken not to force the panels away from cab frame, as this could result in breakage of the cab panel

Right Hand Cab Panels

C006290

Fig 25.

C006280

Fig 24.

C006300

Fig 26.

B-31

9813/2000-02

B-31

Section B - Body and Framework Cab Panels Cab Panel Removal

Left Hand Cab Panels

A408510

Fig 27.

B-32

9813/2000-02

B-32

Section B - Body and Framework Cab Panels Wiper/Wash (Optional)

Wiper/Wash (Optional) Removal and Replacement

Disconnect the wash/wiper tubes.

Removal

Remove the wiper mounting nut.

Remove the wiper motor screws and remove the wiper motor E.

Make the machine safe.

Disconnect the battery cables.

Remove the screw from the motor E.

Disconnect the electrical harness.

Replacement Replacement is a reversal of the removal procedure.

F A D C

P041680-66

Fig 28. Item

B-33

Description

Wiper arm

Wiper blade

Wiper retainer

Screw

Wiper motor

9813/2000-02

Item

Description

Wiper sensor

B-33

Section B - Body and Framework Cab Panels Wiper/Wash (Optional)

Page left intentionally blank

B-34

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B-34

Section C Electrics Service Manual - JS81 Section 1 - General Information Section 2 - Operator’s Manual Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/2000-02

Section C - Electrics

Notes:

C-0

9813/2000-02

C-0

Section C - Electrics Contents

Contents Page No. Circuit Symbols ........................................................................................ C - 1 Inputs and Outputs ............................................................................. C - 1 Schematic Diagram ................................................................................. C - 3 JS81 ................................................................................................... C - 3 Ignition Circuit .......................................................................................... C - 5 Face Fan Circuit ...................................................................................... C - 6 Horn Circuit .............................................................................................. C - 7 Wiper Circuit ............................................................................................ C - 8 Harness Data Main Harness ........................................................................................ C - 10 Roof and Boom Lamp Harness ............................................................. C - 12 ......................................................................................................... C - 12 Cab Harness .......................................................................................... C - 14 Service Procedure Using a Multimeter ................................................................................. C - 15 Measuring DC Voltage ..................................................................... C - 16 Measuring Resistance ...................................................................... C - 16 Measuring Continuity ........................................................................ C - 17 Measuring Frequency ....................................................................... C - 17 Testing a Diode or a Diode Wire ....................................................... C - 18 Alternator ............................................................................................... C - 19 General Description .......................................................................... C - 19 Service Precautions ......................................................................... C - 19 Charging Circuit Test ........................................................................ C - 19 Alternator Charging Test ................................................................... C - 21 Battery ................................................................................................... C - 23 Maintenance ..................................................................................... C - 23 Testing .............................................................................................. C - 23 Specific Gravity Testing .................................................................... C - 25 Wiring Harness Repair .......................................................................... C - 26 Introduction ....................................................................................... C - 26 Repair Procedure ............................................................................. C - 26 Technical Data Fuses ..................................................................................................... C - 29 Monitor Panel ........................................................................................ C - 31 Mode Status ..................................................................................... C - 31 Warning Lights .................................................................................. C - 31

C-i

Section C - Electrics

Technical Data Fuses and Relays Fuses

Relays

Replace

!MCAUTION

For more information K Fig 4. ( T C-4).

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. If a fuse blows, find out why before a new one is installed. For more information on the individual fuses K Fig 1. ( T C-1)

the

individual

relays

Relays - Cab The relays are installed to the right side of the operator seat on the side lower panel. Open the cover to get access to the relays K Fig 2. ( T C-1). For relay identification, a label is attached to the rear of cover K Fig 4. ( T C-4).

Fuse - Cab The fuses are installed to the right side of the operator seat on the side lower panel. Open the cover to get access to the fuses K Fig 1. ( T C-1).

For fuse identification, a label is attached to the rear of cover.

A P040380-76

Fig 2. Item A

Description Relays

P040380-75

Fig 1. Item A

C-1

Description Fuses

9813/2000-02

C-1

Section C - Electrics Technical Data Fuses and Relays

General Item

Specification

System voltage

12V

Fuses Fuses - Cab

P040380-77

Fig 3. Fuse Identification Fuse

Circuit(s) Protected

Rating

Spare fuse

Starter

40A

Livelink

Radio

C-2

9813/2000-02

C-2

Section C - Electrics Technical Data Fuses and Relays Fuse

Circuit(s) Protected

Rating

Spare fuse

10A

ESOS (Engine Shut Off Solenoid)

10A

Power socket

10A

Spare fuse

40A

Radio

10A

Livelink ground

Wiper

10A

Gauge coil

10A

Spare fuse

30A

Swing lock

10A

Lever lock

Horn

10A

Interior lamp

Fuse puller

Wiper

Battery fed

40A

Face fan

10A

Ignition I/P

30A

Fuse box label

CWT lamp

10A

Work/boom lamps

30A

Time relay - Auto idle relay

Parking lights

C-3

10A

9813/2000-02

C-3

Section C - Electrics Technical Data Fuses and Relays

Relays Relays - Cab

P040380-78

Fig 4. Table 1. Relay Identication Relay

Circuit(S)

Horn and auto idle

Buzzer

Starter

Boom/work lights

Timer

Hydraulic and wiper

C-4

9813/2000-02

C-4

Section C - Electrics Technical Data Instruments

Instruments engine coolant. Do not let the needle rise into the red danger zone of the gauge.

Instrument Panel The instrument panel is located at the front of the cab in the line of sight from the operator's seat. The gauges, warning and indicator lamps are grouped together on the instrument cluster.

Fuel gauge:The needle position shows the current level of fuel in the tank. Do not let the tank run dry, or air can enter the fuel system. Warning symbols: The warning symbols illuminate and a buzzer will sound when there is a fault in the machine. All the symbols will go off when the ignition key is turned to the off position. (But the direction indicator, roadlights, mainbeam and hazard warning indicators will continue to operate if their related functions are switched on). Do not use the machine if it has a fault condition, or you can damage the engine and/or the transmission. Mode status: The mode status shows the current speed mode of the machine. You can select different speed modes using the throttle control lever.

D B

P041680-54

Fig 5. Item

Description

Hourmeter

Coolant temperature gauge

Fuel gauge

Warning symbols

Mode status

Hourmeter: The digital hourmenter displays the machine working hours. Coolant temperature gauge: The needle position shows the current temperature of the current temperature of the

C-5

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C-5

Section C - Electrics Technical Data Instruments

Warning and Notification Symbols A

J P041680-55

Fig 6. Lamp test (daily): Turn the ignition key to the on position to do a start-up cycle. Only the symbols shown should illuminate during the start-up cycle. Do not use the machine if any of the warning symbols do not illuminate, contact your JCB dealer.

C-6

Do not use the machine, if it has a fault condition, or you may damage the machine.

Engine coolant temperature (red) Visual only. Illuminates if the engine coolant temperature rises too high. Put the engine into low idle and wait until the temperature is normal.

Hydraulic oil temperature (red)

Visual only. Illuminates, if the hydraulic fluid temperature rises too high.

Engine oil pressure (red)

Visual only. Illuminates, if the engine oil pressure is low. The lamp should go off when the engine is started. if the lamp flashes, this indicates a fault with this function.

Engine intake air filter (red)

Visual only. Illuminates when the air filter is blocked.

Battery charging condition (red)

Visual only. Illuminates if the alternator is not charging. If the lamp has been On for 30s, when the engine is running the buzzer will sound. The lamp should go off a few seconds after the engine is started.

Coolant level (red)

Visual only. Illuminates if the engine coolant level drops too low.

Slew lock ON (red)

Visual only. Illuminates when the machine slew lock is engaged.

Servo isloator ON (red)

Visual only. Illuminates when the machineâ&#x20AC;&#x2122;s servo isolator is engaged.

Water seperator (red)

Visual only. Illuminates if water level reaches the maximum mark in the water seperator.

9813/2000-02

C-6

Section C - Electrics Basic System Operation Circuit Symbols

Basic System Operation Circuit Symbols TC-013

The following notations are used in the description circuit, drawings.

C005310GB-2

Fig 7.

Inputs and Outputs The letters i/p and o/p refer to input and output. The letters in brackets i.e. (C-21) refer to the connector and pin number.

C001660-2

Fig 8.

C-7

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C-7

Section C - Electrics Basic System Operation Circuit Symbols

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C-8

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C-8

Section C - Electrics Basic System Operation Schematic Diagram

Schematic Diagram JS81

Item

The item numbers in the following table are identified on the wiring schematics in this section. K Fig 9. ( T C-10). Item

Tool box lamp

Horn

Refuel pump

Description

Cab Wiper

Face fan

Cabin lamp

Cab work lamp

Radio 12V

Water temperature gauge

Fuel gauge

Hourmeter

Warning cluster

Work lamp switch

Servo isolator switch

Swing lock switch

2 speed switch

Wiper switch

Lock lever switch

Phone charger

Power mode relay

Power mode switch

Horn switch

Ignition switch

Starter motor

Alternator

Low Engine oil pressure switch

Water temperature switch

Engine temperature switch

Air filter switch

Hydraulic temperature switch

Fuel level sensor

Counter weight lamp

Boom Lamp

C-9

Description

9813/2000-02

C-9

C-10

SERVO ISOLATOR SWITCH

WORK LAMP SWITCH

SWING LOCK SWITCH

2 SPEED SWITCH

CAB

PHONE CHARGER

MAIN FRAME FUSE

LOCK LEVER SW 229/00385

WIPER SWITCH

40A 203

201

FUSE 1

C29

C26

845

C27

600

816

825

117

C28

600

816

600

431

603

600

816

C30

600

816

419

110

842

600

816

104

854

830

104

C31

300

600

C32

202

C2 600

418

110

842

419

846

3 2

50A 200

600 1

FUSE 204

805 12V

50A

BATTERY

C39 WIPER

600

STARTER MOTOR

C7 200

825

117

825

826 117 600

POWER MODE SWITCH

POWER MODE RELAY

20 02

202

20 04

204

411

B C8 411

860

LOW ENG. OI PRESSUR SW C11 WATER TEMPERATU SWITCH

101 311

311

ALTERNATO

C10

101

409 C12

ENGINE TEMPERATU SENSOR

600 600

CABIN LAMP C48

82 21

821

10 01

101

114 600

CAB WORK LAMP (OPTIONAL)

IGNITION SWITCH

4 CAB WORK LAMP (OPTIONAL)

C49 114

114

600

300

813

HEAT

114

600

311

C13 402

406

600

40 07

407

40 09

409

870

AIR FILTER SWITCH

415 C14

C40A 1 2

15/54

50a 19

5 6

412

C40B

412

007

320

003 407

407

104

600

411

C42

600

409

430

816

START RELAY 70A C43

TRAVEL(L)

320 007

HOUR METER

409

600 805

FUEL GAUGE

C41

816

405

C37 WATER TEMP GAUGE

104

9813/2000-02

BUZZER

415

03 60

603

117

80 05

805

812

813

84 41

FUEL LEVEL SENSOR

600

C16

841

42 84

842

86 61

861

HYDRAULIC TEMPERATURE SWITCH

407 C15

C51

600

8 9

402

101

30 17

311

IGN CRANK

RADIO 12 V (OPTIONAL)

40 02

40 06

OFF

C50

813

COUNTER WEIGHT LAMP 3DX TYPE

600

C17 812

C44 FRONT LAMP RELAY

C45 REAR LAMP RELAY

600

C46 HORN RELAY

812

E MODE

419

405

TOOL BOX LAMP

C19 821 600

203 101 600 002 9

311

HORN

C24

402 0

415

WATER TEMP

411

416

2 SPEED

870

002

003

202

002

202

C1 B3

101

204

855

002

838

113

813

114

812

300

002

311

830

320

816

117

307

104

202

845

110

B1 RADIO (15A) B2 REFUEL PUMP (20A) B3 INT. LAMP/CHARGER (15A) B4 FACE FAN (10A) B5 HORN (7.5A)

FUSE BOX

002

A1 LEVER LOCK SOL. V (5A) A2 SWING LOCK SOL. V (5A) A3 RELAY REED (5A) A4 WIPER MOTOR (10A)

002

C1 PANEL LIGHTS (5A) C2 POWER MODE SOL. V (5A) C3 WORK LAMPS STD. (15A) C4 WORKLAMPS OPT. (15A) C5 ALTERNATOR SIGNAL (5A) D1 BATTERY FEED (40A)

REFUEL PUMP (OPTIONAL)

002

MASTER WARNING 1

C-10

Fig 9. 332/P2885 - Issue1 - Sheet 1

C22

LEVER LOCK SOLENOID

C21

SWING LOCK SOLENOID

861

HYD OIL TEMP

C23

600

412

842

600

412

841

ENG. OIL PR.

600

431

117

C20

POWER MODE SOLENOID

Schematic Diagram

431

2 SPEED

603

311

Section C - Electrics

402 0

Basic System Operation

WARNING CLUSTER

600

ALTERNATOR

AIR FILTER

BOOM LAMP C18

860 821

419

MASTER WARNING 2

307 104

SLEW LOCK

600 855

418

320 854

861

600 838

418

LOGIC CIRCUIT

861

SERVO ISOLATOR

C25 IGN RELAY (70A)

320 830

P MODE

L C9 W

412

C33

113

867

600 861

C47 114

203

406

113 867

HORN SWITCH

C34

C35 FACE FAN

117

600

C36 7

03 20

Section C - Electrics Basic System Operation Ignition Circuit

Ignition Circuit

50A

204

40A

007 805

320D

A C 320C 320C

D Fig 10. Current from the battery is always ignition switch and the ignition relay. It is also available through a resistor of 40A at the solenoid. When the ignition is ON the relay is energized; it gives a feed to the starter motor solenoid. When the ignition switch is turned to crank, it energizes the start relay and gives current to the solenoid and energizes it. The starter motor solenoid engages the gear of the motor with the flywheel.

Item

C-11

Table 2. Description

Battery 12V

Ignition Switch

Ignition Relay

Starter Motor and Solenoid

9813/2000-02

C-11

Section C - Electrics Basic System Operation Face Fan Circuit

Face Fan Circuit D

C016

114

15A

144

002B(002) 101A

20A

203

003

C013 40A

320D 40A

A 50A

204

Fig 11. When the ignition is ON, the relay gets energized. When the Fan switch is ON, the current is given to the fan.

Item

C-12

Table 3. Description

Battery 12V

Ignition Switch

Ignition Relay

Face Fan

9813/2000-02

C-12

Section C - Electrics Basic System Operation Horn Circuit

Horn Circuit 821

C013

307A

821 104C

860 5A

202C

50A

10A

600F

F10

002A

A 600F

101A

600C

C 203

203 C013 40A

320D

003

40A

204

20A

50A

Fig 12. When the ignition is ON, the ignition relay gets energized. When the horn switch is ON, the current is given to the horn throught the relay.

Item

C-13

Table 4. Description

Battery 12V

Ignition Switch

Ignition Relay

Horn Switch

Relay

Horn

9813/2000-02

C-13

Section C - Electrics Basic System Operation Wiper Circuit

Wiper Circuit C016A 825

825

117A

50A

CRD DIODE

600F

117B

117

117A

A D

825

Fig 13. When the ignition is ON, the ignition relay gets energized. When the horn switch is ON, the current is given to the horn throught the relay.

Item

C-14

Table 5. Description

Battery 12V

Ignition Switch

Ignition Relay

Horn Switch

Relay

Wiper

9813/2000-02

C-14

Section C - Electrics Harness Data Main Harness

Harness Data Main Harness

Fig 14. Main Harness A 332/P2818 - Issue 2

C-15

9813/2000-02

C-15

Section C - Electrics Harness Data Main Harness

Fig 15. Main Harness A 332/P2818 - Issue 2

C-16

9813/2000-02

C-16

Section C - Electrics Harness Data Roof and Boom Lamp Harness

Roof and Boom Lamp Harness

Fig 16. 333/P6344/2 Roof Harness

C-17

9813/2000-02

C-17

Section C - Electrics Harness Data Roof and Boom Lamp Harness

Fig 17. 333/P6344/2 Roof Harness

Fig 18. 332/P2824/1 Boom Lamp Harness

C-18

9813/2000-02

C-18

Section C - Electrics Harness Data Cab Harness

Cab Harness

Fig 19. Cab Harness A 333/P6342 issue 1

C-19

9813/2000-02

C-19

C-20

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9813/2000-02

Section C - Electrics Harness Data Cab Harness

C-20

C-21

Circuit Diagrams Electrical Schematic (Serial Number - 24266501 to 2427000)

Section C - Electrics

Circuit Diagrams

C-21

Electrical Schematic (Serial Number - 24266501 to 2427000)

9813/2000-02 332-L7802-1

Fig 20. 332-L7802-1 (Sheet 1 of 9)

C-22

332-L7802-2

Section C - Electrics Circuit Diagrams

C-22

Electrical Schematic (Serial Number - 24266501 to 2427000)

9813/2000-02

Fig 21. 332-L7802 (Sheet 2 of 9)

C-23

332-L7802-3

Section C - Electrics Circuit Diagrams

C-23

Electrical Schematic (Serial Number - 24266501 to 2427000)

9813/2000-02

Fig 22. 332-L7802 (Sheet 3 of 9)

C-24

332-L7802-4

Section C - Electrics Circuit Diagrams

C-24

Electrical Schematic (Serial Number - 24266501 to 2427000)

9813/2000-02

Fig 23. 332-L7802 (Sheet 4 of 9)

C-25

332-L7802-5

Section C - Electrics Circuit Diagrams

C-25

Electrical Schematic (Serial Number - 24266501 to 2427000)

9813/2000-02

Fig 24. 332-L7802 (Sheet 5 of 9)

C-26

332-L7802-6

Section C - Electrics Circuit Diagrams

C-26

Electrical Schematic (Serial Number - 24266501 to 2427000)

9813/2000-02

Fig 25. 332-L7802 (Sheet 6 of 9)

C-27

332-L7802-7

Section C - Electrics Circuit Diagrams

C-27

Electrical Schematic (Serial Number - 24266501 to 2427000)

9813/2000-02

Fig 26. 332-L7802 (Sheet 7 of 9)

C-28

332-L7802-8

Section C - Electrics Circuit Diagrams

C-28

Electrical Schematic (Serial Number - 24266501 to 2427000)

9813/2000-02

Fig 27. 332-L7802 (Sheet 8 of 9)

C-29

332-L7802-9

Section C - Electrics Circuit Diagrams

C-29

Electrical Schematic (Serial Number - 24266501 to 2427000)

9813/2000-02

Fig 28. 332-L7802 (Sheet 9 of 9)

C-30

Electrical Harness (Serial Number - 2426501 to 2427000) Chassis Harness

Section C - Electrics Circuit Diagrams 335-0625-1

C-30

Electrical Harness (Serial Number - 2426501 to 2427000)

9813/2000-02

Fig 29. 335-0625 (Sheet 1 of 3)

C-31

Circuit Diagrams

Section C - Electrics

335-0625-2

C-31

Electrical Harness (Serial Number - 2426501 to 2427000)

9813/2000-02

Fig 30. 335-0625 (Sheet 2 of 3)

C-32

Circuit Diagrams

Section C - Electrics

335-0625-3

C-32

Electrical Harness (Serial Number - 2426501 to 2427000)

9813/2000-02

Fig 31. 335-0625 (Sheet 3 of 3)

C-33

Cab Harness

Circuit Diagrams

Section C - Electrics

335-G6023-1

C-33

Electrical Harness (Serial Number - 2426501 to 2427000)

9813/2000-02

Fig 32. 335-G6023 (Sheet 1 of 4)

C-34

Circuit Diagrams

Section C - Electrics

335-G6023-2

C-34

Electrical Harness (Serial Number - 2426501 to 2427000)

9813/2000-02

Fig 33. 335-G6023 (Sheet 2 of 4)

C-35

Circuit Diagrams

Section C - Electrics

335-G6023-3

C-35

Electrical Harness (Serial Number - 2426501 to 2427000)

9813/2000-02

Fig 34. 335-G6023 (Sheet 3 of 4)

Section C - Electrics Circuit Diagrams Electrical Harness (Serial Number - 2426501 to 2427000)

335-G6023-4

Fig 35. 335-G6023 (Sheet 4 of 4)

C-36

9813/2000-02

C-36

C-37

Cab Roof Harness

335-D7454-1

Section C - Electrics Circuit Diagrams

C-37

Electrical Harness (Serial Number - 2426501 to 2427000)

9813/2000-02

Fig 36. 335-D7454 (Sheet 1 of 2)

C-38

335-D7454-2

Section C - Electrics Circuit Diagrams

C-38

Electrical Harness (Serial Number - 2426501 to 2427000)

9813/2000-02

Fig 37. 335-D7454 (Sheet 2 of 2)

C-39

Fascia Panel Harness

Circuit Diagrams

Section C - Electrics

335-D7600-01

C-39

Electrical Harness (Serial Number - 2426501 to 2427000)

9813/2000-02

Fig 38. 335-D7600 (Sheet 1 of 2)

Section C - Electrics Circuit Diagrams Electrical Harness (Serial Number - 2426501 to 2427000)

335-D7600-02

Fig 39. 335-D7600 (Sheet 2 of 2)

C-40

9813/2000-02

C-40

Section C - Electrics Circuit Diagrams Electrical Harness (Serial Number - 2426501 to 2427000)

Warning Cluster

335-A2003-1

Fig 40. 335-A2003 (Sheet 1 of 2)

C-41

9813/2000-02

C-41

C-42

335-A2003-2

Section C - Electrics Circuit Diagrams

C-42

Electrical Harness (Serial Number - 2426501 to 2427000)

9813/2000-02

Fig 41. 335-A2003 (Sheet 2 of 2)

C-43

AC Link Harness Pressure Switch

333-K4445

Fig 42. 333-K4445 (Sheet 1 of 1)

Boom Lamp Harness

Section C - Electrics

Circuit Diagrams

C-43

Electrical Harness (Serial Number - 2426501 to 2427000)

9813/2000-02 334-L5447

Fig 43. 334/L5447 (Sheet 1 of 1)

Section C - Electrics Circuit Diagrams Electrical Harness (Serial Number - 2426501 to 2427000)

Page left intentionally blank

C-44

9813/2000-02

C-44

Section C - Electrics

Radio (Optional) Technical Data General Power Supply Requirements

12 Volts DC, Negative Ground

Chassis Dimensions

131.6 (W) x 47.5 (D) x 86 (H)

Loading Impedance

4 - 8 ohms per channel

Tone Controls

Bass (at 100 Hz), 10 dB; Treble (at 10 kHz), 10 dB

Current Drain

1.5 Ampere (max)

FM Tuner Tuning range

87.5 - 108.0

FM mono sensitivity

1.5uV

Stereo separation @ 1 kHz

>25dB

AM Tuner Tuning range

522-1710

Sensitivity

<30uV

Weather Band Sensitivity

<1uV

Amplifier Total system power

15 Watts Maximum

Signal to Noise

>70dB

Specifications subject to change without notice. Note: The manufacturer is not responsible for any radio or TV interference caused by unauthorized modifications to this equipment. Such modifications could void the User's authority to operate the equipment.This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:1) This device may not cause harmful interference, and2) This device must accept any interference received, including interference that may cause undesired operation.

C-45

9813/2000-02

C-45

Section C - Electrics Radio (Optional) Wiring Diagram

Wiring Diagram

Antenna Connector (Black Wire)

2 PCB

6-Pin Connector (Male)

1/4 HEADPHONE OUTPUT

5 Black Wire

WASHER

NUT

8 Heat Shrink Tubing

RUBBER CAP

Left Speaker + (White)

15 Left Speaker (White/Black)

14 Right Speaker + (Gray)

Ground (Black)

Accessory (Red)

Note: Do not connect the red wire to a constant power connection. It should be connected to a vehicle connection with switched power, such as IGN or ACC.

Right Speaker (Gray/Black)

12 Fig 1.

The wiring diagram depicts all the wiring connections required for proper operation of the unit. K Table 1. Component Key ( T C-47)

C-46

Note: Do not connect the red wire to a constant power connection. It should be connected to a vehicle connection with switched power, such as IGN or ACC.

9813/2000-02

C-46

Section C - Electrics Radio (Optional) Wiring Diagram Item

Table 1. Component Key Component

Antenna Connector (Black wire)

PCB

1/4 inch Headphone Output

Washer

Nut

Rubber Cap

Not Used

Heat Shrink Tubing

Not Used

Accessory (Red)

Ground (Black)

Right Speaker -ve (Grey/Black)

Right Speaker +ve (Grey)

Left Speaker -ve (White/Black)

Left Speaker +ve (White)

Black Wire

6 - Pin Connector (Male)

C-47

9813/2000-02

C-47

Section C - Electrics Radio (Optional) Wiring Diagram

Page left intentionally blank

C-48

9813/2000-02

C-48

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 3. AVO 2003

Fig 2. FLUKE 85

Fig 4. A Typical Analogue Meter

C-49

9813/2000-02

C-49

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.

Select the correct range on the multimeter. a

Turn the switch to position 2-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 2-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.

b On the AV0 2003.

Measuring DC Voltage 1

On the FLUKE 85.

On the FLUKE 85. c

Turn the switch to position 2-B.

On an analogue meter. i

b On the AV0 2003.

Move the right hand slider switch to position 3B, 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 3-A, and the left hand slider switch to the appropriate range. c

On an analogue meter. Turn the dial to the appropriate DC Volts range.

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

C-50

9813/2000-02

C-50

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.

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.

The AVO 2003 and the analogue meter are not capable of measuring frequency, therefore a Fluke 85 digital multimeter must be used. 1

Insert the black plug into the COM socket on the meter and attach the probe to the nearest suitable earth point on the chassis, for example, the battery negative terminal.

Insert the red probe into socket 2-J.

Turn the selector switch to position 2-A and depress 2-G repeatedly until 2-F is highlighted on the top row of the display.

Press button 2-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 2-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 2-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 3-B, and the left hand slider switch to position 3-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.

C-51

9813/2000-02

C-51

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 2-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 3-A, and the left hand slider switch to position 3-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.

C-52

9813/2000-02

C-52

Section C - Electrics Service Procedure Alternator

Alternator General Description

The transmission low oil pressure, oil pressure and No charge warning lights should illuminate. If any light fails, K Check 1 ( T C-53).

The alternator is a three phase generator with a rotating field winding and static power windings. (28V 55A). When the starter switch is turned on, the current from the battery flows through the 'No Charge' warning light to the field winding. This creates a magnetic field which increases the residual magnetism in the rotor poles.

Service Precautions 1

Make sure 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 when the engine is running. As this action will cause damage to the regulator or the rectifying diodes.

The main output cables are 'live' even when the engine is not running. Be careful not to earth the connectors in the moulded plug if it is removed from the alternator.

During arc welding on the machine to protect the alternator remove the moulded plug (or if separate output cables are fitted, remove the cables).

If a jump start is necessary, connect the second battery in parallel without disconnecting the vehicle battery from the charging circuit. The second battery can then be safely removed after the engine has started. Make sure to connect the batteries positive to positive, negative to negative.

Start the engine, all of the warning lights should extinguish quickly. If the 'No charge' warning light remains ON. K Check 2 ( T C-54).

As the engine is started, the fan belt drives the rotor and an alternating current is generated in the power windings as they are cut by the rotating magnetic field. The output is controlled by a solid state regulator which varies the field current according to the to electrical demand. A service is restricted to the inspection of the slip ring brushes. The bearings are 'sealed for life'.

Turn the starter switch to the ON position.

If the transmission low oil pressure or the oil pressure warning remains ON, stop the engine Immediately and inspect the engine lubrication system.

Check 1 With the starter switch 'ON' start the heater motor and screen wiper. If they operate normally, check the warning light bulb/LED is not defective. A simultaneous failure of all the items indicates a fault at the starter switch. Check for cable disconnection before the starter switch is replaced. If the 'No charge' warning bulb/LED is okay, remove the Alternator W ring terminal from the back of the alternator. Make a temporary connection between the w ring terminal in the plug and earth as shown below. If the 'No charge' warning bulb/LED does not 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-54).

D+

Charging Circuit Test

B+

Fig 5.

Make sure that all the battery and alternator connections are in position, secure and have a good metal - to - metal contact, especially the 'earth' connections to the chassis and engine.

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

C-53

9813/2000-02

C-53

Section C - Electrics Service Procedure Alternator

Alternator Charging Test

Check 2 Note: Use an analogue (moving pointer) type meter to do he following checks. 1

Stop the engine and turn the starter switch to OFF.

Remove the alternator plug and connect the test meter between the B+ terminal and 'earth'.

Set the meter to measure 24V DC. The meter should show the battery voltage. If the reading is zero, check the cables for continuity, particularly at the starter terminals.

Fig 7. 1

Make sure that all of the battery and alternator connections are in position, secure and have a good metal - to - metal contact, especially the 'earth' connections to the chassis and engine.

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

If the battery is in a fully charged condition, either:

If the voltage is correct, check the alternator. K Alternator Charging Test ( T C-54).

D+ w

B+

Switch on the working lights for 3 minutes before the test is started Operate the starter motor for a few seconds with the engine stop fuse removed. (See Fuse Identification). Fig 6.

C-54

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

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

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

9813/2000-02

C-54

Section C - Electrics Service Procedure Alternator AVO 2002

– Red lead to volts (middle) socket on meter.

Remove the regulator and brush box assembly.

– Black lead to negative on meter. – Right hand slider to DC voltage.

Check the condition of the brushes and, if necessary, clean the slip rings with extra-fine glass paper.

– Left hand slider. K Fig 7. ( T C-54). AVO 2003

To check for faults a, b and c:

– Red lead to amps socket (marked A) on the meter. – Black lead to negative on meter.

The regulator may only be checked by substitution. 12

– Right hand slider to DC voltage

To check for faults d, e and f remove and disassemble the alternator for further testing.

– Left hand 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 me.

Start the engine and run at maximum speed (refer to Technical Data).

The meter should show the maximum alternator output in Amps. (see Technical Data).

Note: The meter reading should be taken as soon as possible after the engine is started, as the charging current will fall rapidly. 9

A zero reading indicates a 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.

Open or short circuit field (rotor) windings.

Open or short circuit power (stator) windings.

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

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9813/2000-02

C-55

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 goggles. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first. Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up. When reconnecting, fit the positive (+) lead first. 5-3-4-12

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-56

Set the CHECK/LOAD switch 8-A to OFF.

Set rocker switch 8-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 8-A to CHECK to read the battery no-load voltage which should be at least 12.4 volts.

Set the CHECK/LOAD switch 8-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 2. Fault Diagnosis ( T C-57), foregoing tests are unsatisfactory.

Battery Tester Readings 1

the Fig 8. Battery Tester

Table 2. Fault Diagnosis Remedy

CHECK: 0 - 12.6 Volts

Renew battery

LOAD: less than 6 Volts 2

CHECK: 6 - 12.4 Volts LOAD: less than 9 Volts and falls steadily but remains in yellow zone.

CHECK: less than 10 Volts LOAD: less than 3 Volts

CHECK: more than 11 Volts

Recharge and re-test. If tests still unsatisfactory renew battery.

Indicates battery has been over-discharged and unlikely to recover. Renew battery. 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 3. 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 Wire Numbers and Functions

Wire Numbers and Functions This section details the allocation of wire numbers and the identification of wires in the wiring harness.

Fig 9. Typical Wire and Harness Number K Fig 9. ( T C-59). The illustration shows a typical connector and wires. Each wire has an individual identification number permanently marked on it, at regular intervals along it's length.

The number stamped on the wire identifies the following:

Table 4. Wire and Harness Number Identification Ident. No.

Description

The # indicates the start of the identification number. It is always printed to the left of the identification number.

If applicable - The colour of the flying lead that the harness wire should mate with. For instance, if wire 819 from harness 719/37100 mated with a flying lead coloured black (colour code B) then the number printed on the wire would be B-819 9/371.

819

The wire's unique identification number. The wire functions and numbers allocated to them are consistent through out the JCB range of products. K Wire Numbers and Functions ( T C-59).

9/371

If applicable - The part number of the harness that the wire originates from. If the harness part number is 719/37100, the number printed on the harness wires will be 9/371 (71 and 00 are common numbers and therefore deleted).

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Section C - Electrics Service Procedure Wire Numbers and Functions

Wires 000-199

Wires 800-999

These numbers are reserved for ignition feeds, heater start circuits and start circuits. These can be further categorised by:

These numbers are reserved for switched supplies to electrical loads, i.e. to lights, etc.

– Wires 000 - 099 are allocated to unfused ignition feeds.

Wires In Splices

Note: Feeds via ignition relays are classed as ignition feeds.

The main input wire is allocated with a wire number and a suitable description, i.e. Wire 640 earth splice to earth. The additional wires in the splice are allocated the same wire number and a postfix, i.e. 640A, 640B, etc. K Fig 11. ( T C-60).

Wires 200-399

Note: The letters I, O, Q and S are not used.

– Wires 100 - 199 are allocated to fused ignition feeds.

These numbers are reserved for battery feeds, They can be further categorised by: – Wires 200 - 299 are allocated to unfused battery feeds. – Wires 300 - 399 are allocated to fused battery feeds.

Wires 400-599 These numbers are reserved for instruments, i.e. alternators to tachos, temperature switches to warning lights, etc. and signal wires used in electronic systems.

Wires 600-799 Fig 11. These numbers are used for earth wires. When the number is printed onto a wire A it is prefixed by the Earth symbol B. K Fig 10. ( T C-60). This symbol is printed onto the wire, it may however be omitted from harness drawings.

General Points 1

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

If all the numbers in a category have been allocated, then the category is re-used with an additional prefix '1', i.e. 1832.

Fig 10. Where a load is switched negative, the wire number from the load to the switch shall be different to that of the wire from the switch to the earth.

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Section C - Electrics Service Procedure Wiring Harness Repair

Wiring Harness Repair TC-004

!MCAUTION

Introduction Instances do occur where it is necessary to incorporate auxiliary electrical components into existing electrical circuits and, although unlikely with present wiring harnesses, repair or replace specific individual wires within a harness. This will also apply to other machines in addition to those of manufacture.

When the heater is in use, the reflector and the air coming out are extremely hot. Keep away to avoid accidental burns. Do not touch the reflector until it has had time to cool down after switching off. If flame reappears at the reflector when the heater is in use, the catalytic element is damaged or used up. Stop work immediately and replace the heater.

To ensure that either the inclusion of an auxiliary electrical component or a repair within a harness is completed to an acceptable standard it is strongly recommended that the following tools, equipment and procedures are always used. Note that JCB harnesses have an International Protection rating of 67 (I.P.67).

ELEC-2-3

The sheath covering of the recommended splice is heat shrunk onto the original wire insulation. This results in a seal and corresponding joint to IP 67 specifications.

!MCAUTION When installing Auxiliary Electrical Components always ensure that the additional load rating is suitable for that particular circuit. It is unacceptable to simply increase the fuse rating as this can cause overloading and consequential failure of wiring, along with failure of integral circuit components, which the fuse is protecting.

