Factory PDF Jcb Js130 Js160 _Repair_Workshop

General Information

1

Care & Safety

2

Routine Maintenance

3

Attachments

A

Service Manual

Body & Framework

B

Electrics

C

JS130

Hydraulics

E

Transmission

F

R

from machine no. 758000

JS160 from machine no. 702000

Brakes PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE: © WORLD PARTS CENTRE UTTOXETER, STAFFORDSHIRE, ST14 7BS, ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND Publication No. 9803/6410 Issue 1

Track & Running Gear Engine

G J K

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

= = =

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

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

= =

Attachments Body & Framework ...etc

The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual. Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. ‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards. Note: In this manual the term ‘swing’ may sometimes be used in place of ‘slew’ and the term ‘arm’ may sometimes be used in place of ‘dipper’.

9803/6410

Issue 1

Section 1

General Information

Section 1

i

i

Contents

9803/6410

Page No.

Bolt and Nut Torque Specifications

1-1

Torque Settings

1-2

Service Tools * Section B - Body and framework Section C - Electrics Section E - Hydraulics * Section F - Transmission

3-1 4-1 5-1 6-1

*Sealing and Retaining Compounds

7-1

Issue 2*

Section 1

General Information

Section 1

Bolt and Nut Torque Specifications

1-1

1-1

JS130/JS160 and Variants Tighten the bolts and nuts according to the table. Before and after daily work, check the bolts and nuts for looseness and for those missing. Tighten if loose and renew if missing. Tighten the bolts and nuts after the first 50 hours of the running-in stage and every 250 hours thereafter. Tightening Torque Table JS130/JS160 No

Tightening Point

Bolt Diameter Wrench

Tightening Torque kgf m

lbf ft

1† Travel Motor

M16

mm 24

270~310

27.6~31.8

200~230

2† Drive Sprocket

M16

24

220~310

27.6~31.8

200~230

3† Idler Wheel

M16

24

270~310

27.6~31.8

200~230

4† Upper (Carrier) Roller

*

M16/M20

24/30

270~310/520~608

27.6~31.8/53.2~62.2

200~230/385~450

5† Lower (Track) Roller

M16

24

270~310

27.6~31.8

200~230

6† Track Guard

M16

24

270~310

27.6~31.8

200~230

M16

24

310~360/640~750

32~37/65~76.5

229~266/472~553

7

Shoe Bolt

8

Counter weight

M27

41

845~980

86~100

622~723

9† Turntable Bearing (Undercarriage)

M16/M20

24

280~310/475~550

28.4~31.8/48.4~55.3

205~230/350~400

10† Turntable Bearing (Slew Frame)

M16/M20

24

280~310/475~550

28.4~31.8/48.4~55.3

205~230/350~400

11† Slew Equipment

M16/M20

24

280~310/475~550

28.4~31.8/48.4~55.3

205~230/350~440

12† Engine (Engine Mount)

M16

24

265~310

27~32

195~230

13† Engine Bracket

M10

17

65~75

6.5~7.6

47~55

14 Radiator

*

Nm

M12

19

60~70

6.2~7.2

45~52

15† Hydraulic Pump

M10

17

65~75

6.5~7.6

47~55

16† Hydraulic Oil Tank

M16

24

205~285

21~29

152~210

17† Fuel Tank

M16

24

225~285

22.4~29

162~210

18† Control Valve

M16

24

270~310

27.6~31.8

200~230

19† Rotary Coupling

M12

19

110~125

11.1~13.0

80~94

20 Cab

M16

24

127~137

13~14

94~101

21 Battery

M10

17

20~30

2.1~2.9

15~21

Note: Use JCB Threadlocker and Sealer (High Strength) (adhesive) on those marked † and tighten to the torque listed in the above table. The tightening torques for the bolts and nuts not listed above are as follows: Bolt Diameter (size) Wrench Hex. bolt Tightening Torque Wrench Hex. socket head bolt

Tightening Torque

9803/6410

M6

M8

M10

M12

M14

M16

M18

M20

mm

10

13

17

19

22

24

27

30

Nm

6.9

15.7

32.3

58.8

98.0

137.2

196.0

274.4

kgf m

0.7

1.6

3.2

5.9

9.8

13.7

19.6

27.4

lbf ft

5

12

24

43

72

101

145

202

mm

5

6

8

10

12

14

14

17

Nm

8.8

21.6

42.1

78.4

117.6

176.4

245.0

343.0

kgf m

0.88

2.2

4.2

7.8

11.8

17.6

24.5

34.3

lbf ft

6.5

16

31

58

87

130

181

253

Issue 2*

Section 1

General Information

Section 1

Torque Settings

1-2

1-2

Torque Settings Note 1: The figures quoted are for non-plated fasteners and are to be used only when there is no torque setting specified in the relevant procedure in this service manual. Note 2: The 4T grade settings DO NOT APPLY to fasteners used on the engine. If any 4T specification fasteners are found on the engine, these must be tightened to the figure quoted in the relevant engine manual.

Bolt Size

Strength Grade of Bolt or Stud 4T

9803/6410

8.8

10.9

Nm

kgf m

lbf ft

Nm

kgf m

lbf ft

Nm

kgf m

lbf ft

M3

0.39

0.04

0.28

-

-

-

-

-

-

M4

0.78

0.08

0.57

-

-

-

-

-

-

M5

1.67

0.17

1.2

-

-

-

-

-

-

M6

2.84

0.29

2.1

8.04

0.82

5.9

11.3

1.15

8.3

M8

7.06

0.72

5.2

19.6

2.00

14.5

27.7

2.82

20.4

M10

14.0

1.43

10.3

39.1

3.99

28.8

55.0

5.61

40.6

M12

24.6

2.51

18.1

68.5

6.98

50.5

96.2

9.81

71

M16

61.9

6.31

45.7

173

17.6

127.6

242

24.7

178.5

M20

122

12.4

90

337

34.4

249

475

48.4

350

M22

167

17.0

123

464

47.3

342

652

66.5

481

M24

210

21.4

155

584

59.5

431

821

83.7

606

M27

311

31.7

229

864

88.1

637

1220

124

900

M30

420

42.8

310

1170

119

863

1650

168

1217

M33

576

58.7

425

1600

163

1180

2260

230

1667

M36

736

75.1

543

2050

209

1512

2880

294

2124

M39

961

98.0

709

2680

273

1977

3760

383

2773

M42

1190

121

878

3300

336

2434

4640

473

3422

M45

1490

152

1099

4140

422

3054

5820

593

4293

M48

1780

182

1312

4960

506

3659

6970

711

5141

Issue 1

Section 1

General Information

Section 1

3-1

3-1

Service Tools (SECTION B) BODY AND FRAMEWORK

S186240

S186270

Hand Cleaner - special blend for the removal of polyurethane adhesives.

Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc.

4104/1310 (454g; 1lb tub)

892/00845

'

S186250

12V Mobile Oven - 1 cartridge capacity - required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket (715/04300).

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

992/12300

892/00843

S186280

S186260

240V Static Oven - available with 2 or 6 cartridge capacity - required to pre-heat adhesive prior to use. No plug supplied. Note: 110V models available upon request - contact JCB Technical Service 992/12400 - 2 cartridge x 240V 992/12600 - 6 cartridge x 240V

9803/6410

S186300

Glass Lifter - minimum 2 off - essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage. 892/00842 Issue 1

Section 1

General Information

Section 1

3-2

3-2

Service Tools (cont’d) (SECTION B) BODY AND FRAMEWORK

S186310

S186340

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

Cut-out Knife - used to remove broken glass. 992/12800

892/00848

'

S186350

S186320

Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass.

'L' Blades - 25mm (1in.) cut - replacement blades for cut-out knife (above).

892/00846

992/12801 (unit quantity = 5 off)

S186330 S186360

Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool (above).

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

892/00849 (approx 25m length)

892/00844

9803/6410

Issue 1

Section 1

General Information

3-3

Section 1 3-3

Service Tools (cont’d) (SECTION B) BODY AND FRAMEWORK

S186470

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

9803/6410

S186550

Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame. 926/15500 (unit quantity = 500 off)

Issue 1

Section 1

General Information

Section 1

4-1

4-1

Service Tools SECTION C - ELECTRICS

Electrical Test Equipment

993/85700

9803/6410

1

892/00283

Tool Kit Case

2

892/00281

AVO Meter

3

892/00286

Surface Temperature Probe

4

892/00284

Microtach Digital Tachometer

5

892/00282

Shunt - open type

6

892/00285

Hydraulic Oil Temperature Probe

7

892/00298

Fluke 85 Multimeter

Battery Tester

Issue 2*

Section 1

General Information

Section 1

5-1

5-1

Service Tools (continued) SECTION E - HYDRAULICS

Hydraulic Pressure Test Gauges and Connections 1

892/00279

Pressure Gauge 0-400 bar (0-6000 lbf/in2)

2

892/00346


3

892/00347

Connector

4

892/00254

Hose

5

892/00280


3 4

1/2/5

Pressure Test ‘T’ Adapters

Pressure Test Adapters

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

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

9803/6410

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

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

Issue 2*

Section 1

General Information

Section 1

5-2

5-2


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

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

816/50005 816/60096 816/00018

1/2 in BSP (A) x 1/2 in BSP (B) 3/4 in BSP (A) x 3/4 in BSP (B) 1 in BSP (A) x 1 in BSP (B)

Female Cone Blanking Plug

Male Cone Blanking Plug

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

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

9803/6410

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

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

Issue 1

Section 1

General Information

Section 1

5-3

5-3


JS07050

Ram Piston Nut Removal/Fitting Spanner

Ram Piston Nut Removal/Fitting Rig 993/99525 993/99522 993/99523 993/99524 556/43400 545/18000 811/50232

9803/6410

Rig Assembly (not including spanners and ram) Anchor Side Plate (supplied loose unwelded) Anchor Cross Member (supplied loose unwelded) Ram Eye End Modification Plate Assembly Lift Ram Lynch Pin 1,1/4” Pivot Pin

993/99512 993/99513 993/99514 993/99515 993/99516 993/99517 993/99518 993/99519 993/99520 993/99521 SSP0046 SSP0047

Spanner 55 mm A/F Spanner 60 mm A/F Spanner 65 mm A/F Spanner 70 mm A/F Spanner 75 mm A/F Spanner 85 mm A/F Spanner 90 mm A/F Spanner 100 mm A/F Spanner 110 mm A/F Spanner 115 mm A/F Spanner 80 mm A/F Spanner 95 mm A/F

Issue 1

Section 1

General Information

Section 1

5-4

5-4


30

¿70 (2.76")

¿38.+- 0.2 (1.50"+-0.008)

¿61.+- 0.2 (2.40"+-0.008)

Slew Motor Unit - JS130

o

2 (0.079") 14 (0.55")

155 (6.10")

4 (0.16") Seal Fitting Tool (Oil Seal 2)

¿32.2.+- 0.1 (¿1.27+-0.004)

¿35.5.+- 0.1 (¿1.40+-0.004)

¿42 (1.65")

JS07110

100 (3.94") 110 (4.33")

5o

¿31.4+-0.1 (1.24"+-0.004)

JS07120

¿40 (1.57")

¿38 (1.50")

Fitting Tool for Inner Ring of Taper Roller Bearing 3

50 (1.97") 80 (3.15")

50 (1.97") 60 (2.36") JS07130

JS07140

Seal Protector Heat polyvinyl tube in hot water and form to required shape.

9803/6410

Fitting Tool for Inner Ring 1

Issue 1

Section 1

General Information

Section 1

5-5

5-5

Service Tools (continued) SECTION E - HYDRAULICS Slew Motor Unit - JS160

40 (1.57")

2 x ¿9 (0.35")

200 250 (9.84")

100 (3.94")

40 (1.57")

10 (0.39")

Inner diameter ¿11 (0.43")

M10 180 (7.09") 240 (9.45") JS07100

Puller for Brake Piston Stud is threaded M10 on both ends for 20 mm (0.8 in) and fitted with two M10 nuts.

9803/6410

Issue 1

Section 1

General Information

Section 1

5-6

5-6

Service Tools (continued) SECTION E - HYDRAULICS Hydraulic Tank - JS130, JS160

A

Dia. 40 mm (1.57 in)

B

Dia. 26 mm (1.02 in)

C

40 mm (1.47 in)

D

50 mm (1.97 in)

E

Dia. 10 mm (0.39 in)

F

550 mm (21.7 in)

G

9 mm (0.35 in)

H

24 mm (0.94+0in)

I

Dia. 81 mm

J

Dia. 76 mm

K

24 mm (0.94 in)

L

95 mm (3.74 in)

M

Radius 0.7 mm (0.028 in)

A

N

120 mm (16.5 in)

B

O

4.0 mm (0.157 in)

P

3.0 mm (0.118 in)

Q

15°

O-ring

G75

+0 -0.004

-0.1

+0 (3.91 -0.1

in

) +0 -0.004

(2.99 in

)

C

D

E

F

N G M

Q

O

H

L P J I K

JS07150

Blank for Suction Strainer

9803/6410

Issue 1

Section 1

General Information

Section 1

5-7

5-7

Service Tools (continued) SECTION E - HYDRAULICS Remote Control Valve - JS130, JS160

13

¿26.5 23.5

1

2

19

17

25

42

50

65

¿19 ¿28

¿21 ¿25 ¿30

JS07160

Joint Removal Tool

15

Items 1 and 2 are assembled with an interference fit.

9803/6410

Issue 1

Section 1

General Information

5-8

Section 1 5-8

Service Tools (continued) SECTION E - HYDRAULICS Hydraulic Pump

Guide Rods

Rear Shaft Protection Tool Swash Plate Levelling Tool

Oil Seal Insertion Tool

Front Shaft Protection Tool

Bearing Insertion Tool

9803/6410

Issue 1

Section 1

General Information

5-9

Section 1 5-9

Service Tools (continued) SECTION E - HYDRAULICS Hydraulic Rams Reconditioning

Bush Removal/Assembly Jig

Seal Ring Insertion Jig (Inner)

Bush Removal/Assembly Jig

Seal Ring Bedding Jig

Cylinder Head Insertion Jig

Wiper Ring Installation Jig

Seal Ring Insertion Jig (Outer)

9803/6410

Issue 1

Section 1

General Information

Section 1

6-1

Service Tools (continued) SECTION F - TRANSMISSION Slew Gearbox - JS130

15 o ø94.5 +- 0.2 (3.72" +- 0.008) ø120 (4.72")

ø65 (2.56")

5o

60 (2.36")

3 (0.118")

14 15 (0.55") 6 (0.59") 30 (0.236") (1.18")

ø50 (1.97")

100 (3.94")

JS07180

ø130 (5.43") JS07170

Seal Protector Heat polyvinyl tube in hot water and form to the required shape on the pinion shaft

Seal Fitting Jig

Slew Gearbox - JS160

ø100 (ø3.937")

2.5 (0.098")

ø155 (ø6.094")

80 +0.3 -0 (3.15"+0.012" ) -0

*

6-1

ø149 (ø5.866") JS07200

JS07190

Bearing and Oil Seal assembly Jig

9803/6410

Seal Fitting Jig

Issue 2*

Section 1

General Information

Section 1

6-2

6-2

Service Tools (continued) SECTION F - TRANSMISSION Slew Gearbox - JS160 (continued)

3

ø30.5.+- 0.1 (ø46.5 +-0.1)

15

9

15

ø36 (ø50)

30

ø50

100

ø99.8

110

ø124 ø158

JS07230 JS07210

Jig for Taper Roller Bearing Inner Ring

Seal Fitting Jig

o

80

ø49.5

ø75

30

2 16

155 4 JS07220

Seal Fitting Jig (SST0033)

9803/6410

Issue 1

Section 1

General Information

Section 1

7-1

7-1

Sealing and Retaining Compounds JCB Multi-Gasket

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

4102/1212

A high strength locking fluid for use with threaded components.

4102/0551

JCB Retainer (High Strength)

For retaining parts which are unlikely to be dismantled.

4101/0651

JCB Threadlocker and Sealer

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

4101/0251

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

4101/0451

JCB Threadlocker and Sealer (High Strength)

A medium to high strength locking fluid for retention and sealing of ram piston heads.

4101/0552

JCB Activator

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

4104/0251 4104/0253

Aerosol Bottle

JCB Cleaner/Degreaser

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

4104/1557

Aerosol

Anti-Seize Paste

A compound used for assembly and prevention of parts seizure.

JCB High Strength Threadlocker

JCB Threadlocker

50ml

4003/0211

Direct Glazing Kit

For one pane of glass; comprises items marked † below plus applicator nozzle etc.

† Ultra Fast Adhesive

For direct glazing

4103/2109

310 ml

† Active Wipe 205

For direct glazing

4104/1203

250 g

† Black Primer 206J Clear Silicone Sealant

For direct glazing To seal butt jointed glass.

4201/4906 4102/0901

30 ml

The part numbers and descriptions of sealing and retaining compounds available from JCB Service have been revised with effect from January 1997 (see MI 563/H, 507/HA, 511/E). References to these products on subsequent pages in this service manual will be progressively updated, but for convenience a cross reference table is shown below. Old Description

Old Part Number

New Description

New Part Number


4102/0502


4102/0551

JCB High Strength Retainer

4101/0602

JCB Retainer (High Strength)

4101/0651

JCB Lock & Seal

4101/0202

JCB Threadlocker & Sealer

4101/0251

Loctite 243

4101/1101

Use 4101/0251

JCB Multi-Gasket

4102/1204

JCB Multi-Gasket

4102/1212

High Strength Lock and Seal

4104/0502

JCB Threadlocker & Sealer (High Strength)

4101/0552

JCB Threadlocker

4101/0402

JCB Threadlocker

4102/0451

Loctite Activator N

4104/0101 Aerosol 4104/0102 Bottle

JCB Activator

4104/0251 4104/0253

Super Clean Safety Solvent

4104/0601 Aerosol

No longer available, Replaced by

4104/1557

JCB Cleaner & Degreaser

4104/1538 Aerosol

JCB Cleaner/Degreaser

4104/1557

Note: High Strength Threadlocker was previously called High Strength Gasketing (4102/0502).

9803/6410

Issue 1

Section 2

Care & Safety

Section 2

i

i

Contents

9803/6410

Page No.

Safety Notices

1-1

General Safety

2-1

Operating Safety

3-1

Maintenance Safety

4-1

Issue 1

Section 2

Care & Safety

1-1

Section 2 1-1

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

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

! WARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-3

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

9803/6410

Issue 1

Section 2

Care & Safety

Section 2

2-1

2-1

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

Note: This section includes a certain amount of operating safety information. But remember that whenever you drive the machine or operate its controls, you are in effect a machine operator. Therefore you should read and understand the information given in the Operator Handbook before driving the machine or operating its controls.

Do not start any job until you are sure that you and those around you will be safe. If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE GEN-1-6

As well as the warnings in the following pages, specific warnings are given throughout the book. This section is designed to give a safety code for use of the machine generally and for operation and maintenance practices.

General Safety ! WARNING

! WARNING

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

Care and Alertness All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards. INT-1-3-5

INT-1-3-7

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

9803/6410

Raised Equipment Raised equipment can fall and injure you. Do not walk or work under raised equipment unless safely supported. 13-1-1-6

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

Issue 1

Section 2

Care & Safety

Section 2

3-1

3- 1

Operating Safety !WARNING

!WARNING

Engine The engine has rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open.

Ramps and Trailers Water, mud, ice, grease and oil on ramps or trailers can cause serious accidents. Make sure ramps and trailers are clean before driving onto them. Use extreme caution when driving onto ramps and trailers.

INT-2-1-6

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

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

!WARNING Visibility Accidents can be caused by working in poor visibility. Keep windows clean and use your lights to improve visibility. Do not operate the machine if you cannot see properly. INT-2-1-11

!WARNING

INT-2-2-6

!WARNING Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands. INT-2-2-3

! DANGER Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust. INT-2-2-10

!WARNING Controls Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls. If that happens, you will lose control of the machine. 2-2-3-6

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

!WARNING Exhaust Gases Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, fit an exhaust extension. If you begin to feel drowsy, stop the machine at once. Get out of the cab into fresh air. INT-2-1-10

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

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Issue 1

Section 2

Care & Safety

Section 2

4-1

4-1

Maintenance Safety !WARNING

!WARNING

Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground.

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

INT-3-2-4

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

Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbondioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Fire fighters should use self-contained breathing apparatus.

INT-3-1-3

INT-3-2-7/1

!WARNING Communications Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing. Before starting the engine, make sure the others are clear of the danger areas; examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken. INT-3-1-5

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

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

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

!WARNING Battery A battery with frozen electrolyte can explode if it is used or charged. Do not use a machine with a frozen battery. To help prevent the battery from freezing, keep the battery fully charged. INT-3-1-7

!WARNING Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter. INT-3-1-8

!WARNING Battery Terminals The machine is negatively earthed. Always connect the negative pole of the battery to earth. When connecting the battery, connect the earth (-) lead last. When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9

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

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

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Issue 1

Section 2

Care & Safety

Section 2

4-2

4-2

Maintenance Safety (cont’d) ! CAUTION

!WARNING

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

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

8-3-4-8

! CAUTION

Arc Welding Before carrying out any arc welding on the machine, completely remove the Control Computer to avoid damage to the circuits; also disconnect the alternator plug and battery leads. When welding items to the mainframe make sure that the earth clamp is positioned on the mainframe and when welding to the undercarriage make sure that the earth clamp is positioned on the undercarriage. If you earth one and weld the other, you may cause severe damage to the slew ring. Always connect the earth clamp to any other component being welded, i.e. boom or dipper, to avoid damage to pivot pins and bushes. 8-1-2-6/1

INT-3-1-10/1

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

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

!WARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: Damaged end fittings Chafed outer covers Ballooned outer covers Kinked or crushed hoses Embedded armouring in outer covers Displaced end fittings. INT-3-3-2

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

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

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

! CAUTION

8-3-4-4/1

!WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open. INT-3-1-11/1

If the machine is operated at full load, before its initial run-in procedure is complete, it may cause scuffing and seizing which can adversely effect the service life of the machine. 8-3-1-5

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

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

i

i

Contents Fluids and Lubricants Lubricants - Health and Safety

1-1 1-2

Service Schedules Service Intervals for Hydraulic Oil and Filters when using a Breaker or Crusher Initial Precautions For New Machine Usage Operating Hours Schedule

2-1 2-2 2-3

Greasing Slew Ring Bearing Slew Ring Teeth and Slew Pinion Excavator End

3-1 3-1 3-2

Battery

4-1

Fuses

*

9803/6410

Page No.

See Section C

Hydraulics Air bleeding procedures Releasing tank pressure Air bleeding from hydraulic pump Air bleeding from ram Air bleeding from the slew motor Checking the fluid level Topping up fluid level Changing the hydraulic oil Changing the Return Filter Element Flushing Filters Cleaning/Changing the Suction Strainer Changing the Air Breather Element Draining Tank Impurities Changing the Pilot Oil Filter Changing the Breaker In-line Filter Changing the Drain Line Filter Changing the Nephron Filter

5-1 5-1 5-2 5-2 5-3 5-4 5-4 5-5 5-6 5-6 5-7 5-8 5-9 5-9 5 - 10 5 - 10 5 - 11

Transmission Checking Track Gearbox Oil Level Changing the Track Gearbox Oil Checking the Slew Gearbox Oil Level Changing the Slew Gearbox Oil Replenishing Slew Gearbox Grease

6-1 6-1 6-2 6-2 6-2

Tracks and Running Gear Cleaning the Tracks Checking/Adjusting the Track Tension Checking the Shoe Plate Checking the Rollers and Idler Wheels for Oil Leaks

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

Issue 2*

Section 3

Routine Maintenance

Section 3

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ii

Contents

*

9803/6410

Page No.

Engine Changing the Air Filter Elements Checking the Oil Level Changing the Oil and Filter(s) Checking the Coolant Level Coolant Mixtures Changing the Coolant Adjusting the Fan Belt Fitting a New Fan Belt Cleaning the Radiator and Oil Cooler Draining Fuel Tank Impurities Draining the Water Separator Changing the Fuel Filter Element Bleeding the Fuel System

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

Component Location Diagrams

9-1

Performance Evaluation

10 - 1

Falling Objects Protection Structure (FOPS) Checking the FOPS structure

12 - 1

Issue 2*

Section 3

Routine Maintenance

Section 3

Fluids and Lubricants

1-1

1-1

CAPACITIES AND SPECIFICATIONS Capacity

International Item

Lubricant

Specification

JS130

JS160

12.1 litres (2.7 UK gal) (3.2 US gal)


ENGINE

(see separate chart)

TRACK GEARBOX

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105

2 x 3.0 litres (2 x 0.66 UK gal) (2 x 0.79 US gal)

2 x 3.0 litres (2 x 0.66 UK gal) (2 x 0.79 US gal)

SLEW GEARBOX

JCB HD90 Gear Oil


JCB Special HP Grease

Lithium based No. 2 consistency

5 litres (1.09 UK gal) (1.31 US gal) 1 litre (0.22 UK gal) (0.26 US gal)

5 litres (1.09 UK gal) (1.31 US gal) 1 litre (0.22 UK gal) (0.26 US gal)

TRACK ROLLERS IDLER WHEEL

JCB HD 90 Gear OIl


-

-

RECOIL SPRING CYLINDER


Lithium based, No. 2 consistency

-

-

HYDRAULIC SYSTEM

JCB Hydraulic Fluid 46

ISO VG46

124 litres (27.3 UK gal) (32.8 US gal)


SLEW RING - BEARING


-

-

- GEAR TEETH


Lithium based No. 2 consistency Lithium based No. 2 consistency

11kg (24.25 lb)

17kg (37.48 lb)

-

-

ALL OTHER GREASE POINTS


Lithium based No. 2 consistency

COOLING SYSTEM

see Coolant Mixtures

-



FUEL TANK

see Type of Fuel

-



*ENGINE LUBRICATION CHART - ALL COUNTRIES EXCEPT NORTH AMERICAN

-30

Use according to ambient temperature (°C) -10 0 10 20

-20

30

40

JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG JCB SUPER 10W/30 MULTIGRADE ENGINE OIL API CF4/SG *ENGINE LUBRICATION CHART - NORTH AMERICAN Use according to ambient temperature (°F) -22

-5

0

14

32

50

68

90

104

JCB 15W/40 MULTIGRADE ENGINE OIL API CF4/SG JCB 10W ENGINE OIL API CF4/SG 9803/6410

Issue 2*

Section 3

Routine Maintenance

Section 3

Lubricants - Health and Safety

1-2

1-2

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

First Aid - Oil

Handling

Swallowing

New Oil

If oil is swallowed you should not induce vomiting. Get medical advice.

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

Used Oil Skin In the case of excessive skin contact you should wash with soap and water.

Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer.

Eyes

Here are precautions to protect your health when handling used engine oil:

In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention.

1. Avoid prolonged, excessive or repeated skin contact with used engine oils.

Fires

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

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

! WARNING Do not use water to put out an oil fire. This will only spread it because oil floats on water. Extinguish oil and lubricant fires with carbon dioxide, dry chemical or foam. Fire fighters should use self contained breathing apparatus. 7-3-1-3/1

3. Note the following when removing engine oil from skin: a. Wash your skin thoroughly with soap and water. b. Using a nail brush will help. c. Use special hand cleansers to help clean dirty hands. d. Never use petrol, diesel fuel or gas oil. e. Avoid skin contact with oil soaked clothing. f. Don't keep oily rags in pockets.

Hygiene

g. Wash dirty clothing before re-use.

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

h. Throw away oil-soaked shoes.

Waste Disposal

However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.

All waste products should be disposed of in accordance with all the relevant regulations.

Low viscosity oils are more likely to do this, therefore particular care is necessary in handling used oils which can be diluted with fuel contamination.

The collection and disposal of used engine oil should be in accordance with any local regulations. Never pour used engine oil into sewers or drains.

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

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

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

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

Service Schedules

2-1

2-1

Service Intervals for Hydraulic Oil and Filters when using a Breaker or Crusher When using a breaker or crusher, contamination and degradation of the hydraulic oil occurs much more quickly than in normal excavating use. If the machine is used with increasingly degrading oil it can cause problems in the control valve, premature wear of the hydraulic pump and damage to the hydraulic system as a whole. Servicing of the hydraulic oil and filters must be done more frequently according to the percentage of total operating hours involving use of the breaker or crusher. When a breaker or crusher is fitted, ensure that the oil and filters are changed at the intervals shown in the table below. The hydraulic oil must be sampled and checked for contamination and degradation at the intervals shown.

Item

Time (hrs)

Hydraulic Oil

Use Frequency 100%

Use Frequency 40%

10

600

10

●

●

100

●

300

Use Frequency 20%

1500

10

●

●

●

800 4000

●

●

●

Suction Filter

¹

Drain Filter

●

●

●

●

Servo Filter

●

●

●

●

Nephron Filter

●

●

●

●

Breaker In-Line Filter

●

●

●

●

Hydraulic Oil Sampling

Every 200 hrs

Every 300 hrs

Every 600 hrs

Every 800 hrs

● Change

●

¹

●

10

Return Filter

● Check oil level and top up as required

●

600 3000

Use Frequency 10%

●

¹

● ●

¹

●

¹ Clean

Note: The filters must be changed whenever the period of breaker/crusher use exceeds 100hrs, regardless of the total number of hours the machine has worked.

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Issue 1

Section 3

Routine Maintenance

2-2

Service Schedules

Section 3 2-2

Initial Precautions for New Machine Usage ! CAUTION If the machine is operated at full load, before its initial run-in procedure is complete it may cause scuffing and seizing which can adversely effect the life of the machine. 8-3-1-5

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

1

Carry out the Daily inspection procedure

2

Always warm up the machine sufficiently

3

Hold the engine speed to 80% of the maximum

4

Check to see if the machine is running normally

5

Avoid running or swinging the machine rapidly

6

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

7

Where applicable, grease the front pins daily

8

At 50 hrs carry out servicing

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

Service Schedules

2-3

2-3

Every 10 Operating Hours or Daily

Every 100 Operating Hours or 2-Weekly

Whichever occurs first


1

Clean a Machine generally.

1

Do a 50 hour service plus:

2.

2

Grease (If operating in very wet conditions)

Clean a Battery terminals.†.

3

Check (Engine Stopped) a Generally for damage.

b Fuel lift pump strainer†. 3

b For oil and coolant leakage. c

b Engine oil main filter element †.

Security of bolts and nuts ††.

c

d For disconnected or shorted wiring, loose terminals. e

Change a Engine oil †.

d Engine oil filter by-pass element †.

Hydraulic fluid level.

e

f Engine oil level.

g Track and slew gearbox oil†.

h Windscreen washer fluid level.

l 4

h Fuel filter element†.

Fuel system for leaks.

k Fuel level.

4

c

d Excavator operation.

f

Operation of track and slew brakes.

Bucket pivot pin grease seals†.

d Track plate condition.

Exhaust for excessive smoke.

Transmission operation.

Hose and pipework for chafing or damage.

b Condition of ram piston.

b Operation of other electrical equipment.

e

Check (Engine Stopped) a

The breaker oil filter visual indicator (if using a rockbreaker).

Check (Engine Running) a Operation of warning lights and audible alarm.

c

Return filter element†.

f Drain filter element †.

g Track tension.

j

Servo oil filter element †.

e

Track and running gear.

f

Top and bottom track rollers for oil leaks †.

g Track idler wheels for oil leaks †. h Security of major unit mounting bolts and nuts†. If loose, tighten to specified torque.

g Operation of hour meter.

Every 50 Operating Hours or Weekly Whichever occurs first

i

Wiring for chafing.

j

Fan belt tension†.

k

Accumulator operation.

l

Radiator for damage†.

1

Do the daily jobs plus:

2

Clean a Drain water and sediment from fuel tank.

n Battery electrolyte level†.

b Drain fuel water separator.

p Exhaust system security†.

Grease a All pivot pins.

r

3

m Oil cooler for damage†.

5

Check (Engine Running) a

††

Tapping with a hammer will identify any loose nuts and bolts which should then be tightened to the specified torque.

Operation of throttle system†.

b Operation of overload warning†. c †

9803/6410

Teeth and sidecutters†.

Operation of stop control†.

These procedures are only to be carried out after the first 100 hours use of a new machine. Thereafter they are to be carried out as detailed in the following periodic checks.

Issue 1

Section 3

Routine Maintenance

Section 3

Service Schedules

2-4

2-4

Every 250 Operating Hours or Monthly

Every 1000 Operating Hours or 6-Monthly



1


1


2

Clean a Drain water and deposits from hydraulic oil tank.

2

Clean a Fuel lift pump strainer.

b Air cleaner dust valve. c 3

b

Pre-cleaner

3

Grease a Door and canopy hinges.

c

b Security of major unit mounting bolts and nuts. If loose, tighten to specified torque.

e

Nephron filter. †††

f

Servo oil filter element. †††

g Drain filter. †††

Track and slew gearbox oil level.

4.

d Fan belt adjustment. e

Track and slew gearbox oil.

d Return filter element. †††

Check (Engine Stopped) a Battery electrolyte level.

c

Change (Engine Stopped) a Engine air filter element (outer). b Hydraulic tank air breather element.

b Slew ring bearing. 4

Hydraulic fluid suction strainer.

Check (Engine Stopped) a Track wear.

Air inlet system security

Every 2000 Operating Hours or Yearly Whichever occurs first

Every 500 Operating Hours or 3-Monthly Whichever occurs first

1


2

Change a Hydraulic fluid suction strainer.

1


2

Clean a Radiator, grille and oil cooler fins.

3

Grease a Slew ring teeth.

4

Change a Engine oil.

Every 4000 Operating Hours or 2 Years

b Engine oil full flow filter element.


c

1


2

Change a Long life coolant.

Fuel filter element.

d Engine oil by-pass filter element. 5

6

Check (Engine Stopped) a Exhaust system security.

b Engine air filter element (inner). 3 *

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

b Fuel hose (fuel tank - engine).

b Top and bottom track rollers for oil leaks.

c

c

d Hydraulic pump exit hose (pump - operation valve).

Track idler wheels for oil leaks.

Fuel hose (fuel filter - injection pump).

d Hydraulic oil (check the degradation and cleanliness by sampling).

e

Boom ram line hose.

f

Dipper ram line hose.

e

Seat belt condition and security.

g Bucket ram line hose.

f

Teeth and sidecutters.

Check (Engine Running) a

Operation of throttle system.

††† If using a breaker or crusher, see page 2 - 1 for revised servicing schedules.

b Operation of overload warning. c

Operation of stop control.

9803/6410

Issue 2*

Section 3 2-5

Routine Maintenance Service Schedules

Section 3 2-5

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


2

Change Hydraulic oil. Hydraulic tank air breather element. Hydraulic suction filter. †††

††† If using a breaker or crusher, see page 2 - 1 for revised servicing schedules.

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

Greasing

3-1

! WARNING

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

3-1

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

Slew Ring Bearing 1

The three grease nipples are grouped together on the front of the machine.

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

Make the Machine Safe Stop the engine and remove the starter key.

2

Grease the Slew Ring a

Remove the Inspection port cover A (on the lower centre section).

b Remove the grease discharge port cover B (on the lower inner side). c

Remove contaminated grease.

d Replace the discharge port cover. e 3

Apply grease to the slew ring via aperture C.

Slew the Machine Start the engine and slew the machine a few degrees. Stop the engine, remove the starter key and apply grease again. Repeat until the whole ring is greased. Check that grease exudes around the entire circumference.

4

Refit the Cover

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Issue 1

Section 3

Routine Maintenance

Section 3

Greasing (continued)

3-2

3-2

! WARNING

Excavator End

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

16 Grease Points

8-3-1-3

Greasing Points

(No.) Reference drawing

Boom Boom ram, eye end pin

3. 1

Dipper ram, dump end pin Boom ram, dump end pin

2.

2

2. 3

1. 1.

Dipper to Bucket pin

1.

Bucket ram, dump end pin

1.

Boom to Dipper, connecting pin

9803/6410

Centralised greasing (total of 6 points)

2.

Dipper to Bucket Linkage pin

Dipper ram, eye end pin

}

1.

Bucket ram to Bucket linkage pin Bucket linkage to Bucket pin

Number of greasing points

4

1.

(total of 5 points)

(total of 3 points)

1.

Issue 1

Section 3 3-3

Routine Maintenance Greasing (continued)

Section 3 3-3

Excavator End

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

Battery

4-1

4-1

First Aid - Electrolyte

Check the Electrolyte Level

EYES

1

Open the Battery Compartment A

FLUSH WITH WATER FOR 15 MINUTES. GET MEDICAL HELP FAST.

IF SWALLOWED DO NOT INDUCE VOMITING. DRINK LARGE QUANTITIES OF WATER OR MILK. Then drink milk of magnesia, beaten egg or vegetable oil.

SKIN Remove the bolts securing the metal plate above the battery. Remove the plate.

FLUSH WITH WATER. REMOVE AFFECTED CLOTHING.

! WARNING Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and naked flames.

2

Remove covers and look at the level in each cell. The electrolyte should be 6 mm. (0.25 inch) above the plates. Top up if necessary with distilled water or de-ionized water.

Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zippers etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches in the cab to OFF before disconnecting the battery. When disconnecting the battery, take off the earth (-) lead first.

Check the Level

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

3

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

When reconnecting, fit the positive (+) lead first. Re-charge the battery away from the machine, in a wellventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up. 5-3-4-3

! CAUTION

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

Charge Rate Depending on the Battery specific Gravity Temperature 20°C

0°C

-10°C

100% (satisfactory)

1.26

1.27

1.28

90% (satisfactory)

1.24

1.25

1.26

80% (charge)

1.22

1.23

1.24

Charge Rate

75% (charge) 1.21 1.22 1.23 If the battery is charged and the charge rate is less than 75%, replace the battery.

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

Hydraulics

5-1

5-1

Air Bleeding Procedures Air Bleeding Sequence

! WARNING

Air Bleeding Air Bleeding Air Bleeding from slew Check from pump from ram motor

Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open. INT-3-1-11/1

Hydraulic oil or pump replacement

O

Ram replacement

O

O

O

O O

Slew motor replacement

O

O

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

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

1

Prepare the Machine a

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

b

Locate the hydraulic oil tank filler cap A or filler plate.

c

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

A

B

A

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

Hydraulics (continued)

5-2

5-2

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

A

INT-3-1-11/1

1

Prepare the Machine a Position the Machine on level ground. Stop the engine. Remove the starter key. b Loosen the air bleeding plug A to check that oil comes from the air bleeding port. c

If oil does not come out, remove the air bleeding plug A and fill hydraulic oil into the pump case through the air bleeding port.

d Temporarily tighten the air bleeding plug A. e

Idle the engine at low speed, slightly loosen the air bleeding plug and continue to run the engine until oil comes out from the air bleeding port.

f

Completely tighten the air bleeding plug A.

g Stop the engine and allow the bubbles to make their way through the hydraulic tank.

Air Bleeding from Ram ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open. INT-3-1-11/1

! WARNING

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

1


Position the Machine on level ground.

b Idle the engine at low speed and retract each ram 4 or 5 times without reaching the stroke end (about 100mm (4 in.) before the end of the ram. c

Operate each ram 3 or 4 times to the stroke end to completely bleed the air.

d Stop the engine and allow the bubbles to make their way through the hydraulic tank.

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3


5-3

Air Bleeding from the Slew Motor ! WARNING DO NOT remove the hydraulic tank filler cap or cover plate when the engine is running. The hydraulic system is under pressure. You or others could be injured. First stop the engine and then release the pressure.

5-3

JS130

JS160

8-3-4-4/1

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

1

Prepare the Machine a Position the machine on level ground.

A

A

b Idle the engine at low speed, loosen the air bleeding plug A and check that oil comes out from the air bleeding port. DO NOT SLEW THE MACHINE. c If no oil comes out, stop the engine, remove the air bleeding plug A and fill the motor case with hydraulic oil. d Temporarily tighten the air bleeding plug. e

Idle the engine at low speed and continue to run until oil comes out from the air bleeding port.

f

Completely tighten the air bleeding plug.

g Idle the engine at low speed and slowly slew the machine left to right evenly more than 2 turns. h Stop the engine and allow the bubbles to make their way through the hydraulic tank.

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3


5-4

5-4

For location of hydraulic oil tank see Component Location Diagram.

! WARNING

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

A

INT-3-1-10/1

Checking the Fluid Level 1

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

2

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

B

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

1

Prepare the Machine Position the Machine on level ground as at A. Stop the engine. Remove the starter key.

2

Locate the Hydraulic Oil Tank or Filler Plate See Component location Diagrams.

3

Release Tank Pressure See Releasing Tank Pressure.

4

Add Fluid. a Remove plug C. b Refill oil through the filler port using a suitable tundish. c Check the level through the level gauge on the side of the tank.

C

d Refit plug C.

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3


5-5

5-5

Changing the Hydraulic oil ! WARNING DO NOT remove the hydraulic tank filler cap or cover plate when the engine is running. The hydraulic system is under pressure. You or others could be injured. First stop the engine and then release the pressure.

A

8-3-4-4/1

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

1

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

2

Locate the Hydraulic oil tank or Filler Plate. See Component Location Diagrams at the end of the section.

3

Release Tank Pressure See Releasing Tank Pressure. a

Remove the filler port cover B and 'O'-ring C.

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

Remove the drain plug D on the bottom of the Tank and drain the remaining oil from the tank (have a drain pan ready).

4

Replace the Suction Strainer E See Changing the Suction Strainer.

5

Replace the Return Filter F See Changing the Return Filter.

6

Seal the system a Refit Drain plug D. b Refill the Tank Refill the Tank with Hydraulic oil (See Lubricants and Capacities for the type of fluid) to the specified level see Checking the Fluid Level. c

Install the 'O'-ring C and filler port cover B.

Note: If the 'O'-Ring C is damaged, replace it with a new one. 7

Bleed the Hydraulic Components See Air Bleeding Procedures

8

Check for leaks a Start the engine and run it for around 5 minutes without load. b Slowly operate the Travel, slew and cylinders several times.

9

Check the fluid level See Checking the Fluid Level.

9803/6410

Issue 1

Section 3 5-6

Routine Maintenance Hydraulics (continued)

5-6

Changing the Return Filter Element 1

C

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

2

Locate the Return filter. See Components Location Diagram at the end of this section.

3

Release Tank Pressure. See Releasing Tank Pressure.

4

Section 3

A B

D E

Removing the Element a Remove the retaining bolts A and washers B and take off the cover plate C complete with its 'O'-ring seal.

F

b Remove the spring D, bypass valve E and element F.

*

5

Fit a New Element Re-assemble in reverse order, using a new filter element F and replace the 'O'-ring with a new one if the one removed is worn or damaged.

6

Seal the system Refit the cover plate C and secure with bolts A and washers B.

Flushing Filters A slave hydraulic flushing element can now be obtained for the machine. It is a mandatory requirement that the hydraulic system is flushed when: 1

The hydraulic system has become contaminated with debris.

2

Major hydraulic components such as pumps, valve blocks, ram, tanks, motors etc. are changed.

3

5

Run the machine as described below: The filter should be left in the machine for a minimum of 4 hours, during which time all hydraulic services must be operated a minimum of 20 times to ensure complete system cleanliness.

6

After the required flushing time has elapsed, stop the engine and vent hydraulic pressure (see Releasing Tank Pressure).

An oil sample report indicates that the system needs to be cleaned.

7

Remove flushing filter element and save in a clean condition until step 10 is completed.

The slave filter should be fitted in place of the main return filter during flushing only.

8

Fit new main hydraulic filter and refit tank cover.

1

9

Take oil sample and send for analysis.

10

If analysis shows that the oil is out of specification the flushing procedure should be repeated until analysis confirms that the oil is satisfactory.

Vent hydraulic tank pressure (see Releasing Tank Pressure) and then remove tank cover C, main hydraulic filter F, relief valve E and spring D.

2

Fit flushing filter element, relief valve G and spring D.

3

Refit tank cover C, ensuring that the ‘O’ ring is positioned correctly.

4

Start up machine and test for leaks.

9803/6410

Element Required SSP0061

All JS Machines up to and including JS160.

Issue 2*

Section 3 5-7

Routine Maintenance

Section 3


5 -7

Cleaning/Changing the Suction Strainer 1

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

2

Locate the Suction Strainer

3


4

Remove the suction Strainer a Remove the retaining bolts A and washers D, lift off cover plate B. b Remove the suction strainer C and clean with a suitable solvent or, if renewing discard.

5

Fit the Suction Strainer Fitting is a reversal of removal.

6

Check the Hydraulic fluid Level See Checking the Fluid Level.

7

Seal the System Refit the cover plate B together with its 'O'-ring.

B

D

A

Note: Check the 'O'-ring, if it is worn or damaged replace it with a new one and secure with bolts A and washers B.

C

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3


5-8

5-8

Changing the Air Breather Element 1


2


3

Locate the Air Breather Cover A See illustration.

4

A

Replace the air Breather Element B a Remove the hexagonal nut D and sealing washer E. b Remove the cover A (note: slot). c

5

Replace the air breather element B, when installing re-fit the sponge packing F above element.

H

Re-fit Breather Cover A a Align the slot on the air breather cover A with the slot on the cover plate G. b Refit the sealing washer E, hexagonal nut D and nut cap C.

C D E slot A F B

G

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3


5-9

5-9

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

1

Prepare the Machine Position the machine on level ground. stop the engine. Remove the Starter Key.

2


3

Drain the Tank Impurities Remove the tank drain plug A and drain off accumulated water and other deposits (have ready some means of collecting the impurities). The task is complete when clean hydraulic fluid flows out.

4

Seal the System Refit the drain plug A.

A

Changing the Pilot Oil Filter 1


2

Release Tank Pressure (See Releasing Tank Pressure).

3

Locate the Pilot Oil Filter

4

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

5

Clean the Filter Base and Case Discard any fluid in the filter case. Clean out the case and the underside of the head.

6

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

Screw the filter case A to the head B and tighten with the wrench.

9803/6410

Issue 1

Section 3

Routine Maintenance

5 - 10


Section 3 5 - 10

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


2


3

Locate the Filter

4

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

5

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

Changing the Drain Line Filter 1


2


3

Locate the Filter

4

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

5

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

9803/6410

JS02830

Issue 1

Section 3

Routine Maintenance

Section 3


5 - 11

5 - 11

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

1


2


3

Remove the Nephron Filter A a Close the two stop cocks B of the nephron filter case C. b Remove the retaining bolts D, washers E and lift the cover F, together with the 'O'-ring G and spring H. c

Slowly lift the Nephron filter A and remove.

Note: Be careful not to drop any dirt from the nephron filter A. 4

Replace the Nephron filter A a Peel off the 4 foil seals of the new nephron filter (one on the upper and lower side, and the other two on the sides).

Note: If the foil is not removed, the filter will not function properly.

D

G

H I

F

E B

b Slowly sink the new nephron filter A into its case. c

Install the spring H, 'O'-ring G and cover F, secure with bolts D and washers E.

d Open the two stop cocks B on the nephron filter case C. 5

C A

Air Bleeding a Start the engine and set at low idling, loosen the plug I, tighten the plug when hydraulic oil flows out. b Stop engine and Check the hydraulic oil level. See Checking the Fluid Level.

9803/6410

Issue 1

Section 3

Routine Maintenance Transmission

6-1

Section 3 6-1

Note: There are two alternative configurations of filler, level and drain plugs as shown in figures X and Y. The following text covers both configurations.

Checking the Track Gearbox Oil Level 1

Prepare the Machine Position the machine on level ground with the level and drain plugs on a perpendicular line, with the level plug uppermost.

2

Check the Level on One Side Clean the area around filler/level plug A or filler plug C/level plug D and remove one or both plugs. Oil should run from plug A or D. Top up through plug A or C if necessary. (See Fluids and Capacities for oil types).

3

Clean and Refit the Plug(s) Make sure they are tight.

4

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

Changing the Track Gearbox Oil 1

Prepare the Machine See Checking Track Gearbox Oil Level.

2

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

! CAUTION Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the drain plug.

Key A B C D

filler/level plug drain plug filler plug level plug

2-3-4-2

b Remove filler/level plug A or filler plug C and drain plug B. Allow the oil to drain out. c

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

d Wrap seal tape on the drain plug and refit. 3

Fill with New Oil See Lubricants and Capacities for oil type and volume. a

Pour new oil through filler/level plug A or filler plug C until oil runs out of plug A or D.

b Clean and wrap seal tape around the plugs. Tightly refit filler/level plug A or filler plug C/level plug D. 4

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

5

Check for Leaks Run the machine, operate the tracking controls and t h e n make sure there are no leaks.

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

Transmission (continued)

6-2

6-2

Checking the Slew Gearbox Oil Level 1

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

2

Locate the Slew Gearbox See Component Location Diagrams at the end of this section.

3

Check the Level a Remove the dipstick A, wipe it clean and re-fit.

JS130

b Remove the dipstick again and check that the oil level is within the range B. c 4

If necessary, top up through filler port C. (See Lubricants and Capacities for oil type).

Refit the Dipstick. F

Changing the Slew Gearbox Oil 1


2

Drain the Oil a Remove the drain plug D. Allow the oil to drain out.

E

b Wipe the drain plug clean. Remove any metallic particles. c 3

Refit the drain plug. Make sure it is tight.

Fill with New Oil See Lubricants and Capacities for oil type and volume.

JS160

Fill with new oil through filler port C until it reaches the full mark on the dipstick when settled. refit the dipstick. 4

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

Replenishing Slew Gearbox Grease 1


2

Remove Air Bleed Plug E. F

! CAUTION Failure to remove the bleed plug before adding grease could damage the inner seal.

E

8-3-4-7

3

Fill Up with Grease See Lubricants and Capacities for grease type. Pump in grease through nipple F until the grease starts to ooze from bleed plug E. Refit and tighten the bleed plug.

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

7- 1

Tracks and Running Gear

7-1

Cleaning the Tracks ! WARNING

! WARNING

If two people are doing this job make sure that the person working the controls is a competent operator. If the wrong control lever is moved, or if the controls are moved violently, the other person could be killed or injured.

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

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

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

To clean the tracks you must turn them. When the tracks are turning, keep clear of rotating parts. Before starting this job, make sure that you have no loose clothing (cuffs, ties, etc) which could get caught in rotating parts.

8-3-3-2

4

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

5

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

6

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

Keep people not involved with the job well away! 8-3-3-1

1

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

2

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

3

Rotate the Track

9803/6410

Issue 1

Section 3 7-2

Routine Maintenance Tracks and Running Gear (continued)

Section 3 7-2

Checking/Adjusting the Track Tension 1

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

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

2

Check the Tension Measure gap A in line with the third roller from the front and between the lower surface of the track frame and the upper surface of the shoe. The dimension should be 275-295 mm for hard ground conditons. For operation on soft sand or sticky mud it should be 320-340mm.

3

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

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

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

If a gap C exists between the idler wheel shaft and the track frame, you may use pressure to apply the grease.If there is no gap C after the application of grease, then the necessary repairs must be carried out. Note: Excessive tension can cause the track rail to wear the drive rollers and sprocket, insufficient tension can cause wear to the drive sprocket and track rail. 4

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

5

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

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

Tracks and Running Gear (continued)

7-3

7-3

Checking the Shoe Plate 1

Prepare the Machine a Position the machine on level ground. Run it backwards and forwards several times. Stop after running it forwards. b Stop the engine and remove the starter key.

2

Checking the Shoe Bolts A Check to see if any are loose or damaged.

3

Tightening the Shoe Bolts A Tighten the shoes bolts A in the sequence shown to the correct torque. See Bolt Torque Specifications.

A

Checking the Rollers and Idler Wheels for Oil Leaks 1

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

2

Look for Oil Leaks Check the top and bottom rollers and the idler wheels for oil leaks.

! CAUTION Do not run the machine if you discover oil leaks in the top or bottom rollers or idler wheels. Failure to rectify such leaks could cause damage to the machine. 8-3-4-6/1

3

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

4

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

9803/6410

Issue 1

Section 3

Routine Maintenance

8-1

Section 3

Engine

8-1

Changing the Air Filter Elements 1

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

2

Stop the Engine Remove the starter key.

Note: Renew the inner element every second time you renew the outer element. As a reminder, mark the inner element with a felt tip pen when you renew only the outer element.

B

C

A

Outer element must be changed sooner if the filter warning light on the instrument panel lights up. DO NOT run engine with end cover or dust valve removed. DO NOT attempt to wash or clean elements they must be removed. 3

Locate the Air Filter (See Component Location Diagram).

4

Open the Hydraulic Compartment

5

Remove the Elements Remove end cover A. Remove the outer element B. Remove the inner element C.

6

Clean the Filter Clean the pre-cleaner, the inside of the canister D, the end cover A, and dust valve E.

7

Fit the New Elements Carefully insert the new inner element into the canister. Make sure it seats correctly. Carefully insert the new outer element B. Make sure it seats correctly.

8

Assemble the Filter Fit the end cover A onto the canister. Make sure the dust valve E is fitted, then fasten the retaining clips. Fit the pre-cleaner. Make sure the air filter blocked switch connector is fitted.

9803/6410

D

E

Issue 1

Section 3

Routine Maintenance

Section 3

Engine (continued)

8-2

8-2

Checking the Oil Level 1

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

2

Stop the Engine

3

Open the Engine Compartment

4

Check the Oil Level Remove the dipstick A. The correct oil level should be between the two indicator marks. Add oil if necessary through filler B. Use the recommended oil (see Lubricants and Capacities). Make sure that the dipstick and filler cap are secure.

Changing the Oil and Filters 1

Do steps 1-3 of checking the Oil Level

2

Drain the Oil Place an oil collecting container of suitable size beneath the engine sump drain point. Remove drain plug D.

B

A

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

3

Change the Filters a Unscrew the filters C. b Clean the filter heads. c

4

Smear the seal on each new filter with oil. Screw in the new filter canisters hand tight only.

Fill the System Securely tighten the drain plug D and refill the engine with new oil through filler cap B (See Lubricants and Capacities). Wipe off any spilt oil. Make sure the filler cap B is secure.

5

C

D

A

Check for leaks a Before starting the engine, turn the engine over with the Engine Shutdown control pressed down until the oil pressure warning light goes out . b Start the engine and let it idle for a few minutes c

Stop the engine, and let it stand for a few minutes, remove the key.

d Check the engine for any leaks, and check the oil level. See Checking the Oil Level. Note: Check the oil level only after about 20 minutes. If you check it straight after the engine has stopped, the oil level indicated will be false as the oil is still distributed around the engine and needs to fall.

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

Engine (continued)

8-3

8-3

Checking the Coolant Level

Coolant Mixtures

1

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

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

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

2

Release System Pressure For location of engine cooling radiator, see Component Location Diagrams at the end of this section. Carefully slacken cap A. Let any pressure escape. Remove the cap.

3

4

Check the Level The level should be between the FULL and LOW marks on the expansion bottle B. Top up the bottle with pre-mixed water/anti-freeze if necessary. See Coolant Mixtures.

Antifreeze Solution 55%

Starts to freeze at -36°C(-33°F)

Never use less than a 50% solution otherwise there will not be enough corrosion protection. Never use more than 60% solution otherwise the cooling system may be damaged. Leave the antifreeze in all year round as it gives protection against corrosion. Check the strength of antifreeze solution at least once a year, preferably at the start of the cold period. Always renew the antifreeze every two years. A 50% antifreeze mixture should be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant's boiling point.

Refit the Pressure Cap A Make sure it is tight.

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

A

B

9803/6410

Issue 1

Section 3

Routine Maintenance Engine (continued)

8-4

Section 3 8-4

Changing the Coolant 1

Do Steps 1 and 2 of 'Checking the Coolant Level'

2

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

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

3

Flush the System If necessary. Use clean water.

4

Refit the Drain Plug Clean and refit the drain plug B, making sure it is tight. Close the radiator drain tap A.

5

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

6

Refit the Radiator Pressure Cap Make sure it is tight.

7

Refit the Expansion Bottle Cap Make sure it is tight.

8

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

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

Engine (continued)

8-5

8-5

Adjusting the Fan Belt ! WARNING D

Make sure the engine cannot be started. Disconnect the battery before doing this job. A

2-3-3-5

1

Check the Fan Belt Tension There must be 10 mm (0,4 in) slack at D on the belt.

2

Loosen the Alternator Slacken bolts A and B.

3

Adjust the Fan Belt Use tension bolt C to adjust the alternator so that there is 10 mm (0.4 in) slack at point D on the belt. Note: If the fan belt is stretched so much that it cannot be adjusted correctly, fit a new belt (see below).

4

C

B

Secure the Alternator Re-tighten bolts B. Then re-tighten bolt A.

Fitting a New Fan Belt 1

Loosen the Alternator Slacken bolts A and B and adjust tensioner C so that the fan belt can be removed.

2

Fit a New Fan Belt With the alternator located as in 1, fit a new belt, making sure its 'V' profile locates in the pulleys correctly. Note: It may be necessary to apply slight leverage to the new belt to get it over the pulleys.

3

Adjust the Fan Belt Carry out steps 3 and 4 of Adjusting the Fan Belt.

4

Re-check the Fan belt Tension After about 1 hour's running re-check the belt tension.

9803/6410

Issue 1

Section 3

Routine Maintenance Engine (continued)

8-6

Section 3 8-6

Cleaning the Radiator and Oil Cooler A clogged radiator and/or oil cooler can lead to engine overheating. Regularly check for a build-up of dirt and debris and, if necessary, use compressed air to clean out the grille. At the same time check all hoses for damage or perishing, and replace if necessary. Note: Do not use high-pressure steam as it can deform the radiator. 1

Cleaning the Radiator Net Remove the net for cleaning. When using the machine in dusty conditions, inspect the net for clogging every day, then replace.

2

Swing-out Type Oil Cooler (if fitted) a Remove the oil cooler mounting bolts/washers A, the housing cover and stays, then swing the cooler out. b Clean the oil cooler and then return it to its normal position. c

Fasten securely.

d Start the engine and check for leaks. 3

Non-Swing Oil Cooler a Remove the oil cooler mounting bolts/washers A. b Remove the oil cooler. c

Clean the oil cooler and then return it to its normal position.

d Fasten securely. e

Start the engine and check for leaks.

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

Engine (continued)

8-7

8-7

Draining Fuel Tank Impurities Stop the engine and remove the key. Loosen the drain tap A on the underside of the fuel tank. Drain the water and deposits until clean diesel oil flows out. Close the drain tap firmly.

