Page 1 Hydraulics JS70 from machine no. 695501 Transmission Brakes PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT Track & Running Gear OF JCB SERVICE: © ROCESTER, STAFFORDSHIRE, ST14 5LS, ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND Engine Publication No. 9803/6020 Issue 0...
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 General Torque Settings 1 - 2 Service Tools Section C - Electrics 4 - 1 Section E - Hydraulics 5 - 1 Section F - Transmission 6 - 1 Sealing and Retaining Compounds 7 - 1...
Page 4: Bolt And Nut Torque Specifications
39~48 20† Rotary Coupling 63~73 6.4~7.4 46~54 21 Cab 79~88 58~65 22 Battery 20~30 15~22 Note: Use JCB Threadlocker and Sealer (High Strength) on those marked and tighten to the torque listed in the above † table. 9803/6020 Issue 1...
Page 5: General Torque Settings
Section 1 General Information Section 1 1 - 2 General Torque Settings 1 - 2 General 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.
Page 6: Service Tools
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 7: 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 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in 892/00898 Pressure Gauge 0-100 bar (0-1500 lbf/in 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in 892/00280 Pressure Gauge 0-600 bar (0-8500 lbf/in...
Page 8 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 9 Section 1 General Information Section 1 5 - 3 5 - 3 Service Tools (continued) SECTION E - HYDRAULICS JS07050 JS07050 Ram Piston Nut Removal/Fitting Spanner JS07050 993/99512 Spanner 55mm A/F 993/99513 Spanner 60mm A/F Ram Piston Nut Removal/Fitting Rig 993/99514 Spanner 65mm A/F 993/99515...
Page 10 Section 1 General Information Section 1 5 - 4 5 - 4 Service Tools (continued) SECTION E - HYDRAULICS Seal press-fit jig Seal protector 9803/6020 Issue 1...
Page 11 Section 1 General Information Section 1 5 - 5 5 - 5 Service Tools (continued) SECTION E - HYDRAULICS Jig to press fit the taper roller bearing inner rings Barrel pulling out jig More than 140 Approximate Hexagon socket head set screw M12 x100 (Full dog point) Hanger assembling jig 9803/6020...
Page 12 Section 1 General Information Section 1 6 - 1 6 - 1 Service Tools (continued) SECTION F - TRANSMISSIONS Special tool III Work Bench for pressing the oil seal 132 into the spindle. Special tool IV Use to locate the outer race of the bearing 22 and tap Hub 1/ spindle 2 Securing jig to secure the bearing to the crankshaft.
Page 13: Sealing And Retaining Compounds
A medium strength sealant suitable for all sizes of gasket flanges and for hydraulic fittings of 25-65 mm diameter. 4102/1212 JCB High Strength Threadlocker A high strength locking fluid for use with threaded components. 4102/0551 Gasketing for all sizes of flange where the strength of the joint is important.
Page 14 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 9803/6020 Issue 1...
Page 15 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 16 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 17 It should not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor. INT-2-1-14 9803/6020 Issue 1...
Page 18 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 19 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 20 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 2 - 1 Initial Precautions For New Machine Usage 2 - 2 Operating Hours Schedule 2 - 3...
Page 21 Section 3 Routine Maintenance Section 3 Contents Page No. Engine Changing the Air Filter Elements 8 - 1 Checking the Oil Level 8 - 3 Changing the Oil and Filter 8 - 3 Checking the Coolant Level 8 - 4 Coolant Mixtures 8 - 4 Changing the Coolant...
Page 22: Fluids And Lubricants
Types of Fuel Nos 1D, 2D (30.8 UK gal) Engine Lubrication Chart Use according to ambient temperature (°C) JCB SUPER 15W/40 MULTIGRADE ENGINE OIL API CF4/SG MIL L-2104F JCB SUPER UNIVERSAL AGRICULTURAL (10W/30) API CE/SF MIL L-2104D 9803/6020 Issue 1...
Page 23: 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 24: 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 When using a breaker, contamination and degradation of the hydraulic oil occurs much more quickly than in normal excavating use.
Page 25: 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 26 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 27 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 100 hour service plus: Do a 500 hour service plus: 2 Clean Clean a Fuel lift pump strainer.
Page 28 Section 3 Routine Maintenance Section 3 2 - 5 Service Schedules 2 - 5 Every 5000 Operating Hours or 2 Years 6 Months Whichever occurs first 1 Do a 1000 hour service plus: 2 Change a Hydraulic oil.††† b Hydraulic tank air breather element. c Hydraulic fluid suction strainer.†††...
Page 29: Greasing
Section 3 Routine Maintenance Section 3 3 - 1 Greasing 3 - 1 You must grease the machine regularly to keep it working Do not mix different types of grease. Keep them separate. efficiently. Regular greasing will also lengthen the ! WARNING machine's working life.
Page 30: Excavator End (Standard Boom)
Section 3 Routine Maintenance Section 3 3 - 2 Greasing (continued) 3 - 2 ! WARNING Excavator End (Standard Boom) (50 hours) You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery.
Page 31: Excavator End (Offset Boom)
Section 3 Routine Maintenance Section 3 3 - 3 3 - 3 ! WARNING Excavator End (Offset Boom) (50 hours) You will be working close into the machine for these jobs. Lower the attachments if possible. Remove Read general information about greasing at the beginning starter key and disconnect the battery.
Page 32: Battery
Section 3 Routine Maintenance Section 3 4 - 1 Battery 4 - 1 First Aid - Electrolyte Checking the Electrolyte Level EYES Remove the Battery Compartment Cover A Maintenance free batteries used in normal temperate FLUSH WITH WATER FOR 15 MINUTES. GET MEDICAL climate applications should not need topping up.
Page 33: Hydraulics
Section 3 Routine Maintenance Section 3 5 - 1 Hydraulics 5 - 1 Air Bleeding Procedures ! 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 34 Section 3 Routine Maintenance Section 3 5 - 2 Hydraulics (continued) 5 - 2 Air Bleeding Procedures After replacing the hydraulic oil or repairing or replacing hydraulic components or removing hydraulic pipes, bleed air from the hydraulic circuit. Bleeding Air from the Hydraulic Pump If the air is not completely bled, the life of the pump will be reduced or serious trouble can occur.
Page 35 Section 3 Routine Maintenance Section 3 5 - 3 Hydraulics (continued) 5 - 3 Air Bleeding Procedures (continued) Bleeding Air from the Rams If air is not bled from the rams when replaced or repaired, the piston and/or seals may be damaged. Prepare the Machine Idle the engine at low speed and extend and retract each ram 4 or 5 times, stopping the ram 100 mm...
Page 36: Changing The Fluid
Section 3 Routine Maintenance Section 3 5 - 4 Hydraulics (continued) 5 - 4 Changing the Fluid Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key. Locate Breather Mounting Plate A and Drain Plug C These are, respectively, on the top and bottom of the hydraulic oil tank (see Identification of Machine Components).
Page 37: Changing The Return Filter Element
Section 3 Routine Maintenance Section 3 5 - 5 Hydraulics (continued) 5 - 5 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 Refer to Component Location Diagrams. Release Tank Pressure (See Releasing Tank Pressure).
Page 38: Changing The Nephron Filter
Section 3 Routine Maintenance Section 3 5 - 6 Hydraulics (continued) 5 - 6 Changing the Nephron Filter Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key. Locate Nephron Filter A Refer to Component Location Diagrams. Release Tank Pressure (See Releasing Tank Pressure).
Page 39: Changing The Air Breather Element
Section 3 Routine Maintenance Section 3 5 - 7 Hydraulics (continued) 5 -7 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 W Refer to Component Location Diagrams.
Page 40: Changing The Servo Oil Filter
Section 3 Routine Maintenance Section 3 5 - 8 Hydraulics (continued) 5 - 8 Changing the Servo Oil Filter Prepare the Machine Position the machine on level ground. Stop the engine by pressing the Emergency Engine Stop Switch. Operate all the hydraulic servo controls to release system pressure.
Page 41: Changing The Breaker In-Line Filter (If Fitted)
Section 3 Routine Maintenance Section 3 5 - 9 Hydraulics (continued) 5 - 9 Changing the Breaker In-line Filter (if fitted) Note: This filter should be changed at the intervals stated in Service Schedules or when the visual indicator X has popped up.
Page 42: Transmission
Section 3 Routine Maintenance Section 3 6 - 1 Transmission 6 - 1 Checking the Track Gearbox Oil Level Prepare the Machine Position the machine on level ground with the filler plug A and level plug B positioned as shown. Check the level on One Side Clean the area around the filler and level plugs and remove both plugs.
Page 43: Replenishing Slew Gearbox Grease
Section 3 Routine Maintenance Section 3 6 - 2 Transmission (continued) 6 - 2 Replenishing Slew Gearbox Grease Prepare the Machine Position the machine on level ground. Stop the engine and remove the starter key. Locate the Slew Gearbox Refer to Component Location Diagram at the end of this section.
Page 44: Tracks And Running Gear
Section 3 Routine Maintenance Section 3 7 - 1 Tracks and Running Gear 7 - 1 Clean the Tracks ! WARNING If two people are doing this job make sure that the person working the controls is a competent operator. If the wrong control lever is moved, or if the controls are moved violently, the other person could be killed or injured.
Page 45: Checking/Adjusting The Track Tension
Section 3 Routine Maintenance Section 3 7 - 2 Tracks and Running Gear 7 - 2 (continued) Checking/Adjusting the Track Tension Prepare the Machine Position the machine on firm and level ground. ! WARNING NEVER position yourself or any part of your body under a raised machine which is not properly supported.
Page 46: Checking The Track Shoes
Section 3 Routine Maintenance Section 3 7 - 3 7 - 3 Tracks and Running Gear (continued) Checking the Track Shoes Prepare the Machine Position the machine on level ground and switch off the engine. Inspect the Track Shoes Check the shoes for wear and for loose mounting bolts.
Page 47 Section 3 Routine Maintenance Section 3 8 - 1 Engine 8 - 1 Changing the Outer Element Note: Renew the inner element every second time you Remove the End Cover renew the outer element. As a reminder, mark the inner element with a felt tip pen when you renew only the outer Undo knob A.
Page 48 Section 3 Routine Maintenance Section 3 8 - 2 Engine (continued) 8 - 2 Changing the Inner Element Locate the Air Filter Clean the Canister See Component Location Diagrams at the end of Clean the inside of the canister D, the end cover H this section.
Page 49 Section 3 Routine Maintenance Section 3 8 - 3 8 - 3 Engine (continued) Checking the Oil Level Prepare the Machine Check for Leaks Park the machine on level ground. Lower the bucket to the ground. Start the engine and go through the warming-up procedure (see Engine Warm-Up).
Page 50 - before the cold weather starts. Change it every two years. Coolant Mixtures To prevent the coolant freezing in cold conditions, antifreeze must be added. JCB Universal Antifreeze will give protection down to the temperatures shown in the table. Antifreeze Solution Starts to freeze at -36 °C (-33 °F)
Page 51 Section 3 Routine Maintenance Section 3 8 - 5 Engine (continued) 8 - 5 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 52 Section 3 Routine Maintenance Section 3 8 - 6 Engine (continued) 8 - 6 Checking Fan Belt Tension ! WARNING Make sure that the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5 Prepare the Machine Put the machine on level ground, lower the bucket to the ground.
Page 53 Section 3 Routine Maintenance Section 3 8 - 7 Engine (continued) 8 - 7 Draining Fuel Tank Impurities Stop the engine and remove the key. Remove screws A and take off cover B. Loosen the drain tap C on the underside of the fuel tank. Drain the water and deposits until clean diesel oil flows out.
Page 54 Section 3 Routine Maintenance Section 3 8 - 8 Engine (continued) 8 - 8 Changing the Fuel Filter Element Stop the Engine Stop the engine and remove the key. Disconnect the Battery Open the Engine Compartment Locate the fuel filter element A. Remove the Element Using a chain wrench, unscrew the filter element from the filter head.