Repair Procedure Part No.

Table 5. Tools Required Description

892/00350

Butane Heater assembly

892/00349

Crimp tool

892/00351

Splice 0.5-1.5 mm (Red)

892/00352

Splice 1.5-2.5 mm (Blue)

892/00353

Splice 3.0-6.0 mm (Yellow)

Qty

Cut the wire and remove the protective insulation for a suitable distance dependent upon the size of wire and splice to be used. For the splices detailed in K Table 5. ( T C-61), the dimension is 7mm.

ELEC-2-1

!MWARNING In addition to the warnings incorporated into this procedure, extreme care should be taken when handling the gas heating tool to ensure that the flame does not damage or set fire to any items in the vicinity of the repair, i.e. other wires, floor panels, floor mats, sound proofing, paintwork, etc. This tool should not be used in any restricted location prohibiting the use of "Naked Flames" or where risk of explosive gas or similar safety parameters apply. No other heat source should be used to attempt a sealed joint.

Fig 12.

ELEC-2-2

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Using the correct sized splice, attach the new section of wire required or auxiliary flying lead to the existing harness and secure using the crimp tool. K Fig 12. ( T C-61). Note that each of the splices detailed is colour-coded to make size and range

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Section C - Electrics Service Procedure Wiring Harness Repair readily visible. They are secured using the corresponding size and matching colour-coded jaws of the crimp tool to ensure joint security. This tool also incorporates a ratchet closing mechanism which will not release until the splice is fully closed to the correct compression size. 3

With the Butane heater assembly, connection. K Fig 13. ( T C-62). a

seal

the

Remove the cap 14-A from the end of the disposable gas cartridge 14-B.

Fig 15. d Turn the small ring 16-E so that the air holes at 16F are completely closed. Fig 13. b Before assembling the gas cartridge to the reflector element 15-C, turn the red ring 15-D to the left, (in the direction of the minus sign marked on the ring).

Fig 16. e Fig 14. c

C-62

Position the tube hanging down from inside the reflector assembly into the hole at the top of the gas cartridge. Then press the gas cartridge up into the reflector assembly as far as possible until the two elements are clasped firmly together. K Fig 15. ( T C-62). A click will be heard.

Turn the red ring 17-D to the right (in the direction of the plus sign) in order to turn on the gas.

Important: Before turning the heater on, make sure that the cartridge is not hotter than the reflector element. This may occur if the cartridge is held in the hand for a long time. The temperature difference between the cartridge and the reflector element may cause long yellow flames to appear on ignition.

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Section C - Electrics Service Procedure Wiring Harness Repair i

Side wings 19-G down, reflector head completely open. In this mode the infra-red heat waves are dominant (recommended for the light coloured plastic splices).

Fig 17. f

Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown. Hold the heater vertically for 1 to 2 minutes until the catalytic reaction occurs. This is indicated when the blue flame fades and the ceramic element glows red. Then turn the small ring 18-E until the air holes at 18-F are completely open. The tool is ready for use.

Fig 19. ii

Side wings 20-G up, reflector head opening reduced. In this mode the heating is done only by the hot gas (use for dark coloured plastic splices).

Note: The fact that the sound of liquid cannot be heard when the cartridge is shaken does not mean it is empty. No sound will be heard even when the cartridge is full.

Fig 20. h To switch off the heater, turn the red ring 20-D to the left (in the direction of the minus sign). Fig 18. g The heater can be used in two modes:

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Section C - Electrics Service Procedure Wiring Harness Repair

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Section C - Electrics

Routine Maintenance Procedures Scheduled Tasks The table below lists the Electrical related Scheduled tasks. The procedures are in addition to the Daily/Weekly tasks. For details of all applicable maintenance schedules refer to Section 2.

Note: Maintenance schedules can vary according to machine operating conditions and environments. Refer to Section 2.

Table 6. Item

Task

Refer to

Starter motor

Check (Condition)

K Check (Condition) ( T C-66)

Alternator

Check (Condition)

K Check (Condition) ( T C-67)

Alternator - output

Check (Condition)

K Check (Condition) ( T C-67)

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Section C - Electrics Routine Maintenance Procedures Starter Motor

Starter Motor Check (Condition) Inspect the starter motor installation as follows: – Check the security of the starter motor to engine fixing bolts. Make sure that they are tightened to the correct torque. – Check that the electrical connections at the starter motor are clean and secure. – Repair or replace related electrical cables, wiring and connectors if they are defective. – Check the operation of the starter motor. If it fails to operate normally or makes excessive noise repair or replace as necessary.

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Section C - Electrics Routine Maintenance Procedures Alternator

Alternator Check (Condition) Inspect the alternator installation as follows: – Check the security of the alternator to engine fixing. – Check that the electrical connections at the alternator are clean and secure. – Repair or replace related electrical cables, wiring and connectors if they are defective. – Check the alternator drive pulley security. – Start the engine and check the machine instrumentation for electrical charging fault warnings. Check the fault log for electrical charging related faults. Refer to Section 2. If there are related warnings or fault codes fault find the electrical charging system.

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Section C - Electrics Routine Maintenance Procedures Alternator

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Section E Hydraulics Service Manual - JS81 Section 1 - General Information Section 2 - Operator’s Manual Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

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Section E - Hydraulics

Notes:

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Section E - Hydraulics Contents Page No. Technical Data General Data ............................................................................................ E-1 Main Hydraulic Pump ........................................................................... E-1 Servo Pump .......................................................................................... E-1 Slew Motor/Gearbox ............................................................................. E-1 Main Control Valve ............................................................................... E-2 Dozer Control Valve ............................................................................. E-2 Boom Ram ........................................................................................... E-2 Dipper Ram .......................................................................................... E-2 Bucket Ram .......................................................................................... E-3 Dozer Ram ........................................................................................... E-3 Specifications ....................................................................................... E-3 Basic System Operation Introduction to Hydraulic Schematic Symbols .......................................... E-5 General (Basic and Functional Symbols) ............................................. E-5 Control Valves ...................................................................................... E-9 Example of Schematic Circuit ............................................................ E-10 Circuit Descriptions Hydraulic Schematic ................................................................................ E-11 Hydraulic Schematic (Serial Number - 24266501 to 2427000) .............. E-13 Servo Line .............................................................................................. E-16 Pilot Pressure and Return Line ............................................................... E-17 Neutral Circuit ......................................................................................... E-18 Travel - Single Speed ............................................................................. E-20 Boom Up ................................................................................................ E-22 Boom Down ............................................................................................ E-24 Dipper Out .............................................................................................. E-26 Dipper In ................................................................................................. E-28 Bucket Opening ...................................................................................... E-30 Bucket Closing ........................................................................................ E-32 Swing ...................................................................................................... E-34 Remote Control Valve (Hand Control) Operation ................................................................................................ E-37 Function .............................................................................................. E-37 Removal and Replacement .................................................................... E-39 Removal ............................................................................................. E-39 Replacement ...................................................................................... E-39 Dismantling and Assembly ..................................................................... E-41 Dismantling ......................................................................................... E-41 Inspection ........................................................................................... E-45 Assembly ............................................................................................ E-45 Fault Finding ....................................................................................... E-46 Main Control Valve Description .............................................................................................. E-47 Slew Motor Reduction Gearbox Assembly Reduction Gear Structure and Working Principles ................................. E-57 Dismantling and Assembly ..................................................................... E-58 Dismantling ......................................................................................... E-60 Assembly ............................................................................................ E-68

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Section E - Hydraulics Contents

Contents Page No. Slew Motor Motor Operating Principles ..................................................................... E-77 Slew Brake Operation ............................................................................. E-78 Fault Finding ........................................................................................... E-79 Motor Does Not Rotate ....................................................................... E-79 Motor Rotates in the Reverse Direction ............................................. E-79 Motor Speed is Low ............................................................................ E-79 Motor Brake Working Poorly .............................................................. E-80 Motor is Driven by Exterior Torque ..................................................... E-80 Oil Leakage ........................................................................................ E-80 Removal and Replacement .................................................................... E-81 Removal ............................................................................................. E-81 Replacement ...................................................................................... E-82 Slew Motor Configuration ....................................................................... E-83 Dismantling and Assembly ..................................................................... E-84 Dismantling ......................................................................................... E-84 Assembly ............................................................................................ E-88 Hydraulic Pump/Regulator Hydraulic Pump Operation ..................................................................... E-97 General Description ............................................................................ E-97 Pump Hydraulic Circuit Diagram ........................................................ E-98 Hydraulic Pump Exploded View ........................................................ E-99 Replacement .................................................................................... E-100 Removal ........................................................................................... E-100 Disassembly ..................................................................................... E-101 Assembly .......................................................................................... E-104 Pump Maintenance Criteria .............................................................. E-107 Hydraulic Rams Precautions During Use ........................................................................ E-109 Installation ........................................................................................ E-109 Caution During Use .......................................................................... E-109 Maintenance, Inspection Points ....................................................... E-109 Removal and Replacement ................................................................... E-111 Typical Bucket Ram ........................................................................... E-111 Typical Boom Ram ............................................................................E-115 Typical Dipper Ram .......................................................................... E-120 Assembling and disassembling procedures ......................................... E-125 Cylinder Disassembly ....................................................................... E-125 Cylinder Assembly ............................................................................ E-131 Doâ&#x20AC;&#x2122;s in a Hydraulic Cylinder ............................................................. E-137 Dontâ&#x20AC;&#x2122;s in a Hydraulic Cylinder .......................................................... E-137 Rotary Coupling Operation .............................................................................................. E-139 Removal and Replacement .................................................................. E-140 Removal ........................................................................................... E-140 Replacement .................................................................................... E-141 Dismantling ........................................................................................... E-142 Assembly .............................................................................................. E-145 Service Procedure Make the Machine Safe ........................................................................ E-149

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Section E - Hydraulics Contents

Contents Page No. Pressure Testing - General ................................................................... E-150 Confirmation of the Oil Temperature ................................................ E-150 Warming-up Procedure .................................................................... E-150 Pressure Testing Points .................................................................... E-151 Pressure Relief Valve Location ............................................................. E-153 Main Relief Valve (MRV) Pressure ....................................................... E-155 Servo Relief Pressure ........................................................................... E-157 Slew Motor Pressure Relief .................................................................. E-158 Auxiliary Relief Valves .......................................................................... E-160 General ............................................................................................. E-160 Boom Ram ....................................................................................... E-161 Dipper Ram ...................................................................................... E-163 Bucket Ram ...................................................................................... E-164 Option ARV (Monoboom) ................................................................. E-165 Travel Motor Relief Pressure ................................................................ E-166 Routine Maintenance Procedures Scheduled Tasks .................................................................................. E-167 Service Points ....................................................................................... E-168 Upper Structure ................................................................................ E-168 Hydraulic Compartment .................................................................... E-169 Dozer Assembly ................................................................................... E-170 Fuel Tank .............................................................................................. E-171 Hydraulic Oil ......................................................................................... E-172 Replace ............................................................................................ E-172 Hydraulic Tank Breather ....................................................................... E-173 Replace ............................................................................................ E-173 Return Filter .......................................................................................... E-174 Replace ............................................................................................ E-174 Drain Filter ............................................................................................ E-175 Replace ............................................................................................ E-175 Suction Strainer .................................................................................... E-176 Clean / Replace ................................................................................ E-176 Major Component Mounting Bolts ........................................................ E-177 Check ............................................................................................... E-177 Breaker In-Line Filter Element .............................................................. E-178 Replace ............................................................................................ E-178 Relief Valves ......................................................................................... E-180 Check (Condition) ............................................................................. E-180 Slew Gearbox ....................................................................................... E-181 Check (Condition) ............................................................................. E-181 Check (Oil Level) .............................................................................. E-181 Replace (Oil) .................................................................................... E-181 Fault Finding Hydraulic Contamination ...................................................................... E-183 Hydraulic Fluid Quality ..................................................................... E-183 Effects of Contamination .................................................................. E-183 Cleaning Operation .......................................................................... E-183 Contaminant Standards .................................................................... E-184 Filters ................................................................................................ E-184 Main Control Valve ............................................................................... E-185 Relief Valve ........................................................................................... E-186 Hydraulic System .................................................................................. E-187 Slew Motor ............................................................................................ E-188

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Section E - Hydraulics Contents

Contents Page No. Hydraulic Pump .................................................................................... E-190 Hydraulic Rams .................................................................................... E-191 Hydraulic Ram Faults and Remedies ............................................... E-191 Fault Finding Tests ............................................................................... E-196 Slow or Underpowered: .................................................................... E-196 Harsh Operation When Selecting: .................................................... E-196 Tracking Off Line .............................................................................. E-196 Poor Tractive Effort ........................................................................... E-196 Loss of Creep Speed ........................................................................ E-196 Loss of High Speed .......................................................................... E-197 Machine Selects High Speed Travel ................................................. E-197 Slew Bearing Faults ......................................................................... E-197 Test 001: Testing Negative Control Signal ............................................ E-198 Test 002: Test Max Flow Signal ............................................................ E-199 Test 003: Testing Main Pump Pressure ................................................ E-200 Test 004: Testing Horsepower Control .................................................. E-201 Test 005: Checking the Operation of the Main Hydraulic Spool ........... E-203 Test 006: Test the Pressure Switches ................................................... E-205 Symptoms of Pressure Switch Failures ............................................ E-207 Test 007: Testing Engine Speed Settings ............................................. E-208 Pressure Switches vs Engine Speed ................................................ E-209 Test 008: Testing Machine Cycle Times ................................................ E-211 Bucket Ram Speed ............................................................................E-211 Dipper Ram Speed ........................................................................... E-212 Boom Ram Speed ............................................................................ E-212 Slew Speed ...................................................................................... E-213 Travel Speed .................................................................................... E-213 Travel Linearity ................................................................................. E-213 Test 011: Testing Swing Brake Pressure .............................................. E-214 Test 012: Testing Track Motor Relief Valve Settings ............................. E-215 Test 013: Testing Track Motor Drain Line Flow Rate ............................ E-216 Test 014: Loss of High Speed Tracking ................................................ E-217 Additional information ....................................................................... E-217 Test 015: High Gear Selection, Monitor Displays Another Travel Gear E-218 Test 016 - Flow Testing Hydraulic Pumps - Record Sheet ................... E-219 Test 017: Testing Slew Bearing ............................................................ E-221 Checking Slew Bearing Backlash ..................................................... E-221 Checking Slew Bearing Vertical Lift .................................................. E-222 Ram Creep Tests - All Services ............................................................ E-224 Test for Ram Creep .......................................................................... E-224

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Section E - Hydraulics

Technical Data General Data Main Hydraulic Pump Table 1. Twin variable displacement axial piston pump

Type Displacement volume

37 cm3/rev x2

Boom down ARV

304 bar

Main relief valve

294 bar

Operating pressure rated

294 bar (300 kgf/cm2, 4264 lb/in ) 2

Maximum output @ 2200 rpm(tracking)

81.4 litre/min. x2

Pump controller

Servo

Direction of the shaft

Clockwise

Fuild specification

Anti wear hydraulic fuild

Servo Pump Table 2. Type

Fixed displacement gear pump

Displacement volume

9.5 cm3/rev

Maximum pressure

3.9 bar (56.8 lb/in2)

Slew Motor/Gearbox

Type Maximum Displacment Allowable viscocity Allowable temperature Working pressure maximum Set pressure relief Reduction gears Reduction gear ratio Brake torque Dry weight

E-1

Table 3. From 1799466

To 1799466

Fixed displacement piston motor

45.5 cm3/rev

10 - 1000 mm2/s

-30 +95

190 bar (2755 lb/in2)

19 bar (275 Ib/in2)

Planetary gears with 2 gear reduction Planetary gears with 2 gear reduction 20 :1

19.464 :1

165 Nm

20 kg

67 kg (147 lb)

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Section E - Hydraulics Technical Data General Data

Main Control Valve Table 4. Type

Hydraulic Pilot System

Operating system

Set pressure relief

Main relief pressure

300 Bar

Overload relief pressure

30.5 mpa at 20 l/min

Oil temperature range

-25 to 950 C

Bucket open/closed

284 bar (4119 lb/in2)

Dipper

284 bar (4119 lb/in2)

Boom raising

284 bar (4119 lb/in2)

Boom lowering pressure

284 bar (4119 lb/in2)

Swing

190 bar (2755 lb/in2)

Pilot

35 bar (507 lb/in2)

Dozer Control Valve Table 5. Type

Manual Control

Operating system

Set pressure relief

Main relief pressure

226 Bar

Overload relief pressure

225 Bar (A Port); 305 Bar (B port)

Boom Ram Table 6. Cylinder diameter

100 mm (3.9 in)

Rod diameter

65 mm (2.56 in)

Maximum contracted length

2310 mm (90.94 in)

Stroke

927 mm (36.49 in)

Dry weight

94 kg (207 lb)

Dipper Ram Cylinder diameter

E-2

Table 7. 95 mm (3.74 in)

Rod diameter

60 mm (2.36 in)

Maximum contracted length

2242 mm (88.28 in)

Stroke

878 mm (34.56 in)

Dry weight

84 kg (185 lb)

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Section E - Hydraulics Technical Data General Data

Bucket Ram Cylinder diameter

Table 8. 85 mm (3.3 in)

Rod diameter

55 mm (2.1 in)

Maximum contracted length

1718 mm (67.65 in)

Stroke

688 mm (27 in)

Dry weight

64 kg (141 lb)

Dozer Ram Cylinder diameter

Table 9. 110 mm (4.0 in)

Rod diameter

60 mm (2.0 in)

Maximum contracted length

722 mm (28.0 in)

Stroke

195 mm (7.0 in)

Dry weight

45 kg (99.3 lb)

Specifications Boom weight

E-3

Table 10. 418 kg

Arm weight

185 kg

Revolver weight

961 kg

Cab weight

310 kg

Track speed

3.5 kmph

Dozer blade height

85 mm

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Section E - Hydraulics Technical Data General Data

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

Table 2. Rams Single acting

Double acting

Double ended

Double acting with damping at rod area end

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

Spring Flow restriction affected by viscosity

Fixed capacity motor one direction of flow

Direction of flow Fixed capacity motor two directions of flow

Indication of rotation

Variable capacity motor one direction of flow

Indication of direction and paths of flow

Variable capacity motor two directions of flow

Variable control

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

Throttling orifice - normally closed

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

Throttling orifice - normally open

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

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

Variable restrictor

Non-return valve Non-return valve with back pressure spring

Pilot operated non-return valve

One way restrictor

High pressure selector (shuttle valve)

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

Reservoir - return line below fluid level

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 Quick release couplings connected

Cooler - with no indication of coolant flow

Cooler - indicating direction of coolant flow

Heater

Quick release couplings disconnected

Reservoir - return line above fluid level

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

Rotating shaft - one direction

Solenoid two windings

Rotating shaft - two directions

Detent

Locking device

Electric motor operated

Internal pressure pilot operated

Over centre device

External pressure pilot operated

Simple linkage

Pressure operated spring release

General control

Pilot operated by solenoid pilot valve

Push button operated

Pilot operated by a solenoid or seperate pilot valve

Lever operated Pressure guage Pedal operated Pressure switch Stem operated

Spring operated

Roller operated

Roller trip operated (one directional)

E-8

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E-8

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

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

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

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

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

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

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

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

E-9

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Fig 6.

E-9

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

Example of Schematic Circuit

A B

C D

E F

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

Example Circuit Key 7-A

Hydraulic Tank

7-B

Strainer

7-C

Fixed Displacement Pump

7-D

Relief Valve

7-E

Spool

7-F

One Way Valve

7-G

Double Acting Hydraulic Ram

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

E-10

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E-10

Section E - Hydraulics Circuit Descriptions Hydraulic Schematic

Circuit Descriptions Hydraulic Schematic The item numbers in the following table are identified on the Hydraulic Schematic diagrams. K Fig 1. ( T E-12)

Item

Description

Shuttle valve

Pressure Switch

Item

Table 1. Component identification Description

Remote Valve LH

Slew Motor

Valve

Dipper Ram

Pressure Switch

Boom Priority Valve

Quick Relief Coupling

Track Motor and Gearbox

Valve

Rotary Coupling

Relief Valve

Bucket Ram

Line Filter

Boom Ram LH

Solenoid Valve

Boom Ram RH

Quick Relief Coupling

Shuttle Valve

Manifold Block

Control Valve

Pressure Switch

Hose Burst Check Valve

Remote Valve RH

Hose Burst Check Valve

Pressure Switch

In line Filter

Pressure Switch

Check Valve

Radiator

Slew Gearbox

Air Breather

Tank

In line Filter

Strainer

Relief Filter

Return Filter

Stop Valve

Filter

Stop Valve

Check Valve

Pressure Switch

Solenoid Valve

Accumulator

Actuator

In line Filter

Hydraulic Pump

Remote Control Valve

E-11

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E-11

E-12

15 DOZER

13 D2

A1 LOW

RED

LOW

10 D1 P2

DOZER

DOZERBLADEP/P MOUNTED ON ENGINE

T1 D1

4 T

8 7

1 5

ARM RAM

ROD

POO

A5 B5 (BOTTOM)

Pb5

ARM(2)

ARM(1)

Pb9

Pa9 Pc2 A8

Pa5 Pc3

GREASE FILLING PORT

Pb4

BOOM(1)

Pb8 Pa8 B7

Pa4

RG OIL FILLING PORT

B8 BOOM(2)

SWING

Pb3

A7 Pb7

BUCKE T

Pa3 Pi2 Dr4 B2

A2 Pb2 P4 Pa2

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AIRVENT PORT IN CASEOFOIL FILLING

(ROD)

(BOTTOM)

Pa7 Pi 1 B6 OPTION

TRAVE L(R)

A6 Pb6 Pa6 BUCKE T RAM

BOOM RAM

ARAVE T L(L) 1

Pb1

Pa1

KAYABA VALVE GB

Dr DRAWN PORT

GA B

2 IN

OUT

RIGHT

LEFT

8 4

a1 P5

TRAVE L(L)

TRAVE L(R) ACC

BACKWARD

FORWARD

BACKWARD A3 CT1

P BOOM

CT2

BUCKET

CT3

CT5

P2 CT4

Dr1

GP DOWN

OPEN

CLOS E

150MES H

Fig 1. Hydraulic Schematic

E-12

Hydraulic Schematic

Circuit Descriptions

1.3 bar

Section E - Hydraulics

Section E - Hydraulics Circuit Descriptions Hydraulic Schematic (Serial Number - 24266501 to 2427000)

Hydraulic Schematic (Serial Number - 24266501 to 2427000) The item numbers in the following table are identified on the Hydraulic Schematic diagrams. K Fig 2. ( T E-14)

Item

Table 2. Component identification Description

Pump

Main control valve

Pilot control valve

Accumulator

Servo filter

Cab manifold

Hand control valve RH

Hand control valve LH

Foot control valve

Dozer pump

Dozer valve

Swing motor

travel motor

Rotary coupling

Dozer cylinder

Boom cylinder

Arm cylinder

Bucket cylinder

Check valve

Hydraulic tank

Check valve

Radiator

Return filter

Relief valve

Strainer

Air breather

Hydraulic pilot control valve

Shuttle valve

ABI Auto idler

E-13

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E-13

E-14

Circuit Descriptions

Section E - Hydraulics

335-H2608

E-14

Hydraulic Schematic (Serial Number - 24266501 to 2427000)

9813/2000-02

Fig 2. Hydraulic Schematic

Section E - Hydraulics Circuit Descriptions Hydraulic Schematic (Serial Number - 24266501 to 2427000)

Page left intentionally blank

E-15

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E-15

Section E - Hydraulics Circuit Descriptions Servo Line

Servo Line 1

Cab Manifold

Main Control Valve

Left hand Joystick

Travel Pedal

Right hand Joystick

1 4

2 Fig 3. Servo/Pilot Line Schematic - 332/P3491/2

E-16

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E-16

Section E - Hydraulics Circuit Descriptions Pilot Pressure and Return Line

Pilot Pressure and Return Line 1

Main Control valve

Pilot Control Valve

Cab Manifold

Swing Motor

Servo Filter

Rotary coupling

Servo Pump

3 5

6 Fig 4. Servo/Pilot Pressure and Return Line Schematic - 332/P3656/5

E-17

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E-17

Section E - Hydraulics Circuit Descriptions Neutral Circuit

Neutral Circuit For schematic, K Fig 5. ( T E-19) With all the controls in the neutral position, flow from pump A1 enters the main control valve 14 at port P2 and flow from pump A2 enters the main control valve 14 at port P1. Oil is allowed to flow across all of the spools via the neutral gallery when all controls are in the neutral position. Oil from pump A1 exits port Ps1 and oil from pump A2, exits port Ps2 at the top of the main control valve. Both flows of oil meet a separate restrictor and relief valve. Some oil will pass through the restrictor and back to tank, creating back pressure in the line. The back pressure is sensed at pump, which destrokes the swash plate leading to less flow. Flow from the servo pump enters the valve block at port Pp, where it meets 3 restrictors. These maintains the pressure on the input side at full servo pressure. Oil that crosses the restrictors, is allowed back to tank after passing over the neutral gallery of the spools. No pressure is created in this line whilst all controls are in neutral, allowing all pressure switches to remain in the open position.

E-18

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E-18

Section E - Hydraulics Circuit Descriptions Neutral Circuit

T1 D1

POO A5 B5 Pb5

ARM(2)

ARM(1)

Pb9

Pa9 Pc2 A8

Pa5 Pc3 Pb4

B8 BOOM(2)

BOOM(1)

Pb8 Pa8 B7

Pa4

Pb3

A7 Pb7

BUCKET

SWING

Pa3 Pi2 Dr4 B2

Pa7 Pi1 B6

A2 OPTION Pb2 P4 Pa2

TRAVEL(R)

A6 Pb6 Pa6

B1 A TRAVEL(L) ( ) 1

Pb1

Pa1

KAYABA VALVE

ACC

C3 A3

CT1

Keyto Oil Flow & Pressure Full Pressure Pressure

Servo Neutral

CT2

CT3

CT5

P2 Dr1 CT4

Exhaust GP

Cavitation Lock Up

Fig 5. Neutral Circuit For description, K Neutral Circuit ( T E-18)

E-19

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E-19

Section E - Hydraulics Circuit Descriptions Travel - Single Speed

Travel - Single Speed When both tracks are selected, servo pressure from port 2 (LH travel lever), and port 4 (RH travel lever) enters the main control valve at Pa1 and Pa6 respectively, selecting the left and right hand travel spools K Fig 6. ( T E-21). Flow from pump A1 is available at the LH travel spool and is directed to the LH travel motor via port A1 of the Main control valve, through the rotary coupling and into port P1 on the LH travel motor. Exhaust oil from the motor enters the main control valve at port B1 and is directed by the LH travel spool to the tank port.

E-20

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E-20

E-21 D2 P3

P3 D2

LOW

LOW HI

RED

D1 P2

P2 D1

14 T1 D1

8 1 5

POO A5 B5 Pb5

ARM(2)

ARM(1)

Pb9

Pa9 Pc2 A8

Pa5 Pc3 Pb4

B8 BOOM(1)

BOOM(2)

Pb8

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Pa8 B7

Pa4

Pb3

A7 Pb7

BUCKET

Pa3 Pi2 Dr4 B2

(ROD)

(BOTTOM)

Pa7 Pi1 B6 A6 P

A2 OPTION Pb2 P4 Pa2

TRAVEL(R) b6

Pa6

B1 A( ) TRAVEL(L) 1

Pb1

Pa1

KAYABA VALVE

FORWARD

ACC

BACKWARD

A3 CT1

CT2

CT3

CT5

P2 Dr1

CT4

E-21

Fig 6. Travel Circuit

Travel - Single Speed

BACKWARD

TRAVEL(R)

Circuit Descriptions

a1 TRAVEL(L)

Section E - Hydraulics

Section E - Hydraulics Circuit Descriptions Boom Up

Boom Up For schematic, K Fig 7. ( T E-23). Servo pressure from the hand controller enters the servo restriction valve and is divided between the Boom (1) spool valve port Pa8 and the boom (2) spool on the main control valve 10. The servo restriction valve provides a smoothing effect to the service circuits. Flow from pump A2 is stopped by the Boom (1) spool and diverted via the parallel gallery to the Boom (1) spool. The oil passes through the spool and merges with the flow from pump A1. Flow from pump A1 in the neutral gallery is stopped by the Boom (2) spool and diverted via the parallel gallery to the Boom (2) spool. The oil passes through the spool and merges with the flow from pump A2. The pressure lifts the Boom holding valve BHV off its seat allowing oil to leave the main control valve at port B8 to enter the Boom rams 7 and 8. Exhaust oil enters the Main control PS1and P2 at port B8 and crosses the Boom (1) spool to tank. Pressure is lost on both negative control ports Ps1 and Ps2, which is sensed at the pumps which come onto full flow.

E-22

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E-22

E-23

T1 D1

POO A5 B5 Pb5

ARM(2)

ARM(1)

Pb9

Pa9 Pc2 A8

Pa5 Pc3 Pb4

B8 BOOM(1)

BOOM(2)

Pb8 Pa8 B7

Pa4

Key to Oil Flow & Pressure

Pb3

A7 Pb7

BUCKET

Pa3 Pi2 Dr4 B2

Full Pressure Pressure

(BOTTOM)

Pa7 Pi1 B6

A2 OPTION Pb2 P4 Pa2

Servo Neutral

(ROD)

TRAVEL(R)

A6 Pb6 Pa6 BOOM RAM

Exhaust

A1 TRAVEL(L) ( ) Pb1

Cavitation

Pa1

Lock Up

KAYABA VALVE

9813/2000-02

OUT

RIGHT

LEFT

ACC

A3 CT1

CT2

CT3

6 P

BOOM

BUCKET

CT5

P2 Dr1 CT4

GP DOWN

OPEN

Boom Up

E-23

Circuit Descriptions

Fig 7. Boom Up Schematic

Section E - Hydraulics

Section E - Hydraulics Circuit Descriptions Boom Down

Boom Down Servo pressure from the Hand controller enters the Servo Shuttle valve 30 at port A4 and is distributed to: 1

Port C2 to the Main control valve at port Pc2. The Boom holding spool valve is moved across allowing pressure at the top of the Boom Holding Valve BHV to exhaust to tank.

Port B4 to port E of the Cushion control valve 34. The oil flows across the unrestricted part of the spool and out of port G to the main control valve at port Pb8, moving the spool to the down position.

Flow from pump A2 travels through the neutral gallery to the Boom (1) spool. The flow is restricted allowing a reduced pressure at port Ps2 which is sensed at Pm2 of the pump A2 which increases flow (less than full flow). Oil flow also passes through the parallel gallery to the Boom (1) spool and is directed to the Boom rams 6 via port B8. Exhaust oil passes through to the Main control valve at 10 port A8, lifts the Boom Holding Valve BHV off its seat and passes through the Boom (1) spool and exhausts to tank. Exhaust oil passing through the spool can be regenerated into the feed side of the rams. A check valve in the spool allows oil to enter the pressure side of the spool, if the returning oil is at a higher pressure, due to the weight of the boom or load, item A. The restrictor creates back pressure, causing the check valve to open K Fig 8. ( T E-25).

E-24

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E-24

Section E - Hydraulics Circuit Descriptions Boom Down

ps1 pcc pc1 A5 B5

DIPPER 2

DIPPER 1

pb5

pb9 pa9 pc2

BHV

pa5 pc3

A8 B8

BOOM 2

BOOM 1

pb8

pb4 pa4

pa8

B3 A3

B7 c

BUCKET

OPTION 1

TRAVEL

SLEW

pa4

A7 pb7

pa3 B2 A2

pb2 P4 pa2

pa7 B6 A6

BOOM RAM

pb6 pa6

B1 A1

LINEAR TRAVEL TRAVEL

pb1

pa1 Ts3 Ts6

R1 R2

OUT

RIGHT

LEFT

ACC

A3 CT1

CT2

CT3

6 P

BOOM

BUCKET

CT5

P2 Dr1 CT4

GP DOWN

OPEN

3 7

Fig 8. Boom Down Schematic

E-25

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E-25

Section E - Hydraulics Circuit Descriptions Dipper Out

Dipper Out Servo pressure from the Hand controller 39 is sent directly to port C3 and port Pa 9 of the main control valve 10, to activate the dipper spool, and through restriction valve to port Pa5 on the main control valve 10, activating the Dipper (1) spool. Flow from pump A1 is available at the Dipper (1) spool via the left hand neutral passage and the Linear travel spool via the parallel gallery. Flow from pump A2 is blocked at the Dipper (2) spool and joins the flow from pump A1 just after the Dipper (1) spool. Exhaust oil from the ram enters the Main control valve at port B5 and has a path to tank via the Dipper (1) and Dipper (2) spools K Fig 9. ( T E-27).

E-26

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E-26

E-27

Keyto Oil Flow & Pressure T

Full Pressure Pressure

C2 C2

Servo Neutral

M D

Exhaust Cavitation P

Lock Up

BL E

P S1

D1 D2

P S2

P C1 A5 B5

ARM(2)

ARM(1)

P b5

P b9

P a9 P c2 A8

P a5 P c3 P b4

B8 BOOM(2)

BOOM(1)

P a8 B7

P a4

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P b3

LEFT 1

SWING RIGHT 2

P b8

ARM IN 3

OUT 4

SWING

h BUCKET

P a3 P i2 Dr4 B2

P a7 B6

A2 OPTION d P b2 P4 P a2

i TRAVEL(R)

A6 P b6 P a6

B1 A 1 TRAVEL(L) P b1

A7 P b7

LINEARTRAVEL

P a1

E-27

Dipper Out

Fig 9. Dipper Out Schematic

Circuit Descriptions

Section E - Hydraulics

Section E - Hydraulics Circuit Descriptions Dipper In

Dipper In Servo pressure from the Hand controller 39 is distributed to C4 Port Pb9 on the Main control valve. From the out port of the restriction valve, it flows to port Pb5 and port Pc1 on the Main control valve 10 and to the Dipper (1) spool and the dipper load hold check valve DHV respectively. Flow from pump A1 is available at the Dipper (1) spool via the left hand neutral gallery or after passing over the straight line travel spool via the parallel gallery. At the Dipper spool flow is diverted to the Dipper ram 2. Pressure is sensed at the regeneration spool RGS and moves it to the lesser restricted position. Flow from pump A2 is blocked at the Dipper (2) spool and joins the flow of pump A1 just after the Dipper (1) spool. Exhaust oil from the ram passes to the Main control valve 10 at port A5 through Dipper hold check valve DHV (that has been released by servo pressure) to the Dipper (1). This can be at a higher pressure than the feed oil due to the effect of gravity on the dipper arm when first selected. This causes the regeneration check valve RG to open, feeding a proportion of exhaust oil into the feed side. The remaining exhaust oil returns to tank passing over the regeneration spool RGS. The regeneration spool has two restrictors, one more restrictive than the other. The restrictors cause back pressure, encouraging the regeneration check valve to open. As the pressure drops the regeneration spool moves across to the more restricted position. When the feed pressure is greater than the exhaust pressure the regeneration check valve will close. Exhaust oil from the Dipper (1) spools travels over restrictors R2 and R 3 and to tank via the unselect travel spool K Fig 10. ( T E-29).