! WARNING

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

Draining the Water Separator The water separator should be drained at least every 50 hours, but more often if necessary. Stop the engine and remove the key. Open the drain plug B to release the accumulated water in the bowl. Under no circumstances should the float C be allowed to rise above the red line D or water could get taken further into the system with serious consequences.

D C

B

Changing the Fuel Filter Element 1

Stop the Engine Stop the engine and remove the key.

2

Disconnect the Battery

3

Open the Engine Compartment Locate the fuel filter.

4

Remove the Element A Using a chain wrench, unscrew the filter element from the filter head. Avoid spilling the fuel retained in the element.

5

Fit the New Element a Smear the new filter element sealing ring with fuel oil and hand tighten onto the filter head. Use a chain wrench to tighten by a further 2/3 turn.

A

b After installation, bleed the air. c

Wipe up any spilled fuel.

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3

Engine (continued)

8-8

8-8

Bleeding the Fuel System Air in the fuel system could cause misfiring or failure to start. Air will enter the system if any part of it is disconnected or emptied.

C

Note: Running the engine with air in the system could damage the fuel injection pump. After maintenance, remove air from the fuel system as detailed below. 1

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

2

Disconnect the Battery Remove the - ve lead to chassis.

3

Open the Engine Compartment Locate the priming pump and bleed point (see Illustrations).

4

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

5

Bleed the System Loosen bleed plug C. Depress knob A to bleed air from filter.

6

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

7

Check for Leaks

B

A

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

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

9803/6410

Issue 1

Section 3 9-1

9803/6410

Routine Maintenance Component Location Diagram

Section 3 9-1

Issue 1

Section 3

Routine Maintenance Performance Evaluation

10 - 1

Section 3 10 - 1

Introduction It is important before taking measurements that control conditions are maintained. a

Position the machine on a level safe site.

b Adhere strictly to the safety operation. c

Confirm the setting when an adjustment is made.

The items to prepare are:a

The check sheet

b Tape measure c

Dial gauge with magnetic stand

d Angle gauge e

Chalk

f

Stop watch

Basic Measurement Conditions When checking the performance valve, certain vehicle conditions should be fulfiled:a

The vehicle should be in the S mode.

b The hydraulic oil temperature should be 45°C-55°C. c

The engine speed should be within ±50 rpm of the reference value.

d The hydraulic equipment should be operated several times before testing. e

The operation to be measured should be operated three times and an average taken.

f

Measure on level hard ground.

These consist of two basic types of measurement:1

Speed Measurements a

Bucket ram speed.

b Dipper ram speed. c Boom ram speed. d Slew speed. e 2

Travel speed.

Other Measurements a

Travel linearity.

b Slew backlash. c

Lateral movement in turntable bearing.

d Slew brake. e

Slew lock characteristics.

f

Natural internal leakage, natural ram drop.

g Ram piston rod seal leakage.

9803/6410

Issue 1

Section 3 10 - 2


Section 3 10 - 2

Speed Measurements a

Bucket Ram speed. The conditions for checking are that the Dipper should be level. Measurement is of the time it takes the bucket to fully open and close from each end of the stroke

b

Dipper Ram speed The conditions for checking are that the Dipper should be level with the bucket open. Measurement of the time it takes the Dipper to open and close from each end of the stroke.

c

Boom Ram speed The conditions for checking are that the Dipper and the bucket are open. Measurement of the time it takes for the boom to go from a fully raised to fully lowered position.

Note: Place a wooden block where the Dipper would make contact with the ground, so as to prevent a shock loading of the arm, when it is lowered.

d

Slew Speed The conditions for checking are that the attachment is facing forwards and that a vertical line is chalked on the turntable bearing and lower ring, then place the attachment in the minimum slew position. Rotate the upper framework and after one complete rotation, then measure the time it takes for the next rotation.

e

Travel Speed The conditions for checking are that the main unit is jacked up, then marks are made on the Traction Motor and side frame. Rotate the sprocket two times or more to warm the motor then, record the time it takes for the motor to complete ten revolutions. Measurement should be done with the machine in each mode, low, medium and high speed and three measurements in each direction in each mode should be done to obtain an average.

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3


10 - 3

10 - 3

Other Measurements a

Travel Linearity.

MEASUREMENT METHOD

The conditions for checking are that the vehicle should have an approach of 5 metres and a travel distance of 20 metres; measurement is of the amount of deviation after 20 metres between the reference line and track shoe. Approach the reference line and adjust the position of the track shoe/travel direction against the reference line in the first 5 metres, then without adjusting, allow the machine to travel 20 metres, then measure the deviation, then complete the same procedure in reverse.

b

MEASUREMENT METHOD

Slew Backlash. 1

The conditions for checking are to position the bucket in the open position slightly above ground and to stop the engine.

2

Gently push the bucket from the side and put a mark on the ground, this becomes the 'Zero Point'.

3

Then do the same for the opposite side of the bucket and make a mark, the distance the bucket has moved is the amount of backlash.

Note: If the front attachment is pushed from side to side repeatedly or if there is leakage or the attachments are loose, correct measurement will not be possible. If the attachments are loose, position a dial gauge on the turntable bearing and measure the movement here.

9803/6410

Issue 1

Section 3

Routine Maintenance

Section 3


10 - 4

10 - 4

Other Measurements (continued) c

Lateral Movement in Turntable Bearing.

1

First set the Dipper in a perpendicular position and position the bucket 200 mm above the ground, stop the engine.

2

Install a dial gauge and set the needle to the Zero Point.

3

Start the engine and lift the main body with the bucket, when the bottom of the shoe is 100 mm above ground, note the reading on the dial gauge. The needle will turn in the counter clock wise direction. This value becomes L1, lower the body to the ground and confirm the needle reads zero.

4

Then rotate the main body 180° and repeat the procedure, this time the needle will rotate clock wise. This value becomes L3.

5

Next, place the dial gauge on the rear of the vehicle and repeat the two above procedures to obtain L2 and L4.

6

The average lateral movement is shown as the result of the equation L1 + L2 + L3 + L4. 2

Note: Always stop the engine when installing or removing the dial gauge or reading the dial gauge.

9803/6410

Issue 1

Section 3


10 - 5

Section 3 10 - 5

Other Measurements (continued) d

Slew Brake 1

The slew brake performance is measured at the minimum slew position. Mark the turntable bearing and lower ring.

Note: The person must stand well out of the machines slew radius on the front side, and also to confirm that no other personnel are in the vicinity.

e

2

Rotate the upper body and when the machine has completed its full initial start rotation, indicate to the operator when the two marks will coincide on the next rotation. The operator then moves the lever to neutral.

3

After the swinging has stopped, measure the distance between the two indicating marks.

Slew Lock Characteristics. 1 The conditions for checking this is to load the bucket with soil at the maximum working radius. Then drive up a slope of 20° , then set the attachment to a 90° position relative to the direction of travel.

f

2

Confirm with an angle gauge that the vehicle is at 20° and mark the turntable bearing and lower ring.

3

Stop the engine and remove the key. Measure the distance the Upper Slew Body has moved relative to the lower frame after 30 minutes.

Natural Internal Leakage, natural ram drop. 1

The conditions for checking are that the dipper is fully open with the bucket open.

2

Using a marker pen, mark the wiper seal on the bucket ram piston rod, then mark the wiper seal on the dipper ram rod.

3

Gently raise the dipper till the bucket is 2 m above ground.

4

Make a mark 100 mm from the wiper seal on the boom ram rod.

5

Switch the engine off and remove the key. Wait 10 minutes then measure the distance from the ground to the bucket. Measure the movement of each:Ram Rod Boom Dipper Bucket

9803/6410

Issue 1

Section 3


10 - 6

Section 3 10 - 6

Other Measurements (continued) g

Ram Piston Rod Seal Leakage As described below, check each ram in tur n to determine the amount of leakage via the ram rod seal. 1

Extend the ram fully and wipe the piston rod and check that there are no scratches.

2

Extend and retract the ram until the rod has moved a total of 100 metres (see the ram specification in Technical Data, Section E to determine the number of ram strokes needed to achieve the required total ram movement).

3

Measure the width of the oil ring on each ram rod to see if it is within specifications (see below). Rings B to G are satisfactory, but ring A indicates that the rod seal should be renewed. 2mm (0.079")

A

B

C

D

1mm (0.039")

E

F

G

JS03220

This completes the measurement procedure for the Performance Evaluation.

9803/6410

Issue 1

Routine Maintenance

Section 3

Section 3 12-1

FOPS Structure

12-1 Checking the FOPS Structure

All excavators are designed so that an operator’s protective structure can be fitted. In certain applications such as demolition, machines must be fitted with the optional Falling Objects Protection Structure (FOPS). It is the operator’s responsibility to identify the risk of an application.

! WARNING

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

Check that all the FOPS mounting bolts are in place and undamaged. Check the FOPS mounting bolts for correct torque tightness. Torque Setting A Torque tightness is 78 Nm (57.5 lbf ft) B Torque tightness is 343 Nm (253 lbf ft) C Torque tightness is 343 Nm (253 lbf ft) D Torque tightness is 78 Nm (57.5 lbf ft) E Torque tightness is 343 Nm (253 lbf ft) F Torque tightness is 137 Nm (101 lbf ft)

8-3-5-4

B A

C

F

9803/6410

E

D

Issue 1

Section B

Body & Framework

i

Section B i

Contents Contents

Page No.

Cab *Direct Glazing Undercarriage - JS130 Dimensions

2-1

Undercarriage - JS160 Dimensions

2-2

Weights - JS130, JS160 Main Body

3-1

Maintenance Specifications - JS130 Boom and Slew Frame Installation Boom Ram Installation Dipper Ram Installation Dipper Pivot Installation Dipper and Dipper Ram Installation Bucket Ram Installation Dipper and Dipper Link Installation Bucket and Bucket Link Installation Bucket Link and Bucket Ram Installation Bucket and Dipper Installation Shim Adjustment Table

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

Maintenance Specifications - JS160 Boom and Slew Frame Installation Boom Ram Installation Dipper Ram Installation Dipper Pivot Installation Dipper and Dipper Ram Installation Bucket Ram Installation Dipper and Dipper Link Installation Bucket and Bucket Link Installation Bucket Link and Bucket Ram Installation Bucket and Dipper Installation Shim Adjustment Table

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

*Air Conditioning (Optional) Operation Control Safety Procedures Fault Finding Checking Refrigerant charge Level Leak Testing Tightening Leaking Hoses System Diagnosis

9803/6410

1-1

12 - 1 12 - 3 12 - 3 12 - 4 12 - 7 12 - 7 12 - 7 12 - 8

Issue 2*

Section B

Body & Framework Cab

1-1

Section B 1-1

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

Always wear safety glasses during both removal and replacement.

2

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

3

Wear protective overalls.

4

DO NOT smoke - the activators and primers used in the procedures are highly flammable.

5

Do not attempt to handle or move panes of glass unless you are using glass lifters (see Service Tools, Section 1).

Several special tools are required to successfully complete the removal and replacement procedures. Reference is made to the tools in the text. The majority of these tools can be obtained locally and the remainder from JCB Service (see Service Tools, Section 1). The work must only be carried out in a dry, frost free environment. A protective canopy may be required or the machine/frame must be moved to a sheltered area. In damp or wet conditions, hinged doors and window frames can be removed from the machine and taken to a more suitable (dry) environment. Glass should not be replaced at temperatures below 5°C (41°F). Removing the Broken Glass and Old Sealant

! WARNING Always wear safety glasses when removing or installing screen glass. Never use a power operated knife when removing the sealant around a toughened glass screen. The action of the knife could cause particles of glass to be thrown with sufficient force to cause serious injury, even when safety glasses are being worn. Use only hand operated tools when working with toughened glass. BF 2-3/1

9803/6410

Issue 1

Section B

Body & Framework

Section B

Cab

1-2

1-2

Direct Glazing (cont'd) Removing the Broken Glass and Old Sealant (cont'd) 1

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

2

Toughened glass - remove as much of the shattered glass as possible prior to cutting out the old sealant.

3

Cut out the old sealant, leaving approximately 1 to 2 mm on the cab frame. There are several tools and techniques for doing this: a Braided Cutting Wire and Handles B. This method uses a 3-core wire, a wire starter tube and two handles (see Service Tools, Section 1).

B

D C

D

E

E D

(i) Insert the steel tube C into the old sealant on the inside of the glass.

S189870

(ii) Insert the braided cutting wire D down the centre of the steel tube. If necessary, from the outside, cut out local sealant at the point of the tube to gain access to the wire. (iii) Using suitable pliers, pull the cutting wire through the sealant to the outer side of the glass. (iv) Secure each end of the braided cutting wire in the special handles E. (v) Move the cutting wire backwards and forwards in a sawing motion and at the same time gently push or pull the wire to cut through the old sealant.

9803/6410

C

S189880

Issue 1

Section B

Body & Framework Cab

1-3

Section B 1-3

Direct Glazing (cont'd) Removing the Broken Glass and Old Sealant (cont'd) b Cut-out Knife F. The cut-out knife can be used as a left handed or right handed tool. For the knife and its replaceable blades, refer to Service Tools, Section 1.

F

(i) Insert the knife blade into the sealant. (ii) Make sure that the blade of the knife is against the glass as shown at G.

G

(iii) Use the 'pull-handle' to pull the knife along and cut out the old s ealant. c Craft Knife H. The blades are replaceable. (i) Insert the knife blade into the sealant.

S189890

(ii) Pull the knife along and cut out the old sealant. Note: There are other tools available to cut out the old sealant. For example, there is a long handle type craft knife to give extended reach. Refer to Service Tools, Section 1, for details of this and any other tools. 4

Toughened glass - remove the cut off sealant and all remaining particles of shattered glass.

5

If necessary, trim off the remaining old sealant to leave approximately 1 to 2 mm on the upright face of the cab frame aperture, as shown at J.

6

H

S186370

Apply a coat of 'Black Primer 206J' to the paintwork if: a Paintwork was damaged or scratched during the glass/sealant removal procedures.

J

b The old sealant was inadvertently cut back to the cab frame during the glass/sealant removal procedures. Preparing the Cab Frame Aperture 1

If damp or wet, dry the aperture area using a hot air gun (sourced locally).

2

Use 'Active Wipe 205' to thoroughly clean and 'prime' the trimmed sealant. Use a lint free cloth to apply the 'Active Wipe 205', allow 5 minutes flash off (drying) time. S189900

Note: Do not use any other type of cleaning fluids, otherwise they may be absorbed into the old sealant and ultimately prevent the new glass from bonding.

9803/6410

Issue 1

Section B

Body & Framework

1-4

Direct Glazing (cont'd) Preparing the New Glass 1

Section B

Cab

1-4

K

Make sure that the new glass correctly fits the frame aperture K.

M

a Put two spacer blocks L onto the bottom part of the frame aperture. b Install the new glass on the spacer blocks - ALWAYS USE GLASS LIFTERS M (see Service Tools, Section 1). Check that there is an equal sized gap all round the edge of the glass. Note: The spacer blocks are rectangular in section to give two common gap widths. If necessary they can be trimmed to a smaller size to give an equal sized gap around the glass.

L S189910

IMPORTANT: The glass edges MUST NOT touch the frame, otherwise movement of the frame will chip and eventually break the newly installed glass. 2

After checking for size, remove the new glass and place it on a purpose made glass stand N (see Service Tools, Section 1).

N

Small panes of glass will need locating on a 600 x 700 mm x 15 to 19 mm thick plywood board P (sourced locally to fit the glass stand N). It is recommended that an access hole is cut in the board to accommodate the glass lifter, making it easier and safer to handle small panes of glass. The board should be covered with felt or carpet to give an anti-scratch surface. Resting the glass on four spacer blocks will ensure clearance of the cartridge nozzle tip during application of the polyurethane sealant. 3

4

Make sure the glass is positioned on the stand the correct way up (i.e. with the black ceramic ink band upwards) ready for application of primer etc.

S186280

P

a Use 'Active Wipe 205' to thoroughly clean and 'prime' the black ceramic ink band printed on the glass (see Note 1). Use a lint free cloth to apply the 'Active Wipe 205', allow 5 minutes flash off (drying) time.

Note 1: Do not touch the glass after cleaning with the 'Active Wipe 205'. b If the glass does not have a black ceramic ink band, paint a band on the glass using 'Black Primer 206J'. The band should be approximately 25mm (1in) wide, and the edge should be a neat straight line as shown at R.

S186291

R

S189920

9803/6410

Issue 1

Section B

Body & Framework

1-5

Direct Glazing (cont'd)

Section B

Cab

1-5

S

Preparing the New Glass (cont'd) 5

Install the Ultra Fast Adhesive cartridge (see Sealing and Retaining Compounds, Section 1 and Note 2 below) into a suitable applicator gun:

10-15 mm

a Remove the aluminium disc cover from the base of the cartridge and discard the 'dessicant capsule'.

T

8-10 mm A186410

b Make sure that the rolled edge of the cartridge is not damaged - if necessary, the edges should be pressed flat, otherwise it will be difficult to remove the cartridge from the applicator gun.

A186410

c Pierce the front 'nozzle' end of the cartridge to its maximum diameter. d Fit the pre-cut nozzle shown at S. e Install the cartridge in the applicator gun.

T

Note 2: Cold material will be very difficult to extrude. The cartridges must be pre-heated in a special oven (see Service Tools) for 1 hour to a temperature of 80°C (176°F). Pre-heating the cartridges makes the adhesive more workable and also brings the 'curing' time down to 30 minutes. 6

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

S189930

W

Note 3: Once the pre-heated adhesive has been applied to the glass, install the glass in the aperture as soon as possible. After approximately 10 minutes the sealant will form a 'skin', this will prevent the glass from bonding. 7

After applying the adhesive, leave a small amount of sealant protruding from the nozzle. This will prevent any adhesive left in the cartridge from 'curing'.

Installing the New Glass 1

If the internal trim strip is damaged, renew it (cut to length as required) before fitting the new glass. Make sure the two spacer blocks are in position (see step 1 of Preparing the New Glass).

2

Install the glass in the frame aperture: a ALWAYS use the special lifting tools when moving the glass. Use a lifting strap to hold large panes of glass in position as shown W. b Sit the bottom edge of the glass on the spacer blocks as shown X. c Make sure that the glass is correctly positioned, then gently press around the edges of the glass and ensure full adhesive contact is achieved. Do not press too hard or too much adhesive will squeeze out.

9803/6410

X

S189910

Issue 1

Section B

Body & Framework

1-6

Cab

Section B 1-6

Direct Glazing (cont'd) Installing the New Glass (cont'd) 3

Make the inside seal smooth: a Wearing surgical gloves, dip your finger in a soapy water solution. b Use your finger to make the inside seal smooth.

4

All exposed edges must be sealed using Black Polyurethane Sealant (see Sealing and Retaining Compounds, Section 1).

5

Fit the external trim strip by cutting to length and pressing into position.

6

Clean the glass after installation:

IMPORTANT: Use extreme caution when wiping the inside of the new glass - pushing too hard on the inside of the glass will affect the integrity of the bonded seal. a Small amounts of sealant can be cleaned from the glass using the 'Active Wipe 205'. b Large amounts of excess sealant should be left to 'cure' (see Note 4) and then cut off with a sharp knife. Note 4: On completion of the glass replacement procedures, the sealant 'curing' time is 30 minutes. This means that the machine can be driven and used after 30 minutes, but it MUST NOT be used during the curing period of 30 minutes. c Clean the glass using a purpose made glass cleaner. 7

On completion of the glass installation procedures tidy the work area: a Remove ALL broken glass from the cab area. b Remove the protective covers from the cab seat and control pedestals. c Renew all 'warning' and 'information' decals so that the new installation conforms with the original cab installation.

9803/6410

Issue 1

Section B 2-1

JS130 - Dimensions

9803/6410

¿120mm (¿4.7") ¿140mm (¿5.5") 21mm (1")

228.5mm (9") 188mm (7.4")

178mm (7") 200mm (7.8")

Body & Framework Undercarriage

883.5mm (2’11") JS03170

Section B 2-1

Issue 1

¿150mm (¿6") 25mm (1")

¿120mm (¿4.7")

99.5m (4") 11.5m (0.5")

473.5mm (1’6.6")

Body & Framework

Undercarriage

465.5mm (1’6.3")

177.5mm (7")

Section B

279.5mm (11")

2-2

215mm (8.4")

200mm (7.8")

JS160 - Dimensions

9803/6410 189mm (7.4")

883.5mm (2’11") JS03160

1061mm (3’5.7")

Section B

2-2

Issue 1

Section B

Body & Framework

Section B

Main Body

3-1

3-1

Weights

B

C

A

G H

D

E

F

I

Description

Weight kg (lb) JS130* JS160*

Description

A

Overall Mass

12200 (26900)

15200 (33520)

F

Machine Main Body

B

Upper Mechanism Includes counterweight and slew ring bearing

5690 (12550)

6850 (15110)

G H

C

Counterweight

2540 (5600)

2930 (6460)

I

D

Undercarriage (with grouser shoe)

4090 (9020)

5950 (13120)

E

Shoe (600 mm grouser) (one side)

9803/6410

Weight kg (lb) JS130* JS160* 10030 (22120)

12800 (28224)

Attachment

2200 (4850)

2400 (5290)

Boom (including rams)

1210 (2670)

1600 (3530)

Dipper (including ram and link)

580 (1280)

600 (1320)

* Assumes the following options are fitted: 840 (1850)

Boom

2.5m (8ft 2.4in)

2.7m (8ft 10.3in)

Shoe (grouser)

600mm (2 ft)

600mm (2 ft)

1160 (2560)

Issue 1

Section B

Body & Framework

Section B

Main Body

3-2

3-2

Weights (cont’d)

(Dry Weight)

Weight Part Name

9803/6410

JS130

JS160

1

Travel motor

166 kg (366 lb)

225 kg (496 lb)

2

Drive sprocket

57 kg (126 lb)

56 kg (125 lb)

3

Idler wheel

70 kg (154 lb)

87 kg (192 lb)

4

Top roller assembly

13 kg (29 lb)

17 kg (37 lb)

5

Bottom roller assembly

26 kg (57 lb)

35 kg (77 lb)

6

600 mm grouser shoe assembly

841 kg (1854 lb)

1167 kg (2573 lb)

7

700 mm grouser shoe assembly

995 kg (2194 lb)

1377 kg (3036 lb)

8

Slew mechanism

101 kg (223 lb)

197 kg (434 lb)

9

Slew ring bearing

170 kg (375 lb)

242 kg (534 lb)

10

Counterweight

2540 kg (5601 lb)

2930 kg (6461 lb)

11

Engine

387 kg (853 lb)

354 kg (781 lb)

12

Radiator

64 kg (141 lb)

85 kg (187 lb)

13

Hydraulic pump

84 kg (185 lb)

83 kg (183 lb)

14

Fuel tank

85 kg (187 lb)

82 kg (181 lb)

15

Hydraulic tank

105 kg (232 lb)

95 kg (209 lb)

16

Control valve

111 kg (245 lb)

104 kg (229 lb)

17

Rotating coupling

27 kg (60 lb)

23 kg (51 lb)

18

Boom

744 kg (1641 lb)

947 kg (2088 lb)

19

Dipper

345 kg (761 lb)

450 kg (992 lb)

20

Boom ram

116 kg (256 lb)

169 kg (373 lb)

21

Dipper ram

160 kg (353 lb)

226 kg (498 lb)

22

Bucket ram

97 kg (214 lb)

122 kg (269 lb)

Issue 1

Section B

Body & Framework Maintenance Specifications

4-1

Section B 4-1

Attachments Boom and Slew Frame Installation JS130 Equipment Name 1. Boom and slew frame installation

2. Boom ram and slew frame installation

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Slew frame

a

569

579

Boom

b

568

566

Clearance

c

1.0-3.5

Shim for adjustment

Pin

d

Ø75

Ø74

Bushing (boom)

e

Ø75

Ø76.5

Slew frame

a

86

92

Boom ram (dump end)

b

85

83

Clearance

c

1.0-2.5

Shim for adjustment

Pin

d

Ø65

Ø64

Bushing (boom ram)

e

Ø65

Ø66.5

Boom Ram Installation JS130

Equipment Name 3. Boom and boom ram installation

9803/6410

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Boom ram (dump end)

a

92

90

Boom

b

434

428

Clearance

c

1.0-2.5

Shim for adjustment

Pin

d

Ø70

Ø69

Bushing (boom ram)

e

Ø70

Ø71.5

Issue 1

Section B


4-2

Section B 4-2

Attachments (continued) Dipper Ram Installation JS130 Equipment Name

Part Name

Code

Standard Value (mm)

Service Limit (mm)

4. Dipper ram installation

Boom

a

99

105

Dipper ram (dump end)

b

98

96

Clearance

c

0.5-3.0

Shim for adjustment

Pin

d

Ø70

Ø69

Bushing (Dipper ram)

e

Ø70

Ø71.5

9803/6410

Issue 1

Section B


4-3

Section B 4-3

Attachments (continued) Dipper Pivot Installation JS130 Equipment Name 5. Dipper Pivot installation

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Boom

a

231

234

Dipper

b

230.5

228.5

Clearance

c

0.5-1.8

Shim for adjustment

Pin

d

Ø75

Ø74

Bushing (Dipper)

e

Ø75

Ø76.5

Bushing (boom)

f

Ø75

Ø76.5

Boom

g

Ø65

Ø63

Dipper and Dipper Ram Installation JS130

Equipment Name 6. Dipper and Dipper ram installation

9803/6410

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Boom

a

99

105

Dipper ram (eye end)

b

98

96

Clearance

c

0.5-3.0

Shim for adjustment

Pin

d

Ø70

Ø69


e

Ø70

Ø71.5

Issue 1

Section B


4-4

Section B 4-4

Attachments (continued) Bucket Ram Installations JS130 Equipment Name 7. Bucket Ram installation

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Dipper

a

88

94

Bucket ram (eye end)

b

87

85

Clearance

c

0.5-3.0

Shim for adjustment

Pin

d

Ø65

Ø64

Bushing (bucket ram)

e

Ø65

Ø66.5

Dipper and Dipper Link Installation JS130

Equipment Name 8. Dipper and Dipper link installation

9803/6410

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Dipper Link

a

37

34

Dipper

b

254

252

Clearance

c

1.0-1.5

Shim for adjustment

Pin

d

Ø65

Ø64

Bushing (Dipper)

e

Ø65

Ø66.5

Issue 1

Section B


4-5

Section B 4-5

Attachments (continued) Bucket and Bucket Link Installation JS130

Equipment Name 9. Bucket and bucket link installation

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Bucket

a

255

261

Bucket link

b

254

252

Clearance

c

1.0-3.5

Shim for adjustment

Pin

d

Ø65

Ø64

Bushing (bucket link)

e

Ø65

Ø66.5

Bucket Link and Bucket Ram Installation JS130 Equipment Name 10. Bucket link and bucket ram installation

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Dipper Link

a

37

34

Bucket link

b

254

252

Clearance

c

1.0-1.5

Shim for adjustment

Bucket link

d

99

101


e

98

96

Clearance

f

1.0-2.0

Shim for adjustment

Pin

g

Ø65

Ø64

Bushing (Bucket link)

h

Ø65

Ø66.5

i

Ø65

Ø66.5

Bushing (Bucket ram)

9803/6410

Issue 1

Section B


4-6

Section B 4-6

Attachments (continued) Bucket and Dipper Installation JS130

Equipment Name 11. Bucket and dipper installation

9803/6410

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Bucket

a

255

261

Dipper

b

254

252

Clearance

c

1.0-3.5

Shim for adjustment

Bushing (bucket)

d

16

8

Pin

e

Ø65

Ø64

Bushing (bucket)

f

Ø65

Ø66.5

Bushing (bucket)

g

Ø65

Ø66.5

Issue 1

Section B

Body & Framework

Section B

Maintenance Specifications

4-7

4-7

Attachments (continued) Shim Adjustment Table (Unit: mm) Pin Diameter

Shim Thickness

Shim Outer Diameter 90

100

110

120

130

135

140

145

150

160

1.2 60 1.2

KNV0538

BHV1034

65 1.2

KNV0696

KNV0539

70 1.2

KRV1176

KHV0169

KNV0534

75 1.2

KRV1197

KRP1349

80 1.2

KRV1178

KHV0170

85 1.2

KBV0837

KSP0268

90 1.2

KNV0468

95 1.2 100 1.2 105 1.2 110 1.2 115 1.2 120 1.2 125 1.2 130

9803/6410

Issue 1

Section B

Body & Framework

Section B


4-8

4-8

Attachments (continued) Shim Adjustment Table (continued) (Unit: mm) Pin Diameter


170

180

185

190

200

210

220

230

240

250

60 65 70

75

80

85 KBV0764

KRV1180

90 95 KBV0474 100

105

110

115 KRV1159 120

125 KBV0713 130

9803/6410

Issue 1

Section B


5-1

Section B 5-1

Attachments (continued) Boom and Slew Frame Installation JS160

Equipment Name 1. Boom and slew frame installation

2. Boom ram and slew frame installation

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Slew frame

a

636

646

Boom

b

635

633

Clearance

c

1.0-3.5

Shim for adjustment

Pin

d

Ø80

Ø79

Bushing (boom)

e

Ø80

Ø81.5

Slew frame

a

111

117

Boom ram (dump end)

b

110

108

Clearance

c

1.0-2.5

Shim for adjustment

Pin

d

Ø70

Ø69

Bushing (boom ram)

e

Ø70

Ø71.5

Boom Ram Installation JS160

Equipment Name 3. Boom and boom ram installation

9803/6410

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Boom ram (dump end)

a

100

98

Boom

b

474

468

Clearance

c

1.0-2.5

Shim for adjustment

Pin

d

Ø80

Ø79

Bushing (boom ram)

e

Ø80

Ø81.5

Issue 1

Section B


5-2

Section B 5-2

Attachments (continued) Dipper Ram Installation JS160 Equipment Name 4. Dipper Ram installation

9803/6410

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Boom

a

111

117

Dipper ram (dump end)

b

110

108

Clearance

c

0.5-3.0

Shim for adjustment

Pin

d

Ø70

Ø69


e

Ø70

Ø71.5

Issue 1

Section B


5-3

Section B 5-3

Attachments (continued) Dipper Pivot Installation JS160 Equipment Name 5. Dipper Pivot installation

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Boom

a

275

278.5

Dipper

b

274.5

272.5

Clearance

c

0.5-1.1

Shim for adjustment

Pin

d

Ø80

Ø79

Bushing (Dipper)

e

Ø80

Ø81.5

Bushing (boom)

f

Ø80

Ø81.5

Boom

g

60

58

Dipper and Dipper Ram Installation JS160

Equipment Name 6. Dipper and Dipper ram installation

9803/6410

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Boom

a

111

117

Dipper ram (eye end)

b

110

108

Clearance

c

0.5-3.0

Shim for adjustment

Pin

d

Ø70

Ø69


e

Ø70

Ø71.5

Issue 1

Section B


5-4

Section B 5-4

Attachments (continued) Bucket Ram Installations JS160

Equipment Name 7. Bucket ram installation

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Dipper

a

91

97


b

90

88

Clearance

c

0.5-3.0

Shim for adjustment

Pin

d

Ø65

Ø64

Bushing (bucket ram)

e

Ø65

Ø66.5

Dipper and Dipper Link Installation JS160

Equipment Name 8. Dipper and Dipper link installation

9803/6410

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Dipper Link

a

37

34

Dipper

b

261

258

Clearance

c

1.0-1.5

Shim for adjustment

Pin

d

Ø65

Ø64

Bushing (Dipper)

e

Ø65

Ø66.5

Issue 1

Section B


5-5

Section B 5-5

Attachments (continued) Bucket and Bucket Link Installation JS160

Equipment Name 9. Bucket and bucket link installation

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Bucket

a

301

307

Bucket link

b

300

298

Clearance

c

1.0-3.5

Shim for adjustment

Pin

d

Ø80

Ø79

Bushing (bucket link)

e

Ø80

Ø81.5

Bucket Link and Bucket Ram Installation JS160 Equipment Name 10. Bucket link and bucket ram installation

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Dipper Link

a

37

34

Bucket link

b

260

258

Clearance

c

1.0-1.5

Shim for adjustment

Bucket link

d

91

93


e

90

88

Clearance

f

1.0-2.0

Shim for adjustment

Pin

g

Ø70

Ø69

Bushing (Bucket link)

h

Ø70

Ø71.5

i

Ø70

Ø71.5

Bushing (Bucket ram)

9803/6410

Issue 1

Section B


5-6

Section B 5-6

Attachments (continued) Bucket and Dipper Installation JS160

Equipment Name 11. Bucket and Dipper installation

9803/6410

Part Name

Code

Standard Value (mm)

Service Limit (mm)

Bucket

a

301

307

Dipper

b

300

298

Clearance

c

1.0-3.5

Shim for adjustment

Bushing (bucket)

d

16

8

Pin

e

Ø80

Ø79

Bushing (bucket)

f

Ø80

Ø81.5

Bushing (bucket)

g

Ø80

Ø81.5

Issue 1

Section B

Body & Framework

Section B


5-7

5-7

Attachments (continued) Shim Adjustment Table (Unit: mm) Pin Diameter

Shim Thickness


100

110

120

130

135

140

145

150

160

1.2 60 1.2

KNV0538

BHV1034

65 1.2

KNV0696

KNV0539

70 1.2

KRV1176

KHV0169

KNV0534

75 1.2

KRV1197

KRP1349

80 1.2

KRV1178

KHV0170

85 1.2

KBV0837

KSP0268

90 1.2

KNV0468

95 1.2 100 1.2 105 1.2 110 1.2 115 1.2 120 1.2 125 1.2 130

9803/6410

Issue 1

Section B

Body & Framework

Section B


5-8

5-8

Attachments (continued) Shim Adjustment Table (continued) (Unit: mm) Pin Diameter


170

180

185

190

200

210

220

230

240

250

60 65 70

75

80

85 KBV0764

KRV1180

90 95 KBV0474 100

105

110

115 KRV1159 120

125 KBV0713 130

9803/6410

Issue 1

Section B

Body & Framework

Section B

Air Conditioning

12 - 1

12 - 1

2

3

Direction of flow through air conditioning system

1

7

A306820

6 5 4

9803/6410

1 2 3 4 5 6 7

Compressor Condenser Receiver/Drier Expansion Valve Evaporator Coil Air Filter Air Filter

Issue 1

Section B 12 - 2

Body & Framework

Section B

Air Conditioning

12 - 2

Operation To maintain optimum operator comfort in warm climates or during seasons of high ambient temperature, the air conditioning system recirculates, clean, dehumidified air into the cab. Cooling is provided by passing the recirculated air, over an evaporator coil in the air conditioning unit. The air conditioning system is a closed circuit through which the refrigerant is circulated, its state changing from gas to liquid and back to gas again, as it is forced through the system. The major components of the system are the compressor 1, condenser 2, receiver drier 3, expansion valve 4 and evaporator coil 5.

Heater/Air Conditioning Controls Located on the Left side of the Rear Panel, the heater/air conditioning controls are used in conjunction with the heater fan controls.

The compressor 1 draws in low pressure refrigerant gas from the suction line (evaporator to compressor) and increases refrigerant pressure through compression. This process also increases the refrigerant temperature. High pressure refrigerant is forced from the compressor to the condenser 2, which is mounted on the radiator on the side of the engine. Ambient air is drawn across the condenser by the engine-driven cooling fan. In the condenser, the refrigerant changes state to a high pressure, high temperature liquid but with a lower heat content. The refrigerant passes through the receiver drier 3, which contains a desiccant to remove moisture from the system. The receiver drier serves as a reservoir for refrigerant and also includes a filter to remove foreign particles from the system.

Heater Controls A Ventilation control - with the control turned fully clockwise, air to the heater is taken directly from outside the cab. With the control turned fully anti-clockwise, air to the heater is drawn from inside the cab and recirculated. Settings between the two extremes result in varying mixtures of fresh and re-circulated air. B Air flow control - with the control turned fully clockwise, air flow from the heater is directed into the body of the cab. With the control turned fully anti-clockwise air flow from the heater is directed at the windscreen. Settings between the two extremes result in degrees of partial flow to the cab and to the windscreen. C Heat control - with the control turned fully clockwise, air flow from the heater is hot. With the control turned fully anti-clockwise air flow from the heater is cool. Settings between the two extremes result in varying temperatures.

A296850

A D

Air Conditioning Controls (if fitted) D Air conditioning ON/OFF control - this two position rocker switch is used to select or deselect the facility. When the ‘snow flake’ icon is pressed to switch air conditioning ON, the switch illuminates. Air conditioning system power is generated from the engine, via an electromagnetic clutch to the compressor. Three switches, connected in series, are included in the clutch supply line, all must be closed for the clutch and therefore the air conditioning system to operate.

B

C

JS10470

9803/6410

Issue 1

Section B 12 - 3

Body & Framework

Section B

Air Conditioning

Operation (cont'd) The high temperature, high pressure refrigerant is forced by compressor action into the expansion valve 4, which meters the amount of refrigerant entering the evaporator. In the expansion valve the refrigerant instantaneously expands to become a low pressure, low temperature liquid. The refrigerant is drawn through the evaporator coil 5 by the suction of the compressor. The temperature of refrigerant is now considerably below that of the air being drawn across the evaporator coil by the blowers. Heat is transferred from the ambient and recirculated air to the refrigerant, causing the low pressure liquid to vaporise and become a low pressure gas. Moisture in the air condenses on the evaporator coil and is drained away via condensate. Cool de-humidified air is emitted through air vents into the cab.

Safety Procedures The air conditioning system includes a pressurised closed circuit containing a non-CFC, environmentally friendly refrigerant, Type R-134a. Any service procedure which breaks into the closed circuit and therefore requires discharging of the system, must only be carried out by service personnel with specialist knowledge of air conditioning systems. The following guidelines should be adhered to by all personnel servicing the air conditioning system.

! WARNING

The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer. or a suitable trained person You can be severely frostbitten or injured by escaping refrigerant 4-3-4-1/2

The low temperature, low pressure, high heat content refrigerant gas, is now drawn by suction back to the compressor, where the cycle is completed.

Control

12 - 3

! CAUTION

Do not operate the air conditioning system when there is no refrigerant in the system, otherwise the compressor will be damaged. 4-3-4-4

Control of the system is achieved by the cyclic action of the compressor's electromagnetic clutch. When current is fed to the field coil of the compressor's clutch, a magnetic field develops between the field coil and the armature which pulls the field coil, complete with clutch assembly, onto the compressor's rotor. Since the clutch assembly is turned constantly by the crankshaft pulley drive belt, the compressor armature turns, starting the refrigeration cycle.

1

It is critical that the correct refrigerant (R-134a) is used and that charging is done only by qualified personnel. As a precaution, in case of accidental leakage, discharging and charging of the vehicle refrigerant system must be conducted in a well ventilated area.

2

Containers of refrigerant should be stored in a cool environment away from direct sunlight.

Current is fed to the field coil through three series switches whose contacts are controlled by the following:

Do not carry out welding operations close to the air conditioning refrigerant circuit. A poisonous gas is produced when refrigerant comes into contact with naked flames. Do not smoke or allow naked flames close to the refrigerant circuit.

1

The manual switch D in the cab

2

The thermostat switch monitoring the evaporator temperature

3

The high and low level pressure switch

Switch D will start the refrigeration cycle provided that the ambient temperature in the cab is greater than 0°C and the refrigerant pressure remains within the specified limits.

! WARNING

BF 1- 9

3

Do Not perform welding operations close to refrigerant hoses (maintain a distance of at least 0.5m from hoses).

4

Do Not steam clean refrigerant system components.

5

When charging or discharging the refrigerant system refrain from smoking. Naked flames must not be allowed in the immediate vicinity. The refrigerant does not give off a poisonous odour, however, when it comes into contact with a naked flame, a poisonous gas is produced.

6

When handling refrigerant, rubber gloves and goggles should be worn. Operators should ensure that no refrigerant comes into contact with the skin. Particular care should be taken when connecting or disconnecting charging hoses or pressure switches. When these components are connected to the system, a short release of refrigerant occurs. This results in a high velocity, very cold gas being emitted from the connection point.

The thermostat has its sensor inserted in the evaporator coil. It controls the refrigeration cycle by switching the compressor clutch on and off to prevent freezing of the condensate on the evaporator coil. The pressure level switch is housed in a common assembly located on the Receiver Drier. If the refrigerant pressure exceeds the upper pressure limit specified or falls below the lower limit, the contacts will open and the clutch will disengage, closing down the refrigeration cycle. Pressures Switch Settings High Pressure Switch 28 bar (406 lbf/ in2) Low Pressure Switch 2.1 bar (30.4 lbf/ in2)

9803/6410

Issue 1

Section B

Body & Framework

Section B

Air Conditioning

12 - 4

12 - 4

Operation (cont'd) Note: In dusty conditions, it is recommended that air be recirculated within the cab, otherwise the filter may become clogged. Two air vents M are located in the cab rear panel, and two air vents N and P are located on the right hand console. One air vent Q is located under the drivers seat. The vents can be turned to direct the air flow where required. When the vents are open, hot or cold air will flow directly into the cab. For the most effective front window demisting, the air vents should be closed and air circulation control turned fully to the left.

N

M

M

P

Q

A306810

9803/6410

Issue 1

Section B

Body & Framework

Section B

Air Conditioning

12 - 5

12 - 5

Fault Finding Procedures that require charging or discharging the system are not given in this manual as they require special equipment that is usually held only by trained refrigeration engineers. Fault indications are given in the table below. The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment. It is recommended that, to locate faults on the system accurately and quickly, an electronic leak detector and a refrigerant pressure gauge should be used. However, leaks can be detected on the system by using soapy water applied to the suspected leak area and system pressure can be assessed by the state of refrigerant passing through the receiver drier sight glass. Following sections of the manual deal with the major components of the air conditioning system and give further fault finding and maintenance information. General Fault Indications There are several indications that may help to determine the fault area on a system not working efficiently: a)

Poor performance

Low system pressure Condenser coil air flow restricted -

Evacuate and recharge system. Remove debris from around coil using compressed air or low pressure water.

Air filters blocked Compressor drive belt too slack

Clean with detergent and water. Adjust to correct tension.

b)

Warm or slightly cool air emitted from unit

Expansion valve stuck open or closed -

Renew expansion valve.

c)

Blower does not operate

Fuse blown Circuit fault

Replace fuse (20A) and retest. Fault find and repair.

d)

Compressor clutch continually cuts out

Condenser coil blockage Overcharging of refrigerant systemBlocked expansion valve/condenser -

Remove debris from around coil/renew condenser. Evacuate and recharge system. Clear blocked component .

Sight Glass Indications An approximate indication of the condition of the refrigerant can be seen through the receiver/drier sight glass when the compressor is running. Refer also to Checking Refrigerant Charge Level, on page 12-8.

Clear - No fault indicated unless the system is unable to provide cool air. The indication then is that the system is completely discharged of refrigerant. S201520A

Foam or bubbles - Refrigerant low and in need of charging.

S201520B

Clouded - Desiccant breakdown in the receiver-drier.

S201520C

Note: Sight glass indications cannot always give a positive identification of a problem. Further diagnosis, preferably by a refrigeration engineer using pressure gauges, is advisable before reaching a definite conclusion.

9803/6410

Issue 1

RELAY BLOWER 1

G

9803/6410

W

G

CNA

L

RELAY BLOWER 3

LIGHT SWITCH

O

CNC

AIR CON SWITCH

+

KEY B W Br P V G O

BLACK WHITE BROWN PINK VIOLET GREEN ORANGE

R Y Lg Sb L Gr

B W

B W

W/L L/B L/Y

L L/W L/B

RED YELLOW LIGHT GREEN SKY BLUE BLUE GREY

W/L

L/O

B

O

O

L/B

G

R

B

G

R

B

THERMOSTAT

M

30

L/Y

86 85

87

87a

30

86 85

L/Y

87

A306910

87a

12 - 6

RELAY BLOWER 2

COMPRESSOR CLUTCH

PRESSURE SWITCH

HEATER AIR CON FUSE

Section B Body & Framework Section B

Air Conditioning 12 - 6

Issue 1

Section B

Body & Framework

12 - 7

Section B

Air Conditioning

12 - 7

Fault Finding (cont'd) No Air Conditioning CHECK

ACTION

1

Are the controls set correctly, i.e. air conditioning selected, thermostat switch set to coldest position and blower switched on?

YES: NO:

Check 2 Reset controls and retest.

2

Is the air conditioning (evaporator) blower working?

YES: NO:

Check 3. Check 4.

3

Is the compressor running (visual check of pulley/clutch)?

YES: NO:

Check 9 Check 5.

4

Is the air conditioning fuse(s) blown?

YES: NO:

Renew fuse(s) and retest. Check 8.

5

Is there a 24V supply to the pressure switch harness?

YES: NO:

Check 6. Check 7.

6

Does the compressor clutch engage with pressure switch assembly bypassed?

YES: NO:

Replace pressure switch assembly. Renew the compressor clutch and retest.

7

Does the clutch engage with thermostat switch bypassed?

YES: NO:

Renew thermostat switch and retest. Check all electrical connections.

8

Are blower switch and wiring OK?

YES: NO:

Renew blower unit complete. Renew switch or wiring.

9

Is sight glass indication OK?

YES: NO:

Check 10. Charge check required by refrigeration engineer.

10 Is condenser air flow blocked?

YES: NO:

Clean condenser and radiator. Check 11.

11 Is evaporator air flow blocked?

YES: NO:

Clean filter and, if necessary the evaporator. Call in refrigeration engineer.

9803/6410

Issue 1

Section B

Body & Framework

Section B

Air Conditioning

12 - 8

Checking Refrigerant Charge Level The pressure in the system, i.e. the refrigerant charge level can be determined by checking the state of refrigerant at the receiver drier sight glass. The receiver drier is mounted on the radiator on the side of the engine. If the level of charge is correct the sight glass will be clear. If the charge is low bubbles will be seen. Bubbles may also be an indication of inadequate cooling, due to a restriction of air flow around the condenser coil. Recharging of the system should be carried out by an air conditioning engineer. Check refrigerant charge level as follows: 1

Park the machine on firm, level ground. Lower the excavator arms to the ground. Engage the parking brake.

2

Open the left hand side, rear door.

12 - 8

Leak Testing ! WARNING Leak testing in Air Conditioning systems should be carried out only in a well ventilated area. BF 1-2

Note: The refrigerant is heavier than air and will leak downwards from the defective component. Check in still conditions but in a well ventilated area. Hose or pipe connections are likely leakage points of any refrigerant circuit. To test for leaks in the high pressure side of the system i.e. from the compressor output to the expansion valve, run the air conditioning for a few minutes then switch off the engine and test for leakage using an electronic leak detector or soapy water. To test for leakage in the low pressure side of the system, switch off the air conditioning and leave for a few minutes before testing.

Tightening Leaking Hoses

A PostScript Picture (Bubble.EPS)

! WARNING The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system must be disconnected except by a qualified refrigeration engineer. You can be severely frostbitten or injured by escaping refrigerant 4-3-4-1/1

The refrigerant hoses have crimped ferrule end fittings. The hose connectors have an 'O' ring seal which compresses when the connection is tight, creating an air tight seal. Hoses are used to connect the inlets and outlets of the compressor, condenser, receiver drier and expansion valve (the evaporator coil is connected to the expansion valve within the air conditioning unit using rigid pipes). If leakage is detected from a hose connector, either by means of an electronic leak detector or soapy water, tighten the connector up and repeat the leakage test. If leakage is still evident, it will be necessary to de-gas the system and renew the connector 'O' ring seal. 3

Start the engine and run at idle. Switch air conditioning ON to circulate refrigerant.

4

Check refrigerant charge level at sight glass A.

9803/6410

Issue 1

Section B

Body & Framework

Section B

Air Conditioning

12 - 9

12 - 9

System Diagnosis

Normally Functioning A/C System

Normal gauge readings will depend on system components and ambient conditions, make sure that the valves are closed and the readings are stable and that the system has a full charge.

Gauge Readings: Low Side Gauge - Normal. High Side Gauge - Normal.

The pressures on the manifold at 25 °C with the engine at 1500 RPM, the blower on maximum and the thermostat set to maximum, should be approximately:

Other symptoms: Sight Glass - Clear. Discharge Air - Cold.

Typically, the high pressure is 6 - 8 times the low pressure. LOW SIDE - 2.0 bar (2.0 kgf/cm2)(29 lbf/in2) HIGH SIDE - 14.8 bar (15.1 kgf/cm2)(215 lbf/in2)

C

0

50 100

350

0

0 110 00 1

30 40 5 20

12

0

0

5 30 3

0

0 1 0

B

200 250

15

30

0

70 80

90

60

HIGH SIDE (BLUE) Normal

40

LOW SIDE (RED) Normal

0

500 45

A

A High Pressure/Temperature Gas. B Low Pressure/Temperature Gas. C High Pressure Liquid. A307050

9803/6410

Issue 1

Section B

Body & Framework

12 - 10

Section B

Air Conditioning

12 - 10

System Diagnosis (cont'd)

Low R-134a Charge

70 80 50 1 0 0

350 0

0

40

12 0 110 00 1

200 250 0

Diagnosis: System slightly low on R-134a, due to leak or incorrect charge.

0

15

30

30 40 5 20 0

60

HIGH SIDE (BLUE) Low

90

Other symptoms: Sight Glass - Bubbles continuously visible.

LOW SIDE (RED) Low

0

Gauge Readings: Low Side Gauge - Low. High Side Gauge - Low.

5 30 3

0

500 45

0 1 0

Correction: 1. Leak test system. 2. Evacuate A/C system. 3. Repair system leaks. 4. Charge system with R-134a. 5. Operate system and check performance.

A268030

LOW SIDE - 0.76 bar (0.77 kgf/cm2)(11 lbf/in2) HIGH SIDE - 8.3 bar (8.5 kgf/cm2)(121 lbf/in2)

Poor Refrigerant Circulation LOW SIDE (RED) Zero to negative

200 250

40

0

5 30 3

0

12

350

50 100

0 110 00 1

0

30 40 5 20

0 1 0

Diagnosis: Refrigerant flow obstructed by dirt, receiver-drier clogged.

0

15

0 30

Other symptoms: Receiver-Drier - Frost on tubes from receiver-drier to evaporator unit.

70 80 90

60


0

Gauge Readings: Low Side Gauge - Zero to negative. High Side Gauge - Low.

0

500 45

Correction: 1. Evacuate A/C system. 2. Replace receiver-drier. 3. Charge system with R-134a. 4. Operate system and check performance.

A268040

LOW SIDE - -1.0 bar (-1.1 kgf/cm2)(-15 lbf/in2) HIGH SIDE - 5.4 bar (5.5 kgf/cm2)(78 lbf/in2)

9803/6410

Issue 1

Section B

Body & Framework

12 - 11

Section B

Air Conditioning

12 - 11


No Refrigerant Circulation

50 1 0 0

350 0 40

12 0 110 00 1

0

5 30 3

0

500 45

0 1 0

A268050


LOW SIDE (RED) High

70 80

200 250

40

0

0

5 30 3

0

12

350

50 100

0 110 00 1

30 40 5 20

0

15

0 30

0

60

HIGH SIDE (BLUE) High

90

Gauge Readings: Low Side Gauge - High. High Side Gauge - High.

0 1 0

Other symptoms: Sight Glass - No bubbles visible even at lower engine RPM.

200 250 0

Insufficient Cooling of Condenser or Refrigerant Overcharge

0

15

30

Diagnosis: Refrigerant flow obstructed by dirt, moisture or gas leakage from expansion valve heat sensing tube. Correction: 1. Evacuate A/C system. 2. Check heat sensing tube at expansion valve. Replace expansion valve if necessary. 3. Remove expansion valve and attempt removal of dirt. If dirt cannot be removed, replace expansion valve. 4. Replace receiver-drier. 5. Charge system with R-134a. 6. Operate system and check performance.

70 80

30 40 5 20 0

60


90

Other symptoms: Receiver-Drier - Frost or moisture on tubes before and after receiver-drier.

LOW SIDE (RED) Zero to negative

0

Gauge Readings: Low Side Gauge - Zero to negative. High Side Gauge - Low.

0

500 45

Diagnosis: Refrigerant overcharge, condenser cooling fins clogged with dirt or cooling fans malfunctioning. Correction: 1. Clean condenser cooling fins. 2. Check cooling fan operation. 3. Evacuate A/C system. 4. Charge system with R-134a. 5. Operate system and check performance. A268060


9803/6410

Issue 1

Section B

Body & Framework

12 - 12

Section B

Air Conditioning

12 - 12


Air in System

70 80

0

50 1 0 0

0

40

0

350

0

12 0 110 00 1

200 250

15

30

30 40 5 20 0

60


90

0 1 0

Other symptoms: Sight Glass - Bubbles visible during system operation. Pipes - Low pressure pipes are hot to the touch.

LOW SIDE (RED) High

0


5 30 3

0

500 45

Diagnosis: Air is present in the system, possibly from inadequate evacuation procedure. Correction: 1. Evacuate A/C system. 2. Check compressor oil for contamination. Check compressor for proper oil amount. Correct if necessary. 3. Charge system with R-134a. 4. Operate system and check performance. A268070


LOW SIDE (RED) High

70 80

200 250

40

0

5 30 3

0

12

350

50 100

0 110 00 1

30 40 5 20

0 1 0

Other symptoms: Pipes - Large amount of frost or moisture on low side pipes.

0

15

0 30

0

60

90



0

Expansion Valve Improperly Mounted or Heat Sensing Tube Defective (Opening Too Wide)

0

500 45

Diagnosis: Excessive refrigerant in low side pipes possibly from expansion valve being opened too wide. Correction: 1. Leak test system. 2. Evacuate A/C system. 3. Repair system leaks. 4. Charge system with R-134a. 5. Operate system and check performance. A268080


9803/6410

Issue 1

Section B

Body & Framework

Section B

Air Conditioning

12 - 13

12 - 13


Compressor Malfunction LOW SIDE (RED) High

Correction: 1. Evacuate A/C system. 2. Repair or replace compressor. 3. Charge system with R-134a. 4. Operate system and check performance.

50 1 0 0

350 0

0

40

12 0 110 00 1

0 1 0

compressor

200 250 0

or

0

15

30

leak

70 80

30 40 5 20 0

60

90

Diagnosis: Internal compressor mechanically broken.


0

Gauge Readings: Low Side Gauge - High. High Side Gauge - Low.

5 30 3

0

500 45

A268090


Some Moisture in the System

70 80

0

200 250

15

350

50 100

0

0

5 30 3

40 0

12

20

30 40 5

0 110 00 1

0

60

HIGH SIDE (BLUE) Normal to high

0 30

0 1 0

Diagnosis: Moisture in system freezes, temporarily stopping cycle, normal system operation returns when ice melts.

LOW SIDE (RED) Normal to low

90

Gauge Readings: Low Side Gauge - Normal, then sometimes drops to below zero. High Side Gauge - Normal, then sometimes goes high.

0

500 45

Correction: 1. Evacuate A/C system. 2. Replace receiver-drier. 3. Remove moisture by repeatedly evacuating system. 4. Charge system with R-134a. 5. Operate system and check performance.

A268020


9803/6410

Issue 1

Section C

Electrics

Section C i

i

Contents

Page No.

Torque Specification

1-1

Technical Data

2-1

Battery Testing

2-2

Schematic Diagram

2-3

Layout Operator’s Cab Right Console Left Console Monitor Control, Function, Operation

3-1 3-2 3-4 3-5 3-6

Engine Control Basic Operation Stepping Motor Throttle Related Function Stop Motor Function Redundancy (back-up) Throttle Control Automatic Engine Adjustment Idling Control Revolution Control for each Mode Control of Engine Speed for Breaker Operation Engine Auto Warm-up Detection of Throttle Motor Assy Defect Engine Reverse Rotation Prevention Pump Control Schematic Flow Chart Boom Lowering Speed Regulation Cushioned Boom Starting Pressure Increasing System 3 Speed Travel and Max Flow Cut Soft/Hard Switch Power Supply Cut Delay Swing Brake/Swing Lock Lever Lock Travel Warning Power Transistor Protection Display Monitor Throttle Motor Throttle Motor and Throttle Link Replacement Automatic Adjustment * Initial Set-up of the Controller for Machine Identification

5-1 5-3 5-4 5-5 5-7 5-10 5-14 5-15 5-17 5-21 5-23 5-24 5-25 6-1 6-3 6-3

Revolution Sensor Installation

7-1

Self Test

8-1

Fault Finding Fault Diagnosis Emergency Engine Stop Refuel Coolant Refill Air Cleaner Clogged Low Engine Oil Pressure Engine Oil Filter Fluid Overheat, water, oil Battery Charging Electrical System, Message Fault Engine Problem Sensor Resistance Valve 9803/6410

4-1 4-1 4-3 4-6 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-14

9-1 9-4 9-5 9-6 9-7 9-8 9-9 9-10 9-12 9-13 9-16 9-19 Issue 2*

Section C

Electrics

Section C

Torque Specifications

1-1

1-1

Torque Specifications Component Battery (securing bolts)

9803/6410

Nm

kgfm

lb ft

19.6-29.4

2-3

14.46-21.69

Remarks

Issue 1

Section C

Electrics

Section C

Technical Data

2-1

2 -1

Circuit Protection; Fuse rating and circuit names BACK UP 10A

COMPUTER P. 15A

KEY SW. 10A

COMPUTER C. 10A

AIRCON., HEATER 20A

SHUT DOWN 15A

LAMP 15A

LEVER LOCK 10A

LAMP (SPARE) 15A

LUBRICATOR 10A

LAMP (SPARE) 15A

WARNING BEACON 10A

LAMP (SPARE) 15A

OIL PUMP 20A

WIPER, WASHER 15A

CONDENSER MOTOR 15A

HORN, ROOM LAMP 10A

SPARE 10A

RADIO, LIGHTER 10A

SPARE 10A

(A)

Fuse Replacement See illustration on the right for location of Fuse Box (A). 1. Prepare the machine, stop the engine remove the starter key. 2. Prepare an appropriate fuse of the correct amperage, remove cover. Note: The fuse cover’s right corner is the grip. 3. Replace the blown fuse with a new one. 4. Install the fuse cover. Note: If the reason for the blown fuse is unknown or the fuse fails repeatedly, check the electrical circuit(s) concerned.

