8018 Hydraulic

Section E Hydraulics Service Manual - 8014, 8016, 8018, 8020 Section 1 - General Information Section 2 - Care Care and Safety Section 3 - Maintenance Section A - Attachments Section Se ction B - Body and Framework Section C - Electrics Section Se ction D - Controls Section Se ction E - Hydraulics Section F - Gearboxes Section J - Track and Running Gear Section K - Engine

Publication No.

9803/9350-6

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

Section E - Hydraulics

Notes:

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Notes:

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Section E - Hydraulics Contents

Page No.

Service Tools Numerical List ........................................................................................... E-1 Technical Data All Machines ..................................................................... ........................ E-3 Basic System Operation Introduction to Hydraulic Schematic Symbols ........................... ............... E-8 General (Basic and Functional Symbols) ............................................. .... ......................................... E-8 Control Valves ................................................................... ................. E-12 Example of Schematic Circuit ........................................................... . E-13 Hydraulic Circuit ........................ ............................................................. E-14 Neutral Pressure Circuit .............................................. ....................... E-14 Servo Circuit ............................................................................. .......... E-14 Schematic Circuits 8014, 8016 Tier 2 Machines (Early Machines) ....................................... .... ................................... E-16 Component Key ........................................................................... ....... E-16 Hose Colour Data ............................................................................... E-18 8018 Tier 3 Machines up to May 2012, 8014 / 8016 Tier 3 Machines up to February 2013 ....................... ....................................................................... E-20 Component Key ........................................................................... ....... E-20 Hose Colour Data ............................................................................... E-22 8018 Tier 3 Machines from June 2012, 8014, 8016, 8020 Tier 3 Machines from March 2013 ................................................................... .. ................................................................. ......................... E-24 Component Key ........................................................................... ....... E-24 Hose Colour Data ............................................................................... E-26 8020 Tier 3 Machines up to February 2013 ............................................ E-28 Component Key ........................................................................... ....... E-28 Hose Colour Data ............................................................................... E-30 Fault Finding Hydraulic System ....................................................................... ............. E-32 General Fault Diagnosis ..................................................................... E-32 Slew Motor and Gearbox .................................................................. ...... E-34 Service Procedures Hydraulic Contamination ................. ....................................................... E-35 Hydraulic Fluid Quality ...................................................................... . E-35 Effects of Contamination ................... ................................................. E-35 Cleaning Operation ............................................................................ E-35 Contaminant Standards .................................................................. .... E-36 Filters ........................................................................... ....................... E-36 Pressure Testing ..................................................................................... E-37 Main Relief Valves .......................................................................... .... E-37 Auxiliary Relief Valves Valves ....................................................................... . E-39 Servo Pressure ............................................................................... .... E-40 Cross Line Relief Valves ................................................................... . E-41 Control Valve Description ................................................................. ............................. Component Locations (Early Machines) ............................................ Component Locations (Later Machines) ............................................ Control Valve Sections (Early Machines) Machines) ........................................... Control Valv Valve e Sections (Later Machines) Machines) ...........................................

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E-42 E-42 E-44 E-46 E-55

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Contents

Page No.

Removal and Replacement .............................. ...................................... E-56 Removal (Early Machines) ................................................ ................. E-56 Replacement ........................................................................ .............. E-56 Removal (Later Machines) ................................ ................................. E-57 Replacement ........................................................................ .............. E-57 Dismantling and Assembly .................. ................................................... E-58 Dismantling .................................................................. ....................... E-58 Inspection ....................................................................... .................... E-59 Assembly ........................................................................... ................. E-59 Hydraulic Pump (8014, 8016, 8018 Machines) General Description ............................................................. ................... E-60 Dismantling, Inspection and Assembly ................................................... E-62 Dismantling .................................................................. ....................... E-62 Inspection ....................................................................... .................... E-62 Assembly ........................................................................... ................. E-62 Pump Flow Testing .............................................................. ................... E-64 Hydraulic Pump (8020) General Description ............................................................. ................... E-65 Removal and Replacement .............................. ...................................... E-67 Removal ...................................................................... ....................... E-67 Replacement ........................................................................ .............. E-68 Pump Flow Testing .............................................................. ................... E-69 Troubleshooting ................................................................... ................... E-71 Main Relief Valve Removal and Replacement .............................. ...................................... E-72 Removal ...................................................................... ....................... E-72 Replacement ........................................................................ .............. E-72 Auxiliary Relief Valves Removal, Dismantling, Inspection and Assembly ................................... E-74 Removal ...................................................................... ....................... E-74 Dismantling ........................................................................... .............. E-75 Inspection ....................................................................... .................... E-75 Assembly ........................................................................... ................. E-75 Pressure Maintenance Valve and Dual Solenoid Valve Removal and Replacement .............................. ...................................... E-76 Removal ...................................................................... ....................... E-76 Replacement ........................................................................ .............. E-76 Track Motor General Description ............................................................. ................... E-77 Normal Operation ................................................................. .............. E-79 Braking ................................................................. .............................. E-79 Counterbalance Operation ................................................................. E-79 Motor Low Speed, High Traction Selected (where applicable) ........... E-79 Motor High Speed, Low Traction Selected (where applicable) ........... E-81 Auto Kick Down Function (where applicable) ..................................... E-83 Track Motor Dismantling and Assembly .............................................. ... E-84 Dismantling .................................................................. ....................... E-84 Assembly .............................................................................. .............. E-84

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Contents

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Brake Valve Dismantling and Assembly ................................................. E-86 Dismantling .................................................................. ....................... E-86 Assembly .............................................................................. .............. E-86 Slew Motor General Description ............................................................. ................... E-87 Hydraulic Motor Section ....................... .............................................. E-89 Cross Line Relief Valve Section ..................................................... .... E-90 Anti Cavitation Valve Section .............................................................. E-91 Removal and Replacement .............................. ...................................... E-92 Removal ...................................................................... ....................... E-92 Replacement ........................................................................ .............. E-93 Dismantling and Assembly .................. ................................................... E-94 Dismantling .................................................................. ....................... E-95 Assembly .............................................................................. .............. E-95 Rotary Coupling 8014, 8016 Single Speed Machines ....................................................... E-96 Removal ...................................................................... ....................... E-96 Replacement ........................................................................ .............. E-96 Dismantling ........................................................................... .............. E-98 Inspection ....................................................................... .................... E-98 Assembly ........................................................................... ................. E-98 8016, 8018 Two Speed Machines .......................................................... E-99 Removal ...................................................................... ....................... E-99 Replacement ........................................................................ .............. E-99 Dismantling ........................................................................... ............ E-101 Inspection .................................................................... ..................... E-101 Assembly .................................................................. ........................ E-101 8018, 8020 Two Speed and Extending Undercarriage Machines .............. ........................................................ E-102 Removal ...................................................................... ..................... E-102 Replacement ........................................................................ ............ E-102 Dismantling ........................................................................... ............ E-104 Inspection .................................................................... ..................... E-104 Assembly .................................................................. ........................ E-104 Hydraulic Rams Precautions During Use .................................................................... .... E-105 Installation ................................................................... ..................... E-105 Caution During Use ........................................................................ .. E-105 Maintenance, Inspection Points ....................................................... E-105 Removal and Replacement ................................. ................................. E-107 Boom, Dipper and Bucket Rams ...................................................... E-108 Dozer Ram ........................................................................................E-110 Swing Ram ........................................................................................E-112 Dismantling and Assembly ..................................................... ............... E-113 All Rams ......................................................................... ...................E-113

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Contents

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Page No.

E-iv


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

details of all tools, including the content of kits and sets, refer to Tool Detail Reference, Section 1 . Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.

Part Number

Description

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

331/22966

Pump Drive Alignment Tool

331/31069

Test Block for A.R.V.

892/00039

Spool Clamp

892/00137

Micro-Bore Hose

892/00223

Hand Pump

892/00253

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

892/00254

Hose

892/00271

Adapter

892/00272

Adapter

892/00273

Adapter

892/00274

Adapter

892/00275

Adapter

892/00276

Adapter

892/00277

Adapter

892/00279

Gauge

892/00280

Gauge

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Section E - Hydraulics Service Tools Numerical List Part Number

Description

892/00334

Ram Seal Fitting Tool

892/00346

Gauge

892/00347

Connector

892/00706

Test Probe

892/01016

Ram Protection Sleeve for 25 mm Rod Diameter

892/01017


892/01018


892/01019


892/01020

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

892/01021


892/01022

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

892/01023


892/01024


892/01025


892/01026


892/01027

Piston Seal Assembly Tool

992/02800

ARV Extractor

992/09300

Hexagon Spanner 55mm A/F

992/09400


992/09500


992/09600


992/09700


992/09900


992/10000


992/10100

Spool Clamp

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Technical Data All Machines 8014/8016

8018/8020

Pump

Type

Three section gear pump driven directly from the engine crankshaft.

Flow Rates at neutral circuit pressure Pumps P1 and P2

13.5 l/min. (3.0 UK gall/min.) @ 2450 rev/min

Pump P3

12.2 l/min. (2.7 UK gall/min.) @ 2450 rev/min

Machines Up To May 2012

8014

15.7 l/min. (3.5 UK gal/min.) @ 2450 rev/min

8016

8018/8020

bar

lbf/in2

bar

lbf/in2

bar

lbf/in2

Swing/Dozer/Slew

160

2320

160

2320

160

2320

Tracks/Dipper/Aux

230

3335

230

3335

220

3190

Tracks/Boom/Bucket

230

3335

230

3335

220

3190

Maintenance Valve - Single Speed

30

435

30

435

30

435

Maintenance Valve - Two Speed

30

435

30

435

30

435

Boom rod side

275

3988

275

3988

275

3988

Dipper rod and head side

275

3988

275

3988

275

3988

Dozer head side

220

3190

220

3190

220

3190

160

2320

160

2320

160

2320

Relief Valve Operating Pressures (1)

Main Relief Valves (M.R.V.)

Servo Pressure

Auxiliary Relief Valves (A.R.V.)

Slew Crossline Relief Valves (1)

At hydraulic oil temperature of 50 °C (122 °F)

Machines From June 2012

All Machines bar

lbf/in2

Swing/Dozer/Slew

160

2320

Tracks/Dipper/Aux

230

3335

Tracks/Boom/Bucket

230

3335

30

435


Main Relief Valves (M.R.V.)

Servo Pressure Maintenance Valve - Single Speed Maintenance Valve - Two Speed

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Section E - Hydraulics Technical Data All Machines Machines From June 2012

All Machines bar

lbf/in2

Boom rod side

275

3988

Dipper rod and head side

275

3988

Dozer head side

220

3190

160

2320


Auxiliary Relief Valves (A.R.V.)

Slew Crossline Relief Valves (1)

E-4

At hydraulic oil temperature of 50 °C (122 °F)

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Section E - Hydraulics Technical Data All Machines Bore Rams

Rod Dia

Stroke

mm

in

mm

in

mm

in

Boom - Machines up to May 2012

55

2.16

30

1.18

369

14.5

Boom (8014, 8016, 8018) Machines from June 2012

65

2.56

35

1.38

388

15.28

Boom (8020) Machines from June 2012

70

2.76

35

1.38

388

15.28

Dipper (8014, 8016) Machines up to May 2012

50

1.97

30

1.18

410

16.14

Dipper (8014, 8016) Machines from June 2012

50

1.97

30

1.18

430

16.93

Dipper (8018, 8020) Machines up to May 2012

55

2.16

30

1.18

410

16.14

Dipper (8018) Machines from June 2012

55

2.16

30

1.18

430

16.93

Dipper (8020) Machines from June 2012

60

2.36

35

1.38

425

16.73

Bucket (8014, 8016)

50

1.97

30

1.18

292

11.5

Bucket (8018, 8020)

55

2.16

30

1.18

292

11.5

Swing (8014, 8016)

50

1.97

30

1.18

311.5

12.26

Swing (8018, 8020)

55

2.16

30

1.18

311.5

12.26

Dozer (8014, 8016)

70

2.76

35

1.38

85

3.35

Dozer (8018

70

2.76

35

1.38

85

3.35

Undercarriage Extension

55

2.16

30

1.18

360

14.17

Ram Speed at max. Engine Revs.

8014/8016

8018/8020

8018

up to May 2012

From June 2012

Boom Up

3.0 Sec

2.3 Sec

2.5 Sec

Boom Down

2.1 Sec

1.8 Sec

3.1 Sec

Dipper In

3.7 Sec

3.8 Sec

3.5 Sec

Dipper Out

2.5 Sec

3.0 Sec

2.9 Sec

Bucket Dump

1.8 Sec

2.2 Sec

2.0 Sec

Bucket Crowd

2.7 Sec

2.9 Sec

2.7 Sec

Dozer Up

1.5 Sec

1.5 Sec

2.6 Sec

Dozer Down

1.9 Sec

1.9 Sec

3.6 Sec

Slew (5 rev) Left

30.7 Sec

30.7 Sec

35.6 Sec

Slew (5 rev) Right

30.7 Sec

30.7 Sec

35.6 Sec

Tracking (25 m)

40.2 Sec

40.2 Sec

40.5 Sec (1 spd) 22.6 Sec (2 spd)

Swing Left

3.3 Sec

3.3 Sec

4.4 Sec

Swing Right

2.7 Sec

2.7 Sec

5.0 Sec

Track Motors

Single Speed

Two Speed

Two Speed

Type

PHK-120-37-5-8431A

PHV-120-37-5T-8424A

PHV-1B-12B-9376A

Displacement

8.9 cm3/rev

9.5 cm3/rev

10.9/5.6 cm3/rev

Max Operating Pressure

23 MPa

22 MPa

23 MPa

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Section E - Hydraulics Technical Data All Machines Track Motors

Single Speed

Two Speed

Two Speed

Max Flow

12.94 l/min

15 l/min

14 l/min

Reduction ratio

36.96:1

36.96:1

36.96:1

Weight

14.5 kg (32.0 lb)

18 kg (39.7 lb)

17 kg (37.5 lb)

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Section E - Hydraulics Technical Data All Machines Slew Motor

8014/8016/8018

8020

Type

Piston - PCR-50-10-1S28295A

Piston - PCR-1B-05A-8747A

Displacement

18.1 cm3/rev

18.1 cm3/rev

Max. Flow

12 l/min

12 l/min

Gear Ratio

10 : 1

10 : 1

Weight

22 kg (48.5 lb)

22 kg (48.5 lb)

Filtration

Main Bypass pressure

2.5 bar (36 lbf/in2)

Hydraulic System Capacities

Hydraulic System

E-7

28 litres (6.2 UK Gal)

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Basic System Operation Introduction to Hydraulic Schematic Symbols TE-001

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

Table 2. Rams

Single acting

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

Double ended

Double acting with damping at rod area end

Table 3. Pumps and Motors

Variable capacity pump two directions of flow

Spring Flow restriction affected by viscosity

Fixed capacity motor one direction of flow

Direction of flow Fixed capacity motor two directions of flow

Indication of rotation

Variable capacity motor one direction of flow

Indication of direction and paths of flow

Variable capacity motor two directions of flow

Variable control

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Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols Table 4. Control Valves

Used to enclose several valves indicating they are supplied as one unit

Throttling orifice - normally closed

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

Throttling orifice - normally open

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

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

Variable restrictor

Non-return valve

Non-return valve with back pressure spring

Pilot operated non-return valve

One way restrictor

High pressure selector (shuttle valve)

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Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols Table 5. Energy Transmissions and Conditioning

Working line, return or feed

Reservoir - return line below fluid level

Pilot control Drain lines Header tank Flexible pipe

Pressure sealed tank Line junction

Accumulator

Crossing lines

Filter or strainer

Water trap Air bleed

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

Cooler - with no indication of coolant flow

Cooler - indicating direction of coolant flow

Quick release couplings connected Heater Quick release couplings disconnected

Reservoir - return line above fluid level

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

Solenoid one winding

Rotating shaft - one direction

Solenoid two windings

Rotating shaft - two directions

Detent

M

Locking device

Electric motor operated

Internal pressure pilot operated

Over centre device

External pressure pilot operated

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

Spring operated

Roller operated

Roller trip operated (one directional)

E-11

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

Control Valves Control valves are usually represented by one or more square boxes. Fig 1. ( E-12) shows a control valve represented by three boxes. The number of boxes indicates the number of possible valve operating positions, (3 boxes - 3 positions etc).

