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jcb JS130 Service Manual

jcb JS130 Service Manual

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Service

Manual

JS130

from machine no. 758000

JS160

from machine no. 702000

PUBLISHED BY THE

TECHNICAL PUBLICATIONS DEPARTMENT

OF JCB SERVICE: ©

WORLD PARTS CENTRE

UTTOXETER, STAFFORDSHIRE, ST14 7BS,

ENGLAND

Tel. ROCESTER (01889) 590312

PRINTED IN ENGLAND

Publication No. 9803/6410

Issue 1

General Information

Care & Safety

Routine Maintenance

R

Attachments

Body & Framework

Electrics

Hydraulics

Transmission

Brakes

Track & Running Gear

Engine

1

2

3

A

B

C

E

F

G

J

K

Table of Contents

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Summary of Contents for jcb JS130

Page 1 758000 JS160 Transmission from machine no. 702000 Brakes PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE: © Track & Running Gear WORLD PARTS CENTRE UTTOXETER, STAFFORDSHIRE, ST14 7BS, ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND Engine Publication No.
Page 2 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.
Page 3: Table Of Contents
Section 1 General Information Section 1 Contents Page No. Bolt and Nut Torque Specifications 1 - 1 Torque Settings 1 - 2 Service Tools Section B - Body and framework 3 - 1 Section C - Electrics 4 - 1 Section E - Hydraulics 5 - 1 Section F - Transmission...
Page 4: General Information Section
20~30 2.1~2.9 15~21 Note: Use JCB Threadlocker and Sealer (High Strength) (adhesive) on those marked † and tighten to the torque listed in the above table. The tightening torques for the bolts and nuts not listed above are as follows:...
Page 5: Torque Settings
Section 1 General Information Section 1 1 - 2 Torque Settings 1 - 2 Torque Settings Note 1: The figures quoted are for non-plated fasteners and are to be used only when there is no torque setting specified in the relevant procedure in this service manual. Note 2: The 4T grade settings DO NOT APPLY to fasteners used on the engine.
Page 6: Service Tools
Glass Lifter - minimum 2 off - essential for glass No plug supplied. Note: 110V models available upon installation, 2 required to handle large panes of glass. request - contact JCB Technical Service Ensure suction cups are protected from damage during storage.
Page 7 Section 1 General Information Section 1 3 - 2 3 - 2 Service Tools (cont’d) (SECTION B) BODY AND FRAMEWORK S186310 S186340 Wire Starter - used to access braided cutting wire Cut-out Knife - used to remove broken glass. (below) through original polyurethane seal. 992/12800 892/00848 S186350...
Page 8 Section 1 General Information Section 1 3 - 3 3 - 3 Service Tools (cont’d) (SECTION B) BODY AND FRAMEWORK S186470 S186550 Nylon Spatula - general tool used for smoothing Rubber Spacer Blocks - used to provide the correct sealants - also used to re-install glass in rubber glazing set clearance between glass edge and cab frame.
Page 9: Section C - Electrics
Section 1 General Information Section 1 4 - 1 4 - 1 Service Tools SECTION C - ELECTRICS Electrical Test Equipment 892/00283 Tool Kit Case 892/00281 AVO Meter 892/00286 Surface Temperature Probe 892/00284 Microtach Digital Tachometer 892/00282 Shunt - open type 892/00285 Hydraulic Oil Temperature Probe 892/00298...
Page 10: Section E - Hydraulics
Section 1 General Information Section 1 5 - 1 5 - 1 Service Tools (continued) SECTION E - HYDRAULICS Hydraulic Pressure Test Gauges and Connections 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in 892/00347 Connector 892/00254 Hose...
Page 11 Section 1 General Information Section 1 5 - 2 5 - 2 Service Tools (continued) SECTION E - HYDRAULICS Hand Pump Equipment 892/00223 Hand Pump 892/00137 Micro-bore Hose 1/4 in BSP x 5 metres 892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 892/00706...
Page 12 Section 1 General Information Section 1 5 - 3 5 - 3 Service Tools (continued) SECTION E - HYDRAULICS JS07050 Ram Piston Nut Removal/Fitting Spanner 993/99512 Spanner 55 mm A/F 993/99513 Spanner 60 mm A/F 993/99514 Spanner 65 mm A/F 993/99515 Spanner 70 mm A/F 993/99516...
Page 13 Section 1 General Information Section 1 5 - 4 5 - 4 Service Tools (continued) SECTION E - HYDRAULICS Slew Motor Unit - JS130 2 (0.079") 14 (0.55") 155 (6.10") 4 (0.16") Seal Fitting Tool (Oil Seal 2) JS07110 100 (3.94") 110 (4.33")
Page 14 Section 1 General Information Section 1 5 - 5 5 - 5 Service Tools (continued) SECTION E - HYDRAULICS Slew Motor Unit - JS160 2 x ¿9 (0.35") (1.57") Inner diameter ¿11 (0.43") (7.09") (9.45") JS07100 Puller for Brake Piston Stud is threaded M10 on both ends for 20 mm (0.8 in) and fitted with two M10 nuts.
Page 15 Section 1 5 - 6 5 - 6 Service Tools (continued) SECTION E - HYDRAULICS Hydraulic Tank - JS130, JS160 Dia. 40 mm (1.57 in) Dia. 26 mm (1.02 in) 40 mm (1.47 in) 50 mm (1.97 in) Dia. 10 mm (0.39 in) 550 mm (21.7 in)
Page 16 Section 1 General Information Section 1 5 - 7 5 - 7 Service Tools (continued) SECTION E - HYDRAULICS Remote Control Valve - JS130, JS160 ¿26.5 23.5 ¿19 ¿28 ¿21 ¿25 ¿30 JS07160 Joint Removal Tool Items 1 and 2 are assembled with an interference fit.
Page 17 Section 1 General Information Section 1 5 - 8 5 - 8 Service Tools (continued) SECTION E - HYDRAULICS Hydraulic Pump Guide Rods Rear Shaft Protection Tool Swash Plate Levelling Tool Oil Seal Insertion Tool Front Shaft Protection Tool Bearing Insertion Tool 9803/6410 Issue 1...
Page 18 Section 1 General Information Section 1 5 - 9 5 - 9 Service Tools (continued) SECTION E - HYDRAULICS Hydraulic Rams Reconditioning Bush Removal/Assembly Jig Seal Ring Insertion Jig (Inner) Bush Removal/Assembly Jig Seal Ring Bedding Jig Cylinder Head Insertion Jig Wiper Ring Installation Jig Seal Ring Insertion Jig (Outer) 9803/6410...
Page 19 Section 1 General Information Section 1 6 - 1 6 - 1 Service Tools (continued) SECTION F - TRANSMISSION Slew Gearbox - JS130 ø50 (1.97") 60 (2.36") 15 o 100 (3.94") JS07180 ø94.5 (3.72" 0.008) ø120 (4.72") ø130 (5.43") Seal Protector...
Page 20 Section 1 General Information Section 1 6 - 2 6 - 2 Service Tools (continued) SECTION F - TRANSMISSION Slew Gearbox - JS160 (continued) ø50 ø99.8 ø124 ø158 JS07230 JS07210 Jig for Taper Roller Bearing Inner Ring Seal Fitting Jig JS07220 Seal Fitting Jig (SST0033) 9803/6410...
Page 21 To seal butt jointed glass. 4102/0901 The part numbers and descriptions of sealing and retaining compounds available from JCB Service have been revised with effect from January 1997 (see MI 563/H, 507/HA, 511/E). References to these products on subsequent pages in this service manual will be progressively updated, but for convenience a cross reference table is shown below.
Page 22 Section 2 Care & Safety Section 2 Contents Page No. Safety Notices 1 - 1 General Safety 2 - 1 Operating Safety 3 - 1 Maintenance Safety 4 - 1 9803/6410 Issue 1...
Page 23 Section 2 Care & Safety Section 2 1 - 1 1 - 1 In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. ! DANGER Denotes an extreme hazard exists.
Page 24 All construction and agricultural equipment can be Note: This section includes a certain amount of operating hazardous. When a JCB Excavator is correctly operated and safety information. But remember that whenever you drive properly maintained, it is a safe machine to work with. But...
Page 25 This machine is designed for use in normal outdoor atmospheric conditions. It shoul not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor. INT-2-1-14 9803/6410...
Page 26 Section 2 Care & Safety Section 2 4 - 1 4 - 1 Maintenance Safety ! WARNING ! WARNING Soft Ground Fires A machine can sink into soft ground. Never work under a If your machine is equipped with a fire extinguisher, make machine on soft ground.
Page 27 Section 2 Care & Safety Section 2 4 - 2 4 - 2 Maintenance Safety (cont’d) ! CAUTION ! WARNING Never use water or steam to clean inside the cab. The use of Hydraulic Fluid water or steam could damage the on-board computer and Fine jets of hydraulic fluid at high pressure can penetrate the render the machine inoperable.
Page 28 Section 3 Routine Maintenance Section 3 Contents Page No. Fluids and Lubricants 1 - 1 Lubricants - Health and Safety 1 - 2 Service Schedules Service Intervals for Hydraulic Oil and Filters when using a Breaker or Crusher 2 - 1 Initial Precautions For New Machine Usage 2 - 2 Operating Hours Schedule...
Page 29 Section 3 Routine Maintenance Section 3 Contents Page No. Engine Changing the Air Filter Elements 8 - 1 Checking the Oil Level 8 - 2 Changing the Oil and Filter(s) 8 - 2 Checking the Coolant Level 8 - 3 Coolant Mixtures 8 - 3 Changing the Coolant...
Page 30 (63.4 US gal) (63.4 US gal) *ENGINE LUBRICATION CHART - ALL COUNTRIES EXCEPT NORTH AMERICAN Use according to ambient temperature (°C) JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG JCB SUPER 10W/30 MULTIGRADE ENGINE OIL API CF4/SG *ENGINE LUBRICATION CHART - NORTH AMERICAN Use according to ambient temperature (°F)
Page 31: Lubricants - Health And Safety
7-3-1-3/1 f. Don't keep oily rags in pockets. Hygiene g. Wash dirty clothing before re-use. JCB lubricants are not a health risk when used properly for h. Throw away oil-soaked shoes. their intended purposes. Waste Disposal However, excessive or prolonged skin contact can remove...
Page 32: Service Schedules
Section 3 Routine Maintenance Section 3 2 - 1 Service Schedules 2 - 1 Service Intervals for Hydraulic Oil and Filters when using a Breaker or Crusher When using a breaker or crusher, contamination and degradation of the hydraulic oil occurs much more quickly than in normal excavating use.
Page 33: Initial Precautions For New Machine Usage
Section 3 Routine Maintenance Section 3 2 - 2 Service Schedules 2 - 2 Initial Precautions for New Machine Usage ! CAUTION If the machine is operated at full load, before its initial run-in procedure is complete it may cause scuffing and seizing which can adversely effect the life of the machine.
Page 34 Section 3 Routine Maintenance Section 3 2 - 3 Service Schedules 2 - 3 Every 10 Operating Hours or Daily Every 100 Operating Hours or 2-Weekly Whichever occurs first Whichever occurs first Clean Do a 50 hour service plus: a Machine generally. Clean Grease a Battery terminals.†.
Page 35 Section 3 Routine Maintenance Section 3 2 - 4 Service Schedules 2 - 4 Every 250 Operating Hours or Monthly Every 1000 Operating Hours or 6-Monthly Whichever occurs first Whichever occurs first Do a 500 hour service plus: Do a 100 hour service plus: Clean Clean a Drain water and deposits from hydraulic oil tank.
Page 36 Section 3 Routine Maintenance Section 3 2 - 5 Service Schedules 2 - 5 Every 5000 Operating Hours or 2 Years 6 Months Whichever occurs first Do a 1000 hour service plus: Change Hydraulic oil. Hydraulic tank air breather element. Hydraulic suction filter.
Page 37: Greasing
Section 3 Routine Maintenance Section 3 3 - 1 Greasing 3 - 1 ! WARNING General Notes You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the For the type of grease to use at each point, see Lubricants starter key and disconnect the battery.
Page 38: Excavator End
Section 3 Routine Maintenance Section 3 3 - 2 Greasing (continued) 3 - 2 ! WARNING Excavator End You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the 16 Grease Points starter key and disconnect the battery. This will prevent the engine being started.
Page 39 Section 3 Routine Maintenance Section 3 3 - 3 Greasing (continued) 3 - 3 Excavator End 9803/6410 Issue 1...
Page 40: Battery
Section 3 Routine Maintenance Section 3 4 - 1 Battery 4 - 1 First Aid - Electrolyte Check the Electrolyte Level Open the Battery Compartment A EYES FLUSH WITH WATER FOR 15 MINUTES. GET MEDICAL HELP FAST. IF SWALLOWED DO NOT INDUCE VOMITING. DRINK LARGE QUANTITIES OF WATER OR MILK.
Page 41: Hydraulics
Section 3 Routine Maintenance Section 3 5 - 1 Hydraulics 5 - 1 Air Bleeding Procedures Air Bleeding Sequence ! WARNING Air Bleeding Air Bleeding Air Bleeding from slew Check Hydraulic Pressure from pump from ram motor Hydraulic oil or Hydraulic fluid at system pressure can injure you.
Page 42: Air Bleeding From Hydraulic Pump
Section 3 Routine Maintenance Section 3 5 - 2 Hydraulics (continued) 5 - 2 Air Bleeding from Hydraulic Pump ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses.
Page 43: Air Bleeding From The Slew Motor
Hydraulics (continued) 5 - 3 Air Bleeding from the Slew Motor ! WARNING JS130 JS160 DO NOT remove the hydraulic tank filler cap or cover plate when the engine is running. The hydraulic system is under pressure. You or others could be injured. First stop the engine and then release the pressure.
Page 44: Checking The Fluid Level
Section 3 Routine Maintenance Section 3 5 - 4 Hydraulics (continued) 5 - 4 For location of hydraulic oil tank see Component Location Diagram. ! WARNING Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks.
Page 45: Changing The Hydraulic Oil
Section 3 Routine Maintenance Section 3 5 - 5 Hydraulics (continued) 5 - 5 Changing the Hydraulic oil ! WARNING DO NOT remove the hydraulic tank filler cap or cover plate when the engine is running. The hydraulic system is under pressure. You or others could be injured. First stop the engine and then release the pressure.
Page 46: Changing The Return Filter Element
Section 3 Routine Maintenance Section 3 5 - 6 Hydraulics (continued) 5 - 6 Changing the Return Filter Element Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter Key. Locate the Return filter. See Components Location Diagram at the end of this section.
Page 47: Cleaning/Changing The Suction Strainer
Section 3 Routine Maintenance Section 3 5 - 7 Hydraulics (continued) 5 -7 Cleaning/Changing the Suction Strainer Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key. Locate the Suction Strainer Release Tank Pressure See Releasing Tank Pressure.
Page 48: Changing The Air Breather Element
Section 3 Routine Maintenance Section 3 5 - 8 Hydraulics (continued) 5 - 8 Changing the Air Breather Element Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key. Release Tank Pressure See Releasing Tank Pressure. Locate the Air Breather Cover A See illustration.
Page 49: Draining Tank Impurities
Section 3 Routine Maintenance Section 3 5 - 9 Hydraulics (continued) 5 - 9 Draining Tank Impurities ! WARNING Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary.
Page 50: Changing The Breaker In-Line Filter
Section 3 Routine Maintenance Section 3 5 - 10 Hydraulics (continued) 5 - 10 Changing the Breaker In-line Filter Note: This filter should be changed at the intervals stated in Service Schedules or when the visual indicator X has popped up. DO NOT USE THE BREAKER WITH A BLOCKED FILTER.
Page 51: Changing The Nephron Filter
Section 3 Routine Maintenance Section 3 5 - 11 Hydraulics (continued) 5 - 11 Changing the Nephron Filter ! WARNING The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools down (less than 40°C) before beginning maintenance.
Page 52: Checking Track Gearbox Oil Level
Section 3 Routine Maintenance Section 3 6 - 1 Transmission 6 - 1 Note: There are two alternative configurations of filler, level and drain plugs as shown in figures X and Y. The following text covers both configurations. Checking the Track Gearbox Oil Level Prepare the Machine Position the machine on level ground with the level and drain plugs on a perpendicular line, with the level plug...
Page 53: Checking The Slew Gearbox Oil Level
6 - 2 Checking the Slew Gearbox Oil Level Prepare the Machine Position the machine on level ground. Stop the engine JS130 and remove the starter key. Locate the Slew Gearbox See Component Location Diagrams at the end of this section.
Page 54: Tracks And Running Gear
Section 3 Routine Maintenance Section 3 7- 1 Tracks and Running Gear 7 - 1 Cleaning the Tracks ! WARNING ! WARNING Rotating the tracks off the ground may cause stones and If two people are doing this job make sure that the other debris to be thrown with considerable force.
Page 55: Checking/Adjusting The Track Tension
Section 3 Routine Maintenance Section 3 7 - 2 Tracks and Running Gear (continued) 7 - 2 Checking/Adjusting the Track Tension Prepare the Machine Position the machine on level ground. Run it backwards and forwards several times. Stop after running it forwards. Carry out steps 1 to 3 of Cleaning the Tracks.
Page 56: Checking The Shoe Plate
Section 3 Routine Maintenance Section 3 7 - 3 Tracks and Running Gear (continued) 7 - 3 Checking the Shoe Plate Prepare the Machine a Position the machine on level ground. Run it backwards and forwards several times. Stop after running it forwards.
Page 57: Changing The Air Filter Elements
Section 3 Routine Maintenance Section 3 8 - 1 Engine 8 - 1 Changing the Air Filter Elements Prepare the Machine Put the machine on level ground. Lower the bucket to the ground. Stop the Engine Remove the starter key. Note: Renew the inner element every second time you renew the outer element.
Page 58: Checking The Oil Level
Section 3 Routine Maintenance Section 3 8 - 2 Engine (continued) 8 - 2 Checking the Oil Level Prepare the Machine Park the machine on level ground. Lower the bucket to the ground. Stop the Engine Open the Engine Compartment Check the Oil Level Remove the dipstick A.
Page 59: Checking The Coolant Level
Park the Machine on Level Ground To prevent the coolant freezing in cold conditions, antifreeze Stop the engine and let it cool down. Open the engine must be added. JCB Universal Antifreeze will give protection compartment. down to the temperatures shown in the table.
Page 60: Changing The Coolant
Section 3 Routine Maintenance Section 3 8 - 4 Engine (continued) 8 - 4 Changing the Coolant Do Steps 1 and 2 of 'Checking the Coolant Level' Drain the System Open the radiator drain tap A. Remove the cylinder block drain plug B. Remove the expansion bottle cap (see Checking the coolant Level).
Page 61: Adjusting The Fan Belt
Section 3 Routine Maintenance Section 3 8 - 5 Engine (continued) 8 - 5 Adjusting the Fan Belt ! WARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5 Check the Fan Belt Tension There must be 10 mm (0,4 in) slack at D on the belt.
Page 62: Cleaning The Radiator And Oil Cooler
Section 3 Routine Maintenance Section 3 8 - 6 Engine (continued) 8 - 6 Cleaning the Radiator and Oil Cooler A clogged radiator and/or oil cooler can lead to engine overheating. Regularly check for a build-up of dirt and debris and, if necessary, use compressed air to clean out the grille.
Page 63: Draining Fuel Tank Impurities
Section 3 Routine Maintenance Section 3 8 - 7 Engine (continued) 8 - 7 Draining Fuel Tank Impurities Stop the engine and remove the key. Loosen the drain tap A on the underside of the fuel tank. Drain the water and deposits until clean diesel oil flows out. Close the drain tap firmly.
Page 64: Bleeding The Fuel System