Lighting and Horn Working light

Tank

Boom Roof light Horn

9803/6410

Cab

Voltage

Wattage

No. off

24 V

70 W

1

24 V

70 W

1

24 V

10 W

1

24 V

2

Issue 1

Section C

Electrics

Section C

2-2

2-2

Batteries Testing - Specific Gravity The specific gravity of the electrolyte gives an idea of the state of charge of the battery. Readings should be taken using a hydrometer, when the electrolyte temperature is 15 °C (60 °F). If the battery has recently been on charge, wait approximately one hour (or slightly discharge the battery) to dissipate the 'surface charge' before testing.

Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell. If the electrolyte temperature is other than 15 °C (60 °F) a 'correction factor' must be applied to the reading obtained. Add 0.007 per 10 °C (18 °F) if the temperature is higher than 15 °C (60 °F) and subtract the same if the temperature is lower.

Specific Gravity at 15 °C (60 °F)

Ambient temperature up to 27 °C (80 °F) Ambient temperature above 27 °C (80 °F)

Fully Charged

Half Discharged

Fully Discharged

1.270-1.290 1.240-1.260

1.190-1.210 1.170-1.190

1.110-1.130 1.090-1.110

Battery Testing This test is to determine the electrical condition of the battery and to give an indication of the remaining useful ‘life’. Before testing ensure that the battery is at least 75% charged (SG of 1.23 to 1.25 for ambient temperature up to 27 °C). Ensure that the battery is completely disconnected from the vehicle.

5

Set the CHECK/LOAD switch A to LOAD and hold down for 5 - 10 seconds until the meter reading stabilises. The reading should be at least 9 volts.

Note: Do not hold the switch in the load position for more than 10 seconds. 6

If the foregoing tests are unsatisfactory, consult Fault Diagnosis below.

Connect up the battery tester (part no. 993/85700) as follows: 1

Set the CHECK/LOAD switch A to OFF.

2

Set rocker switch B to the battery voltage (12V).

3

Connect the red flying lead to the battery positive (+) terminal and the black flying lead to the battery negative (-) terminal.

A

B

4

Set the CHECK/LOAD switch A to CHECK to read the battery no-load voltage which should be at least 12.4 volts. Fault Diagnosis

239510

Battery Tester Readings

Remedy

1

CHECK: LOAD:

0 - 12.6 Volts less than 6 Volts

Renew Battery

2

CHECK: LOAD:

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

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

3

CHECK: LOAD:

less than 10 Volts less than 3 Volts

Indicates battery has been over-discharged and unlikely to recover. Renew battery.

4

CHECK: LOAD:

more than 11 Volts 6 - 10 Volts steady

Charge battery which will probably recover.

9803/6410

Issue 1

Section C

Electrics

Section C

Schematic Diagram

2-3

2-3

Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19A 19B 19C 20A 20B 20C 20D 20E 20F 20G 20H 20J 20K 20L 20M 20N 21 22 23 24 25 26/28 27/29 30A 30B 31 32 33 34 35 36 40A 40B 41 42 43 44 45 46 47 48 49 50

Cigar Lighter Loudspeaker Radio Aerial Lead Radio (Standard) Radio (AM/FM) (Optional) System Controller (Computer) Fuse Box Switch Panel - Left Hand (Standard) Switch Panel - Left Hand (Optional) Limit Switch - Lever Lock (Gate) Limit Switch - Lever Lock (Console) Switch - Free Swing (Optional) Horn Push Switch Panel - Right Hand Switch - Speed Change Switch - One Touch Idle Monitor, Controller Driver Push-button - Breaker Pilot Pressure Push-button - Boom Pilot Pressure Push-button - Swing Pilot Pressure Relay - Fan 1 Relay - Fan 2 Relay - Fan 3 Relay - Horn Relay - Horn Volume Relay - Screenwasher Relay - Screenwiper Relay - Lamp (Boom) Relay - Auxiliary Lamps (Optional) Relay - Cab Light Relay - Lever Lock Relay - Engine Shutdown 1 Relay - Engine Shutdown 2 Indicator Lamp-wiper Motor Air Conditioning Unit Cab Heater Starter Switch Motor - Engine Shut-down Batteries - Standard Batteries - Heavy Duty (Optional) Fusible Link - Starter Switch/Back-up Fuses Fusible Link - Engine Shut-down Fuse Fusible Link - Fuse Box Relay - Battery Solenoid Valve Free Swing (Optional) Solenoid Valve Block Solenoid Valve - Swing Brake/Swing Lock Engine Block Sensor - Water Temperature Sensor - Hydraulic Oil Temperature Warning Buzzer Air Conditioning - Drier Switch Air Conditioning - Compressor Magnetic Clutch Motor - Screen Washer Relay - Engine Glow Plugs Horn - Loud Horn - Standard Working Lights - Cab Mounted Working Lights - Boom Mounted Sensor - Fuel Level

9803/6410

51 52 53 54 57 58 59 60 61 62 63 64A 64B 64C 65 66 68

Switch - Hydraulic Oil Overheat Switch - Hydraulic Oil Reserve Tank Level Switch - Air Filter Blocked Control - Hydraulic Pump Pressure Switch - Upper Pilot Pressure Motor - Engine Throttle Solenoid - Breaker Pilot Pressure (Optional) Pressure Switch - Travel Pilot Pressure Pressure Switch - Angle Sensor (Optional) Controller - Optional Monitor - Optional Angle Sensor - Dipper (Optional) Angle Sensor - Bucket (Optional) Angle Sensor - Boom (Optional) Solenoid (3) - Optional Switch - Double (Optional) Monitor - Optional

Issue 1

Section C 3-1

Electrics Layout

Section C 3-1

Operator’s Cab

9803/6410

Issue 1

Section C

Electrics

Section C

Layout

3-2

3-2

Right Console For correct operation and description see 'Operator’s Manual' RIGHT CONSOLE

JS03290

Right Console tilt handle

Idle Switch

Throttle Volume Control

Work lamp Switch

Wiper Switch

Mode Selection

S

H

L

F Washer Switch

One Touch/Auto change switch

9803/6410

Issue 1

Section C

Electrics

Section C

Layout

3-3

3-3

Right Console (continued) Soft/Hard

Horn Volume

Buzzer Stop Switch

Starter Switch

F ON OF

ART ST

HEA T

Power-up button

JS03010

Right Console (side panel)

+ +

Time Adjust

-

ADJUST/CLOCK H

Back-up

M

CLOCK

9803/6410

Issue 1

Section C

Electrics

Section C

Layout

3-4

3-4

Left Console For correct operation and description see 'Operator’s Manual'

LEFT CONSOLE

JS003300

Left Console Tilt Handle

Lever-lock Switch

Horn Switch

Cigarette Lighter

JS03000

Hour Meter

Heater and Air Conditioning

FAN

Emergency Stop Switch

STOP

Swing Brake Switch

SWING BRAKE

P 9803/6410

Issue 1

Section C

Electrics

Section C

Layout

3-5

3-5

Monitor For correct operation see 'Operator’s Manual'

WORK MODE

Message MODE

CLOCK

WATER TEMP HYD. OIL TEMP

FUEL

Water Temp

Machine Condition Indicators

Red Green White WATER TEMP

Lock Indicator

Fuel Indicator

LOCK

Green

P SWING

CONTROLS

Red FUEL

Work Mode Indicator

Brightness Control

WORK MODE MODE

Time Indicator

Message Indicator

CLOCK

Bar Graph Hydraulic Oil Temp

Red Green White HYD. OIL TEMP 9803/6410

Issue 1

Section C

Electrics

Section C

Layout

3-6

3-6

Control, Function, Operation

CONTROL

FUNCTION

OPERATION

Slight difference of RPM between each mode

a

b

9803/6410

Engine revolutions automatic adjustment.

Idling RPM is regulated according to the mode selected.

Engine speed varies according to mode: S Mode is100rpm less than H mode L Mode is 200rpm less than H mode

One-touch/auto idle RPM is reduced to the machine’s original idling RPM.

Idle Mode Revolutions

An operator can adjust engine RPM by one-touch.

Engine RPM and idle RPM selected according to throttle volume in the Fmode.

The one touch/automatic idle switch can be set to ‘AUTO’ so that engine automatically idles when not under load.

When auto idle is selected, automatically decreased to idle RPM 15 seconds after lever is put into neutral.

Breaker revolution control.

When breaker pedal is operated, the engine speed changes automatically to suit the breaker.

Pressure in Breaker pilot line activates a switch which signals the control of engine speed

Engine automatic warm-up.

When starting a cool engine, a special warming up process is begun automatically.

Increases RPM gradually from starting, and warms up & circulates lubricating oil around the engine.

Detection of throttle motor assembly defect.

Detects assembly in which throttle motor damage is highly possible and alarm is given.

Monitors for an abnormality in the motor position at which the limit switch is closed. If an abnormality exists, motor stops.

Engine reverse rotation prevention.

Reverse rotation of an engine is detected, and is stopped

After the engine has been operating for 12 seconds, the engine oil pressure switch is monitored. If an ON status is detected for more than 3 seconds, engine stops.

Idling Control.

900rpm

Issue 1

Section C

Electrics

Section C

Layout

3-7

3-7

Control, Function, Operation CONTROL

FUNCTION

OPERATION

The supply current to electromagnetic proportional pressure reducing valve which is built into the pump, is regulated.

3

Pump control

Pump control depends on work such as, H mode, large working load, S mode, good fuel economy, and L mode, for fine operation.

3

Boom lowering speed regulation

It also decreases boom lowering speed in L/F mode.

When L/F mode is selected the boom lowering stroke of control valve spool is restricted.

4

Cushioned Boom Starting

Prevents shock loads when starting to lower the boom.

When starting, a momentary negative control signal is generated.

5

Pressure raising system

Power increased when more force is desired, or during travel.

Pressure raised by 2-stage MRV being operated by solenoid valve.

6

3-speed travel and max. flow cut

High, middle or low speed travel operation obtained by switch. Performance improved during F mode.

Selects travel motor 2-speed positions, to give function of restricting max. flow of pump.

Cushion control

When cushion control is selected shock is relieved when boom and arm are de-selected. When hard operation is selected, the cushion is turned off.

Modulates movement of control valve boom/arm spools when they are deselected.

Power cut delay

A power supply is maintained to allow electrical devices to be operated after key switch is turned to OFF .

After the key switch is turned OFF there is a 5 seconds delay before the battery relay is cut OFF.

Swing brake/swing lock

Key OFF or lock SW ON: 100% swing brake. Key ON and operation other than swing: 50% swing brake. Swing operation: 0% (release).

Pressure is maintained by a pressure reducing valve, dependent upon brake selection.

10

Lever lock (Left console)

Unless the controls are immobilised, by raising the left console, entering and leaving the cab is impossible. In an emergency, it is possible to shut off the services immediately by raising the console.

With left console raised the controls are isolated.

12

Overload protection

If power transistor output of controller is shorted, the controller is protected.

Monitor display

Radiator water temperature Hydraulic oil temperature Fuel remaining Warning display

7

8

9

13

9803/6410

An overcurrent sensing circuit is fitted within the controller. When the output is shorted, the power transistor output is stopped, thus preventing an internal overload in the computer.

Issue 1

Section C

Electrics

Section C

Engine Control

4-1

4-1

Basic Operation The engine throttle control is done with the electric throttle motor.

A stepping motor is now used as part of the throttle motor.

Stepping Motor This rotates in direct synchronization with the amount of pulses received from the pulse oscillator. Pulse oscillator This circuit is used to make the pulse signal that determines the degree of rotation and rotational speed of the stepping motor. The stepping motor rotates when it is synchronised with the pulse signal from the pulse oscillator. The degree of rotation is dependant on the frequency of the pulse.

A

B

C D

E

F

Stepping Motor Basic Drive Structure

Component Key A B C D E F

Pulse oscillator (pulse signal) Logic part (phase splitting circuit) Amp Direct current Drive circuit (driver) Stepping motor

9803/6410

Issue 1

Section C 4-2

Electrics Engine Control

Section C 4-2

Stepping Motor (continued) Driver Circuit (driver) The driver circuit of a stepping motor consists of a logical section which forms and distributes a pulsed signal from an oscillator and an amplifying section which amplifies and supplies the signal to the motor.

Stepping motor principle (if 1st - phase is on drive)

The wound phases of A, B and C are rolled on the stator. When a pulse enters A phase, rotor is in (1) condition and A-a, A-c are energised. The excitation of A phase breaks down and then the pulse of B phase enters, B-b, B-d are energised and results in (2) condition. When the rotor rotates in a counter clockwise direction it sets up the condition (A-B-C). When a pulse is registered in the order (C-B-A) the rotor is rotating clockwise.

9803/6410

Issue 1

Section C 4-3


Section C 4-3

Throttle related function

A signal enters CN2-9 of the controller and ACC of the motor driver from ACC key switch. (24V) The controller and the driver sense that the key switch is ON, when this signal enters. The controller sends a clockwise rotation instruction (CN8-2) to the driver, and the driver sends a pulse clockwise rotation (ABA1B1) to the throttle motor. When the throttle motor rotates clockwise, the limit switch is depressed, and a signal is then sent to the controller (CN4-9) through the driver, to inform the controller that the 'O point detection' of the throttle motor has been achieved. (O pulse) After 'O point detection' has been achieved, in order for the controller to confirm the throttle volume position, the voltage (CN10-2) from the throttle volume control is converted to a pulse number.

9803/6410

Issue 1

Section C 4-4


Section C 4-4

Throttle related function (continued) For the Throttle motor to rotate to the position required by the throttle volume, an instruction from (CN8-4) to rotate counter clockwise is sent from the controller to the motor driver, and when received, sends a counter clockwise pulse from the motor driver to the throttle motor. Confirmation of the received pulse by the motor driver is achieved by a feedback signal pulse sent back to the controller, at (CN4-1). When the throttle motor pulse (that is the pulse which is converted by controller voltage from the throttle volume) eventually becomes equal to the pulse which is sent to the controller as a feedback signal from the driver, the throttle motor will stop rotating.

Revolution increase When the throttle volume control is rotated clockwise, the voltage of the throttle input increases, because of this the controller sends a counter clockwise revolution signal to the driver, and the driver sends a counter-clockwise pulse to the throttle motor, again the controller gets confirmation by a feedback signal pulse sent from the driver. When the throttle motor pulse (that is the pulse which is converted by the controller voltage from throttle volume) eventually becomes equal to the pulse which is sent to the controller as a feedback signal from the driver, the throttle motor will stop rotating.

Engine Stop When turning the key switch to OFF, the signal of the ACC line of the motor driver switches to OFF. When this signal is turned OFF, the driver sends a pulse to the throttle motor until the limit switch of clockwise rotation is turned ON. The governor lever moves to the stop side, causing the engine to stop, at the same time another circuit operates and moves the fuel cut lever to the stop position.

9803/6410

Issue 1

Section C


4-5

Section C 4-5

Controller rotational instructions

1

After key switch ON When the transistor on the CW side of the controller is turned ON, 5V from a driver circuit drops to ground. At this point the CW line is 0V and CCW line is 5V at the driver side.

CCW5V CW0V 2

➡

Rotation instruction of clockwise direction is set.

After CW side limit switch ON The controller turns OFF the transistor on the CW side, and turns ON the CCW side on the driver. CW line is 5V and CCW side is 0V.

CCW0V CW5V 3

➡

Rotation instruction of counterclockwise direction is set.

The stop status in volume position CCW and CW of a transistor are turned OFF, and both lines at the driver side are 5V.

CCW5V CW5V 9803/6410

➡

Motor rotation stops.

Issue 1

Section C

Electrics

Section C

Engine Control

4-6

4-6

With the key switch in the ON position, the power flows through relay and energises the actuating coil of relay 2 which supplies current to rotate the stop motor.

Stop Motor Function A Key Switch ON

G

H

C

J

K

L

D E

The stop motor and the switch within the motor are interlocked. When the motor moves to the operating position, the switch switches to the lower position, and the power supply of the motor turns OFF and stops.

N

F

K

J

L B Key Switch OFF

G

H

J

C

M

D E

F

The stop motor rotates and when the motor moves to the stop position, the switch switches to the upper position and the power supply of the motor turns OFF and stops. The engine stops.

N

K

J

M 9803/6410

Issue 1

Section C

Electrics

Section C

Engine Control

4-7

4-7

Emergency stop button ON

G

H

C

J

M

D E

F

The coil of relay 1 is excited when the emergency stop button is pressed when the key switch is ON (previous section A), and the relay switch turns to the lower position.

N

Since the excitation voltage to relay 2 collapses, the relay switch is returned to the upper position. The power supply circuit of the motor is formed, rotates, turns to the stop position, and the engine stops. The motor switch is switched to upper position, and it stops.

P Component Key (Pages 4-6 and 4-7) C D E F G H J K L M N P

Key switch Emergency stop button Fuse Controller Shut-down relay 1 Shut-down relay 2 Stop motor Switch Motor control - operating position Motor control - stop position To motor driver Emergency stop signal

9803/6410

K

J M

Issue 1

Section C 4-8


Section C 4-8

Redundancy (Back-up) throttle control

If the throttle control does not operate due to a controller defect, press the redundancy switch. Throttle control is then taken over by the manual throttle buttons. When pressing a redundancy switch, control power supply to the controller is turned OFF, and the manual throttle circuit is activated. There is a signal of 5V on the motor driver side. When pressing manual throttle, instruction of a rotational direction is sent to a motor driver, same method as in previous section Controller rotational instructions. To stop engine, manual throttle is pressed DOWN, or the key switch is turned OFF. While running the engine, if the redundancy switch is turned OFF (normal status), the engine stops so that the 0 position of throttle motor is detected.

9803/6410

Issue 1

Section C

Electrics

Section C

Engine Control

4-9

4-9

Automatic Engine Adjustment To give accurate control, store the required RPM setting on the controller by carrying out the automatic engine adjustment procedure. This will be necessary after fitting a new controller or throttle motor or after adjusting/replacing the control link between the engine and throttle motor. Note: If a new throttle motor is fitted or cable/linkage adjusted, the controller must have the memory wiped before programming can commence.

FULL RS RL RI

: H MODE MAX Revolutions : S MODE MAX Revolutions : L MODE MAX Revolutions : IDLE Revolutions

RPM D1

100

D2

200

R1

900

Automatic adjustment explanation 1

Engine RPM at the time of full throttle: FULL is read. (H mode MAX)

2

While monitoring engine RPM, RPM is decreased automatically. RS = FULL-D1 RL = FULL-D2 RI = Idling revolutions = 900 rpm When each RPM is reached, position of a throttle motor, PS, PL and PI are read.

3

PS, PL and PI are stored by the controller.

Refer to adjustment instructions for automatic adjustment method.

9803/6410

Issue 1

Section C 4 - 10

Electrics

Section C

Engine Control

4 - 10

Idling Control

Time Chart With the key switch ON pressing the one-touch switch causes the switch lamp to come on. A

One-touch idle operation is possible when in one-touch idling mode regardless of whether the pilot pressure switches of IN2, IN3, IN4 are ON or OFF.

B

When pressing the change switch, (lamp goes off) the Auto idle mode is activated. When changing to Auto idle, and with all IN2, IN3, IN4 switches tur ned OFF the engine automatically goes into the idle mode after 15 seconds have elapsed. To exit from the idle mode, this is only possible by pressing the idle switch, regardless of the position of the switches IN2, IN3, IN4.

When the engine key is turned OFF during auto idle, if it is turned on again, auto idle is disengaged, and results in a one-touch idle status.

9803/6410

Issue 1

Section C 4 - 11


Section C 4 - 11

Revolution Control for Each Mode

The machine is in the standard mode when the key switch is ON. This position is 100 rpm less than the FULL rotational position (H mode). Also note the position where it has decreased by 200 rpm from FULL rotation in L and F modes. Relation of throttle volume and pulse are shown in diagram below. Even though the position of throttle volume is the same, engine RPM varies with each mode. However, when pressing a mode switch button, the above four modes can be selected together with their corresponding engine RPM.

9803/6410

Issue 1

Section C 4 - 12


Section C 4 - 12

Control of Engine Speed for Breaker Operation

Note: It is necessary to preset the engine r.p.m. to a speed which delivers the flow rate required for breaker operation (see Setting Function under Self Test Function). The breaker can only be operated when the throttle control lever is set to give a higher engine speed (condition B) than that required for breaker operation (condition A). The following brief explanation assumes that this criteria has been met. If the throttle control lever setting gives an engine speed lower (condition C) than condition A the breaker circuit is inhibited. When the breaker foot pedal is pressed, the breaker pilot switch closes to apply a logic ‘1’ signal to the controller. The controller output causes the throttle motor to reduce the engine speed to the breaker pre-set speed. When the foot pedal is released the logic ‘1’ signal is disconnected and the controller, via the throttle motor, causes the engine speed to revert (increase) to that set by the throttle control lever.

9803/6410

Issue 1

Section C 4 - 13


Section C 4 - 13

Engine Auto Warm-up

Time Chart Conditions for automatic warming up 1

Water temperature is less than 50°C.

2.

Upper Pilot pressure switch is OFF. (attachment is not operating.)

3

Lower Pilot pressure switch is OFF. (travel is not operating.)

4

One-touch idle is turned OFF.

5

12 seconds after engine start.

6

Throttle dial not moved.

Note: The automatic warming up sequence will function only when the above conditions are adhered to.

9803/6410

Issue 1

Section C

Electrics

Section C

Engine Control

4 - 14

4 - 14

Detection of Throttle Motor Assembly Defect (Out-of-step) Fault When the pulse signal cannot be interrupted by the driver, and deviates from regular rotation. Possible Factors 1. If the adjusting screw of the throttle link is loosened, and the length of the link is changed more than the deflection of the spring. 2. If the key switch is ON (also during running), and the throttle motor rotates by abnormal external force and shifts to the stop position. Out of step detection (Safety device works to protect throttle motor from breakage when above problem occurs.) 1. After the key switch is ON, the limit switch of clockwise direction (stop position) is not turned on after 2 seconds. 2. After the key switch is ON, the clockwise limit switch is turned on and afterwards even though the key switch is not turned OFF or the emergency stop switch is not pressed, the clockwise limit switch is turned ON again. Any of the above conditions will stop the drive of the throttle motor, and 'electric system abnormality' is displayed on the message and '0000' is displayed on the clock.

Check the throttle link position first if the above is displayed. Refer to throttle link installation procedures.

Engine Reverse Rotation Prevention If the engine goes into a reverse rotation, this feature will stop the engine in order to protect it and the hydraulic circuit. When the engine changes to reverse rotation from forward rotation, the engine oil pressure decreases. Twelve seconds after the engine has been started, the pressure switch turns on for 3 seconds and the throttle motor is moved to the engine stop position.

9803/6410

Issue 1

Section C

Electrics

Section C

Pump Control

5-1

5-1

Schematic

Current is sent to electromagnetic proportional pressure reducing valve of the pump in each mode to control pump flow rate. In the H mode, engine RPM is raised and current value is variable between Imax and Imin. This utilises maximum output of the engine. The S,L, and F modes have fixed current values.

Current value of each mode

Mode Machine Type

H

S

L

F

Imax

Imin

IS

IL

IF

JS130

495 mA

300 mA

305 ± 20 mA

0 + 10 mA

0 + 10 mA

JS160

520 mA

325 mA

330 ± 20 mA

0 + 10 mA

0 + 10 mA

9803/6410

Issue 1

Section C

Electrics

Section C

Pump Control

5-2

5-2

Schematic (continued) Torque T1 Ts= 0.9TT TL=0.7TT H

Horsepower N

Horsepower

N

Flow S L

Electric current value I max

IS

H MODE

I min IL

Revolution

Target

Pressure

(At H Mode max. revolutions)

S MODE:

Pump torque equals 90% of engine target torque T, IS is the constant current value.

L MODE:

Pump torque equals 70% of engine target torque T, IL is the constant current value. (Same as F mode).

If engine RPM is less than 1200rpm: the current is the same as L MODE irrespective of mode selection. When L or F MODE are selected at the same time as travel (upper side pressure SW OFF, travel pressure SW ON) the current is the same as S MODE providing engine speed is greater than 1200 rpm. (Purpose; travel smoothness).

9803/6410

Issue 2*

Section C 5-3

Electrics Pump Control

Section C 5-3

FLOW CHART

9803/6410

Issue 1

Section C 5-4


Section C 5-4

Boom Lowering Speed Regulation Circuit Diagram

Time Chart

Flow Chart - Boom Lowering Speed Regulation

Regulating the speed of the boom lowering procedure is activated only in L, F mode. When changing to L, F mode, a transistor in the controller turns ON, and switches a solenoid valve. Pilot pressure is sent on the raising side of the boom spool on the control valve, and the movement of the spool is regulated.

9803/6410

Issue 1

Section C 5-5


Section C 5-5

Cushioned Boom Starting Circuit Diagram

Time Chart

When the boom lowering pressure switch turns ON, the solenoid valve switches on for 0.4 sec, and pilot pressure is sent to the negative control signal port of the pump. This pilot pressure adjusts the pump swashplate angle to temporarily reduce the output flow and thereby initially slow down (cushion start) the boom lowering facility. If travel and boom lowering procedure are initiated together, the boom cushioned start facility is not available, the travel pilot pressure being monitored and inhibiting the facility.

9803/6410

Issue 1

Section C 5-6


Section C 5-6

Cushioned Boom Starting (continued) Flow Chart

9803/6410

Issue 1

Section C 5-7


Section C 5 -7

Pressure Increasing System (One-touch digging force UP, Travel power UP)

A In only H or S modes, when the one-touch digging force UP switch is turned ON (IN5), the signal enters the controller through the timer in the panel switch and remains for 8 sec, 24V is output from the controller to the now activated solenoid valve. Pilot pressure enters the main relief valve, and pressure setting increases. IN6 switches for 8 seconds after onetouch digging force UP switch is turned ON. 'One-touch digging force UP is displayed on the monitor at the same time. If the one-touch digging force UP switch is pressed for a long period the pressure setting increases only for 8 seconds. B Always in the F mode or when the travel pressure switch is turned on, 24V is output to the solenoid valve and pressure setting increases. It increases while travel pressure switch is ON (no timer setting). It is not displayed on the monitor. In turning ON the one-touch digging force UP switch in this condition, digging force UP appears on the monitor for 8 seconds. Though it is in the travel plus an attachment condition (one-touch digging force UP switch OFF) the pressure setting increases, and the pressure setting of the attachment also increases its pressure.

9803/6410

Issue 1

Section C 5-8


Section C 5-8

Pressure Increasing System (continued) L Mode

A Even though the one-touch digging force UP switch is pressed, the voltage is not output to the solenoid valve, and a pressure increase is not obtained. B Pressure raising is performed in H, S mode when travel pressure switch is ON. A pressure increase is obtained in travel plus an attachment function.

F Mode When F mode is set, voltage is output to the solenoid valve regardless of one-touch digging force UP, and results in pressure raising condition.

Result 1 A pressure increase is obtained when the travel lever is moved (not displayed on the monitor). 2 There is a pressure increase when travel and an attachment function is called for, even though the digging force UP switch is not pressed. 3 H,S,F mode: pressure increases during an attachment function. However, in H, S mode digging force UP switch must be pressed. It is displayed on the monitor. In F mode, the pressure will always increase for improvement of lifting work ability. It is not displayed on the monitor.

9803/6410

Issue 1

Section C 5-9


Section C 5-9

Pressure Increasing System (continued) Flow Chart

9803/6410

Issue 1

Section C 5 - 10

Electrics

Section C

Pump Control

5 - 10

3-Speed Travel and Max. Flow (Q) Cut

A

B

1

2

3

Travelling at middle speed (always middle speed as the key is switched ON). Even though travel and upper pressure switches are ON, there is no output to solenoid valves A and B. Travel motor swash plate is in low speed position. Pump: Standard flow.

1

At middle speed travel Travel motor swash plate: low side Pump: Standard

2

At high speed travel Travel motor swash plate: Upper side

Travelling at high speed (pressing IN5 switch once when travelling at middle speed, shifts to high speed.) The travel motor switching solenoid valve turns ON and swash plate of the motor shifts to high speed position.

3

At low speed travel Pump: Q cut Same as in S mode.

Travelling at low speed (pressing IN5 switch once when travelling at high speed, shifts to low speed.) When a travel pressure switch is switched, the max. flow cut solenoid valve turns ON and flow (Q) is cut. Swash plate of the motor shifts to low speed position. Pump flow is cut. When upper pressure switch is turned on, max. flow rate cut solenoid valve is de-energised to prevent excavator circuits being slowed

9803/6410

Issue 1

Section C 5 - 11

Electrics

Section C

Pump Control

5 - 11

3-Speed Travel and Max. Flow Cut (continued)

1

At middle speed travel Travel motor swash plate: low side Pump: Standard

2

At high speed travel Travel motor swash plate: Upper side

3

At low speed travel Pump: Q cut

Q cut is done by F mode using the ON signal of upper pressure S/W for the first time. 1

At middle speed travel Travel only operation

Travel motor swash plate: Low side Pump: Standard

Upper only operation Pump: Q cut Travel + upper combined

2

At high speed travel Travel only operation

Travel motor swash plate: Low side Pump: Q cut

Travel motor swash plate: Upper side Pump: Standard

Upper only operation Pump: Q cut Travel + upper combined Pump: Q cut 3

At low speed travel Travel only operation

Travel motor swash plate: Low side Pump: Standard

Upper only operation Pump: Q cut Travel + upper combined

9803/6410

Travel motor swash plate: Low side Pump: Q cut

Issue 1

Section C


5 - 12

Section C 5 - 12

3-Speed Travel and Max. Flow (Q) Cut (continued) Relation of Travel Mode and Motor Swash Plate, Pump Flow (Q) Cut

High Speed Middle Speed Low Speed Travel motor

Upper side

Low side

Low side

Pump output quantity

Standard

Standard

Q cut

9803/6410

Relation of Travel Mode and Motor Swash Plate, Pump flow (Q) Cut Work mode is independent. However, since MAX. rotation changes by the working mode, the travel speed changes by travel mode, and working mode.

Issue 1

Section C 5 - 13


Section C 5 - 13

3-Speed Travel and Max. Flow Cut (continued) Flow Chart

9803/6410

Issue 1

Section C 5 - 14


Section C 5 - 14

Cushion (Soft/Hard) Switch Circuit Diagram

Time Chart

Flow Chart - Cushion (Soft/Hard) Switch Output to the soft/hard solenoid valve is OFF when key switch is ON. This is its SOFT status After the engine is started, the signal received from the panel switch is altered. The signal of IN1 turns to LO, and 24V is output to the solenoid valve from the controller. When the solenoid valve switches, the hard condition exists.

9803/6410

Issue 1

Section C 5 - 15


Section C 5 - 15

Power Supply Cut Delay Circuit Diagram

Time Chart

When the signal (IN1) from the key switch is turned OFF, 24V from OUT 3 is output from the controller for 3 seconds. After 3 seconds the output of OUT 3 stops, and power to the coil from the electric battery relay is cut, contacts on the electric battery relay break, and the power supply is cut.

9803/6410

Issue 1

Section C 5 - 16


Section C 5 - 16

Power Supply Cut Delay Flow Chart

9803/6410

Issue 1

Section C

Electrics

Section C

Pump Control

5 - 17

5 - 17

Swing Brake/Swing Lock (1) Swing Brake 1) Engine is running and swing lever is in neutral (50% brake).

Swing lever

Swing lock SW

SOL:1 100% lock

SOL: 2 50% brake

SOL: 3 Shut off

OFF

OFF

OFF

ON

OFF

Monitor (P)

24V is output to the swing brake solenoid valve (SOL:2), the pilot pressure which ran through the pressure reducing valve enters the swing motor, and operates with a braking force of 50%.

9803/6410

Issue 1

Section C

Electrics

Section C

Pump Control

5 - 18

5 - 18

Swing Brake/Swing Lock (continued) 2) Engine is running and swing lever operation (brake release)

a

b

a

Swing lever

Swing lock SW

SOL:1 100% lock

SOL: 2 50% brake

SOL: 3 Shut off

OFF

OFF

OFF

ON

OFF

ON

OFF

OFF

OFF

OFF

OFF

OFF

OFF

5 sec. after lever in neutral

ON

Monitor (P)

OFF

In operating the swing lever, the signal of the pressure switch enters the controller, and the output to the swing brake solenoid valve (SOL: 2) is turned OFF. Pilot pressure enters directly, and the brake is fully released.

b In returning the swing lever to neutral, the signal of the pressure switch goes OFF. The computer then outputs 24V on the swing brake solenoid valve (SOL: 2) and after the 5 seconds delay the brake operates at 50%.

9803/6410

Issue 1

Section C

Electrics

Section C

Pump Control

5 - 19

5 - 19

Swing Brake Swing Lock (continued) (2) Swing Lock (Swing Lock Switch ON, 100% Brake)

Swing lever

Swing lock SW

SOL:1 100% lock

SOL: 2 50% brake

SOL: 3 Shut off

Monitor (P)

OFF

ON

5 sec. after lever in neutral

ON

ON

(P)

ON When the swing lock switch is turned on a 24 V is output to the swing shut off solenoid (SOL:3) and the solenoid valve shifts. Pilot pressure enters both ends of the swing section of the control valve, and the pilot pressure is then shut off instantly (spool of control V does not move). b

After 5 seconds, 24V is output to the swing lock solenoid valve (SOL: 1) and the solenoid valve shifts. Oil within the brake piston of the motor flows to the tank. The brake locks by torque at 100%.

c

Also 24V is output on the swing brake solenoid valve (SOL: 2) and the solenoid valve shifts.

9803/6410

Issue 1

Section C 5 - 20


Section C 5 - 20

Swing brake/Swing lock (continued) Flow Chart

9803/6410

Issue 1

Section C 5 - 21


Section C 5 - 21

Lever Lock Circuit Diagram

Time Chart

9803/6410

Issue 1

Section C 5 - 22


Section C 5 - 22

Lever Lock (continued) Flow Chart

9803/6410

Issue 1

Section C 5 - 23

Electrics

Section C

Pump Control

5 - 23

Travel Warning Circuit Diagram

A travel pilot pressure switch is turned ON by travel lever operation and 24V is output for 10 seconds to the buzzer.

9803/6410

Issue 1

Section C

Electrics

Section C

Pump Control

5 - 24

5 - 24

Power Transistor Protection Controller Position 8 Spare 7 Spare 6 Spare 5 Swing shut off solenoid V 4 Lever lock solenoid V 3 Travel alarm 2 Pressure raising solenoid V 1 Free swing solenoid V 16 Negative control solenoid V 15 Spare 14 Spare 13 Soft/Hard change solenoid V 12 Max. flow cut solenoid V 11 Swing lock solenoid V 10 Warning lamp 9 Boom lowering speed regulation solenoid V 20 Travel 2-speed change solenoid V 19 Swing brake solenoid V 18 Heating relay 17 Battery relay

If a solenoid valve or relay is shorted, it stops the output of a power transistor, in order to protect the controller. 'Electric system abnormality' is indicated at this time in message display. By performing a self check, the position of the abnormality is indicated. Check wiring and components of the relevant circuit.

9803/6410

Issue 1

Section C 5 - 25


Section C 5 - 25

Display Monitor Radiator Water Temperature Circuit Diagram

1 2 3 4 5 6 7

Overheat switch position and the ON signal of the thermostat sensor are OR processed and number 8 is lit. Overheat switch position and the OFF signal of the thermostat sensor are AND processed and number 8 turns off. Number 8 is lit on the condition that numbers 1-7 are lit. When numbers 1-7 are off and the signal for number 8 is transmitted, they light-up in numerical sequence after a 30 second delay. Number 7 is put out on the condition that number 8 is turned out. If the signal to switch off number 7 is transmitted when number 8 is lit, the lights-out signal of the Thermostat sensor must also occur. When number 8 is lit, 'OVER HEAT' is indicated.

9803/6410

Issue 1

Section C 5 - 26


Section C 5 - 26

Display Monitor (continued) Hydraulic Oil Temperature Circuit Diagram

1 2 3 4 5 6 7

Overheat switch position and the ON signal of the thermostat sensor are OR processed and number 8 is lit. Overheat switch position and the OFF signal of the thermostat sensor are AND processed and number 8 turns off. Number 8 is lit on the condition that numbers 1-7 are lit. When numbers 1-7 are off and the signal for number 8 is transmitted, they light-up in numerical sequence after a 30 second delay. Number 7 is put out on the condition that number 8 is turned out. If the signal to switch off number 7 is transmitted when number 8 is lit, the lights-out signal of the Thermostat sensor must also occur. When number 8 is lit, 'OVER HEAT' is indicated.

9803/6410

Issue 1

Section C


5 - 27

Section C 5 - 27

Display Monitor (continued) Fuel Remaining Circuit Diagram

FUEL REMAINING

9803/6410

RESISTANCE

(litres)

(OHM)

MONITOR

284~

13~10

8

243~284

21~13

7

200~243

27~21

6

158~200

34~27

5

115~158

44~34

4

72~115

59~44

3

39~72

78~59

2

39

80~78

1 (1 hour left - Refuel)

Issue 1

Section C

Electrics

Section C

Pump Control

5 - 28

5 - 28

Display Monitor (continued) Warning Display (Message Display) START Message Display Key SW ON

Warning

Key SW ON & Engine Running

! Overheat ! Electric system abnormality ! Refuel ! Refill coolant ! Engine emergency stop

! Battery charging Deficient ! Engine oil pressure down ! Air cleaner clogged ! Engine filter clogged !Replenish battery fluid

Idling Free swing Engine warm up

Auto warm-up One-touch digging force up

YES

NO

H: Heavy mode S: Standard mode L: Light mode F: Fine mode

Note 1: If several instructions are displayed they appear alternately every 5 seconds. Note 2: When AUTO GLOW warm-up is finished, buzzer is sounded for 3 seconds.

!

Engine emergency stop

Engine emergency stop (emergency stop switch “ON”) is displayed.

!

Refuel

Fuel amount indicated if low. Check, and supply fuel.

!

Refill coolant

Coolant level is low. Check and supply cooling water.

!

Replenish battery fluid

Battery liquid level sensor is not fitted. Fault should not be displayed.

!

Air cleaner clogged

Air cleaner element is clogged. Wash or replace element.

!

Engine oil pressure down

Pressure of engine oil low. Check engine oil quantity, and replenish if low.

!

Engine filter clogged

Engine oil filter is clogged. Replace engine oil filter. (When replacing engine oil filter, also replace engine oil).

!

Over heat

Engine coolant or hydraulic oil temperature is high. Turn engine to low idling, to lower the water or oil temperature. (Check radiator, and clean it.)

!

Battery Charging Deficient

Abnormal charging system is displayed. Check the electric circuit.

!

Electric system abnormality

Abnormal electric system (short and disconnection) is displayed. Check the electric circuit.

9803/6410

Issue 1

Section C

Electrics

Section C

Throttle Motor

6-1

6 -1

Throttle Motor and Throttle Link Replacement 1

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

2

Locate the throttle motor and link See Component Location Diagram in Routine Maintenance.

Note: Upon delivery of the Throttle motor the position of the output axis shaft is in a random position, so it needs adjusting. 3

Throttle motor replacement Connect the wiring of the Throttle motor and switch it to the redundancy position. Position the motor so that the output shaft is rotated counter clockwise.

4

Removal of Throttle Link Remove the nuts of the throttle link at the control lever A, then remove the nuts on the opposite end of the throttle link at the throttle lever end B. Then remove the link without disassembly.

A

B

5

Checking operation of Throttle Link a

Confirm whether the Spring chamber C of the link operates normally before installing the throttle motor.

C

b Stand the link and press on it from the top, and confirm that the spring has compressed (approx 20 mm). c

If using the throttle link when the spring does not compress because of its internal corrosion, the motor will be damaged. d If the spring does not compress, replace it.

6

Disassembly of throttle link a

While it is possible to disassemble the link it is advisable to replace the unit with a new one.

b If it is disassembled, reassemble the unit to the dimensions shown opposite. Note: The overall dimensions shown are not fixed as each installation may vary.

9803/6410

Issue 1

Section C

Electrics

6-2

Throttle Motor

Throttle Motor and Throttle Replacement (continued)

Link

7

Section C 6-2

Installation of the throttle link lever a Install the lever on the new throttle motor without forcing it. b Coat the screws D with loctite before fastening. D

D

D

8

Installation of the throttle link a

9

After installation of the throttle motor, install the throttle links to the throttle lever and the control link.

Adjustment of Throttle Link a Switch it to redundancy. b Adjust the link of the engine side of the governor so that it hits the stopper bolt on the Max side of the throttle UP switch. c

After checking that it does hit the screw, rotate the spring chamber out 3 Complete rotations (counter clockwise) from that position.

d Adjust the length of the link so that the stroke of the spring chamber is 1.5-5mm. 10 Confirmation of Throttle Motor Operations a Confirm that the 'electric system abnormality' is not displayed in the monitor when the key switch is ON. b With the throttle volume at engine MAX position, confirm that the spring chamber contracts, after the link of the engine side governor hits the stop. c

At the STOP side, with the throttle volume knob at the engine MIN position, confirm that the spring chamber contracts after the key switch is OFF.

Note: Perform the automatic adjustment after confirmation of the above adjustment.

9803/6410

Issue 1

Section C

Electrics

Section C

Throttle Motor

6-3

6-3

Automatic Adjustment Always perform the automatic adjustment when the controller and or the throttle motor or linkage is replaced or the throttle cable or linkage is adjusted. The controller must be programmed to suit the machine model. There are differences in the controller’s programming for various models and territories.

Initial Set-up of the Controller for Machine Identification * When the CAPS controller is programmed, it has to be given information concerning three things:1 The machine model. 2 The territory. 3 The desired language for the message display.

5

Self-check

To set the machine, the controller’s original programming must be cleared. 1

H

MANUAL THROTTLE

M

UP

BACK UP

Change

Pattern

Select

Reset

Message

Remove plastic cover from around redundant mode switches.

ADJUST/CLOCK

Press SELECT button until RESET is displayed in the message display.

RESET

Self-check Change

Pattern

Select

Reset

DOWN

6

Press RESET button for 20 sec until buzzer sounds. Self-check

Cover installation screws x 2

Change

Pattern

Select

Reset

Self-check Change

Pattern

Select

Reset

2 Switch ignition on. 7 3

Press CHANGE button once.

*

When the ignition is switched on, the monitor digital clock will display 9999, the mode screen will display 9 and the symbol for high speed travel will be lit. This condition indicates that the CAPS controller’s memory has been wiped. This will also be the condition of the monitor when a new CAPS controller is fitted and the ignition switched on.

Self-check

4

Change

Pattern

Select

Reset

Press PATTERN button once.

Switch ignition off. Controller’s original programme is now cleared.

8

Switch ignition on (9999 displayed). Work Mode

Self-check

9803/6410

Change

Pattern

Select

Reset

MODE

Time Message

Issue 2*

Section C

Electrics

Section C

Throttle Motor

6-4

6-4

Initial Set-up of the Controller for Machine Identification (continued) 9

Repeatedly press S Mode switch until the monitor’s desired language is displayed on the mode screen.

11

Repeatedly press L Mode switch until ‘E’ is displayed on the clock (1st digit). All other displays are for nonJCB applications and are therefore not applicable.

Mode MODE

Time

H F

S L

Mode MODE

JS03260

Time

H F

S L

JS03280

LANGUAGE

MODE SCREEN

JAPANESE

0

ENGLISH

1

THAI

2

CHINESE

3

GERMAN

4

FRENCH

5

ITALIAN

6

SPANISH

7

PORTUGUESE

8

DUTCH

H

DANISH

L

NORWEGIAN

F

SWEDISH

Self-check

* 13

C

Time

Pattern

Select

Reset

Start engine. If the engine is cold, allow it to idle for a few minutes before proceeding.

Press CUSHION switch once. The following sequence will occur: 1 Engine goes to maximum rpm - CAPS fine tunes for H mode. 2 Engine speed decreases by 100 rpm - CAPS fine tunes for S mode. 3 Engine speed decreases by a further 100 rpm CAPS fine tunes for L mode. 4 Engine speed returns to idle - CAPS fine tunes idling speed. Programming is complete when a digging mode is displayed in the message screen.

15

Switch the ignition off.

Mode MODE

Change

14

Repeatedly press H Mode switch until the machine model is displayed on the clock (last 3 digits).

*

Press RESET button once.

EC

FINNISH

10

12

S L

H F JS10950

*

MODEL

CLOCK

MODE SCREEN

JS 130

121

1

JS 160

151

1

* Important Note: Never attempt to reset the computer when ! ELECTRICAL FAULT or any other warning message is displayed on the message monitor. If a warning is displayed the computer will not be able to complete its reset cycle.

* If the last digit in the clock window does not read 1 (e.g. 129), press the ‘F’ mode switch until the digit reads ‘1’.

9803/6410

Issue 2*

Section C 7-1

Electrics Revolution Sensor

Section C 7-1

Revolution Sensor Removal and Installation 1


2

Locate the Flywheel housing a The flywheel housing is machined to accommodate the sensor. b Remove the sensor by unscrewing it.

Note: Check the 'O'-ring for damage or wear, replace if necessary. 3

Installation is by screwing the sensor in the machined section at a torque of 44.13-53.0 Nm(33-40 lb ft).

Note: The clearance between the sensor and the flywheel is 3.1 +0.4 mm.

9803/6410

Issue 1

Section C

Electrics Self Test

8-1

Section C 8-1

Self Test Function This series of vehicles contains numerous sensors to enable the machine to perform its own self test diagnosis. Below is a list of functions which are monitored by the system. 1

Destination, Model Name, Languages

2

Engine R.P.M

3

Pump Input Amperage

4

No. of Throttle Pulses

5

Hydraulic Oil Temperature

6

Water Temperature

7

Fuel Sensor Resistance Value

8

Throttle Volume Voltage Input

9

Transistor Output

10 Pressure Switch Input The items to be checked, appear in the MESSAGE display Section

Message

The data is displayed on the CLOCK display

Message

9803/6410

Issue 1

Section C

Electrics

Section C

Self Test

8-2

8-2

Self Test Function (continued) Each item is changed with the Self Check Switches located on the right hand side of the back-up switch. There are four Self Check Switches 1

The CHANGE switch which is used to change to the self-check mode.

2

PATTERN switch which changes from the service check function to the setting function.

3

SELECT switch which moves from item to item.

4

RESET which locks the set values into the controller.

ADJUST/CLOCK

H

MANUAL THROTTLE

M

UP

Cover installation screws x 2

This set of four switches is usually covered so that the operator cannot accidentally operate them.

Checking Methods When the engine key is inserted and turned to the ON position, the "STANDARD MODE" is displayed in the Message display section, and S is displayed in the WORK mode section and theTIME is displayed in the CLOCK display.

Self-check

BACK UP

Change

Pattern

Select

Reset

DOWN

Self-check Change

Pattern

Select

Reset

Message

S : STANDARD MODE WORK MODE

Self-check MODE

Change

Pattern

Select

Reset

CLOCK

* When the CHANGE switch is pressed the Model designation is displayed:

*

Message 121 = JS130 151 = JS160

CH : MN WORK MODE

Self-check MODE

CLOCK

9803/6410

Change

JS10940

Issue 2*

Section C 8-3

Electrics

Section C

Self Test

8-3

Self Test Function (continued) The Self Check items can be displayed by pressing the SELECT SWITCH after every singular display in the following order. When the SELECT switch is pressed the Engine RPM is displayed

ENGINE RPM Message

CH : RPM WORK MODE

Self-check MODE

Select CLOCK

Pressing SELECT changes the display as shown. With the S mode displayed it will show 330 mA, the H mode will show 520mA, if the engine is at maximum speed

PUMP INPUT AMPERAGE Message

CH : PWM (mA) WORK MODE

Self-check MODE

Select CLOCK

Pressing SELECT changes the display as shown. With the throttle motor set at its minimum position it will output approximately 620 pulses to a maximum of 1023 as displayed in the clock display.

No. OF MOTOR TRANSMISSION PULSES Message

CH : PLS WORK MODE

Self-check MODE

Select CLOCK

Pressing SELECT changes the display as shown.

HYDRAULIC OIL TEMPERATURE ¡C Message

CH : OS WORK MODE

Self-check MODE

Select CLOCK


WATER TEMPERATURE ¡C Message

CH : WS WORK MODE

Self-check MODE

Select CLOCK

9803/6410

Issue 1

Section C

Electrics

Section C

Self Test

8-4

Self Test Function (continued)

8-4

FUEL SENSOR RESISTANCE VALUE Message


CH : FS

The fuel sensor resistance is shown in Ohms in the clock display.

WORK MODE

Self-check MODE

Select JS02480

CLOCK


THROTTLE VOLUME VOLTAGE Message

A value of 0 to a maximum of 4.5 Volts will be displayed in the clock display depending on the position of the throttle.

CH : TV WORK MODE

Self-check MODE

Select CLOCK

Pressing SELECT changes the display as shown.This monitors transistor block output.

TRANSISTOR OUTPUT VOLTAGE Message

When TR is displayed, pressing the reset button once will initiate the controller to test all the transistor block outputs 1 through 20. If a faulty output is detected it will stop at that output number. Monitor will display “ELEC. PROBLEM” (short circuits only).

CH : TR WORK MODE

Self-check MODE

To detect open circuits, select different services in turn and check screen display:

Select CLOCK

e.g. ‘1’ = closed circuit ‘0’ = open circuit

C O N T R O L L E R

T R A N S I S T O R

1 2 3 4 5 6 7 8

Free swing solenoid valve 2 stage MRV control solenoid valve Low flow hydraulic circuit Servo isolator solenoid valve Slew shut off solenoid valve Not used Not used Not used

Block 1

O U T P U T

9 10 11 12 13 14 15 16

Boom lower speed restriction solenoid valve Not used Slew lock solenoid valve Max flow cut solenoid valve Cushion solenoid valve Not used Not used Negative control solenoid valve

Block 2

17 18 19 20

Battery relay Glow plug relay Slew brake solenoid 2 speed travel solenoid valve

Block 3

N U M B E R S

1 0 1

0 = Output off, 1 = Output on

Block 3 Block 2 Block 1 9803/6410

Issue 1

Section C

Electrics

Section C

Self Test

8-5


8-5

PRESSURE SWITCH INPUT Message

Start engine. Pressing SELECT changes the display as shown. This monitors pressure switch information in the clock display. 0 =Switch open 1 =Switch closed

CH : PS WORK MODE

Self-check MODE

0 1

Select CLOCK

Excavating Pressure switch

Travel/Boom/Slew/Hammer Pressure switch

When the CHANGE switch is pressed when the checks are completed and the system will return to the STANDARD MODE for normal operation.

Message


Note: Engine has to be started to perform the above procedure. Select boom down, display should be:

1 1

Select swing left or right, display should be:

1 1

Select any other excavator service, display should be:

1 0

Select travel, display should be:

0 1

Select Hammer, display should be:

0 1

9803/6410

Self-check MODE

Change

CLOCK

Issue 1

Section C

Electrics

Section C

Self Test

8-6

8-6

Self Test Function (continued) Setting Function This section deals with setting separate parameters: 1

Breaker engine speed.

2

Automatic idle time.

In addition to the previous sections displays, the following switches are used.

Message

S

H

L

F

WORK MODE

Self-check MODE

CLOCK

Setting Breaker Engine Speed With the starter key in the ON position the display is as shown. Start the engine.

Message


Self-check MODE

Change

CLOCK

Press the CHANGE switch to produce the display shown right.

DESTINATION, MODEL NAME Message

CH: MN WORK MODE

Self-check MODE

Change

CLOCK

Press the PATTERN switch to produce the display shown right. Engine RPM is displayed in the CLOCK window.

SETTING BREAKER ENGINE RPM Message

EA: B(RPM) WORK MODE

Self-check MODE

Pattern

CLOCK

9803/6410

Issue 1

Section C

Electrics

Section C

Self Test

8-7


8-7

Message

Using the THROTTLE CONTROL knob, set the engine speed to that required for breaker operation (as displayed in the CLOCK window).


Note: Different breakers may require different engine speeds. Check that the breaker engine RPM setting is correct for the breaker being used as given in the following table:

Self-check MODE

CLOCK

*

Machine

Hammermaster

Engine RPM

Normal flow l/min

JS130

850

2150

115

1050

2280

120

1050

2200

120

Message


JS160

20 Seconds

Self-check MODE

When the desired RPM is shown, press and hold the RESET switch for 20 seconds to enter the setting into the controller. A buzzer will sound when the setting is complete. The controller will now automatically adjust the engine RPM to the selected speed when the breaker is operated.

Reset CLOCK

Turn the starter key to OFF to silence the buzzer. Setting Automatic Idle Time

SETTING AUTOMATIC IDLE TIME Message

Switch the ignition on, and press the CHANGE button. Press the PATTERN button once, then press the SELECT button repeatedly until the monitor displays EA:A1.

EA : AI

The ‘S’ and ‘H’ MODE select switches are used to reset the AUTOMATIC IDLE TIME.

WORK MODE

Self-check MODE

Select CLOCK

To reduce the AUTOMATIC IDLE TIME press the STANDARD MODE switch. Each press reduces the delay displayed in the CLOCK window by 1 second. ‘S’ is displayed in the WORK MODE window during this operation.

Mode

Message

EA : AI WORK MODE

Standard

Heavy

Fine operation

Finish

Self-check MODE

CLOCK

Mode

Message

To increase the AUTOMATIC IDLE TIME displayed in the CLOCK window, press the HEAVY MODE switch. Each press increases the delay displayed in the CLOCK window by 1 second. ‘H’ is displayed in the WORK MODE window during this operation.

EA : AI(RPM) WORK MODE

Standard

Heavy

Fine operation

Finish

Self-check MODE

CLOCK

9803/6410

Issue 2*

Section C

Electrics

Section C

Self Test

8-8

8-8

Self Test Function (continued) Message When the desired AUTOMATIC IDLE TIME is reached, press and hold the RESET switch for 20 seconds to enter the setting into the controller. A buzzer will sound when the setting is complete.


Turn the starter switch to OFF to silence the buzzer.

20 Seconds

Self-check MODE

Reset CLOCK

Other functions Other functions, not applicable in normal use, can be displayed using the SELECT button: CH:1 = Min engine RPM for scrap magnet use. CH:7 = Changing Proportional Solenoid mA Value. If kerosene fuel is to be used it is necessary to reduce the current at the proportional solenoid on the hydraulic pump as follows: 1 2 3 4 5 6 7

Switch ignition on. Press CHANGE button once. Press PATTERN button once. Press SELECT button repeatedly until monitor reads CH:7 Press H MODE switch to change mA value. (0=normal,1= reduced current). Press RESET button for 20 sec until buzzer sounds. Switch ignition off. The proportional solenoid mA value is now reduced.

CH:8 = Battery level sensor.

9803/6410

Issue 1

Section C 9-1

Electrics Fault Finding

Section C 9-1

Fault Diagnosis This section is designed to simplify the Task of Fault Finding. When a message is displayed, the description of the fault is shown and the Problem No. is shown; this in turn then relates to the relevant page showing the Problem No. Procedure Depending on the result of the inspection or measurement inside the box, continue on to either the YES or NO branch and onto the next box. Inside each box, the inspection or measurement method or values are written. The necessary preparatory work, operations and values are listed. Make sure the preparatory work is carried out, that is checking the procedures and equipment, as mistakes in judgements and procedures can seriously damage the equipment. Note: When removing or checking a piece of electrical equipment turn the key switch OFF. * Important: Refer to Initial Set-up of the Controller for Machine Identification for information regarding Programming and Re-programming the computer.

9803/6410

Issue 2*

Section C

Electrics

Section C

Fault Finding

9-2

9-2

Fault Diagnosis (continued) This explains how to trouble shoot in the event that the message does not go out even though suitable measures are taken to check and clear the problem. !Mark

Message Display

Trouble Description

Problem No.

!

Engine emergency stop

Even though the emergency stop button is pressed, the message does not go out.

1

!

Refuel

Even though fuel is supplied, the message does not go out.

2

!

Refill coolant

Even though cooling water is supplied, the message does not go out.

3

!

Replenish battery fluid

Battery fluid sensor not fitted, fault should not be displayed.

4

!

Air cleaner clogged

Even though filter is cleaned, the message does not go out.

5

!

Engine oil pressure Drop

Even though engine oil is correct, the message does not go out.

6

!

Engine filter clogged

Even though the engine oil filter is replaced and the engine oil is correct, the message does not go out.,

7

!

Over heat

Even though hydraulic oil temperature is less than 84°C and the engine cooling water temperature is less than 92°C, the message does not go out.

8

!

Battery Charging Deficient

The message does not go out.

9

!

Electric system abnormality The message does not go out.

10

This explains how to trouble shoot when an operation is not indicated on a message, but it does not operate normally. 1

Engine control area Trouble Description

Trouble No. YES

Engine does not start.

“Electric system abnormality” is indicated on monitor. NO

Controlling engine rotation is not possible.

9803/6410

Engine rotation does not change with throttle volume

Refer to trouble No. 10. 11

12

Issue 1

Section C

Electrics

Section C

Fault Finding

9-3

9-3

Fault Diagnosis (continued) Judgement Value

Measure

1. Fuel amount check

-

Refuel

2. Inspection for fuel contaminant

-

Clean, drain

3. Hydraulic oil amount check

-

Refill oil

4. Inspection of hydraulic oil strainer

-

Clean, drain

5. Inspection of oil amount for each reduction gear

-

Refill oil

6. Inspection of engine oil amount (amount in oil pan)

-

Refill oil

7. Coolant amount check

-

Refill water

8. Dust indicator clogging check

-

Clean or replace

9. Inspection for looseness, corrosion of battery terminal and wiring

-

Tighten or replace

10. Inspection for looseness, corrosion of alternator terminal and wiring

-

Tighten or replace

11. Inspection for looseness, corrosion of starter terminal and wiring

-

Tighten or replace

12. Abnormal sound, smell check

-

Repair

13. Oil leakage check

-

Repair

14. Air-bleeding

-

Air bleeding

25-26V

Replacement

16. Battery fluid sensor not fitted, fault should not be displayed.

-

Replenish or replace

17. Inspection for discolouration, burning, peeling of wiring

-

Replacement

18. Inspection for wiring clamp removal, sagging

-

Repair

19. Inspection for wet wiring (special attention to wet connector and terminal)

-

20. Inspection for fuse breakage, corrosion

-

Replacement

27.5~29.5V

Replacement

-

Replacement

Lubricants • Coolants Hydraulic • Mechanical Equipment

Electric Equipment

Start-up Inspection items

Item

Electricity • Electric Equipment

Other Inspection Items

15. Battery voltage (engine stopped) check

21. Alternator voltage check (engine revolution more than 1/2 throttle) (When battery insufficiently charged, may be about 25V right after starting.) 22. Battery relay making noise (when starter switch is ON or OFF)

9803/6410

Disconnect and dry

Issue 1

Section C

Electrics

Section C

Fault Finding

9-4

9-4

Fault Diagnosis (continued) Emergency Engine Stop, Problem No.1 Note: Even if the emergency stop button is pressed the message does not go out. Prior Confirmation Items 1

The "MODE" of the mode display is not flashing.

