JCB JS210 LC Tracked Excavator Service Repair Manual – PDF Download by www.heydownloads.com

Service Manual

General Information

Care & Safety

Routine Maintenance

Attachments

Body & Framework

Electrics

Hydraulics

Transmission

Brakes

JS 210 LC 110026 On

PUBLISHED BY THE PRODUCT SUPPORT DEPARTMENT

Track & Running Gear

Engine

OF JCB SERVICE : 23/7, MATHURA ROAD, BALLABHGARH, FARIDABAD TEL. : 0129-4299000 Part No. : 9803/6510

Section 1

General Information

Section 1

i CONTENTS

PAGE NO.

Machine Identification Plate

1-1

Typical Vehicle Identification Number (VIN)

1-1

Typical Engine Identification Number

1-1

Torque Settings

2-1

Service Tools - Body and Frame

4-1

- Electrics

4-3

- Hydraulics

4-6

- Transmission Sealing and Retaining Compounds

4 - 14 5-1

Issue 1

Section 1

General Information

Section 1

Issue 1

Section 1

General Information

Section 1

Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dir t. Finally, please remember above all else SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 1 2 3

= = =

General Information - includes torque settings and service tools. Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. Routine Maintenance - includes service schedules and recommended lubricants for all the machine.

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

= =

Attachments

Body & Framework ...etc.

The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual. Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each alphabetically coded section. All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third.

Issue 1

Section 1

General Information

Section 1

Colour Coding 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 M.R.V. operating pressure.

~ Pink

Pressure

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

~ Orange

Servo

Oil pressure used in controlling a device (servo).

~ Blue

Neutral

Neutral circuit pressure.

~ -

Green - Exhaust

Light - Cavitation

Green Oil subjected to a partial vacuum due to a drop in pressure (cavitation). - Yellow - Lock Up Oil trapped within a chamber or line, preventing movement of components (lock up). A390940

Issue 1

Section 1

General Information

Section 1

1-1

1 -1 Typical Vehicle Identification Number (VIN)

Machine Identification Plate Your machine has an identification plate mounted outside the cab at A. The serial numbers of the machine and its major units are stamped on the plate. The machine serial number is inscibed at B which is the base plate of the rear frame and the engine number is at C.

SLP

JS915

0 930000

World Manufacturer Identification

Machine Model Code

Year of Manufacture:

2 3 4 5 6 7 8

= = = = = = =

2002 2003 2004 2005 2006 2007 2008

401730

JCB HEAVY PRODUCTS LTD UTTOXETER, STAFFS ST14 8TL, ENGLAND

VIN

Manufacturer Location (E = England)

Product Identification Number (PIN)

Typical Engine Identification Number

Vehicle Identification Number

Product Identification Number

6 A

MACHINE WEIGHT kg ENGINE SERIAL No. ENGINE POWER kW RPM CONSTRUCTION YEAR

BGI B

145941 C

Engine Type “6 Cylinder”

Build code

Engine Identification Number

JS06060

Issue 1

Section 1

General Information

Section 1

2-1

Torque Settings Use only where no torque setting is specified in the test. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threade the values should be REDUCED by one third.

UNF Grade ‘S’ Bolts Bolt Size In 1/4 5/18 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 11/4 11/2

(mm) (6.3) (7.9) (9.5) (11.1) (12.7) (14.3) (15.9) (19.0) (22.2) (25.4) (31.7) (38.1)

Hexagon (A/F) In 7/16 1/2 9/16 5/8 3/4 13/16 15/16 11/8 15/16 11/2 17/8 21/4

Nm 14 28 49 78 117 170 238 407 650 970 1940 3390

Torque Settings kgf m 1.4 2.8 5.0 8.0 12.0 17.3 24.3 41.5 66.3 99.0 198.0 345.0

Ibf ft 10 20 36 58 87 125 175 300 480 715 1430 2500

Metric Grade 8.8 Bolts Bolt Size M5 M6 M8 M10 M12 M16 M20 M24 M30 M36

Hexagon (A/F) (mm) (5) (8) (8) (10) (12) (16) (20) (24) (30) (36)

mm 8 10 13 17 19 24 30 36 46 55

Torque Settings Nm 7 12 28 56 98 244 476 822 1633 2854

kgf m 0.7 1.2 3.0 5.7 10 25 48 84 166 291

Ibf ft 5 9 21 42 72 180 352 607 1205 2105

River Nut Bolts/Screws Bolt Size M3 M4 M5 M6 M8 M10 M12

(mm) (3) (4) (5) (6) (8) (10) (12)

Torque Settings (for steel rivet nuts) Nm kgf m 1.2 0.12 3.0 0.3 6.0 0.6 10.0 1.0 24.0 2.5 48.0 4.9 82.0 8.4

Ibf ft 0.9 2.0 4.5 7.5 18.0 35.5 60.5

Note : All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

Issue 1

Section 1 4-1

General Information

Section 1

Service Tools

4-1

Service Tools SECTION B - Body and Framework

Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc. JCB part number 892/00845

Hand Cleaner - special blend for the removal of polyurethane adhesives. JCB pan number - 4104/1310 (454g; 1 Ib tub) S186270

S186240

Folding Stand for Holding Glass essential for preparing new glass prior to installation.

12V Mobile Oven - 1 canridge capacity - required to pre-heat adhesive prior to use. It is fitted with a male

JCB part number 892/00843

plug (703/23201) which fits into a female socket (715/04300). JCB pan number - 992/12300

S186280

S186250

240V Static Oven - available with 2 or 6 canridge

Glass Lifter - minimum 2 off - essential for glass

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

installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.

JCB pan number: 992/12400 - 2 Canridge x 240V 992/12600 - 6 Can ridge x 240V

JCB part number - 892/00842

S186260

S186300

Issue 1

Section 1

General Information

4-2

Section 1

Service Tools

4-2

Service Tools (cont’d) SECTION B - Body and Framework (cont’d)

Wire Starter - used to access braided cutting wire(below) through original polyurethane seal.

Cut-Out Knife - used to remove broken glass. JCB part number - 992/12800 JCB part number - 892/00848 S186340 S186310

‘L’ Blades - 25 mm (1 in) cut - replacementblades for cut-out knife (above). JCB part number - 992/12801 (unit quantity = 5 off)

Glass Extractor (Handles) - usedwith braided cutting wire (below) to cut out broken glass. JCB Part number - 892/00846 S186320

S186350

Braided Cutting Wire - Consumble heavy duty

Long Knife - used to give extended reach for normally inaccessible areas.

cut-out wire used with the glass extraction tool (above).

JCB part number - 892/00844

JCB part number - 829/00849 (approx 25m length)

S186330

S186360

Issue 1

Section 1

General Information

4-3

Service Tools

Section 1 4-3

Service Tools SECTION B - Body and Framework (contâ&#x20AC;&#x2122;d) Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame. JCB part number - 926/15500 (unit quantity = 500 off)

Nylon Spatula (unit quantity = 500 off) general tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge. JCB part number - 892/00847 S186470

826/01099 826/01101 826/01103 826/01102 826/01104 826/01105

S186550

M6 x 16mm Rivet Nut M6 x 19mm Rivet Nut M8 x 18mm Rivet Nut M8 x 21 mm Rivet Nut M10 x 23mm Rivet Nut M10 x 26mm Rivet Nut

Installation Tool Available from: Bollhoff Fastenings Ltd. Midacre The Willenhall Estate Rose Hill Willenhall West Midlands, WV13 2JW S261210

Issue 1

Section 1 4-4

General Information

Section 1

Service Tools

4-4

Service Tools SECTION C - Electrics

Electrical Test Equipment

1 892/00283

Tool Kit Case

2 892/00281

AVO Meter

3 892/00286

Surface Temperature

4 892/00284

Microtach Digital Tachometer

5 892/00282

Shunt - open type

6 892/00285

Hydraulic Oil Temperature Probe

7 892/00298

Fluke 85 Multimeter

993/85700

Battery Tester

Issue 1

Section 1

General Information

4-5 Service Tools

Section 1

Service Tools

4-5

SECTION C - Electrics (contâ&#x20AC;&#x2122;d) Electronic Service Tool Kit 892/01033 Kit comprises: 1

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

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

Interconnecting cable, DLA to machine ECU diagnostics socket.

Kit carrying case.

721/01885-

Interconnecting cable, DLA to machine ECU diagnostics socket. (part of 892/01033 Kit above) A408030

Issue 1

Section 1 4-6

General Information

Section 1

Service Tools

4-6

Service Tools (cont’d) SECTION E - Hydraulics

Hydraulic Pressure Test Gauges and Connections 1 892/00279 Pressure Gauge 0-400 bar (0-6000 Ibf/in2) 2 2 892/00346 Pressure Gauge 0-70 bar (0-1000 Ibf/in2) 3 892/00347 Connector 4 892/00254 Hose

PressureTest’T’Adapters

Pressure Test Adapters

892/00262 816/55038 816/55040 892/00263 892/00264 892/00265 892/00266 892/00267

892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261

1/4 in BSP x 1/4 in F BSP x Test Point 3/8 in BSP x 3/8 in F BSP x Test Point 1/2 in BSP x 1/2 in F BSP x Test Point 5/8 in BSP x 5/8 in F BSP x Test Point 3/4 in BSP x 3/4 in F BSP x Test Point 1 in M BSP x 1 in F BSP x Test Point 1,1/4 in M BSP x 1,1/4 in F BSP x Test Point 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point

1/4 in BSP x Test Point 3/8 in BSP x Test Point 1/2 in BSP x Test Point 5/8 in BSP x Test Point 3/4 in BSP x Test Point 1 in BSP x Test Point 1,1/4 in BSP x Test Point 5/8 in UNF x Test Point

Issue 1

Section 1 4 -7

General Information

Section 1

Service Tools

4 -7

Service Tools (cont’d) SECTION E - Hydraulics (con’d)

Hand Pump Equipment 892/00223 892/00137 892/00274 892/00262 892/00706 892/00278 892/00279 892/00280

Hand Pump Micro-bore Hose 1/4 in BSP x 5 metres Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1/4 in M BSP x 1/4 in F BSP x Test Point Test Probe Gauge 0 - 40 bar (0 - 600 Ib/in2) Gauge 0 - 400 bar (0 - 6000 Ib/in2) Gauge 0 - 600 bar (0 - 8500 Ib/in2)

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) 816/00018 1 in BSP (A) x 1 in BSP (B)

Female Cone Blanking Plug

Male Cone Blanking Plug

892/00055 892/00056 892/00057 892/00058 892/00059 892/00060

816/00294 816/00189 816/00190 816/00197 816/00196 816/00193

1/4 in BSP 3/8 in BSP 1/2 in BSP 5/8 in BSP 3/4 in BSP 1 in BSP

Issue 1

Section 1

General Information

4-8

Section 1

Service Tools

4-8

Service Tools (cont’d) SECTION E - Hydraulics (con’d) Socket Box Wrench For

disassembly and assembly of slew motor gearbox.

Nut Adapter

For disassembly and assembly of slew motor gearbox.

Issue 1

Section 1

General Information

4-9

Section 1

Service Tools

4-9

Service Tools (cont’d) SECTION E - Hydraulics (con’d)

Seal Ring Tool

for assembly and disassembly of slew motor gearbox seal

Stopper

for assembly of slew motor gearbox.

A40890

Issue 1

Section 1 4 - 10

General Information

Section 1

Service Tools

4 - 10

Service Tools (cont’d) SECTION E - Hydraulics (con’d)

Bearing Rig

for removal of slew m otor bearing.

