General Information Care & Safety Routine Maintenance Attachments
Service Manual 3CX, 4CX, & Variants
Body & Framework Electrics Controls Hydraulics
From M/c No. 400001 To 460000
Transmision Brakes
Publicación No. 9803/3260 Issue 9
Engine
1 2 3 A B C D E F G 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 machine.
= = =
General Information - includes torque settings and service tools. Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. Routine Maintenance - includes service schedules and recommended lubricants for all the
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. With the exception of slewing operations 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.
*
Throughout this manual abbreviations are used to identify various machine types. The abbreviations and their full explanation are as follows: AWS 2WS 2WD 4WD
*
-
All Wheel Steer 2 Wheel Steer 2 Wheel Drive 4 Wheel Drive
The contents page at the beginning of each section will clearly identify using parenthesis () when a procedure/description is pertinent to a particular machine, for example: Loader Arm Safety Strut (AWS Machines) - Fitting and Removing Loader Arm Safety Strut (2WS Machines) - Fitting and Removing
9803/3260
Issue 2*
Section 1
General Information
Section 1
i
i
Contents Machine Identification Plate
1-1
Typical Machine Identification Number
1-1
Typical Engine Identification Number
1-1
Unit Identification
1-2
Torque Settings
2-1
Service Tools Numerical List
3-1
Service Tools - Attachments * - Body & Framework - Electrics - Hydraulics - Transmission - Engine Sealing and Retaining Compounds
9803/3260
Page No.
4-1 4-1 4-5 4-6 4 - 10 4 - 13 5-1
Issue 4*
Section 1
General Information
Section 1
1-1
1-1
Machine Identification Plate Your machine has an identification plate X mounted on the loader tower as shown. The serial numbers of the machine and its major units are stamped on the plate. The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered. The machine and engine serial numbers can help identify exactly the type of equipment you have.
Typical Machine Identification Number SLP
3CX
A
B
T
S
R
E
C
D
E
F
0430001 G
A World Manufacturer Identification B Machine Model C Steer Type (T= 2WS, F=4WS) D Build Type (S=Sideshift, C=Centremount, L=Loader) E Year of Manufacture: R = 1994 S = 1995 T = 1996 V = 1997 W = 1998 X = 1999 Y = 2000
1 = 2001 2 = 2002 3 = 2003 4 = 2004 5 = 2005 6 = 2006 7 = 2007
F Manufacturer Location (E = England) G Machine Serial Number:
Typical Engine Identification Number AB
50262
U
500405
P
B
C
D
E
A
A Engine Type AB = 4 cylinder turbo B Build Number C Country of Origin D Engine Sequence Number E Year of Manufacture
S218130
9803/3260
X Issue 2
Section 1
General Information
Section 1
1-2
1-2
Unit Identification Engine Serial Plate
* Front Axle Serial Plate (All Wheel Steer Machines)
The engine serial number is stamped on a label which is fastened to the left side of the cylinder block (looking from the rear).
The front axle serial number is stamped on a plate mounted on the axle.
S145300
Syncro Shuttle Serial Plate The Syncro Shuttle serial number is stamped on a label which is mounted to the rear face of the unit.
* Front Axle Serial Plate (2 Wheel Steer Machines) The front axle serial number is stamped on a plate mounted on the the axle.
S088471
9803/3260
Issue 2*
Section 1
General Information
1-3
Section 1 1-3
Unit Identification (cont'd) Rear Axle Serial Plate (All Wheel Steer Machines) The rear axle serial number is stamped on a plate mounted to the front face of the axle, as shown.
* Powershift Serial Plate The powershift serial number is stamped on a plate which is mounted to the side of the unit as shown.
S146790
S143050
Rear Axle Serial Plate (2 Wheel Steer Machines) The rear axle serial number is stamped on a plate mounted to the front face of the axle, as shown.
S156570
9803/3260
Issue 2*
Section 1
Section 1
General Information
2-1
2-1
Torque Settings Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third. UNF Grade 'S' Bolts Bolt Size in
(mm)
Hexagon (A/F) in
1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 11/4 11/2
(6.3) (7.9) (9.5) (11.1) (12.7) (14.3) (15.9) (19.0) (22.2) (25.4) (31.7) (38.1)
7/16 1/2 9/16 5/8 3/4 13/16 15/16 11/8 15/16 11/2 17/8 21/4
Nm 14 28 49 78 117 170 238 407 650 970 1940 3390
Torque Settings kgf m
lbf ft
1.4 2.8 5.0 8.0 12.0 17.3 24.3 41.5 66.3 99.0 198.0 345.0
10 20 36 58 87 125 175 300 480 715 1430 2500
Torque Settings kgf m
lbf ft
Metric Grade 8.8 Bolts Bolt Size (mm) M5 M6 M8 M10 M12 M16 M20 M24 M30 M36
(5) (6) (8) (10) (12) (16) (20) (24) (30) (36)
Hexagon (A/F) mm 8 10 13 17 19 24 30 36 46 55
Nm 7 12 28 56 98 244 476 822 1633 2854
0.7 1.2 3.0 5.7 10 25 48 84 166 291
5 9 21 42 72 180 352 607 1205 2105
Rivet Nut Bolts/Screws Bolt Size
M3 M4 M5 M6 M8 M10 M12
(mm)
Torque Settings (for steel rivet nuts) Nm kgf m lbf ft
(3) (4) (5) (6) (8) (10) (12)
1.2 3.0 6.0 10.0 24.0 48.0 82.0
0.12 0.3 0.6 1.0 2.5 4.9 8.4
0.9 2.0 4.5 7.5 18.0 35.5 60.5
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
9803/3260
Issue 1 SXXXXXX
SXXXXXX
SXXXXXX
Section 1
General Information
3-1
3-1
Service Tools Numerical List 1406/0011 1406/0014 1406/0018 1406/0021 1406/0029 1604/0003 1604/0004 1604/0006 1604/0008 1606/0003 1606/0004 1606/0007 1606/0008 1606/0009 1606/0012 1606/0014 1606/0015 1606/0017 1612/0006 2401/0103 4101/0202 4101/0402 4101/0502 4101/0602 4102/0502 4102/1201 4102/1901 4104/0101 4104/0102 4104/1538 816/00017 816/00189 816/00190 816/00193 816/00196 816/00197 816/00294 816/00439 816/00440 816/15007 816/15008 816/15118 816/20008 816/20013 816/50005 816/50043 816/55038 816/55040 816/60096 825/00410 825/99833 826/01099 826/01101 826/01102 826/01103 826/01104 826/01105 892/00011 892/00039 892/00041 892/00047 892/00048 892/00049 9803/3260
Section 1
Bonded Washer Bonded Washer Bonded Washer Bonded Washer Bonded Washer Male Adapter Male Adapter Male Adapter Adapter Male Adapter Male Adapter Male Adapter Male Adapter Male Adapter Male Adapter Male Adapter Male Adapter Male Adapter Adapter 'O' Ring Lock and Seal Loctite 932 Loctite 262 High Strength Retainer High Strength Gasketing Multi-Gasket Loctite 577 Activator N (Aerosol) Activator N (Bottle) JCB Cleaner & Degreaser Adapter Blanking Cap Blanking Cap Blanking Cap Blanking Cap Blanking Cap Blanking Cap Male Adapter Male Adapter Male Adapter Male Adapter Pressure Test Adapter Adapter Adapter Adapter Adapter Pressure Test 'T' Adapter Pressure Test 'T' Adapter Adapter Crowfoot Wrench Adapter for 825/00410 Rivet Nut Rivet Nut Rivet Nut Rivet Nut Rivet Nut Rivet Nut Spool Clamp Spool Clamp & A.R.V. Clamp De-glazing Tool Adapter Adapter Adapter
Page No.
Page No. 4-7 4-7 4-7 4 - 6, 4 - 7 4-7 4-7 4-7 4 - 6, 4 - 7 4-6 4-7 4-7 4-7 4-7 4-7 4 - 6, 4 - 7 4-7 4 - 6, 4 - 7 4-7 4-6 4-7 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 4-8 4-8 4-8 4-8 4-8 4-8 4-8 4-7 4-7 4-7 4-7 4-6 4-6 4-6 4-8 4-8 4-6 4-6 4-8 4-5 4-5 4-1 4-1 4-1 4-1 4-1 4-1 4-8 4-8 4 - 13 4-8 4-8 4-8
892/00051 892/00055 892/00056 892/00057 892/00058 892/00059 892/00060 892/00071 892/00074 892/00075 892/00076 892/00077 892/00078 892/00137 892/00167 892/00174 892/00176 892/00177 892/00178 892/00179 892/00180 892/00182 892/00223 892/00224 892/00225 892/00231 892/00232 892/00233 892/00253 892/00255 892/00256 892/00257 892/00258 892/00259 892/00260 892/00261 892/00262 892/00263 892/00264 892/00265 892/00268 892/00269 892/00270 892/00271 892/00272 892/00273 892/00274 892/00275 892/00276 892/00277 892/00278 892/00279 892/00282 892/00283 892/00284 892/00285 892/00286 892/00293 892/00294 892/00295 892/00298 892/00301
Adapter 4-8 Blanking Plug 4-8 Blanking Plug 4-8 Blanking Plug 4-8 Blanking Plug 4-8 Blanking Plug 4-8 Blanking Plug 4-8 Male Adapter 4-7 Female Connector 4-8 Female Connector 4-8 Female Connector 4-8 Female Connector 4-8 Connector 4-6 Micro-Bore Hose 1/4in. BSP, 3 Metres 4 - 7 Gland Seal Fitting Sleeve 4-9 Measuring Cup 4 - 12 Extractor 4-9 Extractor Collets 4-9 Extractor Collets 4-9 Bearing Press 4 - 10 Seal Fitting Tool 4-9 Bearing Pad Driver 4 - 11 Hand Pump 4-7 Impulse Extractor 4 - 12 Adapter for Extractor 4 - 12 Gland Seal Fitting Sleeve 4-9 Gland Seal Fitting Sleeve 4-9 Gland Seal Fitting Sleeve 4-9 Pressure Test Kit 4-6 Pressure Test Adapter 4-6 Pressure Test Adapter 4-6 Pressure Test Adapter 4-6 Pressure Test Adapter 4-6 Pressure Test Adapter 4-6 Pressure Test Adapter 4-6 Pressure Test Adapter 4-6 Pressure Test 'T' Adapter 4 - 6, 4 - 7 Pressure Test 'T' Adapter 4-6 Pressure Test 'T' Adapter 4-6 Pressure Test 'T' Adapter 4-6 Flow Monitoring Unit 4-6 Sensor Head 4-6 Load Valve 4-6 Adapter 4-6 Adapter 4-6 Sensor Head 4-6 Adapter 4-7 Adapter 4-6 Adapter 4-6 Adapter 4-6 Gauge 4-7 Gauge 4-7 Shunt 4-5 Tool Kit Case 4-5 Tachometer 4-5 Hydraulic Oil Temperature Probe 4-5 Surface Temperature Probe 4-5 Connector Pipe 4-6 Connector Pipe 4-6 End Float Setting Tool 4 - 10 Fluke Meter 4-5 Flow Test Adapter 4 - 10
Issue 5
Section 1
General Information
Section 1
3-2
3-2
Service Tools Numerical List (cont'd) Page No.
*
892/00302 892/00304 892/00309 892/00333 892/00334 892/00335 892/00706 892/00812 892/00817 892/00818 892/00819 892/00822 892/00825 892/00836 892/00842 892/00843 892/00844 892/00845 892/00846 892/00847 892/00848 892/00849 892/00882 892/00891 926/15500 990/00083 992/00800 992/01003 992/04000 992/04800 992/07601 992/07603 992/07604 992/07606 992/07607 992/07609 992/07614 992/00800 992/09100 992/09200 992/09300 992/09400 992/09500 992/09600 992/09700 992/10000 992/10100 992/10200 992/12300 992/12400 992/12600 992/12800 992/12801 993/59300 993/59500 993/68100 993/69800 993/85700 4104/1310
9803/3260
Flow Test Adapter Flow Test Adapter ARV Test Kit (Excavator Valve) Heavy Duty Socket Gland Seal Fitting Tool ARV Cartridge Removal Tool Test Probe Drive Coupling Spanner Heavy Duty Socket Heavy Duty Socket Heavy Duty Socket Splined Bolt Socket End Float Setting Tool Lifting Wire Assembly Glass Lifter Folding Stand Long Knife Cartridge Gun Glass Extractor (Handles) Nylon Spatula Wire Starter Braided Cutting Wire Alternator Pulley Socket Wheel Hub Seal - Fitting Tool Rubber Spacer Blocks End Float Setting Tool Extractor Plug Torque Multiplier Flange Spanner Spanner Replacer - Bearing Cup Replacer - Bearing Cone Measuring Cup - Pinion Bearing Preload Spacer Bearing Adapter Bearing Adapter Pivot Pin Extractor Tool Spool Clamp Charging Tool Ram Spanner Ram Spanner Ram Spanner Ram Spanner Ram Spanner Ram Spanner Spool & A.R.V. Clamp Body 12V Mobile Oven Static Oven - 2 Cartridge Static Oven - 6 Cartridge Cut-Out Knife "L" Blades 2/4WD Pressure Test Tool Impulse Extractor Adapter Slide Hammer Kit Seal Kit Battery Tester Hand Cleaner
4 - 10 4 - 10 4-7 4 - 11 4-9 4-7 4-7 4 - 10 4 - 11 4 - 11 4 - 11 4 - 12 4 - 10 4 - 13 4-2 4-2 4-3 4-2 4-3 4-4 4- -3 4- -3 4-5 4 - 12 4-4 4 - 10 4-4 4-7 4 - 12 4 - 12 4 - 11 4 - 11 4 - 11 4 - 11 4 - 11 4 - 11 4 - 11 4-4 4-8 4-1 4-8 4-8 4-8 4-8 4-8 4-8 4-8 4-7 4-2 4-2 4-2 4-3 4-3 4 - 10 4 - 12 4-4 4-6 4-5 4-2
The following parts are replacement items for kits and would normally be included in the kit numbers quoted on pages 1/3-1 and 1/3-2. Service Tools Numerical List Replacement item for kit no. 892/00180 892/00181
Page No. 4-9
Replacement items for kit no. 892/00253 892/00201 Replacement Gauge 892/00202 Replacement Gauge 892/00203 Replacement Gauge 892/00254 Replacement Hose
4-6 4-6 4-6 4-6
Replacement items for kit no. 992/09200 05/900137 Spring 1406/0011 Bonded Washer 1/4 in. BSP, 2 off 1410/0001 Washer 1604/0002 Adapter 1/4in. x 1/4in. BSP, 1 off 2401/0006 'O' Ring 2401/0104 'O' Ring 823/00242 Washer 823/00248 Washer 826/00696 Screw 892/00135 Adapter 892/00150 Pressure Gauge 992/09206 Bleed Screw 992/09207 Snap Ring
4-1 4-1 4-1 4-1 4-1 4-1 4-1 4-1 4-1 4-1 4-1 4-1 4-1
Hammermaster 260 only 892/00823 Charging Device 892/00824 Adapter
4-1 4-1
Replacement items for kit no. 892/00309 892/00340 Test Block Body 892/00341 Setting Body 892/00343 Spanner 892/00345 Anti-Cavitation Lock Out Bung 993/68300 Adjusting Pin
4-7 4-7 4-7 4-7 4-7
Replacement items for kit no. 993/68100 993/68101 Slide Hammer 993/68102 End Stops 993/68103 Adaptor - M20 x 5/8" UNF 993/68104 Adaptor - M20 x 1" UNF 993/68105 Adaptor - M20 x M20 993/68106 Adaptor - M20 x M24 993/68107 Bar - M20 x M20 X 800MM 993/68108 Adaptor - M20 x 7/8" UNF 993/68109 Adaptor - M20 x M12 993/68110 Adaptor - M20 x 5/8" UNF (Shoulder) 993/68111 Adaptor - M20 x 1/2" UNF
4-4 4-4 4-4 4-4 4-4 4-4 4-4 4-4 4-4 4-4 4-4
Issue 6*
Section 1
General Information
Section 1
4-1
4-1
Service Tools (cont'd) Section A - Attachments
3
992/09200
4 5 6 7 8 9 10 11 12 13 14 15 16
892/00150 892/00135 1406/0011 1604/0002 992/09206 823/00248 2401/0006 05/900137 1410/0001 992/09207 2401/0104 826/00696 823/00242
Nitrogen Charging Tool for Roadbreakers :Pressure Gauge :Adapter :Washer :Adapter :Bleed Screw :Washer :'O' Ring :Spring :Washer :Snap Ring :'O' Ring :Screw :Washer
Hammermaster 260 only 892/00823 892/00824
:Charging Device :Adapter
Section B - Body & Framework
826/01099 826/01101 826/01103 826/01102 826/01104 826/01105
M6 x 16mm Rivet Nut M6 x 19mm Rivet Nut M8 x 18mm Rivet Nut M8 x 21mm Rivet Nut M10 x 23mm Rivet Nut M10 x 26mm Rivet Nut
Installation Tool Available from: Bollhoff Fastenings Ltd. Midacre The Willenhall Estate Rose Hill Willenhall West Midlands, WV13 2JW
9803/3260
Issue 1
Section 1
General Information
Section 1
4-2
4-2
Service Tools (cont'd) * Section B -
Body & Framework
Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc. JCB part 892/00845
number
-
Hand Cleaner - special blend for the removal of polyurethane adhesives. JCB part number - 4104/1310 (454g; 1 lb tub)
S186270
S186240
Folding Stand for Holding Glass essential for preparing new glass prior to installation. 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).
JCB part 892/00843
number
-
JCB part number - 992/12300 S186280
S186250
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.
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.
JCB part number: 992/12400 - 2 Cartridge x 240V 992/12600 - 6 Cartridge x 240V
JCB part number - 892/00842
S186260
9803/3260
S186300
Issue 2*
Section 1
General Information
Section 1
4-3
4-3
Service Tools (cont'd) * Section B -
Body & Framework
Wire Starter - used to access braided cutting wire (below) through original polyurethane seal. Cut-Out Knife - used to remove broken glass. JCB part number - 992/12800 JCB part number - 892/00848 S186310
S186340
'L' Blades - 25 mm (1 in) cut - replacement blades for cut-out knife (above). JCB part number - 992/12801 (unit quantity = 5 off)
Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass. JCB part number - 892/00846 S186350
S186320
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. JCB part number - 892/00844
JCB part number - 892/00849 (approx 25 m length)
S186330
9803/3260
S186360
Issue 2*
Section 1
General Information
Section 1
4-4
4-4
Service Tools (cont'd) Section B - Body & Framework Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame. JCB part number - 926/15500 (unit quantity = 500 off)
Nylon Spatula general tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge. JCB part number - 892/00847
S186550
S186470
Slide Hammer Kit - 993/68100 1 :993/68101 Slide Hammer 2 :993/68102 End Stops 3 :993/68103 Adaptor - M20 x 5/8" UNF 4 :993/68104 Adaptor - M20 x 1" UNF 5 :993/68105 Adaptor - M20 x M20 6 :993/68106 Adaptor - M20 x M24 7 :993/68107 Bar - M20 x M20 X 800MM 8 :993/68108 Adaptor - M20 x 7/8" UNF 9 :993/68109 Adaptor - M20 x M12 10 :993/68110 Adaptor - M20 x 5/8" UNF (Shoulder) 11 :993/68111 Adaptor - M20 x 1/2" UNF 2 11
2 5
1
3
6
2
4
9 10 8 7
S196910
*
992/00800 - Pivot Pin Extractor for Front Axle
S218880
9803/3260
Issue 6*
Section 1
General Information
Section 1
4-5
4-5
Service Tools (cont'd) Section C - Electrics
AVO Test Kit 1
892/00283
Tool Kit Case
2
892/00298
Fluke Meter 85
3
892/00286
Surface Temperature Probe
4
892/00284
Venture
5
892/00282
100 amp Shunt - open type
6
892/00285
Hydraulic Temperature Probe
Microtach
Digital
Tachometer
S188231
* 993/85700
Battery Tester
892/00882
S239510
825/00410 825/99833
Socket for Alternator Pulley Nut (machines from serial number 430001)
S216770
15 mm Crowfoot Wrench Adapter
S216200
9803/3260
Issue 4*
Section 1
General Information
Section 1
4-6
4-6
Service Tools (cont'd) Section E - Hydraulics
Hydraulic Circuit Pressure Test Kit
*
892/00253 :892/00201 :892/00202 :892/00203 :892/00254 993/69800
Pressure Test Kit Replacement Gauge 0-20 bar (0-300 lbf/in2) Replacement Gauge 0-40 bar (0-600 lbf/in2) Replacement Gauge 0-400 bar (0-6000 lbf/in2) Replacement Hose Seal Kit for 892/00254 (can also be used with probe 892/00706)
S188121
S188131
Pressure Test Adapters Pressure Test 'T' Adapters 892/00262 816/55038 816/55040 892/00263 892/00264 892/00265
1/4 in M BSP x 1/4 in F BSP x Test Point 3/8 in M BSP x 3/8 in F BSP x Test Point 1/2 in M BSP x 1/2 in F BSP x Test Point 5/8 in M BSP x 5/8 in F BSP x Test Point 3/4 in M BSP x 3/4 in F BSP x Test Point 1 in M BSP x 1 in F BSP x Test Point
892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261
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
S200141
Flow Test Equipment 892/00268 892/00269 892/00293 892/00270 1406/0021 1604/0006 1612/0006 892/00271 892/00272 816/20008 892/00275 892/00276 892/00277 892/00273 892/00294 1606/0015 892/00078 1604/0008 1606/0012 816/20013
9803/3260
Flow Monitoring Unit Sensor Head 0 - 100 l/min (0 - 22 UK gal/min) Connector Pipe Load Valve Bonded Washer Adapter 3/4 in M x 3/4 in M BSP Adapter 3/4 in F x 3/4 in M BSP Adapter 3/4 in F x 5/8 in M BSP Adapter 5/8 in F x 3/4 in M BSP Adapter 3/4 in F x 1/2 in M BSP Adapter 1/2 in F x 3/4 in M BSP Adapter 3/4 in F x 3/8 in M BSP Adapter 3/8 in F x 3/4 in M BSP Sensor Head 0 - 380 l/min Connector Pipe Adapter 1.1/4 in M BSP x 1 in M BSP Connector 1 in F x 1 in F BSP Adapter 1 in M x 1 in M BSP Adapter 1 in M x 3/4 in M BSP Adapter 3/4 in F x 1 in M BSP
S188151
Issue 3*
Section 1
General Information
Section 1
4-7
4-7
Service Tools (cont'd) Section E - Hydraulics
Components for Loader Valve Block A.R.V. Testing 1 2 3 4
2401/0103 1406/0018 992/01003 992/10200
Components for Excavator Valve Block A.R.V. Testing
*
'O' Ring Bonded Washer Plug Body for Hamworthy A.R.V.
1 2 3 4 5 6
892/00309 : 892/00340 : 892/00341 : 993/68300 : 892/00343 : 892/00345 892/00335
A.R.V. Pressure Test Kit Test Block Body Setting Body Adjusting Pin Spanner Anti-cavitation Lock Out Bung A.R.V. Cartridge Removal Tool 6 4 2
S196400
1
3 5 S196700
Hand Pump Equipment 892/00223 892/00137 892/00274 892/00262 892/00706 892/00278 892/00279
Hand Pump Micro-bore Hose 1/4 in BSP x 3 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 lbf/in2) Gauge 0 - 400 bar (0 - 6000 lbf/in2)
Bonded Washers 1406/0011 1406/0018 1406/0014 1406/0021 1406/0029
1/4 in. BSP 1/2 in. BSP 5/8 in. BSP 3/4 in. BSP 1.1/4 in. BSP S188140
S193850
Male Adapters - BSP x NPT (USA only)
Male Adapters - BSP x BSP
816/00439 816/00440 816/15007 816/15008
1606/0003 1604/0003 892/00071 1606/0004 1606/0007 1604/0004 1606/0017 1606/0008 1606/0009 1604/0006 1606/0012 1606/0014 1606/0015
3/8 in. x 1/4 in. 1/2 in. x 1/4 in. 3/8 in. x 3/8 in. 1/2 in. x 3/8 in.
3/8 in. x 1/4 in. 3/8 in. x 3/8 in. 3/8 in. x 3/8 in. taper 1/2 in. x 1/4 in. 1/2 in. x 3/8 in. 1/2 in. x 1/2 in. 5/8 in. x 1/2 in. 3/4 in. x 3/8 in. 3/4 in. x 1/2 in. 3/4 in. x 3/4 in. 3/4 in. x 1 in. 3/4 in. x 1.1/4 in. 1 in. x 1.1/4 in.
S193860
9803/3260
Issue 4*
Section 1
General Information
Section 1
4-8
4-8
Service Tools (cont'd) * Section E -
Hydraulics
Female Cone Blanking Plug 892/00055 1/4 in. BSP 892/00056 3/8 in. BSP 892/00057 1/2 in. BSP 892/00058 5/8 in. BSP 892/00059 3/4 in. BSP 892/00060 1 in. BSP
Male Cone Blanking Cap 816/00294 1/4 in. BSP 816/00189 3/8 in. BSP 816/00190 1/2 in. BSP 816/00197 5/8 in. BSP 816/00196 3/4 in. BSP 816/00193 1 in. BSP
S193880
S193870
*
S193900
892/00047 892/00048 892/00049 816/50043 892/00051 816/50005 816/60096 816/00017
3/8 in. BSP (A) x 1/4 in. BSP (B) 1/2 in. BSP (A) x 1/4 in. BSP (B) 5/8 in. BSP (A) x 1/4 in. BSP (B) 3/4 in. BSP (A) x 1/4 in. BSP (B) 1 in. BSP (A) x 1/4 in. BSP (B) 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)
992/09100 992/10100 892/00011 892/00039
Excavator Spool Clamp Hamworthy Loader Spool & A.R.V. Clamp Spool Clamp Spool Clamp (Hamworthy A.R.V.)
Female Connectors
S193890
S216210
9803/3260
892/00074 892/00075 892/00076 892/00077
3/8 in. BSP x 3/8 in. BSP 1/2 in. BSP x 1/2 in. BSP 5/8 in. BSP x 5/8 in. BSP 3/4 in. BSP x 3/4 in. BSP
Hexagon Spanners for Ram Pistons and End Caps 992/09300 55mm A/F 992/09400 65mm A/F 992/09500 75mm A/F 992/09600 85mm A/F 992/09700 95mm A/F 992/10000 125mm A/F
S193930
Issue 2*
Section 1
General Information
Section 1
4-9
4-9
Service Tools (cont'd) * Section E -
Hydraulics
892/00176 Bearing Extractor for Hamworthy Pumps 892/00177 Bearing Collets (A) for 1900 Series Pumps 892/00178 Bearing Collets (A) for 2200 Series Pumps
S\216220
892/00180 Seal Fitting Tool for fitting 'O' ring and kin ring to Danfoss Orbitrol Unit 892/00181 Replacement Plastic Boss
S216230
Gland Seal Protection Sleeves 892/00334 892/00231 892/00232 892/00233 892/00167
For 60 mm Rod Diameter For 70 mm Rod Diameter For 75 mm Rod Diameter For 90 mm Rod Diameter
Gland Seal Fitting Tool
S216250
S216240
9803/3260
Issue 2*
Section 1
General Information
Section 1
4 - 10
4 - 10
Service Tools (cont'd) Section F - Transmission 892/00295
892/00825
End Float Setting Tool
Reverse Clutch End Float Setting Tool (Powershift transmission only)
S190760
S188190
990/00083
End Float Setting Tool 892/00812
Drive Coupling Spanner for front and rear axle yoke couplings and for 4WD output coupling on Syncro Shuttle
S188180
892/00179
S196720
A B C
Bearing Press (use with appropriate adapters)
892/00304 892/00301 892/00302
Flow Test Adapter Flow Test Adapter Flow Test Adapter
S188210 S188200
* 993/59300
2/4 WD Pressure Test Adaptor & Clamp
S196750
9803/3260
Issue 4*
Section 1
General Information
Section 1
4 - 11
4 - 11
Service Tools (cont'd) Section F - Transmission
S216260 S216270
992/07604
Replacer - Crownwheel Bearing and Differential Bearing Cones
992/07609
Adapter - Steer/Drive Axle Pinion Bearing Cone
992/07606
Measuring Cup - Pinion Bearing
S188160 S216290
S216280
992/07607
Spacer - Pinion Bearing Preload
892/00817 892/00818 892/00819 892/00333
17 mm A/F x 3/4in. square drive 22 mm A/F x 3/4in. square drive 15 mm A/F x 1/2in. square drive 19 mm A/F x 3/4in. square drive
S216300
992/07614
Adapter Set - Bull Pinion Bearing Remover/Replacer
S216310
892/00182
S216320
992/07601
9803/3260
Spanner for Half Shaft Nuts
Bearing Pad Driver
S216330
992/07603
Replacer - Pinion Head Bearing Cup
Issue 1
Section 1
General Information
Section 1
4 - 12
4 - 12
Service Tools (cont'd) Section F - Transmission
992/04000 Torque Multiplier (use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts)
S197030
992/04800 Flange Spanner - for locking pinion flange while pinion nut is slackened or torque set 892/00174 Measuring Cup - Pinion Head Bearing
S190770
S197040
892/00224 Impulse Extractor Set for Hub Bearing Seals
S197070
892/00822 Splined Bolt Socket for driveshafts
S197060
* 892/00225
993/59500
9803/3260
Adapter - Impulse Extractor Small 17mm to 25mm Medium 25mm to 45mm Large 45mm to 80mm Adapter - Impulse Extractor (syncro shuttle and powershift transmission)
892/00891 Fitting Tool Assembly for Wheel Hub Seals
S227760
Issue 3*
Section 1
General Information
Section 1
4 - 13
4 - 13
Service Tools (cont'd) Section F - Transmission
Fixture for Syncro Shuttle & Powershift Gearbox removal & replacement Drawing available from: JCB Service Rocester Staffordshire ST14 5LS Note: When removing/replacing a Syncro Shuttle Gearbox, use items 1, 2 and 3. When removing/replacing a Powershift Gearbox, use items 1 and 4.
Section K - Engine
892/00836 Lifting Wire Assembly (for engine removal) S192390
S219080
892/00041
De-glazing Tool for Cylinder Bores (to assist bedding-in of new piston rings)
* For
details of other engine service tools refer to Perkins Service Manual, Publication No. 9806/0100
9803/3260
Issue 2*
Section 1
General Information
Section 1
5-1
5-1
Sealing and Retaining Compounds JCB Multi-Gasket
A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65mm diameter.
4102/1201
For all size of flanges where the strength of the joint is important.
4102/0502
For all retaining parts which are unlikely to be dismantled.
4101/0602
A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50mm diameter, and for hydraulic fittings up to 25mm diameter.
4101/0202
Loctite 577
A medium strength thread sealing compound.
4102/1901
Loctite 262
A medium to high strength locking fluid for retention and sealing of ram piston heads.
4101/0502
A locking fluid for use on threads larger than 50mm dia.
4101/0402
JCB High Strength Gasketing
* JCB High Strength Retainer JCB Lock and Seal
Loctite 932
Loctite Activator N
Direct Glazing Kit
A cleaning primer which speeds the curing rate of anaerobic products.
4104/0101 4104/0102
Aerosol Bottle
For one pane of glass, comprises items marked † below plus applicator nozzle etc.
993/55700
† Ultra Fast Adhesive
For direct glazing
4103/2109
310 ml
† Active Wipe 205
For direct glazing
4104/1206 4104/1203
30 ml 250 g
† Black Primer 206J
For direct glazing
4201/4906
30 ml
Clear Silicone Sealant
To seal butt jointed glass
4102/0933
Black Polyurethane Sealant
To finish exposed edges of laminated glass
4102/2309
310 ml
For degreasing components prior to use of anaerobic adhesives and sealants.
4104/1538
Aerosol
* JCB Cleaner & Degreaser
9803/3260
Issue 3*
Section 2
Section 2
Care & Safety
i
i
Contents
9803/3260
Page No.
Safety Notices
1-1
General safety
2-1
Operating safety
3-1
Maintenance safety
4-1
Issue 2
Section 2
Care & Safety
1-1
Section 2 1-1
Safety Notices In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.
! DANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured. INT-1-2-1
! WARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-2
! CAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine. INT-1-2-3
9803/3260
Issue 1
Section 2
Section 2
Care & Safety
2-1
2-1
All construction and agricultural equipment can be hazardous. When a JCB machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. Do not work with the machine until you are sure that you can control it. Do not start any job until you are sure that you and those around you will be safe. If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE GEN-1-6
General Safety
! WARNING Decals You can be injured if you do not obey the decal safety instructions. Keep decals clean. Replace unreadable or missing decals with new ones before operating the machine. Make sure replacement parts include warning decals where necessary.
! 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
INT-1-3-4
! WARNING Care and Alertness All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards.
! WARNING Raised Attachments Raised attachments can fall and injure you. Do not walk or work under raised attachments unless they are safely blocked. INT-1-3-8
INT-1-3-5
! 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
9803/3260
Issue 1 SXXXXXX
SXXXXXX
SXXXXXX
Section 2
Section 2
Care & Safety
3-1
3-1
Operating Safety ! WARNING
! WARNING Machine Condition A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this handbook are completed before using the machine. INT-2-1-2
! 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.
ROPS/FOPS Structure machine is fitted with a Roll Over Protection Structure (ROPS) and a Falling Objects Protection Structure (FOPS). You could be killed or seriously injured if you operate the machine with a damaged or missing ROPS/FOPS. If the ROPS/FOPS has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification.
* The
INT-2-1-9/3
! WARNING
INT-2-1-3
! WARNING Machine Limits Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications.
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
INT-2-1-4
! WARNING Engine/Steering Failure If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected. INT-2-1-5
! 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
! 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. INT-2-1-6
! WARNING 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-2-2-6
! 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
! 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
9803/3260
Issue 2*
Section 2
Care & Safety
3-2
Section 2 3-2
Operating Safety (cont'd) ! WARNING The transmission is in 4 wheel drive until de-selected by hydraulic pressure to 2 wheel drive. If the machine is to be raised and the engine/transmission run, make sure all four wheels are off the ground and supported by axle stands. If only the rear wheels are raised, the machine could still drive through the front axle. Trans 2-2/1
! WARNING Powershift Transmission
* Do not change from a high gear to a low gear (for instance,
4th to 1st) in one sudden movement whilst the machine is moving. Otherwise the machine will rapidly decelerate, you or others could be killed or seriously injured. When selecting lower gears, allow the engine speed to drop before each gear change. 2-1-1-9/1
9803/3260
Issue 2*
Section 2
Section 2
Care & Safety
4-1
4-1
Maintenance Safety ! WARNING
! WARNING Repairs Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer. GEN-1-5
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 Modifications and Welding Non-approved modifications can cause injury and damage. Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Contact your JCB distributor for advice before modifying the machine. INT-3-1-2/1
! WARNING 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 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
! 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.
! WARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.
When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9
! WARNING
INT-3-1-4
! 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 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.
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
! DANGER 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
INT-3-1-6
9803/3260
Issue 1
Section 2
Section 2
Care & Safety
4-2
4-2
Maintenance Safety (cont'd) ! CAUTION
! 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.
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
INT-3-2-2
! CAUTION ! 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
Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents. INT-3-2-11
! 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 Triochloroethane or paint thinners near 'O' rings and seals. INT-3-2-12
Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground.
! WARNING
INT-3-2-4
! WARNING Tyres and Rims Over-inflated or over-heated tyres can explode. Follow the instructions in this handbook for inflating the tyres. Do not weld or cut rims. Get a tyre/wheel specialist to do any repair work. INT-3-2-6
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. Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an elecrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use self-contained breathing apparatus. INT-3-2-7/1
! WARNING Hot Coolant The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the 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
! WARNING
! WARNING Jacking A machine can roll off jacks and crush you unless the wheels have been chocked. Always chock the wheels at the opposite end of the machine that is to be jacked. Do not work underneath a machine supported only by jacks. Always support a jacked-up machine on axle stands before working underneath it. INT-3-2-8
Always wear safety glasses when dismantling assemblies components under pressure from springs. This will protect against eye injury from components accidently flying out.
* containing GEN 6-2
9803/3260
Issue 2*
Section 2
Section 2
Care & Safety
4-3
4-3
Maintenance Safety (cont'd) ! WARNING
! 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.
To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a wire brush to clean components. HYD 1-3
! WARNING JCB Extradig Dipper Lubricant JCB Extradig dipper lubricant contains 1.53% lead. The repeated swallowing of very small quantities can cause chronic lead poisoning. Do not smoke or touch food while handling this lubricant. Dispose of waste (rags etc.) in accordance with local regulations.
INT-3-3-2
! WARNING
2-1-1-8
Safety Strut Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut.
! WARNING
2-1-1-6
! WARNING A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-1
! WARNING Waxoyl contains turpentine substitute, which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. 5-3-1-9
*
Fluoroelastomeric Materials Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton, Fluorel and Technoflon. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN. New fluoroelastomeric components at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose temperatures have not exceeded 300°C require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA. Used fluoroelastomeric components subjected to temperatures greater than 300°C (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: 1 Ensure that components have cooled then remove and place material into plastic bags. 2 Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.
! WARNING
3 Thoroughly wash contaminated area with detergent and water.
Make the machine safe before working underneath it. Park the machine on level ground, lower the arms. Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels.
4 Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.
Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-2
DO NOT BURN FLUOROELASTOMERIC MATERIALS. If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately. INT-3-3-5/1
9803/3260
Issue 2*
Section 3
Routine Maintenance
Section 3
i
i
Contents Lubricants & Capacities
1-1
Service Schedules
2-1
Greasing - Loader Arms - 6-in-1 Clamshovel - Backhoe Quick-Hitch - Loader Quick-Hitch - Stabilisers (Centremount Machines) - Backhoe (Sideshift Machines) - Backhoe (Centremount Machines) - Knuckle Boom (4CN (216) Models) - Front Axle (2-Wheel Drive Machines) - Front Axle (4-Wheel Drive Machines) - Front Axle (All Wheel Steer Machines) - Rear Axle (All Wheel Steer Machines) - Extending Dipper - Hydraulic Pump Driveshaft (2WS Machines) - Front and Rear Propshafts * - Backhoe Quick Hitch (Hydraulic)
9803/3260
Page No.
3-1 3-2 3-2 3-2 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3 - 10 3 - 10 3 - 11 3 - 11
Oiling - Parking Brake Cable - Control Levers - Boom Lock
4-1 4-1 4-1
Loader Arm Safety Strut - Fitting and Removing
5-1
Slew Gearbox (Sideshift Machines) - Draining Water & Checking Oil Level
6-1
Hydraulic Fluid - Check Level
7-1
Hydraulic Tank Breather - Clean
7-1
Hydraulic Filter - Renew Element - Renew Element (from M409448)
7-2 7-3
Syncro Shuttle Transmission - Check Level - Renew Filter - Change Oil & Clean Strainer
8-1 8-1 8-1
Powershift Transmission - Check Level - Renew Filter - Change Oil & Clean Strainer
8-2 8-2 8-2
Front Axle Oil Level - Check Differential Oil Level - Change Differential Oil - Check Hub Oil Level - Change Hub Oil
9-1 9-1 9-1 9-1
Issue 5*
Section 3
Routine Maintenance
Section 3
ii
ii
Contents
Page No.
Rear Axle Oil Level (AWS Machines) - Check Differential Oil Level - Change Differential Oil - Check Hub Oil Level - Change Hub Oil
9-2 9-2 9-2 9-2
Rear Axle (2WS Machines) - Check the Oil Level - Change the Oil
9-3 9-3
Engine Oil and Filter (To Serial No. 430000) - Check Level - Change Oil & Filter
10 - 1 10 - 1
Engine Oil and Filter (From Serial No. 430001) - Check Level - Change Oil & Filter
10 - 2 10 - 2
* Fuel Filter (Glass Bowl Type) - Drain - Renew Element
10 - 3 10 - 3
* Fuel Filter (Spin-on Cartridge Type)) - Drain - Renew Element
10 - 3 10 - 3
* Fuel Sediment Bowl - Drain - Clean
10 - 4 10 - 4
* Fuel System
9803/3260
- Bleeding
10 - 4
Cooling System - Antifreeze - Check Level - Drain & Refill
12 - 1 12 - 1 12 - 2
Fan Belt - Check Tension - Adjust
13 - 1 13 - 1
Cab Heater Filter (To Serial No. 430000) - Clean
13 - 1
Cab Heater Filter (From Serial No. 430001) - Clean
13 - 2
Air Filter Pre-Cleaner - Empty
14 - 1
Air Filter - Renew Outer Element - Renew Inner Element
14 - 2 14 - 2
Parking Brake - Check Adjustment - Pad Renewal
15 - 1 15 - 1
Issue 4*
Section 3
Routine Maintenance
Section 3
iii
iii
Contents
Page No.
* Service Brakes (To Serial No. 430000) - Checking The Foot Brake Fluid Level
15 - 2
* Service Brakes (From Serial No. 430001) - Checking The Foot Brake Fluid Level
15 - 2
Battery - First Aid - Checking Electrolyte Level - Cleaning the Battery - Jump Starting (Safety) - Jump Starting (Procedure)
16 - 1 16 - 1 16 - 1 16 - 2 16 - 2
Boom Lock (To Serial No. 430000) - Checking the Hydraulic Fluid Level
17 - 1
* Boom Lock (From Serial No. 433724) - Checking the Hydraulic Fluid Level
9803/3260
17 - 1
Hydraulic Oil Cooler - Clean
18 - 1
Bulb Replacement - Headlight Bulb - Front Sidelight Bulb - Worklight Bulb - Front Indicator Light Bulb - Rear Brake/Sidelight Bulb - Fog Light Bulb - Number Plate Light - Cab Interior Light - Rotating Beacon Bulb - Switch Illumination Bulbs
19 - 1 19 - 1 19 - 2 19 - 2 19 - 3 19 - 3 19 - 4 19 - 4 19 - 5 19 - 5
Issue 4*
Section 3
Routine Maintenance
Section 3
1-1
1-1
Lubricants & Capacities ITEM
CAPACITY Litres UK Gal
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Fuel Tank
100
Diesel Oil
ASTM D975-66T Nos. 1D, 2D
JCB 15W/40 Multigrade
SAE15W/40, MIL-L-46152B,
-10 °C to 50 °C (14 °F to 122 °F)
API CD/SE, MIL-L-2104D
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30, MIL-L-2105, MIL-L-46152, API CD/SE, MIL-L-2104C
22
Engine (Oil) ➀ 2 Wheel Steer Machines - Build AA 9.7 - Build AA (Hot Climate) 11.0 - Build AB 10.0
2.1 2.4 2.2
4 Wheel Steer Machines - Build AB 10.0
2.2
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
SAE10W, MIL-L-46152, MIL-L-2104D, API CD/SE
Engine (Coolant)
20.0
4.4
JCB Universal Antifreeze/water
ASTM D3306-74
Syncro Shuttle (2WD) ➁
15.75
3.5
JCB Special Transmission Fluid
ESP-M2C 33G
Syncro Shuttle (4WD) ➁
16.25
3.6
JCB Special Transmission Fluid
ESP-M2C 33G
JCB Special Transmission Fluid
ESP-M2C 33G
(machines up to serial number 431230) Syncro Shuttle (2WD) ➁
13.0
2.9
Syncro Shuttle (4WD) ➁
14.0
3.1
(machines from serial number 431230 to TBA)
*
Syncro Shuttle (2WD) ➁
14.4
3.2
Syncro Shuttle (4WD) ➁
15.4
3.4
(machines from serial number TBA - fitted with 12.2 inch convertors) Powershift ➁
14.75
3.25
JCB Special Transmission Fluid
ESP-M2C 33G
13 18
2.86 3.96
JCB HD90 Gear Oil
API-GL-5 MIL-L-2105C
Hubs (x2)
2.0
0.44
Rear Axle (AWS) Housing Hubs (x2)
18 2.0
3.96 0.44
JCB Special Gear Oil Plus
API-GL-4
Rear Axle (2WS)
23
5.0
JCB Special Gear Oil Plus
API-GL-4
Slew Gearbox
4.3
0.9
JCB HD90 Gear Oil
API-GL-5, MIL-L-2105C
Brake System - Standard - Servo
1.2 1.4
0.26 0.31
JCB Light Hydraulic Fluid ISO VG15 ! CAUTION: DO NOT USE ORDINARY BRAKE FLUID
Hydraulic System ➂
135
29.7
JCB High Performance Hydraulic Oil
Front Axle (4WD) Housing (2WS) Housing (AWS)
*
*
➅
ISO VG46
(Above 38 °C, 100 °F) JCB Hydraulic Fluid HP32 (Below 38 °C, 100 °F)
ISO VG32
Refrigerant
Freon 12
* Air Conditioning System
9803/3260
1544 g
3.4 lb
Issue 6*
Section 3
Routine Maintenance
Section 3
1-2
1-2
Lubricants & Capacities (continued) * ITEM
CAPACITY Litres UK Gal
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
Air Conditioning System 1200 g 2lb 10oz (machines from serial number 430001)
Refrigerant
R134a
Boom Lock
1.0
JCB Light Hydraulic Fluid
ISO VG15
Grease Points
---
JCB MPL Grease or JCB HP Grease ➃
Lithium based, No. 2 consistency.
Extending Dipper
---
(machines up to serial number 430000)
*
Electrical connections
➀
0.22
---
Waxoyl ➄ As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly.
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 piston 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). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system. Figures quoted within ±0.5 litre (0.11 U.K. gal).
➁
Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system. Figures quoted within ±1.0 litre (0.22 U.K. gal).
➂
Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank.
➃
Note: JCB HP Grease is a high specification grease, in certain applications this grease must be used, for instance transmission bearings during an overhaul.
➄
! WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. GEN-1-3
* ➅
Note: AWS axles with limited slip differential must use JCB Special Gear Oil Plus.
9803/3260
Issue 2*
Section 3
Routine Maintenance
Section 3
2-1
2-1
Service Schedules A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition.
! WARNING
Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut. GEN 3-2
Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately. Calendar equivalents: 10 Hours = Daily 50 Hours = Weekly 500 Hours = Six Months 1000 Hours = Yearly 2000 Hours = 2 Years
Pre-start Cold Checks Service Points and Fluid Levels
*
*
ENGINE Oil level Oil and Filter ➃ Air Cleaner Dust Valve Air Cleaner Outer Element Air Cleaner Inner Element Fuel Filter Fuel Filter Coolant Quality/Level Fuel Sedimenter Fan Belt Tension/Condition Valve Clearances ➂ Engine Mounting Bolts for Tightness ➂ Radiator All Hoses - Condition Precleaner
TRANSMISSION, AXLES AND STEERING Transmission Oil Level Transmission Oil Transmission Filter Axle Oil Level (incl. Hubs when applicable) ➀ Axle Oil (incl. Hubs when applicable) Axle Oil (Limited Slip Diff.) Tyre Pressures/Condition Front Hub Bearings ➂ Transmission Strainer Drive Shafts Steer Axle Movement/Shimming ➂ Steer Axle Pivots and Linkages ➆
Operation
- Check - Change - Clean - Change - Change - Change - Drain - Check - Drain and Clean - Check - Check and Adjust - Check - Clean - Check - Clean
- Check - Change - Change - Check - Change - Change - Check - Check - Clean - Security/Grease - Check - Grease
10 Hr
50 Hr
†100 Hr
500 Hr
1000 2000 Hr Hr
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9803/3260
Issue 6*
Section 3
Routine Maintenance
Section 3
2-2 Pre-start Cold Checks Service Points and Fluid Levels
HYDRAULICS Oil Level ➁ Oil ➂ Oil Filter Hoses - Damage or Leaks Pipework - Damage or Leaks Rams - External Leaks Rams - Chrome Condition Hydraulic Oil Cooler Boom Lock Fluid Level Hydraulic Oil Strainer Hydraulic Tank Filler Cap (with integral filter)
BRAKES Brake System Fluid Level Brake System Fluid ➂ Parking Brake Master Cylinder Rod ➂
ELECTRICS Battery Electrolyte Level (if applicable) Wiring for Chaffing/Routing Battery Terminals for Condition and Tightness
BODYWORK AND CAB Slew Actuator Oil Level ➀ Slew Actuator (in below freezing conditions) Pins and Bushes Door/Window Hinges All Cables Cab Heater Filter ➅ Extending Dipper Hydraclamp Shimming ➂ Door - Fit and Catches Cab Seat - Operation Cab Floor Mat - Condition Toe Plate Condition Front Mudguards - Security (if fitted) Windscreen Washer Fluid Level Condition of Paintwork Machine Generally Machine Generally for Leaks and/or Damage ➄
ATTACHMENTS 6-in-1 Clam Shovel Backhoe & Loader Quick Hitch Stabilisers (Centremount Machines)
9803/3260
2-2 Operation
10 Hr
- Check - Sample/Change - Change - Check - Check - Check - Check - Clean - Check - Clean - Change
- Check - Change - Check and Adjust - Adjustment Check
- Grease - Grease - Grease
†100 Hr
500 Hr
1000 2000 Hr Hr
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- Check - Check - Check
- Check - Drain Water - Check and Grease - Lubricate - Lubricate - Clean - Adjust/Grease - Check and Adjust - Check - Check - Check - Check - Check - Check - Check - Check and Clean - Check
50 Hr
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Issue 5
Section 3
Routine Maintenance
Section 3
2-3 Functional Test and Final Inspection
ENGINE Idle Speed ➂ Maximum Governed Speed ➂ Stall Speed ➂ Maximum No-Load Speed ➂ Exhaust Smoke (excessive) Exhaust System Security ➂ Air Inlet System Security Throttle System and Control Cable ➂
TRANSMISSION, AXLES AND STEERING Steer Modes - Operation Steer Phasing ➂ Steering Proximity Switch - Operation ➂ 2WD/4WD Selection Wheel Nuts Torque Forward/Reverse and Gear Change - Operation Hydraulic Speed Control - Operation (if fitted) Steer Circuit Pressure ➂ Transmission Main Line Pressure ➂ Clutch Disconnect Neutral Start Operation Power Shift Selection (if fitted) Clutch Pack Pressures ➂
HYDRAULICS MRV Pressure ➂ Operation All Services Hose Burst Protection Valves (if fitted) Offloader Valve Pressure ➂ Auxiliary Circuit & Pressures ➂
2-3 Operation
- Check and Adjust - Check and Adjust - Check - Check and Adjust - Check - Check - Check - Check
- Check - Check - Check - Check - Check - Check - Check - Check - Check - Check - Check - Check - Check
●
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- Check - Check - Check
ELECTRICS Starter Motor Alternator - Output Wipers/Washers Beacon - Operation (if fitted) Heater - Operation Warning Lights Lights and Instruments
- Check - Check - Check - Check - Check - Check - Check
50 Hr
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500 Hr
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- Check and Adjust - Check - Check - Check and Adjust - Check and Adjust
BRAKES Foot Brake - Operation Parking Brake - Operation Servo Operation (if fitted)
9803/3260
10 Hr
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1000 2000 Hr Hr
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Issue 4
Section 3
Routine Maintenance
Section 3
2-4
2-4
Functional Test and Final Inspection
Operation
ELECTRICS (continued) Horn - Operation Reverse Alarm Shovel Reset/Return to Dig (if fitted) Air Conditioner (if fitted) Operation of Stop Control/E.S.O.S.
- Check - Check - Check - Check - Check
BODYWORK AND CAB Teeth and Side Cutters Doors and Hinges - Fitment/Leaks Locks and Keys Seat/Seat Belts
- Check - Check - Check - Check
ATTACHMENTS Attachment Operation
- Check
10 Hr
50 Hr
†100 Hr
500 Hr
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1000 2000 Hr Hr
† Note: First 100 Hours Service only, to be completed by your JCB Distributor.
➀ Note: Check for leaks every 50 hours, check level if leaking. ➁ Note: Check the hydraulic fluid level with the loader and backhoe in the travel position. ➂ Note: Jobs which should only be done by a specialist are indicated by a ➂. ➃ Note: If operating under arduous conditions, change the engine oil filter every 250 hours. ➄ Note: Check generally for leaks on ALL systems, for example, hydraulic, engine (coolant, fuel and oil), transmission, brakes, axles etc. If a leak is evident find the source and repair as required. Make sure that the system is topped up with the recommended fluid after repair. Examples of machine general damage are paintwork, toe plate, glazing rubbers etc., repair any damage as required.
➅ Note: If operating in dusty working environments, clean the cab heater filter more frequently.
* ➆ Note: The axles are factory greased with a high performace grease, if during service a standard grease is used, then the interval must be reduced to every 50 hours.
9803/3260
Issue 2*
Section 3
Routine Maintenance
Section 3
3-1
3-1
Greasing * Note: The illustration shows an all wheel steer machine, the
Loader Arms - for Interval see Service Schedule For each grease point there is another on the other side of the machine.
loader arms grease points are identical for 2WS and AWS machines.
11 grease points each side Total 22 grease points. Normally two strokes of the grease gun should be sufficient. Stop greasing when fresh grease appears at the joint.
2 1
4 3 5 6
7 8
9
140210
9803/3260
Issue 2*
Section 3
Routine Maintenance
Section 3
3-2
3-2
Greasing (cont'd) 6 - in - 1 Clamshovel - for Interval see Service Schedule
Backhoe Quick-Hitch - for Interval see Service Schedule
For each grease point there is another at the other end of the bucket.
For grease points 2 and 3 there is another on the opposite side of the Quick-Hitch (4 and 5).
3 grease points each side Total 6 grease points.
Total 5 Grease Points
B
1
24
3
35
2
S137251 S089961
* Stabilisers (Centremount Machines) - for Interval see Service Schedule
3 grease points on each stabiliser Total 6 grease points. Loader Quick-Hitch - for Interval see Service Schedule
1
2 grease points each side Total 4 grease points.
2
2 1 3
3 4 S089921
9803/3260
S138941
Issue 2*
Section 3
Routine Maintenance
3-5
Section 3 3-5
Greasing (cont'd) * Knuckle Boom (4CN Models) - for Interval see Service Schedule 18 Grease Points
9803/3260
Issue 2*
Section 3
Routine Maintenance
3-6
Section 3 3-6
Greasing (cont'd) * Front Axle (2 Wheel Drive Machines) - for Interval see Service Schedule 12 Grease Points
9803/3260
Issue 2*
Section 3
Routine Maintenance
Section 3
3-7
3-7
Greasing (cont'd) Front Axle (4 Wheel Drive Machines) - for Interval see Service Schedule
* 10 Grease Points
1 2
3
4
5
6
8 7
9
0
S199790
9803/3260
Issue 3*
Section 3
Routine Maintenance
3-8
Section 3 3-8
Greasing (cont'd) Front Axle (All Wheel Steer Machines) - for Interval see Service Schedule 12 Grease Points
S143010
9803/3260
Issue 1
Section 3
Routine Maintenance
3-9
Section 3 3-9
Greasing (cont'd) Rear Axle (All Wheel Steer Machines) - for Interval see Service Schedule 10 Grease Points
S143050
9803/3260
Issue 1
Section 3
Routine Maintenance
3 - 10
Section 3 3 - 10
Greasing (cont'd) Extending Dipper - for Interval see Service Schedule
! WARNING Waxoyl contains turpentine substitute, which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. GEN-1-3
Extend the dipper. Coat the working surfaces with Waxoyl.
S140080
Hydraulic Pump Driveshaft (2 Wheel Steer Machines) - for Interval see Service Schedule 1 Grease Point (if fitted)
S157371
9803/3260
Issue 1
Section 3
Routine Maintenance
Section 3
3 - 11
3 - 11
Greasing (cont'd) * Backhoe Quick Hitch (Hydraulic) - for Interval see Service
Rear Propshaft - for Interval see Service Schedule
Schedule 3 Grease Points
! CAUTION Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.
3
1
5-3-1-9
Coat the slide A with Waxoyl . 4 Grease Points
2
S157510
4 3 1 2
Front Propshaft (4 Wheel Drive ) - for Interval see Service Schedule 3 Grease Points
A
3
2
1
S211750
S157500
9803/3260
Issue 2*
Section 3
Routine Maintenance
Section 3
4-1
4-1
Oiling Boom Lock - for Interval see Service Schedule
Parking Brake Cable - for Interval see Service Schedule Oil the clevis at the brake end of the cable and at the base of the lever.
S152200
Oil the clevis at the back end of the remote boom lock.
S094680
Control Levers - for Interval see Service Schedule Oil the clevis at the bottom of every attachment control lever.
S144460
S104990
9803/3260
Issue 1
Section 3
Section 3
Routine Maintenance
5-1
5-1
Loader Arm Safety Strut
X
Fitting and Removing Install the loader arm safety strut as detailed below before working underneath raised loader arms.
* Depending on the age and type of machine, the strut may be stowed inside the cab, mounted on the left hand fender cladding, as shown at X. Alternatively, the strut may be
C
stowed on the loader arm, as shown at Y. Fitting
! WARNING The loader arm safety strut must be fitted before any work is done beneath raised loader arms. Make sure the shovel is empty, then fit the safety strut as instructed below.
A
S164101
GEN-1-7
1
Fully raise the loader arms and stop the engine.
2
Release fastener A and withdraw strut C from its stowage bracket.
3
Push the strut C over the ram piston rod and secure the strut in position with strap B.
4
Y
A
Start the engine and slowly lower the loader arms until the weight of the arms is just taken by the strut.
C
Removing 1
Raise the loader arms to take the weight off the strut, then stop the engine.
2
Undo strap B, remove the strut C and return it to its stowage position.
3
S215110
Secure the strut in its stowage position with fastener A.
C B S161710
9803/3260
Issue 4* SXXXXXX
Section 3
Section 3
Routine Maintenance
6-1
6-1
* Slew Gearbox (Sideshift Machines) Draining Water and Checking Oil Level - for interval see Service Schedule Note: In freezing conditions this procedure must be carried out each working day. 1
Preparation Park machine on level ground. Extend the dipper and lower the boom to rest the bucket on the ground. Engage the parking brake. Stop engine. Remove starter key.
2
Draining Water Slacken plug B. Close the plug when water stops flowing and oil appears.
3
Check Oil Level Remove fill/level plug A. Top up to bottom of filler hole with oil specified on page 3/1-1.
S148080
9803/3260
Issue 2* SXXXXXX
SXXXXXX
Section 3
Routine Maintenance
7-1
*
Section 3 7-1
Hydraulic Fluid Level
Hydraulic Tank Breather
Check Level - for Interval see Service Schedule
Clean - for Interval see Service Schedule
Position the machine on level ground. Set the loader shovel on the ground. Retract the extending dipper if fitted. Raise the boom, swing in the dipper and close the bucket. Stop the engine. Remove the starter key.
Remove screw C, washer D and cap E.
Look at the fluid level in the lens A. The level should be at the red mark (or above). If the fluid is cloudy, water or air has entered the system. Water or air in the system could damage the hydraulic pump. Contact your JCB distributor if the fluid is cloudy. Note: Earlier machines have a sight tube H, the level should
Remove filter F and wash in clean fuel. *
Clean inside cap E and re-assemble onto valve body G. Note: On machines from Serial No. M409559 the hydraulic tank breather (and filter) forms an integral part of the hydraulic tank filler cap B. Replace the filler cap (and breather filter) with a new one at the recommended interval (see Service Schedules).
be between the two marks on the tube. If required, top up at B with hydraulic fluid specified on page 3/1-1.
The filler cap is threaded and must be screwed onto the filler neck, torque tighten the cap to 20 Nm (15 lbf ft), - this is equivalent to hand tight plus a further quarter turn using a spanner.
B C D A
E F
H
G S209960
9803/3260
S145380
Issue 2*
Section 3
Routine Maintenance
7-2
Section 3 7-2
Hydraulic Filter Renew Element- for Interval see Service Schedule Position machine as at A and remove tank cap B.
*
Remove screws C, cover plate D and gasket E, discard the gasket. Remove complete element assembly F and seal G.
Note: New machines are fitted with a 10 micron rated element to eliminate all possible traces of contamination from the hydraulic system. At the initial 100 hour service, fit a new 25 micron rated element. If the hydraulic system should become contaminated after the initial service, then fit a 10 micron filter element for 100 operating hours to remove the contamination. After 100 hours fit a new 25 micron element.
Remove nut and spring H. Remove element from spindle. Remove the 'L' shaped seal K.
* Clean magnets J (see note). Fit a new element and gasket E. Refit cover plate D and tighten screws C to 7Nm (5lbf ft).
* Top up hydraulic tank and refit cap B. Note: The filter core (item J) on machines from serial number 402727 is non-magnetic.
S142871
9803/3260
Issue 2*
Section 3
Routine Maintenance
Section 3
7-3
7-3
Hydraulic Filter (from M/C Serial No 409448) Replacement
Renew Element Note: New machines are fitted with a 10 micron rated element to eliminate all possible traces of contamination from the hydraulic system. At the initial 100 hour service, fit a new 25 micron rated element. If the hydraulic system should become contaminated after the initial service, then fit a 10 micron filter element for 100 operating hours to remove the contamination. After 100 hours fit a new 25 micron element. Position the machine as at A on page 7 - 2.
Fit a new seal H. Make sure that seal J is fitted in the new element. Push the element G into its canister F and rotate the elemen 90° to lock it into position. Check that the element has locked into position by pulling on handle E. Install the element assembly in the hydraulic tank. Fit spring D and new gasket C. Fit cover plate B and tighten screws A to 5 lbf ft (7 Nm).
Removal Remove screws A. Remove the cover plate B and gasket C, discard the gasket.
Add oil through filler.
Remove the spring D. Hold handle E and pull the element assembly from the hydraulic tank. Hold canister F. Hold handle E and rotate the element G 90°.
E
J
G A B D
C
H F
S185850
9803/3260
Issue 1*
Section 3
Routine Maintenance
Section 3
8-1
8-1
Syncro Shuttle Transmission Check Level - for Interval see Service Schedule
Renew Filter - for Interval see Service Schedule
A -
Unscrew and discard element E.
Dipstick/Filler
Oil level should be to the full mark on the dipstick when the oil is cold i.e. before starting machine operation.
Smear seal F with transmission oil, and fit new element hand tight only.
DO NOT OVERFILL
Fill system to dipstick mark with JCB Special Transmission Fluid.
Change Oil & Clean Strainer - for Interval see Service Schedule Drain oil by removing strainer B. Clean strainer using a suitable solvent. When refitting strainer, renew gasket C and apply JCB Lock and Seal to bolts D. Torque Settings Item D
Nm 10
kgf m 1.0
lbf ft 7.4
143030
9803/3260
Issue 1
Section 3
Routine Maintenance
Section 3
8-2
8-2
Powershift Transmission Check Level - for Interval see Service Schedule
Renew Filter - for Interval see Service Schedule
A -
Unscrew and discard element E.
Dipstick/Filler
Oil level should be to the full mark on the dipstick when the oil is cold i.e. before starting machine operation.
Smear seal F with transmission oil, and fit new element hand tight only.
DO NOT OVERFILL
Fill system to dipstick mark with JCB Special Transmission Fluid.
Change Oil & Clean Strainer - for Interval see Service Schedule Drain oil by removing drain plug B. Remove and clean strainer G. Clean strainer using a suitable solvent. When refitting strainer, renew gasket C and apply JCB Lock and Seal to bolts D. Torque Settings Item D
Nm 10
kgf m 1.0
lbf ft 7.4
S143040
9803/3260
Issue 1
Section 3
Routine Maintenance
Section 3
9-1
9-1
Front Axle Oil Level
Check Hub Oil Level - for Interval see Service Schedule
Check Differential Oil Level - for Interval see Service Schedule
1
Make sure the OIL LEVEL mark on the hub is horizontal.
1
Remove fill/level plug A. Oil should be level with the bottom of the fill/level hole.
2
Remove fill/level plug C. Oil should be level with the bottom of the fill/level hole.
2
If necessary, top up with JCB recommended axle oil.
3
If necessary, top up with JCB recommended axle oil. Clean and refit fill/level plug C.
Clean and refit fill/level plug A, torque to 79 Nm (58 lbf ft).
Change Hub Oil - for Interval see Service Schedule Change Differential Oil - for Interval see Service Schedule 1 1
*
Remove fill/level plug A and drain plug B (see note). Allow time for the oil to drain out.
ground. Manually rotate the wheels to bring the OIL LEVEL mark on the hubs to the vertical position, with the fill/level plugs C at the bottom.
Note: On 2WS machines, drain plug B is positioned on the underside of the axle. 2
Clean and refit drain plug B, torque to 79 Nm (58 lbf ft).
3
Fill the axle with JCB recommended axle oil through the
Set the machine level, with the tyres just clear of the
fill/level hole A. Oil should be level with the bottom of the fill/level hole. 4
Clean and refit fill/level plug A, torque to 79 Nm (58 lbf ft).
S113430
2
Remove fill/level plugs C. Allow time for the oil to drain out.
3
Set OIL LEVEL marks to the horizontal.
S113430
4
Fill the hubs with JCB recommended axle oil through the fill/level holes C. Oil should be level with the bottom of the fill/level hole.
S162260
5 9803/3260
Clean and refit fill/level plugs C. Issue 2*
Section 3
Routine Maintenance
Section 3
9-2
9-2
* Rear Axle Oil Level (All Wheel Steer Machines) Check Differential Oil Level - for Interval see Service Schedule 1
2
Remove fill/level plug A. Oil should be level with the bottom of the fill/level hole.
1
Make sure the OIL LEVEL mark on the hub is horizontal.
2
Remove fill/level plug C. Oil should be level with the bottom of the fill/level hole.
3
If necessary, top up with JCB recommended axle oil. Clean and refit fill/level plug C.
If necessary, top up with JCB recommended axle oil. Clean and refit fill/level plug A.
Change Hub Oil - for Interval see Service Schedule
Change Differential Oil - for Interval see Service Schedule 1
Check Hub Oil Level - for Interval see Service Schedule
1
Set the machine level, with the tyres just clear of the ground. Manually rotate the wheels to bring the OIL
Remove fill/level plug A and drain plug B. Allow time for the oil to drain out.
LEVEL mark on the hubs to the vertical position, with the fill/level plugs C at the bottom.
2
Clean and refit drain plug B.
3
Fill the axle with JCB recommended axle oil through the fill/level hole A. Oil should be level with the bottom of the fill/level hole.
4
Clean and refit fill/level plug A.
2
Remove fill/level plugs C. Allow time for the oil to drain out.
3
Set OIL LEVEL marks to the horizontal.
4
Fill the hubs with JCB recommended axle oil through
S113450
the fill/level holes C. Oil should be level with the bottom of the fill/level hole. 5 9803/3260
Clean and refit fill/level plugs C. Issue 2*
Section 3
Routine Maintenance
Section 3
9-3
9-3 Change Oil - for Interval see Service Schedule
Rear Axle Oil Level (2 Wheel Steer Machines)
1
Check Oil Level - for Interval see Service Schedule Note: It is essential that the machine is parked on level ground to ensure accurate oil level checking. 1
At the drive head casing remove fill/level plug A. Oil should be level with the bottom of the fill/level hole.
2
If necessary, top up with JCB recommended axle oil.
Set the machine level, with the machine tyres just clear of the ground. Manually rotate both wheels of the axle to bring the OIL LEVEL mark on the hubs to the vertical position, with the fill/level plugs C at the bottom.
Clean and refit fill/level plug A.
S113440
2
Remove fill/level plugs C from the hubs and drain plug B from the drive head casing. Allow time for the oil to drain out.
S113450
3
Clean and refit drain plug B.
4
Set both hub OIL LEVEL marks to the horizontal.
5
Fill the axle with the specified quantity of oil through drive head casing fill/level plug A. If the machine has been set level, oil should just dribble out both hub fill/level points.
6
Clean and refit both hub fill/level plugs C and fill/level plug A.
S113400
9803/3260
Issue 1
Section 3
Routine Maintenance
Section 3
10 - 1
10 - 1
Engine Oil and Filter Check Level - for Interval see Service Schedule 1
Make sure that the oil level is between the two marks on the dipstick A.
2
If necessary, top up with JCB recommended oil through filler point B.
3
Replace dipstick and filler cap.
Change Oil & Filter - for Interval see Service Schedule
! CAUTION 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
Remove drain plug C and discard the 'O' ring. Drain the oil into a suitable container. Clean and refit the drain plug with a new 'O' ring. Tighten to 34 Nm (25 lbf ft).
2
Change the filter: a b c d
Unscrew oil filter canister D. Clean the filter head E. Smear the new filter canister seal F with engine oil. Screw in the new filter canister - hand tight only.
3
Fill the engine with new oil. Wipe off any spilt oil. Check the system for leaks.
4
Replace filler cap.
After refilling with oil, extract from the fuse box (adjacent to the instrument console) the fuse controlling the electric fuel shut off valve (mounted on the fuel injection pump) then operate the starter until the oil pressure warning light is extinguished. Reinsert the electric shut off valve fuse, run the engine at idling speed for a few seconds, then check for oil leaks again.
S142900
9803/3260
Issue 1
Section 3
Routine Maintenance
Section 3
10 - 2
10 - 2
Engine Oil and Filter (From Serial No. 430001) Checking the Oil Level - for Interval see Service Schedule 1
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine.
2
Open the bonnet.
3
Check that the oil level is between the two marks on the dipstick A. Add oil if necessary, through filler B. Make sure that the dipstick and filler cap are fully inserted and tightened.
Changing the Oil and Filter - for Interval see Service Schedule
! 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
Place a container that can hold at least 12 litres (3 gal) beneath the engine (to catch the oil).
2
Remove drain plug C and its 'O' ring. Let the oil drain out, then clean and refit the drain plug with a new 'O' ring. Tighten to 34 Nm (25 lbf ft).
3
Change the filter: a Unscrew the filter canister D. Remember that it will be full of oil. b Check that adapter G is secure. c Clean the filter head F. d Add clean engine lubricating oil to the new filter canister. Allow enough time for the oil to pass through the filter element. e Smear the seal E on the new filter with oil. Screw in the new filter canister - hand tight only.
4
Fill the engine to the max mark on the dipstick with new oil through the filler. Check for leaks. Make sure the filler cap is correctly refitted.
5
Obtain oil pressure: Make sure the engine will not start and turn the starter switch to operate the starter motor until the oil pressure light is extinguished. (To make sure the engine will not start, remove the engine shut-off solenoid fuse, housed in the fuse box).
6
Check for leaks: Re-insert the engine shut-off solenoid fuse and operate the engine. Check for leaks. When the engine has cooled, check the oil level.
A
B
D
F S209020
9803/3260
E
C
G Issue 3
Section 3
Routine Maintenance
Section 3
10 - 3
10 - 3
* Fuel Filter (Glass Bowl Type)
* Fuel Filter (Spin-on Cartridge Type)
Drain - for Interval see Service Schedule
Drain - for Interval see Service Schedule
Drain off any water in bowl B by turning tap A.
Drain off any water in the element G by turning tap H.
Renew Element - for Interval see Service Schedule
Renew Element - for Interval see Service Schedule
1
Hold bowl B and unscrew bolt C, remove bowl and filter element E. Wash the bowl in clean fuel.
1
Unscrew the filter element G. The element is hand tight but may require a strap wrench to remove. The filter will be full of fuel.
2
Inspect seals D and 'O' ring seals F, renew if damaged. 2
3
Fit new element E, seals D, 'O' rings F and bowl B. Tighten bolt C. Check for leaks.
To assist with bleeding, fill the new filter element with fuel before fitting. Install new element G hand tight only. Check for leaks.
4
Bleed the fuel system as described on page 3/10-4.
3
Bleed the fuel system as described on page 3/10-4.
C F F
D E D
G
B D
A 9803/3260
D
H S142950
Issue 2*
Section 3
Routine Maintenance
Section 3
10 - 4
10 - 4
Fuel Sediment Bowl
Bleed the Fuel System ! CAUTION
Drain - for Interval see Service Schedule Drain off any water in bowl by turning tap G.
Running the engine with air in the system could damage the fuel injection pump. After maintenance, remove air from the system as detailed below.
Clean - for Interval see Service Schedule
2-3-3-7
1
Hold bowl J and unscrew bolt K. Remove and wash the bowl in clean fuel.
1
2
Refit the bowl; make sure seals are seated correctly.
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine.
3
Bleed the fuel system as described on page 3/10 - 4.
2
Set the starter key to the IGN position.
! WARNING
Note: Do not over-tighten bolt K.
Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. 2-3-3-2
3
Operate the fuel lift pump priming lever X slowly, for approximately two minutes. The engine is now ready to start. If the engine runs smoothly for a short time, and then begins to run roughly or stops, check again for air in the fuel system. Check all seals and connections, especially in the low pressure side of the system.
Note: If no fuel is moved when the fuel lift pump priming lever X is operated, then the pump diaphragm may have rested in a 'maximum lift' position. To move the diaphragm, use the starter key to turn the engine, then try the priming lever again.
K
J G
X S142960
9803/3260
S209040
Issue 1
Section 3
Section 3
Routine Maintenance
12 - 1
12 - 1
Cooling System Check Level - for Interval see Service Schedule
Antifreeze The protection provided by JCB Universal Anti-freeze is shown below. If any other anti-freeze is used, refer to the manufacturers' instructions and ensure that a corrosion inhibitor is included.
The engine coolant level can be visually checked when the engine is hot or cold. However if coolant needs to be added then make sure that the engine has cooled before removing the coolant reservoir cap.
DO NOT use solutions of more than 60% or less than 50% or damage to the cooling system will occur.
1
Park the machine on level ground.
2
Visually check the coolant level reservoir. The coolant level must be between the two marks indicated on the reservoir, shown at A.
Solution
Maintains circulation down to: deg C deg F
Protects against damage down to: deg C deg F
55%
-36
-41
-33
-42
The strength of the anti-freeze solution must be checked at least once a year, preferably at the beginning of the cold period. It is an advantage to leave the anti-freeze in all the year round as it gives continued protection against corrosion. Always renew the anti-freeze every two years. A 50% anti-freeze mixture must be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant's boiling point.
! WARNING The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the cap. Let the system cool before removing the cap. ENG-1-2
3
If necessary, top up with pre-mixed water/anti-freeze. Re-fit the cap.
* Note: After adding anti-freeze or topping up with pre-mixed solution ensure that the cab heater control is in the hot position and the engine run. This will ensure the coolant mixture circulates through the entire cooling system.
9803/3260
Issue 2*
Section 3
Routine Maintenance
12 - 2
Section 3 12 - 2
Cooling System Drain and Refill - for Interval see Service Schedule
! WARNING The cooling system is pressurised when the coolant is hot. Hot coolant will burn you. Make sure the engine is cool before draining the system. ENG-1-3
1
Park the machine on level ground.
2
Wait until the engine has cooled down.
3
Carefully loosen filler cap A and let any pressure escape, then remove the cap.
4
Remove drain plug C from the cylinder block and drain the coolant.
5
Remove the bolts holding the front radiator grille in position. Remove the grille to gain access to the radiator bottom hose.
6
Remove the radiator hose at D and drain the coolant.
7
Flush the system with clean water.
8
Refit drain points C and D, and the front radiator grille.
9
Fill the system with a correct water/anti-freeze mixture and refit filler cap A.
9803/3260
Issue 1
Section 3
Section 3
Routine Maintenance
13 - 1
13 - 1
Fan Belt
Cab Heater Filter
Check Tension - for Interval see Service Schedule
Clean - for Interval see Service Schedule
! WARNING
Adjustment
The filter may be filled with dust. Wear goggles and a face mask when removing the filter.
1
Park the machine on level ground.
2
Loosen bolts A, B, C, and D holding the alternator.
3
Reposition the alternator until belt deflection at point X is approximately 10mm (3/8 in.).