Section 3 Routine Maintenance Section 3 8 - 8 Engine (continued) 8 - 8 Bleeding the Fuel System Air in the fuel system could cause misfiring or failure to start. Air will enter the system if any part of it is disconnected or emptied.
Page 65 Routine Maintenance Section 3 Section 3 Component Location Diagram 9 - 1 9 - 1 Issue 1 9803/6410...
Page 66: Performance Evaluation
Section 3 Routine Maintenance Section 3 10 - 1 Performance Evaluation 10 - 1 Introduction It is important before taking measurements that control conditions are maintained. a Position the machine on a level safe site. b Adhere strictly to the safety operation. c Confirm the setting when an adjustment is made.
Page 67 Section 3 Routine Maintenance Section 3 10 - 2 Performance Evaluation 10 - 2 Speed Measurements Bucket Ram speed. The conditions for checking are that the Dipper should be level. Measurement is of the time it takes the bucket to fully open and close from each end of the stroke Dipper Ram speed The conditions for checking are that the Dipper should...
Page 68 Section 3 Routine Maintenance Section 3 10 - 3 Performance Evaluation 10 - 3 Other Measurements Travel Linearity. MEASUREMENT METHOD The conditions for checking are that the vehicle should have an approach of 5 metres and a travel distance of 20 metres;...
Page 69 Section 3 Routine Maintenance Section 3 10 - 4 Performance Evaluation 10 - 4 Other Measurements (continued) Lateral Movement in Turntable Bearing. 1 First set the Dipper in a perpendicular position and 2 Install a dial gauge and set the needle to the Zero position the bucket 200 mm above the ground, stop Point.
Page 70 Section 3 Routine Maintenance Section 3 10 - 5 Performance Evaluation 10 - 5 Other Measurements (continued) Slew Brake 1 The slew brake performance is measured at the minimum slew position. Mark the turntable bearing and lower ring. Note: The person must stand well out of the machines slew radius on the front side, and also to confirm that no other personnel are in the vicinity.
Page 71 Section 3 Routine Maintenance Section 3 10 - 6 Performance Evaluation 10 - 6 Other Measurements (continued) Ram Piston Rod Seal Leakage As described below, check each ram in tur n to determine the amount of leakage via the ram rod seal. 1 Extend the ram fully and wipe the piston rod and check that there are no scratches.
Page 72: Checking The Fops Structure
Routine Maintenance Section 3 Section 3 12-1 12-1 FOPS Structure Checking the FOPS Structure Check that all the FOPS mounting bolts are in place and All excavators are designed so that an operator’s undamaged. Check the FOPS mounting bolts for correct protective structure can be fitted.
Page 73 1 - 1 Undercarriage - JS130 Dimensions 2 - 1 Undercarriage - JS160 Dimensions 2 - 2 Weights - JS130, JS160 Main Body 3 - 1 Maintenance Specifications - JS130 Boom and Slew Frame Installation 4 - 1 Boom Ram Installation...
Page 74 Reference is made to the tools in the text. The majority of these tools can be obtained locally and the remainder from JCB Service (see Service Tools, Section 1). The work must only be carried out in a dry, frost free environment.
Page 75 Section B Body & Framework Section B 1 - 2 1 - 2 Direct Glazing (cont'd) Removing the Broken Glass and Old Sealant (cont'd) Position the machine on level ground and apply the parking brake. Stop the engine. Put protective covers over the cab seat and control pedestals.
Page 76 Section B Body & Framework Section B 1 - 3 1 - 3 Direct Glazing (cont'd) Removing the Broken Glass and Old Sealant (cont'd) b Cut-out Knife F. The cut-out knife can be used as a left handed or right handed tool. For the knife and its replaceable blades, refer to Service Tools, Section (i) Insert the knife blade into the sealant.
Page 77 Section B Body & Framework Section B 1 - 4 1 - 4 Direct Glazing (cont'd) Preparing the New Glass Make sure that the new glass correctly fits the frame aperture K. a Put two spacer blocks L onto the bottom part of the frame aperture.
Page 78 Section B Body & Framework Section B 1 - 5 1 - 5 Direct Glazing (cont'd) Preparing the New Glass (cont'd) Install the Ultra Fast Adhesive cartridge (see Sealing and Retaining Compounds, Section 1 and Note 2 10-15 mm below) into a suitable applicator gun: a Remove the aluminium disc cover from the base of 8-10 mm the cartridge and discard the 'dessicant capsule'.
Page 79 Section B Body & Framework Section B 1 - 6 1 - 6 Direct Glazing (cont'd) Installing the New Glass (cont'd) 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. All exposed edges must be sealed using Black Polyurethane Sealant (see Sealing and Retaining Compounds, Section 1).
Page 80 200mm 178mm (7.8") (7") 188mm 228.5mm (7.4") (9") ¿140mm (¿5.5") ¿120mm 21mm (¿4.7") (1") 883.5mm (2’11")
Page 81 189mm 200mm (7.4") (7.8") 215mm 279.5mm 177.5mm (8.4") (11") (7") ¿150mm 99.5m (¿6") (4") ¿120mm 25mm 11.5m (¿4.7") (1") (0.5") 465.5mm (1’6.3") 473.5mm (1’6.6") 883.5mm (2’11") 1061mm (3’5.7")
Page 82 Section B Body & Framework Section B 3 - 1 Main Body 3 - 1 Weights Weight kg (lb) Weight kg (lb) Description JS130* JS160* Description JS130* JS160* Overall Mass 12200 (26900) 15200 (33520) Machine Main Body 10030 (22120) 12800 (28224)
Page 83 Section B 3 - 2 Main Body 3 - 2 Weights (cont’d) (Dry Weight) Weight Part Name JS130 JS160 Travel motor 166 kg (366 lb) 225 kg (496 lb) Drive sprocket 57 kg (126 lb) 56 kg (125 lb) Idler wheel...
Page 84 Section B Body & Framework Section B 4 - 1 Maintenance Specifications 4 - 1 Attachments Boom and Slew Frame Installation JS130 Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 1. Boom and Slew frame slew frame...
Page 85 Section B Body & Framework Section B 4 - 2 Maintenance Specifications 4 - 2 Attachments (continued) Dipper Ram Installation JS130 Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 4. Dipper ram Boom installation Dipper ram (dump end)
Page 86 Ø75 Ø74 Bushing Ø75 Ø76.5 (Dipper) Bushing Ø75 Ø76.5 (boom) Boom Ø65 Ø63 Dipper and Dipper Ram Installation JS130 Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 6. Dipper and Boom Dipper ram installation Dipper ram...
Page 87 Bucket (eye end) Shim for Clearance 0.5-3.0 adjustment Ø65 Ø64 Bushing Ø65 Ø66.5 (bucket ram) Dipper and Dipper Link Installation JS130 Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 8. Dipper and Dipper Link Dipper link...
Page 88 Section B Body & Framework Section B 4 - 5 Maintenance Specifications 4 - 5 Attachments (continued) Bucket and Bucket Link Installation JS130 Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 9. Bucket and Bucket bucket link...
Page 89 Section B Body & Framework Section B 4 - 6 Maintenance Specifications 4 - 6 Attachments (continued) Bucket and Dipper Installation JS130 Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 11. Bucket and Bucket dipper installation Dipper...
Page 90 Section B Body & Framework Section B 4 - 7 Maintenance Specifications 4 - 7 Attachments (continued) Shim Adjustment Table (Unit: mm) Shim Shim Outer Diameter Diameter Thickness KNV0538 BHV1034 KNV0696 KNV0539 KRV1176 KHV0169 KNV0534 KRV1197 KRP1349 KRV1178 KHV0170 KBV0837 KSP0268 KNV0468 9803/6410...
Page 91 Section B Body & Framework Section B 4 - 8 Maintenance Specifications 4 - 8 Attachments (continued) Shim Adjustment Table (continued) (Unit: mm) Shim Outer Diameter Diameter KBV0764 KRV1180 KBV0474 KRV1159 KBV0713 9803/6410 Issue 1...
Page 92 Section B Body & Framework Section B 5 - 1 Maintenance Specifications 5 - 1 Attachments (continued) Boom and Slew Frame Installation JS160 Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 1. Boom and Slew frame slew frame installation Boom Shim for...
Page 93 Section B Body & Framework Section B 5 - 2 Maintenance Specifications 5 - 2 Attachments (continued) Dipper Ram Installation JS160 Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 4. Dipper Ram Boom installation Dipper ram (dump end) Shim for Clearance 0.5-3.0...
Page 94 Section B Body & Framework Section B 5 - 3 Maintenance Specifications 5 - 3 Attachments (continued) Dipper Pivot Installation JS160 Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 5. Dipper Pivot Boom 278.5 installation Dipper 274.5 272.5 Shim for Clearance...
Page 95 Section B Body & Framework Section B 5 - 4 Maintenance Specifications 5 - 4 Attachments (continued) Bucket Ram Installations JS160 Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 7. Bucket ram Dipper installation Bucket (eye end) Shim for Clearance 0.5-3.0...
Page 96 Section B Body & Framework Section B 5 - 5 Maintenance Specifications 5 - 5 Attachments (continued) Bucket and Bucket Link Installation JS160 Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 9. Bucket and Bucket bucket link installation Bucket link Shim for...
Page 97 Section B Body & Framework Section B 5 - 6 Maintenance Specifications 5 - 6 Attachments (continued) Bucket and Dipper Installation JS160 Equipment Part Code Standard Service Name Name Value (mm) Limit (mm) 11. Bucket and Bucket Dipper installation Dipper Shim for Clearance 1.0-3.5...
Page 98 Section B Body & Framework Section B 5 - 7 Maintenance Specifications 5 - 7 Attachments (continued) Shim Adjustment Table (Unit: mm) Shim Shim Outer Diameter Diameter Thickness KNV0538 BHV1034 KNV0696 KNV0539 KRV1176 KHV0169 KNV0534 KRV1197 KRP1349 KRV1178 KHV0170 KBV0837 KSP0268 KNV0468 9803/6410...
Page 99 Section B Body & Framework Section B 5 - 8 Maintenance Specifications 5 - 8 Attachments (continued) Shim Adjustment Table (continued) (Unit: mm) Shim Outer Diameter Diameter KBV0764 KRV1180 KBV0474 KRV1159 KBV0713 9803/6410 Issue 1...
Page 100 Section B Body & Framework Section B 12 - 1 Air Conditioning 12 - 1 Direction of flow through air conditioning system A306820 Compressor Condenser Receiver/Drier Expansion Valve Evaporator Coil Air Filter Air Filter 9803/6410 Issue 1...
Page 101 Section B Body & Framework Section B 12 - 2 Air Conditioning 12 - 2 Operation The compressor 1 draws in low pressure refrigerant gas To maintain optimum operator comfort in warm climates or from the suction line (evaporator to compressor) and during seasons of high ambient temperature, the air increases refrigerant pressure through compression.
Page 102 Section B Body & Framework Section B 12 - 3 Air Conditioning 12 - 3 Operation (cont'd) Safety Procedures The high temperature, high pressure refrigerant is forced by compressor action into the expansion valve 4, which meters The air conditioning system includes a pressurised closed the amount of refrigerant entering the evaporator.
Page 103 Section B Body & Framework Section B 12 - 4 Air Conditioning 12 - 4 Operation (cont'd) Note: In dusty conditions, it is recommended that air be recirculated within the cab, otherwise the filter may become clogged. Two air vents M are located in the cab rear panel, and two air vents N and P are located on the right hand console.
Page 104 Section B Body & Framework Section B 12 - 5 Air Conditioning 12 - 5 Fault Finding Procedures that require charging or discharging the system are not given in this manual as they require special equipment that is usually held only by trained refrigeration engineers. Fault indications are given in the table below. The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment.
Page 105 Section B Body & Framework Section B 12 - 6 Air Conditioning 12 - 6 9803/6410 Issue 1...
Page 106 Section B Body & Framework Section B 12 - 7 Air Conditioning 12 - 7 Fault Finding (cont'd) No Air Conditioning CHECK ACTION Are the controls set correctly, i.e. air conditioning YES: Check 2 selected, thermostat switch set to coldest position Reset controls and retest.
Page 107 Section B Body & Framework Section B 12 - 8 Air Conditioning 12 - 8 Checking Refrigerant Charge Level Leak Testing ! WARNING The pressure in the system, i.e. the refrigerant charge level Leak testing in Air Conditioning systems should be can be determined by checking the state of refrigerant at the carried out only in a well ventilated area.
Page 108 Section B Body & Framework Section B 12 - 9 Air Conditioning 12 - 9 System Diagnosis Normally Functioning A/C System Normal gauge readings will depend on system components and ambient conditions, make sure that the valves are Gauge Readings: closed and the readings are stable and that the system has a Low Side Gauge - Normal.
Page 109 Section B Body & Framework Section B 12 - 10 Air Conditioning 12 - 10 System Diagnosis (cont'd) Low R-134a Charge LOW SIDE (RED) HIGH SIDE (BLUE) Gauge Readings: Low Side Gauge - Low. High Side Gauge - Low. Other symptoms: Sight Glass - Bubbles continuously visible.
Page 110 Section B Body & Framework Section B 12 - 11 Air Conditioning 12 - 11 System Diagnosis (cont'd) No Refrigerant Circulation LOW SIDE (RED) HIGH SIDE (BLUE) Gauge Readings: Zero to negative Low Side Gauge - Zero to negative. High Side Gauge - Low. Other symptoms: Receiver-Drier - Frost or moisture on tubes before and after receiver-drier.
Page 111 Section B Body & Framework Section B 12 - 12 Air Conditioning 12 - 12 System Diagnosis (cont'd) Air in System LOW SIDE (RED) HIGH SIDE (BLUE) Gauge Readings: High High Low Side Gauge - High. High Side Gauge - High. Other symptoms: Sight Glass - Bubbles visible during system operation.
Page 112 Section B Body & Framework Section B 12 - 13 Air Conditioning 12 - 13 System Diagnosis (cont'd) Compressor Malfunction LOW SIDE (RED) HIGH SIDE (BLUE) Gauge Readings: High Low Side Gauge - High. High Side Gauge - Low. Diagnosis: Internal compressor leak...
Page 113 Section C Electrics Section C Contents Page No. Torque Specification Technical Data Battery Testing Schematic Diagram Layout Operator’s Cab Right Console Left Console Monitor Control, Function, Operation Engine Control Basic Operation Stepping Motor Throttle Related Function Stop Motor Function Redundancy (back-up) Throttle Control Automatic Engine Adjustment Idling Control 4-10...
Page 114: Torque Specification
Section C Electrics Section C 1 - 1 Torque Specifications 1 - 1 Torque Specifications Component kgfm lb ft Remarks Battery (securing bolts) 19.6-29.4 14.46-21.69 9803/6410 Issue 1...
Page 115: Technical Data
Section C Electrics Section C 2 - 1 Technical Data 2 -1 Circuit Protection; Fuse rating and circuit names BACK UP COMPUTER P. KEY SW. COMPUTER C. AIRCON., HEATER SHUT DOWN LAMP LEVER LOCK LAMP (SPARE) LUBRICATOR LAMP (SPARE) WARNING BEACON LAMP (SPARE) OIL PUMP WIPER, WASHER...
Page 116: Battery Testing
Section C Electrics Section C 2 - 2 2 - 2 Batteries Testing - Specific Gravity The specific gravity of the electrolyte gives an idea of the Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation state of charge of the battery.
Page 117: Schematic Diagram
Section C Electrics Section C 2 - 3 Schematic Diagram 2 - 3 Main Components Cigar Lighter Switch - Hydraulic Oil Overheat Loudspeaker Switch - Hydraulic Oil Reserve Tank Level Radio Aerial Lead Switch - Air Filter Blocked Radio (Standard) Control - Hydraulic Pump Radio (AM/FM) (Optional) Pressure Switch - Upper Pilot Pressure...
Page 119: Operator's Cab
Section C Electrics Section C 3 - 1 Layout 3 - 1 Operator’s Cab 9803/6410 Issue 1...
Page 120: Right Console
Section C Electrics Section C 3 - 2 Layout 3 - 2 Right Console For correct operation and description see 'Operator’s Manual' RIGHT CONSOLE JS03290 Right Console Idle Switch tilt handle Work lamp Switch Throttle Volume Control Wiper Switch Mode Selection Washer Switch One Touch/Auto change switch...
Page 121 Section C Electrics Section C 3 - 3 Layout 3 - 3 Right Console (continued) Horn Volume Soft/Hard Starter Switch Buzzer Stop Switch Power-up button JS03010 Right Console (side panel) Time Adjust Back-up ADJUST/CLOCK CLOCK 9803/6410 Issue 1...
Page 122: Left Console
Section C Electrics Section C 3 - 4 Layout 3 - 4 Left Console For correct operation and description see 'Operator’s Manual' LEFT CONSOLE JS003300 Left Console Lever-lock Switch Tilt Handle Horn Switch Cigarette Lighter JS03000 Hour Meter Heater and Air Conditioning Emergency Stop Switch STOP...
Page 123: Monitor
Section C Electrics Section C 3 - 5 Layout 3 - 5 Monitor For correct operation see 'Operator’s Manual' WORK MODE Message MODE CLOCK WATER TEMP HYD. OIL TEMP FUEL Water Temp Machine Condition Indicators Green White WATER TEMP Lock Indicator Fuel Indicator LOCK Green...
Page 124: Control, Function, Operation
Section C Electrics Section C 3 - 6 Layout 3 - 6 Control, Function, Operation FUNCTION CONTROL OPERATION Slight difference of RPM between each mode Engine speed varies according to mode: Idling RPM is regulated S Mode is100rpm less than H mode Engine revolutions automatic according to the mode L Mode is 200rpm less than H mode...
Page 125 Section C Electrics Section C 3 - 7 Layout 3 - 7 Control, Function, Operation FUNCTION CONTROL OPERATION The supply current to Pump control depends on work such electromagnetic proportional as, H mode, large working load, S Pump control pressure reducing valve mode, good fuel economy, and L which is built into the pump, mode, for fine operation.
Page 126: Engine Control
Section C Electrics Section C 4 - 1 Engine Control 4 - 1 Basic Operation The engine throttle control is done with the electric throttle motor. A stepping motor is now used as part of the throttle motor. Stepping Motor This rotates in direct synchronization with the amount of pulses received from the pulse oscillator.
Page 127 Section C Electrics Section C 4 - 2 Engine Control 4 - 2 Stepping Motor (continued) Driver Circuit (driver) The driver circuit of a stepping motor consists of a logical section which forms and distributes a pulsed signal from an oscillator and an amplifying section which amplifies and supplies the signal to the motor.
Page 128: Throttle Related Function
Section C Electrics Section C 4 - 3 Engine Control 4 - 3 Throttle related function A signal enters CN2-9 of the controller and ACC of the motor driver from ACC key switch. (24V) The controller and the driver sense that the key switch is ON, when this signal enters. The controller sends a clockwise rotation instruction (CN8-2) to the driver, and the driver sends a pulse clockwise rotation (ABA1B1) to the throttle motor.
Page 129 Section C Electrics Section C 4 - 4 Engine Control 4 - 4 Throttle related function (continued) For the Throttle motor to rotate to the position required by the throttle volume, an instruction from (CN8-4) to rotate counter clockwise is sent from the controller to the motor driver, when received, sends a counter clockwise pulse from the motor driver to the throttle motor.
Page 130 Section C Electrics Section C 4 - 5 Engine Control 4 - 5 Controller rotational instructions After key switch ON When the transistor on the CW side of the controller is turned ON, 5V from a driver circuit drops to ground. At this point the CW line is 0V and CCW line is 5V at the driver side.
Page 131: Stop Motor Function
