JCB JS200 Series Tracked Excavators T4, T2 Engines Service Repair Manual – PDF Download by www.heydownloads.com

Service Manual JS 200 Series Tracked Excavators - T4 and T2 Engines Section 1 - General Information Section 2 - Operator’s Manual Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/3200-03

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

Section 1 General Information Service Manual - JS 200 Series Tracked Excavators - T4 and T2 Engines Section 1 - General Information Section 2 - Operator’s Manual Section B - Body and 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 1 - General Information

Notes:

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Section 1 - General Information Contents Page No. Introduction Identifying Your Machine ........................................................................... 1-1 Safety Introduction ................................................................................................ 1-3 Use Introduction ................................................................................................ Scope ........................................................................................................ Format ....................................................................................................... Left Side, Right Side .................................................................................. Hydraulic Schematic Codes ...................................................................... General Procedures Introduction .............................................................................................. Parking the Machine and Making it Safe ................................................. Venting the Hydraulic Pressure ............................................................... Connecting/Disconnecting Hydraulic Hoses ............................................ Battery Disconnection/Connection .......................................................... Removing and Replacing Components ................................................... Battery Charging System Precautions ..................................................... Gas Hydraulic Bladder Accumulators ......................................................

1-5 1-6 1-7 1-8 1-9

1-11 1-12 1-13 1-14 1-15 1-16 1-17 1-18

Service Consumables Introduction .............................................................................................. 1-21 Sealing and Retaining Compounds ......................................................... 1-22 Torque Settings Introduction .............................................................................................. Zinc Plated Fasteners and Dacromet Fasteners ..................................... Hydraulic Connections ............................................................................. `Positional Type' Hydraulic Adaptors .......................................................

1-23 1-24 1-28 1-35

Service Tools Numerical List .......................................................................................... 1-37 Tool Detail Reference .............................................................................. 1-40

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Section 1 - General Information Contents

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Page No.

1-ii

Section 1 - General Information

Introduction Identifying Your Machine For information about identifying your machine and its main components, refer to Section 2, About the Machine, Machine and Component Identification.

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Section 1 - General Information Introduction Identifying Your Machine

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Section 1 - General Information

Safety Introduction In this manual and on the machine there are safety notices. The safety notices have different signal words as follows: – DANGER – WARNING – CAUTION – Notice For an explanation of the safety notice signal words, refer to Section 2, Introduction, Safety. For general safety notices, Introduction, Safety.

refer

Section

For maintenance safety notices, refer to Section 2, Maintenance, Maintenance Safety. For safety notices specific to maintenance procedures, refer to the relevant procedure. If you do not fully understand a safety notice ask your employer to explain it.

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Section 1 - General Information Safety Introduction

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Section 1 - General Information

Use Introduction This topic contains information about the structure of the manual and how to use the manual.

K Scope ( T 1-6) K Personnel ( T 1-6) K Applications ( T 1-6) K Newest Data ( T 1-6) K Format ( T 1-7) K Left Side, Right Side ( T 1-8) K Hydraulic Schematic Codes ( T 1-9) K Colour Codes ( T 1-9)

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Section 1 - General Information Use Scope

Scope Personnel This manual is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Finally, please remember above all else SAFETY MUST COME FIRST!

Applications This manual contains data relevant to a range of machines. Make sure you reference the data for the correct machine.

Newest Data From time to time new machines, systems or devices require the manual to be re-issued. Make sure you have the newest issue. Always check the on-line JCB data system for relevant technical information.

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Section 1 - General Information Use Format

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

General Information - The section includes general information such as torque settings and service tools.

Operator Manual - The section contains a copy of the applicable machine Operator Manual. Refer to this section when necessary for information about the main machine components and controls. Refer also to the safety and daily / weekly maintenance information.

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

Attachments

Body and Framework...etc.

Each section contains data such as technical data, descriptions, fault finding and test procedures. Some sections contain procedures and specifications for different variants. This happens because of market requirements, or when the machine specification changes after a period of time. Where applicable, a table contains information to help you identify the correct data and procedures.

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Section 1 - General Information Use Left Side, Right Side

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

A C017280

Fig 1.

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Section 1 - General Information Use Hydraulic Schematic Codes

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

Red

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

Pink

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

Orange

Blue

Green

Light Green

Yellow

1-9

Pilot: Oil pressure used in controlling a device (Pilot).

Neural: Neutral circuit pressure.

Exhaust:

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

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

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Section 1 - General Information Use Hydraulic Schematic Codes

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Section 1 - General Information

General Procedures Introduction When work is done on the machine it is important that the correct care is taken. This will help to prevent personal injury and reduce the risk of component failure. As part of the procedures in this manual you will need to do some general procedures. Two examples of these general procedures are; parking the machine and making it safe, and venting hydraulic pressure. These procedures are given here as an alternative to again and again in the manual. Where applicable you will see a cross reference to this section so that you can refer to the detailed procedures.

K Parking the Machine and Making it Safe ( T 1-12) K Venting the Hydraulic Pressure ( T 1-13) K Connecting/Disconnecting Hydraulic Hoses ( T 1-14) K Battery Disconnection/Connection ( T 1-15) K Removing and Replacing Components ( T 1-16) K Battery Charging System Precautions ( T 1-17) K Gas Hydraulic Bladder Accumulators ( T 1-18)

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Section 1 - General Information General Procedures Parking the Machine and Making it Safe

Parking the Machine and Making it Safe For the correct procedures to park and make the machine safe, refer to Section 2, Maintenance, Maintenance Positions.

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Section 1 - General Information General Procedures Venting the Hydraulic Pressure

Venting the Hydraulic Pressure

!MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication. HYD-1-5

For the correct procedures to vent the hydraulic pressure, refer to Section 2, Maintenance, Hydraulic System, General, Discharge.

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Section 1 - General Information General Procedures Connecting/Disconnecting Hydraulic Hoses

Connecting/Disconnecting Hydraulic Hoses

For the correct procedures to connect/disconnect hydraulic hoses, refer to Section 2, Attachments, Connecting/Disconnecting Hydraulic Hoses.

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Section 1 - General Information General Procedures Battery Disconnection/Connection

Battery Disconnection/Connection For the correct procedures to disconnect/connect the battery, refer to Section 2, Maintenance, Electrical System, Battery.

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Section 1 - General Information General Procedures Removing and Replacing Components

Removing and Replacing Components Preparation

– Make sure that all the applicable component assemblies are correct.

Before removing and replacing components do the following:

– Make sure that the applicable fixings are to the correct specification. If necessary discard the original fixings and replace them with new ones. The relevant procedures indicate when this is necessary.

– To prevent contamination of the machine systems, clean the machines in the area of the applicable components. Refer to Section 2, Preservation and Storage, Cleaning the Machine. – Make sure that the correct maintenance procedures are available. – Make sure that the correct tools and equipment are available. – Make sure that the correct replacement parts, consumables, fluids and lubricants are available.

Original Components Always Install new oil seals, gaskets, etc. Components showing obvious signs of wear or damage should be replaced with new ones.

– Make sure that the applicable fixings and threaded holes are free from contamination. This includes; dirt, debris, old sealants and compounds, fluids and lubricants. This manual provides reference to the correct torque settings as follows: – Where no torque setting is given in the applicable procedure, use the standard torque setting. To obtain the correct standard torque setting refer to Torque Settings in this section. – Where torque settings are given in the applicable procedure use the settings given. These settings may be different to the standard torque settings in the case of special fixings for example.

Before re-installing original components do the following: – Clean components using the applicable cleaning materials. – Inspect components for signs of excessive wear or defects. – Check the component specifications such as wear limits where applicable.

New Components Make sure that the correct new components are installed. Do not substitute components from another machine. Components may look the same but may not be interchangeable. Refer to the JCB parts systems.

Torques and Fixings When replacing components always tighten the applicable fixings to the correct torque. For the torque setting to be effective do the following before installing the fixings:

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Section 1 - General Information General Procedures Battery Charging System Precautions

Battery Charging System Precautions Obey the procedures below to prevent damage to the alternator and battery. – Ensure that the battery negative terminal is connected to the earthing cable. – Never make or break connections to the battery or alternator, or any part of the charging circuit whilst the engine is running. Disregarding this instruction will result in damage to the regulator or rectifying diodes. – Main output cables are 'live' even when the engine is not running. Take care not to earth connectors in the moulded plug if it is removed from the alternator. – When arc welding on the machine, protect the alternator by removing the moulded plug (or if separate output cables fitted, remove the cables). – Follow the correct procedures when jump starting the engine. Refer to Section 2, Operation, Moving a Disabled Machine.

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Section 1 - General Information General Procedures Gas Hydraulic Bladder Accumulators

Gas Hydraulic Bladder Accumulators

!MWARNING

Some hydraulic circuits and valve blocks are fitted with gas hydraulic bladder type accumulators. Before removing accumulators make sure hydraulic pressure is vented. K Venting the Hydraulic Pressure ( T 1-13) Even when the hydraulic pressure is vented the accumulator still contains pressurised nitrogen gas. DO NOT attempt to discharge the gas pressure.

Use only nitrogen gas to charge accumulators. The use of any other gas can cause the accumulators to explode. Remember that although nitrogen is not poisonous you can be killed by suffocation if it displaces the air in your workplace. Do not allow excessive quantities of nitrogen to be discharged into the atmosphere. B-3-1-6

DO NOT transport accumulators charged with pressurised gas by air freight.

Replacement

Replacement accumulators are generally supplied in a discharged state with no nitrogen gas. A label attached to the accumulator indicates the gas charge state.

Charging

K Fig 1. ( T 1-18)

4 7

Important: The following charging procedure is only applicable to accumulators supplied in a discharged state.

To carry out the charging procedure the following is required: â&#x20AC;&#x201C; Pressurised bottle of nitrogen gas with a suitable pressure reducing valve (3). â&#x20AC;&#x201C; Correct gas bottle adaptor depending on territory. â&#x20AC;&#x201C; Charging kit 892/00239. Refer to Section 1. C110540-C2

Fig 1.

Operating charge pressures; accumulators are charged to different operating pressures depending on the application. For the correct charge pressure refer to the applicable system specifications.

Before fitting a replacement accumulator charge it with nitrogen gas as follows:

Note: Some accumulators are supplied with a measured quantity of oil inside the gas chamber. Take care to prevent oil loss. 2

Hold the accumulator upright and remove the plastic cap from the top of the accumulator.

Using a suitable allen key, slowly remove the filler plug 2. Lightly oil the sealing washer beneath. Replace the washer and plug. Loosen the plug by 1/8 of a turn.

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Section 1 - General Information General Procedures Gas Hydraulic Bladder Accumulators 3

Connect the accumulator adaptor 1 (from kit 892/ 00239) to the accumulator. Connect the charging unit 6 to the accumulator adaptor. Connect the charging hose to the pressure regulator 3 using the correct adaptor. Set the pressure regulator 3 to the minimum pressure.

Via the charging tool knob 7, open the filler plug 2 by three turns.

Open the discharge valve 5 on the charging unit.

1 3

Carefully open the nitrogen gas bottle valve 4 and confirm that the nitrogen gas flows freely.

Shut the gas bottle valve and the discharge valve 5. 6

Carefully open the gas bottle valve. Slowly increase the pressure using the gas bottle pressure regulator and watching the gauge 8 on the charging unit, allow nitrogen to flow until the pressure reading reaches 4 bar (72.5 psi) ABOVE the operating charge pressure.

C110550

Fig 2. 12

Important: DO NOT exceed the maximum working pressure of the accumulator. The maximum working pressure is marked on the accumulator body. Close the gas bottle valve. 7

Wait 10 minutes to dissipate the heat generated during charging.

Reduce the pressure in the accumulator to the specified operating charge pressure by carefully opening and closing the discharge valve 5. Turn the knob 7 to shut the filler plug 2 and tighten to a torque of 20 Nm (15 lb ft).

Release the pressure from the charging hose by opening the discharge valve 5.

K Fig 2. ( T 1-19) Remove the discharged state label 3 and attach the pressurised warning label 2 at position 1 on the accumulator. Install the accumulator and make sure pressurised warning label is clearly visible.

the

Disconnect the charging unit and adaptor from the accumulator. 10

Check the gas-tightness of filler plug 2 by pouring some oil around it.

Replace the plastic cap.

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Section 1 - General Information General Procedures Gas Hydraulic Bladder Accumulators

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Section 1-9 - General Information

Service Consumables Introduction Consumables such as sealing and retaining compounds are necessary to complete some procedures. Before you start work make sure that the consumables show in the tables are available.

K Sealing and Retaining Compounds ( T 1-9-2)

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Section 1-9 - General Information Service Consumables Sealing and Retaining Compounds

Sealing and Retaining Compounds T11-001_4

Table 1. Type

Description

JCB Multi-Gasket

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

50 ml

JCB High Strength Threadlocker

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

50 ml

JCB Retainer (High Strength)

For all retaining parts which are unlikely to be dismantled.

4101/0601

10 ml

4101/0651

50 ml

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

4101/0250

10 ml

4101/0251

50 ml

JCB Threadlocker and Sealer (High Strength)

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

10 ml 200 ml

JCB Threadseal

A medium strength thread sealing compound.

4102/1951

50 ml

JCB Activator

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

4104/0251

200 ml (Aerosol)

4104/0253

1 ltr (Bottle)

JCB Cleaner/Degreaser

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

4104/1557

400 ml (Aerosol)

Direct Glazing Kit

For one pane of glass; comprises of:

993/55700

JCB Threadlocker and Sealer

Part No.

Quantity

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

For direct glazing.

4103/2109

310 ml

Active Wipe 205

For direct glazing.

4104/1203

250 ml

Black Primer 206J

For direct glazing.

4201/4906

30 ml

Clear Silicone Sealant

To seal butt jointed glass.

4102/0901

Plastic to Metal Bonder

To seal plastic to metal joints.

4103/0956

50 g

Black Polyurethane Sealant

To finish exposed edges of laminated glass.

4102/2309

310 ml

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1-9-2

Section 1-7 - General Information

Torque Settings Introduction This topic contains information about torques. Torque values are given for types and sizes of bolts and hydraulic connectors and adaptors. Where a torque is given as a single figure it may be varied by plus or minus 3%. Torque figures are given for fasteners with different surface treatments. Make sure you use the correct torque figures. Where torques are given in topics within the other sections always use these values.

K Zinc Plated Fasteners and Dacromet Fasteners ( T 1-7-2) K Introduction ( T 1-7-2) K Bolts and Screws ( T 1-7-2) K Hydraulic Connections ( T 1-7-6) K 'O' Ring Face Seal System ( T 1-7-6) K 'Torque Stop' Hose System ( T 1-7-12) K `Positional Type' Hydraulic Adaptors ( T 1-7-13) K Fitting Procedure ( T 1-7-13)

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1-05-01 Issue 02

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

Zinc Plated Fasteners and Dacromet Fasteners T11-002

Introduction

Bolts and Screws

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

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

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

Torque settings are given for the following conditions:

Fastener Type

Table 1. Fastener Types Colour Part No. Suffix

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

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

Zinc and Yellow

Golden finish

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

Dacromet

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

Condition 2 – Zinc flake (Dacromet) fasteners

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

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

Verbus Ripp Bolts

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

1-7-2

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

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Section 1-7 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Hexagon (A/F) Condition 1

Bolt Size

Condition 2

in.

kgf m

lbf ft

kgf m

lbf ft

1/4

6.3

7/16

11.2

1.1

8.3

10.0

1.0

7.4

5/16

7.9

1/2

22.3

2.3

16.4

20.0

2.0

14.7

3/8

9.5

9/16

40.0

4.1

29.5

36.0

3.7

26.5

7/16

11.1

5/8

64.0

6.5

47.2

57.0

5.8

42.0

1/2

12.7

3/4

98.00

10.0

72.3

88.0

9.0

64.9

9/16

14.3

13/16

140.0

14.3

103.2

126.0

12.8

92.9

5/8

15.9

15/16

196.0

20.0

144.6

177.0

18.0

130.5

3/4

19.0

1 1/8

343.0

35.0

253.0

309.0

31.5

227.9

7/8

22.2

1 15/16

547.0

55.8

403.4

492.0

50.2

362.9

25.4

1 1/2

814.0

83.0

600.4

732.0

74.6

539.9

1 1/8

31.7

1 7/8

1181.0

120.4

871.1

1063.0

108.4

784.0

1 1/4

38.1

2 1/4

1646.0

167.8

1214.0

1481.0

151.0

1092.3

Table 3. Torque Settings - Metric Grade 8.8 Fasteners Hexagon (A/F) Condition 1

Bolt Size ISO Metric Thread

kgf m

Condition 2

lbf ft

kgf m

lbf ft

5.8

0.6

4.3

5.2

0.5

3.8

9.9

1.0

7.3

9.0

0.9

6.6

24.0

2.4

17.7

22.0

2.2

16.2

M10

47.0

4.8

34.7

43.0

4.4

31.7

M12

83.0

8.5

61.2

74.0

7.5

54.6

M16

205.0

20.9

151.2

184.0

18.8

135.7

M20

400.0

40.8

295.0

360.0

36.7

265.5

M24

690.0

70.4

508.9

621.0

63.3

458.0

M30

1372.0

139.9

1011.9

1235.0

125.9

910.9

M36

2399.0

244.6

1769.4

2159.0

220.0

1592.4

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1-05-01 Issue 02

1-7-3

Section 1-7 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Hexagon (A/F) Condition 1

Bolt Size ISO Metric Thread

kgf m

Condition 2 lbf ft

kgf m

lbf ft

8.1

0.8

6.0

7.3

0.7

5.4

13.9

1.4

10.2

12.5

1.3

9.2

34.0

3.5

25.0

30.0

3.0

22.1

M10

67.0

6.8

49.4

60.0

6.1

44.2

M12

116.0

11.8

85.5

104.0

10.6

76.7

M16

288.0

29.4

212.4

259.0

26.4

191.0

M20

562.0

57.3

414.5

506.0

51.6

373.2

M24

971.0

99.0

716.9

874.0

89.1

644.6

M30

1930.0

196.8

1423.5

1737.0

177.1

1281.1

M36

3374.0

344.0

2488.5

3036.0

309.6

2239.2

Table 5. Metric Grade 12.9 Fasteners Hexagon (A/F) Condition 1

Bolt Size

Condition 2

ISO Metric Thread

kgf m

lbf ft

kgf m

lbf ft

9.8

1.0

7.2

8.8

0.9

6.5

16.6

1.7

12.2

15.0

1.5

11.1

40.0

4.1

29.5

36.0

3.7

26.5

M10

80.0

8.1

59.0

72.0

7.3

53.1

M12

139.0

14.2

102.5

125.0

12.7

92.2

M16

345.0

35.2

254.4

311.0

31.7

229.4

M20

674.0

68.7

497.1

607.0

61.9

447.7

M24

1165.0

118.8

859.2

1048.0

106.9

773.0

M30

2316.0

236.2

1708.2

2084.0

212.5

1537.1

M36

4049.0

412.9

2986.4

3644.0

371.6

2687.7

1-7-4

1-05-01 Issue 02

1-7-4

Section 1-7 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread

kgf m

lbf ft

1.2

0.1

0.9

3.0

0.3

2.0

6.0

0.6

4.5

10.0

1.0

7.5

24.0

2.5

18.0

M10

48.0

4.9

35.5

M12

82.0

8.4

60.5

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

1-7-5

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

1-05-01 Issue 02

1-7-5

Section 1-7 - General Information Torque Settings Hydraulic Connections

Hydraulic Connections 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45Â° seat machined into the face of the tapped port. Table 8. Torque Settings - BSP Adaptors BSP Adaptor Hexagon (A/F) Size

1-7-6

in.

kgf m

lbf ft

1/4

19.0

18.0

1.8

13.0

3/8

22.0

31.0

3.2

23.0

1/2

27.0

49.0

5.0

36.0

5/8

30.0

60.0

6.1

44.0

3/4

32.0

81.0

8.2

60.0

38.0

129.0

13.1

95.0

1 1/4

50.0

206.0

21.0

152.0

Table 9. Torque Settings - SAE Connections SAE Port Hexagon (A/F)

SAE Tube Size

Thread Size

kgf m

lbf ft

7/16 - 20

15.9

20.0 - 28.0

2.0 - 2.8

16.5 - 18.5

9/16 - 18

19.1

46.0 - 54.0

4.7 - 5.5

34.0 - 40.0

3/4 - 16

22.2

95.0 - 105.0

9.7 - 10.7

69.0 - 77.0

7/8 - 14

27.0

130.0 - 140.0

13.2 - 14.3

96.0 - 104.0

1 1/16 - 12

31.8

190.0 - 210.0

19.4 - 21.4

141.0 - 155.0

1 5/16 - 12

38.1

290.0 - 310.0

29.6 - 31.6

216.0 - 230.0

1 5/8

47.6

280.0 - 380.0

28.5 - 38.7

210.0 - 280.0

1-05-01 Issue 02

1-7-6

Section 1-7 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors

Fig 2. Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring 2-C which is compressed into a 45Â° seat machined into the face of the adaptor port.

BSP Hose Size in.

1-7-7

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

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

1/8

14.0

14.0 - 16.00

1.4 - 1.6

10.3 - 11.8

1/4

19.0

24.0 - 27.0

2.4 - 2.7

17.7 - 19.9

3/8

22.0

33.0 - 40.0

3.4 - 4.1

24.3 - 29.5

1/2

27.0

44.0 - 50.0

4.5 - 5.1

32.4 - 36.9

5/8

30.0

58.0 - 65.0

5.9 - 6.6

42.8 - 47.9

3/4

32.0

84.0 - 92.0

8.6 - 9.4

61.9 - 67.8

38.0

115.0 - 126.0

11.7 - 12.8

84.8 - 92.9

1 1/4

50.0

189.0 - 200.0

19.3 - 20.4

139.4 - 147.5

1 1/2

55.0

244.0 - 260.0

24.9 - 26.5

180.0 - 191.8

1-05-01 Issue 02

kgf m

lbf ft

1-7-7

Section 1-7 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size

1-7-8

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

1-05-01 Issue 02

1-7-8

Section 1-7 - General Information Torque Settings Hydraulic Connections Procedure

– The swivel-nut is hand-tight 4.

Torque all of the O-Ring face seal fittings. Always make sure that the correct torque is used to tighten the specific fitting size. K Table 12. ( T 1-7-10).

– The swivel-nut is tightened to the correct torque setting 5.

To prevent damage to the O-Ring during the assembly procedure its important to use the double-spanner method of tightening. K Fig 3. ( T 1-7-9). – Torque spanner 1. – Open ended/combination spanner.2.

T044490

Fig 5.

T044470

Fig 3.

Key Points A rubber trapezoid O-Ring seal 3 is pre-installed in the Captive O-Ring Groove (CORG). This groove is the halfdovetail type and has very secure retention properties as the seal is below the lip of the groove. K Fig 4. ( T 1-7-9).

T044480

Fig 4. Swivel-nut line marking, K Fig 5. ( T 1-7-9).

1-7-9

the

broken-line

method.

1-05-01 Issue 02

1-7-9

Section 1-7 - General Information Torque Settings Hydraulic Connections Table 12. Assembly Torques for UNF Threads on the ORFS Fittings Product

Thread size

Series

T Series Port connections males stud and swivel fittings

Port dash size -4

Non-adjustable end Adjustable end

Inch

7/16-20

UNF

-5

1/2-20

UNF

-6

9/16-18

UNF

-8

3/4-16

UNF

-10

7/8-14

UNF

135

-12

1.1/16-12

UNF

185

-16

1.5/16-12

UNF

270

-20

1.5/8-12

UNF

340

-24

1.7/8-12

UNF

415

Dash size of tube or hose ends

UNF thread size

Flats from wrench resistance

Swivel nut torque Nm (Ref)

9/16-18

UNF

1/2 to 3/4

-6

11/16-16

UNF

1/2 to 3/4

-8

13/16-16

UNF

1/2 to 3/4

-10

1-14

UNF

1/2 to 3/4

-12

1. 3/16-12

UNF

1/3 to 1/2

122

-16

1.7/16-12

UNF

1/3 to 1/2

156

-20

1.11/16-12 UNF

1/3 to 1/2

200

-24

2-12

UNF

1/3 to 1/2

256

-32

2.1/2-12

UNF

Hose ends ORFS female swivel -4

1-7-10

Assembly torque

ISO 11296

1-05-01 Issue 02

1-7-10

Section 1-7 - General Information Torque Settings Hydraulic Connections General If there is a leak from the hydraulic system: – Before the hose is disconnected to examine the Oring, examine the hose swivel-nut for the broken-line white marker. If there is no visible white marker, photograph the hose and adaptor. K Fig 5. ( T 17-9). – Open a Tech Web call. Attach the photographs and make a report of the hose and adaptor part numbers, and the effected service. Always check the torque of the hose before its disassembled. If the hose or the adaptor is loose, you must specify which component is the cause of the leak. For example if the hose is tight and the adaptor turns in the valve block, record this information in the Tech Web call. – Examine the O-rings, adaptor thread, hose swaging and hose damage in the usual method. If the hose leaks because of chaffing, photograph the chafe point and attach the photographs to the Tech Web call. – When a warranty claim is submitted, refer the claim to the Tech Web call. – A failure to supply the relevant information could delay the warranty claim process and possibly cause the warranty claim to be declined.

1-7-11

1-05-01 Issue 02

1-7-11

Section 1-7 - General Information Torque Settings Hydraulic Connections

'Torque Stop' Hose System

Fig 6. `Torque Stop' Hoses 6-B screwed into adaptors 6-A seal onto an 'O' ring 6-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 6-D, which acts as a physical stop. Note: Minimum dimension 6-E fixed by shoulder 6-D.

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

1-7-12

in.

kgf m

lbf ft

1/8

14.0

1.4

10.0

1/4

19.0

27.0

2.7

20.0

3/8

22.0

40.0

4.1

30.0

1/2

27.0

55.0

5.6

40.0

5/8

30.0

65.0

6.6

48.0

3/4

32.0

95.0

9.7

70.0

38.0

120.0

12.2

89.0

1 1/4

50.0

189.0

19.3

140.0

1 1/2

55.0

244.0

24.9

180.0

1-05-01 Issue 02

1-7-12

Section 1-7 - General Information Torque Settings `Positional Type' Hydraulic Adaptors

`Positional Type' Hydraulic Adaptors Fitting Procedure On a typical machine, some hydraulic components may utilise `Positional Type' SAE Hydraulic Adaptors. When fitting `Positional Type' Hydraulic Adaptors it is important to adopt the following procedure. If this procedure is not followed correctly, damage to the `O' ring seal 7-A can occur resulting in oil leaks. 1

Ensure the locknut 7-B is screwed back onto the body of the adaptor as far as possible as shown.

Check the `O' ring backing washer 7-C is a tight fit on the adaptor. Note that the washer should not move freely, if the washer is slack do not use the adaptor.

Check the `O' ring 7-A is fitted and that it is free from damage or nicks. Before fitting the adaptor, smear the `O' ring with clean hydraulic fluid.

Fig 7.

Note: The dimensions and shore hardness of the `O' ring is critical. Should it become necessary to replace the `O' ring, ensure that only JCB Genuine Parts are used. 4

Screw the adaptor into the port of the hydraulic component as far as possible, so that ALL the threads engage and the `O' ring is correctly seated against the sealing face.

Set the angular position of the adaptor as required, then secure by tightening the locknut 7-B.

Note: When fitted correctly no more than one thread should be visible at 8-Z as shown. 6

Torque tighten the locknut to 81 Nm (60 lbf ft).

Fig 8.

1-7-13

1-05-01 Issue 02

1-7-13

Section 1-7 - General Information Torque Settings `Positional Type' Hydraulic Adaptors

Page left intentionally blank

1-7-14

1-05-01 Issue 02

1-7-14

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. K 993/68100 Slide Hammer Kit ( T 1-40)

Rivet Nut Tool. K Rivet Nut Tool ( T 1-40)

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 Adaptors - BSP x BSP. K Male Adaptors ( T 1-45)

Male Adaptors - BSP x NPT (USA only). K Male Adaptors ( T 1-45)

Pressure Test Points - Adaptors. K Pressure Test Adapters ( T 1-45)

Pressure Test Points - 'T' Adaptors. K Pressure Test 'T' Adapters ( T 1-45)

'T' Adaptors. K 'T' Adapters ( T 1-46)

1-37

9813/3200-03

1-37

Section 1 - General Information Service Tools Numerical List Part Number

Description

See Section

Female Blanking Caps

Male Cone Blanking Caps. K Male Cone Blanking Caps ( T 1-46)

Female Connectors. K Female Connectors ( T 1-46)

Bonded Washers. K Bonded Washers ( T 1-46)

Ram Protection Sleeves. K Ram Protection Sleeves ( T 1-47)

892/00239

Nitrogen Charging Tool Kit (Hydac bladder accumulators). K 892/00239 Accumulator Gas Charge Kit ( T 1-57)

892/00334

Ram Seal Fitting Tool

Hexagon Spanners. K Hexagon Spanners for Ram Pistons and End Caps ( T 1-47)

892/01027

Piston Seal Assembly Tool

Hydraulic Flow Test Equipment. K Flow Test Equipment ( T 1-48)

Hydraulic Circuit Pressure Test Kit. K 892/ 00253 Hydraulic Circuit Pressure Test Kit ( T 1-49)

Hydraulic Hand Pump Equipment. K Hand Pump Equipment ( T 1-50)

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. K Ram Jigs ( T 1-58)

Ram Piston Nut Spanners. K Ram Piston Nut Removal/Fitting Spanner ( T 1-51)

Socket Box Wrench

Nut Adaptor

Seal Ring Tool

Stopper

Bearing Rig

Inserting Seal Ring and Correction Jig. K Inserting Seal Ring and Correction Jig ( T 1-58)

Jig for Pulling Out, Press-fitting Bushing. K Jig for Pulling Out, Press-fitting Bushing ( T 1-58)

Jig for Press-fitting Wiper Ring. K Jig for Press-fitting Wiper Ring ( T 1-58)

Jig for Inserting Cylinder Head. K Jig for Inserting Cylinder Head ( T 1-58)

Seal Ring and Connector Jig. K Seal Ring and Connector Jig ( T 1-58)

1-38

9813/3200-03

1-38

Section 1 - General Information Service Tools Numerical List Part Number

Description

See Section

Bush Removal Jig. K Bush Removal Jig ( T 1-59)

Bush Fitting Jig. K Bush Fitting Jig ( T 1-59)

Wiper Ring Fitting Jig. K Wiper Ring Fitting Jig ( T 1-59)

1-39

9813/3200-03

1-39

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 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 11. 892/00842 Glass Lifter

1-40

9813/3200-03

1-40

Section 1 - General Information Service Tools Tool Detail Reference

Fig 15. 892/00847 Nylon Spatula General tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge.

Fig 12. 892/00843 Folding Stand Essential for preparing new glass prior to installation.

Fig 16. 892/00848 Wire Starter Used to access braided cutting wire through original polyurethane seal.

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

Fig 14. 892/00846 Glass Extractor (Handles) Used with braided cutting wire to cut out broken glass.

1-41

9813/3200-03

1-41

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. 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).

1-42

Fig 22. 992/12801 'L' Blades 25 mm (1 in.) cut. Replacement blades for cut-out knife. Unit quantity = 5 off.

9813/3200-03

1-42

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).

1-43

9813/3200-03

1-43

Section 1 - General Information Service Tools Tool Detail Reference

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

2 D

E F

5 4 Fig 24. 892/00298 Fluke Meter

6 Fig 27. 892/01174

Fig 25. 892/00285 Hydraulic Temperature Probe

Interconnecting cable, DLA to machine ECU diagnostics socket.

Kit carrying case.

Interconnecting cable, DLA to laptop PC.

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

Interconnecting cable, DLA to laptop PC.

Fig 26. 892/00284 Venture Microtach Digital Tachometer

1-44

9813/3200-03

1-44

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 28. 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 29. 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 30. Pressure Test 'T' Adapters

1-45

9813/3200-03

1-45

Section 1 - General Information Service Tools Tool Detail Reference

Fig 31. '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 32. 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 33. 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 34. Female Connectors

Fig 35. Bonded Washers

1-46

1406/0021

3/4 in. BSP

1406/0029

1.1/4 in. BSP

9813/3200-03

1-46

Section 1 - General Information Service Tools Tool Detail Reference

Fig 36. 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 37. 892/00334 Ram Seal Fitting Tool 5mm

m 3m

110mm 175mm 3o

Fig 38. 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

1-47

1.4

Fig 39. 892/01027 Piston Seal Assembly Tool

9813/3200-03

1-47

Section 1 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11046 JCB ServiceMaster Flow Test Kit. K Fig 41. ( T 1-48).

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 40. 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 41. 998/11046 JCB ServiceMaster Flow Test Kit

1-48

9813/3200-03

1-48

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 43. ( T 1-49).

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 42. 892/ 00253 Hydraulic Circuit Pressure Test Kit

Fig 43. 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit

1-49

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1-49

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 44. Hand Pump Equipment

Fig 45. Spool Clamps 892/00039

Spool Clamp

992/10100

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

992/02800

ARV Extractor

Fig 46. 331/31069 - Test Block for A.R.V.

Fig 47. 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 48. Hydraulic Circuit Test Gauges and Connections

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Section 1 - General Information Service Tools Tool Detail Reference

JS07050

Fig 49. Ram Piston Nut Removal/Fitting Spanner

1-51

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

1-52

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Section 1 - General Information Service Tools Tool Detail Reference

A408860

Fig 51. Nut Adaptor 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 52. 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 53. 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 54. 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

C118440

Fig 55. 892/00239 Accumulator Gas Charge Kit Use with Hydac bladder type accumulators Kit comprises the following: 1

Pressure gauge

Connection hose

Mounting bracket (pressure gauge)

Gas bottle adaptor (G2)(1)

Hydac bladder accumulator adaptor

Testing and charging unit

Spare seal (accumulator plug)

(1) Some territories require a different adaptor.

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Section 1 - General Information Service Tools Tool Detail Reference Ram Jigs 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

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

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

Jig for Press-fitting Wiper Ring

Jig for Inserting Cylinder Head

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

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

Bush removal jig 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

Page left intentionally blank

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

Bush removal jig 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

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Section 2 Operator’s Manual Service Manual - JS 200 Series Tracked Excavators - T4 and T2 Engines Section 1 - General Information Section 2 - Operator’s Manual Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/3200-03

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

Notes:

2-0

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2-0

Foreword The Operator's Manual

OPERATOR'S MANUAL JS115, JS130, JS145, JS160, JS180, JS190, JS200, JS210, JS220, JS235

EN - 9821/9967 - ISSUE 1 - 06/2015

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. 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 2015 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:

9821/9967-1

Table of Contents

Contents

Page No.

Acronyms Glossary ....................................................................................................................................... viii 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 2 3 3 4 5

About the Product Introduction General .................................................................................................................................................. 7 Name and Address of the Manufacturer .............................................................................................. 7 Product Compliance .............................................................................................................................. 7 Description General .................................................................................................................................................. 8 Intended Use ......................................................................................................................................... 8 Log Moving/Object Handling ................................................................................................................. 8 Optional Equipment and Attachments .................................................................................................. 8 Danger Zone ......................................................................................................................................... 8 Main Component Locations .................................................................................................................. 9 Product and Component Identification Machine ............................................................................................................................................... 10 Engine ................................................................................................................................................. 11 Operator Protective Structure ............................................................................................................. 12 Safety Labels General ................................................................................................................................................ 14 Safety Label Identification ................................................................................................................... 14 Operator Station Component Locations ......................................................................................................................... 17 Console Switches General ................................................................................................................................................ 18 Work Lights ......................................................................................................................................... 18 Beacon ................................................................................................................................................ 18 Seat Heater ......................................................................................................................................... 18 Seat Ventilation ................................................................................................................................... 19 Control Locks ...................................................................................................................................... 19 Excavator Arm Quickhitch .................................................................................................................. 19 Radio Mute .......................................................................................................................................... 19 Engine Stop Switch ............................................................................................................................ 19 SCR Refresh ....................................................................................................................................... 19 Slew Lock ........................................................................................................................................... 19 Cushion ............................................................................................................................................... 20 Window Washer .................................................................................................................................. 20 Window Wipers ................................................................................................................................... 20 i

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Table of Contents

Front Lower Window Wiper ................................................................................................................ Cab Raise/Lower ................................................................................................................................ Interior Switches Ignition Switch ..................................................................................................................................... Cab Interior Light ................................................................................................................................ Operation Introduction General ................................................................................................................................................ Operating Safety General ................................................................................................................................................ 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 ................................................................................................................................. Heated Seat Controls ......................................................................................................................... Seat Ventilation Controls .................................................................................................................... Seat Belt General ................................................................................................................................................ Inertia Reel Seat Belt ......................................................................................................................... Static Seat Belt ................................................................................................................................... Mirrors General ................................................................................................................................................ Starting the Engine General ................................................................................................................................................ Immobilizer .......................................................................................................................................... Warming Up ........................................................................................................................................ Stopping and Parking General ................................................................................................................................................ Preparing for Travel General ................................................................................................................................................ Preparing for Worksite Travel ............................................................................................................. Beacon ................................................................................................................................................ Locks General ................................................................................................................................................ Control Lock ........................................................................................................................................

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23 24 26 27 29 30 34 36 38 39 41 43 45 45 47 47 48 48 49 52 57 58 59 61 62 62 63 64 64

Table of Contents

Drive Controls Track Controls ..................................................................................................................................... 66 Travel Speed Selector ........................................................................................................................ 67 Instruments General ................................................................................................................................................ 69 Instrument Panel ................................................................................................................................. 70 Getting the Machine Moving General ................................................................................................................................................ 94 Driving the Machine General ................................................................................................................................................ 97 Towing Other Equipment .................................................................................................................... 98 Operating Levers/Pedals General ................................................................................................................................................ 99 Control Layouts ................................................................................................................................... 99 Excavator Arm Controls ...................................................................................................................... 99 Dozer Blade Controls ....................................................................................................................... 107 Auxiliary Circuit Controls ................................................................................................................... 108 Lifting and Loading General .............................................................................................................................................. 111 Load Charts ...................................................................................................................................... 111 Overload Warning System ................................................................................................................ 112 Working with the Excavator Arm General .............................................................................................................................................. 114 Preparing to Use the Excavator Arm ............................................................................................... 114 Lifting With the Excavator Arm ......................................................................................................... 114 Digging .............................................................................................................................................. 115 Changing the Bucket Linkage .......................................................................................................... 120 Dipper Stroke Limiter ........................................................................................................................ 121 Working with the Dozer Blade General .............................................................................................................................................. 124 Dozing and Grading .......................................................................................................................... 124 Scraping and Cutting ........................................................................................................................ 124 Backfilling .......................................................................................................................................... 124 Slopes General .............................................................................................................................................. 126 Driving on Slopes ............................................................................................................................. 126 Working on Slopes ........................................................................................................................... 128 Heating, Ventilating and Air-Conditioning (HVAC) General .............................................................................................................................................. 130 Air-Conditioning Controls .................................................................................................................. 130 Power Sockets Auxiliary Power Socket ..................................................................................................................... 133 Battery Isolator General .............................................................................................................................................. 134 Fire Extinguisher General .............................................................................................................................................. 135 Moving a Disabled Machine General .............................................................................................................................................. 137 Getting the Machine Unstuck ........................................................................................................... 137 Jump-Starting the Engine ................................................................................................................. 138 Retrieval ............................................................................................................................................ 139 iii

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iii

Table of Contents

Excavator Arm (Emergency Operation) ............................................................................................ Lifting the Machine General .............................................................................................................................................. Transporting the Machine General .............................................................................................................................................. Loading the Machine onto the Transporting Vehicle/Trailer ............................................................. Unloading the Machine from the Transporting Vehicle/Trailer .......................................................... Operating Environment General .............................................................................................................................................. Operating in Low Temperatures ....................................................................................................... Operating in High Temperatures ....................................................................................................... Cab Filters ......................................................................................................................................... Refueling General .............................................................................................................................................. Low Fuel Levels ................................................................................................................................ Filling the Tank .................................................................................................................................. Attachments Working with Attachments Introduction ........................................................................................................................................ Attachments for your Machine .......................................................................................................... Connecting/Disconnecting Hydraulic Hoses ..................................................................................... Impact Protection .............................................................................................................................. Direct-Mounted Attachments General .............................................................................................................................................. Quickhitch Excavator Arm Quickhitch ................................................................................................................ Buckets General .............................................................................................................................................. Bucket Teeth ..................................................................................................................................... Preservation and Storage Cleaning General .............................................................................................................................................. Preparation ........................................................................................................................................ Checking For Damage General .............................................................................................................................................. Storage General .............................................................................................................................................. Put into Storage ................................................................................................................................ During Storage .................................................................................................................................. Take out of Storage .......................................................................................................................... Security General .............................................................................................................................................. JCB Plantguard ................................................................................................................................. LiveLink ............................................................................................................................................. Anti-Vandal Guards ...........................................................................................................................

139 141 143 143 146 148 148 148 149 150 150 150

153 153 154 157 158 161 164 164

169 169 171 172 172 173 173 174 174 174 174

Maintenance Introduction General .............................................................................................................................................. 177 Owner/Operator Support ................................................................................................................... 177 Service/Maintenance Agreements .................................................................................................... 178 iv

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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 ......................................................................................................... Radiator Cover .................................................................................................................................. Tools General .............................................................................................................................................. Toolbox .............................................................................................................................................. Lubrication General .............................................................................................................................................. Preparation ........................................................................................................................................ Attachments General ............................................................................................................................................. Body and Framework General ............................................................................................................................................. Slew Ring Bearings .......................................................................................................................... Pivot Pins .......................................................................................................................................... Operator Station General ............................................................................................................................................. Operator Protective Structure ........................................................................................................... Seat ................................................................................................................................................... Seat Belt ........................................................................................................................................... Controls ............................................................................................................................................. Engine General ............................................................................................................................................. Oil ...................................................................................................................................................... Drive Belt .......................................................................................................................................... Air Filter General ............................................................................................................................................. Pre-Cleaner ....................................................................................................................................... Dust Valve ........................................................................................................................................ Fuel System General ............................................................................................................................................. Tank .................................................................................................................................................. Fuel Filter .......................................................................................................................................... v

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178 179 180 184 184 184 186 189 191 191 192 203 203 204 205 207 209 209 210 210 211 212 212 213 215 215 217 217 218 219 219 221 222 222 222 223 223 224 v

Table of Contents

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 ................................................................................................................................................ Relays ............................................................................................................................................... Window Washer ................................................................................................................................ Miscellaneous Fire Extinguisher ............................................................................................................................... Technical Data Static Dimensions General .............................................................................................................................................. Dimensions ........................................................................................................................................ Weights ............................................................................................................................................. Performance Dimensions Excavator Arm Dimensions and Performance .................................................................................. Driving Performance ......................................................................................................................... Noise Emissions General .............................................................................................................................................. Noise Data ........................................................................................................................................ Vibration Emissions Vibration Data ................................................................................................................................... Fluids, Lubricants and Capacities General .............................................................................................................................................. Fuel ................................................................................................................................................... Diesel Exhaust Fluid (DEF) .............................................................................................................. Coolant .............................................................................................................................................. Torque Values General .............................................................................................................................................. Electrical System General .............................................................................................................................................. Fuses ................................................................................................................................................. Relays ............................................................................................................................................... Batteries ............................................................................................................................................ vi

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225 227 227 228 229 230 231 231 232 233 234 234 235 236 236 237 238 239 239 241

243 244 260 265 312 313 313 314 315 318 321 322 324 343 343 345 346 vi

Table of Contents

Engine Engine Emissions ............................................................................................................................. Exhaust After Treatment (EAT) ......................................................................................................... Tracks General .............................................................................................................................................. Warranty Information Service Record Sheet ....................................................................................................................... Engine Emissions .............................................................................................................................

vii

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vii

Table of Contents

Acronyms Glossary ARV

Auxiliary Relief Valve

DECU

Display Electronic Control Unit

DEF

Diesel Exhaust Fluid

ECM

Engine Control Module

ECU

Electronic Control Unit

EGR

Exhaust Gas Recirculation

FOGS

Falling Object Guard System

FOPS

Falling Object Protective Structure

HVAC

Heating Ventilation Air Conditioning

ISO

International Organization for Standardization

LED

Light Emitting Diode

MAF

Mass Air Flow

Product Identification Number

PPE

Personal Protective Equipment

ROPS

Roll-Over Protective Structure

SAE

Society of Automotive Engineers

SCR

Selective Catalytic Reduction

SWL

Safe Working Load

TAB

Triple Articulated Boom

TOPS

Tip-Over Protective Structure

VGT

Variable Geometry Turbocharger

viii

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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: JS115 02424001 02424600 JS130 02424001 02424600 JS145 02424001 02424600 JS160 02424601 02424850 JS180 02424601 02424850 JS190 02424601 02424850 JS200 02424851 02425350 JS210 02424851 02425350 JS220 02424851 02425350 JS235 02424851 02425350

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, even if you have used machines of a similar/same type before as the technical specification, systems and controls of the machine may have changed. 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.

9821/9967-1

Introduction About this Manual

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 2).

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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: • • •

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

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Introduction Safety

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. In some markets and for work on certain jobsites you may be required to have been trained and assessed in accordance with an operator competence scheme. Make sure that you and your machine complies relevant local laws and jobsite requirements - it is your responsibility. Care and Alertness All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards. 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 jewelry. 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. Cell Phones Switch off your cell 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 cell phone when refueling 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 prevailing legislative requirements. It must not be altered in any way which could affect or invalidate its compliance. For advice consult your JCB dealer.

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Introduction Safety

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, gage, 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 Excavators Limited, Lakeside Works, Rocester, Uttoxeter, United Kingdom, ST145JP

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 markings, and may have been supplied with a Declaration/Certificate of Conformity. These markings 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 markings 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 and in the environmental conditions as described in this manual. When used normally with a bucket fitted the machine the work cycle consists of, digging, elevating, slewing and the discharging of material without movement of the undercarriage. Applications include earthmoving, road construction, building and construction, landscaping and similar applications. An excavator can also be used for object handling if it is suitably equipped with relevant parts and systems. Refer to: Operation > Lifting and Loading (Page 111). The machine is not intended for use in mining and quarrying applications, in demolition activities, forestry, any use underground or in any kind of explosive atmosphere. If the machine is to be used in applications where there is a high silica concentration, risk due to materials containing asbestos or similar hazards, additional protective measures such as the use of PPE (Personal Protective Equipment) may be required. The machine should not be operated by any person who does not have an appropriate level of qualification, training or experience of use of this type of machine. Prior to use of the machine, its suitability (size, performance, specification etc.) should be considered with regards to the intended application and any relevant hazards that may exist. Contact your JCB dealer for support in determining the appropriate JCB machine, attachment and any optional equipment that is suitable for the application and environment.

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. The danger zone includes the area in immediate proximity to any hazardous moving parts, areas into which working equipment and attachments can be moved to quickly, the machine normal stopping distances and also areas into which the machine can quickly turn under normal conditions of use. Depending on the application at the time, the danger zone could also include the area into which debris, from use of an attachment or working tool, could be projected and any area into which debris could fall from the machine. During the operation of the machine, keep all persons out of the danger zone. Persons in the danger zone could be injured. Before you do a maintenance task, make the product safe. 8

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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

The boom dipper and bucket are collectively referred to as the excavator end, or dig end.

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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

8085

01536000

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

Description World manufacturer identification. For example, JCB = UK Build. Machine type and model. For example, 8025 = 8025. Random check letter. The check letter is used to verify the authenticity of a machine's PIN. Machine serial number.

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About the Product Product and Component Identification

Figure 5. JCB HEAVY PRODUCTS LTD. LAKESIDE WORKS, ROCESTER, UTTOXETER UNITED KINGDOM, ST14 5JP

MADE IN THE UK

Product Identification Number PIN, ISO10261

WEIGHT (kg), ISO 6016 YEAR OF MANUFACTURE

ENGINE SERIAL NUMBER

TYPE

ENGINE POWER (kW @ RPM) ISO 14396

DESIGNATION

JCB HEAVY PRODUCTS LTD. LAKESIDE WORKS, ROCESTER, UTTOXETER UNITED KINGDOM, ST14 5JP

Product Identification Number PIN, ISO10261

OPERATING MASS (kg) ISO6016

YEAR OF MANUFACTURE

DESIGNATION

ENGINE SERIAL NUMBER

YEAR OF MODEL

TYPE

ENGINE POWER (kW @ RPM) ISO 14396

334/J9252

Identification plate

Engine The engine data labels are attached to the cylinder block as shown. Figure 6.

B B D A B C D

Engine data label - rocker cover Engine data label - tread plate Engine identification number Stamp

The data label includes the engine identification number. 11

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About the Product Product and Component Identification

Table 3. Example of the engine identification number SD 1-2

Digit

320/40001 3-10

U 11

00001 12-16

04 17-18

Table 4. Digit 12 SJ SL DJ

Engine Type 4.4L (1USgal) turbocharged and aftercooled electronic common rail fuel injection (tier 4F) >55kW (73.7hp) 4.4L (1USgal) turbocharged and aftercooled electronic common rail fuel injection (tier 4F) <55kW (73.7hp) 4.8L (1 ⁄2USgal) turbocharged and aftercooled electronic common rail fuel injection (tier 4F) >55kW (73.7hp) 1

4.8L (1 ⁄2USgal) turbocharged and aftercooled electronic common rail fuel injection (tier 4F) <55kW (73.7hp) 1

Table 5. Explanation of the engine identification number Digit 3-10 11 12-16 17-18

Explanation Engine part number Country of manufacture. U = United Kingdom Engine serial number Year of manufacture

The country of manufacturer, engine serial number and year of manufacture of the engine are also stamped on the cylinder block. Refer to Figure 6.

Operator Protective Structure WARNING Machines with a ROPS, FOPS,FOGS or TOPS are equipped with a seat belt. The ROPS, FOPS,FOGS or TOPS is designed to give you protection in an accident. If you do not wear the seat belt you could be thrown off the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine. WARNING Modified and wrongly repaired ROPS, TOPS and FOGS are dangerous. Do not modify the TOPS. Do not attempt to repair the ROPS, TOPS and FOGS. If the ROPS, TOPS and FOGS has been in an accident, do not use the machine until the structure has been examined and repaired. This must be done by a qualified person. For assistance, contact your JCB dealer. Failure to take precautions could result in death or injury to the operator.

FOGS Data Plate WARNING Do not use the machine if the falling objects protection level provided by the structure is not sufficient for the application. Falling objects can cause serious injury. If the machine is used in any application where there is a risk of falling objects then a FOGS (Falling Object Guard System) must be installed. For further information, contact your JCB dealer. The FOGS has a data plate attached. The data plate indicates what level of protection the structure provides. There are two levels of FOGS: • •

Level I Impact Protection - impact strength for protection from small falling objects (e.g. bricks, small concrete blocks, hand tools) encountered in operations such as highway maintenance, landscaping and other construction site services. Level II Impact Protection - impact strength for protection from heavy falling objects (e.g. trees, rocks) for machines involved in site clearing, overhead demolition or forestry. 9821/9967-1

About the Product Product and Component Identification

Figure 7.

The cab mounted FOGS available for the JS excavator range are tested to ISO 10262 level 2 and comply with EN 13627:2000. The frame mounted FOGS available for the JS excavator range are tested to ISO 3449 level 2 and comply with EN 13627:2000.

ROPS Data Plate WARNING Your machine may be fitted with a Roll-Over Protective Structure (ROPS) indicating that the purchaser specified the machine for use in applications where there is risk of roll-over. ROPS is a device to protect the operator in the event of roll-over. Any damage or modification to the structure may invalidate the ROPS certification. If damage has occurred then an authorised JCB dealer should be consulted. An excavator with a ROPS (Roll-Over Protective Structure) can be identified by referring to the identification plate. Work place (work site, job site) risk assessment should facilitate the machine selection and the need for an excavator with a ROPS.

TOPS Data Plate An excavator with a TOPS (Tip-Over Protective Structure) can be identified by referring to the cab identification plate. Work place (work site, job site) risk assessment should facilitate the machine selection and the need for an excavator with a TOPS. Figure 8.

XXXX

XXXX XXXX

XXXX

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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. 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 9. A

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About the Product Safety Labels

Figure 10.

Table 6. Safety Labels Item A

Part No. 332/J2896

B C

817/70005 332/P4679

D E F

817/70024 817/70003 817/70116

G H J

817/18541 817/19470 332/J9693

Description (Combination label) The coolant is under pressure. Risk of severing of hands/fingers in the rotating parts. Hot surfaces. Remove the ignition key and refer to the operator's manual and the service manual. Hot fluid under pressure. Do not touch, consult operator's manual. Severing of hands and fingers. Keep clear of/do not reach into rotating parts. Read the Service Manual. Warning. Do not use as a step. Crushing/shearing of hands. Do not touch. Fall. Unexpected machine movement due to accidental contact with the controls when the hydraulics are not isolated. Read the operator's manual before you operate the machine. The arm or bucket may move, keep clear. (Combination label) The bucket can foul the boom when dipper is swinging inwards. Maintain the clearance between the bucket and boom. Danger of collision, maintain the clearance between the bucket and cab. Risk of tripping, raise the control lock lever before you exit the machine. Risk of injury by crushing, do not lean out of the window. Risk of electrocution, maintain the minimum clearance recommended by your local electricity supplier. 9821/9967-1

Qty. 1 1 1 1 1 1 1 1 1

About the Product Safety Labels

Item K L M

Part No. 817/70027 817/70001 333/J2439

N O

332/F5860 817/18532

335/E7623

Description Crushing of whole body. Keep a safe distance. Falling hazard. Keep a safe distance from the edge. Strike to the whole body (machine swing). Keep a safe distance from the machine. Hot fluid under pressure. Read the Operator's Manual. 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. Burns to fingers and hands. Keep a safe distance from machine.

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Qty. 1 1 1 1 1 1

About the Product Operator Station

Operator Station Component Locations Figure 11. B

A C

Q P N

F G

H J

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

Left hand track control,Refer to: Operation > Drive Controls > Track Controls (Page 66). DECU (Display Electronic Control Unit)Refer to: Operation > Instruments > Instrument Panel (Page 70). Right hand track control,Refer to: Operation > Drive Controls > Track Controls (Page 66). Optional circuit pedal,Refer to: Operation > Operating Levers/Pedals > Auxiliary Circuit Controls (Page 108). Right joystick,Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 99). Machine power band controller,Refer to: Operation > Instruments > General (Page 69). Ignition switch,Refer to: About the Product > Interior Switches > Ignition Switch (Page 21). Dozer lever, Right switch console,Refer to: About the Product > Console Switches (Page 18). 12V auxiliary power socket,Refer to: Operation > Power Sockets > Auxiliary Power Socket (Page 133). Door lever,Refer to: Operation > Doors > Operator Door (Page 36). Left switch console,Refer to: About the Product > Console Switches (Page 18). Controls isolation lever,Refer to: Operation > Locks > Control Lock (Page 64). Seat,Refer to: Operation > Operator Seat (Page 45). Left joystick,Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 99).

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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 12. 1

A B

Graphic symbol Light bar

Work Lights 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.

Beacon Two or three position rocker switch. The switch functions operate when the ignition switch is in the on and off positions. Position : 1 = Off Position : 2 = Cab beacon on Position : 3 = Cab and two rear beacons on (option). Refer to: Operation > Preparing for Travel > Beacon (Page 63).

Seat Heater Two position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Heater off, suspension adjustment on Position : 2 = Heater on, suspension adjustment off.

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About the Product Console Switches

Seat Ventilation Two position rocker switch. The switch functions operate when the ignition is in the on position. Position : 1 = Seat ventilation off Position : 2 = Seat ventilation on

Control Locks 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.

Excavator Arm Quickhitch Three position rocker switch. The switch functions operate when the ignition switch is in the on position and the controls are active. Position : 1 = Quickhitch deactivate Position : 2 = Off Position : 3 = Quickhitch activate.

Radio Mute Two position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Radio is on Position : 2 = Radio is muted.

Engine Stop Switch Two position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Engine run Position : 2 = Engine stop. Engine cannot be cranked.

SCR Refresh Two position momentary rocker switch. The switch functions operate when the ignition switch is in the on positions. Position : 1 = Off Position : 2 = SCR initiate/defer Refer to: Operation > Instruments > Instrument Panel (Page 70).

Slew Lock 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.

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About the Product Console Switches

Cushion Two position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Off Position : 2 = On.

Window Washer Two position momentary rocker switch. The switch functions when the ignition switch is in the on position. The window washers will operate as long as the switch is held in the momentary position. The upper wiper will operate automatically as the window is washed. Position : 1 = Off. Window washers are off. Position : 2 = Momentary position. Window washers are on.

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.

Front Lower Window Wiper Three position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Off Position : 2 = Upper wiper continuous on Position : 3 = Momentary position. Window washers upper and lower are on.

Cab Raise/Lower Three position rocker switch (spring loaded). The switch functions operate when the ignition switch is in the on position and the engine is running. Position : 1 = Cab raise (Push and hold) Position : 2 = Neutral Position : 3 = Cab lower (Push and hold).