2-3-3-6
! WARNING Make the machine safe before getting beneath it. Lower the attachments to the ground; engage the parking brake; remove the starter key, disconnect the battery. 2-3-2-2
! CAUTION If any leverage is necessary, use a length of wood at the drive end bracket only; otherwise damage to the alternator may be caused.
1
Park the machine on level ground.
2
The filter is located beneath the cab. Remove the retaining screws E. Carefully slide the filter from its holder.
ENG 1-4
4
Tighten bolts A, B, C, and D ensuring that bolt at the rear of the alternator is the last to be tightened.
Note: If a new belt is fitted, the belt tension must be checked again after the first 20 hours of operation.
3
Knock loose dust off the filter. Wash the filter in clean water. Allow to dry.
Note: Do not squeeze the filter to dry it. Shake off the bulk of the water, then let the rest drain off. If the filter was clogged, clean it more often. 4
Carefully slide the filter into its holder. Fit and tighten the retaining screws E.
S099850
9803/3260
S145280
Issue 1
Section 3
Routine Maintenance
13 - 2
Section 3 13 - 2
Cab Heater Filter (From Serial No. 430001) Clean - for Interval see Service Schedule 1
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the attachments to the ground and stop the engine.
2
Remove the cover retaining screws (2 off) and then remove the cover, item E.
3
Knock loose dust off the filter F. Carefully blow compressed air through all the folds of the filter, blow in the opposite direction to the arrows marked on the filter.
Note: The compressed air must be set at a pressure no greater than 7 bar (100 lb/in2). 4
Refit the cover E and secure with the retaining screws (2 off).
F E
9803/3260
S209400
Issue 1
Section 3
Routine Maintenance
14 - 1
Section 3 14 - 1
AIr Filter Pre-Cleaner * Note: DO NOT run the engine with the pre-cleaner removed. Empty Pre-cleaner - for Interval see Service Schedule 1
Unscrew wingnut C and lift off cover D.
2
Carefully remove the dust bowl E and empty out any dust. Make sure that no dust is spilt into the air intake.
3
Wipe the bowl clean and re-assemble the pre-cleaner.
Note: To clean oil and grease from the pre-cleaner, wash in hot water with a little detergent. Dry before refitting. Note: Certain types of collector bowl may not have indicator markings, in which case empty the unit when one third full.
S142940
9803/3260
Issue 2*
Section 3
Routine Maintenance
Section 3
14 - 2
14 - 2
Air Filter Renew Outer Element - for Interval see Service Schedule
! CAUTION The outer element must be renewed immediately if the warning light on the instrument panel illuminates. 2-3-3-1
Renew Inner Element - for Interval see Service Schedule The inner element must be renewed at latest every third time the outer element is renewed. As a record, mark the inner element with a felt tip pen each time the outer element is renewed. 1
Prevent dust from entering the engine by disconnecting the induction hose H.
* Note: The elements must be renewed only. Do not attempt to clean them with an airline or by washing. Do not run the engine with raincap, pre-cleaner or dust valve removed.
2
Unscrew nut A and remove outer element B.
1
Unscrew nut A and remove outer element B.
3
Unscrew nut E and remove inner element F.
2
Clean inside canister and dust valve C.
4
Clean inside canister and dust valve C.
3
Fit new element B. Test seating of seal D by smearing with grease and checking for witness mark at base of canister.
5
Test seating of seal G by smearing with grease prior to
If the seal is correct, re-insert new outer element and
6
4
inserting new element F, then removing to check for witness mark at base.
tighten nut A.
If the seal is correct, re-insert new inner element and tighten nut E.
5
Ensure that dust valve C is at the bottom when refitting.
7
Insert new outer element B and test seating of seal D as previously described.
6
Check the security and condition of the induction hose and its clips. Ensure that the restriction indicator sensor is connected.
8
If the seal is correct, re-insert new outer element and tighten nut A.
9
Reconnect the induction hose H. Ensure that the restriction indicator sensor is reconnected.
S142970
9803/3260
Issue 2*
Section 3
Routine Maintenance
Section 3
15 - 1
15 - 1
Parking Brake The parking brake should be fully engaged when the lever is vertical. The parking brake indicator light should light when the brake is engaged with the forward/reverse lever away from neutral (starter switch at IGN).
! CAUTION The parking brake must not be used to slow the machine from travelling speed, except in an emergency, otherwise the efficiency of the brake will be reduced. Whenever the parking brake has been used in an emergency, always renew the brake pads. 4-2-1-1/1
! WARNING Asbestos dust can damage your lungs. The brake pads contain asbestos. Wear a face mask and gloves when working on or near the brake pads. Dispose of brake dust and used brake pads in accordance with local regulations. 2-1-1-7
Check Adjustment - for Interval see Service Schedule Pads should just touch disc as at A. Adjust at handle grip B if required and then test the parking brake as described on page G/21 - 1. Pad Renewal Renew pads when thickness C of the friction material is 3 mm (0.125 in). Back off all adjustment, slacken nut D and withdraw pads. Install new pads and set the parking brake as described on page G/21 - 1.
B
D
C
A 9803/3260
S151890
Issue 1
Section 3
Routine Maintenance
Section 3
15 - 2
15 - 2
Parking Brake - 5 Speed Gearbox Only To renew the brake pads, the parking brake caliper assembly must be removed, for this reason we recommend that only competent maintenance engineers renew the pads.
Test the parking brake as described on page G/24-2. If the machine moved during the test, check the pads and/or take up the cable slack.
The parking brake should be fully engaged when the lever is vertical. The parking brake indicator light should light when the brake is engaged with the forward/reverse lever away from neutral (starter switch at IGN).
1
Check the Pads Use feeler gauges and check the gap between the brake disc A and the face of the brake caliper housing (B). The gap should be greater than 1mm (0.040 in.). If the gap is less than 1mm renew the pads.
2
Take Up the Cable Slack Disengage the parking brake (lever horizontal). Turn handle grip C clockwise, half a turn. Test the parking brake. If the brake fails the test, repeat procedure.
3
Renew the Brake Pads a Disengage the parking brake (lever horizontal). Turn handle grip C to bring pin D central in its slot. b Remove clevis E, from top hole. c Loosen and remove bolts F, remove the caliper assembly. d Remove the old brake pads from the caliper housing. Fit new pads, align the flat G and raised portion H appropriately in the caliper housing. e Refit the caliper assembly to the gearbox, torque tighten bolts F to 244 Nm (180 lbf ft). f Refit clevis E, in the top hole. g Set the parking brake as described on page G/242.
! CAUTION The parking brake must not be used to slow the machine from travelling speed, except in an emergency, otherwise the efficiency of the brake will be reduced. Whenever the parking brake has been used in an emergency, always renew the brake pads. 4-2-1-1/1
! WARNING Before adjusting the parking brake, make sure that the machine is on level ground. Put chocks each side of all four wheels. Disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you. 2-3-2-4
B C
D
mm 1.0 0 in.) 4 (0.0
A F
E
A236450
F S234140A
G S236080
9803/3260
H
S234140B
Issue 4
Section 3
Routine Maintenance
Section 3
15 - 3
15 - 3
Service Brakes ! WARNING Faulty brakes can kill. If you have to add oil to the brake reservoir regularly get the brake system checked by your JCB distributor. Do not use the machine until the fault has been put right. 2-3-2-5
Checking The Foot Brake Fluid Level (to serial number
* 430000) - for interval see Service Schedules
* Checking The Foot Brake Fluid Level (from serial number 430001) - for interval see Service Schedules
1
If an adjustable steering column is fitted, slacken steering wheel tilt lock A. Move the steering wheel towards the rear of the machine.
2
Remove the reservoir cap B and check the level. The MAX and MIN marks are etched on the side of the reservoir.
1
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine.
2
Remove the reservoir cap A and check the level. The MAX and MIN marks are marked on the side of the reservoir B. If necessary, add fluid as in Step 3.
! WARNING
Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure.
If the system has fallen below the MIN mark add brake fluid and then bleed the system (see page G/11-1).
BRAK 1-1
3
If necessary, add fluid. If the system has fallen below the MIN mark add brake fluid and then bleed the system (see page G/11-1).
! CAUTION
! WARNING Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure. BRAK 1-1
Make sure the steering column is fully clamped before driving the machine.
3
If required, carefully pour the recommended fluid (DO NOT USE ORDINARY BRAKE FLUID) until it reaches the correct level.
4
Refit the reservoir cap. Wipe up any spillage.
5-2-1-3
4
Refit the reservoir cap. If an adjustable steering column is fitted, adjust the column to give the required position. Secure the steering column with tilt lock A.
A B B
A
S145080
S208981
9803/3260
Issue 1
Section 3
Routine Maintenance
16 - 1
Section 3 16 - 1
Battery ! WARNING *
Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches in the cab to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first. When reconnecting, fit the positive (+) lead first. Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up. 5-3-4-3
First Aid - Electrolyte EYES 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 FLUSH WITH WATER. REMOVE AFFECTED CLOTHING. Cleaning the Battery Check the battery regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the battery can cause a discharged condition in the battery. Use baking soda or ammonia and flush the outside of the battery with water. Use a special cleaner to prevent corrosion on the battery terminals. Checking the Electrolyte Level
! WARNING Do not top the battery up with acid. The electrolyte could boil out and burn you. 2-3-4-6
Remove covers. Look at the level in each cell. The 9803/3260
Issue 2*
Section 3
Routine Maintenance
Section 3
16 - 2
16 - 2
Battery Jump Starting - Safety
Jump Starting - Procedure 1
Make sure that the parking brake has been engaged and the transmission set to neutral.
2
Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge.
Lower the loader shovel to the ground, if it is not already there. If the machine is fitted with hose burst protection valves, the shovel will not lower, in this instance, install the loader arm safety strut.
3
Set all switches in the cab to the 'OFF' position.
Batteries give off a flammable gas that can explode.
4
a Connect the positive (+) jump lead from the booster supply to the positive (+) battery terminal.
! WARNING If you try to charge a frozen battery, or jump-start and run the engine, the battery could explode
Do not smoke when checking the battery electrolyte levels. When starting from another machine, make sure the two machines do not touch. This prevents any chance of sparks near the battery. Sparks could ignite the battery gas. If that happens the battery could explode. Even with the starter switch set to off some circuits will be energized when the external power supply is connected. Set all the machine switches to their OFF positions before connecting the external power supply. Do not connect a booster supply directly across the starter motor. Doing this could bypass the neutral safety switch and the engine can start with the transmission in gear. The machine could then run away and kill or injure bystanders.
b Connect the negative (-) jump lead from the booster supply to a good frame earth, away from the battery. Note: A good frame earth is part of the machine mainframe, free from paint and dirt. 5
Start the engine.
6
a Disconnect the negative (-) jump lead from the machine frame earth. b Disconnect the positive (+) jump lead from the positive (+) battery terminal.
Use only booster cables which are in good condition with securely attached connectors. Connect both ends of one booster cable before connecting the other one. 5-2-2-3
9803/3260
Issue 1
Section 3
Routine Maintenance
Section 3
17 - 1
*
17 - 1
Boom Lock - Checking the Hydraulic Fluid Level Note 1: Machines from serial number 430001 to 433723 have the boom lock operated by a cable, not hydraulic fluid. Machines to Serial Number 430000 1
Remove cover A.
2
Remove the reservoir cap B and check the level. The MAX and MIN marks are marked on the side of the reservoir.
3
Top up as required, use JCB recommended fluid. If the level has fallen below the MIN mark, bleed the system. See page D/10 - 2.
B
A
S148100
Machines from Serial Number 433724 1
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the backhoe and loader end to the ground and stop the engine.
2
Check that the oil level is between the MAX and MIN marks on the reservoir B.
3
If required, remove the reservoir cap C and add recommended fluid (see Note 2). If the level has fallen below the MIN mark, bleed the system. See page D/10 - 2.
4
Refit the cap.
C B
Note 2: The initial fluid used at JCB contains a blue dye to ease the assembly process. This dye will not be present in the standard recommended fluid.
S229090
9803/3260
Issue 3*
Section 3
Routine Maintenance
18 - 1
Section 3 18 - 1
Hydraulic Oil Cooler Clean - for Interval see Service Schedule 1
Raise and lock the loader arms, see page 3/5 - 1.
2
Release bolts A and remove the radiator grille.
3
Brush off all debris from the cooler tubes and fins. Make sure the loosened material is brushed out of the cooler enclosure.
4
Refit the radiator grille.
S145230
9803/3260
Issue 1
Section 3
Routine Maintenance
19 - 1
Section 3 19 - 1
Bulb Replacement Headlight Bulb 1
Release 4 cover screws A, support the light unit and remove the cover.
2
Release the sealed beam unit B from its electrical socket (see note).
Note: Because of legislative requirements, some territories may have a replaceable bulb fitted in the headlight unit, not a sealed unit. 3
Fit a new sealed unit (see note) and assemble light unit.
Front Sidelight Bulb 1
Release 4 cover screws A, support the light unit and remove the cover.
2
Release the sealed beam unit B from its electrical socket (see note).
Note: Because of legislative requirements, some territories may have a replaceable bulb fitted in the headlight unit, not a sealed unit. 3
Release sidelight bulb C from its holder.
4
Fit a new sidelight bulb.
5
Refit the sealed unit (see note) and assemble light unit.
S152260
9803/3260
Issue 1
Section 3
Routine Maintenance
Section 3
19 - 2
19 - 2
Bulb Replacement (cont'd) Note: Do not touch the new worklight bulb with bare fingers, otherwise the bulb will be rendered useless. Front Indicator Light Bulb Worklight Bulb 1
Remove screws H (2 off), support the light unit J otherwise it could fall and break.
2
Lift and turn light unit J to gain access to connector L.
3
Disconnect at L.
4
Remove bulb by releasing clips M.
5
Do not touch bulb with bare fingers. Fit a new bulb.
6
Reassemble light unit in the reverse order.
1
Remove screws A (2 off) to release lens glass.
2
Release bulb by pushing in and turning 1/8 turn anticlockwise. Remove the bulb.
3
Fit a new bulb. Make sure it is secure.
4
Reassemble light unit in the reverse order.
S152250
9803/3260
Issue 1
Section 3
Routine Maintenance
Section 3
19 - 3
19 - 3
Bulb Replacement (cont'd) Rear Brake/Sidelight & Indicator Bulb
* Note:
The illustration shows a sideshift machine, on centremount machines the rear light assembly is mounted in the cab roof. 1 2
Fog Light Bulb (if fitted) 1
Remove screws B (2 off) to release lens glass.
2
Release bulb by pushing in and turning 1/8 turn anticlockwise. Remove the bulb.
3
Fit a new bulb. Make sure it is secure.
4
Reassemble light unit in the reverse order.
Remove screws A (2 off) to release lens glass. Release bulb by pushing in and turning 1/8 turn anticlockwise. Remove the bulb.
3
Fit a new bulb. Make sure it is secure.
4
Reassemble light unit in the reverse order.
S152230
9803/3260
Issue 2*
Section 3
Routine Maintenance
Section 3
19 - 4
19 - 4
Bulb Replacement (cont'd) * Note: The following text is not applicable to machines in the U.S.A.
Cab Interior Light Bulb 1
Carefully lever light unit F from the roof, using a screwdriver in the slot at one end.
2
Ease the spring contact G to release the bulb.
3
Fit a new bulb. Make sure the bulb is seated in the spring contact holes.
4
Refit light unit F, take care not to trap the wires.
Number Plate Light Bulb 1
Remove screw B to release light cover.
2
Ease spring contact C to release the bulb.
3
Fit a new bulb. Make sure the bulb is seated in the spring contact holes.
4
Reassemble light unit in the reverse order.
S152220
9803/3260
Issue 2*
Section 3
Routine Maintenance
Section 3
19 - 5
19 - 5
Bulb Replacement (cont'd) Note: Do not touch the new beacon bulb with bare fingers, otherwise the bulb will be rendered useless.
*
Note: The following text is not applicable to machines in the U.S.A. Switch Illumination Bulbs Rotating Beacon Bulb 1
Unscrew the centre portion J of the switch.
2
Carefully remove the bulb using a pair of tweezers. It is a straight pull from the holder, do not twist the bulb.
Disconnect bulb at E.
3
Fit a new bulb.
4
Do not touch bulb with bare fingers. Fit a new bulb. Make sure the bulb is seated correctly and the spring clip C is secure.
4
Refit the centre portion of the switch.
5
Reassemble light unit in the reverse order.
1
Remove screws A (3 off) and remove cover B.
2
Release spring clip C and ease bulb from holder D.
3
S152240
9803/3260
Issue 2*
Section A
Attachments
Section A
i
i
Contents
Page No.
Hydraulic Tool Circuit (H.T.C.) Schematic Hydraulic Circuit Circuit Description Flow Diverter Valve Removal and Replacement Flow Diverter Valve Dismantling and Assembly Flow Testing & Pressure Testing
1-1 1-2 1-3 1-4 1-5
Extradig Dipper Wear Pads - Upper/Lower Inspecting the Top Wear Pads Adjusting the Bottom Wear Pads
2-1 2-2
Auxiliary Valve Removal and Replacement Dismantling and Assembly Pressure Testing
5-1 6-1 7-1
* Schematic Hydraulic Circuits Low Flow Circuit High Flow Circuit Extending Dipper fitted with Rockbreaker
9803/3260
10 - 1 11 - 1 12 - 1
Issue 3*
Section A 1-1
Attachments Hydraulic Tool Circuit (H.T.C.)
Section A 1-1
Schematic Hydraulic Circuit Component Key 1
Hydraulic Tank
2
Pump (Section 2)
3
Steering Priority Valve
4
Priority Flow Divider
5
Excavator Auxiliary Valve Block
6
Loader Valve Block
7
B.H.T.M.A. Class 'C' Quick Release Couplings
8
HTC Switch
S209080
9803/3260
Issue 1*
Section A 1-2
Attachments Hydraulic Tool Circuit (H.T.C.)
Section A 1-2
Circuit Description Oil from section P2 of hydraulic pump 2 enters the steering priority valve 3 (associated circuits not shown). From here the oil passes to flow diverter valve 4. This valve establishes a priority (and controlled) flow to the hydraulic tool circuit (HTC). If the hydraulic tool circuit has not been selected, the oil passes from port B of valve 4 to the auxiliary backhoe valve 5. From here the oil passes via the loader valve 6 to tank 1. When the HTC is selected a solenoid inside valve 4 is energised, this causes the flow of oil inside the valve to be diverted to port P and on to the HTC via quick release couplings 7. Return oil from the HTC passes directly to tank via hose C. The flow of oil from port P is regulated regardless of changes in load pressure or pump flow. Any excess oil is distributed to port B for use in other actuators (eg. extending dipper). The diverter valve 4 also incorporates a relief valve; when the
S209070
9803/3260
Issue 1*
Section A
Section A
Attachments Hydraulic Tool Circuit (H.T.C.)
1-3
1-3
Flow Diverter Valve Removal and Replacement
! WARNING Make the machine safe before working underneath it. Park the machine on level ground, lower the arms. Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-2
Removal 1
2
3
4
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the backhoe and loader end to the ground and stop the engine.
Replacement Replacement is a reversal of the removal sequence.
! 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 immendiately. INT-3-1-10/1
Make sure that the hoses are correctly installed. The hose connections from the flow diverter valve are as follows: Port E = to the steering priority valve. Port P = to the HTC quick release coupling
Operate the loader valve block control levers back and forth to vent residual hydraulic pressure.
Port B = to the excavator auxiliary valve block
Disconnect all hydraulic hoses from the valve block and plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct refitting.
Note: The flow diverter valve ports should be stamped 'E', 'P', 'B' and 'T'.
Remove the electrical solenoid connector.
Port T = to the hydraulic tank
After replacement check the flow setting and the relief valve pressure settings (see pages A/1 - 5 and A/1 - 6).
S209060
9803/3260
Issue 1*
Section A 1-4
Section A
Attachments Hydraulic Tool Circuit (H.T.C.)
1-4
Flow Diverter Valve Dismantling and Assembly
Torque Settings
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Item 4
Nm 30
kgf m 3.0
lbf ft 22
22
45
5.4
33
For assembly the sequence should be reversed. When Assembling
After assembly make sure that the valve is set for the correct flow and pressure, refer to page A/1 - 5 and A/1 - 6.
Renew all seals and 'O' rings. Lubricate with JCB Special Hydraulic Fluid.
S209360
9803/3260
Issue 1*
Section A 1-5
Attachments Hydraulic Tool Circuit (H.T.C.)
Section A 1-5
Flow Testing & Pressure Testing
A209090
9803/3260
Issue 1*
Section A
Attachments Hydraulic Tool Circuit (H.T.C.)
1-6
Section A 1-6
Flow Testing & Pressure Testing ! WARNING
4
Pressure Testing
Hydraulic Fluid 4.1 Use the flow restrictor valve to pressurise the circuit. As the pressure rises watch the flow reading, it should start to fall when the pressure reaches 138 bar (2000 lb/in2).
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.
4.2 If adjustment is required, loosen locknut E and turn adjusting screw F until the correct pressure is obtained.
INT-3-1-10/1
! WARNING
5
Stop the engine, vent residual pressure and remove the pressure gauge, flow meter and flow restrictor valve.
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
Prepare the Machine 1
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the backhoe and loader end to the ground and stop the engine.
2
Operate the loader valve block control levers back and forth to vent residual hydraulic pressure.
3
Flow Testing 3.1 Connect a suitable pressure gauge, flow meter and flow restrictor valve across the flow and return couplings on the machine, as shown at A. For reference, items are identified as: X = Pressure Gauge Y = Flow Meter Z = Flow Restrictor Valve
CAUTION: Make sure that the flow restrictor valve Z is fully OPEN (the adjusting knob screwed fully out) before starting the engine. 3.2 Start the engine and set the R.P.M. to 1500. 3.3 Enable the HTC circuit, i.e. press the HTC switch B to the 'ON' position. 3.4 Note the flow meter reading, the valve should be set at 20 litres/min. If adjustment is required, loosen locknut C and turn adjusting screw D until the 9803/3260
Issue 1*
Section A
Attachments Extradig Dipper Wear Pads - Upper/Lower
2-1
Section A 2-1
The Extradig dipper wear pads are bolt-on replaceable items. They support and guide the inner dipper section during extension and retraction. The following procedures explain how to inspect, and where applicable, adjust the pads.
Inspecting the Top Wear Pads
There is a front and rear set of pads, each set comprises top wear pads A and bottom wear pads B.
Position the boom and dipper as shown at C. Retract the
The top wear pads A are not adjustable and must be replaced with new pads once they have worn to their limit. See Inspecting the Top Wear Pads. The bottom wear pads B are adjustable and take up the wear on both the top and bottom pads. They must also be replaced with new pads once they have worn to their limit. See Adjusting the Bottom Wear Pads, page 2 - 2.
Park the machine on level ground. Engage the parking brake and put the transmission in neutral.
Extradig dipper D. Make sure that the bucket is clear of the ground and the dipper is supported. Stop the engine. Inspect all the top wear pads, if the pads are worn to the recess as shown at E then the pads must be replaced with new ones. If the pads are worn near to their limit then inspect them more frequently than recommended in the Service Schedules.
New wear pads A and B must be replaced as a set and fitted by a qualified service engineer.
E A
A B
B
D
C
S148110
9803/3260
Issue 1*
Section A
Section A
Attachments Extradig Dipper Wear Pads - Upper/Lower
2-2
2-2
If the gap is greater than 1/16 in (1.5 mm) then adjust as follows:
Adjusting the Bottom Wear Pads Park the machine on level ground. Engage the parking brake and put the transmission in neutral.
a Remove one adjusting bolt H and discard one washer J.
Support the boom and dipper as shown at C.
b Refit and tighten bolt H.
Stop the engine.
c Repeat the procedure for the remaining 3 adjusting
Clean the sliding faces of the inner dipper F with a suitable solvent.
d Visually re-check the gap is no greater than 1.5 mm
Start the engine. Retract the Extradig dipper D. Make sure that the bucket is clear of the ground and the dipper is supported.
for the other 4 bolts H on the opposite side of the dipper. e Make sure that the inner dipper seats central to the sides of the outer dipper.
bolts H on the same side of the dipper.
Stop the engine. With grease, mud etc. removed from the sliding faces visually check the gap between inner dipper and top wear pad A, as shown at G. The gap should be no greater than 1.5 mm (1/16 in).
(1/16 in) as shown at G, if necessary repeat steps a to c
Note: Remember to alternate sides each time an adjustment is made. Note: When all the adjusting washers J have been removed and the clearance is greater than 1.5 mm (1/16 in), then wear pads A and B must be replaced as a set and fitted by a qualified service engineer. When the adjustments have been completed, apply Waxoyl to the runners of the inner dipper F.
J
J G H
A
G
A
F
H
D H
C S148120
9803/3260
Issue 1*
Section A
Attachments
Section A
Auxiliary Valve
5-1
5-1
Auxiliary Valve
Replacement
Removal and Replacement
Replacement is a reversal of the removal sequence.
! WARNING
Make the machine safe before working underneath it. Park the machine on level ground, lower the arms. Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-2
! 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. INT-3-1-10/1
Removal 1
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the attachments to the ground and stop the engine.
2
Operate the auxiliary valve control pedal back and forth to vent residual pressure.
3
Remove clevis pin A to disconnect the auxiliary pedal from the valve block spool.
4
Disconnect all hydraulic hoses from the valve block and plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct position when refitting.
Note: For clarity, the illustration shows some of the hoses removed. 5
After replacement check the auxiliary relief valve (A.R.V.) pressure settings. For pressure testing the A.R.V.'s, refer to page A/7-1. For dismantling and assembling the auxiliary valve, refer to page A/6-1. For reference, the port connections are as follows: Port C D E F G
Destination (low flow circuit) Excavator Valve Pipework (exhaust) Loader Valve Low Flow Attachment (e.g. extending dipper ram) Low Flow Attachment (e.g. extending dipper ram) Priority Valve (feed from)
Note: On the high flow circuit, port F is blanked (port E feeds the high flow attachment). Also, the diverter valve X is fitted.
Loosen and remove nuts B and remove the auxiliary valve assembly.
A C
B F
A218180
D
G
E
B X
9803/3260
S218170
Issue 1
Section A
Section A
Attachments Auxiliary Valve
6-1
6-1
5 4 3 1, 2 8 30 9 10 23 S218220
1
22
2
6
30A
19
Z
26 7
Y
27 25 28
24
X 21 20
S218240
18 17 16
A
29A
15
29
S218930
14 13 12 11 9803/3260
S218210
Issue 1
Section A 6-2
Section A
Attachments Auxiliary Valve
6-2
Auxiliary Valve Following removal of the valve from the machine, plug all ports and thoroughly clean the outside of the casing. Dismantling and Assembly Make sure the working area is clean. The numerical sequence on the illustration is intended as a guide to dismantling. For assembly reverse the sequence. Depending on the nature of the fault, it may only be necessary to work on individual parts of the assembly as follows: 1
If there is an oil leak between the units, carry out the sequence involving items 1 to 7.
2
3
4
When Assembling Fit new 'O' rings, back-up seals and shims to replace those discarded in the dismantling procedures. Use a suitable rod through the operating linkage hole to prevent spool 19 rotating while installing shoulder screw 13. When installing valve guide 24, make sure the hole in the side aligns with the tie-rod hole in the casing. When clamping the units together, position the assembly on the bench with the tie-rods horizontal. Tighten nuts 1 onto tie-rods in the order X, Y, Z and then X again. Fit seal retainers 10 and 18 with rounded radius (item A) nearest the housing.
If a spool is faulty carry out the sequence involving items 8 to 23.
Relief Valves
If a check valve is faulty, remove tie-rod X and carry out the sequence involving items 24 to 28.
Ensure that ARV's 29 and 30 are correctly adjusted and fitted in their specified positions. Refer to page A/7-1 for pressure testing procedures.
Pressure relief valves 29 and 30 can be individually removed.
Torque tighten the ARV's to 20 - 24 Nm (14.75 - 17.7 lbf ft, 2.04 - 2.44 kgf m).
When Dismantling
Torque Settings
If removing units 4, place the assembly with its output unit 5
Item 1
Nm 26 - 28
Kgf.m 2.65 - 2.85
lbf.ft 19.1 - 20.6
8, 11, 13
5-8
0.51 - 0.82
3.7 - 5.9
resting on a firm flat surface with tie-rods X, Y and Z vertical. Remove and discard seals 6 and shims 7 from between the units. Identify the relative positions of the units. The exploded view shows valve section 4. To facilitate removal of shoulder screw 13, prevent spool 19 rotating by inserting a suitable rod (e.g. a screwdriver blade) in the operating linkage hole at the end of the spool. In the course of dismantling: 1
Discard wiper seals 20, 23 and 'O' rings 21, 22.
2
Unless damaged, do not remove 'O' ring 27 and back-up seal 28 from valve guide 24. If damaged remove and discard.
3
Discard 'O' rings 29A.
4
Discard 'O' rings 30A.
9803/3260
Issue 1
Section A
Section A
Attachments Auxiliary Valve
7-1
7-1
Pressure Testing Auxiliary Relief Valve (A.R.V.) Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F). Lower the backhoe bucket and loader shovel to rest on the ground, lower the stabilisers and stop the engine. Note: For clarity, the illustration shows some of the hoses removed. 1
4
Knuckle Boom: 4.1 Set the engine speed to 1000 RPM. 4.2 Raise the boom. Swing the knuckle to the left, the pressure gauge will indicate the setting of the head side ARV (item B). Refer to Technical Data, page E/1-3.
Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector A next to the priority valve.
2
Make sure that the area is clear of all personnel.
3
Extending Dipper: 3.1 Set the engine speed to 1000 RPM. 3.2 Raise the boom and dipper. Fully extend the extradig dipper and hold, the pressure gauge will indicate the setting of the head side ARV (item B). Refer to Technical Data, page E/1-3.
4.3 If the pressure is incorrect, slacken locknut C and adjust cap D as required. Re-tighten the locknut after the correct setting has been achieved. 4.4 Raise the boom. Swing the knuckle to the right, the pressure gauge will indicate the setting of the rod side ARV (item E). If the pressure is incorrect, slacken locknut F and adjust cap G as required. Re-tighten the locknut after the correct setting has been achieved.
3.3 If the pressure is incorrect, slacken locknut C and adjust cap D as required. Re-tighten the locknut after the correct setting has been achieved. 3.4 Raise the boom and dipper. Fully retract the extradig dipper and hold, the pressure gauge will indicate the setting of the rod side ARV (item E). If A218200
the pressure is incorrect, slacken locknut F and adjust cap G as required. Re-tighten the locknut after the correct setting has been achieved.
G F
E
A C S147680B
9803/3260
B D
S218190
Issue 1
T
Section A
10 - 1
9803/3260
Low Flow Attachment Circuit
6
6A
S
3 4
4V 4M
3H
P1 1A
4E 3M
26
3Q
4W
3L
4N 4P
4F 13
1A
3N
3B
3P
2A
Attachments
P2
Hydraulic Schematic Circuits
3C
3A 7 EF
7B
P
P2A
CF
12 12A 12D
PP
67
10 - 1
Issue 1
A257880
Section A
12B
12C
9803/3260
Low Flow Attachment Circuit Refer also to basic machine circuit on page E/2-2. Schematic below shows additional items used with ‘Low Flow’ attachment circuit. Component Key
Issue 1
P1 P2 P2A S T 1A 2A 3 3A 3B 3C 3H 3L 3M 3N 3P 3Q 4 4E 4F 4M 4N 4P 4V 4W 6 6A 7 7B 12 12A 12B 12C 12D 13 26 67 Bucket)
Pump, Main Section Pump, Secondary Section Pressure Test Point (auxiliary attachments) Suction Line Tank Neutral Circuit Line Neutral Circuit Line Loader Valve Block Pressure Test Point (M.R.V.) Main Relief Valve Loader Lift Ram Spool Load Hold Check Valve Unloader Valve Spool Unloader Pilot Valve Unloader Check Valve Pressure Test Point (Unloader) Hydraulic Speed Control Solenoid Excavator Valve Block Dipper Spool Bucket Spool Dipper Ram Head Side A.R.V. Dipper Ram Rod Side A.R.V. Bucket Ram Head Side A.R.V. Load Hold Check Valve Load Hold Check Valve In-tank Filter Filter By-pass Valve Priority Valve Connection to Steer Circuit Attachment Valve Block Attachment Valve Spool Load Hold Check Valve Attachment A.R.V. Attachment A.R.V. Anti-cavitation Check Valve Hydraulic Oil Cooler Low Flow Attachment (e.g. Extradig, Jaw
T
Section A
11 - 1
9803/3260
High Flow Attachment Circuit
6 4
4V 6A
4M 4E
4W S
4N
3
4P 4F
P2
3H
P1 1A
4Q
21
3M 26
3Q
3L 9 8 9A
13
1A
3N
3B
3P
2A
Attachments
Hydraulic Schematic Circuits
3C
3A 7 EF
7B
68
P
P2A
CF
12 12A 12D
PP
12B
12C
23
23
Section A
11- 1
Issue 1
A259430
9803/3260
High Flow Attachment Circuit Refer also to basic machine circuit on page E/2-2. Schematic below shows additional items used with ‘High Flow’ attachment circuit. Component Key P1 P2 P2A S T 1A 2A 3 3A 3B 3C 3H 3L 3M 3N 3P 3Q 4 4E 4F 4M 4N 4P 4Q 4V 4W 6 6A 7 7B
Pump, Main Section Pump, Secondary Section Pressure Test Point (auxiliary attachments) Suction Line Tank Neutral Circuit Line Neutral Circuit Line Loader Valve Block Pressure Test Point (M.R.V.) Main Relief Valve Loader Lift Ram Spool Load Hold Check Valve Unloader Valve Spool Unloader Pilot Valve Unloader Check Valve Pressure Test Point (Unloader) Hydraulic Speed Control Solenoid Excavator Valve Block Dipper Spool Bucket Spool Dipper Ram Head Side A.R.V. Dipper Ram Rod Side A.R.V. Bucket Ram Head Side A.R.V. Bucket Ram Rod Side A.R.V. (see note) Load Hold Check Valve Load Hold Check Valve In-tank Filter Filter By-pass Valve Priority Valve Connection to Steer Circuit
Note: Auxiliary relief valve 4Q is only fitted on machines equipped with a Powerbreaker circuit.
8 9 9A 12 12A 12B 12C 12D 13 21 23 26 68
Diverter Valve Solenoid Valve Check Valve Attachment Valve Block Attachment Valve Spool Load Hold Check Valve Attachment A.R.V. Attachment A.R.V. Anti-cavitation Check Valve Sequence Valve Quick Release Coupling Hydraulic Oil Cooler High Flow Attachment (e.g. Powerbreaker)
Issue 1
T
Section A
12 - 1
9803/3260
Extending Dipper fitted with Rockbreaker
6 4
4V 6A
4M 4E
4W S
4N
3
4P 4F
P2
3H
P1 1A
4Q
21
3M 26
3Q
3L 9 8 9A
13
1A
3N
3B
3P
2A
Attachments
Hydraulic Schematic Circuits
3C
3A 7 EF
7B
68
P
P2A
CF
12 12A 12D
PP
12B
12C
23
23
Section A
12- 1
Issue 1
A259430
9803/3260
Extending Dipper fitted with Rockbreaker Refer also to basic machine circuit on page E/2-2. Schematic below shows additional items used on ‘Extending Dipper fitted with Rockbreaker’ attachment circuit. Component Key P1 P2 P2A S T 1A 2A 3 3A 3B 3C 3H 3L 3M 3N 3P 3Q 4 4E 4F 4M 4N 4P 4Q 4V 4W 6 6A 7 7B
Pump, Main Section Pump, Secondary Section Pressure Test Point (auxiliary attachments) Suction Line Tank Neutral Circuit Line Neutral Circuit Line Loader Valve Block Pressure Test Point (M.R.V.) Main Relief Valve Loader Lift Ram Spool Load Hold Check Valve Unloader Valve Spool Unloader Pilot Valve Unloader Check Valve Pressure Test Point (Unloader) Hydraulic Speed Control Solenoid Excavator Valve Block Dipper Spool Bucket Spool Dipper Ram Head Side A.R.V. Dipper Ram Rod Side A.R.V. Bucket Ram Head Side A.R.V. Bucket Ram Rod Side A.R.V. (see note) Load Hold Check Valve Load Hold Check Valve In-tank Filter Filter By-pass Valve Priority Valve Connection to Steer Circuit
Note: Auxiliary relief valve 4Q is only fitted on machines equipped with a Powerbreaker circuit.
8 9 9A 12 12A 12B 12C 12D 13 21 22 23 26 67 Bucket) 68
Diverter Valve Solenoid Valve Check Valve Attachment Valve Block Attachment Valve Spool Load Hold Check Valve Attachment A.R.V. Attachment A.R.V. Anti-cavitation Check Valve Sequence Valve Ball Valve (see note 2) Quick Release Coupling Hydraulic Oil Cooler Low Flow Attachment (e.g. Extradig, Jaw High Flow Attachment (e.g. Powerbreaker)
Note 2: To operate a high flow attachment, disconnect extending dipper ram at quick release couplings (23). Attach hoses from auxiliary valve block 12 to the quick release couplings of the high flow attachment. Turn ball valve 22 to the off position (no through flow).
Issue 1
Section B
Body & Framework
Section B
i
i
Contents
Page No.
Bodywork/Frame Engine Side Panels - Removal and Replacement
1-1
Engine Cover - Removal and Replacement
1-1
Rivet Nuts - Fitting Procedure - Specifications
2-1 2-1
Slide hammer Kit - Procedures
3-1
Cab Rops/Fops Structure - Checking
10 - 1
* Air Conditioning (machines up to serial number 430000) - Operation - Control - Safety Procedures - Fault Finding - Checking Refrigerant Charge Level - Leak Testing - Tightening Leaking Hoses - Blower Motor Removal and Replacement - Thermostat - Compressor Clutch Relay - Pressure Switches - Testing - Removal and Replacement - Condensor Coil Cleaning - Adjusting the Compressor Drive Belt
* Air Conditioning (machines from serial number 430001) - Technical Data * - Safety Procedures * * - Operation - Control * - Fault Finding * - Checking Refrigerant Charge Level * - Refrigerant Charging & Discharging * - Leak Testing * * - Tightening Leaking Hoses * - Blower Motor Removal and Replacement * - Pressure Switches * - Testing * - Removal and Replacement * - Condensor Coil Cleaning * - Adjusting the Compressor Drive Belt Glazing - General - Rubber Seal Glazing - Direct Glazing
9803/3260
12 - 1 12 - 5 12 - 3 12 - 4 12 - 7 12 - 7 12 - 7 13 - 1 13 - 1 13 - 1 13 - 2 13 - 2 13 - 3 13 - 3
14 - 1 14 - 1 14 - 2 14 - 3 14 - 4 14 - 6 14 - 6 14 - 6 14 - 6 14 - 21 14 - 22 14 - 22 14 - 23 14 - 24 15 - 2 15 - 2 15 - 2
Issue 5*
Section B
Body & Framework
Section B
ii
ii
Contents
9803/3260
Page No.
Loader Front End Loader Arms - Removal and Replacement
20 - 1
Stabiliser Legs (Sideshift Machines) - Removal and Replacement
25 - 1
Stabiliser Legs Centremount Machines) - Removal and Replacement
26 - 1
Backhoe Slew Cylinders (Sideshift Machines) - Dismantling and Assembly
30 - 1
King Post & Carriage (Sideshift Machines) - Dismantling and Assembly
31 - 1
Boom & Dipper - Removal and Replacement
35 - 1
Issue 1
Section B
Section B
Body & Framework
1-1
1-1
Engine Side Panels
Engine Cover
Removal and Replacement
Removal and Replacement 1
Remove the side panels.
! WARNING Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut. GEN 3-2
! WARNING A hot exhaust will burn you. Make sure the exhaust stack is cool before removing it. 2-3-1-6
1
Raise and lock the loader arms. 2
Loosen clamp F and remove exhaust stack D.
3
Loosen clamp C and remove pre-cleaner B.
4
Remove bolts E, pull cover G forward to release pins H.
5
Lift the engine cover off.
! WARNING Do not remove the engine side panels while the engine is running. 2-3-1-5
2
Stop the engine and remove the key.
3
Remove the side panel fixing screw A. Lift the side panel off.
4
To replace the side panel; slot into position and secure
Replacement is a reversal of the removing procedure.
with fixing screw A.
S145240
S146060
9803/3260
Issue 1
Section B
Body & Framework
2-1
Section B 2-1
Rivet Nuts Fitting Procedure A 'Rivet Nut' is a one piece fastener installed 'blind' from one side of the machine body/framework. The rivet nut is compressed so that a section of its shank forms an 'upset' against the machine body/framework, leaving a durable thread (see illustrations). Rivet nuts are fitted to various parts of the machine body and framework. They are used in a number of applications, for instance, hose clamp and cab floor plate retention etc. Various sized rivet nuts are available, see the table below to determine the size of rivet nut to be used for particular applications. If for any reason a new rivet nut requires fitting, then the correct installation procedure must be followed: 1
Drill a hole in the machine body/framework where the rivet nut is to be fitted. De-burr hole edges.
2
Screw the rivet nut onto the mandrel of the installation tool. The bottom of the mandrel should be in line with the bottom of the rivet nut, shown at A.
3
Wind the body of the installation tool down the threaded mandrel until it touches the head of the rivet nut, shown at B.
4
Insert the rivet nut (assembled to the tool) into the hole drilled in step 1.
5
Hold handle C and at the same time draw the mandrel into the installation tool by turning nut D. The rivet nut will contract in length and form an 'upset' (smooth bulge) seating itself against the body/framework (see inset E).
Note: The thread of the rivet nut must not be stripped, take care when 'upsetting' the rivet nut. 6
Remove the installation tool.
Specifications (all dimensions in mm) Rivet Nut Thread Diameter
Rivet Nut Outside Diameter
Material Thickness
M5
7
M6
M8
9803/3260
Rivet Length (Total)
Drill Hole Dia.
0.25 - 3.00 3.00 - 5.50
14.00 17.00
7.10
9
0.50 - 3.00 3.00 - 5.50
16.00 19.00
9.10
11
0.50 - 3.00 3.00 - 5.50
18.00 21.00
11.10
S150970
Note: In an emergency, and if no installation tool is available, it is possible to fit a rivet nut by using a nut and bolt the same thread diameter as the rivet nut being installed. However, this is not the recommended method.
Issue 1
Section B
Body & Framework
3-1
Section B 3-1
Slide Hammer Kit Procedures The slide hammer kit is used to remove pivot pins that must be extracted, i.e. cannot be 'knocked through'. The purpose of this description is to explain how the kit and the various components are used to remove the pivot pins. The adaptors A that form part of the kit have a screwed thread at each end. One of the threads will always be M20 size, this is to accommodate the end stops, items B and C. The other end of the adaptor will have varying thread sizes to suit the different size of threads in the pivot pins.
1
2
5
Fit the 'slide hammer', item F, onto the slide bar as shown.
6
Finally, fit another end stop, item C, at the end of the slide bar, as shown. The slide hammer kit is now ready to use.
7
To extract the pivot pin, slide the hammer along the bar
Prepare the pivot pin, for instance, if fitted, remove the pivot pin retaining bolt. Determine the thread size of the pivot pin and then fit the appropriate adaptor A as shown. Use the spanner flats D to securely fit the adaptor.
3
Fit an end stop B onto the other end of the adaptor (M20 thread size), make sure that the adaptor threads are fully engaged.
4
Fit the 'slide bar' E into the end stop. Again make sure that the threads are fully engaged.
until it contacts end stop C. Repeat this step until the pivot pin is released. 8
To remove the slide hammer kit, reverse the steps described above.
S196900
9803/3260
Issue 1
Section B
Body & Framework
10 - 1
Section B 10 - 1
Roll Over Protection & Falling Object Protection (ROPS/FOPS) Structure Checking
! WARNING The Machine is fitted with a roll over protection structure (ROPS) and a falling object protection structure (FOPS). You could be killed or seriously injured if you operate the machine with a faulty or missing ROPS/FOPS. Modified and incorrectly repaired ROPS/FOPS are dangerous. If the ROPS/FOPS has been in an accident, do not use the machine until the structure has been repaired and inspected by suitably qualified personnel. INT-2-1-9/1
For assistance, contact your JCB distributor. Failure to take these precautions could result in death or injury to the operator. Check the structure for damage. Check that the mounting bolts are installed and undamaged. Check the bolt torques. Tighten them to the correct torque if necessary. Bolts A 237 Nm (175 lbf ft) Bolts B 476 Nm (352 lbf ft) Bolts C 237 Nm (175 lbf ft)
S144180
9803/3260
Issue 1
Section B
Body & Framework
Section B
Air Conditioning
12 - 1
A
D
L
K
E
C
B
12 - 1
9803/3260
Issue 1*
Section B 12 - 2
Body & Framework Air Conditioning
Section B 12 - 2
Operation To maintain optimum operator comfort in warm climates or during seasons of high ambient temperature, the air conditioning system delivers cool, dehumidified air into the cab. Cooling is provided by passing the warm ambient air, together with recirculated air, over an evaporator coil in the air conditioning unit.
Provided that the ambient temperature is above 0°C and the blower switch is away from the OFF position, the air conditioning will switch on. The compressor's electromagnetic clutch operates, engaging the compressor drive from the engine pulley system. The compressor A draws in low pressure refrigerant gas from the suction line (evaporator to compressor) and increases refrigerant pressure through compression. Increasing pressure also increases refrigerant temperature.
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.
High pressure refrigerant is forced from the compressor to the condenser B, mounted below the cab. Ambient air is drawn across the condenser fins by three integral cooling fans. In the condenser, the refrigerant changes state to a high pressure, high temperature liquid but with a lower heat content.
The major components of the system are the compressor A, condenser B, receiver drier C, expansion valve D and evaporator coil E. To operate the air conditioning, the operator turns the air conditioning switch F clockwise to the ON position and turns the blower switch G clockwise to select a suitable blower running speed for the ambient conditions. Air vents H can be adjusted as at X to vary and direct the airflow. If the air conditioning system pressure is too low or too high, the amber light J will illuminate.
The refrigerant passes through the receiver drier C. The receiver drier serves as a reservoir for refrigerant and also contains a desiccant to remove moisture from the system.
G
A181590
9803/3260
Issue 1*
Section B 12 - 3
Body & Framework
Section B
Air Conditioning
12 - 3
Operation (cont'd)
Safety Procedures
The high temperature, high pressure refrigerant is forced by compressor action into the expansion valve D, 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 air conditioning system uses refrigerant under pressure in a closed circuit. Any service procedure which breaks into the closed circuit and therefore requires discharging of the system, must only be carried out by an air conditioning engineer. The following guidelines should be adhered to by all personnel servicing the air conditioning system.
The refrigerant is drawn through the evaporator coil E 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 drain tubes through the cab floor.
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.
! WARNING
4-3-4-1
1
It is critical that the correct refrigerant is used and that charging is done only by qualified personnel. It is illegal to discharge the refrigerant into the atmosphere but 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.
Cool de-humidified air is emitted through air vents into the cab. The low temperature, low pressure, high heat content refrigerant gas, is now drawn by suction back to the compressor, where the cycle is completed.
Control Control of the system is achieved by the cyclic action of the compressor's electromagnetic clutch. The thermostat switch senses the evaporator coil temperature by means of a capillary tube and cycles the compressor clutch on and off to prevent freezing of condensate on the evaporator coil.
! WARNING Do not carry out welding operations close to the air conditioning refrigerant circuit. A poisonous gas is produced when refrigerant comes into contact with naked flames. Do not smoke or allow naked flames close to the refrigerant circuit. BF 1- 9
The signal from the thermostat switch is sent to the compressor clutch via two pressure switches. These are designed to disengage the compressor clutch and protect the system from damage that would be caused by either refrigerant loss or excessive pressure.
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.
The low pressure switch K is connected to the suction hose adjacent to the compressor. If the pressure in the suction hose falls below the low pressure switch setting, it opens, interrupting the supply from the thermostat to disengage the compressor clutch. At the same time, lamp J illuminates.
5
When charging or discharging the refrigerant system, no smoking or naked flames should 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.
The high pressure switch L is connected to the discharge hose adjacent to the compressor. If the pressure in the discharge hose rises above the high pressure switch setting, it opens, interrupting the supply from the thermostat to disengage the compressor clutch. At the same time, lamp J illuminates.
6
When handling refrigerant, rubber gloves and goggles should be worn. Operators should ensure 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.
Switch Pressures Low Pressure Switch Cut in = 2.1-2.6 bar (30-38 lbf/ in2) Cut out = 0.3-0.6 bar (4-8 lbf/ in2) High Pressure Switch Cut in = 15.5-19 bar (225-275 lbf/ in2) Cut out = 23.4-24.8 bar (340-360 lbf/ in2)
9803/3260
Issue 1*
Section B
Body & Framework
Section B
Air Conditioning
12 - 4
12 - 4
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. 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 systems 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.
b)
Warm or slightly cool air emitted from unit
Expansion valve stuck open or closed -
Renew expansion valve.
c)
Blower operates on fan speed 3 only
Blower resistor failed Blower motor failed -
Renew resistor. Renew blower motor.
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 B/4-1.
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.
Foam or bubbles - Refrigerant low and in need of charging.
Clouded - Dessicant breakdown in the receiver-drier.
S201520
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.
9803/3260
Issue 1*
Section B 12 - 5
Body & Framework
Section B
Air Conditioning
12 - 5
Fault Finding (cont'd) Harness Wires
Colour Code
Use the illustration below to complete continuity checks on the air conditioning system harness wires.
BL Black Br Brown R Red
Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Fuse, 25A Pressure Switch Pressure Switch Clutch Relay Compressor Clutch Fuse, 25A Blower Relay Cooling Fans Fan Relay Blower ON/OFF/Speed Switch Blower Warning lIght Warning Light Relay Thermostat From Starter Switch
Zones A B C
Engine Cab Air Conditioning Unit
A209120
9803/3260
Issue 1
Section B
Body & Framework
12 - 6
Section B
Air Conditioning
12 - 6
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:
Check11. Check 7.
4
Is the air conditioning fuse(s) blown?
YES: NO:
Renew fuse(s) and retest. Check 5.
5
Is there a 12V supply to the pressure switch harness? (See Pressure Switch Testing)
YES: NO:
Check 6. Check 9.
6
Does the compressor clutch engage with both pressure switches bypassed? (See Pressure Switch Testing)
YES: NO:
Check 7. Renew the compressor clutch and retest.
7
Does the compressor clutch engage with HP switch bypassed? (See Pressure Switch Testing)
YES: NO:
Renew high pressure switch and retest. Check 8.
8
Does the compressor clutch engage with LP switch bypassed? (See Pressure Switch Testing)
YES: NO:
Renew low pressure switch and retest. Charge check required by refrigeration engineer.
9
Does the clutch engage with thermostat switch bypassed?
YES: NO:
Renew thermostat switch and retest. Check all electrical connections.
10 Are blower switch and wiring OK?
YES: NO:
Renew blower motor. Renew switch or wiring.
11 Is sight glass indication OK?
YES: NO:
Check 12. Charge check required by refrigeration engineer.
12 Is condensor air flow blocked?
YES: NO:
Clean condensor and radiator. Check 13.
13 Is evaporator air flow blocked?
YES: NO:
Clean filter and, if necessary the evaporator. Call in refrigeration engineer.
9803/3260
Issue 1
Section B
Body & Framework
Section B
Air Conditioning
12 - 7
12 - 7
Checking Refrigerant Charge Level
Leak Testing
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 beneath the cab, on the left hand main chassis side member.
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.
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:
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.
1
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.
2
Park the machine on firm, level ground. Lower the backhoe and loader to the ground. Engage the parking brake. Chock the wheels, to prevent movement.
! WARNING
! WARNING
Leak testing in Air Conditioning systems should be carried out only in a well ventilated area. BF 1-2
Make the machine safe before getting beneath it. Lower the attachments to the ground; engage the parking brake; remove the starter key, disconnect the battery. 2-3-2-2
3
4
Start the engine and run at idle. Switch air conditioning ON to circulate refrigerant. Check refrigerant charge level at sight glass A. (It will be necessary to use a mirror and torch to view the sightglass, which is located at the top of the receiver drier).
Tightening Leaking Hoses ! 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. 4-3-4-1
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.
9803/3260
Issue 1
Section B
Section B
Body & Framework Air Conditioning
13 - 1
Blower Motor
4
Carefully lower the shroud away from the cab roof, taking care not to snag cables etc. or the thermostat capillary tube.
5
Disconnect the blower motor connecting wires. Support
Removal Note: Record all electrical connections prior to removal.
13 - 1
the motor assembly 15 and remove screws 14. Carefully lower the assembly clear.
1
Disconnect the battery
2
Prepare the shroud assembly 13 for removal as follows:
Replacement is the reverse of the removal procedure. If necessary, renew the blower mounting flange gasket.
a
Remove and disconnect the radio speakers 1, 2 (to
Thermostat
gain access for steps b - f). b
Disconnect the cab light 3.
c
Disconnect warning light 4.
d
Disengage the blower switch 7 by pulling off knob 5 and removing nut 6.
e f
3
To remove the thermostat, remove the shroud as described for the blower motor. Disconnect the electrical wires from thermostat 10 and disengage the sensor end of its capillary tube from the evaporator fins.
Repeat step d for the air conditioning switch (thermostat) 10.
For replacement the sequence should be reversed.
Disconnect and remove any optional switches etc. which may be mounted on the shroud assembly.
Compressor Clutch Relay
Support the shroud and remove screws 11 and 12. Note that screws 12 are located inside the ventilation louvres
The compressor clutch relay is mounted on the battery compartment. To remove it, simply disconnect it and remove its securing screw.
X.
12
11
X
4
1
11
13
14 3
2
14
X 14 11 12
7 5
14 15
6 10 8
9 S209110
9803/3260
Issue 1*
Section B
Section B
Body & Framework
13 - 2
Air Conditioning
13 - 2
Pressure Switches The 12V supply is fed from the thermostat to the compressor clutch via the low and high pressure switches which are wired in series.
Removal and Replacement
The low pressure switch requires a minimum refrigerant charge level to close its contact. The high pressure switch requires the charge level to remain below the maximum limit to keep its contact closed.
Goggles and rubber gloves must be worn when pressure switches are removed or fitted. A small amount of refrigerant is released which can be harmful to the skin and eyes.
! WARNING
BF 1-10
Both pressure switch contacts must be closed for the compressor clutch to operate. If the compressor clutch will not operate when air conditioning is selected, the fault may be either electrical or system pressure.
Removal 1
Disconnect the electrical connections and unscrew the pressure switch.
Pressure Switch Testing Replacement 1
2
Switch the engine off so that the air conditioning system cannot operate. Disconnect the pressure switch harness from the main vehicle harness and connect an external 12V power supply to the pressure switch harness connector. If both pressure switches are working correctly, and the system is at the correct charge level, the compressor clutch will operate. If the compressor clutch does not operate with the external power supply, one of the pressure switches is faulty or the level of refrigerant charge is insufficient to close the low pressure switch.
Note: The high pressure switch has a red body, the low pressure switch has a bronze body, both have 1/4 UNF female threads. 1
Screw the pressure switch into the pressure switch port and torque tighten sufficiently to form a gas-tight seal.
2
Run the air conditioning and check the pressure switches for leaks. If any leaks are found, tighten the pressure switch further until the leaking stops.
High Pressure Switch Testing 1
Disconnect the air conditioning harness male/female connectors from the high pressure switch 1.
2
2 1
Connect an external 12V power supply to the harness connectors. If the compressor clutch does not operate, renew the high pressure switch. If the clutch operates check the low pressure switch.
Low Pressure Switch Testing 1
If the refrigerant charge level in the system is correct, but the clutch will still not function, disconnect the air conditioning harness male/female connectors from the low pressure switch 2.
2
Connect an external 12V power supply to the harness connectors. If the compressor clutch does not operate, renew the low pressure switch.
S181600
Note: If both pressure switches operate correctly, check all electrical connections and the compressor clutch relay.
9803/3260
Issue 1*
Section B
Section B
Body & Framework Air Conditioning
13 - 3
Condenser Coil
13 - 3
Adjusting the Compressor Drive Belt
It is likely that over a period of time, because of the machine's working environment, the airflow around the condenser coil will become restricted due to a build up of airborne particles. If the build up of particles is severe, heat dissipation from the refrigerant to the air will be significantly reduced, resulting in poor air conditioning performance. In extreme cases, over pressurisation of the system occurs, causing the high pressure cut out switch to operate and switch off the system.
! WARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5
1
Park the machine on firm, level ground. Lower the backhoe and loader to the ground.
2
Remove the starter key.
3
Remove the left hand side panel.
High pressure cut out can also be caused by an internal blockage of the condenser coil.
4
Loosen bolts A, B and C.
Condenser Coil Cleaning
5
Position the compressor so that there is 10 mm (3/8 in)
Take care not to damage the condenser fins or tubes. Damaged fins must be straightened out to ensure a good airflow through the coil.
slack at point X. 6
Tighten bolt A, then bolts B and C.
The condensor is located beneath the cab at the rear of the machine.
! WARNING
1
Park the machine on firm, level ground. Lower the backhoe and loader to the ground.
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.
2
Remove the starter key.
4-3-4-1
3
Chock both wheels
A
! WARNING Make the machine safe before getting beneath it. Lower the attachments to the ground; engage the parking brake; remove the starter key, disconnect the battery.
B
2-3-2-2
4
Use compressed air or low pressure water to backflow through the coil fins. Take care not to damage the fins.
5
Run the air performance..
conditioning
and
check
cooling
C
X S181600
9803/3260
Issue 1*
Section B 14 - 1
Body & Framework
Section B
Air Conditioning (machines from serial number 430001)
Technical Data Refrigerant R134a System Capacity 1200g (2 lb 10oz) Switch Pressures Low Pressure Switch (white) Cut in = 3.2 bar max. (47 lbf/ in2 max.) Cut out = 1.6-1.8 bar (23-26 lbf/ in2) High Pressure Switch (blue) Cut in = 15.2-19.3 bar (220-280 lbf/ in2) Cut out = 26.2-29 bar (380-420 lbf/ in2)
14 - 1
Safety Procedures The air conditioning system uses refrigerant under pressure in a closed circuit. Any service procedure which breaks into the closed circuit and therefore requires discharging of the system, must only be carried out by an air conditioning engineer. 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 suitably trained person. You can be severely frostbitten or injured by escaping refrigerant. 4-3-4-1/2
1
It is critical that the correct refrigerant is used and that charging is done only by qualified personnel. It is illegal to discharge the refrigerant into the atmosphere but 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.
! WARNING Do not carry out welding operations close to the air conditioning refrigerant circuit. A poisonous gas is produced when refrigerant comes into contact with naked flames. Do not smoke or allow naked flames close to the refrigerant circuit. BF 1- 9
9803/3260
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, no smoking or naked flames should 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 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.
Issue 1
Section B
Body & Framework
Section B
Air Conditioning (machines from serial number 430001)
14 - 2
14 - 2
B
A
L
D
E
C
K
G
F
S210951
Operation
S257690
9803/3260
Issue 1
Section B 14 - 3
Body & Framework Air Conditioning (machines from serial number 430001)
Section B 14 - 3
Operation To maintain optimum operator comfort in warm climates or during seasons of high ambient temperature, the air conditioning system delivers cool, dehumidified air into the cab. Cooling is provided by passing the warm ambient air, together with 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 A, condenser B, accumulator C, orifice tube D and evaporator coil E. To operate the air conditioning, the operator presses the air conditioning switch F to the ON position. Control G is rotated anti-clockwise to decrease the temperature from ambient to cold. Air vents can be adjusted to vary and direct the airflow. The compressor A draws in low pressure refrigerant gas from the accumulator C. The accumulator contains a desiccant bag which retains any liquid that may be in the system. This insures that liquid refrigerant will not enter and damage the compressor. The action of the compressor changes the state of the refrigerant from a low pressure gas to a high pressure gas. High pressure gas leaves the compressor and enters the condenser B. Ambient air is drawn across the condenser fins by the engine driven cooling fan and the gas is cooled . In the condenser, the refrigerant changes state to a high pressure liquid.
Control 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 rotor. Since the clutch assembly is turned constantly by the crankshaft pulley drive belt, the compressor armature turns, starting the refrigeration cycle. Current is fed to the field coil through three switches in series; 1) the manual ON/OFF switch F; 2) a low pressure switch K; 3) a high pressure switch L. The (white) low pressure switch K is located in the pipe that connects the evaporator E to the accumulator C. If the pressure falls below the low pressure switch setting, the switch opens, interrupting the electrical supply to the compressor clutch. Low pressure leads to a lack of refrigerant borne lubricant for the compressor which can suffer severe damage as a result. Possible causes of the low pressure are low refrigerant charge or low ambient temperatures. The (blue) high pressure switch L is located in the pipe that connects the condenser B to the evaporator E. If the pressure rises above the high pressure switch setting, the switch opens, interrupting the electrical supply to the compressor clutch. Continued high pressure is likely to damage hoses and seals. The most likely reason for excessively high pressure is debris causing a blockage in the condenser B or the orifice tube D.
The refrigerant passes from the condenser to the evaporator E via metering orifice tube D. The orifice tube monitors the amount of refrigerant entering the evaporator and therefore reduces the pressure of the refrigerant. Air in the cab is forced through the evaporator coil by a blower fan. Heat is transferred from the ambient and recirculated air to the refrigerant, causing the low pressure liquid to vapourise and become a low pressure gas. The resulting cool air is circulated to the interior of the cab through ducts and vents. The low pressure gas is now drawn by suction back to the compressor via the accumulator, where the cycle begins again.
9803/3260
Issue 1
Section B
Body & Framework
Section B
Air Conditioning (machines from serial number 430001)
14 - 4
14 - 4
Fault Finding 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. 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 accumulator pressure-
Plugged orifice tube Repair or replace accumulator Evacuate & recharge
Condenser coil air flow restricted -
Remove debris from around coil using compressed air or low pressure water.
System overcharged-
Evacuate & recharge
b)
Blower operates on fan speed 3 only
Blower resistor failed Blower motor failed -
Renew resistor. Renew blower motor.
c)
Compressor clutch continually cuts out
Condenser coil blockage Overcharging of refrigerant system-
Remove debris from around coil/renew condenser. Evacuate and recharge system.
Wiring Diagram Use the illustration below to complete continuity checks on the air conditioning system harness wires. Refer also to the main machine circuit diagram in Section C. Key 40 41 42 92 93 94 95
Heater Motor Heater Resistor Air Conditioning Compressor Heater Switch Air Conditioning Switch Air Conditioning Pressure Switch Air Conditioning Pressure Switch
6
40
122
41
92 94
93
9803/3260
95
42 A257780
Issue 1
Section B 14 - 5
Body & Framework
Section B
Air Conditioning (machines from serial number 430001)
14 - 5
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:
Check11. Check 7.
4
Is the air conditioning fuse blown?
YES: NO:
Renew fuse and retest. Check 5.
5
Is there a 12V supply to the pressure switch harness? (See Pressure Switch Testing)
YES: NO:
Check 6. Check 9.
6
Does the compressor clutch engage with both pressure switches bypassed? (See Pressure Switch Testing)
YES: NO:
Check 7. Renew the compressor clutch and retest.
7
Does the compressor clutch engage with HP switch bypassed? (See Pressure Switch Testing)
YES: NO:
Renew high pressure switch and retest. Check 8.
8
Does the compressor clutch engage with LP switch bypassed? (See Pressure Switch Testing)
YES: NO:
Renew low pressure switch and retest. Charge check required by refrigeration engineer.
9
Are blower switch and wiring OK?
YES: NO:
Renew blower motor. Renew switch or wiring.
10 Is condensor air flow blocked?
YES: NO:
Clean condensor and radiator. Check 11.
11 Is evaporator air flow blocked?
YES: NO:
Clean filter and, if necessary the evaporator. Call in refrigeration engineer.
9803/3260
Issue 1
Section B
Body & Framework
Section B
Air Conditioning (machines from serial number 430001)
14 - 6
Checking Refrigerant Charge Level
14 - 6
Leak Testing
On machines from serial number 430001 there is no inspection glass to check the charge level. If the air conditioning system is not performing adequately complete the fault finding procedures.
Refrigerant Charging & Discharging Procedures for charging and discharging the system are not given in this manual as they require special equipment and training. Training can be arranged through the JCB International Training Centre. The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment. The service valves are Schrader type and can be located at the compressor A, on the suction and discharge ports.
! 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 orifice tube, run the air conditioning for a few minutes then switch off the engine and test for leakage using an electronic leak detector. 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.
The (white) low pressure switch K is located in the pipe that connects the evaporator to the accumulator. The (blue) high pressure switch L is located in the pipe that connects the condenser to the evaporator.
Tightening Leaking Hoses ! 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 suitably trained person. You can be severely frostbitten or injured by escaping refrigerant. 4-3-4-1/2
L K A
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, orifice tube, evaporator coil and suction accumulator and at bulkhead connectors above and below the cab floor. If leakage is detected from a hose connector, 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.
S257700
9803/3260
Issue 1
Section B 14 - 21
Body & Framework
Section B
Air Conditioning (machines from serial number 430001)
14 - 21
Blower Motor Removal 1
Disconnect the battery.
2
Loosen and remove the side console screws A and remove side console B.
3
Loosen and remove bottom console screws C and remove the bottom console D.
4
Disconnect the electrical connector to the heater blower.
5
Loosen and remove M6 flanged bolts E.
6
Carefully remove the heater assembly F from its housing.
Replacement Replacement is a reversal of the removal procedure, make sure that the seal located between the housing and heater is in good condition - replace if necessary.
Note: The heater assembly is of a modular design. This enables the air conditioning evaporator matrix to be housed next to the standard heater matrix. Complete removal of the air conditioning unit will require the refrigerant to be drained from the system.
B
C
A
A
A A
C D
C
S210341
E
F S257790
9803/3260
Issue 1
Section B 14 - 22
Body & Framework
Section B
Air Conditioning (machines from serial number 430001)
14 - 22
Pressure Switches The 12V supply is fed to the compressor clutch field coil through three switches in series; 1) the manual ON/OFF switch F; 2) a low pressure switch K; 3) a high pressure switch L. The low pressure switch requires a minimum refrigerant charge level to close its contact. The high pressure switch requires the charge level to remain below the maximum limit to keep its contact closed.
Removal and Replacement
! WARNING Goggles and rubber gloves must be worn when pressure switches are removed or fitted. A small amount of refrigerant is released which can be harmful to the skin and eyes. BF 1-10
Removal Both pressure switch contacts must be closed for the compressor clutch to operate. If the compressor clutch will not operate when air conditioning is selected, the fault may be either electrical or system pressure.
1
Disconnect the electrical connections and unscrew the pressure switch.
Replacement High Pressure Switch Testing 1
Switch off the engine and disconnect the electrical connector to the high pressure switch L.
2
Fit a link wire between the two terminals on the high pressure switch harness connector.
3
Switch on the engine and the air conditioning system, if the system operates the high pressure switch is faulty replace it with a new one. If the system does not operate continue to test the Low Pressure Switch.
Note: The high pressure switch has a blue body, the low pressure switch has a white body. 1
Screw the pressure switch into the pressure switch port and torque tighten sufficiently to form a gas-tight seal.
2
Run the air conditioning and check the pressure switches for leaks. If any leaks are found, tighten the pressure switch further until the leaking stops.
Low Pressure Switch Testing 1
Switch off the engine and disconnect the electrical connector to the low pressure switch K.
2
Fit a link wire between the two terminals on the low pressure switch harness connector.
3
Switch on the engine and the air conditioning system, if the system operates the low pressure switch is faulty replace it with a new one. If the system does not operate check all electrical connections, fuses etc.
F
L K A
S257700
9803/3260
Issue 1
Section B
Body & Framework
Section B
Air Conditioning (machines from serial number 430001)
14 - 23
14 - 23
Condenser Coil It is likely that over a period of time, because of the machine's working environment, the airflow around the condenser coil B will become restricted due to a build up of airborne particles. If the build up of particles is severe, heat dissipation from the refrigerant to the air will be significantly reduced, resulting in poor air conditioning performance.
A
In extreme cases, over pressurisation of the system occurs, causing the high pressure cut out switch to operate and switch off the system. High pressure cut out can also be caused by an internal blockage of the condenser coil. Condenser Coil Cleaning Take care not to damage the condenser fins or tubes. Damaged fins must be straightened out to ensure a good airflow through the coil. The condensor is located at the front of the machine, behind the nose grille A. 1
Park the machine on firm, level ground. Lower the backhoe and loader to the ground. Remove the starter key.
2
Remove the front grille fixing screws. Use compressed air or low pressure water to backflow through the coil fins. Take care not to damage the fins.
3
Run the air performance.
conditioning
and
check
S257800
cooling
B
S257700
9803/3260
Issue 1
Section B
Body & Framework Air Conditioning (machines from serial number 430001)
14 - 24
Section B 14 - 24
Adjusting the Air Conditioning Compressor Drive Belt ! 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 suitably trained person. You can be severely frostbitten or injured by escaping refrigerant. 4-3-4-1/2
! WARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5
1
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine.
2
Loosen bolts A, B and C. Position the compressor so that there is 10 mm (3/8 in) slack at point X.
3
Tighten bolt A, then bolts B and C.
X A
B
C S209392
9803/3260
Issue 1
Section B 15 - 1
9803/3260
Body & Framework Cab
Section B 15 - 1
Issue 2
Section B
Section B
Body & Framework Cab
15 - 2
15 - 2
Glazing - General
Direct Glazing
The original glazing on the machines is of the rubber seal type. From September 1992, the 'direct' method of glazing was gradually phased in. The sectional diagrams below provide a comparison of the two methods, A being the
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:
rubber seal type and B the direct type. Note: Depending on availability, it is permissible to re-glaze any of the machines by either method, although the preference should be for direct glazing. If both types of system are available, note that the glass used for direct glazing is slightly larger than that used with a rubber seal. DO NOT attempt to direct glaze using the glass intended for use with a rubber seal, or vice-versa.
A
B
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).
A191050
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
Rubber Seal Glazing Installing New Glass (refer to fig on page B/15-1). Position the machine on level ground and apply parking brake. Stop the engine. 1
Fit glazing seal around edge of glass.
2
Wind string around the seal. Pull string tight to compress the inner seal. Apply soap to the seal.
3
Place glass into frame from outside the cab. Make sure that the glass is in the centre of the frame.
9803/3260
Note: The front screen glass is laminated, the other glass is toughened. If a laminated pane breaks it will stay in one piece even though the glass is cracked. A toughened pane will shatter and fall apart. The method of removal of the glass depends upon which type it is. See WARNING below.
! 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
Issue 2*
Section B
Section B
Body & Framework Cab
15 - 3
15 - 3
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
a Laminated glass - leave installed until the old sealant has been cut away, after which it will be possible to lift the broken screen away from its frame housing in one piece.
A
S186380
b Toughened glass - remove as much of the shattered glass as possible prior to cutting out the old sealant. 3
Cut out the old sealant, leaving approximately 1 to 2 mm on the cab frame. There are several tools and techniques for doing this: a
D C
Pneumatic Knife A provides one of the easiest methods of removing the sealant around laminated glass. The tool, powered by compressed air, should be sourced locally.
Note: This tool must not be used on toughened glass (see WARNING on previous page). (i)
B
D
E
E D
Press the handle to start the knife blade oscillating.
(ii) Insert the knife blade into the sealant. S189870
(ii) Slowly move the knife along the sealant with the blade positioned as close to the glass as possible. Do not allow the knife blade to overheat or the sealant will melt. b 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). (i)
C
Insert the steel tube C into the old sealant on the inside of the glass.
(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.
S189880
(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.
9803/3260
Issue 1
Section B
Body & Framework Cab
15 - 4
Section B 15 - 4
Direct Glazing (cont'd) Removing the Broken Glass and Old Sealant (cont'd) c 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. (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.
(iii)
G
Use the 'pull-handle' to pull the knife along and cut out the old sealant.
d
Craft Knife H. The blades are replaceable.
(i)
Insert the knife blade into the sealant.
(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
F
S189890
H
a Laminated glass - lift out the broken pane using glass lifters (see Service Tools, Section 1). S186370
b 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
Apply a coat of 'Black Primer 206J' to the paintwork if:
J
a Paintwork was damaged or scratched during the glass/sealant removal procedures. b The old sealant was inadvertently cut back to the cab frame during the glass/sealant removal procedures. Preparing the Cab Frame Aperture 1
If damp or wet, dry the aperture area using a hot air gun (sourced locally).
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
9803/3260
Issue 1
Section B
Section B
Body & Framework Cab
15 - 5
Direct Glazing (cont'd) Preparing the New Glass
15 - 5
K
! CAUTION
M
The laminated front screen must be handled with extra care to prevent breakage. Wherever possible, store and handle it in a vertical attitude. When placing or lifting the screen in a horizontal attitude it must be supported over its whole area, not just at the edges. BF 1-8
1
Make sure that the new glass correctly fits the frame aperture K.
L
a Put two spacer blocks L onto the bottom part of the frame aperture.
S189910
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.
N
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. IMPORTANT: The glass edges MUST NOT touch the frame, otherwise movement of the frame will chip and eventually break the newly installed glass. 2
S186280
After checking for size, remove the new glass and place it on a purpose made glass stand N (see Service Tools, Section 1).
P
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.
S186291
R
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'.
9803/3260
S189920
Issue 1
Section B
Section B
Body & Framework Cab
15 - 6
Direct Glazing (cont'd) Preparing the New Glass (cont'd)
15 - 6
S
S
10-15 mm
5
Install the Ultra Fast Adhesive cartridge (see Sealing
T
8-10 mm A186410
and Retaining Compounds, Section 1 and Note 2 below) into a suitable applicator gun:
T
a Remove the aluminium disc cover from the base of the cartridge and discard the 'dessicant capsule'.
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. c Pierce the front 'nozzle' end of the cartridge to its maximum diameter. d Fit the pre-cut nozzle shown at S.
T
e Install the cartridge in the applicator gun.
S189930
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
W
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.
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'.
S186440
X
Installing the New Glass 1
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
S189910
blocks as shown X. 9803/3260
Issue 1
Section B
Body & Framework Cab
15 - 7
Section B 15 - 7
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
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
6
Clean the glass using a purpose made glass cleaner.
On completion of the glass installation procedures tidy the work area: a Remove ALL broken glass from the cab area. b Remove the protective covers from the cab seat and control pedestals. c Renew all 'warning' and 'information' decals so that the new installation conforms with the original cab installation.
9803/3260
Issue 1
Section B
Body & Framework
Section B
20 - 2
20 - 2
Loader Arms
12
Sling the loader arms as shown at Y. Make sure that the sling is wrapped around the loader arms only and not the level links.
13
Remove nut and bolt H. Remove retaining ring J and shim K.
Removal and Replacement Removal 1
2
Park the machine on firm level ground. Engage the parking brake and set the transmission to neutral. Remove loader end attachment (such as a shovel) if fitted. If the attachment is hydraulically operated, disconnect attachment hoses and plug/cap immediately. Vent residual hydraulic pressure prior to removing hoses by operating the control levers with the engine switched off.
! WARNING The loader arm interlevers are potentially dangerous, when pivoting about their centre they form a 'scissor' point with the loader arm. Make sure the interlevers are securely blocked when working in the loader arm area. BF 2-1
14
Secure the interlever lever linkage as shown at Z, otherwise with level link pivot pin L removed, the interlever linkage could pivot about its centre and cause injury and/or damage.
15
Use extractor tool 992/00800 and remove pivot pin L.
16
Repeat steps 13 to 15 for the opposite level link pivot pin.
! WARNING DO NOT work under raised loader arms unless they are adequately supported by stands and/or slings. BF 3-1
3
Remove the engine cover, see page B/1-1.
4
Raise the loader arms to give access to the lift ram pivot pins A.
17
Remove nut and bolt M. Remove retaining ring N and shim P.