Page 55 Section 3 Routine Maintenance Section 3 8 - 9 Engine (continued) 8 - 9 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 56 Section 3 Routine Maintenance Section 3 Main Components 9 - 1 9 - 1 Description Bucket Link Bucket ram Dipper Dipper ram Boom Boom ram Fuel tank Hydraulic oil tank Return filter Nephron filter Control valve Muffler Pump Engine Engine hood Radiator Expansion bottle Air cleaner...
Page 57 Section B Body & Framework Section B Contents Contents Page No. Weights Weights 1 - 1 9803/6020 Issue 1...
Page 58 Section B Body & Framework Section B 1 - 1 Weights 1 - 1 Weights 288230 Description Weight kg (lb) Description Weight kg (lb) Overall mass 6700 (14773) Attachment 1075 (2370) Upper mechanism 3115 (6868) Boom 620 (1367) Includes (including ram) Counterweight and Dipper 250 (551)
Page 59 Section B Body & Framework Section B 1 - 2 Weights 1 - 2 Weights (cont’d) (Dry Weight) Part Name Weight Travel motor 90 kg (198 lb) Drive sprocket 22 kg (48 lb) Idler wheel 37 kg (82 lb) Top roller assembly 8 kg (18 lb) Bottom roller assembly (Out) 46 kg (101 lb)
Page 60 Section C Electrics Section C Contents Page No. Torque Specification Technical Data Battery Testing Schematic Diagram Layout Operator’s Cab Right Console Left Console Display Monitor Control, Function, Operation Electrical Equipment Layout Cab Relays 3-10 Engine Control Basic Operation of Engine Control One Touch Idle Control Speed Control for Each Mode Emergency Stop...
Page 61: Torque Specification
Section C Electrics Section C 1 - 1 Torque Specifications 1 - 1 Torque Specifications Component kgfm lb ft Battery (securing bolts) 19.6-29.4 14.46-21.69 9803/6020 Issue 1...
Page 62: Technical Data
Section C Electrics Section C 2 - 1 Technical Data 2 - 1 Circuit Protection; Fuse rating and circuit names ! CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5 Fuses The electrical circuits are protected by fuses located in fuse box A on the front face of the right console (below the Right Excavator Joystick).
Page 63: 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 64: Schematic Diagram
Section C Electrics Section C 2 - 3 Schematic Diagram 2 - 3 Main Components BLACK Cigar Lighter WHITE YELLOW Radio Aerial Lead BROWN LIGHT GREEN Panel (LH) PINK SKY BLUE Limit Switch (Gate) VOILET BLUE Horn Button GREEN GREY Panel (RH) ORANGE Pressure Switch (Breaker) - Optional...
Page 66 Section C Electrics Section C 3 - 1 Cab Layout 3 - 1 JS08150 Right Console Left Hand Track Control Right Excavator Joystick Control Travel Speed Range Change Switch Display Monitor Left Excavator Joystick Control Dozer Blade Lever 10 Control Lock Lever Rockbreaker/Offset Boom Control Pedal 11 Left Console Right Hand Track Control...
Page 67: Right Console
Section C Electrics Section C 3 - 2 Cab Layout 3 - 2 Right Console 1 2 3 4 5 6 MODE MODE JS08130 Throttle Control Starter Switch. This rotary control provides progressive engine speed a START POSITION control over the full range. Engine starting position.
Page 68 Section C Electrics Section C 3 - 3 Cab Layout 3 - 3 Right Console (cont’d) Work Lamp Switch This switch turns the work lamp ON and OFF. Switch Lamp Work Lamp All Off 1 On Right hand Cab Working light Only 2 On Right hand Cab &...
Page 69: Left Console
Section C Electrics Section C 3 - 4 Cab Layout 3 - 4 Left Console 00009 JS08140 Control Lock Lever Raising lever 1 provides a method of isolating the hydraulic controls (in addition to operating the Servo Isolator Switch (paragraph 5)) and is an integral part of the procedure for vacating the cab.
Page 70 Section C Electrics Section C 3 - 5 Cab Layout 3 - 5 Servo Isolator Switch Left Console (cont’d) This switch provides a method of isolating the hydraulic controls (in addition to raising the Control Horn Switch Lock Lever (paragraph 1)). When the switch is When you press the switch located on top of the left pressed the controls are isolated and the Monitor side operation lever, the horn will sound.
Page 71: Display Monitor
Section C Electrics Section C 3 - 6 Cab Layout 3 - 6 Display Monitor JS08120 The monitor provides indications of the machine’s Servo Isolator Switch Indicator operating condition and draws the operator’s attention to Illuminates when the Servo Isolator Switch is immediate or imminent problems by means of indicating switched on.
Page 72 Section C Electrics Section C 3 - 7 Cab Layout 3 - 7 Display Monitor (cont’d) Problem Warning Indicators Servo controls immobilisation Note: Illumination of any of the warning indicators detailed There are two means of immobilising the machine working below is accompanied by sounding of the warning buzzer.
Page 73: Control, Function, Operation
Section C Electrics Section C 3 - 8 Cab Layout 3 - 8 Control, Function, Operation FUNCTION OPERATION CONTROL Control of the engine speed by the A stepping motor is used on Basic Operation of Engine one touch idle switch. Stop the the throttle motor.
Page 74: Electrical Equipment Layout
Section C Electrics Section C 3 - 9 Electrical Equipment Layout 3 - 9 Working Lamp Battery Relay Pressure Switch Travel Fusible Link Fuel Sensor Safety Relay Solenoid Valve Fusible Link Throttle Motor Battery Sensor Oil Temperature Overheat Switch Battery Oil Pressure Switch Pressure Switch Swing Left Water Temperature Thermo Sensor...
Page 75: Cab Relays
Section C Electrics Section C 3 - 10 Electrical Equipment Layout 3 - 10 Cab Relays 291200 Relay - Engine Shutdown Relay - Working Lights (Boom mounted) Relay - Wiper Relay - Lever Lock Relay - Fan 3 Relay - Fan 1 Relay - Fan 2 Relay - Horn Relay - Washer...
Page 76: Engine Control
Section C Electrics Section C 4 - 1 Engine Control 4 - 1 Basic Operation of Engine Control BLACK WHITE YELLOW BROWN LIGHT GREEN PINK SKY BLUE VIOLET BLUE GREEN GREY ORANGE 4 5 67 8 9 0 ! 288300 Starter Switch OFF Revolution Increase Motor angle...
Page 77 Section C Electrics Section C 4 - 2 Engine Control 4 - 2 Basic Operation of Engine Control Revolution increase, Maximum revolution Starter Switch OFF When the throttle switch moves clockwise the voltage rises. When the starter switch is OFF, there is no voltage, Since this produces a different voltage to the Potentiometer either from the ACC voltage (24V) from the starter switch voltage, a pulse is sent until an equal voltage is reached.
Page 78: One Touch Idle Control
Section C Electrics Section C 4 - 3 Engine Control 4 - 3 One Touch Idle Control 4 5 6 7 8 9 0 ! 288340 One Touch Idle BLACK 1 Potentiometer WHITE YELLOW Switch BROWN LIGHT GREEN Potentiometer PINK SKY BLUE Right Switch Panel VIOLET...
Page 79: Speed Control For Each Mode
Section C Electrics Section C 4 - 4 Engine Control 4 - 4 One Touch Idle Control When the one touch idle button is pressed, the motor driver is moved into idle. There is a fixed voltage set in the motor driver, governing the motor angle voltage of the throttle motor.
Page 80: Emergency Stop
Section C Electrics Section C 4 - 5 Engine Control 4 - 5 Emergency Stop 1 2 3 4 5 6 7 8 9 0 ! 288360 1 Potentiometer A Left Switch Panel BLACK Potentiometer Starter Switch WHITE YELLOW BROWN LIGHT GREEN Throttle Switch Input One Touch Idle Switch...
Page 81 Section C Electrics Section C 4 - 6 Engine Control 4 - 6 Emergency Stop When the emergency button is pressed, the emergency stop input (terminal 9) of the motor driver and the engine stop input (terminal 15 of CN13) on the right switch panel are live.
Page 82: Swing Brake/Swing Lock
Section C Electrics Section C 4 - 7 Engine Control 4 - 7 Swing Brake/Swing Lock 288370 A Left Switch Panel Control Valve (Swing) Remote Control Switch Swing Pressure Switch Swing Lock Swing Brake Reducing Valve Right Switch Panel Swing Lock Switch Swing Lock Input Swing Pressure Switch Input Swing Brake Output / Swing Lock Output...
Page 83 Section C Electrics Section C 4 - 8 Engine Control 4 - 8 Swing Brake/Swing Lock Swing lever Swing lock SOL4 SOL2 Engine is running and the swing lever is in neutral (50% Monitor Switch Swing brake Swing lock brake) solenoid solenoid (100%)
Page 84 Section C Electrics Section C 4 - 9 Engine Control 4 - 9 Swing Brake/Swing Lock (continued) Swing lever SOL2 Monitor Swing lock SOL4 Swing brake Switch Swing lock solenoid solenoid Swing Lock (100% brake) (50%) (100%) After a further five seconds of no swing operation with the swing lock switch selected on the left switch panel, a 24V signal is sent from CN13 terminal (swing lock 5 seconds after...
Page 85: High Travel
Section C Electrics Section C 4 - 10 Engine Control 4- 10 High Travel When the Travel change foot switch is pressed, the electrical power from the fuse box passes through the solenoid valve for high speed travel and the travel switching foot switch is earthed.
Page 86 Section C Electrics Section C 4 - 11 Engine Control 4 - 11 Lever Lock OFF 288410 Lever Lock Monitor Input A Left Switch Panel Lever Lock Relay Output Lever Lock Switch Lever Lock Monitor Output Limit Switch Monitor Lever Lock Relay Fuse Box To Pilot Line Light Illuminates...
Page 87: Lever Lock
Section C Electrics Section C 4 - 12 Engine Control 4 - 12 Lever Lock When the lever lock switch is OFF, the CN 13 terminal 8 (lever lock relay output) is OFF and the lever lock relay circuit is closed. The electrical power from the fuse box passes through the servo isolator solenoid to the limit switch to the lever lock relay and is earthed.
Page 88: Power Supply Cut Delay
Section C Electrics Section C 4 - 13 Engine Control 4 - 13 Power Supply Cut Delay When the starter switch is on, the signal from the starter A Right Switch Panel switch ACC enters the right switch panel, passes Starter Switch through the timer, operates the transistor on the battery relay line on the right switch panel from the CN13...
Page 89: Transistor Protection
Section C Electrics Section C 4 - 14 Engine Control 4 -14 Transistor Protection NPN Transistor Instead of using the protection circuit to cut on the electrical power side the JS 70 system uses the NPN transistor to control the solenoid valve on the earth side. A short circuit would not cause the transistor to burn out, but when there is a short circuit, the solenoid valve is on.
Page 90: Monitor Display
Section C Electrics Section C 4 - 15 Engine Control 4 - 15 Monitor Display A Monitor Display Engine Preheating 288460 2 Speed Travel Lever Lock Swing Lock Refuel Battery Fluid Level Battery Charge Overheat Engine Oil Pressure Starter Switch Right Switch Panel Lamp Check Button Lamp Check...
Page 91 Section C Electrics Section C 4 - 16 Engine Control 4 - 16 Monitor Display The ACC line for the starter system is connected commonly on the positive end of each lamp. The negative end is controlled by the transistor on the right switch panel, when the transistor is earthed the lamp is illuminated.
Page 92: Throttle Control Assembly Adjustment
Section C Electrics Section C 4 - 17 Engine Control 4 - 17 Throttle Control Assembly Adjustment 298040 298050 298060 A Full Throttle K Special Spring ( When Installed) Engine Stop Plain Washer Adjustment Rod Lever Idling Lever Operation Angle of Lever Snap Ring C.L.