A408870

Issue 1

Section 1

General Information

4 - 11

Section 1

Service Tools

4 - 11

Service Tools (contâ&#x20AC;&#x2122;d) SECTION E - Hydraulics (contâ&#x20AC;&#x2122;d) Ram Dismantling and Assembly Ram Piston Head Nut Item

Part Number

Description

Quantity

993/99525

Rig assembly (not including spanners and ram)

993/99522

Anchor side plate (supplied loose unwelded)

993/99523

Anchor cross member (supplied loose unwelded)

993/99524

Ram eye end modification

556/43400

Lift ram

545/18000

Lynch pin

811/50232

11/4 in Pivot pin

Spanner Requirements 993/99518

Bucket ram

90 mm A/F Nut

SSPO047

Boom ram

95 mm A/F Nut

993/99519

Dipper ram

100 mm A/F Nut

993/99519

Bucket ram

100 mm A/F Nut

993/99519

Boom ram

100 mm A/F Nut

993/99521

Dipper ram

115 mm A/F Nut

Note: All spanners have operating centres of 500 mm.

Issue 1

Section 1

General Information

4 - 12

Service Tools

Section 1 4 - 12

Service Tools (cont’d) SECTION E - Hydraulics (cont’d) Ram Dismantling and Assembly (cont’d) Jig for inserting and correcting seal ring WDB 2052 WDB 2054 WDB 2164 WDB 2056

Bucket Boom 125mm Boom 130mm Arm 150mm

120mm Cylinder inner diameter Cylinder inner diameter Cylinder inner diameter Cylinder inner diameter

Jig for pulling out, press-fitting bushing WDB 2166 WDB 2167 WDB 2170 WDB 2168 WDB 2168 WDB 2171

Bucket 80mm Boom 85mm Arm 100mm Bucket 90mm Boom 90mm Arm 105mm

Piston Rod diameter Piston Rod diameter Piston Rod diameter Piston Rod diameter Piston Rod diameter Piston Rod diameter

Jig for press-fitting wiper ring WDB 2166-1 WDB 2167-1 WDB 2170-1 WDB 2168-1 WDB 2168-1 WDB 2171-1

Bucket 80mm Boom 85mm Arm 100mm Bucket 90mm Boom 90mm Arm 105mm

Piston Rod diameter Piston Rod diameter Piston Rod diameter Piston Rod diameter Piston Rod diameter Piston Rod diameter

Jig for inserting cylinder head WDB 2174 WDB 2175 WDB 2178 WDB 2176 WDB 2176 WDB 2179

Bucket 80mm Boom 85mm Arm 100mm Bucket 90mm Boom 90mm Arm 105mm

Cylinder rod inner diameter Cylinder rod inner diameter Cylinder rod inner diameter Cylinder rod inner diameter Cylinder rod inner diameter Cylinder rod inner diameter

Issue 1

Section 1

General Information

4 - 13

Service Tools

Section 1 4 - 13

Service Tools (cont’d) SECTION E - Hydraulics (cont’d) Ram Dismantling and Assembly (cont’d) Seal Ring and Connector Jig WDB 2052 Seal Ring insert and connection jig set Note: The above Part no. is applicable to a tube diameter of 120mm. Bush Removal Jig WDB 2166

Bush removal jig

WDB 2166-1

Retainer

Note: The above Part no. is applicable to a rod diameter of 80mm. Bush Fitting Jig WDB 2166

Bush press fitting jig

WDB 2166-1

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.

Issue 1

Section 1

General Information

4 - 14

Section 1

Service Tools

4 - 14

Service Tools (contâ&#x20AC;&#x2122;d) SECTION F - Transmission Track Gearbox Jig STO037Re-sealing Tool (All dimensions are in mm.)

Stopper

for the assembly of Hydraulic motor on track gearbox

A409010

Issue 1

Section 1

General Information

4 - 15

Service Tools

Section 1 4 - 15

Service Tools (cont’d) SECTION F - Transmission (cont’d) Track Gearbox Jig SSTOO40 Ring Nut Tool SSTOO41 Planet Gear Tool (All dimensions are in mm.)

SST0040

SST0041

Issue 1

Section 1

General Information

5-1

Section 1

Service Tools

5-1

Sealing and Retaining Compounds JCB Multi-Gasket

JCB High Strength Threadlocker

JCB Retainer (High Strength)

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

4102/1212

50ml

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

4102/0551

50ml

For all retaining parts which are unlikely to be dismantled.

4101/0651

50ml

JCB Threadlocker and Sealer

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

4101/0250 4101/0251

10ml 50ml

Threadseal

A medium strength thread sealing compound.

4102/1951

50ml

Threadlocker

A locking fluid for use on threads larger than 50mm dia.

4101/0451

50ml

4104/0251 4104/0253

(1Itr) Bottle

400ml

Activator

A cleaning primer which speeds the curing rate of anaerobic products. (200ml)

Cleaner / Degreaser

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

4104/1557

For one pane of glass, comprises items marked t below plus applicator nozzle etc.

993/55700

† Ultra Fast Adhesive

For direct glazing

4103/2109

310 ml

† Active Wipe 205

For direct glazing

† Black Primer 206J

For direct glazing

4104/1206 4104/1203 4201/4906

30 ml 250 g 30 ml

Clear Silicone Sealant

To seal butt jointed glass

4102/0933

Black Polyurethane Sealant

To finish exposed edges of laminated glass

4102/2309

310 ml

JCB Cleaner & Degreaser

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

4104/1538

Aerosol

Direct Glazing Kit

Issue 1

Section 2

Care and Safety

Section 2

i CONTENTS

PAGE NO.

Safety Notices

1-1

General Safety

1-1

Operating Safety

1-3

Maintenance Safety

1-5

Safety Decals

1-7

Issue 1

Section 2

Care and Safety

Section 2

Care and Safety

1-1

Section 2 1 -1

In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.

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

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

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

Issue 1

Section 2

Care and Safety

Section 2

1-2

1 -2

All construction and agricultural equipment can be hazardous. When a JCB Excavator is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. Do not work with the machine until you are sure that you can control it. Do not start any job until you are sure that you and those around you will be safe.

As well as the warnings in the following pages, specific warnings are given throughout the book. This section is designed to give a safety code for use of the machine generally and for operation and maintenance practices. Note: This section includes a certain amount of operating safety information. But remember that whenever you drive the machine or operate its controls, you are in effect a machine operator.Therefore you should read and understand the information given in the Operator Handbook before driving the machine or operating its controls.

If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE GEN-1-6

General Safety

WARNING

Handbook You and others can be injured if you operate or maintain the machine without first studying this handbook. Read the safety instructions before operating the machine. If you do not understand anything, ask your employer or JCB distributor to explain it. Keep this handbook clean and in good condition. Do not operate the machine without a handbook in the cab, or if there is anything on the machine you do not understand.

Clothing You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, ear- protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained.

INT-1-3-2

INT.1.3.6

WARNING

Decals You can be injured if you do not obey the decal safety instructions. Keep decals clean. Replace unreadable or missing decals with new ones before operating the machine. Make sure replacement parts include warning decals where necessary.

Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job.

INT-1-3-4

INT.1.3.7

WARNING 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.

WARNING Raised Equipment Raised equipment can fall and injure you. Do not walk or work under raised equipment unless safely supported. 13-1.1-6

INT-1-3-5

DANGER

WARNING 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 whilst operating the machine or attachments. Be aware of medicines which can cause drowsiness.

Before removing the boom from the machine, ensure that the counterweight is adequately supported as in certain ground conditions the machine could tip I backwards. Never travel or transport the machine with I the boom removed. BF6-3

INT-1-3-9

Issue 1

Section 2

Care and Safety

Section 2

1-3

Operating Safety

WARNING

Practice You or others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practice away from the work site on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely.

Exhaust Gases Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, fit an exhaust extension. If you begin to feel drowsy, stop the machine at once. Get out of the cab into fresh air.

INT-2-1-1

INT-2-1-10

WARNING

DANGER

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 handbook are completed before using the machine.

Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust.

INT-2-1-2

INT -2-2-10

CAUTION If you have an attachment which is not covered in this handbook, donâ&#x20AC;&#x2122;t 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.

WARNING Engine The engine has exposed rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open. INT-2-1-6/1

5-5-1-1

WARNING Entering/Leaving Always face the machine when entering and leaving the cab. Use the step(s) and handrails. Make sure the step(s), handrails and your boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls as handholds, use the handrails. INT-2-1-7

WARNING Controls You or others can be killed or seriously injured if you operate the control levers from outside the cab. Operate the control levers only when you are correctly seated inside the cab. INT-2-1-3

WARNING Visibility Accidents can be caused by working in poor visibility. Keep windows clean and use your lights to improve visibility. Do not operate the machine if you cannot see properly.

WARNING Passengers Passengers in or on the machine can cause accidents. The JCB Excavator is a one man machine. Do not carry passengers. INT -2-2-2

WARNING Safe Working Loads Overloading the machine can damage it and make it unstable. Study the lifting and/or digging specifications in this handbook before using the attachment. INT-2-2-11/1

WARNING The Long Reach is larger and higher than a normal excavating rig. You must take extra care when you are working in dangerous or restricted height locations such as under power lines, bridges, etc. 8-2-8-10

INT-2-1-11

WARNING Machine Limits Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications. INT-2-1-4

Issue 1

Section 2

Care and Safety

1-4

Section 2 1-4

Operating Safety (contâ&#x20AC;&#x2122;d)

CAUTION Because of the extra length and height of the Long Reach boom and dipper, you must be very careful when slewing. Do not slew quickly and strike the dipper against any obstacle. You may cause severe damage to the rig structure. 8-2-8-11

WARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when fitted). Please inspect these areas frequently and clean at the beginning of each work shift or more often if required. Before opening the engine cover, ensure that the top is clear of debris. 5-3-1-12/2

WARNING 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. Buried Electric Power Cables Before you start using the machine, check with your electricity supplier if there are any buried power cables on the site. Overhead Electric Power Cables There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier. 2-2-5-4

CAUTION With certain combinations of bucket or attachment and boom/ dipper configuration, it is possible for the bucket teeth or attachment extremities to contact and cause damage to the structure of the machine. Check the limit of free movement as the dipper is brought in towards the machine. 8-2-5-2

WARNING Hazardous Atmospheres This machine is designed for use in normal outdoor atmospheric conditions. It should not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor. INT-2-1-14

Issue 1

Section 2

Care and Safety

Section 2

1-5

Maintenance Safety

WARNING Modifications and Welding Non-approved modifications can cause injury and damage. Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Contact your JCB distributor for advice before modifying the machine. INT-3-1-2/1

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

WARNING Diesel Fuel Diesel fuel is flammable; keep naked flames away from the machine. Do not smoke while refuelling the machine or working on the engine. Do not refuel with the engine running. There could be a fire or injury if you do not follow these precautions. INT-3-2-2

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

WARNING Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the operatorâ&#x20AC;&#x2122;s cab until you need to use it. Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use self-contained breathing apparatus. INT -3-2-7/1

WARNING Hot Coolant The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the filler cap. Let the system cool before removing the filler cap. To remove the cap; turn it to the first notch and let the steam pressure escape, then remove the cap. INT-3-2-9/1

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

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

NT -3-2-3

CAUTION WARNING

Hydraulic Fluid Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not place your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates the skin, get medical help immediately. INT-3-1-10/1

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

WARNING

Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open.

Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: Damaged end fittings Chafed outer covers Ballooned outer covers Kinked or crushed hoses Embedded armouring in outer covers Displaced end fittings.

INT-3-1-11/1

INT-3-3-2

WARNING

Issue 1

Section 2

Care and Safety

Section 2

1-6

Maintenance Safety (cont’d)

CAUTION ‘0’ rings, Seals and Gaskets Badly fitted, damaged or rotted ‘0’ rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Trichloroethane or paint thinners near ‘0’ rings and seals. INT-3-2-12

WARNING Battery A battery with frozen electrolyte can explode if it is used or charged. Do not use a machine with a frozen battery. To help prevent the battery from freezing, keep the battery fully charged.