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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 13. A

B A B

Ignition switch Ignition key Table 7. Switch Positions

Position 0 I II III

Function Off/Stop the Engine: Turn the ignition key to this position to stop the engine. Make sure the controls are in neutral and the excavator and dozer are lowered before you stop the engine. 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. When the cab interior light is in the center position, it will turn on automatically when the cab door is opened and turn off when the door is closed. A timer will switch off the cab interior light if the cab door is left open for prolonged periods. Make sure the cab interior light is turned off when you intend to leave the machine for a long period of time.

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About the Product Interior Switches

Figure 14.

Cab interior light

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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 Training Make sure that you have had adequate training and that you are confident in your ability to operate the machine safely before you use it. Practice using the machine and its attachments until you are completely familiar with the controls and what they do. With a careful, well trained and experienced operator, your machine is a safe and efficient machine. With an inexperienced or careless operator, it can be dangerous. Do not put your life, or the lives of others, at risk by using the machine irresponsibly. Before you start to work, tell your work mates what you will be doing and where you will be working. On a busy site, use a signalman. Before doing any job not covered in this manual, find out the correct procedure. Your local JCB distributor will be glad to advise you. Fuel Fuel is flammable, keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refueling 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.

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Operation Operating Safety

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, vapor 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 vapors, gas or dust, without first consulting your JCB dealer. Regulations Obey all laws, worksite and local regulations which affect you and your machine. 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. Traveling at High Speeds Traveling 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. Modification of the machine's configuration by the user (e.g. the fitting of large and non-approved attachments) may result in a restriction of the machine visibility. 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.

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Operation Operating Safety

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. 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 practicing them. Practice 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 fiber optic cable, Do not look into the end of it, your eyes could be permanently damaged. An applicable worksite organization is required in order to minimize hazards that are caused by restricted visibility. The worksite organization is a collection of rules and procedures that coordinates the machines and people that work together in the same area. Examples of worksite organization include: â&#x20AC;˘ â&#x20AC;˘ 26

Restricted areas Controlled patterns of machine movement 9821/9967-1

Operation Operating Safety

•

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. 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 supervizor 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 tires 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 tires? Are there any obstacles or hazards in the area, for example, debris, excavations, manhole covers, power lines? Is the space sufficient for safe maneuvering? Are any other machines or persons likely to be in or to enter the area while operations are in progress?

The Route to be Traveled • 27

How solid is the ground, will it provide sufficient traction and braking? 9821/9967-1

Operation Operating Safety

•

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. 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 229). 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 203). 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 controls isolation lever is in the fully raised position. 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 36). 2. Make sure that the controls lock lever is in the raised position. Refer to: Operation > Locks > Control Lock (Page 64). 3. Hold the two handrails (one each side of the cab entrance), then use the step between the top and bottom tracks to climb onto the top of the track. Refer to Figure 15. Figure 15. A

C B B

A B C

Handrails Step Track

4. Keep hold of the left handrail, then climb into the cab and swing yourself into the operator's 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 99). 30

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Operation Entering and Leaving the Operator Station

3. Stop the engine. 4. Turn the ignition key to the on position. 5. Operate the hydraulic controls several times to release any residual hydraulic pressure in the system. Refer to: Operation > Moving a Disabled Machine > Excavator Arm (Emergency Operation) (Page 139). 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 step. Refer to Figure 16. Figure 16. A

C B B

A B C

Handrails Step Track

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

Hydraulically Raised Cab Introduction Read and understand this section before you start working with the machine. The hydraulically raised cab is raised and lowered through a pantograph linkage operated by a pair of hydraulic cylinders. The cab raise/lower switch installed in the cab controls the hydraulic cylinders. Refer to: About the Product > Console Switches > Cab Raise/Lower (Page 20). WARNING! Keep yourself and all others away from the lifting mechanism. Never allow persons to walk below a raised cab at any time. Do not carry passengers. WARNING! Only raise/lower the cab if the environment is safe. Do not lower the cab if persons are within a 1 radius of 5m (5 â &#x201E;2yd) WARNING! Do not work below a raised cab unless the cab is secured in position and safely supported.

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Operation Entering and Leaving the Operator Station

Entering the Cab 1. Open the cab door and if necessary latch it in the open position. 2. Make sure that the controls lock lever is in the raised position. 3. Hold the two handrails (one each side of the cab entrance), then use the step between the top and bottom tracks to climb onto the top of the track. Refer to Figure 17. Figure 17.

B C

A B C

Handrail Handrail Step

4. Use the handrails to side-step to the cab entrance. Refer to Figure 18. Figure 18.

B C

B D

Handrail Handrail

5. Keep hold of the left handrail, then climb into the cab and swing yourself into the operator's seat. 6. Close the door.

Raising the Cab 1. Get access to the cab, refer to Entering the Cab. 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. 32

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Operation Entering and Leaving the Operator Station

2. Fasten the seat belt. Refer to: Operation > Seat Belt (Page 48). 3. Start the Engine. Refer to: Operation > Starting the Engine (Page 57). 3.1. An alarm will sound if the door is open. 4. Operate the horn. 5. Push and hold the cab raise/lower switch until you get to the required or maximum position of the cab. Release the switch to stop the movement. Refer to: About the Product > Console Switches > Cab Raise/Lower (Page 20). When the cab is fully raised, the position of the cab is 590mm (23in) forward and 2,140mm (84 â &#x201E;2in) higher than when it is fully lowered. 1

Lowering the Cab 1. Park the machine on solid, level ground with the upper structure parallel to the undercarriage. 2. Operate the horn. 3. Push and hold the cab raise/lower switch until you get to the required or lowest position of the cab. Release the switch to stop the movement. 4. Stop the engine and remove the ignition key. 5. Make sure the cab is at its lowest position before you leave the cab. (Refer to Leaving the Cab.)

Leaving the Cab 1. Park the machine on solid, level ground with the upper structure parallel to the undercarriage. 2. Stop the engine. 3. Turn the ignition key to the on position. 4. Operate the hydraulic controls several times to release any residual hydraulic pressure in the system. 5. Turn the ignition key to the off position. 6. Open the cab door and secure it in the open position. 7. Raise the controls lock lever. 8. Leave the cab. (Reverse the instructions of Entering the Cab).

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Operation Entering and Leaving the Operator Station

Emergency Exit Standard Cab Figure 19.

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.

Hydraulically Raised Cab Emergency Lowering of the Hydraulic Cab Introduction If the cab cannot be lowered because of a hydraulic failure or a failure of the switch, an emergency lowering valve is installed in the cab to the left of the operator, down the side of the seat. An emergency switch and secondary emergency lowering valve are installed inside the battery compartment. If the door cannot be used turn the backrest of the seat fully forward/down. Use the glazing breaker to hit the rear window near the corner to shatter the window. Emergency Lowering Valve - Cab 1. Locate the emergency valve lever. Refer to Figure 20. 2. Make sure it is safe to lower the cab. 3. Raise the emergency valve lever until the cab is at its lowest position. 4. When the fault is corrected make sure the emergency valve lever is reset (pushed down). This will prevent an oil leakage and the incorrect operation of the system.

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Operation Entering and Leaving the Operator Station

Figure 20. A

Emergency valve lever

Emergency Switch - Battery Compartment 1. Get safe access to the emergency switch in the battery compartment. Refer to Figure 21. 2. Make sure it is safe to lower the cab. 3. Press the emergency switch downwards until the cab is at its lowest position, then release the emergency switch. Figure 21.

C B B C

Emergency switch Emergency valve control knob

Secondary Emergency Lowering Valve - Battery Compartment 1. Get safe access to the emergency valve control knob in the battery compartment. Refer to Figure 21. 2. Make sure it is safe to lower the cab. 3. Turn the emergency valve control knob anticlockwise until the cab is at its lowest position. 4. When the fault is corrected make sure the emergency valve control knob is turned fully clockwise. This will prevent an oil leakage and the incorrect operation of the system.

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Operation Doors

Doors Operator Door To open the door from the outside, unlock it with the key provided and pull the handle towards you to release the latch. To open the door from inside, pull the lever towards you. Figure 22. 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 pull the lever in the cab up.

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Operation Doors

Figure 23.

Lever

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Operation Windows

Windows Front Window Depending on machine specification, windows are provided to function as guards. Damaged windows must be replaced with those of equivalent specification before the machine is used again. Is is the responsibility of the operator to assess whether the attachment they are using and/or the operation they are performing requires the protection offered by a screen. Keep the windows closed when there is a risk of flying debris.

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, press and hold down the buttons. 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 24. C

A B C

Handles Buttons Latches

To close the window: 1. Hold the handles, press and hold down the buttons. 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.

Removing and Installing the Front Window Lower Panel When the lower window is removed it must be securely stowed behind the operator seat in its correct stowage position. Before the lower window is removed, turn the ignition off and isolate the machine hydraulics. Refer to: Operation > Locks > Control Lock (Page 64). 38

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Operation Windows

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 the window can be removed. Pinch the locks between finger and thumb and pull the window out of the brackets at the bottom of the frame. Figure 25.

D E F

Locks Lower latch positions Brackets

To stow the front lower window: 1. Locate the bottom edge of the window into the lower latches. 2. Pinch the locks between finger and thumb and locate the locks into the upper latches. Figure 26.

G H J

Locks Lower latches Upper latches

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.

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Operation Windows

To open the window, operate the latch and slide the window to the required position. To close the window, slide the window fully shut and check that the latch has located into position at one of the slots. Figure 27. A B

A B

Latch Slot

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Operation Sun Visor/Sunblind

Sun Visor/Sunblind Sunblind Standard Sunblind The sunblind is installed in the cab roof and can be secured in three positions: 1. Use the handle in the centre of the sunblind lower edge to pull the sunblind forward. Figure 28.

Handle

2. Attach both sides of the sunblind edge on to the front hooks or upper hooks. Figure 29.

B C

Front hooks Upper 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.

Optional Sunblind - Full Length The sunblind is installed at the top of the cab front window and can be secured in three positions on the front window or alternatively secured in position on the ceiling: 1. Use the handle in the center of the sunblind lower edge to pull the sunblind downwards or backwards. 2. Attach both sides of the sunblind edge on to the front hooks or upper hooks. 41

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Operation Sun Visor/Sunblind

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. Figure 30. C

A B C

Handle Front hooks Upper hooks

Optional Sunblind - Half Length The sunblind is installed at the top of the cab front window and can be secured in a position to suit the operator: 1. Use the handle in the center of the sunblind lower edge to pull the sunblind down to the required position. The sunblind will hold itself in position. 2. To release the sunblind, gently pull the hoop, while holding the handle and let the sunblind slowly rewind back into the stowed position. Figure 31.

B A B 42

Handle Hoop

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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. WARNING Secure all loose articles. Loose articles can fall and strike you or roll on the floor. You could be knocked unconscious, or the controls could get jammed. If that happens you could lose control of the machine. CAUTION Machines installed with hose burst protection valves cannot have their attachments lowered with the engine stopped. Start the engine and lower the attachments before doing the walk-around inspection. 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 148). 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 223). 3. Lower the excavator bucket and dozer to the ground, if they are not already there. They will lower themselves under their own weight when you operate the controls. Operate the controls carefully to control the rate of descent. Refer to: Operation > Operating Levers/Pedals (Page 99). 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 29). 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. Examine the ROPS (Roll-Over Protective Structure), FOPS (Falling Object Protective Structure) and FOGS (Falling Object Guard System) for damage. Get your JCB dealer to repair any damage. Make sure all securing bolts are installed and correctly tightened. Refer to: Maintenance > Operator Station > Operator Protective Structure > Check (Condition) (Page 215). 4.7. Check around the cab for loose or missing bolts, screws etc. Replace or tighten where necessary. 4.8. Check the excavator lever gaiters are not damaged or loose, replace or attach as required with new fasteners. 4.9. Examine the seat belt and its mountings for damage and excessive wear. Refer to: Maintenance > Operator Station > Seat Belt > Check (Condition) (Page 217). 4.10.Make sure that the following operate correctly: lights, horn, all switches, front window washer and wipers (if installed). Refer to: Maintenance > Electrical System (Page 236). 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 45). 6. Adjust the rear view mirrors (where applicable) to give you a good view close behind the machine, when you are correctly seated. 43

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Operation Before Starting the Engine

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. Stop using the machine if the operator's seat becomes defective. Repair or replace the seat before using the machine again.

Suspension Seat Seat Adjustments Cushion Tilt Lift the cushion tilt lever and use your weight to adjust the height of the front of the cushion as required. Release the lever.

Cushion Slide Lift the cushion slide lever and slide the cushion into the required position. Release the lever.

Armrest To position the armrests, turn the armrest adjusters on the underside of each armrest.

Backrest Lift the backrest lever and move the backrest to the required angle. Release the lever.

Weight Turn the suspension adjuster or the push/pull lever to increase or decrease the suspension of the seat to match the operator weight. Check the indicator.

Console Fore/Aft Lift the console fore/aft lever and slide the console into the required position. Release the lever. Make sure the console is locked in position.

Lumbar Turn the lumbar adjuster to increase or decrease the lumbar support.

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Operation Operator Seat

Seat Options Mechanical Suspension Seat Figure 32.

G F A B C D E F G

Cushion tilt lever Cushion slide lever Armrest adjuster Backrest lever Indicator Suspension adjuster Console fore/aft lever

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Operation Operator Seat

Heated Air Suspension Seat Figure 33. H

G F A B C D E F G H

Cushion tilt lever Cushion slide lever Armrest adjuster Backrest lever Indicator Suspension adjuster Console fore/aft lever Lumbar adjuster

Heated Seat Controls A switch on the left console operates the heated seat. Refer to: About the Product > Operator Station > Component Locations (Page 17). The seat heater is controlled by a thermostat. When the heated seat is on, the adjustment of the seat weight may not be possible.

Seat Ventilation Controls A switch on the left console operates the ventilated seat. Refer to: About the Product > Console Switches (Page 18). . 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 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 a slope. Figure 34.

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 and pull. The seat belt should 'lock'. Refer to Figure 35.

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Operation Seat Belt

Figure 35.

C D

Seat Belt Button

Release the Seat Belt WARNING Release the seat belt only after safely stopping the machine, 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 36. 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 37. D A

A B C D

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

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Operation Seat Belt

Figure 38. 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 operator's 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. Figure 39.

A B C

Mirror position Mirror position Mirror position

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Operation Mirrors

Cab Mirrors - Position A and B 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 40.

D,E F

D E F

Cap-screw Nut Protective cap

Rear Mirror - Position C Secure the mirror to the counterweight: 1. Remove the bolt from the mounting lug on the counterweight. 2. Use the bolt, spring washer and washer to secure the mirror support to the counterweight. 3. Remove the protective cap from the back of the mirror and tighten the nut to secure the mirror to the support. 4. Replace the protective cap after the adjustment. Do not fully tighten the fittings until the mirror is adjusted correctly.

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Operation Mirrors

Figure 41.

G H

L M F G H L M

Protective cap Bolt Spring washer Washer Mirror support

Hydraulically Raised Cab Mirror Secure the mirror to the screen guard: 1. Use the bolts provided with the mirror support in place of the bolts in the screen guard. 2. Secure the flexible portion of the mirror support with the nuts and bolts. 3. Remove the protective cap from the back of the mirror and tighten the nut to secure the mirror to the support. 4. Replace the protective cap after the adjustment. Do not fully tighten the fittings until the mirror is adjusted correctly. Figure 42. G D,E

F D E F G

Cap-screw Nut Protective cap Bolt

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. 54

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Operation Mirrors

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 (39in) above 1 14 ground level and a width of 0.75m (29 ⁄2in), continuing to a width of 3.5m (138in) at ground level, 30m (98 ⁄32ft) behind the rear end of the machine. Figure 43. Side Mirror Y A

V B

T A B C D T V X Y Z

Field of vision Filament position center point Outer borderline Inner borderline Measurement at ground level 1 Measurement at 1m (39 ⁄2in) above ground level 3.5m (138in) 14 30m (98 ⁄32ft) 1 750mm (29 ⁄2in)

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Operation Mirrors

Rear Mirror 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.

Hydraulically Raised Cab Mirror 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 hazardous zone below the cab during raising and lowering and a 1m (1yd) zone along the side of the machine and front.

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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. CAUTION Do not use ether or other starting fluids to assist cold starting. Using these fluids may result in an explosion causing possible injury and/or damage to the engine. 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 43). 2. Make sure the controls isolation lever is raised. 3. If the machine has an immobilizer then you must disarm the immobilizer before you can start the engine. 4. Turn the ignition key to the on position. Figure 44. 0

1 2

0 1 2 3

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

5. Check the DECU (Display Electronic Control Unit) for error messages. Correct any critical faults before starting the engine. 6. Sound the horn as a warning. 7. 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 8. If the engine does not start, turn the ignition key to the off position. 9. Let the starter motor cool for a few minutes before you repeat the steps 7 and 8. 10. When the engine has started, check the DECU for critical faults. If any critical faults are displayed, stop the engine as soon as it is safe to do so. 11. Warm the engine and hydraulics. Refer to: Operation > Starting the Engine > Warming Up (Page 59).

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Operation Starting the Engine

Immobilizer Introduction If your machine has an immobilizer system installed, then your JCB dealer must enable the system as part of the standard machine installation.

Coded Immobilizer System Introduction Before you try to disarm the immobilizer, make sure that the machine is ready to start and that you have your four digit security code available. If you are unsure of the security code, then do not start this procedure. If the security code is incorrectly entered five times the immobilizer will lock. 15min If this occurs, it is recommended that you contact the machine owner for confirmation of the security code. The security code must be entered every time that the ignition key is in the off position for more than the time specified. 2min

Disarm the Immobilizer 1. Put the ignition key in the ignition switch. 2. Turn the ignition key to the on position. 3. Push the rotary control. Refer to: Operation > Instruments > General (Page 69). 4. Turn the rotary control left or right to display the first digit. Figure 45.

5. Repeat for digits 2 to 4. 6. Push rotary control button to finalize the security code entry. 7. If the correct security code is entered, a grey unlocked padlock is displayed for a very short time and the machine can be started.

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Operation Starting the Engine

Figure 46.

8. If an incorrect security code is entered a red locked padlock is displayed. Turn the ignition key to the off position and repeat steps 2 to 5. A divided bar under the PIN numbers shows the number of tries left. 8.1. After five failed tries the system will lock. Duration: 15min 8.2. A red locked padlock is displayed with a minute timer. For the time to expire the ignition must be left on. Figure 47.

Arm the Immobilizer 1. Stop the engine. 2. Remove the ignition key. The immobilizer arms automatically after the time specified. Duration: 2min 3. If you restart the engine within the time, the system disarms automatically.

Add/Change/Delete a Security Code Immobilizer codes can only be added, changed or deleted using JCB Servicemaster software. Contact your local JCB dealer.

Warming Up Before starting work in temperatures below -15Â°C (5.0Â°F), the hydraulic fluid must be warmed. 1. Warm up the engine. 1.1. Start the engine. 1.2. Do not operate any services. 2. After the warm up period make sure that everyone is clear of the machine. 3. Warm up the hydraulic oil. 3.1. Increase the machine power to maximum. 59

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Operation Starting the Engine

3.2. Warm up the hydraulic oil by repeatedly selecting bucket crowd by moving the right hand lever to the left for: Duration: 5s 3.3. Repeat for several minutes. 3.4. Select dozer up (if installed) by moving the dozer control lever backward, keep it selected for: Duration: 1min 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 in both directions fully five times. 4.5. Slew the upper structure clockwise for one revolution and stop. 4.6. Slew the upper structure anticlockwise 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. 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. 1. Stop the machine. Refer to: Operation > Drive Controls > Track Controls (Page 66). 2. Align the upper structure and undercarriage to allow you to use the handrails and steps. 3. Lower the attachment. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 99). 4. If applicable, lower the dozer blade. Before you stop the engine, run it at idle speed for 30s, to let the turbocharger cool down. 1. Stop the engine. 1.1. Press the controls isolation switch. Refer to: Operation > Locks > Control Lock (Page 64). 1.2. Turn the ignition key to the 0 position. Figure 48. 0 1 2

0 1 2 3

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

2. If you are going to leave the machine, remove the ignition key and make sure that all unnecessary switches are set to off. 3. Leave and secure the machine: 3.1. Lift the controls isolation lever. Refer to: Operation > Locks > Control Lock (Page 64). 3.2. If you are leaving the machine for a long period, close and latch the window(s) and lock the door. 3.3. Use the handrails and steps to leave the cab. Refer to: Operation > Entering and Leaving the Operator Station > General (Page 30). 3.4. Make sure that the fuel filler cap is locked (if a lock is installed). 61

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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 63). 2. Move the cab so that it faces forward over the dozer blade. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 99). 3. If applicable, lift the dozer blade. 4. Uneven worksite conditions: Lower the boom so that the bucket or attachment is clear of the ground. Figure 49.

B A B

Beacon 150mm (6in)

5. Level worksite conditions: 5.1. All machines except the long reach models: fold the attachment as shown, so that the attachment is a sufficient distance from the ground. Distance: 500mm (19 â &#x201E;2in) 1

Figure 50.

5.2. Long reach machines: install the tracking strut to support the dipper and move the excavator to the position shown.

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Operation Preparing for Travel

Figure 51.

Tracking strut

Beacon In certain territories you will break the law if you do not install a beacon before you travel on site/public highways, make sure you comply with the local laws. Be careful when you operate the machine with a beacon. The total height of the machine is increased when the beacon is in the operating position. 1. Put the beacon on the cab roof. A magnetic base keeps the beacon in position. Figure 52. A

A B C

Beacon Plug Socket

2. Put the plug into the socket. 3. Use the beacon switch in the cab to operate the beacon. The indicator light in the switch illuminates when the beacon is operating. Refer to: About the Product > Console Switches (Page 18).

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Locks General WARNING The slew lock must be engaged when traveling on road or trailer, otherwise the boom could slew 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 machine's hydraulic controls: 1. Raise the controls isolation lever. Refer to: Operation > Locks > Control Lock (Page 64). 2. Push the controls isolation switch. Refer to: About the Product > Console Switches > Control Locks (Page 19). If either of the two methods of isolating the hydraulic controls is used, the other method cannot be used to reactivate the controls. WARNING! Activate the drive and lift arm isolation switches 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 by activating drive and lift arm isolate switches.

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 53. 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 machine is fitted with hydrostatic track motors. The motors have a built-in spring-applied parking brake which is automatically applied shortly after the pressure feed is removed from the motor. The operator is able to control the feed to the motors by means of two pedal and lever operated valves mounted under the cab floor. When the pedal/lever is released the valve automatically returns to the central position which removes the motor feed. Service braking is accomplished by a counterbalance system built into the motor. The system is designed so that the machine is stopped by the hydraulic braking when the feed is reduced/removed and then held by the mechanical parking brake when it has stopped. The motors are of the swash plate type with two swash angles. The angle is set by hydraulically operated pistons which can be controlled by the operator (by means of an electrical switch). When these rams receive servo pressure, the motor swash angle is reduced, reducing tractive effort but increasing speed for a given flow and pressure. The motors automatically shift to the higher swash angle if the pressure rises above a threshold. 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 forward, (towards the recoil units). Before a travel lever/pedal is moved, check if the undercarriage faces forward or backward. Figure 54. 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 traveling, do not put your feet on the travel pedals. Push the left and right travel levers slowly forward, to travel forward or pull them toward you, to travel backward.

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Operation Drive Controls

Figure 55.

To turn the machine to the right, push the left travel lever forward. To turn the machine to the left, push the right travel lever forward. 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 67). The simultaneous movement of the left and right travel levers, moved in the opposite directions will cause the machine to turn around its center. To move the machine backward in a straight line pull both levers in a backward motion equally. Both tracks will operate in a reverse direction.

Travel Speed Selector Figure 56.

AUTO

n/min n/min

H+

Travel speed change button

The travel speed of the machine can be changed between fast, creep and slow. (The travel speed is recorded when the engine is shut down and the travel speed is re-applied at the next engine start-up.) Each press of the travel speed change button selects as follows: Fast, Slow, Creep, Slow, Fast, Slow, Creep etc. Dependant on the machine software installed it may be necessary to press and hold the travel speed change button for 1.5s to select creep speed. 67

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The travel speed selected is shown in the top left corner of the DECU (Display Electronic Control Unit): Figure 57. B

B C D

Fast (hare) Slow (tortoise) Creep (snail)

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Instruments General Machine Power Band Controller The machine power band controller matches engine speed and hydraulic pump output dependent on the machine power selected by the operator. Machine power can be varied from Light (L), General (G), Heavy (H) and Heavy Plus (H+) using the rotary control. The machine power selected is displayed on the DECU (Display Electronic Control Unit) with bars. Refer to: Operation > Instruments > Instrument Panel (Page 70). Small, slow rotation of the rotary control offers precise control of machine power. Large, fast rotation of the rotary control gives a large jump up or down the power band. Figure 58.

H+

Table 8. Display Bars 0 1 2 3 4 5 6 7 8

Machine Power Idle L1 L2 L3 G1 G2 G3 H H+

At idle and low power there will be no bars on the DECU. Powers L1,L2 and L3 are for precision and lifting operations. These powers give you low hydraulic pump flow but permanent high pressure (two stage relief activated). This allows a precise control of the services for accuracy. The auto idle function is not active, only one touch idle can be used. Overload caution is on Powers G1,G2 and G3 are for general operations. These powers have increased engine speed, increased hydraulic pump flow without permanent power boost. These powers are for general digging and loading work with good fuel efficiency. Power boost is selectable. The DECU will not give any indication if you use the power boost button. Each power boost will give you 3s of higher hydraulic power for extra tearout. Once the 3s has elapsed the system will automatically deactivate for 9s. The DECU will not give any indication of this occurring. Power H is for heavy duty operations. Fuel economy is reduced. High speed operation of all hydraulic functions/ services is enabled. Selectable power boost is also available as per general mode. H+ is for very heavy digging or increased work output. To select H+ first select power H using the rotary control. Then press the H+ button on the power band controller to select H+ power. If the machine power does not change even after turning the control it is because the auto idle button or one touch idle is selected. Refer to Figure 59. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 99). When the engine is started in ambient temperatures between -19째C (-2.2째F) and 2째C (35.6째F) the machine will default to engine idle for between 2s and 30s Press the automatic idle button to activate the automatic engine idle system. The engine speed will drop to idle when the machine has been idle for 5 seconds. The time delay can be adjusted by the DECU. 69

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Figure 59.

AUTO

n/min n/min

H+

A B C

Rotary control Automatic idle button H+ button

Instrument Panel The color display is located at the front of the cab in the line of sight from the operator's seat. It provides the interface with the machines electronic system.

4 Inch Color Display The display has mechanical gages for fuel level and engine coolant temperature as well as a digital display. Figure 60.

7 Inch Color Display The display is digital. The digital display can incorporate images from multiple cameras (option). When the operator switches of the ignition and leaves the cab (closing the door) the display will remain in a sleep state for 90min. After this time the display will automatically shut down. 70

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To wake the display from sleep state open the cab door. The display will become active within 12s. During this time it is still possible to start the engine. Figure 61.

Camera system WARNING The camera system is a supplementary vision device that requires the operator to use it in conjunction with the rear view mirror and side mirrors for maximum coverage. WARNING If the camera image is not clear or seems distorted, it may be covered with water droplets, snow, mud or any other substance. If this occurs, clean the camera lens before using the camera system. Clean the lens with a soft, lint-free cloth and non-abrasive cleaner. The camera(s) contain automatic heaters that de-mist/de-frost the lens automatically. Do not rely on the rear view camera system when operating from cold until the heaters have cleared the lens. If the image is still not clear after cleaning/heating, have the system inspected by your JCB dealer. WARNING Objects displayed may be closer than they appear WARNING At night or in dark areas, the camera system relies on the counterweight lamp for light, therefore it is important that the counterweight lamp is operating correctly to obtain a clear image on the display. If the lamp is not operating correctly stop using the camera system, at least in the dark, until the lamp repaired. WARNING Objects that are close to the corners of the counterweight or under the bodywork may not be visible on the display due to the limited coverage of the camera system. NOTICE Reverse as slowly as possible since higher speeds may limit your reaction time to stop the machine. If the rear of the machine is hit or damaged, ask your JCB dealer to check the camera system for correct coverage and operation. When a 7inch display is installed the machine can also be installed with one or two cameras. Camera one is a rear view camera. Camera two is a side camera. Camera one can be displayed in the bottom half of the display only. Camera two can be displayed in the top or bottom half of the display. The rear view camera can be shown normal or mirrored for operator preference. To view a camera on the display: 1. Press the home button again. 2. Select either the top left or bottom of the screen with the rotary control and select button. Select a camera with the rotary control and select button. When selecting camera one it can be selected as a normal image or a mirrored image 71

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3. Press the home button again. Figure 62.

1 1 2

Camera one bottom of screen, normal. Camera two, top of screen. Figure 63.

1 1 2

Camera one bottom of screen, mirrored Camera two, top of screen.

If the back button is pressed whilst cameras one and two are displayed on the screen the home screen is shown for 3s.

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Operation Instruments

Controls Figure 64. A

G A B C D E F G

Back button Minus button Home button Plus button Enter button Rotary control and select button Fault indicator

Press the home button to return to the home screen. Press the back button to return to the previous screen. Press the minus key to decrease a numerical entry. When at the home screen, press the minus key to decrease the display brightness. Press the plus key to increase a numerical entry. When at the home screen, press the plus key to increase the display brightness. Press the enter key to enter a numerical entry or command into the display. Use the control wheel to navigate through the various screens. Press the button to select an item. The fault indicator is wired direct to the machine ECU (Electronic Control Unit) and will function even if the display fails. If the indicator illuminates red, stop the machine and turn off the engine as soon as it is safe to do so. If the indicator illuminates amber, proceed with caution, stop the machine and turn off the engine as soon as it is safe to do so.

Display Screens Start-Up Screen When the cab door is opened the JCB logo is displayed followed by a machine hours, hours to service and fuel level screen. The 7 Inch display shows a egg timer next to the JCB logo to indicate it is loading.

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Figure 65.

Figure 66.

The work lights screen is displayed to warn that the work lights are left on and the ignition is off. The buzzer will sound in this state after 15s. Figure 67.

Immobilizer Screen If the JCB immobilizer option is enabled the operator must enter the 4 digit immobilizer code before the engine will start. Refer to: Operation > Starting the Engine > Immobilizer (Page 58). Figure 68.

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Main Display Screens After the engine has been started the operator can select one of three main display screens using the control wheel. Turn the rotary control right or left to navigate the screens. Default Operating Screen (Home Screen) Displays the engine speed, inside and outside air temperature, selected travel speed, time, isolator status. Figure 69. F B

D A B C D E F

Travel Speed Auto idle/Controls isolation Clock Inside/outside temperature, Fan speed, A/C Engine speed Power band

Customization of the Home Screen To personalize the split screen home screen: 1. Press the home button to display the home screen. 2. Press the home button again. A split screen with the right side highlighted is displayed. 3. Use the rotary controller to choose the right side split screen. 4. Press the select to confirm. A split screen with the left side highlighted is displayed. 5. Use the rotary controller to choose the left side split screen. 6. Press the select to confirm. If either side of the screen is left blank then the home screen shall revert to a single screen.

Second Level Display Screens Pressing the control wheel on any one of the three main display screens will take the operator to the second level display screens. Turn the rotary control right or left to navigate the screens.

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Machine Status Figure 70.

Press the rotary control again to display machine status information. Turn the rotary control to switch between screen 1 and 2. Press the back button to return. Figure 71. A B C D A B C D

Battery voltage Alternator voltage Coolant temperature Hydraulic temperature Figure 72. E F G

E F G

Barometric pressure Hydraulic pump current Engine speed

Service Information Figure 73.

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Operation Instruments

Press the rotary control again to display service information. Turn the rotary control to switch between screen 1 and 2. Press the back button to return. Figure 74. A B C D A B C D

Engine hours Machine type Vehicle identification number Time to next service Figure 75. E F G H J

E F G H J

Display ECU software version Machine ECU software version Hydraulic ECU software version Wheeled ECU software version LiveLink software version

User/Machine Information Figure 76.

Press the rotary control again to display user/machine information. Turn the rotary control to switch between screens 1, 2 and 3. Press the back button to return. Press the rotary control again on screens 1 to 3 to change settings.

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Figure 77. A B C D A B C D

Time Date Units Display brightness Figure 78. A B C D

A B C D

Auto refuel maximum level Auto idle time Kerosene Overload warning system Figure 79. A B C

A B C

Slew/boom priority default Dipper arm limiter setup ISO/SAE controls selection

Error Log Figure 80.

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Operation Instruments

Press the rotary control again to display a list of the machine faults recorded. Turn the rotary control to switch between screens 1 and 2. Press the back button to return. Figure 81.

Figure 82.

The fault log screen is used to provide information on the active and previously active faults on the machine. The fault log display screen displays the fault code, time, date, engine hours and number of times that the fault has been active. By default, the fault log display shall only display active faults. It shall be possible to view active and historical faults by going to the diagnostic menu. Faults shall be displayed in the color of their severity (critical = red, warning = yellow, trivial = gray). GPS Figure 83.

Press the rotary control again to display the GPS position of the machine. Press the back button to return.

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Operation Instruments

Figure 84.

Attachments- Basic Tool Select Figure 85.

Press the rotary control again to change between hammer and auxiliary mode. A tick next to the hammer enables hammer. A cross next to the hammer enables auxiliary. Figure 86.

Press the rotary control to access the auxiliary settings. Press the back button to return to the home screen. Figure 87.

Turn the rotary control clockwise to scroll down the list and anti clockwise to scroll up the list.

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Figure 88.

Turn the rotary control until the High flow auxiliary is selected then press the rotary control. Figure 89.

Turn the rotary control to change the setting. Press the back button to return to the auxiliary settings. Machines can be equipped with Hydraulic High Flow Circuits in 3 types. • • •

High Flow Single Direction – The Oil only flows one way through the Boom Pipes (If an Auger were fitted it would only rotate one way). High Flow Two Direction – The Oil can flow two ways through the Boom Pipes (If an Auger were fitted it could rotate both ways). Super High Flow Two Direction Merged – The Oil from the combined output of two pumps can flow two ways through the Boom Pipes (If an Auger were fitted it could rotate both ways). Figure 90. High Flow Auxiliary Off

Figure 91. High Flow Hammer

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Operation Instruments

Figure 92. High Flow Auxiliary Single Direction

Figure 93. High Flow Auxiliary Two Direction

Figure 94. Super High Flow Auxiliary Two Direction

Figure 95.

Turn the rotary control until the flow rate is selected then press the rotary control. Figure 96.

Turn the rotary control to change the flow rate to the desired level. press the back button to return to auxiliary settings. The default pressure for all selectable flow settings is 170bar (2,464psi). 82

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Attachment- Advanced Tool Select Figure 97.

From the home screen, Advanced Tool Select is accessed by selecting the attachment icon. Figure 98.

In the attachment overview screen,turn the rotary control to scroll through the available attachments. Press the rotary control to set the highlight attachment as being active or inactive. If the attachment is active, it will shown in green. Figure 99.

Press enter on the display to show the attachment detail screen. The attachment detail screen are presented with the attachment type and can scroll to either the high or low flow settings for this attachment. Press the back button to return to the previous screen. Press the home button to return to the home screen. To edit the attachment setting go back to the attachment overview screen and press and hold the rotary control on your selected attachment for 5s seconds.

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Operation Instruments

Figure 100.

The attachment settings can then be modified by selecting the attachment and entering the attachment detail screen using the rotary control. Figure 101.

The attachment type can be changed from any of the icons as shown above. To edit the High-Flow settings: Figure 102.

•

High-Flow control type select from: •

Single direction high-flow Figure 103.

•

Two direction high-flow

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Operation Instruments

Figure 104.

•

Two direction super high-flow Figure 105.

•

High-Flow operating flow - This is normally set according to the recommended flow rating on the attachment data sheet but can be adjusted lower to optimize attachment performance.

•

High-Flow operating pressure - This is set normally between 20–50bar (289.9–724.6psi) below the ARV (Auxiliary Relief Valve) pressure and can be adjusted to optimize attachment performance.

•

High-Flow ARV pressure - This is set according to the recommended pressure rating on the attachment data sheet.

To edit the Low-Flow settings: Figure 106.

•

Low-Flow operating flow - This is normally set according to the recommended flow rating on the attachment datasheet but can be adjusted lower to optimize attachment performance.

•

Low-Flow operating pressure - This is set normally between 10–30bar (144.9–434.8psi) below the ARV pressure and can be adjusted to optimize attachment performance.

•

Low-Flow ARV pressure - This is set according to the recommended pressure rating on the attachment data sheet.

Make the attachment active in the attachment overview screen to be begin operation.

Faults If a service fault is recognized by the machine's electronic system a fault icon and fault code is displayed on the right side of the home screen. The fault indicator is illuminated amber. The buzzer sounds momentarily when 85

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a service fault is active. The code will remain until it is acknowledged by pressing the enter button. The fault indicator remains on if the fault is acknowledged with the enter button. If multiple service faults are active, the fault screen (icon and fault code) shall alternate through the active faults. Figure 107.

When a critical fault is active, the left area of the main screen will show the fault icon and the right area of the main screen will show the 3 or 4 digit fault code. The fault indicator is illuminated red. The buzzer sounds when a critical fault is active. It sounds until the critical fault is no longer active. The active fault screen alternates with the standard main screen but with a color substitution: Figure 108.

Figure 109.

If multiple critical faults are active, the fault screen (icon and fault code) shall alternate through the active critical faults). Pressing the control wheel will take the operator to the active error log screen. Press enter on this screen to acknowledge all active faults. Critical faults take precedence over service faults. If both service and critical faults are active, only critical faults shall be displayed.

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Operation Instruments

Figure 110.

Notification Symbols Table 9. Quickhitch entry

Quickhitch hose reminder

Quickhitch exit and confirm

Boom and dipper not aligned

Boom aligned, dipper not aligned

Boom not aligned, dipper aligned

Boom and dipper aligned

Boom and dipper aligned, crowd pressed raised

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Operation Instruments

Boom and dipper aligned, crowd pressure raised, joystick unlock button pressed.

Hammer engaged (green)

Hammer overwork alarm (amber)

Hammer overwork alarm (red)

Engine automatic warm-up (blue)

Cold Idle (blue)

Engine pre-heat (amber)

Engine stop (red)

Work lights (amber). Warns that the work lights are on and the ignition is off. The buzzer will sound in this state after 15.

Overload caution alarm (red)

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Operation Instruments

Overload caution enabled (green)

Scrap magnet (amber)

Throttle recalibrate (amber). Informs the operator that they must calibrate the throttle in order to control the engine speed.

Engine shutdown (red)

Service event (amber). When a service is required the service symbol is displayed and the fault indicator is illuminated amber. They remain on even when the operator turns the ignition switch off and on. The service should be performed by your JCB dealer. The symbol and fault indicator can only be canceled by your JCB dealer. Engine oil change event (amber). When an engine oil change is required the oil change symbol is displayed and the fault indicator is illuminated amber. They remain on even when the operator turns the ignition switch off and on. The operator can perform the oil change and then cancel the symbol and fault indicator by pressing the enter button. When the operator has pressed the enter button, the display will set the time for the next service event from the time when the enter button was pressed. Seat belt/occupancy (red)

Water in fuel (amber)

Hydraulics oil temperature high (red)

Hydraulic oil temperature high (amber)

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Fuel level low (amber)

Coolant temperature high (amber)

Engine (amber)

Engine (red)

Engine oil pressure low (red)

Engine oil level low (amber)

Coolant temp high (red)

CAN lost communications (red)

Coolant level low (amber)

Battery no charge (amber)

Air filter blocked (amber)

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Livelink (amber)

Livelink (red)

Buzzer The buzzer is activated to notify the operator of a message or a fault. Some messages/faults can be acknowledged and will silence the buzzer and some messages/faults cannot be acknowledged and the buzzer will continue until the message/fault clears. If a message/fault can be acknowledged, it can be silenced by pressing the enter button on the display. The buzzer will come on constantly while the Quickhitch mode is enabled and cannot be acknowledged. The buzzer will change to an intermittent signal while the Quickhitch is unlocked and cannot be acknowledged.

SCR Exhaust After Treatment Notification Symbols Table 10. After treatment system critical failure/malfunction red icon. Contact your JCB dealer.

After treatment system failure/malfunction - amber icon. Contact your JCB dealer.

DEF (Diesel Exhaust Fluid) level low - amber icon. Refill with DEF as soon as possible.

DEF level critical - red icon on a black background. Refill as soon as possible. Engine de-rate commencing.

Engine stop critical, stop the engine as soon as it is safe to do so - red icon. Contact your JCB dealer.

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Engine low power due to DEF level - black icon on a amber background. Refill with DEF as soon as possible.

SCR (Selective Catalytic Reduction) overloaded, a manual refresh may be required - amber icon.

SCR plugged, a manual refresh is required - red icon.

Plugged/Manual SCR refresh deferring - red icon.

DEF Level The color display will display the DEF level bargraph for 5s when the ignition is turned on (the ignition must have been off for more than 30min). After this time the operator selected home screen is shown. When the ignition is turned on the DEF level bargraph display can be canceled to revert to the operator selected home screen by pressing the rotary select or enter button. If the DEF level is less than 10% when the ignition is turned on, the color display will display the DEF level bargraph in the left hand window until the enter button is pressed. Figure 111.

If you would like the DEF level to be displayed continuously press the home button then turn the rotary select counter clockwise or clockwise from the home screen. Each half bar represents 5%

SCR Refresh The catalyst that forms a key part of the emissions control system can become plugged over time, dependent on machine duty cycle, leading to in-efficiency with the emissions control system. The ECM (Engine Control Module) can request and enact an alternative combustion calibration to burn off any contaminants and refresh the SCR. SCR Refresh - Automatic SCR refresh is automatic, If the duty cycle of the machine is not sufficient for an automatic refresh then an amber light will be displayed. 92

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SCR Refresh - Manual A manual refresh can be performed if an amber or red icon is displayed and the SCR refresh switch in the switch console is flashing. 1. Move the machine to a safe area and position it stationary with the engine running so that a manual refresh can occur. 2. Raise the controls isolation lever. 3. Press and hold the refresh switch on the switch console for longer than 5 seconds (less than 10 seconds) to initiate manual refresh. If the controls isolator lever is down then the following icon will be displayed indicating that the lever needs to be raised. Figure 112.

4. The machine engine revs must be greater than 1500 rpm and engine coolant temperature must be greater than 70 degC. Once the control isolation lever is in the raised position press the refresh switch in the switch console to acknowledgeâ&#x20AC;&#x2122; Figure 113.

If you need to cancel a stationary refresh then either hold down the console switch for 3 seconds, key off the machine or press the emergency stop switch. During stationary refresh the engine revs will increase to 1700rpm then 1800rpm and lock out the machine functionality. Once the engine has completed a full stationary refresh the controls and engine speed will return to normal. SCR Refresh Deferring If you are about to enter a potentially hazardous environment (entering into enclosed environment for example), it may be necessary to defer an SCR refresh. To defer a SCR refresh press and hold the SCR switch on the switch console for 1â&#x20AC;&#x201C;5s.

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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 62). 2. Select a general power band. Refer to: Operation > Instruments > General (Page 69). 3. Check the area around the machine, then sound the horn to warn other personnel of a machine operation. 4. Use the track controls to move the machine in the required direction. Refer to: Operation > Drive Controls > Track Controls (Page 66). 5. 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 67).

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 114.

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 115.

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 116.

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 117.

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 the ground at a time and turn the track to remove the mud. Figure 118.

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 119.

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

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Operation Getting the Machine Moving

Figure 120.

When you travel over a mound, always support the chassis with the dig end to prevent shock loads. Figure 121.

Figure 122.

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 123.

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 124.

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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 manoeuvers, 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 125. 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 126.

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 127. E

E F

Spin right Spin left

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Operation Driving the Machine

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. Use the minimum force to move the equipment slowly (not greater than 2km/h (1.2mph)) 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 it is advisable to have the super structure swung in line with the chassis. It is possible that part of the dig end 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 and isolator switches are 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/SAE Controls This machine's operation conforms to the ISO operating method unless they have the ISO to SAE option installed. With this option the machines excavating controls can be set to one of two operating patterns, ISO or SAE. These operating patterns are shown on a label on the front window. Use the DECU (Display Electronic Control Unit) to select the different operating patterns. Refer to: Operation > Instruments > Instrument Panel (Page 70).

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 boom and the bucket. When released, the joystick returns to the neutral position. 99

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Operation Operating Levers/Pedals

The boom will move within its limits for as long as you hold the joystick forward or backward. It will stop automatically when you release the joystick. To raise the boom, pull the joystick backward (position 1). To lower the boom, push the joystick forward (position 2). If the engine stops and will not re-start, to lower the attachment to the ground: 1. Make sure the ignition is on. 2. Make sure the controls isolation lever is down and the controls isolation switch is off. Refer to: Operation > Locks > Control Lock (Page 64). 3. Push the joystick forward (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 power boost button to enable improved breakout for 3s.Refer to: Operation > Instruments > General (Page 69). When a Quickhitch system is installed (position the bucket on the floor), press the Quickhitch button to release the Quickhitch. Press the button again to engage the Quickhitch. Press the one touch idle switch to instantly change the engine rpm back and forth between that selected for working and a low idling speed. The proportional auxiliary control (low flow) switch is a variable position switch, spring loaded to the central off position. The switch supplies a bi-directional flow for relevant attachments, for example weed cutter, grab rotate. Press and hold the switch to the right or left, as applicable, for as long as the attachment is to be used. Release the switch to turn off the attachment.

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Operation Operating Levers/Pedals

Figure 128. 1

3 1

4 1 2 3 4 A B C D

101

Backward: Raise the boom Forward: Lower the boom Left: Fill the bucket Right: Empty the bucket Power boost Quickhitch One touch idle Proportional auxiliary control low flow (option)

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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 slew to the left, move the joystick to the left (position 1). To slew to the right, move the joystick to the right (position 2). The dipper will move within its limits as long as you hold the joystick forward or backward. It will stop automatically when you release the joystick. To move the dipper outward, move the joystick forward (position 3). To move the dipper inward, move the joystick backward (position 4). Press and hold the boom priority switch to change the priority from slew to boom raise. Release the switch to deselect boom priority. Select the boom 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. Auxiliary hold is particularly useful when continuous prolonged hydraulic flow is required. To activate, move the joystick slider away from the neutral position and then briefly press button A. This will store the position for continuous hydraulic flow. Press button A again to de-select the stored position. Press the horn switch to sound the horn, to give a signal before the machine is started or before you engage travel or slew. The proportional auxiliary control (high flow) switch is a variable position switch, spring loaded to the central off position, it supplies bi-directional flow for the relevant attachments, for example weed cutter, grab rotate. Press and hold the switch to the right or left, as applicable, for as long as the attachment is to be used. Release the switch to turn off the attachment. The rockbreaker/auxiliary foot pedal can be used but with on/off functionality only. On machines with a 'Supershort' dipper or a 'Triple Articulated Boom', the bucket can foul the boom when the dipper is moved inward. Be careful when you move the dipper inward.

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Operation Operating Levers/Pedals

Figure 129.

1 4

2 1 1 2 3 4 A B C D

Left: Slew to the left Right: Slew to the right Forward: Move the dipper outward Backward: Move the dipper inward Auxiliary hold (proportional control only) Boom priority (if fitted) Horn Proportional auxiliary control high flow (option)

SAE 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 dipper and the bucket. When released, the joystick returns to the neutral position. The dipper will move within its limits for as long as you hold the joystick forward or backward. It will stop automatically when you release the joystick. To move the dipper outward, move the joystick forward (position 2). To move the dipper inward, move the joystick backward (position 1). 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 power boost button to enable improved breakout for 3s. When a Quickhitch system is installed (position bucket on floor), press the Quickhitch button to release the Quickhitch. Press again to re-apply the Quickhitch. 103

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Operation Operating Levers/Pedals

Press the one touch idle switch to instantly change the engine rpm back and forth between that selected for working and a low idling speed. The proportional auxiliary control (low flow) switch is a variable position switch, spring loaded to the central off position, it provides bi-directional flow for the relevant attachments, for example weed cutter, grab rotate. Press and hold the switch to the right or left, as applicable, for as long as the attachment is to be used. Release the switch to turn off the attachment. Figure 130.

3 1

A 1

4 1 2 3 4 A B C D

104

Backward: Swing the dipper inward Forward: Swing the dipper outward Left: Fill the bucket Right: Empty the bucket Power boost Quickhitch One touch idle Proportional auxiliary control low flow (option)

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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 boom. 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 swing operation. The operation of the bucket attachment is reversed when it is fitted in the reverse position, be careful. To slew to the left, move the joystick to the left (position 1). To slew to the right, move the joystick to the right (position 2). The dipper will move within its limits for as long as you hold the joystick forward or backward. It will stop automatically when you release the joystick. To raise the boom, pull the joystick backward (position 4). To lower the boom, push the joystick forward (position 3). If the engine stops and will not re-start, to lower the attachment to the ground: 1. Make sure the ignition is on. 2. Make sure the controls isolation lever is down. 3. Make sure the controls isolation switch button is off. 4. Push the joystick forward (position 2). Press and hold the boom priority switch to change priority of slew to boom raise. Release the switch to deselect boom priority. Selecting the boom priority switch during simultaneous slew and boom operation will restrict flow to the slew motor and therefore give more flow to the boom up operation. Press and hold the auxiliary hold button to remember the last position of the proportional control (if fitted). Release the button to stop the flow. This is particularly useful where continuous prolonged hydraulic flow is required. A momentary press of the auxiliary hold button whilst the proportional control is not in the neutral position will store the position. Press the horn switch to sound the horn. Sound the horn to give a signal before the machine is started or before you engage travel or slew. The proportional auxiliary control (high flow) switch is a variable position switch, spring loaded to the central off position, it provides bi-directional flow for relevant attachments, e.g. weed cutter, grab rotate. Press and hold the switch to the right or left, as appropriate, for as long as the attachment is to be used. Release the switch to turn off the attachment. The hammer/auxiliary foot pedal can be used but with on/off functionality only. On machines with a 'Supershort' dipper or a 'Triple Articulated Boom', the bucket can foul the boom when the dipper is swung inward. Be careful when you swing the dipper inward.

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Operation Operating Levers/Pedals

Figure 131. 4

A 3

2 1 1 2 3 4 A B C D

Left: Slew to the left Right: Slew to the right Forward: Lower the boom Backward: Raise the boom Auxiliary hold (proportional control only) Boom priority (if fitted) Horn Proportional auxiliary control high flow (option)

Triple Articulating Boom (Option) On a machine with a triple articulating boom, the boom is in two parts, as shown. Operate the pedal in the cab to extend or retract the ram. This operation in combination with the joystick controls, gives a wide range of boom/dipper positions for more versatility when excavating. To extend the ram, push on the heel end of the pedal. To retract the ram, push on the toe end of the pedal. The ram will stay in the last selected position. On machines with a 'Supershort' dipper or a 'Triple Articulated Boom', the bucket can foul the boom when the dipper is swung inward. Be careful when you swing the dipper inward.

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Operation Operating Levers/Pedals

Figure 132. 1 E

1 D E 1 2

Pedal Ram Heel end of the pedal: Extend the ram Toe end of the pedal: Retract the ram

Dozer Blade Controls NOTICE Before operating the dozer blade, make sure that large rocks or other objects will not jam the dozer mechanism. The dozer blade (option) 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 backward. At the required position release the control lever. To lower the dozer blade, push the control lever forward. At the required position release the control lever. Figure 133.

C A B C

107

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

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Operation Operating Levers/Pedals

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 and have read its operator's manual.

General The auxiliary controls are on the excavator arm controls. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 99). 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. Figure 134.

A A

Auxiliary control pedal

Attachment Systems Your machine may be equipped with one of four systems, for operating attachments requiring high flow or a system for operating attachments requiring both standard and high flow. An optional low flow two-way circuit is also available in addition to or as an alternative to the above.

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. Automatic engine speed reduction is incorporated, to prevent damage to the rockbreaker because of excessive oil flow.

Two-Way Auxiliary Circuit This system supplies a two-way flow, controlled by the pedal. It is suitable for attachments which need a relatively high flow in either direction.

Combined Rockbreaker and Two-Way Auxiliary Circuit This system allows the operation of a rockbreaker and two-way attachments without changing the pipework.

Rockbreaker, Two-Way Auxiliary and Merged Flow System This system allows the operation of a rockbreaker and standard flow two-way attachments. The outputs of both pumps can be merged to give a greater flow for high capacity attachments such as large demolition cutters and crushers.

Low Flow Auxiliary Circuit This system lets the joystick operate a low flow attachment (for example a weedcutter).

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Operation Operating Levers/Pedals

Change-Over Valves To change from the bucket to the grab option operate the change-over valve. Figure 135. A

Change-over valve

If you operate the change-over valve with stored pressure in the hydraulic system its seals will be damaged. When the change-over valve is operated, you must follow the procedure below to prevent damage to its seals. Remove the handle from the change-over valve when the machine is in use, to prevent the accidental operation of the change-over valve.

Bucket Mode to Grab Mode 1. Fully retract the bucket ram, extend the arm and lower the boom to the ground. 2. Extend the bucket ram until the bucket sits flat on the ground. 3. Set the engine speed to minimum. 4. Put the isolator bar down. Do not operate the machine services. Let the engine idle for Duration: 10s 5. Stop the engine with the engine shutdown button. 6. Operate the two hand controllers to release the pressure in the hydraulic system. 7. Apply the servo isolator. 8. Turn the ignition key to the off position. 9. Set the change-over valve to the grab position.

Grab to Bucket Mode In grab mode the bucket ram will fully retract and hold this position during operation. To select bucket mode the attachment must be stopped in a position so that no load is applied to the rod side of the ram. Any force exerted by the attachment on the ram must be in a direction that pushes the ram in. How the excavator is positioned to do this will depend on the attachment used. 1. Park the machine as described above. 2. Put the isolator bar down. 3. Stop the engine with the engine shutdown button.

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Operation Operating Levers/Pedals

4. Operate the two hand controllers to release the pressure in the hydraulic system. Make sure any force exerted by the attachment on the ram is in a direction that pushes the ram in. 5. Turn the ignition key to the off position. 6. Set the change-over valve to the bucket position.

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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 189). Check with your local JCB dealer for further advice.

Load Charts WARNING Rated operating capacities and lift capacities are based on the criteria of the machine being level on a firm supporting ground. When the machine is operated in conditions that deviate from these criteria (e.g. on soft or uneven ground, on a slope or when subject to slide loads), these conditions shall be taken into account by the operator. CAUTION The load chart shown is only an example. Do not use it to find the loading limits on your machine. Before lifting or placing loads, refer to the load charts in the cab of your machine. The SWL (Safe Working Load) of the machine depends on how far the lift arm is extended and the angle it is raised to.

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Operation Lifting and Loading

All lifting operations must be done using the load charts in the cab. The load charts refer to the lift capacities relevant to the machine specification when equipped with an approved JCB tipping link, shackle and bucket ram. The weights of buckets, slings and auxiliary devices must be deducted from these capacities. Care must be taken to make sure that these loads are not exceeded. If a load chart is not installed in the cab, the machine is not designed for lifting. The load chart is only installed on machines with object handling equipment, it is attached to the right hand window. The load chart shows how far you can raise and extend a load without exceeding the SWL. Each machine model has its own specific load chart. The relevant load chart for your machine has a part number. If the load chart is missing or damaged a new label must be attached, contact your JCB dealer for advice if you are not sure. Figure 136. C G

JSXXXX XX

XXXMPa

XXm

XXXMPa XXXXkg

C B

XXXX

A = 1.9 m

A = 2.4 m

Z1 Z2 Z3

A = 3.0 m

XXXX

XXXX XXXX

XXXX

A B C D E F G

5 XXXX

9 8 7 6 5 4 3 2 1 0 -1 -2 -3 -4 -5 -6 -7 10 9 8 7 6 5 4 3 2 1

Holding circuit pressure Refer to the operators manuals before you try to lift a load Working circuit pressure Complete slew of the upper structure Lift with the bucket cylinder retracted Weight of the counterweight Width of the track

Overload Warning System WARNING When the overload protection system buzzer sounds, you must decrease the machine lift. If you do not decrease the machine lift a stability hazard could occur. When the machine is in a safe position the buzzer stops. When the machine is used for lifting it may become unstable, there is a requirement for an audible and visible warning system. The overload warning system senses the pressure in the boom lift pressure circuit, and gives a visual and audible warning when the pressure exceeds the pre-determined limits and there is a risk that the machine could become unstable. When the machine is used for lifting, the system must be turned on. The overload warning system must be enabled through the DECU (Display Electronic Control Unit). When the system is active the DECU will show the enabled icon in the lower section of the DECU.

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Operation Lifting and Loading

Figure 137.

If the safe operating lift limit is exceeded, the buzzer will sound and the icon in the lower section will turn red. A red hook notification symbol is also displayed in the right section of the DECU. When the buzzer sounds and the icon appears, the operator must take the necessary action to lower the lift. When this is done, the buzzer and icon are canceled and the system resets automatically. When the machine is not used for object handling the system must be turned off through the DECU, or the buzzer may sound and the icon may appear during a digging operation. All of the lifting operations must be done in accordance with the local lifting regulations.

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113

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. Slew 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 114). 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 laborer, make sure you both understand what each other will be doing. Learn and use the recognized signaling 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 164).