Section C Electrics Section C 4 - 6 Engine Control 4 - 6 Stop Motor Function With the key switch in the ON position, the power flows through relay and energises the actuating coil of relay 2 A Key Switch ON which supplies current to rotate the stop motor.
Page 132 Section C Electrics Section C 4 - 7 Engine Control 4 - 7 Emergency stop button ON The coil of relay 1 is excited when the emergency stop button is pressed when the key switch is ON (previous section A), and the relay switch turns to the lower position. Since the excitation voltage to relay 2 collapses, the relay switch is returned to the upper position.
Page 133: Redundancy (Back-Up) Throttle Control
Section C Electrics Section C 4 - 8 Engine Control 4 - 8 Redundancy (Back-up) throttle control If the throttle control does not operate due to a controller defect, press the redundancy switch. Throttle control is then taken over by the manual throttle buttons. When pressing a redundancy switch, control power supply to the controller is turned OFF, and the manual throttle circuit is activated.
Page 134: Automatic Engine Adjustment
Section C Electrics Section C 4 - 9 Engine Control 4 - 9 Automatic Engine Adjustment To give accurate control, store the required RPM setting on the controller by carrying out the automatic engine adjustment procedure. This will be necessary after fitting a new controller or throttle motor or after adjusting/replacing the control link between the engine and throttle motor.
Page 135: Idling Control
Section C Electrics Section C 4 - 10 Engine Control 4 - 10 Idling Control Time Chart With the key switch ON pressing the one-touch switch causes the switch lamp to come on. One-touch idle operation is possible when in one-touch idling mode regardless of whether the pilot pressure switches of IN2, IN3, IN4 are...
Page 136: Revolution Control For Each Mode
Section C Electrics Section C 4 - 11 Engine Control 4 - 11 Revolution Control for Each Mode The machine is in the standard mode when the key switch is ON. This position is 100 rpm less than the FULL rotational position (H mode).
Page 137 Section C Electrics Section C 4 - 12 Engine Control 4 - 12 Control of Engine Speed for Breaker Operation Note: It is necessary to preset the engine r.p.m. to a speed which delivers the flow rate required for breaker operation (see Setting Function under Self Test Function).
Page 138 Section C Electrics Section C 4 - 13 Engine Control 4 - 13 Engine Auto Warm-up Time Chart Conditions for automatic warming up Water temperature is less than 50°C. Upper Pilot pressure switch is OFF. (attachment is not operating.) Lower Pilot pressure switch is OFF. (travel is not operating.) One-touch idle is turned OFF.
Page 139 Section C Electrics Section C 4 - 14 Engine Control 4 - 14 Detection of Throttle Motor Assembly Defect (Out-of-step) Fault When the pulse signal cannot be interrupted by the driver, and deviates from regular rotation. Possible Factors 1. If the adjusting screw of the throttle link is loosened, and the length of the link is changed more than the deflection of the spring.
Page 140 The S,L, and F modes have fixed current values. Current value of each mode Mode Machine Imax Imin Type JS130 495 mA 300 mA 305 ± 20 mA 0 + 10 mA 0 + 10 mA JS160 520 mA 325 mA 330 ±...
Page 141 Section C Electrics Section C 5 - 2 Pump Control 5 - 2 Schematic (continued) Torque Ts= 0.9TT TL=0.7TT Horsepower Flow Horsepower Electric current value I max MODE I min Target Pressure Revolution (At H Mode max. revolutions) S MODE: Pump torque equals 90% of engine target torque T, IS is the constant current value.
Page 142 Section C Electrics Section C 5 - 3 Pump Control 5 - 3 FLOW CHART 9803/6410 Issue 1...
Page 143 Section C Electrics Section C 5 - 4 Pump Control 5 - 4 Boom Lowering Speed Regulation Circuit Diagram Time Chart Flow Chart Boom Lowering Speed Regulation Regulating the speed of the boom lowering procedure is activated only in L, F mode. When changing to L, F mode, a transistor in the controller turns ON, and switches a solenoid valve.
Page 144 Section C Electrics Section C 5 - 5 Pump Control 5 - 5 Cushioned Boom Starting Circuit Diagram Time Chart When the boom lowering pressure switch turns ON, the solenoid valve switches on for 0.4 sec, and pilot pressure is sent to the negative control signal port of the pump.
Page 145 Section C Electrics Section C 5 - 6 Pump Control 5 - 6 Cushioned Boom Starting (continued) Flow Chart 9803/6410 Issue 1...
Page 146 Section C Electrics Section C 5 - 7 Pump Control 5 -7 Pressure Increasing System (One-touch digging force UP, Travel power UP) A In only H or S modes, when the one-touch digging force UP switch is turned ON (IN5), the signal enters the controller through the timer in the panel switch and remains for 8 sec, 24V is output from the controller to the now activated solenoid valve.
Page 147 Section C Electrics Section C 5 - 8 Pump Control 5 - 8 Pressure Increasing System (continued) L Mode A Even though the one-touch digging force UP switch is pressed, the voltage is not output to the solenoid valve, and a pressure increase is not obtained.
Page 148 Section C Electrics Section C 5 - 9 Pump Control 5 - 9 Pressure Increasing System (continued) Flow Chart 9803/6410 Issue 1...
Page 149 Section C Electrics Section C 5 - 10 Pump Control 5 - 10 3-Speed Travel and Max. Flow (Q) Cut Travelling at middle speed (always middle speed as At middle speed travel the key is switched ON). Travel motor swash plate: low side Even though travel and upper pressure switches are ON, Pump: Standard there is no output to solenoid valves A and B.
Page 150 Section C Electrics Section C 5 - 11 Pump Control 5 - 11 3-Speed Travel and Max. Flow Cut (continued) Q cut is done by F mode using the ON signal of upper At middle speed travel pressure S/W for the first time. Travel motor swash plate: low side At middle speed travel Pump: Standard...
Page 151 Section C Electrics Section C 5 - 12 Pump Control 5 - 12 3-Speed Travel and Max. Flow (Q) Cut (continued) Relation of Travel Mode and Motor Swash Plate, Pump Flow (Q) Cut Relation of Travel Mode and Motor Swash Plate, Pump flow (Q) Cut High Speed Middle Speed Low Speed Work mode is independent.
Page 152 Section C Electrics Section C 5 - 13 Pump Control 5 - 13 3-Speed Travel and Max. Flow Cut (continued) Flow Chart 9803/6410 Issue 1...
Page 153 Section C Electrics Section C 5 - 14 Pump Control 5 - 14 Cushion (Soft/Hard) Switch Circuit Diagram Time Chart Flow Chart - Cushion (Soft/Hard) Switch Output to the soft/hard solenoid valve is OFF when key switch is ON. This is its SOFT status After the engine is started, the signal received from the panel switch is altered.
Page 154 Section C Electrics Section C 5 - 15 Pump Control 5 - 15 Power Supply Cut Delay Circuit Diagram Time Chart When the signal (IN1) from the key switch is turned OFF, 24V from OUT 3 is output from the controller for 3 seconds. After 3 seconds the output of OUT 3 stops, and power to the coil from the electric battery relay is cut, contacts on the electric battery relay break, and the power supply is cut.
Page 155 Section C Electrics Section C 5 - 16 Pump Control 5 - 16 Power Supply Cut Delay Flow Chart 9803/6410 Issue 1...
Page 156 Section C Electrics Section C 5 - 17 Pump Control 5 - 17 Swing Brake/Swing Lock (1) Swing Brake 1) Engine is running and swing lever is in neutral (50% brake). SOL: 2 Swing Swing lock SOL:1 SOL: 3 Monitor lever 100% lock brake...
Page 157 Section C Electrics Section C 5 - 18 Pump Control 5 - 18 Swing Brake/Swing Lock (continued) 2) Engine is running and swing lever operation (brake release) SOL: 2 Swing Swing lock SOL:1 SOL: 3 Monitor lever 100% lock brake Shut off ( P ) 5 sec.
Page 158 Section C Electrics Section C 5 - 19 Pump Control 5 - 19 Swing Brake Swing Lock (continued) (2) Swing Lock (Swing Lock Switch ON, 100% Brake) SOL: 2 Swing Swing lock SOL:1 SOL: 3 Monitor lever 100% lock brake Shut off ( P ) 5 sec.
Page 159 Section C Electrics Section C 5 - 20 Pump Control 5 - 20 Swing brake/Swing lock (continued) Flow Chart 9803/6410 Issue 1...
Page 160 Section C Electrics Section C 5 - 21 Pump Control 5 - 21 Lever Lock Circuit Diagram Time Chart 9803/6410 Issue 1...
Page 161 Section C Electrics Section C 5 - 22 Pump Control 5 - 22 Lever Lock (continued) Flow Chart 9803/6410 Issue 1...
Page 162 Section C Electrics Section C 5 - 23 Pump Control 5 - 23 Travel Warning Circuit Diagram A travel pilot pressure switch is turned ON by travel lever operation and 24V is output for 10 seconds to the buzzer. 9803/6410 Issue 1...
Page 163 Section C Electrics Section C 5 - 24 Pump Control 5 - 24 Power Transistor Protection Controller Position Spare Spare Spare Swing shut off solenoid V Lever lock solenoid V Travel alarm Pressure raising solenoid V Free swing solenoid V Negative control solenoid V Spare Spare...
Page 164 Section C Electrics Section C 5 - 25 Pump Control 5 - 25 Display Monitor Radiator Water Temperature Circuit Diagram Overheat switch position and the ON signal of the thermostat sensor are OR processed and number 8 is lit. Overheat switch position and the OFF signal of the thermostat sensor are AND processed and number 8 turns off. Number 8 is lit on the condition that numbers 1-7 are lit.
Page 165 Section C Electrics Section C 5 - 26 Pump Control 5 - 26 Display Monitor (continued) Hydraulic Oil Temperature Circuit Diagram Overheat switch position and the ON signal of the thermostat sensor are OR processed and number 8 is lit. Overheat switch position and the OFF signal of the thermostat sensor are AND processed and number 8 turns off.
Page 166 Section C Electrics Section C 5 - 27 Pump Control 5 - 27 Display Monitor (continued) Fuel Remaining Circuit Diagram FUEL REMAINING RESISTANCE (litres) (OHM) MONITOR 284~ 13~10 243~284 21~13 200~243 27~21 158~200 34~27 115~158 44~34 72~115 59~44 39~72 78~59 (1 hour 80~78 left - Refuel)
Page 167 Section C Electrics Section C 5 - 28 Pump Control 5 - 28 Display Monitor (continued) Warning Display (Message Display) START Message Display Key SW ON Key SW ON & Engine Running ! Battery charging Deficient ! Overheat ! Engine oil pressure down ! Electric system abnormality ! Air cleaner clogged ! Refuel...
Page 168 Section C Electrics Section C 6 - 1 Throttle Motor 6 -1 Throttle Motor and Throttle Link Replacement Prepare the machine Position the machine on level ground. Stop the engine and remove the starter key. Locate the throttle motor and link See Component Location Diagram in Routine Maintenance.
Page 169 Section C Electrics Section C 6 - 2 Throttle Motor 6 - 2 Throttle Motor Throttle Link Replacement (continued) Installation of the throttle link lever a Install the lever on the new throttle motor without forcing it. b Coat the screws D with loctite before fastening. Installation of the throttle link a After installation of the throttle motor, install the throttle links to the throttle lever and the control link.
Page 170 Section C Electrics Section C 6 - 3 Throttle Motor 6 - 3 Automatic Adjustment Always perform the automatic adjustment when the controller and or the throttle motor or linkage is replaced or the throttle cable or linkage is adjusted. The controller must be programmed to suit the machine model.
Page 171 Repeatedly press S Mode switch until the monitor’s Repeatedly press L Mode switch until ‘E’ is displayed desired language is displayed on the mode screen. on the clock (1st digit). All other displays are for non- JCB applications and are therefore not applicable. Mode MODE Mode...
Page 172 Section C Electrics Section C 7 - 1 Revolution Sensor 7 - 1 Revolution Sensor Removal and Installation Prepare the Machine Position the machine on level ground. Stop the engine and remove the starter key. Locate the Flywheel housing a The flywheel housing is machined to accommodate the sensor.
Page 173 Section C Electrics Section C 8 - 1 Self Test 8 - 1 Self Test Function This series of vehicles contains numerous sensors to enable the machine to perform its own self test diagnosis. Below is a list of functions which are monitored by the system.
Page 174 WORK MODE Self-check Change Pattern MODE Select Reset CLOCK When the CHANGE switch is pressed the Model designation is displayed: Message 121 = JS130 CH : MN 151 = JS160 WORK MODE Self-check Change MODE JS10940 CLOCK 9803/6410 Issue 2*...
Page 175 Section C Electrics Section C 8 - 3 Self Test 8 - 3 Self Test Function (continued) ENGINE RPM The Self Check items can be displayed by pressing the Message SELECT SWITCH after every singular display in the following order. CH : RPM When the SELECT switch is pressed the Engine RPM is displayed...
Page 176 Section C Electrics Section C 8 - 4 Self Test 8 - 4 Self Test Function (continued) FUEL SENSOR RESISTANCE VALUE Message Pressing SELECT changes the display as shown. CH : FS The fuel sensor resistance is shown in Ohms in the clock display.
Page 177 Section C Electrics Section C 8 - 5 Self Test 8 - 5 Self Test Function (continued) PRESSURE SWITCH INPUT Message Start engine. Pressing SELECT changes the display as shown. CH : PS This monitors pressure switch information in the clock display. WORK MODE 0 =Switch open Self-check...
Page 178 Section C Electrics Section C 8 - 6 Self Test 8 - 6 Self Test Function (continued) Setting Function This section deals with setting separate parameters: Breaker engine speed. Automatic idle time. In addition to the previous sections displays, the following switches are used.
Page 179 Check that the breaker engine RPM setting is correct for the breaker being used as given in the following table: CLOCK Message Machine Hammermaster Engine Normal flow l/min EA: B ( RPM ) JS130 2150 1050 2280 20 Seconds WORK MODE Self-check JS160 1050 2200 MODE...
Page 180 Section C Electrics Section C 8 - 8 Self Test 8 - 8 Self Test Function (continued) Message When the desired AUTOMATIC IDLE TIME is reached, press EA: B ( RPM ) and hold the RESET switch for 20 seconds to enter the setting into the controller.
Page 181 Section C Electrics Section C 9 - 1 Fault Finding 9 - 1 Fault Diagnosis This section is designed to simplify the Task of Fault Finding. When a message is displayed, the description of the fault is shown and the Problem No. is shown; this in turn then relates to the relevant page showing the Problem No.
Page 182 Section C Electrics Section C 9 - 2 Fault Finding 9 - 2 Fault Diagnosis (continued) This explains how to trouble shoot in the event that the message does not go out even though suitable measures are taken to check and clear the problem. !Mark Message Display Trouble Description...
Page 183 Section C Electrics Section C 9 - 3 Fault Finding 9 - 3 Fault Diagnosis (continued) Judgement Item Value Measure 1. Fuel amount check Refuel 2. Inspection for fuel contaminant Clean, drain 3. Hydraulic oil amount check Refill oil 4. Inspection of hydraulic oil strainer Clean, drain 5.
Page 184 Section C Electrics Section C 9 - 4 Fault Finding 9 - 4 Fault Diagnosis (continued) Emergency Engine Stop, Problem No.1 Note: Even if the emergency stop button is pressed the message does not go out. Prior Confirmation Items The "MODE" of the mode display is not flashing. Confirm that the fuses in the fuse box are normal.
Page 185 Section C Electrics Section C 9 - 5 Fault Finding 9 - 5 Fault Diagnosis (continued) Refuel, Problem No.2 Note: Message does not go out even if refuelled Prior Confirmation Items The "MODE" of the mode display is not flashing. Fuel bar graph displays one.
Page 186 Section C Electrics Section C 9 - 6 Fault Finding 9 - 6 Fault Diagnosis (continued) Coolant Refill, Problem No 3 Note: Message does not go out even if coolant is refilled Prior Confirmation Items The "MODE" of the mode display is not flashing. Troubleshoot Cause Remedy...
Page 187 Section C Electrics Section C 9 - 7 Fault Finding 9 - 7 Fault Diagnosis (continued) Air Cleaner clogged, Problem No. 5 Note: Message does not go out even if the filter is washed. Prior Confirmation Items The "MODE" of the mode display is not flashing. Troubleshoot Cause Remedy...
Page 188 Section C Electrics Section C 9 - 8 Fault Finding 9 - 8 Fault Diagnosis (continued) Low Engine Oil Pressure. Problem No. 6 Note: Message does not go out even if engine oil is satisfactory. Prior Confirmation Items The "MODE" of the mode display is not flashing. Troubleshoot Cause Remedy...
Page 189 Section C Electrics Section C 9 - 9 Fault Finding 9 - 9 Fault Diagnosis (continued) Engine Oil Filter Blocked, Problem No 7 Note: Message does not go out even if the engine oil filter is replaced and the oil is satisfactory. Prior Confirmation Items The "MODE"...
Page 190 Section C Electrics Section C 9 - 10 Fault Finding 9 - 10 Fault Diagnosis (continued) Fluid Overheating, water, oil, Problem No 8 Note: Message does not go out even if the actual temperature is below the following; Hydraulic Oil Temperature 84°C. Engine Coolant Temperature 92°C.
Page 191 Section C Electrics Section C 9 - 11 Fault Finding 9 - 11 Fault Diagnosis (continued) Fluid Overheating, water, oil, Problem No 8 (continued) Note: Message does not go out even if the actual Temperature is below the following:- Hydraulic Oil Temperature 84°C Engine Coolant Temperature 92°C Troubleshoot Cause...
Page 192 Section C Electrics Section C 9 - 12 Fault Finding 9 - 12 Fault Diagnosis (continued) Battery Charging, Problem No 9 Note: Message does not go out. Prior Confirmation Items The "MODE" of the mode display is not flashing. Troubleshoot Cause Remedy Remove CN2 connector and...
Page 193 Section C Electrics Section C 9 - 13 Fault Finding 9 - 13 Fault Diagnosis (continued) Electrical Systems, Message Fault, Problem No 10 Note: Message does not go out. 9803/6410 Issue 1...
Page 194 Section C Electrics Section C 9 - 14 Fault Finding 9 - 14 Fault Diagnosis (continued) Electrical System, Message Fault, Problem No. 10 (continued) Note: Message does not go out. Troubleshoot Cause Remedy Key switch ON Replace When transistor When electro Electro-magnetic electro output is carried...
Page 195 Section C Electrics Section C 9 - 15 Fault Finding 9 - 15 Fault Diagnosis (continued) Electrical System, Message Fault, Problem No.10 (continued) Note: Message does not go out. Troubleshoot Cause Remedy Continued from previous page Remove driver connector Breakage or defective CN15 and measure wiring between Repair...
Page 196 Section C Electrics Section C 9 - 16 Fault Finding 9 - 16 Fault Diagnosis (continued) Engine Trouble, Problem No 11 Note: Engine does not start even though the message "electrical system abnormal" is not displayed. Prior Confirmation Items No abnormalities in engine or fuel system. Fuse is not blown.
Page 197 Section C Electrics Section C 9 - 17 Fault Finding 9 - 17 Fault Diagnosis (continued) Engine Trouble, Problem No 11 (continued) Troubleshoot Cause Remedy Key switch ON Engine system Inspect Is fuel cut lever on stop side Abnormality engine system.