Page 93 Section C Electrics Section C 4 - 18 Engine Control 4 - 18 Throttle Control Assembly Adjustment Insert the lever N into the axis of the throttle motor and fix it with the retaining screw. Bend the special spring into the shape for installing as illustrated K.
Page 94 Section E Hydraulics Section E Contents Page No. Technical Data 1 - 1 Schematics Schematic Hydraulic Circuit 3 - 1 Travel - High Speed 3 - 3 Travel - Low Speed 3 - 5 Linear Travel 3 - 7 Swing Operation (0% Swing Brake) 3 - 9 Swing - No Swing Operation (50% Swing Brake) 3 - 11...
Page 95: Technical Data
Hydraulics Section E Section E Contents Page No. Multiple Valves Operation 60 - 1 Fault Finding 60 - 3 Dismantling and Assembly 60 - 4 Hydraulic Rams Specifications and Torque Settings 70 - 1 Precautions During Use 71 - 1 Bucket Ram Removal and Replacement 72 - 1 Dipper Ram Removal and Replacement...
Page 96 Section E Hydraulics Section E 1 - 1 Technical Data 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 36 cm /rev x 2 (2.196 in /rev x 2) Working Pressure...
Page 97 Section E Hydraulics Section E 1 - 2 Technical Data 1 - 2 Travel Equipment Type Variable Displacement Piston Motor (automatic 2-speed change) Suction Capacity 37.22/25.75 cm /rev (2.27/1.57 in /rev) Working Pressure 284.4 bar (4125 lbf/in Working Flow 75.6 l/min (16.6 U.K. gal/min) Reduction Gear Ratio 52.8 : 1 Parking Brake...
Page 98: Schematic Hydraulic Circuit
Section E Hydraulics Section E 3 - 1 Schematics 3 - 1 Schematic, Hydraulic Circuit Blade Ram (Left) Blade Ram (Right) Traction Motor Rotary Coupling Line Filter Slew Motor Filter Radiator Control Valve Return Manifold Relief Valve Control Valve Stop Valve Relief Valve Manifold Line Filter...
Page 100: Travel - High Speed
Section E Hydraulics Section E 3 - 3 Schematics 3 - 3 Travel - High speed 289400 9803/6020 Issue 1...
Page 101 Section E Hydraulics Section E 3 - 4 Schematics 3 - 4 Travel - High Speed During 2 speed travel the two step swash plate angle of the travel motor is shifted to the minimum angle side and 2 speed travel is initiated. Pressurised oil is discharged from port A1(front pump)and enters port 5P of the control valve.
Page 102: Travel - Low Speed
Section E Hydraulics Section E 3 - 5 Schematics 3 - 5 Travel - Low Speed Q N n e 289410 9803/6020 Issue 1...
Page 103 Section E Hydraulics Section E 3 - 6 Schematics 3 - 6 Travel - Low Speed During Low speed travel the swash plate of the travel motor is shifted to the maximum angle side and Low speed travel is initiated. In Low speed travel, no electric signal is sent to the 2 speed travel solenoid valve inside the multiple valve.
Page 104: Linear Travel
Section E Hydraulics Section E 3 - 7 Schematics 3 - 7 Linear Travel 289420 9803/6020 Issue 1...
Page 105 Section E Hydraulics Section E 3 - 8 Schematics 3 - 8 Linear Travel When performing travel operation and attachment or travel and swing operation, this function maintains linear travel. Example: Low speed travel and boom up operation. During travel operation, pressurised oil from port A1 (front pump) enters port 5P of the control valve.
Page 106: Swing Operation (0% Swing Brake)
Section E Hydraulics Section E 3 - 9 Schematics 3 - 9 Swing Operation (0% Swing Brake) 289440 9803/6020 Issue 1...
Page 107 Section E Hydraulics Section E 3 - 10 Schematics 3 - 10 Swing Operation (0% Swing Brake) Before swing operation the swing mechanical brake is maintained at 50% (operations other than swing operation). In performing swing operation, the mechanical brake is released and normal swing movement is possible.
Page 108: Swing - No Swing Operation (50% Swing Brake)
Section E Hydraulics Section E 3 - 11 Schematics 3 - 11 Swing - No Swing Operation (50% Swing Brake) 289430 9803/6020 Issue 1...
Page 109 Section E Hydraulics Section E 3 - 12 Schematics 3 - 12 Swing - No Swing Operation (50% Swing Brake) The swing mechanical brake is maintained at 50% when the engine is running. When the engine is running and the swing pressure switch is OFF (operations other than swing operation) the swing brake solenoid valve is energised via the switch panel.
Page 110: Swing Lock Operation (100% Swing Brake)
Section E Hydraulics Section E 3 - 13 Schematics 3 - 13 Swing Lock Operation (100% Swing Brake) 289470 9803/6020 Issue 1...
Page 111 Section E Hydraulics Section E 3 - 14 Schematics 3 - 14 Swing Lock Operation (100% Swing Brake) The swing mechanical brake is maintained at 100% when the swing lock switch is in the ON position. Swing will not occur even if the swing lever is operated. When the swing lock switch is in the ON position, an electric signal enters the monitor and illuminates the P lamp.
Page 112: Swing Brake Operation
Section E Hydraulics Section E 3 - 15 Schematics 3 - 15 Swing Brake Operation 289450 9803/6020 Issue 1...
Page 113 Section E Hydraulics Section E 3 - 16 Schematics 3 - 16 Swing Brake Operation Five seconds after the swing brake lever is returned to neutral, the swing mechanical brake is maintained at 50%. When the swing lever is returned to neutral, the swing spool returns to its neutral state so that the pressurised oil from port A1 (front pump) is intercepted and cannot flow to the swing motor side.
Page 114 Section E Hydraulics Section E 3 - 17 Schematics 3 - 17 Swing and Dipper In Simultaneous Operation (Swing Priority) 289460 9803/6020 Issue 1...
Page 115: Swing And Dipper In Simultaneous Operation
Section E Hydraulics Section E 3 - 18 Schematics 3 - 18 Swing and Dipper In Simultaneous Operation (Swing Priority) When operating the swing and dipper simultaneously as in bank shaving or cutting operations, swing priority is achieved by using a restrictor regardless of the amount of dipper work pressure in the dipper circuit.
Page 116: Swing Over-Run Prevention Operation
Section E Hydraulics Section E 3 - 19 Schematics 3 - 19 Swing Over-run Prevention Operation The swing over-run prevention valve is installed inside the swing motor to prevent the swing back when the swing is stopped. No swing (Figure 1) The swing over-run prevention valve is in neutral state.
Page 117: Swing Reduction Gear Oil Recycling
Section E Hydraulics Section E 3 -20 Schematics 3 - 20 Swing Reduction Gear Oil Recycling To aid maintenance, the drain oil from the motor section is used as lubricating oil for the swing gearbox, eliminating the need to replace the oil in the gearbox. Pressure Line Return Line Decelerating Recycling Line...
Page 118: Attachment Boom Up
Section E Hydraulics Section E 3 - 21 Schematics 3 - 21 Attachment - Boom Up 289500 9803/6020 Issue 1...
Page 119 Section E Hydraulics Section E 3 - 22 Schematics 3 - 22 Attachment - Boom Up Pressurised oil from port A2 (rear pump) enters port 4P of the control valve. Pressurised oil from port A1 (front pump) enters port 5P of the control valve. When operating boom up with the hand controls, the pilot pressurised oil flows through the cushion valve into port 4Pb3 of the control valve and switches boom spool...
Page 120: Attachment Boom Down
Section E Hydraulics Section E 3 - 23 Schematics 3 - 23 Attachment - Boom Down Pump 289510 9803/6020 Issue 1...
Page 121 Section E Hydraulics Section E 3 - 24 Schematics 3 - 24 Attachment - Boom Down Pressurised oil from port A2 (rear pump) enters port 4P of the control valve. When operating boom down with the right hand joystick, the pilot pressurised oil enters port 4Pa3 of the control valve and switches boom spool (1) and pressurised oil of port 4P flows to the boom ram.
Page 122: Attachment - Dipper Out
Section E Hydraulics Section E 3 - 25 Schematics 3 - 25 Attachment - Dipper Out 289520 9803/6020 Issue 1...
Page 123 Section E Hydraulics Section E 3 - 26 Schematics 3 - 26 Attachment - Dipper Out Pressurised oil from port A1 (front pump) enters port 5P of the control valve. Pressurised oil from port A2 (rear pump) enters port 4P of the control valve. When operating dipper out with the left hand joystick, the pilot pressurised oil flows through the cushion valve into port 5Pb2 and switches dipper spool (1) and dipper...
Page 124: Attachment - Dipper In
Section E Hydraulics Section E 3 - 27 Schematics 3 - 27 Attachment - Dipper In Pump 289530 9803/6020 Issue 1...
Page 125 Section E Hydraulics Section E 3 -28 Schematics 3 - 28 Attachment - Dipper In Pressurised oil from port A1 (front pump) enters port 5P of the control valve. Pressurised oil from port A2 (rear pump) enters port 4P of the control valve. When operating dipper In with the left hand joystick, the pilot pressurised oil flows to port 5Pa2 of the control valve and switches arm spool (1).
Page 126: Attachment - Bucket Open
Section E Hydraulics Section E 3 -29 Schematics 3 - 29 Attachment - Bucket Open Pressure Line Pressurised oil from port A2 (rear pump) enters the control Return Line valve port 4P. Pilot Line When operating bucket open with the right hand joystick, the Control Valve pilot pressurised oil enters the control valve into port 4Pb2 and switches the bucket spool and bucket open operation is...
Page 127: Attachment - Bucket Close
Section E Hydraulics Section E 3 - 30 Schematics 3 - 30 Attachment - Bucket Close Pressurised oil from port A2 (rear pump) enters the control valve port 4P. When operating bucket close with the right hand joystick, the pilot pressurised oil enters the control valve Pressure Line into port 4Pa2 and switches the bucket spool and Return Line...
Page 128: Attachment - Blade Up
Section E Hydraulics Section E 3 - 31 Schematics 3 - 31 Attachment - Blade Up Pressurised oil from port A3 (third pump) enters the blade control valve port P. When operating blade up with the hand lever control, the pilot pressurised oil enters port Pb1 and switches the blade spool.
Page 129: Attachment - Blade Down
Section E Hydraulics Section E 3 -32 Schematics 3 - 32 Attachment - Blade Down Pressurised oil from port A3 (third pump) enters the blade control valve port P. When operating blade down with the hand lever control, the pilot pressurised oil enters port Pa1 and switches the blade spool.
Page 130: Quick Heat Circuit
Section E Hydraulics Section E 3 - 33 Schematics 3 - 33 Quick Heat Circuit Pressure Line For reducing the warm-up time of the pilot circuit, a Remote Control Valve quick heat circuit is installed. Multiple Valve When the lock lever is in the OFF position, the Control Valve hydraulic oil circulates only in the pilot circuit Restrictor...
Page 131: Pilot Control Line
Section E Hydraulics Section E 3 - 34 Pilot Control Line 3 - 34 Pilot Control Line Remote Control Valve (RH) Remote Control Valve (LH) Remote Control Valve (Travel) BLUE LIGHT GREEN BROWN GREY Bucket Open Port Swing Right Port Right Forwd.
Page 132: Hydraulic Pump
Section E Hydraulics Section E 3 - 35 Pilot Pressure and Return Line 3 - 35 Pilot Pressure and Return Line Manifold BLUE LIGHT GREEN BROWN GREY Hose Assembly COLOURLESS ORANGE PINK WHITE Control Valve YELLOW VOILET SKY BLUE Valve GREEN YELLOW/GREEN Oil Tank...