Fig 4. Fig 1. Fig 2. ( E-12) - In circuit diagrams the pipework is usually shown connected to the b ox which represents the unoperated condition. (Hydraulic circuit diagrams are usually shown in the unoperated condition).

It must be noted that not all spools are of the same type. Their operating designs can be seen by following the path the flow arrows take in their respective operating squares. Three typical JCB style spools are known as 'D' spools, 'F' spools and 'N' spools. The 'D' spools generally control rams because when in the neutral position the outlet ports are blocked, preventing ram movement. Fig 4. ( E-12) shows a 'D' type spool.

Fig 2. Fig 4. ( E-12) shows a valve described as a 3position, 4-port control valve. Port describes the openings to and from the valve by which the hydraulic fluid enters or leaves. In the fig shown, Position 2 indicates that in an unoperated condition all 4 ports are blocked.

Fig 5. ( E-12) - 'F' spools are often shown as four position spools with the three normal positions for neutral and service control; and the forth position, which has a detent, connects both sides of the ram together to allow the service to 'float'.

Fig 5. Fig 6. ( E-12) - 'N' spools are sometimes used to control hydraulic motors, and it can be seen from the flow arrows, that in neutral position both service ports are connected to the exhaust oil port

Fig 3.

If the valve spool was moved to Position 1, movement of the spool would connect Port P1 to Port P2, and Port P3 to Fig 4. ( E-12). Port P4. If the valve spool was moved to Position 3, movement of the spool would connect Port P1 to Port P4, and Port P3 to Port P2. Fig 4. ( E-12).

E-12

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Fig 6.

E-12

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

Example of Schematic Circuit

A B

G

C D

E F

Fig 7. Simple Schematic Circuit

Some of the symbols described on the preceding pages have been arranged into a simple schematic circuit. Fig 7. ( E-13). Hydraulic tank 7-A is a pressurised tank with an internally mounted strainer 7-B on the suction line to the fixed displacement pump 7-C. System pressure is limited to the setting of relief valve 7-D. Valve spool 7-E is an open-centre spool that is in neutral position; flow from the pump passes through the spool and returns to the hydraulic tank.

Example Circuit Key 7-A

Hydraulic Tank

7-B

Strainer

7-C

Fixed Displacement Pump

7-D

Relief Valve

7-E

Spool

7-F

One Way Valve

7-G

Double Acting Hydraulic Ram

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

E-13

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E-13

Section E - Hydraulics Basic System Operation Hydraulic Circuit

Hydraulic Circuit Note: Circuit and description are for ISO Machines.

(rod side only) from damage that might be generated through over-pressure conditions during operation.

Note: The annotations relate to the Hydraulic Schematic. .

The hydraulic circuit is fed from a hydraulic oil tank 11, located behind operator's cab. The system is powered by a three section pump 9, connected directly to the engine crankshaft. Sections P1, P2 and P3 are fixed displacement gear pumps. When the engine is running, the pump draws fluid from the tank and routes it through the main control valve block 4. Pump section P1 supplies the control valve sections for: 4a

Track Right

4b

Boom Ram

4c

Bucket Ram

When the A.R.V.'s are open, over pressure fluid is routed to the control valve exhaust chamber and back to tank 11. The service lines to the dozer ram, the track motors and the pilot line from the high speed selector to the track motors are routed through a rotary coupling 3. This device allows the machine upper structure to turn without damaging hoses connected to services mounted on the undercarriage. The remaining service lines connect directly to their relevant devices. Return fluid from services or from the neutral pressure circuit is routed back to tank through an exhaust line and return filter 10.

Neutral Pressure Circuit With the engine running, but no service selected, the pump flows are routed from pump sections P1, P2 and P3 to their respective sections of the control valve.

Pump section P2 supplies the control valve sections for: 4f

Track Left

4e

Dipper Ram

4d

Aux

The valve spools are spring loaded to the neutral position, allowing fluid to pass through the valve's neutral circuit and returned to tank through the return line.

Pump section P3 supplies the control valve sections for: 4h

Dozer Ram

4g

Swing Ram

4j

Slew

Excess pressure in the selected circuit opens the M.R.V. associated with the valve section supplied and vents excess pressure back to tank 11.

Servo Circuit

Supply from all three pumps is also directed to the pressure maintenance valve 8, fitted with a servo Isolation solenoid valve 8a and two speed tracking solenoid 8b (8016, 8018, 8020 only).

With the isolator solenoid 8a energised, neutral circuit pressure from the pumps connects to the hand controllers 5 and 6. As the hand controllers are operated, the neutral circuit pressure is directed to and begins to select the desired excavator spool.

Main relief valves (M.R.V.) 4K, 4L and 4M are fitted in the main control valve blocks to vent hydraulic pressure, venting excess flow to tank 11. Auxiliary relief valves (A.R.V.) 4N are fitted to protect the dipper (rod and head side), boom (rod side only) and dozer

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Section E - Hydraulics Basic System Operation Hydraulic Circuit

Page left intentionally blank

E-15

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Section E - Hydraulics Schematic Circuits 8014, 8016 Tier 2 Machines (Early Machines)

) s e n i h c a s M t i l y u r a c E r ( i e C s n i c h i t c a a M m 2 e r e h i c T S 6 1 0 8 , 4 1 0 8

m a R g m n i a m m w m R a a S a t R R r e m R k m e o m c o z o r u o o B A B B D

3 4 5 6 7 1 1 1 1 1

y e K t n e n o p m o C

E-16

.

) 1 2 E ( . 9 g i F

e v l e a v V l a d V i o r g n o r t e r n o o i l t e r l o n l i o M e o l S e a l r t M k v t l o n n r n i k c a t o r c a o k a i V t n r r e a c l a p t o T C M l r g l o t o o i t l m T d i C o r n n t d B e s i F o r u n n I d d o n w u P n M a y d n a J o n r s o t r a H y C l a H l n t l S r u k w o s v a e i r i e m e l H t r n e m k H t f i e e a i e n r e a V h h v v w a l i n t t V f g t a a o c x m a o z e f g a P S M R T S R i o o i u u r o R o l r r e e L R R M T B B A A T B D S A M L R M

a b c d e f g h j k m a 0 1 2 1 2 3 4 4 4 4 4 4 4 4 4 4 4 4 5 6 7 8 8 9 1 1 1

9803/9350-6

E-16


a 8

a 4

b 4 k 4

c 4

d 4

e 4 k 4

f 4 m 4

m 4

g 4 k 4

h j m 4 4 4

2 1 e u s s i 3 2 0 0 6 / 6 3 2 . 8 g i F

4

E-17

9803/9350-6

E-17


Hose Colour Data From

To

Colour

PUMP

VALVE BLOCK

RED

VALVE B3

SWING RAM DUMP

D ORANGE

VALVE A3

SWING RAM ROD

S ORANGE

VALVE B1

LH PORT SLEW

S LIGHT GREEN

VALVE A1

RH PORT SLEW

D LIGHT GREEN

P1

PMV P1

RED

P2

PMV P2

RED

P3

PMV P3

RED

PMV P

PRESSURE BLOCK

RED

PMV T

TANK BLOCK

BLUE

RHJ1 (RIGHT HAND JOYSTICK) BOOM TOP

S WHITE

RHJ3

BOOM BOTTOM

D WHITE

RHJ4

BUCKET TOP

S GREY

RHJ2

BUCKET BOTTOM

D GREY

RHJT

TANK BLOCK

BLUE

RHJP

PRESSURE BLOCK

RED

LHJ3 (LEFT HAND JOYSTICK)

DIPPER TOP

S PURPLE

LHJ1

DIPPER BOTTOM

D PURPLE

LHJ2

SLEW BOTTOM

D LIGHT GREEN

LHJ4

SLEW TOP

S LIGHT GREEN

LHJP

PRESSURE BLOCK

RED

LHJT

TANK BLOCK

BLUE

BOTTOM OIL COOLER

FILTER

BLUE

VALVE RETURN

TOP OIL COOLER

BLUE

VALVE B8

BOOM ROD

S WHITE

VALVE A8

BOOM DUMP

D WHITE

VALVE B5

DIPPER ROD

S PURPLE

VALVE A5

DIPPER DUMP

D PURPLE

RJ1 (ROTARY JOINT)

LH TRACK

D PINK

RJ2

LH TRACK

S PINK

RJ3

RH TRACK

S LILAC

RJ4

RH TRACK

D LILAC

RJ7

RH TRACK DRAIN

BLUE

RJ7

LH TRACK DRAIN

BLUE

RJ5

DOZER DUMP

D YELLOW

RJ6

DOZER ROD

S YELLOW

E-18

9803/9350-6

Comment

E-18

Section E - Hydraulics Schematic Circuits 8014, 8016 Tier 2 Machines (Early Machines) From

To

Colour

VALVE B2

RJ5

D YELLOW

VALVE A2

RJ6

S YELLOW

VALVE A9

RJ1

D PINK

VALVE B9

RJ2

S PINK

VALVE B4

RJ3

S LILAC

VALVE A4

RJ4

D LILAC

VALVE LOCKOUT

PRESSURE BLOCK

RED

VALVE LOCKOUT

VALVE LOCKOUT

RED

RJ TANK

TANK

BLUE

SLEW DRAIN

ROTARY JOINT

BLUE

TANK BLOCK

TANK

BLUE

SLEW MOTOR LH SIDE

TANK DRAIN

BLUE

SINGLE ACTING AUX KIT

S BROWN


D BROWN

Comment

VALVE B7

BUCKET ROD

S GREY

LONG DIPPER

VALVE A7

BUCKET DUMP

D GREY

LONG DIPPER

VALVE B7

BUCKET ROD

S GREY

XL DIPPER

VALVE A7

BUCKET DUMP

D GREY

XL DIPPER

VALVE B7

BUCKET ROD

S GREY

GRAVEMASTER

VALVE A7

BUCKET DUMP

D GREY

GRAVEMASTER

BUCKET

BUCKET

S GREY

BUCKET

BUCKET

D GREY

BOOM PILOT

BOOM PILOT

D WHITE

BUCKET PILOT

BUCKET PILOT

D GREY

DIPPER PILOT

DIPPER PILOT

D PURPLE

E-19

9803/9350-6

E-19

Section E - Hydraulics Schematic Circuits 8018 Tier 3 Machines up to May 2012, 8014 / 8016 Tier 3 Machines up to February 2013

3 1 0 2 y r a u r b e F o t p u s e n i h c a M 3 r e i T 6 1 0 8 / 4 1 e m v a 0 l m a R 8 a m m m R a a V r , e a t R R e d 2 g R e m r n n e k 1 e c o z a t m 0 o h r u o x A B B D C E 2 y a 4 5 6 7 8 9 M 1 1 1 1 1 1 o t p u s e n i h c a M r o r t 3 o o t r o M e e M k v l i c k a a T y c r V a l T r t o 8 e . T r n t d i 1 K ) n d n o n a J o 0 t 1 2 a H l C y 8 n e E H t r n e n o p m o C

E-20

( . 9 g i F

t f e L

e d v i l e a o v V n l e a d l o V i o S n g e g r n l i n e r l o i n l i k e o l S a c l r t m t a o n n r r n a i t o i T r a k o t n r R e c M l p a d o C t g l o g o i t C d l o e n n e i e m F o i s B r u n I d p P n w w u M a y d n r l s o S S S t r a H n k l s v u o a i t n w e i e m r l H t f i e r o e m k i a i v m h t h n r e w a e a l v o e w V V t z o c x o f m g o a a g P S T M R T S a e R a i o i u u r o R o o l r r e R R M T B B A A T B D S A M L R M B

a b c d e f g h j k m a b 0 1 2 3 1 2 3 4 4 4 4 4 4 4 4 4 4 4 4 5 6 7 8 8 8 9 1 1 1 1