Page 198 Section C Electrics Section C 9 - 18 Fault Finding 9 - 18 Fault Diagnosis (continued) Engine Problem, Problem No 12 Note: Engine revolutions do not change with throttle volume control. Prior Confirmation Items The message "Engine emergency stop" is not displayed. Troubleshoot Cause Remedy...
Page 199 Section C Electrics Section C 9 - 19 Fault Finding 9 - 19 Sensor Resistance Valve Water temperature (Oil temperature) Minimum Maximum 20°C 8.00k 10.20k 30°C 5.35k 6.50k 40°C 3.60k 4.55k 50°C 2.50k 3.10k 60°C 1.70k 2.20k 70°C 1.20k 1.55k 80°C 0.85k 1.15k...
Page 200 Page No. Technical Data JS130 1 - 1 Technical Data JS160 1 - 3 Schematics Schematic Hydraulic Circuit JS130 3 - 1 Schematic Hydraulic Circuit JS160 3 - 2A Shuttle Block 3 - 4 Pilot Control Line Hose Connection Diagram...
Page 201: Operation
Hydraulics Section E Section E Contents Page No. Shuttle Valve Introduction 55 - 1 General Information 55 - 2 Operation 55 - 4 Cushion Valves Schematics, Technical Data 56 - 1 Operation 56 - 2 Slew Brake Valve Introduction, Technical Data 60 - 1 Operation 60 - 3...
Page 202 Section E Hydraulics Section E 1 - 1 Technical Data (JS130) 1 - 1 Note: For full specification details see information in each section. Pump Type 2 stage tandem, variable capacity swash plate type axial piston pump Displacement Volume 55 cm /rev x 2 (3.36 in...
Page 203 Section E Hydraulics Section E 1 - 2 Technical Data (JS130) 1 - 2 Travel Equipment Type Fixed Displacement Piston Motor (automatic 2-speed change) Suction Capacity 86.3 cm /rev (5.27 in /rev) Working Pressure Refer to Pressure Testing (Section E 4-1)
Page 204 Section E Hydraulics Section E 1 - 3 Technical Data (JS160) 1 - 3 Note: For full specification details see information in each section. Pump Type 2 stage tandem, variable capacity swash plate type axial piston pump Displacement Volume 60 cm /rev x 2 (3.66 in /rev x 2) Working Pressure...
Page 205 Section E Hydraulics Section E 1 - 4 Technical Data (JS160) 1 - 4 Travel Equipment Motor Fixed displacement piston motor (automatic 2-speed change) Suction Capacity 104.8 cm /rev (6.39 in /rev) Working Pressure Refer to Pressure Testing (Section E 4-1) Working Flow Reduction Gear Ratio 48 : 1...
Page 206: Schematic Hydraulic Circuit Js130
Section E Hydraulics Section E 3 - 1 Schematics 3 - 1 Schematic, Hydraulic Circuit JS130 MOTOR; SLEW VALVE; SHUTTLE RAM; DIPPER ACCUMULATOR VALVE; ASSEMBLY VALVE; CHECK MOTOR; TRACTION FILTER; LINE ROTARY COUPLING PUMP; HYD RAM; BUCKET VALVE; REMOTE CONT RAM;...
Page 208: Schematic Hydraulic Circuit Js160
Section E Hydraulics Section E 3 - 2A Schematics 3 - 2A Schematic, Hydraulic Circuit JS160 MOTOR; SLEW VALVE; SHUTTLE RAM; DIPPER ACCUMULATOR VALVE; ASSEMBLY VALVE; CHECK MOTOR; TRACTION FILTER; LINE ROTARY COUPLING PUMP; HYD RAM; BUCKET VALVE; REMOTE CONT RAM;...
Page 210: Shuttle Block
Section E Hydraulics Section E 3 - 4 Schematics 3 - 4 Shuttle Block 9803/6410 Issue 2*...
Page 211: Pilot Control Line Hose Connection Diagram
Hydraulics Section E Section E 3 - 5 Schematics 3 - 5 Pilot Control Line Hose Connection Diagram JS03540 9803/6410 Issue 2*...
Page 212 Hydraulics Section E Section E 3 - 6 Schematics 3 - 6 Pilot Control Line Hose Connection Diagram JS03540 9803/6410 Issue 1...
Page 213: Pressure Measuring Points
Section E Hydraulics Section E 4 - 1 Pressure Testing 4 - 1 Pressure Measuring Points JS130 Main Pump P1 Main Pump P2 Servo Pressure (JS 160) Servo Pressure (JS 130) JS160 A302850 A302860 Pressure Relief Valves Main relief valve...
Page 214: Pressure Testing
Section E Hydraulics Section E 4 - 2 Pressure Testing 4 - 2 Pressure Testing - General Operate the bucket control slowly until it reaches one end Confirmation of the oil Temperature of its travel and leave it there for 30 seconds. Confirm the oil temperature is between 45°...
Page 215 Section E Hydraulics Section E 4 - 3 Pressure Testing 4 - 3 Main Relief Valve (MRV) Prepare the Machine a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the bucket on the ground.
Page 216: Servo Accumulator
Section E Hydraulics Section E 4 - 4 Pressure Testing 4 - 4 Servo Accumulator JS 160 Prepare the Machine a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the bucket on the ground.
Page 217: Pilot Relief Valve
Section E Hydraulics Section E 4 - 5 Pressure Testing 4 - 5 Pilot Relief Valve Prepare the Machine Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the bucket on the ground.
Page 218: Slew Motor Relief Valve
Section E Hydraulics Section E 4 - 6 Pressure Testing 4 - 6 Slew Motor Relief Valve Prepare the machine Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground.
Page 219: Auxiliary Relief Valves
Section E Hydraulics Section E 4 - 7 Pressure Testing 4 - 7 Auxiliary Relief Valves General The auxiliary relief valves (ARV’s) are set to a higher pressure than the main relief valve (MRV). To permit pressure testing of the ARV’s it is necessary to temporarily adjust the MRV to a higher setting (refer to view B on page 4 - 1).
Page 220 Section E Hydraulics Section E 4 - 8 Pressure Testing 4 - 8 Auxiliary Relief Valves (continued) Boom Ram Prepare the machine a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground.
Page 221 Section E Hydraulics Section E 4 - 9 Pressure Testing 4 - 9 Auxiliary Relief Valves (continued) Boom Ram (continued) Boom Down Prepare the machine Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground.
Page 222 Section E Hydraulics Section E 4 - 10 Pressure Testing 4 - 10 Auxiliary Relief Valves (continued) Dipper Ram Prepare the Machine. a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground.
Page 223 Section E Hydraulics Section E 4 - 11 Pressure Testing 4 - 11 Auxiliary Relief Valves (continued) Bucket Ram Prepare the Machine a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground.
Page 224 Section E Hydraulics Section E 4 - 12 Pressure Testing 4 - 12 Auxiliary Relief Valves (continued) Rockbreaker ARV (Monoboom) Prepare the Machine. a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground.
Page 225: Travel Motor Relief Pressure
Section E Hydraulics Section E 4 - 13 Pressure Testing 4 - 13 Travel Motor Relief Pressure Prepare the Machine. a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the bucket on the ground.
Page 226: Hydraulic Pump/Regulator
(Pp) to provide pilot circuit pressure for operator control of machine functions. Pumps P1 and P2 each incorporate a regulator which adjusts the output flow rate according to system demand. Specifications Axial Piston Pumps JS130 JS160 Maximum displacement cc (in )/rev 55 (3.36) x 2 60 (3.66) x 2...
Page 227 Section E Hydraulics Section E 10 - 2 Hydraulic Pump/Regulator 10 - 2 Pump Hydraulic Circuit Diagram JS00040 Pump Configuration JS00050 Negative control signal Pump input Maximum flow signal Pump outputs Mode change - electrical signal Swash plate angle Solenoid proportional pressure control (SPPC) valve P1 Front pump Total horsepower control electrical signal P2 Rear pump...
Page 228 Section E Hydraulics Section E 10 - 3 Hydraulic Pump/Regulator 10 - 3 Operation In the following descriptions the bold figures (e.g. 4) relate to The fixed valve plate 9 contains two crescent shaped ports the items on the sectional and exploded views on pages X.
Page 229 Section E Hydraulics Section E 10 - 4 Hydraulic Pump/Regulator 10 - 4 Operation Pilot Pump (Pp) JS00070 Regulator JS00080 Negative control signal Maximum flow signal Horsepower control signal (from pump proportional solenoid control valve) Swash plate angle P1 Front pump P2 Rear pump Pp Pilot pump 9803/6410...
Page 230 Section E Hydraulics Section E 10 - 5 Hydraulic Pump/Regulator 10 - 5 Operation (cont’d) Pilot Pump (Pp) As the pump gears revolve, oil from the inlet port Y is Horsepower Control trapped between the gears and the housing and carried to the outlet port Z.
Page 231 Section E Hydraulics Section E 10 - 6 Hydraulic Pump/Regulator 10 - 6 Operation (cont’d) Pilot Relief Valve Pilot pressure is controlled by the pilot relief valve setting. Pressure can be varied using adjuster 56-6 which holds poppet 56-2 against seat 56-3 by means of spring 56-5. If the pressure exceeds the set value, the poppet lifts to vent excess Pp pressure to tank.
Page 232: Fault Finding
Section E Hydraulics Section E 12 - 1 Hydraulic Pump/Regulator 12 - 1 Fault finding As a first step towards locating a fault, carry out the following checks. Check the hydraulic filter for the presence of excessive foreign materials. The nature of the foreign materials could yield a clue as to the source of damage or wear.
Page 233 Section E Hydraulics Section E 12 - 2 Hydraulic Pump/Regulator 12 - 2 Fault finding (cont’d) Symptom Possible cause Remedy Pump is producing abnormal Air is being drawn in due to low Top up the hydraulic oil and bleed air noise.
Page 234: Dismantling And Assembly
Section E Hydraulics Section E 14 - 1 Hydraulic Pump/Regulator 14 - 1 Dismantling and Assembly JS00010 9803/6410 Issue 1...
Page 235: Dismantling And Assembly
Section E Hydraulics Section E 14 - 2 Hydraulic Pump/Regulator 14 - 2 Dismantling and Assembly (cont’d) 9803/6410 Issue 1...
Page 236: Dismantling And Assembly
Section E Hydraulics Section E 14 - 3 Hydraulic Pump/Regulator 14 - 3 Dismantling and Assembly (cont’d) 9803/6410 Issue 1...
Page 237: Hydraulic Pump/Regulator
Section E Hydraulics Section E 14 - 4 Hydraulic Pump/Regulator 14 - 4 Component List Description Qty. Description Qty. Pump housing Mounting flange Flange Rear cover Cylinder block assembly Shaft Plug Piston assembly Plug Swash plate (front) Plug Swash plate (rear) Plug Valve plate (front) Plug...
Page 238 Section E Hydraulics Section E 14 - 5 Hydraulic Pump/Regulator 14 - 5 Dismantling Refer to the illustrations on pages 14 - 1 to 14 - 3 and the The following procedures show a complete strip down, but, component list on page 14 - 4. In the following procedures, unless absolutely necessary, avoid disturbing or dismantling the part numbers in bold type (e.g.
Page 239 Section E Hydraulics Section E 14 - 6 Hydraulic Pump/Regulator 14 - 6 Dismantling (cont’d) Unscrew the two bolts 77 and remove gear pump 57. Unscrew the four socket head bolts 74. Remove sub- block assembly 50 and put to one side. Unscrew the six socket head bolts 73 and remove rear Remove bearing 13 on the rear side, using the bearing cover 3.
Page 240 Section E Hydraulics Section E 14 - 7 Hydraulic Pump/Regulator 14 - 7 Dismantling (cont’d) Remove rear swash plate 8 and the assembly Unscrew the four socket head bolts 75 and take out oil comprising cylinder block 4, piston assembly 6, retainer seal case 16.
Page 241 Section E Hydraulics Section E 14 - 8 Hydraulic Pump/Regulator 14 - 8 Dismantling (cont’d) Remove front swash plate 7 and the assembly Unscrew the three socket head bolts 72 on the rear comprising cylinder block 4, piston assembly 6, retainer side and remove cover ‘LR’...
Page 242 Section E Hydraulics Section E 14 - 9 Hydraulic Pump/Regulator 14 - 9 Dismantling (cont’d) Unscrew the three socket head bolts 73 on the rear Unscrew the three socket head bolts 72 on the front side and remove cover ‘R’ 30. side and remove cover ‘LF’...
Page 243 Section E Hydraulics Section E 14 - 10 Hydraulic Pump/Regulator 14 - 10 Dismantling (cont’d) Loosen plug 35 and remove it along with spring 36. By Return to sub-block assembly 50 removed at step 4. hooking it with a wire, take out spool 34 together with Remove the ‘O’-rings 89 (1 off), 91 (1 off), 93 (2 off) and sleeve 33.
Page 244 Section E Hydraulics Section E 14 - 11 Hydraulic Pump/Regulator 14 - 11 Dismantling (cont’d) Using a screwdriver remove oil seal 15 from oil seal case 16 and discard the seal. 9803/6410 Issue 1...
Page 245 Section E Hydraulics Section E 14 - 12 Hydraulic Pump/Regulator 14 - 12 Inspection All parts should be checked for signs of damage or wear, paying particular attention to the parts detailed below. Renew if these conditions exist Piston assembly 6 Any sliding part is deeply scratched or has a rough surface.
Page 246 Section E Hydraulics Section E 14 - 13 Hydraulic Pump/Regulator 14 - 13 Assembly Clean each part in a suitable solvent and dry using compressed air. All tapped holes and gasket faces should be thoroughly degreased by washing, as liquid packing and adhesive is Inspect all parts and renew as required.
Page 247 Section E Hydraulics Section E 14 - 14 Hydraulic Pump/Regulator 14 - 14 Assembly (cont’d) Assemble the front piston/cylinder block assembly as Pass shaft 5 through cylinder block assembly 4 from follows: the rear, double splined end first. a Mount spring seat 20 on cylinder block assembly 4 followed by conical spring assembly 19 and retainer holder 12.
Page 248 Section E Hydraulics Section E 14 -1 5 Hydraulic Pump/Regulator 14 - 15 Assembly (cont’d) Using suitable blocks to allow the shaft to clear the a Fit the two guide assemblies 21 and slide metal 22 work surface, position the pump housing on the bench, to swash plate 7.
Page 249 Section E Hydraulics Section E 14 - 16 Hydraulic Pump/Regulator 14 - 16 Assembly (cont’d) JS00110 Using a swash plate levelling jig (see Service Tools, Install two guide rods (see Special Tools, Section 1) Section 1), adjust swash plate 7 so that it is parallel into opposite threaded holes in the pump housing with the outer face of pump housing 1, by ensuring the flange.
Page 250 Section E Hydraulics Section E 14 - 17 Hydraulic Pump/Regulator 14 - 17 Assembly (cont’d) Repeat step 8 to assemble and fit rear swash plate 8. Repeat step 11. Fit bearing 13 into swash plate 8, using a bearing Repeat steps 12 and 13 referring to rear cover 3 instead insertion tool (see Service Tools, Section 1) and fit of flange 2.
Page 251 Section E Hydraulics Section E 14 - 18 Hydraulic Pump/Regulator 14 - 18 Assembly (cont’d) Insert spring 36. Fit ‘O’-ring 84 onto plug 35 and then Fit ‘O’-ring 88 and back-up ring 98 onto sleeve 39, screw the plug into the pump housing and tighten to a taking care not to damage the wire mesh filter around torque of 157 Nm (116 lbf ft, 16 kgf m).
Page 252 Section E Hydraulics Section E 14 - 19 Hydraulic Pump/Regulator 14 - 19 Assembly (cont’d) JS01840 Fit ‘O’-ring 83 onto sleeve 37. Insert the three pistons Using a suitable tool (see Service Tools, Section 1) and 38 and piston 54 into the sleeve. a press, fit oil seal 15 squarely into oil seal case 16 with the open side of the seal facing flange 2.
Page 253 Section E Hydraulics Section E 14 - 20 Hydraulic Pump/Regulator 14 - 20 Assembly (cont’d) Assemble sub-block 50 as follows: Fit sub-block 50 assembly onto the pump housing and secure with the four socket head bolts 74, tightened to a Fit relief valve 56. a torque of 33 Nm (24 lbf ft, 3.3 kgf m).
Page 254 Section E Hydraulics Section E 18 - 1 Hydraulic Pump/Regulator JS130, JS160 18 - 1 Introduction The pump/regulator consists of two variable displacement type axial piston pumps (P1 and P2) supplying pressurised oil to operate machine functions, plus one gear type pilot pump, (Pp) to provide pilot circuit pressure for operator control of machine functions.
Page 255 Section E Hydraulics Section E 18 - 2 Hydraulic Pump/Regulator JS130, JS160 18 - 2 Pump Hydraulic Circuit Diagram (FRONT) (REAR) 417110 Delivery port Suction port Drain port Pilot port i1,2 Proportional pressure reducing valve cut port m1,2 Gauge port...
Page 256 Section E Hydraulics Section E 18 - 3 Hydraulic Pump/Regulator JS130, JS160 18- 3 Hydraulic Pump/Regulator 9803/6410 Issue 1...
Page 257 Section E Hydraulics Section E 18 - 4 Hydraulic Pump/Regulator JS130, JS160 18 - 4 Operation Main Pumps (P1 and P2) The fixed valve plate contains two crescent shaped ports. The valve plate is located so that when a piston reaches its...
Page 258 Section E Hydraulics Section E 18 - 5 Hydraulic Pump/Regulator JS130, JS160 18 - 5 Proportional Reducing Valve 9803/6410 Issue 1...
Page 259 Section E Hydraulics Section E 18 - 6 Hydraulic Pump/Regulator JS130, JS160 18 - 6 Hydraulic Pump 416150 9803/6410 Issue 1...
Page 260 Section E Hydraulics Section E 18 - 7 Hydraulic Pump/Regulator JS130, JS160 18 - 7 Hydraulic Pump Dismantling and Assembly The working environment must be clean and the workbench covered with a cloth or rubber sheet to prevent damage to the components.
Page 261 Section E Hydraulics Section E 18 - 8 Hydraulic Pump/Regulator JS130, JS160 18 - 8 Hydraulic Pump (cont’d) Dismantling and Assembly (cont’d) Dismantling (cont’d) Remove the four socket head screws 7. Place the pump on the workbench with its regulator mounting face downwards.
Page 262 Section E Hydraulics Section E 18 - 9 Hydraulic Pump/Regulator JS130, JS160 18 - 9 Hydraulic Pump (cont’d) Dismantling and Assembly (cont’d) Dismantling (cont’d) Match mark the mating flanges of swash plate support 18 and pump casing 5. Separate the swash plate...
Page 263 Section E Hydraulics Section E 18 - 10 Hydraulic Pump/Regulator JS130, JS160 18 - 10 Hydraulic Pump (cont’d) Dismantling and Assembly (cont’d) Dismantling (cont’d) 11 Remove valve plates 25 from valve block 8. 379600 12 If necessary, remove plugs 26 and 27, servo piston 28 and tilting pin 29 from pump casing 5.
Page 264 Section E Hydraulics Section E 18 - 11 Hydraulic Pump/Regulator JS130, JS160 18 - 11 Hydraulic Pump (cont’d) Assembly Before assembling: Thoroughly clean all components with clean hydraulic oil and dry with compressed air. Apply clean hydraulic oil to all sliding surfaces, bearings, etc.
Page 265 Section E Hydraulics Section E 18 - 12 Hydraulic Pump/Regulator JS130, JS160 18 - 12 Hydraulic Pump (cont’d) Assembly If bearings have ben removed, install each shaft 21 through its bearing 24 and secure with bearing spacers 23 and snap ring 22.
Page 266 Section E Hydraulics Section E 18 - 13 Hydraulic Pump/Regulator JS130, JS160 18 - 13 Hydraulic Pump (cont’d) Assembly (cont’d) Attach valve plate 25 to valve block 8, engaging the location pin in the process. Check that the suction and delivery ports of the plate are not transposed.
Page 267 Section E Hydraulics Section E 18 - 14 Hydraulic Pump/Regulator JS130, JS160 18 - 14 Regulator 9803/6410 Issue 1...
Page 268 Section E Hydraulics Section E 18 - 15 Hydraulic Pump/Regulator JS130, JS160 18 - 15 Regulator Dismantling and Assembly The working environment must be clean and the workbench covered with a cloth or rubber sheet to prevent damage to the components.
Page 269 Section E Hydraulics Section E 18 - 16 Hydraulic Pump/Regulator JS130, JS160 18 - 16 Regulator (cont’d) Dismantling and Assembly (cont’d) Dismantling (cont’d) From regulator body 1, withdraw outer spring 13, inner spring 14 and spring seat 15. Also withdraw adjusting ring 16 (see Note 1), pilot spring 17 and spring seat 18.