WARNING Arc Welding Before carrying out any arc welding on the machine, completely remove the Control Computer and The Display Monitor to avoid damage to the circuits; also disconnect the alternator and battery leads. When welding items to the mainframe make sure that the earth clamp is positioned on the mainframe and when welding to the undercarriage make sure that the earth clamp is positioned on the undercarriage. If you earth one and weld the other, you may cause severe damage to the slew ring. Always connect the earth clamp to any other component being welded, i.e. boom or dipper, to avoid damage to pivot pins and bushes. 0008

INT-3-1-7

WARNING

WARNING Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter.

Repairs Do not try to do repairs or any other type of maintenance work you do not understand. Get a Service Manual from your JCB distributor, or get the work done by a specialist engineer. INT-3-1-1

WARNING

INT-3-1-8

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

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

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

CAUTION Never use water or steam to clean inside the cab. The use of water or steam could damage the on-board computer and render the machine inoperable. Remove dirt using a brush or damp cloth. 8-3-4-8

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

Issue 1

Section 2

Care and Safety

1-7

Section 2 1-7

Safety Decals

445971

LABEL

PART No.

DEFINITION

A B C D

817/18542 JLP0283 JRP0142 817/18535

E F G H J K L M N P Q

817/18536 817/18537 817/18538 817/18566 JHP0121 817/18528 817/02370 817/18533 JHP0111 817/18539 817/18541

Warning, Arm or bucket may move; Keep clear. Warning, Do not use excavator for lifting loads. Warning, Bucket can foul the boom when dipper is swinging inwards.â&#x20AC;&#x2DC;Supershortâ&#x20AC;&#x2122; booms only. 1-Warning, Coolant under pressure. 2-Warning, Risk of severing hands/fingers in rotating parts. 3-Warning, Hot surfaces. 4-Remove ignition key and refer to operator handbook and maintainance manual. Warning, Hot surfaces; Keep hands away. Warning, High pressure and hot coolanVsystem ; Keep hands away. Warning, Risk of severing finger/hand in rotating parts; Keep hands away. Do not walk or place any body weight on this part. Warning, Do not lift machine here. Warning counterweight or whole machine may move; Keep clear. Warning, 24V. Warning, Risk of trapping fingers/hand in door; Keep hands away. Warning. No hosing or jet washing in cab. Warning, Unexpected movement of part or whole machine; Move lock lever to the lock position. Warning, Read the operation and maintainance manual.

Issue 2*

Section 2

Care and Safety

1-8

Section 2 1-8

Safety Decals (continued)

LABEL

PART No.

DEFINITION

JHP0134

S T V W

817/18527

817/18529

X Y

817/18531 817/18532

Warning, High pressure hydraulic system; 1-Stop the engine. 2-Unscrew the box nut. 3-Depress the pressure relief valve until all the tank pressure is released. 4-Remove filler plug/breather assembly as required. Diesel fuel, Warning, Flamable substance; No ignition source. Lubrication chart. Refer to ‘Chart Definitions’ for details. Lifting chart. Refer to ‘Chart Definitions’ for details. 1-Warning, Damage may occur when starting from cold temperatures; Refer to the operator’s handbook. 2-Warning, Risk of electrocution; Maintain the minimum clearance recomended by your local electricity supplier. 3-Warning, Risk of injury by crushing; Do not lean out of the front window. 4-Warning, Risk of tripping; raise the control lock lever before exiting. Warning, Edges without protective railings; Keep clear of edges. Warning, Hoses that may eject a high velocity jet capable of penetrating the skin; Remove ignition key and refer to operator handbook and maintainance manual.

Issue 2*

Section 2

Care and Safety

Section 2

1-9

Chart definitions Icon identifier

Typical Lubrication Chart JS200/210/220 NC/SC/LC

Excavator grease

Hydraulic tank breather filter change

Engine oil change

Hydraulic oil filter change

Engine oil filter change

Hydraulic oil filter clean

Engine coolant change

Hydraulic oil level

Engine air filter change

Engine oil level

Engine air filter clean

Fuel tank level

Transmission oil change

Drain off water/sediment

Transmission oil level

When using hammer/crusher/ pulveriser

Fuel (diesel)

When using bio-degradeable oil

Fuel filter change

When using in wet or severe conditions

Hydraulic oil change 817/18523

Location identifier A B C D E F G

Travel gearbox Engine oil filter Plexus filter Engine oil pan Engine cooling system Servo oil filter Fuel filter

H J K L M N P

Swing ring bearing Air cleaner, outer Air cleaner, inner Drain line filter Fuel separator Hydraulic return filter Hydraulic tank air breather

Q R S T U V W

A B C D E F

Suction strainer Hydraulic tank Swing ring gear teeth Fueltank Slew gearbox Boom/arm grease points Boom/arm grease points

Holding circuit pressure Refer to operators manual before attempting to lift Working circuit pressure For complete swing of upper structure Lift with bucket cylinder retracted Mass of counterweight

Issue 1

Section 2

Care and Safety

Section 2

Section 3

Routine Maintenance

Section 3

i Contents Identification of Machine Components

1-1

Lubricants - Health and Safety Hygiene Storage Handling First Aid - Oil Spillage Fires

2-1 2-1 2-1 2-1 2-1 2-1

Service Capacities and Lubricants

3-1

Service Schedules

3-2

Checking for Damage

4-1

Cleaning the Machine

4-1

Daily Checks

5-1

Greasing

6-1

Fuel System Types of fuels Filling Tank and Check Fuel Level Changing Fuel Filter Element * Cleaning Lift Pump Strainer Draing Fuel Tank Impurites Draining Sediment Bowl Bleeding the Fuel System

7-1 7-1 7-2 7-2 7-3 7-3 7-4

Engine Changing the Oil and Filter Checking Oil Level Changing the Air Filter Adjustment/Changing Fan Belt Checking Coolant Level Cleaning the Radiator and Oil Cooler Changing Coolant 8 - 7 Hydraulic System Checking the Hydraulic Fluid Level Releasing Tank Pressure Topping-up Fluid Level Changing the Hydraulic Fluid Draining Water and Sediement from the Hydraulic Tank Cleaning/Changing Suction Strainer Changing the Return Filter Changing the Plexus Filter Changing the Air Breather Element Changing the Servo Oil Filter (Pilot) Changing the Breaker In-line Filter Changing the Drain Line Filter Air Bleeding from Hydraulic Pump Air Bleeding from Rams Air Bleeding from Slew Motor

Page No.

8-1 8-1 8-2 8-4 8-6 8-6

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

Issue 2*

Section 3

Routine Maintenance

Section 3

ii Contents Battery * Checking Electrolyte Battery Disconnection/Relplacement Terminal Cleaning Warning Symbols

Page No. 10 - 1 10 - 2 10- 2 10 - 3

Slew Unit Checking the Slew Gearbox Oil Level Changing the Slew Gearbox Oil

11 - 1 11 - 1

Travel Gear Box Checking the Track Gearbox Oil Level Changing the Track Gearbox Oil

12 - 1 12 - 1

Tracks and Running Gear Checking/Adjusting the Track Tension 13 - 1 Checking Rollers and Idler Wheels for Oil Leaks 13 - 2 Cleaning the Tracks 13 - 3

Bucket Checking/Adjusting for Side Play

14 - 1

Safety Related Components Periodic Replacement

15 - 1

Trouble Shooting

16 - 1

Issue 2*

Section 3

Routine Maintenance

Section 3

1- 1

1-1

Identification of Machine Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Bucket Bucket Link Dipper Link Bucket Ram Dipper Dipper Ram Boom Boom Ram Operatorâ&#x20AC;&#x2122;s Cab Slew Gearbox Fuel Tank Hydraulic Oil Tank Battery Air Cleaner Engine and Radiator Counterweight Slew Ring Track Plate Track Gearbox Lower Roller

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Upper Roller Recoil Spring Idler Wheel Front Attachment Pin Engine Oil Pan Servo (Pilot Line) Filter Fuel Filter Engine Oil Filter Return Filter Suction Strainer Drain Line Filter Air Filter Air Breather Plexus Filter Breaker Filter Hydraulic Pump Main Valve block

401910

Issue 1

Section 3 2-1

Routine Maintenance

Section 3

Lubricants - Health and safety

It is most important that you read and understand this information and the publications referred to. Make sure all your colleagues who are concerned with lubricants read it too.

2-1

Apply a barrier cream to the skin before handling used oil.

Note the following when removing engine oil from skin:

Hygiene

Wash your skin thoroughly with soap and water.

JCB lubricants are not a health risk when used properly for their intended purposes.

Using a nail brush will help.

Use special hand cleansers to help clean dirty hands.

Never use petrol, diesel fuel, or paraffin for washing.

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

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

Waste Disposal All waste products should be disposed of in accordance with all the relevant regulations. The collection and disposal of used oil should be in accordance with any local regulations. Never pour used engine oil into sewers, drains or on the ground.

Avoid skin contact with oil soaked clothing.

5 6

Donâ&#x20AC;&#x2122;t keep oily rags in pockets. Wash dirty clothing before re-use.

Throwaway oil-soaked shoes.

First Aid - Oil Eyes. In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention. Swallowing. If oil is swallowed do not induce vomiting. Get medical Iadvice. Skin. In the case of excessive skin contact, wash with soap and water.

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

Handling

Fires

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

Extinguish with carbon dioxide, dry chemical or foam. Firefighters should use self-contained breathing apparatus.

Used Oil Used engine crankcase lubricants contain har mful contaminants. Here are precautions to protect your health when handling used engine oil: 1

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

Issue 1

Section 3

Routine Maintenance

3-1

Section 3

Service Capacities and Lubricates

3-1

JS200/JS210/JS220/JS240/JS260 and Variants JS200-JS220 Capacity

JS240/260 Capacity

21.5 litres (4.7 UK gal) (5.64 US gal)

21.5 litres (4.7 UK gal (5.64 US gal

API-GL-5, MIL-L-21 05

2 x 4.7 litres (2 x 1 UK gal) (2 x 1.2 US gal)

2 x 4.7litres (2 x 1 UK gal) (2 x 1 .2 US gal

JCB HD90 Gear Oil

API-GL-5, MIL-L-21 05

5 litres (1.09 UK gal) (1.31 US gal)

6 litres (1.3 UK gal) (1.56 US gal)

TRACK ROLLERS AND IDLER WHEEL

JCB HD90 Gear Oil

API-GL-5, MIL-L-21 05

RECOIL SPRING CYLINDER

JCB Special HP Grease

Lithium complex (NLGI) inc. extreme pressure additives

HYDRAULIC SYSTEM

JCB Hydraulic Fluid 46

200 litres (44 UK gal) (52.8 US gal)

241 lit res (53 UK gal) (63.6 US gal)

Item

Lubricant

International Specification

ENGINE

(see separate chart)

TRACK GEARBOX

JCB HD90 Gear Oil

SLEW GEARBOX

ISO VG46

SLEW RING - BEARING

JCB Special HP Grease

Lithium complex (NLGI) inc. extreme pressure additives

- GEAR TEETH

JCB Special HP Grease

Lithium complex (NLGI) inc. extreme pressure additives

17 kg (37.48 Ib)

ALL OTHER GREASE POINTS

JCB Special HP Grease

Uthium complex (NLGI) inc. extreme pressure additives

COOLING SYSTEM

see Coolant Mixtures

25.5 litres (5.6 UK gal) (6.7 US gal)

26.8 litres (5.9 UK gal) (7.1 US gal)

FUEL TANK

see Type of Fuel

343 litres (75.5 UK gal) (90.6 US gal)

17 kg (37.48 Ib)

ENGINE LUBRICATION CHART Use according to ambient temperature (OC) -30

-20

-10

JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F

JCB SUPER 10W/30 MULTIGRADE ENGINE OIL LA I API CF4/SG MIL L-2104F

Issue 2*

Section 3

Routine Maintenance

3-2

Section 3

Service Schedules

3-2

Regular Maintenance and Lubrication Schedules A poorly maintained machine is a hazard. Doing the regular maintenance and lubrication jobs listed in these schedules will help keep the machine in safe running order.