9803/9350-6

E-20


b 8 a 8

a 4 m 4

b 4 k 4

c 4

d 4

e 4 k 4

f 4 m 4

g 4 k 4

h j m 4 4 4

3 1 e u s s i 5 2 0 0 6 / 6 3 2 . 9 g i F

4

E-21

9803/9350-6

E-21



To

Colour

PUMP

VALVE BLOCK

RED

VALVE B9

RJ 1

S PINK

VALVE A9

RJ5

D PINK

VALVE B4

RJ 2

S LILAC

VALVE A4

RJ 6

D LILAC

VALVE B3

SWING RAM DUMP

D ORANGE

VALVE A3

SWING RAM ROD

S ORANGE

VALVE B1

LH PORT SLEW

S LIGHT GREEN

VALVE A1

RH PORT SLEW

D LIGHT GREEN

VALVE B2

CHANGE VALVE TOP

D YELLOW

VALVE A2

CHANGE VALVE BOT

S YELLOW

PMV 2 SPEED

RJ9

RED

CHANGE VALVE D

RJ7

D YELLOW

CHANGE VALVE D1

RJ8

S YELLOW

CHANGE VALVE P

RJ3

D DARK GREEN

CHANGE VALVE P1

RJ4

S DARK GREEN

P1

PMV P1

RED

P2

PMV P2

RED

P3

PMV P3

RED

TANK

RJ BLUE

PMV P

PRESSURE BLOCK

RED

PMV T

TANK BLOCK

BLUE


S WHITE

RHJ3

BOOM BOTTOM

D WHITE

RHJ4

BUCKET TOP

S GREY

RHJ2

BUCKET BOTTOM

D GREY

RHJT

TANK BLOCK

BLUE

RHJP

PRESSURE BLOCK

RED


DIPPER TOP

S PURPLE

LHJ1

DIPPER BOTTOM

D PURPLE

LHJ2

SLEW BOTTOM

D LIGHT GREEN

LHJ4

SLEW TOP S

LIGHT GREEN

LHJP

PRESSURE BLOCK

RED

LHJT

TANK BLOCK

BLUE

BOTTOM OIL COOLER

FILTER

BLUE

VALVE RETURN

TOP OIL COOLER

BLUE

E-22

9803/9350-6

Comment

E-22

Section E - Hydraulics Schematic Circuits 8018 Tier 3 Machines up to May 2012, 8014 / 8016 Tier 3 Machines up to February 2013 From

To

Colour

VALVE B8

BOOM ROD

S WHITE

VALVE A8

BOOM DUMP

D WHITE

VALVE B5

DIPPER ROD S

PURPLE

VALVE A5

DIPPER DUMP

D PURPLE

RJ5 (ROTARY JOINT)

LH TRACK

D PINK

RJ1

LH TRACK

S PINK

RJ2

RH TRACK

S LILAC

RJ6

RH TRACK

D LILAC

RJ8

DOZER ROD

S YELLOW

VALVE LOCKOUT

PRESSURE BLOCK

RED

VALVE LOCKOUT

VALVE LOCKOUT

RED

SLEW DRAIN

ROTARY JOINT

BLUE

TANK BLOCK

TANK

BLUE

RJ3

EXT RAM DUMP

D DARK GREEN

RJ4

EXT RAM ROD

S DARK GREEN

RJ TEE

t MOTOR DRAIN

BLUE

RJ TEE

T MOTOR 2 SPEED

RED

RJ7

DOZER DUMP

D YELLOW

SLEW MOTOR LH SIDE

BLUE


S BROWN


D BROWN

Comment

VALVE B7

BUCKET ROD

S GREY

LONG DIPPER

VALVE A7

BUCKET DUMP

D GREY

LONG DIPPER

VALVE B7

BUCKET ROD

S GREY

XL DIPPER

VALVE A7

BUCKET DUMP

D GREY

XL DIPPER

VALVE B7

BUCKET ROD

S GREY

GRAVEMASTER

VALVE A7

BUCKET DUMP

D GREY

GRAVEMASTER

BUCKET

BUCKET

S GREY

BUCKET

BUCKET

D GREY

BOOM PILOT

BOOM PILOT

D WHITE

BUCKET PILOT

BUCKET PILOT

D GREY

E-23

9803/9350-6

E-23

Section E - Hydraulics Schematic Circuits 8018 Tier 3 Machines from June 2012, 8 014, 8016, 8020 Tier 3 Machines from March 2013

8018 Tier 3 Machines from June 2012, 8014, 8016, 8020 Tier 3 Machines from March 2013 Component Key Fig 10. (

E-25)

19

Pilot Valve

20

Check Valve

21

ISO/SAE Option

1

Right Hand Track Motor

21a

Dual Solenoid Valve

2

Left Hand Track Motor

22

Changeover Valve

3

Rotary Joint

23

Oil Cooler

4

Main Control Valve

24

Optional Pump

4a

Bucket Section

25

Hand Held Auxiliary Option

4b

Boom Section

25a

Auxiliary Return

4c

RH Travel Section

25b

Auxiliary Feed

4d

Inlet Pressure Section

4e

LH Travel Section

4f

Dipper Section

4g

Auxiliary Section

4h

Confluence Section

4j

Swing Section

4k

Dozer Section

4m

Slew Section

5

Left Hand Controller

6

Right Hand Controller

7

Manifold Block

8

Pressure Maintaining Valve

8a

Accumulator

8b

Two Speed Tracking Solenoid

9

Main Pump

10

Return Filter

11

Tank

12

Slew Motor

13

Extending Undercarriage Ram (not fitted on 8014 or 8016 machines)

14

Dozer Ram

15

Bucket Ram

16

Boom Ram

17

Dipper Ram

18

Boom Swing Ram

E-24

9803/9350-6

E-24

Section E - Hydraulics Schematic Circuits 8018 Tier 3 Machines from June 2012, 8014, 8016, 8020 Tier 3 Machines from March 2013 1 t e e h s 2 2 2 2 7 u 3 3 3

1 2 a 1 2

a 8

b 8

8 5

6

7

3 2 2 1

0 2 9

4 2

8 1

7 1

5 2

9 1

m 4

k 4

6 1 a 5 2

j 4

b 5 2 5 1

0 1

2 2

1 1

2 e u s s i 2 2 2 7 U / 3 3 3 . 0 1 g i F

h 4 g 4

4 1 3 1

f 4

e 4 d 4 c 4

2

b 4 a 4

1

E-25

9803/9350-6

E-25

Section E - Hydraulics Schematic Circuits 8018 Tier 3 Machines from June 2012, 8 014, 8016, 8020 Tier 3 Machines from March 2013


To

Colour

LHJ 1(LEFT HAND JOYSTICK)

VALVE a5

D PURPLE

LHJ 2

VALVE a1

S GREEN

LHJ 3

VALVE b5

S PURPLE

LHJ 4

VALVE b1

D GREEN

LHJ P

MANIFOLD 2

S RED

LHJ T

MANIFOLD B

S BLUE

MANIFOLD C

TANK RUN

S BLUE

OIL COOLER OUT

RETURN FILTER IN

S BLUE

PMV ACC

ACCUMULATOR

S RED

PMV B

RJ9

S RED

PMV C

VALVE Pp1

S RED

PMV D

VALVE P3

S RED

PMV JS

MANIFOLD 5

S RED

PMV JS (T-BRANCH)

VALVE Pp1

S RED

PMV P

PUMP P1

T RED

PMV PP

VALVE Pp

S RED

PMV T

MANIFOLD D

S BLUE

RHJ 1 (RIGHT HAND JOYSTICK) VALVE a8

S WHITE

RHJ 2

VALVE a9

D GREY

RHJ 3

VALVE b8

D WHITE

RHJ 4

VALVE b9

S GREY

RHJ P

MANIFOLD 1

S RED

RHJ T

MANIFOLD A

S BLUE

RJ3

CHANGE VALVE E1

D GREEN

RJ4

CHANGE VALVE E

S GREEN

RJ7

CHANGE VALVE D1

D YELLOW

RJ8

CHANGE VALVE D

S YELLOW

RJD

TANK BRANCH

S BLUE

SLEW MOTOR DR

RJD

S BLUE

VALVE A1

SLEW MOTOR B

S GREEN

VALVE A2

CHANGE VALVE V1

D YELLOW

VALVE A3

SWING RAM HEAD

D ORANGE

VALVE A6

RJ1

D PINK

VALVE A7

RJ2

S LILAC

VALVE A8

BOOM RAM ROD

S WHITE

E-26

9803/9350-6

Comment

E-26

Section E - Hydraulics Schematic Circuits 8018 Tier 3 Machines from June 2012, 8 014, 8016, 8020 Tier 3 Machines from March 2013 From

To

Colour

VALVE B1

SLEW MOTOR A

D GREEN

VALVE B2

CHANGE VALVE V

S YELLOW

VALVE B3

SWING RAM ROD

S ORANGE

VALVE B6

RJ5

S PINK

VALVE B7

RJ6

D LILAC

VALVE B8

BOOM RAM HEAD

D WHITE

VALVE P1

PUMP P3

S RED

VALVE P2

PUMP P2

D RED

VALVE Pp1 CAP DRAIN

SLEW MOTOR DR

S BLUE

VALVE T1

OIL COOLER T BRANCH

S BLUE

VALVE T1

SLEW MOTOR T

S BLUE

VALVE T2

OIL COOLER T RETURN

S BLUE

E-27

9803/9350-6

Comment

E-27

Section E - Hydraulics Schematic Circuits 8020 Tier 3 Machines up to February 2013

3 1 0 2 y r a u r b e F o t p u s e n i h c a M 3 r e i T 0 2 0 8

e m v a l m a R a m m m R a a V r e a t R R e d g R e m r n n e k e c o z a t m o h r u o x A B B D C E

4 5 6 7 1 1 1 1

y e K t n e n o p m o C

E-28

.

) 1 2 E ( . 9 g i F

8 9 1 1

e d v i l e a o v V n l e a i d l o V o S r n g o r t e g r n l o o i n t e r l o i n l i o M k e o l S e a c l r t M k v m t l a o n n r r n a i k c a t o i T r c a a k o V t n r r R e a c l p a d o T C t r g l o g t o o M l i t T d i C d l o e r n n t n e i e m F o i s B r u n n I d d o n p P n w w u M a y d n a J o n r l s o S S S t r a H y C l a H n k l s v u o a i t n w e i e m r l H t r n e m k H t f i e r o e m a i v o c i h n r e w a e a l v o e w V V t t t z x o f h f m g g P S T M R T S a a e a R a i o o i u u r o R o o l r r e e L R R M T B B A A T B D S A M L R M B

a b c d e f g h j k m a b 0 1 2 3 1 2 3 4 4 4 4 4 4 4 4 4 4 4 4 5 6 7 8 8 8 9 1 1 1 1

9803/9350-6

E-28


8 1 1 E 1 V

) E V L A V ( V

M 8 V P D L O F K I C N O A L M B

4

b 8

A

7 R P

P

E

D

T P

a 8

3

T

1 D

V P

2

0 0 M 2 P 2 R T

R E L L O R T N O C H R

E 1 P

9

P M U P

1 1 P

2 P

6

r a b 0 3

4

1 S

2 P

3 P

3 P

I P

r a b 0 1

M

0

3

T P

2

R E L L O R T N O C H L

1 e u s s i 1 0 6 6 T 2 3 3 . 1 1 g i F

5

1

a 4

1 p P

b c 4 4

8 a P

7 a P

m k 4 4

r a b 0 3 2

L E V A R T

9 A

9 B

k 4 r a b 5 7 2

2 p P

m 4

r a b 5 7 2

r a b

m j 4 g h 4 4 4 k 4 1 a P

1 T

U B

m m 2 . 1

8 A

8 B

7 B

6 A

6 B

5 A

4 A

5 B

5 b P

7 b P

3 A

4 B

3 B

N

R E U 0 R T T L I 1 E R F

E S T S U A P L Y O B S B R A A B 0 . 1 5 2

W E L S

G N I W S M O O B

L E V A R T

M R A

7 A

8 b P

0 3 2

. X U A

T E K C

r a b 0 6 1

r a b

0 3 2

M O O B

1 P

5 a P

2 T

r a b 5 7 2

f 4

e 4

d 4

R E Z

O D

2 A

2 B

1 1 A B

2 P

3 P

1 b P

R E N I A R T S 5 2 1

A

Y R T A T N I O O R J

!

B

3

B

B

P P

R O W T E L O S M

2 1

9 1

6 1

M O O B

R E Z

R E D N E T X E

O D R D

D E R

K C R A O R T T O H L M

1

E-29

!

P P

T

D E R

R D

T E K C U B

5 1

4 1

R E P P I D

N 1 K T 1 A

R D G N I W S M O O B

3 1

. D E R

K C R A O R T T O H R M

2

9803/9350-6

E-29



To

Colour

PUMP

VALVE BLOCK

RED

VALVE B9

RJ 1

S PINK

VALVE A9

RJ5

D PINK

VALVE B4

RJ 2

S LILAC

VALVE A4

RJ 6

D LILAC

VALVE B3

SWING RAM DUMP

D ORANGE

VALVE A3

SWING RAM ROD

S ORANGE

VALVE B1

LH PORT SLEW

S LIGHT GREEN

VALVE A1

RH PORT SLEW

D LIGHT GREEN

VALVE B2

CHANGE VALVE TOP

D YELLOW

VALVE A2

CHANGE VALVE BOT

S YELLOW

PMV 2 SPEED

RJ9

RED

CHANGE VALVE D

RJ7

D YELLOW

CHANGE VALVE D1

RJ8

S YELLOW

CHANGE VALVE P

RJ3

D DARK GREEN

CHANGE VALVE P1

RJ4

S DARK GREEN

P1

PMV P1

RED

P2

PMV P2

RED

P3

PMV P3

RED

TANK

RJ BLUE

PMV P

PRESSURE BLOCK

RED

PMV T

TANK BLOCK

BLUE


S WHITE

RHJ3

BOOM BOTTOM

D WHITE

RHJ4

BUCKET TOP

S GREY

RHJ2

BUCKET BOTTOM

D GREY

RHJT

TANK BLOCK

BLUE

RHJP

PRESSURE BLOCK

RED


DIPPER TOP

S PURPLE

LHJ1

DIPPER BOTTOM

D PURPLE

LHJ2

SLEW BOTTOM

D LIGHT GREEN

LHJ4

SLEW TOP S

LIGHT GREEN

LHJP

PRESSURE BLOCK

RED

LHJT

TANK BLOCK

BLUE

BOTTOM OIL COOLER

FILTER

BLUE

VALVE RETURN

TOP OIL COOLER

BLUE

E-30

9803/9350-6

Comment

E-30

Section E - Hydraulics Schematic Circuits 8020 Tier 3 Machines up to February 2013 From

To

Colour

VALVE B8

BOOM ROD

S WHITE

VALVE A8

BOOM DUMP

D WHITE

VALVE B5

DIPPER ROD S

PURPLE

VALVE A5

DIPPER DUMP

D PURPLE

RJ5 (ROTARY JOINT)

LH TRACK

D PINK

RJ1

LH TRACK

S PINK

RJ2

RH TRACK

S LILAC

RJ6

RH TRACK

D LILAC

RJ8

DOZER ROD

S YELLOW

VALVE LOCKOUT

PRESSURE BLOCK

RED

VALVE LOCKOUT

VALVE LOCKOUT

RED

SLEW DRAIN

ROTARY JOINT

BLUE

TANK BLOCK

TANK

BLUE

RJ3

EXT RAM DUMP

D DARK GREEN

RJ4

EXT RAM ROD

S DARK GREEN

RJ TEE

t MOTOR DRAIN

BLUE

RJ TEE

T MOTOR 2 SPEED

RED

RJ7

DOZER DUMP

D YELLOW

SLEW MOTOR LH SIDE

BLUE


S BROWN


D BROWN

Comment

VALVE B7

BUCKET ROD

S GREY

LONG DIPPER

VALVE A7

BUCKET DUMP

D GREY

LONG DIPPER

VALVE B7

BUCKET ROD

S GREY

XL DIPPER

VALVE A7

BUCKET DUMP

D GREY

XL DIPPER

VALVE B7

BUCKET ROD

S GREY

GRAVEMASTER

VALVE A7

BUCKET DUMP

D GREY

GRAVEMASTER

BUCKET

BUCKET

S GREY

BUCKET

BUCKET

D GREY

BOOM PILOT

BOOM PILOT

D WHITE

BUCKET PILOT

BUCKET PILOT

D GREY

E-31

9803/9350-6

E-31


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

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

2

The hydraulic fluid, filter and suction strainer are clean.