5
Sling the loader arms as shown at X. Make sure that the slings are taut and therefore holding the weight of the loader arms.
18
Use extractor tool 992/00800 and remove pivot pin Q.
19
Repeat steps 17 and 18 for the opposite loader arm pivot pin. When all four pivot pins have been removed, carefully reverse the machine clear of the loader arms
6
Switch off the engine and vent residual hydraulic pressure from the loader end by operating the loader controls back and forth several times.
20
7
Remove the lift ram pivot pins A (see Note 1).
Replacement
Note 1: Care must be taken when removing the lift ram pivot pin, once the pin is removed the ram will drop. Either hold the ram using a sling or have a second person hold the ram before removing the pin. 8
Lower the loader arms to the ground using the slings, it may be necessary to retract the lift rams to enable the loader arms to rest fully on the ground. Make sure the lift rams do not foul when retracted.
Replacement is a reversal of the removal sequence. Check operation of loader shovel reset switch (if fitted). Apply rust inhibiting oil to all static bores and pivot pins before assembly into rams and mainframe (except for pivot pins/bores L and Q ). Apply anti-seize paste to bearing bores of pivot pins L and Q.
9
Make sure residual hydraulic pressure has been vented. Disconnect the shovel ram and auxiliary (if fitted) hoses, shown at B. Plug and cap the hoses immediately.
All klipring installations to have a maximum end float of 2 mm (0.078 in).
10
Disconnect the electrical connections (not shown) to the loader shovel reset switch (if fitted).
Fit new liner bearings in the loader arms and/or the level link using a shouldered mandrel as shown.
11
Remove pivot pin retaining bolts D, E, F and G (see Note 2).
Note 2: To gain access to bolts D and F and their retaining nuts, remove cover C. To gain access to bolts E and G and their retaining nuts, remove the battery and use access slot W.
9803/3260
Issue 1
Section B
Body & Framework
Section B
25 - 1
25 - 1
F D
C
E
A
G
B
S216800
9803/3260
Issue 1
Section B
Body & Framework
Section B
25 - 2
25 - 2
Stabiliser Leg (Sideshift Machines)
! WARNING
Removal and Replacement
Make the machine safe, place blocks underneath the sideshift rails
The following steps (1 to 11) describe the removal procedures for the stabiliser inner leg, the stabiliser foot and the stabiliser ram. However, it is possible to remove these items as a complete assembly, see step 12.
BF 2-5
11
Removal 1
2
Park the machine on firm level ground. Engage the parking brake and set the transmission to neutral.
Note: Use the widest backhoe bucket available (if possible, a 5ft ditching bucket).
Lower the loader shovel to the ground. 12
3
Use the boom and dipper to raise the rear of the machine, as shown at G. Do not raise the machine too high but allow just enough room for the stabiliser inner leg to slide clear. Refer to the warning above.
Make sure that the backhoe assembly is set central to the mainframe as shown. If necessary 'sideshift' the backhoe into a central position.
4
Lower the stabiliser legs until the approximately 1 in. (25mm) off the ground.
pads
5
Remove the bottom locking nut A and bolt B.
6
Drive out the bottom pivot pin C.
are
If required, the stabiliser inner leg, stabiliser foot and stabiliser ram can be removed as a complete assembly: 12.1
Complete steps 1 to 4.
12.2
Make sure the engine is switched off, vent residual hydraulic pressure by moving the backhoe and stabiliser control levers back and forth.
12.3
Loosen and remove the stabiliser hoses D and E, label the hoses before removing (as an aid to assembly). Plug all open orifices to prevent loss of fluid and ingress of dirt.
Note: Steps 7 to 10 only apply if renewing or repairing the stabiliser ram, however, removing the ram will give more room when refitting the stabiliser inner leg. 7
8
9
Make sure the engine is switched off, vent residual hydraulic pressure by moving the backhoe and stabiliser control levers back and forth. Loosen and remove the stabiliser hoses D and E, label the hoses before removing (as an aid to assembly). Plug all open orifices to prevent loss of fluid and ingress of dirt.
! WARNING Make the machine safe, place blocks underneath the sideshift rails BF 2-5
12.4
Loosen and remove the top pivot pin retaining nut and bolt, as shown at F.
12.5
Use the widest backhoe bucket available (if possible, a 5ft ditching bucket), and position the backhoe as shown at G. Do not raise the machine too high but allow just enough room for the stabiliser leg assembly to slide clear. Refer to the warning above.
Loosen and remove the top pivot pin retaining nut and bolt, as shown at F.
! CAUTION The ram is heavy. It is recommended that the ram is removed with the assistance of a sling and suitable lifting appliance. BF 2-4
10
Inspection Remove the stabiliser ram - take the ram out from the top. Be careful, the ram is heavy.
The inner leg should be free from nicks, marks or scores. Replacement Replacement is a reversal of the removal sequence. Use suitable lifting appliances to locate the stabiliser ram. After replacing or fitting the stabiliser leg, connect the hydraulic pipes, make sure that the ram and leg operate freely and do not foul.
9803/3260
Issue 1
Section B
Body & Framework
Section B
26 - 1
26 - 1
G F
C A
D
B
E D
C
S216810
9803/3260
Issue 1 SXXXXXX
SXXXXXX
Section B
Body & Framework
Section B
26 - 2
26 - 2
Stabiliser Leg (Centremount Machines) Removal and Replacement
Replacement
Removal
Replacement is a reversal of the removal sequence.
1
Use suitable lifting appliances to locate the stabiliser ram and the stabiliser leg.
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the backhoe and loader end to the ground and stop the engine.
2
Lower the stabiliser legs to the ground.
3
Make sure the engine is switched off, vent residual hydraulic pressure by moving the backhoe and stabiliser control levers back and forth.
4
Remove the stabiliser ram:
After replacing or fitting the stabiliser leg, connect the hydraulic pipes, make sure that the ram and leg operate freely and do not foul.
4.1 Carefully disconnect hydraulic hoses A and B from the stabiliser hydraulic ram, label the hoses before removing (as an aid to assembly). Release the connections slowly. 4.2 If a stabiliser foot is fitted, remove 'C' washers C and washers D. Drive out the foot retaining pin E.
! CAUTION The ram is heavy. It is recommended that the ram is removed with the assistance of a sling and suitable lifting appliance. BF 2-4
4.3 Wrap a suitable sling around the stabiliser ram, make sure that the weight of the ram is supported by the sling. 4.4 Remove the ram pivot pin retaining nut and bolt, drive out the ram pivot pin as shown at F. 4.5 Remove the stabiliser ram. 5
Remove the stabiliser leg:
! CAUTION This component is heavy. Do not attempt to remove it unless its weight is held by a sling. Make sure that the sling is attached to a suitable lifting appliance. HYD 2-3/1
5.1 Wrap a suitable sling around the stabiliser leg, make sure that the weight of the leg is supported by the sling. 5.2 Remove the stabiliser leg pivot pin retaining nut and bolt, drive out the stabiliser leg pivot pin, as shown at G. 5.3 Remove the stabiliser leg.
9803/3260
Issue 1
Section B
Body & Framework
30 - 1
Section B 30 - 1
* Slew Cylinders (Sideshift Machines) Dismantling and Assembly Drain the oil from the slew gearbox.
! WARNING Slacken but DO NOT remove the cylinder retaining bolts when using hydraulic pressure to break the seal. Severe injury can be caused if the cylinder is released suddenly under pressure. BF 2-2
Slacken bolts A and use hydraulic pressure to break the seal between cylinder B and the gearbox body. Disconnect and blank hose C. Remove the bolts and cylinder. The piston head seals D can be renewed with the piston head still fitted. To remove the piston head, unscrew bolt E. Note: If the rack is to be removed, the piston head will not pass through the rack housing. Prevent rack rotation when slackening bolt E by leaving the pinion in engagement with the rack. Ensure that the new 'O' ring F and spacer G are correctly located.
*
Apply JCB Multi-gasket on joint face between cylinders B and the gearbox body. Refill gearbox with oil specified on page 3/1-1. Torque Settings Item A
Nm 970
kgf m 99
lbf ft 715
E
405
41
300
9803/3260
Issue 2*
Section B 31 - 1
Body & Framework
Section B 31 - 1
S8365
9803/3260
Issue 1
Section B
Body & Framework
Section B
31 - 2
31 - 2
Kingpost & Carriage - Sideshift Machines Dismantling and Assembly If required, kingpost 9 and carriage 18 can be removed and replaced without disturbing the slew cylinders; but if the rack, or pinion 8B are damaged it is advisable to clean out the cylinders (see page 30 - 1). If removing the piston heads, leave driveshaft 8A in position to prevent rack rotation whilst turning the piston head bolts. If removing the kingpost with the carriage still fitted, ensure that there is a clearance of at least 850 mm (34 in) below the kingpost to allow driveshaft removal. Alternatively, the kingpost and carriage may be removed as an assembly and dismantled in a horizontal position. Before removing the driveshaft, slew the kingpost to dead centre, drain the gearbox oil (plug 1) and remove the boom and dipper. Support the kingpost using a hoist and position a jack under cover plate 4 to support the driveshaft.
Apply anti-seize paste to all bearing surfaces and the upper splined area on the driveshaft. When fitting the driveshaft, ensure that the kingpost and rack are central. Ensure that the dowel in cover plate 4 enters the hole in housing 6. Ensure that roll pins B and D are fitted and do not protrude above the splines. The roll pins should align with master splines E and C on assembly. Bleed the Hydraclamps by opening the bleed screw at clamp 17 and operating the clamps until air-free oil flows from the screw. Fill the gearbox with oil (see page 3/1-1).
Knock back locktabs 2, unscrew bolts 3 and lower the jack to remove the driveshaft.
Grease bushes 15, 16 through their grease nipples.
When Assembling
Note: Do not inject more than 30-50 ml of grease through the grease nipple for item 16.
Apply JCB High Strength Retainer to the inner and outer faces of liner ring 19 and to the outer faces of bushes. Fit liner ring 19 with its internal chamfer at the bottom.
Torque Settings
Fit bush 21 with the grooved end at the top and the other end flush with the bottom of the housing. Ensure that raincap 20 is clipped onto the bush.
Item 3
Nm 170
kgf m 17.5
lbf ft 125
* Tighten
nut 17 until clearance is 2 - 4 mm (0.08 - 0.16 in) with the hydra-clamp in the 'ON' position, as shown at A.
Bottom bush 16 must be fitted, with the outside groove at the bottom, to a depth of 7.5 mm (0.295 in) below the top face of the parent bore. Top bush 15 must be fitted, 'O' ring groove downwards, to a depth of 6 mm (0.236 in) below the top face. Ensure that the grease holes in the bush are at right angles to the grease nipple. Ensure that seals 10 and 13 face in the direction shown.
2 - 4 MM
A
A204860
9803/3260
S156530
Issue 3*
Section B 35 - 1
Body & Framework
Section B 35 - 1
159880
9803/3260
Issue 1
Section B
Body & Framework
35 - 2
Section B
Backhoe
35 - 2
Boom & Dipper
Replacement
Removal & Replacement
Replacement is generally a reversal of the installation procedure.
Always label hydraulic hoses before disconnecting them, this will ensure that they are correctly reconnected. Plug and cap all hose open ends to prevent ingress of dirt and loss of hydraulic fluid. Removal 1
Remove the backhoe bucket and place the backhoe in the position shown at A.
2
Lower the stabilisers.
3
Stop the engine and disconnect the battery (to prevent the engine being started).
4
Operate the backhoe control levers back and forth several times to release pressure trapped in the hydraulic hoses.
5
Remove the dipper from the boom assembly: 5.1 Disconnect hoses 10, 11, 12 and 13. 5.2 Place a suitable support underneath the dipper ram as shown at L. 5.3 Wrap a sling around the dipper as shown at M. Make sure the weight of the dipper is held by the sling before removing pivot pins etc.
* The boom to dipper pivot pin T must be retained using two
M12 thin nuts (in place of a single nut as shown at R). Fit the first thin nut to within 1mm (0.040 in.) of the pivot boss face. Fit the second thin nut and tighten onto the first nut - torque to 43 Nm (32 lbf ft). When fitting the dipper to the boom, the maximum permissible side float is 1.5mm (0.060in). If necessary, fit shim between the boom nose and dipper, as shown at V. When fitting the boom and dipper assembly to the kingpost and carriage, the maximum permissible side float between kingpost and boom is 3.00mm (0.118in). If necessary, fit shim, item J, on the right hand side of the machine only (see notes 1 and 3). Note 1: With the exception of slewing operations 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards. The hoses should have been clearly labelled before removing, however shown below is a key to the hoses and their final destination: Hose
Destination
1 2
Auxiliary ram (see note 2) Auxiliary ram (see note 2)
3 4 5 6
Boom ram (head side) Boom ram (rod side) Dipper ram (rod side) Dipper ram (head side)
7 8
Crowd ram (rod side) Crowd ram (head side)
9
Remote boom lock
10 11
Crowd ram (rod side) Crowd ram (head side)
12 13
Auxiliary ram (see note 2) Auxiliary ram (see note 2)
5.4 Remove nut N, bolt P and pivot pin Q. 5.5 Remove nut R, bolt S and pivot pin T.
* Note:
From machine serial number 416130, two thin M12 nuts are used in place of the single nut R. The new arrangement allows the pivot pin retaining bolt to be secured without inducing a lateral tension. 5.6 Hoist the dipper clear of the boom. 6
Remove the boom from the kingpost and carriage assembly: 6.1 Wrap a sling around the boom as shown at B. Make sure the weight of the boom is held by the sling before removing pivot pins etc. 6.2 Disconnect hoses 1, 2, 3, 4, 5, 6, 7 and 8. 6.3 Make sure that the boom lock is secured in the raised position. Disconnect the remote boom lock hydraulic hose 9. 6.4 Place a suitable support underneath the boom ram as shown at D. 6.5 Remove nut E, bolt F and pivot pin G. 6.6 Remove circlip H and shim J (if fitted). Remove pivot pin K. 6.7 Hoist the boom clear of the kingpost and carriage assembly.
9803/3260
Note 2: Hoses 1, 2, 12 and 13 feed auxiliary services such as extending dipper, jaw bucket etc. Hose final destinations, i.e. auxiliary ram head side or rod side positions, vary depending on which auxiliary attachment is fitted. Note 3: Later machines utilise a slightly longer pivot pin and 2-off 5 mm thick washers, one at each end. On reassembly the washers must be positioned adjacent to their circlips. Shims may still be required between the boom and kingpost to keep side float within the limit given above. Note that the maximum permissible clearance between boom and pivot pin is 1.0 mm (0.039 in). Add shims between the 5 mm spacers and the boom as required.
Issue 3*
Section C
Electrics
Section C
i
i
Contents
* *
Page No.
Technical Data General Electrical Data Circuit Protection - to serial number 430000) - from serial number 430001) Relay Identification - Syncro Shuttle Machines - to serial number 409434 - from serial number 409435 to 430000 Relay Identification - Powershift Machines - to serial number 409434 - from serial number 409435 to 430000 Relay Identification - All Models (from serial number 430001) Test Methods Use of Multimeter Measuring DC Voltage Measuring Resistance Measuring Continuity How to Test a Diode or Diode Wire Parking Brake Switch Adjustment Circuit Diagrams & Component Lists (to serial number 430000) Basic Machine Circuit Options and Variations - Steer Circuit (AWS Machines Only) - Powershift Transmission - 2/4 Wheel Drive (up to serial number 409434) - Transmission Dump Circuit (up to serial number 413772) - Instrument Lights Test Button (up to serial number 404502) - Hydraulic Speed Control (HSC) - 2 Relays - (up to serial number 406613)
9803/3260
1-1 1-2 1-3 1-4 1-4 1-5 1-5 1-6
2-1 2-3 2-3 2-3 2-4
10 - 1
15 - 1 15- 3 15 - 4 15 - 5 15 - 5 15 - 6 15 - 6
Circuit Diagrams & Component Lists (from serial number 430001) Basic Machine (2WS) Circuit Options and Variations - Powershift Transmission & Steer Circuit (AWS Machines Only) - Powershift Transmission (2WS Machines Only) - Steer Circuit for 3CX 4x4x4 Machines - 3CXE (214E) Machine Only
18 - 5 18 - 7 18 - 7 18 - 9
*
Batteries Safety Specfic Gravity Test Battery Testing
20 - 1 20 - 2 20 - 2
* * * *
Wiring Harness Repair Harness Repair Introduction Tools Required Procedure
25 - 1 25 - 1 25 - 1
18 - 1
Issue 7*
Section C
Electrics
Section C
ii
ii
Contents
*
Starter Motor Starting Circuit Test Removal and Replacement Dismantling Service and Renewal Assembly
38 - 1 38 - 4 38 - 4 38 - 4 38 - 4
Alternator Charging Circuit Test Service Precautions Removal and Replacement Dismantling and Assembly Dismantling and Assembly (Magneti Marelli Type)
39 - 1 39 - 3 39 - 3 39 - 5 39 - 7
Harness Location Harness Location - up to serial number 430000 Harness Location - from serial number 430001
40 - 1 40 - 2
Wire Number Identification Wire/Harness numbers - Explanation of: Wire numbers (to serial number 430000) - 000 to 199 - 200 to 599 - 600 to 799 - 800 to 999 Wire numbers (from serial number 430001) - 000 to 199 - 200 to 599 - 600 to 799 - 800 to 999
9803/3260
Page No.
41 - 1 41 - 2 41 - 4 41 - 4 41 - 6 42 - 1 42 - 3 42 - 4 42 - 7
Issue 3*
Section C
Electrics Technical Data
1-1
Section C 1-1
General Electrical Data System Type
12 Volt, negative earth
Battery (Heavy Duty) - Cold crank amps for 1 minute to 1.4 volts per cell at -18 deg C (0 deg F)
550
- Reserve capacity (minutes) for 25 amp load
220
Battery (Temperate) - Cold crank amps for 1 minute to 1.4 volts per cell at -18 deg C (0 deg F)
410
- Reserve capacity (minutes) for 25 amp load
170
Alternator
* * *
2WS
Lucas - 65 Amp maximum output
4WS
Magnetti Marelli - 72 Amp maximum output
4WS (air conditioning or ServoPlus builds)
Magneti Marelli - 85 Amp maximum output
Starter Motor
Lucas
Light Bulbs Head lights - main/dip
45/37.5W
Work lights
55W Halogen (front & rear)
Front side lights
5W
Tail/stop lights
5/21W
Fog light
21W
Direction turn indicators
21W (front & rear)
Instruments
1.2W
Warning lights
3W
† Number plate light
2 x 5W
* Interior light † Beacon
10W 70W Halogen
† Note: These items are not apllicable to U.S.A.
9803/3260
Issue 3*
Section C
Electrics Technical Data
1-2
Section C 1-2
Circuit Protection * The electrical circuits are protected by fuses. The fuses are located in a fuse box to the right of the steering pedestal. If a fuse melts, find out why and rectify the fault before fitting a new one. The fuses are identified using column letters (A, B and C) and row numbers (1 to 9).
! CAUTION
*
Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5
COLUMN 'A'
*
1
Reverse alarm, brake lights, 2/4WD solenoid †††.
Fuse Rating 10 Amp
2
Gauges, stabiliser lock relay.
5 Amp
3
Left hand sidelights, dipper light.
5 Amp
Gauge illumination, right hand sidelights.
5 Amp
5
Rear wiper.
5 Amp
6
Hazard warning lights.
10 Amp
7
Beacon, Interior light.
10 Amp
8
Radio.
9
Horn, headlight flash, front wiper/washer.
* 4 *
5 Amp
†
Note: Machines prior to serial number 400077 have the fog light circuit protected by fuse B3, not C4 as indicated.
††
Note: Steering solenoids and proximity switches are fitted to AWS machines only.
10 Amp
COLUMN 'B'
*
S143211
1
Junction box, remote unload solenoid (HSC).
10 Amp
2
Fuel pump solenoid (engine stop).
3
Dip beam†.
10 Amp
4
Main beam.
10 Amp
5
Front work lights.
10 Amp
6
Direction turn indicators.
5 Amp
7
Dump relay.
5 Amp
8
Heater.
9
Hand dump, buzzer.
5 Amp
††† Note: Machines up to serial number 403024 have the brake lights protected by fuse A1. Machines from serial number 403025 to 404851 have the brake lights protected by fuse C3. Machines from serial number 404852 have the brake lights, and 2/4WD solenoid protected by fuse A1 (as indicated in the fuse identification chart).
15 Amp 5 Amp
COLUMN 'C'
*
1
Rear work lights.
2
Steering solenoids, proximity switches ††.
3
2/4 WD switch & relay, forward relay and solenoid, reverse relay and solenoid.
4
* 5 *
10 Amp 5 Amp
Powershift only - forward high/low relay & solenoid, reverse high/low relay & solenoid, drive (mainshaft/layshaft) relay & solenoid, neutral relay.
10 Amp
Fog light †.
10 Amp
When applicable - heated seat, clock & cigar lighter.
15 Amp
9803/3260
Issue 3*
Section C
Electrics
Section C
Technical Data
1-3
1-3
Circuit Protection (from machine serial number 430001) The relays and fuses are located in the side console underneath cover A.
! CAUTION
Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5
Fuse Identification If a fuse melts, find out why and rectify the fault before fitting a new one. The fuses are identified using column letters (A, B and C) and row numbers (1 to 9). Note that all the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown on this page.
A S247030
COLUMN 'A' Fuse Rating 1 Brake lights. 5 Amp 2 Warning lights, buzzer, gauges. 5 Amp 3 Left hand sidelights. 5 Amp 4 Right hand sidelights. 5 Amp 5 Rear wiper/washer. 5 Amp 6 Hazard warning lights. 10 Amp 7 Beacon, Interior light. 10 Amp 8 Radio. 5 Amp 9 Horn, headlight flash, front wiper/washer. 15 Amp COLUMN 'B' 1 Junction box 2 Fuel pump solenoid (engine stop). 3 Dip beam. 4 Main beam. 5 Front work lights. 6 Indicators. 7 4WD (automatic brake). 8 Heater. 9 Rear horn. COLUMN 'C' 1 Rear work lights. 2 Steer mode, hydraulic speed control (HSC) 3 Gearbox control, reverse alarm. 4 Fog light. 5 Heated seat, clock & cigar lighter 6 Forward and reverse controls, reverse alarm
10 Amp 5 Amp 10 Amp 10 Amp 10 Amp 5 Amp 5 Amp 30 Amp 10 Amp
4W 10 Amp 5 Amp 10 Amp 5 Amp 15 Amp 3 Amp
R A254290A
Note: Fuse C6 is only fitted on machines from serial number: 3CX (214) - 438636; 4CX (214S) - 437866. Prior to this, the gear controls were protected by fuse C3.
9803/3260
Issue 4
Section C
Electrics
Section C
Technical Data
1-4
1-4
Relay Identification - Syncro Shuttle M/c's Relays are used in electrical circuits for a variety of reasons. However, the more usual application is to protect components like switches etc. from being overloaded. A relatively small current (from the switch) energises the relay coil, this coil causes internal contacts to open (or close) and therefore controls a (larger) current in another circuit. Although relays look similar, internally they can be different, for example, they can be single contact or double contact; normally closed or normally open. Make sure you fit the correct type of relay, otherwise the machine electrical circuits will not function properly. All the relays on your machine (except items T & U) are housed in the front console as shown. Items T & U are secured to the parking brake mounting bracket, as shown in the inset. Relay B C D E F G H J K L R S T U V
Description (to serial no. 409434) Neutral Start Stabiliser Leg Lock (if fitted) Reverse Alarm (if fitted) Buzzer Road Lights Parking Brake Forward Drive Reverse Drive Flasher Transmission Dump 2/4WD Brake 2WD Select Hydraulic Speed Control † Hydraulic Speed Control † -
Description (from 409435 to 430000) Neutral Start Stabiliser Leg Lock (if fitted) Reverse Alarm (if fitted) Buzzer Road Lights Parking Brake Brake Lights 2WD Select Flasher Transmission Dump Forward Drive Reverse Drive Hydraulic Speed Control † Hydraulic Speed Control † Parkbrake Dump ††
Note † : From machine serial number 406613 the hydraulic speed control circuit is operated with a single relay, not two relays as shown. Note ††: The parkbrake dump relay is only applicable on machines from serial number 413772.
E DC B
F
G
H
J
K
L
T U
9803/3260
R
S
V
Issue 2
Section C
Electrics
Section C
Technical Data
1-5
1-5
Relay Identification - Powershift M/c's Relay A B C D E F G H J K L M N P Q R S T U V
Description (to serial no. 409434) Ignition Neutral Start Stabiliser Leg Lock (if fitted) Reverse Alarm (if fitted) Buzzer Road Lights Parking Brake Forward Drive Reverse Drive Flasher Transmission Dump Forward High/Low Ratio Reverse High/Low Ratio Drive (Layshaft/Mainshaft) Neutral (Powershift) 2/4WD Brake 2WD Select Hydraulic Speed Control † Hydraulic Speed Control † -
Description (from 409435 to 430000) Ignition Neutral Start Stabiliser Leg Lock (if fitted) Reverse Alarm (if fitted) Buzzer Road Lights Parking Brake Forward High/Low Ratio Reverse High/Low Ratio Flasher Transmission Dump Forward Drive Reverse Drive Drive (Layshaft/Mainshaft) Neutral (Powershift) Brake Lights 2WD Select Hydraulic Speed Control † Hydraulic Speed Control † Parkbrake Dump ††
Note †: From machine serial number 406613 the hydraulic speed control circuit is operated with a single relay, not two relays as shown. Note ††: The parkbrake dump relay is only applicable on machines from serial number 413772.
E
A D C B F
G
R
S
K
L
T U
H J
9803/3260
M N
P
Q V
S215400
Issue 1
Section C
Electrics
Section C
Technical Data
1-6
1-6
Relay Identification - All Machine Models (from machine serial number 430001) The relays and fuses are located in the side console underneath cover A. Note that all the relays are shown (including optional equipment relays). Your machine may not be equipped with all the relays shown on this page.
*
* * * *
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
With the introduction of different machine models, services and options, the position of the relays may vary from that shown in the illustration. If unsure about the position of a realy, check the wire numbers at the rear of the relay base against the wire descriptions.
Ignition Neutral Start Indicators Ignition Neutral Transmission Dump Hydraulic Speed Control (HSC) Forward Drive Buzzer Parking Brake Reverse Drive Reverse Horn Auxiliary Attachment (Jaw) Heater Lights Worklights (Italian Requirement Only) Hammer Circuit All Wheel Braking Forward High/Low Ratio ➀ 2 Wheel Drive ➁ 2 Wheel Steer ➂ Reverse High/Low Ratio ➀ Drive (Layshaft/Mainshaft) ➀ 4 Wheel Steer ➂
➀ ➁ *➂
* Note:
Powershift Machines Only All Wheel Steer Machines Only 3CX 4x4x4 Machines Only
A S247030
0
1
0
7
4
P
10
13
16
F19
R22
17 0
2
N 5
F R 8
D
11
14
R 3
6
9
12
20
23
21
24
4W 15
18
A254290B
9803/3260
Issue 3*
Section C
Section C
Electrics Test Methods
2-1
2-1
Use of Multimeter * These instructions are intended to cover the use of the recommended multimeters.
A
OFF V/A
A
V/A
B C
A171900 S153070
1
Make sure that the test leads are plugged into the correct sockets. The black test lead should be plugged into the black socket (sometimes, this socket is also marked by a " – ", or "E" or marked as "COMMON" or "COM"). The red test lead should be plugged into the red socket marked with "+", "V" or " ".
2
When making measurements ensure that the test probes have a good clean contact with bare metal, free from grease, dirt, and corrosion as these can cause a false reading.
3
When measuring voltage: Make sure that the correct range is selected, that is set the selector to a value equal to or greater than that you are about to measure. e.g. If asked to measure 12 Volts, set the selector to the 12V range. If there is no 12V range, set the selector to the next range higher, 20V for instance. If the meter is set to a range that is too low, it may be damaged. e.g. setting to the 2V range to measure 12V.
9803/3260
Issue 2*
Section C 2-2
9803/3260
Electrics Test Methods
Section C 2-2
Issue 1
Section C 2-3
Electrics
Section C
Test Methods
2-3
Measuring DC Voltage On the FLUKE 85 Turn the switch to position B. On the AV0 2003 Move the right slider switch to position A, and the left hand slider switch to the appropriate range. On an analogue meter Turn the dial to the appropriate DC Volts range. Connect the black probe to the nearest available suitable earth point, usually this will be the starter motor earth, the battery negative, or the chassis. Connect the red probe to the wire or contact from which you are measuring the voltage.
Measuring Resistance Make sure there is no power to the part of the circuit you are about to measure. Connect one probe at one end of the component or wire to be checked and the other probe at the other end. It does not matter which way round the two probes are placed. On the FLUKE 85 Turn the switch to position C and check that the sign at the right hand side of the display window is on. If the F sign is on instead, press the blue button G to change the reading to . Touch the meter lead probes together and press the REL ³ key on the meter to eliminate the lead resistance from the meter reading. On the AV0 2003 Move the right hand slider switch to position B, and the left hand slider switch to the appropriate Ohms ( ) range. On an analogue meter Move the dial to the appropriate Ohms ( ) range.
Measuring Continuity Make sure there is no power to the part of the circuit you are checking for continuity. Connect one probe to one end of the component or wire to be checked and the other probe to the other end. It does not matter which way round the two probes are placed. On the FLUKE 85 Turn the switch to position C and check that the beeper symbol appears at the left hand side of the display window. If the F sign is on instead, press the button labelled F in the meter drawing. If there is continuity in the circuit, the beeper will sound. If there is no continuity (open circuit), the beeper will not sound. On the AV0 2003 Move the right hand slider switch to position B, and the left hand slider switch to position C. If there is continuity (i.e. very low resistance) between two points the buzzer will sound. On an analogue meter Turn the dial to the lowest Ohms ( ) range. If there is continuity (i.e. very low resistance) between two points the needle will move across fully (or almost fully) to the right hand side of the scale.
9803/3260
Issue 3
Section C 2-4
Electrics Test Methods
Section C 2-4
How to Test a Diode or a Diode Wire A diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end. The diode is sealed in heatshrink sleeving. On the FLUKE 85 Turn the switch to position D. Press the HOLD button and check that the H sign appears at the top right hand side of the display window. Connect the black probe to the end of the diode with a band or to the male connector of the diode wire. Connect the red probe to the other end of the diode or diode wire. If the beeper does not sound the diode or diode wire is faulty. Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. If the beeper sounds or the meter does not read O.L., the diode or diode wire is faulty. Press the HOLD button and check that the H sign disappears from the right hand side of the display window. On the AV0 2003 Move the right hand slider to position A, and the left hand slider switch to position C. Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe should be connected to the other end of the diode or diode wire. If the Avometer does not buzz the diode is faulty. Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. If the Avometer does not read "1" the diode is faulty. On an analogue meter Select the Ohms 1000s (1k) range. Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe should be connected to the other end of the diode or diode wire. The meter should read 20-400 K , if it reads more than this the diode is faulty. Select the Ohms 100s range. Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. The meter should read 300-400 , if it reads less than this the diode is faulty.
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Issue 2
Section C 10 - 1
Section C
Electrics Parking Brake Switch
10 - 1
Adjustment Note: Depending on machine type, the parking brake switch may be mounted as shown at A or B. Select the starter switch to the ON position, do not start the engine. Select either forward or reverse. Raise the handbrake to the ON position. Screw the parking brake switch C in a clockwise direction until the audible alarm sounds and the visual warning is illuminated. Lock switch C in position with lock nuts D. Release the parking brake and the audible alarm should cease and the visual alarm extinguish. For adjustment of the Parking Brake, see Section G, 'Parking Brake Caliper'.
A C D
D
B D D C
S218320
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Issue 3
Section C 15 - 2
Electrics Circuit Diagrams and Component Lists
Basic Machine Component List (to serial number 430000) The 'basic' machine circuit diagram shows the electrical circuit for a Syncro Shuttle transmission, for Powershift transmission, refer to page C/15-4. 1 2 3 4 5 6 7 8 9 9A 10 11 11A 12 13 14 15 16 17 18 19 20 21 22 23 24 26 27 28 29 30 31 32 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
Battery Starter Switch Thermostart Starter Solenoid Starter Motor Neutral Start Relay Transmission Dump Relay Forward Relay Transmission Foot Dump Switch Transmission Hand Dump Switch Forward Solenoid Park Brake Relay Park Brake Dump Relay Reverse Relay Reverse Solenoid Park Brake Switch Coolant Temperature Gauge Coolant Temperature Sender Fuel Gauge Fuel Gauge Sender Diode Bank Engine Coolant Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Restriction Switch Speedometer / Tachometer Alternator Alternator Warning Warning Buzzer Park Brake Indicator Light Brake Light Switch ➁ Brake Lights ➁ 2/4 Wheel Drive Solenoid ➂ 2/4 Wheel Drive Relay ➂ 2/4 Wheel Drive Brake Relay ➂ 2/4 Wheel Drive Select Switch ➂ Rear Wiper Motor Rear Wiper Switch Fuel Pump Solenoid Indicator Flasher Relay Hazard Warning Switch Hazard Warning Lamp RH Direction Indicators LH Direction Indicators Direction Indicator Switch Diode Heater Motor Heater Switch Beacon Beacon Switch Interior Lamp Interior Light Switch Radio Washer Motor Front Washer/Wiper Switch
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Section C 15 - 2
57 58 59 60 61 62 63 64 65 67 69 70 71 72 75 76 77 78 79 80 81 82 83 84 85 87 88 89 90 119 120 125 126
Front Wiper Motor Horn (Front) Horn Push (Front) Head Light Flasher Switch Head Light Main Beam Lamps Main Beam Warning Dipped Head Light Lamps Head Light Dip Switch Head and Side Lights Switch Front Working Lights Front Working Lights Switch Lighting Relay Rear Working Lights Rear Working Lights Switch Gauge Illumination (Tacho, Water, Fuel) Reverse Alarm Relay Reverse Alarm Side Light Left Hand Tail Light Left Hand Socket (Dipper Light) LH Number Plate Light (Cab) Number Plate (Chassis) Side Light Right Hand Tail Light Right Hand Hydraulic Speed Control Switch Hydraulic Speed Control Switch Hydraulic Speed Control Relay Hydraulic Speed Control Solenoid Socket (Junction Box Feed) Rear Fog Light ➀ Rear Fog Light Switch ➀ Rear Washer Motor Rear Washer Switch
➀
Note: Machines prior to serial number 400077 have the fog light circuit protected by fuse B3, not C4 as indicated.
➁
Note: Machines up to serial number 403024 have the brake lights protected by fuse A1. Machines from serial number 403025 to 404851 have the brake lights protected by fuse C3. Machines from serial number 404852 have the brake lights and 2/4WD solenoid protected by fuse A1 (as indicated in the fuse identification chart).
➂
Applicable to 2WS machines only (from serial number 409435). For 2WS machines prior to 409434 and all 4WS machines, refer to page C/15-5.
Fuses A1 - A9 B1 - B9 C1 - C4 Refer to Technical Data pages at the beginning of Section C for further fuse details and ratings.
Issue 3
Section C
Electrics Circuit Diagrams and Component Lists
15 - 5
Section C 15 - 5
Circuit Options and Variations 2/4 Wheel Drive (all machines up to serial number 409434)
Transmission Dump Circuit (machines up to serial number 413772)
Component List 2 Starter Switch 31 Brake Light Switch 32 Brake Lights 34 2/4 Wheel Drive Solenoid 35 2/4 Wheel Drive Relay 36 2/4 Wheel Drive Brake Relay 37 2/4 Wheel Drive Select Switch
Component List 2 Starter Switch 6 Neutral Start Relay 7 Transmission Dump Relay 8 Forward Relay 9 Transmission Foot Dump Switch 9A Transmission Hand Dump Switch 10 Forward Solenoid 11 Park Brake Relay 12 Reverse Relay 13 Reverse Solenoid 14 Park Brake Switch 19 Diode Bank 29 Warning Buzzer
600CB
34 A216960 600BR
600AB
32
853 600AA
816
35 853A 854
818
36
108B 877
37
107D
31 108
A1
C3 2 A216950
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Issue 3
Section C
Section C
Electrics Circuit Diagrams and Component Lists
15 - 6
15 - 6
Circuit Options and Variations Instrument Lights Test Button (machines up to serial number 404502)
Hydraulic Speed Control - 2 Relays (machines up to serial number 406613)
Component List 2 Starter Switch 19 Diode Bank 20 Engine Coolant Temperature Switch 21 Transmission Oil Temperature Switch 22 Engine Oil Pressure Switch 23 Transmission Oil Pressure Switch 24 Air Filter Restriction Switch 25 Warning Lights Test Button 29 Warning Buzzer
Component List 2 Starter Switch 85 Hydraulic Speed Control Switch 86 Hydraulic Speed Control Warning 87 Hydraulic Speed Control Switch 88 Hydraulic Speed Control Relay 89 Hydraulic Speed Control Solenoid
600C
600BU
600BP
600CF
21
23
25
85 600CK
20
22
89
24 867A 101A
86
410
88
867B
867
88 866A 101C
866
404 406
405 403
402
87 101A
A2
19 29
101
2 B1
2
B9 A216970
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A216940
Issue 2
Section C 18 - 2
Electrics
Section C
Circuit Diagrams and Component Lists
18 - 2
Basic Machine Component List (from serial number 430001) * The basic circuit shows a standard 3CX (214) machine fitted with syncro shuttle transmission and 2 wheel steer. The remaining pages in section C/18 show machine circuits that differ from the ‘basic’. Note that ONLY the differences are shown. Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 6 Forward Solenoid 7 Reverse Solenoid 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 10 Fuel Pump Solenoid 11 Hydraclamp Solenoid 12 Hydraulic Speed Control Solenoid 13 Socket (Junction Box Feed) 14 Shovel Reset Solenoid 15 Rear Horn 16 Diode 17 Indicator Flasher Unit 18 Side Instrument Console 19 Coolant Temperature Sender 20 Fuel Gauge Sender 21 Tachometer 22 Coolant Temperature Gauge 23 Fuel Gauge 24 Hourmeter 25 Front Instrument Console 26 Alternator 27 Cigar Lighter 28 Clock 29 Face Level Fan 30 Heated Seat 31 Rear Washer Motor 32 Rear Wiper Motor 33 Washer Motor 34 Front Wiper Motor 35 Horn (Front) 36 Socket (Dipper Light) 37 Beacon 38 Tracker 39 Radio 40 Heater Motor 41 Heater Resistor 42 Air Conditioning Compressor 54 Warning Buzzer
Switches 60 Transmission Dump Switch (Gear) 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 65 Brake/Drive Select Switch 66 Hydraclamp Switch 67 Hydraulic Speed Control Switch 68 Hydraulic Speed Control Switch 69 Shovel Reset Switch 70 Rear Horn 71 Hazard Warning Switch 72 Direction Indicator Switch 73 Engine Coolant Temperature Switch 74 Transmission Oil Temperature Switch 75 Engine Oil Pressure Switch 76 Transmission Oil Pressure Switch 77 Air Filter Restriction Switch 78 Face Level Fan Switch 79 Heated Seat Switch 80 Rear Washer/Wiper Switch 81 Head Light Flasher Switch 82 Front Washer/Wiper Switch 83 Horn Push (Front) 84 Rear Fog Light Switch 85 Head and Side Lights Switch 86 Head Light Dip Switch 87 Front Working Lights Switch 88 Rear Working Lights Switch 89 Interior Light Switch 90 Interior Light Switch 91 Beacon Switch 92 Heater Switch 93 Air Conditioning Switch 94 Air Conditioning Pressure Switch 95 Air Conditioning Pressure Switch
*
Fuses A1 - A9 B1 - B9 C1 - C6
* Note: Fuse C6 is only fitted on machines from serial number: 3CX (214) - 438636; 4CX (214S) - 437866. Prior to this, the gear controls were protected by fuse C3.
Refer to Technical Data pages at the beginning of Section C for further fuse details and ratings. ..... continued
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Issue 2*
Section C 18 - 3
Electrics Circuit Diagrams and Component Lists
Section C 18 - 3
Basic Machine Component List (from serial number 430001) Relays 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 117 Hydraulic Speed Control Relay 118 Rear Horn Relay 119 Ignition Relay ‘2’ 120 Road Lights Relay 121 Italian Worklight Relay 122 Heater Relay
Wire Number Identification Refer to pages C/42-1 on for full wire number identification and descriptions.
Lights 140 LH Brake Light 141 RH Brake Light 142 LH Front Indicator 143 LH Rear Indicator 144 RH Front Indicator 145 RH Rear Indicator 146 Alternator Warning Indicator Light 147 Park Brake Indicator Light 148 Water Temperature Indicator Light 149 Transmission Temperature Indicator Light 150 Engine Oil Pressure Indicator Light 151 Transmission Oil Pressure Indicator Light 152 Air Filter Blocked Indicator Light 153 Hazard Warning Indicator Light 154 Main Beam Warning Indicator Light 155 Gauge Illumination 156 Turn Signal Indicator Light 157 Master Warning Lights 158 Side Lights Indicator Light 159 Rear Work Lights Indicator Light 160 Front Work Lights Indicator Light 161 Rear Fog Light Indicator Light 162 Rear Fog Light 163 LH Main Beam Light 164 RH Main Beam Light 165 LH Dip Beam Light 166 RH Dip Beam Light 167 LH Number Plate Light 168 LH Tail Light 169 LH Side Light 170 RH Number Plate Light 171 RH Tail Light 172 RH Side Light 173 Front Working Lights 174 Rear Working Lights
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Issue 1
9803/3260
Switches 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 96 4 Wheel Drive Switch 97 Powershift Column Switch 98 Front Proximity Switch 99 Rear Proximity Switch 100 Steer Mode Select Switch 101 4 WS/Crab Selector (part of PCB - item 53) 102 2 WS/4 WS Selector (part of PCB - item 53)
Fuse C6 is only fitted on machines from serial number: 3CX (214) - 438636; 4CX (214S) - 437866 Prior to this, the gear controls were protected by fuse C3.
* Note:
Wire Number Identification Refer to pages C/42-1 on for full wire number identification and descriptions.
Lights 175 4 Wheel Steer Indicator Light 176 Crab Steer Indicator Light 177 2 Wheel Steer Indicator Light 178 Front Instrument Console Illumination
Relay 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 119 Ignition Relay ‘2’ 123 Neutral Relay 124 Auto 2 Wheel Drive Relay 125 Drive Relay (Layshaft & Mainshaft) 126 Forward High/Low Relay 127 Reverse High/Low Realy
18 - 6
Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 16 Diode 43 Mainshaft Solenoid 44 Layshaft Solenoid 45 Forward Low Solenoid 46 Forward High Solenoid 47 Reverse High Solenoid 48 Reverse Low Solenoid 49 Crab/4 Wheel Steer Solenoid 50 4 Wheel Steer Solenoid 51 Crab Solenoid 52 2 Wheel Steer Solenoid 53 Steer Mode Printed Circuit Board
Note: Except for the transmission and steer circuits (shown above), the AWS electrical circuit is the same as shown on Page C/18- 1 to C/18-4.
Powershift Transmission & Steer Circuit - AWS Machines Only (from Serial Number 430001)
Section C Electrics Section C
Circuit Diagrams and Component Lists 18 - 6
Issue 2*
9803/3260
3
A228981
1
5
4
2
110
111
112
16
61 63
147
115
FUSE C2
FUSE C6
123
62
113
114
8 9
119
116
65
140
64
141
43
125
44
16
126
45 46
97
16 16
127
Powershift Transmission - 2WS Machines Only (from Serial Number 430001) and Steer Circuit for 3CX 4x4x4 Machines
47
48
98
100
99
50
129
52
131
130
177 178
101
18 - 7
FUSE BI
Section C Electrics Section C
Circuit Diagrams and Component Lists 18 - 7
Issue 3
NO CRAB RELAY
9803/3260
Switches 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 65 Brake/Drive Select Switch 97 Powershift Column Switch 98 Front Proximity Switch 99 Rear Proximity Switch 100 Steer Mode Select Switch
*
Note: Fuse C6 is only fitted on machines from serial number: 3CX (214) - 438636; 4CX (214S) - 437866 Prior to this, the gear controls were protected by fuse C3.
Wire Number Identification Refer to pages C/42-1 on for full wire number identification and descriptions.
Lights 140 LH Brake Light 141 RH Brake Light 147 Park Brake Indicator Light 177 2 Wheel Steer Indicator Light 178 Front Instrument Console Illumination
Relay 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 119 Ignition Relay ‘2’ 123 Neutral Relay 125 Drive Relay (Layshaft & Mainshaft) 126 Forward High/Low Relay 127 Reverse High/Low Relay 129 4 Wheel Steer Relay 130 2 Wheel Steer Relay 131 Relay
18 - 8
Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 16 Diode 43 Mainshaft Solenoid 44 Layshaft Solenoid 45 Forward Low Solenoid 46 Forward High Solenoid 47 Reverse High Solenoid 48 Reverse Low Solenoid 50 4 Wheel Steer Solenoid 52 2 Wheel Steer Solenoid
Note: Except for the transmission circuit (shown above), the 2WS electrical circuit is the same as shown on Page C/18- 1 to C/18-4.
* Powershift Transmission - 2WS Machines Only (from Serial Number 430001) and Steer Circuit for 3CX 4x4x4 Machines
Section C Electrics Section C
Circuit Diagrams and Component Lists 18 - 8
Issue 3*
Section C 18 - 10
Electrics
Section C
Circuit Diagrams and Component Lists
18 - 10
3CXE (214E) Machine Only - Component List (from serial number 430001) Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 6 Forward Solenoid 7 Reverse Solenoid 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 10 Fuel Pump Solenoid 15 Rear Horn 16 Diode 17 Indicator Flasher Unit 18 Side Instrument Console 19 Coolant Temperature Sender 20 Fuel Gauge Sender 21 Tachometer 22 Coolant Temperature Gauge 23 Fuel Gauge 24 Hourmeter 25 Front Instrument Console 26 Alternator 35 Horn (Front) 37 Beacon 54 Warning Buzzer 55 Hammer Solenoid Switches 60 Transmission Dump Switch (Gear) 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 70 Rear Horn 71 Hazard Warning Switch 72 Direction Indicator Switch 73 Engine Coolant Temperature Switch 74 Transmission Oil Temperature Switch 75 Engine Oil Pressure Switch 76 Transmission Oil Pressure Switch 77 Air Filter Restriction Switch 83 Horn Push (Front) 87 Front Working Lights Switch 88 Rear Working Lights Switch 96 4 Wheel Drive Switch 103 Hammer Isolator Switch 104 Hammer Footswitch
9803/3260
Relays 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 118 Rear Horn Relay 119 Ignition Relay ‘2’ 120 Road Lights Relay Lights 140 LH Brake Light 141 RH Brake Light 142 LH Front Indicator 143 LH Rear Indicator 144 RH Front Indicator 145 RH Rear Indicator 146 Alternator Warning Indicator Light 147 Park Brake Indicator Light 148 Water Temperature Indicator Light 149 Transmission Temperature Indicator Light 150 Engine Oil Pressure Indicator Light 151 Transmission Oil Pressure Indicator Light 152 Air Filter Blocked Indicator Light 155 Gauge Illumination 156 Turn Signal Indicator Light 173 Front Working Lights 174 Rear Working Lights Wire Number Identification Refer to pages C/42-1 on for full wire number identification and descriptions. Fuses A1 - A9 B1 - B9 C1 - C6 Refer to Technical Data pages at the beginning of Section C for further fuse details and ratings.
Issue 1
Section C
Electrics
Section C
Batteries
20 - 1
20 - 1
Safety ! WARNING Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you.
Maintenance To ensure that the battery provides optimum performance the following steps should be observed: 1
Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion.
2
When applicable - never allow the electrolyte level to fall below the recommended level - 6 mm (1/4 in) above the plates. Use only distilled water for topping up.
3
Keep the battery at least three quarters charged, otherwise the plates may become sulphated (hardened) - this condition makes recharging the battery very difficult.
Set all switches in the cab to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first. When reconnecting, fit the positive (+) lead first. Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up.
First Aid - Electrolyte Do the following if electrolyte:
Extra precautions must be taken when bench charging maintenance free batteries, they are more prone to damage by overcharging than the standard type of battery: -
NEVER boost-charge a maintenance free battery.
-
NEVER charge a maintenance free battery at a voltage in excess of 15.8 Volts.
-
NEVER continue to charge a maintenance free battery after it begins to gas.
GETS INTO YOUR EYES Immediately flush with water for 15 minutes, always get medical help. IS SWALLOWED Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help. GETS ONTO YOUR SKIN Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help. 5-3-4-3/1
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Issue 3
Section C 20 - 2
Electrics
Section C
Batteries
20 - 2
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 0.07 per 10 °C (18 °F) if the temperature is higher than 15 °C (60 °F) and subtract the same if the temperature is lower.
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.
4
A
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 Battery Tester Readings 1
CHECK: 0 - 12.6 Volts LOAD: less than 6 Volts
2
CHECK: 6 - 12.4 Volts LOAD: less than 9 Volts and falls steadily but remains in yellow zone.
3
CHECK: less than 10 Volts LOAD: less than 3 Volts
4
CHECK: more than 11 Volts LOAD: 6 - 10 Volts steady
9803/3260
B
239510
Remedy Renew battery
Recharge and re-test. If tests still unsatisfactory renew battery. Indicates battery has been over-discharged and unlikely to recover. Renew battery. Charge battery which will probably recover.
Issue 4
Section C
Electrics
Section C
Wiring Harness Repair
25 - 1
25 - 1
Harness Repair Introduction
Tools Required
Instances do occur where it is necessary to incorporate auxiliary electrical components into existing electrical circuits and, although unlikely with present wiring harnesses, repair or replace specific individual wires within a harness. This will also apply to other machines in addition to those of JCB manufacture.
892/00350 892/00349 892/00351 892/00352 892/00353
Butane Heater assembly Crimp tool Splice 0.5-1.5 mm (Red) Splice 1.5-2.5 mm (Blue) Splice 3.0-6.0 mm (Yellow)
1 1 50 50 50
Procedure To ensure that either the inclusion of an auxiliary electrical component or a repair within a harness is completed to an acceptable standard it is strongly recommended that the following tools, equipment and procedures are always used. Note that JCB harnesses have an International Protection rating of 67 (I.P.67). The sheath covering of the recommended splice is heat shrunk onto the original wire insulation. This results in a seal and corresponding joint to IP 67 specifications.
1
Cut the wire and remove the protective insulation for a suitable distance dependent upon the size of wire and splice to be used. For the splices detailed above, the dimension is 7mm.
2
Using the correct sized splice, attach the new section of wire required or auxiliary flying lead to the existing harness and secure using the crimp tool X, part number 892/00349. Note that each of the splices detailed is colour-coded to make size and range readily visible. They are secured using the corresponding size and matching colour-coded jaws of the crimp tool to ensure joint security. This tool also incorporates a ratchet closing mechanism which will not release until the splice is fully closed to the correct compression size.
! CAUTION When installing Auxiliary Electrical Components always ensure that the additional load rating is suitable for that particular circuit. It is unacceptable to simply increase the fuse rating as this can cause overloading and consequential failure of wiring, along with failure of integral circuit components, which the fuse is protecting. ELEC 2 - 1
! WARNING
3
With the Butane heater assembly, 892/00350, seal the connection using the procedure on the next page.
....continued
In addition to the warnings incorporated into the procedure, extreme care should be taken when handling the gas heating tool to ensure that the flame does not damage or set fire to any items in the vicinity of the repair, i.e. other wires, floor panels, floor mats, sound proofing, paintwork. etc. This tool should not be used in any restricted location prohibiting the use of "Naked Flames' or where risk of explosive gas or similar safety parameters apply. No other heat source should be used to attempt a sealed joint .
7
ELEC 2 - 2
! CAUTION When the heater is in use, the reflector and the air coming out are extremely hot. Keep away to avoid accidental burns. Do not touch the reflector until it has had time to cool down after switching off. If flame reappears at the reflector when the heater is in use, the catalytic element is damaged or used up. Stop work immediately and replace the heater.
X
ELEC 2-3
S189530
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Issue 4
Section C 25 - 2
Electrics
Section C
Wiring Harness Repair
25 - 2
Procedure (cont'd) With the Butane Heater assembly 892/00350, seal the connection using the following procedure.
A
3.1 Remove the cap A from the end of the disposable gas cartridge B.
B
S189490/1
3.2 Before assembling the gas cartridge to the reflector element C, turn the red ring D to the left, (in the direction of the minus sign marked on the ring).
C
D
S189490/2
3.3 Position the tube hanging down from inside the reflector assembly into the hole at the top of the gas cartridge. Then press the gas cartridge up into the reflector assembly as far as possible until the two elements are clasped firmly together. A click will be heard.
S189490/3
3.4 Turn the small ring E so that the air holes at F are completely closed.
F E
S189490/4
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Issue 1
Section C 25 - 3
Electrics
Section C
Wiring Harness Repair
25 - 3
Procedure (cont'd) 3.5 Turn the red ring D to the right (in the direction of the plus sign) in order to turn on the gas. IMPORTANT: Before turning the heater on, make sure that the cartridge is not hotter than the reflector element. This may occur if the cartridge is held in the hand for a long time. The temperature difference between the cartridge and the reflector element may cause long yellow flames to appear on ignition.
D
S189490/5
3.6 Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown. Note: The fact that the sound of liquid cannot be heard when the cartridge is shaken does not mean it is empty. No sound will be heard even when the cartridge is full.
F E
Hold the heater vertically for 1 to 2 minutes until the catalytic reaction occurs. This is indicated when the blue flame fades and the ceramic element glows red. Then turn the small ring E until the air holes at F are completely open. The tool is ready for use. S189490/6
The heater can be used in two modes: 3.7 Side wings G down, reflector head completely open. In this mode the infra-red heat waves are dominant (recommended for the light coloured plastic splices).
G
Side wings G up (see fig at step 3.8), reflector head opening reduced. In this mode the heating is done only by the hot gas (use for dark coloured plastic splices).
S189490/7
3.8 To switch off the heater, turn the red ring D to the left (in the direction of the minus sign).
G
D
S189490/8
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Issue 1
Section C
Section C
Electrics Starter Motor
38 - 1
38 - 1
Starting Circuit Test * Before
carrying out the voltmeter tests, check the battery condition (see Battery Testing) and ensure that all connections are clean and tight.
* To
prevent the engine starting during the tests ensure that the engine stop fuse is removed, (refer to fuse identification page).
Test 3 Connect the voltmeter between the solenoid terminal C and a good earth. Minimum permissible reading in 'start' position: 8.0V.
Check the readings in the following sequence using a voltmeter. Unless otherwise stated, the readings must be taken with the starter switch held in the 'start' position ('HS') and the transmission forward/reverse selector in neutral.
C
Note: Do not operate the starter motor for more than 20 seconds at one time. Let the starter motor cool for at least two minutes between starts. Test 1 Connect the voltmeter across the battery terminals. Reading in 'start' position: 10.0V approximately. Minimum permissible reading in 'start' position 9.5V.
S151010
A low reading probably indicates a fault in the starter motor. Test 3a If the reading is less than specified, connect the voltmeter between the neutral start relay terminal D and earth. An increase in reading to 8.0V indicates a fault in the wiring from the start relay to the solenoid.
S151000
Test 2 Connect the voltmeter between the starter main terminal A
F N R
810C
004
842
D
and the commutator end bracket B. In the 'start' position, the reading should not be more than 0.5V below the reading obtained in Test 1. Minimum permissible reading in 'start' position 9.0V. If the reading is within this limit, continue to Test 3. If the reading is outside the limit, proceed to Tests 4 and 5.
600V
H
C
E
+
A B
B
A S151030
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-
A215660
Issue 2*
Section C
Electrics
Section C
Starter Motor
38 - 2
38 - 2
Starting Circuit Test (cont'd) Test 5
Test 3b
Connect the voltmeter between battery positive and the starter main terminal A. With the starter switch 'off', the voltmeter should indicate battery voltage, but it should fall to practically zero when the switch is turned to the 'on' position, maximum permissible reading 0.25V.
If the reading between terminal D and earth is below 8.0V, connect the voltmeter between terminal E and earth. An increase in the reading to 8.0V indicates either a faulty start relay or a fault in the feed from the transmission selector switch to the relay solenoid. Check also the solenoid earth connection.
* If the reading between E and earth is less than 8.0V, the fault must be in either the starter switch or in the wiring between the solenoid, starter switch, and the start relay. Test 4 Connect the voltmeter between battery negative and starter earth connection B. The reading in the 'start' position should be practically zero, maximum permissible reading 0.25V.
A S151050
Test 5a If the reading is above 0.25V, a high resistance is present in the insulated lead or in the solenoid. Connect the voltmeter between the battery positive and solenoid connection H. If the voltmeter now reads zero with the switch closed, the fault is in the solenoid.
B S151040
If the reading is above 0.25V, a high resistance in the earth lead or connections is indicated.
H
* Finally refit the engine stop fuse.
9803/3260
Issue 2*
Section C 38 - 3
Electrics Starter Motor
Section C 38 - 3
S02043C
9803/3260
Issue 1
Section C 38 - 4
Electrics Starter Motor
Section C 38 - 4
Removal and Replacement Disconnect cables and remove battery. Remove cables from main starter terminal and solenoid terminal. Using special tool 825/00410 (and adapter 825/99833 if required) unscrew three securing nuts and remove starter motor. Replace by reversing the removal sequence.
Dismantling Note: Dismantle only to item 34 unless the field windings are to be renewed. Test the windings electrically before removing them from the motor yoke 15. Using a slotted steel tube, displace ring 23 to permit withdrawal of ring 22. Allow brake shoes 28 to remain in the end plate 11 unless requiring renewal.
Servicing and Renewal Renew brushes 14 and 14A if their length is less than 8mm (0.3in.).
Assembly Align crosspin C with the notches in the brake shoes 28 before assembling brush carrier and back plate to motor yoke. Ensure that brushes 14A are correctly located in the insulated brush boxes. Smear drive shaft splines and operating collar bearing surface with JCB MPL Grease before assembly. Assemble operating fork 19 with curved face toward the armature. Set the movement of drive pinion 24 by connecting a 6v battery and switch as shown. Operate switch and check dimension D. Adjust to 0.13-1.14mm (0.005-0.045in.) by slackening locknut 17 and rotating eccentric pin 18 as necessary. Re-tighten locknut.
Clean the commutator A. If individual copper bars are burned or eroded the armature has broken windings and must be renewed. Otherwise polish with fine grade glass paper (not emery). Renew armature if commutator diameter is 38mm (1.5in.) or less. Check the field windings for open circuits by connecting a multimeter set to measure resistance (see page C/2-2) between the stud terminal B and each positive brush 14A in turn. A high or infinity reading indicates an open circuit. Similarly, connect the meter between brushes 14A and the motor yoke 15. Any reading other than infinity indicates a short circuit between the coils and the yoke. Renew the coils as necessary, removing screws 36 with a pole shoe screwdriver C50 (obtainable from Lucas dealers).
D S02303A
Check bronze bushes 32 and 34 for wear.
9803/3260
Issue 1
Section C
Electrics
Section C
39 - 1
Alternator
39 - 1
Charging Circuit Test
Check 2
Ensure that all battery and alternator connections are in place, secure and making good metal - to - metal contact, especially the 'earth' connections to chassis and engine.
Note: the following checks should be made using an analogue (moving pointer) type meter. Stop the engine and turn the starter switch to OFF.
Adjust the alternator drive belt tension if necessary and make sure that the battery is well charged. Turn the start switch to the ON position. 'Oil pressure' and 'No charge' warning lights should glow.
* Withdraw
the alternator plug and connect the test meter between the large terminals and 'earth'. With the meter set to measure 12V DC, the meter should show battery voltage. If the reading is zero, check the cables for continuity, particularly at the starter terminals.
If any light fails, proceed to Check 1. Start the engine; all warning lights should extinguish rapidly. If the 'No charge' warning light remains ON proceed to Check 2. If the oil pressure warning remains on STOP ENGINE IMMEDIATELY and investigate the engine lubrication system. Check 1 With start switch 'ON' try the heater motor and screen wiper.
If the voltage is correct, check the alternator as follows:
If they operate normally, check the warning light bulb for blown filament.
Alternator Charging Test
Simultaneous failure of all items indicates a fault at the start switch. Check for cable disconnection before condemning the switch itself.
*
If the 'No charge' warning bulb is in good order, withdraw the triple plug from the back of the alternator. Make a temporary connection between the SMALL terminal in the plug and earth as shown below. If the 'No charge' warning bulb still fails to light, check the cable for continuity. If the bulb now lights, check the alternator for a defective regulator (see Alternator Charging Test).
* If
the battery is in a fully charged condition, switch on the working lights for 3 minutes before commencing the test. Alternatively, operate the starter for a few moments with fuse B2 removed. Install a 100 amp open - type shunt between the battery positive lead and the battery positive terminal. Connect the test meter and select DC Amps range.
Start the engine and run at maximum speed (see Page K/11). Meter should show maximum alternator output (see Technical Data). Note: The meter reading should be taken as soon as possible after starting the engine, as the charging current
9803/3260
Issue 2*
Section C
Electrics
Section C
39 - 2
Alternator
39 - 2
A zero reading indicates failure of the alternator and may be caused by one of the following conditions. These are listed in the order of probability. a
Defective suppression capacitor.
b
Dirty slip rings or worn brushes.
c
Defective regulator.
d
Defective rectifier.
e
Open or short - circuited field (rotor) windings.
f
Open or short - circuited power (stator) windings.
To check for fault a, disconnect the capacitor and repeat the charging test. Renew the capacitor if necessary.
*
To check for faults b and c, remove the regulator and brush box assembly. Check the condition of the brushes and, if necessary, clean the sliprings using extra - fine glasspaper. The regulator may only be checked by substitution. Faults d, e, and f may be checked only by removing and dismantling the alternator for further testing.
* Terminal 'W' Output (Tachometer) Test With the test meter set to 12V DC, measure the output at the 'W' terminal as shown. If the reading is less than 7V DC the regulator will need to be replaced. If the output reading at the 'W' terminal is satisfactory then the problem would lie with the instrument panel tachometer head.
9803/3260
Issue 3*
Section C
Electrics
Section C
39 - 3
Alternator
39 - 3
Service Precautions a
Ensure that the battery negative terminal is connected to the earthing cable.
b
Never make or break connections to the battery or alternator, or any part of the charging circuit whilst the engine is running. Disregarding this instruction will result in damage to the regulator or rectifying diodes.
c
Main output cables are 'live' even when the engine is not running. Take care not to earth connectors in the moulded plug if it is removed from the alternator.
d
During arc welding on the machine, protect the alternator by removing the moulded plug (or if separate output cables fitted, remove the cables).
e
If slave starting is necessary, connect the second battery in parallel without disconnecting the vehicle battery from the charging circuit. The slave battery may then be safely removed after a start has been obtained. Take care to connect batteries positive to positive, negative to negative.
B A
S099850A
Removal and Replacement Disconnect cables from rear of alternator, remove bolts A, B and C and withdraw unit from machine. Replace by reversing the removal sequence. Position the alternator until belt deflection is approximately 10mm (3/8 in) before tightening bolts B and C. It may be necessary to slacken bolt D to allow full movement of alternator. Tighten bolt A last of all.
C
D S099850B
9803/3260
Issue 1
Section C
Electrics
Section C
39 - 4
Alternator
39 - 4
S215650
9803/3260
Issue 1
Section C
Electrics
Section C
39 - 5
Alternator
39 - 5
Dismantling and Assembly When Dismantling Remove suppressor 2 (if fitted) by removing nut 1 and disconnecting lead E from terminal F. Unscrew bolts 3 and disconnect lead G from terminal H to remove the brush box and regulator assembly 4. If the brush length is less than 5mm (0.2 in.), new length 17mm (0.67 in.), or if spring pressure is less than 1.3N the brush box and regulator assembly must be renewed. Remove nuts and washers 5, bolts 6 and nuts 7. Remove slip ring end bracket 8. Carefully remove rectifier 10 and stator 11 as an assembly. Unsolder the interconnecting wires at X, Y, and Z only if renewing either of these components. Remove nut and washer 12 using an 8mm Allen key in the shaft hexagon hole to prevent rotation. If necessary, use a press to remove rotor 19 from the drive end bracket 17. Check the rotor poles and the inner faces of the stator for signs of rubbing, which indicates worn bearings. The drive end bearing is part of bracket 17 and cannot be removed separately. If requiring renewal, needle roller bearing 20 should be pressed out in the direction of the arrow. When Assembling Reverse the dismantling procedure, but note the following: Ensure that spacers 14,16, and 18 are correctly positioned as shown. Ensure that the slip rings J are clean and smooth, using extra fine glasspaper to rectify slight imperfections. Ensure that insulation bushes 9 and washers 5 are positioned as shown. Take care not to damage the brushes when fitting the brush box and regulator assembly. Torque Settings Item 3
Nm 2.7
kgf m 0.28
lbf ft 2.0
5
4.1
0.41
3.0
6
3.4
0.35
2.5
7
5.4
0.55
4.0
12
60.0
6.10
44.2
9803/3260
Issue 1
Section C
Electrics
Section C
39 - 6
Alternator
39 - 6
5 A 4
1 2
3
5
6
7 8
9 £
@
!
0
B
216870
9803/3260
Issue 1
Section C
Electrics
Section C
39 - 7
Alternator
39 - 7
Dismantling and Assembly - Magneti Marelli Type When Dismantling Remove nuts 1 and cover 2. Check the protruding length of the brushes A. If this is less than 10 mm (0.4 in), the brushes must be renewed. This will involve renewal of the regulator and brush box assembly 6 as the brushes are not available separately. Un-clip slip-ring shroud 3. Remove screw 4 and nuts 5 to
When Assembling Reverse the dismantling procedure, but note the following: Ensure that slip ring faces are clean and smooth, using very fine glasspaper if required. Do not use emery cloth. Ensure that stator connecting wires will not touch against the rotor. Lightly polish side faces of brushes to ensure free movement in brush box.
remove regulator and brush box assembly 6. Do not separate the rectifier 7 from the slip-ring end bracket
Torque Settings
8 as the gasket between them and its jointing paste provide a special heat conducting path which must not be disturbed.
Item 1
Nm 3.0-4.0
Kgf m 0.3-0.4
lbf in 26-36
If further dismantling is required, note the positions of the six leads B and unsolder them from their locating tags on the rectifier.
4
2.0-2.5
0.2-0.25
18-21
5 (M5)
1.7-2.3
0.2-0.23
15-20
5 (M6)
3.6-5.1
0.4-0.5
32-45
Using special socket 892/00882, remove nut 9, washer 10
Item
Nm
Kgf m
lbf ft
9
70-90
7.2-9.1
52-66
and pulley 11. If necessary, press the drive end bearing, complete with the rotor 12, out of the bracket and stator assembly 13.
9803/3260
Issue 1
Section C
Section C
Electrics Harness Location
40 - 1
40 - 1
Harness Location - Machines upto Serial Number 430000 4
3 6
1 2
5 S164091
Note: The illustration shows a typical machine.
ITEM
DESCRIPTION
1 2 3 4 5 6
Mainframe Harness Panel Harness Cab Harness Cab Roof Harness Solenoid Harness Rear Light Extension Harnesses (see note)
9803/3260
Issue 3
Section C
Section C
Electrics Harness Location
40 - 2
40 - 2
Harness Location - Machines from Serial Number 430001 3
4
2
6
7
5
1
Note: The illustration shows a typical machine.
ITEM
DESCRIPTION
1 2 3 4 5 6 7
Mainframe Harness Panel Harness Cab Harness Cab Roof Harness Solenoid Harness Rear Light Harnesses (see note) Engine Shut Off Harness
9803/3260
Issue 4
Section C
Electrics Harness and Wire Number Identification
41 - 1
Section C 41 - 1
Wire/Harness Numbers - Explanation of: Each wire has its own unique identification number, this number is printed on the wire every 50 mm (2 inches). The wire numbers listed on the next few pages identify the source and final destination of all the wires used on the machine. Also printed on the wire is the part number of the harness the wire originates from; the harness part number is shortened, so for instance, if the harness part number is 719/37100, the number printed on the harness wires will be 9/371 (71 and 00 are common numbers and therefore deleted).
*
Although the machine harness wires are all now identified using numbers, there will be instances when electrical components installed on the machine will have coloured flying leads. To ensure that numbered wires mate with the correct corresponding coloured flying lead a prefix will be added to the wire number; this prefix identifies the colour(s) of the flying lead that the numbered wire should mate with. For instance, if wire 819 from harness 719/37100 mated with a flying lead coloured black (colour code B) then the number printed on the wire would be B-819 9/371. The illustration shows a typical connector and wires. To summarize, the number stamped on the wire in the example shown identifies the following: B 819 9/371
= = =
The colour of the flying lead that the harness wire should mate with. The wire's unique identification number. The part number of the harness that the wire originates from.
S164110
Finally, some more points to notice regarding wire identification: 1
*2 3
Wires will continue to have the same number even after passing through a bulk head connector into a different harness. Wires in splices are identified by using the original input wire number and then a suffix letter. So for instance wire 000 is an original input wire, splices from this original wire are identified 000A, 000B and so on. The wire number categories shown in the tables on the following pages are as follows: 3.1 Wire numbers 000 to 199. Wires in this number bracket are allocated to live feeds when the starter switch is at IGN position, heater start circuits and start circuits. 3.2 Wire numbers 200 to 399. Wires in this number bracket are allocated to battery feeds. 3.3 Wire numbers 400 to 599. Wires in this number bracket are allocated to instruments, (alternator to tacho, fuel gauge senders to fuel gauges etc. 3.4 Wire numbers 600 to 799. Wires in this number bracket are allocated to earth paths. 3.5 Wire numbers 800 to 999. Wires in this number bracket are allocated to switched supplies to lights, horn etc from switches and relays.
9803/3260
Issue 3*
Section C
Electrics
Section C
Harness and Wire Number Identification Wire Numbers - 000 to 199 (to serial number 430000)
41 - 2
Wire No 000 000 409435 000A 000A 000B 000B 409435 000C 000C 409435 000D 000D 409435 000E 000E 409435 000F 409435 001 001A 001B 001C 001D 001E 001F 001H 001J 002 002A 002B 002C 002D 002E 002F 002G 002H 002H 409435 002J 002J 409435 002K 002K 409435 002L 002L 409435 002P 409435 002S 409435 003 004 100 100A 101 101A 101B 101P 102 102A
41 - 2
Source Starter Switch Starter Switch
Destination Fusebox - Fuse B1 Panel Harness Splice (Fusebox)
Wire Gauge 4.00 4.00
Fuse B1a Panel Harness Splice (Fusebox) Fuse A9a Panel Harness Splice (Fusebox)
Fuse A9a Fuse A9a Fuse B8a Fuse B8a
2.00 2.00 2.00 1.40
To m/c no. 409434 From m/c no.
Fuse B8a Panel Harness Splice (Fusebox)
Fuse B2a Fuse B2a
1.00 1.00
To m/c no. 409434 From m/c no.
Fuse B2a Panel Harness Splice (Fusebox)
Fuse B7a Fuse B7a
1.00 1.00
To m/c no. 409434 From m/c no.
Fuse B7a Panel Harness Splice (Fusebox)
Fuse B9a Fuse B9a
1.00 1.00
To m/c no. 409434 From m/c no.
Panel Harness Splice (Fusebox)
Fuse B1a
2.00
From
Starter Switch Panel Harness Splice Panel Harness Splice Panel Harness Splice Panel Harness Splice Panel Harness Splice Panel Harness Splice Panel Harness Splice Panel Harness Splice Panel Harness Splice Panel Harness Splice Panel Harness Splice Panel Harness Splice Panel Harness Splice Panel Harness Splice Panel Harness Splice Panel Harness Splice Fuse A9a Panel Harness Splice
Panel Harness Feed Splice 'Ignition' Relay Coil Feed Fusebox - Fuse C3a Fusebox - Fuse A1a Fusebox - Fuse A2a Fusebox - Fuse A5a Fusebox - Fuse B6a Fusebox - Fuse C5a Fusebox - Fuse C7a 'Ignition' Relay Fusebox - Fuse A1a Fusebox - Fuse A2a Fusebox - Fuse A5a Fuseboc - Fuse B6a Fusebox - Fuse C2a Fusebox - Fuse B1a Fusebox - Fuse A9a Fuse B8a Fusebox - Fuse A9a
4.00 1.50 3.00 1.00 1.00 1.00 1.50 1.40 1.00 8.00 1.00 1.00 1.00 1.50 1.00 4.00 2.00 2.00 1.40
Powershift m/c's Powershift m/c's Powershift m/c's Powershift m/c's Powershift m/c's Powershift m/c's Powershift m/c's To m/c no. 409434 From m/c no.
Fuse B8a Panel Harness Splice
Fuse B2a Fuse B2a
1.00 1.00
To m/c no. 409434 From m/c no.
Fuse B2a Panel Harness Splice
Fuse B7a Fuse B7a
1.00 1.00
To m/c no. 409434 From m/c no.
Fuse B7a Panel Harness Splice
Fuse B9a Fuse B9a
1.00 1.00
To m/c no. 409434 From m/c no.
Panel Harness Splice
Fuse C5a
2.00
From
m/c
no.
Panel Harness Splice
Fuse C7a
1.00
From
m/c
no.
Starter Switch Starter Switch Fuse B7 Dump Relay Fuse B1 Panel Harness Junction Box Splice Panel Harness Junction Box Splice Junction Box Fuse B8 Heater Switch
Thermostart Neutral Start Relay Dump Relay Foot Dump Switch Panel Harness Junction Box Splice Junction Box Bucket Reset Hydraulic Speed Control Switch Heater Switch Heater Switch Warning Light
3.00 3.00 1.00 1.00 2.00 2.00 1.00 1.00 1.50 1.00
From
m/c
no.
9803/3260
Comment To m/c no. 409434 From m/c no. To m/c no. 409434
m/c
no.
Powershift m/c's Syncro Shuttle m/c's Syncro Shuttle m/c's Syncro Shuttle m/c's Syncro Shuttle m/c's Syncro Shuttle m/c's Syncro Shuttle m/c's
Issue 4
Section C
Electrics
Section C
Harness and Wire Number Identification Wire Numbers - 000 to 199 (to serial number 430000)
41 - 3
Wire No 409435 103 103 409435 103A 103A 409435 103B 409435 103C 409435 103E 409435 103G 409435 104 104 409435 104A 409435 104B 409435 104C 409435 105 106 106A 107 107A 107B 107C 107D 107D 409435 107E 107E 107F 107F 409435 107K 409435 107L 409435 107M 413772 107N 413772 108 108 108A 108A 108B 109 109A 109B 109C 109D 109E 109F 110 110A 110B
41 - 3
Source
Destination
Wire Gauge
Comment
Fuse A5 Fuse A5
Rear Wiper / Wash Cab Harness Splice
1.50 1.00
To m/c no. 409434 From m/c no.
Rear Wiper Switch Cab Harness Splice
Rear Wiper Auxillary Feed Rear Wiper Switch
1.50 1.50
To m/c no. 409434 From m/c no.
Cab Harness Splice
Rear Work Light Switch Illumination
1.00
From
m/c
no.
Cab Harness Splice
Hydraulic Speed Control Switch Illumination 1.00
From
m/c
no.
Cab Harness Splice
Rear Wipe (only) Switch
1.00
From
m/c
no.
Cab Harness Splice
REar Wash/Wipe Switch Illumination
1.00
From
m/c
no.
Fuse B6 Panel Harness Hazard Splice
Hazard Switch (Indicators) Hazard Switch
1.50 1.40
To m/c no. 409434 From m/c no.
Fuse B6
Panel Harness Hazard Splice
1.40
From
m/c
no.