Page 133 Section E Hydraulics Section E 3 - 36 Pilot Pressure and Return 3 - 36 Multiple Valve Servo Isolator Solenoid Swing Brake Solenoid 2 Speed Tracking Solenoid Swing Lock Solenoid Reducing Valve Quick Heat restrictor Pilot Relief Valve 291050 9803/6020 Issue 1...
Page 134 Section E Hydraulics Section E 4 - 1 4 - 1 Pressure Measuring Points A297090 Main, Dipper, Swing Main, Boom, Bucket Pilot, Accumulator Blade Pressure Relief Valves Front Front 292430 Main relief valve Boom raise relief valve Boom lower relief valve Bucket open relief valve Bucket close relief valve Dipper out relief valve...
Page 135 Section E Hydraulics Section E 4 - 2 Pressure Testing 4 - 2 Auxiliary Relief Valves Swing Right Relief Valve Swing Left Relief Valve Pilot Relief Valve Blade Main Relief Valve Blade Up Relief Valve Blade Down Relief Valve Control Valve for Blade Swing Motor Multiple Valve 292440...
Page 136: Pressure Testing
Section E Hydraulics Section E 4 - 3 Pressure Testing 4 - 3 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 137 Section E Hydraulics Section E 4 - 4 Pressure Testing 4 - 4 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 138 Section E Hydraulics Section E 4 - 5 Pressure Testing 4 - 5 Accumulator 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 139 Section E Hydraulics Section E 4 - 6 Pressure Testing 4 - 6 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 140 Section E Hydraulics Section E 4 - 7 Pressure Testing 4 - 7 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 141 Section E Hydraulics Section E 4 - 8 Pressure Testing 4 - 8 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 142 Section E Hydraulics Section E 4 - 9 Pressure Testing 4 - 9 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 143 Section E Hydraulics Section E 4 - 10 Pressure Testing 4 - 10 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 144 Section E Hydraulics Section E 4 - 11 Pressure Testing 4 - 11 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 145 Section E Hydraulics Section E 4 - 12 Pressure Testing 4 - 12 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 146 Section E Hydraulics Section E 4 - 13 Pressure Testing 4 - 13 Blade Main 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 147 Section E Hydraulics Section E 4 - 14 Pressure Testing 4 - 14 Blade Auxiliary 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 148 Section E Hydraulics Section E 5 - 1 Functions Chart (Hydraulics) 5 - 1 Operation Function High Speed Travel When the High speed travel switch is selected the solenoid valve is energised. The motor rotating angle is set at the minimum and the speed is increased. Low Speed Travel This is normal travel speed.
Page 149 Section E Hydraulics Section E Hydraulic Pump 24 - 1 24 - 1 Hydraulic Pump Description Description Description Pump Shaft Snap Ring Shaft Case Part Intermediate Frame Shim Shim Gear Case Piston Pump Assembly Plate Cover Gear Pump Drive Gear O-ring Control Plate Idle Gear...
Page 150 Section E Hydraulics Section E 24 - 2 Hydraulic Pump 24 - 2 Dismantling Refer to the sectional drawings of the pump on page 24 - 8 as a guide to dismantling and assembly. The numbers in the text in bold type (e.g. 10) refer to the annotations on the drawings.
Page 151 Section E Hydraulics Section E 24 - 3 Hydraulic Pump 24 - 3 Dismantling (cont’d) Remove spring seat 29 and spring 28. Remove spring seat 27. Remove guide 24. Remove the spring 21 and spring seat 20. 9803/6020 Issue 1...
Page 152 Section E Hydraulics Section E 24 - 4 Hydraulic Pump 24 - 4 Dismantling (cont’d) Using wire or similar, pull out spool 18. Hook the barrel extractor tool (see Service Tools, Section 1) on the inner side of barrel 19 and pull it out. Remove the piston pump assembly.
Page 153 Section E Hydraulics Section E 24 - 5 Hydraulic Pump 24 - 5 Dismantling (cont’d) Remove snap ring. Remove seal case using two flat tipped screwdrivers. Remove shim 3 and 'O' ring using a flat tipped screwdriver. Tap the end of shaft 1 with a plastic hammer and withdraw the shaft from the housing.
Page 154 Section E Hydraulics Section E 24 - 6 Hydraulic Pump 24 - 6 Dismantling (cont’d) Remove the four socket head bolts 62. Remove cover 61, 'O' ring 59 and shim 60. Remove snap ring 53. Screw an M6 bolt (use one of those removed in step 16) into the tapped hole in shaft 54A.
Page 155 Section E Hydraulics Section E 24 - 7 Hydraulic Pump 24 - 7 Dismantling (cont’d) 20 Remove swash plate 56, taking care to retain the two pressure plates (one on each side). 21 Remove the three plugs 33 and 'O' rings 32, followed by servo piston 31 and spool.
Page 156 Section E Hydraulics Section E 24 - 8 Hydraulic Pump 24 - 8 Dismantling (cont’d) 24 Remove distance piece 11. 25 Remove control piston 34. 26 Remove screw-in plug 16. 27 Insert an M5 bolt into plug 16 aperture, screw into the tapped puller hole of shaft 37 and remove it.
Page 157 Section E Hydraulics Section E 24 - 9 24 - 9 Hydraulic Pump Dismantling (cont’d) 28 Remove the Hex socket head bolts 49 and remove the pilot pump 50 . 29 Remove the Hex socket head bolts 89 and remove the plate 81.
Page 158 Section E Hydraulics Section E 24 - 10 Hydraulic Pump 24 - 10 Dismantling (cont’d) 32 Remove the plate 81. 33 Push out the drive gear 76 and remove the side plate Note: Care must be taken not to lose the square ring 88 attached to the side plate 79 .
Page 159 Section E Hydraulics Section E 24 - 11 Hydraulic Pump 24 - 11 Dismantling (cont’d) 36 Remove the gear case 74 and intermediate frame 73 . 37 Remove the four socket head bolts 103 which secure Housing 93 to Front frame 92. 38 Remove thrust plate, square ring 100 and back-up ring 98.
Page 160 Section E Hydraulics Section E 24 - 12 Hydraulic Pump 24 - 12 Pump inspection Clean all parts in a suitable solvent and dry using compressed air. Wear Limits Table Part(s) Inspection/Measurement Standard Permissible Measuring Corrective Action Area Value Tolerance Tool Piston/shoe Lateral wear between...
Page 161 Section E Hydraulics Section E 24 - 13 Hydraulic Pump 24 - 13 Pump Inspection (continued) Clean all parts in a suitable solvent and dry using compressed air. 1 Wear Limits Table (continued) Part(s) Inspection/Measurement Standard Permissible Measuring Corrective Action Area Value Tolerance...
Page 162 Section E Hydraulics Section E 24 - 14 Hydraulic Pump 24 - 14 Pump Inspection (continued) Measurement Procedures a Measuring lateral wear between piston A and shoe For tolerance see Wear Limits Table, Item 1 (a). b Measuring clearance between piston A and cylinder block C.
Page 163: Fault Finding
Section E Hydraulics Section E 25 - 1 Hydraulic Pump 25 - 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 164 Section E Hydraulics Section E 25 - 2 Hydraulic Pump 25 - 2 Fault finding (cont’d) Symptom Possible cause Remedy Pressure does not increase. Relief valve is set low. Reset the relief valve. Switching valve or actuator leakage. Replace the switching valve actuator. Inadequate pump displacement.
Page 165 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 166 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 167 Boom - Anti drift drain Dipper - Anti drift drain Bolt - High strength M12 x 30 Washer - High strength 12 FRONT JCB Threadlocker and sealer Control Valve Bracket Rubber Cushion (L = 165) Rubber Cushion (L = 185)
Page 168: Control Valve
Section E Hydraulics Section E 31 - 3 Control Valve 31 - 3 Control Valve (Blade) No. Description Qty Note Inlet section assembly Outlet section Spool section assembly Main relief valve assembly 22.6 MPa (230kgf/cm Overload relief valve assembly 25.5 MPa (260kgf/cm Tie rod Plug PF1/4...
Page 169: Operation
Section E Hydraulics Section E 31 - 4 Control Valve 31 - 4 Operation 2. Signal Passage (Refer to Fig. 2, 12) The oil from the signal hydraulic source enters port PP, flows The control valve is constructed with the 4-spool and 5- through the filter (1), the restriction (2) and is guided to the spool sides overlapping and integrated into one.
Page 170 Section E Hydraulics Section E 31 - 5 Control Valve 31 - 5 Fig. 2 289770 9803/6020 Issue 1...
Page 171 Section E Hydraulics Section E 31 - 6 Control Valve 31 - 6 Operation (cont’d) Individual Operation 1. Travel Spool Switch (Refer to Fig. 1, 2, 3). When port 4Pa1(4Pb1) is pressurised and the travel right spool is selected, the neutral passage (a) is closed with the downward flow cut off.
Page 172 Section E Hydraulics Section E 31 - 7 Control Valve 31 - 7 Operation (cont’d) Individual Operation 2. Service Spool Switch (Refer to Fig. 1, 2, 4). When port 5Pa4 (5Pb4) is pressurised and the service spool is switched (under neutral status), the neutral passage (A) is closed and the oil is delivered from port 5P into the parallel passage.
Page 173: Operation
Section E Hydraulics Section E 31 - 8 Control Valve 31 - 8 Operation (cont’d) The return oil from cylinder port 4A3 flows from boom 1 spool neck and is released to the tank passage. Boom Spool Selection 3. Lower (Refer to Fig. 1, 7). 1.
Page 174 Section E Hydraulics Section E 31 - 9 Control Valve 31 - 9 Boom 2 Fig. 6 Boom 1 Raise Lower Fig. 7 289810 9803/6020 Issue 1...
Page 175 Section E Hydraulics Section E 31 - 10 Control Valve 31 - 10 Operation (cont’d) 3. Swing Spool Switch (Refer to Fig.1, 2, 8) When the pilot port 5Pb1 (5Pa1) is pressurised and the swing spool is selected (Fig. 8), the 4-spool neutral passage (A) is cut off and the oil delivered from port 5P flows through the 4-spool parallel passage (B), pushes open the load check valve (17) and flows through passage (F) and the...
Page 176 Section E Hydraulics Section E 31 - 11 Control Valve 31 - Operation (cont’d) Dipper Spool Selection 1. Dump 2 Speed Confluence (Refer to Fig. 1, 2, 9). When the arm 1 spool is selected, the arm 2 spool is When the pilot port 5Pb2 is pressurised and the arm 1 spool pressurised through passage (17) and the neutral passage is selected and the neutral passage (A) is closed, oil...
Page 177 Section E Hydraulics Section E 31 - 12 Control Valve 31 - Operation (cont’d) 2. Crowd 2 Speed Confluence (Refer to Fig. 1, 2, 10,). When the pilot port 5Pa2 is pressurised and arm 1 spool is selected (Fig. 10), the neutral passage (A) is closed, oil delivered from port 5P pushes up the tandem check valve (19) and flows through the passage (G) and the spool neck and flows to the cylinder port 5A2.
Page 178 Section E Hydraulics Section E 31 - 13 Control Valve 31 - 13 Operation (cont’d) Relief valve 1. Main Relief Valve (Refer to Fig. 1, 2, 11). The oil from port 5P pushes up the check valve (26) passes through the 5-spool parallel passage (B) and passage (18) which connects to the inlet passage (19) to the relief valve.
Page 179 Section E Hydraulics Section E 31 - 14 Control Valve 31 - 14 Operation (cont’d) Combination Operation In this way, the left and right traction motors are activated so 1. Travel Combination Operation (Refer to Fig. 12,). straight travel can be maintained while simultaneous actions The signal passage and tank passage are cut off when the with other services are carried out.