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 WARNING You must turn on the overload warning system before you use the excavator for object handling, or a stability hazard could occur. All lifting operations must be done with the overload warning system turned on. Refer to: Operation > Lifting and Loading > Overload Warning System (Page 112). Use a signalman when lifting with the excavator. Make sure you both understand and use the recognized 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 SWL (Safe Working Load)for the bucket. If a hook is installed a shackle may not be required. Refer to: Technical Data > Static Dimensions (Page 243). 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 243). 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. 114

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Operation Working with the Excavator Arm

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 (1â&#x20AC;&#x201C;2in) 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. A

A B

Figure 138.

Lifting hook Shackle

6. Slowly maneuver 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 Do not use pedals which are not locked in position as foot rests. NOTICE When carrying out deep digging it is advisable to have the super structure swung in line with the chassis. It is possible that part of the dig end may contact the machine. Take extra care when digging to avoid damaging the machine. 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 Do not use the side of the excavation to stop the bucket when slewing back into position for the next dig. Similarly, do not use the side of the bucket to push soil into the excavation. Both these practices will damage the machine.

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 machine's hydraulic force to dig. Figure 139.

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Operation Working with the Excavator Arm

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 140.

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. Figure 141.

Stability A machine which is stable during operation, increases productivity, extends the life of the machine and makes sure of operator safety. Figure 142.

The dig point affects stability, if the dig point is too far away the machine can become unstable. Figure 143.

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

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Operation Working with the Excavator Arm

Figure 144.

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. Figure 145.

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 146.

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 128). 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.

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Operation Working with the Excavator Arm

Figure 147.

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. Figure 148.

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.

Traveling 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 an 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 99). 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. 118

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Operation Working with the Excavator Arm

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 power band L1,L2 or L3 dependent on the load being maneuvered. The machine must be in power band L1,L2 or L3 at all times. Refer to: Operation > Instruments > General (Page 69). 7. Select creep speed travel. Maintain creep travel speed at all times. Refer to: Operation > Drive Controls > Travel Speed Selector (Page 67). 8. 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. 9. When you travel with the load, do not apply sharp adjustments to the controls.

Dumping Into a Truck 1. To prevent unnecessary maneuvering, put the truck(s) in position, as shown. Refer to Figure 149. Figure 149.

2. Do not dump the material in one sudden movement. Roll the bucket forward in stages until it is empty. Refer to Figure 150. 3. Use the joystick to move the bucket backward and forward 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 center 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.

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Operation Working with the Excavator Arm

Figure 150. 3

1 1 2 3

3 1 2

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. Figure 151.

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 152. Figure 152.

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 151. 120

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Operation Working with the Excavator Arm

5.1. The distance should be approximately: Distance: 0.8mm ( â &#x201E;32in) 1

6. If the clearance is incorrect, contact your JCB dealer.

Dipper Stroke Limiter 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. NOTICE It is the operator's responsibility that the position of the sensor is correctly adjusted to prevent the attachment striking the cab.

General The dipper stroke limiter allows the inward stroke of the dipper to be restricted and prevent the attachment from accidentally striking the cab. The adjustment of the dipper stroke limiter is governed by a proximity switch 22 installed on the boom. The dipper stroke limiter is factory set to 500mm (19 â &#x201E;32in) For the dipper stroke limiter to operate it must be enabled by the JCB Service Master set up tool. When enabled, it is set up by the DECU (Display Electronic Control Unit). The dipper stroke limiter defaults to on, every time the ignition key is turned to the on position, but can be temporarily turned off by the DECU. When the dipper moves to a preset position detected by the proximity switch, the stroke of the dipper-in service is stopped. The dipper-out service will continue to operate and when the dipper moves away from the preset position the dipper-in service is available. The DECU will show an icon when the dipper gets to the preset position.

Adjusting the Clearance 1. Disable the dipper stroke limiter. Refer to: Operation > Instruments > Instrument Panel (Page 70). 2. Adjust the positions of the boom, dipper and attachment until the attachment is the correct clearance from the operator's cab. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 99).

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Operation Working with the Excavator Arm

Figure 153.

Clearance

3. Fully crowd the bucket and lower the boom until the bucket is on the ground. Do not retract or extend the dipper ram. 4. Stop the engine and remove the ignition key. 5. Remove the proximity switch cover, then loosen the proximity switch sensor fixings. Figure 154.

C B A A B C

Proximity switch cover Proximity switch sensor Sensor fixings

6. Put the proximity switch sensor on the slot, so that it is in line with the pick up block on the dipper. 7. Tighten the proximity switch sensor in position, then check that the distance between the sensor and the pick up block is Distance: 4.5 ± 0.5mm ( ⁄32 ± ⁄32in) 6

8. Install the proximity switch cover. 122

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Operation Working with the Excavator Arm

9. Check the Clearance.

Check the Clearance 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. 1. Set the machine as shown with boom ram fully extended. Refer to Figure 153. 2. Move the dipper out and then slowly back in, make sure the dipper stops short of a full stroke on the dipper ram. 3. Make sure the clearance is correct.

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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 155.

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 62). Keep the dozer blade high during travel as this increases the machine's ground clearance.

Scraping and Cutting If a deep cut is to be made, do it in steps of about 50mm (2in). 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 156.

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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 forward when loaded. Going downhill, travel forward 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 35°. On slopes greater than 10° 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 ± 50mm (10 ± 2in) above the ground (in the position shown) and drive at a low speed. Refer to Figure 157. Figure 157.

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 158.

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Operation Slopes

Figure 158.

Driving Up a Slope When you drive up a slope, make sure that the bucket is set 250 ± 50mm (10 ± 2in) above the ground (in the position shown). Refer to Figure 159. Figure 159.

When you drive up a steep slope, make sure that the bucket is set 250 ± 50mm (10 ± 2in) above the ground (in the position shown). Refer to Figure 160. Figure 160.

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. 127

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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 161. Figure 161.

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 162. Figure 162.

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 163. Figure 163.

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 164. 3

When you climb a ramp, it is easier and safer if the work equipment is used to help the machine. Figure 165. 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. Poorly 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 Heater Only Controls Introduction Figure 166.

C A B C 1 2

Recirculation switch Temperature control switch 3-speed fan switch Recirculation switch - position '1' Recirculation switch - position '2'

The heater control panel is installed on the left console. The temperature is adjusted by the recirculation switch, a 3-speed heater fan switch and the temperature control switch. Adjust the air vents to direct the hot air flow to the front window (for demisting) and/or the cab floor.

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. Position '2' can also be used to increase the heater performance during cab warmup and when machine coolant temperatures are below optimum.

Heat Control Turn the temperature control switch clockwise to increase the temperature. Turn the temperature control switch anticlockwise to decrease the temperature.

Heater Fan Turn the 3-speed fan switch to adjust the speed of the heater fan. This functions only when the ignition key is in position I.

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Operation Heating, Ventilating and Air-Conditioning (HVAC)

Heater/Air Conditioning Controls Introduction Figure 167.

G A B C D E F G

Display Fan speed switch Temperature control switch Defrost/Demist switch Recirculation switch Automatic mode switch On/Off switch

The heater/air conditioning control panel is installed on the left console. Adjust the air vents to direct the hot air flow to the front window (for demisting) and/or the cab floor. To activate the control panel push the On/Off switch, the switch LED (Light Emitting Diode) and the panel will illuminate.

Automatic Mode The heater can be set to a selected temperature. The fan speed and the temperature are then automatically controlled to maintain the set temperature. 1. Push the automatic mode switch to start the automatic mode. The LED will illuminate and the letter 'A' is shown on the display. 2. Turn the temperature control switch to set the required temperature. This temperature is shown on the display and the fan speed is automatically set to reach and then maintain this set temperature. 3. If the fan speed switch is adjusted, then the automatic mode will have to be reset. Push the automatic mode switch to reactivate. 4. In hot weather or dusty environments, the recirculation mode should be used. Push the recirculation switch.

Recirculation Mode To start, push the defrost/demist switch, the LED will illuminate and the switch symbol is shown on the display. In hot weather to produce comfortable working conditions: 1. Close the door and windows. 2. Push the recirculation switch. 3. Turn the fan speed switch clockwise and direct the air flow into the body of the cab. 4. Turn the temperature control switch fully antilockwise for maximum defrost. If the temperature in the cab drops too low turn the switch clockwise.

Defrost/Demist Mode In cold/damp weather, to minimize misting: 131

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Operation Heating, Ventilating and Air-Conditioning (HVAC)

1. Close the door and windows. 2. Push the defrost/demist switch. 3. Turn the fan speed switch fully clockwise and direct the air flow onto the front window. 4. Turn the temperature control switch fully clockwise to heat the dehumidified conditioned air, demist the screen and generally dehumidify the cab air.

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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 17). 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. NOTICE Do not isolate the machine electrics when the engine is running, this may cause damage to the machine electrics. To allow the engine ECU (Electronic Control Unit) to shut down correctly, you must wait 30s before you isolate the battery. The 30s period starts when you turn the ignition off. Figure 168.

Disconnect the Machine Electrics: 1. Turn the ignition key to the off position. 2. Wait for the engine ECU to shutdown correctly. Duration: 30s 3. Get access to the battery isolator. Refer to: Maintenance > Service Points > General (Page 192). 4. Turn the battery isolator key in an anticlockwise 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 The fire extinguisher is stowed in a bracket behind the seat. Keep the fire extinguisher in the bracket until you need to use it. Figure 169.

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. Remove the fire extinguisher from its bracket. 2. Remove the safety pin. 3. Aim directly at the fire from an upwind position, if possible. 4. Squeeze the trigger to operate the fire extinguisher, release the trigger to stop the flow.

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Operation Fire Extinguisher

Figure 170. B

A B

136

Safety pin Trigger

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Operation Moving a Disabled Machine

Moving a Disabled Machine 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 parts of the hydraulic system. 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 99). 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 171. 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 171.

2. Both of the Tracks are Bogged Down. Refer to Figure 172. 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 Machine

Figure 172.

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 jewelry 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 99). 2. Set all switches in the cab to their off positions. 3. Get access to the battery. Refer to: Maintenance > Access Apertures (Page 203). 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.

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Operation Moving a Disabled Machine

7. Disconnect the booster cables: 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 173. Notice: Do not use the tow eye or tie down points to tow the machine, as this will cause damage to the machine. Figure 173.

A B

Tow eye Tie down points

Use the minimum force necessary to slowly move the machine (not greater than 2km/h (1.2mph)) smoothly and without shocks. Tow the machine the minimum distance (not to exceed 20m (22yd)) to a safe area for recovery by lifting. Refer to: Operation > Lifting the Machine > General (Page 141). Do not use the tow eye or tie down points to tow the machine, as this will potentially 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: 139

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Operation Moving a Disabled Machine

1. Turn the ignition key to the on position. 2. Enable the controls. Refer to: Operation > Locks > Control Lock (Page 64). 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 233). 5. Turn the ignition key to the off position.

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Operation Lifting the Machine

Lifting the Machine General Figure 174.

A C

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 174. Refer to: Operation > Operating Levers/Pedals > General (Page 99). 2. Stop the engine. 3. Push the controls isolation switch. Refer to: Operation > Locks > Control Lock (Page 64). 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 244). 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 244). 10. Maintain the correct height to the lifting-hook. Refer to: Technical Data > Static Dimensions > Dimensions (Page 244).

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Operation Lifting the Machine

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 center of gravity of the machine is approximately above the slew center.

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Operation Transporting the Machine

Transporting the Machine 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 243). 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 Machine onto the Transporting Vehicle/Trailer CAUTION The machine must be securely tied down to the transport vehicle to prevent lateral movement, fore-and-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 175.

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 175. 7. Start the machine. Refer to: Operation > Starting the Engine (Page 57). 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 99).

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Operation Transporting the Machine

9. Lift the bucket/attachment. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 99). WARNING! The machine must be clean and free of any debris and the contact surfaces must be clean, undamaged, without frost, ice or snow covered. If this is not the case then special precautions may be taken to increase the friction contact with the loading surface through the addition of certified anti-slip matting. 10. If applicable, lift the dozer blade. Refer to: Operation > Operating Levers/Pedals > Dozer Blade Controls (Page 107). 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 center of gravity will move suddenly. Refer to: Operation > Drive Controls (Page 66). 12. When the machine is safely in position, slew the cab to face forward. 13. Engage the slew lock. Refer to: About the Product > Console Switches > Slew Lock (Page 19). WARNING! For rail transportation additional rubber transport mats will be required between the tracks and transport carriage under all weather conditions. 14. Put the boom, dipper and bucket in the positions shown. Refer to Figure 176. Figure 176.

B A B

Undercarriage securing method Dipper securing method

15. Put wooden blocks on the transport trailer in 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 64). 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. WARNING! Chain lashings for the machine should be rated to the minimum capacity shown.

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Operation Transporting the Machine

24. Attach chains at four positions (two front and two rear) to secure the undercarriage to the transport trailer, as shown. Make sure the chains are strong enough for the purpose. Cross the chains. Refer to Figure 177. Figure 177.

E C

A B D E G

Chain angle to center of chaining zone Chain angle to center of chaining zone Chains attached to tie down points Center line of machine Chaining zone

25. Use either the hook, shackle or link as applicable, to secure the dipper to the transport trailer, as shown. Refer to Figure 176. 26. The correct tie down positions are identified on the machine by their labels. Refer to Figure 178. Figure 178.

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 11.

JS115-145 JS115-145 with dozer 145

Angle A Â° 34,5 30,5

Angle B Â° 14 5,5

Dimension C mm (in) 1275 1275 9821/9967-1

Dimension F mm (in) 1450 1570

Dimension G mm (in) 500 500 145

Operation Transporting the Machine

JS160-190 JS200-235

37 34

14,5 14,5

1275 1275

1220 1440

500 500

Table 12. Lashing Capacity dN 7470 8230 7880 9620

JS115-145 JS115-145 with dozer JS160-190 JS200-235

Unloading the Machine 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 179. 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 179.

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 57). 9. Enable the controls. Refer to: Operation > Locks > Control Lock (Page 64). 10. Disengage the slew lock. Refer to: About the Product > Console Switches > Slew Lock (Page 19). 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 99). 146

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Operation Transporting the Machine

12. Lift the bucket. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 99). 13. If applicable, lift the dozer blade. 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 315). 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 and DEF (Diesel Exhaust Fluid) tank (if applicable) 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 fuel, oil and coolant heaters. Ask your JCB dealer for advice. Temperature: -20째C (-4.0째F) 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 0째C (32.0째F)) 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. 7. If the engine is installed with a DEF system the DEF pipes are protected from freezing by an automatic heating system. This does not require any control by the operator.

Operating in High Temperatures 1. Use the correct viscosity engine lubricating oil. 2. Use the correct coolant mixture. 148

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Operation Operating Environment

3. Check the coolant system regularly, keep the coolant at the correct level. Make sure there are no leaks. 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 pressurized. 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, odor filter used for general applications which do not require special filtration.

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Operation Refueling

Refueling 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 gage 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 223). You must bleed the fuel system after changing the fuel filter(s).

Filling the Tank WARNING Do not use gas in this machine. Do not mix gas with the diesel fuel. In storage tanks the gas will rise to the top and form flammable vapors. NOTICE No warranty liability whatsoever will be accepted for failure of fuel injection equipment where the failure is attributed to the quality and grade of the fuel used. NOTICE No warranty liability whatsoever will be accepted for failure of the emissions control system where the failure is attributed to contamination of the diesel exhaust fluid (DEF). NOTICE No warranty liability whatsoever will be accepted for failure of the emissions control system where the failure is attributed to contamination of the diesel fuel. NOTICE No warranty liability whatsoever will be accepted for failure of the emissions control system where the failure is attributed to the quality and grade of the diesel exhaust fluid (DEF) used. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 315). If you use the incorrect type of fuel or fuel which is contaminated, then damage to the fuel injection system can occur. Fill the fuel tank and DEF (Diesel Exhaust Fluid) tank (if applicable) at the end of each work period, this will help to prevent condensation forming on the tank walls. Always replenish the DEF tank at the same as you refill the diesel tank. It is recommended that the DEF tank is not continually run down to the minimum, as this may drag contamination into the system. DEF has a totally separate tank of its own. You can recognize your DEF tank by its blue cap or an AdBlue Ă&#x201A;ÂŽ label.

Filling the Diesel Tank NOTICE Make sure that you use the fuel filler and not the DEF filler. Even small amounts of fuel in the DEF tank may damage the system. If there is any possibility that the DEF system has been contaminated with fuel, the engine must not be started before cleaning the system. Contact your JCB dealer. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 191). 150

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Operation Refueling

2. Remove all unwanted material around the diesel fuel cap. 3. Remove the diesel fuel tank cap. Refer to: Maintenance > Service Points (Page 192). 4. Add the fuel through the filler neck as necessary. 5. Install the diesel fuel tank cap. 6. Lock the diesel fuel tank cap to prevent theft and tampering.

Filling the Diesel Exhaust Fluid Tank NOTICE Make sure that you use the DEF filler and not the fuel filler. Even small amounts of DEF in the fuel tank may damage the system. If there is any possibility that the fuel system has been contaminated with DEF, the engine must not be started before cleaning the system. Contact your JCB dealer. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 191). 2. Remove all unwanted material around the DEF cap. 3. Remove the DEF cap. Refer to: Maintenance > Service Points (Page 192). 4. Add the DEF through the filler neck as necessary. 5. Install the DEF cap. 6. Lock the DEF cap to prevent theft and tampering. The amount of fuel in the tank is shown on the fuel gage on the side of the tank. The maximum level is to the center of the gage. The level is also shown on the instrument panel in the cab, be alert for the red warning indicator on the gage. You must fill the tank at the earliest opportunity when the red warning indicator comes on. Refer to: Operation > Instruments > Instrument Panel (Page 70). Figure 180. A

Maximum level

Refueling pump The refueling pump will not function when the engine is running. 1. Remove the fuel filler cap to let the air escape. Refer to: Maintenance > Service Points (Page 192). 2. Remove the fuel hose from the securing clips and the support. 3. Make sure the suction end of the fuel hose is clean and open the close-off valve. If dirty, use a small container of fuel to clean the suction end. 4. Put the suction end of the fuel hose into the fuel container. 5. Push the switch to select Auto mode or Manual mode. 151

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Operation Refueling

6. Auto Mode: 6.1. To start the pump, push the switch once for less than: Duration: 2s 6.2. Push the switch again to stop the pump. 6.3. The pump will automatically stop when the level gage reaches the tank capacity. To fill the tank fully, use Manual mode. 7. Manual Mode: 7.1. Push and hold the switch until the required amount of fuel is pumped into the tank. 8. Remove the fuel hose from the fuel container. 9. Tighten the close-off valve down. 10. Stow the hose. 11. Replace the filler cap. Figure 181.

A C

A B C

152

Fuel hose Close-off valve Switch

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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 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 machine's center of gravity or overall dimensions. These changes 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 machine's 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 Machine 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 191). 2. Vent the hydraulic system. Refer to: Maintenance > Hydraulic System > General > Discharge (Page 233). 3. Check the hoses and adaptors for damage. Refer to: Maintenance > Hydraulic System > General > Check (Condition) (Page 233). 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 182.

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 183.

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Attachments Working with Attachments

4.5. To allow for length changes when the hose is pressurized, do not clamp at the bend. The curve absorbs the change. Figure 184.

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 191). 2. Vent the hydraulic system. Refer to: Maintenance > Hydraulic System > General > Discharge (Page 233). 3. Disconnect the hoses. 4. Check the hoses and adaptors for damage. Refer to: Preservation and Storage > Checking For Damage (Page 171). 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 185. 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 center 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. 156

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Attachments Working with Attachments

3. Make sure that the 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 186. 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 the 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 slew the boom to the side during operation of the attachment. Consult your JCB dealer for further information. Figure 187. A

332/V3761-1

A B

157

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 99). 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 188. 7. At the dipper nose, remove the locking pin from the pivot pin. Figure 188.

20mm A B

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

8. Lift the bucket from the ground by the specified distance. Distance: 20mm (1in) 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. 158

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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 189. 7. Insert a solid steel bar with the specified diameter through the bores at position 'C'. Dimension: 50mm (1 â &#x201E;32in) 31

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 (1 â &#x201E;32in) 31

10. Lift the boom until the bucket is off the ground hanging on the steel bars. Figure 189.

C D

159

Position 'C' Position 'D'

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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 (1in) 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 190. 17. Carefully move the bucket link forward 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 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 190.

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.

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Attachments Quickhitch

Quickhitch Excavator Arm Quickhitch General CAUTION When the Quickhitch is installed and its attachment attached, there is a danger of the attachment hitting the machine. Operate the boom and dipper carefully when the Quickhitch and its attachment are attached. CAUTION When the Quickhitch is attached to the machine, allowance must be made for the weight of the Quickhitch on the rated operating load. The mass of the Quickhitch is stamped on the data plate. The excavator Quickhitch, which is attached to the dipper enables the fast removal and installation of buckets and other attachments. To prevent premature wear, failure and breakage, the Quickhitch assembly must be used with a rockbreaker for short periods only. If the machine is to be used for rock breaking for a long period of time, it is recommended that the rockbreaker is installed directly on the machine. When using a rockbreaker, it must be curled towards the machine (as a typical digging operation). Do not use the rockbreaker as a lever as this causes excessive loads on the locking mechanism.

Operation If at any point in the Quickhitch process, the operator can move the Quickhitch switch to position 1 to deactivate the system (confirm using the color display when necessary), the operation will be canceled and the system shall revert to an inactive state. 1. Start the machine and enable the controls. 2. Lift the Quickhitch off of the ground with the dipper approximately vertical. 3. Crowd the Quickhitch. 4. To activate Quickhitch move the Quickhitch switch to position 3. The switch LED (Light Emitting Diode) will illuminate red and the buzzer will sound constantly. Refer to: Attachments > Quickhitch > Excavator Arm Quickhitch (Page 161). Figure 191.

5. The color display will display a reminder to the operator to disconnect the attachment hoses before continuing. The reminder screen is displayed for up to 5 seconds and the buzzer sounds constantly until the Quickhitch button on the right joystick is pressed to confirm Quickhitch mode. If the 5 second timer expires the system will revert to an inactive state. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 99). Figure 192.

6. Press the Quickhitch button on the right joystick to confirm Quickhitch mode, the buzzer will sound intermittently and the Boom Warning light and switch LED will flash. If the Quickhitch button on the right joystick is not pressed then the system will return to the Quickhitch inactive state. 161

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Attachments Quickhitch

Refer to: Operation > Instruments > Instrument Panel (Page 70). 7. Align the boom and dipper so that the color display displays the green boom and dipper symbols. A grey boom or dipper symbol signifies mis-alignment. When the boom and dipper are aligned, the Quickhitch is in the Quickhitch ready state. Refer to: Operation > Instruments > Instrument Panel (Page 70). Figure 193.

8. Crowd the bucket to raise system pressure. The boom warning light and switch LED will be illuminated constantly. 9. Press and hold the Quickhitch button on the right joystick to confirm unlock of the Quickhitch. The Quickhitch will start to unlock and will remain unlocked for as long as the button is pressed. Maneuver the machine to remove the attachment and fix on the new attachment. Once the Quickhitch button is released the Quickhitch will start to lock. 10. The Quickhitch display screen is displayed for 3 seconds as a reminder to the operator to re-connect any hoses. Figure 194.

11. Physically check the attachment is properly fitted. Rotate the rotary dial to select â&#x2C6;&#x161; and press enter to acknowledge that you have inspected the security of the attachment. If the attachment is incorrectly fitted then re-start the QuickHitch Process Figure 195.

Installation This operation is easier done by two people, one person to operate the controls and one to line up the pivots. 1. Before the Quickhitch is installed, make sure that the tipping lever locking bolt assembly is attached with the nut. 2. Put the Quickhitch on solid, level ground. Use the safe and correct lifting equipment to move the Quickhitch. 3. Move the machine so that the dipper arm and Quickhitch are aligned. 4. Engage the dipper: 4.1. Operate the controls to line up the hole in the dipper arm with the holes in the Quickhitch. 4.2. Install the pivot pin and secure it with the nut and bolt.

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Attachments Quickhitch

5. Engage the tipping link: 5.1. Operate the controls to line up hole in the tipping link with hole in the Quickhitch. 5.2. Install the pivot pin and attach it with the nut and bolt.

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

Maintenance Examine the Quickhitch daily for broken or missing parts. Remove any debris from the latch hook locking mechanism. If the Quickhitch is cleaned by high pressure water, always grease the latch hook pivot pin. Always grease the latch hook pin every week.

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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 compromized, then select a smaller bucket or reposition the machine. Use the 300mm (12in) wide bucket for narrow excavations or for maximum penetration when digging in hard, rocky or clay soils. Larger buckets are ideally suited to bulk shifting light or loose materials. Notice: When buckets750mm (29 â &#x201E;2in) or wider are attached to the machine, use extreme caution in operation to avoid contact with the cab. 1

Bucket Teeth Standard Teeth Removal 1. Park the machine on solid, level ground. 2. Put the bucket on the ground. 3. Stop the engine. 4. Remove the ignition key. 5. Discharge the hydraulic pressure. Refer to: Maintenance > Hydraulic System > General > Discharge (Page 233). 6. Remove the nut and bolt. 7. Remove the tooth. Figure 196.

B A

A B

164

Tooth Nut and bolt

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Attachments Buckets

Installation 1. Put the tooth in position. 2. Install the nuts and bolts to secure the tooth in position.

ESCO Teeth Introduction This information only relates to the ESCO buckets supplied by JCB. If a bucket from another source is used, refer to the relevant manufacturer's manual. A wide range of Super V-teeth are available for your machine, which are suitable for all digging conditions. The Super V system consists of an adaptor, tooth and locking pin. Refer to Figure 197. The adaptor remains attached to the bucket and the teeth can be easily and quickly changed by one person. The method of removal/installation is the same for all types of teeth. Figure 197. C A

B A B C

Adaptor Tooth Locking pin

Removal 1. Move the bucket into position. 1.1. Make sure that the bucket is securely supported off the ground with sufficient space for the removal of the locking pin. 2. Stop the engine. 3. Remove the ignition key. 4. Remove the locking pin. 4.1. Use a hammer and suitable drift, to carefully knock the locking pin down and out of its guide. Refer to Figure 198.

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Attachments Buckets

Figure 198.

5. Remove the tooth from the adaptor. Refer to Figure 199. Figure 199.

Installation 1. Install the tooth over the adaptor. (The reverse movement of step 5, in the Removal procedure.) Refer to Figure 199. 2. Install a new locking pin. Make sure that the locking pin is in the correct position, (the arrow points downward on the outside edge). Refer to Figure 200.

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Attachments Buckets

Figure 200.

3. Carefully hit the locking pin with a hammer until it is flush with its guide and locks in position. Refer to Figure 201. Figure 201.

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Notes:

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Preservation and Storage Cleaning

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 184).

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

Pressure Washing and Steam Cleaning CAUTION When using a steam cleaner, wear safety glasses or a face shield as well as protective clothing. Steam can cause personal injury. 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 191). 169

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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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Checking For Damage General Refer to the individual condition checks throughout the Maintenance section. Refer to: Maintenance > Maintenance Schedules (Page 184).

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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: -40째C (-39.9째F) to 30째C (86.0째F) 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. Refer to: Preservation and Storage > Storage > During Storage (Page 173). 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. Touch-up any damaged paint. 4. Apply grease to the moving parts. 5. Examine the product for worn or damaged parts. Replace if necessary. 6. Fill the diesel fuel and DEF tanks to prevent a build up of condensation in the tank. 7. Examine the coolant condition. Replace if necessary. 8. 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.

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During Storage Operate the machine functions each week to prevent a build up of rust in the engine and hydraulic circuits, and to minimize the deterioration of the hydraulic seals. 1. Remove the grease or petroleum jelly from the ram piston rods. 2. Examine all fluid levels. If necessary, add more fuel and DEF (Diesel Exhaust Fluid). 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.

Effects of Storage on the DEF System (if applicable) If the engine has been shutdown correctly and there are no faults with the DEFsystem, the DEF system and engine can remain in a deactivated state under the following conditions: Table 13. Storage Period Up to 9 months

Longer than 9 months

Storage Actions Fill DEF tank to maximum level with fresh DEF. Do not disconnect any electrical or hydraulic connections. Make sure the ambient temperature is between the values shown. -40 (-39.9) to 30 (86.0) Carry out recommissioning process

Take out of Storage 1. Examine the coolant condition. Replace if necessary. 2. Examine all fluid levels. If necessary, add more fluid. 3. Clean the machine to remove all unwanted material and corrosive products. Dry the machine to remove solvents and moisture. 4. Remove the grease or petroleum jelly from the ram piston rods. 5. Install a charged battery. 6. Start the engine. 7. Operate the hydraulic controls. Make sure that the hydraulic functions operate correctly.

DEF Recommissioning Process (if applicable) 1. Drain the DEF (Diesel Exhaust Fluid) tank. 2. Refill DEF tank with fresh fluid. 3. If a DEF system failure is detected, consult JCB service.

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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!

JCB Plantguard JCB Plantguard is a comprehensive package available to help you safeguard your machine. It includes such devices as vandal proof covers, window etching, immobilizer, concealed serial number, battery isolator, tracker security system etc. Remember that the installation of any one of these security devices will help to minimize not only the damage or loss of your machine, but also subsequent lost productivity. It could also help to reduce insurance premiums.

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 center. 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.

Anti-Vandal Guards Anti-Vandalism Guards (option) The anti-vandalism guards are stored in a purpose built cage on the roof of the machine. Make sure the cage is locked before the machine is moved. 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.

Unpacking the Guards Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 191). Unlock the cage and remove the guards. Leave the guards 2, 3 and 4 in the cage, they are installed from the top of the machine.

Installing the Guards It is recommended that a hard hat is worn during the installation procedure and that any part of the machine that you may need to climb on is clean. Access steps may be required to safely fit some of the guards. The guards are individually numbered to aid storage, install each numbered guard in the position shown.

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Figure 202.

C A

F E

4 3

1 6

A B C D E F G

175

Front top panel Front bottom panel Door front panel Door rear panel Boom side panel Boom side panel Rear window panel

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Guard 7, Front top panel - position A Hook the guard onto the rail above the front window, make sure the top lip of the guard is correctly installed on the rail.

Guard 6, Front bottom panel - position B Attach to the guard 7 and lock onto the two locking points on the cab front.

Guard 1, Door front panel - position C Make sure that the cut-out on the top of the guard aligns with the marker on the rail, then install the guard onto the roof rail. Lock onto the locking points on the guard 7 and the cab side.

Guard 5, Door rear panel - position D Put the top of the guard onto the roof rail and over the edge of the guard 1. Lock onto the locking point on the side of the machine.

Guards 3 and 4, Boom side panels - position E and F Open the guards and using the handle on top of the guard 3 slide onto the roof rail. Do not lock the guard 3 to the locking point on the guard 7 until the guard 2 has been installed.

Guard 2, Rear window panel - position G Install the guard with the cut-outs uppermost and lock to the four locking points on the guards 5 and 4. Lock onto the guard 5 first.

Removing the Guards Use the key provided to unlock and remove the guards in the reverse order of installation.

Storing the Guards The guards are numbered and can only be stored in the order and orientation shown below. The arrows on the guards should point towards the front of the cab when they are stowed. Close and lock the cage. Table 14. Guards 1 2 3 4 5 6 7

176

Guard 1 - number up Guard 2 - number up Guard 3 - number up Guard 4 - number up Guard 5 - number down Guard 6 - number up Guard 7 - number down

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Maintenance Introduction

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 specified intervals and it is recommended that this is done by an approved JCB dealer using genuine JCB parts. 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 competent person. Only the Your 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 which makes them best placed 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 machine. 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 machine was installed. To get the most from your dealer please help them to satisfy you by providing them with: 1. Your name, address and telephone number. 2. Your product model and serial number. 3. The date of purchase and hours of work. 4. The 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 programs covering warranty, fixed price servicing, safety inspections, including weight tests, covering both legal and insurance requirements.

Environmental Protection Agency and California Air Resources Board The original owner and all subsequent owners of this machine are free to elect a suitable competent repair shop or person of the owners choosing to conduct maintenance, replacement or repair of engine parts/systems. JCB strongly recommend the use of genuine JCB Service approved parts when conducting maintenance, replacement or repair of any engine component in order to assure the performance and safety of the machine. If replacement parts other than genuine JCB Service approved parts are used, only manufacturer warranted parts of equivalent performance should be used. In this case, the remaining emissions component warranties remain in effect; unless damage is caused to such components by the non-JCB Service approved parts. 177

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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.

Obtaining Spare Parts If you use non-genuine JCB parts or consumables, then you can compromize 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 10). 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 1 welded no more than 0.6m ( â &#x201E;2yd). 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. 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.

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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 (571.6°F) require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions. Do not touch component or surrounding area. Used fluoroelastomeric components subjected to temperatures greater than 300°C (571.6°F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains. Thoroughly wash contaminated area with detergent and water. Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations. Do not burn fluoroelastiometric materials. Hydraulic Hoses Never re-use hydraulic hose end crimps or use reusable hose end crimps.

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 gas, 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 refueling 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.

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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 unlabeled 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 authorized 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 CAUTION The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools before beginning maintenance.

New Oil There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices.

Used Oil Used engine crankcase lubricants contain harmful contaminants. Here are precautions to protect your health when handling used engine oil: • •

• • • •

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 gas, 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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Figure 203. A

A B C D E F

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

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.

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

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First Aid - DEF (if applicable) Do not drink or inhale DEF (Diesel Exhaust Fluid). If large quantities of DEF have been swallowed a doctor should be called immediately. Do not induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to an unconscious person. Avoid prolonged or repeated skin contact. After contact with skin wash thoroughly with plenty of soap and water. If irritation develops seek medical advice. Avoid contact with eyes, skin and clothing. Wear chemical resistant gloves, overalls and safety goggles complying with an approved standard. If in contact with eyes, rinse immediately with plenty of clean water. If irritation occurs seek medical attention. Always wash hands and arms thoroughly after handling before eating, drinking, smoking or using the lavatory.

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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 gage 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 15. 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 16. 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 pulverizer, 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 184

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problems in the control valve, premature wear of the hydraulic pump and damage to the hydraulic system as a whole. 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 17. Check the oil level, add more oil as required Change Clean Table 18. 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)

Servo 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 21. 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 21.

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Table 19. Important Parts Fuel hose (Fuel tank - engine) Fuel hose (Fuel filter - injection pump)

Replacement Interval Every 2 years or every 4000 hours, whichever comes first. Table 20.

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

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

Pre-start Cold Checks, Service Points and Fluid Levels Table 22. 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) Hydraulic raised cab)

Lubricate Lubricate Lubricate Lubricate Lubricate

Operator Station Operator Protective Structure

Check (Condition)

Seat Belt

Check (Condition)

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Component Task Cab heater/air-conditioning fil- Replace ter Engine Oil Check (Leaks) Oil

Check (Level)

Oil

Replace

(4)

FEAD belt FEAD belt Fan belt

250

500 1,000 2,000 4,000

Check (Condition) Replace

(9)

Check (Condition) Replace

Fan belt

(10)

(2)

Valves

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) DEF (Diesel Exhaust Fluid) (5) supply module filter DEF tank cap

Clean

Air Filter Air filter (outer)

Replace Clean Replace

(5)

Air filter (inner)

Replace

Air filter (dust valve)

Clean

Crankcase ventilation filter

Replace

Fuel System Fuel system

Check (Leaks)

Main fuel filter/sedimenter

Replace

Main fuel filter/sedimenter

Clean

Engine Fuel Filter

Replace

Engine Fuel Filter

Drain/Clean

Primary fuel filter

Replace

Primary fuel filter

Clean Replace

Fuel injectors

(2, 11)

Fuel injectors leak-off rail

Replace

High pressure fuel lines Cooling System Coolant

Replace Check (Leaks)

Coolant

Check (Condition)

(2, 11)

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Component Coolant

Task 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)

(3)

Track gearbox oil

Replace

Slew gearbox oil

Replace

(3, 8)

Tracks Track plate condition and bolt torque Idler wheels oil and seals

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

Hydraulic tank breather

Replace

Hydraulic cylinders (rams)

Check (Condition)

Return filter

Replace

Drain filter

Replace Clean

Replace

(3, 6)

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 cylinder (ram) hoses

Replace

Dipper line cylinder (ram) hoses Bucket line cylinder (ram) hoses Electrics

Replace

(3, 6)

188

500 1,000 2,000 4,000

Check (Condition) Check (Condition)

(3, 6)

250

Check (Condition)

Track tension

(10)

Replace

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Maintenance Maintenance Schedules

Component Wiring

Task Check (Condition)

Battery

Clean

Battery electrolyte level (if applicable) Battery Isolator

Check (Level)

Starter Motor

Check (Condition)

Alternator

Check (Condition)

Window washer fluid level

Check (Level)

Miscellaneous Fire Extinguisher

Check (Condition)

250

500 1,000 2,000 4,000

Check (Operation)

(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) 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 conditions do these tasks more frequently. (6) If using a breaker, crusher or pulverizer, 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.

Functional Tests and Final Inspection Table 23. Component Body and Framework Excavator lever and pedal locks Doors and locks

Task

Seat and seat belt

Check (Condition/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 189

Check (Leaks) 9821/9967-1

189

Maintenance Maintenance Schedules

Component Transmission Slew brake

Task

250

500 1,000 2,000 4,000

Check (Operation)

Electrics General

Check (Operation)

Alternator - output

Check (Condition)

Miscellaneous Fit for purpose test

Check (Operation)

Optional Equipment Overload warning system

Check (Operation)

Refuel pump

Check (Operation)

(2)

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

190

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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 191).

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 61). 2. If necessary, lower the dozer blade. 3. Lower the excavator so the dipper is flat on the ground. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 99). Figure 204.

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 233). 7. Isolate the battery to prevent the accidental operation of the engine. Refer to: Maintenance > Electrical System > Battery Isolator > Check (Operation) (Page 237).

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Maintenance Service Points

Service Points General For: DJ Engine, JS200, JS210, JS220, JS235 ...................................................................... Page 192 For: JS115, JS130, JS145, JS160, JS180, JS190, SJ Engine ............................................... Page 197

(For: DJ Engine, JS200, JS210, JS220, JS235) 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 Figure 205. D

A B C D E F G H J

192

Engine oil dipstick Radiator cap and expansion bottle Engine oil filler cap Diesel level indicator Diesel fuel filler cap Hydraulic tank breather Hydraulic oil filler cap DEF (Diesel Exhaust Fluid) filler cap DEF breather filter

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Maintenance Service Points

Access to the Upper Structure Figure 206.

Figure 207.

193

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Maintenance Service Points

Figure 208.

1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 191). 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 206. 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 207. Refer to Figure 208.

194

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Maintenance Service Points

Battery Compartment Figure 209. A

A B C D E

195

Air Intake Radiator(s) Batteries Window washer fluid bottle Battery Isolator

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195

Maintenance Service Points

Hydraulic Compartment Figure 210.

E C

A D

A B C D E F G

196

Main fuel filter Hydraulic Oil Level Indicator Engine Fuel Filter Fuel tap Lubricity filter (option) Engine oil filter Hydraulic oil pilot filter

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Maintenance Service Points

Undercarriage Figure 211. A

A B

Track rollers Track tensioner

(For: JS115, JS130, JS145, JS160, JS180, JS190, SJ Engine) 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 Figure 212. D

A B 197

Engine oil dipstick Radiator cap and expansion bottle 9821/9967-1

197

Maintenance Service Points

C D E F G H J

Engine oil filler cap Diesel level indicator Diesel fuel filler cap Hydraulic tank breather Hydraulic oil filler cap DEF filler cap DEF breather filter

Access to the Upper Structure Figure 213.

Figure 214.

198

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Maintenance Service Points

Figure 215.

1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 191). 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 213. 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 214. Refer to Figure 215.

199

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Maintenance Service Points

Battery Compartment Figure 216.

A B

A B C D E

200

Air Intake Radiator(s) Batteries Window washer fluid bottle Battery Isolator

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200

Maintenance Service Points

Hydraulic Compartment Figure 217.

B F

C A

E D

A B C D E F

201

Main fuel filter Hydraulic Oil Level Indicator Engine Fuel Filter Fuel tap Engine oil filter Hydraulic oil pilot filter

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Maintenance Service Points

Undercarriage Figure 218. A

A B

202

Track rollers Track tensioner

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202

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 For: JS115, JS130, JS145, JS160, JS180, JS190 ................................................................. Page 203 For: JS200, JS210, JS220, JS235 ......................................................................................... Page 204

(For: JS115, JS130, JS145, JS160, JS180, JS190) Open 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 191). 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 219.

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.

203

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Maintenance Access Apertures

(For: JS200, JS210, JS220, JS235) Open 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 191). 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 220.

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 191). 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.

204

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204

Maintenance Access Apertures

Figure 221. B

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. Fasten the latches. 5. Use the ignition key to lock the cover.

Hydraulic Compartment Cover For: JS115, JS130, JS145, JS160, JS180, JS190 ................................................................. Page 205 For: JS200, JS210, JS220, JS235 ......................................................................................... Page 206

205

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Maintenance Access Apertures

Figure 222.

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.

206

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Maintenance Access Apertures

Figure 223.

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.

Radiator Cover Open 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 191). 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. 5. Open the cap cover.

207

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207

Maintenance Access Apertures

Figure 224.

A B C D

Lock Handle Cover Cap Cover

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

Access to the Radiator and Condenser 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 191). 2. Let the engine cool 3. Release the latch and open radiator/condenser on its hinge. Figure 225.

208

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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 226.

209

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 186). 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 315). Attach the dust caps after greasing (if installed).

Preparation Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 191). You can complete the greasing procedures with the excavator lowered.

210

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Maintenance Attachments

Attachments General Lubricate Where applicable, refer to the specific manufacturer's 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.

211

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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 191). The slew ring bearings have two grease nipples on the front of the machine and one on the front of 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 227.

D D 212

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 191). Grease the pivot pins. Figure 228. 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 H

Figure 229. K

A A B C D E F G H J K

213

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 Positioning ram, dump end pin Positioning ram, eye end pin Upper/lower boom pin

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213

Maintenance Body and Framework

Figure 230. P

M L M N P

Bucket ram to bucket linkage pin Bucket linkage to bucket pin Dipper to bucket pin Dipper to bucket linkage pin Figure 231.

B C B B C

Boom ram, eye and pin Dipper ram, dump end pin

Hydraulically Raised Cab For machines fitted with a hydraulically raised cab the single point greasing system all the hydraulic cab grease points, except where indicated, will be automatically greased. Remove the cap and apply grease until grease appears at the grease points. A powered greaser may be required to provide the force needed to enable sufficient greasing. Figure 232.

214

Cap

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214

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.

Operator Protective Structure Check (Condition) WARNING You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS/FOGS/TOPS. If the ROPS/FOPS/FOGS/TOPS has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS/FOGS/TOPS certification. WARNING When replacing or repairing the ROPS/FOPS/FOGS/TOPS structure you must replace the fixings. Never re-use fixings. Use only new genuine JCB fixings tightened to the torque figures specified in the operator's manual. All excavators are designed so that an operator's protective structure can be installed. In certain applications for example demolition, the machines must have the optional FOGS (Falling Object Guard System) installed. It is the operators responsibility to identify the risk of an application. A failure to do these precautions can cause death or injury to the operator. For assistance, contact your JCB dealer. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 191). 2. Check the structure for damage. 3. Make sure that all of the ROPS (Roll-Over Protective Structure)/FOGS /TOPS (Tip-Over Protective Structure) mounting bolts are undamaged and in position. 4. Make sure that the ROPS/FOGS /TOPS mounting bolts are tightened to the correct torque setting.

215

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Maintenance Operator Station

Figure 233. Cab Mounted FOGS

2 1 2 3

Torque tightness is 104N·m (76.7lb.ft) Torque tightness is 60N·m (44.2lb.ft) Torque tightness is 259N·m (191.0lb.ft) Figure 234. Frame Mounted FOGS - XD machines Only

1 2 1 3 1 4 1 2 3 4

216

Torque tightness is 259N·m (191.0lb.ft) Torque tightness is 104N·m (76.7lb.ft) Torque tightness is 104N·m (76.7lb.ft) Torque tightness is 259N·m (191.0lb.ft)

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Maintenance Operator Station

Figure 235. Frame Mounted ROPS (FOGS)

4 2

3 1 2 3 4

Torque tightness is 874N路m (644.6lb.ft) Torque tightness is 506N路m (373.2lb.ft) Torque tightness is 506N路m (373.2lb.ft) Torque tightness is 104N路m (76.7lb.ft)FOGS

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.

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Maintenance Operator Station

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.

218

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218

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 191). 2. Get access to the engine compartment (if applicable) Refer to: Maintenance > Access Apertures (Page 203). 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) WARNING Never check the oil level or add oil with the engine running. Be careful of hot lubricating oil. Danger of scalding. 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 191). 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 203). 4. Remove and clean the dipstick. Refer to: Maintenance > Service Points (Page 192). 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. 219

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Maintenance Engine

Refer to: Maintenance > Service Points (Page 192). 8.2. Add the recommended oil slowly through the filler point Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 315). 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 authorized waste disposal sites. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 191). 2. Get access to the engine compartment. Refer to: Maintenance > Access Apertures (Page 203). 3. Remove the oil filler cap. Refer to: Maintenance > Service Points (Page 192). 4. Remove the engine oil drain plug. Drain the oil in to a suitable container. Refer to: Maintenance > Service Points (Page 192). 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 324). 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 324). 10. Add the correct specification and quantity of oil. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 315). 11. Check the oil level. Refer to: Maintenance > Engine > Oil > Check (Level) (Page 219). 12. Install the oil filler cap. 220

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Maintenance Engine

13. Close and secure the engine cover. 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 compromized. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 191). 2. Get access to induction system. Refer to: Maintenance > Access Apertures (Page 203). 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) • • • •

222

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 WARNING Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. The fuel system is self bleeding when the engine is running.

Check (Leaks) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 191). 2. Get access to the engine compartment/hydraulic compartment. Refer to: Maintenance > Access Apertures (Page 203). 3. Check the engine compartment/hydraulic compartment, fuel lines and the area below for leaks. 4. 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 191). 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.

223

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Maintenance Fuel System

Figure 236.

A B A B

Self sealing drain kit Pipe

Clean the Filler Cap 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 191). 2. Get access to the fuel filler cap. Refer to: Maintenance > Service Points > General (Page 192). 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 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 191). 2. Get access to the filter and tap. Refer to: Maintenance > Access Apertures (Page 203). 3. Turn the fuel feed tap off (to stop back syphoning). A decal next to the tap describes the on and off positions. 4. Drain and remove the separator bowl. Refer to: Maintenance > Fuel System > Water Separator (Page 225). 5. Replace the fuel filter. 6. Install the separator bowl. 7. Turn the fuel feed tap on. A decal next to the tap describes the on and off positions.

224

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Maintenance Fuel System

Figure 237.

A B C

Filter Bowl Fuel feed tap

Water Separator Clean Draining the Water Separator 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 191). 2. Get access to the filter. Refer to: Maintenance > Service Points (Page 192). 3. If there is water but no sediment, open the tap to drain the water. If there is any sediment in the bowl replace the fuel filter element. Do not disconnect the electrical connector (if installed). 4. Tighten the drain tap when all the water is drained.

225

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Maintenance Fuel System

Figure 238.

B A

A B

226

Tap Bowl

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226

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 191). 2. Get access to the cooling pack. Refer to: Maintenance > Access Apertures (Page 203). 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 322).

Check (Level) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 191). 2. Let the engine cool. 3. Get access to the coolant expansion bottle. Refer to: Maintenance > Access Apertures (Page 203). CAUTION! The cooling system is pressurized 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. 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 192). 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 315). 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 cab heater to hot and full blower speed. Refer to: Operation > Heating, Ventilating and Air-Conditioning (HVAC) > Air-Conditioning Controls (Page 130). 7. Turn the slew lock on. Refer to: Operation > Operating Levers/Pedals (Page 99).

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Maintenance Cooling System

8. Stall the 'dipper in' service until the coolant reaches the specified temperature. Temperature: 90Â°C (193.9Â°F) Refer to: Operation > Instruments (Page 69). 9. Stop the engine. 10. Remove the ignition key. 11. Let the engine cool. 12. 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 191). 2. Let the engine cool. 3. Get access to the cooling pack. Refer to: Maintenance > Access Apertures (Page 203). 4. If necessary, use a soft bristle brush or compressed air to remove all debris from the cooling pack.

Check (Condition) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 191). 2. Let the engine cool. 3. Get access to the cooling pack. Refer to: Maintenance > Access Apertures (Page 203). 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 recognized signaling 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 99). 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 239. Figure 239.

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 backward and forward several times, then move the machine forward and stop it on level ground. 3. Stop the engine. 4. Check the track tension. Figure 240. 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 351). 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. 230

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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 351). 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 324).

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 230). 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 230). 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 191). A

Figure 241.

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 315). 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 324). 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 191). 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 64). 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 99). 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 192).

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 armoring 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 99). 3. Stop the engine. Do not raise the controls isolation lever. Refer to: Operation > Locks (Page 64). 4. Lower the boom. Stop the boom several meters 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. 233

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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 191). 2. Open the access covers. Refer to: Maintenance > Access Apertures (Page 203). 3. Check the hydraulic hoses for damage. Refer to: Maintenance > Hydraulic System > General > Check (Condition) (Page 233). 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 191). 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 192). 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 315). 4.1. Release the pressure from the hydraulic tank. Refer to: Maintenance > Hydraulic System > General > Discharge (Page 233). 4.2. Get safe access to the hydraulic filler port. Refer to: Maintenance > Service Points (Page 192). 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. 234

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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, leaks or similar defects. Make the machine safe before inspecting each ram. If a ram piston appears defective, contact your service engineer or JCB dealer.

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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. DANGER 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 routeing 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 191). 2. Get access to the battery. Refer to: Maintenance > Access Apertures (Page 203). 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 242.

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Maintenance Electrical System

Figure 242.

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 237). 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 134).

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 191). 2. Get access to the batteries. Refer to: Maintenance > Access Apertures (Page 203). 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 134). 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. 237

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Maintenance Electrical System

1. Isolate the machine electrics. Refer to: Operation > Battery Isolator (Page 134). 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: Technical Data > Electrical System > Fuses (Page 343).

Fuse - Cab The fuses are installed in the rear stowage area. Open the cover to get access to the fuses. For fuse identification, a label is attached to the rear of cover. Figure 243.

Cover

Fuses - Battery Bay The fuses are installed in the battery bay. Remove the cover and open the box to get access to the fuses. Figure 244. B B

A A B

238

Box Cover

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Maintenance Electrical System

Relays Replace Introduction For more information on the individual relays: Refer to: Technical Data > Electrical System > Relays (Page 345).

Relays - Cab The relays are installed in the rear stowage area. Open the cover to get access to the relays. For relay identification, a label is attached to the rear of the cover. Figure 245.

Cover

Relays - Battery Bay The relays are installed in the battery bay. Remove the cover and open the box to get access to the relays. Figure 246. B B

A A B

Box Cover

Window Washer Check (Level) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 191). 2. Get access to the front window washer bottle. Refer to: Maintenance > Service Points > General (Page 192).

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Maintenance Electrical System

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 315). 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.

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Maintenance Miscellaneous

Miscellaneous Fire Extinguisher Check (Condition) In addition to the operator check the extinguisher must be serviced every 12 months by a suitably qualified person. 1. Examine the fire extinguisher for damage and leaks. 2. Make sure the fire extinguisher is correctly attached. 3. Make sure that the gage indicates that the extinguisher is charged i.e. the needle is in the green segment 3.1. If the needle is in or very near the red segment at either end of the gage, the extinguisher must be serviced or replaced. 4. Make sure the safety pin is correctly installed. Figure 247. B

A B

241

Gage Safety Pin

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241

Notes:

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Technical Data Static Dimensions

Technical Data

Static Dimensions General For: JS115, JS130, JS145 ..................................................................................................... Page 243 For: JS160, JS180, JS190 ..................................................................................................... Page 243 For: JS200, JS210, JS220, JS235 ......................................................................................... Page 243

(For: JS115, JS130, JS145) Lifting the Machine Table 24. Item Lifting angle Height to lifting-hook

Dimension 75° 3,700mm (145 ⁄2in) 1

Lifting Hook/Lug Options Refer to: Operation > Working with the Excavator Arm > Lifting With the Excavator Arm (Page 114). Table 25. Lifting hook Lifting lug

5t (11,023lb) 7.6t (16,755lb)

(For: JS160, JS180, JS190) Lifting the Machine Table 26. Item Lifting angle Height to lifting-hook

Dimension 75° 4,500mm (177in)

Lifting Hook/Lug Options Refer to: Operation > Working with the Excavator Arm > Lifting With the Excavator Arm (Page 114). Table 27. Lifting hook Lifting lug

7.5t (16,534lb) 13.5t (29,762lb)

(For: JS200, JS210, JS220, JS235) Lifting the Machine Table 28. Item Lifting angle Height to lifting-hook for SC machines Height to lifting-hook for LC machines

Dimension 75° 4,500mm (177in) 5,000mm (197in)

Lifting Hook/Lug Options Refer to: Operation > Working with the Excavator Arm > Lifting With the Excavator Arm (Page 114). 243

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Technical Data Static Dimensions

Table 29. Lifting hook Lifting lug

12.5t (27,558lb) 17t (37,478lb)

Dimensions For: For: For: For: For: For: For: For: For:

JS115 .............................................................................................................................. JS130 .............................................................................................................................. JS145 .............................................................................................................................. JS160 .............................................................................................................................. JS180 .............................................................................................................................. JS190 .............................................................................................................................. JS200 .............................................................................................................................. JS220, JS235 ................................................................................................................. JS210 ..............................................................................................................................

Page Page Page Page Page Page Page Page Page

244 245 246 249 251 254 256 257 259

(For: JS115) JS115 - Monoboom Figure 248.

Table 30. A

Description Track length on ground

Length

Undercarriage overall length

Track gage

3,317mm (130 ⁄2in)

D D D

Width over tracks (500 shoes) Width over tracks (600 shoes) Width over tracks (700 shoes)

2,580mm (101 ⁄2in) 1 1

1,990mm (78 ⁄2in) 2,490mm (98in) 2,590mm (102in) 2,690mm (106in) 1

Table 31. Dipper lengths

1,950mm (77in)

2,800mm (110in)

E Transport length

2,250mm (88 ⁄2in)

7,357mm (289 ⁄2in) 2,864mm (113in)

2,864mm (113in)

F Transport height

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7,392mm (291in)

244

Technical Data Static Dimensions

Table 32. G

Description Counterweight clearance

H I J K L

Tailswing radius Width of superstructure Height over cab Height over grab rail Ground clearance

Track height

Length 905mm (35 ⁄2in) 2,135mm (84in) 2,410mm (95in) 2,839mm (112in) 2,864mm (113in) 1

464mm (18 ⁄2in) 767mm (30in) 1

(For: JS130) JS130 - Monoboom Figure 249. E H

Table 33. A B C

Description Track length on ground Undercarriage overall length Track gage

D D D

Width over tracks (500 shoes) Width over tracks (600 shoes) Width over tracks (700 shoes)

Length 2,865mm (113in) 3,605mm (142in) 1,990mm (78 ⁄2in) 2,490mm (98in) 2,590mm (102in) 2,690mm (106in) 1

Table 34. Dipper lengths E F

Transport length Transport height

2,500mm (98 ⁄2in) 7,620mm (300in) 2,867mm (113in) 1

3,000mm (118in) 7,572mm (298in) 3,289mm (129 ⁄2in) 1

Table 35. G

Description Counterweight clearance

H I J K

Tailswing radius Width of superstructure Height over cab Height over grab rail

245

Length 905mm (35 ⁄2in) 2,135mm (84in) 2,410mm (95in) 2,845mm (112in) 2,867mm (113in) 1

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245

Technical Data Static Dimensions

Description Ground clearance

Track height

Length 425mm (16 ⁄2in) 811mm (32in) 1

(For: JS145) JS145 - Monoboom Figure 250. E I

J F

M A B

C D Table 36. A B C

Description Track length on ground Undercarriage overall length Track gage

D D D D

Width over tracks (500 shoes) Width over tracks (600 shoes) Width over tracks (700 shoes) Width over tracks (850 shoes)

Length 2,865mm (113in) 3,605mm (142in) 1,990mm (78 ⁄2in) 2,490mm (98in) 2,590mm (102in) 2,690mm (106in) 2,840mm (112in) 1

Table 37. Dipper lengths E F

Transport length Transport height

2,500mm (98 ⁄2in) 7,620mm (300in) 2,867mm (113in) 1

3,000mm (118in) 7,572mm (298in) 3,289mm (129 ⁄2in) 1

Table 38. G

Description Counterweight clearance

H I J K L

Tailswing radius Width of superstructure Height over cab Height over grab rail Ground clearance

Track height

246

Length 905mm (35 ⁄2in) 2,135mm (84in) 2,410mm (95in) 2,845mm (112in) 2,867mm (113in) 1

425mm (16 ⁄2in) 811mm (32in) 1

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Technical Data Static Dimensions

JS145HD - Monoboom Figure 251. E I

J F

M A B

C D Table 39. A

Description Track length on ground

Length

B C

Undercarriage overall length Track gage

D D D D

Width over tracks (500 shoes) Width over tracks (600 shoes) Width over tracks (700 shoes) Width over tracks (850 shoes)

3,090mm (121 ⁄2in) 3,940mm (155in) 1

2,200mm (86 ⁄2in) 2,800mm (110in) 2,900mm (114in) 3,000mm (118in) 3,100mm (122in) 1

Table 40. Dipper lengths E Transport length F Transport height

2,100mm (82 ⁄2in)

2,500mm (98 ⁄2in)

3,000mm (118in)

7,715mm (303 ⁄2in)

7,735mm (304 ⁄2in)

7,765mm (305 ⁄2in)

3,014mm (118 ⁄2in)

Table 41. G

Description Counterweight clearance

H I J K

Tailswing radius Width of superstructure Height over cab Height over grab rail

Ground clearance

Track height

247

Length 1,050mm (41 ⁄2in) 2,135mm (84in) 2,410mm (95in) 2,895mm (114in) 1

3,014mm (118 ⁄2in) 1

470mm (18 ⁄2in) 1

880mm (34 ⁄2in) 1

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Technical Data Static Dimensions

JS145 - Triple Articulated Boom Figure 252. E

M A B

C D Table 42. A B C

Description Track length on ground Undercarriage overall length Track gage

D D D D

Width over tracks (500 shoes) Width over tracks (600 shoes) Width over tracks (700 shoes) Width over tracks (850 shoes)

Length 2,865mm (113in) 3,605mm (142in) 1,990mm (78 ⁄2in) 2,490mm (98in) 2,590mm (102in) 2,690mm (106in) 2,840mm (112in) 1

Table 43. Dipper lengths E

Transport length

Transport height

2,500mm (98 ⁄2in)

3,000mm (118in)

7,662mm (301 ⁄2in) 2,867mm (113in)

7,629mm (300 ⁄2in)

3,186mm (125 ⁄2in) 1

Table 44. G

Description Counterweight clearance

H I J K L

Tailswing radius Width of superstructure Height over cab Height over grab rail Ground clearance

Track height

248

Length 905mm (35 ⁄2in) 2,135mm (84in) 2,410mm (95in) 2,845mm (112in) 2,867mm (113in) 1

425mm (16 ⁄2in) 811mm (32in) 1

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Technical Data Static Dimensions

JS145 LR Figure 253. L

F M

A B

K Table 45.