Initial Precautions for New Machine Usage :-

Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hour meter reading. Do not use a machine which is due for a regular service. Rectify any defects found during regular maintenance before clearing the machine for use.

If the machine is operated at full load before its initial run-in procedure is complete it may cause scuffing and seizing which can adversely effect the life of the machine.

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

CAUTION

8-3-1-5

A new machine is only dispatched when all inspection procedures are complete, but operating it under severe conditions from new will affect its performance and shorten its service life. 1

Carry out the daily inspection procedure.

Always warm up the machine (see Warming-up under Using Your Machine).

Check to see if the machine is running normally.

Avoid running or slewing the machine rapidly. â&#x20AC;&#x2DC;-

Avoid sudden shocks e.g. suddenly stopping the boom when lowering.

Where applicable, grease the front pins daily.

Issue 1

Section 3 3-3

Routine Maintenance Service Schedules

Section 3 3-3

Every 10 Operating Hours or Daily

Every 250 Operating Hours or Monthly

Whichever occurs first

1 Clean a Machine generally.

1 2

2 Grease (If operating in very wet or severe conditions) a Boom/bucket/dipper pivot points. (except boom base and boom/dipper pivot - bushes)

3 Check (Engine Stopped) a Generally for damage. b For oil and coolant leakage. c Security of bolts and nuts â&#x20AC; . d For disconnected or shorted wiring, loose terminals. e Hydraulic fluid level. f Engine oil level. g Track tension. h Windscreen washer fluid level. j Fuel system for leaks. k Fuel level. I The auxiliary circuit hydraulic oil filter visual indicator (if using a rockbreaker)

Check (Engine Stopped) a b c d e f g h j k I m n 0 p

â&#x20AC; Tapping with a hammer will identify any loose nuts and bolts which should then be tightened to the specified torque. 4 Check (Engine Running) a Operation of warning lights and audible alarm. b Operation of other electrical equipment. c Exhaust for excessive smoke. d Excavator operation. e Transmission operation. f Operation of track and slew brakes. g Operation of hour meter.

Do a 50 hour service plus: Clean a Drain water and deposits from hydraulic oil tank. b Air cleaner dust valve. c Pre-cleaner a Battery terminals. Grease a Door and canopy hinges. b Slew ring bearing.

Battery electrolyte level. Security of major unit mounting bolts and nuts. If loose, tighten to specified torque. Track and slew gearbox oil level. Fan belt adjustment. Air inlet system security Hoses and pipework for chafing or damage. Condition of ram piston. Bucket pivot pin grease seals. Track plate condition and bolt torque. Track and running gear. Top and bottom track rollers for oil leaks . Track idler wheels for oil leaks. Wiring for chafing. Radiator for damage. Oil cooler for damage.

Check (Engine Running) a Operation of throttle system. b Operation of overload warning. c Operation of stop control.

Every 50 Operating Hours or Weekly Whichever occurs first 1 Do the daily jobs plus: 2 Clean a Drain water and sediment from fuel tank. b Drain fuel water separator. 3 Grease a All pivot pins. (except boom base and boom/dipper pivot-bushes)

Issue 2*

Section 3

Routine Maintenance

3-4

Section 3

Service Schedules

3-4

Every 500 Operating Hours or 3-Monthly

Every 1000 Operating Hours or 6-Monthly

Whichever occurs first

1 2

Do a 250 hour service plus: Clean a Radiator, grille and oil cooler fins. b Fuel lift pump strainer t. c Hydraulic fluid suction strainer t.

1 2

Do a 500 hour service plus: Clean a Fuel lift pump strainer. b Hydraulic fluid suction strainer.

3 3

Grease a Slew ring teeth.

Grease a Pivot pins. (including boom base pivot and boom/ dipper main pivot bushes).

Change a Engine oil. b Engine oil full flow filter element. c Fuel filter element. d Engine oil filter by-pass element. e Servo oil filter element t. f Return filter element t. g Drain filter element t. h Track and slew gearbox oil level t.

Change (Engine Stopped) a Engine air filter element (outer). b Hydraulic tank air breather element. c Track and slew gearbox oil. d Return filter element.†† e Plexus filter.†† f Servo oil filter element.†† g Drain filter.††

5 5

Check (Engine Stopped) a Fan belt adjustment. b Accumulator operation. c Battery electrolyte level. d Exhaust system security. e Teeth and sidecutters. f Top and bottom track rollers for oil leaks. g Track idler wheels for oil leaks. h Hydraulic oil (check the degradation and cleanliness by sampling). j Seat belt condition and security.

Check (Engine Stopped) a Track wear. b Valve clearance. c Engine oil (check the degradation and cleanliness by sampling).

Every 2000 Operating Hours or Yearly

Check (Engine Running) a Operation of throttle system. b Operation of overload warning. c Operation of stop control.

† These procedures are only to be carried out after the first 500 hours use of a new machine. Thereafter they are to be carried out as detailed in the following periodic checks.

Whichever occurs first 1

Do a 1000 hour service plus:

Check (Engine Stopped) a Sample hydraulic oil and replace if necessary.

Change a Hydraulic fluid suction strainer. b Engine air filter element (inner). c Hydraulic Oil (for machines with biodegradable oil).

Every 4000 Operating Hours or 2 Years Whichever occurs first 1 2

Do a 2000 hour service plus: Change a Long life coolant. b Fuel hose (fuel tank - engine). c Fuel hose (fuel filter - injection pump). d Hydraulic pump exit hose (pump - operation valve). e Boom ram line hose. f Dipper ram line hose. g Bucket ram line hose.

†† If using a breaker, crusher or pulverizer, see revised servicing schedules.

Issue 2*

Section 3 3-5

Routine Maintenance Service Schedules

Section 3 3-5

Every 5000 Operating Hours or 2 Years 6 Months Whichever occurs first 1 2

Do a 1000 hour service plus: Change Hydraulic oil (for machines with non biodegradable oil). Hydraulic tank air breather element. Hydraulic suction filter. tt

â&#x20AC; â&#x20AC; If using a breaker, crusher or pulverizer, see revised servicing schedules.

Issue 1

Section 3

Routine Maintenance

3-6

Section 3

Service Schedules

3-6

Service Intervals for Hydraulic Oil and Filters when using a Breaker, Crusher or Pulverizer 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 problems in the control valve, premature wear of the hydraulic pump and damage to the hydraulic system as a whole. 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 fitted, ensure 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. Consult your JCB Distributor who will have the facilities to do this work and ensure that the hydraulic system is properly maintained.

Service Intervals for Hydraulic Oil and Filters according to Frequency of Breaker, Crusher or Pulverizer Use

Item

Time (hrs)

Hydraulic Oil

Use Freauency 100%

Use Frequency 40%

Use Frequency Use Frequency 20% 10%

600

100

300 1500

800 4000

Suction Filter

Drain Filter

Servo Filter

Plexus Filter

Breaker In-Line Filter

Every 200 hrs

Every 300 hrs

Every 600 hrs

Check oil level and top up as required

Change

Return Filter

Hydraulic Oil Sampling

600 3000

Every 800 hrs

Clean

Note: 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.

Issue 1

Section 3 4-1

Routine Maintenance

Section 3

Checking For Damage

Inspect steelwork for damage. Note damaged paintwork for future repair.

4-1

Check all bucket teeth for damage and security. Check all lamp lenses for damage.

Make sure all pivot pins are correctly in place and secured by their locking devices. Ensure that the steps and handrails are undamaged and secure. Check for broken, cracked or crazed window glass. Replace damaged items.

Check that all safety decals are in place and undamaged. Fit new decals where necessary. Check for sufficient track tension and any loose Track Plate bolts.

Cleaning the Machine

Exterior Clean the exterior of the machine using water and/or steam. If steam is used the machine must be completely greased afterwards. (See Greasing). Pay particular attention to the cab windows. Make sure that the radiator grille is not blocked.

Interior

Do not allow mud to build up on the tracks and running gear. (See Tracks and Running Gear).

Issue 1

Section 3

Routine Maintenance

5-1

Section 3

Daily Checks

5-1

Daily Checking It is vital to check certain machine functions and components daily to ensure that the machine can be operated safely and efficiently. 1

Engine (Inspection Before Starting) a Follow steps 1-3 of daily checking.

Prepare the Machine Park the machine on level ground, lower the bucket to the ground.

Locate the Components to be Checked (See Identification of Machine Components).

Engine oil level check and refilling , Check the oil level before starting the engine and 30 minutes or more after stopping the engine. Use dipstick A to check that the oil level is correct. If low, refill with engine oil through oil filler port B. Re-check the oil level about 10-15 minutes after refilling.

WARNING The coolant system is pressurised when the coolant is hot. Hot coolant will burn you. Make sure that the engine is cool before checking the coolant level or draining the system. 2-3-3-3

Stop the Engine Remove the starter key.

Visual Check Check the machine for the following: a Oil, fuel and coolant leakage. b Fasteners properly attached. c Wire breakage, short circuit of cables and terminal anchorage. d Oil cleanliness. e Dust accumulation.

Coolant level check and refilling. Check the level of coolant in the reserve tank C. Remove the reserve tank cap D and refill with coolant. The correct level is between the FULL and LOW markings.

Checking After Initial Start-up a Operation of horn and gauges. b Ease of engine starting, abnormal noise and exhaust gas colour. c Oil, fuel and coolant leakage.

428050

403620

Issue 2*

Section 3

Routine Maintenance

5-2

Daily Checks

Section 3 5-2

Daily Checking (contâ&#x20AC;&#x2122;d) 7

Fuel level check a Check the fuel level by inspecting the fuel gauge A located on the front of the tank and the monitor display. If low, refill through the fuel filler port B.

Crawler a Check the shoes E for looseness, wear and breakage. b Check the track motor, F upper/lower rollers G, H and idler wheel J for oil leakage and wear.

Note: The illustration below is only typical. The number of upper rollers G and lower rollers H varies according to the machine model. c

Check each mounting bolt for looseness and/or missing bolts.

JS03642

WARNING DO NOT remove the hydraulic tank filler or cover plate when the engine is running.The hydraulic system is under pressure. You or others could be injured. First stop the engine and then release the pressure. 8-3-4-4/2

Hydraulic oil level check and refilling a Follow steps 1-3 of the daily checking procedure leaving the boom, dipper and bucket positioned as shown above. b Check to see that the hydraulic oil level is near the centre of the level gauge C c If it is low, remove the filler plug D and refill. Take care that no dirt or dust gets into the hydraulic oil when refilling. d Check the mounting bolts of the fuel and hydraulic oil tanks for looseness and for fuel and hydraulic oil leakage. e Check the mounting bolts of the electrical parts and battery terminals for looseness and wire breakage.

10 Boom/Dipper a Check the high pressure hoses/joints and the hydraulic rams for oil leakage. 11 Bucket and Linkage. a Check the bucket teeth and side cutter for looseness, wear and breakage b Check the lubr ication of the linkage K and surrounding parts. Check to see if the bucket side play is within allowable range. (Refer to the Bucket Section for side play adjustment.)

JS03755

Issue 2*

Section 3

Routine Maintenance

6-1

Section 3

Greasing

General Notes For the type of grease to use at each point, (see Lubricants and Capacities). Do not mix different types of grease. Keep them separate.

6-1

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

Slew Ring Bearing 1

The two grease nipples are grouped together on the front of the machine and one on the front of the ring.

Slew Ring Teeth and Slew Pinion Ensure slew ring is kept full of grease. Always grease whenever the machine has been steam-cleaned. For location of the slew ring gear refer to Identification of Machine Components. 1 2

Make the Machine Safe Stop the engine and remove the starter key. Grease the Slew Ring a 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. Slew the Machine Start the engine and slew the machine a few degrees. Stop the engine, remove the starter key and apply grease again.