E-28

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E-28

E-29

Keyto Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust

P S1

Cavitation

D1 D2

P S2

Lock Up

P C1 A5 B5 P b5

ARM(1)

ARM(2)

P b9

P a9

P c2 A8

P a5 P c3 P b4

LEFT 1

SWING RIGHT 2

ARM IN 3

OUT 4

P a4

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P a3 P i2 Dr4 B2 A2 OPTION P b2 P4 P a2

B8 BOOM(1)

BOOM(2)

P b8 P a8 B7

BUCKET

A7 P b7

SWING

P a7 B6

TRAVEL(R) A 6

P b6 P a6

B1 A 1 TRAVEL(L) P b1

P a1

R2 R3

P C1

DHV

ARM(1)

RGS

Fig 2

E-29

Dipper In

Fig 10. Dipper In Schematic

Circuit Descriptions

P b5

Section E - Hydraulics

Section E - Hydraulics Circuit Descriptions Bucket Opening

Bucket Opening Servo pressure from port 2 of the Hand controller 33 selects the bucket spool open position via port Pa7 of the Main control valve. Flow from pump A2 is available to the Bucket spool via the parallel gallery. At the spool the flow is diverted to port B7 of the Main control valve 10 to the Bucket ram 6. Returning oil enters the Main control valve 10 at port A7 and is diverted by the Bucket spool to the tank. Pressure in the neutral circuit drops after the Bucket spool is selected. This is sensed at the port Ps2 and at the pump, bringing it onto full flow K Fig 11. ( T E-31).

E-30

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E-30

E-31

D1 D2

P S2

Keyto Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up

f ARM(2)

P b9

P a9 P c2 A8 B8 g BOOM(1)

P b8 P a8 B7

BUCKET A 7

9813/2000-02

P b7 P a7

B6 i

TRAVEL(R) A 6

P b6 BUCKET CLOSE OPEN

P a6

BOOM DOWN UP 4

Bucket Opening

E-31

Fig 11. Bucket Opening Schematic

Circuit Descriptions

Section E - Hydraulics

PT PP

Section E - Hydraulics Circuit Descriptions Bucket Closing

Bucket Closing Servo pressure from the hand controller is sent from port 1 to port Pb7 of the Main control valve and moves the Bucket spool into the bucket close position. Flow from pump A2 is available at the Bucket spool via the parallel gallery. Flow is diverted to port A7 of the Main control valve to the Bucket ram 6. Returning oil from the Bucket ram enters the Main control valve at port B7 and is diverted to tank by the Bucket spool. When returning oil from the Bucket ram enters the spool it crosses a restrictor which causes back pressure. If the pressure in the return line is greater than that of the feed line, the valve will open allowing return oil to be regenerated into the feed line K Fig 12. ( T E-33).

E-32

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E-32

E-33

Fig 3 BUCKET T3

P S1

D1 D2

P S2

P C1 A5 B5 P b5

ARM(1)

f ARM(2)

Keyto Oil Flow & Pressure P b9

Full Pressure Pressure

P a9

Servo Neutral

P c2 A8

P a5

Exhaust

P c3 P b4

BOOM(2)

g BOOM(1)

Cavitation

P b8

Lock Up

P a8 B7

P a4

P b3

SWING

BUCKET

9813/2000-02

P a3 P i2 D r4 B2 A2 OPTION P b2 P4 P a2

A7 P b7 P a7 B6

TRAVEL(R)

A6 P b6 P a6

B1 A 1 TRAVEL(L) P b1

P a1

P2 P

BUCKET CLOSE OPEN 1 2

BOOM DOWN 3

UP 4

E-33

Bucket Closing

A406070

Fig 12. Bucket Close Schematic

Section E - Hydraulics

Circuit Descriptions

Section E - Hydraulics Circuit Descriptions Swing

Swing When Ignition is ON, the swing lock solenoid is energized and allows 40 bar pressure to go to the swing brakes to release them. The machine is still locked hydraulically. Servo pressure from the Hand controller 51 enters port B2 to the slew spool at port Pa3 on the Main control valve 10 to move the spool across. Flow from the pump A1 is stopped in the neutral gallery by the slew spool. The flow passes through the linear travel into the parallel gallery to the slew spool. The spool flow is then directed via port A3 to the slew motor 1. Exhaust oil enters the main control valve at B3 to the slew spool and to tank through a restriction K Fig 13. ( T E-35).

E-34

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E-34

E-35

Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral

Exhaust Cavitation

Lock Up

P S1

D1 D2

P S2

P C1 Mu RIGHT

A5 B5

LEFT

P b5

ARM(2)

ARM(1)

P b9

P a9 P c2

oil servo pump

SDV

P a5 P

P b4

B8 BOOM(2)

BOOM(1)

P b8 P a8 B7

9813/2000-02

P a4 P b3 BUCKET

A7 P b7

SWING

P a3 P i2 Dr4 B2

P a7 B6

A2 OPTION P b2 P4 P a2

TRAVEL(R)

A6 P b6 P a6

B1 A 1 TRAVEL(L) P b1 P a1

SWING RIGHT

Fig 13. Slew Circuit

Swing

E-35

Circuit Descriptions

LEFT

Section E - Hydraulics

Section E - Hydraulics Circuit Descriptions Swing

Page left intentionally blank

E-36

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E-36

Section E - Hydraulics

Remote Control Valve (Hand Control) Operation TE-008

The remote control valve is a pressure reduction valve used to control the servo pressure operated system. Four pressure reduction valves used to control the servo pressure are located in the main housing. Direction of the output servo pressure is controlled by selective movement of the control lever. The valves and control levers are mounted in the arm rests on both sides of the operator's seat.

springs also provide a resistive force, giving the operator a `tactile feel' of the controls. The control handles contain electrical push button and rocker switches which are used to operate auxiliary services.

The pressure reduction unit is comprised of spools 17, pressure control springs, return springs and spring seats 13. The spools 17 are held against the plungers 11 by the return springs 15. When the control handle is tilted, the plungers 11 move down, depressing the return spring seats 13, simultaneously compressing the pressure control springs moving the spool, allowing hydraulic oil to flow to the designated pilot port. The lower end of the main body contains the main inlet port P, outlet port T to tank and the servo pressure outlet ports 1, 2, 3 and 4. The servo pressure controls the stroke and direction of the main control valve spools. This is achieved by providing a spring at one end of the main control valve spools and applying pilot pressure to the opposite end. (In some cases, pilot pressure is applied to both ends of the control valve spool.)

Function Oil supplied by the hydraulic servo pump enters at port P and the function of the spools 17 is to direct oil from the inlet port P to the output ports 1, 2, 3 and 4 or alternatively, to the exhaust port T to tank. The pressure control springs act on the spools 17 to determine pressure at each port. Plungers 11 slide in the guides to vary the compression in the springs. The control handle, fixed to the adjusting nut 24 and circular rocker plate 25 is operated to move the plungers 11. The control handle is able to rotate 360Â° around the knuckle joint 26. The return springs operate between the casing and the seats 13, regardless of the outlet pilot pressure, returning the plungers 11 to their outer positions, ensuring the spools 17 return to their neutral (closed) positions. The

E-37

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E-37

Section E - Hydraulics Remote Control Valve (Hand Control) Operation

24 26 25 11 11

13 13 T

P 2,4

1,3 A409170-C1

Fig 1.

4 JS03240-C1

Fig 2.

E-38

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E-38

Section E - Hydraulics Remote Control Valve (Hand Control) Removal and Replacement

Removal and Replacement

!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

Lift the remote control valve clear of the arm rest.

Note: Care should be taken when removing right arm rest, remove switches, using a thin flat bladed screw driver and disconnect electrical connections.

Replacement Replacement is the reversal of the removal sequence. Note: All hydraulic adapters that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adapter.

!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

Removal 1

Lower dipper and place bucket on the ground

Turn off engine.

Operate both control joysticks back and forth and side to side to vent residual pressure.

Remove the two screws A from each side, and loosen screws B (one either side of the arm rest). Remove front panel C.

Disconnect electrical connection to remote control valve.

Disconnect all hydraulic hoses and pipes from the remote control valve and plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct position when refitting.

Remove the two screws D, two screws E and loosen the two screws F. Remove panel G.

Lift up gaiter H and remove the fours bolts holding the valve to the arm rest.

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E-39

Section E - Hydraulics Remote Control Valve (Hand Control) Removal and Replacement

E F

A C A407780-C1

Fig 3.

Left hand Control Valve

E-40

Table 1. Right hand Control Valve

Port

Hose Colour

Port

Hose Colour

Orange

Green

Blue

Violet

Yellow

Pink

Red

White

9813/2000-02

E-40

Section E - Hydraulics Remote Control Valve (Hand Control) Dismantling and Assembly

Dismantling and Assembly Dismantling

Note: Ensure retaining plate moves freely to prevent sudden release due to spring pressure beneath.

Note: All parts are precision made and require the utmost care when being handled.

Note: During dismantling, do not use excessive force to separate components which could cause scratches or burrs on bearing surfaces. Failure to observe this instruction will cause oil leaks leading to poor performance.

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

If the return springs 15 are weak, the sliding resistance of the seal 9 will cause the guides 8 to stick in the casing. Using a screw driver, carefully ease out the guides 8 and plungers 11.

Note: Label all parts during dismantling, to ensure correct assembly. Note: Storing the valve when dismantled could cause rusting of parts. Ensure they are suitably protected by antirust treatment. Note: Refer to the illustration for part number identification K Fig 4. ( T E-43). 1

Push down upper section of gaiter 19 and remove roll pin 20.

Note: Care must be taken to prevent damage to the guides when removing. Ensure the guides do not fly out due to the force of the return springs. 9

Note: Identify each set of parts and their locations for assembly. 10

Loosen the two hex bolts 27 on the base of the valve. Remove the base plate and `O'-ring 30 from the valve casing.

Slacken and remove body assembly screw 6. Remove and discard `O'-ring 7.

Separate upper and lower body sections 1 and 2 and remove dowel pins 5. Remove and discard `O'-rings 3 and 4.

Remove control handle from mounting knuckle 3.

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

Remove spring seats13, split washers 12, return springs 15, pressure control springs 14 and spools 17.

Remove gaiter 19 from valve housing.

Slacken locknut 22 and remove mounting knuckle 23.

Slacken and remove joint nut 24 and rocker plate 25.

Note: The surface of spool 17 and spring 13 can be damaged by mis-handling. Take care not to damage the surface of the spool during removal and do not push the spring seat down more than 6mm (0.24 in).

!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.

Hold spools 17 firmly on the work bench and depress spring seat 13 and remove split washers 12.

GEN-6-2

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

Note: The return spring 15, retaining plate 18 and plunger 11 will rise when knuckle joint 26 is loosened.

Separate spools 17, spring seats 13, springs 14 and 15 and shims 16.

Using a jig, slacken and unscrew knuckle joint 26, releasing retaining plate 18.

Remove plungers 11 from guides8.

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E-41

Section E - Hydraulics Remote Control Valve (Hand Control) Dismantling and Assembly 17

Remove seals 9 and 10 from guide 8 and discard.

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

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E-42

Section E - Hydraulics Remote Control Valve (Hand Control) Dismantling and Assembly

21 26 18 8

9 10 2 20 23

11 12

3 4

5 22

13 14

24 16 7

30 29

28 27 A408130-C1

Fig 4.

E-43

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E-43

Section E - Hydraulics Remote Control Valve (Hand Control) Dismantling and Assembly Item

Description

Qty.

Item

Table 2. Description

Qty.

Item

Description

Qty.

Lower body

Plunger

Control handle

Upper body

Split Washer

Locknut

`O'-ring

Spring seat

Mounting knuckle

`O'-ring

Compression spring

Joint nut

Dowel pin

Return spring

Rocker plate

Body assembly screw

Shims

Knuckle joint

`O'-ring

Spool

Hex Bolt

Plunger guide

Retaining plate

Washer

Seal

Gaiter

Base plate

Seal

Roll pin

`O'- ring

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E-44

Section E - Hydraulics Remote Control Valve (Hand Control) Dismantling and Assembly

Inspection Note: Before assembling the remote control valve make sure that a thorough inspection of all the components is carried out. Remember that although a failed component may be easy to identify, the cause may be less easy to trace. It is also possible that a failed component may have caused damage to other areas of the valve. 1

Carefully clean all components using a suitable degreasing agent.

Carefully inspect all components for signs of excessive wear or damage. If wear or damage is evident, components must be renewed.

24 25

Note: `O'-rings and other sealing materials should preferably be replaced each time the valve is disassembled but they may be re-used provided a careful check is made that they are un-damaged.

Assembly 18 Note: During assembly, ensure all parts are clean and free from burrs and scratches. Remove minor damage by lapping.

Note: Renew all `O'-rings, seals and back-up rings. Take care to install seals the correct way around. Note: During assembly apply hydraulic oil to `O'-rings and seals. Note: Ensure all screws and bolts are tightened to the torque settings given. The numerical sequence given previously is a guide to dismantling. For assembly the sequence should be reversed noting the following details: 1

Locate retaining plate 18 onto plunger guides 8 and using the jig, screw knuckle joint into position. Locate rocker plate 25 and tighten until it makes contact with the plungers 11. Ensure the plungers are not depressed at this stage.

Holding the rocker plate 25 in its position, screw down joint nut 24.

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

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6,7 JS03250-C1

Fig 5. Item

Kgf m

lbf ft

29.5

14.7

E-45

Section E - Hydraulics Remote Control Valve (Hand Control) Dismantling and Assembly

Fault Finding Symptom Low secondary pressure.

Unstable secondary pressure.

High secondary pressure.

Possible cause

Remedy

Primary pressure is low.

Apply the correct primary pressure.

Spring 4 is damaged.

Renew the spring.

Clearance between the spool and seating is too large.

Renew the remote control valve assembly.

The handle unit is loose.

Dismantle, reassemble or renew the handle unit.

Sliding parts are sticking.

Release the sticking part.

Fluctuations in the tank line pressure.

Check return line and filter for blockage.

Air is trapped in the piping.

Operate the valve several times to remove the air.

The tank line pressure is too high.

Check return line and filter for blockage. Release the sticking part.

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E-46

Section E - Hydraulics

Main Control Valve Description Key A

Negative control valve Ps1

Restrictor orifice

Negative control valve Ps2

Load hold check valves

Dipper regeneration valve

Slew over dipper priority valve

Merge

Excavator over travel priority valve

Main Relief Valve (MRV)

Restrictor orifice, J1 Travel restrictor orifice, J2 Excavator restrictor Orifice

Auxiliary Relief Valves (ARV) K1 Boom up, K2 Bucket, K3 Option, K4 Dipper out, K5 Dipper in, K6 Option, K7 Bucket, K8 Boom down, K9 Option, K10 Option, K12 Option, K13 Option pump

L1 Boom load hold valve, L2 Dipper load hold valve

MRV check valves

Spools

O1 Travel pressure switch, O2 Excavator pressure switch, O3 Power boost pressure switch

P1 Pump 1, P2 Pump 2, PR Option pump

Tank return

K Fig 1. ( T E-48)

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E-47

Section E - Hydraulics Main Control Valve Description

DR2

ps1

T1 DR3

DR1 ps2

A pc1

L2 L2

A5 B5

pb5

pb4

pa4

pb2 P4 pa2

N7 D7

K2 D3

pa8

N8 D6

pb8

K7 N3

B1 A1 pb1

pc2

pa3 B2 A2

pa9

pa4 B3 A3

pa5 pc3 B4

pb9

A7 pb7 pa7 B6 A6 pb6 pa6

D4 N10

pa1

Ts3 Ts6

J2 J1 P1

PP PA

Fig 1. Main Control Valve

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E-48

Section E - Hydraulics Main Control Valve Description

16 17

9 pc3

8 pb9

pb5

pb8

pb4

18 19 20

pb7

pb3

pb6

pb2

22 23

4 3

pb1

25 Ts5

Ts3

Fig 2. Main Control Valve viewed from rear of machine For port identification, K Table 1. ( T E-50).

E-49

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E-49

Section E - Hydraulics Main Control Valve Description Table 1. Port Identification Item Port Function 1

Ts3

Not used tank port Linear travel spool

pb6

Travel

pb7

Bucket

ARV bucket

ARV boom 1

pb8

Boom down 1 spool

pb9

Dipper 2 spool

Slew over dipper priority

Blank

pc3

18 19

Merge valve Blank

pb5

Dipper in 1 spool ARV dipper in

pb4

Boom 2

pb3

Slew spool

ARV option

pb2

Option spool

pb1

Travel spool

Ts5

Not used tank line

For port location, K Fig 2. ( T E-49).

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E-50

Section E - Hydraulics Main Control Valve Description

38 37 39

36 ps1

40 B5

pc1

42 A3

28 27

Fig 3. Main Control Valve viewed from right hand side of machine For port location, K Table 2. ( T E-52).

E-51

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E-51

Section E - Hydraulics Main Control Valve Description Table 2. Port Identification Item Port Function 27

Boost Pressure Switch (03) Travel priority check valve

Travel

Option priority check valve

Option

Slew

Not used

Dipper 1

Slew load hold check valve

36 37

Dipper load hold check valve ps1

P1 negative Boom 2 load hold check valve

Dipper out

pc1

Dipper load holding valve

Blank

Slew

Option

Travel pressure switch

Excavator pressure switch

Blank

Travel

Pump 1

For port location, K Fig 3. ( T E-51).

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E-52

Section E - Hydraulics Main Control Valve Description

59 66 58

67 DR

57 pa5

pa9

pa4

pa8

pa3

pa7

56 55 54 53

70 pa2

52 51

pa6

71 72

pa1

73 50

Fig 4. Main Control Valve Viewed from front of machine K Table 3. ( T E-54).

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E-53

Section E - Hydraulics Main Control Valve Description Table 3. Port Identification Item Port Function 50 51

Item Port Function 64

MRV check valve PP

Pressure switch feed

ARV option

pa2

Option

pa3

Slew spool

pa4

Boom 2 spool

pa5

Dipper out spool

pa9

Dipper 2 out spool

pa8

Boom 1 spool

ARV boom up

70 71

P1 negative control valve

Dipper regeneration spool

60 61 62 63

Drain line P2 negative control valve

ARV dipper out

ARV bucket

pa7

Bucket

pa6

Travel

MRV check valve

Linear travel spool

MRV

pa1

Travel

For port location, K Fig 4. ( T E-53).

85 pbu

pcc

ps2 T2

95 96

82 A8

pc2 B7

98 99 100

101

105

102 103

104 Fig 5. Main Control Valve viewed from left of machine K Table 4. ( T E-55)

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E-54

Section E - Hydraulics Main Control Valve Description Table 4. Port Identification Item Port Function 78

Travel

Bucket

Boom 1

pc2

Boom load holding valve

Blank

ps1

P2 negative control signal

pcc

Merge signal

pbu

Drain for slew over dipper priority

Tank line

Boom down

96 97

Load hold check valve

98 99

Dipper load hold check valve B7

Bucket

Travel

100 101

Boom load hold check valve

102

Blank

103

Merge out

104

Pump feed

105

Bucket load hold check valve

For port location, K Fig 5. ( T E-54).

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E-55

Section E - Hydraulics Main Control Valve Description

Page left intentionally blank

E-56

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E-56

Section E - Hydraulics

Slew Motor Reduction Gearbox Assembly Reduction Gear Structure and Working Principles

Fig 1.

Table 1. Key A Chamber

B Chamber

Torque path

Due to the severe conditions under which the output shaft operates, an oil seal 61 is provided in the centre of gear case 58 to protect the bearings from metal waste worn from the gears. The bearing in chamber A is lubricated with gear oil and the bearing in chamber B with grease.

Power transmitted by the hydraulic motor output shaft is transmitted to second sun gear 77 via first sun gear 66, planetary gear 69 and holder 65. Power is then transmitted to output shaft 53 via second sun gear 77, planetary gear 72 and holder 76. The output shaft is constructed with an integral pinion and is supported in gear case 58 by bearings 57 and 62.

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E-57

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

Dismantling and Assembly

P041530-23

Fig 2. Slew Gearbox

E-58

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E-58

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly Equipment

E-59

Table 2. Special Tools Required Code

Puller

6689969018

Stopper

6689961540

Multifier

ATZ090320

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E-59

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

Dismantling Important: Initial inspection can be made disassembling the slew drive from the machine.

without

Important: Before slew drive disassembling, make sure that the oil is discharged according to instructions specified in section "Oil draining and replacement". 1

Remove the 1st stage Sun gear 25.

P041530-25

Fig 4. 3

Remove the motor adaptor flange 22.

P041530-24

Fig 3. 2

Unscrew the nos.8 socket head screws M10X55 24, grade 8.8 and the washers 23 from the motor adaptor flange 22.

P041530-26

Fig 5. 4

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9813/2000-02

Remove the O-ring seal 34 from the motor adaptor flange 22.

E-60

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

Remove the 1st reduction 21. P041530-29

Fig 7. 7

Remove the 2nd stage sun gear 15.

P041530-28

Fig 6. 6

Remove the toothed ring 20. P041530-30

Fig 8. 8

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Remove the O-ring seal 18 from its seat in the end cover 16.

E-61

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

P041530-31

P041530-33

Fig 9. 9

Fig 11.

Unscrew the nos.4 socket head screws M10x55 19 grade 8.8 and the nos.12 socket head screws M10x65 17 grade 12.9 from the end cover 16.

Remove the O-ring seal 12 from its seat in the end cover 16.

P041530-34

Fig 12. P041530-32

Fig 10. 10

By using two crowbars, remove the 2nd reduction 14.

Remove the end cover 16.

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E-62

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

P041530-37

Fig 15.

P041530-35

Fig 13. 13

Note: In order to proceed with the gearbox disassembly, it is now necessary to remove it from the machine and bring it to a properly equipped workshop

Remove the toothed ring 13.

Straight the lip of the staking on the nut 11.

P041530-36

Fig 14. 14

P041530-38

Remove the O-ring seal 12 from its seat in the gearbox housing 14.

Fig 16. 16

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9813/2000-02

By using a tackle, place the torque multiplier (ATZ090320) on the ring nut 11.

E-63

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

P041530-40

P041530-39

Fig 19.

Fig 17. 17

By using the torque multiplier (ATZ090320) loosen the ring nut 11.

Note: In case of lifting of the unit, screw partially the ring nut on the flanged hub to avoid that the gearbox housing falls down. 19

Remove the spacer 10.

P041530-41

Fig 18. 18

Remove the ring out 11.

P041530-42

Fig 20. 20

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9813/2000-02

By using a puller, remove the pinion shaft 1 from the gearbox housing 4.

E-64

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

P041530-43

Fig 21. 21

P041530-45

Remove the bearing inner ring 3 from the gearbox housing 4.

Fig 23. 23

By using a metal stopper, remove the seal ring 8 from the gearbox housing 4.

P041530-44

Fig 22. 22

Remove the gearbox housing 4. P041530-46

Fig 24. Note: Disassemble the seal ring only in case of replacement, because this will damage it. 24

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By using a puller, remove the bearing outer ring 3 from the gearbox housing 4.

E-65

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly 26

Assemble the puller (6689969018) on the bearing inner ring 3.

P041530-47

Fig 25. 25

P041530-49.

Turn the gearbox housing 4 upside down, by using a puller take out the bearing outer ring 9.

Fig 27. 27

By using a puller and a tool (6689969018) take out the bearing inner ring 3 from the pinion shaft 1.

P041530-48

Fig 26.

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E-66

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

P041530-50

Fig 28. 28

Note: The gearbox disassembly ends with the above operation. All the parts are now available for the necessary inspections.

Remove the nilos ring 2.

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E-67

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

Assembly 1

Fill the nilos ring 3 with grease SHELL GADUS S5 T460 or similar product.

P041530-54

Fig 31. 4 P041530-52

By using a pressr and a metal stopper, push the bearing inner ring 3 against the pinion shaft shoulder 1.

Fig 29. 2

Insert the nilos ring 2 on the pinion shaft 1.

P041530-55

Fig 32. P041530-53

Fig 30. 3

Apply a coat of grease SHELL GADUS S5 T460 o similar product on the bearing inner ring 6.

Place the bearing inner ring 3 on the pinion shaft 1.

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E-68

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

P041530-58

Fig 35.

P041530-56

Fig 33. 6

Place the seal ring 8 into its seat in the gearbox housing 4.

Place the bearing outer ring 9 inside the gearbox housing 9.

P041530-59

Fig 36.

P041530-57

Fig 34. 9 7

By using a rubber hammer and the stopper (6689961540), push the seal ring 8 against the gearbox housing 5 shoulder.

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By using a press and a metal stopper push the bearing outer ring 9 against the gearbox housing 9 shoulder.

E-69

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

P041530-60

P041530-62

Fig 37. 10

Fig 39.

Turn the gearbox housing 4 upside down and place into it the bearing outer ring 3. By using a press and a metal stopper assemble the bearing outer ring 3.

Assemble the gearbox housing 4 on the pinion shaft 1.

P041530-63

Fig 40.

P041530-61

Fig 38. 13 11

Turn the gearbox housing 4 upside down. Fill with grease SHELL GADUS S5 T460 or similar product the bearing chamber.

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Place the bearing inner ring 9 on the pinion shaft 1.

E-70

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

P041530-64

P041530-66

Fig 41. 14

Fig 43.

Place a metal stopper on the bearing inner ring 9. By using a press and a metal stopper assemble the output unit.

Apply LOCTITE 243 or similar product on the new ring nut thread 11.

P041530-67

Fig 44.

P041530-65

Fig 42. 17 15

Insert the spacer 10 on the pinion shaft 1.

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By using a tackle place the torque multiplier (ATZ090320) on the ring nut 11.

E-71

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

P041530-68

P041530-70

Fig 45. 18

Fig 47.

By using the multiplier (ATZ090320), tighten the ring nut 11, by a torque wrench with an input multiplier torque of 36 ± 2 Nm corresponding to an output multiplier torque of 1000 ± 50 Nm.

Assemble the O-ring 5 into its seat in the gearbox housing 4.

P041530-71

Fig 48. P041530-69

Fig 46. 19

Assemble the toothed ring 13.

Stake the ring nut 11 next to nos.6 spaces at 60° of the pinion shaft spline 1.

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E-72

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

P041530-72

P041530-73

Fig 49. 22

Fig 51.

Insert the 2nd reduction assembly 14.

Assemble the connecting cover 16.

P041530-74

P041530-75

Fig 50. 23

Fig 52.

Assemble the O-ring 12 into its seat in the connecting cover 16.

Tighten the nos.4 socket head screws M10x55 19, grade 8.8, by a torque wrench at 50 Nm torque. Tighten the nos.12 socket head screws M10x65 (17),grade 12.9, by a torque wrench at 85 Nm torque.

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E-73

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

P041530-78

P041530-76

Fig 55.

Fig 53. 26

Insert the 2nd reduction sun gear 15.

Assemble the toothed ring 20.

P041530-79

P041530-77

Fig 56.

Fig 54. 27

Assemble the O-ring 18 into its seat in the connecting cover 16.

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Insert the 1st reduction assembly 21.

E-74

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

P041530-80

Fig 57. 30

Assemble the O-ring 18 into its seat in the motor adaptor flange 22.

P041530-82

Fig 59. 32

Tighten the nos.8 socket head screws M10x55 24, grade 8.8, by a torque wrench at 50 Nm torque with the washers 23

P041530-81

Fig 58. 31

Assemble the motor adaptor flange 22 on the gearbox. P041530-83

Fig 60. 33

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Insert the 1st reduction sun gear 25

E-75

Section E - Hydraulics Slew Motor Reduction Gearbox Assembly Dismantling and Assembly

P041530-83

Fig 61. Important: Verify by a depth slide gauge the correct assembly of the unit checking the axial distance as shown.

If the value will be lower reduce the width of the 2nd reduction sun gear 15 in the axial direction flattening the support plane (pinion shaft side). If the value will be higher introduce an adjusting spacers between the 2nd reduction sun gear 15 and the 1st reduction 21.

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E-76

Section E - Hydraulics

Slew Motor Motor Operating Principles The following detailed description explains the operating cycle of an individual piston.

expels low pressure hydraulic fluid T via the output side A(b) of the control plate, port b and back to tank. Driving force F2 varies according to the flow rate of the high pressure hydraulic fluid input.

High pressure hydraulic fluid P from the pump flows via input port a and control valve A into cylinder B when it is aligned with the input side A (a) of the control plate. The force F against piston C generates a force F2 (shown vectorially) which acts on piston shoe D. The piston shoe moves against stationary swash plate E, causing cylinder block F and hence drive shaft G to rotate. This situation exists for 180Â° of rotation of the cylinder block i.e. until the cylinder aligns with the output side A(b) of the control plate. For the next 180Â° of rotation of the cylinder block the piston

G F1

There are nine pistons equally spaced around the cylinder block. As each one in turn goes through the cycle described, a continuous even rotation of the output shaft is produced. By reversing the hydraulic fluid flow direction i.e. high pressure feed into port b, the motor rotation is reversed.

A(b)

A(a)

C075110

Fig 1.

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E-77

Section E - Hydraulics Slew Motor Slew Brake Operation

Slew Brake Operation Cylinder block F is splined to output shaft G. Two friction plates A are splined to the outer edge of the cylinder block and are interleaved between three counter plates B which are fixed to the slew motor casing E.

locking cylinder block F and casing E and preventing rotation. The brakes are released when hydraulic pressure is applied to port X. Oil enters chamber Y and pushes brake piston D up, against the pressure of spring C, to release the previously locked friction plates A and counter plates B. Cylinder block F is now free to rotate within casing E.

The brakes are applied when the hydraulic pressure at port X is zero. Spring C pressure forces piston D down to press the friction plates and the counter plates together, thereby

C E

Y X C075120

Fig 2.

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E-78

Section E - Hydraulics Slew Motor Fault Finding

Fault Finding Motor Does Not Rotate Symptom The pressure is low.

Cause The relief valve is not set correctly.

Remedy Set to the correct value.

The relief valve does not work properly. Plunger sticking.

The pressure is correct but no rotation.

Repair or renew the plunger.

Plunger orifice contaminated.

Dismantle and clean.

Plunger not seating correctly.

Renew the plunger seat.

Overload protection operating.

Remove the cause of overload.

The moving part is burnt.

Check and repair the piston/shoe, cylinder/valve plate, etc.

No release pressure acting on the rake.

Check and repair the circuit.

The brake piston is sticking.

Dismantle and clean/repair.

The brake friction plate is burnt and sticking to counter plate.

Dismantle and renew the damaged parts.

Motor Rotates in the Reverse Direction Symptom Reverse rotation.

Cause

Remedy

The motor has been incorrectly assembled.

Check step 16 of the Assembly procedure to verify that the valve housing 303 and main housing 301 are in their correct relative positions. Rectify if necessary.

Inlet/outlet hoses reversed.

Re-locate hoses.

Motor Speed is Low Symptom Slow rotation.

E-79

Cause

Remedy

The oil flow volume is low.

Check the pump output and the circuit to the motor.

The temperature is high and leakage is serious.

Check the oil cooling circuit.

The sliding parts are worn out or broken.

Renew suspect parts.

9813/2000-02

E-79

Section E - Hydraulics Slew Motor Fault Finding

Motor Brake Working Poorly Symptom Low brake torque.

Cause

Remedy

The friction plate is worn out.

Dismantle and renew worn parts.

The brake piston is sticking.

Dismantle and clean.

The brake releasing pressure is low.

Check and repair the supply circuit.

The spline of the friction plate is broken.

Dismantle and renew the broken parts.

Motor is Driven by Exterior Torque Symptom Slip volume is high.

Cause

Remedy

The relief valve is not set correctly.

Set to correct value or renew.

Relief valve plunger not seating cleanly.

Renew.

The reversal protecting valve does not work properly.

Renew.

Drain volume exceeds 500 cc/mm.

Dismantle and check for signs of wear. Renew suspect parts.

Oil Leakage Symptom Oil leaking from around the drive shaft oil seal.

Cause

Remedy

Oil seal lip damaged.

Renew the oil seal.

The shaft is damaged or worn.

Repair or renew the shaft.

High pressure in casing, causing the lip of Clear the drain pipes. the oil seal to become rolled. The drive shaft is corroded. Oil leaking from mating surfaces of O-ring not installed or damaged. main housing and valve housing. The seal surface is damaged.

Dismantle and repair. Install or renew the O-ring. Dismantle and repair.

The securing bolts are damaged or loose. Renew and/or tighten to the required torque.

E-80

9813/2000-02

E-80

Section E - Hydraulics Slew Motor Removal and Replacement

Removal and Replacement TE-027

X C078320

Fig 3.

Removal

Make an alignment line across the gearbox and motor mounting flanges, to provide a reference during assembly.

Remove bolts X.

Using suitable lifting equipment carefully lift slew motor until clear of machine, refer to Section E, Technical Data.

!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

Make the machine safe, refer to Section E, Service Procedures.

Disconnect all hydraulic hoses from the slew motor and plug all orifices to prevent ingress of dirt. Label each hose before disconnection.

E-81

9813/2000-02

E-81

Section E - Hydraulics Slew Motor Removal and Replacement

Replacement Replacement is a reversal of the removal sequence.

Check slew gearbox oil level, refer to Section 3, Routine Maintenance

After replacement check the main relief valve (M.R.V.) and auxiliary relief valve (A.R.V.) pressure settings.

E-82

9813/2000-02

E-82

Section E - Hydraulics Slew Motor Slew Motor Configuration

Slew Motor Configuration

Slew Unit

Planetary 2-stage Reduction Gear

Swash Plate Type Axial Piston Hydraulic Motor

Mechanical Brake

Relief Valve

By-pass Valve

Make-up Valve Fig 4.

E-83

9813/2000-02

E-83

Section E - Hydraulics Slew Motor Dismantling and Assembly

Dismantling and Assembly Dismantling

Before attempting to dismantle the slew motor assembly, the inlet and outlet ports should be blanked and the outer surfaces washed down with a suitable solvent to remove all dirt and dust. Dry using compressed air. 1

Loosen the bolts 34 with a 10 mm socket wrench. Place the motor with the output shaft downgrades and remove the cover 28. K Fig 7. ( T E-84)

Remove the relief assembly 23 using a 27 mm A/F hexagonal key and the bypass valve assembly 31 with 8mm hexagonal socket. K Fig 5. ( T E-84)

28 31

23 D066710-3

D066710-5

Fig 5.

Fig 7.