A B C

Description Track length on ground Undercarriage overall length Counterweight clearance

Length 2,865mm (113in) 3,605mm (142in)

Tailswing radius

E F G H

Width of superstructure Height over cab Height over grab rail Ground clearance

2,050mm (80 ⁄2in) 2,410mm (95in) 2,845mm (112in) 2,867mm (113in)

Track gage

K K K K L M N

Width over tracks (700 shoes) Width over tracks (800 shoes) Width over tracks (850 shoes) Width over tracks (900 shoes) Transport length Transport height Track height

905mm (35 ⁄2in) 1

425mm (16 ⁄2in) 1

1,990mm (78 ⁄2in) 2,690mm (106in) 2,790mm (110in) 2,840mm (112in) 2,890mm (114in) 10,490mm (413in) 2,867mm (113in) 811mm (32in) 1

(For: JS160) JS160 - Monoboom Figure 254. E I

J F

M A B

C D 249

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Technical Data Static Dimensions

Table 46. A

Description Track length on ground

Length

B C

Undercarriage overall length Track gage

D D D

Width over tracks (500 shoes) Width over tracks (600 shoes) Width over tracks (700 shoes)

3,090mm (121 ⁄2in) 3,940mm (155in) 1

1,990mm (78 ⁄2in) 2,490mm (98in) 2,590mm (102in) 2,690mm (106in) 1

Table 47. Dipper lengths

2,250mm (88 ⁄2in)

2,700mm (106 ⁄2in)

8,338mm (328 ⁄2in) 2,992mm (118in)

8,298mm (326 ⁄2in) 2,992mm (118in)

Transport length

Transport height

Table 48. G

Description Counterweight clearance

H I J

Tailswing radius Width of superstructure Height over cab

K L

Height over grab rail Ground clearance

Track height

Length 1,050mm (41 ⁄2in) 2,338mm (92in) 2,470mm (97in) 1

2,965mm (116 ⁄2in) 2,992mm (118in) 1

470mm (18 ⁄2in) 1

880mm (34 ⁄2in) 1

JS160 - Triple Articulated Boom Figure 255. E

M A B

C D Table 49. A

Description Track length on ground

B C

Undercarriage overall length Track gage

Width over tracks (500 shoes)

250

Length 3,090mm (121 ⁄2in) 3,940mm (155in) 1

1,990mm (78 ⁄2in) 2,490mm (98in) 1

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250

Technical Data Static Dimensions

D D

Description Width over tracks (600 shoes) Width over tracks (700 shoes)

Length 2,590mm (102in) 2,690mm (106in) Table 50.

Dipper lengths

2,250mm (88 ⁄2in)

2,700mm (106 ⁄2in)

8,624mm (339 ⁄2in)

8,646mm (340 ⁄2in) 2,738mm (108in)

Transport length

Transport height

2,854mm (112 ⁄2in) 1

Table 51. G

Description Counterweight clearance

H I J

Tailswing radius Width of superstructure Height over cab

K L

Height over grab rail Ground clearance

Track height

Length 1,050mm (41 ⁄2in) 2,338mm (92in) 2,470mm (97in) 1

2,965mm (116 ⁄2in) 2,992mm (118in) 1

470mm (18 ⁄2in) 1

880mm (34 ⁄2in) 1

(For: JS180) JS180 - Monoboom Figure 256. E H

J F

C D

A B Table 52.

Description Track length on ground

B C

Undercarriage overall length Track gage

D D D

Width over tracks (500 shoes) Width over tracks (600 shoes) Width over tracks (700 shoes)

251

Length 3,370mm (132 ⁄2in) 4,170mm (164in) 1

1,990mm (78 ⁄2in) 2,490mm (98in) 2,590mm (102in) 2,690mm (106in) 1

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Technical Data Static Dimensions

Table 53. Dipper lengths

2,250mm (88 ⁄2in)

2,700mm (106 ⁄2in)

8,366mm (329 ⁄2in)

3,014mm (118 ⁄2in)

Transport length

Transport height

Table 54. G H I J

Description Counterweight clearance Tailswing radius Width of superstructure Height over cab

Length 1,072mm (42in) 2,338mm (92in) 2,740mm (108in)

Height over grab rail

L M

Ground clearance Track height

3,014mm (118 ⁄2in) 486mm (19in) 885mm (35in)

2,987mm (117 ⁄2in) 1 1

JS180 - Triple Articulated Boom Figure 257. E

C D

A B Table 55.

Description Track length on ground

B C

Undercarriage overall length Track gage

D D D

Width over tracks (500 shoes) Width over tracks (600 shoes) Width over tracks (700 shoes)

Length 3,370mm (132 ⁄2in) 4,170mm (164in) 1

1,990mm (78 ⁄2in) 2,490mm (98in) 2,590mm (102in) 2,690mm (106in) 1

Table 56. Dipper lengths E

Transport length

Transport height

252

2,250mm (88 ⁄2in)

2,700mm (106 ⁄2in)

8,652mm (340 ⁄2in) 2,876mm (113in)

8,674mm (341 ⁄2in)

9821/9967-1

2,760mm (108 ⁄2in) 1

252

Technical Data Static Dimensions

Table 57. G H I J

Description Counterweight clearance Tailswing radius Width of superstructure Height over cab

Length 1,072mm (42in) 2,338mm (92in) 2,740mm (108in)

Height over grab rail

L M

Ground clearance Track height

3,014mm (118 ⁄2in) 486mm (19in) 885mm (35in)

2,987mm (117 ⁄2in) 1 1

JS180 LR Figure 258. L

F M

N A B

K Table 58.

Description Track length on ground

B C D E F

Undercarriage overall length Counterweight clearance Tailswing radius Width of superstructure Height over cab

Height over grab rail

H J

Ground clearance Track gage

K K K K L M N

Width over tracks (700 shoes) Width over tracks (800 shoes) Width over tracks (850 shoes) Width over tracks (900 shoes) Transport length Transport height Track height

253

Length 3,370mm (132 ⁄2in) 4,170mm (164in) 1,072mm (42in) 2,338mm (92in) 2,740mm (108in) 1

2,987mm (117 ⁄2in) 1

3,014mm (118 ⁄2in) 486mm (19in) 1

2,200mm (86 ⁄2in) 2,900mm (114in) 3,000mm (118in) 3,050mm (120in) 3,100mm (122in) 1

885mm (35in)

9821/9967-1

253

Technical Data Static Dimensions

(For: JS190) JS190 - Monoboom Figure 259. E H

J F

C D

A B Table 59.

Description Track length on ground

B C

Undercarriage overall length Track gage

D D D

Width over tracks (500 shoes) Width over tracks (600 shoes) Width over tracks (700 shoes)

Length 3,370mm (132 ⁄2in) 4,170mm (164in) 1

1,990mm (78 ⁄2in) 2,490mm (98in) 2,590mm (102in) 2,690mm (106in) 1

Table 60. Dipper lengths E

Transport length

Transport height

2,250mm (88 ⁄2in)

2,700mm (106 ⁄2in)

8,366mm (329 ⁄2in)

3,014mm (118 ⁄2in)

Table 61. G H I J

Description Counterweight clearance Tailswing radius Width of superstructure Height over cab

Length 1,072mm (42in) 2,338mm (92in) 2,740mm (108in)

Height over grab rail

L M

Ground clearance Track height

3,014mm (118 ⁄2in) 486mm (19in) 885mm (35in)

254

2,987mm (117 ⁄2in) 1 1

9821/9967-1

254

Technical Data Static Dimensions

JS190 - Triple Articulated Boom Figure 260. E

C D

A B Table 62.

Description Track length on ground

B C

Undercarriage overall length Track gage

D D D

Width over tracks (500 shoes) Width over tracks (600 shoes) Width over tracks (700 shoes)

Length 3,370mm (132 ⁄2in) 4,170mm (164in) 1

1,990mm (78 ⁄2in) 2,490mm (98in) 2,590mm (102in) 2,690mm (106in) 1

Table 63. Dipper lengths E

Transport length

Transport height

2,250mm (88 ⁄2in)

2,700mm (106 ⁄2in)

8,652mm (340 ⁄2in) 2,876mm (113in)

8,674mm (341 ⁄2in)

2,760mm (108 ⁄2in) 1

Table 64. G H I J

Description Counterweight clearance Tailswing radius Width of superstructure Height over cab

Length 1,072mm (42in) 2,338mm (92in) 2,740mm (108in)

Height over grab rail

L M

Ground clearance Track height

3,014mm (118 ⁄2in) 486mm (19in) 885mm (35in)

255

2,987mm (117 ⁄2in) 1 1

9821/9967-1

255

Technical Data Static Dimensions

(For: JS200) JS200 - Monoboom Figure 261. E

G H

K F M

A B

D Table 65. A B

Description Track length on ground Undercarriage overall length

C D

Track gage Width over tracks (500 shoes)

Width over tracks (600 shoes)

Width over tracks (700 shoes)

Width over tracks (800 shoes)

Width over tracks (900 shoes)

Length 3,660mm (144in) 4,460mm (175 ⁄2in) 2,390mm (94in) 1

2,700mm (106 ⁄2in) 1

2,990mm (117 ⁄2in) 1

3,090mm (121 ⁄2in) 1

3,190mm (125 ⁄2in) 1

3,290mm (129 ⁄2in) 1

Table 66. Dipper lengths

1,900mm (75in)

Transport length

9,570mm (377in)

Transport height

3,055mm (120 ⁄2in) 1

2,400mm (94 ⁄2in) 1

9,560mm (376 ⁄2in) 1

3,060mm (120 ⁄2in) 1

Table 67. G H J

Description Counterweight clearance Tailswing radius Width of superstructure

K L M N

Height over cab Height over grab rail Ground clearance Track height

256

Length 1,066mm (42in) 2,825mm (111in) 2,549mm (100 ⁄2in) 2,946mm (116in) 3,025mm (119in) 486mm (19in) 885mm (35in) 1

9821/9967-1

256

Technical Data Static Dimensions

(For: JS220, JS235) JS220 - Monoboom Figure 262. E

G H

K F M

A B

D Table 68. A B

Description Track length on ground Undercarriage overall length

C D

Track gage Width over tracks (500 shoes)

Width over tracks (600 shoes)

Width over tracks (700 shoes)

Width over tracks (800 shoes)

Width over tracks (900 shoes)

Length 3,660mm (144in) 4,460mm (175 ⁄2in) 2,390mm (94in) 1

2,700mm (106 ⁄2in) 1

2,990mm (117 ⁄2in) 1

3,090mm (121 ⁄2in) 1

3,190mm (125 ⁄2in) 1

3,290mm (129 ⁄2in) 1

Table 69. Dipper lengths

1,900mm (75in)

Transport length

9,570mm (377in)

Transport height

3,055mm (120 ⁄2in) 1

2,400mm (94 ⁄2in) 1

9,560mm (376 ⁄2in) 1

3,060mm (120 ⁄2in) 1

Table 70. G H J

Description Counterweight clearance Tailswing radius Width of superstructure

K L M N

Height over cab Height over grab rail Ground clearance Track height

257

Length 1,066mm (42in) 2,825mm (111in) 2,549mm (100 ⁄2in) 2,946mm (116in) 3,025mm (119in) 486mm (19in) 885mm (35in) 1

9821/9967-1

257

Technical Data Static Dimensions

JS220 - Triple Articulated Boom Figure 263. E

G H

K F

L M

C D

A B Table 71.

A B

Description Track length on ground Undercarriage overall length

C D

Track gage Width over tracks (500 shoes)

Width over tracks (600 shoes)

Width over tracks (700 shoes)

Width over tracks (800 shoes)

Width over tracks (900 shoes)

Length 3,660mm (144in) 4,460mm (175 ⁄2in) 2,390mm (94in) 1

2,700mm (106 ⁄2in) 1

2,990mm (117 ⁄2in) 1

3,090mm (121 ⁄2in) 1

3,190mm (125 ⁄2in) 1

3,290mm (129 ⁄2in) 1

Table 72. Dipper lengths

1,900mm (75in)

E F

9,598mm (378in) 3,128mm (123in)

Transport length Transport height

2,400mm (94 ⁄2in) 9,573mm (377in) 1

3,065mm (120 ⁄2in) 1

Table 73. G H J

Description Counterweight clearance Tailswing radius Width of superstructure

K L M N

Height over cab Height over grab rail Ground clearance Track height

258

Length 1,066mm (42in) 2,825mm (111in) 2,549mm (100 ⁄2in) 2,946mm (116in) 3,025mm (119in) 486mm (19in) 885mm (35in) 1

9821/9967-1

258

Technical Data Static Dimensions

JS220 LR Figure 264. L

F M

A B

K Table 74.

A B

Description Track length on ground Undercarriage overall length

C D E

Counterweight clearance Tailswing radius Width of superstructure

F G H J K

Height over cab Height over grab rail Ground clearance Track gage Width over tracks (700 shoes)

Width over tracks (800 shoes)

Width over tracks (850 shoes)

Width over tracks (900 shoes)

L M N

Transport length Transport height Track height

Length 3,660mm (144in) 4,460mm (175 ⁄2in) 1,066mm (42in) 2,825mm (111in) 1

2,549mm (100 ⁄2in) 2,946mm (116in) 3,025mm (119in) 486mm (19in) 2,390mm (94in) 1

3,090mm (121 ⁄2in) 1

3,190mm (125 ⁄2in) 1

3,240mm (127 ⁄2in) 1

3,290mm (129 ⁄2in) 12,545mm (494in) 3,025mm (119in) 885mm (35in) 1

(For: JS210) JS210 - Monoboom Figure 265. E

K F M

A B

D 259

G H

9821/9967-1

259

Technical Data Static Dimensions

Table 75. A B

Description Track length on ground Undercarriage overall length

Length 3,660mm (144in)

Track gage

Width over tracks (500 shoes)

2,170mm (85 ⁄2in)

Width over tracks (600 shoes)

Width over tracks (700 shoes)

Width over tracks (800 shoes)

Width over tracks (900 shoes)

4,460mm (175 ⁄2in) 1

2,700mm (106 ⁄2in) 1

2,990mm (117 ⁄2in) 1

3,090mm (121 ⁄2in) 1

3,190mm (125 ⁄2in) 1

3,290mm (129 ⁄2in) 1

Table 76. Dipper lengths

1,900mm (75in)

Transport length

9,570mm (377in)

Transport height

3,055mm (120 ⁄2in) 1

2,400mm (94 ⁄2in) 1

9,560mm (376 ⁄2in) 1

3,060mm (120 ⁄2in) 1

Table 77. G H J

Description Counterweight clearance Tailswing radius Width of superstructure

K L M N

Height over cab Height over grab rail Ground clearance Track height

Length 1,066mm (42in) 2,825mm (111in) 2,549mm (100 ⁄2in) 2,946mm (116in) 3,025mm (119in) 486mm (19in) 885mm (35in) 1

Weights For: For: For: For: For: For: For: For: For: For:

DJ Engine, JS200 ........................................................................................................... DJ Engine, JS220 ........................................................................................................... DJ Engine, JS210 ........................................................................................................... DJ Engine, JS235 ........................................................................................................... JS115, SJ Engine ........................................................................................................... JS130, SJ Engine ........................................................................................................... JS145, SJ Engine ........................................................................................................... JS160, SJ Engine ........................................................................................................... JS180, SJ Engine ........................................................................................................... JS190, SJ Engine ...........................................................................................................

Page Page Page Page Page Page Page Page Page Page

260 261 261 262 262 262 263 263 263 264

(For: DJ Engine, JS200) Shipping Weight An approximate weight when the machine has a monoboom, medium length dipper, bucket, operator and a full fuel tank.

260

9821/9967-1

260

Technical Data Static Dimensions

Table 78. JS200NC Track shoe width 500mm (19 ⁄2in) 1

600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

Weight 20,095kg (44,301lb) 20,345kg (44,853lb) 20,600kg (45,415lb) Table 79. JS200SC

Track shoe width 500mm (19 ⁄2in) 1

600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

Weight 20,175kg (44,478lb) 20,430kg (45,040lb) 20,680kg (45,591lb) Table 80. JS200LC

Track shoe width 600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

800mm (31 ⁄2in) 1

900mm (35 ⁄2in) 1

Weight 20,855kg (45,977lb) 21,120kg (46,561lb) 21,390kg (47,156lb) 21,440kg (47,267lb)

(For: DJ Engine, JS220) Shipping Weight An approximate weight when the machine has a monoboom, medium length dipper, bucket, operator and a full fuel tank. Table 81. JS220NC Track shoe width 500mm (19 ⁄2in) 1

600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

Weight 21,394kg (47,165lb) 21,646kg (47,721lb) 21,898kg (48,276lb) Table 82. JS220SC

Track shoe width 500mm (19 ⁄2in) 1

600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

Weight 21,477kg (47,348lb) 21,729kg (47,904lb) 21,981kg (48,459lb) Table 83. JS220LC

Track shoe width 600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

800mm (31 ⁄2in) 1

900mm (35 ⁄2in) 1

Weight 22,154kg (48,841lb) 22,422kg (49,432lb) 22,690kg (50,022lb) 22,740kg (50,133lb)

(For: DJ Engine, JS210) Shipping Weight An approximate weight when the machine has a monoboom, medium length dipper, bucket, operator and a full fuel tank. 261

9821/9967-1

261

Technical Data Static Dimensions

Table 84. JS210LC Track shoe width 600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

800mm (31 ⁄2in) 1

900mm (35 ⁄2in) 1

Weight 21,340kg (47,046lb) 21,605kg (47,630lb) 21,875kg (48,226lb) 21,925kg (48,336lb)

(For: DJ Engine, JS235) Shipping Weight An approximate weight when the machine has a monoboom, medium length dipper, bucket, operator and a full fuel tank. Table 85. JS235HD Track shoe width 550mm (21 ⁄2in) 1

Weight 24,271kg (53,508lb)

An approximate weight when the machine has a TAB (Triple Articulated Boom), bucket, operator and a full fuel tank. Table 86. JS235HD TAB Track shoe width 550mm (21 ⁄2in) 1

Weight 23,222kg (51,195lb)

(For: JS115, SJ Engine) Shipping Weight An approximate weight when the machine has a monoboom, medium length dipper, bucket, operator and a full fuel tank. Table 87. Track shoe width 500mm (19 ⁄2in) 1

600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

Weight 12,492kg (27,540lb) 12,670kg (27,932lb) 12,847kg (28,322lb)

(For: JS130, SJ Engine) Shipping Weight An approximate weight when the machine has a monoboom, medium length dipper, bucket, operator and a full fuel tank. Table 88. Track shoe width 500mm (19 ⁄2in) 1

600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

262

Weight 13,393kg (29,526lb) 13,583kg (29,945lb) 13,774kg (30,366lb)

9821/9967-1

262

Technical Data Static Dimensions

(For: JS145, SJ Engine) Shipping Weight An approximate weight when the machine has a monoboom, medium length dipper, bucket, operator and a full fuel tank. Table 89. JS145 Track shoe width 500mm (19 ⁄2in) 1

600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

850mm (33 ⁄2in) 1

Weight 14,471kg (31,903lb) 14,578kg (32,139lb) 14,686kg (32,377lb) 14,848kg (32,734lb) Table 90. JS145HD

Track shoe width 600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

800mm (31 ⁄2in) 1

900mm (35 ⁄2in) 1

Weight 17,277kg (38,089lb) 17,577kg (38,750lb) 17,877kg (39,412lb) 18,221kg (40,170lb)

(For: JS160, SJ Engine) Shipping Weight An approximate weight when the machine has a monoboom, medium length dipper, bucket, operator and a full fuel tank. Table 91. JS160 Track shoe width 500mm (19 ⁄2in) 1

600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

800mm (31 ⁄2in) 1

900mm (35 ⁄2in) 1

Weight 17,445kg (38,459lb) 17,748kg (39,127lb) 17,984kg (39,648lb) 18,248kg (40,230lb) 18,646kg (41,107lb) Table 92. JS160 Triple Articulated Boom

Track shoe width 500mm (19 ⁄2in) 1

600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

800mm (31 ⁄2in) 1

900mm (35 ⁄2in) 1

Weight 18,209kg (40,144lb) 18,512kg (40,812lb) 189,748kg (418,318lb) 19,012kg (41,914lb) 19,410kg (42,791lb)

(For: JS180, SJ Engine) Shipping Weight An approximate weight when the machine has a monoboom, medium length dipper, bucket, operator and a full fuel tank. 263

9821/9967-1

263

Technical Data Static Dimensions

Table 93. JS180 Narrow Long Carriage Track shoe width

Weight 18,546kg (40,887lb)

500mm (19 ⁄2in) 1

19,107kg (42,123lb)

600mm (23 ⁄2in) 1

Table 94. JS180 Long Carriage Track shoe width

Weight 19,360kg (42,681lb)

600mm (23 ⁄2in) 1

19,648kg (43,316lb)

700mm (27 ⁄2in) 1

Table 95. JS180 Narrow Long Carriage - Triple Articulated Boom Track shoe width

Weight 19,310kg (42,571lb)

500mm (19 ⁄2in) 1

19,871kg (43,808lb)

600mm (23 ⁄2in) 1

Table 96. JS180 Long Carriage - Triple Articulated Boom Track shoe width 600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

Weight 20,124kg (44,365lb) 20,412kg (45,000lb)

(For: JS190, SJ Engine) Shipping Weight An approximate weight when the machine has 3.05m (3 ⁄2yd) dipper, bucket, operator and a full fuel tank. 1

Table 97. JS190 NLC Mono Track shoe width 600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

800mm (31 ⁄2in) 1

Weight 19,876.5kg (43,820lb) 20,231.5kg (44,602lb) 20,586.5kg (45,385lb) Table 98. JS190 NLC TAB

Track shoe width 600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

800mm (31 ⁄2in) 1

Weight 20,640.5kg (45,504lb) 20,995.5kg (46,287lb) 21,350.5kg (47,069lb) Table 99. JS190 LC Mono

Track shoe width 500mm (19 ⁄2in) 1

600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

Weight 20,084.5kg (44,278lb) 20,210.5kg (44,556lb) 20,565.5kg (45,339lb) Table 100. JS190 LC TAB

Track shoe width 500mm (19 ⁄2in) 1

600mm (23 ⁄2in) 1

700mm (27 ⁄2in) 1

264

Weight 20,848.5kg (45,963lb) 20,974.5kg (46,240lb) 21,329.5kg (47,023lb) 9821/9967-1

264

Technical Data Performance Dimensions

Performance Dimensions Excavator Arm Dimensions and Performance For: For: For: For: For: For: For: For: For: For:

JS115 JS130 JS145 JS160 JS180 JS190 JS200 JS220 JS210 JS235

.............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. ..............................................................................................................................

Page Page Page Page Page Page Page Page Page Page

265 268 270 278 282 288 294 298 305 309

(For: JS115) Digging JS115 - Monoboom Figure 266. A B

G 10 9 8 7 6

5 4

3 2 1

Met res

C F

Met res

Table 101. Boom length Dipper length A Maximum digging reach B Maximum digging reach (on ground) C Maximum digging depth D Maximum digging height 265

4,400mm (173in) 1,950mm 2,500mm 1 (77in) (98 ⁄2in) 7,547mm 7,822mm (297in) (308in) 7,324mm 7,669mm 1 (302in) (288 ⁄2in) 4,375mm (172in)

5,024mm (198in)

8,505mm (335in)

8,638mm (340in)

9821/9967-1

2,800mm (110in) 8,281mm (326in) 8,136mm 1 (320 ⁄2in) 5,571mm 1 (219 ⁄2in) 8,843mm (348in) 265

Technical Data Performance Dimensions

Boom length Dipper length E Maximum dumping height F Maximum vertical wall cut depth G Maximum swing radius

4,400mm (173in) 1,950mm 2,500mm 1 (77in) (98 ⁄2in) 6,112mm 6,331mm 1 1 (240 ⁄2in) (249 ⁄2in) 4,435mm 4,715mm 1 1 (174 ⁄2in) (185 ⁄2in) 2,136mm 2,168mm 1 (84in) (85 ⁄2in)

2,800mm (110in) 6,601mm (260in) 5,351mm 1 (210 ⁄2in) 2,558mm 1 (100 ⁄2in)

Lifting Figure 267.

JS115

266

9821/9967-1

266

Technical Data Performance Dimensions

Figure 268.

JS115D

267

9821/9967-1

267

Technical Data Performance Dimensions

(For: JS130) Digging JS130 - Monoboom Figure 269. A B

10 9 8 7 6

4 3 2 1 0 -1 -2

-3 -4 -5 -6

Table 102. Boom length Dipper length

4,700mm (185in)

3,000mm (118in)

Maximum digging reach

2,500mm (98 ⁄2in)

Maximum digging reach (on ground)

8,340mm (328 ⁄2in)

8,796mm (346 ⁄2in) 8,660mm (341in)

Maximum digging depth

Maximum digging height

E F

Maximum dumping height Maximum vertical wall cut depth

Maximum swing radius

268

8,197mm (322 ⁄2in) 1

5,530mm (217 ⁄2in) 9,118mm (359in) 1

6,028mm (237 ⁄2in) 1

6,729mm (265in)

9,440mm (371 ⁄2in) 7,041mm (277in)

3,625mm (142 ⁄2in) 2,231mm (88in)

4,050mm (159 ⁄2in) 2,591mm (102in)

9821/9967-1

268

Technical Data Performance Dimensions

Lifting Figure 270.

JS130LC

Figure 271.

JS130LCD

269

9821/9967-1

269

Technical Data Performance Dimensions

(For: JS145) Digging JS145 - Monoboom Figure 272. A B

10 9 8 7 6

4 3 2 1 0 -1 -2

-3 -4 -5 -6

Table 103. Boom length Dipper length

4,700mm (185in)

3,000mm (118in)

A Maximum digging reach

2,500mm (98 ⁄2in) 8,340mm (328 ⁄2in)

8,796mm (346 ⁄2in) 8,660mm (341in)

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

270

8,197mm (322 ⁄2in) 1

5,530mm (217 ⁄2in) 9,118mm (359in) 1

6,028mm (237 ⁄2in) 1

6,729mm (265in)

9,440mm (371 ⁄2in) 7,041mm (277in)

3,625mm (142 ⁄2in) 2,231mm (88in)

4,050mm (159 ⁄2in) 2,591mm (102in)

9821/9967-1

270

Technical Data Performance Dimensions

JS145HD - Monoboom Figure 273.

A B

G 10 9 8 7 6

5 4

3 2 1

Met res

C F

Met res

Table 104. Boom length Dipper length A Maximum digging reach B Maximum digging reach (on ground) C Maximum digging depth

4,700mm (185in) 2,100mm 2,500mm 1 1 (82 ⁄2in) (98 ⁄2in) 7,970mm 8,340mm 1 (314in) (328 ⁄2in) 7,750mm 8,130mm (305in) (320in) 5,010mm 5,410mm (197in) (213in)

D Maximum digging height

8,960mm (353in)

E Maximum dumping height

6,570mm 1 (258 ⁄2in) 4,440mm (175in)

F Maximum vertical wall cut depth G Maximum swing radius

271

2,050mm 1 (80 ⁄2in)

9821/9967-1

9,230mm 1 (363 ⁄2in) 6,840mm 1 (269 ⁄2in) 4,840mm 1 (190 ⁄2in) 2,050mm 1 (80 ⁄2in)

3,000mm (118in) 8,790mm (346in) 8,590mm (338in) 5,910mm 1 (232 ⁄2in) 9,550mm (376in) 7,160mm (282in) 5,300mm 1 (208 ⁄2in) 2,410mm (95in)

271

Technical Data Performance Dimensions

JS145 - Triple Articulated Boom Figure 274. A B

10 9 8 7 6

4 3 2 1 0 -1 -2

-3 -4 -5 -6

Table 105. Boom length Dipper length

4,700mm (185in)

3,000mm (118in)

A Maximum digging reach

2,500mm (98 ⁄2in)

B Maximum digging reach (on ground) C Maximum digging depth

8,751mm (344 ⁄2in) 8,614mm (339in) 5,786mm (228in)

9,096mm (358in)

D Maximum digging height

9,635mm (379 ⁄2in)

E Maximum dumping height

9,226mm (363in) 6,281mm (247 ⁄2in) 10,012mm (394in) 1

F Maximum vertical wall cut depth

7,229mm (284 ⁄2in) 4,140mm (163in)

7,606mm (299 ⁄2in)

G Maximum swing radius

2,746mm (108in)

3,162mm (124 ⁄2in)

272

9821/9967-1

4,580mm (180 ⁄2in) 1 1

272

Technical Data Performance Dimensions

JS145 LR Figure 275. A B

45º

Table 106. Boom length

7,400mm (291 ⁄2in) 1

Dipper length

5,300mm (208 ⁄2in) 1

Maximum digging reach

B C D E F G H

Maximum digging reach (on ground) Maximum digging depth Maximum digging height Maximum dumping height Minimum dumping height Bucket struck radius Minimum swing radius

J K

Minimum swing radius height Maximum ground level span

13,100mm (515 ⁄2in) 13,010mm (512in) 10,090mm (397in) 12,671mm (499in) 10,620mm (418in) 1

2,730mm (107 ⁄2in) 1

Table 107. Bucket rotation Dipper tearout Bucket tearout

273

182°

9821/9967-1

273

Technical Data Performance Dimensions

Lifting Figure 276.

JS145LC

Figure 277.

JS145LCD

274

9821/9967-1

274

Technical Data Performance Dimensions

Figure 278.

JS145HD

Figure 279.

JS145LR

275

9821/9967-1

275

Technical Data Performance Dimensions

Figure 280.

JS145LC TAB

Figure 281.

JS145HD TAB

276

9821/9967-1

276

Technical Data Performance Dimensions

Figure 282.

JS145LCD TAB

277

9821/9967-1

277

Technical Data Performance Dimensions

(For: JS160) Digging JS160 - Monoboom Figure 283. A B

10 9 8 7 6

5 4

3 2 1

Met res

Table 108. Boom length Dipper length A Maximum digging reach B Maximum digging reach (on ground)

5,150mm (203in) 2,250mm 2,700mm 1 1 (88 ⁄2in) (106 ⁄2in) 8,507mm 8,908mm 1 (335in) (350 ⁄2in) 8,326mm 8,735mm (328in) (344in)

C Maximum digging depth

5,482mm (216in)

5,940mm (234in)

D Maximum digging height

8,863mm (349in)

E Maximum dumping height

6,535mm 1 (257 ⁄2in) 4,912mm 1 (193 ⁄2in) 3,000mm (118in)

9,050mm 1 (356 ⁄2in) 6,726mm (265in)

F Maximum vertical wall cut depth G Maximum swing radius

278

9821/9967-1

5,370mm 1 (211 ⁄2in) 3,000mm (118in)

3,050mm (120in) 9,223mm (363in) 9,056mm 1 (356 ⁄2in) 6,286mm 1 (247 ⁄2in) 9,219mm (363in) 6,891mm 1 (271 ⁄2in) 5,646mm 1 (222 ⁄2in) 3,000mm (118in) 278

Technical Data Performance Dimensions

JS160 - Triple Articulated Boom Figure 284. A B

G 12 11 10 9 8 7 6

4 3 2 1

Met res

Table 109. 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

279

5,350mm (210 ⁄2in) 2,250mm 2,700mm 1 1 (88 ⁄2in) (106 ⁄2in) 8,831mm 9,260mm 1 1 (347 ⁄2in) (364 ⁄2in) 8,652mm 9,094mm 1 (358in) (340 ⁄2in) 5,376mm 5,808mm 1 1 (211 ⁄2in) (228 ⁄2in) 10,226mm 10,652mm 1 1 (402 ⁄2in) (419 ⁄2in) 7,976mm 8,366mm 1 (314in) (329 ⁄2in) 4,254mm 4,721mm 1 (186in) (167 ⁄2in) 2,170mm 2,227mm 1 1 (85 ⁄2in) (87 ⁄2in) 1

9821/9967-1

3,050mm (120in) 9,592mm 1 (377 ⁄2in) 9,463mm 1 (372 ⁄2in) 6,130mm 1 (241 ⁄2in) 10,800mm (425in) 8,667mm (341in) 5,233mm (206in) 2,587mm (102in)

279

Technical Data Performance Dimensions

Lifting Figure 285.

Figure 286.

280

9821/9967-1

280

Technical Data Performance Dimensions

Figure 287.

Figure 288.

281

9821/9967-1

281

Technical Data Performance Dimensions

(For: JS180) Digging JS180 - Monoboom Figure 289. A B

10 9 8 7 6

5 4

3 2 1

Met res

Table 110. 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

282

5,150mm (203in) 2,250mm 2,700mm 1 1 (88 ⁄2in) (106 ⁄2in) 8,514mm 8,908mm 1 (335in) (350 ⁄2in) 8,368mm 8,769mm 1 (345in) (329 ⁄2in) 5,799mm 1 (228 ⁄2in) 9,398mm (370in) 7,048mm 1 (277 ⁄2in) 5,229mm (206in) 3,000mm (118in) 9821/9967-1

3,050mm (120in) 9,223mm (363in) 9,088mm (358in)

6,252mm (246in)

6,598mm (260in)

9,663mm 1 (380 ⁄2in) 7,321mm (288in)

9,888mm 1 (389 ⁄2in) 7,543mm (297in)

5,682mm 1 (223 ⁄2in) 3,000mm (118in)

6,028mm 1 (237 ⁄2in) 3,000mm (118in) 282

Technical Data Performance Dimensions

JS180 - Triple Articulated Boom Figure 290. A B

12 11 10 9 8 7 6

4 3 2 1

Mèt res

C F

Mèt res

Table 111. 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

283

5,350mm (210 ⁄2in) 2,250mm 2,700mm 1 1 (88 ⁄2in) (106 ⁄2in) 8,831mm 9,260mm 1 1 (347 ⁄2in) (364 ⁄2in) 8,652mm 9,094mm 1 (358in) (340 ⁄2in) 5,354mm 5,786mm (211in) (228in) 1

10,248mm 1 (403 ⁄2in) 8,000mm (315in) 4,232mm 1 (166 ⁄2in) 2,170mm 1 (85 ⁄2in)

9821/9967-1

3,050mm (120in)

10,674mm (420in)

9,592mm 1 (377 ⁄2in) 9,463mm 1 (372 ⁄2in) 6,108mm 1 (240 ⁄2in) 10,822mm (426in)

8,444mm 1 (332 ⁄2in) 4,699mm (185in)

8,672mm 1 (341 ⁄2in) 5,211mm (205in)

2,227mm 1 (87 ⁄2in)

2,587mm (102in)

283

Technical Data Performance Dimensions

JS180 LR Figure 291. A B

45º

Table 112. Boom length Dipper length A Maximum digging reach

7,266mm (286in) 5,183mm (204in)

Maximum digging reach (on ground)

Maximum digging depth

12,996mm (511 ⁄2in)

Maximum digging height

E F

Maximum dumping height Minimum dumping height

G H J K

Bucket struck radius Minimum swing radius Minimum swing radius height Maximum ground level span

13,115mm (516 ⁄2in) 1

9,998mm (393 ⁄2in) 1

11,698mm (460 ⁄2in) 9,400mm (370in) 1

2,830mm (111 ⁄2in) 1,200mm (47in) 3,890mm (153in) 9,150mm (360in) 13,340mm (525in) 1

Table 113. Bucket rotation Dipper tearout Bucket tearout

284

182°

9821/9967-1

284

Technical Data Performance Dimensions

Lifting Figure 292.

Figure 293.

285

9821/9967-1

285

Technical Data Performance Dimensions

Figure 294.

Figure 295.

286

9821/9967-1

286

Technical Data Performance Dimensions

Figure 296.

287

9821/9967-1

287

Technical Data Performance Dimensions

(For: JS190) Digging JS190 - Monoboom Figure 297. A B

10 9 8 7 6

5 4

3 2 1

Met res

Table 114. 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

288

3,050mm (120in) 9,223mm (363in) 9,088mm (358in)

6,252mm (246in)

6,598mm (260in)

9,663mm 1 (380 ⁄2in) 7,321mm (288in)

9,888mm 1 (389 ⁄2in) 7,543mm (297in)

5,682mm 1 (223 ⁄2in) 3,000mm (118in)

6,028mm 1 (237 ⁄2in) 3,000mm (118in) 288

Technical Data Performance Dimensions

JS190 - Triple Articulated Boom Figure 298. A B

12 11 10 9 8 7 6

4 3 2 1

Mèt res

C F

Mèt res

Table 115. 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

289

5,350mm (210 ⁄2in) 2,250mm 2,700mm 1 1 (88 ⁄2in) (106 ⁄2in) 8,831mm 9,260mm 1 1 (347 ⁄2in) (364 ⁄2in) 8,652mm 9,094mm 1 (358in) (340 ⁄2in) 5,354mm 5,786mm (211in) (228in) 1

10,248mm 1 (403 ⁄2in) 8,000mm (315in) 4,232mm 1 (166 ⁄2in) 2,170mm 1 (85 ⁄2in)

9821/9967-1

3,050mm (120in)

10,674mm (420in)

9,592mm 1 (377 ⁄2in) 9,463mm 1 (372 ⁄2in) 6,108mm 1 (240 ⁄2in) 10,822mm (426in)

8,444mm 1 (332 ⁄2in) 4,699mm (185in)

8,672mm 1 (341 ⁄2in) 5,211mm (205in)

2,227mm 1 (87 ⁄2in)

2,587mm (102in)

289

Technical Data Performance Dimensions

Lifting Figure 299.

290

9821/9967-1

290

Technical Data Performance Dimensions

Figure 300.

291

9821/9967-1

291

Technical Data Performance Dimensions

Figure 301.

292

9821/9967-1

292

Technical Data Performance Dimensions

Figure 302.

293

9821/9967-1

293

Technical Data Performance Dimensions

(For: JS200) Digging JS200 - Monoboom Figure 303. A B

D E

Table 116. Boom length Dipper length

5,700mm (224 ⁄2in) 1,910mm (75in)

A Maximum digging reach

8,890mm (350in)

B Maximum digging reach (on ground)

8,700mm (342 ⁄2in)

C Maximum digging depth D Maximum digging height E Maximum dumping height

5,530mm (217 ⁄2in) 1

8,950mm (352 ⁄2in) 1

F Maximum vertical wall cut depth

6,310mm (248 ⁄2in) 4,900mm (193in)

G Maximum swing radius

3,760mm (148in)

294

9821/9967-1

2,400mm (94 ⁄2in) 1

9,340mm (367 ⁄2in) 1

9,160mm (360 ⁄2in) 6,020mm (237in) 1

9,200mm (362in) 6,530mm (257in) 5,470mm (215 ⁄2in) 3,710mm (146in) 1

294

Technical Data Performance Dimensions

Lifting Figure 304.

295

9821/9967-1

295

Technical Data Performance Dimensions

Figure 305.

296

9821/9967-1

296

Technical Data Performance Dimensions

Figure 306.

297

9821/9967-1

297

Technical Data Performance Dimensions

(For: JS220) Digging JS220 - Monoboom Figure 307. A B

D E

Table 117. Boom length Dipper length

5,700mm (224 ⁄2in) 1,910mm (75in)

A Maximum digging reach

8,890mm (350in)

B Maximum digging reach (on ground)

8,700mm (342 ⁄2in)

C Maximum digging depth D Maximum digging height E Maximum dumping height

5,530mm (217 ⁄2in) 1

8,950mm (352 ⁄2in) 1

F Maximum vertical wall cut depth

6,310mm (248 ⁄2in) 4,900mm (193in)

G Maximum swing radius

3,760mm (148in)

298

9821/9967-1

2,400mm (94 ⁄2in) 1

9,340mm (367 ⁄2in) 1

9,160mm (360 ⁄2in) 6,020mm (237in) 1

9,200mm (362in) 6,530mm (257in) 5,470mm (215 ⁄2in) 3,710mm (146in) 1

298

Technical Data Performance Dimensions

JS220 - Triple Articulated Boom Figure 308. A B

11 10 9 8 7 6

4 3 2 1

Metres

Table 118. Boom length Dipper length A Maximum digging reach

5,700mm (224 ⁄2in) 1,910mm (75in) 1

B Maximum digging reach (on ground)

9,000mm (354 ⁄2in) 8,810mm (347in)

C Maximum digging depth

5,290mm (208 ⁄2in)

D Maximum digging height

2,400mm (94 ⁄2in) 1

9,440mm (371 ⁄2in) 1

9,260mm (364 ⁄2in) 5,770mm (227in) 1

10,540mm (415in)

E Maximum dumping height F Maximum vertical wall cut depth

10,200mm (401 ⁄2in) 7,310mm (288in) 4,040mm (159in)

G Maximum swing radius

2,500mm (98 ⁄2in)

2,550mm (100 ⁄2in)

299

9821/9967-1

7,650mm (301in) 4,540mm (178 ⁄2in) 1 1

299

Technical Data Performance Dimensions

JS220 LR Figure 309. A B

45º

Table 119. Boom length

8,700mm (342 ⁄2in) 6,400mm (252in) 15,600mm (614in) 15,490mm (610in) 11,990mm (472in) 1

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 G H

Minimum dumping height Bucket struck radius Minimum swing radius

Minimum swing radius height

Maximum ground level span

12,660mm (498 ⁄2in) 1

10,450mm (411 ⁄2in) 1,910mm (75in) 1,200mm (47in) 1

5,450mm (214 ⁄2in) 1

10,270mm (404 ⁄2in) 14,000mm (551in) 1

Table 120. Bucket rotation Dipper tearout Bucket tearout

300

182° 4,500kg (9,920.70lb) 5,900kg (13,007.14lb)

9821/9967-1

300

Technical Data Performance Dimensions

Lifting Figure 310.

301

9821/9967-1

301

Technical Data Performance Dimensions

Figure 311.

Figure 312.

302

9821/9967-1

302

Technical Data Performance Dimensions

Figure 313.

Figure 314.

303

9821/9967-1

303

Technical Data Performance Dimensions

Figure 315.

304

9821/9967-1

304

Technical Data Performance Dimensions

(For: JS210) Digging JS210 - Monoboom Figure 316. A B

D E

Table 121. Boom length Dipper length

5,700mm (224 ⁄2in) 1,910mm (75in)

A Maximum digging reach

8,890mm (350in)

B Maximum digging reach (on ground)

8,700mm (342 ⁄2in)

C Maximum digging depth D Maximum digging height E Maximum dumping height

5,530mm (217 ⁄2in) 1

8,950mm (352 ⁄2in) 1

F Maximum vertical wall cut depth

6,310mm (248 ⁄2in) 4,900mm (193in)

G Maximum swing radius

3,760mm (148in)

305

9821/9967-1

2,400mm (94 ⁄2in) 1

9,340mm (367 ⁄2in) 1

9,160mm (360 ⁄2in) 6,020mm (237in) 1

9,200mm (362in) 6,530mm (257in) 5,470mm (215 ⁄2in) 3,710mm (146in) 1

305

Technical Data Performance Dimensions

JS210 - Triple Articulated Boom Figure 317. A B

11 10 9 8 7 6

4 3 2 1

Metres

Table 122. Boom length Dipper length A Maximum digging reach

5,700mm (224 ⁄2in) 1,910mm (75in) 1

B Maximum digging reach (on ground)

9,000mm (354 ⁄2in) 8,810mm (347in)

C Maximum digging depth

5,290mm (208 ⁄2in)

D Maximum digging height

2,400mm (94 ⁄2in) 1

9,440mm (371 ⁄2in) 1

9,260mm (364 ⁄2in) 5,770mm (227in) 1

10,540mm (415in)

E Maximum dumping height F Maximum vertical wall cut depth

10,200mm (401 ⁄2in) 7,310mm (288in) 4,040mm (159in)

G Maximum swing radius

2,500mm (98 ⁄2in)

2,550mm (100 ⁄2in)

306

9821/9967-1

7,650mm (301in) 4,540mm (178 ⁄2in) 1 1

306

Technical Data Performance Dimensions

Lifting Figure 318.

307

9821/9967-1

307

Technical Data Performance Dimensions

Figure 319.

308

9821/9967-1

308

Technical Data Performance Dimensions

(For: JS235) Digging JS235 - Monoboom Figure 320. A B

D E

Table 123. Boom length Dipper length

5,700mm (224 ⁄2in) 1,910mm (75in)

A Maximum digging reach

8,890mm (350in)

B Maximum digging reach (on ground)

8,700mm (342 ⁄2in)

C Maximum digging depth D Maximum digging height E Maximum dumping height

5,530mm (217 ⁄2in) 1

8,950mm (352 ⁄2in) 1

F Maximum vertical wall cut depth

6,310mm (248 ⁄2in) 4,900mm (193in)

G Maximum swing radius

3,760mm (148in)

309

9821/9967-1

2,400mm (94 ⁄2in) 1

9,340mm (367 ⁄2in) 1

9,160mm (360 ⁄2in) 6,020mm (237in) 1

9,200mm (362in) 6,530mm (257in) 5,470mm (215 ⁄2in) 3,710mm (146in) 1

309

Technical Data Performance Dimensions

JS235 - Triple Articulated Boom Figure 321. A B

11 10 9 8 7 6

4 3 2 1

Metres

Table 124. Boom length Dipper length A Maximum digging reach

5,700mm (224 ⁄2in) 1,910mm (75in) 1

B Maximum digging reach (on ground)

9,000mm (354 ⁄2in) 8,810mm (347in)

C Maximum digging depth

5,290mm (208 ⁄2in)

D Maximum digging height

2,400mm (94 ⁄2in) 1

9,440mm (371 ⁄2in) 1

9,260mm (364 ⁄2in) 5,770mm (227in) 1

10,540mm (415in)

E Maximum dumping height F Maximum vertical wall cut depth

10,200mm (401 ⁄2in) 7,310mm (288in) 4,040mm (159in)

G Maximum swing radius

2,500mm (98 ⁄2in)

2,550mm (100 ⁄2in)

310

9821/9967-1

7,650mm (301in) 4,540mm (178 ⁄2in) 1 1

310

Technical Data Performance Dimensions

Lifting Figure 322. Monoboom

Figure 323. Triple Articulated Boom

311

9821/9967-1

311

Technical Data Performance Dimensions

Driving Performance The maximum travel speed of all JS Tracked Excavators is no more than 6 kph (3.7 mph).

312

9821/9967-1

312

Technical Data Noise Emissions

Noise Emissions General The noise data values for this type of machine have been provided on the following page(s) and may be used for the assessment of risks to exposure from noise. For information relating to this machine when used with other JCB approved attachments, please refer to the literature accompanying the attachments. Table 125. Definition of terms Term LpA LwA

Definition A-weighted sound pressure level measured at the operator's station. Equivalent A-weighted sound power level emitted by the machine.

Notes Determined in accordance with the test method defined in ISO 6396.

Noise Data For: JS115, JS130, JS145 ..................................................................................................... Page 313 For: JS160, JS180, JS190 ..................................................................................................... Page 313 For: JS200, JS210, JS220, JS235 ......................................................................................... Page 313

(For: JS115, JS130, JS145) Table 126. All Machines Engine rating 74kW (99hp) 81kW (109hp)

(1)

LpA

LwA

72 72

100 100

LpA

LwA

71 73

100 100

LpA

LwA

102

(1) Net installed power.

(For: JS160, JS180, JS190) Table 127. Engine rating 93kW (125hp) 97kW (130hp)

(1)

(1) Net installed power.

(For: JS200, JS210, JS220, JS235) Table 128. Engine rating 129kW (173hp)

(1)

(1) Net installed power.

313

9821/9967-1

313

Technical Data Vibration Emissions

Vibration Emissions Vibration Data Figure 324. Y

m/s² A(8)

0.39

0.29

0.03 D1 X-Z D1 D2 D3

Dominant axis Machine operating duty: Low idle Machine operating duty: Excavating Machine operating duty: Tracking (rough terrain)

The whole-body vibration emission under representative operating conditions (according to the intended use) are shown. Refer to Figure 324. The whole-body vibration emission calculated in accordance with ISO 2631-1:1997 for this machine type is 0.29m/s² (1.0feet/s²) normalized to an 8h reference period [A(8)] and based upon a test cycle defined in SAE J1166. The hand-arm vibration calculated in accordance with the dynamic test conditions defined in ISO 5349-2: 2001 does not exceed 2.5m/s² (8.2feet/s²). The error bars are due to variations in vibration emissions due to measurement uncertainty (50% in accordance with EN 12096:1997).

314

9821/9967-1

314

Technical Data Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities General For: JS115, JS130, JS145 ..................................................................................................... Page 315 For: JS160, JS180, JS190 ..................................................................................................... Page 315 For: DJ Engine, JS200, JS210, JS220, JS235, SJ Engine .................................................... Page 316

(For: JS115, JS130, JS145) 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 129. Fluids, Lubricants and Capacities Item

Capacity

Fluid/Lubricant

JCB Part Number

Fuel Tank

253L 27 (66 ⁄32USgal) 20.4L 12 (5 ⁄32USgal)

Diesel

Engine (Oil)

(2)

Cooling System Track Gearbox (each) Slew Gearbox Track Rollers and Idler Wheels Recoil Spring Cylinder Hydraulic System

Above -10°C (14°F): JCB Engine Oil 4001/1805 EP 15W/40 -20°C (-4°F) to 50°C (122°F): JCB Cold Climate Engine Oil EP 5W40

7 19.7L (5 ⁄32US- JCB Antifreeze HP/Coolant gal) 30 JCB HD90 Gear Oil 3.5L ( ⁄32USgal) 19 JCB HD90 Gear Oil 2.2L ( ⁄32USgal) JCB HD90 Gear Oil

124L 24 (32 ⁄32USgal)

4001/2705 4006/1120 4001/0305 4000/0305 4000/0305

JCB Special HP Grease

4003/2017

JCB Hydraulic Fluid HP32-20°C (-4°F) to 15°C (59°F)

4002/1024

JCB Hydraulic Fluid HP46-10°C (14°F) to 30°C (86°F)

4002/0803

JCB Hydraulic Fluid HP680°C (32°F) 4002/0701 to 40°C (104°F) Slew Ring Bearings Slew Ring Gear Teeth All Other Grease

0.06kg (0.13lb) 11kg (24lb)

JCB Special HP Grease

4003/2017

JCB Special HP Grease

4003/2006

As required

JCB Special HP Grease

4003/2017

Container (1) Size 20L (5 ⁄32USgal) 9

20L (5 ⁄32USgal) 9

20L (5 ⁄32USgal) 0.4kg (0.9lb) 9

200L 27 (52 ⁄32USgal) 200L 27 (52 ⁄32USgal) 200L 27 (52 ⁄32USgal) 0.4kg (0.9lb) 12.5kg (27.6lb) 0.4kg (0.9lb)

(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.

(For: JS160, JS180, JS190) 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.

315

9821/9967-1

315

Technical Data Fluids, Lubricants and Capacities

Table 130. Fluids, Lubricants and Capacities Item

Capacity

Fluid/Lubricant

JCB Part Number

Fuel Tank

253L 27 (66 ⁄32USgal) 20.4L 12 (5 ⁄32USgal)

Diesel

Engine (Oil)

(2)

Cooling System Track Gearbox (each) Slew Gearbox

-10°C (14°F) to 50°C (121.9°F): JCB 4001/1805 Engine Oil EP 15W/40 -20°C (-4°F) to 50°C (122°F): JCB Cold Climate Engine Oil EP 5W40

7 19.7L (5 ⁄32US- JCB Antifreeze HP/Coolant gal) 5 4.4L (1 ⁄32US- JCB HD90 Gear Oil gal) 19 6L (1 ⁄32USgal) JCB HD90 Gear Oil

4001/2705 4006/1120 4001/0301 4000/0305

Track Rollers and Idler Wheels

JCB HD90 Gear Oil

4000/0305

Recoil Spring Cylinder Hydraulic System

JCB Special HP Grease

4003/2017

JCB Hydraulic Fluid HP32-20°C (-4°F) to 15°C (59°F)

4002/1024

JCB Hydraulic Fluid HP46-10°C (14°F) to 30°C (86°F)

4002/0803

142L 16 (37 ⁄32USgal)

JCB Hydraulic Fluid HP680°C (32°F) 4002/0701 to 40°C (104°F) Slew Ring Bearings Slew Ring Gear Teeth All Other Grease

0.075kg (0.17lb) 11kg (24lb)

JCB Special HP Grease

4003/2017

JCB Special HP Grease

4003/2006

As required

JCB Special HP Grease

4003/2006

Container (1) Size 20L (5 ⁄32USgal) 9

20L (5 ⁄32USgal) 9

5L (1 ⁄32USgal) 10

20L (5 ⁄32USgal) 9

20L (5 ⁄32USgal) 0.4kg (0.9lb) 9

200L 27 (52 ⁄32USgal) 200L 27 (52 ⁄32USgal) 200L 27 (52 ⁄32USgal) 0.4kg (0.9lb) 12.5kg (27.6lb) 12.5kg (27.6lb)

(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.

(For: DJ Engine, JS200, JS210, JS220, JS235, SJ Engine) 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.

316

9821/9967-1

316

Technical Data Fluids, Lubricants and Capacities

Table 131. Fluids, Lubricants and Capacities Item

Capacity

Fluid/Lubricant

JCB Part Number

Fuel tank

343L 20 (90 ⁄32USgal)

Diesel

DEF (Diesel Ex- 54L haust Fluid) Tank (148⁄32USgal)

DEF

Specification Refer to: Technical Data > Fluids, Lubricants and Capacities > Fuel (Page 318). Refer to: Technical Data > Fluids, Lubricants and Capacities > Diesel Exhaust Fluid (DEF) (Page 321). API CJ-4

-30°C (-22°F) to 30°C (86.0°F) 4001/3105 20L 9 JCB Engine Oil UP 5W/30 (5 ⁄32USgal) -30°C (-22°F) to 46°C 4001/3405 20L 9 (114.7°F) JCB Engine Oil UP (5 ⁄32USgal) 5W/40 -15°C (5°F) to 46°C (115°F): 4001/3005 20L 9 JCB Engine Oil UP 10W/30 (5 ⁄32USgal) Cooling System 33L JCB Antifreeze HP/Coolant 4006/1120 20L ASTM 23 9 (8 ⁄32US(5 ⁄32USgal) D3306, ASTM D4985, ASTM gal) D6210,SAE (Society of Automotive Engineers) J1034, BS6580 (1992), AFNOR NF R15- 60 Track Gearbox 4.7L JCB HD90 Gear Oil 4001/0301 5L 8 10 (each) (1 ⁄32USgal) (1 ⁄32USgal) Slew Gearbox 5L JCB HD90 Gear Oil 4000/0305 20L 10 9 (1 ⁄32US(5 ⁄32USgal) gal) Track Rollers and JCB HD90 Gear Oil 4000/0305 20L 9 Idler Wheels (5 ⁄32USgal) Recoil Spring JCB Special HP Grease 4003/2017 0.4kg Cylinder (0.9lb) Hydraulic System 200L JCB Hydraulic Fluid HP32, 4002/1024 200L 27 27 (52 ⁄32US- -20°C (-4°F) to 15°C (59°F) (52 ⁄32USgal) gal) JCB Hydraulic Fluid HP46, 4002/0803 200L 27 -10°C (14°F) to 30°C (86°F) (52 ⁄32USgal) JCB Hydraulic Fluid HP68, 4002/0701 200L 27 0°C (32°F) to 40°C (104°F) (52 ⁄32USgal) Slew Ring Bear- 0.1kg JCB Special HP Grease 4003/2017 0.4kg ings (0.22lb) (0.9lb) Engine (Oil)

(2)

317

17.5L 20 (4 ⁄32USgal)

Container (1) Size -

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Technical Data Fluids, Lubricants and Capacities

Item

Capacity

Fluid/Lubricant

Slew Ring Gear Teeth All Other Grease

17kg (37lb) JCB Special HP Grease As required JCB Special HP Grease

JCB Part Number

Container (1) Size 4003/2006 12.5kg (27.6lb) 4003/2006 12.5kg (27.6lb)

Specification

(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.