Page 180 Section E Hydraulics Section E 31 - 15 Control Valve 31 - 15 Operation (cont’d) Combination Operation 2. Anti-drift valve - Boom, Arm Section (Refer to Fig. 12, 13 and 14) The anti-drift valve is installed on the cylinder port of the arm to prevent the boom or arm rams from naturally sinking.
Page 181 Section E Hydraulics Section E 31 - 16 Control Valve 31 - 16 Boom Raising (Arm Dump) Fig. 14 Boom Lowering (Arm Crowd) Fig. 15 289870 9803/6020 Issue 1...
Page 182 Section E Hydraulics Section E 31 - 17 Control Valve 31 - 17 Operation (cont’d) Main Relief Valve Relief Valve Operation The relief valve is situated between the neutral passage (HP) and low pressure passage (LP). The oil flows through the main poppet contraction hole and fills the inner space (D).
Page 183 Section E Hydraulics Section E 31 - 18 Control Valve 31 - 18 Operation (cont’d) Overload Relief Valve Relief Valve Operation The Overload relief valve is situated between the cylinder port (HP) and low pressure passage (LP). The oil flows through the piston hole (C) and fills the inner space (G).
Page 184 Section E Hydraulics Section E 32 - 1 Control Valve 32 - 1 Control Valve Fault Finding Control Valve in General Symptoms Possible Causes Countermeasures Spool sticking 1. Oil temperature is abnormally high. Remove the obstruction. 2. Hydraulic oil is dirty Replace the hydraulic oil and clean the circuit at the same time.
Page 185 Section E Hydraulics Section E 32 - 2 Control Valve 32 - 2 Control Valve Fault Finding (continued) Relief Valve Symptoms Possible Causes Countermeasures Pressure does not rise at all 1. The main poppet, sleeve or pilot Check whether foreign matter is in each poppets are sticking open or poppet.
Page 186: Dismantling And Assembly
Section E Hydraulics Section E 33 - 1 Control Valve 33 - 1 Control Valves Dismantling and Assembly ! 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 187 Section E Hydraulics Section E 33 - 2 Control Valve 33 - 2 Description Qty. Valve Housing Spool - Travel Right Spool - Bucket Spool - Boom 1 Spool - Arm2 Spool - Swing Spool - Arm 1 Spool - Boom 2 Spool - Reserve Spool - Travel Left O-ring...
Page 188 Section E Hydraulics Section E Control Valves 33 - 3 33 - 3 Control Valve 291410-50 9803/6020 Issue 1...
Page 189 Section E Hydraulics Section E Control Valves 33 - 4 33 - 4 Control Valve 291360- 9803/6020 Issue 1...
Page 190 Section E Hydraulics Section E 33 - 5 Control Valve 33 - 5 Cap Section Assembling the Cap Dismantling the Cap Section Install the poppet (58) and the spring (59) to each pilot Loosen the plug (60) of each pilot port (not PA and PB) and remove the spring (59) and poppet (58) port (not ports PA and PB).
Page 191 Section E Hydraulics Section E 33 - 6 Control Valve 33 - 6 Spool Section Dismantling the Spool Section (See view on page 33-3) Loosen the socket head bolts (40, 42), remove the long cap and the O-ring(11) from the cap groove. Care must be taken to avoid the plug (34), spring (23) and poppet (33) being propelled out of the valve by the remaining inner pressure.
Page 192 Section E Hydraulics Section E 33 - 7 Control Valve 33 - 7 Mating parts for the Cap and Valve Housing Dismantling the Mating parts for the Cap and Valve Housing On the port 5B2 side of the arm, remove the O-ring (56), the plug (39) back up rings (57).
Page 193 Section E Hydraulics Section E 33 - 8 Control Valve 33 - 8 Boom Arm Anti-drift Valve Dismantling the Boom /Dipper Anti-drift Valve Loosen the plug assembly (14) and remove the O-ring. Remove the piston (4), the spool (5) and the spring (7). Carefully loosen the plug (3) and remove the O-ring (13).
Page 194 Section E Hydraulics Section E 33 - 9 Control Valve 33 - 9 Load Check Section Assembling the Load Check Valve Assemble the spring (27) and the poppet (26) on the Dismantling the Load Check Section surface of arm 1 sleeve (38), insert the poppet (28) and the spring (29) into the sleeve and insert into the valve Remove the plug (31) of the arm 1 load check valve.
Page 195 Section E Hydraulics Section E 33 - 10 Control Valve 33 - 10 Port Plug Dismantling the Port Plug Remove the plug assembly (47) and remove the O-rings. Remove the plug assembly (45) of the boom 2 and remove the O-ring. Cleaning / Inspection Clean the dismantled parts with a coating of clean oil.
Page 196 Section E Hydraulics Section E 33 - 11 Control Valve 33 - 11 Relief Valves Dismantling the Relief Valve Remove the overload relief valves (49, 52). Remove the main relief valve (48). Cleaning / Inspection Clean the dismantled parts with a coating of clean oil. Dry with compressed air.
Page 197 Section E Hydraulics Section E 33 - 12 Control Valve 33 - 12 Shut-Off Valve Assembly Dismantling the Shut-Off Valve Assembly Loosen the hex nut (50-5) and remove the socket head bolt (50-6). Loosen the plug (50-4), pull out the shut-off valve assembly from the main body and remove the O-ring (50-3).
Page 198 Section E Hydraulics Section E 33 - 13 Control Valve 33 -13 Plugs Dismantling the Remaining plugs Remove the plug assembly (44) and remove the O-ring. Remove the plug assembly (45) and remove the O-ring. Remove the plug assembly (21) and remove the O-ring. Do not dismantle the filter.
Page 199 Section E Hydraulics Section E 33 - 14 Control Valve 33 -14 Main Relief Valve 10 After removing the cap and plug, Check that there is no paint residue around the body socket on the edge surface of the plug. Any remaining paint would cause Removal contamination, which is the main source of malfunction Remove the whole assembly.
Page 200 Section E Hydraulics Section E 33 - 15 Control Valve 33 - 15 Over-load Relief Valve Dismantling Replace the whole assembly. Loosen the cap 1 with a spanner. Remove the O-ring 2 and discard. Loosen the adjustor 3 and replace the O-ring 4. Clean and Inspect Remove the over-load relief valve assembly.
Page 201 Section E Hydraulics Section E 40 - 1 Remote Control Valve 40 - 1 Schematics, Technical Data JS03600 Symbol Part Name Qty Symbol Part Name Qty Symbol Part Name Case Plug 221-2 Spring Port plate 212-1 Push rod 221-3 Spring Seal washer 212-2 Push rod...
Page 202 Section E Hydraulics Section E 40 - 2 Remote Control Valve 40 - 2 Schematics, Technical Data Working pressure 40 kgf/cm (38.6 bar, 568.9 lb/in Primary pressure Max. 100 kgf/cm (96.7 bar, 1422 lb/in Secondary pressure 0~45 (maximum control pressure) kgf/cm (0-43 bar, 639.2 lb/in (differs for each machine type) Allowable back pressure...
Page 203 Section E Hydraulics Section E 40 - 3 Remote Control Valve 40 - 3 Operation The structure of the pilot valve is shown in the assembly drawings (see previous page). The pressure reduction valve unit is built into the vertical bore in the casing. The pressure reduction unit consists of the spools (201), secondary pressure setting springs (241), return springs (221), washers 1 (215), spring seats (216) and washers 2 (217).
Page 204 Section E Hydraulics Section E 41 - 1 Remote Control Valve 41 - 1 Dismantling Notes: All parts are manufactured with a high degree of precision and require the utmost care when handling. Do not let parts knock against each other and take extra precautions when handling parts to prevent them being dropped.
Page 205 Section E Hydraulics Section E 41 - 2 Remote Control Valve 41 - 2 Dismantling (continued) 4. Wash the pilot valve (by itself) with kerosene. Note: Blank off the parts with plugs. 5. Using a copper or lead plate for protection, secure the pivot valve in the vice.
Page 206 Section E Hydraulics Section E 41 - 3 Remote Control Valve 41 - 3 Dismantling (continued) 8. Remove the Plate (151) 9. If the return springs (221) are weak, the sliding resistance of the 'O'-ring causes the plugs (211) to stick in the casing.
Page 207 Section E Hydraulics Section E 41 - 4 Remote Control Valve 41 - 4 Dismantling (continued) 12. Remove the port plate (111) and 'O'-ring (122) from the casing. 13. Remove the bushing (131) from the casing. 14. To disassemble the pressure reduction assembly, stand the spool (201) on a level work bench, pull the spring seat (216) down and remove the two semicircular washers 1 (215) with a small screwdriver.
Page 208 Section E Hydraulics Section E 41 - 5 Remote Control Valve 41 - 5 Dismantling (continued) 16. Remove the push rod (212) from the plug (211). 17. Remove the 'O'-ring (214) and the seal (213) from the plug (211). Use a small straight-headed screwdriver to remove the seal.
Page 209 Section E Hydraulics Section E 41 - 6 Remote Control Valve 41 - 6 Assembly Mount the bushing (131) and 'O'-ring (122) on the casing (101). Attach the port plate with hexagonal socket head bolts (125) and seal washer (121) to the casing (101). Note: Align the plate so that the spring pins (126) enter the holes in the casing.
Page 210 Section E Hydraulics Section E 41 - 7 Remote Control Valve 41 - 7 Assembly (continued) Tighten the hexagonal socket head bolts (125) to the specified torque. 29.4 Nm (21.69 lbf ft). Note: Tighten the bolts alternately a little at a time until they are tightened to the specified torque.
Page 211 Section E Hydraulics Section E 41 - 8 Remote Control Valve 41 - 8 Assembly (continued) 7. Mount the 'O'-rings (214) into the plug (211). 8. Mount the seals (213) into the plug (211). Note: Mount the seals so that the lips are as shown in the illustration.
Page 212 Section E Hydraulics Section E 41 - 9 Remote Control Valve 41 - 9 Assembly (continued) 10. Mount the plug assembly into the casing. If the return springs are weak, the sliding resistance of the 'O'-rings will hold the plugs in place in the casing. 11.
Page 213 Section E Hydraulics Section E 41 - 10 Remote Control Valve 41 - 10 Assembly (continued) 14. Mount the adjusting nut (312) and tighten it to the specified torque, using a spanner on the flats of the disk. (Adjusting nut tightening torque 68.6 ± 4.9 Nm (50 ±...
Page 214 Section E Hydraulics Section E 42 - 1 Remote Control Valve 42 - 1 Fault Finding Symptoms Possible Causes Counter measures 1. Low secondary pressure a. Primary pressure is low. Apply the correct primary pressure. b. Spring (241) is damaged. Replace the spring.
Page 215: Maintenance Specifications
Section E Hydraulics Section E 43 - 1 Remote Control Valve 43 - 1 Maintenance Specifications Maintenance Item Standard Note Leakage Amount Replace if the leakage exceeds 1000cc/min Condition with the handle in the neutral position or Primary pressure 30 kgf/cm 2000cc/min during operation.
Page 216 Section E Hydraulics Section E 55 - 1 Cushion Valve 55 - 1 Cushion Valve 291600-30 9803/6020 Issue 1...
Page 217 Section E Hydraulics Section E 55 - 2 Cushion Valve 55 - 2 Cushion Valve Operation Plunger Restrictor When the pressurised oil flows from port A to port B, the Spring plunger 1 is moved towards the right. Orifice Connector When the pressurised oil flows from port B to port A, the Body plunger 1 is moved to the left.
Page 218 Section E Hydraulics Section E 60 - 1 Multiple Valve 60 - 1 Multiple Valve Pressure Reducing Valve During Operation Operation (Solenoid valve 2 - ON, Spring Chamber - T). Relief Valve (E) Reduces the inlet pressure to the set pressure of the This is a direct driven type relief valve to produce the inlet pressure reducing valve and supplies the shuttle valve.