3

There are no visible leaks in the system.

4

Engine maximum speed and condition is as specification.

5

General Fault Diagnosis 1

ALL:Check 2. ONE:Check 6. 2

Hydraulic pressures for each service are correct to specification.

1

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

2

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

3

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

4

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

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

3

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

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

Is the fault in all services or one only?

NO:Adjust. 4

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

5

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

6

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

7

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

E-32

9803/9350-5

E-32

Section E - Hydraulics Fault Finding Hydraulic System 8

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

17

YES:Check 9.

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

NO:Adjust cable. 9

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

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

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

NO:Check 10. 10

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

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

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

NO:Reset or renew. 11

Is the valve block section cracked?

19

YES:Renew section and check valve block mounting

Is high speed engaging? YES:Check 20.

12 Are the rams faulty?

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

YES:Overhaul or renew. 20 13

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

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

21

Is the slew motor performance/braking poor?

ONE: Check 15. 14

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

Is the servo system operating correctly? YES: Check 15. 22

NO:Check servo pressure maintenance valve. 15

Is the hand controller plunger leaking/sticking?

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

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

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

E-33

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E-33

Section E - Hydraulics Fault Finding Slew Motor and Gearbox

Slew Motor and Gearbox Fault

Motor does not turn (The supplied pressure is correct)

Insufficient torque

Abnormal noise

Table 7. Possible Cause

Action

Relief valve pressure too low or faulty

Renew the relief valve

Motor has too much internal leakage

Renew the motor assembly

Motor has burned inner parts


Reduction gears damaged

Renew the gears

Overload

Remove the overload



Motor has too much internal leakage


Motor has burned inner parts



Renew the gears

Bearings damaged

Renew the bearings

Cavitation noise due to insufficient flow Check oil level and pipework Motor has damaged sliding parts



Renew the gears

Bearings damaged

Renew the bearings

Pinion gear damaged

Renew pinion

Damaged Ò' rings

Renew Ò' rings

Loose bolts

Retighten

Oil leakage at pinion gear

Damaged oil seal

Renew oil seal

Delay in starting



Check valve internal leakage

Renew check valve

Motor has burned or damaged sliding parts



Renew the gears

Bearings damaged

Renew the bearings

Oil leakage at housing joint face

Excessive heat generation

E-34

9803/9350-5

E-34


Service Procedures Hydraulic Contamination TE-002_2

Hydraulic Fluid Quality

cleaning unit. also refers.

Construction machinery uses a large volume of flui d in the hydraulic system for power transmission, equipment lubrication, rust prevention and sealing. According to a survey conducted by a pump manufacturer, seventy per cent of the causes of problems in hydraulic equipment were attributable to inadequate maintenance of the quality of the hydraulic fluid. Therefore, it is obvious that control of the quality of the hydraulic fluid helps prevent hydraulic equipment problems and greatly improves safety and reliability. Furthermore from an economic angle it extends the life of the hydraulic fluid if quality is maintained.

Fig 12. (

E-35). General Bulletin 011

Procedure Connect the cleaning unit in place of the hydraulic filter. Fig 12. ( E-35). Run the system for sufficient time to pump all the hydraulic fluid through the unit. Disconnect the cleaning unit and reconnect the filter. Top up the system with clean hydraulic fluid as required.

Effects of Contamination Once inside the system, hydraulic circuit contaminants greatly effect the performance and life of hydraulic equipment. For example, contaminants in a hydraulic pump develop internal wear to cause internal leakage and hence lower discharges. Wear particles generated will circulate with the hydraulic fluid to cause further deterioration in the performance of this and other equipment. Contaminants also enter principal sliding sections of the equipment causing temporary malfunction, scuffing, sticking and leakage and can lead to major problems.The main contaminants can be classified as follows: 1

Solid Particles - sand, fibres, metallic particles, welding scale, sealing materials and wear particles etc.

2

Liquid - usually water and incompatible oils and greases.

3

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

Fig 12. Cleaning Unit

These contaminants can appear during manufacture, assembly and operation.

Cleaning Operation The purpose of cleaning oil is to remove contaminants of all types and sludge by filtering hydraulic fluid through a

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E-35

Section E - Hydraulics Service Procedures Hydraulic Contamination

Contaminant Standards Dirt that damages your system is in many cases too small to be seen with the eye. The particle size is measured in microns. 1 micron = 0.001 mm (0.0000394 in). Listed below are a few typical comparisons: – Red Blood Cell = 8 microns (0.008 mm, 0.000315 in) – Human Hair = 70 microns (0.07 mm, 0.00275 in) – Grain of Salt = 100 microns (0.1 mm, 0.00394 in) Smallest particle visible to the naked eye is 40 microns (0.00157) approximately. Standards will often be quoted to ISO (International Standards Organisation) for which literature can be obtained.

Filters The filter assembly fitted to all product ranges is designed to filter all the contamination that is generated through use to the required level of cleanliness. The filter must be serviced to the requirements of the machine Service Schedules. To ensure optimum performance and reliability it is important that the machines hydraulic system is serviced periodically in accordance with the manufacturers requirements.

E-36

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E-36

Section E - Hydraulics Service Procedures Pressure Testing

Pressure Testing Main Relief Valves

Table 8. Pump 3 Section

A 1

2

Connect a 0 - 400 bar (0 - 6000 lbf/in ) pressure gauge to the port on the single or double solenoid pressure maintenance valve as below.

Dozer, Swing, Slew. B

Track Left Section

Track left, Dipper, Auxilliary. C

Track Right Section

Track right, Boom, Bucket.

B

C

A

3 P 2 P 1 P

A V P

R P

T T P

Fig 13. 2

Fig 14.

With the engine running at maximum speed and hydraulic fluid at normal working temperature, operate to full travel one of the rams in the circuit served by the valve under test Table 8. ( E-37) Fig 14. ( E-37)

3

Check the gauge reading is as detailed in Technical Data. If incorrect, use a spanner to prevent body F from turning and remove cap nut D. With the ram held at full travel and body F still prevented from turning, use a screwdriver to adjust the M.R.V. by means of the screw E until the gauge reads the correct pressure.

4

Fit cap nut D and tighten to 25 Nm (18 lbf ft). Do not overtighten. Check gauge reading is correct. Repeat procedure as necessary. If body F is disturbed, tighten to 50 Nm (37 lbf ft).

Note: Torque setting of the MRV is very critical to ensure correct MRV pressure and prevent oil leakage. The adjuster cap nut D can removed and refitted once only

E-37

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E-37

Section E - Hydraulics Service Procedures Pressure Testing using the existing washer and then tightened to 25 Nm (18 lbf ft). If the cap is removed and refitted again, a new washer must be fitted and the cap tightened to 22 Nm (16 lbf ft). 5

Switch off engine. Remove pressure gauge and refit blanking cap.

E D F

Fig 15.

E-38

9803/9350-5

E-38


Auxiliary Relief Valves 1

Remove the auxiliary relief valve from the control valve and plug the valve port.

2

Install the auxiliary relief valve into the test block B part number 331/31069.

3

Connect a 0 - 400 bar (0 - 6000lbf/in2) pressure gauge and hand pump, part number 892/00223, to test block.

4

Operate pump and adjust pressure setting plug C Technical until valve opens at correct pressure, Data ( E-3).

5

Lock the pressure setting plug with the locknut D and retest. Remove auxiliary relief valve from test block and refit to control valve.

Fig 16.

E-39

9803/9350-5

E-39


Servo Pressure 1

Remove the blanking cap and connect a 0 - 40 bar (0 - 600 lbf/in2) pressure gauge to the test point PR on the pressure maintenance valve (PMV).

2

With the engine running at maximum speed and hydraulic fluid at normal working temperature, operate the dipper service and check the gauge reading.

3

Technical If the servo pressure is incorrect Data ( E-3), adjust as follows: Slacken lock nut A and turn adjusting screw B clockwise to increase the pressure or anti-clockwise to decrease. Tighten lock nut to 25 Nm (18 lbf ft). Recheck the pressure as described in step 2.

4

Switch off engine. Remove pressure gauge and refit blanking cap. 3 P 2 P 1 P

A V P

R P

T T P

B

A Fig 17.

E-40

9803/9350-5

E-40


Cross Line Relief Valves There is a single relief valve A and B for each direction of slew. These valves are located in the head of the slew motor. The pressures should be checked to the values Technical quoted using the method described below Data ( E-3) . Ensure the hydraulic system is at correct operating temperature.

A 3 P 2 P 1 P

A V P

R P

T T P

B

Fig 19.

Fig 18.

3

Engage slew lock. With the engine running at maximum speed and the hydraulic fluid at working Techni cal Data ( E-3), fully select temperature slew left and hold whilst checking the pressure gauge reading.

4

Check that the pressure gauge reading equals the Technical Data ( E-3). cross line relief setting The relief valve cartridges are not pressure adjustable, if the recorded pressure is low, remove the valve from the motor and check for debris or failed seals. Clean valve components and renew seals if necessary, refit to motor and retest. if the correct pressure is still not obtainable the relief valve should be changed for a new one.

5

Repeat the test fully selecting slew right.

6

Stop the engine, remove the pressure gauge and fit blanking cap.

Cross Line Relief Valves A and B 1

Gain access to the slew motor.

2

Connect a 0 - 400 bar (0 - 6000lbf/in2) pressure gauge at test point on the pressure maintenance valve, as shown.

E-41

9803/9350-5

E-41


Control Valve Description Component Locations (Early Machines)

8

9

7 5

19

6 15

4 3 1

2

12

14 18

11

B8

17

B7

10 B6

B5 B3

P1

B4 A8

B2 A7

B1

A9

A6

T1

P2 A3 A2

P3

B9

A5

A4

A1

16 13

Fig 20.

E-42

9803/9350-6

E-42

Section E - Hydraulics Control Valve Description Spools

Auxiliary Relief and Anti-Cavitation Valves

1

Slew (

E-52)

2

Dozer (

E-51)

3

Swing (

E-50)

4

Track Left (

5

Dipper (

6

Au xi li ary (

7

Bucket (

8

Boom (

9

Track Right (

Dozer 10

Swing

E-46)

E-54) E-53)

E-47)

A2 Port

11

Anti-cavitation valve, Rod side

A3

12

Anti-cavitation valve, Head side

B3

E-49) E-48)

ARV, Rod side

Port

Dipper

Port

13

ARV, Rod side

B5

14

ARV, Head side

A5

Pump Ports

Boom

Port

P1

Pump Section 1

15

ARV, Rod side

B8

P2

Pump Section 2

16


A8

P3

Pump Section 3

Service Ports

Main Relief Valve 17

MRV, LH Track, Boom, Bucket

A1 to A9

18

MRV, Dozer, Swing, Slew, Dipper boost

B1 to B9

19

MRV, Dipper, Boom Boost

Tank Ports T1

E-43

Tank Line

9803/9350-6

E-43

Section E - Hydraulics Control Valve Description

Component Locations (Later Machines) B1 B2

14 B3

T1

A1 A2

B4 A3

17 B5

12

T2

A4 15

2

1

19

B6

P3

13

P1

A5

3

B7

21 B8

A6 16

B9

P2 A7

4

18

A8

5

20

6 7

A9

9 8 10 11 C126510

Fig 21.

Spool

Pump Ports

1

Slew

2

Dozer

3

Swing

4

Confluence

5

Auxiliary

6

Dipper

7

LH Track

8

Inlet

9

RH Track

10

Boom

11

Bucket

E-44

P1

Pump Section 1

P2

Pump Section 2

P3

Pump Section 3

Service ports

A1 to A9 B1 to B9

9803/9350-6

E-44

Section E - Hydraulics Control Valve Description Tank Ports

T1

Tank Line

T2

Tank Line

Auxiliary Relief and Anti-Cavitation Valves Dozer

Port

ARV and Anti-cavitation valve, Head side

A2

Swing

Port

13


A3

14

Anti-cavitaion valve, Rod side

B3

Dipper

Port

16

ARV and Anti-cavitation valve, Head side

A5

17

ARV and Anti-cavitaion valve, Rod side

B5

Boom

Port

20

Anti-cavitation valve, Rod side

A8

21

ARV and Anti-cavitaion valve, Head side

B8

12

Main Relief Valve

15

MRV, Slew, Dozer, Swing

18

MRV, Auxiliary, Dipper, LH Track

19

MRV, RH Track, Dozer, Swing

E-45

9803/9350-6

E-45


Control Valve Sections (Early Machines) 1

Track Left

1A Note: These sections are not interchangable

2

3

B

A

4 5

Fig 22. Torque Settings and Key Table 9. A

Head side port

B

Rod side port

1

MRV Adjuster Cap

2

See Note

See Note

MRV

50 Nm

37 lbf ft

3

Capscrew

4.5 Nm

40 lbf in

4

Capscrew

2.5 Nm

22 lbf in

5

Spring Adjuster

4.5 Nm

40 lbf in

2 Note: Torque setting of the MRV is very critical to ensure correct MRV pressure and prevent oil leakage. The adjuster cap 1 can removed and refitted once only using the existing washer 1A and then tightened to 25 Nm (18 lbf ft). If the cap is removed and refitted again, a new washer must be fitted and the cap tightened to 22 Nm (16 lbf ft).