Page 270 Section E Hydraulics Section E 18 - 17 Hydraulic Pump/Regulator JS130, JS160 18 - 17 Regulator (cont’d) Dismantling and Assembly (cont’d) Dismantling (cont’d) Remove snap ring 28 and take out fulcrum plug 29, complete with pin 33. Remove snap ring 30 and take out adjusting plug 31.
Page 271 Section E Hydraulics Section E 18 - 18 Hydraulic Pump/Regulator JS130, JS160 18 - 18 Regulator (cont’d) Dismantling and Assembly (cont’d) Dismantling (cont’d) Withdraw feedback lever 35. 379460 10 Remove lever 36 from pin 37 (in the regulator body) leaving pin 37A in position on the lever.
Page 272 Section E Hydraulics Section E 18 - 19 Hydraulic Pump/Regulator JS130, JS160 18 - 19 Regulator (cont’d) Dismantling and Assembly (cont’d) Assembly Before assembling: Thoroughly clean all components with clean hydraulic oil and dry with compressed air. Apply clean hydraulic oil to all sliding surfaces, bearings, etc.
Page 273 Section E Hydraulics Section E 18 - 20 Hydraulic Pump/Regulator JS130, JS160 18 - 20 Regulator (cont’d) Dismantling and Assembly (cont’d) Assembly (cont’d) Locate pin 33A in lever 32 in the groove of pilot piston 38. Position lever 32 in regulator body 1.
Page 274 Section E Hydraulics Section E 18 - 21 Hydraulic Pump/Regulator JS130, JS160 18 - 21 Regulator (cont’d) Dismantling and Assembly (cont’d) Assembly (cont’d) 10 Insert set spring 22 into hole A of regulator body. Insert compensating piston 41 and piston case 40 into hole B of regulator body 1.
Page 275 Section E Hydraulics Section E 30 - 1 Control Valve 30 - 1 Introduction The control valve is located on the mainframe to the rear of the boom mounting. Its function is to direct pressurised oil by means of the operator’s controls to the rams and motors which supply power for the machine’s operation. The valve is designed to perform the following functions: Controlling oil flow direction.
Page 276: Precautions During Use
Section E Hydraulics Section E 31 - 1 Control Valve 31 - 1 Precautions During Use Installation Ensure that excessive force is not put on the valve by the piping. Tighten the installation bolts to the specified torque. Take care when welding work is done near the valve, excessive heat can damage the seals.
Page 277: Spool Location
Section E Hydraulics Section E 32 - 1 Control Valve 32 - 1 Spool Location JS01950 Left hand track motor Right hand track motor Dipper ram OPT = Auxiliary supply to attachment (if fitted) Slew motor supply BKT = Bucket ram Boom rams 9803/6410 Issue 1...
Page 278 Section E Hydraulics Section E 32 - 2 Control Valve 32 - 2 Hydraulic Circuit Diagram JS01700 9803/6410 Issue 1...
Page 279: Neutral Circuit
Section E Hydraulics Section E 33 - 1 Control Valve 33 - 1 Neutral Circuit JS01610 9803/6410 Issue 1...
Page 280 Section E Hydraulics Section E 33 - 2 Control Valve 33 - 2 Neutral Circuit (cont’d) Note: The following description is for that part of the neutral circuit supplied from pump P1. The neutral circuit supplied from pump P2 operates in a similar way. Oil from pump P1 to the inlet port PL passes through the neutral gallery A over each spool B and returns to tank via the foot release valve section C.
Page 281 Section E Hydraulics Section E 33 - 3 Control Valve 33 - 3 Auxiliary (OPT) Operation When pilot pressure is applied to port bl1 by operating the Auxiliary Pedal, the spool E moves to the right, closing off neutral gallery F. Oil from the pump is directed to outlet port BL2, by lifting check valve G.
Page 282 Section E Hydraulics Section E 33 - 4 Control Valve 33 - 4 Dipper (AM) Operation When pilot pressure is applied to port bl3, by operating the left hand joystick controller, the spool E moves to the right closing off the neutral gallery F. Oil from the pump P1 is directed to the outlet port BL3 by lifting check valve G.
Page 283 Section E Hydraulics Section E 33 - 5 Control Valve 33 - 5 Bucket (BKT) Operation When pilot pressure is applied to port br2 by operating the right hand joystick controller, the spool E moves to the left, closing off the neutral gallery F. Oil from pump P2 is directed to the outlet port BR2 by lifting the check valve G.
Page 284 Section E Hydraulics Section E 33 - 6 Control Valve 33 - 6 Boom Raise (BM) Operation 9803/6410 Issue 1...
Page 285 Section E Hydraulics Section E 33 - 7 Control Valve 33 - 7 Boom Raise (BM) Operation (cont’d) When pilot pressure is applied to port br1, by operating the right hand joystick controller, spool B moves to the left closing off the neutral gallery, allowing oil from pump P2 to enter the gallery J.
Page 286 Section E Hydraulics Section E 33 - 8 Control Valve 33 - 8 Boom Lower (BM) Operation When pilot pressure is applied by operating the right hand joystick controller, spool B moves to the right, closing off the neutral gallery and allowing oil from pump P2 to enter the cylinder port.
Page 287 Section E Hydraulics Section E 33 - 9 Control Valve 33 - 9 Slew Operation (SW) Priority Circuit JS01770 9803/6410 Issue 1...
Page 288 Section E Hydraulics Section E 33 - 10 Control Valve 33 - 10 Slew Operation (SW) Priority Circuit (cont’d) When pilot pressure is applied to port al1, by operating the left hand joystick controller, the spool C moves to allow oil from pump P1 to lift the check valve F and enter outlet port AL1.
Page 289 Section E Hydraulics Section E 33 - 11 Control Valve 33 - 11 Travel Operation (TL, TR) Priority Circuit JS01760 9803/6410 Issue 1...
Page 290 Section E Hydraulics Section E 33 - 12 Control Valve 33 - 12 Travel Operation (TL, TR) Priority Circuit (cont’d) This circuit maintains linear travel when other operations are carried out at the same time. Oil from pump P1 (X) flows to the outlet port BL4 when pilot pressure is applied at port bl4, by operating the travel lever (or pedal) control.
Page 291: Removal And Replacement
Section E Hydraulics Section E 34 - 1 Control Valve 34 - 1 Removal and Replacement Removal ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.
Page 292: Control Valve
Section E Hydraulics Section E 34 - 2 Control Valve 34 - 2 Dismantling and Assembly Sub-assembly Location Headings identified on sub-assembly location layout opposite. Item Page Valve block 34 - 5 Spool assemblies 34 - 6 Centre bypass valve (4-spool section) 34 - 8 Centre bypass valve (3-spool section) 34 - 9...
Page 293 Hydraulics Section E Section E 34 - 3 Control Valve 34 - 3 Dismantling and Assembly (cont’d) JS01820 9803/6410 Issue 1...
Page 294 Section E Hydraulics Section E 34 - 4 Control Valve 34 - 4 Dismantling and Assembly (cont’d) Note: Ensure all work surfaces are clean. Discard and renew all seals, ‘O’-rings and back-up rings. Lubricate all new seals and ‘O’-rings on assembly, using a suitable grease or clean hydraulic oil and ensure seals are firmly and correctly seated.
Page 295 Section E Hydraulics Section E Control Valve 34 - 5 34 - 5 Valve Block Dismantling Remove socket screw 1 from 4 spool section. Remove socket screws 2 and 3 from 3 spool section. Carefully separate the two halves of the valve body. Note: Ensure that ‘O’-rings and check valve assembly are retained in the 4 spool section of the body and the check valve and spring are retained in the 3 spool section.
Page 296 Section E Hydraulics Section E 34 - 6 Control Valve 34 - 6 Spool Assemblies Dismantling Remove socket screws 1 from the valve body. Remove cover 2. Remove ‘O’-ring and discard. Withdraw spool 3. Note: Identify spools during removal to ensure correct JS01000 replacement.
Page 297 Section E Hydraulics Section E 34 - 7 Control Valve 34 - 7 Spool Assemblies (cont’d) Dismantling Dipper Spool with Check Valve See Spool Assemblies, Dismantling items 1 - 7. Remove sealing plug 8. Remove ‘O’-ring and backing ring 9 and discard. Withdraw spring 10 and check valve 11.
Page 298 Section E Hydraulics Section E 34 - 8 Control Valve 34 - 8 Centre Bypass Valve (4 Spool Section) Dismantling Remove end cap 1. Remove ‘O’-ring 2 and discard. Remove piston 3. Unscrew and remove sleeve 4. Withdraw spool 5. JS01050 Encase spool in holder and clamp into a vice.
Page 299 Section E Hydraulics Section E 34 - 9 Control Valve 34 - 9 Centre Bypass Valve (3 Spool Section) Dismantling Remove end cap 1. Remove ‘O’-ring 2 and discard. Withdraw spool 3. Encase spool in holder and clamp into a vice. Note: See page 34 - 4 for details of holder.
Page 300 Section E Hydraulics Section E 34 - 10 Control Valve 34 - 10 Foot Relief Valve Dismantling Remove relief valve sub-assembly 1. Note: Pressure setting is critical - do not dismantle the valve sub-assembly. Remove ‘O’-ring 2 and discard. Remove screwed plug 3. Remove ‘O’-ring 4 and discard.
Page 301 Section E Hydraulics Section E 34 - 11 Control Valve 34 - 11 Load Holding Valve JS01170 JS01140 JS01150 JS01190 JS01160 JS01200 9803/6410 Issue 1...
Page 302 Section E Hydraulics Section E 34 - 12 Control Valve 34 - 12 Load Holding Valve Dismantling Torque Settings Remove socket screws 1. 98 Nm (72 lbf ft) Remove cover assembly 2. 30 Nm (22 lbf ft) Remove ‘O’-ring 3 and discard. 49 Nm (36 lbf ft) Remove spring 4.
Page 303 Section E Hydraulics Section E 34 - 13 Control Valve 34 - 13 Logic Check Valve Dismantling Remove screwed cap 1. Remove ‘O’-ring 2 and discard. Withdraw piston 3. Remove spring 4. Insert a small puller into the transverse hole and withdraw sleeve 5.
Page 304 Section E Hydraulics Section E 34 -14 Control Valve 34 - 14 Linear Travel Switching Valve Dismantling Unscrew and remove cover 1. Remove 'O’-ring 2 and discard. Withdraw spool 3. Encase spool in holder and clamp into a vice. Note: See page 34 - 4 for details of holders. JS01240 Slacken and remove locknuts 4, spring seating washers 5 and spring 6.
Page 305 Section E Hydraulics Section E 34 - 15 Control Valve 34 - 15 Main Relief Valve Dismantling Secure adjusting screw 1 and housing 10. Slacken locknut 2. Secure relief valve body 4. Slacken locknut 3. Slacken relief valve body 4 and remove assembly from main control valve housing.
Page 306 Section E Hydraulics Section E 34 - 16 Control Valve 34 - 16 Main Relief Valve (cont’d) Assembly Assembly is the reverse of the dismantling procedure. High Pressure Setting Insert relief valve assembly into control valve housing and tighten relief valve body 4. Tighten down adjusting screw 1 until piston 12 seats onto internal surface Z.
Page 307 Section E Hydraulics Section E 34 - 17 Control Valve 34 - 17 Overload Relief Valve Dismantling Slacken the valve housing 1 and remove complete from the control valve body. Note: Because pressure adjustment is difficult, do not dismantle the adjusting screw 2 and poppet assembly. Remove ‘O’-ring 3 and discard.
Page 308 Section E Hydraulics Section E 34 - 18 Control Valve 34 - 18 Dipper Load Diverter Valve Dismantling Remove cover plug 1. Remove ‘O’-ring 2 and discard. Remove spring seating washer 3 and spring 4. Remove housing 5. Remove ‘O’-ring 6 and discard. JS01330 Withdraw spool 7.
Page 309 Section E Hydraulics Section E 34 - 19 Control Valve 34 - 19 Boom (Lower) Stroke Limit Valve Dismantling Remove cover plug 1. Remove ‘O’-ring 2 and discard. Remove socket screws 3 and housing 4. Withdraw piston 5. Cleaning, Inspection Clean all parts in clean oil and dry with compressed air.
Page 310 Section E Hydraulics Section E 34 - 20 Control Valve 34 - 20 Load Check Valve (Boom and Slew) Dismantling Remove housing 1. Remove ‘O’-ring 2, back-up ring 3 and discard. Remove spring 4 and check valve 5. Remove nylon plug 6. Cleaning, Inspection Clean all parts in clean oil and dry with compressed air.
Page 311 Section E Hydraulics Section E 34 - 21 Control Valve 34 - 21 Load Check Valve (Dipper, Bucket, Auxiliary, Left and Right Tracks) Dismantling Remove housing 1. Remove ‘O’-ring 2 and back-up ring 3 and discard. Remove check valve 4. Remove spring 5 and check valve 6.
Page 312 Section E Hydraulics Section E 34 - 22 Control Valve 34 - 22 Pilot Valve Dismantling Remove housing 1. Remove ‘O’-ring 2 and back-up ring 3 and discard. Cleaning, Inspection Clean all parts in clean oil and dry with compressed air. Inspect all parts.
Page 313 Section E Hydraulics Section E 34 - 23 Control Valve 34 - 23 Check Valve (4 Spool Section) Dismantling Remove housing 1. Remove ‘O’-ring 2 and discard. Withdraw check valve 3 and spring 4. Cleaning, Inspection Clean all parts in clean oil and dry with compressed air. Inspect all parts.
Page 314 Section E Hydraulics Section E 34 - 24 Control Valve 34 - 24 Bucket Flow Check Valve Dismantling Remove cover plug 1. Remove ‘O’-ring 2 and discard. Withdraw spring 3 and check valve 4. Cleaning, Inspection Clean all parts in clean oil and dry with compressed air. Inspect all parts.
Page 315 Section E Hydraulics Section E 34 - 25 Control Valve 34 - 25 Diverter Valve Dismantling Remove cover plug 1. Remove ‘O’-ring 2 and discard. Using a steel rod X with one end threaded M5 x 0.8, screw into sleeve 3 and withdraw from control valve body.
Page 316 Section E Hydraulics Section E 34 - 26 Control Valve 34 - 26 Inner Parallel Check Valve Dismantling Remove cover plug 1. Remove ‘O’-ring 2 and discard. Remove spring 3 and check valve 4. Cleaning, Inspection Clean all parts with clean oil and dry with compressed air.
Page 317: Operation
Section E Hydraulics Section E 40 - 1 Remote Control Valve (Services) 40 - 1 Introduction This section deals with the Remote Control Valve which provides pilot pressure for slewing, boom/dipper and bucket operation. The remote control valve is a pressure reduction valve used to control the pilot pressure operated system. Four pressure reduction valves used to control the pilot pressure are located in the main housing.
Page 318 Section E Hydraulics Section E 40 - 2 Remote Control Valve (Services) 40 - 2 Technical Data JS03240 JS03210 Item Description Qty. Item Description Qty. Item Description Qty. Lower body Seal Gaiter Upper body Plunger Roll pin ‘O’-ring Split washer Control handle ‘O’-ring Spring seat...
Page 319 Section E Hydraulics Section E 40 - 3 Remote Control Valve (Services) 40 - 3 Operation The assembly of the pilot pressure control valve is shown on page 40 - 2. The pressure reduction unit is comprised of spools 17, pressure control springs 14, return springs 15, spring seats 13 and split washers 12.
Page 320 Section E Hydraulics Section E 41 - 1 Remote Control Valve (Services) 41 - 1 Dismantling and Assembly Notes: All parts are precision made and require the utmost care when being handled. During dismantling, do not use excessive force to separate components which could cause scratches or burrs on bearing surfaces.
Page 321 Section E Hydraulics Section E 41 - 2 Remote Control Valve (Services) 41 - 2 Dismantling and Assembly (cont’d) Dismantling (cont’d) Remove mounting screws (4 off) and lift out control valve. Clean the valve exterior using approved solvent and using soft metal pads for protection, clamp the valve body into a vice.
Page 322 Section E Hydraulics Section E 41 - 3 Remote Control Valve (Services) 41 - 3 Dismantling and Assembly (cont’d) Assembly The numerical sequence given previously is a guide to dismantling. For assembly the sequence should be reversed noting the following details: Locate retaining plate 18 onto plunger guides 8 and using the jig, screw knuckle joint into position.
Page 323 Section E Hydraulics Section E 42 - 1 Remote Control Valve (Services) 42 - 1 Fault finding Symptom Possible cause Remedy Low secondary pressure. Primary pressure is low. Apply the correct primary pressure. Spring 14 is damaged. Renew the spring. Clearance between the spool Renew the remote control valve and seating is too large.
Page 324 Section E Hydraulics Section E 43 - 1 Remote Control Valve (Services) 43 - 1 Maintenance Specification Maintenance Item Standard Note Leakage Amount Replace if the leakage exceeds 1.0 litre/min Condition: (0.22 gal/min) with the handle in the neutral Primary pressure 29 bar position or 2.0 litre/min (0.44 gal/min) (30 kgf/cm 426.5 lbf/in...
Page 325 Section E Hydraulics Section E 45 - 1 Remote Control Valve (Travel) 45 - 1 Introduction This section deals with the remote control valves which provide pilot pressure for the track drives. The valves are mounted centrally below the cab floor and are operated by either the control levers or the foot pedals. Specification Working pressure 40 kgf/cm...
Page 326 Section E Hydraulics Section E 45 - 2 Remote Control Valve (Travel) 45 - 2 Technical Data Item Part Shim (0.004 in) Shim (0.008 in) Body Spool Sleeve Cover Plunger Boot Collar Compression spring Compression spring Name plate Shim Socket head cap screw Flange screw Plain washer Plain washer...
Page 327 Section E Hydraulics Section E 46 - 1 Remote Control Valve (Travel) 46 - 1 Dismantling and Assembly Notes: All parts are precision made and require the utmost During assembly ensure all parts are clean and free care when being handled. from burrs and scratches.
Page 328: Remote Control Valve (Travel)
Section E Hydraulics Section E 46 - 2 Remote Control Valve (Travel) 46 - 2 Dismantling and Assembly (cont’d) Dismantling Using pliers, withdraw pin 8. Take off cam 14. Using soft metal pads for protection, clamp the valve Remove cover 6 and spring pins 22. Remove ‘O’-ring body into a vice.
Page 329 Section E Hydraulics Section E 46 - 3 Remote Control Valve (Travel) 46 - 3 Dismantling and Assembly (cont’d) Dismantling (cont’d) Remove plunger assembly 28 from cover 6. Remove Withdraw spool assembly from valve body 3. ‘O’-ring 25 and discard. Note: Record spool locations to ensure correct reassembly.
Page 330 Section E Hydraulics Section E 46 - 4 Remote Control Valve (Travel) 46 - 4 Dismantling and Assembly (cont’d) Assembly Install ‘O’-ring 25 and plunger assembly 28 into cover Note: If the spool assembly has been dismantled do the following: Using soft metal pads, clamp spool 4 into a vice.
Page 331 Section E Hydraulics Section E 46 - 5 Remote Control Valve (Travel) 46 - 5 Dismantling and Assembly (cont’d) Assembly (cont’d) Locate washer 20 on pin 8 and insert split pin 23 into Refit boot 9 onto body 3. the hole in pin 8. Bend open split pin ends to retain pin 9803/6410 Issue 1...
Page 332 Section E Hydraulics Section E 55 - 1 Shuttle Valve 55 - 1 Introduction The shuttle valve is incorporated into the main control circuit to act as a pilot signal diverter valve. Pressurised hydraulic oil, directed by the operator’s controls from the remote control valves to the main control valve is redirected by the shuttle valve to perform additional pilot control functions.
Page 333 Section E Hydraulics Section E 55 - 2 Shuttle Valve 55 - 2 General Information Key to illustrations: Front Right slew Left slew Boom up Boom down Bucket open Bucket close Dipper open Dipper close Right slew Left slew Boom up Boom down Bucket close Bucket open...
Page 334 Section E Hydraulics Section E 55 - 3 Shuttle Valve 55 - 3 General Information (cont’d) Y = Steel ball Z = Valve seats 9803/6410 Issue 1...