2

Confirm that the fuses in the fuse box are normal.

3

The engine does not run.

Troubleshoot

Cause

Remedy

Key switch ON When CN11 connector is removed, does message go out?

Defective LW wiring from switch panel or switch panel defective.

YES

NO Remove CN2 connector and measure voltage of female side of LB. Is it within the range of 20~30V?

NO

YES

Measure voltage of LW with shut down relay 1 connector connected. Is it within the range of 20~30V. NO

YES

Remove shut off relay 1 connector and measure NO (°°) resistance of 1 and 2 of relay side. Connect 1 to +, 2 to -. Is it 250 . YES

9803/6410

Repair wiring or replace switch panel.

Bad connection of CN2 connector or controller defect.

Clean CN2 connector terminal or replace controller.

Breakage of LW wiring between shut off relay 1 and controller.

Repair LW wiring.

Defective shut off relay 1.

Breakage of LR wiring between shut off relay 1 and fuse.

Replace shut off relay 1.

Repair LR wiring.

Issue 1

Section C

Electrics

Section C

Fault Finding

9-5

9-5

Fault Diagnosis (continued) Refuel, Problem No.2 Note: Message does not go out even if refuelled Prior Confirmation Items 1


2

Fuel bar graph displays one.

Troubleshoot Key switch ON Measure resistance value of sensor at self-check. Is it within the range of values in chart below? (Refer to resistance values in chart below.)

NO

Cause

YES

Controller defect

Remedy

Replace controller.

Key switch OFF

Remove sensor coupler and measure resistance on sensor side. Is it within the range of values in chart below? (Refer to resistance values in chart below.)

YES

NO

Remove CNE connector and measure resistance between male side terminal YR and GR. Is it within the range of values in chart below? (Refer to resistance values in chart below.)

YES

NO

Remove CN10 connector and measure resistance between female side terminal YR and GR. Is it within the range of values in chart below? (Refer to resistance values in chart below.)

NO

Fuel sensor defect

Replace sensor or inspect it.

Bad connection of fuel sensor connector

Clean connector terminal.

Bad connection of CNE

Clean CNE connector terminal.

Controller defect or bad connection of CN10

YES

Replace controller or clean CN10 connector terminal.

Note: When there is breakage in the wiring, the bar graph goes out completely. Resistance Value between YR and GR Monitor

1 Refuel.

2

Resistance Value (OHM)

80~78

78~59

9803/6410

3

4

5

59~44 44~34 34~27

6

7

8

27~21 21~13 13~10 Issue 1

Section C

Electrics

Section C

Fault Finding

9-6

9-6

Fault Diagnosis (continued) Coolant Refill, Problem No 3 Note: Message does not go out even if coolant is refilled Prior Confirmation Items 1


Troubleshoot

*

Cause

Remedy

Key switch ON

When reserve tank level switch connector is removed, does message go out?

NO

YES

Reserve tank level switch defect

When reserve tank level switch connector is removed, does message go out?

Defective YW wiring between reserve tank level switch and CNB

YES

YES

NO

9803/6410

Replace reserve tank switch.

Repair YW wiring.

Defective YW wiring between CNB and CN7

Repair YW wiring.

Controller

Replace controller.

Issue 2*

Section C

Electrics

Section C

Fault Finding

9-7

9-7

Fault Diagnosis (continued) Air Cleaner clogged, Problem No. 5 Note: Message does not go out even if the filter is washed. Prior Confirmation Items 1


Troubleshoot

Cause

Remedy

Air filter switch defect

Replace air filter switch.

Key switch ON When spade terminal of air filter switch on YL side is removed, does message go out?

NO

YES

When CNB connector is removed, does message go out?

NO

When CN7 connector is removed, does message go out?

NO

9803/6410

Breakage or bad connection of BW wiring between CNB and air filter switch

YES

YES

Breakage or bad connection of BW wiring between CNB and CN5

Controller defect

Repair BW wiring.

Repair BW wiring.

Replace controller

Issue 1

Section C

Electrics

Section C

Fault Finding

9-8

9-8

Fault Diagnosis (continued) Low Engine Oil Pressure. Problem No. 6 Note: Message does not go out even if engine oil is satisfactory. Prior Confirmation Items 1


Troubleshoot

Cause

Remedy

Confirm after 12 seconds have passed after starting the engine. YES

When oil pressure switch connector is removed, does message go out?

NO


NO

YES


NO

9803/6410

YES

Oil pressure switch defect

Replacement

Defective YG wiring between CNB and oil pressure switch

Repair YG wiring.

Defective YG wiring between CNB and oil pressure switch

Controller defect

Repair YG

Replace controller

Issue 1

Section C

Electrics

Section C

Fault Finding

9-9

9-9

Fault Diagnosis (continued) Engine Oil Filter Blocked, Problem No 7 Note: Message does not go out even if the engine oil filter is replaced and the oil is satisfactory. Prior Confirmation Items 1


Troubleshoot

Cause

Remedy

Oil filter switch defect

Replace switch.

Defective LB wiring between CNB and oil filter switch

Repair LB wiring.

Defective LB wiring between CN7 and CNB

Repair wiring.

Controller defect

Replace controller.

Engine starts

YES

When oil filter connector is removed, does message go out?

NO


NO

YES


NO

9803/6410

YES

Issue 1

Section C

Electrics

Section C

Fault Finding

9 - 10

9 - 10

Fault Diagnosis (continued) Fluid Overheating, water, oil, Problem No 8 Note: Message does not go out even if the actual temperature is below the following; Hydraulic Oil Temperature 84°C. Engine Coolant Temperature 92°C. Prior confirmation Items 1 3

The "MODE" of the mode display is not flashing. 2. Each bar graph displays more than one graduation. Confirm that the water and oil temperature bar graph is lit at 8 graduations.

Troubleshoot 1. Water temperature bar graph lit at 8 graduations. Key switch ON Is thermo sensor (water) temperature abnormal at selfcheck? (comparison of actual and indicated temperature) • Display water temperature with self-check • Measure actual temperature

NO

When thermo switch (water) connector is removed, does message go out?

YES

NO

Key switch OFF Remove thermo sensor (water) connector and measure resistance of sensor side. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)

YES

Remedy

Thermo switch (water) defect

Replace switch

Defective YR wiring between CNB and thermo switch

Repair YR wiring

Defective YR wiring between CN3 and CNB

Repair YR wiring.

YES

When CNB connector is removed, does message go out? NO

Cause

YES YES


Controller defect

Replace controller

Thermo switch (water) defect

Replace sensor.

Bad connection of thermo (water) connector

Clean sensor connector terminal

NO NO

Remove CNE connector and measure resistance between male side terminal YB and GR. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)

YES

NO

Remove CN10 connector and measure resistance between female side terminal YB and GR. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)

YES

NO


Controller defect or bad connection CN10

Clean CNE connector terminal Replace controller or clean CN10 connector terminal

Note: When there is breakage in the wiring, the bar graph goes out completely. 9803/6410

Issue 1

Section C

Electrics

Section C

Fault Finding

9 - 11

9 - 11

Fault Diagnosis (continued) Fluid Overheating, water, oil, Problem No 8 (continued) Note: Message does not go out even if the actual Temperature is below the following:Hydraulic Oil Temperature 84°C Engine Coolant Temperature 92°C

Troubleshoot 1. Oil temperature bar graph lit at 8 graduations. Key switch ON Is thermo sensor (oil) temperature abnormal at self-check? (comparison of actual and indicated temperature) • Display oil temperature with self-check • Measure actual temperature

NO

When thermo switch (oil) connector is removed, does message go out?

YES

NO

Key switch OFF Remove thermo sensor (oil) connector and measure resistance of sensor side. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)

YES

Remedy

Thermo switch (oil) defect

Replace switch

Defective Br wiring between CNB and thermo switch (oil)

Repair Br wiring

Defective Br wiring between CN3 and CNB

Repair Br wiring.

YES

When CNB connector is removed, does message go out? NO

Cause

YES YES


Controller defect

Replace controller

Thermo switch (oil) defect

Replace sensor.

Bad connection of thermo sensor (oil) connector

Clean sensor connector terminal

NO NO

Remove CNE connector and measure resistance between male side terminal BrW and GR. Is it within the range of values in separate chart? (Refer to resistance values in separate chart)

YES

NO

Remove CN10 connector and measure resistance between female side terminal BrW and GR.

YES

NO


Controller defect or bad connection CN10

Clean CNE connector terminal Replace controller or clean CN10 connector terminal

Note: When there is breakage in the wiring, the bar graph goes out completely.

9803/6410

Issue 1

Section C

Electrics

Section C

Fault Finding

9 - 12

9 - 12

Fault Diagnosis (continued) Battery Charging, Problem No 9 Note: Message does not go out. Prior Confirmation Items 1


Troubleshoot

Does hour meter operate?

Cause

Remove CN2 connector and measure voltage between female side terminal WR and ground? Is it more than 10V?

YES

NO

YES

NO

Remove spade terminal of alternator R and measure voltage between female side and ground. Is it more than 10V?

Repair WR

Bad connection of CN2 or controller defect

Clean CN2 connector terminal or replace controller.

Alternator defect

Remove CNC connector and measure voltage between male side terminal WR and ground? Is it more than 10V? YES

9803/6410

Defective WR wiring between CN2 and CNC

NO

YES NO

Remedy

Breakage of WR wiring between CNC and alternator or bad connection of alternator spade terminal

Replace alternator

Repair WR wiring between CNC and alternator or clean spade terminal.

Issue 1

Section C 9 - 13


Section C 9 - 13

Fault Diagnosis (continued) Electrical Systems, Message Fault, Problem No 10 Note: Message does not go out.

9803/6410

Issue 1

Section C

Electrics

Section C

Fault Finding

9 - 14

9 - 14

Fault Diagnosis (continued) Electrical System, Message Fault, Problem No. 10 (continued) Note: Message does not go out. Troubleshoot

Cause

Remedy

Key switch ON

Does Clock display “0000”?

When transistor output is carried out with self-check, are any abnormal points found?

NO

NO

When electro magnetic proportional valve is removed, does message go out?

YES

YES

YES

NO

When display solenoid valve YES connector is removed, does message go out?

For example when swing lock no. 11 is displayed (Display number explanation on separate sheet).

Electro-magnetic proportional valve defect or defective BrB wiring


Repair BrB wiring

NO When CN8 connector is removed, does message go out?

NO

Defective BrB wiring between CNB and electro-magnetic proportional valve

YES

Replace electro magnetic proportional valve or repair BrB wiring

YES

NO

When CNA connector is removed, does message go out? NO

Defective BrB wiring between CNB and CN8

Repair BrB wiring.

Controller defect

Replace controller.

Solenoid valve defect

Replace solenoid valve.

Defective wiring between CNA and solenoid valve

Repair wiring.

Defective wiring between CN6 and CNA

Repair wiring.

Controller defect

Replace controller.

YES When CN7 connector is removed, does message go out? NO

When CN6 connector is also removed, does message go out?

* When there are multiple abnormalities the smaller number is displayed and after it is repaired, the next number is displayed.

YES

NO

Reconnect CN6, CN7 connectors.

Throttle link system abnormality

YES Is throttle motor out of step?

NO NO Does throttle motor operate with redundancy?

Remove throttle motor connector, measure resistances between B and Br, B and R, B and O, B and Y. (Are they within NO range of 3.0~3.6 ?)

Throttle motor abnormality (energising coil defect)

YES

YES

Remove throttle motor connector. Is it continuous between W and L on NO throttle motor side?

Throttle motor abnormality (limit switch defect)

YES Remove CNI and measure resistances between male side terminals R and B, R and G, R and W, R and Y.. (Are they within range of 3.0~3.6 ?) Throttle motor or driver abnormality Continues to next page B

YES

NO Remove CNI. Is it continuous between male side terminal GL and LgR? YES

9803/6410

NO

Inspect and adjust throttle motor. (Automatic adjustment necessary) Replace throttle motor. (Automatic adjustment necessary) Replace throttle motor. (Automatic adjustment necessary)

Breakage or defective wiring between CNI and throttle motor

Repair wiring.

Breakage or defective wiring between CNI and throttle motor

Repair wiring.

Continues to next page A Issue 1

Section C

Electrics

Section C

Fault Finding

9 - 15

9 - 15

Fault Diagnosis (continued) Electrical System, Message Fault, Problem No.10 (continued) Note: Message does not go out.

Troubleshoot

Cause

Remedy

B Continued from previous page A

Remove driver connector CN15 and measure resistances between female side terminals R and B, R AND G R and W, R and Y. Are they within the range of 3.0~3.6 .

YES

NO

Breakage or defective wiring between CNI and CN15

Repair wiring

Breakage or defective wiring between CNI and CN15

Repair wiring

Breakage of wiring P between CN15 and fuse box

Repair P wiring

Breakage of wiring RY between CN15 and key switch

Repair RY wiring

Same work as *1 YES Remove driver connector CN15. Is it continuous between female side terminals GL and LgR?

NO

Ignition switch YES

Remove driver connector CN15 and measure voltage between female side terminals P and BG, connecting P to + and BG to -. Is it within the range of 20~30V?.

NO

* Ignition switch YES

Remove driver connector CN15 and measure voltage between female side terminals RY and BG, connecting RY to + and BG to -. Is it within the range of 20~30V?

NO

YES

Driver defect

Replace driver

Controller defect

Replace controller

Redundancy switch OFF, ignition switch ON

Remove controller side connector CN8 and measure voltage between GY and ground. YES Is it 0V? Measure voltage between GR and ground. Control System Is it 5V?

NO

Abnormalities

YES

9803/6410

Breakage of wiring GY or GR between controller CN8 and driver CN15

Repair GR or GY wiring

Issue 1

Section C 9 - 16


Section C 9 - 16

Fault Diagnosis (continued) Engine Trouble, Problem No 11 Note: Engine does not start even though the message "electrical system abnormal" is not displayed. Prior Confirmation Items ● ● ● ● ●

No abnormalities in engine or fuel system. Fuse is not blown. The message "Engine emergency stop" is not displayed. Redundancy switch is OFF. Starter motor rotates and engine is cranking.

9803/6410

Issue 1

Section C

Electrics

Section C

Fault Finding

9 - 17

9 - 17

Fault Diagnosis (continued) Engine Trouble, Problem No 11 (continued)

Troubleshoot

Cause

Remedy

Engine system Abnormality

Inspect engine system.

Key switch ON NO

Is fuel cut lever on stop side

YES Remove the stop motor connector and connect female side (cab side) to service connector (6 pin). Measure voltage between LR and ground, connecting LR to + and ground to -. Is it within the range of 20~30V.

Breakage of LR wiring between stop motor connector and CND or between CND and fuse

NO

Repair LR wiring.

YES Remove the stop motor connector and attach service connector to female side. Confirm continuity between L and LW. Is the following true? Key switch ON: Continuity Key switch OFF: °°

NO

Measure voltage between shut down relay 1 connector L and ground, connecting L to + and ground to -. Is the following true? Emergency stop button ON: 0V Emergency stop button OFF: 20~30V

YES

To judge if relay is defective or not, interchanging the relay with one in the centralized relay is another method.

9803/6410

YES

Stop motor defect

NO

Replace stop motor.

Shut down relay defect

Replace shut down relay 1.

Shut down relay 2 Defect or breakage of L wiring between shut down 1 and 2

Replace shut down relay 2 or repair L wiring.

Issue 1

Section C

Electrics

Section C

Fault Finding

9 - 18

9 - 18

Fault Diagnosis (continued) Engine Problem, Problem No 12 Note: Engine revolutions do not change with throttle volume control. Prior Confirmation Items 1

The message "Engine emergency stop" is not displayed.

Troubleshoot

Cause

Remedy

Key switch ON Change voltage moving throttle volume with self-check. Is it within the range of 0~4.5V?

YES

NO

Without removing CN10 connector, change the voltage between GrR + and Gr - moving the throttle volume. Is it within the range of 0~4.5V?

YES

Controller defect or bad connection of CN10 connector

NO Remove throttle volume connector, measure resistance between throttle volume side connector GrR and GrL. Is it within the range of 0~1 ?

YES

NO

Replace throttle volume.

Breakage or defective wiring GrL, GrR, Gr between CN10 and throttle volume

Repair of the GrL, GrR, Gr.

Controller defect

Replace controller.

Breakage of GL wiring

Repair GL wiring

Driver defect

Replace driver.

NO Remove throttle volume connector, measure resistance between throttle volume side connector GrR and Gr. Is it within the range of 0~1 ?

Check motor transmitted pulse by self-check. Is it within the range of 500~1023?

Throttle volume defect.

NO

YES

YES

Remove controller CN4 and driver CN15. Is GL wiring continuous?

NO

Even though the throttle motor is moving. YES

9803/6410

Replace controller or clean CN10 connector terminal.

Issue 1

Section C

Electrics

Section C

Fault Finding

9 - 19

9 - 19

Sensor Resistance Valve

9803/6410

Water temperature (Oil temperature)

Minimum

Maximum

20°C

8.00k

10.20k

30°C

5.35k

6.50k

40°C

3.60k

4.55k

50°C

2.50k

3.10k

60°C

1.70k

2.20k

70°C

1.20k

1.55k

80°C

0.85k

1.15k

Issue 1

Hydraulics

Section E

Section E

i

i

Contents

Page No.

Technical Data JS130

1-1

Technical Data JS160

1-3

Schematics Schematic Hydraulic Circuit JS130 Schematic Hydraulic Circuit JS160 Shuttle Block Pilot Control Line Hose Connection Diagram

3-1 3 - 2A 3-4 3-5

Pressure Testing Pressure Measuring Points Pressure Relief Valves Pressure Testing - General Main Relief Valve Servo Accumulator Pilot Relief Valve Slew Motor Relief Valve Auxiliary Relief Valves Travel Motor Relief Pressure

4-1 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4 - 13

Hydraulic Pump/Regulator Introduction, Specifications Schematics Operation Fault Finding Dismantling and Assembly

10 - 1 10 - 2 10 - 3 12 - 1 14 - 1

* Hydraulic Pump/Regulator

Introduction, Specifications Schematics Operation Dismantling and Assembly

9803/6410

18 - 1 18 - 2 18 - 4 18 - 6

Control Valve Introduction, Technical Data Precautions During Use Spool Location Schematic Hydraulic Circuit Neutral Circuit Operation Removal and Replacement Dismantling and Assembly (Sub-assembly Location)

30 - 1 31 - 1 32 - 1 32 - 2 33 - 1 33 - 3 34 - 1 34 - 2

Remote Control Valve (Services) Introduction, Specification Technical Data, Schematics Operation Dismantling and Assembly Fault Finding Maintenance Specifications

40 - 1 40 - 2 40 - 3 41 - 1 42 - 1 43 - 1

Remote Control Valve (Travel) Introduction, Specification Technical Data Dismantling and Assembly

45 - 1 45 - 2 46 - 1 Issue 3*

Hydraulics

Section E

Section E

ii

ii

Contents Shuttle Valve Introduction General Information Operation

55 - 1 55 - 2 55 - 4

Cushion Valves Schematics, Technical Data Operation

56 - 1 56 - 2

Slew Brake Valve Introduction, Technical Data Operation

60 - 1 60 - 3

Hydraulic Rams Specifications and Torque Settings Precautions During Use Bucket Ram Removal and Installation Dipper Ram Removal and Installation Boom Ram Removal and Installation Dismantling and Assembly Re-Conditioning Fault Finding Maintenance Specifications

70 - 1 71 - 1 72 - 1 73 - 1 74 - 1 75 - 1 76 - 1 78 - 1 79 - 1

Rotary Coupling Technical Data Operation Removal Replacement Dismantling Assembly

80 - 1 81 - 1 82 - 1 82 - 2 82 - 3 82 - 5

Slew Motor Hydraulic Motor Components Reduction Gear Components Hydraulic Circuit Operation Specification Maintenance Specifications Motor Assembly/Cylinder Assembly Dismantling and Assembly Relief Valve Dismantling and Assembly Reduction Gear Dismantling and Assembly Fault Finding

9803/6410

Page No.

83 - 1 83 - 2 83 - 3 90 - 1 91 - 1 91 - 2 92 - 1 93 - 1 94 - 1 95 - 1

Issue 2*

Section E 1-1

Hydraulics

Section E

Technical Data (JS130)

1-1

Note: For full specification details see information in each section.

Pump

*

Type

2 stage tandem, variable capacity swash plate type axial piston pump

Displacement Volume

55 cm3/rev x 2 (3.36 in3/rev x 2)

Working Pressure

Refer to Pressure Testing (Section E 4-1)

Maximum Output

122.7 l/min (27 gal/min)

Fixed Displacement Gear Pump Displacement Volume

9.08 cm3/rev (0.55 in3/rev)

Working Pressure


Maximum Output

20.2 l/min (4.5 gal/min)

Dry weight

TBA

Control Valve

*

Type

Hydraulic Pilot System

Operating System

Set pressure relief

Main Relief Standard Pressure Maximum Pressure

Refer to Pressure Testing (Section E 4-1) Refer to Pressure Testing (Section E 4-1)

Overload Relief Pressure Boom Raising, Dipper, Bucket Boom Lowering Pressure


Function

Travel priority, Slew priority, Boom and Dipper holding valves, Boom and Dipper 2-Speed internal confluence

Dry Weight

104 kg (229.3 lb)

Slew Motor Type

Fixed displacement piston motor

Suction Capacity

65 cm3/rev (3.97 in3/rev)

Working Pressure

285 kgf/cm2 (4052 lbf/in2)

Work Flow

121 l/min (26.62 gal/min)

Set Pressure Relief


Reduction Gears Reduction Gear Ratio

Planetary gears with 2 gear reduction 17.03 : 1

Slew Brake Brake Torque Brake Pressure Release

More than 30 kgf m (217 lbf ft) (not including reduction gear) Min 30 kgf/cm2 (426 lbf/in2)

Dry Weight

99 kg (218 lb)

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Issue 2*

Section E 1-2

Hydraulics

Section E


1-2

Travel Equipment Type

Fixed Displacement Piston Motor (automatic 2-speed change)

Suction Capacity

86.3 cm3/rev (5.27 in3/rev)

Working Pressure


Working Flow

TBA

Reduction Gear Ratio

39 : 1

Parking Brake Brake Torque Brake Pressure Release Brake Valve Pressure Relief

26 kgf/m (188 lbf ft) including reduction gear > 10 kgf/cm2 (142 lbf/in2) TBA

Dry Weight

165 kg (364 lb)

Boom Ram Cylinder Inside Diameter

100 mm (3.94 in)

Rod Diameter

75 mm (2.95 in)

Max Contracted Length

1561 mm (61.46 in)

Stroke

1081 mm (42.56 in)

Dry Weight

116 kg (256 lb)

Dipper Ram Cylinder Inside Diameter

115 mm (4.53 in)

Rod Diameter

80 mm (3.15 in)


1714 mm (67.48 in)

Stroke

1205 mm (47.44 in)

Dry Weight

160 kg (353 lb)

Bucket Ram Cylinder Inside Diameter

95 mm (3.74 in)

Rod Diameter

70 mm (2.76 in)


1422 mm (55.99 in)

Stroke

924 mm (36.38 in)

Dry Weight

97 kg (214 lb)

9803/6410

Issue 2*

Section E 1-3

Hydraulics

Section E


1-3

Note: For full specification details see information in each section.

Pump Type

2 stage tandem, variable capacity swash plate type axial piston pump

Displacement Volume Working Pressure

60 cm3/rev x 2 (3.66 in3/rev x 2) Refer to Pressure Testing (Section E 4-1)

Maximum Output Fixed Displacement Gear Pump Displacement Volume

139.8 l/min (30.75 gal/min) 9.08 cm3/rev (0.55 in3/rev)

Working Pressure


Maximum Output

21.2 l/min (4.6 gal/min)

Dry Weight

TBA

Control Valve Type

Hydraulic Pilot System

Operating System

Set relief pressure

Main Relief Standard pressure Maximum pressure

Refer to Pressure Testing (Section E 4-1) Refer to Pressure Testing (Section E 4-1)

Overload Relief Pressure Boom Raising, Arm, Bucket Boom Lowering Pressure


Function

Travel priority, Slew priority, Boom and Dipper holding valves, Boom and Dipper 2-Speed internal confluence

Dry Weight

104 kg (229.3 lb)

Slew Motor Type Suction Capacity Working Pressure

Fixed displacement piston motor 151 cm3/rev (9.21 in3/rev) 285 kgf/cm2 (4052.7 lbf/in2)

Work Flow


Set Pressure Relief


Reduction Gears Reduction Gear Ratio

Planetary gears with 2 gear reduction 13.34 : 1

Slew Brake Brake Torque Brake Pressure Release

More than 68.5 kgf m (495.3 lbf ft) (Not including reduction gear) Min 32 kgf/cm2 (455 lbf/in2)

Dry Weight

197 kg (434 lb)

9803/6410

Issue 2*

Section E 1-4

Hydraulics

Section E


1-4

Travel Equipment Motor Suction Capacity

Fixed displacement piston motor (automatic 2-speed change) 104.8 cm3/rev (6.39 in3/rev)

Working Pressure


Working Flow

TBA

Reduction Gear Ratio Parking Brake Brake Torque Brake Pressure Release Brake valve pressure relief

48 : 1 26 kgf/m (188 lbf ft) including reduction gear > 11 kgf/cm2 (156 lbf/in2) TBA

Dry Weight

225 kg (496 lb)

Boom Rams Cylinder Inside Diameter

115 mm (4.53 in)

Rod Diameter

80 mm (3.15 in)


1689 mm (66.65 in)

Stroke

1184 mm (46.61 in)

Dry Weight

157 kg (346 lb)

Dipper Ram Cylinder Inside Diameter

125 mm (4.92 in)

Rod Diameter

90 mm (3.54 in)


1875 mm (73.82 in)

Stroke

1335 mm (52.56 in)

Dry Weight

210 kg (463 lb)

Bucket Ram Cylinder Inside Diameter

105 mm (4.13 in)

Rod Diameter

75 mm (2.95 in)


1057 mm (59.33 in)

Stroke

997 mm (39.25 in)

Dry Weight

117 kg (258 lb)

9803/6410

Issue 2*

Section E

Hydraulics

Section E

Schematics

3-1

3-1

Schematic, Hydraulic Circuit JS130

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

9803/6410

MOTOR; SLEW RAM; DIPPER VALVE; ASSEMBLY MOTOR; TRACTION ROTARY COUPLING RAM; BUCKET RAM; BOOM (L) RAM; BOOM (R) VALVE; SHUTTLE VALVE; CONTROL VALVE; SOLENOID ORIFICE FILTER; LINE VALVE; CHECK VALVE; CHECK RADIATOR RADIATOR BREATHER; AIR TANK; SUMP FILTER; LINE STRAINER VALVE; RELIEF FILTER; RETURN VALVE; STOP NEPHRON FILTER VALVE; STOP VALVE; CHECK SWITCH; PRESS. VALVE; SOLENOID

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

VALVE; SHUTTLE ACCUMULATOR VALVE; CHECK FILTER; LINE PUMP; HYD VALVE; REMOTE CONT VALVE; REMOTE CONT VALVE; SHUTTLE SWITCH; PRESS VALVE; STOP CUSHION VALVE SWITCH PRESS. VALVE; STOP VALVE; SPL VALVE; RELIEF FILTER; LINE

Issue 1

Section E

Hydraulics

Section E

Schematics

3 - 2A

3 - 2A

Schematic, Hydraulic Circuit JS160

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

9803/6410

MOTOR; SLEW RAM; DIPPER VALVE; ASSEMBLY MOTOR; TRACTION ROTARY COUPLING RAM; BUCKET RAM; BOOM (L) RAM; BOOM (R) VALVE; SHUTTLE VALVE; CONTROL VALVE; SOLENOID ORIFICE FILTER; LINE VALVE; CHECK VALVE; CHECK RADIATOR RADIATOR BREATHER; AIR TANK; SUMP FILTER; LINE STRAINER VALVE; RELIEF FILTER; RETURN VALVE; STOP NEPHRON FILTER VALVE; STOP VALVE; CHECK SWITCH; PRESS. VALVE; SOLENOID

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

VALVE; SHUTTLE ACCUMULATOR VALVE; CHECK FILTER; LINE PUMP; HYD VALVE; REMOTE CONT VALVE; REMOTE CONT VALVE; SHUTTLE SWITCH; PRESS VALVE; STOP CUSHION VALVE SWITCH PRESS. VALVE; STOP VALVE; SPL VALVE; RELIEF FILTER; LINE

Issue 1

Section E

Schematics

3-4 * Shuttle

9803/6410

Hydraulics

Section E 3-4

Block

Issue 2*

Section E

Schematics

3-5

* Pilot

Hydraulics

Section E 3-5

Control Line Hose Connection Diagram

JS03540

9803/6410

Issue 2*

Section E 3-6

Hydraulics Schematics

Section E 3-6

Pilot Control Line Hose Connection Diagram

JS03540

9803/6410

Issue 1

Section E

Hydraulics Pressure Testing

4-1

A

Section E 4-1

Pressure Measuring Points JS130

Key G1 G2 G3 G4

Main Pump P1 Main Pump P2 Servo Pressure (JS 160) Servo Pressure (JS 130)

G1

G2 JS160

G3 G4

A302850

A302860

B

Pressure Relief Valves

F E

G

D

L

B C

A A306490

9803/6410

Key A B C D E F G L

Main relief valve Boom raise relief valve Boom lower relief valve Bucket open relief valve Bucket close relief valve Dipper out relief valveA306490 Dipper in relief valve Hammer relief valve Issue 1

Section E

Hydraulics

Section E

Pressure Testing

4-2

4-2

Pressure Testing - General Confirmation of the oil Temperature Confirm the oil temperature is between 45° - 55° C using the self check function. If the temperature is low use the following warm-up procedure.

5

Operate the bucket control slowly until it reaches one end of its travel and leave it there for 30 seconds.

6

Operate the bucket control slowly to the other end of its travel and leave it there for 30 seconds.

7

Repeat steps 5 and 6 for 10 minutes to warm up the hydraulic circuit.

8

Now operate the excavating controls three to five times in each direction to distribute warm hydraulic oil around the system.

Warming-up Procedure 1

Turn the Throttle Control to mid-range and make sure the Work Mode Selection Switch is set to S.

2

Press the One Touch Idle Switch.

3

Run the engine until the Coolant Temperature gauge reads within the normal (green) range.

4

Set the Servo Isolator Switch to ON to enable the hydraulic servo controls to be operated.

Pressure bar (lb/in2)

Part Name

Measurement Method

Measurement Port

Standard: 314 - 320 bar (4554 - 4641 lb/in2) Dipper Relief Power Boost: 343 - 350 bar (4975 - 5076 lb/in2)

G1(G2)

Raise

358 - 365 bar (5192 - 5294 lb/in2)

Boom Up Relief

G2

Lower

295 - 305 bar (4278 - 4423 lb/in2)

Boom down Relief

G2

Bucket Port Relief

Open/Close

358 - 365 bar (5192 - 5294 lb/in2)

Bucket Relief

G2

Dipper Port Relief

Out/In

358 - 365 bar (5192 - 5294 lb/in2)

Dipper Relief

G1

Swing Port Relief

Left/Right

275 - 285 bar (3988 - 4133 lb/in2)

Swing Relief

G1

Pilot Relief

37 - 43 bar (536 - 624 lb/in2)

Lever Neutral

G3

Accumulator

15 ± 5 bar (217 ± 72.5 lb/in2)

G3

Track Motor Relief

338 - 348 bar (4902 - 5047 lb/in2)

G1(G2)

Main Relief

Boom Port Relief

9803/6410

Issue 1

Section E

Hydraulics

Section E

Pressure Testing

4-3

4-3

Main Relief Valve (MRV) 1

Prepare the Machine a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the bucket on the ground. Stop the engine. Release the hydraulic oil tank pressure. (See Releasing Tank Pressure). b Install a 0 - 400 bar (0 - 6000 lb/in 2 ) pressure gauges at test points G1 and G2 (see view A on page 4 - 1). c

Start the engine, and confirm that the engine is at its maximum no-load speed and it is in the S mode.

d Raise the boom and then operate the dipper out control. Read the pressure gauges with the dipper ram stalled at the end of its stroke. 2 Pressure Setting Note: For accurate setting, the pressure should be adjusted up to the required level. Release lock nut X. Adjust setting screw Y to indicate a pressure below the required level and then bring the pressure back up for final setting. Tighten lock nut X. a

A A306490

X

The pressure gauges reading should be compared to the technical data at the start of the section. If it is outside the limits, adjust MRV as above.

3

Stop the engine

4

Confirmation of the rated pressure a Start the engine, raise the r.p.m to maximum in the S mode. Check for leakage at the adjusted points. b Operate the dipper in control to bring the ram to the end of its stroke. Continue to hold the lever with the ram stalled in this position.

Y 312450

d The pressure gauge reading should be compared to the technical data at the start of the section. If it is outside the limits, repeat the procedure from step 2. 5

Stop the engine and relieve the pressure in the hydraulic oil tank (see Releasing Tank Pressure) . Remove the pressure gauges and adaptors.

9803/6410

Issue 1

Section E

Hydraulics Pressure Testing

4-4

Servo Accumulator 1

Section E 4-4

JS 160


Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the bucket on the ground. Stop the engine. Release the hydraulic oil tank pressure. (See Releasing Tank Pressure).

2

Accumulator Pressure

3

With the servo isolator lever lowered, start the engine.

4

Raise the boom to its full height and stop the engine. switch the ignition ON.

5

Move the boom operating lever fully from neutral to lower and back to neutral and check the boom begins to lower and then stops. Repeat six times, checking that the boom lowers after each time.

6

If the boom lowers three or more times, the gas pressure in the accumulator is satisfactory.

7

If the boom lowers twice or less, investigate for internal leakage. G4

A302850

JS 130

G3

A302860

9803/6410

Issue 1

Section E 4-5

Hydraulics

Section E

Pressure Testing

4-5

Pilot Relief Valve 1

Prepare the Machine Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the bucket on the ground. Stop the engine. Release the hydraulic oil tank pressure. (See Releasing Tank Pressure).

2

Before testing the Pilot Relief valve (K), connect a 0-100 bar (0-1500 lb/in2) pressure gauge to test point G3 (see view A on page 4-1).

3

Start the engine and confirm that the engine is at its maximum no-load speed and it is in the S mode. The pressure gauge reading should be compared to the technical data at the start of this section. If it is outside the limits adjust the pilot relief valve as below.

4

Stop the engine.

5

The valve is adjusted by turning relief valve K ( one turn of the adjustment screw equals 39.2 bar).

6

After locking, check the relief pressure again. If it is not within the limits above, perform steps 3 to 6 again.

7

Stop the engine, release the tank pressure (see Releasing Tank Pressure) and then remove the pressure gauge.

K

JS06711

9803/6410

Issue 1

Section E

Hydraulics

Section E

Pressure Testing

4-6

4-6

Slew Motor Relief Valve 1

Prepare the machine Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the bucket on the ground. Stop the engine. Release the hydraulic oil tank pressure. (See Releasing Tank Pressure).

2

Connect a 0-400 bar (0-6000 lb/in2) pressure gauge and adaptor to pressure test point G2 (see view A on page 4 - 1).

Note: Pressure can also be measured on the upper section of the slew motor. 3

296590a

B

A

Initiate slew lock procedures. a

Remove the water-proof connector (dark green wire) from swing shut off solenoid valve V, which is mounted at the side of the hydraulic pump.

A296530

b Press the slew lock switch ON (on the cab left console) and confirm that the slew lock symbol appears on the monitor. c

V

Start the engine, and operate the engine at around 1000 r.p.m, and operate the slew lever slowly. Listen to confirm that the relief valve is heard to operate and check that the machine does not slew.

Note: If the water-proof connector of the slew lock solenoid valve is not removed (step 3a), slew lock status can be obtained with the slew lock switch ON (step 3b), but the slew relief valve does not operate. 312470

d Run the engine at maximum no-load speed in the S mode. e

Operate the slew lever.

4

The pressure gauge reading should be 279 ± 10 bar (4045 ± 145 lb/in2).

5

If the pressure is within the limits, stop engine, release tank pressure and remove the gauge and adaptor. If the readings are outside the limits, continue as below.

6

W X

Pressure Adjustment Repeat step 3 above and confirm pressure setting.

302880

Adjust the appropriate slew motor relief valve (W for right slew, X for left slew). a

Remove screw cap Y.

b Adjust the pressure by altering the thickness of shim Z (increasing the thickness increases the pressure, decreasing the thickness decreases the pressure). c

Z

Refit screw cap Y.

Y

d After locking, check the relief pressure again. If it is not within the specified limits (see step 4 above) repeat steps 6a to 6d. e

Repeat step 5 above.

9803/6410

JS06250

Issue 1

Section E 4-7

Hydraulics

Section E

Pressure Testing

4-7

Auxiliary Relief Valves General The auxiliary relief valves (ARV’s) are set to a higher pressure than the main relief valve (MRV). To permit pressure testing of the ARV’s it is necessary to temporarily adjust the MRV to a higher setting (refer to view B on page 4 - 1). Proceed as follows: 1

Prepare the machine a Put the operator levers into neutral and lower gate lock lever. Start the engine and park machine on level ground. Operate the dipper and lower the boom to set the bucket on ground.

the the out the

b Run the engine at maximum no-load speed in the S mode. 2

Increase MRV Pressure Loosen MRV lock nut Y and turn pressure adjusting screw Y 180° clockwise. Tighten lock nut X.

3

Restore Original MRV Pressure After completion of all ARV pressure testing, loosen lock nut X and turn adjusting screw Y, 180° anticlockwise and restore the original MRV setting pressure.

4

296590a

X

Y 312450

Stop the engine

9803/6410

Issue 1

Section E

Hydraulics

Section E

Pressure Testing

4-8

4-8

Auxiliary Relief Valves (continued) Boom Ram 1

Prepare the machine a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the bucket on the ground. Stop the engine. Release the hydraulic oil tank pressure. (See Releasing Tank Pressure). 296590a

b Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure gauge and adaptor to port G2 on the hydraulic pump (see view A on page 4 - 1). 2

If not already done, temporarily increase the pressure setting of the MRV (see Auxiliary Relief Valves, General, step 2).

3

Start the engine, lower the gate lock lever and run the engine at maximum no-load speed in the S mode.

4

Pressure Adjustment

B

Boom up Note: For accurate setting, the pressure should be adjusted up to the required level. Release lock nut X. Adjust setting screw Y to indicate a pressure below the required level and then bring the pressure back up for final setting. Tighten lock nut X. a

306490

Fully raise the boom and then continue to operate the right control lever as at A.

b The pressure gauge reading should be compared to the technical data at the start of the section. If it is outside the limits, adjust ARV B.

A

A296530

X

Y 289910

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Issue 1

Section E

Hydraulics

Section E

Pressure Testing

4-9

4-9

Auxiliary Relief Valves (continued) Boom Ram (continued) Boom Down 5

Prepare the machine Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the bucket on the ground. Stop the engine. Release the hydraulic oil tank pressure. (See Releasing Tank Pressure). 305511a

6

It is not physically possible to fully close the boom ram, without lifting the undercarriage of the ground. Therefore the ARV’s B and C must be swapped over. a

Fully raise the boom and then continue to operate the right control lever as at A.

b The pressure gauge reading (Boom down) should be compared to the technical data at the start of the section. If it is outside the limits, adjust ARV. 7

8

9

Stop the engine and release the hydraulic pressure, (see Releasing Tank Pressure). Remove the pressure gauge and adaptor. The Relief Valves for Boom up and Boom down must be swapped and returned to the correct ports. If further ARV tests are necessary carry out the relevant procedures detailed in this section. If no further ARV tests are required restore the MRV pressure setting to its original value (see Auxiliary Relief Valve, General, step 3).

C

B

306490

Stop the engine and release the hydraulic pressure, (see Releasing Tank Pressure). Remove the pressure gauge and adaptor.

A

A296530

X

Y 312460

9803/6410

Issue 1

Section E

Hydraulics

Section E

Pressure Testing

4 - 10

4 - 10

Auxiliary Relief Valves (continued) Dipper Ram 1

Prepare the Machine. a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the bucket on the ground. Stop the engine. Release the hydraulic oil tank pressure. (See Releasing Tank Pressure).

JS03511a

b Connect a 0 - 400 bar (0 - 6000 lb/in ) pressure gauge and adaptor to port G1 on the hydraulic pump (see view A on page 4 - 1). 2

2


3


4

Pressure Adjustment

F G

Note: For accurate setting, the pressure should be adjusted up to the required level. Release lock nut X. Adjust setting screw Y to indicate a pressure below the required level and then bring the pressure back up for final setting. Tighten lock nut X. a

A306490

Raise the boom to its full height.

306490

b Move the dipper fully out and then continue to operate the control lever, as at A. c

The pressure gauge reading (Dipper out) should be compared to the technical data at the start of the section. If it is outside the limits, adjust ARV F.

A

d Move the dipper fully in and then continue to operate the control lever, as at B. e

Compare the pressure gauge reading to that stated in the technical data section at the start of the section. If it is outside the limits, adjust Auxiliary Relief Valve G.

5

If further ARV tests are necessary carry out the relevant procedures detailed in this section. If no further ARV tests are required, restore the MRV pressure setting to its original value (see Auxiliary Relief Valve, General, step 3).

6

Stop the engine and release the hydraulic pressure (see Releasing Tank Pressure). Remove the pressure gauge and adaptor.

B A296530

X

Y 312460

9803/6410

Issue 1

Section E

Hydraulics

Section E

Pressure Testing

4 - 11

4 - 11

Auxiliary Relief Valves (continued) Bucket Ram 1

Prepare the Machine a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the bucket on the ground. Stop the engine. Release the hydraulic oil tank pressure. (See Releasing Tank Pressure).

JS 03511a

b Connect a 0 - 400 bar (0 - 6000 lb/in ) pressure gauge and adaptor to port G2 on the hydraulic pump (see view A on page 4 - 1). 2

2


3


4

Pressure Adjustment

E

D

Note: For accurate setting, the pressure should be adjusted up to the required level. Release lock nut X. Adjust setting screw Y to indicate a pressure below the required level and then bring the pressure back up for final setting. Tighten lock nut X. a

Raise the boom.

306490

b Open the bucket fully and then continue to operate the control lever at A. c

The pressure gauge reading should be compared to the technical data at the start of the section. If it is outside the limits, adjust ARV D.

d Close the bucket fully and then continue to operate the control lever, as at B.

B

A

e Repeat step 4c and, if necessary, adjust ARV E. 5

6

If further ARV tests are necessary, carry out the relevant procedures detailed in this section. If no further ARV tests are required, restore the MRV pressure setting to its original value (see Auxiliary Relief Valve, General, step 3).

A296530


X

Y 312460

9803/6410

Issue 1

Section E

Hydraulics

Section E

Pressure Testing

4 - 12

4 - 12

Auxiliary Relief Valves (continued) Rockbreaker ARV (Monoboom) 1

Prepare the Machine. a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the hammer on the ground. Stop the engine. Release the hydraulic oil tank pressure. (See Releasing Tank Pressure). A296590

b Fit two caps B to the hammer pipes on the dipper. c

Connect a 0 - 400 bar (0-6000 lbf/in 2) pressure gauge to test point G1 (see view A on page 4 - 1).

2


3

Operate the hammer by pressing the button C on the front of the L.H. control lever. Check the pressure on the gauge, adjust ARV L.

4

JS 06720

Pressure Adjustment

Note: For accurate setting, the pressure should be adjusted up to the required level. Release lock nut X. Adjust setting screw Y to indicate a pressure below the required level and then bring the pressure back up for final setting. Tighten lock nut X. 5

B

C


JS 04121

L

306490

X

Y

312460

9803/6410

Issue 1

Section E

Hydraulics

Section E

Pressure Testing

4 - 13

4 - 13

Travel Motor Relief Pressure 1

Prepare the Machine. a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the bucket on the ground. Stop the engine. Release the hydraulic oil tank pressure. (See Releasing Tank Pressure). b Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure gauge and adaptor to port G1 and G2 on the hydraulic pump (see view A on page 4 - 1).

2


3

Insert a Lock Pin P between the drive sprocket to be measured and the side frame.

4


5

Slowly engage the locked travel motor and measure the pressure in forward and reverse.

6

Pressure Adjustment

JS 03511a

P

ø35

Note: For accurate setting, the pressure should be adjusted up to the required level. Release lock nut A. Adjust setting screw B to indicate a pressure below the required level and then bring the pressure back up for final setting. Tighten lock nut A. a

300

ø80

150

P

The pressure gauge reading (Travel motor) should be compared to the technical data at the start of the section. If it is outside the limits, adjust relief valve pressure. JS 03230a

7

6

If further ARV tests are necessary carry out the relevant procedures detailed in this section. If no further ARV tests are required, restore the MRV pressure setting to its original value (see Auxiliary Relief Valve, General, step 3). Stop the engine and release the hydraulic pressure (see Releasing Tank Pressure). Remove the pressure gauge and adaptor.

B A

A B

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Issue 1

Section E

Hydraulics

Section E

Hydraulic Pump/Regulator

10 - 1

10 - 1

Introduction The pump/regulator consists of two variable displacement type axial piston pumps (P1 and P2) supplying pressurised oil to operate machine functions, plus a gear type pilot pump (Pp) to provide pilot circuit pressure for operator control of machine functions. Pumps P1 and P2 each incorporate a regulator which adjusts the output flow rate according to system demand.

Specifications Axial Piston Pumps Maximum displacement

JS130

JS160

55 (3.36) x 2

60 (3.66) x 2

set

319 bar (4551 lbf/in2, 320 kgf/cm2)

319 bar (4551 lbf/in2, 320 kgf/cm2)

maximum

343 bar (4978 lbf/in2, 350 kgf/cm2)

343 bar (4978 lbf/in2, 350 kgf/cm2)

2230

2330

122.7 (27.0) (US 32.4)

139.8 (30.8) (US 36.9)

147 (108.4)

281 (207)

JS130

JS160

9.08 (0.55)

9.08 (0.55)

42 bar (612 lbf/in2, 43 kgf/cm2)

42 bar (612 lbf/in2, 43 kgf/cm2)

20.2 (5.34) (US 5.3)

21.2 (5.60) (US 5.6)

cc (in3)/rev

Working pressure (travel)

Speed

rpm

*

Maximum flow

*

Maximum input torque

l (UK gal) (US gal)/min Nm (lbf ft)

Gear pump Displacement Working pressure Maximum flow

9803/6410

cc (in3)/ rev maximum l (UK gal) (US gal)/min

Issue 2*

Section E 10 - 2

Hydraulics Hydraulic Pump/Regulator

Section E 10 - 2

Pump Hydraulic Circuit Diagram

JS00040

Pump Configuration

JS00050

Key A B C E F G

Negative control signal Maximum flow signal Mode change - electrical signal Solenoid proportional pressure control (SPPC) valve Total horsepower control electrical signal Pilot pressure relief valve

9803/6410

H J L P1 P2 Pp

Pump input Pump outputs Swash plate angle Front pump Rear pump Pilot pump

Issue 1

Section E 10 - 3


Section E 10 - 3

Operation In the following descriptions the bold figures (e.g. 4) relate to the items on the sectional and exploded views on pages 14 - 1 to 14 - 3 and the component list on page 14 - 4.

Main Pumps (P1 and P2) Each pump consists of a cylinder block 4, containing nine piston/shoe assemblies 6. Driven by shaft 5, the block rotates between a variable angle, non-rotating swash plate (7 on P1, 8 on P2) and a fixed valve plate (9 on P1, 10 on P2). Retainer plate 11 holds the piston shoes against the swash plate. Due to the angle of the swash plate, as the cylinder block rotates the pistons are forced to move back and forth in their cylinders. The piston stroke, and therefore the pump displacement, varies according to the swash plate angle, which is controlled by machine demand.

The fixed valve plate 9 contains two crescent shaped ports X. The valve plate is located so that when a piston reaches its nearest point to the plate it comes into line with the pump inlet port H. During the next 180° of cylinder block rotation the piston draws oil into the cylinder bore. When the piston reaches its furthest point from the plate it ceases to be in line with the inlet port and comes into line with pump outlet port J. The next 180° of cylinder block rotation causes the piston to force oil from the cylinder bore through the outlet port. The process is carried out sequentially by the nine pistons to provide a continuous smooth pump output.

JS00060

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Issue 1

Section E 10 - 4


Section E 10 - 4

Operation Pilot Pump (Pp)

JS00070

Regulator

JS00080

Key A B K L P1 P2 Pp

Negative control signal Maximum flow signal Horsepower control signal (from pump proportional solenoid control valve) Swash plate angle Front pump Rear pump Pilot pump

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Issue 1

Section E 10 - 5


Section E 10 - 5

Operation (cont’d) Pilot Pump (Pp) As the pump gears revolve, oil from the inlet port Y is trapped between the gears and the housing and carried to the outlet port Z.

Horsepower Control The operation of the pump is based on the principle that at a given horsepower setting:

Regulator “pressure x output flow rate = constant” The function of each regulator is to maximise the efficiency of its associated pump circuit by making it respond to system demand i.e. adjusting the output flow to satisfy the changing requirements of the machine services. This is achieved by varying the angle of the pump swash plate. The following description refers to pump P1. The circuit for pump P2 functions in exactly the same way. Flow Control Pump P1 pressure is routed to piston 32, regulator piston 24 (small diameter chamber ‘a’) and spool 40. Pump P2 pressure is also routed to piston 32. Pilot pump Pp pressure and horsepower control signal K (which is derived from Pp pressure and related to the operating mode selected) produce control pressure PC which is equal to 5% of total pump pressure (P1 + P2).

The setting can be varied using the signal K as described under Flow Control. Signal K is controlled by the Solenoid Proportional Pressure Control valve (SPPC), the output of which is determined by electric signals according to the working mode selected. Maximum Flow Cut When the maximum flow cut signal B is present, it acts on piston 54 to operate spool 40 via piston 38, as described under Flow Control. Due to the diameter of piston 54 being smaller than that of piston 38, maximum flow is 65% of that obtainable under normal flow control conditions.

Pressure PC, routed to piston 38, increases with pump pressure. The piston moves spool 40 to the left to direct pump P1 pressure to the large diameter chamber ‘A’ of regulator piston 24. This causes piston 24 to move to the right to reduce the swash plate angle and decrease oil flow. Bridging piece 29, connected to piston 24, compresses springs 43/44 to act against PC pressure through piston 38. When PC pressure and the pressure of springs 43/44 are equal the regulator piston stops moving. Pressure PC decreases as pump pressure falls and springs 43/44 cause spool 40 to move to the right, connecting chamber ‘A’ of regulator piston 24 to the case drain. P1 pressure at chamber ‘a’ causes regulator piston 24 to move to the left to increase the swash plate angle and increase oil flow. When pressure PC and the pressure of springs 43/44 are equal the regulator piston stops moving. Negative Control When the pump output is not being used (or is at a very low rate) pressure signal A, derived from the main control valve, acts on piston 38 in the same way as pressure signal PC, described under Flow Control, to minimise oil flow.

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Issue 1

Section E 10 - 6


Section E 10 - 6

Operation (cont’d) Pilot Relief Valve Pilot pressure is controlled by the pilot relief valve setting. Pressure can be varied using adjuster 56-6 which holds poppet 56-2 against seat 56-3 by means of spring 56-5. If the pressure exceeds the set value, the poppet lifts to vent excess Pp pressure to tank.

Solenoid Proportional Pressure Control (SPPC) Valve The function of the SPPC valve is to provide a means of varying the horsepower settings of the two pumps according to the operating mode selected. Each mode selection causes an electrical signal F to be applied to the valve solenoid. The signal current level is dependent on the mode selected. The solenoid converts the electrical signal into a thrust from plunger E. When solenoid 58 is energised, the thrust of plunger E moves spool 103 to the left to connect input port B (at pilot pump Pp pressure) to output port C. The output pressure at port C is routed to chamber A where it acts as a back pressure to oppose the thrust of plunger E. High back pressure causes spool 103 to move so that output port C connects to drain port D lowering the output pressure and hence the back pressure. The result is a level output (horsepower signal) pressure which is proportional to solenoid plunger thrust and determined by the proportion of input pressure (at port B) connected to port C via spool 103.

9803/6410

Issue 1

Section E

Hydraulics

Section E


12 - 1

12 - 1

Fault finding As a first step towards locating a fault, carry out the following checks. 1

Check the hydraulic filter for the presence of excessive foreign materials. The nature of the foreign materials could yield a clue as to the source of damage or wear.

2

Check the flow rate and condition of the oil drained from the pump.

3

Check for abnormal sounds and vibration.

4

Check the pressure at each of the pump pressure test points.

Symptom 1 No oil is delivered from the pump.

2

Possible cause a

Suction strainer or suction line is blocked.

Clean the suction strainer or clear the suction line.

b

The suction strainer is above the oil level of the tank.

Top up the hydraulic oil tank and bleed air from the system.

c

The pump itself is faulty.

Dismantle and damaged parts.

a

Incorrect operation of various control valves or hydraulic motors served by the pump, causing low flow rate or loss of pressure.

Renew or inspect and repair the defective control valve or hydraulic motor.

b

The sliding area of the pump is worn, allowing a large amount of pressurised oil to escape from the drain port.

Low pump flow rate, or circuit pressure does not build-up.

c

d

e

9803/6410

Remedy

Excessive suction resistance.

worn

or

Dismantle the pump and, if possible, polish or repair by lapping. If repair is not possible fit new parts. i

Check the hydraulic connections for looseness and tighten if necessary.

ii

Check the hydraulic lines and seals for damage.

Air is being drawn into the pump.

The suction strainer is blocked or above the oil level of the tank.

renew

Clean the suction strainer or, if necessary, renew. Top up the hydraulic oil tank and bleed air from the system. Check for abnormal oil temperature or viscosity, or other factors causing cavitation. Take the necessary remedial steps.

Issue 1

Section E

Hydraulics

Section E


12 - 2

12 - 2

Fault finding (cont’d) Symptom 3

4

5

Pump is producing abnormal noise.

Engine overload - engine operates at extremely low speeds or stops.

Oil leakage.

9803/6410

Possible cause

Remedy

a

Air is being drawn in due to low oil level in the hydraulic oil tank.

Top up the hydraulic oil and bleed air from the system.

b

Pump cavitation due clogged suction strainer.

a

Clean the strainer. If excessively clogged, flush the hydraulic system and/or renew the hydraulic oil

c

Excessively low oil temperature, or pump cavitation due to high viscosity.

Check that the correct hydraulic oil for the ambient conditions is being used. If not, renew the oil.

d

Resonance with external parts.

Check mounting bolts and tighten if necessary.

a

The torque regulator is set too high.

Readjust the regulator.

b

The filter incorporated in the pump is clogged.

Clean the filter. If excessively clogged, flush the hydraulic system and/or replace the hydraulic oil.

c

The pilot oil passage and orifice inside the regulator are clogged, or some parts are thermally seized or damaged.

Readjust the regulator. If no changes are observed, dismantle the regulator for inspection and repair.

d

Seizure or wear of pump internal parts.

Dismantle and damaged parts.

a

Oil seal failure originating from an increased drain flow and raised pump internal pressure.

Dismantle and renew the oil seal, taking particular care not to damage the lip when fitting the new oil seal.

b

Oil seal failure originating from restricted drain line and raised pump internal pressure.

Change the drain lines so that pressure no higher than 3 bar (43 lb/in2) is exerted on the oil seal. Renew the oil seal. (Take particular care not to damage the lip when fitting the new oil seal.)

to

renew

worn

or

Issue 1

Section E 14 - 1


Section E 14 - 1

Dismantling and Assembly

JS00010

9803/6410

Issue 1

Section E 14 - 2


Section E 14 - 2

JS00030

Dismantling and Assembly (cont’d)

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Issue 1

Section E 14 - 3


Section E 14 - 3

JS00020


9803/6410

Issue 1

Section E

Hydraulics

Section E


14 - 4

14 - 4

Component List No

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Pump housing Flange Rear cover Cylinder block assembly Shaft Piston assembly Swash plate (front) Swash plate (rear) Valve plate (front) Valve plate (rear) Retainer plate Retainer plate holder Bearing Bearing Oil seal Oil seal case Shim Shim Conical spring assembly Spring seat Guide assembly Slide metal Regulator piston Stopper Stopper Set screw Set screw Nut Bridging piece Cover (R) Plug Piston Sleeve Spool Plug Spring Sleeve Piston Sleeve Spool Spring seat Spring seat Spring Spring Plug Spring seat Spring Nut Nut Sub-block Disc filter Cover (LF) Cover (LR) Piston Steel ball Relief valve assembly Pilot gear pump Solenoid valve Hose Adjustable elbow

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Qty.

No.