JS03671

Repeat until the whole ring is greased. Check that grease exudes around the entire circumference. 4

Refit the Cover

Issue 2*

Section 3

Routine Maintenance

6-2

Section 3

Service Schedules

6-2

Excavator End

WARNING You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started.

Greasing Point

Grease Points

Hours

Boom Base

1000

Boom ram, eye end pin

Dipper ram, dump end pin

Boom ram, dump end pin

Bucket ram to Bucket linkage

Bucket linkage to Bucket pin

Dipper to Bucket Linkage pin

Dipper to Bucket pin

Bucket ram, dump end pin

Dipper ram, eye end pin

Boom to Dipper, connecting pin

1000

TAB positioning ram, dump end pin 1

TAB positioning ram, eye end pin

TAB upper/lower boom pivot pin

8-3-1-3

429301

JS03482

JS03722

JS03750

Issue 2*

Section 3

Routine Maintenance

7-1

Fuel System

Types of Fuel Use good quality diesel fuel to get the correct power and performance from your engine. The recommended fuel specification is given below. Cetane Number : Viscosity : Density : Sulphur :

Section 3

45 (minimum) 2.5/4.5 centistokes at 40°C (104°F) 0.836/0.866 kg/litre (1.046/1.084 Ib/pint) 0.5% of mass (maximum)

Filling the Tank and Fuel Level Checking For location of fuel tank refer to Identification of Machine Components at the end of this section

WARNING Diesel fuel is flammable. Keep flames away from the machine. Do not smoke while fuelling the machine or working on the engine. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions.

Distillation : 85% at 350°C (662°F)

INT-3-2-2

Cetane Number Indicates ignition performance. Fuel with a low cetane number can cause cold start problems and affect combustion.

Viscosity This is the resistance to flow. If this is outside limits, the engine performance can be affected. Density Lower density will reduce engine power. Higher density will increase both engine power and exhaust smoke. Sulphur High sulphur content can cause engine wear. (High sulphur fuel is not normally found in North America, Europe or Australia). If you have to use a high sulphur fuel you must also use a highly alkaline engine lubricating oil; or change the normal oil more frequently. Distillation This indicates the mixture of different hydrocarbons in the fuel. A high ratio of lightweight hydrocarbons can affect the combustion characteristics.

7-1

Prepare the Machine Park the machine on level ground. Lower the bucket to the ground. 2. Stop the Engine Remove the starter key. 3 Filling the tank a At the end of every working day, fill the tank with the correct type of fuel. This will prevent overnight condensation from developing in the fuel tank. b We recommend that you lock the fuel cap to prevent theft and tampering. c After filling, check the fuel level by looking at the fuel gauge. Petrol

WARNING Do not use petrol in this machine. Do not mix petrol with, the diesel fuel, in storage tanks the petrol could rise to the top and form flammable vapours. INT-3-1-6

Low Temperature Fuels Special winter fuels may be available for engine operation at temperatures below DoC (32°F). These fuels have a lower viscosity. They also limit wax formation in the fuel at low temperatures. (Wax forming in the fuel can stop the fuel flowing through the filter). Flow improvers may also be available. These can be added to the fuel to reduce wax formation. Advice Consult your fuel supplier or JCB distributor concerning the suitability of any fuel you are not sure about. If you have to use non-standard fuels, contact your JCB distributor for advice on engine adjustments and oil change periods. Fatty Acid Methyl Ester Fuels as a replacement for Diesel Fuels Fuel resources such as Rape Methyl Ester and Soybean Methyl Ester, collectively known as Fatty Acid Methyl Esters are being used as alternatives and extenders for mineral oil. Fatty Acid Methyl Esters must conform to certain standards to be of acceptable quality, just as mineral oils do at present. Consult your JCB distributor for advice about the use of Fatty Acid Methyl Ester fuels, as improper application may impair engine performance.

Issue 2*

Section 3

Routine Maintenance

7-2

Fuel System

Section 3 7-2

Changing the Fuel Filter Element

WARNING Fuel oil is highly flammable. Completely wipe off any spilt fuel which could cause a fire. 8-3-4-3

Prepare the Machine Park the machine on level ground, lower the bucket to the ground.

Stop the Engine Remove the starter key.

Open the Engine Compartment Locate the fuel filter.

Remove the Element Using a chain wrench, unscrew the filter element A from the filter head.

Fit the New Element Smear the new filter element sealing ring with fuel oil and hand tighten onto the filter head. Use a chain wrench to tighten by a further 2/3. Bleed the system (see Bleeding the Fuel System) Wipe up any spilt fuel.

* Cleaning the Lift Pump Strainer 1

Stop the Engine

Switch off the engine and remove the key. Disconnect the battery

Open the Engine Compartment Locate the priming pump B.

Remove the Pump Strainer Unscrew banjo bolt C and remove complete with strainer D.

Clean the Strainer

WARNING When using compressed air, wear safety glasses and gloves. Do not direct compressed air at your skin. 8-3-4-2

Blow clean with compressed air and then rinse in clean fuel oil. 6

Refit the Pump Strainer Insert the clean strainer into the banjo bolt and refit the bolt to secure the pump feed pipe. Do not overtighten.

Issue 2*

Section 3

Routine Maintenance

7-3

Fuel System

Section 3 7-3

Draining Fuel Tank Impurities 1

Stop the engine and remove the key.

Remove screws and take off the cover plate from below the fuel tank.

Position a suitable container under the drain tap.

Loosen the drain tap X on the underside of the fuel tank. Drain the water and deposits until clean diesel oil flows out.

Close the drain tap firmly and refit cover.

WARNING Fuel oil is highly inflammable. Completely wipe off any I spilt fuel which could cause a fire. 8-3-4-3 401801

Draining the Water Separator The water separator should be drained at least every 50 hours, but more often if necessary. 1

Stop the engine and remove the key.

Drain off any water in the bowl by turning tap A.

Make sure tap A is turned off and secure.

Cleaning the Water Separator If the bowl B contains sediment carry out the following: 1

Hold the bowl B and unscrew the domed nut C.

Remove the bowl, wash the bowl in clean fuel.

Clean strainer D.

Refit the bowl. Make sure the gasket is in good condition and positioned correctly.

Retighten the nut C, take care not to over tighten.

Bleed the fuel system. See Bleeding the Fuel System.

Issue 2*

Section 3

Routine Maintenance

7-4

Fuel System

Section 3 7-4

Bleeding the Fuel System Air in the fuel system could cause misfiring or failure to start. Air will enter the system if any part of it is disconnected or emptied. Note: Running the engine with air in the system could damage the fuel injection pump. After maintenance, remove air from the fuel system as detailed below. 1

Stop the Engine Switch off the engine and remove the key.

Disconnect the Battery Remove the -ve lead to chassis.

Open the Engine Compartment Locate the priming pump.

Prepare for Bleeding Loosen the knob A on the priming pump B by turning it anti-clockwise. The knob will be lifted by spring pressure.

Bleed the System a Loosen the eye bolt C. Operate the priming pump knob A until fuel filter is full.

Next, tighten the eye bolt C, and continue to move the feed pump handle.

When the handle becomes difficult to move and the air is heard being expelled, then air bleeding is complete.

Restore the System to Normal Depress knob A and turn clockwise to lock into the priming pump B.

WARNING Fuel oil is highly inflammable. Completely wipe off any spilt fuel which could cause a fire. 8-3-4-3

Wipe up any spilled fuel. Then start the engine and check for leaks.

Issue 2*

Section 3

Routine Maintenance

8-1

Engine

Section 3 8-1

Changing the Oil and Filter

CAUTION Hot oil and engine components can burn you. Make sure the engine is cold before doing this job. 2-3-3-2

Prepare the Machine Park the machine on level ground. Lower the bucket to the ground.

Stop the Engine a b

Remove the starter key. Let the engine stand until it is warm. Do not check the oil straight after the engine has stopped, the oil level indicated will actually be lower than it is.

Drain the Oil a

Place an oil collecting container of suitable size beneath the engine sump drain point.

Note: The machine is fitted with a self sealing drain plug A.

Remove the self sealing drain plug outer threaded cover.

Fit the self sealing drain kit threaded union (with attached pipe) B and drain sump oil into a suitable container.

Remove the self seal drain kit, clean and refit the outer cover. (Do not over tighten the cover).

Change the Filters a b c d e

Remove the filter D. Clean the filter head. Smear the seal on the new filter D with oil. Tighten the filter until the seal bites onto the filter housing. Tighten the filter a minimum of one more full turn.

Fill the System Fill the engine with new oil through filler C (see Lubricants and Capacities) for the type and amount. Wipe off any spilt oil. Check for leaks. Make sure the filler cap is correctly refitted.

Check for Leaks Before starting the engine, turn the engine over with the Emergency Stop Button ON until the oil pressure warning light goes out. Allow the engine to stand before checking the oil level (see Checking the Oil Level).

Checking the Oil Level 3

Open the Engine Compartment

Check the Oil Level Locate the dipstick E and remove. Oil should be between the two marks. Add oil if necessary through filler C. Use only the recommended oil, (see Lubr icants and Capacities). Re-check the oil level about 10-15 minutes after refilling. Make sure that the dipstick and filler cap are secure.

Issue 2*

Section 3

Routine Maintenance

8-2

Section 3

Engine

8-2

Air Filter Changing the Outer Element

CAUTION The outer element must be renewed immediately if the warning light on the instrument panel illuminates.

Stop the engine.

Press clips A and lift off cover B. Remove outer element C. Take care not to tap or knock the element.

Clean the inside of cover B and canister D.

Insert a new element into the canister, check seal E is fully seated. Fit cover B with dust valve F at the bottom. Push the cover firmly into position and make sure it is secured by clips A.

Make sure that the wire is connected to the Air Filter Blocked switch.

Check all hoses for condition and tightness.

2-3-3-1

Note: Do not attempt to wash or clean the elements - they must only be renewed. Note: Do not run the engine with the dust valve F removed. Note: Change the outer element more frequently if operating in dusty conditions. A new inner element must be fitted at least every third time the outer element is changed. As a reminder, mark the inner element with a felt tipped pen each time the outer element is changed.

A336941

Issue 1

Section 3

Routine Maintenance

8-3

Section 3

Engine

8-3

Air Filter

Clean the inside of cover B and canister D.

Changing the Inner Element

Note: Do not attempt to wash or clean the elements - they must only be renewed.

Carefully insert the new inner element G into the canister. Make sure it seats correctly. Check seal H is fully seated.

Insert a new outer element C into the canister, check seal E is fully seated. Fit cover B with dust valve F at the bottom. Push the cover firmly into position and make sure it is secured by clips A.

Make sure that the wire is connected to the Air Filter Blocked switch.

Check all hoses for condition and tightness.

Note: Do not run the engine with the dust valve F removed. Note: A new inner element must be fitted at least every third time the outer e.iement is changed. As a reminder, mark the inner element with a felt tipped pen each time the outer element is changed. 1

Stop the engine.

Press clips A and lift off cover B. Remove outer element C.

Lift up pulls J and remove inner element G.

A336941

Issue 1

Section 3

Routine Maintenance

8-4

Engine

Section 3 8-4

Checking the Fan Belt Tension

WARNING Make sure that the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5

Prepare the Machine Put the machine on level ground, lower the bucket to the ground.

Stop the Engine Remove the starter key.

Check the Fan Belt Tension There must be 10 mm (0.4 in) slack midway between the altemator and water pump.

Loosen the Alternator Slacken bolts A and B.

Adjust the Fan Belt a Use a lever to re-position the alternator so as to adjust the fan belt tension.

A344071

Note: If the fan belt is stretched so much that it cannot be adjusted correctly, fit a new belt.