Panel Harness Hazard Splice
Beacon Switch Warning Light
1.00
From
m/c
no.
Panel Harness Hazard Splice
Main Lights Warning Light
1.00
From
m/c
no.
Fuse B2 Fuse A2 Fuse A2 Fuse C3 Panel Harness Splice (Gears) Panel Harness Splice (Gears) Panel Harness Splice (Gears) Panel Harness Splice (Gears) Panel Harness Splice (Gears)
Engine Shut-off Solenoid Fuel Gauge Feed Stabiliser Lock Relay Panel Harness Splice (Gears) Column Switch Forward Relay 2WD Relay 2WD Switch Brake Mode Switch Splice
1.00 1.00 1.00 1.50 1.00 1.00 1.00 1.00 1.00
To m/c no. 413771 To m/c no. 404851 To m/c no. 409434 From m/c no.
Forward Relay Gears Control Feed Splice Reverse Relay Panel Harness Splice (Gears)
Reverse Relay Reverse Relay Drive Relay Drive Relay
1.00 1.00 1.00 1.00
To m/c no. 409434 409435 to 413771 To m/c no. 409434 From m/c no.
Panel Harness Splice (Gears)
Brake Mode Switch
1.00
From
m/c
no.
Panel Harness Splice (Gears)
Brake Mode Switch
1.00
From
m/c
no.
Panel Harness Splice (Gears)
Parkbrake Dump Relay
1.00
From
m/c
no.
Panel Harness Splice (Gears)
Parkbrake Dump Relay - Coil Feed
1.00
From
m/c
no.
Fuse A1 Reverse Alarm Relay Fuse A1 Brake Relay Fuse A1 Fuse C2 Solenoid Harness Steer Mode Splice Solenoid Harness Steer Mode Splice Solenoid Harness Steer Mode Splice Solenoid Harness Steer Mode Splice Solenoid Harness Steer Mode Splice Solenoid Harness Steer Mode Splice Fuse A9 Panel Harness Column Switch Splice Panel Harness Column Switch Splice
Foot Brake Switch Foot Brake Switch Reverse Alarm Relay Reverse Alarm Relay 2 Wheel Drive Relay Feed Solenoid Harness Steer Mode Splice Front Proximity Switch Rear Proximity Switch 4 Wheel Steer Solenoid Crab Solenoid Crab/4 Wheel Steer Solenoid 2 Wheel Steer Solenoid Panel Harness Column Switch Splice Flasher Front Wiper/Washer
1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 2.00 1.00 1.00
To m/c no. 404851 From m/c 404852 To m/c no. 404851 From m/c 404852 From m/c 404852 AWS m/c's only AWS m/c's only AWS m/c's only AWS m/c's only AWS m/c's only AWS m/c's only AWS m/c's only
9803/3260
Issue 5
Section C
Electrics
Section C
Harness and Wire Number Identification Wire Numbers - 200 to 599 (to serial number 430000)
41 - 4
Wire No 110C 111 111A 114
200 200A 200B 200C 200D 200E 200F 200G 200H 200J 200K 300 302 303 303A 303B 303C 303D 303F 409435 304 401 402 403 404 405 406 407 408 409 410 411
41 - 4
Wire Gauge 1.00 1.00 1.00
Source Panel Harness Column Switch Splice Fuse B9 Fuse B9 Fuse C5
Destination Horn Buzzer Hand Dump Switch Deluxe Options
Alternator Alternator Starter Solenoid Starter Solenoid Starter Solenoid Starter Solenoid Starter Solenoid Starter Solenoid Fuse C1a Fuse A7a Fuse A6a Fuse A6 Fuse C1 Fuse A7 Cab Harness Splice Cab Harness Splice Cab Harness Splice Cab Harness Splice Fuse A7
Starter Solenoid Starter Solenoid Starter Switch Starter Relay Starter Relay Road Lights Relay Road Lights Relay Fusebox - Fuse C1a Fuse A7a Fuse A6a Fuse A8a Hazard Switch Rear Work Lights Switch Cab Harness Interior Light Splice Interior Light Beacon Front Wiper Clock Beacon Switch
4.50 4.50 4.00 4.00 3.00 3.00 2.50 4.00 2.00 2.00 1.00 4.00 2.00 1.50 2.00 1.50 1.00 0.60 1.40
Fuse A8 Park Brake Relay Air Filter Switch Engine Oil Pressure Switch Transmission Oil Temperature Switch Transmission Oil Pressure Switch Water Temperature Switch Alternator Fuel Gauge Water Temperature Gauge Test Button Buzzer
Radio Warning Light Warning Light Warning Light Warning Light Warning Light Warning Light Warning Light Sender Sensor Warning Lights Instrument Cluster
1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
9803/3260
Comment
See Note ➀ See Note ➀
To m/c no. 409434
From
m/c
no.
See Note ➀
To m/c no. 404502
Issue 4
Section C
Electrics
Section C
Harness and Wire Number Identification Wire Numbers - 600 to 799 (to serial number 430000)
41 - 5
Wire No 412
Source Alternator
Destination Instrument Cluster
41 - 5
Wire Gauge 1.00
Comment
Note ➀: Terminals 200, 200A and 407 may be either separate terminals or combined in a 'euro plug'.
600 600A 600B 600C 600D 600E 600F 600G 600H 600J 600K 600L 600M 600N 600P 600P 409435 600R 600R 409435 600S 600T 600U 600U 409435 600V 600V 409435 600W 600W 409435 600X
Starter Earth Starter Earth Mainframe Harness Earth Splice Mainframe Harness Earth Splice Mainframe Harness Earth Splice Mainframe Harness Earth Splice Mainframe Harness Earth Splice Mainframe Harness Earth Splice Mainframe Harness Earth Splice Starter Earth Starter Earth Starter Earth Panel Harness Earth Splice Panel Harness Earth Splice Fog Light Switch Earth Panel Harness Earth Splice
Engine Shut - off Solenoid Mainframe Harness Earth Splice Horn Transmission Oil Temperature Switch Loader Valve Rear Lights Italian Number Plate Light L/H Rear Combination Light R/H Rear Combination Light Panel Harness Earth Splice Panel Harness Earth Splice Steer Mode Relay PCB Cab Earth Splice Fog Light Switch Front Work Lights Switch Earth Front Work Lights Switch Earth
1.00 2.00 2.00 1.00 1.00 1.00 1.00 1.00 1.00 4.00 4.00 2.00 4.00 1.00 1.00 1.00
Front Work Lights Switch Earth Panel Harness Earth Splice
Radio Radio
1.00 1.00
To m/c. no. 409434 From m/c no.
Panel Harness Earth Splice Panel Harness Earth Splice Reverse Alarm Relay Earth Panel Harness Earth Splice
Reverse Alarm Relay Instrument Cluster Stabilizer Lock Relay Stabilizer Lock Relay
1.00 1.00 1.00 1.00
To m/c. no. 409434 From m/c no.
Stabilizer Lock Relay Earth Panel Harness Earth Splice
Neutral Start Relay Neutral Start Relay
1.00 1.00
To m/c. no. 409434 From m/c no.
2WD Switch Panel Harness Earth Splice
Ignition Relay Earth Ignition Relay Earth
1.00 1.00
To m/c. no. 409434 From m/c no.
Panel Harness Earth Splice
Head Light Earth Splice
3.00
9803/3260
AWS m/c's only
To m/c. no. 409434 From m/c no.
Issue 4
Section C
Electrics
Section C
Harness and Wire Number Identification Wire Numbers - 600 to 799 (to serial number 430000)
41 - 6
Wire No 600Y 600Z 600AA 600AB 600AB 409435 600AC 600AD 600AD 409435 600AE 600AE 409435 600AF 600AF 409435 600AG 600AG 409435 600AH 600AH 409435 600AJ 600AK 600AL 600AM 600AN 600AP 600AR 600AS 600AT 600AU 600AV 600AW 600AX 600AY 600AZ 600BA 600BB 600BC 600BD 600BE 600BF 600BG 600BH 600BJ 600BK 600BL 600BL 409435 600BM 600BM 409435 600BN 600BN 409435 600BP 600BR 600BR 600BS 600BT 600BU
41 - 6
Source Panel Harness Earth Splice Panel Harness Earth Splice Panel Harness Earth Splice 4 Wheel Drive Brake Relay Earth Panel Harness Earth Splice
Destination Dump Relay Solenoids Earth Splice 4 Wheel Drive Brake Relay 2 Wheel Drive Relay 2 Wheel Drive Relay
Wire Gauge 1.50 2.00 1.00 1.00 1.00
Panel Harness Earth Splice Forward Relay Earth Panel Harness Earth Splice
Forward Relay Reverse Relay Reverse Relay
1.00 1.00 1.00
To m/c. no. 409434 From m/c no.
Forward High/Low Relay Earth Panel Harness Earth Splice
Reverse Relay Forward High/Low Relay
1.00 1.00
To m/c. no. 409434 From m/c no.
Reverse High/Low Relay Earth Panel Harness Earth Splice
Forward High/Low Relay Reverse High/Low Relay Earth
1.00 1.00
To m/c. no. 409434 From m/c no.
Drive Relay Earth Panel Harness Earth Splice
Reverse High/Low Relay Drive Relay Earth
1.00 1.00
To m/c. no. 409434 From m/c no.
Neutral Relay Earth Panel Harness Earth Splice
Drive Relay Neutral Relay Earth
1.00 1.00
To m/c. no. 409434 From m/c no.
Cab Harness Earth Splice Cab Harness Earth Splice Cab Harness Earth Splice Cab Harness Earth Splice Cab Harness Earth Splice Cab Roof Harness Earth Splice Cab Roof Harness Earth Splice Cab Roof Harness Earth Splice Cab Roof Harness Earth Splice Cab Roof Harness Earth Splice Cab Roof Harness Earth Splice Cab Roof Harness Earth Splice Cab Roof Harness Earth Splice Cab Roof Harness Earth Splice Head Light Earth Splice Earth Splice Link Earth Splice Earth Splice Earth Splice Earth Splice Earth Splice Earth Splice Earth Splice Earth Splice Earth Splice Dump Relay Earth Panel Harness Earth Splice
Interior Light Front Wiper Cab Roof Harness Earth Splice Cab Roof Harness Earth Splice Cab Roof Harness Earth Splice Beacon R/H Front Light L/H Front Light L/H Rear Combination Light L/H Number Plate Light L/H Rear Work Light R/H Rear Combination Light R/H Number Plate Light R/H Rear Work Light R/H Head light Earth Splice Rear Socket L/H Head Light Rear Wiper Rear Work Light Warning Light Hand Brake Switch Front Washer Motor Heater Rear Fog Light Rear Washer Motor Indicator Relay Indicator Relay
1.00 1.00 2.00 2.00 2.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.50 1.50 2.00 1.50 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
To m/c. no. 409434 From m/c no.
Indicator Relay Earth Panel Harness Earth Splice
Road Lights Relay Road Lights Relay
1.00 1.00
To m/c. no. 409434 From m/c no.
R/D Lights Relay Earth Panel Harness Earth Splice
Hand Brake Relay Hand Brake Relay
1.00 1.00
To m/c. no. 409434 From m/c no.
Hand Brake Relay Earth Test Button Earth Panel Harness Earth Splice Solenoid Earth Splice Solenoid Earth Splice Solenoid Earth Splice
Test Button 2 Wheel Drive Warning Light 2 Wheel Drive Warning Light Forward Solenoid Reverse Solenoid Transmission Oil Pressure Switch
1.00 1.00 1.00 1.00 1.00 1.00
To m/c no. 404502 To m/c no. 404502 To m/c no. 404502
9803/3260
Comment
To m/c. no. 409434 From m/c no.
Issue 3
Section C
Electrics
Section C
Harness and Wire Number Identification Wire Numbers - 800 to 999 (to serial number 430000)
41 - 7
Wire No 600BV 600BW 600BX 600BY 600BZ 600CA 600CB 600CC 600CZ 409435 600DF 409435 600DJ 409435 600DN 409435 600DP 409435 600DR 409435 600DW 409435 600DX 409435 600DY 409435 600EB 409435 600EF 409435 601 602 603 409435
800 800A 800B 802 803 803A
Source Solenoid Earth Splice Solenoid Earth Splice Solenoid Earth Splice Solenoid Earth Splice Solenoid Earth Splice Solenoid Earth Splice Solenoid Earth Splice Junction Box Earth Cab Harness Splice (link)
Destination Rear Proximity Switch Front Proximity Switch Forward Low Solenoid Layshaft Solenoid Mainshaft Solenoid Reverse Low Solenoid 2 Wheel Drive Solenoid Earth Splice Cab Harness Splice
Cab Harness Splice
41 - 7
Wire Gauge 1.00 1.00 1.00 1.00 1.00 1.00 1.00 2.00 2.00
Comment AWS m/c's only AWS m/c's only
From
m/c
no.
Hydraulic Speed Control Switch Illumination 1.00
From
m/c
no.
Panel Harness Earth Splice (link)
Panel Harness Earth Splice
1.00
From
m/c
no.
Panel Harness Earth Splice (link)
Panel Harness Earth Splice
1.00
From
m/c
no.
Panel Harness Earth Splice (link)
Panel Harness Earth Splice
1.00
From
m/c
no.
Panel Harness Earth Splice (link)
Panel Harness Earth Splice
1.00
From
m/c
no.
Panel Harness Earth Splice
Main Lights Warning Light Earth
1.00
From
m/c
no.
Panel Harness Earth Splice
Hazard Switch Warning Light Earth
1.00
From
m/c
no.
Panel Harness Earth Splice
Beacon Switch Warning Light Earth
1.00
From
m/c
no.
Cab Harness Splice
Heater Switch Illumination
1.00
From
m/c
no.
Cab Harness Splice
Rear Worklight Switch Illumination
1.00
From
m/c
no.
Radio Radio Hydraulic Speed Control Relay
L/H Speaker -ve R/H Speaker -ve Hydraulic Speed Control Switch
1.00 1.00 1.00
From
m/c
no.
Heater Switch Heater Switch Heater Switch Hazard Switch Hazard Switch Indicator Relay
Heater (Low) Heater (Medium) Heater (High) Indicator Relay Indicator Relay Column Switch
1.00 1.00 1.00 1.50 1.50 1.00
9803/3260
To m/c. no. 409434
Issue 3
Section C
Electrics
Section C
Harness and Wire Number Identification Wire Numbers - 800 to 999 (to serial number 430000)
41 - 8
Wire No 804 804A 805 805A 805B 805C 805D 805E 805F 806 806A 806B 806C 806D 806E 806F 807 808 808A 809 810 810 409435 810A 810B 810C 811 812 813 814 815 815A 413772 816 816A 816B 816C 816D 816E 817 818 818A 819 819 409435 819A 409435 819B 409435 820 821 822 823
41 - 8
Source Hazard Switch Hazard Switch Hazard Switch Panel Harness LH Indicator Splice Panel Harness LH Indicator Splice Panel Harness LH Indicator Splice Panel Harness LH Indicator Splice Panel Harness LH Indicator Splice Panel Harness LH Indicator Splice Diode Panel Harness RH Indicator Splice Panel Harness RH Indicator Splice Panel Harness RH Indicator Splice Panel Harness RH Indicator Splice Panel Harness RH Indicator Splice Panel Harness RH Indicator Splice Reverse Alarm Relay Column Switch Reverse Alarm Relay Column Switch Column Switch Panel Harness Splice
Destination Instrument Warning Light Diode Panel Harness LH Indicator Splice Warning Light (Cluster) Column Switch LH Indicator (Chassis) Cab Harness LH Indicator Splice Front LH Indicator Rear LH Indicator Panel Harness RH Indicator Splice Warning Light (Cluster) Column Switch RH Indicator (Chassis) Cab Harness RH Indicator Splice Front RH Indicator Rear RH Indicator Reverse Alarm Reverse Alarm Relay Coil Reverse Relay Forward Relay Coil Panel Harness Neutral Start Splice Powershift Neutral Relay
Wire Gauge 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
Panel Harness Splice Panel Harness Splice Panel Harness Splice Reverse High/Low Relay Forward High/Low Relay Powershift Neutral Relay Coil Feed Column Switch Park Brake Relay Parkbrake Dump Relay
Park Brake Relay Coil Stabiliser Lock Relay Coil Neutral Start Relay Coil Reverse Solenoid Forward Solenoid Forward Relay Horn Park Brake Switch Parkbrake Relay
1.00 1.00 1.00 1.00 1.00 1.00 2.00 1.00 1.00
Panel Harness Splice Panel Harness Splice Panel Harness Splice Panel Harness Splice Main Frame Harness Splice Main Frame Harness Splice Powershift Neutral Relay Feed 2 Wheel Drive Relay Coil Feed 2 Wheel Drive Relay Coil Feed Front Proximity Switch Front Proximity Switch
Brake Relay Cab Harness Splice Main Frame Harness Splice Brake Relay LH Brake Light RH Brake Light Reverse Relay 2 Wheel Drive Switch 2 Wheel Drive Diode Gate Feed Steer Switch Panel Harness Splice
1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
To m/c. no. 409434 From m/c no.
Panel Harness Splice
Steer Switch
1.00
From
m/c
no.
Panel Harness Splice
Steer Switch
1.00
From
m/c
no.
Rear Proximity Switch Steer Switch Steer Switch Steer Switch
Steer Switch Steer Mode PCB (Crab) Steer Mode PCB (2 Wheel Steer) Steer Mode PCB (4 Wheel Steer)
1.00 1.00 1.00 1.00
Comment
To m/c. no. 409434 From m/c no.
From
m/c
no.
See Note ➁
Note ➁: Wire 816C is applicable only on machines up to serial number 403024. Also, on machines up to serial number 403024, wire 816 source is Panel Harness Brake Light Splice and its destination is Foot Brake Switch (refer to Technical Information Bulletin 2/066).
9803/3260
Issue 2
Section C
Electrics
Section C
Harness and Wire Number Identification Wire Numbers - 800 to 999 (to serial number 430000)
41 - 9
Wire No 824 824A 824B 825 825A 825B 826 826A 826B 827 827A 828 828 409435 828A 828B 828B 409435 828C 829 829A 829B 829C 829D 829E 829F 829G 830 830A 830B 830C 830D 830D 409435 830E 830E 409435 830F 830G 830K 409435 831 832 832A 832B 409435 833 834 834A 834B 834C 835 835A 836 837 837A 837B 837C 838 838A 839 840
41 - 9
Source Crab Solenoid Panel Harness Steer Splice Panel Harness Steer Splice 2 Wheel Steer Solenoid Panel Harness Steer Splice Panel Harness Steer Splice 4 Wheel Steer Solenoid Panel Harness Steer Splice Panel Harness Steer Splice Side Light Switch Side Light Switch Side Light Relay Fusebox - Fuse A3
Destination Panel Harness Steer Splice Crab Steer Warning Light Crab Steer Mode PCB Panel Harness Steer Splice 2 Wheel Steer Warning Light 2 Wheel Steer Mode PCB Panel Harness Steer Splice 4 Wheel Steer Warning Light 4 Wheel Steer Mode PCB Road Light Relay Head Light Switch Fusebox - Fuse A3a Main Lights Switch
Wire Gauge 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 2.00 2.00
Fuse A3a Road Light Relay Road Light Relay
Fuse A4a Work Light Switch Flying Lead Main Lights Switch
2.00 2.00 2.00
To m/c. no. 409434 From m/c no.
Work Light Switch Flying Lead Fuse A3 Panel Harness LH Side Light Splice Panel Harness LH Side Light Splice Main Frame LH Side Light Splice Main Frame LH Side Light Splice Cab Harness LH Side Light Splice Cab Harness LH Side Light Splice Cab Harness LH Side Light Splice Fuse A4 Panel Harness Splice Panel Harness Splice Panel Harness Splice Cab Harness RH Side Light Splice Panel Harness Splice
Work Light Switch Panel Harness LH Side Light Splice Cab Harness Side Light Splice Main Frame LH Side Light Splice Italian Number Plate Light LH Rear Tail Light LH Front Side Light Cab Roof Harness Side Light Splice LH Number Plate Light Panel Harness Splice Gauge Illumination RH Rear Combination Lights Cab Harness RH Side Light Splice RH Side Light Work Light Switch Warning Light
2.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
To m/c. no. 409434 From m/c no.
Cab Harness RH Side Light Splice Panel Harness Splice
Rear Socket Hazard Switch Warning Light
1.00 1.00
To m/c. no. 409434 From m/c no.
Cab Harness RH Side Light Splice Cab Harness RH Side Light Splice Cab Harness RH Side Light Splice
Cab Roof Harness RH Side Light Splice RH Number Plate Light Deluxe Option Plug
1.00 1.00 1.00
From
Front Work Light Switch Main Lights Switch Fusebox - Fuse C4a Main Lights Switch
Fusebox - Fuse B5a RH Column Switch (Dip) Head Lights Switch Work Light Relay Coil
2.00 2.00 1.00 1.00
To m/c. no. 409434 From m/c no.
RH Column Switch (Dip) Fuse B3 Cab Harness Dip Head Light Splice Cab Harness Dip Head Light Splice Fuse B3 Fog Light Switch Fog Light Switch Main Beam Switch Fuse B4 Cab Harness Main Beam Splice Cab Harness Main Beam Splice Fuse B4 Foot Dump Switch Dump Relay Column Switch Column Switch
Fuse B3a Cab Harness Dip Head Light Splice RH Head Light LH Head Light Fog Light Switch Fog Light Warning Light Fuse B4 Cab Harness Main Beam Head Light Splice RH Head Light LH Head Light Main Beam Warning Light Dump Relay Hand Dump Switch Front Washer Pump Front Wiper
1.50 3.00 1.50 1.50 1.00 1.00 1.00 1.50 3.00 2.00 2.00 1.00 1.00 1.00 1.00 1.00
9803/3260
Comment
To m/c. no. 409434 To m/c. no. 409434 To m/c. no. 409434 From m/c no.
m/c
no.
To m/c no. 400076 To m/c no. 400076
Issue 1
Section C
Electrics
Section C
Harness and Wire Number Identification
42 - 1
42 - 1
Wire Numbers - 000 to 199 (from Serial Number 430001) Note: The heading 'Harnesses Affected' refers to the harness(es) that house the individual wires, in some instances wires pass through more than one harness, refer to the illustration on page C/40-2 for harness location. MF = Mainframe Harness, P = Panel Harness, Cab = Cab Harness, CR = Cab Roof, TR = Transmission, Conditioning Harness, Aux = Auxiliary Hydraulics Harness (e.g. Hammer), RL = Rear Lights Harness Wire No 001 001A 001K 001L 001M 002 002D 002E 002F 002J * 002N 002R 003 003A 004 007 007A 007B 007C 007D 007E 007F 009 009A 009B 009C 009D 101 101A 101AA 101AB 101AG 101AH 101B * 101D 101L 101P 101S 101Y 101Z 102 102B 102C 103 103A 103B 103F 104 105
Description Ignition Switch to Feed Splice Ignition Splice to Ignition Relay 1 Ignition Splice to Fuse B8 Ignition Splice to Ignition Relay 2 Ignition Splice to Lights Relay Ignition Relay 1 to Feed Splice Relay 1 Feed Splice to Fuse B6 Relay 1 Feed Splice to Fuse C2 Relay 1 Feed Splice to Fuse B1 Relay 1 Feed Splice to Fuse B2 Relay 1 Feed Splice to Fuse C6 Relay 1 Feed Splice to Fuse C3 Ignition Switch to Thermostat Ignition Switch Link Ignition Switch to Neutral Start Relay Ignition Relay 2 to Feed Splice Relay 2 Feed Splice to Brake Switch Relay 2 Feed Splice to Fuse A9 Relay 2 Feed Splice to Fuse C5 Relay 2 Feed Splice to Fuse A2 Relay 2 Feed Splice to Fuse B9 Relay 2 Feed Splice to Fuse A5 Lights Relay to Feed Splice Panel Feed Splice to Main Light Switch Lights Splice to Front Work Light Connector Lights Splice to Fuse C1 Work Lights Connector to Fuse B5 Fuse to Feed Splice Splice to Junction Box Feed Splice to Hammer Switch Splice to Rear Horn Switch Fuse B1 to Feed Splice Feed Splice to Hydraclamp Switch Splice to Reset Switch Hammer Connector to Hammer Isolator Switch ➁ Feed Splice to Jaw Change-over (C/O) Relay Feed Splice to Hydraulic Speed Control Switch Feed Splice to Hammer Relay Mainframe Splice to Aux. Hyd. Feed Splice Feed Splice to Jaw Change-over (C/O) Switch Heater Fast Relay to Heater Switch Fuse B8 to Heater Fast Relay Heater Switch to Air Con Switch Fuse A5 to Feed Splice Feed Splice to Rear Wash Wipe Switch Feed Splice to Rear Wash Wipe Switch Feed Splice to Rear Wiper Fuse B6 to Hazard Switch Fuse B2 to E.S.O.S.
9803/3260
Wire Gauge 4.00 0.60 4.00 0.60 0.60 4.00 1.40 2.00 2.00 2.00 1.00 1.40 2.00 2.00 2.00 4.00 1.00 2.00 2.00 1.00 1.40 1.00 3.00 1.40 1.40 1.40 1.40 2.00 2.00 1.00 1.00 2.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 2.00 4.00 1.00 1.00 1.00 1.00 1.00 1.40 1.00
MF
MF
MF MF
P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P
Harnesses Affected Cab CF TR A/C
A/C = Air
AUX
RL
Cab
Cab
Aux MF P P MF P P P P MF
MF
Aux Aux P P P P P P P P P
A/C
Cab
Issue 4*
Section C
Electrics
Section C
Harness and Wire Number Identification
42 - 2
42 - 2
Wire Numbers - 000 to 199 (from Serial Number 430001) Wire No
Description
* 106 * 106B 106C 107 107A 107B 107D 107E 107F 107G 107H * 107J 107L 107L 107M 107N 107P 107R * 107S 109 109A 109B 109C 109D 109E 109F 110 110A 110B 110H 110J 114 114A 114B 114C 114E 114F 116 117 118 * 125
Fuse A2 to Instrument Panel Buzzer to Master Warning Light Cluster Fuse A2 to Buzzer Fuse C3 to Feed Splice Feed Splice to LH Column Switch (Powershift) Feed Splice to Forward Relay Feed Splice to 4WD Switch Feed Splice to Reverse Relay Feed Splice to Drive Shaft Relay Column Switch Feed Forward/Reverse (Syncro) Feed Splice to Cab Feed Splice Cab Harness Splice to LH Column Switch ➁ Feed Splice to Brake Mode Switch (2WS Machines) Feed Splice to Steer Mode Switch (AWS Machines) Feed Splice to Dump Relay Feed Splice to Dump Relay Feed Splice to 4 Wheel Brake Relay Column Switch Feed Forward/Reverse (Powershift) Feed Splice to Brake Mode Switch (2WS Machines) ➀ Fuse C2 to Mainframe Feed Splice Splice to Front Proximity Switch Splice to Rear Proximity Switch Splice to 4WD Solenoid Splice to Crab Steer Solenoid Splice to 4WS/Crab Steer Solenoid Splice to 2WS Steer Solenoid Fuse A9 to Column Switches Feed Splice to Flash Feed Feed Splice to Front Wash/Wipe Feed Feed Splice to Column Switch Horn (Powershift) Feed Splice to Column Switch Horn (Syncro Shuttle) Fuse C5 to Feed Splice Feed Splice to Clock Feed Splice to Cigarette Lighter Feed Splice to Heated Seat Switch Feed Splice to Face Level Fan Feed Splice to Mainframe Feed Splice Fuse B5 to Front Work Light Switch Fuse C1 to Rear Work Light Switch Fuse B9 to Rear Horn Relay Fuse C6 to Column Switch (Gears, Forward/Reverse)
9803/3260
Wire Gauge 1.00 1.00 1.00 1.40 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.60 1.00 0.60 0.60 1.00 1.00 1.00 2.00 1.00 1.00 1.00 1.00 1.00 1.00 2.00 1.00 1.00 2.00 2.00 2.00 0.60 1.40 1.00 1.40 1.40 1.40 1.40 1.40 1.00
MF
P P P P P
Harnesses Affected Cab CF TR A/C
AUX
RL
Cab
Cab P Cab P P P P P P P P
MF MF MF MF MF MF MF
P P
P
Cab Cab Cab Cab Cab
Cab Cab
Cab Cab Cab Cab Cab
P Cab Cab P P P P P P P
Cab
Cab
Issue 3*
Section C
Electrics
Section C
Harness and Wire Number Identification
42 - 3
42 - 3
Wire Numbers - 200 to 599 (from Serial Number 430001) Wire No 200 200A 200B 200C 200D 200E 200G 200H 200J 200K 200M 200N 300 303 303A 303B * 303B 303C 303D 303F 304 401 402 403 404 405 * 405 406 407 408 409 411 411A 412 412A 412B
Description
Wire Gauge Alternator to Starter Solenoid 6.00 Alternator to Starter Solenoid 6.00 Starter Solenoid to Ignition Switch 4.00 Starter Solenoid to Ignition Switch/Relay 4.00 Starter Solenoid to Ignition Relay 4.00 Starter Solenoid to Road Lights Relay 3.00 Starter Solenoid to Fuse Box 4.00 Feed Splice to Fuse A7 2.00 Feed Splice to Fuse A6 1.40 Feed Splice to Fuse A8 1.00 Starter Solenoid to Ignition Relay 2 4.00 Feed Splice to Main Lights Switch 1.00 Fuse A6 to Hazard Switch 1.40 Fuse A7 to Cab Feed Splice 1.40 Feed Splice to Interior Light 1.00 Fuse A7 to Rotating Beacon Switch 1.40 Fuse A7 to Rotating Beacon Socket ➁ 1.40 Feed Splice to Front Wiper Aux. Feed 1.00 Feed Splice to Clock 0.60 Feed Splice to Interior Light 1.00 Fuse A8 to on Board Entertainment System 1.00 Parkbrake Relay to Warning Light 0.60 Air Cleaner Switch to Warning Lamp 1.00 Engine Oil Pressure Switch to Warning Lamp 1.00 Transmission Oil Temp. Switch to Warning Lamp 1.00 Transmission Oil Pressure Switch to Warning Lamp 1.00 Trans. Pressure Switch to Warn. Lamp ➁ 1.00 Water Temperature Switch to Warning Lamp 1.00 Alternator to Warning Lamp 1.00 Fuel Sender to Fuel Gauge 1.00 Water Temperature Sender to Water Temperature Gauge 1.00 Instrument Panel to Warning Buzzer 1.00 Warning Buzzer to Master Warning Lights 1.00 Alternator 'W' Terminal to Warning Lamp 1.00 Tachometer Splice to Tachometer 0.60 Tachometer Splice to German Tachometer 0.60
9803/3260
MF MF MF MF MF MF MF MF
MF
P
P P P P P P P P P P P P P P
MF MF MF MF MF MF MF MF MF
MF
P P P P P P P P P P P P P P P P
Harnesses Affected Cab CF TR A/C
AUX
RL
Cab Cab Cab Cab Cab Cab Cab Cab
CR
TR TR
Cab
Cab
Issue 3*
Section C
Electrics
Section C
Harness and Wire Number Identification
42 - 4
42 - 4
Wire Numbers - 600 to 799 (from Serial Number 430001) Wire No
Description
600 Earth Splice to E.S.O.S. 600A Starter Earth to Earth Splice 600AA Panel Earth Splice to 4 Wheel Brake Relay Earth 600AB Panel Earth Splice to 2 Wheel Drive Relay Earth 600AC Panel Earth Splice to Forward Relay Earth 600AD Panel Earth Splice to Reverse Relay Earth 600AE Panel Earth Splice to Forward High/Low Relay Earth 600AF Panel Earth Splice to Reverse High/Low Relay Earth 600AG Panel Earth Splice to Drive Shaft Relay Earth 600AH Panel Earth Splice to Neutral Relay Earth 600AJ Interior Light Earth 600AK Front Wiper Earth 600AL Panel Earth Splice to Cab Roof Earth Splice 600AM Panel Earth Splice to Cab Roof Earth 600AN Panel Earth Splice to Cab Roof Earth 600AP Earth Splice to Beacon Earth 600AR Earth Splice to RH Work Light 600AS Earth Splice to LH Work Light 600AT LH Earth Splice to LH Combination Light 600AU LH Earth Splice to LH No. Plate Light 600AV LH Earth Splice to LH Work Light 600AW RH Earth Splice to RH Combination Light 600AX RH Earth Splice to RH No. Plate Light 600AY RH Earth Splice to RH Work Light 600AZ RH Headlight Earth 600B Earth Splice to Front Horn 600BA Panel Earth Splice to Cab Earth Splice 600BB Dipper Socket Earth 600BC LH Headlight Earth 600BC Cab Earth Splice to Earth Splice (Austria) 600BD Panel Earth Splice to Rear Wiper Earth 600BE Panel Earth Splice to Rear Work Lights Switch 600BF Parkbrake Switch Earth 600BG Earth Splice to Front Wash Pump 600BH Starter Earth to Panel Earth Splice 600BJ Rear Fog Light Earth 600BK Earth Splice to Rear Wash Pump 600BL Panel Earth Splice to Indicator Relay Earth 600BN Panel Earth Splice to Park Brake Relay 600BR 4WD Switch Light Earth 600BS Earth Splice to Forward High Solenoid Earth * 600BS Earth Splice to Forward Solenoid Earth ➁ 600BT Earth Splice to Reverse High Solenoid Earth * 600BT Earth Splice to Reverse Solenoid Earth ➁ 600BU Earth Splice to Transmission Oil Press Switch * 600BUEarth Splice to Transmission Oil Press Switch ➁ 600BV Earth Splice to Rear Proximity Switch 600BW Earth Splice to Front Proximity Switch 600BX Earth Splice to Forward Low Sol Earth 600BY Earth Splice to Layshaft Solenoid Earth 600BZ Earth Splice to Mainshaft Solenoid Earth 600C Earth Splice to Transmission Oil Temperature Switch 600CA Earth Splice to Reverse Low Sol Earth 600CB Earth Splice to 4WD Sol Earth
9803/3260
Wire Gauge 1.00 2.50 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 1.00 1.00 2.00 1.40 1.40 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 2.00 1.40 1.40 1.40 1.00 0.60 1.00 1.00 4.00 1.00 1.00 0.60 0.60 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
MF
P
Harnesses Affected Cab CF TR A/C
AUX
RL
MF MF P P P P P P P P
P P P
Cab Cab Cab Cab Cab
CR CR CR CR CR CR CR CR CR CR CR CR
Cab MF P
Cab Cab Cab
P P Cab MF MF
P Cab
MF P P Cab TR MF TR MF TR MF MF MF TR TR TR MF TR TR
Issue 3*
Section C
Electrics
Section C
Harness and Wire Number Identification
42 - 5
42 - 5
Wire Numbers - 600 to 799 (from Serial Number 430001) Wire No
Description
Wire Gauge
* 600CBEarth Splice to 4WD Solenoid Earth ➁ * 600CCEarth Splice to Junction Box * 600CDReverse Alarm Earth * 600CE Earth Splice to Fuel Sender 600CF Earth Splice to Air Cleaner 600CH Panel Earth Splice to Aux. Hyd. Switch 600CJ Earth Splice to Hammer Solenoid 600CK Earth Splice to Water Temperature Switch 600CU Panel Earth Splice to Jaw Change-over Relay Earth 600CX Earth Splice to Jaw Change-over Solenoid 600D Earth Splice to Loader Valve 600DA Panel Earth Splice to Heated Seat Switch 600DB Cigarette Lighter Earth 600DC Clock Earth 600DE Earth Splice to Hydraulic Speed Control 600DF Panel Earth Splice to Hydraulic Speed Control Switch 600DG Earth Splice to Hydraulic Speed Control Switch 600DH Panel Earth Splice to Heated Seat 600DJ Panel Earth Splice to Earth Splice 600DN Panel Earth Splice to Earth Splice 600DP Panel Earth Splice to Earth Splice 600DW Main Lights Switch Work Light Earth 600DX Hazard Lights Switch Work Light Earth 600DY Panel Earth Splice to Beacon Switch * 600DX 4WD Switch to Cab Harness Splice 600E Panel Earth to Rear Lights Earth Splice 600EA Panel Earth Splice to Hammer Relay Earth 600EF Panel Earth Splice to Rear Wash/Wipe Switch 600EG Face Level Fan Earth 600EJ Interior Light Earth 600EK Master Warning Lights Earth * 600EL Rear Horn to Cab Harness Earth Splice ➂ * 600EL Rear Horn to Mainframe Harness Earth Splice ➂ * 600EN Mainframe Earth Splice to Aux. Hydraulics Connector 600EP Earth Splice to Starter Earth 600ER Earth Splice to Starter Earth 600ES Earth Splice to Hydra Clamp Valve 600EZ Earth Splice to Dump Switch 600F Earth Splice to Number Plate Light 600FA Panel Earth Splice to Italian Work Light Relay 600FB Panel Earth Splice to Air Conditioner Switch 600FC Panel Earth Splice to Hydraclamp Switch 600FF Panel Earth Splice to Ignition 2 Relay Earth 600FG Panel Earth Splice to Rear Horn Relay Earth 600FH Panel Earth Splice to Heater Fast Relay Earth 600FJ Panel Earth Splice to Lights Relay Earth * 600FK Starter Motor Earth to Panel Harn. Earth Splice 600FL Earth Splice to Transmission Dump Switch (Gear Lever) * 600FL Earth Splice to Transmission Dump Switch (Gear Lever) ➁ 600FM Earth Splice to LH Headlight 600FN Earth Splice to Bucket Lights Earth Splice 600G Earth Splice to LH Rear Lights 600H Earth Splice to RH Rear Lights 600J Starter Earth to Panel Earth Splice
9803/3260
1.00 2.00 1.00 1.00 1.00 0.60 1.00 1.00 0.60 1.00 1.00 0.60 1.40 0.60 1.00 0.60 1.00 1.00 0.60 0.60 0.60 1.00 1.00 0.60 0.60 1.40 0.60 0.60 1.40 1.00 1.00 1.40 1.40 1.00 1.00 3.00 1.00 1.00 1.00 0.60 0.60 0.60 0.60 0.60 0.60 0.60 4.00 1.00 1.00 1.00 1.40 1.00 1.00 4.00
MF
P
Harnesses Affected Cab CF TR A/C
AUX
RL
MF MF Cab MF MF P Aux MF P Aux MF P Cab Cab MF P MF P P P P Cab Cab P Cab P P P
RL
Cab Cab Cab Cab MF MF MF MF MF MF
Aux
RL
MF
P P P P P P P P
A/C
TR MF
RL RL MF
P
Issue 2*
Section C
Electrics
Section C
Harness and Wire Number Identification
42 - 6
42 - 6
Wire Numbers - 600 to 799 (from Serial Number 430001) Wire No
Description
* 600K * 600L * 600M * 600N * 600P * 600R * 600T 600V 600W 600X 600Z 601 602 603
Starter Earth to Panel Earth Splice Earth Splice to Steer Mode Unit Panel Earth Splice to Cab Earth Splice Panel Earth Splice to Fog Light Switch Panel Earth Splice to Front Work Light Switch Panel Earth Splice to on Board Entertainment System Panel Earth Splice to Instrument Panel Panel Earth Splice to Neutral Start Relay Earth Panel Earth Splice to Ignition Relay 1 Earth Panel Earth Splice to Cab Earth Splice Earth Splice to Solenoids Earth Splice Radio to Left Hand Speaker Radio to Right Hand Speaker Hydraulic Speed Control Switch Earth
9803/3260
Wire Gauge 4.00 1.00 2.00 0.60 0.60 1.00 0.60 0.60 0.60 1.40 1.40 0.60 1.00
MF
P
MF
P P P P P P P P P P
Harnesses Affected Cab CF TR A/C
RL
Cab
Cab
MF
MF
AUX
TR P P P
Cab Cab
Issue 2*
Section C
Electrics
Section C
Harness and Wire Number Identification
42 - 7
42 - 7
Wire Numbers - 800 to 999 (from Serial Number 430001) Wire No
Description
* 800 800A 800B 800C 802 803 803A 803B 804 804A 805 805B 805C * 805C 805E * 805E 805F * 805F 805G 805H 805J 806 806B 806C * 806C 806E * 806E 806F * 806F 806H 806K 808 808B 808C 809 809A 809B * 810 810A 810C 811 811 * 811 811A 812 812 * 812 813 814 814A 814B 815 815A 816 816A
Heater Switch to Heater Resistors Heater Switch to Heater Resistors Heater Fast Relay to Heater Resistor Heater Switch to Heater Fast Relay Indicator Flasher to Hazard Switch Indicator Flasher to Hazard/Column Switch Column Switch Indicator Feed Indicator Splice to Hazard Switch Hazard Switch to Master Warning Lights Hazard Switch to Diode Hazard Switch to LH Indicator Splice LH Indicator Splice Column Switch Feed LH Indicator Cab Splice to LH Rear Indicator LH Indicator Splice to LH Rear Indicator ➁ LH Cab Indicator Splice to LH Indicator Splice LH Indicator Splice to LH Front Indicator ➁ Cab Plug to LH Indicator Cab Harn. Splice to Roof Harn. Splice ➁ LH Indicator Master Warning Light Feed LH Indicator Splice to LH Indicator LH Indicator Splice to LH Bucket Indicator Diode to RH Indicator Splice RH Indicator Splice Column Switch Feed RH Indicator Cab Splice to RH Rear Indicator RH Indicator Splice to RH Rear Indicator ➁ RH Front Indicator Light Feed RH Indicator Splice to RH Front Indicator ➁ Cab Plug to RH Indicator Cab Harn. Splice to Roof Harn. Splice ➁ RH Indicator Master Warning Light Feed RH Indicator Splice to RH Head Light Column Switch to Reverse Relay LH Column Switch to Reverse Splice (Powershift) LH Column Switch to Reverse Splice (Syncro) Column Switch to Forward Relay LH Column Switch to Forward Splice (Powershift) LH Column Switch to Forward Splice (Syncro) LH Column Switch to Neutral Start Splice Neutral Start Splice to Park Brake Relay Coil Neutral Start Splice to Neutral Start Relay Reverse Relay to Reverse High Solenoid (Powershift) Reverse Relay to Reverse Solenoid (Syncro) Reverse Relay to Reverse Solenoid ➁ Reverse Relay to Reverse Alarm (Syncro) Forward Relay to Forward High Solenoid (Powershift) Forward Relay to Forward Solenoid (Syncro) Forward Relay to Forward Solenoid ➁ Forward Relay to Neutral Relay Coil Horn Switch to Horn LH Column Switch to Horn Splice (Powershift) LH Column Switch to Horn Splice (Syncro) Park Brake Relay to Park Brake Switch Park Brake Relay to Diode Gate Fuse A1 to Brake Light Splice Cab Plug to Brake Light Splice (USA)
9803/3260
Wire Gauge 1.40 2.00 4.00 0.60 1.40 1.40 1.00 1.40 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.60 1.00 1.00 0.60 1.00 1.00 0.60 0.60 0.60 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.60 2.00 2.00 2.00 0.60 0.60 1.00 1.00
MF
P P P P P P P
P
Harnesses Affected Cab CF TR A/C
Cab Cab Cab Cab Cab Cab Cab Cab Cab
AUX
RL
RL CR
Cab Cab Cab Cab
P
CR CR CR
Cab Cab Cab
RL CR
Cab
P
P
MF MF MF MF MF MF MF
P P P P P P P P P P P P
P P P P
Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab
CR CR CR
TR TR Cab TR TR
Cab Cab Cab Cab
Cab Issue 2*
Section C
Electrics
Section C
Harness and Wire Number Identification
42 - 8
42 - 8
Wire Numbers - 800 to 999 (from Serial Number 430001) Wire No
Description
* 816A * 816A * 816B * 816D * 816E * 816F * 816G * 817 * 818A 819 819A 819B 820 821 822 823 824 824A 824B 825 825A 825B 825C 826 826A 826B 828 828A 828D 828E 828F 828G 828H 829 829A 829AA 829B 829C 829D 829E 829F 829G 829H 829J 829K 829L 829M 829R 829S 829T 829U 829V 829W 829X
Cab Plug to Brake Light Splice Fuse A1 to Cab Harness Brake Light Splice ➁ Panel Brake Splice to Brake Lights Splice Brake splice to LH Brake Light Brake splice to RH Brake Light Brake Splice to LH Combination Light Brake Splice to RH Combination Light Reverse Relay to Neutral Start Relay 2WD Relay to Diode Gate Front Proximity Switch to Steer Switch Panel Feed Splice to Steer Mode Switch Panel Feed Splice to Steer Mode Switch Rear Proximity Switch to Steer Switch Steer Mode Switch to Steer Mode Unit (Crab) Steer Mode Switch to Steer Mode Unit (2WS) Steer Mode Switch to Steer Mode Unit (AWS) Crab Solenoid to Crab Splice Crab Splice to Warning Lamp Steer Mode Unit to Crab Splice 2WS Solenoid to 2WS Splice 2WS Splice to Warning Lamp Steer Mode Unit to 2WS Splice 2WS Splice to Master Warning Light 4WS Solenoid to 4WS Splice 4WS Splice to 4WS Warning Lamp Steer Mode Unit to 4WS Splice Main Lights Switch to Fuse A3 Fuse A3 to Fuse A4 Side Lights Switch Work Light Feed Master Warning Lights Sidelight Feed Hazard Switch illumination 2/4WD Switch Illumination Side Lights Splice Feed Fuse A3 to LH Side Lights Splice LH Side Splice to LH Cab Side Splice Air Conditioning Switch Illumination Panel Splice to LH Side Light Splice Side Light Splice to Number Plate Light Side Light Splice to LH Side Light LH Cab Sidelight Splice to Sidelight Splice Cab Plug to LH Tail Light Splice Cab Plug to LH No. Plate Light LH Tail Splice to LH No. Plate Light LH Tail Splice to LH Combination Light Sidelight Splice to LH Sidelight Sidelight Splice to RH Bucket Sidelight Sidelight Splice to LH Bucket Sidelight Front Work Light Switch Illumination Beacon Switch Illumination Hydraulic Speed Control Switch Illumination Fog Light Switch Illumination Rear Work Light Switch Illumination Rear Wash/Wipe Switch Illumination Hydraclamp Switch Illumination
9803/3260
Wire Gauge 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.60 0.60 1.00 0.60 0.60 1.00 0.60 0.60 0.60 1.00 0.60 1.00 1.00 0.60 1.00 0.60 1.00 0.60 1.00 1.00 1.00 1.00 1.00 0.60 0.60 1.00 1.00 1.00 0.60 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.60 0.60 0.60 0.60 0.60 0.60 0.60
MF
P P P
Harnesses Affected Cab CF TR A/C Cab
AUX
RL
CR CR RL RL RL CR CR
MF
MF
MF
MF
P P P P P P P P P P P P P P P P
Cab Cab Cab Cab Cab Cab
Cab
MF P P P P
Cab Cab Cab Cab Cab Cab
P P P P
Cab A/C RL RL RL Cab Cab
CR CR CR CR
P P P P P P P
Issue 2*
Section C
Electrics
Section C
Harness and Wire Number Identification
42 - 9
42 - 9
Wire Numbers - 800 to 999 (from Serial Number 430001) Wire No
Description
* 829Y * 829Z * 830 * 830A * 830B * 830C * 830D * 830E * 830F 830G 830H 830J 830L 832 832A 832B 833 834 834A 834B 835 835B 835C 836 837 837A 837B 837D 839 840 841 842 844 845 846 847 847A 848 849 850 851 852 853 * 853 853B 853B * 853C 855 855A 855B 855C 855D * 855E * 855F
Aux. Hyd. Switch Illumination Heated Seat Switch Illumination Fuse A4 to RH Side Lights Splice (Cigarette Lighter) RH Side Lights Splice to Gauge Illumination RH Side Lights Splice to RH Rear Side Light RH Side Light Splice to RH Cab Side Splice RH Side Lights Splice Feed Dipper Socket Feed Cab Plug to RH Tail Light Splice Cab Plug to RH No. Plate Light RH Tail Splice to RH Combination Light RH Tail Splice to RH No. Plate Light RH Side Lights Clock Feed Mainlights Switch to Column Switch Main Lights Switch to Fuse C4 Fuse C4 to Italian Worklights Relay Column Switch Dip Feed to Fuse B3 Fuse B3 to Dip Headlights Splice RH Dipped Headlight Feed LH Dipped Headlight Feed Fog Light Switch to Fog Light Cab Splice Fog Light Feed Fog Light Master Warning Light Feed Column Switch Mainbeam Feed to Fuse B4 Fuse B4 to Main Beam Splice RH Headlight Main Beam Feed LH Headlight Main Beam Feed Master Warning Light Main Beam Feed Column Switch to Front Washer Pump Front Wiper Motor Feed Front Wiper Motor Return Neutral Start Relay to Starter Solenoid Shovel Reset Switch to Loader Valve Steer Mode Unit to 4WS/Crab Solenoid Forward Relay to Forward High / Low Relay Reverse Relay to Reverse High / Low Relay Reverse Relay to Reverse Alarm (Powershift) Forward High/Low Relay to Forward Low Solenoid Reverse High/Low Relay to Reverse Low Solenoid Driveshaft Relay to Layshaft Solenoid Driveshaft Relay to Mainshaft Solenoid Transmission Dump Relay to Column Switch (For./Rev.) 4WD Relay to 4WD Solenoid 4WD Switch to 4WD Solenoid ➁ 4WD Relay to Steer Mode Switch (AWS Machines) Auto 2WD Relay to 4WD Relay (2WS Machines) Brake Mode Switch to 4Wheel Brake Relay ➀ Cab Plug to Front Work Light Feed Splice Feed Splice to RH Front Work Light Feed Splice to LH Front Work Light Front Work Light Cab Roof Feed Master Warning Light Front Work Light Feed Front Work Light Switch to Panel Harn. Splice ➁ 4WD Switch to Cab Harness Splice ➁
9803/3260
Wire Gauge 0.60 0.60 1.00 0.60 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.60 1.40 1.00 1.00 1.40 1.40 1.00 1.00 1.00 1.00 1.00 1.40 1.40 1.00 1.00 1.00 1.00 1.00 1.00 2.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.40 1.00 1.00 1.40 1.00 0.60 0.60
MF
P P P P P P P
P P P P
P
P P
MF
P
MF MF MF
P
MF MF MF MF MF MF
P P P P P P P P P P P P P P P
Harnesses Affected Cab CF TR A/C
AUX
RL
Cab RL Cab Cab Cab Cab
CR CR CR CR
RL
Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab
Cab TR TR TR TR Cab TR Cab Cab Cab Cab
CR CR CR
Cab Cab P Cab
Issue 2*
Section C 42 - 10
Electrics
Section C
Harness and Wire Number Identification
42 - 10
Wire Numbers - 800 to 999 (from Serial Number 430001) Wire No
Description
* 855G * 855H * 855J * 855K * 855L * 856 * 856A * 856B * 857 * 858 * 858A * 858B * 858C * 858D * 859 * 860 * 861 * 861A 861B 861C 861D 862 863 864 865 866 867B 868 870 * 871 * 871 * 871A 872 873 874C 875 875A 877 877B 883 883B 884 884A 884B 884C 886 894 898 899 899A 902 903 904 909A 912 * 912 * 912A
Hazard Switch to Cab Harness Splice ➁ Hammer Isolator Switch to Panel Harn. Splice ➁ Front Work Light Switch to Panel Harn. Splice ➁ Panel Harn. Splice to Cab Harn. Splice ➁ Rear Work Light Switch to Panel Harn. Splice ➁ Column Switch to 2nd Speed Splice 2nd Speed Splice to Diode Gate 2nd Speed Splice to Diode Gate Column Switch to Diode Gate (3rd Speed) Column Switch to 4th Speed Slice 4th Speed Splice to Diode Gate 4th Speed Splice to Diode Gate Column Switch to 4th Speed Splice Tachometer Feed to Master Warning Light (4th Speed) Radio Cassette to LH Speaker (+VE) Radio Cassette to RH Speaker (+VE) Cab Plug to Rear Work Light Splice Rear Work Splice to RH Work Light Rear Work Splice to LH Work Light Rear Work Light Cab Roof Feed Rear Work Light Master Warning Light Feed Rear Wiper Switch to Rear Wiper Rear Wiper Switch to Rear Wash Pump Rear Wiper Switch to Return Feed H.S.C. Switch to 'Off' Relay Feed H.S.C. Switch to 'On' Relay Feed Mainframe Solenoid Splice to Relay 'Off' Feed Fuse C4 to Fog Light Switch Hi-Low Microswitch to Solenoid Rear Horn Relay to Rear Horn ➂ Rear Horn to Harness (Panel) Plug ➂ Rear Horn Relay to Harness (Mainframe)Plug ➂ Jaw Change-over Relay to Aux Hyd. Switch Jaw Change-over Relay to Aux Hyd. Switch Aux Hyd. Switch to Jaw/Ext Dipper Solenoid Jaw/Ext Dipper Switch to Jaw Change-over Relay Coil Diode Gate to Jaw Change-over Relay Coil Fuse B7 to 4 Wheel Brake Relay Coil Fuse B7 to Brake Mode Switch Column Switch to Drive Shaft Relay Coil Drive Shaft Relay to Diode Gate Diode Gate to Forward / Reverse Splice Diode Gate to Forward / Reverse Splice Forward / Reverse Splice to Reverse Relay Coil Forward / Reverse Splice to Reverse Relay Coil Heated Seat Switch to Heated Seat Beacon Switch to Beacon Socket Hammer Relay to Aux Hyd. Switch Hammer Switch to Hammer Relay Hammer Relay to Diode Gate Air Conditioning Switch to Pressure Switch 1 Air Conditioning Pressure Switch to Compressor Pressure Switch 2 to Pressure Switch 1 4 Wheel Brake Relay Coil Feed Driveshaft Relay Feed (Powershift) Dump Relay to Forward Relay (Syncro) Forward Relay to Reverse Relay (Syncro)
9803/3260
Wire Gauge 0.60 0.60 1.40 1.40 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 1.00 1.00 0.60 0.60 1.40 1.00 1.00 1.40 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.40 1.40 1.40 1.00 1.00 1.00 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 1.00 1.40 1.00 0.60 0.60 1.00 1.00 1.00 0.60 1.00 1.00 1.00
MF
P
Harnesses Affected Cab CF TR A/C
AUX
RL
Cab P P P P P P P P P P P
P P P
Cab Cab
Cab Cab
Cab Cab Cab Cab Cab
CR CR CR
Cab Cab MF
MF MF
P P P P P P P P P
Aux Cab
MF
MF MF
MF
MF
P P P P P P P P P P P P P P P P P P P
Aux Aux
Cab Cab
Cab
Aux A/C A/C A/C
P P P P P
CR
Cab
Issue 2*
Section C 42 - 11
Electrics
Section C
Harness and Wire Number Identification
42 - 11
Wire Numbers - 800 to 999 (from Serial Number 430001) Wire No
Description
Wire Gauge
920 921 922 933 933A 934 934A 934B 934B 934C 935 935A 935B 977
Hydraclamp Switch to Hydraclamp Rear Horn Switch to Rear Horn Relay 2/4WD Switch to Auto 2WD Relay Fuse A1 to Brake Switch Fuse A1 to Fuse B7 Dump Relay Coil Earth to Hand Dump Switch Dump Splice to Hand Dump Splice Dump Splice to Transmission Dump Switch (Gear Lever) Dump Splice to Trans. Dump Switch (Gear Lever) ➁ Dump Relay Coil Earth to Diode Gate (P/Brake) Feed Splice to Blower Motor Feed Splice to Heater Resistor Feed Splice to Heater Relay Hammer Isolator Switch to Hammer Connector ➁
1.00 0.60 1.00 1.00 0.60 1.00 1.00 1.00 1.00 0.60 4.00 4.00 4.00 1.00
MF
P
MF MF
P P P P P P
MF MF MF MF
Harnesses Affected Cab CF TR A/C
AUX
RL
Cab Cab
TR P P P P P
➀ Note: Only applicable to machines fitted with 2/4WD clutches that must be pressurised to give 2WD. ➁ Note: Only applicable on 3CXE (214E) machines. ➂ Note: Machines from serial number, 3CX (214) - 438636; 4CX (214S) - 437866, have the rear horn connection from the mainframe harness, prior to this the connection was from the cab harness.
9803/3260
Issue 1
Section D
Controls
Section D
i
i
Contents
Page No.
Machine Controls Loader Control Knob - Dismantling and Assembly
1-1
* Tilt Type Steering Column Dismantling and Assembly
5-1
* Fixed Steering Column Dismantling and Assembly Boom Lock (up to serial number 430000) Master Cylinder - Removal and Replacement - Dismantling and Assembly Slave Cylinder - Removal and Replacement - Dismantling and Assembly Boom Lock (from serial number 430001 to 433723) Installation Boom Lock (from serial number 433724) Master Cylinder - Removal and Replacement - Dismantling and Assembly Slave Cylinder - Removal and Replacement - Dismantling and Assembly Transmission Controls Dump Pedal Microswitch (up to serial no. 430000) - Removal and Replacement
9803/3260
5-3
10 - 1 10 - 1 10 - 2 10 - 2
10 - 3
10 - 5 10 - 5 10 - 5 10 - 5
20 - 1
Issue 5*
Section D 1-1
Controls Machine Controls
Section D 1-1
Loader Control Knob
When Assembling
On machines fitted with a hydraulic speed control, the loader control knob houses two microswitches; one microswitch energises the transmission dump solenoid and the other microswitch energises the remote unload valve solenoid.
Apply JCB Lock and Seal to microswitch adapter 5 prior to assembly. Note: Microswitch 5 is a non-service item, and must be replaced as an assembly.
For clarity, only one microswitch is shown dismantled. Make sure that all electrical connections are clearly labelled before removing the microswitch. Remove and replace microswitches one at a time. Note: Machines not fitted with a remote unload valve will only have one microswitch fitted in the loader control knob. Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. When Dismantling To gain access to the microswitch gently prise off top cover 1. Disconnect wiring harness 2, remove locknut 3 and shakeproof washer. Microswitch 4, adapter 5, and rubber cover 6 may now be withdrawn through the knob.
S217040
9803/3260
Issue 1
Section D
Controls Machine Controls
5-1
Section D 5-1
28
D
217080
9803/3260
S108000
Issue 2
Section D 5-2
Section D
Controls Machine Controls
5-2
Tilt Type Steering Column When Assembling
* On
some machine models the steering column assembly can be tilted to improve operator reach and comfort levels. This type of assembly is referred to as a 'tilt column'. Non tilting columns are referred to as a 'fixed column'. Dismantling and Assembly
*
extension shaft 20 and the steer valve with a minimum of misalignment.
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Note: Machines from serial number 430001 have no
For assembly the sequence should be reversed.
mounts directly into the orbitrol valve as shown at D.
* Technical
Information Bulletin 2/132 (C34/N.AM) advised of changes to the method of securing the forward/reverse lever to the steering column assembly (from serial number 415000). This improvement can be completed on machines built prior to serial number 415000. Refer to pages D/6-1 and D/6-2 for a description of the new securing method.
* Machines
from serial number 430001 have the flexible coupling assembly mounting directly into the steer orbitrol valve as shown at D. The dismantling and assembly procedures (including end float settings) remain the same as described.
When Dismantling Remove the front instrument housing and the steering column pedestal cover to gain access to the steering column. Note the electrical connections before disconnecting the components mounted on the housing.
*
To avoid excessive side loading on the steer valve, assemble the steering column 14, flexible coupling 22,
It should be noted that the top and bottom bearings 28 housed in the outer column assembly are non serviceable parts. They may be removed for cleaning and inspection, but if the bearing(s) have failed, a new outer column assembly must be used.
extension shaft 20 fitted, instead the coupling assembly
Insert pin 8 into the appropriate groove in spacer 9 to
* achieve
correct endfloat of inner column 14 in the outer
column 12(correct endfloat is 0.5 to 1.5 mm (0.020 to 0.060 in). Make sure that the extension shaft 20 (if fitted) is correctly installed in the flexible coupling 22. The coupling bolt 21 must be engaged with the cut-out in the shaft, shown at B. Remove all dirt etc from the splined socket of steering valve A before fitting the column assembly. Install E-clip 19 as close as possible to the splines on extension shaft 20. Insert the extension shaft spline into the splined socket, shown at C (maximum engagement to be no more than 12 mm). Make sure that there is a 0.5 to 1.5 mm (0.020 to 0.060 in) gap between the splined shaft and socket, shown at D. The shaft must not touch the bottom of the splined socket. Apply JCB Lock and Seal to the threads of bolts 16 before fitting them.
To remove the steering column complete, remove bolts 11 and slacken nut 13. Then withdraw the column from the flexible coupling 22.
9803/3260
Issue 2*-
Section D 5-3
Section D
Controls
5-3
Machine Controls
D
S217070
S164070
9803/3260
Issue 2
Section D 5-4
Controls
Section D 5-4
Machine Controls
* Fixed Type Steering Column When Assembling
* On
some machine models the steering column assembly can be tilted to improve operator reach and comfort levels. This type of assembly is referred to as a 'tilt column'. Non tilting columns are referred to as a 'fixed column'.
* To
avoid excessive side loading on the steer valve, assemble the steering column 13, flexible coupling 26, extension shaft 24 and the steer valve with a minimum of
Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling.
misalignment before tightening securing bolts 11, 16 and 25.
* Note: Machines from serial number 430001 have no extension shaft 24 fitted, instead the coupling assembly
For assembly the sequence should be reversed.
mounts directly into the orbitrol valve as shown at D.
* Technical
Information Bulletin 2/132 (C34/N.AM) advised of changes to the method of securing the forward/reverse lever to the steering column assembly (from serial number 415000). This improvement can be completed on machines built prior to serial number 415000. Refer to pages D/6-1 and D/6-2 for a description of the new securing method.
*
Press in bearing 15 until flush with end of outer column, and bearing 14 until it can be secured by the retaining tabs. Note: Machines fitted with the later type column assemblies have an additional thrust washer 14A.
* Machines
from serial number 430001 have the flexible coupling assembly mounting directly into the steer orbitrol valve as shown at D. The dismantling and assembly procedures (including end float settings) remain the same as described.
* Achieve
minimum end-float (maximum permissible 2.0 mm 0.08in.) by selecting groove in spacer 9. Fit additional spacing washers 19 above set pin 18 if necessary.
Make sure that the extension shaft 24 (if fitted) is correctly When Dismantling Remove the front instrument housing and the steering column pedestal cover to gain access to the steering column. Note the electrical connections before disconnecting the components mounted on the housing.
*
*
Bend back retaining tabs to permit removal of upper bearing 14. Note that later type column assemblies have a thrust washer 14A added. It should be noted that the top and bottom bearings 14 and 15 housed in the outer column assembly are non serviceable parts. They may be removed for cleaning and inspection, but if the bearing(s) have failed, a new outer column assembly must be used.
installed in the flexible coupling 26. The coupling bolt 25 must be engaged with the cut-out in the shaft, shown at B. Remove all dirt etc from the splined socket of steering valve A before fitting the column assembly. Install E-clip 23 as close as possible to the splines on extension shaft 24. Insert the extension shaft spline into the steer valve splined socket. Make sure that there is a 0.5 to 1.5 mm (0.020 to 0.060 in) gap between the splined shaft and socket, shown at C. The shaft must not touch the bottom of the splined socket. Apply JCB Lock and Seal to the threads of bolts 16 before fitting them.
To remove the steering column complete, remove bolts 11 and slacken nut 16. Then withdraw the column from the flexible coupling 26.
9803/3260
Issue 2*
Section D 6-1
Controls
Section D 6-1
Machine Controls
TILT STEER COLUMN
FIXED STEER COLUMN
S214540
9803/3260
Issue 1 SXXXXXX
SXXXXXX
Section D 6-2
Controls
Section D 6-2
Machine Controls
Forward/Reverse Lever Retention Machines from serial number 415000 now have an improved method of locating the forward/reverse lever to the steering column. An additional lockplate A is now used, and JCB Lock & Seal (part number 4101/0202) is applied to the threads of retaining screws B. If a new lever assembly is required for machines prior to 415000, it is recommended the lockplate is fitted, refer to PROCEDURE. If the lockplate is already fitted, but the steering column assembly is being dismantled, refer to steps 1, 2, 3, 5, 6 and 7 for the correct removal and replacement procedures.
PROCEDURE 1
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the backhoe and loader end to the ground and stop the engine.
2
Remove the steering wheel and front console.
3
Remove the forward/reverse lever assembly C and then outer steering column D.
4
Using a suitable saw, cut a slot in the outer steering column, as shown in the illustrations.
5
Refit the outer column D, insert pin E into the appropriate groove in spacer F to achieve correct endfloat of inner column in the outer column (correct endfloat is 0.5 to 1.5mm (0.020 to 0.060in.)).
6
Fit the forward/reverse lever assembly, make sure lockplate A is located in the slot. Add JCB Lock & Seal to the two retaining bolts B, torque bolts to 2.4Nm (1.7 lbf ft).
7
Refit steering wheel and front console, torque tighten steering wheel retaining nut G to 176Nm (130lbf ft).
9803/3260
Issue 1 SXXXXXX
Section D 10 - 1
Controls
Section D 10 - 1
Machine Controls
Boom Lock Master Cylinder Removal Slacken the bleed nipple on the slave cylinder and operate the lever until all fluid is expelled. Uncouple the clevis from the lever and disconnect the hydraulic hose. Unscrew the mounting bolts and remove the cylinder from the machine complete with reservoir (not illustrated). Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. Use only JCB Light Hydraulic Fluid for cleaning and lubrication - DO NOT USE NORMAL BRAKE FLUID.
Fit new seals 6 and 12. Position seal 12 on stem 11 as shown at A. Ensure that seal 6 and thimble 7 are fitted as at B. Replacement When refitting the master cylinder to the machine, adjust the position of the clevis so that the pivot pin can be easily fitted with the master cylinder pushrod fully retracted and the hand lever fully down. When connecting the hydraulic hose to the slave cylinder, tighten to 35 - 40 Nm (20 - 30 lbf ft). See page D/10 - 2 for information on bleeding.
107781
9803/3260
Issue 1
Section D 10 - 2
Controls Machine Controls
Section D 10 - 2
Boom Lock Slave Cylinder Removal
Replacement
Disconnect hydraulic hose from cylinder and plug to avoid excessive fluid loss.
Refit the slave cylinder to the machine by reversing the removal sequence.
Unscrew mounting bolts and remove cylinder from machine.
When connecting the hydraulic hose to the cylinder, tighten to 35 - 40 Nm (20 - 30 lbf ft).
Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. Use only JCB Light Hydraulic Fluid for cleaning and lubrication - DO NOT USE NORMAL BRAKE FLUID.
Bleeding After refitting, bleed air from the system by means of bleed nipple 5. Loosen the bleed nipple when the boom lock operating lever in the cab is fully up. Ensure that the master cylinder reservoir is kept topped up with JCB Light Hydraulic Fluid.
Fit a new seal 4.
107860
9803/3260
Issue 1
Section D
Controls
Section D 10 - 3
Machine Controls
10 - 3
Boom Lock Installation (from Serial Number 430001 to 433723) * Note:
The boom lock is cable operated on machines from serial number 430001 to 433723. The boom lock on machines after serial number 433723 is hydraulically operated (with a cable inter-connect). Refer to pages D/10-4 to 10- 5. If the boom lock assembly has been dismantled (say to replace the boom lock cable), use the following procedure to reset the boom lock. Drawing shows assembly of sideshift builds, the centremount builds are similar except for pivot pin retention (see step 1b).
1
Fit boom lock (item 1) to boom: a
Sideshift Machines - use pivot pins (item 8) and tension pins (item 9).
b
Centremount Machines - use pivot pins (item 8), M8 bolts and M6 locknuts (not shown).
2
Secure the control cable swivel flange to the cable retaining bracket on the boom with M6 screws (item 5) and M6 nuts (item 3).
3
Attach the cable assembly to the ball joint (item 10) and tighten the cable. Tighten the M6 locknut fitted on the cable.
4
Fit the ball joint (item 10) to the boom lock (item 1) using M8 locknut (item 6). Tighten locknut. Make sure that the swivel joint moves freely and is not restricted.
5
Position cable in bracket and tighten M12 nuts fitted on cable.
6
Attach spring (item 4) to boom lock and spring reaction bracket.
➃
A
A
➀ ➇
➈
➂➄ ➅➉
SECTION 'A - A'
A217001
9803/3260
Issue 2
Section D
Controls
Section D 10 - 4
Machine Controls
10 - 4
Boom Lock Assembly (from Serial Number 433724)
X 14
S235330A
FIG 1 9803/3260
131
S242170
Issue 1
Section D 10 - 5
Controls
Section D 10 - 5
Machine Controls
Boom Lock Assembly (from Serial Number 433724) Boom Lock Slave Cylinder - Removal (FIG 1) Boom Lock Master Cylinder - Removal (FIG 1) 1
2
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the backhoe and loader end to the ground and stop the engine. Slacken the bleed nipple on the slave cylinder 31 and operate the lever 1 until all fluid is expelled.
3
Unscrew banjo bolt 22 and remove hydraulic hose 21.
4
Remove clevis pin 16 and clip 17.
5
Uncouple the clevis 14.
6
Unscrew the mounting bolts 11 and remove the cylinder 10 from its mounting bracket 8.
Boom Lock Master Cylinder - Inspection The boom lock master cylinder is a non serviceable part. Check that the push rod moves freely in the cylinder, check visually for obvious signs of wear, damage or leakage. If required, replace the full master cylinder assembly.
Boom Lock Master Cylinder - Replacement (FIG 1)
1
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the backhoe and loader end to the ground and stop the engine.
2
Disconnect the hydraulic hose 28 from cylinder, plug the hose to avoid excessive fluid loss.
3
Unscrew mounting bolts 37 and remove the cylinder from the machine.
Boom Lock Slave Cylinder - Dismantling and Assembly (FIG 2) The numerical sequence shown on the illustration below is intended as a guide to dismantling. For assembly the sequence should be reversed. Use only JCB Light Hydraulic Fluid for cleaning and lubrication - DO NOT USE NORMAL BRAKE FLUID. Boom Lock Slave Cylinder - Replacement (FIG 2) Replacement of the slave cylinder is a reversal of the removal procedures. After refitting, bleed air from the system by means of bleed nipple 5. Loosen the bleed nipple when the boom lock operating lever is fully up. Ensure that the master cylinder reservoir is kept topped up with JCB Light Hydraulic Fluid.
Replacement of the master cylinder is a reversal of the removal procedures. To adjust and correctly set the boom lock, note the following: 1
Position lever 1 fully down on last ratchet.
2
Screw clevis 14 on to pushrod to achieve a setting distance of 131mm (5.157in. - shown in inset X). Pushrod must not be pushed in cylinder.
3
Fill the system with JCB Light Hydraulic fluid.
4
Bleed the system using the bleed nipple on the slave cylinder 31.
5
Make sure that the boom lock 39 fully engages and disengages.
S107860
FIG 2
9803/3260
Issue 1
Section D 20 - 1
Controls
Section D 20 - 1
Transmission Controls
* Dump Pedal Microswitch (machines up to serial number 430000) The dump pedal and microswitch is only required on machines fitted with a Syncro Shuttle transmission. Because the Powershift transmission is a fully electrohydraulic unit, it is not necessary to disconnect the drive whilst changing gear, therefore the dump pedal and microswitch are not required on machines equipped with Powershift transmission.
B
Removal and Replacement 1
Lift away cab floor mat from base of front control consoles.
2
Remove bolts A and take off the steering pedestal cover B.
3
Remove the left hand side console. If necessary, label and disconnect electrical wires to the switches and radio (if fitted).
A
S152680A
4
Disconnect the microswitch lead from the panel harness, shown at D.
5
Loosen screws C and remove the microswitch.
*6
Replacement is a reversal of the removal sequence. The torque tightening figure for screw C is 0.8 to 1.0 Nm (0.6 to 0.7 lbf ft).
D
C
S152680B
9803/3260
Issue 3*
Section E
Hydraulics
Section E
i
i
Contents
Page No.
Technical Data Machine Hydraulics (AWS & 2WS Machines) Steer Hydraulics (AWS Machines) * Steer Hydraulics (2WS Machines) * 3CXE (214E) Machines
1-1 1-4 1-4 1-5
Schematics Basic Machine (2WS & AWS Machines) - From Serial No. 402174 Circuit Variations * Steer Hydraulics (AWS Machines) * Steer Hydraulics (2WS Machines) * 3CXE (214E) Machines Only
2-1 2-3 2-5 2-6 2-7
Descriptions Basic Machine Neutral Circuit * 3CXE (214E) Machines - Neutral Circuit
3-2 3-4
Pump Operation Loader Valve - Operation 1 - Operation 2 - Operation 3 - Hydraulic Speed Control (H.S.C.) Load Hold Check Valve(s) - Operation 1 - Operation 2
9803/3260
4-2 5-2 5-4 5 - 4B 5-6 5-8
Arms Lower Operation
5 - 10
Float Operation
5 - 12
Main Relief Valve (M.R.V.) Operation Main Relief Valve (M.R.V.) Operation ('Husco')
6-2 6-4
Auxiliary Relief Valve (A.R.V.) Operation
7-2
Excavator Valve - Neutral Circuit
8-2
Excavator Valve - Operation 1 - Operation 2
8-4 8-6
Excavator Valve - One Way Restrictor - Operation 1 - Operation 2
8-6 8-8
Slew Operation
9-2
Slew Auxiliary Relief Valve And Anti-cavitation Operation
9-4
Excavator Valve - Auxiliary Relief Valve (A.R.V.)
10 - 2
Excavator Valve - Auxiliary Relief Valve (A.R.V.) - Operations 1, 2 and 3
10 - 4
Excavator Valve - Dipper Make-up Check Valve & Anti-cavitation Operation
10 - 6
Issue 6*
Section E
Hydraulics
Section E
ii
ii
Contents
*
Descriptions (cont'd) Excavator Valve - Anti-cavitation Operation
10 - 8
Hydraclamp Operation (Sideshift Machines) - to serial number 430000 - from serial number 430001
11 - 2 11 - 4
Ram Operation and End Damping
12 - 2
Twin Ram Slew Operation (Centremount M/c's)
12 - 4
Hose Burst Protection Valve - to Machine Serial No. 402173 - Operations 1 & 2 - Operations 3 & 4
13 - 2 13 - 4
Hose Burst Protection Valves - from Machine Serial No. 402174 - Operation 1 & 2 - Operation 3 & 4 - Emergency Operation
13 - 6 13 - 8 13 - 8
Stabiliser Check Valve (Sideshift M/c's)
14 - 2
Stabiliser Check Valve with Relief Valve (Centremount M/c's)
15 - 2
Hydraulic Filter Operation
16 - 2
Steering Priority Valve (AWS Machines) - Neutral Operation - Turning Operation
18 - 2 18 - 4
Steering Priority Valve (2WS Machines) - Neutral Operation - Turning Operation
18 - 6 18 - 8
Steering (AWS Machines) - 2 Wheel Steer Select - 4 Wheel Steer Select - Crab Steer Select
19 - 2 19 - 4 19 - 6
Hydraulic Steer Unit (AWS Machines) - Operation 1 - Neutral - Operation 2 - Right Turn - Operation 3 - Left Turn - Operation 4 - Left Turn, Unassisted - Operation 5 - Shock Valve
20 - 2 20 - 4 20 - 6 20 - 8 20 - 10
Hydraulic Steer Unit (2 WS Machines) - Operation 1 - Neutral - Operation 2 - Right Turn - Operation 3 - Left Turn - Operation 4 - Left Turn, Unassisted - Operation 5 - Shock Valve
20 - 12 20 - 14 20 - 16 20 - 18 20 - 20
Introduction to Hydraulic Schematic Symbols Fault Finding 9803/3260
Page No.