Fuel Acceptable and Unacceptable Fuels NOTICE No warranty liability whatsoever will be accepted for failure of fuel injection equipment where the failure is attributed to the quality and grade of the fuel used. WARNING Do not use gas in this machine. Do not mix gas with the diesel fuel. In storage tanks the gas will rise to the top and form flammable vapors.

Fuel Groups The major world fuels standards are divided into three categories. Those that are fully accepted as suitable fuels, those that are acceptable from a "warranty" point of view, but may have undesirable affects on the expected life of the engine performance, and lastly those that are viewed as unacceptable for use (fuels shown on the same line as each other are considered equivalents). The lists below are not exhaustive of all diesel fuel standards encountered in the marketplace. If comment is required on the suitability of fuel standards not on the list, requests with, if possible, specification details showing at least the key characteristics described above should be forwarded to JCB Service for assessment and comment. Table 132. Group 1 Fuel Advice EN590 Diesel fuel types - Auto/C0/ Preferred and may be used with no C1/C2/C3/C4 restrictions or conditions. BS2869 : 2010 A1 : 2011 Class A2 ASTM D975-14A No2-15ppm

Service Requirements For fuel with unspecified parameters, EN590 values apply. Fuel grades within each standard must be appropriate to the ambient temperature. The appropriate level of fuel cleanliness at the FIE inlet after filtration has to be ensured by the customer.

Table 133. Group 2 Fuel Group1 fuels with HFFR WSD in the range 460μm (18,110μin) to 1 520μm (20,472 ⁄2μin) ASTM D975 No1 DS-15ppm

Advice Service Requirements Not preferred and may be used but may lead to reduced FIE life and / or loss of performance.

(1) See your JCB dealer for advice on service requirements. Table 134. Group 3 Fuel Advice Unmodified Vegetable Oils and Biodiesels over 20% Unacceptable concentration AVTUR FS11 (NATO F34, JP8, MIL T83133, DEF Unacceptable as will damage aftertreatment system. STAN 91-87, DERD 2463) 318

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Technical Data Fluids, Lubricants and Capacities

Fuel Advice AVCAT FS11 (NATO F44, JP5, MIL T5624, DERD 2452, AVTOR)) JET A1 (NATO F35, DEF STAN 91-91, DERD 2494) AVCAT (NATO F43, JP5 without additives) JET A (ASTM D1655) ASTM D3699 Kerosene JP7 (MIL T38219 XF63) NATO F63

Additives Diesel fuels are blended by fuel companies and subjected to test to ensure fuel and aftertreatment systems are not impacted. JCB do not recommend the use of further additive products.

Warranty JCB have shown a commitment to support the environment by approving the use of biodiesel blended fuels. Using a B5 blend of biodiesel requires caution and additional servicing of the engine is required. Failure to follow the additional recommended service requirements may lead to a warranty claim being declined. Failures resulting by the incorrect use of biodiesels or other fuel additives are not defects of the engine workmanship and therefore will not be supported by JCB Warranty.

Usage and Effects of Fuels The information that follows does indicates the types of fuel that are acceptable or unacceptable.

Acceptable Fuels Ultra Low Sulfur Diesel (EN590) Available throughout the UK, Europe and North America since March 1999. This fuel has a maximum sulfur content of 0.001% (0.0015% in North America) by weight and a further reduction in the natural lubricity and aromatic content than experienced with low sulfur diesel. Major oil producers will add lubrication improvers and also maintain the total aromatic content to an acceptable level.

Unacceptable Fuels B20 Biodiesel Biodiesel refers to pure fuel before it is blended with diesel fuel. When biodiesel is blended with diesel fuel it is referred to as B5, B20 etc., where the number indicates the percentage of biodiesel in the fuel, for example B5 contains 5% biodiesel. Biodiesel has different characteristics than mineral based fuels, this could lead to seals swelling, fuel system corrosion and seal damage. Using B20 biodiesel can result in unburnt fuels accumulating in the engine oil, ultimately this can affect the engine oil efficiency and lead to engine damage (with standard diesel any unburnt fuel evaporates off the lubricating oil). Using B20 biodiesel can result in poisoning of the SCR (Selective Catalytic Reduction) system. The natural properties of biodiesel make it a good medium for micro bacterial growth, these microbes can cause fuel system corrosion and early fuel filter blocking.

319

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Technical Data Fluids, Lubricants and Capacities

B100 - Chemically Modified Vegetable Oils (FAME/ VOME) These fuels have been derived from a wide range of vegetable oils and animal fats, resulting in better stability, viscosity and cetane number than those produced from unmodified vegetable oils, but it is recognized that there are potential problems associated with the finished fuel characteristics. These oils are less stable than mineral oil derived fuels when stored and they will readily degrade producing fatty acids, methanol and water, none of which are desirable in the FIE. These effects are known to be accelerated when the fuel is stored in the presence of air and water together. An extract 'common statement' from the FIE manufactures specifies that "The fuel injection equipment manufacturers can accept no liability whatsoever for failure attributable to operating their products with fuels for which the products were not designed, and no warranties or representations are made as to the possible effects of running these products with such fuels".

Unmodified Vegetable Oils Burned in diesel engines neat or used as an extender to mineral derived fuel. When these are subjected to heat in the fuel injection system they form sticky deposits that can be found inside the fuel pump and a hard lacquer in the injectors where exposure to even higher temperatures takes place.

Sulfur Content NOTICE A combination of water and sulfur will have a corrosive chemical effect on fuel injection equipment. Use of high sulphur fuels will poison the SCR catalyst and must not be used.

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

Dirt A severely damaging contaminant. Finely machined and mated surfaces such as delivery valves and distributor rotors are susceptible to the abrasive nature of dirt particles - increased wear will almost inevitably lead to greater leakage, uneven running and poor fuel delivery.

Water Water can enter fuel through poor storage or careless handling, and will almost inevitably condense in fuel tanks. The smallest amounts of water can result in effects that are just as disastrous to the fuel injection pump as dirt, causing rapid wear, corrosion and in severe cases, even seizure. It is vitally important that water is prevented from reaching the fuel injection equipment. The filter/water trap must be drained regularly.

Wax Wax is precipitated from diesel when the ambient temperature falls below that of the fuel's cloud point, causing a restriction in fuel flow resulting in rough engine running. Special winter fuels may be available for engine operation at temperatures below 0Â°C (32.0Â°F). These fuels have a lower viscosity and limit wax formation.

Chemical Contamination NOTICE Using fuel which has been exposed to surfaces containing Copper (Cu), Zinc (Zn) or Lead (Pb) can poison the SCR catalyst. Fuel must never be exposed to these contaminants. It should be noted that exposure of fuel to surfaces containing Copper (Cu), Zinc (Zn) or Lead (Pb) can adversely affect fuel quality and should be minimized.

320

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Technical Data Fluids, Lubricants and Capacities

Diesel Exhaust Fluid (DEF) Diesel Exhaust Fluid (DEF) NOTICE No warranty liability whatsoever will be accepted for failure of the emissions control system where the failure is attributed to the quality and grade of the diesel exhaust fluid (DEF) used. NOTICE No warranty liability whatsoever will be accepted for failure of the emissions control system where the failure is attributed to contamination of the diesel exhaust fluid (DEF). This engine has exhaust gas treatment using selective catalytic reduction technology. In SCR (Selective Catalytic Reduction) technology, a liquid called diesel exhaust fluid is injected into the exhaust gasses. DEF (Diesel Exhaust Fluid) is used within SCR systems on diesel engines to reduce harmful exhaust gas emissions known as NOx. When the DEF is injected into the exhaust stream it turns into ammonia and water, this ammonia enters the catalyst and reacts with the NOx molecules to form nitrogen and water. Naturally occurring and harmless, they are then released into the atmosphere. The DEF consumption depends on the duty cycle of the engine. DEF is a highly purified, colorless liquid containing demineralized water 67.5% and Urea 32.5%. DEF is specified under ISO 22241 and is marketed under various names such as AdBlue®, ARLA 32 or AUS 32. Make sure that genuine DEF is used. Do not dilute DEF or mix it with other substances, it may damage the catalyst. The DEF tanks and pipes are heated if there is any danger of freezing, the congealing point of DEF at 32.5% is -11°C (12.2°F). The DEF storage tank on the machine will be heated from the engine cooling system automatically. If a problem is detected within the DEF system for any problem including contamination, engine power will be reduced.

Storage Always use polyethylene, polypropylene, stainless steel or plastic containers for storing DEF, as DEF can be corrosive to most metals (eg steel, copper This applies to any funnels, jugs, pipes, pumps and other handling equipment Avoid decanting wherever possible to prevent contamination from dirt or trace amounts of metals that can occur when metal containers are used. Even the use of apparently clean items such as jugs or funnels may introduce damaging contaminants if they have ever been used for other purposes. Always ensure any caps on DEF storage containers are screwed tight to prevent evaporation and crystallization. DEF can be stored for up to 12 months in a sealed container, and must be kept between -6°C (21°F) and 25°C (77°F) in a shaded area out of direct sunlight and ultraviolet radiation.

Spillages A small DEF spill can be diluted with water. It is best to mop up the spillage and avoid flushing it down a drain or waterway In case of a large spill, try to prevent the spillage from entering drains or waterways. Contain the spill with sand, earth or your spill kit and dispose of it properly The surface on which you spill DEF may become slippery. Make sure that you clean up the spill as quickly as possible to prevent slips and falls. If a spill occurs on the machine, wash away with water as white crystals will form and these will eventually become corrosive to paintwork and, in turn, metal work

321

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Technical Data Fluids, Lubricants and Capacities

DEF should never be spilled onto electrical connectors as it will destroy terminals quickly. It can also travel easily by capillary action between the insulation and copper wires in harnesses.

Preventing Contamination of the DEF tank In order to prevent damage to the SCR system, DEF used must be compliant to the ISO 22241-1 standard. ISO 22241-1 DEF is available from all JCB dealers Every machine equipped with a JCB SCR system is fitted with a quality sensor in the DEF tank to help prevent problems caused by cross contamination with other fluids DEF needs to be kept free from dirt and other particle contaminants at all times to prevent damage to the SCR system. There is a mesh strainer fitted in the JCB DEF filler. DEF needs to be kept free from liquid contaminants such as diesel, oil, antifreeze, screenwash and other fluids at all times. Even one drop of diesel or oil can pollute 20L (5USgal) of DEF. If diesel is poured into the DEF tank this can damage the after treatment system, do not start the engine, please contact your local JCB dealer immediately so they can correctly flush the system to avoid an expensive repair. A range of special tools and fluid analysis services are available at your local JCB dealer to check DEF quality via simple hydrocarbon test paper strips, or a more comprehensive laboratory service. Digital and optical concentration measuring devices are also available. If any cross contamination is detected JCB will not be liable for any further diagnosis or repairs to the SCR system.

Preventing Cross Contamination of Diesel Fuel and DEF The opening for your DEF tank is narrower than the opening for a diesel tank, so you should not be able to put diesel in the wrong tank (as the nozzle does not fit) The DEF cap on every JCB machine is blue and clearly marked with AdBlue ÂŽ, DEF and the ISO (International Organization for Standardization) symbol in white lettering . There are warning decals next to the DEF filling point The diesel cap is also clearly marked with lettering. Every JCB DEF cap is lockable with a special key with a blue key fob, which can be given to a site supervisor or other person of responsibility. There is a special magnet fitted in the DEF filler neck which will allow some DEF electric dispensing pumps to start if it has the matching ISO feature, as all forecourt dispensing systems have, thus preventing DEF being dispensed if nozzle is not in the DEF tank. If contamination occurs do not start the engine. Please contact your local JCB dealer immediately so they can correctly flush the system to avoid an expensive repair.

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.

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Technical Data Fluids, Lubricants and Capacities

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 135. Concentration 50% (Standard) 60% (Extreme Conditions Only)

Level of protection Protects against damage down to -40°C (-40°F) Protects against damage down to -56°C (-69°F)

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

323

Make sure that the antifreeze complies with International Specification ASTM D6210 Always read and understand the manufacturer's instructions Make sure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used Make sure that the antifreeze is ethylene glycol based and does not use Organic Acid Technology (OAT).

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Technical Data Torque Values

Torque Values General For: For: For: For: For: For: For: For: For:

Page Page Page Page Page Page Page Page Page

324 327 329 331 333 335 337 339 341

(For: JS115) JS115 and Variants 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 136. For the tightening torques of the bolts and nuts not listed, Refer to Table 137. Table 136.

(1)

6 7 8

(1)

13 14

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 24

Tightening Torque (N.m) 290

Checking Torque (N.m) 265

Travel motor

M16

Drive sprocket Idler wheel

M16

290

265

M16

290

265

Upper (carrier) roller

M16/M20

24/30

290/550

265/515

Lower (track) roller

M16

290

265

Track guard

M16

290

265

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M16 M27 M16/M20

24 41 24/30

382-440 925 296/525

344-396 840 275/470

M16/M20

24/30

296/525

275/470

M16/M20

24/30

290/550

265/515

Engine (engine mount)

M16

290

265

Engine bracket

M10/M12

17/19

68/118

62/107

Radiator Hydraulic pump

M12 M10

19 17

104 60

94 54

Hydraulic oil tank

M16

250

225

Fuel tank

M16

250

225

Control valve

M16

290

265

Battery Rotary coupling

M6 M12

10 19

7 116

6 105

Cab

M16

132

125

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. 324

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Technical Data Torque Values

Table 137. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

325

(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

9821/9967-1

325

Technical Data Torque Values

Figure 325. 10

7 12

12 11 8

326

9821/9967-1

326

Technical Data Torque Values

(For: JS130) JS130 and Variants 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 138. For the tightening torques of the nuts and bolts not listed, Refer to Table 139. Table 138.

(1)

6 7 8

(1)

13 14

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 24

Tightening Torque (N.m) 290

Checking Torque (N.m) 265

Travel motor

M16

Drive sprocket

M16

290

265

Idler wheel

M16

290

265

Upper (carrier) roller

M16/M20

24/30

290/550

265/515

Lower (track) roller

M16

290

265

Track guard

M16

290

265

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M16 M27 M16/M20

24 41 24/30

382-440 925 296/525

344-396 840 275/470

M16/M20

24/30

296/525

275/470

M16/M20

24/30

290/550

265/515

Engine (engine mount)

M16

290

265

Engine bracket

M10/M12

17/19

68/118

62/107

Radiator Hydraulic pump

M12 M10

19 17

104 60

94 54

Hydraulic oil tank

M16

250

225

Fuel tank

M16

250

225

Control valve

M16

290

265

Battery Rotary coupling

M6 M12

10 19

7 116

6 105

Cab

M16

132

125

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 139. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

327

(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

9821/9967-1

327

Technical Data Torque Values

Figure 326. 10

7 12

12 11 8

328

9821/9967-1

328

Technical Data Torque Values

(For: JS145) JS145 and Variants 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 140. For the tightening torques of the bolts and nuts not listed, Refer to Table 141. Table 140.

(1)

6 7 7 8

(1)

13 14

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 24

Tightening Torque (N.m) 290

Checking Torque (N.m) 265

Travel motor

M16

Drive sprocket

M16

290

265

Idler wheel

M16

290

265

Upper (carrier) roller

M16/M20

24/30

290/550

265/515

Lower (track) roller

M16

290

265

Track guard

M16

290

265

Shoe bolt (JS145) Shoe bolt (JS145HD) Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M16 M20 M27 M16/M20

24 27 41 24/30

363-421 643-757 925 296/525

327-379 579-681 840 275/470

M16/M20

24/30

296/525

275/470

M16/M20

24/30

290/550

265/515

Engine (engine mount)

M16

290

265

Engine bracket

M10/M12

17/19

68/118

62/107

Radiator Hydraulic pump

M12 M10

19 17

104 60

94 54

Hydraulic oil tank

M16

250

225

Fuel tank

M16

250

225

Control valve

M16

290

265

Battery Rotary coupling

M6 M12

10 19

7 116

6 105

Cab

M16

132

125

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 141. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

329

(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

9821/9967-1

329

Technical Data Torque Values

Figure 327. 10

7 12

12 11 8

330

9821/9967-1

330

Technical Data Torque Values

(For: JS160) JS160 and Variants 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 142. For the tightening torques of the bolts and nuts not listed, Refer to Table 143. Table 142.

(1)

6 7 8

(1)

13 14

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 24

Tightening Torque (N.m) 215

Checking Torque (N.m) 194

Travel motor

M16

Drive sprocket

M20

415

374

Idler wheel

M16

290

265

Upper (carrier) roller

M16/M20

24/30

290/550

265/515

Lower (track) roller

M16

290

265

Track guard

M16

290

265

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M20 M30 M16/M20

27 46 24/30

643-757 1147 296/525

579-681 1050 275/470

M16/M20

24/30

296/525

275/470

M16/M20

24/30

290/550

265/515

Engine (engine mount)

M20/M16

27/24

529/271

476/244

Engine bracket

M12

125

113

Radiator Hydraulic pump

M12 M10

19 17

104 68

94 62

Hydraulic oil tank

M16

250

225

Fuel tank

M16

250

225

Control valve

M16

290

265

Battery Rotary coupling

M6 M12

10 19

7 116

6 105

Cab

M16

132

125

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 143. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

331

(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

9821/9967-1

331

Technical Data Torque Values

Figure 328. 10

7 12

12 11 8

332

9821/9967-1

332

Technical Data Torque Values

(For: JS180) JS180 and Variants 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 144. For the tightening torques of the bolts and nuts not listed, Refer to Table 145. Table 144.

(1)

6 7 8

(1)

13 14

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 24

Tightening Torque (N.m) 215

Checking Torque (N.m) 194

Travel motor

M16

Drive sprocket

M20

415

374

Idler wheel

M16

290

265

Upper (carrier) roller

M16/M20

24/30

290/550

265/515

Lower (track) roller

M16

290

265

Track guard

M16

290

265

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M20 M30 M16/M20

27 46 24/30

643-757 1147 296/525

579-681 1050 275/470

M16/M20

24/30

296/525

275/470

M16/M20

24/30

290/550

265/515

Engine (engine mount)

M20/M16

27/24

529/271

476/244

Engine bracket

M12

125

113

Radiator Hydraulic pump

M12 M10

19 17

104 68

94 62

Hydraulic oil tank

M16

250

225

Fuel tank

M16

250

225

Control valve

M16

290

265

Battery Rotary coupling

M6 M12

10 19

7 116

6 105

Cab

M16

132

125

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 145. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

333

(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

9821/9967-1

333

Technical Data Torque Values

Figure 329. 10

7 12

12 11 8

334

9821/9967-1

334

Technical Data Torque Values

(For: JS190) JS190 and Variants 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 146. For the tightening torques of the bolts and nuts not listed, Refer to Table 147. Table 146.

(1)

6 7 8

(1)

13 14

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 24

Tightening Torque (N.m) 215

Checking Torque (N.m) 194

Travel motor

M16

Drive sprocket

M20

415

374

Idler wheel

M16

290

265

Upper (carrier) roller

M16/M20

24/30

290/550

265/515

Lower (track) roller

M16

290

265

Track guard

M16

290

265

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M20 M30 M16/M20

27 46 24/30

643-757 1147 296/525

579-681 1050 275/470

M16/M20

24/30

296/525

275/470

M16/M20

24/30

290/550

265/515

Engine (engine mount)

M20/M16

27/24

529/271

476/244

Engine bracket

M12

125

113

Radiator Hydraulic pump

M12 M10

19 17

104 68

94 62

Hydraulic oil tank

M16

250

225

Fuel tank

M16

250

225

Control valve

M16

290

265

Battery Rotary coupling

M6 M12

10 19

7 116

6 105

Cab

M16

132

125

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 147. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

335

(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

9821/9967-1

335

Technical Data Torque Values

Figure 330. 10

7 12

12 11 8

336

9821/9967-1

336

Technical Data Torque Values

(For: JS200) JS200 and Variants 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 148. For the tightening torques of the bolts and nuts not listed, Refer to Table 149. Table 148.

(1)

6 7 8

(1)

13 14

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 24

Tightening Torque (N.m) 290

Checking Torque (N.m) 265

Travel motor

M16

Drive sprocket

M16

290

265

Idler wheel

M16

290

265

Upper (carrier) roller

M16/M20

24/30

290/550

265/515

Lower (track) roller

M16

290

265

Track guard

M16

290

265

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M20 M30 M20

30 46 30

840-890 1147 525

756-801 1050 470

M20

525

470

M20/M24

30/36

550/950

515/900

Engine (engine mount)

M20/M16

27/24

529/271

476/244

Engine bracket

M12

125

113

Radiator Hydraulic pump

M12 M10

19 17

55 60

50 54

Hydraulic oil tank

M16

250

225

Fuel tank

M16

250

225

Control valve

M16

290

265

Battery Rotary coupling

M6 M12

10 19

7 116

6 105

Cab

M16

132

125

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 149. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

337

(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

9821/9967-1

337

Technical Data Torque Values

Figure 331. 10

7 12

12 11 8

338

9821/9967-1

338

Technical Data Torque Values

(For: JS220, JS235) JS220 and Variants 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 150. For the tightening torques of the bolts and nuts not listed, Refer to Table 151. Table 150.

(1)

6 7 8

(1)

13 14

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 24

Tightening Torque (N.m) 290

Checking Torque (N.m) 265

Travel motor

M16

Drive sprocket

M16

290

265

Idler wheel

M16

290

265

Upper (carrier) roller

M16/M20

24/30

290/550

265/515

Lower (track) roller

M16

290

265

Track guard

M16

290

265

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M20 M30 M20

30 46 30

840-890 1147 525

756-801 1050 470

M20

525

470

M20/M24

30/36

550/950

515/900

Engine (engine mount)

M20/M16

27/24

529/271

476/244

Engine bracket

M12

125

113

Radiator Hydraulic pump

M12 M10

19 17

55 60

50 54

Hydraulic oil tank

M16

250

225

Fuel tank

M16

250

225

Control valve

M16

290

265

Battery Rotary coupling

M6 M12

10 19

7 116

6 105

Cab

M16

132

125

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 151. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

339

(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

9821/9967-1

339

Technical Data Torque Values

Figure 332. 10

7 12

12 11 8

340

9821/9967-1

340

Technical Data Torque Values

(For: JS210) JS210 and Variants 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 152. For the tightening torques of the bolts and nuts not listed, Refer to Table 153. Table 152.

(1)

6 7 8

(1)

13 14

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 24

Tightening Torque (N.m) 290

Checking Torque (N.m) 265

Travel motor

M16

Drive sprocket

M16

290

265

Idler wheel

M16

290

265

Upper (carrier) roller

M16/M20

24/30

290/550

265/515

Lower (track) roller

M16

290

265

Track guard

M16

290

265

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M20 M30 M20

30 46 30

840-890 1147 525

756-801 1050 470

M20

525

470

M20/M24

30/36

550/950

515/900

Engine (engine mount)

M20/M16

27/24

529/271

476/244

Engine bracket

M12

125

113

Radiator Hydraulic pump

M12 M10

19 17

55 60

50 54

Hydraulic oil tank

M16

250

225

Fuel tank

M16

250

225

Control valve

M16

290

265

Battery Rotary coupling

M6 M12

10 19

7 116

6 105

Cab

M16

132

125

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 153. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

341

(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

9821/9967-1

341

Technical Data Torque Values

Figure 333. 10

7 12

12 11 8

342

9821/9967-1

342

Technical Data Electrical System

Electrical System General Table 154. Item System voltage

Specification 24V

Fuses Fuses - Cab Figure 334.

F9 F8 F7 F6 F5 F4 F3 F2 F1 F11 F10

F16 F15 F14 F13 F12 F20 F19 F18 F17 F29 F28 F27 F26 F25 F24 F23 F22 F21

Table 155. Fuse Identification Fuse F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 343

Circuit(s) Protected Beacon Backlight Cushion solenoid Ignition wakeup Livelink 2 ECU (Electronic Control Unit) ignition Auxiliary ignition supplies Spare 1 Heated/Suspension/Ventilated seat Camera system HVAC (Heating Ventilation Air Conditioning) Engine crank Engine ignition Revolver ignition Livelink 2 ECU ground Livelink 2 ECU B+ Cab worklight 9821/9967-1

Rating 10A 5A 7.5A 5A 5A 15A 10A 10A 5A 20A 30A 10A 5A 3A 3A 10A 343

Technical Data Electrical System

Fuse F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29

Circuit(s) Protected Machine ECU B+ Hydraulic ECU B+ Ignition and refueling pump switch Diagnostic connector Interior light 12â&#x20AC;&#x201C;24V connector Standard worklamps Horn Wash wipe Engine stop Refueling pump Display ECU

Rating 30A 20A 20A 20A 10A 5A 15A 15A 10A 10A 10A 15A 5A

Fuses - Battery Bay Figure 335.

F1-12 R1-7

PFA

PFC

PFB

PFD

F8 F9 F10

PFA-D

F1 F2 F3

F11

F12

F5 F6 F7

R5 R6

Table 156. Fuse Identification Fuse F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 344

Circuit(s) Protected Engine ECM (Engine Control Module) supply 4 Engine ECM supply 3 Engine ECM supply 1 Engine ECM supply 2 EGR (Exhaust Gas Recirculation) VGT (Variable Geometry Turbocharger) Not used Power hold Ignition Fuel lift pump Fuel lift pump 9821/9967-1

Rating 10A 10A 10A 10A 10A 10A 3A 3A 10A 15A 3A 344

Technical Data Electrical System

Fuse F12 PFA PFB PFC PFD

Circuit(s) Protected Engine ECM ignition Fuse box battery supply Alternator JCB engine/pod box Ignition relay/fuse box ignition supply

Rating 3A 50A 50A 50A 50A

Relays Relay - Cab Figure 336.

F9 F8 F7 F6 F5 F4 F3 F2 F1 F11 F10

F16 F15 F14 F13 F12 F20 F19 F18 F17 F29 F28 F27 F26 F25 F24 F23 F22 F21

Table 157. Relay Identification Relay R1 R2 R3 R4 R5

345

Circuit(s) Engine crank Horn Wash wipe Engine stop Refuel pump

9821/9967-1

345

Technical Data Electrical System

Relay - Battery Bay Figure 337.

F1-12 R1-7

PFA

PFC

PFB

PFD

F8 F9 F10 F1 F2 F3 F4

PFA-D

F5 F6 F7

F11

F12 R5 R6

Table 158. Relay Identification Relay RL1 RL2 RL3 RL4 RL5 RL6 RL7

Circuit(s) Power hold 12V Fuel lift pump 12V Ignition sense 24V Not used Voltage dropper 24V Voltage dropper 12V Not used

Batteries California Proposition 65 WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

346

9821/9967-1

346

Technical Data Engine

Engine Engine Emissions California Proposition 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Exhaust After Treatment (EAT) Introduction Your engine is equipped with an SCR (Selective Catalytic Reduction) after-treatment system. This is a fully automated system in which DEF (Diesel Exhaust Fluid) is fed into the exhaust to remove nitrogen oxides. It has a sophisticated system of self-monitoring and fault detection to ensure it is both reliable and compliant to applicable emissions legislation. In order that the machine can be compliant across all duty cycles the performance of the SCR must be maintained. If a machine is used for a prolonged period (100s of hours) in light duties the SCR can become less efficient. Therefore the engine is equipped with a mode which runs the after-treatment system at typical operating temperatures whilst the machine is being lightly used. In this way the SCR is refreshed while the machine is running normally. This is automatic and seamless to the operator and the machine can continue to be operated normally while this is happening. Should the duty cycle continue to be very light the operator will be warned. If this occurs the operator has a choice to either operate the machine at a higher duty or complete the refresh cycle with the machine stationary. This again is a fully automatic process once initiated by the operator. If the operator ignores the warnings and does not complete a stationary refresh then the SCR will cease to be compliant and the engine will derate in accordance with the legislative requirements until a stationary refresh has been completed. The system has been designed such that the majority of customers should not have to invoke a stationary refresh, however the mode exists to ensure all products remain compliant. Typically the earliest a refresh would be required is around 700-1000 hours.

Stationary Refresh •

The engine is equipped with a setting that will automatically run the exhaust system hot enough while the machine is stationary. The operator will need to park the machine in a safe position and acknowledge that the machine can run a stationary refresh by initiating the procedure. Refer to the machine operator manual stationary refresh initiation procedure. Refer to: Operation > Instruments (Page 69).

DEF Levels The engine or SCR will not be damaged when you run out of DEF. To protect itself the machine performance will be reduced. Refill the DEF tank to restore performance. The engine will not shut down if you run out of DEF, however it will: • • •

Give the driver a warning when the remaining level falls low, which if continually ignored will progressively automatically reduce engine torque and reduce engine speed to tick over, preventing effective working activity. Allow only enough power for ‘limp home’ i.e to move the machine to a safe area or onto a trailer. Restore power when the DEF tank is refilled.

Attempting to operate the machine without DEF is a Federal Offence in the United States of America, operators may be prosecuted under the Clean Air Act. DEF is required for type approval, operators attempting to operate the machine without DEF may be liable for civil and criminal prosecution in the European Union. 347

9821/9967-1

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Technical Data Engine

If there are no other engine or emission system faults, the information below explains when the engine power and speed de-ratings occur, according to DEF tank level. Figure 338. DEF Level Warning Graph

X 1 2 A

A B C D E F 1 2 X Y

E F Y DEF level Low. Early warning to operator - Fill up this shift DEF level indicated critical low. Last warning to operator - Fill up now 0%DEF level indicated on level gauge. Machine starts to derate (reduced torque) - Fill up now Engine torque will remain at the levels shown for a period - Fill up now Engine torque begins reduce further, engine maximum speed begins to reduce - Fill up now Engine torque and engine maximum speed will remain at the levels shown. The engine will no longer respond when the accelerator is operated - Fill up now Engine speed Engine torque Percentage Time D

Emissions System- First Fault The presence of emissions system related faults will result in (initially) warnings given and engine power reduction. If the warnings continue to be ignored, it will lead to the engine being only able to idle, and then only at reduced idle power. If the engine is shut down by the operator during these steps, unless the fault is repaired, the duration of the step will resume from the point at which it was left. If the fault is still detected again when the engine is restarted, the engine will continue at reduced power.

348

9821/9967-1

348

Technical Data Engine

Figure 339. Emissions System First Fault Graph

X 1 2 A A B C D

Fault detected Fault continues to be ignored, engine torque reduction begins, engine maximum speed is unaffected Engine torque will remain at the levels shown for a period Fault continues to be ignored, engine torque begins reduce further, engine maximum speed begins to reduce Engine torque and engine maximum speed will remain at the levels shown. The engine will no longer respond when the accelerator is operated Engine speed Engine torque Percentage Time

E 1 2 X Y

Emissions Systems Faults - Additional Faults Within 40 Hours of The First Fault If the emissions system detects a second fault within 40 engine hours of a previous fault occurring, the system will reduce power immediately to protect the engine, this is usually indicative of a more serious fault with the system. The system will return to normal operation when the fault(s) are repaired. Table 159. Emissions system-Faults occurring in less than 40 hours Parameter Engine power output Engine RPM limit Driver/operator action needed

Subsequent Fault Effects Initial full power further reduces to limited power at idle speed only over time. Reducing to idle speed only over time If appropriate to the application, park the machine in a safe place. Contact your JCB engines dealer immediately

DEF DO's and DON'Ts DO's • • • • •

Before engine start up, locate and identify both separate diesel and DEF tanks, they do not share the same tank. Do not allow cross contamination between diesel and DEF. Act on machine warnings that DEF is running low. Ensure that there is sufficient DEF in the machine at all times. Use only high quality DEF to ISO 22241-1 from a reputable source. Keep all DEF, tanks, tank necks, drums and dispensing equipment clean to prevent contamination.

DON'Ts • • • • 349

Don't allow contamination of your DEF by dirt or fluid as it will damage the SCR system. Don't mix DEF with your diesel; it is not a fuel additive. Don't put DEF in your diesel tank – if you do, do not start the engine, call your JCB dealer immediately. Don't add chemicals to your DEF to prevent freezing. 9821/9967-1

349

Technical Data Engine

â&#x20AC;˘ â&#x20AC;˘

350

Don't dilute DEF with water or any other fluids or the machine may stop or be permanently damaged. When the engine is switched off, there is a small pump in the DEF system which purges the line from the supply module to the dosing injector. Don't remove the battery isolator for 30s so this operation can be completed and the system shut down correctly. Some machines may be fitted with a power hold relay to prevent this purge from being interrupted by operating the isolator.

9821/9967-1

350

Technical Data Tracks

Tracks General Refer to: Maintenance > Tracks (Page 229). Table 160. Track tension Minimum Track Tension 25mm (1in)

351

Maximum Track Tension 30mm (1in)

9821/9967-1

351

Technical Data Warranty Information

Warranty Information Service Record Sheet Table 161. Date

Annual Insurance (Yes)

Hours

Signature and stamp

Figure 340. Installation Checklist

Figure 341. 500h/3 Month

Figure 342. 1000h/6 Month

352

9821/9967-1

352

Technical Data Warranty Information

Figure 343. 1500h/9 Month

Figure 344. 2000h/12 Month

Figure 345. 2500h/15 Month

Figure 346. 3000h/18 Month

353

9821/9967-1

353

Technical Data Warranty Information

Figure 347. 3500h/21 Month

Figure 348. 4000h/24 Month

Figure 349. 4500h/27 Month

Figure 350. 5000h/30Month

354

9821/9967-1

354

Technical Data Warranty Information

Figure 351. 5500h/33 Month

Figure 352. 6000h/36 Month

Figure 353. 6500h/39 Month

Figure 354. 7000h/42 Month

355

9821/9967-1

355

Technical Data Warranty Information

Figure 355. 7500h/45 Month

Figure 356. 8000h/48 Month

Figure 357. 8500h/51 Month

Figure 358. 9000h/54 Month

356

9821/9967-1

356

Technical Data Warranty Information

Figure 359. 9500h/57 Month

Figure 360. 10000h/60 Month

Figure 361. 10500h/63 Month

Figure 362. 11000h/66 Month

357

9821/9967-1

357

Technical Data Warranty Information

Engine Emissions Emission Control System Maintenance and Warranty Statement (all EPA and CARB Regulated Territories) Emissions Control System Warranty JCB warrant the ultimate purchaser and each subsequent purchaser that the emissions control system of the purchased engine is: â&#x20AC;˘ â&#x20AC;˘

Designed, built, and equipped so as to conform to all applicable regulations adopted by the EPA and CARB. Free from defects in materials and workmanship which would cause the failure of a warranted part for a period of 5 years or 3000 hours of operation, whichever occurs first.

The warranty period shall begin on the date the machine is first delivered to the original retail purchaser. If the machine has been placed in service for demonstration purposes prior to first delivery to the original retail customer, the warranty period shall begin from the date the machine is first placed in demonstration service.

Maintenance, Replacement And Repair Of Emission Control System Warrantied Components Warranty service conducted by an approved JCB Service representative will be free of charge to the owner (including parts, labor and any fault diagnostic activity). If service is conducted by a party other than an approved JCB Service representative JCB hold no responsibility to cover the cost under warranty. Any parts repaired or replaced under the emissions control system warranty shall be warranted for the remainder of the emissions control system warranty period or until component first scheduled service as identified in machine operator manual (whichever is sooner).

Terms Of Emission Control System Warranty The original owner and all subsequent owners of the machine are responsible for performance of the required maintenance listed in the operator manual. JCB cannot deny emissions control system warranty solely for lack of documentation evidence of scheduled maintenance or for failure to make sure the performance of all scheduled maintenance unrelated to claim. In order to make sure any warranty claims are handled in an efficient manner JCB recommends that you retain all receipts covering maintenance, replacement and repair of engine emissions control system related components, and that such documentation is transferred with the machine from original owners to all subsequent owners. JCB may deny warranty if the warranted part has failed due to abuse, neglect, improper maintenance or unapproved modifications (including tampering of machine hourmeter). JCB accept no warranty liability for failure of emission control system equipment where the failure is attributed to use of a non-preferred grade of fuel as described in the machine operator manual supplied with this supplement. JCB may refuse warranty if failure is attributed to accident damage, act of God or any event outside of JCB control. JCB may additionally refuse any warranty claim if the machine has under any owner operated outside the United States. JCB is not to be held responsible for any loss of time, inconvenience or commercial loss attributable to any emissions control system warranty issue. It is a violation of the EPA Clean Air Act to disable any emission control system certified by the US Environmental Protection Agency. Disabling of any emission control system will invalidate any emission control system warranty and may invalidate any further engine or machine warranties. Replacement items which are not genuine JCB Service approved parts or authorized by JCB are excluded from the emission control system warranty. 358

9821/9967-1

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Technical Data Warranty Information

Emission Control System Maintenance And Warranty Statement (EPA Regulated Territories Only) Items Covered By Emissions System Warranty Materials covered under the emissions control system warranty (where installed) are defined by the EPA: 1. Fuel Injection System (High Pressure) 2. Air Induction System 2.1. Inlet tract 2.2. Turbocharger 2.3. Charge air cooling system 3. Exhaust System 3.1. Exhaust Manifold 3.2. EGR (Exhaust Gas Recirculation) valve and EGR cooler 4. Advanced Oxides of Nitrogen (NOX) controls 4.1. Selective catalyst reduction 4.2. Reagent containers and dispensing systems 5. Crankcase Ventilation System 5.1. PCV valve (closed loop system) 5.2. Oil filler cap 5.3. CCV filter 6. Electronic Control System 6.1. ECU (Engine control unit) 6.2. Sensors associated with emissions control 7. Miscellaneous Items Used in Above Systems 7.1. Gaskets, pipework, hoses and fasteners associated with the above systems 7.2. Emissions control information label

Emission Control System Maintenance And Warranty Statement (CARB) California Emission Control Warranty Statement Your Warranty Rights And Obligations The California Air Resources Board and JCB Power Systems are pleased to explain the emission control system warranty on your 2015 model year engine. In California, new heavy-duty off-road engines must be designed, built and equipped to meet the Stateâ&#x20AC;&#x2122;s stringent anti-smog standards. JCB Power Systems must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine. Your emission control system may include parts such as the fuel injection system and the air induction system. Also included may be hoses, belts, connectors and other emission related assemblies. Where a warrantable condition exists, JCB will repair your heavy-duty off-road engine at no cost to you including diagnosis, parts and labor.

359

9821/9967-1

359

Technical Data Warranty Information

Manufacturers Warranty Coverage The 2015 model year heavy-duty off-road engines are warranted for 5 years or 3000 hours of operation. If any emission related part on your engine is defective, the part will be repaired or replaced by JCB. Owner’s Warranty Responsibilities. •

• • •

As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. JCB recommends that you retain all receipts covering maintenance on your heavy-duty off-road engine, but cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. As the heavy-duty off-road engine owner, you should however be aware that JCB may deny you warranty coverage if your heavy-duty off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with California’s emission requirements. You are responsible for initiating the warranty process. The CARB suggests that you present your heavyduty off-road to a JCB dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.

If you have any questions regarding your warranty rights and responsibilities, you should contact JCB at 912-447-2000. Items Covered By Emissions System Warranty Materials covered under the emissions control system warranty (where installed) are defined by the CARB: 1. Fuel Injection System, comprising: 1.1. High pressure fuel injection pump, including boost control device (smoke puff limiter) 1.2. High pressure pipes 1.3. Injectors 1.4. Common rail assembly 2. Air Induction System 2.1. Inlet manifold, gaskets and fasteners 2.2. Turbocharger 2.3. Charge air cooling system 3. Exhaust System 3.1. Exhaust manifold, gaskets and fasteners 3.2. EGR valve and EGR coolers 4. 4. Advanced Oxides of Nitrogen (NOX) controls 4.1. SCR (Selective Catalytic Reduction) 4.2. Reagent containers and dispensing systems 5. Positive Crankcase Ventilation System 5.1. PCV valve 5.2. Oil filler cap 5.3. CCV filter 6. Electronic Control System 6.1. Engine control unit (ECU) 6.2. Crank and camshaft position sensors 360

9821/9967-1

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Technical Data Warranty Information

6.3. Coolant and lubricant temperature sensors 6.4. Inlet/exhaust manifold temperature/pressure sensor 6.5. MAF (Mass Air Flow) sensor 6.6. Sensor/injector wiring harness 7. Miscellaneous Items Used in Above Systems 7.1. Piping and connectors â&#x20AC;&#x201C; fuel injection pump boost control to inlet manifold 7.2. Turbocharger crossover tube, hoses and clamps 7.3. Block temperature sensor 7.4. Wiring harness connecting block temperature sensor to cold servo advance device on the fuel injection pump 7.5. Breather and hose clips â&#x20AC;&#x201C; closed loop systems 7.6. Sealing washers 7.7. Emission control information label

361

9821/9967-1

361

Notes:

362

9821/9967-1

362

Technical Data Torque Values

Figure 374. 10

7 12

12 11 8

363

9821/9700-1

363

Technical Data Torque Values

(For: JS360) JS360 and Variants 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 15. For the tightening torques of the bolts and nuts not listed, Refer to Table 16. Table 15.

(1)

6 7 8

(1)

13 14

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 36

Tightening Torque (N.m) 923

Checking Torque (N.m) 831

Travel motor

M24

Drive sprocket

M20

506

456

Idler wheel

M16

330

297

Upper (carrier) roller

M16

259

233

Lower (track) roller

M20

506

456

Track guard

M20

506

456

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M22 M27 M24

32 41 36

981-1128 1452 874

883-1015 1307 787

M24

874

787

M20/M24

30/36

410/874

369/787

Engine (engine mount)

M20

290

261

Engine bracket

M12

104

Radiator Hydraulic pump

M16 M10

24 17

260 60

211 54

Hydraulic oil tank

M16

259

233

Fuel tank

M16

259

233

Control valve

M16

259

233

Battery Rotary coupling

M6 M12

10 19

7 104

6 94

Cab

M16

196/245

176/221

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 16. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

364

(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

9821/9700-1

364

Technical Data Torque Values

Figure 375. 10

7 12

12 11 8

365

9821/9700-1

365

Technical Data Torque Values

(For: JS200) JS200 and Variants 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 17. For the tightening torques of the bolts and nuts not listed, Refer to Table 18. Table 17.

(1)

6 7 8

(1)

13 14

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 24

Tightening Torque (N.m) 290

Checking Torque (N.m) 265

Travel motor

M16

Drive sprocket

M16

290

265

Idler wheel

M16

290

265

Upper (carrier) roller

M16/M20

24/30

290/550

265/515

Lower (track) roller

M16

290

265

Track guard

M16

290

265

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M20 M30 M20

30 46 30

840-890 1147 525

756-801 1050 470

M20

525

470

M20/M24

30/36

550/950

515/900

Engine (engine mount)

M20/M16

27/24

529/271

476/244

Engine bracket

M12

125

113

Radiator Hydraulic pump

M12 M10

19 17

55 60

50 54

Hydraulic oil tank

M16

250

225

Fuel tank

M16

250

225

Control valve

M16

290

265

Battery Rotary coupling

M6 M12

10 19

7 116

6 105

Cab

M16

132

125

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 18. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

366

(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

9821/9700-1

366

Technical Data Torque Values

Figure 376. 10

7 12

12 11 8

367

9821/9700-1

367

Technical Data Torque Values

(For: JS220, JS235) JS220 and Variants 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 19. For the tightening torques of the bolts and nuts not listed, Refer to Table 20. Table 19.

(1)

6 7 8

(1)

13 14

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 24

Tightening Torque (N.m) 290

Checking Torque (N.m) 265

Travel motor

M16

Drive sprocket

M16

290

265

Idler wheel

M16

290

265

Upper (carrier) roller

M16/M20

24/30

290/550

265/515

Lower (track) roller

M16

290

265

Track guard

M16

290

265

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M20 M30 M20

30 46 30

840-890 1147 525

756-801 1050 470

M20

525

470

M20/M24

30/36

550/950

515/900

Engine (engine mount)

M20/M16

27/24

529/271

476/244

Engine bracket

M12

125

113

Radiator Hydraulic pump

M12 M10

19 17

55 60

50 54

Hydraulic oil tank

M16

250

225

Fuel tank

M16

250

225

Control valve

M16

290

265

Battery Rotary coupling

M6 M12

10 19

7 116

6 105

Cab

M16

132

125

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 20. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

368

(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

9821/9700-1

368

Technical Data Torque Values

Figure 377. 10

7 12

12 11 8

369

9821/9700-1

369

Technical Data Torque Values

(For: JS210) JS210 and Variants 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 21. For the tightening torques of the bolts and nuts not listed, Refer to Table 22. Table 21.

(1)

6 7 8

(1)

13 14

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 24

Tightening Torque (N.m) 290

Checking Torque (N.m) 265

Travel motor

M16

Drive sprocket

M16

290

265

Idler wheel

M16

290

265

Upper (carrier) roller

M16/M20

24/30

290/550

265/515

Lower (track) roller

M16

290

265

Track guard

M16

290

265

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M20 M30 M20

30 46 30

840-890 1147 525

756-801 1050 470

M20

525

470

M20/M24

30/36

550/950

515/900

Engine (engine mount)

M20/M16

27/24

529/271

476/244

Engine bracket

M12

125

113

Radiator Hydraulic pump

M12 M10

19 17

55 60

50 54

Hydraulic oil tank

M16

250

225

Fuel tank

M16

250

225

Control valve

M16

290

265

Battery Rotary coupling

M6 M12

10 19

7 116

6 105

Cab

M16

132

125

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 22. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

370

(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

9821/9700-1

370

Technical Data Torque Values

Figure 378. 10

7 12

12 11 8

371

9821/9700-1

371

Technical Data Electrical System

Electrical System General Table 1. Item System voltage

Specification 24V

Fuses For: JS115, JS130, JS145, JS160, JS180, JS190, JS200, JS210, JS220, JS235, ................ Page 372 For: JS330, JS360 ................................................................................................................. Page 374

(For: JS115, JS130, JS145, JS160, JS180, JS190, JS200, JS210, JS220, JS235,) Fuses - Cab Figure 379.

F9 F8 F7 F6 F5 F4 F3 F2 F1 F11 F10

F16 F15 F14 F13 F12 F20 F19 F18 F17 F29 F28 F27 F26 F25 F24 F23 F22 F21

Table 1. Fuse Identification Fuse F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 372

Rating 10A 5A 7.5A 5A 5A 15A 10A 10A 5A 20A 30A 372

Technical Data Electrical System

Fuse F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29

Circuit(s) Protected Engine ignition Revolver ignition Livelink 2 ECU ground Livelink 2 ECU B+ Cab worklight Machine ECU B+ Hydraulic ECU B+ Ignition and refuelling pump switch Diagnostic connector Interior light 12â&#x20AC;&#x201C;24V connector Standard worklamps Horn Wash wipe Engine stop Refuelling pump Display ECU

Rating 10A 5A 3A 3A 10A 30A 20A 20A 20A 10A 5A 15A 15A 10A 10A 10A 15A 5A

Fuses - Battery Bay Figure 380.

PFA

PFC

PFB

PFD

F1-12 R1-7 R1

F8 F9 F10 F1 F2 F3 F4

PFA-D

F5 F6 F7

F11

F12 R5 R6

Table 2. Fuse Identification Fuse F1 F2 F3 F4 F5 F6 F7 373

Rating 10A 10A 10A 10A 10A 10A 3A 373

Technical Data Electrical System

Fuse F8 F9 F10 F11 F12 PFA PFB PFC PFD

Circuit(s) Protected Power hold Ignition Fuel lift pump Fuel lift pump Engine ECM ignition Fuse box battery supply Alternator JCB engine/pod box Ignition relay/fuse box ignition supply

Rating 3A 10A 15A 3A 3A 50A 50A 50A 50A

(For: JS330, JS360) Fuses - Cab Figure 381.

F9 F8 F7 F6 F5 F4 F3 F2 F1 F11 F10

F16 F15 F14 F13 F12 F20 F19 F18 F17 F29 F28 F27 F26 F25 F24 F23 F22 F21

Table 3. Fuse Identification Fuse F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 374

Circuit(s) Protected Beacon Backlight Cushion solenoid Ignition wakeup Livelink 2 ECU ignition Auxiliary ignition supplies Spare 1 Heated/Suspension/Ventilated seat Camera system HVAC

Rating 10A 5A 7.5A 5A 5A 15A 10A 10A 5A 20A 9821/9700-1

374

Technical Data Electrical System

Fuse F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29

Circuit(s) Protected Engine crank Engine ignition Revolver ignition Livelink 2 ECU ground Livelink 2 ECU B+ Cab worklight Machine ECU B+ Hydraulic ECU B+ Ignition and refuelling pump switch Diagnostic connector Interior light 12â&#x20AC;&#x201C;24V connector Standard worklamps Horn Wash wipe Engine stop Refuelling pump Display ECU

Rating 30A 10A 5A 3A 3A 10A 30A 20A 20A 20A 10A 5A 15A 15A 10A 10A 10A 15A 5A

Fuses - Battery Bay Figure 382. PFA

PFC

PFB

PFD

Table 4. Fuse Identification Fuse PFA PFB PFC PFD

375

Circuit(s) Protected Fuse box battery supply Alternator JCB engine/pod box Ignition relay/fuse box ignition supply

Rating 50A 50A 50A 50A

9821/9700-1

375

Technical Data Electrical System

Fuses - Radiator Bay Figure 383.

RL3

F1 F2 F3 F4 F5 F6 F7 F8 F9

RL2

RL1 F10 F11 F12 F13 F14 F15 F16 F17

Table 5. Fuse Identification Fuse F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17

376

Circuit(s) Protected

Not used Not used Not used Not used

Not used Not used Not used Not used Not used

Rating 3A 10A 3A

10A 10A

9821/9700-1

376

Technical Data Electrical System

Relays For: JS115, JS130, JS145, JS160, JS180, JS190, JS200, JS210, JS220, JS235, ................ Page 377 For: JS330, JS360 ................................................................................................................. Page 379

(For: JS115, JS130, JS145, JS160, JS180, JS190, JS200, JS210, JS220, JS235,) Relay - Cab Figure 384.

F9 F8 F7 F6 F5 F4 F3 F2 F1 F11 F10

F16 F15 F14 F13 F12 F20 F19 F18 F17 F29 F28 F27 F26 F25 F24 F23 F22 F21

Table 1. Relay Identification Relay R1 R2 R3 R4 R5

377

Circuit(s) Engine crank Horn Wash wipe Engine stop Refuel pump

9821/9700-1

377

Technical Data Electrical System

Relay - Battery Bay Figure 385.

F1-12 R1-7

PFA

PFC

PFB

PFD

F8 F9 F10 F1 F2 F3 F4

PFA-D

F5 F6 F7

F11

F12 R5 R6

Table 2. Relay Identification Relay RL1 RL2 RL3 RL4 RL5 RL6 RL7

378

Circuit(s) Power hold 12V Fuel lift pump 12V Ignition sense 24V Not used Voltage dropper 24V Voltage dropper 12V Not used

9821/9700-1

378

Technical Data Electrical System

(For: JS330, JS360) Relay - Cab Figure 386.

F9 F8 F7 F6 F5 F4 F3 F2 F1 F11 F10

F16 F15 F14 F13 F12 F20 F19 F18 F17 F29 F28 F27 F26 F25 F24 F23 F22 F21

Table 3. Relay Identification Relay R1 R2 R3 R4 R5

Circuit(s) Engine crank Horn Wash wipe Engine stop Refuel pump

Relay - Radiator Bay Figure 387.

RL3

F1 F2 F3 F4 F5 F6 F7 F8 F9

RL2

RL1 F10 F11 F12 F13 F14 F15 F16 F17

379

9821/9700-1

379

Technical Data Electrical System

Table 4. Relay Identification Relay RL1 RL2 RL3

380

Circuit(s) Power hold 12V Ignition sense 24V Fuel lift pump12V

9821/9700-1

380

Technical Data Engine

Engine Engine Emissions Diesel Engine Emissions Rating JCB Ecomax engines bearing emissions labels with the type-approval numbers listed below are certified in the EU under directive 97/68/EC to Stage 3B emissions levels without need for engine/exhaust after treatment e.g DPF or SCR. Any JCB engine which does not have one of these four type-approval numbers on the engine emissions label is not certified as Stage 3B compliant without after treatment. Please refer to www.jcbtier4.com for further details. The EC type-approval number (for your machine) is shown on the engine identification plate. Refer to: About the Machine > Machine and Component Identification (Page 8). Table 1. Engines (Stage 3B compliant without after treatment) 55kW 68kW81kW93kW 108kW 108kW129kW

e11*97/68PA*2010/26*1771*##

(1)

e11*97/68MA*2010/26*1661*##

(1)

e11*97/68MA*2010/26*2548*01, and 02 e11*97/68MA*2011/88*2655*##

(1)

(1) XX refers to all revision levels of the type-approval.

381

9821/9700-1

381

Technical Data Tracks

Tracks General Table 1. Track Tension Minimum Track Tension 25mm

382

Maximum Track Tension 30mm

9821/9700-1

382

Technical Data Declaration of Conformity

Declaration of Conformity General A completed copy of the EC Declaration of Conformity is supplied with all machines manufactured according to EC type examination and/or self-certification requirements. A sample copy of the EC Declaration of Conformity and a summary of the information that can appear is provided. Refer to: Technical Data > Declaration of Conformity > Machine Data (Page 383).

Machine Data Table 1. A B C D E F G H J K L M N P

383

JCB Heavy Products Limited, Lakeside Works, Rocester, Staffordshire, United Kingdom, ST14 5JP. Excavators, Rope Or Hydraulic (Hydraulic, Tracked). Refer to: Introduction > About this Manual > Machine Model and Serial Number (Page 1). Refer to: About the Machine > Machine and Component Identification > Machine (Page 8). EN 474-1:2006+A1:2009, EN 474-4:2006 +A1:2009. Engineering Manager, JCB Heavy Products Limited, Lakeside Works, Rocester, Staffordshire, United Kingdom, ST14 5JP. Mr C J Knowles, J. C. Bamford Excavators Limited, Lakeside Works, Rocester, Staffordshire, United Kingdom, ST14 5JP. ANNEX VI PROCEDURE 1. A. V. Technology, A. V. House, Birdhall Lane, Stockport, Cheshire, United Kingdom, SK3 0XU. Refer to: Technical Data > Noise Emissions > Noise Data (Page 334). Refer to: Technical Data > Noise Emissions > Noise Data (Page 334). Rocester. Managing Director. Excavator.

9821/9700-1

383

Technical Data Declaration of Conformity

Figure 388.

384

9821/9700-1

384

Technical Data Warranty Information

Warranty Information Machine Service Record Sheet Table 1. Date

Annual Insurance (Yes)

Hours

Signature and stamp

Figure 389. Installation Checklist

Figure 390. 500h/3 Month

Figure 391. 1000h/6 Month

385

9821/9700-1

385

Technical Data Warranty Information

Figure 392. 1500h/9 Month

Figure 393. 2000h/12 Month

Figure 394. 2500h/15 Month

Figure 395. 3000h/18 Month

386

9821/9700-1

386

Technical Data Warranty Information

Figure 396. 3500h/21 Month

Figure 397. 4000h/24 Month

Figure 398. 4500h/27 Month

Figure 399. 5000h/30Month

387

9821/9700-1

387

Technical Data Warranty Information

Figure 400. 5500h/33 Month

Figure 401. 6000h/36 Month

Figure 402. 6500h/39 Month

Figure 403. 7000h/42 Month

388

9821/9700-1

388

Technical Data Warranty Information

Figure 404. 7500h/45 Month

Figure 405. 8000h/48 Month

Figure 406. 8500h/51 Month

Figure 407. 9000h/54 Month

389

9821/9700-1

389

Technical Data Warranty Information

Figure 408. 9500h/57 Month

Figure 409. 10000h/60 Month

Figure 410. 10500h/63 Month

Figure 411. 11000h/66 Month

390

9821/9700-1

390

Section B Body and Framework Service Manual - JS 200 Series Tracked Excavators - T4 and T2 Engines Section 1 - General Information Section 2 - Operator’s Manual Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/3200-03

Section B - Body and Framework

Notes:

B-0

9813/3200-03

B-0

Section B - Body and Framework Contents Page No. Technical Data Air Conditioning (option) ........................................................................... B-1 Basic Operation Automatic Temperature Control (ATC) System ........................................ B-3 Fault Finding Air Conditioning ....................................................................................... B-11 Service Procedures HV/HVAC Unit ........................................................................................ B-19 Air Conditioning Compressor .................................................................. B-21 Cab Structure ......................................................................................... B-22 Cab Panels Removal and Replacement .................................................................... B-31 Routine Maintenance Procedures Scheduled Tasks .................................................................................... Doors and Locks ..................................................................................... Excavator Lever and Pedal Locks .......................................................... Slew Ring Pinion and Gear Teeth ........................................................... Fit For Purpose Test ............................................................................... Cab Heater/Air-Conditioning Filter ..........................................................