While levering the alternator pinch the bolt A and check the tension on the belt.

If it is not correctly tensioned complete steps 4 and 5.

When correct tension is achieved fully tighten bolts A and B.

Issue 1

Section 3

Routine Maintenance

8-5

Engine

Section 3 8-5

Fitting a New Fan Belt Complete steps 1 and 2. 1

Loosen the Alternator Slacken bolts A, B and adjust plate C so that the alternator is levered towards the engine, so that the fan belt D can be removed.

Fit a New Fan Belt Remove the fan belt D and replace it with a new one, make sure the â&#x20AC;&#x2DC;Vâ&#x20AC;&#x2122; profile locates in the pulleys correctly.

Note: It may be necessary to apply leverage to the new belt to get it over the pulleys. 3

Adjust the Fan Belt Carry out step 5 of Adjusting the Fan Belt.

Re-check the Fan Belt Tension Check after running the machine for 1 hour.

A344071

Issue 1

Section 3

Routine Maintenance

8-6

Engine

Section 3 8-6

Checking the Coolant Level 1

Park the Machine on Level Ground Stop the engine and let it cool down. Open the engine compartment.

WARNING The cooling system is pressurised when the coolant is hot. Hot coolant will burn you. Make sure that the engine is cool before checking the coolant level or draining the system. 2-3-3-3

Release System Pressure For location of engine cooling radiator, refer to Identification of Machine Components. Carefully slacken cap A. Let any pressure escape. Remove the cap.

3 Check the Level The radiator should be filled completely and the level in the expansion bottle C should be between the FULL and LOW marks. Remove the Cap B and Top-up the bottle with premixed water/antifreeze if necessary. Refit Cap B (See Coolant Mixtures). 4

Refit the Pressure Cap A Make sure it is tight.

Note: Check the quality of the antifreeze mixture every year before the cold weather starts. Change it every two years.

Cleaning the Radiator and Oil Cooler

A344180

A clogged radiator and/or oil cooler can lead to engine overheating. Regularly check for a build-up of dirt and debris and if necessary, use compressed air to clean-out the grille. At the same time check all hoses for damage or perishing, and replace if necessary.

Issue 1

Section 3

Routine Maintenance

8-7

Section 3

Engine

8-7

Changing The Coolant

Coolant Mixtures

Do Steps 1 and 2 of Checking the Coolant Level.

Drain the system.

To prevent the coolant freezing in cold conditions, antifreeze must be added. JCB Four Seasons Antifreeze and Summer Coolant will give protection down to the temperatures shown in the table.

Remove the radiator pressure cap. Open the radiator drain tap A. Remove the cylinder block drain plug B. Remove the expansion bottle cap (see Checking the Coolant Level). Let the coolant drain out.

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

Antifreeze Solution 55%

Starts to freeze at -36°C (-33°F)

Never use less than a 50% solution, otherwise there will not be enough corrosion protection. Never use more than 60% solution, otherwise the cooling system may be damaged.

Flush the system If necessary. Use clean water.

Leave the antifreeze in all the year round as it gives. protection against corrosion.

Refit the drain plug Clean and refit the cylinder block drain plug, making sure it is tight. Close the radiator drain tap.

Check the strength of antifreeze solution at least once a year, preferably at the start of the cold period. Always renew the antifreeze every two years.

Fill the system Using the necessary mix of clean, soft water and antifreeze (see Coolant Mixtures) fill via the expansion bottle cap until the level in the bottle is between the FULL and LOW marks.

A 50% antifreeze mixture should be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant’s boiling point.

Refit the Radiator Pressure Cap Make sure it is tight.

Refit the Expansion Bottle Cap Make sure it is tight.

Check for Leaks Run the engine for a while to raise the coolant to working temperature and pressure. Stop the engine. Check for leaks. Re-check the level in the expansion bottle and top up if necessary.

Issue 1

Section 3

Routine Maintenance

9-1

Hydraulic System

Section 3 9-1

WARNING The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools down (less than 40Â°C) before beginning maintenance. 8-3-4-10

WARNING Hydraulic Fluid Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin get medical help immediately. INT-3-1-10/1

Checking the Hydraulic Fluid Level 1

Prepare the Machine Position the machine on level ground with the bucket and dipper rams fully extended and the boom lowered to rest the attachment on the ground, as at A.

Check the Level Look at the fluid level in the sight tube B. The level should be between the two marks on the tube. If the fluid is cloudy, water or air has entered the system.

JS03641

Water or air in the system could damage the hydraulic pump.

Issue 1

Section 3

Routine Maintenance

9-2

Hydraulic System

Section 3 9-2

Releasing Tank Pressure

WARNING DO NOT remove the hydraulic tank filler cap or cover plate when the engine is running.The hydraulic system is under pressure. You or others could be injured. First stop the engine and then release the pressure. 8-3-4-4/1

Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key.

Locate the Hydraulic Oil Tank Filler Plate C Refer to Identification of Machine Components.

Release Tank Pressure Remove the box nut B of the breather on top of the hydraulic oil tank, press the projection and release the pressure from the tank.

Topping-up Fluid Level 1

Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key.

Release Tank Pressure (See Releasing Tank Pressure)

Add Fluid a

Remove plug C

Refill oil through the filler por t using a suitable tundish.

Check the level through the level gauge on the side of the tank.

Refit plug C.

JS 03610

Issue 1

Section 3

Routine Maintenance

9-3

Section 3

Hydraulic System

9-3

Changing the Hydraulic Fluid 1

Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key.

Locate the Filler Port and Drain Plug

Release Tank Pressure (See Releasing Tank Pressure)

Remove the Oil a Remove cover A and a-ring B. b

Use a pump and discharge the hydraulic oil into an empty container.

Remove the drain plug C on the bottom of the tank and drain the remaining oil from the tank.

Note: Have a drain pan ready. 5

Renew the Suction Strainer D and Return Filter E (See Changing the Suction Strainer and Changing the Return Filter).

Tighten the Drain Plug C Securely

Refill the tank with the specified oil to the specified level.

Seal the System a Install the a-ring B and filler port cover A.

JS03760

Note: If the a-ring is damaged, replace it with a new one. 9

Bleed air from the hydraulic components (See Air Bleeding Procedures).

10 Start the engine and run it for 5 minutes without load. Slowly operate the rams several times and then put the machine in the hydraulic oil checking position. 11 Check that the hydraulic oil is within the proper range.

Issue 1

Section 3

Routine Maintenance

9-4

Hydraulic System

Section 3 9-4

Draining Water and Sediment from the Hydraulic Tank 1

Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key.

Release Tank Pressure (See Releasing Tank Pressure).

Draining the Water and Sediment Carefully loosen the drain plug A on the bottom of the tank and drain the sediment and water accumulated at the bottom of the tank.

Note: Have a drain pan ready. The task is complete when clean hydraulic fluid flows out. 4

Seal the System Tighten the drain plug A.

JS03761

Cleaning/Changing the Suction Strainer 1

Prepare the Machine on level ground Stop the engine. Remove the starter key.

Locate the Suction Strainer

Release the Tank Pressure (See Releasing Tank Pressure).

Remove the Suction Strainer a Remove the filler port cover A and a-ring B. b

Remove the suction strainer C from the tank and renew.

Fit the Suction Strainer Fitting is a reversal of removal. When changing the suction strainer, fit a new a-ring seal to the filler port cover A and secure the fasteners.

Check the Hydraulic Fluid Level

JS03761

Issue 1

Section 3 9-5

Routine Maintenance Hydraulic System

Section 3 9-5

Changing the Return Filter 1

Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key.

Locate the Return Filter.

Release Tank Pressure (See Releasing Tank Pressure)

Remove the Element a Remove the cover A and O-ring B. b Remove spring C, valve D and return filter E from the tank. Fit a New Element Re-assemble in reverse order using a new filter element E and a new cover a-ring B.

Changing the Plexus Filter 1

Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key.

Locate the Plexus Filter

Release Tank Pressure (See Releasing Tank Pressure).

Remove the Plexus Filter a b c d e

Close the two filter case cocks Band C by turning them to position X. Remove bolts and washers E. Slacken the nuts G and insert the screws F to lift off the cover D. Remove the cover D and remove the a-ring H. Lift up the Plexus filter A carefully and remove. Take care not to drop any sediment.

Fit a New Element a Slowly immerse the new Plexus filter A. Install the O-ring H, cover D, nuts G and bolts F and bolts E. b Torque tighten bolts E to 20Nm (14.75Ibf ft) c Open the cocks Band C by tur ning them to position Y.

Priming the Plexus Filter a Start the engine and set at low idling, loosen plug J, then tighten the plug when hydraulic oil flows out. b Stop the engine, check the hydraulic oil level and top-up if low. (See Checking the fluid level).

Issue 1

Section 3 9-6

Routine Maintenance

Section 3

Hydraulic System

9-6

Changing the Air Breather Element 1

Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key.

Release Tank Pressure (See Releasing Tank Pressure).

Locate the Air Breather Element

Replace the Air Breather Element a Remove first the hexagonal nut A, seal washer B and cover C.

Note: The cover C can only fit in one of two positions because of the slot G in the cover which locates over a similar shaped protrusion on the mounting stud.

Remove the old filter element D together with the sponge packing E.

Replace the old filter element D, with a new one. When installing the new filter element D place the sponge packing E on the element.

JS03660

Refit the Filter cover C a Adjust the cover so that it fits over the stud, and install in the following order: Seal washer B, hexagonal nut A and box nut F.

Issue 1

Section 3

Routine Maintenance

9-7

Hydraulic System

Section 3 9-7

Changing the Pilot Oil Filter (Servo) 1

Prepare the Machine Position the machine on level ground. Stop the engine. Remove the star1er key.

Release Tank Pressure (See Releasing Tank Pressure).

Locate the Pilot Oil Filter (Refer to Identification of Machine Components).

Dismantle the Filter a Using a wrench on the case, unscrew the filter case A from the filter head B.Take care not to spill the oil it contains. b Remove and discard the element C and a-ring D.

Clean the Filter Base and Case Discard any fluid in the filter case. Clean out the case and the underside of the head. â&#x20AC;&#x2DC;

Fit New Filter Components a Coat the new a-ring D with hydraulic fluid and locate in the filter head B. b Coat the seal area of the new element C and install it in the filter case A. c Screw the filter case A to the head B and torque tighten with the wrench.

Torque Settings Item Nm A 24.5 to 34.3

kgf m 2.5 to 3.5

JS03793

Ibf ft 18.07 to 25.5

Note: When refitting the pilot filter bowl after changing the filter element, it is impor1ant that the filter bowl is tightened carefully to avoid damaging the threads in the filter housing.

Changing the Breaker In-line Filter Note: This filter should be changed at the intervals stated in Service Schedules or when the visual indicator X has popped up. DO NOT USE THE BREAKER WITH A BLOCKED FILTER. 1

Prepare the Machine Position the machine on level ground. Stop the engine. Remove the star1er key.

Release Tank Pressure (see Releasing Tank Pressure).

Locate the Filter

Remove the Oil Filter Unscrew and remove filter A from head B.

JS06700

Fit the New Filter Coat the seal of the new filter with clean hydraulic fluid. Screw the new filter into head B and tighten. Check and top up the hydraulic fluid level.

Issue 1

Section 3

Routine Maintenance

9-8

Hydraulic System

Section 3 9-8

Changing the Drain Line Filter 1

Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key.

Release Tank Pressure (see Releasing Tank Pressure).

Locate the Filter

Remove the Oil Filter Unscrew and remove filter A from head B.

Fit the New Filter Coat the seal of the new filter with clean hydraulic fluid. Screw the new filter into head B and tighten. Check and top up the hydraulic fluid level.

Air Bleeding Procedures

JS02830

After replacing the hydraulic oil or repairing or replacing hydraulic components or removing hydraulic pipes, bleed air from the hydraulic circuit.