Page 335 Section E Hydraulics Section E 55 - 4 Shuttle Valve 55 - 4 Operation Note: The following description is for the slew operation. Other operations are similar. When right slew operation is selected by the control lever, pressurised oil from the remote control valve enters port A1 in the shuttle block.
Page 336 Section E Hydraulics Section E 56 - 1 Cushion Valves 56 - 1 Schematic Dipper Control Valve Boom Control Valve Hydraulic Oil Tank Line Filter Cushion Valve Cushion Valve Solenoid Valve Cushion Switch Dipper Remote Control Valve Boom Remote Control Valve Pilot Gear Pump JS02010 9803/6410...
Page 337 Section E Hydraulics Section E 56 - 2 Cushion Valves 56 - 2 Operation Whenever the machine ignition is first switched on, the dipper and boom circuits default to the cushioned mode i.e. solenoid valve 6 is de-energised. The following descriptions deal only with the ‘dipper in’ function, but the ‘dipper out’, ‘boom in’...
Page 338 Section E Hydraulics Section E 56 - 3 Cushion Valves 56 - 3 Operation (cont’d) Cushioned Mode - Remote Control Lever to ‘Dipper In’ a Pilot pressure enters port A of cushion valve 5 from dipper remote control valve 8. The left hand cushion spool Z and spool Y both move to the right.
Page 339 Section E Hydraulics Section E 56 - 4 Cushion Valves 56 - 4 Operation (cont’d) Cushioned Mode - Remote Control Lever Moved From ‘Dipper In’ to ‘Neutral’ a When dipper control lever 8 is set to neutral there is no pilot pressure from the dipper remote control valve.
Page 340 Section E Hydraulics Section E 56 - 5 Cushion Valves 56 - 5 Operation (cont’d) Non-Cushioned Mode When cushion switch 2 is switched ON, solenoid valve 6 is energised and pilot pressure 39.2 bar (40 kgf/cm is fed to port S of cushion valve 5. The two cushion spools Z are forced into the centre by pilot pressure so that the unrestricted oilways of the cushion valve spools are open to the pilot outputs from...
Page 341 The valve is used to control the application and release of the slew brake at either 50% or 100% pressure. The valve is operated by pilot pressure selected by the operator’s control lever. Specification JS130 Working pressure 40 kgf//cm (569 lbf/in Rated flow 16 l/min (3.52 gal/min)
Page 342: Technical Data Js130
Section E Hydraulics Section E 60 - 2 Slew Brake Valve 60 - 2 Technical Data (JS130) Solenoid control valve (slew lock) Solenoid control valve (slew brake) Pressure reducing valve Waterproof, 2-pin electrical contact housing Power source (pink) Ground (grey) Low voltage cable 0.85 mm (.00132 in...
Page 343: Technical Data Js160
Section E Hydraulics Section E 60 - 3 Slew Brake Valve 60 - 3 Technical Data (JS160) Solenoid control valve (slew lock) Solenoid control valve (slew brake) Pressure reducing valve Waterproof, 2 pin electrical contact housing Power source Ground Protective tube (yellow) Protective tube (black) JS02090 9803/6410...
Page 344 Section E Hydraulics Section E 60 - 4 Slew Brake Valve 60 - 4 Operation (JS130) Slew Brake Release Pilot pressure at 40 kgf/cm (569 lbf/in ), selected by the operator’s control lever, enters port P, passes over the outer surface of solenoid spool 1 and enters passageway a.
Page 345 Section E 60 - 5 Slew Brake Valve 60 - 5 Operation (JS130) (cont’d) Slew Brake (50% Application) Five seconds after the control lever has been returned to neutral, an electric signal from the controller operates solenoid valve 7 and spool 1 moves down.
Page 346 Section E 60 - 6 Slew Brake Valve 60 - 6 Operation (JS130) (cont’d) Slew Brake (100% Application) When the solenoid valve 6 for slew lock is energised, the spool 1 moves down, stopping oil from passageway C. Return oil from the slew motor enters port B and flows through spool passage 2 to tank port T.
Page 347 Section E Hydraulics Section E 70 - 1 Hydraulic Rams 70 - 1 Specifications JS130 JS160 Boom Ram Cylinder Inside Diameter: 100 mm (3.94 in) Cylinder Inside Diameter: 115 mm (4.53 in) Left & Right Rod Diameter: 75 mm (2.95 in)
Page 348 If leaving for more than one week, apply anti-rust oil to the rod surface. Use genuine JCB parts when replacing parts. If parts other than genuine JCB parts are used, the desired results may not be obtained. Use only genuine JCB parts. Caution during dismantling and reassembly.
Page 349 Section E Hydraulics Section E 72 - 1 Hydraulic Rams 72 - 1 Bucket Ram - Removal ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses.
Page 350 Section E Hydraulics Section E 72 - 2 Hydraulic Rams 72 - 2 Bucket Ram - Removal (cont’d) Remove the nuts and bolts from the rod end of the ram. Push the pin out using a bar and hammer. ! WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out.
Page 351 Section E Hydraulics Section E 72 - 3 Hydraulic Rams 72 - 3 Bucket Ram - Removal (cont’d) Attach a sling to support the ram. Remove the nuts and bolts from the cylinder end of the ram. Push out the pin using a bar and hammer. Lift the ram clear.
Page 352 Section E Hydraulics Section E 72 - 4 Hydraulic Rams 72 - 4 Bucket Ram - Replacement (cont’d) Connect the hoses. Hoist the ram to align with the link. Install the pin, bolt and nuts. Note: Stroke the ram to release entrapped air. After releasing the air, check for oil leakage.
Page 353 Section E Hydraulics Section E 73 - 1 Hydraulic Rams 73 - 1 Dipper Ram - Removal ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses.
Page 354 Section E Hydraulics Section E 73 - 2 Hydraulic Rams 73 - 2 Dipper Ram - Removal (cont’d) Remove the nuts and bolts from the rod end of the ram. Push out the pin, using a bar and hammer. ! WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out.
Page 355 Section E Hydraulics Section E 73 - 3 Hydraulic Rams 73 - 3 Dipper Ram - Removal (cont’d) Remove the grease tube. Attach a sling to support the ram. Remove the nuts and bolts from the cylinder end of the ram, push out the pin using a bar and hammer.
Page 356 Section E Hydraulics Section E 73 - 4 Hydraulic Rams 73 - 4 Dipper Ram - Replacement (cont’d) Install the pin, bolts and nuts. ! 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.
Page 357 Section E Hydraulics Section E 73 - 5 Hydraulic Rams 73 - 5 Dipper Ram - Replacement (cont’d) Install the pin, bolt and nuts. Note: Stroke the ram to release entrapped air. After releasing the air, check for oil leakage. ! WARNING Metal Splinters You can be injured by flying metal splinters when driving...
Page 358 Section E Hydraulics Section E 74 - 1 Hydraulic Rams 74 - 1 Boom Ram - Removal ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses.
Page 359 Section E Hydraulics Section E 74 - 2 Hydraulic Rams 74 - 2 Boom Ram - Removal (cont’d) a Remove the nuts, bolt and collar. b Push out the pin, using a bar and hammer. ! WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out.
Page 360 Section E Hydraulics Section E 74 - 3 Hydraulic Rams 74 - 3 Boom Ram - Removal (cont’d) Remove the hoses, and install plugs or caps to prevent contamination. Remove the nut and bolt and push out the pin with a hammer and bar.
Page 361 Section E Hydraulics Section E 74 - 4 Hydraulic Rams 74 - 4 Boom Ram - Replacement (cont’d) Install the pin and then the bolt and nuts. ! WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out.
Page 362 Section E Hydraulics Section E 74 - 5 Hydraulic Rams 74 - 5 Boom Ram - Replacement (cont’d) Install the collar and then the bolt and nuts. Connect the grease tube. Note: Stroke the ram and release entrapped air. After releasing the air, check for oil leakage.
Page 363 Section E Hydraulics Section E 75 - 1 Hydraulic Rams 75 - 1 Dismantling Details of Service Tools used in the dismantling and Assembly procedures are given in Service Tools, Section 1 . Before starting work, clean all surfaces with a suitable solvent and dry with compressed air.
Page 364 Section E Hydraulics Section E 75 - 2 Hydraulic Rams 75 - 2 Dismantling (cont’d) Remove the piston rod. Make sure that the piping ports are opened. Catch the oil coming out from the rod side (cylinder head side) port. With the piston rod extended fully, remove the cylinder head carefully.
Page 365 Section E Hydraulics Section E 75 - 3 Hydraulic Rams 75 - 3 Dismantling (cont’d) Remove the piston, cushion bearing, cushion seal, cylinder head in that order. (There is no cushion seal for the bucket ram). Remove the piston seal. The piston rings can be easily removed by hand.
Page 366 Section E Hydraulics Section E 75 - 4 Hydraulic Rams 75 - 4 Dismantling (cont’d) Dismantling the retraction side cushion (dipper ram). When there is a cushion bearing installed on the piston rod, after removing the nut A, dismantle as indicated below.
Page 367 Section E Hydraulics Section E 75 - 5 Hydraulic Rams 75 - 5 Assembly Note: See Torque Setting Figures. Clean each part in a suitable solvent and dry using compressed air. Inspect all parts and renew as required. Care must be taken not to let dust or dirt adhere to parts after cleaning and that parts do not become dented, scratched or damaged.
Page 368 Section E Hydraulics Section E 75 - 6 Hydraulic Rams 75 - 6 Assembly (cont’d) Piston Assembly. a Place the piston N on the press and using the jig P as shown, install the seal ring Q (pre-assemble the 'O'-ring R and one back up ring S beforehand). b After attaching the seal ring Q and one more back- up ring T, ensure the seal ring Q is fully seated by using jig U.
Page 369 Section E Hydraulics Section E 75 - 7 Hydraulic Rams 75 - 7 Assembly (cont’d) Retraction side cushion assembly (dipper ram) Where there is a cushion at the retraction side (end of piston rod JJ) assemble the cushion bearing as follows: a Expand the slit of the cushion seal HH and place seal on the end of the piston rod JJ.
Page 370 Section E Hydraulics Section E 75 - 8 Hydraulic Rams 75 - 8 Assembly (cont’d) Assemble the piston rod into the cylinder. a Secure the cylinder vertically or horizontally, insert the piston into the cylinder. Note: When inserting the piston into the cylinder take care prevent the piston rings from falling off.
Page 371 Section E Hydraulics Section E 75 - 9 Hydraulic Rams 75 - 9 Assembly (cont’d) Inspection after Assembly No-load Operation Operations are smooth and there are no abnormalities with each part after full stroking more Inspection than five times with no load. Measurement Confirm the maximum extension and stroke.
Page 372 Section E Hydraulics Section E 75 - 10 Hydraulic Rams 75 - 10 Ram Piston Head Nut - Removal and Fitting JS00980 9803/6410 Issue 1...
Page 373 ) or from rig with the piston rod supported by block J. the auxiliary circuit of a JCB machine equipped with quick- release couplings. In either case, small bore hoses E (Part Secure the eye end of the piston rod to the rig at No.
Page 374 F in the rig circuit (with the spanner at 90° to the rig ram) and converting it according to the table above. Note: The pressures in the above table assume that the rig is used with spanners having 500 mm centres. Table 2 JS130 Ram Location Dimensions Piston Nut Piston Nut Torque...
Page 375 Section E Hydraulics Section E 76 - 1 Hydraulic Rams 76 - 1 Reconditioning Note: Jig details are in accordance with ram sizes. See Service Tools, Section 1. Procedures for inserting and bedding the seal ring. Stretch the 'O'-ring by hand and fit it into the piston O-ring installation groove.
Page 376 Section E Hydraulics Section E 76 - 2 Hydraulic Rams 76 - 2 Reconditioning (cont’d) Mount the outer guide jig over the inner guide jig and Outer guide jig fitting using the plate, continue pressing the plate by hand until the outer guide jig touches the seal ring.
Page 377 Section E Hydraulics Section E 76 - 3 Hydraulic Rams 76 - 3 Reconditioning (cont’d) Set the bedding jig underneath the press. Bedding jig preparation Apply a thin coat of lubricant to the tapered section of the bedding jig and place the jig with the tapered section facing up.
Page 378 Section E Hydraulics Section E 76 - 4 Hydraulic Rams 76 - 4 Reconditioning (cont’d) After completion of the bedding of the seal ring, remove Removal of bedding jig the jig in the following order. Retract the press rod. Remove the bedding jig. This completes the fitting and bedding of the seal ring.
Page 379 Section E Hydraulics Section E 77 - 1 Hydraulic Rams 77 - 1 Reconditioning (cont’d) Bushing Removal Note: Jig details are in accordance with ram sizes. See Service Tools, Section 1. Place the cylinder head on the work bench with the Cylinder head setting cylinder tube connecting surface facing up.
Page 380 Section E Hydraulics Section E 77 - 2 Hydraulic Rams 77 - 2 Reconditioning (cont’d) Bushing Removal (cont’d) Gradually insert the chuck assembly into the cylinder Setting the chuck assembly head until its blade end reaches the bushing end. Insert the chuck assembly into the cylinder head, taking care that parts of the blade do not damage the inner circumferential surface.
Page 381 Section E Hydraulics Section E 77 - 3 Hydraulic Rams 77 - 3 Reconditioning (cont’d) Bushing Removal (cont’d) Gently place the retainer on the stepped portion of the Attaching the retainer wedge inside the chuck assembly. Place so that the collar is uppermost as shown. Keep the press bench clean to prevent dust, chipped metal and other foreign material causing damage to the bottom of the chuck assembly.
Page 382 Section E Hydraulics Section E 77 - 4 Hydraulic Rams 77 - 4 Reconditioning (cont’d) Bushing Removal (cont’d) Choose a block suitable in shape and size from the table Block preparation below. Position the cylinder head centrally on the block as shown.
Page 383 Section E Hydraulics Section E 77 - 5 Hydraulic Rams 77 - 5 Reconditioning (cont’d) Bushing Removal (cont’d) After removing the cylinder head assembly from Removing chuck assembly with bushing under the press, remove the retainer from the attached cylinder head and, grasping both sides of the cylinder head, set aside.
Page 384 Section E Hydraulics Section E 77 - 6 Hydraulic Rams 77 - 6 Reconditioning (cont’d) Bushing Removal (cont’d) With the chuck assembly and bushing removed, turn the Retightening the adjuster adjuster with your fingers until there is no gap between the adjuster and the wedge upper surface.
Page 385 Section E Hydraulics Section E 77 - 7 Hydraulic Rams 77 - 7 Reconditioning (cont’d) Bushing Assembly Note: Jig details are in accordance with ram sizes. See Service Tools, Section 1. Set the cylinder head on the press bench with the tube Cylinder head setting connecting surface facing up.
Page 386 Section E Hydraulics Section E 77 - 8 Hydraulic Rams 77 - 8 Reconditioning (cont’d) Bushing Assembly (cont’d) Gently place the retainer so that its end is aligned with Attaching the retainer the wedge stepped section of the chuck assembly. Place the retainer so that the larger diameter part is facing up as shown.
Page 387 Section E Hydraulics Section E 77 - 9 Hydraulic Rams 77 - 9 Reconditioning (cont’d) Bushing Assembly (cont’d) At the press, push on the bolt head of the adjuster and Press-fitting the bushing gradually press-fit the bushing into the specified position in the cylinder head.
Page 388 Section E Hydraulics Section E 77 - 10 Hydraulic Rams 77 - 10 Reconditioning (cont’d) Wiper Ring Assembly Note: Keep the work bench clean so that no dust or other Setting the cylinder head foreign matter can damage the bottom surface of the cylinder head.
Page 389 Section E Hydraulics Section E 77 - 11 Hydraulic Rams 77 - 11 Reconditioning (cont’d) Wiper Ring Assembly (cont’d) Position the cylinder head and retainer underneath the Preparation for press-fitting press. Adjust so that the shaft centre of the press and retainer are in line as shown.
Page 390 Section E Hydraulics Section E 77 - 12 Hydraulic Rams 77 - 12 Reconditioning (cont’d) Cylinder Head Assembly Handle the piston rod with care to prevent damage to its Fixing the piston rod outer surface. Position the piston rod so that the threaded part is facing you.
Page 391 Section E Hydraulics Section E 77 - 13 Hydraulic Rams 77 - 13 Reconditioning (cont’d) Cylinder Head Assembly (cont’d) Insert the cylinder head onto the piston rod, wiper ring Inserting the cylinder head side first, to the specified position, sliding on the peripheral surface of the guide.
Page 392: Fault Finding
Section E Hydraulics Section E 78 - 1 Hydraulic Rams 78 - 1 Fault Finding The chart below lists some possible problems and suggested remedies. The types of problems fall into four main categories as follows: Item Symptoms Oil leakage from piston rod sliding part. Oil leakage from cylinder head joint.
Page 393 Section E Hydraulics Section E 78 - 2 Hydraulic Rams 78 - 2 Fault Finding (cont’d) Item Symptoms Related Parts Trouble Treatment Packing rubber is perished. The packing life or hydraulic oil deterioration and high temperature are possible reasons. 1 Renew hydraulic oil. Rod packing 2.
Page 394 Section E Hydraulics Section E 78 - 3 Hydraulic Rams 78 - 3 Fault Finding (cont’d) Item Symptoms Related Parts Trouble Treatment Foreign matter on inner • Remove foreign matter. and outer diameters. • Renew 'O'-ring if damaged. • Inspect inside tube: if any scratches or O-ring damaged.
Page 395 Section E Hydraulics Section E 78 - 4 Hydraulic Rams 78 - 4 Fault Finding (cont’d) Item Symptoms Related Parts Trouble Treatment Poor Bending to more than the • Replace with new part. operation Piston rod specified limit. The seal and sliding part material may cylinder tube (Bending distortion: damaged too, so inspect.
Page 396: Operation
Section E Hydraulics Section E 78 - 5 Hydraulic Rams 78 - 5 Fault Finding (cont’d) Item Symptoms Related Parts Trouble Treatment Air remaining inside ram. • Bleed the air. Operation is unsteady For rams that do not have an air bleeder, operate back and forth several times at low pressure and low speed to bleed the air.
Page 397 Section E Hydraulics Section E 80 - 1 Rotary Coupling 80 - 1 Technical Data Item Part Name Axle V-ring Rotor ‘O’-ring Packing ring Thrust plate Hexagonal socket head screw ‘O’-ring Cover Hexagonal socket head screw Plug Plug JS01810 9803/6410 Issue 1...
Page 398 Section E Hydraulics Section E 80 - 2 Rotary Coupling 80 - 2 Technical Data (cont’d) Item Part Name High strength bolt High strength washer Loctite 262 Lock bar Seal washer Seal cap Rubber packing Seal ring Rotary coupling The unit weighs 35 kg. 9803/6410 Issue 1...
Page 399 Section E Hydraulics Section E 81 - 1 Rotary Coupling 81 - 1 Operation The coupling is located in the centre of the machine between the lower and upper sections and rotates around the slew centreline. The supply and return oil flow to the coupling, piped from the upper to the lower section, is not affected by the rotational movement and allows the machine to slew 360°...
Page 400 Section E Hydraulics Section E 82 - 1 Rotary Coupling 82 - 1 Removal Details of the service tools used in the dismantling and assembly procedures are given in Service Tools, Section 1. Prepare the machine a Stop the machine and release the hydraulic pressure (see Releasing Tank Pressure).