Page 219 Section E Hydraulics Section E Multiple Valves 60 - 2 60 - 2 Multiple Valve SOL No. SOL1 SOL2 SOL3 SOL4 Colour Blue White Green Code To shuttle Valve. From Pressure Reducing Valve. To P’ Circuit. Pressure Reducing Valve. Relief Valve. Shut off Valve 1or Port A1.
Page 220: Fault Finding
Section E Hydraulics Section E 60 - 3 Multiple Valve 60 - 3 Fault Finding Trouble Causes Solutions Set pressure is high Back pressure on port T. Adjust the port T back pressure. Small hole in the Poppet 4 is Dismantle and clean valve, blocked.
Page 221: Dismantling And Assembly
Section E Hydraulics Section E 60 - 4 Multiple Valve 60 - 4 Dismantling and Assembly Replace all seals and ‘O’ rings each time the valve is Ensure screws and bolts are tightened to the correct dismantled. torque figures to prevent distortion of parts. Do not replace spools 18,19, sleeve 9 and body 15 of After dismantling, use a suitable solvent to clean all the solenoid valve or spool 16 and body 15 of the shut...
Page 222 Section E Hydraulics Section E 60 - 5 Multiple Valve 60 - 5 Relief valve Shut off Valve 1 Dismantling the Relief Valve Dismantling the Shut off Valve 1 Loosen the plug 12 with a spanner. Loosen the hexagonal socket bolt 33 with a hex. spanner.
Page 223 Section E Hydraulics Section E 60 - 6 Multiple Valves 60 - 6 Shut off Valve 2 Assembling the Pressure Reducing Valve Dismantling the Shut off Valve 2 Install the o-ring 44 onto the plug 31. Loosen the plug 29 with a spanner. Install the spool 13, the shim 1 and the spring 21 into Remove the plug 29 and the ‘O’...
Page 224 Section E Hydraulics Section E 60 - 7 Multiple Valves 60 - 7 Solenoid Valve (1- 4) Optional Solenoid Valve Dismantling the Solenoid Valve (1-4) Dismantling the Optional Solenoid Valve (1-4) Note: The sleeve 11, the spools 23, 23 and the body 15 are Note: This is the dismantling procedure during the operating clearance packed separately, the position of the the solenoid of the optional solenoid valve.
Page 225 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 226 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 227 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 228 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 229 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 230 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 231 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 232 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 233 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 234 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 235 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 236 Section E Hydraulics Section E 74 - 2 Hydraulic Rams 74 - 2 Boom Ram - Removal (cont’d) Lower the boom ram and support it on a stand. 284460 Fasten a wire to hold the piston rod inside the cylinder. 284470 With the engine stopped, the starter switch set to ON and the operation control switch set to ON, operate the...
Page 237 Section E Hydraulics Section E 74 - 3 Hydraulic Rams 74 - 3 Boom Ram - Removal (cont’d) Remove the nuts and bolt securing the body pivot pin. 284490 Knock out the pivot pin with a bar and hammer. ! WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out.
Page 238 Section E Hydraulics Section E 74 - 4 Hydraulic Rams 74 - 4 Boom Ram - Replacement (cont’d) Install the body pivot pin. Secure with the bolt and nuts. 284530 Connect the hoses to the boom ram. 284540 Raise the boom ram and align the boom piston rod eye with the boom pivot point.
Page 239 Section E Hydraulics Section E 75 - 1 Hydraulic Rams 75 - 1 Offset 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 240 Section E Hydraulics Section E 75 - 2 Hydraulic Rams 75 - 2 Offset Boom Ram - Removal (cont’d) Use a wire to hold the piston rod inside the cylinder. 284970 Disconnect the two offset ram hoses. Install plugs or caps to prevent contamination. 286990 Remove the nuts and bolt securing the main boom pivot pin.
Page 241 Section E Hydraulics Section E 75 - 3 Hydraulic Rams 75 - 3 Offset Boom Ram - Replacement (cont’d) Use a suitable hoist and sling (the ram weighs 42 kg (92 lb)), to align the offset ram cylinder ram eye with the main boom pivot point.
Page 242 Section E Hydraulics Section E 75 - 4 Hydraulic Rams 75 - 4 Offset Boom Ram - Replacement (cont’d) Install the pivot pin and secure with the bolt and nuts. ! WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out.
Page 243 Section E Hydraulics Section E 76 - 1 Hydraulic Rams 76 - 1 Blade Rams - 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 244 Section E Hydraulics Section E 76 - 2 Hydraulic Rams 76 - 2 Blade Ram - Removal (cont’d) Use a wire to hold the piston rod inside the cylinder. 284900 Disconnect the blade ram hoses. Install plugs or caps to prevent contamination. 284910 Using a hoist capable of supporting the ram weight of 42 kg (92 lb), attach a sling to the ram.
Page 245 Section E Hydraulics Section E 76 - 3 Hydraulic Rams 76 - 3 Boom Ram - Removal (cont’d) Lift the blade ram clear. 284940 Blade Rams - Replacement Use a suitable hoist and sling (the ram weighs 42 kg (92 lb)) to align the ram cylinder eye with the blade pivot point.
Page 246 Section E Hydraulics Section E 76 - 4 Hydraulic Rams 76 - 4 Blade Rams - Replacement (cont’d) Connect the hoses to the blade ram. 284980 Manoeuvre the blade ram to align the cylinder rod eye with the body pivot point. 284990 Install the pivot pin and secure with the bolt and nuts.
Page 247 Section E Hydraulics Section E 77 - 1 Hydraulic Rams 77 - 1 Ram Piston Head Nut - Removal and Fitting JS00980 9803/6020 Issue 1...
Page 248 ) 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 249 Section E Hydraulics Section E 77 - 3 Hydraulic Rams 77 - 3 Ram Piston Head Nut (cont’d) Nut Fitting (cont’d) Table 1 Required Tightening Necessary Gauge Torques Pressure lbf ft lbf/in 1400 1033 1470 1084 10.1 1790 1320 12.3 1840 1357 12.7...
Page 250 Section E Hydraulics Section E 77-4 Torque Specifications 77 - 4 Bucket Ram kgf m lbf ft Part No. Remarks End Cap 490 ± 110 49.98 ± 11.2 361.4 ± 81.13 M90 x 2 Grub Screw 16.2 ± 3.04 1.65 ± 0.31 11.9 ±...
Page 251 Section E Hydraulics Section E 78 - 1 Hydraulic Rams 78 - 1 Reconditioning Note: Jig details are in accordance with ram sizes. 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 252 Section E Hydraulics Section E 78 - 2 Hydraulic Rams 78 - 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 253 Section E Hydraulics Section E 78 - 3 Hydraulic Rams 78 - 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 254 Section E Hydraulics Section E 78 - 4 Hydraulic Rams 78 - 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 255: Fault Finding
Section E Hydraulics Section E 79 - 1 Hydraulic Rams 79 - 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 256 Section E Hydraulics Section E 79 - 2 Hydraulic Rams 79 - 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 257 Section E Hydraulics Section E 79 - 3 Hydraulic Rams 79 - 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’...
Page 258 Section E Hydraulics Section E 79 - 4 Hydraulic Rams 79 - 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 be cylinder tube (Bending distortion: damaged too, so inspect.
Page 259 Section E Hydraulics Section E 79 - 5 Hydraulic Rams 79 - 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 260 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 Hexagonal socket head screw Cover 284420 9803/6020 Issue 1...
Page 261 Section E Hydraulics Section E 80 - 2 Rotary Coupling 80 - 2 Technical Data (cont’d) Item Part Name High strength bolt High strength washer Threadlocker and sealer Lock bar Seal washer Seal cap Seal ring Rotary coupling MAIN PORT A B C D The unit weighs 35 kg.
Page 262 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 263 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 264 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. 287190 Replacement Align the assembly to the lower frame and tighten rotating joint installation bolts 1 and washers 2.
Page 265 Section E Hydraulics Section E 82 - 3 Rotary Coupling 82 - 3 Dismantling Remove screws G and cover K. 287050 Remove and discard 'O'-ring H. 287060 Remove screws J and thrust plate F. 287070 Using a jig (see Special Tools, Section 1), push off axle A from the rotor C.
Page 266 Section E Hydraulics Section E 82 - 4 Rotary Coupling 82 - 4 Dismantling (cont’d) Remove and discard V-ring B from axle A. 287100 Remove and discard 'O'-ring D and packing rings E from rotor C. 287110 9803/6020 Issue 1...
Page 267 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 268 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 269 Section E Hydraulics Section E 82 - 7 Rotary Coupling 82 - 7 Assembly (cont’d) Install 'O'-ring H into the rotor C. 287200 Install cover K onto the rotor C using cap screws G. Torque Settings 31.46 - 37.29 Nm (23.2 - 27.5 lbf ft) 287210 9803/6020 Issue 1...
Page 270 Section E Hydraulics Section E 83 - 1 Slew Motor 83 - 1 Hydraulic Motor Components 288550 Note: Item numbers are referred to on the following pages. 9803/6020 Issue 1...
Page 271 Section E Hydraulics Section E 83 - 2 Slew Motor 83 - 2 Reduction Gear Components A chamber B chamber 288530 Note: Item numbers are referred to on the following pages. 9803/6020 Issue 1...
Page 272 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 9803/6020 Issue 1...
Page 273 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 274 Section E Hydraulics Section E 91 -1 Slew Motor 91 - 1 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 275 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 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 dirt and dust.
Page 276 Section E Hydraulics Section E 92 - 2 Slew Motor 92 - 2 Motor Assembly/Cylinder Assembly Dismantling (cont’d) Remove the snap ring 2 with a scriber and remove the inner ring of the needle bearing 3 and balance plate 7. The inner ring of the needle bearing 3 is pressed into the male axis of the cover 28.
Page 277 Section E Hydraulics Section E 92 - 3 Slew Motor 92 - 3 Motor Assembly/Cylinder Assembly Dismantling (cont’d) It may be difficult to remove brake piston 15 from housing 21 due to resistance caused by ‘O’-rings 6 and 30. Remove brake piston 15 using the tapped M6 holes with a wrench A and a support block B as shown in the illustration.
Page 278 Section E Hydraulics Section E 92 - 4 Slew Motor 92 - 4 Motor Assembly/Cylinder Assembly Dismantling (cont’d) Remove the outer rings D of the taper roller bearing 1 from the housing 21. 288740 Attach a puller to the inner ring E of taper roller bearing 1 at two places and on the end of cylinder spline 16, then extract bearing inner ring 22..
Page 279 Section E Hydraulics Section E 92 - 5 Slew Motor 92 - 5 Motor Assembly/Cylinder Assembly Dismantling (cont’d) Remove the spring 17 from the cylinder 16. 288730 ! 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 280 Section E Hydraulics Section E 92 - 6 Slew Motor 92 - 6 Motor Assembly/Cylinder Assembly Assembly (cont’d) Apply grease to the curved part of cylinder 16 (contact face with spring 17) and mount spring 17. 288930 Position the piston assemblies 18 into the holes of retainer plate 19.
Page 281 Note: The end face of the cylinder should be protected by a soft cloth to prevent it from being damaged while pre fitting. 288970 Apply a thin coat of JCB Retainer G where the inner ring is mounted on motor output shaft 16. 288980 Mount the inner ring 22 on the cylinder 16 using a press fitting jig F.
Page 282 Section E Hydraulics Section E 92 - 8 Slew Motor 92 - 8 Motor Assembly/Cylinder Assembly Assembly (cont’d) 10 Apply grease to the lip of the oil seal. Hold the end of cylinder 16 by hand and carefully insert the cylinder assembly into housing 21.
Page 283 Section E Hydraulics Section E 92 - 9 Slew Motor 92 - 9 Motor Assembly/Cylinder Assembly Assembly (cont’d) Insert the brake unit springs 14 back into brake piston 15. Note: Insert the springs 14 the same order as they were found during dismantling.