E-46

9803/9350-6

Fig 23.

E-46

Section E - Hydraulics Control Valve Description Track Right 1

Note: These sections are not interchangeable.

1A 2

3

B

A

Fig 24.

4

Torque Settings and Key

5 Table 10. A

Head side port

B

Rod side port

1

MRV Adjuster Cap

2

See Note

See Note

MRV

50 Nm

37 lbf ft

3

Capscrew

4.5 Nm

40 lbf in

4

Capscrew

2.5 Nm

22 lbf in

5

Spring Adjuster

4.5 Nm

40 lbf in

Note: Torque setting of the MRV is very critical to ensure correct MRV pressure and prevent oil leakage. The adjuster cap 1 can removed and refitted once only using the existing washer 1A and then tightened to 25 Nm (18 lbf ft). If the cap is removed and refitted again, a new washer must be fitted and the cap tightened to 22 Nm (16 lbf ft).

2

Fig 25.

E-47

9803/9350-6

E-47

Section E - Hydraulics Control Valve Description Boom

3

4

B

5 A

Fig 26.

7


1

6

A

Head side port

B

Rod side port

1

Capscrew

4.5 Nm

40 lbf in

2

Spring Adjuster

4.5 Nm

40 lbf in

3

Cap

22 Nm

16 lbf ft

4

ARV

50 Nm

37 lbf ft

5

Check Valve Plug

20 Nm

15 lbf ft

6

Cap

22 Nm

16 lbf ft

7

ARV/Anti-cavitation Valve

30 Nm

22 lbf ft

2

4 7 Fig 27.

E-48

9803/9350-6

E-48

Section E - Hydraulics Control Valve Description Bucket

2

1 4

Fig 28.

A

Torque Settings and Key A

Head side port

B

Rod side port

1

Capscrew

4.5 Nm

40 lbf in

2

Spring Adjuster

4.5 Nm

40 lbf in

3

Check Valve Plug

20 Nm

15 lbf ft

4

Blanking Plug

30 Nm

22 lbf ft

3

B

3 4

Fig 29.

E-49

9803/9350-6

E-49

Section E - Hydraulics Control Valve Description Swing 3 1

4

B

5 A

6 Fig 30. Torque Settings and Key

7 2

A

Head side port

B

Rod side port

1

Capscrew

4.5 Nm

40 lbf ft

2

Spring Adjuster

4.5 Nm

40 lbf ft

3

Cap

22 Nm

16 lbf in

4

Anti-cavitation Valve

30 Nm

22 lbf in

5

Check Valve Plug

20 Nm

15 lbf ft

6

Anti-cavitation Valve

30 Nm

22 lbf ft

7

Cap

22 Nm

16 lbf ft

8

Capscrew

2.5 Nm

22 lbf ft

8

6

4 Fig 31.

E-50

9803/9350-6

E-50

Section E - Hydraulics Control Valve Description Dozer

7 1

B 6

A

Fig 32.

5


4

A

Head side port

B

Rod side port

1

Capscrew

4.5 Nm

40 lbf in

2

Spring Adjuster

4.5 Nm

40 lbf in

3

Capscrew

2.5 Nm

22 lbf in

4

Cap

22 Nm

16 lbf ft

5

ARV

50 Nm

37 lbf ft

6

Check Valve Plug

20 Nm

15 lbf ft

7

Blanking Plug

30 Nm

15 lbf ft

2 3

7 5 Fig 33.

E-51

9803/9350-6

E-51

Section E - Hydraulics Control Valve Description Slew

B 3

A

Fig 34. Torque Settings and Key

1

A

Head side port

B

Rod side port

1

Capscrew

4.5 Nm

40 lbf in

2

Spring Adjuster

4.5 Nm

40 lbf in

3

Check Valve Plug

20 Nm

15 lbf ft

2

Fig 35.

E-52

9803/9350-6

E-52

Section E - Hydraulics Control Valve Description Auxiliary

4

1

B

3 A

4

Fig 36. Torque Settings and Key

2 A

Head side port

B

Rod side port

1

Capscrew

4.5 Nm

40 lbf in

2

Capscrew

2.5 Nm

22 lbf in

3

Plug

20 Nm

15 lbf ft

4

Blanking Plug

30 Nm

22 lbf ft

Fig 37.

E-53

9803/9350-6

E-53

Section E - Hydraulics Control Valve Description Dipper 7

6

B

5

A

Fig 38.

4


2

1

Spring Adjuster

4.5 Nm

40 lbf in

2

Capscrew

2.5 Nm

22 lbf in

3

Cap

22 Nm

16 lbf ft

4

ARV/AntiCavitation Valve

50 Nm

37 lbf ft

5

Check Valve Plug

20 Nm

15 lbf in

6

ARV

50 Nm

37 lbf ft

7

Cap

22 Nm

16 lbf ft

3 1

4 6

Fig 39.

E-54

9803/9350-6

E-54


Control Valve Sections (Later Machines) A

B

C D E F G

H J K L

C126510-C1

Fig 40. Section A

Slew

B

Dozer

C

Swing

D

Confluence

E

Auxiliary

F

Dipper

G

LH Track

H

Inlet

J

RH Track

K

Boom

L

Bucket

E-55

9803/9350-6

E-55

Section E - Hydraulics Control Valve Removal and Replacement

Removal and Replacement Removal (Early Machines)

!

A

WARNING

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

A

INT-3-1-10_2

1

Position the machine on firm level ground. Stop the engine and vent the hydraulics.

2

Raise the cab, see Section B, Cab Tilting.

3

Remove the controls assembly, see Section D, Control Bar .

4

Undo and plug the feed and return hoses to the hydraulic tank.

5

Disconnect the hydraulic hoses from the valve block, plug both the hoses and the valve block to prevent the ingress of dirt. Identify the hoses as they are removed, ready for replacement.

6

Remove the linkages to the valve spools.

7

Remove the three screws and washers A securing the valve block to the frame. Remove the valve block from the machine to a clean working area.

E-56

A Fig 41.

Replacement Replacement is a reversal of the removal procedure. On completion, check the linkage for freedom of operation, top up the hydraulic system and test the circuits for circuit operation, leakage etc.

9803/9350-6

E-56

Section E - Hydraulics Control Valve Removal and Replacement

Removal (Later Machines)

!

WARNING A

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

B B

INT-3-1-10_2

1

Position the machine on firm level ground. Stop the engine and vent the hydraulics.

A A

2


3

Remove the controls assembly, see Section D, Control Bar .

A C126390

4

Undo and plug the feed and return hoses to the hydraulic tank.

5

Disconnect the hydraulic hoses from the valve block, plug both the hoses and the valve block to prevent the ingress of dirt. Identify the hoses as they are removed, ready for replacement.

6

Remove the linkages to the valve spools.

7

Remove the four bolts A securing the valve block to the frame.

8

Remove the three bolts B securing the valve block to the plate. Remove the valve block from the machine to a clean working area.

E-57

Fig 42.

Replacement Replacement is a reversal of the removal procedure. On completion, check the linkage for freedom of operation, top up the hydraulic system and test the circuits for circuit operation, leakage etc.

9803/9350-6

E-57

Section E - Hydraulics Control Valve Dismantling and Assembly

Dismantling and Assembly Dismantling Important: Absolute cleanliness is essential stripping and assembling hydraulic components.

when

Note: It is not necessary to separate valve sections to remove valve spools, connections, relief valves etc. from the valve block. If spools are removed, label them to make sure they are assembled in their original positions and facing the correct direction as each one is machined to match its bore. 1

Remove the nuts A from one end of the valve tie rods.

2

Stand the valve vertically on the other end of the tie rods.

3

Withdraw the sections one by one, discarding the intersection Ò' rings as you proceed. Note the position and orientation of the sections before removing them.

A

A C126380

Fig 44. Later Machines

Fig 43. Early Machines

E-58

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E-58

Section E - Hydraulics Control Valve Dismantling and Assembly

Inspection 1

Check the mating faces of the valve sections for scratching, pitting, burrs and/or corrosion. Renew valve sections as necessary.

2

Check the Ò' ring seatings, check valve locations and check valves for scratching, pitting, burrs and/or corrosion. Renew control valve sections or check valves as necessary.

Assembly Note: Use new seals and Ò' rings, smeared with h ydraulic fluid on assembly. Note: If a load check valve has been dismantled then when assembling check the valve poppet and seat for scratches, damage and cleanliness. Begin assembly with the poppet, followed by the spring and finally the plug. Screw the unit in by hand to feel for any misalignment or cross threading. Note: If a spool is removed, when assembling ensure that the Ò' ring and wiper seal (if fitted) are correctly seated and not damaged. Pay particular attention to cleanliness and the smooth finish of the spool. Ensure that the spools are fitted in their correct positions. 1

Ensure all sections are returned to their original location. Assembly must be carried out on a clean, smooth surface.

2

Screw the nuts to one end of each tie rod (to the end with the shortest length of thread).

3

Insert the tie rods into the first section of the valve. Place the section on the bench with the free length of the tie rod uppermost.

4

Lubricate the necessary Ò' rings and place on the required seats. Add the elements to the tie rods ensuring that mating surfaces are thoroughly clean.

5

After all elements are installed screw the nuts into the tie rods and tighten to 50% of the required torque.

6

Tighten the tie rods to a torque of 25 Nm (18.5 lbf ft) using a torque wrench.

E-59

9803/9350-6

E-59


Hydraulic Pump (8014, 8016, 8018 Machines) General Description The three section gear pump A is driven directly from the engine crankshaft. All three gear pump drive shafts P1, P2 and P3 are linked together via a splined coupling B. Each pump consists of two equal sized gears C running in mesh, one gear is part of the pump driven shaft and the second gear is part of an idler shaft. The basic principle of a gear pump depends on the meshing of these two equal size spur gears C. On the inlet side of the pump, oil is picked up and trapped in the space between the teeth on both gear wheels and the pump body. As the gears rotate the oil is carried around the pump until the spaces are filled by the meshing teeth of the second gear. This forces the oil out of the space, through the pump outlet and into the machine's hydraulic circuit. The three section pumps have a single inlet port D to the centre pump section, the two end pumps are fed via an internal gallery E.

E-60

9803/9350-5

E-60

Section E - Hydraulics Hydraulic Pump (8014, 8016, 8018 Machines) General Description

E D E

B B

717310

Fig 45.

E-61

9803/9350-5

E-61

Section E - Hydraulics Hydraulic Pump (8014, 8016, 8018 Machines) Dismantling, Inspection and Assembly

Dismantling, Inspection and Assembly Dismantling

the bushes should not show any prominent signs of wear.

For assembly the sequence should be reversed.

5

The numerical sequence shown on the illustration is intended as a guide to dismantling. Note: Before starting, lightly mark the pump sections, flange and end cover to ensure correct alignment on reassembly. 1

2

Use a soft-faced hammer to separate the pump sections but do not hammer the coupling off the shaft as this will result in internal damage. Do not use levers of any kind to separate pump components. Bushes 12 - 15, 29 - 32 and 46 - 49 must be marked to denote their location within the body. Do not dismantle sub-assemblies A, B or C until this has been done.

Note: The bushes are split into two halves, e.g. items 12 and 13. Each half must be individually marked to ensure correct re-assembly. 3

Remove bushes, gears and seals, keeping components of each section of the pump together in their relative positions.

Note: Note: Replacement pump sections are available.

Gear side faces, teeth and journals must be free from scoring, wear steps, bruising or pitting.

Assembly 1

Renew all seals and 'O' rings.

2

If refitting used components, ensure that they are fitted in their original positions.

3

Fit seal 55 with its spring inwards.

4

Tighten screw 4 to the torque settings given below.

Item

Nm

Kgf m

lbf ft

4

47 - 55

4.8 - 5.6

34.6 - 40.5

5

After assembly, pour a small amount of hydraulic oil into each outlet port and check that the shaft can be rotated without undue force, using a smooth jawed hand wrench hooked around the shaft or a suitable half coupling locked against the key.

Note: After fitting to the vehicle, check and top up hydraulic fluid level before starting. see Section 3, Routine Maintenance .

Inspection 1

Bodies 18, 35 and 52 can only be re-used if the 'cutin'(where the gears wipe into the body) is bright and polished in appearance and the depth does not exceed 0.076 mm (0.003 in.)

2

Ensure that the end cover, spacer plates and flange are free from damage which could result in oil leakage in the region of the seal contact faces.

3

If the shaft seal bore is worn, JCB Threadlocker and Sealant should be applied to the outside diameter of the seal.

4

The bushes must be perfectly flat on the faces which contact the gear side faces. The bearing bores must be free from scoring or other damage. The outside of

E-62

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E-62

Section E - Hydraulics Hydraulic Pump (8014, 8016, 8018 Machines) Pump Flow Testing

Pump Flow Testing Note: To achieve accurate flow figures it is recommended that the following procedure is adopted.

10

Move flow meter to pumps P1 and P2 in turn. To measure pump P1 the bucket service should be operated to maximum ram travel and held at maximum M.R.V. pressure. Similarly, to measure pump P2 output the dipper service should be operated and stalled to M.R.V. pressure, ensuring engine speed is readjusted.

9803/9350-5

E-64

Note: When gear pump testing, the two main pumps P1 & P2 are equal capacity capacity,, it may therefore only be necessary to compare the flows one to another.

!

WARNING

Accurate pump performance can only be measured with the hydraulic system at normal operating temperature. Consequently various hose connections may be required with HOT hoses, pipes and fittings. Care must be taken to avoid touching metallic fittings with bare hands and prevent hot oil dripping onto the skin. 8-3-5-9

1

With the hydraulic system at the correct working temperature, park the machine with the excavator end resting on the ground.