24 - 1 25 - 1 Issue 5*
Section E
Hydraulics
Section E
iii
iii
Contents
Page No.
Pumps Pump Flow Testing
*
30 - 2
Hydraulic Pump & Drive Assembly (AWS Machines) - Removal & Replacement
31 - 2
Pump Drive Unit (AWS Machines) - Dismantling & Assembly
31 - 4
Hydraulic Pump (2WS Machines) - Removal & Replacement
31 - 6
Hydraulic Pump ('Hamworthy' type) - Dismantling & Assembly
31 - 8
Hydraulic Pump ('Ultra' type) - Dismantling & Assembly
31 - 10
Hydraulic Pump - 3CXE (214E) Machines Only - Dismantling & Assembly
31 - 13
Valves Loader Valve - Removal and Replacement
41 - 1
'Hamworthy' Loader Valve - Dismantling & Assembly - Standard Spool 41 - 3 - Float Spool 41 - 5 - Electric Detent Spool 41 - 7 - M.R.V. 41 - 8 - A.R.V. 41 - 9 - Load Hold Check Valves 41 - 10 - Unloader Spool 41 - 12 - Unloader Check Valve 41 - 13
* * * * * *
'Husco' Loader Valve - Dismantling & Assembly - Standard Spool - Float Spool - Electric Detent Spool - M.R.V. - A.R.V. & L.H.C.V. - Unloader Valve Assembly
41 - 21 41 - 23 41 - 25 41 - 27 41 - 29 41 - 31
'Husco' Loader Valve - 3CXE (214E) Machines Only Dismantling & Assembly - Standard Spool - Float Spool - M.R.V. - A.R.V.
41 - 41 41 - 43 41 - 45 41 - 45
'Hamworthy' Loader Valve - Pressure Testing - Main Relief Valve (M.R.V.) - Unloader Valve - Hydraulic Speed Control (HSC) - Loader A.R.V.'s (using hand pump) - Shovel Ram Head Side A.R.V. (In Position) - Shovel Ram Rod Side A.R.V. (In Position)
9803/3260
42 - 1 42 - 2 42 - 2 42 - 3 42 - 4 42 - 5
Issue 5*
Section E
Hydraulics
Section E
iv
iv
Contents
Page No.
Valves (cont'd) 'Husco' Loader Valve - Pressure Testing - Main Relief Valve (M.R.V.) - Unloader Valve - Hydraulic Speed Control (HSC) - Shovel Ram Head Side A.R.V. (In Position) - Shovel Ram Rod Side A.R.V. (In Position)
9803/3260
42 - 10 42 - 11 42 - 11 42 - 12 42 - 13
Excavator Valve - Dismantling & Assembly
43 - 3
Excavator Valve - Relief Valves - Dismantling & Assembly Hydraclamp Valve (Sideshift Machines) - Dismantling & Assembly (to serial no. 430000) - Dismantling & Assembly (from serial no. 430001)
44 - 1 44 - 2
Excavator Valve - Pressure Testing - Excavator A.R.V.'s (using hand pump) - Excavator A.R.V.'s (In Position - Sideshift M/c's) - Excavator A.R.V.'s (In Position - C/mount M/c's)
45 - 1 45 - 6 45 - 7
Hose Burst Protection Valve - to Machine Serial No. 402173 - Dismantling & Assembly - Pressure Testing, Dipper Ram - Pressure Testing, Boom Ram
46 - 3 45 - 5 46 - 7
Hose Burst Protection Valve - from Machine Serial No. 402174 - Dismantling and Assembly - Pressure Testing, Dipper Ram - Pressure Testing, Boom Ram - Pressure Testing, Loader Arm Lift Ram
47 - 2 47 - 4 47 - 6 47 - 8
Stabiliser Check Valve with Relief Valve - Dismantling & Assembly
48 - 2
Stabiliser Check Valve - Dismantling & Assembly
48 - 4
Priority Valve - Removal and Replacement - Dismantling & Assembly
49 - 1 49 - 1
Hydraulic Steering Unit - Removal and Replacement - Dismantling & Assembly
50 - 1 50 - 3
Steering System - Pressure Testing
50 - 7
Steering Valve Assembly (AWS Machines) - Removal and Replacement - Dismantling & Assembly
51 - 1 51 - 2
Steering System - Bleeding Procedure
52 - 1
Issue 6
Section E
Hydraulics
Section E
v
v
Contents Rams Typical Ram - Dismantling & Assembly
61 - 1
Typical Ram (with Dowelled Piston Head) - Dismantling & Assembly
61 - 3
Steer Ram - Removal and Replacement - Dismantling & Assembly
62 - 1 62 - 3
Gland Seal Fitting Procedure
9803/3260
Page No.
64 - 1
Issue 1
Section E
Hydraulics
Section E
Technical Data
1-1
1-1
* Machine Hydraulics (AWS and 2WS Machines - excluding 3CXE) Hydraulic Pumps ('Hamworthy' type) Hydraulic Pump - Option 1 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure Hydraulic Pump - Option 2 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure Hydraulic Pump - Option 3 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure Hydraulic Pump - Option 4 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure
Double pump/190906 Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 82.2 18.0 58.4 12.8 See - Relief Valve Operating Pressures
Double pump/190706 Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 66.2 14.6 58.4 12.8 See - Relief Valve Operating Pressures
Double pump/190705 Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 66.2 14.6 43.6 9.6 See - Relief Valve Operating Pressures
Double pump/190606 Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 58.4 12.8 58.4 12.8 See - Relief Valve Operating Pressures
Hydraulic Pump Applicability Chart Pump Type
2-Wheel Steer Machines 3CX
S/Master
H/Master
All Wheel Steer Machines 4CX
4C
4CN
-
-
-
S/Master
190906 190706
-
-
-
190705
-
-
-
-
190606 Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted on the pump) to determine exactly which type of pump is fitted to your machine.
9803/3260
Issue 5*
Section E
Hydraulics
Section E
Technical Data
1-2
1-2
* Machine Hydraulics (AWS and 2WS Machines - excluding 3CXE) Hydraulic Pumps ('Ultra' type) Hydraulic Pump - Option 1 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure Hydraulic Pump - Option 2 Model/Reference Rotation Mounting: AWS M/c's 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure Hydraulic Pump - Option 3 Model/Reference Rotation Mounting: 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure Hydraulic Pump - Option 4 Model/Reference Rotation Mounting: 2WS M/c's Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Pump section 1 (mounting flange end) Pump section 2 Maximum working pressure
Double pump/4071 (2WS), 4075 (AWS) Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 81.2 17.9 57.4 12.6 See - Relief Valve Operating Pressures
Double pump/4072 (2WS), 4074 (AWS) Clockwise (AWS), Anti-clockwise (2WS) Engine Timing Case Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 65.3 14.4 57.4 12.6 See - Relief Valve Operating Pressures
Double pump/4070 (2WS) Anti-clockwise Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 65.3 14.4 45.5 10.0 See - Relief Valve Operating Pressures
Double pump/4073 (2WS) Anti-clockwise Chassis (driveshaft driven) See - Hydraulic Pump Applicability Chart litres/min UK gal/min 57.4 12.6 57.4 12.6 see - Relief Valve Operating Pressures
Hydraulic Pump Applicability Chart Pump Type
2-Wheel Steer Machines 3CX
S/Master
H/Master
-
-
-
-
-
-
All Wheel Steer Machines 4CX
4C
4CN
S/Master
-
-
-
-
4071 4075 4072 4074 4070 4073 Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted on the pump) to determine exactly which type of pump is fitted to your machine. 9803/3260
Issue 5*
Section E
Hydraulics
Section E
Technical Data
1-3
1-3
* Machine Hydraulics (AWS and 2WS Machines - excluding 3CXE) Relief Valve Operating Pressures
bar
kgf/cm2
lbf/in2
Main Relief Valve (M.R.V.) @ 1500 RPM
*
228 - 230
233 - 235
3300 - 3335
Unloader Valve
*
203 - 207
207 - 211
2950 - 3000
*
165 - 179 303 - 317
168 - 183 309 - 323
2400 - 2600 4400 - 4600
241 - 255
246 - 260
3500 - 3700
303 - 317 338 - 352
309 - 323 344 - 358
4400 - 4600 4900 - 5100
Auxiliary Relief Valves (A.R.V.) † Loader Shovel Ram Head Side Shovel Ram Rod side
Backhoe Boom Ram Head Side Boom Ram Rod Side * to m/c 435209 (Sideshift ), 434984 (C/mount) * from m/c 435210 (Sideshift ), 434985 (C/mount) Bucket Ram Head Side Centremount (17' backhoe - 217 models only) Centremount (14' backhoe) Centremount (15' 6" backhoe up to M/C 413521) Centremount (15' 6" backhoe from M/C 413522 except knuckle boom) Sideshift Bucket Ram Rod Side (Machines with Powerbreaker only) Dipper Ram Head Side Dipper Ram Rod Side Slew Left and Right
303 - 317 241 - 255 241 - 255
309 - 323 246 - 260 246 - 260
4400 - 4600 3500 - 3700 3500 - 3700
303 - 317 241 - 255 241 - 255 241 - 255 241 - 255 255 - 269
309 - 323 246 - 260 246 - 260 246 - 260 246 - 260 260 - 274
4400 - 4600 3500 - 3700 3500 - 3700 3500 - 3700 3500 - 3700 3700 - 3900
Attachments Extradig Ram Head Side Extradig Ram Rod Side Jaw Bucket Ram Head Side Jaw Bucket Ram Rod Side Knuckle Ram Head Side Knuckle Ram Rod Side Hammermaster Roadbreaker Sequence Valve
bar 138 - 145 207 - 214 138 - 145 207 - 214 138 - 145 207 - 214 207 - 214 138 - 150 21
kgf/cm2 141 - 148 211 - 218 141 - 148 211 - 218 141 - 148 211 - 218 211 - 218 141 - 153 21
lbf/in2 2000 - 2100 3000 - 3100 2000 - 2100 3000 - 3100 2000 - 2100 3000 - 3100 3000 - 3100 2000 - 2200 300
bar
kgf/cm2
lbf/in2
303 - 317 303 - 317 303 - 317
309 - 323 309 - 323 309 - 323
4400 - 4600 4400 - 4600 4400 - 4600
250 250 250
255 255 255
3625 3625 3625
303 - 317
309 - 323
4400 - 4600
bar
kgf/cm2
lbf/in2
1.5
1.5
22
* *
Hose Burst Protection Valves (optional) Machine Serial Numbers - up to 402173 Boom Ram Rod Side Dipper Ram Rod Side Loader Lift Rams Head Side Machine Serial Numbers - from 402174 Boom Ram Rod Side Dipper Ram Rod Side Loader Lift Rams Head Side Stabiliser Check Valve Relief Valve (Centremount M/c's) Return Line Filter By-pass pressure
*
† When setting 'Hamworthy' Loader Valve A.R.V.'s using a hand pump, set 15 bar (220 lbf/in2) below nominal figure shown. † When setting 'Husco' Loader Valve A.R.V.'s using a hand pump, set to the figure shown above. Note: Later type loader valves are produced by a different manufacturer (Husco). When appropriate, the loader valve will be identified using the manufacturer's name, (Hamworthy - earlier type, or Husco - later type). In some instances, there will be no need to differentiate (e.g., descriptions of operation - the valves operate in the same manner).
9803/3260
Issue 7*
Section E 1-4
Hydraulics
Section E
Technical Data
1-4
Steer Hydraulics (AWS Machines) System Type Hydraulic Supply Control Unit Type Control Unit Relief Valve Operating Pressure (at 1500 revs/min) Control Unit Shock Valve Operating Pressure
Full Power Hydrostatic From Main Hydraulic Pump Via Priority Valve Load Sensing With Integral Relief Valve 120 ± 3.5 bar 175 - 190 bar
122 ± 3.5 kgf/cm2 1740 ± 50 lbf/in2 178 - 199 kgf/cm2 2538 - 2756 lbf/in2
Front Steer Ram(s) Dimensions Bore Rod Diameter Stroke End Cap Assembly A/F Piston Head Assembly A/F
60 mm (2.362 in) 30 mm (1.181 in) 210.6 mm (8.290 in) 55 mm (2.165 in) 41 mm (1.614 in)
Rear Steer Ram(s) Dimensions Bore Rod Diameter Stroke End Cap Assembly A/F Piston Head Assembly A/F
60 mm (2.362 in) 30 mm (1.181 in) 210.6 mm (8.290 in) 55 mm (2.165 in) 41 mm (1.614 in)
Steer Ram Torque Settings Piston Head End Cap
Nm 405 678
kgf m 41 69
lbf ft 300 500
* Steer Hydraulics (2WS Machines) System Type Hydraulic Supply Control Unit Type Control Unit Relief Valve Operating Pressure (at 1500 revs/min) Control Unit Shock Valve Operating Pressure Steer Ram(s) Dimensions 2 Wheel Drive Machines Location Bore Rod Diameter Stroke End Cap Assembly A/F Piston Head Assembly A/F 4 Wheel Drive Machines Location Bore Rod Diameter Stroke End Cap Assembly A/F Piston Head Assembly A/F
Steer Ram Torque Settings Piston Head End Cap
9803/3260
Full Power Hydrostatic From Main Hydraulic Pump Via Priority Valve Load Sensing With Integral Relief Valve 120 ± 3.5 bar 175 - 190 bar
122 ± 3.5 kgf/cm2 1740 ± 50 lbf/in2 178 - 199 kgf/cm2 2538 - 2756 lbf/in2
1 Ram - Front Axle (Right Hand Side) 70 mm (2.756 in) 30 mm (1.181 in) 290 mm (11.417 in) 65 mm (2.559 in) 55 mm (2.165 in)
1 Ram - Front Axle (Left Hand Side) 70 mm (2.756 in) 30 mm (1.181 in) 290 mm (11.417 in) 65 mm (2.559 in) 55 mm (2.165 in)
Nm 405 678
kgf m 41 69
lbf ft 300 500
Issue 4*
Section E 1-5
Hydraulics
Section E
Technical Data
1-5
3CXE (214E) Machines Hydraulic Pump Model/Reference: Rotation: Mounting: Machines/Models applicable to: Flow at 2200 rev/min and system pressure: Maximum working pressure
Single pump/6197 Anti-clockwise Chassis (driveshaft driven) 3CXE (214E) machines only 99.0 litres/min; 21.9 UK gal/min; 26.3 US gal/min 230 bar; 234.5 kg/cm2; 3335 lbf/in2
*
Relief Valve Operating Pressures Main Relief Valve (M.R.V.) @ 1500 RPM
*
Auxiliary Relief Valves (A.R.V.) Loader Shovel Ram Head Side Rod side Backhoe Boom Ram Head Side Rod Side Bucket Ram Head Side Rod Side Dipper Ram Head Side Rod Side Slew Ram Left and Right Stabiliser Check Valves Left and Right Steering Attachments Hammermaster
bar
kgf/cm2
lbf/in2
*
228 - 230
233 - 235
3300 - 3335
*
170 - 174 308 - 312
173 - 177 314 - 318
2465 - 2520 4475 - 4525
245 - 252 308 - 312
249 - 257 314 - 318
3550 - 3650 4475 - 4525
245 - 252 245 - 252
249 - 257 249 - 257
3550 - 3650 3550 - 3650
245 - 252 245 - 252
249 - 257 249 - 257
3550 - 3650 3550 - 3650
258 - 266
263 - 271
3750 - 3850
303 - 317 120 - 125
309 - 323 122 - 127
4400 - 4600 1740 - 1813
170
173
2465
Loader Valve Identification (Fig 1) 1 Loader Arm Spool 2 Shovel Spool 2A Rod Side 2B Head Side 3 Auxiliary Relief Valve 4 Inlet Port 5 Outlet Port 6 High Pressure Carry Over Port
3 1 2
5
2A 6
2B
4
3 A248220
Fig 1 9803/3260
Issue 4*
Section E
Hydraulics Schematics
2-1
Section E 2-1
Basic Machine (2WS & AWS Machines) - from Serial No. 402174 Component Key
* * *
* * *
* * * * * *
* * *
P1 P2 P2A S T 1A 1B 2A 3 3A 3B 3C 3D 3E 3F 3G 3H 3J 3K 3L 3M 3N 3P 3Q 4 4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4R 4S 4T 4U 4V 4W 4X 6 6A 7 7B 13 25 26 31 32 33 34 35 36
Pump, Main Section Pump, Secondary Section Pressure Test Point (auxiliary attachments) Suction Line Tank Neutral Circuit Line Neutral Circuit Line Neutral Circuit Line Loader Valve Block Pressure Test Point (M.R.V.) Main Relief Valve Loader Lift Ram Spool Loader Shovel Ram Spool Clamshovel Spool Shovel Ram Head Side A.R.V. Shovel Ram Rod Side A.R.V. Load Hold Check Valve Load Hold Check Valve Load Hold Check Valve Unloader Valve Spool Unloader Pilot Valve Unloader Check Valve Pressure Test Point (Unloader) Hydraulic Speed Control Solenoid Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool Hydraclamp Valve Slew A.R.V. Slew A.R.V. Boom Ram Rod Side A.R.V. Boom Ram Head Side A.R.V. Dipper Ram Head Side A.R.V. Dipper Ram Rod Side A.R.V. Bucket Ram Head Side A.R.V. Load Hold Check Valve Load Hold Check Valve Load Hold Check Valve Load Hold Check Valve Load Hold Check Valve Load Hold Check Valve Make-up Check Valve In-tank Filter Filter By-pass Valve Priority Valve Connection to Steer Circuit (see following pages) Anti-cavitation Check Valve Sequence Valve Hydraulic Oil Cooler Shovel Ram R.H. Shovel Ram L.H. Lift Ram R.H. Lift Ram L.H. Clam Shovel Ram R.H. Clam Shovel Ram L.H.
9803/3260
51 52 53 54 55 56 57 58 59 61 62 62A 64 65 66
Bucket Ram Boom Ram Stabiliser Ram Stabiliser Ram Dipper Ram Left Hand Slew Ram(Centremount Machines Only) Right Hand Slew Ram(Centremount Machines Only) One Way Restrictor Stabiliser Check Valve (Standard on Centremount, Optional on Sideshift Machines) Hose Burst Protection Valve (optional) Hydraclamps (Sideshift Machines Only) Hydra-clamp Exhaust Line Slew Cylinders (Sideshift Machines Only) One Way Restrictor (Centremount Machines Only) Hose Burst Protection Valve (optional)
Note: Excavator services shown here are to the JCB control pattern. If ISO, Case or Ford control pattern is used, the excavator spools and relief valves will apply to different services.
* Note: The policy of JCB is one of continuous improvement, therefore as products develop, there may be variations to the circuits. Page E/2-3 titled 'Circuit Variations' will identify these differences.
Issue 4*
Section E
Hydraulics
Section E
Schematics
2-3
2-3
Circuit Variations The hydraulic schematic diagram shown on page E/2-2 shows the latest machine hydraulic circuit. The purpose of this page is to identify 'older' circuit variations, where possible the machine serial numbers will be given to help identify the machine range(s). Hose Burst Protection Valves (to Serial Number 402173) The illustration shows the HBPV when fitted to the boom circuit. This valve is also fitted on the dipper ram and the loader arms. 4 61 4S
4B 4K
C2
Component Key
V2
4 4S 4K 4L 4B 52 61
V1 C1
4L
52
A196780
Excavator Valve Block Load Hold Check Valve Boom Ram Rod Side A.R.V. Boom Ram Head Side A.R.V. Boom Spool Boom Ram Hose burst Protection Valve (Optional)
'Hamworthy' Type Loader Valve The illustration shows the 'Hamworthy' type loader valve, the latest type loader valve (Husco) has the pilot valve solenoid (used to control the unloader spool) as an integral part of the valve block, not a separate item as shown at 3Q.
1A 3M
3 Component Key 3L
3N 3P 3Q T
P2
P1 P2 T 1A 3 3L 3M 3N 3P 3Q
Pump, main Section Pump, Secondary Section Tank Neutral Circuit Line Loader Valve Block Unloader Valve Spool Unloader Pilot Valve Unloader Check Valve Pressure Test Point (Unloader) Hydraulic Speed Control Solenoid
P1 A197090
9803/3260
Issue 4
Section E
Hydraulics
Section E
Schematics
2-4
2-4
Circuit Variations (cont'd) Hydraclamp Control Valve (to Serial Number 430000) The illustration shows the manual type hydraclamp control valve. Machines from serial number 430001 have the hydraclamp valve operated by a switch (and solenoid).
Component Key T 1B 4 4A 4G 4H 4R 4X 62
Tank Neutral Circuit Line Excavator Valve Block Slew Spool Hydraclamp Valve Slew A.R.V. Load Hold Check Valve Make-up Check Valve Hydraclamps (Sideshift Machines Only)
1B
T
4 62 4G 4X
4R
4H
4A
A217690
9803/3260
Issue 4
9803/3260
*
Some of the exhaust oil flows directly back to the tank through an in-tank filter 6, and some of the exhaust oil returns to tank via the hydraulic oil cooler A.
On 2-wheel steer machines, the hydraulic pump is driven by the engine via a driveshaft, as shown in the main illustration. On 4-wheel steer machines, the pump is mounted directly to the engine as shown in the inset.
Oil from the larger section P1 flows direct to the loader valve 3. Oil from pump section P2, flows to steering priority valve 7, and in neutral circuit flows through the priority valve to join flow from P1 at the loader valve.
From the loader valve neutral gallery, oil flows via a high pressure carry-over line to the excavator valve 4.
Oil is drawn from the hydraulic tank T by the hydraulic pump. The pump has two sections, P1 and P2.
* Basic Machine Neutral Circuit
hydra-clamp exhaust hose is only fitted on sideshift machines (there are no clamps required on centremount machines).
* The
part of the neutral circuit is the hydra-clamp exhaust hose 62A. The hose connects the hydraclamp spool into the exhaust circuit via adapter B which is attached to the anti-cavitation check valve 13. Connecting the hydra-clamps directly into the exhaust circuit prevents the clamps from 'lockingup' when the sideshifting operation is required.
* Also,
To help prevent excavator dipper ram and loader lift ram cavitation, there is a check valve 13 fitted to the return line. The check valve raises approximately 5 bar (75 lbf/in2) of pressure in the line, which improves the operation of the respective anti-cavitation valves.
Section E Hydraulics Section E
3-2
Descriptions 3-2
Issue 3*
9803/3260
From the loader valve neutral gallery, oil flows via a high pressure carry-over line 1B to the excavator valve 4. Some of the exhaust oil flows directly back to the tank through an in-tank filter 6, and some of the exhaust oil returns to tank via the hydraulic oil cooler A.
Oil is drawn from the hydraulic tank T by the single stage hydraulic pump P. The pump is mounted on the chassis and is engine driven via a driveshaft.
Pressurised oil from the pump flows to steering priority valve 7, and in neutral circuit flows through the priority valve to the loader valve 3.
3CXE (214E) Machines - Neutral Circuit To help prevent excavator dipper ram and loader lift ram cavitation, there is a check valve 13 fitted to the return line. The check valve raises approximately 5 bar (75 lbf/in2) of pressure in the line, which improves the operation of the respective anti-cavitation valves.
Section E Hydraulics Section E
3-4
Descriptions 3-4
Issue 1
9803/3260
Oil is picked up by the gear teeth on the suction side of the pump and carried around between the teeth and the pump body. As the gears come into mesh, the space carrying the oil is filled by a gear tooth on the mating gear, forcing the oil out of the space and through the pump outlet.
The basic principle of the gear pump depends on the meshing of two spur gears A, one of which is engine - driven while the other is an idler.
All machines in the range are fitted with a doublesection pump as shown. Both sections P1 and P2 operate as described below.
Pump Operation
The side of each wear plate that faces the gears has two recesses D. The recess on the inlet side of the pump assists the flow of oil into the gear spaces, thus raising the cavitation threshold of the pump. The recess on the outlet side vents oil trapped between meshing gear teeth to prevent compression loads on the bearings.
The wear plates B are loaded towards the gears by pressurised oil which is fed to the backs of the wear plates via channels C. This ensures that the clearance between the wear plates and gears is prevented from becoming excessive as outlet pressure rises.
Section E Hydraulics Section E
4-2
Descriptions 4-2
Issue 1
9803/3260
Unloader spool operation protects the engine from being overloaded if a service is being worked particularly hard, for example when using the excavator to tear out. It does this by dumping the oil from pump section P2 to tank, allowing engine power to be applied fully to the main pump section P1.
Operation 1
Loader Valve
Combined oil flow from P1 and P2 passes the main relief valve 3B (M.R.V.) and fills the parallel gallery B. From the parallel gallery the oil flows around the waisted central portions of spools 3C, 3D and 3E (all in neutral position) and flows on to feed the excavator valve via high pressure carry over line 1B.
Oil from pump section P1 enters the loader valve at 1A.
In neutral circuit hydraulic oil from pump section P2 enters the loader valve at 1C via a steering priority valve. On entering the valve block, oil flows around the waisted section of the unloader valve 3L, past check valve 3N and joins flow from pump P1.
Loader valve block Main Relief Valve Lift Ram Spool Shovel Ram Spool Clam Shovel Spool Unloader Valve Spool Unloader Pilot Valve Check Valve Solenoid Valve
Also, the Husco valve block may differ in appearance slightly from the valve block shown in the following illustrations, however, the descriptions of operation etc. are still applicable.
Later design valve blocks (Husco) have the pilot valve solenoid assembly 3Q fitted as an integral part of the loader valve - not a separate solenoid valve as shown at 3Q.
* Note:
3 3B 3C 3D 3E 3L 3M 3N 3Q
Component Key
The exhaust gallery is connected to the tank return line via port T.
Pressure in the inlet gallery C is sensed by pilot valve 3M via the bore of spool 3L. At pressure below the setting of the unloader valve, both pilot valve 3M and spool 3L remain closed.
Section E Hydraulics Section E
5-2
Descriptions 5-2
Issue 2*
9803/3260
This creates a pressure differential between the spring cavity 3P and gallery C. Higher pressure in gallery C acts on the face of spool 3L causing the spool to be moved off its seat.
If the pressure in the inlet gallery C rises to the setting of pilot valve 3M, this valve will open, allowing oil in spring cavity 3P to escape more quickly than it can be replaced by oil entering through the small drilling D.
Operation 2
Loader Valve
High pressure in gallery C also holds check valve 3N firmly closed, preventing oil from pump P1 from also being dumped.
Oil entering the valve block from pump P2 now flows directly to tank (T).
When pressure in the inlet gallery C falls, for example if the excavator has stopped tearing out, pilot valve 3M will close. This means oil in spring cavity 3P will be at the same pressure as oil in gallery C, spring pressure will move spool 3L back onto its seat, closing pump P2 connection to tank.
Section E Hydraulics Section E
5-4
Descriptions 5-4
Issue 1
9803/3260
The weight of the loaded shovel, as indicated by the arrows, produces a higher pressure in service line D than in the parallel gallery B. This pressure differential causes load hold check valve 3J to close, thus preventing the load from dropping.
The illustration shows 'arms raise' being selected by the lift ram spool.
Operation 1
Load Hold Check Valve(s)
Section E Hydraulics Section E
5-6
Descriptions 5-6
Issue 1
9803/3260
At this point, load hold check valve 3J opens, allowing oil to flow from the parallel gallery into the service line and operate the lift rams 33 and 34.
As the neutral circuit has been blocked by the central land of the selected spool 3C, the pressure in parallel gallery B increases until it is greater than that in service line D.
Operation 2
Load Hold Check Valve(s)
Section E Hydraulics Section E
5-8
Descriptions 5-8
Issue 1
9803/3260
The lower land of the selected spool E blocks the flow from the parallel gallery to the head side port and oil returning from the rams is diverted into the exhaust gallery.
When a spool is selected as shown at 3C, the central land of the spool C blocks the neutral circuit. Oil from the pump, entering at 1A, is diverted into the parallel gallery B, opens the load hold check valve 3J, and flows around the waisted section of the spool D and out to the rod side of lift rams 33 and 34.
Arms Lower Operation
Section E Hydraulics Section E
5 - 10
Descriptions 5 - 10
Issue 1
9803/3260
Oil can then be displaced from either end of the lift rams 33 and 34 into the exhaust gallery, allowing the rams to open and close as required.
This is achieved by moving the lift spool 3C down beyond 'arms lower' into the 'float' detent, when the feed from the parallel gallery to the service ports is blocked and the neutral circuit is reopened. Both service ports are connected to exhaust via the spool waists A.
The float facility is provided to allow the arms to move up and down so that the shovel can follow the surface contours as the machine is driven over uneven ground.
Float Operation
Section E Hydraulics Section E
5 - 12
Descriptions 5 - 12
Issue 1
9803/3260
Valve at Rest
E. Pump pressure outside the chamber is not high enough to lift the plunger off its seat.
which enters chamber D through the small drilling
combined effect of spring C and the pump pressure
The main plunger A is held on its seat B by the
Illustration 1 shows a loader service selected by spool 3D causing pressure to rise in the service line and back through the loader valve to the pump via line 1A. The service is operating under light load and the pressure is not sufficient to cause any response in the M.R.V.
The main relief valve (M.R.V.) 3B, situated in the loader valve block, provides control of both loader and excavator pressures.
1
Main Relief Valve (M.R.V.) Operation Pilot Valve Opens
Unless the pressure continues to rise, plunger A will remain on its seat.
vented into the exhaust gallery H.
(against spring G), the pressure in chamber D is
enough to force the pilot valve F from its seat
If, as shown in view 2, pump pressure rises high
2
Valve Moves off its Seat
spring C to force the main plunger A back onto its seat.
As the pump pressure decreases, the pilot valve is able to reseat and pressure in chamber D assists
spring C and the pressure in chamber D. The plunger then moves off its seat, allowing pressure to be released into the exhaust gallery.
Pressure acting on the upper faces of main plunger A is therefore greater than the combined force of
valve F is larger than small drilling E and oil is unable to fill the chamber as quickly as it is being exhausted.
In view 3, pump pressure at 1A has risen to the setting of the main relief valve but pressure in chamber D has not risen because the seat orifice of pilot
3
Section E Hydraulics Section E
6-2
Descriptions 6-2
Issue 1
9803/3260
Note: The MRV fitted to the loader valve is slightly different in appearance to the valve shown in the descriptions, but the principle of operation is exactly the same.
vant service by means of cap-nut G (see note).
The force of spring F is adjustable to suit the rele-
The force of springs D and F, combined with the service pressure acting on the upper faces of poppet B and piston C, keeps poppets B and E tightly seated.
hollow piston C.
Oil continues to escape from cavity L but the incoming flow to the cavity has been cut off. This produces a pressure drop above poppet B, causing the poppet to lift and release service pressure into exhaust gallery K.
between the upper and lower surfaces of piston C causes this piston to rise and seat on the point of pilot poppet E.
into the exhaust gallery K.
Main Poppet Opens
into cavity H and pass down the sides of sleeve J
3
poppet B and will also be felt inside the valve via
Pilot Valve Opens As service pressure continues to rise and oil escapes from cavity L, the pressure differential
2 As service pressure reaches the pilot setting of the valve, pilot poppet E lifts, allowing oil to escape
Valve at Rest
When the service is in neutral and there are no excessive forces acting on the equipment, service pressure at A will be acting on the lower face of
1
(Husco Loader Valve)
Main Relief Valve Operation
Section E Hydraulics Section E
6-4
Descriptions 6-4
Issue 1
9803/3260
If, as illustrated, the shovel is fully tipped when the arms are being raised, the shovel is unable to tip further, producing back pressure in the head side of the shovel rams 31 and 32 and cavitation in the rod side.
Under normal operating conditions, with the shovel in the 'carry' position, the mechanical linkage keeps the shovel level as the arms are raised, to prevent spillage of the load.
Auxiliary Relief Valve (ARV) Operation
The rod side A.R.V. 3G senses a higher pressure in the exhaust gallery than in the service port and therefore opens to allow exhaust oil to overcome the cavitation.
As the arms continue to rise, the back pressure increases until it reaches the setting of A.R.V. 3F. This A.R.V. then opens, allowing the excess back pressure to be dumped to exhaust and prevent the rams and linkage from being damaged. * Note: On the Husco type loader valve the ARV operation is the same as for those in the excavator valve.
Section E Hydraulics Section E
7-2
Descriptions 7-2
Issue 2*
9803/3260
Bucket Spool
Note: Machines with ISO control pattern have the boom and dipper spools interchanged.
4F
4E Dipper Spool
4D Stabiliser Spool
4C Stabiliser Spool
4B Boom Spool
4A Slew Spool
Component Key (JCB Control Pattern)
Oil from the loader valve enters the excavator valve at A and flows through the neutral gallery around the waists of the solid spools, as shown by the flow arrows. It also fills the parallel gallery B but is not at a high enough pressure to open the load hold check valves C.
Excavator Valve - Neutral Circuit
Section E Hydraulics Section E
8-2
Descriptions 8-2
Issue 1
9803/3260
controlled by the load hold check valve 4S which is a spring-loaded non-return valve operating across the pressure feed from the parallel gallery B. The valve prevents reverse flow from the rams into the pressure feed line, so maintaining ram pressure until exceeded by system pressure. The illustration shows a service selected but back pressure D exceeds system pressure which closes the load hold check valve 4S.
Flow to the service via a typical solid spool 4B is
Operation 1
Excavator Valve
Section E Hydraulics Section E
8-4
Descriptions 8-4
Issue 1
9803/3260
Operation 1 Because of its weight, the excavator end could take over control when boom lower was selected. The falling boom would tend to push oil out of the ram faster than the head side was being filled. Consequently, when the excavator had reached the ground, there would be a time lapse while the ram filled with oil before the service would operate again.
Operation 2
When pressure in the feed line exceeds back pressure, the load hold check valve 4S opens and oil operates the ram. The remaining load hold check valves are also opened by system pressure but the galleries are dead-ended because the spools are in neutral.
To prevent this from happening, the boom service is fitted with a one way restrictor. When the boom is being raised, the poppet in restrictor E is held off its seat by pressurised oil flow, therefore oil delivery to the boom ram rod side is unrestricted.
Excavator Valve One Way Restrictor
Excavator Valve
Section E Hydraulics Section E
8-6
Descriptions 8-6
Issue 1
9803/3260
When the boom is being lowered, the oil flow through the one way restrictor E re-seats the poppet, therefore the flow of oil is restricted through the small drilling in the base of the poppet. This slows the boom down to a controllable speed.
Operation 2
Excavator Valve One Way Restrictor
Section E Hydraulics Section E
8-8
Descriptions 8-8
Issue 1
9803/3260
The lower illustration shows the actuator reaching the end of its travel and the restrictor collar E contacting the end wall of the slew cylinder, partially closing off the exhaust port. End damping is achieved by two radial slots across the outer ridge of the collar which allow restricted flow to exhaust.
flows from the parallel gallery B, out past A.R.V. 4H to the right hand side of the slew actuator. Here it pushes on the piston and rack, causing the excavator end to slew to the right. Displaced oil from the left hand side of the slew actuator flows back through the upper service port D and back to tank.
The illustration shows right hand slew selected. The lower port C has been pressurised by the spool. Oil
Slew Operation (Sideshift)
Section E Hydraulics Section E
9-2
Descriptions 9-2
Issue 1
9803/3260
The spool 4A is in neutral but the momentum of the slewing excavator end creates back pressure in the left hand slew cylinder. This opens A.R.V. 4J and dumps oil to exhaust. At this point the right hand slew cylinder cavitates and exhaust oil pressure causes A.R.V. 4H to open, allowing oil from the exhaust gallery to fill the right hand cylinder.
Slew Auxiliary Relief Valve and Anti-cavitation Operation
Section E Hydraulics Section E
9-4
Descriptions 9-4
Issue 1
9803/3260
In normal operation oil flow from the pump enters the steering unit via the right hand port, opening a spring-loaded non-return valve H. The flow is directed by the steering unit to achieve the desired turn (right hand shown). In the event of a pressure shock wave being generated in the system by an outside force, shock valve G1 vents this pressure to exhaust preventing damage to the steering unit.
Operation 5 - Shock Valve
Hydraulic Steer Unit (2 Wheel Steer Machines)
generated pressure and non-return valve H closes to prevent the shock wave being fed back to the pump. Some of the excess flows via non-return valve J2 to the opposite side of the ram to prevent cavitation occuring.
Non-return valve J1 is held on its seat by the
Section E Hydraulics Section E
20 - 20
Descriptions 20 - 20
Issue 1
Section E
Hydraulics
Section E
24 - 1
Introduction Symbols
24 - 1
to
Hydraulic
Schematic Pumps & Motors
Complex hydraulic components and circuits can be described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used. There are many symbols in use and it would be impossible to include them all here. However it should be noted that most are only variations or refinements on the basic principles explained here. If more detailed information is required you are recommended to obtain a copy of BS2917 or IS01219. Once familiar with the symbols, the engineer can use hydraulic circuit diagrams as an aid to fault finding. It will be possible to see the complete hydraulic circuit and decipher the relationship between hydraulic components.
Fixed capacity pump one direction of flow
Fixed capacity pump two directions of flow
Variable capacity pump one direction of flow
Variable capacity pump two directions of flow
General (Basic & Functional Symbols) Spring
Flow restriction affected by viscosity
Fixed capacity motor one direction of flow
Direction of flow
Fixed capacity motor two directions of flow
Indication of rotation
Indication of direction and paths of flow Variable control
Variable capacity motor one direction of flow A189660
Variable capacity motor two directions of flow
Rams Single acting
Double acting
Double ended
Double acting with damping at rod area end A189670
9803/3260
A189680
Issue 1
Section E
Hydraulics
Section E
24 - 2
Introduction to Symbols (cont'd)
24 - 2
Hydraulic
Schematic
Control Valves
Used to enclose several valves indicating that they are supplied as one unit
One way restrictor
3-Position, 4-Port spring centred pilot operated valve
High pressure selector (shuttle valve)
3-Position, 6-Port spring centred hand operated valve
Throttling orifice normally closed
3-Position, 4-Port spring centred solenoid & pilot pressure operated valve
Throttling orifice normally open
3-Position, 4-Port spring centred detent hand operated valve
Relief valve Non - return valve
Non - return valve with back pressure spring Variable restrictor
Pilot operated non - return valve
A189690
9803/3260
A189700
Issue 1
Section E
Hydraulics
Section E
24 - 3
Introduction to Symbols (cont'd)
24 - 3
Hydraulic
Schematic
Energy Transmissions and Conditioning Working line, return or feed
Reservoir - return line above fluid level
Pilot control
Drain lines
Reservoir - return line below fluid level
Flexible pipe
Header tank
Pressure sealed tank
Line junction
Accumulator Crossing lines
Filter or strainer
Air bleed
Water trap
Line plugged, also pressure test point
Cooler - with no indication of coolant flow
Line plugged with take off line
Cooler - indicating direction of coolant flow
Quick release couplings - connected
Heater
A189710
A189720
Quick release couplings - disconnected 9803/3260
Issue 1
Section E
Hydraulics
Section E
24 - 4
24 - 4
Introduction to Symbols (cont'd)
Hydraulic
Schematic
Control Mechanisms Rotating shaft-one direction
Solenoid one winding
Rotating shaft-two directions Solenoid two winding Detent M
Electric motor operated
Locking device Internal pressure pilot operated Over centre device External pressure pilot operated Simple linkage Pressure operated spring release General control Pilot operated by solenoid pilot valve Push button operated Pilot operated by a solenoid or separate pilot valve Lever operated
Pressure gauge
Pedal operated
Stem operated
Pressure switch
Spring operated
Roller operated
Roller trip operated (one directional)
9803/3260
S189730
S189740
Issue 1
Section E
Hydraulics
Section E
24 - 5
Introduction to Symbols (cont'd)
24 - 5
Hydraulic
Schematic FIG 1
Control Valves
Position 1
Position 2
Position 3
Control valves are usually represented by one or more square boxes. Fig. 1 shows a control valve represented by three boxes. The number of boxes indicates the number of possible valve operating positions, (4 boxes - 4 positions etc). FIG 2 Fig. 2 - In circuit diagrams the pipework is usually shown connected to the box which represents the unoperated condition. (Hydraulic circuit diagrams are usually shown in the unoperated condition). Fig. 3 shows a valve described as a 3- position, 4-port control valve. Port describes the openings to and from the valve by which the hydraulic fluid enters or leaves. In the fig shown, Position 2 indicates that in an unoperated condition all 4 ports are blocked. Port 1
If the valve spool was moved to Position 1, movement of the spool would connect Port 1 to Port 2, and Port 3 to Port 4.
Port 3
FIG 3
If the valve spool was moved to Position 3, movement of the spool would connect Port 1 to Port 4, and Port 3 to Port 2. It must be noted that not all spools are of the same type. Their operating designs can be seen by following the path the flow arrows take in their respective operating squares. Three typical JCB style spools are known as 'D' spools, 'F' spools and 'N' spools.
Port 2
Port 4
The 'D' spools generally control rams because when in the neutral position the outlet ports are blocked, preventing ram movement. Fig 3 shows a 'D' type spool. FIG 4 Fig 4 - 'F' spools are often shown as four position spools with the three normal positions for neutral and service control; and the forth position, which has a detent, connects both sides of the ram together to allow the service to 'float'. Fig 5 - 'N' spools are sometimes used to control hydraulic motors, and it can be seen from the flow arrows, that in neutral position both service ports are connected to the exhaust oil port FIG 5
A189760
9803/3260
Issue 1
Section E
Hydraulics
Section E
24 - 6
24 - 6
Introduction to Symbols (cont'd)
Hydraulic
Schematic
Example of Schematic Circuit Some of the symbols described on the preceding pages have been arranged into a simple schematic circuit shown below. Hydraulic tank A is a pressurised tank with an internally mounted strainer B on the suction line to the fixed displacement pump C. System pressure is limited to the setting of relief valve D.
Example Circuit Key A B C D E F G
Hydraulic Tank Strainer Fixed Displacement Pump Relief Valve Spool One Way Valve Double Acting Hydraulic Ram
Valve spool E is an open-centre spool that is in neutral position; flow from the pump passes through the spool and returns to the hydraulic tank. If the lever operated spool is moved away from neutral position hydraulic fluid is directed to either head side or rod side of hydraulic ram G. Notice that the fluid must first open one way valve F before flowing to the ram.
A B
C
G D E F
A189770
9803/3260
Issue 1
Section E
Hydraulics
Section E
25 - 1
Fault Finding
25 - 1
Fault Finding Contents
Introduction Page No.
Introduction
25 - 1
Lack of power in all hydraulic functions
25 - 1
All hydraulic rams slow to operate
25 - 2
One hydraulic service fails to operate or is slow to operate
25 - 2
The engine tends to stall when the hydraulics are under load
25 - 2
A spool is sticking
25 - 3
Leaking Oil Seal (Control Valves)
25 - 3
Ram creep
25 - 3
Hydraulic oil becomes too hot
25 - 4
Steering fails to operate or is stiff to operate Steering fails to respond to selected mode
Fault 1
Lack of power in all hydraulic functions.
The purpose of this section is to help you trace hydraulic faults to a faulty unit (valve, actuator, ram etc). Once you have traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the hydraulics section. To help identify circuits, valves, rams etc mentioned in the fault finding procedures, refer to the hydraulic schematic diagrams (near the beginning of the Hydraulics Section). 1
Before you begin fault finding, read the Safety information at the beginning of this manual.
2
Make simple checks before say, stripping a major component.
3
Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F).
4
What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.
5
Make any relevant electrical checks before moving on to the hydraulics.
6
Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit.
7
Replace any seals such as 'O' rings before reassembling hydraulic components.
25 - 4
25 - 4
Probable Cause
Action
Insufficient hydraulic fluid.
Check for leaks and top up as required.
Hydraulic leaks in system.
Check hoses, replace as required.
Engine performance.
Check engine performance, see transmission section for stall speed test procedures.
Main relief valve (MRV) setting incorrect.
Check and adjust as required.
Low pump flow.
Check pump flow, if required service or replace pump.
Hydraulic tank breather
Clean or replace the breather
Tank filter by-pass valve
Check condition of hydraulic filter
Unloader valve pressure setting too high
Check pressure setting of the unloader valve.
..... continued
9803/3260
Issue 2
Section E
Hydraulics
Section E
25 - 2
Fault Finding
25 - 2
Fault 2
3
All hydraulic rams slow to operate.
One hydraulic service fails to operate or is slow to operate.
Probable Cause
Action
Neutral circuit or low pressure lines leaking, damaged, trapped or kinked.
Check pipe lines and replace as required.
Low pump flow.
Check pump flow, if required service or replace pump.
Priority valve operating
Check if the priority valve is sticking, rectify as required.
Main relief valve (MRV) setting incorrect.
Check and adjust as required.
Unloader valve
Check if unloader valve is sticking, i.e. dumping flow from pump section P2.
Tank filter by-pass valve
Check condition of hydraulic filter
Hydraulic tank breather
Clean or replace the breather
Associated service pipe lines , leaking damaged, trapped or kinked.
Check hoses, replace as required.
Associated ram leaking.
Complete ram leakage check, replace seals as required.
Auxiliary relief valve (ARV) setting incorrect.
Check and adjust as required.
Associated valve block section leaking or not operating.
Check for leaks, rectify as required. Also, see fault 6 'Leaking Oil Seal (Control Valves)'. Make sure that the associated load hold check valve is operating. Check that the control lever and associated linkages is operating the spool, rectify as required. Also, see fault 5, 'A spool is Sticking'.
Check valve malfunctioning (if fitted, e.g. stabiliser circuit)
Test check valve, rectify as required.
Hose burst protection valve (if fitted) malfunctioning.
Test HBPV, service as required.
Piston rod is bent
Replace piston rod, check pressure settings of MRV and ARV. Check that associated pivot pins are adequately greased
4
The engine tends to stall when hydraulics are under load.
9803/3260
M.R.V setting incorrect.
Check and adjust as required.
Poor engine performance.
Check engine performance, see transmission section for stall speed test procedures.
Unloader valve pressure setting too high
Check pressure setting of the unloader valve.
Issue 2
Section E
Hydraulics
Section E
25 - 3
Fault Finding
25 - 3
Fault 5 A spool is sticking. and
Probable Cause Oil temperature abnormally high.
Action Check for correct fluid, see Lubricants Capacities. Check oil cooler and grille for blockage.
The hydraulic fluid is dirty.
Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system Fill with clean hydraulic fluid.
The service pipe connection is over tightened.
Check tightening torque.
The valve housing was twisted during installation.
Loosen retaining bolts and tighten to correct torque figures.
Pressure too high.
Check system pressure.
A control linkage is bent
Disconnect the linkage. Repair the if possible, or fit a new
A spool is bent
Dismantle the control valve. Renew spool as necessary.
A return spring is broken.
Renew as necessary.
A return spring or cap is out of alignment.
Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts
Temperature distribution within control valve not uniform.
Warm the entire system up before using service.
Paint or dirt on the seal face.
Remove the seal and clean.
The back pressure in the valve circuit is excessively high.
Check circuit pressures. Adjust if Otherwise investigate thoroughly.
Spool damaged.
Dismantle. Inspect all parts. Renovate or renew as necessary.
The seal is not secured.
Clean the seal and tighten the retaining bolts to the correct torque.
The seal is cut or damaged.
Fit a new seal.
Associated ram or pipe lines from ram leaking.
Check and rectify as required.
Check valve malfunctioning (if fitted, e.g. stabiliser circuit)
Test check valve, rectify as required.
Associated valve section spools leaking.
Rectify, check for contamination.
Associated ARV leaking
Rectify, check for contamination
linkage one
6
Leaking Oil Seal (Control Valves)
possible.
7
Ram creep.
.
..... continued
9803/3260
Issue 2
Section E
Hydraulics
Section E
25 - 4
Fault Finding
25 - 4
Fault 8
9
Hydraulic oil becomes too hot
Steering fails to operate or is stiff to operate
Probable Cause
Action
Oil cooler obstructed
Remove debris from cooler fins
Restriction in neutral circuit lines
Check hoses, replace as necessary
Hydraulic filter clogged and by-pass valve not working
Change hydraulic filter
Tyres not inflated to correct pressure
Inflate tyres to correct pressure
Insufficient hydraulic fluid.
Check for leaks and top up as required.
Low pump flow.
Check pump flow, if required service or replace pump.
Leaks in the relevant hoses or component connections
Check hoses and connections for leaks
Steer relief valve set incorrectly
Check pressure setting of steer unit relief valve, adjust as required.
Priority valve not operating correctly
Check if the priority valve is sticking, rectify as required. Check the load sense line from the steer unit to the priority valve for signs of leaking or poor connection.
Steer mode valve not operating correctly
Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required
Mechanical failure
Check for damaged axle components, such as rams, trackrods, linkages etc. Check for damaged steer unit components. Steering column and associated components not set correctly.
10 Steering fails to respond to selected mode
Selector switch faulty
Check selector switch, replace a required
Proximity switches not operating correctly
Check setting of proximity switches, reset or replace switches as required.
Steer mode valve not operating correctly
Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required.
9803/3260
Leaks in the relevant hoses or component connections
Check hoses and connections for leaks
Electrical failure
Check relevant electrical connectors, if problem still persists, do a wiring continuity check on relevant circuits. Issue 2
Section E 30 - 1
Hydraulics Pumps
Section E 30 - 1
S193200
S193210
9803/3260
Issue 1
Section E
Hydraulics
Section E 30 - 2
Pumps
30 - 2
Pump Flow Testing FIG X = All Wheel Steer Machines FIG Y = 2 Wheel Steer Machines Before removing the pump it is necessary to determine the source of any problem by measuring the output flow at system pressure from both of the pump outlet ports.
Removing
To check flow it is necessary to fit flow meter A into the output line of each pump section in turn. If available, load valve B (JCB Part No. 892/00270) should also be installed (see Note 1). Make sure the flow meter is installed with its arrow pointing away from the pump and, if applicable, located between the pump and the load valve.
Checking Flow
Removing is the reverse of fitting.
1
Check the setting of the Main Relief Valve (MRV) as described in Loader Valve, Pressure Testing. Adjust if necessary.
2
a
Using a load valve - fit a flow meter and load valve, as described in Fitting, to each pump outlet in turn. Fit a 0-400 bar (0-6000 lbf/in2) pressure gauge to the load valve pressure test connector.
b
If no load valve is available - fit a flow meter, as described in Fitting, to each pump output in turn.
Note 1: If no load valve is available, ignore the references to the load valve in Fitting/Removing a Flow Meter and Load Valve below. An alternative method of determining flow is included in the Checking Flow procedures following.
Fitting/Removing a Flow Meter and Load Valve Before fitting/removing a flow meter and load valve, switch off the machine and operate the loader/excavator controls a few times to vent system pressure.
3
Start the engine and bring the hydraulics up to normal operating temperature. Set the engine speed to 2200 rpm.
4
a
Using a load valve - adjust the load valve so that the pressure gauge reading is just below the MRV setting.
b
If no load valve is available - raise or lower the loader arms until the rams are fully open or closed. Continue to operate the raise/lower control so that system pressure builds up. Watch the flow meter and note its reading at the moment the MRV operates.
! WARNING 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 Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. TRANS 1-2
5
The flow reading should be as listed in Technical Data, Machine Hydraulics (AWS and 2WS Machines), Hydraulic Pumps.
Fitting 1
AWS machines a Pump section 1 - disconnect hose C from the pump. Fit the flow meter and load valve (see Note 2) between hose C and the pump. b Pump section 2 - due to the limited access at the rear of the pump, disconnect hose D from priority valve E. Fit the flow meter and load valve (see Note 2) between hose D and the priority valve.
2
2WS machines Connect the flow meter and load valve (see Note 2) between the pump port and the disconnected machine hose. Hose F connects to pump section 1 and hose G to pump section 2.
Note 2: Make sure the load valve is in the open position, i.e. with the adjusting knob screwed fully out, before carrying out the Checking Flow procedure.
9803/3260
Issue 1
Section E
Hydraulics
Section E
Valves
41 - 1
41 - 1
Loader Valve Replacement
Removal and Replacement
Replacement is a reversal of the removal sequence.
! WARNING Make the machine safe before working underneath it. Park the machine on level ground, lower the arms. Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-2
! 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.
Note: The illustration shows a 'Hamworthy' type valve fitted.
INT-3-1-10/1
difference being the hose routing from pump sections P1 and P2. Make sure all hoses are clearly labelled before removing them.
After replacement check the main relief valve (M.R.V.) and auxiliary relief valve (A.R.V.) pressure settings.
* The 'Husco' type valve is similiarly mounted. The main
Removal 1
Operate the valve block levers back and forth to vent residual pressure.
2
Remove clevis pins A to disconnect the control levers from the the valve block spools.
3
Disconnect all hydraulic hoses from the valve block and plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct position when refitting.
4
Loosen and remove nuts B, the loader valve and spacing washers C.
Note: All hydraulic adapters that are installed together with a bonded sealing washer must also have sealant (Loctite 577) applied to the threads of the adapter. For dismantling and assembling the loader valve see pages
* E/41-2 to E/41-13 (Hamworthy type valve) and pages E/4120 to E/41-31 (Husco type valve).
C
A
B
C B
B C
S144460
9803/3260
Issue 2*
Section E 41 - 2
9803/3260
Hydraulics Valves
Section E 41 - 2
Issue 1
Section E
Hydraulics Valves
41 - 3 *
Section E 41 - 3
'Hamworthy' Loader Valve - Standard Spool Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. When Dismantling Hold the spool in clamp 992/10100, unscrew bolt 11 and remove spring 13 with cups 12 and 14. When Assembling Renew seal 3 and 'O' rings 8 and 9. When fitting bolt 11 or eye end 15, clean the threads thoroughly using Super Clean Safety Solvent, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads. Do not overtighten eye end 15. Torque Settings Item 1 5 11 15
9803/3260
Nm 6.5 6.5 14 15
kgf m 0.7 0.7 1.4 1.5
lbf ft 5 5 10 11
Issue 2*
Section E 41 - 4
9803/3260
Hydraulics Valves
Section E 41 - 4
Issue 1
Section E
Hydraulics Valves
41 - 5 *
Section E 41 - 5
'Hamworthy' Loader Valve - Float Spool Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. When Dismantling Carefully remove collar 14 and collect detent balls 15. Remove spacer 16 and lift off spring housing 17. Using tool 992/10100 to hold the spool, unscrew bolt 18 and remove ball cage 19, spacer 20, spring 21 and cups 22 and 23. When Assembling Renew seal 3 and 'O' rings 6, 8 and 9. When fitting bolt 18 or eye end 24, clean the threads thoroughly using Super Clean Safety Solvent, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads. Apply grease liberally to cage 19 to hold balls 15 in position during assembly and to provide lubrication. Do not overtighten eye end 24. Torque Settings Item 1 7 18 24
9803/3260
Nm 6.5 6.5 14 15
kgf m 0.7 0.7 1.4 1.5
lbf ft 5 5 10 11
Issue 2*
Section E 41 - 6
9803/3260
Hydraulics Valves
Section E 41 - 6
Issue 1
Section E
Hydraulics Valves
41 - 7 *
Section E 41 - 7
'Hamworthy' Loader Valve - Electric Detent Spool Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. When Dismantling Using tool 992/10100 to hold the spool, remove capscrew 11, washer 12 and housing 13. Unscrew bolt 14 and remove spring 15 with cups 16 and 17. When Assembling Renew seal 3 and 'O' rings 7 and 8. When fitting capscrew 11, bolt 14 or eye end 18, clean the threads thoroughly using Super Clean Safety Solvent, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads. Do not overtighten eye end 18. Apply JCB Multi-Gasket to the threads of solenoid 10. Tighten to 20 Nm (15 lbf ft). Check the operation of the solenoid after assembly by connecting a 12V supply . The spool should be held when it is pushed into the detent position and returned when the supply is disconnected. Torque Settings Item 1 5 14 18
9803/3260
Nm 6.5 6.5 14 15
kgf m 0.7 0.7 1.4 1.5
lbf ft 5 5 10 11
Issue 2*
Section E
Hydraulics
41 - 8 *
Section E
Valves
41 - 8
'Hamworthy' Loader Valve - Main Relief Valve (M.R.V.) Dismantling and Assembly
When Assembling
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Renew all 'O' rings. Lubricate parts with JCB Hydraulic Fluid before assembling.
For assembly the sequence should be reversed. Ensure that the small drilling A in the main plunger 11 is clear. Adjust pressure setting as required (see page E/42 - 1). Torque Settings Item 1 5
Nm 28 20
kgf m 2.9 2.0
lbf ft 21 15
S143150
9803/3260
Issue 2*
Section E 41 - 9 *
Hydraulics Valves
Section E 41 - 9
'Hamworthy' Loader Valve - Auxiliary Relief Valve (A.R.V.) Dismantling and Assembly
When Assembling
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Renew all 'O' rings.
For assembly the sequence should be reversed.
Hold valve 5 in clamp 992/10100 when removing and replacing the adjusting screw. If any parts are worn, renew valve complete. Lubricate parts with JCB Hydraulic Fluid before assembling. Adjust pressure setting as required (see page E/42 - 3).
S143160
9803/3260
Issue 3*
Section E 41 - 10 *
Hydraulics Valves
Section E 41 - 10
'Hamworthy' Loader Valve - Load Hold Check Valves Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. When Assembling Renew 'O' rings. Lubricate parts with JCB Hydraulic Fluid before assembling. Tighten item 1 to 75-81Nm (55-60lbf ft).
S143170
9803/3260
Issue 2*
Section E 41 - 11
Hydraulics Valves
Section E 41 - 11
S143180
9803/3260
Issue 2
Section E
Hydraulics Valves
41 - 12 *
Section E 41 - 12
'Hamworthy' Loader Valve - Unloader Valve Spool Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. When Dismantling Use a nylon rod to push out spool assembly item 15, DO NOT damage spool bore. When Assembling Renew all 'O' rings and seals. Lubricate parts with JCB Hydraulic Fluid before assembling. Apply JCB Lock and Seal to all threads except the pressure adjusting screw 6. Ensure that the small drillings through the centre of items 1, 15 and 16 are clear. Check pressure setting after refitting (see page E/42 - 2). Torque Settings Item 1 5 11
9803/3260
Nm 28 20 28
kgf m 2.9 2.0 2.9
lbf ft 21 15 21
Issue 2*
Section E
Hydraulics Valves
41 - 13 *
Section E 41 - 13
'Hamworthy' Loader Valve - Unloader Check Valve Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. When Assembling Renew all 'O' rings. Lubricate parts with JCB Hydraulic Fluid before assembling. Apply JCB Lock and Seal to threads of item 1. Torque Settings Item 1
Nm 41 - 47
kgf m 4.2 - 4.8
lbf ft 30 - 35
S143190
9803/3260
Issue 2*
Section E
Hydraulics
Section E
Valves
41 - 20
41 - 20
1 2 3 4
15 14
13
8
12 11 10
7
9 6
5
S197440
9803/3260
Issue 1
Section E
Hydraulics
41 - 21
Section E
Valves
41 - 21
'Husco' Loader Valve - Standard Spool Dismantling and Assembly
When Assembling
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Renew seal 3 and 'O' rings 4 and 15. Make sure the 'O' rings and wiper seals are not trapped or damaged.
For assembly the sequence should be reversed.
When fitting bolt 9, clean the threads thoroughly using Super Clean Safety Solvent, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads of the spool.
The following points MUST be avoided when dismantling and assembling the valve:
• • •
CONTAMINATION DAMAGE TO SPOOL DAMAGE TO SEAL GROOVES
All or any of the above points may result in possible problems with the valve. When Dismantling Remove the lever linkage from the tang (lever) end of the spool. When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves, for instance, item 3, which is a wiper seal and is a press fit in the counterbore.
Make sure that all the parts move freely, check that item 10 does not interfere with item 13. Re-connect the lever mechanism to the tang (lever) end of the spool. Run the engine and inspect the valve for external leaks. Torque Settings Item 1 5 9
Nm 5.4 9.5 9.5
kgf m 0.6 0.96 0.96
lbf ft 4 7 7
Care must be taken to ensure that the spool 8 is not damaged when removing it from the valve block. Hold the spool in clamp 992/10100, unscrew bolt 9 and remove spring 12, spacer 10 and cups 11 and 13. Check for surface contamination on the under side of the seal plates 2 and 14. Clean if necessary. Check for the flatness of the seal plate. If found to be bent - replace with new (any work previously carried out on this valve may have resulted in the bending of the seal plate).
9803/3260
Issue 1
Section E
Hydraulics
Section E
Valves
41 - 22
41 - 22
1
2 4
3 5 6 22
7
13 17
21 16
20 12 19 18
25 15
11 24 10 14 9
23 8
S197460
9803/3260
Issue 1
Section E
Hydraulics
41 - 23
Section E
Valves
41 - 23
'Husco' Loader Valve - Float Spool Dismantling and Assembly
When Assembling
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Renew seal 3 and 'O' rings 4, 6 and 17. Make sure the 'O' rings and wiper seals are not trapped or damaged.
For assembly the sequence should be reversed.
When fitting detent pin 22, clean the threads thoroughly using Super Clean Safety Solvent, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads of the spool.
The following points MUST be avoided when dismantling and assembling the valve:
• • •
CONTAMINATION DAMAGE TO SPOOL DAMAGE TO SEAL GROOVES
All or any of the above points may result in possible problems with the valve. When Dismantling Remove the lever linkage from the tang (lever) end of the spool. When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves, for instance, item 3, which is a wiper seal and is a press fit in the counterbore.
Apply grease liberally balls 12, this will help to hold the balls in position whilst assembling. Re-connect the lever mechanism to the tang (lever) end of the spool. Run the engine and inspect the valve for external leaks.
Torque Settings Item 1 8 22
Nm 9.5 9.5 9.5
kgf m 0.96 0.96 0.96
lbf ft 7 7 7
Care must be taken to ensure that the spool 15 is not damaged when removing it from the valve block. Carefully remove collar 11 and collect detent balls 12. Using tool 992/10100 to hold the spool, remove circlip 18, plug 19, ball 20 and spring 21. Unscrew detent pin 22 and remove spring 24 and cups 23 and 24. Check for surface contamination on the under side of the seal plates 2 and 16. Clean if necessary. Check for the flatness of the seal plate. If found to be bent - replace with new (any work previously carried out on this valve may have resulted in the bending of the seal plate).
9803/3260
Issue 1
Section E
Hydraulics
Section E
Valves
41 - 24
41 - 24
2
1
3 4
11 10
9 6 18 17
16 12
8 5 15 14 13 7
S197450
9803/3260
Issue 1
Section E
Hydraulics
41 - 25
Section E
Valves
41 - 25
'Husco' Loader Valve - Electric Detent Spool Dismantling and Assembly
When Assembling
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Renew seal 3 and 'O' rings 4 and 11. Make sure the 'O' rings and wiper seals are not trapped or damaged.
For assembly the sequence should be reversed.
When fitting spool end 15, clean the threads thoroughly using Super Clean Safety Solvent, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads of the spool.
The following points MUST be avoided when dismantling and assembling the valve:
• • •
CONTAMINATION DAMAGE TO SPOOL DAMAGE TO SEAL GROOVES
All or any of the above points may result in possible problems with the valve. When Dismantling Remove the lever linkage from the tang (lever) end of the spool. When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves, for instance, item 3, which is a wiper seal and is a press fit in the counterbore. Care must be taken to ensure that the spool 12 is not damaged when removing it from the valve block. Use tool 992/10100 to hold the spool, remove circlip 13 and 'clapper' 14. Unscrew spool end 15 and remove spring 17 with cups 16 and 18.
Make sure that the chamfer on item 14 faces away from the solenoid, item 6. Check the operation of the solenoid 6 after assembly by connecting a 12V supply . The spool should be held when it is pushed into the detent position and returned when the supply is disconnected. Re-connect the lever mechanism to the tang (lever) end of the spool. Run the engine and inspect the valve for external leaks.
Torque Settings Item 1 5 15
Nm 5.4 9.5 9.5
kgf m 0.6 0.96 0.96
lbf ft 4 7 7
Check for surface contamination on the under side of the seal plates 2, 8 and 10. Clean if necessary. Check for the flatness of the seal plate. If found to be bent - replace with new (any work previously carried out on this valve may have resulted in the bending of the seal plate).
9803/3260
Issue 1
Section E
Hydraulics
Section E
Valves
41 - 26
41 - 26
15 16 14 13 11
12 10 9
19
8
18
7 17 6
5 4
3 2 1
S197410
9803/3260
Issue 1
Section E
Hydraulics
41 - 27
Section E
Valves
41 - 27
'Husco' Loader Valve - Main Relief Valve (M.R.V.) Dismantling and Assembly
When Assembling
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Renew all 'O' rings and back-up rings.
For assembly the sequence should be reversed.
Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.
The following points MUST be avoided when dismantling and assembling the valve:
Make sure that the 'O' rings and back-up rings are fitted the correct way, items 15, 16 and 11, 12.
• • •
Fit chamfered end of spring 6 against head of pilot poppet item 7.
CONTAMINATION DAMAGE TO SPOOL DAMAGE TO SEAL GROOVES
All or any of the above points may result in possible problems with the valve. When Dismantling When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the seal grooves.
Adjust pressure setting as required (see page E/42-10). Torque Settings Item 3 8 18
Nm 5.4 45 45
kgf m 0.6 4.6 4.6
lbf ft 4 33 33
Discard ALL 'O' rings and back up rings. DO NOT use worn or damaged items. Inspect the valve components for scratches, nicks or any other type of damage, replace with new if required.
9803/3260
Issue 1
Section E
Hydraulics
Section E
Valves
41 - 28
41 - 28
1 18 2 3 4
17 16 15
5 6 8 9 11
10
14
B
A
13 12
7
S197420
9803/3260
Issue 1
Section E
Hydraulics
41 - 29
Section E
Valves
41 - 29
'Husco' Loader Valve Auxiliary Relief Valves (ARV) and Load Hold Check Valves (LHCV) When Assembling Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.
Renew all 'O' rings and back-up rings. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. Fit back-up ring 13 on the upper side of 'O' ring 12.
The following points MUST be avoided when dismantling and assembling the valve:
Fit flat face of sleeve 9 against shoulder of poppet 10.
• • •
Torque tighten item 14 using the special tool (see Service Tools, Section 1), until its shoulder seats firmly against item 1.
CONTAMINATION DAMAGE TO SPOOL DAMAGE TO SEAL GROOVES
All or any of the above points may result in possible problems with the valve.
Pressure test the relief valves using the procedure described on page E/45-1.
The ARV's are identical in design but have different pressure settings (see Technical Data).
Torque Settings
The LHCV's are identical. When Dismantling
Item 1 3 15
Nm 65 24 81
kgf m 6.6 2.5 8.3
lbf ft 48 18 60
When removing 'O' rings and seals, use an an appropriately rounded tool that WILL NOT cause any damage to the seal grooves. Discard ALL 'O' rings and back up rings. DO NOT use worn or damaged items. Dismantle sub-assembly 14 from item 1 using a special tool (see Service Tools, Section 1). The special spanner locates in cross holes B. Make sure that small drilling A is not blocked. Ensure good condition of seating faces on poppet 18 and on the mating face of the valve block. Inspect the valve components for scratches, nicks or any other type of damage, replace with new if required.
S143160
9803/3260
Issue 1
Section E
Hydraulics
Section E
Valves
41 - 30
41 - 30
3 4
23
15
7 6 5
19 16 25
24 26
2
1
18 17 21 22
27
11 10 9 8
14
13
12
S197430
9803/3260
Issue 1
Section E
Hydraulics
41 - 31
Section E
Valves
41 - 31
'Husco' Loader Valve - Unloader Valve Assembly Dismantling and Assembly
When Assembling
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Renew all 'O' rings and back-up rings.
For assembly the sequence should be reversed.
Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.
The following points MUST be avoided when dismantling and assembling the valve:
Ensure that the small drilling through the centre of items 23, is clear.
• • •
Shims 21 are intended to limit the maximum pressure setting, the specified pressure setting is achieved by adjusting capnut 15. If the specified pressure cannot be achieved under test, it is permissible to add shims as required. There MUST be at least one hardened shim next to the spring item 22.
CONTAMINATION DAMAGE TO SPOOL DAMAGE TO SEAL GROOVES
All or any of the above points may result in possible problems with the valve. When Dismantling When removing 'O' rings and seals, use an an appropriately rounded tool that WILL NOT cause any damage to the seal grooves. Discard ALL 'O' rings and back up rings. DO NOT use worn or damaged items.
Do not over-tighten the solenoid assembly, it may effect the operation of the solenoid, use the spanner flats and torque tighten to figure indicated in the table below (items 1 and 5). Fit chamfered end of spring 22 against head of pilot poppet item 23. Check pressure setting after refitting, see page E/42-11.
Use a nylon rod to push out spool assembly item 23, DO NOT damage spool bore.
Check the operation of the hydraulic speed control, see page E/42-11.
Inspect the valve components for scratches, nicks or any other type of damage, replace with new if required.
Torque Settings Item 1 5 8 12 16 19
9803/3260
Nm 6.7 27 81 81 45 34
kgf m 0.7 2.8 8.3 8.3 4.6 3.5
lbf ft 5 20 60 60 33 25
Issue 1
Section E
Hydraulics
Section E
Valves
41 - 40
41 - 40
A248450
S248430
9803/3260
Issue 1
Section E
Hydraulics
41 - 41
Section E
Valves
41 - 41
'Husco' Loader Valve - Standard Spool (3CXE (214E) Machines Only) Dismantling and Assembly
When Assembling
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Renew wiper seals 5 and 14 and ‘O’ rings 6, 15 and 18.
For assembly the sequence should be reversed. The following points MUST be avoided when dismantling and assembling the valve:
• • •
CONTAMINATION DAMAGE TO SPOOL DAMAGE TO SEAL GROOVES
When fitting bolt 9, clean the threads thoroughly using JCB Cleaner & Degreaser, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads of the spool. Re-connect the lever mechanism to the tang (lever) end of the spool. Run the engine and inspect the valve for external leaks.
All or any of the above points may result in possible problems with the valve.
Torque Settings
When Dismantling
Item 7 9
Remove the lever linkage from the tang (lever) end of the spool.
Nm 6.1 - 7.5 9.5 - 10.9
kgf m 0.62 - 0.76 0.97 - 1.11
lbf ft 4.5 - 5.5 7-8
When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves, for instance, item 5, which is a wiper seal and is a press fit in the counterbore. Care must be taken to ensure that the spool 19 is not damaged when removing it from the valve block. Check for surface contamination on the under side of the seal plates 4 and 13. Clean if necessary. Check for the flatness of the seal plate. If found to be bent - replace with new (any work previously carried out on this valve may have resulted in the bending of the seal plate).
9803/3260
Issue 1
Section E
Hydraulics
Section E
Valves
41 - 42
41 - 42
A248460
S248440
9803/3260
Issue 1
Section E
Hydraulics
41 - 43
Section E
Valves
41 - 43
'Husco' Loader Valve - Float Spool (3CXE (214E) Machines Only) Dismantling and Assembly
When Assembling
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Renew wiper 5 and 'O' rings 6, 20, 21 and 24.
For assembly the sequence should be reversed. The following points MUST be avoided when dismantling and assembling the valve:
• • •
CONTAMINATION DAMAGE TO SPOOL DAMAGE TO SEAL GROOVES
All or any of the above points may result in possible problems with the valve.
Apply grease liberally to detent pin 14 to hold detent balls 11 in position during assembly and to provide lubrication. When fitting detent pin 14, clean the threads thoroughly using JCB Cleaner & Degreaser, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads of the spool. Re-connect the lever mechanism to the tang (lever) end of the spool. Run the engine and inspect the valve for external leaks.
When Dismantling Remove the lever linkage from the tang (lever) end of the spool. When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves, for instance, item 5, which is a wiper seal and is a press fit in the counterbore.
Torque Settings Item 9 14
Nm 6.1 - 7.5 9.5 - 10.9
kgf m 0.62 - 0.76 0.97 - 1.11
lbf ft 4.5 - 5.5 7-8
Care must be taken to ensure that the spool 25 is not damaged when removing it from the valve block. Remove retainer 7 and spacer 8. Using a suitable tool on ball 12, compress spring 13 and allow detent balls 11 to roll into their holes in the detent pin 14. Carefully remove the spool cap 10 and collect detent balls 11. Check for surface contamination on the under side of the seal plate 4 and spacer 19. Clean if necessary. Check for the flatness of the seal plate. If found to be bent - replace with new (any work previously carried out on this valve may have resulted in the bending of the seal plate).
9803/3260
Issue 1
Section E
Hydraulics
Section E
Valves
41 - 44
41 - 44
A248460
S248440
9803/3260
Issue 1
Section E
Hydraulics
41 - 45
Section E
Valves
41 - 45
'Husco' Loader Valve - M.R.V & A. R. V’s (3CXE (214E) Machines Only) Dismantling and Assembly
When Assembling
Note: The M.R.V. and loader valve A.R.V.'s are identical in design.
Renew all 'O' rings and back-up rings.
The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. The following points MUST be avoided when dismantling and assembling the valve:
• • •
Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. Make sure that the 'O' rings and back-up rings are fitted the correct way, items 12, 13 and 18, 19. Adjust pressure setting as required. Torque Settings
CONTAMINATION DAMAGE TO SPOOL DAMAGE TO SEAL GROOVES
All or any of the above points may result in possible problems with the valve.
Item 1 3 5 10
Nm 5.4 - 8.2 41 - 68 5.4 - 8.2 41 - 68
kgf m 0.55 - 0.83 4.15 - 6.9 0.55 - 0.83 4.15 - 6.9
lbf ft 4-6 30 - 50 4-6 30 - 50
When Dismantling When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the seal grooves. Discard ALL 'O' rings and back up rings. DO NOT use worn or damaged items. Inspect the valve components for scratches, nicks or any other type of damage, replace with new if required.
9803/3260
Issue 1
Section E
Hydraulics Valves
42 - 1 *
Section E 42 - 1
'Hamworthy' Loader Valve - Pressure Testing Main Relief Valve (M.R.V.)
* Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F).
Lower the excavator bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure. 1
Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector A on the loader valve, (see Service Tools, Section 1).
* 2
With the engine running at 1500 revs/min, check M.R.V. pressure by raising or lowering the loader arms until the rams are fully open or closed and noting the maximum gauge reading. CAUTION: Do not select 'float'. The maximum pressure should be as stated in Technical Data.
Note: The rams must be 'held' open or closed when reading gauge. 3
If the pressure is incorrect, slacken locknut B and adjust screw C. Turn it clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut.
C
B
A
S144440
9803/3260
Issue 2*
Section E
Hydraulics Valves
42 - 2 *
Section E 42 - 2
'Hamworthy' Loader Valve - Pressure Testing Unloader Valve
* Hydraulic Speed Control (HSC)
* Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F). Lower the excavator bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure.
The following procedure can be used to establish if the hydraulic speed control facility is working correctly. 1
Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector D.
2
With the engine running at maximum speed, slowly operate arms raise, raise the pressure to approximately 137 bar (2000 lbf/in2).
3
Make sure that the HSC rocker switch (mounted on the console) is in the OFF position.
4
Press the HSC control button (mounted on the loader control knob). The pressure gauge reading should drop to zero (or near zero).
5
Repeat the above procedure but this time press the HSC rocker switch on (instead of the button on the loader control knob). The pressure gauge reading should drop to zero (or near zero).
6
If there is no pressure drop at steps 4 and 5, then check the HSC hydraulic and electrical circuits for any faults.
Make sure that the 'hydraulic speed control' facility is NOT switched on, otherwise the correct unloader valve pressure cannot be obtained. If the machine has a front- mounted roadbreaker, ensure that the roadbreaker control valve lever is in the 'off' position (lever down), otherwise the roadbreaker relief valve will operate and prevent unloader valve pressure from being reached. 1
Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector D on the loader valve, (see Service Tools, Section 1).
2
With the engine running at 1500 revs/min, slowly operate arms raise or lower.