Note: Before removing the motor from the reduction gear, it is advisable to make an alignment mark on the mating faces to facilitate reassembly. K Fig 6. ( T E-84)

Remove the snap ring 2 and remove the inner ring of the needle bearing 3 and balance plate 7. The inner ring of the needle bearing 3 is pressed into the male axis of the cover 28 and must be removed with a gear puller. K Fig 8. ( T E-85)

28 Note: Record the relative positions of the parts to ensure correct reassembly.

D066710-4

Fig 6.

E-84

9813/2000-02

E-84

Section E - Hydraulics Slew Motor Dismantling and Assembly

13 3 7

28 28

D066710-6

Fig 8. 4

D066710-8

Fig 10.

Remove the â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; ring 8. K Fig 9. ( T E-85) 6

Remove the springs 14 from the brake piston 15. K Fig 11. ( T E-85)

Note: Keep the springs in the order in which they are to be re-inserted.

21 D066710-7

Fig 9. 5

Remove the bushings 11 with teflon rings 13 and the plate springs 12. K Fig 10. ( T E-85) D066710-8

Fig 11.

E-85

9813/2000-02

E-85

Section E - Hydraulics Slew Motor Dismantling and Assembly 7

It may be difficult to remove brake piston 15 from housing 21 due to resistance caused by â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; rings 6 and 30. Remove the brake piston 15 using the tapped M6 holes with a wrench A and a support block B as shown in the illustration. K Fig 12. ( T E-86)

Note: The outer ring of the taper roller bearing 1 remains in the housing. Note: The end face C of the cylinder 16 is a sliding face and should be protected with a clean cloth to prevent it being damaged. 10

Make alignment marks or write numbers on the piston bores of the cylinder 16 and the piston assemblies 18 so that the piston assemblies can be replaced in the same bores during reassembly. K Fig 14. ( T E-86)

D066710-10

Fig 12. 8

Remove the friction plate 4 and the mating plate 5. K Fig 13. ( T E-86)

D066710-12

Fig 14. 11

Remove the outer ring D of the taper roller bearing 1 from the housing 21. K Fig 15. ( T E-87)

D066710-11

Fig 13. 9

Hold the end of the cylinder 16 by hand and pull out the cylinder assembly from the housing 21. K Fig 14. ( T E-86)

E-86

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E-86

Section E - Hydraulics Slew Motor Dismantling and Assembly

D066710-13

Fig 15. 12

Attach a puller to the inner ring E of taper roller bearing 1 at two places and on the end of cylinder spline 16, then remove bearing inner ring 22. K Fig 16. ( T E-87)

D066710-15

Fig 17. 14

Move the cam plate 20 from the sliding faces of the piston assemblies. K Fig 18. ( T E-87)

Note: Make sure that there is no damage to the cam plate during handling.

D066710-14

Fig 16. D066710-16

Remove the cam plate 20, return plate 19 and piston assemblies 18 from the cylinder. K Fig 17. ( T E-87)

E-87

Fig 18. 15

9813/2000-02

Remove the spring 17 from the cylinder 16. K Fig 19. ( T E-88)

E-87

Section E - Hydraulics Slew Motor Dismantling and Assembly

Assembly Check all parts before assembly and remove any scratches with a fine oil stone or carborundum paper. Wash with a suitable solvent and blow dry. Replace all seals with new ones. Apply clean hydraulic oil to all sliding faces during assembly.

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

!MCAUTION

D066710-17

Fig 19.

'O' rings, Seals and Gaskets Badly fitted, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals. INT-3-2-12

Lap the sliding contact faces of piston assemblies 18, balance plate 20 and swash plate 7 with very fine paste on a flat surface. K Fig 20. ( T E-88)

D066710-18

Fig 20. 2

E-88

9813/2000-02

Apply grease to the curved part of the cylinder 16 (contact face with spring 17) and mount spring 17. K Fig 21. ( T E-89)

E-88

Section E - Hydraulics Slew Motor Dismantling and Assembly 4

Install the piston assemblies 18 together with return plate 19 into the cylinder 16. K Fig 23. ( T E-89)

Note: Put the piston assemblies into the same bores from which they were removed. 5

Apply the hydraulic oil to the bores of cylinder 16 before reassembling.

D066710-19

Fig 21. 3

Put the piston assemblies 18 into the holes of the retainer 19. K Fig 22. ( T E-89)

D066710-21

Fig 23. 6

Apply clean hydraulic oil to piston assembly 18 shoe sliding surface and mount the cam plate 20. K Fig 24. ( T E-90)

D066710-20

Fig 22.

E-89

9813/2000-02

E-89

Section E - Hydraulics Slew Motor Dismantling and Assembly

D066710-22

Fig 24. 7

Install the inner ring E of the taper roller bearing 1 on the cylinder 16 by hand and press using a press fitting jig F. K Fig 25. ( T E-90)

Note: The end face of the cylinder should be protected by a soft cloth to prevent it from being damaged while pre fitting.

D066710-23

Fig 25. 8

Apply a thin coat of JCB retainer G where the inner ring is mounted on motor output shaft 16. K Fig 26. ( T E-90)

D066710-24

Fig 26.

E-90

9813/2000-02

E-90

Section E - Hydraulics Slew Motor Dismantling and Assembly 9

Install the inner ring 22 on the cylinder 16 using a press fiting jig F. Wipe off excess sealing material spilled between the inner ring 22 and the taper roller bearing. K Fig 27. ( T E-91)

Apply grease to the lip of the oil seal. Hold the one end of cylinder 16 and carefully insert the cylinder assembly into housing 21. Use the seal protector on the spines. K Fig 29. ( T E-91)

Note: The splines of the cylinder assembly protrude beyond the housing, so use a guide of 30-50 mm (1.2-1.9 in) on the lower part of the housing. Verify that spring 17 is inserted correctly into the back face of retainer 19. Confirm that the cylinder end is approximately 7.5 mm (0.3in) lower than the housing.

D066710-25

Fig 27. 10

D066710-27

Install the outer ring 1 of the taper roller bearing into the housing 21. K Fig 28. ( T E-91)

Fig 29. 12

Install the friction plate 4 and the mating plate 5. K Fig 30. ( T E-92)

Note: Before installing the plates, apply hydraulic oil to both faces.

D066710-26

Fig 28.

E-91

9813/2000-02

E-91

Section E - Hydraulics Slew Motor Dismantling and Assembly 14

Apply hydraulic oil to the sliding surface around piston 15 and slide it into the housing 21. K Fig 32. ( T E-92)

Note: It is difficult to insert the piston 15 into the housing due to ‘O’ rings 6 and 30. Therefore hold the piston 15 horizontally and push it into the housing with one movement.

D066710-28

Fig 30. 13

D066710-30

Install the ‘O’ ring 30 in housing 21 and ‘O’ ring 6 on piston 15. K Fig 31. ( T E-92)

Fig 32. 15

Note: Before ingstalling the ‘O’ ring, apply grease on it.

Insert the brake unit springs 14 back into brake piston 15 in the same order as they were found during dismantling. K Fig 33. ( T E-92)

D066710-31

Fig 33. 16 D066710-29

Fig 31.

E-92

9813/2000-02

Install the bushings 11 wings 13 and the plate springs 12 and the balance plate 7 into the bushing holes in cover 28. K Fig 34. ( T E-93)

E-92

Section E - Hydraulics Slew Motor Dismantling and Assembly Note: Before installing, apply a coating of grease to the end faces and peripheries of the bushings 11 and to the Teflon rings 13. As this helps in preventing them from falling out when the cover is mounted onto the housing. Note: When assembling balance plate 7 and cover 28, confirm alignment marks on the mating faces to facilitate reassembly.

D066710-34

Fig 36. 19

To prevent the oil leakage from the cover bolt holes, apply JCB multi-gasket H to the mating surface of the housing 21 and the cover 28. K Fig 37. ( T E-93)

D066710-32

Fig 34. 17

Press needle bearing 3 with inner ring into the cover 28 and attach snap ring 2. K Fig 35. ( T E-93)

D066710-35

Fig 37. D066710-33

Fig 35. 18

Apply grease to the ‘O’ ring and put ‘O’ ring 8 to the cover 28. K Fig 36. ( T E-93)

E-93

Lift the cover 28 and the balance plate 7. Mount them carefully on the housing 21. K Fig 38. ( T E-94)

Note: Make sure that the balance plate 7 and bushing do not fall out while putting the cover 28. Align housing 21 and the cover 28 as per alignment marks which were made before dismantling.

9813/2000-02

E-93

Section E - Hydraulics Slew Motor Dismantling and Assembly socket) into the cover 28 with 39 Nm (29 lbf ft) torque value. K Fig 40. ( T E-94)

D066710-38

Fig 40. D066710-36

Fig 38. 21

Tighten the bolts 34 (with 10mm A/F hexagonal socket) which attach the cover 28 to the housing 21 with 103 Nm (76 lbf ft) torque value. K Fig 39. ( T E-94)

Open the inlet and outlet ports and apply 39.2 bar (40 kg/cm2) (569 lbf/in2) pilot pressure to the brake release port. (Make sure that oil will be discharged from the drain port.) Check that the drive shaft can be rotated smoothly for at least one full revolution by applying a torque of approximately 24.5 Nm (18.0 lbf ft).

Note: If the shaft does not turn, the unit has not been assembled correctly so dismantle again and inspect.

D066710-37

Fig 39. 22

Tighten and insert the relief assemblies 23 with a 27mm A/F hexagonal socket) into the cover 28 to a torque of 39 Nm (29 lbf ft). Tighten and insert the bypass valve assemblies 31 (with 8mm A/F hexagonal

E-94

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E-94

Section E - Hydraulics Slew Motor Dismantling and Assembly Fault Finding

Symptom Cause

Motor does not run

Table 1. External Inspection Countermeasure

Internal damage to the Measure the oil drain motor volume

High possibility of damage Refer to K Table 2. to the sliding surfaces if the ( T E-96) supply volume is approximately equal to the drain volume. Dismantle and inspect it.

Internal damage to the Open the motor inlet and motor outlet ports and apply 39 bar (40 kgf/cm2) (569 lbf/ in2) pilot pressure to the brake release port. Try to rotate the shaft with a torque of approximately 24.40 Nm (18 lbf ft)

High possibility of internal Renew damaged parts or damage to the motor if the renew the motor supply shaft does not rotate assembly. smoothly when this torque is applied. Dismantle and inspect it.

Relief valve in circuit not set correctly.

Reset to the prescribed setting.

Measure pressure

Wear or damage to the Measure the oil drain motor sliding surfaces volume Excessive or to the high-pressure seal slip Oil hot and excessive Measure the oil leakage in the motor. temperature

E-95

–

Leakage is too high if the oil Refer to K Table 2. ( T E-96) drain volume exceeds 5 Vmin (1.1 gal/min.). Dismantle and inspect. Reduce the oil temperature

–

Seizure of motor sliding parts or circuit

Check for any metallic matter deposited in motor drain oil or drain filter. Apply a 39 bar (40 kgf/ cm2) (569 Ibf/in2) pilot pressure to the brake release port and try to rotate the shaft with a torque of approximately 24.40 Nm (18 Ibf ft).

Damage or wear to oil seal lip.

–

Renew the oil seals.

Damage or wear of the shaft seal.

–

Repair the problem or renew the motor assembly.

Abnormal Heating

Leakage from oil seals

Repair

If metallic matter is discovered or the supply shaft does not rotate smoothly when torque is applied, there is a high possibility of internal damage to the motor. Dismantle and inspect.

9813/2000-02

Repair or renew the damaged parts. Renew the motor assembly.

E-95

Section E - Hydraulics Slew Motor Dismantling and Assembly Symptom

Cause

External Inspection

Wear or seizure of the Open motor inlet and motor sliding surfaces. outlet ports and apply 40 kgf/cm2 (569 Ibf/in2) pilot pressure to the brake release port. Try to rotate the shaft with a torque of approximately 24.40 (18 Ibf ft). Insufficient Torque Relief valve in the Measure relief pressure circuit is not set correctly. Internal damage to the Check if any metallic motor. matter is deposited in the motor drain oil or drain filter.

Abnormal Noise

Countermeasure

Repair

High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect it.

Inspect the parts and bearing according to K Table 2. ( T E-96) and renew any defective parts.

Reset to the prescribed setting. High possibility of internal damage to the motor if metallic matter is discovered. Dismantle and inspect it.

–

Repair or renew damaged parts. Renew the motor assembly.

Large amount of air mixed in the oil.

Check the oil in the tank Thoroughly bleed the air. and motor casing

–

Loosening of bolts or pipes

Check if the piping Tighten to the specified connections, torque. attachment mounting bolts, motor attachment bolts or other bolts are loose

–

‘O’ ring is damaged – Oil leakage Seal face is damaged. – from mating Bolts are loose. Check the bolt surface tightness.

–

Renew ‘O’ rings.

–

Repair seal face or renew

Tighten the bolts to the correct torque.

–

Table 2. No.

Parts Inspected

Repair

Wear of the sliding surface of balance plate 7.

Repair or renew the part

Damage to sliding surface of cam plate 20.

Repair the part or renew the motor.

Damage to sliding surface of the piston assemblies 18.

Repair the part or renew the motor.

External wear to the piston assemblies 18.

Repair the part or renew the motor.

Wear to piston bores in cylinder assembly 16.

Renew the motor.

Damage to Teflon ring 13.

Renew the part.

E-96

9813/2000-02

E-96

Section E - Hydraulics

Hydraulic Pump/Regulator Hydraulic Pump Operation General Description



The K3SP pump can supply two separate flows by using the well-designed special cylinder and valve plate. Therefore, this series has realized remarkably small installation dimensions as compared with the conventional double pump.

Function



The pumps are of rotary group performing a rotary motion and working as the major part of the whole pump function. The swash plate group that varies the delivery rates; and the valve cover group that changes over oil suction and discharge.

Rotary Group The rotary group consists of drive shaft (111), cylinder block (141). piston shoes (151, 152), set plate (153), spherical bush (156) and cylinder spring (157). The drive shaft is supported on both sides by the bearings (128, 124). The shoe is caulked on the piston and forms the spherical coupler, It has a pocket to relieve thrust force generated by loading pressure and to take hydraulic balance so that it slides lightly over the plate (211). The sub group, which is made up of the piston and shoe is pressed against the shoe plate by action of the cylinder via a retainer and a spherical bush. Similarly, the cylinder block is pressed against valve plate (313) by the action of the cylinder spring. Drive shaft is driven by the engine, the cylinder block rotates simultaneously with the spline coupling. If the swash plate is tilted as shown in K Fig 1. ( T E-97), the piston in the cylinder block rotates simultaneously with the cylinder block and causes reciprocal motion relative to the cylinder. Therefore, during one rotation, the piston moves away from the valve plate for 180° (enough for oil suction) and approaches the valve plate for the remaining 180°. When the swash plate has a tilting angle of zero, the piston makes no stroke and discharges no oil.

E-97

Fig 1.

Swash Plate Group The swash plate group consists of swash plate (121) pivot ball (215, 216), tilting bush (214), tilting pin (531) and servo piston (532). The swash plate is a ball shaped on the opposite side of the sliding surface of the shoe and is supported by pivot ball, if the servo piston moves to the right and left as hydraulic force controlled by regulator is admitted to hydraulic chamber located on both sides of the piston, the swash plate slides over the swash plate support via the spherical part of the tilting pin to change the tilting angle (α).

Valve Block Group The valve block group consists of valve cover (312), valve plate (313) and valve plate pin (885). The valve having two melon-shaped ports is fixed to the valve block and feeds and collects oil to and from the cylinder cover. The oil changed over by the plate is connected to an external pipeline by way of the valve cover.

9813/2000-02

E-97

Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation

Pump Hydraulic Circuit Diagram

Dr1

B1 B3 D067760

Fig 2.

A1,2

Table 1. Key Delivery port

Suction port

Dr1,Dr2

Drain port

a1,2

Gauge port

Gear pump delivery port

Gear pump suction port

E-98

9813/2000-02

E-98

Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation

Hydraulic Pump Exploded View 405

630 924

611

620

404 627

273

700

712

606 789 706

624 625

532

153

714

705

626

151

601 953

709

535 767 710

215

651 156

611

653 651

111

652

151

216

152

531 190 190 190 190

825 123

190 190 622

667

707

657

704

624

655 535

127

774

621

703 707

468 706

467 706 541 545 543 706

901

461 706

403 312

712 401

706

190

401

543 706 541 545

313

124

111

626

111

156

885

702

885

157

D067760-1

Fig 3.

E-99

9813/2000-02

E-99

Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation

!MWARNING

Replacement Replacement is the reversal of removal procedure but note the following:

This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

– When fitting a new pump, the shaft end spline may be coated with a anti-rust coating. Remove this coating with a suitable cleaning agent and apply a lubricant to the shaft being careful not to get either on to the oil seal of the pump. – Fill the pump casing inside fully with oil and operate at low engine revs with no services selected for 3 minutes.

Make the machine safe, refer to Section E, Service procedures.

Drain the hydraulic fluid from the hydraulic tank.

Disconnect all hydraulic hoses and pipes from the hydraulic pump and plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct position when refitting.

Disconnect electrical connection solenoid on hydraulic pump.

Attach lifting eyes to the pump. Support weight of the pump with suitable lifting apparatus, refer to Section E, Technical Data.

proportion

INT-3-1-10_3

– If there is any air left in the circuit or pump, this may cause faulty operation or damage so be sure to bleed the air completely. – It is not desirable to leave the pump motor unused for a long period of time (more than one year.) At intervals, start the engine even if for short periods of time. When left unused by itself, rotating the shaft end by hand can be effective. If left unused for an extended period of time, inspection for overhaul will become necessary.

Removal

E-100

9813/2000-02

E-100

Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation

Disassembly 1

Remove drain port plug 467 and let the oil drain into a suitable receptacle.

Loosen hexagon socket head bolts 402 from gear pump 04 and then remove the pump 04 and spline coupling.

D067550-2

Fig 5. 4

Remove the valve cover 312 from the pump casing.

D067550-1

Fig 4. 3

Loosen hexagon socket head bolts 401 from valve cover and pump casing.

D067550-3

Fig 6.

E-101

9813/2000-02

Remove the valve plate 313 from the pump casing 271.

E-101

Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation

D067550-6

Fig 9.

D067550-4

Fig 7. 8 6

Pull the cylinder 141 from the pump casing 271 straightly over drive shaft 111, then pull out pistons 151, set plate 153, spherical bush 156 and cylinder springs 157 simultaneously.

Pull out the snap ring 825 from the pump casing 271. Tap lightly on the shaft 111 and pull it from the pump casing.

Note: Make sure that not to damage sliding surfaces of cylinder, spherical bush, shoes, swash plate etc.

D067550-7

Fig 10. Note: While removing shaft, make sure that the oil seal which is fitted on pump casing should not be damaged. D067550-5

Fig 8. 7

Pull pivot balls 215, 216 from the pump casing 271.

E-102

9813/2000-02

Remove the hexogon socket head bolts 404, servo cover 641, inner spring 625, outer spring 626 and spring seat 624.

E-102

Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation

D067550-8

Fig 11.

D067550-10

Fig 13. 10

Remove the hexagon socket head bolt 404 and then remove top cover 273.

Pull out the plug 468, pin 655.

Pull the feed back lever 611 from the pump casing.

D067550-11 D067550-9

Fig 14.

Fig 12. 11

Remove the sleeve 651, spool 652 and compensator piston 621.

E-103

9813/2000-02

E-103

Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation Fit the pivot ball 215, 216 to pump casing 271.

Assembly

Before assembling:

Note: Place pump casing with its top cover surface on top,right pivot ball 215 and left pivot ball 216. These are different diameter for miss assembling prevention.

– Thoroughly clean all components with clean hydraulic oil and dry with compressed air. – Apply clean hydraulic oil to all sliding surfaces, bearings, etc.

Caution – After servo piston 532, tilting pin 531 stopper S (535), lock nut 803 set screw 534, fit them soon on pump casing in advance for reassembling. – While tighetening servo piston and tilting pin, use a protector to prevent damage to the tilting pin head. In addition, apply lock-tight (medium strength e.g. Three Bond NC.1300B) to their threaded section. (Tightening torque 1000kgf-cm) – Confirm with fingers of both hands that servo piston 532 can be removed smoothly. – Fit plug 467 soon to pump casing in advance for reassembling.

D067550-13

Fig 16.

– Do not tap drive shaft with hammer. – Assemble them into support, tapping outer race of bearing lightly with plastic hammer. Fit them fully, using steel bar. 1

Fit the drive shaft set with bearing 123, bearing spacer 127 and snap ring 824 and then put snap ring 825 on pump casing.

Note: Apply grease to sliding sections of swash plate and pivot balls.

D067550-12

Fig 15.

E-104

Fit titling bush of swash plate 212 to tilting pin and fit swash plate to pump casing correctly.

9813/2000-02

D067550-14

Fig 17.

E-104

Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation 4

Fit the pin 655 and ROH plug 468 to pump casing.

D067550-17

Fig 20. D067550-15

Fig 18. 5

Fit the feedback lever 611 to pump casing. Fit the top cover 273 and tighten hexgon socket head bolts 406.

Fit the compensator piston 621 to the pump casing.

D067550-18

Fig 21. D067550-16

Fig 19. 6

Fit the sleeve 651 and spool 652 to pump casing.

E-105

9813/2000-02

E-105

Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation 8

To pump casing, fit servo cover 641, set with inner spring 625, outer spring 623, spring seat C 624.

Note: Apply grease to fitting face of valve plate and valve cover for removing prevention. Note: Confirm that for restrictor 508 are fitted to pump casing and valve cover.

D067550-19

Fig 22. 9

Assemble piston cylinder subassembly (cylinder 141, piston subassembly 151,152, set plate 153, spherical bush 156 and cylinder spring 157). Fit spline phases of retainer and cylinder, then insert piston cylinder subassemblyinto pump casing.

D067550-21

Fig 24. 11

Fit the spline coupling 114 to valve cover in the rear and fit the gear pump 04. Then, tighten hexagon socket head bolts 402.

D067550-20

Fig 23. 10

Fit valve plate 313 to valve cover 312 entering pin into pin hole. Then fit valve cover to pump casing 271 and tighten hexagon socket head bolts 410.

E-106

9813/2000-02

D067550-22

Fig 25.

E-106

Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation

Pump Maintenance Criteria Worn Part Replacement Criteria When a part exceeds any of the following crteria, replace or readjust it. However, when a part is damaged seriously in appearance, replace it without fail.

Part Name and Inspection Item

Clearance between piston and cylinder bore (D-d)

Standard Dimension/Recommended Replacement Value Pump Type

Countermeasures

K3SP36 0.036

Replace piston or cylinder

0.056 0-0.1

Replace assembly of piston and shoe 0.3

Thickness of shoe (t)

3.9

Replace assembly of piston and shoe 3.7

Free height of cylinder spring (L)

Combined height of set plate and spherical bush (H-h)

E-107

31.0

Replace cylinder spring

29.9

Replace retainer or set plate

19.0 18.3

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Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation

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Section E - Hydraulics

Hydraulic Rams Precautions During Use TE-006

Special seal materials are necessary so check to see if the ram that you are using is suitable or not.

Installation 1

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.

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.

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.

E-109

The installed ram cannot maintain the same position for a long period of time, because the oil inside the ram may leak and the hydraulic oil volume decreases as it cools. Stop or store the machine in a safe and fixed position.

Maintenance, Inspection Points

Use only under designated conditions. a

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.

Install the ram only when it is clean.

Caution During Use 1

In cold conditions the rod seals may be frozen, so if the ram is operated at maximum pressure and maximum speed, the seals will be damaged.

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.

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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

E-109

Section E - Hydraulics 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

E-110

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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E-110

Section E - Hydraulics Hydraulic Rams Removal and Replacement

Removal and Replacement Typical Bucket Ram P11-E001_2

Removal

803090

Fig 2. 3

INT-3-1-11_2

Stop the engine, remove the key. Release the tank pressure, see Releasing the Tank Pressure.

!MWARNING Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job. INT-1-3-7

Lower the attachment to the ground.

709600

Fig 3. 4

Remove the nuts and bolts from the rod end of the ram.

709670

Fig 1. 2

Place a wooden block under the bucket ram.

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E-111

Section E - Hydraulics Hydraulic Rams Removal and Replacement

803091

Fig 6.

803140

Fig 4. 5

Remove the ram hoses and install plugs or caps to prevent contamination.

Attach slings to support the ram.

Push the pin out using a bar and hammer.

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

803095-1

Fig 7. 9

Remove the nuts and bolts from the cylinder end of the ram. Push out the pin using a bar and hammer. Lift the ram clear.

!MWARNING 803141

Fig 5. 6

Restrain the eye end of the ram piston rod to the ram cylinder to prevent the piston rod from extending.

E-112

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

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E-112

Section E - Hydraulics Hydraulic Rams Removal and Replacement 2

Install the pin, bolt and nuts to the cylinder end of the ram.

803093

Fig 10. 803092

Fig 8.

Replacement 1

Attach slings to the ram and lift it into position on the dipper.

Fig 11. Note: When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight to the pivot boss but must have approximately 3mm of play so that the pin is free from tension. 3

Connect the hoses.

803096-1

Fig 9.

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E-113

Section E - Hydraulics Hydraulic Rams Removal and Replacement

A409820-C2

Fig 14. 803094

Fig 12.

Note: When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight to the pivot boss but must have approximately 3mm of play so that the pin is free from tension.

803142

Fig 13. 4

Hoist the ram to align with the link. Install the pin, bolt and nuts.

Note: Stroke the ram to release entrapped air. After releasing the air, check for oil leakage.

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E-114

Section E - Hydraulics Hydraulic Rams Removal and Replacement

Typical Boom Ram P11-E002_2

Removal

!MWARNING

Fig 16.

Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job. INT-1-3-7

Lower the attachment to the ground, as shown.

Remove the nuts, bolt and collar.

Push out the pin, using a bar and hammer.

709670

Fig 15. Stop the engine, remove the key. 2

Remove the grease tube and attach slings to the boom ram.

803211

Fig 17. 4

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Lower the ram and place it on a stand.

E-115

Section E - Hydraulics Hydraulic Rams Removal and Replacement 6

Release the tank pressure, see Releasing the Tank Pressure.

709600

Fig 20. 7

Remove the hoses, and install plugs or caps to prevent contamination.

803222-1

Fig 18. 5

Restrain the eye end of the piston rod to the ram cylinder, to prevent movement of the rod.

803220-1

Fig 21. 8

Remove the nut and bolt and push out the pin with a hammer and bar.

Fig 19.

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E-116

Section E - Hydraulics Hydraulic Rams Removal and Replacement Replacement 1

Attach slings to the ram. Align the ram to its installation position.

803223-1

Fig 22. 9

Lift the ram away from the unit.

803224-1

Fig 23. 2

Install the pin and then the bolt and nuts.

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E-117

Section E - Hydraulics Hydraulic Rams Removal and Replacement

803226-1

Fig 26. 803225-1

Fig 24.

Lift the ram and align the rod eye end with the pin position.

A409820-C2

Fig 25.

803213-1

Install the hoses.

Fig 27. 5

Install the pin with a bar and hammer.

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E-118

Section E - Hydraulics Hydraulic Rams Removal and Replacement Note: When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight to the pivot boss but must have approximately 3mm of play so that the pin is free from tension. 7

Connect the grease tube.

Note: Stroke the ram and release entrapped air. After releasing the air, check for oil leakage.

803212-1

Fig 28. 6

Install the collar and then the bolt and nuts.

803214-1

Fig 29.

A409820-C2

Fig 30.

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E-119

Section E - Hydraulics Hydraulic Rams Removal and Replacement

Typical Dipper Ram P11-E003_1

Removal

803190

INT-3-1-11_2

Fig 32.

!MWARNING

Stop the engine, remove the key. Release the tank pressure, see Releasing the Tank Pressure

Lower the attachment to the ground, as shown.

709600

Fig 33. 709670

Fig 31. 2

Remove the nuts and bolts from the rod end of the ram.

Place a wooden block under the dipper ram.

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E-120

Section E - Hydraulics Hydraulic Rams Removal and Replacement

803151

Fig 34. 803150

!MWARNING

Fig 35.

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.

Restrain the eye end of the ram piston rod to the ram cylinder to prevent the piston rod from extending.

INT-3-1-3_2

Push out the pin, using a bar and hammer.

803160

Fig 36. 7

Remove the ram hoses, and install plugs or caps to prevent contamination. Remove the grease tube.

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E-121

Section E - Hydraulics Hydraulic Rams Removal and Replacement

803170

Fig 37. 8

Attach slings to support the ram.

803200-1

Fig 39.

Replacement 1

Attach slings and lift the ram onto the boom.

803180-1

Fig 38. 9

Remove the nuts and bolts from the cylinder end of the ram, push out the pin using a bar and hammer. Lift the ram clear.

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Section E - Hydraulics Hydraulic Rams Removal and Replacement

803201

Fig 41. 803181-1

Fig 40. 2

Install the pin, bolts and nuts.

A409820-C2

Fig 42. Note: When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight to the pivot boss but must have approximately 3mm of play so that the pin is free from tension. 3

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Install the grease tube and connect the hoses.

E-123

Section E - Hydraulics Hydraulic Rams Removal and Replacement

A409820-C2

803171

Fig 45.

Fig 43. 4

Hoist the ram to align the piston rod eye end with the dipper pin position.

Install the pin, bolt and nuts.

Note: Stroke the ram to release entrapped air. After releasing the air, check for oil leakage.

803152

Fig 44.

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E-124

Section E - Hydraulics Hydraulic Rams Assembling and disassembling procedures

Assembling and disassembling procedures Cylinder Disassembly 1

Remove the cylinder from the equipment

Drain the oil from the cylinder

Tap the head end cover out using nylon mallet as shown in K Fig 47. ( T E-125)

Note: Do not hit the cylinder with hammer.

Note: Do not open the cylinder or pull the piston rod out unless the oil is drained. 3

Put the cylinder on a wooden V-block

Clean the cylinder with clean cotton cloth

Clamp the cap end using rod and de-torque the hexagonal bolts. SeeK Fig 46. ( T E-125)

Note: Do not heat the cylinder using welding flames for opening the head end cover. Note: Do not chisel the head end cover

D065410

Fig 47.

Disassembly of Piston Rod 1

Put the piston rod on a V block support

Ensure direction of cushioning bush during assembly as shown in K Fig 48. ( T E-125)

D065420

Fig 48. D065400

Fig 46.

E-125

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Remove grub screw K Fig 49. ( T E-126)

and

locking

ball.

See

E-125

Section E - Hydraulics Hydraulic Rams Assembling and disassembling procedures

D065430

Fig 49.

D065450

Fig 51.

D065440

Fig 50.

E-126

D065460

Fig 52.

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E-126

Section E - Hydraulics Hydraulic Rams Assembling and disassembling procedures

D065470

Fig 53.

D065490

Fig 55.

D065480

Fig 54.

E-127

D065500

Fig 56.

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Section E - Hydraulics Hydraulic Rams Assembling and disassembling procedures

D065510

Fig 57.

D065530

Fig 59.

D065520

Fig 58.

E-128

D065540

Fig 60.

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E-128

Section E - Hydraulics Hydraulic Rams Assembling and disassembling procedures

D065550

D065570

Fig 61.

Fig 63. A

Snap Ring

Wiper

Secondary Rod Seal

Primary Rod Seal

Bimetal Bush

D065560

Fig 62.

D065580

Fig 64.

E-129

Soft Bearing Strips

Piston Seal

Hard Bearing Strips

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E-129

Section E - Hydraulics Hydraulic Rams Assembling and disassembling procedures

D065610

Fig 67. D065590

Fig 65. I

Primary Seal

Backup Ring

Wiper

Secondary Seal

Remove secondary rod seal back up ring as shown in K Fig 68. ( T E-130)

Disassembly of Seals in Head End Cover 1

Remove wiper locking snap ring as shown in K Fig 66. ( T E-130)

D065620

Fig 68. 4

Remove primary seal using bend screw driver as shown in K Fig 69. ( T E-131)

D065600

Fig 66. 2

Remove secondary seal using bend screw driver as shown in K Fig 67. ( T E-130)

E-130

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E-130

Section E - Hydraulics Hydraulic Rams Assembling and disassembling procedures Disassembly of Seals in Piston 1

Remove hard and soft bearing strips

Then remove the K Fig 64. ( T E-129)

piston

seal.

See

Cylinder Assembly 1

Clean the component with clean solvent

Note: Do not clean the component with kerosene. Note: Do not file any of the components.

D065630

Dry with clean cloth

Polish all sharp edge with scorch bright

Apply clean hydraulic oil onto the seal

Fig 69. 5

Remove wiper as shown in K Fig 70. ( T E-131)

Assembly of Seals in Head End Cover 1

Assemble primary rod seal and then put backup ring. See K Fig 71. ( T E-131) and K Fig 72. ( T E-132)

D065650

Fig 71. D065640

Fig 70.

E-131

Note: Make sure that, K Fig 73. ( T E-132)

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the

lip

direction

per

E-131

Section E - Hydraulics Hydraulic Rams Assembling and disassembling procedures

D065680

D065660

Fig 74.

Fig 72.

D065690

Fig 75. Note: Make sure that, K Fig 76. ( T E-133)

the

lip

direction

per

D065670

Fig 73. 2

Assemble secondary rod backup ring first then put secondary rod seal. See K Fig 74. ( T E-132) and K Fig 75. ( T E-132)

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E-132

Section E - Hydraulics Hydraulic Rams Assembling and disassembling procedures

D065750

Fig 78.

D065730

Fig 76. 3

Assemble wiper K Fig 77. ( T E-133) and then put the snap ring K Fig 79. ( T E-133).

D065760

Fig 79.

D065740

Fig 77.

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E-133

Section E - Hydraulics Hydraulic Rams Assembling and disassembling procedures

D065780

Fig 80. Snap Ring

D065800

Secondary Rod Seal with Backup Ring

Primary Rod Seal with Backup Ring

Bimetal Bush

Fig 82.

Assembly of Seals in Piston 1

Assemble the piston seal first and then the bearing strips. See K Fig 81. ( T E-134), K Fig 82. ( T E-134) and K Fig 83. ( T E-134)

D065810 D065790

Fig 83.

Fig 81.

E-134

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E-134

Section E - Hydraulics Hydraulic Rams Assembling and disassembling procedures 4

Assemble the head K Fig 86. ( T E-135)

end

cushioning

bush

D065840

Fig 86. D065820

Fig 84.

Note: Make sure that, the correct direction of the cushioning bush. The wider part of the slot should be facing the head end cover. See K Fig 87. ( T E-135)

Assembly of Head End Cover 1

Apply clean hydraulic oil inside the head end cover (at seals and wiper area)

Insert gently the head end cover onto the piston rod sub assembly.

Note: Make sure that, the seal lip does not touch the piston rod threads or the same is not reversed or twisted during assembly. 3

Check for smooth movement of head end cover on piston rod. See K Fig 85. ( T E-135)

D065850

Fig 87.