B-i

B-35 B-36 B-37 B-38 B-39 B-40

B-i

Section B - Body and Framework Contents

B-ii

Page No.

B-ii

Section B - Body and Framework

Technical Data Air Conditioning (option) Automatic Temperature Control (ATC) System Table 1. Pressure Switch Setting

Bar

lbf/in2

1.4 (+/- 0.1)

20 (+/- 1.5)

Low Pressure Cut Out

0.3 (+/- 0.1)

4 (+/- 1.5)

High Pressure Cut In

17.2 (+/- 0.7)

250 (+/- 10)

High Pressure Cut Out

27.6 (+/- 0.7)

400 (+/- 10)

Low Pressure Cut In

Table 2. Refrigerant Gas

Charge Weight

R-134a

1400 g +/- 10g Table 3.

Lubrication Oil PAG (PolyAlkylene Gycol) oil to ISO 100

B-1

Oil Quantity Full System

150 g +/- 5 g

Evacuation/Charge

If the system is being evacuated, add 57 g (59 ml) of lubrication oil to the system before or during the charge.

B-05-00 issue 01

B-1

Section B - Body and Framework Technical Data Air Conditioning (option)

B-2

B-05-00 issue 01

B-2

Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System

Basic Operation Automatic Temperature Control (ATC) System B H D

E C

A G X

C132090

Fig 1. System components

B-3

9813/3200-03

B-3

Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System Item

Description

ATC HVAC Unit

Condenser

High Pressure Switch

Receiver/Drier

Compressor

Control Panel

Low Pressure Recharge Point

High Pressure Recharge Point

ATC Electronic Control Module

Pulse Width Modulation (PWM) Module

Cab Air Sensor

Thermal Expansion Valve (TXV)

Low Pressure Switch

Water Valve

Air-off Sensor

Evaporator Temperature Sensor

Evaporator Matrix

Blower Motor

Actuator

Recirculation Air Filter

Fresh Air Filter

Heater Hose, heater inlet (red)

Heater Hose, heater outlet (blue)

B-4

9813/3200-03

B-4

Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System

Q J

M U

W L

V T014090-C1

Fig 2. ATC HVAC unit components

B-5

9813/3200-03

B-5

Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System

Heater/Air Conditioning Controls (ATC)

Rotate control 5 to set the desired temperature.

The heater/air conditioning can be set for automatic temperature control (ATC).

The set temperature will be displayed on panel 7.

The fan speed will be automatically set to reach and then maintain the set temperature.

The heater system is controlled by the following switches:

Note: If control 6 is moved, Auto mode will have to be reset. Press switch 2 to reactivate.

In hot weather or dusty environments, re-circulation mode should be used. Select switch 3.

Defrost/Demist Mode To activate press switch 4, the LED will illuminate and switch symbol will be displayed on 7.

In hot weather to produce comfortable working conditions.

T006520

Fig 3.

Close the door and windows.

On/Off switch.

b Select re-circulation switch 3.

Auto mode switch.

Re-circulation switch.

Defrost/Demist switch.

Temperature control switch.

Fan speed switch.

Display.

Rotate control 6 clockwise and direct air into the body of the cab.

d Rotate control 5 fully counter-clockwise for maximum defrost. If the in cab temperature drops to low turn control clockwise. 2

In cold/damp weather, to minimise misting. a

Close the door and windows.

b Select re-circulation switch 3.

Heater Controls

c Hot air can be directed to the front window (for demisting) and/or the cab floor by adjusting the air vents. To activate controls press switch 1, the switch LED and panel 7 will illuminate.

Set control 6 fully clockwise and direct air onto the front window.

d Set control 5 fully clockwise to heat the dehumidified conditioned air, de-mist the screen and generally de-humidify the cab air.

Auto Mode The heater can be set to a selected temperature. The fan speed and temperature control will then be automatically controlled to maintain the set temperature. 1

B-6

Auto mode is activated by switch 2, the LED will illuminate and an `A' will appear on the display 7.

9813/3200-03

B-6

Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System

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

refrigerant is now considerably below that of the air being drawn across the evaporator matrix by the blowers. Heat is transferred from the ambient and re-circulated air to the refrigerant, causing the low pressure liquid to vaporise and become a low pressure gas. Moisture in the air condenses on the evaporator matrix and is drained away via condensate. K Fig 1. ( T B-3). Cool de-humidified air is emitted through air vents into the cab. The low temperature, low pressure, high heat content refrigerant gas, is now drawn by suction back to the compressor, where the cycle is completed.

The major components of the system are the compressor E, condenser B, receiver drier D, expansion valve L and evaporator matrix A.K Fig 1. ( T B-3). Air conditioning system power is generated from the engine, via an electromagnetic clutch to the compressor. The electromagnetic clutch is controlled by the ATC Electronic Control Unit (ECU). The ATC ECU therefore controls when the air conditioning system operates. The compressor E, draws in low pressure refrigerant gas from the suction line (evaporator to compressor) and increases refrigerant pressure through compression. This process also increases the refrigerant temperature. K Fig 1. ( T B-3). High pressure refrigerant is forced from the compressor to the condenser B, which is mounted on the radiator on the side of the engine. Ambient air is drawn across the condenser by the engine-driven cooling fan. In the condenser, the refrigerant changes state to a high pressure, high temperature liquid but with a lower heat content. K Fig 1. ( T B-3). The refrigerant passes through the receiver drier D, which contains a desiccant to remove moisture from the system. K Fig 1. ( T B-3).The receiver drier serves as a reservoir for refrigerant and also includes a filter to remove foreign particles from the system. The high temperature, high pressure refrigerant is forced by compressor action into the expansion valve L, which meters the amount of refrigerant entering the evaporator. In the expansion valve the refrigerant instantaneously expands to become a low pressure, low temperature liquid. K Fig 1. ( T B-3). The refrigerant is drawn through the evaporator matrix A, by the suction of the compressor. The temperature of

B-7

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B-7

Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System

ATC Control Panel

T013670

Fig 4. The ATC system includes an electronic control system that protects the system components if a problem occurs. The electronic control system also lets the operator control the cab temperature, fan speed and air flow direction at the ATC control panel. The ATC control panel (user Interface) on the right hand side console in the cab is connected to an electronic control module (ECM). The ECM is attached to the top of the ATC unit. The ECM monitors the inputs and controls the outputs in the system as selected by the operator and as the temperature conditions change. If a system problem occurs, the LCD display shows an error code.

Cab Temperature Sensor The cab temperature sensor is on the inlet vent in the ATC unit in the cab. The sensor operates with the outlet temperature sensor to let the ATC control panel know when the cab temperature is correct. Outlet Temperature Sensor (Air Off) The outlet temperature sensor is on the outlet vent in the ATC unit in the cab. The outlet temperature sensor operates with the cab temperature sensor to let the ATC control panel know when the cab temperature is correct.

Inputs Outputs High Pressure Switch PWM Module (Pulse Width Modulation) The high pressure switch is on the receiver drier. The switch is an input used to monitor the fluid pressure in the high pressure side of the system. The switch tells the ATC control panel when the high pressure is abnormal.

The PMW module is in the ATC unit above the filter panel, access is through a removable plate. The PMW module controls the output signals from the ECU through actuators and a fan motor.

Low Pressure Switch The low pressure switch is in the ATC unit. The switch is used to monitor the low pressure gas on the low pressure side of the system. The switch tells the ATC control panel when the low pressure is abnormal. Evaporator Temperature Sensor The evaporator temperature sensor is in between the evaporator cores in the ATC unit in the cab. The sensor tells the ATC control panel the evaporator temperature. This temperature is for control of the compressor clutch and output to stop the evaporator cores freezing

B-8

The components controlled by the PWM module are as follows: â&#x20AC;&#x201C; Blower Motor. The PWM module changes the signal to the blower motor as requested on the fan speed dial on the ATC control panel to increase or decrease the motor speed. â&#x20AC;&#x201C; Re-circulation Motor (Actuator). The PWM module changes the signal to the re-circulation motor (Actuator) as requested on the ATC control panel to

9813/3200-03

B-8

Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System change where the inlet air is drawn in from by moving a control flap. â&#x20AC;&#x201C; Water valve (Actuator). The PWM module changes the signal to the Water valve as requested on the temperature dial on the ATC control panel. This adjusts the quantity of heater coolant into the heater core to obtain the correct cab temperature. â&#x20AC;&#x201C; Compressor Drive Clutch. The compressor drive clutch is in the compressor mounted on the engine. The compressor drive clutch receives an output signal from the ATC control panel to control when the clutch must be engaged or disengaged. This depends upon what temperature is selected on the ATC control panel. When the clutch is engaged, a snowflake symbol is shown in the top right hand corner of the LCD display. The drive clutch can automatically disengage if an error occurs in the system and an error code shows on the LCD display. This is to prevent the system from more damage.

B-9

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B-9

Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System

Safety Procedures

refrigerant system must be conducted in a well ventilated area.

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

!MWARNING

Containers of refrigerant should be stored in a cool environment away from direct sunlight.

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

The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person. You can be severely frostbitten or injured by escaping refrigerant. 4-3-4-1_2

Do Not perform welding operations close to refrigerant hoses (maintain a distance of at least 0.5m from hoses).

Do Not steam clean refrigerant system components.

When charging or discharging the refrigerant system refrain from smoking. Naked flames must not be allowed in the immediate vicinity. The refrigerant does not give off a poisonous odour, however, when it comes into contact with a naked flame, a poisonous gas is produced.

When handling refrigerant, rubber gloves and goggles should be worn. Operators should ensure that no refrigerant comes into contact with the skin. Particular care should be taken when connecting or disconnecting charging hoses or pressure switches. When these components are connected to the system, a short release of refrigerant occurs. This results in a high velocity, very cold gas being emitted from the connection point.

!MWARNING The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person. You can be severely frostbitten or injured by escaping refrigerant. 4-3-4-1_2

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

It is critical that the correct refrigerant (R-134a) is used and that charging is done only by qualified personnel. As a precaution, in case of accidental leakage, discharging and charging of the vehicle

B-10

9813/3200-03

B-10

Section B - Body and Framework

Fault Finding Air Conditioning TB-010_2

Preliminary Checks Before any checks are carried out on the refrigerant circuit the following checks should be made: 1

Check the compressor drive belt is serviceable and correctly tensioned.

Check the condenser and engine radiator are not blocked by debris, clean with compressed air or water if necessary.

Check that the condenser fins are not flattened or damaged, the fins must allow air to pass freely.

Check the cab fresh air inlet filter for blockage.

Check that, with the ignition switch on (engine not running), the blower operates over whole speed range.

Check that, with the ignition switch on (engine not running), the blower and air conditioning switched on, the compressor clutch engages.

Charge level: Note: It is not possible to check refrigerant charge level with R134a systems using the receiver drier sightglass. Any bubbles seen at the sight glass on the receiver drier may be bubbles of oil and are perfectly normal. â&#x20AC;&#x201C; Gas -1400g R134A +/- 10g â&#x20AC;&#x201C; Oil - 150g +/- 5g PAG (PolyAlkylene Gycol) oil to ISO 100 Fault finding: Important: Refer to appropriate remove and replace procedures before working on any system component

B-11

9813/3200-03

B-11

Section B - Body and Framework Fault Finding Air Conditioning

Error Codes / Error Diagnosis (Automatic Temperature Control (ATC) System) Table 4. Error Code 1 - High Pressure Lock Out Causes

Effect

Description

The unit cannot cool the cab The compressor disengages.

The high pressure switch operates twice In 1 minute.

The system is overcharged.

Remedy Check the continuity of switch (usually open switch). Check the gas in system and recharge, refer to table.

There is no power to the high pressure switch.

Check for 24V at the switch. Check the continuity between ATC control module pin 33 and switch.

There is a bad earth on the high Check the earth wire between pressure switch. ATC control module pin 34 and switch. There is a defective switch. Note: If, an Error code shows after one minute this can show a system Error.

Note: If, an Error code shows instantly this can show a wiring Error.

Table 5. Error Code 2 - Low Pressure Lock Out Causes

Effect

Description

The unit cannot cool the cab The compressor disengages.

The low pressure switch opens for longer than 1 minute.

Replace the switch.

The system is undercharged.

Remedy Check the continuity of switch (usually closed switch). Check the gas in system and recharge, refer to table.

There is no power to the low pressure switch.

Check for 24V at the switch.

There is a bad earth on the low pressure switch.

Check the earth wire between ATC control module pin 36 and switch.

There is a defective switch.

Replace the switch.

Check the continuity between ATC control module pin 35 and switch.

Note: If an Error code shows after one minute this can show a system error. Note: If an Error code shows instantly this can show a wiring error. Note: Battery reset may be required to remove the error after repair.

B-12

9813/3200-03

B-12

Section B - Body and Framework Fault Finding Air Conditioning Effect

Table 6. Error Code 3 - Blower Potentiometer Error (User Interface / Control Panel) Causes Remedy

The Blower motor speed is irregular in Wiring Error (open or short-circuit). Auto mode.The Blower motor speed is fixed or cannot be changed in manual mode. There is no blower speed signal from the user interface to the ATC Control Module.

Check for 24V at blower motor. Check the continuity from blower motor earth to Pin 7 on PWM. Check the continuity from pin C15 on user interface to pin 28 on ATC control module. (Expected reading on Pin 28 0.5V to 3.0 V).

There is no signal from the ATC control Check the continuity from Pin 5 on ATC module to the PWM. control module to Pin 6 on PWM unit.

Effect

Defective potentiometer.

Replace user interface / control panel.

There is no temperature signal from the user interface to the ATC control module.

Check the continuity from Pin D1 on the user interface to pin 29 on ATC control Module. (Expected reading on Pin 29 - 0.5V to 3.0 V).

There is no temperature signal from the ATC control module to the PWM.

Check the continuity from Pin 3 on ATC control module to Pin D on water valve. Check the continuity from Pin A on water valve to Pin 5 on PWM.

There is a bad earth on water valve / PWM.

Check for good earth as shown on schematic.

Defective potentiometer.

Replace user interface / control panel.

Table 8. Error Code 7 - Cab Air Sensor Error (Air Inlet Temperature Sensor) Causes Remedy

The unit cannot cool the cab. The compressor disengages.The Demist mode does not work / The Recirculation Mode is O.K.There is no temperature change / the fan speed operates correctly in Auto mode. The temperature changes on LCD display. The cab temperature does not correspond.

B-13

Check for good earth as shown on schematic.

Table 7. Error Code 4 - Water Valve Potentiometer Error (User Interface / Control Panel) Causes Remedy

The temperature shown on the display cycles between 22 degrees and error code 4.There is no temperature change There is no fan speed in Manual Mode.There is no temperature change / the fan speed operates correctly in Auto mode.

Effect

Bad earth on blower motor / PWM.

There is no temperature signal from Check the continuity between pin1 on the sensor to the ATC control module. the cab temperature sensor to pin 21 on ATC control module. There is a bad earth on the cab air sensor.

Check for good earth as shown on schematic.

There is a defective sensor.

Replace the cab air sensor.

9813/3200-03

B-13

Section B - Body and Framework Fault Finding Air Conditioning Effect

Table 9. Error Code 8 - Evaporator Temperature Sensor Error Causes Remedy

The unit cannot cool the cab The compressor disengages.

There is no temperature signal from the sensor to ATC control module.

Check the continuity between pin1 on the evaporator temperature sensor to pin 23 on ATC control module.

There is a bad earth on the evaporator Check for good earth as shown on temperature sensor. schematic. There is a defective sensor.

Effect

Make sure the sensor connections are correct. Replace the evaporator temperature sensor.

Table 10. Error Code 9 - Outlet Temperature Sensor Error Causes Remedy

The fan speed stays at maximum in AUTO mode. The manual mode blower operates as normal.

There is no temperature signal from the sensor to ATC control module.

Check the continuity between pin1 on the outlet temperature sensor to pin 22 on ATC control module.

There is a bad earth on The outlet temperature sensor.

Check for good earth as shown on schematic.

There is a defective sensor

Make sure the sensor connections are correct. Replace the outlet temperature sensor.

Table 11. Error Code E19 - No Communications Between User Interface / Control Panel and ATC Control Module. Effect Causes Remedy The unit cannot cool the cab / The compressor disengages.The ATC / Heater control does not operate.The fan speed stays at maximum in Auto mode / The fan speed operates as normal in Manual mode.

Wiring Error

Check power at pins on User Interface and ATC control module. Check Earth at pins on User Interface and ATC control module. Check the Continuity between the wires that connect the User Interface and the ATC control module.

Connector Error

Check the connector plugs between User Interface and ATC control module are in good condition.

Defective user interface / Control panel Replace the defective unit or ATC control unit

Effect

Table 12. PWM Failure (No Fault Code Displayed) Causes Remedy

The unit cannot cool the cab / The compressor disengages.Fan speed unable to adjust in both auto and manual modes (fan speed defaults to max or min.) Temperature will be on maximum hot or maximum cold and unable to change.

B-14

Wiring Error

Check power and earths on PWM as shown on schematic. Expected readings for inputs to WM during normal operation.Pin 5 and Pin 6 Minimum 0.016 volts to maximum 11.18 volts

9813/3200-03

B-14

Fig 5. Electrical Schematic (Automatic Temperature Control (ATC) System)

T013690-1

Section B - Body and Framework Fault Finding Air Conditioning

B-15

9813/3200-03

B-15

B-16

YW/BK

0.75

YW/BL

BK/RD

9813/3200-03

1.50

0.75

1.5

0.75

BL/BK

0.75

BL/GN

BL/WH

0.75

WH/BK

WH/YW

0.75

RD/BN

1.50

RD/BN

RD/OR

OR/WH

910D

910C

910A

910B

957

956

955

160B

950

953

952

150F

BN/OR

2.00

213

30H

201

160A

950A

160

0.75

921

30M

946A

RD/BN

951

4 RECIRC ACTUATOR

100

250

380

350

970

1060

235

2010

480

970

330

215

165

C11

MOLEX 5558

PACKARD 12084912

PACKARD 12103881

5 ATC CONTROLLER

17 LOW PRESSURE SENSOR

SP8

PACKARD 12084912

PACKARD 12089649

D13 36

PACKARD 12089649

D12

PACKARD 12084912

5 ATC CONTROLLER

2 USER INTERFACE

SP6

I VEHICLE HARNESS

AMP 770008-3

PACKARD 12084912

DEUTSCH 1060-16-0122

MOLEX 5558

PACKARD 12048074

2 1

AMP 5-160558-2 PACKARD 12048074

PACKARD 12048074

A 1

AMP 770008-3

PACKARD 12089649

AMP 5-160558-2

DEUTSCH 1060-16-0122

D14

PACKARD 12084912

PACKARD 12089649

DEUTSCH 1060-16-0122

PACKARD 12089649

C10

C16

PACKARD 12048074

PACKARD 12047757

MOLEX 5558

PACKARD 12048074

42281-2

AMP 5-160558-2

11 PWM UNIT

2 USER INTERFACE

1 VEHICLE HARNESS

SP6

1 VEHICLE HARNESS

6 OUTLET TEMP SENSOR

860

750

370

4 RECIRC ACTUATOR

11 PWM UNIT 10 WATER VALVE ACTUATOR 13 BLOWER MOTOR

11 PWM UNIT

2 USER INTERFACE

13 BLOWER MOTOR

1 VEHICLE HARNESS

5 ATC CONTROLLER

380

450

200

725

810

990

945

930

490

590

124

2 USER INTERFACE

2 C

10 WATER VALVE ACTUATOR

PACKARD 12084912

7 CAB AIR TEMP SENSOR

8 EVAP TEMP SENSOR

4 RECIRC ACTUATOR

18B C/F CONNECTOR

15 COMP CLUTCH RELAY

2 USER INTERFACE

909

5 ATC CONTROLLER 5 ATC CONTROLLER 5 ATC CONTROLLER

PACKARD 12084912

SP9

N N

Fig 6.

SP9

SP8

5 ATC CONTROLLER

1 VEHICLE HARNESS

SP4

SP5

SP6

5 ATC CONTROLLER

15 COMP CLUTCH RELAY 15 COMP CLUTCH RELAY

SP6

5 ATC CONTROLLER

SP2

5 ATC CONTROLLER

SP5

SP6

SP5

SP6

SP2

SP4

11 PWM UNIT

PACKARD 12084912

DEUTSCH 0462-201-16141 PACKARD 12084912

Seal

PACKARD 12048046

PACKARD 12084912

AMP 5-160558-2

PACKARD 12084912

AMP 770008-3

PACKARD 12084912

PACKARD 12103881

5 ATC CONTROLLER

AMP 42460-2

PACKARD 12089649

17 LOW PRESSURE SENSOR

1 D1

C15

D7 PACKARD 12089649

PACKARD 12089649

D10

AMP 5-160558-2

86 -

AMP 770008-3

PACKARD 12048074

MOLEX 5558

PACKARD 12047757

Terminal

SP4

SP2

2 USER INTERFACE

18A C/F CONNECTOR

2 USER INTERFACE

PACKARD 12048046

31 26

2 USER INTERFACE

5 ATC CONTROLLER

2 USER INTERFACE

PACKARD 12084912

SP2

SP4

15 Comp Clutch Relay

SP4

11 PWM UNIT

SP4

10 WATER VALVE ACTUATOR

7 CAB AIR TEMP SENSOR 8 EVAP TEMP SENSOR

PACKARD 12084912

Cavity

Connector

1 VEHICLE HARNESS

PACKARD 12084912

15 PACKARD 12084912

PACKARD 12084912

5 12

PACKARD 12084912

3 4

PACKARD 12084912

Seal

5 ATC CONTROLLER

730

From Terminal

Cavity

5 ATC CONTROLLER

Connector

945

916

915

907

990

340

950

850

480

850

260

908

GN/BN

970

913

30A

30B

30C

30J

30K

30L

GN/OR

0.75

RD/BN

1.50

0.75

RD/BN

RD/BL

0.75

1.50

0.75

BL/OR

0.75

BL/BK

914

912

30E

970

920

918

970

520

475

970

475

1190

475

720

1230

1330

Length mm

923

30D

150B

911

150A

548

150

202

211

210

Ident

0.75

BL/RD

0.75

BK/RD

YW/GN

0.75

BK/OR

0.75

Type

0.75

RD/BN

BL/RD

RD/BN

RD/YW

RD/BN

0.75

GN/BL

0.75

GN/YW

0.75

GN/WH

0.75

Colour

Size mm

Wire No

SP2 30

CONSTRUCTION DETAILS - SPLICE 2

CONSTRUCTION DETAILS - SPLICE 4

SP4

160 SP 5

160B

SP 6

CONSTRUCTION DETAILS - SPLICE 6

SPLICE TO BE COVERED WITH ADHESIVE LINED HEATSHRINK (ATUM OR EQUIVALENT)

946A

950A

950

150F

SPLICE TO BE COVERED WITH ADHESIVE LINED HEATSHRINK (ATUM OR EQUIVALENT)

160A

CONSTRUCTION DETAILS - SPLICE 5

SPLICE TO BE COVERED WITH ADHESIVE LINED HEATSHRINK (ATUM OR EQUIVALENT)

907 150 150A 124 150B

SPLICE TO BE COVERED WITH ADHESIVE LINED HEATSHRINK (ATUM OR EQUIVALENT)

30L 30M

921 30B 30H 30C 30J 30A

30K 913 908 30D

= = = = = = = = = =

RED WHITE GREEN BLACK BLUE PINK YELLOW BROWN PURPLE ORANGE

SP 8

SP 9

SPLICE TO BE COVERED WITH ADHESIVE LINED HEATSHRINK ( ATUM OR EQUIVALENT )

910D

CONSTRUCTION DETAILS - SPLICE 9

SPLICE TO BE COVERED WITH ADHESIVE LINED HEATSHRINK ( ATUM OR EQUIVALENT )

910A

CONSTRUCTION DETAILS - SPLICE 8

RD WH GN BK BL RS YW BN PU OR

COLOUR CODES:

910C 910

910C 910B

T013690-2

Section B - Body and Framework Fault Finding Air Conditioning

B-16

B-17

A B

Cavity

Colour BL BL/BK

150F

RD/BN

BK RD/BN WH/YW

25 53 57

9813/3200-03

SP2 SP5 2

SP6

To SP9 5 15

912 914

920 953

WH/BK BK/OR BK/RD

YW/BL YW/GN

OR RD/OR

10 1

2 58 12 13

14 15

11 49

31 64

23 25

28 29 31 32

33 34

26 27

17 18

BL/GN

YW/BL BL/BK

GN/YW

GN/BN

YW GN/WH

RD/BN BK

BL/WH

59 8 9

910B

915

917 910D

918 30E

211 956

213

210

923

150B 30D

911 957

201 150A

RD/BN RD/YW GN/OR RD/BN BL/RD

4 5

42 6

4 5

Ident 202 150 948

11 12

Colour GN/BL

Wire 3

Cavity

SP8

1 SP9

2 2

8 2 2 18

SP4 SP2

11 4 SP4

SP4

To 10

2 -

D7 D8

C15 D1

1 D12 D5 1

D10

D13

C14

D -

Cavity

Seals :- 12110489 + 12110488

Terminals :- 12084912

Wire 47 7 17 48

Cavity 33 87

Cavity 30 86 85 87

Colour BN/OR WH/OR BK OR/WH

Cavity C3 3

280

To SP6 2 SP2 1

LABEL LOCATION

Ident 10 900 30L 952

Seals :- N/A

Terminals :- AMP.250 FASTON/Equivalent

Part No :- 500-002 or Equivalent

Manufacturer :- STEWART AUTOMOTIVE

Part No :- 12110487 + 12110490

Manufacturer :- PACKARD

Cavity 35 -

COMPRESSOR CLUTCH RELAY

ATC CONTROLLER

30 160B 955

Ident 910 917 952

Colour BL/BK YW/BL OR/WH

Wire 30 31 48

Wedge :- W12P

Terminals :- 1060-16-0122

Part No :- DTO4-12P-CL06

Cavity 1 2 3 4 5 6 7 8 9 10 11 12

Ident 915 910A

VEHICLE HARNESS

Wire 28 62

Seals :- N/A

SP9

100

190

150

100

40 18B

18A

Cavity C1 C2 C3 C9 C10 C11 C12 C13 C14 C15 C16 D1 D2 D3 D4 D5 D6 D7 D8 D10 D12 D13 D14

Wire 57 35 26 23 14 24 15 12 11 49 10 58 59 36

Colour WH/YW GN BL/RD YW/BK YW/BL BL YW/GN BK/OR OR RD/OR YW WH/BK BL/WH BK

Ident 955 124 907 908 912 913 914 918 920 953 923 956 957 921

To 1 SP4 SP4 SP2 5 SP2 5 5 5 5 5 5 5 SP2

360

F E D

C to

FCONNECTOR

To 5

FCONNECTOR

Ident 30E

Cavity Wire 18

Colour BK/RD

Receptical housing: Ident 30E

To SP2

480054

MANUFACTURER:- AMP / TYCO Receptical 42281-2

C to

Colour BK/RD

480053-3

Wire 13

Tab Housing Cavity 1

42460-2

Tab

MANUFACTURER:- AMP / TYCO

Cavity 11 28 29 26 31 32 20 25 16 -

Anti-backout inserts: 12045890 x1 / 12045889 x1

Terminals :- 12089649

Part No :- 12110207

SP4

Cavity

F E D

CONVELUTE TO BE ADDED IN THIS AREA APPLY BLACK INSULATION TAPE AT EACH END OF CONVELUTE & AT 150mm INTERVALS

SP8

To SP5 SP2 5

Ident 160A 3OJ 201

640

Colour RD/BN BK GN/OR

USER INTERFACE

SP2

Wire 41 19 42

Manufacturer :- Packard

CONNECTOR EXTERNAL FROM CONVELUTE

Cavity A C D

Seals :- 12048086,12052850,12059168

Terminals :- 12048074

Terminals :- 12103881

Part No :- 12052848

Part No :- 12162443

To 5 SP8

RECIRC ACTUATOR

Manufacturer :- PACKARD

LOW PRESSURE SENSOR

Manufacturer :- DEUTSCH

A B C

Cavity 22 -

A B C

10 WATER VALVE ACTUATOR

290

280

380

PWM UNIT

Cavity

Cavity 27

210

Wire 44 43

SP5

1 2

Cavity

Colour GN/BN BK

Ident 213 30H

1 2

Cavity Wire 40 34

Colour RD BK

To SP6 11

Cavity

To SP5 SP2 5

Fig 7.

Ident 950A 951

Seals :- N/A

Terminals :- 160917-2

Part No :- N/A

Ident 160 30A 202

130

Colour RD/BN BK GN/BL

BLOWER MOTOR

170

Wire 39 22 3

110

Cavity A C D

Cavity 3

Seals :- 12048086,12052850,12059168

Terminals :- 12048074

Manufacturer :- AMP / TYCO

SP6

100

110

F E D

Manufacturer :- PACKARD Part No :- 12052848

Wire 38 50 5 34 37 -

Ident 946A 950 948 951 30M -

A B

Wire 1 21

Colour GN/WH BK

Ident 210 30B

Seals :- N/A

Terminals :- 12047767

Part No :- 12047662

Cavity

To SP7 SP6 5 13 SP2 -

21 -

Cavity

Cavity 5 2 -

To 5 SP2

CAB TEMP SENSOR

Colour RD/BL RD RD/YW BK BK -

Wedge :- N/A

Manufacturer :- PACKARD

Cavity 1 2 3 4 5 6

Terminals :- 770008-3

Part No :- 770020

11 Manufacturer :- TYCO /AMP

Seals :- N/A

Terminals :- 5558 To 5 SP2

OUTLET TEMP SENSOR Part No :- 39-01-3023

Manufacturer :- MOLEX

Wire 2 20

Colour GN/YW BK

Ident 211 30C

Seals :- N/A

Terminals :- 5558

Part No :- 39-01-3023

Manufacturer :- MOLEX

Cavity 1 2

RED WHITE GREEN BLACK BLUE PINK YELLOW BROWN PURPLE ORANGE

To 5 SP2

EVAP TEMP SENSOR

= = = = = = = = = =

COLOUR CODES: RD WH GN BK BL RS YW BN PU OR

23 -

Cavity

T013690-3

NOTES:1. ALL CABLES TO BE THIN WALL AUTOMOTIVE - FLRYW. 2. CABLE TIE AT BREAKOUTS AND AT 100mm INTERVALS. 3. ALL SPLICES TO BE SOLDERED AND INSULATED WITH HEAT SHRINK. 4. WIRE HARNESSES TO BE FULLY TESTED FOR CORRECT PINOUTS. 5. TOLERANCES TO CONFORM TO SPECIFICATIONS IN WIRE HARNESS TOLERANCE DIAGRAM. 6. GROMMET: STRAIN RELIEF COLLAR TYPE. TO FIT 20 HOLE IN 1mm THK MATERIAL. 7. ALL FASTON .250 TYPE TERMINALS TO INCORPORATE LOCKING PIP.

Section B - Body and Framework Fault Finding Air Conditioning

B-17

Section B - Body and Framework Fault Finding Air Conditioning

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Section B - Body and Framework

Service Procedures HV/HVAC Unit Removal K Fig 8. ( T B-20) The machine can be fitted with a HV unit (Heating and Ventilation) or a HVAC unit (Heating Ventilation and Air Conditioning). Before removing the HVAC unit, the air conditioning system must be discharged. K Safety Procedures ( T B-10) 1

Working in the cab, remove the operators seat from its runners.

Remove the plastic panel from the rear of the cab to get access to the HV/HVAC unit 1. Refer to Cab Panels.

Remove two bolts and lift the bracket 4 together with harness connectors 2 clear of the HV/HVAC unit.

Disconnect the connector 3.

Disconnect the ventilation hoses 7 at the HV/HVAC unit

Label the water hoses 9 and disconnect them at the HV/HVAC unit.

Label the air conditioning hoses 8 (if applicable) and disconnect them at the HVAC unit.

Remove four mounting screws 6 from both sides of the HVAC unit and lift the unit from the machine.

HV/HVAC

electrical

harness

Replacement Replacement is the reverse of the removal procedure. Note: Ensure the two drain hoses 5 are threaded through the holes in the cab floor and are not trapped under the HVAC unit.

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B-19

Section B - Body and Framework Service Procedures HV/HVAC Unit

3 1

9 9

6 5 C130360

Fig 8.

B-20

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B-20

Section B - Body and Framework Service Procedures Air Conditioning Compressor

Air Conditioning Compressor Removal and Replacement Removal

Disconnect the electrical connector 1 at the compressor 7.

Remove bolt 4 and disconnect the low pressure hose 6 from the compressor.

Remove bolt 3 and disconnect the high pressure hose 5 from the compressor.

Cap all open contamination.

Support the compressor and remove three bolts 2. Lift the compressor from the machine.

!MWARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5

Discharge the air conditioning system refrigerant. K Safety Procedures ( T B-10) Remove the FEAD belt 9 from the compressor pulley 8. Refer to Section K, Routine Maintenance.

ports

and

hoses

prevent

Replacement Replacement is the reverse of the removal procedure.

2 4

7 9

7 C130500

Fig 9.

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B-21

Section B - Body and Framework Service Procedures Cab Structure

Cab Structure Direct Glazing

Removing the Broken Glass and Old Sealant 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.

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

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

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

Several special tools are required to successfully complete the removal and replacement procedures. Reference is made to the tools in the text. The majority of these tools can be obtained locally and the remainder from JCB Service (see Service Tools). The work must only be carried out in a dry, frost free environment. A protective canopy may be required or the machine/frame must be moved to a sheltered area. In damp or wet conditions, hinged doors and window frames can be removed from the machine and taken to a more suitable (dry) environment.

Laminated glass - leave installed until the old sealant has been cut away, after which it will be possible to lift the broken screen away from its frame housing in one piece.

b Toughened glass - remove as much of the shattered glass as possible prior to cutting out the old sealant. 3

Cut out the old sealant, leaving approximately 1 to 2 mm on the cab frame. There are several tools and techniques for doing this: a

Glass should not be replaced at temperatures below 5Â°C (41Â°F).

!MWARNING

Pneumatic Knife. K Fig 10. ( T B-23). This provides one of the easiest methods of removing the sealant around laminated glass. The tool, powered by compressed air, should be sourced locally.

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

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B-22

Section B - Body and Framework Service Procedures Cab Structure ii

Insert the braided cutting wire 11-B down the centre of the steel tube. If necessary, from the outside, cut out local sealant at the point of the tube to gain access to the wire.

iii Using suitable pliers, pull the cutting wire through the sealant to the outer side of the glass. Fig 10. Pneumatic Knife i

iv Secure each end of the braided cutting wire in the special handles 11-C.

Press the handle to start the knife blade oscillating.

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

Move the cutting wire backwards and forwards in a sawing motion and at the same time gently push or pull the wire to cut through the old sealant.

Insert the knife blade into the sealant. c

iii Slowly move the knife along the sealant with the blade positioned as close to the glass as possible. Do not allow the knife blade to overheat or the sealant will melt.

Cut-out Knife. K Fig 12. ( T B-23). The cut-out knife can be used as a left handed or right handed tool.

b Braided Cutting Wire and Handles. K Fig 11. ( T B-23). This method uses a 3-core wire, a wire starter tube and two handles. i

Insert the steel tube 11-A into the old sealant on the inside of the glass.

Fig 12. Cut-out Knife i

Insert the knife blade into the sealant.

Make sure that the blade of the knife is against the glass 12-A.

iii Use the 'pull-handle' to pull the knife along and cut out the old sealant. d Craft Knife. K Fig 13. ( T B-24). The blades 13-A are replaceable. Fig 11. Braided Cutting Wire and Handles

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9813/3200-03

Insert the knife blade into the sealant.

Pull the knife along and cut out the old sealant.

B-23

Section B - Body and Framework Service Procedures Cab Structure 2

Use 'Active Wipe 205' to thoroughly clean and 'prime' the trimmed sealant. Use a lint free cloth to apply the 'Active Wipe 205', allow 5 minutes flash off (drying) time.

Note: Do not use any other type of cleaning fluids, otherwise they may be absorbed into the old sealant and ultimately prevent the new glass from bonding.

Preparing the New Glass

!MWARNING

Fig 13. 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.

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 14. ( T B-24)

Make sure that the new glass correctly fits the frame aperture 15-A. a

1-2 mm

Put two spacer blocks 15-B onto the bottom part of the frame aperture.

b Install the new glass on the spacer blocks Always use glass lifters 15-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 14.

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

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

Paintwork was damaged or scratched during the glass/sealant removal procedures.

b The old sealant was inadvertently cut back to the cab frame during the glass/sealant removal procedures.

Preparing the Cab Frame Aperture 1

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

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B-24

Section B - Body and Framework Service Procedures Cab Structure

Fig 17.

Fig 15. 2

Make sure the glass is positioned on the stand the correct way up (i.e. with the black ceramic ink band upwards) ready for application of primer etc.

Clean the glass a

After checking for size, remove the new glass and place it on a purpose made glass stand. K Fig 16. ( T B-25).

Use 'Active Wipe 205' to thoroughly clean and 'prime' the black ceramic ink band printed on the glass (see Note). Use a lint free cloth to apply the 'Active Wipe 205', allow 5 minutes flash off (drying) time.

Note: Do not touch the glass after cleaning with the 'Active Wipe 205'. b If the glass does not have a black ceramic ink band, paint a band on the glass using 'Black Primer 206J'. The band should be approximately 25mm (1in) wide, and the edge should be a neat straight line. K Fig 18. ( T B-25).

Fig 16. Glass Stand Small panes of glass will need locating on a 600 x 700 mm x 15 to 19 mm thick plywood board 17-A, sourced locally to fit the glass stand. It is recommended that an access hole is cut in the board to accommodate the glass lifter, making it easier and safer to handle small panes of glass. The board should be covered with felt or carpet to give an anti-scratch surface. Resting the glass on four spacer blocks will ensure clearance of the cartridge nozzle tip during application of the polyurethane sealant.

B-25

Fig 18. 5

9813/3200-03

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

B-25

Section B - Body and Framework Service Procedures Cab Structure a

Remove the aluminium disc cover from the base of the cartridge and discard the 'dessicant capsule'.

b Make sure that the rolled edge of the cartridge is not damaged - if necessary, the edges should be pressed flat, otherwise it will be difficult to remove the cartridge from the applicator gun. c

Pierce the front 'nozzle' end of the cartridge to its maximum diameter.

Note: Once the pre-heated adhesive has been applied to the glass, install the glass in the aperture as soon as possible. After approximately 10 minutes the sealant will form a 'skin', this will prevent the glass from bonding. 7

Installing the New Glass 1

If the internal trim strip is damaged, renew it (cut to length as required) before fitting the new glass. Make sure the two spacer blocks are in position. K Preparing the New Glass ( T B-24) - step 1.

Install the glass in the frame aperture:

d Fit the pre-cut nozzle. K Fig 19. ( T B-26). e

Install the cartridge in the applicator gun.

Note: Cold material will be very difficult to extrude. The cartridges must be pre-heated in a special oven for 1 hour to a temperature of 80Â°C (176Â°F). Pre-heating the cartridges makes the adhesive more workable and also brings the 'curing' time down to 30 minutes.

After applying the adhesive, leave a small amount of sealant protruding from the nozzle. This will prevent any adhesive left in the cartridge from 'curing'.

Always use the special lifting tools when moving the glass. Use a lifting strap to hold large panes of glass in position. K Fig 21. ( T B-26)

Fig 19. 6

Apply the pre-heated adhesive to the glass (do not start in a corner). Keep the nozzle guide 20-A against the edge of the glass and make sure that the adhesive forms a continuous 'pyramid' shape. K Fig 20. ( T B-26)

Fig 21. Typical M/c. Installation b Sit the bottom edge of the glass on the spacer blocks. K Fig 22. ( T B-27)

Fig 20.

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B-26

Section B - Body and Framework Service Procedures Cab Structure 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 22. c

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

Make the inside seal smooth: a

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

b Use your finger to make the inside seal smooth. 4

All exposed edges must be sealed using Black Polyurethane Sealant (see Sealing and Retaining Compounds, Section 1).

Important: Use extreme caution when wiping the inside of the new glass - pushing too hard on the inside of the glass will affect the integrity of the bonded seal. 5

Clean the glass after installation: a

Small amounts of sealant can be cleaned from the glass using the 'Active Wipe 205'.

b Large amounts of excess sealant should be left to 'cure' and then cut off with a sharp knife. Note: On completion of the glass replacement procedures, the sealant 'curing' time is 30 minutes. This means that the machine can be driven and used after 30

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B-27

Section B - Body and Framework Service Procedures Cab Structure

Checks

bolt torques. Tighten them to the correct torque if necessary.

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

Item

Table 13. Torque Settings Nm Kgf m lbf ft

132

Fig 23.

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B-28

Section B - Body and Framework Service Procedures Cab Structure

Checking the FOPS Structure

Torque Setting

All excavators are designed so that an operator's protective structure can be fitted. In certain applications such as demolition, machines must be fitted with the optional Falling Objects Protection Structure (FOPS). It is the operator's responsibility to identify the risk of an application.

!MWARNING You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protection Structure (ROPS)/Falling Objects Protection Structure (FOPS) has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification. INT-2-1-9_6

Check that all the FOPS mounting bolts are in place and undamaged. Check the FOPS mounting bolts for correct torque tightness.

Fig 24.

B-29

Torque tightness is 78 Nm (57.5 lbf ft)

Torque tightness is 343 Nm (253 lbf ft)

Torque tightness is 78 Nm (57.5 lbf ft)

Torque tightness is 343 Nm (253 lbf ft)

Torque tightness is 137 Nm (101 lbf ft)

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B-29

Section B - Body and Framework Service Procedures Cab Structure

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Section B - Body and Framework Cab Panels Removal and Replacement

Cab Panels Removal and Replacement The cab is fitted with five plastic trim panels. The panels are fixed to the cab frame with screws.

LH ‘C’ Post Cover. K Fig 26. ( T B-33)

Fixings - 4 x screws and nylon washers

Components, such as electrical switches, locate in some of the cab panels. During removal and replacement be sure to disconnect and reconnect the applicable harness connectors.

Coat hook

Fixings - 2 x screws and nylon washers

Remove the rear panel 2 to get access to the fixings Remove / replace the coat hook 5B

Do not force the panels away from the cab frame, be sure to remove all the fixings. If a cab panel is replaced with a new one transfer the applicable components to the new panel. The table lists the cab panels and their fixings: 1

RH ‘C’ Post Panel. K Fig 25. ( T B-32)

Fixings - 4 x screws and nylon washers

Emergency hammer

Remove the emergency hammer 1B to get access to the fixings. Remove the centre console panel 3 to get access to the fixings 2

Rear Panel. K Fig 25. ( T B-32)

Fixings - 7 x screws and nylon washers

Disconnect / connect the ventilation hoses at the rear of the panel 3

Centre Console Panel. K Fig 25. ( T B-32)

Fixings - 8 x screws and nylon washers

Fixing - 1 x bolt and nylon washer

Stowage plate

Cover

Remove the rear panel 2 to get access to the fixings Remove the cover 3D to get access to the fixing Remove / replace the stowage plate 3C 4

‘A’ Post Panel. K Fig 25. ( T B-32)

Fixings - 2 x screws and nylon washers

Fixings - 2 x bolts and nylon washers

Remove / replace the stowage plate 3C Remove / replace the DECU ECU. Refer to Section C.

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B-31

Section B - Body and Framework Cab Panels Removal and Replacement

1B 1

1A 1A 2A

3A 3 3B

4A 3A 3A

4 3C 4B

C130450

Fig 25.

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B-32

Section B - Body and Framework Cab Panels Removal and Replacement

5B 5A

5 5A

C130490

Fig 26.

B-33

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B-33

Section B - Body and Framework Cab Panels Removal and Replacement

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Section B - Body and Framework

Routine Maintenance Procedures Scheduled Tasks The table below lists the Body and Framework related Scheduled tasks. The tasks are in addition to the tasks detailed in Section 2. 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 14. Item

Task

Refer to

Doors and locks

Check (Condition)

K Check (Condition) ( T B-36)

Excavator lever and pedal locks

Check (Operation)

K Check (Operation) ( T B-37)

Slew ring pinion and gear teeth

Lubricate

K Lubricate ( T B-38)

Fit for purpose test

Check (Operation)

K Fit For Purpose Test ( T B-39)

Cab heater/air-conditioning filter

Replace

K Cab Heater/Air-Conditioning Filter ( T B-40)

B-35

B-04-01 issue 02

B-35

Section B - Body and Framework Routine Maintenance Procedures Doors and Locks

Doors and Locks Check (Condition) Check the condition of the cab doors and locks as follows: – Check the operation of the latches and locks. Replace worn or defective components if the latches fail to latch, release, lock or unlock correctly. – Lubricate the locks and latches with light lubricating oil. – Check that the machine doors and access covers open and close correctly. Make sure that the hinges and retaining devices operate correctly. replace missing, worn or defective components. – Lubricate the door and access cover pivots with light lubricating oil.

B-36

B-04-01 issue 02

B-36

Section B - Body and Framework Routine Maintenance Procedures Excavator Lever and Pedal Locks

Excavator Lever and Pedal Locks Check (Operation) Check the operation of the machine control locks. refer to Section 2, Operation, Machine Locks. If the control locks do not operate correctly, carry out the necessary procedures to repair them. Important: DO NOT operate the machine if the control locks are defective.

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B-04-01 issue 02

B-37

Section B - Body and Framework Routine Maintenance Procedures Slew Ring Pinion and Gear Teeth

Slew Ring Pinion and Gear Teeth General Ensure slew ring is kept full of grease. Always grease whenever the machine has been steam-cleaned.

Lubricate Lubricate the slew ring pinion and gear teeth as follows: 1

Prepare the machine Maintenance.

Grease the slew ring as follows: a

Refer

Section

Remove the inspection port cover A (on the lower centre section).

b Remove the grease discharge port cover B (on the lower inner side). c

Remove contaminated grease.

d Replace the discharge port cover. e

Apply grease to the slew ring via aperture C.

JS03672-C1

Fig 27. Tracked Machines 3

Start the engine and slew the machine a few degrees. Stop the engine, remove the starter key and apply grease again. Repeat until the whole ring is greased. Check that grease exudes around the entire circumference.

Refit the inspection port cover.

812270

Fig 28. Wheeled Machines

B-38

B-04-01 issue 02

B-38

Section B - Body and Framework Routine Maintenance Procedures Fit For Purpose Test

Fit For Purpose Test Fit for Purpose Tests for Lifting Equipment T3-097

All lifting equipment (for example forks, lifting hooks and shackles) need regular inspection and testing by a competent person to ensure they are fit for purpose. This may be needed every six months or at least annually in some countries to meet and comply with legislation and for insurance purposes. Check with your local JCB distributor for further advice.

B-39

B-04-01 issue 02

B-39

Section B - Body and Framework Routine Maintenance Procedures Cab Heater/Air-Conditioning Filter

Cab Heater/Air-Conditioning Filter General There are two cab heater/air-conditioning filters. A fresh air filter 2 and a re-circulation filter 3. The filters are located in

the Heating Ventilation and Air-Conditioning (HVAC) unit 1 inside the cab. The HVAC unit is located at the rear of the operatorâ&#x20AC;&#x2122;s seat.

6 3 5 4

C130140

Fig 29.

Replace

Prepare the machine. Refer to Section Maintenance, Maintenance Positions.

Slide the cover 5 up and remove it from the HVAC unit 1.

Remove the re-circulation filter 3.

Remove the fresh air filter 2.

B-40

B-04-01 issue 02

Install the new filters followed by the cover. Make sure that the cover sealing strips 4 and 6 locate correctly at each end of the cover.

B-40

Section B - Body and Framework Routine Maintenance Procedures Fit For Purpose Test

Fit For Purpose Test Fit for Purpose Tests for Lifting Equipment T3-097

B-41

B-04-01 issue 02

B-41

Section B - Body and Framework Routine Maintenance Procedures Cab Heater/Air-Conditioning Filter

Cab Heater/Air-Conditioning Filter General There are two cab heater/air-conditioning filters. A fresh air filter 2 and a re-circulation filter 3. The filters are located in

the Heating Ventilation and Air-Conditioning (HVAC) unit 1 inside the cab. The HVAC unit is located at the rear of the operatorâ&#x20AC;&#x2122;s seat.

6 3 5 4

C130140

Fig 29.

Replace

Prepare the machine. Refer to Section Maintenance, Maintenance Positions.

Slide the cover 5 up and remove it from the HVAC unit 1.

Remove the re-circulation filter 3.

Remove the fresh air filter 2.

B-42

B-04-01 issue 02

Install the new filters followed by the cover. Make sure that the cover sealing strips 4 and 6 locate correctly at each end of the cover.

B-42

Section C Electrics Service Manual - JS 200 Series Tracked Excavators - T4 and T2 Engines Section 1 - General Information Section 2 - Operator’s Manual Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/3200-03

Section C - Electrics

Notes:

C-0

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C-0

Section C - Electrics Contents Page No. Overview and Schematics Circuit Symbols ......................................................................................... C-1 Circuit Concepts ....................................................................................... C-3 Pulse Width Modulation (PWM) ................................................................ C-6 Using a Multimeter .................................................................................... C-7 Schematic Diagrams - Machines with Ecomax Engines ........................ C-11 Schematic Diagrams - Machines with Ecomax Engines T4f .................. C-36 Schematic Diagrams - Machines with Dieselmax Engines ..................... C-62 Battery Maintenance ........................................................................................... C-87 Test Procedures ...................................................................................... C-88 Disconnection and Connection ............................................................... C-90 Fuses and Relays Introduction ............................................................................................. C-91 Cab Fuse and Relay Box - Connector Identification ............................... C-92 Harness Systems Installation and Interconnections ............................................................ C-93 Earth Points .......................................................................................... C-100 Harness Drawing List, JS200 - JS235 .................................................. C-103 Drawings ............................................................................................... C-106 Connector Codes .................................................................................. C-176 Wire Numbers and Functions ............................................................... C-180 Wiring Harness Repair ......................................................................... C-182

C-i

ECUs and CANbus CANbus System ................................................................................... Machine Electronic Control Unit (MECU) ............................................. Hydraulic Electronic Control Unit (HECU) ............................................ Display ECU (DECU) ............................................................................ Engine ECU .......................................................................................... SCR ECU ............................................................................................. Testing of ECU Inputs + Outputs ..........................................................

C-186 C-190 C-194 C-198 C-203 C-206 C-207

Engine and Power Control Battery Power Supply and Distribution ................................................. Ignition Power Supply and Distribution ................................................. Engine Start/Stop - Ecomax Engines .................................................... Engine Start/Stop - Dieselmax Engines ................................................ Engine Cranking ................................................................................... Engine 24V to 12V Converter ............................................................... Engine Fuse and Relay Box ................................................................. Engine Fuel Lift Pump .......................................................................... Engine Throttle and Power Mode Control ............................................ Engine Cold Idle ................................................................................... Ambient Air Temperature Sensor ......................................................... Engine Automatic Warm Up ................................................................. Engine Automatic Idle ........................................................................... Variable Geometry Turbo (VGT) Actuator ............................................. Exhaust Gas Re circulation (EGR) Actuator ......................................... TMAF Sensor ....................................................................................... Electro Viscous Fan .............................................................................. Engine Coolant Temperature Switch ....................................................

C-209 C-215 C-218 C-220 C-223 C-225 C-227 C-228 C-229 C-238 C-239 C-240 C-242 C-243 C-245 C-247 C-249 C-253

C-i

Section C - Electrics Contents Page No. Engine Coolant Level Switch ................................................................ C-254 Engine Oil Level Switch ........................................................................ C-257 Vacuum Switch ..................................................................................... C-259 Fuel Level Sensor ................................................................................. C-261 Water In Fuel (WIF) Sensor .................................................................. C-264 Alternator .............................................................................................. C-265 Refuelling Pump ................................................................................... C-268 Hydraulic Systems Control 8 Station Solenoid Valve ....................................................................... 8 Station Solenoid Valve (T4f engines) ................................................. Pressure Switches ................................................................................ Pressure Switches (T4f engines) .......................................................... 3-Speed Travel ..................................................................................... Controls Enable (Lever Lock) ............................................................... Controls Enable (Lever Lock ISO) ........................................................ Slew Brake and Slew Lock ................................................................... Pump Proportional Control Solenoid ................................................... Cushion Control .................................................................................... Overload Caution (option) .................................................................... Boost Pressure ..................................................................................... Maximum Flow Cut Solenoid (if fitted) .................................................. Hydraulic Oil Temperature Sensor ........................................................ Quickhitch (option) ................................................................................

C-271 C-273 C-275 C-277 C-279 C-282 C-284 C-286 C-289 C-291 C-293 C-295 C-297 C-298 C-300

Cab Systems and Lighting Camera System .................................................................................... Standard Work Lights ........................................................................... Cab Work Lights ................................................................................... Beacon ................................................................................................. Horn ...................................................................................................... Wipers and Washers ............................................................................ Cab Interior Lamp ................................................................................. 24 to 12 Volt Converter ......................................................................... HVAC Control .......................................................................................

C-305 C-307 C-309 C-311 C-313 C-315 C-319 C-321 C-324

Machine Diagnostic Modes Overview ............................................................................................... C-329 Selecting the Diagnostic Mode Screen ................................................. C-330 Time to Next Service Display Reset .................................................................................................... C-334

C-ii

Fault Code SYSTEM Operation Overview .............................................................................. Engine ‘P’ Codes .................................................................................. Cab Area ‘B’ Codes .............................................................................. Chassis ‘C’ Codes ................................................................................ CANbus ‘U’ Codes ................................................................................

C-336 C-339 C-340 C-341 C-346

Servicemaster SYSTEM Introduction ........................................................................................... Why Use ServiceMaster? ..................................................................... What is Servicemaster? ........................................................................ How to Set-up Servicemaster ...............................................................

C-348 C-349 C-350 C-352

C-ii

Section C - Electrics Contents Page No. Servicemaster Tools Set Introduction ........................................................................................... C-370 Tools Suites .......................................................................................... C-371 Diagnostics Connectors ........................................................................ C-375 Servicemaster Machine Selection ........................................................ C-376 Servicemaster Engine Selection ........................................................... C-377 Routine Maintenance Procedures Scheduled Tasks .................................................................................. Starter Motor ......................................................................................... Alternator .............................................................................................. Overload Warning System ....................................................................

C-iii

C-378 C-379 C-380 C-381

C-iii

Section C - Electrics Contents

C-iv

Page No.

C-iv

Section C - Electrics Overview and Schematics Circuit Symbols

Overview and Schematics Circuit Symbols TC-013

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

C005310GB-2

Fig 1.

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 2.

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Section C - Electrics Overview and Schematics Circuit Symbols

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C-2

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C-2

Section C - Electrics Overview and Schematics Circuit Concepts

Circuit Concepts Inputs There are two main types of input, Digital and Analogue. Digital type inputs are on/off type inputs (i.e. switches) and can be Low side inputs or High side inputs. Low side inputs are inputs that provide a ground to the ECU. High side inputs are inputs that provide a positive feed to the ECU. Analogue Inputs are sensor type inputs that provide a varying type input to the ECU, this input could be a resistance or frequency type input.

Digital inputs (on/off switch type inputs) 1

C007180GB-2

Fig 4.

Low side input. The low side input is the most frequently used input on the A.M.S system. The low side input can be in the form of rocker switches or pressure switches.

C007170GB-2

Fig 3. 2

C-3

High side input. The high side input is used on circuits that require a positive feed when the ignition is switched off, i.e. sidelights or hazard lights. The high side input is also used on the engine preheat circuit.

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Section C - Electrics Overview and Schematics Circuit Concepts Analogue input (i.e. sensor type inputs)

C045960GB-2

Fig 5.

C-4

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Section C - Electrics Overview and Schematics Circuit Concepts

Outputs There are three main types of outputs Low side output, High side output and Modulated output. In the Low side output circuit the actuator (solenoid, relay etc.) which is being driven already has a positive feed available, the ECU then provides the ground side of the circuit. In the High side output circuit the actuator which is being driven already has a ground available, the ECU provides the positive side of the circuit.

C007230GB-2

Fig 7. In the Modulated Output circuit the ECU provides a PWM (Pulse Width Modulation) signal to a proportional valve. As the ECU varies the duty cycle of the signal the proportional valve will select more or less depending on the change in duty cycle. 1

Modulated outputs. Circuits using the modulated output are throttle control, pump control and boom priority.

Low side output. Circuits using low side output are pre heat relay, stop solenoid relay and work lights.

C007240GB-2

Fig 8.

C007220GB-2

Fig 6. 2

C-5

High side output. The high side output is used to operate solenoids, bulbs and horn.