Bleeding Air from the Hydraulic Pump If the air is not completely bled, damage could occur within the pump. 1

Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key.

Locate the Hydraulic Pump

Temporarily loosen the air bleeding plug C to check that oil does not come out of the plug.

If oil comes out re-tighten the plug, if it does not come out remove the air bleeding plug C and pour hydraulic oil into the pump case through the air bleeding port until the pump body is full. Retighten the bleed plug.

Run the machine at idle for five minutes.

A409710

Issue 1

Section 3

Routine Maintenance

9-9

Hydraulic System

Section 3 9-9

Air Bleeding from Rams If air is not bled from the rams when replaced or repaired, the piston and/or seals may be damaged. 1

Prepare the Machine Idle the engine at low speed and extend and retract each ram 5 times, stopping the ram 100 mm before the end of each stroke.

Bleeding Operate each ram 4 times for the full stroke to completely bleed the air.

Air Bleeding from the Slew Motor If air is not completely bled from the slew motor the motor bearing or other parts may be damaged. 1

Prepare the Machine Position the Machine on level ground, stop the Engine.

Locate the Slew Motor

Checking Oil Procedure a Loosen the Air Bleeding Plug A and check that oil seeps out from the Air Bleeding Port. b c

If no oil comes out, remove the Air Bleeding Plug A, and fill the motor case with Hydraulic Oil. Tighten the Air Bleeding Plug A.

Sealing the System a Idle the Engine at low speed and slowly slew the machine left to right evenly, two times.

Issue 1

Section 3

Routine Maintenance

10 - 1

Section 3

Battery

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

10 - 1

Checking the Electrolyte Level Maintenance free batteries used in normal temperate climate applications should not need topping up. However, in certain conditions (such as prolonged operation at tropical temperatures or if the alternator overcharges) the electrolyte level should be checked as described below. 1

Open the Battery Compartment A Remove the bolts securing the metal plate above the batteries. Remove the plate.

Set all switches in the cab to OFF before disconnecting the battery. When disconnecting the battery, take off the earth (-) lead first. When reconnecting, fit the positive (+) lead first. Re-charge the battery away from the machine, in a wellventilated 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.

First Aid - Electrolyte

JSO3353

Do the following if electrolyte:

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

Check the Level Remove the covers and check the electrolyte level in each cell. The electrolyte should be 15 mm (0.6 in) above the plates. Top-up if necessary with distilled water or de-ionised water.

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

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

GETS INTO YOUR SKIN Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.

Check the Connections Make sure that the terminals are tight and clean. Coat them with petroleum jelly to prevent corrosion.

5-3-4-3/1

CAUTION Do not disconnect the alternator, the battery, or any part of the charging circuit with the engine running. 8-3-4-1

A361680

Issue 1

Section 3

Routine Maintenance

10 - 2

Battery

10 - 2

Battery Disconnection/Replacement

Terminal Cleaning

Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key.

Open the Battery Compartment a Disconnect the earth - terminal first. For connection, connect the earth - terminal last. b If removing the battery, remove the bolts securing the battery retaining plates above the battery. Then remove plates above the battery. Then remove both batteries after cable disconnection. c Replacement is a direct reversal of the removal procedure.

Open the Battery Compartment a b c

d e

Replacement When replacing the battery do not mix old and new batteries together, they must be replaced as a pair, as the service life of the new battery will be shortened.

Section 3

Remove the terminals, (see Battery Disconnection). If the terminal is dirty, clean the post. 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. After cleaning, apply a thin coat of petroleum jelly to the terminal. Re-connect the terminals according to the Battery Disconnection/Replacement procedure.

A361680

Issue 1

Section 3

Routine Maintenance

10 - 3

Section 3

Battery

10 - 3

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

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

WARNING

Keep away from children.

Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.

A289230

INT-3-1-4

Shield eyes.

DANGER 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.

A289260

No smoking, no naked flames, no sparks. A289280

Explosive Gas

INT-3-2-1/3

CAUTION Damaged or spent batteries and any residue from fires or spillage should be put in a closed acid proof receptacle and must be disposed of in accordance with local environmental waste regulations. INT-3-1-12

A289250

WARNING Battery acid.

A289240

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. INT-3-1-8

Note operating instructions.

A289270

Issue 1

Section 3

Routine Maintenance

11 - 1

Slew Unit

Section 3 11 - 1

Checking the Slew Gearbox Oil Level 1

Prepare the Machine Position the machine on level ground. Stop the engine and remove the starter key.

Locate the Slew Gearbox (Refer to the Identification of Machine Components).

Check the Level a Remove the dipstick A, wipe it clean and re-fit. b Remove the dipstick again and check that the oil level is within the range B. c If necessary, top up through filler port C. (Refer to Lubricants and Capacities for oil type). Refit the Dipstick

Changing the Slew Gearbox Oil 1

Prepare the Machine Position the machine on level ground. Stop the engine and remove the starter key.

Drain the Oil a Remove the drain plug D. Allow the oil to drain out. b Wipe the drain plug clean. Remove any metallic particles. c Refit the drain plug. Make sure it is tight. /

Fill with New Oil (Refer to Lubricants and Capacities for oil type and volume). Fill with new oil through filler port C until it reaches the full mark on the dipstick A. Refit the dipstick.

Check for Leaks Run the machine, operate the slew controls and make sure there are no leaks.

Issue 1

Section 3

Routine Maintenance

12 - 1

Travel Gear Box

Section 3 12 - 1

Checking the Track Gearbox Oil Level 1

Prepare the Machine Position the machine on level ground with the level and drain plugs as illustrated.

Check the Level on One Side Clean the area around filler/level plug A and remove it. Oil should be level with plug A. Top up through plug A if necessary. (See Lubricants and Capacities for oil types).

Clean and Refit the Plug Make sure it is tight.

Check the Level on the Other Side Repeat steps 1 to 3.

315841

Changing the Track Gearbox Oil 5 1

Prepare the Machine See Checking Track Gearbox Oil Level.

Drain the Oil on One Side a Place a container below the drain plug to catch the oil. The container must be large enough to hold the maximum gearbox capacity (see Lubricants and Capacities).

Check for Leaks Run the machine, operate the tracking controls and then make sure there are no leaks.

Key A B

filler/level plug drain plug

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

Remove filler/level plug A and drain plug B. Allow the oil to drain out.

Wipe the plugs clean. Make sure you remove all metal particles.

Wrap seal tape on drain plug B and refit.

Fill with New Oil See Lubricants and Capacities for oil type and volume. a Pour new oil through filler/level plug A until oil runs out of plug A. b Check the condition of the o-ring, renew if it is damaged. Refit filler/level plug.

Change the Oil on the Other Side Repeat steps 1 to 3.

Issue 1

Section 3

Routine Maintenance

Section 3

13 - 1

Tracks and Running Gear

13 - 1

Checking/Adjusting the Track Tension 1

Prepare the Machine Position the machine on level ground. Run it ( backwards and forwards several times. Stop after \ running it forwards. Carry out steps 1 to 3 of Cleaning the Tracks. Block up the undercarriage frame. Finish track rotation by running the track forwards. Stop the engine and remove the starter key.

WARNING NEVER position yourself or any part of your body under a raised machine which is not properly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed.

Note: Excessive tension can cause the track rail to wear the drive rollers and sprocket, insufficient tension can cause wear to the drive sprocket and track rail. 4

Lower the Track Remove the blocks from beneath the undercarriage and lower the track to the ground using the boom and dipper controls.

Repeat for the Opposite Track Slew the boom round to the other side and repeat steps 1 to 4 above.

INT-3-3-7

Check the Tension Measure gap A in line with the third roller from the front and between the lower surface of the track frame and the upper surface of the shoe. The dimension should be 275-295 mm for hard ground conditons. For operation on soft sand or sticky mud it should be 340-360mm.

Adjust the Track Tension Adjustment is made by either injecting or releasing grease from the check valve B. Inject grease to reduce the gap (increase the tension) or open to release grease and increase the gap.

JS03770

WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out. If you over-loosen too much grease could spurt out or the valve cover fly out and cause serious injury. 8-3-4-5

WARNING Under no circumstances must the check valve be dismantled or any attempt made to remove the grease nipple from the check valve 8-3-4-9

If a gap C exists between the idler wheel shaft and the track frame, you may use pressure to apply the grease. If there is no gap C after the application of grease, then the necessary repairs must be carried out by your JCB distributor.

A343970

Issue 1

Section 3

Routine Maintenance

Section 3

13 - 2

Tracks and Running Gear

13 - 2

Checking Rollers and Idler Wheels for Oil Leaks 1

Prepare the Machine (See Checking/Adjusting the Track Tension, step 1).

Look for Oil Leaks Check the top and bottom rollers and the idler wheels for oil leaks. If leaks are found contact your JCB distributor for service.

Track Plate Inspection 1

Note: If a shoe bolt is used when it is loose, it may be broken. Immediately tighten the shoe bolts whenever they are found to be loose. 2

CAUTION Do not run the machine if you discover oil leaks in the top or bottom rollers or idler wheels. Failure to rectify such leaks could cause damage to the machine.

Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key.

Check and Tighten Torque tighten the bolts in the sequence shown and check that the nuts and shoe are closely fitted to the link joining surface.

8-3-4-6/1

Machine Torque JS200/JS210/JS220/JS240/JS260 640-750Nm (472-553lbf ft)

Lower the Track (See Checking/Adjusting the Track Tension, step 4).

Repeat for the Opposite Track Slew the boom to the other side and repeat steps 1 to 3 above.

Repeat the Procedure a Start the engine and move the machine forwards or backward. Stop the engine. b

Repeat the above procedure until the whole track is tightened.

Issue 1

Section 3

Routine Maintenance

Section 3

13 - 3

Tracks and Running Gear

13 - 3

Cleaning the Tracks

Rotate the Track

WARNING

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.

Rotating the tracks off the ground may cause stones and other debris to be thrown with considerable force. If you are on the outside, keep well clear. Keep other people well clear. 8-3-3-2

If you will be working with another person, make sure you both understand what the other will be doing. Learn and use the recognised signalling procedures. Do not rely on shouting - he will not hear you.

When it is safe to do so and you are sure that everyone is clear of the machine, operate the controls to rotate the track which is off the ground. Rotate it first one way and then the other to shake off the mud. If necessary, the person outside may use water to get the mud off.

To clean the tracks you must turn them. When the tracks are turning, keep clear of rotating parts. 4

Inspect the Track When you have finished, inspect the track rollers, sprockets and idler wheels for damage and oil leaks.

Lower the Track Operate the boom and dipper controls to lower the track to the ground

Repeat for the Opposite Track Swing the boom round to the other side and repeat steps 2 to 5 inclusive for the other track.

Before starting this job, make sure that you have no loose clothing (cuffs, ties, etc.) which could get caught in rotating parts. Keep people not involved with the job well away! 8-3-3-1

Prepare the Machine Park the machine on level ground. Open the bucket and swing the boom until it is at 90Â° to the track. Lower the bucket to the ground.

Raise the Track Operate the boom and dipper controls so that the track on the side nearest the bucket is lifted up clear of the ground.

Issue 1

Section 3

Routine Maintenance

14 - 1

Bucket

Section 3 14 - 1

Checking/Adjusting for Side Play It is possible to compensate for lateral wear which leads to sideways play of the bucket. Regular use of this compensating facility leads to less wear on the bucket swivel pin A and the dipper bushes B. 1

Prepare the machine Position the machine on level ground. Set the bucket as shown opposite. Turn it slightly to the left and position it so that the dipper end is pressed to the side which is not to be adjusted. Stop the engine, remove the starter key.

Measure the Clearance at C The clearance should be approximately 0.8 mm

JS03751

Check the clearance

Issue 1

Section 3 15 - 1

Routine Maintenance

Section 3

Safety Related Components

15 - 1

Periodic Replacement of Safety Related Components Routinely replace important parts concemed with safety. It is difficult to determine by visual inspection or from operation the service life of specific parts, so routinely replace them as important parts every 2 years.