Assembly of Piston and Piston Nut 1

Assemble the piston onto piston rod sub-assembly threads using special fixture and torque wrench/pins as shown in K Fig 88. ( T E-136)

Torque it to the specified value mentioned as mentioned in the drawings

D065830

Fig 85.

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E-135

Section E - Hydraulics Hydraulic Rams Assembling and disassembling procedures

D065860

Fig 88. 3

Assemble the piston rod nut and torque it to the specified value as mentioned in the drawings

Note: Piston rod nut is left hand threaded/where ever applicable 4

Assemble the alloy steel ball

Apply loctite 242 or Anabond 118 on hex socket set screw and assemble the same

Torque it to value specified in the drawings and then caulk at two places

D065870

Fig 89.

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E-136

Section E - Hydraulics Hydraulic Rams Assembling and disassembling procedures

Do’s in a Hydraulic Cylinder

Assembly of Piston Rod Sub-assembly 1

Support the tube sub-assembly on the ground

Apply little hydraulic oil inside the tube sub assembly and piston seal outer portion to ensure smooth entry on the piston rod sub assembly

Note: Make sure that, piston rod sub-assembly and tube sub-assembly are in line to ensure smooth assembly. 3

Assemble the hex socket head cap screw and torque it to the specified value Push the piston rod sub-assembly completely inside the assemble the protection cover

Note: Make sure that, the cylinder is filled with hydraulic oil for protection.

– Use soft lint-free cloth, never use cotton waste it may contain metal chips which will damage working surface of the components – Periodically clean the dust/mud accumulated on Wiper seals – Ensure that the oil is in cold condition before opening the cylinder – Ensure that the cylinder is assembled and disassembled in clean dust free atmosphere – Ensure usage proper lifting tackles (Rope, Belts, etc.) while handling the cylinder – Apply grease on extended piston rod, if any welding is being carried out near the cylinder. This is to avoid welding spatters from getting stuck on the piston rod surface. Wipe off the grease after welding is completed – Use only the specified grade of hydraulic oil – Use Grease gun to ensure proper greasing and apply grease at all the greasing points periodically – Ensure that there are no obstructions at the working area like electrical line, inflammable material, etc. – Check the hydraulic oil contamination and change if required

D065880

Fig 90.

– Apply rust preventive oil on the exposed surface of the piston rod during prolonged storage

Dont’s in a Hydraulic Cylinder – Don’t operate the machine beyond the specified load/ pressure limit – Don’t use the bucket to push rocks, boulders, etc. – Don’t load the bucket unevenly – Don’t use the hydraulic cylinder as a conductor for welding purpose – If you have to weld on structure connect earth wire to the structure only not on the cylinder – Earth must be given close to the point of welding – Don’t paint on the working surface of the piston rods and wiper seal – Don’t heat hydraulic cylinder while dismantling – Don’t open hydraulic connections without releasing the system pressure – Don’t carry out welding without removing the battery terminals

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Section E - Hydraulics Hydraulic Rams Assembling and disassembling procedures

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Section E - Hydraulics

Rotary Coupling Operation The coupling is located in the centre of the machine between the lower and upper sections and rotates around the slew centre line. The supply and return oil flow to the coupling, piped from the upper to the lower section, is not affected by the rotational movement and allows the machine to slew 360Â° in both directions. The rotary coupling consists of the inner axle 11 and outer rotor 13 with packing rings, 'O'-rings, thrust plate and cover. In the axle and rotor there are pairs of ports and oil passages, each pair being sealed from the others by packing rings and 'O'-rings. Both the axle and rotor can rotate and the oil can flow freely through the oil grooves.

Item

Table 1. Part Name

Axle

V-ring

Rotor

O-ring

Packing ring

Thrust plate

Socket head screw

O-ring

Cover

Socket head screw

Fig 1.

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E-139

Section E - Hydraulics Rotary Coupling Removal and Replacement

Removal and Replacement

!MWARNING

Removal 1

Jack up the machine by pressing the boom/dipper on the ground. Install wooden blocks under the tracks. K Fig 2. ( T E-140).

!MWARNING Do not go underneath the machine with the engine running. Switch off the engine, apply the park brake and block both sides of all wheels before going underneath the machine.

JS10510

Fig 2.

TRANS-2-1

Stop the engine and release hydraulic system pressure (see Section3, Releasing Hydraulic Pressure).

Attach identification tags to the rotary coupling hoses for reconnection purposes. Remove the hoses and install blind plugs and caps to prevent contamination.

Remove the belly plates.K Fig 3. ( T E-140)

Remove the three screws/washers A and lift off locking bar B.

JS10520

Fig 3.

E-140

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E-140

Section E - Hydraulics Rotary Coupling Removal and Replacement Table 2.

Item

Description

Torque

Bolt - Lock bar to rotary joint

259Nm

Bolts - Rotary Joint to Frame 116Nm

Replacement

Installation is the reverse of removal. Apply JCB Threadlocker and Sealer to screws A.

!MWARNING A

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

T023400

Fig 4. 6

Remove the three mounting bolts C and lift the rotary coupling assembly D clear of the lower frame.

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Section E - Hydraulics Rotary Coupling Dismantling

Dismantling as a guide to the dismantling and assembly procedures refer to the sectional illustration, K Fig 1. ( T E-139). 1

Remove the bolt B and cover A.

Remove the 'O'-ring C. Do not reuse the 'O'-ring C.

Remove bolts D and the thrust plate E.

Remove seal F.

C D

F C031300-C1

Fig 6. 6

Remove the V-ring J and nylon ring K from the axle H.

Note: Do not reuse the V-ring J and nylon ring K. 716630-C1

Fig 5. 5

Using a jig push off the axle G from the rotor H. Do not hit with a hammer.

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E-142

Section E - Hydraulics Rotary Coupling Dismantling

J X

K H

C068260

Fig 8. 8

C031310-C1

Remove the 'O'-rings, and packing rings from the rotor G.

Note: Do not reuse 'O'-rings and the packing rings.

Fig 7. 7

Remove dust seal X from the axle H.

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E-143

Section E - Hydraulics Rotary Coupling Dismantling

716710-C1

Fig 9.

E-144

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E-144

Section E - Hydraulics Rotary Coupling Assembly

Assembly Inspect the parts for signs of wear, pitting, scratching, discolouration etc. Polish out scratches using a fine grade oil stone. Before assembly, thoroughly clean all parts using a suitable solvent: Do NOT use solvents on 'O'-rings, backup rings and seals. Fit new 'O'-rings, backup rings and seals. Lubricate all 'O'-rings, backup rings and seals, with clean hydraulic fluid before fitting. 1

Clean the rotor G with cleaning fluid or compressed air.

716660-C1

Fig 10. After cleaning, check to see if there are any scratches or roughness on the inner side of the rotor or grooves. 2

Check the number of packing rings and 'O'-rings. Coat with Vaseline and install in the order below. a

Set one packing ring in each groove starting from the 2nd groove from the top.

b Set the 'O'-ring in the top groove.

C716700-C1

Fig 11.

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E-145

Section E - Hydraulics Rotary Coupling Assembly 3

After installing the 'O'-ring, packing rings and packing, check with a mirror to see if they are installed correctly. After checking, coat with grease then check once more for any protrusion, twisting, etc.

Install the new dust seal X on the axle H.

H H

C031320-C1

Fig 13. C068260

Fig 12. 5

Install the V-ring J and nylon ring K on the axle H and grease adequately. Take care to prevent contamination of the grease by water or dirt.

E-146

Install the axle H to the rotor G.

Note: Set the V-ring J so that it will not be cut or scratched.

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E-146

Section E - Hydraulics Rotary Coupling Assembly

C D

H C031340-C1

Fig 15. 11 C031330-C1

On completion of assembly ensure the dust seal is fitted correctly as shown.

Fig 14. 7

Install a new seal F.

Install the thrust plate E and bolts D.

Install a new 'O'-ring C.

Install the cover A and bolts B.

Fig 16.

E-147

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E-147

Section E - Hydraulics Rotary Coupling Assembly

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E-148

Section E - Hydraulics

Service Procedure Make the Machine Safe TE-009

Note: You can complete most of the maintenance procedures with the boom lowered. Unless a maintenance procedure instructs you differently, you must lower the boom. You must make the machine safe before you complete any service procedures. 1

Park the machine on firm level ground.

Apply the parking brake (if fitted).

Lower the equipment or, raise and fit the applicable safety strut.

Stop the engine.

Turn the ignition to the `ON' position.

Operate the hand controllers to release pressure in the hydraulic system.

Turn the ignition to the `OFF' position.

Remove the starter key

Disconnect the battery (if necessary).

Release the hydraulic oil tank pressure.

Chock the wheels/tracks as applicable.

If the machine is raised from the ground make sure it is securely chocked. NEVER WORK UNDER A MACHINE RAISED ON STABILISERS OR JACKS.

If you wish to arc weld the machine disconnect the alternator and electronic control units (if fitted).

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E-149

Section E - Hydraulics Service Procedure Pressure Testing - General

Pressure Testing - General Confirmation of the Oil Temperature Confirm the oil temperature is between 45Â°C - 55Â°C using the self check function. If the temperature is low use the following warm-up procedure.

Warming-up Procedure 1

Turn the throttle control to mid-range and make sure the work mode is set to E.

Run the engine until the coolant temperature gauge reads within the normal (green) range.

Set the servo isolator switch to ON to enable the hydraulic servo controls to be operated.

Operate the bucket control slowly until it reaches one end of its travel and leave it there for 10 seconds.

Operate the bucket control slowly to the other end of its travel and leave it there for 10 seconds.

Repeat steps 4 and 5 for 10 minutes to warm up the hydraulic circuit.

Operate the excavating controls three to five times in each direction to distribute warm hydraulic oil around the system.

Note: All pressure testing to be carried out with the engine set at minimum engine revs unless otherwise stated.

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E-150

Section E - Hydraulics Service Procedure Pressure Testing - General

Pressure Testing Points

1 2

Fig 1. 1

TP1 - Pump 1

TP2 - Pump 2

TP3 - Servo/Pilot Pressure

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Section E - Hydraulics Service Procedure Pressure Testing - General JS81 Table 1. Sensor

Test Name Boom lift dom

Arm in dom

Arm out dom

Bucket open dom

Bucket close dom

Swing lift dom

Swing right dom

JS81

Pressure 1

277-291

Pressure 2

277-291

Pressure 3

39-41

Pressure 1

277-291

Pressure 2

277-291

Pressure 3

39-41

Pressure 1

277-291

Pressure 2

277-291

Pressure 3

39-41

Pressure 1

277-291

Pressure 2

0-15

Pressure 3

39-41

Pressure 1

277-291

Pressure 2

0-15

Pressure 3

39-41

Pressure 1

0-15

Pressure 2

185-195

Pressure 3

39-41

Pressure 1

0-15

Pressure 2

185-195

Pressure 3

39-41

RBC

ARV

175-(+)5

Flow in LPM

40-68

Pressure at required flow

110-140

Note: Pressure 1: Pressure at Pump 1, Pressure 2: Pressure at Pump 2, Pressure 3: Pressure at Pilot Pump Note: Above pressure values to be measured at Oil Temp 60 0C. Note: Swing testing to be done in a controlled area.

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E-152

Section E - Hydraulics Service Procedure Pressure Relief Valve Location

Pressure Relief Valve Location

prb2

pra2

prb1

pra1

pc3

2 pb9

pb5

pa5

pa9

pa4

pa8

pa3

pa7

5 pb8

pb4

3 pb7

pb3

8 pb6

pa2

pb2

pb1

Ts3

9 pa6

pa1

Ts5

1 Fig 2. For description, K Table 2. ( T E-154)

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E-153

Section E - Hydraulics Service Procedure Pressure Relief Valve Location 1

Table 2. Main Relief Valve (MRV)

Boom Up Relief Valve

Boom Down Relief Valve

Dipper Out Relief Valve

Dipper In Relief Valve

Bucket Open Relief Valve

Bucket Close Relief Valve

Option Relief Valve

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E-154

Section E - Hydraulics Service Procedure Main Relief Valve (MRV) Pressure

Main Relief Valve (MRV) Pressure TE-012

Prepare the Machine a

Operate the dipper out and lower the boom to set the bucket on the ground.

C030150-1

Fig 3. b Make the machine safe, refer to Section E, Service Procedures. c

Install a 0 - 400 bar (0 - 6000 lb/in2) pressure gauge in TP1 or TP2.

d Start the engine, and confirm that the engine is at its maximum no-load speed and it is in the E mode to test standard pressure and L mode to test power boost pressure. e

A406580-C1

Raise the boom and then operate the dipper out control. Read the pressure gauge with the dipper ram stalled at the end of its stroke.

If it is outside the limits, stop the engine and adjust the MRV as below.

b Remove servo hose E and plug hose.

Fig 4.

Note: For accurate setting, the pressure should be adjusted up to the required level. 2

High Pressure Setting (Power Boost)

Make the machine safe, refer to Section E, Service Procedures.

Start the engine, and confirm that the engine is at its maximum no-load speed and it is in the E mode.

d Stall the dipper. e

Hold nut C and release lock nut B and screw the low pressure setting nut A clockwise all the way in.

Hold nut C and slacken nut D. Screw nut C in, to increase pressure or out to decrease pressure.

g Once required pressure is achieved on the pressure gauge, hold nut C and lock nut D back up. 3

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Low Pressure Setting (Standard)

E-155

Section E - Hydraulics Service Procedure Main Relief Valve (MRV) Pressure a

confirm that the engine is at its maximum no-load speed and it is in the L mode.

b Stall the dipper. c

Hold nut C and slacken locknut B. Screw nut A out to reduce pressure or in to increase pressure.

d Once required pressure is achieved on the pressure gauge, lock nut B against nut C.

Make the machine safe, refer to Section E, Service Procedures.

Re-attach the servo hose to MRV.

Check the pressures.

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E-156

Section E - Hydraulics Service Procedure Servo Relief Pressure

Servo Relief Pressure TE-013

Prepare the Machine a

Start the engine and confirm that the engine is at its minimum no-load speed and it is in the E mode. The pressure gauge reading should be compared to the technical data at the start of this section. If it is outside the limits adjust the pilot relief valve as below.

Loosen the lock nut B of the pilot Relief Valve.

The valve is adjusted by turning relief valve adjusting screw A (one turn of the adjustment screw equals 39.2 bar, (568.5 lb in2).

Tighten lock nut B to 17 Nm (12. Ibf ft), check the relief pressure again.

Operate the dipper out and lower the boom to set the bucket on the ground.

C030150-1

Fig 5. b Make the machine safe, refer to Section E, Service Procedures. 2

Before testing the Pilot Relief valve C K Fig 6. ( T E-157), connect a 0-100 bar (0-1500 lb/ in2) pressure gauge to test point TP3.

TP3

C B

A405800-C3

Fig 6. Note: For accurate setting, the pressure should be adjusted up to the required level.

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E-157

Section E - Hydraulics Service Procedure Slew Motor Pressure Relief

Slew Motor Pressure Relief TE-015

Prepare the machine a

Note: If the water-proof slew lock solenoid valve is not removed. Full slew pressure can not be read.

Operate the dipper out and lower the boom to set the bucket on the ground.

Note: Pressure measurement is also possible on the slew motor, upper section. 5

If the readings are outside the limits, continue as below.

Pressure Adjustment

C030150-1

Fig 7. b Make the machine safe, refer to Section E, Service Procedures. 2

Connect a 0-400 bar (0 - 6000 lb/in2) pressure gauge and adaptor to test point TP2.

Initiate slew lock procedures. a

b Remove relief valve to be adjusted. c

Remove the water-proof connector on the slew lock solenoid valve.

b Press the slew lock switch which is on the right hand console inside the cab, and confirm that the slew lock symbol appears on the monitor.

Note: If both relief valves are removed at the same time, mark them left and right to facilitate re-assembly in the correct position. 8

graphicA335121I

Disassembly

F D

Operate the slew lever.

The pressure gauge reading should be compared to the technical data at the start of this section. If it is outside the limits adjust the slew motor relief valve as below.

E-158

Place the relief valve in a vice and remove the cap A with a 14 mm hexagonal socket, take out the piston C, liner B poppet E, spacer D, shims E and spring F.

Start the engine, (error codes may appear for disconnected solenoid) and operate the engine at around 1000 rpm, then operate the slew lever slowly. Listen to confirm that the relief sound is heard and that the machine does not slew.

d Run the engine at minimum no-load speed and in the E mode. e

The difference between the set pressure and the present pressure determines the number of shims E required for adjustment.

Remove the relief valve assembly from the slew motor.

Make the machine safe, refer to Section E, Service Procedures.

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A A405850-C1

Fig 8. b Add shim to increase pressure. Remove shim to decrease pressure.

E-158

Section E - Hydraulics Service Procedure Slew Motor Pressure Relief c

Re-assemble relief valve assembly

d Fix the sleeve into a vice and install the cap A with a torque of 156.9 Nm (115.17 lb ft). e

E-159

Install the relief assembly in the slew motor unit, and confirm the pressure.

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E-159

Section E - Hydraulics Service Procedure Auxiliary Relief Valves

Auxiliary Relief Valves TE-014_2

General 1

Prepare the machine a

Operate the dipper out and lower the boom to set the bucket on the ground.

C030150-1

Fig 9. b Make the machine safe, refer to Section E, Service Procedures. 2

Increase MRV Pressure, refer to Section E, Service Procedures.

Test the ARVs with the engine at idle using the appropriate test points.

Restore Original MRV Pressure, refer to Section E, Service Procedures.

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E-160

Section E - Hydraulics Service Procedure Auxiliary Relief Valves

Boom Ram Boom Up 1

Prepare the machine a

Operate the dipper out and lower the boom to set the bucket on the ground.

C030150-1

Fig 10. b Make the machine safe, refer to Section E, Service Procedures. c

Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure gauge and adaptor to port TP1 on the hydraulic pump.

Increase MRV Pressure, refer to Section E, Service Procedures.

Start the engine, lower the gate lock lever and run the engine at minimum no-load speed in the E mode. a

C002690-C1

Fig 11. b The pressure gauge reading should be compared to the technical data at the start of the section. If it is outside the limits, adjust the ARV. Note: For accurate pressure setting, the pressure should be adjusted up to the required level. Release lock nut X. Adjust setting screw Y to a pressure below the required level and then bring the pressure back up for final setting. Tighten lock nut X.

Fully raise the boom and then continue to operate the right control lever as at A.

312460-C1

Fig 12. 4

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Restore Original MRV Pressure, refer to Section E, Service Procedures.

E-161

Section E - Hydraulics Service Procedure Auxiliary Relief Valves b The pressure gauge reading (Boom down) should be compared to the technical data at the start of the section. If it is outside the limits, adjust the ARV.

Boom Down 1

Prepare the machine a

Operate the dipper out and lower the boom to set the bucket on the ground.

Note: For accurate pressure setting, the pressure should be adjusted up to the required level. Release lock nut X. Adjust setting screw Y to a pressure below the required level and then bring the pressure back up for final setting. Tighten lock nut X.

C030150-1

Fig 13. b Make the machine safe, refer to Section E, Service Procedures. c

Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure gauge and adaptor to port TP1 on the hydraulic pump.

It is not physically possible to fully close the boom ram, without lifting the undercarriage of the ground. Therefore the ARV's must be swapped over. a

312460-C1

Fig 15. 3

The relief valves for boom up and boom down must be swapped and returned to the correct ports.

Restore Original MRV Pressure, refer to Section E, Service Procedures.

Fully raise the boom and then continue to operate the right control lever as at A at minimum no-load speed in the E mode.

C002690-C1

Fig 14.

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E-162

Section E - Hydraulics Service Procedure Auxiliary Relief Valves

Dipper Ram 1

Prepare the Machine a

Operate the dipper out and lower the boom to set the bucket on the ground.

C030150-1

Fig 16. b Make the machine safe, refer to Section E, Service Procedures. c

C002700-C1

Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure gauge and adaptor to port TP2 on the hydraulic pump.

Fig 17.

Increase MRV Pressure, refer to Section E, Service Procedures.

The pressure gauge reading (Dipper Out) should be compared to the technical data at the start of the section. If it is outside the limits, adjust the ARV.

Start the engine, lower the gate lock lever and run the engine at minimum no-load speed in the E mode.

d Move the dipper fully in and then continue to operate the control lever, as at B.

Pressure Adjustment

Raise the boom enough to allow the Dipper to move freely.

b Move the dipper fully out and then continue to operate the control lever, as at A.

Compare the pressure gauge reading (Dipper In) to that stated in the technical data section at the start of the section. If it is outside the limits, adjust ARV.

Note: For accurate setting, the pressure should be adjusted up to the required level. Release lock nut X. Adjust setting screw Y to indicate a pressure below the required level and then bring the pressure back up for final setting. Tighten lock nut X.

312460-C1

Fig 18. 5

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Restore Original MRV Pressure, refer to Section E, Service Procedures.

E-163

Section E - Hydraulics Service Procedure Auxiliary Relief Valves

Bucket Ram 1

Prepare the Machine a

Operate the dipper out and lower the boom to set the bucket on the ground.

C030150-1

Fig 19. b Make the machine safe, refer to Section E, Service Procedures. c

C002690-C2

Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure gauge and adaptor to port TP1 on the hydraulic pump.

Fig 20.

Increase MRV Pressure, refer to Section E, Service Procedures.

The pressure gauge reading (Bucket Open) should be compared to the technical data at the start of the section. If it is outside the limits, adjust the ARV.

Start the engine, lower the gate lock lever and run the engine at minimum no-load speed in the E mode.

d Close the bucket fully and then continue to operate the control lever, as at B.

Pressure Adjustment

Raise the boom.

b Open the bucket fully and then continue to operate the control lever at A.

The pressure gauge reading (Bucket Closed) should be compared to the technical data at the start of the section. If it is outside the limits, adjust ARV.

312460-C1

Fig 21. 5

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Restore Original MRV Pressure, refer to Section E, Service Procedures.

E-164

Section E - Hydraulics Service Procedure Auxiliary Relief Valves

Option ARV (Monoboom) 1

Prepare the Machine. Operate the dipper out and lower the boom to set the bucket on the ground.

Operate the option by pressing the foot pedal. Check the pressure on the gauge, adjust the ARV.

Restore Original MRV Pressure, refer to Section E, Service Procedures.

C030150-1

Fig 22. b Make the machine safe, refer to Section E, Service Procedures. Fit two caps B to the option pipes on the dipper.

312460-C1

Fig 24.

JS06720-C1 JS06720-C1

Fig 23. d Connect a 0 - 400 bar (0-6000 lbf/in2) pressure gauge to TP1. 2

Increase MRV Pressure, refer to Section E, Service Procedures.

Start the engine, lower the gate lock lever and run the engine at minimum no-load speed in the E mode.

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E-165

Section E - Hydraulics Service Procedure Travel Motor Relief Pressure

Travel Motor Relief Pressure TE-016

Prepare the Machine a

Start the engine, select MID speed travel, lower the gate lock lever and run the engine at minimum noload speed in the E mode.

Slowly engage the locked travel motor and measure the pressure in forward and reverse.

The pressure gauge reading (travel motor) should be compared to the technical data at the start of the section. If it is outside the limits, adjust relief valve pressure.

Operate the dipper out and lower the boom to set the bucket on the ground.

C030150-1

Fig 25. b Make the machine safe, refer to Section E, Service Procedures. c

Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure gauge to test point TP1 or TP2.

Increase MRV Pressure, refer to Section E, Service Procedures.

Insert a lock pin P between the drive sprocket to be measured and the side frame.

â&#x2C6;&#x2026;35

Note: For accurate setting, the pressure should be adjusted up to the required level. Release lock nut A. Adjust setting screw B to indicate a pressure below the required level and then bring the pressure back up for final setting. Tighten lock nut A.

â&#x2C6;&#x2026;80

A B 300

150 TOOL-C1 716370-C8

Fig 26.

Fig 28. 7

Restore Original MRV Pressure, refer to Section E, Service Procedures.

C002730-C1

Fig 27.

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E-166

Section E - Hydraulics

Routine Maintenance Procedures Scheduled Tasks The table below lists the Hydraulic System related Scheduled tasks. The tasks are in addition to the Daily/ Weekly scheduled tasks. For details of all applicable maintenance schedules refer to Section 2.

Note: Maintenance schedules can vary according to machine operating conditions and environments. Refer to Section 2.

Table 1. Item

Task

Hydraulic oil

Sample

Hydraulic oil

Replace

K Replace ( T E-172)

Hydraulic tank breather

Replace

K Replace ( T E-173)

Return filter

Replace

K Replace ( T E-174)

Drain filter

Replace

K Replace ( T E-175)

Suction strainer

Clean

K Clean / Replace ( T E-176)

Suction strainer

Replace

K Clean / Replace ( T E-176)

Security of mounting bolts on major components

Check (Condition)

K Check ( T E-177)

Breaker in-line filter element

Replace

K Replace ( T E-178)

Pump line exit hose

Replace

Boom ram hoses

Replace

Dipper line ram hoses

Replace

Bucket line ram hoses

Replace

Relief valves

Check (Condition)

K Check (Condition) ( T E-180)

Slew gearbox security

Check (Condition)

K Check (Condition) ( T E-181)

Slew gearbox oil

Check (Level)

K Check (Oil Level) ( T E-181)

Slew gearbox oil

Replace

K Replace (Oil) ( T E-181)

Slew brake

Check (Operation)

E-167

Refer to

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E-167

Section E - Hydraulics Routine Maintenance Procedures Service Points

Service Points Upper Structure J

C D

P03630

Fig 1. Item

Description

Engine fuel filter

Engine oil dipstick

Engine oil filler cap

Engine oil filter

Radiator cap and expansion bottle

Hydraulic tank breather

Fuel filler cap

Wndows washer fluid bottle

Diesel level indicator

E-168

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E-168

Section E - Hydraulics Routine Maintenance Procedures Service Points

Hydraulic Compartment

P036300-82.

Fig 2. Item

Description

Hydraulic level indicator

Primary fuel filter

Water seperator

E-169

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E-169

Section E - Hydraulics Routine Maintenance Procedures Dozer Assembly

Dozer Assembly A

C B

P041530-02

Fig 3. Item

Description

Dozer pump

Dozer control

Dozer line undercarriage

Blade assembly

Dozer line main frame

Floor mat

E-170

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E-170

Section E - Hydraulics Routine Maintenance Procedures Fuel Tank

Fuel Tank C D

E P041530-01

Fig 4. Fuel Tank Item

Description

Fuel tank

Fuel sensor

Fuel cap lockable vented

Fuel filter

Drain plug valve

Fuel/oil sight gauge with shroud

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E-171

Section E - Hydraulics Routine Maintenance Procedures Hydraulic Oil

Hydraulic Oil Replace

Prepare the machine. Refer to Section Maintenance, Maintenance Positions.

Release tank pressure. Refer to Section 2, Maintenance, Hydraulic System.

Remove cover A and O-ring B.

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

A B

Remove the hydraulic oil as follows:

Remove the drain plug C on the bottom of the tank and drain the remaining hydraulic oil from the tank.

Note: Have a drain pan ready. 4

Renew the suction strainer D and return filter E. Strainer ( T E-176) K Return K Suction Filter ( T E-174)).

Tighten the drain plug C securely.

Refill the tank with the specified hydraulic oil to the specified level.

Seal the system. Install the O-ring B and filler port cover A.

Note: If the O-ring is damaged, replace it with a new one. 8

Bleed air from the hydraulic components. Refer to Section 1, General Procedures.

Start the engine and run it for five minutes without load. Slowly operate the rams several times and then check the hydraulic oil level. Refer to Section 2, Maintenance, Hydraulic System.

C 810400

Fig 5.

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E-172

Section E - Hydraulics Routine Maintenance Procedures Hydraulic Tank Breather

Hydraulic Tank Breather Replace 1

Prepare the machine. Refer to Section Maintenance, Maintenance Positions.

Adjust the cover so that it fits over the stud, and install hexagonal nut B and rubber boot A.

Release tank pressure. Refer to Section 2, Maintenance, Hydraulic System.

Get access to the hydraulic tank breather. K Service Points ( T E-168)

Replace the hydraulic tank breather element as follows: a

Refit the filter cover C

Remove the rubber boot A, locking nut B and cover C.

A B F

E D

Fig 6. Note: The cover C will only fit in one of two positions by means of slot F. The slot locates over a similar shaped protrusion on the mounting stud. b Remove the old element D together with the sponge packing E. c

E-173

Replace the old element D, with a new one. When installing the new element D place the sponge packing E on the element.

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E-173

Section E - Hydraulics Routine Maintenance Procedures Return Filter

Return Filter Replace

Prepare the machine. Refer to Section Maintenance, Maintenance Positions.

Release Tank Pressure. Refer to Section 2, Maintenance, Hydraulic System.

Get access to Points ( T E-168)

the

return

filter.

Remove the return filter as follows: a

Remove the cover A and O-ring B.

b Remove spring C, valve D and return filter E from the tank. 5

K Service

Install a new return filter E. Re-assemble in the reverse order using a new cover O-ring B.

A B

C D

Fig 7.

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E-174

Section E - Hydraulics Routine Maintenance Procedures Drain Filter

Drain Filter Replace 1

Prepare the machine. Refer to Section Maintenance, Maintenance Positions.

Release tank pressure. Refer to Section 2, Maintenance, Hydraulic System.

Get access to Points ( T E-168)

Unscrew and remove filter A from head B.

Fit the new filter. Coat the seal of the new filter with clean hydraulic oil. Screw the new filter into head B and tighten.

Start the engine and run it for five minutes without load. Slowly operate the rams several times and then check the hydraulic oil level. Refer to Section 2, Maintenance, Hydraulic System.

the

drain

filter.

K Service

JS02830-C1

Fig 8.

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E-175

Section E - Hydraulics Routine Maintenance Procedures Suction Strainer

Suction Strainer Clean / Replace

Prepare the machine. Refer to Section Maintenance, Maintenance Positions.

Release the tank pressure. Refer to Section 2, Maintenance, Hydraulic System.

Remove the filler port cover A and O-ring B.

b Remove the suction strainer C from inside the hydraulic tank. 5

Get access to the suction strainer. K Service Points ( T E-168)

At the applicable service interval clean the suction strainer using a suitable cleaning fluid. Refer to Section 2, Maintenance, Maintenance Schedules. Make sure that the strainer is free from contamination. If the strainer is defective replace it with a new one.

A B

Remove the suction strainer as follows:

At the applicable service interval replace the suction strainer with a new one. Refer to Section 2, Maintenance, Maintenance Schedules.

Installation of the suction strainer is a reversal of removal. Fit a new O-ring seal to the filler port cover A and secure the fasteners.

Fig 9.

E-176

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E-176

Section E - Hydraulics Routine Maintenance Procedures Major Component Mounting Bolts

Major Component Mounting Bolts Check Check the security and torque of the major component mounting bolts as detailed in Section 2, Technical Data, Torque Values.

E-177

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E-177

Section E - Hydraulics Routine Maintenance Procedures Breaker In-Line Filter Element

Breaker In-Line Filter Element Replace

B A

P0350130-23

Fig 10. 1

Prepare the machine. Refer to Section Maintenance, Maintenance Positions.

Empty the hydraulic oil from the filter case. Clean the filter case and the underside of the filter head.

Release tank pressure. Refer to Section 2, Maintenance, Hydraulic System.

Fit new filter components as follows:

Get access to breaker in-line filter A assembly. K Service Points ( T E-168)

Dismantle the filter as follows:

Coat the new O-ring with hydraulic oil and locate in the filter head .

b Coat the seal area of the new filter element and install it in the filter case.

Unscrew four screws cap of filter head .Take care not to spill the hydraulic oil it contains.

Screw the filter cap to the case and torque tighten with the wrench..

b Remove and discard the filter element inside and O-ring.

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E-178

Section E - Hydraulics Routine Maintenance Procedures Breaker In-Line Filter Element Table 2. Torque Settings Item Nm A

Note: When refitting the filter case, it is important that the filter case is tightened carefully to avoid damaging the threads in the filter head. 7

Start the engine, operate the breaker and then check the hydraulic oil level. Refer to Section 2, Maintenance, Hydraulic System.

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E-179

Section E - Hydraulics Routine Maintenance Procedures Relief Valves

Relief Valves For relief valve locations refer to Service Procedures in this section.

Check (Condition) Check the condition of the relief valve installations as follows: â&#x20AC;&#x201C; Check the adjustment lock nut security. â&#x20AC;&#x201C; Check the security of anti-tamper caps and locking devices. Replace relief valves if they have been tampered with. Make sure the replacement relief valve is the correct pressure setting.

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E-180

Section E - Hydraulics Routine Maintenance Procedures Slew Gearbox

Slew Gearbox Check (Condition)

Replace the dipstick.

Check the general condition and operation of the slew gearbox as follows:

Refit the filler plug.

Make the machine safe. Refer to Section 2, Maintenance, Maintenance Positions.

Get access to the slew gearbox. K Service Points ( T E-168)

Inspect the slew gearbox casings for defects and oil leaks. Ensure that all the casing fixings are present and tightened to the correct torque. Ensure that the dipstick A and oil filler port plug B(if fitted) are installed correctly.

Test the operation of the slew function in both directions. Make sure that the slew gearbox operates smoothly with no abnormal noise.

Rectify slew gearbox defects as necessary.

Check (Oil Level) 1

Make the machine safe. Refer to Section 2, Maintenance, Maintenance Positions.

P036300-83.

Fig 11. 2

Remove and clean the slew gearbox dipstick A.

Replace the dipstick.

Remove the dipstick.

Check the oil level. The oil should be between the two marks on the dipstick.

If necessary, add a

Replace (Oil) 1

Make the machine safe. Refer to Section 2, Maintenance, Maintenance Positions.

Get access to the slew gearbox. K Fig 12. ( T E-182)

Remove the filler plug B.

b Add the recommended oil slowly through the filler port. c

Replace the dipstick.

d Remove the dipstick. e

E-181

Check the oil level, if necessary add more oil.

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E-181

Section E - Hydraulics Routine Maintenance Procedures Slew Gearbox

P0350130-21

Fig 12. 3

Drain the oil as follows: a

Get access to the drain plug from below the machine. Remove the remote slew gearbox drain plug A. Allow the oil to drain out.

b Wipe the drain plug clean. Remove contamination such as metallic particles. c 4

Refit the drain plug. Make sure it is tight.

Fill with the specified oil through filler port B. If there is no separate filler port fitted, top up through the dipstick port.K Fig 11. ( T E-181)

Check the oil level. K Check (Oil Level) ( T E-181)

Check for oil leaks. Run the machine, operate the slew controls and make sure there are no oil leaks.

E-182

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E-182

Section E - Hydraulics

Fault Finding Hydraulic Contamination TE-002_2

cleaning unit. K Fig 1. ( T E-183). General Bulletin 011 also refers.