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C-5

Section C - Electrics Overview and Schematics Pulse Width Modulation (PWM)

Pulse Width Modulation (PWM) Ohms law states that, the amount of current flow in a circuit is determined by the voltage, and the resistance. A 24v circuit with a resistance of 6 ohms, would draw a current of 4 amps. This would be the case for a standard solenoid, which is either on or off. Once the voltage is applied to the circuit, it is present 100% of the time. This would be known as a 100% duty cycle. Therefore the circuit will draw 4 amps constantly.

The graph A although unstable would give a current rating of three amps. To stabilize the current in the circuit, the frequency would need to be increased. If the time scale on the graph A was one second, the frequency would be 4Hz (Hertz (cycles per second)). The graph B shows the same duty cycle, but at a higher frequency of 32 Hz. The proportional solenoids fitted to JS machines operate at a frequency of 75 Hz.

C007260GB-2

Fig 9.

C007270GB-2

Fig 10.

A proportional solenoid requires differing amounts of current, depending on its condition. As the coil has a fixed resistance, changing the current rating can be done in either of two ways, 1

Having lots of different resistors switched in and out of the circuit at different times to change the current flowing.

To change the duty cycle of the solenoid.

It is easier, more economical, and more reliable to change the duty cycle of the circuit, especially using today's computer/ controller technology. The duty cycle is the amount of time a component is switched on compared to the time it is switched off. If a solenoid is on for three seconds, then off for one second, on for three, off for one etc. this would be a 75% duty cycle.

C-6

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C-6

Section C - Electrics Overview and Schematics Using a Multimeter

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 12. AVO 2003

Fig 11. FLUKE 85

Fig 13. A Typical Analogue Meter 1

C-7

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Make sure that the test leads are plugged into the correct sockets. The black test lead should be

C-7

Section C - Electrics Overview and Schematics Using a Multimeter 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". 2

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.

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.

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

On the FLUKE 85. i

Measuring DC Voltage 1

Select the correct range on the multimeter. a

b On the AV0 2003.

On the FLUKE 85.

Turn the switch to position 11-B. b On the AV0 2003.

Move the right slider switch to position 12-A, and the left hand slider switch to the appropriate range. c

Turn the switch to position 11-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 11-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.

Move the right hand slider switch to position 12-B, and the left hand slider switch to the appropriate Ohms (立) range.

On an analogue meter. i

Move the dial to the appropriate Ohms (立) range.

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

C-8

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

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Section C - Electrics Overview and Schematics Using a Multimeter

Measuring Continuity

Measuring Frequency

Make sure there is no power to the part of the circuit you are checking for continuity.

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

Connect one probe to one end of the component or wire to be checked and the other probe to the other end. It does not matter which way round the two probes are placed.

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

Insert the red probe into socket 11-J.

Turn the selector switch to position 11-A and depress 11-G repeatedly until 11-F is highlighted on the top row of the display.

Press button 11-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 11-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 11-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 12-B, and the left hand slider switch to position 12-C. If there is continuity (i.e. very low resistance) between two points the buzzer will sound. c

On an analogue meter. Turn the dial to the lowest Ohms (ÎŠ) range. If there is continuity (i.e. very low resistance) between two points the needle will move across fully (or almost fully) to the right hand side of the scale.

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C-9

Section C - Electrics Overview and Schematics 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 11-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 12-A, and the left hand slider switch to position 12-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-10

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C-10

C-11

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K Component Keys ( T C-30)

(1) The machine electrical harnesses connect to the engine electrical harnesses at connector IC23. For details of the engine electrical harness and devices refer to the applicable engine Service Manual.

K Sheet 19 of 19 - JCB Ecomax Engine ( T C-29)(1)

K Sheet 18 of 19 - Heating Ventilation and Air Conditioning (HVAC) Option ( T C-28)

K Sheet 17 of 19 - Heater Only Option, Hydrauilc Raise Cab ( T C-27)

K Sheet 16 of 19 - Options - Arm Limiter, Dual ISO/SAE Controls, Auxiliary Hydraulics, Reversing Fan ( T C-26)

K Sheet 15 of 19 - Hydraulic ECU (HECU) Connector J2 ( T C-25)

K Sheet 14 of 19 - Hydraulic ECU (HECU) Connector J1 ( T C-24)

K Sheet 13 of 19 - CANbus ( T C-23)

K Sheet 12 of 19 - Earth Connections (Cab) ( T C-22)

K Sheet 11 of 19 - Earth Connections (Revolving Frame) ( T C-21)

K Sheet 10 of 19 - DECU J1 and J2, Livelink, Cameras ( T C-20)

K Sheet 9 of 19 - Cab Roof Electrical Components - Wiper, Worklights, Radio Speakers ( T C-19)

K Sheet 8 of 19 - Worklights and Beacon, Operator Seat Electrical Functions ( T C-18)

K Sheet 7 of 19 - Screen Wash and Wipers ( T C-17)

K Sheet 6 of 19 - Machine ECU (MECU) - Connector J2 ( T C-16)

K Sheet 5 of 19 - Machine ECU (MECU) - Connector J1 ( T C-15)

K Sheet 4 of 19 - Secondary Fuses and Power Distribution ( T C-14)

K Sheet 3 of 19 - Ignition, 12 Volt Distribution, Switch Backlighting ( T C-13)

Table 1. Sheets K Sheet 2 of 19 - High Current and Power Distribution - Ecomax Engines ( T C-12)

Schematic Diagrams - Machines with Ecomax Engines

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-11

C-12

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 14. Sheet 2 of 19 - High Current and Power Distribution - Ecomax Engines

333-K8484-5 Sheet 2.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-12

C-13

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 15. Sheet 3 of 19 - Ignition, 12 Volt Distribution, Switch Backlighting

333-K8484-5 Sheet 3.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-13

C-14

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 16. Sheet 4 of 19 - Secondary Fuses and Power Distribution

333-K8484-5 Sheet 4.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-14

C-15

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 17. Sheet 5 of 19 - Machine ECU (MECU) - Connector J1

333-K8484-5 Sheet 5.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-15

C-16

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 18. Sheet 6 of 19 - Machine ECU (MECU) - Connector J2

333-K8484-5 Sheet 6.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-16

Section C - Electrics Overview and Schematics

C-17

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K Sheets ( T C-11) K Component Keys ( T C-30)

Fig 19. Sheet 7 of 19 - Screen Wash and Wipers

333-K8484-5 Sheet 7.eps

Schematic Diagrams - Machines with Ecomax Engines

C-17

C-18

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 20. Sheet 8 of 19 - Worklights and Beacon, Operator Seat Electrical Functions

333-K8484-4 Sheet 8.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-18

C-19

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 21. Sheet 9 of 19 - Cab Roof Electrical Components - Wiper, Worklights, Radio Speakers

333-K8484-5 Sheet 9.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-19

C-20

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 22. Sheet 10 of 19 - DECU J1 and J2, Livelink, Cameras

333-K8484-5 Sheet 10.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-20

C-21

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 23. Sheet 11 of 19 - Earth Connections (Revolving Frame)

333-K8484-5 Sheet 11.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-21

C-22

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 24. Sheet 12 of 19 - Earth Connections (Cab)

333-K8484-5 Sheet 12.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-22

Section C - Electrics Overview and Schematics

C-23

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K Sheets ( T C-11) K Component Keys ( T C-30)

Fig 25. Sheet 13 of 19 - CANbus

333-K8484-5 Sheet 13.eps

Schematic Diagrams - Machines with Ecomax Engines

C-23

C-24

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 26. Sheet 14 of 19 - Hydraulic ECU (HECU) Connector J1

333-K8484-5 Sheet 14.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-24

C-25

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 27. Sheet 15 of 19 - Hydraulic ECU (HECU) Connector J2

333-K8484-5 Sheet 15.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-25

C-26

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 28. Sheet 16 of 19 - Options - Arm Limiter, Dual ISO/SAE Controls, Auxiliary Hydraulics, Reversing Fan

333-K8484-5 Sheet 16.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-26

C-27

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 29. Sheet 17 of 19 - Heater Only Option, Hydrauilc Raise Cab

333-K8484-5 Sheet 17.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-27

C-28

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 30. Sheet 18 of 19 - Heating Ventilation and Air Conditioning (HVAC) Option

333-K8484-5 Sheet 18.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-28

Section C - Electrics Overview and Schematics

C-29

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K Sheets ( T C-11) K Component Keys ( T C-30)

Fig 31. Sheet 19 of 19 - JCB Ecomax Engine

333-K8484-5 Sheet 19.eps

Schematic Diagrams - Machines with Ecomax Engines

C-29

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines

Component Keys Connector Code

Device

Connector Code Harness Location

Device

Harness Location

Sheet

C026

Motor: Revolver Screenwash Pump Harness

C001

ECU: JCB Engine

Revolver Harness

C027

Sensor: Air Filter Restriction

Revolver Harness

C002

Resistor: CAN Termination

Revolver Harness

C028

Sensor: Coolant Level

Revolver Harness

C003

Module: JCB Engine Fuse & Relay

Revolver Harness

C030

Fusebox: Primary

Revolver Harness

C033

Relay: Ignition

Converter: Voltage Revolver 24/12V Harness

Revolver Harness

C004

C036

Pump: Fuel Lift

Revolver Harness

Sensor: Pressure - Revolver Upper Pilot Harness

C006

C037

Sensor: Water In Fuel

Revolver Harness

Sensor: Pressure Travel Pilot

Revolver Harness

C007

C038

Sensor: Engine Oil Revolver Level Harness

Solenoid: Cooling Fan Control

Revolver Harness

C008

C039

Solenoid: Engine Starter Motor

Revolver Harness

Sensor: Pressure - Revolver AC Harness

C009

C040

Motor: Starter+

Revolver Harness

Solenoid: AC Compressor Clutch

Revolver Harness

C010 C012

Switch: Battery Isolator

Revolver Harness

C041

Alarm Travel

Revolver Harness

C015

ECU: Machine Control (J1)

Cab Harness

C042

Alternator: 24V 55A

Revolver Harness

C016

ECU: Machine Control (J2)

Cab Harness

C045

Solenoid: Pump Control

Revolver Harness

C018

Light: Working Revolver RH

Revolver Harness

C046

Sensor: Hydraulic Oil Temperature

Revolver Harness

C019

Pump: Re-fuelling

Revolver Harness

C047

Solenoid: Max Flow

Revolver Harness

C020

Switch: ReFuelling Pump

Revolver Harness

C048

Solenoid: Travel Speed

Revolver Harness

C021

Sensor: Fuel Level Revolver Harness

C049

Solenoid: Swing Lock

Revolver Harness

C022

Alarm Horn

Revolver Harness

C050

Solenoid: Swing Isolate

Revolver Harness

C023

Sensor: Boom Overload

Revolver Harness

C051

Solenoid: Controls Revolver Enable Harness

C024

Diode: Alternator Suppression

Revolver Harness

C052

Solenoid: MRV Boost

Revolver Harness

C025

Socket: Beacon Main

Revolver Harness

C053

Solenoid: Swing Brake

Revolver Harness

C-30

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C-30

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines Connector Code

Device

Harness Location

Sheet

Connector Code

Device

Harness Location

Sheet

C054

Solenoid: Cushion Revolver Harness

C077

LED: Heater Panel Heater Illumination Harness

C055

Light: Working Cab RH

Roof Harness

C078

Sensor: Hammer Pilot pressure

Cab Harness

C056

Light: Working Cab LH

Roof Harness

C079

Sensor: Boom Up

Cab Harness

C080

C057

Connector: Radio Power

Roof Harness

Sensor: Pressure - Cab Harness Swing Pilot

C081

Motor: Wiper Upper

Roof Harness

Relay: Ignition (24V Input)

Revolver Harness

C058

C082

Light: Interior Illumination

Roof Harness

Module: Heater Unit

Cab Harness

C059

C085

Joystick: LH Handle

Cab Harness

Light: Quickhitch Boom Status

Boom Harness 15

C060

C086

Switch: Lever Lock Cab Harness 1

Switch: Seat Ventilation

Cab Harness

C063

C090

C064

Converter: Voltage Revolver 24/12V Harness

Sensor: Pressure Pilot Hydraulics

C091

Connector: Vehicle Cab Harness Diagnostic

Solenoid: Boom Priority

Revolver Harness

C065

C092

Connector: Camera Power

Element: Heated Seat

Cab Harness

C066

C093

Converter: Voltage Cab Harness 24/12V

Motor: Seat Ventilation

Cab Harness

C067

C094

Camera: Counterweight

Camera Harness

Potentiometer: Cab Harness Throttle Set/Adjust

C068

C095

Camera: Offside

Camera Harness

Joystick: RH Handle

Cab Harness

C069

C097

Sensor: Temperature Ambient Â°C

Boom Harness 6

Switch: Ignition Keyswitch

Cab Harness

C070

C100

Fuse & Relay Module - Cab

Cab Harness

C071

Connector: HVAC CAN

Cab Harness

C107

Switch: Heated Seat

Cab Harness

C072

Connector: Heater Cab Harness / Air Conditioning

C109

ECU: Display (J1)

Fascia Harness

C073

Socket: Auxiliary IGN 24V (1)

C110

ECU: Display (J2)

Fascia Harness

C074

Switch: Fan Speed Heater Harness

C111

Switch: Radio Mute

Cab Harness

C075

Switch: ReCirculation

Heater Harness

C113

Switch: Worklights Fascia Std Harness

C076

Potentiometer: Temperature

Heater Harness

C-31

Cab Harness

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8 19

C-31

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines Connector Code

Device

Harness Location

Sheet

Connector Code

Device

Harness Location

Sheet

C114

Switch: Worklights Fascia Cab Harness

C142

Switch: Wiper Interlock

Roof Harness

C115

Switch: Beacon

Fascia Harness

C143

Connector: Radio Speakers

Roof Harness

C116

Switch: Main Wipers

Fascia Harness

C145

Revolver Harness

C117

Switch: Screenwash

Fascia Harness

Connector: Primary Fuse Supply

C147

Fascia Harness

Switch: Lower Wiper

Light: Console Illumination

C148

Roof Harness

Switch: Engine Stop

Fascia Harness

Sensor: Door Open

C149

Fascia Harness

Revolver Harness

Switch: Swing Lock

Sensor: TMAP Sensor

C150

Cab Harness

Switch: Quickhitch Fascia Harness

Motor: Seat Suspension

C151

Fascia Harness

Switch: Controls Enable

Socket: Auxiliary 12V (1)

C152

Cab Harness

Switch: Module Auto Idle/H+/ Speed

Cab Harness

Socket: Auxiliary IGN 24V (2)

C153

ECU: Hydraulic Control ECU (J1)

Cab Harness

C124

Light: Worklight Boom LH

Boom Harness 8

C154

ECU: Hydraulic Control ECU (J2)

Cab Harness

C125

Light: Worklight Counterweight

Revolver Harness

C155

Solenoid: Quickhitch

Revolver Harness

C126

Motor: Wiper Lower

Cab Harness

C156

Sensor: Pressure - Revolver Quickhitch Harness

C127

Diode: Wake-up - Cab Harness Refuel/Door Open

C157

Sensor: Alignment Boom Harness 15 - Boom

C128

Switch: Cushion

Fascia Harness

C158

Sensor: Alignment Boom Harness 15 - Arm

C129

ECU: Livelink Telematics

Fascia Harness

C159

Solenoid: Arm Limiter

Options Harness

C130

Connector: USB

Fascia Harness

C160

Solenoid: Low Flow ‘A’

Revolver Harness

C138

Connector: LH Rear Beacon

Revolver Harness

C161

Solenoid: Low Flow ‘B’

Revolver Harness

C139

Connector: RH Rear Beacon

Revolver Harness

C162

Light: Worklight Boom RH

Boom Harness 8

C140

Speaker: RH

Roof Harness

C163

Cab Harness

C141

Speaker: LH

Roof Harness

Socket: Auxiliary 12V (2)

C118 C119 C120 C121 C122 C123

C-32

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C-32

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines Connector Code

Device

Harness Location

Sheet

Connector Code

Device

Harness Location

Sheet

C225

Switch:Lever Lock 2

C226

Switch: Cab Raise (cab)

C231

Diode: HRC- Low Flow Priority

C240

Solenoid: HRC Low Flow Priority

C243

Solenoid: HRC Raise

C244

Solenoid: HRC Lower

C245

Sensor: Cab lowered and docked

C164

Solenoid: Proportional High Flow ‘A’

Cab Harness

C165

Solenoid: Proportional High Flow ‘B’

Cab Harness

C167

Solenoid: Auxiliary/Hammer Changeover

Revolver Harness

C169

Sensor: Seat Belt / Cab Harness Occupancy

C171

Sensor: Pressure Lo Flow Aux

Revolver Harness

C172

Sensor: Pressure Hi Flow Aux

Revolver Harness

C173

Solenoid: Merge Flow ‘A’

Cab Harness

C246

Switch: Cab Raise (revolving chassis)

C174

Solenoid: Merge Flow ‘B’

Cab Harness

C269

Fuse: Inlet Manifold Heater

C175

Solenoid: Low Cab Harness Flow Variable ARV

C268

Relay: Inlet Manifold Heater

C176

Solenoid: Hi Flow Variable ARV

Cab Harness

C270

Inlet Manifold Heater

C178

Solenoid: Dual Controls (A)

Options Harness

C318

Relay: LiveLink

C179

Solenoid: Dual Controls (B)

Options Harness

C30-X1

Sensor: Arm Limit Proximity

Arm Harness

Revolver Harness

C194

Connector: Primary Fuse B+

C42-X1

Antenna: FM Radio

Roof Harness

Revolver Harness

C195

Alternator: R Terminal

C42-X2

Resistor: CAN Termination

Fascia Harness

Revolver Harness

C200

Alternator: L Terminal

C214

Switch: Reversing Fan

Splice Code

Function

C215

Controller: Reversing Fan

C216

Fuse: Reversing Fan

C217

Sensor: Low Flow Pilot

C218

Sensor: High Flow Pilot

C-33

Main Wire

Harness Location

Sheet

S001

Splice: Earth Roof

6093 Roof Harness 9

S004

Splice: Forward Worklights

8002 Revolver Harness

S006

Splice: 24V B+ MECU

3002 Cab Harness

S008

Splice: 24V Ign Wash/Wipe

8100 Cab Harness

9813/3200-03

C-33

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines Splice Code

Function

Main Wire

Harness Location

Sheet

Splice Code

Function

Main Wire

Harness Location

Sheet

S009

Splice: 0V MECU 4000 Cab Harness - Cab

S032

Splice: 24V Ign Cab

1010 Cab Harness

S010

Splice: 5V MECU 4005 Cab Harness - Cab

S033

Splice: 24V Ign ECU Wake Up

1006 Cab Harness

S011

Splice: 24V Ign Wash/Wipe

8100 Cab Harness

S034

Splice: Cab Worklights

8004 Roof Harness 9

S012

Splice: Backlighting Fascia

1009 Fascia Harness

S035

Splice: Earth - Hi- 6091 Cab Harness Current

S039

Splice: Screenwash Pump

8008 Cab Harness

Splice: Backlighting Cab

1009 Cab Harness

S014

S041

3007 Cab Harness

S016

Splice: 24V Ign Revolver

1001 Revolver Harness

Splice: 24V B+ Re-Fuelling/Ign Switch

S042

Splice: Crank

4023 Cab Harness

S017

Splice: Dual Controls

8093 Options Harness

S053

Splice: Worklights 8002 Fascia Standard Harness

S019

Splice: Earth Revolver 2

6020 Revolver Harness

S056

Splice: Worklights 8002 Cab Harness Standard

S020

Splice: Earth Revolver 3

6033 Revolver Harness

S057

Splice: Lightning - 8005 Cab Harness Interior

S021

Splice: Earth JCB Engine

6054 Revolver Harness

S060

Splice: 24V B+ HECU

S022

Splice: Earth Options Harness

6200 Options Harness

S062

Splice: Worklights 8002 Boom - Boom B Harness

S023

Splice: 12V B+ Fused

3009 Revolver Harness

S063

Splice: Earth MECU

6153 Cab Harness

S024

Splice: 12V Ign Fused

1008 Fascia Harness

S070

Splice: 0V HECU Revolver

4110 Aux Hydraulic 16 Harness

S025

Splice: 24V Ign Engine Stop

1012 Cab Harness

S109

Splice: 12V Ign Fused

1012 Revolver Harness

S026

Splice: Earth Fascia

6075 Fascia Harness

S137

Slice: SCR ECU Earth Slice

6300 DEF Control Harness

S027

Splice: Camera Power +

1023 Camera Harness

S138

6302 DEF Control Harness

S028

Splice: Camera Power -

6110 Camera Harness

Splice: After Treatment Fuse and Relay Ground

S029

Splice: Earth Heater Only

6092 Heater Harness

S139

S030

Splice: 24V Ign Fascia

1006 Fascia Harness

Splice: NOx and 6302 DEF Control Head unit Sensor Harness Ground

S140

Splice: 12V Heater Only

1008 Heater Harness

Splice: NOx and 8223 DEF Control Head unit Sensor Harness +ve Supply

S031

C-34

9813/3200-03

3012 Cab Harness

C-34

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines Splice Code

Function

Main Wire

Harness Location

Sheet

S141

Splice: NOx Sensor +ve Supply

8223 Revolver Harness

S142

Splice: NOx Sensor Ground

6302 Revolver E Harness

S143

Splice: Hose Heater +ve Supply

8214 DEF Control Harness

S144

Splice: SCR ECU 3100 DEF Control +ve Supply Harness

S145

Splice: SCR System Earth

6300 DEF Control Harness

S148

Splice: Engine Shutdown

8032 Revolver Harness

S152

Splice: Permanent Negative

6047 Revolver Harness

C-35

9813/3200-03

C-35

C-36

9813/3200-03

K Component Keys ( T C-56)

K Sheet 20 of 20- After Treatment System T4f ( T C-55)

K Sheet 19 of 20 - JCB Ecomax Engine T4f ( T C-54)(1)

K Sheet 18 of 20 - Heating Ventilation and Air Conditioning (HVAC) Option T4f ( T C-53)

K Sheet 17 of 20 - Heater Only Option, Hydrauilc Raise Cab T4f ( T C-52)

K Sheet 16 of 20 - Options - Arm Limiter, Dual ISO/SAE Controls, Auxiliary Hydraulics, Reversing Fan T4f ( T C-51)

K Sheet 15 of 20 - Hydraulic ECU (HECU) Connector J2 T4f ( T C-50)

K Sheet 14 of 20 - Hydraulic ECU (HECU) Connector J1 T4f ( T C-49)

K Sheet 13 of 20 - CANbus T4f ( T C-48)

K Sheet 12 of 20 - Earth Connections (Cab) T4f ( T C-47)

K Sheet 11 of 20 - Earth Connections (Revolving Frame) T4f ( T C-46)

K Sheet 10 of 20 - DECU J1 and J2, Livelink, Cameras T4f ( T C-45)

K Sheet 9 of 20 - Cab Roof Electrical Components - Wiper, Worklights, Radio Speakers T4f ( T C-44)

K Sheet 8 of 20 - Worklights and Beacon, Operator Seat Electrical Functions T4f ( T C-43)

K Sheet 7 of 20 - Screen Wash and Wipers T4f ( T C-42)

K Sheet 6 of 20 - Machine ECU (MECU) - Connector J2 T4f ( T C-41)

K Sheet 5 of 20 - Machine ECU (MECU) - Connector J1 T4f ( T C-40)

K Sheet 4 of 20 - Secondary Fuses and Power Distribution T4f ( T C-39)

K Sheet 3 of 20 - Ignition, 12 Volt Distribution, Switch Backlighting T4f ( T C-38)

Table 2. Sheets K Sheet 2 of 20 - High Current and Power Distribution - Ecomax Engines T4f ( T C-37)

Schematic Diagrams - Machines with Ecomax Engines T4f

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-36

C-37

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 32. Sheet 2 of 20 - High Current and Power Distribution - Ecomax Engines T4f

334-J4258-3-Sheet2

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-37

C-38

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 33. Sheet 3 of 20 - Ignition, 12 Volt Distribution, Switch Backlighting T4f

334-J4258-3-Sheet3.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-38

C-39

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 34. Sheet 4 of 20 - Secondary Fuses and Power Distribution T4f

334-J4258-3-Sheet4.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-39

C-40

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 35. Sheet 5 of 20 - Machine ECU (MECU) - Connector J1 T4f

334-J4258-3-Sheet5.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-40

C-41

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 36. Sheet 6 of 20 - Machine ECU (MECU) - Connector J2 T4f

334-J4258-3-Sheet6.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-41

Section C - Electrics Overview and Schematics

C-42

9813/3200-03

K Sheets ( T C-36) K Component Keys ( T C-56)

Fig 37. Sheet 7 of 20 - Screen Wash and Wipers T4f

334-J4258-3-Sheet7.eps

Schematic Diagrams - Machines with Ecomax Engines T4f

C-42

C-43

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 38. Sheet 8 of 20 - Worklights and Beacon, Operator Seat Electrical Functions T4f

334-J4258-3-Sheet8.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-43

C-44

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 39. Sheet 9 of 20 - Cab Roof Electrical Components - Wiper, Worklights, Radio Speakers T4f

334-J4258-3-Sheet9.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-44

C-45

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 40. Sheet 10 of 20 - DECU J1 and J2, Livelink, Cameras T4f

334-J4258-3-Sheet10.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-45

C-46

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 41. Sheet 11 of 20 - Earth Connections (Revolving Frame) T4f

334-J4258-3-Sheet11.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-46

C-47

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 42. Sheet 12 of 20 - Earth Connections (Cab) T4f

334-J4258-3-Sheet12.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-47

Section C - Electrics Overview and Schematics

C-48

9813/3200-03

K Sheets ( T C-36) K Component Keys ( T C-56)

Fig 43. Sheet 13 of 20 - CANbus T4f

334-J4258-3-Sheet13.eps

Schematic Diagrams - Machines with Ecomax Engines T4f

C-48

C-49

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 44. Sheet 14 of 20 - Hydraulic ECU (HECU) Connector J1 T4f

334-J4258-3-Sheet14.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-49

C-50

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 45. Sheet 15 of 20 - Hydraulic ECU (HECU) Connector J2 T4f

334-J4258-3-Sheet15.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-50

C-51

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 46. Sheet 16 of 20 - Options - Arm Limiter, Dual ISO/SAE Controls, Auxiliary Hydraulics, Reversing Fan T4f

334-J4258-3-Sheet16.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-51

C-52

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 47. Sheet 17 of 20 - Heater Only Option, Hydrauilc Raise Cab T4f

334-J4258-3-Sheet17.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-52

C-53

9813/3200-03

K Component Keys ( T C-56)

K Sheets ( T C-36)

Fig 48. Sheet 18 of 20 - Heating Ventilation and Air Conditioning (HVAC) Option T4f

334-J4258-3-Sheet18.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines T4f

C-53

Section C - Electrics Overview and Schematics

C-54

9813/3200-03

K Sheets ( T C-36) K Component Keys ( T C-56)

Fig 49. Sheet 19 of 20 - JCB Ecomax Engine T4f

334-J4258-3-Sheet19.eps

Schematic Diagrams - Machines with Ecomax Engines T4f

C-54

Section C - Electrics Overview and Schematics

C-55

9813/3200-03

K Sheets ( T C-36) K Component Keys ( T C-56)

Fig 50. Sheet 20 of 20- After Treatment System T4f

334-J4258-3-Sheet20.eps

Schematic Diagrams - Machines with Ecomax Engines T4f

C-55

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines T4f

Component Keys Connector Code

Device

Connector Code Harness Location

Device

Harness Location

Sheet

C026

Motor: Revolver Screenwash Pump Harness

C001

ECU: JCB Engine

Revolver Harness

C027

Sensor: Air Filter Restriction

Revolver Harness

C002

Resistor: CAN Termination

Revolver Harness

C028

Sensor: Coolant Level

Revolver Harness

C003

Module: JCB Engine Fuse & Relay

Revolver Harness

C030

Fusebox: Primary

Revolver Harness

C033

Relay: Ignition

Converter: Voltage Revolver 24/12V Harness

Revolver Harness

C004

C036

Pump: Fuel Lift

Revolver Harness

Sensor: Pressure - Revolver Upper Pilot Harness

C006

C037

Sensor: Water In Fuel

Revolver Harness

Sensor: Pressure Travel Pilot

Revolver Harness

C007

C038

Sensor: Engine Oil Revolver Level Harness

Solenoid: Cooling Fan Control

Revolver Harness

C008

C039

Solenoid: Engine Starter Motor

Revolver Harness

Sensor: Pressure - Revolver AC Harness

C009

C040

Motor: Starter+

Revolver Harness

Solenoid: AC Compressor Clutch

Revolver Harness

C010 C012

Switch: Battery Isolator

Revolver Harness

C041

Alarm Travel

Revolver Harness

C015

ECU: Machine Control (J1)

Cab Harness

C042

Alternator: 24V 55A

Revolver Harness

C016

ECU: Machine Control (J2)

Cab Harness

C045

Solenoid: Pump Control

Revolver Harness

C018

Light: Working Revolver RH

Revolver Harness

C046

Sensor: Hydraulic Oil Temperature

Revolver Harness

C019

Pump: Re-fuelling

Revolver Harness

C047

Solenoid: Max Flow

Revolver Harness

C020

Switch: ReFuelling Pump

Revolver Harness

C048

Solenoid: Travel Speed

Revolver Harness

C021

Sensor: Fuel Level Revolver Harness

C049

Solenoid: Swing Lock

Revolver Harness

C022

Alarm Horn

Revolver Harness

C050

Solenoid: Swing Isolate

Revolver Harness

C023

Sensor: Boom Overload

Revolver Harness

C051

Solenoid: Controls Revolver Enable Harness

C024

Diode: Alternator Suppression

Revolver Harness

C052

Solenoid: MRV Boost

Revolver Harness

C025

Socket: Beacon Main

Revolver Harness

C053

Solenoid: Swing Brake

Revolver Harness

C-56

9813/3200-03

C-56

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines T4f Connector Code

Device

Harness Location

Sheet

Connector Code

Device

Harness Location

Sheet

C054

Solenoid: Cushion Revolver Harness

C077

LED: Heater Panel Heater Illumination Harness

C055

Light: Working Cab RH

Roof Harness

C078

Sensor: Hammer Pilot pressure

Cab Harness

C056

Light: Working Cab LH

Roof Harness

C079

Sensor: Boom Up

Cab Harness

C080

C057

Connector: Radio Power

Roof Harness

Sensor: Pressure - Cab Harness Swing Pilot

C081

Motor: Wiper Upper

Roof Harness

Relay: Ignition (24V Input)

Revolver Harness

C058

C082

Light: Interior Illumination

Roof Harness

Module: Heater Unit

Cab Harness

C059

C085

Joystick: LH Handle

Cab Harness

Light: Quickhitch Boom Status

Boom Harness 15

C060

C086

Switch: Lever Lock Cab Harness 1

Switch: Seat Ventilation

Cab Harness

C063

C090

C064

Converter: Voltage Revolver 24/12V Harness

Sensor: Pressure Pilot Hydraulics

C091

Connector: Vehicle Cab Harness Diagnostic

Solenoid: Boom Priority

Revolver Harness

C065

C092

Connector: Camera Power

Element: Heated Seat

Cab Harness

C066

C093

Converter: Voltage Cab Harness 24/12V

Motor: Seat Ventilation

Cab Harness

C067

C094

Camera: Counterweight

Camera Harness

Potentiometer: Cab Harness Throttle Set/Adjust

C068

C095

Camera: Offside

Camera Harness

Joystick: RH Handle

Cab Harness

C069

C097

Sensor: Temperature Ambient Â°C

Boom Harness 6

Switch: Ignition Keyswitch

Cab Harness

C070

C100

Fuse & Relay Module - Cab

Cab Harness

C071

Connector: HVAC CAN

Cab Harness

C107

Switch: Heated Seat

Cab Harness

C072

Connector: Heater Cab Harness / Air Conditioning

C109

ECU: Display (J1)

Fascia Harness

C073

Socket: Auxiliary IGN 24V (1)

C110

ECU: Display (J2)

Fascia Harness

C074

Switch: Fan Speed Heater Harness

C111

Switch: Radio Mute

Cab Harness

C075

Switch: ReCirculation

Heater Harness

C113

Switch: Worklights Fascia Std Harness

C076

Potentiometer: Temperature

Heater Harness

C-57

Cab Harness

9813/3200-03

8 19

C-57

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines T4f Connector Code

Device

Harness Location

Sheet

Connector Code

Device

Harness Location

Sheet

C114

Switch: Worklights Fascia Cab Harness

C142

Switch: Wiper Interlock

Roof Harness

C115

Switch: Beacon

Fascia Harness

C143

Connector: Radio Speakers

Roof Harness

C116

Switch: Main Wipers

Fascia Harness

C145

Revolver Harness

C117

Switch: Screenwash

Fascia Harness

Connector: Primary Fuse Supply

C147

Fascia Harness

Switch: Lower Wiper

Light: Console Illumination

C148

Roof Harness

Switch: Engine Stop

Fascia Harness

Sensor: Door Open

C149

Fascia Harness

Revolver Harness

Switch: Swing Lock

Sensor: TMAP Sensor

C150

Cab Harness

Switch: Quickhitch Fascia Harness

Motor: Seat Suspension

C151

Fascia Harness

Switch: Controls Enable

Socket: Auxiliary 12V (1)

C152

Cab Harness

Switch: Module Auto Idle/H+/ Speed

Cab Harness

Socket: Auxiliary IGN 24V (2)

C153

ECU: Hydraulic Control ECU (J1)

Cab Harness

C124

Light: Worklight Boom LH

Boom Harness 8

C154

ECU: Hydraulic Control ECU (J2)

Cab Harness

C125

Light: Worklight Counterweight

Revolver Harness

C155

Solenoid: Quickhitch

Revolver Harness

C126

Motor: Wiper Lower

Cab Harness

C156

Sensor: Pressure - Revolver Quickhitch Harness

C127

Diode: Wake-up - Cab Harness Refuel/Door Open

C157

Sensor: Alignment Boom Harness 15 - Boom

C128

Switch: Cushion

Fascia Harness

C158

Sensor: Alignment Boom Harness 15 - Arm

C129

ECU: Livelink Telematics

Fascia Harness

C159

Solenoid: Arm Limiter

Options Harness

C130

Connector: USB

Fascia Harness

C160

Solenoid: Low Flow ‘A’

Revolver Harness

C138

Connector: LH Rear Beacon

Revolver Harness

C161

Solenoid: Low Flow ‘B’

Revolver Harness

C139

Connector: RH Rear Beacon

Revolver Harness

C162

Light: Worklight Boom RH

Boom Harness 8

C140

Speaker: RH

Roof Harness

C163

Cab Harness

C141

Speaker: LH

Roof Harness

Socket: Auxiliary 12V (2)

C118 C119 C120 C121 C122 C123

C-58

9813/3200-03

C-58

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines T4f Connector Code

Device

Harness Location

Sheet

Connector Code

Device

Harness Location

Sheet

C225

Switch:Lever Lock 2

C226

Switch: Cab Raise (cab)

C231

Diode: HRC- Low Flow Priority

C240

Solenoid: HRC Low Flow Priority

C243

Solenoid: HRC Raise

C244

Solenoid: HRC Lower

C245

Sensor: Cab lowered and docked

C164

Solenoid: Proportional High Flow ‘A’

Cab Harness

C165

Solenoid: Proportional High Flow ‘B’

Cab Harness

C167

Solenoid: Auxiliary/Hammer Changeover

Revolver Harness

C169

Sensor: Seat Belt / Cab Harness Occupancy

C171

Sensor: Pressure Lo Flow Aux

Revolver Harness

C172

Sensor: Pressure Hi Flow Aux

Revolver Harness

C173

Solenoid: Merge Flow ‘A’

Cab Harness

C246

Switch: Cab Raise (revolving chassis)

C174

Solenoid: Merge Flow ‘B’

Cab Harness

C269

Fuse: Inlet Manifold Heater

C175

Solenoid: Low Cab Harness Flow Variable ARV

C268

Relay: Inlet Manifold Heater

C176

Solenoid: Hi Flow Variable ARV

Cab Harness

C270

Inlet Manifold Heater

C178

Solenoid: Dual Controls (A)

Options Harness

C318

Relay: LiveLink

C179

Solenoid: Dual Controls (B)

Options Harness

C334

Sensor: Exhaust Inlet Temerature

Revolver Harness

C194

Sensor: Arm Limit Proximity

Arm Harness

C335

Sensor: NOx Downstream/ Tailpipe

Revolver Harness

C195

Antenna: FM Radio

Roof Harness

C336

Sensor: NOx Revolver Upstream/Eng Out Harness

C200

Resistor: CAN Termination

Fascia Harness

C337

Valve: DEF Metering

C214

Switch: Reversing Fan

C339

Sensor: Head Unit DEF Control Quality Harness

C215

Controller: Reversing Fan

C340

DEF Control Harness

C216

Fuse: Reversing Fan

Module: After Treatment Fuse and Relay

C341

Sensor: Low Flow Pilot

Element: Pressure DEF Control Line Hose Heater Harness

C217

C342

Sensor: High Flow Pilot

Element: Backflow DEF Control Hose Heater Harness

C218

C-59

9813/3200-03

Revolver Harness

C-59

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines T4f Connector Code

Device

Harness Location

Sheet

Splice Code S012

Splice: Backlighting Fascia

1009 Fascia Harness

S014

Splice: Screenwash Pump

8008 Cab Harness

Function

Main Wire

Harness Location

Sheet

C343

Element: Suction Hose Heater

DEF Control Harness

C344

Module: After Treatment Supply

DEF Control Harness

C345

Valve: Coolant

Revolver Harness

C346

ECU: SCR ECU

DEF Control Harness

S016

Splice: 24V Ign Revolver

1001 Revolver Harness

C347

Resistor: After Traetment CAN Termination

DEF Control Harness

S017

Splice: Dual Controls

8093 Options Harness

S018

Relay: Isolator Power Hold

Revolver Harness

6008 Revolver Harness

C352

Splice: Earth Revolver 1

S019

Fuse: Isolator Power Hold

Revolver Harness

Splice: Earth Revolver 2

6020 Revolver Harness

C353

S020

Splice: Earth Revolver 3

6033 Revolver Harness

C30-X1

Connector: Primary Fuse B+

Revolver Harness

S021

Splice: Earth JCB Engine

6054 Revolver Harness

C42-X1

Alternator: R Terminal

Revolver Harness

S022

Splice: Earth Options Harness

6200 Options Harness

C42-X2

Alternator: L Terminal

Revolver Harness

S023

Splice: 12V B+ Fused

3009 Revolver Harness

S024

Splice: 12V Ign Fused

1008 Fascia Harness

S025

Splice: 24V Ign Engine Stop

1012 Cab Harness

S026

Splice: Earth Fascia

6075 Fascia Harness

S027

Splice: Camera Power +

1023 Camera Harness

S028

Splice: Camera Power -

6110 Camera Harness

S029

Splice: Earth Heater Only

6092 Heater Harness

S030

Splice: 24V Ign Fascia

1006 Fascia Harness

S031

Splice: 12V Heater Only

1008 Heater Harness

S032

Splice: 24V Ign Cab

1010 Cab Harness

S033

Splice: 24V Ign ECU Wake Up

1006 Cab Harness

Splice Code S001 S003 S004 S006 S008 S009 S010 S011

C-60

Function

Main Wire

Harness Location

Sheet

Splice: Earth Roof

6093 Roof Harness 9

Splice: 0v MECU - Revolver

4000 Revolver G Harness

Splice: Forward Worklights

8002 Revolver Harness

Splice: 24V B+ MECU

3002 Cab Harness

Splice: 24V Ign Wash/Wipe

8100 Cab Harness

Splice: 0V MECU 4000 Cab Harness - Cab

Splice: 5V MECU 4005 Cab Harness - Cab

Splice: 24V Ign Wash/Wipe

8100 Cab Harness

9813/3200-03

C-60

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines T4f Splice Code

Function

Main Wire

Harness Location

S034

Splice: Cab Worklights

S035

Splice: Earth - Hi- 6091 Cab Harness Current

S036

Splice: Fused B+ Revolver

S039 S041

Sheet

Function

Main Wire

Harness Location

Sheet

S067

Splice: 5V HECU Cab

4105 Cab Harness

S070

Splice: 0V HECU Revolver

4110 Aux Hydraulic 16 Harness

3007 Revolver Harness

S109

Splice: 12v Ign Fused

1012 Revolver Harness

Splice: Backlighting Cab

1009 Cab Harness

S141

8223 Revolver Harness

Splice: 24V B+ Re-Fuelling/Ign Switch

3007 Cab Harness

Splice: NOx Sensor +ve Supply

S142

Splice: NOx Sensor Ground

6302 Revolver Harness

S042

Splice: Crank

4023 Cab Harness

S148

Splice: 12V Ign Fused

1008 Cab Harness

8032 Revolver Harness

S044

Splice: Engine Shutdown

S152

Splice: 24V Ign Fused Seat

1018 Cab Harness

6303 Revolver Harness

S045

Splice: Permanent Negative

S046

Splice: Earth Cab

6115 Cab Harness

S047

Splice: Earth Livelink

6048 Cab Harness

S053

Splice: Worklights 8002 Fascia Standard Harness

S055

Splice: Beacon Rear

S056

Splice: Worklights 8002 Cab Harness Standard

S057

Splice: Lightning - 8005 Cab Harness Interior

S058

Splice: Earth 24v/12v Converter

6066 Revolver Harness

S060

Splice: 24V B+ HECU

3012 Cab Harness

S062

Splice: Worklights 8002 Boom - Boom B Harness

S063

Splice: Earth MECU

6153 Cab Harness

S065

Splice: 24V Ign Auxiliary Power Sockets

1028 Cab Harness

S066

Splice: 0V HECU Cab

4110 Cab Harness

C-61

8004 Roof Harness 9

Splice Code

8054 Revolver Harness

9813/3200-03

C-61

C-62 Table 3. Sheets

9813/3200-03

K Component Keys ( T C-81)

K Sheet 19 of 19 - JCB Dieselmax - Engine Side ( T C-80)

K Sheet 18 of 19 - HVAC System - ATC Option ( T C-79)

K Sheet 17 of 19 Heater Only Builds, Reversing Fan ( T C-78)

K Sheet 16 of 19 - Options - Arm Limiter, Dual ISO/SAE Controls, Auxiliary Hydraulics, Hyd Raise Cab ( T C-77)

K Sheet 15 of 19 - Hydraulic ECU (HECU) Connector J2 ( T C-76)

K Sheet 14 of 19 - Hydraulic ECU (HECU) Connector J1 ( T C-75)

K Sheet 13 of 19 - CANbus Network ( T C-74)

K Sheet 12 of 19 - Cab Earthing ( T C-73)

K Sheet 11 of 19 - Revolver Earthing ( T C-72)

K Sheet 10 of 19 - Display, Livelink, Camera System ( T C-71)

K Sheet 9 of 19 - Cab Roof - Worklights/Wiper/Radio ( T C-70)

K Sheet 8 of 19 - Worklights/Beacon, Seats ( T C-69)

K Sheet 7 of 19 - Screen Wash/Wipers ( T C-68)

K Sheet 6 of 19 - Machine ECU (MECU) Connection J2 ( T C-67)

K Sheet 5 of 19 - Machine ECU (MECU) Connection J1 ( T C-66)

K Sheet 4 of 19 - Secondary Fusing/Power Distribution ( T C-65)

K Sheet 3 of 19 - Key Switch/Ignition Relay,12V, Backlighting ( T C-64)

K Sheet 2 of 19 - Hi-Current and Power Distribution ( T C-63)

Schematic Diagrams - Machines with Dieselmax Engines

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-62

C-63

9813/3200-03

K Component Keys ( T C-81)

K Sheets ( T C-62)

Fig 51. Sheet 2 of 19 - Hi-Current and Power Distribution

333-K8485-4_Sheet2.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-63

C-64

9813/3200-03

K Component Keys ( T C-81)

K Sheets ( T C-62)

Fig 52. Sheet 3 of 19 - Key Switch/Ignition Relay,12V, Backlighting

333-K8485-4_Sheet3.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-64

C-65

9813/3200-03

K Component Keys ( T C-81)

K Sheets ( T C-62)

Fig 53. Sheet 4 of 19 - Secondary Fusing/Power Distribution

333-K8485-4_Sheet4.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-65

C-66

9813/3200-03

K Component Keys ( T C-81)

K Sheets ( T C-62)

Fig 54. Sheet 5 of 19 - Machine ECU (MECU) Connection J1

333-K8485-4_Sheet5.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-66

C-67

9813/3200-03

K Component Keys ( T C-81)

K Sheets ( T C-62)

Fig 55. Sheet 6 of 19 - Machine ECU (MECU) Connection J2

333-K8485-4_Sheet6.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-67

Section C - Electrics Overview and Schematics

C-68

9813/3200-03

K Sheets ( T C-62) K Component Keys ( T C-81)

Fig 56. Sheet 7 of 19 - Screen Wash/Wipers

333-K8485-4_Sheet7.eps

Schematic Diagrams - Machines with Dieselmax Engines

C-68

Section C - Electrics Overview and Schematics

C-69

9813/3200-03

K Sheets ( T C-62) K Component Keys ( T C-81)

Fig 57. Sheet 8 of 19 - Worklights/Beacon, Seats

333-K8485-4_Sheet8.eps

Schematic Diagrams - Machines with Dieselmax Engines

C-69

C-70

9813/3200-03

K Component Keys ( T C-81)

K Sheets ( T C-62)

Fig 58. Sheet 9 of 19 - Cab Roof - Worklights/Wiper/Radio

333-K8485-4_Sheet9.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-70

C-71

9813/3200-03

K Component Keys ( T C-81)

K Sheets ( T C-62)

Fig 59. Sheet 10 of 19 - Display, Livelink, Camera System

333-K8485-4_Sheet10.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-71

Section C - Electrics Overview and Schematics

C-72

9813/3200-03

K Sheets ( T C-62) K Component Keys ( T C-81)

Fig 60. Sheet 11 of 19 - Revolver Earthing

333-K8485-4_Sheet11.eps

Schematic Diagrams - Machines with Dieselmax Engines

C-72

Section C - Electrics Overview and Schematics

C-73

9813/3200-03

K Sheets ( T C-62) K Component Keys ( T C-81)

Fig 61. Sheet 12 of 19 - Cab Earthing

333-K8485-4_Sheet12.eps

Schematic Diagrams - Machines with Dieselmax Engines

C-73

Section C - Electrics Overview and Schematics

C-74

9813/3200-03

K Sheets ( T C-62) K Component Keys ( T C-81)

Fig 62. Sheet 13 of 19 - CANbus Network

333-K8485-4_Sheet13.eps

Schematic Diagrams - Machines with Dieselmax Engines

C-74

C-75

9813/3200-03

K Component Keys ( T C-81)

K Sheets ( T C-62)

Fig 63. Sheet 14 of 19 - Hydraulic ECU (HECU) Connector J1

333-K8485-4_Sheet14.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-75

C-76

9813/3200-03

K Component Keys ( T C-81)

K Sheets ( T C-62)

Fig 64. Sheet 15 of 19 - Hydraulic ECU (HECU) Connector J2

333-K8485-4_Sheet15.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-76

C-77

9813/3200-03

K Component Keys ( T C-81)

K Sheets ( T C-62)

Fig 65. Sheet 16 of 19 - Options - Arm Limiter, Dual ISO/SAE Controls, Auxiliary Hydraulics, Hyd Raise Cab

333-K8485-4_Sheet16.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-77

C-78

9813/3200-03

K Component Keys ( T C-81)

K Sheets ( T C-62)

Fig 66. Sheet 17 of 19 Heater Only Builds, Reversing Fan

333-K8485-4_Sheet17.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-78

Section C - Electrics Overview and Schematics

C-79

9813/3200-03

K Sheets ( T C-62) K Component Keys ( T C-81)

Fig 67. Sheet 18 of 19 - HVAC System - ATC Option

333-K8485-4_Sheet18.eps

Schematic Diagrams - Machines with Dieselmax Engines

C-79

C-80

9813/3200-03

K Component Keys ( T C-81)

K Sheets ( T C-62)

Fig 68. Sheet 19 of 19 - JCB Dieselmax - Engine Side

333-K8485-4_Sheet19.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-80

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Dieselmax Engines

Component Keys Connector Code

Device

Connector Code Harness Location

Device

Harness Location

Sheet

C026

Motor: Revolver Screenwash Pump Harness

C001

ECU: JCB Engine

Revolver Harness

C027

Sensor: Air Filter Restriction

Revolver Harness

C002

Resistor: CAN Termination

Revolver Harness

C028

Sensor: Coolant Level

Revolver Harness

C003

Module: JCB Engine Fuse & Relay

Revolver Harness

C030

Fusebox: Primary

Revolver Harness

C033

Relay: Ignition

Converter: Voltage Revolver 24/12V Harness

Revolver Harness

C004

C036

Pump: Fuel Lift

Revolver Harness

Sensor: Pressure - Revolver Upper Pilot Harness

C006

C037

Sensor: Water In Fuel

Revolver Harness

Sensor: Pressure Travel Pilot

Revolver Harness

C007

C038

Sensor: Engine Oil Revolver Level Harness

Solenoid: Cooling Fan Control

Revolver Harness

C008

C039

Solenoid: Engine Starter Motor

Revolver Harness

Sensor: Pressure - Revolver AC Harness

C009

C040

Motor: Starter+

Revolver Harness

Solenoid: AC Compressor Clutch

Revolver Harness

C010 C012

Switch: Battery Isolator

Revolver Harness

C041

Alarm Travel

Revolver Harness

C015

ECU: Machine Control (J1)

Cab Harness

C042

Alternator: 24V 55A

Revolver Harness

C016

ECU: Machine Control (J2)

Cab Harness

C045

Solenoid: Pump Control

Revolver Harness

C018

Light: Working Revolver RH

Revolver Harness

C046

Sensor: Hydraulic Oil Temperature

Revolver Harness

C019

Pump: Re-fuelling

Revolver Harness

C047

Solenoid: Max Flow

Revolver Harness

C020

Switch: ReFuelling Pump

Revolver Harness

C048

Solenoid: Travel Speed

Revolver Harness

C021

Sensor: Fuel Level Revolver Harness

C049

Solenoid: Swing Lock

Revolver Harness

C022

Alarm Horn

Revolver Harness

C050

Solenoid: Swing Isolate

Revolver Harness

C023

Sensor: Boom Overload

Revolver Harness

C051

Solenoid: Controls Revolver Enable Harness

C024

Diode: Alternator Suppression

Revolver Harness

C052

Solenoid: MRV Boost

Revolver Harness

C025

Socket: Beacon Main

Revolver Harness

C053

Solenoid: Swing Brake

Revolver Harness

C-81

9813/3200-03

C-81

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Dieselmax Engines Connector Code

Device

Harness Location

Sheet

Connector Code

Device

Harness Location

Sheet

C054

Solenoid: Cushion Revolver Harness

C077

LED: Heater Panel Heater Illumination Harness

C055

Light: Working Cab RH

Roof Harness

C078

Sensor: Hammer Pilot pressure

Cab Harness

C056

Light: Working Cab LH

Roof Harness

C079

Sensor: Boom Up

Cab Harness

C080

C057

Connector: Radio Power

Roof Harness

Sensor: Pressure - Cab Harness Swing Pilot

C081

Motor: Wiper Upper

Roof Harness

Relay: Ignition (24V Input)

Revolver Harness

C058

C082

Light: Interior Illumination

Roof Harness

Module: Heater Unit

Cab Harness

C059

C085

Joystick: LH Handle

Cab Harness

Light: Quickhitch Boom Status

Boom Harness 15

C060

C086

Switch: Lever Lock Cab Harness 1

Switch: Seat Ventilation

Cab Harness

C063

C090

C064

Converter: Voltage Revolver 24/12V Harness

Sensor: Pressure Pilot Hydraulics

C091

Connector: Vehicle Cab Harness Diagnostic

Solenoid: Boom Priority

Revolver Harness

C065

C092

Connector: Camera Power

Element: Heated Seat

Cab Harness

C066

C093

Converter: Voltage Cab Harness 24/12V

Motor: Seat Ventilation

Cab Harness

C067

C094

Camera: Counterweight

Camera Harness

Potentiometer: Cab Harness Throttle Set/Adjust

C068

C095

Camera: Offside

Camera Harness

Joystick: RH Handle

Cab Harness

C069

C097

Sensor: Temperature Ambient Â°C

Boom Harness 6

Switch: Ignition Keyswitch

Cab Harness

C070

C100

Fuse & Relay Module - Cab

Cab Harness

C071

Connector: HVAC CAN

Cab Harness

C107

Switch: Heated Seat

Cab Harness

C072

Connector: Heater Cab Harness / Air Conditioning

C109

ECU: Display (J1)

Fascia Harness

C073

Socket: Auxiliary IGN 24V (1)

C110

ECU: Display (J2)

Fascia Harness

C074

Switch: Fan Speed Heater Harness

C111

Switch: Radio Mute

Cab Harness

C075

Switch: ReCirculation

Heater Harness

C113

Switch: Worklights Fascia Std Harness

C076

Potentiometer: Temperature

Heater Harness

C-82

Cab Harness

9813/3200-03

8 19

C-82

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Dieselmax Engines Connector Code

Device

Harness Location

Sheet

Connector Code

Device

Harness Location

Sheet

C114

Switch: Worklights Fascia Cab Harness

C142

Switch: Wiper Interlock

Roof Harness

C115

Switch: Beacon

Fascia Harness

C143

Connector: Radio Speakers

Roof Harness

C116

Switch: Main Wipers

Fascia Harness

C145

Revolver Harness

C117

Switch: Screenwash

Fascia Harness

Connector: Primary Fuse Supply

C147

Fascia Harness

Switch: Lower Wiper

Light: Console Illumination

C148

Roof Harness

Switch: Engine Stop

Fascia Harness

Sensor: Door Open

C149

Fascia Harness

Revolver Harness

Switch: Swing Lock

Sensor: TMAP Sensor

C150

Cab Harness

Switch: Quickhitch Fascia Harness

Motor: Seat Suspension

C151

Fascia Harness

Switch: Controls Enable

Socket: Auxiliary 12V (1)

C152

Cab Harness

Switch: Module Auto Idle/H+/ Speed

Cab Harness

Socket: Auxiliary IGN 24V (2)

C153

ECU: Hydraulic Control ECU (J1)

Cab Harness

C124

Light: Worklight Boom LH

Boom Harness 8

C154

ECU: Hydraulic Control ECU (J2)

Cab Harness

C125

Light: Worklight Counterweight

Revolver Harness

C155

Solenoid: Quickhitch

Revolver Harness

C126

Motor: Wiper Lower

Cab Harness

C156

Sensor: Pressure - Revolver Quickhitch Harness

C127

Diode: Wake-up - Cab Harness Refuel/Door Open

C157

Sensor: Alignment Boom Harness 15 - Boom

C128

Switch: Cushion

Fascia Harness

C158

Sensor: Alignment Boom Harness 15 - Arm

C129

ECU: Livelink Telematics

Fascia Harness

C159

Solenoid: Arm Limiter

Options Harness

C130

Connector: USB

Fascia Harness

C160

Solenoid: Low Flow ‘A’

Revolver Harness

C138

Connector: LH Rear Beacon

Revolver Harness

C161

Solenoid: Low Flow ‘B’

Revolver Harness

C139

Connector: RH Rear Beacon

Revolver Harness

C162

Light: Worklight Boom RH

Boom Harness 8

C140

Speaker: RH

Roof Harness

C163

Cab Harness

C141

Speaker: LH

Roof Harness

Socket: Auxiliary 12V (2)

C118 C119 C120 C121 C122 C123

C-83

9813/3200-03

C-83

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Dieselmax Engines Connector Code

Device

Harness Location

Sheet

Connector Code C225

Switch:Lever Lock 2

C226

Switch: HRC - Cab Raise (cab)

C231

Diode: HRC - Low Flow Priority

C240

Solenoid: HRC low flow priority

C243

Solenoid: HRC Cab Raise

C244

Solenoid: HRC Cab Lower

C245

Sensor: Cab lowered and docked

C246

Switch: HRC - Cab Raise (revolving chassis)

C318

Relay: LiveLink

C30-X1

Connector: Primary Fuse B+

Revolver Harness

C42-X1

Alternator: R Terminal

Revolver Harness

C42-X2

Alternator: L Terminal

Revolver Harness

Splice Code

Function

C164

Solenoid: Proportional High Flow ‘A’

Cab Harness

C165

Solenoid: Proportional High Flow ‘B’

Cab Harness

C166

Potentiometer: Aux Hyds (High Flow)

Cab Harness

C167

Solenoid: Auxiliary/Hammer Changeover

Revolver Harness

C169

Sensor: Seat Belt / Cab Harness Occupancy

C171

Sensor: Pressure Lo Flow Aux

Revolver Harness

C172

Sensor: Pressure Hi Flow Aux

Revolver Harness

C173

Solenoid: Merge Flow ‘A’

Cab Harness

C174

Solenoid: Merge Flow ‘B’

Cab Harness

C175

Solenoid: Low Cab Harness Flow Variable ARV

C176

Solenoid: Hi Flow Variable ARV

Cab Harness

C178

Solenoid: Dual Controls (A)

Options Harness

C179

Solenoid: Dual Controls (B)

Options Harness

C194

Sensor: Arm Limit Proximity

Arm Harness

C195

Antenna: FM Radio

Roof Harness

C200

Resistor: CAN Termination

Fascia Harness

C216

Fuse: Reversing Fan

C214

Switch: Reversing Fan

C215

Controller: Reversing Fan

C-84

Device

Harness Location

Main Wire

Harness Location

Sheet

S001

Splice: Earth Roof

6093 Roof Harness 9

S004

Splice: Forward Worklights

8002 Revolver Harness

S006

Splice: 24V B+ MECU

3002 Cab Harness

S008

Splice: 24V Ign Wash/Wipe

8100 Cab Harness

S009

Splice: 0V MECU 4000 Cab Harness - Cab

S010

Splice: 5V MECU 4005 Cab Harness - Cab

S011

Splice: 24V Ign Wash/Wipe

9813/3200-03

8100 Cab Harness

C-84

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Dieselmax Engines Splice Code

Function

Main Wire

Harness Location

Sheet

Splice Code S035

Splice: Earth - Hi- 6091 Cab Harness Current

S039

Splice: Backlighting Cab

1009 Cab Harness

S041

Splice: 24V B+ Re-Fuelling/Ign Switch

3007 Cab Harness

4023 Cab Harness

Function

Main Wire

Harness Location

Sheet

S012

Splice: Backlighting Fascia

1009 Fascia Harness

S014

Splice: Screenwash Pump

8008 Cab Harness

S016

Splice: 24V Ign Revolver

1001 Revolver Harness

3 S042

Splice: Crank

S017

Splice: Dual Controls

8093 Options Harness

S053

Splice: Worklights 8002 Fascia Standard Harness

S019

Splice: Earth Revolver 2

6020 Revolver Harness

S056

Splice: Worklights 8002 Cab Harness Standard

S020

Splice: Earth Revolver 3

6033 Revolver Harness

S057

Splice: Lightning - 8005 Cab Harness Interior

S021

Splice: Earth JCB Engine

6054 Revolver Harness

S060

Splice: 24V B+ HECU

S022

Splice: Earth Options Harness

6200 Options Harness

S062

Splice: Worklights 8002 Boom - Boom B Harness

S023

Splice: 12V B+ Fused

3009 Revolver Harness

S063

Splice: Earth MECU

6153 Cab Harness

S024

Splice: 12V Ign Fused

1008 Fascia Harness

S070

Splice: 0V HECU Revolver

4110 Aux Hydraulic 16 Harness

S025

Splice: 24V Ign Engine Stop

1012 Cab Harness

S026

Splice: Earth Fascia

6075 Fascia Harness

S027

Splice: Camera Power +

1023 Camera Harness

S028

Splice: Camera Power -

6110 Camera Harness

S029

Splice: Earth Heater Only

6092 Heater Harness

S030

Splice: 24V Ign Fascia

1006 Fascia Harness

S031

Splice: 12V Heater Only

1008 Heater Harness

S032

Splice: 24V Ign Cab

1010 Cab Harness

S033

Splice: 24V Ign ECU Wake Up

1006 Cab Harness

S034

Splice: Cab Worklights

8004 Roof Harness 9

C-85

9813/3200-03

3012 Cab Harness

C-85

Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Dieselmax Engines

Page left intentionally blank

C-86

9813/3200-03

C-86

Section C - Electrics

Battery 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.