Description

1 1 1 2 1 18 1 1 1 1 2 2 2 4 1 1 1 1 2 2 4 2 2 2 2 2 2 4 2 2 1 1 1 1 1 1 2 6 2 2 2 2 2 2 2 2 2 2 2 1 2 1 1 2 2 1 1 1 1 2

61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 107 108 109 110 111

Mounting flange Pin Pin Pin Plug Plug Plug Plug Plug Plug Socket head bolt Socket head bolt Socket head bolt Socket head bolt Socket head bolt Plug Bolt ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring Back-up ring Back-up ring Back-up ring Back-up ring Back-up ring Name plate Drive screw Eyebolt Sleeve Spool Spring Plug ‘O’-ring Washer Orifice ‘O’-ring

Qty. 1 2 2 4 1 1 2 1 2 4 4 6 18 4 4 8 2 2 1 1 1 2 4 1 2 1 3 3 1 2 1 2 2 2 2 2 2 3 1 2 1 1 1 1 1 1 2 1 1

Issue 1

Section E 14 - 5


Section E 14 - 5

Dismantling Refer to the illustrations on pages 14 - 1 to 14 - 3 and the component list on page 14 - 4. In the following procedures, the part numbers in bold type (e.g. 71) correspond with the numbers on the illustrations. Before attempting to dismantle the hydraulic pump, drain all oil, blank all inlet and outlet ports and wash the outer surfaces with a suitable solvent to remove all dirt and dust. Dry using compressed air. Make different alignment marks across each sub-assembly joint face as an aid to assembly.

The following procedures show a complete strip down, but, unless absolutely necessary, avoid disturbing or dismantling the control elements of the pump, i.e. those retained by covers 30, 52 and 53 and by plugs 31 and 35. Any interference with setting screws will affect pump output control, necessitating precision re-setting on the bench. The pump/regulator unit contains two pressure pumps, P1 and P2. Take care not to get the parts from one mixed in with parts from the other. During dismantling, record the number and dimensions of shims. Take care to reassemble in the same manner.

The cylinder block assemblies, servo pump, relief valve and proportional pressure reduction valve must be replaced as complete assemblies.

Note: Protect the clamping faces when supporting the pump housing in the vice. 1

2

Remove hose 59.

Support pump housing 1 in a vice, clamped across the inlet and outlet port flanges. Unscrew the four socket head bolts 71 and remove mounting flange 61.

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Issue 1

Section E 14 - 6


Section E 14 - 6

Dismantling (cont’d)

3

Unscrew the two bolts 77 and remove gear pump 57.

4

Unscrew the four socket head bolts 74. Remove subblock assembly 50 and put to one side.

5

Unscrew the six socket head bolts 73 and remove rear cover 3. Then remove bearings 14 from the swash plate.

6

Remove bearing 13 on the rear side, using the bearing removal tool and the rear shaft protection tool (see Service Tools, Section 1).

Note: It may be necessary to lightly tap the rear cover with a plastic hammer to assist removal.

9803/6410

Issue 1

Section E 14 - 7


Section E 14 - 7


7

9

Remove rear swash plate 8 and the assembly comprising cylinder block 4, piston assembly 6, retainer plate 11, retainer holder 12, spring 19, spring seat 20 and valve plate 10.

Unscrew the six socket head bolts 73 and remove flange 2. Then remove the bearings 14 from the swash plate.

8

Unscrew the four socket head bolts 75 and take out oil seal case 16.

Note: Take care not to damage the oil seal lip with the shaft spline.

10

Remove bearing 13 on the front side, using the bearing removal tool and the front shaft protection tool (see Service Tools, Section 1).

Note: It may be necessary to lightly tap the flange with a plastic hammer to assist removal.

9803/6410

Issue 1

Section E 14 - 8


Section E 14 - 8


11

Remove front swash plate 7 and the assembly comprising cylinder block 4, piston assembly 6, retainer plate 11, retainer holder 12, spring 19, spring seat 20 and valve plate 9.

12

Unscrew the three socket head bolts 72 on the rear side and remove cover ‘LR’ 53. At this point, sleeve 37 may come out with the cover. Take care not to allow the pistons 38 and 54 to fall out.

Note: Take care not to mix these parts with those removed from the rear end at step 7.

13

If necessary, remove sleeve 37 complete with pistons 38 and 54. Remove the three pistons 38 and piston 54 from the sleeve.

9803/6410

14

Remove spool 40, spring seats 41 and 42 and springs 43 and 44 in the same direction as sleeve 37.

Issue 1

Section E 14 - 9

Hydraulics

Section E


14 - 9


15

Unscrew the three socket head bolts 73 on the rear side and remove cover ‘R’ 30.

16

Unscrew the three socket head bolts 72 on the front side and remove cover ‘LF’ 52. Remove sleeve 37 and spool 40 assembly.

Note: Take care not to mix these parts with those removed at step 12.

17

Remove the stoppers 24 and 25 on the rear side using an M6 bolt screwed into the threaded hole in the end of each one.

18

Remove plug 31 complete with piston 32.

Take out regulator piston 23 and bridging piece 29. Repeat for front side, removing stoppers 24 and 25, regulator piston 23 and bridging piece 29. Note: Take care not to mix rear and front side components.

9803/6410

Issue 1

Section E 14 - 10


Section E 14 - 10


19

Loosen plug 35 and remove it along with spring 36. By hooking it with a wire, take out spool 34 together with sleeve 33.

20

Return to sub-block assembly 50 removed at step 4. Remove the ‘O’-rings 89 (1 off), 91 (1 off), 93 (2 off) and 111 (1 off), plus disc filter 51.

21

Unscrew the four securing bolts and remove solenoid 58 from sub-block 50. Remove sleeve 102 and spool 103.

22

Remove relief valve assembly 56 and adjustable elbow 60 from sub-block 50. Remove plug 107 and take out spring 104 and disc filter 51.

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Issue 1

Section E 14 - 11


Section E 14 - 11


23

Using a screwdriver remove oil seal 15 from oil seal case 16 and discard the seal.

9803/6410

Issue 1

Section E

Hydraulics

Section E


14 - 12

14 - 12

Inspection All parts should be checked for signs of damage or wear, paying particular attention to the parts detailed below.

art Piston assembly 6

Renew if these conditions exist a

Any sliding part is deeply scratched or has a rough surface.

b

The clearance between any piston and its cylinder is 0.050 mm (0.002 in) or more.

c

The shoe/ball clearance X is 0.39 mm (0.0157 in) or more.

a


b

The spline is excessively worn or damaged.

Valve plates 9, 10

a

The cylinder block sliding contact surface is deeply scratched or has a rough surface.

Swash plates 7, 8

a

The piston shoe sliding contact surface is deeply scratched or has a rough surface.

b

Flaking or peeling on the roller bearing 14 contact surface.

Retainer plate 11 Retainer holder 12

a

The sliding surface is deeply scratched, thermally seized or unevenly worn or has a rough surface.

Shaft 5

a

The oil seal 15 contact surface is deeply scratched or has a rough surface.

b

The spline is excessively worn or damaged.

a

Flaking or peeling on the rolling surface.

b

The bearing does not operate smoothly and freely.

Oil seal 15

a

The lip has been damaged, excessively worn or hardened.

Body 1 Regulator piston 23

a

The piston and/or its bore is deeply scratched or has a rough surface.

Relief valve assembly 56

a

Any problem occurs, e.g. the set pressure has been lowered

Servo regulator parts (spool, sleeve, piston)

a


Cylinder block assembly 4

Bearings 13, 14

9803/6410

X

Issue 1

Section E 14 - 13


Section E 14 - 13

Assembly Clean each part in a suitable solvent and dry using compressed air. Inspect all parts and renew as required.

All tapped holes and gasket faces should be thoroughly degreased by washing, as liquid packing and adhesive is used on all gasket surfaces and threads.

Care must be taken not to let dust or dirt adhere to parts after cleaning and that parts do not become dented, scratched or damaged.

Apply adhesive to the final few threads of a bolt or screw. Do not apply excessive amounts of adhesive. Wipe off any surplus.

Fit new ‘O’-rings, plugs, packing, oil seals and fastener seals.

Leave the pump for at least twelve hours after assembly to allow the adhesive to dry fully.

Apply Lithium grease to all new oil seals (particularly the lip areas) and ‘O’-rings, and clean hydraulic fluid to all sliding parts before installation.

Ensure that all components are re-fitted to the positions from which they were removed, paying particular attention not to intermix components from identical sets front and rear.

1

2

Install regulator piston 23 and bridging piece 29 into the front of pump housing 1.

Note: Make sure the bridging piece is orientated as shown on page 14 - 3.

Fit ‘O’-ring 82 and back-up ring 94 to stopper 24. Insert the stopper into pump housing 1. Fit ‘O’-ring 85 and back-up ring 95 to stopper 25. Insert the stopper into pump housing 1.

Note 1: Install stoppers 24 and 25 with the tapped centre holes facing outwards. Note 2: The back-up ring is fitted to the end of the stopper nearest the tapped hole, with the ‘O’-ring innermost. Note 3: The stoppers must be fitted flush with the housing to prevent damage to the ‘O’-rings.

9803/6410

Issue 1

Section E 14 - 14


Section E 14 - 14

Assembly (cont’d)

3

Assemble the front piston/cylinder block assembly as follows: a

4

Pass shaft 5 through cylinder block assembly 4 from the rear, double splined end first.

6

Install cylinder block 4/shaft 5 assembly into pump housing 1 with the piston shoes outermost.

Mount spring seat 20 on cylinder block assembly 4 followed by conical spring assembly 19 and retainer holder 12.

b Install piston assembly 6 into retainer plate 11 and insert the pistons in cylinder block assembly 4.

5

Insert pin 63 into the front side of the pump housing. Install valve plate 9, stepped face outermost, so that the slot on its rear face locates the pin.

9803/6410

Issue 1

Section E 14 -1 5

Hydraulics

Section E


14 - 15

Assembly (cont’d)

7

Using suitable blocks to allow the shaft to clear the work surface, position the pump housing on the bench, front end uppermost.

8

a

Fit the two guide assemblies 21 and slide metal 22 to swash plate 7.

Note: The hole in slide metal 22 is not central. Install with the hole furthest from the pistons. b Assemble swash plate 7 into the pump housing. Note: Position regulator piston 23 with the groove for slide metal 22 in the centre and locate the two during assembly.

9

Using a suitable tool (see Service Tools, Section 1) and a press, fit bearing 3 onto shaft 5.

10

Fit bearing cage/rollers 14 on swash plate 7. Set guide assembly 21 in the cut-out of the bearing cage, standing upright.

Note: This job can be carried out by drifting the bearing into place, taking care not to scratch or damage the bearing, the shaft or any other parts.

9803/6410

Issue 1

Section E 14 - 16


Section E 14 - 16

Assembly (cont’d)

JS00110

11

Using a swash plate levelling jig (see Service Tools, Section 1), adjust swash plate 7 so that it is parallel with the outer face of pump housing 1, by ensuring the same height A on the left and the right

12

Install two guide rods (see Special Tools, Section 1) into opposite threaded holes in the pump housing flange.

13

a

14

Lay the pump housing on its side and repeat steps 1, 2 and 3 at the rear end of the housing. Fit the cylinder block assembly on the spline of shaft 5.

Insert two pins 64 into flange 2, then fit the outer race of bearing 13 into the flange.

b Fit ‘O’-ring 78 into the flange. c

Insert pin 62 into pump housing 1 and then assemble flange 2 onto the housing along the guide rods fitted at step 12.

Using suitable blocks to allow the shaft to clear the work surface, position the pump housing on the bench, rear end uppermost.

d Install four socket head bolts 73 into the vacant mounting holes. Remove the two guide rods and insert the remaining two bolts 73. Tighten the bolts evenly to a torque of 129 Nm (95 lbf ft, 13.1 kgf m).

9803/6410

Issue 1

Section E 14 - 17


Section E 14 - 17

Assembly (cont’d)

15

16

Repeat step 8 to assemble and fit rear swash plate 8.

Repeat step 11.

Fit bearing 13 into swash plate 8, using a bearing insertion tool (see Service Tools, Section 1) and fit bearing cage/rollers 14 with guide assembly 21 in the cut-out of the bearing cage, standing upright (see step 10).

Repeat steps 12 and 13 referring to rear cover 3 instead of flange 2.

Fit ‘O’-rings 81, 86, 87 and 88 and back-up rings 96, 97 and 98 onto plug 31. Insert piston 32 into the end of plug 31.

17

Insert spool 34 into sleeve 33 and, after verifying that piston 32 is installed in plug 31, fit the sleeve into pump housing 1.

With plug 31 horizontal to prevent the piston falling out, fit it into the pump housing and tighten to a torque of 229 Nm (169 lbf ft, 23.4 kgf m).

9803/6410

Issue 1

Section E 14 - 18


Section E 14 - 18

Assembly (cont’d)

18

Insert spring 36. Fit ‘O’-ring 84 onto plug 35 and then screw the plug into the pump housing and tighten to a torque of 157 Nm (116 lbf ft, 16 kgf m).

19

Fit ‘O’-ring 88 and back-up ring 98 onto sleeve 39, taking care not to damage the wire mesh filter around the outside. Install the sleeve into cover ‘R’ 30 and temporarily tighten with nut 48. In order, install spring seat 46, spring 47 and plug 45 with ‘O’-ring 92 fitted into sleeve 39 and fit locking nut 49. Install set screw 26 complete with locking nut 28 into cover ‘R’ 30.

20

Install assembled cover ‘R’ 30 into the pump housing, first aligning the slot in bridging piece 29 (by means of a piece of wire from the opposite side) to accommodate sleeve 39. Install the three socket head bolts 73 and tighten to a torque of 129 Nm (95 lbf ft, 13.1 kgf m).

21

Install spring seat 41, springs 43 and 44 and spring seat 42 onto spool 40.

Note: The larger diameter side of spring seat 42 should be against springs 43 and 44.

Note: Having been dismantled it will be necessary to make adjustments on the bench to the variable components secured by locking nuts 28, 48 and 49. On completion of the adjustments torque tighten as follows: 28 73 Nm (54 lbf ft, 7.5 kgf m) 48 182 Nm (134 lbf ft, 18.5 kgf m) 49 45 Nm (33 lbf ft, 4.5 kgf m) Repeat steps 19 and 20 for cover ‘F’ 30.

9803/6410

Issue 1

Section E 14 - 19


Section E 14 - 19

Assembly (cont’d)

JS01840

22

Fit ‘O’-ring 83 onto sleeve 37. Insert the three pistons 38 and piston 54 into the sleeve.

23

Using a suitable tool (see Service Tools, Section 1) and a press, fit oil seal 15 squarely into oil seal case 16 with the open side of the seal facing flange 2. Fit ‘O’-ring 79 onto the oil seal case.

25

Fit ‘O’-ring 80 into rear cover 3. Install gear pump 57 and secure with washer 109 and the two bolts 77 tightened to a torque of 45 Nm (33 lbf ft, 4.5 kgf m).

Fit set screw 27 and locking nut 28 into front cover 52. Install spool 40 assembly, followed by sleeve 37 assembly into the pump housing, making sure spool 40 moves freely and that pistons 38 (3 off) and 54 do not fall out. Secure cover 52 with the three socket head bolts 72 tightened to a torque of 129 Nm (95 lbf ft, 13.1 kgf m). Repeat steps 22 and 23 for rear cover 53.

24

Fit shims 17 and 18 (if used) and oil seal case 16 assembly onto flange 2. Install the four socket head bolts 75 and torque tighten to 33 Nm (24 lbf ft, 3.3 kgf m).

Note: Shims 17 and 18 provide clearance adjustment, if required. Always re-fit the shims removed during dismantling.

9803/6410

Issue 1

Section E


14 - 20

Section E 14 - 20

Assembly (cont’d)

26

Assemble sub-block 50 as follows: a

27

Fit relief valve 56.

b Fit adjustable elbow 60, making sure the elbow faces away from the relief valve. c

Tighten the following parts of the sub-block assembly to the specified torque: Relief valve 56 - 83 Nm (61 lbf ft, 8.5 kgf m) Plug 107 - 52 Nm (38 lbf ft, 5.2 kgf m) Solenoid 58 retaining screws (x 4) - 4.2 Nm (3.1 lbf ft, 0.43 kgf m)

Insert disc filter 51 followed by spring 104 and plug 107 complete with ‘O’-ring 108.

d Insert spool 103 into sleeve 102 with the drilled end of the spool corresponding to the stepped end of the sleeve. Insert the assembly, stepped end of sleeve first, into the block. Mount solenoid 58. e

Fit sub-block 50 assembly onto the pump housing and secure with the four socket head bolts 74, tightened to a torque of 33 Nm (24 lbf ft, 3.3 kgf m).

Into the mounting face of the block, insert ‘O’-rings 89, 91, 93 (2 off), and 111, the second disc filter 51 and orifice 110.

Note: Check that the orifice and its mounting position are not clogged.

28

Connect hose 59 to the two adjustable elbows 60 and tighten to a torque of 52 Nm (38 lbf ft, 5.2 kgf m).

9803/6410

* 29

Tighten plugs 65 and 66 to a torque of 71 Nm (52 lbf ft, 7.2 kgf m) and plug 67 to 30 Nm (22 lbf ft, 3.0 kgf m). Fit mounting flange 61 to flange 2 and secure with the four socket head bolts 71 tightened to a torque of 275 Nm (203 lbf ft, 28 kgf m).

Issue 2*

Section E

Hydraulics

Section E

Hydraulic Pump/Regulator JS130, JS160

18 - 1

18 - 1

Introduction The pump/regulator consists of two variable displacement type axial piston pumps (P1 and P2) supplying pressurised oil to operate machine functions, plus one gear type pilot pump, (Pp) to provide pilot circuit pressure for operator control of machine functions. Pumps P1 and P2 each incorporate a regulator which adjusts the output flow rate according to system demand.

Specifications Axial Piston Pumps Maximum Displacement

cc (in3)/rev

Working pressure bar (lbf/in2)

set maximum

Rated Speed Maximum flow

rpm l (UK gal)/min

Gear Pump

JS130

JS160

55 ( 3.36) x 2

60 (3.66) x 2

TBA 343 (4974)

343 (4974)

2030

2330

112 x 2 (24.6 x 2)

140 x 2 (30.8 x 2)

JS130

JS160

Displacement

cc (in3)/rev

10.0 (0.66)

10.0 (0.66)

Maximum pressure (relief)

bar (lbf/in2)

39 (566)

39 (566)

I (UK gal)/min

20 (4.4)

23 (5.0)

Maximum flow

9803/6410

Issue 1

Section E

Hydraulics

Section E


18 - 2

18 - 2

Pump Hydraulic Circuit Diagram

A2

A1

(FRONT)

a1

(REAR)

a2

Pm1

Pm2

Pi1

Pi2 a3 P1 a4

Dr 1

B1

B3

A3 417110

Key A1,2

Delivery port

B1

Suction port

Dr1

Drain port

Pi1,2

Pilot port

P1

Proportional pressure reducing valve

Pm1,2

Q max cut port

a1-3

Gauge port

a4

Gauge port

A3

Gear pump delivery port

B3

Gear pump suction port

9803/6410

Issue 1

Section E

Hydraulics

Section E


18 - 3

18- 3

B1

a2

Pi2

a1

Pm1 Pm2

Pi2 Pm2

Dr1

Pi1 a4

a1

Dr1

Pi1

Dr1

Pi1

Pm1

a4

P1

B3

A3

a3

A3

B3

Pi2

B3

a2

A3

P1

A1 A2


9803/6410

Issue 1

Section E

Hydraulics

Section E


18 - 4

18 - 4

Operation Main Pumps (P1 and P2) Each pump P1 or P2 consists of a cylinder block, containing nine piston/shoe assemblies. Driven by shaft, the block rotates between a variable angle, non-rotating swash plate and a fixed valve plate. A retainer plate and a set of cylinder springs hold the piston shoes against the swash plate. Due to the angle of the swash plate, as the cylinder block rotates the pistons are forced to move back and forth in their cylinders. The piston stroke, and therefore the pump displacement, varies according to the swash plate angle, which is controlled by machine demand.

The fixed valve plate contains two crescent shaped ports. The valve plate is located so that when a piston reaches its nearest point to the plate it comes into line with the pump inlet port. During the next 180° of cylinder block rotation the piston draws oil into the cylinder bore. When the piston reaches its furthest point from the plate it ceases to be in line with the inlet port and comes into line with pump outlet port. The next 180° of cylinder block rotation causes the piston to force oil from the cylinder bore through the outlet port. The process is carried out sequentially by all the pistons to provide a continuous smooth pump output.

PISTON ASSEMBLY SWASH PLATE

PUMP 1

9803/6410

PUMP 2

Issue 1

Section E 18 - 5

Hydraulics Hydraulic Pump/Regulator JS130, JS160

Section E 18 - 5

Proportional Reducing Valve

9803/6410

Issue 1

Section E

Hydraulics

Section E


18 - 6

18 - 6

Hydraulic Pump

26 29 28 B

27 33

21A 23 24 23

5A

22

25 16

6

30 32

18A

6A 7

8

31 30 314 9 13 12 11

1

10 19 34 20 14 15 3

4

17

2 16

21

416150 9803/6410

Issue 1

Section E 18 - 7

Hydraulics

Section E


18 - 7

Hydraulic Pump Dismantling and Assembly The working environment must be clean and the workbench covered with a cloth or rubber sheet to prevent damage to the components. The illustration opposite shows both halves of the tandem double axial piston pump, but the procedures refer mostly to Pump 1. These procedures should also be applied to Pump 2 except where indicated otherwise. Note 1: The components from one pump section must not be mixed up with the corresponding components from the other section and should be returned to the section from which they came. The item numbers called up in the following procedures correspond with those in the exploded view. Dismantling Before dismantling, the pump ports should be plugged and the external surfaces thoroughly cleaned to prevent the ingress of dirt into the pump mechanism. 1

2

Remove drain plug 1 and let the oil drain into a suitable receptacle.

3

As an aid to re-assembly, match mark the mating flanges of regulator 4 and pump casing 5. Remove socket head screws 2 and 3 (2 off each) and lift off the regulator. Put the regulator to one side in readiness for dismantling if required (see Regulator, Dismantling).

2

4

5

3

Remove the gear pump assembly 6.

379380

9803/6410

Issue 1

Section E 18 - 8

Hydraulics

Section E


18 - 8

Hydraulic Pump (cont’d) Dismantling and Assembly (cont’d) Dismantling (cont’d) 4

Remove the four socket head screws 7.

5

Place the pump on the workbench with its regulator mounting face downwards. Match mark the mating flanges of pump casing 5 and valve block 8. Separate the pump casing from the valve block.

7

8 6

Remove the piston/cylinder assembly Z comprising cylinder 9, piston assemblies 10, set plate 11, spherical bush 12 and cylinder springs 13 from pump casing 5. Take care not to damage the sliding surfaces of the components.

5

379540

5

Z

379550

7

Pump 1 only: Remove socket head screws 14 and then remove seal cover 15 and ‘O’ ring 16, taking care not to damage the oil seal 17. This task can be simplified by inserting a pull-out bolt into the tapped hole in the cover.

14

15 379560

9803/6410

Issue 1

Section E 18 - 9

Hydraulics

Section E


18 - 9

Hydraulic Pump (cont’d) Dismantling and Assembly (cont’d) Dismantling (cont’d) 8

Match mark the mating flanges of swash plate support 18 and pump casing 5. Separate the swash plate support complete with drive shaft from the pump casing by lightly tapping the support around its flange using a plastic hammer.

5A (5)

18A (18)

379570

9

Remove shoe plate 19 and swash plate 20 from pump casing 5.

19 20 5

379580

10 Using a plastic hammer, gently tap shaft 21 out of swash plate support 18, complete with its support bearing 24 and spacers 23. If necessary remove the circlip 22 and drive the shaft out of the bearing 24.

21A (21)

18A (18)

379590

9803/6410

Issue 1

Section E 18 - 10

Hydraulics

Section E


18 - 10

Hydraulic Pump (cont’d) Dismantling and Assembly (cont’d) Dismantling (cont’d) 11 Remove valve plates 25 from valve block 8.

8

25

379600

12 If necessary, remove plugs 26 and 27, servo piston 28 and tilting pin 29 from pump casing 5.

Note 2: When removing the tilting pin use a protector to prevent damage to the pin head. Also take care not to damage the servo piston as a result of the retaining compound used to secure it.

13 Remove needle bearings 30 (see Note 3) and splined coupling 31 from valve block 8. Note 3: Do not remove the needle bearing assembly unless it needs renewing. Note 4: To avoid the risk of changing the flow settings, do not loosen nut 32 in valve block 8 or nut 33 in swash plate support 18.

9803/6410

Issue 1

Section E 18 - 11

Hydraulics

Section E


18 - 11

Hydraulic Pump (cont’d) Assembly Before assembling: a

Thoroughly clean all components with clean hydraulic oil and dry with compressed air.

b

Apply clean hydraulic oil to all sliding surfaces, bearings, etc.

1

If previously removed from pump casing 5, install tilting pin 29 and servo piston 28. Use a protector to prevent damage to the tilting pin head and feedback pin.

2

Take care to align the flange match marks and then fit swash plate support 18 to pump casing 5 by gently tapping it with a plastic hammer.

5A (5) 18A (18)

379610

3

Place the pump casing on the workbench with its regulator mounting face downwards. Attach swash plate tilting bush 34 to tilting pin 29. Smear the sliding surfaces of swash plate support 18 and swash plate 20 with grease. Install the swash plate against the support and manually check that the swash plate slides smoothly.

5A (5) 18A (18)

20

379620

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Issue 1

Section E 18 - 12

Hydraulics

Section E


18 - 12

Hydraulic Pump (cont’d) Assembly 4

If bearings have ben removed, install each shaft 21 through its bearing 24 and secure with bearing spacers 23 and snap ring 22.

5A (5)

From outside pump casing 5, install shaft and bearing assembly, small splined end first, through its swash plate support 18 as far as it will go. 24A (24)

21A (21) 5

Grease oil seal 17 and fit seal cover 15 to swash plate support 18 using new ‘O’ ring 16. Secure it with socket head screws 14 tightened to a torque of 11.8 Nm (8.7 lbf ft).

379630

5A (5) 17A (17) 15A (15)

14

379640

6

Assemble the piston/cylinder sub-assembly Z comprising cylinder 9, piston assemblies 10, set plate 11, spherical bush 12 and cylinder springs 13. Make sure the internal splines of the cylinder and the spherical bearing are aligned.

9 11

12

10

Insert the piston/cylinder sub-assembly into pump casing 5. 13

Z

379650

9803/6410

Issue 1

Section E 18 - 13

Hydraulics

Section E


18 - 13

Hydraulic Pump (cont’d) Assembly (cont’d) 7

8

Attach valve plate 25 to valve block 8, engaging the location pin in the process. Check that the suction and delivery ports of the plate are not transposed.

25

Insert splined coupling 31 into valve block 8. Ensuring that new ‘O’ rings are positioned on joint faces, fit the valve block to pump casing 5, taking care to align the match marks. Engage the spline on shaft 21 with the splined coupling. Secure with the four socket head screws 7, tightened to a torque of 235 Nm (173 lbf ft). 8

416160

9

3

Refit regulator 4 to pump casing 5 using a new ‘O’ ring. Take care to locate the feedback pin of tilting lever 29 with the lever of the regulator. Secure the regulator with socket head screws 2 and 3, tightened to a torque of 30 Nm (22 lbf ft).

2

4

5

379380

10 Refit gear pump assembly 6. Tighten the securing screws 6A to a torque of 7 Nm (5 lbf ft).

9803/6410

Issue 1

9803/6410

23

24

25

19

20

26

39

D

37A

B

21

A

F

36 34

33A

35

14

A

G

B

32

12

C

38

C

3

E

18

17

1

2

16

4

D

31

8

G

10

33 29 28A 28

11

9

379671

10

Hydraulics

30

30A

F

37

E

7

6

5

18 - 14

22

40

41

42

15

13

Section E Section E

Hydraulic Pump/Regulator JS130, JS160 18 - 14

Regulator

Issue 1

Section E 18 - 15

Hydraulics

Section E


18 - 15

Regulator Dismantling and Assembly The working environment must be clean and the workbench covered with a cloth or rubber sheet to prevent damage to the components. The item numbers called up in the following procedures correspond with those in the exploded view opposite. Dismantling Before dismantling, remove dust, rust, etc. using clean hydraulic oil. Retain all washers, snap rings etc. for later re-use. O-rings should be renewed. 1

3

If not already done, separate the regulator 1 from the pump casing by removing socket head screws 2 and 3 (2 off each).

2

1

379380

2

Remove the four socket head screws 5 and lift off cover 6 complete with adjusters 7/8, adjusting screw 9, two locking nuts 10, mounting nut 11 and adjusting ring 12. Do not interfere with the settings of any of these components as this could alter the pre-set flow settings.

5 6

379390

9803/6410

Issue 1

Section E 18 - 16

Hydraulics

Section E


18 - 16

Regulator (cont’d) Dismantling and Assembly (cont’d) Dismantling (cont’d) 3

From regulator body 1, withdraw outer spring 13, inner spring 14 and spring seat 15. Also withdraw adjusting ring 16 (see Note 1), pilot spring 17 and spring seat 18.

13 14 15

Note 1: Use an M4 screw Z attached to the end of adjusting ring 16 to facilitate its easy removal.

16

1

18 17

Z

379400

4

Remove socket head screws 19 and 20 and lift off pilot cover 21. Take out set spring 22.

22

20

21 19 379410

5

Remove snap ring 23 taking care not to allow the components behind it to spring out. Take out spring seat 24, return spring 25 and sleeve 26 (complete with snap ring 27).

25 23 26 1 24 379420

9803/6410

Issue 1

Section E 18 - 17

Hydraulics

Section E


18 - 17


Remove snap ring 28 and take out fulcrum plug 29, complete with pin 33. Remove snap ring 30 and take out adjusting plug 31.

1

Note 2: Use an M6 screw Y attached to the ends of fulcrum plug 29 and adjusting plug 31 to facilitate their easy removal.

33

29

28

Y 31 30 379430

7

Remove lever 32 leaving pin 33A in position on the lever.

1

32 33A

8

Knock out pin 34 (4 mm dia.) using a suitable metal rod X and a plastic hammer.

X 1

379450

9803/6410

Issue 1

Section E 18 - 18

Hydraulics

Section E


18 - 18


Withdraw feedback lever 35.

1

35

379460

10 Remove lever 36 from pin 37 (in the regulator body) leaving pin 37A in position on the lever.

11 Draw out pilot piston 38 and spool 39.

12 Withdraw piston case 40, compensating piston 41 and compensating rod 42. Note 3: Piston case 40 can be removed by pressing compensating rod 42 from the opposite side of regulator body 1.

9803/6410

Issue 1*

Section E 18 - 19

Hydraulics

Section E


18 - 19

Regulator (cont’d) Dismantling and Assembly (cont’d) Assembly Before assembling: a

Thoroughly clean all components with clean hydraulic oil and dry with compressed air.

b

Apply clean hydraulic oil to all sliding surfaces, bearings, etc.

c

Renew any damaged components.

d

Renew all O-rings and other seals.

1

Insert compensating rod 42 into hole B of regulator body 1.

2

Locate pin 37A in lever 36 in the groove of compensating rod 42. Locate lever 36 on pin 37 in regulator body 1.

3

Fit spool 39 and sleeve 26 into hole A of regulator body 1. Check that the spool and the sleeve slide smoothly in the body without binding. Check the orientation of the spool with respect to feedback lever 35 (see right).

35 Feedback Lever

Spool

39

379470

4

Install feedback lever 35, orientating it as shown right and aligning its pin hole with that of spool 39. Insert pin 34.

Lever(1)side 36

32 Lever(2)side (Fulcrum plug of adjusting plug side

35

379480

5

Insert pilot piston 38 into hole C of regulator body 1. Check that the piston slides freely without binding.

9803/6410

379480

Issue 1

Section E 18 - 20

Hydraulics

Section E


18 - 20

Regulator (cont’d) Dismantling and Assembly (cont’d) Assembly (cont’d) 6

Locate pin 33A in lever 32 in the groove of pilot piston 38. Position lever 32 in regulator body 1.

7

Fit fulcrum plug 29 so that integral pin 33 locates with lever 32. Fit a new seal 28A and install snap ring 28.

29

1

379490

8

Insert adjusting plug 31. Fit a new seal 30A and install snap ring 30. Check that feedback lever 35 moves freely but does not have excessive play.

9

Insert return spring 25 and spring seat 24 into hole A of regulator body 1. Compress the spring and secure with snap ring 23.

23 24 25

1

379500

9803/6410

Issue 1

Section E 18 - 21

Hydraulics

Section E


18 - 21

Regulator (cont’d) Dismantling and Assembly (cont’d) Assembly (cont’d) 1 10 Insert set spring 22 into hole A of regulator body. Insert compensating piston 41 and piston case 40 into hole B of regulator body 1.

22

Fit pilot cover 21 and secure with socket head screws 19 and 20 tightened to a torque of 11.8 Nm (8.7 lbf ft).

41 40

379510

11 Insert spring seat 18 (flat face first), pilot spring 17 and adjusting ring 16 into hole E of regulator body 1. Insert spring seat 15 (flat face first) inner spring 14 and outer spring 13 into hole D of regulator body 1.

13 14 15 1

16 17 18

379520

12 Install the cover 6 assembly comprising adjusting screws 7/8, adjusting ring 12, mounting nut 11, two locking nuts 10 and adjusting screw 9.

5

5

Secure the cover using socket head screws 5 tightened to a torque of 11.8 Nm (8.7 lbf ft).

6

1

379530

9803/6410

Issue 1

Section E

Hydraulics

Section E

30 - 1

Control Valve

30 - 1

Introduction The control valve is located on the mainframe to the rear of the boom mounting. Its function is to direct pressurised oil by means of the operator’s controls to the rams and motors which supply power for the machine’s operation. The valve is designed to perform the following functions: a

Controlling oil flow direction.

b

Operating the hydraulic system smoothly, accurately and safely.

c

Maintaining the hydraulic circuit pressure within specified ranges.

Integrated control valves operate a tandem circuit to provide maximum pressure when simultaneous operations are required. Check valves are incorporated to provide load hold functions. Identification of spool functions, as marked on the valve body, is as follows: TL TR AM OPT SW BKT BM

= = = = = = =

Left hand track motor Right hand track motor Dipper ram Auxiliary supply to attachment (if fitted) Slew motor supply Bucket ram Boom rams

Technical Data Rated flow


Maximum pressure for normal use

350 kgf/cm2 (4978 lbf/in2)

Oil temperature range

- 20 ~ 90 °C (-4.4 ~ 194 °F)

Maximum oil temperature

100 °C (212 °F)

Pilot maximum allowable pressure

40 kgf/cm2 (569 lbf/in2)

Pilot operation pressure

2.8 ~ 24 kgf/cm2 (40 ~ 341 lbf/in2)

Spool stroke

8 mm (0.315 in)

Control method

Hydraulic pilot operation

Main relief valve

2-step pressure switching type relief valve

Standard pressure setting

320 kgf/cm2 (4550 lbf/in2) @ 91 l/min (20.02 gal/min)

Maximum pressure setting


Overload relief valve

Pilot operated type relief valve plus make-up valve

Standard pressure setting (boom raise, dipper, bucket)


Maximum pressure setting (boom lower)


Spool

Solid type

Weight

104 kg (229.3 lb)

Function

Travel priority, slew priority, boom/dipper with load holding, bucket, auxiliary

9803/6410

Issue 1

Section E

Hydraulics

Section E

31 - 1

Control Valve

31 - 1

Precautions During Use Installation Ensure that excessive force is not put on the valve by the piping. Tighten the installation bolts to the specified torque. Take care when welding work is done near the valve, excessive heat can damage the seals. To prevent foreign matter from entering the ports, do not remove the plugs from the ports until installation. Running Operate only after confirming that the hydraulic circuit and hydraulic oil are clean. Use the hydraulic oil specified in this manual. Do not raise the pressure of the main relief valve or port relief valve set pressures. The difference between the main relief valve and port relief valve set pressures should be more than 20 kgf/cm2 (285 lbf/in2). Carry out warming up sufficiently before beginning actual operations. Because of the low temperature of the oil and valve, note the following points in particular, to prevent seizure of the main spools due to heat shock: 1

Do not operate the main relief valve or port relief valve continuously on a cold machine, but operate so that the hydraulic oil in each ram can circulate, thereby warming up each part uniformly.

2

Fine and combined operations cause heat build-up, do not perform sudden operations at low temperatures.

9803/6410

Issue 1

Section E

Hydraulics

Section E

32 - 1

Control Valve

32 - 1

Spool Location

JS01950

Key TL TR AM OPT SW BKT BM

9803/6410

= = = = = = =

Left hand track motor Right hand track motor Dipper ram Auxiliary supply to attachment (if fitted) Slew motor supply Bucket ram Boom rams

Issue 1

Section E

Hydraulics

Section E

32 - 2

Control Valve

32 - 2

Hydraulic Circuit Diagram

JS01700

9803/6410

Issue 1

Section E

Hydraulics

Section E

33 - 1

Control Valve

33 - 1

Neutral Circuit

JS01610

9803/6410

Issue 1

Section E

Hydraulics

Section E

33 - 2

Control Valve

33 - 2

Neutral Circuit (cont’d) Note: The following description is for that part of the neutral circuit supplied from pump P1. The neutral circuit supplied from pump P2 operates in a similar way. Oil from pump P1 to the inlet port PL passes through the neutral gallery A over each spool B and returns to tank via the foot release valve section C. When no spools are operated a balance of forces acting on spool D causes it to move to the right. This allows a pressure signal (based on neutral circuit pressure) to be sent via port H to the pump controller, which reduces pump output to a minimum.

9803/6410

Issue 1

Section E

Hydraulics

Section E

33 - 3

Control Valve

33 - 3

Auxiliary (OPT) Operation When pilot pressure is applied to port bl1 by operating the Auxiliary Pedal, the spool E moves to the right, closing off neutral gallery F. Oil from the pump is directed to outlet port BL2, by lifting check valve G. At the same time, because neutral gallery F is closed, the foot release valve H closes and stops signal pressure FL to the pump controller, enabling the pump to deliver maximum flow. When pilot pressure is applied to port al1 the reverse operation occurs.

JS01710

9803/6410

Issue 1

Section E

Hydraulics

Section E

33 - 4

Control Valve

33 - 4

Dipper (AM) Operation When pilot pressure is applied to port bl3, by operating the left hand joystick controller, the spool E moves to the right closing off the neutral gallery F. Oil from the pump P1 is directed to the outlet port BL3 by lifting check valve G. At the same time, pressure is appiled to the centre bypass valve J. This causes oil from pump P2, flowing through the neutral gallery F, to be re-directed into the dipper circuit. Therefore the high pressure flow from both pumps is used to raise the dipper. Oil returns to tank via port AL3. When pilot pressure is applied to port al3, the reverse operation occurs.

JS01720

9803/6410

Issue 1

Section E

Hydraulics

Section E

33 - 5

Control Valve

33 - 5

Bucket (BKT) Operation When pilot pressure is applied to port br2 by operating the right hand joystick controller, the spool E moves to the left, closing off the neutral gallery F. Oil from pump P2 is directed to the outlet port BR2 by lifting the check valve G. Oil from pump P1 flowing through the neutral gallery F is re-directed by applying pilot pressure to the centre bypass valve J, combining the high pressure flow from both pumps to crowd the bucket. Oil returns to tank via port AR2. When pilot pressure is applied to port ar2, the reverse operation occurs.

JS01730

9803/6410

Issue 1

Section E

Hydraulics

Section E

33 - 6

Control Valve

33 - 6

Boom Raise (BM) Operation

L

9803/6410

Issue 1

Section E

Hydraulics

Section E

33 - 7

Control Valve

33 - 7

Boom Raise (BM) Operation (cont’d) When pilot pressure is applied to port br1, by operating the right hand joystick controller, spool B moves to the left closing off the neutral gallery, allowing oil from pump P2 to enter the gallery J. Pilot pressure is also applied to port C in the load holding valve X. Check valve D opens, causing piston E to open poppet valve F, connecting passageways G and H. Because check valve K is closed, ports G and L are shut off. Oil bleeds from check valve M through pilot hole P to gallery J, causing check valve M to open allowing oil to enter the outlet port BR1. Combined flow from both pumps is achieved when pilot pressure is applied to port N in the logic check valve Y. Oil from pump P2 flows through gallery T. When this pressure falls below the pressure delivered by pump P1 to port R, the check valve S moves to the left against the spring pressure and allows oil to flow from port R into gallery T and to the outlet port BR1.

9803/6410

Issue 1

Section E

Hydraulics

Section E

33 - 8

Control Valve

33 - 8

Boom Lower (BM) Operation When pilot pressure is applied by operating the right hand joystick controller, spool B moves to the right, closing off the neutral gallery and allowing oil from pump P2 to enter the cylinder port. Oil below check valve M flows through ports G and H to open check valve K and pass through port L to the gallery J. Pressure in gallery J depresses the check valve M allowing oil to flow from the ram to the exhaust gallery. Without pilot pressure, the centre bypass valve and the logic check valve allow the oil to enter the low pressure gallery N and return to tank.

JS01750

9803/6410

Issue 1

Section E

Hydraulics

Section E

33 - 9

Control Valve

33 - 9

Slew Operation (SW) Priority Circuit

JS01770

9803/6410

Issue 1

Section E

Hydraulics

Section E

33 - 10

Control Valve

33 - 10

Slew Operation (SW) Priority Circuit (cont’d) When pilot pressure is applied to port al1, by operating the left hand joystick controller, the spool C moves to allow oil from pump P1 to lift the check valve F and enter outlet port AL1. When the slew and dipper spools are operated simultaneously, the main flow of oil from pump P1 opens check valve F and operates the slew motor. Oil also passes through a restrictor G and is directed via the parallel gallery to the dipper ram, thus ensuring priority oil feed to the slew motor. Oil flowing from pump P2 passes through the high pressure gallery into the open port of the dipper spool to combine with the flow from pump P1. Oil returns to tank via port AL3.

9803/6410

Issue 1

Section E

Hydraulics

Section E

33 - 11

Control Valve

33 - 11

Travel Operation (TL, TR) Priority Circuit

JS01760

9803/6410

Issue 1

Section E

Hydraulics

Section E

33 - 12

Control Valve

33 - 12

Travel Operation (TL, TR) Priority Circuit (cont’d) This circuit maintains linear travel when other operations are carried out at the same time. Oil from pump P1 (X) flows to the outlet port BL4 when pilot pressure is applied at port bl4, by operating the travel lever (or pedal) control. This flow is directed to the left hand track drive. Oil from pump P2 (Y) flows to the outlet port BR3 when pilot pressure is applied at port br3, by operating the travel lever (or pedal) control. This flow is directed to the right hand track drive. Swing Operation with Linear Travel As the pilot signal, operated by the left hand joystick controller, starts to operate the slew spool, the signal inside the control valve is initially delayed. The delivery ports of the left and right hand spools supplying oil to the travel motors are connected to balance the flow to the drives. When the pilot signal fully operates the slew spool, oil from pump P1 has priority flow to the slew motor and oil from pump P2 continues to supply the drives. In order to prevent sudden changes in speed, surplus oil from the slew operation is diverted to the left and right hand track drives.

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 1

Control Valve

34 - 1

Removal and Replacement Removal

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

Before working on the hydraulic system, ensure that the engine is switched off and the starter key removed. JS01780

Disconnect all hydraulic hoses from valve ports A. Seal exposed connections to prevent the ingress of dirt. Mark the hoses to ensure correct re-connection. Disconnect all pilot hoses from spool housing B. Seal ports to prevent ingress of dirt. Mark the hoses to ensure correct reconnection. Remove securing screws C (3 off) and lift the valve block from the machine.

Replacement Replacement is the reverse of the removal procedure. Ensure all hoses and ports are clean and free from dirt.

Torque Settings C

JS01790

267 - 312 Nm (197 - 230 lbf ft)

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 2

Control Valve

34 - 2

Dismantling and Assembly Sub-assembly Location Headings identified on sub-assembly location layout opposite. Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Valve block Spool assemblies Centre bypass valve (4-spool section) Centre bypass valve (3-spool section) Foot relief valve Load holding valve Logic check valve Linear travel switching valve Main relief valve Overload relief valve Dipper load diverter valve Boom (lower) stroke limit valve Load check valve (BM, SW) Load check valve (AM, BKT, OPT, TR, TL) Pilot valve Check valve (4-spool section) Bucket flow check valve Diverter valve Inner parallel check valve ‘O’-rings

9803/6410

Page 34 - 5 34 - 6 34 - 8 34 - 9 34 - 10 34 - 11 34 - 13 34 - 14 34 - 15 34 - 17 34 - 18 34 - 19 34 - 20 34 - 21 34 - 22 34 - 23 34 - 24 34 - 25 34 - 26 -

Issue 1

Section E

Hydraulics

Section E

34 - 3

Control Valve

34 - 3


JS01820

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 4

Control Valve

34 - 4

Dismantling and Assembly (cont’d) Note: 1

Ensure all work surfaces are clean.

2

Discard and renew all seals, ‘O’-rings and back-up rings.

3

Lubricate all new seals and ‘O’-rings on assembly, using a suitable grease or clean hydraulic oil and ensure seals are firmly and correctly seated.

4

During dismantling, ensure all components are clearly identified to assist assembly.

5

Handle components and sub-assemblies with care, they are precision made and are easily damaged.

6

Prior to assembly, all components should be liberally coated with hydraulic oil to ensure full movement between moving parts.

7

Ensure screws and bolts are tightened to the correct torque figures to prevent distortion of parts.

8

After dismantling, use a suitable solvent to clean all components, dry using compressed air.

9

Torque tightening values in assembly procedures are for threads lubricated with hydraulic oil.

11

JS01510

Key A

70 - 100 mm (2.7 - 3.9 in)

B

3 - 6 mm (0.12 - 0.24 in)

C

30 - 40 mm (1.18 - 1.57 in)

D

22 mm (0.87 in)

To prevent surface damage when working on spools, ensure they are encased in protective wooden blocks as detailed opposite.

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 5

Control Valve

34 - 5

Valve Block Dismantling 1

Remove socket screw 1 from 4 spool section.

2

Remove socket screws 2 and 3 from 3 spool section.

3

Carefully separate the two halves of the valve body.

Note: Ensure that ‘O’-rings and check valve assembly are retained in the 4 spool section of the body and the check valve and spring are retained in the 3 spool section. 4

Remove ‘O’-rings and discard.

Assembly 1

Clean surfaces of valve block sections.

2

Renew ‘O’-rings.

3

Rejoin the two halves of the valve body and insert socket screws 1, 2 and 3. Tighten to a torque of 97 Nm (72 lbf ft).

JS00990

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 6

Control Valve

34 - 6

Spool Assemblies Dismantling 1

Remove socket screws 1 from the valve body.

2

Remove cover 2.

3

Remove ‘O’-ring and discard.

4

Withdraw spool 3.

Note: Identify spools during removal to ensure correct replacement. 5

JS01000

Encase spool in holder blocks 4 and clamp into a vice.

Note: See page 34 - 4 for details of holder. 6

Remove locating screw 5 holding spring guides 6.

7

Remove spring guides 6 and spring 7.

Cleaning 1

Clean all parts with clean oil and dry with compressed air. Inspect all parts.

2

Ensure spool 3 moves smoothly.

3

Check spring 6 has no defects, deformation or wear.

4

Remove slight defects by lapping.

5

Renew damaged or badly worn parts.

JS01010

JS01020

Assembly Assembly is the reverse of the dismantling procedure.

Torque Settings 1

30 Nm (22 lbf ft)

5

60 Nm (44 lbf ft)

JS01030

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 7

Control Valve

34 - 7

Spool Assemblies (cont’d) Dismantling Dipper Spool with Check Valve 1

See Spool Assemblies, Dismantling items 1 - 7.

2

Remove sealing plug 8.

3

Remove ‘O’-ring and backing ring 9 and discard.

4

Withdraw spring 10 and check valve 11. JS01040

Cleaning, Inspection 1


2

Ensure check valve 11 moves smoothly.

3


4


5



Torque Setting 8

30 Nm (22 lbf ft)

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 8

Control Valve

34 - 8

Centre Bypass Valve (4 Spool Section) Dismantling 1

Remove end cap 1.

2

Remove ‘O’-ring 2 and discard.

3

Remove piston 3.

4

Unscrew and remove sleeve 4.

5

Withdraw spool 5.

6

Encase spool in holder and clamp into a vice.

JS01050


Slacken and remove locknuts 6, spring seating washers 7 and spring 8.



2

Ensure spool 5 and piston 3 move smoothly.

3


4


5


JS01060


Torque Settings 1

60 Nm (44 lbf ft)

4

60 Nm (44 lbf ft)

6

25 Nm (18 lbf ft)

9803/6410

JS01070

Issue 1

Section E

Hydraulics

Section E

34 - 9

Control Valve

34 - 9

Centre Bypass Valve (3 Spool Section) Dismantling 1

Remove end cap 1.

2


3

Withdraw spool 3.

4




JS01080



2


3

Check the spring has no defects, deformation or wear.

4

Remove slight defects by lapping. JS01090

5



Torque Settings 1

60 Nm (44 lbf ft)

4

25 Nm (18 lbf ft) JS01100

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 10

Control Valve

34 - 10

Foot Relief Valve Dismantling 1

Remove relief valve sub-assembly 1.

Note: Pressure setting is critical - do not dismantle the valve sub-assembly. 2


3

Remove screwed plug 3.

4


5

Remove socket screws 5.

6

Remove cover 6.

7


8

Withdraw bushing 8, sleeve 9, spring 10, spool 11, outer sleeve 12 and spacer 13.

JS01100



2


3

Check spring has no defects, deformation or wear.

4


5


JS01120


Torque Settings 1

48 Nm (36 lbf ft)

3

30 Nm (22 lbf ft)

5

48 Nm (36 lbf ft)

9803/6410

JS01130

Issue 1

Section E

Hydraulics

Section E

34 - 11

Control Valve

34 - 11

Load Holding Valve

JS01170 JS01140

JS01150

JS01190

JS01160

JS01200

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 12

Control Valve

34 - 12

Load Holding Valve Dismantling

Torque Settings

1

Remove socket screws 1.

1

98 Nm (72 lbf ft)

2

Remove cover assembly 2.

6

30 Nm (22 lbf ft)

3


10

49 Nm (36 lbf ft)

4

Remove spring 4.

14

58 Nm (43 lbf ft)

5

Withdraw check valve 5.

17

49 Nm (36 lbf ft)

6

Remove plug 6 and discard ‘O’-ring 7.

7

Withdraw piston 8.

8

Remove spring 9.

9

Remove plug 10.

10


11

Remove spring 12 and check valve 13.

12

Remove cap 14.

13

Remove ‘O’- ring 15 and discard.

14

Withdraw piston 16.

15

Remove cap 17.

16


17

Remove spring 19.

18

Withdraw poppet valve 20.

19

Tilt and tap cover to remove sleeve 21.

Note: Ensure the sliding surface of the sleeve is protected.

Cleaning and Inspection 1


2

Ensure check valve 5, pistons 8 and 16 and poppet 20 move smoothly.

3

Check springs 4, 9, 12 and 19 have no defects, deformation or wear.

4


5


Assembly Assembly is the reverse of the dismantling procedure. 9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 13

Control Valve

34 - 13

Logic Check Valve Dismantling 1

Remove screwed cap 1.

2


3

Withdraw piston 3.

4

Remove spring 4.

5

Insert a small puller into the transverse hole and withdraw sleeve 5.

6


7

Remove spring 7.

8

Remove check valve 8.

JS01210

Note: Ensure internal surfaces of the sleeve are protected. 9

Screw a rod (having one end threaded M5 x 0.8), into sleeve 9 and withdraw.

10

Remove spring 10.

11

Remove check valve 11. JS01220



2

Ensure piston 3, sleeve 5, check valve 8, sleeve 9 and check valve 11 move smoothly.

3

Check springs 4, 7 and 10 have no defects, deformation or wear.

4


5

Renew damaged or badly worn parts. JS01230


Torque Setting 1

98 Nm (72 lbf ft)

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 -14

Control Valve

34 - 14

Linear Travel Switching Valve Dismantling 1

Unscrew and remove cover 1.

2

Remove 'O’-ring 2 and discard.

3

Withdraw spool 3.

4


Note: See page 34 - 4 for details of holders. 5

JS01240




2


3


4


5


JS01250


Torque Setting 1

98 Nm (72 lbf ft)

4

25 Nm (18 lbf ft)

9803/6410

JS01260

Issue 1

Section E

Hydraulics

Section E

34 - 15

Control Valve

34 - 15

Main Relief Valve Dismantling 1

Secure adjusting screw 1 and housing 10.

2

Slacken locknut 2.

3

Secure relief valve body 4.

4

Slacken locknut 3.

5

Slacken relief valve body 4 and remove assembly from main control valve housing.

6

Remove O’-ring 5 and discard.

7

Withdraw outer sleeve 6 from main control valve housing.

8

Remove sleeve 7.

9

Remove spring 8.

JS01270

Note: Pilot seat 9 is press fitted into the relief valve body 4. Do not attempt to remove it. 10

Remove adjusting screw 1 with locknut 2 from housing 10.

11


12

Remove adjustment screw housing 10 with locknut 3 from relief valve body 4.

13

Remove spring seat 12, spring 13 and poppet 14 from housing 10.

JS01280


Clean all components in clean oil and dry with compressed air.

2

Check that the seat surfaces on the end of the poppet 14 and seating 9 are defect free and contact surfaces are uniform.

3

Check that the poppet sleeve 7 and outer sleeve 6 move smoothly and freely.

4

Check springs 8 and 13 have no defects, deformation or wear.

5

Check that there is no foreign matter blocking orifices in the main poppet or pilot seat.

6

Remove any minor defects by lapping.

7

Renew the relief valve if any damaged or badly worn parts are found.

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 16

Control Valve

34 - 16

Main Relief Valve (cont’d) Assembly Assembly is the reverse of the dismantling procedure.

High Pressure Setting 1

Insert relief valve assembly into control valve housing and tighten relief valve body 4.

2

Tighten down adjusting screw 1 until piston 12 seats onto internal surface Z.

3

Adjust housing 10 until high pressure setting is correct (see Pressure Testing).

4

JS01290

Tighten locknut 3.

Low Pressure Setting 1

Slacken adjusting screw 1 and adjust until low pressure setting is correct (see Pressure Testing).

2

Tighten locknut 2.

Torque Settings 2

58 Nm (43 lbf ft)

3

58 Nm (43 lbf ft)

4

58 Nm (43 lbf ft)

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 17

Control Valve

34 - 17

Overload Relief Valve Dismantling 1

Slacken the valve housing 1 and remove complete from the control valve body.

Note: Because pressure adjustment is difficult, do not dismantle the adjusting screw 2 and poppet assembly. 2


3

Slacken relief valve seat 4 and remove as a sub assembly.

4


5

Remove poppet housing sleeve 6, piston 7, poppet 8 and spring 9.

6

Remove ‘O’-rings and seals 10 and 11 and discard.

JS01300


Clean all parts in clean oil and dry with compressed air. Inspect all parts.

2

Ensure piston 7 and poppet sleeve 6 move smoothly.

3

Check spring 9 has no defects, deformation or wear. JS01310

4


5



Torque Settings 1

39 Nm (29 lbf ft)

4

58 Nm (43 lbf ft)

JS01320

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 18

Control Valve

34 - 18

Dipper Load Diverter Valve Dismantling 1

Remove cover plug 1.

2


3

Remove spring seating washer 3 and spring 4.

4

Remove housing 5.

5


6

Withdraw spool 7.

7

Remove sleeve 8 and piston 9.

8


JS01330



2

Ensure spool 7, piston 9 and check valve 11 move smoothly.

3

Check that springs 4 and 10 have no defects, deformation or wear.

4


5



Torque Settings 1

58 Nm (43 lbf ft)

5

58 Nm (43 lbf ft)

9803/6410

JS01340

Issue 1

Section E

Hydraulics

Section E

34 - 19

Control Valve

34 - 19

Boom (Lower) Stroke Limit Valve Dismantling 1


2


3

Remove socket screws 3 and housing 4.

4

Withdraw piston 5.



2

Ensure piston 5 moves smoothly.

3


4


JS01350


Torque Settings 1

58.3 Nm (43 lbf ft)

3

29.8 Nm (22 lbf ft)

9803/6410

JS01360

Issue 1

Section E

Hydraulics

Section E

34 - 20

Control Valve

34 - 20

Load Check Valve (Boom and Slew) Dismantling 1

Remove housing 1.

2

Remove ‘O’-ring 2, back-up ring 3 and discard.

3


4

Remove nylon plug 6.



2


3

Check that spring 4 has no defects, deformation or wear.

4


5


Assembly JS01370

Assembly is the reverse of the dismantling procedure. Note: Renew nylon plug 6.

Torque Settings 1

97.63 Nm (72 lbf ft)

JS01380

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 21

Control Valve

34 - 21

Load Check Valve (Dipper, Bucket, Auxiliary, Left and Right Tracks) Dismantling 1

Remove housing 1.

2

Remove ‘O’-ring 2 and back-up ring 3 and discard.

3

Remove check valve 4.

4


5

Remove nylon plug 7.



2

Ensure check valves 4 and 6 move smoothly.

3


4


5


JS01390

Assembly Assembly is the reverse of the dismantling procedure. Note: Renew nylon plug 7.

Torque Settings 1

97.63 Nm (72 lbf ft)

JS01400

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 22

Control Valve

34 - 22

Pilot Valve Dismantling 1

Remove housing 1.

2

Remove ‘O’-ring 2 and back-up ring 3 and discard.



2

Ensure pilot holes are clean and free from sediment and foreign matter.

3


4



Torque Settings 1

97.63 Nm (72 lbf ft)

9803/6410

JS01410

Issue 1

Section E

Hydraulics

Section E

34 - 23

Control Valve

34 - 23

Check Valve (4 Spool Section) Dismantling 1

Remove housing 1.

2


3

Withdraw check valve 3 and spring 4.



2


3


4

Remove slight damage by lapping.

5



Torque Settings 1

39.32 Nm (29 lbf ft)

JS01420

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 24

Control Valve

34 - 24

Bucket Flow Check Valve Dismantling 1


2


3

Withdraw spring 3 and check valve 4.



2


3


4


5

Ensure pilot holes in check valve 4 are clean and free from sediment and foreign matter.

6


JS01430

Assembly Assembly is the reverse of the dismantling procedure. JS01440

Torque Settings 1

97.63 Nm (72 lbf ft)

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 25

Control Valve

34 - 25

Diverter Valve Dismantling 1


2


3

Using a steel rod X with one end threaded M5 x 0.8, screw into sleeve 3 and withdraw from control valve body.

4




2

Ensure sleeve 3 moves smoothly.