Hydraulic Fluid Quality Construction machinery uses a large volume of fluid in the hydraulic system for power transmission, equipment lubrication, rust prevention and sealing. According to a survey conducted by a pump manufacturer, seventy per cent of the causes of problems in hydraulic equipment were attributable to inadequate maintenance of the quality of the hydraulic fluid. Therefore, it is obvious that control of the quality of the hydraulic fluid helps prevent hydraulic equipment problems and greatly improves safety and reliability. Furthermore from an economic angle it extends the life of the hydraulic fluid if quality is maintained.

Procedure Connect the cleaning unit in place of the hydraulic filter. K Fig 1. ( T E-183). Run the system for sufficient time to pump all the hydraulic fluid through the unit. Disconnect the cleaning unit and reconnect the filter. Top up the system with clean hydraulic fluid as required.

Effects of Contamination Once inside the system, hydraulic circuit contaminants greatly effect the performance and life of hydraulic equipment. For example, contaminants in a hydraulic pump develop internal wear to cause internal leakage and hence lower discharges. Wear particles generated will circulate with the hydraulic fluid to cause further deterioration in the performance of this and other equipment. Contaminants also enter principal sliding sections of the equipment causing temporary malfunction, scuffing, sticking and leakage and can lead to major problems.The main contaminants can be classified as follows: 1

Solid Particles - sand, fibres, metallic particles, welding scale, sealing materials and wear particles etc.

Liquid - usually water and incompatible oils and greases.

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

Fig 1. Cleaning Unit

These contaminants can appear during manufacture, assembly and operation.

Cleaning Operation The purpose of cleaning oil is to remove contaminants of all types and sludge by filtering hydraulic fluid through a

E-183

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E-183

Section E - Hydraulics Fault Finding 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 Fault Finding Main Control Valve

Main Control Valve Symptoms Spool sticking

Table 1. Possible Causes

Countermeasures

1. Oil temperature is abnormally high.

Remove the obstruction.

2. Hydraulic oil is dirty

Replace the hydraulic oil and clean the circuit at the same time.

3. Port connector is tightened too much

Check the torque.

4. Valve housing is deformed due to Installation

Loosen the installation bolt and check.

5. Pressure is too high

Attach pressure gauge to pump port and ram port and check the pressure.

6. Spool is bent

Replace the valve assembly.

7. Return spring is damaged

Replace the damaged parts.

8. Spring or cap is not on straight

Loosen the cap and after aligning, tighten.

9. Temperature inside valve is not even.

Warm up the circuit.

Spool does not stroke

1. Valve is clogged inside with dirt

Remove the dirt (flushing).

Load cannot be maintained

1. Oil leakage from the ram

Check the ram.

2. Oil is by-passing from the valve spool

Replace the valve assembly.

3. Oil leakage from the port relief valve

Remove the port relief from the housing and clean the housing seat and relief valve seat.

4. Oil leakage from the lock valve

Disassemble the lock valve and clean the poppet seat and sleeve, plug seat. If the seat is damaged, replace the poppet, or lap the poppet and seat.

1. Foreign matter in load check valve

Disassemble the check valve and clean.

2. Check valve poppet or seat damaged

Replace the poppet or lap the poppet and seat part.

When the spool is selected from neutral to raise position, the load falls.

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E-185

Section E - Hydraulics Fault Finding Relief Valve

Relief Valve Symptoms Pressure does not rise at all

Table 2. Possible Causes

Countermeasures

1. The main poppet, sleeve or pilot poppets 1 are sticking open or foreign matter is in the valve seat. 2 3

Relief pressure is unstable

1. The pilot poppet seat is damaged.

Check whether foreign matter is in each poppet. Check whether each part is sliding smoothly. Clean all the parts.

Replace the damaged parts.

2. The piston is sticking to the main poppet. Remove the surface scratches. Clean all the parts. Relief pressure is out of control 1. Wear due to foreign matter.

Oil leakage

E-186

Replace the worn parts

2. Lock nut and adjuster are loose.

Reset the pressure and tighten the lock nut to the rated torque.

1. Damaged seat or worn O-ring.

Replace damaged or worn parts. Check whether each part is sliding smoothly.

2. Parts are sticking due to foreign matter.

Check for scratches, cuts or foreign matter. Clean all the parts.

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Section E - Hydraulics Fault Finding Hydraulic System

Hydraulic System Symptoms The hydraulic system is not working well or not at all

E-187

Table 3. Possible Causes

Countermeasures

1. Pump problem.

Check the pressure or replace the pump.

2.Foreign matter clogging inside the relief valve.

Disassemble the relief valve and clean.

3. Relief valve trouble.

Check according to the maintenance procedures.

4. Ram trouble.

Repair or replace.

5. Load is too heavy.

Check the circuit pressure.

6. Crack in the valve.

Replace the valve assembly.

7. Spool does not stroke fully.

Check the spool movement and operation link.

8. Oil level too low.

Replenish hydraulic oil.

9. Filters inside circuit are clogged.

Clean filter or replace.

10. Hose runs are kinked.

Check the hoses.

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Section E - Hydraulics Fault Finding Slew Motor

Slew Motor Symptom

Cause

Motor does Internal damage to the not run motor.

Excessive slip

Table 4. External Inspection

Countermeasure

Repair

Measure the oil drain volume.

High possibility of damage to the sliding surfaces if the supply volume is approximately equal to the drain volume. Dismantle and inspect.

Internal damage to the motor.

Open the motor inlet and outlet ports and apply 20 kgf/cm2 (284 lbf/in2) pilot pressure to the brake release port. Try to rotate the shaft with a torque of approx. 39 Nm (29 lbf ft).

High possibility of internal Renew damaged parts or damage to the motor if renew the motor the supply shaft does not assembly. rotate smoothly when this torque is applied. Dismantle and inspect.

Relief valve in circuit not set correctly.

Measure pressure.

Reset to the prescribed setting.

K Table 5. ( T E-189).

Wear or damage to the Measure the oil drain motor sliding surfaces or volume. to the high-pressure seal.

Leakage is too high if the K Table 5. ( T E-189). oil drain volume exceeds 5 l/min (1.1 gal/min). Dismantle and inspect.

Oil hot and excessive parts or circuit.

Measure the oil temperature.

Reduce the oil temperature.

K Table 5. ( T E-189).

Abnormal heating

Seizure of motor sliding parts or circuit.

Check for any metallic matter deposited in motor drain oil or drain filter. Apply a 30 kgf/cm2 (427 lbf/in2) pilot pressure to the brake release port and try to rotate the shaft with a torque of approx.39 Nm (29 lbf ft).

If metallic matter is discovered or the supply shaft does not rotate smoothly when torque is applied, there is a high possibility of internal damage to the motor. Dismantle and inspect.

Repair or renew the damaged parts. Renew the motor assembly.

Leakage from oil seals

Damage or wear to oil seal lip.

Renew the oil seals.

Damage or wear of the shaft seal.

Repair the problem or renew the motor assembly.

Abnormal pressure in the Check the pressure in the Set the pressure in the casing. casing and measure the casing below 3 kg/cm2. drain volume. (43 lbf/in2) Dismantle and inspect if drain volume is excessive.

Renew the oil seal. Repair or renew the damaged parts. Renew the motor assembly.

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E-188

Section E - Hydraulics Fault Finding Slew Motor Symptom Insufficient torque

Abnormal noise

Cause

External Inspection

Countermeasure

Repair

Wear or seizure of the motor sliding surfaces.

Open motor inlet and outlet ports and apply 20 kgf/cm2 (284 lbf/in2) pilot pressure to the brake release port.Try to rotate the shaft with a torque of approx. 39 Nm (29 lbf ft).

High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect.

Inspect the parts and bearing according to a-e and renew any defective parts.K Table 5. ( T E-189)

Relief valve in the circuit is not set correctly.

Measure relief pressure.

Reset to the prescribed setting.

Internal damage to the motor.

Check if any metallic matter is deposited in the motor drain oil or drain filter.

High possibility of internal Repair or renew damage to the motor if damaged parts. Renew metallic matter is the motor assembly. discovered. Dismantle and inspect.

Large amount of air mixed in the oil.

Check the oil in the tank and motor casing.

Thoroughly bleed the air.

Loosening of bolts or pipes

Check if the piping Tighten to the specified connections, attachment torque. mounting bolts, motor attachment bolts or other bolts are loose.

Oil leakage O-ring is damaged from mating Seal face is damaged. surfaces Bolts are loose.

Renew O-rings. Repair seal face or renew. Check the bolt tightness. Tighten the bolts to the correct torque. Table 5.

No.

Part Inspected

Repair

Wear of the sliding surface of balance plate

Repair or renew the part

Damage to sliding surface of cam plate

Repair the part or renew the motor.

Damage to sliding surface of the piston assemblies

Repair the part or renew the motor.

External wear to the piston assemblies

Repair the part or renew the motor.

Wear to piston bores in cylinder assembly

Renew the motor.

Damage to Teflon ring 19 or `O'-rings

Renew the part.

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E-189

Section E - Hydraulics Fault Finding Hydraulic Pump

Hydraulic Pump Often the regulator and attendant valves or pump are combined which makes it very difficult to discover the reason for the trouble. Inspect the following categories which will assist in discovering the abnormal point. 1

Filter and Drain Oil Inspection. Inspect the filter element. Check to see whether there is an abnormally large amount of foreign matter. There will be a small amount of metallic powder due to wear of the shoe or cylinder, but if there is a large amount of metallic powder in the filter, it may be due to trouble with the shoe. Also check the drain oil in the pump casing.

Cause Are the revolutions - pressure higher than pre-determined values?

Abnormal Vibration and Sound. Check to see if there is any abnormal vibration or sound in the pump main body. Check to see if it is like the regular frequency sound of the regulator's working or attendant valve relief working. If it is an abnormal vibration or sound, it is possible that there is damage or cavitation inside the pump.

Measure Pressure of Each Part. When it is a control problem, do not unnecessarily open ports for inspection purposes, measure the pressure for each section and find the abnormal item.

Table 6. Prime Mover Overload Treatment

Note

Set to pre-determined value.

Is the regulator torque setting too high? Re-inspect regulator.

Refer to regulator instructions.

Seizure or damage of pumps internal parts

Replace damaged parts.

Check the filter or drain oil for signs of abnormal wear.

Wrong regulator hose connection.

Correct hose lines.

Table 7. When pump flow is extremely low, delivery pressures does not increase Cause Treatment Note Regulator breakdown

Repair the regulator

Refer to regulator instructions

Seizure or damage of pump internal parts.

Replace damaged parts.

Check filter, drain oil.

Pump breakdown.

Replace damaged parts.

Remove pump and inspect shaft coupling.

Attendant valve breakdown.

Inspect attendant valve.

Incorrect regulator hose connection.

Correct hose lines.

Cause Cavitation.

Table 8. Abnormal Sound and Vibration Treatment Prevent cavitation. Check to see if hydraulic oil is white and cloudy.

Damage of shoe caulking part.

Replace piston, shoe, shoe plate.

Crack in cylinder.

Replace cylinder

Bad installation of pump.

Correct installation.

Relief valve bouncing.

Repair relief valve.

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Note

Boost pressure is low. Pump is broken. Air is sucked by suction pipe. Suction resistance is high.

Refer to relief valve instructions.

E-190

Section E - Hydraulics Fault Finding Hydraulic Rams

Hydraulic Rams Hydraulic Ram Faults and Remedies It is often not easy to find the part causing the fault. In the table possible problems are listed. K Table 9. ( T E-191). Repair is difficult, refer to the estimated cause and treatment listed in the table. The general phenomenon, estimated causes and treatment are shown. K Table 10.

Item

E-191

( T E-192). However, machine trouble is most often caused, not by just one faulty part, but its relationship with other parts. Not all of the possible causes and treatments are listed in the tables therefore, it may be necessary for the person responsible for repairs to make further investigations to find the cause of the trouble.

Table 9. Symptoms

Oil leakage from piston rod sliding part

Oil leakage from cylinder head meeting part

Faulty operation

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Section E - Hydraulics Fault Finding Hydraulic Rams Item

Symptoms

Related Parts

Table 10. Trouble On the sliding surface, there are 1 scratches and rust that can be felt by the fingernail.

Use an oil stone and remove the scratch and make the sliding surface smooth. (Less than 1.5 S). If oil leakage continues even though the rod surface is made smooth, the scratch may cause damage to the U-ring and other seals, so disassemble and inspect.

If the scratches and rust cover such a wide area that they cannot be repaired by an oil stone, replace the piston rod and Uring, wiper ring and seals and the piston rod bearing member.

Piston rod

Treatment

The plating is peeling.

Re-plate or replace the piston rod. Also inspect the seal and piston rod bearing member and replace if damaged.

Foreign matter is biting into the inner and outer surfaces of the packing.

Remove foreign matter. If there is damage to packing, replace it.

There is a scratch on the inner Replace. and outer surface of the packing.

Piston rod sliding part oil leakage

Rod packing (Buffer ring, Uring)

The lip and groove parts are locally carbonized (burned).

Possibly due to burning caused by adiabatic compression from air remaining inside the ram. After replacing the packing, first operating the ram at low-pressure, low speed to sufficiently bleed the air.

Packaging rubber elasticity is gone and breaks into pieces.

The packing life or hydraulic oil deterioration and high temperature are possible reasons.

Lip is deficient all around.

Renew hydraulic oil.

Check the hydraulic oil temperature (Below 80 C is advisable).

Check if high temperature locally.

Replace. It is possible that abnormal high pressure is working on the packing.

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Check the operation pressure, cushion pressure.

Part which is attached to the buffer ring may be abnormal. Inspect the buffer ring.

E-192

Section E - Hydraulics Fault Finding Hydraulic Rams Item

Symptoms

Related Parts Back up ring

Piston rod sliding part oil leakage

Wiper ring

Bushing

Trouble

Treatment

The protrusion of the heel of the As a rule, replace the rod packing at the same packing is excessive. time. (It is desirable to replace parts which are attached to the buffer ring at the same time). It is possible that abnormal high pressure is the cause. Check the same as above (heel of packing protruding). Foreign matter is biting into the lip. The lip is damaged.

Remove the foreign matter.

There are also other abnormal damage.

Replace.

Wear is large and the clearance Replace. with piston rod exceeds the *maximum permissible value. (*Refer to maintenance standards for maximum permissible value.) Large scratch on the sliding part. Replace. Also inspect the piston rod.

Cylinder head

Scratches, rust on the seal attachment parts.

Remove scratch, rust with oil stone. If it cannot be repaired, replace the cylinder head.

Foreign matter biting on inner and outer diameter.

Remove foreign matter

O-ring damaged.

Inspect inside tube: if any scratches or rust, make surface smooth with oil stone

Replace 'O'-ring if damaged.

Inspect cylinder head 'O'-ring groove: if any scratches or rust, make surface smooth with oil stone.

O-ring

Inspect back up ring: if any deformation or protrusion, replace. Confirm the above and replace 'O'-ring. 2

Oil leakage from cylinder head joint

Back up ring

Deformation, protrusion Looseness

Replace with 'O'-ring. Disassemble cylinder head and inspect 'O'-ring and back up ring. Check tube and cylinder head thread for damage. If any damage, replace.

Cylinder head

After inspection, tighten to specified torque. Bolt Cylinder tube

E-193

Looseness, stretching, broken

Replace all bolts and tighten to specified torque.

Abnormal bulge

Replace with new parts. Oil leakage from connecting parts may be caused by abnormal pressure (including cushion pressure). Inspect the tube for bulges, deformation and check the circuit pressure.

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E-193

Section E - Hydraulics Fault Finding Hydraulic Rams Item

Symptoms Oil leakage from pipe and cylinder tube welded seam

Related Parts

Trouble Crack in welding

Treatment Replace with new parts. Cracks will develop into fractures. Fractures are very dangerous, so if any cracks are found, stop work immediately and replace with new parts.

Cylinder tube pipe (hollow piston rod)

Welding on top of cracks will have no effect. Poor operation

Piston rod cylinder tube

Bending is more than the Replace with new part. The seal and sliding specified limit. (Bending part material may be damaged too, so inspect. distortion: Refer to maintenance If abnormal, replace. standards)

Cylinder tube

There is a recess

4 4-1 Movement not smooth

E-194

Piston rod cylinder rod sliding part

Replace with new part. As above, inspect the seal and sliding part material.

Abnormal wear, damage of sliding parts.

Replace with new part

Foreign matter intruding on piston and cylinder head sliding area

Remove foreign material.

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As above, inspect the seal and sliding part material. As above, inspect the seal and sliding part material.

E-194

Section E - Hydraulics Fault Finding Hydraulic Rams Item

Symptoms

Related Parts

Trouble

4-2 Inner oil leakage. Piston rod extends when work stops or lowers abnormally during work. Also, specified operating speed is not achieved.

Piston seal

Scratches, wear are present

Cylinder tube

Scratches, rust on the inside

Treatment Replace with new part. Inspect the cylinder tube inner surface. Remove the scratches/rust by honing or with an oil stone and make the surfaces smooth. If the scratch is deep and cannot be repaired, replace the cylinder Replace piston seal.

Piston Nut Valves

Loose nut

Tighten to specified torque

Leak from valve

Inspect the valve leakage amount and service.

Note: Note: Hydraulic oil expands and contracts due to changes in temperature and pressure. Accordingly, the ram also expands and this can be mistaken for internal leakage. When inspecting for internal leakage, do so at set conditions 4-3

Air

Air remaining inside ram Operation is unsteady

Bleed the air. For rams that do not have an airbleeder, operate back and forth several times at low pressure and low speed to bleed the air. For rams with an air bleeder, remove the load to reduce the pressure then loosen the air bleeder and completely bleed the air. Note: The ram may expand if it is stopped suddenly. This is due to the compression of the hydraulic oil. This occurs especially with long stroke rams.

4-4 Heavy Pin bushing, Pin Gap between installation part shock and pin bushing is too large loading when changing from extension to retraction and back

Measure the pin and pin bushing and replace parts if measurements exceed the specifications.

4-5 Noisy operation

Add oil.

Oil supply

Insufficient oil

Pin bushing, Pin Scuffing at connecting part

Replace with new part and add oil.

Note: If left in the state where operation is poor, the ram will no longer move and other parts will be affected adversely. Inspect early and carry out appropriate measures.

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E-195

Section E - Hydraulics Fault Finding Fault Finding Tests

Fault Finding Tests Slow or Underpowered:

Additional information Measure the amount of deviation over a 20 m (165.6 ft) distance and record ground conditions.

– boom up operation – bucket service operation – dipper service operation

Deviation limit = 1 m (39.4 in) deviation in 20 m (165.6 ft) of travel.

– slew service operation Carry out the following tests: Test 001

If machine is fitted with priority valve in pump line (this valve usually feeds low flow/weedcutter circuit) try connecting the two main service hoses together that are connected to the valve. Does this change the fault?

Testing negative control signal

Test 002

Testing max. flow cut signal

Test 003

Testing main pump pressures

Test 004

Testing horsepower control

Test 005

Testing operation of main hydraulic spool

Test 006

Testing operation of pressure switches

Test 007

Testing engine speed settings

Test 008

Testing machine cycle times

Test 016

Testing Pump Flow

Swap the two main hoses on the hydraulic pump. Does the problem change direction?

Poor Tractive Effort Carry out the following tests:

Harsh Operation When Selecting: – boom down – slew service

Testing negative control signal (Boom down only)

Test 011

Testing operation of Slew brake (Slew only)

Test 006

Testing operation of pressure switches

Test 001

Testing negative control signal

Test 003

Testing main pump pressures

Test 012

Testing track motor relief valve settings

Test 013

Testing track motor drain line rates

Test 008

Testing track motor speeds

E-196

Test 003

Testing main pump pressures

Test 012

Testing track motor relief valve settings

Test 013

Testing track motor drain line rates

What travel gear is the machine operating in when the problem occurs?

Test 001

Carry out following tests:

Testing negative control signal

Additional Information

Carry out the following tests:

Tracking Off Line

Test 001

See: Machine Selects High Gear Even Though Monitor Displays Another Travel Gear

Loss of Creep Speed Carry out the following tests: Test 012

Testing max.l flow cut signal

Test 008

Testing track motor speeds

Test 006

Testing pressure switches

Additional information When creep speed tracking is selected is `tortoise' symbol displayed on monitor? yes / no

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Section E - Hydraulics Fault Finding Fault Finding Tests

Loss of High Speed Carry out the following tests: Test 006

Testing operation of main hydraulic spool

Test 008

Testing engine speed settings

Test 012

Testing track motor relief valve settings

Test 014

Testing track motor speeds and pressure switches.

Machine Selects High Speed Travel Carry out the following tests: Test 015

Checking servo pressure and solenoid voltage.

Slew Bearing Faults Carry out the following tests: Test 017

E-197

Checking slew bearing vertical lift and backlash.

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E-197

Section E - Hydraulics Fault Finding Test 001: Testing Negative Control Signal

Test 001: Testing Negative Control Signal

Pt1

Pt2 Fig 2.

Fit test gauges (0 - 60 bar, 10 - 1000 lb/in2) into hose connections to ports Pt1 + Pt2 with T-piece adapter

Warm up machine hydraulic temperature to 50 Â°C (122 Â°F)

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Section E - Hydraulics Fault Finding Test 002: Test Max Flow Signal

Test 002: Test Max Flow Signal

Pm1

Pm2 Fig 3.

Fit test gauges 0 - 60 bar (10 - 1000 lb/in2) into hose connections to ports Pm1 + Pm2 with a T-piece adapter

Warm up machine hydraulic temperature to 50 Â°C (122Â° F)

Table 11. (expected pressures) Port Pm1 With max engine rpm's and no services selected record max flow cut control pressure in E mode

Port Pm2

0 - 1.5 bar (0 - 21.8 lb/in )

0 - 1.5 bar (0 - 21.8 lb/in2)

Select L mode and record pressure

40 bar (580 lb/in2)

Select standard mode, select low speed tracking (tortoise on monitor) then select track service record pressure

40 bar (580 lb/in2)

Note: 40 bar = 80 lb/in2, 1.5 bar = 21.75 lb/in2

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Section E - Hydraulics Fault Finding Test 003: Testing Main Pump Pressure

Test 003: Testing Main Pump Pressure

G1 G2

Fig 4. 1

Fit test gauges 0 - 600 bar (8700 lb/in2) into ports G1 and G2.

Warm up machine hydraulic temperature to 50 Â°C (122 Â°F).

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E-200

Section E - Hydraulics Fault Finding Test 004: Testing Horsepower Control

Test 004: Testing Horsepower Control 5

Warm up machine hydraulic temperature to 50 Â°C (122 Â°F)

+ -

E + -

F Fig 6. T024140

Fig 5. 1

Fit gauge 0 - 60 bar (0 -1000 lb/in2) into proportional solenoid secondary pressure measurement port A using suitable adapter (port thread is 1/4 BSP O-ring fitting).

Separate proportional solenoid electrical connector.

Using service connector from electrical test kit WDB0055 connect fluke meter in series as shown right.

Brown/Black (BrB)

Pump side harness

Link wire

OR 4

Using link wire, connect fluke meter in series as shown.

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E-201

Section E - Hydraulics Fault Finding Test 004: Testing Horsepower Control Function

Table 12. Expected Expected PSV PSV Pressure Pressure

Expected PSV Pressure

Expected Milliamps

JS115JS145

JS160JS180

JS200-220

JS115JS145

JS160JS180

JS200-220

2-5 bar

590mA

650mA

With maximum engine RPM and no services operated, select "E" mode.

11-15 bar

505mA

500mA

365mA

With maximum engine RPM and no services operated, select "L" mode.

32-36 bar

0mA

With maximum engine RPM selected on the throttle dial and no service selected in "A" Mode. Note: The auto pressure switch must be shorted out during this test.

To achieve the above values the following conditions have to be met: 1

Feed pressure in port "P" of the solenoid to be 39 bar.

Back pressure to be no more than 10 bar.

Oil temperature to be 55 Â°C +/- 10 Â°C.

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E-202

Section E - Hydraulics Fault Finding Test 005: Checking the Operation of the Main Hydraulic Spool

Test 005: Checking the Operation of the Main Hydraulic Spool A

C F

Cylinder port B

Cylinder port A

Pilot port a

Valve block

Main spool

Pilot port b

D Fig 7. Sectional view of valve block showing spool and pilot ports lnsert a piece of stiff clean wire (Approximately 2 mm (0.08 in) diameter)) through the adapter in the port not being selected until the spool end is felt. Slowly select the spool from the selected end using the portapower pack, measure the distance the spool moves and check against the graph below. (If using the accumulator pressure, turn on the machines ignition, lower the lever lock and select the service.

Identify which is main directional spool for service being tested, and which side of that spool is supplied pilot pressure when service is operated in desired direction Fit pressure gauges 0 - 60 bar (0 - 1000 lb/in2) to this port and also to port on opposite end of spool Warm up hydraulic system to 50 Â°C (122 Â°F)

Note: The accumulator may require recharging by running the engine for a short period). Remove Spool cap from the main withdraw the spool checking for imperfections, or any signs of sticking. and out of the valve block, rotating it checking for smoothness.

valve block and any scratches/ Slide the spool in at the same time

Remove the hose from the spool port that is not being selected and plug the hose. Remove the hose from the spool end that is being selected and plug the hose. Couple a hand pump (see Service tools) with a pressure 60 bar (0 - 1000 lb/in2) gauge attached. (Instead of using a hand pump, the pressure from the accumulator may be used by leaving the hose and Pressure gauge attached, but will not be as accurate, and should only be used if only full spool selection is being measured.)

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E-203

Section E - Hydraulics Fault Finding Test 005: Checking the Operation of the Main Hydraulic Spool

Fig 8. Table 13. Pressure at spool port which is Pressure at spool port at which being selected is not being selected With max engine rpm and no service selected With service fully selected

E-204

(expected pressure)

0 - 3 bar (43.5 lb/in )

0 - 3 bar (43.5 lb/in2)

36 - 40 bar (522 - 580 lb/in2)

0 - 3 bar (43.5 lb/in2)

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Section E - Hydraulics Fault Finding Test 006: Test the Pressure Switches

Test 006: Test the Pressure Switches TE-021

POWER MODE

C030620

Fig 9. 1

Start the engine.

Press the SET and MODE buttons together to access the sub menu.

Use the UP and DOWN arrow buttons until `PILOT SWITCH' is displayed on the screen.

Press the ACK button.

Use the UP and DOWN buttons to scroll through the individual switches and check them using the information given in the table. K Table 14. ( T E-206).

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Section E - Hydraulics Fault Finding Test 006: Test the Pressure Switches Table 14. Pressure Switch

Function Boom up

Boom up

Dipper in

Dipper out

OFF

Hammer

OFF

Slew

OFF

Travel

OFF

Upper

Boost

Auto

Only if main pump pressure is above switching pressure (298/ 335 bar)

Only if servo pressure from hand controller is above 20 bar

Only if main pump pressure is above switching pressure (298/ 335 bar)

Only if servo pressure from hand controller is above 20 bar

Only if main pump pressure is above switching pressure (298/ 335 bar)

Only if servo pressure from hand controller is above 20 bar

Bucket in and out

OFF

Only if main pump pressure is above switching OFF pressure (298/ 335 bar)

Slew left and right

OFF

Travel

OFF

Hammer

OFF

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E-206

Section E - Hydraulics Fault Finding Test 006: Test the Pressure Switches

Symptoms of Pressure Switch Failures Table 15. Pressure switches that need to be closed when selected, to avoid the issues described. Upper pilot

Travel

Auto mode

In Auto/one touch idle, engine will not return to full RPM when service is selected.

Closed when Closed when Closed when selected selected selected

In Auto mode the engine fails to rise to full engine RPM when Boom or Dipper are fully selected.

Closed when selected

Slow speed travel (Tortoise) does not work.

Closed when selected

2nd Stage MRV (power boost) does not work in Auto mode. (For testing power boost, refer to Section E, Fault Finding, Test 003: Testing Main Pump Pressure).

Closed when selected

Slew start up and slow down Closed when very erratic and juddering. selected

Boost

Hammer

Slew

Closed when selected

Note: For location of pressure switches refer to Section E, Circuit Descriptions, Main Control Valve/Shuttle Valve

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E-207

Section E - Hydraulics Fault Finding Test 007: Testing Engine Speed Settings

Test 007: Testing Engine Speed Settings 1

Warm Engine water temperature above 50 °C (122 °F).

Press Set + Mode for 5 seconds (On the EMS).

Use the up and down arrows to scroll to the RPM value.

Press ACK to view engine speed.

B Fig 11. B Auto Power Boost Pressure Switch Note: The harness connector should be labelled with a green marker tape

Fig 10. Table 16. Expected RPM Dipper Close Expected RPM Bucket Close Stalled Stalled

Mode

Expected RPM High idle, no load

"A" mode with the auto pressure switch shorted out

JS115-JS145 2200 +/- 50 JS160-JS220 2050 +/- 50

"A" mode with the auto pressure switch connected

JS115-JS145 2050 +/- 50 JS160-JS220 1950 +/- 50

JS115-JS145 2200 +/- 50 JS160-JS220 2050 +/- 50

"E" mode.

JS115-JS145 2050 +/- 50 JS160-JS220 1950 +/- 50

JS115-JS145 2050 +/- 50 JS160-JS180 1950 +/- 50

"L" & "P" mode

JS115-JS145 1950 +/- 50 JS160-JS220 1850 +/- 50

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E-208

Section E - Hydraulics Fault Finding Test 007: Testing Engine Speed Settings

Pressure Switches vs Engine Speed The following graphic shows the relationship between the auto mode, upper and travel pressure switches and the engine speed.

Example (JS160-JS220): 1

The track levers are operated, the travel pressure switch is activated and the engine speed rises from 900 rpm (idle) upto 2050 rpm.

The track lever is returned the centre position, the travel pressure switch is deactivated and engine speed remains at 2050 rpm for a further 3 secs.

The engine speed drops to 1950 rpm for X seconds where X is the auto idle time as determined in EMS (5-30 seconds).

The engine speed drops to 900 rpm (idle).

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Section E - Hydraulics Fault Finding Test 007: Testing Engine Speed Settings Machine

Auto

Table 17. Economy

Auto Idle

Idle

JS115-JS145

2200 rpm

2050 rpm

1150 rpm

950 rpm

JS160-JS180

2050 rpm

1950 rpm

1150 rpm

900 rpm

JS200-JS220

2050 rpm

1950 rpm

1150 rpm

900 rpm

A B C

D E

F Fig 12.

E-210

Item

Table 18. Auto Mode Pressure Switch

Auto Pressure Switch

Upper Pressure Switch

Travel Pressure Switch

Full Auto

Economy

Idle (or auto idle if enabled or in Auto mode)

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Section E - Hydraulics Fault Finding Test 008: Testing Machine Cycle Times

Test 008: Testing Machine Cycle Times

Machine

Bucket Ram Speed

Table 19. Time (seconds)

Service Operated

JS115-145 JS160-180 JS200-220

Bucket In

3.7

4.0

2.7

Bucket Out

1.9

2.4

2.2

Arm In

3.6

3.4

3.6

Arm Out

3.8

2.6

2.8

Boom Up

3.4

3.0

3.5

Boom Down

3.6

3.2

Slew

4.4

5.8

4.9

Position the dig end as shown.

A357571

Table 20. Expected Gearbox RPM

Travel Speed Machine

A357570-C2

Fig 13.

JS115

JS130145

JS160180

JS200220

Middle

34.5

32.7/ 28.4

High (Rabbit)

51.0

55.5/ 47.6

Low

Measure the time it takes the bucket ram to open from the closed position.

Repeat five times and calculate the average time.

Measure the time it takes the bucket ram to close from the open position.

Repeat five times and calculate the average time.

Note: Cycle times in A mode. No quick hitch or attachment fitted. Oil temperature 40 degrees C. Variation +/-0.2 seconds 1

Operate all services 10 times to ensure warm hydraulic oil is circulated through all the services.

If the machine is fitted with HBCVs and any delay is felt when operating dipper in, then the HBCV must be bled of any air and the test repeated.

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Section E - Hydraulics Fault Finding Test 008: Testing Machine Cycle Times

Dipper Ram Speed 1

Boom Ram Speed

Position the dig end as shown.

A357571

A357570-C2

Fig 14. 2

Measure the time it takes the dipper ram to open from the closed position.

Repeat five times and calculate the average time.

Measure the time it takes the dipper ram to close from the open position.

Repeat five times and calculate the average time.

A357573-C2

Fig 15. 2

Measure the time it takes the boom ram to open from the closed position.

Repeat five times and calculate the average time.

Measure the time it takes the boom ram to close from the open position.

Repeat five times and calculate the average time.

Note: Place a wooden block where the dipper would make contact with the ground, so as to prevent a shock loading of the dipper, when it is lowered.

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Section E - Hydraulics Fault Finding Test 008: Testing Machine Cycle Times

Slew Speed

Travel Linearity

Position the dig end in the minimum slew position facing forwards.

The machine should have an approach A of 5 metres (16.5 ft) and a travel distance B of 20 metres (65.62 ft).

Rotate the upper framework and after one complete rotation measure the time it takes for the next 5 rotations. Calculate the speed of one rotation.

Approach the reference line C and adjust the position of the track shoe/travel direction against the reference line in the first 5 metres (16.5 ft).

Without adjustment allow the machine to travel 20 metres (65.62 ft). K Fig 16. ( T E-213) .

Measure the amount of deviation X after 20 metres (65.62 ft) between the reference line and track shoe.

Repeat the procedure K Fig 17. ( T E-213).

Travel Speed 1

Raise one track off the ground by slewing the machine through 90 degrees and lifting the machine using the boom and dipper.

Make a mark on the outside edge of the track gearbox.

Operate the track motor in forward and reverse for 5 minutes, changing gear at regular intervals to distribute warm oil through the system.

reverse.

X C

Record the time it takes for the motor to complete ten revolutions. Calculate the gearbox speed. Measure the speed in each direction three times and calculate the average speed.

B T041430

Fig 16.

X C

A T041430-1

Fig 17.

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Section E - Hydraulics Fault Finding Test 011: Testing Swing Brake Pressure

Test 011: Testing Swing Brake Pressure

A405810-C1

Fig 18. 1

Fit pressure test gauge 0 - 60 bar (1000 lb in2) into hose connection on hose A on the slew motor.

Warm up hydraulic system to 50 Â°C.

K Table 21. ( T E-214) Table 21. Pressure at port A (expected pressure)

With engine at max rpm's no services selected record pressure

0 bar

Select slew service record pressure

40 bar (580 lb/in2)

Deselect slew service record pressure

40 bar (580 lb/in2)

Select 100% slew lock record pressure

after 5 secs 0 - 1.5 bar (21.75 lb/in2)

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Section E - Hydraulics Fault Finding Test 012: Testing Track Motor Relief Valve Settings

Test 012: Testing Track Motor Relief Valve Settings

ARV

ARV 716370-C1

Fig 19. 1

Fit pressure gauges 0 - 600 bar (8700 lb in2) to test ports B.