2

Stop the engine, leave the isolator lever in the 'down' position and ignition switch 'on', operate all excavator services to vent residual pressure.

3

Remove ignition key for safety.

4


5

Disconnect pump P3 pressure hose from the pressure testing steel pipe.

6

Insert flow meter into pump P3 pressure line ensuring there is a least 1 metre (36 in) of straight hose with straight fittings from pump to flow meter, this will prevent oil turbulence interfering with the recorded flow on the flow meter.

7

Startt the engine and run at rated speed. Star Data ( E-3)

8

Operate the dozer service to maximum M.R.V. pressure and check engine speed, readjust if necessary.

9

Note maximum flow recorded on meter. Technical Data ( E-3) for correct flow limit, if pump output falls below service limit, renew pump.

E-64

Technical


Hydraulic Pump (8020) General Description Fig 48. (

E-66).

The hydraulic pump is a small lightweight compact unit containing single piston pump A components, which is able to supply two equal flows to the hydraulic system. Mounted on the back of the pump body is a gear pump B supplying oil to the aux, dipper boost, dozer, slew and swing circuits. The piston pump rotating group of components seal against a fixed valve plate C in the pump casing. The valve plate has a single groove S machined for suction, but two concentric pressure grooves P1 & P2 both bridging the piston bores in the rotating barrel D, the outer groove supplies one hydraulic circuit whilst the inner groove supplies the second, both circuits receive equal flows.

When the machine starts to dig the pressures in the circuits begin to rise, this is sensed back to the pump and registers against the crown of the pistons G as the barrel rotates. The force of the pressure felt on the piston crowns is transmitted onto the swash plate and once the spring force of the summator is exceeded, the swash plate angle progressively decreases. decreases. This in turn decreases the piston stroke reducing the volume of oil pumped into the hydraulic circuits. The gear pump is a fixed displacement pump, and should this come under pressure whilst the machine is digging, the horsepower demands on the engine will increase. However, there is a pilot gallery H sensing gear pump pressure, running through the main pump housing to a plunger J behind the swash plate. This increases the load against the summator springs E decreasing the angle of swash plate further and so reducing the piston pump flows thus maintaining a constant horsepower demand on the engine.

P1 S

swash plate draws the pistons out of the barrel, filling the vacated space on top of the piston with oil, once past top dead centre the swash plate pushes the pistons back into the barrel displacing the oil out into the hydraulic circuits of the machine.

P2

C

A395070

Fig 47.

The piston pump has a constant horsepower control E which responds to hydraulic system pressure demands, as pressure in the circuits rise so the volume of oil being pumped into the circuits decreases, maintaining the horsepower demands within the power output of the engine and preventing an engine stall situation. The constant horsepower control, or summator, is a simple design incorporating a trunnion mounted 'swash plate' F which governs the stroke of the pistons in the pump barrel. This swash plate is spring loaded to an angle matching the maximum piston stroke hence maximum flow position. As the pistons G and barrel D rotate, driven by the engine, the

E-65

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E-65

Section E - Hydraulics Hydraulic Pump (8020) General Description

Fig 48.

E-66

9803/9350-5

E-66

Section E - Hydraulics Hydraulic Pump (8020) Removal and Replacement

Removal and Replacement Removal

Fig 49.

!

5

WARNING

Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. INT-3-1-10_2

1

Remove the left hand counterweight. (Weight approximately 180 kg.)

Note: The lifting eye on the counterweight is at the point of balance. 6

Drain the hydraulic tank into a clean container of suitable capacity, for reuse.

7

Disconnect hydraulic hoses and pipes 1, 2, 3 and 4 from the pump, cap open ports to prevent dirt ingress.

8

Remove the screws and washers 5 securing the pump to the engine flywheel housing.

Gain access to the engine compartment.

2

Select the starter switch to the ON position.

3

Relieve pressure from the hydraulic system.

4

Select the starter switch to the OFF position and remove the key. Disconnect the battery.

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E-67

Section E - Hydraulics Hydraulic Pump (8020) Removal and Replacement

Replacement Fig 49. (

E-67).

1

Renew filtered adaptor B fitted to gear pump.

2

Fill pump body with clean hydraulic fluid through suction port adaptor A. Cap adaptor to prevent oil draining whilst pump is refitted to flywheel housing.

3

Engage the pump driveshaft into coupling K, ensuring the shaft gear teeth mesh correctly with the splines in the coupling. Torque set bolts 5 to 98 Nm (72 lbf ft).

4

Replace pump connections 1, 2, 3 and 4. When fitting the adapters 2, 3 and 4, slacken the lock nuts completely and screw in the adaptors as far as possible. With the adaptors correctly phased, tighten the lock nuts to 108 Nm (80 lbf ft).

Note: There should not be any thread showing between lock nuts and adapters. 5

Refit suction hose 1 to adaptor A as quickly as possible to prevent oil loss, tighten worm drive clips.

6

Refit the left hand counterweight.

7

Refill hydraulic tank with oil to the correct level.

8

Ensure maximum no load engine speed does not exceed the figure specified, Technical Data.

Running-In A new pump is correctly bedded in by the manufacturer and will require no further running in after fitting.

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E-68

Section E - Hydraulics Hydraulic Pump (8020) Pump Flow Testing

Pump Flow Testing The following procedure can be used to establish hydraulic pump performance. The hydraulic pump is factory set and should not be adjusted. If the performance of the pump is poor it should be returned to JCB Service for inspection.

Y

Note: When variable displacement pump flow testing the results are critical to assessing the pumps performance and therefore the flow meters and pressure gauges must be checked for accuracy.

!

B Z

X

A D

WARNING

Accurate pump performance can only be measured with the hydraulic system at normal operating temperature. Consequently various hose connections may be required with HOT hoses, pipes and fittings. Care must be taken to avoid touching metallic fittings with bare hands and prevent hot oil dripping onto the skin.

C

P3 P1+P2

8-3-5-9

Fig 50.

Note: Before the following flow testing is attempted all hydraulic pressures should be checked for accuracy. It may be an incorrectly set relief valve causing engine over load or poor machine performance.

4

Open the engine cover and disconnect pumps P1 and P2 pressure hoses from the pressure testing steel pipes.

1

With the hydraulic system at the correct working temperature, park the machine with the excavator end resting on the ground.

5

Connect suitable lengths of hose to both steel pipes and join together with a Tee piece.

2

Stop the engine, leave the isolator lever in the 'down' position and ignition switch 'on'. Operate all excavator services to vent residual pressure.

6

3

Remove ignition key for safety.

Run a 1 metre (36 in) length of hose (to prevent oil turbulence interfering with the flow meter) to a suitably accurate reading flow meter and pressure gauge A and manual pressure loading restrictor valve B.

7

Run a length of hose from the meter to a second Tee piece then divide the flows along the correct neutral circuit paths X & Y of pumps P1 and P2.

8

Disconnect the hose from pump P3. Run a 1 metre (36 in) length of hose (to prevent oil turbulence interfering with the pressure gauge). to a suitably accurate reading pressure gauge C and manual pressure loading restrictor valve D.

9

Connect the resulting flow along the correct neutral circuit path Z for pump P3.

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E-69

Section E - Hydraulics Hydraulic Pump (8020) Pump Flow Testing Important: Both the load valves B and D must be fully open, otherwise major pump damage will occur. 10

Ensure the load valves B and D are fully open so that no hydraulic pressure is imposed on engine start.

11

Start the engine and set the throttle to the rated speed as detailed in Techni cal Data.

12

Slowly and progressively screw load valve D in to increase the load on pump P3 to 190 bar (8025Z and 8030Z) or 206 bar (8035Z) as recorded on the pressure gauge C.

13

Note the flow and pressure figures on the pressure gauge and flow meter A.

14

Slowly and progressively screw the load valve B in to increase the load on pumps P1 and P2 by 50 bar as recorded on the pressure gauge A.

15

Note the flow and pressure figures on the pressure gauge and flow meter A.

16

Continue to increase the load on pumps P1 and P2 in 50 bar intervals up to a maximum load of 300 bar.

17

Compare the results against the data shown to determine pump performance.

Fig 52. Theoretical Pump Performance

40 35

) n i m30 / s e r 25 t i l ( 2 20 P + 1 15 P w10 o l F

P3 = 190 bar

5 0

0

100

200

300

400

Pressure P1 + P2 (bar) Fig 51. Theoretical Pump Performance

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E-70

Section E - Hydraulics Hydraulic Pump (8020) Troubleshooting

Troubleshooting

Fault

Possible cause

Action

Overload to Engine

Speed is higher than standard

Re-adjust it as standard

Setting pressure is higher than specifications

Re-adjust it to specifications

Damage of internal parts of pump

Repair or renew

Speed down of Engine

Re-adjust Engine speed

Wrong Coupling

Repair or renew

Damage of internal parts of pump

Repair or renew

Air in the Oil

Check piping. Bleed the air in the hydraulic circuit

Water in the Oil

Renew Oil

Clogged up Suction filter

Clean or Renew

High Suction pressure

Correct the pressure

Damage of Piston shoe

Renew Piston shoe

Installation condition is no good

Correct installation condition

Wrong Coupling

Renew Coupling

Damage of O ring or packing

Renew O ring

Loosened Plug

Tighten Plug

Leaking from Oil seal

Renew Oil Seal

Low Pump flow or low pressure

Abnormal noise or abnormal vibration (Cavitations)

Oil Leakage

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E-71


Main Relief Valve Removal and Replacement Removal

A

C

The M.R.V.'s are located in the two track sections and the swing section of the control valve on early machines and in the confluence and inlet sections on later machines. A

Pump 3 Section - Dozer, Swing and Slew

B

Pump 2 Section - Track Left, Dipper, Aux

C

Pump 1 Section - Track Right, Boom, Bucket

B C

B C126510-C2


A

!

WARNING


1

Obtain access to the control valve, see Section E, Control Valve.

2

Relieve hydraulic pressure, if necessary disconnect and blank hydraulic hoses from the valve block.

3

Unscrew the M.R.V.(s) from the valve block, covering the port(s) to prevent the ingress of dirt. Remove to a clean working area.


Replacement Note: Seals are made from special material, ensure correct replacements are used. Note: Torque setting of the M.R.V. is very critical to ensure correct M.R.V. pressure and prevent oil leakage. The

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E-72

Section E - Hydraulics Main Relief Valve Removal and Replacement adjuster cap can removed and refitted once only using the existing washer and then tightened to 25 Nm (18 lbf ft). If the cap is removed and refitted again, a new washer must be fitted and the cap tightened to 22 Nm (16 lbf ft). 1

Screw the M.R.V. assembly into the valve block and tighten to 50 Nm (37 lbf ft).

2

Reconnect hydraulics and set the valve.

3

Refit the components removed to gain access to the valve(s).

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E-73


Auxiliary Relief Valves Removal, Dismantling, Inspection and Assembly Removal

B A

ARV's are located in the following sections of the main control valve: A

Dozer

B

Dipper

C

Boom

C

B C B

A

C126510-C3


!

WARNING



E-74

1

Obtain access to the control valve, see Section E, Control Valve.

2

Relieve hydraulic pressure, disconnect and blank any hoses or pipes which may interfere with the removal of the relief valve(s).

3

Unscrew the auxiliary relief valve(s) from the control valve and remove to a clean working area.

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E-74

Section E - Hydraulics Auxiliary Relief Valves Removal, Dismantling, Inspection and Assembly

Dismantling

Inspection

1

Prise off plastic locking cap.

2

Release adjuster lock nut 1 and remove adjuster screw 2.

3 4

Check valve components for scratching, pitting, distortion and/or corrosion. Note: If any part other than O-rings and washer are damaged the entire valve must be renewed.

Remove spring 3 and relief valve poppet 4. Unscrew upper valve body 5 and remove poppet 6 and springs 7.

If the valve has been dismantled it should be pressure tested before refitting.

Assembly 1 2 3 4

1

Clean the valve body and components in an appropriate solvent.

2

Assemble in the reverse order of dismantling.

3

If the valve has been dismantled it should be pressure tested before refitting.

5

7

6

Fig 57.

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E-75


Pressure Maintenance Valve and Dual Solenoid Valve Removal and Replacement Removal

Replacement

!

1

WARNING

Replacement procedure.

is

the

reverse

of

the

removal


1

Stop the machine on level ground with the bucket resting on the ground. Stop the engine and vent residual pressure from the servo accumulator by turning the ignition on and lowering the L.H. arm rest to the excavator operate position. Operate both excavator control levers in all directions until stored servo pressure in the accumulator has been exhausted.

2

Remove the key. Remove the left and right side skirts to gain access to the pressure maintenance valve and dual solenoid valve.

Note: It is possible to remove a valve cartridge for cleaning or resealing without removing the complete valve from the machine. 3

To remove the valve, mark hoses for correct replacement and remove. plug hoses to prevent the ingress of dirt. On the d ual solenoid valve, disconnect the cables.

4

Remove the bolts holding the valve to the slew frame.

Important: If there is evidence of damage to the valve or its seat caused by debris then the cartridges will require renewing. If a cartridge or valve complete is renewed it is recommended that the filtered adapters in the feed ports of the valve are also renewed.

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E-76


Track Motor General Description The track motor consists of a fixed section, made up of a hydraulic motor and valve unit, and a rotary section which is a simple double-step planetary speed reduction. When both tracks are selected to operate, the pump section P1 feeds the valve block section for the RH travel motor, P2 feeds the valve block section for the LH travel motor. Track feeds from the selected spools flow through the rotary coupling to the respective track motors. The motor valve plate A has two sets of ports B and C. B and C are connected to the motor inlet and outlet lines via the counterbalance valve. When pressurised fluid is introduced through A, pistons E, on the B side are forced against the swash plate D.

Reaction force from the swash plate generates radial force causing rotation of the cylinder block F. Torque generated at the cylinder block is transmitted to the output shaft G, through splines on the cylinder block. The end of the output shaft G has a spline connected gear which drives two sets of planetary gears H. These reduce output speed in two steps and transmit rotation to the rotary section of the motor via an integral ring gear J. Exhaust fluid is discharged from C. When the control valve, on the main valve block, is selected to opposite position, C becomes inlet port, B becomes outlet and rotation is reversed. For low speed operation (if two speed option is fitted), the 2-speed control valve supplies fluid to all ports on the port B side (or port C side), producing maximum torque.