3


4



Torque Settings 1

29.8 Nm (22 lbf ft)

9803/6410

Issue 1

Section E

Hydraulics

Section E

34 - 26

Control Valve

34 - 26

Inner Parallel Check Valve Dismantling 1


2


3




2


3


4

Repair slight damage by lapping.

5



Torque Settings 1

29.8 Nm (22 lbf ft)

9803/6410

Issue 1

Section E 40 - 1

Hydraulics

Section E

Remote Control Valve (Services)

40 - 1

Introduction This section deals with the Remote Control Valve which provides pilot pressure for slewing, boom/dipper and bucket operation. The remote control valve is a pressure reduction valve used to control the pilot pressure operated system. Four pressure reduction valves used to control the pilot pressure are located in the main housing. Direction of the output pilot pressure is controlled by selective movement of the control lever. The valves and control levers are mounted in the arm rests on both sides of the operator’s seat.

Specification Series type

4TH6.IX/YU

Control operation angles

Single handle

± 19°

Weight

Single handle

2.8 kg

9803/6410

Issue 1

Section E

Hydraulics

Section E


40 - 2

40 - 2

Technical Data 1

T

P

P 6,7 1

2

3

4

21 JS03240

26

18 8

19

9 10 2

11 12

20 3

23

13

4 5

14 22

1 15

24 16 7

25

17 6

JS03210

Item 1 2 3 4 5 6 7 8 9

9803/6410

Description Lower body Upper body ‘O’-ring ‘O’-ring Dowel pin Body assembly screw ‘O’-ring Plunger guide Seal

Qty. Item 1 1 1 1 2 1 1 4 4

10 11 12 13 14 15 16 17 18

Description

Qty.

Item

Seal Plunger Split washer Spring seat Compression spring Return spring Shims Spool Retaining plate

4 4 4 4 4 4 4 1

19 20 21 22 23 24 25 26

Description Gaiter Roll pin Control handle Locknut Mounting knuckle Joint nut Rocker plate Knuckle joint

Qty. 1 1 1 1 1 1 1 1

Issue 1

Section E 40 - 3

Hydraulics Remote Control Valve (Services)

Section E 40 - 3

Operation The assembly of the pilot pressure control valve is shown on page 40 - 2. The pressure reduction unit is comprised of spools 17, pressure control springs 14, return springs 15, spring seats 13 and split washers 12. The spools 17 are held against the plungers 11 by the return springs 15. When the control handle is tilted, the plungers 11 move down, depressing the return spring seats 13, simultaneously compressing the pressure control springs 14, moving the spool, allowing hydraulic oil to flow to the designated pilot port. The lower end of the main body 1 contains the main inlet port P, outlet port T to tank and the pilot pressure outlet ports 1, 2, 3 and 4. The pilot pressure controls the stroke and direction of the main control valve spools. This is achieved by providing a spring at one end of the main control valve spools and applying pilot pressure to the opposite end. (In some cases, pilot pressure is applied to both ends of the control valve spool.) Function Oil supplied by the hydraulic pilot pump enters at port P and the function of the spools 17 is to direct oil from the inlet port P to the output ports 1, 2, 3 and 4 or alternatively, to the exhaust port T to tank. The pressure control springs 14 act on the spools 17 to determine pressure at each port. Plungers 11 slide in the guides 8 to vary the compression in the springs 14. The control handle, fixed to the adjusting nut 24 and circular rocker plate 25 is operated to move the plungers 11. The control handle is able to rotate 360° around the knuckle joint 26. The return springs 15 operate between the casing 1 and the seats 13, regardless of the outlet pilot pressure, returning the plungers 11 to their outer positions, ensuring the spools 17 return to their neutral (closed) positions. The springs 15 also provide a resistive force, giving the operator a ‘tactile feel’ of the controls.

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Issue 1

Section E 41 - 1


Section E 41 - 1

Dismantling and Assembly Notes: 1

All parts are precision made and require the utmost care when being handled.

2

During dismantling, do not use excessive force to separate components which could cause scratches or burrs on bearing surfaces. Failure to observe this instruction will cause oil leaks leading to poor performance.

3

Label all parts during dismantling, to ensure correct assembly.

4

Storing the valve when dismantled could cause rusting of parts. Ensure they are suitably protected by anti-rust treatment.

5

During assembly, ensure all parts are clean and free from burrs and scratches. Remove minor damage by lapping.

6

Renew all ‘O’-rings, seals and back-up rings. Take care to install seals the correct way around.

7

During assembly apply hydraulic oil to ‘O’-rings and seals.

8

Ensure all screws and bolts are tightened to the torque settings given.

Dismantling Details of the service tools used in the dismantling and assembly procedures are given in Service Tools, Section 1. Note: For part number identification for the main valve assembly, see illustration on page 40 - 2. 1

Push down upper section of gaiter 19 and remove roll pin 20.

2

Remove control handle from mounting knuckle 23.

Note: Take care when removing handle to avoid damage to wiring loom and switches. 3

Remove gaiter 19 from valve housing.

4

Slacken locknut 22 and remove mounting knuckle 23.

5

Slacken and remove joint nut 24 and rocker plate 25.

6

Using a jig, slacken and unscrew knuckle joint 26, releasing retaining plate 18.

Note: Ensure retaining plate moves freely to prevent sudden release due to spring pressure beneath.

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Section E 41 - 2


Section E 41 - 2

Dismantling and Assembly (cont’d) Dismantling (cont’d) 7

Remove mounting screws (4 off) and lift out control valve.

8

Clean the valve exterior using approved solvent and using soft metal pads for protection, clamp the valve body into a vice.

9

If the return springs 15 are weak, the sliding resistance of the seal 9 will cause the guides 8 to stick in the casing. Using a screw driver, carefully ease out the guides 8 and plungers 11.

Note: Care must be taken to prevent damage to the guides when removing. Ensure the guides do not fly out due to the force of the return springs. 10

Remove spring seats 13, split washers 12, return springs 15, pressure control springs 14 and spools 17.

Note: Identify each set of parts and their locations for assembly. 11

Slacken and remove body assembly screw 6. Remove and discard ‘O’-ring 7.

12

Separate upper and lower body sections 1 and 2 and remove dowel pins 5.

13

Remove and discard ‘O’-rings 3 and 4.

14

Hold spools 17 firmly on the work bench and depress spring seat 13 and remove split washers 12.

Note: Avoid scratching the surface of the spools. Do not depress the spring seats more than 6 mm (0.24 in). 15

Separate spools 17, spring seats 13, springs 14 and 15 and shims 16.

16

Remove plungers 11 from guides 8.

17

Remove seals 9 and 10 from guide 8 and discard.

Note: Leave all parts to soak in suitable solvent until dirt is loosened. Using clean solvent wash all parts and allow to air dry. Apply rust inhibitor to all parts.

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Issue 1

Section E 41 - 3

Hydraulics

Section E


41 - 3

Dismantling and Assembly (cont’d) Assembly The numerical sequence given previously is a guide to dismantling. For assembly the sequence should be reversed noting the following details: 1

Locate retaining plate 18 onto plunger guides 8 and using the jig, screw knuckle joint into position. Torque tighten to 30 Nm (3 kgf m, 22 lbf ft).

2

Locate rocker plate 25 and torque tighten to 30 Nm (3 kgf m, 22 lbf ft), until it makes contact with the plungers 11. Ensure the plungers are not depressed at this stage.

3

4

24

Holding the rocker plate 25 in its position, screw down joint nut 24. Torque tighten to 30 Nm (3 kgf m, 22 lbf ft).

25

When fitting the body assembly screw 6 torque tighten to 40 Nm (4 kgf m, 29.5 lbf ft).

26

18

1

P

6,7 JS03250

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Issue 1

Section E

Hydraulics

Section E


42 - 1

42 - 1

Fault finding Symptom 1

2

3

Low secondary pressure.

Unstable secondary pressure.

High secondary pressure.

9803/6410

Possible cause

Remedy

a

Primary pressure is low.

Apply the correct primary pressure.

b

Spring 14 is damaged.

Renew the spring.

c

Clearance between the spool and seating is too large.

Renew the remote control valve assembly.

d

The handle unit is loose.

Dismantle, reassemble or renew the handle unit.

a

Sliding parts are sticking.

Release the sticking part.

b

Fluctuations in the tank line pressure.

Check return line and filter for blockage.

c

Air is trapped in the piping.

Operate the valve several times to remove the air.

a

The tank line pressure is too high.

Check return line and filter for blockage.

b

Sliding parts are sticking.

Release the sticking part.

Issue 1

Section E

Hydraulics

Section E


43 - 1

43 - 1

Maintenance Specification Maintenance Item

Standard

Note

Leakage Amount

Replace if the leakage exceeds 1.0 litre/min (0.22 gal/min) with the handle in the neutral position or 2.0 litre/min (0.44 gal/min) during operation.

Condition: Primary pressure 29 bar (30 kgf/cm2 426.5 lbf/in2). Oil viscosity 23 cSt.

Spool

Replace when the sliding contact faces are worn more than 0.01 mm (0.0004 in) or more than the non-sliding contact faces.

The conditions are approximately the same as for the leakage above.

Replace if the tip is worn more than 1 mm (0.039 in).

Plunger

JS02060

Loose movement operating controls.

Actuation stability.

in

the

Replace the parts if the wear in the pin and joint lead to loose movement of more than 2 mm (0.079 in).

Investigate if abnormal noises, jerky operation or drops in primary pressure are experienced during operation. Replace the valve if the problem cannot be solved.

Note: Ensure that ‘O’-rings and other seals are renewed during reassembly. If the body assembly screw 6 is loosened, always replace the ‘O’-ring 7.

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Section E 45 - 1

Hydraulics

Section E

Remote Control Valve (Travel)

45 - 1

Introduction This section deals with the remote control valves which provide pilot pressure for the track drives. The valves are mounted centrally below the cab floor and are operated by either the control levers or the foot pedals.

Specification Working pressure

40 kgf/cm2 (568.8 lbf/in2)


-20 °C to + 95 °C (-4.4 to + 194 °F)

Weight

5 kg (11.0 lb)

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Issue 1

Section E 45 - 2

Hydraulics

Section E


45 - 2

Technical Data

Key Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 28 29

Part Shim (0.004 in) Shim (0.008 in) Body Spool Sleeve Cover Plunger Pin Boot Collar Compression spring Compression spring Name plate Cam Shim Socket head cap screw Flange screw Plain washer Plain washer Rivet screw Spring pin Split pin Steel ball ‘O’-ring ‘O’-ring Plunger assembly Body assembly

JS10850

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Issue 1

Section E 46 - 1

Hydraulics

Section E


46 - 1

Dismantling and Assembly Notes: 1

All parts are precision made and require the utmost care when being handled.

2

During dismantling do not use excessive force to separate components. This could cause scratches or burrs on bearing surfaces. Failure to observe this instruction will cause oil leaks leading to poor performance.

3

Label all parts during dismantling to ensure correct assembly.

4

Storing the valve when dismantled could cause rusting of parts. Ensure they are suitably protected by anti-rust treatment.

5

During assembly ensure all parts are clean and free from burrs and scratches. Remove minor damage by lapping.

6

Renew all ‘O’-rings, seals and back-up rings.

7

During assembly apply hydraulic oil to ‘O’-rings and seals.

8

Ensure all screws and bolts are tightened to the torque settings given.

Dismantling

1

Remove boot 9 from body 3.

2

Remove split pin 23.

Note: Removal of one pin is sufficient.

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Section E 46 - 2

Hydraulics Remote Control Valve (Travel)

Section E 46 - 2

Dismantling and Assembly (cont’d) Dismantling

3

Using pliers, withdraw pin 8.

4

Take off cam 14.

5

Using soft metal pads for protection, clamp the valve body into a vice. Remove socket head cap screw 17.

6

Remove cover 6 and spring pins 22. Remove ‘O’-ring 26 and discard.

Note: Remove screw with care - spring pressure may lift the cover 6 without warning.

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Section E 46 - 3

Hydraulics

Section E


46 - 3

Dismantling and Assembly (cont’d) Dismantling (cont’d)

7

Remove plunger assembly 28 from cover 6. Remove ‘O’-ring 25 and discard.

8

Withdraw spool assembly from valve body 3.

Note: Record spool locations to ensure correct reassembly. Note: Avoid scratching surfaces when removing ‘O’-rings.

9

Note: The spool assembly is pre-adjusted with shim 15 and should not be dismantled unless necessary. If parts are damaged or badly worn do the following:

10

Dismantled parts.

Using soft metal pads, clamp spool 4 into a vice, slacken and remove screw 18. Remove sleeve 5, shims 1, 2 and spring 11.

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Section E 46 - 4


Section E 46 - 4

Dismantling and Assembly (cont’d) Assembly

1

Install ‘O’-ring 25 and plunger assembly 28 into cover 6.

2

Note: If the spool assembly has been dismantled do the following: Using soft metal pads, clamp spool 4 into a vice. Assemble washer 19, shim 15, spring 11 and sleeve 5. Fit screw 18 and tighten to a torque of 2.98 Nm (2.2 lbf ft). Insert spring 12 with the spool assembly into the body 3. Ensure spools are in the correct locations.

3

Using soft metal pads, clamp valve body 3 into a vice. Install ‘O’-ring 26 and spring pins 22 into valve body 3. Locate cover 6 and tighten socket head screws to a torque of 77.3 Nm (57 lbf ft).

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4

Install cam 14 with pin 8.

Issue 1

Section E 46 - 5


Section E 46 - 5

Dismantling and Assembly (cont’d) Assembly (cont’d)

5

Locate washer 20 on pin 8 and insert split pin 23 into the hole in pin 8. Bend open split pin ends to retain pin 23.

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6

Refit boot 9 onto body 3.

Issue 1

Section E

Hydraulics

Section E

55 - 1

Shuttle Valve

55 - 1

Introduction The shuttle valve is incorporated into the main control circuit to act as a pilot signal diverter valve. Pressurised hydraulic oil, directed by the operator’s controls from the remote control valves to the main control valve is redirected by the shuttle valve to perform additional pilot control functions. The valve is mounted in front of the battery assembly.

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Section E

Hydraulics

Section E

55 - 2

Shuttle Valve

55 - 2

General Information

Key to illustrations: X A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8 C1 C2 C3 S1 S2 S3 S4 S5

Front Right slew Left slew Boom up Boom down Bucket open Bucket close Dipper open Dipper close Right slew Left slew Boom up Boom down Bucket close Bucket open Dipper open Dipper close Slew pressure switch Boom up Boom up, down Slew brake valve Boom lowering pressure switch Bucket open Dipper close Slew shut-off

JS01970

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Issue 1

Section E

Hydraulics

Section E

55 - 3

Shuttle Valve

55 - 3

General Information (cont’d)

Key Y Z

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= Steel ball = Valve seats

Issue 1

Section E

Hydraulics

Section E

55 - 4

Shuttle Valve

55 - 4

Operation Note: The following description is for the slew operation. Other operations are similar. When right slew operation is selected by the control lever, pressurised oil from the remote control valve enters port A1 in the shuttle block. The oil moves steel ball a to the left and continues through port B1 to operate the right slew control valve spool. Pressurised oil entering port A1 passes through hole d into chamber e and moves steel ball b to the left, allowing oil to pass through port C1 to the slew pressure switch, and through port S1 to the slew brake valve. Return oil from the slew spool pilot control enters port B2 and moves steel ball c to the right, and returns to the remote control valve via port A2.

JS01990

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Issue 1

Section E 56 - 1

Hydraulics Cushion Valves

Section E 56 - 1

Schematic

Key 1 2 3 4 5 6 7 8 9 10

Dipper Control Valve Boom Control Valve Hydraulic Oil Tank Line Filter Cushion Valve Cushion Valve Solenoid Valve Cushion Switch Dipper Remote Control Valve Boom Remote Control Valve Pilot Gear Pump

JS02010

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Issue 1

Section E 56 - 2

Hydraulics

Section E

Cushion Valves

56 - 2

Operation Whenever the machine ignition is first switched on, the dipper and boom circuits default to the cushioned mode i.e. solenoid valve 6 is de-energised. The following descriptions deal only with the ‘dipper in’ function, but the ‘dipper out’, ‘boom in’ and ‘boom out’ circuits operate in exactly the same way. 1

Cushioned Mode - Remote Control Lever in Neutral When the remote control lever is in neutral the hot oil taken from the oil cooler line enters port R of cushion valve 5 and flows through the centre of spool Y to oilways e and f. From oilways e and f, oil flows via the outer surface of the cushion spools and returns to the hydraulic oil tank via port T.

JS02020

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Section E


56 - 3

Section E 56 - 3

Operation (cont’d) 2

Cushioned Mode - Remote Control Lever to ‘Dipper In’ a

Pilot pressure enters port A of cushion valve 5 from dipper remote control valve 8. The left hand cushion spool Z and spool Y both move to the right.

b The pilot pressure to the cushion spool enters oilway g through the centre of the spool. It passes spool Y outer surface and enters the dipper control valve via port C. c

The pilot return oil from the dipper control valve enters oilway f via port D and the outer surface of spool Y. From oilway f it passes the cushion spool outer surface and returns to the hydraulic oil tank port T.

d Oilways e and f are shut off by the movement to the right of spool Y. This causes hot oil to flow from port R through oilway h to orifice c. Thence it flows via port B to the dipper control valve which warms up.

JS02030

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Section E


56 - 4

Section E 56 - 4


Cushioned Mode - Remote Control Lever Moved From ‘Dipper In’ to ‘Neutral’ a

When dipper control lever 8 is set to neutral there is no pilot pressure from the dipper remote control valve. Spool Y returns to neutral.

b Left hand cushion spool Z also returns to neutral, allowing pilot oil returning from the control valve via port C to pass through orifice b. The cushion spool moves further to the left side due to the pressure differential across orifice b so that the pilot return oil flows through and is restricted by orifice a. c

Due to this restrictive effect, the spool of dipper control valve 1 only slowly returns to the neutral (stop) position.

JS02040

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Issue 1

Section E 56 - 5


Section E 56 - 5


Non-Cushioned Mode When cushion switch 2 is switched ON, solenoid valve 6 is energised and pilot pressure 39.2 bar (40 kgf/cm2) is fed to port S of cushion valve 5. The two cushion spools Z are forced into the centre by pilot pressure so that the unrestricted oilways of the cushion valve spools are open to the pilot outputs from dipper remote control valve 8. The hot oil from port R returns to the hydraulic oil tank via port T when dipper remote control lever 8 is at neutral. When the dipper remote control is operated, pilot pressure from the lever to port A is fed via the left hand cushion valve and port C directly to dipper control valve 1. At the conclusion of lever operation the returning pilot oil goes straight back to the lever, i.e. there is no cushioning.

JS02050

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Section E 60 - 1

Hydraulics Slew Brake Valve

Section E 60 - 1

Introduction The valve is used to control the application and release of the slew brake at either 50% or 100% pressure. The valve is operated by pilot pressure selected by the operator’s control lever.

Specification JS130 Working pressure

40 kgf//cm2 (569 lbf/in2)

Rated flow


Pressure reducing valve setting

12.5


TBA

Weight

TBA

Voltage

24 V DC

Power rating

12 W

+0 -1

0 kgf/cm2 (177.7 +- 14.2 lbf/in2)

JS160 Working pressure

40 kgf//cm2 (569 lbf/in2)

Rated flow


Pressure reducing valve setting

16 kgf/cm2 (228 lbf/in2)


20 °C ~ + 95 °C (-4.4 °F ~+ 203 °F)

Weight

4.3 kg (9.5 lb)

Voltage

24 V DC

Power rating

14.5 W

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Issue 1

Section E 60 - 2


Section E 60 - 2


Key 6 7 8

Solenoid control valve (slew lock) Solenoid control valve (slew brake) Pressure reducing valve

Key 1 2 3 4 5 6 7 8

Waterproof, 2-pin electrical contact housing Power source (pink) Ground (grey) Low voltage cable 0.85 mm (.00132 in2) Mounting holes, 2 - M10 x 1.5, 15 (0.591 in) deep Solenoid control valve slew lock Solenoid control valve slew brake Pressure reducing valve

JS02080

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Issue 1

Section E 60 - 3

Hydraulics

Section E

Slew Brake Valve

60 - 3


Key 6 7 8

Solenoid control valve (slew lock) Solenoid control valve (slew brake) Pressure reducing valve

Key 1 2 3 4 5

Waterproof, 2 pin electrical contact housing Power source Ground Protective tube (yellow) Protective tube (black)

JS02090

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Issue 1

Section E 60 - 4


Section E 60 - 4

Operation (JS130) Slew Brake Release Pilot pressure at 40 kgf/cm2 (569 lbf/in2), selected by the operator’s control lever, enters port P, passes over the outer surface of solenoid spool 1 and enters passageway a. The oil then passes over the lower end of the pressure reducing valve spool 2 and enters chamber b, which is connected to passageway C. As oil enters passageway C, the steel ball 3 is lifted and allows oil to pass over the outer surface of solenoid spool 4 to outlet port B. Pilot pressure at 40 kgf/cm2 (569 lbf/in2) leaving port B enters the brake port of the slew motor and releases the brake.

JS02100

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Section E 60 - 5


Section E 60 - 5

Operation (JS130) (cont’d) Slew Brake (50% Application) Five seconds after the control lever has been returned to neutral, an electric signal from the controller operates solenoid valve 7 and spool 1 moves down. Oil in the pressure reducing valve spring chamber d is connected to tank passageway T. Pilot pressure entering port P flows to passageway a and chamber b and tries to lift the reducing valve spool 2. Oil in chamber b is throttled into passageway e and spring chamber d and continues to tank. Simultaneously, part of the flow from chamber b flows through passageway c to the solenoid control valve 6, through port B and to the brake port of the slew motor. Oil at the spring release pressure of the reducing valve 8 enters the brake area of the slew motor and 50% brake force is applied.

JS02110

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Section E 60 - 6


Section E 60 - 6

Operation (JS130) (cont’d) Slew Brake (100% Application) When the solenoid valve 6 for slew lock is energised, the spool 1 moves down, stopping oil from passageway C. Return oil from the slew motor enters port B and flows through spool passage 2 to tank port T. Simultaneously, brake release pressure oil enters port B and flows to tank T, allowing 100% brake force to be applied.

JS02120

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Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

70 - 1

70 - 1

Specifications Ram

JS130

JS160

Boom Ram Left & Right

Cylinder Inside Diameter: Rod Diameter: Max. Contraction: Stroke: Dry Weight:

100 mm 75 mm 1561 mm 1081 mm 116 kg

(3.94 in) (2.95 in) (61.46 in) (42.56 in) (256 lb)


115 mm 80 mm 1689 mm 1184 mm 157 kg

(4.53 in) (3.15 in) (66.65 in) (46.61 in) (346 lb)

Dipper Ram


115 mm 80 mm 1714 mm 1205 mm 160 kg

(4.53 in) (3.15 in) (67.48 in) (47.44 in) (353 lb)


125 mm 90 mm 1875 mm 1335 mm 210 kg

(4.92 in) (3.54 in) (73.82 in) (52.56 in) (463 lb)

Bucket Ram


95 mm 70 mm 1422 mm 924 mm 97 kg

(3.74 in) (2.76 in) (55.99 in) (36.38 in) (214 lb)


105 mm 75 mm 1057 mm 997 mm 117 kg

(4.13 in) (2.95 in) (59.33 in) (39.25 in) (258 lb)

Torque Settings Model

Ram Location

Dimensions Bore x Rod (mm)

Piston Nut A/F (mm)

JS130

Boom Arm Bucket

100 x 75 115 x 80 95 x 70

75 85 75

2430 5650 3270

(1798) (4181) (2420)

31.5 ± 5.9 56.9 ± 10.7 31.5 ± 5.9

(23.3 ± 4.4) (42.1 ± 7.9) (23.3 4.4)

171 267 171

(127) (198) (127)

JS160

Boom Arm Bucket

115 x 80 125 x 90 105 x 75

85 95 80

3770 7420 4310

(2790) (5491) (3190)

56.9 ± 10.7 56.9 ± 10.7 56.9 ± 10.7

(42.1 ± 7.9) (42.1 ± 7.9) (42.1 ± 7.9)

267 267 171

(198) (198) (127)

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Piston Nut Torque Nm (lbf ft)

Grub Screw Torque Nm (lbf ft)

Gland Torque Nm (lbf ft)

Issue 1

Section E 71 - 1

Hydraulics Hydraulic Rams

Section E 71 - 1

Precautions During Use 1

Precautions when installing the ram on the machine When installing and removing from the machine, suspend the ram safely. Suspending the ram by the piping is not only dangerous, but can also cause damage to the cylinder. 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. 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. 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. Install the ram only when it is clean.

2

Caution During Use Use only under designated conditions. 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. In high temperature environments (approx. 90°C and above) or low temperature environments (below -20°C), seals quickly become damaged. Special seal materials are necessary so check to see if the ram that you are using is suitable or not. The number one cause of ram oil leakage is rod damage. Be careful not to damage the rod. Warm up sufficiently before beginning work. 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. 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. Before beginning work, always move the ram at full stroke with no load and expel air from the cylinder. When stopping or storing, do it at a safe and fixed position. 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.

3

Maintenance, Inspection Points. Carry out daily maintenance and inspection. 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. If leaving for more than one week, apply anti-rust oil to the rod surface. Use genuine JCB parts when replacing parts. 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. 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. 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. Follow the instructions in the diagrams regarding torque tightening for screwed parts. If the torque is too high or too low, it can cause damage.

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Section E


72 - 1

Section E 72 - 1

Bucket Ram - Removal ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open. INT-3-1-11/1

! WARNING

Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job. INT-1-3-7

1

Lower the attachment to the ground, as shown.

2

Place a wooden block under the bucket ram.

3

Stop the engine, remove the key. Release the tank pressure, see Releasing the Tank Pressure.

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Cap nut of breather

Issue 1

Section E


72 - 2

Section E 72 - 2

Bucket Ram - Removal (cont’d) 4

Remove the nuts and bolts from the rod end of the ram.

5

Push the pin out using a bar and hammer.

! WARNING

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

6

Restrain the eye end of the ram piston rod to the ram cylinder to prevent the piston rod from extending.

7

Remove the ram hoses and install plugs or caps to prevent contamination.

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Section E


72 - 3

Section E 72 - 3

Bucket Ram - Removal (cont’d) 8

Attach a sling to support the ram.

9

Remove the nuts and bolts from the cylinder end of the ram. Push out the pin using a bar and hammer. Lift the ram clear.

! WARNING

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

Bucket Ram - Replacement 1

Attach a sling to the ram and lift it into position on the dipper.

2

Install the pin, bolt and nuts to the cylinder end of the ram.

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Section E 72 - 4


Section E 72 - 4

Bucket Ram - Replacement (cont’d) 3

Connect the hoses.

4

Hoist the ram to align with the link.

5

Install the pin, bolt and nuts.

Note: Stroke the ram to release entrapped air. After releasing the air, check for oil leakage.

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Section E


73 - 1

Section E 73 - 1

Dipper Ram - Removal ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open. INT-3-1-11/1

! WARNING

Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job. INT-1-3-7

1

Lower the attachment to the ground, as shown.

2

Place a wooden block under the dipper ram.

3

Stop the engine, remove the key. Release the tank pressure (see Releasing the Tank Pressure).

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Issue 1

Section E


73 - 2

Section E 73 - 2

Dipper Ram - Removal (cont’d) 4

Remove the nuts and bolts from the rod end of the ram.

5

Push out the pin, using a bar and hammer.

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

6

Restrain the eye end of the ram piston rod to the ram cylinder to prevent the piston rod from extending.

7

Remove the ram hoses, and install plugs or caps to prevent contamination.

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Issue 1

Section E


73 - 3

Section E 73 - 3

Dipper Ram - Removal (cont’d) 8

Remove the grease tube.

9

Attach a sling to support the ram.

10

Remove the nuts and bolts from the cylinder end of the ram, push out the pin using a bar and hammer. Lift the ram clear.


Dipper Ram - Replacement 1

Attach a sling and lift the ram onto the boom.

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Issue 1

Section E


73 - 4

Section E 73 - 4

Dipper Ram - Replacement (cont’d) 2

Install the pin, bolts and nuts.


3

Install the grease tube.

4

Connect the hoses.

5

Hoist the ram to align the piston rod eye end with the dipper pin position.

9803/6410

Issue 1

Section E


73 - 5

Section E 73 - 5

Dipper Ram - Replacement (cont’d) 6

Install the pin, bolt and nuts.

Note: Stroke the ram to release entrapped air. After releasing the air, check for oil leakage.


9803/6410

Issue 1

Section E


74 - 1

Section E 74 - 1

Boom Ram - Removal ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open. INT-3-1-11/1

! WARNING Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job. INT-1-3-7

1

Lower the attachment to the ground, as shown. Stop the engine, remove the key.

2

Remove the grease tube.

3

Attach a sling to the boom ram.

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Issue 1

Section E


74 - 2

Section E 74 - 2

Boom Ram - Removal (cont’d) 4

a

Remove the nuts, bolt and collar.

b Push out the pin, using a bar and hammer.


5

Lower the ram and place it on a stand.

6

Restrain the eye end of the piston rod to the ram cylinder, to prevent movement of the rod.

7.

Release the tank pressure (see Releasing the Tank Pressure).

9803/6410

Issue 1

Section E


74 - 3

Section E 74 - 3

Boom Ram - Removal (cont’d) 8

Remove the hoses, and install plugs or caps to prevent contamination.

9

Remove the nut and bolt and push out the pin with a hammer and bar.


10

Lift the ram away from the unit.

Boom Ram - Replacement 1

Attach a sling to the ram. Align the ram to its installation position.

9803/6410

Issue 1

Section E


74 - 4

Section E 74 - 4

Boom Ram - Replacement (cont’d) 2

Install the pin and then the bolt and nuts.


3

Install the hoses.

4

Lift the ram and align the rod eye end with the pin position.

5

Install the pin with a bar and hammer.


9803/6410

Issue 1

Section E 74 - 5


Section E 74 - 5

Boom Ram - Replacement (cont’d) 6

Install the collar and then the bolt and nuts.

7

Connect the grease tube.

Note: Stroke the ram and release entrapped air. After releasing the air, check for oil leakage.

9803/6410

Issue 1

Section E 75 - 1


Section E 75 - 1

Dismantling Details of Service Tools used in the dismantling and Assembly procedures are given in Service Tools, Section 1 . Before starting work, clean all surfaces with a suitable solvent and dry with compressed air. Each part is precision made, so handle with care do not force any part as this may cause damage. Protect the dismantled parts if they are to be left for a period of time. 1

Drain the oil

2

Disconnect the external piping.

3

Secure the ram.

Note: Fix the ram in a vertical or horizontal position. The vertical position is more favourable for dismantling/reassembly work. Use the bottom pin hole for preventing the ram from turning on its axis and for fixing the ram in the axial position. Remove the cylinder head cap screws (12 off) with an Allen wrench. Use an extension pipe such as shown in the figure below to facilitate bolt loosening.

9803/6410

Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

75 - 2

75 - 2

Dismantling (cont’d) 4

Remove the piston rod. Make sure that the piping ports are opened. Catch the oil coming out from the rod side (cylinder head side) port. With the piston rod extended fully, remove the cylinder head carefully. Lay down the piston rod and the cylinder head together on wood blocks.

Note: Once all the bolts are removed, do not lift the piston rod, as the cylinder may fall suddenly when separating.

! WARNING Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job. INT-1-3-7

! WARNING Raised Equipment Raised equipment can fall and injure you. Do not walk or work under raised equipment unless safely supported. 13-1-1-6

When pulling out the piston rod from a horizontally positioned ram, be careful to prevent the rod from falling just after it leaves the cylinder. During removal of the piston rod, support it horizontally on blocks. 5

Secure the piston rod. Use the flat rod head or the rod end eye to prevent the piston rod from rotating.

6

Remove the piston nut. Remove the set screw, noting the following:

A

After being installed, the set screw is crimped at two places with a punch. Remove the crimped portions with a drill A, then loosen the set screw. Remove the steel ball B located below the end of the set screw.

B

JS00120

Remove the piston nut. Note: The piston nut was torque tightened on assembly. A torque 1.5 times the tightening torque is necessary to loosen the piston nut. Prepare a power wrench using a hydraulic cylinder (see Ram Piston Head Nut - Removal and Fitting).

9803/6410

Issue 1

Section E 75 - 3

Hydraulics

Section E

Hydraulic Rams

75 - 3

Dismantling (cont’d) Remove the piston, cushion bearing, cushion seal, cylinder head in that order. (There is no cushion seal for the bucket ram).

7

Remove the piston seal. The piston rings can be easily removed by hand. To move the seal ring, put a screwdriver against the seal ring as shown and hammer the driver until the seal ring is cut out. Remove the 'O'-ring.

Note: Discard the removed seals. Do not reuse. 8

Remove the buffer ring. A buffer ring (Teflon ring) is installed in a groove in the cylinder head inside wall. To remove, thrust a sharptipped tool into the buffer ring, pull out the ring from the groove to allow insertion of a pry bar under the ring then remove the ring.

JS03130

Note: Discard the removed seals. Bushing

9

Remove the U-ring, back up ring and wiper ring. Remove the U-ring and back-up ring with a screwdriver. Remove the press-fitted wiper ring.

Note: Discard the removed seals. 10

Removing the bushing. Remove the snap ring from the cylinder head. Remove the bushing using a jig and push out with a press.

Note: Cleaning and storage.

Bushing

After cleaning the removed parts with solvent, coat with hydraulic oil and cover for storage. If left dismantled, rust and dust may adhere and prevent full performance after reassembly.

9803/6410

Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

75 - 4

75 - 4


Dismantling the retraction side cushion (dipper ram).

A D

When there is a cushion bearing installed on the piston rod, after removing the nut A, dismantle as indicated below. a

Tap the snap ring B on the piston rod C with a plastic hammer and remove.

E

B

b Push the cushion bearing D back and remove locating ring E. c

Remove cushion bearing D then widen the slit of the cushion seal F and remove.

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C

F

Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

75 - 5

75 - 5

Assembly Note: See Torque Setting Figures. C

Clean each part in a suitable solvent and dry using compressed air.

B A

Inspect all parts and renew as required. Care must be taken not to let dust or dirt adhere to parts after cleaning and that parts do not become dented, scratched or damaged. Fit new 'O'-rings, and seals when assembling together with a new back up ring. Take care to install the back up ring in the proper position. Apply grease or hydraulic oil to all new oil seals and 'O'rings, and clean hydraulic fluid to all sliding parts before installation. 1

F

D E G

Cylinder head assembly. a

Assemble the bushing A using a jig B and press C.

C

b Assemble the wiper ring D using a jig E and press C. c

Assemble the back up ring F and U-ring G. FF

2

Buffer ring assembly.

Note: After installing the square ring K in the groove, bend the buffer ring FF into a U-shape J and set it in the groove H, then press on the outer circumference of the ring to fit it into place. Bending the ring in too small a radius causes wrinkles which remain in the ring after installation. Keep the bending radius at 6 mm or greater. Make sure there are no wrinkles in the ring after installation. Note: Be careful to install the seal in the proper direction. Installing it backwards causes extremely high pressure to build up between it and the U-ring and could cause deformation of the cylinder head. a

J

K H

Install the snap ring M to prevent the bushing A from coming off.

FF

9803/6410

A

M

Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

75 - 6

75 - 6

Assembly (cont’d) 3

Piston Assembly. a

Place the piston N on the press and using the jig P as shown, install the seal ring Q (pre-assemble the 'O'-ring R and one back up ring S beforehand).

T U

b After attaching the seal ring Q and one more backup ring T, ensure the seal ring Q is fully seated by using jig U. P N Q

R S

4

Piston Rod Assembly. a

V

Secure the piston rod.

b Fit the cylinder head onto the piston rod using assembly jig V. Note: Do not get the wiper ring D and the U-ring G, caught on the stepped portion. c

Fit the cushion seal W, cushion bearing X and piston Y in place.

Note: The cushion seal W is unnecessary for the bucket cylinder. Where there is a cushion at the retraction side (end of piston rod), assemble the cushion bearing as detailed in step 5 before fitting the piston Y. d Insert a shim AA and tighten the piston nut BB to the specified torque.

W

Note: Prepare a power wrench using a hydraulic cylinder (see Ram Piston Head Nut - Removal and Fitting) Note: Face the cushion seal slit W towards the piston side. e

Tighten piston nut BB using the rig and procedure described in Ram Piston Head Nut - Removal and Fitting. After tightening the piston nut BB, insert the steel ball CC and install the set screw DD, tighten it to the specified torque, then stake the set screw in two places with a punch EE.

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Issue 1

Section E


75 - 7

Section E 75 - 7


Retraction side cushion assembly (dipper ram) Where there is a cushion at the retraction side (end of piston rod JJ) assemble the cushion bearing as follows: a

Expand the slit of the cushion seal HH and place the seal on the end of the piston rod JJ.

b Insert the cushion ring KK on the P surface and install the collar LL. Note: While fitting the collar LL, take care that it does not break. c

Move the cushion ring KK to the right until it is in contact with the collar LL.

d Tap the snap ring GG with a plastic hammer to install. e

Install the piston nut FF after assembling the snap ring GG.

Note: Ensure the cushion seal HH and cushion ring KK are installed the correct way round and the cushion ring KK is free to move.

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Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

75 - 8

75 - 8


Assemble the piston rod into the cylinder. a

Secure the cylinder vertically or horizontally, insert the piston into the cylinder.

A

Note: When inserting the piston into the cylinder take care to prevent the piston rings from falling off. b Use a jig A (split nylon pipe) to compress the piston rings B during insertion. c

7

B

Phase the gaps of piston rings B at 180°.

Position the cylinder head as shown. Install the mounting bolts, temporarily tighten them in the order shown and re-tighten the bolts to the specified torque in the sequence shown.

8

Installing the piping. a

Make sure the 'O'-rings C are properly installed in the respective grooves.

b Fasten the bolts at each port first. c

Fasten the bolts to the specified torque.

d Fasten the piping band screws D equally on both sides to the specified torque so that the gap clearances E are eliminated.

D

E

D

E

C

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Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

75 - 9

75 - 9


Inspection after Assembly No-load Operation Inspection Measurement Inspection External Leakage

Operations are smooth and there are no abnormalities with each part after full stroking more than five times with no load. Confirm the maximum extension and stroke. There is no looseness, permanent deformation or external leakage after applying the test pressure shown in the diagram for three times to each stroke end. Check the oil leakage amount at the rod. Maximum allowable leakage rates (in millilitres per 10 minutes) inner diameter mm ( in)

Internal Leakage Inspection

9803/6410

32 40 50 63 80

(1.26) (1.58) (1.97) (2.48) (3.15)

oil leakage amount 0.4 0.6 1.0 1.6 2.3

inner diameter mm (in) 100 125 140

(3.94) (4.92) (5.51)

oil leakage amount 4.0 5.6 6.0

inner diameter mm (in) 160 180 200 220 250

(6.30) (7.09) (7.87) (8.66) (9.84)

oil leakage amount 10.0 12.6 15.6 20.0 22.0

Issue 1

Section E 75 - 10


Section E 75 - 10

Ram Piston Head Nut - Removal and Fitting

JS00980

9803/6410

Issue 1

Section E 75 - 11


Section E 75 - 11

Ram Piston Head Nut (cont’d) Due to the high piston nut tightening torques used on the rams, it is necessary to use a special rig (consisting of the special tools shown in the Tables) for ram piston head nut fitting and removal (see Section 1 - Service Tools). As shown in illustrations A and B, the rig uses a modified lift ram C acting on a heavy-duty ring spanner D to loosen or tighten the piston nut. Hydraulic power to operate the rig may be obtained from a suitable hydraulic power pack (maximum pressure required 150 bar (2175 lb/in2) or from the auxiliary circuit of a JCB machine equipped with quickrelease couplings. In either case, small bore hoses E (Part No. 892/00137 - 2 off) must be used to connect the rig to the power source to limit the speed of operation of ram C. In addition F, test point (Part No. 892/00262) and pressure gauge (Part No. 892/00279) should be fitted in the line to the piston side of the ram C to measure the tightening pressure being applied.

Nut Fitting Before assembly ensure that all components have been thoroughly cleaned and all new seals, backing rings and ‘O’rings are available. Smear all seals, etc. with hydraulic fluid. 1

Assemble the piston rod components as detailed earlier for individual rams.

2

Install the piston rod assembly in the nut removal/fitting rig with the piston rod supported by block J.

3

Secure the eye end of the piston rod to the rig at position G, using a suitable pivot pin.

4

Fit a ring spanner to the piston nut and connect it to the eye end of ram C at position K.

5

Using the rig, tighten the piston head nut H to the torque specified for individual rams by powering the ram slowly downwards. The torque required is indicated by gauge F (see Table 1 on following page).

6

Remove the piston rod assembly from the rig and insert into the ram cylinder as detailed earlier for individual rams.

See Table 1 on the following page for details of the pressure necessary to achieve the required tightening torques. The torque settings themselves are given on Table 2 of the same page. Nut Removal It is assumed that the ram has been removed from the machine, hydraulic piping removed and the piston rod assembly separated from the cylinder. Note: Before using the nut removal/fitting rig, operate the rig cylinder over its full range for 5 or 6 strokes to remove all air from the cylinder. 1

Install the piston rod assembly in the dismantling/assembly rig with the piston rod supported by block J.

2

Secure the eye end of the piston rod to the rig at position G, using a suitable pivot pin.

3

Fit a ring spanner to the piston nut and connect it to the eye end of ram C at position H.

4

Power the ram slowly downwards, noting the pressure at which the piston nut first moves on the piston rod. (The pressure should be 1.0 to 1.5 times the tightening pressure for the particular size).

5

Remove the piston nut.

6

Remove the piston rod assembly from the rig and then proceed with dismantling as detailed earlier for individual rams.

9803/6410

Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

75 - 12

75 - 12

Ram Piston Head Nut (cont’d) Nut Fitting (cont’d) Table 1 Required Tightening Torques Nm lbf ft 640 472 1400 1033 1470 1084 1790 1320 1840 1357 1900 1401 2230 1645 2300 1696 2620 1933 3480 2567 3580 2641 3590 2648 4590 3385 4820 3555 5140 3791 6220 4588 8700 6417 9100 6712 9330 6882 9425 6952 10700 7892 10740 7922 12700 9367 12750 9404 14000 10326 16900 12465 17700 13055 19615 14468 21000 15490 21500 15858

Necessary Gauge Pressure bar lbf/in2 4.4 64 9.6 140 10.1 147 12.3 179 12.7 184 13.1 190 15.4 223 15.9 230 18.1 262 24.0 348 24.7 358 24.7 359 31.6 459 33.2 482 35.4 514 42.8 622 60.0 870 62.7 910 64.3 933 64.9 942 73.8 1070 74.0 1074 87.6 1270 87.9 1275 96.5 1400 116.5 1690 122.0 1770 135.2 1961 144.8 2100 148.3 2150

The torque is determined by reading the pressure on gauge F in the rig circuit (with the spanner at 90° to the rig ram) and converting it according to the table above. Note: The pressures in the above table assume that the rig is used with spanners having 500 mm centres. Table 2 JS130 Ram Location


Piston Nut AF (mm)




Boom

100 x 75

75

2430 (1798)

31.5 ± 5.9 (23.3 ± 4.4)

171 (127)

Dipper

115 x 80

85

5650 (4181)

56.9 ± 10.7 (42.1 ± 7.9)

267 (198)

Bucket

95 x 70

75

3270 (2420)

31.5 ± 5.9 (23.3 ± 4.4)

171 (127)

Ram Location


Piston Nut AF (mm)




Boom

115 x 80

85

3770 (2790)

56.9 ± 10.7 (42.1 ± 7.9)

267 (198)

Dipper

125 x 90

95

7420 (5491)

56.9 ± 10.7 (42.1 ± 7.9)

267 (198)

Bucket

105 x 75

80

4310 (3190)

56.9 ± 10.7 (42.1 ± 7.9)

171 (127)

JS160

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Issue 1

Section E


76 - 1

Section E 76 - 1

Reconditioning Note: Jig details are in accordance with ram sizes. See Service Tools, Section 1.

Procedures for inserting and bedding the seal ring.

1

O-ring installation

Stretch the 'O'-ring by hand and fit it into the piston groove. Be sure not to twist the 'O'-ring. A twisted 'O'-ring may cause oil leakage.

2

Attaching the inner guide jig

Fit the inner guide jig on the upper section of the piston. Carefully fit the thinner end of the inner-guide jig on the upper section of the piston.

3

Seal ring installation

Apply a thin coat of lubricant to the inner guide jig periphery and then set the seal ring on the inner guide jig. Make sure that any foreign matter like dust, chipped metal and lint do not adhere to the outer surface of the inner guide jig.

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Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

76 - 2

76 - 2

Reconditioning (cont’d)

4

Outer guide jig fitting

Mount the outer guide jig over the inner guide jig and using the plate, continue pressing the plate by hand until the outer guide jig touches the seal ring. Be sure to set the seal ring squarely on the inner guide jig.

5

Press-fitting

Continue to press the plate on the outer guide jig by hydraulic press until the seal ring fits into the groove. Be sure to press the plate carefully so that the seal ring will fit squarely on the inner guide jig and into the groove. Carry out this operation smoothly.

6

Removal of jig

After confirming that the seal ring is completely fitted into the piston groove, remove the jigs in the following order. 1

Retract the press rod.

2

Remove the plate.

3

Remove the outer guide jig.

4

Remove the inner guide jig.

The fitting of the seal ring is completed at this stage. Next, correct the fitting of the seal ring using the bedding jig.

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Issue 1

Section E


76 - 3

Section E 76 - 3


7

Set the bedding jig underneath the press.

Bedding jig preparation

Apply a thin coat of lubricant to the tapered section of the bedding jig and place the jig with the tapered section facing up. Be careful that no dust, chipped metal and lint adheres to the jig.

JS02130

8

Inserting the piston

Slowly and evenly insert the piston, with the seal ring fitted, into the bedding jig.

JS02140

9

Carefully press the piston into the bedding jig until the seal is in full contact with the bedding surface.

Press fit

JS02150

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Issue 1

Section E


76 - 4

Section E 76 - 4


10

After completion of the bedding of the seal ring, remove the jig in the following order.

Removal of bedding jig

1

Retract the press rod.

2

Remove the bedding jig.

This completes the fitting and bedding of the seal ring.

JS02160

9803/6410

Issue 1

Section E


77 - 1

Section E 77 - 1

Reconditioning (cont’d) Bushing Removal Note: Jig details are in accordance with ram sizes. See Service Tools, Section 1.

1

Cylinder head setting

Place the cylinder head on the work bench with the cylinder tube connecting surface facing up. The work bench should be clean so that no dust or other foreign matter can cause damage to the pipe joint .

2

Removing snap ring

Remove the bushing securing snap ring. Secure the cylinder head in a vice, etc. and using a screwdriver blade, pull out the snap ring and remove.

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Issue 1

Section E


77 - 2

Section E 77 - 2

Reconditioning (cont’d) Bushing Removal (cont’d) 3

Setting the chuck assembly

Gradually insert the chuck assembly into the cylinder head until its blade end reaches the bushing end. 1

Insert the chuck assembly into the cylinder head, taking care that parts of the blade do not damage the inner circumferential surface.

2

Be careful that the blade does not jump out from the bushing end surface.

JS02310

4

Temporary tightening

1

Fit the Allen wrench into the chuck assembly adjuster head and at the same time insert the lever into the chuck assembly rear hole.

2

Tighten enough so that when the cylinder head is lifted, the jig will not fall off.

Note: Tightening torque less than 5 kgf m (36.16 lbf ft) is sufficient. Move the cylinder head and chuck assembly to the press bench, gripping the assembly as shown.

9803/6410

Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

77 - 3

77 - 3


Gently place the retainer on the stepped portion of the wedge inside the chuck assembly.

Attaching the retainer

1

Place so that the collar is uppermost as shown.

2

Keep the press bench clean to prevent dust, chipped metal and other foreign material causing damage to the bottom of the chuck assembly.

JS02170

6

Tightening

Press the upper part of the retainer gradually so that the blade part of the chuck assembly digs into the bushing surface part of the retainer. Note: Press load should be 2~3 tonnes. If necessary use a retainer when pressing.

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Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

77 - 4

77 - 4


Choose a block suitable in shape and size from the table below. Position the cylinder head centrally on the block as shown.

Block preparation

Rod Dia. mm

d1 mm

d2 mm

h mm

75

82

110

80

80

87

112

80

85

92

124

80

90

97

130

80

95

102

136

80

100

107

140

80

105

112

146

80

110

117

150

80

JS02180

8

Removing bushing

1

Position the block and cylinder head assembly underneath the press.

2

Gradually press the retainer upper surface until the bushing falls out from the cylinder head.

Note: Normally it falls out with a load of less than 3 tonnes. The press ram stroke varies with the cylinder head size and is about 32~52 mm. 1

Use a retainer when pressing.

2

If the shaft centre of the block and cylinder head assembly become misaligned, stop the press work and realign before proceeding.

JS02190

9803/6410

Issue 1

Section E


77 - 5

Section E 77 - 5


Removing chuck assembly with bushing attached

1

After removing the cylinder head assembly from under the press, remove the retainer from the cylinder head and, grasping both sides of the cylinder head, set aside.

2

Remove the chuck assembly with bushing attached and move to the work bench.

Note: Keep the work bench clean so that no dust or foreign matter adheres to, or damages the bottom surface of the chuck or the outer periphery. Also ensure that the work bench is level.

JS02200

10

Removing bush

1

Place the chuck assembly with bushing on the work bench horizontally and insert the Allen wrench into the chuck assembly adjuster head section. At the same time insert a lever into the round hole of the chuck assembly rear section.

2

Use the lever and Allen wrench to loosen the adjuster as shown.

3

Place the chuck assembly vertically and turn the adjuster with your finger until the wedge rises about 5 mm.

4

After confirming that the bushing is not touching the chuck blade section, gently remove the bushing from the chuck assembly.

JS02210

9803/6410

Issue 1

Section E


77 - 6

Section E 77 - 6


Retightening the adjuster

With the chuck assembly and bushing removed, turn the adjuster with your fingers until there is no gap between the adjuster and the wedge upper surface. Note: Do not remove the adjuster and wedge from the chuck assembly .

9803/6410

Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

77 - 7

77 - 7

Reconditioning (cont’d) Bushing Assembly Note: Jig details are in accordance with ram sizes. See Service Tools, Section 1.

1

Cylinder head setting

Set the cylinder head on the press bench with the tube connecting surface facing up. 1

Keep the work bench clean so that dust or other foreign matter does not damage the bottom surface of the cylinder head. Also make sure that it is level.

2

Use compressed air to remove the foreign matter.

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

2

Temporary setting of bushing

Temporarily place the bushing evenly inside the cylinder head inner diameter. Check that there is no foreign matter adhering to the inner and outer peripheral surfaces.

3

Attaching chuck assembly

Supporting the chuck assembly with your fingers, gradually attach it to the cylinder head. Check that there is no gap between the chuck assembly adjuster and wedge.

JS02230

9803/6410

Issue 1

Section E


77 - 8

Section E 77 - 8

Reconditioning (cont’d) Bushing Assembly (cont’d) 4

Gently place the retainer so that its end is aligned with the wedge stepped section of the chuck assembly.


Place the retainer so that the larger diameter part is facing up as shown.

JS02220

5

Place the cylinder with the retainer and chuck assembly attached underneath the press.

Preparation for press-fitting

Adjust so that the shaft centre of the press is in line with that of the retainer and chuck assembly.

JS02240

9803/6410

JS02250

Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

77 - 9

77 - 9

Reconditioning (cont’d) Bushing Assembly (cont’d) 6

At the press, push on the bolt head of the adjuster and gradually press-fit the bushing into the specified position in the cylinder head.

Press-fitting the bushing

The press load should be less than 5 tonnes. Check that the bushing end surface is below the snap ring groove.

JS02260

7

Removal of retainer and chuck assembly

After the press-fitting of the bushing is completed, remove the retainer and chuck assembly from the cylinder head. Continue attaching the seals and pressfitting the wiper ring. Check that the bushing is press-fitted correctly.

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Issue 1

Section E 77 - 10


Section E 77 - 10

Reconditioning (cont’d) Wiper Ring Assembly 1

Setting the cylinder head

Note: Keep the work bench clean so that no dust or other foreign matter can damage the bottom surface of the cylinder head. Position the cylinder head on the work bench as shown.

2

Inserting the wiper ring

Check that there is no foreign matter in the groove where the wiper ring or the retainer is to be inserted. Insert the wiper ring into the groove in the retainer, lip side first as shown.

3


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Gently place the retainer on the cylinder head as shown.

Issue 1

Section E 77 - 11

Hydraulics

Section E

Hydraulic Rams

77 - 11

Reconditioning (cont’d) Wiper Ring Assembly (cont’d) 4

Position the cylinder head and retainer underneath the press.

Preparation for press-fitting

Adjust so that the shaft centre of the press and retainer are in line as shown.

JS02270

5

Press-fitting wiper ring

Press-fit the wiper ring into the specified position in the cylinder head. Press fit until the retainer's collar contacts the cylinder head. The press load should be less than 1 tonne.

JS02280

6

Removing the retainer

After the wiper ring press-fitting is completed, remove the retainer from the cylinder head. Check that the wiper ring is correctly in position.

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Issue 1

Section E 77 - 12


Section E 77 - 12

Reconditioning (cont’d) Cylinder Head Assembly 1

Handle the piston rod with care to prevent damage to its outer surface.

Fixing the piston rod

Position the piston rod so that the threaded part is facing you.

2

Attaching guide

Ensure that the piston rod thread and shaft are free from damage by dust or other foreign matter. Locate the guide onto the piston rod, to the end of the shaft as shown. Take care not to damage the piston thread.

JS02290

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Issue 1

Section E 77 - 13


Section E 77 - 13

Reconditioning (cont’d) Cylinder Head Assembly (cont’d) 3

Insert the cylinder head onto the piston rod, wiper ring side first, to the specified position, sliding on the peripheral surface of the guide.

Inserting the cylinder head

1

Support the cylinder assembly with both hands, taking care not to drop it.

2

If oil is thinly coated on the peripheral surface of the guide and piston rod, the cylinder assembly can be inserted smoothly.

JS02320

4

After checking that the cylinder head assembly has been completely inserted on the piston rod, remove the guide from the piston rod. Next, assemble the piston, etc. on the piston rod.

Removal of Guide

When removing the guide, be careful not to damage the threaded part of the piston rod.

JS02300

9803/6410

Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

78 - 1

78 - 1

Fault Finding The chart below lists some possible problems and suggested remedies. The types of problems fall into four main categories as follows:

Item

Item Symptoms

Symptoms

1

Oil leakage from piston rod sliding part.

2

Oil leakage from cylinder head joint.

3

Oil leakage from pipe and cylinder tube welds.

4

Faulty operation

Related Parts

Trouble On the sliding surface, there are scratches and rust that can be felt by the fingernail.

other inspect.

Treatment 1 Use an oil stone and remove the scratch and make the sliding surface smooth. If oil leakage continues even though the rod surface is made smooth, the scratch may have damaged the U-ring and seals, so dismantle and

Piston rod 2 If the scratches and rust cover such a wide area that they cannot be repaired by an oil stone, renew the piston rod and U-ring, wiper ring and seals and the piston rod bearing member.

1

Piston rod sliding part oil leakage

Rod packing (Buffer ring U-ring)

The plating is peeling.

Re-plate or renew the piston rod. Also inspect the seal and piston rod bearing member and renew if damaged.

Foreign matter is biting into the inner and outer surfaces of the packing.

Remove foreign matter. If there is damage to packing, renew it.

There is a scratch on the inner surface.

Renew.

The lip and groove parts are locally carbonized (burned).

9803/6410

Possibly due to burning caused by adiabatic compression from air remaining inside the ram. After renewing the packing, first operate the ram at low-pressure, low speed to sufficiently bleed the air.

Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

78 - 2

78 - 2

Fault Finding (cont’d) Item Symptoms

Related Parts

Trouble Packing rubber is perished.

Treatment The packing life or hydraulic oil deterioration and high temperature are possible reasons. 1 Renew hydraulic oil.

Rod packing (Buffer ring, U-ring)

2. Check the hydraulic oil temperature. (Below 80 C is advisable). 3 Check if high temperature locally. Lip is deficient all around.

Renew. It is possible that abnormally high pressure is working on the packing. 1 Check the operation pressure, cushion pressure. 2 Part which is attached to the buffer ring may be abnormal. Inspect the buffer ring.

The protrusion of the heel of the packing is excessive. 1

Piston rod oil leakage

Back up ring

As a rule, renew the rod packing at the same time. (It is desirable to renew parts which are attached to the buffer ring at the same time). It is possible that abnormally high pressure is the cause. Check the same as above (heel of packing protruding).

Wiper ring

Bushing

Cylinder head

9803/6410

Foreign matter is biting into the lip. The lip is damaged.

Remove the foreign matter.

There is also other abnormal damage.

Renew.

Wear is excessive and the clearance with piston rod exceeds the *maximum permissible value. (*Refer to maintenance standards for maximum permissible value.)

Renew.

Large scratch on the sliding part.

Renew. Also inspect the piston rod.

Scratches, rust on the seal attachment parts.

Remove scratch, rust with oil stone. If it cannot be repaired, renew the cylinder head.

Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

78 - 3

78 - 3


Related Parts

Trouble Foreign matter on inner and outer diameters. O-ring damaged.

Treatment • Remove foreign matter. • Renew 'O'-ring if damaged. • Inspect inside tube: if any scratches or rust, make surface smooth with oil

stone. ‘O’-ring

• Inspect cylinder head 'O'-ring groove: if any scratches or rust, make surface smooth with oil stone. • Inspect back up ring: if any deformation or protrusion, renew. Confirm the above and renew 'O'-ring.

Back up ring 2

Oil leakage from cylinder head joint

Deformation, protrusion

• Renew, with the 'O'-ring.

Looseness

• Dismantle cylinder head and inspect 'O'-ring and back up ring. • Check tube and cylinder head thread for damage. If any damage, renew.

Cylinder head

• After inspection, tighten to specified torque. Bolt

Looseness, stretching, broken

Renew all bolts and tighten to specified torque.

Abnormal bulge

Replace with new parts. Oil leakage from connecting parts may be caused by abnormal pressure (including cushion pressure). Inspect the tube for bulges, deformation and check the circuit pressure.