Page 401 Section E Hydraulics Section E 82 - 2 Rotary Coupling 82 - 2 Removal (cont’d) Remove lock bar mounting screws X, washer Y and lock bar Z. Remove rotary coupling installation bolts 1 and washers 2. JS00180 Replacement Align the assembly 9 to the lower frame and tighten rotating joint installation bolts 1 and washers 2.
Page 402 Section E Hydraulics Section E 82 - 3 Rotary Coupling 82 - 3 Dismantling Remove screws 20 and cover 19. JS00140 Remove and discard 'O'-ring 18. JS00150 Remove screws 17 and thrust plate 16. JS00160 Using a jig (see Special Tools, Section 1), push off axle 11 from the rotor 13.
Page 403 Section E Hydraulics Section E 82 - 4 Rotary Coupling 82 - 4 Dismantling (cont’d) Remove and discard V-ring 12 from axle 11. Remove and discard 'O'-ring 14 and packing rings 15 from rotor 13. JS00190 9803/6410 Issue 1...
Page 404 Section E Hydraulics Section E 82 - 5 Rotary Coupling 82 - 5 Assembly Inspect the parts for signs of wear, pitting, scratching, discolouration etc. Polish out scratches using a fine grade oil stone. Before assembly, thoroughly clean all parts using a suitable solvent: Do NOT use solvents on 'O'-rings, back-up rings and seals.
Page 405 Section E Hydraulics Section E 82 - 6 Rotary Coupling 82 - 6 Assembly (cont’d) After installing the 'O'-ring and packing rings, check with a mirror to see if they are installed correctly. After checking, coat with grease then check once more for any protrusion, twisting, etc.
Page 406 Section E Hydraulics Section E 82 - 7 Rotary Coupling 82 - 7 Assembly (cont’d) Install 'O'-ring 18 into the rotor 13. Install cover 19 onto the rotor 13 using cap screws 20. Torque Settings 31.46 - 37.29 Nm (23.2 - 27.5 lbf ft) JS00200 9803/6410 Issue 1...
Page 407 Section E Hydraulics Section E 83 - 1 Slew Motor 83 - 1 Hydraulic Motor Components Drain port Pilot port Pilot hole Flow paths Piston bore Flow paths By pass valve Inlet port Outlet port Anti-cavitation check valve Mechanical brake Cross-line relief valve A side cavity B side cavity...
Page 408 Section E Hydraulics Section E 83 - 2 Slew Motor 83 - 2 Reduction Gear Components JS00970 A chamber B chamber Torque path Note: Item numbers are referred to on the following pages. 9803/6410 Issue 2*...
Page 409 Section E Hydraulics Section E 83 - 3 Slew Motor 83 - 3 Hydraulic Circuit Hydraulic motor (151 cm /rev) Bypass/Anti-pendulum valve Anti-cavitation check valve Relief valve (285 kgf/cm @ 155 l/min) Mechanical brake Tank line Drain line JS02680 9803/6410 Issue 1...
Page 410 Section E Hydraulics Section E 90 - 1 Slew Motor 90 - 1 Operation Slew Motor Configuration Slew Unit Planetary 2-stage Reduction Gear Swash Plate Type Axial Piston Hydraulic Motor Mechanical Brake Relief Valve By-pass Valve Make-up Valve The above diagram indicates the relationships between the main components of the slew motor, whose working principles are described on the following pages.
Page 411 Section E Hydraulics Section E 90 - 2 Slew Motor 90 - 2 Operation (cont’d) Hydraulic Motor Working Principles Make-Up Valve Working Principles (illustration reference page 83 - 1) Under partial hydraulic cross-line relief braking Oil supplied from the pump via the control valves enters port (relief valve not functioning).
Page 412 Section E Hydraulics Section E 90 - 3 Slew Motor 90 - 3 Operation (cont’d) Relief Valve Working Principles Reduction Gear Structure and Working On starting Principles (illustration reference page 83 - 2) Due to the superstructure’s inertia there is a build-up of Power transmitted by the hydraulic motor output shaft is pressure in the motor when it begins to slew.
Page 413 Hydraulics Section E 91 - 1 Slew Motor 91 - 1 Specifications JS130 Motor type Fixed displacement piston motor Reduction gear type Planetary gear with 2 gear reduction Slew parking brake type Mechanical lock (slew lever and slew lock switch interlocked...
Page 414: Maintenance Specifications
Section E Hydraulics Section E 91 - 2 Slew Motor 91 - 2 Maintenance Specifications Item Inspection and Maintenance Standards The crescent-shaped ports in the balance plate, which are in sliding contact with the end face of the cylinder assembly shaft, act to switch between high and low oil pressure.
Page 415 Section E Hydraulics Section E 92 - 1 Slew Motor 92 - 1 Motor Assembly/Cylinder Assembly Dismantling Refer to the sectional drawing on page E/83-1 as a guide to Remove the level gauge with a pipe wrench. dismantling and assembling. Before attempting to dismantle the slew motor assembly, the inlet and outlet ports should be blanked and the outer surfaces washed down with a suitable solvent to remove all...
Page 416 Section E Hydraulics Section E 92 - 2 Slew Motor 92 - 2 Motor Assembly/Cylinder Assembly Dismantling (cont’d) Remove the caps 37 with 14 mm A/F hexagonal Remove the caps 30 with a 14 mm A/F hexagonal key sockets and remove relief valves 34 from the motor. and take out the springs 31 and check valves 29.
Page 417 Section E Hydraulics Section E 92 - 3 Slew Motor 92 - 3 Motor Assembly/Cylinder Assembly Dismantling (cont’d) Place the motor with the main shaft downwards and lift Remove snap ring 23 and remove the inner ring of off cover 17. needle bearing 22.
Page 418 Section E Hydraulics Section E 92 - 4 Slew Motor 92 - 4 Motor Assembly/Cylinder Assembly Dismantling (cont’d) Remove the bushings 20 with Teflon rings 19 and the Remove the springs 14 from brake piston 12. plate springs 18. Note: Keep the springs in the order in which they are to be reinserted.
Page 419 Section E Hydraulics Section E 92 - 5 Slew Motor 92 - 5 Motor Assembly/Cylinder Assembly Dismantling (cont’d) Attach a puller to the inner ring of taper roller bearing 3 Remove swash plate 6, piston assemblies 8 and at two places and on the end of cylinder 24 spline, then retainer plate 7 together from cylinder 24.
Page 420 Section E Hydraulics Section E 92 - 6 Slew Motor 92 - 6 Motor Assembly/Cylinder Assembly Dismantling (cont’d) Hold the end of cylinder 24 by hand and pull out the Remove the outer ring of taper roller bearing 3 from the cylinder assembly from housing 25.
Page 421 Section E Hydraulics Section E 92 - 7 Slew Motor 92 - 7 ! CAUTION Motor Assembly/Cylinder Assembly Assembly Cleaning Cleaning metal parts with incorrect solvents can cause Refer to the sectional drawing on page 83 - 1 as a guide to corrosion.
Page 422 Section E Hydraulics Section E 92 - 8 Slew Motor 92 - 8 Motor Assembly/Cylinder Assembly Assembly (cont’d) Apply grease to the curved part of cylinder 24 (contact Position the piston assemblies 8 into the holes of face with spring 5) and mount spring 5. retainer plate 7.
Page 423 Motor Assembly/Cylinder Assembly Assembly (cont’d) Mount collar 53 and inner ring of taper roller bearing 1 Apply a thin coat of JCB Retainer where the inner ring on motor output shaft 24. is mounted on motor output shaft 24. Using a jig, (see Special Tools, Section 1) mount inner Apply grease to the lip of seal 2 and use a press and jig ring 1 on output shaft 24.
Page 424 Section E Hydraulics Section E 92 - 10 Slew Motor 92 - 10 Motor Assembly/Cylinder Assembly Assembly (cont’d) Mount the outer ring of the taper roller bearing into 11 Hold the end of cylinder 24 by hand and carefully insert housing 25.
Page 425 Section E Hydraulics Section E 92 - 11 Slew Motor 92 - 11 Motor Assembly/Cylinder Assembly Assembly (cont’d) Apply hydraulic oil to the sliding surface around piston Insert the brake unit springs 14 back into brake piston 12 and slide it into housing 25. Note: It is difficult to insert piston 12 into the housing due to Note: Insert the springs 14 the same order as they were O'-rings 11 and 13.
Page 426 Press needle bearing 22 inner ring into cover 17 and attach snap ring 23. Apply grease to the 'O'-ring and install 'O'-ring 13 to To prevent oil leakage from the cover bolt holes apply cover 17. JCB Multi-gasket to the surface. 9803/6410 Issue 1...
Page 427 Section E Hydraulics Section E 92 - 13 Slew Motor 92 - 13 Motor Assembly/Cylinder Assembly Assembly (cont’d) Lift cover 17 and balance plate 21 by hand and mount Tighten the cap screws 27 (with a 12 mm A/F them carefully on housing 25. hexagonal socket) which attach cover 17 to housing 25 to a torque of 157 Nm (116 lbf ft).
Page 428 Section E Hydraulics Section E 92 - 14 Slew Motor 92 - 14 Motor Assembly/Cylinder Assembly Assembly (cont’d) Final checks after assembling. Degrease the mating faces of the gear unit ring gear 64 and motor housing 25 and apply Multi-gasket to the ring gear.
Page 429 Section E Hydraulics Section E 92 - 15 Slew Motor 92 - 15 Motor Assembly/Cylinder Assembly Assembly (cont’d) Insert plug 26 with an 8 mm Allen key and tighten to Apply grease (type and capacity is given in Fluids and torque of 39.32 Nm (29 lbf ft).
Page 430 Section E Hydraulics Section E 93 - 1 Slew Motor 93 - 1 Relief Valves Dismantling Refer to the sectional drawing on page E/83-1 as a guide to dismantling and assembling. Take steps during dismantling to ensure that all the parts are returned to their original positions.
Page 431 Section E Hydraulics Section E 93 - 2 Slew Motor 93 - 2 Relief Valves Assembly Press fit seat 44 into sleeve 39 which has an 'O'-ring Mount poppet 43, spring 42, shim 40, piston 38, liner 51 onto sleeve 39. Screw cap 37 (with a 14 mm A/F hexagonal socket) with 'O'-ring 36 and back-up 35 mounted, on to sleeve 39 and tighten to a torque of 157 Nm (116 lbf ft).
Page 432 Section E Hydraulics Section E 94 - 1 Slew Motor 94 - 1 Reduction Gear Dismantling Refer to the sectional drawing on page E/83-2 as a guide to dismantling and assembling. Removal of the sun gear, 1st stage holder assembly. Remove the spur gear and 2nd stage holder assembly Remove sun gear 66 and 1st stage holder assembly 65.
Page 433 INT-3-1-3 Ring gear removal Removal of pinion gear assembly. Remove ring gear 64 from gear case 58. JCB High Remove snap ring 55 with a screwdriver using the Strength Gasketing is applied on the assembly to notch in the case for leverage.
Page 434 Section E Hydraulics Section E 94 - 3 Slew Motor 94 - 3 Reduction Gear Dismantling (cont’d) Support the flange part of gear case 58 on 300 mm Remove the roller bearing 62 from gear case 58. (11.8 in) blocks and press shaft end with a hydraulic press to push out shaft 53, collar 54, plate 56, self- aligning roller bearing 57, snap ring 60 and collar 59 from the assembly.
Page 435 Section E Hydraulics Section E 94 - 4 Slew Motor 94 - 4 Reduction Gear Dismantling (cont’d) Carry out the following procedure only when bearing 57 is damaged or badly wor n, and dismantling is necessary. Support the self aligning roller bearing 57, then press the motor end of shaft 53 to remove bearing 57, plate 56 and collar 54 from the shaft 53.
Page 436 Section E Hydraulics Section E 94 - 5 Slew Motor 94 - 5 Reduction Gear Assembly Refer to the sectional drawing on page E/83-2 as a guide to dismantling and assembling. Apply clean hydraulic fluid to all sliding contact faces during assembly.
Page 437 Degrease the periphery of oil seal 61 and its mounting Use the seal protector to prevent the splines of pinion face in gear case 58 and apply JCB High Strength shaft 53 from scratching the lip of the oil seal.
Page 438 Degrease the contact surfaces of gear case 58 and ring gear 64. Mount the collars 63 on the gear case and apply JCB Multi-gasket. Also apply a thin coat on the gear case. Holder assembly mounting b Drive in spring pins 75.
Page 439 Section E Hydraulics Section E 94 - 8 Slew Motor 94 - 8 Reduction Gear Assembly (cont’d) Holder assembly 65 mounting b Drive in the spring pin. a Insert planetary gear 69 and the thrust plate into Note: Drive in the pins with the splits facing towards holder 65 and insert shaft assembly 67.
Page 440 Section E Hydraulics Section E 94 - 9 Slew Motor 94 - 9 Reduction Gear Assembly (cont’d) Sun gear 1st stage holder assembly mounting b Carefully insert sun gear 66 and mesh the teeth of planetary gear 69. a Carefully lower the holder assembly so that it meshes correctly with the internal teeth of ring gear 64.
Page 441 Section E Hydraulics Section E 95 - 1 Slew Motor 95 - 1 Fault Finding Table 1. Symptom Cause External Inspection Countermeasure Repair Internal damage to the Measure the oil drain High possibility of Refer to Table 2. motor. volume. damage to the sliding surfaces if the supply volume is approximately...
Page 442 Section E Hydraulics Section E 95 - 2 Slew Motor 95 - 2 Fault Finding (cont’d) Symptom Cause External Inspection Countermeasure Repair Wear or seizure of the Open motor inlet and High possibility of Inspect the parts and motor sliding surfaces. outlet ports and apply 20 internal damage to the bearing according to...
Page 443: Section F - Transmission
Motor Bleeding 6 - 5 Testing 6 - 6 Cross-Sectional View - JS130 7 - 1 Exploded View (Motor) - JS130 7 - 2 Exploded View (Gearbox) - JS130 7 - 3 Component List - JS130 7 - 4 Cross-Sectional View - JS160...
Page 444: Traction Motor/Reduction Gear
Section F Transmission Section F 2 - 1 Traction Motor/Reduction Gear 2 - 1 Specification JS130 JS160 Reduction gear ratio 39 : 1 48 : 1 Hydraulic motor Maximum stroke volume/rev 86.3 cc (5.27 in 104. 8 cc (6.39 in...
Page 445: Operation
Section F Transmission Section F 3 - 1 Operation 3 - 1 Traction Motor The motor is of the variable swash plate, axial piston type. Pressurised oil is routed via rear flange 101 and timing plate 109 into cylinder block 104. The fixed timing plate directs oil to force piston 105 against swash plate 103, until it reaches the end of its power stroke, causing the cylinder block to rotate 180°.
Page 446 Section F Transmission Section F 3 - 2 Operation 3 - 2 Brake Valve During Travel - Brake Released During travel, pressurised oil is fed into port A to open valve 127 and supply oil via port C to traction motor M. The pressurised oil also enters chamber b through drilling a of spool 123.
Page 447 Section F Transmission Section F 3 - 3 Operation 3 - 3 Parking Brake During Travel During travel, pressurised oil is fed to chamber a of the parking brake from the brake valve (see Brake Valve, During Travel - Brake Released). When the oil pressure exceeds the force of spring 113, piston 112 moves to the left causing plate 116 and friction plate 115 to separate.
Page 448 Section F Transmission Section F 3 - 4 Operation 3 - 4 Automatic 2-Speed Switching Speed range changing is achieved by altering the angle of the traction motor swash plate. A solenoid operated valve routes pilot oil to the swash plate adjusting mechanism, as appropriate, in response to range selection commands.
Page 449 Section F Transmission Section F 3 - 5 Operation 3 - 5 Automatic 2-Speed Switching (cont’d) Automatic Switching - High Speed/Low Speed During normal ‘high speed’ operation the pressure at port A or B is less than 98 bar (1422 lbf/in , 100 kgf/cm ).
Page 450: Operation
Section F Transmission Section F 4 - 1 Traction Motor/Reduction Gearbox 4 - 1 Preparation for Use Before installing the motor unit, ensure there are no loose parts and that nuts, screws etc. have been tightened to the correct torque values. All ports should be plugged and sealed to prevent the ingress of dirt.
Page 451: Fault Finding
Section F Transmission Section F 5 - 1 Traction Motor/Reduction Gear 5 - 1 Fault finding Symptom Possible cause Remedy Motor does not start - no oil Low relief valve set pressure. Set correct pressure. pressure present. Pump failure. Check operation of services other than travel.
Page 452 Section F Transmission Section F 5 - 2 Traction Motor/Reduction Gear 5 - 2 Fault finding (cont’d) Symptom Possible cause Remedy High temperature of reduction Insufficient gear oil. Top up oil gear case surface. Pitching is generated in bearing. Dismantle and renew damaged parts. Entry of hydraulic oil into gear Renew oil seal.
Page 453 Section F Transmission Section F 5 - 3 Traction Motor/Reduction Gear 5 - 3 Fault finding (cont’d) Symptom Possible cause Remedy Does not change from high Faulty operation of switching Check for spool damage. Repair or speed to low speed. valve.
Page 454: Removal And Replacement
Section F Transmission Section F 6 - 1 Traction Motor/Reduction Gear 6 - 1 Removal and Replacement Removal Move the track link until the master pin is over the take-up roller in the position shown, place a wooden block under the track shoe as shown. JS02770 Slacken the check valve to bleed out the grease.
Page 455 Section F Transmission Section F 6 - 2 Traction Motor/Reduction Gear 6 - 2 Removal and Replacement (cont’d) Removal (cont’d) Operate the traction motor to remove the track. Lift the side of the undercarriage high enough to permit drive sprocket removal. Support with wooden blocks.
Page 456 Section F Transmission Section F 6 - 3 Traction Motor/Reduction Gear 6 - 3 Removal and Replacement (cont’d) Removal (cont’d) Support the motor so that the cables are in tension, then remove the motor installation bolts. Replacement Before fitting, clean the assembly and bleed air out as follows: Turn the assembly so that the hydraulic oil ports are facing upwards.
Page 457 Section F Transmission Section F 6 - 4 Traction Motor/Reduction Gear 6 - 4 Removal and Replacement (cont’d) Replacement (cont’d) a Install the covers over the motor. b Check the amount of oil in the gearbox. c Bleed air from the motor (see Motor Bleeding). d If the traction motor has been dismantled and serviced, carry out the functional tests detailed under Testing later in this section.
Page 458: Motor Bleeding
Section F Transmission Section F 6 - 5 Traction Motor/Reduction Gear 6 - 5 Removal and Replacement (cont’d) Replacement (cont’d) Apply grease through the check valve to adjust the track tension (see Tracks and Running Gear, Checking/Adjusting the Track Tension, Section 3). Motor Bleeding Bleeding must be done whenever a track motor is being fitted.
Page 459: Testing
Measure the amount of drain oil collected in the receptacle. This should not exceed 1.2 litres (0.27 gal) for JS130 or 1.5 litres (0.3 gal) for JS160. Note: The drain oil quantities given are applicable to a new motor.
Page 460: Cross-Sectional View - Js130
Section F Transmission Section F 7 - 1 Traction Motor/Reduction Gear 7 - 1 Cross-sectional View - JS130 JS00250 9803/6410 Issue 1...
Page 461 Section F Transmission Section F 7 - 2 Traction Motor/Reduction Gear 7 - 2 Exploded View (Traction Motor) - JS130 9803/6410 Issue 1...
Page 462 Section F Transmission Section F 7 - 3 Traction Motor/Reduction Gear 7 - 3 Exploded View (Reduction Gear) - JS130 JS00260 9803/6410 Issue 1...
Page 463 Section F Transmission Section F 7 - 4 Traction Motor/Reduction Gear 7 - 4 JS130 Component List Description Description Retainer plate Thrust ball Spindle Kit Timing plate Spindle Washer Flange Piston Reamer bolt Spring Spring Gear assembly Friction plate Gear A...