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E-77

Section E - Hydraulics Track Motor General Description

Fig 58. Note: The track motor shown is typical only. The motors fitted to this machine differs in detail.

E-78

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E-78


Normal Operation Fig 59. (

Counterbalance Operation

E-79).

Fig 59. (

When travel is selected, pressure is fed from the main pump to one of the motor control valve ports, either X or Y depending on the direction of travel. Each port provides a restricted feed to either end of plunger Z via a small drilling from the port into the plunger bore. Pressure from the inlet port causes the plunger to move across, allowing flow to enter the motor via the control valve to port C. Oil is returned through the other port back to the tank.

E-79).

When the machine is on an incline it will tend to travel under gravity. Under such conditions the motor overspeeds, acting as a pump, increasing outlet pressure and lowering inlet pressure. Differential pressure causes the counterbalance plunger Z to shift and allow more flow from the counterbalance valve. Increased flow from counterbalance valve to motor causes motor inlet pressure to rise and balance outlet pressure compensating for gravitational action.

Motor Low Speed, High Traction Selected (where applicable) Fig 60. (

E-80).

With the high speed button deselected, the return spring A above two speed selector spool B returns the spool to the low speed position. Service ports C and D are connected via the rotary coupling to the track spool in the valve block. Depending on whether track forward or track reverse is selected either port C or D may be pressurised, the other port then returns exhaust oil back to tank via the rotary coupling and the track spool.

Fig 59.

Braking Fig 59. (

E-79).

When the control valve is reset to neutral, ports X and Y are connected to the tank return line. Pressure on both ends of the plunger is reduced to exhaust value and the plunger is re-centred. The metering notches on the plunger gradually limit the flow of return fluid from the motor and machine speed is smoothly reduced.

E-79

The illustration shows the upper service port C pressurised. Because the two speed tracking selector is not selected, the return spring A holds the selector spool B down allowing this pressurised oil to cross the spring cavity and on to two inlet ports in the valve plate E as well as across the top waisted section of the spool into the centre port of the valve plate. This means that at least four of the motor pistons receive high pressure oil, driving the motor at maximum torque (tractive effort) although at the lower speed. The opposite four pistons of the track motor are connected to tank via the lower waisted section of the two speed selector spool.

9803/9350-5

E-79


Fig 60. Motor Low Speed, High Traction Selected (where applicable) ( E-79).

E-80

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E-80


Motor High Speed, Low Traction Selected (where applicable) Fig 61. (

E-82).

With the high speed button selected, servo pressure from the servo pressure maintenance valve via the rotary coupling fills the cavity under the two speed selector spool B and lifts it against the return spring A. Service ports C and D are connected via the rotary coupling to the track spool in the valve block. Depending on whether track forward or track reverse is selected either port C or D may be pressurised, the other port then returns exhaust oil back to tank via the rotary coupling and the track spool. The illustration shows the upper service port C pressurised. Because servo pressure has lifted spool B, pressurised oil crosses the top waisted section only of the spool into the centre port of the valve plate E, supplying a maximum of two of the motor pistons, driving the motor at maximum speed (minimum torque/tractive effort). The opposite two pistons of the track motor displace the oil to tank via the lower waisted section of the two speed selector spool.

E-81

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E-81


Fig 61. Motor High Speed, Low Traction Selected (where applicable) ( E-81).

E-82

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E-82


Auto Kick Down Function (where applicable) When the pilot switch for high speed is turned on, the pilot pressure for high speed is lead into chamber #1 of the auto kick down valve A, and force F1 is applied. Force F1 overcomes spring force F4 , and shifts the auto kick down valve to the right, then the motor is switched to high speed mode. On the other hand, drive pressure of the hydraulic motor is lead into chambers #2 and #3, generating forces F2 and F3. At this point, force F3 is larger than force F2 due to the larger cross-sectional area. The difference between F2 and F3 becomes larger when higher pressure is applied. When the motor drive pressure exceeds the specified value to change the speed from high to low mode, the total force of F3 and F4 becomes larger than the total of F1 and F2, and the auto kick down spool shifts to the left, then the motor is switched to low speed mode.

Fig 62.

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E-83

Section E - Hydraulics Track Motor Track Motor Dismantling and Assembly

Track Motor Dismantling and Assembly Dismantling Fig 63. (

Assembly

E-85).

Fig 63. (

The numerical sequence shown on the illustration is intended as a guide to dismantling. Note: Brake Valve Dismantling As sem bl y ( E-86) for components of item 2.

For assembly the sequence should be reversed. 1

Renew all O-rings and oil seals.

2

Before fitting the oil seal 24, fill the inside of the lip with grease.

3

Install the oil seal 24 and the bearing 22 with a compression force of approximately 500 kgf (1100 lbf).

4

Before fitting the body 2 to body 26, pour hydraulic fluid into body 26.

and

When dismantling, remove pistons 11 for inspection. If pistons or cylinder bores are worn, renew the complete cylinder block and pistons assembly 9.

Item 1

E-84

E-85).

9803/9350-5

Table 11. Torque Settings Nm Kgf m

28 - 30

2.8 -3.0

lbf ft

20 - 22

E-84

Section E - Hydraulics Track Motor Track Motor Dismantling and Assembly

20 23

22 24

26

19

1 25

6 5 4

14 16

18

8 2

7

12 3

10 15 17

13

11

T020470 T020470

Fig 63.

E-85

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E-85

Section E - Hydraulics Track Motor Brake Valve Dismantling and Assembly

Brake Valve Dismantling and Assembly

7 1 2

5

6

8

9

10

11

4 3 17 18 19 20 21

16 15 14

12

13 Fig 64.

Dismantling

Assembly

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed. Renew all the Ò' rings supplied in the seal kit.

1

Cover all open orifices to prevent dirt entering the hydraulic system.

2

When removing the valve spools, note their orientation; they must be refitted correctly or the valve will not operate properly.

E-86

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E-86


Slew Motor General Description The slew motor consists of a reduction gearbox G, hydraulic motor M and hydraulic cross-line relief valve assembly C.

G

The hydraulic motor is an axial piston type and converts hydraulic energy supplied from the hydraulic pump into a rotary motion.

M

The hydraulic valve consists of cross-line relief valves D, which in conjunction with a double acting spool fitted to the valve block ensures that the inertia produced when stopping the machine is absorbed through the cross-line relief valves . This in turn produces a smooth machine stop also preventing the hydraulic motor becoming overloaded.

( )

Reduction Gearbox

M

Hydraulic Motor

C

Cross Line Relief Valve Assembly

D

Cross Line Relief Valves

E

Anti-Cavitation Valve

DR

Drain Port

A

A Port

B

B Port

T

T Port

C

)(

The gearbox is a single step planetary type, the gearing converts high speed rotary motion from the hydraulic motor into low-speed high torque, transmitted to the pinion shaft. G

D

D

( )

)(

E

DR A

E

T

B 760260

Fig 65.

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E-87

Section E - Hydraulics Slew Motor General Description D

C

T

B A DR

D

G M

760240

Fig 66.

E-88

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E-88

Section E - Hydraulics Slew Motor General Description

Hydraulic Motor Section 2

5

3 1

A 4 B Fig 67.

The hydraulic motor is an axial piston type, and changes the hydraulic energy supplied from the pump to the rotary motion required to drive the gearbox. Through a hydraulic valve, the pressurized oil is supplied to the valve plate 1. When the pressurized oil is supplied to the A port, this pressurized oil pushes the piston 2 in the cylinder barrel 3. This pushing force is changed to the rotational power by the swash plate 4 and transmitted to the shaft 5 which is connected to the gear section. The return flow from the cylinder port is going out through the B port of the valve plate 1. To reverse rotation, pressurized oil is supplied to the B port and returning oil exits through the A port.

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E-89


Cross Line Relief Valve Section

First Stage

The shockless relief valve consists of the direct relief valve (poppet) 1 and the piston 2 for changing the spring force in two stages. Fig 68. ( E-90)

When the P1 pressure is going up, the poppet 1 opens due to the pressure of the spring force F1.

Second Stage When hydraulic pressure is removed from port A or port B of the hydraulic motor, the motor carries on running due to inertia. The motor works as a pump, and the pressure (brake pressure) is felt on the output port side. The shockless relief valve releases this brake pressure with two stages of operation. This makes the shock smooth, and prevents the motor being damaged. It also makes the start of the motor smooth.

When P1 pressure enters the second chamber through the orifices A and B, the piston moves to its stroke-end C. With this action, the spring is compressed, the spring force becomes stronger, stronger, and the P1 pressure is increased to the setting pressure Ps.

Fig 68.

E-90

9803/9350-5

E-90


Anti Cavitation Valve Section

T020230-2

Fig 69.

When the swing motor is decelerated by operating the control valve, it continues to be moved by the inertia of the machine. Then, it works as pump, and the pressure of chamber C tends to become negative. However, when B port pressure is below cracking pressure of the relief valve, all flow in A port goes out from B port through the motor. Therefore, if chamber C can get flow only from the control valve, the flow will not be enough to prevent the negative pressure; as a result, cavitation could occur. The anticavitation valve 12 works to supply the flow from T port to chamber C, and thus prevents cavitation.

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E-91

Section E - Hydraulics Slew Motor Removal and Replacement

Removal and Replacement D

D

M Y

F

X

G Fig 70.

Removal

!

Vent residual pressure from within the hydraulic tank by releasing the tank filler cap. Gain access to the slew motor by raising the cab. See Section B, Cab Tilting Procedure.

2

Label, then disconnect the hydraulic hoses from the motor head, plug hoses and blank open ports to prevent the ingress of dirt.

3

Mark gearbox casing X and motor casing Y to aid reassembly.

4

Remove ring of capscrews F locating motor casing to gearbox casing.

5

Lift motor clear of gearbox and remove to a clean area for dismantling, if required.

6

Protect open gearbox from ingress of dirt.

WARNING

Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. immediately. INT-3-1-10_2

It is not necessary to remove the motor/gearbox complete to service either the motor M or the cross-line relief valves D. Important: Lubrication drain hose is a direct connection to hydraulic tank, consequently it must be plugged immediately to prevent excessive oil loss.

E-92

1

9803/9350-5

E-92

Section E - Hydraulics Slew Motor Removal and Replacement 7

If it is necessary to remove the gearbox, omit step 4 above and remove capscrews G. Remove the complete assembly to a clean area, then remove capscrews F.

Replacement

!

CAUTION

If gearbox mounting dowels have been left in slew frame, make sure the holes in the gearbox flange accurately align with the dowels on reassembly. Incorrectly aligned dowels may be pushed through the slew frame and abut against the slew ring as the gearbox retaining bolts are tightened. If this occurs the slew frame may need separating from the undercarriage to retrieve the dowels. 8-3-1-6

1

Remove protective cover from gearbox, position slew motor over gearbox, ensuring correct engagement of drive shaft splines.

2

Align marks made prior to dismantling, fit capscrews F and tighten to 26 - 32 Nm (19 - 23 lbf ft).

3

If fitting a new motor or one that has been drained of oil, fill the motor casing with hydraulic oil via port T before starting the engine.

4

Check relief valve Testing ( E-37)

5

When fitting gearbox to mainframe, tighten capscrews G to 215 - 275 Nm (160 - 200 lbf ft).

E-93

settings.

Pressure

9803/9350-5

E-93

Section E - Hydraulics Slew Motor Dismantling and Assembly

Dismantling and Assembly

9 8

7 4 5 2

6

1 12

3

11 10 13

14

15

Fig 71.

E-94

9803/9350-5

E-94

Section E - Hydraulics Slew Motor Dismantling and Assembly

Dismantling The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. Remove pistons for inspection. If pistons or cylinder bores are worn, renew the complete cylinder block and pistons assembly 8.

Assembly Renew all O-rings and oil seals. Before fitting the valve plate 9, ensure copper face is uppermost and smear with oil.

Item

Table 12. Torque Settings Nm Kgf m

Cross Line Relief Valve Check Valve

E-95

lbf ft

127-166

13.0-17.0

93-122

56-61

5.7-6.2

41-44

9803/9350-5

E-95


Rotary Coupling 8014, 8016 Single Speed Machines Removal Note: Before removing a suspected leaking coupling, ensure that the leak is from the coupling core and not a hose adaptor. Ensure all adaptors are tight.

!

WARNING


1

Raise cab to gain access to rotary coupling, see Cab tilting procedure Section B .

!

WARNING

Postion the machine on a firm, level surface before tilting the cab. The tilting gas struts must be fully raised and locked in position before attempting any service procedure. 8-5-1-4

2

Identify and remove the hydraulic hoses from the adaptors A and B. Blank both the hoses and the adaptors.

3

Remove the four bolts, nuts a nd washers C securing the rotary coupling to the undercarriage and lift clear of the mainframe.

Replacement 1

Replace in reverse order of removal.

2

Reconnect hydraulic lubricated 'O' rings.

3

Test the assembly for leaks.

E-96

hoses

using

new

lightly

9803/9350-5

E-96

Section E - Hydraulics Rotary Coupling 8014, 8016 Single Speed Machines A

A

A

K

H

L

J

F

M

B

B

C

G

B

M E D Fig 72.

E-97

9803/9350-5

E-97

Section E - Hydraulics Rotary Coupling 8014, 8016 Single Speed Machines

Dismantling 1

Note the positions and remove the adaptors A and B from the coupling. Discard the O-rings.

2

Remove the external circlip D and the ring E from the base of the coupling.

3

From the top of the coupling, carefully withdraw the core F from the shell G.

4

Remove the `V' seal H and the ring J.

5

Remove and discard the 'O' rings K and seals from the shell L.

Inspection 1

All 'O' rings and seals must be replaced with new.

2

If the core or shell show signs of wear, replace the complete rotary coupling.

Assembly 1

Assemble in reverse order of dismantling, fitting new O-rings and back-up rings, lightly lubricate with hydraulic fluid.

2

Fit lip seal M in the position and attitude shown.

E-98

9803/9350-5

E-98

Section E - Hydraulics Rotary Coupling 8016, 8018 Two Speed Machines

8016, 8018 Two Speed Machines Removal Note: Before removing a suspected leaking coupling, ensure that the leak is from the coupling core and not a hose adaptor. Ensure all adaptors are tight.