â&#x20AC;&#x201C; Never boost-charge a maintenance free battery. â&#x20AC;&#x201C; Never charge a maintenance free battery at a voltage in excess of 15.8 Volts. â&#x20AC;&#x201C; Never continue to charge a maintenance free battery after it begins to gas.

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:

!MWARNING Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear personal protective equipment (PPE). Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first. Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up. When reconnecting, fit the positive (+) lead first. 5-3-4-12_2

C-87

9813/3200-03

C-87

Section C - Electrics Battery Test Procedures

Test Procedures High Rate Discharge Test

Note: Do not hold the switch in the LOAD position for more than 10 seconds.

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).

Check the results against the table: Table 1. Tester Readings and Remedies Battery Tester Readings Remedy CHECK: 0 - 12.6 volts

Ensure that the battery is completely disconnected from the machine.

Renew battery

LOAD: Less than 6 volts CHECK: 6 - 12.4 volts

Recharge and re-test. If LOAD: less than 9 Volts and tests still unsatisfactory falls steadily but remains in renew battery. yellow zone. CHECK: less than 10 volts LOAD: Less than 3 volts

Indicates battery has been over-discharged and unlikely to recover. Renew battery.

CHECK: more than 11 volts Charge battery which will probably recover. LOAD: 6 - 10 volts

C096270

Fig 1. Battery Tester Check: 1

Connect the battery tester to the battery. Ensure that the positive terminal is connected first.

Use rocker switch A to select the correct battery voltage.

Hold switch B to the ‘Check’ position. The battery noload voltage should be at least 12.4 volts.

Test: 1

Hold down switch B to the ‘Load’ position for 5-10 seconds until the meter reading stabilises. The reading should be at least 9 volts.

C-88

9813/3200-03

C-88

Section C - Electrics Battery Test Procedures

Specific Gravity Testing The specific gravity of the electrolyte gives an idea of the state of charge of the battery. Readings should be taken using a hydrometer, when the electrolyte temperature is 15°C (60°F). If the battery has recently been on charge, wait approximately one hour (or slightly discharge the battery) to dissipate the surface charge before testing.

Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell. If the electrolyte temperature is other than 15°C (60°F) a 'correction factor' must be applied to the reading obtained. Add 0.07 per 10°C (18°F) if the temperature is higher than 15°C (60°F) and subtract the same if the temperature is lower.

Table 2. Specific Gravity at 15°C (60°F) Fully Charged Half Discharged

Fully Discharged

Ambient temperature up to 27°C (80°F)

1.270 - 1.290

1.190 - 1.210

1.110 - 1.130

Ambient temperature above 27°C (80°F)

1.240 - 1.260

1.170 - 1.190

1.090 - 1.110

C-89

9813/3200-03

C-89

Section C - Electrics Battery Disconnection and Connection

Disconnection and Connection

Battery Disconnection/Connection

!MWARNING

T3-019_2

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. 5-2-2-4

Disconnection 1

Open the battery compartment. See Battery Cover.

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

Connection 1

Check the battery. a

If the terminal is dirty, clean the post.

Fig 2. b If the terminal post is corroded and generates white powder wash the terminal with hot water. If considerable corrosion is detected, clean with a wire brush or abrasive paper. c

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

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

Close and lock the battery compartment.

C-90

9813/3200-03

C-90

Section C - Electrics

Fuses and Relays Introduction

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

For details of the machine fuses and relays refer to Section 2, Technical Data.

C-91

9813/3200-03

C-91

Section C - Electrics Fuses and Relays Cab Fuse and Relay Box - Connector Identification

Cab Fuse and Relay Box - Connector Identification ST2 ST3

C100 - X1

C100 - X3 10 7 4 1 11 8 5 2 12 9 6 3

1 3 5 7 2 4 6 8

C100 - X4

C100 - X2

16 13 10 7 4 1 17 14 11 8 5 2 18 15 12 9 6 3

7 4 1 8 5 2 9 6 3

C129520.eps

Fig 1.

C-92

9813/3200-03

C-92

C-93

9813/3200-03

Machine ECU (MECU) (cab)

Printed Circuit Board (PCB) mounted fuses and relays (cab)

Voltage converter (cab)

Engine ECU connector

Engine fuse and relay box (engine compartment)

Voltage converter (engine compartment)

Multi function display connector (cab)

Throttle controller (cab)

Batteries

NOx exhaust gas sensors - CANbus interfaces(1)

(1) T4f engines

Hydraulic ECU (HECU) (cab)

Revolving chassis harness

Facia harness

Boom harness

Cab harness

Description

Item

The illustration shows a representation of the basic routing of the main machine harnesses. Some of the main electrical components are also shown to give an indication of harness positioning within the machine structure.

K Harness and Interconnector Locations Machines with T2 and T4i engines ( T C-94) K Harness and Interconnector Locations Machines with T4f engines ( T C-95)

Installation and Interconnections

Harness Systems

Section C - Electrics Harness Systems

Installation and Interconnections

C-93

C-94

IC08

IC03

IC01

IC10

IC07

9813/3200-03

3 2

IC04

Fig 2. Harness and Interconnector Locations - Machines with T2 and T4i engines

IC22

IC23

C132350

Section C - Electrics Harness Systems

Installation and Interconnections

C-94

C-95

IC08

IC03

IC01

IC10

IC07

IC22

9813/3200-03

IC38

IC04

Fig 3. Harness and Interconnector Locations - Machines with T4f engines

IC23

C146400

Section C - Electrics Harness Systems

Installation and Interconnections

C-95

C-96

1 - Cab

Harness

IC08

IC03

IC22

IC10

IC01

IC07

IC15

Auxiliary Hydraulics Harness

IC07

Cab Roof IC12

IC38(1)

3 - Revoling Chassis

Option Harness

IC03

IC01

3 - Revolving Chassis 3 - Revolving Chassis

IC08

IC10

2 - Facia

IC22

2 - Facia 2 - Facia

RH rear corner of cab structure above HVAC unit

Side of SCR exhaust aftertreatment control compartment

RH rear corner of cab structure above HVAC unit

Inside cab to rear of RH facia

Table 1. Harness Interconnections Connecting Interconnect Location Harness

K Table 5. ( T C-98)

K Table 9. ( T C-99)

K Table 8. ( T C-98)

K Table 3. ( T C-98)

K Table 6. ( T C-98)

K Table 4. ( T C-98)

K Table 8. ( T C-98)

Connector Pins

Section C - Electrics Harness Systems

Installation and Interconnections

9813/3200-03

C-96

C-97

(1) If fitted

IC23

Engine

IC23

IC04

4 - Boom

3 - Revolving Chassis Above engine rocker cover

Interconnect Location

Connecting Harness

Harness

K Table 2. ( T C-98)

K Table 7. ( T C-98)

Connector Pins

Section C - Electrics Harness Systems

Installation and Interconnections

9813/3200-03

C-97

C-98

9813/3200-03

Bulkhead connectors.

Details

Table 3. Harness interconnectors IC01 Connector Pins

Bulkhead connectors with threaded coupling ring.

Table 2. Harness interconnectors IC23 Connector Pins Details

6 7 8 9 10

5 4 3 2 1

20 19 18 17 16 15 14 13 12 11

10 9 8 7

In - line connectors.

Details

11 12 13 14 15 16 17 18 19 20

1 2 3 4

Table 5. Harness interconnectors IC07 Connector Pins

In - line connectors.

Details

Table 4. Harness interconnectors IC10 Connector Pins

In - line connectors.

Table 8. Harness interconnectors IC22, IC03 Connector Pins Details

4 1

In - line connectors.

Table 7. Harness interconnectors IC04 Connector Pins Details

In - line connectors.

Table 6. Harness interconnectors IC08 Connector Pins Details

Section C - Electrics Harness Systems

Installation and Interconnections

C-98

C-99

Bulkhead connectors with threaded coupling ring.

Table 9. Harness interconnectors IC38 Connector Pins Details

Section C - Electrics Harness Systems

Installation and Interconnections

9813/3200-03

C-99

C-100

9813/3200-03

Earths, SCR harness

Earth cable, battery

EP15

EC01

Earth strap, cab

ES01

Earth strap, DEF control compartment to revolving chassis

Earths, cab harness

EP07 EP08

ES03 EP15 EP16

Earths, engine

EP04

Earth strap cab to revolving chassis

Earths, revolving chassis harness

EP03

ES02

Description

Item

Inside battery compartment on the revolving chassis to the rear of the washer fluid bottle

Bottom RH front corner of DEF control compartment

Under the cab below ES01

Inside cab on the floor to the rear of the LH facia and adjacent to the HVAC unit

Inside engine compartment below engine ECU

K Fig 4. ( T C-101)

K Fig 5. ( T C-102)

K Fig 4. ( T C-101)

The illustration shows the machine electrical earth point locations. This can be useful when tracing electrical faults, typically when several electrical devices are malfunctioning.

Inside battery compartment adjacent to the washer fluid bottle

Access

K Fig 5. Earth Points - SCR harness and DEF control compartment ( T C-102)

K Fig 4. Earth Points ( T C-101)

Earth Points

EP07 EP08

ES01

Section C - Electrics Harness Systems Earth Points

C-100

Section C - Electrics Harness Systems

EP04

EP07

ES01

Fig 4. Earth Points

EC01

EP03

ES02

C146490

Earth Points

C-101

9813/3200-03

C-101

EP14 EP15

C-102

9813/3200-03

Fig 5. Earth Points - SCR harness and DEF control compartment

EP16

ES03

C146480

Section C - Electrics Harness Systems Earth Points

C-102

Section C - Electrics Harness Systems Harness Drawing List, JS200 - JS235

Harness Drawing List, JS200 - JS235 Drawings are reproduced from production electrical harness drawings. Each harness drawing includes tables showing wire connections and destinations for all the connectors on the harness.

Harness No. 1

The harness number refers to and corresponds with the annotations in the drawing. K Fig 2. ( T C-94) Refer to the table for the connector code key. K Connector Codes ( T C-176)

Issue Remarks

Drawing

Cab 333/K8486

To April 2014

K Fig 6. ( T C-107)

334/J4255

May 2014 On

K Fig 12. ( T C-113)

334/J9431

Jan 2015 On (T4f)

K Fig 18. ( T C-119)

333/K5337

High Rise Cab (HRC) variant To april 2014

K Fig 24. ( T C-125)

Main components connected to this harness:

Printed Circuit Board (PCB) mounted fuses and relays LH joystick RH joystick Heating Ventilation and Air Conditioning (HVAC) unit Machine ECU (MECU) Hydraulic ECU (HECU) Hydraulic control valve solenoids Throttle control unit Ignition switch

Facia 333/K8487

To April 2014

K Fig 30. ( T C-131)

333/K9798

May 2014 On

K Fig 32. ( T C-133)

Main components connected to this harness:

Facia switches Multi function display CANbus termination resistor Livelink ECU (if fitted)

Revolving Chassis 333/K8491

Machines with Dieselmax Engines, to Dec 2013 K Fig 34. ( T C-135)

333/K8818

Machines with Dieselmax Engines, Jan 2014 on K Fig 40. ( T C-141)

333/K8490

Machines with Ecomax Engines, to Dec 2013

K Fig 46. ( T C-147)

333/K8813

Machines with Ecomax Engines, Jan 2014 on

K Fig 52. ( T C-153)

334/J8659

Machines with Ecomax Engines (T4f)

K Fig 58. ( T C-159)

Main components connected to this harness:

Gearbox control solenoids Hydraulic control valve solenoids Alternator TMAF sensor Engine cooling fan Starter motor Engine oil level switch

C-103

9813/3200-03

C-103

Section C - Electrics Harness Systems Harness Drawing List, JS200 - JS235 AC compressor clutch Engine fuses and relays module Voltage converter Primary fuses Engine ECU CANbus termination resistor Fuel lift pump Water In Fuel (WIF) sensor SCR Harness

Machines with Ecomax Engines (T4f)

334/J8789

K Fig 64. ( T C-165)

Main components connected to this harness:

DEF supply module DEF dosing module DEF sender/sensor unit DEF coolant solenoid NOx and exhaust temperature sensors SCR ECU

Auxiliary Hydraulics 333/K6657 4

Low flow / Super High Flow (SHF)

Boom 333/K0181

Main components connected to this harness:

Boom work lights Ambient temperature sensor

Cab Roof 333/K0017

K Fig 66. ( T C-167)

Main components connected to this harness:

Radio speakers Interior lights Door and window switches Cab work lights

Heater Harness 333/K3883

Heater unit (machines without air conditioning) K Fig 68. ( T C-169) Heater controls

Heating, Ventilation and Air Conditioning (HVAC)

Refer to Section B

Camera Harness 333/K4284

Dual camera system

K Fig 69. ( T C-170)

333/K4283

Single camera system

K Fig 70. ( T C-171)

Auxiliary Hi/Lo Flow Hydraulics 333/K4639

K Fig 71. ( T C-172)

HRC Harness

C-104

9813/3200-03

C-104

Section C - Electrics Harness Systems Harness Drawing List, JS200 - JS235 334/J2060

Main components connected to this harness:

May 2014 On Switch: Cab raise - Chassis Solenoid: HRC lower Solenoid: HRC raise Diode: HRC low flow priority Solenoid: HRC low flow priority

C-105

9813/3200-03

C-105

Section C - Electrics Harness Systems Drawings

Drawings Drawings are reproduced from production electrical harness drawings. Each harness drawing includes tables showing wire connections and destinations for all the connectors on the harness. To identify the correct harness drawing for a particular machine refer to the relevant Harness Drawings table.

C-106

9813/3200-03

C-106

Section C - Electrics Harness Systems

333/K8486 Issue 3

Fig 6. 333-K8486-3 Sheet 1

333-K8486-2_Sheet1.eps

Drawings

C-107

9813/3200-03

C-107

Section C - Electrics Harness Systems

Fig 7. 333-K8486-3 Sheet 2

333-K8486-3_Sheet2.eps

Drawings

C-108

9813/3200-03

C-108

Section C - Electrics Harness Systems

Fig 8. 333-K8486-3 Sheet 3

333-K8486-3_Sheet3.eps

Drawings

C-109

9813/3200-03

C-109

Section C - Electrics Harness Systems

Fig 9. 333-K8486-3 Sheet 4

333-K8486-3_Sheet4.eps

Drawings

C-110

9813/3200-03

C-110

Section C - Electrics Harness Systems

Fig 10. 333-K8486-3 Sheet 5

333-K8486-3_Sheet5.eps

Drawings

C-111

9813/3200-03

C-111

Section C - Electrics Harness Systems

Fig 11. 333-K8486-3 Sheet 6

333-K8486-3_Sheet6.eps

Drawings

C-112

9813/3200-03

C-112

Section C - Electrics Harness Systems

334/J4255 Issue 1

Fig 12. 334-J4255-1 Sheet 1

334-J4255-1_sheet1

Drawings

C-113

9813/3200-03

C-113

Section C - Electrics Harness Systems

Fig 13. 334-J4255-1 Sheet 2

334-4255-1_Sheet2.eps

Drawings

C-114

9813/3200-03

C-114

Section C - Electrics Harness Systems

Fig 14. 334-J4255-1 Sheet 3

334-J4255-1_Sheet3.eps

Drawings

C-115

9813/3200-03

C-115

Section C - Electrics Harness Systems

Fig 15. 334-J4255-1 Sheet 4

334-J4255-1_Sheet4.eps

Drawings

C-116

9813/3200-03

C-116

Section C - Electrics Harness Systems

Fig 16. 334-J4255 Sheet 5

334-J4255-1_Sheet5.eps

Drawings

C-117

9813/3200-03

C-117

Section C - Electrics Harness Systems

Fig 17. 334-J4255 Sheet 6

334-J4255-1_Sheet6.eps

Drawings

C-118

9813/3200-03

C-118

Section C - Electrics Harness Systems

334/J9431 Issue 1

Fig 18. 334-J9431-1 Sheet 1

334-J9431-1-Sheet1

Drawings

C-119

9813/3200-03

C-119

Section C - Electrics Harness Systems

Fig 19. 334-J9431-1 Sheet 2

334-J9431-1-Sheet2.eps

Drawings

C-120

9813/3200-03

C-120

Section C - Electrics Harness Systems

Fig 20. 334-J9431-1 Sheet 3

334-J9431-1-Sheet3.eps

Drawings

C-121

9813/3200-03

C-121

Section C - Electrics Harness Systems

Fig 21. 334-J9431-1 Sheet 4

334-J9431-1-Sheet4

Drawings

C-122

9813/3200-03

C-122

Section C - Electrics Harness Systems

Fig 22. 334-J9431-1 Sheet 5

334-J9431-1-Sheet5.eps

Drawings

C-123

9813/3200-03

C-123

Section C - Electrics Harness Systems

Fig 23. 334-J9431-1 Sheet 6

334-J9431-1-Sheet6.eps

Drawings

C-124

9813/3200-03

C-124

Section C - Electrics Harness Systems

333/K5337 Issue 1

Fig 24. 333-K5337 SHEET-1

333-K5337-1-SHEET-1.eps

Drawings

C-125

9813/3200-03

C-125

Section C - Electrics Harness Systems

Fig 25. 333-K5337 SHEET-2

333-K5337-1-SHEET-2.eps

Drawings

C-126

9813/3200-03

C-126

Section C - Electrics Harness Systems

Fig 26. 333-K5337 SHEET-3

817/17260

333-K5337-1-SHEET-3.eps

Drawings

C-127

9813/3200-03

C-127

Section C - Electrics Harness Systems

Fig 27. 333-K5337 SHEET-4

333-K5337-1-SHEET-4.eps

Drawings

C-128

9813/3200-03

C-128

Section C - Electrics Harness Systems

Fig 28. 333-K5337 SHEET-5

333-K5337-1-SHEET-5.eps

Drawings

C-129

9813/3200-03

C-129

Section C - Electrics Harness Systems

Fig 29. 333-K5337 SHEET-6

333-K5337-1-SHEET-6.eps

Drawings

C-130

9813/3200-03

C-130

333/K8487 Issue 2

Fig 30. 333-K8487-2 Sheet 1

C-131

9813/3200-03 C

333-K8487-2_Sheet1.eps

Section C - Electrics Harness Systems Drawings

C-131

Section C - Electrics Harness Systems

Fig 31. 333-K8487-2 Sheet 2

333-K8487-2_Sheet2.eps

Drawings

C-132

9813/3200-03

C-132

Section C - Electrics Harness Systems

333K9798 Issue 1

Fig 32. 333-K9798-1 Sheet 1

333-K9798-1_Sheet1.eps

Drawings

C-133

9813/3200-03

C-133

Section C - Electrics Harness Systems

Fig 33. 333-K9798-1 Sheet 2

333-K9798-1_Sheet2.eps

Drawings

C-134

9813/3200-03

C-134

333/K8491 Issue 1

C-135

2 3

5 4

2 3

6 5 4

Fig 34. 333-K8491-1 Sheet 1

333-K8491-1_Sheet1.eps

Section C - Electrics Harness Systems Drawings

9813/3200-03

C-135

A B

BLUE

GREY

A B

Fig 35. 333-K8491-1 Sheet 2

B C

333-K8491-1_Sheet2.eps

Section C - Electrics Harness Systems Drawings

C-136

9813/3200-03

C-136

Section C - Electrics Harness Systems

C-137

9813/3200-03

Fig 36. 333-K8491-1 Sheet 3

333-K8491-1_Sheet3.eps

Drawings

C-137

Section C - Electrics Harness Systems

Fig 37. 333-K8491-1 Sheet 4

333-K8491-1_Sheet4.eps

Drawings

C-138

9813/3200-03

C-138

Section C - Electrics Harness Systems

Fig 38. 333-K8491-1 Sheet 5

333-K8491-1_Sheet5.eps

Drawings

C-139

9813/3200-03

C-139

Section C - Electrics Harness Systems

Fig 39. 333-K8491-1 Sheet 6

333-K8491-1_Sheet6.eps

Drawings

C-140

9813/3200-03

C-140

333/K8818 Issue 1

C-141

817/17268

Fig 40. 333-K8818 SHEET-1

333-K8818-1-SHEET-1.eps

Section C - Electrics Harness Systems Drawings

9813/3200-03

C-141

Section C - Electrics Harness Systems

Fig 41. 333-K8818 SHEET-2

333-K8818-1-SHEET-2.eps

Drawings

C-142

9813/3200-03

C-142

Section C - Electrics Harness Systems

Fig 42. 333-K8818 SHEET-3

333-K8818-1-SHEET-3.eps

Drawings

C-143

9813/3200-03

C-143

Section C - Electrics Harness Systems

Fig 43. 333-K8818 SHEET-4

333-K8818-1-SHEET-4.eps

Drawings

C-144

9813/3200-03

C-144

Section C - Electrics Harness Systems

Fig 44. 333-K8818 SHEET-5

333-K8818-1-SHEET-5.eps

Drawings

C-145

9813/3200-03

C-145

Section C - Electrics Harness Systems

Fig 45. 333-K8818 SHEET-6

333-K8818-1-SHEET-6.eps

Drawings

C-146

9813/3200-03

C-146

333/K8490 Issue 1

C-147

5 4

817/17268

Fig 46. 333-K8490 SHEET-1

333-K8490-2-SHEET-1.eps

Section C - Electrics Harness Systems Drawings

9813/3200-03

C-147

A B

BLUE

GREY

A B

C-148

9813/3200-03

Fig 47. 333-K8490 SHEET-2

333-K8490-2-SHEET-2.eps

Section C - Electrics Harness Systems Drawings

C-148

Section C - Electrics Harness Systems

C-149

9813/3200-03

Fig 48. 333-K8490 SHEET-3

333-K8490-2-SHEET-3.eps

Drawings

C-149

Section C - Electrics Harness Systems

Fig 49. 333-K8490 SHEET-4

333-K8490-2-SHEET-4.eps

Drawings

C-150

9813/3200-03

C-150

Section C - Electrics Harness Systems

Fig 50. 333-K8490 SHEET-5

333-K8490-2-SHEET-5.eps

Drawings

C-151

9813/3200-03

C-151

Section C - Electrics Harness Systems

Fig 51. 333-K8490 SHEET-6

333-K8490-2-SHEET-6.eps

Drawings

C-152

9813/3200-03

C-152

333/K8813 Issue 1

C-153

817/17268

Fig 52. 333-K8813 SHEET-1

333-K8813-1-SHEET-1.eps

Section C - Electrics Harness Systems Drawings

9813/3200-03

C-153

Section C - Electrics Harness Systems

Fig 53. 333-K8813 SHEET-2

333-K8813-1-SHEET-2.eps

Drawings

C-154

9813/3200-03

C-154

Section C - Electrics Harness Systems

Fig 54. 333-K8813 SHEET-3

333-K8818-1-SHEET-3.eps

Drawings

C-155

9813/3200-03

C-155

Section C - Electrics Harness Systems

Fig 55. 333-K8818 SHEET-4

333-K8813-1-SHEET-4.eps

Drawings

C-156

9813/3200-03

C-156

Section C - Electrics Harness Systems

Fig 56. 333-K8813 SHEET-5

333-K8813-1-SHEET-5.eps

Drawings

C-157

9813/3200-03

C-157

Section C - Electrics Harness Systems

Fig 57. 333-K8813 SHEET-6

333-K8813-1-SHEET-6.eps

Drawings

C-158

9813/3200-03

C-158

Section C - Electrics Harness Systems

334/J8659 Issue 1

Fig 58. 334-J8659 SHEET-1

334-J8659-1-Sheet1

Drawings

C-159

9813/3200-03

C-159

Section C - Electrics Harness Systems

Fig 59. 334-J8659 SHEET-2

334-J8659-1-Sheet2.eps

Drawings

C-160

9813/3200-03

C-160

Section C - Electrics Harness Systems

Fig 60. 334-J8659 SHEET-3

334-J8659-1-Sheet3.eps

Drawings

C-161

9813/3200-03

C-161

Section C - Electrics Harness Systems

Fig 61. 334-J8659 SHEET-4

334-J8659-1-Sheet4.eps

Drawings

C-162

9813/3200-03

C-162

Section C - Electrics Harness Systems

Fig 62. 334-J8659 SHEET-5

334-J8659-1-Sheet5.eps

Drawings

C-163

9813/3200-03

C-163

Section C - Electrics Harness Systems

Fig 63. 334-J8659 SHEET-6

334-J8659-1-Sheet6.eps

Drawings

C-164

9813/3200-03

C-164

Section C - Electrics Harness Systems

334/J8789 Issue 1

Fig 64. 334-J8789-1 SHEET-1

334-J8789-1-Sheet1

Drawings

C-165

9813/3200-03

C-165

Section C - Electrics Harness Systems

Fig 65. 334-J8789-1 SHEET-2

334-J8789-1-Sheet2.eps

Drawings

C-166

9813/3200-03

C-166

Section C - Electrics Harness Systems

333/K0017 Issue 1

Fig 66. 333-K0017 SHEET-1

333-K0017-1-SHEET-1

Drawings

C-167

9813/3200-03

C-167

Section C - Electrics Harness Systems

Fig 67. 333-K0017 SHEET-2

333-K0017-1-SHEET-2

Drawings

C-168

9813/3200-03

C-168

Section C - Electrics Harness Systems

333/K3883 Issue 1

Fig 68. 333-K3883 SHEET-1

333-K3883-1-SHEET-1.eps

Drawings

C-169

9813/3200-03

C-169

Section C - Electrics Harness Systems

333/K4284 Issue 1

Fig 69. 333-K4284 SHEET-1

333-K4284-1-SHEET-1.eps

Drawings

C-170

9813/3200-03

C-170

333/K4283 Issue 1

Fig 70. 333-K3883 SHEET-1.eps

333-K3883-1-SHEET-1.eps

Section C - Electrics Harness Systems Drawings

C-171

9813/3200-03

C-171

Section C - Electrics Harness Systems

333/K4639 Issue 1

Fig 71. 333-K4639 SHEET-1

333-K4639-1-SHEET-1.eps

Drawings

C-172

9813/3200-03

C-172

Section C - Electrics Harness Systems

333/K5288 Issue 1

Fig 72. 333-K5288 SHEET-1

333-K5288-1-SHEET-1.eps

Drawings

C-173

9813/3200-03

C-173

334/J2060 Issue 1

Fig 73. 334-J2060-1 SHEET-1

334-J2060-1-SHEET-1.eps

Section C - Electrics Harness Systems Drawings

C-174

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C-174

Section C - Electrics Harness Systems

Fig 74. 334-J2060-1 SHEET-2

334-J2060-1-SHEET-2.eps

Drawings

C-175

9813/3200-03

C-175

Section C - Electrics Harness Systems Connector Codes

Connector Codes Connector Code

Device

Connector Code

Harness Location

Device

Harness Location

C001

ECU: JCB Engine

Revolver Harness

C030

Fusebox: Primary

Revolver Harness

C002

Resistor: CAN Termination

Revolver Harness

C033

Relay: Ignition

Revolver Harness

C036

Module: JCB Engine Fuse & Relay

Revolver Harness

Sensor: Pressure Excavator Pilot

Revolver Harness

C003

C037

Converter: Voltage 24/ Revolver Harness 12V

Sensor: Pressure Travel Pilot

Revolver Harness

C004

C038

Pump: Fuel Lift

Revolver Harness

Solenoid: Cooling Fan Control

Revolver Harness

C006 C007

Sensor: Water In Fuel

Revolver Harness

C039

Sensor: Pressure - AC Revolver Harness

C008

Sensor: Engine Oil Level

Revolver Harness

C040

Solenoid: AC Compressor Clutch

C009

Solenoid: Engine Starter Motor

Revolver Harness

Revolver Harness or Engine Harness(1)

C041

Alarm Travel

Revolver Harness

C010

Motor: Starter+

Revolver Harness

C042

Alternator: 24V 55A

Revolver Harness

C012

Switch: Battery Isolator Revolver Harness

C045

Revolver Harness

C015

ECU: Machine Control Cab Harness (J1)

Solenoid: Pump Control

C046

Revolver Harness

Sensor: Engine Oil Pressure

Sensor: Hydraulic Oil Temperature

C047

Solenoid: Max Flow

Revolver Harness

Solenoid: Travel Speed Revolver Harness

C014

Engine Harness

C016

ECU: Machine Control Cab Harness (J2)

C048 C049

Solenoid: Swing Lock

Revolver Harness

C018

Light: Working Revolver RH

Revolver Harness

C050

Solenoid: Swing Isolate

Revolver Harness

C019

Pump: Re-fuelling

Revolver Harness

C051

Revolver Harness

C020

Switch: Re-Fuelling Pump

Revolver Harness

Solenoid: Controls Enable

C052

Solenoid: MRV Boost

Revolver Harness

C021

Sensor: Fuel Level

Revolver Harness

C053

Solenoid: Swing Brake Revolver Harness

C022

Alarm Horn

Revolver Harness

C054

Solenoid: Cushion

Revolver Harness

C023

Sensor: Boom Overload

Revolver Harness

C055

Light: Working - Cab RH

Roof Harness

C024

Diode: Alternator Suppression

Revolver Harness

C056

Light: Working - Cab LH

Roof Harness

C025

Socket: Beacon - Main Revolver Harness

C057

Motor: Screenwash Pump

Revolver Harness

Connector: Radio Power

Roof Harness

C026

C058

Motor: Wiper -Upper

Roof Harness

C027

Sensor: Air Filter Restriction

Revolver Harness

C059

Light: Interior Illumination

Roof Harness

C028

Sensor: Coolant Level

Revolver Harness

C060

Joystick: LH Handle

Cab Harness

C-176

9813/3200-03

C-176

Section C - Electrics Harness Systems Connector Codes Connector Code

Device

Harness Location

Connector Code

C063

Switch: Lever Lock 1

C064

Converter: Voltage 24/ Revolver Harness 12V

Cab Harness

Device

Harness Location

C094

Potentiometer: Throttle Cab Harness Set/Adjust

C095

Joystick: RH Handle

Cab Harness Cab Harness

C065

Connector: Vehicle Diagnostic

Cab Harness

C097

Switch: Ignition Keyswitch

C066

Connector: Camera Power

Cab Harness

C100

Fuse & Relay Module - Cab Harness Cab

C067

Converter: Voltage 24/ Cab Harness 12V

C107

Switch: Heated Seat

C109

ECU: Display (J1)

Fascia Harness

C068

Camera: Counterweight

Camera Harness

C110

ECU: Display (J2)

Fascia Harness

C069

Camera: Offside

Camera Harness

C111

Switch: Radio Mute

Fascia Harness

C070

Sensor: Temperature - Boom Harness Ambient Â°C

C113

Switch: Worklights Std

Fascia Harness

C114

Switch: Worklights Cab Fascia Harness Switch: Beacon

Cab Harness

C071

Connector: HVAC CAN Cab Harness

C115

C072

Connector: Heater / Air Cab Harness Conditioning

C116

Switch: Main Wipers

Fascia Harness

C117

Switch: Screenwash

Fascia Harness

C073

Socket: Auxiliary IGN 24V (1)

Cab Harness

C118

Switch: Lower Wiper

Fascia Harness

C119

Switch: Engine Stop

Fascia Harness

C074

Switch: Fan Speed

Heater Harness

C120

Switch: Swing Lock

Fascia Harness

C075

Switch: Re-Circulation

Heater Harness

C121

Switch: Quickhitch

Fascia Harness

C076

Potentiometer: Temperature

Heater Harness

C122

Switch: Controls Enable

Fascia Harness

C077

LED: Heater Panel Illumination

Heater Harness

C123

Switch: Module - Auto Idle/H+/Speed

Cab Harness

C078

Sensor: Hammer Pilot

Cab Harness

C124

Sensor: Boom Up

Cab Harness

Light: Worklight Boom LH

Boom Harness

C079 C080

Sensor: Pressure Swing Pilot

Cab Harness

C125

Light: Worklight Counterweight

Revolver Harness

C081

Relay: Ignition (24V Input)

Revolver Harness

C126

Motor: Wiper - Lower

Cab Harness

C127

Cab Harness

C082

Module: Heater Unit

Heater Harness

Diode: Wake-up Refuel/Door Open

C085

Light: Quickhitch Boom Boom Harness Status

C128

Switch: Cushion

Fascia Harness

C129

Switch: Seat Ventilation

ECU: Livelink Telematics

Fascia Harness

C086

C130

Connector: USB

Fascia Harness

C090

Sensor: Pilot Pressure Cab Harness

C138

Solenoid: Boom Priority

Revolver Harness

Connector: LH Rear Beacon

Revolver Harness

C091

C139

Element: Heated Seat

Cab Harness

Connector: RH Rear Beacon

Revolver Harness

C092 C093

Motor: Seat Ventilation Cab Harness

C140

Speaker: RH

Roof Harness

C-177

Cab Harness

9813/3200-03

C-177

Section C - Electrics Harness Systems Connector Codes Connector Code

Device

Connector Code

Harness Location

C141

Speaker: LH

C142

Switch: Wiper Interlock Roof Harness

C143

Connector: Radio Speakers

C145

Harness Location

C168

Sensor: Cold Start Advance

Engine Harness

Roof Harness

C169

Sensor: Seat Belt / Occupancy

Cab Harness

Connector: Primary Fuse Supply

Revolver Harness

C171

Sensor: Pressure Lo Flow Aux

Revolver Harness

C147

Light: Console Illumination

Fascia Harness

C172

Sensor: Pressure Hi Flow Aux

Revolver Harness

C148

Sensor: Door Open

Roof Harness

C173

Cab Harness

C149

Sensor: TMAP Sensor Revolver Harness

Solenoid: Merge Flow ‘A’

C150

Motor: Seat Suspension

Cab Harness

C174

Solenoid: Merge Flow ‘B’

Cab Harness

C151

Socket: Auxiliary 12V (1)

Fascia Harness

C175

Solenoid: Low Flow Variable ARV

Cab Harness

C152

Socket: Auxiliary IGN 24V (2)

Cab Harness

C176

Solenoid: Hi Flow Variable ARV

Cab Harness

C153

ECU: Hydraulic Control Cab Harness ECU (J1)

C177

RH Joystick Handle AUX

Cab Harness

C154

ECU: Hydraulic Control Cab Harness ECU (J2)

C178

Solenoid: Dual Controls (A)

Options Harness

C155

Solenoid: Quickhitch

Revolver Harness

C179

Solenoid: Dual Controls (B)

Options Harness

C156

Sensor: Pressure Quickhitch

Revolver Harness

C194

Sensor: Arm Limit Proximity

Arm Harness

C157

Sensor: Alignment Boom

Boom Harness

C195

Antenna: FM Radio

Roof Harness

C158

Sensor: Alignment Arm

Boom Harness

C200

Resistor: CAN Termination

Fascia Harness

C159

Solenoid: Arm Limiter

Options Harness

C225

Switch: Lever Lock 2

Cab Harness

C160

Solenoid: Low Flow ‘A’ Auxiliary Harness

C226

Switch: Cab Raise (HRC)

Cab Harness

C161

Solenoid: Low Flow ‘B’ Auxiliary Harness

C231

Light: Worklight Boom RH

Boom Harness

Diode: Cab Low Flow Priority (HRC)

Revolver Harness

C162

C241

Socket: Auxiliary 12V (2)

Cab Harness

Solenoid: Low Flow Priority (HRC)

Revolver Harness

C163

C243

Solenoid: Proportional High Flow ‘A’

Auxiliary Harness

Solenoid: Cab Raise (HRC)

Revolver Harness

C164

C244

Solenoid: Proportional High Flow ‘B’

Auxiliary Harness

Solenoid: Cab Lower (HRC)

Revolver Harness

C165

C245

Solenoid: Auxiliary/ Hammer Changeover

Revolver Harness

Sensor: Cab Lowered and Docked (HRC)

Cab Harness

C167

C246

Switch: Cab Raise (HRC)

Revolver Harness

C-178

Roof Harness

Device

9813/3200-03

C-178

Section C - Electrics Harness Systems Connector Codes Connector Code

Device

Harness Location

C318

Relay: LiveLink

Facia Harness

C348(1)

Relay: Fuel Lift Pump

Cab Harness

C30-X1

Connector: Primary Fuse B+

Revolver Harness

C42-X1

Alternator: R Terminal

Revolver Harness

C42-X2

Alternator: L Terminal

Revolver Harness

(1) Depending on machine variant

C-179

9813/3200-03

C-179

Section C - Electrics Harness Systems 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.

S164111-C1

Fig 75. Typical Wire Number K Fig 75. ( T C-180). 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 10. Wire Identification Ident. No.

Description

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

8191

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-180).

C-180

9813/3200-03

C-180

Section C - Electrics Harness Systems Wire Numbers and Functions

Wires 000-199, 1000-1999 These numbers are reserved for ignition feeds, heater start circuits and start circuits. These can be further categorised by:

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.

Wires 800-999, 8000-9999

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

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

– Wires 100 - 199 and 1000 - 1999 are allocated to fused ignition feeds.

Note: Can also include power supplies output by ECU’s.

Note: Feeds via ignition relays are classed as ignition feeds. Note: Can also include power supplies output by ECU’s.

Wires 200-399, 2000-3999 These numbers are reserved for battery feeds, They can be further categorised by:

Wires In Splices The main input wire is allocated with a wire number and a suitable description, i.e. Wire 640, earth splice. The additional wires in the splice are allocated the same wire number and a postfix, i.e. 640A, 640B, etc. K Fig 77. ( T C-181). Note: The letters I, O, Q and S are not used.

– Wires 200 - 299 and 2000 - 2999 are allocated to unfused battery feeds. – Wires 300 - 399 and 3000 - 3999 are allocated to fused battery feeds. Note: Can also include power supplies output by ECU’s.

Wires 400-599, 4000-5999 These numbers are reserved for instruments, sensors and variable input/output signal wires used in electronic systems. CANbus wires also use numbers in this series. T011680-C1

Fig 77.

Wires 600-799, 6000-7999 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 76. ( T C-181). This symbol is printed onto the wire, it may however be omitted from harness drawings.

General Points Wires continue to have the same number even after passing through a connector block to another harness. The descriptions are applicable to JCB specification wiring harnesses. The machine may be fitted with some wiring that does not conform to the JCB specifications, typically when it is part of equipment supplied by other manufacturers.

Fig 76.

C-181

9813/3200-03

C-181

Section C - Electrics Harness Systems 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 11. 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 11. ( T C-182), 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 78.

ELEC-2-2

C-182

9813/3200-03

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 78. ( T C-182). Note that each of the splices detailed is colour-coded to make size and range

C-182

Section C - Electrics Harness Systems 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 79. ( T C-183). a

seal

the

Remove the cap 80-A from the end of the disposable gas cartridge 80-B.

Fig 81. d Turn the small ring 82-E so that the air holes at 82F are completely closed. Fig 79. b Before assembling the gas cartridge to the reflector element 81-C, turn the red ring 81-D to the left, (in the direction of the minus sign marked on the ring).

Fig 82. e Fig 80. c

C-183

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 81. ( T C-183). A click will be heard.

Turn the red ring 83-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.

9813/3200-03

C-183

Section C - Electrics Harness Systems Wiring Harness Repair i

Side wings 85-G down, reflector head completely open. In this mode the infra-red heat waves are dominant (recommended for the light coloured plastic splices).

Fig 83. f

Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown. Fig 85. 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 84-E until the air holes at 84-F are completely open. The tool is ready for use.

Side wings 86-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 86. h To switch off the heater, turn the red ring 86-D to the left (in the direction of the minus sign). Fig 84. g The heater can be used in two modes:

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C-184

Section C - Electrics Harness Systems Wiring Harness Repair

Page left intentionally blank

C-185

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C-185

Section C - Electrics

ECUs and CANbus CANbus System Modern machines use Electronic Control Units (ECU’s) to control machine systems such as hydraulics, transmission and engine. In much the same way as office computers can be ‘networked’ to communicate with each other the machine ECU’s can be ‘networked’. Some advantages of networking are: – Improved, more intelligent control systems – More comprehensive instrumentation

and

reliable

in-cab

– Service software tools can be used for fault finding and machine control set-up. For example the engine ECU can communicate with other machine ECU’s using a CANbus network system.

C-186

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C-186

Section C - Electrics ECUs and CANbus CANbus System

CANbus Communications System C

Controller

Area

Network

An electronic communications system that connects all the machine ECU’s to one pair of data wires called the CANbus. Coded data is sent to and from the ECU’s on the CANbus. By connecting Servicemaster diagnostic software to the CANbus, data is seen and decoded for use by a service engineer.

1 5

8 C128140-C3

Fig 87. CANbus System Item

Description

Harness Connectors

Engine ECU (bound)(1)

C001

Livelink ECU (if fitted) (bound)(1)

C129

C346

(2)

SCR ECU

Display ECU (DECU) (bound)

C110 J1

Automatic Temperature Control (ATC) ECU (if fitted)

C071

Machine control ECU (MECU)

C015 J1

Hydraulic control ECU (HECU) (if fitted)

C153 J1

Servicemaster diagnostics connector (cab fuse and relay PCB)

C100 X2

CAN termination resistors

C200, C002

CANbus wires

(1)

(1) The ECU is ‘bound’ on the CANbus. Refer to ‘ECU Set-up’ for information about bound ECU’s. (2) Machines with electronic F.I. engines and exhaust after treatment only.

C-187

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C-187

C-188

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C346

K Fig 88. Circuit ( T C-188)

C001/C136

C015

Fig 88. Circuit

C015

C100 X2

C153

C071

C129

C110

C129570-C2

Section C - Electrics ECUs and CANbus CANbus System

C-188

Section C - Electrics ECUs and CANbus CANbus System

ECU Set-up When replacing an ECU or operating software - a set-up procedure must be completed. Some ECU’s installed on the machine have a unique identification to enable them to communicate (bind) with other ECU’s, the electronic immobiliser system and LiveLink system (if fitted). These ECU’s are called ‘bound ECU’s. A new ECU or software update will require the following set-up procedures: – Bound ECU’s must be unlocked from the CANbus before removal of ECU’s or installation of operating software. For security reasons an unlock code must be obtained from JCB Service to enable completion of the procedure. Refer to the Servicemaster documentation and JDS Technical Information for the correct procedures. – The correct ECU software must be installed if the ECU is blank. – The ECU must be configured to match the machine build options. – A bound ECU must be registered on the CANbus system and LiveLink system. Refer to the Servicemaster documentation and JDS Technical Information for the correct procedures. – Machines fitted with an immobiliser must have the unlock and lock codes updated within 24 hours of installation of replacement bound ECUs or operating software. Refer to the Servicemaster documentation and JDS Technical Information for the correct set-up procedures. If the ECU is not configured to the machine build options correctly there may be a loss of some machine functions. If a bound ECU is not registered on the CANbus or to the LiveLink system the machine will not operate.

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C-189

Section C - Electrics ECUs and CANbus Machine Electronic Control Unit (MECU)

Machine Electronic Control Unit (MECU) Location The MECU 2 is located inside the cab on the rear bulkhead 3. To get access to the MECU remove the rear access panel 1. Refer to Section B.

2 1

C128250-C3

Fig 89.

Operation Overview The MECU receives inputs from various switches and sensors. The MECU is also connected to the CANbus and is capable of sending and receiving CAN messages to and from other CAN enabled ECUs on the machine. The main function of the MECU is control of the machine power bands and modes. This is achieved by control of the engine rpm/torque and the power setting for the main and Power hydraulic pump. K Engine Control ( T C-209) Internal software data enables the MECU to process inputs and respond with the applicable outputs and CAN messages.

C-190

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C-190

Section C - Electrics ECUs and CANbus Machine Electronic Control Unit (MECU)

Wires and Connectors

C015 J1

C016 J2

C128270

Fig 90. Harness Connectors C015, C016 Harness Connector C015 - J1 (black)

Pins Details

Power signal - wake up (door open, refuel)

Output - cooling fan solenoid

CAN shield

Battery (+ 24V)

High side output - travel speed solenoid

Battery (+ 24V)

High side output - cab interior light

Battery (+ 24V)

High side output - refuel pump relay

Battery (+ 24V)

Regulated sensor supply (+ 5V)

Analog input - fuel level sensor

Not used

Digital input - excavator pilot pressure switch

Analog input - engine oil temperature sensor

Not used

Digital input - slew lock switch

Power signal - ignition

CAN_L

Low side output - hydraulic pump proportional solenoid

CAN_H

Not used

High side output - slew brake solenoid

Earth - sensors

Earth

Analog input - ambient temperature sensor

Not used

Digital input - air filter vacuum switch

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C-191

Section C - Electrics ECUs and CANbus Machine Electronic Control Unit (MECU) Harness Connector C016 - J2 (grey)

Digital input - lever lock switch

Digital input - boom overload pressure switch

Pins Details 1

Low side output - cooling fan PWM return

Digital input - coolant level switch

Digital input - boom up pressure switch

High side output - travel alarm

High side output - MRV boost solenoid

High side output - controls enable solenoid

High side output - starter relay

High side output - warning buzzer, Malfunction Indicator Light (MIL)

(1) Machines with T2, T4i engines. (2) Machines with T4f engines.

High side output - slew lock solenoid

High side output - auxiliary/hammer change over solenoid

High side output - slew shut solenoid

High side output (PWM) - hydraulic pump proportional solenoid

Digital input - engine oil level switch

Digital input - swing pilot pressure switch

Digital input - one touch idle button

Digital input - travel speed mode select button

Digital input - auto idle enable/disable button

Not used

Analog input - refuel pump button

Digital input - engine start/stop switch

Analog input - hand throttle potentiometer

Earth

High side output - maximum flow cut solenoid(1) High side output - isololator power hold relay(2)

Low side output - controls isolate indicator LED

Digital input - controls isolate switch

Digital input - travel pilot pressure switch

Digital input - boom priority button

Digital input - H+ power mode switch

Digital input - boost button

Input - cab interior light switch

Analog input - alternator

Digital input - engine stop switch

Frequency input - cooling fan speed

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C-192

Section C - Electrics ECUs and CANbus Machine Electronic Control Unit (MECU)

Removal and Replacement Guide The MECU is a reliable and robust component. Before removing and replacing the MECU carry out all the relevant diagnostic and fault finding procedures. Most faults are usually due to damaged wires, connectors or connected devices such as sensors or solenoids.

Disconnect the black harness connector 3 (J1) and the grey harness connector 4 (J2) at the MECU. Do not touch the connector pins. Put some tape over the connectors to protect the pins.

Remove four screws 2 and their associated washers.

Replacement

1 2

Replace the MECU as follows: 1

Connect the harness connectors at the correct sockets on the MECU.

Carry out the correct power up procedure. K ECU Set-up ( T C-189)

Use Servicemaster to install the ECU software. Refer to Servicemaster SYSTEM.

Use Servicemaster to enter the applicable machine set-up options. Refer to Servicemaster SYSTEM.

Use Servicemaster to bind the machine ECUâ&#x20AC;&#x2122;s. K ECU Set-up ( T C-189)

Use Servicemaster to update the immobiliser lock and unlock codes. K ECU Set-up ( T C-189)

4 C128250-C4

Fig 91.

Removal The MECU is bound on the CANbus system. Do not remove or disconnect the MECU unless you have access to the applicable JCB Servicemaster software tools. 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2, Maintenance.

Use Servicemaster to view the machine Set-up. Record the details from the Set-up screen. Refer to Servicemaster SYSTEM.

Carry out the unlock binding procedure. Refer to the ECU Set-up instructions. K ECU Set-up ( T C-189)

Carry out the correct power down sequence. K ECU Set-up ( T C-189)

C-193

Note: Do not replace the MECU with a unit from another machine. ECUâ&#x20AC;&#x2122;s may look the same but have different software installations.

9813/3200-03

C-193

Section C - Electrics ECUs and CANbus Hydraulic Electronic Control Unit (HECU)

Hydraulic Electronic Control Unit (HECU) Location The HECU 2 (if fitted) is located inside the cab on the rear bulkhead 3. To get access to the HECU remove the rear access panel 1. Refer to Section B.

2 1

C128250

Fig 92.

Operation Overview The HECU is a programmed to control some of the machine hydraulic systems. It receives inputs from the LH and RH joystick control thumb wheels, various switches and sensors. Outputs control solenoid valves for control of the auxiliary hydraulics. The system is designed for simple set-up of the auxiliary hydraulics for efficient and safe operation of the machine.

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Section C - Electrics ECUs and CANbus Hydraulic Electronic Control Unit (HECU)

Wires and Connectors

C153 J1

C154 J2

C128270-C1

Fig 93. Harness Connectors C153, C154 Harness Connector C153 - J1 (black)

Not used

Pins Details

Not used

High side output - proportional solenoid - high flow A

Digital input - arm limit proximity switch

Not used

Battery (+ 24V)

CAN shield

Battery (+ 24V)

Not used

Battery (+ 24V)

High side output - quickhitch solenoid

Battery (+ 24V)

High side output - arm limit solenoid

Battery (+ 24V)

Not used

High side output - quichitch boom status indicator LED

Not used

Regulated sensor supply (+ 5V)

Not used

Digital input - hammer pilot pressure switch

Not used

Power signal - ignition

Analog input - low flow auxiliary pressure sensor

Low side output - low flow auxiliary proportional solenoid

Digital input - High Rise Cab (HRC) cab lowered and docked sensor

High side output - high flow proportional solenoid B

CAN_L

CAN_H

Earth - sensors

Low side output - high flow variable ARV solenoid

Earth

Analog input - high flow auxiliary pressure sensor

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Section C - Electrics ECUs and CANbus Hydraulic Electronic Control Unit (HECU) 35

Digital input - quickhitch pressure switch

Harness Connector C154 - J2 (grey) Pins Details 1

Low side output - high flow auxiliary proportional solenoids return

Not used

Digital input - quickhitch switch

Not used

High side output - merge flow A solenoid

High side output - merge flow B solenoid

High side output - dual controls solenoids

High side output - quickhitch switch status LED (red)

High side output - low flow variable ARV solenoid

High side output - high flow variable ARV solenoid

Not used

High side output - low flow B proportional solenoid

Not used

Digital input - quickhitch switch

Digital input - quickhitch button (RH joystick)

Not used

Analog input - LH joystick thumbwheel

Not used

Earth

High side output - low flow A solenoid

Low side output - low flow variable ARV solenoid

Not used

Digital input - constant auxiliary button (LH joystick)

Digital input - arm alignment switch

Analog input - RH joystick thumbwheel

Not used

Digital input - boom alignment switch

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Section C - Electrics ECUs and CANbus Hydraulic Electronic Control Unit (HECU)

Removal and Replacement Guide

– Connect the harness connectors at the correct sockets on the HECU.

The HECU is a reliable and robust component. Before removing and replacing the HECU carry out all the relevant diagnostic and fault finding procedures. Most faults are usually due to damaged wires, connectors or connected devices such as sensors or solenoids.

– If the HECU is a replacement unit refer to the ECU Set-up instructions. K ECU Set-up ( T C-189)

Note: Do not replace the HECU with a unit from another machine. ECU’s may look the same but have different software installations.

Test Procedures

Use Servicemaster to identify possible faults with the relevant wiring, connectors or electrical devices. Do not use a multimeter on the ECU connector pins. Do not touch the ECU connector pins.

C128250-C1

Fig 94.

Removal The HECU is not a ‘bound ECU’. 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2, Maintenance.

Disconnect the battery.

Disconnect the black harness connector 3 (J2) and the grey harness connector 4 (J1) at the HECU. Do not touch the connector pins. Put some tape over the connectors to protect the pins.

Remove four screws 2 and their associated washers.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

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Section C - Electrics ECUs and CANbus Display ECU (DECU)

Display ECU (DECU) Location The DECU is part of the LCD monitor mounted in the cab.

C128570

Fig 95.

Operation Overview The DECU 3 controls the information shown on the LCD monitor 4. The controls 6 and LCD monitor are part of the ECU. The DECU is connected to the CANbus and is capable of sending and receiving CAN messages to and from other CAN enabled ECUs on the machine. Internal software data enables the DECU to process inputs and respond by configuring the LCD to show the applicable graphics and data. Note: Two LCD variants are available. The 3.5 in variant (shown) has two mechanical gauges 5. The 7 in variant replaces the mechanical gauges with digital gauges shown by the LCD. This variant also uses the LCD to display the input from the camera visibility system. To get access to the electrical connectors on the DECU remove three screws 1 and cover 2.

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Section C - Electrics ECUs and CANbus Display ECU (DECU)

Wires and Connectors K Fig 97. Circuit ( T C-200)

C109 J1

C128580

Fig 96. Harness Connectors C109 Harness Connector C109 - J1 (grey) Pins Details 1

Digital input - work lights switch

Wake up signal (+ 24V ignition)

Not used

CAN shield

CAN_L

CAN_H

Earth

Battery (+ 24V)

Digital input - seat occupant switch, seat belt switch

Not used

High side input - MECU (warning buzzer Malfunction Indicator Light (MIL) activation)

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C-200

C016 MECU (J2)

CAN HI

CAN LO

CAN SHD

C113

CANbus

24V ICN ECU WAKE - UP

4094

4014

4071

3017

4093

6090

Fig 97. Circuit

4092 4091

4102L

4101L

4100L

1006D

8002D

C109/C110

C068/C069 CAMERA MONITORS: COUNTERWEIGHT AND OFFSIDE

C129140

Section C - Electrics ECUs and CANbus Display ECU (DECU)

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C-200

Section C - Electrics ECUs and CANbus Display ECU (DECU)

Removal and Replacement Guide The DECU is a reliable and robust component. Before removing and replacing the DECU carry out all the relevant

diagnostic and fault finding procedures. Most faults are usually due to damaged wires, connectors or connected devices such as switches or sensors.

5 C128590

Fig 98.

Removal

The DECU is bound on the CANbus system. Do not remove or disconnect the DECU unless you have access to the applicable JCB Servicemaster software tools.

Replacement

Support the DECU and remove four screws 3. Remove the DECU from the machine.

Replace the DECU as follows: 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2, Maintenance.

Connect the harness connectors at the correct sockets on the DECU.

Torque tighten the screws 7 and 3 to 4 Nm.