Cylinder tube

Crack in welding

3

Oil leakage from pipe and cylinder tube welded seam

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Cylinder tube pipe (hollow piston rod)

Replace with new parts. • Cracks will develop into fractures. Fractures are very dangerous, so if any cracks are found, stop work immediately and replace with new parts. • Welding on top of cracks will have no effect.

Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

78 - 4

78 - 4

Fault Finding (cont’d) Item Symptoms Poor operation

Related Parts Piston rod

Trouble Bending to more than the specified limit.

Treatment • Replace with new part. The seal and sliding part material may

be cylinder tube 4-1 Movement not smooth

4-2 Inner oil leakage. Piston rod extends when work stops or lowers abnormally during work. Also, specified operating speed is not achieved.

damaged too, so inspect. If abnormal, renew.

Tube scored

• Replace with new part. As above, inspect the seal and sliding part material.

Abnormal wear, damage of sliding area

• Replace with new part. As above, inspect the seal and sliding part material. • Remove foreign material. As above, inspect the seal and sliding part material.

Cylinder tube

Piston rod cylinder rod sliding part

4

(Bending distortion: refer to maintenance standards)

Foreign matter intruding on piston and cylinder head sliding area Scratches, wear are present

• Replace with new part. Inspect the cylinder tube inner surface also.

Scratches, rust on inside

• Remove the scratches, rust by honing or with an oil stone and make the surface smooth. If the scratch is deep and cannot be repaired, renew cylinder tube.

Piston seal

Cylinder tube

• Renew piston seal. Piston nut Valves

Loose nut

• Tighten to specified torque.

Leak from valve

• Inspect the valve leakage amount and service.

Note: Hydraulic oil expands and contracts due to changes in temperature and pressure. Accordingly, the ram also expands and this can be mistaken for internal leakage. When inspecting for internal leakage, do so at set conditions.

9803/6410

Issue 1

Section E

Hydraulics

Section E

Hydraulic Rams

78 - 5

78 - 5


Related Parts

4-3

Trouble Air remaining inside ram. Operation is unsteady

Air

Treatment • Bleed the air. For rams that do not have an air bleeder, operate back and forth several times at low pressure and low speed to bleed the air. For rams with an air bleeder, remove the load to reduce the pressure then loosen the air bleeder and completely bleed the air. Note: The ram may expand if it is stopped suddenly. This is due to the compression of the hydraulic oil. This occurs especially with long stroke rams.

4 4-4 Heavy shock loading when changing from extension to retraction and back 4-5 Noisy operation

Pin bushing/pin

Oil supply Pin bushing/pin

Gap between mounting and pin bushing is too large.

Measure the pin and pin bushing and renew parts if measurements exceed the specifications.

Insufficient oil.

• Add oil.

Scuffing at connecting part.

• Replace with new part and add oil.

Note: If left in the state where operation is poor, the ram will no longer move and other parts will be affected adversely. Inspect early and carry out appropriate measures.

9803/6410

Issue 1

Section E 80 - 1

Hydraulics

Section E

Rotary Coupling

80 - 1

Technical Data Item

Part Name

11

Axle

12

V-ring

13

Rotor

14

‘O’-ring

15

Packing ring

16

Thrust plate

17

Hexagonal socket head screw

18

‘O’-ring

19

Cover

20

Hexagonal socket head screw

21

Plug

22

Plug

JS01810

9803/6410

Issue 1

Section E 80 - 2

Hydraulics

Section E

Rotary Coupling

80 - 2

Technical Data (cont’d) Item

Part Name

1

High strength bolt

2

High strength washer

3

Loctite 262

4

Lock bar

5

Seal washer

6

Seal cap

7

Rubber packing

8

Seal ring

9

Rotary coupling

The unit weighs 35 kg.

9803/6410

Issue 1

Section E 81 - 1

Hydraulics Rotary Coupling

Section E 81 - 1

Operation The coupling is located in the centre of the machine between the lower and upper sections and rotates around the slew centreline. The supply and return oil flow to the coupling, piped from the upper to the lower section, is not affected by the rotational movement and allows the machine to slew 360° in both directions. The rotary coupling consists of the inner axle and outer rotor with packing rings, 'O'-rings, thrust plate and cover. In the axle and rotor there are pairs of ports and oil passages, each pair being sealed from the others by packing rings and 'O'-rings. Both the axle and rotor can rotate and the oil can flow freely through the oil grooves.

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Issue 1

Section E


82 - 1

Section E 82 - 1

Removal Details of the service tools used in the dismantling and assembly procedures are given in Service Tools, Section 1. 1

Prepare the machine a

Stop the machine and release the hydraulic pressure (see Releasing Tank Pressure).

b Jack up the machine and insert wooden blocks under the tracks.

! 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

2

Remove the access panel.

3

Attach identification tags to the rotary coupling hoses for reconnection purposes. Remove the hoses and install blind plugs and caps to prevent contamination.

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Issue 1

Section E 82 - 2


Section E 82 - 2

Removal (cont’d) 4

Remove lock bar mounting screws X, washer Y and lock bar Z. Remove rotary coupling installation bolts 1 and washers 2.

JS00180

Replacement 1

Align the assembly 9 to the lower frame and tighten rotating joint installation bolts 1 and washers 2. Install lock bar Z and tighten mounting screws X and washers Y to specified torque of 109-127 Nm (80.2893.28 lbf ft, 11.1-12.9 kgf m).

JS00180

2

Reconnect the hoses and install the access cover. Remove the wooden block, then lower the machine to the ground. Start the machine and check for leaks.

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Issue 1

Section E 82 - 3


Section E 82 - 3

Dismantling 1

Remove screws 20 and cover 19.

JS00140

2

Remove and discard 'O'-ring 18.

JS00150

3

Remove screws 17 and thrust plate 16.

JS00160

4

Using a jig (see Special Tools, Section 1), push off axle 11 from the rotor 13. (Do not hit with a hammer.)

JS00170

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Issue 1

Section E 82 - 4


Section E 82 - 4


Remove and discard V-ring 12 from axle 11.

6

Remove and discard 'O'-ring 14 and packing rings 15 from rotor 13.

JS00190

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Issue 1

Section E


82 - 5

Section E 82 - 5

Assembly Inspect the parts for signs of wear, pitting, scratching, discolouration etc. Polish out scratches using a fine grade oil stone. Before assembly, thoroughly clean all parts using a suitable solvent: Do NOT use solvents on 'O'-rings, back-up rings and seals. Fit new 'O'-rings, back-up rings and seals. Lubricate all 'O'-rings, back-up rings and seals, with clean hydraulic fluid before fitting.

1

a

Clean the rotor 13 with cleaning fluid or compressed air.

b After cleaning, check to see if there are any scratches or roughness on the inner side of the rotor or grooves.

JS00220

2

Coat packing rings 15 and ‘O’-ring 14 with hydraulic oil and install in the order given below: a

Set one packing ring 15 in each groove starting from the 2nd groove from the top.

b Set 'O'-ring 14 in the top groove.

JS01800

9803/6410

Issue 1

Section E 82 - 6

Hydraulics

Section E

Rotary Coupling

82 - 6


After installing the 'O'-ring and packing rings, check with a mirror to see if they are installed correctly. After checking, coat with grease then check once more for any protrusion, twisting, etc.

4

Install V-ring 12 on axle 11 and coat with grease. Take care to prevent contamination of the grease by water or dirt.

5

Install axle 11 to the rotor 13.

Note: Set V-ring 12 so that it will not be cut or scratched.

6

Install thrust plate 16 onto the axle 11 using cap screws 17.

17

Torque Settings 16 17

31.46 - 37.29 Nm (23.2 - 27.5 lbf ft)

11

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Issue 1

Section E 82 - 7


Section E 82 - 7


Install 'O'-ring 18 into the rotor 13.

8

Install cover 19 onto the rotor 13 using cap screws 20.

Torque Settings 20

31.46 - 37.29 Nm (23.2 - 27.5 lbf ft)

JS00200

9803/6410

Issue 1

Section E 83 - 1

Hydraulics Slew Motor

Section E 83 - 1

Hydraulic Motor Components

Key a a1 b1 a2 a3 b c d e f g h i j A B C D J K L M N P R S T U V W X Y Z

Drain port Pilot port Pilot hole

Flow paths Piston bore Flow paths By pass valve Inlet port Outlet port Anti-cavitation check valve Mechanical brake Cross-line relief valve A side cavity B side cavity Intermediate cavity A side seat B side seat Anti-pendulum valve Anti-pendulum valve Pilot hole Spring chamber Make-up port Piston Mechanical brake release port Motor output shaft Slipper foot JS00960

Note: Item numbers are referred to on the following pages.

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Issue 1

Section E


83 - 2

Section E 83 - 2

Reduction Gear Components

JS00970

Key A B C

A chamber B chamber Torque path

Note: Item numbers are referred to on the following pages.

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Issue 2*

Section E

Hydraulics

Section E

Slew Motor

83 - 3

83 - 3

Hydraulic Circuit

E

G A

B

A B C D E F G

D

D

Key Hydraulic motor (151 cm3/rev) Bypass/Anti-pendulum valve Anti-cavitation check valve Relief valve (285 kgf/cm2 @ 155 l/min) Mechanical brake Tank line Drain line

C

C F

JS02680

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Issue 1

Section E

Hydraulics

Section E

Slew Motor

90 - 1

90 - 1

Operation Slew Motor Configuration

Slew Unit

Planetary 2-stage Reduction Gear

Swash Plate Type Axial Piston Hydraulic Motor

Mechanical Brake

By-pass Valve

Relief Valve

Make-up Valve

The above diagram indicates the relationships between the main components of the slew motor, whose working principles are described on the following pages.

9803/6410

Issue 1

Section E 90 - 2

Hydraulics

Section E

Slew Motor

90 - 2

Operation (cont’d) Hydraulic Motor Working Principles (illustration reference page 83 - 1) Oil supplied from the pump via the control valves enters port A (or port B) on cover 17 and is discharged from port B (or port A).

Make-Up Valve Working Principles 1

When slowing down the slew structure with the hand control valve lever in the half-way position, the volume of oil supplied to port A from the pump is reduced. If the rotational speed of the slew structure is relatively high, the motor acts as a pump and causes a negative pressure to develop at c and oil must be supplied to avoid cavitation. If the pressure at port B is lower than the cross-line relief valve operating pressure and the supply of oil from the control valve is insufficient to provide the amount of oil needed, the make-up check valve assembly 29 - 31 operates to make up the insufficiency at c from the make-up port V.

Oil which leaks past and through clearances between the sliding parts returns to the tank via the drain port a in cover 17. The pressurised oil supplied to port A passes through path b in cover 17 and path c in bush 20. It is supplied for 180° of each revolution of the motor, passing through path d in balance plate 21 (which has crescent-shaped ports to switch between supply and discharge), through path e of cylinder 24 and then to piston bores f of the cylinder. Oil pressure in bores f of the piston assemblies 8 forces the pistons down on the angled swash plate 6 via slipper feet Z. The angle of the swash plate causes the slipper feet to ‘slide’ around the plate, rotating the cylinder assembly 24 to produce torque at the output shaft Y. In this way, each of piston assemblies 8 is supplied with pressurised oil during its stroke from the top dead point to the bottom dead point and this hydraulic pressure is converted to torque which turns cylinder assembly 24. The oil is discharged during the piston stroke from the bottom dead point to the top dead point. The oil discharge path is the reverse of the supply path described above and the oil is discharged from port B. The output torque of the hydraulic motor is determined by the supply pressure and the rotational speed.

Under partial hydraulic cross-line relief braking (relief valve not functioning).

2

Under full hydraulic braking (cross-line relief valve functioning). When the lever is rapidly moved to the neutral position from the position in paragraph 1, the supply of oil from the pump to port A drops to zero, but the slew structure continues to rotate due to inertia. In this case, port B cross-line relief valve J operates and the oil from the relief valve passes through the paths g and h, pushes open port B make-up check valve 29 and is supplied to paths b and c. As oil is short by the amount of leakage past motor pistons, the make-up check valve opens and oil is supplied to paths b and c from the make-up port to prevent cavitation.

Mechanical Brake Working Principles The mechanical brake serves as a parking brake for the machine. Friction plate 9 is splined to the periphery of cylinder assembly 24 and mating plate 10 is connected to housing 25. When the servo pressure at the brake release port X is zero, the spring 14 force acts through brake piston 12 to press the friction and mating plates together, locking cylinder 24 (output shaft) to housing 25 so that it cannot rotate. When the servo pressure at brake release port X is 40 kgf/cm 2 (568 lbf/in 2 ), the pressure at the brake piston overcomes the spring force and the brake piston moves to the end face between the friction and mating plates, releasing the brake.

Halfway Position = Partially Selected

Partial Braking

Full Braking

JS02750

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Issue 1

Section E 90 - 3


Section E 90 - 3

Operation (cont’d) Relief Valve Working Principles 1

On starting Due to the superstructure’s inertia there is a build-up of pressure in the motor when it begins to slew. To prevent damage, excess pressure is diverted between ports A and B via poppet valves 43 (part of cross-line relief valve J).

2

When the brake is applied (cushioning) When the slew control valve is returned to neutral the oil retur n path from the motor is closed. While the superstructure is coming to a halt it is, in effect, ‘driving’ the motor as a pump. This results in a pressure build-up at the outlet port (A or B depending on slew direction). This increased pressure opens poppet valve 43, which allows oil to flow via paths g and h, opening check valve 29 and relieving the pressure into cavity C.

Reduction Gear Structure and Working Principles (illustration reference page 83 - 2) Power transmitted by the hydraulic motor output shaft is transmitted to second sun gear 77 via first sun gear 66, planetary gear 69 and holder 65. Power is then transmitted to output shaft 53 via second sun gear 77, planetary gear 72 and holder 76. The output shaft is constructed with an integral pinion and is supported in gear case 58 by bearings 57 and 62. Due to the severe conditions under which the output shaft operates, an oil seal 61 is provided in the centre of gear case 58 to protect the bearings from metal waste worn from the gears. The bearing in chamber A is lubricated with gear oil and the bearing in chamber B with grease.

At the same time, oil flows between the two ports via the cross-line relief valve J, which has already been partially opened by poppet valve 43. The result is a 2-stage relief action which momentarily delays the pressure build-up as the superstructure comes to a halt. This reduces the shocks arising due to sudden braking. 3

Anti-Pendulum Feature While the superstructure is coming to a halt, as described in 2, it drives the motor as a pump. The initial result is a braking effect on the superstructure. However, the resulting pressure build-up in port A (or B, depending on direction) tends to cause the superstructure to ‘bounce back’ a little. The process repeats itself to create what is known as a ‘pendulum effect’. To prevent this happening, check valves 50 and flow control valves 48 work together to divert oil pressure between ports A and B until the superstructure has come to a halt.

9803/6410

Issue 1

Section E 91 - 1

Hydraulics

Section E

Slew Motor

91 - 1

Specifications JS130 Motor type


Reduction gear type

Planetary gear with 2 gear reduction

Slew parking brake type

Mechanical lock (slew lever and slew lock switch interlocked system)

Suction capacity

65 cm3/rev (3.97 in3/rev)

Working pressure

285 kgf/cm2 (4052.7 lbf/in2)

Normal flow


Relief pressure

285 kgf/cm2 (4052.7 lbf/in2) at 107 l/min (23.54 gal/min) 278 kgf/cm2 (3953.2 lbf/in2) at 40 l/min (8.8 gal/min)

Gear reduction - deceleration ratio

17.03

Slew brake torque (excluding reduction gear)

More than 30 kgf m (217 lbf ft)

Brake release pressure

Min. 30 kgf/cm2 (426.6 lbf/in2)

Weight

99 kg (218 lb)

JS160 Motor type


Reduction gear type

Planetary gear with 2 gear reduction

Slew parking brake type

Mechanical lock (slew lever and slew lock switch interlocked system)

Suction capacity

151 cm3/rev (9.21 in3/rev)

Working pressure

285 kgf/cm2 (4052.7 lbf/in2)

Normal flow


Relief pressure

285 kgf/cm2 (4052.7 lbf/in2) at 126 l/min (27.72 gal/min) 275 kgf/cm2 (3910.5 lbf/in2) at 40 l/min (8.8 gal/min)

Gear reduction - deceleration ratio

13.34

Slew brake torque (excluding reduction gear)

More than 68.5 kgf m (495.3 lbf ft)

Brake release pressure

Min. 32 kgf/cm2 (455 lbf/in 2)

Weight

197 kg (434 lb)

9803/6410

Issue 1

Section E

Hydraulics

Section E

Slew Motor

91 - 2

91 - 2

Maintenance Specifications Item

Balance Plate 21

Piston assembly 8 slipper feet

Piston assembly 8 pistons

Inspection and Maintenance Standards The crescent-shaped ports in the balance plate, which are in sliding contact with the end face of the cylinder assembly shaft, act to switch between high and low oil pressure. Any damage to the sliding contact face will increase leakage, causing a decrease in volumetric efficiency and an increase in slip. Any seizure of the sliding contact face causes a reduction in mechanical efficiency and can lead to further damage. If the grooves or marks depths are less than 0.03 mm (.001 in), the plate can be corrected using fine emery cloth. If the wear is greater than 0.03 mm (.001 in), the plate should be renewed. The plate should be renewed if it shows any sign of seizure. Correct any damage to the sliding contact face of the slipper feet by using fine emery cloth. Renew the motor if the depth of any slipper foot oil groove is less than 0.45 mm (.018 in) or if the slipper foot surfaces are seriously damaged. The external surfaces of the piston assemblies should be practically unworn. The motor should be renewed if a piston assembly shows any sign of seizure.

Cylinder assembly 24 piston bores

The piston bores should be practically unworn. The motor should be renewed if bores show any sign of seizure or are badly damaged.

HYDRAULIC MOTOR Taper roller bearing 3 Needle bearing 22 REDUCTION GEAR Self-aligning roller bearing 57 Roller Bearing 62

The bearings should be renewed if any slight damage is noticed on the contact surfaces of the rollers or needles. It is recommended that all bearings be renewed on reassembly of the motor because bearings can be damaged when the motor is dismantled.

the

HYDRAULIC MOTOR Oil seal 2 REDUCTION GEAR Oil seal 61 HYDRAULIC MOTOR O-rings 11, 13, 33, 36, 41, 45, 52 HYDRAULIC MOTOR Back-up ring 32, 35, 46

Renew any oil seal if damage to the lip is apparent. New seals must be used when reassembling the motor.

Renew any 'O'-ring that appears to be damaged. New 'O'-rings must be used when reassembling the motor. The back-up rings must be renewed when reassembling the motor.

! CAUTION

! WARNING

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

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

8-3-1-5

! WARNING

INT-3-1-11/1

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

9803/6410

Issue 1

Section E 92 - 1

Hydraulics

Section E

Slew Motor

92 - 1

Motor Assembly/Cylinder Assembly Dismantling

Refer to the sectional drawing on page E/83-1 as a guide to dismantling and assembling.

1

Remove the level gauge with a pipe wrench.

3

Loosen the bolts with a 19 mm socket wrench and remove the motor.

Before attempting to dismantle the slew motor assembly, the inlet and outlet ports should be blanked and the outer surfaces washed down with a suitable solvent to remove all dirt and dust. Dry using compressed air.

2

Remove plug 26 with an 8 mm Allen key and drain the gear oil.

Note: Before removing the motor from the reduction gear, it is advisable to make an alignment mark on the mating faces to facilitate reassembly.

9803/6410

Issue 1

Section E 92 - 2


Section E 92 - 2

Motor Assembly/Cylinder Assembly Dismantling (cont’d)

4

Remove the caps 37 with 14 mm A/F hexagonal sockets and remove relief valves 34 from the motor.

5

Note: Record the position of relief valves 34 to ensure correct reassembly.

Remove the caps 30 with a 14 mm A/F hexagonal key and take out the springs 31 and check valves 29. Remove by-pass valve assembly by unscrewing cap 28 using a 10 mm A/F hexagonal key.

Note: Record the relative positions of the parts to ensure correct reassembly.

6

It is advisable to make alignment marks on cover 17 and housing 25 with white paint, etc. to facilitate reassembly.

9803/6410

7

Loosen the bolts attaching cover 17 and housing 25 with a 12 mm hexagonal key.

Issue 1

Section E 92 - 3


Section E 92 - 3


8

Place the motor with the main shaft downwards and lift off cover 17.

9

Remove snap ring 23 and remove the inner ring of needle bearing 22.

10

Remove 'O'-ring 13.

11

Remove balance plate 21. Remove the pins 15 from the balance plate.

Note: The balance plate 21 must be reinstalled correctly on cover 17. (The alignment of the hair groove and round groove which select high and low pressure is very important. Before removing the balance plate, note the correct relationship with cover 17.)

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Issue 1

Section E 92 - 4

Hydraulics

Section E

Slew Motor

92 - 4


12

Remove the bushings 20 with Teflon rings 19 and the plate springs 18.

13

Remove the springs 14 from brake piston 12.

Note: Keep the springs in the order in which they are to be reinserted.

14

It may be difficult to remove brake piston 12 from housing 25 due to resistance caused by ‘O’-rings 11 and 13. Therefore remove brake piston 12 using the tapped M6 holes as shown in the photograph.

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15

Remove ‘O’-ring 11 from housing 25 and ‘O’-ring 13 from brake piston 12.

Issue 1

Section E 92 - 5

Hydraulics

Section E

Slew Motor

92 - 5


16

Attach a puller to the inner ring of taper roller bearing 3 at two places and on the end of cylinder 24 spline, then extract bearing inner ring 1. Take out collar 53.

17

Remove swash plate 6, piston assemblies 8 and retainer plate 7 together from cylinder 24.

18

Slide swash plate 6 from the sliding faces of the piston assemblies.

19

Remove friction plate 9 and mating plate 10.

Note: Take care not to damage the swash plate during handling.

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Issue 1

Section E 92 - 6


Section E 92 - 6


20

Hold the end of cylinder 24 by hand and pull out the cylinder assembly from housing 25.

21

Remove the outer ring of taper roller bearing 3 from the housing.

23

Remove the spring from cylinder 24.

Note: The oil seal 2 and the outer ring of taper roller bearing 3 remain in the housing. The end face of the cylinder should be protected by clean cloth to prevent it from being damaged. Make alignment marks or write numbers on the piston bores and the piston assemblies so that the piston assemblies can be replaced in the same bores during reassembly.

22

Tap oil seal 2 with a screwdriver and hammer to remove it from housing 25.

Note: The oil seal cannot be reused.

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Issue 1

Section E 92 - 7

Hydraulics

Section E

Slew Motor

Motor Assembly/Cylinder Assembly Assembly Refer to the sectional drawing on page 83 - 1 as a guide to dismantling and assembling.

92 - 7

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

Check all parts before assembly and remove any scratches with a fine oil stone or carborundum paper. Wash with a suitable solvent and blow dry. Replace all seals with new ones. Apply clean hydraulic oil to all sliding faces during assembly.

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

1

Lap the sliding contact faces of piston assemblies 8, balance plate 21 and swash plate 6 with very fine paste on a flat surface.

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Issue 1

Section E 92 - 8


Section E 92 - 8

Motor Assembly/Cylinder Assembly Assembly (cont’d)

2

Apply grease to the curved part of cylinder 24 (contact face with spring 5) and mount spring 5.

3

Position the piston assemblies 8 into the holes of retainer plate 7.

4

Mount the piston assemblies 8 together with retainer plate 7 into cylinder 24.

5

Apply clean hydraulic oil to piston assembly 8 shoe sliding surface and mount the swash plate 6.

Note: Insert the piston assemblies into the same bores from which they were removed. Apply clean hydraulic oil to all cylinder 24 bores before reassembling.

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Issue 1

Section E 92 - 9


Section E 92 - 9


6

Mount collar 53 and inner ring of taper roller bearing 1 on motor output shaft 24.

7

Apply a thin coat of JCB Retainer where the inner ring is mounted on motor output shaft 24.

8

Using a jig, (see Special Tools, Section 1) mount inner ring 1 on output shaft 24.

9

Apply grease to the lip of seal 2 and use a press and jig (see Special Tools, Section 1) to force fit the seal into position.

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Issue 1

Section E 92 - 10


Section E 92 - 10


10

Mount the outer ring of the taper roller bearing into housing 25.

11 Hold the end of cylinder 24 by hand and carefully insert the cylinder assembly into housing 25. Use the seal protector on the splines. Note: The splines of the cylinder assembly protrude beyond the housing, so use a guide of 30-50 mm (1.2-1.9 in) on the lower part of the housing. Verify that spring 5 is inserted correctly into the back face of retainer plate 7.

12

Mount friction plate 9 and mating plate 10.

Note: Apply hydraulic oil to both faces before mounting the plates.

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13

Mount 'O'-ring 11 in housing 25 and 'O'-ring 13 on piston 12.

Note: Grease the 'O'-rings before mounting.

Issue 1

Section E 92 - 11


Section E 92 - 11


14

Apply hydraulic oil to the sliding surface around piston 12 and slide it into housing 25.

15

Insert the brake unit springs 14 back into brake piston 12.

Note: It is difficult to insert piston 12 into the housing due to O'-rings 11 and 13. Hold the piston horizontally and push it into the housing with one movement.

Note: Insert the springs 14 the same order as they were found during dismantling.

16

17

Mount the bushings 20 with Teflon rings 19 and the plate springs 18 into the bushing holes in cover 17.

Generously grease the pins 15 and insert into cover 17.

Note: Apply a coating of grease to the end faces and peripheries of the bushings 20 and to the Teflon rings 19 before mounting them, as this helps prevent them from falling out when the cover is mounted onto the housing.

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Issue 1

Section E 92 - 12


Section E 92 - 12


18

Mount balance plate 21 onto cover 17.

19

Press needle bearing 22 inner ring into cover 17 and attach snap ring 23.

20

Apply grease to the 'O'-ring and install 'O'-ring 13 to cover 17.

21

To prevent oil leakage from the cover bolt holes apply JCB Multi-gasket to the surface.

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Issue 1

Section E 92 - 13


Section E 92 - 13


22

Lift cover 17 and balance plate 21 by hand and mount them carefully on housing 25.

23

Tighten the cap screws 27 (with a 12 mm A/F hexagonal socket) which attach cover 17 to housing 25 to a torque of 157 Nm (116 lbf ft).

25

Insert the relief valve assemblies 34 into cover 17 and tighten the caps 37 (14 mm A/F hexagonal sockets) to a torque of 78.65 Nm (58 lbf ft).

Take care that balance plate 21 and bushings 20 do not fall out while mounting cover 17. Align housing 25 and cover 17 alignment marks which were made before dismantling.

24

Assembling the Make-up and by-pass valves. Assemble the check valves 29 and springs 31 in cover 17 and tighten the caps 30 (14 mm A/F hexagonal sockets) to a torque of 137 Nm (101 lbf ft). Assemble by-pass valve assembly 28 to cover 17 and tighten the caps (10 mm A/F hexagonal sockets) to a torque of 78.65 Nm (58 lbf ft).

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Note: Ensure that the relief valves are replaced in their original positions.

Issue 1

Section E 92 - 14

Hydraulics

Section E

Slew Motor

92 - 14


26

Final checks after assembling.

27

Degrease the mating faces of the gear unit ring gear 64 and motor housing 25 and apply Multi-gasket to the ring gear.

29

Attach the level gauge A with a pipe wrench, setting the height as shown.

Open the inlet and outlet ports and apply 30 kgf/cm2 (427 lbf/in2) pilot pressure to the brake release port. (Take care as oil will be discharged from the drain port). Check that the drive shaft can be rotated smoothly for at least one full revolution by applying a torque of approx. 39.32 Nm (29 lbf ft). Note: If the shaft does not turn, the unit has not been assembled correctly so dismantle again and inspect.

28

Attach the motor with hexagonal bolts and spring washers.

A

Size: 19 mm Tightening torque: 103 Nm (76 lbf ft).

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Issue 1

Section E 92 - 15


Section E 92 - 15


30

Insert plug 26 with an 8 mm Allen key and tighten to torque of 39.32 Nm (29 lbf ft). Fill with gear oil through the filler port.

Note: Fill the hydraulic motor case with hydraulic oil before connecting the piping to the drain port. See Fluids and Lubricants, Section 3, for type and quantity of oil.

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31

Apply grease (type and capacity is given in Fluids and Lubricants).

Note: Bleed air in the chamber from the air bleed port before filling with grease, as a build-up of internal pressure can damage the oil seal. After the unit is filled, run it for around 10-15 minutes at zero load, and at low speed and verify that there is no abnormal noise or vibration. Gradually bring the system into high speed and loaded operation.

Issue 1

Section E 93 - 1


Section E 93 - 1

Relief Valves Dismantling Refer to the sectional drawing on page E/83-1 as a guide to dismantling and assembling. Take steps during dismantling to ensure that all the parts are returned to their original positions. Clean the parts with a suitable solvent and blow them dry. Replace all used 'O'-rings

1

If not already done, remove cap 37 (with a 14 mm A/F hexagonal socket) from the relief assemblies 34 and remove piston 38, liner 51, shim 40, poppet 43 and spring 42.

2

The seat 44 is press-fitted into sleeve 39. Remove it using a soft object, taking care not to scratch the seat face.

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Issue 1

Section E 93 - 2


Section E 93 - 2

Relief Valves Assembly 1

Press fit seat 44 into sleeve 39 which has an 'O'-ring 41.

2

Mount poppet 43, spring 42, shim 40, piston 38, liner 51 onto sleeve 39.

3

Screw cap 37 (with a 14 mm A/F hexagonal socket) with 'O'-ring 36 and back-up 35 mounted, on to sleeve 39 and tighten to a torque of 157 Nm (116 lbf ft). Check the relief set pressure. The correlation between the set pressure of the relief valve and the adjusting shims is shown below. However, adjustment must not be attempted if the pressure cannot be checked. A 0.1 mm (0.003 in) shim equals 5 kgf/cm2 (71 lbf/in2) approximately.

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Issue 1

Section E


94 - 1

Section E 94 - 1

Reduction Gear Dismantling Refer to the sectional drawing on page E/83-2 as a guide to dismantling and assembling.

1

Removal of the sun gear, 1st stage holder assembly.

2

Remove the spur gear and 2nd stage holder assembly 76.

4

Support planetary gears 69 by hand and withdraw shaft 67 from holder 65.

Remove sun gear 66 and 1st stage holder assembly 65.


3

Dismantling of the 1st stage holder assembly. Drive the spring pins into shaft 67.

Note: The spring pins cannot be reused.

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Issue 1

Section E


94 - 2

Section E 94 - 2

Reduction Gear Dismantling (cont’d)

5

Dismantling of 2nd stage holder assembly.

6

Support planetary gears 72 by hand and withdraw shaft 70 from holder 76.

8

Removal of pinion gear assembly.

Drive spring pins 75 into shaft 70. Note: The spring pins cannot be reused.


7

Ring gear removal Remove ring gear 64 from gear case 58. JCB High Strength Gasketing is applied on the assembly to prevent oil leaks from between the ring gear and gear case. To remove ring gear 64 use the notch on gear case 58.

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Remove snap ring 55 with a screwdriver using the notch in the case for leverage.

Issue 1

Section E 94 - 3

Hydraulics

Section E

Slew Motor

94 - 3


9

Support the flange part of gear case 58 on 300 mm (11.8 in) blocks and press shaft end with a hydraulic press to push out shaft 53, collar 54, plate 56, selfaligning roller bearing 57, snap ring 60 and collar 59 from the assembly.

10

Remove the roller bearing 62 from gear case 58.

11

Remove and discard oil seal 61 from gear case 58 by tapping.

12

Remove snap ring 60 from pinion shaft 53 and remove collar 59.

Note: Before removing collar 59, make a note of which way round it is, to ensure correct reassembly.

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Issue 1

Section E 94 - 4


Section E 94 - 4


13

Carry out the following procedure only when bearing 57 is damaged or badly wor n, and dismantling is necessary. Support the self aligning roller bearing 57, then press the motor end of shaft 53 to remove bearing 57, plate 56 and collar 54 from the shaft 53.

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Issue 1

Section E 94 - 5


Section E 94 - 5

Reduction Gear Assembly Refer to the sectional drawing on page E/83-2 as a guide to dismantling and assembling. Apply clean hydraulic fluid to all sliding contact faces during assembly.

1

Position collar 54 on pinion shaft 53 and mount the plate 56. Take care to mount in the correct direction.

2

Heat the bearing 57 to 50 °C above ambient temperature and press fit it on the pinion shaft.

Note: Do not heat to a temperature greater than 100 °C.

3

Mount collar 59 and put snap ring 60 in position. Take care to mount the collar in the correct direction, as noted in Dismantling.

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4

Grease the rollers of bearing 57.

Note: Although the total grease capacity is 1000 cc, only 400 cc is used in the above procedure; the rest should be added after assembly.

Issue 1

Section E 94 - 6


Section E 94 - 6

Reduction Gear Assembly (cont’d)

5

Degrease the periphery of oil seal 61 and its mounting face in gear case 58 and apply JCB High Strength Retainer to these surfaces. Press the oil seal into the gear case using a jig. Grease the oil seal after it has been pressed into place.

6

Use the seal protector to prevent the splines of pinion shaft 53 from scratching the lip of the oil seal. (Refer to the Service Tools section for the seal protector.) a

Note: Refer to seal press-fitting jig in the Service Tools section.

Turn gear case 58 so that the output shaft is upwards and mount the pinion shaft assembly 53 onto the gear case using an M16 eye bolt screwed into the tapped hole in the output end of the pinion shaft.

b To prevent the seal protector hitting the work bench, place 150 mm (6 in) blocks under gear case 58.

7

Mount the snap ring 55. To make it easy to remove the snap ring again, position the gap in the snap ring approx. 30 mm (1.2 in) away from the notch in the gear case.

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8

Turn the output shaft of the gear case downwards. Heat the inner ring of the roller bearing 62 to 50°C over the ambient temperature and mount it on the shaft.

Issue 1

Section E


94 - 7

Section E 94 - 7


9

Ring gear mounting a

b Mount ring gear 64.

Degrease the contact surfaces of gear case 58 and ring gear 64. Mount the collars 63 on the gear case and apply JCB Multi-gasket. Also apply a thin coat on the gear case.

10

Holder assembly mounting a

Insert the planetary gear 72, bushing 71 and thrust plate 73 into holder 76 and then insert shaft assembly 70.

b Drive in spring pins 75. Note: Drive in the pins with the splits facing towards planetary gears 72.

Note: Apply gear oil to the internal surface of the spur gear and shaft assembly outer surface.

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Issue 1

Section E

Hydraulics

Section E

Slew Motor

94 - 8

94 - 8


11

Holder assembly 65 mounting a

Insert planetary gear 69 and the thrust plate into holder 65 and insert shaft assembly 67.

Note: Apply gear oil to the spur gear internal surface and shaft assembly outer surface.

b Drive in the spring pin. Note: Drive in the pins with the splits facing towards planetary gear 69.


12

Holder assembly 76 and spur gear mounting

planetary gears 72. a

Carefully lower holder assembly 76 so that it meshes correctly with the internal teeth of ring gear 64. Turn the holder assembly slightly to engage the splines of pinion shaft 53.

b Insert the sun gear 77 so that the teeth mesh with 9803/6410

Issue 1

Section E


94 - 9

Section E 94 - 9


13

Sun gear 1st stage holder assembly mounting a

14

b Carefully insert sun gear 66 and mesh the teeth of planetary gear 69.

Carefully lower the holder assembly so that it meshes correctly with the internal teeth of ring gear 64. Turn the holder assembly slightly to mesh the teeth of the spur gear with the teeth of holder 65.

Turn the 1st stage holder assembly by hand to check that the output shaft rotates smoothly.

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Issue 1

Section E

Hydraulics

Section E

Slew Motor

95 - 1

95 - 1

Fault Finding Table 1.

Leakage from oil seals

Abnormal heating

Excessive slip

Motor does not run

Symptom

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Cause

External Inspection

Countermeasure

Repair

Internal damage to the motor.

Measure the oil drain volume.

High possibility of damage to the sliding surfaces if the supply volume is approximately equal to the drain volume. Dismantle and inspect.

Refer to Table 2.


Open the motor inlet and outlet ports and apply 20 kgf/cm2 (284 lbf/in2) pilot pressure to the brake release port. Try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft).

High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect.

Renew damaged parts or renew the motor assembly.

Relief valve in circuit not set correctly.

Measure pressure.

Reset to the prescribed setting.

Wear or damage to the motor sliding surfaces or to the high-pressure seal.

Measure the oil drain volume.

Leakage is too high if the oil drain volume exceeds 5 l/min (1.1 gal/min). Dismantle and inspect.

Refer to table 2.

Oil hot and excessive leakage in the motor.

Measure the oil temperature.

Reduce the oil temperature.

Refer to table 2.

Seizure of motor sliding parts or circuit.

Check for any metallic matter deposited in motor drain oil or drain filter. Apply a 30 kgf/cm2 (427 lbf/in2) pilot pressure to the brake release port and try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft).

If metallic matter is discovered or the supply shaft does not rotate smoothly when torque is applied, there is a high possibility of internal damage to the motor. Dismantle and inspect.

Repair or renew the damaged parts. Renew the motor assembly.

Damage or wear to oil seal lip.

Renew the oil seals.

Damage or wear of the shaft seal.

Repair the problem or renew the motor assembly.

Abnormal pressure in the casing.

Check the pressure in the casing and measure the drain volume.

Set the pressure in the casing below 3 kg/cm2. (43 lbf/in2) Dismantle and inspect if drain volume is excessive.

Renew the oil seal. Repair or renew the damaged parts. Renew the motor assembly.

Issue 1

Section E

Hydraulics

Section E

Slew Motor

95 - 2

95 - 2

Fault Finding (cont’d)

Oil leakage from mating surfaces

Abnormal noise

Insufficient torque

Symptom

Cause

External Inspection

Countermeasure

Wear or seizure of the motor sliding surfaces.

Open motor inlet and outlet ports and apply 20 kgf/cm2 (284 lbf/in2) pilot pressure to the brake release port.Try to rotate the shaft with a torque of approx. 39.32 Nm (29 lbf ft).

High possibility of internal damage to the motor if the supply shaft does not rotate smoothly when this torque is applied. Dismantle and inspect.

Relief valve in the circuit is not set correctly.

Measure relief pressure.

Reset to the prescribed setting.


Check if any metallic matter is deposited in the motor drain oil or drain filter.

High possibility of internal damage to the motor if metallic matter is discovered. Dismantle and inspect.

Large amount of air mixed in the oil.

Check the oil in the tank and motor casing.

Thoroughly bleed the air.

Loosening of bolts or pipes

Check if the piping connections, attachment mounting bolts, motor attachment bolts or other bolts are loose.

Tighten to the specified torque.

Repair Inspect the parts and bearing according to Table 2 a-e and renew any defective parts.

Repair or renew damaged parts. Renew the motor assembly.

O-ring is damaged

Renew O-rings.

Seal face is damaged.

Repair seal face or renew.

Bolts are loose.

Check the bolt tightness.

Tighten the bolts to the correct torque.

Table 2. No.

Part Inspected

Repair

a

Wear of the sliding surface of balance plate 21.

Repair or renew the part

b

Damage to sliding surface of cam plate 6.

Repair the part or renew the motor.

c

Damage to sliding surface of the piston assemblies 8.


d

External wear to the piston assemblies 8.


e

Wear to piston bores in cylinder assembly 24.

Renew the motor.

f

Damage to Teflon ring 19 or ‘O’-rings 52.

Renew the part.

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Issue 1

Section F

Transmission

Section F

i

i

Contents Traction Motor/Reduction Gear Specifications Operation Preparation for Use Fault Finding Removal and Replacement Motor Bleeding Testing Cross-Sectional View - JS130 Exploded View (Motor) - JS130 Exploded View (Gearbox) - JS130 Component List - JS130 Cross-Sectional View - JS160 Exploded View (Motor) - JS160 Exploded View (Gearbox) - JS160 Component List - JS160 Traction Motor Dismantling Inspection Assembly

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Page No. 2-1 3-1 4-1 5-1 6-1 6-5 6-6 7-1 7-2 7-3 7-4 7-6 7-7 7-8 7-9

8-1 8 - 10 8 - 12

Reduction Gear - JS130 Dismantling Inspection Assembly Adjustments

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

Reduction Gear - JS160 Dismantling Inspection Assembly Adjustments

10 - 1 10 - 5 10 - 6 10 - 8

Issue 1

Section F

Transmission

Section F

Traction Motor/Reduction Gear

2-1

2-1

Specification JS130

JS160

39 : 1

48 : 1

86.3 cc (5.27 in3)

104. 8 cc (6.39 in3)

Reduction gear ratio Hydraulic motor Maximum stroke volume/rev Maximum rotational speed

2400 rpm

Maximum pressure

2800 rpm

343 bar (4978

lbf/in2,

350

kgf/cm2)

19.6 - 68.6 bar (284 - 296 lbf/in2, 20 - 70 kgf/cm2)

2-Speed switching pressure Parking brake Braking torque Release pressure Overall weight

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255 Nm (188 lbf ft, 26 kgf m) 9.8 bar (142

lbf/in2,

10 kgf/cm2)

165 kg (364 lbs)

10.8 bar (156 lbf/in2, 11 kgf/cm2) 225 kg (496 lbs)

Issue 1

Section F 3-1

Transmission Operation

Section F 3-1

Traction Motor The motor is of the variable swash plate, axial piston type. Pressurised oil is routed via rear flange 101 and timing plate 109 into cylinder block 104. The fixed timing plate directs oil to force piston 105 against swash plate 103, until it reaches the end of its power stroke, causing the cylinder block to rotate 180°. When the piston reaches the end of its power stroke, the cylinder is disconnected from the oil supply line and instead is connected to the return line. The next 180° of cylinder block rotation causes the piston to complete its cycle by expelling the oil from the cylinder back to tank. Altogether there are nine pistons, operating sequentially as described above to provide smooth continuous rotation of the cylinder block, which is spline coupled to drive shaft 102.

JS01620

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Issue 1

Section F 3-2


Section F 3-2

Brake Valve During Travel - Brake Released During travel, pressurised oil is fed into port A to open valve 127 and supply oil via port C to traction motor M. The pressurised oil also enters chamber b through drilling a of spool 123. The pressure build-up in chamber b causes spool 123 to move to the left to connect motor return port D to port B. The result is unrestricted oil flow and, therefore, rotation of the motor. The movement of spool 123 also allows pressurised oil to flow through port P into piston 112 of the parking brake, overcoming the parking brake spring to release the brake pressure.

JS01630

Travel Stopped - Brake Activated When travel is de-selected, there is no pressure at port A. Spool 123 is no longer under the influence of pressurised oil (as described above) and returns to its neutral position under the influence of the two springs 128. This spool position completely shuts off ports A and B from the motor feed and return ports C and D. The inertia of motor M immediately following de-selection of travel causes a build-up of pressurised oil in port D. This pressurised oil passes through the drilling of valve 201B into chamber f and thence chamber g. The pressure moves piston 213 up to force oil into chamber h. The pressure build-up in port D opens valve 201B to allow the oil to flow from port D to port C to prevent cavitation. When piston 213 reaches the end of its pressure induced stroke, the pressure in chamber f and g increases and the valve 201B closes again, allowing a further increase in pressure in port D. This causes valve 201A to open, passing the oil in port D (at a higher pressure than that of the machine main relief valve) into port C. The pressure in port D is thereby controlled in two steps to provide smooth braking to a standstill.

JS01640

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Issue 1

Section F 3-3


Section F 3-3

Parking Brake During Travel During travel, pressurised oil is fed to chamber a of the parking brake from the brake valve (see Brake Valve, During Travel - Brake Released). When the oil pressure exceeds the force of spring 113, piston 112 moves to the left causing plate 116 and friction plate 115 to separate. This releases the braking force from cylinder block 104, which is free to rotate.

JS01650

Travel Stopped When travel is de-selected, pressurised oil is no longer fed to chamber a, allowing piston 112 to move to the right under the force of spring 113. Plate 116 and friction plate 115 are thereby clamped together to prevent cylinder block 104 from rotating.

JS01660

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Issue 1

Section F 3-4


Section F 3-4

Automatic 2-Speed Switching Speed range changing is achieved by altering the angle of the traction motor swash plate. A solenoid operated valve routes pilot oil to the swash plate adjusting mechanism, as appropriate, in response to range selection commands. Low speed Operation When ‘low speed’ is selected there is no pilot oil pressure at port D. Spool 186 is pushed upwards by spring 189 and pressure from port A or B. Oil is released from chamber E into the motor case via spool 186 and drain H, allowing swash plate 103 to pivot on fulcrum F to the maximum angle (O1) up against surface Y of spindle 2. In this swash plate position the piston stroke volume is maximised to produce low speed revolution.

JS01670

High Speed Operation When ‘high speed’ is selected, pilot pressure greater than 39 bar (569 lbf/in2, 40 kgf/cm2) is applied to port D where it overcomes the force of spring 189 and the pressure from port A or B to push spool 186 down. The pressurised oil at port C goes via spool 186 into chamber G and thence into chamber E. Piston 161 pivots swash plate 103 about its fulcrum F until it contacts surface X of spindle 2. At this minimum angle (O2) position, the piston stroke volume is minimised to produce high speed revolution.

JS01680

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Issue 1

Section F

Transmission

3-5

Operation

Section F 3-5

Automatic 2-Speed Switching (cont’d) Automatic Switching - High Speed/Low Speed During normal ‘high speed’ operation the pressure at port A or B is less than 98 bar (1422 lbf/in 2, 100 kgf/cm2). As machine load increases, so does the pressure at port A or B. When the pressure reaches 235 bar (3414 lbf/in2, 240 kgf/cm2) this overcomes the pilot pressure at port D forcing spool 186 upwards to produce the condition described under Low Speed Operation. When the pressure at A or B falls below 235 bar (3414 lbf/in2, 240 kgf/cm2) spool 186 is forced downwards to reproduce the conditions described under High Speed Operation.

JS01690

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Issue 1

Section F 4-1

Transmission

Section F

Traction Motor/Reduction Gearbox

4-1

Preparation for Use Before installing the motor unit, ensure there are no loose parts and that nuts, screws etc. have been tightened to the correct torque values. All ports should be plugged and sealed to prevent the ingress of dirt.

1

Check the direction of rotation of the motor and identify the connection ports accordingly.

A

Reduction Gearbox Oil

B

Note: The gearbox fill/level and drain plugs will be as shown at fig. 1 or 2. Set the reduction gearbox so that the filler/level and drain plugs are on a perpendicular line, with the filler/level plug uppermost.

2

C

Select the correct lubricating oil for the gearbox (see Capacities and Specifications, Section 3).

D

To fill the gearbox, remove the filler plug and level plug (or fill/level plug) and add the correct grade of gear oil until it begins to overflow from the port.

B

Clean off surplus oil, seal-tape the plug threads and securely tighten into position.

JS03200

Note: Gearbox lubricating oil grades must not be mixed. Key Operation The motor and reduction gearbox should initially be operated at low speed, without load. Several operations (forward/reverse) should be carried out, checking for leaks and noting any hydraulic hammer caused by air in the hydraulic system.

A B C D

Fill/level plug Drain plug Filler plug Level plug

Air should be bled from the system and the hydraulic oil replenished as necessary. Operate the motor and apply load gradually, ensuring the system is free from vibration and noise.

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Issue 1

Section F

Transmission

Section F


5-1

5-1

Fault finding Symptom 1

2

3

4

5

6

7

Possible cause

Motor does not start - no oil pressure present.

Motor does not start - oil pressure present.

Oil leakage surfaces.

from

mating

Remedy

a

Low relief valve set pressure.

Set correct pressure.

b

Pump failure.

Check operation of services other than travel. Repair pump if necessary.

c

Direction switching valve failure.

Check spool for damage. Repair if necessary.

a

Brake valve failure

If spool or valve is thermally seized, repair or renew.

b

Hydraulic motor failure.

Check hydraulic oil and renew if necessary.

c

Gear teeth are broken.

Dismantle reduction gear and renew broken parts.

d

Overloaded.

Remove load.

a

Mating surface is scratched.

Lap surfaces using wet stone or emery paper.

b

Bolts loose.

Tighten bolts and recheck.

a

Plug is loose.

Tighten plug.

b

Cracks caused by stone, etc.

Dismantle reduction gear and renew damaged parts.

a

Sliding surface is worn.


b

Seepage past ‘O’-ring.


a

Mounting bolts loose.

Retighten bolt(s).

b

‘O’-ring is damaged.

Renew ‘O’-ring.

c

Seal surface is scratched.

Lap surface using wet stone or emery paper.

a

Poor motor efficiency.

Renew traction motor.

b

Excessive leakage inside brake valve.

Renew brake valve and/or rear flange.

c

Parking brake spring broken.

Renew spring.

d

Parking brake friction plate worn

Renew friction plate and/or other plate.

Oil leakage from case.

Oil leakage from floating seal.

Oil leakage from hydraulic motor.

Slips down on slope.

9803/6410

Issue 1

Section F

Transmission

Section F


5-2

5-2


9

10

11

High temperature of reduction gear case surface.

Does not travel in a straight line at ‘low speed’.

Does not travel in a straight line at ‘high speed’.

Does not speed up - pump delivery slow.

Possible cause

Remedy

a

Insufficient gear oil.

Top up oil

b

Pitching is generated in bearing.

Dismantle and renew damaged parts.

c

Entry of hydraulic oil into gear case.

Renew oil seal.

a

Uneven delivery flow between right and left sides.

Repair pump and/or regulator.

b

Uneven motor drain leakage between right and left sides.

Dismantle motor/reduction gear and repair.

a

Uneven delivery flow between right and left sides.

Repair pump and/or regulator.

b

Uneven motor drain between right and left sides.

Dismantle motor/reduction gear and repair.

c

Non-uniform operation of right and left brake valves.

Renew brake valve and/or rear flange.

d

Drop in relief pressure in right or left control valve.

Set correct pressure and/or renew relief valve.

a

Pump regulator and/or related parts faulty.

Repair regulator and/or related parts.

b

Leakage outside excessive.

Repair or renew pump.

pump

is

12

Does not speed up.

a

Internal leakage is excessive.

Dismantle reduction gear and repair.

13

Abnormal sound.

a

Motor or reduction gear is broken.

Dismantle motor and/or reduction gear and repair.

b

Vibration of pipework.

Clamp pipework securely.

a

Faulty operation of high pressure selection check valve.

Inspect and repair or renew if necessary.

b

Faulty operation of switching valve.

Check to see if spool is normal, and repair or renew if necessary.

c

Low pilot pressure.

Set to specified pressure.

d

Faulty operation of 2-speed switching piston.


14

Does not change from low speed to high speed.

9803/6410

Issue 1

Section F

Transmission

Section F


5-3

5-3


Does not change from high speed to low speed.

9803/6410

Possible cause

Remedy

a

Faulty operation of switching valve.

Check for spool damage. Repair or renew if necessary.

b

Faulty operation of 2-speed switching piston.


Issue 1

Section F

Transmission

Section F


6-1

6-1

Removal and Replacement Removal 1

Move the track link until the master pin is over the take-up roller in the position shown, place a wooden block under the track shoe as shown.

JS02770

2

Slacken the check valve to bleed out the grease.

! WARNING Slacken the check valve slowly and stop when grease is released. The grease and valve are under extremely high pressure and could cause injury if suddenly released. TRANS 6-2

3

Disconnect the track link by removing the locking pin and knocking out the master pin. a

Remove bolts and lift off the track shoes adjacent to the master pin.

b Position a suitable hydraulic press so that its ram aligns with the master pin. c

Insert the spacer bar between the master pin and the hydraulic ram.

d Slowly operate the hydraulic ram and press out the master pin.

!

WARNING

Stand clear and to one side of the track while you remove the master pin. When the master pin is removed the track could fall forward and injure you. TRACK 1-1

e

Remove the seal rings from each side of the chain link.

JS02790

9803/6410

Issue 1

Section F 6-2

Transmission Traction Motor/Reduction Gear

Section F 6-2

Removal and Replacement (cont’d) Removal (cont’d) 4

Operate the traction motor to remove the track.

5

Lift the side of the undercarriage high enough to permit drive sprocket removal. Support with wooden blocks.

6

Stop the engine and operate the control lever to relieve pressure in the hydraulic system. Release pressure in the hydraulic tank (See Releasing Tank Pressure, Section 3).

7

Remove the motor cover, attach identification tags to the motor hoses, disconnect the hoses from the motor and install plugs and caps.

9803/6410

Issue 1

Section F 6-3


Section F 6-3

Removal and Replacement (cont’d) Removal (cont’d) 8

Support the motor so that the cables are in tension, then remove the motor installation bolts.

Replacement 1

Before fitting, clean the assembly and bleed air out as follows: Turn the assembly so that the hydraulic oil ports are facing upwards. Remove plugs from ports A and B. Fill the motor through port A with the specified hydraulic oil. Fit plugs to ports A and B.

2

Lift the assembly and position it on the undercarriage. Install the bolts and washers, using Loctite 262 on the bolt threads. Tighten the bolts in a diagonal sequence.

Torque Settings 267-312 Nm (196-229 lbf ft)

3

Remove the plugs and connect the motor hoses.

9803/6410

Issue 1

Section F


6-4

Section F 6-4

Removal and Replacement (cont’d) Replacement (cont’d) 4

a

Install the covers over the motor.

b Check the amount of oil in the gearbox. c

Bleed air from the motor (see Motor Bleeding).

d If the traction motor has been dismantled and serviced, carry out the functional tests detailed under Testing later in this section. e

Install the drive sprocket (see Drive Sprocket, Replacement, Section J).

f

Remove the wooden blocks.

g Position the lower frame on the track. h Move the track link by reversing step 1 of Removal. i

Clean the seal ring housings in the chain link. Insert the seal rings and clamp into position.

j

Using a plastic hammer, tap the upper link down to align holes.

Note: As the links overlap, the seal rings will be held in position. Remove ‘G’ clamps. k

Insert the pointed guide pin from the inner face and tap through its full length.

l

Position a suitable hydraulic press so that its ram aligns with the guide pin.

JS02800

m Insert the master pin into its locating hole. n Slowly operate the hydraulic ram and press the master pin into position. o Re-locate the track shoes and tighten the bolts (see Checking Shoe Plate, Routine Maintenance, Section 3).

JS02810

JS02820

9803/6410

Issue 1

Section F 6-5


Section F 6-5

Removal and Replacement (cont’d) Replacement (cont’d) 5

Apply grease through the check valve to adjust the track tension (see Tracks and Running Gear, Checking/Adjusting the Track Tension, Section 3).

Motor Bleeding Bleeding must be done whenever a track motor is being fitted. Note: If a track gearbox assembly is being fitted to the machine with the motor attached, bleed it as described in step 1 of page 6 - 3. When the motor is being fitted to a gearbox already fitted to the machine, bleed the air from the motor by one of the three methods detailed below. Note: Method 1 will take considerable time as air in the motor is very difficult to purge. Methods 2 or 3 may be quicker.

Method 1 After fitting the motor but before connecting the pipework, remove plug from upper drain port A but make sure that a plug is fitted to lower drain port B. Fill the motor with specified hydraulic oil through port A. Connect the pipes.

Method 2 Fit the motor and connect all pipes except the two drains. Remove plug from port A. Make sure that a steel plug is fitted to bottom drain port B. Run the engine and operate the track control lever slightly, without allowing the sprocket to rotate. If necessary, prevent the sprocket from turning by means of a steel bar or tube jammed in the track. Return the lever to neutral when airfree oil flows from port A. Connect the drain pipes.

Method 3 Fit the motor and connect all pipes. Prevent the sprocket from turning by means of a steel bar or tube jammed in the track. Run the engine and fully select the track control lever for about 1 minute. This will fill the motor case with oil.

9803/6410

Issue 1

Section F


6-6

Section F 6-6

Testing After dismantling and assembly of the traction motor/reduction gear assembly, install on the machine (see Removal and Replacement), but do not fit the track at this stage. Carry out the ‘no load’ functional tests detailed below. Preparation for Testing Obtain the following test equipment: Pressure gauge - 35 bar (500 lbf/in2, 35 kgf/cm2). Receptacle for motor drain oil - 5 litre (1.1 gal) capacity. Stopwatch. Connect the pressure gauge to test point P3 (left hand motor) or P2 (right hand motor) on the inboard face of the rear flange. Run-in the traction motor by operating in both forward and reverse directions at 10 rpm and 20 rpm for at least one minute in each direction at each speed setting. Functional Tests 1

Run the motor until the hydraulic oil temperature reaches 45 - 55 °C (113 - 131 °F) and the reduction gear hub external temperature reaches 40 - 80 °C (104 - 176 °F).

2

With the motor running at 10 rpm read the hydraulic pressure, which should not be greater than 19.6 bar (284.4 lbf/in2, 20 kgf/cm2).

3

a

Stop the engine and operate the travel controls to release system residual pressure. Disconnect the hose from motor casing drain port D1 (left hand motor) or D2 (right hand motor). In place of the hose removed, connect an open ended hose long enough to reach the oil receptacle.

b Start the engine and, using the travel control, run the traction motor at 10 rpm for one minute and then stop it. Measure the amount of drain oil collected in the receptacle. This should not exceed 1.2 litres (0.27 gal) for JS130 or 1.5 litres (0.3 gal) for JS160.

JS01500

Note: The above illustration shows the inboard view of the motor mounted on the left hand side of the machine, with X indicating the front of the machine. To visualise the motor mounted on the right hand side of the machine, rotate each image through 180° so that P3 is above P2 and D2 is above D1.

Note: The drain oil quantities given are applicable to a new motor. These will increase slightly as wear takes place. 4

If the above tests are satisfied, install the machine track. If either of the tests fail, remove the motor/reduction gear assembly from the machine. Dismantle and thoroughly check the motor section for further damage and/or wear and replace any suspect parts. Repeat steps 1 to 4.