Page 284 Motor Assembly/Cylinder Assembly Assembly (cont’d) 18 To prevent oil leakage from the cover bolt holes apply JCB Multi-gasket H to the mating surface of the housing 21 and the cover 28. 289090 19 Lift the cover 28 and the balance plate 7 by hand and mount them carefully on the housing 21.
Page 285 Section E Hydraulics Section E 92 - 11 Slew Motor 92 - 11 Motor Assembly/Cylinder Assembly Assembly (cont’d) Final checks after assembling. Open the inlet and outlet ports and apply 40 kgf/cm (569 lbf/in ) pilot pressure to the brake release port. (Take care as oil will be discharged from the drain port).
Page 286 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 287 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 40 internal damage to the bearing according to...
Page 288 Section F Transmission Section F Contents Page No. Traction Motor/Reduction Gear Operation 3 - 1 Fault Finding 5 - 1 Removal and Replacement 6 - 1 Motor Bleeding 6 - 5 Testing 6 - 6 Cross-Sectional View 7 - 1 Exploded View (Motor) 7 - 2 Exploded View (Gearbox)
Page 289: 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 290 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. The pressurised oil also enters chamber b through drilling a of spool 123.
Page 291 Section F Transmission Section F 3 - 3 Operation 3 - 3 Brake Valve (Continued) Over-Running When the machine is travelling down a steep sloping surface, the travelling speed is higher and the hydraulic motor will rotate beyond the supply from the hydraulic pump, this is called over-run.
Page 292 Section F Transmission Section F 3 - 4 Operation 3 - 4 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 293 Section F Transmission Section F 3 - 5 Operation 3 - 5 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 294: 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 295 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 296 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 297: 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. 284040 Slacken the check valve to bleed out the grease.
Page 298 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 299 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 300 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 301: 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). 284370 Motor Bleeding Bleeding must be done whenever a track motor is being...
Page 302: Testing
Section F Transmission Section F 6 - 6 Traction Motor/Reduction Gear 6 - 6 Testing After dismantling and assembly of the traction motor/reduction gear assembly, install on the machine (see Removal and Replacement), but do not fit the track at this stage.
Page 303: Cross-Sectional View
Section F Transmission Section F 7 - 1 Traction Motor/Reduction Gear 7 - 1 Cross-sectional View 287540-60 9803/6020 Issue 1...
Page 304 Section F Transmission Section F 7 - 2 Traction Motor/Reduction Gear 7 - 2 Exploded View (Traction Motor) 9803/6020 Issue 1...
Page 305 Section F Transmission Section F 7 - 3 Traction Motor/Reduction Gear 7 - 3 Exploded View (Reduction Gear) 298570 9803/6020 Issue 1...
Page 306: Component List
Section F Transmission Section F 7 - 4 Traction Motor/Reduction Gear 7 - 4 Component List Description Description Piston kit Piston Shoe Spindle Kit Spindle Retainer plate Flange Thrust ball Reamer bolt Timing plate Expander Washer Piston Gear assembly Spring Gear A Spring Gear B...
Page 307: Dismantling
Section F Transmission Section F 8 - 1 Track Gearbox 8 - 1 Dismantling Refer to the exploded drawings of the traction motor and gearbox as a guide to dismantling and assembly. The numbers in bold type (e.g. 33) refer to annotations on the drawings.
Page 308 Section F Transmission Section F 8 - 2 Track Gearbox 8 - 2 Dismantling (cont’d) Place a receptacle of a volume greater than 1.7 litres (0.37 gal) under the bench. Turn the gearbox assembly over so that cover 8 is underneath. Remove the socket head plugs 33 and let the oil drain completely.
Page 309 Section F Transmission Section F 8 - 3 Track Gearbox 8 - 3 Dismantling (cont’d) Insert a steel rod through the drilled hole and press out ring 18 so that it protrudes above cover 8. 10 Completely remove ring 18. 11 Insert PT 3/8 eyebolts (see Service Tools, Section 3) into two of the plug 33 tapped holes.
Page 310 Section F Transmission Section F 8 - 4 Track Gearbox 8 - 4 Dismantling (cont’d) 13 Remove snap ring 24 from shaft 102. 14 Remove input gear 6 from shaft 102. Note: Steps 15 and 16 should only be carried out if rear flange 101 is to be dismantled (see Steps 26 to 29).
Page 311 Section F Transmission Section F 8 - 5 Track Gearbox 8 - 5 Dismantling (cont’d) 17 Unscrew the four socket head bolts 170 and remove body 155 from flange 101. Remove and discard 'O' rings 138 (2 off) and 140. 18 Unscrew the eight socket head bolts 143 from spindle 2.
Page 312 Section F Transmission Section F 8 - 6 Track Gearbox 8 - 6 Dismantling (cont’d) 21 Remove 'O' ring 30 from spindle 2. 22 Place the rear flange 101 on the bench with its mating face upwards. Remove timing plate 109. Note: If necessary due to the plate sticking, insert a knife into the groove around the edge of the plate and lever the timing plate upwards.
Page 313 Section F Transmission Section F 8 - 7 Track Gearbox 8 - 7 Dismantling (cont’d) 25 Unscrew the two plugs 124 from rear flange 101. Remove and discard 'O' rings 136. 26 Remove the two springs 128 followed by spring seats 125.
Page 314 Section F Transmission Section F 8 - 8 Track Gearbox 8 - 8 Dismantling (cont’d) 29 Remove the ‘O’ ring 136 from the plug 124. 30 Remove the ‘O’ ring 137 from the plug 126. 31 Unscrew plug 160 from valve body 155. Remove and discard 'O' ring 137.
Page 315 Section F Transmission Section F 8 - 9 Track Gearbox 8 - 9 Dismantling (cont’d) 33 Extract spool 156, taking care not to damage the sliding surfaces. Note: If inspection reveals that either the spool 156 or the valve body 155 need replacing, both should be renewed as a matching pair.
Page 316 Section F Transmission Section F 8 - 10 Track Gearbox 8 - 10 Dismantling (cont’d) 37 If necessary remove socket head plug 152, taking steps not to drop steel ball 168. Clean and refit immediately, if necessary, renewing the ball 168. Tighten the plug to a torque of 29.5 Nm (21.7 lbf ft).
Page 317 Section F Transmission Section F 8 - 11 Track Gearbox 8 - 11 Dismantling (cont’d) 41 Turn the track motor on its side. By hand, turn the cylinder block 104 back and forth a few times to release the piston shoes 106 from swash plate 103. Remove the cylinder block from spindle 102, complete with piston 105, piston shoes 106, brake plates 116 and friction plates 115.
Page 318 Section F Transmission Section F 8 - 12 Track Gearbox 8 - 12 Dismantling (cont’d) 45 Remove the three parallel pins 151 from cylinder block 104. Note: Only carry out steps 46 and 47 if you intend to replace spring 114. 46 Working with the cylinder block on a press bench or, alternatively, in a vice, use special tool I (A) (see Special Tools, Section 1) to compress washer 110 and spring...
Page 319 Section F Transmission Section F 8 - 13 Track Gearbox 8 - 13 Dismantling (cont’d) 48 Remove swash plate 103. 49 Tap shaft 102 from the reduction gear side and remove from spindle 2 complete with bearing 149. 50 Connect a hydraulic hand pump (see Service Tools, Section 1) to the speed change port of the spindle and use it to force out piston 161/piston shoe 162 assembly.
Page 320 Section F Transmission Section F 8 - 14 Track Gearbox 8 - 14 Dismantling (cont’d) 52 Remove the three snap rings 25 from the ends of crankshafts 9. 53 Remove the three spur gears 7. 54 Remove the three distance pieces 14. 55 Turn the track gearbox over.
Page 321 Section F Transmission Section F 8 - 15 Track Gearbox 8 - 15 Dismantling (cont’d) 56 Turn the track gearbox over again. Remove the three snap rings 20, marking each one so that it can be returned to its original location during assembly. 57 Loosen and remove the three reamer bolts 19.
Page 322 Section F Transmission Section F 8 - 16 Track Gearbox 8 - 16 Dismantling (cont’d) 60 Install two eyebolts (see Special Tools (B), Section 1) diametrically opposite one another into the tapped holes in spindle 2. Use a hoist to lift the spindle clear of hub 1. Remove floating seal 31, the three taper roller bearings 22 and oil seal 132.
Page 323 Section F Transmission Section F 8 - 17 Track Gearbox 8 - 17 Dismantling (cont’d) 64 Leave the padded container below the bench and turn the track gearbox over. Using a hammer A and pin punch B, tap collar 11 at several points around its circumference to remove inner bearing 21.
Page 324 Section F Transmission Section F 8 - 18 Track Gearbox 8 - 18 69 Thoroughly wash hub 1, spindle 2, cover 8 and rear flange 101 to remove external dirt. It may be necessary to brush off some of the more persistent dirt. 70 Rough clean all parts in a suitable solvent by immersing them and allowing time for dirt and oil to float off.
Page 325 Section F Transmission Section F 8 - 19 Track Gearbox 8 - 19 Gearbox Inspection All parts should be inspected for signs of wear or damage, paying particular attention to the parts detailed below. Part(s) Inspection Standard Permissible Measuring Corrective Action Measurement Value Tolerance/...
Page 326 Section F Transmission Section F 8 - 20 Track Gearbox 8 - 20 Inspection (cont’d) Part(s) Inspection Standard Permissible Measuring Corrective Action Measurement Value Tolerance/ Tool Area Condition Timing plate Wear for cylinder Surface Wear 0.005 mm Contour/ Lap the slide surface block 104 roughness (0.0002 in)
Page 327 Section F Transmission Section F 8 - 21 Track Gearbox 8 - 21 Measurement Procedures (continued) Measurement of eccentric wear of timing plate surface of cylinder block 104 - use a contour and roughness tester to measure the wear at points A and B. For tolerance, see Wear Limits Table, item 1 (h).
Page 328 Section F Transmission Section F 8 - 22 Track Gearbox 8 - 22 Measurement Procedures (continued) Measurement of outer diameter of spool 123 - take measurements at points A to E in both the X and Y directions. Deduct the average of these readings from those in (g) below.
Page 329 Section F Transmission Section F 8 - 23 Track Gearbox 8 - 23 Assembly Before starting to assemble the track gearbox, bear in mind the following points: All parts must be thoroughly cleaned. All 'O' rings, oil seals and floating seals should be renewed and coated with grease to assist installation.
Page 330 Section F Transmission Section F 8 - 24 Track Gearbox 8 - 24 Assembly (cont’d) Insert inner bearing 21 into the hub. Gently tap the outer shell of the bearing all round its circumference until it seats against collar 11. Coat 'O' ring 28 with grease and install in the groove of hub 1.
Page 331 Section F Transmission Section F 8 - 25 Track Gearbox 8 - 25 Assembly (cont’d) Fit two eyebolts into diametrically opposite tapped holes in spindle 2. Install the spindle into hub 1. Use three hub/spindle securing jigs (see Service Tools, Section 1), equally spaced, to clamp the hub 1 and spindle 2 together.
Page 332 Section F Transmission Section F 8 - 26 Track Gearbox 8 - 26 Assembly (cont’d) 12 Install the twenty-four pins 17, coated with grease, between the pin grooves of the hub and the tooth grooves of the reduction gears 4 and 5. 13 Fit outer bearing 21 onto hub 1.
Page 333 Track Gearbox 8 - 27 Assembly (cont’d) 15 Coat the threads of new† reamer bolts 19 with JCB Threadlocker and Sealer, and the reamer surfaces with a thermal seizure prevention lubricant. Progressively and evenly tighten the reamer bolts to seat the holding flange 3 evenly with bearing 21.