SAFETY PARTS CHART Fuel System Important Parts

Replacement Interval

Fuel Hose (Fuel Tank - Engine)

Every 2 years or every 4000 hours, whichever comes first

Fuel Hose (Fuel Filter - Injection Pump) Hydraulic System Important Parts

Pump Exit Hose (Pump - Operation Valve)

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

Important Parts

Replacement Interval

Boom Ram Line Hose

Every 2 years or every 4000 hours, whichever comes first

Dipper Ram Line Hose Bucket Ram Line Hose

If any abnormality is found with any of these parts before the replacement time, repair or replace as you would do normally. When replacing the hoses, if the hose clamps are found to be deformed or cracked, replace the clamps at the same time as the hoses. Regarding hydraulic hoses not included in the routine replacement of safety parts, carry out the inspection described below and re tighten, replace, etc, when any abnormality is found. Note: Replace a-rings, gaskets at the same time as hoses. Carry out inspection of the hydraulic hoses and fuel hoses at the routine inspection listed below. Inspection Classification Start-up Inspection Special Independent Inspection (Monthly Inspection) Special Independent Inspection (Yearly Inspection)

Inspection Item Fuel, Hydraulic hose connections, Oil Leakage from caulked parts . Fuel, Hydraulic hose connections, Oil Leakage from caulked parts Fuel, Hydraulic hose damage (cracks, wear, picking) . Fuel, Hydraulic hose connections, all Leakage from caulked parts Fuel, Hydraulic hose interference, squeezing, aging, twisting, damage (cracks, wear, picking)

Obtaining Replacement Parts The machineâ&#x20AC;&#x2122;s serial number is stamped on a data plate on the right hand side inside the cab. (See Identifying Your Machine). The data plate also shows the engine serial number. But remember if the e,ngine has been changed the serial number on the data plate may be wrong. Check on the engine itself.

Issue 1

Section 3

Routine Maintenance

16 - 1

Section 3

Trouble Shooting

16 - 1

To extend the service life and improve the operation of the machine, daily inspection and lubrication are necessary as well as immediately isolating any problem found and dealing with it. If the machine is operated with the problem uncorrected, it may lead to larger trouble and possibly to a big accident. If trouble occurs, search for the cause in the items below and make adjustments, repairs, etc. as necessary.

Engine and Related Area Problem

Cause Defective starter switch (Starter does not run) Defective rotation of starter (Starter rotates slowly) Improper viscosity of engine oil Excessive cooling of engine (Cold weather)

Engine does not start

Possible seizure in engine Incomplete air bleeding of fuel system No fuel in fuel tank Fuel quality unsuitable Fuel filter clogged Low compression Defective fuel injection pump

Remedy Connect, repair connection. Discharged battery, starter problems, contaminated or loose wiring connection. Inspect and replace as necessary. Preheat with air heater. Warm up the coolant (add hot water). *Repair. Completely bleed air. Refill. Inspect and replace as necessary. Clean or replace. *Repair *Repair.

Engine stops during operation

No fuel in fuel tank Fuel filter clogged Air is mixed in the fuel system

Refill. Clean and replace. Retighten fuel pipe connections and bleed system.

Low oil pressure

Low oil Defective oil pressure switch Oil filter clogged Low oil viscosity Improper operation of oil pump Oil leakage at connections

Refill. Replace. Replace element. Replace with oil of viscosity matching temperature. *Replace parts. Tighten connections.

Excessive oil consumption Excessively low oil viscosity Excessive cooling by radiator Improper fuel injection timing Low compression

Disassemble and repair, replace parts. Replace with correct oil. Adjust. *Adjust or replace if necessary. *Disassemble and repair, replace parts.

Exhaust gas from engine is black or dark grey

Improper fuel Improper valve clearance Defective fuel injection pump/injectors Low compression Insufficient air intake (air cleaner clogged)

Replace with correct fuel. Adjust. *Adjust or replace if necessary. *Disassemble and repair, replace parts. Clean or replace the element.

Excessive fuel consumption

Defective fuel injection pump Improper spray from fuel injection nozzle Improper fuel injection timing Improper fuel Low compression Insufficient air intake

*Adjust or replace if necessary. *Adjust or replace if necessary. *Adjust or replace if necessary. Replace with correct fuel. Disassemble and repair, replace parts. Clean or replace element.

Excessive oil Low oil viscosity Oil leakage Worn cylinder piston rings

Drain oil to proper level. Replace with oil of viscosity matching temperature. Retighten and replace parts if necessary. *Disassemble and repair, replace parts.

Bad fuel Damage inside muffler

Replace. Replace.

Exhaust gas from engine is white or blue

Excessive engine oil consumption Abnormal noise.(Fuel or mechanical)

*Refer to Engine Service Manual Publication No. 9803/2210

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Section 3

Routine Maintenance

16 - 2

Section 3

Trouble Shooting

16 - 2

Engine and Related Area (contâ&#x20AC;&#x2122;d) Problem

Engine overheating (Water temperature reads too high)

Defective battery charge

Cause

Remedy

Low coolant Water leakage Elongated or oil dirtied belt Defective radiator Broken fan Incorrect mixture of anti-freeze solution Defective thermostat Defective water pump Defective water sensor.

Refill. Repair. Clean or replace. Repair or replace. Replace. Replace. Replace. Replace. Replace.

Improper belt tension Wiring trouble Defective battery Defective regulator Defective alternator

Adjust. Repair. Replace. Replace. Replace.

*Refer to Engine Service Manual Publication No. 9803/2210

Issue 1

Section 3

Routine Maintenance

16 - 3

Section 3

Trouble Shooting

16 - 3

Monitor Display - Fault Messages Cause WATER TEMP

Remedy

Water leakage Belt elongation, soiled with oil Defective radiator Broken fan Improper anti-freeze mixture Defective thermostat II Defective water pump Dirty oil cooler (clogged) Dirty radiator (clogged) Defective dust protection net (clogged) Defective monitor

Repair. Clean or replace. Repair or replace. Replace. Replace. Replace. Replace. Clean. Clean. Clean. Replace.

Low Engine oil Oil leakage at connections Defective engine oil pressure sensor Engine oil viscosity low Defective engine oil pump Defective monitor

Refill. Repair. Replace. Replace with oil of viscosity matching the temperature. Adjust, clean, replace. Replace.

AIR FILTER

Air filter element clogged Intake system clogged, foreign matter inside

Clean, replace. Clean.

LOW FUEL LEVEL

Fuel low Defective sensor

Refill. Replace.

ALTERNATOR

Belt tension Wiring fault Defective battery Defective regulator Defective alternator

Adjust. Repair. Replace. Replace. Repair or replace.

LOW COOLANT

Coolant low Defective sensor

Refill. Replace.

ENG. OIL FILTER

Engine oil dirty Defective sensor

Replace engine oil, oil filter. Replace.

ELEC. FAULT

Short circuit, etc abnormalities

Inspect, repair.

HYDRAULIC OIL TEMP

LOW OIL PRESSURE

Issue 1

Section 3

Routine Maintenance

16 - 4

Section 3

Trouble Shooting

16 - 4

Operations Problem Operating controls hard to operate

Cause Foreign matter caught on control valve spool Valve sticking Improper lubrication of lever link Lever link seizure

Remedy Wash the control valve. Repair or replace valve assembly. Grease. Grease.

Hydraulic Pump Problem

Cause

Remedy

Oil not delivered by oil pump

Low hydraulic oil Clogged suction filter

Refill. Repair.

Hydraulic pump does not build pressure

Oil leakage inside hydraulic pump Air inside the hydraulic pump Main relief valve pressure set too low

Replace hydraulic pump. Refill oil or check hose on suction side. Adjust pressure.

Abnormal noise from hydraulic pump

Cavitation resulting from deformed hose on the suction side or suction filter clogged Joint of the suction side is loose or hydraulic oil is low and air is being sucked in

Oil leakage from hydraulic pump

Replace filter, replace hydraulic oil if dirty. Retighten or grease the joints. Check that oil is filled to proper level inside casing.

Cavitation resulting from excessively high viscosity of hydraulic oil

Replace with hydraulic oil of suitable viscosity.

Defective seal in hydraulic pump

Replace seal or hydraulic pump.

Working Attachments Problem

Overall low power

Defective operations

Insufficient work powe

Attachment sinks down Abnormal noise from joints of the attachment

Cause

Remedy

Insufficient engine output Function drops due to wear of hydraulic pump Defective main relief valve Low hydraulic oil Viscosity of hydraulic oil incorrect Suction filter clogged

Refer to Engine Service Manual. Replace hydraulic pump. Adjust the pressure or replace. Refill. Replace with hydraulic oil of proper viscosity. Replace suction filter.

Hydraulic pump broken Hydraulic oil low

Replace hydraulic pump. Replace suction filter.

Set pressure for main or port relief valve is low or incorrect Damaged hydraulic ram seals Damaged hydraulic ram, cylinder

Adjust pressure or replace relief valve. Replace hydraulic ram seals. Replace hydraulic ram/cylinder or the assembly.

Damaged hydraulic ram seals Damaged hydraulic ram, cylinder Oil leakage inside control valve Oil leakage inside holding valve

Replace hydraulic ram seals. Replace hydraulic ram/cylinder or the assembly. Repair valve assembly, replace. Repair valve assembly, replace.

Insufficient grease Connecting pin seizure

Grease. Replace the bushing and/or pin.

Issue 1

Section 3 16 - 5

Routine Maintenance

Section 3

Trouble Shooting

16 - 5

Travel Problem

Insufficient travel force.

Rough travel

Crooked travel

Cause

Remedy

Pressure setting for main relief valve is too low Defective counterbalance valve Performance reduction of travel motor Swivel joint packing damage Performance reduction of hydraulic pump

Adjust the pressure. Replace the counterbalance valve. Replace travel motor. Replace swivel joint packing. Replace hydraulic pump.

Excessively tightened track Stone or foreign matter caught in track Defective valve Performance reduction of travel motor Air in travel motor

Adjust to proper tension. Remove stone or foreign matter. Repair valve or replace. Replace travel motor. Refill with oil.

Left and right tracks are not equally tightened

Bleed air from left and right, adjust tracks to equal tension. Replace hydraulic pump. Replace travel motor. Replace valve housing assembly. Replace swivel joint packing. Adjust.

Performance reduction of hydraulic pump Performance reduction of travel motor Oil leakage inside control valve Swivel joint packing damage Loose lever link

Slew Problem

Cause

Remedy

Insufficient slew force

Performance reduction of slew motor Thermal seizure of slew shaft

Replace slew motor. Supply grease or replace the slew shaft.

Idle slew during slew braking

Low setting of brake valve Clogged valve Performance reduction of slew motor Internal oil leakage of control valve

Adjust the pressure. Wash the valve. Replace slew motor. Repair or replace valve assembly.

Idle slew during slew stopping

Low setting of brake valve or port relief valve Clogged valve Performance reduction of slew motor Internal oil leakage of control valve

Adjust the pressure. Wash the valve. Replace slew motor. Repair or replace valve assembly.

Abnormal noise during slew

Air in slew motor Insufficient greasing of slew bearing

Refill with oil. Add grease.

Hydraulic Ram Problem

Cause

Remedy

Insufficient force of hydraulic ram

Low pressure setting for the relief valve Oil leakage inside the hydraulic ram Damage of the hydraulic ram or rod Oil leakage inside the control valve

Adjust the pressure. Replace the ram seals. Replace the hydraulic ram or rod. Repair or replace the valve assembly.

Oil leakage outside the hydraulic ram

Defective hydraulic ram seals Hydraulic cylinder rod damage

Replace hydraulic ram seals. Replace hydraulic ram rod.