Warm up hydraulic system to 50 Â°C (122Â°F).

Disconnect the travel pressure switch A on the main control valve.

Temporarily increase the pressure setting of the MRV.

Select L mode.

Stall the track motor using an old track pin or similar.

K Table 22. ( T E-215)

OR Table 22. Expected relief valve setting Select and stall left hand track motor forward

343 bar (4973.5 lb/in2)

Select and stall left hand track motor reverse

343 bar (4973.5 lb/in2)

Select and stall right hand track motor forward

343 bar (4973.5 lb/in2)

Select and stall right hand track motor reverse

343 bar (4973.5 lb/in2)

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E-215

Section E - Hydraulics Fault Finding Test 013: Testing Track Motor Drain Line Flow Rate

Test 013: Testing Track Motor Drain Line Flow Rate

716370-C2

Fig 20. View of track motor (Cover removed) 1

Warm up hydraulic system to 50 Â°C (122 Â°F).

Remove tank hose from drain port D on left hand track motor.

Set machine to max engine rpm's in middle gear (arrow on monitor).

K Table 11. ( T E-199)

Plug hose.

Refit hose to track motor.

Fit hose between drain port D and measuring container.

Repeat above procedure for right hand track motor.

Refit hose to track motor.

Table 23. Expected drain line rate litres/min. JS115-JS180

JS200-220

Select and stall left hand track motor forward for 1 min.

3 - 4 litres (0.66 - 0.88 UK gal)

5 litres (1.1 UK gal)

Select and stall left hand track motor reverse for 1 min.

3 - 4 litres (0.66 - 0.88 UK gal)

5 litres (1.1 UK gal)

Table 24. Expected drain line rate litres/min. JS115-JS180

JS200-220

Select and stall right hand track motor forward for 1 min.

3 - 4 litres (0.66 - 0.88 UK gal)

5 litres (1.1 UK gal)

Select and stall right hand track motor reverse for 1 min.

3 - 4 litres (0.66 - 0.88 UK gal)

5 litres (1.1 UK gal)

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Section E - Hydraulics Fault Finding Test 014: Loss of High Speed Tracking

Test 014: Loss of High Speed Tracking If experiencing loss of high speed tracking, carry out following checks: Test 008

Testing track motor speeds

Test 006

Testing pressure switches

When high speed tracking has been selected is electrical voltage seen at high speed tracking solenoid A ? yes/no ?

Additional information When high speed tracking is selected is `hare' symbol displayed on monitor? yes / no When high speed tracking has been selected what pressure is seen at pilot port D to select high gear on track motor, K Fig 21. ( T E-217).

Fig 21.

T023460

Fig 22. Front View of 8 spool valve

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E-217

Section E - Hydraulics Fault Finding Test 015: High Gear Selection, Monitor Displays Another Travel Gear

Test 015: High Gear Selection, Monitor Displays Another Travel Gear If machine selects high tracking gear `by itself' even though the operator has not selected high gear and the monitor display has not changed carry out following checks:

Middle tracking gear is selected?

High tracking gear is selected?

What pressure is seen at pilot port D when: 1

middle tracking gear is selected?

middle tracking gear is selected and tracking service is stalled, forwards and backwards on both left and right hand tracks?

high tracking gear is selected?

Fig 23.

T023460

Fig 24. Front View of 8 spool valve What electrical voltage is seen at high speed tracking solenoid A when:

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E-218

Section E - Hydraulics Fault Finding Test 016 - Flow Testing Hydraulic Pumps - Record Sheet

Test 016 - Flow Testing Hydraulic Pumps - Record Sheet Minimum Flow Pump 1 Mode

Pressure in P1

Pressure in P2

Minimum Flow Pump 2 Flow

Rpm

Mode

P Maximum Flow Pump 1

Mode

Pressure in P1

Pressure in P2

Flow

Rpm

Mode A

P Horsepower Control Pump 1 A Mode Flow

Pressure in P2

Flow

Rpm

Flow

Rpm

Maximum Flow Pump 1

Pressure in P1 Pressure in P2

Pressure in P1

Rpm

Pressure in P1

Pressure in P2

Horsepower Control Pump 2 A Mode Pump Ma

Pressure in P1 Pressure in P2

Flow

Rpm

Pump Ma

Horsepower Control Pump 1 E Mode Pressure in P1 Pressure in P2

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Flow

Rpm

Pump Ma

E-219

Section E - Hydraulics Fault Finding Test 016 - Flow Testing Hydraulic Pumps - Record Sheet Horsepower Control Pump 1 E Mode

Horsepower Control Pump 2 E Mode Pressure in P1 Pressure in P2

Flow

Rpm

Pump Ma

Horsepower Control Pump 1 P Mode Pressure in P1 Pressure in P2

Flow

Rpm

Pump Ma

Horsepower Control Pump 2 P Mode Pressure in P1 Pressure in P2

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Flow

Rpm

Pump Ma

E-220

Section E - Hydraulics Fault Finding Test 017: Testing Slew Bearing

Test 017: Testing Slew Bearing Checking Slew Bearing Backlash

Fig 25. Set bucket 1 m (40 in) above ground with dipper fully extended. Attach dial test indicator to lower half of slew bearing and set needle to bolt head on top half of slew bearing.

record measurement and check against limits below.

Slew Backlash Limits

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

Table 25. New Machine

Limit of Use

6 mm (0.24 in)

12 mm (0.48 in)

By hand, push bucket fully to other side and record measurement on dial test indicator. Alternatively Set bucket 1 m (40 in) above ground with dipper fully extended, stop machine. By hand, push bucket fully to one side and hold whilst a mark is made across the two halves of slew bearing. By hand, push bucket fully to other side and hold, make a further mark on bottom half of bearing (which is in line with original mark on top half of bearing).

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E-221

Section E - Hydraulics Fault Finding Test 017: Testing Slew Bearing

Checking Slew Bearing Vertical Lift

Fig 26. 1

Fig 28.

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

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

Fig 27. 2

Install a dial gauge and set the needle to the zero point

Fig 29. 4

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

E-222

Section E - Hydraulics Fault Finding Test 017: Testing Slew Bearing Note: Always stop the engine when installing or removing the dial gauge or reading the dial gauge.

Fig 30. 5

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

Fig 31. 6

The average lateral movement is shown and as the result of the equation: L1+L2+L3+L4 2 Table 26. New Machine

Limit of Use

1.2 mm (0.05 in)

3.6 mm (0.15 in)

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E-223

Section E - Hydraulics Fault Finding Ram Creep Tests - All Services

Ram Creep Tests - All Services TE-030

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/ Piston Leakage, Spool Leakage, ARV Leakage.

Raise the boom and move the dipper to it's fully closed position.

Note: This service procedure should be carried out with a standard empty bucket fitted

Using a felt tip pen and ruler, make a mark 100mm (4 in) from the edge of the wiper seal on the piston rod.

Note: The procedures are not applicable for rams fitted with hose burst protection valves.

!MWARNING

Repeat the test by raising the boom and move the dipper to it's fully open position.

Using a felt tip pen and ruler, make a mark 100mm (4 in) from the edge of the wiper seal on the piston rod.

Measure the actual movement of the piston rod over a period of 10 minutes

Refer the measured figure to the table, if measured figure is outside the allowed tolerance then complete the basic checks at the end of this section.

can be measured using a hydraulic oil temperature probe, refer to Section 1, Service Tools.

Bucket Service

Test for Ram Creep 1

Operate the machine to bring the hydraulic oil to a normal working temperature of 50°C (122°F) which can be measured using a hydraulic oil temperature probe, refer to Section 1, Service Tools.

Raise the boom and move the dipper and the bucket to the fully closed position.

Raise the boom to it's full height.

Using a felt tip pen and ruler, make a mark 100mm from the edge of the wiper seal on the piston rod.

Using a felt tip pen and ruler, make a mark 100mm (4 in) from the edge of the wiper seal on the piston rod.

Repeat the test by raising the boom and move the dipper and bucket to it's fully open position.

Measure the actual movement of the piston rod over a period of 10 minutes

Using a felt tip pen and ruler, make a mark 100mm from the edge of the wiper seal on the piston rod.

Refer the measured figure to the table, if measured figure is outside the allowed tolerance then complete the basic checks at the end of this section.

Measure the actual movement of the piston rod over a period of 10 minutes

Refer the measured figure to the table, if measured figure is outside the allowed tolerance then complete the basic checks at the end of this section.

Boom service 1

Dipper service 1

Operate the machine to bring the hydraulic oil to a normal working temperature of 50°C (122°F) which

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Note: The table indicates the MAXIMUM permitted ram movement.

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E-224

Section E - Hydraulics Fault Finding Ram Creep Tests - All Services Allowable ram creep rates

Port relief valve (ARV) failure

Boom

30mm

Dipper

60mm

Bucket

20mm

If the port relief valve itself had failed, if contamination was stuck on the valve seat or if the valve seat itself was damaged then this would allow oil to constantly bypass to tank causing ram creep.

Basic Checks (after determining that the ram creep is outside of the allowable tolerance.)

!MWARNING Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. TRANS-1-2

Ram seal bypass If the ram creep is in only one direction of the ram then it is unlikely to be caused by failed ram seals, if however the creep is excessive in both directions of the ram stroke then it is possible that the seals have failed. Check for seal bypass using the following procedure: 1

Place a load in the bucket of the machine.

Lower the attachment to the ground and vent all hydraulic pressure.

Blank off the port on the ram, which will be supporting the attachment.

Remove the hose from the other port on the ram, blank the hose and leave the port on the ram open to atmosphere.

Raise the attachment off the ground

After initial movement, note the movement of the ram over a 10 minute period.

A visual check can be made by removing the port relief valve and checking the condition of the valve seat and the seat in the valve casing, any damage of either of these two items would require rectification or replacement. To check for failed port relief valve, loosen the adjuster locknut and wind the adjuster of the port relief valve fully in, until it locks the relief section. Re-check the ram rate, any change in the creep rate would indicate that further investigation of the port relief is required. If there is no change in the creep rate the cause may be the ARV seat in the valve block.

Quick hitch/Auxiliary circuits It is common practice to take oil from the excavator service to operate quick hitch and auxiliary circuits. If the excavator service which is suffering from excessive ram creep has any other services connected to it then the best policy is to disconnect the quick hitch and auxiliary circuit and test again the creep rate.

After the initial movement of the ram when first raised from the ground, a continual movement of the ram or continuous trickle of oil from the open port of the ram would indicate that the ram seals require further inspection. Basic Checks (after determining that the ram creep is outside of the allowable tolerance.)

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Section E - Hydraulics Fault Finding Ram Creep Tests - All Services

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Section F Transmission Service Manual - JS81 Section 1 - General Information Section 2 - Operator’s Manual Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/2000-02

Section F - Transmission

Notes:

F-0

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F-0

Section F - Transmission Contents

Contents Page No. Technical Data .................................................................................................................. F-1 Track Motor & Gear box Dismantling and Assembly ........................................................................ F-3 Dismantling ............................................................................................F-5 Inspection ............................................................................................F-21 Track Motor Description ............................................................................................... F-25 Operation ................................................................................................. F-26 Middle Speed .......................................................................................F-26 Slow Speed Travel (Creep) .................................................................F-26 High Speed ..........................................................................................F-28 Brake Valve .........................................................................................F-30 Parking Brake ......................................................................................F-34 Rotation Direction ................................................................................F-35 Removal and Replacement ..................................................................... F-36 Removal ..............................................................................................F-36 Precautions During Installation ............................................................F-37 Replacement .......................................................................................F-38 Start Up and Running In .......................................................................... F-41 Start Up ...............................................................................................F-41 Running In ...........................................................................................F-41 Fault Finding Transmission ........................................................................................... F-43 Traction Motor .....................................................................................F-43 Parking Brake ......................................................................................F-44 Relief Valve .........................................................................................F-45 Counterbalance Valve .........................................................................F-46 Speed Range Changing ......................................................................F-47

F-i

Section F - Transmission

Technical Data

Table 1.

F-1

From 1799466

To 1799466

Type

Fixed displacement piston motor

Working pressure maximum

190 bar (2755 lb/in2)

Set pressure relief

19 bar (275 Ib/in2)

Reduction gears

Planetary gears with 2 gear reduction

Reduction gear ratio

20 :1

19.464 :1

Motor max. speed

Brake torque

165 Nm

Dry weight

67 kg (147 lb)

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F-1

Section F - Transmission Technical Data

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F-2

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F-2

Section F - Transmission Track Motor & Gear box Dismantling and Assembly

Track Motor & Gear box Dismantling and Assembly

D067750

Fig 1. Hydraulic Motor

F-3

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F-3

Section F - Transmission Track Motor & Gear box Dismantling and Assembly

D067750-1

Fig 2. Reduction Gear

F-4

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F-4

Section F - Transmission Track Motor & Gear box Dismantling and Assembly moisture or dirt. If you have to interrupt work before completion, be careful to take measures to protect against rust or dust.

Dismantling Note: Before hydraulic motor disassembling, make sure that the oil is discharged.

Place a counter mark on mating faces of parts when disassembling.

Arrange removed parts neatly when disassembling so as not to damage or lose the parts while working.

As a rule, once any type of seal is disassembled it should be replaced with a new one even if it shows no signs of damage. You should have a new ready when disassembling.

The photographs and drawings contained in the manual are of representative models. Disassembly procedure is however not affected even if the product you are using differs in part.

Preparations Perform the following preparations before disassembling. 1

Workbench preparations a

Provide a travel motor workbench

b Provide a steady workbench with which the internal parts of the travel motor can be disassembled or assembled, is wide enough to place parts so they do not move or fall off the bench while working. c 2

Spread a rubber or vinyl sheet on the workbench

Preparation of tools and materials a

Cleaning the Travel Motor 1

Provide the tools and materials.

Attach the eye bolts A to spindle B.

Note: For mounting the spindle, attach the two eye bolts in the screw holes so that they are positioned symmetrically.

General Suggestion When Working Note: Internal parts are coated with hydraulic fluid and gear oil during disassembly and are slippery. If a part slips out of your hand and falls, it could result in bodily injury or could damage the part. Be very careful when handling. Note: Combustibles such as white kerosene are used for washing parts. These combustibles are easily ignited, and could result in fire or injury. Be careful when handling. 1

Before disassembling, perform inspections and clearly determine the nature of any abnormalities which might be occurring, and work according to the disassembly procedure.

Each part is manufactured to extreme precision. Handle with care and be sure not to hit the parts together or drop them.

F-5

When working, do not attempt to forcefully beat or wrench tightly fitting parts. Doing so could produce burrs or damage the parts so they canâ&#x20AC;&#x2122;t be mounted or may reduce their performance. You should exercise patience when working.

D067340

Fig 3. 2

Hook the wire in the eyebolts.

Hoist the travel motor with a crane and carry to washing tank.

Clean each part of the travel motor with a brush.

If you leave parts disassembled or partially disassembled, rust could develop on the parts due to

9813/2000-02

F-5

Section F - Transmission Track Motor & Gear box Dismantling and Assembly Note: Earth and sand get in the clearance between hub 1 and spindle 2 (floating seal mounting section). Be sure to wash this part with special care.

Note: Tighten the hexagon socket head cap screws securely. If fails do so, could result in injury caused by the travel motor falling when it is inverted.

D067340-3

D067340-1

Fig 6.

Fig 4.

Lubricating Oil Extraction

Installation of Travel Motor 1

Set the travel motor on a workbench.

Note: If disassembling the rear flange only, proceed to K Rear Flange Removal ( T F-9)

Note: While matching the screw holes of hub 1 and screw holes of the workbench, carefully place the travel motor in the mounting holes of the workbench.

Invert the travel motor. (Turn up the side of reduction gear)

Loosen and remove the plugs D and E.

D067340-2

Fig 5. 2

F-6

Mount the travel motor on the workbench so that two hexagon socket head cap screws C are positioned symmetrically.

D067340-4

Fig 7. Note: When extracting the lubricating oil, place a container under the workbench.

9813/2000-02

F-6

Section F - Transmission Track Motor & Gear box Dismantling and Assembly 3

Invert slowly the travel motor and extract the lubricating oil. (Turn up the side of motor)

Place a block against two bolts H outside of the cover removal jig and tighten the bolts to allow the cover to come off little by little.

D067340-5

Fig 8. 4

Cover Removal 1

D067340-7

Remove the ‘O’ ring from the plugs D and E, then discard it.

Turn the workbench. The side of the reduction gear is turned up. Remove the ring F using steel rod.

Fig 10. Note: If the cover is hard to remove because of resistance of ‘O’ ring, lift it up slowly and tap the outer rim of the cover by a plastic hammer. 5

Remove the ‘O’ ring from the cover and discard it.

Sun Gear Removal 1

Remove sun gear A.

Remove the steel ball B from the sun gear.

D067340-6

Fig 9. 3

Fix two bolts G of a cover removal jig to the threaded holes of the plugs E of cover. (The plugs E are fixed usually.)

D067340-8

Fig 11.

F-7

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F-7

Section F - Transmission Track Motor & Gear box Dismantling and Assembly Carrier Assembly Removal 1

Remove the carrier assembly C from the hub.

Note: The carrier assembly may pull out together with thrust collar.

D067340-10

Fig 13.

Planetary Gear Removal 1

Loosen the hexagon head bolts F (4x) and remove them from spindle.K Fig 14. ( T F-8) and discard it.

Remove planetary gear G (4x), needle roller bearing (4x) and inner ring (4x). K Fig 15. ( T F-9)

Remove the thrust washer (4x) from the spindle.

Remove the thrust collar from the spindle.

D067340-9

Fig 12. 2

Disassemble the carrier assembly. Remove the hexagon head bolts, the thrust washer, planetary gear, needle roller bearing and inner ring from the carrier.

Note: Do not reuse the hexagon head bolts which are removed. 3

Remove the retaining ring D from the sun gear.

Remove the sun gear E from the carrier.

D067340-11

Fig 14.

F-8

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F-8

Section F - Transmission Track Motor & Gear box Dismantling and Assembly

D067340-12

Fig 15.

D067340-14

Fig 17.

Rear Flange Removal 1

Turn the workbench to bring the position of rear flange on top.

Note: Do not loosen the bolts if the rear flange inside is not disassembled. 2

Slightly loosen the sleeve (2x) and the plugs (2x).

D067340-15

Fig 18.

D067340-13

Fig 16.

F-9

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F-9

Section F - Transmission Track Motor & Gear box Dismantling and Assembly

D067340-17

D067340-16

Fig 21.

Fig 19. 3

Loosen and remove the hexagon socket bolt A (8x) from the rear flange. K Fig 20. ( T F-10)

Note: Hold the rear flange by both hands, hold it up gently upright to remove it. Perform the work with care not to forcibly strike the flange. Otherwise it may cause the timing plate to drop and be damaged. 5

Pull out parallel pin B (2x) from the spindle.

D067340-17

Fig 20. 4

Remove the rear flange from the spindle. D067340-19

Fig 22. 6

F-10

9813/2000-02

Remove the â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; K Fig 23. ( T F-11)

ring

from

the

spindle.

F-10

Section F - Transmission Track Motor & Gear box Dismantling and Assembly 4

Pull out the parallel pin L from the rear flange.

D067340-20

Fig 23. D067340-22

Disassembly of the Rear Flange Mounting

Fig 25.

Put the rear flange on the workbench (Face up the mating face with spindle)

Remove the spring (10x) from the rear flange.

Remove the timing plate K from the rear flange.

Pull out the ball bearing M from the rear flange.

D067340-23

Fig 26. Disassemble SRV from Rear Flange D067340-21

Fig 24.

Remove the sleeve A (2x) from the rear flange. K Fig 27. ( T F-12)

Note: If the timing plate stucked to the mating face of the rear flange, then insert a flat bar into the groove of the rear flange and raise the timing plate slowly. Never try to ply the timing plate off with a sharp or pointed tool or the precision finished mating faces will suffer costly damage.

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F-11

Section F - Transmission Track Motor & Gear box Dismantling and Assembly

D067340-26

D067340-24

Fig 29.

Fig 27. 2

Remove the ‘O’ ring and backup ring from the valve seat one by one. Discard it.

Remove the ‘O’ ring from the sleeve and discard it.

Disassemble the Brake Valve from Rear flange. 1

Remove plug (2x) from the rear flange.

D067340-25

Fig 28. D067340-27

Fig 30. 2

Remove spring retainer (2x) and spring (2x) from the rear flange.

Remove the spool B from the rear flange. K Fig 31. ( T F-13)

Note: To remove spool, place your hand on one part of the plug port of the rear flange and tilt it down. Then the spool falls down. Hold the tip and remove it.

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F-12

Section F - Transmission Track Motor & Gear box Dismantling and Assembly

D067340-28

Fig 31. D067340-30

Fig 33.

Remove the ‘O’ ring from the plug and the discard it. 6

Remove the spring (2x) and valve D (2x) from the rear flange.

D067340-29

Fig 32. 5

Remove the plug C (2x) from the rear flange. D067340-31

Fig 34. 7

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Remove the ‘O’ ring from the plug, and then discard it. K Fig 35. ( T F-14)

F-13

Section F - Transmission Track Motor & Gear box Dismantling and Assembly

D067340-34

D067340-32

Fig 37.

Fig 35.

Disassembly of the Parking Brake

Removal of Pilot Valve from the Rear Flange. 1

Remove the plug from the rear flange.

Note: The abrupt injection of compressed air could cause the piston to pop out.To ensure your safety hold a protective cover over the piston. 1

Remove the piston from the spindle by injecting compressed air into the access hole in the spindle.

D067340-33

Fig 36. 2

Remove the ‘O’ ring from the plug, and then discard it.

Remove the spool A and spring from the rear flange. K Fig 37. ( T F-14)

D067340-35

Fig 38. 2

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Remove the ‘O’ ring from the pistion and then discard it.

F-14

Section F - Transmission Track Motor & Gear box Dismantling and Assembly

D067340-38

D067340-36

Fig 41.

Fig 39. 4

Disassembly of the Hydraulic Motor Note: Place an oil receptacle just below the motor to catch the oil. 1

Turn the GM motor 90ยบ.

Hold the cylinder block by hand, turn alternately 2-3 times and cut-off shoe adhered on the swash plate.

Note: If remove the cylinder block as it is, shoe remains adhered on swash plate, and the parts ( piston, shoe and etc.) mounted on the cylinder block will come off the cylinder block and fall into the spindle. 5

Draw out the cylinder block from the shaft.

D067340-37

Fig 40. 2

Drain the hydraulic oil from the motor.

D067340-39

Fig 42. 3

Take out mating plate (3x) and friction plate (2x). 6

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Remove the piston assembly (piston and shoe) and retainer plate from the cylinder block.

F-15

Section F - Transmission Track Motor & Gear box Dismantling and Assembly

D067340-40

D067340-42

Fig 43.

Fig 45.

Note: When removing the piston assembly, grip retainer plate with both hands and remove togther with the retainer plate. The piston assembly is a minimum unit. If replacement is necessary, replace the piston assembly as one unit. 7

Remove the piston assembly (piston and shoe) from the retainer plate.

Remove thrust ball A from the cylinder block. K Fig 44. ( T F-16)

Removal of the Spring inside the Cylinder Block. 1

Put the cylinder block on the press bench.

D067340-43

Fig 46. Note: The spring should remove only when it needs to be replace. The spring is removed by lining up the shaft centers of holder K and washer in order to prevent damage to the cylinder block through conatct. Cover the cylinder block with a vinyl sheet to prevent the sliding surfaces of the cylinder block from being damaged. D067340-41

Fig 44. 9

Remove the washer, roller from the cylinder block.

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F-16

Section F - Transmission Track Motor & Gear box Dismantling and Assembly Removal of the Swash Plate 1

Pull out the swash plate A from the shaft. K Fig 49. ( T F-17)

Note: When removing the swash plate, ensure that pivot is not adhered on the swash plate.

D067340-44

Fig 47. 2

Put holder K on the washer, while clamping the holder with the press, remove snap ring with a snap ring pliers. K Fig 47. ( T F-17)

Note: Release press slowly. Sudden releasing may cause spring to fly out incurring the danger of injury. 3

Remove the snap ring, washer, and spring from inside cylinder block.

D067340-46

Fig 49. 2

Pull the shaft from the spindle, then remove ball bearing.

D067340-45

Fig 48.

D067340-47

Fig 50. Note: Be careful to lightly strike the tip of the shaft on the reduction side using a plastic hammer to allow the shaft to come off easily. Otherwise the shaft may pop out. 3

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Takeout pivot an parallel pin from the spindle.

F-17

Section F - Transmission Track Motor & Gear box Dismantling and Assembly 4

Blow compressed air through passage of the spindle and then takeout teh 1st/2nd speed piston kit and spring from the spindle.

Removal of the Ring Nut 1

Fix the hub and spindle with the fixture. The fixture should be tightened in symmetrical positions with each other.

D067340-48

Fig 51. D067340-50

Note: The ball bearing removed only when it needs to be replace. 5

Put the holder L on the press bench and put shaft into the holder.

Fig 53. 2

Invert the GM motor (the side of the reduction gear is turned up.)

Remove the hexagon socket set screw.

D067340-49

D067340-51

Fig 52. 6

Fig 54.

Remove the ball bearing from the shaft by pressing on the shaft end with press.

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Loosen ring nut with the bearing preload adjuster, and then discard ring nut. K Fig 55. ( T F-19)

F-18

Section F - Transmission Track Motor & Gear box Dismantling and Assembly

D067340-52

D067340-54

Fig 55.

Fig 57.

Removal of the Spindle from Hub 1

Invert the GM motor. (Turn up the side of the motor)

Remove the fixture

Fasten the eye bolts (2 bolts, for M16) in the mounting holes of the spindle so they are symmetrically positioned.

D067340-53

Fig 56. 5

Take out the ring nut B from the spindle. K Fig 57. ( T F-19) D067340-55

Fig 58. 4

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Put a hook on the eye bolts, gently and slowly hoist with a crane and remove spindle from hub. At the same time, the floating seal and oil seal come off together.

F-19

Section F - Transmission Track Motor & Gear box Dismantling and Assembly Removal of Ball Bearing 1

Remove the floating seal A from the hub and the discard it. K Fig 59. ( T F-20)

Tap the end face of outer race of ball bearing with aluminum rod (pin punch) and hammer then remove the ball bearing from the hub.

Note: Remove ball bearing by slowly tapping the end face of outer race of the ball bearing at 3 or 4 points so that the ball bearing doesnâ&#x20AC;&#x2122;t get stuck.

Removal of the Spindle Fittings 1

Remove the floating seal from the spindle.

D067340-56

Fig 59. 2

Tap the end face of the ball bearing with aluminum rod (pin punch) and hammer then remove ball bearing from face. D067340-58

Fig 61. 2

Remove the oil K Fig 62. ( T F-20)

seal

from

the

spindle.

D067340-57

Fig 60. Note: When the fit section of the outer race of ball bearing comes out of hub, the ball bearing drops from the hub. Therefore place a receptacle under the workbench and spread a rubber mat on the receptacle so as not to damage the parts. 3

D067340-59

Fig 62.

Turn over the travel motor.

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F-20

Section F - Transmission Track Motor & Gear box Dismantling and Assembly Washing 1

Separate hub, spindle, cover and rear flange from the other parts. (hereafter called the built-in parts)

D067340-61

Fig 64. 3

Fill a primary washing vessel with kerosene. Put the builtin parts in it and wash them.

After washing, rinse the washed parts in the rinsing sink filled with clean kerosene by gently shaking each parts in the kerosene.

Note: Wash all parts carefully with kerosene. Notice if there is any possible combustibilty.

Use clean cloth and wipe each rinsed part to remove dripping kerosene.

Note: To prevent the built-in parts from being marred by dirt during washing, immerse the parts in kerosene long enough for any dirt or oil to become loose and surface before washing them.

Note: Dry the inside of hub and spindle by spraying with compressed air until they are dray and clean. Let other parts dry naturally until they are dry and clean. After drying, coat every part with oil.

D067340-60

Fig 63. 2

Wash the built-in parts in a wash tank.

Inspection

Item No.

Part Name

Hub

Replace all parts which show striking damage.

Replace if various parts have the following problems (phenomenon).

Phenomenon – Serious damage in appearance.

Standard

Service Limit

–

– Occur pitting phenomenon on tooth flank of ring gear. – Abnormal wear such as scuffing. 2

Spindle

– Serious damage in appearance.

Carrier Assembly

– Abnormal wear such as scuffing.

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Section F - Transmission Track Motor & Gear box Dismantling and Assembly Item No.

Part Name

Phenomenon

4 6 5 7

Sun Gear 1 Sun Gear 2 Planetary Gear 1 Planetary Gear 2

– Pitting on tooth surface.

10 11 12

Thrust washer 1 Thrust washer 2 Thrust washer 3

– Sliding surface is tarnished.

Ball bearing

– Has indentation

Standard

Service Limit

–

– Flaking phenomenon on rolling surface of bearing.

– Sliding surface is abnormally worn.

– Exhibits flaking phenomenon – Worn unequally 27 28

Needle roller bearing

– Pitting phenomenon on roller

29 30

Inner Race

– Exhibit flaking phenomenon on rolling face of bearing.

301

Rear flange

– Flaw on sliding part with spool

–

102

Shaft

– Working face with oil seal is worn.

–

– Cage end face has abnormally worn

– Spline is worn 103

Swash plate

– Has burning phenomenon.

–

104

Cyinder Block

– Spline section is worn.

–

– Inner surface of bore is worn too much. – Flaw and wear on sliding surface with timing plate. 105 106

107

Piston assembly Piston Shoe

– Clearance is found in the axial direction Clearance 0.05mm between piston and shoe.

Retainer Plate

– Sliding part with shoe is worn unequally.

Clearance 0.15mm

– Shoe is abnormally worn and unequally worn. –

–

– Flaw and unequal wear on sliding surface with thrust ball. 108

Thrust ball

– Ball surface sliding part with retainer plate is worn unequally

–

109

Timing plate

– Sliding surface has burning phenomenon and unequal wear.

–

115 116

Friction plate Mating plate

– Both end faces are unequally worn.

112

Piston

– Flaw on circumference.

–

149 150

Ball bearing

– Has indentation

–

– Torque is not specified. – Has burning phenomenon

Braking torque Braking torque 120Nm or more 120Nm or more (12.3kgf.m) (12.3kgf.m)

– Exhibits flaking phenomenon – Worn unequally

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F-22

Section F - Transmission Track Motor & Gear box Dismantling and Assembly Item No.

Part Name

161 162

Piston Kit Piston Shoe

– Circumference is abnormally worn.

323 363

Spool

– Circumference worn unequally.

F-23

Phenomenon

Standard

Service Limit

–

– Shoe is abnormally worn and unequally worn. – Flaw on circumference.

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F-23

Section F - Transmission Track Motor & Gear box Dismantling and Assembly

Page left intentionally blank

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F-24

Section F - Transmission

Track Motor Description The motor is of the variable swash plate, axial piston type. Pressurised oil is routed via rear flange A and timing plate F into cylinder block D.

connected to the return line. The next 180Â° of cylinder block rotation causes the piston to complete its cycle by expelling the oil from the cylinder back to tank.

The fixed timing plate directs oil to force piston E against swash plate C, until it reaches the end of its power stroke, causing the cylinder block to rotate 180Â°. When the piston reaches the end of its power stroke, the cylinder is disconnected from the oil supply line and instead is

Altogether there are nine pistons, operating sequentially as described above to provide smooth continuous rotation of the cylinder block, which is spline coupled to drive shaft B.

F A

Fig 1.

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F-25

Section F - Transmission Track Motor Operation

Operation Middle Speed Note: Second stage MRV is not selected during travel on this machine. Oil from the valve block enters the motor at either P1 or P2. In this case the oil enters at P2. K Fig 2. ( T F-27). Pressure entering the motor crosses the counterbalance spool 1 and directed to the travel motor and the Auxiliary Relief Valve (ARV) ports. At this point the motor cannot move as the brakes B are applied. The pressure also travels to the end of the counterbalance via: 1

The restrictor which restricts the flow to the spool.

The check valve which will allow full flow to the spool end. This is the normal path for the oil to take.

The counterbalance spool 1 is selected at 8.4 - 12.4 bar (122-180 lb/in2) which in turns diverts the flow of oil to the travel motor in 2 directions: 1

Oil can flow over the spool and direct to the motor. This is also available to the motor ARV and the 2 speed travel spool 2 that is in the neutral position. Once the brake is lifted the motor will start to turn.

Also diverted to the travel motor brake via a restrictor.

the restrictor, allowing the counterbalance spool to return slowly. Returning oil from the motor is slowly blocked in its path to tank and as the back pressure rises, braking occurs. Once the counterbalance spool is in the neutral position any additional pressure within the motor due to inertia (motor pumping function) above 343 bar (4975 lb/in2) is relieved through the ARV and is fed back to the opposite side to prevent cavitation. The pressure in the brake piston is also released slowly due the restrictor in the brake line restricting the flow, so the brake remains off initially to allow the motor to stop by hydraulic breaking, to protect the brakes components from damage.

Slow Speed Travel (Creep) When slow travel speed is selected the electronic control unit 1 (ECU1) sends a signal to the max. flow cut solenoid CT4 on the 8-spool solenoid block. This then allows servo pressure to the ports Pm1 and Pm2 of the main hydraulic pump and reduces the pump flow to the drive motors. The drive motors work in exactly the same way as in middle speed travel. Only the pump flow is reduced to achieve slow-speed travel.

If the pressure in the brake rises to 14 bar (203 lb/in2) the brake is released. This flow of oil also crosses the brake piston and is available at the end of the two speed travel spool and along with the assistance of a spring, holds the two speed spool in the low speed position. With the two speed spool in this position the swash plate angle piston head is vented to the tank port and the motor stays on maximum displacement. (Low speed). Once the pressure rises to 343 bar (4975 lb/in2) the motor's ARVs will open and allow excess pressure to be exhausted to the return side. The ARV's are of the shockless type to reduce harsh starting and stopping. When travel is deselected by the driver the P2 port loses pressure. Pressure is also lost to the end of the counterbalance spool (1) which is cushioned to reduce the shock when stopping. The cushioning is achieved by the check valve trapping the pressure at the spool end and only allows it to vent through

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F-26

Section F - Transmission Track Motor Operation Pm1

P1 P2

T1 - T2

2 Ps

Pm2

Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A709370-C1

Fig 2. Travel Motor Operation Schematic (Middle Speed) For description, K Middle Speed ( T F-26)

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F-27

Section F - Transmission Track Motor Operation

High Speed When high-speed travel is selected, the electronic control unit 1 (ECU1) sends a signal to solenoid CT5 on the 8spool solenoid block. The solenoid energises, allowing servo pressure to cross the solenoid and sends a signal to port Ps of the drive motor, which moves the two speed travel spool 1 to the high-speed position. Pressure that is available to the drive motor now crosses the two speed spool and acts on the swash plate piston to move the motor to minimum displacement (High speed). The pressure in the system is also seen at the opposite side of two speed spool 1 via the brake piston and acts against the servo pressure. Due to the larger surface area that the servo pressure acts against, the servo pressure can hold the two speed spool in the high-speed position until the system pressure rises to 258 bar (3741 lb/in2). (This is based on the servo pressure being 39 bar (565.5 lb/in2)). At this point the system pressure can overcome the servo pressure and moves the two speed spool 1 back into the low speed position. This releases the pressure acting on the swash plate piston and allows the swash plate to return to maximum displacement to increase the torque of the motor. If the system pressure then falls back below 258 bar (3741 lb/in2) the servo pressure can overcome the system pressure and move the 2-speed spool back into the highspeed position.