Note: The arms raise or lower service is specified because it has no auxiliary relief valve (A.R.V.). Selecting this service ensures that the pressure vents through the unloader and not an A.R.V.
* 3
When the service reaches full travel, the gauge reading should rise slowly to unloading pressure then fall back to zero. The maximum reading should be as specified in Technical Data.
4
If the pressure is incorrect, slacken locknut E and adjust screw F. Turn it clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut.
F E D
S143200
9803/3260
Issue 2*
Section E
Hydraulics Valves
42 - 3 *
Section E 42 - 3
'Hamworthy' Loader Valve - Pressure Testing Loader A.R.V.'s (Using Hand Pump) Auxiliary relief valves (A.R.V's.) are set 15 bar (220 lbf/in2) below the nominal figure stated on the Technical Data page when using a hand pump. For example: Shovel ram rod ARV = 303 to 317 bar (4400 to 4600 lbf/in2) Nominal figure
= 310 bar (4500 lbf/in2)
Hand pump setting = 310 - 15 = 295 bar (4280 lbf/in2) Insert the A.R.V. B into test block A, part number 992/10200. Connect hand pump 892/00223 and a 0-400 bar(0-6000 lbf/in2) pressure gauge. Pressurise until oil begins to escape at C when the gauge will indicate the A.R.V. setting. Remember to set the A.R.V. 15 bar (220 lbf/in2) below the nominal figure shown on the Technical Data page. If required, adjust the pressure by holding the valve in clamp 992/10100 and turning the adjusting screw using an allen key as shown.
A B C S159120
S159130
9803/3260
Issue 2*
Section E
Hydraulics Valves
42 - 4 *
Section E 42 - 4
'Hamworthy' Loader Valve - Pressure Testing Shovel Ram Head Side A.R.V. (In Position) Testing of A.R.V's on the machine should be avoided (use hand pump method as described on page E/42 - 3). However, the procedure described below is a secondary checking method which can be used if no hand pump is available. When checking the shovel ram head side A.R.V. on the machine using main pump flow, the following tolerances must apply: Pump Type
Engine Revs Temperature Pressure
P2AJ190705 1000 r.p.m.
50 - 80 °C (122-176°F)
170 - 192 bar (2465-2785 lbf/in2)
P2AJ190606 1000 r.p.m.
50 - 80 °C (122-176°F)
170 - 195 bar (2465-2830 lbf/in2)
P2AJ190706 1000 r.p.m.
50 - 80 °C (122-176°F)
170 - 200 bar (2465-2900 lbf/in2)
P2AJ190906 1000 r.p.m.
50 - 80 °C (122-176°F)
170 - 205 bar (2465-2970 lbf/in2)
A S143200
Procedure
* Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F). Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to test connector A on the loader valve. (See Service Tools, Section 1.) Run the engine at 1000 revs/min, hold the shovel ram fully open and check the maximum gauge reading, which should equal the operating pressure shown in Technical Data. If necessary, adjust as detailed below
S159130
A.R.V. Adjustment Remove the A.R.V. from the control valve and hold in clamp 992/10100 as shown. Turn the adjusting screw using an allen key. Adjust clockwise to increase the setting and anticlockwise to decrease the setting.
9803/3260
Issue 2*
Section E 42 - 5 *
Hydraulics Valves
'Hamworthy' Loader Valve - Pressure Testing
Section E 42 - 5
X
Shovel Ram Rod Side A.R.V. Testing of A.R.V's on the machine should be avoided (use hand pump method as described on page E/42 - 3). However, the procedure described below is a secondary checking method which can be used if no hand pump is available. The shovel ram rod side A.R.V. is set at a higher pressure than the M.R.V. (maximum system pressure). To raise the pressure in the shovel ram rod side service line above system pressure it is necessary to disconnect/connect hoses (as shown in the following procedures) so that oil displaced from the LIFT ram (rod side) is fed through the A.R.V.
S132870
* Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F). Rest the shovel on the ground, stop the engine and vent all services. Disconnect hoses B and C from metal pipes B1 and C1 respectively, shown at X.
Y
Screw a tee piece fitted with a 0-400 bar (0-6000 lbf/in2) pressure gauge to metal pipe B1, shown at Y. Pull the hose C down from behind the loader arm and fit to the other side of the tee piece as shown at Y. Fit a cap to metal pipe C1 and fit a plug to hose B. Note: For reference, C is the service hose for the shovel ram, rod side. B is the service hose for the lift ram, rod side. With the engine running at 1000 revs/min, select and operate slowly the loader arms lift service until the ram creeps, keep raising the arms slowly until a reading on the pressure gauge is obtained. S132890
The highest pressure value shown on the gauge will be the setting of the shovel ram rod side A.R.V. (see Technical Data). If necessary, adjust as detailed below. A.R.V . Adjustment Remove the A.R.V. from the control valve and hold in clamp 992/10100 as shown. Turn the adjusting screw using an allen key. Adjust clockwise to increase the setting and anticlockwise to decrease the setting.
S159130
9803/3260
Issue 2*
Section E
Hydraulics
Section E
Valves
42 - 10
42 - 10
'Husco' Loader Valve - Pressure Testing Main Relief Valve (M.R.V.) Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F). Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure. 1
Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector A on the loader valve, (see Service Tools, Section 1).
2
With the engine running at 1500 revs/min, check M.R.V. pressure by raising or lowering the loader arms until the rams are fully open or closed and noting the maximum gauge reading. CAUTION: Do not select 'float'. The maximum pressure should be as stated in Technical Data.
Note: The rams must be 'held' open or closed when reading gauge. 3
If the pressure is incorrect, remove cap D and its Oring, slacken locknut B and adjust screw C. Turn it clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut and refit the cap with its O-ring..
C
B A
D S197660
9803/3260
Issue 1
Section E
Hydraulics
42 - 11
Section E
Valves
42 - 11
'Husco' Loader Valve - Pressure Testing Unloader Valve
Hydraulic Speed Control (HSC)
Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F).
The following procedure can be used to establish if the hydraulic speed control facility is working correctly.
Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure.
1
Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector D (see note 2 opposite).
2
With the engine running at maximum speed, slowly operate arms raise, raise the pressure to approximately 137 bar (2000 lbf/in2).
3
Make sure that the HSC rocker switch (mounted on the console) is in the OFF position.
4
Press the HSC control button (mounted on the loader control knob). The pressure gauge reading should drop to zero (or near zero).
5
Repeat the above procedure but this time press the HSC rocker switch on (instead of the button on the loader control knob). The pressure gauge reading should drop to zero (or near zero).
6
If there is no pressure drop at steps 4 and 5, then check the HSC hydraulic and electrical circuits for any faults.
Make sure that the 'hydraulic speed control' facility is NOT switched on, otherwise the correct unloader valve pressure cannot be obtained. If the machine has a front- mounted roadbreaker, ensure that the roadbreaker control valve lever is in the 'off' position (lever down), otherwise the roadbreaker relief valve will operate and prevent unloader valve pressure from being reached. 1
Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector D on the loader valve, (see Service Tools, Section 1).
2
With the engine running at 1500 revs/min, slowly operate arms raise or lower.
Note 1: The arms raise or lower service is specified because it has no auxiliary relief valve (A.R.V.). Selecting this service ensures that the pressure vents through the unloader and not an A.R.V. 3
When the service reaches full travel, the gauge reading should rise slowly to unloading pressure then fall back to zero. The maximum reading should be as specified in Technical Data.
4
If the pressure is incorrect, slacken locknut E and adjust cap F. Turn it clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut. If the correct pressure cannot be achieved, add or subtract shims as required, see page E/41-30 and E/41-31 for shim description and location.
Note 2: The illustration shows the unloader pressure test connector D fitted to the loader valve block. On some machines, there is a plug fitted at point D. The pressure test point in this instance is located next to the steering priority valve, it is the same test point that is used to check the steering circuit pressures.
F E
D S197670
9803/3260
Issue 1
Section E
Hydraulics Valves
42 - 12
Section E 42 - 12
'Husco' Loader Valve - Pressure Testing Shovel Ram Head Side A.R.V. (In Position) Testing of A.R.V's on the machine should be avoided (use hand pump method as described on page E/45-1). However, the procedure described below is a secondary checking method which can be used if no hand pump is available. Procedure Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F). Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to test connector A on the loader valve. (See Service Tools, Section 1.) Run the engine at 1000 revs/min, hold the shovel ram fully open and check the maximum gauge reading, which should equal the operating pressure shown in Technical Data. If necessary, adjust as detailed below A.R.V. Adjustment If the pressure is incorrect, the A.R.V. must be adjusted using the procedure described on pages E/45-1 to E/45-4.
A
S197670
9803/3260
Issue 1
Section E
Hydraulics
42 - 13
Valves
'Husco' Loader Valve - Pressure Testing Shovel Ram Rod Side A.R.V.
Section E 42 - 13
X
Testing of A.R.V's on the machine should be avoided (use hand pump method as described on page E/45-1). However, the procedure described below is a secondary checking method which can be used if no hand pump is available. The shovel ram rod side A.R.V. is set at a higher pressure than the M.R.V. (maximum system pressure). To raise the pressure in the shovel ram rod side service line above system pressure it is necessary to disconnect/connect hoses (as shown in the following procedures) so that oil displaced from the LIFT ram (rod side) is fed through the A.R.V. Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F).
S132870
Rest the shovel on the ground, stop the engine and vent all services. Disconnect hoses B and C from metal pipes B1 and C1 respectively, shown at X. Screw a tee piece fitted with a 0-400 bar (0-6000 lbf/in2) pressure gauge to metal pipe B1, shown at Y.
Y
Pull the hose C down from behind the loader arm and fit to the other side of the tee piece as shown at Y. Fit a cap to metal pipe C1 and fit a plug to hose B. Note: For reference, C is the service hose for the shovel ram, rod side. B is the service hose for the lift ram, rod side. With the engine running at 1000 revs/min, select and operate slowly the loader arms lift service until the ram creeps, keep raising the arms slowly until a reading on the pressure gauge is obtained. The highest pressure value shown on the gauge will be the setting of the shovel ram rod side A.R.V. (see Technical Data). If necessary, adjust as detailed below.
S132890
A.R.V . Adjustment If the pressure is incorrect, the A.R.V. must be adjusted using the procedure described on pages E/45-1 to E/45-4.
9803/3260
Issue 1
Section E 43 - 2
Hydraulics
Section E 43 - 2
Valves
161860
9803/3260
Issue 1
Section E
Hydraulics Valves
43 - 3
Section E 43 - 3
Excavator Valve Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. Check Valves Each of the identical load hold check valves 4R to 4W can be removed as shown at 4W. Make-up check valve 4X is a smaller size but otherwise identical. Ensure good condition of seating faces on poppets 4 and 8 and on the mating faces in the valve block. Spools Spools 4A, 4B, 4E and 4F are identical but must not be interchanged as they are matched to their bores. Stabiliser spools 4C and 4D are identical to each other but different from the excavator spools. All spools have the same centring and sealing components items 9 to 21. To completely dismantle a spool, follow the sequence 9 to 21. To prevent spool rotation when turning screw 15, hold a rod through the eye end of the spool. If only renewing the seals, dismantle as far as cap 14 then remove items 15 to 22 as an assembly. Lubricate new seals with JCB Hydraulic Fluid and take care to prevent them from being damaged by the sharp edges of the spool. Apply JCB Lock and Seal to threads of screw 15. Relief Valves A.R.V's 4H to 4P appear identical but have various pressure settings (see page E/1 - 1). Ensure that they are correctly adjusted and fitted in their specified positions. For dismantling and assembly procedure see page E/43 - 4. Note: All hydraulic adapters that are installed together with a bonded sealing washer must also have sealant (Loctite 577) applied to the threads of the adapter. Torque Settings Item 1 5 13 15 23
Nm 122 80 7 11 95
9803/3260
kgf m 12.4 8.3 0.7 1.1 10
lbf ft 90 60 5 8 70
Issue 1
Section E
Hydraulics
Section E 43 - 4
Valves
43 - 4
Excavator Valve - Relief Valves Dismantling and Assembly
Fit back-up ring 13 on the upper side of 'O' ring 12 as shown in the inset.
Eight A.R.V's are fitted at positions 4H to 4Q. These are identical in design but have various pressure settings (see Technical Data).
Fit flat face of sleeve 9 against shoulder of poppet 10.
Note: Valve 4Q is only fitted to machines equipped with a Powerbreaker.
Torque tighten item 14 using the special tool (see Service Tools, Section 1), until its shoulder seats firmly against item 1.
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Pressure test the valve using the procedure described on page E/45-1.
For assembly the sequence should be reversed.
Torque Settings
When Dismantling
Item 1 3
Dismantle sub-assembly 14 from item 1 using a special tool(see Service Tools, Section 1). The special spanner locates in cross holes B.
Nm 65 24
kgf m 6.6 2.5
lbf ft 48 18
Dismantle sub-assembly 14 into its component parts. Make sure that small drilling A is not blocked. Discard old and worn O-rings and back-up rings. When Assembling Renew all O-rings and back-up rings. Lubricate O-rings and back-up rings with JCB Hydraulic Fluid.
161880
9803/3260
161700
Issue 1
Section E 44 - 1
Hydraulics
Section E 44 - 1
Valves
* Hydraclamp Valve (Sideshift Machines) Dismantling and Assembly
When Assembling
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Ensure that orifice X is clear. Lubricate new seals with JCB Hydraulic Fluid.
For assembly the sequence should be reversed. When Dismantling Plug hose 1 to prevent loss of oil and entry of dirt.
Screw item 8 fully home into housing then back-off by no more than 180° until the flats align with capscrew centre-line as shown at A. (This is the 'Clamps Off' position.) Fit plate 6 in position shown and connect clevis 2. If necessary, adjust position of clevis 2 so that plate 6 can be operated over full extent of its travel.
* Torque Settings Item 14 16
Nm 7 7
kgf m 0.7 0.7
lbf ft 5 5
164230
9803/3260
Issue 1
Section E
Hydraulics
Section E 44 - 2
Valves
44 - 2
Hydraclamp Valve - from Serial Number 430001 (Sideshift Machines)
Inspect the valve components for scratches, nicks or any other type of damage, particularly on the poppet and seat faces. Replace with new if required.
Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. The following points MUST be avoided when dismantling and assembling the valve: • CONTAMINATION • DAMAGE TO POPPET AND SEAT • DAMAGE TO SEAL GROOVES All or any of the above points may result in possible problems with the valve.
When Assembling Renew all 'O' rings. The parts microfiche will identify the correct seal kit part numbers for items 2, 4, 6, 10 and 14. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. Ensure that the small drilling through the centre of item 3, is clear.
When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the seal grooves. Discard ALL 'O' rings DO NOT use worn or damaged items.
Do not over-tighten the solenoid assembly, it may affect the operation of the solenoid, use the spanner flats and torque tighten to figure indicated in the table below (items 11 and 13). For information, the hydraclamp solenoid valve is the same type as the 'Hydraulic Speed Control' solenoid valve, shown on page E/41-30.
Note that the hydraclamp comprises two separate valve assemblies; 1) the check valve assembly (items 1 to 8); 2) the solenoid assembly (items 11 to 14).
Check the operation of the electric hydraclamp, see page E/11-4 for a description of operation.
When Dismantling
Torque Settings
Loosen nut 1 (turn anti-clockwise) and then remove the check valve assembly from the valve block. If required, the check valve assembly can be dismantled into its component parts (items 1 to 8).
Item 1 3 5 11 13
Nm 13.5 24.5 13.5 5.5 24.5
kgf m 1.4 2.5 1.4 0.5 2.5
lbf ft 10 18 10 4 18
14
13 12
11 10 9
1
2
4
3
5
6
7
8
S217500
9803/3260
Issue 1
Section E
Hydraulics
Section E
Valves
45 - 1
45 - 1
Excavator Valve - Pressure Testing Excavator A.R.V.'s (Using Hand Pump)
4 3
* To pressure test and re-set the auxiliary relief valves (A.R.V.'s), service kit 892/00309 must be used. The service kit comprises; a test block 1, a setting body 2 with adjusting pin 3, a special spanner 4, a T-bar adjuster key 5 and an anti-cavitation lock out bung 6. A.R.V. cartridge removal tool 892/00335 comprises; an extractor cap 11 and a 'C' washer 12.
1
2 6
* Note: Later type LOADER valve blocks are the 'Husco' type, the A.R.V.'s in these valve blocks must be set using the procedures described below. 1
Fit extractor cap 11 over the A.R.V. sub-assembly 7, into the excavator valve block E.
1.2
Fit 'C' washer 12 on top of the extractor cap, but under the anti-cavitation spring seat as shown.
1.3
Unscrew the extractor cap, - the A.R.V. subassembly will withdraw with the extractor cap.
5
S162570A
Remove the complete A.R.V. assembly from the excavator valve block. If the A.R.V. sub-assembly 7 remains in the valve block, proceed as follows: 1.1
@
!
E
!
@
7
S162560
2
Use special spanner 4 located in cross holes A and separate the A.R.V. sub-assembly 7 from its cap 8.
A 4 8 7 3
S162570B
Install adjusting pin 3 into setting body 2.
* Note: Earlier type service kits comprised two types of adjusting pin; one has a screwdriver form and the other an hexagonal form (see inset). Fit the adjusting pin to suit the form in the A.R.V. adjusting screw. Later type kits have a single adjusting pin that can be used on all A.R.V.'s.
2 3 S162570C
9803/3260
Issue 3*
Section F 45 - 2
Hydraulics Valves
Section F 45 - 2
Excavator Valve - Pressure Testing 4
Install the A.R.V. sub-assembly into setting body 2. Make sure that the adjusting pin 3 correctly locates in adjusting screw 9. Make sure that the lock nut 10 correctly locates in the setting body socket - the anti-cavitation cone should still be closed, as shown at B.
5
Install the A.R.V. sub-assembly and setting body into test block 1. Make sure that the assembly is installed in the port marked 'RV' (relief valve).
6
Connect a hydraulic hand pump to port 'P' (pump) of the test block 1. Make sure that the hand pump is filled with JCB Hydraulic fluid. Connect a 0 to 400 bar (0 to 6000 lbf/in2) pressure test gauge to port 'G' (gauge) of the test block 1. Port 'T' (tank) can be left open when using a hydraulic hand pump.
7
Raise the pressure at the valve inlet using the hydraulic hand pump, when the A.R.V. 'cracks' and oil escapes from the port marked 'T' the pressure gauge will indicate the A.R.V. setting. If the A.R.V. setting is correct, move to step 12. If the A.R.V. setting is not correct, move to step 8.
9803/3260
Issue 1
Section F 45 - 3
Hydraulics Valves
Section F 45 - 3
Excavator Valve - Pressure Testing 8
Use the hand pump to raise approximately 172 bar (2500 lbf/in2) pressure at the valve inlet.
Note: Raising the pressure at the valve inlet locks the anticavitation cone C onto its seat, this allows the A.R.V. adjusting screw lock nut 10 to be loosened (step 10). If the pressure is maintained move to step 10. If the pressure falls off rapidly, or if no pressure can be obtained it is possible that the anti-cavitation cone is not seating effectively, in this instance move to step 9.
9
If no pressure can be raised (see step 8) at the valve inlet, remove the A.R.V. assembly and install anticavitation lock-out bung 6 in the port marked 'RV', make sure that the bung O-ring face seal D is facing out. Re-fit the A.R.V. assembly.
Note: The anti-cavitation lock-out bung seals and locks the A.R.V. anti-cavitation function. The bung is only suitable for the test block application and must NEVER be fitted to the excavator valve block. The bung can be extracted using a 3/8 - 16 UNC threaded bolt.
10
Release the A.R.V. adjusting screw lock nut (see note): Engage the nut at the end of setting body 2 using the slot in special spanner 4, turn the nut anti-clockwise to release the A.R.V. adjusting screw lock nut.
Note: Remember, it will not be possible to release the lock nut if there is not approximately 172 bar (2500 lbf/in2) pressure at the valve inlet.
11
Insert T-bar adjuster key 5 into adjusting pin 3. Push the adjusting pin down and make sure it has engaged with the A.R.V. adjusting screw. Rotate the T-bar clockwise to increase the pressure setting and anti-clockwise to decrease the pressure setting. After adjustment, use the slot in spanner 4 to lock the A.R.V. adjusting screw lock nut (see note).
Note: Remember, pressure must be maintained at the valve inlet to ensure the lock nut is tightened.
9803/3260
Issue 1
Section F 45 - 4
Hydraulics Valves
Section F 45 - 4
Excavator Valve - Pressure Testing 12
When the correct A.R.V. setting has been attained, release the pressure in the test block. Remove the A.R.V. sub-assembly and its setting body from the test block. Separate the A.R.V. sub-assembly from its setting body. Install the A.R.V. sub-assembly into its cap.
9803/3260
Issue 1
Section F 45 - 5
9803/3260
Hydraulics Valves
Section F 45 - 5
Issue 1
Section F
Hydraulics
Section F
Valves
45 - 6
45 - 6
Excavator Valve - Pressure Testing (Sideshift Machines) Excavator A.R.V.'s (In Position) Testing of A.R.V's on the machine should be avoided (use hand pump method as described on pages E/45-1 to E/454. However, the procedure described below can be used to check the A.R.V. pressure setting.
4Q 4N
4L 4J
4P 4M
4K 4H
1 - Preparation Position kingpost to the side of the machine as shown at A. Slew kingpost to the operator's right and engage boom lock Z. Stop engine. Operate boom and dipper controls to vent pressure. Note: View X shows the normal pipework connections. View Y shows the pipework connected ready for the test. The upper hoses K are for the attachment service. When no attachment is fitted, hose E will be the top hose on the kingpost.
! WARNING
It is dangerous to disconnect hoses without engaging the boom lock first. HYD 2-1
Disconnect hose B from pipe C and fit plug 892/00057 to hose B. Fit tee-piece D (892/00048) to pipe C and connect a 0-400 bar (0-6000 lbf/in2) gauge as shown. Disconnect hose E from pipe F and fit plug 892/00057 to hose E. Fit additional test hose G (613/02000) between tee piece D and pipe F. This links the rod side of the dipper ram to the boom rod side port on the valve block. Connections will now be as shown at view Y.
A.R.V. Position Key
2 - Testing Start engine and close dipper ram by selecting 'boom raise' at the same time as 'dipper out'.
Control Layout JCB
ISO
Case
Ford
Run engine at 1000 revs/min and slowly select 'dipper in'. When the dipper ram just starts to open, check gauge reading which will indicate the operating pressure of boom rod side A.R.V. (see Technical Data for correct pressure).
Slew Right
4H
4H
4H
4H
Slew Left
4J
4J
4J
4J
If the pressure is incorrect, the A.R.V. msut be adjusted using the procedure described on pages E/45-1 to E/45-4.
Dipper Rod
4N
4L
4K
4N
Dipper Head
4M
4K
4L
4M
Note: The position of the boom rod side A.R.V. varies according to the excavator control pattern (see table).
Bucket Rod
4Q
4Q
4Q
4P
Bucket Head
4P
4P
4P
4Q
Move each A.R.V. in turn to the boom rod side position and repeat the test for each A.R.V.
Note: The bucket rod side A.R.V. is only fitted to machines equipped with a Powerbreaker.
Boom Rod
4K
4M
4M
4K
Boom Head
4L
4N
4N
4L
When testing is complete, return all A.R.V's to their original positions and reconnect pipework as shown at X.
9803/3260
Issue 2*
Section F 45 - 7
9803/3260
Hydraulics Valves
Section F 45 - 7
Issue 1
Section F
Hydraulics
Section F
Valves
45 - 8
45 - 8
Excavator Valve - Pressure Testing (Centremount Machines) Excavator A.R.V's. (In Position) Testing of A.R.V's on the machine should be avoided (use hand pump method as described on pages E/45-1 to E/454). However, the procedure described below is a secondary checking method which can be used if no hand pump is available.
4Q 4N
4L 4J
4P 4M
4K 4H
1 Preparation Position boom central as at A and engage boom lock Z. Stop engine. Operate boom and dipper controls to vent pressure. Note: Views X show the normal pipework connections. View Y shows the pipework connected ready for the test. The upper pipes K are for the attachment service. If no attachment is fitted, hose E will be the top hose on the kingpost.
! WARNING It is dangerous to disconnect hoses without engaging the boom lock first. HYD 2-1
Disconnect hose B from pipe C and fit plug 892/00057 to hose B. Fit tee-piece D (892/00048) to pipe C and connect a 0-400 bar (0-6000lbf/in2) gauge as shown. Disconnect hose E from pipe F and re-connect hose E to tee-piece D. Connections will now be as shown at Y. 2 Testing Start engine and close dipper ram by selecting 'boom raise' at the same time as 'dipper out'. Run engine at 1000 revs/min and slowly select 'dipper in'. When the dipper ram just starts to open, check gauge reading which will indicate the operating pressure of the boom rod side A.R.V. (see Technical Data for correct pressure).
A.R.V. Position Key
If the pressure is incorrect, the A.R.V. must be adjusted using the procedure described on pages E/45-1 to E/45-4.
Slew Right
4H
4H
4H
4H
Slew Left
4J
4J
4J
4J
Note: The position of the boom rod side A.R.V. varies according to the excavator control pattern (see table). Move each A.R.V. in turn to the boom rod side position and repeat the test for each A.R.V. When testing is complete, return all A.R.V's to their original positions and reconnect pipework as shown at X.
Control Layout JCB
ISO
Case
Ford
Boom Rod
4K
4M
4M
4K
Boom Head
4L
4N
4N
4L
Dipper Rod
4N
4L
4K
4N
Dipper Head
4M
4K
4L
4M
Bucket Rod
4Q
4Q
4Q
4P
Bucket Head
4P
4P
4P
4Q
Note: The bucket rod side A.R.V. is only fitted to machines equipped with a Powerbreaker.
9803/3260
Issue 1
Section E 46 - 2
Hydraulics
Section E 46 - 2
Valves
108100
9803/3260
Issue 1
Section E
Hydraulics
46 - 3
Valves
Section E 46 - 3
* Hose Burst Protection Valve (to Machine Serial No. 402173) This type of HBPV is fitted to the dipper and boom rams. Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. Note: Port connections are identified by the codes C1 , C2, V1, and V2 which are stamped on the body of the valve. When Dismantling To avoid disturbing pressure settings, remove cartridges by unscrewing hexagons 1 and 5 and do not remove capnuts 22 or 25. To eject piston 12, apply compressed air to the small pilot drilling inside port V1. Then use a thin rod to push out spool 15 in the opposite direction to piston 12. Do not try to dismantle sequence valve cartridge 1. To clean, use a non-metallic probe to operate the plunger while the nose of the cartridge is submersed in cleaning fluid. When Assembling Check condition of all visible seating faces. If any are damaged, renew complete cartridge or valve assembly. Ensure that small drilling A through poppet 3 is not blocked. Renew all seals, ensuring that the black 'O' rings are fitted into the grooves before the white back-up rings. When refitting valve to machine, ensure that pressure settings are correct (seeTechnical Data).
9803/3260
Issue 2*
Section E 46 - 4
9803/3260
Hydraulics Valves
Section E 46 - 4
Issue 1
Section E
Hydraulics
Section E 46 - 5
Valves
46 - 5
* Hose Burst Protection Valves (to Machine Serial No. 402173) Pressure Testing - Dipper Ram Sequence Valve Setting Procedure Preparation Before starting the pressure testing procedure vent hydraulic system pressure as follows:
The sequence valve is set using a functional test. Before commencing with the test allow the machine hydraulics to warm up.
1
Fully extend the dipper and then operate the dipper control lever to retract the dipper slightly, this will reduce pressure on the dipper ram rod side.
1
Make sure that the relief valve is set at the correct pressure, as detailed in 'Relief Valve Pressure Test'.
2 2
Lower the boom until the bucket is resting on the ground as shown at X.
Position the machine so that the boom is raised and the dipper extended, as shown at Z.
3
Set the engine revs to 1000 RPM.
3
Switch off the engine. 4
4
Operate all the excavator control levers back and forth to vent hydraulic pressure from the services.
Operate the dipper control lever to bring the dipper in slowly, the dipper movement should be smooth.
5
If the dipper movement is irregular or 'juddering' remove cap C and its copper washer, adjust the sequence valve setting:
Relief Valve Pressure Test If the hose burst protection valve has been stripped and cleaned, then pre-set the valve as detailed in step 1. The pressure test procedure is described in steps 2 to 5. For information; one full turn of the relief valve adjusting screw is equivalent to approximately 90 bar (1300 lbf/in2). 1
a
Using an Allen key, turn the adjusting screw anticlockwise to remove all tension.
b
Turn the adjusting screw clockwise until 'judder' is removed.
c
Refit the cap and washer.
Pre-set the relief valve: a
Remove cap B and its copper washer. Using an Allen key, turn the adjusting screw anti-clockwise to remove all tension
b
Using your fingers, turn the adjusting screw clockwise until a soft force (resistance) is felt.
c
Using an Allen key, turn the adjusting screw a further 3 1/2 turns (315 bar, 4570 lbf/in2) to pre-set the relief valve. Refit the cap and washer.
2
Remove plug A and screw a tee piece fitted with a 0400 bar(0-6000 lbf/in2) pressure gauge to the valve in place of A.
3
Connect a hand pump to the other end of the tee piece as shown at Y. Make sure that the hand pump has been filled with oil.
4
Use the hand pump to increase the pressure, the maximum gauge reading will be the setting of the hose burst relief valve (see Technical Data). If necessary, adjust as detailed in the next paragraph.
5
Remove cap B and its copper washer. Using an allen key, turn the adjusting screw clockwise to increase the pressure and anti-clockwise to decrease the pressure. Replace the cap and washer. Repeat pressure test, adjust as necessary.
9803/3260
Issue 2*
Section E 46 - 6
Hydraulics
Section E 46 - 6
Valves
147050
9803/3260
Issue 1
Section E
Hydraulics
Section E 46 - 7
Valves
46 - 7
* Hose Burst Protection Valves (to Machine Serial No. 402173) Pressure Testing - Boom Ram Preparation Before starting the pressure testing procedure vent hydraulic system pressure as follows: 1
Bring the dipper in and fully raise the boom, operate the boom control lever to lower the boom slightly, this will reduce pressure on the boom ram rod side.
2
Slew the backhoe to one side as shown.
3
Move the dipper out slightly and bring the bucket to rest on a block of wood, as shown at X (see Note).
4
Switch off the engine.
5
Operate all control levers back and forth to vent hydraulic system pressure from the services.
4
Use the hand pump to increase the pressure, the maximum gauge reading will be the setting of the hose burst relief valve (see Technical Data). If necesary, adjust as detailed in the next paragraph.
5
Remove cap B and its copper washer. Using an allen key, turn the adjusting screw clockwise to increase the pressure and anti-clockwise to decrease the pressure. Replace the cap and washer. Repeat pressure test, adjust as necessary.
Sequence Valve Setting Procedure
Note: When testing the H.B.P.V. on the boom ram, a hand pump is attached to the 'raise' (rod) side of the boom ram. If the bucket is brought to rest on the ground during the preparation stage, the boom will have to travel further (than if brought to rest on a block of wood) before the H.B.P.V. 'cracks' or opens. Relief Valve Pressure Test If the hose burst protection valve has been stripped and cleaned, then pre-set the valve as detailed in step 1. The pressure test procedure is described in steps 2 to 5. For information; one full turn of the relief valve adjusting screw is equivalent to approximately 90 bar (1300 lbf/in2). 1
The sequence valve is set using a functional test. Before commencing with the test allow the machine hydraulics to warm up. 1
Make sure that the relief valve is set at the correct pressure, as detailed in 'Relief Valve Pressure Test'.
2
Raise the boom as shown at Z.
3
Set the engine revs to 1000 RPM.
4
Operate the boom control lever to lower the boom slowly, the boom movement should be smooth.
5
If the boom movement is irregular or 'juddering' remove cap C and its copper washer, adjust the sequence valve setting: a
Using an Allen key, turn the adjusting screw anticlockwise to remove all tension.
b
Turn the adjusting screw clockwise until 'judder' is removed.
c
Refit the cap and washer.
Pre-set the relief valve: a
Remove cap B and its copper washer. Using an Allen key, turn the adjusting screw anti-clockwise to remove all tension.
b
Using your fingers, turn the adjusting screw clockwise until a soft force (resistance) is felt.
c
Using an Allen key, turn the adjusting screw a further 3 1/2 turns to pre-set the relief valve. Refit the cap and washer.
2
Remove plug A and screw an elbow joint piece fitted with a length of hose in place of A.
3
Connect a hand pump fitted with a 0-400 bar (0-6000 lbf/in2) pressure gauge to the other end of the hose as shown at Y. Make sure that the hand pump has been filled with hydraulic oil.
9803/3260
Issue 2*
Section E 47 - 1
9803/3260
Hydraulics Valves
Section E 47 - 1
Issue 1
Section E 47 - 2
Hydraulics
Section E 47 - 2
Valves
Hose Burst Protection Valves (from Machine Serial No. 402174) This type of HBPV is fitted to the dipper, boom and loader arm rams. Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.
When Assembling DO NOT apply JCB Lock & Seal or any other type of locking fluid to the threads of item 17. The threads form an integral part of the valve operating sequences - applying locking fluid to the threads will seriously effect the operation of the valve. Ensure that the small drilled holes C and D in items 2 and 17 respectively are not blocked.
When Dismantling If possible, avoid disturbing pressure settings, remove cartridges by unscrewing hexagons 1 and 13 and do not remove capnuts 3 and 16.
Renew all seals. If fitting new Teflon rings A & B, use a conical guide, such as item E, to expand the rings gradually. Complete the ring fitting procedure as quickly as possible, otherwise the ring will stretch. See below.
Spool 2 and check valve 11 each have a Teflon ring fitted (items A and B respectively). These Teflon rings should only be removed and replaced with new ones if they are damaged.
E
Do not try to dismantle items 20, 21 and 22 (these items are shown for pictorial reference only). To clean, use a nonmetallic probe to move the ball 21 against spring 22 whilst assembly 17 is submersed in cleaning fluid. Note: HBPV's fitted to the loader arm lift circuits do not have restrictor ball 21 fitted. Check condition of all visible seating faces. If any are damaged, renew complete cartridge or valve assembly. Check valve bores and spools for nicks, scratches or scoring, if necessary, renew complete cartridge or valve assembly.
B
F 11 A183490
Note: There is an O-ring F fitted underneath each Teflon ring, if the Teflon rings are to be renewed, make sure that new O-rings are fitted first. After assembly, make sure that the valve parts move freely, if they don't, check that all the seals are correctly fitted. After refitting the valve to the machine, ensure that pressure settings are correct (see Technical Data, page E/1-2). If the pressure settings were disturbed, then the valve must be re-set, refer to the pressure testing procedures on pages E/47-3 to E/47-8.
9803/3260
Issue 2
Section E 47 - 3
Hydraulics
Section E 47 - 3
Valves
181480
9803/3260
Issue 1
Section E 47 - 4
Hydraulics
Section E 47 - 4
Valves
Hose Burst Protection Valves (from Machine Serial No. 402174) Pressure Testing - Dipper Ram Relief Valve Pressure Test Preparation Before starting the pressure testing procedure, vent hydraulic system pressure as follows: 1
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the loader arms to the ground.
2
Lower the stabilisers so that the stabiliser pads are just touching the ground (not lifting the machine).
3
Manoeuvre the boom and dipper into the position shown at Y (on sideshift machines, make sure the backhoe assembly is set central). Make sure dipper ram rod extension is approximately 25 - 50 mm (1 - 2 in), shown at W.
4
Select 'BOOM LOWER' to raise the stabiliser pads approximately 25 - 50 mm (1 - 2 in) off the ground, shown at X.
If the hose burst protection valve has been stripped and cleaned, then pre-set the valve as detailed in step 1. The pressure test and setting procedure is described in steps 2 to 7. 1
Pre-set the relief valve: a
Remove cap B and its copper washer. Using an Allen key, turn the adjusting screw anti-clockwise to remove all tension.
b
Using your fingers, turn the adjusting screw clockwise until a soft force (resistance) is felt.
c
Using an Allen key, turn the adjusting screw a further 21/4 turns to pre-set the relief valve. Refit the cap and washer.
2
Remove hose G from port C2. Plug and cap the hose and valve port adapter respectively (the valve port adapter MUST be capped, otherwise the test procedure will not work).
5
Switch off the engine.
6
Make sure all personnel are clear of the machine before completing step 7.
3
Remove hose J from port V2, plug the hose but DO NOT cap the valve port adapter.
7
Select 'DIPPER OUT' - this will vent residual hydraulic pressure from the dipper ram (rod side), shown at Z.
4
Remove plug A and screw a tee piece fitted with a 0400 bar (0-6000 lbf/in2) pressure gauge to the valve in place of A.
8
Move all the backhoe control levers back and forth to vent any other residual hydraulic pressure from the backhoe service hoses.
5
Connect a hand pump to the other end of the tee piece as shown at Y. Make sure that the hand pump has been filled with hydraulic oil.
6
Use the hand pump to increase the pressure. When the pressure reaches the setting of the relief valve, oil will escape from port V2, shown at K. Note the maximum gauge reading (the setting of the hose burst relief valve) which should be 250 bar (3625 lbf/in2).
7
If necessary, adjust the pressure setting as follows:
Pilot Valve Setting Procedure The pilot valve assembly, shown at C, must be set correctly before doing the relief valve pressure test. If the pilot valve is screwed too far into the HBPV it will create a flow path connection from port C2 to port V2 (see descriptions of operation). To Set the pilot valve assembly: 1
Remove pilot housing, item D, from the HBPV.
2
Check that the end face of the pilot valve assembly, item C, is flush (level) with the end face of its housing D, as shown at E.
3
If necessary, remove end cap F and, using a suitable Allen key, adjust the pilot valve as required.
4
Refit the end cap.
9803/3260
a
Remove cap B and its copper washer.
b
Using an Allen key, turn the adjusting screw clockwise to increase the pressure or anticlockwise to decrease the pressure. For information; one full turn of the relief valve adjusting screw is equivalent to approximately 110 bar (1595 lbf/in2).
c
Replace the cap and washer.
d
Repeat pressure test, adjust as necessary.
Issue 1
Section E 47 - 5
9803/3260
Hydraulics Valves
Section E 47 - 5
Issue 1
Section E 47 - 6
Hydraulics
Section E 47 - 6
Valves
Hose Burst Protection Valves (from Machine Serial No. 402174) Pressure Testing - Boom Ram Preparation Before starting the pressure testing procedure vent hydraulic system pressure as follows: 1
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the loader arms to the ground.
Relief Valve Pressure Test If the hose burst protection valve has been stripped and cleaned, then pre-set the valve as detailed in step 1. The pressure test procedure is described in steps 2 to 6. 1
Pre-set the relief valve:
2
Lower the stabilisers so that the stabiliser pads are just touching the ground (not lifting the machine).
a
3
Manoeuvre the boom and dipper into the position shown at Y (on sideshift machines, make sure the backhoe assembly is set central).
Remove cap B and its copper washer. Using an Allen key, turn the adjusting screw anti-clockwise to remove all tension.
b
Using your fingers, turn the adjusting screw clockwise until a soft force (resistance) is felt.
c
Using an Allen key, turn the adjusting screw a further 21/4 turns to pre-set the relief valve. Refit
4
Select 'DIPPER LOWER' to raise the stabiliser pads approximately 25 - 50 mm (1 - 2 in) off the ground, shown at Z.
5
Switch off the engine.
6
Make sure all personnel are clear of the machine before completing step 7.
7
8
the cap and washer. 2
Remove hose G from port C2. Cap and plug the hose and valve port adapter (the valve port adapter MUST be plugged, otherwise the test procedure will not work).
Select 'BOOM RAISE' - this will vent residual hydraulic pressure from the boom ram (rod side), shown at X.
3
Remove hose J from port V2. Plug the hose but DO NOT cap the valve port adapter.
Move all the backhoe control levers back and forth to vent any other residual hydraulic pressure from the backhoe service hoses.
4
Remove plug A and in its place fit a 0-400 bar (0-6000 lbf/in2) pressure gauge connected to a hand pump.
Pilot Valve Setting Procedure The pilot valve assembly, shown at C, must be set correctly before doing the relief valve pressure test. If the pilot valve is screwed too far into the HBPV it will create a flow path connection from port C2 to port V2 (see descriptions of operation).
Note: The working space around the boom ram HBPV is limited, for this reason it may be necessary to fit an elbow joint in place of plug A. Connect a hose of suitable length to the elbow joint and then connect a hand pump and pressure gauge to the other end of the hose. 5
Use the hand pump to increase the pressure. When the pressure reaches the setting of the relief valve, oil will escape from port V2, shown at K. Note the maximum gauge reading (the setting of the hose burst relief valve) which should be 250 bar (3625 lbf/in2).
6
If necessary, adjust the pressure setting as follows:
To set the pilot valve assembly: 1
Remove pilot housing, item D, from the HBPV.
2
Check that the end face of the pilot valve assembly, item C, is flush (level) with the end face of its housing D, as shown at E.
3
If necessary, remove end cap F and, using a suitable Allen key, adjust the pilot valve as required.
4
Refit the end cap.
9803/3260
a
Remove cap B and its copper washer.
b
Using an Allen key, turn the adjusting screw clockwise to increase the pressure or anticlockwise to decrease the pressure. For information; one full turn of the relief valve adjusting screw is equivalent to approximately 110 bar (1595 lbf/in2).
c
Replace the cap and washer.
d
Repeat pressure test, adjust as necessary.
Issue 1
Section E 47 - 7
9803/3260
Hydraulics Valves
Section E 47 - 7
Issue 1
Section E 47 - 8
Hydraulics
Section E 47 - 8
Valves
Hose Burst Protection Valves (H.B.P.V.) (from Machine Serial No. 402174) Pressure Testing - Loader Arms Lift Ram The following text describes the pilot valve setting procedures and pressure testing sequences for ONE HBPV only, repeat the procedures for BOTH loader arm lift rams. Preparation Before starting the pressure testing procedure vent hydraulic system pressure as follows: 1
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.
2
Lower the loader arms to the ground (not lifting the machine).
3
Select 'ARMS LOWER' to raise the front wheels approximately 25 - 50 mm (1 - 2 in) off the ground.
4
Switch off the engine.
5
Make sure all personnel are clear of the machine before completing step 6.
6
7
Relief Valve Pressure Test If the hose burst protection valve has been stripped and cleaned, then pre-set the valve as detailed in step 1. The pressure test procedure is described in steps 2 to 6. 1
a
Remove cap B and its copper washer. Using an Allen key, turn the adjusting screw anti-clockwise to remove all tension.
b
Using your fingers, turn the adjusting screw clockwise until a soft force (resistance) is felt.
c
Using an Allen key, turn the adjusting screw a further 21/4 turns to pre-set the relief valve. Refit the cap and washer.
2
Remove hose G from port C2. Cap and plug the hose and valve port adapter (the valve port adapter MUST be plugged, otherwise the test procedure will not work).
Select 'ARMS RAISE' - this will vent residual hydraulic pressure from the loader rams (head side).
3
Remove hose J from port V2. Plug the hose but DO NOT cap the valve port adapter.
Move all the backhoe control levers back and forth to vent any other residual hydraulic pressure from the backhoe service hoses.
4
Remove plug A and in its place fit a 0-400 bar (0-6000 lbf/in2) pressure gauge connected to a hand pump.
5
Use the hand pump to increase the pressure. When the pressure reaches the setting of the relief valve, oil will escape from port V2, shown at K. Note the maximum gauge reading (the setting of the hose burst relief valve) which should be 250 bar (3625 lbf/in2).
6
If necessary, adjust the pressure setting as follows:
Pilot Valve Setting Procedure The pilot valve assembly, shown at C, must be set correctly before doing the relief valve pressure test. If the pilot valve is screwed too far into the HBPV it will create a flow path connection from port C2 to port V2 (see descriptions of operation). To set the pilot valve assembly: 1
Remove pilot housing, item D, from the HBPV.
2
Check that the end face of the pilot valve assembly, item C, is flush (level) with the end face of its housing D, as shown at E.
3
If necessary, remove end cap F and, using a suitable Allen key, adjust the pilot valve as required.
4
Pre-set the relief valve:
a
Remove cap B and its copper washer.
b
Using an Allen key, turn the adjusting screw clockwise to increase the pressure or anticlockwise to decrease the pressure. For information; one full turn of the relief valve adjusting screw is equivalent to approximately 110 bar (1595 lbf/in2).
c
Replace the cap and washer.
d
Repeat pressure test, adjust as necessary.
Refit the end cap.
9803/3260
Issue 1
Section E
Hydraulics Valves
48 - 2
Section E 48 - 2
Stabiliser Check Valve (With Relief Valve) Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. When Assembling
Relief Valve Pressure Testing Connect a hydraulic hand pump and pressure gauge to the port identified 'C' on the valve block. Raise the pressure until hydraulic fluid emerges through drilling A, indicating that the relief valve has opened. Check that the pressure gauge reading is as given in Technical Data. Adjust at 12 if necessary.
Renew all seals and 'O' rings. Lubricate with JCB 'Special' Hydraulic Fluid. Torque Settings Item 1
Nm 61
9803/3260
kgf m 6.2
lbf ft 45
Issue 1
Section E
Hydraulics Valves
48 - 4
Section E 48 - 4
Stabiliser Check Valve Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. When Assembling Renew all seals and 'O' rings. Lubricate with JCB 'Special' Hydraulic Fluid. Torque Settings Item 1
Nm 61
9803/3260
kgf m 6.2
lbf ft 45
Issue 1
Section E
Hydraulics
Section E 49 - 1
Valves
49 - 1
Priority Valve Removal and Replacement
Dismantling and Assembly
The priority valve is mounted on the left hand side chassis member, behind the hydraulic tank. It is attached to the chassis member by one bolt A, and is accessible from below.
The numerical sequence shown on the illustration is intended as a guide to dismantling.
There are four connections to the valve as follows:
When Dismantling
P CF EF LS PP
-
from hydraulic pump to steering valve to valve block pilot connection from steering valve port is plugged
When replacing always renew sealing washers 2, 4, 6, and 10.
For assembly the sequence should be reversed.
Press out the spool item 14 using a nylon pin. Take care not to damage the bores of the valve. When Assembling Make sure that spring seat of spool 14 faces toward LS connection. Clean all parts in clean paraffin. Lubricate all parts with hydraulic fluid. Renew aluminium washers 8 and 12. Note: All hydraulic adapters that are installed together with a bonded sealing washer must also have sealant (Loctite 577) applied to the threads of the adapter. Torque Settings Item 7 11
Nm 50 50
lbf ft 37 37
! WARNING Make the machine safe before getting beneath it. Lower attachments to the ground; engage the parking brake; remove the starter key, disconnect the battery.
* the
2-3-2-2
To bleed the LS line, start the engine, loosen the connection
* on the valve, turn and hold the steering wheel fully in either direction. When bubble free oil flows from the joint, tighten the connection.
9803/3260
Issue 2*
Section E
Hydraulics
50 - 1
Section E 50 - 1
Valves
Hydraulic Steering Unit Removal and Replacement When Removing
When Replacing
Park the machine on level ground, engage the parking brake and set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.
Replacement is a reversal of the removal sequence.
Turn the steering wheel to the left and to the right several times to vent system pressure. Remove bolts A and take off the steering pedestal cover B to gain access to the steering unit. Disconnect and cap all hydraulic hoses from the steering unit. Label the hoses to ensure correct refitting. Take hold of the steering unit, loosen and remove bolts C. Lift the steering unit from the machine.
Make sure that the hoses are correctly installed. The hose connections are as follows: P L R LS T
-
to priority valve (CF port) to steering valve assembly (P port) to front axle to priority valve (pilot connection, LS port) to tank
Bleed the steering system, see page E/52 - 1. If a new steering unit has been fitted then the system relief valve must be tested for correct pressure setting, see page E/50 - 7. Note: All hydraulic adapters that are installed together with a bonded sealing washer must also have sealant (Loctite 577) applied to the threads of the adapter.
S147670
9803/3260
Issue 1
Section E 50 - 2
Hydraulics Valves
Section E 50 - 2
S10221A
9803/3260
Issue 1
Section E 50 - 3
Hydraulics Valves
Section E 50 - 3
Hydraulic Steering Unit Dismantling and Assembly Use the numerical sequence on page E/50 - 2 as a guide to dismantling. During manufacture, a small mark X will have been made on sleeve 12 and spool 15, close to one of the slots for the centring springs 13. Before removing the centring springs, check that this mark is visible; if not, make a new mark to ensure correct assembly. Shock valves (items 29 to 35) are pressure set during manufacture and the adjusting screw 31 secured with Loctite. Due to the difficulty of resetting the pressure it is recommended that the valves are not disturbed. If dismantling is unavoidable, however, measure and record the depth of adjusting screw 31 below the top face of the steering unit before removing the screw. Assembly Note: The unit illustrated in the following sequence represents a typical Danfoss valve. The relief valve (items 25 to 28) and shock valves (items 29 to 35) are not therefore shown in the photographs. 1
Fit spool 15 into sleeve 12, aligning slots for centring springs 13 and checking that the small marks X are aligned. Ensure that three slots in spool partially uncover three holes in sleeve, as at A.
2
Fit two flat centring springs 13 with four curved springs between them, as shown at B.
3
Fit seal 24 into steer unit body and insert sleeve of tool 892/00180. Fit back up ring 20 and seal 21 onto plastic boss, and position on tool spindle, as shown.
9803/3260
Issue 1
Section E
Hydraulics Valves
50 - 4
Hydraulic Steering Unit
50 - 4
- Assembly (continued)
4
Lower steering unit body and tool sleeve over tool spindle until plastic bush is flush with end of bore. Assemble sleeves 12 and 15 with cross pin 14 and centring springs 13. Fit bearing components 16 to 19 with chamfered face of 17 facing away from bearing 18.
5
Remove body from tool leaving plastic bush in position, and lower body over assembled spool.
6
Apply downward pressure on body until plastic boss is forced out of bore, leaving seals correctly located.
7
Invert unit and place on a suitable hollow support so that body does not rest on protruding sleeve, thus preventing displacement of the new seals (support example is a pump drive housing). Place ball 23 into check valve hole and fit bush 22.
9803/3260
Section E
Issue 1
Section E
Hydraulics Valves
50 - 5
Hydraulic Steering Unit
50 - 5
- Assembly (continued)
8
Fit new 'O' ring 10.
9
Fit distributor plate 9 ensuring that holes align. Locate shaft 11 onto cross-pin 14, noting position of slot. When rotor 7 is fitted, slot must align with hollows of rotor as shown at C.
10
Use a suitable piece of rigid flat material, 0.25mm (0.010 in.) thick, to support the shaft and ensure positive engagement with the splines of rotor 7.
11
Locate rotor onto shaft, ensuring alignment as at C. Fit spacing bush 6 into rotor.
9803/3260
Section E
Issue 1
Section E
Hydraulics Valves
50 - 6
Hydraulic Steering Unit
Section E 50 - 6
- Assembly (continued)
12
Fit 'O' rings 4 and 8 each side of body 5, then position body over rotor.
13
Refit the end plate and fit at least one bolt 2 before removing support material.
14
Fit remaining bolts, ensuring that special bolt 1 is correctly located. Tighten all bolts to 29Nm (22 lbf ft).
Pressure Relief Valve Cartridge After renewing the 'O' ring, torque tighten the cartridge to 50Nm (37lbf ft). The valve is preset at 120bar (122kgf/cm2, 1740lbf/in2) but the setting should be rechecked after fitting the steering unit to the machine (see page E/50 - 7). Shock Valves If the shock valves have been dismantled, clean the threads of adjusting screw 31 and the threads in the bore of the steering unit body using Super Clean Safety Solvent and allow to dry. Assemble seat 35, ball 34, cap 33 and spring 32 then coat threads of screw 31 with JCB Lock and Seal. Assemble screw to depth measured during dismantling (see page E/50 - 3) then fit plug 29 and washer 30.
9803/3260
Issue 1
Section E
Hydraulics Valves
50 - 7
Section E 50 - 7
Steering System - Pressure Testing Park the machine on level ground, engage the parking brake and set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key. Turn the steering wheel to the left and to the right several times to vent system pressure.
! WARNING Make the machine safe before working underneath it. Park the machine on level ground, lower the arms. Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-2
The pressure test point for the steering circuit is fitted next to the priority valve as shown. Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to test adaptor A.
*
Run the engine at 1500 revs/min and turn the steering to full lock. Check the gauge reading which should equal the relief valve pressure given in Technical Data. Note: The steering wheel must be held on full lock whilst the gauge reading is being checked. If necessary, adjust the pressure setting by removing plug B, on the orbitrol steering unit. Adjust screw C using an 'allen key' until the correct pressure is shown on the gauge. Refit plug B.
9803/3260
Issue 2*
Section E
Hydraulics
Section E 51 - 1
Valves
51 - 1
Steering Valve Assembly (AWS Machines) Removal and Replacement
When Replacing
When Removing
Replacement is a reversal of the removal sequence.
Park the machine on level ground, engage the parking brake and set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.
Make sure that the electrical solenoid connections are refitted in the correct position.
! WARNING
Make sure that the hoses are correctly installed. The hose connections from the steer valve assembly are as follows:
Make the machine safe before working underneath it. Park the machine on level ground, lower the arms. Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-2
Turn the steering wheel to the left and to the right several times to vent system pressure. The steer valve assembly is fitted to a bracket which is
* mounted on the right hand side of the machine in front of the rear axle. Early type machines have the valve mounted vertically, as shown at Y, and later types are mounted horizontally, as shown at X. Disconnect the electrical solenoid connections, the wires should be identified A, B, C and D as shown.
P B A T
-
to orbitrol steer unit (L port) to left hand rear steer ram (rod side) to right hand rear steer ram (rod side) to front steer rams (rod side - right hand ram, head side left hand ram)
Note: The steer valve ports should be stamped 'P', 'B', 'A' and 'T'. Left and right hand are as viewed from the rear of the machine. For reference, the electrical connections are as follows: Connector A feeds the 2 WHEEL STEER solenoid
* Connector B feeds the 4 WHEEL STEER/CRAB solenoid Connector C feeds the CRAB STEER solenoid
* Connector D feeds the 4 WHEEL STEER solenoid. Bleed the steering system, see page E/52 - 1.
Disconnect and cap all hydraulic hoses from the steering valve assembly. Label the hoses to ensure correct refitting. Take hold of the steering valve, loosen and remove bolts E. Lift the steering valve and its retaining bracket from the machine.
X
Y
S147661
9803/3260
S217510
Issue 3*
Section E
Hydraulics
51 - 2
Section E 51 - 2
Valves
* Steering Valve Assembly (AWS Machines) Dismantling and Assembly
When Assembling
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Renew all 'O' rings.
For assembly the sequence should be reversed. When Dismantling Before dismantling scratch an alignment mark X along the faces of the solenoid valves and the manifold block. Take care not to lose the detent balls A from items 16 and 18.
Lubricate parts with JCB Special Hydraulic fluid before assembling. Use the alignment marks X (see dismantling) to ensure that the solenoids and the manifold block are assembled correctly. Torque Settings
* Item 1
Nm 7.1-9.1
lbf in 63-80
S147650
9803/3260
Issue 2*
Section E 52 - 1
Hydraulics Valves
Section E 52 - 1
Steering System - Bleeding Procedure Whenever any hydraulic steering component is disconnected or removed the system must be bled as follows. With the engine running, this procedure must be carried out in the correct order that is laid down. You must not alter the order of selections and operations.
1
Select 2 Wheel Steer (a) Turn steering wheel to left, until front wheels are fully locked to the left. (b) Turn steering wheel to right, until front wheels are fully locked to the right.
2
Select 4 Wheel Steer (a) Turn steering wheel to left, until front wheels are fully locked to the left.
3
Select 2 Wheel Steer (a) Turn steering wheel to full right lock. (b) Turn steering wheel to full left lock. (c) Turn steering wheel to full right lock.
4
Select 4 Wheel Steer (a) Turn steering wheel to left, until the front wheels are fully locked to the left.
5
Select 2 Wheel Steer (a) Turn steering wheel to full right lock. (b) Turn steering wheel to full left lock. (c) Turn steering wheel to full right lock.
6
Select 4 Wheel Steer (a) Turn steering wheel to left, until front wheels are fully locked to the left.
7
Select 2 Wheel Steer (a) Turn steering wheel to full right lock. (b) Turn steering wheel to full left lock. (c) Turn steering wheel to full right lock.
8
Select 4 Wheel Steer (a) Turn steering wheel to left, until the front and rear wheels are fully locked.
9803/3260
Issue 1
Section E
Hydraulics
Section E 61 - 1
Rams
61 - 1
Typical Ram Dismantling and Assembly When Dismantling Place ram assembly on a locally manufactured strip/rebuild bench as shown. If a split replacement seal is available it is not necessary to remove the piston head in order to renew the wiper seal H. Renew snap ring J. Slacken end cap using special spanner (see Service Tools, Section 1) and remove the piston rod assembly from the cylinder.
A B E H J
! WARNING
If air or hydraulic pressure is used to force out the piston assembly, ensure that the end cap is securely fitted. Severe injury can be caused by a suddenly released piston rod. HYD 1-2
Position piston rod assembly on bench in place of ram cylinder. Remove seals and back-up rings from piston head. Remove snap ring C. Heat piston head to 180-210 °C to degrade the Loctite between piston head and rod. To check temperature, use Surface Temperature Probe (see Service Tools, Section 1). CAUTION: Do not exceed 300 °C or the Loctite will char, causing thread pick-up.
J
! WARNING
To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a wire brush to clean components.
A H B
S249860
HYD 1-3
Remove piston head from rod using special spanner (see Service Tools, Section 1). Remove gland bearing and end cap from piston rod and remove the seals and back-up rings. Ensure that metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the gland seal. When Assembling
X
Clean threads of piston rod, piston head, end cap and cylinder using a wire brush.
*
Use JCB Cleaner & Degreaser to ensure that all threads are free from grease, hydraulic oil and old Loctite. Allow 15 minutes for solvent to dry before applying Loctite. Ensure that lubricants used during assembly do not come into contact with Loctite. ....cont'd
D C S249870
9803/3260
Issue 2*
Section E
Hydraulics
Section E 61 - 2
Rams
61 - 2
Typical Ram When Assembling (cont'd) Refer to the 'Gland Seal Fitting Procedure' on page E/64-1. Fit seal H into end cap first, followed by ring J. Insert seal A and back-up ring B into the end cap. Renew external 'O' ring. Use sleeve F (see Service Tools, Section 1) fitted over piston rod threads to protect the gland seals from damage and the threads from oil and grease. Fit gland bearing into end cap and push the assembly over the sleeve onto the rod. Apply Loctite Activator N to threads of piston rod, end cap and cylinder. Allow Activator to dry for 15 minutes before bringing into contact with Loctite. Note: Neither Loctite nor Activator must be allowed to contact seals, bearing rings, or 'O' rings. Apply Loctite 262 to all threads of piston rod. Renew 'O' ring in piston head, lubricating only the 'O' ring with JCB MPL Grease. Fit and torque tighten the piston head. Fit a new snap ring C. DO NOT re-use the original snap ring.
8030A
Ensure that end damping spring X is engaged with collar and piston head. Note: The end damping spring and collar X are fitted to the dipper ram only. Fit new seals and bearing rings to piston head. Position cylinder on bench and install rod assembly into cylinder. Apply Loctite 932 to thread of end cap, fit a new 'O' ring and torque tighten the end cap into the cylinder. Note: If hydraulic oil contacts uncured Loctite a weakening of the bond will result. Cure times vary according to the ambient temperature and type of Activator used. The following approximate cure times apply at 20 °C and are the minimum periods between assembly and filling the ram with oil. Loctite 262 or 932 with Activator N - 1 hour Loctite 262 or 932 with Activator T - 2 hours Torque Settings Item D E
Nm 405 678
kgf m 41.3 69.2
lbf ft 300 500
Note: Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working.
9803/3260
Issue 1
Section E
Hydraulics
Section E 61 - 3
Rams
61 - 3
Typical Ram (with dowelled piston head) Dismantling and Assembly When Dismantling Place ram assembly on a locally manufactured strip/rebuild bench as shown. Slacken end cap using special spanner (see Service Tools, Section 1) and remove the piston rod assembly from the cylinder.
A B
! WARNING
If air or hydraulic pressure is used to force out the piston assembly, ensure that the end cap is securely fitted. Severe injury can be caused by a suddenly released piston rod.
E H J
HYD 1-2
Position piston rod assembly on bench in place of ram cylinder. Remove seals and back-up rings from piston head. Extract dowel C from the piston head using a metric screw(M3, M4, or M6 depending on ram size) threaded into the extractor hole. Remove piston head from rod using special spanner (see Service Tools, Section 1). Remove gland bearing and end cap from piston rod and remove the seals and back-up rings. Ensure that metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the gland seal.
J
When Assembling
A
Clean threads of piston rod, piston head, end cap and
* cylinder using a wire brush. Use JCB Cleaner & Degreaser to
H S249860
B
ensure that all threads are free from grease, hydraulic oil and old Loctite. Allow 15 minutes for solvent to dry before applying Loctite. Ensure that lubricants used during assembly do not come into contact with Loctite. Refer to the 'Gland Seal Fitting Procedure' on page E/64-1. Fit seal H into end cap first, followed by circlip J. Insert seal A and back-up ring B into the end cap. Renew external 'O' ring.
K
Y
X
Use sleeve F, shown overleaf, fitted over piston rod threads to protect the seals from damage and the threads from oil and grease. Fit gland bearing into end cap and push the assembly over the sleeve onto the rod. Apply Loctite Activator T to threads of end cap and cylinder. Allow Activator to dry for 15 minutes before bringing into contact with Loctite.
C
L
Note: Neither Loctite nor Activator must be allowed to contact seals, bearing rings, or 'O' rings. Ensure that end damping spring X, shown overleaf, is engaged with collar and piston head (dipper ram only).
9803/3260
S151930
Issue 2*
Section E
Hydraulics
Section E 61 - 4
Rams
61 - 4
Typical Ram (with dowelled piston head) When Assembling (cont'd) Fit locking dowel C to piston head/rod as follows:
Note: Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working.
1
Fit 'O' ring L into piston head K.
DRILLING DETAILS FOR PISTON HEAD RETENTION (all dimensions in mm)
2
Fit piston head to piston rod and torque tighten to 405 Nm (300 lbf ft).
Ram Size
Dowel Size
3
New ram Shaft and piston head fitted. - If both are required, the following procedure should be followed:
80 x 50
i
ii
Drill through piston head into piston rod, shown at Z. Use an undersized diameter drill first as a guide and then drill with the correct size diameter drill to suit; refer to the table for drill diameters and depths. Remove all swarf and contamination. Insert dowel C into drilled hole, make sure tapped extractor hole is to outside.
4
New piston head fitted on a pre-drilled piston rod. Re-drill and dowel BOTH the piston head and piston rod at 90° from the existing drilled dowel hole in the piston rod. Follow the procedures described in step 3.
5
New piston rod fitted to a pre-drilled piston head. Use the pre-drilled hole in the piston head. Care must be taken not to elongate the existing hole in the piston head. i
Use a drill the same diameter as the pre-drilled hole in the piston head to make a 'centre mark' in the piston rod. DO NOT drill the piston rod at this stage.
ii
Use an undersized diameter drill as a guide and drill into the piston rod to the required depth (see table), make sure the drill has centred correctly on the 'centre mark' made at step 5i.
iii
Use the correct size diameter drill to suit the dowel and drill to the required depth (see table).
iv
Remove all swarf and contamination, insert the dowel.
Guide Drill Ø
Guide Drill Depth
Dowel Drill Ø X
Dowel Drill Depth Y
6Ø x 20
4
21
6.02/6.10
22/23
90 x 50 8Ø x 25 100 x 60
5
24
8.02/8.10
27/28
110 x 60 12Ø x 30 110 x 65
8
28
12.02/12.10 32/33
120 x 65 12Ø x 35 130 x 75
8
33
12.02/12.10 37/38
8030A
Position cylinder on bench and install rod assembly into cylinder. Apply Loctite 932 to first three threads of cylinder, torque tighten the end cap to 678 Nm (500 lbf ft). Note: If hydraulic oil contacts uncured Loctite a weakening of the bond will result. Cure times vary according to the ambient temperature and type of Activator used. The following approximate cure times apply at 20 °C and are the minimum periods between assembly and filling the ram with oil.
9803/3260
Issue 1
Section E
Hydraulics Rams
62 - 1
Section E 62 - 1
Steer Ram Removal and Replacement This procedure is for a typical steering ram removal and replacement.
! WARNING
Make the machine safe before working underneath it. Park the machine on level ground, lower the arms. Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-2
! WARNING Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut. GEN 3-2
When Removing Disconnect and cap hydraulic hoses to prevent loss of fluid and ingress of dirt. Label hoses for identification and correct refitting. Remove locking bolts A and pivot pins B. Remove steering ram from machine. When Replacing Replace steering ram by reversing the removal procedure. Apply anti-seize paste, part number 4003/0211 to pivot pins B, to facilitate subsequent removal. After connecting hoses check hydraulic fluid level, if necessary top up. Bleed hydraulic steering system (see page E/52 - 1).
9803/3260
Issue 1
Section E 62 - 2
9803/3260
Hydraulics Rams
Section E 62 - 2
Issue 1
Section E
Hydraulics
Section E 62 - 3
Rams
62 - 3
Steer Ram Dismantling and Assembly
When Assembling
The numerical sequence shown on the illustration is intended as a guide to dismantling.
Clean threads of piston rod, piston head, end cap and cylinder using a wire brush.
For assembly the sequence should be reversed.
* Use JCB Cleaner & Degreaser to ensure that all threads are
When Dismantling
free from grease, hydraulic oil and old Loctite. Allow 15 minutes for solvent to dry before applying Loctite.
Place ram assembly on a locally manufactured strip/rebuild bench as shown.
Ensure that lubricants used during assembly do not come into contact with Loctite.
Slacken end cap 1 using special spanner (see Service Tools, Section 1) and remove the piston rod assembly 2 from the cylinder.
Refer to the 'Gland Seal Fitting Procedure' on page E/64-1. Fit seals 10 and 11 into end cap then fit the end cap onto the piston rod.
! WARNING
If air or hydraulic pressure is used to force out the piston assembly, ensure that the end cap is securely fitted. Severe injury can be caused by a suddenly released piston rod. HYD 1-2
Position piston rod assembly on bench in place of ram cylinder. Remove seal and wear rings from piston head. Remove locking ring 3. Heat piston head to 180-210 °C to degrade the Loctite between piston head and rod. To check temperature, use Surface Temperature Probe (see Service Tools, Section 1). CAUTION: Do not exceed 300 °C or the Loctite will char, causing thread pick-up.
! WARNING To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a wire brush to clean components. HYD 1-3
Remove piston head from rod using special spanner (see Service Tools, Section 1). Remove end cap from piston rod and remove the seals and 'O' ring. Ensure that metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the gland seal.
Apply Loctite Activator N to threads of piston rod, end cap and cylinder. Allow Activator to dry for 15 minutes before bringing into contact with Loctite. Note: Neither Loctite nor Activator must be allowed to contact seals, bearing rings, or 'O' rings. Apply Loctite 262 to all threads of piston rod. Renew 'O' ring in piston head, lubricating only the 'O' ring with JCB MPL Grease. Fit and torque tighten the piston head. Fit a new locking ring 3. Fit new seal and wear rings to piston head. Position cylinder on bench and install rod assembly into cylinder. Apply Loctite 932 to thread of end cap, fit a new 'O' ring 9 and torque tighten the end cap into the cylinder. Note: If hydraulic oil contacts uncured Loctite a weakening of the bond will result. Cure times vary according to the ambient temperature and type of Activator used. The following approximate cure times apply at 20 °C and are the minimum periods between assembly and filling the ram with oil. Loctite 262 or 932 with Activator N - 1 hour Loctite 262 or 932 with Activator T - 2 hours Torque Settings Item 7 1
Nm 405 678
kgf m 41.3 69.2
lbf ft 300 500
Note: Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working.
9803/3260
Issue 2*
Section F 64 - 1
Transmission Rams
Section F 64 - 1
Gland Seal Fitting Procedure The size (diameter) and position of pins A is determined by the diameter and radial width of the gland seal being fitted. The pins are screwed into threaded holes in the tool body, the spacing of the holes are designed to suit small or large diameter gland seals. To fit a new gland seal:
1
Open the tool as shown at X and insert the new gland seal, the seal must be fitted behind the two front pins but in front of the rear pin as shown.
2
Close the tool as shown at Y. The seal must form a reniform (kidney shape).
3
Locate the seal in the end cap groove, shown at Z, when the seal is in position, open the tool to release the seal. Make sure the seal is correctly installed in its groove and remove the tool.
9803/3260
Issue 1
Section F
Transmission
Section F
i
i
Contents
Page No.
Technical Data Front Axle - All Wheel Steer Machines - 2 Wheel Steer Machines - 2 Wheel Steer (2 Wheel Drive) Machines Rear Axle - All Wheel Steer Machines - 2 Wheel Steer Machines Tyre Sizes and Pressures - All Wheel Steer Machines - 2 Wheel Steer Machines Syncro Shuttle Transmission Powershift Transmission Pump/Transmission Stall Speed Combinations * - AWS m/c with 11 inch convertor * - 2WS m/c with 11 inch convertor * - AWS m/c with 12.2 inch convertor * - 2WS m/c with 12.2 inch convertor
1-8 1-9 1 - 10 1 - 11
Towing Procedure * Syncro Shuttle Gearbox * Powershift Gearbox
1 - 12 1 - 12
Descriptions Cutaway of Front Axle Cutaway of Rear Axle Syncro Shuttle Transmission - General Description and Operation - Syncromesh - Clutch Operation - 4 Wheel Drive Operation - 2 Wheel Drive Operation - 4 Wheel Drive Operation (from M/C 415012) -2 Wheel Drive Operation (from M/C 415012) Powershift Transmission - General Description - Hydraulic Operation - Drivepaths - Clutch Operation - 2/4 Wheel Drive Operation
9803/3260
1-1 1-1 1-1 1-2 1-2 1-3 1-3 1-4 1-6
2-1 2-2 3-1 3-4 3-5 3-6 3-7 3-8 3-9 4-1 5-1 6-1 7-1 7-1
Fault Finding Syncro Shuttle Transmission 2/4 Wheel Drive Clutch Powershift Transmission 2/4 Wheel Drive Clutch (from M/C 415012)
12 - 1 13 - 1 14 - 1 15 - 1
Propshafts Removal and Replacement
18 - 1
Front Axle Torque Figures Removal & Replacement Proximity Switch Setting Procedure Renewing the Pinion Oil Seal Hub and Driveshaft - Dismantling Hub and Driveshaft - Assembly Drivehead - Dismantling (AWS Machines) Drivehead - Assembly (AWS Machines)
20 - 1 21 - 1 21 - 3 22 - 1 23 - 1 23 - 7 24 - 1 24 - 3 Issue 6*
Section F
Transmission
Section F
ii
ii
Contents * * * *
Page No.
Drivehead - Dismantling (2WS Machines) Drivehead - Assembly (2WS Machines) Removal & Replacement (2 Wheel Drive Machines) Dismantling and Assembly (2 Wheel Drive Machines)
Rear Axle Torque Figures Removal & Replacement Proximity Switch Setting Procedure Renewing the Pinion Oil Seal Brakes - Dismantling Brakes - Assembly Hub and Driveshaft - Dismantling Hub and Driveshaft - Assembly Drivehead - Dismantling Drivehead - Assembly
40 - 1 41 - 1 41 - 3 42 - 1 43 - 1 43 - 4 44 - 1 44 - 1 45 - 1 45 - 4
Limited Slip Differential - Dismantling and Assembly
46 - 1
Syncro Shuttle Transmission Removal & Replacement Gearbox - Dismantling Gearbox - Assembly Solenoid Valve - Dismantling and Assembly Reverser Unit - Dismantling Reverser Unit - Assembly Hydraulic 2/4 Wheel Drive Unit - Dismantling and Assembly (to serial no. 400077) - Dismantling and Assembly (from 400078 to 415011) - Dismantling and Assembly (from serial no. 415012) Torque Converter - Removal Torque Converter - Replacement Torque Converter Stall Test Pressure and Flow Testing Polytetrafluoroethene (PTFE) Piston Ring Seals - Fitting Procedure Powershift Transmission Removal & Replacement Gearbox - Dismantling Gearbox - Assembly Input Clutch & Reverser Clutch - Dismantling - Assembly Mainshaft - Dismantling Mainshaft - Assembly Layshaft - Dismantling Layshaft - Assembly 2/4 Wheel Drive Unit - Dismantling & Assembly Torque Converter - Removal & Replacement Solenoid Identification Torque Converter Stall Test Testing for Clutch Leakage Pressure & Flow Testing
9803/3260
25 - 1 25 - 3 26 - 1 27 - 1
61 - 1 62 - 1 62 - 11 63 - 1 64 - 1 64 - 3 65 - 1 65 - 11 65 - 14 66 - 1 66 - 1 67 - 1 67 - 1 68 - 1
81 - 1 82 - 1 82 - 10 83 - 1 83 - 3 85 - 1 85 - 5 86 - 1 86 - 5 88 - 1 88 - 1 91 - 1 91 - 1 91 - 2 91 - 3
Issue 6*
Section F
Transmission Technical Data
1-1
Section F 1-1
* Front Axle Note: It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle with a different ratio to the axle being replaced.