Page 334 Section F Transmission Section F 8 - 28 Track Gearbox 8 - 28 Assembly (cont’d) Fit the three spur gears 7 onto crankshafts 9, aligning the punch marks A as shown below. Fit a snap ring 25 to each crankshaft. Turn the track gearbox over.
Page 335 Section F Transmission Section F 8 - 29 Track Gearbox 8 - 29 Assembly (cont’d) 23 Grease the two ball bearings 167 and fit to their mounting recesses on spindle 2. Attach the piston 161/shoe 162 assembly to the spindle. Tilt the track gearbox so that the spindle is horizontal.
Page 336 Section F Transmission Section F 8 - 30 Track Gearbox 8 - 30 Assembly (cont’d) 27 Transfer the cylinder block to a press bench (if available) or to a vice. Use Special Tool I (see Service Tools, Section 1) to compress the spring and two washers. Install snap ring 145 into the cylinder block groove.
Page 337 Section F Transmission Section F 8 - 31 Track Gearbox 8 - 31 Assembly (cont’d) 31 Dip the first friction plate 115, in hydraulic oil. Then install it, locating it with the grooves in cylinder block 104. Install the first brake plate 116, locating it with the grooves in spindle 2.
Page 338 Section F Transmission Section F 8 - 32 Track Gearbox 8 - 32 Assembly (cont’d) 35 Temporarily tighten the plugs 126 with an Allen key. 36 Coat spool 123 with hydraulic oil and insert into rear flange 101. Take special care during insertion to avoid damaging the spool and its bore.
Page 339 Section F Transmission Section F 8 - 33 Track Gearbox 8 - 33 Assembly (cont’d) 39 Temporarily tighten the two plugs 124 with a spanner. Coat spool 156 with hydraulic oil and insert into surge cut valve body 155. Take special care during insertion to avoid damaging the spool and its bore.
Page 340 Section F Transmission Section F 8 - 34 Track Gearbox 8 - 34 Assembly (cont’d) Tighten the plug 160 to a torque of 142 - 191 Nm (105 - 141 lbf ft). Position the rear flange with its mating face upwards. Coat valve 163 with hydraulic oil and insert into the rear flange 101.
Page 341 Section F Transmission Section F 8 - 35 Track Gearbox 8 - 35 Assembly (cont’d) 46 Slightly compress the open ends of new ring 165 and install in the groove in the rear flange. Correct fitting of the ring is important, otherwise high/low speed switching will not be possible.
Page 342 Section F Transmission Section F 8 - 36 Track Gearbox 8 - 36 Assembly (cont’d) 49 Coat one side of timing plate 109 and, using pins 141 as a guide, fit the plate to the rear flange. 50 Position the track gearbox with its mating surface upwards.
Page 343 Section F Transmission Section F 8 - 37 Track Gearbox 8 - 37 Assembly (cont’d) 53 Secure the rear flange to the spindle using eight socket head bolts 143. Tighten the bolts progressively and evenly to a torque of 48 - 67.7 Nm (35.4 - 49.9 lbf ft). 54 Coat new 'O' rings 138 (2 off) and 'O' ring 140 with grease and fit to rear flange 101.
Page 344 Section F Transmission Section F 8 - 38 Track Gearbox 8 - 38 Assembly (cont’d) 57 Turn the track gearbox over. Fit input gear 6 to shaft 102, aligning it with the three spur gears 7. 58 Install snap ring 24 in the groove on shaft 102. Fill the track gearbox with lubricating oil (see Lubricants and Capacities, Section 3).
Page 345 Section F Transmission Section F 8 - 39 Track Gearbox 8 - 39 Assembly (cont’d) 61 Fit ring 18 into the groove in hub 1, positioning the gap in the ring approximately 20 mm (0.8 in) from the hole drilled in step 8 of the dismantling procedure. 62 Wrap sealing tape at least two turns round the thread of sealing plugs 33.
Page 346 Section F Transmission Section F 8 - 40 Track Gearbox 8 - 40 Setting-up Procedures Pre-load of Bearings 21 Install the main bearing pre-load adjusting jig (see Service Tools, Section 1) into the spindle 2, making sure the jig seats evenly with bearing 21 and does not foul taper bearing 22.
Page 347 Section F Transmission Section F 8 - 41 Track Gearbox 8 - 41 Assembly (cont’d) Remove the bearing pre-load adjusting jig from spindle Proceed to step 14 of the assembly procedure. Axle Clearance of Taper Bearings 22 To ensure that the crankshaft/reduction gear assembly is fully inserted in spindle 2, use Special Tool IV (see Service Tools, Section 1) to tap the outer shell of bearing Fit the thinnest of the twelve available thicknesses of...
Page 348 Section F Transmission Section F 8 - 42 Track Gearbox 8 - 42 Setting-up Procedures (continued) Axial Clearance of Taper Bearings 22 (continued) Gently tap the snap ring using Special Tool IV. Use a feeler gauge to measure the clearance between snap ring 20 and bearing 22 outer shell.
Page 349 Section J Track and Running Gear Section J Contents Page No. Removal and Replacement 2 - 1 Replacing the Shoe Plate 2 - 5 Replacing the Track Link 2 - 6 Idler Wheel and Recoil Unit Removal 3 - 1 Replacement 3 - 2 Idler Wheel...
Page 350 Section J Track and Running Gear Section J 2 - 1 Tracks 2 - 1 Removal Move the track until the master pin is over the idler wheel in the position shown. Place a wooden block as shown. 284040 Loosen the check valve to bleed out grease and slacken the track.
Page 351 Section J Track and Running Gear Section J 2 - 2 Track 2 - 2 Removal (continued) Drive the machine forward until the track is positioned as shown. 284070 Raise the side of the machine using the boom and dipper. Put wooden support blocks under the frame.
Page 352 Section J Track and Running Gear Section J 2 - 3 Tracks 2 - 3 Replacement (continued) Hoist the track end with a chain puller and engage it on the drive sprocket. 284110 Slowly operate the drive sprocket in the forward direction.
Page 353 Section J Track and Running Gear Section J 2 - 4 Tracks 2 - 4 Replacement (continued) Insert the master pin into its locating hole. 284050 Slowly operate the hydraulic ram and press the master pin into position. JS02820 Re-locate the track shoes and tighten the bolts (see Checking Shoe Plate, Routine Maintenance, Section 284140 9803/6020...
Page 354 Section J Track and Running Gear Section J 2 - 5 Tracks 2 - 5 Replacing a Shoe Plate Position the damaged shoe plate over the drive sprocket as shown. Remove the four mounting nuts and bolts. 248150 Remove the damaged shoe plate. 284160 Position a new shoe plate on the track link.
Page 355 Section J Track and Running Gear Section J 2 - 6 Tracks 2 - 6 Replacing a Track Link Position the link to be replaced over the idler wheel and place a block as shown to support the link below the one to be removed.
Page 356 Section J Track and Running Gear Section J 2 - 7 Tracks 2 - 7 Replacing a Track Link (continued) Remove the damaged link. 284200 Align the replacement link parts with the existing links. 284210 Install the new track pins using a portable press. 284220 Re-install the three shoe plates (see Replacing a Shoe Plate ).
Page 357 Section J Track and Running Gear Section J 2 - 8 Tracks 2 - 8 Replacing a Track Link (continued) Adjust track tension (see Routine Maintenance, Section Remove the wooden block from under the track. 284140 9803/6020 Issue 1...
Page 358: Removal And Replacement
Section J Track and Running Gear Section J 3 - 1 Idler Wheel and Recoil Unit 3 - 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 359: Replacement
Section J Track and Running Gear Section J 3 - 2 Idler Wheel and Recoil Unit 3 - 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 360: Dismantling And Assembly
Section J Track and Running Gear Section J 4 - 1 Idler Wheel 4 - 1 Dismantling and assembly - General 284240 9803/6020 Issue 1...
Page 361: Dismantling
Section J Track and Running Gear Section J 4 - 2 Idler Wheel 4 - 2 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 H from hub C and drain the oil. 284250 On the rear side of the unit only, remove the wire clip G and separate the hub C from shaft B.
Page 362: Assembly
Section J Track and Running Gear Section J 4 - 3 Idler Wheel 4 - 3 Dismantling (cont’d) Remove floating seal E from each hub C using a pry bar. Discard the floating seal. 284300 Remove floating seal E from each side of the idler wheel A using a pry bar.
Page 363 Section J Track and Running Gear Section J 4 - 4 Idler Wheel 4 - 4 Assembly (cont’d) Apply a coating of grease and install a new floating seal E into each side of the idler wheel A. 284310 Apply a coating of grease and install a new floating seal E into hub C.
Page 364 Section J Track and Running Gear Section J 4 - 5 Idler Wheel 4 - 5 Assembly (cont’d) Apply grease to a new 'O'-ring F and install it on the rear end of shaft B. Clean the metallic face of the seal E, coat the metallic face with engine oil and install the hub C onto the shaft B.
Page 365: Recoil Unit
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 366: 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, starting with spring guide/retainer F, then spring B and yoke E. Raise hydraulic jack A to compress recoil spring B.
Page 367: Grease Cylinder
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 368: Drive Sprocket
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 369: Replacement
Replacement Support the sprocket and position it on the gearbox. Install the bolts and washers, using JCB Threadlocker and Sealer on the bolt threads. Tighten the bolts in a diagonal sequence to a torque of 267 - 312 Nm (197 - 230 lbf ft, 27 - 31 kgf m).
Page 370: Top Roller
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 371: Replacement
284350 With the track supported as shown under Removal, step 2, install the roller. Apply JCB Threadlocker and Sealer to the threads and fit the two mounting bolts. Torque tighten the bolts to 267 - 312 Nm (197 - 230 lbf ft.).
Page 372 Section J Track and Running Gear Section J 10 - 1 Top Roller 10 - 1 Item Part Name Roller Plug Cover ‘O’-ring Bolt Thrust plate Shaft Floating seal Bush Bush Mounting bracket 286660 9803/6020 Issue 1...
Page 373: 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. 286670 Remove the bolts E, and cover C. From from the roller. Remove the 'O'-ring D from the cover C.
Page 374: Assembly
Section J Track and Running Gear Section J 10 - 3 Top Roller 10 - 3 Dismantling (cont’d) Remove the pivot seal H from the upper roller A using a pry bar. Discard the seal. 286710 If badly worn or damaged, remove the bushes J and I, from the roller A using a press or a puller.
Page 375 Section J Track and Running Gear Section J 10 - 4 Top Roller 10 - 4 Assembly (cont’d) If the bushes are to be replaced, use a jig M, and hammer, insert the bushes I and J into the roller A. 286740 Install a new floating seal H into the roller A.
Page 376 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 F and install it on the shaft using bolts E Torque tighten to 62 - 73 Nm (46 - 54 lbf ft.).
Page 377: 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 378: Replacement
Lower the undercarriage sufficient to allow the mounting bolts to be installed. Apply JCB Threadlocker and Sealer to the threads and install the mounting bolts. Tighten to a torque of 109 - 127 Nm (80 - 94 lbf ft)
Page 379 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 286650 9803/6020 Issue 1...
Page 380: 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 381: 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 382 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 383 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 384 Section K Engine Section K Contents Page No. Routine Maintenance See Section 3 Technical Data 1 - 1 9803/6020 Issue 1...
Page 385 Section K Engine Section K 1 - 1 1 - 1 Technical Data Type Isuzu 4JB1, 4 cylinder turbocharged,diesel Model 4JB1 PAA-04 Bore 93mm (3.7 in) Stroke 102 mm (4 in) Swept Volume 2771cm (170 in Compression Ratio 18.2 :1 Firing Order 1-3-4-2 Valve Clearance...

jcb JS70 Service Manual

Section 1 General Information Section 1

Section 3 Routine Maintenance Section 3

Section C Electrics Section C

Section E Hydraulics Section E

Section F Transmission Section F

Section J Track and Running Gear Section J

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