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F-28

Section F - Transmission Track Motor Operation Pm1

P1 P2

T1 - T2

Pm2

Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A709400-C1

Fig 3. Travel Motor Operation Schematic (High Speed) For description, K High Speed ( T F-28).

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F-29

Section F - Transmission Track Motor Operation

Brake Valve Brake Function When control valve A is returned to neutral, the pressurised oil from the pump is blocked, and pressure at P1 and P2 becomes equal, and the plunger tries to return to neutral position by the spring. When the plunger moves,

the plunger diaphragm opening becomes smaller and because the piston motor continues to rotate due to inertia (motor pumping function), the pressure at M2 port side rises and braking occurs. At this time, when the M2 port side pressure attains the relief valve set pressure, the relief valve works and allows oil to escape to M1 port side, absorbs shock pressure caused by inertia of M2 port side while also preventing M1 port side cavitation.

C076860

Fig 4.

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F-30

Section F - Transmission Track Motor Operation Counterbalance Valve The counterbalance valve serves to prevent the stoppage of the axial piston motor and its overrun. When in neutral,

control valve A has no pressure at ports P1 or P2, so ports M1 and M2 are blocked by the flange and check valve and the motor does not rotate.

C076880

Fig 5. Motor Not Rotating

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F-31

Section F - Transmission Track Motor Operation

C076890

Fig 6. Motor Rotating When hydraulic oil delivered from the hydraulic pump is guided to P1 port of the counterbalance valve through the control valve, the hydraulic oil goes through the check valve and flows into the piston motor from M1 port and tries to rotate the motor. On the other hand, the return oil from the piston motor can flow from M2 port to the counterbalance valve but is prevented by the check valve so that pump delivery pressure rises. The boosted hydraulic oil at P1 port side goes past the orifice and works on the flange face, and resisting the spring on the opposite side with a force

F-32

proportional to the pressure, it tries to move the plunger to the right side. When a certain pressure is reached, the plunger moves towards the right and the hydraulic oil of M2 port passes through the notch of the plunger outer perimeter and generates back pressure at M2 port while flowing to Ps port and returns to the tank through the control valve. When the pump delivery pressure rises the plunger diaphragm opening enlarges and the M2 port back pressure decreases. In this way, the opening of the plunger notch diaphragm automatically adjusts the return side

9813/2000-02

F-32

Section F - Transmission Track Motor Operation passageway area so the piston motor will rotate at a speed suitable to P1 port side pressure, that is, the P1 port side flow rate.

Shuttle Function The counterbalance valve has a shuttle function. When the plunger moves from the state in the top illustration to that in the lower illustration, the parking brake release port P3 is opened to guide the pressurised oil to the brake releasing cylinder. This releases the parking brake. When the motor stops, the counterbalance valve becomes as shown in the top illustration and P3 port is blocked and the drain port in the motor case is opened. The pressurised oil in the brake releasing cylinder drains into the motor case to activate the brake.

C076910

Fig 7.

C076920

Fig 8.

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F-33

Section F - Transmission Track Motor Operation

Parking Brake The parking brake consists of alternate friction and counter plates (A and B), a piston C and an activating spring D. Pressurised oil is guided to the parking brake release cylinder E via the counter balance spool. The force on the brake piston overcomes the activating spring to force the

E D

brake piston across, thereby un-clamping the friction and counter plates to release the parking brake. When parking or stopping the machine the shuttle function causes the pressurised oil in the parking brake cylinder to be released via the motor case drain. The brake piston is forced back by the activating spring to clamp the friction and counter plates and operate the parking brake.

B A

Fig 9.

F-34

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F-34

Section F - Transmission Track Motor Operation

Rotation Direction The relationship between the flow direction of the hydraulic oil and the rotation direction is as shown below.

Oil Input Port

Table 1. Oil Output Rotation direction (viewed Port from output shaft end of motor)

Clockwise

Counter Clockwise

P1 P2

Fig 10.

P1 - P2

Table 2. Port Identification Service Ports

T1 - T2

Drain Port

2 Speed control Port

Pm1 - Pm2

Test Ports

Note: When connecting the drain hose, the upper most drain port must be used.

T2 P2 Ps P1

T2 Pm2

Ps P1

Pm1

709940

Fig 11.

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F-35

Section F - Transmission Track Motor Removal and Replacement

Removal and Replacement Removal 1

Move the track link until the master pin is over the take-up roller in the position shown, place a wooden block under the track shoe as shown.

Fig 14. b Position a suitable hydraulic press so that its ram aligns with the master pin.

JS02770

Fig 12. 2

Slacken the check valve to bleed out the grease.

!MWARNING Slacken the check valve slowly and stop when grease ie released. The grease and valve are under extremely high pressure and could cause injury if suddenly released. TRANS-6-2

JS02790C1

Fig 15. c

Insert the spacer bar between the master pin and the hydraulic ram.

d Slowly operate the hydraulic ram and press out the master pin.

!MWARNING

Fig 13. 3

Disconnect the track link by removing the locking pin and knocking out the master pin. a

F-36

Remove bolts and lift off the track shoes adjacent to the master pin.

Stand clear and to one side of the track while you remove the master pin. When the master pin is removed the track could fall forward and injure you. TRACK-1-1

9813/2000-02

F-36

Section F - Transmission Track Motor Removal and Replacement e

Remove the seal rings from each side of the chain link.

Operate the traction motor to remove the track.

Fig 18. 8

Fig 16. 5

Support the motor so that the cables are in tension, then remove the motor installation bolts.

Lift the side of the undercarriage high enough to permit drive sprocket removal. Support with wooden blocks.

Fig 19.

Precautions During Installation

Fig 17. 6

Stop the engine and operate the control lever to relieve pressure in the hydraulic system. Release pressure in the hydraulic tank, refer to Section 3, Routine Maintenance.

Before installation, check the overall condition of the axial piston motor, check for loose parts, check P1, P2 drain ports and pilot ports are completely sealed so that contaminants cannot enter the axial piston.

Remove the motor cover, attach identification tags to the motor hoses, disconnect the hoses from the motor and install plugs and caps to prevent the loss of oil and ingress of dirt.

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F-37

Section F - Transmission Track Motor Removal and Replacement

Replacement 1

Before fitting, clean the assembly. Make sure that all ports are plugged to prevent the ingress of dirt.

Lift the assembly and position it on the undercarriage.

B A Fig 20. Install the bolts and washers, using JCB Threadseal on the bolt threads. Tighten the bolts in a diagonal sequence. For torque settings, refer to Section 3, Routine Maintenance.

A408272-C1

Fig 21. 3

Remove the plugs and connect the motor hoses.

Fig 22.

F-38

Do not fit the track at this stage. Follow the Start Up and Running In procedure. K Start Up and Running In ( T F-41).

Install the covers over the motor.

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F-38

Section F - Transmission Track Motor Removal and Replacement 6

Check the amount of oil in the gearbox, refer to Section 3 Routine Maintenance.

Install the drive sprocket, refer to Section J, Track and Running Gear.

Remove the wooden blocks.

Position the lower frame on the track.

Move the track link.

Insert the pointed guide pin from the inner face and tap through its full length.

JS02810C1

Fig 25. 14

Position a suitable hydraulic press so that its ram aligns with the guide pin.

Insert the master pin into its locating hole.

Slowly operate the hydraulic ram and press the master pin into position.

Fig 23. 11

Clean the seal ring housing in the chain link. Insert the seal rings and clamp into position.

JS02820C1

Fig 26. 17

Re-locate the track shoes and tighten the bolts. For torque settings, refer to Section 3, Routine Maintenance.

Apply grease through the check valve to adjust the track tension, refer to Section 3, Routine Maintenance.

JS02800-C1

Fig 24. 12

Using a plastic hammer, tap the upper link down to align holes.

Note: As the links overlap, the seal rings will be held in position. Remove `G' clamps.

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F-39

Section F - Transmission Track Motor Removal and Replacement

Fig 27.

F-40

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F-40

Section F - Transmission Track Motor Start Up and Running In

Start Up and Running In

709910-C1

Fig 28.

Start Up

Note: The presence of residual air in the hydraulic circuit will manifest itself with the presence of foam in the tank and will lead to a jerking of the motor as well as excessive noise coming from the motor and the valves.

Start the track motor at a low speed and gradually increase it after having verified that it is functioning correctly without any noises or vibrations.

Running In

!MWARNING

INT-3-1-11_2

In this first stage it is advised to follow the measures given below: 1

Remove hose from drain port B. Fully fill the piston motor case with clean hydraulic oil at the drain port B. Also bleed air from each part of the piping. Make sure all hoses are correctly fitted.

Check hydraulic fluid level, top up if necessary. refer to Section 3, Routine Maintenance.

Check gearbox oil level, refer to Section 3, Routine Maintenance.

F-41

During the running-in stage follow the steps given below. 1

9813/2000-02

Check the correct revolution and direction of rotation.

F-41

Section F - Transmission Track Motor Start Up and Running In 2

Make sure that the motor is functioning correctly, with out any excessive noises and vibrations.

Make sure that the oil temperature does not exceed 90Â°. After having terminated this first running-in follow the steps given below:

Check that there are no oil leakages.

Check the level of lubricating oil in the gear box.

The opening action of the brake could be slowed down due to the presence of air during the first startup. It is advised to repeat the opening and closing function of the brake by starting and stopping the motor several times.

Check that there are no other problems.

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F-42

Section F - Transmission Fault Finding Transmission

Fault Finding Transmission Traction Motor Symptom

Possible Cause

Remedy

a Motor does not run.

1 Device external to the piston motor or reduction gear malfunctioning.

Check that the specified pressurised oil is delivered to the motor input side. Inspect all associated devices and repair if necessary.

2 Sliding area of motor is excessively worn, allowing pressurised oil to escape.

Renew the excessively worn part. Remove scratches and burrs from the surface and completely clean all parts. Reassemble.

3 Malfunction resulting from damaged motor part(s), resulting in excessive noise.

Dismantle and renew the damaged part(s). Completely clean all parts and then reassemble.

4 Relief valve operating due to excessive motor Check the load and only operate the machine loading. with a suitable load. b Motor speed low.

1 Oil not supplied to motor at specified rate due Check that the specified pressurised oil is to problems in hydraulic pump, pressure control delivered to the motor input side. Inspect all associated devices and repair if necessary. valve etc. 2 Volume efficiency of motor low.

c Motor speed varies greatly.

d Oil leaks.

After dismantling, check for abnormal wear of the sliding area and repair or renew the worn parts.

1 Large amount of pressurised oil escapes and Dismantle and renew excessively worn parts. flows out of the drain port due to wear on the Clean all parts and reassemble. sliding area of the motor. 2 Wear in the bearings.

Renew motor bearings.

3 Motor load is excessive and automatic 2speed function is operating.

Check the load and only operate the machine with a suitable load.

1 Oil leaks due to damaged oil seals or O-rings. Renew damaged oil seals or O-rings. When fitting an oil seal, be careful not to damage the lip. Check the system to ensure the running temperature does not exceed 80 Â°C. Take the necessary steps to ensure the temperature remains within the acceptable range. 2 Refer to a2 and/or c1. K Traction Motor ( T F-43)

Refer to a2 and/or c1. K Traction Motor ( T F-43)

3 Clogging due to foreign matter in drain pipe or Clean the clogged drain piping. Recheck the long, narrow pipes causing the oil seal to break. piping system and reduce the passage resistance. Renew the oil seal taking care not to damage the lip. e Abnormal noise, excessive speed and pressure variation due to cavitation.

F-43

1 When the motor works as a pump, when the closed circuit is used, when the boost pressure is low (standard: 0.4 -5 kgf/cm2) or when the double counterbalance valve operates improperly, negative pressure is generated on the suction side of the motor, resulting in cavitation.

9813/2000-02

Recheck the hydraulic circuit and by remedying or renewing the double counterbalance valve, prevent the generation of negative pressure. Dismantle the motor and renew any abnormally worn or broken parts.

F-43

Section F - Transmission Fault Finding Transmission

Parking Brake Symptom

Possible Cause

Remedy

a Braking force is low or insufficient.

1 Friction plates worn.

Renew discs. Completely remove foreign matter and repair damaged areas. After cleaning, reassemble.

2 Counter places surface damaged or making poor contact.

Grind and recondition the affected area. Reassemble after cleaning. Renew plates if excessively damaged.

3 Spring is deformed or damaged.

Renew the spring. Completely remove foreign matter and reassemble after cleaning.

b Motor speed low.

F-44

1 Brake not releasing. i Oil leaks due to broken O-ring.

Renew broken O-ring.

ii Orifice is clogged.

Clean and reassemble.

9813/2000-02

F-44

Section F - Transmission Fault Finding Transmission

Relief Valve Symptom

Possible Cause

Remedy

a Motor does not run or 1 Relief valve not closing fully: rotation speed is slow. i Foreign matter clogging components.

ii Spring broken.

Completely remove foreign matter, repair damaged part and reassemble after cleaning. Renew if damage or leakage is excessive. Renew the spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.

2 The cracking pressure of relief valve is low.

b Motor does not stop or stops slowly.

i Spring is deformed.

Renew relief valve sub-assembly.

ii Poppet orifice is clogged.

After cleaning, reassemble.

1 Relief valve not closing fully. i Foreign matter clogging components.

Completely remove foreign matter, repair damaged part(s) and reassemble after cleaning. Renew if damage or leakage is excessive.

ii Spring broken.

Renew the spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.

2 Refer to a2. K Relief Valve ( T F-45)

Refer to a2. K Relief Valve ( T F-45)

c Motor does not run or 1 Shockless function does not work. rotation speed is slow. i Foreign matter in piston section.

F-45

Completely remove foreign matter, repair damaged part and reassemble after cleaning. Renew if damage or leakage is excessive.

ii Spring broken.

Renew the spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.

iii Relief valve pressure set too high.

Adjust the relief valve set pressure.

9813/2000-02

F-45

Section F - Transmission Fault Finding Transmission

Counterbalance Valve Symptom

Possible Cause

Remedy

a Motor does not run or 1 Plunger not switching. rotation speed is slow. i External pilot pressure not present.

b Motor does not stop or stops slowly.

c Rotation varies.

d Abnormal noise is heard.

e Travel not linear.

F-46

Inspect the piping for damage.

ii Foreign matter between plunger and body.

Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.

iii Orifice clogged.

Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.

iv Foreign matter caught between dumper piston and cap.

Renew spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.

1 Plunger does not return. i Foreign matter between plunger and body.

Completely remove foreign matter, repair the damaged part and reassemble after cleaning. Renew if damage or leakage is excessive.

ii Spring broken.

Renew spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.

iii Spring not fitted.

Fit spring in specified position.

iv Orifice clogged.

Reassemble after cleaning.

1 Plunger does not move smoothly. i Foreign matter between plunger and body.

Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.

ii Orifice clogged.

Reassemble after cleaning.

1 Plunger does not return. i Foreign matter between plunger and body.

Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.

ii Spring broken.

Renew spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if damage or leakage is excessive.

iii Orifice clogged.

Reassemble after cleaning.

1 Dumper piston or cap is excessively worn.

Renew dumper piston and cap. Completely remove foreign matter, repair any damage and reassemble after cleaning.

9813/2000-02

F-46

Section F - Transmission Fault Finding Transmission

Speed Range Changing Symptom

Possible Cause

a Travel is not linear.

1 Plunger not switching.

Remedy

i Foreign matter between plunger and body.

Completely remove foreign matter, repair the damage and reassemble after cleaning. Replace if the damage or leakage is large.

ii Spring not installed.

Install spring.

iii Spring broken.

Renew spring. Completely remove foreign matter, repair any damage, reassemble after cleaning. Renew if the damage or leakage is excessive.

iv Foreign matter is caught between the two spools.

Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is large.

2 Pressurised oil leaks due to excessive wear of Renew the 2-speed control piston. 2-speed control piston. Completely remove foreign matter and reassemble after cleaning.

b Will not go into high speed.

3 2-speed control piston is not installed.

Install 2-speed control piston.

4 Steel balls badly worn.

Renew steel balls. Completely remove foreign matter and reassemble after cleaning.

5 Set pressure is rising due to excessive spool wear.

Renew the two spools. Completely remove foreign matter and reassemble after cleaning.

6The orifice of the 2-speed piston compartment oil passage is incorrect.

Fit a new orifice of correct diameter.

7 The orifice of the 2-speed piston compartment oil passage is clogged.

Reassemble after cleaning.

8 Number of washers is different, making set pressure different between the left and right.

Confirm number of washers.

1 Plunger not switching. i Foreign matter between plunger and body.

Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is excessive.

ii Foreign matter is caught between the two spools.

Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is excessive.

2 Pressurised oil leaking due to excessive wear of Renew 2-speed control piston. Completely 2-speed control piston. remove foreign matter and reassemble after cleaning.

c Will not go into low speed.

F-47

3 2-speed control piston not installed.

Install the 2-speed control piston.

4 The orifice of the 2-speed piston compartment oil passage is clogged.

Reassemble after cleaning.

1 Spring is not installed.

Install spring.

9813/2000-02

F-47

Section F - Transmission Fault Finding Transmission Symptom

F-48

Possible Cause

Remedy

2 Spring is broken.

Renew spring. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is excessive.

3 Set pressure rising due to excessive wear of one or both spools.

Renew one or both spools. Completely remove foreign matter, repair any damage and reassemble after cleaning. Renew if the damage or leakage is excessive.

9813/2000-02

F-48

Section J Track & Running Gear Service Manual - JS81 Section 1 - General Information Section 2 - Operator’s Manual Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/2000-02

Section J - Track and Running Gear

Notes:

J-0

9813/2000-02

J-0

Section J - Track and Running Gear Contents Page No. Technical Data Torque Specifications ............................................................................... J - 1 Idler Wheel and Recoil Unit Removal ................................................................................................... J - 3 Replacement ............................................................................................ J - 5 Idler Wheel Dismantling ............................................................................................... J - 7 Assembly .................................................................................................. J - 9 Grease Cylinder Removal and Replacement .................................................................... J - 11 Dismantling and Assembly ..................................................................... J - 14 Drive Sprocket Removal and Replacement .................................................................... J - 15 Top Roller Removal ................................................................................................. J - 17 Replacement .......................................................................................... J - 18 Dismantling ............................................................................................. J - 19 Assembly ................................................................................................ J - 22 Bottom Roller Removal ................................................................................................. J - 25 Replacement .......................................................................................... J - 26 Dismantling ............................................................................................. J - 27 Assembly ................................................................................................ J - 30

J-i

Section J - Track and Running Gear

Idler Wheel and Recoil Unit Removal P11-J003

Slacken the check valve to bleed out grease.

!MWARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out. If you over-loosen too much grease could spurt out or the valve cover fly out and cause serious injury. 8-3-4-5

C004520

Fig 2. 3

Fasten a sling around the idler wheel and recoil assembly and remove it from the undercarriage.

C004260

Fig 1. 2

Disconnect the track link, see Section F, Track Motor/Reduction Gear. Move the idler wheel and recoil assembly to the end of the undercarriage using a bar.

!MWARNING Stand clear and to one side of the track while you remove the master pin. When the master pin is removed the track could fall forward and injure you. TRACK-1-1

J-3

C004530

Fig 3. 4

9813/2000-02

Remove the bolts and remove the idler wheel from the recoil unit.

J-3

Section J - Track and Running Gear Idler Wheel and Recoil Unit Removal

!MWARNING RECOIL UNITS ARE DANGEROUS. They must not be dismantled without using suitable tools to compress the spring safely. The spring pressure can cause serious injury if suddenly released. Scrap units must be made harmless by compressing the spring in a hydraulic press and cutting through the end of the shaft before slowly releasing the pressure. TRACK-1-10

Note: See Grease Cylinder, Removal for Recoil Spring dismantling details.

C004540

Fig 4.

J-4

9813/2000-02

J-4

Section J - Track and Running Gear Idler Wheel and Recoil Unit Replacement

Replacement 1

Before fitting the idler wheel, check the oil level at A. If required, top up with the specified oil (see Section 3). Assemble the idler wheel to the recoil unit and fit the mounting bolts.

C004520

Fig 7. 4

C004560

Connect the track link, see Section F, Track Motor/ Reduction Gear. Apply grease through the check valve to adjust the track tension, see Section 3, Checking/Adjusting the Track Tension.

Fig 5. 2

Fasten a sling around the idler wheel and recoil assembly and enter it into the undercarriage.

C004330

Fig 8. C004570

Fig 6. 3

J-5

Position the idler wheel in the undercarriage using a bar.

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J-5

Section J - Track and Running Gear Idler Wheel and Recoil Unit Replacement

Page left intentionally blank

J-6

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J-6

Section J - Track and Running Gear

Idler Wheel Dismantling and Assembly Disassembly 1

Remove the plug by using a wrench and oil.

P041680-74

Fig 3.

P041680-72

Fig 1. 2

Remove the bearing, shaft, O-ring and F/seal.

Remove the bush by using a JIG A and B.

Remove the bolt by using a tool.

P041680-75

Fig 4. P041680-73

Fig 2. 3

J-7

Remove the pin by using a press or hammer.

Assembly It is the same as the reversal of Disassembly.

9813/2000-02

J-7

Section J - Track and Running Gear Idler Wheel Dismantling and Assembly

Page left intentionally blank

J-8

9813/2000-02

J-8

Section J - Track and Running Gear

Grease Cylinder Removal and Replacement Removal 1

Slacken the check valve to bleed out grease.

Fig 2. 3

Fasten a sling around the idler wheel and recoil assembly and remove it from the undercarriage.

Fig 1. 2

Disconnect the track link, see Track Motor/ Reduction Gearbox, Removal and replacement, Section F. Move the idler wheel and recoil assembly to the end of the undercarriage using a bar.

!MWARNING

Fig 3.

Stand clear and to one side of the track while you remove the master pin. When the master pin is removed the track could fall forward and injure you.

Remove the bolts and remove the idler wheel from the recoil unit.

TRACK-1-1

J-12

9813/2000-02

J-12

Section J - Track and Running Gear Grease Cylinder Removal and Replacement

Fig 4.

!MWARNING

Fig 5.

RECOIL UNITS ARE DANGEROUS. They must not be dismantled without using suitable tools to compress the spring safely. The spring pressure can cause serious injury if suddenly released. Scrap units must be made harmless by compressing the spring in a hydraulic press and cutting through the end of the shaft before slowly releasing the pressure.

Replacement 1

Re-assembly of Components. a

TRACK-1-10

Note: If it becomes necessary to dismantle the recoil spring assembly, the following procedure should be used.

b Extend jack A and compress recoil spring B. c

Prepare the jig for Recoil Spring Disassembly. Place the re-coil spring unit as shown. Jack up the hydraulic jack A and compress the Recoil Spring B.

Remove the Recoil Spring. Pull out the Spring Pin C and remove the castellated nut D. Let the jack A down to relieve the pressure on the recoil spring B. Remove the components from the jig, firstly the yoke E, spring B and finally, the grease cylinder F.

J-13

9813/2000-02

Set the components in the jig, firstly the grease cylinder F, then place the spring B on top, and finally, the yoke E.

Install the castellated nut D on the threaded section of the grease cylinder F which protrudes through the yoke E. Tighten nut D, aligning the castellations with the pin hole.

d Remove the recoil spring assembly from the jig. See Recoil Spring Installation. e

Renew and install spring pin C.

Release jack A carefully and allow recoil spring B to expand. Remove assembly from the jig.

J-13

Section J - Track and Running Gear Grease Cylinder Removal and Replacement

Fig 6.

J-14

9813/2000-02

J-14

Section J - Track and Running Gear Grease Cylinder T-Spring

T-Spring Disassembly 1

Remove the plug by using a wrench.

P041680-78

Fig 9. 4

Press is moved farward. Remove the grease which is flowing out.

P041680-76

Fig 7. 2

Load the tension spring on the press machine.

P041680-79

Fig 10. 5

Press is moved farward (minimum distance would be enough to release the nut).

P041680-77

Fig 8. 3

Press is moved farward. Remove the Valve by using a tool.

P041680-80

Fig 11. 6

J-15

9813/2000-02

Back Press up.

J-15

Section J - Track and Running Gear Grease Cylinder T-Spring

P041680-81

Fig 12. 7

Remove the washer by pushing spring back.

P041680-84

Fig 15.

Assembly P041680-82

Fig 13. 8

It is the same as the reversal of Disassembly.

Remove the spring, rod, piston and holder, cylinder.

P041680-83

Fig 14. 9

Put the holder and piston on the JIG A. Input a round bar (Ă&#x2DC;20) into the hole of the holder. Remove the holder and piston by using a press.

J-16

9813/2000-02

J-16

Section J - Track and Running Gear

Drive Sprocket Removal and Replacement Removal 1

Slacken the check valve to bleed out grease.

Fig 2. 3

Lift the side of the undercarriage high enough to permit drive sprocket removal. Support with wooden blocks.

Fig 1. 2

Disconnect the track link, see Track Motor/ Reduction Gearbox, Removal and Replacement.

!MWARNING Stand clear and to one side of the track while you remove the master pin. When the master pin is removed the track could fall forward and injure you. TRACK-1-1

J-16

Fig 3. 4

9813/2000-02

Support the drive sprocket, remove the bolts and lever it away from the gearbox unit.

J-16

Section J - Track and Running Gear Drive Sprocket Removal and Replacement

Fig 6. Fig 4. 3

Replacement 1

Apply grease through the check valve to adjust the track tension (see Checking/Adjusting the Track Tension, Section 3).

Support the sprocket and position it on the gearbox. Install the bolts and washers, using Threadseal on the bolt threads. Tighten the bolts in a diagonal sequence to a torque of 267 - 312 Nm (197 - 230 lbf ft, 27 - 31 kgf m).

Fig 7.

Fig 5. 2

Remove the wooden blocks. Connect the track link.

J-17

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J-17

Section J - Track and Running Gear Drive Sprocket Removal and Replacement

Page left intentionally blank

J-18

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J-18

Section J - Track and Running Gear

Top Roller Removal P11-J004

Slacken the check valve to bleed out grease.

!MWARNING

Loosen but do not remove the mounting bolts. Tap the upper roller with a copper mallet to separate it from the side frame.

When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out. If you over-loosen too much grease could spurt out or the valve cover fly out and cause serious injury. 8-3-4-5

C004760

Fig 3. 4 C004260

Fig 1. 2

Fasten a sling to the upper roller. Remove the mounting bolts and lift the upper roller clear.

Jack up the track high enough to permit roller removal. Put wooden blocks between track link and side frame.

C004770

Fig 4.

C004750

Fig 2.

J-18

9813/2000-02

J-18

Section J - Track and Running Gear Top Roller Replacement

Replacement 1

Before fitting the roller, check the oil level and, if necessary, top up, see Section 3, Fluids and Lubricants, . Install the plug A using an appropriate pipe thread sealant.

C004800

Fig 7.

5 802958

Fig 5. 2

With the track supported as shown under Removal, step 2, install the roller.

Apply JCB Threadseal to the threads and install the mounting bolts. Tighten to a torque of 259 Nm (191 lbf ft).

Apply grease through the check valve to adjust the track tension, see Section 3, Checking/Adjusting the Track Tension.

C004330

Fig 8.

C004790

Fig 6. 4

Remove the wooden blocks and jack.

J-19

9813/2000-02

J-19

Section J - Track and Running Gear Top Roller Top Roller

Top Roller Disassembly 1

Use 6mm â&#x20AC;&#x2DC;Lâ&#x20AC;&#x2122; wrench to remove the plug 9 from Cover 4. K Fig 9. ( T J-20).

P041680-56

Fig 9. Note: Some of fabrics should be prepared in order to avoid any dirty which is caused by the oil comes from inside of the roller (Around 30cc). 2

Remove Cover 4 by using a JIG A to remove Cover. K Fig 10. ( T J-20).

P041680-57

Fig 10. JIG to remove Cover. K Fig 11. ( T J-21).

J-20

9813/2000-02

J-20

Section J - Track and Running Gear Top Roller Top Roller

P041680-58

Fig 11. A

Ø100

Ø90

Ø63

Remove the F/seal 5 from body 1 and T/ring 5. K Fig 10. ( T J-20).

Remove the Shaft 2 by using a JIG B to remove the Shaft. K Fig 12. ( T J-21). JIG to remove Shaft B: Ø30x50L P041680-59

Fig 12. 5

J-21

9813/2000-02

Remove the washer. K Fig 13. ( T J-22).

J-21

Section J - Track and Running Gear Top Roller Top Roller

P041680-60

Fig 13. 6

Remove the bushing 4 from the body 1. Remove by putting pressure JIG A after insert JIG B. K Fig 14. ( T J-22).

P041680-61

Fig 14. JIG A to remove bushing: Ă&#x2DC;30x80L

J-22

9813/2000-02

J-22

Section J - Track and Running Gear Top Roller Top Roller

P041680-62

Fig 15. A

Ă&#x2DC;34.5

Ă&#x2DC;29.7

JIG B to remove bushing. Note: The pressure should be put using the oil pressure press. Also you must be careful not to cause "expulsion and surface flash".

Assembly It is the same as the reversal of Disassembly.

J-23

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J-23

Section J - Track and Running Gear Top Roller Top Roller

Page left intentionally blank

J-24

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J-24

Section J - Track and Running Gear

Bottom Roller Removal P11-J005

Slacken the check valve to bleed out grease.

!MWARNING

Lift the side of the undercarriage high enough to permit bottom roller removal. Support with wooden blocks. Tap the bottom roller with a copper mallet to separate it from the side frame.

C004280

Fig 3. 4

Remove the roller.

C004260

Fig 1. 2

Remove the bolts securing the mounting brackets to the side frame.

C005120

Fig 4.

C005110

Fig 2.

J-26

9813/2000-02

J-26

Section J - Track and Running Gear Bottom Roller Replacement

Replacement 1

Before fitting the roller, fill with oil, see Section 3, Fluids and Lubricants. Install the plug using an appropriate pipe thread sealant. With the undercarriage lifted and supported with wooden blocks, position the roller on the track link as shown. Align the holes in the mounting brackets with the tapped holes in the undercarriage.

C005110

Fig 7. 4

Apply grease through the check valve to adjust the track tension, see Section 3, Checking/Adjusting the Track Tension.

C005130

Fig 5. 2

Lower the undercarriage sufficient to allow the mounting bolts to be installed.

C004330

Fig 8. C005130

Fig 6. 3

Apply JCB Threadseal to the threads and install the mounting bolts. Tighten to a torque of 506 Nm (373 lbf ft).

J-27

9813/2000-02

J-27

Section J - Track and Running Gear Bottom Roller Bottom Roller

Bottom Roller Disassembly 1

Use 6mm ”L” wrench to remove the plug 8 from Collar 2. K Fig 9. ( T J-28).

P041680-64

Fig 10. 7

Remove F/Seal 5 from the seperated Collar sub assembly E and body 1.

Remove Pin 6 from the seperated Collar assembly E by using a hammer and toil to remove pin.

Remove shaft 3 from the Collar 2.

Remove O-ring 7 from the shaft 3.

Remove bushing K Fig 11. ( T J-29).

P041680-63

Fig 9. Note: Some of fabrics should be prepared in order to avoidany dirty which is caused by the oil comes from inside of the roller. 2

Use a hammer D and tool to remove pin C to remove the one side of pin 6. K Fig 9. ( T J-28).

from

the

body

Remove by putting pressure JIG A after JIG B.

Tool: Ø9 x 70L 3

Remove the Collar 2, which is the side of pin 6.

Remove F/Seal 5, from the seperated Collar 2 and body 1.

Remove O-ring 7 from the shaft 3. (It would be difficult to seperate Collar sub assembly of the opposite side, if O-ring is not seperated).

Remove Collar sub assmbly E, which is the opposite side one from body 1. K Fig 10. ( T J-28).

J-28

Note: The pressure should be put using the oil pressure press. Also you must be careful not to cause "expulsion and surface flash".

9813/2000-02

J-28

Section J - Track and Running Gear Bottom Roller Bottom Roller

P041680-62

Fig 12.

P041680-65

Ø45.5

Ø39.7

Fig 11. 12

Remove bushing 4 in the same way after turn body. K Fig 12. ( T J-29).

Assembly It is the same as the reversal of Disassembly.

JIG A to remove bushing. Round bar: Ø40 x 150L JIG B to remove bushing.

J-29

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J-29

Section J - Track and Running Gear Bottom Roller Bottom Roller

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J-30

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J-30

Section K Engine Service Manual - JS81 Section 1 - General Information Section 2 - Operator’s Manual Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/2000-02

Section K - Engine

Notes:

K-0

9813/2000-02

K-0

Section K - Engine

Technical Data Engine K-1 Engine Mounts K-3

K-1

Section K - Engine

Technical Data Engine Refer to the Engine Operator and Maintenance manual for complete details 9806-6000.

Type

Table 1. KOEL Vertical, Four Cylinder, Water-Cooled,Four-Stroke Cycle

Model

4R1040

Bore

95.4 mm (3.76 in)

Stroke

107 mm (4.21 in)

Displacement

3059 cc (186.67 in3)

Compression ratio

17:1

Rated output

65HP @ 180.0 rpm

Max. torque

143ft Ib @ 1600 rpm

Max. no load speed

650 rpm +/- 20

Firing order

1-3-4-2

Valve clearance (cold) Inlet

0.4mm (0.016 in)

Exhaust

0.4mm (0.016 in)

Dry weight (approximately)

K-1

494 kg (1334 lb)

9813/2000-02

K-1

Section K - Engine Technical Data Engine

Fig 1. Installation with Engine

K-2

9813/2000-02

K-2

Section K - Engine Technical Data Engine Mounts

Engine Mounts Note: Lower engine mount rubbers are held in place on castings using loctite or permabond adhesive.

A B

Item

K-3

Fig 2. Description

Torque (Nm)

Bolt M16 x 130

205

Bolt M12 x 35

125

Bolt M14 x 90

200

Bolt M12 x 40

125

9813/2000-02

K-3

Section K - Engine Technical Data Engine Mounts

Page left intentionally blank

K-4

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K-4