!

WARNING


1


!

WARNING


2


3


Replacement 1


2


3


E-99

hoses

using

new

lightly

9803/9350-5

E-99


A

M N A

A

K L H

P

B

B

C

J

B E B

D

F G

Fig 73.

E-100

9803/9350-5

E-100


Dismantling 1


2

Remove the four capscrews F retaining cover plate G.

3

Remove the external circlip D and spacer ring E from the base of the coupling.

4

From the top of the coupling carefully withdraw the coupling core H from the shell J.

5

Remove the `V' seal K and the ring L.

6

Remove and discard back-up rings N and O-rings M from the core.

Inspection 1

All rotary coupling core O-rings and back-up rings must be replaced with new and are only available as a set.

2

If the core H or shell J show signs of wear replace the complete rotary coupling.

Assembly 1


2

Fit lip seal P in the position and attitude shown.

E-101

9803/9350-5

E-101

Section E - Hydraulics Rotary Coupling 8018, 8020 Two Speed and Extending Undercarriage Machines

8018, 8020 Two Speed and Extending Undercarriage Machines Removal Note: Before removing a suspected leaking coupling, ensure that the leak is from the coupling core and not a hose adaptor. Ensure all adaptors are tight.

!

WARNING


1


!

WARNING


2


3


Replacement 1


2


3


E-102

hoses

using

new

lightly

9803/9350-5

E-102


F

G

A

J

H

B

C

Fig 74.

E-103

9803/9350-5

E-103


Dismantling 1


2

Remove the external circlip F and ring G from the top of the coupling.

3

From the top of the coupling carefully lift the coupling shell H from the core J.

4

Remove and discard back-up rings and O-rings from the core.

Inspection 1

All rotary coupling core O-rings and back-up rings must be replaced with new and are only available as a set.

2

If the core or shell show signs of wear replace the complete rotary coupling.

Assembly 1


E-104

9803/9350-5

E-104


Hydraulic Rams Precautions During Use TE-006

Installation 1

Precautions when installing the ram on the machine. a

2

Warm up sufficiently before beginning work. a

In cold conditions the rod seals may be frozen, so if the ram is operated at maximum pressure and maximum speed, the seals will be damaged.

c

Secure the piston rod with a band. It is very dangerous if the rod extends unexpectedly. Also, the rod can be damaged and become unusable.

b

There is a large amount of air in a new ram or one which has been left for a long time, so the ram will not operate smoothly. Also, if pressure is applied suddenly without bleeding the air, high temperatures will be generated due to adiabatic compression and the seals may burn.

c

Before beginning work, always move the ram at full stroke with no load and expel air from the cylinder.

Welding after installing the ram may result in damage. If electric welding is done even at a point away from the ram, there may be sparking inside the ram and it will become necessary to replace the ram with a new one.

When painting the machine, mask the ram.

3

If paint adheres to the rod surface or to the wiper ring and the ram is operated, the wiper ring will not function properly and foreign matter and paint can easily enter the ram. This will cause damage to the seals, drastically shortening the life of the ram.

When stopping or storing, do it at a safe and fixed position. a

Install the ram only when it is clean.

1

Use only under designated conditions. a

If hydraulic oil other than the designated oil is used, the seals quickly degenerate and become damaged. If the relief valve is set at a value higher than specified, it may cause ram damage and is dangerous.

b

In high temperature environments (approx. 90°C and above) or low temperature environments (below -20°C), seals quickly become damaged.

E-105

The installed ram cannot maintain the same position for a long period of time, because the oil inside the ram may leak and the hydraulic oil volume decreases as it cools. Stop or store the machine in a safe and fixed position.

Maintenance, Inspection Points

Caution During Use 1

2

The number one cause of ram oil leakage is rod damage. Be careful not to damage the rod.

Suspending the ram by the piping is not only dangerous, but can also cause damage to the cylinder.

a

4

When installing and removing from the machine, suspend the ram safely.

c

b

a

3

Special seal materials are necessary so check to see if the ram that you are using is suitable or not.

9803/9350-6

Carry out daily maintenance and inspection. a

The key point for correct long-term ram function is daily maintenance and inspection. Carry out maintenance and inspection so that the ram functions fully at all times. Always remove any mud, water, dust or oil film adhering to the rod and keep it in normal condition. However, when cleaning the wiper ring and seals, do not get them wet with water but wipe clean with a rag. To prevent rust forming during storage, the amount of exposed ram piston rod should be kept to a

E-105

Section E - Hydraulics Hydraulic Rams Precautions During Use minimum. If leaving for more than one week, apply a light coating of suitable grease or petroleum jelly to the exposed part of the ram piston rod. 2

Use genuine JCB parts when replacing parts. a

3

If parts other than genuine JCB parts are used, the desired results may not be obtained. Use only genuine JCB parts.

Caution during dismantling and reassembly. a

Dismantling the ram while it is still installed on the machine can be dangerous as unexpected movements of the machine can occur. Remove the ram from the machine and then dismantle.

b

If reassembled with dirty hands, foreign matter can enter the ram causing a shorter life span and also the other hydraulic equipment may be damaged. Reassemble in a clean state.

c

Follow the instructions in the diagrams regarding torque tightening for screwed parts. If the torque is too high or too low, it can cause damage.

E-106

9803/9350-6

E-106

Section E - Hydraulics Hydraulic Rams Removal and Replacement

Removal and Replacement !

WARNING

Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses and gloves. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. INT-3-1-10_3

!

WARNING

A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-1

!

WARNING

If air or hydraulic pressure is used to force out the piston assembly, ensure that the end cap is securely fitted. Severe injury can be caused by a suddenly released piston rod. HYD-1-2

E-107

9803/9350-6

E-107


Boom, Dipper and Bucket Rams Removal 1

With the engine idling, set the machine with the bucket on the ground.

2

Support the excavator under the angle between the dipper and boom to ensure it will not move when the ram is removed.

3

B

A

On boom and bucket rams, remove the protection plate. Support the ram under the gland bearing and remove locknut A and bolt B from the pivot at the eye end of the ram. Drive out the pivot pin C.

Z

C Z

Z

Z Z

C123730-2

Fig 76. Later Machines 4

With the engine idling, gently retract the ram rod into the cylinder by operating the relevant service.

5

Run the engine at idle and with the servo isolator lock in the operate position, move the control lever rapidly in both directions to vent any trapped pressure. Stop the engine.

!

WARNING

It is not possible to vent all residual pressure. Loosen the connection one full turn and allow the pressure to dissipate. Keep face and hands well clear of pressurised hydraulic oil and wear protective glasses. HYD-4-3

6

Support the ram and remove the locknut A and the bolt B from the pivot at the base of the piston. Drive out the pivot pin C. Disconnect the hoses. Remove the ram from the machine.


E-108

9803/9350-6

E-108

Section E - Hydraulics Hydraulic Rams Removal and Replacement Replacement 1

Locate the pivot point on the ram into the location on the machine structure. Fit the pivot pin C and secure using the bolt B and new locknut A.

2

Support the ram under the gland end of the cylinder, reconnect the hoses. With the engine idling, slowly extend the ram until the eye end locates correctly in the machine structure. Fit pin C. Secure using the bolt B and new locknut A.

3

Apply grease to the pivot points through the grease nipples. For grease specification see, Section 1, Fluids Lubric ants and Capacities. Capacities.

4

Connect the hoses to the cylinder, torque tighten.

5

On the bucket and boom rams, fit the protection plate and secure using the bolts.

E-109

9803/9350-6

E-109


Dozer Ram B

G

G C E A F D

Fig 77.

Removal

5

1

Set the machine in the posture shown with the dozer grounded onto suitable supports.

2

With the starter switch turned OFF, relieve residual hydraulic pressure by operating the hydraulic controls.

3

Disconnect the hydraulic hoses. Blank off the hoses and the open ports of the ram.

4

Remove locknut A and the bolt B from the pivot at the rod end of the ram. Support the ram and drive out the pin C. Lower the ram end onto a suitable support.

E-110

9803/9350-6

Remove locknut D and bolt E. Support the ram and drive out pin F. Carefully remove the ram from the machine.

E-110

Section E - Hydraulics Hydraulic Rams Removal and Replacement Replacement 1

Locate the pivot point on the cylinder end of the ram into the dozer frame.

2

Fit pivot pin F and secure with bolt E and new locknut D.

3

Fit the pivot point at the rod end of the ram to the machine.

4

Fit the pivot pin C and secure using the bolt B and new locknut A.

5

Apply grease to the pivot points through the grease nipples G.

6

Connect the hoses to the cylinder.

Note: Refer to Standard Torque Settings ( Section 1) and Retaining Compounds ( Section 1) for torque settings and sealant information.

E-111

9803/9350-6

E-111


Swing Ram C

Removal 1

Position the machine with upper structure slewed at 90º right to the tracks.

2

Swing the machine dig end fully to the right and lower the excavator to the ground.

3

Remove keep plate A at the rod end of the ram.

B

4

Support the cylinder and drive out the pivot pin B. With the engine idling, slowly retract the ram until the eye end clears the king post C. Stop the engine.

A

5

Operate the swing pedal in both directions to vent any residual pressure.

6

Remove floor mat and floorplates. Disconnect the ram feed hoses at the valve block, Plug the hoses and cap the open ports of the valve.

7

Locate the ram from underneath the upper structure. Remove the bolts and the spring washers securing the keep plate at the base end of the cylinder.

8

Remove the pivot pin.

9

Withdraw ram with hoses attached.

C123750-2


Replacement 1

Connect hoses to new/serviced ram. Locate the ram into the machine upper structure and align the cylinder end pivot point with the mating location in the machine frame.

2

From underneath the upper structure fit the pivot pin and secure with bolt, washer and keep plate.

3

Reconnect the hoses.

4

With the engine idling, slowly extend the ram until the rod end locates into the kingpost C, stop the engine.

5

Fit the pivot pin B. Refit and secure keep plate A.

Note: Refer to Standard Torque Settings ( Section 1) and Retaining Compounds ( Section 1) for torque settings and sealant information.


E-112

9803/9350-6

E-112

Section E - Hydraulics Hydraulic Rams Dismantling and Assembly

Dismantling and Assembly All Rams

!

6

Ensure that metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the seals.

7

Check the bore of the ram cylinder for damage.

8

Discard all seals and Ò' rings.

WARNING

If air or hydraulic pressure is used to force out the piston assembly, ensure that the end cap is securely fitted. Severe injury can be caused by a suddenly released piston rod. HYD-1-2

Inspection

Dismantling

Piston Rod Warp

The numerical sequence shown on the illustrations are intended as a guide to dismantling only.

1

Support the piston rod on a pair of 'V' blocks.

2

Set a dial test indicator (D.T.I.) at the approximate centre of the rod. Set the D.T.I. to zero.

3

Rotate the piston rod in its blocks, noting any variation in D.T.I. reading.

4

If warp (half the difference between maximum and minimum readings) exceeds 0.5 mm (0.02 in) the piston rod must be replaced.

For assembly the sequence should be reversed. Bucket Ram (

E-114)

Dozer Ram (

E-115)

Swing Ram (

E-115)

Boom Ram (

E-116)

Dipper Ram (

E-116)

Extending Undercarriage Ram ( 1

Pivot Bush Clearances

E-117)

1

Using an internal micrometer measure the internal diameter (I.D.) of the pivot pin bushes in the piston rod and cylinder ends.

2

Compare the readings with the permitted tolerances shown. Remove and replace pin bushes as necessary.

Support ram assembly as shown.

Piston Rod/Rod Bush Clearances 1

Using internal and external micrometers, measure the piston rod outside diameter (O.D.) and the rod bush inside diameter (I.D.).

2

Compare the readings taken with the permitted clearances. If necessary, renew the piston rod and/or the rod bush.

H07890-B1

Fig 80. 2

Slacken end cap 1 using Hook spanner / spanner and remove the piston rod assembly 2 from the cylinder.

3

Position piston rod assembly on bench in place of ram cylinder. Remove seals 3 and wear rings from piston head.

4

Undo nut/locking pin and remove / unscrew piston head from rod.

5

Remove end cap 1 from piston rod and remove the remaining Ò' rings and seals. Check the end cap bush for damage, scores or nicks. If damaged, the bush must be replaced as part of the end cap assembly.

E-113

Pin Bush Clearances 1

Using internal and micrometers, measure the inside diameter (I.D.) of the pin bushes in the piston rod and cylinder ends.

2

Compare the readings taken with the permitted clearances. Remove and replace pin bushes as necessary.

9803/9350-6

E-113

Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Assembly

Bucket Ram

1

Completely remove oil, grease, dirt and hardened locking compound from all threads. Remove all traces of rust using a wire brush.

2

Apply JCB Activator to threads of piston rod and cylinder. Apply JCB Threadlocker and Sealer to threads of end cap 1. Wait 15 minutes before Torque assembly, using correct torque figures. Settings ( E-114)

2 9 1 8

Table 13. Torque Settings End Cap (1) Lock Nut (5) Nm (lbf ft) Nm (lbf ft)

8014/8016 Bucket Ram, Swing Ram, Dipper Ram

490 (361)

8018/8020 Bucket Ram

637 (470)

343 (253)

8018/8020 Swing Ram, Dipper Ram

637 (470)

274 (202)

Boom Ram

637 (470)

274 (202)

Dozer Ram

588 (433)

490 (361)

Extending Undercarriage Ram

637 (470)

343 (253)

3

11 10 4

274 (202)

6

7

3

5

Use new seals and Ò' rings, lubricated with hydraulic fluid before assembly. Fig 81.

4

Take care not to damage seals during assembly.

5

Apply JCB High Strength Threadlocker & Sealer to thread of lock nut / locking pin.

6

Allow one hour at 20°C before filling the ram with oil.

E-114

9803/9350-6

E-114

Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Dozer Ram

Swing Ram

2

2 9 1

9 1

8 11

8 4

10 11

6

4

10 7

3

6

7

3 5

5

Fig 83. Fig 82.

E-115

9803/9350-6

E-115

Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Boom Ram

Dipper Ram

2

2 9

9

1

1

8

8 12

11

11

10

10 4

6

4 7

3

6

7 3

5

5

Fig 84. Fig 85.

E-116

9803/9350-6

E-116

8018 Hydraulic

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