Page 464 Section F Transmission Section F 7 - 5 Traction Motor/Reduction Gear 7 - 5 JS130 (cont’d) Component List (cont’d) Description Relief valve Valve kit Valve Sleeve Spring retainer Plug Shim Spring ‘O’-ring ‘O’-ring ‘O’-ring Back-up ring Body kit ‘O’-ring Body...
Page 465: Cross-Sectional View - Js160
Section F Transmission Section F 7 - 6 Traction Motor/Reduction Gear 7 - 6 Cross-sectional View - JS160 JS00280 9803/6410 Issue 1...
Page 466 Section F Transmission Section F 7 - 7 Traction Motor/Reduction Gear 7 - 7 Exploded View (Traction Motor) - JS160 9803/6410 Issue 1...
Page 467 Section F Transmission Section F 7 - 8 Traction Motor/Reduction Gear 7 - 8 Exploded View (Reduction Gear ) - JS160 JS00290 9803/6410 Issue 1...
Page 468 Section F Transmission Section F 7 - 9 Traction Motor/Reduction Gear 7 - 9 JS160 Component List Description Description Hub kit Retainer plate Thrust ball Ring gear Timing plate Parallel pin Washer Washer Spindle Piston Coupling gear Spring Spring Friction plate Floating seal kit Plate Distance piece...
Page 469 Section F Transmission Section F 7 - 10 Traction Motor/Reduction Gear 7 - 10 JS160 (cont’d) Component List (cont’d) Description Relief valve Valve Sleeve Spring retainer Plug Shim Spring ‘O’-ring ‘O’-ring ‘O’-ring Back-up ring Body kit Body Piston ‘O’-ring Plug Plug Steel ball Back-up ring...
Page 470: Dismantling
Refer to the following pages: Make different alignment marks across each sub assembly joint faces as an aid to assembly. JS130 7 - 1 and 7 - 2 (illustrations) 7 - 4 to 7 - 5 (component list) The cylinder block assemblies, servo pump, relief valve and...
Page 471 Section F Transmission Section F 8 - 2 Traction Motor 8 - 2 Dismantling (cont’d) Remove rear flange 101 from spindle 2. Remove two plugs 124 from rear flange 101. Remove ‘O’-rings 155 from plugs 124. Remove two springs 128, two plungers 125 and spool 123 from the rear flange.
Page 472 Section F Transmission Section F 8 - 3 Traction Motor 8 - 3 Dismantling (cont’d) Remove two springs 130 and two valves 127 from the rear flange 101. Remove ‘O’-rings 156 from plugs 126. Take care to avoid damaging the seat of the valve or its mating seat in the flange.
Page 473 Section F Transmission Section F 8 - 4 Traction Motor 8 - 4 Dismantling (cont’d) 11 Remove valve 119 as follows: Depress valve seat 118 with a steel rod A and remove ring 122 by pressing the notch B with a sharp-pointed tool C.
Page 474 Section F Transmission Section F 8 - 5 Traction Motor 8 - 5 Dismantling (cont’d) 14 Loosen and remove the two plugs 215. Remove ‘O’-ring 219 from each plug 215 and discard. 15 Take the two steel balls 216 out of body 212. 16 Unscrew one of the sleeves 202 from body 212.
Page 475 Section F Transmission Section F 8 - 6 Traction Motor 8 - 6 Dismantling (cont’d) 17 Unscrew plug 204 from sleeve 202. Remove ‘O’-ring 210 and shim 205 from plug 204. Discard the ‘O’-ring. 18 Remove spring retainer 203, spring 206 and valve 201 from sleeve 202.
Page 476 Section F Transmission Section F 8 - 7 Traction Motor 8 - 7 Dismantling (cont’d) 19 Repeat steps 16 to 18 for the second sleeve 202. 20 Remove timing plate 109, two pins 141, ten springs 113, bearing 150, ‘O’-rings 29 and 39. Discard the ‘O’-rings.
Page 477 If it is necessary to remove these components refer to Reduction Gear, Dismantling. 24 Remove the swash plate 103/thrust plate 153 (JS130 only) assembly, the two steel balls 167 (pivots 167 on JS160) and the 2-speed switch piston assembly (piston 161, shoe 162, spring 179 (191 on JS160) out of spindle 2.
Page 478 Section F Transmission Section F 8 - 9 Traction Motor 8 - 9 Dismantling (cont’d) 25 To remove circlip 145, place the cylinder block on a press capable of exerting a pressure of at least 100 kgf (220 lbf) and compress spring 114 by means of a suitable tubular tool (see Service Tools, Section 1) pressing on washer 110.
Page 479 Section F Transmission Section F 8 - 10 Traction Motor 8 - 10 Inspection All parts should be inspected for signs of wear or damage, paying particular attention to the parts detailed below. Part Renew if these conditions exist Rear flange 101 Spool 123 bore is scratched.
Page 480 Section F Transmission Section F 8 - 11 Traction Motor 8 - 11 Inspection (cont’d) Part Renew if these conditions exist Valve 119 Outer circumference surface is scratched. Seat surface is scratched. Bearings 149, 150 Pressure marks observed. Flaking is occurring. Unevenly worn.
Page 481 Section F Transmission Section F 8 - 12 Traction Motor 8 - 12 Assembly Clean each part in a suitable solvent and dry using compressed air. All tapped holes and gasket faces should be thoroughly degreased by washing as liquid packing and adhesive is Inspect all parts and renew as required.
Page 482 Section F Transmission Section F 9 - 1 Reduction Gear - JS130 9 - 1 Dismantling Refer to the following pages: Make different alignment marks across each sub assembly joint face as an aid to assembly. 7 - 1 and 7 - 3...
Page 483 Section F Transmission Section F 9 - 2 Reduction Gear - JS130 9 - 2 Dismantling (cont’d) In turn, remove each of the three snap ring 25/spur gear 7/distance piece 14 sets from the crankshaft 9. If the traction motor has already been dismantled, shaft 102 can now be removed complete with bearing 149.
Page 484 Section F Transmission Section F 9 - 3 Reduction Gear - JS130 9 - 3 Dismantling (cont’d) Remove flange 3 complete with the inner race of bearing 21 from spindle 2. Note: The component parts of bearing 21 are a matched set and must remain together.
Page 485 Section F Transmission Section F 9 - 4 Reduction Gear - JS130 9 - 4 Dismantling (cont’d) Remove floating seal 31 from spindle 2. a Remove the outer race of bearing 22 from flange 3 using an aluminium bar A and hammer as shown.
Page 486 Section F Transmission Section F 9 - 5 Reduction Gear - JS130 9 - 5 Inspection Part Renew if these conditions exist Spindle 2 Excessive damage or wear. Flange 3 Reamer bolt 19 † Gear A 4 Gear teeth unevenly worn.
Page 487 Section F Transmission Section F 9 - 6 Reduction Gear - JS130 9 - 6 Assembly General Clean each part in a suitable solvent and dry using All tapped holes and gasket faces should be thoroughly compressed air. degreased by washing, as liquid packing and adhesive is used on all gasket surfaces and threads.
Page 488 Section F Transmission Section F 9 - 7 Reduction Gear - JS130 9 - 7 Assembly (cont’d) When Assembling (cont’d) When installing spur gears 7 on flange 3 position alignment marks X as shown. JS00470 If bearing 149 has been removed from shaft 102 it will be necessary to fit a new bearing.
Page 489 Section F Transmission Section F 9 - 8 Reduction Gear - JS130 9 - 8 Adjustments Determining the Thickness of Flange 3 This procedure must be carried out if any of the following components have been renewed: hub 1, spindle 2, flange 3, bearing 21.
Page 490 Section F Transmission Section F 9 - 9 Reduction Gear - JS130 9 - 9 Adjustments (cont’d) Determining the Thickness of Flange 3 (cont’d) On flange 3, measure dimension D which should be the same as the dimension C determined in step 3.
Page 491 Section F Transmission Section F 9 - 10 Reduction Gear - JS130 9 - 10 Adjustments (cont’d) Determining the Thickness of Snap Ring 20 This procedure must be carried out if any of the following components have been renewed: spindle 2, flange 3, gear assembly (items 4, 5, 9, 22 and 23).
Page 492 Section F Transmission Section F 10 - 1 Reduction Gear - JS160 10 - 1 Dismantling Refer to the following pages: Make different alignment marks across each sub assembly joint face as an aid to assembly. 7 - 6 and 7 - 8 (illustrations) 7 - 9 to 7 - 10 (component list)
Page 493 Section F Transmission Section F 10 - 2 Reduction Gear - JS160 10 - 2 Dismantling (cont’d) Make matching marks on ring gear 4 and hub 1 to aid assembly. Using a bar, withdraw ring gear 4 and remove the adhesive from the engagement surfaces of the ring gear and hub.
Page 494 Section F Transmission Section F 10 - 3 Reduction Gear - JS160 10 - 3 Dismantling (cont’d) Dismantle spindle 2 parts as follows: a Remove and discard ‘O’-ring 29. Note: Remove oil seal 132 only if it needs renewing. b Tur n the spindle 180° and using a flat end screwdriver and hammer as shown, remove and discard oil seal 132.
Page 495 Section F Transmission Section F 10 - 4 Reduction Gear - JS160 10 - 4 Dismantling (cont’d) Remove ring 15 and coupling gears 8 from ring gear 5. 10 Do not attempt to dismantle the carrier assembly (comprising carrier 3, cluster gears 6, shafts 9, thrust collars 14, bearings 25 and parallel pins 34).
Page 496 Section F Transmission Section F 10 - 5 Reduction Gear - JS160 10 - 5 Inspection Part Replace if these conditions exist Spindle 2 Excessive damage or wear. Coupling gears 8 Pins 17 † Carrier 3 Excessive damage or wear. †...
Page 497 Section F Transmission Section F 10 - 6 Reduction Gear - JS160 10 - 6 Assembly General Clean each part in a suitable solvent and dry using All tapped holes and gasket faces should be thoroughly compressed air. degreased by washing as liquid packing and adhesive is used on all gasket surfaces and threads.
Page 498 Section F Transmission Section F 10 - 7 Reduction Gear - JS160 10 - 7 Assembly (cont’d) When Assembling (cont’d) Completely degrease the threaded holes of spindle 2 and then apply thread adhesive. Also degrease bolts 35 and then apply an anti-seize coating beneath the bolt head.
Page 499 Section F Transmission Section F 10 - 8 Reduction Gear - JS160 10 - 8 Assembly (cont’d) When Assembling (cont’d) Tighten the plug and bolts to the torques indicated below: Torques Part lbf ft kgf m Plug 30 59 ± 20 43.4 ±...
Page 500 Section F Transmission Section F 10 - 9 Reduction Gear - JS160 10 - 9 Adjustments (cont’d) Determining the Thickness of Distance Piece 12 (cont’d) Select a suitable distance piece from the nine detailed below. Distance piece 12 - Classification Symbol AA 3.70 mm (0.146 in) 3.80 mm (0.150 in)
Page 501 Section F Transmission Section F 10 - 10 Reduction Gear - JS160 10 - 10 Adjustments (cont’d) Determining the Thickness of Thrust Bearing 20 (cont’d) Calculate the optimum thickness ‘T’ of thrust bearing 20 as follows: T = (C - X) - (0.3 to 0.6) mm Select a suitable thrust bearing from the table below.
Page 502 Section J Track and Running Gear Section J Contents Page No. Torque Specifications 1 - 1 Idler Wheel and Recoil Unit Removal 2 - 1 Replacement 2 - 2 Idler Wheel Dismantling 3 - 1 Assembly 3 - 2 Wear Limits 4 - 1 Recoil Unit Dismantling...
Page 503 267 - 312 27.2 - 31.8 197 - 230 installation bolt Grease cylinder 267 - 312 27.2 -31.8 197 - 230 mounting bolts Note: Apply Loctite 262 (JCB Part No. 4101/0502) to the threads of the above bolts. 9803/6410 Issue 1...
Page 504: Removal
Section J Track and Running Gear Section J 2 - 1 Idler Wheel and Recoil Unit 2 - 1 Removal Slacken the check valve to bleed out grease. ! WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out.
Page 505: Replacement
Section J Track and Running Gear Section J 2 - 2 Idler Wheel and Recoil Unit 2 - 2 Replacement Before fitting the idler wheel, check the oil level at A. If required, top up with the specified oil (see section 3). Assemble the idler wheel to the recoil unit and fit the mounting bolts.
Page 506: Dismantling
Section J Track and Running Gear Section J 3 - 1 Idler Wheel 3 - 1 Dismantling Carry out steps 1 to 4 of Idler Wheel and Recoil Unit, Removal. Clean the idler wheel with a suitable solvent. Remove the plug A from hub B and drain the oil. On one side of the unit only, remove the wire clip E or roll pin F and separate the hub C from shaft D.
Page 507 Section J Track and Running Gear Section J 3 - 2 Idler Wheel 3 - 2 Dismantling (cont’d) Remove floating seal J from each hub C using a pry bar. Remove floating seal J from each side of idler wheel G using a pry bar.
Page 508 Section J Track and Running Gear Section J 3 - 3 Idler Wheel 3 - 3 Assembly (cont’d) Apply a coating of grease and install a new floating seal J into each side of the idler wheel G. Apply a coating of grease and install a new floating seal J into hub C.
Page 509 Section J Track and Running Gear Section J 3 - 4 Idler Wheel 3 - 4 Assembly (cont’d) Apply grease to a new 'O'-ring I and install it on the shaft D. Clean the metallic face of the seal, coat the metallic face with engine oil and install the hub C onto the shaft D.
Page 510 4 - 1 Idler Wheel 4 - 1 Wear Limits Item Dimension Machine Standard Size Service Limit Action Wheel Diameter JS130 20.08 19.92 Build up or renew JS160 19.45 19.29 Build up or renew JS130 0.75 Build up or renew JS160 0.83...
Page 511 Section J Track and Running Gear Section J 5 - 1 Recoil Unit 5 - 1 Dismantling Carry out steps 1 to 4 of Idler Wheel and Recoil Unit, Removal. ! WARNING RECOIL UNITS ARE DANGEROUS. They must not be dismantled without using suitable tools to compress the spring safely.
Page 512: Assembly
Section J Track and Running Gear Section J 5 - 2 Recoil Unit 5 - 2 Assembly a Position the recoil unit component parts in the spring compression jig (see Service Tools, Section 1), starting with spring guide/retainer F, then spring B and yoke E.
Page 513: Dismantling
Section J Track and Running Gear Section J 6 - 1 Grease Cylinder 6 - 1 Dismantling Carry out steps 1 to 3 of Idler Wheel and Recoil Unit, Removal. Remove the lower roller immediately below the grease cylinder (see Bottom Roller, Removal). Remove bolts A and washers B and remove grease cylinder C through the bottom of side frame D.
Page 514: Removal
Section J Track and Running Gear Section J 7 - 1 Drive Sprocket 7 - 1 Removal Slacken the check valve to bleed out grease. ! WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out.
Page 515: Replacement
Section J Track and Running Gear Section J 7 - 2 Drive Sprocket 7 - 2 Replacement Support the sprocket and position it on the gearbox. Install the bolts and washers, using Loctite 262 on the bolt threads. Tighten the bolts in a diagonal sequence to a torque of 267 - 312 Nm (197 - 230 lbf ft, 27 - 31 kgf Remove the wooden blocks.
Page 516 Section J Track and Running Gear Section J 8 - 1 Drive Sprocket 8 - 1 Wear Limits Item Dimension Machine Standard Size Service Limit Action Width JS130 58.9 2.32 2.09 Renew JS160 2.60 2.36 Renew Diameter JS130 23.01 22.78 Renew JS160 22.93...
Page 517: Removal
Section J Track and Running Gear Section J 9 - 1 Top Roller 9 - 1 Removal Slacken the check valve to bleed out grease. ! WARNING When opening the check valve, always stand to one side and loosen a little at a time until grease starts to come out.
Page 518: Replacement
Section J Track and Running Gear Section J 9 - 2 Top Roller 9 - 2 Replacement Before fitting the roller, check the oil level and, if necessary, top up (see Fluids and Lubricants, Section 3). Install the plug using an appropriate pipe thread sealant.
Page 519 Section J Track and Running Gear Section J 10 - 1 Top Roller 10 - 1 Item Part Name Roller Plug Circlip Cover ‘O’-ring Bolt Thrust plate Shaft Floating seal Bush Bush Mounting bracket JS01540 9803/6410 Issue 1...
Page 520: Dismantling
Section J Track and Running Gear Section J 10 - 2 Top Roller 10 - 2 Dismantling Clean the upper roller A with an appropriate detergent. Remove the plug B from the cover and drain the oil. Remove the circlip C, and remove cover D. From cover D, remove 'O'-ring E and discard.
Page 521 Section J Track and Running Gear Section J 10 - 3 Top Roller 10 - 3 Dismantling (cont’d) Remove the floating seal I from the upper roller A. If badly worn or damaged, remove the bushes J and K, from the roller A. Remove floating seal I from bracket L using a pry bar.
Page 522: Assembly
Section J Track and Running Gear Section J 10 - 4 Top Roller 10 - 4 Assembly (cont’d) Using a jig M, and hammer, insert the bushes J and K into the roller A. JS01550 Install a new floating seal I into the roller A. Coat the metallic face of the seal with engine oil.
Page 523 Section J Track and Running Gear Section J 10 - 5 Top Roller 10 - 5 Assembly (cont’d) Apply grease to the inside face of thrust plate G and install it on the shaft using bolts F. JS01560 Apply grease to a new 'O'-ring E and install it onto cover D.
Page 524: Bottom Roller
Section J Track and Running Gear Section J 12 - 1 Bottom Roller 12 - 1 Removal Slacken the check valve to bleed out grease. ! WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out.
Page 525: Replacement
Section J Track and Running Gear Section J 12 - 2 Bottom Roller 12 - 2 Replacement Before fitting the roller, fill with oil (see Fluids and Lubricants, Section 3). Install the plug using an appropriate pipe thread sealant. With the undercarriage lifted and supported with wooden blocks, position the roller on the track link as shown.
Page 526 Section J Track and Running Gear Section J 13 - 1 Bottom Roller 13 - 1 Item Part Name Plug Locking wires Shaft Mounting bracket Mounting bracket Floating seal ‘O’-ring Roller (outer flange) Roller (inner flange) Bushing JS01590 9803/6410 Issue 1...
Page 527: Dismantling
Section J Track and Running Gear Section J 13 - 2 Bottom Roller 13 - 2 Dismantling Clean the roller with a suitable solvent. Remove the plug A and drain the oil. Remove locking wire B from each end of shaft C. Remove mounting brackets D and E from shaft C.
Page 528: Assembly
Section J Track and Running Gear Section J 13 - 3 Bottom Roller 13 - 3 Dismantling (cont’d) Remove floating seals F from roller H or J using a pry bar. If badly worn or damaged, remove and discard bushes K from roller H or J, using a press or puller.
Page 529 Section J Track and Running Gear Section J 13 - 4 Bottom Roller 13 - 4 Assembly (cont’d) Coat shaft C with grease. Insert the shaft into roller H or J. Apply grease to new 'O'-rings G and install them on shaft C.
Page 530 Section J Track and Running Gear Section J 13 - 5 Bottom Roller 13 - 5 Assembly (cont’d) Complete the installation of locking wires B by tapping with a hammer Fill the unit with oil (see Fluids and Lubricants, Section 3) and install plug A using an appropriate pipe thread sealant.
Page 531 Track and Running Gear Section J 14 - 1 Bottom Roller 14 - 1 Wear Limits Item Dimension Machine Standard Size Service Limit Action Roller diameter JS130 5.51 5.20 Renew JS160 5.90 5.59 Renew JS130 0.59 Renew JS160 0.59 Renew...
Page 532: Technical Data
Engine Section K Section K Contents Page No. Technical Data 1 - 1 9803/6410 Issue 1...
Page 533 Engine Section K 1 - 1 1 - 1 Technical Data Type Isuzu A4BG1T, 4 cylinder in-line, turbocharged, direct injection diesel. Model - JS130 A4BG1T-S1 - JS160 A4BG1T-S2 Bore 105 mm (4.13 in) Stroke 125 mm (4.92 in) Swept Volume 4329 cm (264.2 in...

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