*
*
*
ALL WHEEL STEER MACHINES Type Designation Installation Number of steer rams Weight (dry, with no steer rams and without wheels) Overall Gear Ratio Crownwheel and Pinion Ratio Number of Teeth Crownwheel Pinion Hub Reduction Input Type Oscillation Toe - in Castor Angle Camber Angle King - pin inclination
2 WHEEL STEER MACHINES (4 Wheel Drive) Type Designation Installation Number of steer rams Weight (dry, with no steer rams and without wheels) Hub Reduction Input Type Oscillation Toe - in Castor Angle Camber Angle King - pin inclination Ratios Overall Crownwheel and Pinion Number of Teeth Crownwheel Pinion 2 WHEEL STEER MACHINES (2 Wheel Drive) Type Installation Weight (dry, with steer ram and without wheels) Oscillation Toe - in Castor Angle Camber Angle
9803/3260
JCB spiral bevel input with epicyclic hub reduction SD70 Centre pivot 2 385 kg (850 lbs) approximately 24.975:1 4.625:1 37 8 5.4:1 Yoke ± 5° 0° 0° 1° 0°
JCB spiral bevel input with epicyclic hub reduction SD55 Centre pivot 1 330 kg (728 lbs) approximately 5.4:1 Yoke ± 5° 0° 0° 1° 0° OPTION 1 OPTION 2 16.2:1 19.2:1 3:1 3.556:1 33 11
32 9
JCB centre oscillation, non-driven Centre pivot 239 kg (525 lbs) ± 5° 0° 0° 3 ° positive
Issue 2*
Section F
Transmission Technical Data
1-2
Section F 1-2
Rear Axle Note: It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle with a different ratio to the axle being replaced. ALL WHEEL STEER MACHINES Type Designation Installation Number of steer rams Weight (dry, with no steer rams and without wheels) Half (Axle) Shaft Braking/Type Input Type Oscillation Toe - in Castor Angle Camber Angle King - pin inclination Hub Reduction Ratios Overall Crownwheel and Pinion Number of Teeth Crownwheel Pinion
3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard braking SD70 Rigid pad mount 2 410 kg (904 lbs) approx. 5 plate (each half shaft) Yoke ± 5° 0° 0° 1° 0° 5.4:1 OPTION 1 OPTION 2 15.78:1 18.16:1 2.923:1 3.363:1 38 13
37 11
* 2 WHEEL STEER MACHINES Type Designation Installation Weight (dry and without wheels) Half (Axle) Shaft Braking/Type Input Type Hub Reduction Ratios Overall Crownwheel and Pinion Number of Teeth Crownwheel Pinion
9803/3260
3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard braking PD70 Rigid pad mount 386 kg (851 lbs) approx. 5 plate (each half shaft) Yoke 5.4:1 OPTION 1 OPTION 2 15.78:1 18.16:1 2.923:1 3.363:1 38 13
37 11
Issue 3*
Section F
Transmission
Section F
Technical Data
1-3
1-3
Tyre Pressures * Note: If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures. Two Wheel Steer Machines Type
Size
Ply bar
Pressure lbf/in2
Front - 2WD Ribbed (Armstrong) Ribbed (Goodyear) Industrial Industrial Industrial
11L x 16 11.0 x 16 11L x 16 10.5 x 18 12.0 x 18
12 12 12 10 12
4.4 4.2 4.4 3.8 3.5
64 60 64 55 50
Front - 4WD † Industrial Traction Industrial (Firestone) Industrial (Olympic) Radial Industrial † Radial † Radial Industrial * Radial
14 x 17.5 10.5 x 18 12.0 x 18 12.0 x 18 335/80 x R18 12.5/80 x 18 335/80 - R20 12.5 - R20 12.5/12.0 x 18 340/80 x R18
10 10 12 12 XM27 10 XM27 XM27 12
3.8 3.8 3.5 4.5 3.5 4.25 3.0 3.0 3.5 3.2
55 55 50 65 50 61 43.5 43.5 50 46
Rear - 2WD & 4WD Industrial * Industrial Industrial Industrial Industrial Traction (Goodyear) Traction (Olympic) Industrial * Traction Industrial Radial Industrial
16.9 x 24 16.9 x 24 19.5L x 24 19.5L x 24 21L x 24 18.4 x 26 18.4 x 26 18.4 x 26 16.9 x 28 16.9 x 28 16.9 - R28 18.4 x 30
10 12 10 12 12 12 12 12 12 12 XM27 14
2.2 2.2 1.9 2.3 2.2 2.5 2.0 2.0 2.2 2.2 3.1 2.0
32 32 27.5 33 32 36 29 29 32 32 45 29
14.9 x 24 16.9 x 28 16.9 x 28 16.9 x 28 16.9 x 28 16.9 x 24 16.9 x R28 16.9 x R28 15.5 x 25
12 10 12 12 14 12 XM27
2.75 2.2 2.6 2.6 2.6 2.6 2.7 2.5 2.5
40 32 38 38 38 38 39 36 36
All Wheel Steer Machines Front and Rear - 4WD * Industrial † Industrial † Industrial * † Traction † Industrial * † Industrial * † Radial (Michelin) * † Radial (Goodyear) Radial
XTLA
Note: 12 ply tyres must be fitted on rear wheels when any backhoe attachment is used. For the correct pressure see the table above. The front wheels from machine serial number 400001 are made from a stronger construction than front wheels fitted prior to 400001. Wheels fitted to Backhoe Loaders prior to 400001 must not be used on the new Backhoe Loaders. †
Steering lock restriction stops must be fitted to 4 wheel drive machines that have this type of tyre fitted, consult your JCB Distributor for advice.
9803/3260
Issue 3*
Section F
Transmission
Section F
Technical Data
1-4
1-4
Syncro Shuttle Description
*
Combined torque converter, reverser, and gearbox unit with integral parking brake. SS640 (4 wheel drive)
Designation Weight (dry) 2WD 4WD Number of Teeth Transfer Gear Layshaft Gear Ratios 1st 2nd 3rd 4th
157 kg (346 lb) 176 kg (388 lb) Std Ratio Low Ratio 36 38 19 17 Std Ratio Low Ratio 5.56:1 6.56:1 3.45:1 4.06:1 1.83:1 1.90:1 1.00:1 1.00:1
* Torque Convertor (machines up to serial no. TBA) Torque Converter Dia. Torque Multiplication at Stall Torque Converter Colour Coded Dots Minimum Engine Rev/Min at Converter Stall
279mm (11in.) 2.20:1 or 2 purple 2 Orange 1 White 1 Green See page 1 - 8 and 1 - 9
2.40:1 or 3 Brown
2.80:1
* Torque Convertor (machines from serial no. TBA) Torque Converter Dia. Torque Converter Identification Torque Multiplication at Stall Torque Convertor Colour Coded Dots Minimum Engine Rev/Min at Converter Stall
310 mm (12.2 in.) 12.2” - D 12.2” - P 2.82:1 2 Purple 2 Orange 1 Yellow 1 Yellow See page 1 - 10 and 1 - 11
2.54:1
Converter Pressures (in neutral) Converter In at 50 deg.C 1000 rev/min 2000 rev/min
bar 2.4 - 3.4 5.2 - 6.5
kgf/cm2 2.5 - 3.5 5.3 - 6.7
lbf/in2 35 - 50 75 - 95
Converter In at 100 deg.C
1000 rev/min 2000 rev/min
1.3 - 2.0 5.2 - 5.9
1.4 - 2.1 5.3 - 6.0
20 - 30 75 - 85
Converter Out at 50 deg.C
1000 rev/min 2000 rev/min
1.0 - 1.7 2.0 max
1.1 - 1.8 2.0 max
15 - 25 29 max
Converter Out at 100 deg.C
1000 rev/min 2000 rev/min
0.3 - 0.6 1.0 - 1.7
0.3 - 0.6 1.1 - 1.8
4.0 - 8.0 15 - 25
6.5
6.7
95
Converter Inlet Relief Valve Pressure (max.)
.....cont'd
9803/3260
Issue 4*
Section F
Transmission
Section F
Technical Data
1-5
1-5
Syncro Shuttle (cont'd) * Lubrication Pressures (in neutral)
kgf/cm2 0.2 - 0.4 0.4 - 0.7
lbf/in2 3.0 - 5.0 6.0 - 10.0
At 50 deg.C
1000 rev/min 2000 rev/min
bar 0.2 - 0.3 0.4 - 0.7
At 100 deg.C
1000 rev/min 2000 rev/min
0.1 - 0.2 0.3 - 0.6
0.1 - 0.2 0.3 - 0.6
2.0 - 3.0 4.0 - 8.0
11inch convertor - m/c’s up to serial number TBA At 50 deg. C 1000 rev/min 2000 rev/min
bar 9.3 - 10.3 10.7 - 11.7
kgf/cm2 9.5 - 10.5 10.9 - 12.0
lbf/in2 135 - 150 155 - 170
At 100 deg.C
9.3 - 10.3 9.3 - 10.3
9.5 - 10.5 9.5 - 10.5
135 - 150 135 - 150
12.2 inch convertor - m/c’s from serial number TBA At 50 deg. C 1000 rev/min 2000 rev/min
bar 9.7 - 12.8 11.4 - 14.1
kgf/cm2 9.8 - 13.0 11.6 - 14.4
lbf/in2 140 - 185 165 - 205
At 100 deg.C
11.4 - 12.8 11.4 - 13.4
11.6 - 13.0 11.6 - 13.7
165 - 185 165 - 195
* Main Line Pressure (in neutral) †
1000 rev/min 2000 rev/min
* Main Line Pressure (in neutral) †
* Clutch Pressures † Flow Rates (in neutral) Cooler at 50 deg.C
1000 rev/min 2000 rev/min
All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2):
1000 rev/min 2000 rev/min
L/min 10.4 - 13.6 14.5 - 20.0
US gal/min 2.8 - 3.6 3.8 - 5.3
UK gal/min 2.3 - 3.0 3.2 - 4.4
Cooler at 100 deg.C
1000 rev/min 2000 rev/min
10.2 - 12.5 22.7 - 26.1
2.7 - 3.3 6.0 - 6.9
2.3 - 2.8 5.0 - 5.7
Pump at 50 deg.C
1000 rev/min 2000 rev/min
11.0 - 15.0 22.5 - 29.5
2.9 - 4.0 6.0 - 7.8
2.5 - 3.3
† Note: For brand new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).
9803/3260
Issue 3*
Section F
Transmission
Section F
Technical Data
1-6
1-6
Powershift Description
Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft and 4 wheel drive clutch packs. Torque converter and parking brake integral . PS740 (4 wheel drive)
Designation
* Weight (dry)
2WD 4WD Number of Teeth Transfer Gear Layshaft Gear Ratios 1st 2nd 3rd 4th
220 kg (484 lb) 236 kg (519 lb) Std Ratio 45 18 Std Ratio 5.72:1 3.23:1 1.77:1 1.00:1
Low Ratio 46 16 Low Ratio 6.58:1 3.71:1 1.77:1 1.00:1
* Torque Convertor (machines up to serial no. TBA) Torque Converter Dia. Torque Multiplication at Stall Torque Converter Colour Coded Dots Minimum Engine Rev/Min at Converter Stall
279mm (11in.) 2.20:1 or 2 purple 2 Orange 1 White 1 Green See page 1 - 8 and 1 - 9
2.40:1 or 3 Brown
2.80:1
* Torque Convertor (machines up to serial no. TBA) Torque Converter Dia. Torque Converter Identification Torque Multiplication at Stall Torque Convertor Colour Coded Dots Minimum Engine Rev/Min at Converter Stall
310 mm (12.2 in.) 12.2” - D 12.2” - P 2.82:1 2 Purple 2 Orange 1 Yellow 1 Yellow See page 1 - 10 and 1 - 11
2.54:1
Converter Pressures (in neutral) Converter In at 50 deg.C 1000 rev/min
bar 2.8 - 4.1
kgf/cm2 2.8 - 4.2
lbf/in2 40 - 60
2000 rev/min
4.8 - 6.2
4.9 - 6.3
70 - 90
1000 rev/min
1.9 - 2.3
1.9 - 2.3
27 - 33
2000 rev/min
2.3 - 2.7
2.3 - 2.7
33 - 39
6.5
6.7
95
Converter Out at 50 deg.C
Converter Inlet Relief Valve Pressure (max.)
..... continued
9803/3260
Issue 3*
Section F
Transmission
Section F
Technical Data
1-7
1-7
Powershift (cont'd) * Lubrication Pressures (in neutral) At 50 deg.C
1000 rev/min
bar 0.14 - 0.28
kgf/cm2 0.14 - 0.28
lbf/in2 2.0 - 4.0
2000 rev/min
0.28 - 0.55
0.28 - 0.56
4.0 - 8.0
* Mainline Pressure (in neutral) † 11 inch convertor - m/c’s up to serial number TBA At 50 deg. C 1000 rev/min 2000 rev/min
* Main Line Pressure (in neutral) †
12.2 inch convertor - m/c’s from serial number TBA At 50 deg. C 1000 rev/min 2000 rev/min
* Clutch Pressures † Flow Rates (in neutral) Cooler at 50 deg.C
Pump at 50 deg.C
bar 9.0 - 10.0
kgf/cm2 9.1 - 10.2
lbf/in2 130 - 145
9.7 - 11.0
9.8 - 11.3
140 - 160
bar 9.7 - 12.8
kgf/cm2 9.8 - 13.0
lbf/in2 140 - 185
11.4 - 14.1
11.6 - 14.4
165 - 205
All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2):
1000 rev/min
litres/min 10.4 - 13.6
US gal/min 2.8 - 3.6
UK gal/min 2.3 - 3.0
2000 rev/min
14.5 - 20.0
3.8 - 5.3
3.2 - 4.4
1000 rev/min
11.0 - 15.0
2.9 - 4.0
2.5 - 3.3
2000 rev/min
22.5 - 29.5
6.0 - 7.8
5.0 - 6.5
* † Note: For brand new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).
9803/3260
Issue 2*
Section F
Transmission
Section F
Technical Data
1-8
1-8
* Pump/Transmission Stall Speed Combinations - All Wheel Steer Machines with 11 inch Convertors The figures given below and on the following page apply to 'bedded-in' engines, i.e. engines that have done a minimum of 250 working hours, therefore they should not be used for PDI checks. They are intended to be used as guideline figures only and should not be considered as servicing parameters. ALL WHEEL STEER MACHINES 4CX
4CX 214S 215S N.Am. ServoPlus
4CX option Nordic Iceland
4CX option Malasia
217S N.Am.
max r.p.m. min. r.p.m.
2170 2100
2130 2065
2160 2085
2120 2055
2100 2030
max. r.p.m. min. r.p.m.
1795 1700
1770 1670
1685 1575
1660 1550
1640 1530
●
●
●
●
●
●
●
●
●
●
●
● ●
●
●
Engine Stall Speed 1 Converter only
2
Converter + MRV
Build Specification Engine Size
N.A. (74 bhp) T2 (90 bhp) T3 (96 bhp)
Converter Type
SSL 11 (2.8:1) WH 11 (2.4:1) W11 (2.2:1)
Pump Size (UK gals)
26 gal 28 gal 30 gal 34 gal
Fan Ratio
1 to 1 1 to 1.25 1 to 1.36
9803/3260
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● ●
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Issue 4*
9803/3260
max r.p.m. min r.p.m.
2 Convertor + MRV
N.A. (74 bhp) T2 (90 bhp) T3 (96 bhp)
SSL 11 (2.8:1) WH 11 (2.4:1) W11 (2.2:1)
26 UK gal. 28 UK gal. 30 UK gal. 34 UK gal.
1 to 1 1 to 1.25 1 to 1.36
Convertor Type
Pump Size (U.K. gals)
Fan Ratio ●
●
●
●
1360 1260
1755 1695
●
●
●
●
1340 1245
1735 1670
3CX
●
●
●
●
1830# 1730#
2215# 2145#
214 N.Am.
●
●
●
●
1525 1420
1900 1830
3CXT
●
●
●
●
1510 1405
1875 1810
3CXT
●
●
●
●
1515 1410
1890 1820
3CXT+
●
●
●
●
1495 1390
1870 1800
3CXT+
●
●
●
●
1380 1220
1880 1810
3CXT option Nordic Iceland
●
●
●
●
1365 1200
1860 1790
3CXT option South Africa
●
●
●
●
1730 1630
2070 2000
214T N.Am.
●
●
●
●
1675 1570
2065 1995
215 N.Am.
●
●
●
●
1465 1345
1915 1840
217 N.Am.
1-9
Engine Size
Build Specification
max r.p.m. min r.p.m.
1 Convertor Only
Engine Stall Speed
3CX
Note: All tests conducted with single pump option selected unless specified thus #, then tests to be conducted with double pump option selected.
Pump/Transmission Stall Speed Combinations - Two Wheel Steer Machines with 11 inch Convertors
Section F Transmission Section F
Technical Data 1-9
*
Issue 2*
Section F
Transmission
Section F
Technical Data
1 - 10
1 - 10
Pump/Transmission Stall Speed Combinations - All Wheel Steer Machines with 12.2 inch Convertors NOTE.All tests conducted with single pump option selected 4CX 4CXSup.
4CX 214S 215S
4C/4CN 4CX option Nordic Iceland
4CX option Malaysia
217S U.S.A.
3CXSup.
3CXSup.
Engine Speed @ Stall Combination. 1.Convertor only. Max.r.p.m. Min.r.p.m.
2100 2000
2065 1970
2085 1990
2060 1960
2035 1940
2040 1935
2010 1905
2.Convertor + M.R.V. Max.r.p.m. Min.r.p.m.
1755 1665
1730 1650
1660 1570
1640 1550
1625 1530
1635 1510
1610 1485
●
●
●
●
●
●
Std. or High Lift Excavator Build specification. Engine size. N.A.(74) T2(90) T3(96)
●
●
●
●
●
Convertor type. 12.2D(2.82) 12.2P(2.54)
●
●
●
●
●
●
● ●
●
●
Pump size. 24 gal. 26 gal. 28 gal. 30 gal. 34 gal. Fan Ratio. 1 to 1 1 to 1.25 1 to 1.36
9803/3260
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● ●
● ●
Issue 2
9803/3260
3CX
1365 1195
2.Convertor + M.R.V. Max.r.p.m. Min.r.p.m.
●
●
●
High
1435 1335
1860 1760
●
High
1650 1525
2050 1950
3CX.T
●
1625 1500
2020 1915
3CX.T
●
1635 1510
2040 1935
●
1610 1485
2010 1905
3CXSM+ 3CXSM+
●
1480 1310
2025 1925
3CX.T option Nordic Iceland
●
1450 1280
1995 1895
3CX.T option South Africa
●
1610 1485
2010 1905
214 T U.S.A.
●
High
1610 1485
2010 1905
215 U.S.A.
1625 1530
2035 1940
217 U.S.A.
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Transmission
Fan Ratio. 1 to 1 1 to 1.25 1 to 1.36
Pump size. 24 gal. 26 gal. 28 gal. 30 gal. 34 gal.
●
●
●
1645 1540
2120 2015
3CX Malaysia
Convertor type. 12.2D(2.82) 12.2P(2.54)
●
1710 1615
2120 2015
214 U.S.A.
●
●
1450 1350
1870 1775
214 U.S.A.
Engine size. N.A.(74) T2(90) T3(96)
Build specification.
1470 1370
1895 1800
3CX
1 - 11
Std. or High Lift Excavator
2105 2005
1.Convertor only. Max.r.p.m. Min.r.p.m.
Engine Speed @ Stall Combination.
214E U.S.A.
Note.All tests conducted with single pump option selected .
Pump/Transmission Stall Speed Combinations - Two Wheel Steer Machines with 12.2 inch Convertors
Section F Section F
Technical Data 1 - 11
Issue 1
Section F 1 - 12
Transmission
Section F
Towing Procedure
1 - 12
Syncro Shuttle & Powershift Gearbox If there is no transmission damage, the machine may be towed for a distance of approximately 1.5 kilometres (1 mile). Always use a rigid tow bar, ensure that the gear lever is in neutral (applicable to Syncro Shuttle machines only). Restrict towing speed to 25 k.p.h. (15 m.p.h.). If it is necessary to tow the machine for a distance in excess of 1.5 kilometres (1 mile) the propshafts should be disconnected to prevent damage to the transmission system.
! WARNING When the rear propshaft is disconnected the parking brake will not function. It is essential that the following procedure be adopted. TRAN 1-5
Position the machine on firm level ground and block the wheels securely to prevent any movement. Select neutral (Syncro Shuttle machines only) and release the parking brake. Disconnect the rear propshaft from the axle, and tie up the shaft securely well clear of the rotating axle yoke. Alternatively remove the shaft completely. Connect the towing vehicle via the towbar BEFORE removing the blocks from the wheels. Restrict the towing speed to 25 k.p.h. (15 m.p.h.). When towing is complete, block the wheels securely BEFORE removing the towbar and reconnecting the propshafts. Important: In some countries neither of the above procedures may be legally acceptable for towing on public highways.
9803/3260
Issue 1
9803/3260
Drive is transmitted finally via the output shaft K to the rear axle. If 4 wheel drive is selected, the front wheels are also driven via 4 wheel drive output flange L. A full description of 2/4 wheel drive clutch operation is given on pages F/3 - 6 and F/3 - 7.
carries the 1st/2nd synchromesh unit J. The synchromesh units are of the 'Blocking Pin' type, a full description of which is given on Pages F/3 - 3 and F/3 - 4.
synchromesh unit G, and to the layshaft H, which In neutral the flow of the pressurised oil is blocked at the solenoid valve.
Oil from the torque converter flows out of the transmission to the external oil cooler, returning at the rear of the transmission unit to pass through the centre of the reverser shaft for clutch lubrication.
the solenoid valve E for clutch selection. Excess oil from the maintenance valve flows back through the casing to the torque converter. Oil enters the converter between the converter hub and the stator support, and leaves between the stator and the input shaft. Pressure in the converter is controlled by relief valve N which dumps oil from the converter line back to the sump.
maintenance valve D, which maintains pressure to
passage via the filter M to the pressure
Oil from the pump B is fed through an internal
When either forward or reverse is selected, the solenoid valve E diverts pressurised oil via the reverser shaft to the appropriate clutch in the reverser unit A. A restrictor orifice P in the feed to the solenoid valve modulates the pressure to the clutch to give a smooth engagement. Pressure from the other clutch is vented back to the sump via the solenoid valve spool.
3-2
Drive is transferred from the reverser unit by helical gears to the mainshaft F, which carries the 3rd/4th
controlled by maintenance valve D, and clutch selection is achieved by means of an electric solenoid valve E.
the torque converter C. The oil pressure is
The reverser unit A has a pair of hydraulically operated clutches giving forward - neutral - reverse drive. Oil pressure is provided by a crescent type pump B driven at engine speed by the drive lugs of
The JCB Syncro Shuttle consists of a torque converter, hydraulic reverser unit, and integral manual 4-speed gearbox.
General Description and Operation
Syncro Shuttle Gearbox
Section F Transmission Section F
Descriptions 3-2
Issue 1
Section F 3-3
9803/3260
Transmission Descriptions
Section F 3-3
Issue 1
Section F 3-4
Transmission Descriptions
Section F 3-4
Synchromesh Description The gearbox is fitted with 'Blocking Pin' synchromesh, comprising the following parts. SYNCHRO HUB (A) controls the operation of the synchromesh unit and gear selection, the selector fork fitting into the outer groove. Internal dog teeth link the selected gear to the drive shaft. Through the synchro hub centre are two sets of holes for the blocker pins (C) and the split energiser pins (D), spaced alternately. SYNCHRO RINGS (B) are rigidly joined by the blocker pins, with the split energiser pins held, in counterbores, between the two synchro rings. BLOCKER PINS (C) have a narrow neck in the centre, against which the synchro hub transmits radial drive during gear changes. The edges of the blocker pin neck and their mating synchro hub holes are designed so that, as the radial loads are reduced, the synchro hub can slide over the shoulder of the blocker pin. SPLIT ENERGISER PINS (D) take the initial axial load of the synchro hub on the shoulder of the split energiser pin neck. As the axial load reaches approximately 400 N (40.8 kg; 90 lb) the internal springs allow the split energiser pin to collapse and the synchro hub to move axially. SYNCHRO CUPS (E) take the frictional drive from the
9803/3260
Operation Diagram F shows the gearbox with first gear engaged. Synchro ring B is in contact with synchro cup E and the synchro hub dog teeth are linking first gear to the shaft gear. In this position the split energiser pins D are 'collapsed'. When selecting second gear the synchro hub A slides along the split energiser pins until the pin recess and the synchro hub flange are in line. At this point the split energiser pins open and the synchro rings are moved by the synchro hub pushing on the split energiser pin shoulder. Initial contact between the synchro ring and the synchro cup starts to synchronise the speed of the shaft and second gear. The rotational force of the synchro ring is taken by the blocker pin against the edge of the synchro hub hole, as at G. As the axial load on the synchro hub increases, the split energiser pin 'collapses' and the conical faces of the blocking pin and synchro hub hole come into contact, as at H. Further increases in the axial loads increase the frictional grip of the synchro ring and the synchro cup, causing the shaft and gear speeds to synchronise. As the speeds are synchronised the radial load on the blocker pin and the synchro hub is reduced. This allows the synchro hub to slide freely along the blocker pin and engage its dog teeth with second gear, see diagram J.
Issue 1
Section F 4-1
9803/3260
Transmission Descriptions
Section F 4-1
Issue 2
9803/3260
shaft K.
a parking brake disc J mounted on splined output
assembly D, 2/4 wheel drive clutch assembly F and
Reverse drive is transmitted via constant meshing of spur gears Z.
The reverse clutch assembly C is similar to the input clutch assembly. It contains two hydraulically operated clutches; one clutch provides a reverse low ratio drive and the other a reverse high ratio drive. 3-position solenoid valve L, when energised, directs pressurised oil to either the reverse low or reverse high clutch.
Input clutch assembly B contains two hydraulically operated clutches; one clutch provides a forward low ratio drive and the other a forward high ratio drive. 3-position solenoid valve G, when energised, directs pressurised oil to either the forward low or forward high clutch.
The torque converter is a fluid coupling bolted to a drive plate which in turn is bolted to the engine flywheel. As the engine starts to rotate, the converter gives smooth power take off gradually increasing the torque transmitted. This torque is transferred from the converter assembly to the clutch/gear assemblies via input shaft H.
Pages F/6-5 and F/6-6 illustrate drive paths and which clutches are engaged for 1st gear forward with 2 wheel drive selected and 1st gear reverse with 4 wheel drive selected.
Pages F/6-1 to F/6-4 illustrate drive paths and which clutches are engaged for all 4 gear ratios in forward drive (4 wheel drive).
Pages F/5-1 & F/5-2 describe the Powershift in operation when 1st gear forward has been selected.
Filter P is used to prevent potential system contamination by filtering dirt particles.
The 2/4 wheel drive unit also has a single clutch. In normal operation the clutch is spring loaded and therefore engaged to give 4 wheel drive. When 2 wheel drive is selected, solenoid valve N is energised and directs pressurised oil to the 2/4 wheel drive clutch. The pressurised clutch 'deselects' the transmission to 2 wheel drive.
Both the mainshaft and the layshaft assemblies have a single clutch each. 3-position solenoid valve M, when energised, directs pressurised oil to either the mainshaft clutch or the layshaft clutch.
4-2
assembly C, layshaft assembly E, mainshaft
The Powershift unit consists of a torque converter A, input clutch assembly B, reverse clutch
A combined lever/swivel switch on the steering column actuates both gear ratio and direction solenoids.
Electrically operated solenoid valves divert pressurised oil (provided by pump Q) to the selected clutch packs.
The JCB Powershift is an electro-hydraulic transmission unit. Gearshifting and direction selection are controlled using multi-disc clutch packs.
General Description
Powershift Transmission
Section F Transmission Section F
Descriptions 4-2
Issue 2
9803/3260
Oil from the torque converter flows out of the transmission unit to the external oil cooler V. From the cooler, the oil flows to pipe cluster W which distributes the oil to pass through the centre of all the clutches for lubrication purposes.
Excess oil from the maintenance valve flows through the casing to the torque converter. Oil enters the converter between the converter hub and the stator support, and leaves between the stator and the input shaft. Pressure in the converter is controlled by relief valve T which dumps oil from the converter line back to the sump.
The solenoid adaptor block houses the solenoid valves which are used to divert oil to the clutch packs.
Oil from the pump Q is fed through an internal passage via the filter Y to the pressure maintenance valve R, which maintains a constant pressure to the solenoid valve adapter block S.
Restrictor orifices X in the feed lines to the solenoid valves modulate the pressure to the clutches, this ensures a smooth clutch engagement. Pressure from clutches not engaged will vent back to the sump via internal galleries and the solenoid spools.
Pages F/6-5 and F/6-6 illustrate drive paths and which clutches are engaged for 1st gear forward with 2 wheel drive selected and 1st gear reverse with 4 wheel drive selected.
Pages F/6-1 to F/6-4 illustrate drive paths and which clutches are engaged for all 4 gear ratios in forward (4 wheel) drive.
The drive from the engine is then transferred via the engaged clutches and gears to the output flange (and finally to the road wheels).
With 1st gear forward selected solenoid valves G and M are energised. The energised valves cause internal spools to move, which then divert pressurised oil to clutch packs B and E via internal galleries.
In neutral, the flow of pressurised oil is blocked at the solenoid valves.
5-2
For the purpose of this description, clutches not used when 1st gear forward is selected are not shown.
The illustration shows 1st gear forward selected, therefore the two engaged clutches will be forward low ratio clutch B and layshaft drive clutch E.
There must always be two clutches engaged before the machine will drive; 1) a direction ratio clutch, for instance forward low, and 2) a drive clutch (layshaft or mainshaft).
Different combinations of engaged clutches give four gear ratios in forward and reverse drive.
When the Powershift is operated multi-disc clutch packs are pressurised and engaged. The engaged clutch packs then transfer drive from the engine to the road wheels (via the torque converter A, input shaft H and drive shafts).
Hydraulic Operation
Powershift Transmission
Section F Transmission Descriptions
Section F 5-2
Issue 1
9803/3260
When the solenoid is de-energised, the friction/counter plates freely rotate, therefore no drive is transmitted through the 5th gear (item 6).
When 5th gear is selected, the 5th speed clutch (item 3) AND the mainshaft clutch (item 8) are pressurised, page F/6-7 shows the drivepath for the 5th gear.
The clutch works on a similar principle to the normal 'reverser' clutch found in the standard syncro shuttle transmission (see page F/3-5), that is, the pressurised oil enters the clutch and forces a piston against a friction/counter plate assembly. Because the friction/counter plates are forced together, drive is transmitted through the clutch pack to the 5th gear (item 6).
5
4
1
2
9
6
➆ 3
8 A235661
S235640
5-3
The constant meshing gears will freely rotate until the 5th speed clutch solenoid (item 7) is energised. When the solenoid is energised, pressurised oil is diverted via a solenoid spool to the 5th speed clutch (item 3).
Gear (item 1) is mounted on the input reverser shaft (item 4) and is driven via the torque converter. The converter has an additional integral splined spigot when compared to a 'standard' converter, this additional spline is used to directly drive gear assembly (item 1) via gear (item 5).
The drive for the 5th gear is transmitted by constant mesh from gear (item 1) through transfer gear (item 2) to the 5th speed clutch assembly (item 3). If the clutch pack is not pressurised, the 5th gear (item 6) is meshed and freely rotating with input gear (item 9) - but no drive is being transferred.
5th Gear - 5-Speed Gearboxes Only
Powershift Transmission
Section F Transmission Section F
Descriptions 5-3
Issue 1
Section F 6-1
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Transmission Descriptions
Section F 6-1
Issue 1
Section F
Transmission Descriptions
6-2
Section F 6-2
Powershift - Drivepaths Figure 1 - 1st GEAR FORWARD (4 Wheel Drive)
Clutches Engaged
Solenoids Active
F -
Forward Low Ratio
F -
Forward Low
H -
Layshaft
H -
Layshaft
*K
-
2/4 wheel drive (see note)
* Note:
Powershift transmissions installed in machines prior to serial number 415012 have the 4-wheel drive clutch spring loaded in the 'on' position to give 4WD, as shown at K. On machines after serial number 415012, the clutch must be pressurised to select 4WD. Refer to pages F/3-6 to F/3-9 for a description of the 4-wheel drive clutch operation.
Figure 2 - 2nd GEAR FORWARD (4 Wheel Drive)
*
Clutches Engaged
Solenoids Active
E -
Forward High Ratio
E -
Forward High
H -
Layshaft
H -
Layshaft
K -
2/4 wheel drive (see note above)
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Issue 2*
Section F 6-3
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Transmission Descriptions
Section F 6-3
Issue 1
Section F
Transmission
Section F 6-4
Descriptions
6-4
Powershift - Drivepaths (cont'd) Figure 3 - 3rd GEAR FORWARD (4 Wheel Drive)
Clutches Engaged
Solenoids Active
F -
Forward Low Ratio
F -
Forward Low
G -
Mainshaft
G -
Mainshaft
*K
-
2/4 wheel drive (see note)
* Note:
Powershift transmissions installed in machines prior to serial number 415012 have the 4-wheel drive clutch spring loaded in the 'on' position to give 4WD, as shown at K. On machines after serial number 415012, the clutch must be pressurised to select 4WD. Refer to pages F/3-6 to F/3-9 for a description of the 4-wheel drive clutch operation.
Figure 4 - 4th GEAR FORWARD (4 Wheel Drive)
Clutches Engaged
Solenoids Active
E -
Forward High Ratio
E -
Forward High
G -
Mainshaft
G -
Mainshaft
K -
2/4 Wheel Drive
* Note that when 4th gear is selected, the 2/4 wheel drive clutch solenoid K is automatically energised, which therefore places the transmission in 2 wheel drive (only applicable on machines up to serial number 409435). Refer also to the note above.
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Issue 2*
Section F 6-5
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Transmission Descriptions
Section F 6-5
Issue 1
Section F
Transmission Descriptions
6-6
Section F 6-6
Powershift - Drivepaths (cont'd) Figure 5 - 1st GEAR FORWARD (2 Wheel Drive)
Clutches Engaged
Solenoids Active
F -
Forward Low Ratio
F -
Forward Low
H -
Layshaft
H -
Layshaft
K -
2/4 Wheel Drive
Note that the 2/4 wheel drive clutch has been pressurised via solenoid valve K and therefore disengaged.
* Note:
Powershift transmissions installed in machines prior to serial number 415012 have the 4-wheel drive clutch spring loaded in the 'on' position to give 4WD. On machines after serial number 415012, the clutch must be pressurised to select 4WD. Refer to pages F/3-6 to F/3-9 for a description of the 4-wheel drive clutch operation.
Figure 6 - 1st GEAR REVERSE (4 Wheel Drive)
*
Clutches Engaged
Solenoids Active
I
Reverse Low Ratio
I
H -
Layshaft
H -
K -
2/4 wheel drive (see note above)
-
-
Reverse Low Layshaft
Note that reverse drive is achieved through the meshing of spur gears Z.
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Issue 2*
Section F
Transmission
Section F 6-7
Descriptions
6-7
Powershift - Drivepaths (cont'd) Figure 7 - 5th GEAR FORWARD - 5 SPEED GEARBOX ONLY
Clutches Engaged
Solenoids Active
G -
Mainshaft
G -
Mainshaft
L -
5th Speed
L -
5th Speed
For 5-speed gearboxes the 1st, 2nd, 3rd and 4th gear clutch/solenoid combinations are the same as described on the previous pages. Refer also to page F/5-3 for 5th speed drive description. Note that the 2/4 wheel drive clutch must be pressurised to give 4 wheel drive.
L G
L Sxxxxxx
G
S
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Issue 1
Section F 7-1
Transmission Descriptions
Section F 7-1
Powershift Gearbox Clutch Operation The Powershift input clutch and reverse clutch assemblies operate in exactly the same manner as the forward/reverse clutch in the Syncro Shuttle transmission unit - please refer to page F/3-5. The Powershift mainshaft and layshaft assemblies each have a single clutch. Again, the principle of operation is similar to the description given on page F/3-5, ie the mainshaft/layshaft solenoid valve diverts pressurised oil to either the mainshaft clutch or the layshaft clutch.
2/4 Wheel Drive Operation The Powershift 2/4 wheel drive operation is similar to the description given on pages F/3-6 & F/3-7 (Syncro Shuttle transmission). However, please note that the Powershift 2/4 wheel drive solenoid valve is mounted on the solenoid block (shown at K), not on the 2/4 wheel drive housing (as is the case for Syncro Shuttle transmissions).
9803/3260
Issue 1
Section F
Transmission
12 - 1
Section F
Fault Finding
12 - 1
Syncro Shuttle Gearbox Before carrying out the checks listed the machine should, if possible, be operated to determine the fault area(s), and bring the systems to their normal working temperatures. Ensure that the correct quantity and grade of oil is used and that there are no obvious leaks. A
If the transmission is noisy, start at check 1.
B
If the transmission is overheating, start at check 4.
C
If the transmission will not pull, start at check 12.
D
If there is no drive in one or both directions, start at check 17.
E
If the transmission is jumping out of gear, start at check 29.
F
If the transmission is sticking in gear, start at check 39.
G
If ratios are 'crash changing', start at check 41.
CHECK
ACTION
1
Is there noise when selecting direction?
YES: Check 3 NO: Check 2
2
Is there noise when running with direction selector in neutral and ratio selector in 1st?
YES: Check 9 NO: Check 19
3
Is there air in the hydraulic system?
YES: Continue running to expel air. NO: Check 4
4
Is the fluid level correct?
YES: Check 5 NO: Check level only when machine is cold and top-up as required.
5
Are the oil passages restricted?
YES: Clear the restriction. NO: Check 6
6
Is the suction strainer restricted?
YES: Remove and clean strainer. NO: Check 7
7
Is pump pressure as specified?
YES: Check 9 NO: Check clutch pressure maintenance valve is free to operate.
8
When flow testing pump, is output low?
YES: Renew pump. NO: Check converter sprag clutch for wear or slip.
9
Does the noise continue when direction selector is in forward or reverse?
YES: Check 10 NO: Check 11
10
Is transmission misaligned?
YES: Renew mountings and check position. NO: Check 'converter out' pressure and flow.
11
Are the pump bushes worn?
YES: Renew NO: Check converter for wear or cooler for restriction to flow.
12
Is the transmission not pulling in one direction only?
YES: Check 16
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Issue 1
Section F 12 - 2
Transmission
Section F
Fault Finding
12 - 2
Syncro Shuttle Gearbox (cont'd) CHECK
ACTION
14
Is 'converter in' pressure as specified?
YES: Check 15 NO: Inspect converter relief valve for damage. Check cooler bypass valve pressure setting.
15
Is pump being driven by converter?
YES: Check pump pressure. NO: Renew damaged parts.
16
Are clutch sealing rings damaged?
YES: Tap pressure gauge into clutch feed lines to monitor pressure. NO: Check clutch plates for damage.
17
Is there drive in one direction only?
YES: Check 19 NO: Check 18
18
Is the start switch in the run position and supplying current to the neutral start relay?
YES: Check 19 NO: Rectify.
19
Is the fault only when the transmission is hot?
YES: Dismantle solenoid and check components. NO: Check microswitches, relay and wiring loom.
20
Is the noise a growl, hum or grinding?
YES: Check gears for damage or wear. NO: Check 21
21
Is the noise a hiss, thump or bumping?
YES: Check bearings for damage or wear. NO: Check 22
22
Is the noise a squeal?
YES: Check free running gears for seizure. NO: Check 23
23
Is the noise present when in neutral or when in gear? NEUTRAL: Check 24 IN GEAR: Check 27
24
Is the countershaft or its bearings worn or damaged?
YES: Renew damaged parts. NO: Check 25
25
Is there excessive backlash in the gears?
YES: Adjust by checking shaft end float. NO: Check 26
26
Is the mainshaft pilot bearing worn?
YES: Renew. NO: Check gear teeth for scuffing.
27
Is the mainshaft rear bearing worn?
YES: Renew. NO: Check 28
28
Are the sliding gear teeth worn or damaged?
YES: Renew gears. NO: Check 29
29
Are the selector forks loose?
YES: Tighten screws. NO: Check 30
30
Are the selector fork pads or grooves in gears worn?
YES: Renew worn parts. NO: Check 31
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Issue 1
Section F 12 - 3
Transmission
Section F
Fault Finding
12 - 3
Syncro Shuttle Gearbox (cont'd) CHECK
ACTION
33
Are the selector rods worn or damaged?
YES: Renew. NO: Check 34
34
Are the selector fork pads out of position?
YES: Reposition or renew (check interlock). NO: Check 35
35
Is there excessive end float in gears or shafts?
YES: Adjust. NO: Check thrust washers and mating faces.
36
Is the synchroniser bronze worn?
YES: Renew synchro pack. NO: Check 37
37
Are steel chips embedded in the bronze?
YES: Continue using, chips will either embed below bronze or be rejected. NO: Check 38
38
Are the synchroniser components damaged?
YES: Renew. NO: Check free running gears for seizure or damage.
39
Are the sliding gears tight on the splines?
YES: Free or renew. NO: Check 40
40
Are chips wedged between splines of shaft or gear?
YES: Remove chips. NO: Ensure that clutch is disengaged when dump pedal is pressed.
41
Are steel chips embedded in the bronze?
YES: Continue using, chips will either embed below bronze or be rejected. NO: Check 42
42
Are the synchroniser spring pins damaged?
YES: Renew synchro. NO: Check 43
43
Is the synchroniser bronze worn?
YES: Renew synchro. NO: Check blocker pins.
9803/3260
Issue 1
Section F 13 - 1
Transmission
Section F
Fault Finding
13 - 1
2/4 Wheel Drive Clutch 2WD Cannot be Engaged In normal operation the 2/4 wheel drive clutch is spring loaded and therefore engaged to give 4 wheel drive. The clutch must be pressurised to give 2 wheel drive. Before starting the more detailed fault finding procedures - eliminate the obvious: 1 2 3 4 5 6
Check that the transmission oil level is correct. Check that the fuse (C3) for the 2/4WD circuit is intact. Check that the 4-wheel drive external pipework is not damaged. Check that all the electrical connections are clean and secure. Check that the mainline pressure is correct (see 'Low Mainline Pressure'). Check that the pump flow rate is correct.
Possible Cause
Remedy
7
7
Low mainline pressure (Minimum pressure required to disengage 2/4WD clutch is 8.6 bar; 125 lb/in2).
Identify if the fault is related to the 2/4WD disconnect: 7.1 Disconnect the external pipework to the 2/4WD clutch. Cap and plug open orifices. 7.2 Check the mainline pressure - if the pressure is correct, the fault must be within the 2/4WD (see step 8). If the reading is still low check the transmission in the normal manner.
8
Low mainline pressure (due to 2/4WD clutch):
8
8.1 2/4WD solenoid spool sticking.
8.1 Strip, clean and re-assemble solenoid valve, renew valve if required.
8.2 2/4WD solenoid permanently energised.
8.2 Check the 2/4WD relay and select switch, replace as necessary.
8.3 2/4WD solenoid spool O-ring failed.
8.3 Renew O-ring.
8.4 Clutch shaft sealing rings leaking.
8.4 Renew clutch shaft sealing rings.
8.5 Excessive clutch shaft end float.
8.5 Rectify fault, renew parts as required, reset end float (should not exceed 0.03 mm; 0.001 in)
8.6 Wrong type clutch piston fitted.
8.6 Fit correct type clutch piston (ie, without bleed hole).
8.7 Clutch piston O-ring failed. 9
8.7 Replace clutch piston O-ring.
Defective 2/4WD clutch: 9.1 Worn pressure plate 9.2 Worn actuating sleeve. (Later machines have a new type of 2/4WD clutch fitted,
Rectify fault:
9
Rectify fault: 9.1 Inspect pressure plate, renew as required. 9.2 Measure length of actuating sleeve and renew as required, sleeve length should be:
4WD Cannot be Engaged No pressure is required to engage 4WD (spring loaded). Check that the front wheel drive train is intact (ie propshaft and axle). Also check that the solenoid spool is not sticking (in the 2WD position). Finally check the 2/4 wheel drive switch and relays. 9803/7110
Issue 1
Section F
Transmission Fault Finding
14 - 1
Section F 14 - 1
Powershift Fault Finding - Introduction The Powershift fault finding procedures concern themselves with general problems normally associated with this type of transmission system, and so the layout is a 'Possible Cause and Remedy' type. Full flow, pressure and stall testing procedures for the Powershift transmission start on page F/91-1. Before commencing with the fault finding procedure make sure that the correct type of transmission fluid has been used (JCB Special Transmission Fluid).
Powershift Fault Finding - Index Page No. Lack of Power
14 - 2
Low Mainline Pressure
14 - 2
High Stall Speeds (On All Clutches)
14 - 2
Low Stall Speeds (On All Clutches)
14 - 2
Low Converter Out Pressure
14 - 2
Low Pump Flow
14 - 2
High Converter Out Pressure
14 - 2
Low Lubrication Pressure
14 - 3
* Low Clutch Pressure and/or Clutch Slipping Overheating
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14 - 3 14 - 3
Issue 2*
Section F
Transmission
14 - 2
Section F
Fault Finding
14 - 2
Powershift Fault Finding
*
LACK OF POWER Possible Cause
Remedy
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
Poor engine condition. Low oil level. Worn pump. Torque converter damage. Low mainline pressure. Clutches slipping. Internal leakage. High stall speeds. Low stall speeds. Overheating
Check and if necessary repair engine. Top up system. Check and if necessary repair or renew pump. Check and if necessary repair or renew torque converter. See fault 'Low Mainline Pressure'. Check clutch pressures, check clutch piston rings. Check internal cored galleries and the casting for porosity. See fault 'High Stall Speeds (on ALL clutches)'. See fault 'Low Stall Speeds (on ALL clutches)'. See fault 'Overheating'.
LOW MAINLINE PRESSURE Possible Cause
Remedy
1 2 3 4
Worn pump. Blocked suction strainer. Pressure maintaining valve sticking/leaking. Oil aerated (foaming).
1 2 3 4
5
Oil leak thru' 2/4WD circuit.
5
Check and if necessary repair or renew pump. Clean suction strainer. Free off or renew valve. a) Internal leakage (cored galleries) - inspect/repair transmission. b) Dirty suction strainer - clean strainer. c) High oil level - drain to proper level. d) Incorrect grade of oil - drain then refill with correct oil. a) Check external pipework for 2/4WD circuit. b) Check 2/4WD (pressure) circuit - refer to 2/4 wheel drive clutch fault finding procedure on pages F/13-1 or F/151.
HIGH STALL SPEEDS (ON ALL CLUTCHES) Possible Cause
Remedy
1 2 3
1 2 3
Damaged converter blades. Clutches slipping. Internal leakage.
Check and if necessary repair or renew converter. Strip, inspect and fit new clutch friction/counter plates. Check internal cored galleries and the casting for porosity.
LOW STALL SPEEDS (ON ALL CLUTCHES) Possible Cause
Remedy
1 2
1 2
Poor engine condition. Torque converter reaction member clutch slipping.
Check and if necessary repair engine. Check and if necessary repair torque converter.
LOW CONVERTER OUT PRESSURE Possible Cause
Remedy
1 2 3 4
1 2 3 4
Low mainline pressure. Converter internal leakage. Converter relief valve faulty. Restriction in converter feed.
See fault heading 'Low Mainline Pressure'. Check and if necessary renew converter. Check and if necessary repair relief valve. See item 10 in fault 'Overheating'.
LOW PUMP FLOW Possible Cause
Remedy
1 2 3
1 2 3
Low oil level Blocked suction strainer. Worn Pump.
HIGH CONVERTER OUT PRESSURE Possible Cause
*1 *2
Oil cooler/lines blockage. Converter in pressure incorrect.
9803/3260
Top up system. Clean suction strainer. Repair or renew pump
Remedy 1 2
Clean cooler, free blockage. Check converter in pressure correct. Issue 2*
Section F 14 - 3
Transmission Fault Finding
Section F 14 - 3
Powershift Fault Finding LOW LUBRICATION PRESSURE Possible Cause
Remedy
* *
1 2 3 4 5 6 7
1 2 3 4 5 6 7
* * *
LOW CLUTCH PRESSURE AND/OR CLUTCH SLIPPING Possible Cause 1 Low mainline pressure. 2 Worn pump. 3 Blocked restrictor orifice in solenoid valve block.
*4 5
*6
Low mainline pressure Oil cooler/lines blockage. Ruptured lubrication line. Converter internal leakage. Converter relief valve faulty. Leak at pump to case joint (indicated by low cooler flow) Restriction in converter feed
Clutch seals worn. Clutch piston rings worn. Mechanical failure.
See fault 'Low Mainline Pressure'. Clean cooler, free blockage. Repair line. Check and if necessary renew converter. Check and if necessary repair or renew relief valve. Check and if necessary repair or replace as necessary. See item 10 in fault 'Overheating'
Remedy 1 See fault heading 'Low Mainline Pressure'. 2 Check flow and if necessary repair or renew pump. 3 Remove solenoid(s) and clear restriction in solenoid valve block. 4 Confirm with a clutch leak test, if required renew clutch seals. 5 Confirm with a clutch leak test, renew piston rings. 6 Strip and rebuild clutch, renew parts as required.
OVERHEATING Possible Cause
Remedy
1 2 3 4 5 6 7
1 2 3 4 5 6 7
Low oil level. High oil level. Trapped or kinked hoses in cooler system. Low converter out pressure and flow rate. Oil cooler blockage. Operating in wrong gear range usage. Water system overheating.
8 Oil aerated (foaming). 9 Clutch piston(s) sticking on return stroke. 10 Cored galleries on front housing pump mounting face wrong depth (indicated with an excessively low pressure and flow on the converter out cooling line). See illustration below. 11 Leakage across pump mounting face and front case.
8 9
Top up system. Drain oil to correct level. Renew or repair hoses. Repair or renew the converter relief valve. Clean cooler. Select correct gears to suit working conditions. Rectify water system problems, eg radiator, cooler lines, low water level etc. See fault 'Low Mainline Pressure', item 4. Check and repair clutch piston(s) and seal(s).
10 Replace front housing (or rectify existing housing). 11 Check for damaged surface on both components and loose pump mounting bolts.
S154080
9803/3260
Issue 2*
Section F
Section F
Transmission
15 - 1
Fault Finding
15 - 1
2/4 Wheel Drive Clutch (from Machine No. 415012) 4WD CANNOT BE ENGAGED In normal operation the 2/4 wheel drive clutch is spring loaded off and therefore disengaged to give 2 wheel drive. The clutch must be pressurised to give 4 wheel drive. Before starting the more detailed fault finding procedures - eliminate the obvious: 1
Check that the transmission oil level is correct.
2
Check that the fuse (C3) for the 2/4WD circuit is intact.
3
Check that the 4-wheel drive external pipework is not damaged and that the drive train is intact.
4 5
Check that all the electrical connections are clean and secure. Also check that the solenoid spool is not sticking (in the 2WD position). Check that the mainline pressure is correct (see 'Low Mainline Pressure').
6
Check that the pump flow rate is correct.
If the fault is not rectified after eliminating the obvious, check the following:
Possible Cause
Remedy
7
7
Low mainline pressure
Identify if the fault is related to the 2/4WD disconnect: 7.1 Disconnect the external pipework to the 2/4WD clutch. Cap and plug open orifices. 7.2 Check the mainline pressure - if the pressure is correct, the fault must be within the 2/4WD (see step 8). If the reading is still low check the transmission in the normal manner.
8
Low mainline pressure (due to 2/4WD clutch):
8
Rectify fault:
8.1 2/4WD solenoid spool sticking.
8.1 Strip, clean and re-assemble solenoid valve, renew valve if required.
8.2 2/4WD solenoid spool O-ring failed.
8.2 Renew O-ring.
8.3 Clutch shaft sealing rings leaking.
8.3 Renew clutch shaft sealing rings.
8.4 Excessive clutch shaft end float.
8.4 Rectify fault, renew parts as required, reset end float (should not exceed 0.03 mm; 0.001
in)
9
8.5 Wrong type clutch piston fitted.
8.5 Fit correct type clutch piston (ie, without bleed hole).
8.6 Clutch piston O-ring failed.
8.6 Replace clutch piston O-ring.
Defective 2/4WD clutch: 9.1 Worn friction/counter plates
9803/3260
9
Rectify fault: 9.1 Inspect friction/counter plates, renew as required.
Issue 1
Section F
Section F
Transmission
15 - 2
15 - 2
Fault Finding
2/4 Wheel Drive Clutch (from Machine No. 415012) (cont'd) 2WD CANNOT BE ENGAGED No pressure is required to engage 2WD(spring loaded). Check that the solenoid spool is not sticking (in the 4WD position), then see below. Possible Cause
Remedy
10
10
Incorrect type of solenoid valve fitted.
Check solenoid. Note: Powershift and Syncro Shuttle machines have different types of solenoid - check parts list.
11
Non-return valve faulty (noticeable because 2WD cannot be engaged).
11
Check the non-return valve. Note: NOT fitted on Powershift machines.
12
2/4WD solenoid permanently energised.
9803/3260
12
Check the 2/4WD relay and select switch, replace as necessary.
Issue 1
Section F
Transmission
Section F
Propshafts
18 - 1
18 - 1
Propshafts Removing and Replacing When Removing Before removing propshafts always mark both companion flanges and also mark the sliding joints prior to removal. When Replacing Upon reassembly, after lubricating sliding joints with JCB MPL Grease, align the shafts against identification marks previously made or, in the case of a shaft being renewed, use the manufacturer's alignment markings.
REAR
Apply JCB Lock and Seal to threads of all flange bolts. Retaining straps C stretch with use, therefore these straps must always be replaced with new ones. The propshaft must have both ends exactly on the same plane as shown at X. The yokes must not be at right angles as at Y or at an intermediate angle as at Z. Torque Settings Item A B
X
Nm 75 - 85 118
kgf m 7.7 - 8.7 12
lbf ft 55 - 63 87
B
A
S157510
C
2
A
S232350
Y
3
A
4
A
Z
S157500 S189610
FRONT 9803/3260
Issue 1
9803/3260 S161440
Transmission Front Axle
Wheel Nuts 680 Nm; 69 kgf m; 500 lbf ft
Differential Case Bolts - JCB Lock & Seal M/C Grade Torque 4WS 8.8 56 Nm; 5.7 kgf m; 42 lbf ft 2WS 8.8 28 Nm; 2.9 kgf m; 21 lbf ft 2WS 12.9 46 Nm; 4.7 kgf m; 34 lbf ft
Drain & Fill Plugs 79 Nm; 8 kgf m; 60 lbf ft
Crownwheel Retaining Bolts AWS M/c’s = 166 Nm; 16.9 kgf m; 122 lbf ft 2WS M/c’s = 94 Nm; 9.6 kgf m; 70 lbf ft
Planet Carrier Bolts (8.8)JCB Lock & Seal 56 Nm; 6 kgf m; 42 lbf ft
Trunnion Bolts JCB Lock & Seal 98 Nm; 10 kgf m; 72 lbf ft
20 - 1
Stake Nut See page F/22 - 1
Propshaft Retaining Bolts (12.9) 79 Nm; 8 kgf m; 58 lbf ft
Drivehead Bolts - JCB Multi-Gasket Axle Bolt Grade Torque SD55 M10 8.8 56 Nm; 5.7 kgf m; 42 lbf ft SD55 M10 12.9 94 Nm; 9.6 kgf m; 70 lbf ft SD70, SD80 M12 8.8 98 Nm; 10 kgf m; 72 lbf ft SD70, SD80 M12 12.9 166 Nm; 17 kgf m; 122 lbf ft
Typical axle shown, torque figures apply to AWS and 2WS machines - differences are indicated in text. When appropriate, the grade of the bolt is indicated either in the text or in parenthesis, e.g. ‘(12.9)’. Refer also to relevant dismantling and assembly procedures.
Front Axle Torque Figures
Section F Section F 20 - 1
Issue 1
Section F
Transmission
Section F 21 - 2
Front Axle
21 - 2
Removal and Replacement Note: The following procedure can be applied to both AWS and 2WS machines. Dis-regard information not applicable to your machine type, for instance, 2 wheel steer machines will not have steering proximity switches fitted.
! 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
Replacement Replacement is the reverse of the removal sequence.
! WARNING If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged. 2-3-2-8
Whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct. Apply JCB Lock & Seal to the threads of bolts A.
Removal
The front axle must be shimmed to give a maximum fore and
! WARNING Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut.
* aft movement of 0.5mm (0.020 in.). If necessary add shims to correct end float movement. The shims locate on the front axle pivot pin G, in-between the front of the axle and the axle yoke plate, as shown below.
GEN 3-2
1
Release screws J and remove the front grille.
2
Release bolts K and remove the proximity switch bracket together with the proximity switch assembly.
3
Using tool 892/00822 remove bolts A to disconnect the drive shaft from the axle.
4
Disconnect the hydraulic pipes B from the steer rams, blank off all exposed connections.
5
Disconnect remote grease nipples H.
6
Loosen the road wheel retaining nuts D.
7
Make sure that the rear wheels are blocked, use the loader arms to raise the front end of the machine.
8
Prop the machine on each side as shown at C.
9
Remove the front road wheels.
10
Position a jack underneath the balance point (see Note) of the axle and support the axle weight.
S218110
Note: Because the drivehead assembly is offset, the balance point of the axle is not the centre of the axle. Attach a 'cradle' to the jack that will partially embrace the axle. 11
Remove nut E and pivot pin retaining bolt F.
12
Use puller (tool no. 992/00800) and remove the pivot pin G and axle shims.
13
Lower the jack so that the axle is clear of the mounting yoke and remove the axle.
*
9803/3260
#If the setting of the steering proximity switch has been disturbed, then complete the front axle proximity switch setting procedure, as described on page F/21-3. Torque Settings Item A D
Nm 79 680
kgf m 8 69
lbf ft 58 500
Issue 3*
Section F
Transmission
Section F 21 - 3
Front Axle
21 - 3
Proximity Switch Setting Procedure X
! WARNING
±5mm (0.197in) Front ±6mm (0.236in) Rear
Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut. GEN 3-2
To set the front axle proximity switch:
A186150
A186150 1
Check wheels are in 'straight ahead' position as follows:
2
Measure ram extension X (FIG 1), the measurement should be the same for both the left and right hand rams (on the front axle). If not, turn the steering wheel in the required direction until the distances are equal for both sides.
3
Adjust the proximity switch C (FIG 2) so that there is a 5mm (0.197in.) gap between the lower face of the proximity switch and the top face of the sensor plate (use 5mm [0.197in.] thick plate as a setting tool).
FIG 1
Note: The proximity switch to sensor plate setting figure used to be 6mm (0.236in.). To improve performance, the proximity switch is now set at 5mm (0.196in) above the sensor plate. 4
Loosen the track rod sensing plate retaining bolts A (FIG 2).
5
Move the sensor plate B (FIG 2) fully to the left then gently adjust the plate to the right until the light emitting diode (L.E.D.) on the proximity switch illuminates. Mark two lines at each end of the slotted plate on the track rod.
6
Move the sensor plate B (FIG 2) fully to the right then gently adjust the plate to the left until the light emitting diode (L.E.D.) on the proximity switch illuminates. Mark two lines at each end of the slotted plate on the track rod.
7
Set the sensor plate ends central to the markings made in steps 5 and 6 as shown at D (FIG 3).
C B
A
S186130
FIG 2
D
S186160
8
Tighten the sensor plate retaining bolts A.
9
Fit the guard E (FIG 4), the guard must be set with 3mm (0.125in) between the lower face of guard and top face of the sensing plate B.
FIG 3
B E
S186120
FIG 4 9803/3260
Issue 2
Section F 23 - 5
Transmission
Section F
Front Axle
23 - 5
Hub and Driveshaft - Dismantling (cont'd) 16
Remove and discard the wear ring; 'stretch' the ring by tapping the rubbing surface with a ball pein hammer, then tap the ring off.
Note 1: Some axles have an O-ring fitted behind the wear ring, remove and discard the O-ring if fitted. Note 2: The latest type of axle has a combination seal fitted, this seal is a combined oil seal and wear ring (no O-ring required). When assembling the axle, a new combination seal must be used.
S248880
17
Mark position of top and bottom trunnions H and remove. Retain shims (see note 2) with each trunnion. Withdraw the hub carrier.
Note 1: Trunnions may be removed easily and without damage to the shims by pumping grease through the grease nipple.
H
* Note
2: Later type axles are not fitted with shims (the top face height of the swivel casting is increased by 1mm (0.040in.). These castings are identified with a small drill mark in the position shown at X (see illustration step 18).
S248890
* 18
Use adaptor 993/59500 with slide hammer tool 892/00224 and remove driveshaft seal and needle roller bearing from the hub carrier.
X
19
Use a puller to remove the trunnion seal and bearing.
S248900
9803/3260
Issue 3*
Section F
Transmission
Section F
Front Axle
23 - 8
23 - 8
Hub and Driveshaft - Assembly (cont'd) 5
Fit driveshaft needle roller bearing to the hub carrier. Pack the cavity between the oil seal lips with grease and then fit the seal.
X
S161460
6
Locate hub carrier and fit bottom trunnion. Apply JCB Lock and Seal (part no. 4101/0202) to the bottom trunnion bolt threads, fit and tighten to 98Nm (72 lbf ft). Fit top trunnion and leave top trunnion bolts finger tight.
S248890
7
Attach a spring balance to track rod swivel as shown and note the reading. Tighten the top trunnion bolts to eliminate end float but no bearing pre-load, ie no increase in spring balance reading.
S248850
8
Measure gap at top trunnion and subtract 1 mm (0.040 in) to give shim thickness (bearing pre-load). For example: Gap = 1.55 mm (0.061 in) less 1.00 mm (0.040 in) Shim =
0.55 mm (0.021 in)
* Note: Later type axles are not fitted with shims (the top face height of the swivel casting is increased by 1mm (0.040in.). These castings are identified with a small drill mark in the position shown at X (see illustration at step 5).
9803/3260
S248860
Issue 3*
Section F
Transmission
Section F
Front Axle
23 - 9
23 - 9
Hub and Driveshaft - Assembly (cont'd) 9
Refit top trunnion. Apply JCB Lock and Seal to the top trunnion bolt threads, fit and tighten to 98 Nm (72 lbf ft). Check spring balance reading which should be 4.5 kgf (10 lbf) more than the reading recorded at fig. 7.
* 10
Lightly oil the inner wheel bearing. Assemble the inner and outer bearing cups, and the inner bearing cone into the bearing carrier.
S248850
Measure the dimension between the wheel bearing face and the outer face of the wheel bearing carrier. If the dimension is 25 to 26mm (shown at A) fit the oil seal by using service tool C (part number 892/00891) with the spacer D until the oil seal is level with the wheel bearing carrier face as shown. If the dimension is 28 to 30mm (shown at B) fit the oil seal by using the service tool (but do not use spacer). When fitted, the seal will fit 2 to 3mm below the carrier face as shown.
C
D 11
A
B
S226311
Fit the bearing carrier onto the axle arm. Lightly oil the outer wheel bearing race. Fit the bearing onto the axle arm. Rotate the bearing during fitting.
S248920
12
Assemble the annulus ring to the annulus carrier. Secure with the circlip G.
G
S248910
9803/3260
Issue 3*
Section F
Transmission Front Axle
23 - 10
Section F 23 - 10
Hub and Driveshaft - Assembly (cont'd) 13
Fit annulus assembly in the same angular position as removal (see Note, page F/23 - 3, step 11) using new 'Verbus Ripp' bolts. Do not fully tighten bolts but allow the bearing carrier to rock slightly. Measure seal drag rolling force - see step 14.
S248540
14
To measure seal drag rolling force: -
Refit the planet gear carrier - DO NOT FIT THE DRIVESHAFT AND SUN GEAR.
-
Use a spring balance and cord wrapped around the planet carrier flange as shown.
-
Pull the spring balance so that the hub rotates, do several times to let the seal bed in and record the reading.
-
Remove planet gear carrier. S248870
*
15
Tighten M14 Verbus Ripp bolts to 320 Nm (236 lbf ft, 33 kgf m) and then measure rolling force - see step 16.
16
To measure rolling force: -
Refit the planet gear carrier - DO NOT FIT THE DRIVESHAFT AND SUN GEAR. Use a spring balance and cord wrapped around the planet gear carrier flange as shown. Pull the spring balance so that the hub rotates and record the reading.
-
To get the rolling force, subtract seal drag rolling force (see step 14) from reading obtained at this step, the result should be 14 to 152 N (3 to 34 lbf).
-
If the resulting figure is outside these limits check: the seal is fitted correctly; and/or renew bearings if necessary; and /or new fitted components.
-
Remove planet gear carrier.
9803/3260
S248540
S248870
Issue 4*
Section F 24 - 1
9803/3260
Transmission Front Axle
Section F 24 - 1
Issue 1
Section F
Transmission
24 - 2
Front Axle
Section F 24 - 2
* Drive Head - Dismantling (All Wheel Steer Machines) The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. 1
Drain the oil from the axle centre casing. Remove the propshaft from the gearbox to the front axle.
2
Remove both hub assemblies complete driveshafts (see pages F/23-1 to F/23-11).
3
Mark the installation position of the drive head carrier,
with
item 2. 4
Remove the drive head carrier retaining bolts, item 1, and remove the drive head carrier 2 from the axle casing.
5
Clean the drive head carrier and axle casing mating faces.
6
Pull out tension pins 3 and 4, and remove castellated nuts 5 and 6.
7
Remove bearing outer races 7 and 8.
8
Drive off the taper roller bearing cone 9 from the crownwheel differential case half.
9
Remove the differential assembly 10 from the carrier.
10
Remove the differential assembly retaining bolts 11 and separate case halves 12 and 13.
11
Remove the differential side gears and thrust washers 14 and 15 respectively (2 off each).
12
Remove planet gears and thrust washers 16 and 17 respectively (4 off each) from trunnion pins B.
13
Pull off taper roller bearing cone 18 from differential case half 12.
14
Remove 'verbus ripp' bolts 19 and separate the crownwheel 20 from the differential case half 13.
15
Use service tool 892/00812 to prevent drive flange 23 from rotating and remove pinion nut 21 and washer 22. Remove the drive flange.
16
Press the pinion 24 from the drive head carrier 2.
9803/3260
Issue 2*
Section F
Transmission Front Axle
24 - 3
Section F 24 - 3
* Drive Head - Assembly (All Wheel Steer Machines) Pinion Depth Setting Procedure 1
Place new pinion inner bearing 32 and outer race 29 (see page F/24-1) on a flat surface and position bearing cup 892/00174 over the bearing assembly.
2
Measure gap A (e.g. 0.20mm) and add this to the cup depth stamped on the tool (e.g. 30.01mm) to obtain the bearing depth.
3
From the face of the pinion, obtain the etched deviation figure (e.g. + 2) which is in units of 0.01mm. If positive, add this to the bearing depth; if negative, subtract from the bearing depth.
4
Obtain the deviation figure (e.g. —1) stamped on the differential housing bolt flange. If negative, add to bearing depth; if positive, subtract from bearing depth.
5
Subtract the total of the above figures from the standard value of 31.19mm. The result will be the thickness of shims required behind the pinion inner bearing outer race.
Example (all dimensions in millimeters) Cup Depth Gap A Bearing Depth Pinion Deviation (+ 2) Housing Deviation (—1)
30.01 + 0.20 30.21 + 0.02 + 0.01
Total
30.24
Standard Value Less Total From Above
31.19 30.24
Shim Thickness
0.95
Note: In rare instances, it is possible that the setting data stamp may be omitted from the drivehead casing. In these circumstances the following setting procedure should be used: Revise the shim pack size by the difference in setting height marked on the old and new crownwheel and pinion sets.
9803/3260
Issue 2*
Section F 24 - 4
9803/3260
Transmission Front Axle
Section F 24 - 4
Issue 1
Section F
Transmission
Drive Head - Assembly (All Wheel Steer Machines) Note 1: The crownwheel 20 and pinion 24 are matched and should be renewed as a pair if either one is damaged or excessively worn. The two differential case halves 12 and 13 are also matched as are gears 14 and 16. Do not use unmatched halves or gears.
9
Position top case half 12 onto bottom half assembly 13 aligning the match mark letters (see Note 1 opposite). Apply JCB Lock & Seal to the threads of bolts 11 then fit and torque tighten to 56 Nm (42 lbf ft; 6 kgf m). Check the gears for free rotation.
10
Press taper roller bearing cone 18 onto the spigot of case half 12.
Make sure all bearings are lightly oiled before fitting and setting. Make sure bearings are rotated whilst being set. 1
24 - 5
Front Axle
24 - 5
Section F
11
Install the differential assembly 10 into the drive head carrier 2.
Fit to the drive head carrier 2 the pinion inner bearing 12
outer race 28 together with the required thickness of
Press taper roller bearing cone 9 onto the spigot of case half 13.
shim(s) 29 to give correct pinion depth. (See Pinion Depth Setting Procedure, page F/24-3). Fit the shims behind the outer race as shown.
13
Fit bearing outer races 7 and 8, castellated nuts 5 and 6 to the drive head carrier 2.
2
Fit new taper roller bearing cone 31 and a new 14
collapsible spacer 30 onto pinion 24. 3
Fit outer race 27 to the drive head carrier 2.
4
Insert the pinion 24 into its bore. (Before inserting, ensure that the pinion matches the crownwheel. The code numbers etched on the pinion end face and the crownwheel perimeter should be the same).
5
Fit new taper roller bearing cone 26. Pack the cavity
Note 2: Measure the pre-load by taking another rolling torque reading and subtracting the torque figure measured at step 6.3. The difference is the bearing pre-load. 15
Measure the crownwheel backlash which should be 0.13 to 0.2 mm (0.005 to 0.008 in). Adjust castellated nuts 5 and 6 by equal amounts when altering backlash. When backlash and pre-load are both correct, fit tension pins 3 and 4.
16
Verify crownwheel and pinion are set correctly: Use engineers marker on three of the pinion teeth and check markings on the crownwheel are as indicated on page F/24-6. Adjust if necessary.
* 17
Apply JCB Multi-Gasket to the drive head carrier mating face then fit to the axle casing (the carrier assembly locates on two dowels). Make sure the assembly is fitted in the same match marked position (see step 3, dismantling, page F/24-2).
18
Apply JCB Lock & Seal to bolts 1 and torque tighten as detailed in Notes 3 and 4.
19
Assemble both hub and driveshafts, refit the propshaft to the gearbox.
20
Fill the axle with recommended oil.
between the lips of the new oil seal 25 with grease and fit the seal to the drive head carrier 2. 6
Adjust castellated nuts 5 and 6 to give a bearing preload (see Note 2) of 1.36 to 2.5 Nm (1.0 to 1.84 lbf ft; 0.14 to 0.26 kgf m).
Install the drive coupling yoke 23 and secure it with a new stake nut 21 and washer 22: 6.1 Hold the yoke 23 with Service Tool 892/00812. 6.2 Tighten the stake nut until end float is almost zero then check seal drag torque is between 0.40 to 0.75 Nm (3.5 to 6.6 lbf in). 6.3 Continue to tighten the stake nut to collapse spacer 30 and give a rolling torque of 1.7 to 2.8 Nm (1.3 to 2.1 lbf ft) excluding seal drag, crownwheel not fitted. IF THE STAKE NUT IS OVER-TIGHTENED, THE COLLAPSIBLE SPACER MUST BE RENEWED. Make sure that yoke 23 is rotated in both directions to fully seat bearings before measuring rolling torque. 6.4 When the torque is correct, stake the nut to the pinion shaft using a square ended staking tool, shown at A.
9803/3260
*
Note 3: Torque tightening depends on bolt type. The grade
* is stamped on the bolt head. If standard grade 8 bolt, tighten to 98 Nm (72 lbf ft; 10 kg fm). If Verbus Rip 12.9 grade bolt; tighten to 166 Nm (122 lbf ft;
Issue 3*
Section F
Transmission
24 - 6
Front Axle
Section F 24 - 6
* Drive Head - Assembly (All Wheel Steer Machines) Crownwheel and Pinion Adjustment Meshing of the gears should be checked by marking three of the pinion teeth with engineers marking compound and rotating the pinion. The marking will then be transferred to the crown wheel teeth.
Correct tooth marking.
Pinion too deeply in mesh. Decrease the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel towards the pinion to correct the backlash.
Pinion too far out of mesh. Increase the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel away from the pinion to correct the backlash.
9803/3260
Issue 2*
Section F 26 - 1
Section F
Transmission
26 - 1
Front Axle
Removal and Replacement (2 Wheel Drive Machines) The removal and replacement procedures for the 2 wheel drive axle (beam type) is the same as described on pages F/21-1 and F/21-2. Dis-regard any information which is not pertinent to the 2 wheel drive axle. Please note when using a 'cradle' to remove the axle from the machine, the balance point (see step 10, page F/21-2), of the axle on 2 wheel drive machines will be the centre of the axle, NOT offset as described on page F/21-2.
9803/3260
Issue 1 SXXXXXX
SXXXXXX
SXXXXXX
Section F
Section F
Transmission
27 - 1
27 - 1
Front Axle
Dismantling and Assembly (2 Wheel Drive Machines)
Bed in bearings 6 and 8 by rotating hub in each direction whilst tightening nut 3. When correct torque setting has been achieved, back off one flat and fit split pin 2.
When Dismantling Torque Settings The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. A suitable press will be required to remove and replace stub axle 24.
Item 3
Nm 40†
kgf m 4.0†
lbf ft 30†
9
30
3.0
21
11
30
3.0
21
† Back off one flat before fitting split pin. When Assembling Fit bushes 20 and 22 with open ends of grease grooves facing the axle beam. Add shims 18 as required to give zero to 0.1mm (0.004in) clearance between axle beam and bearing 17. Apply JCB Lock and Seal to threads of bolts 9 and 11. Pack JCB Special MPL Grease into hubs 5 and between lips of seals 7.
9803/3260
Issue 1
9803/3260
Axle Arm Bolts JCB Multi-Gasket Grade 8.8 - 244 Nm; 24.9 kgf m; 178 lbf ft Grade 12.9 - 400 Nm; 40.8 kgf m; 295 lbf ft S235450
Axle Mounting Bolts 607 Nm; 62 kgf m; 448 lbf ft
Differential Case Bolts (8.8) JCB Lock & Seal 56 Nm; 6 kgf m; 42 lbf ft
Transmission
Propshaft Retaining Bolts (12.9) 79 Nm; 8 kgf m; 58 lbf ft
Stake Nut See page F/22 - 1
Crownwheel Retaining Bolts (12.9) 166 Nm; 16.9 kgf m; 122 lbf ft
Trunnion Bolts JCB Lock & Seal 98 Nm; 10 kgf m; 72 lbf ft
Drain & Fill Plugs 79 Nm; 8 kgf m; 60 lbf ft
40 - 1
Planet Carrier Bolts (8.8)JCB Lock & Seal 56 Nm; 6 kgf m; 42 lbf ft
Wheel Nuts 680 Nm; 69 kgf m; 500 lbf ft
Typical axle shown, torque figures apply to AWS and 2WS machines - differences are indicated in text. When appropriate, the grade of the bolt is indicated either in the text or in parenthesis, e.g. ‘(12.9)’. Refer also to relevant dismantling and assembly procedures.
Rear Axle Torque Figures
Section F Section F
Rear Axle 40 - 1
Issue 1
Section F 41 - 1
9803/3260
Transmission Rear Axle
Section F 41 - 1
Issue 1
Section F
Transmission
Section F 41 - 2
Rear Axle
41 - 2
Removal and Replacement Replacement
! WARNING
Replacement is the reverse of the removal sequence.
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.
! WARNING If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged.
Disconnect the battery, to prevent the engine being started while you are beneath the machine.
2-3-2-8
GEN 1-1
Whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct.
Removal
! WARNING
! WARNING
When the propshaft is disconnected the parking brake will no longer function. The machine must be securely chocked to prevent any machine movement before disconnecting the propshaft.
Bleed the brake system before driving the machine. BRAK 1-6
TRAN 1-3
Bleed the brake system as described on page G/11-1.
Removing 1
Using tool 892/00822 remove bolts A to disconnect the drive shaft from the axle.
2
Disconnect the brake pipes from the brake piston housings, shown at H. Remove tee piece B retaining bolt and remove the tee piece. Blank off exposed connections.
3
Release bolts C and remove the proximity switch bracket together with the proximity switch assembly.
4
Label and then disconnect hydraulic pipes D from the steer rams, blank off all exposed connections.
5
Loosen the road wheel retaining nuts E.
6
Make sure that the front wheels are blocked, use the stabiliser legs to raise the rear end of the machine.
7
Prop the machine on each side as shown at F.
8
Remove the rear road wheels.
9
Position a jack underneath the balance point (centre) of the axle and support the axle weight.
Apply JCB Lock & Seal to the threads of bolts A. If the setting of the steering proximity switch has been disturbed, then complete the rear axle proximity switch setting procedure, as described on page F/41-3. Torque Settings Item A E G
Nm 79 680 607
kgf m 8 69 62
lbf ft 58 500 448
*
Note: Attach a 'cradle' to the jack that will partially embrace the axle. 10
Remove nuts G, bolts J and washers K.
11
Lower the jack and remove the axle.
9803/3260
Issue 2*
Section F
Transmission
Section F 41 - 3
Rear Axle
41 - 3
Proximity Switch Setting Procedure X
±5mm (0.197in) Front ±6mm (0.236in) Rear
! 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
A186150
FIG 1
To set the rear axle proximity switch: 1
Check wheels are in 'straight ahead' position as follows:
2
Measure ram extension X (FIG 1), the measurement should be the same for both the left and right hand rams (on the rear axle). If not, turn the steering wheel in the required direction until the distances are equal for both sides.
3
C A
Adjust the proximity switch C (FIG 2) so that there is a 5mm (0.197in.) gap between the lower face of the proximity switch and the top face of the sensor plate (use 5mm [0.197in.] thick plate as a setting tool).
Note: The proximity switch to sensor plate setting figure used to be 6mm (0.236in.). To improve performance, the proximity switch is now set at 5mm (0.196in) above the sensor plate. 4
Loosen the track rod sensing plate retaining bolts A (FIG 2).