9803/6410

Issue 1

Section F 7-1


Section F 7-1

Cross-sectional View - JS130

JS00250

9803/6410

Issue 1

Section F 7-2


Section F 7-2

JS00270

Exploded View (Traction Motor) - JS130

9803/6410

Issue 1

Section F 7-3


Section F 7-3

Exploded View (Reduction Gear) - JS130

JS00260

9803/6410

Issue 1

Section F

Transmission

Section F


7-4

7-4

JS130 Component List No

Description

1

Hub

Qty

No

Description

Qty

1

107 108 109 110 112 113 114 115 116 118 119 120 121 122 124 125 126 127 128 130 132 133 135 138 139 140 141 142 143 145 147 148 149 150 151 153 155 156

Retainer plate Thrust ball Timing plate Washer Piston Spring Spring Friction plate Plate Valve seat Valve Spring Plug Ring Plug Stopper Plug Valve Spring Spring Oil seal ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring Parallel pin Parallel pin Bolt Snap ring Back-up ring Back-up ring Bearing Bearing Needle roller bearing Thrust plate ‘O’-ring ‘O’-ring

1 1 1 2 1 10 1 2 2 1 1 1 1 1 2 2 2 2 2 2 1 1 1 2 1 1 2 2 9 1 1 1 1 1 3 1 2 4

Spindle Kit 2 Spindle 3 Flange 19 Reamer bolt

1 1 3

Gear assembly 4 Gear A 5 Gear B 9 Crankshaft 22 Conical roller bearing 23 Needle roller bearing

1 1 3 6 6

6

Input gear

1

Spur gear kit 7 Spur gear

3

8

1

Cover

Floating seal kit 10 Distance piece 31 Floating seal

1 1

11 14 17 20 21 24 25 27 28 29 30 33 35 36 37

1 3 24 3 2 1 3 2 1 1 1 2 12 12 1

Ring Distance piece Pin Snap ring Ball bearing Snap ring Snap ring ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring Plug Bolt Washer Spring pin

Rear flange kit 101 Rear flange 123 Spool 152 Plug 154 Expander 180 Plug 197 Orifice 198 Expander 199 Name plate

1 1 2 1 3 1 3 1

102 103 104

1 1 1

Shaft Swash plate cylinder block

Piston kit 105 Piston 106 Shoe 9803/6410

Piston kit (2-speed switch) 161 Piston 162 Shoe

1 1

167 168 169 170 171 179 186 187 188 189 190

2 2 1 4 4 1 1 1 1 1 1

Steel ball Steel ball Plate Socket head bolt Washer Spring Spool Stopper Joint Spring ‘O’-ring

9 9 Issue 1

Section F


7-5

Section F 7-5

JS130 (cont’d) Component List (cont’d) No

Description

Qty

Relief valve Valve kit 201 Valve 202 Sleeve 203 Spring retainer 204 Plug 205 Shim 206 Spring 208 ‘O’-ring 209 ‘O’-ring 210 ‘O’-ring 211 Back-up ring

2 1 1 1 1 1 1 1 1 1 2

Body kit 209 212 213 214 215 216 217 218 219 220

2 1 1 1 2 2 4 6 2 5

9803/6410

‘O’-ring Body Piston Plug Plug Steel ball Back-up ring ‘O’-ring ‘O’-ring Plug

Issue 1

Section F 7-6


Section F 7-6

Cross-sectional View - JS160

JS00280

9803/6410

Issue 1

Section F 7-7

Transmission

Section F


7-7

JS00300

Exploded View (Traction Motor) - JS160

9803/6410

Issue 1

Section F 7-8


Section F 7-8

Exploded View (Reduction Gear ) - JS160

JS00290

9803/6410

Issue 1

Section F

Transmission

Section F


7-9

7-9

JS160 Component List No

Description

Qty

Hub kit 1 4 27

Hub Ring gear Parallel pin

1 1 10

2 8 17

Spindle Coupling gear Pin

1 1 10

Floating seal kit 10 Distance piece 31 Floating seal

1 1

3 5 6 7 9 12 13 14 15 19 20 23 24 25 29 30 32 33 34 35 36 37 39 40 41

1 1 3 1 3 1 1 6 1 1 2 1 2 6 1 3 20 20 3 10 1 1 2 1 2

Carrier Ring gear (B) Cluster gear Sun gear (A) Shaft Distance piece Cover Thrust collar Ring Coupling Thrust bearing Sealing ring Deep groove bearing Needle roller bearing ‘O’-ring Plug Bolt Washer Parallel pin Bolt Steel ball ‘O’-ring ‘O’-ring ‘O’-ring Ring - C-type with socket

Rear flange kit 101 Rear flange 123 Spool 152 Plug 154 Expander 180 Plug 197 Orifice 198 Expander 199 Nameplate

1 1 2 1 3 1 3 1

102 103 104

1 1 1

Shaft Swash plate Cylinder block

Piston kit 105 Piston 106 Shoe

9803/6410

No

Description

Qty

107 108 109 110 111 112 113 114 115 116 118 119 120 121 122 124 125 126 127 128 130 132 133 135 138 139 141 142 143 145 147 148 149 150 151 155 156

Retainer plate Thrust ball Timing plate Washer Washer Piston Spring Spring Friction plate Plate Valve seat Valve Spring Plug Ring Plug Stopper Plug Valve Spring Spring Oil seal ‘O’-ring ‘O’-ring ‘O’-ring ‘O’-ring Parallel pin Parallel pin Bolt THS snap ring Back-up ring Back-up ring Bearing Bearing Needle roller bearing ‘O’-ring ‘O’-ring

1 1 1 2 1 1 10 1 2 2 1 1 1 1 1 2 2 2 2 2 2 1 1 1 2 1 2 2 9 1 1 1 1 1 3 2 4

Piston kit (2-speed switch) 161 Piston 162 Shoe

1 1

167 168 169 170 171 186 187 188 189 190 191 192

2 2 1 4 4 1 1 1 1 1 1 2

Pivot Ball Plate Bolt Washer Spool Stopper Coupling Spring ‘O’-ring Spring Parallel pin

9 9

Issue 1

Section F


7 - 10

Section F 7 - 10

JS160 (cont’d) Component List (cont’d) No

Description

Qty

Relief valve 201 Valve 202 Sleeve 203 Spring retainer 204 Plug 205 Shim 206 Spring 208 ‘O’-ring 209 ‘O’-ring 210 ‘O’-ring 211 Back-up ring

2 2 2 2 2 2 2 2 2 4

Body kit 212 213 209 214 215 216 217 218 219 220

1 1 2 1 2 2 4 5 2 1

9803/6410

Body Piston ‘O’-ring Plug Plug Steel ball Back-up ring Plug ‘O’-ring ‘O’-ring

Issue 1

Section F

Transmission Traction Motor

8-1

Section F 8-1

Dismantling Refer to the following pages: JS130

7 - 1 and 7 - 2 (illustrations) 7 - 4 to 7 - 5 (component list)

JS160

7 - 6 and 7 - 7 (illustrations) 7 - 9 to 7 - 10 (component list)

In the following procedures, the part numbers in bold type (e.g. 170) correspond with the numbers on the illustrations.

Make different alignment marks across each sub assembly joint faces as an aid to assembly. The cylinder block assemblies, servo pump, relief valve and proportional pressure reduction valve must be renewed as complete assemblies. During dismantling, record the number and dimensions of shims. Take care to reassemble in the same manner.

Before attempting to dismantle the traction motor, drain all oil, blank all inlet and outlet ports and wash the outer surfaces with a suitable solvent to remove all dirt and dust. Dry using compressed air. 1

Loosen, but do not remove plug 204 and the two sleeves 202 in relief valve body 212.

2

Unscrew the four socket head bolts 170 and remove relief valve body 212 from rear flange 101. Remove the two ‘O’-rings 156 from the rear flange and discard.

3

Remove nine hexagonal socket bolts 143.

9803/6410

Issue 1

Section F 8-2


Section F 8-2


Remove rear flange 101 from spindle 2.

5

Remove two plugs 124 from rear flange 101. Remove ‘O’-rings 155 from plugs 124.

6

Remove two springs 128, two plungers 125 and spool 123 from the rear flange. Take care to avoid damaging the mating surfaces of spool and rear flange.

7

Remove the two plugs 126 from rear flange.

9803/6410

Issue 1

Section F 8-3


Section F 8-3


Remove two springs 130 and two valves 127 from the rear flange 101. Remove ‘O’-rings 156 from plugs 126. Take care to avoid damaging the seat of the valve or its mating seat in the flange.

9

Unscrew adaptor 188 from the rear flange. Remove and discard ‘O’-ring 138.

JS00310

10 Remove spool 186, spring 189 and plunger 187. If necessary, use an M5 socket head bolt in the threaded hole of plunger 187 to assist removal. Remove and discard ‘O’-ring 190 from plunger 187.

JS00320

9803/6410

Issue 1

Section F 8-4


Section F 8-4

Dismantling (cont’d) 11 Remove valve 119 as follows: Depress valve seat 118 with a steel rod A and remove ring 122 by pressing the notch B with a sharp-pointed tool C. Insert spool 123, block the hole in valve plate 118 and force out the valve plate using oil pressure directed through the brake pressure port. Extract spring 120 and seat 119. Remove and discard ‘O’-ring 133. Discard ring 122.

JS00340

JS00350

12 Remove plug 214. Remove the ‘O’-ring from plug 214 and discard.

13 Remove piston 213 from body 212.

9803/6410

Issue 1

Section F 8-5


Section F 8-5

Dismantling (cont’d) 14 Loosen and remove the two plugs 215. Remove ‘O’-ring 219 from each plug 215 and discard.

15 Take the two steel balls 216 out of body 212.

16 Unscrew one of the sleeves 202 from body 212. Remove and discard ‘O’-ring 208 and the two back-up rings 211 from sleeve 202. Remove and discard ‘O’-ring 209 and the two back-up rings 217 from body 212.

9803/6410

Issue 1

Section F 8-6


Section F 8-6

Dismantling (cont’d) 17 Unscrew plug 204 from sleeve 202. Remove ‘O’-ring 210 and shim 205 from plug 204. Discard the ‘O’-ring.

18 Remove spring retainer 203, spring 206 and valve 201 from sleeve 202.

9803/6410

Issue 1

Section F


8-7

Section F 8-7

Dismantling (cont’d) 19 Repeat steps 16 to 18 for the second sleeve 202.

20 Remove timing plate 109, two pins 141, ten springs 113, bearing 150, ‘O’-rings 29 and 39. Discard the ‘O’-rings.

21 Remove piston 112, by applying compressed air through the brake pressure port. Place a protective cover over the piston to stop it from flying out.


22 Remove and discard ‘O’-rings 135 and 139 also backup rings 147 and 148.

9803/6410

Issue 1

Section F


8-8

Section F 8-8

Dismantling (cont’d) 23 Place the travel motor horizontally, taking care to collect any oil left inside. Holding the cylinder block 104 with both hands, rotate it to the right and left two or three times in order to separate shoes 106 from swash plate 103. Note: Failure to do this could cause piston parts to stick to the swash plate and fall into the spindle. Remove cylinder block 104, plates 116, friction plates 115, and plate 169 from spindle 2. Remove the piston assembly comprising pistons 105, shoes 106, retainer plate 107, thrust bowl 108, washer 111 (JS160 only) and pins 151 from cylinder block 104. Note: Hydraulic motor shaft 102, bearing 149 and oil seal 132 cannot be removed from this side of the reduction gear. If it is necessary to remove these components refer to Reduction Gear, Dismantling.

24 Remove the swash plate 103/thrust plate 153 (JS130 only) assembly, the two steel balls 167 (pivots 167 on JS160) and the 2-speed switch piston assembly (piston 161, shoe 162, spring 179 (191 on JS160) out of spindle 2. Separate the swash plate and thrust plate by prying apart (JS130 only). Note: Piston 161 and shoe 162 are a matched set. If either shows signs of wear or damage, renew both as a set. Note: Remove 2-speed control piston assembly, comprising piston 161, shoe 162 and spring 191, by applying compressed air to port A spindle 2.


9803/6410

Issue 1

Section F 8-9


Section F 8-9

Dismantling (cont’d) 25 To remove circlip 145, place the cylinder block on a press capable of exerting a pressure of at least 100 kgf (220 lbf) and compress spring 114 by means of a suitable tubular tool (see Service Tools, Section 1) pressing on washer 110. During this operation, protect the machined surface of the cylinder block with suitable sheeting.

26 Remove circlip 145, followed by washer 110, spring 114 and the second washer 110.

27 Remove shaft 102 complete with inner race of bearing 149.

28 If bearing 149 is to be renewed, press the shaft 102 out of the bearing inner race. Support the bearing by means of a suitable tube D (see Service Tools, Section 1).

9803/6410

Issue 1

Section F

Transmission

Section F

Traction Motor

8 - 10

8 - 10

Inspection All parts should be inspected for signs of wear or damage, paying particular attention to the parts detailed below.

Part Rear flange 101


Spool 123 bore is scratched.

b

Valve 127 contact area is scratched.

c

Depth to 127 contact area is large.

a

Clearance to flange 101 bore exceeds 0.025 mm (0.001 in).

b

Outer surface is scratched or unevenly worn.

a

Oil seal 132 contact area is worn.

b

Spline is worn.

Swash plate 103

a

Evidence of thermal seizure.

Cylinder block 104

a

Spline is worn.

b

Inner surface of bore excessively worn.

c

Timing plate 109 sliding surface scratched or unevenly worn.

a

Clearance between piston and shoe exceeds 0.15 mm (0.006 in)

b

Shoe is abnormally or unevenly worn.

Retainer plate 107

a

Edge surface of inner circumference unevenly worn.

Thrust ball 108

a

Spherical retainer plate 107 sliding surface unevenly worn.

Timing plate 109

a

Sliding surface is thermally seized and unevenly worn.

Lining plate 115 Plate 116

a

Both edge surfaces unevenly worn.

b

Thermal seizure is observed.

c

Braking torque is less than the specified 255 Nm (188 lbf ft, 26 kgf m).

a

Seat surface is scratched.

Spool 123

Shaft 102

Piston 105 Shoe 106

Valve seat 118

9803/6410

Issue 1

Section F


8 - 11

Section F 8 - 11

Inspection (cont’d)

Part Valve 119


Outer circumference surface is scratched.

b


a

Pressure marks observed.

b

Flaking is occurring.

c

Unevenly worn.

Relief valve body 212

a

Piston 213 sliding surface is scratched.

Piston 213

a

Clearance to body 212 exceeds 0.025 mm (0.001 in).

b


Sleeve 202

a


Valve 201

a

Sliding surface along sleeve 202 is abnormally worn.

b

Clearance to sleeve 202 exceeds 0.020 mm (0.0008 in).

c


Bearings 149, 150

9803/6410

Issue 1

Section F

Transmission

Section F

Traction Motor

8 - 12

8 - 12

Assembly Clean each part in a suitable solvent and dry using compressed air. Inspect all parts and renew as required.

All tapped holes and gasket faces should be thoroughly degreased by washing as liquid packing and adhesive is used on all gasket surfaces and threads.

Care must be taken not to let dust or dirt adhere to parts after cleaning and that parts do not become dented, scratched or damaged.

Apply adhesive to the final few threads of a bolt or screw. Do not apply excessive amounts of adhesive. Wipe off any surplus.

Fit new ‘O’-rings, plugs, packing, oil seals and fastener seals.

Leave the unit for at least twelve hours after assembly to allow the adhesive to fully dry.

Apply Lithium grease to all new oil seals (particularly the lip areas) and ‘O’-rings, and clean hydraulic fluid to all sliding parts before installation.

Ensure that all components are re-fitted to the positions from which they were removed, paying particular attention not to intermix components from identical sets front and rear.

When Assembling Assembly is the reverse of dismantling, but note the following points: 1

When installing the cylinder block assembly into spindle 2 take care not to touch the housing. Carefully align the recesses in swash plate 103 with the steel balls 167 (pivots 167 on JS160) already installed in the housing. When the motor is fully assembled, rotate the cylinder block and check for freedom from backlash. If backlash is present, inspect and take remedial action.

2

Tighten the plugs, etc to the torques indicated below.

Torques Part Nm

lbf ft

kgf m

Plug 121

58 ± 10

43 ± 7

6±1

Plug 124

333 ± 49

246 ± 36

34 ± 5

Plug 126

133 ± 19

98 ± 14

13.5 ± 2

Socket head bolt 143

163 ± 24

120 ± 18

16.6 ± 2.5

Connector 188

98 ± 19

72 ± 14

10 ± 2

Sleeve 202

127 ± 19

94 ± 14

13 ± 2

Plug 204

80 ± 19

59 ± 14

8±2

Plug 214

98 ± 19

72 ± 14

10 ± 2

Plug 215

30 ± 5.4

22 ± 4

3±5

9803/6410

Issue 1

Section F

Transmission Reduction Gear - JS130

9-1

Section F 9-1

Dismantling Refer to the following pages: 7 - 1 and 7 - 3 7 - 4 to 7 - 5

(illustrations) (component list)


Make different alignment marks across each sub assembly joint face as an aid to assembly. During dismantling, record the number and dimensions of shims. Take care to reassemble in the same manner.

Before attempting to dismantle the reduction gear, drain all oil, blank all inlet and outlet ports and wash the outer surfaces with a suitable solvent to remove all dirt and dust. Dry using compressed air.

1

Place the traction motor/reduction gear assembly on the bench with cover 8 uppermost. Remove the two plugs 33. Remove the twelve bolts 35 and super lock washers 36.

2

Install eye bolts into the tapped holes vacated by plugs 33. Attach suitable lifting gear to the eye bolts and remove cover 8, if necessary gently tapping the rim with a plastic hammer to overcome the resistance of ‘O’-ring 29. Remove and discard ‘O’-ring 29 from cover 8. Drain the lubricant (3.6 litres (0.79 gal)) from the reduction gear.

3

Remove snap ring 24 and input gear 6 from shaft 102.

9803/6410

Issue 1

Section F 9-2


Section F 9-2


In turn, remove each of the three snap ring 25/spur gear 7/distance piece 14 sets from the crankshaft 9.

5

If the traction motor has already been dismantled, shaft 102 can now be removed complete with bearing 149. Using a plastic hammer, gently tap out the shaft from the cover 8 end.

6

To prevent hub 1 and spindle 2 separating during the following procedures, take steps to obtain or manufacture a clamping jig to hold them together. Remove the three snap rings 20 from flange 3, identifying each snap ring with its hole in the flange. Loosen and remove the three reamer bolts 19.

Note: Adhesive is used on the threads of the reamer bolts 19, which may be difficult to loosen. To overcome this, loosen the reamer bolts as slowly as possible. If a bolt locks when partially undone do not attempt to continue by using force; re-tighten slightly and then resume.

9803/6410

Issue 1

Section F


9-3

Section F 9-3


Remove flange 3 complete with the inner race of bearing 21 from spindle 2.

Note: The component parts of bearing 21 are a matched set and must remain together.

8

Remove the gear assembly comprising gear 4, gear B 5, crankshaft 9, bearing 22 and bearing 23 from hub 1.

Note: Do not dismantle the gear assembly. If any part is damaged, renew the complete gear assembly as a set. Remove the twenty-four pins 17 from the inner circumference of hub 1. Remove the clamping jig installed at step 6.

9

Fit two eye bolts (M16) to spindle 2. Attach suitable lifting gear to the eye bolts and raise spindle 2, slowly to avoid damaging the cage of bearing 21, away from hub 1.

10

Remove the parts from inside hub 1 as follows: a

Remove distance piece 10 and spring pin 37.

b Remove and discard ‘O’-ring 28. c

Remove bearing 21 inner race (with balls and cage).

Note: Do not remove bearing 21 outer race (as described below) unless it needs renewing. d Position an aluminium bar A as shown against the inner circumference of bearing 21 outer race and remove the race by striking with a hammer. 9803/6410

JS00360

Issue 1

Section F


9-4

Section F 9-4


Remove floating seal 31 from spindle 2.

12

a

Remove the outer race of bearing 22 from flange 3 using an aluminium bar A and hammer as shown.

Note: Do not remove bearing 21 inner race, (as described below) unless it need renewing. b Remove the inner race of bearing 21 from flange 3.

JS00370

13 Note: Do not remove oil seal 132 unless it needs renewing. Do not re-use an oil seal that has been removed. Remove oil seal 132 by putting a screwdriver against the outer edge of the oil seal inside spindle 2, and striking with a hammer.

JS00380

14 Note: Do not remove bearing 149 unless it needs renewing. Do not re-use a bearing that has been removed. Use a suitable press tool B, to support shaft 102. Use press C to force shaft 102 out of bearing 149.

JS00390

9803/6410

Issue 1

Section F


9-5

Section F 9-5

Inspection

Part

Renew if these conditions exist

Spindle 2 Flange 3 Reamer bolt 19

a

Excessive damage or wear.

† Gear A 4 † Gear B 5

a

Gear teeth unevenly worn.

† Crankshaft 9 † Bearing 22 † Bearing 23

a

Crankshaft does not rotate freely in the bearings.

Distance piece 10

a

Sliding surface scratched or unevenly worn.

Bearing 21

a

Pressure marks present.

b

Flaking surfaces.

c

Unevenly worn.

† If any of these components show signs of the conditions listed, renew the complete gear assembly.

9803/6410

Issue 1

Section F 9-6


Section F 9-6

Assembly General Clean each part in a suitable solvent and dry using compressed air.

All tapped holes and gasket faces should be thoroughly degreased by washing, as liquid packing and adhesive is used on all gasket surfaces and threads.

Inspect all parts and renew as required. Care must be taken not to let dust or dirt adhere to parts after cleaning and that parts do not become dented, scratched or damaged. Fit new ‘O’-rings, plugs, packing, oil seals and fastener seals. Apply Lithium grease to all new oil seals (particularly the lip areas) and ‘O’-rings, and clean hydraulic fluid to all sliding parts before installation.

Apply adhesive to the final few threads of a bolt or screw. Do not apply excessive amounts of adhesive. Wipe off any surplus. Leave the unit for at least twelve hours after assembly to allow the adhesive to fully dry. Ensure that all components are re-fitted to the positions from which they were removed, paying particular attention not to mix components from identical sets front and rear.

When Assembling Assembly is the reverse of dismantling, but note the following points: 1

If certain components have been renewed, it will be necessary to check specified clearances and, if necessary make adjustments at the appropriate stage of assembly. Failure to make the necessary adjustments could result in poor performance and/or premature damage. Refer to Adjustments, following these notes, for details of the components and procedures involved.

2

When installing the gear assembly into spindle 2, align the inner race of bearing 22 with the outer race already installed in the spindle. Lower gently to avoid damaging the bearing.

3

The outer race of bearing 21 is an interference fit in hub 1. To install, position an aluminium rod A as shown, at various points around the circumference and tap gently until the race is fully seated.

JS00460

4

When fitting the reamer bolts 19 to secure flange 3, tighten them evenly and progressively so that the flange remains square with its associated components.

5

Unless new snap rings 20 are being fitted (see Adjustments) make sure that they are returned to the position on flange 3 from which they were removed.

9803/6410

Issue 1

Section F

Transmission

Section F

Reduction Gear - JS130

9-7

9-7

Assembly (cont’d) When Assembling (cont’d) 6

When installing spur gears 7 on flange 3 position alignment marks X as shown.

JS00470

7

If bearing 149 has been removed from shaft 102 it will be necessary to fit a new bearing. Heat the bearing to 100 ± 10 °C (212 ± 18 °F) before fitting. Smear the outer face of the outer race with molybdenum disulphide grease.

8

Tighten the plug and bolts to the torques indicated below: Torques Part Nm

lbf ft

kgf m

Reamer bolt 19

540 ± 69

398 ± 51

55 ± 7

Plug 33

58 ± 26

43 ± 14

6±2

Bolt 35

102 ± 16

75 ± 12

10.4 ± 1.6

9803/6410

Issue 1

Section F 9-8


Section F 9-8

Adjustments Determining the Thickness of Flange 3

This procedure must be carried out if any of the following components have been renewed: hub 1, spindle 2, flange 3, bearing 21.

1

Fit clearance measuring jig E (see Service Tools, Section 1) to spindle 2 as shown.

JS00500

2

Tighten the special nut F of the jig to a torque of 58 Nm (43 lbf ft, 6 kgf m).

3

Using a micrometer G through a hole in the clearance measuring jig, measure depth A. Since dimension B of the clearance measuring jig is known, calculate the clearance C as follows: C=A-B Note: If dimension B is not stamped on the jig it must be measured.

JS00510

9803/6410

Issue 1

Section F


9-9

Section F 9-9

Adjustments (cont’d) Determining the Thickness of Flange 3 (cont’d) 4

On flange 3, measure dimension D which should be the same as the dimension C determined in step 3.

JS00520

5

Depending on the result in step 4, proceed as follows: a

If D is less than C, trim off surface G, using a lathe, until D = C.

b If D = C no further action is necessary. c

6

If D is greater than C fit a new spindle 2 and flange 3, then repeat steps 1 to 4. (Note that the replacement flange will include a grinding allowance.)

Remove the clearance measuring jig from spindle 2.

9803/6410

Issue 1

Section F


9 - 10

Section F 9 - 10

Adjustments (cont’d) Determining the Thickness of Snap Ring 20 This procedure must be carried out if any of the following components have been renewed: spindle 2, flange 3, gear assembly (items 4, 5, 9, 22 and 23). The procedure, referring to only one crankshaft 9, should be repeated for all three. 1

Lightly tap the outer ring of bearing 22 installed on crankshaft 9 of gear assembly H, using press jig J and a hammer to make sure the gear is fully seated in spindle 2.

2

Install the thinnest snap ring 20 into the snap ring groove in flange 3.

3

Lightly tap the outer part of the snap ring with the press jig and a hammer.

4

Use a feeler gauge between snap ring 20 and bearing 22 to measure the clearance.

5

The required snap ring thickness T = feeler gauge thickness + thickness of snap ring installed ± 0.05 mm (0.002 in). Select a suitable snap ring from the twelve detailed below.

JS00530

T Snap ring 20 Identification

Min

Max

A

2.20 mm (0.0866 in)

2.25 mm (0.0886 in)

B

2.25 mm (0.0886 in)

2.30 mm (0.0906 in)

C

2.30 mm (0.0906 in)

2.35 mm (0.0925 in)

D

2.35 mm (0.0925 in)

2.40 mm (0.0945 in)

E

2.40 mm (0.0945 in)

2.45 mm (0.0965 in)

F

2.45 mm (0.0965 in)

2.50 mm (0.0984 in)

G

2.50 mm (0.0984 in)

2.55 mm (0.100 in)

H

2.55 mm (0.100 in)

2.60 mm (0.102 in)

I

2.60 mm (0.102 in)

2.65 mm (0.104 in)

J

2.65 mm (0.104 in)

2.70 mm (0.106 in)

K

2.70 mm (0.106 in)

2.75 mm (0.108 in)

L

2.75 mm (0.108 in)

2.80 mm (0.110 in)

9803/6410

Issue 1

Section F


10 - 1

Section F 10 - 1

Dismantling Refer to the following pages: 7 - 6 and 7 - 8 7 - 9 to 7 - 10

(illustrations) (component list)


Make different alignment marks across each sub assembly joint face as an aid to assembly. During dismantling, record the number and dimensions of shims. Take care to reassemble in the same manner.

Before attempting to dismantle the reduction gear, drain all oil, blank all inlet and outlet ports and wash the outer surfaces with a suitable solvent to remove all dirt and dust. Dry using compressed air.

1

Place the traction motor/reduction gear assembly on the bench with cover 13 uppermost. Remove the three plugs 30 and the twenty bolts 32/super lock washers 33.

2

Insert eye bolts in the cover holes vacated by plugs 30. Use suitable lifting gear to remove cover 13. Remove outer thrust bearing 20. Using a suspension fitting 1 (see Service Tools, Section 1) lift out the carrier 3 assembly. Remove steel ball 36, sun gear 7, coupling 19 and inner thrust bearing 20.

3

Drain the gear oil from the reduction gear housing.

9803/6410

Issue 1

Section F 10 - 2


Section F 10 - 2


Make matching marks on ring gear 4 and hub 1 to aid assembly. Using a bar, withdraw ring gear 4 and remove the adhesive from the engagement surfaces of the ring gear and hub. Remove the ten parallel pins 27 from hub 1.

JS00550

5

Remove the ten socket bolts 35.

Note: There is adhesive on the threads of the socket bolts 35. So a loosening torque higher than the tightening torque will be required. Take extra care that seizures do not occur. Match mark the coupling gear 8 and spindle 2 to aid assembly. Remove the coupling gear.

6

Install four eye bolts (M12) in the threaded holes on the flange of hub 1. Use suitable lifting gear to separate hub 1 from spindle 2. The two bearings 24, seal ring 23, ‘O’-ring 40, coupling gear 8, ring gear 5, ring 15 and distance piece 12 will also be released at this time.

9803/6410

Issue 1

Section F


10 - 3

Section F 10 - 3


Dismantle spindle 2 parts as follows: a

Remove and discard ‘O’-ring 29.

Note: Remove oil seal 132 only if it needs renewing. b Tur n the spindle 180° and using a flat end screwdriver and hammer as shown, remove and discard oil seal 132. Note: Remove distance piece 10 only when renewing floating seal 31. JS00570

c

Remove distance piece 10.

d Remove and discard ‘O’-ring 37.

JS00580

8

Dismantle hub 1 parts as follows: a

Remove floating seal 31.

Note: Bearings 24 are a shrink fit onto the hub and should not be removed unnecessarily. Having been removed, the bearings should be discarded and renewed. b Remove one bearing 24 using a steel bar X and hammer as shown. Seal ring 23 will be removed at the same time. c

Turn the hub over and remove the other bearing 24.

d Remove and discard ‘O’-ring 40.

JS00590

9803/6410

JS00600

Issue 1

Section F 10 - 4


Section F 10 - 4


Remove ring 15 and coupling gears 8 from ring gear 5.

10 Do not attempt to dismantle the carrier assembly (comprising carrier 3, cluster gears 6, shafts 9, thrust collars 14, bearings 25 and parallel pins 34). If damage to any of the individual components is evident renew the complete assembly.

9803/6410

Issue 1

Section F


10 - 5

Section F 10 - 5

Inspection

Part

Replace if these conditions exist

Spindle 2 Coupling gears 8 Pins 17

a


† Carrier 3 † Cluster gears 6 † Shafts 9 † Thrust collars 14 † Bearings 25 † Parallel pins 34

a


b

Uneven tooth wear on cluster gears 6.

c

Rotation of cluster gears 6 not smooth.

Ring gear 4 Ring gear 5

a

Uneven wear or damage to gear teeth.

Sun gear 7

a

Uneven wear or damage to gear teeth.

b

Worn splines.

Coupling gear 8

a

Uneven wear or pitting on teeth.

Coupling 19

a

Worn splines.

Thrust bearing 20

a

Axial clearance to coupling gear 8 and cover 13 exceeds 0.8 mm (0.031 in).

Distance piece 12

a

Sliding surface scratched or worn.

Bearings 24

a

Pressure marks visible.

b

Flaking.

c

Uneven wear.

Carrier Assembly

† If any of these components show signs of the conditions listed, renew the complete carrier assembly.

9803/6410

Issue 1

Section F 10 - 6


Section F 10 - 6

Assembly General Clean each part in a suitable solvent and dry using compressed air. Inspect all parts and replace as required. Care must be taken not to let dust or dirt adhere to parts after cleaning and that parts do not become dented, scratched or damaged. Fit new ‘O’-rings, plugs, packing, oil seals and fastener seals. Before installation, apply Lithium grease to all new ‘O’-rings and oil seals (particularly the lip areas). Apply clean hydraulic fluid to all sliding parts before installation.

All tapped holes and gasket faces should be thoroughly degreased by washing as liquid packing and adhesive is used on all gasket surfaces and threads. Apply adhesive to the final few threads of a bolt or screw. Do not apply excessive amounts of adhesive. Wipe off any surplus. Leave the unit for at least twelve hours after assembly to allow the adhesive to fully dry. Ensure that all components are re-fitted to the positions from which they were removed, paying particular attention not to intermix components from identical sets front and rear.

When Assembling Assembly is the reverse of dismantling, but note the following points. 1

If certain components have been renewed, it will be necessary to check specified clearances and, if necessary make adjustments at the appropriate stage of assembly. Failure to make the necessary adjustments could result in poor performance and/or premature damage. Refer to Adjustments, following these notes, for details of the components and procedures involved.

2

When fitting bearings 24 to hub 1, pre-heat the hub to 90 ± 5 °C (194 ± 9 °F). Then tap main bearing press jig A (see Service Tools, Section 1) with a hammer to install the bearing in the hub. If the jig is not available, carefully tap the bearing outer race with an aluminium bar and a hammer.

JS01470

3

When fitting coupling gear 8 lightly coat its contact surface with grease to prevent distance piece 12 dropping out. Install using the coupling gear suspension fitting (see Service Tools, Section 1).

9803/6410

Issue 1

Section F 10 - 7


Section F 10 - 7


Completely degrease the threaded holes of spindle 2 and then apply thread adhesive. Also degrease bolts 35 and then apply an anti-seize coating beneath the bolt head.

5

If renewing the inner races of bearings 149 and 150, pre-heat to 100 ± 10 °C (212 ± 18 °F) and install using press tool B (see Service Tools, Section 1) as shown.

JS00610

6

Before installing the carrier 3 assembly, set-up the cluster gears 6 with matching marks (positions C as shown). Insert sun assembly tool (see Service Tools, Section 1) to lock the gears relative to each other. Install the carrier into ring gear 5 and then install the ring gear assembly into hub 1. Remove the sun gear assembly tool.

JS00640

7

Accurate positioning of ring gear 4 relative to hub 1 is essential. Degrease the two surfaces where the ring gear contacts the hub and apply a light coat of liquid gasket. Install ring gear 4 into hub 1, taking care to mesh the teeth of the ring gear with those of cluster gears 6. Rotate the ring gear so that its match mark D aligns with the match mark of hub 1, as shown opposite.

JS00650

9803/6410

Issue 1

Section F

Transmission

Section F

Reduction Gear - JS160

10 - 8

10 - 8


Tighten the plug and bolts to the torques indicated below:

Torques Part Nm

lbf ft

kgf m

Plug 30

59 ± 20

43.4 ± 14.5

6±2

Bolt 32

102 ± 15.7

75.2 ± 11.6

10.4 ± 1.6

Bolt 35

348 ± 54

257 ± 40

35 ± 5.5

Adjustments Determining the Thickness of Distance Piece 12 This procedure must be carried out if any of the following components have been renewed: hub 1, spindle 2, ring gear 4, coupling gear 8, pin 17, bearings 24 or parallel pins 27. 1

Install the distance piece clearance gauge B (see Service Tools, Section 1) in spindle 2 in place of distance piece 12.

2

Lightly tighten three evenly spaced bolts 35.

3

Measure dimension ‘A’ with depth micrometer as shown.

4

Measure dimension ‘C’ of the assembled coupling gear 8.

5

Clearance X = A - B, where ‘B’ is the dimension of gauge B. Calculate the optimum thickness ‘T’ of distance piece 12 as follows: T = C + X ± 0.1 mm

JS00660

9803/6410

Issue 1

Section F


10 - 9

Section F 10 - 9

Adjustments (cont’d) Determining the Thickness of Distance Piece 12 (cont’d) 6

Select a suitable distance piece from the nine detailed below.

Distance piece 12 Classification Symbol AA

T Min

Max

A

3.70 mm (0.146 in)

3.80 mm (0.150 in)

B

3.80 mm (0.150 in)

3.90 mm (0.154 in)

C

3.90 mm (0.154 in)

4.00 mm (0.157 in)

D

4.00 mm (0.157 in)

4.10 mm (0.161 in)

E

4.10 mm (0.161 in)

4.20 mm (0.165 in)

F

4.20 mm (0.165 in)

4.30 mm (0.169 in)

X

3.40 mm (0.134 in)

3.50 mm (0.138 in)

Y

3.50 mm (0.138 in)

3.60 mm (0.142 in)

Z

3.60 mm (0.142 in)

3.70 mm (0.146 in)

JS01480

Determining the Thickness of Thrust Bearing 20 This procedure must be carried out if any of the following components have been replaced: hub 1, spindle 2, carrier 3 assembly, ring gear 4, coupling gear 8, cover 13, pin 17 or parallel pins 27. 1

Install one of the two thrust bearings 20 into coupling gear 8. Use the thinnest distance piece 12 at this time. Install coupling 19 onto shaft 102. Insert sun gear 7 into coupling 19. Insert the carrier 3 assembly into hub 1 having first set up the assembly as in When Assembling, Step 6. Correctly engage the teeth of ring gear 5 and cluster gear 6.

2

Carry out step 7 of When Assembling.

3

Install thrust bearing adjustment jig C (see Service Tools, Section 1) onto hub 1 and lightly secure with two M12 hexagon socket bolts. Measure dimension ’A’ with micrometer A as shown. Measure dimension ‘C’ of cover 13.

4

Determine dimension ‘X’, the distance between the end of carrier 3 and ring gear 4, as follows: X=B-A where ‘B’ is the dimension of bearing adjustment jig C. JS00680

9803/6410

Issue 1

Section F


10 - 10

Section F 10 - 10

Adjustments (cont’d) Determining the Thickness of Thrust Bearing 20 (cont’d) 5

Calculate the optimum thickness ‘T’ of thrust bearing 20 as follows: T = (C - X) - (0.3 to 0.6) mm

6

Select a suitable thrust bearing from the table below.

Thrust bearing 20 Classification Symbol BB

T

1

5.7 ± 0.05 mm (0.224 ± 0.002 in)

2

6.0 ± 0.05 mm (0.236 ± 0.002 in)

3

6.3 ± 0.05 mm (0.248 ± 0.002 in)

9803/6410

JS01490

Issue 1

Section J

Track and Running Gear

Section J

i

i

Contents

9803/6410

Page No.

Torque Specifications

1-1

Idler Wheel and Recoil Unit Removal Replacement

2-1 2-2

Idler Wheel Dismantling Assembly Wear Limits

3-1 3-2 4-1

Recoil Unit Dismantling Assembly

5-1 5-2

Grease Cylinder Dismantling Assembly

6-1 6-1

Drive Sprocket Removal Replacement Wear Limits

7-1 7-2 8-1

Top Roller Removal Replacement Dismantling Assembly Wear Limits

9-1 9-2 10 - 1 10 - 3 11 - 1

Bottom Roller Removal Replacement Dismantling Assembly Wear Limits

12 - 1 12 - 2 13 - 1 13 - 3 14 - 1

Issue 1

Section J

Track and Running Gear Torque Specifications

1-1

Component

Nm

kgf m

lbf ft

Drive sprocket fastening bolts

267 - 312

27.2 - 31.8

197 - 230

Idler wheel mounting bolts

267 - 312

27.2 - 31.8

197 - 230

Top roller mounting bolts

267 - 312

27.2 - 31.8

197 - 230

Bottom roller mounting bolts

267 - 312

27.2 - 31.8

197 - 230

Recoil spring installation bolt

267 - 312

27.2 - 31.8

197 - 230

Grease cylinder mounting bolts

267 - 312

27.2 -31.8

197 - 230

Section J 1-1

Note: Apply Loctite 262 (JCB Part No. 4101/0502) to the threads of the above bolts.

9803/6410

Issue 1

Section J

Track and Running Gear Idler Wheel and Recoil Unit

2-1

Section J 2-1

Removal 1

Slacken the check valve to bleed out grease.

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

2

Disconnect the track link (see Track Motor/Reduction Gearbox, Removal and Replacement, Section F). Move the idler wheel and recoil assembly to the end of the undercarriage using a bar.

! WARNING Stand clear and to one side of the track while you remove the master pin. When the master pin is removed the track could fall forward and injure you. TRACK 1-1

3

Fasten a sling around the idler wheel and recoil assembly and remove it from the undercarriage.

4

Remove the bolts and remove the idler wheel from the recoil unit.

! WARNING

RECOIL UNITS ARE DANGEROUS. They must not be dismantled without using suitable tools to compress the spring safely. The spring pressure can cause serious injury if suddenly released. Scrap units must be made harmless by compressing the spring in a hydraulic press and cutting through the end of the shaft before slowly releasing the pressure. TRACK 1-10

Note: See Grease Cylinder, Removal for Recoil Spring dismantling details.

9803/6410

Issue 1

Section J 2-2

Track and Running Gear Idler Wheel and Recoil Unit

Section J 2-2

Replacement 1

Before fitting the idler wheel, check the oil level at A. If required, top up with the specified oil (see section 3). Assemble the idler wheel to the recoil unit and fit the mounting bolts.

2

Fasten a sling around the idler wheel and recoil assembly and enter it into the undercarriage.

3

Position the idler wheel in the undercarriage using a bar.

4

Connect the track link (see Track Motor/Reduction Gearbox, Removal and Replacement, Section F). Apply grease through the check valve to adjust the track tension (see Checking/Adjusting the Track Tension, Section 3).

9803/6410

Issue 1

Section J 3-1


Section J

Idler Wheel

3-1

Dismantling 1

Carry out steps 1 to 4 of Idler Wheel and Recoil Unit, Removal. Clean the idler wheel with a suitable solvent. Remove the plug A from hub B and drain the oil.

A

B

2

On one side of the unit only, remove the wire clip E or roll pin F and separate the hub C from shaft D. F D C E H

3

Remove 'O'-ring I from shaft D. Pull out the shaft D from the idler wheel G.

D I

C

G

4

Remove the wire clip E or roll pin F and separate hub C from shaft D. Remove 'O'-ring I from shaft D. F D I C E

9803/6410

Issue 1

Section J 3-2


Section J

Idler Wheel

3-2


Remove floating seal J from each hub C using a pry bar.

C J

J

C

J 6

G

Remove floating seal J from each side of idler wheel G using a pry bar.

J J

J

7

If badly worn or damaged, remove the bushes K from idler wheel G using a press or puller.

K G

Protect parts from moisture and dust if left dismantled for some time.

K

Assembly 1

Clean all parts thoroughly in a suitable solvent. Dry shaft and bore of idler wheel using compressed air in a place free of dust and moisture. Check components for wear as detailed under Wear Limits. Polish out scratches and roughness using an oil stone. Then apply a coat of engine oil to all parts.

L

K

G

Carefully drive the new bushes K into the idler wheel G, using a suitable dolly L.

9803/6410

Issue 1

Section J 3-3


Section J

Idler Wheel

3-3


Apply a coating of grease and install a new floating seal J into each side of the idler wheel G.

J

G

J J

G

J

3

C

Apply a coating of grease and install a new floating seal J into hub C.

J

J

C

4

Grease a new 'O'-ring I and install on one end only of shaft D. Install shaft D into hub C. Fit new wire clip E or roll pin F.

F D I C E

5

Coat shaft D with grease. Clean the metallic face of the seal, coat the metallic face with engine oil and insert the shaft into the idler wheel G. D

G 9803/6410

Issue 1

Section J 3-4


Section J

Idler Wheel

3-4


Apply grease to a new 'O'-ring I and install it on the shaft D. Clean the metallic face of the seal, coat the metallic face with engine oil and install the hub C onto the shaft D. Fit new wire clip E or roll pin F.

F G D I

Wrap sealing tape around the plug A with one thread remaining uncovered. Insert this plug but leave the other one out until after testing.

C E A

7

8

Using extreme care to prevent water entering the assembly, lower it into a tank of water. Connect compressed air at M and apply pressure of 1.9 bar (28 lbf/in2). Check for air bubbles.

M

Remove the assembly from the tank. Dry with compressed air. Add engine oil via plug A aperture. Install plug using an appropriate pipe sealant.

A

9

Carry out steps 1 to 4 of Idler Wheel and Recoil Unit, Replacement.

9803/6410

Issue 1

Section J


Section J

Idler Wheel

4-1

4-1

Wear Limits Item

Dimension

Machine

Standard Size mm in

Service Limit mm in

a

JS130 JS160

510 494

20.08 19.45

506 490

19.92 19.29

Build up or renew Build up or renew

b

JS130 JS160

19 21

0.75 0.83

-

-


Wheel Width

c

JS130 JS160

68.6 83.8

2.70 3.31

64.5 80

2.54 3.15


Shaft Diameter

d d

JS130 JS160

55 65

2.17 2.56

54.6 64.5

2.15 2.54

Renew Renew

Bush Bore

d d

JS130 JS160

55 65

2.17 2.56

55.9 65.8

2.20 2.59

Renew Renew

Length over Bush/Seal

e e

JS130 JS160

55 69

2.17 2.72

54.6 68.6

2.15 2.70

Renew Renew

Hub

f f

JS130 JS160

19.8 12.4

0.78 0.49

19.3 11.9

0.76 0.47

Renew Renew

Wheel Diameter

9803/6410

Action

Issue 1

Section J


Section J

Recoil Unit

5-1

5-1

Dismantling 1

Carry out steps 1 to 4 of Idler Wheel and Recoil Unit, Removal.

! WARNING

RECOIL UNITS ARE DANGEROUS. They must not be dismantled without using suitable tools to compress the spring safely. The spring pressure can cause serious injury if suddenly released. Scrap units must be made harmless by compressing the spring in a hydraulic press and cutting through the end of the shaft before slowly releasing the pressure. TRACK 1-10

2

Place the recoil unit in the spring compression jig (see Service Tools, Section 1), yoke E uppermost. Raise hydraulic jack A to compress recoil spring B.

B

A

3

Pull out roll pin C and remove castellated nut D. Lower jack A to release the pressure on recoil spring B. Remove the recoil unit component parts from the jig: yoke E first, then spring B and, finally spring guide/retainer F.

B

E

D C

F

9803/6410

Issue 1

Section J


Section J

Recoil Unit

5-2

5-2

Assembly 1

a

Position the recoil unit component parts in the spring compression jig (see Service Tools, Section 1), starting with spring guide/retainer F, then spring B and yoke E. Raise hydraulic jack A to compress recoil spring B. B

b Install castellated nut D on the threaded section of spring guide/retainer F which protrudes through yoke E, fully tighten and then install roll pin C. c

A

Lower jack A to allow recoil spring B to expand and then remove the recoil unit from the jig.

B

E

D C

F JS02460

2

Carry out steps 1 to 4 of Idler Wheel and Recoil Unit, Replacement.

9803/6410

Issue 1

Section J 6-1

Track and Running Gear Grease Cylinder

Section J 6-1

Dismantling 1

Carry out steps 1 to 3 of Idler Wheel and Recoil Unit, Removal. Remove the lower roller immediately below the grease cylinder (see Bottom Roller, Removal).

2

Remove bolts A and washers B and remove grease cylinder C through the bottom of side frame D.

JS01520

Assembly Assembly is the reverse of dismantling. When Assembling 1

Before installing grease cylinder C, remove check valve E and use a press (as shown) to fully retract the cylinder and expel the grease. Refit the check valve.

JS01530

2

Apply Loctite 262 to the threads of mounting bolts A.

3

When installing the grease cylinder, make sure it is orientated so that check valve E is facing outwards to the side of the machine.

4

Tighten bolts A to a torque of 267 - 312 Nm (197 230 lbf ft, 27 - 31 kgf m).

9803/6410

Issue 1

Section J

Track and Running Gear Drive Sprocket

7-1

Section J 7-1

Removal 1


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

2

Disconnect the track link (see Track Motor/Reduction Gearbox, Removal and Replacement).

! WARNING Stand clear and to one side of the track while you remove the master pin. When the master pin is removed, the track could fall forward and injure you. TRACK 1-1

3

Lift the side of the undercarriage high enough to permit drive sprocket removal. Support with wooden blocks.

4

Support the drive sprocket, remove the bolts and lever it away from the gearbox unit.

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Issue 1

Section J 7-2

Track and Running Gear Drive Sprocket

Section J 7-2

Replacement 1

Support the sprocket and position it on the gearbox. Install the bolts and washers, using Loctite 262 on the bolt threads. Tighten the bolts in a diagonal sequence to a torque of 267 - 312 Nm (197 - 230 lbf ft, 27 - 31 kgf m).

2

Remove the wooden blocks. Connect the track link.

3

Apply grease through the check valve to adjust the track tension (see Checking/Adjusting the Track Tension, Section 3).

9803/6410

Issue 1

Section J


Section J

Drive Sprocket

8-1

8-1

Wear Limits Item

Dimension

Machine

Standard Size mm in

Service Limit mm in

Action

Width

a

JS130 JS160

58.9 66

2.32 2.60

53 60

2.09 2.36

Renew Renew

Diameter

b

JS130 JS160

585 582

23.01 22.93

579 577

22.78 22.70

Renew Renew

Diameter

c

JS130 JS160

584 659

25.67 25.95

646 653

25.43 25.71

Renew Renew

Diameter

d

JS130 JS160

636 645

25.02 25.38

-

-

Renew Renew

Centres

P

JS130 JS160

171 190

6.75 7.48

-

-

Renew Renew

9803/6410

Issue 1

Section J

Track and Running Gear Top Roller

9-1

Section J 9-1

Removal 1


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

2

Jack up the track high enough to permit roller removal. Put wooden blocks between track link and side frame.

3

Loosen but do not remove the mounting bolts. Tap the upper roller with a copper mallet to separate it from the side frame.

4

Fasten a sling to the upper roller. Remove the mounting bolts and lift the upper roller clear.

9803/6410

Issue 1

Section J 9-2


Section J 9-2

Replacement 1

Before fitting the roller, check the oil level and, if necessary, top up (see Fluids and Lubricants, Section 3). Install the plug using an appropriate pipe thread sealant.

2

With the track supported as shown under Removal, step 2, install the roller. Apply Loctite 262 to the threads and fit the mounting bolts.

3

Remove the wooden blocks and jack.

4


9803/6410

Issue 1

Section J 10 - 1


Section J

Top Roller

10 - 1

Item

Part Name

A

Roller

B

Plug

C

Circlip

D

Cover

E

‘O’-ring

F

Bolt

G

Thrust plate

H

Shaft

I

Floating seal

J

Bush

K

Bush

L

Mounting bracket

JS01540

9803/6410

Issue 1

Section J


10 - 2

Section J

Top Roller

10 - 2

Dismantling 1

Clean the upper roller A with an appropriate detergent. Remove the plug B from the cover and drain the oil.

A

B

2

A

Remove the circlip C, and remove cover D. From cover D, remove 'O'-ring E and discard.

E D C

3

Remove bolt F, and the thrust plate G from the end of the shaft.

G A

F

4

Pull the upper roller A from the shaft H. A

H

9803/6410

Issue 1

Section J


10 - 3

Section J

Top Roller

10 - 3


Remove the floating seal I from the upper roller A. A I

6

If badly worn or damaged, remove the bushes J and K, from the roller A.

K A

J

7

Remove floating seal I from bracket L using a pry bar. Protect parts from moisture and dust if left dismantled for some time.

I H L

H

I L

Assembly 1

L

Clean all parts thoroughly in a suitable solvent. Dry shaft and bore of roller using compressed air in a place free of dust and moisture. Check components for wear as detailed under (Wear Limits). Polish out scratches and roughness using an oil stone. Then apply a coat of engine oil to all parts.

H

If a new shaft or bracket are required, press-fit shaft H into bracket L, taking care to protect the threads of the tapped holes in the end of the shaft.

9803/6410

Issue 1

Section J


10 - 4

Section J

Top Roller

10 - 4


Using a jig M, and hammer, insert the bushes J and K into the roller A.

JS01550

3

Install a new floating seal I into the roller A. A

Coat the metallic face of the seal with engine oil.

I

4

Install a new seal I into the bracket L. Coat the metallic face of the seal with engine oil.

I H L I

H L

5

Coat the shaft H with grease. Install the roller A onto the shaft H.

A

H

9803/6410

Issue 1

Section J 10 - 5


Section J 10 - 5


Apply grease to the inside face of thrust plate G and install it on the shaft using bolts F.

JS01560

7

Apply grease to a new 'O'-ring E and install it onto cover D. Install the cover D to the roller A. Retain with circlip C.

JS01570

8

Remove plug B and connect compressed air pipe V to the port. Using extreme care to prevent water entering the assembly, lower it into a tank of water. Apply air pressure of 1.9 bar (28 lbf/in2) and check that there are no bubbles leaking from the unit. If leakage occurs dismantle and re-assemble, taking extra care when fitting new seals.

JS01580

9

Remove the assembly from the tank. Dry with compressed air. Fill with oil (see Fluids and Lubricants, Section 3) and install plug B using an appropriate pipe thread sealant.

B

9803/6410

Issue 1

Section J

Track and Running Gear Bottom Roller

12 - 1

Section J 12 - 1

Removal 1


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

2

Remove the bolts securing the mounting brackets to the side frame.

3

Lift the side of the undercarriage high enough to permit bottom roller removal. Support with wooden blocks. Tap the bottom roller with a copper mallet to separate it from the side frame.

4

Remove the roller.

9803/6410

Issue 1

Section J 12 - 2

Track and Running Gear Bottom Roller

Section J 12 - 2

Replacement 1

Before fitting the roller, fill with oil (see Fluids and Lubricants, Section 3). Install the plug using an appropriate pipe thread sealant. With the undercarriage lifted and supported with wooden blocks, position the roller on the track link as shown. Align the holes in the mounting brackets with the tapped holes in the undercarriage.

2

Lower the undercarriage sufficient to allow the mounting bolts to be installed.

3

Apply Loctite 262 to the threads and install the mounting bolts. Tighten to a torque of 267 - 312 Nm (197 - 230 lbf ft, 27 - 31 kgf m).

4


9803/6410

Issue 1

Section J 13 - 1


Section J

Bottom Roller

13 - 1

Item

Part Name

A

Plug

B

Locking wires

C

Shaft

D

Mounting bracket

E

Mounting bracket

F

Floating seal

G

‘O’-ring

H

Roller (outer flange)

J

Roller (inner flange)

K

Bushing

JS01590

9803/6410

Issue 1

Section J 13 - 2


Section J

Bottom Roller

13 - 2

Dismantling 1

Clean the roller with a suitable solvent. Remove the plug A and drain the oil.

A

2

Remove locking wire B from each end of shaft C. Remove mounting brackets D and E from shaft C.

E

B

B

C

A D

3

Using a pry bar, remove floating seals F from brackets D and E and discard.

D, E

F

4

Remove and discard 'O'-rings G from shaft C. Pull out shaft C from roller H or J.

G C J

G H

9803/6410

Issue 1

Section J


13 - 3

Section J

Bottom Roller

13 - 3


Remove floating seals F from roller H or J using a pry bar. J

F H F

6

If badly worn or damaged, remove and discard bushes K from roller H or J, using a press or puller. Otherwise do not disturb. Protect parts from moisture and dust if left dismantled for some time.

J

K H K

Assembly 1

Clean all parts thoroughly in a suitable solvent. Dry shaft and bore of roller using compressed air in a place free of dust and moisture.

J

Check components for wear as detailed under Wear Limits. Polish out scratches and roughness using an oil stone. Then apply a coat of engine oil to all parts. K

If being replaced, install bushes K into roller H or J, using a dolly and hammer.

H K

2

Install new floating seals F into roller H or J. J

F

H F 9803/6410

Issue 1

Section J 13 - 4


Section J

Bottom Roller

13 - 4


Coat shaft C with grease. Insert the shaft into roller H or J. Apply grease to new 'O'-rings G and install them on shaft C. G C

J

G

H

4

Install new floating seals F into brackets D and E. Coat the metallic face of each seal with engine oil. D,E

F

5

Press mounting brackets D and E onto shaft C and partially insert new locking wires B.

B

E

Wrap sealing tape around one plug A with one thread remaining uncovered. Install this plug, but leave the other one out until after pressure testing (step 6).

B

C

D A

6

Connect compressed air pipe V to the vacant plug A port. Using extreme care to prevent water entering the assembly, lower it into a tank of water. Apply air pressure of 1.9 bar (28 lbf/in2) and check that there are no bubbles leaking from the unit. If leakage occurs dismantle and re-assemble, taking extra care when fitting new seals.

JS01600

9803/6410

Issue 1

Section J 13 - 5


Section J

Bottom Roller

13 - 5


Complete the installation of locking wires B by tapping with a hammer B

B

8

Fill the unit with oil (see Fluids and Lubricants, Section 3) and install plug A using an appropriate pipe thread sealant.

A

9803/6410

Issue 1

Section J


Section J

Bottom Roller

14 - 1

14 - 1

Wear Limits Item

Standard Size mm in

Service Limit mm in

Action

JS130 JS160

140 150

5.51 5.90

132 142

5.20 5.59

Renew Renew

b

JS130 JS160

15 15

0.59 0.59

-

-

Renew Renew

Inner flange width

c

JS130 JS160

72 86

2.84 3.39

66 80

2.60 3.15

Renew Renew

Outer flange width

d

JS130 JS160

146 173

5.75 6.81

152 179

5.98 7.05

Renew Renew

Shaft diameter

e

JS130 JS160

50 60

1.97 2.36

49.5 58.9

1.95 2.32

Renew Renew

Bushing diameter

e

JS130 JS160

50 60

1.97 2.36

50.8 61

2.0 2.4

Renew Renew

Length

f

JS130 JS160

53 65

2.09 2.56

52.6 64

2.07 2.52

Renew Renew

Collar

g

JS130 JS160

24.4 28.7

0.96 1.13

23.9 28.2

0.94 1.11

Renew Renew

Roller diameter

Dimension

Machine

a

Inner Flange

Outer Flange

9803/6410

Issue 1

Engine

Section K

Section K

i

i

Contents Technical Data

9803/6410

Page No. 1-1

Issue 1

Section K

Engine

Section K

1-1

1-1

Technical Data Type Model - JS130 - JS160 Bore Stroke Swept Volume Compression Ratio Compression Pressure at 200 rev/min Firing Order Valve Clearance (cold) - Inlet - Exhaust Dry Weight (approximately)

Isuzu A4BG1T, 4 cylinder in-line, turbocharged, direct injection diesel. A4BG1T-S1 A4BG1T-S2 105 mm (4.13 in) 125 mm (4.92 in) 4329 cm3 (264.2 in3) 17.0 : 1 31 bar (450 lbf/in2) 1, 3, 4, 2 0.4 mm (0.016 in) 0.4 mm (0.016 in) 361 kg

Fuel System Max. Speed (No Load) - JS130 - JS160 Injection Timing (static) Injector Opening Pressure

Less than 2570 rev/min Less than 2571 rev/min 12° BTDC 180 bar (2630 lbf/in2)

Induction System Air Cleaner Type

2 stage, dry element with in-cab warning indicator.

For further details, see engine service manual, Publication No.

9806/2120

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

9803/6410

Issue 1

Factory PDF Jcb Js130 Js160 _Repair_Workshop

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