5
Move the sensor plate B (FIG 2) fully to the left then gently adjust the plate to the right until the light emitting diode (L.E.D.) on the proximity switch illuminates. Mark two lines at each end of the slotted plate on the track rod.
6
Move the sensor plate B (FIG 2) fully to the right then gently adjust the plate to the left until the light emitting diode (L.E.D.) on the proximity switch illuminates. Mark two lines at each end of the slotted plate on the track rod.
7
Set the sensor plate ends central to the markings made in steps 5 and 6 as shown at D (FIG 3).
8
Tighten the sensor plate retaining bolts A.
9
Fit the guard E (FIG 4), the guard must be set with 3mm (0.125in) between the lower face of guard and top face of the sensing plate B.
B
S161290A
FIG 2
D S161290B
FIG 3
E
B S161290C
FIG 4 9803/3260
Issue 2
Section F 42 - 1
Section F
Transmission
42 - 1
Rear Axle
Renewing the Pinion Oil Seal The procedure for renewing the rear axle pinion oil seal is the same as for the front axle pinion oil seal. Please refer to pages F/22-1 and F/22-2 for a full description of the procedure.
9803/3260
Issue 1 SXXXXXX
SXXXXXX
SXXXXXX
Section F
Transmission
Section F
46 - 1
46 - 1
Limited Slip Differential
5 6
1
7
8
9 13
14
12 9 3
10
8
7
6
11 10
15 2 4
S212800
S212790
9803/3260
S171530
Issue 2
Section F
Transmission
46 - 2
Section F 46 - 2
Limited Slip Differential Dismantling and Assembly
Friction Plate Wear Limits
The numerical sequence shown on the illustration is intended as a guide to dismantling
Measure and note the thickness of the friction plate, the result must not be less than 1.25 mm (0.049 in).
When Dismantling
Check the condition of the friction material, which should be even over both surfaces.
Mark the two differential halves before dismantling, for subsequent assembly.
If in doubt, discard the set (friction and counter plates).
Note the relative positions of the friction and counter plates before dismantling, they must be fitted in the same positions. If worn, the friction and counter plates must be renewed as a complete set. When Assembling
* 1
Assemble trunnion pins 12, side gears 11 with pressure plates 10, counter plates 8, friction plates 9, planet gears 13 and thrust washers 14 into the 'crownwheel half of the differential assembly 5.
Note: Do not fit the shims 6 at this point. 2
Align the two halves of the differential assembly with the marks made during dismantling. Assemble using bolts 3.
3
Using a dial test indicator (or feeler gauges), with two screwdrivers or suitable levers, gently apply pressure to side gear 11 away from the trunnion pins 12 as shown. Measure and note the end-float of the side gear.
4
Turn the differential assembly over and repeat step 3 for the second side gear.
5
Dismantle the differential assembly. Add shims 6 to give end-float between 0.1 and 0.2mm (0.004 and 0.008in.).
*
*
Note: Shimming must be carried out whenever the differential is dismantled, however the end float 0.1 and 0.2 mm (0.004 and 0.008 in.) can be exceeded on previously assembled differential as this is only an initial setting figure which allows for bedding in. 6
Repeat steps 2, 3, and 4. If the end float is correct, tighten bolts 3 to 56 Nm (41 lbf ft).
7
Fit crownwheel 2 using new Verbus Ripp bolts 1, refer to page F/20-1 for torque figures.
*
9803/3260
Issue 2*
Section F 61 - 1
9803/3260
Transmission Synchro Shuttle Transmission
Section F 61 - 1
Issue 1
Section F
Section F
Transmission
61 - 2
Synchro Shuttle Transmission
61 - 2
Removal and Replacement
13
Using the trolley jack, lower the transmission and engine to gain access to the top flywheel housing to engine block retaining bolts J.
14
Disconnect the transmission oil cooler at the
Park the machine on firm level ground.
! WARNING
transmission unit, shown at B and N.
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.
15
Disconnect the battery, to prevent the engine being started while you are beneath the machine.
16
Remove the breather pipe from the pressure maintenance valve block to top of the dipstick tube as shown at M.
17
Put a support under the engine as shown at G to prevent it from dropping when the transmission is removed.
18
Remove the flywheel housing to engine bolts J.
19
Manoeuvre the transmission with the torque convertor clear of the engine housing.
20
Lower the trolley jack and pull the transmission and torque convertor clear of the machine.
Disconnect the transmission solenoid valve flying lead connectors A and the pressure sender. Label the connectors for identification when refitting.
GEN 1-1
Removal 1
Rest the bucket on the ground and raise the stabiliser legs sufficiently to allow room for the transmission to be pulled clear. Block/support the machine.
2
Drain the transmission system, see page 3/8-1.
3
Remove the engine bonnet, see page B/1-1.
4
Remove the engine fan retaining bolts P (4 off) and remove the fan, see note 1.
Note 1: At a later stage the transmission is tilted to give access to retaining bolts, if the fan is not removed at this stage it will foul.
Replacement
5
transmission as shown at D.
Set the parking brake cable as described on page 3/15-1. If the parking brake caliper has been removed reset central to the parking brake disc, see page G/11 - 2.
6
Remove rear axle drive shaft bolts E.
Set the torque converter as described on page F/66 - 1.
7
Remove 4WD shaft bolts F (use tool 892/00822) and 4WD solenoid flying lead connector L.
Fill the transmission with the specified amount of JCB Special Transmission Fluid (see page 3/1-1 for capacity). Leave hose N off until the filling operation is complete. After filling refit hose N.
Disengage the parking brake clevis at the parking brake caliper and remove outer cable retaining circlip as shown at C.
Torque Settings
8
9 10
11
Disconnect the gearshift lever from the top of the
Remove the transmission dipstick tube and filter. Remove the access bung/plate at the bottom of the flywheel housing. Through the access hole, loosen and remove the torque convertor to engine flywheel retaining bolts Q.
Replacement is a reversal of the removal procedure.
Item E
Nm 118
kgf m 12
lbf ft 87
F
79
8
58
J
98
10
72
K
237
24
175
P
44
4.5
33
Q
19
2
14
Support the transmission with a trolley jack as shown at H, see note 2.
Note 2: Attach a 'cradle' to the trolley jack that will partially embrace the transmission, see Service Tools, Section 1.
9803/3260
Issue 1
Section F 63 - 1
Transmission Synchro Shuttle Transmission
Section F 63 - 1
Solenoid Valve Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. For clarity, only one solenoid has been numbered in the dismantling sequence. When Dismantling Unscrew the knurled nut 2 and remove O-ring 3, withdraw the solenoid 4 and O-ring 5. Hold the solenoid valve body 6 in a vice, using the spanner flats A, remove spindle 7 and O-ring 8. Pull out actuating pin 9, spring 10, spring retainer 11 and spool 12. Dismantle the opposite solenoid in the same sequence as described above. Inspect the spool and spool bore for signs of wear, nicks scratches etc. When Assembling Renew all O-rings. Lightly lubricate all parts with clean transmission fluid before assembling. Check that the flying leads are secure and that the connectors are intact.
9803/3260
Issue 1
Section F 64 - 1
Transmission
Section F
Syncro Shuttle Transmission
64 - 1
Reverser Unit - Dismantling 1
Carefully remove piston ring seals.
Note: If the piston ring seals are excessively worn then check for burrs or damage on the shaft grooves. If necessary remove burrs with a fine grade abrasion paper and oil.
1
S232720
2
Loosen the clutch end bearing by tapping the assembly on a piece of wood as shown. Remove the bearing using pullers.
2
S232730
3
Remove the bearing, thrust washer and plastic type washer.
Note: Earlier assemblies have one thick thrust washer, one thrust bearing and one thin thrust washer, as shown at A. 4
A 3
Withdraw the gear and splined hub assembly with the needle roller bearing.
4 S232330
5
Remove plastic type washer and thrust washer.
5
Note: Earlier assemblies have one thin thrust washer, one thrust bearing and one thick thrust washer, as shown at B. 6
7
Remove the clutch friction/counter plates retaining circlip.
6
A232340
Remove pressure (end) plate.
7
B
S217540
9803/3260
Issue 2
Section F 64 - 2
Transmission
Section F
Syncro Shuttle Transmission
64 - 2
Reverser Unit - Dismantling (cont'd) 8
Remove the clutch friction/counter plates. Keep them together in sets, DO NOT mix the plates with those from other clutches.
9
Remove pressure (end) plate.
10
Remove disc spring assembly.
Note: The disc spring is assembled within a liner (not shown) to protect the hub support spline.
8
9 10
S232740
11
Position clutch assembly in press to compress piston spring then remove circlip.
12
Lift off spring retaining plate.
13
Remove spring.
11 12 13
Note: Earlier assemblies have an oil baffle plate 13A fitted. S145000
13A S217560
14
Knock the clutch shaft on a piece of aluminimum (or wood) to remove the piston.
Note: If the piston does not loosen when the clutch shaft is knocked on aluminimum, then hand pump air down the shaft oil inlet hole.
S145010
15
Remove and discard piston and shaft ‘O’ rings. Make sure the piston liner is secure. The liner must be a tight fit on the piston.
Note: Earlier type piston 15A shown. 16
Repeat steps 2 to 15 to dismantle the opposite clutch.
15
15A
S217570
9803/3260
Issue 2
Section F 64 - 3
Transmission
Section F
Syncro Shuttle Transmission
64 - 3
Reverser Unit - Assembly 1
Fit new 'O' rings onto the piston and shaft, lubricate with oil then press piston fully into bore of clutch housing.
Note: Earlier type piston 1A shown.
1A
1
S217570
2
Install the piston spring, make sure the spring seats in the piston.
4 3
Note: Earlier assemblies fitted with an aluminimum piston must fit oil baffle plate 2A, make sure that the baffle plate seats on the piston.
3
2
Fit the spring retaining plate. S145000
4
Compress spring and secure with circlip.
2A S217560
5
Fit the disc spring assembly. Fit the assembly so that the outer diameter curves away from the clutch piston.
Note: The disc spring is assembled within a liner (not shown) to protect the hub support spline. 6
Fit pressure (end) plate. Make sure that the prongs on the pressure plate DO NOT locate in the large grooves in the hub (the ones with drilled holes).
7
Firstly, fit one friction plate followed by one steel counter plate.
8
Continue fitting alternate friction and plain steel plates, finishing with a friction plate.
9
10
Fit the pressure (end) plate. Make sure that the prongs on the pressure plate DO NOT locate in the large grooves in the hub (the ones with drilled holes).
7
6 5
S217550
10
Fit the clutch friction/counter plates retaining circlip.
9
S217580
9803/3260
Issue 2
Section F 64 - 4
Transmission
Section F
Syncro Shuttle Transmission
64 - 4
Reverser Unit - Assembly (cont'd) 11
Using a dial test indicator as shown, measure the end float of the pressure (end) plate, which should be 3.2 to 4.4 mm (0.126 to 0.173 in). If necessary, fit shim between the retaining circlip and pressure (end) plate to correct end float inaccuracies.
Note: Later type shim has teeth on the outside diameter; the teeth prevent it from spinning during operation. If the shim removed from the clutch does not have teeth then discard it and use the new type shim.
S217590
12
Fit thrust washer and plastic type washer.
Note: Earlier assemblies have one thick thrust washer, one thrust bearing followed by one thin thrust washer shown at B.
12 A232340
B
S217600
13
Fit gear and splined hub assembly.
Note: Prior to fitting gear, align teeth of clutch plates using a thin rod (screwdriver). 14
Fit needle roller bearing.
15
Fit plastic type washer and thrust washer.
15 14 A232360
Note: Earlier assemblies have one thin thrust washer, one thrust bearing followed by one thick thrust washer shown at B.
B
13
S232370
16
Smear the clutch end bearing with JCB MPL Grease and press the bearing onto shaft.
17
Fit piston ring seals.
Note: If the piston ring seals are the polytetrafluoroethene (PTFE) type then see page F/68-1 for the correct fitting procedure. 18
17 16
Repeat steps 1 to 16 for the opposite clutch, make sure that the opposite clutch end taper roller bearing is packed with grease. S232720
9803/3260
Issue 2
Section F 65 - 11
Transmission
Section F 65 - 11
Synchro Shuttle Transmission
* Hydraulic 2/4 Wheel Drive Unit (from machine serial number 400077 to 415011)
S173590
9803/3260
Issue 2*
Section F 65 - 12
Transmission
Section F
Synchro Shuttle Transmission
* Hydraulic 2/4 Wheel Drive Unit (from machine serial number 400077 to 415011) Later type 2/4 wheel drive clutch assemblies have been revised in order to simplify the clutch pack setting procedure. The new clutch has no middle spacer, ie the actuating sleeve (item 15) is 12.2 mm; 0.480 inches longer. Detailed below is the correct dismantling and assembly procedure for the new clutch.
65 - 12
Assembly
* Note:
There is now a presure test adaptor and clamp assembly that can be used to 'bench test' the clutch. Bench testing will ensure the clutch operates correctly prior to reassembling and installing in the machine. Refer to 'Pressure Testing the 2/4WD Clutch' on page F/65-13. 1
Grease the shaft 22 then fit the piston housing 21 by pressing the shaft squarely into the housing (make sure the housing is securely supported).
2
Fit new O-rings 19 and 20 to piston 17, locate the piston into housing 21. Fit spring steel ring 18 ensuring that it seats firmly in its groove.
Dismantling 1
Remove the 2/4WD unit from the transmission - loosen the output yoke retaining nut before removal.
2
Remove bearing 1, only if to be renewed.
3
Place the disc spring 16 into the housing 21.
3
Remove seal ring 2. Note, If the piston ring seal is damaged or excessively worn then check for burrs or damage on the shaft groove. If necessary remove burrs with a fine grade abrasion paper and oil.
4
Position the actuating sleeve 15 onto the disc spring 16.
5
Install the clutch drum 14 in the housing. Fit support washer 13 and drum securing circlip 12.
4
Pull off the 4WD output gear 5, together with its bearing 3, needle roller bearing 6 and thrust washer 4.
6
5
Using a suitable press, compress disc springs 8A, 8B and remove the circlip 7.
Build up the clutch pack 11, installing friction plates and counter plates alternately, starting with a counterplate and finishing with a friction plate.
7
Install shim(s) 10 and pressure plate 9.
8
Use the output gear 5 to align the clutch plate splines. Ensure that all the plates are engaged with the gear shaft splines. Rotate the output gear back and forth to create maximum backlash then withdraw the gear taking care not to disturb the pack.
9
Place the first two disc springs 8B with their convex sides uppermost, onto the clutch pack. (There are four disc springs, which are identical). Place the other two disc springs 8A, with their convex sides down, onto the first two - refer to inset A.
10
Using a suitable press, compress the disc springs 8A and 8B, fit circlip 7.
11
Use levers to remove free play, as shown at B. Measure the gap between pressure plate 9 and actuating sleeve 15. The gap should be 0.75 - 1.5 mm; 0.030 - 0.059 inches. If necessary fit new shim 10 to achieve the correct gap. (Shim 10 can be a combination of a single counter plate, shim (thinner than the counter plate) or both counter plate and shim). Check that the clutch pack splines are still aligned - see step 8.
12
Install the 4WD output gear 5 and its needle roller bearing 6.
13
Install thrust washer 4 and bearing 3.
14
Fit sealing ring 2 and bearing 1.
15
Fit the 2/4WD unit to the transmission using a new gasket C. Apply JCB Lock & Seal to the mounting bolts D, torque tighten the bolts to 56 Nm; 42 lbf ft.
CAUTION: There is approximately 26700N (6000lbf) clamping force acting on the springs. 6
Remove disc springs 8A, 8B, pressure plate 9, shim(s) 10 (keep the shim(s) separate from the counter plates), and clutch pack friction plates and counter plates 11.
7
Remove the clutch drum retaining circlip 12 and support washer 13.
8
Remove clutch drum 14 and actuating sleeve 15 .
9
Remove disc spring 16.
10
Remove the piston 17 and its spring steel ring 18.
11
Remove and discard piston O-rings 19 and 20.
12
Remove the piston housing 21 only if necessary, the housing is a press fit on shaft 22.
9803/3260
Issue 2*
Section F 65 - 13
Transmission
Section F 65 - 13
Synchro Shuttle Transmission
* Hydraulic 2/4 Wheel Drive Unit (from machine serial number 400077 to 415011) Assembly (cont'd) 16
17
18
Fit the output yoke E retaining nut F and washer G, torque tighten the nut to 400 Nm; 295 lbf ft. Check shaft end float which should not exceed 0.03 mm; 0.001 inch. Note, rotate shaft whilst measuring to fully seat bearings. If the end float is incorrect, remove the output yoke E and bearing retaining circlip H. Note, if the end float is correct, it will still be necessary to remove the yoke - to fit the oil seal, see step 19. Add or subtract shims J to obtain correct setting. Shims should be fitted between bearing outer race K and spacer L. Replace the circlip and yoke and re-check the shaft end float.
19
When the shaft end float is correct, remove the yoke and fit a new oil seal M.
20
Refit the output yoke E and tighten the new retaining nut F to 400 Nm; 295 lbf ft, stake the nut to the shaft using a square ended staking tool, as shown at N.
21
Refit the hydraulic pipework and electrical connections.
* Pressure Testing the 2/4WD Clutch 1
Assemble the 2/4 wheel drive clutch, as described in 'Assembly'.
2
Check the clutch pack end float and adjust as required (see Assembly, step 11).
3
Insert the adaptor A into the oil gallery in the end of the 2/4 wheel drive clutch shaft as shown. Hold the adaptor in position with clamp B.
4
Use a hand pump to pressurise the clutch assembly until gear, item 5 can be turned by hand. Note the 2 pressure gauge reading - DO NOT EXCEED 200 lbf/in (13.8 bar).
5
If the pressure gauge reading is between 125 - 135 2 lbf/in (8.6 - 9.3 bar) then the clutch is operating correctly and can be fitted in the transmission.
6
If however the pressure gauge reading is above 135 2 lbf/in (9.3 bar) then re-check the clutch for assembly defects, especially the clutch pack end float (the shim may not be to the correct thickness). Re-test after checking for (and rectifying) assembly defects.
B A
S185720
9803/3260
Issue 2*
Section F 65 - 14
9803/3260
Transmission Synchro Shuttle Transmission
Section F 65 - 14
Issue 1
Section F 65 - 15
Transmission Synchro Shuttle Transmission
Hydraulic 2/4 Wheel Drive Unit from M415012
Section F 65 - 15
4
Build up the clutch pack, installing friction plates 11 and counter plates 12 alternately, starting with a counter plate and ending with a friction plate. Use the 4WD output gear 5 to align the clutch plate splines. Ensure that all the plates are engaged with the gear shaft splines. Rotate the output gear back and forth to create maximum backlash then withdraw the gear taking care not to disturb the pack.
5
Install pressure plate 10, shim(s) 9 and circlip 8 (Note that the shimming should be such that it is just possible to fit the circlip).
6
Measure the clutch pack end float using two screwdrivers as shown at B. End float should be between 1.0 mm and 2.3 mm. Adjust as necessary, by adding or removing shims 9.
Remove the 2/4WD unit from the casing - (loosen the output yoke retaining nut before removal if there is to be a complete strip down of the unit).
7
Fit thrust washer 7, 4WD gear 5, needle roller bearings 6 and thrust washer 4.
2
Remove the shaft components E - M.
8
3
Remove bearing 1, only if to be renewed.
Press bearing 3 squarely onto the shaft to seat on thrust washer 4, taking care not to exert any force on the housing i.e. rest the unit on the opposite shaft end, not the housing.
4
Remove seal ring 2. Note, If the piston ring seal is damaged or excessively worn then check for burrs or damage on the shaft groove. If necessary remove burrs with a fine grade abrasion paper and oil.
9
Fit new seal 2.
10
If required, press a new bearing 1 into position, taking care not to exert any force on the housing (see Step 8).
11
Fit the 2/4WD unit to the transmission using a new gasket C. Apply JCB Lock & Seal to the mounting bolts D, torque tighten the bolts to 56 Nm; 42 lbf ft.
12
Fit the output yoke E, retaining nut F and washer G, torque tighten the nut to 400 Nm; 295 lbf ft. Check shaft end float which must not exceed 0.03 mm; 0.001 in.
The gearbox may incorporate this type of 2/4 Wheel Drive Unit, which can be distinguished from the other two types by its external appearance. The Pressure-ON(4WD)/SpringOFF(2WD) Unit can be recognised by the 4 groups of 3 holes located around the clutch pack housing. Note: This type of unit is not interchangeable with the other types, which are Spring-ON (4WD)/Pressure- OFF (2WD). Dismantling Note: To aid working on this item, use the output yoke as a stand. 1
5
6
Pull off the 4WD output gear 5, together with its bearing 3, needle roller bearings 6 and thrust washer 4. Remove thrust washer 7. (Note that thrust washers 4 and 7 are not interchangeable). Remove circlip 8 and shim(s) 9 if fitted. Retain any shims as a set for reassembly.
Note: If only the clutch pack was to be removed, the job is now complete.
*
Note: Rotate shaft whilst measuring to fully seat bearings.
* Later assemblies use a flanged bolt in place of items F and G
7
Remove pressure plate 10, the clutch pack friction plates 11 and counter plates 12.
(the 4WD shaft has an internal thread). This bolt must be torque tightened to 395 Nm; 291 lbf ft.
8
Using a suitable press and an adapter similar to Y, compress spring 15 and remove circlip 13.
13
9
Remove spring retainer plate 14 and spring 15.
If the end float is incorrect, remove the output yoke E and bearing retaining circlip H. Note, if the end float is correct, it will still be necessary to remove the yoke - to fit the oil seal, see step 15.
10
Withdraw piston 16 then remove and discard 'O' rings 17 and 18.
14
Add or subtract shims J to obtain correct setting. Shims must be fitted between bearing outer race K and spacer L. Replace the circlip and yoke and re-check the shaft end float.
15
When the shaft end float is correct, remove the yoke and fit a new oil seal M.
16
Refit the output yoke E and tighten the new retaining nut F to 400 Nm; 295 lbf ft. Stake the nut to the shaft using a square ended staking tool, as shown at N.
17
Refit the hydraulic pipework and electrical connections.
Note: The piston housing cannot be separated from the shaft, as on the other types of 2/4WD units. Assembly If only the clutch pack has been removed, begin at step 4. 1
Grease the shaft, fit new 'O' rings 17 and 18 then locate piston 16 over the shaft and into the housing.
2
Locate spring 15 into the piston and position the retainer plate 14 over the spring.
3
Using a press and adapter Y, compress spring 15 and fit circlip 13.
9803/3260
Issue 2*
Section F
Transmission Synchro Shuttle Transmission
66 - 1
Section F 66 - 1
Torque Converter Removal and Replacement Removal See pages F/61-1 and F/61-2 for transmission/torque converter removal. Before Replacing Ensure that flywheel face, drive plate, and hardware are clean and free from burrs or other surface imperfections. When Replacing Attach drive plate 1 and drive plate annulus 2 to torque converter, tightening bolts 3 finger tight only.
A
Bolt drive plate to flywheel and check that run-out of pump drive shaft A does not exceed maximum permissible 0.38mm (0.015in.). If incorrect, tap torque converter by hand to reposition. When correct, remove the torque converter and drive plate/annulus sub-assembly from the flywheel. Torque tighten converter drive plate/annulus bolts 3. Install the torque converter with its drive plate/annulus subassembly onto the transmission input shaft, make sure that the dogs on the converter pump drive shaft engage with the recesses in the pump, also take care not to damage the oil seal. Rotate the engine flywheel so that one bolt hole is in a six O' clock position. Rotate the torque converter and drive plate assembly so that one bolt hole is in a six O' clock position. Install the transmission/torque converter assembly to the engine. Remove the access plate from the bottom of the engine flywheel housing and through the access hole fit and hand tighten one bolt (item 5) in the six 'O' clock position Note: It is important to mount washers 4 with the outside diameter radius against the drive plate, (ie) facing toward the flywheel. Rotate the flywheel until the next bolt hole is accessible, fit and hand tighten the next bolt 5. Repeat the operation until all bolts are fitted. Finally torque tighten bolts, rotating the flywheel each time to align bolts 5 with access hole. Refit plate. Torque Settings Item 3 5
Nm 40 19
9803/3260
kgf m 5 2
lbf ft 30 14
Issue 1
Section F 67 - 1
9803/3260
Transmission Synchro Shuttle Transmission
Section F 67 - 1
Issue 1
Section F
Transmission Synchro Shuttle Transmission
67 - 2
Section F 67 - 2
Torque Converter Stall Test Ensure that the engine and transmission are at normal working temperature. Run engine at maximum speed and check the No Load Speed (High Idle Speed - U.S.A). See Engine Technical Data for correct figure; adjust if necessary.
2
Start engine and run at 1000 rev/min. The flowmeter will show the Pump Flow which should be as shown in Technical Data. A low reading indicates a worn pump or blocked suction strainer. The pressure gauge will show the Main Line Pressure (see Technical Data). A low reading can be caused by either a faulty pressure maintenance valve or a worn pump. A high reading indicates a faulty pressure maintenance valve or, if the pump flow is low, the oil cooler may be blocked.
3
Stop engine, remove flow test adapters and refit filter. Connect pressure gauge and flowmeter into converter out line as shown at F. Run engine at 1000 rev/min with transmission in Neutral and note Converter Out Pressure and Oil Cooler Flow, which should be as shown in Technical Data. A high pressure together with low flow could be caused by a blocked oil cooler. (See also check 7.)
4
With parking brake and footbrake firmly applied, select Forward and check flow reading, which should not fall by more than 4.5 litres (1 UK gal; 1.2 US gal) per minute. A low reading indicates a high leakage rate in that particular clutch, which could be caused by worn or broken piston seals or shaft sealing rings. Select Reverse and repeat the test.
5
If the clutch leakage rate is high, the Clutch Pressures may be checked by connecting the pressure gauge into ports G and H and repeating test 4. A low reading (see Technical Data) would confirm a high leakage rate in the particular clutch selected.
6
Stop engine, connect the pressure gauge into port J in the transmission, and fit a load valve L into the converter out line (see note).
Apply parking brake and footbrake firmly, select 4th Speed Forward and open throttle fully. Engine speed should be as specified at Torque Converter Stall in Transmission Technical Data. Select Reverse and repeat test.
* Note:
On machines from serial number 413772, when fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the machine from being driven with the parkbrake on. Therefore, so that we can complete the test, move the parkbrake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the parkbrake will not be fully operational. Alternatively, disconnect the switch at the park brake. DO NOT stall the converter for longer than 10 seconds or the transmission fluid will overheat. If engine speeds are higher than the stated figures check the transmission for clutch slippage or internal leakage. If engine speeds are below the stated figures either the engine is losing power and should be serviced/overhauled or the torque converter reaction member clutch is slipping. To check the engine, select Neutral, open throttle fully and operate an excavator service to 'blow off' the main relief valve. Engine speed should fall to slightly above the Maximum Governed Speed (see Engine Technical Data). If engine speed is correct the torque converter is faulty. Note: Maximum Governed Speed is a datum figure only. It cannot be adjusted or checked with the engine installed in the machine.
Note: Make sure that the load valve L has been screwed fully out before starting the engine, otherwise the converter seals will be damaged.
Pressure and Flow Test Start engine, run at 1000 rev/min and slowly screw down the load valve whilst observing the gauge reading, which should rise to the setting of the Converter Relief (Safety) Valve (see Technical Data). DO NOT allow the pressure to exceed 10.3 bar (150 lbf/in2) or damage to the converter seals will be caused.
Note: The tests must be carried out only in the following order, step by step.
! WARNING Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. Trans 1-2
*
1
Stop engine, remove transmission filter, and screw adapter A (892/00304) on to the threaded spigot. Fit test adapter B (892/00301) and secure with adapter C (892/00302). Connect flowmeter D (892/00229) as shown and connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector E (see Service Tools, Section 1).
9803/3260
If the reading is higher than specified, the relief (safety) valve must be faulty. A low reading indicates a faulty relief (safety) valve, leaking converter 'piston ring' type seal or leaking pump seal. 7
Stop engine and connect pressure gauge and flowmeter into return line from oil cooler to transmission as shown at K. Start engine, and with transmission in Neutral check flowmeter reading, which will show the Cooler Flow Rate (see Technical Data). The pressure gauge will show the Lubrication Pressure (see Technical Data). Low flow and pressure readings could indicate a blocked oil cooler.
Issue 2*
Section F 68 - 1
Transmission Synchro Shuttle Transmission
1
Wind the PTFE piston ring seal around your finger as shown, so that the seal forms a 'coil'.
2
Smear the seal with grease and then fit the seal to the shaft.
Section F 68 - 1
Make sure that the seal sits below or flush with the outer diameter of the shaft. If necessary, use finger pressure as shown to make the seal flush with the shaft. CAUTION: If the seal is not set below or flush with the outer diameter of the shaft, then the seal will 'cut' when the shaft is fitted to its mating component.
9803/3260
Issue 1
Section F 81 - 1
9803/3260
Transmission Powershift Transmission
Section F 81 - 1
Issue 1
Section F
Removal and Replacement
12
Using the trolley jack, lower the transmission and engine to gain access to the top flywheel housing to engine block retaining bolts J - do not remove bolts at this stage.
13
Disconnect the transmission oil cooler at the
Park the machine on firm level ground.
! 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
transmission unit, shown at B and N. 14
Rest the bucket on the ground and raise the stabiliser legs sufficiently to allow room for the transmission to be pulled clear. Block/support the machine.
Disconnect the transmission solenoid valve flying lead connectors A. Label the connectors for identification when refitting.
15
Put a support under the engine as shown at G to prevent it from dropping when the transmission is removed.
16
Remove the flywheel housing to engine bolts J.
17
Manoeuvre the transmission with the torque convertor clear of the engine housing.
18
Lower the trolley jack and pull the transmission and torque convertor clear of the machine.
Removal
2
81 - 2
Powershift Transmission
81 - 2
1
Section F
Transmission
Drain the transmission system, see page 3/8-2.
3
Remove the engine bonnet, see page B/1-1.
4
Remove the engine fan retaining bolts P (4 off) and remove the fan, see note 1.
Replacement Replacement is a reversal of the removal procedure.
Note 1: At a later stage the transmission is tilted to give access to retaining bolts, if the fan is not removed at this stage it will foul.
The solenoids should have been labelled before removing connecters, however page F/91-1 identifies the solenoids and the correct electrical connections.
5
Remove rear axle drive shaft bolts E.
6
Remove 4WD shaft bolts F (use tool 892/00822).
Set the parking brake cable as described on page 3/15-1. If the parking brake caliper has been removed reset central to the parking brake disc, see page G/20 - 2.
7
Disengage the parking brake clevis at the parking brake caliper and remove outer cable retaining circlip as shown at C.
Set the torque converter as described on page F/66 - 1.
8
Remove the transmission dipstick tube and filter, shown at M.
9
10
Fill the transmission with the specified amount of JCB Special Transmission Fluid (see page 3/1-1 for capacity).
Torque Settings Item E
Nm 118
kgf m 12
F
79
8
58
J
98
10
72
K
237
24
175
Support the transmission with a trolley jack attachment
P
44
4.5
33
as shown at H (see Section 1, Tools), refer to note 2.
Q
19
2
14
Remove the access bung/plate at the bottom of the flywheel housing. Through the access hole, loosen and remove the torque convertor to engine flywheel retaining bolts Q.
lbf ft 87
Note 2: The Powershift weight distribution is unbalanced. It is very important that the transmission is securely supported before attempting to complete the removal procedure. The trolley jack attachment prevents the transmission from moving side to side AND front to back when being removed.
9803/3260
Issue 1
Section F 88 - 1
Transmission Powershift Transmission
Section F 88 - 1
Hydraulic 2/4 Wheel Drive Unit Dismantling and Assembly
* The
Powershift 2/4 wheel drive unit dismantling and assembly procedures are the same as for the Syncro Shuttle transmission 2/4 wheel drive units (later type), described on pages F/65-11 to F/65-13, or (from M/C No. 415012) of the 'Pressure-ON/Spring-OFF' type, described on pages F/6514 to F/65-15. Note that the Powershift 2/4 wheel drive clutch assembly is the latest type, that is the new type of clutch has no middle spacer, therefor the actuating sleeve is 12.2 mm (0.480 inches) longer. This arrangement simplifies the clutch pack setting procedure.
Torque Converter Removal and Replacement The Powershift torque converter removal and replacement procedures are the same as for the Syncro Shuttle transmission, described on page F/66-1.
9803/3260
Issue 2*
Section F 91 - 1
Transmission
Section F 91 - 1
Powershift Transmission
Torque Converter Stall Test Note: DO NOT stall the converter for longer than 10 seconds or the transmission fluid will overheat. Make sure that the oil level is correct and at normal operating temperature. Before completing the following test, remove the transmission dipstick. If there is any sign of smoke emitting from the dipstick tube STOP THE TEST IMMEDIATELY and dismantle the transmission for servicing.
If engine speeds are below the stated figures either the engine is losing power and should be serviced/overhauled or the torque converter reaction member clutch is slipping. To check the engine, select Neutral, open throttle fully and operate an excavator service to 'blow off' the main relief valve. Engine speed should fall to slightly above the Maximum Governed Speed (see Engine Technical Data). If engine speed is correct the torque converter reaction member clutch is slipping.
1
Ensure that the engine and transmission are at normal working temperature. Run engine at maximum speed and check the No Load Speed (High Idle Speed U.S.A). See Engine Technical Data for correct figure; adjust if necessary.
If engine speeds are higher than the stated figures check the transmission for clutch slippage or internal leakage. To isolate a suspect clutch, tabulate the recorded readings as shown in the example below:
2
Apply parking brake and footbrake firmly. If necessary, set the machine against a fixed obstruction.
Gear Select
Direction Clutch
Mainshaft or Layshaft Clutch
RPM
2nd 3rd 2nd 3rd
Forward High Forward Low Reverse High Reverse Low
Layshaft Mainshaft Layshaft Mainshaft
2060 1990 1985 1980
Note: On machines from serial number 413772, when fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the machine from being driven with the parkbrake on. Therefore, so that we can complete the test, move the parkbrake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the parkbrake will not be fully operational. Alternatively, disconnect the switch at the park brake. 3
Select 2nd speed forward drive and open throttle fully. Record the engine speed from the tachometer. Repeat the test for 3rd speed forward and record the reading.
4
Repeat step 3 except this time select 2nd and 3rd gear reverse drive respectively. Record the readings.
In the example shown, we can see that the engine speed is abnormally high when 2nd speed forward drive is selected, indicating a slipping clutch. From the table we can see that the layshaft clutch is working normally (2nd speed reverse drive indicates 1985 rev/min). Therefore it follows that the suspect clutch is the forward high. Assuming all other possible faults have been eliminated (see Powershift fault finding) this clutch would be dismantled for servicing.
Note: Using 2nd and 3rd gears in forward and reverse drive will ensure that ALL clutches are energised during the test. 5
All recorded readings should be as specified at Torque Converter Stall in Transmission Technical Data, pages F/1-8 to F/1-9.
9803/3260
Issue 2
Section F
Transmission
Section F 91 - 2
Powershift Transmission
91 - 2
Testing For Clutch Leakage ! WARNING DO NOT go underneath the machine with the engine running. Switch off the engine, apply the parking brake and chock both sides of all wheels before going underneath the machine.
Example Only Gear Ratio Select Clutch
Mainshaft or Layshaft Clutch
bar
lbf/in2
Trans 2-1
1st 2nd 3rd 4th
Layshaft Layshaft Mainshaft Mainshaft
9.65 8.62 9.65 8.62
140 125 140 125
Solenoid Identification When testing individual clutch pressures (see page F/91-3), it is necessary to isolate the clutch being tested. So for instance, to check the layshaft clutch we could select 1st gear forward - this would energise the layshaft and forward low clutches. Because we only want to check the layshaft clutch pressure and not the forward low clutch pressure, remove the electrical connector to the forward low clutch BEFORE selecting 1st gear. Use the table below to determine which solenoid electrical connectors should be removed when pressure testing individual clutches. Gear Selected
Clutches Engaged (Solenoids Engaged)
1st Forward 2nd Forward 3rd Forward 4th Forward
Forward Low & Layshaft (solenoids 2 & 4 ) Forward High & Layshaft (solenoids 1 & 4 ) Forward Low & Mainshaft (solenoids 2 & 3) Forward High & Mainshaft (solenoids 1 & 3)
1st Reverse 2nd Reverse 3rd Reverse 4th Reverse
Reverse Low & Layshaft (solenoids 5 & 4 ) Reverse High & Layshaft (solenoids 6 & 4 ) Reverse Low & Mainshaft (solenoids 5 & 3) Reverse High & Mainshaft (solenoids 6 & 3)
Forward Low Forward High Forward Low Forward High
Readings should not vary between clutches by more than 0.7 bar (10 lbf/in2). In the example shown, we can see that pressure is low when 2nd and 4th gear forward is selected, indicating clutch leakage. From the table we can see that the forward high clutch is used for selection of both 2nd and 4th gear forward. We know from the table that the mainshaft and layshaft clutches are working normally (1st and 3rd gear selection show normal operating pressure). So we can assume that the forward high clutch is leaking. We can now confirm the forward high clutch is leaking by completing an 'Individual Clutch Leakage Test', see next page. Note: Repeat above test using reverse ratios if necessary.
Isolating a Suspect Clutch 1 Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector A (mainline pressure test point). 2
Make sure that both sides of all four wheels are chocked. Apply the footbrake and parking brake.
7
A 1
3
5
Note: On machines from serial number 413772, when fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the machine from being driven with the parkbrake on. Therefore, so that we can complete the test, move the parkbrake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the parkbrake will not be fully operational. Alternatively, disconnect the switch at the park brake. 3
Start engine and run at 1000 rev/min, engage 1st gear forward. Record the pressure reading. Repeat the test for all gear ratios in forward drive and record the pressure readings as shown in the example below: S247710
9803/3260
2
4
6 Issue 2
Section F
Transmission
Section F 91 - 3
Powershift Transmission
91 - 3
Testing For Clutch Leakage Individual Clutch Leakage Test In the following procedures the forward high clutch is tested, therefore in step 2 a pressure gauge is connected to the forward high clutch test point. When testing other suspect clutches connect a gauge to the relevant suspect clutch test point. See page F/91-4 for the position of individual clutch pressure test points. Because the forward high clutch is suspect, a gear must be selected that will use the forward high clutch, in this instance 2nd gear forward. 1
Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector A, (mainline pressure test point), see page F/91-4 .
2
Connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector G (forward high ratio clutch test point), see page F/91-4 .
3
Remove the layshaft clutch solenoid feed connector 4, this ensures that only the forward high clutch is energised when 2nd gear forward is selected.
Note: See page F/91-2 for identification and position of solenoid feed connectors when testing other suspect clutches. 4
Make sure that both sides of all four wheels are chocked. Apply the footbrake and parking brake.
Note: On machines from serial number 413772, when fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the machine from being driven with the parkbrake on. Therefore, so that we can complete the test, move the parkbrake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the parkbrake will not be fully operational. Alternatively, disconnect the switch at the park brake. 5
G A
Start engine and run at 1000 rev/min, select 2nd gear forward. Note the pressure readings on both gauges, which should not vary by more than 0.7 bar (10 lbf/in2). If the difference on the gauges is greater than 0.7 bar (10 lbf/in2) do the following: a
Stop the engine and interchange the gauges.
b
Start the engine and run at 1000 rev/min, select 2nd gear forward. If the difference on the gauges is still greater than 0.7 bar (10 lbf/in2) dismantle the forward high clutch for servicing.
c
If after interchanging the gauges, the readings are different than at step 5, have the gauges calibrated and repeat the testing procedure. S247710
9803/3260
4 Issue 2
Section F 91 - 4
Transmission
Section F 91 - 4
Powershift Transmission
S144482
9803/3260
Issue 2
Section F
Transmission
Section F
Powershift Transmission
91 - 5
91 - 5
Pressure and Flow Testing Before completing any of the transmission pressure/flow tests, make sure that the oil level is correct and at normal operating temperature.
Pump Flow Refer to the illustration on page F/91-4 1
Stop engine, remove transmission filter, and screw adapter X (892/00304) on to the threaded spigot. Fit test adapter Y (892/00301) and secure with adapter Z (892/00302). Connect flowmeter W (892/00229).
2
Start engine and run at 1000 rev/min. With the transmission in neutral the flowmeter will show the Pump Flow which should be as shown in Technical Data, page F/1-7. A low reading indicates a worn pump or blocked suction strainer.
3
Repeat step 2 and note gauge readings with engine running at 2000 rev/min.
4
Stop engine and remove test adapters, refit filter.
All gauges etc used in the following pressure/flow tests are shown in Section 1.
! WARNING Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic oil 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 oil. If hydraulic oil penetrates your skin, get medical help immediately. HYD 1-1
! WARNING Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. Trans 1-2
! WARNING DO NOT go underneath the machine with the engine running. Switch off the engine, apply the parking brake and chock both sides of all wheels before going underneath the machine.
Mainline Pressure Refer to the illustration on page F/91-4 1
Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector A.
2
Start engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will show the Main Line Pressure which should be as shown in Technical Data, page F/1-7. A low reading can be caused by either a faulty pressure maintenance valve or a worn pump. A high or low reading may indicate a faulty pressure maintenance valve.
3
Repeat step 2 and note gauge readings with engine running at 2000 rev/min.
4
Stop engine and remove test gauge.
Trans 2-1
! WARNING Powershift transmission is in 4 wheel drive until selected by hydraulic pressure to 2 wheel drive. If machine is to be raised, make sure all four wheels off the ground. If only the rear wheels are raised, machine could still drive through the front axle.
dethe are the
TEST POINTS A - Mainline pressure B - Converter inlet/converter relief valve pressure C - Converter outlet pressure D - Mainshaft clutch pressure
Converter Out Pressure/Oil Cooler Flow Rate Refer to the illustration on page F/91-4 1
Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge and flowmeter into the converter out line as shown at C and K respectively.
2
Run the engine at 1000 rev/min with transmission in neutral. The pressure gauge indicates the Converter Out Pressure and the flowmeter indicates the Oil Cooler Flow Rate, both readings should be as specified in Technical Data, pages F/1-6 & F/1-7. A high pressure together with low flow could be caused by a blocked oil cooler.
3
Repeat step 2 and note gauge readings with engine running at 2000 rev/min.
4
Stop engine, remove test gauges and refit hoses to original position.
E - Layshaft clutch pressure F - Pump flow (remove filter and fit adapters) G - Forward high ratio clutch pressure H - Forward low ratio clutch pressure J - Lubrication pressure K - Cooler flow (flowmeter in line from cooler to transmission) L - Reverse high ratio clutch pressure M- Reverse low ratio clutch pressure N - 2/4 wheel drive clutch pressure P - Load Valve
9803/3260
Issue 2
Section F 91 - 6
Transmission Powershift Transmission
Section F 91 - 6
Pressure and Flow Testing (cont'd) Converter In Pressure Refer to the illustration on page F/91-4 1
Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test point B.
2
Start the engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will show Converter In Pressure which should be as shown in Technical Data, page F/1-6. A high or low reading could indicate a faulty converter relief valve.
3
Remove pressure test gauge.
Converter Relief (Safety) Valve Pressure Refer to the illustration on page F/91-4 1
Connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test point B.
2
Fit a load valve P into the converter out line.
CAUTION: Make sure the load valve is in the OPEN position(the adjusting knob screwed fully out) before starting the following pressure test. If the load valve is not fully open, damage to the converter seals will be incurred. CAUTION: DO NOT allow the pressure to exceed 10.3 bar(150 lbf/in2) or damage to the converter seals will be caused. 2
Start the engine and run at 1000 rev/min. With the transmission in neutral, slowly screw down the load valve P whilst observing the gauge reading which should rise to the Converter Relief (Safety) Valve setting as specified in Technical Data, page F/1-6.
3
If the reading is higher than specified then the converter relief valve is faulty. A low reading indicates a leaking pump seal or a faulty converter relief valve.
4
Stop engine, remove test gauges and refit hoses to original position.
Lubrication Pressure Refer to the illustration on page F/91-4 1
Stop engine, connect a suitable pressure gauge into the return line from the oil cooler to the transmission as shown at J.
2
Start the engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will indicate the Lubrication Pressure which should be as specified in Technical Data, page F/1-6.
3
Repeat step 2 and note gauge readings with engine running at 2000 rev/min.
4
Stop engine and remove pressure gauge.
9803/3260
Issue 1
Section G
Brakes
Section G
i
i
Contents Technical Data
1-1
Descriptions Compensating Master Cylinder - Pedals Locked - Normal Operation - Pedals Locked - Compensating Operation - Pedals Unlocked - Normal Operation
2-1 2-3 2-5
Fault Finding - Brake System - Brake Piston Seal Leakage Test
5-1 5-4
Brake System - Bleeding
9803/3260
Page No.
11 - 1
*
Parking Brake Caliper (machines up to serial number 441101 - Dismantling and Assembly 20 - 1 - Setting Procedure 21 - 1
* * * * * * *
Parking Brake Caliper (machines from serial number 441102) - Adjusting the Parking Brake 22 - 1 - Testing the Parking Brake 22 - 1 - Adjusting the Brake Pads 22 - 2 - Adjusting the Cable Slack 22 - 2 - Renewing the Brake Pads 22 - 3 - Dismantling and Assembly 22 - 4 Service Brakes - Dismantling and Assembly
Refer to page F/43 - 1
Master Cylinder and Servo Unit - Removal and Replacement - Dismantling and Assembly
30 - 1 31 - 1
Issue 2*
Section G
Brakes Technical Data
1-1
Service Brake Type
Section G 1-1
JCB Oil-Immersed Multi-Plate Disc
Actuation
Hydraulic - vacuum servo assisted for machines powered by model AB turbocharged engine
Location
Rear Axle Centre Casing (2 brake packs)
Friction Plates (5 per brake pack) Outside Diameter Nominal Facing Area per Plate Hydraulic Piston Diameter
220 mm (7.992 in) Inside Diameter 12616 mm2 (19.3 in2) 216 mm (8.5 in)
180 mm (6.811 in)
Master Cylinder (combined servo assistance) Number of Cylinders 2 Type
Frenos compensated master cylinder
Piston Diameter (each)
22.22 mm (0.875 in)
Exhauster Type
Frenos Iruna
Parking Brake Type Disc Diameter
Manually Adjusted Caliper, cable operated, mounted on transmission output 279.4 mm (11 in)
Note: Because the service brakes are located in the rear axle, instructions for dismantling and assembly are shown in the Transmission Section (Rear Axle Brakes).
9803/3260
Issue 1
Section G
Brakes
Section G 5-1
Fault Finding
5-1
Brake System Note: The brakes generate a high temperature when operating, this means that the casing will be hot to touch, this condition is normal. FAULT
*A
*B
One or both brakes do not apply. (Brake travel not excessive, brakes not pulling to one side).
Pedal travel excessive (but not touching floor).
POSSIBLE CAUSE
ACTION
1
Master cylinder fault.
1
Check master cylinder in single and coupled pedal modes to identify fault area, service as required.
2
Friction/counter plate distortion.
2
Check friction/counter plates.
1
Air in hydraulic system.
1
Check fluid reservoir level. Check for fluid/air leaks, rectify as required.
2
Leak in hydraulic system.
2
Check for fluid loss at master cylinder and brake piston, all pipes and fittings for loose connections. Rectify as required.
3
Friction/counter plate distortion.
3
Renew friction/counter BOTH sides.
plates
-
*C
Applying one brake (pedals unlocked) also partially engages the other brake.
1
Valve stem seal inside (non-active) master cylinder piston not sealing.
1
Renew master cylinder piston.
*D
Pedal hard to operate.
1
Tightness at pedal pivot.
1
Inspect pedal off/lubricate.
2
Fluid contamination/seal damage.
2
Flush system and renew all hydraulic seals.
3
Misaligned push rod/pedal.
3
Check and rectify as required.
4
Kinked or crushed brake pipes.
4
Check/renew brake pipework.
pivot.
Free-
Items 5 to 7 are for machines fitted with servo assisted brakes only:
*E
*F
*G
Pedals touch floor under constant pressure - no fluid loss.
Pedals touch floor under constant pressure - and fluid loss.
Pulling to one side when pedals locked together.
9803/3260
5
Vacuum failure due to low vacuum at source.
5
Inspect/service engine mounted exhauster unit as required.
6
Blocked/leaking vacuum pipe.
6
Check/renew vacuum pipe.
7
Servo defect.
7
Renew servo unit.
1
Master cylinder fault.
1
Check master cylinder in single and coupled pedal modes to identify fault area, service as required.
2
Friction/counter plate distortion.
2
Renew friction/counter BOTH sides.
3
Air in hydraulic system.
3
See item B.1.
1
External fluid leaks.
1
Visually check brake circuit for fluid loss, service as required.
2
Internal fluid leaks.
2
See 'Brake Piston Seal Leakage Test' on page G/5-4.
1
Compensating working.
1
Inspect master cylinder compensating operation. Check if blockage in bridging pipe. Service as required.
feature
not
plates
-
Issue 2*
Section G
Brakes
*G
*H
*J
*K
Pulling to one side when pedals locked together (cont'd).
Poor braking (not pulling to one side).
One or both brakes not releasing.
Poor braking when hot.
9803/3260
5-2
Fault Finding
5-2 FAULT
Section G
POSSIBLE CAUSE
ACTION
2
Braking system inoperative on 2 one side.
Unlatch pedals to test circuits individually.
3
Friction plates worn beyond limits 3 or distorted on one side.
Renew friction/counter BOTH sides.
4
Badly adjusted push rods.
4
Adjust push rod (1mm minimum).
5
Annular piston fault (see item J6).
5
See item J6.
1
Friction plates worn beyond limits 1 or distorted on one side.
Renew friction/counter BOTH sides.
2
Master cylinder fault.
2
Check master cylinder in single and coupled pedal modes to identify fault area, service as required.
3
Annular piston fault (see item J6).
3
See item J6.
4
Incorrect/low axle oil.
4
Fill axle with correct type of oil.
5
Vacuum failure (machines fitted 5 with servo assisted brakes only).
1
Brake pedal spring fault.
2
Master cylinder fault (plunger 2 stuck in bore).
Service as required.
3
Blocked hole in master cylinder 3 reservoir cap.
Fit a new reservoir cap.
4
Brake pedal free travel incorrect.
4
Adjust pedal free travel.
5
Fluid contamination/seal damage.
5
Flush system and renew hydraulic seals.
6
Annular brake piston(s) binding in 6.1 Check that correct brake fluid has axle. been used (incorrect fluid could swell the annular brake piston seals). 6.2 Check if annular brake piston seals in good condition. 6.3 Check that annular brake piston rotates freely in its housing with no seals fitted. 6.4 Check that the annular brake piston seal retracts the piston approximately 0.5mm (0.020 in).
7
Kinked or crushed brake pipes.
8
Friction/counter plates not free on 8 splines and/or dowels.
Check friction/counter plates for free movement, replace if required BOTH sides.
1
Moisture in system vapourizing 1 when axle is hot.
Strip axle and clean annular piston to remove moisture. Remove master cylinders and check for corrosion, service as required. Flush hydraulic brake system.
1
7
Inspect vacuum service as required.
plates
plates
-
-
source/pipes,
Fit a new spring.
Check and renew pipes as required.
Issue 2*
Section G
Brakes
*L
Excessive brake noise in operation.
Note: Due to the metal to metal contact of oil immersed brakes, limited noise can be heard which is consistent with this type of design - this is normal.
*M
Fluid loss when machine standing, for instance - overnight (see note).
5-3
Fault Finding
5-3 FAULT
Section G
POSSIBLE CAUSE 1
ACTION
2
Deterioration of axle oil or wrong 1 type of axle oil. 2 Axle oil loss.
3
Friction plates worn beyond limits.
4
Friction/counter plates in poor condition.
1
Slight cut or nick in the brake 1 piston seal, see 'Brake Piston Seal Leakage Test' page G/5-4.
Change axle oil. Refill axle with correct oil and check for leaks.
3
Renew friction/counter plates.
4
Check for distortion or surface pitting and/or roughness of friction/counter plates (annular grooving of counter plates is acceptable). Strip axle, replace seal.
Note: Confirm fault is as indicated by checking that the pedals DO NOT touch floor under constant pressure.
9803/3260
Issue 2*
Section G
Brakes
Section G
Fault Finding
5-4
5-4
Brake Piston Seal Leakage Test The following procedure explains how to check if a brake piston seal is severely damaged/perished or if the seal has a small cut or nick. The test must only be done when the axle is COLD.
5
Repeat steps 1 to 4 for the opposite brake piston seal.
6
Reconnect all brake pipes and bleed the brake system as recommended on page G/11-1.
! WARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK 1-4
! WARNING
Do not drive the machine with any part of its brake system disconnected. When the following test has been completed reconnect all brake pipes and bleed the brake system using the recommended procedure. BRAK 2-1
1
Remove and cap brake piston feed pipe A.
2
Fill the brake piston housing with JCB Light Hydraulic Fluid.
3
Check for severe piston seal damage: 3.1 Install a hand pump (see note 1) fitted with a 0 - 40 bar (0 - 600lbf/in2) pressure gauge to port B, as shown at X.
Note 1: The hand pump MUST be filled with JCB Light Hydraulic Fluid. DO NOT exceed 69bar (1000lbf/in2). 3.2 Use the hand pump to generate a pressure in the brake piston housing. 3.3 If the pressure falls off rapidly, or if no pressure reading can be obtained, the seal is severely damaged and needs replacing with a new one. 4
Check for small cuts or nicks in the piston seal: 4.1 Install an adapter fitted with a piece of clear tube(approximately 122mm [48in.] long) to the brake piston port B, as shown at Y (see note 2).
Note 2: The tube must be kept vertical during the test, use tape to attach the tube to the side of the machine. 4.2 Fill the tube until approximately three quarters full with JCB Light Hydraulic Fluid 4.3 Using a suitable pen, mark the level line of the brake fluid on the tube, as shown at C. 4.4 After approximately 1/2 hour, check if the level has dropped below the original marked line, if it has then check the brake piston seal for slight nicks, cuts or generally for wear.
S159830
9803/3260
Issue 1
Section G
Brakes
Section G 11 - 1
Brake System
11 - 1
Bleeding ! WARNING Before proceeding with the bleeding procedure it is important to ensure that the parking brake is engaged and that one pair of wheels is blocked on both sides. BRAK 1-2
! WARNING Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure. BRAK 1-1
Fill the master cylinder reservoir with the correct fluid (see Lubricants, page 3/1-1), and ensure that throughout the bleeding process the level is not allowed to fall below the MINIMUM mark. Unlatch the pedals, and bleed each brake separately as follows: Right Hand Master Cylinder Attach a tube to the right hand brake bleed screw A, ensuring that the free end of the tube is immersed in fluid contained in a suitable container. Open the brake bleed screw and apply full pedal strokes of the right hand brake pedal until all air is expelled. Close the brake bleed screw with the pedal fully depressed. Left Hand Master Cylinder Repeat procedure as for 'Right Hand Master Cylinder' but use left hand bleed screw and pedal. Bridge Pipe Attach a tube to either the left or right hand brake bleed screw, ensuring that the free end of the tube is immersed in fluid contained in a suitable container. Make sure that the brake pedals are locked together. Open the bleed screw and apply full pedal strokes of the brake pedals until all air is expelled.
A
Close the bleed screw with the pedals fully depressed. Repeat the procedures as necessary. Top up the reservoir to the full mark.
S107710
9803/3260
Issue 1
Section G 20 - 1
9803/3260
Brakes Parking Brake Caliper
Section G 20 - 1
Issue 1
Section G
Brakes Parking Brake Caliper
20 - 2
Section G 20 - 2
Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. When Dismantling To dismantle the parking brake caliper safely the tension in spring 10 must be released; apply and keep hand pressure to item 13, remove items 3 and 4. Allow the spring to open out to its full travel by slowly releasing the hand pressure on item 13. When Assembling Renew pads if thickness of friction lining is less than 3mm (0.125 in.). Lightly grease all pivots and working surfaces, taking care to avoid grease contacting the brake pads. Fit shims A between the mounting bracket 2 and caliper bracket 19 as necessary to align the parking brake caliper assembly centreline to within ± 0.5mm (0.020 in.) of the brake disc centreline. Tighten nut 5 sufficiently to allow lever 7 to move freely with minimum side clearance. Apply JCB Lock & Seal to threads of bolts 1. Set the caliper as described on page G/21 - 1. Torque Settings Item 1 17
Nm 118 6
kgf m 12.0 0.6
lbf ft 87.0 4.4
Dismantling and Assembly The numerical sequence shown in the illustration is intended as a guide to dismantling.
9803/3260
Issue 1
Section G 21 - 1
Brakes Parking Brake Caliper
Section G 21 - 1
X
S152691
9803/3260
Issue 2
Section G
Brakes
Section G 21 - 2
Parking Brake Caliper
21 - 2
Setting Procedure If the parking brake caliper assembly has been dismantled or the brake pads renewed, then the caliper must be set as follows:
5
Make sure that the parking brake switch (item X) is correctly adjusted, refer to Section C, 'Parkbrake Switch Adjustment'.
! WARNING
6
Test the parking brake:
Before adjusting the parking brake, make sure that the machine is on level ground. Put chocks each side of all four wheels. Disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you. BRAK - 008
1
Make sure that the caliper assembly is set central to the parking brake disc (within ± 0.5 mm, ± 0.020 in), see page G/20 - 2.
2
Disengage the parking brake (lever horizontal). Turn handle grip A to bring pin B central to the slot.
3
Set the cable length:
Note: On machines from serial number 413772, when fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the machine from being driven with the parkbrake on. Therefore, so that we can complete the test, move the parkbrake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the parkbrake will not be fully operational. i
Make sure the parking brake is fully engaged (lever vertical - also see note above). Select 2 wheel drive and third gear.
ii i
Disconnect clevis E from the caliper lever by removing dowel pin G.
Make sure the brake pedals are locked together, push down hard on the brake pedals and select forward drive.
ii
Set the caliper lever to 235 mm (9 1/4 in) from face C by adjusting the cable length at adjusting nut D. Refit clevis E and torque tighten D to 27Nm (20 lbf ft) after adjustment is achieved.
If the machine starts to move during the following test, immediately apply the foot brakes and reduce the engine speed.
! WARNING
2-2-5-1
4
Set the caliper lever: i
Disconnect clevis E from the caliper lever by removing dowel pin G.
ii
Set the caliper lever to 225 mm (8 7/8 in) from face C (or until the pads just touch the brake disc) by adjusting nut F.
iii
Slowly release the brake pedals, if the machine has not moved use the accelerator to gradually increase the engine speed to 1500 RPM - the machine should not move. DO NOT test for longer than 20 seconds.
iv
If the machine moved inspect the caliper/pads, reset as described above.
Note: Setting the 225 mm figure will ensure that correct lever effort is applied to the parking brake handle iii
Refit clevis E to the caliper lever using dowel G.
9803/3260
Issue 1
Section G
Brakes
Section G
Parking Brake Caliper (machines from serial number 441102)
22 - 1
22 - 1
Adjusting the Parking Brake
Testing the Parking Brake
1
Disengage the parking brake (lever horizontal)
2
Turn adjuster A clockwise, half a turn.
3
Test the parking brake. See Testing the Parking Brake.
4
If the brake fails the test, repeat steps 1 to 3.
Note: On machines from serial number 413772, when fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the machine from being driven with the parkbrake on. Therefore, so that we can complete the test, move the parkbrake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the parkbrake will not be fully operational.
Note: If after completing the above steps, the parking brake does not pass the testing procedure. See Adjusting the Brake Pads.
1
Make sure the parking brake is fully engaged (lever vertical - also see note above). Select 2 wheel drive and third gear.
2
Make sure the brake pedals are locked together, push down hard on the brake pedals and select forward drive.
! WARNING If the machine starts to move during the following test, immediately apply the foot brakes and reduce the engine speed. 2-2-5-1
3
Slowly release the brake pedals, if the machine has not moved use the accelerator to gradually increase the engine speed to 1500 RPM - the machine should not move. DO NOT test for longer than 20 seconds.
4
If the machine moved inspect the caliper/pads, reset as required.
A
S196790
9803/3260
Issue 1
Section G
Brakes
Section G 22 - 2
Parking Brake Caliper (machines from serial number 441102)
22 - 2
Adjusting the Brake Pads
Adjusting the Cable Slack
1
Turn adjuster A to return pin B to the bottom of the slot.
1
Loosen locknut E and remove pin G (at either end of the cable).
2
Check the pads just touch the disc when the parking brake is disengaged (lever horizontal).
2
Screw in the clevis F only enough to remove the cable slack.
3
Refit pin G and tighten locknut E to 27 Nm (19.9 lbf ft).
4
Test the parking brake, see Testing the Parking Brake.
5
If the brake fails the test, repeat steps 1 to 4.
3
4
If necessary, adjust the pad position by turning nut C until the disc is clamped then back off nut C until the pads have a clearance of 0.5 mm (0.020 in) between the disc and one pad. Engage the parking brake 3 times and repeat step 2.
Note: The cable end must not contact lever H. Note: If the brake cannot be adjusted by adjusting the pads and the cable slack, the cable must be replaced.
Note: Illustration shows typical caliper installation.
B
A
C S196790
F G
E
H S210850
9803/3260
Issue 1
Section G
Brakes
Section G 22 - 3
Parking Brake Caliper (machines from serial number 441102)
22 - 3
Renewing the Brake Pads Renew pads when thickness of friction material is 3mm (0.125 in). 1
Back the pads away from the disc by removing nut A. Retain washer B.
2
Loosen nuts C enough to lift spring lugs clear of items D and E.
3
Remove nuts F. Remove the old pads
4
Fit the new pads and tighten nuts F to 6 Nm (4.4 lbf in).
5
Reseat spring lugs and tighten nuts C.
6
Refit washer B and nut A.
7
Adjust the pads. See Adjusting the Brake Pads.
C F E D F A B S210860
9803/3260
Issue 1
Section G
Brakes
Section G 22 - 4
Parking Brake Caliper (machines from serial number 441102)
22 - 4
Dismantling and Assembly
For assembly the sequence should be reversed.
The numerical sequence shown in the illustration is intended as a guide to dismantling.
When Assembling Lightly grease all pivots and working surfaces, taking care to avoid grease contacting the brake pads. Fit shims 2 to align the parking brake caliper centreline to within ±0.5 mm (0.020 in) of the brake disc centreline. Tighten nut 6 sufficiently to allow lever 8 to move freely with minimum side clearance.
@
2
1
3 £
!
7 &
^ $
%
9
^
0
6
4 5
8 S210860
9803/3260
Issue 1
Section G 30 - 1
9803/3260
Brakes Master Cylinder and Servo Unit
Section G 30 - 1
Issue 1
Section G
Brakes
Section G 30 - 2
Master Cylinder and Servo Unit
30 - 2
Removal and Replacement ! WARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK 1-4
Removal
Replacement
1
Lift away cab floor mat from base of front control consoles.
Replacement is a reversal of the removal sequence.
2
Remove bolts A and take off the steering pedestal cover B.
Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure.
3
Remove the left hand side console. If necessary, label and disconnect electrical wires to the switches and radio (if fitted).
! WARNING BRAK 1-1
4
5
Fill the brake system with JCB Light Hydraulic Fluid, bleed the system as described on page G/11 - 1 and set the pedals (see below).
Loosen and remove brake pipe unions C, plug and cap to prevent loss of fluid and ingress of dirt.
Set the Pedals
Remove the brake pipes from the master cylinders:
1
Unlatch pedals and ensure that pedal pads are level with each other and fully back against their stops.
2
Adjust pedal linkages for free movement to give 1 mm (0.040 in) on each pushrod.
3
With pedals still unlatched, apply an equal force to each pedal and check if pedals remain level. If necessary adjust by increasing the clearance on one of the pushrods. Do not decrease either clearance below 1 mm (0.040 in).
4
Latch pedals and check for straight line braking; if satisfactory straight line braking cannot be achieved refer to fault finding, page G/5 - 1.
5.1 Remove the engine cover, see page B/1-1. 5.2 Remove the battery. 5.3 Working from access hole K loosen and remove the master cylinders bridging pipe D, axle feed pipes E and reservoir supply pipes H. 6
Remove the brake pedals clevis F and disengage the brake pedal from the servo unit (both pedals).
7
Loosen and remove the servo unit retaining nuts G (both units).
8
Remove the left and right hand master cylinder and servo units.
*
Torque Settings Item H
9803/3260
Nm 30-34
kgf m lbf ft 3.0-3.5 22-25
Issue 2*
Section G 31 - 1
9803/3260
Brakes Master Cylinder and Servo Unit
Section G 31 - 1
Issue 1
Section G
Brakes Master Cylinder and Servo Unit
31 - 2
Section G 31 - 2
Dismantling and Assembly The servo unit (not shown) is a non serviceable part. Replace a faulty servo unit with a new one When Dismantling Remove circlip 1 and washer 2. Shake the cylinder, or use compressed air, to eject piston assembly 3. Examine the working surfaces of piston and cylinder. If these are not in perfect condition the master cylinder assembly must be renewed. Only seals and 'O' rings are serviceable. Replace a faulty master cylinder and piston assembly with new ones. When Assembling
! WARNING Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure. BRAK 1-1
Clean and lubricate all components, including new seals, with JCB Special Hydraulic Fluid. DO NOT USE CONVENTIONAL BRAKE FLUID OR SERIOUS DAMAGE WILL BE CAUSED. Take care not to damage the machined faces of piston 3 when assembling new seal 5, which must be located as shown at A.
9803/3260
Issue 1
Section K
Engine
Section K
i
i
Contents Technical Data
Exhaust System Silencer Replacement
Page No. 1-1
10 - 2
* Engine Removel & Replacement
9803/3260
15 - 1
Issue 4*
Section K
Engine
Section K
Technical Data
1-1
Type Bore (nominal) Stroke Swept Volume Compression Ratio Compression Pressure Injection Sequence Valve Clearance - Cold Oil Pressure (hot) at maximum speed Maximum Air Cleaner Restriction
1-1
Perkins 1000 Series 4 cylinder Engines AB - turbocharged, AA - Naturally Aspirated 100mm (3.937 in) 127mm (5.000 in) 4 litres (243 in3) Turbocharged 16.0:1, Naturally Aspirated 16.5:1 28 bar (400 lbf/in2) [maximum variation between cylinders 3.5 bar (50 lbf/in2)] 1,3,4,2 - Inlet 0.20mm (0.008 in) - Exhaust 0.45mm (0.018 in) - AA 2.1 bar (30 lbf/in2) - AB 2.6 bar (40 lbf/in2) 559mm (22 in H2O)
Fuel System Injection System Details Engine Model
Type
Injection Pump
Injectors
BHP
Code
Static Timing
Code
Working/Setting Pressures
96
CM78L/1100/1/2420
15.5° BTDC
JG
230 atm
2 Wheel Steer Machines AA50386 Naturally Aspirated 76 AB50388 Turbocharged 90 AB50389 Turbocharged 96
DM55L/1000/1/2420 GM64L/1000/2/2420 CM78L/1100/1/2420
16.5° BTDC 23.0° BTDC 15.5° BTDC
HZ JK JG
220 atm 220 atm 230 atm
All Wheel Steer Machines AB50364 Turbocharged
Idling Speed Maximum Governed Speed Maximum No-load Speed (High Idle)
- All builds - All builds - All builds
Cooling System Coolant Pressure Coolant Temperature (Normal) Temperature Warning Light operates at:
0.48 bar (7 lbf/in2) 80-85 °C (176-185 °F) 98 °C (208 °F)
9803/3260
750 rev/min 2200 rev/min 2320 - 2420 rev/min
Issue 3
Section K 10 - 1
9803/3260
Engine Exhaust System
Section K 10 - 1
Issue 1*
Section K 10 - 2
Engine Exhaust System
Section K 10 - 2
Silencer Replacement Naturally Aspirated Engines Machines with serial numbers from 400030 onwards are fitted from new with the latest type of silencer. Machines with earlier serial numbers were fitted from new with a now obsolete type of silencer. This should be replaced by one of the latest type in event of failure. To ensure that no unecessary mechanical stress are imposed, adopt the following procedure when fitting a new silencer: 1
When carrying out this preliminary installation all fixings should be finger tightened only. Using bolt/spring washer/plain washer A, attach support bracket B to th engine. Mount the silencer assembly C to the support bracket (using screws/washers D and backing strip E) and the engine exhaust manifold (using nuts/washers F).
2 Once the silencer is loosely installed, tighten screw D to a torque of 28 Nm (20.7 lbf ft). Then tighten nuts F to a torque of 56 Nm (41.3 lbf ft). Finally tighten bolts A to a torque of 56 Nm (41.3 lbf ft). 3 Clamp the exhaust pipe to the silencer outlet. Turo Charged Engines Machines from serial numbers 400841 onwards are fitted with the latest typ of silencer. The latest type G differs from its predecessor by the addition of welded strengthening plates H on the lower tube and h introduction of a new support bracket J. In the event o failure, the latest type o silencer should be fitted to all machines, including those previously fitted with the earlir type.
9803/3260
Issue 1
Section K
Engine
Section K
Removal & Replacement
15 - 1
15 - 1
C D
A
B F
G
E
Q
Q N
M
S H R
L
K
J
P 803/3260
S24400
Issue 1
Section K 15 - 2
Engine
Section K
Removal & Replacement
15 - 2
Engine Removal and Replacement The following procedures describe the removal and replacement of an engine when installed in a two wheel steer machine (3CX, 214). On four wheel steer machines the hydraulic pump is mounted to the side of the engine.
17
Loosen and remove the exhaust silencer retaining bolts, remove the silencer.
18
Loosen and remove the retaining clamp for the heater hose. Remove the hose.
19
Loosen and remove the retaining clamp for the air filter intake hose.
20
Loosen and remove the brake master cylinder reservoir retaining bolts. Do not remove the pipes attached to the master cylinder reservoir but put the reservoir out of the way. Make sure that the fluid level does not drain down.
Note: In the event of engine failure, the loader arms will have to be raised using suitable lifting equipment. Make sure that the loader control lever is in the ‘raise arms’ position before manually lifting the loader arms.
21
Loosen and remove the battery carrier retaining bolts and lift off the carrier with the air filter assembly. Use tape to close the opening in the air intake manifold, this will prevent ingress of dirt.
3
Remove the engine side panels
22
4
Remove the engine cover (including the exhaust stack, and pre-cleaner).
5
Disconnect and remove the battery. When disconnecting the battery, take off the earth (black) lead first.
6
Remove retaining bolts and then lift off the front grille.
7
Remove retaining bolts A and B (both sides) and lift off the front nose guard.
Label and remove all electrical connections, the number of connectors will vary depending on the ancillary equipment fitted to the engine. Typical electrical connectors are: i) starter motor ii) alternator iii) coolant pressure switch iv) coolant temperature sender v) engine oil pressure switch vi) engine temperature sender vii) engine shut off solenoid viii) ether cold start (if fitted) ix) air conditioning compressor (if fitted)
8
Disconnect the hydraulic oil cooler hoses C from the hydraulic oil cooler. Plug and cap open orifices to prevent ingress of dirt.
23
If air conditioning is fitted:
When Removing 1
2
Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Chock the road wheels. Raise the loader arms and fit the loader arm safety strut.
9
Drain the cooling system.
0
Remove the transmission oil cooler hoses D and E.
11
Remove the radiator top hose and bottom hose.
12
Remove the coolant bottle pipe.
13
Make a suitable alignment mark to allow correct repositioning of the radiator shroud, as shown at F.
14
If an engine fan guard is fitted, remove retaining bolts and lift off the guard.
15
Remove retaining bolts G (both sides) and lift off the radiator sub-assembly including radiator, hydraulic cooler, and shroud. Take care not to damage the engine fan, note also that the sub-assembly is heavy, use suitable lifting equipment.
Note: If required, the shroud, radiator and cooler can be removed as individual items. 16
Loosen and remove the hydraulic pump driveshaft retaining bolts, remove the pump driveshaft H.
803/3260
23.1
Remove the belt from the clutch of the air conditioning compressor.
23.2
Disconnect the high and low pressure electrical connectors at the compressor.
23.3
Loosen and remove the air conditioning compressor retaining bolts.
Note: The air conditioning is a pressurised closed loop system, do not disconnect the hoses to the compressor. Leave the hoses to the compressor intact. 23.4
Put the air conditioning compressor out of the way (do not allow the compressor to ‘hang’ on its hoses).
24
Loosen and disconnect the fuel lines J from the fuel sedimenter. Plug and cap open orifices to prevent ingress of dirt and loss of fuel.
25
Loosen and remove the retaining bolts for the fuel sedimenter, remove the sedimenter K.
......cont’d Issue 1
Section K 15 - 3
Engine
Section K
Removal & Replacement
15 - 3
Engine Removal and Replacement When Removing (continued)
When Replacing
26
Replacement is a reversal of the removal procedure.
27
28
29
If fitted, loosen and disconnect the ether cold start fuel line from the engine. Plug and cap open orifices to prevent ingress of dirt and loss of fluid. If fitted, loosen and remove the ether cold start canister retaining bolts, lift off the canister and retaining bracket assembly. Disconnect the throttle linkage L from the arm on the fuel injection pump. Leave at least one of the locking nuts in position, this will ensure that the engine revs are set correctly when reassembling. Loosen and remove the rear propshaft to transmission retaining bolts M.
30
On 4WD machines, loosen and remove the front propshaft to transmission retaining bolts N.
31
Remove the access bung located at the base of the transmission. Through the access hole, loosen and remove the torque converter to engine flywheel retaining bolts P (turn the flywheel to align bolts with access hole).
When mating the transmission/torque converter to engine, ensure that the drive tangs are correctly located in the transmission pump. When the trransmission and engine are bolted together and before bolting the flexi-plate to flywheel, rotate the torque converter by hand. The converter should spin freely. Use the access hole in the bottom of the transmission to fit and tighten the flexi-plate to engine flywheel retaining bolts. Rotate the flywheel to align the next bolt hole, fit and tighten all retaining bolts. When fitting the radiator sub-assembly, including radiator, cooler and shroud take care not to damage the engine fan, align the shroud using alignment mark made at step 13 in ‘When Removing’. Make sure that the front nose guard and the engine cover are correctly aligned. Refill cooling system using correct mixture of water/antifreeze.
32
If manual transmission fitted, disconnect the gearshift lever from the top of the transmission.
Check engine, coolant and brake oil levels.
33
Use a suitable trolley jack and support the weight of the transmission.
When connecting the battery, connect the earth (black) lead last.
Note: Attach a ‘cradle’ to the trolley jack that will evenly support the weight of the transmission. Refer to Special Tools, Section 1.
Make sure that the engine idle speed is correct, adjust as required, refer to Engine Technical Data for speeds.
34
Use a suitable stand and support the weight of the engine.
35
Loosen and remove the transmission mounting bolts Q.
36
Remove the transmission to engine retaining bolts R, pull the transmission and converter clear of the engine, make sure that the converter stays mounted on the transmission shaft.
37
Attach suitable lifting chains to the engine, (see lifting wire assembly 892/00836 in the special tools section). Take the weight of the engine on the hoist.
38
Loosen and remove the engine mounting bolts S (both sides).
39
Lift the engine clear of the machine.
40
Put the engine on a suitable stand, the correct dismantling and assembly procedures are detailed in the engine service manual, publication number 9806/0100.
803/3260
Torque Figures Item M N P Q R S
Nm 118 79 19 237 98 85
Kgf m 12 8 2 24 10 8.7
lbf ft 87 58 14 175 72 63
Description Rear propshaft bolts Front propshaft bolts Flexi-plate to flywheel bolts Transmission mounting bolts Transmission to engine bolts Engine mounting bolts
Issue 1
